INSTRUCTION MANUAL Serial number 08199

Manufacturing company: CONDOROIL IMPIANTI SRL Address: Via Galliani, 50 21020 CASALE LITTA (VA) Italy e-mail impianti@condoroil.it

Customer: VIRAJ PROFILES LIMITED

Specification: Object: RESIBED UNIT Plant: EXISTING PICKLING LINE Location: Tama MUMBAI - INDIA Manufacturing: September 2008

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INDEX
SECTION 1: GENERAL INFORMATION........................................................................................... 5 1.1 INSTRUCTIONS .................................................................................................................................. 5 1.2 CUSTOMER DUTIES ............................................................................................................................ 5 1.3 TECHNICAL ASSISTANCE ...................................................................................................................... 5 1.4 RESTRICTIONS .................................................................................................................................. 5 SECTION 2: HANDLING AND TRANSPORTATION.......................................................................... 6 2.1 HANDLING SKID ................................................................................................................................. 6 SECTION 3: POSITIONING ............................................................................................................ 7 SECTION 4: INSTALLATION .......................................................................................................... 8 4.1 HYDRAULIC CONNECTIONS ................................................................................................................... 8 4.2 PNEUMATIC CONNECTIONS ................................................................................................................... 8 4.3 ELECTRICAL CONNECTIONS................................................................................................................... 9 4.3.1 Electrical connections check...................................................................................................... 9 4.4 PLANT INTERCONNECTIONS ................................................................................................................ 10 4.4.1 First treatment skid ................................................................................................................ 10 4.4.2 Multimedia filter..................................................................................................................... 10 4.4.3 Skid for cartridge filter............................................................................................................ 10 4.4.4 Resibed ................................................................................................................................. 11 4.4.5 Resibed auxiliary skid ............................................................................................................. 11 SECTION 5: SAFETY INSTRUCTION ....................................................................................... 12 5.1 GENERAL SAFETY INSTRUCTIONS ......................................................................................................... 12 5.1.1 Active Safety Measures .......................................................................................................... 12 5.1.2 Passive safety measures......................................................................................................... 12 5.1.3 Other dangers ....................................................................................................................... 13 5.1.4 Environmental Danger............................................................................................................ 13 5.1.5 Noise .................................................................................................................................... 13 SECTION 6: PROCESS DESCRIPTION..................................................................................... 14 6.1 PRE TREATMENT.......................................................................................................................... 14 6.1.a Feeding pickling solution........................................................................................................ 14 6.1.b Sludge separation ................................................................................................................. 14 6.1.c Filtration ................................................................................................................................ 14 6.2 RESIN SECTION ........................................................................................................................... 17 6.2.a Phase 1: water purging .......................................................................................................... 17 6.2.b Phase 2: salts discharge ........................................................................................................ 19 6.2.c Phase 3: pickling solution removal.......................................................................................... 21 6.2.d Phase 4: pickling solution recovery......................................................................................... 23 6.2.e Waiting time ......................................................................................................................... 25 6.3 DRAWINGS ..................................................................................................................................... 25 6.4 COMPONENTS LIST ........................................................................................................................... 26 6.4.1 Pre treatment ........................................................................................................................ 26 6.4.2 Resibed Section ..................................................................................................................... 28 SECTION 7: SET POINT ............................................................................................................... 30 7.1 PRESSURE ...................................................................................................................................... 30

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SECTION 8: WORKING PROCEDURES ......................................................................................... 31 8.1 FIRST START UP .............................................................................................................................. 31 8.2 START UP ...................................................................................................................................... 32 8.2.1 Equipment............................................................................................................................. 32 8.2.3 Control panel ......................................................................................................................... 32 SECTION 9: CONTROL PANEL...................................................................................................... 33 SECTION 10: PLANT STOP........................................................................................................... 38 10.1 EMERGENCY STOP.......................................................................................................................... 38 10.2 NORMAL STOP ............................................................................................................................... 38 SECTION 11: MAINTENANCE........................................................................................................ 39 11.1 GENERAL RULES ............................................................................................................................ 39 11.1.1 Individual protections ........................................................................................................... 39 11.2 PROGRAMMED MAINTENANCE ............................................................................................................ 39 11.3 LOADING FILTER SF101 .................................................................................................................. 42 11.3.1 Loading Multimedia filter FS101 ........................................................................................... 42 11.3.2 FS Maintenance data ......................................................................................................... 43 11.4 CARTRIDGE FILTER FC101 ............................................................................................................... 43 11.4.1 Loading cartridge in FC101 ................................................................................................... 43 11.5 RESIN BED RB101 ......................................................................................................................... 44 11.5.1 Changing the filter nets ........................................................................................................ 44 11.5.2 Loading resins on RB101 ...................................................................................................... 45 SECTION 12: TROUBLE SHOOTING ............................................................................................ 46 12.1 INSTRUCTIONS .............................................................................................................................. 46 SECTION 13: ALARMS ................................................................................................................ 48 13.1 IN CASE OF ALARM .......................................................................................................................... 48

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Section 1: General Information

1.1 Instructions This assembly instruction manual provides the Customer with the information about the assembly of the ACID RETARDATION UNIT. This manual must always be handed over to new owners, till the final dismantling of the installation.
WARNING

The improper use of this installation as well as inappropriate maintenance work may harm people and damage things. The Operator and the Skilled Technician have to know all the rules of this manual, before the installation. The procedures reported in this manual can be applied to this installation only for the allowed purposes. If the Customer uses it for other purposes, he/she becomes automatically liable if people get hurt, because of lack of safety.

