Commissioning Manual - Water and Waste Water Treatment

Uong Bi 300MW Extension Power Plant Goshu Kohsan Co., Ltd.
M4/5/6 Water and Wastewater Treatment

Pre-Com and Commissioning Manual Page 1 of 71 09 Jan., 06 Rev. A
PRE-COMMISSIONING AND COMMISSIONING MANUAL

1. GENERAL

This manual covers the general requirements for the Pre-Commissioning and Commissioning
Works of Water and Wastewater Treatment Plants for Uong Bi 300MW Extension Power Plant,
under the EPC contractor Vietnam Machinery Erection Corporation (LILAMA), which consists of
Raw Water Treatment System, Demineralization System, Wastewater Treatment Plant, and
Domestic Wastewater Treatment Plant. These works shall commence after the completion of
installation work.

2. PRE-COMMISSIONING

The purpose of pre-commissioning work is to check the actual condition of the plant and to
perform necessary adjustments on the equipments in preparation for the commissioning work.

Mechanical Equipment Pre-Commissioning includes the following steps:
1. Flushing and Cleaning
2. Chemical Preparation
3. Filter Media Loading
4. Resin Loading
5. Oil Interceptor Check
6. Trial Run

Electrical & Instrument Equipment Pre-Commissioning includes the following steps:
1. MCC Power Energize
2. MCC Function Test
3. Motor No-Load Test
4. On-Off Valve Loop Test
5. Instrument Loop Test
6. System Function Test
7. Input-Output Test
8. Sequence Test

2.1. MECHANICAL EQUIPMENT PRE-COMMISSIONING

1. FLUSHING and CLEANING
Flush inside of pipe with water for few minutes until effluent is clear.
Open valves slowly to flush all dirt, debris, excess sealant and scale.
Clean inner surface of filters and exchanger vessels.

2. CHEMICAL PREPARATION

Pre-caution:
1. Person who prepares harmful or dusty chemicals should wear suitable protective equipment.
2. Training and advises shall be given to workers in order to understand the cause of harm that
would occur while working with chemicals. Method of prevention and measures to be used
in tending to the accident should be explained clearly to the workers.
3. Provide water for cleaning within the place of preparation.
4. Consider which chemical uses service water for dilution, and which one uses filtered water.

Preparation:
1. Alum is prepared as per the following procedure;
1.1. Coagulation dissolving tank (10GBN10BB001)
Fill the tank with filtered water until half of required level H
Load 255.5 kg/day of alum (flake) into the tank via electrical hoist manually
Further fill the tank with filtered water until required level H = 1,600 mm
Start Agitator (10GBN10AM001) for 1 hour or until alum is dissolved
1.2. Coagulation Feed Tank (10GBN10BB002)
Open On-off valve (10GBN10AA301) manually from local SVB to transfer
dissolved alum at 10% concentration into feed tank by gravity.
1.3. Illustration
M
H
COAGULATION DISSOLVING
TANK (10GBN10BB001)
COAGULATION FEED TANK
(10GBN10BB002)
10GBN10AA301
COAGULATION FEED PUMP
1A/B (10GBN11/12AP001)
CLARIFIER TANK A
(10UGE11BB001)
COAGULATION DISSOLVING TANK
AGITATOR (10GBN10AM001)
ALUM 10%

2. Sodium Hypochlorite is loaded by 8% NaOCl Tank Truck into NaOCl Tank
(10GBN20BB001).
Automatic feeding operation shall be referred to Functional Logic Description in
Appendix C.
3. Polymer is prepared in the Polymer Preparing Unit (10GBN30BB001) as per the following
procedure:
Manually load polymer (flake) into the Polymer Powder Hopper (10GBN30AF001)
Automatic feeding and mixing operation shall be referred to Functional Logic
Description in Appendix C, to produce polymer 0.05% solution.
4. Hydrochloric Acid is loaded by a 30% HCl Tank Truck into HCl Tank (10GCN10BB001).
Appendix C.
5. Sodium Hydroxide is loaded by 50% NaOH Tank Truck into NaOH Tank
(10GCN20BB001).
Appendix C.
6. Table 1 shows the list of chemicals and specification to be prepared for this project.

Table 1: List of Chemical to be Prepared:
No Chemical Name Form Percent Specific Gravity
1 Alum Flake 14% Al
2
(SO
4
)
3
1.72
2 Polymer (C-3310) Liquid 0.05% ~ 1.0
3 Sodium Hypochlorite: NaOCl Liquid 8% 1.2
4 Sodium Hydroxide: NaOH Liquid 50% (45%) 1.53 (1.48)
5 Hydrochloric Acid: HCl Liquid 30% 1.15

3. FILTER MEDIA LOADING

Precautions:
1. Open manholes and check that inner equipment has no damage.
2. Confirm leakage in nozzle and sight glass by filling water into the vessel and check leakage.
If no leaks were found, perform cleaning and flushing of vessel.
3. Confirm that there is no undesirable matter in the vessel.
4. Confirm the size and quantity of filter media.
5. Arrange and distinguish each kind of filter media.

Procedure:
1. Care shall be taken to load media into the filter. Avoid direct pouring of media from the top
manhole as inner paint could be severely damaged.
2. After each layer of media is loaded, the top surface shall be spread evenly and smoothly by
forking or any other means as to prevent leading through of media. After spreading, check
elevation.
3. Type of filter media top layer shall depend on media classification. Quantity of media shall
conform to the spec.
4. After loading, inspect inside of vessel. Take out foreign matter and contaminants. Properly
seal the top manhole.
5. Backwashing of media shall be carried out to remove any floating defective media.
6. Media to be loaded are listed in Table 2.
Table 2: List of Filter Media:
NO VESSEL TO BE
LOADED
KKS NO FILTER MEDIA QUANTITY
1 Auto Gravity Filter 10GBB11/12AT001 Gravel 5.04 m
3

Sand 7.56 m
3

2 A/C Filter (Potable) 10GBB20AT001 Gravel 0.48 m
3

Activated Carbon 0.90 m
3

3 A/C Filter (Demin) A/B 10GCB11/12AT001 Gravel 1.2 m
3

3

4 A/C Filter (WWTP) 10GNB10AT001 Gravel 1.92 m
3

3

4. RESIN LOADING

Precautions:
1. It is important to cross check the resin volumes loaded into each vessel. Record the actual
resin level in delivery form after backwashing and settling.
2. A careful measurement of the freeboard (in delivery form) should be made, reported, and
checked with the original design. If necessary, corrective action should be undertaken to
either load resin or download some.
3. Whenever possible, avoid the direct contact of the active resin with the nozzles.
4. Resins to be loaded are listed in Table 3.

Procedure:
1. Remove the top head of the vessel and top nozzle plate.
2. Fill 1/3 of the vessel with water. Loading resin into water ensures that any air and dirt are
floated off the resin and come out to the surface of the water. This will allow the resin bed to
sit evenly & homogeneously throughout the height of column.
3. Load the active resin as per the specified quantity.
4. Load inert resin as per the specified quantity.
5. Close the top head of the vessel.

