BOP Qual Book Updated - Rafi

Document No:SMPCL-OPN-F-034
Revision No.: 00
SUMMIT MEGHNAGHAT POWER COMPANY LTD. Effective Date: 12 Dec 15
TITLE: BOP Qualification Book Page 1 of 78
BOPE (Balance of Plant Engineer) Qualification Book
Name of the Plant Engineer: Rafiul Hoque Bhuiyan
Current Designation: Balance of Plant Engineer

Submission Date: 23 November 2017
The above plant personnel of SMPCL has completed the basic requirements to qualify for the Balance of Plant
operation. He is qualified to stand in shift duty in field.
Signature Signature Signature
_________________ ____________________ ____________________

Plant Engineer Shift Charge Engineer Operation GM
Date: Date: Date:
Revision No.: 00
Introduction
This book has been produced to provide a record that the named Plant Engineer has a satisfactory knowledge
of the plant and the ability to operate plant BOP equipment.
To meet the requirements of the first part of the book the trainee should be taken on plant to explain plant
equipment and apparatus. Where practicable the trainee should operate the plant to prove his ability.
All actions carried out by the trainee shall be supervised by his/her Senior Engineer. All actions that the
trainee takes shall include the following:-
1. Operates in a manner that is safe to him, others and the plant.
2. Before and after carrying out work on the plant he informs the plant engineer.
3. Good radio communication.

4. Correct procedures taken.
Revision No.: 00
INDEX
1. Safety
2. Water Intake
3. Pretreatment System
4. Service and Potable water System
5. De-mineralized water production system
6. Auxiliary Cooling Water System
7. Waste water collection and treatment
8. Closed Cooling Water system
9. LDO system & waste oil treatment system
10. Instrument Air System
11. Plant Fire Fighting System
12. HVAC system

Revision No.: 00
PART -1: SAFETY
Knowledge Requirement
1. What is MSDS?
Ans: A Material Safety Data Sheet (MSDS) is a document that contains information on the potential
hazards (health, fire, reactivity and environmental) and how to work safely with the chemical product.
It is an essential starting point for the development of a complete health and safety program.
2. Discuss the immediate measures to be taken for responding to personal injury for acid, caustic
spillage and chlorine inhalation?
Ans: In case of any acid, caustic spillage and chlorine inhalation emergency responses are needed to
take as soon as possible.
Acid/Caustic spillage:
 In case of acid Inhalation remove victim into fresh air.
 Allow the person to drink plenty of water.
 Take patient to hospital immediately
 Skin Contact
 Remove contaminated clothing and rinsing.
 Rinse immediately with plenty of water. (Shower if necessary)
 Seek medical attention IMMEDIATELY.
 Eye Contact
 Rinse immediately thoroughly and long (at least 15 min.) with plenty of water
 Remove contact lenses if any.
 Take to eye doctor IMMEDIATELY.
 Keep rising or dripping the eye during transport.
 Ingestion
 DO NOT INDUCE VOMITING. Rinse mouth with water.
 Take patient to hospital IMMEDIATELY.
 Never give anything by mouth to an unconscious person
Chlorine Inhalation:
 Immediately remove the patient/victim from the source of exposure.
 Evaluate respiratory function and pulse.
 Ensure that the patient/victim has an unobstructed airway.
 If shortness of breath occurs or breathing is difficult (dyspnea), administer oxygen.
 Assist ventilation as required. Always use a barrier or bag-valve-mask device.
 If breathing has ceased (apnea), provide artificial respiration.
 Monitor for respiratory distress.
 Examine the moist lining of body passages and cavities (mucous membranes) for corrosive
effects.
 Manage the airway aggressively in patient/victims with evidence of upper airway burns or fluid
accumulation (edema).
 Monitor for and treat spasmodic narrowing of the large airways (bronchospasm) if it occurs.
 Seek medical attention immediately.
Revision No.: 00
3. What are the PPE to be used during acid unloading?
Ans: All personnel who will handle acid should use followings PPE
 Hard hat.
 Close fitting safety goggles.
 Chemical resistant gloves.
 Full face shield (in addition to safety goggles).
 Chemicals resistant boots.
 Chemical protective suit (jacket and pants or coverall).
 The jacket should be buttoned up to the neck, the trousers worn outside the boots, and the shirts
sleeves sealed at the glove unless a job safety analysis determine it is acceptable for the sleeve to
be worn over the glove.
4. What are the PPE to be used during caustic unloading?
Ans: All personnel who will handle caustic should use followings PPE
 Hard hat.
 Close fitting safety goggles.
 Chemical resistant gloves.
 Chemicals resistant boots.
 The jacket should be buttoned up to the neck, the trousers worn outside the boots, and the shirts
sleeves sealed at the glove unless a job safety analysis determine it is acceptable for the sleeve to
be worn over the glove.
5. What do you understand by laboratory safety? What PPE should be stored in lab?
Ans: Laboratory safety is of paramount importance to Environmental Health & Safety, which
manages and responds to all issues and concerns surrounding chemical, biological, radiation, laser,
chemical fume hood, and centrifuge safety as well as biological safety cabinets, compressed gas
cylinders, nanotechnology, emergency spill response, hazardous waste management and other
standard operating procedures.
List of PPE in lab:

 Lab coat
 Safety glass
 Disposable Gloves
 Chemical aprons
 Respirators
 Splash goggles
 Face shield
6. What precautions do you take when you inspect the ton containers in chlorination system?
Revision No.: 00
Ans: Clothing :
Inside ton container and pump room no specialized clothing is required for personnel performing
routine plant operations. However
 Long pants
 Shirts with sleeves.
 Safety glasses with side shields or goggles approved for use with hazardous chemicals.
 Hard hat &
 Safety shoes.
In addition respiratory protection also need for chlorine handling such as
 Personnel should carry or have immediate available an escape type respirator

 Chemical cartridge or full face canister gas mask
 Self contained breathing apparatus should be available nearby or the acceptable locations.
7. What is wind sock and what is the purpose of this?
Ans: A windsock is a conical textile tube (which resembles a giant sock, hence its name) designed to
indicate wind direction and relative wind speed. Windsocks typically are used at airports and at
chemical plants where there is risk of gaseous leakage. They are sometimes located alongside
highways at windy locations.
Wind direction is the opposite of the direction in which the windsock is pointing (note that wind
directions are conventionally specified as being the compass point from which the wind originates;
so a windsock pointing due north indicates a southerly wind). Windspeed is indicated by the
windsock's angle relative to the mounting pole; in low winds, the windsock droops; in high winds it
flies horizontally.
8. What are the basic emergency responses to chlorine leak?
Ans: Basic emergency responses to chlorine leak are as follows

effects.
 Seek medical attention immediately.
9. Explain LTA, Osha Recordable and near miss incidents.
Revision No.: 00
Ans: OSHA Recordable- includes treatment administered by a physician or by registered professional

personnel under the standing orders of a physician. Does not include first aid, even if administered
by a physician.
Lost Time accident:

A work-related accident or illness that renders an employee unable to work in any capacity on his
next regularly scheduled work day.
Near Miss is an incident with lower severity but has the higher potential to result in personnel injury
or damage to property.
10. According to our safety procedures what are the reporting procedure at our plant (Who, to
whom and when)?
Ans: In any case of reporting regarding any incident the reporting person should inform the Central
Control Room first. He can report through walkie-talkie, land phone, intercom or mobile phone.
11. Why is it important to report near miss or first aid cases?
Ans: Here are top 5 reasons why it is important to report near miss or first aid cases.
 It enables companies to pro-actively resolve hazards before a tragic or costly incident occurs.
 It engages the workforce (all workers at all levels) in solving problems
 It increases safety ownership and reinforces workers’ self-esteem
 It exposes valuable information that otherwise might not be discussed
 It develops a positive and necessary attitude surrounding safety
Supervisors have an important role to play in encouraging workers to report near misses by
consistently requiring them to do so, broadening the meaning of incidents to include near misses,
acting on the information workers have given, and making it easy for workers to report near misses,
to name just a few methods of doing so.
12. What do you understand by confined space and what are the main safety precautions to be
taken to work in? Give examples of some in your area.
Ans: “Confined Space” means a space that is large enough and so configured that an employee can
bodily enter and perform assigned work; has limited or restricted means of entry or exit and is not
designed for continuous employee occupancy.
A) Personnel Safety Equipment:
 Providing for emergency rescue including the use of a full body harness, life-Line, standby person
and signal device.
 Providing personal protective clothing or equipment to limit exposure, including respiration,
SCBA or appropriate equipment.
 Calibrate and test equipment prior to use.
 Post “Confined Space” warning signs in immediate proximity of confined spaces being entered.
13. What is the definition of hot work. What are the requirement as per procedure to perform hot
work.
Revision No.: 00
Ans: Any type of job or work which may produce spark or enough heat to cause ignition is defined
as Hot work such as welding, cutting, grinding, chipping etc
14. Describe the steps to issue a lock out – tag out permit?
Ans: This is a safe isolation procedure of an equipment or machine which is need to maintenance or
kept isolated for operational/maintenance convenience. To do so a permit is issued by all concerned
personnel.
The purpose of this permit is to establish the minimum requirements as well as ensuring maximum
safety for locking and tagging out of an Energy isolating devices whenever maintenance is to be done
on plant equipment. The procedure ensures that equipment, devices and energy sources are prevented
from movement or the release of stored energy that could result in personnel injury or damage to the
plant equipment. Also the guideline of “Test” execution of any LOTO equipment as well as removing
that locks & tags after the work completion.
This procedure applies to all plant personnel and contactors. Non compliance with the procedure
could result in disciplinary action.
Scopes:
If an energy-Isolating Device is capable of being locked out the “Lockout Devices” shall be used
accompanied by a “Tag out”.
If an Energy Isolating device is not capable of Locked out then a Tag out with full device isolation
shall be used.
Any person observing equipment or a machine etc. which is locked or tagged out, shall not attempt
to start or use that machine. Tags should not be removed without authorization from the control room
engineer and never to be bypassed, ignored or otherwise defeated.
Where Applicable:
Performing maintenance or service on or around any machine where personnel injury or equipment
damage could result from but is not limited to:
 Unexpected equipment starts;
 Release of stored energy;
 Removing a guard or other safety device;
 Working adjacent to a moving machinery;
 Closing valves restricting the flow of air, steam, water, flammable liquids or chemical present
hazard;
 As a whole any situation where a permit to work would prevent conditions which could cause
injury, pollution or other undesirable results.
Responsibilities:
All permits to Work requests must be made in person in the control room, not by telephone or radio.
The Control room Engineer has immediate charge and control of the equipment requiring Permit to
work and will ensure that the permit to work is prepared and issued in accordance with the procedure.
Revision No.: 00
The Control room engineer may request plant engineer to assist in the hanging of Locks & tags in
accordance with the procedure.
The Locks & tags hung must be verified by the Principal Craft person (Maintenance work will be
carried out under his supervision), signing the “Locks and Tags Verified by” section on the permit to
work. Craft person(s) must be aware of the safety boundaries offered by it.
Flowchart of issuing LOTO:
Principal Craft C/R Engr. Fill up the C/R Engr. Stop C/R or Plant Engr.
person will sections1, 2, 3 of the M/C or shut v/v Will disconnect&
request for “Permit to Work” as mentioned in relieve residual
LOTO form & tag procedure energy
C/R or Plant C/E engr. Specifies is any extra Aft. Placing locks& tags, key
Engr. Will place precaution/permit (Hot will be returned to the control
locks & tags work/Confined space) required r/m lock box & signed in sec. 6
or not of permit form.
Principal C/R person If Breaker rack out & safety Aft. Verification principal craft
will verify locks& tags ground is required then person will fix his own lock to
then sign permit form qualified engineer will do & the CCR lock box. Then
under sec.-06 sign in section-06 maintenance can be started
started.
Completed i.e. fill up permit After work completion, principal craft person Qualified
to work will be kept in CCR will ensure the M/C is ready for start, then Engr.
active folder & a photocopy signing off the Permit to work & remove his Will Br.
at work place. personal lock from the lock box at CCR Rack in
C/R Engr. Will cancel the permit under The completed permit to work is officially
sec-08& informed all concerned documented aft. recording completion date, serial
personnel that maintenance is number in the permit to work log book then in
completed, the system is ready. numerical order in inactive folder for one year.
If shift personnel changes then off-going personnel will provide the on-coming personnel with
detailed information and on-coming personnel will receive the permit i.e. take the charge.
If work is not completed in a single shift or day then

