Professional Documents
Culture Documents
Electro‐Chlorination Plant
Jawa‐1 Combined Cycle Gas
Turbine Power Plant (1760MW)
Albert Lim, De Nora Water Technologies Singapore
May/2021
CONTENTS
• Introduction
• Design Criteria
• Equipment description and control
• Electrodes
• Safety Instructions
• Operation
• Troubleshooting
• Maintenance
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INTRODUCTION
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Biofouling – Definition & Need for Prevention
What is Biofouling?
• Incrustations caused by hard
shell organisms such as
barnacles and mussels
• Slimes caused by bacteria and
algae
What are the negative effects of
biofouling on seawater cooling
circuits?
• Reduce seawater flow
• Reduce heat exchanger
efficiency
• Corrode condenser pipes
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On Site Hypochlorite Generation
Electro‐chlorination – Onsite Sodium Hypochlorite Generation
Biocide to prevent slime and marine growth (biofouling) at Intake Pump Bay and Intake Header
(Riser).
Applications:
Power and industrial plants
Desalination plants
LNG Terminals
Seawater electro‐chlorination generates a powerful biocide and disinfecting agent (dilute
bleach: Clorox is 5%, SEACLOR® is < 0.2%)
• Combines three common consumables: salt, water and electricity
Continuous injection of hypochlorite at the rate of 1 to 3 ppm (seawater temp >15º C) will
assure complete control of biofouling in most cases.
• Dosing rates depend on biological demand
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Generation of Sodium Hypochlorite
Anodes are ACTIVATED with a mixed oxide electro‐catalytic layer, DSA®
H2 (gas)
ANODE + NaOCl
- CATHODE
DSA
Seawater
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Side Reactions
Precipitation of magnesium hydroxide
Precipitation of calcium carbonate
Precipitation of Manganese and iron ions on Anodes
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Principle of Operation
Electrolysis
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SEACLOR® Electrolyzers
Electrolyzer with End Covers Removed Electrode assembly and Body
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DESIGN CRITERIA
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Design Basis
Design atmospheric pressure 1010 mbara
Design ambient temperature 31 degC
Design relative humidity 75%
Seawater temperature available at battery limit 25 – 35 degC
Seawater pressure available at battery limit 2.5 – 6.5 barg
Seawater flow available at battery limit 12.5 – 40.5 m3/hr
Seawater quality available at battery limit See attachment
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Design Parameters
Seawater to be treated 6,500 m3/hr
Hypochlorite solution concentration (at 100% current) 2000 mg/l Cl2 av.
Continuous dosing rate at Seawater Intake Header 3.0 ppm as Cl2
(Riser)
Shock intermittent dosing rate:
• Seawater Intake Header (Riser) 3.0 + 3.0 ppm as Cl2
• Seawater Intake Pump Bay and Pump Station 3.0 + 3.0 ppm as Cl2
Production at 100% of current (Per Electrolyzer): 25 kg/h available Cl2
Total Production: 25 kg/h available Cl2
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EQUIPMENT DESCRIPTION AND CONTROL
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Seawater filtration
Pressure Regulating Valve (00PUS10AA600)
• Regulates incoming pressure from 6.5barg to 2.5barg P&ID
Pressure Safety Valve (00PUS10AA901)
• Sets at 3.5barg.
• Installed after Pressure Regulating Valve (00PUS10AA600) to protect the
plant from over pressure due to Pressure Regulating Valve failed in
opening position.
Automatic Self‐Cleaning Strainer (00PUS11/12AT001)
• 2x 100%, 1 duty, 1 standby
• Rated capacity: 40.5m3/hr
• Screening size: 500 microns
• Remove solids from seawater and automatically eject collected material
to drain without interrupting the main flow of strained water.
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Seawater filtration
Automatic Self‐Cleaning Strainer
(00PUS11/12AT001)
P&ID
• Backwashing start when pressure differential
(00PUS11/12CP001) reaches pre‐set value of 0.4barg
or after a predetermined lapse of time (2‐4 hours).
• Fine screen filter element is cleaned by the suction
scanner whose nozzle spiral across the inner surface of
the screen.
• Filtration cake is “vacuumed” from the screen and
expelled out the exhaust.
(1) Screen cylinder
• Solenoid valve (00PUS11/12AA200) is activated and (2) Inlet
5.7m3/hr of seawater discharge during the duration of (3) Outlet
the cleaning cycle.
(4) Exhaust valve
(5) Drive unit
(6) Suction Scanner
(7) Electronic Flushing Controller
(8) 3‐way Solenoid Valve
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(9) Pressure Differential Switch
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Seawater filtration
Automatic Self‐Cleaning Strainer (00PUS11/12AT001)
• 1 cleaning / flushing cycle ~ 16 seconds. P&ID
• If normal pressure differential is not re‐established,
another cleaning cycle is started.
