Prepared by –

B.V.P. Sitarama Sarma

Chemistry Dept.
 Water is a bipolar molecule, so it tries to catch every thing which 2
comes in contact. That’s why water is called “Universal Solvent”. This property of
universal solubility and high ionising power is very important for many of the
life's reactions to support life and the living world. The nature of universal
solvent makes complication in water treatment also.
DM water is called “Hungry Water”, which is more aggressive
when temperature and pressure increases. These two characteristics plays very
vital role in boiler water chemistry.
This document is prepared for “Quick reference of water
treatment systems and technologies used in KMPCL”. This is an in-house
document, designed with more carefully for internal use. Using representative
diagrams and less literature for better understanding.
“Knowing better leads to doing better”.

JANJGIR-CHAMPA
BALODA
AKALTARA

SHAKTI
AKALTARA

AKALTARA
AKALTARA BAMHA
AKALTA
NIDIH

NAWAGARH
AKALTARA

MALKHARODA
AKALTARA

PAMGARH
AKALTA

JAIJAIPUR
AKALTA

AKALTARA
DABHRA
 3
INDEX PAGE
NAME OF THE SYSTEM PAGE NO. NAME OF THE SYSTEM PAGE NO. FILTRATION SYSTEMS PAGE NO.

OVERVIEW OF WATER TREATMENT PLANT 4 UF & RO CHEMICAL DOSING ROOM 32 - 33 FLY-AHP 59

(WTP)
CATION & ANION REGENERATION SYSTEM 34 BOTTOM-AHP 60
OVERVIEW-2 5
SAC, SBA & MB 35 GENERAL DESCRIPTION 62-92
FLOW DIAGRAMS 7 - 18
DMF, ACF & RTV 36 RIVER WATER PUMP HOUSE 62 - 63
FLOW DIAGRAM OF PT PLANT 7 UF & RO 37 BAR & TRAVELLING SCREENS 64
FLOW DIAGRAM OF DM PLANT 8-9 ACID & CAUSTIC UNLOADING AREA 38 RESERVOIRS 65
ZERO WATER DISCHARGE FLOW CHART 10 - 11 ETP SLUDGE DEWATERING STATION 39 HRSCC 66
WATER BALANCE DIAGRAM 12 - 15 BOILER AREA 41 - 49 CHLORINATION 70

STEAM CYCLE 16 CPU 41 SLUDGE THICKENER 71

STEAM EXTRACTIONS 17 CPU DETAILS 42 SLUDGE TRANSFER PUMP 72

CHLORINE FLOW DIAGRAM 18 CPU REGENERATION SYSTEM 43 DECANTER CENTRIFUGE 73 - 74

PRE TREATMENT PLANT (PTP) 20 - 29 BOILER CHEMICAL DOSING ROOM 44 MULTI GRADE FILTERS 75 - 76
CHEMICAL DOSING & BLOWDOWN 45 ACTIVATED CARBON FILTERS 77 - 78
MEASUREMENTS OF RESERVOIRS 20
LOCATIONS
STRAINERS & DISTRIBUTION HEADERS 79
PUMP DETAILS OF PTPLANT 21 HEATERS & DEAERATOR 46
SELF CLEANING AUTO FILTERS 80 - 81
CHLORINATION BOOSTER PUMP HOUSE 22 DRUM PRESSURE Vs SILICA GRAPH 47
MEMBRANE FILTRATION 82
COMPLEX WATER PUMP HOUSE 23 SWAS PANEL 48
ULTRA FILTRATION 83 - 84
POTABLE WATER TREATMENT PLANT 24 SWAS ONLINE METERS 49
ULTRA FILTRATION - DEAD END & CROSS 85
PTP SLUDGE DEWATERING STATION 25 OTHER AREAS 51 - 60 FLOW

CHLORINATION BUILDING AREA 26 SANITARY SEWAGE TREATEMENT PLANT 51 - 52 MICRON CARTRIDGE FILTERS 86

COOLING TOWERS 27 STATOR COOLING WATER SYSTEM 53 RO-OVERVIEW 87- 88

CT BLOWDOWN SYSTEM 28 HYDROGEN METHODOLOGY 54 RO - PASSES 89

COAL-BEARING WASTE –WTP OVERVIEW 55 RO - STAGES 90

DM PLANT 30 - 40
COAL-BEARING WASTE-WTP 56 ION EXCHANGE RESINS 91 - 92
FILTER WATER PUMP HOUSE 30
OILY WASTE-WTP 57
UF & RO WATER PUMP HOUSE 31 Sarma_bulusu@yahoo.in
ASH HANDLING PLANT (AHP)-OVERIVEW 58 30.03.2015
 4

Reservoir 1 Reservoir 2 Reservoir 3

Raw water pump house

KSK Office
Road

OVER VIEW
OF
WATER TREATMENT PLANT

SEPCO Office
Cooling Tower CT Pump House Cooling Tower
Pre Treatment Plant (PTP) OVERVIEW-2 Post Treatment Plant (DMP)
5

Middle Pond Sludge Pond High Rate Solid Contact Clarifier (HRSCC) Sewage Treatment Plant (STP) Guard Pond

ETP Sludge Thickener

Chemical Dosing ETP Sludge Dehydration Station
Pump House
Chlorination Booster Acid Storage Tank Caustic Storage Tank
Pump House Mixed Bed (MB)
Service air
tanks

Fire Fighting
Clarified Water Storage Tank Strong Base
(CWST)

Complex Water Pump House

Anion (SBA)

Station

ETP Clarifiers
N-PIT Tanks
Sludge Thickener

DMP Pump
Clarifying
Water Tanks Strong Acid

House
Cation (SAC)

DM Water Storage Tanks (DMST)

Filter Water
Tanks
CT Make Up + Service Resin Transfer
Water Pump House Vessel (RTV)

RO Tanks
Cation & Anion

UF Tanks
HRSCC Sludge
Potable Water System
Dehydration Station

UF & RO Pump Chemical Dosing

House Room Multi Grade
Filters (MGF)
PLC

Potable Water Storage Tanks Reverse Osmosis (RO) Ultra Filtration (UF) DM Plant Office
PTP PLC Room & Pumps System System Building
 6

Flow Diagrams
 PRE TREATMENT PLANT (PTP) 7

Raw Water Pumps (6 x 1800 m3/hr) High Rate Solid Contact Clarifier (HRSCC), 5 x 2250 m3/hr

8237 m3/hr

Sludge Pond Sludge (617 m3/hr)

(2 x 4,500 m3)

Chemical Dosing Room

Middle Pond
(2 x 2,500 m3) Chlorination Booster Clarified water
Pump House (8188 m3/hr) Fire Fighting
Station
Clarified Water Storage Tanks
(CWST), 2 x 18,000 m3 Complex Water Pump
4 House

3
Sludge Thickener
(4 x 580 m3/hr) CT make up (7760 m3/hr)

2
Service Water
(218 m3/hr)
1 HRSCC Sludge
Dehydration Station
153 m3/hr

Sludge Balance
Pond (200 m3) (2*1100 m3)
150 m3/hr Colony 130 m3/hr
PTP PLC Room Potable Water Plant 20 m3/hr
System

50 m3/hr Washing water for Potable Water Storage

Solid waste to trucks automobiles (2 m3/hr) Tank & Pumps
 POST TREATMENT PLANT (DMP) 8
(SEE NEXT PAGE ALSO)

ETP SLUDGE ETP SLUDGE DEHYDRATION BULK ACID & CAUSTIC Acid 12th
THICKENER STATION STORAGE AREA Regenerat

Mixed Bed (MB)

ion Area

Anion (SBA)
Strong Base
N-PIT 1 3
Tanks 2
3 4 Caustic 2
Regenerat
2nd 3 1
ion Area
1st

Vessel (RTV) Cation

Clarifying Water 11th
stage

Cation (SAC)
(CF) Tanks

Strong Acid
3

Resin Transfer

(+) & Anion (-)

3rd -
1 2 ETP Clarifiers Filter
Pump 2
+
Filter Water Tanks House 1
4th
DM Water Storage Tanks
2 1
(DMST)
13th
2 4
2 2

Dual Media Filters

10th

Dual Media Filters

14th

(DMF) 1-7

(DMF) 8-14
5th
RO Tanks UF Tanks
1 3
1 1

9th
8th
7th

UF & RO Pump House Chemical Dosing Room Self Cleaning

Filters
6th
RO

UF

DMP PLC Stairs

Stairs

Reverse Osmosis (RO) System Ultra Filtration (UF) System DM Plant Office Building
 DM PLANT FLOW DIAGRAM (240 m3/hr) 9

Raw water Pump House CWST

Reservoirs (3 Nos) Cooling Tower
(6*1800 m3/hr) (2*18,000 m3) (16 *6 cells)
(2*3,00,000 m3, 1*6,00,000 m3) HRSCC (5*2250 m3/hr) CHP

Guard Pond
Filter Water Tanks (2*500 m3)
Clarifying Water CT blow down
Tank tank

(2*1100 m3) 2*9000 m3

FILTER WATER PUMPS Multi Grade Filters ( 14*95 m3/hr) CLARIFIED WATER PUMPS BLOWDOWN WATER TRANSFER
ETP Clarifiers
(2*480, 2*420 m3/hr) (4*580 m3/hr) PUMPS (4*600 m3/hr)
4*380 m3/hr

RO water storage
tanks (2*500 m3)

UF WATER PUMPS RO HIGH PRESSURE

UF water storage (4*200 m3/hr) PUMPS (6*200 m3/hr)
Ultra Filtration tanks (2*500 m3) Reverse Osmosis RO WATER PUMPS
(6*220 m3/hr) (6*150 m3) (4*180 m3/hr)

DM TRANSFER PUMPS
(5*170 m3/hr) MB (3*240 m3/hr) SBA (3*240 m3/hr) SAC (3*240 m3/hr)

CST (6*800 m3) DMST (4*1600 m3)

