DMT-2 UPW O&M-Rev0 - 2 - 14032019

OPERATION MANUAL
FOR
70 m3/hr UPW WATER SYSTEM
OF
FIRST SOLAR VIETNAM DMT2
PREPARED BY:
VINSTAR (M) SDN. BHD.

FIRST SOLAR VIETNAM Vendor : Vinstar (M) Sdn. Bhd.
DMT2- 70m3/Hr UPW System
OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

MANUAL
INTRODUCTION
This manual contains all information for operating and maintaining the Ultra-Pure Water
Treatment Plant at First Solar DMT2 Factory, Ho Chi Minh, Vietnam.
The UPWI plant is designed to provide an optimal impurity removal. This can only be
reached when the instruction given in this manual are taken care off. For detailed information
concerning the equipment installed, please refer to the individual equipment/instrument manufacturer
installation manual /catalogues concerned.
This manual also contains certain instruction about equipment routine inspection, an analysis
of certain parameters on varied time intervals and to maintain a proper record of these. To meet the
required product quality, it is absolute important that these data sheets are controlled and recorded.
Otherwise, the product quality cannot be guaranteed by Vinstar (M) Sdn. Bhd.
Back to Table of Content Page 2 of 57


MANUAL
SAFETY POLICY
BEING A SUPPLIER OF EQUIPMENT WHICH, IF OPERATED IMPROPERLY,

COULD CAUSE SERIOUS PERSONNEL INJURY,
WE AT DARCO ARE VERY SAFETY CONSCIOUS.
BY READING THIS MANUAL AND UNDERSTANDING THE RISKS AND

SOLUTIONS TO THEM, WE HOPE THAT THE POSSIBILITY OF
PERSONNEL INJURY WILL BE GREATLY REDUCED OR ELIMINATED.
IF YOU HAVE ANY QUESTIONS ON PROCEDURES SUGGESTED OR

EQUIPMENT SPECIFIED IN THIS MANUAL, PLEASE DO NOT HESITATE TO CONTACT US AT
DARCO.
THIS SECTION SHALL BE USED IN CONJUNCTION WITH INTEL EHS DESIGN CRITERIA FOR
A/T, IOS, GPBS AND MSBS, INDIVIDUAL EQUIPMENT/INSTRUMENT MANUFACTURER
INSTALLATION AND OPERATION MANUAL
WE TAKE YOUR SAFETY SERIOUSLY!


MANUAL
1. PERSONNEL SAFETY INFORMATION
BACKGROUND
This section is for general use and may have sections not applicable to the system. Specific
chemicals used are contained within the individual modules.
SAFETY NOTES AND PRECAUTIONS

PUMPS
CENTRIFUGAL PUMPS
1. Do not use the lifting eyes of the motors of the Grundfos CR, CRN pumps for lifting the entire
pump.
2. Before removing the terminal box cover and before removing/dismantling the pump, make
sure that the electricity supply has been switched off.
3. Pay attention to the direction of the vent hole and take care to ensure that the escaping
water does not cause injury to persons or damage to the motor or other components.
4. Before starting work on the pump, make sure that all power supplies to the pump have been
switched off and that they cannot be accidentally switched on.
5. Lockout pumps to be worked on and tag it.
6. Never work on a pump when it is running.
7. After working on pumps, reinstate all parts and guards.
8. Lubricate pump and motor as per manufacturer's recommendations.
NOTE:
For all pumps, drain suction and discharge piping prior to working on liquid end of pump.
HYDRAULICS
The UPW system involves the transmission of huge quantities of water through various sizes of
piping and internals. Improper manual operation of this system can cause physical damage to the
internals of the vessels or tanks and may eventually cause personnel injury should a leak occur at
high pressure or volume.
1. Always make sure vessels are full when operating the system. Regularly check for air pockets
by opening the manual vent for a short time.
2. When performing manual steps, allow the system to come to a complete stop before starting the
next flow path.
3. Make sure all piping is adequately supported and anchored.
PNEUMATICS
Clean, dry, oil free instrument air is used to operate the pneumatic valves for UPW system.
Except for the initial blow down of the air line, the air supply should be isolated prior to work being
done on or around an air operated valve.