If work will resume the following day by the same Craft Group/Contractors, his/her personal lock
can remain on the lock box.
Revision No.: 00
If work will continue into the next shift, the on-coming principal Craft person will sign onto the
permit to work, place his/her personal lock on the lock box prior to the off-going principal craft
person signing off the permit to work and removing his/her personal lock from the lock box.
Emergency Lock Removal
In the event any locks are left on and the principal Craft Person who placed the lock is not on the
plant site then his/her team leader / Manager or the plant Manager(or his/her designee) can authorize
an emergency lock removal only after verifying physically that the work is completed and the area is
made safe.
The appropriate operation team leader and the principal craft person’s team leader will complete a
lock accountability form denoting the date, time of removal, reason for removal and sign the form.
The craft person team leader is responsible for informing the individual of the lock removal.
Lock accountability form will be attached to appropriate permit to work. Maintain this record for one
year.
15. What is SFT and when is it used?
Ans: SFT means Sanction for Test. This is a approved safe procedure for operating experimentally
to check the condition of a system which is already isolated, locks& tags are hung under “Permit to
work”
If the need arises during the maintenance action on a machine or system to remove tags or locks from
valves, dampers, gates, drains, vents, breakers or switches etc then SFT is required.
Point to be noted that during the test under SFT, shift or personnel change must not occur.
16. What is lock accountability form used for?
Ans: In the event any locks are left on and the Principal Craft Person who placed the lock is not on
the plant site then his/her team leader or the Plant Manager(or his designee) can authorize an
emergency lock removal only after verifying physically that the work is completed and area is made
safe. Then the appropriate Operation team Leader and the Principal Craft Person’s Team leader will
complete a “Lock accountability form” denoting the time & date of removal, reason for removal and
sign the form.
17. What are the essential first aids need to be maintained?
Ans: The First Aid kits & supplies are need to be maintained are as follows
Absorbent Cotton Wool, Adhesive Tape, Band aid, Burnol Cream, Cold Hot Pack, Cotton Narrow
Bandage, Deep Heat Spray, Dermazine, Diagonostic Lamp, Forceps , Hexisol , Nebanol Powder,
Savlon Cream, Savlon Liquid, Scissors, Sling, Steel Tray, Sterile Eye Drop, Surgical Gauze, Surgical
Hand Gloves, sterilized dressing, Alcohols iodine, Rectified spirit, Analgesic tablet.
18. Would you issue a work permit to a contractor if he directly approaches you?
Ans: No, it is not.

Revision No.: 00
Contractor should go to Contact person, then contact person will arrange permit to work on behalf of
him from control room engineer.
19. When an incident report is required to be filled and how you will prepare it?
Ans: When the following incidents occur an incident report is required to be filled as soon as
practicably possible but not later than 24 hours from the incident occurrence.
The things to be contained are as follows
 Near miss
 First aid
 OSHA
 LTA
 Fatality
The incident report will be completed in detail, indicating the action plan to be implemented,
responsibilities for the completion of the action plan and a completion date
At last the incident investigation team will include

CRE and the personnel involved in the incident (if available)
The CRE will report serious incidents to the Plant Manager and team Leaders immediately.
20. What are the assembly points for SMPCL?
Ans: Here are four assemble points in the plant
 Central Control Room

 In front of Central Control Building
 Gate House
 Jetty Area
21. Who is emergency response coordinator?
Ans: Operation Manager will act as Emergency response coordinator or Incident commander. In his
absence Shift charge Engineer will act as Emergency response coordinator
22. What will be the actions if we have the following situation:

-Chlorine leak
Ans: The action steps are

effects.
Revision No.: 00
 Seek medical attention immediately
Signature Signature
__________________ ____________________
Plant Engineer Shift Charge Engineer
Date: Date:
Part 2: Water Intake & Chlorination

KNOWLEDGE REQUIREMENTS
Revision No.: 00
1. Describe the purpose and function of the Intake System (Coarse bar, Trash Rack, Band Screen,
CWP).
Ans: Water Intake System takes in all the water that the plant requires for its various purposes. The
intake system consists of Stop Gate, Coarse bar, Trash Rack, Band Screen, CWP.
Stop Gate: The stop Gate is installed to stop the water to flow in Raw water pump and Circulating
water pump suction.
Coarse Bar: There are two coarse bar in our plant. One is installed at the entrance of intake system
(river side) and another one is installed before stop gate at intake system. It screens large trash from
water.
Trash Rack: Trash Rake is a equipment to remove the debris screened by coarse bar screen and
composed of the hoisting mechanism, the traversing mechanism, the raking mechanism, debris
hopper and structure.
Band Screen: Band screen is a special type of screen which normally rotates all the time of operation.
It also performs the filtration work with a smaller mesh size. This equipment is a mechanical system
composed of modular fabricated sections and componentized units.
CWP: CWP (circulating water pump) is a vertical mixed flow pump. It mainly supplies condenser
cooling water. We have three CWP in our plant.
2. Make a simplified P+ID of the intake system.
Ans:
Revision No.: 00
ACW for NG station Condenser in steam turbine

hall
To pre-treatment plant
ACW for plate heat
exchanger
Raw Water
Pump
Circulating water pump
Travelling Screen
Trash Rack
Sluice gate
Coarse Bar
Fore bay
CW intake
channel
Coarse Bar
3. What checks are required to start a circulating water pump?

Revision No.: 00
Ans: The points we have to check before starting CW pump are:
 The water level in CW pit is high enough

 The sluice gates are open
 The breaker is racked in and okay.
 The cooling water lines of CW pump are normal.
 The pump has permissive in DCS
 The oil level of the motor bearings, level should be the mere than mid level of the sight glass
 The oil level of the Cooling water pump discharge valve hydraulic system oil level is normal
4. Describe the purpose of the Chlorination. How does it work?
Ans: In order to prevent organism to adhere or grow in the CW system, as a result, further to affect
the flow area of the CW system and reduce the heat transfer efficiency of the condenser and produce
biological corrosion, sterilization and algae cleaning must be carried out for the CW system. Cooling
water adopts chlorine dosing treatment.
5. Make a simplified P & ID of the Chlorination system.

Revision No.: 00
Ans:
Chlorine Ton Chlorine Ton Chlorine Ton Chlorine Ton Chlorine Ton Chlorine Ton
Container 1 Container 1 Container 2 Container 2 Container 3 Container 3
Chlorine
neutralization
system
Chlorine Filter Vacuum Regulator

Evaporator Evaporator Evaporator
Service
water
Ditch
From CW pump To Circulating water fore bay

discharge header
To Circulating water fore bay
Self-cleaning filter Water injector Chlorinator
6. In which point chlorine is injected in the intake.

Revision No.: 00
Ans: The outlet pipes from the CW chlorination system which carry the chlorine solution directly
goes to the CW pit and there divided into 2 branches which are used to dose different distance and
depths in the pit.
7. By stopping one CWP, can we run chlorination system?
Ans: Yes
8. Is chlorine heavier than Air?
Ans: Molecular weight of chlorine and air is 70.9 and 28.9 respectively. So chlorine is approximately
2.5 times heavier than air.
9. At what PPM chlorine leak alarm will activate?
Ans: At 1 ppm chlorine leak alarm will activate.
10. If alarm appears then what will happen.
Ans: If alarm appears, neutralization system will activate and chlorination system will stop.
11. How many alarm detectors in this system.
Ans: There are 9 detectors to detect chlorine leakage.
12. Which chemical you will use to find out a chlorine leak.
Ans: Ammonium Hydroxide solution.
13. Have you read chlorine MSDS? Write something about Chlorine.
Ans: Yes. Chlorine is very harmful gas for living organism. It causes corrosion and burn to any living
tissue. Too much inhale may cause respiratory problem and cough. It is colorless but has odor. Its
boiling point is -34.1 deg cel and freezing point is -101 deg cel. Its specific gravity is 1.47.
14. What is the concentration of NaOH in the neutralization tank?
Ans: About 3-4%.
15. Explain the purpose of major equipment in the Chlorination system.
Ans: The first part is the chlorine cylinder which contains the pressurized chlorine. Then it goes to
the evaporator where with the help of hot water chlorine is vaporized. Then this chlorine gas goes to
the chlorinator where it gets mixed with the water to make a solution and from there it goes to the pit
to be dosed into the water.
16. How many modes for band screen operation?

Revision No.: 00
Ans: 2 Modes. Manual, Automatic according to time interval setting and water level difference
setting.
17. In how many points chlorine are dosed in intake channel?
Ans: 2 points.
18. What are the general safety precautions in the Chlorination system?
Ans: The general pre-cautions are

 The system should be visited in every 3-4 hrs interval.
 To change the cylinder maximum safety must be maintain.
 If any leakage is detected all personal should leave the area.
 Neutralization system is in service
 Gas detectors are working
 Emergency Equipments (SCBA, Gas Mask etc.) are available
 Chlorine Kit is available.
19. What is the raw water pump discharge pressure?
Ans: The discharge pressure of Raw Water pump is about 3bar.
20. Is any minimum flow line in the raw water pump?
Ans: No, there isn’t any minimum flow line for raw water pump.
21. Under what conditions would a Circulating Water Pump trip?
Ans: The CW pump will trip if:

 The winding temperature is high
 The bearing temperature is high
 Water intake level is low
22. When NaOH pump will start?
Ans: The NaOH pump will start when the leakage concentration exceeds 5 ppm.
23. Describe how fish deterrent device work?
Ans: We don’t have any fish deterrent device.
24. What are the differential level settings for band screen auto operation?
Ans: If the water level before and after band screen is different by a given value(300mm) then the
Band Screen will start automatically.
25. When chlorination system will trip in running condition.

Revision No.: 00
Ans: The chlorination system will trip in running condition if

 The leakage concentration is higher than 5ppm
 If evaporator or chlorinator or the booster pump trips.
PERFORMANCE REQUIREMENTS
1. Locate the major components, local instrumentation, and local controls for the
circulating water system.
2. With the help of CRE line –up, Start/stop a main circulating pump.
3. Locate the major equipment in the chlorination system.
4. Start and stop of chlorination system.
5. Start and stop of band screen.
6. Start and stop of Trash Rack.
7. Demonstrate how to change over chlorine ton container.
8. Show how to clean CWP booster pump suction strainer.
9. Show how to clean Chlorine booster pump strainer.
10. Locate the potable water line in the chlorination system.
11. Locate service water and service air point.
Completed Satisfactorily
Signature Signature
__________________ ____________________
Date: Date:
Part-3: Pretreatment System

Revision No.: 00
1. Draw a simple one-line diagram of the raw water production system from clarifier inlet up to
storage tank showing all major components in relation to each other.
Ans:
Water from
Meghna River
Lime dosing
system
Alum dosing Intermediate

system water tank
Clarifier 1 Clarifier 2
Sludge sump in
ETP
2. What is the purpose of clarifier and explain the process in detail?
Ans: The purpose of the clarifier is to clean the suspended particle of the river water and prepare it
for the further use as service, potable or DM water. At the inlet pipe of clarifier coagulant is dosed
which creates flock from the suspended particles in the water. Once the flocks get heavier it
suspended in the bottom of clarifier and the clean water comes out of the clarifier. This water then
further filtered in Pressure filters.
3. What are the chemicals used for the process and what are the functions of each chemical.
Ans: The chemicals used in clarifier are PAC as coagulant and NaOH as coagulant aid. PAC helps
to form bigger flock which suspended quickly and NaOH helps PAC to react faster.
4. What is the effect of pH on coagulation and what is the ideal range to be maintained?
Ans: The pH range in which a coagulation process occurs may be the single most important factor in
proper coagulation. The vast majority of coagulation problems are related to improper pH levels.
Whenever possible, coagulation should be conducted in the optimum pH zone. When this is not done,
it results lower coagulation efficiency, waste of chemicals and lowered water quality.
The ideal range of pH which is to be maintained is 6-9.
Revision No.: 00
5. What is floating bed and what is it’s usage?
Ans: The earlier flocks which are formed inside clarifier, they create a bed when enough of them are
produced. This floating bed helps to newer and smaller flock to suspend quickly.
6. If flocks are not observed in reaction zone what actions are to be taken?
Ans: If flocks are not observed in reaction zone then we have to set the dosing stroke of PAC until
flock formation is visible.
7. What is the acceptable turbidity of clarified water?
Ans: 10NTU.
8. How to adjust turbine speed?
Ans: We can adjust the turbine speed using the speed controller knob inside local control panel.
9. What is the retention time in the clarifier?
Ans: We need to discharge sludge after an interval of 12hours.
10. What is the clarified water basin capacity?
Ans: The capacity of clarified water tank is 200m3.
11. In which point’s alum, polymer and caustic are added?
Ans: Alum/PAC and caustic are added at the inlet mixer of clarifier.
12. When clarifier torque alarm will come?
Ans: If the scrapper faces too much force to rotate then the alarm will come.
13. What will control the operation of sludge pump?
Ans: The level of sludge sump controls sludge pump.
14. What is the purpose of pressure filter and how is it cleaned?
Ans: Pressure filter or Sand filter cleans the clarified water with a higher precision and takes down
the turbidity to less than 2NTU. Sand filters are cleaned by backwashing.
15. What are operating limits of pressure filter?
Ans: The normal flow is about 70m3/hr and turbidity of outlet water is <2NTU. If the turbidity gets
higher than 2NTU then we need to backwash it.
16. How do you decide on service hours?