• > 5 cycles = filter still clogged, generate fault signal.
• Automatic switchover to standby unit every 2 days.
• For the strainer not in use, empty the strainer
completely, fill it with fresh water, then drain fresh
water in order to dissolve and/or remove the last traces
of the salts contained in seawater and finally leave the (1) Screen cylinder
strainer empty until it is placed in use. (2) Inlet
(3) Outlet
(4) Exhaust valve
(5) Drive unit
(6) Suction Scanner
(7) Electronic Flushing Controller
(8) 3‐way Solenoid Valve
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(9) Pressure Differential Switch
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Sodium Hypochlorite Electrolyzer
(00PUS21/22AG001)
• 2 x 100% (1 Duty, 1 standby) P&ID
• H8.100‐R: 8 electrolytic cells of modular construction
• 25 kg/h available Cl2
• Design pressure: 5barg
• Design temperature: 60deg C
• Parallel Plate Bipolar
• Cathodes of every electrolytic call are directly connected to the anodes of next cell.
• Material of Construction
• Filament wound FRP with internal line PVC housing
• Titanium with DSA® platinum group metal oxides coating anode
• DSA® ‐ to decrease the electrolysis potential and prevent titanium corrosion.
• Titanium cathode
• Guaranteed life of electrodes is 5 years.
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Sodium Hypochlorite Electrolyzer
(00PUS21/22AG001)
• Two electrolyzers installed in hydraulic series: 12.5m3/hr of seawater flows from the
P&ID
electrolyzer “1” to “2”. To avoid excessive scaling on the electrode surface, operate the
unit at normal seawater flow of 12.5m3/hr and must not be < 10m3/hr.
• Two electrolyzers are connected in electrical series to the rectifier and are operated in
range of 10~ 100% rated full current.
• Produced sodium hypochlorite solution, together with by‐product hydrogen, flows
through the outlet header to the Hypochlorite Solution Storage Tank (00PUS31BB001).
• Produced by‐product hydrogen: 8.75Nm3/hr
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Grounding Probe
• To isolate stray DC current from electrolyzing other components. Replace when consumed
or every 2 years.
P&ID
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Transformer Rectifier
• Consists of rectifier transformer and one silicon
thyristor rectifier
• 2 x 100% (1 Duty, 1 Standby) P&ID
• Rated D.C current: 1500 ADC, Rated D.C voltage: 80
VDC
• Current efficiency: more than 80%
• Direct current (D.C) specific power consumption: 4.42
kW/kg available Cl2.
• Production rate of 25 kg/h available Cl2 when
electrolyzer is operated at load of 1500 ADC.
• D.C current automatically kept stable by rectifier
control system at the pre‐set value, with accuracy of
±1% rated full current.
• Seawater flow to each Sodium Hypochlorite
Electrolyzer kept constant at 12.5m3/hr.
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Transformer Rectifier
Concentration of Sodium Hypochlorite vs Current
P&ID
Available Chlorine Production vs Temperature
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Sodium Hypochlorite Storage Tank
(00PUS31BB001)
• 1 x 100% P&ID
• Rated capacity: 20 m3
• 15 minutes retention of chlorinated seawater in Sodium Hypochlorite Storage Tank.
• Vertical conical bottom, designed for atmospheric pressure
• Materials of Construction: corrosion resistant GRV + UV Protection
• Accessories: 2 x 100% Air Blowers and Level Transmitters for pump interlocks.
• By product hydrogen, which is lighter in weight than air, disengages from the liquid phase
in the upper part of the tank.
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Dilution Blower (00PUS61/62AN001)
• 2 x 100% (1 Duty, 1 Standby)
• Rated capacity: 1170 Nm3/hr @ 217.1mmH2O
• Duty Dilution Blower dilutes the hydrogen to less than 1% H2 P&ID
(by volume) and safety vented to atmosphere.
• Lower explosive limits (L.E.L) of a hydrogen/air mixture is 4%
hydrogen.
• Standby blower starts automatically once the duty blower fails.
• Inlet filter screen installed on the dilution blower’s suction to
prevent unwanted debris from being admitted into the vent
system.
• Non‐return dampers prevent backflow through the standby
blower during operation.
• Thermal Mass Flow Meter (00PUS60CF001) and Pressure
Transmitter (00PUS60CP001) installed at the common
discharge of the Dilution Blowers.
• Pressure gauge (00PUS61/62CP500) installed at discharge of
each Dilution Blower.