MANUAL
VESSEL OR TANK ENTRY

Confined space warning signage is provided at each manhole of pressure vessels and tanks.
Prior to entering any pressure vessels and tanks, it should be tested for adequate oxygen level.
Permit shall be obtained from Intel EHS prior for confined space entry.
If the vessel is rubber lined or has a surface that could be damaged, soft-soled shoes should be worn.
Always use the “buddy” system when doing vessel inspections. Always have a person outside the
vessel. In visual contact who can assist or get assistance for you should you encounter difficulties.
Use a rope ladder to climb in and out of a vessel.
NOTE:
If only a wire or chain ladder is available, tape around any protrusions to avoid having the ladder cut
the vessel lining.
Care must be taken not to drop tools as this can also cut or chip the lining.
Never smoke or allow anyone to smoke while inside a vessel.
Never leave anything inside the vessel, i.e. tools, spare nuts, bolts, washers, etc.
Do not leave the vessel open when no one is working inside.
LOCKOUT
A tagged/lockout procedure should be used to ensure the safety of persons working on any
equipment.
This should apply not only to the lockout of main power distribution board, rotating or electrical
equipment but also to vessels, water, air, and chemical supply lines.
ACCESS
Proper access should be provided around all UPW equipment.
The practice of storing equipment or parts close to operating plants should be discouraged.
Care should be taken to ensure that all areas are well lit so that operating and maintaining the
equipment can be done in a safe manner.
Where possible, the floor should be treated with an acid and skid resistant surface coating which
should be kept clean.
Any ion exchange resin spills should be swept up immediately. If allowed to dry up, it will become
extremely slippery.


MANUAL
SAFETY GEAR
It is imperative that proper safety clothing be used when working on acid or caustic equipment.
Failure to comply with the above directive may result in permanent personnel injury.
Rubber gloves, full rubber suits, and full-face shields must be used when there is possibility of
expose to acid or caustic.
Safety showers must be kept in good working order.
Flange guards should be fitted to all flanges on piping that contains chemicals.
Spills should be treated in a manner consistent with all relevant codes and local regulation for
disposal.
ELECTRICAL
There are no specific electrical hazards in UPW system. However, all the standard good electrical
practices shall be applied.
Regularly inspect terminations for tightness and proper connection.
Isolate any faulty electrical part prior to repairing or replacing it. Remember that several different
power sources may be feeding a single cabinet. Isolate all feeds prior to working in cabinet.
Inspect any electrical box seals to ensure that water stays on the outside.
Allow only qualified electrical personnel to troubleshoot or repair electrical system.
REMEMBER: "ELECTRICITY IS A GREAT SERVANT AND A DEADLY MASTER".


MANUAL
SAFETY CHECKLIST
Prior to the operation of DARCO system, you should review all safety features listed below:
No. Description Owner Initial Operation &

Maintenance
Team
1. Check operation of all safety showers and eyewash [ ] [ ]

stations.
2. Post phone numbers of all emergency services in a [ ] [ ]

highly visible location.
3. Ensure that all operators of this equipment are [ ] [ ]

familiar with safe working practices as it relates to
this plant (see manual).
4. Be familiar with all pump shut off locations. [ ] [ ]
5. Check that all pumps/valves and starters are [ ] [ ]

properly tagged.
6. Ensure proper access and adequate lighting around [ ] [ ]

all equipment.
7. Supply all required acid/caustic protective gear (full- [ ] [ ]

face shields, rubber suits and gloves) and store it
near the chemical skids.
8. Keep the equipment clean and fully maintained. [ ] [ ]
9. Provide adequate ventilation where necessary. [ ] [ ]
10. Keep up to date records of operation including levels [ ] [ ]

of chemical storage tanks.
11. Do not exceed maximum allowed working pressure [ ] [ ]

on any equipment, pressure vessel or piping system.
12. Obtain confined space work permit prior to tank or [ ] [ ]

vessel entry.
13. Personal protective equipment head been identified [ ] [ ]