Revision No.: 00
Ans: By observing the outlet water turbidity and inlet-outlet DP we can decide the service hours of
Pressure filter.
17. What are the checks to be performed in upset conditions?
Ans: In upset condition we need to check turbidity, inlet-outlet DP, pH.
18. What is FRC and what is the expected limit to be maintained at clarifier outlet?
Ans: FRC means Free Residual Chlorine. In our plant we try to keep the FRC under 0.5ppm after
clarifier.
19. What is the speed of turbine driven unit?
Ans: The speed of turbine driven unit is about 130-150 rpm.
20. What is the clarifier capacity?
Ans: Each clarifier can run on 90m3/hr.
21. What are the turbine drive unit and scrapper rpm?
Ans: The speed of turbine driven unit is about 130-150rpm and scrapper is about 3-4rpm.
22. What is the design turbidity limit after the clarifier and pressure filter?
Ans: After clarifier it is less than 10NTU and after pressure filter it is less than 2NTU.
23. How you will confirm it whether a dosing pump is pumping or not?
Ans: By observing the outlet pressure gauge and level gauge we can confirm the dosing.
24. What is the seasonal effect in river water turbidity?
Ans: The river water turbidity gets higher in rainy season and lower in winter.
25. What is the physical, chemical and biological parameter in the water?
Ans: Turbidity, pH, conductivity, BOD, COD.
26. How turbidity, hardness, silica,O2, CO2 in water remove?
Ans: Turbidity is removed by filtration in clarifier and sand filer, hardness is removed by using CaOH
,silica is removed by dosing phosphate, O2 is removed by hydrazine, and CO2 is removed by
degassifier.
27. What is the chlorine concentration in sodium hypo chloride?
Ans: About 3-4%
28. Explain the medium of pressure filter and purpose of each media.
Revision No.: 00
Ans: There are three types of sand are used in sand filter. They are classified according to their size:
Large, medium and small.
29. What are the normal operation hours of pressure filter?
Ans: About 24hours.
30. How much time you require for pressure filter backwashing?
Ans: From normal practice about 10minutes of back washing and another 5 minutes of normal
washing.
31. Describe the pressure filter back washing steps.
Ans: First of all the filter needs a small wash, then we start the backwash pumps, and finally it needs
a prolonged wash.
32. During backwashing what field checks should be made?
Ans: The checks are

 Backwash pumps are healthy and normal and in auto mode
 Waste water pond is empty enough
 All the pneumatic valves are operating normally
 There is enough service water for backwashing.
33. What is the normal bed expansion during back wash time?
Ans: 60-70mm.
34. What is the normal back wash flow rate?
Ans: About 300m3/hr
35. What is the normal usable capacity of raw water tank?
Ans: About 180m3.
36. What is the normal usable capacity of Demi water tank?
Ans: About 500m3.
37. How many types of medium are used in pressure filter?
Ans: 2 types of medium are used.

38. How to calculate sulfuric acid and caustic storage tank scale.
Ans: According to the outer level gauge.
39. If pressure filter inlet flow rate decrease what you will check.
Revision No.: 00
Ans: We need to check the clarified water transfer pump outlet valve condition, intermediate water
tank level, pressure filter inlet-outlet DP.
40. What is the size of different media inside the pressure filter?
Ans: Bottom layer: 1.0~2.0mm, height 600mm

Middle layer: 0.5~1.0mm, height 200mm
41. What is the storage capacity of acid and caustic storage tank?
Ans: For Acid tank it is 20m3 and for Caustic tank it is 16m3.
42. In full auto mode when pretreatment system will start and stop.
Ans: Start when water storage tank levels are low, stop when level is high.
43. In full auto mode when pressure filter will go in to backwash.
Ans: After operation of 24hours.
44. What is the density for 98% sulfuric acid and 46% caustic?
Ans: The density for 98% sulfuric acid is 1.8 and 46% caustic is 1.4.
45. If DP of pressure filter becomes high it will start regeneration automatically.
Ans: Yes
46. In which point NaOH is dozed into the clarifier.
Ans: In the pipe mixer.
47. Do we have any screen in between clarifier and clarifier water pond?
Ans: No.
48. How to restart CRT panel in case of hang over?
Ans: Restarting the PC.
PRACTICAL DEMONSTRATION
1. Locate the major components of the service and potable water system.
2. Manually fill the raw water tank.
3. How to discharge sludge from clarifier?
Revision No.: 00
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-4: Service and Potable Water

1. Draw a simple one-line diagram of the service water system showing all major components in
relation to each other.
Ans:
Water from
Meghna River
Lime dosing
system
Intermediate
Alum dosing water tank
system 200m3
Clarifier 1 Clarifier 2
Sludge sump in
ETP
Fire & Service water

Sand
Basin 1000m3
filter 1
Fire & Service water Clarified water
Basin 1000m3 transfer pump
Sand
Fire & Service water filter 2
Basin700m3
Sand
Fire & Service water filter 3
Basin 1000m3
Revision No.: 00
2. Draw a simple one-line diagram of the service water distribution system showing all major
components in relation to each other.
Ans:
Fire & Service Fire & Service water Fire & Service water Drinking water
water basin 1000 m3 basin 1000 m3 basin 700 m3 basin 100 m3
Electrical fire pump
Service water Roof
Potable water Roof

Backwash of Sand
Backwash of ACF
ACF in DM plant
Diesel fire pump
Jocky Pump
water basin
water basin
Oil Tank
filter
3. What is the purpose of the service water system?
Ans: In water pre-treatment system service water is produced to use for firefighting, industrial usage,
to produce potable water, to produce DM water.
4. What is the purpose of the potable water system?
Ans: To produce potable water for drinking and other use by human.
5. What are the permissive to go into service mode of A/C filter?
Ans: The service water tank level is high. Filter water transfer pump has no fault.
6. What is the backwash frequency in full-auto mode?
Ans: When DP reaches 0.05MPa.
7. What should be the residual chlorine at potable water tank?
Ans: It should be less than 0.1ppm.
8. After how long operation A/C filter should be backwashed:
Ans: 72hours.
Revision No.: 00
9. Prior to placing a new section of potable water piping or new potable water equipment into
service, what must be done to the piping?
Ans: Properly flushing.
10. How does the potable water system get pressurized?
Ans: In this plant potable water is supplied to all necessary points from the roof tank at the roof of
CCB. The gravitational force due to the height of the tanks helps to pressurize the system.
11. What is the service water pump start permissive?
Ans: The start permissive are

 The pumps are in auto mode
 The level of the service water tank (700m3) is higher than the mid-level.
12. What will cause a service water pump to trip?
Ans: If the water level of service water tank is below the low level.
13. What are the alarm levels for the raw water tank?
Ans: Water level less than 1000mm.
14. What is the volume of the raw water tank?
Ans: 200m3.
15. What is the volume of potable water tank?
Ans: 100m3.
PRACTICAL DEMONSTRATION
1. Locate the major components of the service and potable water system.
2. Manually fill the potable water tank both locally and remote.
3. Line-up and Start/Stop a service water pump.
4. Check the level of the service water tank locally.
5. Check the level of the raw water tank locally.
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-5: De-mineralized Water Production System
1. Draw a simple one-line diagram of the demi water production system from A/C filter up
to storage tank showing all major components in relation to each other.
2. Where does the demineralizer train get its water supply from?
Ans: Demi train gets water supply from Service Water tank (700 m3).
3. What is the purpose of the carbon filter?
Ans: The purpose of carbon filter is to remove free chlorine and organics from the industrial water.
It also filtrates suspended matter.
4. Explain why and how the carbon filter is cleaned?
Revision No.: 00
Ans: Ans: During the service cycle the bed is held compact by the down flow of water. It offers
resistance to the flow of water. As the amount of suspended solid deposited builds up so the
resistance increases. It is necessary to clean the filter when the resistance cause the differential
pressure to increase by 0.5 bar at normal flow as compared to a clean filter. If the total running time
of ACF is exceed 72 hours then need to clean ACF by backwashing process. In practice carbon
filter regeneration start after or before demi train regeneration.
There are two process to clean the ACF. One is water backwashing and another is water
backwashing with air scouring.
Water Backwashing: close the inlet valve and outlet valve, open the backwashing water inlet
valve, backwashing water outlet valve, exhaust valve, start the backwashing pump, good control
backwashing flow between 120 ~ 140 m3 / h, filter medium not run away is for the principle, at the
same time fixed manual butterfly valve opening, when the equipment backwashing later, the valve
need not to adjust, backwashing for about 10 minutes, until the outlet water is clear, stop the
backwashing water pump, close the backwashing water inlet valve, backwashing outlet valve.
Water backwash with air scouring: In this process, after starting backwash pump we need to fill
ACF 75% with water and make sure 25% empty space remaining for the bubble that will produce
when air will scour. Air scouring rate need to maintain 5.7 m3/min.
Positive washing: Open the water inlet valve, when the exhaust valve has the water out, open positive
outlet valve, close exhaust valve, start positive washing, for about 20 minutes, the flow rate of
positive washing is 80 m3 / h, until the outlet water is clear, the water turbidity and residual chlorine
is qualified, equipment put into operation or stand-by.
5. What is the purpose of the cation vessel?
Ans: The purpose of cation vessel where cation resin is stored is to remove acid ion from raw water.
Here all positive ion exchange with H+ ion.
6. When and how does the cation vessel get regenerated?
Ans: Cation filter is regenerated when it is exhausted. Cation exchange resin replaces the entire
positive ion with H+ ion. When cation resin is saturated with positive ion, it can no longer replace
positive ion with H+ ion. Then it is called exhausted. The exhausted cation resin causes the treated
water conductivity to rise, value of Na+ ion will rise (more than 100 mg/l) enabling the operator to
determine when to end the service.
To regenerate the cation resin 3 % HCL acid is used. The steps of regeneration of Cation vessel is
following below.
 Failure
 Small Backwash
 Discharging water
 Pre-ejection
 Acid feeding
 Replacement
 Bleeding and feeding water
 Rapid rinsing
Revision No.: 00
 Standby
7. What is the purpose of the Degasifier?
Ans: The purpose of Degasifier is to remove CO2 from water. Carbonic acid does not dissociate in
acid water and exists in the form of water H2O and carbonic acid gas CO2. In degasifier tower water
containing carbonic acid is passed down ward through medium layer while air is sent upward through
the tower. CO2 is discharged into the atmosphere.
8. How to control degasifier level?
Ans: Adjust anion inlet flow rate and cation outlet flow rate.
9. What is the purpose of the anion vessel?
Ans: The purpose of anion vessel where anion resin is stored to remove base ion from raw water.
Here all negative ions are replaced with OH- ion.
10. When and how does the anion vessel get regenerated?
Ans: Anion filter is regenerated when it is exhausted. Anion exchange resin replaces the entire
negative ion with OH- ion. When anion resin is saturated with negative ion, it can no longer replace
negative ion with OH- ion. Then it is called exhausted. The exhausted anion resin causes the treated
water conductivity to rise, enabling the operator to determine when to end the service. The outlet
conductivity of anion should be less than 5 µS/cm and silica should be less than 100 µg/l
Anion vessel is regenerated by 2 % NaOH. The steps of regeneration of Cation vessel is following
below.
 Failure
 Small Backwash
 Pre-ejection
 Caustic feeding
 Replacement
 Bleeding and feeding water
 Rapid rinsing
 Standby
11. What is the ideal regenerated water temperature and what impact this has on anion
regeneration?
Ans: For A 500 anion resin ideal regeneration temperature is 45°C. At higher temperature resin will
get damaged. At lower temperature removal of silica and organics will be improper.
Revision No.: 00
12. What is the temperature constrains of anion resin?
Ans: The anion will get damaged high temperature. Temperature should not be more than 550C.
13. What is the purpose of the mixed bed vessel?
Ans: Mixed bed is consists of both cation and anion resin. The remaining positive and negative in
the treated water that has already passed through cation and anion vessel is absorbed here.
14. When and how does the mixed bed vessel get regenerated?
Ans: MBP is regenerated when resins of MBP are exhausted. If MBP outlet conductivity is more
than .2 µS/cm and silica is more than 20 µg/L than it can be said that MBP is exhausted.
MBP is regenerated with 3-5 % HCL and 4 % NaOH. The steps of MBP regeneration is following
below
 Backwashing layered
 Standing
 Pre-ejection
 Acid & Alkali feeding
 Replacement
 Water injection
 Series washing
 Drainage
 Mixed resin
 Bleeding & Feeding water
 Rapid rinsing
 Pressure relief
 Standby
15. Explain the basics of the regeneration process? What happens in the resin beads to require
regeneration? What happens to the resin beads when acid and caustic are added?
Ans: Cation Resin: Cation resin becomes saturated by the cation ions and they no longer can
exchange cations.. The service life of Cation Exchanger can be determined from the conductivity
trend of outlet of AE. The higher the conductivity means the higher the leakage of cations(specially
Na+) from the CE. To recuperate the absorption capacity of the resins the resins need to regenerate.
Cation resin is regenerated by HCL.
During service period:
R-H + Ca++ → R- Ca + 2 H+
R-H + Mg++ → R- Mg + 2 H+
R-H + K+ → R- K + H+
R-H + Na+ → R- Na + H+
Revision No.: 00
During regeneration
R- Ca + 2 H+ → R-H + Ca++
R- Mg + 2 H+ → R-H + Mg++
R- K + H+ → R-H + K+
R- Na + H+ → R-H + Na+
Anion Resin: Anion resin becomes saturated by the negative ions present in the raw water and they
no longer can exchange ions. Anion resin is regenerated by 2% NaOH.
During service period
R-OH + SO4- →R-SO4 + OH-
R-OH + CO3- →R-CO3 + OH-
R-OH + PO4- →R-PO4 + OH-
R-OH + NO3- →R-NO3 + OH-
During regeneration
R-SO4 + OH-→ R-OH + SO4-
R-CO3 + OH- → R-OH + CO3-
R-PO4 + OH- → R-OH + PO4-
R-NO3 + OH-→ R-OH + NO3-
16. What is the first ion to slip from the cation vessel? How can that ion slippage be detected?
Ans: The order of preference for a strong acid resin is :

