TRAINING REPORT

BALANCE OF PLANT (BOP)

Submitted to
Mr. Farhan Javed (Team Leader BOP)

Jawad Aslam | December 31, 2013

 ACKNOWLEDGEMENT

I thank Almighty Allah for giving me the strength to complete this Report and for showering His
blessings upon me throughout my training period at the BOP Area.

I would like to thank my Parents for their eternal love and support and for having faith in me
throughout my life. I would like to express my deepest appreciation to my seniors and My Team
Leader Mr. Farhan Javed who continually and convincingly guided me throughout the process.
Without their guidance and help this report would not have been possible.

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Table of Contents
ACKNOWLEDGEMENT................................................................................................................ i
Introduction ..................................................................................................................................... 1
Pre-treatment of Intake Water ......................................................................................................... 2
Raw Water Intake ........................................................................................................................ 2
Settling Basins ............................................................................................................................. 3
Clarifier ........................................................................................................................................ 3
Choice of Coagulant ................................................................................................................ 5
Polymers................................................................................................................................... 6
Dual Media Filters ....................................................................................................................... 8
DMF Cleaning / Backwash ...................................................................................................... 8
Demineralization System............................................................................................................... 10
Multimedia Filters...................................................................................................................... 10
Backwashing of Filters ........................................................................................................... 11
Reverse Osmosis System ........................................................................................................... 12
Reverse Osmosis..................................................................................................................... 12
Chemical Dosing in R.O. System ........................................................................................... 15
Demineralizer Train ................................................................................................................... 15
Regeneration of Demineralizer Train .................................................................................... 17
Cooling Towers ............................................................................................................................. 18
Components of Cooling Tower.................................................................................................. 19
Cooling Tower Specifications ................................................................................................... 21
Cooling Tower Performance ...................................................................................................... 21
Chemical Treatment of Cooling Tower ..................................................................................... 23
Hydrogen Generation System........................................................................................................ 25
Electrolytic Cell ......................................................................................................................... 26
Cell Temperature ................................................................................................................... 26
Electrolyte .................................................................................................................................. 27
Electrolyte Strength................................................................................................................ 28
Hydrogen Mist Eliminator ......................................................................................................... 28
Hydrogen Gas Holder ................................................................................................................ 28
BOP Area Report

Hydrogen Purification System ................................................................................................... 28

Catalytic Purifier ........................................................................................................................ 29
After Cooler ............................................................................................................................... 29
Table of Figures............................................................................................................................. 30
BOP Area Report

Introduction
BOP (Balance of Plant) section at Lalpir Thermal Power Plant is responsible for providing water
according to desired specifications of different areas and equipment at plant, safe disposal of waste
water and hydrogen generation.

There are mainly two sources of raw water at Lalpir,

1. canal water, which is a seasonal source taken into service from April till October
2. well water, which is taken into service when canal water is not available

Raw water from here on is treated to suit the requirement of systems that need water, such as

 Firefighting system
 Service water system
 Portable water system
 Condenser
 Boiler

Boiler, amongst the other water consumers at Lalpir, is the most sensitive user that requires
demineralized water of conductivity less than 0.1 μs/cm and silica content less than 0.01 ppm.

Figure 1 Over-view of BOP Area

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CHAPTER 1

Pre-treatment of Intake Water

Raw Water Intake
Once raw water from the canal is taken, it is passed through a travelling band screen that removes
any debris that may cause damage to the canal water pumps. There are 22 baskets that are in a
continuous revolution such that the water passes through their center. These baskets are made of
strong mesh having a size of 1mm. The baskets scoop the raw water out one by one. Any debris
that may have made its way through the intake is taken up by these baskets and later sprayed into
a waste collecting pit which dumps this debris back into the canal. The debris free water is then
pumped to the plant by canal water pumps. These pumps supply water at a rate of 1200 m3/hr, each.
There is a recirculation valve provided with each pump which when operational, will allow water
to circulate back to the bar screen. The total number of canal water pumps is four, two for each unit.
When functional, one pump is in service and the other is on standby. All four pumps’ lubricating
oil and rubber bearings at shaft are cooled by cooling water. Two separate storage tanks are used
for this purpose.

Figure 2 Raw Water Intake system

When canal goes dry, continuous demand of water is met by 18 well water pumps, 9 for each unit,
located on the north bank on canal. Each pump has discharge rate of 240 m3/hr and 6 pumps remain
in service at a time.

The raw water intake from canal constitutes of the following subsystems:

 Travelling band screens

 Canal water pumps
 Settling basins

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 Clarifier supply pumps

 Distribution box
 Clarifiers
 Clear well
 Dual media filters (DMF)

Settling Basins
There are three types of objects which can be found in water. In order from smallest to largest,
these objects are chemicals in solution, colloidal solids, and suspended solids. The settling basins
are designed to provide ample retention time for settling of heavy suspended particles, debris and
uncharged particles.

All sedimentation basins have four zones - the inlet zone, the settling zone, the sludge zone, and
the outlet zone. Each zone should provide a smooth transition between the zone before and the zone
after. In addition, each zone has its own unique purpose.

Figure 3 Settling Basin

Water from canal pumps through their respective line (PakGen or Lalpir) comes to 3 settling basins
(each of 1000 m3 vol.) having common header with the provision of filling any settling basin, and
by pass line to cooling tower. Settling basins provide primary settling zone for large suspended
particles, sand and silt in canal water. These basins reduce the coagulation cost in clarifier, load on
filters and provide proper suction for clarifier supply pumps.

Canal water from settling basins is fed to distribution box located on clarifiers for further treatment
by clarifier supply pumps of 1050 m3/hr discharge rate.

Clarifier
In clarifiers, water is pumped to the mixing zone, the rake and turbine area in the center, rather than
being pumped at one end and being retrieved from the other. Clarifiers are used to reduce the
number of total dissolved solids present in raw water by coagulation and flocculation.

