Water Supply and Treatment System

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE. M1-ME-612-202 SHEET i OF iii

BASIC STUDY GUIDE FOR
WATER SUPPLY AND TREATMENT SYSTEM
FLOPPY NO. : TCE.00000-ME-FP-138

FILE NAMES: M1ME202R6.DOC AND M1ME202R6.DWG
REV.NO. R3 R4 R5 R6 ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.
PPD.BY MMK Sd/- MMK Sd/- NNS Sd/- NNS
CHD.BY TSR Sd/- TSR Sd/- TSR Sd/- TSR R6
APD.BY RL Sd/- RL Sd/- RL Sd/- RL
DATE 98.07.24 99.03.03 01.04.16 01.09.21
TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION:CONTENTS
TCE. M1-ME-612-202 SHEET ii OF iii
CONTENTS
SL.NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 INPUT DATA TO BE COLLECTED OR GENERATED 1
3.0 SYSTEM DESIGN - WATER STORAGE AND SUPPLY 5
4.0 SYSTEM DESIGN - WATER TREATMENT 7
5.0 NEW ADVANCES IN DEMINERALISATION 19
6.0 MODE OF OPERATION 20
7.0 PUMPING ARRANGEMENT 20
8.0 MATERIALS OF CONSTRUCTION 21
9.0 INSTRUMENTATION REQUIREMENTS 22
10.0 PLANT LAYOUT 23
11.0 EQUIPMENT AND ELECTRICAL LOAD LIST 24
12.0 EFFLUENT DISPOSAL 24
13.0 WATER MASS BALANCE DIAGRAM 25
APPENDICES
1. FORMAT FOR RAW WATER ANALYSIS 27
2. WATER MASS BALANCE DIAGRAM 30
3. FACTORS TO BE CONSIDERED FOR ECONOMIC ANALYSIS 31
4. REFERENCE DOCUMENTS 32
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TCE CONSULTING ENGINEERS LIMITED SECTION:REV.STATUS
TCE. M1-ME-612-202 SHEET iii OF iii
REVISION STATUS
REV. NO. DATE DESCRIPTION
R0 --
R1 92.03.
R2 94.03.31 Addendum added.
R3 98.07.24 Generally revised.
R4 99.03.03 Merged documents TCE.M1-ME-610-001 and

002 in this document. Paras 3.4.2, 4.2.1, 4.7.4,
7.2 and 7.4 of R3 revised. These paras appear
as 3.7.2, 5.2.1, 5.7.4, 8.2 and 8.4 in R4 issue.
R5 01.04.16 Generally revised.

Paras 1.0, 4.2.5, 4.6.1, 4.10.4 and 4.10.7 revised.
R6 01.09.21
Para 4.10.13 added.
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TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE. M1-ME-612-202 SHEET 1 OF 32
1.0 SCOPE
1.1 WATER SUPPLY AND TREATMENT SYSTEM
This document gives guidelines for carrying out a basic study for water supply and
treatment system for chemical, industrial and power plants. The objective of the
basic study is to identify a cost effective and appropriate scheme for conveying raw
water from source to storage facility and treatment plant and decide basic design
parameters of water treatment plant to produce the required quality and quantity of
water for various end uses. For format, structure and other guidelines for
preparation of basic study refer TCE.M9-PCS-25. The basic study shall form the
basis for procurement and detailed engineering of water supply and treatment
system.
1.2 COOLING WATER SYSTEM
If no separate basic study is envisaged for cooling water system, the same shall be
included in the basic study for water supply and treatment system. Refer TCE.M1-
ME-127-201 for cooling tower make-up system and TCE.M6-ME-127-214 for
deciding basic parameters of cooling towers.
2.0 INPUT DATA TO BE COLLECTED OR GENERATED
2.1 Source of raw water and distance and elevation difference between the source and
the proposed location of storage facility
2.2 Raw water analysis in the enclosed format as per appendix 1. It is preferable to get
the analysis over a period of one year, at least once a fortnight. If this is not
possible, obtain :
(a) Representative analysis during summer, winter and monsoon seasons
(b) Design analysis considered for the existing plant, if any
(c) If the raw water analysis is not available at the time of study, such data shall
be obtained from installations nearby or from local municipal or public
health bodies. However, raw water analysis for the plant site shall be
obtained at the earliest and basic study shall be revised accordingly.
2.3 Reliability of the water supply source shall be ascertained.
2.3.1 Check whether the water supply source is perennial i.e. whether water shall be
available at the required quantity continuously throughout the year. If the water
source is not perennial, following shall be checked :
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(a) Maximum number of continuous days during which water may be available
from the source and supply pattern for each month
(b) Availability of any other alternate source of supply during the outage of the
main source. Details of this source with respect to the quality of water,
adequacy of the water quantity and reliability
2.3.2 The following details on the water availability shall be collected :
(a) Flow rate in M3 /Hr at which the water is available on continuous basis
throughout the day
(b) If flow is not continuous throughout the day, following details shall be
collected :
(i) Minimum and maximum flow rate in M3 /Hr
(ii) Duration of supply in a day
(iii) Maximum duration of continuous interruption
(iv) Total water supply in MLD
(v) Pressure at which water may be available at the source, high and low
levels in the source and temperature of water at source
(vi) Charges of water supply in Rs/M3
2.4 If the source of water is the ground water from sha llow wells or deep wells,
following information shall be obtained:
(a) Minimum continuous flow rate from the wells in M3 /Hr
(b) Maximum draw down level in M
(c) Diameter of the well in M
(d) Minimum recommended spacing between wells in M
(e) Cross-section of the well clearly indicating the water bearing strata and soil
strata
2.5 If the source of water is a channel or river, obtain a cross-section of the same clearly
indicating the normal, maximum and minimum water levels. Suitable permission is
required to take a tap-off from the channel or any such source and this aspect shall
be brought to the notice of the client.
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2.6 Desired water quality required for various processes shall be obtained from the
client or process collaborator. The quality of water required for other uses shall be
decided based on the guidelines given in following sub-paras.
2.6.1 Clarified water with suspended solids less than 50 mg/l for toilet flushing and
gardening. Filtered water with suspended solids less than 5 mg/l for service water
system and fire protection system make-up.
2.6.2 Chlorinated and filtered water with turbidity less than 5 Nephlometric Turbidity
Units (NTU) and Total Dissolved Salts (TDS) less than 500 mg/l for potable water
system. Refer IS 10500 and World Health Organisation (WHO) standards for other
parameters.
2.6.3 Soft water or blended water for cooling tower make-up if the raw water has scaling
tendencies. Refer TCE.M1-ME-127-201.
2.6.4 Soft water or partially demineralised (DM) water for low and medium pressure
boilers. The recommended feed water quality for low and medium pressure boilers
is given in IS 10392. Requirement shall be obtained from CE engineer.
2.6.5 Generally, DM water with TDS less than 0.5 mg/l and silica as SiO 2 upto 0.02 to
0.05 mg/l for high pressure boilers. However, this depends on the type of boiler
also. The recommended feed water quality for high pressure boilers is given in IS
10496 and IS 4343. Requirement shall be obtained from CE engineer.
2.6.6 Quality of water required for air washer and chilled water make-up shall be
obtained from AV engineer.
2.7 Quantity of water required for all end uses flow rate in M3 /Hr (normal and
maximum) and consumption in M3 /Day
2.7.1 The water consumption for process shall be obtained from client, collaborator,
process equipment vendors or chemical department
2.7.2 The requirement for potable water shall be calculated as per guidelines given in
TCE.M6-ME-610-221.
2.7.3 The requirement of service water shall be calculated based on number of service
water stations, floor washing requirements, gardening etc. If this information is not
available during preparation of the basic study, the data shall be collected from the
previous projects. Additional water requirement if any for any specific purpose,
shall be obtained from the client or process collaborator.
2.7.4 Steam generator feed water make-up is estimated at 3% Maximum Continuous