 Hydrogen
 Calcium
 Magnesium
 Potassium
 Sodium
When a cation resin approaches the limit of its capacity, the ions shown in the list above begin to
leak through in reverse order, i.e. , sodium will leak first, followed in order by potassium, magnesium
and calcium. In fact a cation resin’s affinity for sodium is so low that some sodium will always leak
through , even when the resin is freshly regenerated.
Na+ forms a highly conductive NaOH as it passes through the anion exchange resins in the anion
vessel. This results in an unmistakable increase in the conductivity of treated water. As a result pH
of cation outlet water will increase.
17. What is the first ion to slip from the anion vessel? How can that ion slippage be detected?
Ans: Silica ion is the first ion to slip from the anion vessel. As result of silica slippage in anion vessel
conductivity and silica in anion outlet water will increase.
18. What is expected pH at CE, AE and MBP outlet?
Ans: In cation vessel all the positive ion are replaced by H+ ion. So cation outlet water should be very
acidic. So pH of CE is around 2~3.
Revision No.: 00
In anion vessel all the negative ion are replaced by OH- ion. So at anion outlet there should be no ion
in the water. Anion outlet water should be neutral. Its pH should be around 7. But in practice anion
outlet water is not neutral. Because cation and anion vessel cannot completely remove of all ions
from raw water.
The remaining positive and negative in the treated water that has already passed through cation and
anion vessel is absorbed in MBP. So, pH of MBP outlet water should be around 7. It should be neutral
in nature.
19. What is the quality of water at the mixed bed outlet?
The quality of water at the MBP should be as follows:

a. Conductivity <0 .2 µS/cm
b. Total Dissolved solids including silica < 0.2 mg/L
c. Silica (as SiO2) < 20 µg/L
d. pH = 7
20. What is blocking flow and what is its impact on regeneration?
Ans: A flow of water that holds the bed down during up flow regeneration is called blocking flow. It
maximizes the contact between the acid and resin.
Prior to the addition of the caustic, the vessel is filled with water and kept under pressure (blocking
flow) to insure that no caustic channels down to the cation resin before it leaves the waste line at the
resin interface.
21. What is regenerate flow rate and what is the influence of this parameter on regeneration
efficiency? Describe the ideal value to be maintained for each tower?
Ans: Regeneration flow rate is the flow rate at which acid solution and caustic solution are feed to
cation and anion to regenerate the resin
If regeneration flow rate is not maintained then cation and anion resin will not be in a
proper contact with the acid and caustic solution so proper regeneration will not happen.
For Cation exchanger: 3% HCL resin. Flow rate: 28-35 m3/hr
For Anion exchanger: 2% NaOH resin. Flow rate: 28-35 m3/hr
22. Following regeneration, what is the expected neutralization tank pH?
Ans: After a regeneration pH of neutralization tank should be 2 ~ 4.
23. Prior to a regeneration, what other aspects of the Entire Process must be considered?
Ans:
 Air blower is Auto mode and proper lineup

 Chemical concentration meter connection check
 All solenoid valves in auto
Revision No.: 00
 Demi water tank level is not low.

 Service water tank level is not low.
 WWT ponds are not full.
 Plant is not starting up.
24. What affects do demineralizer train have on the feed water?
Ans: Feed water can be affected by the conductivity, TDS, hardness, mud, silt & organic matters,
oil, grease, iron & Cu oxides of demineralizer train.
25. If the levels of chlorine are excessive in the feed water, what will happen to the demineralizer
train?
Ans: Excessive chlorine will damage resins of dematerialize train.
26. What is the affect of an inefficient carbon filter?
Ans: In case of insufficient carbon filter organic and chlorine will carry over to cation, anion
exchanger and MBP which may cause resin fouling.
27. What are the alarm levels in the demineralized storage tank?
Ans: HIHI 9000 mm

HI 7000 mm
LOW 4000 mm
LOWLOW 1000 mm
28. What are the capacities of the acid and caustic unloading pumps?
Ans: Acid Transfer Pump: 10 m³/hr

Caustic Transfer Pump: 10 m³/hr
29. Describe the procedure for receiving tanker loads of acid and caustic and where is the
procedure for receiving these materials found?
ACID UNLOADING PROCEDURE
It is to be ensured that safety shower and eyewash station situated near unloading area in good
working condition.
Only unloading personnel who have been properly trained in the required safe handling and first aid
procedures for acid should be assigned to acid unloading process.
Revision No.: 00
Only three containers per truck i.e. maximum of 6 ton of acid could be unloaded at a time. Once
truck loaded with acid containers is spotted, prior to connecting, set the handbrake and chock the
wheels. Park the trucks beside the transfer pumps and make sure the area is free from obstruction.
Suitable warning signs should be posted in the surrounding unloading area using danger tape.
Partly unloaded tank trucks should be moved with extreme caution. The high density of 98% HCL
acid solution approximately 2 times that of water may cause vessel instability during movement.
Unloading Operation Engineer and/or Operation Helper should confirm proper unloading lines
which are dedicated to acid storage tank.
Container trucks should be connected, unloaded, and disconnected in daylight, if possible.

Adequate lighting should be provided if these operations must be done at night.
Before unloading, personnel should confirm the storage tank is properly vented, the vent line is clear
and open, and that the storage tank will hold the entire contents to be unloaded.
Tank trucks should be unloaded over an appropriately designed spill containment area.
Make sure neutralizing chemical for example caustic flake and spill kit are available nearby to handle
leak or any such emergency.
The unloading Operation Engineer and/or Operation Helper should verify the location of all fittings
before unloading. The tank truck unloading operator (supplier) should be familiar with these
locations. It is recommended that you discuss with him the specifics of the vehicle before beginning
unloading operations.
Close discharge of one pump and make sure the other discharge is open.
Condition 1: When initial level is more than 3 ton open the re-circulation valve to storage tank &
Close the suction valve of storage tank
Condition 2: If initial level of the tank is below 3 Ton, then keep the suction valve opened and re-
circulation valve closed till the level becomes higher enough to prime the line by re-circulation.
 Make sure all the discharge valves of the acid containers are closed.
 Connect the hose between container and pump suction.
 Open the vent caps of each container
 Open the transfer valve and slowly open the container discharge valve
 Run the pump to transfer the acid from container to storage tank
 Observe the level of acid in the container.
 After the container is empty stop the pump to close the container valve.
 Start the pump and run for some time to remove residual acid from the hose.
 Make sure the second container valve is closed and vent cap is opened.
 De-couple the hose from 1st container and connect to second container.
Revision No.: 00
 Follow the same procedure for each container.

 After completion of unloading, wash the hose and containers thoroughly with water.
CAUSTIC UNLOADING PROCEDURE
It is to be ensured that safety shower and eyewash station situated near unloading area are in good
working condition.
Only unloading personnel who have been properly trained in the required safe handling and first aid
procedures for caustic soda solution should be assigned to caustic soda unloading process.
Once a tank truck is spotted, but prior to connecting, set the handbrake and chock the wheels. Park
the truck, beside the transfer pumps and makes sure the area is free from obstruction.
Suitable warning signs should be posted in the surrounding unloading area using danger tape.
Partly unloaded tank trucks should be moved with extreme caution. The high density of 50% caustic
soda solution, approximately 1.5 times that of water, may cause vessel instability during movement.
Unloading Operation Engineer and/or Operation Helper should confirm proper unloading lines which
are dedicated to a caustic soda solution storage tank.
Tank trucks should be connected, unloaded, and disconnected in daylight, if possible. Adequate
lighting should be provided if these operations must be done at night.
Before unloading, personnel should confirm the storage tank is properly vented, the vent line is clear
and open, and that the storage tank will hold the entire contents to be unloaded.
Tank trucks should be unloaded over an appropriately designed spill containment area.
The unloading Operation Engineer and/or Operation Helper should verify the location of all fittings
before unloading. The tank truck unloading operator (supplier) should be familiar with these
locations. It is recommended that you discuss with him the specifics of the vehicle before beginning
unloading operations.
 Close discharge of one pump and make sure the other discharge is open.
 Connect the hose between tank and pump suction.
 Make sure the vent cap for tank is kept open.
 Open the transfer valve and slowly open the tank discharge valve
 Run the pump to transfer caustic from tank truck to storage tank
 Observe the tank truck caustic level from time to time.
 Once the tank truck is empty, stop the pump to close the tank discharge valve.
 Start the pump and run for some time to remove residual caustic from the hose.
 After stopping the pump, de-couple the hose from the truck.
Revision No.: 00
30. What are the hazards of handling acid and caustic? What is used to reduce the risk of
exposure to these corrosive substances?
Ans: Acid and caustic are very hazardous substance; they are very corrosive and cause severe damage
to human body if contacted.
PPE to be used during Acid Unloading

All personnel unloading acid solution must wear the following personal protective equipment:
 Hard hat.
 Close fitting safety goggles
 Chemical resistant gloves
 Chemical resistant boots.
 The jacket should be buttoned up to the neck, the trousers worn outside the boots, and the shirt
sleeves sealed at the glove unless a job safety analysis determines it is acceptable for the sleeve
to be worn over the glove.
 The tank truck unloading operator (supplier) should wear the same protective equipment and
obey the safety precautions as per procedures
 Keep on SCBA nearby.
PPE to be used during Caustic Unloading

All personnel unloading caustic soda solution must wear the following personal protective
equipment:
 Hard hat.
 The tank truck unloading operator (supplier) should wear the same protective equipment and
obey the safety precautions as per procedures
 Keep one SCBA available nearby
31. What is the major difference between the acid and caustic tanks?
Ans: Acid tanks are open to atmosphere through silica gel and caustic tanks are open to atmosphere
through no media. Beside this there is no other difference between the acid and caustic tank.
Revision No.: 00
32. Why is there a rinse/recycle step prior to placing the demineralizer train in service?
Ans: During standby period of the demineralizer train some ions (salts ion: cations in cation column
& anion in anion column) get diffused to the water contained in the vessel. These ions contribute
increasing specific conductivity of the water. In order to remove this high conductive water which
may put the demineralizer plant in regeneration, a rinse/recycle step prior to placing the
demineralized train in service is required.
33. How many times acid is inject?
Ans: One times.
34. What is the capacity of demi train?
Ans: approximately 140 m3/hr.
35. What is the name of white material in the acid measuring tank and why it is use?
Ans: Silica gel. To absorb moisture.
36. How you will check is any resin is coming during normal operation or not?
Ans: By checking the drain water if the resin trap is working.
37. What is inside the degasifier?
Ans: There is contact bed inside the tower to increase the mixing surface.
38. How ejector works?
Ans: Fluid is passed through a smaller diameter nozzle shaped (Venturi) tube. This venture is set on
the container or line. As water passed through it, vacuum is created in the container or tube outlet
which sucks out the fluid from the container.
39. How many chemicals use in on line silica analyzer and what are these?
Ans:
 Aluminum Molybdate.
 Ascorbic acid solution
 Oxalic acid
 HCL acid
 Base line solution
 250 ppb standard silica solution
40. What is the changing frequency of these chemicals?