as required to safely operate and maintain this
system


MANUAL
14. Individuals shall be trained for proper selection and

appropriate use of PPE
SAFETY NOTES AND PRECAUTIONS FOR CHEMICAL

Regeneration equipment used in conjunction with the ion exchange vessels or tanks may contain
harmful chemicals and must be used with great caution.
1. The following recommendations are offered to assist the owner, ensuring the safety of all
personnel involved in operating and maintaining the equipment.
2. Ensure that safety eyewash and shower are operational and in close proximity to the
chemical equipment or necessary needed.
3. Ensure that all personnel have been instructed and trained on the safe operation and
maintenance of the equipment. Special attention must be given to the hazards of working
with acid and caustic solutions and to the repair and maintenance of piping, valves, pumps,
and instruments that handle these solutions.
4. Chemical protective clothing must be provided for all personnel working with or near acid and
caustic. As a minimum, pants, jackets, gloves, boots, goggles, and face shield should be
provided. This protective clothing MUST BE WORN by anyone doing maintenance work on
the regeneration skids or on pieces of equipment that may contain chemicals of any
description.
5. Ensure that everyone working with hazardous chemicals is aware of O.S.H.A. and the plant
safety requirements.
6. Never work in a hazardous area alone. Always have a partner immediately outside the
danger zone that will be available to render assistance should an accident occur.
7. Make sure that the chemical areas are extremely well lit and that access is not restricted.
8. Never assume that piping systems are empty. Wear protective clothing and attempt to drain
any system on which you are going to perform maintenance or repair.
9. Consider installing an alarm, which will be activated whenever the emergency eyewash or
shower is used. This alarm should be visible and audible and transmitted to an area that is
always manned.
10. IF YOU ARE UNSURE OR FEEL THAT YOU ARE NOT SUFFICIENTLY TRAINED – STOP!
DO NOT PROCEED -- ASK FOR ASSISTANCE. SAFETY IS EVERYONE'S
RESPONSIBILITY.
11. Areas that should be considered hazardous include but are not limited to the following:
• Working on acid pumps

• Working on caustic pumps
• Checking chemical strengths at the dilution stations even if hydrometer pots are
provided
• Filling the bulk tanks or the day tanks
• Cleaning chemical spills


MANUAL
• Calibrating metering pumps using suction side calibration cylinders or by Discharging

into a container
• Any maintenance of the regeneration piping systems
• Draining or purging the chemical piping
• Cleaning the residue powder/solution from inside of the bulk chemical tanks or from
the day tanks
• Cleaning the chemical pump suction strainers
• Dismantling the liquid ends of chemical metering pumps
• CDA supply piping.
12. Vessel or tanks Entry
• Before entering a vessel, have it checked for oxygen sufficiency.

• Never enter a vessel alone. Always have a partner outside the vessel to assist you if
you become incapacitated.
13. Ensure that everyone associated with the operation and maintenance of the water treatment
system is knowledgeable in the emergency actions to be taken in the event of an accident.
The following sections provide information on the regeneration chemicals. MSDS sheets
should be available for all chemicals in use in the water plant.
14. Vinstar (M) Sdn. Bhd. is most anxious to co-operate with customers in the interests of safety
and urges that they be contacted if there is any question about the condition, operation, or
maintenance of its equipment.
RESIN HAZARDS
The main medium used in ion exchange demineralizers is a copolymer of styrene and is hazardous
to the extent listed below.
1.1.1. TOXICOLOGICAL PROPERTIES (HEALTH HAZARDS)

1. NFPA Health Hazard: 1, Slightly hazardous
2. Route of Entry: Eye contact
3. Effect of Acute Exposure to Product: Can produce mechanical irritation to the eye. May cause
skin irritation of hypersensitive personnel.
4. Effect of Chronic Exposure to Product: Mechanical irritation to the eye and skin irritation to
hypersensitive personnel.
5. Exposure Limits: Not Applicable
6. Sensitization to Product: Not Applicable
7. Reproductive Toxicity: Not Applicable
8. Mutagenicity: Not Applicable
9. Irritancy of Product: Not Applicable
10. Carcinogenicity: Not Applicable
11. Teratogenicity: Not Applicable
12. Toxicologically Synergistic Products: Not Applicable
13. Symptoms of Exposure: Red irritated eyes, itching and feeling that a particle exists between the
eyelid and eye.
14. Medical Conditions Generally Aggravated by Exposure: Not Applicable


MANUAL
1.1.2. FIRST AID MEASURES

Flush eyes and skin with copious quantities of water for 15 minutes. If irritation persists, see a
Physician.
1.1.3. PREVENTIVE MEASURES

