(For Internal Circulation Only)

COS-ISO-00-OGN/OPS/CHEM/018
Rev. No. : 0 July 2006

OPERATION GUIDANCE NOTE

Guidelines for
Performance
Optimization of P.T.
Plant and Chlorination
System
CORPORATE OPERATION SERVICES

NTPC Limited
NTPC LIMITED
OPERATION AND MAINTENANCE FORMAL DOCUMENTATION SYSTEM
OPERATION GUIDANCE NOTE : COS-ISO-00-OGN/OPS/CHEM/018

Rev. No.: 0

Date : July 2006

Guidelines for
Performance
Optimization of P.T.
Plant and Chlorination
System

Approved for
Implementation by ..
Director (O)
Date: ..

Enquiries to: Head of Corp. Operation Services

Guidelines for Performance Optimization of P.T. Plant

and Chlorination System
INDEX
Sl. No.

Contents

Page No.

1.0

Introduction

2.0

Superseded Documents

3.0

Clarifiers

4.0

Clarification

5.0

Operating Criteria

6.0

Maintenance Criteria

7.0

Troubleshooting Criteria

10

8.0

Chlorination Chemistry

12

9.0

Factors to be considered while installing a

chlorination system

15

Review

15

10.0

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Guidelines for Performance Optimization of P.T. Plant and

Chlorination System
1.0

INTRODUCTION
The performance of P.T. Plant and chlorination system profoundly influences the
performance of demineralization plant and cooling water systems. It is important
that the design, operational practices and trouble shooting procedures that ensure
optimum performance of P.T. Plant (clarifiers) and chlorination system needs to be
understood properly by the operating staff. This Operation Guidance Note provides
broad guidelines for optimum performance of clarifiers and chlorination system.

2.0

SUPERSEDED DOCUMENTS
Nil

3.0

CLARIFIERS
Clarifiers constitute a key component of pretreatment plant. The basic size
of a clarifier is a function of flow, configurations of equipment, pumps, sludge
removal mechanism and other miscellaneous apparatus which are usually at the
discretion of the vendor or equipment manufacturer. There are different types of
clarifier designs such as solid contact, sludge blanket, inclined-plate and adsorption
types. Most solid contact and sludge blanket clarifiers are of the up flow design
where the water flows up while the suspended solids settle down. Some of these
designs provide for increased solid contact from various types of internal sludge
recirculation systems which provide additional opportunities for colloidal particle
collisions - typically resulting in enhanced effluent clarity.
Retention time in clarification equipment is typically 1.5 to 3.0 hours, based on
conventional rise rates from 1.2 - 2.4 m/h. Although this range is normal for most
clarification equipment, much shorter retention times (e.g., 18 minutes) have been
utilized successfully.

3.1

Sludge Blanket Clarifiers

Reaction products, or precipitated solids are formed when the coagulant chemicals
and raw water impurities meet, settle slowly toward the bottom of the unit due to
the influence of gravity. In a sludge blanket clarifier the bulk of the precipitate does
not settle to the bottom but rather is kept suspended by a combination of gentle
mechanical agitation and hydraulic flow. The velocity of water flowing through the
clarifier unit is controlled to keep the precipitate in suspension, forming a blanket of
finite depth. Flocculated water from the mixing zone passes upward through the
layer of suspended floc and precipitated particles (sludge blanket) which enhances
agglomeration and capture of floc. Fig. 1 depicts the typical solid contact clarifier
whereas Figure 2 depicts a typical up flow sludge blanket clarifier. Operation of a
sludge blanket type clarifier is based on the principle that a particle is supported by
an upward moving stream of water if the velocity is high enough so that the action
of water on the particle exceeds the pull of gravity. As the upward velocity of a
particle decreases due to decreased water velocity as it ascends, a point is reached at
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which the particle becomes too heavy to be supported by the up flowing movement
of the water and it ceases to rise. As a result of these factors a well-defined
sludge/liquid interface is formed separating the sludge blanket from the clarified
liquid above. The center of the unit is shaped like an inverted cone allowing the
outer zone of the clarifier to possess the desired flow characteristics - decreasing
rise rate with increasing elevation.
Chemical