Revision No.: 00
Ans: Once in a month.
41. What concentrations of acid and caustic are maintained during demi and MBP regeneration
time?
Ans: Cation Exchanger: 3% HCL Acid

Anion Exchanger: 2% Caustic
MBP: 3-5% Acid and 4% Caustic
42. What is the normal life of resin?
Ans: 3 ~ 5 years
43. What are the capacity of degasifier and demi water transfer pump?
Ans: Degasifier pump capacity = 122 m3/h

Demi water transfer pump capacity = 100 m3/h
Reg. Pump: 50 m3/h
44. If after regeneration required quality of demi water cannot be achieved what steps can be
taken?
Ans: The following steps can be taken-

 Rinse the resins (last step of regeneration) for additional time.
 Regenerate the resins again
 Check the resins for fouling, degradation or for both.
 Replace the resin(full or partial)
45. What is the expected water quality after anion bed?
Ans: Conductivity < 5.0 µs/cm

Silica <100 µg/l
46. What is the silica increase trend at the end of anion service?
Ans:
Silica
Conductivity
Revision No.: 00
Silica spillage increases sharply at the end of anion exchanger media service period (exhaustion)
47. How much acid and caustic is used in MBP regeneration?
Ans: Acid approximately = 0.85 m3
Caustic approximately = 0.65 m3
48. What is the hardness of cation outlet water?
Ans: Zero
49. During demi regeneration how much time required for acid and caustic dozing?
Ans: For both acid and caustic during normal regeneration it takes about 30 minutes.
50. What are the acid and caustic metering tank capacity?
Ans:
Acid metering tank for MBP- 0.63 m3
Acid metering tank for Cation Bed- 1.6 m3
Caustic metering tank for MBP and Anion Bed- 1.0 m3
51. What are the dilution water flow rates in chemical injection time for both demi and MBP
regeneration time?
Ans:
Cation exchanger regeneration:
During, HCL injection: 28-35 m3/hr
Anion exchanger regeneration:

During NaOH injection: 28-35 m3/hr
MBP regeneration:
During NaOH injection: 5 m3/hr
During HCL injection: 5 m3/hr
52. Is it possible to operate the Demineralization unit valves from local?
Ans: Yes, it is possible to operate the Demineralization unit valves from local.
53. How many eye wash stations are there in BOP area?
Ans: Three eye-wash station and shower station.
54. Sketch a simple P&ID from demi water transfer pump to the end user?
Revision No.: 00
Ans:
Minimum flow
line Condenser make up water
DM ECW Overhead tank
TAN
K P/P
Feed water to Deaerator
CEP startup sealing water

DM
TAN P/p Vacuum pump startup makeup water
K pP
GTG 1& 2 water injection system
GTG water wash
Auxiliary boiler
55. Give a basic explanation of the pH scale?
Ans: pH is a measure of the acidity or basicity of a solution. It is defined as the co logarithm of the
activity of dissolved hydrogen ions (H+). Hydrogen ion activity coefficients cannot be measured
experimentally, so they are based on theoretical calculations. The pH scale is not an absolute scale;
it is relative to a set of standard solutions whose pH is established by international agreement.
Solution that has pH of 7 is called neutral. Solutions with a pH less than 7 are said to be acidic and
solutions with a pH greater than 7 are said to be basic or alkaline.
56. Give a basic explanation of turbidity and the contributing factors?
Ans: Turbidity is a measure of the degree to which the water loses its transparency due to the presence
of suspended particulates. The more total suspended solids in the water, the murkier it seems and the
higher the turbidity. Turbidity is considered as a good measure of the water. There are various
parameters those cause turbidity in water. They are
 Phytoplankton.
 Sediments from erosion.
 Suspended solids from the bottom.
 Waste discharge.
 Algae growth
 Urban runoff.
The WHO (World Health Organization), establishes that the turbidity of drinking water shouldn't be
more than 5 NTU, and should ideally be below 1 NTU.
Revision No.: 00
The suspended particles absorb heat from the sunlight, making turbid waters become warmer, and so
reducing the concentration of oxygen in the water (oxygen dissolves better in colder water). Some
organisms also can’t survive in warmer water. The suspended particles scatter the light, thus
decreasing the photosynthetic activity of plants and algae, which contributes to lowering the oxygen
concentration even more. As a consequence of the particles settling to the bottom, shallow lakes fill
in faster, fish eggs and insect larvae are covered and suffocated, gill structures get clogged or
damaged.
Turbidity is measured in NTU: Nephelometric Turbidity Units. The instrument used for measuring
it is called nephelometer or turbidimeter, which measures the intensity of light scattered at 90 degrees
as a beam of light passes through a water sample.
57. What is the relationship between TDS and conductivity?
Ans: The TDS concentration of a water sample can be estimated from specific conductance if a linear
correlation between the two parameters is first established. Depending on the chemistry of the water,
TDS (in mg/l) can be estimated by multiplying specific conductance (in micromhos/cm) by a factor
between 0.55 and 0.75.
Conductivity vs TDS
450
400
350
300
TDS, ppm CaCO3
250
200
150
100
50
0
1 10.6 21.2 42.4 63.7 84.8 106 127 149 170 191 212 410 610 812 1008
TDS as ppm CaCO3 0.42 4.2 8.5 17 25.5 34 42.5 51 59.5 68 76.5 85 170 255 340 425
Conductivity, µS/cm
58. What is the capacity of the demineralized storage tank? What are the alarms associated with
the demineralized water storage tank level?
Ans: Capacity 1000 m³

High High: 9000
High: 7000
Revision No.: 00
Low : 4000
Low Low: 1000
59. What feature do the demi transfer pumps have that allow them to operate continuously without
damage even when there is little to no requirement for demineralized water?
Ans: Demi water transfer pumps are equipped with a minimum recirculation line which allows them
to operate continuously without damage even when there is little to no requirement for demineralized
water.
60. What are the permissive to start a demineralized water transfer pump?
Ans: Demi water tank level not LOW.
61. What will trip a demineralized water transfer pump?
Ans: The causes that trip demineralized water pumps are-

 Electrical fault
 Demi tank level LOLO
62. What will cause a demineralized water transfer pump to stand-by start?
Ans: Tripping the running pump will initiates the standby pump to start.
63. What are the permissive to start a regeneration water transfer pump?
Ans: The permissive to start regeneration water transfer pump

 No pump fault for over current
 Demi tank level is not LOLO.
64. What will trip a regeneration water transfer pump?
Ans: Causes of getting tripped of a regeneration water pump are-

 Demi water tank level LOLO
 Electrical fault
65. What will cause a regeneration water transfer pump to stand-by start?
Ans: A trip of the running regeneration water transfer pump initiates stand-by to start.
66. How much are the yearly loss of cation and anion resin in demi system
Ans: About 10% per Year.
Practical Demonstration
1. Locate the major components of the cycle makeup treatment system.
Revision No.: 00
 Demineralized Storage Tank.

 Neutralization Tank.
 Chemical Sump.
 Acid Tank and Acid Receiving Point.
 Acid Tank Vent and Drier.
 Caustic Tank and Caustic Receiving Point.
 Carbon Filter.
 Cation Vessel.
 Degasifier.
 Degasified water transfer pumps and power supply.
 Anion Vessel.
 Mixed Bed Vessel.
 Acid Pumps, power supply, and mixing Tee.
 Caustic Pumps, power supply and mixing Tee.
 Degasifier blowers and power supply.
 Mixed Bed Air Blowers.
 Regeneration Water Pump and Power Supply.
 Regeneration water heater and skid and Power Supply.
 BOP PLC and power supply.
2. Line-up and place in service the demineralizer train.

3. Perform a laboratory analysis of the demineralizer train.
4. Backwash the carbon filter.
5. Perform a concurrent regeneration, in auto of the Cation /Anion Vessels.
6. Perform a concurrent regeneration, in manual, of the Cation /Anion Vessels
7. Receive a tanker off load of acid.
8. Receive a tanker off load of caustic.
9. Demonstrate use of the chemical tank level gauges.
10. Line up and place in service the regeneration water pumps.
11. Explain the normal use for acid transfer pumps.Swap acid pumps over.
12. Explain the normal use for caustic transfer pumps.Swap caustic pumps over.
13. Adjust the regeneration water heater set point.
14. Perform a mixed bed regeneration.
15. Locate the major components of the demi water make up makeup and storage system.
 Demineralized Water Storage Tank

 Demineralized Water Transfer Pumps
 Regeneration Water Pumps
 Connecting valve between regen & demi pump discharge line
16. Line-up and Start/Stop a demineralized water transfer pump.
17. Line-up water to a regeneration water transfer pump
Revision No.: 00
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-6: Auxiliary Cooling Water System

1. What is the purpose of close cooling water?
Ans: Cooling water is used to cool:

 GT and GTG lube oil system
 GTG air cooling system
 GT atomizing air pre-cooler
 GT support legs
 GT flame detectors coolers
 GT liquid fuel check valves
 STG unit lube oil plate coolers
 STG air cooler
 HP FWP coolers
 HP FWP variable speed coupling oil plate coolers
 HP FWP motor coolers
 CPH recirculation pump cooler
 Air compressor cooling
 Boiler chemicals samples cooling
 CEP coolers
 EH oil cooler
2. Why it is called ACW system?
Ans: ACW stands auxiliary cooling water. ACW is used to cool CCW. Primary cooing is done by
CCW. ACW is used only to cool CCW. That’s why it is called auxiliary cooling system.
3. What is the ACW Pump suction and discharge pressure?
Ans: ACW gets its suction from Circulating Water Pump (CWP) and Raw Water Pump (RWP).
Therefore, suction pressure of ACW pump will be equal of discharge pressure of CWP and RWP.
However, ACW suction pressure falls as it gets some resistance due to debris filter.
Suction pressure of ACW: 0.8-1 bar

Discharge pressure of ACW: 2-2.1 bar
4. Which water is being used as ACW system?
Ans: Raw water is used as ACW system.
5. Is there any other source which can be used as make-up?
Ans: There is no other source.

Revision No.: 00
6. Sketch a simplified P & ID for ACW system.
7.Circulating Water ACW pump

Self-Cleaning 1
8. Pump Filter
+ ACW pump
Raw Water Pump 2
Plate heat exchanger

A
Plate heat exchanger

To Siphonic B
water collecting
well Vacuum pump cooler
A
Vacuum pump cooler
B
7. ACW Pump have minimum flow line yes or no?
Ans: No
8. What is the operating range for ACW Ph, Conductivity and Turbidity?
Ans: pH 7.5~8.2
Conductivity <3000 ms/cm
Turbidity < 15 NTU
9. What is COC and how to calculate that?
Ans: COC means cycle of concentration. As pure water is evaporated, minerals are left behind in the
recirculating water. As evaporation continues, the water becomes more concentrated than the original
make up water. This eventually can lead to saturated conditions. The term cycles of concentration
compares the level of solids of the recirculating cooling tower to the level of solids of the original
raw make up water. If the circulating water has four times the solids concentration than that of the
make-up water, then the cycles are 4.
COC= Conductivity of cooling tower / conductivity of Make-up water
Its desired range is 2~4
10. Which chemicals are we using in ACW water quality?
Ans: Only we dose chlorine in Raw water system which used as ACW .
Revision No.: 00
11. In which point we are injecting these chemicals?
Ans: In Water intake system.
12. How to maintain dosage level ?
Ans: Dosing level is maintain out water chlorine content. Outlet water chlorine content will 0.5 ppm
13. What is the alarm set point for suction strainer DP?
Ans: 1 bar.
14. What are the interlocks associated with the pumps?
Ans: Only due to any electrical fault, the stand by ACW will start
15. How many ACW Pump for cooling system in SMPCL?
Ans: Two pumps.
16. Where is suction point of ACW Pump?
Ans: ACW pump have taken water from CWP and RWP discharge.
17. What are ACW Pump capacity?
Ans: 2100 m3/h
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-7: WWC - WASTEWATER COLLECTION AND

TREATMENT
1. Draw a simple one-line diagram of the waste water collection and treatment system showing
all major components in relation to each other.
 Drainage ditch of
chemical dosing room
 Sand filter backwash
 Service water tank
overflow
 LDO waste water
discharge
 Clarifier overflow water
 Sludge enrichment tank
overflow water
 IPE drain water
 Recirculating water Clarifier mud
from Monitoring basin discharge.
Waste Water Integrated Sludge pond

pond Submersible pumps processing unit Mud
discharge Submersible
Water pond
Water pond
pumps
Clarified waste
 Boiler blow down water Sludge