Note: 1m3 = 1000 litres
 10
“ZERO WATER DISCHARGE” - FLOW DIAGRAM
Basantpur (Intake well, Mahanadi River) Seorinarayan Pamgarh Reservoirs Raw Water Pump
House
Complex Water Pump House Clarified Water Storage HRSCC
Tank (CWST)
Chlorination Booster
Pumps (Cl2)
Potable Water System Service Water Pumps Coagulant Dosing
(Drinking Water) Fire Fighting CT Make-up Pumps Pumps (PAC)
Pumps Flocculent Dosing
Potable Water CT Fore Bay Boiler Blow Down Pumps (PAM)
Storage Tank Utilized for fire Cooling Basin
fighting
Evaporation loss &
Cooling Tower Sludge Pond
Drift loss Sludge Thickener

Colony Plant site (Sludge

Cooling Water Blow Down Tank Drain)
Middle Pond
Sewage
(Drainage water) Sludge Balance Pond
Coal Waste Water
Guard Pond
Treatment Plant ETP Clarifier
Sewage Treatment Centrifuge Sludge Feed Pumps
Plant
Clarifying Water Metering Pumps
Ash Handling Sludge Dehydration
Reused water Tank (for dosing PAM)
Plant (AHP) Station
tank Storage Electric Mud Bucket
Spray water for Tank Clarified Water
Green Belt & Pumps
roads Electric Mud Solid Waste discharge to
Coal Handling
Bucket trucks
Night Sludge/ Night Plant (CHP)
Soil (for Plantation) N-PIT DM PLANT Reclaimed Water Tank
(Regeneration waste) (see next page ) (Flushing Water )
RO reject
 Clarified Water Pumps Service Water Pumps
Turbine Condenser
11
Cooling Tower Multi Grade Filters (MGF)
Main Steam (MS)
Filter Back Wash Pumps
Blow Down Drain Filtered Water Tanks Platen Super Heated Steam
Tank
Clarifying water Divisional Super
tank Filtered Water Pumps Heated Steam Low Temperature Super
Heated Steam (LTSH)
ETP Clarifier Self Cleaning Filters (Amiad)
Saturated Steam
Reclaimed Water Ultra Filtration (UF)
Transfer Pumps Boiler Drum Blow down
UF Backwash Pumps
UF Storage Tanks tank
Economizer (Feed)
Reclaimed Water UF feed Pumps Micron Cartridge Filters
Tank High Pressure (HP) heaters
RO High Pressure Pumps
(Overflow) Boiler Feed Pump(BFP)
Reverse Osmosis (RO) RO Flushing Pumps
Guard Pond Deaerator
RO Storage Tank CW Back Water Pumps

Drain Low Pressure (LP) heaters

CHP
AHP RO Water Pumps
(RO reject water)
(non return) Acid Injection
Gland Seal Condenser (GSC)
Strong Acid Cation (SAC)
Coal N-PIT Transfer Pump Caustic Injection
Waste Water Condensate Polishing Unit (CPU)
Treatment Plant Strong Base Anion (SBA)

Neutralization Pit Caustic Injection

Hot Well
(N-PIT) Mixed Bed (MB)
Storage Tank Drain Acid Injection Condensate Makeup
DM Water Storage Tank (DMST) Condensate Storage Tank (CST) Pump
 PRE TREATMENT PLANT WATER BALANCE DIAGRAM 12
(BASED ON WBD)

Mahanadi River (387 m3/hr), Water for DMP Before the

first unit start-up
Clarifying Water
Evaporation and (8257 m3/hr ) (CF) Tank
Percolation Loss
(210 m3/hr), Need when DM is out of Running Boiler Blow Down
(20 m3/hr ) Induced Draft Cooling Basin
Cooling Tower Water for UNNORMAL
Raw Water Reservoirs (see next page) Operating Condition
(567 m3/hr) Floor washing water
(8237 m3/hr) for Main Building
(7760 m3/hr)
(8188 m3/hr) (5 m3/hr)
(218 m3/hr) (65 m3/hr) (29 m3/hr)
HRSCC Clarified Water
Reservoir (CWST) (36 m3/hr) (24 m3/hr)
(617 m3/hr)
(153 m3/hr) Make-up water for Evaporation Cooling
(568 m3/hr)
Air Conditioners water for Blocks
(1 m3/hr)
Sludge Treatment Potable Water Treatment Plant (36 m3/hr) (24 m3/hr)
System
(150 m3/hr)

(50 m3/hr) (2 m3/hr)

Guard Pond (5 m3/hr)
Potable Water Tank Washing water
(see next page)
for Automobiles
(130 m3/hr) (20 m3/hr)
(2 m3/hr)

(15 m3/hr) (16 m3/hr) Reused Water

Potable Water Potable Water Sewage Water Tank
For Colony For Plant Site Treatment Plant (16 m3/hr)
(130 m3/hr) (5 m3/hr) (1 m3/hr)
Spray Water for
Green Belt & Road
Indicates flow meters (16 m3/hr)
 COOLING TOWER & DM PLANT WATER BALANCE DIAGRAM 13
(BASED ON WBD)

Drift Loss Evaporation Loss

(246 m3/hr) (6192 m3/hr)

Clarified Water (62 m3/hr)

(7760 m3/hr) Induced Draft (629 m3/hr) Boiler Blow Down
Reservoir (CWST)
Cooling Tower Cooling Basin
(567+62=629) (567 m3/hr)
(494726 m3/hr) (see previous page) [357+210=567]
(496677 m3/hr)

(494726 m3/hr) (1951 m3/hr) Service water from CWST (Need (210 m3/hr)
when DMP is out of running)
(18600 m3/hr) Cooling Tower See previous page
(476126 m3/hr)
Blow Down Tank
Condensers Auxiliary
Coolers
(4 m3/hr) (955 m3/hr) (992 m3/hr)
Clarifying Water

(357 m3/hr)
(992 m3/hr)
Washing Water for (See next page) ETP Clarifiers (CF) Tank
Air Preheater
(790 m3/hr) (992 m3/hr)
(4 m3/hr)
Drainage (9 m3/hr) (248 m3/hr)
Neutralized Pond Guard Pond UF & RO
(5+4=9) (790+248+15+9+4=1066)
(387 m3/hr)
Backwash (4 m3/hr) (15 m3/hr)
(5 m3/hr) Water for CPU DM Plant
(4 m3/hr) (372 m3/hr)

(256 m3/hr) (33 m3/hr) (12 m3/hr) (62 m3/hr)

Water & Closed DM HVAC Water

Boiler Blow
Steam Loss Water Loss Loss
Down Water
Indicates flow meters (256 m3/hr) (33 m3/hr) (12 m3/hr)
 COOLING TOWER BLOWDOWN TANK WATER BALANCE DIAGRAM 14
(BASED ON WBD)

Induced Draft Cooling Tower

(see previous page)
(496677 m3/hr)

(494726 m3/hr) (1951 m3/hr)

Cooling Tower
Condensers &
Blow Down Tank
Auxiliary Coolers
(see pervious page)

(4 m3/hr) (992 m3/hr)

Washing Water for ETP Clarifiers (955 m3/hr)

Air Preheater (see previous page)
(see previous page)

(1 m3/hr) (790 m3/hr) (164 m3/hr)

Washing Water for Guard Pond Water tank for Coal (43 m3/hr)
Oil Area (see previous two pages) Convey System

(1 m3/hr) (207 m3/hr)

Oil contained waste

(65 m3/hr) (81 m3/hr) (61 m3/hr)
water treatment station
(1 m3/hr)
Spray water for Spray water for coal Washing water for
Equipment's & Pipes coal storage yard convey system Dedust coal convey structures
drainage when checked
(3 m3/hr) (4 m3/hr) (65 m3/hr) (81 m3/hr) (61 m3/hr)

Coal contaminated waste

water treatment system
Indicates flow meters (18 m3/hr)
 GUARD POND WATER BALANCE DIAGRAM 15
(BASED ON WBD)

Cooling Tower Floor washing water Backwash Water Equipment's & Pipes
Blow Down Tank for Main Building for CPU drainage when checked
Drainage (4 m3/hr)
(790 m3/hr) (5 m3/hr)
Neutralized Pond

DM Plant
Oil contained waste
water treatment station
(1 m3/hr) Guard Pond (248 m3/hr)
[Capacity= 3300 m3] UF & RO

(1075 m3/hr)

(391 m3/hr) (24 m3/hr) (660 m3/hr)

Water for Bottom Ash Water for Mill Reject Water for Fly Ash
Handling System Handling System Handling System
(969 m3/hr)
(1360 m3/hr) (660 m3/hr)
(24 m3/hr)
Bottom Ash Yard Fly Ash Yard
(1384 m3/hr) (660 m3/hr)

(415 m3/hr) (660 m3/hr)

(Evaporation Loss) (Evaporation Loss)

Indicates flow meters

 STEAM CYCLE 16
(Based On Heat Balance Diagram & Boiler Operational Manual)
(541⁰C/16.67 Mpa) (358.5⁰C)
(1.021 Mpa)
CST
FINAL SUPER HEATER HP IP LP LP CYCLE MAKE-
(25⁰C) UP ( approx
56 m3/hr)
(499⁰C) (327.8⁰C/
3.853 MPa) (46.7⁰C) HOTWELL
Return Condensate
PLATEN SUPER HEATER (541⁰C) (approx 1140 m3/hr)
(46.7⁰C)
(3.468 MPa)

(443⁰C) GLAND SEAL

REHEATER
CONDENSER
DIVISIONAL SUPER HEATER CEP sample point
Main Steam sample point
(47.3⁰C)
(404⁰C)
LP HEATER# 08
LOW TEMPERATURE
SUPER HEATER (83.4⁰C)

LP HEATER # 07
(394⁰C)

RADIANT ROOF (100.6⁰C)

SUPER HEATER
LP HEATER # 06
Saturated Steam sample point
(>361⁰C) (118.6⁰C)
BOILER DRUM Boiler Drum sample point
(190 kg/cm2) LP HEATER # 05
Deaerator sample point
Economizer or Feed water
sample point (137.2⁰C)
(323⁰C)

ECONOMIZER HP HEATER # 01 HP HEATER # 02 HP HEATER # 03 DEAERATOR

(10 kg/cm2)
(277.6⁰C) (246.4⁰C) (215.7⁰C) (182.0⁰C)
* NOTE: Only Temperature Rising Zones Are Mentioned Here
* NOTE: Feed water quality effected by temperature and pressure
 17
STEAM EXTRACTIONS LP TURBINE-A LP TURBINE-B