Clarified water

Chemical

Secondary Mixing
and Reaction Zone

Draft Tubes
Clean Water
escape surface

Rotor Impeller

Raw
water

Primary mixing and Reaction Zone

Discharge

Blow off and Drain

Slurry pool Indicted by shaded area

Fig 1 Typical Solids Contact Clarifier

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Mixing Zone

Fig 2

Up Flow Sludge Blanket Clarifier

Control of the depth and height of the sludge blanket determines the efficiency of
the unit. Higher sludge solids levels increase the filtration efficiency. The top of the
sludge blanket is carried at the highest practical level so as to prevent floc
carryover. Also, excessive sludge blow down should be avoided as it may disturb
the blanket. The sludge blanket level is responsive to changes in flow, coagulant
addition and temperature.
Variations of sludge blanket clarifiers include types which feature short inclined
plates (lamella) at the bottom of the sludge blanket layer or at the surface of the
water just prior to clarified liquid egress from the vessel. Inclined plates (possibly
equipped with deflectors) are added in an attempt to augment the clarification
process, either by concentrating the sludge blanket or limiting floc carryover as in
the two instances cited. Inclined-plate clarifiers are discussed later in this section.
One clarifier design utilizes a vacuum system to periodically apply a hydraulic
pulse to the sludge blanket layer in an attempt to maintain a stable sludge blanket
layer under higher flow loading conditions of 14.7 m/h depending on the
application. Inclined plates are present within the sludge blanket layer in that design
(Figure 3).

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Figure 3

Modified Sludge Blanket Clarifier

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3.2

Solids Contact Clarifiers

Figure 4 represents a typical inclined plate clarifier design. Raw water and
coagulating chemicals are introduced at the center of the unit where primary mixing
and reactions take place. Sludge and heavier particles settle toward the bottom.
Baffles are employed for flow direction and distribution. Large volumes of sludge
are circulated internally so that incoming chemically treated water will contact with
previously coagulated solids enhancing floc growth and settling characteristics. A
typical sludge recirculation rate is five to 15 times the raw water feed rate. Solid
contact units are particularly beneficial when attempting to promote a precipitation
reaction such as softening. Contact with recirculated sludge improves the efficiency
of the chemical reaction. Outside the reaction and mechanical mixing zones,
solids/liquids separation occurs in much the same manner as in a sludge blanket
type clarifier.

Flow Distribution Orifice

Discharge Plumes

Feed Box
Flocculation Tank

Overflow box

Flash Mix
Tank
Overflow
Effluents
Coagulant
tank

Feed
(Influent)

Lamella
Plate

Vibrator
Pack
Sludge
Hopper

Under flow sludge

Fig 4 Typical Inclined Plate clarifier

4.0

CLARIFICATION
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The clarification of water is a process applied mostly to surface waters for the
removal of suspended solids, finely divided particles present as turbidity or color,
and other colloidal materials. Conventionally the clarification process involves
coagulation, flocculation, and sedimentation. The primary function of the
clarification process is liquids/solids separation. Clarification occurs as a result of
increasing (through inter particle surface reactions) the size and density of particles
in the dispersed phase such that they separate and settle from the bulk liquid.
4.1

Coagulation
Removal of suspended particles which will not settle by gravity alone requires the
addition of chemical compounds commonly referred to as coagulants. Particulate
materials comprising dispersions may range in size from 0.1 to 100 microns (0.004
to 4.0 mils). Materials within this particle size range are termed "colloids". Non
settleable suspended particles present in surface water exhibit the properties of
colloids. The small size of colloids coupled with their surface charge is primarily
responsible for establishing conditions favorable for the creation of dispersions.
Stabilizing factors associated with colloidal dispersions are electrostatic charge and
hydration. These surface phenomena are of greater relative importance due to the
large surface area to total volume ratio of a dispersion of small particles. Further
mixing of coagulant should be carried out in such a manner that the shear imposed
on the water must not break up the floc it coagulates. In other words it should match
the floc strength at various stages of its formation.
Several factors tend to destabilize colloids. They are gravitational and Van der
Waals forces and Brownian movement. Gravitational forces are relatively small due
to the small mass involved in colloidal systems. Van der Waals forces are attractive
forces between particles that operate as molecular cohesive forces and can increase
in magnitude, as particles converge, at a rate thousands of times that of electrostatic
forces. Brownian movement is the random motion imparted to colloidal particles
from impact with molecules of the suspending medium. Kinetic energy of the
molecules increases as temperature increases, as does the intensity of the Brownian
movement. This phenomenon causes a destabilizing effect on dispersions. If
collisions between particles are stimulated, aggregation may result.