1.2 Customer Duties If not otherwise specified in the contract, the Customer has to arrange: The The The The The The plant positioning. connection of the plant to the working tanks. power supply of the control station. supply of compressed air. water supply and connection to the unit. lifting and handling machines for the assembly.

WARNING

CONDOROIL IMPIANTI S.r.l. is not liable for damages or injuries due to an improper GROUNDING or that is not in compliance with the rules of the country where the installation is installed.

1.3 Technical Assistance For technical assistance, please contact CONDOROIL IMPIANTI S.r.l.

1.4 Restrictions The installation or its components cant be modified without the written consent of CONDOROIL IMPIANTI S.r.l.; not allowed modifications may alter the original functions and lead to the expiry of the warranty on the whole supply.

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Section 2: Handling and Transportation

The plant has to be handled by qualified people with a proper and suitable lift truck, and, for the heaviest components, a grane. Before moving the plant, please make sure the tanks are empty and unplug the installation from utilities (power supply, compressed air, inlet and outlet pipes). For transportation no special instructions are required, beside to make sure to handle with care. The plant consists of five different parts:

FIRST TREATMENT SKID MULTIMEDIA FILTER SKID FOR CARTRIDGE FILTER RESIBED AUXILIARY SKID RESIBED
WARNING

Dry Weight Dry Weight Dry Weight Dry Weight Dry Weight

approx. approx. approx. approx approx

1400 Kg 2900 Kg 670 Kg 2000 Kg 4000 Kg

Never cling to or press pipes or other devices because the structure of the installation may give way.

2.1 Handling skid The plant must be handled by means of a bridge crane using special lifting rings or a lift truck. Lifting must be gradual and uniform without brisk movements and sudden interruptions that can cause strong oscillations.

The installation can be lifted from the bottom frame. Then try to position it in such a way that the weight is balanced.

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Section 3: Positioning
The parts of the plant have to be positioned as showed on the Drawing n. 55022_rev06 General Layout and as Drawing Viraj India Layout. A: FIRST TREATMENT SKID This skid has to be positioned next to the picklng line in front of tank n. 3. The battery limit consisting of the valves withdrawing from the pickling tanks facing the pickling line; The panel control on the opposite side. B: MULTIMEDIA FILTER AND SKID FOR CARTRIDGE FILTER These parts are connected and have to be positioned in front of pickling tanks n. 4 and n. 5 The Multimedia Filter in front of pickling tank n.4 (closer to First treatment skid) The connections to skid n.1 First Treatment skid facing it. The cartridge filter on the right, with the blower side facing the pickling line, and the connections to the Multimedia Filter facing it.

C: RESIBED AUXILIARY SKID This skid will be positioned in front of pickling tank n. 6. The battery limit consisting of the valves sending the solution back to the pickling tanks facing the pickling line; The electrical panel on the opposite side.

D: RESIBED This unit will be positioned with the support of a bridge crane in front of pickling tank n. 7. The longer side facing the pickling line. Exact position must be 120 mm off compared to skid n. 3 Resibed Auxilairy skid: the back side must be in line with the back side of skid n. 3.

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Section 4: Installation
To install the unit just follow the instruction on connections as described; the equipment must be connected to the working tanks using PP pipes, with bigger or equal diameters to the ones already assembled on the units. Installation of the plant is limited to the following connections described in the following paragraphs. 4.1 Hydraulic Connections The unit requires the below mentioned hydraulic connections to clients utilities, or discharge:

SKID N. 1 FIRST TREATMENT

Inlet from pickling tanks n. 8 Water inlet Sludge Discharge Overfill back to pickling tanks Butt welded d40 PP Flanged DN50 Flanged DN50 Flanged DN50

SKID N. 2 SKID FOR CARTRIDGE FILTER

Discharge Butt welded d32 PP

MULTIMEDIA FILTER
Discharge (SIDE) Discharge (BOTTOM) Butt welded d63 PP Thread d63 PP

SKID N. 3 RESIBED AUXILIARY SKID

Water inlet Outlet to pickling tanks n. 8 Concentrated salts outlet Butt welded d40 PP Butt welded d40 PP Butt welded d40 PP

Piping is provided with butt welded connections, furthermore piping is supplied with tags identifying the conducted fluid. 4.2 Pneumatic Connections The unit has only one pneumatic feeding with the following characteristics: Compressed air inlet to SKID n. 1 Compressed air inlet to SKID n. 3 Piping type Minimum required pressure P.E. 5 bar

Pneumatic connections from skid n.1 (all ) to the following pneumatic valves on FS101 FC101: EV 107 EV110 EV111 EV112

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4.3 Electrical Connections The unit has N.1 ELECTRICAL FEEDING on SKID N. 1 FIRST TREATMENT with characteristics: Feeding power 415 V 50 Hz Three phase WN Installed power 10 kW following

Control panel is provided with proper connection terminals. The electrical feeding is then supplied to the users according to attached electrical diagrams.
WARNING

Before plugging in the installation make sure that both power supply and frequency comply with what is written on the plate inside the control panel. Remember that the plant NEEDS AN ELECTRIC SUPPLY 415 V 50 Hz, THREE PHASES WITH NEUTRAL. Make sure that there is an interlocked outlet between the electric line and the plant, in order to isolate the machine from the rest of the plant. Check if the earth plate complies with the rules in force and that the section of the supply cable and of the external disconnecting switch is sized for MAXIMUM ABSORBTION. To plug in the plant, connect the supply cable to the terminals: I. R-S-T-N (if any) and EARTH installed inside the power panel. II. After connection, it is necessary to CHECK MOTORS ROTATION DIRECTION

4.3.1 Electrical connections check

If the plant is operated in manual, you just need to turn on engine pump for one second and look at the rotation direction of the rear cooling impeller. It has to comply with what is written on the engine itself. If that is not the case, you have to change the position of the supply cables, by changing two phases (e.g. to exchange the position of the cable in the connecting terminal R with that of the connecting terminal S).
DANGER

As you work inside the panel, before acting, before any operation, please check if the power supply is unplugged.