 Neutralization pond enrichment tank
discharge
 Domestic waste water Monitoring
treatment
 Neutralization pond basin
discharge System Dehydrator
Submersible
Submersible
 Intermediate water tank

pumps
pumps
overflow
CW discharge Transfer
Gardenin channel outward
g
Single-line diagram of Waste water system
2. What are our ‘Consent to Discharge’ permits for site effluent in respect to the following:
 Flow in m3/hour: 20 m3/h

 pH : 6-9
 Temperature: 40C
 TSS : Less than 50 mg/l
3. What is the full meaning of IPE. What three processes occurs inside IPE.
Revision No.: 00
Ans: IPE: Integrated Processing Equipment

Three processes are: Mixing , Reaction and Settling.
4. Describe the IPE process in brief.
Ans: PAC and NaOH dosed at the inlet water of IPE as required. First water flows into the device at
the bottom of the watershed and to carry on the uniform water distribution, water flow rate is reduced,
and slowly entered the high flocculation area, a thorough coagulation reaction. Under the effect of
inclined pipe diversion area, the water flows along the inclined tube upwards.Sludgedeposited under
the action of gravity into the subsidence zone, slipping from along the tilt direction. After this process
clarified water is pushed to the water purification device inside the bucket, and through the inclined
tube clarified water is filtered by upper water purification device into the indoor, and from top to
bottom filtered through filter layer. Filtered water through the filter head together to device at the
bottom of the water area, and the communicating pipe to return to the device at the top of the water
layer. Industrial waste water by the integrated device after precipitation, filtering, processing into the
clear water reservoirs.
5. What is the source of effluents to waste treatment system?
Ans:
 Drainage ditch of chemical dosing room

 Sand filter backwash
 Service water tank overflow
 LDO waste water discharge
 Clarifier overflow water
 Sludge enrichment tank overflow water
 IPE drain water
 Recirculating water from monitoring basin
6. What are the options for water level monitoring of sump tanks?
Ans: There are level transmitters for monitoring water level of sump tanks from both PLC and local.
7. Explain the pH range. In comparison to neutral, 7, what is acid and caustic?
Ans: pH is a measure of the acidity or basicity of a solution. It is defined as the co logarithm of the
activity of dissolved hydrogen ions (H+). Hydrogen ion activity coefficients cannot be measured
experimentally, so they are based on theoretical calculations. The pH scale is not an absolute scale;
it is relative to a set of standard solutions whose pH is established by international agreement.
Solution that has pH of 7 is called neutral. Solutions with a pH less than 7 are said to be acidic and
solutions with a pH greater than 7 are said to be basic or alkaline.
8. What are the precautions that must be considered when handling acid and caustic?
Ans: PPE to be used during Acid and Caustic handling
All personnel handling acid and caustic solution must wear the following personal protective
equipment:
Revision No.: 00
 Hard hat.
 Keep one SCBA available nearby
9. Describe the process of pH control of waste water tank.
Ans: If the pH of waste water found very low (acidic), NaOH dosing should be started at the inlet of
the IPE.
10. How often should the in-line pH meters be calibrated?
Ans:Once in a month
11. What are the dosing provision available for IPE?
Ans: There are NaoH and PAC dosing provision available for IPE.
12. What is the capacity of IPE?
Ans:IPE capacity is 20 m3/h.
13. What is the capacity of sludge enrichment tank?
Ans:Sludge enrichment tank capacity is 80 m3.
14. What chemical used for dehydrator?
Ans:Dil. Flocculent is used for dehydrator.
15. How the filter layer of IPE cleaned.
Ans:IPE filter layer cleaned by auto backwash of IPE.
16. What is the capacity of the waste water pond?
Ans:280 m3.
17. What is the capacity of the sludge pond?
Ans:70 m3.
18. What is the capacity of the Monitoring basin?

Revision No.: 00
Ans:480 m3.
19. What are the main components of Domestic sewage treatment system?
Ans:
 Roots blower for aeration
 Grid Trash-remover
 Adjust tank (30m3)
 Domestic waste water intake pump
 Integrated domestic waste water treatment equipment (2m3/h)
20. Briefly describe the process flow of Domestic sewage treatment.
Ans: Domestic sewerage → Conditioning tank → Sewage lift pump→ Anaerobicpond→

Biologicalcontact Oxidation pond→ Settling pond→ Contact disinfecting pond→ Reach the
standard to Monitoring basin.
Signature Signature
__________________ ____________________
Date: Date:
Part-8: Circulating Closed Cooling Water System

Knowledge Requirement
Revision No.: 00
1. What is the purpose of close cooling water?
Ans: Cooling water is used to cool:

 GT and GTG lube oil system
 GTG air cooling system
 GT atomizing air pre-cooler
 GT support legs
 GT flame detectors coolers
 GT liquid fuel check valves
 STG unit lube oil plate coolers
 STG air cooler
 HP FWP coolers
 HP FWP variable speed coupling oil plate coolers
 HP FWP motor coolers
 CPH recirculation pump cooler
 Air compressor cooling
 Boiler chemicals samples cooling
 CEP coolers
 EH oil cooler
2. Why it is called CCCW system?
Ans: This system is close cooling water system that’s why it is CCCW system.
3. Who are the main users of CCW?
Ans: Turbine legs, Generator, Lube-oil, Flame detector, Atomizing air, Instrument air compressor.
STG L/O Plate C/L, CEP bearing C/L, EH Oil C/L
4. What is the CCW Pump suction and discharge pressure?
Ans: Suction around 1.2 bar and discharge pressure around 5.8 bar.
5. Which water normally used as a makeup of CCW system?
Ans: Generally Demi water is used as a makeup water of CCW system
6. Is there any other water can we use as a make-up?
Ans: No
7. Sketch a simplified P & ID for CCW system.
GT and GTG lube oil system

Revision No.: 00
GTG air cooling system
GT atomizing air pre-cooler
GT support legs
GT flame detectors coolers
GT liquid fuel check valves
STG unit lube oil plate coolers
STG air cooler
HP FWP coolers
DM water
tank HP FWP variable speed
(2x1000m3)
coupling oil plate coolers
CPH recirculation pump
cooler
HP FWP motor coolers
Makeup
from
condensate
system Air compressor cooling
Boiler chemicals samples
ECW cooling
CEP coolers
overhead CWP+RWP
tank(10m3) coupling
EHoil
oilplate
coolercoolers
coupling oil plate coolers
Debris Filter
To siphonic
water collecting
well
Plate heat Plate heat
exchanger A exchanger B
Closed circulating cooling water pump, 2x100% Auxiliary Cooling water pump,2x100%
Capacity: 2000m3/h, 1480 r/min Capacity: 2100m3/h
8. What is the capacity of CCW make up tank?
Ans: 10 m3
Revision No.: 00
9. What is the CCW system volume?
Ans: Around 80 m3.
10. What are the limit for CCW pH, Cond, Turbidity, No2?
Ans: PH = 7.5-9.5
No2 = 600-1000 ppm.
Turbidity > 5 NTU.
Conductivity = Less than 300 µg/cm
11. Which chemicals we are using in the CCCW & why?
Ans: we used No2 for prevent corrosion.
12. Why we are using these chemicals?
Ans: For prevent corrosion.
13. In which point we are injecting these chemicals?
Ans: CCCW Pump suction line.
14. What is the alarm set point for suction strainer DP of CCCW Pump?
Ans: Alarm set point 0.1 bar for Suction strainer DP.
15. What are the inlet- outlet pressure & temperature of CCCW Cooler?
Ans: Approximately inlet pressure 4.5 bar, temperature 340 𝐶 and outlet pressure 4.4 bar
,temperature 290 𝐶
16. What is the purpose of CCW head tank?
Ans: The main purpose of CCW head tank is to makeup CCW line water.
17. What is CCCW Pump capacity?
Ans: 2000 m3
18. CCCW Pump have minimum flow line yes or not ?
Ans: Not.
19. Without ACW pump running CCCW cooling possible or not?
Ans: Possible
20. What is the normal CCCW & ACW valve opening position in the CCW Cooler?
Ans: Full open.

Revision No.: 00
21. How to possible to cool the CCCW without ACW pump running?
Ans: The cooling of CCCW without ACW pump running is possible to run CWP or Raw water pump
using bypass line of the ACW system.
22. What is the normal CCCW make up per day?
Ans: Approximately 100 m3 . Depending on running status .
23. How can you figure out a leakage in the CCCW system?
Ans: By closely observe demi water consumption (Which will be increased) and CCCW
systems Nitrate ppm (Which will be decreased).
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-9: LDO system & waste oil treatment system
1. Draw a simple one-line diagram of LDO system showing all major components in relation to
each other.
2000 m3 storage tank
Unloading pump
7000 m3 storage
tank
2. What are the volume capacity different LDO tanks?

Ans: Tank 2-1, 2-2, 2-3, 2-4 and 2-5 , volume capacity is 2000 m3. Tank 7-1 and 7-2 , volume
capacity is 7000 m3.
3. Describe the piping arrangements of LDO tank.

Ans: Filling line, GT suction line, GT recirculation line, Drain line.
4. How to operate firefighting system of LDO tank area manually?
Ans: If auto not working then we open a box and pulls a handle that’s why water drained which
pressurized deluge valve. After drain, fire lines water impact on tank through sprinkler .
5. Draw a simple one-line diagram of waste oil treatment system showing all major
components in relation to each other.
Revision No.: 00
Chemical dosing tank
Recycling
tank
FILTER
Slag scrapper
Waste water tank
Oil sep:
Sludge
output
Waste water tank
6. What is the capacity of waste oil system.

Ans: 20 m3/h
7. What types of chemical used in waste oil treatment system.

Ans: coagulant, coagulant aid and FeSO4
8. Where are chemical dosing point of waste oil treatment system?

Ans: a) Coagulant dosed before slag scraper
b) Coagulant aid dosed in dehydrator and sedimentation tank
c) FeSo4 dosed in sedimentation tank.
Revision No.: 00
Signature Signature
__________________ ____________________
Date: Date:
Revision No.: 00
Part-10: Instrument Air System

1. What is the difference between service air and instrument air?
Ans: Service air is basically for machines that require air that does not need to be extremely clean or
dry, and usually require large volumes. Instrument air needs to be clean and dry, for pneumatic
instrumentation. This is important for say, a control valve positioner where the feedback baffle/nozzle
can be plugged off by dirt.
2. State the work scope of compressed air in SMPCL?
Ans:
 HRSG 1and 2
 Steam Turbine
 Gas Turbine 1 and 2
 Chemical Plant
 Start-up Boiler
 Water treatment plant
 RMS station
 Natural gas booster stat
3. What are the components of compressed air system?
Ans:
1. Air compressor (00QFQ11AN001, 00QFQ12AN001, 00QFQ13AN001)
2. Air compressor motor
3. Oil separator (00QFQ21AN001, 00QFQ22AT001)
4. Oil cooler
5. After cooler
6. Thermostatic valve
7. Minimum Pressure valve
8. Air intake valve
9. Air dryer (00QFA31AT001, 00QFA32AT001)
10. Air receiver
4. What is the function of air dryer?
Ans: To provide moisture free instrument air. Air dryer absorb moisture of the compressed air.
5. What are the components of air dryer?
Ans:
1. Dryer inlet isolation valve
2. Dryer outlet isolation valve
3. Forward filter (00QFQ21AN001, 00QFQ22AT001)
4. Backward filter (00QFQ41AN001, 00QFQ42AT001)
5. Pressure relief valve
6. Tower A inlet isolation valve
Revision No.: 00
7. Tower B inlet isolation valve