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Clarifiers normally consist of the following zones:

 Reaction and mixing zone
 Settling zone

Figure 4 Over-view of a typical Clarifier

At Lalpir we have three clarifiers (A, B & C). Clarifier A & C are for Lalpir and PakGen unit
respectively, while clarifier B is kept at standby.

The suspended particles in water vary considerably in source, composition charge, particle size,
shape and density. The small particles are stabilized (kept in suspension) by the action of physical
forces on the particles themselves. One of the forces playing a dominant role in stabilization results
from the surface charge present on the particles. Most solids suspended in water possess a negative
charge and, since they have the same type of surface charge, they repel each other. Therefore, they
will remain in suspension rather than clumping together and settle out of the water.

As water is pumped into the clarifier, it is dosed with a coagulant, Ferric Sulfate. This is because
raw water contains small suspended negatively charged particles that are not removed by travelling
band screens or settling basins. These particles need to be removed in order to reduce the total
suspended solids in the water, thus reduction in water turbidity. Coagulation neutralizes these
charged particles and flocculation ensures the removal of these suspended particles. The negatively
charged particles in water settle in with the positively charged particles of the coagulant, thus
neutralizing and increasing in size and weight as well.

Coagulant, more formally, is defined as an electrochemical process of neutralization of surface

charges to allow small colloidal particles to collide and form larger masses capable of settling or
withstanding pressure. Flocculation, on the other hand, is defined as the physical process of the
formation of larger masses, often enhanced by the addition of long-chain polymeric compounds.
Ferric Sulfate is dosed as the coagulant, whereas a polymer solution is injected into the clarifier
reaction and mixing zone to initiate flocculation.

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Figure 5 Illustration of Coagulation Process

The suspended particles settle down on the base of the clarifier after coagulation and flocculation,
thus forming a layer of sludge at the bottom. This level of sludge needs to be maintained at certain
conditions in order to facilitate the filtration process. A rake keeps operating in the sludge area,
thus ensuring that the sludge bed does not get solidified. In order to maintain the level of the sludge
bed, de-sludging is carried out by two de-sludge pumps at different intervals. At the clarifier outlet
the turbidity is thus reduced to a minimum level as the majority of suspended solids have are
removed.

Figure 6 Water Quality at different turbidities

Choice of Coagulant
The choice of coagulant chemical depends upon the nature of the suspended solid to be removed,
raw water conditions, facility design, and the cost of the amount of chemical necessary to produce
the desired result. Final selection of the coagulant should be made following thorough jar testing
and plant scale evaluation. Considerations must be given to required effluent quality, effect upon
downstream treatment process performance, cost, method and cost of sludge handling and disposal,
and net overall cost at the dose required for effective treatment.

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Inorganic Coagulants
Inorganic coagulants such as aluminum and iron salts are the most commonly used. When added
to the water, they furnish highly charged ions to neutralize the suspended particles. The inorganic
hydroxides formed produce short polymer chains which enhance microfloc formation. Inorganic
coagulants usually offer the lowest price per pound, are widely available, and, when properly
applied, are quite effective in removing most suspended solids. They are also capable of removing
a portion of the organic precursors which may combine with chlorine to form disinfection by-
products. They produce large volume of flocs which can entrap bacteria as they settle. However,
they may alter the pH of the water since they consume alkalinity. When applied in a lime soda ash
softening process, alum and iron salts generate demand for lime and soda ash.

They require corrosion-resistant storage and feed equipment. The large volumes of settled flocs
must be disposed of in an environmentally acceptable manner.

Inorganic Coagulant Chemical Equations

Common coagulant chemicals used are alum, ferric sulfate, ferric chloride, ferrous sulfate, and
sodium aluminate. The first four will lower the alkalinity and pH of the solution while the sodium
aluminate will add alkalinity and raise the pH.

At Lalpir we use ferric sulfate as a coagulant and its equation is as follows:

Fe2(SO4)3 + 3 Ca(HCO3)2 2 Fe(OH)3 + 3 CaSO4 + 6 CO2

Polymers
Polymers are becoming more widely used, especially as coagulant aids together with the regular
inorganic coagulants. Anionic (negatively charged) polymers are often used with metal coagulants.
Low-to-medium weight positively charged (cationic) polymers may be used alone or in
combination with the aluminum and iron type coagulants to attract the suspended solids and
neutralize their surface charge. The manufacturer can produce a wide range of products that meet
a variety of source-water conditions by controlling the amount and type of charge and relative
molecular weight of the polymer. Polymers are effective over a wider pH range than inorganic
coagulants. They can be applied at lower doses, and they do not consume alkalinity. They produce
smaller volumes of more concentrated, rapidly settling floc. The floc formed from use of a properly
selected polymer will be more resistant to shear, resulting in less carryover and a cleaner effluent.

Polymers are generally several times more expensive in their price per pound than inorganic
coagulants. Selection of the proper polymer for the application requires considerable jar testing
under simulated plant conditions, followed by pilot or plant-scale trials.

Factors Affecting Coagulation

In a well-run water treatment plant, adjustments are often necessary in order to maximize the
coagulation/flocculation process. These adjustments are a reaction to changes in the raw water
entering the plant. Coagulation will be affected by changes in the water's pH, alkalinity, temperature,
time, velocity and zeta potential.

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 The effectiveness of a coagulant is generally pH dependent. Water with a color will

coagulate better at low pH (4.4-6) with alum.
 Alkalinity is needed to provide anions, such as (OH) for forming insoluble compounds to
precipitate them out. It could be naturally present in the water or needed to be added as
hydroxides, carbonates, or bicarbonates. Generally 1 part alum uses 0.5 parts alkalinity for
proper coagulation.
 The higher the temperature, the faster the reaction, and the more effective is the
coagulation. Winter temperature will slow down the reaction rate, which can be helped by
an extended detention time. Mostly, it is naturally provided due to lower water demand in
winter.
 Time is an important factor as well. Proper mixing and detention times are very important
to coagulation.
 The higher velocity causes the shearing or breaking of floc particles and lower velocity
will let them settle in the flocculation basins. Velocity around 1 ft/sec in the flocculation
basins should be maintained.
 Zeta potential is the charge at the boundary of the colloidal turbidity particle and the
surrounding water. The higher the charge the more is the repulsion between the turbidity
particles, less the coagulation, and vice versa. Higher zeta potential requires the higher
coagulant dose. An effective coagulation is aimed at reducing zeta potential charge to
almost 0.