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4.4

Plant Interconnections

The ACID RETARDATION PLANT consists of five parts connected: a. b. c. d. e. First treatment skid (n.1) Skid for Cartridge filter (n.2) Multimedia filter Resibed auxiliary skid (n.3) Resibed

Please follow the following interconnections

4.4.1 First treatment skid

OUT From skid n.1 (Pre-treatment) to multimedia filter FS 101 - BOTTOM From skid n.1 (Pre-treatment) to multimedia filter FS 101 - SIDE d 63 Head welded d 40 Head welded

4.4.2 Multimedia filter

IN From skid n.1 (Pretreatment) to multimedia filter FS 101 BOTTOM From skid n.1 (Pretreatment) to multimedia filter FS 101 - SIDE From sand filter FS101 to Skid n. 2 (cartridge filter) From sand filter FS101 to Skid n. 2 (cartridge filter blower) Butt welded d63 OUT

Head welded d40 Head welded d40 * Thread d40 *

* Parts are provided, they need to be connected

4.4.3 Skid for cartridge filter

IN From sand filter FS101 to Skid n. 2 (cartridge filter) From skid n. 2 to skid n. 3 (Resibed auxiliary) into tank n. 201 Head welded d40 Head welded d40 OUT

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4.4.4 Resibed
IN From skid n. 3 to Resibed TOP and viceversa From skid n. 3 to Resibed BOTTOM and viceversa Butt welded d40 Butt welded d40 OUT same same

4.4.5 Resibed auxiliary skid

IN From Resibed - TOP to skid n. 3 From Resibed - BOTTOM to skid n. 3 Butt welded d40 Butt welded d40 OUT same same

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Section 5: Safety Instruction

In order to highlight the safety instructions of this manual, the following terms were used:
DANGER This word is employed in the safety instructions or written on plates, to highlight how to prevent a dangerous situation that would lead to peoples injury or death, if not. The safety directions also describe which measures are to be taken in order to avoid a dangerous situation. By not complying with these precautions, the plant may be seriously damaged. WARNING This word is employed in the safety instructions or written on plates, to highlight how to prevent a dangerous situation that would lead to peoples injury and/or cause small damages. This word may also be used to describe dangerous situations which may damage only the plant. IMPORTANT This word refers to precautions to take in order to prevent the installation from lasting less than expected. NOTE This word is used to provide or highlight useful information concerning the operation in process.

When this plant is operated in compliance with all the safety measures, neither the operator, nor the people around it will ever be hurt, nor there will ever be a risk of damaging the plant. For further information about safety directions, please contact CONDOROIL IMPIANTI s.r.l.. 5.1 General Safety Instructions

5.1.1 Active Safety Measures

In order to protect operators and maintenance personnel and to deactivate the plant in case of dangerous component failure, the following safety measures have to be taken: Safety switch (IG) on the panel door access to powered devices and controls is possible only without power supply, that is when the switch is on 0 (OFF). Emergency button when this button is pressed, the installation is immediately unplugged. Level controllers stop the cycle in case of abnormal conditions. Pressure switches - control the pressure inside the circuits and turn on when the calibration Set-Points are exceeded. Air pressure switch stopping the unit, if the compressed air operating the pneumatic valves falls below the Set-Point.

5.1.2 Passive safety measures

Passive safety measures refer to safety measures taken during the design phase, which protect the operator from electric or mechanical danger: Timing case covering electromechanical devices. IP 55 (minimum) protection of the whole electrical equipment. Use of electrical low voltage components Interception valves to isolate each component and to prevent liquids from spilling. Oversized resistors of some components as compared with the actual operating pressure.

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5.1.3 Other dangers

The installation works with pressurized pipes. That is why you should wear protecting cloths and glasses. Same attention may be paid when handling products for cleaning whose data product bulletins and MSDS. Before doing any maintenance work, pipes have to be washed and then washed again at the end of that work. If liquids come out, especially under pressure, you have to be well protected when approaching the installation. Furthermore, when working manually, not all the alarms and safety devices are activated, so you should be careful to avoid damages to the plant and overflow of liquids with negative consequences on people.

5.1.4 Environmental Danger

In view of the plant functioning and disposal of the drains, no risks for the environment are estimated.
DANGER

It should be remebered that the treated waste waters are contaminated with chemical agents and other chemical products are used for cleaning. These products can be accidentally spilled on the pavement or come into contact with operating personnel. In such case product technical and safety data sheets should be consulted.

5.1.5 Noise
The only installation components producing noise are the pumps, certified by the manufacturer.

CONDOROIL IMPIANTI S.r.l. declares that the noise produced by the plant is below 82 dB(A).

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Section 6: Process Description

6.1 PRE TREATMENT

6.1.a Feeding pickling solution

The unit withdraws the pickling solution from one pickling tank at a time, according to the cycle as set in the PLC (some tanks can be excluded, if needed). For example the EV100A (incoming from the first tank) and EV200A (outgoing to the first tank) valves open at the same time and remain open for a certain number of cycles that can be set on the PLC. The unit cycle starts by opening the EV101 valve and starting the PM101 pneumatic valve: the pickling solution is sent to the lamellae sedimentation unit.

