——_——_. 7 oOo PT ENERGI SENGKANG COMBINED CYCLE POWER PLANT KA 8C-2 PRE-TREATMENT AND WATER TREATMENT PLANT JOB NO. 97/003 OPERATING AND MAINTENANCE MANUAL A Prepared by AQUACLEAR TECHNOLOGY PTY LTD 43 George Street NORWOOD SA 5067 AUSTRALIA Ph. +61 (0)8 8431 9223 Fax. +61 (0)8 8431 9224AquaClear Technoligy Pty Ltd. . . PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants TABLE OF CONTENTS 4. INTRODUCTION... : 1 2. DESIGN Basis. 2 21 Raw Water Analysis . 2 22 Supplied Water Analysis - To Water Treatment Plant... 3 2.3 Chemical Requirements. - 4 24 Chemical Dosing Requirements... 4 25 Fier and Exchanger Fillings And Volume 5 2.6 Treated Water Quality. 6 2.7 Effluent Quality... . 6 3. SYSTEM PERFORMANCE DATA. 8 31 Gravity Filter 8 3.2 Activated Carbon Filter. 8 33 Organic Scavenger. 8 3.4 Cation Exchanger... 8 3.5 Anion Exchanger. wo 8 3.6 Mixed Bed Exchanger 8 3.7 Plant Operation Pressure... 9 3.8 Water Treatment Plant Operation Temperature ood 3.9 Instrument Air Pressure (Oil Free) epee 8 3.10 _ Settings. - a 10 4. START-UP/ SHUTDOWN SEQUENCE, sevens 17 41 Start-up procedure... 7 42 Shutdown Procedure a 17 5. ALARMS AND INTERLOCKS..... 19 51° Service alarms. 19 52 Regeneration Alarm: 24 53 Motor Faults... . : a 25 6. MAINTENANCE INSTRUCTIONS. - 26 6.1 Routine maintenance checks... so . 26 6.2 Periodic ‘3 ‘Monthly Checks - . 27 63 Periodic ‘6 ‘Monthly Checks seen - - 27 64 Lubrication schedule. ..... - - 27 65 Blower maintenance... oe sn 27 7. SAFETY INFORMATION : 29 7.1 Summary Of Warning Notices . 29 7.2. Summary Of Caution Notices. ; 29 7.3. Chemical Information. - 30 PRE-TREATMENT PLAN 33, 8 OVERVIEW. - 34 81 PROCESS DESCRIPTION . . sono 34 82 CONTROL PHILOSOPHY - 36 POTABLE WATER os. —— 39 9. POLYELECTROLYTE DOSING SYSTEM oe 42 9.1 Description... esninenni eben 42 9.2 Circuit diagram... - 42 9.3. Operation procedure. see oe seve AD 140. ALUM DOSING SYSTEM se : fone 10.1 Description Sree eee : 44 10.2 Circuit diagram wnonernernnrnnnnrneennn — 7 44 10.3 _ Operation procedure... so eneertntnuene tne "1 ‘Caustic SODA DOSING SYSTEM. 46 111 DeSCHIPUHON. corrrrenmee - en 46 11.2 Circuit diagram : “ ese 46 11.3 _ Operation procedure... . 46 42. Sopium HYPOCHLORITE DOSING SYSTEM... 47 12.1. Deseription.....emenenne os a7 12.2 Circuit diagram soe , 47 ‘Operations & Maintenance Manual Revision 3 *C SS AquaClear Technology Pty Ltd. Job No: 97/003 12.3 _ Operation procedure. 19. CLARIFIER. : 13.1 Description... 13.2 Safety so 13.3 Circuit diagram... 13.4 _ Operating procedure. 14. GRAVITY FILTERS 14.1 Description 142 Satety.. 143° Circuit diagram 14.4 Operating procedure. 15. SERVICE WATER SYSTEM. 15.1 Description. 152 Safety - 15.3 Circuit diagram 154 Operating procedure. 16. SLUDGE HANDLING sysTEM 16.1 — Description. 16.2 Safety 16.3 Circuit diagram 164 — Operating procedure. 17. AGTIVATED CARBON FILTERS, 17.4 Description. 172 Safety 17.3 Circuit diagram 17.4 _ Operating procedure. 18 POTABLE WATER SYSTEM. 181 Description. 182 Safety 18.3 Circuit diagram 184 Operating procedure 19. WASHWATER HANDLING SYSTEM. 19.4 Description... . 19.2 Safety 19.3 Circuit diagram 19.4 _ Operating procedure 20, TROUBLESHOOTING. WATER TREATMENT PLANT 21. GENERAL SYSTEM OVERVIEW. 21.4 Process Description 21.2 _ Regeneration. 22. DEMINERALISATION SYSTEM 22.1 Plant contro! selection... 222 Plant Service Sequence 22.3 Organic Scavenger Description. 22.4 Organic Scavenger Operation... 22.5 Cation Exchanger Description 22.6 — Cation Exchanger Operation 22.7 Anion Exchanger Description 22.8 Anion Exchanger Operation 22.9 _ Summary of Service Sequence. 23. REGENERATION SYSTEM 23.1 Regeneration Function 23.2 Regeneration Chemical Supply. 23.3 Regeneration Sequence. 23.4 Summary of Regeneration Sequence for Exchangers. 24. Mixed BeD PoLisHers 241 Service. 24.2 Regeneration PT Energi Sengkang Pretreatment and Water Treatment Plants 47 48 48 48 48 48 50 50 50 50 50 51 51 5t St 51 52 52 52 52 53 54 54 54 54 54 56 56 56 56 56 87 57 57 57 97 58 59 60 60 6 65 65 65 65 66 66 66 67 67 67 69 69 69 70 75 79 80 80 Operations & Maintenance Manual Revision 3Cr) 0) AquaClear Technology Pty Lte. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants 243 Mixed Bed 1 Valve Sequence 82 25. EXCHANGER BACKWASHING 85 251 Organic Scavenger Backwash... - 86 252 Cation Exchanger Backwash Description ... tee — 86 253 Anion Exchanger Backwash Description .. 88 25.4 Summary of Backwash Procedure. 89 255 — Resin fouling. — 90 CENTRAL CHEMICAL STORAGE AREA DRAINAGE SYSTEM 1 26, GENERAL SYSTEM OVERVIEW. .nsconsnnnns “ 92 26.1 — Process Description a 92 ‘Operations & Maintenance Manual Ww Revision 3AquaClear Technology Pty Ltd Job No: 97/003 Appendices - Manufacturers’ literature A. B. C. . Technical Data Sheets ( Enclosure D ) Pumps . Valves . Mixers . Instrumentation . Drawings . Ladder Logic Program Suppliers List D. E. F. Flow Diagrams G. H L PT Energi Sengkang Pretreatment and Water Treatment Plants Operations & Maintenance Manuat Revision 3AQUACLEAR Technology PTY Ltd. Pt Energi Sengkang Job No: 97/003 Demineralisation Water Treatment Plant 4. INTRODUCTION This manual is prepared by for the Pretreatment and Water Treatment Plants, and the Central Chemical Storage Area Drainage System provided by AquaClear Technology Pty Ltd for Sengkang Combined Cycle Power Station, Indonesia. The systems are laid out in the accompanying process and instrumentation diagrams DRAWING No. 97/ 003 / P003 ~ P007 Rev 8 and 97/003-P009 Rev 2. All instrument and identification symbols have been standardised, ‘The scope of the manual covers the process description, safety issues, control philosophy and operation and maintenance recommendations. The manual is split up later into three sections where the Pretreatment Plant, the Water Treatment Plant and the Central Chemical Storage Area Drainage ‘System will be discussed in details.‘AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 2. DESIGN BASIS 24 Raw Water Analysis Raw water is fed to the Pre-Treatment Plant (PTP) to produce treated water for the Cooling Tower and Water Treatment Plant (WTP) based on the following Raw Water Analysis. Any deviation in the quality of the raw water supplied will affect the performance of the plant. Parameter Based on Patilla 2 conditions A_| PHYSICAL : |_1_| Dissolved Solid 114, Magit 2_| Suspended Solid 220 Mail 3_| Settieable Solid 218 Mail 4_| unsettled Solid 2 Mail 5_| Electrical Conductivity @ 20 °C. 477 US/om, 6_| Temperature Normal cal B_| cHEmicaL 1_| Acidity and Alkalinity _ Mail 2_| Aluminium _ | tg 3_| Calcium Mail 4__| Dissolved Manganese tid maf 8 _| Copper ttd _ mal —6_| Total Chromium mail 7_| Natrium - git -8_| Potassium __ mgil 9_| Total Hardne: 78 _mgil Carbonate _ o mg/l Bicarbonate 101.26 _magil Cyanide - tid malt Sulphide tt magit Fluoride 0.15 mail| Sulphate 8.75 mail Ammonium 0.14 mail 17_| Nitrate _ o4 mgil _18_| Nitrite td [mga 19 | Chloride 2 mail 20_| Silica jo 25 mgt _| 21_| 800 2.2 mg/l 22_| Organic Natural 35.01 gil 23_| Volatile ttd mgit__| 24 | Magnesium —_ 45 mail 25_| Oil and fats tt mail CAUTION AquaClear Technology will not be responsible for quality of water if the plant is] operated under incorrect conditions. That is any impurities in raw water that may reduce performance, foul resin and reduce life span of an exchanger Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 22 Supplied Water Analysis - To Water Treatment Plant Treated water from the Pre-Treatment Plant is fed to the Water Treatment Plant The Water Treatment Plant was designed to produce treated water at 0.1 uS/cm conductivity based on the following Supplied Water from the Pre-Treatment Plant. Any deviation in the quality of the water supplied will affect the performance of the plant. Parameter Based on Patilla 2 conditions Unit 1 pH 7 2 Total Dissolved Solids 114 mit 3 Conductivity @ 20°C 177 uSicm 4 ‘Suspended Solids | “< 10 after filtration mail 5 Turbidity <1 after filtration NTU 6 Total Hardness ~ | 78 CaCO, gf 7 Organics KMnO, 36 mal | 8 BOD. | 2 magi 3 Cations 10 Calcium Ca 24 mg/l 11 | Magnesium Mg” mai 12 | Sodium Na® 8 mgf 13 | Potassium K" 25 gi 14 | Anions Chloride CI 2 magi Nitrate NOs 0.1 gil 7 Sulphate SO, 178.75 mgfl 18 _| Total Alkalinity HCO; 101 mail 4 Fluoride mail F’ 0.15 mail 20 __| Free Carbon Dioxide CO. mail ; 21 | Total Reactive Silica SiOy 13.2 magi 22 | Heavy Metals 23 Aluminium Al* mail 24 Iron Fe®* mgit 25 _| Manganese Mn” 7 i mail ; 26 Zinc Zn?" _ mg/l 7 Copper Cu* mg/l CAUTION AquaClear Technology will not be responsible for quality of water if the plant is operated under incorrect conditions. That is any impurities