Protective Equipment: Wear impervious gloves and splash goggles while handling ion exchange
material. Long sleeve shirts and long trousers are recommended to prevent skin contact.
Specific Engineering Controls Required: Not Applicable
Work/Hygienic Practices: Flush product from hands with soapy water. Care should be taken to avoid
contact with eyes until hands have been completely cleaned. Product has a tendency to cling to skin
due to static charge. Care must be exercised to remove all product from skin. The product causes
areas to become extremely slippery when spilled and can cause falls. Sweep up spilled material and
transfer for proper Disposal. When transferring product to other containers via hydraulic (water)
slurry all safety practices established for use of water in the work space must be observed.
In Case of Spill or Leak: Sweep area of product collecting in a container for Disposal. Areas of spill
can become extremely slippery. All normal safety precautions should be observed.
Waste Disposal: New, unused product can be Disposed of an ordinary trash in accordance with all
federal, state, and local regulations. Used product must be tested for contamination by hazardous
material and Disposed of accordingly.
Handling Procedures and Equipment: No special handling is required beyond those outlined in this
Material Safety Data Sheet. Avoid packing product in an unprotected glass column. Expansion of
the product can cause the glass column to shatter.
Storage Requirements: Avoid freezing or prolonged storage above 50°C because products contain
water, which will freeze and damage product or dry out also damaging the product. Avoid contact
with strong oxidizing agents such as nitric acid.
Special Shipping Information: Avoid freezing


MANUAL
2. SYSTEM DESIGN BASIS

2.1. FEED WATER ANALYSIS
The following water analysis are expressed as the ion in mg/l unless otherwise indicated, represents the anticipated
water to be treated by the UPW Treatment System specified by this proposal.
Parameter Unit Value

pH 7.0 – 8.5
Conductivity µS/cm <1
Total Organic Carbon ppb < 100
Please take note that:

- Any changes to the above-mentioned parameter, may affect our system design, quoted price and warranty.
2.2. PRODUCT WATER SPECIFICATIONS

PRODUCT WATER QUALITY
The product water downstream of the DI system shall meet the below stated water quality:
Parameters Unit Value

On-line Resistivity at 25°C MΩ.cm >18
Particle Count on 0.2 µ filter counts < 50
(sampling 0.25 ml/min)
Temperature °C 24°C ± 1°
Bacteria CFU/100 ml <5
TOC ppb <20
PRODUCT WATER CAPACITY

The system design’s capacity is as per following:
Feed Capacity from Existing 2-pass RO System: 43 m3/hr

Treated Water Capacity from CEDI: 40 m3/hr
UPW Loop Capacity: 70 m3/hr
Operation for Treatment Plant: 24 hours/day
7 days/week
OPERATION HOURS
The design operation hours are 24 hours per day for 7 days a week.


MANUAL
3.0 OPERATIONAL REQUIREMENTS

This section provides the list of basic documents reference for operation and maintenance
3.1. PREREQUISITES
➢ Basic understanding of the System Process Flow.
➢ Basic understanding of valves.
➢ Basic understanding of Controls.
➢ Basic understanding of HMI.
➢ System walks through/Basic overview.
3.2. RESOURCES
➢ Sequence of Operation
➢ System Piping and Instrumentation Diagram
➢ Electrical Drawing Submittal.


MANUAL
4.0 START UP AND OPERATION

This section 4.0 provides necessary information to operate and maintain all the equipment in UPW Treatment
System, Basic Description of the Process Equipment, Troubleshooting and Preventive Maintenance Guideline.
DMT2 UPW system consist of 3 sub-system, which comprised of: -
(a) RO Water Transfer System

