#Operating Manual r1

PT PETROKIMIA GRESIK PROJ NO.
201485 REV 1
PT. ADHI KARYA
(Persero), Tbk. AMMONIA-UREA II PROJECT 201485-20000-TS-04
OPERATING MANUAL COVER
OPERATING MANUAL
PT PADI HIJAU BUANA
PROJECT NAME : AMMONIA UREA II PROJECT
OWNER : PT.PETROKIMIA GRESIK
CONTRACTOR : PT. ADHI KARYA (PERSERO), TBK.
VENDOR NAME : PT Padi Hijau Buana
PACKAGE NAME : Filtered Water and Demineralization

Package
P.O NO. : 201485-Z02-RD-PO
VENDOR DOC NO : PHB-20000-TS-04
1 For Approval YD TFK/DKY RMT 05 May 2017

0 For Approval TFK DKY DDH 24 Jan 2017
REV DESCRIPTION PREPD CHKD APPRD DATE
AMMONIA-UREA II PROJECT PROJ 201485 REV 1
Filtered Water And Demineralization NO.
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
OPERATING MANUAL Sheet 1 of 262
Table of Contents
1 PROCESS DESCRIPTION................................................................................................6
1.1 Filtered Water System..................................................................................................6
1.2 Fire Fighting Water System.........................................................................................7
1.3 Potable Water System..................................................................................................7
1.4 Demineralization Water System..................................................................................8
2 OPERATING PHILOSOPHY...........................................................................................12
2.1 Filtered Water Tank...................................................................................................12
2.2 Pre Filtration..............................................................................................................13
2.3 Potable Water System................................................................................................15
2.4 Filtered Water System................................................................................................18
2.5 Condensate & Demineralized Water Plant................................................................29
2.6 Neutralization Pit (T20209).......................................................................................34
2.7 Chemicals..................................................................................................................35
2.8 Sequence Table..........................................................................................................37
2.9 Loading Media & Resin Procedure...........................................................................43
2.9.1 Loading Media Procedure for MMF............................................................43
2.9.2 Loading Media Procedure for ACF.............................................................49
2.9.3 Loading Resin Procedure for Cation Exchanger & Mixed Bed..................54
2.10 START-UP Procedure & TROUBLESHOOTING for Potable Water System..........58
2.10.1 PRE-COMMISSIONING............................................................................58
2.10.2 MECHANICAL EQUIPMENT PRE-COMMISSIONING.........................59
2.10.3 COMMISSIONING.....................................................................................82
2.11 START-UP Procedure & TROUBLESHOOTING for Filtered Water Plant.............84
2.11.1 GENERAL...................................................................................................84
2.11.2 COMMISSIONING PROCEDURE............................................................85
2.11.3 TROUBLESHOOTING...............................................................................87
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2.12 START UP Procedure & TROUBLESHOOTING for Demineralized Plant.............88

2.12.1 GENERAL...................................................................................................88
2.12.2 START UP...................................................................................................89
2.12.3 COMMISSIONING...................................................................................140
2.13 MSDS Chemical......................................................................................................143
2.13.1 Oxidant for Potable Water (Calcium Hypochlorite)..................................144
2.13.2 Oxidant for Multi Media Filter (Sodium Hypochlorite)............................151
2.13.3 CEB for UF Unit........................................................................................159
2.13.4 CIP for UF Unit..........................................................................................169
2.13.5 Inlet RO Unit.............................................................................................170
2.13.6 CIP for RO Unit.........................................................................................187
2.13.7 Cation Exchanger Regeneration (Sulfuric Acid) (See 2.13.5.1)................197
2.13.8 Mixed Bed Ion Exchanger Regeneration...................................................198
2.13.9 Neutralization.............................................................................................199
3 Control Narrative............................................................................................................200
3.1 General....................................................................................................................200
3.1.1 Permissive Start, Auto start & Auto stop...................................................200
3.1.2 Minimum Flow Protection.........................................................................231
3.1.3 Totalizer.....................................................................................................232
3.2 Filtered Water Tank.................................................................................................232
3.2.1 Filtered Water Tank Level (Minimum Stop for LV-102)...........................232
3.2.2 Filtered Water Tank Low Level Protection (I-01/LALL102B)..................232
3.2.3 Filtered Water Tank Level (LIC-102A).....................................................233
3.2.4 Flow Control to MMF for Demineralized Plant (FIC-104).......................233
3.3 Potable Water System..............................................................................................233
3.3.1 MMF for Potable Water Sequence (KIC-02A)..........................................233
3.3.2 ACF for Potable Water Sequence (KIC-02B/C)........................................235
3.3.3 Potable Water Tank Level (LIC-104).........................................................238
3.3.4 Potable Water Line Distribution Pressure (PIC-117).................................238
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3.3.5 Potable Dosing Ratio Control (FI-105).....................................................238

3.4 Filtered Water System..............................................................................................238
3.4.1 Multi Media Filter for Demineralized Plant (KIC-04A~F).......................238
3.4.2 Normal Mode.............................................................................................238
3.4.3 Activated Carbon Filter for Demineralized Plant Sequence (KIC-05A~F)
241
3.4.4 ACF Filtered Water Tank Level Control (LIC-202A)...............................244
3.4.5 ACF Filtered Water Tank Low Level Protection (I-06/LALL-202B).......244
3.4.6 UF Feed Flow Control...............................................................................244
3.4.7 UF Sequence (KIC-07A~D)......................................................................244
3.4.8 UF Filtered Water Tank Level (LIC-204A)...............................................252
3.4.9 UF Filtered Water Tank Low Level Protection (LALL-204B /I-08).........252
3.4.10 UF Outlet ORP High-High Protection (I-222/AAHH-222).......................252
3.4.11 RO Sequence (KIC-09A~D)......................................................................252
3.4.12 RO Feed Chemical Injection Control (FIC-207).......................................253
3.4.13 RO Feed pH Control (AIC-201)................................................................254
3.4.14 RO Feed ORP Control (AIC-203).............................................................254
3.4.15 RO Feed Flow Control (FIC-208A~D)......................................................254
3.4.16 Stand by RO HP Pump Load Control Selector (HS-P204E).....................254
3.4.17 RO High Pressure Pump Low Pressure Protection (PALL-214A~E/I-
09A~E)..................................................................................................................254
3.4.18 RO Protection (I-09A~D)..........................................................................254
3.4.19 Degassed Water Tank Low Level Protection (LALL-206B/I-11)..............254
3.4.20 Degassed Water Tank Level (LIC-206A)..................................................254
3.4.21 Degassed Water Flow Control (FIC-228)..................................................254
3.5 Condensate & Demineralized Water Plant..............................................................254
3.5.1 ACF for Condensate Sequence (KIC-13A~C)..........................................254
3.5.2 Cation Exchanger Sequence (KIC-14A~B)...............................................257
3.5.3 Condensate Tank Level Control (LIC-210A)............................................259
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3.5.4 Mixed Bed Ion Exchanger Feed Flow Control (FIC-229B)......................259

3.5.5 Mixed Bed Ion Exchanger Sequence (KIC-15A~E).................................259
3.5.6 Demineralized Water Tank Level Control (LIC 212A).............................263
3.5.7 Regeneration Water Tank Level Control (LIC-226)..................................263
3.5.8 Neutralizing Pit pH control (AIC-219)......................................................263
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Abbreviations used:
Abbreviation Description
SCF Self-Cleaning Filter
MMF Multi Media Filter
ACF Activated Carbon Filter
MMF-P Multi Media Filter for Potable Water
ACF-P Activated Carbon Filter for Potable Water
UF Ultra Filtration
CF Cartridge Filter
RO Reverse Osmosis
DEG Degasifier
ACF-C ACF for Condensate
CE Cation Exchanger
MB Mixed Bed Ion Exchanger
IC Iron Cartridge
PHE Condensate Cooler
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1 PROCESS DESCRIPTION
Filtered Water and Demineralization package is designed to support Ammonia 2000
MTPD and Urea 1725 MTPD and related facilities. Filtered Water as raw material
received from other PKG facilities, and processed in this package which can be divided
mainly into four sections:
 Filtered Water System
 Fire-Fighting Water System
 Potable Water System
 Demineralized Water System
1.1 Filtered Water System

Filtered Water supplied from PKG other facilities first stored into Filtered Water
Tank (T20101) with capacity 22.000 m3. Before entering the tank, filtered water
first cleaned from debris through Self-Cleaning Filter (S20212A/B/C). The self-
cleaning filters will automatically backwash based on pressure drop. Filtered
Water supplied to this section has quality as follow:
Parameter Input
pH 7.5 – 8.5
Turbidity (max.) 5 NTU
m-alkalinity, as CaCO3 (max.) 250 ppm
Ca-Hardness, as CaCO3 (max.) 180 ppm
Total Hardness, CaCO3 (max.) 220 ppm
Chloride as Cl- (max.) 62 ppm
SiO2 (max.) 63 ppm
Total Dissolved Solid 370 ppm
Temperature (°C) Ambient
During normal operation, 661.83 ton/h filtered water is needed for continuous
operation of Ammonia-Urea Plant and related facilities. However, it is estimated
that maximum 1021.85 ton/h flow of filtered water needed if Reverse Osmosis
plant maximum capacity, low cycle of Cooling Water and maximum potable water
consumption.
The filtered water tank also used to store fire water. Minimum inventory 5600
3
m must be kept for fire fighting, which corresponds to 8 hours of main fire
fighting pump run.
Filtered water from Filtered Water Tank (T20101) will then distributed to other
sections:
 Demineralized System with FW Pump for DW (P20102A/B/C),
 Ammonia & Urea Cooling Water Make-up with FW Pump for CW
(P20101A/B/C),
 Service Water and Potable Water with FW Pump for Service Unit
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(P20103A/B),
 To Main and Jockey Fire Fighting pumps.
Each of above pumps has one stand by pump.
1.2 Fire Fighting Water System

Fire fighting system designed to supply and maintain pressure on fire fighting
water line for Ammonia – Urea Plant, buildings and its related facilities.
Fire water line maintained at pressure 10 kg/cm 2g by jockey pump. In case fire
happen, jockey pump can’t maintain the fire water header pressurized, the
pressure will decrease until reach preset value 7 kg/cm 2g and automatically start
main fire-fighting pumps P20104A/B. A is motor driven, connected to emergency
power, B is diesel engine driven. Both are centrifugal-horizontal pump type of
proven standard type NFPA No 20.
The capacity of each main fire water pump is 700 m 3/h. In addition, two motor
driven jockey pumps (P20105A/B) with capacity 30 m 3/h provided to maintain the
head pressure.
1.3 Potable Water System

Potable water produced on this system with maximum capacity 30 m 3/h. The
potable water will be used for emergency shower and eyewash, personal use on
buildings for washings, shower and toilet use.
Filtered water pump through FW pump for Service Unit (P20103A/B). Some of
the flow sent to Service Water pipe which used for service water for utility
stations around the Plant area. Some of the flow sent to MMF-P (S20103) and
then ACF-P (S20101A/B to remove residual suspended solid and organics. Before
entering MMF-P, Calcium hypochlorite is dosed into the water and mixed by
Z20102 to prevent microorganism growth on MMF and eliminate microorganism
so the potable water us safe for used.
Cleaned and disinfected Filtered Water become potable water and stored on
Potable Water Tank (T20102) which has capacity of 120 m 3. Potable Water is
pumped into the potable water distribution pipe by the Potable Water Pump
(P20106A/B), some of it used for back wash of MMF-P and ACF-P.
Potable water has quality as per PERMENKES 492/MENKES/PER/IV/201 which is
in general as follow:
Parameter Unit Max. Allowable
E-Coli Total per 100 mL sample 0
Total Coliform bacteria Total per 100 mL sample 0
Total Chromium ppm 0.05
Nitrite (as NO2) ppm 3
Nitrate (as NO3) ppm 50
Odor - Odorless
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Parameter Unit Max. Allowable

Color TCU 15
Total dissolved solids ppm 500
Turbidity NTU 5
Smell - Tasteless
Temperature °C Ambient
Iron ppm 0.3
Hardness ppm 500
Chloride ppm 250
Mangan ppm 0.4
pH - 6.5 – 8.5
Zinc ppm 3
Sulfate ppm 25
Copper ppm 2
Ammonia ppm 1.5
1.4 Demineralization Water System

The demineralization water system comprises of all the facilities to treat and
handle filtered water and condensate from Ammonia, Urea and Service Unit, and
produce demineralized water for the process plant. The system designed to
process:
 Filtered Water to RO product with maximum capacity 250 t/h.
 Activated Carbon and Cation exchanger for process condensate with capacity
maximum 134 t/h outlet.
 Mixed Bed Ion Exchanger with capacity maximum 307 t/h outlet for
processing RO outlet, process condensate, and steam condensate.
 Turbine condensate with maximum flow 214 t/h.
 Demineralized water tank to store Demineralized water together with
turbine condensate and send it to users.
A. Filtered water to RO product
The Demineralization Unit has capacity to process Filtered Water to RO
product with maximum product capacity 250 t/h. Before filtered water can be
processed in RO, the water has to be pre-treated first through MMF, ACF, UF
and cartridge filter.
 Filtered water is pumped into MMF (S20201A~F) and then ACF
(S20202A~F) by FW Pump for DW (P20102A/B/C) to remove suspended
solid and other organic matter and then stored in 150 m 3 ACF Filtered
Water Tank (T20201).
 Calcium hypochlorite as biocide injected into feed of MMF to prevent
organism growth in the equipment and prevent bio-fouling on
Ultrafiltration membrane.
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 From ACF Filtered Water Tank (T20201), the water pumped by UF Feed
Pump (P20201A/B/C) to Ultrafiltration membrane Unit (S20203A~D) to
further remove macromolecular organic to keep the maximum SDI
(Silt Density Index) of effluent is below 5.
 Ultrafiltration membrane is hollow fiber membrane which has nominal
pores of 0.03 µm, any particles in this size will be filtered outside of the
filtered membrane. The build-up solids and increase pressure drop
across the membrane. The membrane will be cleaned periodically
(backwashed) by timer, the membrane will be backwashed to remove
the build-up solids on membrane surface. After certain number of cycles,
the membrane will be chemically backwashed to remove any bio-fouling
that can occur.
 There will be two operation methods of the filtration, dead end and cross
flow operation mode.
 On dead end operation mode, 100% of feed water is converted to
filtrate.
 This mode applied when NTU < 5 and required by the plant.
 On cross-flow operation mode, a part of feed water is rejected during
filtration which is discharged from concentrate port. This mode applied
when turbidity of feed water greater than 5 NTU and required by the
plant.
 In case cross flow operation mode applied, the rejected water, minimum
3.4% of feed water, is collected in Brine Tank (T20204) which has 1000
m3 working volume. This rejected water is for MMF-ACF for DW
(S20201A~F – S2020A~F) backwash.
Expected qualities of Ultrafiltration product are mainly as follow:
Parameter Unit Maximum
Conductivity μS/cm 600
Turbidity NTU 5
SDI - 3
ORP mV 700
Cleaning in Place (CIP) facility is available to clean the Ultrafiltration
membrane when needed.
Each of Ultrafiltration Unit have capacity of 93 m3/h. Total capacity of UF
unit is 372 m3/h. Clean water will pass through the membrane, sent and
stored on UF Filtered Water Tank (T20202) with capacity 200 m 3.
 From UF Filtered Water Tank (T20202), the UF filtered water pumped by
RO Feed Pump (P20203A/B/C) to Reverse Osmosis Membrane unit.
Before can be processed on Reverse Osmosis Membrane, the UF filtered
water must be pre-treated with chemicals:
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- pH adjuster, sulfuric acid for pH adjusting to reduce potential of

calcium carbonate scaling in the RO concentrate. (P20219A/B Acid
Dosing Pump)
- Anti-scale, to inhibit precipitation of calcium carbonate (P20222A/B
Anti-scale Dosing Pump)
- Reductant, to reduce excess oxidant (injected upstream of MMF). Inlet
RO membrane shall be free of residual chlorine. The residual chlorine
or other oxidant biocide reduced using chemical reducing agent such
as sodium meta-bisulfite (SMBS) prior to enter RO membrane.
Reducing agent pumped by P20218A/B Reductant Dosing Pump.
- Non-oxidation Biocide, to reduce biological fouling in membrane
systems. Non-oxidation Biocide pumped by P20221A/B Non-oxidation
Biocide Dosing Pump.
 After pre-treated with chemicals, the RO feed water passed through
cartridge filter which serve as guard filter before entering RO membrane,
and remove particles greater than 5μm in diameter. SDI of RO feed water
is expected to be maximum 3. The feed water then pumped by RO High
Pressure Pump (P20204A~E) to 13.5 kg/cm 2g at pump discharged and
sent to RO Unit (S20205A~D).
 Reverse Osmosis membrane (spiral wound membrane) rejects minerals
from feed water based on reverse osmosis phenomenon. With a high
pressure pump, feed water is continuously pumped at 13.5 kg/cm 2g to
the membrane system. Within the membrane system, the feed water will
be split into a low-saline and/or purified products, called permeate, and
a high saline or concentrated brine, called concentrate or reject. VFD
motor on RO HP feed pump controls the flow of feed water to membrane
system.
Dual stage system is employed in this Plant. The reverse osmosis
membrane system consists of Stage 1 and Stage 2 membrane. Reject of
fist stage membrane enter the second stage as feed water, and the
permeate combine with permeate of Stage 1 become the RO product,
while the reject of Stage 2 become the Reject, or Brine Water. Brine
water stored on Brine water tank (T20204) and can be used for MMF and
ACF backwash.
Recovery (Total Product/Total Feed water) of total system is expected
minimum 75%.
Capacity of each RO skid is 62.5 ton/h permeate, with total 4 skid, than
total capacity of the RO system is 250 ton/h.
Expected qualities of Reverse Osmosis membrane product are mainly as
follow:
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pH - 4–5
SDI - 1
SiO2 ppm 5
TDS ppm 10
Penetrated water of RO Unit (S20205A~D) sent directly to Degasifier
(C20201) to remove dissolved CO 2. Expected RO product maximum
conductivity is 10 µS/cm at 25°C. From Degasifier tank, the RO product
pumped and transferred into Condensate Tank (T20207 capacity 2000
m3) by Degasifier Pump (P20205A/B/C).
B. Activated Carbon and Cation Exchanger for Process Condensate
Process Condensate from Ammonia Plant and Urea Plant treated in this
system before stored together with RO product in Condensate Tank. The
design capacity of process condensate treatment system is 150 m 3/h, which
consist of Activated Carbon Filter and Cation Exchanger. Activated carbon
used to remove organic impurities from process condensate, Cation
exchanger used to remove any cation impurities from process condensate.
Condensate Tank (T20207 capacity 2000 m 3, 8 hours holding capacity) used to
store RO product, treated Process Condensate and Steam Condensate from
urea plant. Condensate from Condensate Tank sent to Mixed Bed Ion
Exchanger (E20203A~E) for final treatment.
C. Mixed Bed Ion Exchanger
Mixed Bed Ion Exchanger (E20203A~E) is designed capable to supply
demineralized water during 101-JT turbine condensate not return. Total
capacity of Mixed Bed Ion Exchanger is 307.2 ton/h (76.7 ton/h each bed).
Mixed Bed Ion Exchanger consists of Cation Exchanger resin and Anion
Exchanger resin bed inside of each vessel. MB will remove remaining ion in
the water to produce pure water for users.
Expected Quality of Mixed Bed Ion Exchanger mainly are as follow:
Conductivity μS/cm 0.3
Total iron as Fe ppm 0.01
Silica as SiO2 ppm 0.02
pH - 6.5 - 8
Product of Mixed Bed Ion Exchanger then sent to Demineralized Water Tank
(T20208 capacity 3100 m3), part of it sent to Regeneration Tank (T20230
capacity 25 m3) for regeneration of Mixed Bed Ion Exchanger.
D. Turbine Condensate
The design capacity of turbine condensate treatment system is 240 m 3/h.
Turbine Condensate from Ammonia, Urea and CW Pump Turbine first sent to
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Iron Cartridge with filtration porous 5 µm (S20206A/B for Ammonia & Urea
Turbine Condensate and S20208A/B for CW Turbine Condensate) to remove
Iron to 0.01 ppm. Then the Turbine Condensate is cooled down to 40°C
through PHE (E20201A/B) and then sent into Demineralized Water Tank
(T20208). The system designed to treat Turbine Condensate with normal
quality. In case turbine condensate contaminated which shown by high
conductivity than the turbine condensate shall be discharged to off spec
process condensate pit.
E. Demineralized Water Tank
Demineralized Water Tank (T20208) with capacity 3100 m 3 and holding time 8
hours used to store Mixed Bed product and Turbine Condensate. From the
tank, the demineralized water distributed to each users such as:
 Ammonia Plant by DW Pumps for Ammonia (P20211A/B; A is Driven by
turbine; B is driven by Motor).
 IPP Plant (Independent Power Plant outside this new plant) by DW
Pumps for IPP (P20210A/B).
F. Neutralizing Pit
Chemical waste water from different sources collected into Neutralizing Pit
(T20209 capacity 200 m3). Waste water in this pit is neutralized by addition of
Sulfuric acid or Caustic soda to reach pH 6 – 9. Neutralized waste water than
sent to Final PKG Water treatment near the sea.
Sources of waste collected in neutralizing pit such as:
 Regeneration process of Mixed Bed Ion Exchanger and Cation Exchanger.
 CIP waste of UF and RO CIP.
 Inside spill wall of CIP package.
 Inside spill wall of WTP chemical dosing.
 Inside spill wall of Acid and Caustic Tank.
 Inside spill wall of CW dosing.
2 OPERATING PHILOSOPHY
2.1 Filtered Water Tank

Filtered Water Tank capacity is 22000 m3 that can hold a minimum for 8 hours
operation and capable to supply for fire water system, cooling water make-up,
demineralized water system, potable water system and service unit. To control
tank level use control valve LV-102 that have Minimum Stop and will be done
from DCS.
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2.2 Pre Filtration