TECHNICAL DATA
Canal Water Pump Capacity 1200 m3/hr
Well Water Pump Capacity 240 m3/hr
Travelling screen baskets 22
Travelling screen wash pump 10 m3/hr
Canal water pumps flow 1200 m3/hr
Clarifier supply pump 1100 m3/hr
Inlet distribution box flow 1023 m3/hr
Clarifier Capacity 2400 m3
Clear well Capacity 165 m3
Coagulant Tank Capacity 15 m3
Polymer Tank Capacity 12 m3

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Dual Media Filters

The filter media is the part of the filter which actually removes the particles from the water being
treated. Filter media is most commonly sand, though other types of media can be used, usually in
combination with sand. The gravel at the bottom of the filter is not part of the filter media, merely
providing a support between the under drains and the media and allowing an even flow of water
during filtering and backwashing.

The sand used in rapid sand filters is coarser (larger) than the sand used in slow sand filters. This
larger sand has larger pores which do not fill as quickly with particles out of the water. Coarse sand
also costs less and is more readily available than the finer sand used in slow sand filtration.

In many cases, multiple types of media are layered within the filter. Typically, the layers (starting
at the bottom of the filter and advancing upward) are sand and anthracite coal, or garnet, sand, and
anthracite coal. The picture below shows a cross-section through a dual media filter.

Figure 7 Media Layers in DMF

The media in a dual or multi-media filter are arranged so that the water moves through media with
progressively smaller pores. The largest particles are strained out by the anthracite. Then the sand
and garnet trap the rest of the particulate matter though a combination of adhesion and straining.
Since the particles in the water are filtered out at various depths in a dual or multimedia filter, the
filter does not clog as quickly as if all of the particles were all caught by the top layer.

DMF Cleaning / Backwash

After 2 hours of running DMF Filters are cleaned/backwashed to remove the carryover suspended
particles. Clear well Level should be above 70%.

 Drain Down (5 Min)

Here the air outlet valve and drain down valves are opened so that any previous reserve is
drained because standing water in DMF is rich in silica. Flow rate is 90 m3 /hr

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 Air Mix (5 min)

In this step air mix inlet valve (air from the DMF air blowers) and air outlet valve are opened
this steps evens the DMF surface same as air scouring. Flow rate is 1380 m3 /hr

 Fill (5 min)

In this step service inlet of water and air outlet valve opens in this step DMF fills itself with
water. Flow rate is 225 m3 /hr

 Backwash (5 min)

Here back wash inlet and outlet valves opens and the water goes to Settling Basin. Flow rate is
680 m3 /hr

 Rinse (5 min)

Service inlet and rinse outlet valves open and the waste water goes to distribution chamber.
Flow rate is 170 m3 /hr.

After these steps DMF is ready for service. DMF Backwash and clear well overflow goes to settling
basin A&B.

By-Passing the Pre-treatment System

All pre-treatment steps (i.e. settling basin, clarifier, DMF) are bypassed when well water is taken
into service. Following steps are used for by-pass

 Close the inlet FCV of clarifier manually from PLC.

 Open the clarifier bypass valve.
 If PG Unit is operating then clarifier pump C discharge bypass valve to cooling tower
would be opened.
 DMF pumps should be OFF and DMF bypass valve must be open.

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CHAPTER 2

Demineralization System
The demineralization system is designed to produce demineralized treated water with a
conductivity of less than 0.1 µ/cm and silica content of less than 0.01 ppm.

Multimedia Filters
Multimedia filtration refers to a pressure filter vessel which utilizes three or more different media
as opposed to a "sand filter" that typically uses one grade of sand alone as the filtration media. In a
single media filter, during the "settling" cycle, the finest or smallest media particles remain on top
of the media bed while the larger, and heavier particles, stratify proportional to their mass lower in
the filter. This results in very limited use of the media depth since virtually all filterable particles
are trapped at the very top of the filter bed or within 1-2 inches of the top where the filter media
particles have the least space between them. The filter run times are thus very short before the filter
“blinds” or develop much differential pressure that it must be backwashed to avoid seriously
impeding or stopping the flow.

Multi-media filters typically have three layers, consisting of anthracite, sand and garnet. These are
often the media of choice because of the differences in mass between the materials. Garnet is by
far the heaviest per unit volume, sand is intermediate while anthracite is the lightest. The idea
behind using these three media of differing densities is that anthracite media, with the largest
particle size, will stratify on top following backwash while the intermediate size media (sand) will
settle in the middle and garnet, the heaviest but having the smallest particle diameter, will settle to
the bottom.

Figure 8 Media Layers in MMF

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This filter media arrangement allows the largest dirt particles to be removed near the top of the
media bed with the smaller and smaller dirt particles being retained deeper and deeper in the media.
This allows much longer filter run times between backwash and much more efficient dirt or
turbidity removal. Sand filters typically remove particles down to 25-50 microns while a well-
operated multi-media filter may remove particles from 10-25 microns.

Pre-treated water from

the filtered water basin
is directed to two
Multi-Media Filters
which remove residual
turbidity and
suspended solids from
the water. Following
multi-media filtration,
the water is injected
with sodium bi-sulfate
to remove trace
quantities of free
chlorine. Multi- Media
filter backwash and
rinse water is directed
to the inlet distribution
box. A portion of the
Figure 9 Multi Media Filter multi-media filtered
water is directed to the
potable water tank and chlorinator. If the raw water source is canal water, the multi-media filtered
water effluent is directed to the permeate tank .If the raw water source is well water, the multi-
media filtered water is directed to the reverse osmosis system. Each multi-media filter is designed
to treat 97 m3 / hr of pre-treated water.

