BASIC ENGINEERING PACKAGE FOR SOFTENING PLANT CLIENT : MAHARASHTRA STATE POWER GENERATION CO.LTD. [Owners Consultant :Development Consultants Private Ltd.,Mumbai BOP Contractor :TATA Projects Ltd., Hyderabad BOP Contractor’ s Consultant :TATA Consulting Engineers Ltd., Bangalore Document No.A4-A20154-12-003 ION EXCHANGE (INDIA) LIMITED R-14, TTC MIDC, THANE BELAPUR ROAD, RABALE, NAVI MUMBAI -400701 TRanARaSiTRA STATE POWER GENERATION CO. wer [ro provecr:|2 x S00 mW SHUSAWAL TES consuavr|: |- roe eancatone avr; [sorrenns plant fonte ENGINEERING PACKAGE [ET BOC HOC | AERODISETE-OOT c PREPARED BY [Vo et a ciecKeD By —[NKP > in feesoves by [ssR [HEC rit —Dare | — ANENOMENT — REPROVED B t DATE [2008“i Gnatan”[ Wr Us Dong (25] AS AAFC] Aer Raa PETE (200m Ea (opm) a Beau [os otba] wamec | 26 C03 [wrmen|es cocoa] asm | as CDs rary norma fier (ry rancor fu An ww fercura foe pee [eco a apeo mr ane TS TS seer oreMAHAGENCO ‘SF Feed Water Analysis Parameters Unit ae assuch_[ as Caco3 [cations Calcium ma/! 107.2 268.0 Magnesium ma/t 18.5 77.0 [Sodium mg/l 93.4 203.0 Potasium ‘mg/l 7.8 10.0 FTotal Hardness mg/l : 345.0 Total Cation ma/t 7 558.0 [Anion Bicarbonates maf 385.7 3162 [Chiorides ma/l 107.8 151.8 Sulphates: mg/l 83.5 87.0 Nitrates ma/l 25 2.0 Flouride mg/t 0.4 1.0 Total Anions mg/l 5 358.0 EMA. ma/t 7 241.80 FMA ma/! : 241.80 Silica ma/t 36.0 30.0 pH 5 30785 5 Temp °C 22 - 30 = [Conductivity uS/cm = = Turbidity (Normal) NTU <2 - [Turbidity (During Monsoon) NTU <2 = {TDS ppm 870.00 = P Alkalinity as CaCO3 ppm : : IM alkalinity as CacO3 ppm’ = = lorganic matter as KMnO4 ppm = Total Alkalinity as CaCO3, ppm ~ : fron as Fe 1.00 5 TON EXCHANGE (INDIA)LTD. [PREPARED BY_ ae [CLIENT : MAHAGENCO / TPL ICHKD & APPD_BY _: NKP_Det~ 4 [CONSULTANT DCPL / TCE DATE 3.06.2008 [SHEET 3 of Ti,‘Sodium Sulphite Dosing System to SF Feed Water a Description Unit Alum Romarks 7 [Flow rate of Each SF mh 250.0 2_[Number of Working Vessel at a ime Nos, 12.0 +258 3 [Total SF Flow mith 3000 3 [Total Feed Pump Flow mh 3200 4 [Maximum Free Residual Chlorine in Feed Water mail 1.00 5 [Sodium Suiphite required per ppm of FRC. mgit 177 [Sodium Suiphite required (100%) gi BETES 7” [Punty of Chemical considered wiv 95 & [Dosing rate gi 5977.76 ‘9 [Strength of Na2SO3 Solution: Yowiv 10 10 [Dosing rate required Iph 60 711 [Pump Capacity provided ph 100. 72 [Pump Head required / provided Es mwe 30 713 [No of Dosing Pump considered : 1 +18 74 [Storage Capacity @ i 15 [Volume ofthe tank required im 0.72 76 [Design margin % 20 17 [Volume ofthe tank calculated m 0.86 Vertical ‘18 [Tank Tyre : Cytindrical 79 [Tank bottom : Dish End 20 |Tankcend : Flat 21 [Material of Consirucion 6s. 22 |profecion RL 23 [Diameter oFtank considered mam 7200 24 [Cross section area nm 7.118 25 |Dead end atthe botlom ofthe tank mm 700 26 |Fres Board mm 250 27 |HOS required : mam 1122 28 |HOS Provided mm 71200 29 [effective volume 0.947 30 [MOC of Agitator 35316 31 [No of Dosing ank Considered 5 One. TON EXCHANGE (INDIA) LIMITED Prepared by VO Giient Wiahagenco7 TPL Checked & Approved by E NKP__N@ refer [Consultant : DCPL/TCE Date 03.06.08 JSHEET NO _:04 of 11MAHAGENCO Softening Prant = Panesion oe = mene 7 [ese : rH 2 [ean Gd a ET 5 [Resenerne ei : wach 