Raw Water (from existing water treatment plant) will be supplied to battery limit
area of Potable and Demineralized Water Treatment Plant with the quality as
follows:
 pH = 7.5 – 8.5
 Turbidity (max.) = 5 NTU
 m-Alkalinity, as CaCO3 (max.) = 250 ppm
 Ca-Hardness, as CaCO3 (max.) = 180 ppm
 Total Hardness, CaCO3 (max.) = 220 ppm
 Chloride as Cl- (max.) = 62 ppm
 SiO2 (max.) = 63 ppm
 Total Dissolved Solids = 370 ppm
 Pressure = 2 – 3 kg/cm2g
 Temperature = Ambient
The SCF area provided to remove debris or dirt having size > 100 mm.
There are 3 sets of SCF manufactured by AMIAD Filtration Systems, with total
1200 m3/h filtration design capacity which will distribute for:
Filtered Water Parameter Normal Maximum
For Cooling Water Make-up
Pressure, kg/cm2g 3 6
Temperature, °C AMB 70
Total flow rate, m3/h 552.2 720
For Service Unit
Total flow rate, m3/h 30 70
For Demineralization System
Fire-fighting
Pressure, kg/cm2g 9 12.5
Incoming water enters the filter through the inlet pipe and passes through a
coarse screen which is designed to protect the cleaning mechanism from large
dirt particles. It should not accumulate large quantities of suspended solids and is
not cleaned automatically. The water then flows through a fine screen that filters
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out the smaller particles. Clean water then flows from the filter through the
outlet. The particle forms a ‘filtration cake’ which accumulates on the fine screen
surface. The cakes build up increase the pressure differential across the fine
screen and at a pre-set value (0.5 kg/cm 2g) the automatic self-cleaning cycle
begins. Clean water continues to flow through the outlet and maintained during
this back flush cycle. Suction nozzle sweep across the surface of the fine screen
pulling debris off and exhausting it out of the drain port and sent to rain sewer.
- Self-Cleaning Cycle
The automatic flushing cycle described below takes a few seconds and does
not interrupt the supply of the process water. Water is flows the inlet through
the coarse and fine screens to the outlet. At a pre-set pressure differential
(0.5 kg/cm2g), the rinse controller activates the piston and opens the flushing
valve. The water from the rotor chamber flows out the drain. The pressure in
the rotor chamber drops, releasing a strong flushing stream that flows
through the filter.
This drop-in pressure and corresponding release of the back flush stream
create suction on the nozzle tips. This effect actuates spot cleaning directly in
front of the openings of each nozzle on the inner surface of the fine screen.
The water and particles passing through the hydraulic rotor cause the dirt
collector to rotate, and the piston moves in an axial direction to the opposite
end of the filter.
The combination of rotational and axial movement of the dirt collector
assembly ensures that the nozzles sweep the entire inner surface of the fine
screen.
When the first stroke is completed, the flushing valve closes and after a very
short interval the rinse controller activates the second back flush stroke. The
dirt collector assembly spins, moving with the piston in the opposite direction
and returning to its original position.
This self-cleaning process takes between 8 – 15 seconds, depending on the
operating pressure.
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The design capacity of MMF-P & ACF-P is to produce 30 m 3/h potable water net
products. The MMF-P & ACF-P operation will be supplied by 2 dedicated pumps
(1 duty, 1 standby) FW Pump for Service Unit (P20103A/B) which deliver filtered
water from Filtered Water Tank (T20101) to MMF-P & ACF-P.
- FW Pump for Service Unit (P20103A/B)
Quantity : 2 units (1 duty, 1 stand by)
Capacity : 70 m3/ h
Head : 40 m
The pumped feed water to be treated is injected with Calcium Hypochlorite in
a certain dosage to eliminate in the absence of bacteria.
Calcium Hypochlorite solution is mixed with feed water in static mixer
Z20102. The preservation of Calcium Hypochlorite solution is prepared in
Calcium Hypochlorite Dosing Tank (T20103) which then delivered by Calcium
Hypochlorite Dosing Pump (P20108A/B). This dosing pump will be running if
FW Pump for Service Unit (P20103A/B) running. Preservation of this chemical
is referred to the Chemical Filling Preparation.
The mixed feed water is then delivered to Potable Water System which is
consists of 1 unit Multi Media Filter (S20103) and 2 units Activated Carbon
Filter (S20101A/B). 1 unit ACF-P is provided either as standby mode or in
backwash cycle.
The input water goes to the top of the MMF-P vessel through internal
distributor, flows downward through the filter media and passes out from the
bottom of the vessel then directly delivered to ACF-P vessel from top of the
ACF-P vessel through internal distributor, flows downward through the filter
media and passes out from the bottom of the vessel. The filtrated water is
collected in Potable Water Tank (T20102).
After that, potable Water is pumped into the potable water distribution pipe
by the Potable Water Pump (P20106A/B). Standby potable water pump will
be auto start if low pressure occurs on potable water header.
Potable Water Parameter Normal Maximum
Pressure, kg/cm2g 4.5 6
- Potable Water Pump (P20106 A/B):

Quantity : 2 units (1 duty, 1 unit standby)
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Package
(Persero), Tbk.
Capacity : 33 m3/ h
Head : 45 m
The MMF & ACF operates based on operating cycle (timer) and pressure
differential. The pre-set values are 11.5 hours operating cycle and/or each
0.7 kg/cm2g pressure differential. When pre-set value achieved, MMF-P &
ACF-P come to exhaust and shall go in backwash mode. Backwash will be
started on MMF-P initially and then followed by ACF-P while stand by ACF-P
will remain in permissive to continue mode.
The increase pressure differential is occurred due to adsorbed sludge/cake
build up in MMF-P and/or ACF-P as killed bacteria or other suspended solids.
The MMF-P & ACF-P is backwashed in a certain step. Backwashing water
comes from Potable Water Tank (T20102) which will be pumped by one of the
two dedicated Backwash Pump (P20107 A/B).
- Backwash Pump for PTW-ACF (P20107A/B)
Quantity : 2 units (1 duty, 1 standby)
Capacity : 114 m3/ h
Head : 20 m
The backwash mode will be carried out in the following steps:
- MMF-P Backwash Mode
Either preset timer or pressure differential achieved, the MMF operation will
STOP. All valves are closed and backwash mode will be carried out,
sequentially:
 Drain and Venting
Valve XV105 and XV107 open for about 180 second to release exceeding
pressure drop in the vessel and decrease water level about 30 cm above
the media and allowing pressure release within the vessel.
 Air Scouring
Valve XV104, XV106 and XV107 open which will deliver plant air from
bottom to top of the vessel for about 240 second. This is for breaking
adsorbed sludge/cake build up on the media. The plant air is from PA
Buffer Tank (T20206) with air pressure maximum 4.5 kg/cm 2g and air flow
rate about 61.23 Nm3/h.
 Backwashing
Valve XV103, XV104 and P20107A/B will ON for about 16 minutes at the
capacity of 114 m3/h. The backwash water will flow from bottom to top of
the vessel to wash broken adsorbed sludge/cake build up on the media
and sent to rain water sewer.
201485-20000-TS-04
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 Settling
P20107A/B OFF, valve XV107 ON while the other valves are closed for
about 120 second. This is to allow media to be settled and back to its
compact bed.
 Service for drain (rinsing) mode
Valve XV101, XV105 and XV107 open and P20103A/B ON for about
300 second to flush water from the vessel at capacity 30 m3/h.
 Service
Valve XV101 and XV102 open and P20103A/B ON at capacity 30 m 3/h. In
this step the MMF is back in its operation mode.
While MMF-P is on backwash mode, the ACF-P either “A” or “B” is on standby
mode and will continue on operation whenever MMF-P on its operation
mode.
- ACF-P Backwash Mode
Either preset timer or pressure differential achieved, the ACF-P operation will
STOP. All valves are closed and backwash mode will be carried out,
sequentially:
 Venting
XV113A open, this is to release exceeding pressure drop in the vessel.
 Backwashing
Valve XV110A, XV111A and P20107A/B will ON for about 17 minutes at
the capacity of 114 m3/h. The backwash water will flow from bottom to
top of the vessel to wash broken adsorbed sludge/cake build upon the
media.
 Settling
XV113A ON while the other valves are closed. This is to allow media to be
settled and back to its compact bed for about 7 minutes.
Valve XV108A, XV112A and XV113A open and P20103A/B ON for about
360 second to flush water from the vessel at capacity of 33 m 3/h.
 Service
Valve XV 108A and XV 109A open and P20103A/B ON capacity of
33 m3/h. Once this cycle above has been done, the S20101A is ready to be
in service mode and wait for permissive start if the second ACF S20101B
on duty.
For the other ACF-P, the same sequence and periods will remain the same as
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
above backwash sequence, suffix “A” replaced by “B”. When one ACF is on
backwash cycle, the production will be served by standby vessels.

Multi Media Filter & Activated Carbon Filter
The MMF-ACF for DW Plant consists of 6 units Multi Media Filter (S20201A~F)
and 6 units Activated Carbon Filter (S20202A~F). Design capacity of each unit of
MMF and ACF is 74.5 m3/h and in normal condition will operate 5 units each to
produce required water production. The rest MMF and ACF is provided either as
standby mode or in backwash cycle. The MMF-ACF operation will be supplied by
3 dedicated pumps (2 duties, 1 standby) FW Pump for DW (P20102A/B/C) which
delivers filtered water from Filtered Water Tank (T20101) to MMF-ACF.
MMF-ACF Water Parameter Normal Maximum
- FW Pump for DW (P20102 A/B/C)

Quantity : 3 units (2 units duty, 1 unit standby)
Normal Capacity : 186 m3/h
Rated Capacity : 205 m3/h
Head : 45 m
The pumped feed water to be treated is injected with an oxidant in a certain
dosage to eliminate in the absence of bacteria. An oxidant solution (Sodium
Hypochlorite) is mixed with feed water in static mixer (Z20212).
The preservation of oxidant solution is prepared in Oxidant Dosing Tank
(T20111) which then delivered by Oxidant Dosing Pump for MMF
(P20216A/B). This dosing pump will be running if P20102A/B/C running.
Preservation of this chemical refer to the Chemical Filling Preparation.
The mixed feed water is then delivered to the top of the MMF vessel through
internal distributor, flows downward through the filter media and passes out
from the bottom of the vessel.
Filtrated water is collected in a header and distributed to ACF vessel which
will deliver from top of the ACF vessel through internal distributor, flows
downward through the filter media and passes out from the bottom of the
vessel. The filtrated water from MMF-ACF is then flow through header pipe to
ACF Filtered Water Tank (T20201).
In initial start-up, the 5 units of MMF and ACF operate at the same time.
While the 6th both MMF and ACF will be backwashed to get them ready for
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PT. ADHI KARYA
Package
(Persero), Tbk.
replacing the operated once when necessary.

MMF & ACF System for DW Plant operates based on operating cycle (timer)
and pressure differential. The pre-set values are 11.5 hours operating cycle
and/or each 0.7 kg/cm2g pressure differential. When pre-set value achieved,
MMF-ACF come to exhaust and shall go in backwash mode. Backwash will be
started on MMF initially and then followed by ACF. The increase pressure
differential is occurred due to absorbed sludge/cake build up in MMF and/or
ACF as killed bacteria or other suspended solids. Whenever pre-set timer or
differential pressure achieved, the backwash cycle will apply in a consecutive
way with the vessel combination of MMF 1 followed by ACF 1 then MMF 2
followed by ACF 2 and other MMF-ACF consecutively. When one combination
is on backwash cycle, the production will be served by standby vessels.
The MMF-ACF is backwashed in a certain step and backwashing water comes
from Brine Tank (T20204) which will be pumped by one of the two dedicated
Backwash Pump for MMF & ACF (P20207 A/B).
- Backwash Pump for MMF & ACF (P20207A/B)
Quantity : 2 units (1 duty, 1 unit standby)
Capacity : 224 m3/h
Head : 20 m
- MMF Backwash
The suffix “A”, “B”, “C”, “D”, “E” and ”F” is applied to the regarded MMF
respectively. Either pre-set timer or pressure differential achieved, one of the
MMF operation will STOP. All valves are closed and backwash mode will be
carried out, sequentially:
 Drain and Venting
Valve XV205 and XV207 open or about 180 second. This is to release
exceeding pressure drop in the vessel and decrease water level about
30 cm above the media.
 Air Scouring
Valve XV204, XV206 and XV207 open which will deliver plant air from
bottom to top of the vessel for about 240 second. This is for breaking
adsorbed sludge/cake build up on the media. The plant air is from PA
Buffer Tank T20206 with air pressure maximum 4.5 kg/cm 2g and air flow
rate about 126.72 Nm3/h.
 Backwashing
Valve XV203, XV204 and P20207 A/B will ON for about 16 minutes in the
the vessel to wash broken adsorbed sludge/cake build up on the media.
 Settling
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XV207 ON while the other valves are closed. This is to allow media to be
settled and back to its compact bed for about 120 second.
Valve XV201, XV205 and XV207 open and P20102A/B/C ON for about
300 second to flush water from the vessel in the capacity of 74.5 m 3/h.
 Service
Valve XV201 and XV202 open and P20102A/B/C ON.
- ACF Backwash
The suffix “A”, “B”, “C”, “D”, “E” and ”F” is applied to the regarded ACF
respectively. Either pre-set timer or pressure differential achieved, the ACF
operation will STOP. All valves are closed and backwash mode will be carried
out, sequentially:
 Venting
XV213 open, this is to release exceeding pressure drop in the vessel.
 Backwash
Valve XV210, XV211 and P20207 A/B will ON for about 17 minutes in the
the vessel to wash broken adsorbed sludge/cake build up on the media.
 Settling
Valve XV208, XV212 and XV213 open and P20207 A/B ON for about
360 second to flush water from the vessel at the capacity of 74.5 m 3/h.
 Service
Valve XV208 and XV209 open and P20102A/B ON. Once this cycle above
has been done, the ACF is ready to be in service mode and wait for
permissive start if the others ACF on duty.
UF Unit
UF unit consist of 4 trains S20203A~D. Each train is designed for input capacity of
93 m3/h and will occupy 18 modules of Dow SFP 2880.
Module features:
 0.03 mm nominal pore diameter for removal of bacteria, viruses and
particles including colloids.
 PVDF polymeric hollow fibers for high strength and chemical resistance.
 Hydrophilic PVDF fiber for easy cleaning and wettability that help maintain
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
long term performance.

 Outside-In flow configuration for high tolerance to feed solids and the use
of air scour cleaning.
 UPVC housings eliminate the need for pressure vessels and are resistant to
UV light.
Modules are assembled with connecting pipe for service, backwash, air scouring
and cleaning lines and stand within support frame. The feed water flow through
header of service pipe line and enter the module at the side port located on the
bottom end cap. Feed begins on the outside of the fiber and filtrated water will
flow through the side port located on the top of end cap and collected in the
internal filtrate pipe header. The concentrate (discharge flow from the outside of
fiber) will flow through concentrate port at the top of end cap and collected in
the internal concentrate pipe header. On normal operation, the routine operating
sequence will include service, air scouring and backwash steps. Operating of UF
will occupy UF Feed Pump (P20201A/B/C) which will deliver water from T20201
to UF Skid.
The suffix “A”, “B”, “C” and “D” is applied to the regarded UF respectively.
Collected filtrated water from each modules and skids flows to UF Filtered Water
Tank (T20202).
UF Water Parameter Normal Maximum
Permeate SDI Max. 3 Max. 3
In normal condition 2 units UF Feed Pump will operate. Operator shall choose
which pumps are operated.
- UF Feed Pump (P20201A/B/C)
Normal Capacity : 186 m3/ h
Rated Capacity : 205 m3/ h
Head : 35 m
On operating service cycle, the contaminants will be detained on outer side
surface of the fiber and will cause trans-membrane pressure will rise. At the
end of preset operating cycle time, backwash sequence is triggered.
Pre-set operating cycle sequentially are:
 Service time
P20201A/B/C ON, XV214, XV215 and XV218 (if cross flow configuration
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PT. ADHI KARYA
Package
(Persero), Tbk.
necessary) open in 90 minutes to produce filtrate water.

 Service stop
P20201A/B/C OFF, followed by shutting XV214, XV215, and XV218 at 1
second after.
 Air scouring
Plant air is delivered through XV219 and out to XV220 for 20 second to
break up sludge/cake build up on outside of the fiber. The plant air is from
PA Buffer Tank (T20206) with air pressure maximum 2.5 kg/cm 2g and air
flow rate about 90 Nm3/h.
 Drain
XV217 and XV220 open to allow water flow gravitationally for 20 second
to side port and send to rain water sewer.
 Top Backwash
P20202A/B ON, XV216 and XV220 open in 30 second in capacity of
138 m3/h,dirt is discharging from concentrate port and send to
Neutralization Pit (T20209).
 Bottom Backwash
P20202A/B ON, XV216 and XV217 within 30 second in capacity of
138 m3/h,dirt is discharging from bottom side port and send to rain water
sewer.
 Forward Flush
P20201A/B/C ON, XV214 and XV220 open within 60 second in the
capacity 84 m3/h, to make sure residual dirt is removed and will flow
through bottom side port and sent to Neutralization Pit (T20209). The UF
Skid is ready in operation mode and every 30 cycle times.
There are 2 dedicated Backwash Pumps for UF (P20202A/B):
- Backwash Pump for UF (P20202 A/B)
Quantity : 2 units (1 unit duty, 1 unit standby)
Head : 20 m
Due to water requirement for backwashing MMF-AC, UF Unit operation will
be in cross-flow configuration with minimum cross-flow is about 3.5% of feed
water capacity. This cross-flow water is delivered to Brine Tank (T20204).
- Chemical Enhanced Backwash (CEB)
 Acid CEB with interval 336 h.
 Alkali & Oxidant CEB with interval 168 h.
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
After interval time, PLC will stop each UF skid sequentially and carry out UF
chemical cleaning (CEB) for about 20 minutes.
Preset CEB sequence:

 Air scouring
Plant air is delivered through XV219 and XV220 within 20 second to break
up sludge/cake build up on outside of the fiber
 Drain
to side port and send to Neutralization Pit (T20209).
 Top Backwash
P20202A/B ON, XV216 and XV220 open, Oxidant Dosing Pump
(P20217A/B) ON and will deliver oxidant solution from T20211. Alkali
Dosing Pump (P20220A/B) ON and will deliver alkali solution from
T20220. Citric Acid Dosing Pump (P20223A/B) ON and will deliver
hydrochloric acid solution from T20217. Each stream then mixed in
Z20213 in total capacity of 138 m 3/h, for 30 second. The output dirt from
XV220 is sent to Neutralization Pit (T20209).
 Bottom Backwash
P20202A/B ON, XV216 and XV217 open, Oxidant Dosing Pump
(P20216A/B) ON and will deliver oxidant solution from T20211. Alkali
Dosing Pump (P20220A/B) ON and will deliver alkali solution from
T20220. Citric Acid Dosing pump (P20223A/B) ON and will deliver
hydrochloric acid solution from T20217. Each stream then mixed in
Z20213 in 138 m3/h, capacity for 30 second. The output dirt from XV217 is
sent to Neutralization Pit (T20209).
 Soaking
P20202A/B OFF, XV216 and XV217 open. Injected chemicals are allowed
to react with contaminants that have attached to the membrane surface
or penetrated fiber wall within 16 minutes.
 Air scouring
Plant air is delivered through XV219 and out to XV220 within 20 second to
break reacted contaminant from fiber surface.
 Drain
XV217 and XV220 open to allow reacted contaminant flow gravitationally
for about 20 second to side port and send to Neutralization Pit (T20209).
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 Top Backwash
P20202A/B ON, XV 216 and XV 220 open within 30 second to discharge
dirt through concentrate port and sent to Neutralization Pit (T20209) in
138 m3/h capacity.
 Bottom Backwash
P20202 A/B ON, XV216 and XV217 open for 30 second, dirt is discharging
from bottom side port and sent to Neutralization Pit (T20209) 138 m 3/h
capacity.
 Forward Flush
P20201A/B/C ON, XV214 and XV220 open for 60 second, to make sure
residual dirt is removed and will flow through bottom side port 84 m 3/h to
Neutralization Pit (T20209).
Chemical used for CEB as follows:
Type Chemical Name Dosage Maximum
CEB Acid HCl 400 ppm
CEB Alkali NaOH 650 ppm
CEB Oxidant NaOCl 250 ppm
- Cleaning In Place (CIP) System

The CIP is on demand operation and carried out in manual mode. The
frequency of CIP depends on the feed water quality but can range from 1 to 3
months. The CIP operation is almost the same as CEB, with the sequence as
follow (example for Acid CIP).
 Dilution
The chemical will be dilute by demineralized water in T20210A and
transferred to UF Skid by chemical cleaning pump P20230.
 Air scouring
up sludge/cake build up on outside of the fiber.
 Draining
to side port and send to rain water sewer.
 Top Backwash
Backwash pump (P20202A/B) ON, XV216 and XV220 open. The output
dirt from XV217 is sent to Neutralization Pit (T20209). If necessary, this
backwash can be repeated 3 – 8 times to remove contaminants or
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Package
(Persero), Tbk.
foulants.
 Bottom Backwash
P20202A/B ON, XV 216 and XV217 open. The output dirt from XV217 is
sent to Neutralization Pit (T20209). If necessary, this backwash mode
repeated 3 – 8 times to remove contaminants or foulants.
 Air scouring
up sludge/cake build up on out.
 Drain
XV217 and XV220 open to allow reacted contaminant flow gravitationally
for about 20 second to side port and send to Neutralization Pit (T20209).
This is to remove excess water and prevent dilution of the CIP chemicals.
 CIP injection
Manual valve in UF Skid where chemical solution entered and to be
recycle back to cleaning tank are opened start P20232 ON for 30 minutes
recycle. This step will let the chemical solution flow on the outside of the
module for 30 minutes through chemical cleaning tank. A small filtrate
stream will also be collected and recycled to the chemical cleaning tank.
 Soaking
All valves closed for 60 minutes or longer depend on the degree of fouling
that has occurred. This step is to allow chemical solution to react with the
contaminants.
 Continue Recycle
Continue the recycle again for 30 minutes.
Air scouring, for 30 second
Drain, to remove concentrated chemicals.
 Backwash
To remove any remaining contaminants on the outside of the fibers within
necessary times.
 Forward flush
To remove any remaining contaminants on the inside of the fibers within
necessary times.
The CIP procedure above is for single alkali or acid chemical solution. If an
acid and alkali cleaning are required, the CIP steps would be repeated for
each chemical solution.
Chemical used for CIP as follows:
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PT. ADHI KARYA
Package
(Persero), Tbk.
Type Chemical Name Dosage Maximum

CIP Acid HCl 2000 ppm
CIP Alkali NaOH 1000 ppm
CIP Oxidant (For UF Only) NaOCl 2000 ppm
The CIP alkali is used when the UF fouling is caused by organics. While the
CIP acid is applied when UF fouling cause by inorganic.
- Chemical Cleaning Pump UF (P20232)

Quantity : 1 unit
Head : 34 m
RO Unit
RO Unit consists of 4 trains. Each train is design for input capacity of 84 m3/h
with salt rejection of 25% and the net product is 63 m3/h per train.
RO system consists of:
 Static Mixer (Z20214)
 Cartridge Filter (S20204A~E)
 RO Feed Pump (P20203A/B/C)
 RO High Pressure Pump (P20204A~E)
 RO Skid (S20205A~D)
Input water from T20202 with minimal level 1 m above suction center line of the
P20203 A/B/C is gravitationally flow through header pipe to static mixer Z20214
to mix with chemical pretreatment.
- RO Feed Pump (P20203A/B/C)
Quantity : 3 units (on normal operation 2 units duty, 1 unit
standby)
Head : 35 m
The pretreatment chemicals used for RO are:
 Anti-scale
Anti-scale solution is come from Anti-scale Tank (T20216) and transferred
by Anti-scale Dosing Pump (P20222A/B).
 Reductant
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(Persero), Tbk.
Reductant solution is come from Reductant Tank (T20212) and transferred

by Reductant Dosing Pump (P20218A/B).
 Non-oxidant Biocide
Non-oxidant Biocide solution is come from Non-oxidant Biocide Tank
(T20215) and transferred by Non-oxidant Biocide Dosing Pump
(P20221A/B).
 Sulfuric Acid
Sulfuric Acid solution is come from Acid Storage Tank (T20219) and
transferred by Acid Dosing Pump (P20219 A/B).
All the chemicals above will be mixed in Z20214. The mixture then is
delivered via header to S20204A~E. Filtrate from each cartridge filter is
then pumped by P20204A~E to RO skid. The suffix “A”, “B”, “C” and “D” is
applied to the regarded RO skid.
The Cartridge Filter is provided in the line to preserve any impurity
absence in the feed water. It is designed for flow rate = 84 m 3/h for each
vessel and total 5 vessels. It consists of cartridge filter with nominal 5 μm
fineness filter cloth.
When the pressure drop within the cartridge increase from preset value
(0.5 kg/cm2g), the cartridge filter must be replaced manually. Filtered
water from cartridge is directly come to the suction of the P20204A~E.
- RO High Pressure Pump (P20204A~E)
Quantity : 5 units (on normal operation 4 units duty, 1 unit
standby)
Head : 140 m
The RO skid will consist of modular spiral wound hollow fiber which
assembled in high pressure vessel and connecting with service, permeate and
concentrate pipe line. In RO skid, water enters through side port and
permeates flow through center port of the module while concentrate
(rejected) will flow to concentrate port. Due to input flow limitation
(allowable minimum flow), the operational of RO Skid shall be operated in a
way that every 2 skids RO will be supplied by 1 unit RO Feed Pump.
Permeate will be delivered to Degasifier (C20201) to transform bi-carbonate
to CO2 gas by air which is supplied by DB (B20201A/B). Then it is collected in
Degassed Water Tank (T20203) and directly pumped with Degasifier Water
Pump (P20205A/B/C) to Condensate Tank (T20207).
- Degasifier Blower (B20201A/B)
The DB (B20201A/B) operates based on the operation of RO High Pressure
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
Pumps (P20204A~E). It operates only when RO P20204A~E in service mode.