4.2

Flocculation
The principal functions of chemical coagulation are destabilization, aggregation and
binding together of particles. This involves neutralization of charges to destabilize
suspended solid particles. Once neutralized particles, no longer repel one another
and can be brought together. Flocculation initiates when neutralized or entrapped
particles begin colliding and growing in size. This process may occur naturally, or
the speed of reaction can be increased by the addition of coagulant chemicals and
coagulant aids. The processes of coagulation and flocculation are usually
accomplished by the addition of one or more of floc-forming compounds which is
usually ferric alum.
Except for sodium aluminate, all common iron and aluminum coagulants are acid
salts which lower the pH of treated water. Depending on initial raw water alkalinity
and pH, an alkali such as lime, soda ash or caustic may have to be added to adjust
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for the pH depression resulting from the addition of these acidic coagulant
materials.
Since pH can affect both particle surface charge and floc precipitation during the
coagulation process, it is an important variable. Iron and aluminum hydroxide flocs
are best precipitated at pH levels which minimize the hydroxide solubility. With
aluminum sulfate (alum), the optimum coagulation efficiency and minimum floc
solubility normally occur at pH 6.0-7.0. Sodium aluminate is alkaline and performs
best at elevated pH, (9.5-11.0). Iron coagulants can be used successfully over the
much broader pH range of 5.0-11.0. They are most often applied at a pH 9.0 and
greater, however, to minimize the solubility of iron in the treated water.
In the coagulation process, the chemical coagulant is added with rapid mixing to the
raw water to be treated. As precipitation initiates, the floc consists of pinpoint sized
particles. Flocculation follows coagulation, and the small floc particles are brought
together using gentle agitation or slow mixing, which forms large particles which
settle more rapidly. Agitation must be controlled so as to provide a high incidence
of collisions between suspended particles and continued adsorption of suspended
matter on the large surface area provided by the floc. Excessive agitation should be
avoided since it tends to shear the floc.
Jar testing is the standard method by which pH, temperature and chemical additives
(including order of addition and mixing conditions) are evaluated experimentally
for application to clarification processes. (Please refer Jar test Procedure as outlined
the Operation Information Note - Manual on Analytical Test Procedures for Water
and Steam in Power Plants: COS-ISO-00-OIN/OPS/CHEM/017)
Color in the raw water typically imparts higher levels of bacterial and algal growth,
causes fouling of anion exchange resin, and interferes with the coagulation and
stabilization of iron and manganese. Color reduction should be a prime objective of
clarification. Most organic color in surface waters is colloidal, negatively charged usually classified as humic or fulvic acids - and can be removed by a combination
of chlorination and coagulation with iron or aluminum salts at low pH values (4.55.5). Optimum pH for turbidity removal is much higher than that for color
reduction. Chlorine will oxidize some organic color compounds and the inorganic
coagulants will neutralize surface charges to effect the removal of those organic
particles which produce the color. However, chlorinated organic materials capable
of passing through the makeup system may also be formed.
Tips to ensure good floc:
1.
Alum works best at pH 6-7and ferric salts at pH 5-6.
2.
The coagulant dose may itself give the correct pH and if required, lime is
beneficial.
3.
Colour i.e. high humic acid is best removed at low pH. Further high humic
concentration interferes with the growth of floc and makes the water
difficult to treat.
4.
The ideal regime for mixing consists of a flash tank with violent stirring
followed by zones of decreasing shear to promote the growth of floc.
5.
Air bubbles should be avoided.
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6.
7.