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Sodium Hypochlorite Dosing
Dilution Pumps with VSD (00PUS51/52AP001)
P&ID
• 2 x 100% (1 Duty, 1 Standby)
• Capacity (Operating/Rated): 19.6 / 22 m3/hr
• Total Differential Head (calculated): 19.6 m3/hr @ 2.44 bar
• Total Differential Head (selected): 22 m3/hr @ 4 bar
Dosing Pumps with VSD (00PUS41/42AP001)
• 2 x 100% (1 Duty, 1 Standby)
• Capacity (Operating/Rated): 19.6 / 22 m3/hr
• Total Differential Head (calculated): 19.6 m3/hr @ 4.81 bar
• Total Differential Head (selected): 22 m3/hr @ 6 bar
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Sodium Hypochlorite Dosing
Dosing Destination Dosing Type Frequency Dilution Pump Dosing Pump Remarks
Continuous 9.8m3/hr 9.8m3/hr
P&ID
Seawater Intake Pump After shock dosing, run Dilution
Bay and Pump Station Pump at 19.6 m3/hr to flush
for 5 minutes.
Plant shutdown 19.6m3/hr Flush for 5 minutes
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Hydrogen Detector (00PUS20CQ001A/B)
• Installed under ceiling of the Chlorination Mechanical Container in the Electrolyzer area.
• Monitor hydrogen level between 0‐100% L.E.L
P&ID
• 1% H2 by volume corresponds to 25% L.E.L and 4% H2 by volume corresponds to 100% L.E.L.
• Detection of hydrogen concentration shall be alarmed and detection of a high high hydrogen
concentration shut down the system.
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Pressure Safety Valves (00PUS45AA901)
• Installed outside the Mechanical Container and along the dosing line to Seawater Intake Header
(Riser).
• Set pressure: 6.9 barg. P&ID
• Protect the dosing piping from high discharge dosing or dilution pressure.
• Discharge piping from Pressure Safety Valve route to Sump Pit.
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Hydrochloric Acid Cleaning System
• Generators of active chlorine by electrolysis of untreated seawater are fouled by precipitation on
the cathodes of hydroxides and carbonates of cations, such as magnesium and calcium, present
in the feed seawater. P&ID
• Fouling takes place as soon as electrolyzers operate and the rate of fouling mainly depends on:‐
• Material and surface finishing of the cathodes.
• Cathodic current density
• Seawater chemical composition, temperature and flowrate through the electrolyzers.
• Low current density together with low seawater flowrate is conducive to electrolyzer fouling.
• Hydrochloric acid cleaning system is necessary to wash the electrolyzers to remove the scaling on
the electrodes surface.
• Cleaning does not require any dismantling and is done by circulating through the electrolyzers a
diluted hydrochloric acid solution (6% HCl by weight).
• Frequency of cleaning: After ~ 4 weeks of continuous operation or operating rectifier voltage
increased by more than 6%.
• Duration of cleaning: ~ 1.5 to 3 hours. Standby electrolyzer is started to assure production of
hypochlorite.
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Hydrochloric Acid Cleaning System
• Progressive scaling of the electrode package will lead to:‐
• Increase of operating voltages
P&ID
• Plugging of the path between the electrodes
• Uneven distribution of flow and current to the electrodes.
• Prolonged operation under above‐mentioned anomalous conditions will lead to:‐
• Increase of power consumption
• Quick damage of anodic coating
• Short circuits between anodes and cathodes.
• Delayed in acid cleaning process / insufficient acid concentration and cleaning duration will lead
to:‐
• Hard scaling of electrodes
• Completely blockage of adjacent electrodes => subsequent cleaning cycles could not be
effective.
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Service Water Supply
• 5m3/hr of service water available at TP‐03.
• Supplied for the following equipment:‐
P&ID
• Fume remover (00PUS74BB001)
• Acid (HCl) Dosing Tank for Acid Cleaning (00PUS72BB001)
• Service Water Hose Station
• Emergency Eyewash and Shower (00PUS70AT001)
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Drainage source and destination
Drainage Source Tag number Medium Drainage Destination
Automatic Self ‐Cleaning Strainer 00PUS11/12AT001 Seawater Intake system
P&ID
Pressure Safety Valve 00PUS10AA901 Seawater Sump Pit
Drainage of Sodium Hypochlorite Electrolyzer 00PUS21/22AG001 Seawater / Sodium Hypochlorite Sump Pit
Drainage of Dilution Pump 00PUS51/52AP001 Seawater Sump Pit
Drainage of Dosing Pump 00PUS41/42AP001 Seawater / Sodium Hypochlorite Sump Pit
Pressure Safety Valve 00PUS45AA901 Sodium Hypochlorite Sump Pit
Drainage of Hypochlorite Solution Storage Tank Bund Wall Seawater / Sodium Hypochlorite Sump Pit
Drainage of valve pit Seawater / Sodium Hypochlorite Sump Pit
Drainage of Bund Wall (Acid) Neutralised water Sump Pit
Drainage of Bund Wall (Caustic) Neutralised water Sump Pit
Emergency Eyewash and Shower 00PUS70AT001 Service Water Sump Pit
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ELECTRODES
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Scaling of electrode
Period between acid cleaning prolonged Effects of Cathode Fouling
Precipitate form on electrode plug path between electrodes
Uneven flow and current to electrodes
Localised heating
Increase in power consumption
Acid clean on regular basis and duration
until all precipitates are dissolved.