Like DMF gravel layer is also used here for supporting the media. The arrangement of media from
top to bottom is as follows:

Material Quantity (m3) Average size (mm)

Garnet 1.06 0.35
Anthracite 1.50 0.90 - 1.00
Filter Sand 1.45 0.45 - 0.55
Fine Gravel 0.50 3.35 - 1.70
Medium Gravel 0.50 6.30 - 12.70
Coarse Gravel 1.90 12.70 - 19

Backwashing of Filters
Backwash and rinse waste water is returned to the distribution box. With one (I) filter in service
and the other in backwash, a second filter feed pump will be activated. Treated water is fed to the
reverse osmosis system when a high total dissolved solids raw water is utilized. Under normal

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circumstances, the R.O. system is bypassed and the multimedia filter effluent is directed to the R.O.
permeate tank. Sodium bi-sulfate is injected into the multimedia filter effluent at a constant,
manually set rate. A flow switch will control the start/stop operation of the bi-sulfate pumps.

Reverse Osmosis System

Osmosis is a natural process involving the fluid flow of across a semi-permeable membrane barrier.
Consider a tank of pure water with a semi-permeable membrane dividing it into two sides. Pure
water in contact with both sides of an ideal semi-permeable membrane at equal pressure and
temperature has no net flow across the membrane because the chemical potential is equal on both
sides. If a soluble salt is added on one side, the chemical potential of this salt solution is reduced.

Osmotic flow from the pure water side across the membrane to the salt solution side will occur
until the equilibrium of chemical potential is restored. In scientific terms, the two sides of the tank
have a difference in their chemical potentials and the solution equalizes, by osmosis, its chemical
potential throughout the system. Equilibrium occurs when the hydrostatic pressure differential
resulting from the volume changes on both sides is equal to the osmotic pressure. The osmotic
pressure is a solution property proportional to the salt concentration and independent of the
membrane.

Reverse Osmosis
Application of an external pressure to the salt solution side equal to the osmotic pressure will also
cause equilibrium. Additional pressure will raise the chemical potential of the water in the salt
solution and cause a solvent flow to the pure water side, because it now has a lower chemical
potential. This phenomenon is called reverse osmosis.

Figure 10 Osmosis vs. Reverse Osmosis

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Technical Data for RO system

5 micron Filters

Quantity/unit 2
Diameter 406 mm
Height 2108 mm
Material 316 stainless steel
Design pressure 10.5 kg/ cm2

Cartridges for 5 micron filters

Manufacturer Filterite
Quantity 22 per filter
Size 5 micron
Material Polypropylene
Design flow rate / filter 88 m3/ hr
Maximum DP 0.7 kg/ cm2

R.O Booster pumps

Quantity 3
Manufacturer Tonkaflo
Material 316 stainless steel
Design flow rate/pump 44 m3/ hr
Operating pressure 24.5 kg/cm2
Min. operating pressure 15.5 kg/cm2
Pump speed 2900 rpm
Motor power rating 56 KW
Electrical Ratings 380V/ 3ph / 50 Hz

R.O membrane element

Manufacturer Hydranautics
Number of elements 72 (36 per R.O bank)
Model no 8040-LSY-CPA2
Membrane type Spiral wound thin film composite
Diameter 201.9 mm
Length 1016 mm
Surface area / element 30.2 m2
Max. Operating temp 45 ºC
Feed water pH range 3-10

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Nominal permeate flow 1.42 m3/ hr

Nominal salt rejection 99%

Membrane Pressure Vessels

Manufacturer Advance structure

Material of construction FRP
Design pressure 28 kg/cm2
Size 289 mm dia × 6594 mm long
No. of housings 12(6 per R.O. bank)
No. of elements/housing 6

R.O System design data

No of R.O banks 2
No of housing/bank 6 (series staged 4:2)
No. Of elements/bank 36
Inlet feed temperature (design) 22 ºC
Minimum temp. 20 ºC
Maximum temp. 38 ºC
Feed pressure (design) 24.5 kg/ cm2
Minimum pressure 15.5 kg/ cm2
Maximum pressure 31.6 kg/ cm2
Product back pressure (design) 0.7 kg/ cm2
Maximum 3.5 kg/cm2
Design feed flow rate per bank 44 m3/ hr
Design permeate flow rate/bank 32.5 m3/ hr
Design reject flow rate/bank 11.5 m3/ hr
Permeate recovery 74%

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Figure 11 Reverse Osmosis (R.O.) banks

Chemical Dosing in R.O. System

Sulfuric Acid (4%)

It is injected into the reverse osmosis feed water to lower the pH. Control of the feed water pH is
affected by pH measurement and modulation of the sulfuric acid pumps stroke positioned. The acid
tank refill is automatically initiated based on the level in the acid tank. Refill is accomplished with
the activation of a dilution water pump, an acid pump and the opening of the mixed bed dilution
water valve and the R.O. acid tank inlet valve. Manual initiation for R.O. acid tank refill is also
available. The R.O. acid tank refill sequence is interlocked with the cation and mixed bed
regeneration sequences to prevent refilling the tank during regeneration of either primary or mixed
bed trains.

Anti - Scalant
The solution is also injected into the reverse osmosis feed water at a constant rate. In the automatic
mode, the acid and anti-sealant feed pumps are started and stopped automatically with the reverse
osmosis booster pumps. Refill of the anti-scalant tank is a manually controlled sequence.