4.3

Constant skilled supervision is needed to keep a pre-treatment plant

perform as per design on regular basis.
The following conversions come in handy in various computations with
respect to Pre-treatment plant :
1 ppm CaCO3 = 2.2.ppm as Al2(SO4)3 18 H2O
= 0.68 ppm as Al2O3
= 0.18 ppm as Al

Sedimentation
Sedimentation is the final step in the clarification process. Flocculated water from
the slow mixing phase flows to the settling zone where aggregated floc particles
settle out. As the aggregated or conglomerated floc settles, clarified (clear) water
rises and is separated from the sediment. Settled floc particles are removed
gravitationally in a thickened state (i.e. sludge) from the bottom of the
sedimentation vessel. Clarified water typically overflows from the surface and is
treated further through filtration equipment.

5.0

OPERATING CRITERIA
The successful operation of units for coagulation, flocculation and sedimentation is
dependent on a number of variables (discussed in ensuing subsections) - including
the following.

5.1

Temperature
pH
Raw water composition
Flow rate
Chemical addition
Effect of mixing and flocculation
Sludge blanket maintenance
Sludge blow down

Effect of Temperature on Coagulation

Coagulation and rate of floc formation are greatly influenced by the temperature of
the inlet water. As temperature decreases, the chemical dosage for effective
coagulation must be increased to ensure proper floc formation. The detrimental
effect of low temperature on floc formation can be minimized by proper design of
equipment to provide thorough mixing during flocculation. Even with optimum
design, more chemicals are required with colder water. Cold water slows both
coagulation and chemical precipitation reactions. In addition, settling rates are
affected by temperature changes. As temperature decreases, water density increases,
thereby lowering the rate at which floc particles settle.

5.2

Effect of pH on Coagulation

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The amount of coagulant required to effect good clarification varies with the nature
and amounts of suspended and soluble solids present in the raw water to be treated.
The pH may affect the magnitude and charge on both dispersed solids in the raw
water and on the micro flocs of precipitated coagulant materials.
The solubility of precipitated material is usually a function of pH. Coagulation
processes operate within a range of pH values in which the solubility of the
coagulant is low. For some processes, optimum pH range is narrow; for others, it is
comparatively wide; and for still others, there is more than one effective range.
Under controlled conditions, maximum flocculation with alum occurs at pH 5.5.
Maximum flocculation does not assure minimum solubility of residual ions
remaining in the treated water. The pH should be adjusted to obtain optimum
conditions for a specific coagulant and water supply.
5.3

Effect of Chemical Addition Sequence on Coagulation

The order in which chemicals are added will have a profound impact on the success
or failure of a coagulation process. Usually, a series of jar tests is conducted on raw
water to determine the best combination and sequence of chemicals to use, to
reduce suspended, colloidal and non-settleable matter from the raw water.
Procedures for conducting jar tests are available from various sources.
For instance, aluminum hydroxide is least soluble in the pH range of 5.8-7.2.
Outside this range, alum is a less efficient coagulant, and any residual aluminum
may foul the media of subsequent treatment equipment. The critical pH for
coagulation of specific impurities and for different types of water may lie in a much
narrower range than for aluminum hydroxide. For organic reduction (color), it is
typically pH 5.8-6.3. The coagulant dose and pH employed in the treatment plant
may then be adjusted to approach that which gave the best results during jar testing.
With experience, the operator will learn to interpret jar test data as a guide to
optimizing clarifier performance.

5.4

Effect of Mixing and Flocculation

An important requisite for successful coagulation and settling of suspended solids is
the rapid, thorough mixing of the various chemicals and the influent water. Rapid
mixing ensures uniform coagulant chemical adsorption onto the suspended
particulate matter destabilizing the colloids, thus increasing the chances for
collision. To prevent floc particles from breaking apart, any mixing speeds which
create excessive shear forces should be avoided. Rapid mixing time normally varies
from three to five minutes. This is followed by slow mixing to permit the floc to
grow in size and agglomerate into readily settleable particles. Slow mixing time
usually varies from 15 to 30 minutes. Shear forces should again be avoided during
floc growth periods to prevent newly formed floc from being torn apart. Sheared
floc particles may not readily agglomerate.