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Concentrated Hydrochloric Acid
Typical analysis of technical grade hydrochloric acid, by synthesis), to be used for acid washing.
free of fluorides
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Monitor Electrode Life
Operator’s duty to fill up the Logsheet on weekly basis.
• Time at which data are recorded should be always the same for consistency
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SAFETY INSTRUCTION
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Hazard Prevention
P&ID
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Chemical Hazard
Operator to ensure safety shower and eyewash is functioning before
operator handles chemicals.
Sodium Hypochlorite
Goggles and rubber gloves should be worn when taking samples.
Cause minor irritation to skin if contacted.
Rinse affected part of body with clean water if contacted.
Flush equipment, that is spilled with hypochlorite solution with freshwater to avoid corrosion.
Hydrochloric Acid (MSDS)
Goggles & rubber gloves should be worn. WATER
When contacted, drench victim immediately with water.
Test safety shower and eye wash stations WEEKLY to ensure they operate properly.
Add ACID to WATER, not the reverse
Do not mix acid with sodium Hypochlorite ACID
Chlorine gas will be generated from this mixture
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Chemical Hazard
Caustic Soda (MSDS)
Caustic soda is very corrosive; it burns skin and eyes.
Rapidly attacks wool and leather. Do not wear wool material.
Rubber is practically unaffected, while cotton is affected to an extent lesser than wool.
Operator should keep the following precautions and instructions in mind
Avoid splashing of caustic liquor
Wear industrial goggles or face shield
Wear rubber gloves, boots and aprons
Wear preferably cottons, not wool clothes.
If by accident, clothes or skin come in contact with caustic solution, immediately remove the wet
clothes and wash with plenty cold water and then, as soon as possible, neutralize with 1% acetic
acid or vinegar solution.
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OPERATION
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Commissioning
COMMISSIONING, START‐UP & SITE PERFORMANCE TEST PROCEDURE
P&ID
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Start‐up (Manual)
Electro‐Chlorination Plant designed to run 1 unit of Sodium Hypochlorite Electrolyzer at one time. 1 running Dilution Blower is sized to dilute hydrogen gas
produced from 1 unit of Sodium Hypochlorite Electrolyzer to 1% H2 in volume. Operator cannot run 2 units of Sodium Hypochlorite Electrolyzers
P&ID concurrently.
HMI Step Description
A Hypochlorite Solution Storage Tank ready to receive sodium hypochlorite solution.
B On LCP (00PUS91GH001), select (1) ‘LCP’, (2) ‘MANUAL’ mode and (3) ‘Generation’ Mode or ‘Acid’ mode for Train A or Train B.
C Dilution Blower
Select ‘AUTO’ mode at LCS
Select ‘REMOTE’ mode at MCC (00PUS90GH001)
‘READY’ status available from MCC (00PUS90GH001) to LCP (00PUS91GH001).
Select one unit as ‘DUTY’ and press START via individual blower’s faceplate.
Ensure 00PUS61CF001 >875Nm3/hr and 00PUS61CP001 >7.38mbarg
D Open inlet isolation valves 00PUS10AA001/002/003
E For Train selected in ‘GENERATION’ Mode, operator to open its isolation valves (00PUS21AA001/002 or 00PUS22AA001/002). Other valves to remain in closed
position.
F Open outlet isolation valves 00PUS11/12AA002 of duty Automatic Self Cleaning Strainer.
G Open inlet on/off valve 00PUS11/12AA300 of duty Automatic Self Cleaning Strainer via the valve’s faceplate and check it is full of seawater.
H Open duty Sodium Hypochlorite Electrolyzer’s inlet and outlet on/off valve (00PUS21/22AA300/301) via valve’s faceplate.