8. Tower A outlet isolation valve
9. Tower B outlet isolation valve
10. Tower A purging air inlet valve
11. Tower B purging air inlet valve
12. Tower A air drain valve
13. Tower B air drain valve
14. Dryer system bypass valve
6. Before starting air compressor what need to be checked?
Ans: Prior to initial startup air system alignment must be completed properly.
1. Check compressor coolant level.
2. Check air filter
3. Check emergency stop push button released.
4. No alarm in the PLC display
5. Start air compressor as per normal start.
6. Visually inspect unit for air or oil leakage & any abnormal sound
7. Describe the operation of Air dryer
The compressed air enters into Tower A through air inlet valve IA, and then the air is dried. The dried
air goes to the outlet from check valve CA, while part of the air is separated as the regenerating air
before going to the outlet, after the flow control by RV, then it goes to tower B from absorption tower
OB after heated by heater. There is moisture absorbed in the last half period in absorption tower B.
The regenerating air takes away these moisture and eliminated by RB and MF. It is the heating
regeneration period.
Revision No.: 00
As the heating time extends, the temperature of tower B will continuously increase, after a while, de-
energize the heater, cool down the regenerative air: this process is called the cooling regeneration
stage.
Based on the set cycle period, the purging time of the regenerative air flow can be determined. After
that, close regenerative valve RB, absorption tower B will start increasing the pressure till the
pressure of the two towers are balanced. It needs a certain time for pressure rising, to make the tower
pressure balanced, otherwise, it can result in pressure fluctuation at the outlet. After half cycle period,
close inlet air valve IA and open the air inlet valve IB at the same time.
Considering the activation time of the valve, the regenerative valve RA can be opened 6s later.
Now absorption tower B start drying the air, while tower A enters into regeneration state, thus one
switchover operation is completed. When the absorption tower B finished half period, it will be back
to regeneration state, then one cycle period is finished.
8. What are the steps of starting air dryer?
Ans:
1. Close dryer inlet valve (A or B)
2. Close dryer outlet valve (A or B)
3 Supply Compressed air up to dryer inlet valve.
4 Slowly open dryer inlet valve and wait for dryer to reach operating pressure. Pressure gauges on
dryer vessel will indicate operating pressure
5 Check all piping connections for air leakage. Remedy leaks before continuing start up.
6 Closely observe forward and backward filter condition.
7. Put selector switch in run mode. Keep it for 48 hr. for purging.
8. Then slowly open dryer outlet valve for service and observed the system Pressure
9. How to change over the air dryer?
Ans: Slowly open outlet valve of stand by dryer. Put selector switch in run mode. Keep it for 48 hours
for purging, then slowly open inlet valve of stand by dryer. Wait 30 minutes, and observed system
air pressure. At first, system pressure gradually decreases by two to three bars then again gradually
increase to normal pressure. If system pressure become steady condition, then put selection switch in
stop mode of running dryer, observe system air pressure again if steady condition, then slowly closed
inlet valve of that dryer. Again selector put in run mode for off line purge keep it for 12 hours. Then
close outlet valve of that dryer. Put selector in stop mode, keep it stand-by.
10. What is the capacity of air compressor?
Ans: 20 Nm3/h/
11. What is the discharge pressure of air compressor?
Ans: 8.5 bar.
12. How the air compressor is cooled?
Ans: It is cooled by cooling water from CCW pump.
13. At what low pressure another air compressor will start in auto?
Revision No.: 00
Ans: 6 bar.
14. What is the type of compressor in SMPCL?
Ans: Fluid-Spraying Double Screw Compressor.
15. What is the range of compressor loading pressure?
Ans: 3.5-7.0 bar.
16. What is the range of compressor regulating pressure?
Ans: 7.0-7.6 bar
17. What is the range of compressor unloading pressure?
Ans: 7.6-7.0 bar.
18. What type of and how many air compressor employed in SMPCL. What is the capacity and
operating criteria of these compressors?
Ans: There are three sets of 20Nm3/min oil spray screw type air compressors, one in service, one
standby and the other one for maintenance standby. There are two sets of compressed air processing
devices, each of which is equipped with one forwarding oil removal filter of 20Nm3/min, one
backward dust removal filter of 20Nm3/min, and micro heating regenerative absorption type dryer
of 20Nm3/min.
19. How many air reservoir/storage tank are in SMPCL, what is the purpose of air storage tank?
Ans: Three storage tanks are equipped, one used for plant purging maintenance air (service air), and
the other two tanks used as instrument air. It can hold pressure for a moment of time when the air
compressor fails. Condensate of compressed air can be extracted from the bottom of the tank.
Signature Signature
__________________ ____________________
Date: Date:
Part-11: Firefighting system

Revision No.: 00
1. What are the protection systems have been adopted for SMPCL?
Ans: The following fire protection systems have been adopted for the dual fuel combined cycle power
plant as follows:
1) Detection System
2) Indoor and Outdoor Fire Hydrants
3) Wet Sprinkler System
4) Deluge System
5) Foam-based Extinguishing System
6) Portable-based Extinguishing System
7) Fire Station with fire station equipment
8) Inert gas extinguishing system.
2. What is the firefighting provision for liquid fuel oil area.
Ans: Fuel oil tanks shall be protected by the foam system. In case fire is detected, the automatic
foam spray system shall be operated on the tank in which fire is detected. Spray system shall
be operated through the deluge valve for simultaneously cooling of the balance tanks. Portable foam
deluge spray / Dry chemical extinguisher will be used in case of small fire.
3. What firefighting equipments should include in fire station building?
Ans:
1) One number 2000 kg. DCP tender with all accessories.
2) One number foam tender with all accessories.
3) One number fire jeep with trailer pumps with all accessories.
4) 4 Nos. of fire suits.
5) 10 Nos. of breathing apparatus.
6) Two sets of first aid kits.
7) Two sets of telescopic ladders.
8) 10 sets of fiber glass blankets.
9) Two (2) nos. multipurpose nozzles.
10) One (1) no. portable thermal imaging camera.
4. Draw a simplified P & ID of fire pump station.

Revision No.: 00
Fire & Service Basin Fire & Service Basin

1000m3 1000m3
Electrical fire Diesel fire

Jocky pump pump pump
Hydro
Pneumatic
tank &
Compressor
Fire water supply
Fire water supply

pipe network
pipe network
5. What is the capacity of jockey pump, Electrical pump and diesel fire pump?
Ans: The capacity of

Jockey pump: 18m3/h
Electrical fire pump: 420m3/h
Diesel fire pump: 420m3/h
6. What is the source and capacity of firefighting water?
Ans: The water storage for the permanent fire protection is based on providing a supply of the largest
fixed fire suppression demand, rounded up to 2000 m3.As recommended by NFPA 850, several
tanks will be used for water storage in fire protection purposes. Clarified water storage tanks of
3x1000 m3will be reserved for fire control. Firewater shall use fresh water after water purification
system treatment. Firewater tank and serviced water tank of this project phase will be built for
combined use, 3x1000 m3Clarified water storage tanks shall be provided in plant water purification
station area, with firewater reserve capacity of 2000m3The maximum firewater consumption
Revision No.: 00
capacity of a conventional firewater supply system is 1762.56m3, therefore, the firewater reserve
capacity of the firewater tanks can fully meet the maximum water consumption required by one
fire in the power plant. The firewater tank level can be displayed on the control panel of the fire pump
house and the firefighting control panel in the control room. These tanks will be connected to
firefighting suction pumps. A check valve prevents firefighting water feedback to the water tanks.
Tanks are fitted with filling and drainage connections, and a visual level. On the firefighting water
tank level switches are designed to store the quantity of water required for firefighting system.
An alarm will warn when level goes down.
7. Explain Hydrant System and Underground Fire Main.
Ans: The system consists of hydrants, hydrant isolation valves, indicator posts with gate valve hand
hose cabinets containing fire hoses, nozzles and tools, and underground fire main. Underground fire
main shall be arranged with hydrants complete with isolating valves and the hydrants shall be located
in a manner that will enable the needed fire flow to be delivered through hose lines to all exterior
sides of any important structures and other yard hazards. The spacing is designed to provide flow and
pressure in accordance with NFPA 850for the oil-immersed transformers and the balance of plant
and NFPA 30 for the fuel-oil storage facilities.
8. Explain Automatic Wet Pipe Sprinkler System.
Ans: Automatic Wet-Pipe Sprinkler Systems are provided for CCB cable Spreading Room,
Workshop and Warehouse. Sprinkler heads in the Wet Pipe Sprinkler System are of the fusible-link
type. This system cannot be activated manually. When a link is released by either heat or damage
to the link, water will flow only from the sprinkler head with the released link. This link will at the
temperature of 68’C. This system consists of alarm check valve, manual water control valves with
tamper switches, nozzles, pipes and fittings, alarms, controls and instrumentation.
9. What is Automatic Water Spray Deluge System?
Ans: An Automatic Water Spray System is used to provide fire suppression for the GT Main
Transformer, Unit Transformer, ST Transformers, Diesel fire pump, LDO tank area etc. The piping
in a Deluge System is maintained dry until water is needed for fire suppression. When the Deluge
valve trips, water flows from all sprinkler heads. Automatic water spray system consists of deluge
valve, manual water supply valves, nozzles, pipe and fittings, fire detection devices, alarms, controls
and instrumentation.
This can be activated from the manual release point connected with fire control panel also can be
activated by operating the bypass valve of solenoid.
10. How Manual Water Spray System works.
Ans: Manual Water Spray System is used to provide fire suppression for Steam Turbine Lube Oil
Console, Steam Turbine Control Oil Unit and Steam Turbine Hydraulic Unit. Manual water spray
system consists of deluge valve; manual water control valves with tamper switches, nozzles, pipes
and fittings, alarms, controls and instrumentation.
This can be activated from the Mezzanine floor manual release point connected with fire control
panel also can be activated from the Ground floor by operating the bypass valve of solenoid.
11. Explain GT CO2 Extinguishing system of SMPCL.

Revision No.: 00
Ans: The high pressure CO2 firefighting system is a significant protection system for the 9E gas
turbine.
 During normal operation the temperatures of different compartments are high.
 Huge fire risk due to the possibility of leakage of gas fuel or volatile gas in lube oil.
 If fire is not put off in time, severe damage may occur.
Once there is fire in compartments, the fire detector will make the system release CO2 gas as soon
as possible and close the ventilation ports among compartments. Fill the compartment with CO2
reducing the natural content of oxygen in this compartment from 21% to less than 15%. Such oxygen
concentration is not sufficient to sustain the fuel oil or lubrication oil combustion. Then the fire
extinguishment is achieved. The flammable material exposed in the high temperature metal may re-
combusted. The system has the subsequent CO2 releasing system, which can sustain the CO2
concentration at the firefighting level for 40-60 min, reducing the re-combustion possibility to
minimum level.
 The major system components include:
1. Carbon dioxide cylinders
2. Discharge pipes and nozzles
3. Solenoid pilot valves
4. Pressure switch
5. Auxiliary compartment fire detectors
6. Turbine compartment fire detectors
7. Load compartment or load tunnel fire detectors
8. Time delay device
Based on the temperature difference of the unit compartment, the unit compartment is divided into
three zones by CO2 firefighting protection system (zone 1, zone 2, zone 4). The auxiliary and gas
turbine & liquid fuel compartment zone are ZONE 1,the loading compartment in ZONE 2 and gas
module compartment in zone 4. The zone 1 is divided into two areas (area 1 and 2). The auxiliary,
liquid fuel in the AREA 1 and the gas turbine compartment is the AREA 2.
 ZONE 1 : 61 CO2 cylinders
Fast releasing gas cylinder : 16 , 1 min
Intermittent releasing gas cylinder : 45, 40 min ,
Reduce oxygen content below 15%
Intermittent releasing gas cylinder : 11, 60 min
Intermittent releasing gas cylinder : 4, 20 min
The solenoid pilot valves which initiate the carbon dioxide discharge are located on the discharge
heads of the pilot cylinders at the cylinder bank. These are automatically actuated by an electric signal
from the heat–sensitive fire detectors. The system may also be manually actuated by manually
depressing pressure switch or by means of a hand wheel located at the top of each pilot CO2 cylinder.
Actuation of the system, either automatically or manually, will trip the turbine.
12. What are the means of supplying firewater?

