Gop-Uty-08 (DMW 1)

Job Qualification Program
GOP-UTY-08
DEMIN WATER 1
DOCUMENT : GOP-UTY-08
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DEMIN WATER 1 EFFECTIVE DATE
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ORIG. PREPARED BY : MT /Oct 2014
Prepared By: ____________________________________________

Mohammad Touseef (UTY Engineer)
Reviewed By: ____________________________________________

Unit Manager, Operations/Unit Manager, Training
Approved By: _____________________________________________

Department Manager (Training & Technology)
Change Record
S No. Rev. No. Date Page No. Section Description of Change
Distribution List
1 LAN
2 Training Manager (Original Copy)
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Content
1. Purpose ................................................................................................................................ 4
2. Abbreviation......................................................................................................................... 4
3. Technical Terms ................................................................................................................... 4
4. Basic Terminologies ............................................................................................................. 5
5. Water Quality Parameters ................................................................................................... 8
6. Ion Exchange ...................................................................................................................... 16
7. Resins ................................................................................................................................. 24
8. Demineralization at EPCL ................................................................................................... 29
9. Process Description ............................................................................................................ 34
10. Regeneration System ......................................................................................................... 36
11. Polisher Regeneration ........................................................................................................ 45
12. Neutralization .................................................................................................................... 48
13. Major Equipment’s Detail .................................................................................................. 51
14. Over View of PLC of Water Treatment .............................................................................. 63
15. Safety Interlocks................................................................................................................. 66
16. Safety Equipment’s ............................................................................................................ 67
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1. Purpose
The purpose of this document is to give detail introduction on the DW-I Process, purpose,
operation, maintenance, taking in service during startup, shut down and emergency handling
troubleshooting.
2. Abbreviation
JQP Job Qualification Program
SOP Standard Operating Procedure
T/A Trade Apprentice
TAE Trainee Assistant Engineer
UMO Unit Manager Operations
VP Manuf. Vice President Manufacturing
3. Technical Terms
IW Industrial water
DW Demineralized water
PW Polished water
TDS Total dissolved solids
KW Kilo Watt
I.A Instrument Air
P.A Plant Air
P & ID Piping and Instrumentation Diagram
CCPP Combined cycle power plant
MCC Motor control center

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4. Basic Terminologies
Total Hardness (TH)

Total quantity of salts of Ca, Mg, and Na are present in water is known as TH of water.
Hardness is of two types.
1- Temporary Hardness
2- Permanent Hardness
Temporary Hardness
Temporary hardness is due to carbonates, Bicarbonates of Ca++, Mg++ and Na+.
Temporary hardness can be reduced only by filtration. Carbonates are insoluble in water, so can
be easily removed by boiling, filtration. Bicarbonates are soluble in water. So 1st we change
bicarbonates in to carbonate then remove them by filtration.
The most common method for changing bicarbonates into carbonate is Clark’s method. This
method is also called lime softening method. In this method Ca (OH)2 is mixed in water as
shown in chemical equation.
Ca (HCO3)2 + Ca (OH)2 2CaCO3 + H2O
Permanent Hardness
Permanent hardness in water is due to sulfates, Chlorides, Nitrates and silicates of Ca++, Mg++
and sodium. This permanent hardness is removed at demineralization plant and/or reverse
osmosis.
P-VALUE
Measurement of carbonates and Hydroxyl ion is called P-value.
M-VALUE
Measurement of total Alkalinity such as carbonates, Bicarbonates and Hydroxyl ion is called M-
value of water.
Cations
+ Ve charged ions in ionic bonds such as Ca++, Mg++, Na+ are present in water is called cations
of water.
Anions
-Ve charged ions in ionic bonds such as sulfates, chlorides Nitrate are present in water are
called as ions.
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Ion
A charged particle either - ve or + ve is called an ion.
Ion Exchange Resin

An ion Exchange resin is an insoluble material containing fixed active group and mobile
exchangeable ions. This insoluble material is called resin. Resin are classified according to
attached active groups. There are two main classes.
1- Cationic Resin: For separating cations.

2- Anionic Resin: For separating anions.
Fouling
De-activation of ion exchange material due to precipitation from the part of insoluble matter
such as Iron, Aluminum oxide, magnesium oxide, colloidal silica, calcium sulfate or algae.
FMA
Free mineral acidity in water is defined as total uncombined mineral acids formed at cation
outlet are called FMA.
Conductivity
The ability of current to pass is called conductivity. The electrical conductance of water is
measured in Micro Simons / cm. It is also assumed as an indirect way to measure salinity in
water.
Demineralization
The removal of all electrically charged particles or ions dissolved in water.
Ionization
The dissociation of dissolved molecules into equal amount of opposite charged particles or ions
Leakage
The phenomenon’s in which some of the influent ions are not absorb and appear at the effluent
when water is passed through the regenerated bed.
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Swelling
Increase in volume of an ion exchange material.
Shrinking
Decrease in volume of an ion exchange material.
Coagulation
The process to neutralize the charged particles by adding some agent. The agents are called
coagulants. The most common coagulants are Alum sulfate and Ferrous sulfate. These particles
are normally -vely charged. The +ve charge from the agents combine with these to form large
size flocks, which easily settle down easily
Flocculation
The process in which we increase the size of a neutral particle by adding some agent. The
agents are called flocculants. The most common flocculent is polyelectrolyte.
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5. Water Quality Parameters
Physical Quality Parameters

Physical parameters define those characteristics of water, which respond to the senses of sight,
touch, taste, or smell. Suspended solids, turbidity, color, taste and odor, and temperature fall
into this category.
Suspended Solids & Turbidity

As noted earlier, solids can be dispersed in water in both suspended and dissolved forms.
Although some dissolved solids may be perceived by the physical senses, they fall more
appropriately under the category of chemical parameters and will be discussed in detail in a
later section.
Solids suspended in water may consist of inorganic or organic particles or of immiscible liquids.
Inorganic solids such as clay, silt, and other soil constituents are common in surface water.
Organic material such as plant fibers and biological solids (algae cells, bacteria, etc.) are also
common constituents of surface waters. These materials are often natural contaminants
resulting from the erosive action of water flowing over surfaces. Because of the filtering
capacity of the soil, suspended material is seldom a constituent of groundwater.
Most turbidity in surface waters results from the erosion of colloidal material such as clay, silt,
rock fragments, and metal oxides from the soil. Vegetable fibers and microorganisms may also
contribute to turbidity. Household and industrial wastewater may contain a wide variety of
turbidity-producing material. Soaps, detergents, and emulsifying agents produce stable colloids
that result in turbidity. Although turbidity measurements are not commonly run on
wastewater, discharges of wastewater may increase the turbidity of natural bodies of water.
Impact
Suspended material may be objectionable in water for several reasons. It is aesthetically
displeasing and provides adsorption sites for chemical and biological agents. Suspended organic
solids may be degraded biologically, resulting in objectionable by-product. Biologically active
(live) suspended solids may include diseases-causing organisms as well as organisms such as
toxin-producing strains of algae. Moreover, it cannot be drink.
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When turbid water in a small, transparent container, such as a drinking glass, is held up to the
light, an aesthetically displeasing opaqueness or “milky” coloration is apparent. The colloidal
material associated with turbidity provides absorption sites for chemicals that may be harmful
or cause undesirable tastes and odors and for biological organisms that may be harmful.
Disinfections of turbid waters is difficult because of the adsorptive characteristics of some
colloids and because the solids may partially shield organisms from the disinfectant.
In natural water bodies, turbidity may impart a brown or other color to water, depending on
the light-absorbing properties of the solids, and may interface with light penetration and
photosynthetic reactions in streams and lakes. Accumulation of turbidity-causing particles in
porous streambeds results in a sediment deposits that can adversely affect the flora and fauna
of the stream.
Measurement
A direct measurement of suspended solids is not usually performed on samples from natural
bodies of water or on portable (drinkable) water supplies. The nature of the solids in these
waters and the secondary effects they produce are more important than the actual quantity.
For such waters a test for turbidity is commonly used.
Turbidity is a measure of the extent to which light is either absorbed or scattered by suspended
material in water. Because absorption and scattering are influenced by both size and surface
characteristics of the suspended material, turbidity is not a direct quantitative measurement of
suspended solids. For example, one small pebble in a glass of water would produce virtually no
turbidity. If this pebble were crushed into thousands of particles of colloidal size, a measurable
turbidity would result, even though the mass of solids had not changed.
Color
Pure water is colorless, but foreign substances often color water in nature. Water whose color
is partly due to suspended matter is said to have apparent color. Color contributed by dissolved
solids that remain after removal of suspended matter is known as true color.
After contact with organic debris such as leaves, conifer needles, weeds, or wood, water picks
up tannins, humic acid, and hamates and takes on yellowish-brown hues. Iron oxides cause
reddish water, and manganese oxides cause brown or blackish water. Industrial wastes from
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textile and dyeing operations, pulp and paper production, food processing, chemical
production, and mining, refining, and slaughterhouse operations may add substantial coloration
to water in receiving streams.
Impact
Colored water is not aesthetically pleasant to the general public. In fact, given a choice,
consumers tend to choose clear, no colored water of otherwise poorer quality over treated
potable water supplies with an objectionable color. Highly colored water is unsuitable for
laundering, dyeing, papermaking, beverage manufacturing, dairy production and other food
processing, and textile and plastic production. Thus, the color of water affects its marketability
for both domestic and industrial use.
While true color is not usually considered unsanitary or unsafe, the organic compounds causing
true color may exert a chlorine demand and thereby seriously reduce the effectiveness of
chlorine as a disinfectant. Perhaps more important are the products formed by the combination
of chlorine with some color-producing organics. Phenolic compounds, common constituents of
vegetative decay products, produce very objectionable taste and odor compounds with
chlorine. Additionally, some compounds of naturally occurring organic acids and chlorine are
neither known to be, or are suspected of being, carcinogens (cancer-causing agents).
Apparently, a glass full of water may look sparklingly transparent, yet for some Pharmaceuticals
and other color sensitive applications, it may still not be very good.
Different means of measuring colors are available that includes:
Filtration @ 0.2M filters & color test.