HIP TURBINE

HP IP BACKWARD STAGE FORWARD STAGE BACKWARD STAGE FORWARD STAGE GENERA

9 8 7 6 5 4 3 2 1 10 11 12 13 14
EXHAUST

EXHAUST

21 20 19 18 17 16 15 15 16 17 18 19 20 21 21 20 19 18 17 16 15 15 16 17 18 19 20 21

B.F.P.T

CRH
6.217 MPa

2.202 MPa

1.016 MPa
3.86 MPa

185.7⁰C, 0.218 MPa

141.714 MT/H

120.342 MT/H

103.147 MT/H

244.4⁰C, 0.38 MPa

128.2⁰C, 0.12 MPa

87.5⁰C, 0.064 MPa

95.983 MT/H

48.446 MT/H

45.721 MT/H

42.799 MT/H

81.684 MT/H
392.2⁰C

327.8⁰C

469.7⁰C

357.6⁰C

HPH # 01 HPH # 02 HPH # 03 DEAERATOR LPH # 05 LPH # 06 LPH # 07 LPH # 08 HOTWELL

252.0⁰C 221.3⁰C 187.6⁰C 124.2⁰C 106.2⁰C 89.0⁰C 52.9⁰C

141.716 MT/H 262.064 MT/H 358.041 MT/H 48.445 MT/H 94.167 MT/H 136.966 MT/H 221.196 MT/H

*CONDITION: TMCR + 3% MAKE-UP *Note:

*Note: Total 42 Stages [(8+1)+5+(2x7)+(2x7)] & 8 Extractions *1% maek-up: 18.949 m3/hr (or) 454.776 m3 of DM water/day/unit/600 MW.
*Please refer: (WAX)D600K-000014ASM & Turbine Cross Section *3% make-up: 56.847/hr (or) 1364.328 m3/day DM water required for one unit under full load.
 18

CHLORINE FLOW DIAGRAM

Rota Meter
Chlorine Injector
Gaseous Chlorine Hot Water Bath showing flow
Contains 900 kgs of
chlorine with 8 Liquid Chlorine
kg/cm2 pressure

COOLING
BOOSTER PUMP
TOWER
FOREBAY
CHLORINE TONNER Chlorinated
EVAPORATOR (84⁰C) water
CHLORINATOR (62.5 kg/hr)

COOLING TOWER MAKE-UP WATER LINE COOLING TOWER

 19

PRE TREATMENT
PLANT
 MEASUREMENTS OF RESERVOIRS 20
Side View RESERVOIR # 01&02 Side View RESERVOIR # 03

270.500 m 271.500 m

3.145 m 3.145 m
267.355 m 8.145 m 268.355 m 8.145 m

5m 5m
262.355 m 263.355 m
0.5 m Dead Volume 0.5 m Dead Volume
(15542 m3) (34363 m3)

0.0 m 0.0 m
Sea Level Sea Level

Top View Top View

291. 920 m
295. 920 m

271. 920 m
308. 5 m

292. 10 m
308. 68 m
296. 10 m

272. 10 m
TOTAL VOLUME: TOTAL VOLUME:
309458 m3 635033 m3
Slope

112.895 m Flat form

250.65 m
132.895 m Slope
270.65 m
136.895 m 274.65 m
149.475 m 287.23 m
 PUMP DETAILS OF PRE TREATMENT PLANT 21

1 2 3 4 5 6

Sludge Ponds Raw water pumps (6*1800 m3/hr) Chemical Dosing Room

PAM Dosing Pumps (650 LPH)

SLUDGE TRANSFER PUMPS
(Enhanced Self-Priming Centrifugal HRSC HRSC HRSC Mixers
C#1 C#2 C#3 PAM (2*25 m3)
Pumps-3*340 m3/hr) HRSCC#1

HRSCC#2
Sludge Drain Line
HRSCC#3
HRSC HRSC
SLUDGE POND C#5 C#4
HRSCC#4
(2*4500 m3)
HRSCC#5

Sludge tr. Pump discharge line Stairs

Level Gauge
REFLUX PUMPS
(Vertically Long Axle Pumps- HRSCC#1
2*1040 m3/hr)
HRSCC#2

HRSCC#3
MIDDLE POND HRSCC#4
(2*2500 m3)
HRSCC#5
PAC (2*25 m3)
PAC Dosing Pumps (732 LPH)
 22
CHLORINATION BOOSTER PUMP HOUSE

HRSCC HRSCC HRSCC

#1 #2 #3
Chlorination Booster Pump House

HRSCC HRSCC
HRSCC#1 (Chlorine Dosing: 7 LPH) #5 #4

HRSCC#2 (Chlorine Dosing: 7 LPH)

Injectors and HRSCC#3 (Chlorine Dosing: 7 LPH)

Control Valves
HRSCC#4 (Chlorine Dosing: 7 LPH) Chlorination Booster Pumps for
Chlorinated Potable water system (20 m3/hr)
water HRSCC#5 (Chlorine Dosing: 7 LPH)

Chlorination Booster Pump for

HRSCC (100 m3/hr)

Chlorine Gas Automatic Self-Cleaning Filters

Raw water line from

HRSCC # 4&5 Outlet
Potable System
(Chlorine Dosing: 2 LPH) Raw water line from CT
Make up Pump

LPH = Liters Per Hour

 23
Diesel Driven Spray pump
(1*410m3/hr)

Motor Driven Spray pump

Inter connection (1*410 m3/hr)
Fire fighting station

Diesel Driven Hydrant pumps

(2*410 m3/hr)

COMPLEX WATER PUMP HOUSE

Motor Driven Hydrant pumps
Clarified Water Storage Tank (CWST)

(2*410 m3/hr)
Jockey pumps (2*60 m3/hr)
Hydropneumatic tank
(1*220 Nm3/min)
CT make up pump house
Fire fighting station:
Jockey pump runs continuously to maintain the pressure in
the line. If pressure dropped below the set-point, then the
second jockey pump starts automatically to maintain the
pressure. Even though the pressure is not maintaining, then the
hydrant pump will start automatically to maintain the pressure in
the line.
High pressure drop in the line indicates that there is an
emergency situation. After completion of work again pressure
build-up and hydrant pump will stop automatically.
Diesel pumps are ready to handle the emergency situation

when there is no power supply.

CT make up pumps
(4*2600 m3/hr)
Hydro Pneumatic Tank

Capacity: 22.6 m3
Design Pressure: 15 kg/cm2
Service water pumps Operating Pressure: 0.7 kg/cm2
(3*290 m3/hr) Design temp: 100’C
Vessel Height: 6520 mm
Water: 1300 mm

Potable water pumps

(3*75 m3/hr)
 CLARIFIED WATER STORAGE TANK (CWST) Complex Water Pump House
Service 24
water line

Potable Water Pumps

POTABLE WATER/DRINKING WATER (3*75 m3/hr)
TREATMENT PLANT Tapping from
Service water line

(150 m3/hr)
Chlorination Line from Booster Pump House
Potable Water
(2 Litres Per Hour/100 Pounds Per Day)
Storage Tank
(2*1100 m3)
To Plant & Colony

Activated Carbon
Filters (3*75 m3/hr)
ACF Chlorine Analyser
ACF ACF

Dual Media Filters

(3*75 m3/hr) DMF DMF DMF

Backwash Water
to Sludge Pond
(1 m3/hr)
CWST
Air Line for Backwash

Filter Blowers
(2*23.6N m3/min)
Potable Backwash Pumps (2*450 m3/hr)
 25
PT PLANT BUILDING (PTP SLUDGE DEWATERING STATION) Top Floor

Extracted Water Horizontal Decanter Centrifuges (5*100 m3/hr)

to HRSCC PRE TREATMENT
PLANT PLC ROOM

Sludge Screw Conveyor (30 m3/hr)

Concentrated
Sludge discharged Sludge Mud Bucket
to Mud Buckets (20 m3/hr),
discharged to Truck s

PAM Dosing To Decanter

Dehydration Coagulant
Sludge water

Dissolved Tanks (2*144 m3)

Centrifuges
To Decanter Centrifuges

PAM Dosing Pumps (5*6791 LPH)

Sludge Transfer Pumps (5*100 m3/hr)

Sludge Balance Pond (200 m3), Underground

Drained Sludge from Sludge Thickeners Ground Floor

enters into Sludge Balance Pond
 26
CHLORINATION BUILDING AREA
Chlorination Booster Pump Cooling
House For Cooling Water Towers
CW Booster 8 Blowers, 8 Chlorine
Leak Chlorine

Waste Pit
Pumps 4*80 Leak Detectors
Cylinder
m3/hr (Set Point-0.5 ppm,
Alarm-0.3 ppm

Automatic Self
Chlorine
Cleaning Filters Caustic
Line BA Set, PPE’s and
Chlorinated water Solution Ammonia Torch
to Forebay Tank (10%) Caustic Spray location
#5
CHLORINATOR ROOM
#4 Scale Inhibitor
*CW Chlorinators (5 Nos) Safety
#3 Dosing Pumps
200 Litres Per Hour/10000 Shower
(3*249 LPH)
#2
Pounds Per Day
#1 Acid Dosing
*RW Chlorinators (2 Nos)
#2 Pumps (3*249
62.5 LPH/3000 PPD
#1 LPH)
*Potable Water Chlorinators #2
(2 Nos), 2 LPH/100 PPD #1 Chlorine Total 52
Tonners Cylinders Sulfuric Acid Bulk

Lime Bags for acid Neutralization

EVAPORATOR ROOM Storage Tank#3
Total (50 Tons)
Weight-
Evaporators For Raw
1600 kgs
Water/Potable Water (80°C-84°C)
Empty Sulfuric Acid Bulk
Evaporators For Cooling Weight- Storage Tank#2
Water (80°C-84°C) 700kgs
(50 Tons)

Sulfuric Acid Bulk

PLC ROOM Chlorine Absorption Tank#2 Chlorine Absorption Tank#1 Storage Tank#1
(20% Caustic Solution) (20% Caustic Solution) (50 Tons)

Recirculation
Pumps (100 m3/hr)
Sulfuric Acid Unloading
Pumps (2*25 m3/hr)
Blowers
 27
COOLING TOWERS