Revision No.: 00
Ans: One electrical motor driven pump (100%) with a rated capacity of 420 m3/h at delivery
pressure of 9 bar (g) at low level in water tank (electrical power about 160 kW)
One emergency diesel motor driven pump (100%) with a rated capacity of 420 m3/h at a net delivery
pressure of 9 bar (g) at low level in water tank .
Two electrical motor driven pumps (jockey pump 2x100%) with a maximum flow of 18 m3/h
at a net delivery pressure of 10 bar (g) .
13. Explain the operation logic for the Jockey pump, Electrical pump and diesel driven pump.
Ans: The firefighting pumps (main and jockey) start automatically on a low-pressure signal from the
system network with the following sequence:
Without any actuation of the Fire Fighting System water, the water pipe network is pressurized by
the jockey pump that starts when the pressure drops to 7 bars. If the pressure drops to 6.5 bars in the
firefighting network, the main electrical pump starts automatically. In case of a black out of the
electrical line or a mechanical failure on the electrical pump, the firefighting water is
supplied by the diesel motor driven pump, which automatically starts on the same value of pressure
detected (5.0 bar) but only after a delay sufficient to avoid the simultaneous starting of the two main
fire pumps. The main pumps can only be stopped manually.
Solely the jockey pump stops automatically on a high pressure signal (9 bars) on the main fire water
distribution ring. A pressurized vessel holder (500 L) copes with any small water demand (leaks).
14. Where is the suction of jockey pump and Diesel engine pump and?
Ans: Both Diesel engine pump and Jockey pump take suction from the #2 1000m3water storage tank.
15. Where is the suction of Electric fire pump?
Ans: Electric fire pump take suction from the #1,1000m3water storage tank.
16. Describe the firefighting system for the CCR building.
Ans: Fire protection system for the Central control room equipped with inert gas system. The inert
gas system shall be total flooding type, and the protection zones of total flooding gas fire
extinguishing system include: emergency power distribution room control building, PC room,
DC power supply room, UPS room, electronic equipment room, engineer room.
17. What are the active fire protection measures for steam turbine area ?
Ans:
Revision No.: 00
Description Type of Fire Protection Type of Fire Detection Type of Actuation

Location
STG building Indoor fire hydrants/ Dry Ionizations Smoke Alarm →Push
chemical extinguisher Detector/ Manual button
alarm push buttons
ST bearings Indoor fire hydrants/ Dry Flame and spot heat Alarm →Push
chemical extinguisher detectors button
ST lube oil tank Automatic water spray Flame detection / heat Automatic
deluge system or smoke detection
Step-up transformer High velocity spray Thermistor flame Automatic
water system (HVWS) detection
Auxiliary HVWS Thermistor flame Automatic
transformer detection
18. What are the active fire protection measures for gas turbine area ?
Ans:
Description Type of Fire Protection Type of Fire Detection Type of Actuation
Location
GTG hall Indoor/outdoor fire Ionizations Smoke Alarm →Push

hydrants / Dry chemical Detector / Manual button
extinguisher alarm push buttons
19. What are the active fire protection measures for Auxiliary Facilities?
Ans:
Description Type of Fire Protection Type of Fire Detection Type of

Location Actuation
Central Control Inert Gas system Ionizations Smoke Alarm →Push

Room Detector button
Electronic Rooms Inert Gas system Ionizations Smoke Automatic

Detector
LV/MV and DC Inert Gas system Ionizations Smoke Automatic

electrical equipment Detector
rooms
Revision No.: 00
Battery Room Portable CO2 Ionizations Smoke Alarm →Push

extinguishers Detector button
12
Description Type of Fire Protection Type of Fire Detection Type of
Location Actuation
Dry Transformers Portable CO2 Ionizations Smoke Alarm →Push

extinguishers Detector button
Emergency Diesel Deluge system Thermistor flame Automatic

Generator Room detection
Water Treatment Dry chemicals Manual alarm push Alarm →Push

Plant Building extinguishers button button
Main Cooling Water Portable CO2 Manual alarm push Alarm →Push
Pump Station extinguishers buttons button
Fuel Oil (HFO) Fixed foam deluge spray spot heat detectors / Alarm →Push
Storage Tanks and cooling system optical sensors button
Fuel Oil (HFO) Portable foam deluge spot heat detectors / Alarm →Push
Pumping Station spray / Dry chemical optical sensors button
extinguisher
Waste Water Dry chemicals Manual alarm push Alarm →Push

Treatment Plant extinguishers button button
Air Compressor Portable CO2 Ionizations Smoke Alarm →Push

Building extinguishers Detector / Manual button
alarm push buttons
Switchyard Control Portable CO2 Ionizations Smoke Alarm →Push

Building extinguishers / Indoor Detector / Manual button
hydrants alarm push buttons
Chlorination Portable CO2 Ionizations Smoke Alarm →Push

Building extinguishers Detector / Manual button
alarm push buttons
Revision No.: 00
Canteen Indoor hydrants / portable Ionizations Smoke Alarm →Push

dry chemical Detector / Manual button
extinguishers alarm push buttons
Signature Signature
__________________ ____________________
Date: Date:
Part-12: HVAC SYSTEM

Revision No.: 00
1. Write down the basic principle of HVAC system.
Answer:
HVAC system working principle is explained as below:
In the background of HVAC system, an HVAC water chiller produces chilled water which is then
circulated throughout the building or space up to cooling coils in air handling units. Blowers move
air on cooling coils which is then distributed into various portions of space or building for providing
comfort or preserving goods/items as per HVAC design. Air is distributed through supply ducts and
return air is collected in air handling units with the help of return ducts. Chilled water and cooling
water pumps provide energy to keep the chilled and cooling water moving.
Exchange of heat:
 Room Air & Chiller water (in AHU)
 Chiller water & Cooling water (in chiller unit)
 Cooling water & ambient air (in cooling tower)
2. Describe main component of HVAC system.
Answer: Main components of HVAC system are:

 Chiller unit
 Air handling unit
 Cooling water pumps
 Chilled water pumps
 Cooling tower
3. How many cooling tower do we have in HVAC system and their standard rating?
Answer: We have two cooling tower. Cooling water flow is 250 m3/h, power consumption 8.3 KW
and 400 volt.
4. What is the function of cooling tower?
Answer: The heat energy absorbed by the chiller needs to be rejected out of the system and into the
atmosphere. Evaporative heat rejection devices called cooling towers are typically used to lower the
water temperature in large chiller systems.
5. What is the output product of HVAC chiller?
Answer: Water chillers are backbone of HVAC cooling systems. Water chiller is a refrigeration
machine which produces chilled water (Approx. 7 Degree C ~ 12 Degree C). The primary function
of a chiller is to lower the temperature of water to such value such that it can be used for producing
cooling effect in integration with other HVAC components. A water chiller is just like a other
refrigerator machine but instead of keeping your food cool or making ice, it produces chilled water.
The output of chiller is a water at lower temperature usually around about 10 o C.
6. Describe working principle of HVAC chiller.

Revision No.: 00
Answer:
An HVAC chiller works on vapor compression or vapor absorption cycle. In vapor compression
cycle, refrigerant circulates in evaporator, compressor, condenser and expansion valve of a chiller. A
thermodynamic process occurs in each of above chillers. Theoretical working of Vapor compression
or compression chillers is explained below.
Heat addition to refrigerant in evaporator ( 1-2):

Refrigerant gets vaporized by taking heat from chilled water in evaporator thus serving its prime
purpose. Refrigerant comes out of evaporator as vapors but on other side chilled water is produced.
Thus heat is added to refrigerant at constant pressure but is extracted from chilled water. Both
refrigerant and chilled water don’t get mixed and are separated by some solid wall in between them
in evaporator like shell and tube design.
Compression of refrigerant vapors in compressor (2 - 3 ):
Refrigerant vapors come out of evaporator and then compressed by chiller compressor to high
pressure and temperature. Compressor requires energy input for its working and hence electric energy
is supplied to it.
Heat rejection by refrigerant in condenser ( 3 - 4):
Similar to evaporator, but reverse is happening here. Refrigerant rejects its heat to outside cooling
liquid or air .In this way, refrigerant gets condensed and outside media is heated. Outside media e.g.
cooling water may be cooled by cooling tower and recycled again into condenser.
Expansion of refrigerant in expansion valve ( 4 -1) :
Refrigerant in condensed form coming out of condenser is expanded in expansion valve and its
pressure and temperature is reduced to level of evaporator so that above cycle is repeated again.
7. How many chillers are there in our plant? What type of chiller are they? What is their
refrigerating capacity?
Answer:
Revision No.: 00
In our plant we have two sets of chillers. They are screw type water cooled chiller. Refrigerating
capacity 852KW.
8. What is the function of expansion tank in HVAC system?
Answer:
One expansion tank is there on the roof of CCB for chilled water. Expansion water tank will be
provided as water makeup and pressure stabilizing.
9. What will happen to HVAC if a fire is detected in CCR/Battery room?
Answer:
Gas fire is supplied for Power Distribution Room, Battery Room, UPS Room, DC Power Room, relay
room, Electrical Room, Centralized Control Room, Engineer Office, Communication Room, So
smoke exhaust ventilation is supplied for these rooms. Air exhaust capacity of these rooms are
designed to allow air changes not less than 12 Times/hour. When the fire is detected, the air handling
unit/air supply system will stop working immediately. And fire damper in the AC duct is closed by
the fire center. After it is confirmed that the fire has been put out, the fire center will open fire damper
and turn on fume exhaust fan for fume exhaust.
10. If we want to control water pump, cooling tower control panel, 2 chiller units and 3 air handling
units from centralized control system then what are the things we must do?
Answer: The switch button on control panel of water pump and cooling tower should be set on auto
mode, while touch screen of water cooler and air handling unit should be set on remote control.
11. Describe the normal startup sequence of HVAC system.
Answer:
Normal Startup sequence:
1. Startup sequence of cooling water inlet valve of chiller unit and inlet valve of cooling tower is 1,
valve opens to position;
2. Base on cooling water returning water temperature to control cooling tower. (T≥26℃,start
cooling fan with start sequence 1; T≥28℃, start cooling fan with start sequence 2; T≤24℃, close
inlet valve of cooling tower and cooling fan with sequence 2; T≤22℃, stop cooling fan with
sequence 1.
3. Start cooling water pump with sequence 1;
4. Open water inlet valve of chiller unit with sequence 1 to position;
5. Start chiller pump with sequence 1;
6. Start chiller unit with sequence 1 after 60s delay.
12. Can we start two cooling water pump, chilled water pump and two cooling tower at a time?
Answer: No it is not possible to run cooling water and chilled water pumps at a time, but we can run
cooling tower both at a time.
Revision No.: 00
13. Write the function of Dehumidifier.
Answer: Temperature-rise type dehumidifier, designed with steam compression refrigerating unit to
decrease the moisture content in the air, has the features of full condense heat recovery and utilization
as well as uncontrolled outlet air temperature. Temperature-rise type dehumidifier can meet specific
requirement on humidity and thus can be widely used in central control room, electrical room &
libraries and archives, as well as in all kinds of warehouses.
Signature Signature
__________________ ____________________
Date: Date:
Standing Shift
Revision No.: 00
The named Plant Engineer has worked in shift with qualified BoP Operation Engineer for 15 days. The
completed Area Log Sheets during this period have been attached herewith.
Shift Charge Engineer Signature Date
The named Plant Engineer has stood shift on his own for 15 days. The completed Area Log Sheets during
this period have been attached herewith.
GM Operation Signature Date
Completion
Revision No.: 00
The named Plant Engineer has completed the Qualification Book.
GM Operation Signature Date

BOP Qual Book Updated - Rafi

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Document No:SMPCL-OPN-F-034

BOPE (Balance of Plant Engineer) Qualification Book

Name of the Plant Engineer: Rafiul Hoque Bhuiyan

Current Designation: Balance of Plant Engineer

Signature Signature Signature

_________________ ____________________ ____________________

1. Operates in a manner that is safe to him, others and the plant.

3. Good radio communication.

4. Service and Potable water System

5. De-mineralized water production system

6. Auxiliary Cooling Water System

7. Waste water collection and treatment

8. Closed Cooling Water system

9. LDO system & waste oil treatment system

10. Instrument Air System

11. Plant Fire Fighting System

12. HVAC system

PART -1: SAFETY

3. What are the PPE to be used during acid unloading?

4. What are the PPE to be used during caustic unloading?

List of PPE in lab:

In addition respiratory protection also need for chlorine handling such as

 Personnel should carry or have immediate available an escape type respirator

7. What is wind sock and what is the purpose of this?

8. What are the basic emergency responses to chlorine leak?

Ans: Basic emergency responses to chlorine leak are as follows

 Immediately remove the patient/victim from the source of exposure.

Ans: OSHA Recordable- includes treatment administered by a physician or by registered professional

Lost Time accident:

11. Why is it important to report near miss or first aid cases?

A) Personnel Safety Equipment:

Flowchart of issuing LOTO:

If work is not completed in a single shift or day then

Emergency Lock Removal

15. What is SFT and when is it used?

16. What is lock accountability form used for?

17. What are the essential first aids need to be maintained?

Ans: No, it is not.

At last the incident investigation team will include

20. What are the assembly points for SMPCL?

Ans: Here are four assemble points in the plant

 Central Control Room

21. Who is emergency response coordinator?

22. What will be the actions if we have the following situation:

Ans: The action steps are

Part 2: Water Intake & Chlorination

2. Make a simplified P+ID of the intake system.

ACW for NG station Condenser in steam turbine

Circulating water pump

3. What checks are required to start a circulating water pump?

Ans: The points we have to check before starting CW pump are:

 The water level in CW pit is high enough

4. Describe the purpose of the Chlorination. How does it work?

5. Make a simplified P & ID of the Chlorination system.

Chlorine Filter Vacuum Regulator

From CW pump To Circulating water fore bay

To Circulating water fore bay

Self-cleaning filter Water injector Chlorinator

Self-cleaning filter Water injector Chlorinator

Self-cleaning filter Water injector Chlorinator

6. In which point chlorine is injected in the intake.

7. By stopping one CWP, can we run chlorination system?

8. Is chlorine heavier than Air?

_ ____