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5.5

Sludge Blanket Maintenance

In most conventional clarifiers, it is absolutely necessary to maintain an adequate
sludge blanket. The sludge blanket serves as a floating filter bed. Water containing
floc passes upward through the sludge blanket or bed where the accumulated solids
tend to filter out the floc. Additionally, floc growth is improved within the blanket,
further enhancing suspended solids removal. The height of the sludge blanket
depends on flow rate through the plant and the extent of sludge blowdown. It is
important to maintain an adequate sludge blanket to promote solids retention but it
is also necessary to maintain a clear zone above the blanket to minimize suspended
solids carryover. A clear or clarified zone of 6.5-10 feet (2-3 m) is preferred to limit
carryover potential". This is perhaps most important in sludge blanket units, but
also a consideration with sludge contact type clarifiers. It is not of importance in an
inclined-plate configuration, and is, in fact, a detriment.

5.6

Sludge Blow down

Sludge removal can be manual or auto. In case of auto blow down system a flow
type removal system is most popular. Each time a fixed quantity of water has
passed, an electric signal or pulse is transmitted to the blow down counter, which
results in one count. The counter is preset by the operator to a desired number of
counts. When the preset number is reached, the blow down valve operates and
sludge is removed. Sufficient blow down should be used to maintain sludge in fluid
condition to prevent plugging of the blow down lines or overloading of the scraper
drive. A back flush arrangement is employed on some designs to back flush the
blow down lines, thus minimizing blow down line pluggage. Operating personnel
should maintain a log on the blow down / backflush schedule used and indicate on
the log any changes made and the reason(s) for them.

5.7

Clarification System Monitoring Requirements

A variety of parameters should be monitored in any clarification system. All of the
following listed criteria should be recorded on appropriate log sheets on two hourly
basis (for flow rate and pH) and other parameters once per day and reviewed to
assess plant operating efficiency.

Flow rate.
Premix tank influent and clarifier effluent pH values.
Turbidity of premix tank influent and clarifier effluent.
Conditions and results of periodic jar testing to determine effectiveness of
coagulant doses.
Chemical dosages and feeder settings.

6.0

MAINTENANCE CRITERIA

6.1

Conventional Clarifications Equipment

One preventative maintenance operation that has proven beneficial is periodic
draining of each clarifier. This affords an opportunity to check underwater parts,
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hoppers, sludge scrapers, seals, bearings, orifices, etc. and remove accumulated
sludge and any scale buildup. Check the equipment supplier's Operations and
Maintenance (O&M) Manual for specific guidelines on draining frequencies.
Circular clarifiers have a gasket seal between the fixed center column and the
rotating mechanism that prevents short-circuiting between mixed water and return
sludge areas. The unit needs to be empty to check the condition of this seal. Sludge
can build up in the corners of noncircular clarifiers with circular scrapers, leading to
anaerobic conditions which can lead to gas generation and floating sludge, which
will carry over with the treated water. These areas can only be cleaned when the
clarifier is emptied. Also, anaerobic conditions can develop in the sludge layer
under the scraper arm, leading to the formation of sulfur-rich deposits. Frequently,
this area is missed during empty vessel inspection periods.
Since there are a variety of hinges, springs, counterweight systems, and other
hardware used by different manufacturers, the manufacturer should be contacted to
develop the best approach to these features. A list should be composed indicating
the equipment and inspection frequency. Detailed maintenance logs should be
maintained.
Other areas to include in the maintenance schedule are sludge blanket level
controls, return sludge flow controls, scum removal, weir levels, coating integrity
and others as indicated in the O&M Manual.
Based on experience, equipment operators will be able to develop their own list of
additional maintenance requirements.
7.0

TROUBLESHOOTING CRITERIA
Improper operation of the clarifier system will produce an unacceptable quality
treated water that will impact performance of all process equipment downstream.
Correction of out-of specification conditions in a timely manner is imperative.
Table 1 provides a list of the common problems associated with clarification and
flocculation systems and their causes and solutions.
Table 1

Symptoms
Causes
High
effluent Inadequate
chemical
turbidity, cloudy
treatment.
appearance,
Insufficient
sludge
in
colloidal silica at
recirculation zone.
clarifier outlet
Change in water quality.

NTPC Limited

Solutions
Check treated water analysis.
Check chemical feeders.
Check mixer speed (rpm)
Check recirculating sludge concentration.
Check automatic blowdown control and
valves for proper operation.
Check direction of recirculation; rotation
should be clockwise.
Perform jar testing to determine proper
treatment program. to address all the issues

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Symptoms
Continuous Floc
Carryover
with
Low sludge level
in setting zone.