Comparator test
Taste and Odor

The terms taste and odor are themselves definitive of this parameter. Because the sensation of
taste and smell are closely related and often confused, a wide variety of tastes and odors may
be attributed to water by consumers. Substances that produce an odor in water will almost
invariably a taste as well. The converse is not true, as there are many mineral substances that
produce taste but no odor.
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Many substances with which water comes into contact in nature or during human use may
impart perceptible taste and odor. These include minerals, metals, and salts from the soil, end
products from biological reactions, and constituents of wastewater. Inorganic substances are
more likely to produce tastes unaccompanied by odor. Alkaline material imparts a bitter taste
to water, while metallic salts may give a salty or bitter taste.
Organic material, on the other hand, is likely to produce both taste and odor. A multitude of
organic chemicals may cause taste and odor problems in water, with petroleum-based products
being prime offenders. Biological decomposition of organics may also result in taste and odor
producing liquids and gases in water.
Principal among these are the reduced products of sulfur that impart a “rotten egg” taste and
odor. Also, certain species of algae secrete an oily substance that may result in both taste and
odor. The combination of two or more substances, neither of which would produce taste or
odor by itself, may sometimes result in taste and odor problems. This synergistic effect was
noted earlier in the case of organics and chlorine.
Impact
Consumers find taste and odor aesthetically displeasing for obvious reasons. Because water is
thought of as tasteless and odorless, the consumer associates taste and odor with
contamination and may prefer to use a tasteless, odorless water that might actually pose more
of a health threat. And odors produced by organic substances may pose more than a problem
of simple aesthetic, since some of those substances may be carcinogenic.
Temperature
Temperature is not used to evaluate directly either potable water or wastewater. It is, however,
one of the most important parameters in natural surface-water systems. The temperature of
surface waters governs to a large extent the biological species present and their rates of
activity. Temperature has an effect on most chemical reactions that occur in natural water
systems. Temperature also has a pronounced effect on the solubility of gases in water.
The temperature of natural water systems responds to many factors, the ambient temperature
(temperature of the surrounding atmosphere) being the most universal. Generally, shallow
bodies of water are more affected by ambient temperatures than are deeper bodies. The use of
water for dissipation of waste heat in industry and the subsequent discharge of the heated
water may result in dramatic though perhaps localized, temperature changes in receiving
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streams. Removal of forest canopies and irrigation return flows can also result in increased
stream temperature.
Impact
Cooler waters usually have a wider diversity of biological species. At lower temperature, the
rate of biological activity, I.e. Utilization of food supplies, growth, reproduction, etc., is slower.
If the temperature is increased, biological activity increases. An increase of 10 °C is usually
sufficient to double the biological activity, if essential nutrients are present. At elevated
temperatures and increased metabolic rates, organism that are more efficient at food
utilization and reproduction flourish, while other species decline and are perhaps eliminated
altogether. Accelerated growth of algae often occurs in warm water and can become a problem
when cells cluster into algae mats. Natural secretion of oils by algae in the mats and the decay
products of dead algae cells can result in taste and odor problems.
Higher-order species, such as fish, are affected dramatically by temperatures and by dissolved
oxygen levels, which are a function of temperature. Game fish generally require cooler
temperatures and high dissolved-oxygen levels.
Temperature changes affect the reaction rates and solubility levels of chemicals, Increased
temperatures accelerate most chemical reactions involving dissolution of solids. The solubility
of gases, on the other hand, decreases at elevated temperatures. Because biological oxidation
of organics in streams and impoundment is dependent on an adequate supply of dissolved
oxygen, decrease in oxygen solubility is undesirable.
Temperature also affects other physical properties of water. The viscosity of water increases
with decreasing temperature. The maximum density of water occurs at 4 °C, and density
decreases on either side of that temperature, a unique phenomenon among liquids. Both
temperature and density have a subtle effect of plank tonic microorganisms in natural water
systems.
Chemical Quality Parameters
Water has been called the universal solvent, and chemical parameters are related to the
solvent capabilities of water. Total dissolved solids, alkalinity, hardness, fluorides, metals,
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organics, and nutrients are chemical parameters of concern in water-quality management. The
following review of some basic chemistry related to solutions should be helpful in
understanding subsequent discussions of chemical parameters.
Total Dissolved Solids (TDS)

The material remaining in the water after filtration for the suspended-solids analysis is
considered to be dissolved. This material is left as a solid residue upon evaporation of the water
and constitutes a part of total solids.
Dissolved material results from the solvent action of waste on solids, liquids, and gases. Like
suspended material, dissolved substances may be organic or inorganic in nature. Inorganic
substances, which may be dissolved in water, include minerals, metals, and gases. Water may
come in contact with these substances in the atmosphere, on surfaces, and within the soil.
Material from the decay products of vegetation, from organic chemicals, and from the organic
gases is a common organic dissolved constituent of water. The solvent capability of water
makes it an ideal means by which waste products can be carried away from industrial sites and
homes.
Impact
Many dissolved substances are undesirable in water. Dissolved minerals, gases, and organic
constituents may produce aesthetically displeasing color, tastes, and odors. Some chemicals
may be toxic, and some of the dissolved organic constituents have been shown to be
carcinogenic. Quite often, two or more dissolved substances - especially organic substances and
member of the halogen group will combine to form a compound whose characteristics are
more objectionable than those of either of the original materials.
Alkalinity
Alkalinity is defined as the quantity of ions in water, which will react to neutralize hydrogen
ions. Alkalinity is thus a measure of the ability of water to neutralize acids.
Impact
In large quantities, alkalinity imparts a bitter taste to water. The principal objection to alkaline
water, however, is the reaction that can occur between alkalinity and certain cations in the
water. The resultant precipitate can foul pipes and other water-systems appurtenances.
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Hardness (TH)
Hardness is defined as the concentration of multivalent metallic cations in solution. At
supersaturated conditions, the hardness cations will react with anions in the water to form a
solid precipitate. Hardness is classified as carbonate hardness and non-carbonate hardness,
depending upon the anion with which it associates.
Carbonate hardness is sensitive to heat and precipitates readily at high temperature. Also
termed as temporary hardness
Heat
Ca (HCO3)2 CaCO3 + CO2 + H2O
Heat
Mg (HCO3)2 Mg (OH) 2 + 2CO2
The multivalent metallic ions most abundant in natural waters are calcium and magnesium.
Others may include iron and manganese in their reduced states (Fe2+, Mn2+), strontium (Sr2+),
and aluminum (Al3+). The latter are usually found in much smaller quantities than calcium and
magnesium, and for all practical purposes, hardness may be represented by the sum of the
calcium and magnesium ions.
Impact
Soap consumption by hard waters represents an economic loss to the water user. Sodium soaps
react with multivalent metallic cations to form a precipitate, thereby losing their surfactant
properties. A typical divalent cation reaction is:
2NaCO2C17H35 + cation 2+ cation2+ (CO2C17H35)2 + 2Na+

Soap Precipitate
Lathering does not occur until all of the hardness ions are precipitated, at which point the water
has been “softened” by the soap. The precipitate formed by hardness and soap adheres to
surfaces of tubs, sinks, and dishwashers and may stain clothing, dishes, and other items.
Residues of the hardness-soap precipitate may remain in the pores, so that skin may feel rough
and uncomfortable. In recent years these problems have been largely alleviated by the
development of soaps and detergents that do not react with hardness.
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Boiler scale, the result of the carbonate hardness precipitate may cause considerable economic
loss through fooling of water heaters and hot-water pipes. Change in pH in the water
distribution systems may also result in deposits of precipitates. Bicarbonate begin to convert to
the less soluble carbonates at pH values above 9.0.
Magnesium hardness, particularly associated with the sulfate ion, has a laxative effect on
persons unaccustomed to it. Magnesium concentration of less than 50 mg/L is desirable in
potable waters, although many public water supplies exceed this amount. Calcium hardness
presents no public health problem. In fact, hard water is apparently beneficial to the human
cardiovascular system.
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6. Ion Exchange
Ion exchange is one of the most widely used processes to remove permanent hardness. Water
treatment, generally is a combination of several processes like:
 Softening
 Ion exchange
 Polishing
 Dealkalization, etc.
Softening is primarily concerned with calcium and magnesium removal. The Ca and Mg ions are
replaced by sodium (Na). Softening is used primarily for boiler feed water makeup; other uses
include cooling tower makeup and home water softening.
Ion exchange uses combinations of anion and cation exchangers. Several types of systems are
possible based on the type of resin used in the exchangers. In one of these general types
(strong acid, strong base), all of the cations are removed and replaced by hydrogen ion (H +),
and all of the anions are removed and replaced by hydroxyl (OH-). The net result is the
replacement of an ionic salt with a water molecule. A common use of demineralizers is high-
pressure boiler feed water makeup; another use is wash water preparation for computer chip
manufacturing.
Ion exchange processes do not remove ions from water - they simply exchange unwanted ions
in the process water for more desirable ions. The exchange medium is a synthetic resin, and the
exchange process is reversible. After the ions exchange resin becomes saturated with the
unwanted ions, it is regenerated by washing the resin with a concentrated solution of the
desired ions. The concentrated regenerant forces the undesired ions from the exchange site
and replace them with the desirable ions. The unwanted ions are then washed to sewer.
Ion exchange resins are designed for reaction either with cations (cation exchangers) or anions
(anion exchangers). A single ion exchange resin cannot react with both.
Polishing is used to further treat the water for better quality. In this process mixed bed of
cation and anion resin is used.
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Dealkalization is used to lower alkalinity (carbonate and bicarbonate) in a water stream. In an

acid regenerated dealkalizer, all cations are replaced by hydrogen (H+). The resulting strong
acidic solution converts bicarbonate ion (HCO3-) to water and carbon dioxide. A degasifier
typically removes the CO2. A dealkalizer is typically used to lower the alkalinity of boiler feed
water makeup. A dealkalizer could also be regenerated by salt, depending on the type of resin
used.
Demineralization by Ion Exchange

Clear raw water contains many dissolved impurities which can cause serious corrosion and
scaling problems in steam generators (boilers). Impurities in a water supply fall into three
general categories i.e. suspended solids, colloidal solids and dissolved solids. These impurities
are therefore removed from raw water by the DEMINERALIZATION PROCESS in order to make it
suitable for use in boilers.
Dissolved solids are present in water as positively charged cations and negatively charged
anions. The following ions are present in natural water in significant concentration:
CATION ANIONS
Calcium Ca Bicarbonate HCO3
Magnesium Mg Carbonate CO3
Sodium Na Chloride Cl
Potassium K Sulphate SO4
Nitrates (Present in a NO3 few supplies)
Maganese Mn Dissolved gas CO2
Demineralization systems are very widely employed, not only for conditioning water for high -
pressure boilers, but also for conditioning various process and rinse waters. The ion-exchange
systems chosen vary according to
 The volumes and composition of the raw waters,