I Open duty Sodium Hypochlorite Electrolyzer’s inlet FCV (00PUS21/22AA304) via valve’s faceplate and feed with seawater flow of ~ 12.5m3/hr. In ‘MANUAL’,
PID controller control output is uncontrolled by algorithm. Operator to enter the desired control output value to control the control valve manually.
Open the vent valve to expel air, then close the vent valve tightly. WE ARE DE NORA 42
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Start‐up (Manual)
Step Description
J When 00PUS31CL001A/B is > 210mm (10%),
P&ID
Select ‘REMOTE’ mode at Rectifier & Transformer
HMI E‐Stop on Rectifier & Transformer released
Select one unit as ‘DUTY’ (Only 1 Rectifier & Transformer can be selected as ‘DUTY’, the other unit as ‘STANDBY’.)
Start the Rectifier & Transformer unit according to Manufacturer’s instructions.
Raise load in incremental step: 150‐300‐450‐600‐750‐900‐1050‐1200‐1350‐1500ADC, waiting about half an hour between each increment. check that
voltage across each electrolyzer is the same.
K When 00PUS31CL001A/B is > 525mm (25%), operator to select ‘Dosing Pump’ and/or ‘Dilution Pump’.
Dosing Pump Dilution Pump
Select ‘AUTO’ mode at LCS Select ‘AUTO’ mode at LCS
Select ‘REMOTE’ mode at MCC (00PUS90GH001) Select ‘REMOTE’ mode at MCC (00PUS90GH001)
‘READY’ status available from MCC ‘READY’ status available from MCC
(00PUS90GH001) to LCP (00PUS91GH001). (00PUS90GH001) to LCP (00PUS91GH001).
Select one unit as ‘DUTY’. (Only 1 pump can be Select one unit as ‘DUTY’. (Only 1 pump can be
selected as ‘DUTY’, the other unit as ‘STANDBY’.) selected as ‘DUTY’, the other unit as ‘STANDBY’.)
Open dosing on/off valve (00PUS44/45AA300) via Open dosing on/off valve (00PUS44/45AA300) via
valve’s faceplate valve’s faceplate
Operator to key in Manipulated Valve (%) and Operator to key in Manipulated Valve (%) and
start duty Dosing Pump via individual pump’s start duty Dilution Pump via individual pump’s
face plate face plate
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Start‐up (Manual)
Critical process conditions:‐
P&ID At any time, 1 unit of Dilution Blower has to be running and must be > 875Nm3/hr.
HMI Seawater inlet flow to running Sodium Hypochlorite Electrolyzer > 10m3/hr.
Temperature at running Sodium Hypochlorite Electrolyzer < 45deg.
Hypochlorite Solution Storage Tank level not at high level (1785mm).
Hydrogen gas level (00PUS20CQ001A/B) < 50% L.E.L.
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Start‐up (Auto Sequence from LCP)
Step Description
P&ID A On LCP (00PUS91GH001), select (1) ‘Generation’ Mode or ‘Acid’ mode for Train A or Train B
HMI B Select Train A or Train B as ‘DUTY’
Ensure on/off valves, FCV relating the Train has no trip signal to LCP (00PUS91GH001).
Select ‘REMOTE’ mode on Rectifier & Transformer (00PUS21/22GT001).
E‐stop on Rectifier & Transformer released.
C On/off valves, relating to the Train in ‘Generation’ Mode, open/close according to sequence logic when in ‘AUTO’ mode.
For FCV, , relating to the Train in ‘Generation’ Mode, control output of PID controller configured in ‘AUTO’ mode will be computed automatically
depending on (1) flow meter reading and (2) required flow setpoint.
D Dilution Blower
Select ‘AUTO’ mode at LCS
Select ‘REMOTE’ mode at MCC (00PUS90GH001)
‘READY’ status available from MCC (00PUS90GH001) to LCP (00PUS91GH001).
Select one unit as ‘DUTY.
E Dosing Pump
Select ‘AUTO’ mode at LCS
Select ‘REMOTE’ mode at MCC (00PUS90GH001)
‘READY’ status available from MCC (00PUS90GH001) to LCP (00PUS91GH001).
Select one unit as ‘DUTY’. (Only 1 pump can be selected as ‘DUTY’, the other unit as ‘STANDBY’.)
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Start‐up (Auto Sequence from LCP)
Step Description
F Dilution Pump
P&ID
Select ‘AUTO’ mode at LCS
HMI Select ‘REMOTE’ mode at MCC (00PUS90GH001)
‘READY’ status available from MCC (00PUS90GH001) to LCP (00PUS91GH001).
Select one unit as ‘DUTY’. (Only 1 pump can be selected as ‘DUTY’, the other unit as ‘STANDBY’.)