Table 3: List of Resin:
NO VESSEL TO BE
LOADED
VESSEL TAG NO RESIN QUANTITY
1 Cation Exchanger A/B 10GCF11/12AT001 Dowex Mono C-600 1,725 Liters
Dowex IF-62 150 Liters
2 Anion Exchanger A/B 10GCF21/22AT001 Dowex Mono A-500 2,225 Liters
Dowex IF-62 225 Liters
3 M/B Exchanger A/B 10GCF31/32AT001 Dowex Marathon C 375 Liters
Dowex Marathon A 475 Liters

5. OIL INTERCEPTOR CHECK

5.1. Make sure that all internal equipments are in place and no tools or other loose items
are left in the interceptor.
5.2. With the automatic closure device in oil chamber feed, fill all interceptor compartments
with clear water to the outlet level.
5.3. Check that the stainless steel automatic device follows the level of the water.
6. TRIAL RUN

General:
The following equipments shall undergo trial run to demonstrate that they can operate safely
and satisfactorily under the required operating conditions.
1. Clarifier tank A/B (RWTS)
2. Gravity filter A/B
Manual backwash
Auto backwash
3. Demin Train A
A/C filter A (Demin) soaking
Manual regeneration
Auto regeneration
4. Demin Train B
A/C filter B (Demin) soaking
Manual regeneration
Auto regeneration
5. Clarifier tank (WWTP)
6. Sludge receiver tank
7. A/C filter (WWTP)
Soaking
Manual backwash
Auto backwash

Manual Backwash:
It is very essential to perform manual backwash operation on each of Auto Gravity and Carbon
Filters before operating to auto-mode so that foreign particle present in the media during
delivery are washed out from the vessel. In this operation, preliminary adjustments of manual &
actuator-operated valves, instrument set points, flowrate, etc. should also be done.

Auto Backwash:
When all necessary adjustments are completed, it is important to perform a trial run in auto
mode for one cycle before performing the commissioning proper in order to counter-check the
adjustments made. Final adjustments shall be done after one cycle, when necessary. Operation
is the same as the commissioning operation (Refer to the section COMMISSIONING).

Activated Carbon Soaking:
Activated carbon is filled with internal pores where air may exist. Before backwashing, bed must
be set in completely submerged condition to allow carbon pores to fill with water. Otherwise, the
reduced density of carbon due to air in the pores may result in excessive backwash losses.

Manual Regeneration:
It is very essential to first perform manual regeneration and backwashing before setting to auto-
mode so that preliminary adjustments in the plant can be done; such as manual and actuator-
operated valves adjustment, instruments set points, flowrate adjustment, chemical dosing
adjustment, etc. This is also essential for the resin in order to wash away foreign particles
present during delivery. This step shall prepare the correct ionic exchanging capacity of resin.
Manual regeneration literally means regeneration of each step of every unit in manual operation.

Automatic Regeneration:
When all necessary adjustments and preparations are completed, it is important to perform a
trial run in auto mode for one cycle before performing the commissioning proper in order to
counter-check the adjustments made. Final adjustments shall be made after one cycle, when
necessary. Operation is the same as the commissioning operation (Refer to the section
COMMISSIONING).

Initial Resin Regeneration:
Irrespective of the form delivered, the resin bed should receive at least a double amount of
regenerant compared to the design level. This means a double-injection-time only, while
displacement and rinse should be performed as per original design.

First Run:
Expected high water quality will be achieved only after final rinsing, after Mixed Bed Exchanger
in the case of Demineralizer, but provided that endpoint is monitored correctly and the plant is
not overrun.

Procedure:
A. Manual and Auto Backwash Operation
1. Set following pumps & blowers to manual mode operation in MCC and Local Control
Panel;
Freshwater Supply Pump (10GAF10AP001)
Backwash Water Pumps A/B (10GBK11/12AP001)
Air Blowers A/B (10GBC11/12AN001)
Filtered Water Transfer Pumps A/B (10GBK41/42AP001)
Demin Feed Pumps A/B (10GCK11/12AP001)
Clarified Water Transfer Pumps A/B (10GNK31/32AP001)
Backwash Pumps A/B (10GNK61/62AP001)
2. Set all actuator-operated valves used in Auto Gravity and Carbon filtering process
into manual mode operation in the Local Control Panel.
3. Perform manual preliminary washing in each filter in order to wash away foreign
particles present in the media during delivery until the effluent is clear.
4. Perform manual backwash operation in accordance with the Operation Chart and
Sequence of Auto Gravity and Carbon Filters, and P&ID.
5. Make necessary adjustments in order to meet the required water quality.
6. Perform backwash operation again, this time in auto backwash operation.
7. Make final adjustments as required.

B. Manual and Auto Regeneration Operation
1. Set the following pumps and blowers into manual mode operation in the MCC and
Local Control Panel;
Demin Feed Pumps A/B (10GCK11/12AP001)
Booster Pumps A/B (10GCK21/22AP001)
Regeneration Pumps A/B (10GCK31/32AP001)
Degasifier Blowers A/B (10GCH11/12AN001)
HCl Feed Pumps A/B (10GCN11/12AP001)
NaOH Feed Pumps A/B (10GCN21/22AP001)
2. Set all actuator-operated valves used in Demineralizer into manual mode
operation in the Local Control Panel.

3. Perform manual regeneration of Demineralizer in accordance with Operation
Chart and Sequence of Demineralization Train A & B by train and P&ID,
sequentially as follows;
A/C Filters A/B (10GCB11/12AT001)
Cation Exchangers A/B (10GCF11/12AT001)
Degasifier Tower & Sump A/B (GCH11/12AW001 & GCH11/12BB001)
Anion Exchangers A/B (10GCF21/22AT001)
Mixed Bed Exchangers A/B (10GCF31/32AT001)
4. Make necessary adjustments in order to meet the required water quality.
5. Perform regeneration operation again, this time in auto mode regeneration.
6. Make final adjustments, as necessary.


FILTER BACKWASH WATER
PIT (10UGH10BB001)
FRESHWATER
PUMP HOUSE
STATION
AUTO-GRAVITY FILTER
(10GBB11/12AT001)
10GBD11/12AA301
CLARIFIER TANK A
(10UGE11BB001)
10GAC21AA001
10GAC21QP001
M
CLARIFIER TANK A AGITATOR
(10GBD11AM001)
NaOH FEED PUMP
(10GBN41/42AP001)
POLYMER FEED PUMP
(10GBN31AP001)
COAGULATION
FEED PUMP
(10GBN11/12AP001)
pH
QT
TRIAL RUN PACKAGE M4:

Steps of Clarifier Tank A (UGE11BB001) Trial Run:

1.) Fill Water
Purpose: To supply raw water from Freshwater pond to Clarifier A (RWTS)
Operation:
Receive freshwater from Freshwater pump house station
Open Control valve (10GAC21AA001) manually from local SVB
Start Chemical feed pumps simultaneously with raw water flow in manual operation
o Coagulation feed pump 1A/B (10GBN11/12AP001)
o NaOH feed pump 2A/B (10GBN41/42AP001)
o Polymer feed pump 1A/B (10GBN31AP001)
Flow rate: 106.5 m
3
/hr
Duration: Until water level is 100mm below overflow line, then close control valve and stop
chemical feed pumps
Illustration:


PIT (10UGH10BB001)
FRESHWATER
PUMP HOUSE
STATION
AUTO-GRAVITY FILTER
(10GBB11/12AT001)
10GBD11/12AA301
CLARIFIER TANK A
(10UGE11BB001)
10GAC21AA001
10GAC21QP001
M
CLARIFIER TANK A AGITATOR
(10GBD11AM001)
NaOH FEED PUMP
(10GBN41/42AP001)
POLYMER FEED PUMP
(10GBN31AP001)
COAGULATION
FEED PUMP
(10GBN11/12AP001)
pH
QT
2.) Agitation
Purpose: To create disturbance inside Clarifier to enhance coagulation and flocculation
Operation:
Start Clarifier tank A agitator (10GBD11AM001) manually from LOP
Duration: ~2 hours or until floc is formed
(Note: Agitation continues until shutdown.)
Illustration:


PIT (10UGH10BB001)
FRESHWATER
PUMP HOUSE
STATION
AUTO-GRAVITY FILTER
(10GBB11/12AT001)
10GBD11/12AA301
CLARIFIER TANK A
(10UGE11BB001)
10GAC21AA001
10GAC21QP00
1
M
CLARIFIER TANK A
AGITATOR (10GBD11AM001)
NaOH FEED PUMP
(10GBN41/42AP001)
POLYMER FEED PUMP
(10GBN31AP001)
COAGULATION
FEED PUMP
(10GBN11/12AP001)
pH
QT
3.) Start Operation
Purpose: To further receive freshwater from Freshwater pump house station
Operation:
Open Control valve (10GAC21AA001) manually from local SVB
Flow rate:
50% of 106.5 m
3
/hr until sludge blanket is 500 mm lower than overflow
100% of 106.5 m
3
/hr
Duration: Continues operation
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
PUMP (GBK11/12AP001)
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
Steps of Auto-Gravity Filter A/B (10GBB11/12AT001) Manual Preliminary Operation:

1.) Washing
Purpose: To wash away foreign particles from gravel in preparation for the filter operation
Operation:
Open On-off valve (10GBB11/12AA301) manually from local SVB
Other On-off valves are closed
Flow rate: 105 m
3
/hr
Duration: Until effluent is clear
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
FILTERED WATER TANK
(10GBL10BB001)
2.) Service
Purpose: To produce filtered water
Operation:
Keep On-off valve (10GBB11/12AA301) open
Close On-off valve (10GBB11/12AA305) manually from local SVB
Start Filtered water pump A/B (10GBK31/32AP001) manually from LOP when
water level in Filtered water pit (10UGG10BB001) is at desired level
Flow rate: 105 m
3
/hr
Duration: Until water level in Filtered Water Tank is 1/3 of height
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
Steps of Auto-Gravity Filter A/B (10GBB11/12AT001) Manual Backwash Operation:

1.) Water Drain
Purpose: To reduce water level in vessel to prevent overflowing of media
Operation:
Flow rate: 0 m
3
/hr
Duration: 10 minutes
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
2.) Air Backwash
Purpose: To polish the media to remove foreign particles that attached to the media
Operation:
Start Air blower A/B (10GBC11/12AN001) manually from LOP
Flow rate: 12.6 Nm
3
/min
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
3.) Water Backwash
Purpose: To remove foreign particles detached from the media out of the vessel
Operation:
Stop Air blower A/B (10GBC11/12AN001) manually from LOP
Start B/W water pump A/B (10GBK11/12AP001) manually from LOP
Flow rate: 500 m
3
/hr
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
4.) Stop
Operation:
Stop B/W water pump A/B (10GBK11/12AP001) manually from LOP
Flow rate: 0 m
3
/hr
Illustration:


AUTO-GRAVITY FILTER
A/B (10GBB11/12AT001)
CLARIFIER TANK A/B
(10UGE11/12BB001)
10GBB11/12AA301
10GBB11/12AA302
FILTERED WATER PIT
(10UGG10BB001)
BACKWASH WATER
AIR BLOWER
(10GBC11/12AN001)
10GBB11/12AA303
10GBB11/12AA306
10GBB11/12AA304
10GBB11/12AA305
PIT (10UGH10BB001)
5.) Washing
Operation:
Flow rate: 105 m
3
/hr
Illustration:

Note: Repeat Manual Backwash Operation Until Effluent Is Clear.


Steps of A/C Filter Potable (10GBB20AT001) Manual Backwash Operation:

1.) Soaking
Purpose: To saturate the carbon with water in order to optimize backwashing
Operation:
Open manhole MH manually
Start Filtered water transfer pump A/B (10GBK41/42AP001) manually from LOP
Open On-off valve (10GBB20AA301) manually from local SVB, then close valve
when water reaches top distributor level by looking through the manhole MH
Close manhole MH manually
Duration: 1 hour or until activated carbon is fully saturated
(Note: If some carbon still found floating on water surface, use any wooden paddle to
sweep or disturb floating carbon so that water may enter into the available pores)
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER
TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
FILTER B/W WATER
PIT
(10UGH10BB001)
AA501


2.) Washing
Purpose: To wash away foreign particles from gravel
Operation:
Keep Filtered water transfer pump A/B (10GBK41/42AP001) running
Keep On-off valve (10GBB20AA301) open
Open On-off valve (10GBB20AA305) manually from local SVB
Flow rate: 10 m
3
/hr
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER
TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
FILTER B/W WATER PIT
(10UGH10BB001)
AA501

Note: Open Air Vent valve (10GBB20AA501) once a day, anytime of the day, to release
some air trapped in vessel


3.) Backwashing
Purpose: To remove foreign particles of filter media
Operation:
Close On-off valve (10GBB20AA301, 10GBB20AA305) manually from local SVB
Open On-off valve (10GBB20AA303, 10GBB20AA304) manually from local SVB
Flow rate: 10 m
3
/hr
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER
TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
(10UGH10BB001)
AA501


4.) Stop
Purpose: To allow floating filter media to settle by gravity
Operation:
Stop Filtered water transfer pump A/B (10GBK41/42AP001) manually from LOP
Close On-off valve (10GBB20AA303, 10GBB20AA304) manually from local SVB
Flow rate: 0 m
3
/hr
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER
TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
(10UGH10BB001)
AA501


5.) Washing
Purpose: To remove foreign particles remaining in the bottom of filter bed
Operation:
Start Filtered water transfer pump A/B (10GBK41/42AP001) manually from LOP
Open On-off valve (10GBB20AA301, 10GBB20AA305) manually from local SVB
Flow rate: 10 m
3
/hr
Duration: 10 minutes or until effluent does not show activated carbon powder
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER
TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
(10UGH10BB001)
AA501


6.) Service
Purpose: To produce potable water
Operation:
Keep On-off valve (10GBB20AA301) open
Close On-off valve (10GBB20AA305) manually from local SVB
Open On-off valve (10GBB20AA302) manually from local SVB, and start NaOCl
feed pump 1A/B (10GBN21/22AP001) simultaneously for chlorination
Flow rate: 10 m
3
/hr
Duration: 540 minutes (90 m
3
/day)
Illustration:
AA301
FILTERED WATER
TRANSFER PUMP A/B
(10GBK41/42AP001)
A/C FILTER
(10GBB20AT001)
POTABLE WATER TANK
(10GKB10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GBK35CF501)
CP501
CP502
MH
(10UGH10BB001)
AA501
NaOCl FEED PUMP 1A/B
(10GBN21/22AP001)



Steps of Demineralization Train A/B Manual Regeneration Operation

For A/C Filter A/B:

1.) Soaking
Operation:
Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP
Open On-off valve (10GCB11/12AA301) manually from local SVB, then close valve
Duration: 1 hour or until carbon is fully saturated
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501


2.) Washing
Operation:
Keep Demin feed pump A/B (10GCK11/12AP001) running
Open On-off valve (10GCB11/12AA301) manually from local SVB
Flow rate: 41 m
3
/hr
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501

Note: Open Air Vent valve (10GCB11/12AA501) once a day, anytime of the day, to
release some air trapped in vessel


3.) Backwashing
Operation:
Close On-off valve (10GCB11/12AA301) manually from local SVB
Flow rate: 41 m
3
/hr
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501


4.) Stop
Operation:
Stop Demin feed pump A/B (10GCK11/12AP001) manually from LOP
Flow rate: 0 m
3
/hr
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501


5.) Washing
Operation:
Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP
Flow rate: 25 m
3
/hr
Duration: 10 minutes or until effluent does not show activated carbon powder
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501


6.) Service
Purpose: To produce filtered water
Operation:
Keep On-off valve (10GCB11/12AA301) open
Flow rate: 41 m
3
/hr
Duration: 1,200 minutes
Illustration:
AA301
DEMIN FEED PUMP A/B
(10GCK11/12AP001)
A/C FILTER A/B
(10GCB11/12AT001)
10UGV10BB001
CATION EXCH. A/B
(10GCF11/12AT001)
P
AA304
AA302
AA305
AA303
P
FI
(10GCK13CF501/502)
CP501
CP502
MH
AA501


For Cation Exchanger A/B:

1.) SAC Compaction
Purpose: To lift the bed without reclassification of cation resin layers and pushes out any
solids or fines that have accumulated on top of the bed.
Operation:
Start Regen pump A/B (10GCK31/32AP001) manually from LOP
Open On-off valve (10GCF11/12AA303) manually from local SVB
Flow rate: 29 m
3
/hr
Duration: 5 minutes
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP
A/B
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


2.) Regenerant HCl 30% Injection
Purpose: To regenerate exhausted cation resin
Operation:
Keep Regen pump A/B (10GCK31/32AP001) running
Close On-off valve (10GCF11/12AA303) manually from local SVB
Keep On-off valve (10GCF11/12AA304) open
Open On-off valves (10GCK62AA801, 10GCF11/12AA801) manually from local SVB
Start HCl feed pump A/B (10GCN11/12AP001) manually from LOP
Open On-off valve (10GCN78AA801) manually from local SVB
Flow rates: HCl 30% = 1.20 m
3
/hr, Regen water = 7.1 m
3
/hr
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP A/B
(10GCN11/12AP001)
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


3.) Acid Displacement (Slow rinse)
Purpose: To push active regenerant from bottom to top of resin bed and start rinsing out
Operation:
Keep On-off valves (10GCF11/12AA304, 10GCK62AA801, ) open
Close On-off valve (10GCN78AA801) manually from local SVB
Stop HCl feed pump A/B (10GCN11/12AP001) manually from LOP
Flow rates: 7.1 m
3
/hr
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP A/B
(10GCN11/12AP001)
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


4.) Resin Bed Settling
Purpose: To allow floating resin to settle by gravity
Operation:
Stop Regen pump A/B (10GCK31/32AP001) manually from LOP
Close On-off valves (10GCF11/12AA304, 10GCK62AA801, 10GCF11/12AA801)
manually from respective local SVBs
Flow rates: 0 m
3
/hr
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP A/B
(10GCN11/12AP001)
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


5.) Rinsing
Purpose: To finally rinse out remaining regenerant and to arrange resin layer
Operation:
Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP to feed
filtered water through A/C filter A/B (10GCB11/12AT001)
Open On-off valves (10GCF11/12AA301, 10GCF11/12AA305) manually from
respective local SVBs
Flow rates: 41 m
3
/hr
Duration: 7 minutes
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP A/B
(10GCN11/12AP001)
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


6.) Service
Purpose: To produce soft water
Operation:
Keep Demin feed pump A/B (10GCK11/12AP001) running to feed filtered water
through A/C filter A/B (10GCB11/12AT001)
Close On-off valve (10GCF11/12AA305) manually from respective local SVBs
Open On-off valve (10GCF11/12AA302) manually from respective local SVBs
Flow rates: 41 m
3
/hr
Illustration:
AA301
AA302
A/C FILTER A/B
(10GCB11/12AT001)
AA304
CATION
EXCH A/B
(10GCF11/12
AT001)
PI
DEGASIFIER TOWER
A/B (10GCH11/12AW001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
HCl FEED PUMP A/B
(10GCN11/12AP001)
AA303
AA801 10GCK62AA801
FT
(10GCK14/15CF001)
FI
(10GCK63CF001)
10GCN78AA801
FI
(10GCN78CF501)
10UGV10BB001
FI
(10GCK62CF502)


For Degasifier A/B

Purpose: To remove CO
2

Operation:
Keep A/C filter A/B (10GCB11/12AT001) and Cation Exchanger A/B
(10GCF11/12AT001) in service
Start Degasifier blower A/B (10GCH11/12AN001) manually from LOP
Flow rates: 41 m
3
/hr
Illustration:
10GCF11/12AA302
DEGASIFIER BLOWER
A/B (10GCH11/12AN001)
DEGASIFIER SUMP A/B
(10GCH11/12BB001)
DEGASIFIER TOWER A/B
(10GCH11/12AW001)
CATION EXCH A/B
(10GCF11/12AT001)
ANION EXCH A/B
(10GCF21/22AT001)
BOOSTER PUMP A/B
(10GCK21/22AP001)
LT


For Anion Exchanger A/B:

1.) SBA Compaction
Purpose: To lift the bed without reclassification of anion resin layers and pushes out any
solids or fines that have accumulated on top of the bed.
Operation:
Flow rate: 29 m
3
/hr
Duration: 5 minutes
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
A/B
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


2.) Regenerant NaOH 50% Injection
Purpose: To regenerate exhausted anion resin
Operation:
Open On-off valves (10GCK62AA803, 10GCF21/22AA801) manually from local SVB
Start NaOH feed pump A/B (10GCN21/22AP001) manually from LOP
Flow rates: NaOH 50% = 0.41 m
3
/hr, Regen water = 7.30 m
3
/hr
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP A/B
(10GCN21/22AP001)
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


3.) Acid Displacement (Slow rinse)
Purpose: To push active regenerant from bottom to top of resin bed and start rinsing out
Operation:
Keep On-off valves (10GCK62AA803, 10GCF21/22AA801) manually from local SVB
Stop NaOH feed pump A/B (10GCN21/22AP001) manually from LOP
Flow rates: 7.30 m
3
/hr
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP A/B
(10GCN21/22AP001)
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


4.) Resin Bed Settling
Purpose: To allow floating resin to settle by gravity
Operation:
Close On-off valves (10GCF21/22AA304, 10GCK62AA803, 10GCF21/22AA801)
manually from respective local SVBs
Flow rates: 0 m
3
/hr
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP A/B
(10GCN21/22AP001)
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


5.) Rinsing
Purpose: To finally rinse out remaining regenerant and to arrange resin layer
Operation:
Start Booster pump A/B (10GCK21/22AP001) manually from LOP
Flow rates: 41 m
3
/hr
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP A/B
(10GCN21/22AP001)
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


6.) Service
Purpose: To produce demin water
Operation:
Keep Booster pump A/B (10GCK21/22AP001) running
Flow rates: 41 m
3
/hr
Illustration:
AA301
AA302
MIXED BED EXCH A/B
(10GCF31/32AT001)
AA304
ANION
EXCH A/B
(10GCF21/22
AT001)
PI
BOOSTER PUMP A/B
(10GCK21/22AP001)
PI
AA305
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP A/B
(10GCN21/22AP001)
AA303
AA801 10GCK62AA803
FT
(10GCK37/38CF001)
FI
(10GCK63CF001)
10GCN91AA801
FI
(10GCN91CF501)
10UGV10BB001
FI
(10GCK62CF504)


For Mixed Bed Exchanger A/B:

1.) Backwashing
Purpose: To separate anion and cation resin layers
Operation:
Flow rate: 8.4 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


2.) Stop
Purpose: To allow floating resins to settle by gravity
Operation:
Close On-off valves (10GCF31/32AA805, 10GCF31/32AA806) manually from
Flow rate: 0 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


3.) Regenerant NaOH 50% Injection
Purpose: To regenerate exhausted anion resin
Operation:
Open On-off valves (10GCF31/32AA801, 10GCF31/32AA802, 10GCF31/32AA804,
10GCK62AA804, 10GCK62AA802) manually from respective local SVBs
Start NaOH feed pump A/B (10GCN21/22AP001) manually from LOP
Flow rate: NaOH 50% = 0.16 m
3
/hr, Downward = 2.10 m
3
/hr, Upward = 2.20 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED
PUMP 1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


4.) Displacement of NaOH 50% (Slow rinse)
Purpose: To displace active NaOH 50% residual from the line before ends of spray nozzle
Operation:
Keep On-off valves (10GCF31/32AA801, 10GCF31/32AA802, 10GCF31/32AA804,
10GCK62AA804, 10GCK62AA802) open
Stop NaOH feed pump A/B (10GCN21/22AP001) manually from LOP
Flow rate: 2.10 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


5.) Regenerant HCl 30%
Purpose: To regenerate exhausted cation resin
Operation:
Start HCl feed pump A/B (10GCN11/12AP001) manually from LOP
Flow rate: HCl 30% = 0.39 m
3
/hr, Upward = 2.20 m
3
/hr, Downward = 2.10 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED
PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