COOLING TOWERS
System Volume 110000 m3
Circulation Rate 82708 m3/hr 4 6
Cold Water Temperature 33⁰C
Hot Water Temperature 43⁰C
Delta (∆) T 10⁰C
Circulating Water (CW) Pumps (set-06)
COC (Cycles of Concentration) 4 Capacity: 11.50 m3/s (41400 m3/hr), Head=24 m
(or) 13.8 m3/s (49680 m3/hr), Head=20 m
Evaporation Loss 1225 m3/hr
Bleed Off 408 m3/hr 16 Cells and 16 CT fans
Make-up 1633 m3/hr
HTI (Holding Time Index) 214 Hours
2
MOC of Condenser Tubes Stainless Steel
MOC of CW pipes Mild Steel

1 3
Cooling Tower (CT) Basin Hold-up Volume – 12,136 m3
(approx)/unit

CT Basin Dimensions:
Length = 82.4x2=164.8 m
Weight = 18.6x2=37.2 m Circulating Water (CW) Pumps (set-06)
Water level: 2 m
 28
COOLING TOWER BLOWDOWN SYSTEM

GUARD POND
CHP

ETP

CT BLOWDOWN PUMPS
(4*600 m3/hr)
COOLING WATER LINE FROM
CONDENSER OF EACH UNIT

COOLING TOWER BLOWDOWN TANK

1*9000 m3 1*9000 m3

TO COOLING TOWER
FOREBAY
 29

DM PLANT
 30
FILTER WATER PUMP HOUSE (DMP)

FILTER WATER PUMPS (2*480, 2*420 m3/hr) FILTER BACK WASH PUMPS (3*340 m3/hr)

Filter water UF system Filter water For Filter

storage tank storage tank backwash

FILTER BLOWERS (3*6.6 1N m3/min) CLARIFIED WATER PUMPS (4*580 m3/hr)

DM Plant
Atmospheric For Filter (DMF) Clarifying water Dual Media
Air backwash storage tank Filters

For
For Anion
Cation
MB#3 MB#2 MB#1
1 2 3 4 5 6 7 Resin
Resin

DUAL MEDIA FILTERS (1-7) RESIN TRANSFER VESSEL (RTV) MIXED BED (MB)

SAC#1 SAC#2 SAC#3 SBA#1 SBA#2 SBA#3

8 9 10 11 12 13 14

DUAL MEDIA FILTERS (8-14) STRONG ACID CATION (SAC) STRONG BASE ANION (SBA)

*Note: Please see page nos. 35,36,74,75,76&77

 31
UF & RO WATER PUMP HOUSE (DMP)
MB REGENERATION DM TRANSFER PUMPS RO WATER PUMPS CW BACK WATER PUMPS RO FLUSHING PUMPS
PUMPS (2*50 m3/hr) (5*170 m3/hr) (4*180 m3/hr) (3*180 m3/hr) (2*200 m3/hr)

DM water MB DM water CST RO water SAC RO water Boiler Blow RO water For RO
Storage Tank Storage Tank storage tank storage tank down tank storage tank Flushing

RO HIGH PRESSURE PUMPS (6*200 m3/hr) UF BACKWASH PUMPS (2*440, 1*480 m3/hr) UF WATER PUMPS (4*200 m3/hr)

UF water pumps RO System UF water For UF UF water RO high pressure

storage tank backwash storage tank pumps

*Note: Please see page nos.

37,79,80,81,82,83,84,86,87,88 & 89

DM Plant

REVERSE OSMOSIS (RO) ULTRAFILTRATION (UF) SELF CLEANING AUTO FILTERS

 32
UF & RO CHEMICAL DOSING ROOM

SCALE INHIBITOR DOSING TANK (2 m3) NaHSO3 DOSING TANK (2 m3) ACID DOSING TANK (2 m3) ALKALI DOSING TANK
(2 m3)
DM Plant

Scale Inhibitor Dosing Sodium Bi-Sulfite Dosing UF ACID Dosing RO ACID Dosing UF Alkali Dosing RO Alkali Dosing
Pumps (2*85 LPH) Pumps (2*115 LPH) Pumps (2*115 LPH) Pumps (2*946 LPH) Pumps (2*235 LPH) Pumps (2*946 LPH)

RO SKID UF SKID
Return line Return line

Recirculation line Recirculation line

Drain

Drain
MF Filter

MF Filter
RO CLEANING UF CLEANING
TANK (5 m3) TANK (5 m3)
Heaters

Heaters

RO Cleaning Pumps (2*210 m3/hr) UF Cleaning Pumps (2*176 m3/hr)

Reclaimed Tank (Under ground, 300 m3) CONTINUE………

 33
UF & RO CHEMICAL DOSING ROOM

Pumps (2*10 m3/hr)

Coagulant Transfer
Coagulant
DM Plant
Preparation
Tank (5 m3)
HYPO Dosing HYPO Dosing
Tank (5 m3) Tank (5 m3)

Coagulant Dosing Pumps

(4*85 LPH) for UF
Coagulant
Dosing Tank (5 HYPO Dosing Pumps HYPO Dosing Pumps
m3) (2*946 LPH) for UF (5*25 LPH) for ETP

To ETP Clarifier
Coagulant Dosing Pumps

Coagulant
(5*946 LPH) for ETP

Dosing Tank (5 Reclaimed water Pumps

(2*145 m3/hr)
m3)
ETP 1
UF Feed line

ETP 2

Over flow water

to N-Pit tank
ETP 3

ETP 4

Reclaimed Tank (Under ground, 300 m3)

 34

5% HCL sol
CATION & ANION
REGENERATION SYSTEM
SAC
DM Plant

DM Water Line 5% HCL solution

Ejector
33% Acid, For SAC N-Pit
from Bulk Acid (1.8 m3) For MB 5% NaOH sol
storage tank 33% HCL (1.2 m3)
33% HCL

Acid Regeneration Area

SBA
GUARD POND

Alkali Regeneration Area

DM Water Line N-PIT

N-Pit
For SBA For MB
48% Caustic, (1.8 m3) (1.8 m3)
from Bulk Caustic 30% NaOH Ejectors 30% NaOH 5% NaOH sol
storage tank

MB
MB

DM Water Line 5% NaOH solution

5% HCL sol N-Pit

 35
SAC, SBA & MB
ø2500 mm

ø2800 mm MB
ø2800 mm SBA
SAC
Resin Bed Height: 1000 mm
Resin Bed Height: 2500 mm Anion Resin: A-23 Cl-
Resin Bed Height: 1200 mm Anion Resin: A-23 Cl-
Cation Resin: T-42 H+ Resin Bed Height: 500 mm
Cation Resin: T-42 H+

STRONG ACID CATION STRONG BASE ANION

MIXED BED (MB)
(SAC) (SBA)
Acid Required for SAC Regeneration 1601 kgs (31%)
Tulsion T-42 H/
Resin Name Tulsion T-42 H Tulsion A-23 Cl Caustic Required for SBA Regeneration 1342 (40%)
Tulsion A-23 Cl
Acid & Caustic Required for MB Acid: 653 kgs (30%)
Resin Volume 7500 ltrs 15000 ltrs 2500 ltrs/ 5000 ltrs
Regenaration Caustic: 1225 kgs(40%)
Bed Height 1200 mm 2500 mm 500 mm/ 1000 mm
DM Water Required for SAC regeneration 60 m3
Type Strong Acid Strong Base
DM Water Required for SBA regeneration 75 m3
Polystyrene
Matrix Structure Polystyrene copolymer DM Water Required for MB regeneration 112 m3
copolymer
Service Cycle of SAC 18 hours (varies)
Quaternary Ammonium
Functional Group Nuclear Sulphonic
Type-1 Service Cycle of SBA 18 hours (varies)
Ionic Form Supplied Hydrogen Chloride Service Cycle of MB 51 hours (varies)
Screen Size 16-50 US Mesh 16-50 US Mesh

Particle Size 0.3-1.2 MM 0.3-1.2 MM

*Note: Please refer “CHEMICAL OPERATION RULES”,
pH range 0-14 0-14 Part 2, Chapter 4, Page No - 35
Stability Max. Temp 120’C 80’C *Note: Please refer “DBR CHEMICAL”,
Moisture Content 52% 53% ANNEXURE-3, Design Calculations, Page No – 24-26
 36
DMF, ACF & RTV ø804 mm

ø804 mm ø3028 mm

ø3000 mm ø3028 mm ACF

(POTABLE WATER)
DMF

ø4300 mm
DMF
(DM PLANT) (POTABLE WATER)

ø2400 mm
Anthracite: 400 mm Anthracite: 400 mm
Size: 0.8-1.8 mm Size: 0.8-1.8 mm
Quantity: 4.2 MT approx Quantity: 4.25 MT approx
Activated Carbon: 2000 mm
Quartz Sand : 800 mm Quartz Sand: 800 mm Quantity: 28 MT approx
Size: 0.6-1.2 mm Size: 0.6-1.2 mm
Quantity: 6.5 MT approx Quantity: 6.6 MT approx

ø804 mm ø804 mm

ø2800 mm ø2800 mm

RTV RTV
ø2500 mm

ø5000 mm
(Resin Transfer Vessel) (Resin Transfer Vessel)

Cation Resin Holding Tank Anion Resin Holding Tank

 UF Skid UF & RO 37

UF Pressure Vessel

Name of the Membrane: Norit XIGA (SXL-225 FSFC PVC)

Filtration: Dead-End filtration
Flow: Outside-In flow
Membrane: Polyethersulfone (PES)
Internals: Free Surface Flow Collector (FSFC)
Housing: Polyvinyl chloride (PVC)
Total Pressure Vessels for each skid : 22
Total Membranes for each skid: 22x4= 88
Total UF Skids: 6 (each 2 in service for one stream)

*Note: Please see page nos. 82,83, & 84

RO 1st Stage RO 2nd Stage

RO Pressure Vessel

Name of the Membrane: DOW FILMTEC BW30-400

High Rejection, High Surface Area Brackish Water RO elements
Filtration: Cross flow filtration
Membrane Type: Polyamide Thin-Film Composite (TFC)
Housing: PVC
Flow: Inside-Out
Pass: 1, Stages: 2
Number of Pressure Vessels in each RO Skid: 34
1st Stage: 22, 2nd Stage: 12
Total number of membranes: 34x6=204
Total RO Skids: 6 (each 2 in service for one stream)