G Operator to select (1) ‘DCS’ or ‘LCP’ and (2) ‘AUTO’ mode. All the following parameters / equipment must be selected as ‘DUTY’ and in healthy condition
before a ‘READY’ status is shown on LCP (00PUS91GH001).
E‐stop at LCP (00PUS91GH001) is released.
Hydrogen gas level (00PUS20CQ001A/B) is healthy (less than 50% L.E.L)
Hypochlorite Solution Storage Tank is not at high level.
No hardwired dry contact from Local Fire Alarm Panel in Seawater Intake Electrical Building sent to LCP (00PUS91GH001).
One of the Dilution Blower selected as ‘DUTY’ and healthy.
One of the Dosing Pump selected as ‘DUTY’ and healthy.
One of the Dilution Pump selected as ‘DUTY’ and healthy.
One of the Automatic Self Cleaning Strainer selected as ‘DUTY’ and healthy.
One of the Train selected as ‘DUTY’ and healthy.
H Operator to press ‘START’ to initiate start sequence.
If ‘DCS’ is selected, Operator can only initiate the system by pressing the ‘START’ command from DCS after receiving a ‘READY TO REMOTE START’ signal from
LCP (00PUS91GH001).
If ‘LCP’ is selected, Operator can only initiate the system by pressing the ‘START’ command from LCP (00PUS91GH001) after receiving a ‘READY’ status on LCP
(00PUS91GH001).
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Start‐up (Auto Sequence from LCP)
Step Description
Dilution Pump and Dosing Pump starts.
P&ID
After 10 seconds, duty Dilution blower will start to run. [In case duty blower fail to run, standby blower will start. If standby blower also fails to run, alarm is
HMI generated and stop]
After 10 seconds, inlet on/off valve, inlet flow control valve and outlet on/off valve of the selected Train set to ‘DUTY’ will open. [In case valves fail top open,
alarm is generated and stop]
System remains in current state for 2 minutes to verify the health of all the process conditions.
Dilution Blower started and > 875Nm3/hr.
Seawater inlet flow to duty Sodium Hypochlorite Electrolyzer > 10m3/hr.
Temperature at duty Sodium Hypochlorite Electrolyzer outlet < 45degC.
Hypochlorite Solution Storage Tank must not be at high level.
Rectifier & Transformer is available.
At expiry of 2minute timer with healthy process conditions met, duty Rectifier & Transformer starts by activating Rectifier & Transformer digital output and to
ramp up until current reaches the required set point.
If healthy process conditions are not met after expiry of 2minute timer, system will shut down without flushing (Rectifier & Transformer has not started, no
hydrogen gas generated). Dilution Blower stops and on/off valve and flow control valve closes.
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‘DCS’ ‘LCP’ mode
Switch from ‘DCS’ to ‘LCP’ control Switch from ‘LCP’ to ‘DCS’ control
Operator to initiate ‘STOP’ command Operator to initiate ‘STOP’ command
from DCS from LCP (00PUS91CH001).
P&ID
Once system comes to a complete stop, Once system comes to a complete stop,
HMI operator to select (1) ‘LCP’ and (2) operator to select (1) ‘DCS’ and (2)
‘MANUAL’ or ‘AUTO’ mode from the ‘AUTO’ mode from the LCP
LCP (00PUS91CH001). (00PUS91CH001).
After selecting ‘AUTO’ mode and with a With a ‘READY TO REMOTE START’
‘READY’ status on LCP signal from LCP (00PUS91GH001),
(00PUS91CH001), operator can initiate Operator can initiate the system by
the system by pressing the ‘START’ starting ‘START’ command from DCS.
command from LCP (00PUS91CH001).
LCP ‘MANUAL’ ‘AUTO’ mode
Switch from ‘LCP’ ‘AUTO’ to ‘MANUAL’ Switch from ‘LCP’ ‘MANUAL’ to ‘AUTO’
mode mode
Operator to initiate ‘STOP’ command Operator to initiate ‘STOP’ command
from LCP (00PUS91CH001). from LCP (00PUS91CH001).
Once system comes to a complete stop, Operator to select (1) ‘LCP’ and (2)
operator to select (1) ‘LCP’ and (2) ‘AUTO’ mode from the LCP
‘MANUAL’ mode from the LCP (00PUS91CH001). With this selection,
(00PUS91CH001). Operator can all equipment, on/off valves and flow
start/stop or open/close equipment control valves come to a complete stop
and valves from the individual and in close status.
faceplate.