- Degasifier Water Pump (P20205A/B/C)
Head : 20 m
RO Water Parameter Normal Maximum
Total inlet capacity, m3/h 79.65 372
Product conductivity, μS/cm < 10 < 10
In its operation, increasing pressure drop will occur due detained

contaminants on outer side surface of the hollow fiber between input and
concentrate pressure. Once the pressure drop increase and achieve the
preset value (3 kg/cm 2g), operator shall choose to shut off RO skid operation
and carry out the cleaning cycle.
- Cleaning Cycle
Cleaning cycle is carried in manual operation. The general guideline for
cleaning is as follow:
 Shut off the RO High Pressure Pump and followed by RO Feed Pump
related to Skid RO which to be cleaned.
 Close the manual feed, permeate and concentrate valves.
 Open input cleaning valve and concentrate valves.
 Chemical Cleaning Pump (P20215) ON which will deliver chemical
solution from T20210B. The solution will enter the RO skid to input port,
flow at the fiber then goes to outside port and collected in concentrated
pipe line and sent back to T20210B. This chemical recirculation is carried
out within 30 minutes.
 Soaking
All valves are closed and cleaning pump P20215 OFF. The solution is
allowed inside the module for about 3 hours to react with the
contaminants.
 Flushing mode
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PT. ADHI KARYA
Package
(Persero), Tbk.
P20206A/B ON, XV221, XV222, XV223 open. Flushing water from T20203
will be delivered by P20206 A/B to input line of RO skid, flow through all
output lines and drained to Neutralization Pit (T20209).
This flushing mode is carried out within necessary time and stop when
drained pH is the same with flushing water.
- Chemical Cleaning Pump RO (P20215)

Quantity : 1 unit
Head : 45 m
2.5 Condensate & Demineralized Water Plant

ACF for Condensate and Cation Exchanger
The ACF-C consists of 3 Activated Carbon Filter with design capacity of each
unit is 75 m3/h and in normal condition will operate 2 units to produce
required water production. The rest ACF-C is provided either as standby mode
or in backwash cycle.
The ACF operates based on operating cycle (timer) and pressure differential.
The pre-set values are 11.5 hours operating cycle and/or each 0.7 kg/cm 2g
pressure differential. When pre-set value achieved, ACF-C come to exhaust
and shall go in backwash mode.
The CE consists of 2 vessels and will only one vessel in service. The second
vessel will remain in standby mode. The design capacity of each cation
exchanger is 150 m3/h with 72 hours pre-set operating cycle. When pre-set
value achieved, E20202 A/B shall be regenerated in regeneration mode.
Water to be treated is from process condensate of ammonia and urea unit.
Both streams are provided with modular flow control (FT 214 & FT 215) and
temperature (TE210 & TE212). However there are some limitation for both
flow and temperature allowed. The flow total allowed for both from Urea and
Ammonia Unit are 150 m3/h. The temperature allowed for both Urea and
Ammonia are 45°C. If one of the Urea or Ammonia Condensate reach
temperature or flow meter set point, the system ACF-C and CE will give alarm.
Combine of both stream flow through header pipe and enter at the top of 2
units ACF-C vessel through internal distributor, flows downward through the
filter media and passes out from the bottom of the vessel.
Filtrate water is collected in a header and then flow to E20202 A or B vessel
which will enter from top of the vessel through internal distributor, flows
downward through the filter media and passes out from the bottom of the
vessel. Filtrated water then flow to Condensate Tank (T20207).
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Package
(Persero), Tbk.
ACF-C Parameter Normal Max

Temperature, °C 40 70
- ACF-C Backwash
The suffix “A”, “B” and “C” is applied to the regarded ACF respectively.
Either pre-set timer or pressure differential achieved, the ACF operation will
STOP. All valves is closed and backwash mode will be carried out, sequentially:
 Venting
XV231 open, this is to release exceeding pressure drop in the vessel.
 Backwashing
XV228, XV229 and P20209 A/B will ON for about 17 minutes.
The backwash water will flow from bottom to top of the vessel to wash
broken adsorbed sludge/cake build up on the media at the capacity of 225
m3/h.
 Settling
Valve XV226, XV230 and XV231 open and condensate water enter for
about 6 minutes to flush water from the vessel in the capacity 75 m 3/h.
 Service
Valve XV226 and XV227 open and condensate water ON in the capacity
75 m3/h.
Once this cycle above has been done, the ACF is ready to be in service
mode and wait for permissive start if the others ACF on duty.
- Backwash Pump for Condensate ACF (P20209A/B)
Head : 20 m
- Cation Exchanger Regeneration
Either pre-set timer or pressure differential achieved, the CE operation will
STOP. All valves is closed and regeneration mode will be carried out,
sequentially: The suffix “A” and “B” is applied to the regarded CE respectively.
The regeneration method is in co-current configuration.
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Regeneration cycle is carried out as follows:

 Backwash
XV 235 and XV 237 open, which will flow ACF-C filtrate water to backwash
CE within 10 minutes at capacity 11.3 m3/h. Water flow from bottom of CE
vessel, goes upwards and out from top of the vessel. The backwash water
is sent to Neutralization Pit (T20209).
 Acid Regeneration
Regeneration Pump (P20212A), P20225A/B ON, XV234, XV236 and XV205.
Demineralized water from Regeneration Tank (T20230) is pumped by
P20212A. Sulfuric acid from T20219 is pumped by P20225A/B. These two
streams are mixed in Z20218. The acid solution flow to cation vessel at
top side of the vessel, allowing it to flow through media and come out
from the bottom of the vessel with the capacity of 9.8 m 3/h. The waste
water is then sent to Neutralization Pit (T20209).
 Acid Displacement
XV232 and XV236 open. Demineralized water from Regeneration Tank
(T20230) is pumped by P20212A flow from top of CE vessel within
39 minutes at 8.6 m3/h and allowing it to go through media and flushing
excess chemical in the vessel. This wastewater is sent to Neutralization Pit
(T20209).
 Filling
XV232 and XV238 open in 30 second which allow input feed water to fill
the vessel.
 Fast rinse
XV232 and XV234 open. This will allow filtrate water from ACF-C at 8.6
3
m /h to flow from top to bottom in CE vessel and the come out water is
sent to Neutralization Pit (T20209) within 6 minutes.
Once this cycle above has been done, the CE is ready to be in service
mode and wait for permissive start if the others CE on duty.
Mixed Bed Ion Exchanger

The MB is a combination of cation and anion resin exchanger to treat further
the decation water to meet standard demineralized water quality required.
There are 5 units of MB, each design for 77.5 m3/h input capacity and 40
hours operating times with allowable maximum conductivity product is 0.3
μS/cm.
Water to be treated is from Condensate Tank (T20207) is pumped with
Deionized Water Pump (P20208A/B/C) to main header pipe and flow to the
mixed bed vessel. Water enters at the top of the vessel through internal
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distributor, flows downward through the filter media and passes out from the
bottom of the vessel. Demineralized water is collected in a header and then
flow to Demineralized Water Tank (T20208).
MB Parameter Normal Maximum

Pressure, kg/cm2g 3 6.4
Temperature, °C 40 70
Product conductivity, μS/cm 0.3 0.3
- Deionized Water Pump (P20208A/B/C)

Normal capacity : 96 m3/h
Head : 30 m
When totalizer set point is reached (3100 m 3/train) the respective mixed bed
will STOP then it will continue to the regeneration mode.
In regeneration cycle of one exchanger, the remaining vessels will still on
operation. Water for backwash is from decation water, so the capacity of
other exchangers which are still on operation will decrease in a certain time.
- Mixed Bed Regeneration
Idle, for 2 second.
 Backwash
XV243, XV244 and P20208A/B/C will ON within 25 minutes to allow
decation water to enter from bottom to top of the vessel in the capacity
8.5 m3/h.
 Drain
XV244 and XV250 open in 85 second to decrease water level inside the
vessel and allowing it to flow gravitational to the Neutralization Pit
(T20209).
- Acid and Alkali Regenerations:
a. Acid Regeneration
XV246, XV248 and XV206 open, P20212B/C and P20226A/B ON. This will
deliver demineralized water from tank T20230 which is pumped by
P20212B/C. The sulfuric acid from T20219 is pump with dosing pump
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P20226A/B and mixed with demineralized water in static mixer Z20219.

The solution then flow to mixed bed from bottom the vessel (XV248), flow
upwards and discharge at XV246 to be sent to Neutralization Pit (T20209).
The capacity of this regeneration is 10.5 m3/h within 52 minutes.
b. Alkali regeneration
XV246, XV247 and XV207 open, P20212B/C and P20230A/B ON. This will
deliver demineralized water from tank T20230 which is pumped by
P20212B/C. The alkali from T20220 is pump with P20224A/B and mixed
with demineralized water in Z20220. The solution then flow to mixed bed
from top side the vessel (XV247), flow downwards and discharge at XV246
to be sent to Neutralization Pit (T20209).
The capacity of this regeneration is 4.1 m3/h within 45 minutes.
Acid Displacement
XV246, XV248 and XV206 open, P20212B/C ON. This will deliver
demineralized water from T20230 which is pumped by P20212C through
Z20219 and enter from bottom the vessel (XV248), flow upwards and
discharge at XV246 to be sent to Neutralization Pit (T20209). The capacity
of this displacement is 2.6 m3/h within 16 minutes.
 Alkali Displacement
XV246, XV247 and XV207 open, P20212B/C ON. This will deliver
demineralized water from T20230 which is pumped by P20212B/C
through Z20220 and enter from top side the vessel (XV247), flow
downwards and discharge at XV246 to be sent to Neutralization Pit
(T20209). The capacity of this regeneration is 5.3 m 3/h within
71 minutes.
 Air Scouring
XV244, XV249 and XV250 and air vent open in 10 minutes which
allows plant air to enter the vessel from bottom of the vessel to mix
both resin components.
 Filling
XV241 and XV250 open in 95 second which allows input feed water to
fill the vessel.
 Fast Rinse
XV241, XV245 and P20208A/B/C will ON in 21 minutes to allow input
feed water to flush remaining water from the vessel and make sure
that conductivity of the produce water is below allowable preset
value.
Iron Cartridge & Condensate Cooler

Turbine Condensate from process unit is delivered to Process Turbine
Condensate Iron Cartridge (S20206A/B) to preserve any impurity absence in
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the feed water. It is designed for 200 m3/h with operating temperature
49.5°C. There will be 2 unit of S20206 which 1 duty and 1 standby.
Turbine Condensate from CW Pump turbine is delivered to Cooling Water
Pump Turbine Condensate Iron Cartridge (S20208 A/B). It is designed for
35 m3/h with operating temperature 49.5°C. There will be 2 unit of S20206
which 1 duty and 1 standby. When the pressure drop within the cartridge
increase from preset value (0.5 kg/cm 2g),the cartridge filter must be replaced
manually.
The filtrate from cartridge is then sent to Condensate Cooler (E20201A/B).
Cooling water supply is provided with maximum temperature 32°C at capacity
227 m3/h to reduce Turbine Condensate temperature from 49.5°C to 40°C
before delivered to Demineralized Water Tank (T20208). There are 2 PHE with
each design capacity 240 m3/h.
2.6 Neutralization Pit (T20209)

Input water to Neutralization Pit (T20209) are from:
 Waste water of ACF for condensate backwash = 225 m3/h within 30 minutes.
 Waste water of condensate for Fast Rinse Cation Exchanger = 8.6 m 3/h within
6 minutes.
 Waste water of DW for Acid Regeneration CE = 9.8 m3/h within 42 minutes.
 Waste water of DW for Acid Displacement CE = 8.6 m3/h within 39 minutes.
 Waste water of condensate for Backwash CE = 11.3 m3/h within 10 minutes.
 Waste water of condensate for Fast Rinse CE = 8.6 m3/h within 6 minutes.
 Waste water of DW for Acid Regeneration MB = 10.5 m 3/h within 52
minutes.
 Waste water of DW for Alkali Regeneration MB = 4.1 m3/h within 45 minutes.
 Waste water of DW for Acid Displacement MB = 2.6 m3/h within 16 minutes.
 Waste water of DW for Alkali Displacement MB = 5.3 m 3/h within 71
minutes.
 Waste water of DW for Backwash MB = 8.5 m3/h within 6 minutes.
 Waste water of DW for Fast Rinse MB = 26.5 m3/h within 10 minutes.
 Waste water of RO for CIP = 52 m3/h within 6 minutes.
 Waste water of UF for Backwash = 138 m3/h within 60 second.
 Waste water of UF for Forward Flush = 84 m3/h within 60 second.
 Waste water of UF for CIP = 27 m3/h within 240 second
 Waste water of UF for CEB Top = 138 m3/h within 60 second.
 Waste water of UF for CEB Bottom = 138 m3/h within 60 second.
 Waste water of UF for Forward Flush CEB = 84 m3/h within 60 second.
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In the worst case which all waste water enters the Neutralization Pit (T20209).
The setting of low level is set to 0.67 m above bottom of the pit. When water
levels reach this setting point, Neutralization Water Pump (P20213A/B) is ON.
Pump will in the first step to circulate water back to Neutralization Pit (T20209).
pH controller is provided at pump discharge.
P20213A/B is interlocked with Acid Dosing Pump (P20228A/B) and Alkali Dosing
Pump (P20231A/B).
Preset value for pH is 6-9 and the electrode will operate either acid or alkali
dosing pump. When pH reaches preset value, then water is discharge to chemical
waste water (TP-13).
- Neutralization Water Pump (P20213A/B)
Head : 50 m
2.7 Chemicals
Acid (Sulfuric Acid)
Acid will be supplied by truck and/or OEP and will be transferred to Acid Storage
Tank (T20219) by Acid Unload Pump (P20227).
Pump operation is manual and filling will regard to level gauge LG216.
- Acid Unload Pump (P20227)
Quantity : 1 unit
Head : 15 m
Alkali (Natrium Hydroxide)
Alkali will be supplied by truck and will be transferred to Alkali Storage Tank
(T20220) by Alkali Unload Pump (P20229).
Pump operation is manual and filling will regard to level gauge LG217.
- Alkali Unload Pump (P20229)
Quantity : 1 unit
Head : 15 m
Chemical Cleaning Tank UF
This tank is used for UF cleaning in CIP mode which is operated manually.
With regards to chemical used for CIP steps, in initial startup dilution water is
fed to T20210A from DW head pipe until it reaches 90% of the total volume of
the tank. P20232 ON in circulating mode by opening bypass valve to give
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stream for mixing in the tank. Chemical is fed to the tank with certain volume
to get required chemical percentage for CIP mode. When the dilution has
finished, pump can be OFF for standby to wait permission or directly carried
out the CIP mode.
Chemical Cleaning Tank RO
This tank is used for RO cleaning in cleaning mode which is operated
manually. With regards to chemical used for cleaning steps, in initial startup
dilution water is fed to T20210B from DW head pipe until it reaches 90% of
the total volume of the tank. P20215 ON in circulating mode by opening
bypass valve to give stream for mixing in the tank. Chemical is fed to the tank
with certain volume to get required chemical percentage for cleaning mode.
When the dilution has finished, pump can be OFF for standby to wait
permission or directly carried out the CIP mode.
Oxidant Dosing Unit
Oxidant solution is prepared in Oxidant Tank (T20211). Filling of the tank is
carried out manually by feeding it with a certain concentration of oxidant
until the reach 90% of total tank volume. Since oxidant solution is used
continuously for MMF-ACF for DW (S20201A~F and S 20202A~F) and UF CEB
mode, the tank is provided with level transmitter and operator have to make
sure for oxidant solution availability. For MMF-ACF, the solution is transferred
by P20216A/B to Z20212. For UF CEB process, the solution is transferred by
P20217 A/B from T20211 to Z20213.
Reductant Dosing Unit
Reductant solution is prepared in Reductant Tank (T20212) in initial startup
dilution water is fed to T20212 from DW head pipe until it reaches 90% of the
total volume of the tank. Mixer A20201 ON due to level achieved. Manually
operator shall feed the reductant powder in a certain volume/weight to give
required solution concentration.
Since reductant solution is used continuously for RO chemical pretreatment
operation, the tank is provided with level transmitter and operator have to
make sure for reductant solution availability. The solution is transferred by
P20218 A/B from T20212 to Z20214.
Citric Acid Dosing Unit
Hydrochloric Acid solution is prepared in citric acid tank (T20217). In initial
startup dilution water is fed to T20217 from DW head pipe until it reaches
90% of the total volume of the tank.
A20204 ON due to level achieved. Manually operator shall feed the citric acid
powder in a certain volume/weight to give required solution concentration.
Since citric acid solution is consumed continuously for UF-CEB operation, the
tank is provided with level transmitter and operator have to make sure citric
acid solution availability. The solution is transferred by P20223 A/B from
T20217 to Z20213.
Non-Oxidant Biocide Dosing Unit
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Non-oxidant Biocide solution is prepared in Non-oxidant Biocide Tank

(T20215). In initial startup dilution water is fed to T20215 from DW head pipe
until it reaches 90% of the total volume of the tank. A20202 ON due to level
achieved.
Manually operator shall feed the non-oxidant biocide powder in a certain
volume/weight to give required solution concentration. Since non-oxidant
biocide solution is consumed continuously for RO chemical pretreatment
operation, the tank is provided with level transmitter and operator have to
make sure non-oxidant solution availability. The solution is transferred by
P20221 A/B from T20215 to Z20214.
Anti-Scale Dosing Unit
Anti-scale solution is prepared in Anti-Scale Tank (T20216). In initial startup
dilution water is fed to T20216 from DW head pipe until it reaches 90% of the
total volume of the tank. A20203 ON due to level achieved. Manually
operator shall feed the anti-scale powder in a certain volume/weight to give
required solution concentration.
Since anti-scale solution is consumed continuously for RO chemical
pretreatment operation, the tank is provided with level transmitter and
operator have to make sure for anti-scale solution availability. The solution is
transferred by P20222 A/B from T20216 to Z20214.
Calcium Hypochlorite Dosing Unit
Calcium Hypochlorite solution is prepared in Calcium Hypochlorite Tank
(T20103) In initial startup dilution water is fed to T20103 from Potable Water
Pump (P20106A/B) until it reaches 90% of the total volume of the tank.
A20101 ON due to level achieved. Manually operator shall feed the Calcium
Hypochlorite in a certain volume/weight to give required solution
concentration. Since calcium hypochlorite solution is consumed continuously
in MMF-P & ACF-P pretreatment operation, the tank is provided with level
transmitter and operator have to make sure for calcium hypochlorite solution
availability. The solution is transferred by P20108 A/B from T20103 to Z20102.
2.8 Sequence Table

" o " = Valve or pump is opened or operating
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MMF & ACF for Potable Water

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MMF & ACF for Demineralization

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UF System
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RO Unit
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ACF & Cation Exchanger System for Condensate

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Mixed Bed Ion Exchanger

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2.9 Loading Media & Resin Procedure

2.9.1 Loading Media Procedure for MMF
2.9.1.1 INTRODUCTION
Scope
This procedure covers general requirement and general guideline for
loading media activity as a part of pre-commissioning stage to be
applied in Ammonia Urea II Project, in Gresik, East Java, Indonesia.
2.9.1.2 SAFETY
Man way Opening & Closing
Remove the man way cover (Top Manhole) on the top of upper side
sheet of the vessel media port. Prior to loading multimedia filter into
vessel, all internal distribution must be inspected already and the vessel
must be cleaned to remove foreign materials.
When it becomes necessary to open a man way the following methods
should be closely followed:
 WARNING: Opening a man way while a vessel is pressurized can
cause serious injury or death. Always verify pressure is relieved
before attempting to remove a cover.
 WARNING: Opening the lower man way on an filter which contains
media can result in large quantities of media being discharged.
Worse still the man way may not be able to be successfully sealed
without removal of the media.
Verify vessel is isolated and relieve pressure using filter vent valve.
Round Bolt Closures

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 Carefully loosen retaining nuts around man way ring. If while

loosening the bolts you hear a hissing or any other indication of
pressure immediately re-tighten the bolts and verify pressure has
been relieved.
 Swing all bolts away from man way cover and slowly open cover. If
gasket sticks to man way cover gently pry away to avoid tearing
the gasket.
 Clean gasket surface.
 Close man way and tighten bolts. It may be necessary to further
tighten bolts after pressure has been applied to filter to prevent
leaking.
Elliptical Sight Glass Closures
 Clean all gasket surfaces for sight glass.
 Close flange sight glass and tighten bolts. It may be necessary to
further tighten bolts after pressure has been applied to filter to
prevent leaking.
Closing the man ways:
 Clean the gasket surface and replace if necessary.
 Apply tape to the gasket and the cover to hold the gasket in place
while it is placed into position.
 Install the gasket between the cover and the man way flange.
Check and make sure gaskets right position at man way flange
 Wrench tightens nuts.
2.9.1.3 PREPARATION
 Ensure that the equipment have been pressure tested
 and install as per general arrangement.
 Ensure all safety equipment if required ready.
 Ensure sufficient hand-holes, manholes have been opened.
 Ensure permanent gasket and bolt is available with the correct size,
material, and rating.
 Ensure all tools are available with good condition.
 Prepare the checklist for loading media activity.
 Packing bag and seal packing of media should be good (not damage)
 Prepare all of Multimedia filter near to the vessel.
2.9.1.4 FILTRATION MEDIA LOADING
Prior to servicing the unit should be closed off from inlet and outlet
lines and any electrical devices or connections should be tagged off.
Before a column is filled with Media, it is important to check the general
condition of the column:
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 Bottom collector, top and intermediate distributors, column lining,

support layer if any.
 The general condition of the Media charge if the bed is just being
topped up. It is advisable to marking outside of the vessel
corresponding to the support layer (or the bottom plate in case of a
nozzle plate collector), the height of the central distributor or
collector, and the height of the top distributor. The media is loaded
manually into the units
Before fill media filter, it is recommended that the inside of the filter be
washed to remove all contamination and any trace of spent media. After
the filter has been washed, the filter should also be checked thoroughly
and any minor maintenance conducted.
2.9.1.5 MEDIA LOADING
 Before loading the media, run water into the vessel until it is 900
mm over the top of the bottom distribution. This “water cushion”
protect the distribution from damage.
 Once the water cushion has been added, load the media by slowly
pouring it through the upper man way on the vessel’s open top.
 Load Gravel (400 Liter 160 mm for Potable water and 773 Liter 160
mm for Demineralized water) from the top distribution into the
vessel slowly pouring it through the upper man way on the vessel’s
open top.
 Load the silica sand 750 liter for PTW and 1449 liter for DW (300 mm
from the upper layer of gravel) into the vessel slowly pouring it
through the upper man way on the vessel’s open top.
 Load the anthracite 750 liter for PTW and 1449 liter for DW (300 mm
from the upper layer of silica sand) into the vessel slowly pouring it
through the upper man way on the vessel’s open top.
 If water level in the vessel rises too high during the loading
procedure, open a drain valve and allow some of the water to drain
out.
 Level the multimedia layer carefully as follows drawing calculation of
multimedia filter doc. No. 201485-S20103-CA-01 and No. 201485-
S20201-CA-01.
 After all of the multimedia has been loaded, it must be rinsed to
remove any dirt with two options:
 Backwash through the open man way
 Backwash flow at a flow rate higher than normal.
This backwash flow must be unrestricted (such as from flow controller)
and continue until water is clear.
 WARNING - Media generates considerable dust. While Multi Media
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poses no health risk the dust can cause respiratory irritation and
occasional skin rash. Therefore we recommended the use of proper
clothing and dust mask during filling operation.
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2.9.1.6 ACCEPTANCE CRITERIA

The criteria for acceptance are:
 Media type, size, weight and quantity should be written in packing
bag.
 Media should be according MSDS.
 Media arrangement shoulbe according with approval design
structure of media.
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2.9.2 Loading Media Procedure for ACF