Rating (MCR) of steam generator for coal fired power plants and 2% for Combined
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Cycle Power Plants (CCPP). DM water required for NOx injection in case of CCPP
shall also be considered. This data shall be obtained from CE engineer.
2.7.5 When steam is consumed for process also, the water requirement shall be obtained
from client or process collaborator.
2.7.6 The water requirement for cooling tower make-up shall be calculated as per
guidelines given in TCE.M1-ME-127-201.
2.7.7 The water requirement for chilled water make-up and air washer shall be obtained
from AV engineer.
2.7.8 The make-up water for fire protectio n system shall be 0.5% to 5% depending on
type and size of the system.
2.8 Pressure of water required for all end uses at the battery limit and location of each
of these
2.9 Space availability for water treatment plant and storage of raw and treated water
2.10 Whether provision is to be made for any future expansion of the plant and if so,
what is the water requirement for future expansion plan
2.11 In case of extension or expansion of the existing water supply and treatment system,
details of existing system shall be collected. Ascertain whether the existing system
has spare capacity and whether the existing system outlet water quality matches
with the new water quality requirements. It is also to be ascertained whether any
additional equipment can be installed in the existing plant so that the new
requirement can be met with.
2.12 Method of disposal of regeneration waste water
2.13 Steam generator parameters such as number of units, MCR, pressure and
temperature and type of boiler
2.14 Availability and supply position of operating chemicals at plant site or storage
available in the process plant. This is required to assess the storage to be provided.
It shall be ascertained whether either of the regenerant is available as a by-product.
2.15 Cost of chemicals-mainly acid and alkali.
2.16 Desired mode of plant operation - manual, semi-automatic or fully automatic.
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3.0 SYSTEM DESIGN - WATER STORAGE AND SUPPLY
3.1 Prepare a mass balance diagram as per guidelines given in paragraph 13.0 and as
shown in appendix 2 and establish the total water requirement.
3.2 Study the reliability of the water source and other data to establish the capacity of
the raw water storage reservoir based on the guidelines given in the following
paragraphs.
3.3 When the source si not perennial, the useful capacity of the raw water storage
reservoir shall be equal to requirement of maximum continuous number of days for
which the supply from the source may be interrupted + at least one day’s
requirement + any other reserve storage like fire protection system etc. if fire water
pumps take suction from this reservoir.
3.4 If the source is perennial, but some forced outage is foreseen on the conveying
system, the useful capacity of the raw water storage reservoir shall be adequate to
meet the requirement during this duration of outage or duration required for getting
supply from some other source.
3.5 If the flow from the source is intermittent, the capacity of the raw water storage
reservoir shall be adequate to meet the requirement for the duration for which there
shall be no flow from the source.
3.6 It is recommended to provide at least one (1) day’s useful storage capacity for the
raw water storage reservoir.
3.7 If provision of clearwell is being considered along with clarifier, an assessment

shall be carried out to ascertain whether raw water storage reservoir can be
eliminated by giving required storage in the clearwell provided the raw water
supply pressure at the terminal point is adequate to provide the required pressure at
the clarifier inlet and the raw water is available at constant rate on 24 hours basis.
3.8 If the raw water supply pressure is adequate, preferably provide the raw water
storage above ground. This has the advantage of providing flooded suction to the
pumps. However, considering size of storage tank, soil conditions, material of
construction and techno-economic analysis, underground or above ground storage
shall be decided in consultation with civil engineer.
3.9 Examine the necessity of the raw water pumps when water is to be conveyed from
the raw water storage reservoir either to the clarifier (if provided) or water treatment
plant or to the distribution system. The type of the pump shall, preferably be one of
the following:
(a) Horizontal pumps if raw water storage reservoir is above ground or under
positive suction conditions.
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(b) Vertical pumps or horizontal pumps located in underground pump house

with positive suction if raw water storage reservoir is underground. Avoid
horizontal pumps with suction lift conditions.
(c) Horizontal pumps, located in above ground pump house for underground
storage tanks with a suction vessel designed for full vacuum. This will avoid
additional space and cost for underground pump house and will also
eliminate foot valve and associated priming and maintenance problems.
While deciding the number and capacity of the raw water pumps at least 50%
standby may be considered.
3.10 Study the plot plan and the pressure available at the raw water supply terminal point
and decide the location of the raw water storage reservoir.
3.11 Decide on the type of pipe (if required) for conveying the water from raw water
supply terminal point to the raw water storage reservoir and to clarifier based on the
following guidelines:
(a) Pump discharge pipes shall be carbon steel pipes for non-saline water and
Carbon Steel-Rubber Lined (CSRL) or cast iron pipes for saline water.
(b) Reinforced-Cement-Concrete (RCC) hume pipes for gravity flows

(minimum P2 class)
(c) If raw water supply is municipal water and is suitable for potable purpose
Galvanised Iron (GI) pipes shall be used to convey water from source to
storage.
Carbon steel pipes when used underground, shall have suitable protection.
3.12 In case of ground water source, establish the number of borewells or deepwells
depending on the yield of each well and the total raw water requirements of the
plant. Provide a minimum of one (1) standby pump for every three (3) deepwell
pumps.
3.13 In case where both external water source such as river water or cana l water and
ground water source are available, study the water analysis and examine whether
this water is suitable for any particular requirement without treatment or may be
with minimum amount of treatment. An economic study may be carried out for the
evaluation. Refer appendix 3 for factors to be considered for economic analysis.
3.14 If the raw water storage is underground, review the necessity of lining the sides and
bottom of the reservoir to avoid any seepage from or to the reservoir.
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3.15 If the raw water supply is limited, examine whether it is possible to reduce the plant
water requirements to suit the available raw water supply or recover water from the
plant effluent after suitable treatment.
4.0 SYSTEM DESIGN - WATER TREATMENT
To achieve desired treated water quality, from the given raw water analysis, the
treatment scheme shall be worked out by selecting from various methods of water
purification in an appropriate sequence. The following table gives the common
impurities found in the water and common means of treatment.
CONSTITUENT MEANS OF TREATMENT
Turbidity Coagulation, flocculation, clarification ,filtration

Suspended solids Coagulation, flocculation, clarification ,filtration
Colour and odour Coagulation, flocculation, filtration, chlorination,
adsorption by activated carbon filter
Oil and Grease (traces) Activated carbon filter
Hardness (calcium and Chemical dosing, lime soda softening, softening by
magnesium) cation resin, nano-filtration
Sodium, potassium, iron Demineralisation by cation resin, reverse osmosis,
(up to 1 mg/l) and other nano-filtration, electro-dialysis, distillation
cations
Bicarbonates, carbonates, Demineralisation by anion resin, reverse osmosis,

hydroxide, sulphate, nano-filtration, electro-dialysis, distillation
chlorides, nitrates, silica,
other anions
Dissolved gasses Aeration, de-areation
Iron and manganese Aeration, chlorination, coagulation, filtration, cation
exchange, MnO 2 filter for iron
Fluoride Coagulation, filtration
Dissolved silica Demineralisation by anion resin, reverse osmosis
Colloidal silica Coagulation, flocculation, clarification, filtration,
Micro Filtration (MF)
Bacteria and organics Chlorination, Ultra Violet (UV) sterilisation,
ozonation, activated carbon filter, Ultra Filtration (UF)
Some of the most commonly used means of treatment are described below.
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4.1 AERATION
Aeration is normally carried out for the purpose of oxidation. In the water treatment
the aeration has following two primary applications:
(a) Oxidation of dissolved iron and manganese to form insoluble hydroxides

which can be clarified and/or filtered out. This can be carried out by
cascading type system or by diffused air system.
(b) Stripping of dissolved gasses such as CO2 and H2 S from the water. In this
type of aeration degasser system is adopted.
4.2 CLARIFICATION
4.2.1 For waters having suspended solids more than 100 mg/l or turbidity more than 100
NTU, it is generally recommended to adopt clarification to avoid heavy load on
downstream treatment units. Prior to clarification, the water shall be dosed with
alum or any other coagulant aid. The table below lists the commonly used
coagulants.
NAME TYPICAL STRENGTH AVAILABLE AS
Aluminium sulphate 17% Al2 O3 Lump, Granular, Powder

