2103 G VD 101 013 - 1 Operation & Maintenance Manual

CONTRACTOR: DETAIL ENGINEER : :
LORDEGAN UREA OWNER
FERTILIZER
Lordegan
PROJECT UREA FERTILIZER CO. (PUBLIC STOCK)
HAMPA Hampa Energy
ENGINEERING Engineering & Design
CORPORATION Company
COVER SHEET DOC. NO.: 2103-G-VD-101-013
Project No.: 2103
Operation & Maintenance

Manual
1 29.01.2018 JY.L QL.S/RX.L J.X For final
0 10.08.2017 JY.L QL.S/RX.L J.X For review
Rev Date Written by Checked by Approved by Remark
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CONTRACTOR: DETAIL ENGINEER : OWNER :
LORDEGAN UREA
FERTILIZER
Lordegan
HAMPA Project No.:
ENGINEERING Hampa Energy
CORPORATION Engineering & Design
Company O&M MANUAL DOC. NO.: 2103-G-VD-101-013
Project No.: 2103
1 SYSTEM DESCRIPTION ................................................................................................................................... 3

1.1 GENERAL ...................................................................................................................................................... 3
1.1.1 Active carbon filter .............................................................................................................................. 3
1.1.2 Cartridge filter ..................................................................................................................................... 4
1.1.3 Mix bed ................................................................................................................................................ 4
1.1.4 Regeneration system ......................................................................................................................... 4
1.1.5 Neutralization system ........................................................................................................................ 4
1.2 PROCESS FLOW DIAGRAM .......................................................................................................................... 5
2 TECHNICAL DOCUMENT ................................................................................................................................ 6
2.1 PERFORMANCE PARAMETERS ..................................................................................................................... 6
2.1.1 Influent Condensate water Quality ................................................................................................... 6
2.1.2 Influent Condensate water Flow Rate ............................................................................................. 6
2.1.3 Treated Condensate water Quality .................................................................................................. 6
2.2 OPERATING DATA ON P&ID ........................................................................................................................ 6
2.3 EQUIPMENT DESCRIPTION ........................................................................................................................... 6
2.3.1 Equipment List .................................................................................................................................... 7
2.3.2 Key Instrument Specification ............................................................................................................ 8
3. OPERATION MANUAL................................................................................................................................. 10
3.1 SYSTEM OPERATING INSTRUCTION ........................................................................................................... 10
3.1.1 Control Basis ..................................................................................................................................... 10
3.1.2 Control System Start-up ................................................................................................................ 12
3.1.3 Control Philosophy Write-up ......................................................................................................... 14
3.1.4 Safety Precautions ............................................................................................................................... 26
3.2 ORIGINAL EQUIPMENT MANUFACTURER (OEM) OPERATION MANUAL ................................................... 29
3.3 STANDARD OPERATING PROCEDURE........................................................................................................ 29
3.3.1 General Operating Information ....................................................................................................... 29
3.3.2 Plant Start-up Procedures ............................................................................................................... 32
3.3.3 Plant Shutdown Procedures ........................................................................................................... 32
3.4 OPERATIONAL SHUTDOWN ........................................................................................................................ 33
3.5 MOUNTING AND ASSEMBLY INSTRUCTIONS .............................................................................................. 33
3.5.1 Pre-operation Guidelines................................................................................................................. 34
3.5.2 Chemical System Installation.......................................................................................................... 35
3.5.3 Pump and blower Installation.......................................................................................................... 35
3.5.4 Interconnection Piping ..................................................................................................................... 35
3.5.5 Drainage Piping ................................................................................................................................ 35
3.5.6 Tubing & Wiring ................................................................................................................................ 36
3.5.7 Electrical Supply ............................................................................................................................... 36
3.5.8 Air Supply .......................................................................................................................................... 36
3.5.9 Control Valves .................................................................................................................................. 36
3.5.10 Instruments ..................................................................................................................................... 37
3.5.11 PLC .................................................................................................................................................. 37
4 MAINTENANCE MANUAL ............................................................................................................................ 38
4.1 REGULAR MAINTENANCE INSTRUCTION .................................................................................................... 38
4.1.1 Maintenance Procedure Recommended Interval ........................................................................ 39
4.1.2 COMPONENTS MAINTENANCE .................................................................................................. 40
4.2 TROUBLE SHOOTING ............................................................................................................................ 42
4.2.1 General Trouble Shooting Tips ...................................................................................................... 42
4.2.2 Troubleshooting Guide .................................................................................................................... 43
4.3 PREVENTIVE MAINTENANCE................................................................................................................. 45
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4.3.1 All Systems ...................................................................................................................................... 45

4.3.2 Chemical Systems ......................................................................................................................... 48
4.3.3 Blowers and Pumps ......................................................................................................................... 48
5 SPARE PARTS ............................................................................................................................................ 49
5.1 GENERAL GUIDELINE ................................................................................................................................. 49
5.2 RECOMMENDED SPARE PARTS LIST ......................................................................................................... 49
6 COMMISSIONING MANUAL......................................................................................................................... 53
6.1 REGULAR MAINTENANCE INSTRUCTION .................................................................................................... 53
6.2 COMMISSIONING PROCEDURES ................................................................................................................. 56
6.2.1 Active Carbon Filter ......................................................................................................................... 56
6.2.2 Mixed Bed.......................................................................................................................................... 64
6.2.3 Neutralized System .......................................................................................................................... 78
6.3 TROUBLE SHOOTING .................................................................................................................................. 82
6.3.1 General Trouble Shooting Tips ...................................................................................................... 82
6.3.2 Troubleshooting Guide .................................................................................................................... 83
6.4 PREVENTIVE MAINTENANCE ...................................................................................................................... 86
6.4.1 All Systems........................................................................................................................................ 86
6.4.2 Chemical Systems ........................................................................................................................... 89
6.4.3 Blowers and Pumps ......................................................................................................................... 89
this part was added
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1 SYSTEM DESCRIPTION
1.1 General
Condensate polishing package belongs to condensate recovery and polishing system which
is provided for complete treatment of process condensate, steam condensate and turbine
condensate. Process condensate which is stored in condensate collecting tank (TK-5201) is
transferred to this package by condensate pumps (P-5201 A/B).
“Process Drain” effluents from different sources in Ammonia unit will be added together and
drains to neutralization pond by gravity via an underground pipe. 98% H2SO4 and 40% NaOH
are utilized for resin regeneration of polisher and neutralization. 98% H2SO4 stored in D-5201
shall be supplied using acid transfer pumps (P-5204 A/B). 40% NaOH stored in D-5202 shall
be supplied using caustic transfer pumps (P-5203 A/B).
1.1.1 Active carbon filter

Firstly, the condensate supplied by condensate pumps (P-5201 A/B) is treated by carbon
filters (3-PU-5201-FT-001A~G) to remove oil and dissolved solids. To prevent damage from
over high temperature of condensate, temperature transmitter (3-TIT-52100) and pneumatic
butterfly valve (3-XV-52127) are equipped before carbon filters. When the inlet condensate
temperature is higher than 52℃，the pneumatic butterfly valve (3-XV-52127) should be shut
off.
The backwash water is controlled by both pressure transmitter (3-PIT -52100) and
Pneumatic control valve (3-PV-52100) to meet a suitable backwash pressure of about
2.5barg. The operation and backwash of the carbon filters (3-PU-5201-FT-001A~G) is
controlled by PLC system. When one of the carbon filters is in backwash procedure, the
other ones maintain service.
There is pressure differential switch (3-PDS-52100A~G) with each carbon filter to alarm and
to start backwash process, when active carbon layer is choked by colloids and particles.
Each carbon filter is followed with a carbon trap to catch leaking active carbon particles.
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1.1.2 Cartridge filter
Secondly, two cartridge filters (3-PU-5201-FT-002A/B) are used before mixed bed to remove
sustainable solids above 5 µm from product water of carbon filters. There is pressure
differential switch (3-PDS-52101A~B) with each cartridge filter to prompt filter element should
be changed.
1.1.3 Mix bed
Finally, condensate is polished by four mixed beds (3-PU-5201-FT-003A~D) with service

time of ≥16 hours under design flow rate and design water quality. Two mixed bed are on
service and the other two mixed beds should be on regeneration or on standby.
Programmable logic controller (PLC) system of condensate polishing package is used for
control of mixed beds operation and regeneration To prevent overpressure of mixed bed, the
pressure relief valve (3-PSV-52100A~D) are equipped on mixed beds to release pressure
when the pressure beyond 10 barg,
There is pressure differential switch (3-PDS-52102A~D) with each mixed bed to alarm and to
start backwash process, when ion exchange resin layer is choked by colloids and particles.
Basket type resin trap is provided at the polisher outlet to trap leaking resin.
1.1.4 Regeneration system
For regeneration of the ion exchanged resin, sulfuric acid (98%) in measuring tank (3-PU-
5201-TK-002) is supplied to mixed bed through acid dosing pumps (3-PU-5201-P-001A/B),
and caustic soda (40%) in measuring tank (3-PU-5201-TK-001) is supplied to mixed bed
through caustic ejector (3-PU-5201-J-001). In order to improve regeneration, one plate heat
exchanger (3-PU-5201-E-001) is supplied to heat polished water at caustic regeneration
system.
1.1.5 Neutralization system
A Neutralization System is in the PU‐5201 package. Neutralization System will neutralize

polishing and ammonia unit drainage to pH range of 6 ‐ 9. The operation and control of the
complete unit is completely automatic through programmable logic controller (PLC) system.
98% H2SO4 or 40% NaOH is added to neutralization sump (3-PU-5201-SU-001) through
pneumatic diaphragm valves (3-XV-52123, 3-XV-52124) controlled by pH analyzer (3-AIT-
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52106), and then the liquid is mixed by air blowing of roots blower (3-PU-5201-C-001A/B)
through pneumatic valve (3-XV-52125). The neutralized water is pumped to utilized area by
self-priming pump (3-PU-5201-P-002A/B) which is interlocked with level switch (3-LS-52101)
and ultrasonic level gauge (3-LIT-52102).
1.2 Process Flow Diagram
Please refer to the as built drawings.
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2 TECHNICAL DOCUMENT
2.1 Performance Parameters
2.1.1 Influent Condensate water Quality
Characteristics of condensate water streams are summarized as below:
ITEM UNIT VALUE

FLUID TEMPER. ℃ ≤50
RAW WATER QUALITY μs/cm conductivity≤25
FLUID pH - 6.5~8
SiO2 µg/L ≤200
2.1.2 Influent Condensate water Flow Rate
The design capacity of the condensate polishing system is 480m3/hr.

2.1.3 Treated Condensate water Quality
The polished water shall meet the following criteria:
ITEM UNIT VALUE

FLUID TEMPER. ℃ ≤50
OUTLET WATER QUALITY μs/cm conductivity≤0.2
FLUID pH - 6.5~8
SiO2 µg/L <20
2.2 Operating Data on P&ID
Please refer to the as built P&ID.

2.3 Equipment Description
This section describes all equipment supplied by POTEN. Detail information of individual
equipment refers to the component literature in the separate Vendor Literature Manual
supplied with this equipment.
NOTE : The vendor literature for this job is contained in section 2.3.3.
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The equipment list for the systems described in this manual follows this page. The purpose
of the equipment list is to convey the quantity and technical specification of all tagged items
shown on the process and instrumentation drawings (P&ID).
2.3.1 Equipment List
No. ITEM SPECIFICATION UNIT QTY MATERIAL

1 Carbon filter
3
Q=80m /h，Φ=3200mm，straight
body: carbon steel
height rubber lined.
3200mm,medium:condensed Rubber
1.1 Carbon filter set 7
water, design/operation pressure
thk:3mm+2mm，
10.0bar/6.5bar, design/operation
filter cap:SS304
temperature 65℃/50℃
Cocoanut active Φ=0.8~1.8mm，iodine
1.2 m³ 105
carbon value:800~900mg/g,K80＜1.7,
1.3 Silica sand Φ=2~4mm，H=0.2m m³ 12 Silica sand
10.0bar/6.5bar, body：carbon steel
outlet/inlet pipe diameter rubber lined，rubber
1.4 Carbon trap set 7
6”,design/operation pressure thickness:3mm, filter
10.0bar/6.5bar, element ：SS304，
Q=202m³/h, temperature 50 ℃,
Backwash ASTM A216
1.5 inlet pressure 5.5bar , outlet set 1
reducing valve GR.WCB
pressure 2.5 bar
2 Cartridge filter
Q=240m³/h，Φ=600mm，
medium: condensed water,
body：SS304
2.1 Cartridge filter design/ operation pressure set 2
thickness:6mm
10.0bar/6.5bar,design/operation
temperature 65℃/50℃
L=40"， Filter fineness：5μm，
2.2 Filter element pc. 15 pp
Q=40m3/h/pc.
3 Mixed bed
3
Q=240m /h, Φ2500, medium
type: condensed water , design / body: carbon steel
operating rubber lined,
3.1 Mixed bed pressure:10.0bar/6.5bar, design / set 4 rubberthk:3mm+2m
m,
operation temperature: 65℃
filter cap:SS316
/50℃, sight glasses number 3
D001 MB strong acid resin, 3
3.2 Cation resins m 14.1
H=500mm
D201 MB strong alkali resin 3
3.3 Anion resins m 21.2
H=1000mm
outlet/inlet pipe diameter body: carbon steel
3.4 Resin trap 8",design/operation pressure set 4 rubber lined,
10.0bar/6.5bar, rubber thk:3mm,
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filter element SS304
4 Regeneration system
regeneration Q=98m³/h, temperature 50 ℃,
4.1 reducing valve of inlet pressure 7bar , outlet set 1 SS304
regeneration pressure 3.5 bar
hot medium inlet: Steam: 225℃,
3.5bar;
Alkali
cold medium inlet: condensed Plate: SS,
4.2 regeneration set 1
water: 5 ℃, 2.5bar，Q=25m3/h; Shell: CS
heat exchanger
cold medium outlet: condensed
water: 40℃;
Carbon steel lined
4.3 Caustic pot V=1500L，Φ×H=1200×1400mm set 1
rubber
4.4 Acid pot V=1000L，Φ×H=1000×1300mm set 1 Carbon steel
Q=350L/h, H=7.0bar, N=0.75kW,

Acid dosing pump head: PVDF
4.5 400V AC, 50Hz, Medium: 98% set 2
pumps diaphragm: PTFE
sulfuric acid solution
Carbon steel lined

4.6 Acid pipe mixer 4",L=1000mm, dosing nozzle 1" set 1
PTFE
3
4.7 Caustic ejector 4“×2”，Q=49m /h set 1 FRP
4.8 Electric heater N=30kW，400V AC set 1 SS316
5 Condensate water neutralization sump
Neutralized suction head 3.5m，

3 pump
5.1 effluent transfer Q=100m /h，H=40m， set 2
case,impellerSS316
pumps N=30kW，400V AC
Blower, Q=9.83m³/min，
P=1.0bar，N=55kW,400V AC
5.2 Air blower Fan of sound enclosure, set 2
Q=46Nm³/min，
N=100W,400V AC
T=1t, lift height 8m, route 12m,
5.3 Electric hoist set 1
N=1.7kW
2.3.2 Key Instrument Specification
SR. MANUFACTUR QUANTITY