Demineralizer Train
Two Demineralizer trains each comprised of a cation unit, anion unit and mixed bed unit,
produce treated water that is stored in the demineralized water storage tanks. A de-carbonator
tower/clear well and de-carbonator water forwarding pumps are common to both trains. A
level transmitter installed in the de-carbonator clear well controls the operation of the de-
carbonator inlet modulating control valve. Level controls in the demineralized water storage
tank controls the operation of the Demineralizer trains. On high level, the “In
Service” primary and mixed bed units will be placed in standby. Return to service is operator
initiated. Water flows through the ion exchanger’s water inlet and into the diffuser. The
diffuser spreads the water over the resin bed. As the water flows through the resin bed, ions

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are removed from the water and exchanged with the hydrogen ions (Cation unit) or hydroxyl
ions (Anion unit) occupying the sites on the resin beads.
The effluent of a cation exchanger is generally acidic, because the hydrogen ions present in
the water form acids. However, after the effluent from a cation exchanger flows through
anion exchanger and mixed bed, it is almost pure demineralized water.
The model reactions that are carried out in demineralizers are described as follows:

Strong Acid Cation Exchange

The following reactions take place in the Cation bed during service.

Ca+ (HCO3)- 2 Ca+

+ R - H2 R- + 2 H2CO3
+
Mg (HCO3)-2 Mg +

Ca+SO4- Ca+
+ R – H2 R- + H2SO4
+ - +
Mg SO4 Mg

Ca+Cl- Ca+
+ R – H2 R- + 2 HCl
+ - -
Mg Cl Mg

(Where R = resin)

De – carbonator
De-carbonator is a device which is used to remove CO2 from the water, produced during cation
removal as:

Ca+(HCO3)2- + R – H2 R – Ca+ + 2 H2CO3

De-carbonator is used to reduce load on anionic bed. Carbonic acid produced is a weak acid and is
dissociated very easily giving carbon dioxide and water as

H2CO3 H2O + CO2

Strong Base Anion Resin

From the above equations it is clear that during cation exchange process, acids are produced (H2SO4,
HCl). Secondly, anions entered into the bed along with water are still present. So in the anion
exchange step these ions are removed and the reactions taking place are

H2+SO4- + R - OH- R - SO4- + H2O

H+Cl- + R - OH- R - Cl- + H2O

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After all the minerals have are removed, ultra-pure water is produced that is stored in demineralized
water storage tank from where it is supplied to boiler.

Regeneration of Demineralizer Train

The resin beads used for ion exchanger have thousands of sites available for exchanging ions.
However, once the hydrogen or hydroxyl ions have been depleted, the beads are no longer useful
for ion exchange. In the exhausted state, the resin bed cannot remove ions from the incoming water.
There are two parameters to monitor resin exhaustion, Silica & Conductivity monitoring.
Demineralized trains are exhausted after cleaning particular amount of water. They are regenerated
with injecting fresh hydrogen & hydroxyl ions. Regeneration is pushbutton initiated. Initiation of
a primary train regeneration sequence will automatically regenerate a cation unit and its
corresponding anion unit concurrently. Following regeneration of a primary train and/or a mixed
bed unit, the units are placed in standby and return to service is pushbutton initiated. The standby
regenerated train may be placed in service during the regeneration procedure when in the semi-auto
mode. Both trains may be placed in service together only in the semi-auto mode. During normal
operation, one train will be in service and one train in standby. During the regeneration of a
demineralizer train, one train remains on standby mode.

Regeneration of the Demineralizer system is normally performed on a “train” basis by regenerating

the cation and anion units of the same train concurrently or a mixed bed unit. Interlocks are provided
to ensure that only one train or a mixed bed unit can be regenerated at any given time. To initiate
regeneration, both trains must first be placed into “Standby” and then press the appropriate
regeneration key(s).

The cation and anion units are regenerated in a split flow counter current manner and therefore will
not be given a full backwash every regeneration. When these units are backwashed (approximately
every 20 regenerations), a double chemical injection will be automatically provided to recondition
the resin at the bottom of the bed.

Regeneration controls are programmed for each cation and anion unit to totalize the number of
regenerations without a full backwash. When the preset value is reached, the unit will be given a
backwash and double chemical injection during its next regeneration cycle and the appropriate
regeneration tantalizers will be reset to zero after this upset regeneration. Provisions have been
made to override the regeneration if necessary; however, under normal operating conditions the
regeneration cycles should be allowed to time out and sequence through to completion. Dilution
water for the acid and caustic regenerate solutions is demineralized water delivered by the diluents
water pumps. Interlocks are provided to ensure that the acid and caustic regenerate solutions are
delivered at the correct flow rates and chemical strength. A heat exchanger is provided to heat the
dilution water during preheat caustic injection and displacement steps of the anion and mixed bed
regeneration procedure. Interlocks are provided to ensure that the minimum anion dilution water
temperature is at 35oC and the mixed bed dilution water is at 49oC. Dilution water flow is controlled
by rate set valves provided for cation acid dilution, mixed bed acid dilution, anion caustic dilution
and mixed bed caustic dilution.

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CHAPTER 3

Cooling Towers
“A Cooling Tower is an equipment used to reduce the temperature of a water stream by
extracting heat from water and emitting it to the atmosphere.”

Cooling towers are a very important part of many industrial plants. They represent a relatively
inexpensive and dependable means of removing low-grade heat from cooling water. The make-up
water source is used to replenish water lost to evaporation. Hot water from heat exchangers is sent
to the cooling tower. The water exiting the cooling tower is sent back to the exchangers or to other
units for further cooling.

Cooling towers fall into two main categories: Natural draft and Mechanical draft.

Cooling
Towers

Natural Mechanical
Draft Draft

Forced Induced
Draft Draft

Counter Counter
Cross Flow Cross Flow
Flow Flow

Cooling towers at Lalpir are Induced Draft counter flow open recirculating type.

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BOP Area Report

Figure 12 Typical Induced Draft Counter flow Cooling Tower

In the counter flow induced draft design, hot water enters at the top, while the air is introduced at
the bottom and exits at the top.