Alum 8.25% Al2 O3 Solution
Aluminium chloride 35% AlCl3 Solution
Ferric sulphate 68% Fe2 (SO4 )3 Granular
Ferric chloride 60% FeCl3 /35 to 45% FeCl3 Crystals/solution
Sodium aluminate 38 to 46% Na2 Al2 O4 Solution
In some cases where, adding coagulant does not produce the desired effect,
polyelectrolytes shall be dosed. Various types of polyelectrolytes available are as
listed below:
• Cationic polyelectrolyte
• Anionic polyelectrolyte
• Non-ionic polyelectrolyte
• Polyelectrolyte for potable water
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Type of coagulant and polyelectrolyte and their dosage rate is decided based on the
jar tests to be conducted by water treatment plant contractor.
4.2.2 The following table lists the commonly used clarification plants:
TYPE APPLICATION
Clariflocculator Treatment of waters having very high turbidity(above 2000

NTU) and with highly fluctuating turbidity
Solids contact type Treatment of waters having high turbidity (above 200 NTU),
high colloidal silica and with highly fluctuating turbidity and
high variation of flow
Parallel plate type Treatment of waters having moderate turbidity( 500 to 2000
NTU), having not much fluctuating turbidity and where space
is a constraint
Tube settler type Treatment of waters having moderate turbidity( 500 to 2000
NTU), having not much fluctuating turbidity and where space
is a constraint
4.2.3 Normally, at the clarifier outlet a turbidity of approximately 20 NTU may be

expected.
4.2.4 The clarified water shall be stored in the clarified water storage tanks. It is
preferable to have compartments in these tanks to facilitate cleaning and
maintenance. Capacity of clarified water storage tank shall be decided based on
downstream plant requirement.
4.2.5 Clarifier waste is either thickened in a thickener and then sent to sludge drying beds
or directly sent to sludge drying beds or sludge handling unit or disposal point (ash
disposal area) by gravity or by disposal pumps. Clarifier waste shall not be taken to
neutralising pit as it is likely to settle in the pit and clog the recirculation-cum-
disposal pumps.
4.3 FILTRATION
4.3.1 Sand filters are the most commonly used filters in the water pre-treatment. These
may be either pressure filters or gravity filters. Pressure filters are recommended for
waters having suspended solid content upto 50 mg/l or turbidity upto 50 NTU.
However, these filters can also be used for higher loads upto 100 mg/l or 100 NTU
with use of coagulant and/or poly-electrolyte dosing. In such cases backwashing
frequency shall be higher and adequate storage on the downstream shall be
considered. Vertical pressure filters shall be considered for capacities upto 150
M3 /Hr or upto maximum shell diameter of four (4) metres. For higher flow rates
multiple streams of vertical pressure filters with automatic backwash facility or
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TCE. M1-ME-612-202 SHEET 10 OF 32
Automatic Valve-less Gravity Filter (AVGF) may be considered. Where space is

abundantly available horizontal pressure filters may also be considered for flow rate
above 150 M3 /Hr. The sand filter outlet water has suspended solids content less
than 2 mg/l, turbidity less than 2 NTU and particle size of about 100 microns.
4.3.2 The filters shall have layers of graded quartz sand supported on gravel and pebbles.
The sand bed depth in the Pressure Sand Filters (PSF) shall be 750 to 900 mm and
at least 50% rising space shall be provided. In case of Multi Grade Filters (MGF)
the bed depth shall be l.0 to 1.2 metres and at least 75% rising space shall be
provided to enable proper backwash.
4.3.3 For water having oil and grease, free chlorine, odour, taste, colour and other such
impurities activated carbon filter shall be used along with the sand filter.
4.3.4 If the water has less suspended solids and impurities such as oil and grease, odour,
taste and colour in small quantities, dual media filter bed comprising of sand bed
and anthracite or granular activated carbon coal bed on top, may be considered .
Anthracite shall be as per BS EN 12909.
4.3.5 The filters shall be backwashed by filtered water stored in filtered water tanks or by
raw water if suspended solid content is low (approximately below 10 NTU).
Normally, backwash is carried out once daily. Provision for leading the filter
backwash to the effluent treatment plant shall be provided.
4.3.6 If the suspended solid content in the raw water is more than 25 mg/l or the filter
diameter exceeds 1.5 metres, air blowers shall be provided for loosening the sand
bed before backwash and thereby saving the water quantity required for backwash.
4.3.7 One of the recent concept is on-line automatic self-cleaning filter. However, this
filter shall be selected after proper evaluation.
4.4 CHLORINATION
4.4.1 Chlorination shall be adopted for disinfection, oxidation of organic matter, removal
of Bio-chemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD),
removal of iron etc.
4.4.2 Gas chlorination, sodium hypochlorite dosing and electro-chlorination are the
commonly used methods. Electro-chlorination can be considered after proper
evaluation where sea water is available and where very large capacities are
required. Gas chlorination shall be adopted for low to high requirements of
chlorine. For small requirement chlorine cylinders with chlorinator shall be
provided. For large capacity, tonners along with evaporators shall be provided. At
least one standby cylinder or tonner shall be provided. For very small requirements
sodium hypochlorite dosing system shall be provided. A typical hypochlorite
dosing system shall comprise of a measuring-cum-dosing tank and two (1W+1S)
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dosing pumps. For higher capacities hypochlorite dosing is not feasible as