Causes
Inadequate
chemical
treatment
Excessive
recirculation
speed
Air entrainment.

Intermittent
or
periodic
floc
carryover with low
sludge level in
settling zone.

Variable
raw
water
composition.
Erratic feeder operation.

Air entrainment.

Malfunctioning of variable
speed drive.
Repeated flow surging.
Variable re-circulating
sludge concentration.
Excessive back flush.

High sludge level

in setting zone.

Excessive quantities
sludge in the unit.
Light sludge.

of

NTPC Limited

Solutions
Check treated water analysis.
Check chemical feeders.
Assess chemical treatment requirements via
jar testing.
Check mixer speed (rpm)
Check raw water piping for air introduction.
Check raw water pumps for air leakage
through glands.
Check chemical pumps for air leakage
through glands.
Check chemical feed system for air
introduced by vortexing.
Check treated water analysis during difficult
period.
Run jar tests to optimize floc formation and
settleability.
Continuously cheek raw water temperature.
Check chemical feeder calibration.
Check chemical feeder for bridging for
calibration.
Check chemical pump delivery.
Check raw water piping for air introduction.
Check raw water pumps for air in leakage
through glands.
Check chemical feed system for air
introduced by vortexing.
Check re-circulator speed (rpm).
Check variable speed drive belt tension.
Check inlet meter for flow surging.
Check level controller for proper operation.
Check instrument air supply system and
pressure.
Check volume-over volume (ten minutes) at
upper and lower draft tubes.
Check blow down controller and valves for
proper operation.
Check back flush water pressure.
Check back flush timer setting.
Check re-activator operation without back
flush.
Check blow down controller setting.
Check blow off valves and timer operation.
Check re-circulating sludge concentration at
upper and lower draft tubes.
Check re-circulator speed (rpm)
Check scraper operation use a pole to feel
the scraper if shaft rotation is very slow.
Check blow off sludge concentration percent

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Symptoms

Causes

Thermal
convection
currents

8.0

Water
temperature
is
higher or lower than
ambient.
Water
temperature
fluctuates rapidly.

Solutions
volume-over-volume for ten minutes.
Check treated water analysis. Check raw
water analysis. Check chemical feeder
operation.
Check for settling rate in jar tests. Check for
septic sludge odor, color and pH. Check
mixer speed (rpm).
Insulate metal surfaces or cover clarifier.
Add storage tank ahead of clarifier to control
temperature variations.

CHLORINATION CHEMISTRY
The two most common chlorination chemicals utilized in fossil plant applications
are chlorine (Cl) and sodium hypochlorite (NaOCI). When gaseous chlorine (Cl) is
dissolved in water to form a solution, the chlorine hydrolyzes to form hypochlorous
acid (HOCI) and hydrochloric acid (HCl) as indicated in Equation (1).
C12+ H2O -- > HOCI + HCl

(1)

Both hypochlorous acid and hypochlorite ion (OCl-) are powerful oxidants, but the
hypochlorous acid (HOCI) can be 80-100 times more powerful as a biocide. The
germicidal efficiency of HOCI is due to the relative ease with which it can
penetrate cell walls but it is a relatively poor disinfectant because of its inability to
diffuse through the cell wall of microorganisms due to the negative electrical
charge. Chlorine is reported to induce a series of events associated with cell
envelope activity and to damage nucleic acids.
When sodium hypochlorite (NaOCI) is dissolved in water to form a solution, the
sodium hypochlorite ionizes to form the hypochlorite (OCl-) ion by the
following reaction (Equation -2).
NaOCI + H2O ---- > Na + + OCl - + H2O

(2)

Equations 1 and 2 represent reactions which would predominate in relatively pure,

buffered waters. In practice, however, there is a dynamic equilibrium between
hypochlorous acid and hypochlorite ion. For disinfection purposes, the desired form
of chlorine in water is as hypochlorous acid. The form in which chlorine is present
is a function of pH and temperature of the chlorinated water. Lower pH and
temperatures are desired because they affect higher ratios of hypochlorous acid to
hypochlorite ion. Chlorine gas decreases the solution pH, while sodium
hypochlorite additions increase the treated water pH.
8.1