Components of Cooling Tower

The basic components of an evaporative tower are: Frame and casing, fill, cold water basin, drift
eliminators, air inlet, louvers, nozzles and fans.

Frame and Casing

Most towers have structural frames that support the exterior enclosures (casings), motors, fans, and
other components. With some smaller designs, such as some glass fiber units, the casing may
essentially be the frame.

Fill
Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximizing water
and air contact. Fill can either be splash or film type.

With splash fill, water falls over successive layers of horizontal splash bars, continuously breaking
into smaller droplets, while also wetting the fill surface. Plastic splash fill promotes better heat
transfer than the wood splash fill.

Film fill consists of thin, closely spaced plastic surfaces over which the water spreads, forming a
thin film in contact with the air. These surfaces may be flat, corrugated, honeycombed, or other

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BOP Area Report

patterns. The film type of fill is the more efficient and provides same heat transfer in a smaller
volume than the splash fill.

Cold Water Basin

The cold water basin, located at or near the bottom of the tower, receives the cooled water that
flows down through the tower and fill. The basin usually has a sump or low point for the cold water
discharge connection. In many tower designs, the cold water basin is beneath the entire fill.

Some forced draft counter flow design, however, the water at the bottom of the fill is channeled to
a perimeter trough that functions as the cold water basin. Propeller fans are mounted beneath the
fill to blow the air up through the tower. With this design, the tower is mounted on legs, providing
easy access to the fans and their motors.

Drift Eliminators
These capture water droplets entrapped in the air stream that otherwise would be lost to the
atmosphere.

Air In-let
This is the point of entry for the air entering a tower. The inlet may take up an entire side of a tower
(cross flow design) or be located low on the side or the bottom of (counter flow designs).

Louvers
Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow into
the fill and retain the water within the tower. Many counter flow tower designs do not require
louvers.

Nozzles
These spray water to wet the fill. Uniform water distribution at the top of the fill is essential to
achieve proper wetting of the entire fill surface. Nozzles can either be fixed and spray in a round
or square patterns, or they can be part of a rotating assembly as found in some circular cross-section
towers.

Fans
Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller fans are
used in induced draft towers and both propeller and centrifugal fans are found in forced draft towers.
Depending upon their size, the type of propeller fans used is either fixed or variable pitch. A fan
with non-automatic adjustable pitch blades can be used over a wide kW range because the fan can
be adjusted to deliver the desired air flow at the lowest power consumption. Automatic variable
pitch blades can vary air flow in response to changing load conditions.

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BOP Area Report

Cooling Tower Specifications

TECHNICAL DATA
Type Mechanical Induced Draft-Counter flow
Circ. Water flow rate 35,000m3 / hour for 2 pumps
Nominal Cell dimension 15.8 m x 19.2 m
Fan stack height 3.8 m
Overall tower height 14.8 m
Number of Cells 8 (per unit)
Total number of fans 8 (per unit)
Design Summer Winter
Hot water (inlet) temperature 41 49 41
Cold water (outlet) temperature 30 36 27
L/G ratio 1.50 1.33 1.26
Drift losses 0.1 % 0.1 % 0.1 %

FANS
Type & Model Axial Flow Propeller Fan (Pitch adjustable)
Manufacturer Hudson Products Corporation
Diameter 9.76 m
Number of Blades 10 per fan
Fan speed 114 RPM
Tip speed 58.2 m/sec
Air delivery(fan) 754 m3 /sec
Pitch angle 13 - 15 degree
Fan static efficiency 64 %

Cooling Tower Performance

Following are the factors that affect cooling tower performance and their calculated values under
different conditions that are observed at Lalpir cooling towers

1. Range is the difference between the cooling tower water inlet and outlet temperature. In
other words, high range would mean better cooling tower performance.

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BOP Area Report

Range (summer) = 49 – 36 = 13 oC

Range (winter) = 41 – 27 = 14 oC

2. Approach is the difference between the cooling tower outlet cold water temperature and
ambient wet bulb temperature. Lower approach means better cooling tower performance.
Approach (summer) = 36 – 28 = 8 oC

Approach (winter) = 27 – 8 = 19 oC

3. Effectiveness (in percentage) is the ratio of range, to the ideal range, i.e., difference
between cooling water inlet temperature and ambient wet bulb temperature, or in other
words it is = Range / (Range + Approach).

Effectiveness (summer) = [13 / (13+8)] x 100 = 62 %

Effectiveness (winter) = [14 / (14+19)] x 100 = 42 %

Figure 13 Temperature profiles

4. Cooling Capacity is the heat rejected in kCal/hr or TR, given as product of mass flow
rate of water, specific heat and temperature difference.
5. Evaporation loss is the water quantity (m3/hr) evaporated for cooling duty. Ideally, for
every 10°F cooling, one percent of the cooling water evaporates. Mathematically,

Evaporation Loss (m3/hr) = 0.00153 x Circulation Rate (m3/hr) x (T1-T2)

Evaporation loss (summer) = 0.00153 x 33600 x (49 – 36) = 668 m3 / hr

Evaporation loss (winter) = 0.00153 x 33600 x (41 – 27) = 720 m3 / hr
6. Cycles of concentration (C.O.C) is the ratio of dissolved solids in circulating water to
the dissolved solids in make-up water. Mathematically,

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BOP Area Report

CoC = Cooling water concentration / Makeup water concentration

CoC (canal) = 560 ppm / 80 ppm = 7.00

CoC (well) = 560 ppm / 120 ppm = 4.66

7. Blow down loss is generally defined as the water lost from the system for all the reasons
except evaporation. Mathematically,
Blow down rate = Evaporation Volume ÷ (CoC – 1)
Blow down (canal) = 668 / (7 – 1) = 111 m3 / hr

Blow down (well) = 720 / (5 – 1) = 180 m3 / hr

8. Liquid-to-gas ration (L/G) of a cooling tower is the ratio between the water and the air
mass flow rates. Cooling towers have certain design values, but seasonal variations require
adjustment and tuning of water and air flow rates to get the best cooling tower effectiveness.
Adjustments can be made by water box loading changes or blade angle adjustments.
Thermodynamic rules also dictate that the heat removed from the water must be equal to
the heat absorbed by the surrounding air.