hypochlorite is available in 6% to 12% concentration only and for the larger
requirements the storage capacity works out to be very large. The chlorine dose
shall be determined from the chlorine demand of the water to be chlorinated. Refer
TCE.M6-ME-612-203.
4.5 SOFTENING
4.5.1 It is recommended to adopt softening by ion-exchange for all the end applications
of treated water that do not require reduction of total dissolved salts but require
removal of hardness only. The outlet hardness is generally less than 5 mg/l.
4.5.2 Whenever the softener diameter exceeds three (3) metres, it is recommended to
have two (2) units of 50% capacity. Provision of a stand-by unit may also be
considered on case to case basis.
4.5.3 For water containing hardness more than 800 mg/l, nano-filtration may be
considered after comparing capital and operating costs.
4.5.4 The softening plant shall be designed to produce net output per day in twenty (20)
hours operating time and four (4) hours shall be provided for regeneration. Unless
specifically required otherwise, a softener shall be regenerated once a day. When
continuous soft water is required for process, adequate capacity storage tank shall
be provided to take care of downtime of softeners. The tank capacity may be
determined by making a balance of inflow and outflow to the tank based on the
operating program and water required for regeneration. If there are more than one
(1) streams operating in parallel, staggered regeneration shall be carried out.
4.5.5 In case the raw water is chlorinated, sodium sulphite dosing system shall be
provided for dechlorination and shall be dosed at inlet to ion-exchange units or
activated carbon filter shall be provided.
4.5.6 For regeneration of softeners, salt regeneration systems comprising of salt saturator,
salt measuring/dilution tank and injectors shall be provided.
The salt saturator may be an elevated RCC tank with bottom of tank about two (2)
metres above ground or an underground tank with pumping facility. Elevated tank
facilitates gravity feed to salt measuring/dilution tanks but requires provision of
suitable conveying system to transfer NaCl from ground level to top of tank for
loading into the tank. Underground tank facilitates direct dumping of NaCl from
salt wagons but requires provision of vertical brine transfer pumps. Normally, the
capacity of salt saturator shall be adequate for seven (7) to fifteen (15) days storage
and salt measuring/dilution tank shall be adequate for one (1) day’s requirement per
softener.
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For small softening plant, however, salt saturator need not be provided and salt
solution may be prepared directly in the salt measuring/dilution tank.
4.5.7 For the softening plant with higher capacity and greater salt consumption, brine
circulation may be considered to cut down the salt consumption.
4.5.8 It is preferable to filter the raw water before softening as it reduces the pressure
drop and clogging in resin bed.
4.5.9 The effluent generated during the regeneration shall be carried to the effluent
treatment plant.
4.5.10 Generally, all softening plants are manually operated, but for softening plants
having multiple streams and higher capacities and based on the client’s requirement
it is recommended to adopt automatic sequential backwash and regeneration
operation.
4.6 DEMINERALISING (DM) PLANT
4.6.1 Based on the DM water requirements and on assessing how much quantity of DM
water is available from existing plant, if any, determine the capacity of the new DM
plant.
DM plants are normally adopted for raw water ionic loads upto 500 mg/l. For
higher values, installation of desalination units such as Reverse Osmosis (RO) or
Electro-Dialysis (ED) upstream of DM plants shall be considered. However, a
comparative analysis shall be carried out for capital and operating cost of DM
plants versus RO/ED before selecting the process. The two (2) bed DM plant outlet
water has TDS less than 10 mg/l and pH between 7.5 and 9.5. Normally, the Mixed
Bed (MB) outlet water has TDS less than 0.1 mg/l, pH between 6.8 and 7.2,
conductivity less than 0.2 µ-mhos/cm and silica less than 0.02 mg/l as SiO2.
4.6.2 Generally, it is recommended to provide one stream of DM plant with adequate

capacity storage tank for DM water considering regeneration downtime and
downstream requirement. However, depending on the process requirement,
capacity of plant, size of vessels and space availability, multiple, parallel operating
streams shall be provided as required.
4.6.3 It is recommended to design the DM plant for one (1) regeneration per day. Each
regeneration shall be considered to require six (6) hours and hence the design flow
rate of each stream is normally decided based on producing one (1) day’s
requirement in eighteen (18) hours.
4.6.4 For MB units, the service cycle shall be of minimum five (5) days continuous
operation. Each regeneration shall be considered to require six (6) hours and hence
the design flow rate of each stream shall be decided accordingly.
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4.6.5 The process and scheme selection and design of DM plant shall be carried out as
per TCE.M6-ME-612-203.
4.6.6 For calculating the resin quantities, the gross output shall be considered by taking
into account the quantity of water required for self regeneration and regeneration of
downstream equipment. For this reason the gross Output Between Regeneration
(OBR) of last unit shall be worked out first and then of preceding units.
4.6.7 Filtered water before admission to cation unit shall be de-chlorinated. Normally,
sodium sulphite dosing is adopted for de-chlorination and is dosed at inlet to DM
plant. Where raw water contains traces of oil and grease or organic matter, the
activated carbon filters shall be provided for de-chlorination. The activated carbon
filter involves additional cost, pressure drop, more space requirement, operating
and maintenance problems and in view of possibility of growth of bacterial
colonies in the filter media, as far as possible, activated carbon filters shall be
avoided.
4.6.8 Regeneration system consisting of bulk acid and caustic storage tanks, acid and
caustic measuring-cum-dilution tanks, caustic preparation tank (in case caustic
flakes are received from which caustic solution is to be prepared and transferred to
bulk caustic tanks), acid and caustic transfer pumps to transfer acid and caustic
from tankers to bulk tanks, injectors etc. shall be provided. The bulk tanks shall be
sized to hold about one (1) month’s acid and caustic or one tanker load of ten (10)
tonnes, whichever is higher, and shall located on the elevated saddles with access
platforms to facilitate gravity feed to measuring tanks. Provision for transfer of
chemicals between chemical tanks shall be provided. Refer TCE.M6-ME-612-205.
Separate acid measuring-cum-dilution tanks shall be provided for cation and MB
units. Separate alkali measuring-cum-dilution tanks shall be provided for anion and
MB units.
Where both HCl and H2 SO4 are available, HCl is preferred because of lesser
handling problems as compared to H2 SO4. Also using of H2 SO4 causes
precipitation of calcium sulphate on the resin bed, which leads to fouling of resins.
4.6.9 The regenerant effluent from cation, anion and MB units shall be led through
effluent trenches to a neutralising pit where, depending upon pH, either acid or
alkali from the bulk tanks shall be added for neutralisation. Vertical sump pump
type pumps installed in the pit shall recirculate the water till it is neutralised (i.e.
pH of around 7.0 is attained) and then disposed off as the neutralised effluent. In
case client insists on provision of horizontal pumps, priming tank shall be provided
on suction side of each pump. Refer TCE.M6-ME-612-207 for details.
4.6.10 It is recommended to adopt automatic operation of regeneration sequence in case of

multiple streams and higher capacity plants.
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4.6.11 In the DM Plant where MB unit is provided, the DM water storage tank shall be
provided with CO2 absorber on vent line. The overflow line of the tank shall be
provided with water seal and the inlet pipe shall be led to the bottom of the tank.
As an additional protection against ingress of CO2 , floating PVC balls may be
provided in the tank. To prevent PVC balls passing through overflow and suction
nozzles, suitable barrier may be provided.
4.7 DECARBONATION
Decarbonator shall be provided for removal of dissolved carbon dioxide gas from
the water treated in strong acid cation unit and reverse osmosis. Unless required
otherwise, the useful capacity of the decarbonated water storage tank shall be equal
to thirty (30) minutes holding capacity or the water requirement for regeneration of
one stream of cation and anion units, whichever is higher. For tank capacities upto
50 M3 the decarbonator can be installed directly on horizontal circular decarbonated
water tank. For higher capacities a vertical storage tank with a separate structure of
RCC or carbon steel shall be provided for supporting the decarbonator. However,
availability of space shall be taken into account before deciding the type of tank.
Both the decarbonator and decarbonated water tank shall be of rubber-lined carbon
steel. The blower provided shall have discharge head not less than 50 mmWC.
4.8 DEALKALISATION SYSTEM
Dealkalisation system is usually adopted to remove the bicarbonates of sodium

present in the softened water. It is normally carried out by passing the raw water
through weak acid cation exchanger, which removes calcium, magnesium and
sodium associated with alkalinity. The carbonic acid is converted to CO2 , which is
removed in decarbonator. In another method, the raw water is split into two (2)
streams, one (1) stream is passed through cation exchanger in sodium form and the
other stream is passed through cation exchanger in hydrogen form and mixture of
two (2) is passed through the decarbonator.
4.9 TYPICAL TREATMENT SCHEMES FOR DM PLANT
SCHEME APPLICATION TYPICAL OUTLET

QUALITY
SAC(CCR)→WBA Si and CO2 are not Conductivity: 10 to 40

objectionable µ-mho/cm, pH : 5
SAC(CCR)→SBA Low alkalinity in raw water, Conductivity : < 20

(CCR) removal of Si and CO2 is µ-mho/cm, Si : 0.1 to 0.2
required mg/l, pH : 8 to 8.5
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SAC(CCR)→DCB High alkalinity in raw water, Conductivity : < 15

→SBA(CCR) removal of Si and CO2 is µ-mho/cm, Si : 0.1 to 0.2
required mg/l, pH : 8 to 8.5
SAC(CCR)→DCB High alkalinity, chloride and Conductivity : < 15