in raw water that may reduce performance, foul resin and reduce life span of an exchanger. ‘Operations & Maintenance Manual Revision 3an ‘AquaCleat Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants 2.3 Chemical Requirements ‘The design of the plant necessitates the following chemicals for one regeneration of each exchanger type. The Cation and Anion Exchangers are normally regenerated together automatically. To maintain the correct standard of system operation, the quality or quantity of the chemicals must not be changed, Exchanger Regenerant Required per batch | Dilution Concentration Organic Scavenger 200 kg 25% NaCl 10% NaCl, 25°C Cation 49.2 kg 32% HCI 3.2% HCI, 25°C Anion 43.2 kg 48% NaOH 4.0% NaOH, 25°C Mixed Bed 31.3 kg 32% HCI 5.0% HCI, 25°C 21 kg 48% NaOH 4% NaOH, 25°C ‘Anion Brine Clean 60 kg 25 % NaCl 10 % NaCi, 25°C 2.4 Chemical Dosing Requirements ‘The dosing rates below are recommended rates under normal conditions for the correct operation of the PTP. These dosing rates correspond to the listed concentrations. ATPL does not recommend changing the chemical concentrations. If these were to be changed for some special reasons then different dosing rates would apply. Under monsoon condition, the dosing rates would be dramatically higher with the exception of sodium hypochlorite dosing Chemical Concentration Dosing Rate alum 30% 40 ~ 50 mail | Clarifier Sodium Hypochlorite r 12.5% 5 mg ‘Sodium Hydroxide 48% 10-40 mgt | Clarifier Polyelectrolyte 17.5% 3-20 mg/l Sludge Polyelectrolyte 03% 30-110mgh | Potable Water Sodium Hypochiorite 125% 1 mai Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd. Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants The chemical dosing requirements below are critical in the correct operation of the WTP. Deviations form the listed values may result in the production of demineralised water which is out of specification. CAUTION AquaClear Technology will not be responsible for quality of water if the plant is operated under incorrect conditions. which might not effectively regenerate the resins. That is, alterations of the regeneration flowrates Ejector Ejection Time Dilution Rate Brine Ejector 60 mins 1000 Uhour Cation Acid Ejector 36 mins 750 L/hour ‘Anion Caustic Ejector 38 mins 750 Wihour Mixed Bed Acid Ejector 36 mins 700 Uhour Mixed Bed Caustic Ejector 36 mins 700 Lhour Neutralisation Acid Ejector varies 700 Uhour Neutralisation Caustic Ejector varies 700 Uhour 2.5 Filter and Exchanger Fillings And Volume Pretreatment Plant: Filter Medium Required Medium Type Gravel 2000 L Sand 0.1-1.6 mm Activated Carbon s10L, Norit PK1-3 Water Treatment Plant: Exchanger Resin Required Resin Type Organic Scavenger 2501 Ambersep 900 Cation 300L ‘Amberjet 1200 H Anion 480 L ‘Amberjet IRA 4600 Mixed Bed Exchanger Cation 100 L ‘Amberjet 1500H Anion 100 L Amberjet 4400C| ‘Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants 2.6 Treated Water Quality After Activated Carbon Filter:- Turbidity <1 ppm Aluminium : <0.2mgil Sulphate <= 200 mgt Total Dissolved Solids < 200 mail pH 6-75 Sodium, <10 mg/l After Mixed Bed Exchanger: Conductivity at 25 degrees C <0.2 us som Silica as SiO2 < 0,02 mg /I Iron as‘Fe < 0.02 mg/! Copper as Cu _ <.03 mg/t Sodium and Potassium < 0.02 maximum ( < 0.01 mg/l average throughout cycle ) Organic TOC <0.3 mg/t 27 Effluent Quality Organic Scavenger Volume 7000 titres Content __ _ Brine solution pH Approx 6 Temperature [28 °c Cation Exchanger Volume 5500 litres Content | Dilute acid pH ‘Approx 2 Temperature 28°C Anion Exchanger Volume 6400 litres Content Dilute caustic pH Approx 12 Temperature 28°C. Operations & Maintenance Manual Revision 3iS AquaClear Technology Pty Ltd, Job No: 97/003, PT Energi Sengkang Pretreatment and Water Treatment Plants Mixed Bed Polisher Volume 9600 litres Content Dilute caustic pH Approx 14 Temperature 28°C ‘Operations & Maintenance Manual Revision 3QO AquaClear Technology Pty Ltd Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants 3. SYSTEM PERFORMANCE DATA 3.4 Gravity Filter. Each Unit Flow Rate (Design) 10m hr each Backwash Frequency 24 hours 32 Activated Carbon Filter. Flow Rate (Design) 40 m’hr Backwash Frequency 72 hours 3.3. Organic Scavenger Each Unit, Flow Rate (Design) 8.5 mine Total Design Capacity 1360 percycle _ Regeneration Frequency (Maximum) 80 hours 3.4 Cation Exchanger Each Unit Flow Rate (Design) 85 Total Design Capacity 68 m per cycle | Flow Rate (Average) Regeneration Frequency (Maximum) 8 hours 3.8 Anion Exchanger Each Unit | e.5 mine Total Design Capacit 68 m per cycle Regeneration Frequency (Maximum) Regeneration Frequency (Maximum) 8 hours 3.6 Mixed Bed Exchanger Each Unit Tn.) Flow Rate (Average) 85m he Total Design Capacity 1360 460 hours Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd dob No: 97/003, PT Energi Sengkang Pretreatment and Water Treatment Plants C 3.7 Plant Operation Pressure WIP Gravity Activated Carbon Filters Maximum Pressure 800 kPa 420 kPa Minimum Pressure 300 kPa 4100 kPa Operation Pressure 550 kPa 350 kPa 3.8 Water Treatment Plant Operation Temperature Maximum Temperature 40°C Design Temperature 209C 3.9 Instrument Air Pressure (Oil Free) C Maximum Air Pressure 700 kPa Minimum Air Pressure 600 kPa © Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Lt Job No: 97/003 3.10 Settings 3.10.1 Polyelectrolyte Dosing PT Energi Sengkang Pretreatment and Water Treatment Plants Item Set point Clarifier dose rate 4-14 Uhr Belt Press dose rate 25 - 250 Uhr Sludge Thickener dose rate 25 - 250 Lihr Batch tank concentration for Clarifier 175% Batch tank concentration for Belt Press 03% Pressure relief valves 60 bar 3.10.2 Alum Dosing Item Set point Alum dose rate 7-75 Uhr Batch tank concentration 30% Pressure relief valve 60 bar 3.10.3 Sodium Hydroxide Dosing Item Set point Sodium Hydroxide dose rate 1-14 Uhr Tank concentration 48% Pressure relief valve 60 bar 3.10.4 Sodium Hypochlorite Item Set point ‘Sodium hypochlorite dose rate 0.08 - 4 Uhr Batch tank concentration 12.5 % Chlorine residual 0.3 mgit 3.10.5 Sodium Hypochlorite for Clarifier Item Set point Calcium Hypochlorite dose rate 4-14 Uhr Batch tank concentration 125% Chiorine residual 1 mg/l, Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd. Job No: 97/003 3.10.6 Clarifier PT Energi Sengkang Pretreatment and Water Treatment Plants Item Set point Clarifier only Raw Water flow 185 m‘/hr One Gravity Filter Raw Water flow 195 m°fhr Both Gravity Filters Raw Water flow 205 m/nr Scraper arm rate 2 mimin at perimeter Scraper maximum torque 5 kNm Number of spring washers 40 dises Spring washers orientation OO000 Spring constant for each washer 14.4 kNimm| Trip force 846 N Spring compression distance 15mm Movement of microswitch for activation 1.6mm Sludge removal interval 10 min Sludge removal duration 1 min 3.10.7 Gravity Filters tem Set point rational level 80% Start one filter level 75% Start both filters level 50% Shutdown both fiters level 90% Shutdown filters high pH level 8.0 Shutdown filters low pH level 60 Shutdown fiters high turbidity level 6ONTU “Backwash interval 24 hours High differential pressure across fiters 0.2m Backwash start water level 50% ; Backwash air sour time mins Backwash water only time Smins Backwash water only flowrate 100 m*/hr 3.10.8 Filtered Water Basin Item’ Set point Low level switch 30% High level switch 20% Operations & Maintenance Manual Revision 3 7‘AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 3.10.9. Carbon Filters Item Setpoint Initial rinse time 14min High pressure difference across filters 100 kPa Backwash duration 10 mins Backwash flow and duration 42 m°hr 3.10.10 Service Water Item Setpoint Pressure switch cut in 550 kPa Pressure switch cut out 710 KPa Pressure water receiver 500 kPa C. [Pressure relief valve 830 KPa 3.10.11 Potable Water Item Setpoint Potable water tank High level alarm 90 % Potable water tank Low level alarm 30 % Tank inflow rate 4.5 myhr Pressure switch cut in 250 kPa Pressure switch cut out 350 kPa Pressure water receiver 630 kPa 3.10.12 Washwater C Item Setpoint Washwater tank High level alarm 90% Washwater tank Low level alarm 30% Backwash delay time until empty tank 60 mins Decant Washwater Tank level 80% Stop decant / start Washwater Sludge Transfer Pump 40% Stop Washwater Sludge Transfer Pump level 20% Washwater recovery sump High level alarm 90% Washwater recovery sump Low level alarm 20% ‘Washwater recovery pump start level 70% Washwater recovery pump stop level 20% c 72 ‘Operations & Maintenance Manual Revision 3a AquaClear Technology Pty Ltd. Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants 3.10.13 Sludge Handling system Item Setpoint Monsoon turbidity setpoint. 200 NTU Start one Sludge Transfer Pump level 20% ‘Start both Sludge Transfer Pumps level 40% ‘Stop both Sludge Transfer Pumps level 10% Low level in Sludge Storage Tank 5% ‘Scraper arm rate 3 mimin at perimeter ‘Scraper maximum torque 40 Nm Torque springs 40 discs ai aenaa ens M00 Spring constant for each washer 44.4 kNimm | Tip force ; 846 N Soring compression distance 15mm Movement of microswitch for activation 1.5mm 3.10.14 Break Tank Item Setpoint Start filling Break Tank level 70% Stop filling Break Tank level ” 95 % Break Tank low level stop WTP 20% 3.10.15 Organic Scavenger Item Setpoint Brine Tank level prior to regeneration 75% Injection complete Brine Tank level 45% Brine injection over run time 60 mins Displacement rinse time 90 mins Final rinse time 30 mins 3.10.16 Cation Exchanger Item Setpoint HCI injection over run time. 50 mins Displacement rinse time 60 mins Final rinse time 30 mins Operations & Maintenance Manual Revision 3 73AquaClear Technology Pty Ltd dob No: 97/003 3.10.17 Anion Exchanger PT Energi Sengkang Pretreatment and Water Treatment Plants Item Setpoint High conductivity time before regeneration start 10 mins Exchangers cycle time 8 hrs NaOH injection over run time 50 mins Displacement rinse time 60 mins Final rinse over run time 60 mins Final rinse / rinse conduetivty level 3 Silom Rinse over run time before regeneration 30 mins Conduetivity high level before regeneration 5 Siem NaCl injection over run time 60 mins Anion brine clean displacement rinse time 90 mins Anion brine clean final rinse time 30 mins - 3.10.18 Mixed Bed Polisher Item Setpoint Backwash time 15 mins HCI NaOH injection over run time 50 mins Displacement rinse time 90 mins Lower water level time 345 sec ‘ir mixing ime 10 mins Water fil ime 60 secs 30 mins Final rinse over run time Final rinse / rinse conductivity level 0.15 wSiem Conductivity high level before regeneration 0.20 wSiem 3.10.19 Demineralised Tank Item Setpoint Start one demin train level 80% Start both demin trains level 60% Stop any train level 93% Low level switch 20% 80% High level switch Operations & Maintenance Manual Revision 3 4‘AquaClear Technology Pty Ltd. Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants 3.10.20 All Valves Not in Fully Opened Position During Service Valve KKS No. Setpoint 19GKB01AA005 1500 Lihr on 18GKBO1CF001 19GCK31AA002 8.5 m’fhr on 19GCK31CF001 19GCK32AA002 8.5 mivhr on 18GCK32CF001 19GCP31AA003 7.0 m°fhr on 49GCK31CFO01 19GCP32AA003 7.0 mfr on 198GCK32CFO01 19GCP41AA005 7.0 m*fhr on 19GCK31CF001 19GCP42AA005 7.0 mfr on 19GCK32CFO01 19GCP51AA005 7.0 m®fhr on 49GCK31CF001 19GCP52AA005 7.0 m*thr on 19GCK32CF001 19GCR61AA002 1200 Uhr on 18GCP10CFO01B 19GCR62AA002 1200 Uhr on 19GCP10CF001B 19GCP61AA201 6.0 m*fhr on 19GCK31CFO01 19GCP62AA201 6.0 m°/hr on 19GCK32CF001 19GCN30AA001 1000 Uhr on 19GCN3OCFO018 19GCN24AA004 750 Lit on 19GCN24CF0018, 49GCN24AA002 30 ~ 40 minutes on HCI Injection 19GCN14AA004 | 780 Lihr on 19GCN14CF0018 19GCN14AA002 30 ~ 40 minutes on NaOH Injection 49GCN23AA004 700 Uhr on 19GCN23CF0018 19GCN23AA002 30 — 40 minutes on Chemical Injection 19GCN13AA004 700 Lit on 49GCN13CFO018 19GCN134A002 30 — 40 minutes on Chemical injection 19GCP25AA001 700 Lint on 19GCP25CF0018 19GCP15AA001 700 Lint on 19GCP15CF0018 19GKB01AA201 %opened 19GCR41AA001 5" position from closed 3.10.21 Torque Setting for ABS Flanges on Resin Removal Handholes Flange Diameter Flange Thickness Recommended Bolt Torque 220 mm, TZ mm 25 Nm, Operations & Maintenance Manual Revision 3 5AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 3.10.22 Set Up Procedure for Clarifier and Sludge Thickener Overtorque Switches a) Insert correct number of spring washers in the correct orientation. Then insert the flat washer. b) Tighten the end nut until the washers just begin to compress. The length of the washers {including the fiat waher) at this point should be 172 mm. c) Then tighten the nut further until the compressed length of the washers is 168.5 mm ) Adjust the position of the microswitch so that there is no gap between the bolt head and the microswitch arm. Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 4, START- UP / SHUTDOWN SEQUENCE For an Automatically controlled plant, AquaClear Technology does not recommend a plant shutdown, except in an emergency situation. The Treatment Plant is designed to operate in a continuous cycle, with all the necessary system controls to protect the plant equipment and ensure the process quality Stopping the Automatic operation of the system can have adverse effects on the process when starting up. The only time the system should be shut down is for major maintenance or repair where the section affected can not be isolated from the rest of the process. 44 Start-up procedure Following start-up of the PTP, steady state condition will take two to three hours to achieve. Water produced during this period should not be expected to meet specification lon exchangers, without water throughput, tend to reverse their exchange, creating a rise in conductivity, After a WTP shut-down of more than 12 hours, this may cause the Automatic system to identify the exchangers as exhausted, if the conductivity does nat come down to service limits within the 5 minute conductivity high time delay, set in the PLC Program. A manual service run should be initiated until conductivity is below 3 uS/cm then the plant placed in automatic made, The normal startup procedure is as follows:- Step Description 1 | Check air pressure on air manifold is reading 600 kPa. Check panel is live and check for any fault conditions (push lamp test) Carry out vessel filing procedure if empty as per Backwash Procedure Check conductivity, turbidity and pH meter is functioning, Switch all motors to “Auto” position. Switch Plant Selector Switch to Run" position, Switch Train Selector Switch to “Auto” position. (For WTP only) 8 | Check Flowmeters and Pressure Gauges. If pressure drop exceeds normal conditions or flow is less than normal shutdown the plant. Ensure all chemical tanks above low level. 10 _| Ensure Sludge Storage air sparge valve is open 4.2 Shutdown Procedure After shutting down the PTP, the sludge must be removed from the Clarifier to ensure an easy sta up. [CAUTION The WTP should only be shutdown when the plant is in service mode; the plant must | not be shutdown during a regeneration. Operations & Maintenance Manual 7 Revision 3‘AquaClear Technology Pty Lid PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants The following procedure is recommended:- 1 ‘Switch Train Selector Switch to "Off" position. All pneumatically Operated valves will close. (For WTP only) 2 _| Switch Plant Selector Switch to “Stop” position. If draining carry out procedure below. 3 _ | Completely clean Belt Presses including belts, The above procedure is for PTP shutdowns for short periods only. For shutdowns for long periods sludge handling operation must continue until clear water is drawn from Clarifier underflow and all the sludge has been transferred to Sludge Thickener and the Belt Press. Drainit g (only when required ) 1 | If draining open air release valves on Filters/Scavengers/Cation/Anion/Mixed Bed units 80 vessels are vented 2__| Open manual drain valves. CAUTION if the ion exchange resins are allowed to dry out, the resin beads will split rendering the resin unserviceable, requiring replacement. | Operations & Maintenance Manual 73 Revision 3Cc & ‘AquaClear Technology Pty Ltd. Job No: 97/003 5. ALARMS AND INTERLOCKS PT Energi Sengkang Pretreatment and Water Treatment Plants Incorporated into the Water Treatment System PLC program are various alarms and protection systems. The alarms are to alert the operator to any process conditions not functioning correctly, pumps not running or other system malfunctions. The alarm system consists of indicator lamps and audible warning buzzer on the Control Panel The "Protection System" will isolate the Pump electrical circuits, to prevent “dry-running” damage should a tank run dry or there is no flow through the related system, With a good knowledge of the Treatment System operation and process steps, an operator should be able to quickly determine the reason for any alarm being raised. The Alarms and the System Status are indicated on the Control Panel. 