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Semi‐Automatic Operation
(1) Dilution Pump Operation
P&ID When Electro‐Chlorination Plant malfunction, operator to press SEMI‐AUTO FLUSH S.I.P (BAY & STATION) or
HMI SEMI‐AUTO FLUSH SEAWATER INTAKE HEADER on Local Control Panel (00PUS91GH001).
This will initiate to run the Dilution pump at 19.6m3/hr to prevent by‐product precipitation on dosing piping.
For this to happen, running status of SIP (Seawater Intake Pump) #1 and/or #2 must be available from DCS.
(2) Acid Cleaning preparation, acid cleaning mode and acid neutralization process.
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Shut Down of individual train (Manual)
• If long‐term shut‐down (i.e. more than one
month) is scheduled, operator should close
P&ID
inlet/outlet valves [00PUS21/22AA001/002
HMI
and 00PUS21/22AA300/304/301] and drain
valves (00PUS21/22AA305) of the Sodium
Hypochlorite Electrolyzer, in order to empty
the unit.
• Then he should perform a thorough acid
washing. At the end of the washing
procedure, after a thorough flushing of the
unit with seawater, Sodium Hypochlorite
Electrolyzer should remain completely empty.
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Shut Down of all trains (Manual)
• Just before shutting completely down the last
Sodium Hypochlorite Electrolyzers, operator
P&ID
should flush generator with seawater for
HMI
approximately 1‐5 minutes. This is in order to
avoid hammer effect on sea water supply
line.
• Finally, operator can close inlet/outlet valves
of the last Sodium Hypochlorite Electrolyzer.
• The Hypochlorite Solution Storage Tank could
be maintained in operation until low level is
reached.
• After dosing stops, it is recommended to flush
injection lines with seawater via dilution
pump in order to remove all possible
deposits.
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Shut Down (Auto Sequence)
(1) Electro‐Chlorination Plant Stop (with Flushing) activated when STOP pushbutton initiated from DCS or LCP.
P&ID Sequence
HMI
Duty Rectifier & Transformer stops. GENERATION TIMER pause.
2‐minute flushing timer starts counting for the respective Sodium Hypochlorite Electrolyzer.
Feed flow to the duty Sodium Hypochlorite Electrolyzer and duty dosing pump and dilution pump and the duty
Dilution Blower continue to run during this period. Feed flow is required to flush hydrogen out of the package
to the Hypochlorite Solution Storage Tank with seawater.
When the 2‐minute timer is completed, inlet and outlet on/off valves and flow control valves of Sodium
Hypochlorite Electrolyzer will close.
Sodium Hypochlorite Electrolyzer’s drain valve and HCl return valve will open to drain the Sodium Hypochlorite
Electrolyzer completely.
When the draining is completed, Sodium Hypochlorite Electrolyzer’s drain valve and HCl return valve will close.
(drainage timer to be determined at site)
After 10 seconds, Dosing and Dilution pump stops and dosing on/off valve closes.
After 10 seconds, inlet on/off valve of Automatic Self Cleaning Strainer closes.
After 10 seconds, Dilution Blower stops. WE ARE DE NORA 52
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Shut Down (Auto Sequence)
Electro‐Chlorination Plant stop during continuous/shock Electro‐Chlorination Plant stop during shock dosing at
dosing at Seawater Intake Header (Riser) Seawater Intake Pump Bay and Pump Station
P&ID
Flushing mode for Seawater Intake Header (Riser) shall Flushing mode for Seawater Intake Pump Bay and
HMI be initiated automatically. Pump Station shall be initiated automatically.
Once Electro‐Chlorination Plant comes to a complete Once Electro‐Chlorination Plant comes to a complete
stop, ensure duty seawater intake pump running stop, ensure duty seawater intake pump running
feedback is available at PLC. feedback is available at PLC.
Then open duty MOV 00PUS11/12AA300 and MOV Then open duty MOV 00PUS11/12AA300 and MOV
00PUS45AA300. 00PUS44AA300.
After confirming duty MOV 00PUS11/12AA300 and After confirming duty MOV 00PUS11/12AA300 and
MOV 00PUS45AA300 is fully open, run duty dilution MOV 00PUS44AA300 is fully open, run duty dilution
pump (00PUS51/52AP001) at 19.6m3/hr for 35 pump (00PUS51/52AP001) at 19.6m3/hr for 5 minutes.
minutes.
After 5 minutes flushing timer expired, stop duty
After 35 minutes flushing timer expired, stop duty dilution pump (00PUS51/52AP001) and close duty
dilution pump (00PUS51/52AP001) and close duty MOV 00PUS11/12AA300 and MOV 00PUS44AA300.
MOV 00PUS11/12AA300 and MOV 00PUS45AA300.