6.) Displacement of HCl 30% (Slow rinse)
Purpose: To displace active HCl 30% residual from the line before ends of spray nozzle
Operation:
Stop HCl feed pump A/B (10GCN11/12AP001) manually from LOP
Flow rate: 2.20 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


7.) Water Drain
Purpose: To reduce water level in vessel to prevent separation of resin during air mixing
Operation:
Close On-off valves (10GCF31/32AA801, 10GCF31/32AA802,
10GCF31/32AA804, 10GCK62AA804, 10GCK62AA802) manually from local SVB
Open On-off valves (10GCF31/32AA305, 10GCF31/32AA801) manually from local SVB
Flow rate: 0 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI
AA801


8.) Resin Air Mixing
Purpose: To mix back cation and anion resins
Operation:
Flow rate: 47.1 Nm
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


9.) Vessel Filling
Purpose: To fill the vessel with water until required level
Operation:
Start Booster pump A/B (10GCK21/22AP001) manually from LOP to feed demin
water through Anion Exchanger A/B (10GCF21/22AT001)
Flow rate: 20.0 m
3
/hr
Duration: 2 minutes
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI
AA801


10.) Rinsing
Purpose: To fill the vessel with water until required level
Operation:
Keep Booster pump A/B (10GCK21/22AP001) running to feed demin water through
Anion Exchanger A/B (10GCF21/22AT001)
Flow rate: 20.0 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI


11.) Service
Purpose: To further polish demin water
Operation:
Keep Booster pump A/B (10GCK21/22AP001) running to feed demin water through
Anion Exchanger A/B (10GCF21/22AT001)
Flow rate: 41.0 m
3
/hr
Illustration:
ANION EXCH A/B
(10GCF21/22AT001)
AA806
DEMIN WATER
TANK A/B
(10GCL11/12BB01)
PI
REGEN PUMP A/B
(10GCK31/32AP001)
NaOH FEED PUMP
1A/B
(10GCN21/22AP001)
AA305
10UGV10BB001
AA804
AA302
AA306
AA803
AA801
AA805
AA802
MIXED BED
EXCH A/B
(10GCF31/32
AT001)
FI
(10GCK63CF001)
FI (10GCK62CF503)
10GCK62AA804
10GCN90AA801
FI (10GCN90CF501)
FI (10GCK62CF501)
10GCK62AA802
FI (10GCN77CF501)
10GCN77AA801
HCl FEED PUMP 1A/B
(10GCN11/12AP001)
AIR RECEIVER
(10QEF10BB001)
10GCF21/22AA302
PI



Steps of Trial Run for pH Adjustment & Mixing Pit, WWTP Clarifier Tank and Sludge
Receiver Tank:

1.) pH Adjustment and Mixing Pit
Purpose: To fill wastewater into the pH adjustment pit and overflows to Mixing pit from
Wastewater pit for coagulation and flocculation process
Operation:
Start Wastewater pump (10GNK21/22AP001) manually from LOP
Start following Chemical feed pumps manually from respective LOPs
o Coagulation feed pump 2A/B (10GNN11/12AP001) = 100 mg/L
o HCl feed pump 2A (10GNN30AP001) = 50 mg/L
o NaOH feed pump 3A (10GNN50AP001) = 100 mg/L
o Polymer feed pump 2A/B (10GNN21/22AP001) = 1 mg/L
Start following Agitators manually from respective LOPs when wastewater level is
over agitators blades
o pH adjustment pit agitator (10GNE10AM001)
o Mixing pit agitator (10GNE20AM001)
Flow rate: 70 m
3
/hr
Duration: Until wastewater overflows
Illustration:
M M
WASTEWATER PUMP
(10GNK21/22AP001)
COAGULATION FEED PUMP 2A/B
(10GNN11/12AP001)
HCl FEED PUMP 2A
(10GNN30AP001)
NaOH FEED PUMP 3A
(10GNN50AP001)
POLYMER FEED PUMP 2A/B
(10GNN21/22AP001)
pH ADJUSTMENT PIT
(10UGP10BB001)
MIXING PIT
(10UGP20BB001)
MIXING PIT AGITATOR
(10GNE20AM001)
pH ADJUSTMENT PIT
AGITATOR (10GNE10AM001)
WWTP CLARIFIER TANK
(10UGQ10BB001)
pH
QT


2.) WWTP Clarifier Tank
Purpose: To separate sludge and clear water
Operation:
Keep Wastewater pump (10GNK21/22AP001) running
Keep Chemical feed pumps simultaneously running
Start WWTP Clarifier tank agitators (10GND10AM001) when wastewater level is
over the blades of agitator
Start Thinner sludge pump A/B (10GNK41/42AP001) manually from LOP to
transfer partially thickened sludge to Sludge receiver tank (10UGT10BB001)
Flow rate: 70 m
3
/hr
Duration: Continuous
Illustration:
M
WWTP CLARIFIER TANK
AGITATOR (10GND10AM001)
MIXING PIT
(10UGP20BB001)
CLARIFIED WASTEWATER
PIT (10UGR10BB001)
WWTP CLARIFIER TANK
(10UGQ10BB001)
THINNER SLUDGE PUMP
A/B (10GNK41/42AP001)


3.) Sludge Receiver Tank
Purpose: To further thickened sludge for disposal
Operation:
Keep Wastewater pump (10GNK21/22AP001) running
Keep Chemical feed pumps simultaneously running
Keep Thinner sludge pump A/B (10GNK41/42AP001) running
Start Sludge receiver tank agitators (10GND10AM001) when wastewater level is
over the blades of agitator
Start Thicker sludge pump A/B (10GNK71/72AP001) manually from LOP to
dispose thickened sludge to Ash slurry pit
Flow rate: 3 m
3
/hr
Duration: Continuous
Illustration:
M
SLUDGE RECEIVER
TANK AGITATOR
(10GNS10AM001)
THINNER SLUDGE PUMP
A/B (10GNK41/42AP001)
WASTEWATER PIT
(10UGN10BB001)
SLUDGE RECEIVER TANK
(10UGT10BB001)
THICKER SLUDGE PUMP
A/B (10GNK71/72AP001)
SLUDGE PUMP A/B
(10GRK11/12AP001)
UNDERFLOW SLUDGE PUMP
A/B (10GBK21/22AP001)


Steps of A/C Filter WWTP (10GNB10AT001) Manual Backwash Operation:

1.) Soaking
Operation:
Start Clarified water transfer pump A/B (10GNK31/32AP001) manually from LOP
Open On-off valve (10GNB10AA301) manually from local SVB, then close valve
Duration: 1 hour or until activated carbon is fully saturated
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501


2.) Washing
Operation:
Keep Clarified water transfer pump A/B (10GNK31/32AP001) running
Open On-off valve (10GNB10AA301) manually from local SVB
Flow rate: 70 m
3
/hr
Duration: 10 minutes or until effluent is clear
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501

Note: Open Air Vent valve (10GNB10AA501) once a day, anytime of the day, to release
some air trapped in vessel


3.) Backwashing
Operation:
Stop Clarified water transfer pump A/B (10GNK31/32AP001) manually from LOP
Close On-off valve (10GNB10AA301, 10GNB10AA305) manually from local SVB
Start Backwash pump A/B (10GNK61/62AP001) manually from LOP
Open On-off valve (10GNB10AA303, 10GNB10AA304) manually from local SVB
Flow rate: 70 m
3
/hr
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501


4.) Stop
Operation:
Stop Backwash pump A/B (10GNK61/62AP001) manually from LOP
Close On-off valve (10GNB10AA303, 10GNB10AA304) manually from local SVB
Flow rate: 0 m
3
/hr
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501