51 Service alarms ALARMS CAUSES EFFECTS REMEDY Alum Batching Tank | Low level switch Low Level Alarm generated at CITECT, Check tank sight giass ‘Stop Alum Transfer Pump if necessary ‘Alum Day Tank Low | Low level switch Level Dosing pump and PTP stops Alarm generated at CITECT. Cheek tank sight glass Transfer new alum batch Ciarifier Polymer Low level switch Batching Tank Low Level ‘Alarm generated at CITECT. Cheek tank sight glass Stop Clarifier Polymer Transfer Pump if necessary Clarifier Polymer Day | Low level switch Tank Low Level Dosing pump and PTP stops in one hour. ‘Alarm generated at citecr. Check tank sight glass Transfer new polymer batch Clarifier CaOcl Low level switch ‘Alarm generated at | Check tank sight glass. Batching Tank Low | CITECT. a eal ransfer more hypochlorite Clarifier C2OCI | Low low level switch | Dosing pump stops. | Check tank sight glass. Batching Tank Low Tanto Alarm generated at__| Transfer more hypochiorite CITECT. NaOH Day Tank Low | Low level switch Level Dosing pump stops Alarm generated at CITECT. Check tank sight glass Transfer more NeOH Sludge Handling Low level switch Alarm generated at | Check tank sight glass. Poumer Batching orreer. Stop Sludge Polymer Transfer Pump i necessary Sludge Handling | Low level switch Dosing pump stops. | Check tank sight glass. Polymer Day Tank Alarm generated at | Transfer new polymer Low Level CITECT. batch ‘Operations & Maintenance Manual Revision 3 19‘AquaClear Technology Pty Lid. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants ALARMS CAUSES EFFECTS Za REMEDY | Washwater Tank Low | Low level switch Washwater Sludge | Check level transmitter. Level ‘Transfer Pump stops. Alarm generated at CITECT. Washwater Recovery | tow level switch Washwater Recovery | Check level transmitter Low Level Pump stops. ‘Alarm generated at CITECT. Sludge Storage Low | Low level switch Sludge Transfer Check level tranmitter. Level Pump stops. Check sludge removal line Alarm generated at | is not blocked. ee Check air sparge in tank Pressure Filter 4 Differential pressure | Alarm generated at | Check pressure gauges. e Differential P switch CITECT. een Pressure Filter 2 Differential pressure | Alarm generated at _ | Check prescure gauges. : Differential P switch CITECT. an Instrument Air Low | Pressure Switch PTP stops and will | Check isolation valve. ee ae Check pressure regulator. cect | Shek pea Potable Water Tank | High level switch Alarm genelated at | Check level transmitter, High Levet GITECT. Check tank sightglass. Potable Water Tank | Low level switch Potable Water Pump | Check level transmitter Low Low Level stops Check tank sightglass. ‘Alarm generated at nae eareer Check inlet isolation valve Check Activated Carbon e Fhers a uring Filtered Water Basin | Low level switch Filter Feed Pumps, | Check level transmitter Low Low Level Service Water Pumps and Backwash Pump. | Check Gravity Fitters are stop running. Alarm generated at | Check modulating valves, CITECT. Check pneumatic valves. Check Clarifier is running Filtered Water Basin | High level switch Alarm generated at | Check level transmitter. High Level CITECT. Check Gravity Fiters are stil running Clarifier NTU out of | Turbidity transmitter | Gravity Filters stop. | Check turbidity transmitter me Alarm generated at | Check Raw Water Pump is CITECT. running, Operations & Maintenance Manual 20 Revision 3‘AquaClear Technology Pty Ltd Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants ALARMS CAUSES EFFECTS REMEDY Clarifier pH out of pH transmitter spec Gravity Filters stop, ‘Alarm generated at CITECT. Check pH transmitter. Check NaOH doing Raw Water High Flow | Flow transmitter Alarm generated at CITECT, Check flow transmitter. Check control valve Gravity Filter 1 High | Level transmitter Level ‘Alarm generated at CITECT. Check level transmitter Gravity Fiiter2 High | Level transmitter Level Alarm generated at | ciTecT, Check level transmitter Filtered Water Sump _| Level transmitter High Level Alarm generated at CITECT. Check level transmitter Sludge Storage Tank | Level transmitter ‘Alarm generated at Check level transmitter C High Level cITeCT Washwater Tank Level transmitter Alarm generated at | Check level transmitter High Level CITECT. Washwater Recovery | Level transmitter Tank High Level Potable Water Tank | Level transmitter High Level | Alarm generated at CITECT. Alarm generated at | cITECT. Check level transmitter Check level transmitter Gravity Filter 1 High | Differential pressure Differential Pressure | transmitter | Alarm generated at CITECT, Check differential pressure transmitter Check modulating valve. Backwash will occur. Gravity Filter 2 High | Differential pressure Differential Pressure | transmitter | Alarm generated at CITECT, Check differential pressure transmitter. Check modulating valve Backwash will occur, Cc Gravity Filters Flow transmitter Backwash High Flow ‘Alarm generated at CITECT. Check flow transmitter. Check modulating valve. Pressure Filters Flow transmitter Backwash High Flow | Alarm generated at | clTecT. Check flow transmitter, Check modulating valve Raw Water Pump 1 _ | Pressure switch High or Low Pressure Raw Water Pump. stops in 5 minutes. Alarm generated at CITECT. Check modulating valve. Check pump isolation and check valves ie Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd. Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants, ALARMS CAUSES EFFECTS REMEDY Raw Water Pump 1_ | Pressure switch High or Low Pressure Raw Water Pump stops in § minutes. Alarm generated at CITECT. Check modulating valve. Check pump isolation and check valves, Raw Water Pump 1 | Low level switch Pit Low Level Raw Water Pump and PTP stop. Alarm generated at CITECT. Check pit level. Check gate vaive. Perform backflush Raw Water Pump 2 | Low low level switch Pit Low Level Raw Water Pump and PTP stop ‘Alarm generated at CITECT. Check pit level. Check gate valve Perform backflush, Raw Water Pump 1 | Low level switch with Pit Waiting For Level | 10 minutes time OK > 10 mins Raw Water Pump and PTP will stop in 10 minutes if level does not rise Alarm generated at CITECT. Check pit level Check gate valve Perform backflush. Raw Water Pump 2 | Low level switch with Pit Waiting For Level | 10 minutes time OK > 10 mins Raw Water Pump and PTP will stop in 10 minutes if level does not rise Alarm generated at CITECT. Check pit level Check gate valve Perform backflush WTP stops ‘Alarm generated at CITECT Check pneumatic valve. Check level controller. Check isolation vaive. Check feedwater line Break Tank Low Low level switch Level Break Tank High High level switch Level Alarm generated at CITECT. Check sight glass. Check level transmitter. Brine Cleaning Tank | High level switch High Level ‘Alarm generated at CITECT. Check sight glass. Check level transmitter Cation HCI Metering | High level switch Tank High Level Alarm generated at CITECT, Check sight glass. Anion NaOH Metering | High level switch Tank High Level Alarm generated at CITECT. Check sight glass. Mixed Bed HCI | High level switch Metering Tank High | Level Alarm generated at cITeCT Check sight glass. Mixed Bed NaOH Metering Tank High Level | High level switch Alarm generated at cITECT Check sight glass. Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd Job No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants ALARMS CAUSES EFFECTS REMEDY HCI Metering Tank High Level High level switch ‘Alarm generated at CITECT. Check sight glass NaOH Metering Tank High Level High level switch Alarm generated at CITECT, Check sight glass, Neutralisation Tank Low Low Level Low low level switch Alarm generated at CITECT. Check sight glass Neutralisation Tank High Level High level switch ‘Alarm generated at CITECT. Check sight glass ‘Sump Pit Low Level Low level switch Alarm generated at CITECT. ‘Sump Pump stops. Check Sump level ‘Sump Pit High Level High level switch ‘Alarm generated at CITECT, ‘Sump Pump starts, Check Sump level HCI Bulk Tank Low Low Level Low level switch ‘Alarm generated at CITECT. Acid Transfer Pumps stop. Check tank sight glass. Refill tank. HCI Bulk Tank High High Level High level switch ‘Alarm generated at CITECT, Check tank sight glass. NaOH Bulk Tank Low Low Level Low level switch Alarm generated at CITECT. NaOH Transfer Pumps stop. Check tank sight glass. | Refil tank, NaOH Bulk Tank High High Level High level switch ‘Alarm generated at CITECT. Check tank sight glass. Demin Water Tank Low Low Level Low level switch Alarm generated at CITECT, Makeup Water Pumps stop. Check level transmitter, Demin Water Tank High Level High level switch ‘Aiarm generated at CITECT. Check level trasnmitter Stormwater Sump High High Level High level switch Alarm generated at CITECT. Check sump level. Train #1 Auto Control Tripped Train 1 in “Off mode