 The effluent quality requirements for different uses,
 The comparative capital and operating costs
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Silica is not removed by hydrogen-cation exchange or sodium zeolite exchange and usually is
only partially removed in cold or hot lime soda processes. It may be a very objectionable
impurity, since it can form a tenacious scale. Silica may be removed from feed water by the use
of dolomitic lime or activated magnesia in the softener. If preliminary coagulation and settling
are carried out, the use of a ferric coagulate will remove some silica. These are especially,
suitable when the silica concentration of makeup water is high.
Briefly, if silica removal is not required, the system may consist of hydrogen-cation-exchangers
until and a weekly basic anion exchanger unit, usually followed by a degasifier to remove, by
aeration, most of the carbon dioxide formed from the bicarbonates in the first step.
When silica removal is required, the system may consist of a hydrogen-cation-exchanger unit
and a strongly basic anion-exchanger unit, usually with a degasifier between the units, to
remove carbon dioxide ahead of the strongly basic anion-exchanger unit. For uses where the
very highest quality of effluent is required, this may be followed by secondary “polishing”
unit(s) consisting of either (1) a hydrogen-cation-exchanger unit and a strongly basic anion-
exchanger unit or (2) a single unit containing an intimately mixed bed of a hydrogen-cation
exchanger and a strongly basic anion exchanger.
The only other process for removing all the ions in water is distillation. Both distilled water and
deionized water should be transported through stainless steel or glass to keep the pure water
from corroding the transport lines. Block tin has been employed for this purpose for many years
but has the disadvantages of extreme softness. Aluminum and molded polyvinyl chloride pipes
are now reasonably satisfactory substitutes for conducting “pure” water. Polyethylene,
polypropylene, and polycarbonates are also sometimes used.
Ion Exchange Chemistry

Resin exchange sites attract and hold charged ions. The exchange site’s holding force is not
equal for all ions. There is a distinct order of preference, which varies based on conditions and
resin type and is related to the charge density of the ion. Table 1 lists ion affinity for standard
strong acid and base resins commonly used in demineralization processes.
Strong Acid Cation Resins

Strong acid cation resins are normally operated in either the sodium form or the hydrogen
form.
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Sodium Exchange
This is the simplest ion exchange process. A strong acid cation resin in sodium form (NaX)
removes Ca+2 and Mg+2 (as well as any other cation held by the resin stronger than sodium)
from water flowing through the exchanger bed, producing soft water.
Ca (HCO3)2 + 2NaX CaX2 + 2NaHCO3
During this process, calcium and magnesium ions are removed from hard water by cation
exchange for sodium ions. When the exchange resin has essentially removed the calcium and
magnesium ions to the limit of its capacity, the resin is regenerated to the sodium form with a
salt solution. The exchange capacity of polystyrene resins is 650 kg /m3, when regenerated with
250 g of salt per kilogram of hardness removed. The sodium or hydrogen-cycle cation
exchangers for water treatment are usually of the styrene-divinylbenzene sulfonated synthetic
resin type. This type is exceptionally stable at high temperatures (up to 150 °C) and over the
wide pH range of 0 to 14. In addition, it is very resistant to oxidizing conditions. The total
exchange capacity is up to 925 kg of CaCO3 per cubic meter of ion exchanger with a hydrogen
cycle and up to 810kg of CaCO3 per cubic meter with a sodium cycle. The usual practical
operating capacities are not so high.
An ion exchange resin is like a storage battery a sodium exchanger continues to release Na+ in
exchange for Ca+2 and Mg+2 until its sodium capacity is exhausted; then a reversal of flow of
these ions, caused by the high Na+ concentration in the salt brine, regenerates it. Ordinary salt
is the source of Na+ for regeneration, the resin being washed with brine.
2NaCl + CaX2 2NaX + CaCl2
A sodium exchanger doesn’t always remove hardness completely at an economical salt dosage.
Hardness in the treated water is referred to as leakage. The amount of leakage in an effluent
water is directly affected by the salt dosage. For economic operation, resin curves should be
used to determine the salt dosage required to achieve a desired leakage rate. Salt dosage also
affects the resin’s operating capacity. Therefore, dosage can be varied to achieve a given
volume of throughput. When working with systems that are already installed, the vessels are
designed for a fixed volume of resin. In such cases, a plant may have to sacrifice a more
economical regenerant dosage (based on allowable water quality) to achieve a desired
throughput capacity.
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Strong acid cation resins used in the sodium form are applied in basic water softening, in
polishers following lime softening processes, and in condensate polishing applications.
Hydrogen Exchange
A strong acid cation resin regenerated with acid (HX) replaces all cations of the raw water with
H+ ions, converting all salts to the corresponding acids. Because carbonic acid (Equation 1) is
simply dissolved CO2, it can be removed by degasification, thereby reducing total solids.
Degasification after cation exchange can therefore be used to reduce the loading on a following
anion unit or used in dealkalization processes. The SO4-2 , Cl-, and NO3- ions form mineral
acids, as shown in Equation 2.
Ca (HCO3)2 + 2HX CaX2 + 2H2CO3 (1)

NaCl + HX NaX + HCl (2)
When the hydrogen exchanger has exhausted its store of H+ ions, it is returned to the hydrogen
form by an acid wash, usually with sulfuric acid:
H2SO4 + CaX2 CaSO4 + 2HX (3)
Hydrochloric acid can also be used. HCl will eliminate some types of precipitation fouling (e.g.,
CaSO4); however, it is more expensive.
Nitric acid is never used under normal circumstances because its oxidizing properties can
present a serious explosion hazard.
Treated effluent contains free mineral acid (FMA), which may now serve as a direct measure of
the concentration of cations (principally sodium) remaining in the cation effluent. The hydrogen
exchanger is never used alone. In dealkalizing water by hydrogen exchange, the hydrogen
exchanger effluent acidity is neutralized, either by blending with sodium exchanger effluent, or
by direct addition of caustic. When demineralizing water by hydrogen exchange, the hydrogen
exchanger effluent is followed by an anion exchanger, the effluent of which is pure water with
only minute traces of soluble impurities.
Weak Acid Resins

Weak acid resins differ from strong acid resins in that the hydrogen ion is held strongly by weak
acid resin and therefore does not exchange readily. Weak acid cation resins have a higher
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preference for hydrogen ions than for any of the cation in the water to be treated. These resins
require the presence alkaline species to react with the tightly held hydrogen ions of the resin.
This then allows other cations to exchange onto the active site and be removed from solution.
In, affect this is a neutralization-dependent exchange, with alkalinity (HCO3-) neutralizing the
hydrogen (H+) from the resin. The reaction is illustrated in Equation 4:
2XCOOH + Ca(HCO3)2 Ca(XCOO)2 + 2H2CO3 (4)
The H2CO3 produced can now be removed by degasification to reduce total solids.
Weak acid resins exhibit a much greater selectivity (preference) for divalent catios than for
monovalent cations. Thus, this type of resin is best for those waters having considerable
hardness (Ca, Mg) associated with bicarbonate alkalinity. Depending upon the water
composition, capacities of 50-60 kilograms /ft3 (6.5-8.0 mg/1) can be achieved vs. 20-30 kg/ft3
(2.5-4.0 mg/1) for strong acid resins.
Weak acid resins exhibit much higher affinity for hydrogen ions than do strong acid resins.
Subsequently, they have much higher regeneration efficiencies and do not depend upon a
concentration driving force. With the strong acid cations, a significant portion of non-utilized
acid remains with the spent regenerant. With the weak acid cations, about 90% of the acid
regenerant is utilized. In addition, acid strength of less than 1.0% can be used.
Because the weak acid resins exhibit very low preference for nonalkaline salts, a strong acid
cation resin usually follows them in a demineralization system. This combination gives excellent
regenerant economy, because the spent regenerant from the strong acid resin can be used to
regenerate the weak acid resin.
Weak acid cation resins have two unique physical properties that must be taken into account
during operation. First, the resin can expand by 50% or more between their regenerated and
exhausted forms, so all vessels must be specifically designed for the weak acid resins. Second,
capacity of the resin is very dependent on the service water flow rate. As the flow rate
increases, the operating capacity drops off substantially.
Strong Base Anion Resins
Strong base anion resins are normally operated in either the hydroxide form or the chloride
form. The hydroxide form is used in demineralization processes; the chloride form is normally
used for dealkalization processes.
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There are two types of strong base anion resins. Type 1 resin is chemically more stable then
Type II resin and has a higher affinity for the ions. However, Type 1 resin has a lower operating
capacity, which makes it less efficient to operate. It is normally used where silica levels in the
raw water are above 25% of the total anions. Type II resin is normally used in dealkalization
applications and in demineralization applications where silica levels in the influent water below
25% of the total anions.
Hydroxide Exchange
A strong base anion can remove all acids (both strong and weak) produced by the hydrogen
exchanger. Therefore, using a strong base anion exchanger regenerated with caustic to treat
the hydrogen exchanger effluent provides a process that completely demineralizes water. The
removal of acid from the hydrogen exchanger effluent is shown by Equation 5:
HCI + XOH XCI + H2O (5)
Regeneration of the strong base resin requires the use of a strong alkali, caustic soda. (See
Figure 4. Because the strong base resin is highly ionized, caustic regenerant utilization is
incomplete, and 200-300% of the stoiciometric amount must be used for regeneration.
To improve the efficiency of the demineralizing process, the CO2 formed by the hydrogen
exchanger units is often removed by degasification (removal of a free gas from water via partial
pressure difference or application of vacuum). Although a strong base exchanger can remove
CO2, it does so at the expense of chemical consumed regenerating the resin. Degasification,
then, reduces chemical operating cost by reducing the load on the anion exchanger and
allowing for smaller sizing of the vessel.
Because the anion resin does not exchange cations, any cations leaking through the hydrogen
exchanger unit will be present in the anion effluent as alkalinity. The leakage through the
hydrogen exchanger unit is usually sodium; a trace of leakage is sometimes desirable because it
provides a satisfactory pH in the finished water, as the anion exchanger converts Na salts to
NaOH.
Chloride Exchange
Salt regeneration of a Type II strong base anion exchanger permits reduction of alkalinity in
waters without the use of acid; bicarbonate, carbonate, nitrate, and sulfate are exchanged for
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chloride in the process. For economic reasons, the process is used to treat only low-sulfate
waters.
The alkalinity leakage in the effluent in the effluent is affected primarily by the regenerant
dosage by the regenerant dosage and the regeneration procedure used. Alkalinity leakage is
also affected by the characteristics of the raw water, total dissolved solids, and chloride
concentration. No reduction of dissolved solids occurs during this dealkalization process.
Additionally, the use of a small amount of caustic (one part caustic to 9 parts salt by weight) in
the brine regenerant produces a water of lower alkalinity and free CO2, and a higher pH.
Weak Base Anion Resins