5.) Washing
Operation:
Start Clarified water transfer pump A/B (10GNK31/32AP001) manually from LOP
Open On-off valve (10GNB10AA301, 10GNB10AA305) manually from local SVB
Flow rate: 40 m
3
/hr
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501


6.) Service
Purpose: To filtered wastewater
Operation:
Keep Clarified water transfer pump A/B (10GNK31/32AP001) running
Keep On-off valve (10GNB10AA301) open
Close On-off valve (10GNB10AA305) manually from local SVB
Flow rate: 70 m
3
/hr
Illustration:
AA301
CLARIFIED WATER
TRANSFER PUMP A/B
(10GNK31/32AP001)
A/C FILTER WWTP
(10GNB10AT001)
NEUTRALIZATION PIT
(10UGU10BB001)
P
AA304
AA302
AA305
AA303
P
FI
(10GNK21CF501)
CP501
CP502
MH
WASTEWATER PIT
(10UGN10BB001)
BACKWASH PUMP A/B
(10GNK61/62AP001)
AA501


2.2. ELECTRICAL & INSTRUMENT EQUIPMENT PRE-COMMISSIONING

1. MCC POWER ENERGIZE
Procedure:
1. Prior to energizing the MCC, the operator should check selector switches of each MCC module for
equipments such as pumps, blowers, agitators, etc., if they are in OFF position. Release to Local signal from
MMI shall not be activated (Logic = 0). Below is a list of equipments with their respective local control panels:
NO KKS NO EQUIPMENT NAME LOP NO
1 10GBN11AP001 COAGULATION FEED PUMP 1A 10GBY10CX101
2 10GBN12AP001 COAGULATION FEED PUMP 1B 10GBY10CX101
3 10GNN11AP001 COAGULATION FEED PUMP 2A 10GBY10CX101
4 10GNN12AP001 COAGULATION FEED PUMP 2B 10GBY10CX101
5 10GBN10AM001 COAG DISSOLVING TANK AGITATOR 10GBY10CX101
6 10GBN21AP001 NaOCl FEED PUMP 1A 10GBY10CX102
7 10GBN22AP001 NaOCl FEED PUMP 1B 10GBY10CX102
8 10GRN11AP001 NaOCl FEED PUMP 2A 10GBY10CX102
9 10GRN12AP001 NaOCl FEED PUMP 2B 10GBY10CX102
10 10GBN31AP001 POLYMER FEED PUMP 1A 10GBY10CX103
11 10GBN32AP001 POLYMER FEED PUMP 1B 10GBY10CX103
12 10GNN21AP001 POLYMER FEED PUMP 2A 10GBY10CX103
13 10GNN22AP001 POLYMER FEED PUMP 2B 10GBY10CX103
14 10GBD11AM001 CLARIFIER TANK A AGITATOR 10GBY10CX104
15 10GBD12AM001 CLARIFIER TANK B AGITATOR 10GBY10CX105
16 10GBK21AP001 UNDERFLOW SLUDGE PUMP A 10GBY10CX106
17 10GBK22AP001 UNDERFLOW SLUDGE PUMP B 10GBY10CX106
18 10GBK31AP001 FILTERED WATER PUMP A 10GBY10CX106
19 10GBK32AP001 FILTERED WATER PUMP B 10GBY10CX106
20 10GBC11AN001 AIR BLOWER A 10GBY10CX106
21 10GBC12AN001 AIR BLOWER B 10GBY10CX106
22 10GBK11AP001 BACKWASH WATER PUMP A 10GBY10CX107
23 10GBK12AP001 BACKWASH WATER PUMP B 10GBY10CX107
24 10GBK41AP001 FILTERED WATER TRANSFER PUMP A 10GBY10CX107
25 10GBK42AP001 FILTERED WATER TRANSFER PUMP B 10GBY10CX107
26 10GKA11AP001 PORTABLE WATER PUMP A 10GBY10CX108
27 10GKA12AP001 PORTABLE WATER PUMP B 10GBY10CX108
28 10GCK21AP001 BOOSTER PUMP A 10GCY10CX101
29 10GCK22AP001 BOOSTER PUMP B 10GCY10CX101
30 10GCH11AN001 DEGASIFIER BLOWER A 10GCY10CX101
31 10GCH12AN001 DEGASIFIER BLOWER B 10GCY10CX101
32 10GCN11AP001 HCl FEED PUMP 1A 10GCY10CX102
33 10GCN12AP001 HCl FEED PUMP 1B 10GCY10CX102
34 10GNN30AP001 HCl FEED PUMP 2A 10GCY10CX102

NO KKS NO EQUIPMENT NAME LOP NO
35 10GNN40AP001 HCl FEED PUMP 2B 10GCY10CX102
36 10GCN21AP001 NaOH FEED PUMP 1A 10GCY10CX103
37 10GCN22AP001 NaOH FEED PUMP 1B 10GCY10CX103
38 10GBN41AP001 NaOH FEED PUMP 2A 10GCY10CX103
39 10GBN42AP001 NaOH FEED PUMP 2B 10GCY10CX103
40 10GNN50AP001 NaOH FEED PUMP 3A 10GCY10CX103
41 10GNN60AP001 NaOH FEED PUMP 3B 10GCY10CX103
42 10GCK51AP001 NEUT WATER DISPOSAL PUMP A 10GCY10CX104
43 10GCK52AP001 NEUT WATER DISPOSAL PUMP B 10GCY10CX104
44 10GCK41AP001 DEMIN WATER TRANSFER PUMP A 10GCY10CX105
45 10GCK42AP001 DEMIN WATER TRANSFER PUMP B 10GCY10CX105
46 10GCK31AP001 REGENERATION PUMP A 10GCY10CX105
47 10GCK32AP001 REGENERATION PUMP B 10GCY10CX105
48 10GCK11AP001 DEMIN FEED PUMP A 10GCY10CX107
49 10GCK12AP001 DEMIN FEED PUMP B 10GCY10CX107
50 10GNK11AP001 OILY WASTEWATER PUMP A 10GNY10CX101
51 10GNK12AP001 OILY WASTEWATER PUMP B 10GNY10CX101
52 10GNC11AN001 MIXING BLOWER A 10GNY10CX102
53 10GNC12AN001 MIXING BLOWER B 10GNY10CX102
54 10GNK41AP001 THINNER SLUDGE PUMP A 10GNY10CX102
55 10GNK42AP001 THINNER SLUDGE PUMP B 10GNY10CX102
56 10GNK71AP001 THICKER SLUDGE PUMP A 10GNY10CX103
57 10GNK72AP001 THICKER SLUDGE PUMP B 10GNY10CX103
58 10GNK21AP001 WASTEWATER PUMP A 10GNY10CX103
59 10GNK22AP001 WASTEWATER PUMP B 10GNY10CX103
60 10GNK61AP001 BACKWASH PUMP A 10GNY10CX104
61 10GNK62AP001 BACKWASH PUMP B 10GNY10CX104
62 10GNK51AP001 TREATED WATER PUMP A 10GNY10CX104
63 10GNK52AP001 TREATED WATER PUMP B 10GNY10CX104
64 10GNK31AP001 CLARIFIED WATER TRANSFER PUMP A 10GNY10CX104
65 10GNK32AP001 CLARIFIED WATER TRANSFER PUMP B 10GNY10CX104
66 10GNS10AM001 SLUDGE RECIEVER TANK AGITATOR 10GNY10CX105
67 10GND10AM001 WWTP CLARIFIER TANK AGITATOR 10GNY10CX106
68 10GNE10AM001 pH ADJUSTMENT PIT AGITATOR 10GNY10CX107
69 10GNE20AM001 MIXING PIT AGITATOR 10GNY10CX107
70 10GNE30AM001 NEUTRALIZATION PIT AGITATOR 10GNY10CX107
71 10GRK11AP001 DWWTP SLUDGE PUMP A 10GNY10CX108
72 10GRK12AP001 DWWTP SLUDGE PUMP B 10GNY10CX108
73 10GRC11AN001 BLOWER A 10GNY10CX109
74 10GRC12AN001 BLOWER B 10GNY10CX109