ITEM ER/ MODEL DESCRIPTION UNI
QTY
NO. NO. T
TYPE SPDT, TYPE OF ELEMENT
1 DP Switch BLD/KC32-494 13 Pic.
Diaphragm type
ACCURACY ±0.2%FS,BODY MATERIAL
2 Transmitters E+H/PMP71 2 Pic.
aluminum alloy with epoxy
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coating ,OUTPUT SIGNAL

4~20mA+HART
ACCURACY ± 0.75 %,ELECTRICAL
Vortex flow KROHNE/VFM4 CONNECTIONS m20×1.5, OUTPUT
3 6 Pic.
meter 070 SIGNAL 4~20mA+HART,HOUSING
MATERIAL AL,with epoxy coating
PADDLEWHE ACCURACY ± 1 %,ELECTRICAL
4 EL FLOW GF/P51530 CONNECTIONS 1/2”, OUTPUT SIGNAL 8 Pic.
METER 4~20mA+HAR
ACCURACY ± 0.5 %,OUTPUT SIGNAL
Electromagnet KROHNE/OPTI
5 4~20mA+HART,HOUSING MATERIAL 1 Pic.
ic flowmeter FLUX4100W
AL,with epoxy coating
CONNECTION TYPE
FLANGED,CONNECTION RATING
ULTRASONIC KROHNE/OPTI
6 CALSS150,FLANGE SIZE 4",CABLE 1 Pic.
level meter SOUND 3020 C
ENTRY M20×1.5,OUTPUT SIGNAL
4~20mA+HART
CABLE ENTRY / POWER
conductivity HACH(9500+83 SUPPLY :M20×1.5 / 110VAC
7 5 Pic.
analyzer 10+8319) 50Hz,,OUTPUT SIGNAL
4~20mA,ACCURACY::reading of ±1%
CABLE ENTRY / POWER
SUPPLY :M20×1.5 / 110VAC
HACH(9500+83
8 pH analyzer 50Hz,,OUTPUT SIGNAL 2 Pic.
62)8350
4~20mA,,MEASURING
RANGE:1~14/2~12
MEASURING
silicon RANGE:0.5~5000μg/L,CABLE ENTRY /
9 HACH(9610) 1 Pic.
analyzer POWER SUPPLY :M20×1.5 / 110VAC
50Hz,,OUTPUT SIGNAL 4~20mA,
MEASURING RANGE:0~16%,CABLE
HACH. ENTRY / POWER SUPPLY :M20×1.5 /
10 alkaline meter 1 Pic.
9500+8398 110VAC 50Hz,,OUTPUT SIGNAL
4~20mA,
MEASURING RANGE:0~30%,CABLE
HACH. ENTRY / POWER SUPPLY :M20×1.5 /
11 acidity meter 1 Pic.
9500+8398 110VAC 50Hz,,OUTPUT SIGNAL
4~20mA,
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3. OPERATION MANUAL
3.1 System Operating Instruction

3.1.1 Control Basis
The diagram on the next page shows the major components of a basic control system.
(1) Input devices such as pH sensors, flow sensors, level sensors, level switches,
(2) These input signals must first go through input modules, which convert them into
signals that the PLC can understand.
(3) The PLC transfers these inputs to the proper addresses in a program installed within
the controller. It also transfers any output signals generated by the program.
(4) The PLC program contains all of the instructions necessary for the controller to
operate the system. It looks at all of the input signals from the field, decides what action
to take, and sends output signals to the field to perform the task.
(5) These output signals must first go through output modules, which convert them into
signals that the output devices can understand.
(6) Output devices such as valves, pumps, and LCS use these signals to operate the
equipment.
(7) The operator controls are devices the customer can use to enter, view, or change any
part of the program. These are items such as programmers, monitors, keyboards,
printers, pushbuttons, and selector switches.
(8) See the illustrated simplified diagram in Figure 3-1 on next page.
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Figure 3-1: Basic Control System Diagram
All operations are controlled from the PLC located in control room and local control station
(LCS), containing a series of selector switches and push buttons. Equipment controls and
system indication are summarized below.
Selector Switches
LOCAL/OFF/REMOTE – These selecting switches are provided for system process control.
In the “LOCAL” position, the associated equipment is energized regardless of PLC signals.
In the “OFF” position, the associated equipment will not be energized regardless of PLC
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signals. In the “REMOTE” position, the associated equipment’s activation is determined by

PLC.
Push Buttons
Pump Start – This push button adjacent to pumps to be used to start the pump manually.
Pump Stop – This push button adjacent to pumps to be used to stop the transfer pump
manually.
Indication Lights
Indication lights in this system are showed both on the local control station (LCP) and PLC.
All lights are wired to the PLC. The types of lights are described below.
Equipment Running – These lights are equipped with green lenses. Illumination indicates
that the associated piece of equipment is energized.
Equipment Fault – These lights are equipped with yellow lenses. Illumination indicates that
the associated piece of equipment is de-energized because of the equipment failure.
3.1.2 Control System Start-up
The automatic process controls must be functional before most of the equipment can be
started.
This section describes general checkout and startup procedures for the process controls and
related electrical components.
Operators may use the controls start-up as a method of familiarizing themselves with the
basic controls and their functions. Refer to the Control Philosophy Write-Up in Section 1.6.4
for a more detailed description of the control system.
Hazardous process fluids, high fluid pressures, and accidental pump

CAUTION operation can cause operator injury or equipment damage.
During the controls checkout, close all hand valves to prevent any fluids
from entering the unit and prevent accidental pump operation by turning
off the circuit breakers or by placing the control selector switches in the
“OFF” position.
(1) Turn “OFF” all of the circuit breakers in the PLC and Local control station (LCS)
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(2) Place all of the station selector switches into their “OFF”, or “LOCAL” positions.
(3) Turn “ON” power to the PLC and turn “ON” its PLC circuit breaker.
(4) Observe the status lights at the PLC and verify that the controller is powered up.
(5) When the PLC is turned “ON”, all program set point values must be checked and
reset as necessary. These set point values are located in timers, counters, and registers
within the PLC program (software).
Before working with the control program, operators must be familiar with the controller and
the control monitor used with this system. More information on these controls can be found
in the Control Philosophy in Section 1.6.4 and in the Vendor Literature Manuals.
NOTE: Operators must become familiar with the control monitor at some point prior to the
startup of the equipment. Operators will usually be required to make some set point
value changes during normal operation of the system.
Compare the values on the control monitor with those listed in the Control Philosophy Write-
Up in Section 1.6.4, and make changes as required.
(6) When all program set point values have been checked, the program can be test run
to verify that step sequences are correct and that the proper output devices reaction.
Turn “ON” all of the circuit breakers in PLC and Local Control Station (LCS). Place the entire
station selector switches into their “REMOTE” positions
During a test run of the control program, the PLC must follow the process mode and step
sequence shown in the Control Philosophy Document in Section 1.6.4.
When the PLC program enters a process mode or step, operators must verify that the
correct process valves open (if supplied with compressed air), the correct process pump
starters are energized, and that other required output devices are activated.
For some modes and steps, inputs from field instruments may have to be simulated or the
instruments “hampered” to prevent alarms and to allow the modes or steps to proceed.
(7) When all of the output circuitry has been tested successfully, the field inputs from
sensing elements and other devices must be tested.
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Instrument technicians must simulate input signals at the field devices and verify that these
signals are being received by the PLC.
Field inputs can be simulated by jumping terminals at “ON/OFF” motor contacts or

instrument switches and by supplying a varying mA signal at analog-type instruments.
NOTE: Position switches on limit-stop and other flow-control valves cannot be properly adjusted until
the valve is adjusted to its control set point.
(8) Final adjustments to position switches on flow-control valves (if applicable) must be made
following the initial startup procedures.
Three-phase pumps can be damaged if run without process and/or seal

CAUTION water present. Also, if certain types of impeller pumps are accidentally
run backward for any period of time, the impellers may loosen and fall
off in the pump housings.
(9) Finally, check the wiring for the various system pumps (if applicable). With all hand
valves still in the closed position and with a worker watching the motor end of a pump,
"bump" the motor. This is done by jogging the pump's selector switch from the “OFF”
position to the “LOCAL” position and back to the “OFF” position quickly. On 3-phase pumps,
note the direction of rotation, if necessary two of the three conductors can be swapped to
reverse motor rotation.
Do not allow the pumps to actually run until proper rotation is verified.
When all three-phase pumps have been checked for proper rotation and rewired as
necessary, Place their control selector switches in the “Remote” position.
(10) When the checkout of the PLC and the field circuitry is complete, make sure that all
equipment is offline before leaving the panel.
3.1.3 Control Philosophy Write-up
3.1.3.1 Vocabulary Precisions

In all the following documents:
“Operator” means person using the Control System.
“On standby” means equipment starting remotely in case of the operating equipment default.
“Alarm” means alarm message, which appears on the MCP/HMI.
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“Running” means equipment work effectively.
“On duty” or “In service” means equipment be able to be started remotely according to its
control philosophy.
“Remote” means action on the equipment from the PLC without operator intervention.
“Remote mode” means control of the equipment by PLC
“Local mode” means action on the equipment from the manually on LCS
LCS means Local Control Station
PLC means Programmable Logic Controller
DI means Discrete Input
DO means Discrete Output
AI means Analog Input
AO means Analog Output
HMI means human machine interface
3.1.3.2 General description

Each motor or group of motor has a switch Local/Off/Remote on PLC. In the “local” position,
the motor is disconnected from the programmable logic controller for local function and in the
“Remote” position, it is not any more locally operable,
Some operations are managed by the programmable logic controller (for example, operation
sequences or PID controller….); for each of them the operation has the choice between an
remote mode and a local mode.
All the rotating equipment have spare parts, the operating one can be selected in the HMI,
after a set time the status of the operating /standby unit can be changed in HMI.
Remote: means can be operated in HMI, and controlled by PLC;
Off: means stop the equipment;
Local: means pump will directly run start without any limitation when in Local state.
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Instrument: Some instruments with 4-20mA output, should send signal to PLC, the
instruments are: level switch, flowmeter, pressure transmitter, pH meter, All the value should
be shown in the HMI.
All the control set point can be changed in the PLC.
3.1.3.3 The influent pneumatic valve

Instruments
Conductivity analyzer 3-AIT-52100
Temperature Transmitter 3-TIT-52100
Analogues variables
Identification Description Format Unit Min. Max.

3-TIT-52100 Temperature of condensate water HH,H ℃ 50 52
3-AIT-52100 Conductivity of condensate water H µS/cm - 30
Operation description
1. The influent pneumatic valve
The influent pneumatic valve 3-XV-52127 is controlled by the Temperature Transmitter 3-

TIT-52100 and the Conductivity analyzer 3-AIT-52100.
Control switch status is described as below:

LOCAL MCC and MCP (PLC)
Control point
Control Signal (PLC input) Control
3-XV-52127 EM Stop Running  Local
Alarm  Off
Remote  Remote: by PLC
Control logic is described as below:

- Remote - The influent pneumatic valve will Close when Influent temperature is
(Remote) mode High-High or influent conductivity is High, indicated at PLC
- - The system will alarm when Influent temperature is high-high level or
Influent conductivity is high.
- Open when Influent temperature is high level.
- -
Control set point:

Identification Tag No Described Functional Description Set point
3-TIT-52100 3-TIT- High High Trigger high high temperature alarm, 52℃
52100 temperature indicated at PLC and MCC, and Close
the influent pneumatic valve3-XV-52127.
3-TIT- High Open the influent pneumatic valve3-XV- 50℃
52100 temperature 52127.
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3-AIT-52100 3-AIT- High Trigger high conductivity alarm, indicated 30µS/cm

52100 conductivity at MCC, and Close the influent
pneumatic valve3-XV-52127.
Remarks: the set points refer to the Appendix 1 Control Philosophy, and the final value will
be adjusted during commissioning.
Alarms
High-high temperature (3-TIT-52100) will lead to iron exchange resign invalid and
consequently the process will be stopped.
3.1.3.4 Active carbon fliter
Equipments
Active carbon filter 3-PU-5201-FT-001A~G
Instruments
Pressure Transmitters 3-PIT-52100
Turbine flow meter 3-FIT-52100, 3-FIT-52101A~G
in situ pressure gauge 3-PI-52100A~G
in situ pressure gauge 3-PI-52101A~G
Pressure difference switch 3-PDS-52100A~G
Analogues variables
3-PDS-52100 Pressure difference of the filter H bar 1
The valves per carbon filter

ITEM NO. Tag NO. NOTE
Filter inlet valve 1 3-XV-52100A~G Pneumatic butterfly valve
Product water valve 1 3-XV-52101A~G Pneumatic butterfly valve
Backwash valve 1 3-XV-52102A~G Pneumatic butterfly valve
Backwash drain valve 1 3-XV-52103A~G Pneumatic butterfly valve
Flush drain valve 1 3-XV-52104A~G Pneumatic butterfly valve
Exhaust valve 1 3-XV-52105A~G Pneumatic butterfly valve
The running program insists of 3 steps and operate in loop way.
(1) Start up
A, opening influent valve 3-XV-52127;
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B, opening filter inlet valve 3-XV-52100A~G and exhaust valve 3-XV-52105A~G, keep
exhausting program for 60s,
C, closing exhaust valve 3-XV-52105A~G, opening product water valve 3-XV-52101A~G,

keep filtering program for 24hr unless the 3-PDS-52100A~G get to set point value within
24hr;
(2) Backwash
A, closing filter inlet valve 3-XV-52100A~G and product water valve 3-XV-52101A~G;
B. opening flush drain valve 3-XV-52104A~G to drain water for a while until the level gets to
100mm above the filter material layer.
C, opening backwash inlet valve 3-XV-52102A~G and backwash drain valve 3-XV-
52103A~G,keep backwash program for 20min;
(3) Flush
A, closing backwash inlet valve 3-XV-52102A~G,keep filter material settled for 3min;
B, closing backwash drain valve 3-XV-52103A~G,opening exhaust valve 3-XV-52105A~G

and inlet valve 3-XV-52100A~G, keep filling for 20s;
C, opening flush drain valve 3-XV-52104A~G, closing exhaust valve 3-XV-52105A~G, keep
wash program for 10min,
Alarms
High pressure difference (3-PDS-52100) will lead to active carbon particles coated by
ipurities and unable to absorb oil anymore.
3.1.3.5 Cartridge fliter

Equipments
Cartridge filters 3-PU-5201-FT-002A/B
Instruments
Pressure difference switch 3-PDS-52101A/B
Analogues variables

3-PDS-52101 Pressure difference of the filter H bar 1
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Alarms
High pressure difference (3-PDS-52101) will lead to filter material coated by impurities and
will be blocked up.
3.1.3.6 Mix bed
Equipment
Mix beds 3-PU-5201-FT-003A/B/C/D
Instruments
Conductivity analyzer 3-AIT-52103A~D
Si analyzer 3-AIT-52102
Vortex flow meter 3-FIT-52102A~D
pH analyzer 3-AIT-52101
Pressure difference switch 3-PDS-52102A~G
Analogues variables