A weak base anion resin can remove the strong mineral acids produced by the hydrogen
exchanger, but not the weak acids such as carbonic and silicic acid. Some industrial operations
do not require complete removal of these weak acids, and the weak base exchanger is used
because it is less costly to operate and more efficient then the strong base. But in producing the
high-quality water needed as makeup for high-pressure boilers, silica and carbon dioxide must
be reduced to very low levels, and a strong base resin is required.
The chemical reactions of weak base and strong resins are slightly different, but the end result
is the same: removal of acid by a weakly basic exchanger is illustrated by Equation 6:
HCI + X XHCl (6)
The whole strong acid molecule is absorbed by the weak base resin in a very efficient process.
Only 110% of the stoichiometric amount of regenerant is required at a 4% concentration. All
that is necessary for regeneration of a weak base resin is any alkali that will neutralize the
mineral acids attached to the exchange sites.
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7. Resins
PUROLITE Ion Exchange Resins
Product Description
PUROLITE C-100 is a high capacity, bead-form, and conventional gel polystyrene sulphonate
cation exchange resin ready for use in household or industrial water-conditioning equipment. It
removes the hardness ions, e.g. calcium and magnesium, replacing them with sodium ions.
When the resin bed is exhausted so that hardness ions begin to break through in the effluent,
capacity is restored by regeneration with common salt. The capacity obtained depends largely
on the amount of salt used in regeneration. Purolite C-100 is also capable of removing in the
same way, dissolved iron, manganese, and also suspended matter by virtue of the filtering
action of the bed. Purolite C-100 is in compliance with the U.S. Food and Drugs code of Federal
Regulations section 21 paragraphs 174.25.
Typical Physical, Chemical, & Operating Characteristics

Polymer Matrix Structure Polystyrene crosslinked with Divinylbenzene
Physical Form and Appearance Clear spherical beads
Whole Bead Count 90 % min
Functional Groups Polystyrene sulphonate
Ionic Form, a shipped Na+
Shipping weight, approx. 850 g /l (53 lb /ft3)
Screen Size Range
British Standard Screen 14-52 mesh, wet
U.S. Standard Screen 16-50 mesh, wet
Particle Size Range +1.2 mm <5%, -0.3 mm <1%
Moisture Retention, Na+ form 44-48%
Specific Gravity, Moist Na+ Form 1.29
Total Exchange Capacity, Na+, 2.0 eq /l min
Dry weight 4.5 eq /kg min
Operating Temperature, Na+ Form 150 °C (300° F) max.
pH Range, Stability 0.14
Operating, Na+ cycle 6.10
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PUROLITE A 400 MB
Purolite A 400 MB is a strong base type 1 anion exchange resin with gel polystyrenic matrix
specially designed for use in mixed bed systems. In fact has a special particle size distribution to
enhance separation from the cation component. The unique structure of Purolite A 400 MB
promotes better kinetics and better diffusion rates into and out of the beads resulting in high
operating capacity. The excellent regeneration efficiency, the good rinse characteristics and the
ability to achieve very low residual silica levels are the peculiarities of this anion exchange resin.
To obtain the best operating performances, it is recommended to use Purolite A 400 MB
together with a mixed bed grade strong acid cation exchanger such as Purolite C 100 MB.
Purolite A 400 MB physical and chemical characteristics are shown in the following table, while
the recommended operating conditions in mixed bed applications are recalled overleaf.
Typical Physical & Chemical Characteristics

Polymer structure Polystyrene crosslinked with DVB
Physical form and appearance Clear spherical beads
Functional groups R - N+ (CH3)3
Ionic form, as shipped Cl
Total capacity, volume, Cl- form 1.3 meq /ml min.
weight, Cl- form 3.7 meq /dry g min.
Moisture retention, Cl form 48-54%
Bead size range 0.3 - 1.2 mm
with 1% max. < 0.3 mm
and 2% max. > 1.2 mm
Specific gravity, moist Cl- form 1.08
Shipping weight 680 - 715 g /l
Max. Operating temperature 60 °C in OH form; 100 °C in Cl- form
pH limits, stability 0 – 14
PUROLITE A 100 DL
Purolite A 100 DL is a weak base, tertiary amine, anion exchange resin with Macroporous
polystyrenic matrix specially designed for use in layered bed anion systems. Thanks to its
Macroporous structure, Purolite A 100 DL has excellent mechanical and osmotic stability, and is
able to remove high molecular weight organics from the influent water, thus protecting the
strong base resin from fouling.
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Purolite A 100 DL is used for the efficient removal of strong acid anions in layered bed
DOUBLITE anion units in conjuction with specially tailored strong base anion exchange resin
such as Purolite A 400 DL or PUROLITE A 200 DL.
Purolite A 100 DL chemical and physical characteristics are recalled herebelow while its
operating performances can be obtained by consulting the Purolite A 100 technical date sheet.
Typical Chemical & Physical Characteristics

Polymer Matrix Structure Macroporous styrene divinylbenzene
Physical form and Appearance Opaque off-while spheres
Functional Groups Tertiary amine
Ionic Form (as shipped) FB form
Shipping weight 645-665 g/l
Particle Size Range 0.3 - 0.6 mm
Moisture Retention, Cl- form 53-60%
-) 20% max.
Specific Gravity, Moist FB Form (Moist Cl- Form) 1.03 (1.05)
Total Exchange Capacity, FB Form (wet, volumetric) 1.3 meq /g min.
(Dry, weight) 3.9meq/g min.
Strong Base Capacity 12-20% of total
Max. Operating Temperature 60 °C in FB form; 100 °C in Cl- form
Chemical Stability Insoluble in all common solvents
PH Range, (stability) 0 – 14
(Operating) 0--9
PUROLITE C 100 MBH

Purolite C 100 MBH is a premium grade strong acid cation exchanger with gel structure and
special particle size distribution to enhance separation from the anion component in mixed bed
systems. The unique structure of Purolite C 100 MBH promotes better kinetics and better
diffusion rates into and out of the beads resulting in high operating exchange capacities. This
resin also possesses high chemical and physical stability.
To obtain the best operating performances, it is recommended to use Purolite C 100 MBH
together with a mixed bed grade strong base anion exchanger such as Purolite A 400 MB.
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PUROLITE C 100 MBH physical and chemical characteristics are shown in the following table,
while the recommended operating conditions in mixed bed applications are recalled over leaf.
Typical Physical and Chemical Characteristics

Polymer structure Polystyrene crosslinked with DVB
Physical form and appearance Dark brown, clear spherical beads
Functional groups R - SO3-
Total capacity, volume, Na+ form 2.0 meq /ml min
weight, Na+ form 4.5 meq /dry g min
Moisture retention, Na+ form 44 - 48%
Bead size range 0.425 - 1.200 mm
with 2% max. < 0.425 mm
with 2% max. > 1.200 mm
Reversible swelling, Na+ + 5% max.
Specific gravity, Na+ form 1.29
Maximum operating temperature 120 °C
PH limits, stability 0 – 14
PUROLITE A 200 DL
Purolite A 200 DL is a strong base type 2 anion exchange resin with gel polystyrenic matrix
specially designed for use in layered bed anion systems. Purolite A 200 DL has high operating
capacity, excellent regeneration efficiency and good rinse characteristics. Purolite A 200 DL also
has an excellent physical stability which allows for long life and overall better operating
efficiency.
Purolite A 200 DL is used for the efficient removal of weak and strong acid anions in layered
bed DOUBLITE anion units in conjuction with the specially tailored weak base anion exchange
resin Purolite A 100 DL.
Purolite A 200 DL chemical and physical characteristics are recalled herebelow while its
operating performances can be obtained by consulting the Purolite A 200 technical data sheet.
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Typical Chemical & Physical Characteristics

Polymer Matrix Structure Macroporous styrene-divinylbenzene
Physical Form and Appearance Clear spherical beads
Functional Groups R - N+ (CH3)2 (C2H4OH)
Ionic Form (as shipped) Chloride
Particle Size Range 0.63 - 1.00 mm
5% max. < 0.63 mm and 25% max. > 1.00 mm
Moisture Retention, Cl- form .45 - 51 %
Reversible Swelling (Cl- -) 15% max.
Specific Gravity, Moist Cl- Form 1.08
Total Exchange Capacity, Cl- Form
(Wet, volumetric) 1.3 meq /ml min.
(Dry, weight) 3.5 meq /g min.
Max. Operating Temperature 40 °C in OH- form; 80 °C in Cl- form
Chemical Stability Insoluble in all common solvents’
PH Range, (stability) 0 - 14
(Operating) 0–9
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8. Demineralization at EPCL
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Clarification of Raw Water

Suspended solids are removed from RW at the plant site by filtration process. For this RW from
PT-8101 is pumped through PU-8101 A/B and passed though sand filter (FL-8101) towards FW
tank (VE-8101). From VE-8101 it is pumped to IW tank (VE-8601) and ultimately feed to demin
train through PU-8601A/B.
Principles of Demineralization by Ion Exchange
Cation Exchanger
Ion exchange materials are organic compounds (resins) to which are attached the hydrogen
(H+) radical in case of cation exchanger and hydroxl (OH) radical in case of anion exchanger.
In cation exchanger, the resin takes up the cations (Ca++, Mg++, Na+) from water and releases
an equivalent amount of its hydrogen ions (H+) to the water. The anions in the water are not
affected and pass through the cation exchanger. The effluent from the cations contains acid,
the type and amount depending on the anions present. Strong acids HCL, H2SO4 are formed
from CI & SO4. These are called FMA (free mineral acids). The following equations will show the
principal reactions when the cation unit is in normal service and during regeneration. The
symbol R.SO3 is used to represent the portion of cation exchange material which does not go
into the reaction.
Normal Service Run