Alarm generated at CITECT. | Put Train 1 in “Auto” mode Train #1 Auto Control Tripped Train 2 in Off" mode Alarm generated at CITECT. Put Train 2 in “Auto” mode. Neutralisation Process Failed 3 Attempts Neutralisation not successful 3 times, | Alarm generated at CITECT. Check pH meters Check if HCI or NaOH is dosing Check mixer. Operations & Maintenance Manual Revision 3 2‘AquaClear Technology Pty Ltd ob No: 97/003 PT Energi Sengkang Pretreatment and Water Treatment Plants 5.2 Regeneration Alarms ALARMS CAUSES EFFECTS REMEDY Acid dilution water Flow switch does not | Alarm raised at local Check manual throttling tow flow meet set point within | panel, valves prior to rotameter 30 seconds of Regeneration Pump starting | Regeneration stopped. and Regeneration Pump. ‘Once fault reset regeneration can restart Caustic dilution water | Flow switch does not low flow meet set point within 30 seconds of Regeneration Pump Alarm raised at local panel Regeneration stopped | Check manual throttling valves prior to rotameter and Regeneration Pump starting ‘Once fault reset regeneration can restart. ‘Any HCI Metering High level switch not | Alarm raised at CITECT. | Must be acknowledged Tank Not Full on before regen Regen stopped. at CITECT. Fill metering tank to high level switch ‘Any NaOH Metering | High level switch not Tank Not Full on before regen ‘Alarm raised at CITECT. Regen stopped | Must be acknowledged at CITECT. Fill metering tank to high tevel switch Acid Tank HI level High level swit Shuts control valves and stops chemical filing Must be acknowledged Caustic Tank HI level _| High level switch Shuts control valves and stops chemical filing Must be acknowledged at CITECT. Acid Injection Over —_| Acid injection time Run Time over set limit. Regen failed Alarm raised at CITECT. Regen stopped Must be acknowledged | at cITECT Must skio regen to next step. Caustic Injection Over | Caustic injection time Run Time. over set limit. Regen failed | Alarm raised at CITECT Regen stopped. Must be acknowledged at CITECT Must skip regen to next | step Final Rinse Over Run | Final rinse time over Alarm raised at CITECT. Must be acknowledged Time set limit at CITECT _ ___| Regen failed. Perform another regen Brine Injection Over | Brine injection time | Alarm raised at CITECT. _| Must be acknowledged Run Time over set limit. Regen stopped. at CITECT Regen failed ‘Must skip regen to next Stormwater pH Out of | pH transmiter Range Alarm raised at CITECT. Stormwater Sump Pumps stop. step | Must be acknowledged | at CITECT | Must be acknowledged Train’A requires a Regeneration’ Manual backwash required Backwash [at CITECT. Train B requires a Regeneration’s =12 | Manual backwash required | Must be acknowledged Backwash at CITECT. ‘Operations & Maintenance Manual Revision 3 2hAquaClear Technology Pty Ltd. Job No: 97/003 5.3. Motor Faults PT Energi Sengkang Pretreatment and Water Treatment Plants ALARMS CAUSES. EFFECTS REMEDY Any Pump or Drive Tripped Failure of drive to operate. MCC circuit breaker tripped on overload Locked button on Local Stop Station. Alarm raised at CITECT. Check failed drive. Unlock stop button, Any pump or Drive Fail to Start Failure of drive to operate MCC circuit breaker tripped on overload. Locked button on Local Stop Station Alarm raised at CITECT, Check failed drive, Unlock stop button ‘Any Pump or Drive Fail to Stop Motor contactor malfunction, Alarm raised at CITECT. Check failed drive. ‘Any Pump or Drive Not Available or Not in Auto Selector switch on Pump set or drive are in OFF or MANUAL position | Alarm raised at CITECT. Put selector switch into AUTO position Belt Press Drive Fail to Stop Starting drive manually at local panel when ‘Auto’ mode is selected in MCC. Alarm raised at CITECT. Operate drive in fully ‘Auto’ mode. Operations & Maintenance Manual Revision 3 2AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants 6. MAINTENANCE INSTRUCTIONS. Maintenance Instructions and requirements for all equipment are detailed in the relevant manufacturer's documentations accompanying each equipment, All manufacturers’ manuals and documentations are provided in a separate folder. In addition to the req followed to ensure all plant machineries are kept in optimum operating condition. ments by the manufacturers, the following maintenance schedule should be Plant operators should at all times be observant and report any abnormalities in any plant operations. Appropriate action should be promptly taken so as to minimise plant production disruption 6.1 Routine maintenance checks. DAILY CHECKS. + As per logsheet ‘+ Check all equipment for proper operation + Check sludge blanket levels in clarifier and thickener, and clear water is overflowing the weir. + Check turbidity meters are draining freely. ‘+ Check lével in Clarifier Polymer Day Tank. WEEKLY CHECKS. General. * Check and Log Operating Parameters as required. ‘+ Check for any abnormalities in operation and report for immediate action ‘+ Calibrate pH instruments. + Check standby motor operation PreTreatment Plant. + Check level in Alum Day Tank. ‘+ Check level in Sodium Hypochlorite tank. + Check level in Sodium Hydroxide tank. ‘+ Check chlorine level in Filtered Water Basin and Potable Water Tank. + Clean turbidity meters. ‘+ Check belt tracking and lanyard switches on Belt Presses are working ‘Operations & Maintenance Manual Revision 3AquaClear Technology Pty Lt. PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants Water Treatment Plant. * Check level in Acid storage tank * Check level in Caustic storage tank ‘+ Check level in Brine storage tank * Check when backwash is required * Check conductivity meters with portable instruments. + Check precipitation at Sump Pit. * Check strainer at Sump Pit. MONTHLY CHECKS. 62 63 64 65 ‘+ Check for oil leaks in machinery and equipment. ‘+ Check tension on belt drives on blowers, * Calibrate pH transmitters using fresh buffer solutions, ‘+ Depressurise vessels and remove air vent valves to clean them, ‘+ Use calibration tube to check dosing rates on pumps, + Manually stroke each valve to ensure correct operation, * Calibrate turbidity meters and conductivity meters Periodic ‘ 3 ‘ Monthly Checks + Check air pressure in Wellmate pressure tanks of Potable Water and Service Water Systems. If pressure not at 10% less than the cut-in pressure of the pump, ie. 630 kPa for Potable Water System and 540 kPa for Service Water System. Periodic ‘ 6 ‘ Monthly Checks + Check Pumps. * Clean precipitation at the bottom of the neutralisation tank and effluent discharge ines to sump pit and drain respectively Lubrication schedule. PUMPS. * Check gland packing condition. If dry, replace. A slight drip in the gland is normal in assisting to lubricate the gland, ‘© Check for any unusual noise or heat generated on the bearing - report for appropriate actions if present Blower maintenance After 100 hour operation. + Change oil * Check belt drive tension, taperlock bush tightness, ‘© Check tightness of lock nut on relief valve. Operations & Maintenance Manual oT Revision 3AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants C ‘+ Check blower for any abnormally noisy operation or heat generated on the bearings - take appropriate action if present. After 4000 hours operation or six months. + Change oil © Clean intake filter. + Check relief valve operation, After 8000 hours operation or 12 months. + Change oil * Check tightness of all bots. ‘+ Check operation of all safety switches and valves. + Check air fiter element. © ‘+ Inspect blower conveyance chamber and rotor for dirt or contact damage. After 20,000 hours or operation. ‘+ Inspect blower, ‘© Check cylinder and rotors, + Check bearings + Check gear wheels. ‘+ Check blower clearances * Check belt drives system including pulleys, belts and bushes. © Check all valves and switches. NOTE: All checks required on the 8000 hours schedule should be carried out every 8000 hours the 20,000 hours check is carried out. C 25 Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 7 SAFETY INFORMATION Before the operation or maintenance of this plant, all personnel concerned are responsible to ensure they fully understand the system layout, functional and operational sequence and functions, of PTP and WTP. Operators and maintenance personnel must understand and follow all the related precautions and procedures correctly, with the safety of themselves and co-workers foremost in their minds. The precautions and instructions contained in this manual are to supplement and highlight safety aspects conceming this Water Treatment System. The