Scope
loading media activity as a part of pre-commissioning stage to be
applied in Ammonia Urea II Project, in Gresik, East Java, Indonesia.
2.9.2.2 SAFETY
Remove the man way cover (Top Manhole) on the top of upper side
sheet of the vessel media port. Prior to loading activated carbon filter
into vessel, all internal distribution must be inspected already and the
vessel must be cleaned to remove foreign materials.
 WARNING: Opening the lower man way on an filter which contains
media can result in large quantities of media being discharged.
Worse still the man way may not be able to be successfully sealed
without removal of the media.
Round Bolt Closures
pressure immediately re-tighten the bolts and verify pressure has
been relieved.
gasket sticks to manway cover gently pry away to avoid tearing the
gasket.
leaking.
prevent leaking.
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 Clean the gasket surface and replace if necessary. Apply tape to
the gasket and the cover to hold the gasket in place while it is
placed into position.
 Install the gasket between the cover and the man way flange.
Check and make sure gaskets right position at man way flange
2.9.2.3 PREPARATION
 Ensure that the equipment have been pressure tested and install as
per general arrangement.
material and rating.
 Prepare the checklist for loading media activity.
 Packing bag and seal packing of media should be good (not damage)
 Prepare all of activated carbon filter near to the vessel.
2.9.2.4 FILTRATION MEDIA LOADING
Before a column is filled with Media, it is important to check the general
condition of the column:
 Bottom collector, top and intermediate distributors, column lining,
support layer if any.
 The general condition of the Media charge if the bed is just being
topped up. It is advisable to marking outside of the vessel
corresponding to the support layer (or the bottom plate in case of a
nozzle plate collector), the height of the central distributor or
collector, and the height of the top distributor. The media is loaded
manually into the units
Before fill media filter, it is recommended that the inside of the filter be
washed to remove all contamination and any trace of spent media. After
the filter has been washed, the filter should also be checked thoroughly
and any minor maintenance conducted.
2.9.2.5 MEDIA LOADING
 Before loading the activated carbon filter, run water into the vessel
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until it is 900 mm over the top of the bottom distribution. This

“water cushion“ protect the distribution from damage.
 Once the water cushion has been added, load the media Gravel and
then activated carbon by slowly pouring it through the upper man
way on the vessel’s open top.
 Load Gravel 400 Liter 160 mm for PTW and 773 liter 160 mm for DW
from the top distribution into the vessel slowly pouring it through
the upper man way on the vessel’s open top.
 Load the Activated carbon 1500 liter for PTW and 2898 liter for DW
(600 mm from the upper layer of gravel) into the vessel slowly
pouring it through the upper man way on the vessel’s open top.
 If water level in the vessel rises too high during the loading
procedure, open a drain valve and allow some of the water to drain
out.
 Level the activated carbon layer carefully as follows Drawing
calculation of multimedia filter doc. No. 201485-S20101-CA-01 and
No. 201485-S20202-CA-01
 After all of the activated carbon has been loaded, it must be rinsed
to remove any dirt with two options:
 Backwash through the open man way
 Backwash flow at a flow rate higher than normal.
This backwash flow must be unrestricted (such as from flow controller)
and continue until water is clear.
 WARNING - Media generates considerable dust. While Multi Media
poses no health risk the dust can cause respiratory irritation and
occasional skin rash. Therefore we recommended the use of
proper clothing and dust mask during filling operation.
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ACTIVATED CARBON
SILICA GRAVEL
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The criteria for acceptance are:
 Media type, size, weight and quantity should be written in packing
bag.
 Media should be according MSDS.
 Media arrangement shoulbe according with approval design
structure of media.
201485-20000-TS-04
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2.9.3 Loading Resin Procedure for Cation Exchanger & Mixed Bed
Scope
loading Resin activity as a part of pre-commissioning stage to be applied
in Ammonia Urea II Project, in Gresik, East Java, Indonesia.
2.9.3.2 SAFETY
 WARNING: Opening the lower man way on a filter which contains
Resin can result in large quantities of Resin being discharged. Worse
still the man way may not be able to be successfully sealed without
removal of the Resin.
Round Bolt Closures
pressure in recently re-tighten the bolts and verify pressure has
been relieved.
gasket sticks to man way cover gently pry away to avoid tearing the
gasket.
leaking.
prevent leaking.
 Clean the gasket surface and replace if necessary. Apply tape to the
gasket and the cover to hold the gasket in place while it is placed
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into position.
 Install the gasket between the cover and the man way flange. Check
and make sure gaskets right position at man way flange
2.9.3.3 PREPARATION
 Ensure that the equipment have been pressure tested and install as
per general arrangement.
material and rating.
 Prepare the checklist for loading resin activity.
 Packing bag and seal packing of Resin should be good (not damage)
 Prepare all of activated carbon filter near to the vessel.
2.9.3.4 RESIN LOADING
Before a column is filled with Resin, it is important to check:
Resin bed ion exchange vessels are those vessels which operate with
one type or two type of resin. Cation exchanger and mixed bed
operated in the co-current regenerated mode, or in water or air blocked
counter current mode, should be loaded according to the following
procedure:
Before loading the resins, make a detailed inspection of the empty
vessel:
 Remove all debris from previous resins or foreign material.
 Clean up distributors and collectors, and inspect all laterals and
splash-plates for damage or plugging.
 Inspect the nozzles, check that they are in good shape, clean and
tight, and gaskets are intact and in place. Whenever possible,
replace with new ones if older than 5 years.
 Inspect the rubber lining (if present) for integrity, and perform a
spark test, if possible.
 Whenever possible, check the pressure loss of the empty vessel at
nominal flow rate and observe the flow patterns for uniformity.
Loading of the resins:
 Make available water in the right quality and quantity.
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 Fill vessel with sufficient water (~1/3 vessel height), or completely in

the case of using a vacuum eductor.
 Load the ion exchange resin by dumping the resin from the top, or
by the use of a vacuum eductor.
 Backwash the resin at maximum available expansion for 30 minutes,
according to the manufacturers recommended flow rates.
 Note: Macro porous resins, especially weak base anion resins,
should be stored in solution overnight in order to wet-out the resins
prior to backwash. Alternatively, if an overnight soak is not feasible,
the bed can be operated for one cycle before a backwash is
performed. This will allow the resin to be wetted during operation,
but care should be taken so that a backwash is not performed on
un-wetted resin, as resin loss will occur.
 Let the resin settle and record the level.
 Close the vessel and carry out a double regeneration. For packed
bed countercurrent regeneration systems, the procedure is the same
as above with the following modifications:
 The freeboard should be calculated on the basis of the total resin
bed height, taking the volume of the resin in the most swollen form.
For a strong acid cation resin, this is the fully regenerated H+ form,
for strong base anion resin, the fully regenerated OH- form, and for
weak base anion and weak acid cation resins, the exhausted form.
 Add approximately half of the resin and backwash as above.
 Add the floating inert resin, level out, and then load the remaining
resin.
 Check the freeboard and adjust if necessary.
 Carry out a double regeneration
Start-up operation:
 Check pretreatment against specifications (Cl2, SS, TOC, etc.)
 Start the run and monitor rinse down and conductivity.
 It is strongly recommend that the first runs be stopped based on
throughput, according to the design. The plant may produce more
after a double regeneration, but if exhausted in this condition it will
take more cycles to reach the final equilibrium at normal
regeneration levels. The expected high water quality at
countercurrent systems will be achieved only after a few runs,
provided that the endpoint is monitored correctly and the plant is
not overrun.
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Illustration for Loading Cation Resin
Loading resin
Cation by dumping
Ilustration for Loading Mixed Bed Resin
Loading resin first

Cation and Anion
second loading by
dumping
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Backwash the resin at maximum

available expansion for 30 minutes,
according to the manufacturers
recommended flow rates.

The criteria for acceptances are:
 Media resin type, size, weight and quantity should be written in
packing bag.
 Media resin should be according MSDS.
 Media resin arrangement should be according with approval design
volume of media.
2.9.3.6 BACKWASH OPERATION
The backwash operation is important to remove from the resin bed any
particles or debris that may have been produced during the loading
process. After the backwash is complete, drain the water from the
column at a rate of about 6 m/h until the water is about 10 cm above
the resin surface. Mark the resin level on the outside of the vessel and
calculate the resin volume. The resin is now ready for regeneration, for
purification or for operation.
The above illustration is for a conventional, down-flow loading unit. In
case of Amberpack™ or other packed bed systems, the resin must be
backwashed with exactly the same care, using the special backwash
column usually supplied with such equipment. Filling the resin into the
ion exchange column, in this case, is combined with backwashing.
2.10 START-UP Procedure & TROUBLESHOOTING for Potable Water System

2.10.1 PRE-COMMISSIONING
The purpose of pre-commissioning work is to check the actual condition
of the plant and to perform necessary adjustments on the equipment in
preparation for the commissioning work.
Mechanical Equipment Pre-Commissioning includes the following steps:
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 Flushing and Cleaning

 Chemical Preparation
 Filter Media Loading
 Oil Interceptor Check
 Trial Run
Electrical & Instrument Equipment Pre-Commissioning includes the
following steps:
 MCC Power Energize
 MCC Function Test
 Motor No-Load Test
 On-Off Valve Loop Test
 Instrument Loop Test
 System Function Test
 Input-Output Test
 Sequence Test
2.10.2 MECHANICAL EQUIPMENT PRE-COMMISSIONING

2.10.2.1 FLUSHING and CLEANING
 Flush inside of pipe with water for few minutes until effluent is clear.
 Open valves slowly to flush all dirt, debris, excess sealant and scale.
 Clean inner surface of filters and exchanger vessels.
2.10.2.2 CHEMICAL PREPARATION
Pre-caution:
 Person who prepares harmful or dusty chemicals should wear
suitable protective equipment.
 Training and advises shall be given to workers in order to understand
the cause of harm that would occur while working with chemicals.
Method of prevention and measures to be used in tending to the
accident should be explained clearly to the workers.
 Provide water for cleaning within the place of preparation.
 Consider which chemical uses service water for dilution, and which
one uses filtered water.
2.10.2.3 PREPARE CHEMICAL FOR PRE-COMMISSIONING

- Chemical solution preparation for Calcium Hypochlorite (CaOCl 2)
solution 2%
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Calculation of chemical solution preparation for 500 liter of 2%

Calcium Hypochlorite (CaOCl2) solution
Calcium Hypochlorite (CaOCl2) is as solid powder 60% Chlorine,
500 liter water is added into chemical tank, 1 kg Calcium
Hypochlorite (CaOCl2) powder is added into the tank, mix until it
solve and homogenous.
Calcium Hypochlorite (CaOCl2) = 60% chlorine
Dosing Chlorine = 5 ppm
Flow capacity = 30 m3/h
Dosing pump capacity = 25 L/h
Consumption of Calcium Hypochlorite (CaOCl2) per hour
= 5 ppm (Dosing) x 30 m3/h (Flow of Potable water)
= 5 ppm / 1000 kg/ m3 x 30 m3/h x 100% / 60%
= 0.25 kg/h
Setting stroke for Dosing pump
= Chlorine Dosing / Capacity of Dosing pump x 100% x concentration
of Chlorine solution
= 0.25 kg/h / 25 L/h x 100/2 x 100%
= 50 % Stroke dosing.
- Operating instruction for Calcium Hypochlorite Agitator (A20101)

Agitator start preparation
1. Ensure the level chemical solution at minimum 200 liter and
maximum 500 liter.
2. Close drain valves and outlet valves at chemical tank.
3. Ensure chemical already complete filled in to water solution in tank.
4. Ensure motor for mixer is already test and approved.
5. Ensure connection electrical system already test and approved.
Agitator start-up and running
Agitator for mixing only and not continuous operate.
Mixing time is 10 – 20 minutes or until completely dissolved.
1. Ensure electrical power ON in local panel for mixer (A20101).
2. Start push button ON mixer agitator in local panel.
3. Unsure mixer in chemical tank is running.
4. Check visual the solution in tank.
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- Operating instruction pump for service unit (P20103A/B)

Start up
1. Service unit coordinated to multimedia filter and activated carbon
for PTW.
2. Open valve suction and discharge of pump
3. Ensure that multimedia and ACF for PTW in service mode
4. Check rotation of motor already correct, clockwise direction.
5. Service water pump (P20103 A/B) start/ stop automatically will
interlock to 20 PT105.
6. Check control valve for service water already setting open.
Normal Operation
1. Service pump will running depend on service water line by Wuhuan
controller.
2. MMF and ACF will running if service pump in running condition.
3. MMF and ACF interlock for off condition from service pump.
4. Read pressure discharge of pump and records.
5. Check the pump and motor.
Shut down
1. The pump is controlled by level in filtered water tank, Low level in
filtered water tank the pump will stop.
2. Pressure 20PT105 low, pump will be start.
- Initial start-up for Calcium Hypochlorite dosing pump

BEFORE SWITCHING ON POWER TO THE PUMP, TURN THE CAPACITY
ADJUSTMENT KNOB TO ZERO. CHECK THAT ALL SHUT-OFF VALVES IN
THE SUCTION AND DISCHARGE LINES ARE OPENED BEFORE INCREASING
THE CAPACITY ADJUSTMENT FROM ZERO.
Manual Capacity Control
To adjust pump capacity, loosen the stroke locking knob located in the
pump-side cover. Pump capacity is adjusted by turning the micrometer
type stroke adjustment knob clockwise to decrease capacity or counter
clockwise to increase capacity as required. The adjustment scale is
marked in percent (%) of full stroke, with calibration lines on the knob at
1% intervals. After adjusting the knob to the desired capacity setting,
hand tighten the stroke locking screw to maintain the capacity setting.
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Filling Pumping System

It is especially important that pump suction and discharge lines be free
of entrained air. To ensure this condition, operate the pump without any
discharge pressure and fill the entire pumping system with liquid before
starting pressure tests. A simple method to assure priming of the pump
is to install a tee and a shut-off valve at the discharge connection of the
pump.
If the pump is idle for long periods, temperature changes in the process
liquid may produce air in the system. To discharge the air, install a valve
in the discharge line which will allow the process liquid to be pumped to
exhaust when starting the pump.
Capacity Calibration
After the first 12 hours of operation, the pump maybe tested and
calibrated to find the exact pump capacity under specific operating
conditions. Usually, calibrating the pump at only 100, 50, and 10 percent
capacity settings is enough to indicate pump performance throughout
the adjustment range. The pump can be calibrated by measuring the
decrease in liquid level pumped from a calibrated vessel. This method is
recommended for hazardous liquids because it eliminates operator
contact with the liquid. Milton Roy test-tube Calibration Columns are
available for convenient and accurate calibration of any pump.
2.10.2.4 Multi Media Filter
- Media Charging
Media charging are used for initial plant commissioning or for
recharge. It is important to prepare an advance schedule to go
through the following steps.
1. Inspect through the vessel and the collection and distribution
system.
2. Check that all media bags are identified and marked properly.
3. Check the condition of the media in each bag and ensure that
the packing is satisfactory.
4. There must be water in the vessel during media charging. To
make sure that the collection system is satisfactory, first 30 – 50
mm. size of gravel media should be charged, make sure gravel
media covers the bottom laterals and second layer 0.6 – 2.36
mm. Size of silica sand media charged from the top of the gravel
media layer and third layer 4 – 6 mm. size of anthracite media
charged from the top of the silica sand media layer, Box up the
vessel, carry out a backwash and run the unit at maximum flow
rate after a through backwash and removal at any foreign
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matter from the top surface, charge media from the top of the
gravel media layer. Box up the man hole.
Flowing handling equipment are required to fill the carbon media
1. Scaffolding / Platform
2. Forklift
- Manual Backwash
It is very essential to perform manual backwash operation on each
of Multi Media filter before operating to auto-mode so that foreign
particle present in the media during delivery is washed out from the
vessel. In this operation, preliminary adjustments of manual
&actuator-operated valves, instrument set points, flow rate, etc.
should also be done
- Auto Backwash
When all necessary adjustments are completed, it is important to
perform a trial run in auto mode for one cycle before performing the
commissioning proper in order to counter-check the adjustments
made. Final adjustments shall be done after one cycle, when
necessary. Operation is the same as the commissioning operation.
- First Run
Expected MMF water quality will be achieved only after final rinsing,
after multimedia filter the case of Multi Media filtered water, but
provided that endpoint is monitored correctly and the plant is not
over run.
- Start up
First backwash and rinsing
1. After loading the filter media, select of the multimedia filter in
manual mode from (PLC) than open valve rinse mode.
2. Start one of the service water pump manually 12 – 20 minutes
3. After fill and rinse step finish, stop the service water pump,
open valve in multimedia filter.
- Backwash
Operation:
1. Close on Off valve manually (20XV101 and 20XV102)
2. Open On Off valve manually (20XV103 and 20XV104)
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3. Other on Off valve are close

4. Start the MMF backwash pump (P20102 A/B) for 15- 20
minutes or until backwash outlet already clear
5. Stop the MMF backwash pump and close the valve again
(20XV103, 20XV104, 20XV105)
Do rinse mode again.
Repeat step backwash and rinsing if multimedia not clear complete
yet.
Illustration for first Backwash:
Illustration for first rinsing:

 Open On-off valve (20XV101 and 20XV105) manually
 Other On-off valves are closed
Start Feed water for Service pump A or B (P20103A) or (P20103B)
manually
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Flow rate: 30 m3/h

Duration: 10 minutes or until effluent is clear
TRIAL RUN PACKAGE:

MMF for Potable Water (S20103)
Step 1: Air Scouring
Air Scouring Purpose: To remove foreign particles of filter media
Operation:
 Close On-off valve manually (20XV101, 20XV102, 20XV104,
20XV105 and 20XV103)
 Open On-off valve manually (20XV106, 20XV107)
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 Make sure PA is running
 If outlet backwash and rinsing has clear multimedia filter ready
to service.
 Flow rate: 98 m3/h
Duration: 5 minutes
Illustration:
Step 2: Backwash
Backwashing Purpose: To remove foreign particles of filter media
Operation:
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 Close On-off valve manually (20XV101 and 20XV102)

 Open On-off valve manually (20XV103, 20XV104 and 20XV105))
 Backwash pump for PTW A or B (P20107A) or (P20107B) running
Duration: 10 minutes
Illustration:
Backwash pump for PTW

(P20107A or P20107B) running
Step 3: Rinsing
Rinsing Purpose: To remove foreign particles remaining in the
bottom of filter bed
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Operation:
 Open On-off valve (20XV101 and 20XV105) manually
 Start Feed water for Service pump A or B (P20103A) or
(P20103B) manually
Duration: 10 minutes or until effluent is clear.
Illustration:
Step 4: Normal operation

Service Purpose: To produce potable water
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Operation:
 Open On-off valve (20XV101 and 20XV102)
 Close On-off valve (20XV103, 20XV204, 20XV105)) manually
from local SVB
 Open On-off valve and start NaOCl feed pump 1A (P20104A)
simultaneously for chlorination
 Keep Filtered water transfer pump A/B (10GBK41/42AP001)
running
 Read the multimedia filter inlet and outlet pressure. Pressure
should read approximately 1.5 kg/cm2g
Duration: 60 minutes (30 m3/day)
Illustration:
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2.10.2.5 Activated Carbon Filter

- Media Charging
Media charging are used for initial plant commissioning or for
recharge. It is important to prepare an advance schedule to go
through the following steps.
1. Inspect thoroughly the vessel and the collection and distribution
system.
2. Check that all media bags are identified and marked properly.
3. Check the condition of the carbon media in each bag and ensure
that the packing is satisfactory.
4. There must be water in the vessel during media charging. To
make sure that the collection system is satisfactory, first 30
– 50 mm size of gravel media should be charged, make sure
gravel media covers the bottom laterals, and second layer 0.6
– 2.36 mm size of Carbon media charged from the top of the
gravel media layer, Box up the vessel, carry out a backwash and
run the unit at maximum flow rate after a through backwash and
removal at any foreign matter from the top surface, charged
media Box up the man hole.
Following handling equipment are required to fill the carbon media
1. Scaffolding / Platform
2. Forklift
- Manual Backwash:
It is very essential to perform manual backwash operation on each
of Carbon Filters before operating to auto-mode so that foreign
particle present in the media during delivery is washed out from the
vessel. In this operation, preliminary adjustments of manual &
actuator-operated valves, instrument set points, flow rate, etc.
should also be done.
- Auto Backwash:
When all necessary adjustments are completed, it is important to
perform a trial run in auto mode for one cycle before performing the
commissioning proper in order to counter-check the adjustments
made. Final adjustments shall be done after one cycle, when
necessary. Operation is the same as the commissioning operation.
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- Activated Carbon Soaking:

Activated carbon is filled with internal pores where air may exist.
Before backwashing, bed must be set in completely submerged
condition to allow carbon pores to fill with water. Otherwise, the
reduced density of carbon due to air in the pores may result in
excessive backwash losses.
- First Run:
Expected high water quality will be achieved only after final rinsing,
after Activated Carbon filter the case of Potable water, but provided
that endpoint is monitored correctly and the plant is not over run.
- Start up
First Backwash and rinsing
1. After loading the Activated carbon media, select of the Activated
carbon filter in manual mode from (PLC) than open valve rinse
mode.
2. Start one of the service water pump manually 12 – 20 minute
3. Multimedia filter running.
4. After fill and rinse step finish, stop the service water pump, open
valve in Activated carbon filter.
- Backwash
Operation:
1. Close on off valve manually (20XV108A/B and 20XV109A/B).
2. Open on off valve manually (20XV110A/B and 20XV111A/B).
3. Other on off valve are close.
4. Start the ACF backwash pump (P20102 A/B) for 15- 20 minutes
or until backwash outlet already clear.
5. Stop the ACF backwash pump and close the valve again
(20XV110, 20XV111), do rinse mode again.
Repeat step backwash and rinsing if Activated carbon media not
clear complete yet.
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Illustration:
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TRIAL RUN PACKAGE:

Steps of ACF for Potable Water (S20101A/B) Manual Operation:
Soaking Purpose: To saturate the carbon with water in order to
optimize backwashing Operation. Start FW service water pump A/B
(P20103A/B) manually from LCP.
Multi Media filter (S20103)
Open On-off valve (20XV101, 20XV105 and 20XV107) manually from
MCC, then close valve when water reaches top distributor level.
Other On-off valves are closed
Activated Carbon filter (S20101A/B)
Open On-off valve (20XV108A/B, 20XV112A/B and 20XV113A/B)
manually from MCC, then close valve when water reaches top
distributor level.
Duration: 1 hour or until activated carbon is fully saturated
Illustration:
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Activated Carbon Filter (S20101A)

Step 1: Backwash
Operation:
 Close On-off valve manually (20XV108A/B, 20XV109A/B)
 Open On-off valve manually (20XV110A/B, 20XV111A/B)
Illustration:
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Step 2: Rinsing
Operation:
 Open On-off valve (20XV101, 20XV102, 20XV108A and
20XV112A) manually
(P20103B) manually
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Illustration:
Step 3: Service (S20101A)

Operation:
 Open On-off valve (20XV101, 20XV102, 20XV108A and
20XV109A) manually
(P20103B) manually
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 Duration: Until potable water tank is full.