3-AIT-52102 Si of condensate water H µg/L - 20
3-AIT-52103 Conductivity of condensate water H µS/cm - 0.2
3-PDS-52102 Pressure difference of mix bed H bar 1
pH analyzer pH of mix bed product water H,L 6 9
Valves of per mix bed

NO. Description NO. Tag number Note
1 Inlet valve 1 3-XV-52106 A~D Pneumatic butterfly valve
2 Product water valve 1 3-XV-52107 A~D Pneumatic butterfly valve
3 Backwash inlet valve 1 3-XV-52108 A~D Pneumatic butterfly valve
4 Backwash drain valve 1 3-XV-52109 A~D Pneumatic butterfly valve
5 Air inlet valve 1 3-XV-52110 A~D Pneumatic butterfly valve
6 exhaust valve 1 3-XV-52111 A~D Pneumatic butterfly valve
7 acid inlet valve 1 3-XV-52112 A~D Pneumatic butterfly valve
8 alkali inlet valve 1 3-XV-52113 A~D Pneumatic butterfly valve
9 upper drain valve 1 3-XV-52114 A~D Pneumatic butterfly valve
10 middle drain valve 1 3-XV-52115 A~D Pneumatic butterfly valve
11 flush drain valve 1 3-XV-52116 A~D Pneumatic butterfly valve
The running program insists of 3 steps and operate in loop way.
(1) Start up
A, opening exhaust valve 3-XV-52111 and inlet valve 3-XV-52106, keep filling water for 6min;
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B, opening flush drain valve 3-XV-52116 and closing exhaust valve 3-XV-52111, keep flush
for 15 min;
C, opening product water valve 3-XV-52107 and closing flush drain valve 3-XV-52116 when
the conductivity of product water is lower than 0.2µS/cm, keep running for 24 hr;
(2) Stop
A, closing inlet valve 3-XV-52106 and product water valve 3-XV-52107, opening exhaust
valve 3-XV-52111, keep for 1min;
B, closing exhaust valve 3-XV-52111;
(3) Backwash
A, opening exhaust valve 3-XV-52111, backwash drain valve 3-XV-52109 and backwash
inlet valve 3-XV-52108, keep backwashing for 15 min;
B, closing backwash inlet valve 3-XV-52108, keep 3-XV-52111 and 3-XV-52109 opening for
5min;
C, opening upper drain valve 3-XV-52114 and keep for about 5min until depth of water above
resin get to 200mm;
D, closing upper drain valve 3-XV-52114, exhaust valve 3-XV-52111 and backwash drain
valve 3-XV-52109;
Alarms
Si of condensate water >20µg/L;
Conductivity of condensate water>0.2µS/cm;
Pressure difference of mix bed>1 bar

3.1.3.7 Regeneration system
Equipments
Acid dosing pump 3-PU-5201-P-001A/B
Acid pot 3-PU-5201-TK-002
Caustic pot 3-PU-5201-TK-001
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Air blower 3-PU-5201-C-001A/B

Electrical heater 3-PU-5201-H-001
Alkali regeneration heat exchanger 3-PU-5201-E-0001
Caustic ejector 3-PU-5201-J-001
Acid pipe mixer 3-PU-5201-MX-001
Instruments
Acid analyzer 3-AIT-52105
Caustic analyzer 3-AIT-52104
Temperature analyzer 3-TIT-52101
Temperature analyzer 3-TIT-52103
Magnetic level gauge 3-LIT-52100
Magnetic level gauge 3-LIT-52101
level switch 3-LS-52100
electromagnetic flow meter 3-FIT-52103
Pressure transmitter 3-PIT-52101
thermometer 3-TI-52100
Analogues variables
3-TIT-52101 Temperature of condensate water H,L ℃ 32 52
3
3-FIT-52103 Flow of condensate water H,L m /h 25 50
3
3-FIT-52104 Flow of condensate water H,L m /h 25 50
3-LS-52100 Level of acid pot LL mm 200 1
3-LIT-52100 Level of caustic pot H,L,LL mm 200 1000
3-LIT-52101 Level of acid pot H,L,LL mm 200 1000
3-PIT-52101 Pressure of condensate water H bar - 3.5
Valves of per mix bed

NO. Description NO. Tag number Note
1 Polish water inlet valve 1 3-FV-52103 Pneumatic V-ball valve
2 Polish water inlet valve 1 3-FV-52104 Pneumatic V-ball valve
3 Caustic inlet valve 1 3-XV-52121 Pneumatic diaphragm valve
4 Acid inlet valve 1 3-XV-52122 Pneumatic diaphragm valve
6 Heat exchanger inlet valve 1 3-XV-52117 Pneumatic butterfly valve
Heat exchanger bypass
7 1 3-XV-52118 Pneumatic butterfly valve
valve
8 Alkali injector inlet valve 1 3-XV-52119 Pneumatic diaphragm valve
9 Acid mixer inlet valve 1 3-XV-52120 Pneumatic diaphragm valve
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Preparation
Caustic pot inlet valve（3-XV-52121） should be opened to let the caustic level reached
1000mm,while the level is below down 200mm.
Acid pot inlet valve（3-XV-52122） should be opened to let the acid level reached
1000mm,while the level is below down 200mm.
The mix beds regeneration program insists of 4 steps including backwash, resin regeneration,
resin mix, flush:
(1) Backwash
A, opening exhaust valve 3-XV-52111, backwash drain valve 3-XV-52109 and backwash
inlet valve 3-XV-52108, keep backwashing for 15 min;
B, closing backwash inlet valve 3-XV-52108, keep 3-XV-52111 and 3-XV-52109 opening for
5min;
C, opening upper drain valve 3-XV-52114 and keep for about 5min until depth of water above
resin get to 200mm;
D, closing upper drain valve 3-XV-52114, exhaust valve 3-XV-52111 and backwash drain
valve 3-XV-52109;
(2) Resin regeneration
A, the liquid level of caustic pot and acid pot 3-LIT-52100/3-LIT-52101 shall be get to
1000mm, and the temperature of caustic 3-TIT-52101 shall be higher than 32℃;
B, caustic regeneration: opening 3-XV-52115, 3-XV-52112, 3-XV-52113, 3-XV-52119 and 3-

FV-52117, keep for 25min. Meanwhile, heat exchanger inlet flow 3-FIT-52103 is regulated to
25m3/h through interlocking with 3-FV-52103, acid mix inlet valve 3-FIT-52104 is regulated
to 25m3/h through interlocking with 3-FV-52104.
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C, Acid regeneration: opening both acid mixer inlet valve 3-XV-52120 and heat exchanger
bypass valve. Closing both alkali injector valve 3-XV-52119 and the heat exchanger inlet
valve 3-XV-52117. Starting the acid dosing pump 3-PU-5201-P-001A/B, keep for 18 min.
Meanwhile, heat exchanger inlet flow 3-FIT-52103 is regulated to 50m3/h through
interlocking with 3-FV-52103, acid mix inlet valve 3-FIT-52104 is regulated to 50m3/h
through interlocking with 3-FV-52104.
D, Secondary acid regeneration: heat exchanger inlet flow 3-FIT-52103 is regulated to

25m3/h through interlocking with 3-FV-52103, acid mix inlet valve 3-FIT-52104 is regulated
to 25m3/h through interlocking with 3-FV-52104.keep for 26min;
E ,Shut down acid dosing pump3-PU-5201-p-001A/B, closing mixer inlet valve 3-XV-52120,
Keep for 30min;
F. Closing heat exchanger bypass valve3-XV-52118, alkali inlet valve 3-XV-52113,acid inlet
valve3-XV-52112, middle drain valve3-XV-52115,3-FV-52103 and 3-FV-52104, opening
exhaust valve3-XV-52111, inlet valve 3-XV-52106, keep for 5 min;
G. Opening flush drain valve 3-XV-52116, keep for 10min;,
H. Closing 3-XV-52106, opening 3-XV-52114,3-XV-52109,3-XV-52111 keep for 5min, then

the liquid level get to 200mm above resin, and closing 3-XV-52114, 3-XV-52109.
(3) Resin mix
A. Opening exhaust valve 3-XV-52111, air blower exhaust valve 3-XV-52126. Starting air
blower 3-PU-5201-C-001A/B, opening air inlet valve 3-XV-52110, Then closing 3-XV-52126
and keep resin mixing for 2min;
B. Opening air blower exhaust valve 3-XV-52126 and shutting down the air blower 3-PU-
5201-C-001A/B. Then closing 3-XV-52126, air inlet valve 3-XV-52110, opening flush drain
valve 3-XV-52116, keep for 3min;
C. Closing 3-XV-52116, opening inlet valve 3-XV-52106, keep water inflowing until water
outflow from exhaust pipe;
(4) Flush
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Closing exhaust valve 3-XV-52111, open flush drain valve 3-XV-52116, keep flushing for
30min. then the flush water conductivity 3-AIT-52103 become smaller than 0.2μs/cm and Si
become smaller than 20ug/L, the flush program shall be ended.
Alarms
Level of caustic pot<200mm;
Level of acid pot<200mm;
Temperature of condensate water>52℃ or<32℃;
3.1.3.7 Wastewater neutralization sump

Equipments
Neutralized effluent transfer pumps 3-PU-5201-P-002A/B
Air blower 3-PU-5201-C-001A/B
Instruments
pH analyzer 3-AIT-52106
ultrasonic level gauge 3-LIT-52102
level switch 3-LS-52101
in situ pressure gauge 3-PI-52114A/B
in situ pressure gauge 3-PI-52115A/B
Analogues variables
3-LIT-52102 Level of neutralization sump HHL,HL,LLL m 0 6.0
3-LS-52101 Level switch in neutralization sump HHL m 0 0.2
3-AIT-52106 pH meter in neutralization sump 0 14
Wastewater neutralization sump level transmitter and the transfer pumps
The transfer pumps 3-PU-5201-P-002A/B are interlocked with the level transmitter 3-LIT-
52102 in the existing influent buffer tank. Once the level of the sump gets high-high level, the
transfer pumps can be started by liquid level switch 3 - LS - 52101as a double insurance, no
matter what result of the pH analyzer 3-AIT–52106 tested.

Control point LOCAL MCC and MCP (PLC)
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3-PU-5201-P-002A/B EM Stop Running  Local
transfer pump Alarm  Off
Control logic is described as below:

- Remote - The Transfer pump will Start when Influent Buffer Tank is Level High
(Remote) mode High AND Transfer Pump is “REMOTE” selected
- - The system will alarm when influent buffer tank is high high level.
- Stop when Influent Buffer Tank is low low level.
- Manual mode - Start or Stop the Pump Manually at HMI
-
Control set point:

Identification Tag No Described Functional Description Set point
3-LIT-52102 3-LIT- High Level Trigger high high level alarm, indicated at -3.9m
52102 MCP, and start the transfer pump.
3-LIT- Low low Trigger low low level alarm and stop the -5.0m
52102 level transfer pump.
3-LS-52101 3-LS- High Level Trigger high high level alarm, indicated at -3.1m
52101 MCP, and start the transfer pump.
3-AIT-52106 3-AIT- pH Trigger pH＞9，indicated at MCP, and -
52106 start the acid diaphragm valve(3-XV-
52124)
Trigger pH＜6，indicated at MCP, and
start the alkali diaphragm valve(3-XV-
52123)
Remarks: the set points refer to the Appendix 1 Control Philosophy, and the final value will
be adjusted during commissioning.
pH meters
A pH meter 3-AIT-52106 is installed in the wastewater neutralization sump (3-PU-5201-SU-

001). The values are displayed both locally and on HMI.
The pH meter will control the Pneumatic acid diaphragm valve and Pneumatic alkali
diaphragm valve. When the pH exceed 9 , the Pneumatic acid diaphragm valve will start.
While the pH below 6 , the pneumatic alkali diaphragm valve will start.
Blower
In normal working conditions, the blower can provide the compressed air for wastewater
neutralization sump to mix the wastewater. The working time of blower is 20min when
started.
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If pH analyzer 3 - AIT - 52106 is not in the range 6 ~ 9 in this time, the blower will stop, if the
pH is not in this range, the blower stops 5 min (adjustable) after the restart.
The blower will be started and stopped according to the status of pH meters3-AIT-52106.
Control point LOCAL MCC and MCP (PLC)
blower EM Stop Running  Local
Alarm  Off
Control logic in PLC is described as below:

- Remote - When pH analyzer is not in the range 6 ~ 9, the blower be started
(Remote) mode simultaneously.
- When pH analyzer is in the range 6 ~ 9, the blower be stopped
simultaneously.
- Manual mode - Start or Stop the blower
3.1.4 Safety Precautions
This section contains general safety guidelines that workers must follow when installing,
operating, and maintaining POTEN condensate polishing water System equipment. This
section must be read and understood prior to system startup. The guidelines listed here must
be followed at all times to prevent worker injury and equipment damage.
3.1.4.1 General Safety Guidelines
This subsection contains the safety precautions that are common for all POTEN condensate
polishing water equipment.
(1) Operator Training
Equipment operators must be trained in the operation of the equipment and in the proper
handling of any hazardous materials or chemicals. Only experienced operators who have
studied this entire manual should be allowed to operate the equipment.
(2) First-Aid Equipment
First-aid equipment must be available in all hazardous areas, such as acid dosing system.
This must consist of items needed to treat most common injuries and the items required by
the Material Safety Data Sheets (MSDS, supplied by chemical suppliers or equipment
suppliers) for the hazardous chemicals and materials used by the system.
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(3) Equipment Access
Operators must be careful when accessing the equipment. All measures must be taken to
prevent falls and other accidents when equipment is being installed or serviced. Use extreme
caution when working around liquid-treatment equipment. Valve handles, sample pipes, and
other protruding components can cause severe injury to body parts that strike them.
Operators should wear hard hats and safety glasses and should move cautiously when
working under piping and around the equipment.
Climbing on piping can cause worker injury or equipment damage

WARNING due to falls and equipment tipping. Never climb on piping to reach
equipment or components.
If equipment to be installed or serviced is above an operator's normal reach, use safe,

approved ladders or lifting devices to reach the required area.
Avoid using "extension" type or single-run ladders to access equipment, especially if there
are no flat and stable surfaces for a single-run ladder to rest against.
Whenever possible, use a wide, stable folding (free-standing) ladder and tie it to the
equipment or piping.
(4) Protective Personal Equipment (PPE)
Maintain the necessary clothing and equipment to protect operating personnel. For protection
when handling hazardous chemicals or materials, refer to the MSDS supplier by suppliers.
(5) Pressures
The sudden release of pressure from pressurized components

WARNING can cause severe injury to workers.
Relieve all pressure from piping and components before performing service. Extreme caution
must be used when working with high air or liquid pressures. Pressure monitoring devices
must always be installed and working properly. The liquid-treatment system must be
operated within the pressure limits given in the equipment specifications.
(6) Servicing System Components and Equipment
Before performing maintenance on system components and equipment, and especially when
disassembling individual components, the operators must be certain that the components are
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isolated from pressure, fluids, and electricity. Spring-loaded devices, such as valves, must
be in their "relaxed" state - that is, with no compression on the loading spring - to avoid the
sudden and accidental motion of individual parts.
An accidental and sudden release of pressure or fluid, accidental contact with energized
electrical components, or the sudden movement of equipment parts during maintenance
procedures can result in severe injury to workers.
Refer to the individual component literature in the Vendor Literature Manuals for specific
maintenance guidelines.
(7) Electricity (If Applicable)
Electricity can shock, injure, or cause death.