information in this manual does not take precedence over manufacturers, suppliers or plant safety procedures or operations. All safety precautions and procedures normally required when operating or working with automatic equipment must be followed This plant incorporates the use of corrosive chemicals, therefore, all related procedures and safety information for chemical handling and disposal must be understood and adhered to. 71 Summary Of Warning Notices WARNING The Regeneration Chemicals used in the production of Demineralised Water| from this Treatment Plant must be handled with care in accordance with all related safety regulations and procedures. WARNING The water produced after the Cation Exchanger is at a low pH and is very acidic and aggressive. Any water taken as a sample, or any solutions leaking from the. Cation Exchanger or piping between the Cation and Anion Exchangers, must be. handled with care, 7.2 Summary Of Caution Notices CAUTION AQUACLEAR Technology will not be responsible for quality of demin water if the plant is operated under incorrect conditions. That is any impurities in raw water that may reduce performance, foul resin and reduce life span of an exchanger. CAUTION Extending the Service of a Mixed Bed over the preset conductivity level, will exhaust the lower section of the resin bed, resulting in poor water quality from the exhausted exchanger. The exchanger will require two regenerations to obtain the design water quality if this ocours. | [CAUTION The service operation of the Treatment Plant using the manual solenoid valve override system, is NOT RECOMMENDED except by SKILLED operators in an EMERGENCY | situation. CAUTION Manually extending the service of any exchanger over the preset cycle time or preset conductivity limits, will completely exhaust the lower section of the resin bed, resulting | in poor water quality from the exhausted exchanger. This can unbalance the exchange | system, requiring extra regeneration to obtain the original system quality | Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants CAUTION Alteration of any of the Chemical Dosing rates or the Dilution Water Flow Rates, | without AQUACLEAR Technology approval, will void the warranty on this treatment system, CAUTION If the ion exchange resins are allowed to dry out, the resin beads will spit rendering the resin unserviceable, requiring replacement. CAUTION Ensure all valves have been returned to the correct position for automatic operation and that the regeneration flow rate has been correctly set before conducting 2 regeneration of the Cation Exchanger. CAUTION Ensure all valves have been retumed to the correct position for automatic operation] and the regeneration flow rate has been set before conducting a regeneration of the Anion Exchanger. CAUTION 7.3. Chemical Information Ensure ail valves have been returned to the correct position for automatic operation and the regeneration flow rate has been set before conducting a regeneration of the Mixed Bed Polisher. WARNING The Regeneration Chemicals used in the production of Demineralised Water from this Treatment Plant must be handled with care in accordance with all related safety regulations and procedures. Sufficient precautions should be taken when handling, transporting or disposing of acidic or caustic chemicals. Even after dilution sufficient acid or caustic can be present to cause severe injury to personnel. Adequate protection for all parts of the body should be used whenever handling these chemicals, and the manufacturer's guide lines (Material Safety Data Sheets) for handling these products should be carefully followed The chemicals use in the PTP must be free of insoluble matter to avoid blockage in the dosing pipelines and in the dosing pumps. ‘The specifications on the purity of the regenerant chemicals (in the WTP) are to ensure trouble-free operation of the ion exchange resins after regeneration. The chemicals have to be free of suspended materials or other materials that may be absorbed and consequently precipitated onto the resin bed They should also be free of ionic species other than the active regenerating agents. Other species will decrease the regeneration efficiency andior increase the leakage of this species during the operational cycle. For example, Sodium Hydroxide (NaOH) containing 2% NaCl, will reduce the efficiency on an anion exchanger by increasing the concentration of chloride (CI") species to be absorbed by the resin bed Different processes and technologies, and different requirements as to the quality of the treated effluent will, therefore, impose different restrictions on the impurity levels in the regeneration ‘Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants chemicals and the dilution water, in the same way, regenerant concentrations and flow rates can affect the efficiency of the operation, Recommendations on the quality of regeneration chemicals are given in the following sections. The recommended qualities should prove sufficient for all ion exchange resin applications. Under certain conditions, lesser qualities can be used including eventual waste chemicals from process streams. 7.3.1 Aluminium Sulphate: Al,(SO,)s (Alum) ‘Alum is acidic and corrosive in nature. Skin and eye contact will cause irritation and burning if not immediately washed away with large volumes of water. Liquid Aluminium Sulphate will give off vapors to atmosphere . Inhalation of these vapors will cause irritation to the lungs resulting in coughing and if swallowed, nausea, vomiting, sore throat, abdominal pain and diarrhea. See chemical data sheet attached 7.3.2 Polyelectrolyte (Polymer) Polyelectrolyte is not a dangerous chemical and cannot be harmful if in contact with skin ete It is an extremely slippery substance when in contact with water and care must be made to avoid spillage onto ground. This will avoid loss of footing and falls. ‘See Chemical Data sheet attached for more information 7.3.3 Sodium Hypochlorite: NaOCl Sodium Hypochlorite must be handled with care and if splashed in eyes then can cause severe permanent damage. Eye wear and gloves must be worn when handling the chemical See attached chemical data sheets 7.3.4 Hydrochloric Acid: HCI ( Muriatic Acid ) Both as a gas and in solution, Hydrochloric Acid is very corrosive and can cause severe burns on contact Mucous membranes of the eyes and the upper respiratory tract are especially susceptible to high atmospheric concentrations. Personnel should avoid inhalation of the fumes and ensure adequate ventilation when handling the acid Hydrochloric Acid is commercially offered as a colourless to light yellow/green liquid, in concentrations of about 28 to 36 weight to weight percent HCI. Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water, Treatment Plants Recommended Maximum Imput Organic Matter 0.01 % Sulphuric Acid (As $O3) 04% tron __ 0.01% Other Metals (Total) 10mg Oxydantia (HNOs, Cla) Smgl Suspended Solids (Measured As Turbidity) None Inhibitors None Hydrochloric Acid from the salt-acid process or by the hydrogen-chlorine process is satisfactory. Hydrochloric Acid from hydrolysis of chlorinated organic materials is not suitable. Hydrochloric Acid solutions are mostly diluted to 4 to 6 percent for the regeneration of strongly acidic ion exchange resins and from 1 to 5 percent for weakly acidic exchange resins. Higher concentrations using 8 to 10 percent HCl are sometimes preferred in some applications. 7.3.5 Sodium Hydroxide: NaOH (Caustic Soda) Sodium Hydroxide or Caustic Soda can cause severe burns on contact with the skin and eyes or if taken internally. Great care must be taken handling the anhydrous material when preparing or handling caustic solutions. Gloves and safety glasses must be worn when handling this chemical. If spillage does occur the area must be washed for 15 minutes under running water. See attached chemical data sheets Caustic soda is commercially offered as solid flakes or pellets of about 98% NaOH, or as liquid in concentrations of 30 to 50 percent. Mercury cell or purified diaphragm cell (rayon) quality Sodium Hydroxide will normally reach these specifications. Regular diaphragm cell quality Caustic Soda can contain over 2 percent NaC! and over 0.1% (1000 mill) of NaClOs, Sodium Hydroxide solutions are mostly diluted to between 2 and § percent for the regeneration of weakly or strongly basic resins. Recommended Maximum Impurity Levels: Density 1.49 kgil @ 20°C NaCl Z (0.05 mgit max | Na,co, 0.05 mit max NaCiO3 <30 mg/l Iron <5 mgil Silica < 60 mg/l Mercury : <0.5 mg/l Operations & Maintenance Manual 32 Revision 3fa ieee ‘AquaClear Technology Pty Ltd. Job No: 97/003 PRE-TREATMENT PLANT PT Energi Sengkang Pretreatment and Water Treatment Plants Operations & Maintenance Manual Revision 3 asc AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants 8. OVERVIEW. 