(R-SO3)H+ Na+ (RSO3) Na + H+
2 (RSO3) H+ Ca++ (RSO3)2 Ca + 2H+
2(RSO3) H+ Mg++ (RSO3)2 Mg + 2 H+
The H+ released react with the anions to form acids. Strong acid will form by the following
reactions:
H+ + CI- HCI
2H+ + SO4- H2SO4
H+ + NO3- HNO3
The acids so formed represent the free mineral acidity (FMA) in the de-cationized water.
Bicarbonate and silica from weak acids, carbonic acid and silica acid respectively as follows:
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2H+ + SiO3- H2SiO3

H+ + HCO3 H2CO3
Regeneration
This step is the opposite of the service run. Regeneration reaction is favorable in the presence
of high concentration of H+ ions.
H+ + Cl- HCI
2H+ + SO4- H2SO4
Hydro chloric acid (HCl) supplies a high concentration of H+ ions which are exchanged with the
cations taken up by the resin during the service run. Other strong acids like H2SO4 and HNO3
can also be used.
RSO3 .Na + H+ RSO3 H + Na+

(RSO3)2 Ca + 2H+ 2RSO3 H + Ca++
(RSO3)2 Mg + 2H+ 2RSO3 H + Mg++
The released cations react with the Cl of Hydro chloric acid and are washed out as dissolved
solids during rinsing step of the regeneration cycle.
Na+ + Cl- NaCl (Soluble)

Ca++ + 2Cl- CaCl2
Mg++ + 2Cl- MgCl2
Regeneration of cation exchanger is carried out when it allows some cations to leave
unexchanged. The first cation to slip through is Na, which is detected at the anions outlet and is
measured in terms of conductance of 30 m.mho (or specified) the cation exchanger is
regenerated. Increase in conductivity means presence of dissolved solids (cation slippage.
De-Gasifier
The CO2 present in water as bicarbonate is removed by a degasifier after the first step in order
to minimize load on the Anion exchanger, which can also remove CO2. CO2 is released
according to the reaction.
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H2CO3 CO2 + H2O
Anion Exchanger
In the second step of the process, an anion exchanger in the alkali condition removes anions in
the form of their corresponding acids. Anion exchangers are of two types, the weakly basic
IRA.93 (i.e. with weak OH concentration) and the strongly basic IRA-402 (i.e. with strong OH
concentration). The weakly basic anion exchangers are capable of removing only the strong
anions (like Cl, SO4, and NO3) and not the weak anions (like CO2, SiO3). The strong basic anion
exchangers on the other hand, can remove both weak and strong anions. The strong basic
anion exchanger preferentially absorbs silica and if this bed alone is used the chances of strong
anion exchanger are used. (Upper weak and bottom strong anion resins)
In practice, metallic cation removed by the cation is usually not complete. A small percentage of
the cations remain in the cation effluent. This is known as cation leakage. An anion exchanger
cannot remove cations. Therefore these will also be present in the anion exchanger. The CO2
formed in the cation exchange step can be removed by a degasifier as well as by a strongly
basic anion exchanger. Operating cost for removal of CO2 is lower when a degasifier is used.
Normal Service Run

With Weak Basic Exchanger
(R4N) OH + CI- (R4N) CI+ OH-
2(R4N) OH + SO4 (R4N) 2 SO4 + OH-
With Strong Basic Exchangers

(R4N) OH + CI- (R4N) CI + OH-
2 (R4N) OH + SO4- (R4N)2 SO4 + 2OH-
(R4N) OH + HCO3- (R4N) HCO3 + OH-
(R4N) OH + HSiO3- (R4N) HSiO3 + OH-
The OH ions released by the anion exchangers are then neutralized by H+ ions coming from the
cations:
OH- + H+ H2O
Effluent from the anion exchanger is demineralized water and is slightly alkaline (PH range 8.0 -
9.0)
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Regeneration Cycle
Caustic Soda (NaOH) supplies a high concentration of OH- ions which are exchanged with the
anions taken up during the normal service run
(R4N) CI + OH- (R4N) OH + CI-

(R4N)2 SO4 + OH- 2(R4N) OH + SO4-
(R4N) HCO3 + OH- (R4N) OH + HCO3-
(R4N) HSiO3 + OH- (R4N) OH + HSiO3-
The released anions react with Na of caustic soda and are washed out as dissolved solids.
Na+ + CI- NaCI

2Na+ + SO4- Na2SO4
Na+ + HCO3- NaHCO3
Na+ +HSiO3- NaHSiO3
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9. Process Description
General Description
The unit is design to demineralize raw water.
Part of demin water is fed to the steam condensate tank and used as boiler feed water (BFW).
Remaining part of demin water is fed to the Polisher unit. Polished water (PW) is used as pure
water for feeding the users of PVC plant.
The unit consists of one Cation tower TW-8501located with strong acid resins, one Degasifier
TW-8502 and one Anion tower TW-8503located with weak / strong basic resins.
Demineralization
Raw water is fed through PU-8601A/B to the Cation Tower and distributed evenly form top of
tower. The tower is equipped with strong cationic resins (Purolite C-100 H or equivalent) where
ions are exchanged. The water flows from top to bottom and comes out from bottom
distributor towards degasifier where CO2 is removed from water. The distributor acts as a
retainer for resin beads and acts as a distributor for acid during regeneration cycle. In this
phase, valve KV8501 (raw water inlet) and valve KV8502 (de-cationized water outlet) remain
open. Degasifier is equipped with pall rings to increase contact area as well as time. Water is
distributed from top and collected at bottom and for CO2 stripping purposes air is injected in
counter flow from bottom through blowers BL-8501A/B. The Degasifier tank (TW 8502) is
equipped with a level transmitter LT 8502 that is connected to the regulating valve LCV 8502; it
performs the level control of tank itself. The level control is performed from PLC. The level
controller (LCV 8502) controls the level of degasifier at 90% (1.233m) by controlling the flow at
inlet of cation tower. From holding basin of degasifier de-cationised and de-carbonated water is
then fed to anion tower through PU-8501A/B and distributed evenly from top distributor. The
Anion tower is equipped with highly basic anion resins Purolite A-200 DL type or equivalent as
well as weakly basic anion resins Purolite A-100 DL type or equivalent to meet the requirements
of demineralised water. The difference in specific gravity and granulometry of strong and weak
anionic resins assure separation between the two resin layers. The demineralised water is
collected from bottom of anion tower and stored in demineralised water tank (VE-8604).
During operation the outlet water quality from Anion Tower is continuously monitored to
control outlet conductivity; the following parameters shall be considered.
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Outlet Design Normal

Silica (Sio2) 1 mg/It max
Total iron 0.3 mg/It max
Conductivity 10 micro-S/cm max
The regeneration of the demin train is started if the conductivity exceeds 10 micro-S/cm or the
train completes its design run length of 1080 m3 (At FQ-8105).
Demineralized Water Quality

Here below the quality of dematerialized water at the inlet of Polisher is reported.
Description Units Design Value

Silica (SiO2) ppm 1
CO2 ppm 1
Fe ppm 0.3
Total Hardness (as CaCO3) ppm 1
Conductivity microS/cm 10
pH -- 6.5-8.5
Color -- Clear and colorless
Operating temperature °C amb.
Operating pressure kg/cm2g 2
Capacity
Normal Flow Rates

Cation tower, Dgasifier, Anion tower = 60m3/h.
Net Capacity between Two Regenerations

Cation tower, Dgasifier, Anion tower = 1080m3
Service Time between Two Regenerations

Cation tower, Dgasifier, Anion tower = 24 hours.
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10. Regeneration System
Demin Train Regeneration
Steps Normal Regeneration

The steps of demin train normal regeneration are:
Cation tower: -Backwashing (50 min) time controlled.

-HCI injection (84 min), level and watchdog controlled.
- Slow rinse (66 min), time controlled.
- Fast rinse (30 min), time controlled.
Anion Tower: -Stand-by (3 min), time controlled
- NaOH injection (88 min), level and watchdog controlled.
- Fast rinse (70 min), conductivity and watchdog controlled.
Double Regeneration Steps

The steps of demin train double regeneration are:
Cation tower: - Backwashing (50 min) time controlled.

- HCI injection 1 (84 min), level and watchdog controlled.
- HCI refilling (25 min), level and watchdog controlled.
- HCI re-injection 2 (84 min), level and watchdog controlled.
- Fast rinse (30 min), time controlled.
Anion Tower: - Backwashing (20 min) time controlled;

- NaOH injection 1 (88 min), level and watchdog controlled.
- NaOH refilling (15 min), level and watchdog controlled.
- NaOH injection 2 (88 min), level and watchdog controlled.
- Fast rinse (70 min), conductivity and watchdog controlled.
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Description of Cation Tower Regeneration Steps

For regeneration of Cation Tower, acid solution will be used at 6% by weight.
Once the regeneration sequence has been started, all the phase here below described will be
time controlled.
Cation Tower Backwash

Resin bed will be backwashed to remove small debris from upper surface. The pump PU-8601
A/B will provide the required backwashing flow. In this phase, valve KV8503 (backwash inlet)
and valve KV8504 (backwash outlet) are open.
NOTE: 50 minutes backwashing is done on manual by toggle switch before single regeneration
and before double regeneration 30minutes on manual and 20 minutes is done by sequence.
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Acid Injection
During this phase, HCI solution (33%), fed by means of PU-8508, is diluted through a mixing TEE
with demineralized water (from pump PU-8502) in order to achieve the required 6%
concentration. This solution is fed upward to the Cation Tower from bottom distributor, while
feeding a counter pressure raw water flow (from pump PU-8601 A/B). The spent chemical is
discharged from middle distributors. In this phase, KV8506 (acid injection), KV8505 (spent
chemicals discharge) and KV8507 (counter pressure flow) valves are opened.
Acid Slow Rinse