→WBA→SBA(CC sulphate in raw water, removal µ-mho/cm, Si : 0.1 to 0.2
R) of Si and CO2 is required mg/l, pH : 8 to 8.5
WAC→SAC(CCR) High hardness, alkalinity, Conductivity : < 15

→DCB→WBA→ chloride and sulphate in raw µ-mho/cm,Si : 0.1 to 0.2
SBA(CCR) water, removal of Si and CO2 mg/l, pH : 8 to 8.5
is required
MB Low solids in the raw water Conductivity : < 5

and high purity required µ-mho/cm,Si : 0.02 to 0.05
mg/l, pH : 6.8 to 7.2
Can be used after any of the Conductivity : < 0.2

above schemes for very low µ-mho/cm, Si : 0.01 to 0.02
conductivity and silica at mg/l, pH : 6.8 to 7.2
outlet
The typical outlet qualities mentioned above are for conventional demineralisation
plant using conventional resins. Coflow regeneration instead of countercurrent
regeneration (CCR) can be adopted for SAC and SBA depending on the treated
water quality requirement. However, with new advances of packed bed counter-
current demineralisation system (para 5.1), SAC and SBA can produce water with
less than 0.1 mg/l sodium and less than 0.05 mg/l silica. This quality could obviate
the need of mixed bed unit
4.10 REVERSE OSMOSIS (RO) SYSTEM
4.10.1 Desalination by reverse osmosis shall be adopted for water having Total Dissolved
Solids more than 500 mg/l and saline water. However, for water having TDS range
of 500 mg/l to 1000 mg/l a preliminary comparative cost evaluation between RO
and DM plant shall be made before selecting the process. The water at the outlet of
RO plant shall have TDS not more than 5% of the raw water. For sea water
desalination the RO plant has lower capital cost as compared to other methods of
sea water desalination and is more economical in plant operation when waste heat
is not available. In nuclear power plants, nuclear waste heat may be used for
desalination of sea water. However, a cost comparison shall be made between Multi
Stage Flash Distillation (MSF) and RO.
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4.10.2 For brackish water having TDS upto 5000 mg/l, a recovery of 65 to 80% shall be
considered, while for waters, with TDS of 5000 to 15000 mg/l range, the recovery
shall be 40% to 65%. For sea water the recovery shall be limited upto 35%.
4.10.3 The number of streams of RO plant shall be decided on process requirement and
space availability. However, it is recommended that for very large plants each bank
of RO system shall not exceed 120 M3 /Hr permeate flow to avoid HT motor (above
175 KW) for RO feed pump.
4.10.4 Depending on the raw water quality, filtration with or without coagulant dosing
shall be considered. If the water is chlorinated, it shall de-chlorinated by dosing
sodium sulphite. Activated carbon filter shall be used as added safety and to
remove other impurities such as oil and grease, colour, etc. Acidification by HCl or
H2 SO4 and Sodium Hexa Meta Phospate (SHMP) dosing shall be incorporated to
achieve optimum recovery and prevent membrane fouling. Special anti- scalants are
also available which can be dosed in lieu of acid and SHMP. This eliminates
decarbonator and elaborate pH control system in the RO feed water.
However, proper evaluation shall be carried out before selection. Softening in place
of acidification shall be considered in case of high alkalinity and lower hardness.
However a cost comparison may be made before deciding. Micron cartridge filters
of 5 micron rating shall be used before RO feed pump to ensure Silt Density Index
(SDI) less than 3. It is recommended to go for higher degree of filtration in case of
sea water RO system or adopt ultrafiltration to ensure longer membrane life.
4.10.5 The RO feed pumps shall be centrifugal multistage pumps and of SS 316
construction. It is recommended to have one (1) pump operating and one (1)
standby to avoid downtime due to pump breakdown. A common standby pump
may be considered in case of multiple streams. Energy recovery turbines shall be
provided in case of sea water RO system, in order to reduce power consumption.
4.10.6 The type of the membranes shall be spiral wound polyamide thin film composite.
The RO tubes shall be of FRP. In order to achieve high system recovery, brine
staging shall be considered. For high permeate quality, permeate staging may be
considered thereby eliminating downstream DM plant where MB quality water is
not required.
4.10.7 Energy recovery turbine shall be provided particularly in sea water RO system and
thereby saving power consumption upto 30%.
4.10.8 Membrane flushing by permeate shall be provided, so that whenever there is plant
shutdown membranes are flushed by permeate to remove reject from system.
4.10.9 A Chemical Cleaning System (CCS) shall be provided for membrane cleaning. It
shall comprise of a chemical tank, cartridge filter, SS 316 centrifugal pump and
other accessories.
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4.10.10 Depending on the end application the permeate shall be treated further to achieve
required treated water quality. Most commonly used post treatment include
decarbonation, pH correction, demineralising, mixed bed polishing, fine filtration,
sterilisation, etc.
4.10.11 While designing the system, care shall be taken that all safety interlocks required
for safe operation of plant are incorporated. The following list gives the minimum
interlocks to be provided for the safety of membranes:
(a) Low level in acid and antiscalent tanks
(b) High RO feed pressure
(c) High differential pressure across membranes
(d) High permeate conductivity
(e) High reject pressure
(f) Feed and permeate pH
4.10.12 Depending on the size of the plant, only 4” or 8” size membranes shall be
considered to ensure a wide choice of makes. The smaller membranes are generally
used for very small domestic RO units and hence need not be considered here.
4.10.13 RO reject shall be taken directly to effluent treatment plant and not to the
neutralising pit as RO reject volumes are normally vary large and continuous
compared to effluent from DM plant which is small and intermittent.
4.11 NANO-FILTRATION (NF)
Wherever high salt rejection is not required but total hardness is to be rejected,
Nano-filtration (membrane softening) technique shall be considered. One of the
important applications of nano-filtration can be cooling tower make-up water or
potable water. Nano-filtration is very significant because of considerably low
power costs involved. Nano-filtration is generally considered for brackish water
and not for sea water. Recoveries upto 80% can be considered. The water at the
outlet of nano-filtration plant shall have nil hardness and TDS removal to the extent
of hardness in the raw water.
4.12 MICRO FILTRATION (MF)
Micro filtration is a membrane process and is used for removal of suspended

particles and colloidal matter. All the particles of size less than 1 micron are
rejected while the dissolved macromolecules and solids pass through the
membranes.
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4.13 ULTRA FILTRATION (UF)
It provides macromolecular separation for particles in range of 20 to 1000

Angstroms (upto 0.1 microns). All colloidal particles, proteins, bacteria, organic
matter are rejected by UF. All smaller molecules and dissolved solids pass through.
4.14 MULTI STAGE FLASH (MSF) DISTILLATION
MSF is an evaporative process of desalination of sea water. It involves application