*Note: Please see page nos. 86,87,88 & 89 RO Skid

 CPU Regeneration
38
Waste
ACID & CAUSTIC UNLOADING AREA,
N-PIT AND GUARD POND AREA Guard Pond
(3300 m3)

CT Blow RO Reject Waste water

Down water tr. Pumps
(3*400 m3/hr)
ACID STORAGE TANKS (2*20 m3) SOLID ALKALI ALKALI STORAGE TANKS (2*20 m3)
DISSOLVED TANK N-Pit water

30-35% 30-35% 45-48% 45-48%

HCl HCl NaOH SSTP
ALKALI UNLOADING
NaOH
ACID UNLOADING
PUMPS (2*15 m3/hr) PUMPS (2*15 m3/hr)

Alkali Dosing Pump

Compressed Air Tanks

Acid Dosing Pump

ROOT BLOWERS
(2*7.3 1N m3/min) N-PIT

(2*12.5 N m3)
DMP
ETP

TOWARDS GUARD
POND
N-PIT: NEURTALIZATION-PIT
(2*320 m3)
Acid waste from Cation bed
after acid regeneration and
Alkali waste from Anion bed Acid waste + Alkali waste = Salty
after caustic regeneration N-PIT WATER TRANSFER water (Acid+Caustic=Salt + water).
mixed and neutralized by each PUMPS (2*150 m3/hr)
other.
Regeneration waste from SAC, SBA &
MB after regeneration
 39
ETP SLUDGE DEWATERING STATION
Top Floor

Horizontal Solid-Bowl Decanter

Centrifuges (2*50 m3/hr) ETP#2 ETP#1
Extracted Water to ETP
Clarifier through Reclaimed
Water Basin

ETP#3 ETP#4

Concentrated
Sludge
ETP
Sludge

PAM Dosing

Sludge water
Tank ETP
Water Mixer
PAM
Mixer
Sludge
Thickener
PAM Powder Overflow Overflow

Drain Drain

PAM Dosing Pumps for Centrifuge (2*946 LPH) PAM Dosing Pumps for ETP (5*235 LPH)

ETP Sludge tr. Pumps

(2*50 m3/hr)

Ground Floor
 40

BOILER AREA
 CONDENSATE POLISHING UNIT (CPU) 41

• The Condensate Polishing Units (CPU) consists of

Deep Mixed Bed Service Vessel with external
Condenser Cooling Water (In & Out) regeneration system.
• CPU is an Auxiliary System of Boiler, and works
like Kidneys in human being. Which continuously
Chances of contamination TURBINE filters the impurities without any disturbance.
takes place • Each MB consists of Cation & Anion resin.
• Cation Exchange Resin is Purolite D001 & Anion
Hot well DM Water make-up Exchange Resin is Purolite D201.
(From DM Plant)

BOILER
1500 m3/hr

750 m3/hr 750 m3/hr

Condensate Extraction Pumps

(CEP), 2*1640 m3/hr
MB-B 12.7 m3
MB-A MB-C

BENEFITS:
* Improvement in the quality of condensate and
"cycle" clean up.
* Reduced blow down and make up
requirements Resin Resin Resin
Trap Trap Trap
* Quick start up and as a result, full load
conditions are reached early giving economics
benefits.
* Orderly shutdown possible in case of
condenser tube leak conditions.
* Improvement in quality of steam which results
in enhanced turbine life. Recirculation Pump Ammonia
(468 m3/hr) Hydrazine
 42
CONDENSATE POLISHING UNIT
(CPU Details)

Strainers in CPU Vessel

CONENSATE POLISHING UNIT (CPU)

Name of the Cation Resin Purolite D001

Name of the Anion Resin Purolite D201

Cation Resin Quantity 5000 Ltrs

Anion Resin Quantity 3360 Ltrs

HCL Required for Single Regeneration 2870 kgs

CPU
NaOH Required for Single Regeneration 1170 kgs
ø3000 mm
For Hydrogen Cycle Chemical Required for Single 100 kgs/m3
RESIN BED Regeneration (HCL or NaOH)
HEIGHT:1000 mm
For Ammonia Cycle Chemical Required for Single 200 kgs/m3
Regeneration (HCL or NaOH)

Chemical Concentration HCL: 4-8%, NaOH: 4%

Hydrogen Cycle 7 days

Ammonia Cycle 14 days

Both Cycles 21 days

*Note: Please refer “DBR CHEMICAL”, DM water required for one regeneration 450-500 m3 (approx)
ANNEXURE – 3, DESIGN METHODOLOGY & SAMPLE CALCULATIONS,
Page No: 26-27
 CPU REGNERATION SYSTEM (External) 43
*CPU regeneration system is an external
system, where mixed resin from CPU Beds
collected through pipeline.
Ф2400/Ф1600
*Mixed resin collected in Resin Separator
Ф1600
Vessel, where stage wise backwash
RESIN SEPARATION
TOWER (25.6 m3) conducted to remove the “CRUD” and
CATION Ф1600
Ф1800, REGENERATION separate the Cation and Anion resins in two
RESIN HOLDING ANION
HEATER (8 m3)
v=10 m3 TANK (13.6 m3) TANK (15.6 m3) REGENERATION separate layers.
TANK (9.16 m3) RESIN TRAP *Later Cation resin transferred to Cation
100⁰C
regeneration unit and Anion resin to Anion
regeneration unit. After that regeneration
done by separately.

To Guard Pond

Ф1800, Ф1800,
v=10 m3 v=10 m3
Waste Water Tank/N-Pit
(320 m3)
[under Ground]
ROOT BLOWER
ROOT BLOWERS
(1*8.87 m3/min)
(2*8.87 m3/min)
Waste Water Pumps
PRESSUREISED AIR STORAGE TANKS (2*100 m3/hr)
(2*12.7 m3)

*After completion of regeneration,

regenerated resin transferred to Resin Caustic Metering Pumps Acid Metering Pumps
holding tank and mixed with air. (3*1617 liters) (3*2356 liters) DN2500, DN2500,
*The mixed resin were transferred to v=20 m3 v=20 m3
the location and taken into service. Caustic Storage Acid Storage
*CPU resins are special resins, which are Tank Tank
designed to sustain in high pressures
and temperatures.
*CPU Removes suspended solids (like
turbidity etc) and dissolved impurities
Caustic Unloading Acid Unloading Pumps
from the return condensate and make-
Acid Metering Tank Pumps (2*12.5 m3/hr) (2*12.5 m3/hr)
up water. Caustic Metering Tank
(2200 liters) (4000 liters)
 44
BOILER CHEMICAL DOSING ROOM

Hydrazine Hydrazine Ammonia Ammonia

Metering Metering Metering Metering
Tank Tank Tank Tank
(1200 ltrs) (1200 ltrs) (1200 ltrs) (1200 ltrs)

Dosing in CPU Outlet line Dosing in Deaerator Outlet line Doing in CPU Outlet line Doing in Deaerator Outlet line
(2*97 ltrs/hr) (2*90 ltrs/hr) (2*97 ltrs/hr) (2*145 ltrs/hr)

There are two Boiler Chemical Dosing Rooms

Phosphate Caustic in KMPCL, one for 1,2,3 units and another for
Metering Metering 4,5,6 units.
Tank Tank For Hydrazine, Ammonia and Phosphate Dosing
(1200 ltrs) Unit#1,2,3 equipment's are three sets for three units
(1200 ltrs) and Caustic Dosing system is one for each
three units.
Like wise two Dosing rooms are there.

Caustic Dosing in CCCW

Dosing in Boiler Drum for three Units
(2*56 ltrs/hr) *Note: Please refer “DBR CHEMICAL”,
(4*97 ltrs/hr)
ANNEXURE – 3, DESIGN METHODOLOGY & SAMPLE
CALCULATIONS, Page No: 32-35
 BOILER CHEMICAL DOSING LOCATIONS AND 45
BLOWDOWN LOCATIONS
CONDENSATE POLISHING UNIT (CPU)

MECHANICAL
DEAERATOR
MB-A MB-B MB-C

CPU OUTLET

AMMONIA (NH3) DEAERATOR

OUTLET
HYDRAZINE (N2H4)

BOILER DRUM
AMMONIA:
Ammonia is a pH booster. At high pH (9-10) boiler corrosion
is very less. But ammonia is a corrosive for yellow metals
(copper).

HYDRAZINE:
TRI SODIUM CONTINUOUS BLOW
Hydrazine Hydrate is an oxygen scavenger. Which avoids
PHOSPHATE DOWN (CBD)
serious corrosion problems. After mechanical deaeration, the
remaining dissolved oxygen (DO) was removed by hydrazine. (Na3PO4)
BCP SUCTION HEADER
PHOSPHATE:
Tri-Sodium Phosphate (TSP) is used to prevent scales in
boiler. TSP reacts with hard scale forming ions and convert
BOTTOM RING HEADER
them into loose precipitates, which were drained through
boiler blow down.
PERIODIC BLOW
Ammonia and Hydrazine are Volatile matters. They present in both water and steam, but phosphate is non-volatile matter, it can't DOWN (PBD)
distribute into steam. So it present only in water.
Ammonia and Hydrazine both are removed in Condensate Polishing Unit along with other impurities. That’s why dosing of Ammonia
and Hydrazine are required continuously.
 46
HEATERS & DEAERATOR
Steam Extractions are used for various purposes, one of the most important is to
raise the temperature of feed water.

LP & HP HEATERS:
Heaters are used to increase the feed water temperature. They are internally
having shell and tubes for heat transfer. See the image showing the internal design
of an heat exchanger.
Shell side: Hot steam, Tube side: Cold water.

BUILT-IN TYPE DEAERATOR:

This equipment is built-in type deaerator used to remove the dissolved oxygen
and other gas that cannot be condensed in feed water, of which the method is
mixing the steam with feed water directly to heat the feed water to the
corresponding saturated temperature under the operating pressure of deaerator.

PRINCIPLE: Gases are easily dissolved in cold water and slightly dissolved in hot
water. Pressure also plays a vital role in dissolution. If a liquid is under high pressure
and low temperatures, than the liquid contains more dissolved gases in it and vice
versa. If a liquid reaches boiling point then there is no dissolved gases present in it.
In Deaerator water is under opposite pressure with temperatures crossing the
boiling point, which removes all dissolved gases present in it.