6.1.b Sludge separation

The solution is then fed to the lamellae sedimentation unit, where the heavy particles precipitate at the bottom of the hopper. In this unit turbolence of the incoming fluid is reduced inside the first sector and distributed all over the tank widthby going through the flow distribution frame. When the fluid falls through the lamellae, the sedimentable material aggregates, concentrates, precipitates and accumulates into the hopper, because of the increased mass. The clarified solution is then stocked by overfall into tank SS101. Periodically (according to time set on the PLC) the sludge is discharged and the piping connected is then rinsed: A first timer opens the EV103 for a fixed period (that can be set on the PLC), A second timer opens EV104 for a different fixed period (that can also be set on the PLC)

After these periods the two valves close and the timers are reset.

6.1.c Filtration Multimedia filter

When the liquid level in SS101 is high and the liquid level in SS201 is low (LT101 and LT201) the system withdraws the solution from SS101 by opening EV105, EV106, EV107 and starting the pump PC102: this way the solution is filtered in the multimedia filter and then the cartridge filter, where the particles with dimensions higher than xx microns cant go through. It is possible that the filters get obstructed because dirty: the differential pressure control dPT(101-102) is set so that when needed the system auytomatically start a discharge backflush flush cycle on the multimedia filter. DISCHARGE The pump PC102 stops, the valves EV105 and EV106 are closed and the valve EV110 is opened: air is blown into the filter and the solution already in the filter is pushed in the piping to the cartridge filter.

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BACKFLUSH FLUSH DISCHARGE The valves EV108 - 109 111 open and the pump PC103 starts. After a fixed period (can be set on the PLC) the two valves EV109 and EV111 close and EV112 and EV113 open so the system starts rinsing according to the flow line. After the dedicated timer reaches its value, the EV108 and EV113 valves close and then the the valve EV110 is opened to blow air into the filter as before; after a given period the blower turns off, the EV110 is closed and then the EV112 is closed. After that with a little delay the EV105, EV106 and EV107 opens again and the cycle is reset.

Cartridge Filter
The FC101 cartridge filter is monitored by the Pressure Transducer PT102: The high setting (PTH) states that the filter is dirty while the extra high setting (PTHH) states that the filter is blocked and stops the unit giving an alarm signal.

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6.2 RESIN SECTION

6.2.a Phase 1: water purging

During this phase the water that is stocked in the resin bed is sent back to the SS202 tank: after checking the level controls, the system opens the EV202, EV204 and EV210 valves and starts the PC202 pump. At this point also the controls on the flowrate (FT201) and the pressure difference (dP 201-202) are activated.

6.2.b Phase 2: salts discharge

During this phase the salts trapped in the resin bed are sent to discharge: the system closes the EV210 valve and open the Ev205 valve. If the level control LT202 is above the low setting, the system starts Phase 3.

6.2.c Phase 3: pickling solution removal

During this phase the pickling solution trapped in the resin bed is sent to tank SS201: the system closes the EV202, EV204 and EV205 valves and open the EV206, EV207 and EV208 valves. When the level control LT202 is on the low setting, the system open the EV201 valve, until the leel control reaches the high setting.

6.2.d Phase 4: pickling solution recovery

During this phase the pickling solution regenerated is sent to the pickling tanks: the system closes the EV208 and opens the EV209 valve.

6.2.e Waiting time

The unit is in stand by for a fixed time (it can be set on the control panel).

During these phases the system monitores the following unit controls: Pressure transducers PT201 and PT202 if the tranducers reach the high setting (maximum pressure on the resin bed), the system shuts down Differential pressure control dP201-202 to check if the resins are plugged (during phase 3 and 4) if the level reaches the high setting the system shuts down Flow transducer FT201 if the flowrate is below the low setting the unit shows a pre-alarm 6.3 Drawings if the flowrate is above the high setting the unit shows a pre-alarm

Drawing Number 55021 Rev07 55022-1 Rev02 55022-2 Rev02 55022-3 Rev02 55022-4 Rev02

Description P&ID Resibed Unit Layout Part 1 Layout Part 2 Layout Part 3 Layout Part 4

6.4 Components List

6.4.1 Pre treatment

ITEM EV100 PM101 SL101 SS101 DESCRIPTION Membrane Valve 2-ways AUT PP NC d40 Membrane pump PVDF/ 150 BLADE TECH 6/0,5/20/60 PP 1000 l PE tank Deep load 2" Flanged Connection Viton 2" Connection PP DN32 PC102 SF01 Horizontal centrifugal pump PE 160 Blower 1.5 kW Manifold Filter E 5 Safety valve Cartridge Pressur Indicator 0-600 Connection E 5 Flexible connection E 5 No return valve EV101 EV102 EV103 EV104 EV105 EV106 EV107 EV108 EV109 EV111 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d32 Membrane Valve 2-ways AUT PP NC d63 Membrane Valve 2-ways AUT PP NC d32 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d63 Membrane Valve 2-ways AUT PP d63 Membrane Valve 2-ways AUT PP NC d63 Membrane Valve 2-ways AUT PP NC d63 CODE VN0066 PM0026 DT0003 KT0034 KA0044 KA0042 KA0043 PC0076 PT0005 PI0012 PI0010 PI0015 PI0011 PI0004 PI0014 PI0013 PI0016 VN0066 VN0008 VN0009 VN0008 VN0066 VN0066 VN0009 VN0074 VN0009 VN0009 QTY 8 1 1 1 1 1 1 2 2 2 1 600 2 2 1 1 1 8 1 1 1 8 8 1 1 1 1 SPECIFICATION 11/4" PP PTFE weld 150 l/m - PVDF dis n. 55026 rev01 1.000 l - D 990 x h 1.470 OR - Viton Flanged DN50 Gas - MA - Viton 6mch - 26m - 3 kW 100 mch Pdiff: 200 mbar For blower PT0005 For blower PT0005 For blower PT0005 For blower PT0005 For blower PT0005 For blower PT0005 For blower PT0005 For blower PT0005 11/4" PP PTFE weld 1" PP PTFE weld 2"PP PTFE weld 1" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 2"PP PTFE weld 2"PP EPDM weld 2"PP PTFE weld 2"PP PTFE weld