(b) CEDI System
(c) UPW Loop
4.1. RO WATER TRANSFER SYSTEM

OVERVIEW
The RO water transfer pumps (P-101A/B) are used to transfer RO Water from DMT-1 RO tanks to DMT-2 RO
Water Tank (TK-101A/B/C). The package has two pumps, one standby and one running in automatic mode. One
unit of RO transfer pump local control panel installed at DMT-1 UPW room for control of these 2 pumps. Interlocking
of DMT-1 RO tank level and DMT-2 RO tank level to control the pump start/stop.
Two unit of dry run sensor (FS-101A, FS-101B) are installed at 2 suction of 2 RO transfer pumps, once individual
dry run sensor alarm triggered, individual RO pump stop.
START-UP PROCEDURE
To start the RO Transfer pumps:
1. Fill the pump with water, to prevent pump cavitation during start up. (Refer Pump vendor’s operation
manual)
2. Fully open the valve on the suction side of the pump and close the discharge valve when starting the pump.
3. Turn on the local control panel isolator.
4. Select switch for RO Transfer pumps to “LOCAL” position on the control panel.
5. Slowly open the Discharge valve.
6. Release and discharge excess air of pump during start up to avoid air trap.
7. If the pump is not pressurized at once, stop it, and repeat the filling with liquid.
8. If the pump is pressurized, open the Discharge valve sufficiently to reach the duty point.
9. After the testing, turn RO Transfer Pumps to “Remote” position on the control panel, and “Auto” on HMI to
run in auto mode.
10. Function test each dry run sensor for each pump


MANUAL
Refer to Control Philosophy for operational sequence for control in automatic mode.
TROUBLESHOOTING AND PREVENTIVE MAINTENANCE

For the maintenance of RO Transfer Pumps, please refer their respective manufacturer manual.
Problem Possible Cause Remedy

Wrong electrical connection (3 Check the electrical connection and remedy,
phases) if necessary. Perform maintenance on foot
valve.
Wrong Direction of rotation. Interchange two phases in the electricity
supply. Clear air bubbles and re-prime pump.
Air in suction pipe. Vent the suction pipe or the pump and
replenish.
Set the duty point in accordance with the
Counter-pressure too high.
data sheet. Check the system for impurities.
The pump Increase the liquid level on the suction side.
delivers no or Completely open the isolating valve in the
Inlet pressure too low.
too little liquid. suction pipe. Make sure that all the
conditions in pipe work section are complied
with.
Suction pipe or impeller blocked Clean the pump.
by impurities.
Check the pipeline seals, pump housing
Pump draws in air due to
gaskets and shaft seals, and replace, if
defective seal.
necessary.
Pump draws in air due to low Increase the liquid level on the suction side
liquid level. and keep it as constant as possible.
Pump blocked by impurities. Clean the pump.
Pump runs over the Dimensioned Set the duty point in accordance with the
duty point. data sheet.
Motor starter Density or viscosity of the liquid is If less power suffices, reduce the flow on the
has tripped out. higher than specified when Discharge side or install a more powerful
Motor is ordering. motor.
overloaded. Check the setting of the motor starter and
Overload setting is incorrect.
replace, if necessary.
Check the electrical connections. Replace
The motor runs on 3 phases.
the fuse, if defective.
Increase the liquid level on the suction side.
Completely open the isolating valve in the
suction pipe. Make sure that all conditions in
pipe work section are complied with.
Pump makes Vent the suction pipe or the pump and
Air in suction pipe or pump.
too much noise. replenish.
Pump runs Counter-pressure is lower than Set the duty point in accordance with the
unevenly and specified. data sheet.
vibrates. Increase the liquid level on the suction side
Pump draws in air due to low
and keep it
liquid level.
as constant as possible.
Impeller out of balance (blocked
Clean and check the impeller.
impeller blades).


MANUAL
Inner parts worn. Replace defective parts.

Pump stressed by the pipe work Mount the pump so that it is not stressed.
(thus causing starting noise). Support the pipes.
Defective bearings. Replace bearings.
Defective motor fan. Replace the fan.
Defective coupling. Replace the coupling. Align the coupling.
Foreign bodies in the pump. Clean the pump.
Pump stressed by the pipe work
Mount the pump so that it is not stressed.
(thus causing leaks in the pump
Support the pipes.
housing or connections).
Leakage in
Defective pump housing gaskets
pump housing Replace the pump housing gaskets or
or gaskets
or in connection gaskets.
in connections.
connections.
Mechanical shaft seal dirty or
Leakage in Check and clean the mechanical shaft seal.
stuck together.
mechanical
Mechanical shaft seal defective. Replace the mechanical shaft seal.
shaft seal.
Leakage in Retighten the stuffing box, repair or replace
Stuffing box defective.
the stuffing
stuffing box.
Replace the shaft or the shaft sleeve.
Shaft surface or shaft sleeve
Replace the packing
defective.
in the stuffing box.
Vent the suction pipe or the pump and
replenish.
Inlet pressure too low. suction pipe. Make sure that all the
with
Too high Bearings lubricated with too little,
temperature in too much Replenish, reduce or replace the lubricant.
pump or motor. or unsuitable lubricant.
Pump with bearing seat stressed
Support the pipes. Check the alignment of
by the pipe work.
the coupling.
Check the relief holes of the impeller and the
The axial pressure is too high.
lock rings on the suction side.
Motor starter is defective or Check the setting of the motor starter and
setting is incorrect. replace, if necessary.