Chlorine Demand
In most makeup treatment applications, sufficient chlorine is added to overcome the
chlorine demand, which refers to the quantity of hypochlorous acid or hypochlorite
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ion required to react with all chlorine-reactable components of the water supply.
The difference between the amount of Chlorine applied and the amount of free
chlorine remaining at the end of the contact period presents the free chlorine
demand of the water. Since the measured demand is specific to the contact period
and the temperature, the time and temperature should be noted when reporting
results.
In order to satisfy the chlorine demand (typically 1-5 ppm chlorine, although
chlorine demands of 10-15 ppm and higher [e.g., 25 ppm] are not uncommon in
some parts of the world), sufficient chlorination chemical has to be added to react
with the chlorine-consuming species and the ammonia or amines present and must
provide the desired free chlorine residual (usually 0.05 - 0.5 ppm). The total dose
applied is referred to as the chlorine requirement.
Table-2
Estimating Chlorine Demand
Concentration, ppm X Factor (Reference) = Amount of Chlorine Demand, ppm Free
CI2
Constituents, As
Iron, Fe
Manganese, Mn
Nitrite, NO,
Ammonia, NH,
Hydrogen Sulfide, HS
Organic Nitrogen, N
8.2

Factor (reference)
0.64, 0.6 , 0.63
1.3
1.5
6.3-8.2
8.3 - 8.5
6

Troubleshooting chart for Gaseous Chlorination Systems

Symptoms

Causes

Solutions

Shut valves leading to containers before

replacing containers. Purge chlorine gas
Corrosion products resulting
lines with dry air before and after long
from reaction of moist air, outages.
Plugging
of
chlorine, and piping while
Clean ports.
Small Ports
changing
containers,
and
Do not allow cylinders to sit in the hot
In Chlorinator
during long shutdowns.
Concentration of impurities in sun. Assure chlorine containers are at
ambient temperature before use. Clean
the chlorine gas as it cools.
ports. Install a gas filter ahead of the
vacuum regulating valve.
Chlorinator Will Insufficient Injector vacuum. Inspect injector operating water pressure.
Not Feed
Remove the throat and tailway and clean a
Properly
replace the part, if necessary.
Check for leaks in chlorinator
NTPC Limited

Page - 15
COS-ISO-00-OGN/OPS/CHEM/018 Rev. No.: 0
Guidelines for Performance Optimisation of P.T. Plant and Chlorination System
Symptoms

Causes

Solutions

Clogged vacuum
check unit.

regulator- Clean vacuum regulator/ check unit as per

instruction manual.
Clean gas supply line, chlorine inlet block
Clogged gas line.
and tube to head block.
Failed injector diaphragm Inspect O-rings and diaphragms; replace
check valve.
if needed.
Insufficient
water
supply
Increase water pressure.
pressure.
Low Vacuum
Reading
On Injector
Vacuum
Gauge

Erroneous
Rotameter
Readings

Inlet to injector throat may be Open and flush roughly. Check strainer
partially plugged by impurities periodically and dean, if necessary.
or small pieces of gravel or Check that all valves are open.
leaves. Discharge application; Chemically dean throat and tailway in
may have some stoppage muriatic acid. Periodically remove
causing high back-pressure.
affected component, steam-clean (metal

Booster pump suction filter parts only), line-dry completely and then
choking
reinstall the component.
Air leak upstream of vacuum
regulator.
Dirty rotameter.

Check all diaphragms and seals. Check

piping connections to the vacuum
regulator.
Check calibration.

Plugged gas filters or drip Periodically clean filters and drip

heater.
heaters.
Low pressure in chlorine Change the chlorine cylinder
Low
Chlorine
cylinder
Feed Rate
Outdoor storage with low
Increase number of chlorine containers in
outdoor temperature (<50service (when chlorine gas is withdrawn
60F, 10-16C).
directly from cylinders or ton containers).
Changing in raw water chlorine Increase chlorine feed.
demand.
Malfunctioning
chlorine
analyzer
(if
present).
Inspect reagent delivery. Check reagent
Low
Chlorine
quantities and replenish if necessary.
Air ingress from the lines
Residual
False
indication
rotameter
Corrosive
Damage
to
Piping
or
Equipment

in

the Recalibrate analyzer.