EV112 EV110 EV114 EV113 PC103 PT101-102 PT101-102 PI101-102 PT101-102 LT101 LT101 LT101 V101

Membrane Valve 2-ways AUT PP NC d63 Membrane Valve 2-ways AUT PP NC d63 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Horizontal Centrifugal pump AISI 316 Pressure Transducer 0/6 Separator d20 1/2"

VN0009 VN0009 VN0066 VN0066 PC0080 ST0002 SM0018

1 1 8 8 2 2 2 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2"PP PTFE weld 2"PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 9mch 20m CER/CARB/FPM 1,5kW 0-6 BAR 1/2" G F/F 1/4" GAS AISI 316 DN15 PP/FPM T/T INS 20 0-200 mbar 1/2" G F/F DN15 PP/FPM T/T INS 20 DN32 PP/FPM Head weld DN32 PP/FPM Head weld DN32 PP/FPM Head weld DN25 PP/FPM T/T INS 32 DN50 DN32 PP/FPM Head weld DN25 PP/FPM T/T INS 32 DN32 PP/FPM Head weld DN25 PP/FPM T/T INS 32 DN32 PP/FPM Head weld DN32 PP/FPM Head weld DN25 PP/FPM T/T INS 32 DN25 PP/FPM T/T INS 32 d32 DN25 PP/FPM T/T INS 32 DN50 PP/FPM T/T INS 63 DN32 PP/FPM Head weld DN50

Pressure Indicator 0-6 bar SM0008 DN 63 Ball valve PP G+F d20 Pressure Transducer 0/200 Separator d20 1/2" Ball Valve PP G+F d20 Ball valve PP G+F d40 Ball valve PP G+F d40 VP0014 ST0010 SM0018 VP0014 VP0040 VP0040 VP0040 VP0013 VP0048 VP0040 VP0013 VP0040 VP0013 VP0040 VP0040 VP0013 VP0013 VP0049 VP0013 VP0012 VP0040 VP0048

VR101 VBP102 V103 V104 V106 VR104 VR103 VR102 V105 V106-107 V112 VSF101 VSF102 VBP101 VR105 V110

Ball valve PP G+F d40 Ball valve PP G+F d32 Butterfly valve PP-H d63 Ball valve PP G+F d40 Ball valve PP G+F d32 Ball valve PP G+F d40 Ball valve PP G+F d32 Ball valve PP G+F d40 Ball valve PP G+F d40 Ball valve PP G+F d32 Ball valve PP G+F d32 Rielief valve GF d32 Ball valve PP G+F d32 Ball valve PP G+F d63 Ball valve PP G+F d40 Butterfly valve PP-H d63

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6.4.2 Resibed Section

ITEM SS201 DESCRIPTION 3000 l PE tank Deep load DN32 PP DN32 connection PP 1/2" connection SS202 3000 l PE tank Deep load DN32 Deep load DN40 PP DN32 connection PP 1/2" connection LT201-202 LT201-202 Pressure Transducer 0/200 Separator d20 1/2" PP ball valve G+F d20 PC202 RB201 XT201-202 XT201-202 EV201 EV202 EV203 EV204 EV205 EV206 EV207 EV209 EV208 EV210 VR201 V204 Horizontal centrifugal pump PE 160 Condores anionic strong Conductivity sensor Conductivity meter - field Membrane Valve 2-ways AUT PP d50 Flan NC Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Membrane Valve 2-ways AUT PP NC d40 Ball valve PP G+F d32 Ball valve PP G+F d32 CODE KT0035 KA0045 KA0043 KA0007 KT0035 KA0045 KA0046 KA0043 KA0007 ST0010 SM0018 VP0014 PC0075 HR0009 SC0015 SC0036 VN0073 VN0066 VN0066 VN0066 VN0066 VN0066 VN0066 VN0066 VN0066 VN0066 VP0013 VP0013 QTY 1 1 1 1 1 1 1 1 1 2 2 2 1 600 2 2 1 1 1 1 1 1 1 1 1 1 1 1 SPECIFICATION 2.850 l - D 1.470 x 1.940 h OR - Viton MA - Viton MA - Viton 2.850 l - D 1.470 x 1.940 h OR - Viton OR - Viton MA - Viton MA - Viton 0-200 mbar 1/2" G F/F DN15 PP/FPM T/T INS 20 6mch - 18m - 2,2 kW 1.3eq/l size 0.150 -0.300mm 0 microS - 2 S 24V Inductive 2x20mA 1 1/2" PP EPDM - Flang 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld 11/4" PP PTFE weld DN25 PP/FPM T/T INS 32 DN25 PP/FPM T/T INS 32

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V201 V202 V203 V205 V208 PT201-202 PT201-202 PI201-202 V206-207