 At the design flow (30 m3/h through the filter read from flow
indicator, the difference in pressure will vary according to the
filter clogging and shall not exceed a maximum at 3 kg/cm 2g
before backwashing is initiated record the inlet and outlet
pressure of the filters once per shift.
Illustration:
Activated Carbon Filter (S20101B)

Step 1: Backwash
Operation:
 Close On-off valve manually (20XV108B, 20XV109B and
20XV112B)
 Open On-off valve manually (20XV110B, 20XV111B)
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 Filter shall be a backwash if it meets any of the following
- It is operating at a high pressure drop due to accumulated
solids
- It has been in of service for 24 hours
- It has been out of service for 24 hours due to maintenance
and is about to be put back in service.
Illustration:
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Step 2: Rinsing
Operation:
 Open On-off valve (20XV101, 20XV102, 20XV108B and
20XV112B) manually
(P20103B) manually
Flow rate: 30 m3/h
Duration: 10 minutes or until effluent is clear
Illustration:
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Step 3: Service (S20101B)

Operation:
 Open On-off valve (20XV101, 20XV102, 20XV108B and
20XV109B) manually
(P20103B) manually
Flow rate: 30 m3/h
Duration: 10 minutes or until effluent does not show particle.
Illustration:
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2.10.2.6 ELECTRICAL & INSTRUMENT EQUIPMENT PRE-COMMISSIONING

- MCC POWER ENERGIZE PROCEDURE
1. Prior to energizing the MCC, the operator should check selector
switches of each MCC module for equipment such as pumps,
blowers, agitators, etc. if they are in OFF position. Release to
Local signal from MMI shall not be activated (Logic=0). Below is a
list of equipment with their respective local control panels:
2. Energizing the MCC
3. Refer to separate manual of MCC for energizing procedure
4. Select the following motor starter modules to remote mode
operation
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NO TAG NO EQUIPMENT NAME LOOP NO

1 P20103 A FILTERED WATER PUMP A
2 P20103 B FILTERED WATER PUMP B
3 P20107 A BACKWASH WATER PUMP A
4 P20107 B BACKWASH WATER PUMP B
5 P20106 A PORTABLE WATER PUMP A
6 P20106 B PORTABLE WATER PUMP B
7 P20104 A CALCIUM HYPOCHLORITE DOSING PUMP A
8 P20104 B CALCIUM HYPOCHLORITE DOSING PUMP A
Energize of each equipment in the MCC as per following
requirements for equipment with auto mode/manual mode, select
of each equipment via MMI.
Operation mode of each equipment shall be selected to the
following:
1. MCC FUNCTION TEST (FAT& SAT)
Refer to Appendix (tba)
2. MOTOR NO-LOAD TEST
Procedure: The procedure of pre-commissioning works for the
above check-items of Electrical and Instrument Equipment shall
be based on Project Standard Procedure. Electric motors of
equipment subject for Motor no-load test are listed in table
below.
3. ON-OFF VALVE LOOP TEST
4. INSTRUMENT LOOP TEST
5. SYSTEM FUNCTION TEST
6. INPUT-OUTPUT TEST
7. SEQUENCE TEST
2.10.3 COMMISSIONING
PHB, Adhi and PKG shall together perform the Commissioning Work, or if
necessary. PHB Staff shall explain the operation of the Water Treatment
Plant and train PKG Staffs, as well.
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2.10.3.1 PERFORMANCE TEST

General
Performance Test shall be done by running the plant for two cycles.
Demineralized and Condensate water quality shall be checked with
conductivity meters. Commissioning results shall be recorded in the
“Commissioning Result” form. Period of commissioning shall be referred
to the Table below:
Table: Commissioning Period
ITEMS
Treating Analysis
SYSTEM Mechanical Electrical
Capacity x Cycle (Raw/Treated)
MMF
30 m3/h x 2 2X 2X 2X
(Potable)
ACF
30 m3/h x 2 2X 2X 2X
(Potable)
Procedure:
1. Run the plant for 24 hours per day for 2 days.
2. Take data of influent flow rates for Multimedia Filter and Activated
Carbon Filter every hour.
3. Take data of pressures for Multimedia Filter and Activated Carbon
Filter every hour.
4. Take data of Flow, Pressure, Turbidity, TSS, pH, Chlorine residual for
Filter and Activated Carbon Filter every running 1 day.
5. Take sampling at sampling cocks of outlet Multimedia Filter and
Activated Carbon Filter every 4 hours for analysis. PKG will take
sampling at the same time and perform internal analysis for
comparison purposes.
6. Take note of the running time of first on-line Potable water
treatment train following switched-over of the standby train.
7. Take note of the duration of backwash period.
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2.10.3.2 TROUBLESHOOTING
Issue Possible Cause Possible Solution

Check electrical service,
1. No power supply.
fuse, etc.
A. Unit fails to initiate are Back
2. Electrical Control has Check control system for
wash cycle.
been interrupted on-off valves.
3. Power failure. Reset time of day.
1. By-pass valve open. Close by-pass valve.
B. FILTER BLEEDS TASTE AND Assure permanent
2. Electrical service to unit
ODOR OR SEDIMENT electrical service (check
has been interrupted
fuse, plug or switch)
Have water sample
3. Quality of feed water
analyzed to determine
has worsened
any change
Be sure control is not
clogged or drain line
4. Filter not backwashing restricted. Be sure water
enough pressure has not
dropped and that pump
has sufficient capacity.
Check if central tube is
5. Leak between valve and cracked or O-ring is
central tube. damaged. Replace faulty
parts.
Replace valve seals,
6. Internal valve leak. spacer, and piston
assembly.
1. Iron or scale builds up
C. Low water pressure. Clean pipes.
inline feeding unit.
Clean control and
2. Iron build up in side address in cleaner to
valve or tank. clean bed. Increase
Backwash frequency.
3. Inlet of control plugged Remove piston and clean
due to foreign material. control valve.
Check well system for
D. Filter media in drain line. 1. Air in water system. proper air eliminator
control.
2. Incorrect drain line flow Check for proper flow
control. rate.
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1. Electrical Control for
Check control system for
E. Valve continuously cycles. valve has been
on-off valves.
interrupted.
1. Valve settings incorrect. Check valve settings.
2. Foreign material in
Clean control.
F. Flow to drain continuously. control valve.
Replace seals, spacers,
3. Internal leak.
and piston assembly.
2.11 START-UP Procedure & TROUBLESHOOTING for Filtered Water Plant

2.11.1 GENERAL
This document will describe general start up and commissioning
procedures for Filtered Water and Demineralization Package Plant, which
consist:
2.11.1.1 Purpose
1. To check if logic/loop in PLC of water treatment system is connect.
2. To check operation sequence in water treatment system works
properly through trial run.
3. To check proper safe of different equipment
4. To facilitate water treatment system works :
Properly through in trial run to satisfy start and stop requirement of unit
and quality unit running securely and stably.
2.11.1.2 Scope
This procedure to apply to commissioning of water treatment system
including regulation and trial run of water and waste water treatment.
2.11.1.3 Pre requisite of test
1. All equipment are erected, aligned, piping assembled have been
installed in accordance with requirement.
2. Monitoring instruments and gauges within the system are complete,
instruments must be carefully checked for correct installation and
calibration by a qualified instrument services man. The entire test
that can be performed to similar operating conditions should be
carried over to ensure that the instruments might operate properly.
3. The MCC and LCP were electrically checked and tested before
leaving the factory. However it is still recommended that the
following checks be made by qualified electricians before electrical
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power is provided to the system.

- Check for shorts between grounds and again between bus and
enclosure.
- Check motors leads to ground. There should be no continuity.
- Perform meager test on motors for conformity
- Check if electrical connection is safe and reliable.
4. Field of trial run site is level, passage is clear and lighting if sufficient.
Trench covers inside water treatment building have been mounted.
5. There are no inflammable and explosive substances on the site. Fire
fighting apparatus are in in readiness.
6. Check if tools and material are complete in type and adequate in
quantity.
7. Check if media and resin for all vessels are complete in charging.
8. Check if the pipeline must be flushed by taking feed water in the
respective tanks flush the pipeline as well as for checking leakage.
9. Check if level in Demineralized water storage tank is not high level
10. Check if level in raw water reservoir is not low level.
11. Check if instrument air for pneumatic valves supply is already
available.
12. Check if Service water is already available.
13. Check settings of running parameter (Which are set up before
delivery)
14. Get running tools and record sheet ready.
15. Get commissioning tools, instruments and apparatus ready.
16. All instruments of the system are complete, calibrated and qualified.
17. Check if DCS is already installed properly.
18. Check if all chemical already available.
2.11.2 COMMISSIONING PROCEDURE

Refer to AMIAD Operation Procedure, before using the filter for the first time,
the following check-list should be carried out and no special training is
required to carry out this activity:
- Check that the upstream pressure at the filter inlet is more than 2.5
kg/cm2 during the rinse cycle.
- Check that the filter is mounted in the correct flow direction
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- Check that all the control tubes are connected properly and that all
connections are tight.
- Check that the three-way mini-valve is turned to automatic position. The
arrow on the knob should point to AUTO, and the sticker ⓿ on the filter in
self-cleaning filter control panel.
- The nominal diameter of the drain pipe should at least 3”.
- If the recommended upstream and downstream isolation valves have been
installed, check they are shut.
GETTING STARTED - First operation of the filter

After completing the preparation check list above, the following steps should
be performed:
1. Slowly open the isolating valve at the filter inlet. Water will flow into the
filter.
2. Check for leaks and repair if necessary.
3. Check that the minimum inlet pressure remains 2.5 kg/cm2g or higher.
4. Slowly open the isolating valve at the outlet of the filter.
5. If there is a by-pass valve, close it slowly.
6. Ensure the flow through the filter does not exceed the filter’s published
maximum flow rate.
7. Start a manual flush by turning the three-way valve to the OPEN position
for a few seconds, and then turn it back to AUTO.
8. During the self-cleaning cycle, check the pressure at the filter inlet and in
the rotor chamber.
The minimum pressure in the rotor chamber should be 1.5 kg/cm 2g lower than
the inlet pressure.
Once above procedure is done, the filter is ready on the filtration mode.
ADJUSTING THE RINSE CONTROLLER

Improper adjusting of the rinse controller may
cause the filter to mal-function.
1. Disconnect the rinse controller drain line.
2. Loosen the locking nut on the long nose
and loosen (CCW) the adjusting screw
until a flush cycle begin.
3. Turn the adjusting screw 1.5 times, and
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then tighten the locking nut. This adjusts

the rinse controller for differential
pressure of 0.5 kg/cm2g.
4. Observe at least one automatic self-
cleaning cycle if possible.
The rinse controller is originally pre-set for a
differential pressure of 0.5 kg/cm 2g.
2.11.3 TROUBLESHOOTING
Problem Possible Cause Solution
The filter does not flush Valve are closed Open valves
Pressure differential is not
Performs a manual flush as
connected follows:
1. Close the filter outlet
valve
2. Check that the filter
outlet and inlet pressure are
equal
3. Perform manual flush as
in item 7
4. Check the pressure at the
inlet valve and in the rotor
chamber
Rinse controller dripper Change dripper
blocked
Rinse controller has been Check and readjust screw
adjusted incorrectly on rinse controller
Excessive pressure in the Drain pipes are not clear Check if drain lines are clear.
rotor chamber If necessary replace with a
larger (diameter) flush drain
line, or shorten the existing
line
Insufficient inlet pressure Inlet valves not fully open Open inlet valves to
(< 2 kg/cm2g) maximum. Increase the
inlet pressure or throttle
the outlet to increase
pressure during the flush
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cycle
Pressure differential Coarse filter is blocked Check the coarse filter
2
exceeds 0.7 kg/cm g Rinse controller needs Adjust rinse controller as in
during normal operation adjusting Adjusting the Rinse
Controller Section.
Check for blockage at high
pressure sensor connection
Water does not flow Inlet lines blocked Check inlet lines
through the filter Isolating valves are closed Open isolating valves
2.12 START UP Procedure & TROUBLESHOOTING for Demineralized Plant

2.12.1 GENERAL
This manual covers the general requirements for the Start-up and
Commissioning Works of Water Treatment Plants for Filtered water and
demineralization package, which consists of Filtered water System, Potable
water system, demineralization System, condensate water system. Reviews
these works shall commence after the completion of installation work.
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2.12.2 START UP
The purpose of Start-up work is to check the actual condition of the plant and
to perform necessary adjustments on the equipment in preparation for the
start-up work.
Mechanical Equipment start up includes the following steps:
1. Rotating Equipment
2. Chemical Preparation
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3. Static Equipment
4. Trial Run
Electrical & Instrument Equipment Start up includes the following steps:
1. MCC Panel
2. PLC HMI Panel
3. On-Off Valve
4. Instrument
2.12.2.1 MECHANICAL EQUIPMENT START UP

ROTATING EQUIPMENT
Before Start up and commissioning the rotating equipment set, make sure
that following conditions are met:
 All rotating equipment set has been mechanically connected as
specified
 All rotating equipment set has been properly connected to the
electrical power supply and equipped with all protection devices.
 The direction of rotating has been checked.
 All auxiliary connections required are connected and operational.
 The lubricants have been checked.
CHEMICAL PREPARATION
Pre-caution:
1. Person who prepares harmful or dusty chemicals should wear suitable
protective equipment.
2. Training and advises shall be given to workers in order to understand
the cause of harm that would occur while working with chemicals.
Method of prevention and measures to be used in tending to the
accident should be explained clearly to the workers.
3. Provide water for cleaning within the place of preparation.
4. Consider which chemical uses service water for dilution, and which
one uses filtered water.
STATIC EQUIPMENT
Before Start up and commissioning the static equipment set, make sure
that following conditions are met:
 All static equipment set has been mechanically connected as
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specified
 All static equipment set has been properly connected to piping and
the Instruments if any and equipped with all protection devices.
 The direction of static positioning has been checked.
 All connections for internal and external accessories required are
connected and operational.
TRIAL RUN
General:
The following equipment shall undergo trial run to demonstrate that they
can operate safely and satisfactorily under the required operating
conditions.
1 Multimedia filter
1. Manual backwash
2. Auto backwash
2 Activated Carbon filter
1. Manual backwash
2. Auto backwash
3. Dosing pump Oxidant
3 Ultrafiltration system
1. Manual backwash
2. Auto backwash
3. Dosing pump Oxidant
4 Reverse osmosis system
1. Manual Flushing
2. Auto Flushing
3. Dosing pump Anti-Oxidant
4. Dosing pump Biocide
5. Dosing pump Anti-scale
6. Dosing pump Acid
5 Degasifier
6 Mixed Bed Ion Exchanger
1. First Regeneration
2. Second Regeneration
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Manual Backwash:
It is very essential to perform manual backwash operation on each of
Multi Media filter and Carbon Filters before operating to auto-mode so
that foreign particle present in the media during delivery are washed out
from the vessel. In this operation, preliminary adjustments of manual
&actuator-operated valves, instrument set points, flow rate, etc. should
also be done.
Auto Backwash:
When all necessary adjustments are completed, it is important to perform
a trial run in auto mode for one cycle before performing the
commissioning proper in order to counter-check the adjustments made.
Final adjustments shall be done after one cycle, when necessary.
Operation is the same as the commissioning operation
Activated Carbon Soaking:
Activated carbon is filled with internal pores where air may exist. Before
backwashing, bed must be set in completely submerged condition to
allow carbon pores to fill with water. Otherwise, the reduced density of
carbon due to air in the pores may result in excessive backwash losses.
First Run:
Expected high water quality will be achieved only after final rinsing, after
Activated Carbon filter the case of Potable water, but provided that
endpoint is monitored correctly and the plant is not over run.
Procedure:
A. Manual and Auto Backwash Operation
 Set following pumps to manual mode operation in MCC and Local
Control Panel;
 FW for Demineralization water (P20102 A/B/C)
 Backwash Pumps For DW (P20207 A/B)
1. Set all actuator-operated valves used in Auto MMF and ACF
process into manual mode operation in the Local Control
Panel.
2. Perform manual preliminary washing in each filter in order to
wash away foreign particles present in the media during
delivery until the effluent is clear.
3. Perform manual backwash operation in accordance with the
Operation Chart and Sequence of Auto MMF and ACF, and
P&ID.
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4. Make necessary adjustments in order to meet the required

water quality.
5. Perform backwash operation again, this time in auto backwash
operation.
6. Make final adjustments as required.
7. Perform manual preliminary washing in each filter in order to
wash away foreign particles present in the media during
delivery until the effluent is clear.
8. Perform manual backwash operation in accordance with the
Operation Chart and Sequence of Auto MMF and ACF, and
P&ID.
9. Make necessary adjustments in order to meet the required
water quality.
10. Perform backwash operation again, this time in auto backwash
operation.
11. Make final adjustments as required.
Steps of MMF and ACF (S20201A-F and S20202A-F) Manual Backwash

Operation:
1.) Soaking Purpose: To saturate the carbon with water in order to
optimize backwashing Operation.
Start FW for Demineralization water pump A/B/C (P20102A/B/C)
manually.
Multi Media filter (S20201A-F)
Open On-off valve (20XV201, 20XV205 and 20XV207) manually from MCC,
then close valve when water reaches top distributor level.
Activated Carbon filter (S20202A-F)
Open On-off valve (20XV208A-F, 20XV212A-F and 20XV213A-F) manually
from MCC, then close valve when water reaches top distributor level.
Duration: 1 hour or until activated carbon is fully saturated
Illustration:
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2.12.2.1.1Multi Media Filter (S20201A-F)

Air Scouring
Air Scouring Purpose: To remove foreign particles of filter media
Operation:
 Open On-off valve manually (20XV206A~F, 20XV207A~F and
20XV204 A~F)
 Make sure Plant air is running
 Flow rate: 126.72 Nm3/h
Duration: 4 minutes
Illustration:
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Backwash
Operation:
 Open On-off valve manually (20XV203, 20XV204)
 Backwash pump for DW A or B (P20207A) or (P20207B) running
 Settling media after backwash for 2 minutes
Illustration:
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Rinsing
Rinsing Purpose: To remove foreign particles remaining in the bottom of
filter bed
Operation:
 Open On-off valve (20XV201, 20XV205 and 20XV207) manually
 Start Feed water for Demineralization pump A/B/C (P20102A),
(P20102B) or (P20102C) manually
Flow rate: 74.5 m3/h
Illustration:
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Service
Service Purpose: To remove particles of water (Reduce TSS)
Operation:
 Open On-off valve (20XV201 and 20XV202)
 Start Oxidant dosing pump 1A (P20216A) simultaneously for Oxidant
 Keep Feed water pump for Demineralization water A/B/C
(P20102A/B/C) running
Duration: 11 hours
Illustration:
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2.12.2.1.2Activated Carbon Filter (S20202A-F)

Backwash
Operation:
 Open On-off valve manually (20XV210A, 20XV211A)
 Backwash pump for DW A - F (P20207A) or (P20207B) running
 Settling media after backwash for 7 minutes
Illustration:
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Rinsing
Rinsing Purpose: To remove foreign particles remaining in the bottom of
filter bed
Operation:
 Open On-off valve (20XV208 A~F, 20XV212A~F and 20XV213 A~F)
manually
 Start Feed water for DW pump A/B/C (P20102A), (P20102B) or
(P20102C) manually
Illustration:
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Service
Operation:
 Open On-off valve ( 20XV208A~F and 20XV209A~F) manually
 Start Feed water for Demineralized water pump A ,B,C (P20102A)
and (P20102B) or (P20102B) manually, 2 running 1 standby
Duration: 11 hours or depending on feed water quality and controlled
by different pressure
Illustration:
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Dosing Pump Oxidant for MMF

Calibration test
Calibration Purpose: To MMF Demineralized water
Operation:
 Fill in Chemical tank with Oxidant up to full
 Open valve to Calibration tube manually up to limit calibration.
 After fill oxidant in to calibration tube close valve from chemical
tank.
 Open valve at discharge dosing pump to Static mixer.
 Setting stroke at 100%.
 Start Dosing pump A or B (P20218A) or (P20218B) manually into
static mixer.
 Check level chemical at calibration tube with timer stop watch.
 Check Actual capacity from calibration tube test.
Flow rate: 50 l/hr.
Duration: Depending on level limit and volume chemical in calibration
tube
Illustration:
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2.12.2.1.3ULTRAFILTRATION
The following procedures should be followed for the start-up of
DOWTM Ultrafiltration modules. Manually start the equipment during
initial operation. Flush the UF parts to remove the preservative used in
shipping or the storage solution before starting the equipment. Target a
permeate flow of 60% of design during initial operations. After 24 hours
the permeate flow can be adjusted to design conditions.
PRE START CHECK
1. The UF pre-treatment system should operate properly and the UF
feed water should meet the design requirements. Ensure that
chemical addition points are properly located and that proper
mixing of chemicals in the feed streams can occur. Check the
addition of pretreatment chemicals.
2. Verify that the drain/waste collection system is functional
3. Verify that the PLC program is loaded and functioning
4. Complete and electrical system check. Verify that the
instrumentation is working and calibration is completed. Calibrate
gauges and meters based on manufacturers’ recommendations.
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5. Clean and connect interconnecting piping. Flush system without

modules to remove fabrication debris. During the flushing operation,
check all pipe connections and valves for leaks. Tighten connections
where necessary.
6. Residual air should be removed from the system during start-up.
START UP
Check that all valves are closed and pumps are off before starting the
system. Start the equipment by following the steps below:
1. Start the feed pump
2. Fill equipment and start a flush
3. Start the backwash pump
4. Set and adjust the backwash pressure
5. Set and adjust the inlet air pressure
6. Set backwash time interval
7. Set air scour time interval
8. Set backwash sequence
UF feed Pumps
 Flow rated: 205 m3/h
 Pressure: 3.5 kg/cm2g
UF feed pump
(P20201A, P20201B or P20201C)
2 running and 1 standby
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UF Dosing Pumps
1. Dosing pump Oxidant for UF (P202017A/B) for CEB
 Flow rated : 315 l/h
2. Dosing pump Acid for UF (P20223 A/B) For CEB
3. Dosing pump Alkali for UF (P20220 A/B) For CEB
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MODUL FLUSHING
The DOW Ultrafiltration modules should be rinsed prior to startup to
remove preservative fluid shipped in the modules. Flushing should be
performed until no foam is observed in the wash water. Depending on
the treatment application, additional rinsing or disposal of permeate
may be required.
NSF / ANSI Standard 61 certified modules require the following
conditioning rinse prior to producing potable water:
1. Rinse the modules at a feed rate of 40 LMH minimum for a period of
70 Hours.
2. Achieve a minimum total rinse volume of 2800 LMH-Hours using the
feed water available.
3. The concentrate bleed rate should be set from between 0% to 20%
with the balance being filtrate.
4. During the rinse cycle, perform standard cleaning protocols as
defined per the manufacturer’s recommendations which are
specifically designed to consider the feed water quality available.
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5. The filtrate should be sent to the appropriate disposal system based

on the regulations that apply to the location where the conditioning
rinse is carried out and not used as potable water.
6. Local regulations may require additional conditioning of the system
prior to producing potable water.
SHUT DOWN
Manual Shut down
To conduct a manual shut down open the concentrate rinse valve and
flush for 15 seconds. Then slowly close the inlet valve.
Equipment shut down during automatic operation
The equipment will automatically stop or will not allow automatic
operation if the feed pump did not start when operation was initiated or
the inlet or permeate pressure is too high to operate.
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Table DOW Ultrafiltration Operating Conditions
Operating Conditions SI US
Feed Pressure, Maximum at Inlet at 40 ºC 3.0 Bar 45 psi
Operating TMP (Maximum) 2.1 Bar 30 psi
Filtrate Flux @25C 40 - 120 L/m2/h 24 - 70 gfd
Temperature (UPVC limited ) 1 – 40°C 34 - 104°F
Operating pH Range 2 - 11
NaOCl, Cleaning Maximum 2,000 ppm