2. Energizing the MCC
Refer to separate manual of MCC for energizing procedure
Select the following motor starter modules to remote mode operation

RAW WATER TREATMENT SYSTEM

NO KKS NO EQUIPMENT NAME
1 10GBK31AP001/10GBK32AP001 FITERED WATER PUMP A/B
2 10GBK11AP001/10GBK12AP001 BACKWASH WATER PUMP A/B
3 10GKA11AP001/10GKA12AP001 PORTABLE WATER PUMP A/B
4 10GBK21AP001/10GBK22AP001 UNDERFLOW SLUDGE PUMP A/B
5 10GBC11AN001/10GBC12AN001 AIR BLOWER A/B
6 10GBK41AP001/10GBK42AP001 FILTERED WATER TRANSFER PUMP A/B
7 10GBD11AM001/10GBD12AM001 CLARIFIER TANK A/B AGITATOR
8 10GBN10AM001 COAGULATION DISOVING TANK AGITATOR
9 10GBN11AP001/10GBN12AP001 COAGULATION FEED PUMP 1A/1B
10 10GBN21AP001/10GBN22AP001 NaOCl FEED PUMP 1A/1B
11 10GBN31AP001/10GBN32AP001 POLYMER FEED PUMP 1A/1B
12 10GBN41AP001/10GBN42AP001 NaOH FEED PUMP 2A/2B

DEMINERALIZATION SYSTEM

1 10GCK11AP001/10GCK12AP001 DEMIN FEED PUMP A/B
2 10GCH11AN001/10GCH12AN001 DEGASIFIER BLOWER A/B
3 10GCK21AP001/10GCK22AP001 BOOSTER PUMP A/B
4 10GCK41AP001/10GCK42AP001 DEMINERALIZED WATER TRANSFER PUMP A/B
5 10GCK31AP001/10GCK32AP001 REGENERATION PUMP A/B
6 10GCN11AP001/10GCN12AP001 HCl FEED PUMP 1A/1B
7 10GCN21AP001/10GCN22AP001 NaOH FEED PUMPS 1A/1B
8 10GCK51AP001/10GCK52AP001 NEUTRALIZED WATER DISPOSAL PUMP A/B

WASTEWATER TREATMENT PLANT

1 10GNK11AP001/10GNK12AP001 OILY WASTEWATER PUMP A/B
2 10GNC11AN001/10GNC12AN001 MIXING BLOWER A/B
3 10GNK21AP001/10GNK22AP001 WASTEWATER PUMP A/B
4 10GNK31AP001/10GNK32AP001 CLARIFIED WATER TRANSFER PUMP A/B
5 10GNK61AP001/10GNK62AP001 BACKWASH PUMP A/B
6 10GNK51AP001/10GNK52AP001 TREATED WATER PUMP A/B
7 10GNK41AP001/10GNK42AP001 THINNER SLUDGE PUMPS A/B
8 10GNK71AP001/10GNK72AP001 THICKENER SLUDGE PUMPS A/B

9 10GNN30AP001/10GNN40AP001 HCl FEED PUMP 2A/2B
10 10GNN50AP001/10GNN60AP001 NaOH FEED PUMP 3A/3B
11 10GND10AM001 CLARIFIER TANK AGITATOR
12 10GNE10AM001 pH ADJUSTMENT PIT AGITATOR
13 10GNE20AM001 MIXING PIT AGITATOR
14 10GNE30AM001 NEUTRALIZATION PIT AGITATOR
15 10GNS10AM001 SLUDGE RECEIVER TANK AGITATOR
16 10GNN11AP001/10GNN12AP001 COAGULATION FEED PUMP 2A/2B
17 10GNN21AP001/10GNN22AP001 POLYMER FEED PUMP 2A/2B
18 10GRC11AN001/10GRC12AN001 BLOWER A/B
19 10GRK11AP001/10GRK12AP001 SLUDGE PUMP A/B
20 10GRN11AP001/10GRN12AP001 NaOCl FEED PUMP 2A/2B

3. Energize each equipment in the MCC as per following requirements
For equipment with auto-mode/ manual-mode, select of each equipment via MMI
Operation mode of each equipment shall be selected to the following;

RAW WATER SYSTEM

NO EQUIPMENT NAME AUTO MANUAL STAND-BY LOP NO.
1 COAGULATION DISSOLVING TANK
AGITATOR
N/A 10GBN10AM001 - 10GBY10CX101
2 COAGULATION FEED PUMP
1A/1B
10GBN11AP001 SELECTABLE 10GBN12AP001 10GBY10CX101
3 NaOCl FEED PUMP 1A/1B 10GBN21AP001 SELECTABLE 10GBN22AP001 10GBY10CX102
4 POLYMER FEED PUMP 1A 10GBN31AP001 SELECTABLE - 10GBY10CX103
5 POLYMER FEED PUMP 1B 10GBN32AP001 SELECTABLE - 10GBY10CX103
6 NaOH FEED PUMP 2A/2B 10GBN41AP001 SELECTABLE 10GBN42AP001 10GCY10CX103
7 CLARIFIER TANK A
AGITATOR
10GBD11AM001 SELECTABLE - 10GBY10CX104
8 CLARIFIER TANK B
AGITATOR
10GBD12AM001 SELECTABLE - 10GBY10CX105
9 FILTERED WATER PUMP A/B 10GBK31AP001 SELECTABLE 10GBK32AP001 10GBY10CX106
10 AIR BLOWER A/B 10GBC11AN001 SELECTABLE 10GBC12AN001 10GBY10CX106
11 UNDERFLOW SLUDGE
PUMP A/B
10GBK21AP001 SELECTABLE 10GBK22AP001 10GBY10CX106
12 BACKWASH WATER PUMP A/B 10GBK11AP001 SELECTABLE 10GBK12AP001 10GBY10CX107
13 FILTERED WATER TRANSFER
PUMP A/B
N/A 10GBK41AP001 10GBK42AP001 10GBY10CX107
14 POTABLE WATER PUMP A/B N/A 10GKA11AP001 10GKA12AP001 10GBY10CX108


1 DEGASIFIER BLOWER A 10GCH11AN001 SELECTABLE - 10GCY10CX101
2 DEGASIFIER BLOWER B 10GCH12AN001 SELECTABLE 10GCH12AN001 10GCY10CX101
3 BOOSTER PUMP A 10GCK21AP001 SELECTABLE - 10GCY10CX101
4 BOOSTER PUMP B 10GCK22AP001 SELECTABLE - 10GCY10CX101

5 HCl FEED PUMP 1A/1B 10GCN11AP001 SELECTABLE 10GCN12AP001 10GCY10CX102
6 NaOH FEED PUMP 1A/1B 10GCN21AP001 SELECTABLE 10GCN22AP001 10GCY10CX103
7 NEUTRALIZED WATER DISPOSAL
PUMP A/B
10GCK51AP001 SELECTABLE 10GCK52AP001 10GCY10CX104
8 DEMINERALIZED WATER
TRANSFER PUMP A
N/A 10GCK41AP001 - 10GCY10CX105
9 DEMINERALIZED WATER
TRANSFER PUMP B
N/A 10GCK42AP001 - 10GCY10CX105
10 REGENERATION PUMP A/B 10GCK31AP001 SELECTABLE 10GCK32AP001 10GCY10CX105
11 DEMIN FEED PUMP A/B 10GCK11AP001 SELECTABLE 10GCK12AP001 10GCY10CX107