Ball valve PP G+F d40 Ball valve PP G+F d40 Ball valve PP G+F d50 Ball valve PP G+F d40 Ball valve PP G+F d40 Pressure transducer 0/6 Separator d20 1/2"

VP0040 VP0040 VP0054 VP0040 VP0040 ST0002 SM0018

1 1 1 1 1 2 2 2 2 1 1 1 2 2 2

DN32 PP/FPM Head weld DN32 PP/FPM Head weld DN40 PP/FPM Head weld DN32 PP/FPM Head weld DN32 PP/FPM Head weld 0-6 BAR 1/2" G F/F 1/4" GAS AISI 316 DN15 PP/FPM T/T INS 20 DN15-100 x SD0005 DN32 11/4" PP PTFE weld 100% PP 100% PP D 1780 d 1530

Pressure Indicator 0-6 bar SM0008 DN 63 Ball valve PP G+F d20 Pressure transducer VP0014 SD0005 SD0006 VN0066 JX0019 JX0020

FT201 EV200

Fitting for pressure transducer Membrane Valve 2-ways AUT PP NC d40 Filter nets 1650 Filter nets support 1650

Gasket for filter nets 1780 JX0021

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Section 7: Set Point

No Instrument 1 2 3 4 5 6 7 8 9 10 11 12 LT101 LT101 LT101 LT101 LT201 LT201 LT201 LT201 LT202 LT202 LT202 LT202 LSLL LSL LSH LSHH LSLL LSL LSH LSHH LSLL LSL LSH LSHH Function pressure pressure pressure pressure pressure pressure pressure pressure pressure pressure pressure pressure transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, transmitter, Lowest level Low level High level Highest level Lowest level Low level High level Highest level Lowest level Low level High level Highest level Set points Set points Units m m m m m m m m m m m m

No Instrument 1 2 3 4 5 6 7 8 9 10 11 12 PT101 LL PT102 LL PT102 H PT102 HH PT201 LL PT201 HH PT202 LL PT202 HH dP(PT101-102)SH dP(PT101-102)SHH dP(PT201-202)SH dP(PT201-202)SHH

Function pressure transmitter, Low level pressure transmitter, Low level pressure transmitter, High level pressure transmitter, Highest level pressure transmitter, Low level pressure transmitter, High level pressure transmitter, Low level pressure transmitter, High level delta pressure transmitter, High level delta pressure transmitter, Highest level delta pressure transmitter, High level delta pressure transmitter, Highest level

Units bar bar bar bar bar bar bar bar bar bar bar bar

7.1 Pressure

VARIABLE

THRESHOLD

PCAir

56

Pressure in bar

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Section 8: Working Procedures

8.1 First Start Up The following operations should be performed before the plant start up: a. Make sure that the lines to the unit are free and manual valves (if any) for industrial water are open. b. The following valves must be open: V101, V102, V103, V104, V105, V107, V108, V110, V112, V201, V202, V203, V204, V205; c. The following valves will be set during start up: VR101, VR102, VR103, VR104, VR105, VR201, VBP101, VBP102; d. Make sure that the discharge and relief valves on the filters are closed; e. Check all the electrical connections and the direction of motor rotation; f. Verify that all the hydraulic connections have been connected: Connections to and from Pickling tanks: EV100 A inlet from first tank (to be treated) EV200A outlet fo first tank (to be treated) Industrial water Concentrate Outlet Discharge from skid n.1 n. 2 Discharges from FS101

FILTERING SECTION FS101 Make sure that filters FS101 has been filled first with proper material (for technical information about it, please contact CONDOROIL IMPIANTI personnel). If necessary the filter is to be loaded as follow (in case its decided to substitute filtering elements follow the indications of Chapters 11.3 of the present manual). Cover the nozzles uniformly using the lateral manhole; Close the lateral and bottom manhole. Carefully clean the flanges before positioning relative gaskets screw the bolts. Fill the filtering column from the upper manhole taking care to distribute the sand uniformly;

Fill the tank with water and pressurize it up to 3 bar to check tightness.

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FC101 Make sure that the filtering cartridges have been installed in accordance with the following procedure: Open the housing locking flange; Replace n. 30 30 5 micron cartridges in each filter. Close the housing. Close drain valve VS102; Open pressure relief valve; Wait for the complete filling of the housing and when the liquid starts overflowing close the pressure relief valve.

INSTRUMENTS It is necessary to check that all the instruments are in good serviceable conditions. In case any of the instruments are not calibrated or not operable proceed with routine maintenance as indicated in chapters 8.2.1 and 8.2.2

8.2 Start Up

8.2.1 Equipment
It is recommended to have available the following instruments and materials:

Safety glasses when working with chemicals; Spare elements; Bottles for water samples.

8.2.3 Control panel

Supply the electric board with electric power. Open the valves for compressed air to the distributing lines and all the pilots that control the pneumatic valves and pneumatic pumps (air pressure 6 bar); Make sure to open the valves to Level controls and Pressure transducers (LT101, LT201, LT202, PT101, PT102, PT201, PT202); Reset all active alarms by pressing the button RESET on the control panel. Acknowledge all the alarms visualized on the display of PANEL VIEW pressing the pushbutton ACK. Set the work parameters from the panel to the page SET POINT SONDS Verify the correct addressing of all hydraulic and electric connections on the page MANUAL CONTROLS Push the button START for operation.

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Section 9: Control Panel

TANKS PROGRAM: the operator can choose the tanks to treat and how many cycles to perform

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UNIT: the operator can check the unit state

RESINS: the operator can set the time for each phase.