81 PROCESS DESCRIPTION Raw water is pumped to the Pre-Treatment Plant at a constant rate equal to the offtake required for the Cooling Tower system, Filtered Water system, Potable Water and Water Treatment Plant feedwater. During normal conditions, a rate of 185 m*vhr of clarified water supplies the Cooling Towers and 10 miihr to the Gravity Filters (ie. a total discharge of 195 m’/hr). During the monsoon season, an additional 10 m*/hr is required for service water purposes. Under normal conditions, the duty filter operates at 10 m°shr and during monsoon conditions both filters operate at 20 m°/hr. Before entering the plant the raw water is dosed with alum, sodium hypochlorite and caustic soda. An in-line static mixer is incorporated to ensure the thorough mixing of the chemicals. Following the mixing, polyelectrolyte is added to aid in the coagulation of the flocculated particles. The water then flows to the central flocculating well of the clarifier. The coagulated particles are removed by sedimentation. The dosing rates for alum, polyelectrolyte and caustic soda are flow paced from a raw water flow and are adjusted for varying turbidities. The dosage for sodium hypochlorite is controlled in the same way but itis not adjusted with varying turbidities Clarified water flows over a V-notch weir into a peripheral launder. An outlet pipe from the launder allows the water to enter the duty Gravity Filter at the design rate. An upstand pipe outlet allows water to flow to the Cooling Towers. This ensures a constant head for the filter pipes to maintain a constant flowrate. Any water in excess of the requirement for the filters will flow to the Cooling Towers. The level in the Filtered Water Basin determines the need for filtered water. The duty Gravity Filter is brought on line whenever the basin level falls below the pre-set level. If the filtered water consumption is low and the sump reaches high level, the filter will be taken off-line, in which case all water entering the Clarifier launder will pass to the Cooling Towers. Water flows through the Gravity filters and into the Filtered Water Basin. Each fitter is provided with level control system, whereby a control loop will modulate the position of the outlet control valve to ensure a constant level is maintained in the filter. Hence as the differential pressure across the filter bed increases as the bed blocks up, the modulating valve opens in order to maintain a constant headloss across the filter / outlet valve system and thus maintain constant level in the filter, When a filter backwash is initiated, the standby filter is brought into operation and the filter to be backwashed will be isolated. During the monsoon conditions both filters will be in duty service and they will be backwashed individually as required and returned to service immediately. The level in the filter to be backwashed is reduced to a level approximately 150 mm above the filter media An air scour will take place for approximately 2 minutes, followed by backwash for approximately 5 minutes. A pair of air blowers system provides air for the air scour operation. Backwash water is pumped from the Filtered Water Basin to the filters at a pre-set backwash rate and into the filter underdrain plenum from where it is pass up through the filter nozzles and the filter bed causing a bed expansion of approximately 50 % - “a Operations & Maintenance Manual Revision 3oO ‘AquaClear Technology Pty Ltd, PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants Washwater from the fiters flows to the Washwater Tank. After a period of approximately one hour, supernatant water is decanted from the tank to the Washwater Recovery Tank and settled sludge is pumped to the Sludge Storage Tank. An actuated valve in the settled sludge offtake line from the Clarifier is opened periodically to allow withdrawal of settled sludge from the clarifier. This settled sludge is passed to the Sludge Storage Tank. Sludge from the Sludge Storage Tank is pumped to the Sludge Thickener according to the levels at the tank Supernatant water from the Sludge Thickener launder flows to the Washwater Recovery Sump whilst thickened sludge is pumped to the duty Belt Filter Press. The dewatered sludge falls from the press into a storage bin. Recovered wastewater is then pumped back to the Sludge Thickener for reprocessing Filtered water is pumped from the Filtered Water Basin to provide service water for chemical preparation systems and belt press washwater. During normal conditions, this amount to approximately 10 m°/hr, increasing to 20 m°/hr during the monsoon conditions when two Belt Presses will operate concurrently. Filtered water is also pumped through Activated Carbon Filters to provide potable water (1.5 m’/hr) and demin feed water (8.5 m’/hr). The carbon filters remove residual chlorine which may be present in the fitered water. The Activated Carbon Filters is then backwashed similarly to the Gravity Filters and washwater will be recovered by the Washwater Recovery system Sodium hypochlorite is dosed into the potable water prior to entering the Potable Water Tank. The chlorine residue at the tank outlet should be checked periodically to ensure the chlorine level not to exceed 1ppm. Operations & Maintenance Manual 35 Revision 3o> AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants 8.2 CONTROL PHILOSOPHY RAW WATER TRANSFER TO CLARIFIER. When a call for water is made from the ABB central control system, it will be read as an input to the PLC. A response is sent to the ABB central control system acknowledging that the call has been received The PLC will control the Raw Water Pumps only when they are selected for REMOTE operation The duty Raw Water Pump will operate in a preset pressure range. If flow is not established within 15 seconds, a no flow fault will be raised and the standby pump will start. The flowrate of water to the plant is controlled by a PID control loop which will read the measured water flow from the raw water flow transmitter and act on a flow control valve in the raw water pipeline, The plant has three flow setpoints which are to be entered by the operator on the CITECT system, + Clarifier only operation + Clarifier and one fiter operation * Clarifier and two filters operation The PLC will then select the appropriate setpoint depending on the number of filters in operation at any time as determined by the level in the Filtered Water Basin and the backwashing situation for the fiters. This is described in later section covering fiter operation. The flowrate of water to the plant is shown on the CITECT system as will the operation of the Raw Water Pumps with standard monitoring on the screen CLARIFIER CHEMICAL DOSING Selection of chemical dosing systems will be made by the operator at the CITECT operator interface systems, The operator will select the system operate and the dose rate for the chemical in mg/L. If'a system is not selected to operate, no dosing of that chemical will occur. The sodium hypochlorite, alum, sodium hydroxide and polyelectrolyte dosing systems is interlocked with the Raw Water Pumps to provide dosing of chemicals whenever the pumps are running and selected for AUTO operation The PLC is programmed with an algorithm which will calculate the necessary dosing pump speed based on the raw water flowrate, dose rate (mg/L) and stroke length (%) of the pump, and concentration (%) and specific gravity of the chemical. The operator will input all the above parameters except for flowrate through CITECT. The derived output from the PLC provides @ remote analogue signal to the relevant dosing pump VF drive. The plant will stop if either the Alum Dosing Pumps or the Clarifier Polymer Dosing Pumps are in OFF or MANUAL operation. This will also occur if the Alum Day Tank reaches low level. However, there is an hour time delay after the Clarifier Polymer Day Tank reaches low level before the plant shuts down. All the dosing pumps are protected by the low level switch in the day tanks. Operations & Maintenance Manual Revision 3my ‘AquaClear Technology Pty Ltd PT Energi Sengkang Job No: 97/003 Pretreatment and Water Treatment Plants CLARIFIER The Clarifier mechanism operates whenever the Raw Water Pumps operate and will continue for two hours after the Raw Water Pumps stop when