WARNING
Always disconnect and lock out electrical power for panels or
components before performing repairs or service.
Operators and workers must use caution when working with motors, PLC, and other
electrical components. These components must be properly wired and grounded, and
should not be allowed to come in contact with process fluids or other liquids.
PLC and instruments must be properly grounded.
(8) Automatic System Testing (Automatic Units Only)
Improper flows of corrosive chemicals or other liquids during a

WARNING system test run can cause worker injury or equipment damage.
During a test run of a system, all hand valves must remain closed
to prevent the accidental entry of process fluids.
The water in concentrated chemical piping must be purged

CAUTION completely with air. Any water remaining in the piping could cause
overheating when chemicals are introduced.
An automatically-controlled system must be test-run with water prior to the initial operation of
the equipment. Operators must be sure that the entire system operates properly (without
leaks) before using chemicals or process liquids.
(9) Servicing Automatically-Controlled Components (Automatic Units Only)
Accidental and unexpected operation of Auto components can

WARNING
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cause personal injury or death.
If controller programming or program modification is performed

while system components are being serviced, disconnect the
controller output devices or the individual component tubing or
wiring to avoid accidental operation.
Workers must use extreme caution when servicing automatically-controlled components.

Sudden and unexpected operation of components being serviced can cause severe injury to
the workers involved. Before working on automatically controlled components, make sure
that the automatic controller is disabled to the point that it can not be used to operate Auto
components. Close, lock, and tag valves and lockout and tag electrical motor starters and
other electrical devices. Finally, inform other operators and control room workers of repairs
or servicing in progress.
3.2 Original Equipment Manufacturer (OEM) Operation Manual
The original equipment manufacturer operation manuals are listed in attachment.
3.3 Standard Operating Procedure
Once all of the necessary installation, inspection, and controls startup procedures have been
completed, initially startup and successfully commissioned, the condensate water treatment
system can be started up for normal operation.
This section covers Start-Up and Operation procedures for the system as a whole.
Operating personnel should study this entire section before attempting to operate the system.
3.3.1 General Operating Information
3.3.1.1 General Operating Guidelines

(1) Before beginning operation, the operating personnel should certain that all pre-
operation procedures have been completed.
(2) Operating personnel must review Section 3.1.3 - “Control Philosophy Write-up”-
before attempting to operate any portion of the subsystem.
(3) Operating personnel must read and understand each of the equipment in the Vendor
Equipment Literatures before attempting to operate any portion of the equipment.
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(4) In order to insure proper operation, the individual sections must be started up in the
logical sequential order as presented in the P& IDs.
(5) During operation, the operator should refer to any available copy of the POTEN
condensate water system as-built drawings for this plant for information on valve and
instrument locations (the Process and Electrical drawings are included in this manual).
NOTE: This is not intended to be a comprehensive system start-up list and

steps or procedures may be added or deleted based on the performance
of the system and an operator’s experience with the system.
3.3.1.2 Operator Responsibilities

During operation, operating personnel are responsible for several general duties and
functions. These responsibilities are listed below.
(1) The most important responsibility is to follow the guidelines presented in this manual.
It is important that the operating personnel be familiar with the contents of this manual
prior to operating this system. An operator with a good understanding of the system and
its processes will find it easier to avoid operating problems.
It is especially important that all process specifications are maintained at the levels or
the quality listed in Section 2.3.1 and that all necessary equipment has been installed
and checked out as required.
During all startup, online, and shutdown procedures, observe all Safety Precautions
described in Section 3.1.4
(2) Peripheral Equipment Maintenance
In addition to following this manual's guidelines, operating personnel are responsible

for maintaining the peripheral equipment, without which this system cannot operate.
This includes, but is not limited to:
 All applicable pumps must be kept running (when required for a process mode or
step sequence).
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 Any chemical tanks must be kept at full or adequate level.
 All the piping, valves, and vessels must remain leak-free.
 The control system components must be kept in a cool and dry area.
 IA (Instrument Air) supply pressure must be adequately maintained at the
required level.
(3) Automatic Operation
Operating personnel must be certain that any automatic portions of the process controller are
functioning properly (when engaged).
During the initial operating period of the equipment and as operating performance data are
collected, it is normal for the operating personnel to make modifications to the operating
parameters shown on the parameter sheets. These modifications are necessary to optimize,
or "fine tune", the equipment performance.
The operating personnel must be familiar with the methods of resetting the instrument and
controller set points for this system.
(4) Manual Operation
Whenever any normally automatic portion of the system is not operating automatically, it
must be operated manually. The operating personnel must simulate the automatic operation
by performing all the tasks that the controller would normally perform.
All manual actions must be performed by experienced operators who have studied this
manual and who understood the purpose of all-operating modes and step sequences.
(5) Sampling and Testing
During normal operation, and especially during initial startup, operating personnel are
responsible for any process stream samples that must be taken. The operating personnel
must also maintain any necessary sample or production records.
(6) Maintenance and Repairs
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Operating personnel are responsible for reporting any process or mechanical problems, and
must see to it that process problems are resolved and that malfunctioning mechanical
components are repaired.
3.3.2 Plant Start-up Procedures
Refer to the P&ID diagrams and “Control Philosophy Write-up” in Section 3.1.3 for
references.
Usually, the system does not require daily startup and shutdown procedures as it is
automatically controlled to suit operating conditions. However, when the system is to be
startup after a shutdown, follow the below procedures:
Check the required utility supplies are all available and correct, e.g. power voltage,
instrument air pressure. Check all emergency stop switches in unlock position. Check all
local switches in ‘AUTO’ mode.
At the HMI, put the following equipment selector to ‘AUTO’ mode in any sequence.
3-PU-5201-FT-001A~G, 3-PU-5201-FT-002A/B, 3-PU-5201-FT-003A~D,
3-PU-5201-P-001A/B, 3-PU-5201-P-002A/B, 3-PU-5201-C-001A/B,
Press “start” on PLC.
Check the outlet flow rate
Closely monitor the operation of equipment for the first few hours to ensure stable running.
RECORD ALL READINGS (PRESSURE, pH, FLOWRATE, CONDUCTIVITY, Si) FOR

DOCUMENTATION PURPOSES.
3.3.3 Plant Shutdown Procedures
Record all readings (pressure, pH, flowrate, conductivity, Si) prior to shut down for
documentation purposes.
CAUTION: CLOSING THE ISOLATION VALVES OF A PUMP WHILE IT IS IN OPERATION

WILL RESULT IN DAMAGE TO THE PUMP AND/OR THE PIPING DUE TO WATER
HAMMER.
BE CERTAIN TO SHUT OFF EQUIPMENT CONTROLS PRIOR TO CLOSING THE
ISOLATION VALVES.
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3.4 Operational Shutdown
If the system is shut down for a short period, (says several hours), and scheduled to operate
again, simply power down the system is recommended.
Press “stop” on PLC
Select ‘OFF’ mode of the following equipment at the HMI in the any sequence.
3-PU-5201-FT-001A~G, 3-PU-5201-FT-002A/B, 3-PU-5201-FT-003A~D,
3-PU-5201-P-001A/B, 3-PU-5201-P-002A/B, 3-PU-5201-C-001A/B,
If the shutdown is planned to shut down for longer time, (says several days to weeks), follow
the aforementioned step first.
Then drain down the equipment, e.g. neutralization sump, acid pot, caustic pot, heat
exchanger, active carbon filters.
The mix bed should be full of clean water and exchange water at regular intervals.
It is IMPORTENT especially during winter time if freezing is possible. Shut off the utility
supplies, e.g. process condensate water, instrument air.
3.5 Mounting and Assembly Instructions
The installation should be performed by qualified technicians or subcontractors in

accordance with applicable plumbing, wiring, and construction codes & procedures.
For detailed information on installing and inspecting a specific component, refer to the
respective Vendor Equipment Manuals.
(1) Position and level all major components as shown on the plant layout and piping
drawings, paying special attention to elevations and center-to-center dimensions.
(2) If components do not attach easily or line up exactly, apply only a moderate amount
of force to install them. Excessive use of force will put high stress on the components,
which could damage them or cause process stream leaks.
(3) When installing an assembly or instrument, do not tighten the bolts and other
fasteners until all of the adjacent assemblies and instruments have been attached to it.
Then evenly tighten all of the assemblies and instruments at the same time.
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(4) Equipment which requires anchoring to the floor will be equipped with anchored bolt
holes. After positioning, aligning, and leveling each piece of the equipment, anchor it to
the plant floor.
NOTE : Vibration-induced movement of equipment can result in misalignment and
thus damage to the piping component.
(5) Mount all loose instruments to their proper locations. Connect the valve/piping
assemblies. Each valve/piping assembly and instrument is labeled with an item number,
which corresponds to the same item number on the piping drawings.
(6) Be sure that all the installed equipment is braced properly so that only a minimum
amount of stress is put on the components and fasteners.
(7) Fabricate and/or install the interconnecting piping between the major components
and their subassemblies, as required. Brace as needed. Always use piping materials that
are compatible with the process stream fluids.
(8) Install electrical controls, instruments and any loose field enclosures next to the
equipment or instruments they will control, and connect the necessary tubing and/ or
wiring from the enclosures to the equipment valves and instruments.
3.5.1 Pre-operation Guidelines
Prior to start-up, the operating personnel should ensure that all equipment, piping, and M&E
components are properly installed according to the piping, wiring, and layout drawings for
this job.
All contractor and assembly works are complete.
All feed reclaim water and other supply systems are connected and operational.
All customer-supplied and utility connections are complete.
Pumps, valves, and other mechanical components have been checked for proper operation.
All instruments have been checked and calibrated.
All piping and vessels have been flushed (where applicable).
All pressure-testing of piping and vessels are complete (where applicable).
The following drawings and documents should be used as reference:
P& ID
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GENERAL ARRANGEMENT FOR CONDENSATE POLISHING PACKAGE.

3.5.2 Chemical System Installation
Because of the potential hazards associated with any chemical feed system, special
attention must be paid to the installation of their components.
(1) Position any chemical piping assemblies as indicated on the plant layout.
(2) Always use chemically resistant materials for the chemical system components.
(3) All supplied caution and warning labels must be installed and maintained at the
chemical storage tanks and nearby facilities. Material safety data sheets (MSDS) should
also be made available at site (from the chemical supplier).
(4) If check valves or chemical ejectors are used, verify that they are installed for the
proper flow direction.
(5) When the installation is complete, the entire chemical system must be pressure
tested with water before actual chemicals are introduced.
3.5.3 Pump and blower Installation
(1) All pumps and blowers must be leveled, aligned, piped, wired, lubricated, and
checked for proper rotation.
(2) Do not couple 3-phase pump or blower motors until proper rotational direction has
been checked.
(3) Many pump and blower manufacturer ship their goods without lubricants installed;
these lubricants are often shipped in separate containers. After pumps and blowers are
mounted and aligned, the proper types and quantities of gear lubricants should be
located and installed.
3.5.4 Interconnection Piping
Make sure all customer-supplied piping must be connected and operational before the
POTEN condensate water system equipment can be operated.
3.5.5 Drainage Piping
(1) The drain piping can be piped into common headers to drain or can be piped
individually to a sump, drain trench, or any open drain.
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(2) Open drains make it easier to take samples and allow for visual observation by the
operator.
(3) If the drain flow contains hazardous or corrosive fluids, be sure to use proper piping
materials that will resist these chemicals.
3.5.6 Tubing & Wiring
Make sure that all customer-supplied tubing of control valves and wiring of instruments must
be completed and operational before the POTEN condensate water system equipment can
be operated.
3.5.7 Electrical Supply
Proper wiring connections are required for controllers, pumps, instruments, etc. Refer to the
POTEN condensate water system wiring diagrams for specific power requirements.
3.5.8 Air Supply
Dry, oil-free clean air is required for the pneumatic valve operation. Air must be filtered to
remove moisture, oil, and particulate.
3.5.9 Control Valves
All control valves should be properly installed and checked for functional operation.
These tests are intended to ensure that the control valves are opening, closing and sealing
properly.
(1) To check for inward leaks, close the valve and pressurize all inlet and outlet headers
with water. Open all manifold sample valves and allow the manifold to drain. If the water
continues to flow from a sample valve after the manifold is drained, a leaking valve is
indicated.
(2) To check for outward leaks, pressurize the vessel and manifold piping with water.
Close all valves and drain any accessible inlet and outlet headers. If the water continues
to flow from the inlet and outlet headers after they are drained, a leaking valve is
indicated.
(3) Valves must be able to hold pressure for a minimum of one (1) hour. Any leaking
valve must be adjusted, repaired, or replaced and then re-tested before the system is
operated.
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3.5.10 Instruments
All instruments should be properly installed, calibrated, and checked for functional operation.
All set-points should be verified.
(1) Where applicable, impulse lines and instruments shall be flushed and/or drained as
required by the application.
(2) The performance of the instruments shall be observed; for flow transmitters the zero
indications shall be checked under operating pressure.
(3) Any abnormal behavior of the instruments (or process) shall be corrected.
(4) Where applicable, controller settings for the proportional, proportional & integral, and
PID control actions shall be optimized and recorded.
3.5.11 PLC
The automatic process controls must be fully functional before most of the equipment can be
started. The operator must become familiar with the process controls at some point prior to
the actual start-up of the system. The operator will be required to make some set-point value
changes during the normal course of the operation of the system.
(1) All program set-point values must be checked and reset as necessary. When all
program set-point values have been checked out, the program can be test run to verify
that all step sequences are correct and that the output devices function properly.
(2) During a test run of the control program, the operator must verify that the correct
process valves open (if supplied with oil-free dry compressed air), the correct process
pump starters are energized, and that other output devices are activated.
(3) For some modes and steps, inputs from field instruments may have to be simulated
or the instruments “jumped” to prevent alarms and to allow the modes or steps to
proceed.
(4) When all of the output circuitry has been tested successfully, the field inputs from
sensing elements from the field devices and verify that these signals are being received
by the control monitor elements and other devices must be tested. The instrument
technician must simulate input signals
37
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4 MAINTENANCE MANUAL
4.1 Regular Maintenance Instruction
General Guidelines
Maintenance personnel should have a thorough understanding of the Safety Procedures

given in Section 3.1.4 before attempting repairs or maintenance of any equipment.
(1) Before working on any of the components and equipment used with this system, the
operators must read and understand the Safety Precautions described in Section 3.1.4
of this manual. Of special importance are the areas of equipment access, pressures,
and servicing system components, and the precautions specific to the types of
equipment in your system.
(2) Maintenance procedures should be performed only by experienced technicians or

maintenance operators who are familiar with the types of components and equipment
used with this system.
(3) Operators who perform maintenance on the components and equipment used with
this system should read and follow all instructions and procedures given in the Vendor
Literature Manuals.
(4) Before attempting to perform maintenance on system components and equipment,

and especially when attempting to disassemble individual components, the operators
must be certain that the components are isolated from pressure, fluids, and electricity.
(5) Spring-loaded devices, such as valves, should be in their "relaxed" state - that is, with
no compression on the loading spring - to avoid the sudden and accidental motion of
individual parts.
(6) The table on the next page contains typical schedules for maintenance of the most
commonly-used system components. This should be used as a general guideline
only; for actual maintenance frequencies, refer to the component instructions in the
Vendor Literature Manuals.
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4.1.1 Maintenance Procedure Recommended Interval
All Systems
Influent and effluent Every 6months or as

liquid samples required for diagnostic purposes
Supports, platform and component As required

painting
Vessel and piping leak Weekly
inspection
Valve operation and As required

leak checking
Instrumentation Every 6 months
independent lab check
PLC & component maintenance Weekly