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MANUAL: the operator can select and control each component

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LEVELS SETUP: the operator can set all the setpoint for the control instruments (level, pressure, and so on)

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SETUP TIMERS: the operator can setup the timers to manage the unit

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Section 10: Plant stop

There are three types of plant stop: 10.1 Emergency stop All the working equipment is switched off immediately and low voltage supply line is disconnected. As soon as the plant has been stopped in emergency a red alarm lamp is lighted. This stop can be caused by: Pressing a red mushroom emergency button on the plant.

10.2 Normal stop When the plant must be stopperd the operator can push the STOP button ont the Control Panel: the system ends the cycle and then all the controls and utilities are de activated (pumps, valves, etc.) When the plant is restarted it starts again from the pretreatment section and in case the level controls in SS201 and SS202 are activated, also the resin cycle starts.

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Section 11: Maintenance

11.1 General Rules The installation has to be used only by qualified, trained and authorised staff. Before using it, operators have to: Read the whole manual. Deeply understand the functions of the various components as well as of control positions and functions. Before doing any maintenance work, supply sources have to be unplugged (i.e. power, hydraulic and pneumatic supply) and a notice, showing that maintenance work is being carried out, must be hanged out.

11.1.1 Individual protections

Operators have to use individual protections as explained in the EEC directives (glasses, gloves, overalls, shoes, etc.) and in the laws in force concerning health and individual safety, especially because potentially dangerous chemical products such as detergents, preservatives etc. are employed in the installation. If anyone comes into contact with a chemical product, please refer to the enclosed product technical and safety data sheet. Please comply with the safety directions of each product, provided by the supplier himself. 11.2 Programmed Maintenance Before doing any maintenance work, it is necessary to: Unplug water supply Disconnect hydraulic connections Unplug pneumatic supply Unplug electrical power supply Appropriate maintenance programme ensures safe and efficient operation of the plant and consents to reduce stops for emergency maintenance activities. The following summary table contains the description of maintenance activities to be performed and their suggested frequency. After the plant has been put into operation the operator can evaluate on the base of experience if it should be necessary to render the described activities more or less frequent. In order to have a record of all the performer operations we suggest that operators should be obligated to fill in tables of programmed maintenance for each component (see Plant operating data).

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Table 11.0 Preventive programming maintenance

COMPONENT

PARTS COMPONENT

OPERATIONS

SUGGESTED FREQUENCY

XT 201-202

CONDUCTIVITY METER

Sensor

SF 101
MULTIMEDIAFILTER

FC101 RB101

CARTRIDGE FILTER RESIN BED

Central collector and arms Fiter nozzle and expanding bolts Gasket Filling material Cartridge FA PP Nets and gaskets Resins

Cleaning, regularly check the thightness of sensor nut Replacement Replacement Replacement Replacement Replacement Replacement Replacement Replacement

EVERY 2 WEEKS

SEMESTRAL EVERY 3 YEARS EVERY 3 YEARS EVERY OPENING EVERY 2 YEARS

At dirty filter signal MONTHLY When they break or leak

EVERY 2 YEARS

Table 11.1 Operating maintenance data Conductivity meter

Design Operator signature Date Operating hours

CALIBRATION CLEANING REPLACEMENT

11.3 Loading Filter SF101 This section contains guidelines for loading and replacement of filtering beds inside the filters.

11.3.1 Loading Multimedia filter FS101

It is recommended to totally replace filtering beds every three years except the cases of premature filter fouling which may require more frequent replacements. All the operations should be performed only after the plant has been shut off. The following procedure to replace filtering bed should be followed: 1. 2. 3. 4. 5. 6. Verify that automatic valve EV107, EV109, EV11, EV113 are closed. Empty the filter discharging the water by opening manual valve V110 Open the upper manhole. Verify with the help of an electric torch that the tank is completely empty. Open the lateral manhole, unscrew all the bolts except the upper bolt. Rotate the blind flange using the screwed bolt as a pivot axis until the manhole is fully open. 7. Take out all the sand from the tank manually. 8. Proceed with attention near the nozzles removing sand with a broom as not to damage the nozzles. 9. Wash nozzles and diffusion plate with water as to fully eliminate all the sand residuals. 10. Open the bottom manhole. 11. Wash the tank section under the diffusion plate from the bottom manhole. 12. Replace the central collector with ways and filtering arms (see Fig. 8.1) 13. Remove the worn nozzle from the diffusion plate. 14. Install new nozzles (see fig. 8.3). 15. Cover the nozzles uniformly with filling material using the lateral manhole. 16. Close the lateral and bottom manhole. Carefully clean the flanges before positioning relative gaskets, screw the bolts. Attention: gaskets must be replaced each time the flange is opened. 17. Fill the filtering column from the upper manhole taking care. 18. Close the upper manhole. Carefully clean the flanges, install the relative gaskets and screw the bolts. Attention: gaskets must be replaced each time the flange is opened 19. Fill the tank with water and pressurize it up to 3 bar to check tightness.

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11.3.2 FS Maintenance data

The following data must be recorded and logged into an appropriate log sheet at least once per shift, unless otherwise stated.
Table 11.2 Maintenance data Multimedia filter SF101 Operator signature Date Operating hours
REPLACED NOZZLE AND EXPANDING BOLTS REPLACED CENTRAL COLLECTOR REPLACED N. 8 FILTERING ARM N. 2 REPLACED TOP MANHOLE GASKET N. 2 REPLACED SIDE MANHOLE GASKET N. 2 REPLACED BOTTOM MANHOLE GASKET REPLACED FILLING MATERIAL

11.4 Cartridge filter FC101

11.4.1 Loading cartridge in FC101

The necessity to replace cartridges is signalled by the plant but it is recommended anyway to change them every month as with the time the filters tend to loose their mechanical properties. To load the cartridge in FC101 it is necessary to: 1. Make sure that valve EV107 is closed 2. Close valve VR105. 3. Open drain valve VS102 and the relative vent valve. 4. Wait for the complete vessel emptying. 5. Open the housing locking flange 6. Replace n. 30 30 5 micron cartridges 7. Close the housing. 8. Close drain valve VS102. 9. Open valve VR105 as previously set. 10. Wait for the complete filling of the housing and when the liquid starts overflowing close the vent valve.