L/G (summer) = 1.33

L/G (winter) = 1.28

Chemical Treatment of Cooling Tower

Chemicals are injected in circulating water system to stop microbiological growth and corrosion
formation. Chemical treatments that are practiced at Lalpir cooling towers are;

Scale Inhibitor
Nalco 23212 is used as a scale inhibitor in the Cooling Tower. It is commonly known as phosphate
treatment. The pH of the circulating water is kept in range (8.5 – 10) so there are less chances of
scale formation in the system. The value of phosphate in circulating water is maintained at 1.5-2.2
ppm.

Acid Dosage
Sulfuric acid is added to reduce the pH of the circulating water & to reduce M-alkalinity. The pH
of the cooling tower is maintained at about 8.2 so as to avoid any scale formation in the system.

Dispersant
The scale formed tends to stay suspended long enough to be removed by either the blow-down or
a filtration system. Dispersant is added to keep microbial scale in system suspended so it can be
treated with biocides and removed from the cooling tower basin.

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BOP Area Report

Two approaches can be taken to ensure adequate control

a. Increase blow-down rate to remove solids and prevent their concentrations from going too
high. Unfortunately this approach also increases the quantities of water and treatment
products used and tends not to be cost effective.
b. Utilize heavy dosage of treatment products to prevent deposition possibly with the
incorporation of an acid-feed system to keep the carbonate equilibrium system in the more
soluble bicarbonate form. This approach can be very costly and is counter to good
environmental practice.

Biocide
The tendency for biological activity and fouling can be effectively controlled by adding biocides.
Chlorine is added as a shock dose, usually at night, to prevent microbial growth. It can be added as
Cl2 or as hypochlorite depending upon the size of the system. The hypochlorite should be sodium
as opposed to calcium (HTH) as the calcium would add to the system's scaling potential. Since
2009, chlorine is replaced by sodium hypo-chloride as a biocide for cooling towers at Lalpir.

Chemical Quantity Remarks

Sodium hypo-chloride 0.3 – 0.5 ppm Periodic dosing
Dispersant 5 ppm Periodic dosing; done 30mins before
sodium hypo-chloride dosage
Scale Inhibitor 35 ppm Batch dosing
Acid 1.5 – 2.5 TPD (well season) Batch dosing
0.6 – 0.9 TPD (canal season)

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BOP Area Report

CHAPTER 4

Hydrogen Generation System

Hydrogen generation system is designed to produce 5 normal cubic meters of hydrogen (when
measured at o degree centigrade and 760 mm of Hg). It can compress and purify 5 normal cubic
meters of hydrogen to a pressure of 175 kg/cm2.

Figure 14 Over-view of Hydrogen Generation system

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BOP Area Report

Hydrogen gas generating system consists of air cooled silicon rectifier, transformer and six Stuart
electrolytic cells connected in series.

Rectifier Specifications
Rated Power 30 KW
Rated AC Voltage 380 +/- 10 Volts
Rated AC Current 58 Amps
Rated Frequency 50 +/- 5% Hz
Number of Phases 3
Rated DC Voltage 15 Volts
Rated DC Current 0 – 2000 A
Percent Ripple 5%
Percent Regulation 1%
Ambient Temperature 50 oC

AC power at 380 volts, 3 phase, and 50 hertz is supplied from the power feeder panel through
circuit breaker to rectifier and transformer. Circuit breaker is provided for short circuit protection.
In rectifier, voltage is reduced by a rectifier transformer and converted to a DC at Voltage up to 14
volts. DC power from rectifier is supplied to electrolytic cells through copper bus bar.

Electrolytic Cell
The Stuart electrolytic cells are of the uni-polar tank type. The cell is known as a 3-plate cell, having
one nickel-plated iron anode plates and two iron cathode plate. The anodes are surrounded by cloth
diaphragms which prevent mixing of the hydrogen and oxygen gases formed in the cell. The
electrolyte is a 25% solution of potassium hydroxide (also referred to as “caustic potash” or KOH
in water)

Cell Temperature
Voltage tends to decrease as cell temperature increases. The recommended cell temperature is
between 65 to 70 °C above which the rate of corrosion of cell component increases significantly.

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BOP Area Report

Figure 15 Electrolytic Cell

Electrolyte
The optimum concentration of KOH is 25% by weight (Specific Gravity of 1.24 measured at
15.5 °C).

DC current from the positive terminal of the rectifier enters the first cell in the bank at the terminals
of the anodes. The current flows down the anodes into the cell, through the electrolyte to the
cathodes, up the cathodes to the cathode terminals (two per cathode), and then on to the anode
terminals of the next cell in the bank. From the last cell in the bank the current flows back to the
negative terminal of the rectifier.

Passage of direct current through the cell causes the water in the cell to be converted into
hydrogen and oxygen gases. Hydrogen forms on the cathode plates while oxygen forms on the
anode plates. This process is known as “electrolysis” and the cell is called an electrolytic cell. The
diaphragms surrounding the anodes are very effective at keeping bubbles of oxygen separated
from bubbles of hydrogen. However, they are less efficient at keeping the actual gases separated.
For this reason the cell is normally operated so that the diaphragms are submerged in the
electrolyte.
If for some reason the electrolyte level should drop to the point where the diaphragms were no
longer submerged, hydrogen could pass through the diaphragms into the oxygen, and vice-versa.
Before this could happen however, the end of the vent pipe would be exposed, allowing the gases
to escape into the cell room.

This reduces the risk of compressing impure gases. The amount of hydrogen vented into the room
is not a hazard provided the room is adequately ventilated.