(automatic unit only)
Liquid contamination of Weekly
Pump and gear lubricants

(if applicable)
39
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4.1.2 COMPONENTS MAINTENANCE
This subsection contains general maintenance procedures for the component types that are
most often used on POTEN condensate water systems but NOT included in the Vendor
Literature Manuals.
The maintenance procedures for all other components on your system are covered by the
component manufacturer's instructions in the Vendor Literature Manuals.
(1) Piping
The main piping on the system vessels may be carbon steel, stainless steel and CPVC
pipe. Any fasteners used on this piping may need periodic tightening to prevent leaks. If the
system is operated within the temperature and pressure limitations given in this manual, little
or no maintenance is required.
(2) Electrical Enclosures
Sparks from components in control enclosures can cause

WARNING explosions in hazardous atmospheres. If explosion-proof
enclosures are used with this system, extra caution must be used
when working with the enclosures.
Be certain that all power is removed from an explosion-proof

enclosure before opening it. If the enclosure is equipped with a
power/door interlock, check the interlock occasionally to be sure
it functions properly.
If purge-type enclosures are used with this system be certain that the purge equipment is
installed correctly and is operating properly.
Any solenoid or other electrical enclosures must be checked occasionally to ensure that the
doors are closed tightly and are latched or fastened properly. Water and other fluids must
not enter the enclosures.
(3) Contact Switches

Externally-mounted switches (on valves, pumps, etc.) should be checked periodically for
corrosion, debris, and loose or broken wires.
Switches that are used to initiate step, modes, or alarms (flow or pressure switches, for
example) should be checked for calibration occasionally. Also, any limit switches used on the
control valves may have to be adjusted periodically.
(4) All Vessels
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The vessels should provide many years of service with only minimal exterior maintenance
(painting), provided the system is operated within the design pressure and temperature
limitations.
If vessels are installed outside and are exposed to freezing temperatures, the vessels and
their piping must be insulated and heated or else must be shut down and drained.
If vessels are stored outside and are exposed to freezing temperatures, they must be
completely drained and must be handled carefully when moved.
(5) Strainer Screens ( Vessel Outlets )
Many systems have protective devices on the vessel outlets designed to guard against solids
to protect transfer pump, Barring this unlikely circumstance, the strainer screens require no
maintenance other than an occasional cleaning.
If sight strainers are removed from the pipe lines, be certain to

CAUTION reinstall them in the correct positions.
As shown on the blueprints for this job, strainer elements must point "upstream" when
installed in the piping runs.
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4.2 Trouble Shooting
This section describes some of the common problems that can occur during operation of this
system and the steps an operator can take in finding their causes. Because the best
troubleshooting tool an operator can have is his knowledge of the normal system operation, it
is recommended that the operator reads and be familiar with the rest of this manual prior to
using this section. During the first few month of system operation operators should carefully
observe and note normal operation characteristics for future reference.
If process problems develop, it is critical that operators have a complete record of the past
operating performance of the system. It is vital that operators maintain an operating logbook
throughout the life of the system.
4.2.1 General Trouble Shooting Tips
(1) The most helpful tool in troubleshooting problems is the operator's knowledge of the
normal operating conditions. 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. Many problems occur because the system is no longer operating under the
conditions stated in this manual.
Selected sampling and testing procedures should be performed regularly during the
operation of this system. While the actual frequency of sampling and testing is at the
discretion of the customer, any tests used with this system must be performed on a regular
basis and must be accurately recorded in a log book.
A well-kept log book of test dates and results and of operator observations is an invaluable
tool for troubleshooting future performance problems.
(2) . Double-check for problem symptoms to be sure that a problem really exists. An
inaccurate instrument or a temporary change in feed water quality, pressure or flow rate
can indicate a problem where none exists.
(3) Don't overlook these simple problems.
A hand valve that is closed
The power turned off to a pump
Wires cut or disconnected
Equipment damaged or missing
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Valve solenoids manually overridden
Incorrect control set points in the process controller
(4) To troubleshoot flow blockage, locate any large pressure drop and investigate all the
equipment in that area until the source of the blockage is found.
(5) To troubleshoot electrical problems, first identify the control flow pattern, which is the
pathway 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 (where applicable).
(6) To troubleshoot an instrumentation problem, refer to the instrument manufacture's

service literature in the Vendor Literature Manual.
(7) To troubleshoot problems with other pieces to equipment, refer to the information
available in the component manufacture's service literature in the Vendor Literature
Manual.
4.2.2 Troubleshooting Guide
This section contains the information on the troubleshooting of some common phenomena
and/or alarms. Please read also the troubleshooting section of Manufacturer’s Data for
individual equipment. Also, none of the charts presented here should be considered to be
exclusive; these charts are intended to point out the most likely causes of the listed problems.
IItem Phenomenon / Alarm Cause and Remedial Action

1 Caustic pot - Defective level switch or improper setting level
Level high high alarm - Level switch entangled
(LAHH, 3-LIT-52100) - Defective pneumatic valve (XV-52121)
Level low low alarm - Level transmitter entangled
(LALL, 3-LIT-52100)
3 Acid pot - Defective level switch or improper setting level
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(LALL, 3-LIT-52101) - Emergence stop the dosing pump (3-PU-5201-P-
001A/B) locked
5 Wastewater - Defective level switch or improper setting level
neutralization sump
- Level switch entangled
Level high high alarm
- Defective neutralization pump (3-PU-5201-P-002A/B)
(LAHH, 3-LIT-52102)
6 Wastewater neutralization - Defective level switch or improper setting level
sump
- Level transmitter entangled
Level low low alarm
- Emergence stop the wastewater transfer pump (3-PU-
(LALL, 3-LIT-52102) 5201-P-002A/B) locked
7 The flow rate(FIT-52100) - Air accumulated in the suction pipe
is lower than normal from
- Something block in the suction pipe
neutralized wastewater
transfer pump (3-PU- - Shut down the pump and air blower, flush the suction
5201-P-002A/B) pipe, fulfill the pipe with water
8 The resin leaks from - Backwashing intensity is higher than normal scope.
backwash pipe when the
- Control the backwashing intensity under normal scope
mix bed is in backwash
procedure,
9 The cation resin and - The resin has not lose efficiency completely,
anion resin bond
- The resin has been contaminated
together, resulting in
mixing between these two - Run the mix bed with 5% NaOH liquid to change the
resin layers resin into Na-cation resin and OH-anion resin
10 The color of the resin - Fe3+ concentration is out of limit
become dark or black and
- Treat the resin with 10%~15% HCl liquid，immersing
the exchange capacity of
the resin is lower than for one or two days.
normal.
44
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4.3 Preventive Maintenance
In addition to the maintenance guidelines listed in Section 4.1 and in the Vendor Literature
Manuals, the operating personnel should be aware of further steps that can be taken to avoid
specific problems. Some common problem areas are listed below.
4.3.1 All Systems
(1) Equipment Problems

Always be sure to operate each piece of equipment within the ranges (flow rate, pressure,
temperature, voltage, etc.) specified by the manufacturer's service literature.
(2) Valve and Piping Problems
Make sure the valves are not opening and closing too fast; this can result in a "hammer"
effect, causing leaky valves and piping. The action of automatic valves controlled by
pneumatic solenoids can be slowed by adjusting the air metering screws on the solenoids.
Operators must verify that all valves close completely. A valve that does not shut tightly can
cause contaminants to leak into the product stream.
(3) Instrument Problems

Be sure the piping is braced securely enough to avoid vibration damage of instruments. Also,
keep dust and water out of instruments.
For pH meters, be sure that the metering probe should always immersed in water to keep
wet.
Instruments such as pressure gauges and pH meters should be cleaned, inspected, and
calibrated periodically. A faulty sensing instrument may indicate a problem where one does
not exist, or may not indicate a problem that does exist.
Instruments can be damaged by excessive vibrations. Instruments that are field-mounted

must be installed in a location that is relatively free of vibrations and impact shocks.
When instruments are mounted on piping at the equipment, the piping must be braced
securely to prevent instrument damage from vibrations and shocks caused by such problems
as water hammer.
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Instruments should be calibrated periodically to avoid erroneous readings. A malfunctioning

instrument may not indicate a problem that exists, resulting in equipment damage or
extended downtime.
(4) Pressure Drops
Operators should monitor the pressure gauges on each piece of equipment to detect
excessive pressure drops. Excessive pressure drops can give an early indication of problems
such as valve or pump malfunction.
(5) Disassembly and Re-assembly of System Components
When workers must disassemble and then reassemble system components, they should
refer to the component instructions in the Vendor Literature Manual and Section 3.5 of the
Operation Manual.
(6) Tightening of System Components
When threaded system components are installed and tightened, correct torque specifications
must be adhered to. Under tightening can cause leakage and over tightening can cause
stripped threads, warped parts, breakage, and leakage.
When flanged components are installed and tightened, alignment of gaskets must be correct
before tightening the clamp. Follow the torque specifications found in the "vendor's literature"
section.
Permanent damage to the gaskets can result if not aligned properly before tightening the
clamps.
(7) System Leaks
Operators should, at all times, be alert for leaking pipes, valves, or other system components.
Detecting and repairing a leak when it is still small may prevent lengthy downtime later.
Influent and effluent sampling and testing should be performed on a regular basis. This will
help to detect changes in operating performance before a major upset occurs.
VWS strongly recommends that a log book be maintained on a daily basis. Such data as flow
rate, pH of feed water, each adjustment tank and treated water can be invaluable if problems
develop in the future.
(9) Feed Quality
The process feed must be within specifications stated in Section 2.1.
46
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It is important that the feed quality guidelines suggested in this manual be followed. Since
the system has been designed according to these guidelines, overloading the system may
result in failure to reach the treatment requirement
Be sure that conduit connections are tight. In wet environments conduit connections
should be sealed with silicon sealer.
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4.3.2 Chemical Systems
(1) System Leaks
Leaks at chemical components can cause equipment damage and

WARNING human injury.
If leaks develop at the chemical dosing system or its piping,

immediately shut down the system, relieve all pressure, and
repair the leaks.
(2) Chemicals for pH adjustment
Each chemical must be made consistently at the required concentrations. If the chemical are
too dilute, the pH adjustment may be unsuccessful; if the chemical are too concentrated
especially for caustic, they could cause crystallization to block the pumps and piping.
Finally, be sure that the entire chemical dosing system (piping, pumps, ejectors, etc.) is
functioning properly.
4.3.3 Blowers and Pumps
Make sure all pumps have seal water (where applicable) and are equipped with a device to
relieve excessive pressure on the discharge line, such as a pressure relief valve (where
applicable). Do not allow the tank feeding the pump to run dry; install controls to shut the
pump off on low storage tank level, if necessary.
Adjust the closing of valves and the starting and stopping of pumps to avoid a water surge or
"hammer" against the pumps.
Operators should be alert for unusual noises, vibrations, or odors from electric motors.
Detecting a problem early may reduce equipment damage and downtime.
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5 SPARE PARTS
5.1 General Guideline
Most of the time failure or malfunction of equipment can be repaired in short period if the
required parts are available. In fact, ordering a part takes several days to months for
delivery usually. Therefore, maintaining an adequate level of spare parts is essential for
smooth and stable long-term running of the Waste Water System.
To order spare parts, always quote the description, part no., model no. of the equipment to
make sure the correct part is referred. The information of the main equipment and
instruments are detailed in the chapter 2.3.1
5.2 Recommended Spare Parts List
Equipment
Spare part Specification Material Units Quantity
name
gasket 8", 5mm EPDM PIC. 56
carbon filter bolt M20*90mm SA193 B7/SA194 2H PIC. 23
bolt M32*150mm SA193 B7/SA194 2H PIC. 7
cap M24 SS304 PIC. 10
mix bed gasket 2", 5mm EPDM PIC. 8
cap M24 SS316L PIC. 8
gasket 3", 3mm grafoil filler+SS316L PIC. 2
gasket 4", 3mm grafoil filler+SS316L PIC. 1
heat exchanger
gasket 1 1/2", 3mm grafoil filler+SS316L PIC. 1
bolt M16*70mm A516 PIC. 12
bolt M12*300mm PIC. 8
dosing pump
gasket 1" PTFE PIC. 4
nutr. transfer
cap PP PIC. 10
pump
reference liquid conductivity SET 1
instrument reference liquid pH SET 1
pressure gauge YTN-100H PIC. 2
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pressure gauge YTNP-100HF2B PIC. 1

3/4",GASKET,CL1
GASK 50,4.5MM, EPDM PIC. 1
RF,ASME B16.20,
2",GASKET,CL15
RF,ASME B16.20
3",GASKET,CL15
RF,ASME B16.20,
4",GASKET,CL15
RF,ASME B16.20,
6"GASKET,CL150
GASK ,4.5MM, EPDM PIC. 32
RF,ASME B16.20,
8"GASKET,CL150
RF,ASME B16.20,
10"GASKET,CL15
pipe
RF,ASME B16.20,
NON-ASBESTOS JOINT
1"CL150, 2.3 MM,
GASK SHEET GASKET COVERED PIC. 5
RF,ASME B16.21
WITH PTFE ENVELOPE,
1 1/2",CL150, 2.3 NON-ASBESTOS JOINT
GASK MM, RF,ASME SHEET GASKET COVERED PIC. 1
B16.21 WITH PTFE ENVELOPE,
NON-ASBESTOS JOINT
2" CL150, 2.3 MM,
GASK SHEET GASKET COVERED PIC. 1
RF,ASME B16.21
WITH PTFE ENVELOPE,
SPIRAL WOUND
GASKET,AISI 304 +
3/4",CL150,4.5MM
GASK GRAFOIL FILLER, CS PIC. 1
,
OUTER RING, RF,ASME
B16.20
1"GASKET,CL150
RF,ASME B16.20,
SPIRAL WOUND
GASK 1 1/2" PIC. 2
GASKET,CL150,4.5MM,AISI
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304 + GRAFOIL FILLER, CS