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M
N.2
6"
N.7 N.10
6" 4"
N.9
4"
N.1
6"
N.8 N.6
3" 6"
N.4
4"
Normal operation
Refers to the routine operating sequence of a system using the DOWTM
Ultrafiltration module and includes the operating and backwash steps.
At initial start up the modules are flushed using a “forward flush” to
remove any residual chemicals or trapped air from the module. The
flush occurs on the outside of the fibers and does not filter the feed
water to make permeate. After the forward flush is discontinued the
modules can be placed in the operating mode. An operating cycle
ranges from 20 to 60 minutes. While operating 100% of the feed water
is converted to permeate. As contaminants are removed during the
operating step the trans membrane pressure will rise. At the end of the
preset operating cycle time, a backwash sequence is triggered.
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Backwash mode
The backwash mode occurs automatically and may include an air scour,
but always includes draining, backwash through the top drain, back
wash through the bottom drain, and a forward flush. The air scour step,
when included, is used to loosen particulates deposited on the outside
of the membrane surface. Air is introduced on the outside of the fibers
and displaced feed flow/concentrate is allowed to discharge through the
top of the module for disposal. After 20 to 30 seconds of air scour the
module is drained by gravity to remove dislodged particulates. If the air
flush is not included, the backwash sequence is started with simply
draining the module by gravity to remove the concentrated feed water
before starting any backwashing.
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After draining the first backwash step is performed. Permeate flow is

reversed from the inside of the fiber to the outside and backwash flow
is removed from the module housing through the top drain on the
module. A top draining backwash is performed first to remove
contaminants in the area of greatest concentration.
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N.2
6"
N.7 N.10
6" 4"
N.9
4"
N.1
6"
N.8 N.6
3" 6"
N.4
4"
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The second backwash step is performed to remove contaminants

through the bottom of the module housing. Permeate flow is reversed
from the inside of the fiber to the outside and backwash flow is
removed from the module housing through the bottom drain on the
module for efficient removal of heavier materials. The two steps of
backwash can be repeated numerous times depending on the degree of
fouling. After backwash is complete, a forward flush is performed to
remove any remaining contaminants and remove any air trapped on the
outside of the fibers. After a backwash, the modules are returned to the
operating mode.
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If the modules are taken out of service, the following steps should be
taken: perform a backwash sequence, dose a chemical preservative to
the modules, and close all valves on the modules.
CEB operation refers to a chemically enhanced backwash. The frequency
of a CEB is dependent on the feed water quality. On high quality feed
waters a CEB may not be required. However a CEB can be performed as
frequently as a backwash. The CEB process occurs automatically but the
frequency can be adjusted after gaining operating experience. The CEB
is performed using UF permeate but with either an acid or base
combined with an oxidant added to more effectively clean contaminants
from the membrane surface. The choice of chemicals added is made
according the DOW Ultrafiltration design software (UFlow) design of the
system.
CEB done twice with different chemical between Acid and Alkali, CEB
allowed for alkali only.
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N.2
6"
N.7 N.10
6" 4"
N.9
4"
N.1
6"
N.8 N.6
3" 6"
N.4
4"
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The soak is performed for 5 to 10 minutes and allows more time for the
oxidant to react with contaminants that have attached to the membrane
surface or penetrated the fiber wall. After the soak a forward flush is
performed to remove any remaining contaminants on the outside of the
fibers. After a CEB and at the start of the operating step, permeate may
be wasted to remove residual chemicals held in the fiber or module.
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M
N.2
6"
N.7 N.10
6" 4"
N.9
4"
N.1
6"
N.8 N.6
3" 6"
N.4
4"
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M
N.2
6"
N.7 N.10
6" 4"
N.9
4"
N.1
6"
N.8 N.6
3" 6"
N.4
4"
2.12.2.1.4BRACKISH WATER REVERSE OSMOSIS

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Loading of Pressure Vessels

This section provides guidelines for loading and unloading FILMTEC™
reverse osmosis (RO) and Nano filtration (NF) elements. For additional
loading instructions, contact the individual pressure vessel
manufacturer.
Preparation
A schematic diagram of the RO system should be prepared for recording
pressure vessel and element locations. It should show the entire piping
system for the skid as well. To identify individual element locations, use
the FILMTEC™ serial numbers written on each label. This diagram will
help you keep track of each individual element in the system.
The following equipment is recommended:
 Safety shoes
 Safety glasses
 Rubber gloves
 Silicone lubricant (Dow Corning® / Molykote® 111 recommended)
 Allen wrench
 Clean rags
 Glycerin
 Hose and water to flush vessel
 Sponge/swab, long stick and rope to clean vessel
1. Load FILMTEC elements into the pressure vessels just prior to
start-up.
2. Before assembling all components, check the parts list and make
sure all items are present and in the right quantities.
3. Carefully remove all dust, dirt, and foreign matter from the
pressure vessels before opening.
4. Remove all end cap assemblies and thrust rings (if provided)
from all pressure vessels in the train or system. Note: There are
several manufacturers of pressure vessels used for spiral-wound
Nano filtration and reverse osmosis elements. Refer to the
manufacturer’s drawing for your pressure vessel during removal
and installation of end cap assembly.
5. Spray clean water through the open pressure vessels to remove
any dust or debris present in the vessels. Note: If additional
cleaning is required, create a swab large enough to fill the inside
diameter of the pressure vessel. Soak the swab in a
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glycerin/water solution (50 vol%) and move it back and forth

through the pressure vessel until the vessel is clean and
lubricated.
Element Loading
1. Install the thrust ring in the concentrate discharge end of the vessel.
Consult the manufacturer’s drawing for specific information on the
thrust ring positioning. This has to be done before the loading of any
elements, there is a risk of not installing it properly.
2. You need to verify whether you are installing iLEC™ (Interlocking
Endcap) or standard elements which require the use of a supplied
interconnect.
3. It’s recommended to stage the elements prior to loading and record
each serial number by position so that in the future you will know
where each element is located inside the pressure vessel.
4. Place the leading end of the first RO or NF element into the feed
water end of the first pressure vessel and slide it in approximately
one-half of the element length. Note: Always load NF or RO
elements into the feed water end of the pressure vessel. Verify that
the U-cup brine seal is properly seated in the end cap groove of the
element such that the brine seal opens in the upstream direction.
5. To Load Standard elements: Lubricate the O-ring seals on the
interconnector and the inside of the product water tube with a very
thin layer of silicone lubricant. Install the interconnector into the
permeate tube of the element. Glycerin may be used but is not
recommended. Although glycerin lubricates during the initial
installation, it quickly washes out during normal operation.
Experience has shown that using a silicone lubricant applied
sparingly to the bore of 8-inch elements or the permeate water tube
outer sealing surface for 4-inch and 2.5-inch elements maintains the
desired lubricity long after the initial start-up. For potable water and
food processing applications, the silicone lubricant Dow Corning®
111 valve lubricant and sealant, which carries both FDA and NSF
approval, works quite well.
a. Apply a thin layer of silicone lubricant to each brine seal. When
silicone is applied, as each element is installed and pushed into
position this will act as a lubricant on the inside of the pressure
vessel which will remain during the operation of the system
making removal much easier.
b. Lift the next element into position and install the trailing end on
the interconnector. Be very careful to hold the next element so
that the weight is not supported by the interconnector, and push
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the element into the pressure vessel until about one-half of the
elements extends outside the vessel.
Pre-Start-Up Check
After having loaded the elements into the pressure vessels and before
starting up the membrane unit, make sure that the whole pretreatment
section is working in accordance with the specifications. If the
pretreatment involved changing of the chemical characteristics of the
raw water, then a full analysis of the water entering the membrane unit
must be made. Furthermore, absence of chlorine, turbidity and SDI
must be determined.
The raw water intake must be stable with respect to:
 Flow
 SDI
 Turbidity
 Temperature
 pH
 Conductivity
 Bacteria (standard plate count)
The following checks of the pretreatment system and the membrane
unit are recommended for the initial start-up (results to be included in
the start-up report) :
Pre-Start-Up Checklist
 Corrosion resistant materials of construction are used for all
equipment from the supply source to the membrane including
piping, vessels, instruments and wetted parts of pumps
 All piping and equipment is compatible with designed pressure
 All piping and equipment is compatible with designed pH range
(cleaning)
 All piping and equipment is protected against galvanic corrosion
 Media filters are backwashed and rinsed
 New/clean cartridge filter is installed directly upstream of the high
pressure pump
 Feed line, including RO feed manifold, is purged and flushed, before
pressure vessels are connected
 Chemical addition points are properly located
 Check/anti-siphon valves are properly installed in chemical addition
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lines
 Provisions exist for proper mixing of chemicals in the feed stream
 Dosage chemical tanks are filled with the right chemicals
 Provisions exist for preventing the RO system from operating when
the dosage pumps are shut down
 Provisions exist for preventing the dosage pumps from operating
when the RO system is shut down
 If chlorine is used, provisions exist to ensure complete chlorine
removal prior to the membranes
 Planned instrumentation allows proper operation and monitoring
of the pretreatment and RO system
 Planned instrumentation is installed and operative
 Instrument calibration is verified
 Pressure relief protection is installed and correctly set
 Provisions exist for preventing the permeate pressure from
exceeding the feed/concentrate pressure more than 5 psi (0.3 bar)
at any time
 Interlocks, time delay relays and alarms are properly set
 Provisions exist for sampling permeate from individual modules
 Provisions exist for sampling raw water, feed, permeate and
concentrate streams from each stage and the total plant permeate
stream
 Pressure vessels are properly piped both for operation and cleaning
mode
 Pressure vessels are secured to the rack or frame per
manufacturer’s instructions
 Assembly and Loading of Pressure Vessels, are taken
 Membranes are protected from temperature extremes (freezing,
direct sunlight, heater exhaust, etc.)
 Pumps are ready for operation: aligned, lubricated, proper rotation
 Fittings are tight
 Cleaning system is installed and operative
 Permeate line is open
 Permeate flow is directed to drain (In double-pass systems,
provisions exist to flush first pass without permeate going through
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the second pass)

 Reject flow control valve is in open position
 Feed flow valve is throttled and/or pump bypass valve is partly
open to limit feed flow to less than 50% of operating feed flow
Start-Up Sequence
Proper start-up of reverse osmosis (RO) and Nano filtration (NF) water
treatment systems is essential to prepare the membranes for operating
service and to prevent membrane damage due to excessive
pressure/flow or hydraulic shock. Following the proper start-up
sequence also helps ensure that system operating parameters conform
to design conditions so that water quality and productivity goals can be
achieved. Measurement of initial system performance is an important
part of the start-up process. Documented results of this evaluation
serve as benchmarks against which ongoing system operating
performance can be measured.
Following is the recommended RO system start-up sequence:
Typical Start-Up Sequence
a. Before initiating the start-up sequence, thoroughly rinse the
pretreatment section to flush out debris and other contaminants
without letting the feed enters the elements. Follow the Pre-Start-
up check described in Section 5.2.2, Pre-Start-up Check and
Commissioning Audit.
b. Check all valves to ensure that settings are correct. The feed
pressure control and concentrate control valves should be fully
open.
c. Use low pressure water at a low flow rate to flush the air out of the
elements and pressure vessels. Flush at a gauge pressure of 30 – 60
psi (0.2 – 0.4 MPa). All permeate and concentrate flows should be
directed to an appropriate waste collection drain during flushing.
Air remaining in the elements and/or in the pressure vessels may
lead to excessive forces on the element in flow direction or in radial
direction and causing fiberglass shell cracking, if the feed pressure
is ramped up too quickly (see also Section 8, Troubleshooting).
d. During the flushing operation, check all pipe connections and valves
for leaks. Tighten connections where necessary.
e. After the system has been flushed for a minimum of 30 minutes,
close the feed pressure control valve.
f. Ensure that the concentrate control valve is open.
Starting against a closed or almost closed concentrate valve could
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cause the recovery to be exceeded which may lead to scaling .

g. Slowly crack open the feed pressure control valve (feed pressure
should be less than 60 psi (0.4 MPa).
h. Start the high pressure pump.
i. Slowly open the feed pressure control valve, increasing the feed
pressure and feed flow rate to the membrane elements until the
design concentrate flow is reached. The feed pressure increase to
the elements should be less than 10 psi (0.07 MPa) per second to
achieve a soft start. Continue to send all permeate and concentrate
flows to an appropriate waste collection drain.
If the feed pressure and/or the feed flow rate are ramped up too
quickly, the housing of the elements may be damaged by excessive
forces in flow direction and/or in radial direction - especially if air is
in the system - leading to telescoping and/or fiberglass shell
cracking (see Section 8, Troubleshooting).
j. Slowly close the concentrate control valves until the ratio of
permeate flow to concentrate flow approaches, but do not exceed
the design ratio (recovery). Continue to check the system pressure
to ensure that it does not exceed the upper design limit.
k. Repeat steps "i" and "j" until the design permeate and concentrate
flows are obtained.
l. Calculate the system recovery and compare it to the system's
design value.
m. Check the addition of pretreatment chemicals (acid, scale inhibitor
and sodium meta-bisulfite if used). Measure feed water pH.
n. Check the Langelier Saturation Index (LSI) or the Stiff & Davis
Stability Index (S&DSI) of the concentrate by measuring pH,
conductivity, calcium hardness, and alkalinity levels and then
making the necessary calculations.
o. Allow the system to run for one hour.
p. Take the first reading of all operating parameters.
q. Check the permeate conductivity from each pressure vessel to
verify that all vessels conform to performance expectations (e.g.,
vessels with leaking O-rings or other evidence of malfunction to be
identified for corrective action).
r. After 24 – 48 hours of operation, review all recorded plant
operating data such as feed pressure, differential pressure,
temperature, flows, recovery and conductivity readings. At the
same time draw samples of feed water, concentrate and permeate
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for analysis of constituents.

s. Compare system performance to design values.
t. Confirm proper operation of mechanical and instrumental safety
devices.
u. Switch the permeate flow from drain to the normal service
position.
v. Lock the system into automatic operation.
w. Use the initial system performance information obtained in steps
"p" through "r" as a reference for evaluating future system
performance. Measure system performance regularly during the
first week of operation to check for proper performance during this
critical initial stage.
Ilustration for Brackish water RO :
RO Chemical Dosing
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Service Mode
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M
M
M
M
Flushing Mode
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2.12.2.1.5Degasifier (C20201)
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Purpose: To remove CO2

Operation:
- Keep Reverse Osmosis A-D in service
- Keep On-off valve (Permeate RO) open
- Start Degasifier blower A/B (B20201A/B) manually
Flow rates: 250 m3/h
Illustration:
2.12.2.1.6Mixed bed
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This procedure offers guidelines for loading and startup of a mixed bed
with ion exchange resins. These procedures are specifically designed for
equipment which is internally regenerated, with an interface collector
between the cation and anion layers.
1. Before loading the resins, make a detailed inspection of the empty
vessel:
 Remove all debris of previous resins or foreign material.
 Clean up distributors and collector, and inspect all laterals for
damage or plugging.
 Inspect the rubber lining for integrity, and perform a spark test,
if possible.
 Whenever possible check the pressure loss of the empty vessel
at nominal flow rate (case of in-situ regeneration) and observe
the flow patterns for uniformity.
2. Loading of the resins:
 Fill vessel with sufficient water (~ 1/3 vessel height) to allow
settling and avoid resin damage.
 Load cation resin to around 5 cm (2 inch) below final desired
level.
 Backwash cation at 12-15 m/h (5-6 gpm/ft2 ) for 30 minutes.
 Settle and drain bed to 5-10 cm (2-4 inches) above resin surface
and fill remaining cation resins up to the level of the central
collector (if in H+ form) or 3-5 cm (1-2 inches) below if in Na+
form. Carry out a second backwash for 10 minutes and settle.
Ensure that the resin surface is even and at the correct level.
 With 1 meter (3 feet) of water above the cation resin, load anion
resin. Backwash at 5 m/h (2 gpm/ft2 ) for 5 minutes.
 If anion resin is in Cl- form or cation resin is in Na- form, carry out
double regeneration on both resin components.
 Rinse resins with flow from top and bottom, with removal of
rinse water through the central collector, for 30 minutes.
 Reduce water level to around 5 cm (2 inches) above the resin
bed and air mix for 15-20 minutes.
3. Start-up operation:
 Start run and monitor rinse down until the specified
conductivity, silica, and TOC levels are achieved.
NOTE:
If the required water quality is not reached, resin clumping may
still be present. To eliminate this, the mixed bed should be run for
minimum 5 hours and then a further 15 minute air mix should be
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carried out at the end of the service run before backwashing to

optimize resin mixing. DO NOT TRY TO SEPARATE NEW OR FRESHLY
REGENERATED RESINS
Mixed Bed Ion Exchanger A-E :
1. Backwashing
Purpose: To separate anion and cation resin layers
Operation:
- Start Deionization pump A/B/C (P20208 A/B/C) manually
- Open On-off valves (20XV243, 20XV244) manually
Illustration:
2. Stop
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Purpose: To allow floating resins to settle by gravity

Operation:
- Stop Regeneration pump A/B (P20214A/B) manually
- Close On-off valves (20XV241, 20XV242, 20XV243, 20XV244 )
manually
Illustration:
3. Regenerant NaOH and H2SO4 Injection

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Purpose: To regenerate exhausted anion and cation resin

Operation:
- Start Regeneration pump A/B (P20214 A/B) manually
- Open On-off valves (20VX2046, 20VX2047, 20VX2048) manually
- Close On-off valve (20XV241, 20XV242, 20XV243, 20XV244,
20XV245 and 20XV250) manually
- Start NaOH (P20226A/B) and H2SO4 (P20230A/B) Dosing pump
(manually)
- Setting flow with flow meter for regent water for Acid regent and
Alkali regent valve manually
Flow rate: NaOH 48% = 367 L/H, Downward = 5.5 m 3/h, H2SO4 98% =
124 L/H Upward = 5.6 m3/h
Illustration:
4. Displacement Ion with NaOH and H2SO4 (Slow rinse)

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Purpose: To displace active NaOH 48% and H2SO4 residual from the
line before ends of spray nozzle
Operation:
- Keep Regeneration pump A/B (P20214A/B) running
- Keep On-off valves (20XV246, 20XV247 and 20XV248) open
20XV245 and 20XV250) manually
- Stop NaOH (P20230A/B) and H2SO4 (P20226A/B) Dosing pump
manually
Flow rate: Downward = 5.5 m3/h, Upward = 11 m3/h
Illustration:
5. Water Drain
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Purpose: To reduce water level in vessel to prevent separation of

resin during air mixing
Operation:
- Stop Regeneration pump A/B (P20214 A/B) manually
- Open On-off valves (20XV246 and 20XV250) manually
- Close other On-off valves are closed
Illustration:
6. Resin Air Mixing

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Purpose: To mix back cation and anion resins

Operation:
20XV245, 20XV246, 20XV247 and 20XV248) manually
- Open On-off valve (20XV249 and 20XV250) manually
Flow rate: 85.93 Nm3/h
Illustration:
7. Vessel Filling
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Purpose: To fill the vessel with water until required level

Operation:
- Start Deionization pump A/B/C (P20208A/B/C) manually
- Open On-off valve (20XV241 and 20XV250) manually
- Other On-off valves are closed
Duration: 2 minutes
Illustration:
8. Rinsing
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Purpose: To fill the vessel with water until required level

Operation:
- Keep Booster pump A/B (10GCK21/22AP001) running to feed
demin water through Anion Exchanger A/B (10GCF21/22AT001)
- Keep On-off valve (10GCF21/22AA302) open
- Open On-off valve (10GCF31/32AA306) manually from local SVB
Illustration:
9. Service
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Purpose: To further polish demineralized water

Operation:
- Keep Deionized water pump (P20208A/B) running to feed
demineralized water
- Keep On-off valve XV-241 & XV-242 open
- Other On-off valves are closed
Duration: 40 hours
Illustration:
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2.12.2.2 ELECTRICAL & INSTRUMENT EQUIPMENT PRE-COMMISSIONING

2.12.2.2.1MCC POWER ENERGIZES Procedure:
1. Prior to energizing the MCC, the operator should check selector
switches of each MCC module for equipment such as pumps, blowers,
agitators, etc., if they are in OFF position. Release to Local signal from
MMI shall not be activated (Logic=0). Below is a list of equipment with
their respective local control panels:
2. Energizing the MCC
3. Refer to separate manual of MCC for energizing procedure
4. Select the following motor starter modules to remote mode operation
NO Tag NO EQUIPMENT NAME Remark
1 P20102 A/B FW PUMP FOR DW A/B
2 P20207 A/B BACKWASH PUMP FOR MMF ACF A/B
3 P20216 A OXIDANT DOSING PUMP FOR MMF A/B
4 P20201 A/B/C UF FEED PUMP A/B/C
5 P20202A/B BACKWASH PUMP FOR UF A/B
6 P20223A/B CITRIC ACID DOSING PUMP A/B
7 P20220A/B ALKALI DOSING PUMP FOR UF A/B
8 P20217A/B OXIDANT DOSING PUMP FOR UF A/B
9 P20203A/B/C RO FEED PUMP A/B/C
10 P20219A/B ACID DOSING FOR RO A/B
11 P20222A/B ANTI-SCALE DOSING PUMP A/B
12 P20218A/B REDUCTANT DOSING PUMP A/B
13 P20221A/B NON-OXIDATION BIOCIDE DOSING PUMP A/B
14 P20204A~E RO HIGH PRESSURE PUMP A-E
15 P20206A/B RO FLUSHING PUMP A/B
18 P20205A/B/C DEGASSIFIER WATER PUMP
19 P20212A/B REGENERATION PUMP
20 P20226A/B ACID DOSING PUMP FOR MIXED BED
21 P20223A/B ALKALI DOSING PUMP FOR MIXED BED
Energize each equipment in the MCC as per following requirements
for equipment with auto mode/manual mode, select of each
equipment via MMI
Operation mode of each equipment shall be selected to the following:
1. MCC FUNCTION TEST (FAT&SAT)
Refer to Appendix
2. MOTOR NO-LOAD TEST
Procedure: The procedure of pre-commissioning works for the above
check-items of Electrical and Instrument Equipment shall be based on
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Project Standard Procedure. Electric motors of equipment subject for

Motor no-load test are listed in table below.
G. ON-OFF VALVE LOOP TEST
Refer to Appendix
H. INSTRUMENT LOOP TEST
Refer to Appendix
I. SYSTEM FUNCTION TEST
Refer to Appendix
J. INPUT-OUTPUT TEST
Refer to Appendix
K. SEQUENCE TEST
Refer to Appendix
2.12.3 COMMISSIONING
PHB, Adhi and PKG shall together perform the Commissioning Work, or if
necessary. PHB Staff shall explain the operation of the Water Treatment
Plant and train PKG Staffs, as well.
2.12.3.1 PERFORMANCE TEST
2.12.3.1.1General:
Performance Test shall be done by running the plant for two cycles.
Demineralized and Condensate water quality shall be checked with
conductivity meters. Commissioning results shall be recorded in the
“Commissioning Result” form. Period of commissioning shall be referred
to the Table below;
Table: Commissioning Period
ITEMS
SYSTEM
Treating Capacity x Analysis
Mechanical Electrical
day x Duration (Raw/Treated)
Multi Media Filter 75 m3/h x 3 x 4 h
Activated Carbon Filter 75 m3/h x 3 x 4 h
Ultrafiltration 93 m3/h x 3 x 4 h
Reverse Osmosis 62.5 m3/h x 3 x 4 h
Degasifier 250 m3/h x 3 x 4 h
Mixed bed 77.5 m3/h x 3 x 4 h
2.12.3.1.2Procedure:
1. Run the plant for 24 hours per day for 5 days.
2. Take data of influent flow rates for Multimedia filter, Carbon Filter,
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Ultrafiltration, Reverse Osmosis, and Mixed Bed Exchanger every hour.