of heat to cause change of phase producing a vapour free of dissolved solids in the
feed water. Condensation of the vapour produces considerably purified water.
This concept makes use of low pressure steam for initial heating of the water before
it enters a chamber which is under partial vacuum. A part of the feed water is
flashed into vapour and the balance water enters next chamber where it is flashed
further. This process continues till the water cools to its boiling point corresponding
to the chamber pressure. The vapour condenses on the water cooled tubes as fresh
water.
The system consists of multiple stages operated successively at low pressures and
water passing to the next stage flashing repeatedly in each stage without addition of
heat. The pretreatment includes filteration, chlorination, deaeration and antiscalant
addition. However, fresh water produced by above method can not be directly used
for any purpose in the plant (except as a feed for DM plant) due to the low
alkalinity content in the same. Hence a certain degree of post treatment (such as
passivation of the desalinated water) is required to be made to make it suitable for
plant services.
As compared to RO, MSF requires higher capital cost for sea water desalination but
are more economical in operation when waste heat is available.
4.15 MULTIPLE EFFECT DISTILLATION (MED)
This is an alternative method to MSF and is used commonly for sea water
desalination. It involves reduction of temperature and pressure in successive stages
with very low grade steam as a heat source. Feed water vaporises in each effect as it
absorbs latent heat through the condensing steam. The vapour moves to next effect
which operates at a slightly lower temperature and pressure. The distilled water is
collected from each effect. Brine follows the sequence from hottest to coolest
effect, successively flashed and cooled to recover the heat and finally discharged.
The fresh water produced by above method can not be directly used for any
purpose in the plant (except as a feed for DM plant) due to the low alkalinity
content in the same. Hence, a certain degree of post treatment such as passivation
of the desalinated water is required to be made to make it suitable for plant
services.
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As compared to RO, MED requires higher capital cost for sea water desalination
but are more economical in operation when waste heat is available.
5.0 NEW ADVANCES IN DEMINERALISATON
5.1 PACKED BED COUNTER CURRENT DEMINERALISATION
Although the packed bed counter-current technology is in use for many years now,
the new development is the use of ion exchange resins, which have a uniform
particle size and a layer of inert resin bed at top. These resins have a very narrow
size distribution curve and overall smaller average bead size. This results in higher
reaction rates and hence higher velocities are possible. Other advantages are as
below :
• Higher operating capacities
• Low chemical and water consumption for regeneration and hence less wastes
• Permits longer service cycles
• Longer resin life and less resin loss
• Less ionic leakage
• More resistant to Silica and organic fouling
5.2 LAYERED BED
This is an packed bed counter current exchanger but has two different layers or
resins such as SBA and WBA. The separation of two resins is ensured by
difference in the particle size distribution and resin density. This has the following
advantages :
• Fewer vessels required
• High regeneration efficiency
• High exchange capacity of WBA
• Increased life of SBA resin as WBA protects it from organic fouling
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5.3 SHORT BED TECHNOLOGY
In this method the bed depth is about 150 mm and the system operates at surface
flow rates as high as 75 M3 /Hr/M2 . The cycle time is generally 5 to 30 minutes and
regeneration time is 20 to 40 seconds followed by one minute rinse. The outlet
water is recirculated till the desired treated water quality is achieved. The advantage
of this system is that it requires very less space and the treated water quality is
better than conventionally obtained at the outlet of SBA. However, MB outlet
quality water cannot be achieved with this method.
6.0 MODE OF OPERATION
Normally, there shall be separate operator for water treatment plant. Regeneration
is normally carried out once a day and regeneration operation is quite simple
involving operation of few valves. Filter backwash operation is also quite simple.
Hence, manually operated plants are normally provided. However, where the
project philosophy is to have as much automation as possible or where the client
prefers automation, or in case of higher capacity plants, a semi-automatic system
with microprocessor based PLC system shall be provided. In such cases, the
operation of putting the stream back into service after regeneration and initiation of
regeneration shall be manual. All subsequent operations shall be fully automatic. In
such cases most of the valves in the plant shall have to be solenoid-actuated
pneumatic valves which adds to the cost. This shall be highlighted in the basic
study and, if possible, additional cost for providing semi-automatic plant shall be
indicated.
7.0 PUMPING ARRANGEMENT
7.1 To supply water from raw water storage reservoir or clearwell to water treatment
plant, provide separate pumps for DM plant and softening plant if located in
different areas. The number of pumps shall be 1+1 (100% capacity each) or 2+1
(50% capacity each) or 3+1 (33% capacity each) depending upon the number of
streams and expected mode of operation.
7.2 From treated water storage tank, provide one (1) pump operating and one (1) stand-
by pump.
7.3 Number of decarbonated water pumps to transfer water from decarbonated water
storage tank to anion unit or MB in case of RO plant shall be equal to the number
of streams with a common standby pump.
7.4 The pump parameters shall be selected carefully on case to case basis so that the
pump operates close to the duty point (best efficiency point) and also meets the
normal and the extreme operating requirements.
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7.5 In critical applications, instead of adding margin on pump head, an additional

margin of 3 to 5% may be added on the pump capacity.
7.6 In case of variable demand, the pumps may be provided with Variable Speed
Drives (VSD). The VSD may be common between working and standby pump.
Alternatively, an additional pump may be provided for meeting the peak demand. A
proper evaluation shall be carried out before providing the VSD and selecting an
alternative, since VSDs are very expensive. Normally, VSDs are considered for
large pumping stations where demand varies considerably and motor ratings are
above 75 KW.
7.7 In case the water supply system is to be installed in two phases, requiring higher
head in the second phase, the pumping system shall be designed for the second
phase except for the pump impeller. The impeller of reduced size may be installed
to meet the first phase requirements and bigger size impeller may be installed in the
second phase.
7.8 In case blending of two different qualities of waters is required, an arrangement

consisting of conductivity meter, control valves, flow meters, PLC, VSD driven
pumps etc. may be used. The pump capacity may be varied depending upon the
required quality of the blended water.
7.9 In case the inflow is highly fluctuating and only a limited storage capacity is
available, the pump may be operated for a short duration at minimum flow
condition. In such a case the friction loss may be higher than the static head and
this may result in pump operating at a very low head and at low efficiency. To
overcome this problem, the delivery header shall be an inverted "U". A vent pipe
shall be provided to break siphon formation. The vent pipe top shall be about one
(1) metre above the maximum hydraulic gradient of the pump so that even under
extreme conditions there is no overflow. Providing such an arrangement increases
the static head artificially for single and two (2) pump operation.
8.0 MATERIALS OF CONSTRUCTION
8.1 For filters the material used shall be carbon steel as per IS 2062 GR.B or IS 2002
GR.2 and internally coated with bituminous or epoxy paint. Fibre Reinforced
Plastic (FRP) may also be considered.
8.2 For anion, cation and mixed bed units the material of construction shall be as per IS
2062 GR.B or IS 2002 GR.2 with rubber lining. FRP may also be considered. For
softening plant the material of construction shall be as per IS 2062 GR.B or IS 2002
GR.2 with epoxy painting or FRP. For softening plant rubber lining may also be
considered from point of view of longer life, less maintenance and uniformity if
anion, cation and mixed bed units also exist in the water treatment plant
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8.3 For storage tanks and pressure vessels for DM plant, refer TCE.M6-ME-610-202.
The pumps used for DM water shall be of SS 316/SS 304.
8.4 In the pre-treatment of the RO plant all equipment shall be as at paras 8.1 to 8.3
above. The RO feed piping shall be of SS 316. The reject piping upto brine control
valve shall be of SS 316 and rubber-lined carbon steel thereafter. The permeate line
shall be rubber-lined carbon steel or PVC.
8.5 For DM water piping refer TCE.M6-ME-610-202. For piping for other services
refer TCE.M4-110-51 to 57.
9.0 INSTRUMENTATION REQUIREMENTS
Wherever applicable, following instruments shall be provided in the water