OUTER RING, RF,ASME
B16.20
SPIRAL WOUND
GASK 3 304 + GRAFOIL FILLER, CS PIC. 1
OUTER RING, RF,ASME
B16.20
SPIRAL WOUND
GASK 4 304 + GRAFOIL FILLER, CS PIC. 1
OUTER RING, RF,ASME
B16.20
GASKET,CL150,4.5MM,
GASK 1 1/2 PIC. 6
RF,ASME B16.20,EPDM
100,U Bolt to grip

U Bolt Nuts & A100 Pipe, C/W 2 BS EN10 025 Grade FE 430A
SET 12
Locknuts M16 Nuts & or Equivalent
Locknuts
150,U Bolt to grip
SET 8
Locknuts
200,U Bolt to grip
SET 6
Locknuts
25,U Bolt to grip
SET 1
Locknuts
250,U Bolt to grip
SET 7
Locknuts
40,U Bolt to grip
SET 6
Locknuts
U Bolt Nuts & 50,U Bolt to grip BS EN10 025 Grade FE 430A
SET 12
Locknuts A100 Pipe, C/W 2 or Equivalent
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M16 Nuts &

Locknuts
ASME A193 GR.B7，ASME

Bolt&Nuts M14×70 A194 GR2H, ASME B1.1 SET 78
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
NUC，ASME B18.2
ASME B1.1 NUC，ASME

Bolt&Nuts M22×190 SET 2
B18.2.2
ASME B1.1 NUC，ASME

Bolt&Nuts M20×180 SET 59
B18.2.2
Fuses 30A/250V Electronic Component Pic. 2

SCR 100A/1600V Electronic Component Pic. 1
UPS
Signaling lamps
and protection Green Electronic Component Pic. 2
device
52
LORDEGAN UREA
FERTILIZER
Lordegan
HAMPA Project No.:
Project No.: 2103
Diod 4148 Electronic Component Pic. 4
6 COMMISSIONING MANUAL
6.1 Regular Maintenance Instruction
General Guidelines
Maintenance personnel should have a thorough understanding of the Safety Procedures

given in Section 3.1.4 before attempting repairs or maintenance of any equipment.
(7) Before working on any of the components and equipment used with this system, the
operators must read and understand the Safety Precautions described in Section 3.1.4
of this manual. Of special importance are the areas of equipment access, pressures,
and servicing system components, and the precautions specific to the types of
equipment in your system.
(8) Maintenance procedures should be performed only by experienced technicians or

maintenance operators who are familiar with the types of components and equipment
used with this system.
(9) Operators who perform maintenance on the components and equipment used with
this system should read and follow all instructions and procedures given in the Vendor
Literature Manuals.
(10) Before attempting to perform maintenance on system components and equipment,

and especially when attempting to disassemble individual components, the operators
must be certain that the components are isolated from pressure, fluids, and electricity.
(11) Spring-loaded devices, such as valves, should be in their "relaxed" state - that is,
with no compression on the loading spring - to avoid the sudden and accidental motion
of individual parts.
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(12) The table on the next page contains typical schedules for maintenance of the most
commonly-used system components. This should be used as a general guideline
only; for actual maintenance frequencies, refer to the component instructions in the
Vendor Literature Manuals.
Maintenance Procedure Recommended Interval
All Systems
Flushing and backwashing every 6months or as
Liquid samples required for diagnostic purposes
Supports, platform and component as required
Painting
Vessel and piping leak Weekly
Inspection
Valve operation and as required
Leak checking
Instrumentation Every 6 months
Independent lab check
PLC & component maintenance weekly
(Automatic unit only)
Liquid contamination of Weekly
Pump and gear lubricants
(If applicable)
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This subsection contains general maintenance procedures for the component types that are
most often used on POTEN condensate water systems but NOT included in the Vendor
Literature Manuals.
The maintenance procedures for all other components on your system are covered by the
component manufacturer's instructions in the Vendor Literature Manuals.
(6) Piping
The main piping on the system vessels may be carbon steel, stainless steel and CPVC
pipe. Any fasteners used on this piping may need periodic tightening to prevent leaks. If
the system is operated within the temperature and pressure limitations given in this manual,
little or no maintenance is required.
(7) Electrical Enclosures
Sparks from components in control enclosures can cause

WARNING explosions in hazardous atmospheres. If explosion-proof
enclosures are used with this system, extra caution must be
used when working with the enclosures.
Be certain that all power is removed from an explosion-proof

enclosure before opening it. If the enclosure is equipped with a
power/door interlock, check the interlock occasionally to be
sure it functions properly.
If purge-type enclosures are used with this system be certain that the purge equipment is
installed correctly and is operating properly.
Any solenoid or other electrical enclosures must be checked occasionally to ensure that the
doors are closed tightly and are latched or fastened properly. Water and other fluids must
not enter the enclosures.
(8) Contact Switches
Externally-mounted switches (on valves, pumps, etc.) should be checked periodically for
corrosion, debris, and loose or broken wires.
55
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Switches that are used to initiate step, modes, or alarms (flow or pressure switches, for
example) should be checked for calibration occasionally. Also, any limit switches used on
the control valves may have to be adjusted periodically.
(9) All Vessels
The vessels should provide many years of service with only minimal exterior maintenance
(painting), provided the system is operated within the design pressure and temperature
limitations.
If vessels are installed outside and are exposed to freezing temperatures, the vessels and
their piping must be insulated and heated or else must be shut down and drained.
If vessels are stored outside and are exposed to freezing temperatures, they must be
completely drained and must be handled carefully when moved.
(10) Strainer Screens ( Vessel Outlets )
Many systems have protective devices on the vessel outlets designed to guard against
solids to protect transfer pump, Barring this unlikely circumstance, the strainer screens
require no maintenance other than an occasional cleaning.
If sight strainers are removed from the pipe lines, be certain to

CAUTION reinstall them in the correct positions.
As shown on the blueprints for this job, strainer elements must point "upstream" when
installed in the piping runs.
6.2 Commissioning procedures
6.2.1 Active Carbon Filter
1) Active Carbon Filter Configuration

There are seven active carbon filters. Equipment contains own valve and communal valve.
(1) Single active carbon filter valve

ite stand
description quantity Tag NO. remarks
m by
56
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3-XV- On-off type pneumatic butterfly

1 Inlet valve 1
52100A~G valve

2 Produced water valve 1
52101A~G valve

3 Backwash inlet valve 1
52102A~G valve
Backwash discharge 3-XV- On-off type pneumatic butterfly

4 1
valve 52103A~G valve
Flushing discharge 3-XV- On-off type pneumatic butterfly

5 1
valve 52104A~G valve

6 Vent valve 1
52105A~G valve
(2) Communal valve
ite quantit
description standby Tag NO. remarks
m y
Backwash main pipe self-regulating regulating

1 1 3-PV-52100
self-regulating valve valve
Inlet main pipe air On-off type pneumatic

2 1 3-XV-52127
power butterfly valve butterfly valve
(3) Instrument
ite quantit
description standby Tag NO. remarks
m y
Water inlet electrical

1 1 3-AIT-52100 Pipe installation
conductivity analyzer
Water inlet
2 temperature 1 3-TIT-52100 Pipe installation
transmitter
Backwash pressure
3 1 3-PIT-52100 Pipe installation
transmitter.
Pressure difference 3-PDS-

4 1
switch 52100A~G
57
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2) Single active carbon filter commissioning procedure

(1) Commissioning
A. Commissioning condition
a) It will alarm when the temperature of the inlet pipe transmitter 3-TIT-52100 measure
the water temperature above 50 ℃ (adjustable) or inlet water main pipe pneumatic
butterfly valve 3-XV-52127 will be closed when the water inlet electrical conductivity
analyzer 3-AIT-52100 is higher than 30 S/cm (adjustable). The procedure cannot run.
b) Backwash pipe regulating valve 3-PCV-52100 will control pressure about 2.5barg,
pressure transmitter 3-pit -52100 measures backwash pressure.
B. Commissioning procedure
a) Open inlet main pipe pneumatic butterfly valve 3-XV-52127
b) Open inlet water valve 3-XV-52100A~G and vent valve 3-XV-52105A~G, keep
venting for 60 seconds.
c) Open produced water valve 3-XV-52101A~G, close vent valve 3-XV-52105A~G.
Note: seven filters can run independently.
(2) backwash
A Commissioning condition
a) Each active carbon filter enters the "backwash" program when it runs a cumulative
24h (adjustable);
b) Some active carbon filter enter the "backwash" program when pressure difference
switch 3-PDS-52100A~G is up to the setting 1.0 barg (adjustable) ;
c) It will alarm when inlet water temperature transmitter 3-TIT-52100 measure

temperature higher than 52℃ and backwash program cannot run ;
d) The requirement of some filter run backwash program is that the other six filters are
in the run program. Otherwise it can run the backwash program until the other six
filters finish the backwash program.
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a) Close inlet water valve 3-XV-52100A~G and produced discharge valve 3-XV-
52101A~G;
b) Open flushing discharge valve 3-XV-52104 A~G for 7min, and close it until the
water level is down to 100mm above filter material.
c) Open backwash discharge valve 3-XV-52103A~G and backwash inlet valve 3-XV-
52102A~G, open vent valve. Run the backwash program for 20min (adjustable);
d) Close backwash inlet valve 3-XV-52102A~G, after standing for 3min (adjustable),
close backwash discharge valve 3-XV-52103A~G.
Note: seven filters can backwash independently.
(3) Flushing
a) Run flushing program after the backwash program;
b) It will alarm when inlet water temperature transmitter 3-TIT-52100 measure

temperature higher than 52℃ and flushing program cannot run ;
a) The filter will run flushing program after backwash.
b) Open vent valve 3-XV-52105A~G and open inlet valve 3-XV-52100A~G to fill water
for 20s (adjustable);
c) Open flushing discharge valve 3-XV-52104A~G and close vent valve 3-XV-
52105A~G then run flushing program for 10min (adjustable).
3) Instrument interlocking condition

The interlocking condition of the activated carbon filter meter is shown in the following two
documents:
（1） Instrument information table - interlocking condition table.
59
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（2） 2103-G-VD-101-007 Cause and Effect diagram
Control sequence diagram of activated carbon filter system
60
LORDEGAN UREA FERTILIZER
PROJECT Lordegan
UREA FERTILIZER CO. (PUBLIC STOCK)
HAMPA Project No.:
Project No.: 2103
Table 1 Control sequence diagram of activated carbon filter system
Inlet
Backwash Flushing
main Produced Backwash remar
item Inlet valve discharge discharge Vent valve time
pipe valve inlet valve k
valve valve
Step sequence valve
3-XV- 3-XV- 3-XV- 3-XV- 3-XV- 3-XV- 3-XV-

52127 52100A~G 52101A~G 52102A~G 52103A~G 52104A~G 52105A~G
1 Standby × × × × × × ×
60s
2 vent ○ ○ × × × × ○
（adjustable）
24h
3 run ○ ○ ○ × × × ×
（adjustable）
7min
4 discharge ○ × × × × ○ ○
（adjustable）
backwash
Valve
5 ○ × × ○ ○ × ○ 5s
opening
61
PROJECT Lordegan
HAMPA Project No.:
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Inlet
Backwash Flushing
main Produced Backwash remar
item Inlet valve discharge discharge Vent valve time
pipe valve inlet valve k
valve valve
Step sequence valve
3-XV- 3-XV- 3-XV- 3-XV- 3-XV- 3-XV- 3-XV-

52127 52100A~G 52101A~G 52102A~G 52103A~G 52104A~G 52105A~G
20min
6 backwash ○ × × ○ ○ × ○
（adjustable）
3min
7 standing ○ × × × ○ × ○
（adjustable）
Valve
8 ○ ○ × × × × ○ 5s
opening
flushing
Water 20s
9 ○ ○ × × × × ○
filling （adjustable）
15min
10 flushing ○ ○ × × × ○ ×
（adjustable）
Explanation:
（1） ○—start/open,×—stop/close;
62
PROJECT Lordegan
HAMPA Project No.:
Project No.: 2103
（2） The sequence diagram is made by single filter；
（3） Start from standby mode in 1-2-3-4-5-6-7-8-9-10 step sequence, the automatic operation cycle will be automatically carried out in 3-4-5-6-7-8-9-10-3
step sequence.
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6.2.2 Mixed Bed
1) Mix bed configuration

There are 4 sets mix bed 3-PU-5201-FT-003A~D, two are on duty and two are standby.
(1) Single set of mix bed

quantit
item description standby Tag NO. remarks
y
On-off type
1 Inlet valve 1 - 3-XV-52106 pneumatic butterfly
valve
On-off type
Produced discharge
2 1 - 3-XV-52107 pneumatic butterfly
valve
valve
On-off type
3 Backwash inlet valve 1 - 3-XV-52108 pneumatic
diaphragm valve
On-off type
Backwash discharge
4 1 - 3-XV-52109 pneumatic
valve
diaphragm valve
On-off type
5 Intake valve 1 - 3-XV-52110 pneumatic butterfly
valve
On-off type
6 Vent valve 1 - 3-XV-52111 pneumatic
diaphragm valve
On-off type
7 Sulfuric acid valve 1 - 3-XV-52112 pneumatic
diaphragm valve
On-off type
8 Caustic valve 1 - 3-XV-52113 pneumatic
diaphragm valve
On-off type
9 Top discharge valve 1 - 3-XV-52114 pneumatic
diaphragm valve
On-off type
Middle discharge
valve
diaphragm valve
On-off type
Flushing discharge
valve
diaphragm valve
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(2) Mix bed communal equipment

quantit
y
Hydraulic
Sulfuric acid metering 3-PU-5201-P-
1 2 1 diaphragm
pump 001A/B
metering pump.
On-off type
Caustic meter box
outlet valve
diaphragm valve
On-off type
Sulfuric acid metering
pump outlet valve
diaphragm valve
On-off type
Caustic meter box
inlet valve
diaphragm valve
On-off type
Sulfuric acid meter
box inlet valve
diaphragm valve
Caustic regeneration
On-off type
heat exchanger cold
refrigerant inlet
valve
control valve
Caustic regeneration
On-off type
heat exchanger cold
refrigerant by-pass
valve
valve
Caustic regeneration Flange type

8 heat exchanger heat 1 - 3-TV-52101 pneumatic control
medium inlet valve valve
Caustic regeneration Flange type

9 heat exchanger cold 1 - 3-FV-52103 pneumatic control
refrigerant inlet valve valve
Flange type
Sulfuric acid pipe
10 1 - 3-FV-52104 pneumatic control
mixer water inlet valve
valve
3-PU-5201-C-
11 Blower 2 1 Roots blower
001A/B
12 1 - 3-XV-52126 On-off type

Booster pneumatic
pneumatic butterfly
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vent valve valve
(3) 相关仪表：Instrument
quantit
y
Differential pressure 3-PDS-