MANUAL
4.2. CEDI SYSTEM
4.2.1. OVERVIEW
Continuous Electro-Deionized System (CEDI) is used to produce high resistivity UPW water. Four unit of CEDI
module is designed for DMT-2 UPW system, with each module capable to produce 12.5M3/Hr of DI Water
CEDI System consist of following components and will explained in detailed on the start-up procedure for each
component.
(a) CEDI Feed Pump (P-102A/B)
(b) CEDI Module (CEDI A/B/C/D)
(c) RO tank pneumatic control diversion valve (CV-102)
(d) UPW tank pneumatic control diversion valve (CV-101)
The CEDI Feed pumps (P-102A/B) are used to transfer RO Water DMT-2 RO Water Tank (TK-101A/B/C) to CEDI
module. The package has two pumps, one standby and one running in automatic mode. CEDI feed pump can be
control from DMT-2 control panel and HMI.
CEDI Feed pump interlocked with RO Tank level (LIT-101A/B/C). In the condition of RO tank low level pump will
stop.
CEDI Feed pump speed (control by VFD) interlocked with quantity of CEDI module running.
If 4 EDI module is running, the EDI feed pump will auto run at 50 Hz to achieve operating flowrate of 44 m3/hr
If 1 EDI module is running, the EDI feed pump will auto run at 40 Hz to achieve operating flowrate of 18.5 m3/hr
If select EDI feed pump in Manual Mode in HMI, operator can manually adjust the pump speed. Minimum pump
speed: 35Hz
Two unit of dry run sensor (FS-102) are installed at 2 the suction of 2 CEDI pumps, once individual dry run sensor
alarm triggered, individual CEDI feed pump stop.
Two unit of pneumatic control diversion valve at the CEDI product line to divert CEDI product water from UPW and
RO Tanks. In the condition of CEDI product quality with low resistivity (< 15Mohm/cm) or UPW tank level
(LIT102A/B/C) high level, Diversion valve to RO Tank (CV-102) will open to divert water to recirculate to RO tank.
Alarm will be triggered if CEDI product quality drop below preset point.
In the condition of CEDI product quality higher then preset point (>15Mohm/cm) AND UPW tank (LIT102A/B/C) not
the high-level diversion valve to UPW tank (CV-101) will open to divert water to filled up UPW tank.
4.2.2. CEDI Feed Pump

START UP PROCEDURE
To start the CEDI Feed pumps:
1. Fill the pump with water, to prevent pump cavitation during start up. (Refer Pump vendor’s operation
manual)


MANUAL
2. Fully open the valve on the suction side of the pump and close the discharge valve when starting the pump.
4. Select switch for CEDI Feed Pump to “LOCAL” position on the control panel. Adjust the speed to 35 Hz
first, then increase speed to achieve design flow rate.
5. Slowly open the Discharge valve.
6. Release and discharge excess air of pump during start up to avoid air trap.
8. If the pump is pressurized, open the Discharge valve sufficiently to reach the duty point.
9. After the testing, turn CEDI Feed to “Remote” position on the control panel, and “Auto” on HMI to run in
auto mode.

For the maintenance of CEDI feed pumps, please refer their respective manufacturer manual.

valve.
Wrong Direction of rotation. Interchange two phases in the electricity
replenish.
with.
by impurities.
defective seal.
necessary.
Motor starter
Pump runs over the Dimensioned Set the duty point in accordance with the
has tripped out.
Motor is
Density or viscosity of the liquid is If less power suffices, reduce the flow on the
overloaded.
higher than specified when Discharge side or install a more powerful