*Note: Please refer “TURBINE OPERATION & MAINTENANCE MANUAL”,

Chapter 8, Deaerator, Page No – 130
 47
DRUM PRESSURE Vs SILICA GRAPH

4000
3800
3600

3200
3200
2800
2600
2400
Silica (ppb)

2000 2200
Silica at 9.0 pH
1800
1600 Silica at 10.0 pH
1600 1400
1200
1150 1100

800 770
850 650
690 440 400
400 550 340
250 220
390
340
310 210 190
0
90 100 110 120 130 140 150 160 166 170 180 190

Drum Pressure (Kg/cm2)

* NOTE: Keeping silica in Main Steam (or) Super Heated Steam restricted to ≤20 ppb (or) ≤0.02 ppm, definitely we have to follow drum pressure
according to drum silica levels to avoid silica carry over.
 48
SWAS PANEL
(STEAM AND WATER ANALYSIS SYSTEM)

MODEL: SQJ-60
NAEG
WATER STEAM CENTRIALIZED SAMPLING DEVICE

Condenser Make-up Super Heated Saturated Steam Economizer Inlet Community Silica Boiler Drum
Water Silica Steam Silica Sodium Hydrazine Analyzer Phosphate
(Limit: <20 ppb) (Limit: <20 ppb) (<5 ppb) (Limit: 10-50 ppb) (Limit: <250 ppb) (Limit: 0.5-3.0 ppm)

HACH POLYMETRON 9210 HACH POLYMETRON 9210 HACH POLYMETRON 9245 HACH POLYMETRON 9186 HACH POLYMETRON 9210 HACH POLYMETRON 9211
Range: 0-1000 ppb Range: 0-1000 ppb Range: 0-10000 ppb Range: 0-500 ppb Range: 0-5000 ppb Range: 0-50 ppm
SEE NEXT PAGE

SAMPLE COLLECTING POINTS IN SWAS PANEL

Generator Stator
Oildom Drain Cooling Water
Super Heated Steam Condensate Make-up
Deaerator Outlet Boiler Drum Water
HP Heater Drain Water
Condensate Economizer Inlet Saturated Steam Reheated Steam LP Heater Drain Closed Cooling Water
Pump Outlet

1 2 3 4 5 6 7 8 9 10 11 12 13
 49
SWAS ONLINE METERS WITH LIMITS
(See Previous Page)

1. CONDENSATE PUMP 2. CONDENSATE PUMP 3. CONDENSATE PUMP 4. CONDANSATE PUMP

OUTLET CC OUTLET SC OUTLET pH OUTLET O2
Limit: <0.3 µS/cm Limit: <10 µS/cm Limit: 8.8-9.2 Limit: <40 ppb

5. DEAERATOR OUTLET O2 6. ECONOMIZER INLET CC 7. ECONOMIZER INLET SC 8. ECONOMIZER INLET pH

Limit: <7 ppb Limit: <0.3 µS/cm Limit: <10 µS/cm Limit: 8.8-9.2

9. BOILER DRUM WATER SC 10. BOILER DRUM WATER pH 11. SATURATED STEAM CC 12. SUPERHEATED STEAM CC
Limit: <50 µS/cm Limit: <9-9.5 Limit: <0.3 µS/cm Limit: <0.3 µS/cm

13. REHEAT STEAM CC 14. LP HEATER DRAIN CC 15. CONDENSER MAKE-UP 16. CLOSED COOLING WATER
Limit: <0-1 µS/cm Limit: <0.3 µS/cm WATER SC SC
Limit: <20 µS/cm Limit: <30 µS/cm

17. SUPERHEATED STEAM DCC 18. CLOSED COOLING WATER 19. GENERATOR STATOR 20. GENERATOR STATOR
Limit: <50 µS/cm pH COOLING WATER SC COOLING WATER pH
Limit: <8-9.5 Limit: <2.0 µS/cm Limit: 6.8-8.0

CC: Cation Conductivity

SC: Specific Conductivity
O2: Dissolved Oxygen

Cation Conductivity (CC): To determine the amount of anions (chlorides, sulfates, acetates, etc.) in
the steam. Degassed cation conductivity provides a measure of the total anion concentration in the
sample.
Specific Conductivity (SC): Specific conductance is one of the most commonly used methods. The
specific conductance of a sample, measured in microsiemens (µS) or micromhos (µmho), is
proportional to the concentration of ions in the sample.
 50

OTHER AREAS
From Sewage Water SANITARY SEWAGE TREATMENT PLANT (SSTP) 51
Pump House

ANAEROBIC TANKS CONTACT OXIDATION TANKS SEDIMENTATION TANKS

SLUDGE TANK

Mechanical Grid

Sewage Pumps
(2*25 m3/hr)
SEWAGE WATER STORAGE
BASIN (350 m3) Sludge Terminal
Carry Away

ANAEROBIC TANKS CONTACT OXIDATION TANKS SEDIMENTATION TANKS

ROAD
GUARD
POND
SSTP

ROAD
DM PLANT
Root Blowers
(4*4.32 m3/min)

Domestic Water

Auto To Rain Water Piping

Chlorinated water Backwash
Filter
(50 m3)

Intermediate Water
Basin Pumps (2*50 m3)
Purified Water Basin
Pumps (2*50 m3)

Safety Shower CHLORINE DIOXIDE INTERMEDIATE WATER BASIN PURIFIED WATER BASIN
GENERATOR (2*400 g/hr) (150 m3) (300 m3)
 52
SEWAGE: Sewage is the term used for wastewater that often contains faeces, urine and laundry waste.

ANAEROBIC TANKS
• Aerobic, means in the presence of air (oxygen); while anaerobic means in the absence of air (oxygen). These two terms
are directly related to the type of bacteria or microorganisms that are involved in the degradation of organic impurities
in a given wastewater.
• Therefore, aerobic Waste Water Treatment Plant processes take place in the presence of air and utilize those
microorganisms (also called aerobes), which use free oxygen to assimilate organic impurities i.e. convert them in to
carbon dioxide, water and biomass.
• The anaerobic treatment processes, on other hand take place in the absence of air (free oxygen) by those
microorganisms (also called anaerobes) which do not require air (free oxygen) to assimilate organic impurities. The final
products of organic assimilation in anaerobic Waste Water Treatment Plant are methane and carbon dioxide gas and
biomass.
tank collected in Intermediate water basin.

CONTACT OXIDATION TANKS

• Aeration in the oxidation tank is provided by aerators fitted with variable speed drives. Dissolved oxygen (DO)
concentrations in the oxidation tank are monitored and results in optimized nitrogen removal capabilities.
• Waste activated sludge and scum is withdrawn from the oxidation tank.

SEDIMENTATION TANKS
• Waste activated sludge is pumped from the oxidation tank to the anaerobic sludge tank. Bio-solids are further stabilized
using anaerobic sludge tanks.
• Supernatant (clear water on top) from the top of sedimentation tank collected in Intermediate water basin.

Inlet sewage: BOD5 <200~400mg/l, SS <200~450mg/l, PH 6~9

Outlet Water Quality: better than the national sewage discharge standards and meet the water quality demand for reuse.
BOD5 <10mg/l, COD≤40 mg/l; chromaticity<30, SS < 5mg/l; PH 6~9

*Note: Please refer “CHEMICAL OPERATION RULES”,

Part 7, Chapter 3, Page No - 106
 53
STATOR COOLING WATER SYSTEM

The major cause of problems in stator cooling systems has not been
corrosion but, rather, deposit accumulation in critical areas. These
deposits are copper oxides released from one area of the stator
coolers and deposited in another. The amount of dissolved oxygen in
the system, and particularly variations in that oxygen concentration,
pH = 7.0
determines when copper oxides are released.
pH = 8.0
Low Dissolved Oxygen Regime: Copper forms Cuprous Oxide (Cu2O) pH = 8.5
under reducing conditions (less than 50 ppb).

High Dissolved Oxygen Regime: Copper forms Cupric Oxide (CuO)

when dissolved oxygen is high (grater than 2000 ppb).

Either of these oxides can be stable and create a passive oxide layer
on the channels in the stator bars. A slightly alkaline pH increases
the stability of the oxide layer.

Design: Neutral pH and High Dissolved Oxygen Regime

pH: 6.8-8.0, DO: >1100 ppb
Stator Cooling Water Demineralizer Resin Quantity: 360 litres
Anion Resin: 240 ltrs
Cation Resin: 120 ltrs

Hardness should be not higher than 2 (microequivalent/L).

The content of silicon dioxide, copper and iron ion shall not
exceed 50ppm.
The content of sulfur and chloride ion shall not exceed 1ppm
respectively.
b. PH value ranges within 7~8.
c. Conductivity is not higher than 1.0μs/cm (at 20℃)
d. Make-up water pressure ranges within 0.2~0.7MPa.

*Note: Please refer “Turbine Operation & Maintenance Manual”,

Chapter 13, Generator Stator Coil Cooling Water System, Page No - 155
 HYDROGEN METHODOLOGY 54
Working Principle :- To ensure high efficiency , hydrogen purity is generally maintained above
The amount of hydrogen and oxygen formed are directly 98%.
proportional to the amount of DC current. Although hydrogen is 14 times more efficient than air in removing heat and
5.625 = 3.750 + 1.875 (Practical) is the lightest of all gases, there can be major disadvantages if not used
H2O = H2 + O2 properly. Hydrogen can be very explosive when mixed with air, and it will
Concentration of Electrolyte = 30 % KOH lose efficiency when its purity decreases. Additionally, high moisture levels
in the hydrogen can lead to generator component failure.
1000 m3 = 666 m3 + 334 m3 (Theoretical) FLAMMABLE LIMIT:
H2O = H2 + O2 LOWER: 4%, UPPER: 74%
Cathode = Hydrogen, Anode = Oxygen
FREEZING POINT: -259.14⁰C
Cathode: 2H2O +2 e → H2 ↑ +2 OH- BOILING POINT: -252.87⁰C
Anode: 2OH-－2e → H2O +1 / 2O2 ↑
The overall reaction: 2H2O → 2H2 ↑ + O2 ↑ DEW POINT: “Dew Point” is defined as the temperature to which a given
volume of gas must be cooled at constant pressure and constant water vapor
content in order for saturation to occur. If the gas is cooled further, some of
DM water for Stator the moisture will condense.
Cooling DRY HYDROGEN DEW POINT: -80⁰C
MOIST HYDROGEN DEW POINT: 20⁰C
Usual industry standard is to achieve control at -20°C, or lower.