3. Take data of pressures for MMF, ACF, UF, RO and Mixed Bed Exchanger
every hour.
4. Take data of conductivity for RO and Mixed Bed Exchanger every hour.
5. Take data of pH in Filtered water Tank, UF tank RO tank and
demineralized tank every hour.
6. Take sampling at sampling cocks of MMF, ACF, UF, RO and Mixed Bed
Exchanger for analysis.
7. Take note of the running time of first on-line Demineralizer train
following switched-over of the standby train.
8. Take note of the duration of regeneration period in every regeneration
cycle.
2.12.3.2 TROUBLESHOOTING
A. Unit fails to initiate 1. No power supply. Check electrical service, fuse, etc.
are Back wash 2. Electrical Control has Check control system for on-off
cycle. been interrupted valves.
3. Power failure. Reset time of day.
B. FILTER BLEEDS 1. By-pass valve open. Close by-pass valve.
TASTE AND ODOR 2. Electrical service to unit Assure permanent electrical service
OR SEDIMENT has been interrupted (check fuse, plug or switch)
3. Quality of feed water has Have water sample analyzed to
worsened determine any change
Be sure control is not clogged or
4. Filter not backwashing drain line restricted. Be sure water
enough pressure has not dropped and that
pump has sufficient capacity.
Check if central tube is cracked or
5. Leak between valve and
O-ring is damaged. Replace faulty
central tube.
parts.
Replace valve seals, spacer, and
6. Internal valve leak.
piston assembly.
C. Low water 1. Iron or scale builds up
Clean pipes.
pressure. inline feeding unit.
Clean control and address in
2. Iron build up in side valve
cleaner to clean bed. Increase
or tank.
Backwash frequency.
3. Inlet of control plugged Remove piston and clean control
due to foreign material. valve.
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D. Filter media in Check well system for proper air
1. Air in water system.
drain line. eliminator control.
2. Incorrect drain line flow
Check for proper flow rate.
control.
1. Electrical Control for
E. Valve continuously Check control system for on of
valve has been
cycles. valves.
interrupted.
1. Valve settings incorrect. Check valve settings.
2. Foreign material in
F. Flow to drain Clean control.
control valve.
continuously.
Replace seals, spacers, and piston
3. Internal leak.
assembly.
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2.13 MSDS Chemical

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2.13.1 Oxidant for Potable Water (Calcium Hypochlorite)

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2.13.2 Oxidant for Multi Media Filter (Sodium Hypochlorite)

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2.13.3 CEB for UF Unit

2.13.3.1 Hydrochloric Acid
2.13.3.2 Natrium Hydroxide
2.13.3.3 Sodium Hypochlorite (See 2.13.2)
201485-20000-TS-04
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Package
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201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
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2.13.4 CIP for UF Unit

2.13.4.1 Hydrochloric Acid (See 2.13.3.1)
2.13.4.2 Natrium Hydroxide (See 2.13.3.2)
2.13.4.3 Sodium Hypochlorite (See 2.13.3.3)
201485-20000-TS-04
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2.13.5 Inlet RO Unit

2.13.5.1 Sulfuric Acid
2.13.5.2 Anti-scale (HYP SI-311)
2.13.5.3 Reductant (SMBS)
2.13.5.4 Non Oxidation Biocide (Bioclean 500CIP)
201485-20000-TS-04
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Package
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201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
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2.13.6 CIP for RO Unit

2.13.6.1 Acid (Opticlean 2000 ACD)
2.13.6.2 Alkali (Opticlean 1000 ALK)
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(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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Package
(Persero), Tbk.
201485-20000-TS-04
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2.13.7 Cation Exchanger Regeneration (Sulfuric Acid) (See 2.13.5.1)

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2.13.8 Mixed Bed Ion Exchanger Regeneration

2.13.8.1 Sulfuric Acid (See 2.13.5.1)
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2.13.9 Neutralization
2.13.9.1 Sulfuric Acid (See 2.13.5.1)
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3 Control Narrative
3.1 General
3.1.1 Permissive Start, Auto start & Auto stop
3.1.1.1 FW Pump for CW (P20101 A/B/C)
Unit :3 un
its (2 duties, 1 stand by)
Capacity : 277 m3/h (normal capacity)
360 m3/h (rated capacity)
Head : 30 m
Pumps can be controlled in either remotely or locally based on the
position remote-local selector on local control station.
Permissive Start :
a. Not on trip condition (20 XA P101A/B/C active).
b. Level on T20101 above Low level (2780 mm).
Auto Stop :
a. Pump trip (20 XA P101A/B/C inactive)
b. LL level on T20101 indicated by 20 LI 102B value equal or below
2200 mm (20 I 01).
3.1.1.1.1 Remote Control
In remote control mode, pumps can be controlled in either
automatically or manually based on the selection provided in HMI.
Remote control mode activated by selecting remote on remote-
local selector on local control station (20 ZL P101A/B/C inactive).
3.1.1.1.2 Auto Mode
Auto Start :
a. Low pressure indicated by 20 PI 104 value below 2 kg/cm 2g
(20 I 21) will force standby pump to run.
b. Tripped running pumps (20 XA P101A/B/C inactive) will also
force standby pump to run.
3.1.1.1.3 Manual Mode
Manual Start :
a. Start button pressed on HMI.
Manual Stop :
a. Stop button pressed on HMI.
3.1.1.1.4 Local Control
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In local control mode, pumps will be controlled by push button

provided in Local Control Station for each pump. Local control
mode activated by selecting remote on remote-local selector on
local control station (20 ZL P101A/B/C active).
3.1.1.2 FW Pump for Service Unit (P20103 A/B)

Unit : 2 units (1 duty, 1 standby)
Capacity : 70 m3/h (rated capacity)
Head : 40 m
Permissive Start:
a. Not on trip condition (20 XA P103A/B active).
Auto Stop:
a. LL level on T20101 indicated by 20 LI 102B value equal or below
2200 mm (20 I 01).
b. Pump trip (20 XA P103A/B inactive)
local selector on local control station (20 ZL P103A/B inactive).
3.1.1.2.2 Auto Mode
Auto Start:
a. Low pressure indicated by 20 PI 105 value below 3 kg/cm 2g (20
I 22) will force standby pump to run.
b. Tripped running pumps (20 XA P103A/B inactive) will also force
standby pump to run.
Manual Start:
Manual Stop:
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local control station (20 ZL P103A/B active).
3.1.1.3 FW Pump for DW (P20102 A/B/C)

Unit : 3 units (2 duties, 1 standby)
Head : 45 m
Permissive Start:
Auto Stop:
a. LL level on T20101 indicated by 20 LI 102B value equal or below
2200 mm (20 I 01).
3.1.1.3.2 Auto Mode
Auto Start:
a. Time based PLC sequence. (20 KIC 04A~F)
Auto Stop:
a. Time based PLC sequence. (20 KIC 04A~F)
Manual Start:
Manual Stop:
201485-20000-TS-04
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3.1.1.4 Potable Water Pump (P20106A/B)
Head : 40 m
Permissive Start:
Auto Stop:
a. LL level on T20102 indicated by 20 LI 104B value equal or below 710
mm (20 I 03).
3.1.1.4.2 Auto Mode
Auto Start :
a. Low pressure indicated by 20 PI 117 value below 2 kg/cm 2g
(20 I 04) will force standby pump to run.
Manual Start:
Manual Stop:
201485-20000-TS-04
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3.1.1.5 Backwash Pump for PTW-ACF (P20107 A/B)
Head : 20 m
Permissive Start:
Auto Stop:
mm (20 I 03).
3.1.1.5.2 Auto Mode
Auto Start:
a. Time based PLC sequence (20 KIC 02A/B/C)
Auto Stop:
a. Time based PLC sequence (20 KIC 02A/B/C)
Manual Start:
Manual Stop:
201485-20000-TS-04
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3.1.1.6 UF Feed Pump (P20201 A/B/C)
Head : 45 m
Permissive Start:
Auto Stop:
mm (20 I 06).
b. Pump trip (20 XA P201A/B/C inactive)
3.1.1.6.2 Auto Mode
Auto Start:
a. Time based PLC sequence. (20 KIC 07A~D)
Auto Stop:
a. Time based PLC sequence. (20 KIC 07A~D)
Manual Start:
Manual Stop:
201485-20000-TS-04
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3.1.1.7 UF Backwash Pump (P20202 A/B)
Head : 20 m
Permissive Start :
Auto Stop:
mm (20 I 08).
3.1.1.7.2 Auto Mode
Auto Start:
a. Time based PLC sequence (20 KIC 07A~D)
Auto Stop:
b. LL level on T20202 indicated by 20 LI 204B value equal or below
730 mm (20 I 08).
c. Pump trip (20 XA P201A/B/C inactive)

Manual Start:
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Manual Stop:
3.1.1.8 RO Feed Pump (P20203 A/B/C)
Head : 35 m
Permissive Start:
Auto Stop:
mm (20 I 08).
b. Pump trip (20 XA P203A/B/C inactive)
3.1.1.8.2 Auto Mode
Auto Start:
a. Time based PLC sequence (20 KIC 09A~E)
Auto Stop:
Manual Start:
201485-20000-TS-04
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Manual Stop:
3.1.1.9 RO High Pressure Pump (P20204A~E)
Head : 140 m
position remote-local selector on local control station. The standby
pump can be running in auto mode if selected in HMI.
Permissive Star:
a. Not on trip condition (20 XA P204A~E active).
b. Pressure indicated by 20 PI 265 above 2 kg/cm2g
Auto Stop:
a. Pump trip (20 XA P204A~E inactive)
b. Pressure indicated by 20 PI 265 below 2 kg/cm2g
c. Energized 20 PSLL 214A~E and 20 PSLL 215A~E (20 I 09A~E)
d. Pressure indicated by 20 PI 217A~E above 14 kg/cm2g
local selector on local control station (20 ZL P204A~E inactive).
3.1.1.9.2 Auto Mode
Auto Start :
a. Time based PLC sequence
Auto Stop:
Manual Start:
201485-20000-TS-04
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Manual Stop:
local control station (20 ZL P204A~E active).
3.1.1.10 Degasifier Water Pump (P20205A/B/C)
Head : 20 m
Permissive Start:
b. Level of T20203 above L level (1000 mm)
Auto Stop:
b. Level on T20203 below LL level (500 mm) (20 I 11)
3.1.1.10.1Remote Control
3.1.1.10.2Manual Mode
Manual Start:
Manual Stop:
3.1.1.10.3Local Control
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3.1.1.11 RO Flushing Pump (P20206 A/B)

Head : 30 m
Permissive Start:
Auto Stop:
a. Pump trip (20 XA P206A/B inactive).
In remote control mode, pumps can be controlled manually
provided in HMI. Remote control mode activated by selecting
remote on remote-local selector on local control station (20 ZL
P206A/B inactive).
Manual Start:
Manual Stop:
3.1.1.12 Backwash Pump for Condensate ACF (P20209A/B)
Head : 20 m
Permissive Start:
201485-20000-TS-04
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Auto Stop:
a. Pump trip (20 XA P209A/B inactive)
3.1.1.12.2Auto Mode
Auto Start:
a. Time based PLC sequence (20 KIC 13A~C)
Auto Stop:
a. Time based PLC sequence (20 KIC 13A~C)
Manual Start:
Manual Stop:
3.1.1.13 Deionized Water Pump (P20208A/B/C)
Head : 30 m
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Permissive Start:
Auto Stop:
3.1.1.13.2Auto Mode
Auto Start:
Auto Stop:
Manual Start:
Manual Stop:
3.1.1.14 Neutralization Water Pump (P20213 A/B)
Head : 60 m
Permissive Start:
b. Level on T20209 (20 LI 215) above Low level (450 mm).
Auto Stop:
a. LL level on T20209 indicated by 20 LI 215 value equal or below 300
mm (20 I 21).
201485-20000-TS-04
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3.1.1.14.2Auto Mode
Auto Start:
a. Level on T20209 above or equal High level (2050 mm).
Manual Start:
Manual Stop:
provided in Local Control Station for each pump.
3.1.1.15 Brine Pump (P20214A/B)
Head : 15 m
Permissive Start :
Auto Stop :
provided in HMI.
Manual Start:
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Manual Stop:
3.1.1.16 Calcium Hypochlorite Dosing Pump (P20108 A/B)
Capacity : 10l/h (rated capacity)
Head : 50 m
Permissive Start:
Auto Stop:
mm (20 I 18).
3.1.1.16.2Auto Mode
Auto Start:
a. Time based PLC sequence (20 KIC 02A)
Auto Stop:
Manual Start:
Manual Stop:
201485-20000-TS-04
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Package
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3.1.1.17 Agitator for Calcium Hypochlorite (A20101)
Unit : 1 unit
Motor can be controlled in either remotely or locally based on the
Permissive Start :
a. Not on trip condition (20 XA A101 active).
provided in HMI.
Manual Start:
Manual Stop:
3.1.1.18 Oxidant Dosing Pump for UF (P20217 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
a. LL level on T20211 indicated by 20 LI 219 value equal or below
200 mm (20 I 13).
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3.1.1.18.2Auto Mode
Auto Start :
a. Time based PLC sequence (20 KIC 04A~F)
Auto Stop :
b. Time based PLC sequence (20 KIC 04A~F)
Manual Start :
Manual Stop :
3.1.1.19 Oxidant Dosing Pump for MMF (P20216 A/B)
Head : 100 m
Permissive Start :
Auto Stop :
mm (20 I 13).
3.1.1.19.2Auto Mode
Auto Start :
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Auto Stop :
Manual Start :
Manual Stop :
3.1.1.20 Agitator for Citric Acid (A20204)
Unit : 1 unit
Permissive Start :
Auto Stop :
a. Pump trip (20 XA A204 inactive).
b. Level on T20217 (20 LI 222) below Low level (200 mm) (20 I 19C).
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.21 Citric Acid Dosing Pump (P20223 A/B)
201485-20000-TS-04
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Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 19C).
3.1.1.21.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
3.1.1.22 Chemical Cleaning Pump for RO (P20215)
Unit : 1 unit (1 duty, 0 standby)
Head : 45 m
Permissive Start :
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b. Inactive 20 LALL 218B (20 I 20B)

Auto Stop :
b. Active 20 LALL 218B (20 I 20B)
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.23 Regeneration Water Pump (P20212A/B/C)
Head : 20 m
Permissive Start :
Auto Stop :
3.1.1.23.2Auto Mode
Auto Start :
a. Time based PLC sequence (20 KIC 14A/B for P20212A/B and 20
KIC 15A~E for P20212B/C)
Auto Stop :
201485-20000-TS-04
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a. Time based PLC sequence (20 KIC 14A/B for P20212A/B and 20
KIC 15A~E for P20212B/C)
Manual Start :
Manual Stop :
3.1.1.24 Agitator for Non-Oxidation Biocide (A20202)
Unit : 1 unit
Permissive Start :
Auto Stop :
b. Level on T20215 (20 LI 224) below Low level (200 mm) (20 I 19D).
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.25 Non-Oxidation Biocide Dosing Pump for RO (P20221 A/B)
201485-20000-TS-04
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Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 19D).
3.1.1.25.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
3.1.1.26 Agitator for Anti Scale (A20203)
Unit : 1 unit
Permissive Start :
Auto Stop :
201485-20000-TS-04
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Package
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b. Level on T20216 (20 LI 225) below Low level (200 mm) (20 I 19E).
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.27 Anti-Scale Dosing Pump for RO (P20222 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 19E).
3.1.1.27.2Auto Mode
Auto Start :
Auto Stop :
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Manual Start :
Manual Stop :
3.1.1.28 Agitator for Reductant (A20201)
Unit : 1 unit
Permissive Start :
Auto Stop :
b. Level on T20212 (20 LI 220) below Low level (200 mm) (20 I 19B).
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.29 Reductant Dosing Pump for RO (P20218 A/B)
Head : 50 m
Permissive Start :
201485-20000-TS-04
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Auto Stop :
mm (20 I 19B).
3.1.1.29.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
3.1.1.30 Acid Unload Pump (P20227A/B)
Head : 15 m
Permissive Start :
b. Level of T20219 below H level (1250 mm)
Auto Stop :
201485-20000-TS-04
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b. Level on T20219 above HH level (1750 mm) (20 I 17D)

provided in HMI.
Manual Start :
Manual Stop :
3.1.1.31 Acid Dosing Pump for Neutralization Pit (P20228 A/B)
Unit :2 units (1 duty, 1 standby)
Capacity : 50 l/h (rated capacity)
Head :100 m
Permissive Start :
Auto Stop :
mm (20 I 17B).
3.1.1.31.2Auto Mode
Auto Start :
a. pH indicated by 20 AIC 219 above 9 (20 I 29)
Auto Stop :
a. pH indicated by 20 AIC 219 at 7 (20 I 29)
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Manual Start :
Manual Stop :
3.1.1.32 Acid Dosing Pump for Mixed-Bed (P20226 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 17B).
3.1.1.32.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
201485-20000-TS-04
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3.1.1.33 Acid Dosing Pump for Cation Exchanger (P20225 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 17B).
3.1.1.33.2Auto Mode
Auto Start :
a. Time based PLC sequence (20 KIC 14A/B)
Auto Stop :
a. Time based PLC sequence (20 KIC 14A/B)
Manual Start :
Manual Stop :
mode also bypasses the interlock for the pumps.
3.1.1.34 Acid Dosing Pump for RO (P20219 A/B)
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Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 17B).
3.1.1.34.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
3.1.1.35 Alkali Unload Pump (P20229A/B)
Head : 15 m
Permissive Start :
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b. Level of T20220 below H level (1250 mm)

Auto Stop :
b. Level on T20220 above HH level (1750 mm) (20 I 17C)
provided in HMI.
Manual Start :
Manual Stop :
3.1.1.36 Alkali Dosing Pump for Neutralization Pit (P20231 A/B)
Head : 70 m
Permissive Start :
Auto Stop :
a. LL level on T20220 indicated by 20 LI 214 value equal or below
200 mm (20 I 17A).
3.1.1.36.2Auto Mode
Auto Start :
a. pH indicated by 20 AIC 219 at below 6 (20 I 29)
201485-20000-TS-04
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Auto Stop :
a. pH indicated by 20 AIC 219 at below 7 (20 I 29)
Manual Start :
Manual Stop :
3.1.1.37 Alkali Dosing Pump for Mixed-Bed (P20224 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 17A).
3.1.1.37.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
201485-20000-TS-04
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3.1.1.38 Alkali Dosing Pump for UF (P20220 A/B)
Head : 50 m
Permissive Start :
Auto Stop :
mm (20 I 17A).
3.1.1.38.2Auto Mode
Auto Start :
Auto Stop :
Manual Start :
Manual Stop :
201485-20000-TS-04
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Package
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3.1.2 Minimum Flow Protection

3.1.2.1 Minimum Flow Protection for P20101 A/B/C
Cooling water system also completed with return flow system to make
sure the cooling water system runs at least at minimum flow of running
pump (65 m3/h for each running pump). When the flow indicated by
20 FIC 102 below minimum flow set point, the flow will be controlling
the opening of 20 FV 102 to be at minimum value.
3.1.2.2 Minimum Flow Protection for P20103 A/B
This system also completed with return flow system to make sure the
potable water system runs at least at minimum flow of running pump
(28.31 m3/h for each running pump). When the flow indicated by
20 FIC 103 below minimum flow set point, the flow will be controlling
the opening of 20 FV 102 to be at minimum value.
FIC-104 control speed of the running P20102A/B/C (20 HIC P102A/B/C)
based on cascade level set point that can be selected in HMI. Set point
of the flow acquired from:
a. DCS set Point
b. Level of T20201 ACF Filtered Water Tank (20 LIC 202A) at max 5100
mm
The flow minimum for running pumps is 55.8 m 3/h for each pump.
When the set point below 111.6 m 3/h, there should be only a pump
activated. When the set point goes below the minimum flow, the alarm
will be triggered and the pump will be stopped.
FI-204 control speed of the running P20201A/B/C (20 HIC P201A/B/C).
the set point of the 20 FI 204 acquired from summary of the running UF
system permeate (83.7 m3/h per train) adjusted with the level of the
level of T20202 (20 LIC 204A) at max 5825 mm.
The flow minimum for running pumps is 55.8 m 3/h for each pump.
When the set point below 100.44 m 3/h, there should be only a pump
activated. When the set point goes below the minimum flow, the alarm
will be triggered and the pump will be stopped.
3.1.2.5 Minimum Flow Protection for P20204 A~E
20 FI-208A~D control speed of the running P20204A~E (20 HIC
P204A~E). The set point of the 20 FIC 208A~D acquired from RO system
permeate (63 m3/h per train).
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The speed of running pumps controlled by the flow meter 20 FIC 228.
Speed will be adjusted to have flow at set point. The set point itself
adjusted from the lowest value from the level on the degasifier tank
(20 LIC 206A) at min 500 mm or the condensate tank (20 LIC 210A) at
max 9100 mm.
For pumps without speed control, the excess flow will be returned to
the T20207 with the opening of 20 FV 229A. Mixed bed flow set point
acquired from accumulating the running system (20 FI 220) and the
level of the Demineralized Water tank (20 LIC 212A) at max 9900 mm.
The set point control the opening of the 20 FV 229B affecting the flow
from the pumps. When the flow indicated by 20 FIC 229A lower than
18.07 m3/h, the 20 FV 229A will be opened as minimum flow protection.
3.1.3 Totalizer
Every totalizer as tag FIQ will be counted from accumulative flow indicate
by its flow rate from flow transmitters per seconds.
3.2 Filtered Water Tank

3.2.1 Filtered Water Tank Level (Minimum Stop for LV-102)
Control for LV-102 will be done from DCS.
3.2.2 Filtered Water Tank Low Level Protection (I-01/LALL102B)
Alarm will be triggered as level of the filtered water tank T20101 reach
2200 mm. The alarm also indicated as LALL-102B and as interlock I-01 to
trip following pumps:
a. P20101A/B/C
b. P20102A/B/C
c. P20103A/B
3.2.3 Filtered Water Tank Level (LIC-102A)
LIC-102A will control the opening of LV-102 as inlet flow controller for the
tank. The set point for LIC-102A will be controlled from DCS.
3.2.4 Flow Control to MMF for Demineralized Plant (FIC-104)
The flow control to MMF for Demineralized plant has been described at
chapter 3.1.2.3
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3.3.1 MMF for Potable Water Sequence (KIC-02A)
The Multi Media Filter for Potable Water (MMF-P) system S20103 has
three different operations regulated by 20 KIC 02A. The operations are:
a. Normal Mode
b. Backwash Mode
c. Standby Mode
3.3.1.1 Normal Mode
3.3.1.1.1 Service for Drain
Permissive run :
a. 20 LI 102B above LL level (2780 mm)
b. At least one P20103A/B on duty
c. Train is enabled at HMI
The system will run automatically after operator press start button
in HMI. If any of permissive condition not met when the system
runs, the system will go to hold condition. Sequence timer will not
be reset in hold condition. Operator must remove the hold
condition with pressing the start button again.
Auto Start :
Auto Stop :
b. Stop button from HMI, sequence time will be reset
c. 20 XV 101 fail to open (20 ZSO 101 inactive) after 5s, system will
go to hold condition
d. 20 XV 107 fail to open (20 ZSO 107 inactive) after 5s, system will
e. 20 XV 105 fail to open (20 ZSO 105 inactive) after 5s, system will
f.
3.3.1.1.2 Service
Permissive run :
b. At least one P20103A/B on duty
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c. Level on T20103 (20 LI 108) above LL level (200 mm)

d. At least one of P20108A/B in Auto mode and not in trip
condition (20XA108A/B active)
If any of permissive condition not met when the system runs, the
system will go to hold condition. Sequence timer will not be reset in
hold condition. Operator must remove the hold condition with
pressing the start button again.
Auto Start :
Auto Stop :
b. High value of 20 PDI 112 (0.7 kg/cm2g)
c. Stop button from HMI, sequence time will be reset
e. 20 XV 102 fail to open (20 ZSO 102 inactive) after 5s, system will
Permissive continue :
a. Neither S20101A nor S20101B on backwash mode
b. Level on T20102 (20 LI 104B) above LL level (710 mm)
c. At least one of P20107A/B in Auto mode and not in trip
condition (20 XA 107A/B active)
If any of the permissive condition not met, the system will force to
stay in normal mode.
3.3.1.2 Backwash Mode
3.3.1.2.1 Drain and Venting
Auto Start :
Auto Stop :
b. 20 XV 105 fail to open (20 ZSO 105 inactive) after 5s, system will
3.3.1.2.2 Air Scouring
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Auto Start :
Auto Stop :
3.3.1.2.3 Backwash
Permissive run :
a. Level on T20102 (20 LI 104B) above LL level (710 mm)
b. At least one of P20107A/B in Auto mode and not in trip
Auto Start :
Auto Stop :
a. Time based PLC Sequence (20 KIC 02A)
b. 20 XV 103 fail to open (20 ZSO 103 inactive) after 5s, system will
d. Stop button from HMI, sequence time will be reset
As the time for backwash mode elapsed, the system will stop in a
while before back to the normal mode automatically.
3.3.2 ACF for Potable Water Sequence (KIC-02B/C)
The Activated Carbon Filter for Potable Water (ACF-P) system S20101A/B
has three different operations regulated by 20 KIC 02B/C. The operations
are:
a. Normal Mode
b. Backwash Mode
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c. Standby Mode
3.3.2.1 Normal Mode
Permissive run :
a. MMF-P on normal mode
b. Train is enabled at HMI
Auto Start :
a. Time based PLC sequence (20 KIC 02B/C)
Auto Stop :
c. 20 XV 108A/B fail to open (20 ZSO 108A/B inactive) after 5s,
system will go to hold condition
d. 20 XV 112A/B fail to open (20 ZSO 112A/B inactive) after 5s,
e. 20 XV 113A/B fail to open (20 ZSO 113A/B inactive) after 5s,
3.3.2.1.2 Service
Permissive run :
a. MMF-P on normal mode
Auto Start :
Auto Stop :
b. High value of 20 PDI 115A/B (0.7 kg/cm2g)
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d. 20 XV 108A/B fail to open (20 ZSO 108A/B inactive) after 5s,

e. 20 XV 109A/B fail to open (20 ZSO 109A/B inactive) after 5s,
3.3.2.2.1 Open Vent
Auto Start :
Auto Stop :
b. 20 XV 113A/B fail to open (20 ZSO 113A/B inactive) after 5s,
3.3.2.2.2 Backwash
Permissive run :
Auto Start :
Auto Stop :
a. Time based PLC Sequence (20 KIC 02B/C)
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3.3.2.2.3 Settling
Auto Start :
Auto Stop :
As the time for backwash mode elapsed, the system will stop
before go to the standby mode automatically.
3.3.2.3 Standby Mode
ACF-P A/B goes to standby mode if there are one of the ACF-P train runs
normal mode. The standby train will go to normal mode when the other
train goes to backwash mode.
3.3.3 Potable Water Tank Level (LIC-104)
LIC-104 will control the inlet flow of the tank with opening the 20 LV 104.
The set point for LIC 104 will be at 4825 mm or inputted from DCS. The
more value of LIC 104 the less opening of the valve.
3.3.4 Potable Water Line Distribution Pressure (PIC-117)
The pressure PIC-117 will be controlling 20 HIC P106A/B. Pressure
indicated at minimum value (2 kg/cm2g) will triggered the auto start of
the pump. When pressure indicated at maximum value (5 kg/cm2g) will
auto stop the running pump. In between, the pressure will control the HIC
P106A/B.
3.3.5 Potable Dosing Ratio Control (FI-105)
The calcium hypochlorite dosing for MMF and ACF for potable system will
be based on the outlet flow of the system. The preservation of this
chemical referred to the Chemical Filling Preparation.