Ensure actual flow of chlorine

Leak(s) exposing non corrosion

Periodic external inspection to identify
resistant materials to chlorine
and correct leaks.
solution.
Inappropriate materials used
Replace affected components with others
for components in contact with
of appropriate materials.
chlorine.
NTPC Limited

Page - 16
COS-ISO-00-OGN/OPS/CHEM/018 Rev. No.: 0
Guidelines for Performance Optimisation of P.T. Plant and Chlorination System
Before performing maintenance on the system, shut off the chlorine gas supply,
purge lines of chlorine, and then turn off the water supply. Other applicable
precautions and procedures indicated in equipment manuals should be followed
also.
9.0

Factors to be considered while installing a chlorination system

1. Determine the pH of the raw water
2. Calculate the contact time (The contact time for the chlorinating agent
and water should be at least 10-15 minutes with longer contact time
more desirable.)
3. Determine or estimate typical temperature variations.
4. Decide the desired free residual chlorine level ( typically it varies
between 0.05 0.5 pm )
5. Determine the chlorine requirement for maintaining a free residual.
6. Determine the chlorine dose from the chlorine requirement and
maximum flow rate of raw water.

10.0

REVIEW
The Head of Operation services will be responsible for reviewing this document
on two yearly basis or as necessary.

NTPC Limited

Document for Distribution to:

CONTROLLED
I. Power Stations
1. General Manager
2. General Manager
3. General Manager
4. General Manager
5. General Manager
6. General Manager
7. General Manager
8. General Manager
9. General Manager
10. General Manager
11. General Manager
12. General Manager
13. General Manager
14. General Manager
15. General Manager
16. General Manager
17. General Manager
18. General Manager
19. Addl. General Manager (I/C)
20. Addl. General Manager (I/C)

UNCONTROLLED
II Regional Head Quarters
21. Executive Director (NR), Lucknow
22. Executive Director (SR), Hyderabad
23. Executive Director (WR), Mumbai
24. Executive Director (ER), Patna
25. Executive Director (NCR), Noida

Rihand
Vindhyachal
Kahalgaon
Farakka
Dadri (Coal & Gas)
Unchahar
Korba
Ramagundam
Singrauli
Talcher Kaniha
Simhadri
Badarpur
Faridabad
Kawas
Tanda
Anta
Auraiya
Jhanor Gandhar
Kayamkulam
Talcher Thermal

III Corporate Head Quarter

26. STA to Chairman & Managing Director, SCOPE, New Delhi
27. STA to Director (Technical), SCOPE, New Delhi
28. STA to Director (Operations) , SCOPE, New Delhi
29. STA to Director (Commercial), SCOPE, New Delhi
30. STA to Director (Projects) , SCOPE, New Delhi
31. Executive Director, PMI, Noida
32. Executive Director (Engg.), EOC, Noida
33. Executive Director (OS),EOC, Noida
34. General Manager (R&D), Noida
35. General Manager (CENPEEP), Noida
36. Concerned Group Heads in Operation Services, CC

IV

Head of O&M

37. Singrauli

38. Korba

39. Ramagundam

40. Farakka

41. Vindhyachal

42. Rihand

43. Kahalgaon

44. Dadri(Coal)

45. Unchahar

46. Talcher Kaniha

47.Talcher Thermal

48. Badarpur

49. Simhadri

50. Auraiya

51. Anta

52. Kawas

55. Kayamkulam

56. Faridabad

53. Jhanor Gandhar 54. Dadri (Gas)

57. Tanda

Head of Chemistry

58. Singrauli

59. Korba

60. Ramagundam

61. Farakka

62. Vindhyachal

63. Rihand

64. Kahalgaon

65. Dadri(Coal)

66. Unchahar

67. Talcher Kaniha

68.Talcher Thermal

69. Badarpur

70. Simhadri

71. Auraiya

72. Anta

73. Kawas

76. Kayamkulam

77. Faridabad

74. Jhanor Gandhar 75. Dadri (Gas)

78. Tanda

79. Sipat