Hydrogen purity:  99.9%

Oxygen purity:  99.2%;
Hydrogen Dew Point in Generator: Normal: -140C
Upper Limit: -50C, Lower Limit: -250C
Hydrogen humidity: Dew point:  -500C
Hydrogen: 2x10 Nm3/h

Hydrogen Gas for Rotor
Cooling
*Note: Please refer “CHEMICAL OPERATION RULES”,
Part 8, Chapter 1, Page No – 113-119
*Note: Please refer “TURBINE O&M MANUAL”,
Chapter 3, Equipment Running, Page No – 63
PREPARATION OF ELECTROLYTE:
a. Prepare 24% 150L (specific gravity is 1.2571 in 30℃) of NaOH solution, add a
small amount of condensate to the clean alkali solution tank, and then add
45Kg chemical pure sodium hydroxide (NaOH) solution till 150L. Plastic stick
can be used to stir in dissolution process, in order to accelerate the dissolution
and heat elimination.
b. After safe dissolution and cooling, the specific gravity of sample measured
by hydrometer is about 1.26, and then adds 380g vanadium pentoxide and
160g cobaltic oxide and stir to dissolve.
 COAL-BEARING WASTE WATER TREATMENT PLANT 55
(OVERVIEW)
Coal Yard
Chemical Dosing
Tanks (1 m3)
Membrane Filters
PAC
2 1 Shion (6 m3)

Unloading Pumps
By Gravity

(6*20 m3/hr)
CAUSTIC
(6 m3)

3 HYPO
(6 m3)
Submersible Sewage
Pumps (3*35 m3/hr)
Storage Tank Coal Yard
Root Blowers (6 m3/min)

FILTER Filtered Water

In First Chamber: Coal dirty water enters into the first
Storage Tank chamber. Chemicals added to lower the turbidity (coal
Overflow Line
Service particles) and smell (organic matter).
In Second Chamber: Coal particles are settle down slowly.
Membrane Filter The accumulated coal particles removed by the help of mud
bucket.
In Third Chamber: With the help of blowers, chemicals are
mixed thoroughly and maintain the coal particles in
suspended form for further filtration.
washing

In Service: Submersible pumps feed the coal water into the

membrane filters from bottom side, where filtration will be
SHION taken place from bottom to top. In the upper chamber, filter
Fine Thick water collects by overflowing.
Coal Slurry In Washing: From bottom to top water recirculates through
(drain) submersible pumps. By touching the membrane filters from
bottom side and collects the fine dust particles, the dirty
water enters into shion, which filter the fine dust.
Thick Coal Slurry 3
(drain)
 56
COAL-BEARING WASTE WATER TREATMENT PLANT

Coal-bearing wastewater is mainly from hydraulic flushing drainage of power plant coal
transporting trestle, HVAC dedusting drainage, transfer station flushing drainage, flushing
drainage of coal bunker layer and coal yard initial rainwater. Coal-bearing wastewater from
these parts is collected in pipelines and then lifted to coal-bearing wastewater treatment
system for treating. The treatment capacity of drainage system is 70m3/h.

After pre-sedimentation, coal-bearing wastewater is transferred to coal-bearing wastewater

sedimentation tank to be oxidized, removed with heavy mental ions and go through
coagulation treatment in the tank, then the wastewater is transferred to membrane filter by
transfer pump to filtrate, and after that the qualified filtered water automatically flows to
coal transportation flushing tank for reuse. Coal slag discharged from the bottom of
membrane filter is transferred to the sludge transfer pump of industrial wastewater
treatment system or conveyed by dollies.

Treatment capacity: 70m3/h

Inlet Water Quality:

Suspended Solid (SS): 5000 mg/L

Outlet water quality:

Suspended Solid (SS): ≤5 mg/L
COD: ≤100 mg/l
COLOUR (chromaticity): ≤50

*Note: Please refer “CHEMICAL OPERATION RULES”,

Part 7, Chapter 1, Page No - 99
 57
OILY WASTEWATER TREATMENT SYSTEM
(Located in FOPH)

Oily wastewater is mainly from flushing drainage of oil tank

farm, rainwater drainage of oil tank farm, flushing drainage of
fuel pump house.
Oily (heavy oil) wastewater entered into oily wastewater
treatment station is treated by oil-separating tank, and then
lifted into oil-water separator for degreasing treatment, the
treated outlet water flows into industrial wastewater pond
for reuse. Floating oil on the upper of oil-separating tank is
transported to the storage tank through floating oil
absorption machine.

Oil-water separation is designed based on Shallow

Precipitation Principle and has been applied in the oil-water
separation of beneficiation water, refining water and oily
wastewater of power station, pretreatment of wastewater
treatment and other areas.

Volume: 10 m3
Water content in recycling waste oil separated: <5%
Oil Content of Outlet Water: ≤10 ppm
Velocity of flow: ≤80 m/h

*Note: Please refer “CHEMICAL OPERATION RULES”,

Part 7, Chapter 2, Page No - 103
 58
ASH HANDLING PLANT
(OVERVIEW)

GUARD POND

ASH WATER SUMP ART

(2*360 m3) approx (AGITATOR RETENTION TANK)
(100 m3) approx

HCSD Pumps
(HIGH CONCENTRATION
ECO DEASHING
SLURRY DISPOSAL)

BOTTOM DEASHING

FLY ASH DYKE

ASH SLURRY SUMP ASH PERCENTAGE IN COAL: 30-40%

BOTTOM ASH, ECO ASH, FLY ASH

BOTTOM ASH RATIO: 20% (In total ash)
ECO ASH RATIO: 5% (In total ash)
BOTTOM ASH DYKE FLY ASH RATION: 70-75% (In total ash)

HSCD ASH WATER RATIO:

ASH CONTENT: 60-70%
WATER CONTENT: 30-40%
 59
FLY ASH HANDLING PLANT

BAG FILTERS AND

ESP HOPPERS

VACUUM PUMPS

COMPRESSOR HOUSE
BUFFER VESSELS

FLY ASH YARD

ASH SILO

MIXING TANK BOOSTER PUMP

HSCD PUMP HOUSE

ASH DISPOSAL THROUGH TRUCKS
 60
BOTTOM ASH HANDLING PLANT
SERVICE WATER LINE
BOILER GUARD POND

HP WATER PUMP HOUSE

BOILER
OVERFLOW
BOTTOM ASH HOPPER

ECONOMIZER HOPPER

OVERFLOW TANK & PUMP

SLURRY TANK

OVERFLOW
SLURRY PUMP

BUFFER TANK CONCENTRATOR

RECYCLING PUMP
HP WATER PUMP HOUSE HOUSE

SEAL WATER PUMPS-02 ECO HP PUMPS-04 BOTTOM ASH DYKE

SUPPLY WATER PUMPS-04 BOTTOM ASH HP PUMPS-04
 61

GENERAL DESCRIPTION OF
“THE IMPORTANT FILTRATION
SYSTEMS USING IN KMPCL”
 62
RIVER WATER PUMP HOUSE
 63
Front View Side View
Intake Well
Intake Well Pumps

Floating Objects Floating Objects

Mahanadi River Screenings

Screenings
Basantpur

Settled Objects
23.64 kms
Settled Objects

Seorinarayan Basantpur Seorinarayan Pamgarh

22.86 kms Total Number of 03 (2W,1S) 02(1W,1S) 04 (2W,2S)

Pumps 02(1W,1S)
Flow 3*2500 m3/hr 2*5000 m3/hr 4*6000 m3/hr
2*2500 m3/hr
Distance 23.64 kms 22.86 kms 14 kms
Pamgarh
Stock One month stock for
14.0 kms total six units

Reservoirs
 64

Bar & Travelling Screens

Screening is the first most step of filtration starting from River Intake well. Which filters, floating objects like trees,
fishes, algae, wood pieces, leaves, stones etc in river water. They are often placed on slight inclination. Which are
moving and cleaned continuously. Coarse screens (50 mm) followed by fine screens (25mm).
 65
RESERVOIRS
 66
RESERVOIRS

3,00,000 m3 3,00,000 m3 6,00,000 m3

1 2 3

Inter connection Gates

Top view
Raw water pump house
HRSCC
KMPCL have 3 reservoirs with the capacities of total 12 lacks .
(3 lacks + 3 lacks + 6 lacks) m3.

The main purpose of reservoirs are to maintain the water stock for 7-15 days and secondary is storage
of raw water.

Raw water storage : There is a noticeable improvement observed in water quality by retention of
water. On retention suspended solids in the water are pulled downwards by the means of gravity. After
some duration there is a reduction in turbidity, total suspended solids (TSS), pathogenic bacteria and
river algae, while at the same time not long enough to encourage other organisms to develop.
 Aeration These three methods are not using in KMPCL for PT Plant 67

Aeration requires only when high amount of dissolved gases are present in
water, generally in ground water. It is the cheapest method for removing excess
amount of dissolved gases & undesirable gases (volatile organic compounds)
from water. Dissolve metals like iron & manganese are oxidized and
precipitated out. In aeration gases are absorbed or liberated from water until
equilibrium is reached.

Greensand Filters

Water containing excessive amounts of iron and manganese can stain clothes,
discolor plumbing fixtures, and sometimes add a "rusty" taste and look to the water. In
general ground water contains iron & manganese in excess compare to river water.
Greensand filters are used to remove iron and manganese from water.

Oil skimmers

Oil skimmers are used to separate oil from water. In general oils/Grease are not
found in natural water, except if any contamination occures. Mostly effluent
water contains oily substances.
In KMPCL tank type oil skimmer is using for separate oil/water in FOPH.
 68

High Rate Solid Contact Clarifier (HRSCC)

Clarifiers removes turbidity, color, colloids and small particles.

Clarifiers works on the principle of Stoke’s law.

Coagulants, flocculants and disinfectants are used to achieve
the quality.

Negatively charged colloidal particles are removed by

Turbidity Water Clear Water
adsorption onto the surface of coagulant (PAC), which
eventually form floc by aggregation of the smaller particles.
In presence of polyelectrolyte (PAM), these flocs form quicker
and settle down easily. The accumulated flocs are than
collected at the bottom of the clarifier. The clear water collects
from the top of the clarifier.