Flushing mode for Seawater Intake Pump Bay and
Flushing mode for Seawater Intake Header (Riser) can Pump Station can also be started upon Operator’s
also be started upon Operator’s initiation on HMI by initiation on HMI by pressing SEMI‐AUTO FLUSH S.I.P
pressing SEMI‐AUTO FLUSH SEAWATER INTAKE (BAY & STATION).
HEADER.
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Shut Down (Auto Sequence)
(2) Electro‐Chlorination Plant Trip (without Flushing) / E‐STOP activated when
P&ID • E‐stop at Local Control Panel (00PUS91GH001) is initiated.
HMI
• Any one of two Hydrogen gas detection High High level (50% LEL) (00PUS20CQ001A/B). Chlorination
Mechanical Container and Electrical Container’s HVAC system is also stopped.
• Activation of either Mechanical Container or Electrical Container’s fire alarm (hardwired dry contact from Local
Fire Alarm Panel in Seawater Intake Electrical Building to Local Control Panel 00PUS91GH001). Chlorination
Mechanical Container and Electrical Container’s HVAC system is also stopped.
• Two out of three air‐conditioners in Mechanical Container is faulty.
• Two out of two air‐conditioners in Electrical Container is faulty.
• In the event (1) duty inlet FCV (00PUS21/22AA304) and MOV (00PUS21/22AA300) and outlet MOV
(00PUS21/22AA301) is open and (2) Duty Dosing Pump (00PUS41/42AP001) not running and (3) Level
Transmitter (00PUS31CL001A) or Level Transmitter (00PUS31CL001B) did not increase from LL level to 50%
within 30 minutes after operator reset LL level signal.
• Both dilution blower motors (00PUS61/62AN001‐M01) failure from MCC (00PUS90GH001).
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Shut Down (Auto Sequence)
(2) Electro‐Chlorination Plant Trip (without Flushing) / E‐STOP
P&ID Sequence
HMI
Alarm
Stops Duty Dilution Blower (00PUS61/62AN001), Dosing Pump (00PUS41/42AP001), Dilution Pump
(00PUS51/52AP001), Rectifier & Transformer (00PUS21/22GT001) (0ADC), Acid (HCl) Dosing Pump for Acid
Cleaning (00PUS75/76AP001) and NaOH Dosing Pump for Neutralisation (00PUS77/78AP001).
Close duty inlet FCV (00PUS21/22AA304) and MOV (00PUS11/12AA300,00PUS21/22AA300) and outlet MOV
(00PUS21/22AA301) after 0 minutes time delay.
Close Acid (HCl) MOV (00PUS72AA300), service water MOV (00PUS72AA301), NaOH MOV (00PUS72AA302)
and all acid cleaning MOV (00PUS70AA300 / 00PUS75AA300 /00PUS21/22AA302 / 00PUS21/22AA303 /
00PUS21/22AA305).
GENERATION TIMER, CONTINUOUS DOSING FOR SEAWATER INTAKE TIMER 1, SHOCK DOSING FOR SEAWATER
INTAKE TIMER, SHOCK DOSING FOR PUMP BAY TIMER, CONTINUOUS DOSING FOR SEAWATER INTAKE TIMER 2,
FLUSHING MODE FOR SEAWATER INTAKE TIMER AND FLUSHING MODE FOR PUMP BAY TIMER pause.
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CONTROL AND INTERLOCKS
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Control and Interlocks
Seawater Inlet Rectifier & Transformer
Automatic Self‐Cleaning Strainer Mechanical Container and Electrical P&ID
Sodium Hypochlorite Electrolyzer Container HVAC Control
Dilution Blower Fire Fighting System Control
Hypochlorite Solution Storage Tank Acid (HCl) Dosing Tank for Acid Cleaning
Dosing Pump Acid (HCl) Dosing Pump for Acid Cleaning
Dilution Pump Acid (HCl) Storage Tank
Hypochlorite Solution Dosing Control
NaOH Storage Tank
Hydrogen Detector
NaOH Dosing Pump for Neutralisation
Dilution Acid Preparation, Cleaning and
Neutralisation Sequence
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TROUBLESHOOTING
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Troubleshooting
Operator to take reference with System Description Document no: J1‐DNW‐SCT‐CRT‐W00‐0029. Operator to also
refer to Operation (including Start‐Up & Shut‐Down) & Maintenance Manual, Document no: J1‐DNW‐SCT‐IOM‐
P&ID W00‐0035 for troubleshooting of individual equipment.
Troubleshooting table
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MAINTENANCE AND REPAIRING
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Maintenance
Maintenance Notes
Maintenance Schedule
Maintenance Instruction
Electrolyzer
Pump
Blower
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