3.4.1 Multi Media Filter for Demineralized Plant (KIC-04A~F)
The Multi Media Filter (MMF) system S20201A~F has three different
operations regulated by 20 KIC 04A~F. The operations are:
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a. Normal Mode
b. Backwash Mode
c. Standby Mode
3.4.2 Normal Mode
3.4.2.1 Service for Drain
Permissive run :
b. At least one of P20102A/B/C in Auto mode and not in trip condition
(20 XA 102A/B/C active)
The system will run automatically after operator press start button in
HMI. If any of permissive condition not met when the system runs, the
hold condition. Operator must remove the hold condition with pressing
the start button again.
Auto Start :
Auto Stop :
c. 20 XV 201 fail to open (20 ZSO 201 inactive) after 5s, system will go
to hold condition
d. 20 XV 207 fail to open (20 ZSO 207 inactive) after 5s, system will go
to hold condition
e. 20 XV 205 fail to open (20 ZSO 205 inactive) after 5s, system will go
to hold condition
3.4.2.1.1 Service
Permissive run :
b. At least one of P20102A/B/C in Auto mode and not in trip
condition (20 XA 102A/B/C active)
e. Train is enabled at HMI
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Auto Start :
Auto Stop :
b. High value of 20 PDI 203A~F (0.7 kg/cm2g)
d. 20 XV 201A~F fail to open (20 ZSO 201A~F inactive) after 5s,
e. 20 XV 202A~F fail to open (20 ZSO 202A~F inactive) after 5s,
Permissive continue:
a. No other MMF or ACF in backwash mode
c. At least one of P20207A/B in Auto mode and not in trip
3.4.2.2.1 Drain and Venting
Auto Start :
Auto Stop :
b. 20 XV 205A~F fail to open (20 ZSO 205A~F inactive) after 5s,
c. 20 XV 207A~F fail to open (20 ZSO 207A~F inactive) after 5s,
Auto Start :
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Auto Stop :
3.4.2.2.3 Backwash
Permissive run :
Auto Start :
Auto Stop :
a. Time based PLC Sequence
3.4.2.2.4 Settling
Auto Start :
Auto Stop :
As the time for backwash mode elapsed, the system will stop before
go to the standby mode automatically.
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3.4.2.3 MMF Flow Totalizer (FIQ-201)

Flow totalizer indicated by FIQ-201 is a totalizer based on cumulative
flow from 20 FI 201 A~E.
3.4.3 Activated Carbon Filter for Demineralized Plant Sequence (KIC-05A~F)
The Activated Carbon Filter (ACF) system S20202A~F has three different
operations regulated by 20 KIC 05A~F. The operations are:
a. Normal Mode
b. Backwash Mode
c. Standby Mode
3.4.3.1 Normal mode
Permissive run :
a. MMF on normal mode
Auto Start :
Auto Stop :
3.4.3.1.2 Service
Permissive run :
a. MMF on normal mode
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Auto Start :
Auto Stop :
c. No other MMF or ACF in backwash mode

3.4.3.2.1 Open Vent
Auto Start :
Auto Stop :
3.4.3.2.2 Backwash
Permissive run :
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Auto Start :
Auto Stop :
3.4.3.2.3 Settling
Auto Start :
Auto Stop :
As the time for backwash mode elapsed, the system will goes to the
standby mode automatically.
ACF A~F goes to standby mode if there are one of the ACF A~F train
runs normal mode. The standby train will go to normal mode when the
other train goes to backwash mode.
3.4.4 ACF Filtered Water Tank Level Control (LIC-202A)
LIC-202A will control the inlet flow of the tank as described at chapter
3.1.2.3
3.4.5 ACF Filtered Water Tank Low Level Protection (I-06/LALL-202B)
The level of the tank indicated on 20 LI 202B. 20 LI 202B has LL alarm at
650 mm as 20 I 06 to trip following pumps:
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a. P20201 A/B/C
3.4.6 UF Feed Flow Control
The feed flow for UF control described at chapter 3.1.2.4.
3.4.7 UF Sequence (KIC-07A~D)
The Ultrafiltration (UF) system S20203A~D has three different operations
regulated by 20 KIC 07A. The operations are:
a. Normal Mode
b. Backwash Mode
c. Chemical Enhanced Backwash mode
d. Standby Mode
3.4.7.1 Normal Mode
Permissive run :
b. At least two of P20201A/B/C in Auto mode and not in trip condition
Auto Start :
Auto Stop :
b. Differential pressure 20 PDI 209A~D caused by difference between
20 PI 209A~D and 20 PI 208
d. 20 XV 214A~D fail to open (20 ZSO 214A~D inactive) after 5s,
e. 20 XV 215A~D fail to open (20 ZSO 214A~D inactive) after 5s,
f. 20 XV 216A~D fail to open (20 ZSO 214A~D inactive) after 5s,
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Permissive continue to backwash :

a. No other UF in backwash mode or Chemical Enhanced Backwash
mode
c. At least one of P20202A/B in Auto mode and not in trip condition
(20 XA 202A/B active)
If any of the permissive condition not met, the system will force to stay
in normal mode. The system will go to Chemical Enhanced Backwash
instead of normal backwash after 30 cycles of normal mode.
Permissive continue to chemical enhanced backwash :
a. No other UF in backwash mode or Chemical Enhanced Backwash
mode
c. At least one of P20202A/B in Auto mode and not in trip condition
d. Level on T20211 (20 LI 219) above LL level (200 mm)
e. At least one of P20217A/B in Auto mode and not in trip condition
f. Level on T20217 (20 LI 222) above LL level (200 mm)
g. At least one of P20217A/B in Auto mode and not in trip condition
h. Level on T20220 (20 LI 214) above LL level (300 mm)
i. At least one of P20220A/B in Auto mode and not in trip condition
in normal mode and alarm will be set.
Auto Start :
Auto Stop :
c. 20 XV 219A~D fail to open (20 ZSO 219A~D inactive) after 5s,
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system will go to hold
3.4.7.2.2 Draining
Auto Start :
Auto Stop :
c. 20 XV 217A~D fail to open (20 ZSO 217A~D) after 5s, system
will go to hold condition
3.4.7.2.3 Backwash Top
Permissive run :
Auto Start :
Auto Stop :
b. 20 XV 216A~D fail to open (20 ZSO 216A~D inactive) after 5s,
3.4.7.2.4 Backwash Bottom

Permissive run :
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Auto Start :
Auto Stop :
3.4.7.2.5 Forward Flush
Permissive run :
b. At least two of P20201A/B/C in Auto mode and not in trip
Auto Start :
Auto Stop :
After the time for backwash mode elapsed, the system will go to
normal mode automatically.
3.4.7.3 Chemical Enhanced Backwash (CEB) Mode
There are 2 types of CEB depends of chemical used, there are alkali and
oxidant backwash and acid backwash. Alkali and oxidant backwash
happens every 24 running hours, acid backwash happens every 168
running hours.
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Auto Start :
Auto Stop :
3.4.7.3.2 Draining
Auto Start :
Auto Stop :
Permissive run :
For alkali and oxidant backwash:
a. Level on T20217 (20 LI 222) above LL level (200 mm)
For acid based backwash:
a. Level on T20217 above Low level (300 mm).
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Auto Start :
Auto Stop :
3.4.7.3.4 Soak
Auto Start :
Auto Stop :
Permissive run :
Auto Start :
Auto Stop :

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Auto Start :
Auto Stop :
3.4.7.3.7 Draining
Auto Start :
Auto Stop :
Permissive run :
Auto Start :
Auto Stop :
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Permissive run :
Auto Start :
Auto Stop :
3.4.7.3.10Forward Flush
Permissive run :
Auto Start :
Auto Stop :
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After the time for backwash mode elapsed, the system will go to
normal mode automatically.
3.4.8 UF Filtered Water Tank Level (LIC-204A)
LIC-204A will control the inlet flow to the UF Filtered Water Tank T20202
described at chapter 3.1.2.4
3.4.9 UF Filtered Water Tank Low Level Protection (LALL-204B /I-08)
The level of the tank indicated on 20 LI 204B. 20 LI 204B has LL alarm at
730 as 20 I 08 to trip following pumps:
a. P20202 A/B
b. P20203 A/B/C
3.4.10 UF Outlet ORP High-High Protection (I-222/AAHH-222)
Inlet water to T20202 analyzed by 20 AI 222 that can set the alarm if it
indicated HH value. The set point can be set from HMI.
3.4.11 RO Sequence (KIC-09A~D)
The Reverse Osmosis (RO) system S20204A~D has three different
operations regulated by 20 KIC 09A. The operations are:
a. Flushing Mode
b. Normal Mode
c. Standby Mode
3.4.11.1 Flushing Mode
Permissive run :
hold condition. Operator has to remove the hold condition with
Auto Start :
Auto Stop :
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e. 20 XV 224A~D fail to open (20 ZSO 224A~D inactive) after 5s,
3.4.11.2 Normal Mode
Permissive run :
b. At least one of P20215A/B in Auto mode and not in trip condition
d. At least one of P20222A/B in Auto mode and not in trip condition
e. Level on T20212 (20 LI 220) above LL level (200 mm)
f. At least one of P20218A/B in Auto mode and not in trip condition
g. Level on T20219 (20 LI 214) above LL level (300 mm)
h. At least one of P20219A/B in Auto mode and not in trip condition
i. P20204A~E in Auto mode and not in trip condition (20 XA 204A~E
active)
Auto Start :
Auto Stop :
a. P20204A~E not running (20 XL 204A~E inactive)
b. Pressure indicated by 20 PI 217A~D above 15 kg/cm2g as 20 I
09A~D, sequence time will be reset
c. Difference between pressure indicated by 20 PI 217A~D and 20 PI
218A~D above 14 kg/cm2g as 20 I 09A~D, sequence time will be
reset
d. Difference between pressure indicated by 20 PI 218A~D and 20 PI
219A~D above 12 kg/cm2g as 20 I 09A~D, sequence time will be
reset
e. Conductivity indicated by 20 AI 205A~E above 10 μs/cm, sequence
time will be reset
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f. Stop button from HMI, sequence time will be reset

When the auto stop triggered, the system will run to flushing mode for
30 seconds then stop entirely. When the auto stop triggered by the
conductivity alarm 20 AAHH 205A~D, valve 20 XV 223A~D will be
opened for 5-15 seconds.
3.4.12 RO Feed Chemical Injection Control (FIC-207)
Anti-scale dosing for RO P20221A/B and non-oxidation biocide
P20222A/B dosing for RO controlled by flow control 20 FIC 207. There is
stroke control for the pumps adjusted by the flow of the RO feed pumps.
The preservation of this chemicals referred to the Chemical Filling
Preparation.
3.4.13 RO Feed pH Control (AIC-201)
Acid dosing for RO P20219A/B controlled by pH control 20 AIC 201. There
is stroke control for the pumps that adjust the acid injection to have RO
feed water pH as it set point. The set point can be adjusted from HMI.
3.4.14 RO Feed ORP Control (AIC-203)
Reductant dosing for RO P20218A/B controlled by ORP control 20 AIC
203. There is stroke control for the pumps that adjust the reductant
injection to have RO feed water ORP as it set point. The set point can be
adjusted from HMI.
3.4.15 RO Feed Flow Control (FIC-208A~D)
RO feed flow by FIC 208A~D described at chapter 3.1.2.5.
3.4.16 Stand by RO HP Pump Load Control Selector (HS-P204E)
P20204E as standby pump can replace any of P20204A~D when there is
any trouble by selecting the replaced pump on HMI (20 HS P204E). The
replacement can be made only when the RO system is not running. All
interlock affected the replaced pump will become interlock for P20204E.
3.4.17 RO High Pressure Pump Low Pressure Protection (PALL-214A~E/I-09A~E)
The interlock described at chapter 3.4.10
3.4.18 RO Protection (I-09A~D)
The interlock I-09A~D described at chapter 3.4.10
3.4.19 Degassed Water Tank Low Level Protection (LALL-206B/I-11)
Degassed water tank (T20203) level indicated by 20 LI 206B. 20 LI 206B
has LL alarm as 20 I 11 to trip following pumps:
a. P20206 A/B
b. P20205 A/B/C
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3.4.20 Degassed Water Tank Level (LIC-206A)

The outlet of the tank will be controlled by the level of the tank from LIC-
206A as described at chapter 3.1.2.6
3.4.21 Degassed Water Flow Control (FIC-228)
The flow control described at chapter 3.1.2.6
3.5 Condensate & Demineralized Water Plant

3.5.1 ACF for Condensate Sequence (KIC-13A~C)
The Activated Carbon Filter for Condensate (ACF-C) system S20207A/B/C
has three different operations regulated by 20 KIC 13A/B/C. The
operations are:
a. Normal Mode
b. Backwash Mode
c. Standby Mode
3.5.1.1 Normal Mode
Permissive run :
a. Train is enabled at HMI
Auto Start :
Auto Stop :
c. 20 XV 226A~C fail to open (20 ZSO 226A~C inactive) after 5s,
d. 20 XV 230A~F fail to open (20 ZSO 230A~C inactive) after 5s,
e. 20 XV 231A~F fail to open (20 ZSO 231A~C inactive) after 5s,
3.5.1.1.2 Service
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Permissive run :
Auto Start :
Auto Stop :
d. 20 XV 226A~C fail to open (20 ZSO 226A~C inactive) after 5s,
e. 20 XV 227A~F fail to open (20 ZSO 227A~C inactive) after 5s,
a. No other ACF in backwash mode
3.5.1.2.1 Open Vent
Auto Start :
Auto Stop :
b. 20 XV 231A~C fail to open (20 ZSO 231A~C inactive) after 5s,
3.5.1.2.2 Backwash
Permissive run :
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Auto Start :
Auto Stop :
b. 20 XV 228A~C fail to open (20 ZSO 228A~C inactive) after 5s,
3.5.1.2.3 Settling
Auto Start :
Auto Stop :
ACF-C A~C goes to standby mode if there are two of the ACF-C A~C train
runs normal mode. The standby train will go to normal mode when the
other train goes to backwash mode.
3.5.2 Cation Exchanger Sequence (KIC-14A~B)
Cation exchanger (CE) system E20202A/B has three different operations
regulated by 20 KIC 14A/B. The operations are:
a. Normal Mode
b. Backwash Mode
c. Standby Mode
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3.5.2.1 Normal Mode

Permissive run :
b. At least one of ACF-C run normal mode
Auto Start :
Auto Stop :
b. No ACF-C runs normal mode
d. 20 XV 232A/B fail to open (20 ZSO 232A/B inactive) after 5s, system
e. 20 XV 233A/B fail to open (20 ZSO 233A/B inactive) after 5s, system
f. Differential pressure indicated by 20 PDI 292A/B at HH value (0.7
kg/cm2g)
a. No other CE in backwash mode
in normal mode.
3.5.2.2.1 Backwash
Auto Start :
Auto Stop :
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e. No ACF-C in normal mode
3.5.2.2.2 Acid Regeneration
Permissive run :
Auto Start :
Auto Stop :
d. 20 XV 205 fail to open (20 ZSO 205 inactive) after 5s, system
e. Stop button from HMI, sequence time will be reset
3.5.2.2.3 Acid replacement
Auto Start :
Auto Stop :
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CE A/B goes to standby mode if there is one of the CE A/B train runs
3.5.3 Condensate Tank Level Control (LIC-210A)
The outlet flow of the tank described at chapter 3.1.2.6
3.5.4 Mixed Bed Ion Exchanger Feed Flow Control (FIC-229B)
The flow control described at chapter 3.1.2.7.
3.5.5 Mixed Bed Ion Exchanger Sequence (KIC-15A~E)
Mixed bed ion exchanger (MBE) system (S20203A~E) B has three different
operations regulated by 20 KIC 15A~E. The operations are:
a. Normal Mode
b. Backwash Mode
c. Standby Mode
3.5.5.1 Normal Mode
Permissive run :
a. Level on T20207 above LL level (850 mm)
b. At least two of P20209A/B/C in Auto mode and not in trip condition
Auto Start :
Auto Stop :
c. 20 XV 241A~E fail to open (20 ZSO 241A~E inactive) after 5s, system
d. 20 XV 242A~E fail to open (20 ZSO 242A~E inactive) after 5s, system
e. Differential pressure indicated by 20 PDI 293A~E at HH value (0.7
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.
kg/cm2g)
a. No other MBE in backwash mode
in normal mode.
3.5.5.2.1 Backwash
Auto Start :
c. Time based PLC sequence
Auto Stop :
b. 20 XV 243A~E fail to open (20 ZSO 243A~E inactive) after 5s,
c. 20 XV 244A~E fail to open (20 ZSO 244A~E inactive) after 5s,
3.5.5.2.2 Chemical Regeneration
Permissive run :
e. Level on T20230 (20 LI 214) above LL level (600 mm)
f. At least one of P20212B/C in Auto mode and not in trip
condition (20 XA 212B/C active)
Auto Start :
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.

Auto Stop :
e. 20 XV 248A~E fail to open (20 ZSO 248A~E inactive) after 5s,
f. 20 XV 206 fail to open (20 ZSO 206 inactive) after 5s, system
g. Stop button from HMI, sequence time will be reset
3.5.5.2.3 Chemical Displacement
Permissive run :
b. At least one of P20212B/C in Auto mode and not in trip
condition (20 XA 212B/C active)
Auto Start :
Auto Stop :
e. 20 XV 248A~E fail to open (20 ZSO 248A~E inactive) after 5s,
f. 20 XV 206 fail to open (20 ZSO 206 inactive) after 5s, system
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.

g. Stop button from HMI, sequence time will be reset
Auto Start :
Auto Stop :
3.5.5.2.5 Filling
Permissive run :
Auto Start :
Auto Stop :
d. 20 XV 249A~E fail to open (20 ZSO 249A~E inactive) after 5s,
3.5.5.2.6 Fast Rinse
Permissive run :
201485-20000-TS-04
PT. ADHI KARYA
Package
(Persero), Tbk.

Auto Start :
Auto Stop :
d. 20 XV 245A~E fail to open (20 ZSO 245A~E inactive) after 5s,
MB goes to standby mode if there are four of the MB A~E train runs
3.5.6 Demineralized Water Tank Level Control (LIC 212A)
The level control described at chapter 3.1.2.7.
3.5.7 Regeneration Water Tank Level Control (LIC-226)
Regeneration tank (T20230) will be controlled by 20 LIC 226 to control
the condition of 20 XV 254 as inlet to the tank. 20 LI 226 has LL alarm as
20 I 16 to trip following pumps:
a. P20212 A/B/C
3.5.8 Neutralizing Pit pH control (AIC-219)
The pH from Neutralizing Pit can be identified from 20 AIC 219. When
the value of pH between 6.5 and 8, the flow from the tank will be
transferred to chemical waste water line. Otherwise, the water will be
returned to the tank.

#Operating Manual r1

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PT PETROKIMIA GRESIK PROJ NO.

OPERATING MANUAL COVER

PT PADI HIJAU BUANA

PROJECT NAME : AMMONIA UREA II PROJECT

OWNER : PT.PETROKIMIA GRESIK

CONTRACTOR : PT. ADHI KARYA (PERSERO), TBK.

VENDOR NAME : PT Padi Hijau Buana

PACKAGE NAME : Filtered Water and Demineralization

P.O NO. : 201485-Z02-RD-PO

VENDOR DOC NO : PHB-20000-TS-04

1 For Approval YD TFK/DKY RMT 05 May 2017

2.12 START UP Procedure & TROUBLESHOOTING for Demineralized Plant.............88

3.3.5 Potable Dosing Ratio Control (FI-105).....................................................238

3.5.4 Mixed Bed Ion Exchanger Feed Flow Control (FIC-229B)......................259

1.1 Filtered Water System

1.2 Fire Fighting Water System

1.3 Potable Water System

Parameter Unit Max. Allowable

1.4 Demineralization Water System

- pH adjuster, sulfuric acid for pH adjusting to reduce potential of

Parameter Unit Maximum

2.1 Filtered Water Tank

2.2 Pre Filtration

2.3 Potable Water System

- Potable Water Pump (P20106 A/B):

2.4 Filtered Water System

- FW Pump for DW (P20102 A/B/C)

replacing the operated once when necessary.

long term performance.

necessary) open in 90 minutes to produce filtrate water.

Preset CEB sequence:

- Cleaning In Place (CIP) System

Type Chemical Name Dosage Maximum

- Chemical Cleaning Pump UF (P20232)

Reductant solution is come from Reductant Tank (T20212) and transferred

Pumps (P20204A~E). It operates only when RO P20204A~E in service mode.

In its operation, increasing pressure drop will occur due detained

- Chemical Cleaning Pump RO (P20215)

2.5 Condensate & Demineralized Water Plant

ACF-C Parameter Normal Max

Regeneration cycle is carried out as follows:

Mixed Bed Ion Exchanger

MB Parameter Normal Maximum

- Deionized Water Pump (P20208A/B/C)

P20226A/B and mixed with demineralized water in static mixer Z20219.

Iron Cartridge & Condensate Cooler

2.6 Neutralization Pit (T20209)

Non-oxidant Biocide solution is prepared in Non-oxidant Biocide Tank

2.8 Sequence Table

MMF & ACF for Potable Water

MMF & ACF for Demineralization

ACF & Cation Exchanger System for Condensate

Mixed Bed Ion Exchanger

2.9 Loading Media & Resin Procedure

Round Bolt Closures

 Carefully loosen retaining nuts around man way ring. If while

 Bottom collector, top and intermediate distributors, column lining,

2.9.1.6 ACCEPTANCE CRITERIA

2.9.2 Loading Media Procedure for ACF

Closing the man ways:

until it is 900 mm over the top of the bottom distribution. This

2.9.2.6 ACCEPTANCE CRITERIA

 Fill vessel with sufficient water (~1/3 vessel height), or completely in

Illustration for Loading Cation Resin