1 4 - Mixer ben
switch 52102A~D
2 Conductivity analyzer 4 - 3-AIT-52103A~D Mixer bed
Mixer bed, triple

3 Silicon analyzer 1 - 3-AIT-52102
channel
3-AIT-52101 Mixer bed

4 pH analyzer 1 - produced water
main pipe
Caustic metering
5 Magnetic flip gauge 1 - 3-LIT-52100
box
Sulfuric metering
6 Magnetic flip gauge 1 - 3-LIT-52101
box
Caustic
Temperature regeneration heat
7 1 - 3-TIT-52101
transmitter exchanger cold
refrigerant outlet
Caustic
Vortex shedding regeneration heat
8 1 - 3-FIT-52103
flowmeter exchanger cold
refrigerant inlet
Vortex shedding Sulfuric pipe mixer

9 1 - 3-FIT-52104
flowmeter water inlet
2) Single mixer bed commissioning procedure

(1) Commissioning
Go into mixer bed commissioning procedure
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B. Commisstioning step sequence
a) Open mixer bed vent valve 3-XV-52111 and mixer bed inlet valve 3-XV-52106, fill
water and vent for 6 min (adjustable, vent valve is out of water)
b) Open mixer flushing discharge valve 3-XV-52116 and close vent valve 3-XV-52111
simultaneously.
c) Monitor conductivity for 5min when it is flushing. Open produced discharge valve 3-
XV-52107 when conductivity lower than 0.2μs/cm (adjustable), close flushing
discharge valve. Go into commissioning step, produced water will be checked by
silicon analyzer (frequency adjustable).
(2) Stop commissioning

a) Close mixer bed inlet valve 3-XV-52106 and open vent valve 3-XV-52111
simultaneously and then close produced discharge valve 3-XV-52107.
b) Close vent valve 3-XV-52111 after 1min, then mixer bed go into standby.
3) Single mixer bed regeneration procedure

Regeneration procedure: stop commissioning+ backwash+ sulfuric acid and caustic
regeneration+ mixing resin+ flushing+ standby
(1) Regeneration condition:

a) Differential pressure switch 3-PDS-52102 numeric is higher than 1.0 barg, alarm
and goes into regeneration procedure.
b) Conductivity analyzer 3-AIT-52103 numeric is higher than 0.2μs/cm, alarm and goes
into regeneration procedure.
c) Silicon analyzer 3-AIT-52102 numeric is higher than 20ug/L (adjustable), alarm and
goes into regeneration procedure.
d) The other two mixer beds are running.
e) Run for 24 hours (adjustable).
67
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(2) Backwash
a) Stop, procedure is as above;
b) Backwash layered: open vent valve 3-XV-52111, backwash discharge valve 3-XV-
52109 and backwash inlet valve 3-XV-52108. Backwash layered for 15min (adjustable);
c) Standing sedimentation: close backwash inlet valve 3-XV-52108, open vent valve 3-
XV-52111 and open backwash discharge valve 3-XV-52109. Standing for 5min.
d) Discharge: open above discharge valve 3-XV-52114 and keep 5min (adjustable)
until water level is 200mm above resin, then close above discharge valve 3-XV-52114,
vent valve 3-XV-52111 and backwash discharge valve 3-XV-52109. And then go into
sulfuric acid and caustic regeneration procedure.
(3) Sulfuric acid and caustic regeneration

1) Regeneration condition:
a) Go into sulfuric acid and caustic regeneration procedure after backwash;
b) The other two mixer beds are running;
c) Caustic metering box 3-LIT-52100 liquid level is lower than 200mm (adjustable),
alarm and sulfuric acid and caustic regeneration procedure will be not run.
d) The numeric of temperature transmitter 3-TIT-52101 which is in Caustic

regeneration heat exchanger cold refrigerant outlet is higher than 52 ℃ or lower than
32 ℃ (adjustable), alarm and sulfuric acid and caustic regeneration procedure will be
not run.
e) Sulfuric acid metering box 3-LIT-52101 liquid level is lower than 200mm (adjustable),
alarm and sulfuric acid and caustic regeneration procedure will be not run.
2) Regeneration sequence
a) Preparation
68
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Open caustic metering box inlet valve 3-XV-52121 when the caustic metering box gauge 3-
LIT-52100 liquid level is lower than 400mm (adjustable) and close it until the level is up to
1000mm (adjustable). Open sulfuric acid metering box inlet valve 3-XV-52122 when the
sulfuric acid metering box gauge 3-LIT-52101 liquid level is lower than 400mm (adjustable)
and close it until the level is up to 1000mm (adjustable).
b) Caustic regeneration
Open the mixer bed middle discharge valve 3-XV-52115, sulfuric acid valve 3-XV-52112,
caustic valve 3-XV-52113, caustic metering outlet valve 3-XV-52119 and caustic
regeneration heat exchanger cold refrigerant inlet valve 3-XV-52117. Open caustic
regeneration heat exchanger cold refrigerant inlet control valve 3-FV-52103 and sulfuric
acid pipe mixer water inlet control valve 3-FV-52104;
Caustic regeneration heat exchanger cold refrigerant inlet vortex flowmeter 3-FIT-52103 will
interlock with caustic regeneration heat exchanger cold refrigerant inlet control valve 3-FV-
52103, control 3-FIT-52103 flowrate to be 25 m3/h;
Sulfuric acid pipe mixer water inlet vortex flowmeter 3-FIT-52104 will interlock with Sulfuric
acid pipe mixer water inlet control valve 3-FV-52104, control 3-FV-52104 flowrate to be 25
m3/h.
Caustic regeneration will continue 25min.
c) Sulfuric first time regeneration
Close caustic metering box outlet valve 3-XV-52119, close caustic regeneration heat
exchanger cold refrigerant inlet valve 3-XV-52117;
Open mixer bed middle discharge valve 3-XV-52115 and sulfuric acid valve 3-XV-52112.
Open sulfuric acid metering pump outlet valve 3-XV-52120 and start sulfuric acid metering
pump 3-PU-5201-P-001A or 3-PU-5201-P-001B, open caustic regeneration heat exchanger
pass-by valve 3-XV-52118;
69
LORDEGAN UREA
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Caustic regeneration heat exchanger cold refrigerant inlet vortex flowmeter 3-FIT-52103 will
interlock with caustic regeneration heat exchanger cold refrigerant inlet control valve 3-FV-
52103, control 3-FIT-52103 flowrate to be 49 m3/h;
Sulfuric acid pipe mixer water inlet vortex flowmeter 3-FIT-52104 will interlock with Sulfuric
m3/h;
Sulfuric first time regeneration will continue 18min.
d) Sulfuric second time regeneration
Keep state of the valves. Caustic regeneration heat exchanger cold refrigerant inlet vortex
flowmeter 3-FIT-52103 will interlock with caustic regeneration heat exchanger cold
refrigerant inlet control valve 3-FV-52103, control 3-FIT-52103 flowrate to be 25 m3/h
(adjustable);
Sulfuric acid pipe mixer water inlet vortex flowmeter 3-FIT-52104 will interlock with sulfuric
m3/h (adjustable);
Sulfuric second time regeneration will continue 26min.
e) Replacement
Stop the sulfuric metering pump 3-PU-5201-P-001A/B, close sulfuric metering pump outlet
valve 3-XV-52120; replacement will continue 30min (adjustable base on PH)
f) Pour water
Close caustic regeneration heat exchanger cold refrigerant pass-by valve 3-XV-52118,
mixer bed caustic valve 3-XV-52113, mixer bed sulfuric acid valve 3-XV-52112, mixer bed
middle discharge valve 3-XV-52115, and caustic regeneration heat exchanger cold
refrigerant inlet control valve 3-FV-52103 and sulfuric acid pipe mixer water inlet control
valve 3-FV-52104. Open mixer beds vent valve 3-XV-52111, mixer bed inlet valve 3-XV-
70
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52106, and pour water 5 min (until the tank is full, adjustable)
g) Flushing
Open mixer bed flushing discharge valve 3-XV-52116, close this valve after flushing 10min.
h) Discharge
Close mixer bed inlet valve 3-XV-52106, open mixer bed above discharge valve 3-XV-
52114 and backwash discharge valve 3-XV-52109, keep mixer bed vent valve 3-XV-52111
opening, discharge for 5min (adjustable, water level is up to 200mm above the resin) and
then close above discharge valve 3-XV-52114,backwash discharge valve 3-XV-52109. Go
into mixing resin procedure.
(4) Mixing resin and flushing

A. Flushing condition
a) Go into mixing resin and flushing procedure after sulfuric acid and caustic
regeneration procedure;
b) The other two mixer beds are running.
B. Flushing step sequence
a) Mixing resin
Keep opening mixer bed vent valve 3-XV-52111, open blower 3-PU-5201-C-001A/B after
opening blower pneumatic vent valve 3-XV-52126 and open mixer bed air inlet valve 3-XV-
52110 at last. Close blower pneumatic vent valve 3-XV-52126 after confirming mixer bed air
inlet valve 3-XV-52110 opening. Mixing resin continue 2min.
b) bed settling
Open blower pneumatic vent valve 3-XV-52126 and then stop blower 3-PU-5201-C-001A/B,
close blower pneumatic vent valve 3-XV-52126 at last, close mixer bed air inlet valve 3-XV-
52110, open mixer bed flushing discharge valve 3-XV-52116 and keep 3min (adjustable)
71
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then close it.
c) Pour water
Open mixer bed inlet valve 3-XV-52106, keep vent valve 3-XV-52111opening until water
come from the vent pipe (5min, adjustable)
d) Flushing
Open mixer bed flushing discharge valve 3-XV-52116, close vent valve 3-XV-52111,
flushing for 30min until the numeric from conductivity analyzer 3-AIT-52103 is lower than
0.2μs/cm and silicon analyzer 3-AIT-52102 lower than 20ug/L.
(5) Standby
A. Standby condition
a) Mixer bed goes into standby procedure after flushing
b) The other two mixer beds are running.
B. Standby step sequence
When the mixer bed flushing procedure is finishing, close mixer bed inlet valve 3-XV-52106
and flushing discharge valve 3-XV-52116. And then mixer bed goes into standby.
4) Interlock condition of instrument

Please refer to the following two documents for the interlocking conditions of mixed bed
instruments：
72
PROJECT Lordegan
HAMPA Project No.:
Project No.: 2103
Table 1 Control sequence diagram of mixer bed
state run stop
Pour water Running and Pressure

Step sequence confirm running standby
and vent flushing relief
Operate time min（adjustable） 6min 15min 5min ~h 1min
Step sequence item 0 1 2 3 4 5
progress
Equipment name Tag. NO. state pause
Inlet valve 3-XV-52106A~D Open 2 hold hold hold close1
Produced
3-XV-52107A~D open1 close2
discharge valve
Backwash inlet
3-XV-52108A~D
valve
Mixer
bed
Backwash
3-XV-52109A~D
discharge valve
Flushing discharge
3-XV-52116A~D open1 hold close1
valve
Vent valve 3-XV-52111A~D open1 close1 open1 close1
73
PROJECT Lordegan
HAMPA Project No.:
Project No.: 2103
Middle discharge
3-XV-52115A~D
valve
Sulfuric acid valve 3-XV-52112A~D
Caustic valve 3-XV-52113A~D
Air inlet valve 3-XV-52110A~D
Above discharge
3-XV-52114A~D
valve
Step sequence execution condition
Active carbon filters and precision filters should run simultaneously when mixer beds are running.
Note: 1） The numeric in the table only the small one is executed and then the big one can be executed; sequence of closing valve contrary to open valve
when step sequence is finished.
2）Every step can step delay, step forward and stop. The commissioning procedure can sent artificial, the time can be adjusted on the upper computer.
3）Procedure cannot sent order when remote control switches local control.
74
LORDEGAN UREA FERTILIZER PROJECT

Lordegan
HAMPA Project No.:
Project No.: 2103
Table 2 Regeneration sequence diagram of mixer bed
state backwash Sulfuric acid and caustic regeneration Mixing resin + flushing standby
Standing Add acid

Backwas discharg preparati Add Add acid replacem Pour Mixing Bed Pour
sequence sediment second flushing discharge Flushing standby
h layered e on caustic first step ent water resin settling water
ation step
Operate time min（adjustable） 15min 5min 5min 15min 25min 18min 26min 30min 5min 10min 5min 2min 3min 5min 30~min
Step sequence item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
progress
Equipment name Tag. NO. state pause
Inlet valve 3-XV-52106A~D open 2 hold close 1 open 1 hold close 3
Produced
discharge 3-XV-52107A~D
valve
Backwash
3-XV-52108A~D open3 close1
inlet valve
Backwash
open 2/
discharge 3-XV-52109A~D open2 hold close 3
close 3
valve
Flushing
discharge 3-XV-52116A~D open 1 open 2 close 1 open 1 close 2
Mix valve
er
bed
Vent valve 3-XV-52111A~D open 1 hold close 2 open 1 hold hold hold hold hold close 1
Middle
discharge 3-XV-52115A~D open 1 hold hold hold close 4
valve
Acid valve 3-XV-52112A~D open 1 hold hold hold close 3
Caustic valve 3-XV-52113A~D open 1 hold hold hold close 2
Air inlet valve 3-XV-52110A~D open 3 close 3
Above
open 1/ open 1/
discharge 3-XV-52114A~D
close 1 close 2
valve
产水电磁阀 3-SV-52100 open 2 close 1

produced
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magnetic
valve
Acid metering
open /
box inlet 3-XV-52122
close
valve
acid
Acid metering
box outlet 3-XV-52120 open 1 hold close 2
valve
Caustic
open /
metering box 3-XV-52121
close
inlet valve
cau
stic
Caustic
metering box 3-XV-52119 open 2 close1
outlet valve
acid pipe mixer

water inlet control 3-FV-52104 open 1 hold hold hold hold close 5
valve
caustic
regeneration heat
exchanger cold 3-FV-52103 open 1 hold hold hold hold close 6
refrigerant inlet
control valve
caustic
regeneration heat
exchanger cold 3-XV-52117 open 1 close 2
refrigerant inlet
valve
caustic
regeneration heat
exchanger cold 3-XV-52118 open 3 hold hold close 1
refrigerant pass-
by valve
Sulfuric acid 3-PU-5201-P-

open 2 hold close 1
metering pump 001A/B
3-PU-5201-C-
Blower open 2 close 1
001A/B
blower pneumatic open 1/ open 1/

3-XV-52126
vent valve close 1 close 2
Step sequence execution condition
Note: 1）The numeric in the table only the small one is executed and then the big one can be executed; sequence of closing valve contrary to open valve when step sequence is finished.
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2）Every step can step delay, step forward and stop. The commissioning procedure can sent artificial, the time can be adjusted on the upper computer.
3）Procedure cannot sent order when remote control switches local control.
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6.2.3 Neutralized System
1) Major device
（1） Neutralized tank
Table 1 Major device list of neutralized tank
Item Description Set Standby Tag. No. Remarks
Neutralized effluent
1 1 1 3-PU-5201-P-002A/B Self-priming pump
transfer pump
2 Air blower 1 1 3-PU-5201-C-001A/B Roots blower
Neutralized tank air

inlet on-off On-off pneumatic
3 1 3-XV-52125
pneumatic butterfly butterfly valve
valve
Neutralized effluent
transfer pump
4 1 3-FIT-52105 Magnetic flowmeter
outlet magnetic
flowmeter
Ultrasonic level Ultrasonic level