5 [Rexeneant Tempers cs 7 [oma fn Pe Siem mn Pe + [nian Fw Per Seen mn Ses @ |x Fw er Set emf 300 2 [busion Tne n 7% TO et Ono er ~ 5000 Tr [we War bow Sea = 8 1 [nat woes m= 308 1 [tate Water Up Seam 7 300 a [ress tut er Ce | 00.0 15 [ves Pw tate am [25000 Tein oa ts G05) re ee OT 17 [issenenton er! 05%) Pr ee Te [scare Cty am | Ss TB [CE Temp eae ; 00 20 tone ato 1 : 10375 21 [eto a2 : 1.000 22 [bern Factor : 0900 25 [tal Corecon Can : 0938 34 [bein age Caney vam [5099 enor Perle [ae 5s [eee Youre sel WO paar 27 [si Sp Fw ae (8 wna [40 35 Et ean oune based on bh ra 70 25 [Eel Resin volo re ETE]30 [Maximum Surface Flow Rate mepiyen? 40 31 [CS area based on Max Sur Flow me 7.500 232 [Maximum Resin Depth ram 73000 133 [es area based on Max BD me Ter [34 [Minimum Cross Section area read = 1424 35 [Minimum Unit Diameter Calculated mon 3813 36 [Unit Diameter Provided mom 4000 37 [Unit Cross Section Area provides mm 1.571 36 [inimur Resin Depth mam 1000 39 [Total Resin Depth rem 2726 40 [eutfer Resin Volume me (0.000 “i [Active Resin Volume me 34.272 42 [Depth OF nert Layer mm 0.000 “43 [Inert Resin Volume m 0.00 “4 [Total Resin Volurme Required = 34272 5 [Resin Bed Depth incid Tart Resin oa 2726 “46 [Resin supplied in - ‘Na Form 47 |Rersin Bed Depth when regenerated 2726 48 |Rersin Bed Depth when Exhausted 2726 TN remariabie change 49 | Free Board Required % 30 50 |Free Board Required mm. 2181 51 [HOS Calculated mm 4907 52 |HOS Provided (Multiple of 500 mm) 5000 53 |Surface Flow Rate @ maximum flow rate meynlen® 23.86 54 [Surface Flow Rate @ mimimum flow rate meng 19.88 '55 [Specific Flow Rate @ maximum flow rate yh 875 '56 [Specific Flow Rate @ minimum flow rete mfivin® 7.25) 57 [Stoich Regenerant Reqd, as CaCO 9 1724.86 158 [Chemical Regen. (100%) kg 2638.92 59 [Conversion Factor i 0.855 60 | chemical / Regen. (as CaCO3) ‘9 2255.43, <1 [Unuttised chem (a5 CaCO3) 9 530.62 (62 [Neutralization Chemical Type NONE 65 [Qty of Neutralization Chemicals (100%) @ e 64 [Regeneration efficiency % 76.47 65 [Pressure Loss Across Bed gfe zi TOR EXCHANGE (INDIA) LTD PREPARED BY EVD. [oueNT TARAGENCO [TAL ‘CHKD & APPROVED BY KE af CONSULTANT | DcPL / TCE DATE, 73.0608 [SHEET NO 05 of IhSoftening Plant Calculation Without Derating Factor MAHAGENCO Z| LE Paramore oa F Remarks 7 [ean ak : ra -| 2 Jes Ga [bron 3 [Regeneron aia : wah 4 JResereraton Howe : erect 5 [Repenerat Tenperstire * 30 © [Rerna ow per Som wm 5 7 [imum Fw ar Stream mh 255 sii Fw er Seam hh 300 9 [esteuston Tine f 20 10 ket ouput Per Gye 7 500 12 [vote Water Se 7 o.a0 12 ste woter Up Seam 7 0.00 1a [oss Onna er Cv m= | 5800.00 15 [res Fw Rte wh | 275.00 Te oc ond GOOD wah [aa aa ar tender spes [7 [Regereravon ve 0050) rah FT| 30 (ove a 16 [bchange Coeety taint [88 zo Gr Temp /Beepth 1000 2o eee Rao : 0378 2a [er fone nave? E 1000 22 [Deratin Factor : 1.000 [without brating 23 fetal corten Gp : 7038 [loss ect eat vain [55.92 25 [nor bone ar Gye ie e075 26 [ef es Volare based on WO me ae829 27 vim Sp ow ate (7) amms |_«9 | 20 Resin Vlune based on bv © 750 aa [eect ean volume_caulted ee 5o rat Resin Volume Proved mL saara_|fenes Ok | excrangeNDIAyEYD iE PREPARED BY VO. [CLIENT [ MAHAGENCO 7 TPL ‘CHKD & APPROVED BY, [NKP_)Refea| CONSULTANT, ‘CPL / TCE Site See ere basaHAHAGENCO, EGNERATION FLO} [co FLOW REGENERATION fe Basis__—| Flow | “time | Vat z Water z jeneration steps or . §| Regeneration steps | in3yhr/m? | mévhe | min | m? | source [val of Spent Brine to be injected aa Spent Brine Injection Rtae 700.0-| mh (Quantity of Fess Salt (10036) 2639 | kas Saturated Salt Soin Conc 30 | % w/v Nolume of saturated Sale Suton 380m Salt injection Concentration 10.07 | % w/w [Volume of Diluted Safe Solution 254 _[ om fresh Brine Injection Time 20.07 —min Dilution Water Rate 52.8_[ mh Fresh Brine Injection Rate 73.2-[ mf —[Seciwash amin [iia se] 943] Feed, § | spent shine Tnjecton ‘Spent brine | 200-00 | —14—| 47.47 | Feed 8 [eateinjection To Se wv Naci|_ 79.17 | —20—| 26.39 | Feed ® [Sole Rinse (1 5V) Dil Water How { 52.78-| 39 | 34.27 [Feed € [final Rinse (36) Service Flow [250 [25] 102.82 | Feed & [rotal Time for SAC Regeneration 03 8 Regeneration Flow | (7am) 1 6.30 For Salt Recycle Half ofthe Injection flow rate + Total Volume of displacement Rinse COUNTER CURRENT REGENERATION, z ; Basis Flow | time | Val Water z jeneration ste basis : Si) et errereanecmere se sit raved | tw] salen m__| source al of Spent Brine to be injected war] [Spent Brine Injection Rae 200.0-| “mh [Quantity of Fress Sal (100%) 2639 | _ kas Saturated Saft Soin Conc 30 | % w/w Rvolume of saturated Salt Solution 3.80_[ om Sale injection Concentration 10.07 | % w/v Volume of Diluted Salt Solution 26.4 | m fresh Brine Injection Time 30.07 —min Dilution Water Rate 52.8 [mh Fresh Brine Injection Rate 73.2_[_m'fh [Baciavosh (Optional) omiya? [asia [as] 943 [eed [Spent Brine iy “Spent Bring1 200.00} —i4 —| 47.47 | Feed TO Nma7h/mz Down Air Hold on eae | asta | Air Fresh Bane Tal TotewvNacl | 7947 | 20 | 2639 [Feed 1 1.0 Nema/hyme “ 5 Down air Hold on zonmsnm2 | 754 | 20 Ai p= Rinse (16) Di water rae | 578 | 52 | 3897 | Feed TO Nen3/h/me * s Down Air Hold on onmsmmima | 754 | 52 A Final Rinse (35W) Service How [250| 25 | Toxez | Feed Total Time for SAC Regeneration 116 Regeneration Flow | (maynima) [630 For Salt Recycle Half of the Injection flow rate Rinse TON EXCHANGE (INDIA) LTD + Total Volume of displacement PREPARED BY VO. [CLIENT TARAGENCO] TOL ICHKD & APPROVED BY KP AROSPA” [CONSULTANT CPL / TCE DATE 03106.08 SHEET, O7 of it[Some essential Information Total Volume of waste Net Output Hardness Slip from SF NaCl used for regeneration Unit SF mm 172.50 im 5000.00 mg/l as CaCOs 5.00 kg (100%) 2638.92 parameters nn SF Feed Water ‘SF Regeneration Waste as such ‘a5 CaCOs ‘as such as CaCO) Physical parameters 7 [pH = 50-85 : 3.00 = 2 [Total Dissolved Sods | mg/l 454.17 zi 74814.91 = [Chemicals parameters. ‘A Cation 1 [calcu mall 107.15 268.0 3070.75 7676.86 2_ [Magnesium mg/l 18.48 77.0 517.05 2154.37 3 [Sodium mg/l 93.38 203.0 1730.26 3761.44 ‘4 [Botasium mg/l 7.81 10.0 7.81 10.0. ~ [Total Hardness _|_-mg/l = 345.0 = 9631.23 FFotal Cation mg/l = 558.0 = 13602.65 @ Anion 1 [P-Alkalinit mg/l = 0.00 = 5 2 [M-Alkalinity mg/l e 316.16 5 316.16 3 |Bicarbonates mg/l_| 385.7104073 | 316.16 3E5.71 316.16 ‘4 |Carbonates mg/l o 0.00 a SI 5 |Hydroxides mg/l o 0.00 = = 6 [Chlorides mg/l_| 107.7694 151.75 9369.50 3196.49, 7 [Sulphates mg/l 83.54 87.02 83.54 87.02 [Nitrate mg/l 2.47 1,99 2.47 1.99 9 [Flourides: mg/l 0.38 1.00 0.38 1.00 = [EMA mg/l - 241.8 : 13286.5, {Total Anion mg/l = 558.0 : 13602.7 © Ohers 1 [silica (Reactive) | ma/l 36.00 29.85 36.00 29.85 2 [co mg/l 6.31 737 6.31 7a? Note : Composition of regeneration waste will be same both for co-flow and counter flow regeneration system due to air hold on sytem for regenarion of counter flow system to prevent the dilution of the spent brine. TON EXCHANGE (INDIA) LIMITED Pepartby v6 cent TARRCENCOTTAL Creo pov Nabe 86h Jeweutans —:0¢PLIToE ba oaes.08 sheet og oftTT 106 1334S] ava] 351/749 INVLINSNOD| aN | Ka TaAOuddW 8 OAHD, Tdi OONSDVHVW inar| Aa Gauvasd “GIT(VIGN_ SONVHOXS NOL 7 Teme 7 cour | oma | om] mes | Seal 00°00€ (00°00, 00°00¢ 00'00e ‘00°0091, we ‘Ayseded| Z : nao | sueyeem0) | sduing stund use stung usa |egunfeuealezundiaruen| enone | - at 48241 auuq sey ‘eug sens | seem 4S rag wu a a SoS BS WEL zz s8z SLZ ez oss w ‘payinbey qy6I9H WEL] EL zo zo zo zo zo w qWBI9H PeaG| ZL £0 oe'o so £0 £0 we pubog 8244! LL or 3 8 coe | are] 8 aT eee ea] Ze EbL air 06 BEL 00002 00'000z eu Ayoeded duiog yea] L oe 00°02 a = - % wibew! ore 6S Ab Gel 002 000z ew (ds ua) Aysedeg dog yes] ¢ zi z z z 2 : SSS aT F = SMEIS / UOHEOT| 904 908 90u Ou 208 - SOW] Z se ant cwrema] uses] mea | amas | 1sca | same | mn S uondusseg iS Burzs Yue L ‘OONSOVHVIN‘Salt Storage Area Ist No Unit Values Remarks 1 _[Saltto be stored for MT 500 2 _|Salt Required per day per regeneration per SF Tons 2.639, 100% '3__[Number of Working SF : 12 “4 _|Salt required per day Tons: 31.667 5 _ [Salt Purity % wh 90.5 6 _ [Total Salt required per day Tons 31.826 7__ [Bulk density of Salt Tons /m> | _0.80-0.90 {8 _|Salt Storage Volume required im 625.0 ‘9 __|Wiath of the Salt Unloading Area provided m 30 10 [Truck appoaching Road Width 7m 8 “11_|Wiath of the Each side Salt Unloading Area provid| mm 1" 12_[Average Stack height of Salt m 1.0) 13 _|Area required m2, 625 14 _ [Length of Length Required m 28.41 16 [Length of Salt Storage Area Provided m 35.0 Unloading Salt Storage Area rest TON EXCHANGE (INDIA) LTD. PREPARED BY ce THAAGENCO, CHKD & APPROVED BY _—_ NEC CONSULTANT |: TCE DATE SHEET NO [10 of IiMAHAGENCO BRINE FILTER, Type. ‘Single Bed Remarks No. of Filters 2 Design flow per gravity filter invita - [Max.flow per gravity filter [m°/he Filtration rate m/b/m* 5.0 Specified in Tender [Size of each bed (L) im. 5.00 Size of each bed (W) [Provided _|m 3.00. Flow rate from each Filter m/h 75.00 Brine depth im. 1.50 Media depth im 0.75 Free board im 7 0.50) (Underbed At Im 0.50) [Total height. [rv 7 3.25 (Considering sequential _air and backwash operation [Backwash air volume basis| INm?/h/m? 75.0 Specified in Tender Blower flowrate INm?/hr 1125.0 [Blower flowrate provided INm?/hr 1200.0 Head g/cm? 0.40 Back wash water velocity m°fiym? |= 30.0 Fliter bed surface area m2 15.0 Backwash flowrate > 450 [Backwash Water Source m*/hr by Filter Water HTime of Backwash min, 5 [Backwash water volume Im = 37.50 [Time of Rinse min z Rinse water volume per Bed im? 6.25 Back wash water Volume per Day m/day [= 87.50 TON EXCHANGE (I TID. PREPARED BY VO, (CLIENT 7 MAHAGENCO. ICHKD & APPROVED BY |: NKP CONSULTANT |: TCE DATE 03.06.08, SHEETNO |: 11 of 47