Sludge
 Big & medium 69
sized particles are
naturally settled
down by gravity in
stagnant water. This
action takes place in
reservoirs.

Tiny charged
particles, repulse
each other and not
able to settle down
easily. For this we
required chemicals
to treat the water.
This action takes
place in the
clarifiers.
 70

Chlorination System

Chlorine is an disinfectant. It kills the micro

organisms like bacteria, algae etc and
improves the color, taste & smell of the water.
Chlorine oxidizes iron and manganese also.
Each chlorine tonner contains 900 kgs of
liquid chlorine out of 1600 kgs of total weight. Legionnella bacteria (found in cooling
Chlorine is a gas but in high pressure gaseous water, causes lung diseases in humans)

chlorine converts into liquid chlorine and vice- Sulfate Reducing

versa. Bacteria (SRB), causes
corrosion in cooling towers
From the tonner chlorine can be collected
in two ways, gaseous chlorine from the top
side and liquid chlorine from the bottom side.
Evaporators (heaters) are used to convert
liquid to gaseous form (80-84°C) for cooling
Algae (causes severe fouling
water treatment. in cooling towers)
 71

Radial flow Sludge Thickener:

Gravity thickening uses the natural tendency of higher-density solids to settle out of liquid to concentrate the
solids.
Thickening is the process by which solids are condensed to produce a concentrated solids product and a
relatively solids-free supernatant. Thickening wastewater solids reduces the volume of residuals, improves
operation, and reduces costs for subsequent storage, processing, transfer, end use, or disposal. For example,
thickening liquid-solids (slurry) from 3 to 6 percent will reduce the volume by 50 percent.

The diameter of each clarifier is 20 m & height is 5.6 m. Total 4 sets (3 working, 1 standby).

SLUDGE THICKENER
OVERVIEW
 72

Sludge Transfer Pump

Progressive Cavity Screw Pumps

Progressive cavity (PC) pumps are commonly referred to in industry as mono-
pumps, screw pumps, eccentric screw pumps or worm pumps. All are positive displacement
pumps.
The PC pump consists of two major components, a rotor and a stator. The rotor is
helix shaped, machined from either stainless steel, hard-coated carbon steel or hard-coated
stainless steel.
PC pump is recommended for highly viscous and/or shear-sensitive liquids and
sludge. Key industries for PC pumps are pulp and paper, wastewater and oil.
 73

Horizontal Solid Decanter

Centrifuge
 74

Decanter Centrifuge
Decanters are horizontal, solids-oriented, solid-wall scroll centrifuges.

Decanter centrifuges are normally based on horizontal separation technology and work at slower
speeds. An important application is dewatering of sludge in wastewater treatment plants. Decanter
centrifuges require a centrifugal force for the separation of the solids from the liquid.

The Horizontal Decanting centrifuge (Decanter) has a vast field of applications in various Processes
where a liquid and a solid phase have to be continuously separated.
 75
Multi Grade Filters
 Quartz Sand
76

Anthracite

Sand

Sand Anthracite
Quartz Sand

Pebbles

Gravels
Gravels Pebbles

Filter Media
 77

Activated Carbon
Filters (ACF)
 Dual Media Filter (DMF) 78

3024 mm
Dual Media Filters are used to remove
turbidity and suspended solids from water.
2470 mm

Well operated Dual Media Filters are able to

Anthracite filter the water 15-20 microns. (Ex: size of
1200 mm

human hair is 50-100 microns).

Quartz Sand

Strainers
(HDPE) Activated Carbon Filter (ACF)

Activated Carbon Filters: Coconut shell activated carbon

is used to remove Free Residual Chlorine (FRC), ACF
organic matter, oil, grease, objectionable taste, odor
and color from water.
Particularly ACF is used to remove chlorine from water. Activated
Chlorine effects the life of RO membranes and Carbon
Resins. In general ACF is not recommended for RO
Sand
plants.
ACF works on the principle of Adsorption. Strainers
(HDPE)
 STRAINERS AND DISTRIBUTION HEADERS
79

*Stainless Steel made Wedge Wire

Screens Distribution headers are used
WEDGE WIRE SCREEN DISTRIBUTION HEADERS
to distribute water in the vessel.
*Stainless Steel/PVC made Filter
Nozzles are used in water treatment
system to trap the filter media (means,
resin, sand, gravel, activated carbon
etc).
*Strainers, Nozzles and Distribution
headers are used in CPU, DM Plant etc.

FILTER NOZZLES FOR WATER TREATMENT

WEDGE WIRE SCREENS

 80

Self Cleaning Auto Filters

 81

Self cleaning auto filters are placed before

UF as a Pre Ultra Filtration (UF). These filters are
designed based on Suction Scanner Technology.

AMIAD-Filtering process:
The water enters through the inlet pipe into
the coarse screen from outside in, and through
the fine screen from inside out. The "filtration
cake” accumulates on the fine screen surface
and causes head loss to develop.

Self-cleaning process:
The filter will start the self-cleaning process when the
pressure differential across the screen reaches a pre-set value
or a predetermined lapse of time.
Suction scanner, which rotates in a spiral movement while
removing the filtration cake from the screen, and expels it out
through the exhaust valve.
82
 83
Ultra Filtration
 84

Ultrafiltration (UF) is similar to RO and NF, but is defined as a crossflow process that does not reject ions. UF rejects solutes
above 1000 daltons (molecular weight).
UF removes larger organics, colloids, bacteria, and pyrogens while allowing most ions and small organics such as sucrose to
permeate the porous structure.
 85
ULTRA FILTRATION (UF)- DEAD END
& CROSS FLOW

UF SYSTEM (UF)

DEAD-END CROSS-FLOW

FEED WATER
PERMEATE

PERMEATE UF SYSTEM-DEAD END PERMEATE FEED WATER UF SYSTEM-CROSS FLOW CONCENTRATE

OUTSIDE-IN MODE INSIDE-OUT MODE

KMPCL installed - “DEAD-END, OUTSIDE-IN FLOW UF SYSTEM”

Membrane Name & Specifications: Norit XIGA (SXL-225 FSFC PVC)

XIGA Dead-End filtration, Outside-In flow concept developed by Norit X-Flow. Membrane is polyethersulfone (PES) having free
surface flow collector (FSFC) internals with polyvinyl chloride (PVC) housing.
Each pressure vessel have four membranes likewise, total 22 pressure vessels per one UF skid.
 86

Micron Cartridge Filters (MCF)

Micron Cartridge Filters (MCF) are Pre RO filters placed before RO skid.

Cartridge filters are effective in the removal of moderate amounts of particles from liquids
in the size range of 50 to 0.035 microns.

Pleated Filter Cartridges A pleated cartridge is a “surface” type filter cartridge that is effective in removing diverse
sized particles in limited quantities.
Pleated cartridges will remove particles of its micron rating with good resistance to being “blinded” by larger particles.
Pleated filter cartridges are particularly effective on surface waters from streams and rivers.
 87

Reverse Osmosis
 RO Reject RO Feed RO Permeate 88

Reverse osmosis is the

newest major method of
water purification and
one of the types of cross-
flow membrane filtration.

Reverse Osmosis is a
process which removes
both dissolved organics
and salts using a
mechanism different from
ion exchange and
activated carbon.

Membrane Name & Specifications: DOW FILMTEC BW30-400

High Rejection, High Surface Area Brackish Water RO elements with Cross flow filtration.
Membrane Type: Polyamide Thin-Film Composite (TFC) membranes.
Two Stage and Single Pass RO. Each RO Skid is having 34 pressure vessels (1st stage 22+ 2nd stage 12), each pressure vessel is
having 6 membranes. So total 204 membranes in one RO skid.
 89
REVERSE OSMOSIS (RO)-PASSES

Feed Water
(The water which requires filtration)

Permeate Water
(which is filtered water)
SINGLE PASS & SINGLE STAGE RO

Reject Water
(which is waste water)

DOUBLE PASS & DOUBLE STAGE RO

Permeate Water Permeate Water

(filtered water) (highly filtered water)

RO 1st PASS RO 2nd PASS

Reject Water
(highly concentrated waste water)

The difference between a single pass RO system and a double pass RO system is that with a double pass RO, the permeate
from the first pass becomes the feed water to the second pass (or second RO) which ends up producing a much higher quality
permeate because it has essentially gone through two RO systems.
 90
REVERSE OSMOSIS (RO)-STAGES

Feed Water
(The water which requires filtration)

Permeate Water
(which is filtered water)
SINGLE PASS & SINGLE STAGE RO

Reject Water
(which is waste water)

SINGLE PASS & DOUBLE STAGE RO

Permeate Water
(filtered water)

RO 1st STAGE RO 2nd STAGE

Reject Water
(concentrated waste water)

KMPCL Installed - “SINGLE PASS, DOUBLE STAGE RO SYSTEM”

In a two-stage system the concentrate (or reject) from the first stage then becomes the feed water to the second stage. The
permeate water is collected from the first stage is combined with permeate water from the second stage. Additional stages
increase the recovery from the system.
 Service flow
91

MB

SAC SBA

Regeneration
HCL NaOH NaOH
Exhaust Resin
Acid Caustic Acid &Caustic
Regeneration Regeneration Regeneration

HCL
Fresh Resin
Cation Resin Anion Resin

Ion Exchange
Resin
 92

• Ion exchange resins are synthetic organic polymers. Most commonly used resins are gel type polystyrene resins.
• Resin beads are insoluble in water and having the size of 0.3 mm - 1.2 mm. Optimum size is 0.6 mm.
• Resins are porous. It contents 45-55 % moisture. It swells after absorption of water. Gel type resins are once wet are
never allowed to dry otherwise, resin will be cracked.
• Cross-linking increases stability of resin but decreases the exchange rate.
• Temperature limit is ≤50⁰C.

• Cation exchange resins are two types, Strong Acid Cation exchange resins (SAC) and Weak Acid
Cation exchange resins(WAC).
• Cation Resin (SAC): Tulsion: T-42 H+. (Make: Thermax)
• Anion exchange resins are two types, Strong Base Anion exchange resins (SBA) and Weak Base
Anion exchange resins (WBA).
• Anion Resin (SBA): A-23 Cl-. (Make: Thermax)
EASY TO DRAIN, BUT
DIFFICULT TO GAIN