5 1 3-LIT-52102
gauge gauge
6 Level switch 1 3-LS-52101 High high level
7 pH analyzer 1 3-AIT-52106 Input type
（2） Sulfuric acid dosing system
Table 2 Major device list of sulfuric acid dosing system
1 Acid metering box 1 3-PU-5201-TK-002
Acid inlet
2 pneumatic 1 3-XV-52124 Flange type
diaphragm valve
（3） Caustic dosing system
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Table 3 Major device list of caustic dosing system
Caustic metering
1 1 3-PU-5201-TK-001
box
Caustic inlet
2 pneumatic 1 3-XV-52123 Flange type
diaphragm valve
2) Control way of dosing room
（1） Local control
A. Neutralized effluent transfer pump (TAG. No. 3-PU-5201-P-002A/B)
B. Acid inlet pneumatic diaphragm valve (TAG. No. 3-XV-52124)
C. Caustic inlet pneumatic diaphragm valve (TAG. No. 3-XV-52123)
（2） Remote control
There are two modes for control: PLC manual operation and automatic operation choose
manual operation we can control the entire device in dosing room; choose automatic control,
the device will operation automatically as follows:
A. Neutralized tank
a) When the mixer bed regeneration is finished and the numeric of pH meters 3-
AIT-52106 higher than 8, start the acid inlet pneumatic diaphragm valve 3-XV-52124,
neutralized tank air inlet on-off pneumatic butterfly valve 3-XV-52125 and start the
blower 3-PU-5201-C-001A/B.
b) When the mixer bed regeneration is finished and the numeric of pH meters 3-
AIT-52106 lower than 6, start the caustic inlet pneumatic diaphragm valve 3-XV-
52123, neutralized tank air inlet on-off pneumatic butterfly valve 3-XV-52125 and start
the blower 3-PU-5201-C-001A/B
c) The valves 3-XV-52123 and 3-XV-52124 open time is about 20s, and the time
of opening and closing automatically can be set base on the site truth. Stop for 1 -2
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min for adjusted every time adding acid or caustic. Stop the blower 3-PU-5201-C-
001A/B and alarm when the PH is not changed after 15min.
d) Stop the blower 3-PU-5201-C-001A/B when the numeric of pH meter 3-AIT-

52106 between 6 and 8.
e) Neutralized sump air inlet valve 3-XV-52125 should keep closing when mixer
bed air inlet valve opens.
f) Start the neutralized sump transfer pump 3-PU-5201-P-002A/B when the

numeric of gauge 3-LIT-52102 is higher than 1.0m and pH meter is between 6 and 9.
g) The neutralized sump transfer pump 3-PU-5201-P-002A/B must start when

the liquid level switch 3-LS-52101 is up to 2.2m and whether the pH analyzer 3-AIT-
52106 is not equal to 6 or less than 9.
h) Stop the neutralized sump transfer pump 3-PU-5201-P-002A/B when the

gauge 3-LIT-52102 lower 0.3m.
B. Sulfuric acid dosing system
The following equipment meets the control requirements of the neutralization sump.
The acid inlet pneumatic diaphragm valve 1 set (Tag. No. : 3-XV-52124).
C. Caustic dosing system
The following equipment meets the control requirements of the neutralization sump.
The caustic inlet pneumatic diaphragm valve 1 set (Tag. No.: 3-XV-52124).
3) Instrument interlock condition

Please refer to the following two documents for the interlocking conditions of neutralized
sump instruments：
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Note:
1. All of the parameters above can be adjusted in PLC.
2. Starting the neutralized transfer pump should meet both of the conditions which are
pH and liquid level.
3. Adjusting pH of neutralization cannot proceed with mixed bed regeneration

simultaneously, when the mixed bed regeneration is processing, caustic inlet
pneumatic diaphragm valve 3-XV-52123, acid inlet pneumatic diaphragm valve 3-XV-
52124 and neutralized tank air inlet on-off pneumatic butterfly valve 3-XV-52125
should keep closing.
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6.3 Trouble Shooting
This section describes some of the common problems that can occur during operation of this
system and the steps an operator can take in finding their causes. Because the best
troubleshooting tool an operator can have is his knowledge of the normal system operation, it
is recommended that the operator reads and be familiar with the rest of this manual prior to
using this section. During the first few month of system operation operators should carefully
observe and note normal operation characteristics for future reference.
If process problems develop, it is critical that operators have a complete record of the past
operating performance of the system. It is vital that operators maintain an operating logbook
throughout the life of the system.
6.3.1 General Trouble Shooting Tips
(1) The most helpful tool in troubleshooting problems is the operator's knowledge of the
normal operating conditions. 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. Many problems occur because the system is no longer operating under the
conditions stated in this manual.
Selected sampling and testing procedures should be performed regularly during the
operation of this system. While the actual frequency of sampling and testing is at the
discretion of the customer, any tests used with this system must be performed on a regular
basis and must be accurately recorded in a log book.
A well-kept log book of test dates and results and of operator observations is an invaluable
tool for troubleshooting future performance problems.
(2) . Double-check for problem symptoms to be sure that a problem really exists. An
inaccurate instrument or a temporary change in feed water quality, pressure or flow rate
can indicate a problem where none exists.
(3) Don't overlook these simple problems.
A hand valve that is closed
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the power turned off to a pump
Wires cut or disconnected
Equipment damaged or missing
Valve solenoids manually overridden
Incorrect control set points in the process controller
(4) To troubleshoot flow blockage, locate any large pressure drop and investigate all the
equipment in that area until the source of the blockage is found.
(5) To troubleshoot electrical problems, first identify the control flow pattern, which is the
pathway 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 (where applicable).
(6) To troubleshoot an instrumentation problem, refer to the instrument manufacture's

service literature in the Vendor Literature Manual.
(7) To troubleshoot problems with other pieces to equipment, refer to the information
available in the component manufacture's service literature in the Vendor Literature
Manual.
6.3.2 Troubleshooting Guide
This section contains the information on the troubleshooting of some common phenomena
and/or alarms. Please read also the troubleshooting section of Manufacturer’s Data for
individual equipment. Also, none of the charts presented here should be considered to be
exclusive; these charts are intended to point out the most likely causes of the listed problems.
IItem Phenomenon / Alarm Cause and Remedial Action
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(LALL, 3-LIT-52100)
(LALL, 3-LIT-52101) - Emergence stop the dosing pump (3-PU-5201-P-

001A/B) locked
5 Wastewater - Defective level switch or improper setting level

neutralization sump
- Level switch entangled
Level high high alarm
- Defective neutralization pump (3-PU-5201-P-002A/B)
(LAHH, 3-LIT-52102)
6 Wastewater neutralization - Defective level switch or improper setting level

sump
- Level transmitter entangled
Level low low alarm
- Emergence stop the wastewater transfer pump (3-PU-
(LALL, 3-LIT-52102) 5201-P-002A/B) locked
7 The flow rate(FIT-52100) - Air accumulated in the suction pipe

is lower than normal from
neutralized wastewater - Something block in the suction pipe
transfer pump (3-PU-
5201-P-002A/B) - Shut down the pump and air blower, flush the suction
pipe, fulfill the pipe with water
8 The resin leaks from - Backwashing intensity is higher than normal scope.
backwash pipe when the
mix bed is in backwash - Control the backwashing intensity under normal scope
procedure,
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9 The cation resin and - The resin has not lose efficiency completely,
anion resin bond
together, resulting in - The resin has been contaminated
mixing between these two
resin layers - Run the mix bed with 5% NaOH liquid to change the
resin into Na-cation resin and OH-anion resin
3+
10 The color of the resin - Fe concentration is out of limit
become dark or black and
the exchange capacity of - Treat the resin with 10%~15% HCl liquid，immersing
the resin is lower than for one or two days.
normal.
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6.4 Preventive Maintenance
In addition to the maintenance guidelines listed in Section 4.1 and in the Vendor Literature
Manuals, the operating personnel should be aware of further steps that can be taken to avoid
specific problems. Some common problem areas are listed below.
6.4.1 All Systems
(1) Equipment Problems
Always be sure to operate each piece of equipment within the ranges (flow rate, pressure,
temperature, voltage, etc.) specified by the manufacturer's service literature.
(2) Valve and Piping Problems
Make sure the valves are not opening and closing too fast; this can result in a "hammer"
effect, causing leaky valves and piping. The action of automatic valves controlled by
pneumatic solenoids can be slowed by adjusting the air metering screws on the solenoids.
Operators must verify that all valves close completely. A valve that does not shut tightly can
cause contaminants to leak into the product stream.
(3) Instrument Problems
Be sure the piping is braced securely enough to avoid vibration damage of instruments. Also,
keep dust and water out of instruments.
For pH meters, be sure that the metering probe should always immersed in water to keep
wet.
Instruments such as pressure gauges and pH meters should be cleaned, inspected, and
calibrated periodically. A faulty sensing instrument may indicate a problem where one does
not exist, or may not indicate a problem that does exist.
Instruments can be damaged by excessive vibrations. Instruments that are field-mounted

must be installed in a location that is relatively free of vibrations and impact shocks.
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When instruments are mounted on piping at the equipment, the piping must be braced
securely to prevent instrument damage from vibrations and shocks caused by such problems
as water hammer.
Instruments should be calibrated periodically to avoid erroneous readings. A malfunctioning

instrument may not indicate a problem that exists, resulting in equipment damage or
extended downtime.
(4) Pressure Drops
Operators should monitor the pressure gauges on each piece of equipment to detect
excessive pressure drops. Excessive pressure drops can give an early indication of problems
such as valve or pump malfunction.
(5) Disassembly and Re-assembly of System Components
When workers must disassemble and then reassemble system components, they should
refer to the component instructions in the Vendor Literature Manual and Section 3.5 of the
Operation Manual.
(6) Tightening of System Components
When threaded system components are installed and tightened, correct torque specifications
must be adhered to. Under tightening can cause leakage and over tightening can cause
stripped threads, warped parts, breakage, and leakage.
When flanged components are installed and tightened, alignment of gaskets must be correct
before tightening the clamp. Follow the torque specifications found in the "vendor's literature"
section.
Permanent damage to the gaskets can result if not aligned properly before tightening the
clamps.
(7) System Leaks
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Flushing and effusing sampling and testing should be performed on a regular basis. This will
help to detect changes in operating performance before a major upset occurs.
VWS strongly recommends that a log book be maintained on a daily basis. Such data as flow
rate, pH of feed water, each adjustment tank and treated water can be invaluable if problems
develop in the future.
(9) Feed Quality
The process feed must be within specifications stated in Section 2.1.
It is important that the feed quality guidelines suggested in this manual be followed. Since
the system has been designed according to these guidelines, overloading the system may
result in failure to reach the treatment requirement
Be sure that conduit connections are tight. In wet environments conduit connections
should be sealed with silicon sealer.
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6.4.2 Chemical Systems
(3) System Leaks
Leaks at chemical components can cause equipment damage and

WARNING human injury.
If leaks develop at the chemical dosing system or its piping,

immediately shut down the system, relieve all pressure, and
repair the leaks.
(4) Chemicals for pH adjustment
Each chemical must be made consistently at the required concentrations. If the chemical are
too dilute, the pH adjustment may be unsuccessful; if the chemical are too concentrated
especially for caustic, they could cause crystallization to block the pumps and piping.
Finally, be sure that the entire chemical dosing system (piping, pumps, ejectors, etc.) is
functioning properly.
6.4.3 Blowers and Pumps
Make sure all pumps have seal water (where applicable) and are equipped with a device to
relieve excessive pressure on the discharge line, such as a pressure relief valve (where
applicable). Do not allow the tank feeding the pump to run dry; install controls to shut the
pump off on low storage tank level, if necessary.
Adjust the closing of valves and the starting and stopping of pumps to avoid a water surge or
"hammer" against the pumps.
89

2103 G VD 101 013 - 1 Operation & Maintenance Manual

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CONTRACTOR: DETAIL ENGINEER : :

LORDEGAN UREA OWNER

Operation & Maintenance

1 29.01.2018 JY.L QL.S/RX.L J.X For final

0 10.08.2017 JY.L QL.S/RX.L J.X For review

Rev Date Written by Checked by Approved by Remark

1 SYSTEM DESCRIPTION ................................................................................................................................... 3

4.3.1 All Systems ...................................................................................................................................... 45

1.1.1 Active carbon filter

1.1.2 Cartridge filter

1.1.3 Mix bed

Finally, condensate is polished by four mixed beds (3-PU-5201-FT-003A~D) with service

1.1.4 Regeneration system

1.1.5 Neutralization system

A Neutralization System is in the PU‐5201 package. Neutralization System will neutralize

1.2 Process Flow Diagram

Please refer to the as built drawings.

2.1 Performance Parameters

2.1.1 Influent Condensate water Quality

Characteristics of condensate water streams are summarized as below:

ITEM UNIT VALUE

2.1.2 Influent Condensate water Flow Rate

The design capacity of the condensate polishing system is 480m3/hr.

The polished water shall meet the following criteria:

ITEM UNIT VALUE

2.2 Operating Data on P&ID

Please refer to the as built P&ID.

2.3.1 Equipment List

No. ITEM SPECIFICATION UNIT QTY MATERIAL

filter element SS304

4.4 Acid pot V=1000L，Φ×H=1000×1300mm set 1 Carbon steel

Q=350L/h, H=7.0bar, N=0.75kW,

Carbon steel lined

4.8 Electric heater N=30kW，400V AC set 1 SS316

5 Condensate water neutralization sump

Neutralized suction head 3.5m，

2.3.2 Key Instrument Specification

SR. MANUFACTUR QUANTITY

coating ,OUTPUT SIGNAL

3.1 System Operating Instruction

Figure 3-1: Basic Control System Diagram

signals. In the “REMOTE” position, the associated equipment’s activation is determined by

Hazardous process fluids, high fluid pressures, and accidental pump

Field inputs can be simulated by jumping terminals at “ON/OFF” motor contacts or

Three-phase pumps can be damaged if run without process and/or seal

3.1.3 Control Philosophy Write-up

3.1.3.1 Vocabulary Precisions

“Operator” means person using the Control System.

“Alarm” means alarm message, which appears on the MCP/HMI.

“Running” means equipment work effectively.

“Remote mode” means control of the equipment by PLC

LCS means Local Control Station

PLC means Programmable Logic Controller

DI means Discrete Input

DO means Discrete Output

AI means Analog Input

AO means Analog Output

HMI means human machine interface

3.1.3.2 General description

Remote: means can be operated in HMI, and controlled by PLC;

Off: means stop the equipment;

All the control set point can be changed in the PLC.

3.1.3.3 The influent pneumatic valve