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BOP Area Report

The amounts of hydrogen and oxygen formed are directly proportional to the amount of DC current
flow through the cell. At 2000 amperes (maximum cell current each cell will produce 0.7 cubic
meters of hydrogen and 0.35 cubic meters of oxygen per hour. (When measured dry at 0 °C, 760
mm of mercury).

The oxygen gas formed on the anodes bubbles up through the electrolyte, inside the diaphragms
which surrounds the anodes, and flows into the oxygen compartment above the electrolyte level.
Similarly, the hydrogen formed on the cathodes bubbles up through the electrolyte, outside the
diaphragms, and flows into the hydrogen compartment above the electrolyte level.

Electrolyte Strength
The recommended electrolyte concentration is 25% by weight, concentrations above or below this
tend to increase cell voltage.

Concentration above 25% also tends to increase the rate of corrosion of cell components. As current
flow through electrolyte to produce hydrogen and oxygen some heat is also evolved.

The gases leaving the cell are cooled in water-cooled gas coolers. Cooling water enters from the
water header flows through the hydrogen and oxygen gas coolers for each cell in series and then
flows to waste.

Hydrogen Mist Eliminator

The hydrogen gas leaving the cells carries off some of the Potassium Hydroxide electrolyte in the
form of an entrained mist. Most of this entrainment is removed in the cell gas cooler and is returned
to the cells. Some is removed at water seal. The remainder is removed in the mist eliminator.

The mist eliminator element consists of a hollow cylindrical fiber packed unit with a mounting
flange at the top end. Mist laden gas flows through the walls of the hollow cylinder. Clean gas
leaves at the center at the top. The entrained mist collects in the fibers of the element and flows
downward to the closed bottom end of the element and rains throughput the dip pipe to the bottom
of the tank. Entrained mist then flows out through the overflow pipe to waste.

Hydrogen Gas Holder

The hydrogen gasholder is a wet-seal type gasholder with a nominal volume of 30 m3. The
operating pressure is approximately 125mm water column.

Gasholder is fitted with four level switches for control of the hydrogen compressors.

Hydrogen Purification System

The hydrogen at the discharge of the oil lubricated compressors contain the following impurities

 Oxygen gas, approximately 0.2% by volume

 Water vapor, 100 percent relative humidity at operating conditions
 Oil Vapor and oil droplets picked up in the oil lubricated compressors
 Moisture condensed out of the hydrogen gas as a result of the increase in pressure

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BOP Area Report

The moisture, oil droplets and oil vapor are removed in a series of filter. Two banks of these filters
are supplied so that one bank can be in service while the other bank is being standby

Catalytic purifier for removal of oxygen impurity in the hydrogen gas. The purifier is fitted with
inlet and outlet temperature gauges, as well as coalescing filter and high temperature switches.
Water cooled heat exchanger for cooling the hot hydrogen leaving the catalytic purifier. The heat
exchanger is fitted with outlet temperature gauge. Condensed water is collected in filter.

The hydrogen then flows to the hydrogen dryer, where it is dried to a dew point of -50 °C. The
hydrogen dryer is a molecular sieve – dual column – heatless – pressure swing type.

The hydrogen then flows through the dust filter where any dirt particles carried over from the dryer
are filtered out. From the dust filter the hydrogen flows through back pressure maintaining valve,
this valve serves to impose a minimum back pressure on the hydrogen dryer of approximately
175kg/cm2 regardless of the pressure in the downstream cylinder storage, thereby ensuring that the
dryer operates at its maximum efficiency.

Catalytic Purifier
The catalytic purifier is used to remove oxygen impurity from the hydrogen gas by causing the
oxygen to catalytically combine with hydrogen to form water vapor. When operating properly the
purifier should remove oxygen to a residual impurity of less than ten parts per million.

A special “wettable” type catalyst is used, which does not require the use of preheaters, temperature
controllers, etc.

When oxygen is catalytically combined with hydrogen, heat is given off and the temperature of the
gas increases. A temperature rise of 16 °C can be expected for each tenth of one percent oxygen
reacted. If too much oxygen is present (more than 4 %) the gas mixture could explode. For this
reason extreme caution must be taken to exclude excessive oxygen from hydrogen in the catalytic
purifier.

After Cooler
The after cooler is supplied to cool the hot hydrogen leaving catalytic purifier, before it enters the
desiccant dryer. If the hydrogen is not sufficiently cooled the desiccant dryer could be overloaded
with harmful effects on the exit dew point.

The After cooler is a shell and tube type heat exchanger, with hydrogen flowing on the tube side
and cooling water flowing on the shell side. Temperature gauge at the after cooler outlet indicates
hydrogen temperature.

From after cooler the hydrogen gas goes to hydrogen storage bottles through coalescing filters.
There are 6 horizontally placed storage bottles with the storage capacity of 1200 m3 of hydrogen
gas at 175 kg/cm2.

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Table of Figures
Figure 1 Over-view of BOP Area.................................................................................................... 1
Figure 2 Raw Water Intake system ................................................................................................. 2
Figure 3 Settling Basin .................................................................................................................... 3
Figure 4 Over-view of a typical Clarifier ........................................................................................ 4
Figure 5 Illustration of Coagulation Process ................................................................................... 5
Figure 6 Water Quality at different turbidities ................................................................................ 5
Figure 7 Media Layers in DMF ....................................................................................................... 8
Figure 8 Media Layers in MMF .................................................................................................... 10
Figure 9 Multi Media Filter ........................................................................................................... 11
Figure 10 Osmosis vs. Reverse Osmosis ....................................................................................... 12
Figure 11 Reverse Osmosis (R.O.) banks ..................................................................................... 15
Figure 12 Typical Induced Draft Counter flow Cooling Tower .................................................... 19
Figure 13 Temperature profiles ..................................................................................................... 22
Figure 14 Over-view of Hydrogen Generation system ................................................................. 25
Figure 15 Electrolytic Cell ............................................................................................................ 27

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