During this phase, only demineralized water (from pump PU-8502) is fed upward to the Cation
Tower from acid injection line while feeding a counter pressure raw water flow (from pump PU-
8601 A/B). In this phase: KV8506, KV8505 and KV8507 valves are opened.
Fast Rinse
During this step the washing of the resin beds is completed. Higher washing velocity is required
in order to get uniform washing of the resins; valves KV8501 and KV8508 (fast rinse discharge)
are open. Feeding pump is PU-8601 A/B (IW Pump).
The following table is showing the breakdown of flow, valves and exercise pumps; times shall
be also considered. Double regeneration step to be added to Normal regeneration step. Once
every 30 Cycles of normal regeneration. In case of Normal regeneration, KV8540 will be closed
In case of Double regeneration, KV8541 will be opened
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Description Of Anion Tower Regeneration Steps

For regeneration of Anion Tower, basic solution NaOH will be used at 5% by weight.
Once the regeneration sequence has been started, all the phases here below described will be
time controlled.
Anion Tower Backwash

In this phase resin bed will be backwashed to remove small debris from upper surface. The
regeneration pump PU-8502 will provide the required backwashing flow. In this phase, valve
KV8511 (backwash inlet) and valve KV8512 (backwash outlet) are open.
NOTE. This phase is required only every 30 cycles and must be followed by double regeneration
(Double chemical injection and double slow rinse).
Caustic Injection
During this phase, NaOH solution (50%), fed by means of PU-8511, is diluted through a mixing
TEE with regeneration water (from pump PU-8502) in order to achieve the required 5%
concentration. Regeneration water will be heated up to 50C by means of a Tube Bundle heat
exchanger HE-8501 for increasing efficiency of caustic regeneration in Anion Tower. This
solution is fed upward to the Anion Tower, while feeding a counter pressure regeneration
water flow (from pump PU-8502). Open valve in this phase, KV8513 (caustic injection), KV8514
(spent chemicals discharge) and KV8516 (counter pressure flow)
Caustic Slow Rinse
During this phase, regenerated water (from pump PU-8502) is fed upward to the Anion Tower
from basic injection line while feeding a counter pressure regeneration water flow (from pump
PU-8502). In this phase, KV8513, KV8514 and KV8516 valves are opened.
Fast Rinse
During this step the washing of the resin beds is completed. Higher washing velocity is required
in order to get uniform washing of the resins. In this phase KV8509 (fast rinse inlet) and KV8515
(fast rinse discharge) valves are opened.
Double regeneration step to be added to Normal regeneration steps. Once every 30 Cycles of
normal regeneration
In case of Normal regeneration, KV8540 will be opened
In case of Double regeneration, KV8541 will be opened
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Polisher
The unit is designed to polish demineralized water collected from Demineralizer Unit.
Demineralized water is fed to the Polisher to reduce ionic load and get the required
conductivity for process water. The polished water is sent to the polished water tank VE-1201
for the uses of PVC plant. Polisher Feed Pump PU-8604 A/B feeds Demin water from Demin
water tank VE-8604 to the Polisher TW-8504. It is distributed evenly from the top through
distributor, passed through mixed bed and collected from bottom and stored in polished water
tank VE-8603. The polisher is equipped with both cationic and anionic resins. Cationic resin is
the strong acid type Purolite C-100 MBH or equivalent. Anion resin is the strong base type A-
400MBH type or equivalent.
Downstream of the Polisher a filter is installed to arrest any resin particles entrained from the
MB polishers. Flow Controller (FQC 8104) with regulating valve (FCV 8104) at the outlet of
Polisher regulates water flow in order to keep the value at 35 m3/h. This controller also
controls level in polished water tank on cascade.
During operation the outlet water quality from polisher is continuously monitored to control
outlet conductivity on conductivity-meter CIT-8101; the following parameters shall be
considered.
Outlet Design Normal
Silica (SiO2) 0.02 mg/It max
Total iron 0.003 mg/It max
Conductivity 1 micro-S/cm
The regeneration of the polisher is started if the conductivity exceeds 01 micro-S/cm or the
train completes its design run length of 5250 m3 At FQ-8104.
Quality of Polished Water

Here below the quality of polished water at the outlet of Polisher is reported.
Description Units Design Value

Silica (SiO2) ppm 0.02
CO2 ppm 1
Fe ppm 0.003
Conductivity micro/Scm 1
pH -- 5-9
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Color -- Clear and colorless

Operating temperature °C amb.
Operating pressure kg/cm2g Min 2.0
CI, Hardness, SO4M-Alcalinity ppm <0.2 (each)
(CaCO3)
Normal Flow Rates

Polisher: 35 M3/H.
Net Capacity between Two Regenerations

Polisher: 5250 M3
Service Time between Two Regenerations
Polisher: 150 H (6.25 Days)
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11. Polisher Regeneration
The steps of Polisher regeneration are

 Backwashing (15 min), time controlled;
 Settling (10 min), time controlled;
 NaOH injection (50 min), level and watchdog controlled;
 NaOH slow rinse (30 min), time controlled;
 NaOH rinse + HCI injection (40 min), level and watchdog controlled;
 NaOH rinse + HCI slow rinse (20 min), time controlled;
 NaOH rinse + HCI rinse (55 min), time controlled;
 Drain (07 min), time controlled;
 Air mixing (20 min), time controlled;
 Refilling (03 min), time controlled;
 Final rinse (70 min), conductivity and watchdog controlled.
Description Of Polisher Regeneration Steps

For regeneration of Polisher, basic solution NaOH at 4% by weight and acid solution at 5% by
weight will be used. Once the regeneration sequence has been started, all the phases’ here
below described will be time controlled by PLC.
Backwash
In this phase resin bed will be backwashed to remove small debris from upper surface and to
loosen the bed of resin to maximize the area of contact with regenerant. The regeneration
pump PU-8502 will provide the required backwashing flow. In this phase, valve KV8520
(backwash inlet) and valve KV8521 (backwash outlet) are open.
Settling
This phase is required to allow hydraulic classification of cationic / anionic resins necessary
before chemicals injection; cationic resin will move to the bottom of polisher and anionic to the
upper side of bed. All valves are closed, all pumps are stopped.
Caustic Injection
During this phase, NaOH solution (50%), fed by means of PU-8512, is diluted through a mixing
TEE with regeneration water (from pump PU-8502) in order to achieve the required 4%
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concentration. Regeneration water will be heated upto 50C by means of a Tube Bundle heat
exchanger HE-8501 for increasing efficiency of caustic regeneration in Polisher.
This solution is fed downward to the Polisher from top distributor. In this phase KV8523 (caustic
injection) and KV8522 (spent chemicals discharge) valves are opened.
Caustic Slow Rinse

During this phase, caustic will be removed from the polisher before the injection of acid
solution. Regenerated water (from pump PU-8502) is fed downward to the Polisher from basic
injection line. Valves KV8523 and KV8522 are open.
Caustic Fast Rinse/Acid Injection

During this phase, regeneration water is fed from caustic injection line in order to complete
anionic resin washing and to protect anionic resin from acid solution (5% HCI) coming from the
bottom: regeneration water is fed downward to the Polisher.
HCI solution (33%), fed by means of PU-8509, is diluted through a TEE with regeneration water
(from pump PU-8502) in order to achieve the required 5%. This solution is fed upward to the
Polisher bottom distributor. In this phase valves KV8523, KV8522 and KV8524 (acid injection)
are opened.
Counter Pressure/ Acid Slow Rinse
During this phase, regenerated water is fed from caustic injection line in order to protect
anionic resin from acid/salt solution coming from the bottom: regeneration water is fed
downward to the Polisher. Acid solution will be removed from the polisher by means of
regenerated water (from pump PU-8502) fed upward to the Polisher from acid injection line.
Valves KV8523, KV8522 and KV8524 are opened.
Cationic /Anionic Fast Rinse

During this step the washing of both the resin beds is completed. Higher washing velocity is
required in order to get uniform washing of the resins. Valves KV8523, KV8522 and KV8524 are
opened.
Drain Down
During this phase water is drained down up to 5 cm above top of the resin bed, valves KV8528
(automatic drain) and KV8526 (automatic vent) are opened. Opening time of these valves shall
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be regulated at site in order to get the actual level of water over the resins bed before starting
the air mixing. In fact air mixing without water in resin bed could damage the resins, and water
level upper than above indicated would cause classification of resins.
Air Mixing
During this phase, air is blown inside the polisher to promote mixing of resins. During this phase
Polisher Mixing Blower BL-8502 is started and valves KV8525 (air inlet), KV8521 and KV8520 are
opened.
Refilling
During this phase, Polisher is refilled with regenerated water from PU-8604 A/B. valve KV8518
and valve KV8526 are open.
Fast Rinse
During this step the washing of the resin beds is done through PU-8604 A/B. Higher washing
velocity is required in order to get uniform washing of the resins. Valves KV8518 and KV8528
(fast rinse discharge) are open.
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12. Neutralization
The Neutralization system is common for both Demin train and Polisher unit. It provides
neutralization to effluents for both plants. To neutralize the effluents of regeneration, the
system uses its own chemical feeding system (VE 8505, VE 8508).
For the regeneration of the effluents two lines are provided to dose caustic soda (NaOH) 50%
and hydrochloric acid (HCL 33%).
Neutralization sequence is started as soon as regeneration of Cation / Anion towers or Polisher
is finished, with the following steps:
a. Start of PU-8503
b. Check of water pH value (pH meter AIT 8520) and caustic / acid solution pH value.
c. Caustic or acid dosing if necessary.
d. Recirculation / discharge of neutralized water.
KV-8531 and KV-8530 are interlocked with pH meter AIT-8520: when pH value is higher than 9
or lower than 6, KV-8531 is open and KV-8530 is close.
When the pH value is between 6-9 KV-8531 is close and KV-8530 is open so that neutralized
waste water can be discharged to the drain.
The neutralization cycle start automatically for the following conditions
1. At the end of normal regeneration of Demin train or Polisher

2. Neutralization pit high level: LSH 8517 or LSH 8518 opened.
3. Manual starts using key soft on Operator interface.
After double regeneration no automatic neutralization start is provided: only signal on Operator
Interface “End double regeneration” and a common alarm (XA 8101) is sent to DCS. The
operator has to start neutralization using manual start.
The neutralization cycle is stopped automatically for the following reasons:

1. Neutralization pit low level: LSL 8517 or LSL 8518 opened.
2. Manual stops using key soft on Operator interface.
3. PU-8504 & PU-8505 is on manual mode.
Two key-soft push buttons are provided for start (HS 8509) or stop (HS 8510) Neutralization
plant.
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The Area Engineer can start the sequence pressing the key-soft “Neutralization start” (HS 8509)
in the operator interface on local panel. The start push button actives the start of the
neutralization sequence. The stop push button (HS 8510) resets the Neutralization plant.
AR
8520
½ DN-8591-A7K-TS
from VE 8508 NEUTRALIZATION SYSTEM AI
8520
AIT
8520 KY
8531
123 1
1 S KY
8530
S 122
1 HC-8572-A1P
from VE 8505 KV KV
8531 8530
123 122 4 WW-8201-A5S
3 WW-8538-A2P
3 WW-8541-A5S
PG
8519
3 WW-8539-A2P
FLX
8506
BALL VALVE 1/2
ACID PROOF
COATING TRENCH
4 WW-8537-A2P
PIT
M
ST
8505 LS
8517 LS
8518
VALVE PIT
VKF206-125 VKF206-124
4 WW-8537-A2P
4 WW-8537-A2P
2 WW-8540-A2P 2 WW-8539-A2P
ACID PROOF
COATING
Description Of Steps For Neutralization Sequence

The sequence follows these steps:
Mixing
The waste water pump PU 8503 is started and the recirculation valve KV 8531 is opened and the
discharge valve KY 8530 is closed. This mixing is performed for 10 min (adjustable time from
Operator Interface).
Ph Reading
At the end of the mixing the pH value is read with 5 sec of delay in order to stabilize the
reading. Two software thresholds are used for check the status of water. If the pH is above the
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H threshold the system goes to step 3 and an alarm appears on Local Panel. If the pH is below
the L threshold the system goes 4 and an alarm appears on Local Panel. If the pH value is in-
between the H and L range the system goes to step 5. These thresholds are presetted inside the
PLC
Acid Dosing
This step is performed if the pH value is above the H switch. In this case the chemical valve KV
8535 will open for 5 sec. (adjustable timer). At the end of this step the system returns to step 1.
Caustic Dosing
This step is performed if the pH value is below the L switch. In this case the chemical valve KV
8539 will open for 5 sec. (adjustable timer). At the end of this step the system returns to step 1.
Discharge
The system discharges the pit by opening the discharge valve KV 8530 and closing the
recirculating valve KV 8531 until the low level LSL 8517 / 8518 is reached. Only at low level the
cycle is resettled. The pump PU-8503 and neutralization valves will close. The recirculating valve
and the discharge valve will invert in order to prepare the system for the next neutralization
cycle. During all steps, the step 1 remains active. The Waste water pump (PU 8503) is running,
the recirculation valve KV 8531 is opened and the discharge valve KV 8530 is closed.
In case of UPS power supply failure the system will position itself at step 1 and will restart the
cycle, automatically by PLC.
Level Switches the Neutralization Pit
A key soft push button (HS 8511) will be used to choose the active neutralization pit. Pushing
this button the system change alternatively the choice for neutralization pit “A” and
neutralization pit “B”. The neutralization pit has two compartments: one has the capacity
accommodating the one time regeneration waste of demineralization unit or polisher unit. One
of the pits will be used as standby.
Area Engineer will open or close manually the loading valve of each pit. The same person must
act on the key-soft “Active Neutralization Pit” (HS 8511) on operator interface to select the
relative level switch (LS 8517 or LS8518).
It is important note that during “Double regeneration” the level switches are contemporary
active. The low level is reached if both pits will be empty. This is due to the increased volume of
regenerated water. It is necessary for a Double regeneration. In this case both pits will be used
con temporary.
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13. Major Equipment’s Detail
Cation Tower (TW-8501)

Design pressure 8 kg/cm2G
Design temperature 60 °C
Vessel material Mild Steel (12 mm thick) ebonite lined (3 mm thick)
Vessel diameter 2200 mm
Vessel height (TL-TL) 3160 mm
Strong cationic resin volume 6750 Itr
Observation port 2 sets
De-Gasifier Tw-8502
Design pressure atm kg/cm2G
Vessel material Mild Steel ebonite lined (3 mm thk)
Packing height 2000 mm
Packing Pall rings 2” - PP
Cylindrical total height 3200 mm
Holding tank 9 m3
Holding tank accessories level gauge, level transmitter
(H & L) Inlet Valve
De-Gasifier Fan BL-8501 A/B

No. of Degasifier Fans 2 (1+1)
Type centrifugal
Air flow rate 1000 Nm3/h
Head 70 mm WC
Material PE
Motor power 1.5 KW
Over load tripping 2.7 ampere (12 seconds)
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De-Gasified Water Pumps PU--8501 A/B

Degasifier water pumps 2 NO (1+1)
Type centrifugal
Water flow rate 60 m3/h
Head 40 m
Motor power 15 KW
Material AISI 316
Over load tripping 28 ampere (15 seconds)
Anion Tower (TW-8503)

Design pressure 5kg/cm2G
Design temperature 60°C
Strong anionic resin volume 4000 Itr
Weak anionic resin volume 3300 Itr
Polisher (TW-8504)
Design pressure 6 kg/cm2G
Strong cationic resin volume 350 Itr
Strong anionic resin volume 350 Itr
Polisher Mixing Blower (BL-8502)

Design flow 100 Nm3/h
Head 3.5 m WC
Type roots
Material CAST IRON
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Motor power 3 KW
Safety Filters
Design pressure 6 kg/cm2g
HCL Tank VE-8501

Item VE-8501 - HCI tank
Volume 14,600 liters
Type Horizontal
Material Carbon Steel ebonite lined (thick. 3mm)
Design pressure ATM
Accessories low level/ high level switches (LS-8531)
Low level 100mm (4.50%) PU-8504 trips
High level 1900 mm (86.36%) PU-8506 trips
Safety hydraulic guard for vent

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HCL Unloading Pump PU-8506

Item PU-8506- HCI Unloading Pump
Type centrifugal
Casing material Teflon
Head 1.65 kg/cm2
Motor power 0.75 KW
HCL Pump PU-8504

Item PU-8504 - HCI pump
Type centrifugal
Water flow rate 6.6 m3/h
Head 1.6 Kg/cm2
Motor power 0.75 KW
Overload tripping 1.85 ampere (12 second)
HCL Measuring Tanks VE-8503

Item VE-8503 - HCI to Cation Tower Tank
Volume 1.0 m3
Material PE
Type vertical
Accessories low /high level switches (LS 8534)
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HCL Dosing Pumps PU-8508

Item PU-8508 - HCI dosing pump to Cation Tower
Type diaphragm (replaced with pneumatic pump)
Casing material PVC
Flow rate 1200 I/h
Head 2 Kg/cm2
Motor of old pump o.37 ampere
HCL Measuring Tanks VE-8504

Item VE-8504 - HCI to Polisher Tank
Volume 0.1 m3
Material PE
Type vertical
Accessories low/high level switches (LS 8535)
HCL Dosing Pumps PU-8509

Item PU-8509 - HCI dosing pump to Polisher
Type diaphragm
HCI 33% flow rate 170 I/h
Head 2 Kg/cm2
Casing material PVC
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NaOH Unloading Pump PU-8507

Item PU-8507 - NaOH Unloading Pump
Type centrifugal
Water flow rate 5.4 m3/h
Head 1.75 Kg/cm2
Motor power 0.75 KW
NaOH Tank VE-8502

Item VE-8502 - NaOH tank
Volume 12,700 Itr
type horizontal
Material Carbon steel
Design pressure ATM
Accessories low level/ high level switches (LS 8524)
Low level 500 mm (22.72%)
High level 1630 mm (74.09%)
Electric heater 9 KW.AC400V-3 phase.
Temperature switch (8522) Control temperature: 84F
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NaOH Pump PU-8505

Item PU-8505 - NaOH Transfer Pump
Type centrifugal
Casing material teflon
Head 4.1 Kg/cm2
Motor power 1.5 KW
Over load tripping 5 ampere (7 seconds)
NaOH Measuring Tanks VE-8506

Item VE-8506 - NaOH to Anion Tower Tank
Volume 0.500 m3
Material PE
Type vertical
NaOH Dosing Pumps PU-8511

Item PU-8511 - NaOH dosing pump to Anion Tower
Type diaphragm
Casing material AISI316
Flow rate 450 I/h
Head 2 Kg/cm2
Motor power 0.37 KW
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NaOH MEASURING TANKS VE-8507

Item VE-8507 - NaOH to Polisher Tank
Volume 0.1 m3
Material PE
Type vertical
NaOH DOSING PUMPS PU-8512

Item PU-8512 - NaOH dosing pump to Polisher
Type diaphragm
Casing material AISI316
Flow rate 70 I/h
Head 2 kg/cm2
Motor power 0.09 KW
Regeneration Pump PU-8502

Item PU-8502 Regeneration pump
Type Centrifugal
Pressure 3 kg/cm
Motor power 11 KW
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Demin Water Heater (HE-8501)

Item HE 8501 - Demin water Heater
Type Tube Bundle
Tube Bundle material AISI 136L
Shell material CS
Water Flow 6,2 m3/h (shell side)
Steam flow 900 kg/h (tube side)
Steam design pressure 11 Kg/cm2G
Steam design temperature 190 °C
Steam operation pressure 9 Kg/cm2G
Steam operation temperature 179 °C
TCV-8521 On/OFF steam valve
TS-8537 50C
Neutralization Pit PT-8501 A/B

The pit will have two compartments, double volume of waste coming from out
demineralization unit.
Useful volume 2 * 130 m3
Material reinforced concrete
Protection anti caustic / acid lining paint suitable for pH range
1-13
LS 8517 For high and low level control pit A
LS 8518 For high and low level control pit B
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Waste Water Pump PU-8503

No. 1
Type centrifugal, horizontal
Material PP
Flow 55 m3/h
Head 20 m
Motor 11 kw
Amperes 20 overload tripping after 15 seconds
HCL Measuring Tanks (VE-8505) for PT-8501

Volume 0.1 m3
Material PE
Type vertical
Accessories low / high level switches (LS 8536)
NaOH Measuring Tank (VE-8508) for PT-8501

Volume 0.1 m3
Material PE
Type Vertical
Accessories low / high level switches (LS 8529)
IW (Industrial Water) Tank
The capacity of IW Tank is 540 m3 corresponding to approx.6 hr, storage of total consumption (based on
Average Flow 80m3), IW consumption is Max. 150m3/hr and Average 80m3/hr
Item VE-8601 - IW Tank