1 COAG FEED PUMP 2A/2B 10GNN11AP001 SELECTABLE 10GNN12AP001 10GBY10CX101
2 POLYMER FEED PUMP 2A/2B 10GNN21AP001 SELECTABLE 10GNN22AP001 10GBY10CX103
3 NaOCl FEED PUMP 2A/2B N/A 10GRN11AP001 10GRN12AP001 10GBY10CX102
4 HCl FEED PUMP 2A 10GNN30AP001 SELECTABLE - 10GCY10CX102
5 HCl FEED PUMP 2B 10GNN40AP001 SELECTABLE - 10GCY10CX102
6 NaOH FEED PUMP 3A 10GNN50AP001 SELECTABLE - 10GCY10CX103
7 NaOH FEED PUMP 3B 10GNN60AP001 SELECTABLE - 10GCY10CX103
8 OILY WASTEWATER PUMP A/B 10GNK11AP001 SELECTABLE 10GNK12AP001 10GNY10CX101
9 MIXING BLOWER A/B 10GNC11AN001 SELECTABLE 10GNC12AN001 10GNY10CX102
10 THINNER SLUDGE
PUMP A/B
N/A 10GNK41AP001 10GNK42AP001 10GNY10CX102
11 WASTEWATER
PUMP A/B
10GNK21AP001 SELECTABLE 10GNK22AP001 10GNY10CX103
12 THICKER SLUDGE
PUMP A/B
N/A 10GNK71AP001 10GNK72AP001 10GNY10CX103
13 CLARIFIEDWATER TRANSFER
PUMP A/B
14 BACKWASH PUMP A/B 10GNK61AP001 SELECTABLE 10GNK62AP001 10GNY10CX104
15 TREATED WATER
PUMP A/B
16 SLUDGE RECEIVER TANK
AGITATOR
10GNS10AM001

SELECTABLE - 10GNY10CX105
17 WWTP CLARIFIER TANK
AGITATOR
10GND10AM001 SELECTABLE - 10GNY10CX106
18 pH ADJUSTMENT PIT
AGITATOR
10GNE10AM001 SELECTABLE - 10GNY10CX107
19 MIXING PIT AGITATOR 10GNE20AM001 SELECTABLE - 10GNY10CX107
20 NEUTRALIZATION PIT AGITATOR 10GNE30AM001 SELECTABLE - 10GNY10CX107
21 DWWTP SLUDGE
PUMP A/B
10GRK11AP001 SELECTABLE 10GRK12AP001

10GNY10CX108
22 BLOWER A/B N/A 10GRC11AN001 10GRC12AN001 10GNY10CX109


2. MCC FUNCTION TEST

Refer to Appendix __

3. MOTOR NO-LOAD TEST

Procedure
The procedure of pre-commissioning works for the above check-items of Electrical and
Instrument Equipment shall be based on GKC Standard Procedure. Electric motors of
equipments subject for Motor no-load test are listed in table below.

RAW WATER TREATMENT SYSTEM

1 10GAF10AP001 FRESHWATER SUPPLY PUMP
2 10GBK31AP001/10GBK32AP001 FITERED WATER PUMP A/B
3 10GBK11AP001/10GBK12AP001 BACKWASH WATER PUMP A/B
4 10GKA11AP001/10GKA12AP001 POTABLE WATER PUMP A/B
5 10GBK21AP001/10GBK22AP001 UNDERFLOW SLUDGE PUMP A/B
6 10GBC11AN001/10GBC12AN001 AIR BLOWER A/B
7 10GBK41AP001/10GBK42AP001 FILTERED WATER TRANSFER PUMP A/B
8 10GBD11AM001/10GBD12AM001 CLARIFIER TANK A/B AGITATOR
9 10GBN10AM001 COAGULATION DISOVING TANK AGITATOR


1 10GCK11AP001/10GCK12AP001 DEMIN FEED PUMP A/B
2 10GCH11AN001/10GCH12AN001 DEGASIFIER BLOWER A/B
3 10GCK21AP001/10GCK22AP001 BOOSTER PUMP A/B
4 10GCK41AP001/10GCK42AP001 DEMINERALIZED WATER TRANSFER PUMP A/B
5 10GCK31AP001/10GCK32AP001 REGENERATION PUMP A/B
6 10GCK51AP001/10GCK52AP001 NEUTRALIZED WATER DISPOSAL PUMP A/B


1 10GNK11AP001/10GNK12AP001 OILY WASTEWATER PUMP A/B
2 10GNC11AN001/10GNC12AN001 MIXING BLOWER A/B
3 10GNK21AP001/10GNK22AP001 WASTEWATER PUMP A/B
4 10GNK31AP001/10GNK32AP001 CLARIFIED WATER TRANSFER PUMP A/B
5 10GNK61AP001/10GNK62AP001 BACKWASH PUMP A/B
6 10GNK51AP001/10GNK52AP001 TREATED WATER PUMP A/B
7 10GNK41AP001/10GNK42AP001 THINNER SLUDGE PUMP A/B

8 10GNK71AP001/10GNK72AP001 THICKENER SLUDGE PUMP A/B
9 10GND10AM001 WWTP CLARIFIER TANK AGITATOR
10 10GNE10AM001 pH ADJUSTMENT PIT AGITATOR
11 10GNE20AM001 MIXING PIT AGITATOR
12 10GNE30AM001 NEUTRALIZATION PIT AGITATOR
13 10GNS10AM001 SLUDGE RECEIVER TANK AGITATOR
14 10GRC11AN001/10GRC12AN001 BLOWER A/B
15 10GRK11AP001/10GRK12AP001 SLUDGE PUMP A/B

4. ON-OFF VALVE LOOP TEST


5. INSTRUMENT LOOP TEST


6. SYSTEM FUNCTION TEST


7. INPUT-OUTPUT TEST


8. SEQUENCE TEST



3. COMMISSIONING

GKC and Lilama Staffs shall together perform the Commissioning Work, or if necessary, with
EVN Staff also. GKC Staff shall explain the operation of the Water Treatment Plant and train
Lilama and EVN Staffs, as well.

3.1. PERFORMANCE TEST

General:
Performance Test shall be done by running the plant for two cycles. Demineralized and
Condensate water quality shall be checked with conductivity meters. Commissioning results
shall be recorded in the Commissioning Result form. Period of commissioning shall be
referred to the Table below;

Table: Commissioning Period
ITEMS
SYSTEM Treating Capacity x
Cycle
Analysis
(Raw/Treated)
Mechanical Electrical
Gravity Filter 105 m
3
/hr x 2 2 x 2 x 2 x
Carbon Filter (Potable) 90 m
3
/day x 2 2 x 2 x 2 x
Carbon Filter (Demin) 41 m
3
/hr x 2 2 x 2 x 2 x
Demineralizer Trains 41 m
3
/hr x 2 2 x 2 x 2 x
Carbon Filter (WWTP) 70 m
3
/hr x 2 2 x 2 x 2 x

Procedure:
1. Run the plant for 24 hours per day for 2 days.
2. Take data of influent flowrates for Clarifier Tank, Gravity Filter, Carbon Filter, Cation
Exchanger, Anion Exchanger, and Mixed Bed Exchanger every hour.
3. Take data of pressures for Gravity Filter, Carbon Filters, Cation Exchanger, Anion
Exchanger, and Mixed Bed Exchanger every hour.
4. Take data of conductivity for Anion Exchanger and Mixed Bed Exchanger every hour.
5. Take data of pH in Clarifier Tank every hour.
6. Take sampling at sampling cocks of Gravity Filter, Carbon Filters, Anion Exchanger, and
Mixed Bed Exchanger every 4 hours for analysis. GKC and Lilama will take sampling at
the same time and perform internal analysis for comparison purposes.
7. Take note of the running time of first on-line Demineralizer train following switched-over of
the standby train.
8. Take note of the duration of regeneration period in every regeneration cycle.

Commissioning Manual - Water and Waste Water Treatment

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Uong Bi 300MW Extension Power Plant Goshu Kohsan Co., Ltd.

M4/5/6 Water and Wastewater Treatment

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