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Table 11.3 Operating maintenance data of Cartridge filter

Operator signature Date Operating hours

FC101 REPLACING CARTRIDGE FA PP 305

Note

11.5 Resin bed RB101

11.5.1 Changing the filter nets

The gaskets and nets must be replaced if broken and everytime the resins are replaced. To change the gasket and nets it is necessary to: Make sure all the valves to and from the unit are closed Open the housing locking flange. Remove the gasket with the filtering nets If it is necessary to change the bottom net: a. Manually remove the resins and stock them if it isnt necessary to change them b. Replace the bottom filtering nets c. Replace or refill the resins until the unit is completely filled 5. Fill it with water and drain the water while open 6. Set top gaskets and nets 7. Close the flange 8. Fill the unit with water and test it with pressure 9. Open the housing lockin flange again and, after removing net and gasket complete filling (the resins should have set) 10. Set gaskets and net 11. Close the flange making sure to tight all the bolts 1. 2. 3. 4.

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11.5.2 Loading resins on RB101

The resins must be replaced when dirtry and when the unit doesnt work as set.. To load the resins it is necessary to: 12. Make sure all the valves to and from the unit are closed 13. Open the housing locking flange. 14. Remove the gasget with the filtering nets 15. Manually remove the resins 16. Rinse the unit with industrial water 17. Replace the resins until the unit is completely filled 18. Fill it with water and drain the water while open 19. Set gaskets and nets 20. Close the flange 21. Fill the unit with water and test it with pressure 22. Open the housing lockin flange again and, after removing net and gasket complete filling (the resins should have set) 23. Set gaskets and net 24. Close the flange making sure to tight all the bolts

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Section 12: Trouble Shooting

12.1 Instructions Use the following table to localize the problem and define remedial measures.

WARNING LACK OF COMPRESSED AIR

ALARM

EQUIPMENT

POSSIBLE CAUSE

REMEDIAL

LACK OF AIR

Low pressure in the compressed air feed line to the electric valves

Check pressure in the line Check eventual lacks on the feeding line of compressed air Check eventual lacks on using line of compressed air Check pressure reducer on the compressed air line is calibrated at 3.8 bar Set the correct limit. Check the transducer operation Check valves operation Check service air pressure

LEVEL EXTRA HIGH SS101 SS201 SS202

MAXIMUM LEVEL SS101 or SS 201 or SS202

LT101 HH LT201 HH LT202 HH

Limit LT101 or LT201 ot LT202 set on PLC is not correct. Inaccurate reading of transducer. LT101: Pneumatic valve EV101 has not been closed. LT201: Pneumatic valve EV201 has not been closed. LT101: Pneumatic valve EV105 has not been opened. LT201: Pneumatic valve EV202 has not been opened LT202: Pneumatic valve EV206 has not been opened LT101: PC102 mulfunction. LT201 LT202: PC202 mulfunction

Check valves operation Check service air pressure

Check pumps operation

LEVEL EXTRA LOW SS101 SS201 SS202

MINIMUM LEVEL SS101 or SS 201 or SS202

LT101 LL LT201 LL LT202 LL

Limit LT101 or LT201 ot LT202 set on PLC is not correct. Inaccurate reading of transducer. LT101: Pneumatic valve EV101 has not opened. LT201: Pneumatic valves EV201 has not opened.

Set the correct limit. Check the transducer operation Check valves operation Check service air pressure

In general valves mulfunction

Check valves operation Check service air pressure

LT101: PC102 mulfunction. LT201 LT202: PC202 mulfunction

Check pumps operation

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WARNING FILTER FC101 clogged

ALARM

EQUIPMENT PT102H H

POSSIBLE CAUSES Filter is clogged.

REMEDIAL

CARTRIDGE FILTER CLOGGED Inaccurate readings of transducers PT102. dP limit is wrong. VR103 valve completely open. PC102 pump mulfunction EV105-106 mulfunction. Inaccurate reading of transducer PT102.

Replace cartridges in accordance with the maintenance instructions. Check the transducers operation. Set the correct limit.

NO LIQUID ON FS101

ABSENCE OF FLUID IN PUMP PC102

PT101 LL

Set the valve. Manually check the pump. Manually check the valves . Set the correct limits Control correct opening of valves and piping. Replace resins or filtering nets in accordance with the maintenance instructions. Check the transducers operation. Set the correct limit.

PT201-202H H RESINS RB201 clogged RESIN BED CLOGGED

Feed pipes are closed or obstructed. Resin bed is clogged.

Inaccurate readings of transducers PT201-202. dP limit is wrong.

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Section 13: Alarms

The unit is equipped with an alarm system. Please note the alarms which can occur. 13.1 In case of alarm

ALARM
RED Light - Find the alarm cause from the tables in previous chapter After having identified the cause of the alarm and having resolved the problem with the help of the table given in Chapter 9.1, push the ACK button on PANEL VIEW and then the black push button RESET on the control panel.

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