treatment plant. For very small or portable plants the necessity of instruments shall
be decided on case to case basis.
9.1 Pressure indicators at inlet and outlet of all vessels and pump discharge lines
9.2 Differential pressure indicators across all filters and RO block. Differential pressure
indicator-cum-switch shall be provided for alarm and in case automatic plant
operation is considered.
9.3 Rate of flow indicators and flow integrators for all ion exchange units, RO feed,
reject and permeate
9.4 Conductivity comparator with alarm or sodium analyser at cation unit outlet.
Conductivity comparator has some operational problems associated with it
whereas, sodium analyser is expensive. Hence, decision shall be taken after
consulting client.
9.5 pH and conductivity indicator with alarm at anion unit outlet, MB unit outlet, RO
feed and permeate outlet
9.6 Recorder at anion unit outlet, MB unit outlet, RO feed and permeate outlet for pH
and conductivity
9.7 Temperature indicator and high temperature switches at alkali regenerant inlet of
anion unit, ifz hot alkali regeneration is adopted, to close the regenerant inlet valve
in case the temperature exceeds the permissible value and chemical cleaning system
in RO plant.
9.8 Temperature controller for hot water tank of alkali regeneration system
9.9 Density indicators at outlet of ejectors of regeneration system
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9.10 Level switches and/or level gauges or level transmitters for all tanks
9.11 Flow indicators at ejector inlets (motive water line of regeneration system)
9.12 pH indicator with recorder at neutralising pumps discharge
9.13 Silica analyser, if insisted by client. Common silica analyser with multipoint
recorder can be provided for anion and MB units.
9.14 SDI kit for RO plant
9.15 ORP meter in RO plant if the raw water is chlorinated.
10.0 PLANT LAYOUT
The proposed layout of the plant shall be enclosed along with the basic study. Take
the help of layout drawings of previous projects. Following guidelines shall be
followed:
10.1 Contact tanks, filters and softening plants shall be located in one row. This
facilitates collection of regeneration and backwash effluents in a common trench
which can be connected to effluent disposal sump or neutralising pit.
10.2 Cation units, anion units and MB units shall be located in one row opposite to
filters. This facilitates collection of regeneration effluents in a lined trench which is
led to the neutralising pit.
10.3 Decarbonator with decarbonated water storage tank and DM water storage tanks
shall be located outside the building on the same side as those of ion-exchange
vessels. Soft water storage tank if envisaged and filtered water storage tanks shall
be located either on roof of water treatment plant building or outside the building
on the same side as filters and softeners.
10.4 Acid and caustic regeneration equipment consisting of bulk storage tanks,
preparation tanks and measuring-cum-dilution tanks shall be located in a dyked
area outside the building as close as possible to ion-exchange vessels.
Salt saturator for softening plant shall be located outside the building on the same
side of softening plant. Salt measuring/dilution tank shall be located inside the
building adjacent to the softening plant.
The location of bulk acid and caustic tanks shall be such that these are easily
accessible for road tankers for filling. This area shall be provided with acid/alkali
resistant tiles on flooring and in drains.
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Elevation of acid or caustic unloading pumps shall be such that positive suction is
ensured with respect to the tanker delivery point.
10.5 Neutralising pit shall be located outside the building preferably adjacent to acid and
alkali tank area. The pit shall, however, be five (5) meters away from the building.
10.6 Between the row of vessels, an operating space of two (2) to three (3) metres clear
width or space adequate to remove the largest vessel to outside shall be provided.
The effluent trenches may, however, be located in the operating space, with
chequered plate covering.
10.7 The MCC room shall be preferably located on one side of the building with control
panel visible from operating space.
10.8 Pumps and blowers shall be located in the space between vessels and building
walls.
10.9 Alum dosing and sodium sulphite dosing equipment shall be located in a dyked
area in one corner of the building adjacent to contact tank and filters.
10.10 In case of small sized plants normally all vessels, pumps and MCC shall be housed
in a single room. However, in large plants, where most of the equipment are
outdoor, the water treatment plant shall be of outdoor type and housing or room
shall be provided only for MCC and control panel.
10.11 Location of the drain trenches and sumps shall be shown. All drains with acid and
alkali shall be provided with acid and alkali resistant tiling .
11.0 EQUIPMENT AND ELECTRICAL LOAD LIST
An appendix covering the equipment list in the plant with major design parameters,
materials and expected electrical load shall be furnished with basic study.
12.0 EFFLUENT DISPOSAL
The filter backwash water, softener regeneration effluent, DM plant regeneration

effluent after neutralisation and RO reject though low in quantity, shall have very
high suspended solids and/or dissolved solids. Following alternatives are available
to meet the pollution regulations:
(a) Disposal of effluent to the main effluent collection channel or tank of the
complex.
(b) Disposal of effluent to ash disposal area.
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(c) Disposal of effluents to cooling water outlet channel where once-through

cooling water system is adopted
(d) "Zero Discharge Concept" shall be adopted in case of the following

conditions:
(i) Scarcity or limited availability of water resources
(ii) High cost of the raw water
(iii) Very high cost of treatment and disposal of effluent
In case zero discharge is not feasible, an effort shall be made to minimise

the effluent quantity so that the cost of the effluent treatment is
minimised. An attempt shall be made to segregate the waste at source itself
and treat it suitably. This shall lead to reduction in the volumes. Various
alternatives may be considered as regards to the quality of the waste and its
recycle and reuse for the specific application. The final scheme may be
selected based on the type, quantity and quality of the waste and the type,
quantity and quality of the water required for various applications.
Refer the paper "Reuse of Waste Water in Power Plants" presented at the in-
house workshop held at TCE (B) in July 2000, for the guidelines on waste
water recycle in the power plants.
Consult chemical department or refer latest notifications of Ministry of

Environment and Forest and Pollution Control Boards.
13.0 WATER MASS BALANCE DIAGRAM
13.1 The water mass balance diagram shall be prepared and enclosed with the basic
study. The water mass balance shall form the basis of P&I diagram and further
detailed engineering of the water supply and treatment system.
13.2 The major input for preparation of the water mass balance diagram is the estimated
quantity and quality of the water requirement for various systems such as boiler
make-up, cooling tower, process water, fire protection, service and potable water,
refrigeration, air-conditioning, compressed air systems etc.
13.3 The downtime and the water requirement for the regeneration and backwashing of
the water treatment plant shall be taken into account for calculating the service and
peak flow rates and tank capacities.
13.4 The margins provided for expected loss and leakage of water and unforeseen
requirements shall be taken into account while calculating the total water
requirement.
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13.5 Following information shall be given in the water mass balance diagram
(a) The water mass balance diagram shall be a standard block diagram indicating
source, storage tanks, pumps, treatment units and all consumers indicating
major parameters such as flow, capacities etc. This diagram shall be in
sequence depending on the process and flow from source to the consumer. It
shall reflect the scheme of water treatment proposed.
(b) The water mass balance diagram shall indicate the mass flow in major flow
lines from source to consumer points as service flow rate in M3 /Hr and total
consumption in M3 /Day
Refer appendix 2 for a typical water mass balance diagram.
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TCE. M1-ME-612-202 SHEET 27 OF 32
APPENDIX 1
FORMAT FOR RAW WATER ANALYSIS
SOURCE __________________ SAMPLE DATE ___________ TEST DATE_______________
TEMPERATURE _________°C COLLECTED BY ___________ TESTED BY_______________
SL. NO. CONSTITUENT UNIT VALUE

1. Colour and odour -
2. Oil and grease mg/l
3. BOD mg/l
4. COD mg/l
5. KMnO 4 value at 250 C mg/l
6. Suspended solids mg/l
7. Turbidity NTU
8. Calcium hardness as CaCO3 mg/l
9. Magnesium hardness as CaCO3 mg/l
10. Sodium + Potassium as Na mg/l
11. Chloride as Cl mg/l
12. Sulphate as SO4 mg/l
13. Sulphide as S mg/l
14. M-Alkalinity (HCO3 ) as CaCO3 mg/l
15. P-Alkalinity as CaCO3 mg/l
16. Nitrates as NO3 mg/l
17. Nitrites as NO2 mg/l
18. Hydrogen sulphide mg/l
19. Silica as SiO 2 – dissolved mg/l
20. Silica as SiO 2 – colloidal mg/l
21. Carbon dioxide mg/l
22. Iron as Fe-dissolved mg/l
23. Iron as Fe-suspended mg/l
24. Total dissolved solids mg/l
ISSUE
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TCE FORM NO. 120 R1

TCE. M1-ME-612-202 SHEET 28 OF 32
APPENDIX 1 (CONTD.)