Volume 540 m3
Type Vertical
Accessories LT 8103 (1~7.5m)
IW Pump PU-8601 A/B

Item PU-8601 A/B
Type Centrifugal
Flow Rate 150m3/hr
D.Press 5.8 Kg/cm2
Motor power 45 kW
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LW (Live Water) Tank

The capacity of LW Tank is 60 m3 corresponding to approx.1Day, Hold up (based on the average
flow). LW supply to the all eye washers in PVC Base Plant.
Item VE-8602 - LW Tank
Volume 60 m3
Type vertical
Accessories LT 8104 (2~4m)
LW PUMP PU-8602 A/B

Item PU-8602 A/B
Type Centrifugal
Flow Rate 11.2 m3/hr
D.Press 5.5 Kg/cm2
Motor power 11 kW
PW (Polish Water) Tank
The capacity of PW Tank is 320 m3 corresponding to approx.12 hr, Hold up (based on the average flow).
It is used for Chemical preparation and in Process area.
Item VE-8603 - PW Tank

Volume 320 m3
Type vertical
PW PUMP PU-8603 A/B

Item PU-8603 A/B
Type Centrifugal
Flow Rate 40m3/h
D.Press 5.1 Kg/cm2
Motor power 11 kW
DW (Demin Water) Tank

The capacity of DW Tank is 320 m3 corresponding to approx.10 hr, Hold up (based on the
average flow). It is used for PW preparation and BFW make up.
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Item VE-8604 - DW Tank

Volume 320 m3
Type vertical
DW UMP PU-8604 A/B

Item PU-8604 A/B
Type Centrifugal
Flow Rate 60 m3/hr
D.Press 4.0 Kg/cm2
Motor power 15 kW
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14. Over View of PLC of Water Treatment
Routine Operation From PLC
1) Data Access
2) Alarm acknowledgements
3) Regeneration initiation
4) Changing of timer
5) Demin train startup/ stop
6) Polisher start up/ stop
7) Neut pit selection
8) Neut startup/ stop
PLC layout
LSL-8531
When Level of Acid Storage tank (VE-8501) decreases to 100 mm,
LSL-8531 switch will actuate & indication will appear on LCP with alarm.
LSL-8534 When level of demin acid day tank (VE-8503) decreases to 200 mm,
LSL-8534 switch will actuate & indication will appear on LCP with alarm
LSL-8535 When level of Polisher acid day tank (VE-8504) decreases to 109 mm,
LSL-8536 When level of acid neut day tank (VE-8505) decreases to 150 mm,
LSL-8524 When level of caustic storage tank (VE-8502) decreases to 500 mm,
LSL-8527 When level of demi caustic day tank (VE-8507) decreases to 150 mm,
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LSL-8528 When level of polisher day tank (VE-8502) decreases to 200 mm,
LSL-8529 When level of Caustic newt day tank (VE-8508) decreases to 100 mm,
CIT-8102 When conductivity of polisher outlet water increases the indication will appear
On LCP with alarm.
CIT-8102 When conductivity of demi outlet water increases the indication will appear On
LCP with alarm.
PS
PS is a push button to check the indication bulb condition.
AQ
AQ is a push button. It is used for acknowledge the alarm.
Control Valves, Action & Failure
S.NO Tag NO Location Action Consequences of Failure

LCV-8103 u/s of VE-8601 Fail to close Vessel will empty &
PU8601A/B can cause of cavitations.
LCV-8502 u/s of TW-8502 Fail to open Degasifier will over flow.
LCV-8506 u/s of VE-8604 Fail to open VE-8604 will over flow.
LCV-8507 u/s of TW-8504 Fail to open VE-8603 will over flow.
TCV-8521 u/s of HE-8501 Fail to close
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JB-01 Cation Tower

1. KV-8501 Cation inlet Fail to close
2. KV-8502 Cation outlet Fail to close.
3. KV-8503 backwash inlet Fail to close
4. KV-8504 backwash outlet Fail to close
5. KV-8505 chemical inlet Fail to close
6. KV-8506 chemical outlet Fail to close
7. KV-8507 counter pressure Fail to close
8. KV-8508 fast rinsing Fail to close
JB-02 Anion Tower

1. KV-8509 Anion inlet Fail to close
2. KV-8510 Anion outlet Fail to close
3. KV-8511 counter pressure Fail to close
5. KV-8513 chemical inlet Fail to close
9. KV-8517 conductivity meter Fail to close
JB-03 Polisher
1. KV-8518 Polisher inlet Fail to close
2. KV-8519 Polisher outlet Fail to close
6. KV-8523 NaOH inlet Fail to close
7. KV-8524 HCl inlet Fail to close
8. KV-8525 Air mix. Inlet Fail to close
9. KV-8526 Air mix. Outlet Fail to close
10. KV-8527 conductivity meter Fail to close
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15. Safety Interlocks
1. PU-8503 will stop, if pit-8501A/B level switch LS-8517 & LS-8518 is actuated.
2. KV-8530 will not open, if pH of pit-8501A/B is out of range (6 ~ 9).
3. Polisher will trip, if LSL-8527, LSL-8528, LSL-8529, LSL-8534, LSL-8535, LSL-8536 is
actuated.
4. PU-8504 will stop, if LSL-8531of VE-8501 is actuate at 100mm.
5. PU-8506 will stop, if LSH-8531of VE-8501 is actuate at 1900mm.
6. PU-8505 will stop, if LSL-8524 of VE-8502 is actuate at 500mm.
7. PU-8507 will stop, if LSH-8531of VE-8502 is actuate at 1630mm.
8. KV-8501, KV-8502, KV-8509, KV-8510, KV-8517, PU-8501A/B & BL-8501A/B will operate
if Demin train is taken into service.
9. KV-8518, KV-8519, KV-8527 will operate if Polsher is taken in service.
10. PU-8502 will operate if Demin train / Polisher regeneration is start.
11. During regeneration TCV-8521 will close if water temperature at HE-8501 is > 50C.
12. During regeneration TCV-8521 will open if water temperature at HE-8501 is < 50C.
13. Regeneration of Demin train / Polisher will not start if pit-8501A & B level is high.
14. Double regeneration of Demin train will not start if pit-8501A or B level is high.
15. Double regeneration of Demin train will stop if PU-8504 & PU-8505 is not started after
HCl / NaOH dosing.
16. Polisher regeneration will stop if PU-8505 & PU-8504 is not started after NaOH / HCl
dosing.
17. LCV-8502 will open, if Degasifire level is low.
18. LCV-8502 will close, if Degasifire level is high.
19. FCV-8506 will open if VE-8604 level is < 6.5m.
20. FCV-8506 will close if VE-8604 level is > 6.5m.
21. FCV-8507 will open if VE-8603 level is < 6.5m.
22. FCV-8507 will close if VE-8603 level is > 6.5m.
23. XSV-8101 will open if VE-8602 level is 2.5m.
24. XSV-8101 will close if VE-8602 level is 3m.
25. PU-8602 A/B (standby pump) will cut in if live water header pressure is 4.5kg/cm 2.
26. LCV-8103 will open if VE-8601level is < 7m.
27. LCV-8103 will close if VE-8601level is > 7m.
28. During demin train double regeneration KV-8541 will open if VE-8604 is <60%.
REV. NO. : 00
ISSUE NO. : 01
PAGE
: JULY-2014
: 67 OF 67
16. Safety Equipment’s
S.NO Name of equipment Tag NO Location
1 Fire extinguisher Box # 16 East of PU-8604A/B
2 Fire extinguisher Box # 17 West of PLC (PWU)
3 Fire extinguisher Box # 18 North of PU-8601A/B
4 Safety shower SP 8400 Near chemical skid of

cooling tower
5 Safety shower SP 8500 West of VE-8501
6 Safety shower SP 8600 In-between of PU-8603 &

PU-8604

Gop-Uty-08 (DMW 1)

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S No. Rev. No. Date Page No. Section Description of Change

SOP Standard Operating Procedure

T/A Trade Apprentice

TAE Trainee Assistant Engineer

UMO Unit Manager Operations

VP Manuf. Vice President Manufacturing

TDS Total dissolved solids

I.A Instrument Air

P.A Plant Air

P & ID Piping and Instrumentation Diagram

CCPP Combined cycle power plant

MCC Motor control center

Total Hardness (TH)

Ca (HCO3)2 + Ca (OH)2 2CaCO3 + H2O

Ion Exchange Resin

1- Cationic Resin: For separating cations.

5. Water Quality Parameters

Physical Quality Parameters

Suspended Solids & Turbidity

Filtration @ 0.2M filters & color test.

Taste and Odor

Chemical Quality Parameters

Total Dissolved Solids (TDS)

2NaCO2C17H35 + cation 2+ cation2+ (CO2C17H35)2 + 2Na+

Dealkalization is used to lower alkalinity (carbonate and bicarbonate) in a water stream. In an

Demineralization by Ion Exchange

 The volumes and composition of the raw waters,

Ion Exchange Chemistry

Strong Acid Cation Resins

Ca (HCO3)2 + 2NaX CaX2 + 2NaHCO3

Ca (HCO3)2 + 2HX CaX2 + 2H2CO3 (1)

H2SO4 + CaX2 CaSO4 + 2HX (3)

Weak Acid Resins

2XCOOH + Ca(HCO3)2 Ca(XCOO)2 + 2H2CO3 (4)

HCI + XOH XCI + H2O (5)

Weak Base Anion Resins

HCI + X XHCl (6)

PUROLITE Ion Exchange Resins

Typical Physical, Chemical, & Operating Characteristics

Typical Physical & Chemical Characteristics

Typical Chemical & Physical Characteristics

PUROLITE C 100 MBH

Typical Physical and Chemical Characteristics

Typical Chemical & Physical Characteristics

Clarification of Raw Water

Principles of Demineralization by Ion Exchange

Normal Service Run

2H+ + SiO3- H2SiO3

RSO3 .Na + H+ RSO3 H + Na+

Na+ + Cl- NaCl (Soluble)

H2CO3 CO2 + H2O

Normal Service Run

With Strong Basic Exchangers

(R4N) CI + OH- (R4N) OH + CI-

Na+ + CI- NaCI

Outlet Design Normal

Demineralized Water Quality

Description Units Design Value

Normal Flow Rates