the plant is taken offline. ‘Sludge withdrawal from the clarifier is effected by operating the sludge outlet valve and will occur on a regular timed basis while the mechanism is operating. The time for which the valve opens and the time interval between desludging operations is selected by the operator via the CITECT system, The clarifier mechanism is fitted with an overtorque limit switch. In the event that an overtorque event occurs, the clarifier is to be stopped and an alarm raised GRAVITY FILTERS The filters are ostensibly duty/standby fiters whereby only one filter will be in operation at any time However, if the level in the Filtered Water Basin is below an intermediate level setpoint and falling (ie. a single filter cannot maintain the level) and the standby filter is available for service (ie. not backwashing), the standby filter will be brought on line. After can be selected for duty operation from the MCC. During normal operating conditions, both fiters will be selected for operation to provide for backup during backwashing operations. The first fier selected for operation will become the duty fiter, with the second filter kept on standby, with all valves closed unless a high rate operation is required as described in the first paragraph of this section in which case both filters will operate A number of level setpoints are provided in the Filtered Water Basin according to the following + High level where both filters are shutdown, + Duty filter start level + Standby filter start level. The flowrate from the Clarifier to the filters is set at commissioning The filter level is controlled via PID loop which will act on the filter outlet valve to maintain a constant level in the filter. Filter backwashing is initiated in three ways + High filter headloss as determined by the dP cell on the filter. + Elapsed time since last backwash ‘+ Operator initiated via the CITECT system. When a backwash is initiated on a filter, the standby filter will be brought on line and the duty filter taken off line for backwashing. When a filter backwash is completed, the filter will remain on standby. Hence the duty/standby designation wil flip flop with backwashing, The backwash sequence proceeds as follows: Anew operating setpoint is entered into the filter level PID loop so that the water level is reduced to a level about 150 mm above the media. This operation is carried out in a stepwise fashion with the level setpoint gradually decreasing (so the difference between the setpoint and measured level is not too great) to ensure the filter outlet valve is not being fully open. a Operations & Maintenance Manual Revision 3AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants When the draindown level setpoint is reached, the level setpoint increases to its normal operating level which will then cause the filter outlet vaive to close. The control system checks that the filter Cutlet valve is closed (by ensuring valve closed limit switch is made) before proceeding, Ifthe valve is not confirmed closed, a fault condition will be raised and the backwash suspended The air scour inlet valve will then open and, provided it is selected for AUTO operations, the duty Air Scour Blower will start and operate for five minutes. Alter the air scour time has elapsed, a combined air/water wash occurs. While the Air Scour Blower is stil operating, the duty Backwash Pump starts (provided it is selected for AUTO operation) and the backwash inlet vaive and washwater outlet valves opens. The flowrate of backwash water is controlled by a PID loop which will act on the backwash water flow control valve to maintain a set flow of 50 m°/hr as measured by the backwash flowmeter. At the end of the combined air/water wash, the blower stops, the air scour inlet valve closes and a water only wash occurs for 5 minutes. The control system enters a higher flowrate (100 m°/hr) setpoint into the backwash water flow control loop to enable a high rate water only wash to occur. At the end of the high rate water only wash, the Backwash Pump stops and the filter backwash water inlet valve and washwater outlet vaive closes and the filter put on standby to be brought into service when required. ‘An interlock is provided to inhibit a backwash from starting if a low level condition exists in the Filtered Water Basin An interlock is also provided to inhibit a backwash if a backwash is occurring on an Activated Carbon Filter In addition, a backwash is inhibited if the Washwater Tank has not drained. SERVICE WATER The duty Service Water Feed Pump and Service Water Pump operate simultaneously when the pressure switch is activated (when the pressure in the line is approximately below 500 kPa), The pumps stop operating after one minute or when the pressure switch is deactivated (when the pressure in the line is approximately above 700 kPa) whichever comes last. An interlock is provided to prevent the pumps from operating if a low level condition exists in the Filtered Water Basin ACTIVATED CARBON FILTERS When a call for water is made from the Break Tank in the WTP or the Potable Water Tank in the PTP, the water inlet and outlet drain valves on the duty Activated Carbon Filter opens and the duty Filter Feed Pump operates as selected on AUTO operation After a rinse time (say 1 minute), the filtered water outlet valve opens and the drain valve closes, thus allowing filtered water to flow to the Potable Water Tank and the Break Tank in the WTP. Backwashing of the Activated Carbon Filters is initiated in three ways: + High filter headloss as determined by the dP switch on a fiter. «Elapsed time since last backwash, © Operator initiated via the CITECT system Operations & Maintenance Manual Revision 3‘AquaClear Technology Pty Ltd. PT Energi Sengkang Job No: 97/003, Pretreatment and Water Treatment Plants When a backwash is initiated on a fiter, the standby fiter will be brought on line and the duty filter taken off line for backwashing. When a fiter backwash is completed, that fiter wil remain on standby Hence the duty/standby designation will fip flop with backwashing, ‘The backwash sequence proceeds as follows: The filter drain valve opens for @ preset time to allow the filter to drain down. The duty backwash pump starts (provided it is selected for AUTO operation and the backwash inlet valve and washwater outlet valve closes and the filter put on standby to be brought into service when required An interlock is provided to inhibit a backwash from starting if a low level condition exists in the filtered water basin. ‘An interlock is also provided to inhibit a backwash if a backwash is occurring on a Gravity Filter. In addition, a backwash is inhibited if the Washwater Tank has not drained. POTABLE WATER The flow into the Potable Water Tank is measured by a flowmeter at the inlet of the tank When there is flow detected sodium hypochlorite is dosed into the inlet pipe. ‘The duty Potable Water Pump operate when the pressure switch is activated (when the pressure after the pressure reducing valve is approximately below 250 kPa). The pumps stop operating after one minute or when the pressure switch is deactivated (when the pressure after the pressure reducing valve is approximately above 350 kPa) whichever comes last. ‘The Potable Water Pumps will continue to operate even if the PTP is shut down. An interlock is provided to prevent the pumps from operating if a low level condition exists in the Potable Water Tank. WASHWATER AND WASHWATER RECOVERY Washwater from the backwashing of Gravity Filters and Activated Carbon Filters flows to the Washwater Tank Whilst a backwash is in progress and for a preset time thereafter (say one hour), the tank remains static with the decant outlet valve closed and the Washwater Sludge Transfer Pumps off. After that time is reached, the decant valve will open and decant the supernatant liquor into the Washwater Recovery tank. The valve will remain open until the washwater tank level is reduced to a decant level setpoint. When the decant level setpoint is reached, the decant valve will close and the duty Washwater Sludge Transfer Pump will start (provided it is selected for AUTO operation} and operate until the level in the tank has been reduced to the low sludge level setpoint The pumps are protected by the low level switch in the Washwater Tank. ‘The duty Washwater Recovery Pump operates whenever the level reaches the high level setpoint. ‘The pumps are protected by the low level switch in the Washwater Recovery Tank. SLUDGE STORAGE AND SLUDGE THICKENER. Operations & Maintenance Manual 3 Revision 3