25. Conductivity at 250 C µ-mho/cm
26. pH at 250 C -
27. Dissolved oxygen as O2 mg/l
ADDITIONAL TESTS FOR POTABLE / PUBLIC WATER SUPPLY

28. Colour Cobalt unit
29. Coliform count / 100 ml -
30. Plankton count / 100 ml -
31. Virus count PFU/1
32. Most Probable Number (MPN) Units/100 ml
33. Radioactive materials:
(a) Alpha emitters Mc/ml
(b) Beta emitters Mc/ml
34. Aluminium as such mg/l
35. Arsenic as such mg/l
36. Barium as such mg/l
37. Cadmium as such mg/l
38. Chromium (total) as such mg/l
39. Chromium (Hexavalent) as such mg/l
40. Copper as such mg/l
41. Cyanide as such mg/l
42. Fluoride as such mg/l
43. Lead as such mg/l
44. Manganese as such mg/l
45. Mercury as such mg/l
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TCE FORM NO. 120 R1

TCE. M1-ME-612-202 SHEET 29 OF 32
APPENDIX 1 (CONTD.)

46. Selenium as such mg/l
47. Silver as such mg/l
48. Zinc as such mg/l
49. Foaming Agents as such (MBAS mg/l
- Methylene Blue Active
Substances)
50. Aldrin as such mg/l
51. Chlordane as such mg/l
52. DDT as such mg/l
53. Dieldrin as such mg/l
54. Endrin as such mg/l
55. Heptachlor as such mg/l
56. Heptachlor Epoxide as such mg/l
57. Lindane as such mg/l
58. Methoxychlor as such mg/l
59. Toxaphane as such mg/l
60. 2, 4 - Dm as such mg/l
61. 2, 4, 5 -TP (Silvex) as such mg/l
62. Chloroform as such mg/l
63. Phenols as such mg/l
BOD : Bio- Chemical Oxygen Demand

COD: Chemical Oxygen Demand
PFU : Plaque Forming Unit
ISSUE
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TCE FORM NO. 120 R1

TCE. M1-ME-612-202 SHEET 31 OF 32
APPENDIX 3
FACTORS TO BE CONSIDERED FOR ECONOMIC ANALYSIS
SL.NO. PARTICULARS EXTERNAL GROUND

SOURCE SOURCE
1.0 CAPITAL INVESTMENT (IN Rs.)
1.1 Raw water supply channel/main
1.2 Raw water storage reservoir
1.3 Raw water/Borewell pumps
1.4 Pump house
1.5 Water treatment plant
1.6 Clearwell
1.7 TOTAL CAPITAL INVESTMENT
2.0 ANNUAL OPERATING CHARGES (IN Rs.)
2.1 Energy charges for pumps and clarifier
2.2 Charges for water treatment plant operation
2.3 Water supply charges
2.4 Maintenance charges
2.5 TOTAL ANNUAL OPERATING CHARGES
2.6 Present worth of annual charges capitalised at

____% interest for _____ years
3.0 Total investment - capitalised (Item 1.7 + 2.6)
NOTE
1. The charges for water treatment plant operation includes chemicals, lubricants,
consumables, replacements etc.
ISSUE
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TCE FORM NO. 120 R1

TCE. M1-ME-612-202 SHEET 31 OF 32
APPENDIX 4
REFERENCE DOCUMENTS
SL. NO. TITLE DOCUMENT NO.
1. Basic Study Guide for Cooling Tower Make-Up TCE.M1-ME-127-201
System
2. Guide for Selection of Materials of Construction TCE.M6-ME-610-202
for Demineralised Water
3. Design Guide for Water Treatment Plant TCE.M6-ME-612-203
4. Design Guide for Chemical Feed System for Boiler TCE.M6-ME-615-204
Water Conditioning
5. Design Guide for Bulk Chemicals Storage and TCE.M6-ME-612-205
Handling
6. Guide for General Chemistry of Water TCE.M6-ME-612-206
7. Design Guide for Neutralising System of DM Plant TCE.M6-ME-612-207
8. Guide for Calculation of Hydraulic Losses for TCE.M6-ME-613-212
Water in Pipes, Fittings and Valves
9. Design Guide for Total Head and NPSH TCE.M6-ME-610-217
Calculations for Centrifugal Pumps
10. Design Guide for Potable Water System TCE.M6-ME-610-221
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TCE FORM NO. 120 R1

Water Supply and Treatment System

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TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE. M1-ME-612-202 SHEET i OF iii

BASIC STUDY GUIDE FOR

WATER SUPPLY AND TREATMENT SYSTEM

FLOPPY NO. : TCE.00000-ME-FP-138

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY MMK Sd/- MMK Sd/- NNS Sd/- NNS

CHD.BY TSR Sd/- TSR Sd/- TSR Sd/- TSR R6

APD.BY RL Sd/- RL Sd/- RL Sd/- RL

DATE 98.07.24 99.03.03 01.04.16 01.09.21

TCE FORM NO. 020R2

SL.NO. TITLE SH. NO.

2.0 INPUT DATA TO BE COLLECTED OR GENERATED 1

3.0 SYSTEM DESIGN - WATER STORAGE AND SUPPLY 5

4.0 SYSTEM DESIGN - WATER TREATMENT 7

5.0 NEW ADVANCES IN DEMINERALISATION 19

6.0 MODE OF OPERATION 20

7.0 PUMPING ARRANGEMENT 20

8.0 MATERIALS OF CONSTRUCTION 21

9.0 INSTRUMENTATION REQUIREMENTS 22

10.0 PLANT LAYOUT 23

11.0 EQUIPMENT AND ELECTRICAL LOAD LIST 24

12.0 EFFLUENT DISPOSAL 24

13.0 WATER MASS BALANCE DIAGRAM 25

1. FORMAT FOR RAW WATER ANALYSIS 27

2. WATER MASS BALANCE DIAGRAM 30

3. FACTORS TO BE CONSIDERED FOR ECONOMIC ANALYSIS 31

TCE FORM NO. 120 R1

REV. NO. DATE DESCRIPTION

R2 94.03.31 Addendum added.

R3 98.07.24 Generally revised.

R4 99.03.03 Merged documents TCE.M1-ME-610-001 and

R5 01.04.16 Generally revised.

TCE FORM NO. 120 R1

1.1 WATER SUPPLY AND TREATMENT SYSTEM

1.2 COOLING WATER SYSTEM

2.0 INPUT DATA TO BE COLLECTED OR GENERATED

(a) Representative analysis during summer, winter and monsoon seasons

(b) Design analysis considered for the existing plant, if any

2.3 Reliability of the water supply source shall be ascertained.

TCE FORM NO. 120 R1

2.3.2 The following details on the water availability shall be collected :

(i) Minimum and maximum flow rate in M3 /Hr

(ii) Duration of supply in a day

(iii) Maximum duration of continuous interruption

(iv) Total water supply in MLD

(vi) Charges of water supply in Rs/M3

(a) Minimum continuous flow rate from the wells in M3 /Hr

(b) Maximum draw down level in M

(c) Diameter of the well in M

(d) Minimum recommended spacing between wells in M

TCE FORM NO. 120 R1

2.7.4 Steam generator feed water make-up is estimated at 3% Maximum Continuous

TCE FORM NO. 120 R1

2.12 Method of disposal of regeneration waste water

2.15 Cost of chemicals-mainly acid and alkali.

2.16 Desired mode of plant operation - manual, semi-automatic or fully automatic.

TCE FORM NO. 120 R1

3.0 SYSTEM DESIGN - WATER STORAGE AND SUPPLY

3.7 If provision of clearwell is being considered along with clarifier, an assessment

TCE FORM NO. 120 R1

(b) Vertical pumps or horizontal pumps located in underground pump house

(b) Reinforced-Cement-Concrete (RCC) hume pipes for gravity flows