MANUAL
ordering. motor.
Check the setting of the motor starter and
pipe work section are complied with.
replenish.
Counter-pressure is lower than Set the duty point in accordance with the
specified. data sheet.
Pump makes Increase the liquid level on the suction side
too much noise. Pump draws in air due to low
and keep it
Pump runs liquid level.
unevenly and
vibrates. Clean and check the impeller.
impeller blades).
Support the pipes.
housing or connections).
Leakage in Defective pump housing gaskets
pump housing Replace the pump housing gaskets or
or gaskets
or in connection gaskets.
in connections.
connections.
Mechanical shaft seal dirty or
Leakage in Check and clean the mechanical shaft seal.
stuck together.
mechanical
Mechanical shaft seal defective. Replace the mechanical shaft seal.
shaft seal.
Leakage in Retighten the stuffing box, repair or replace
stuffing box. the stuffing
Replace the shaft or the shaft sleeve.
Replace the packing
defective.
replenish.
Too high
with
temperature in
Bearings lubricated with too little,
pump or motor.
too much Replenish, reduce or replace the lubricant.
or unsuitable lubricant.
by the pipe work.
the coupling.
The axial pressure is too high. Check the relief holes of the impeller and the


MANUAL

VFD control Open the VFD control panel to ventilation
temperature too Ventilation fan not function Check the function of ventilation fan and
high replace if needed.
4.2.3 CEDI MODULE (CEDI-A/B/C/D)

INTRODUCTION
While both ion exchange and EDI use ion exchange resins, the removal mechanisms are quite different.
Conventional ion exchange utilizes chemically regenerated ion exchange resins which function in a capture
(exhaustion cycle) and discharge (regeneration cycle) mode. This results in a breakthrough of ions at the end of
the service cycle and a rinse out of regenerant at the beginning of the next service cycle. Capacity & selectivity are
most important resin properties in this mode of operation.
EDI (continuous electrodeionization) utilizes a reaction/transport mechanism to remove ions (through resin under
influence of DC field). This requires continuous path of like-charge resin beads. The transport is largely across the
surface of the resin beads. Transport through resin bead (particle diffusion) can be limiting.
OVERVIEW
The IONPURE® VNX-EP high flow module is designed with proven continuous electrodeionization (CEDI)
technology to produce high purity water. Proprietary Flexmount™ connectors create a support system for the
modules, which simplifies the systems design to reduce overall capital cost. The VNX-EP range provides ultrapure
water for critical boilers in the power industry and other bulk deionization high purity applications. Multiple VNX-EP
modules provide for simplified system design with flow rates up to, and greater than 1,000 gpm.
START UP PROCEDURE
1. Test Interlocks
(a) Test flow switches and other interlocks, including the RO interlock if applicable
(b) Test pressure relief if applicable
(c) Set alarm points
2. Startup of VNX Modules
(a) Make sure that modules are correctly connected to the DC power source.
(b) Make sure that the VNX product line is directed to drain.
(c) Turn on the feedwater. Adjust pump and/or valves to obtain the desired flows and pressures in the product
and reject streams. The reject flow is typically set at about 11% of the product flow (this gives a water
recovery of 90%)
(d) Valves are adjusted so the product outlet pressure is about 2 to 5 psig (0.1 to 0.3 bar) higher than the reject
outlet pressure at the desired flow rates.
(e) Adjust the DC power supply to the current setting determined in section 4.2.
(f) Test all flow switches and interlocks to ensure VNX DC power is shut off when flow is interrupted
(g) Continue to direct the product water to drain until it reaches the desired quality.
(h) Once product reaches the desired quality, connect to process. Readjust pressures as required to maintain
product outlet pressure 2 to 5 psi (0.1 to 0.3 bar) above the reject outlet pressure.
(i) Record operating data daily on suitable log sheet The CEDI system should achieve steady-state operation
in a few days,


MANUAL

PREVENTIVE MAINTENANCE
Perform the following tests at least once every six months.
• Check for any water leakage from the module. If leakage is observed, see the Troubleshooting subsection
for possible solutions.
• Periodically tighten all electrical connections
• Periodically check calibration of instrumentation
• Test function of critical interlocks such as low flow protection
TROUBLESHOOTING
The troubleshooting chart in this Section is a diagnostic guide. If the VNX system does not respond to the
recommended solutions, do not attempt further repairs. Call your Local Service Provider. Before calling:
Become thoroughly familiar with the module and all troubleshooting procedures.
Prepare a list of all problems encountered while operating the equipment.
Have your monitoring log sheets at hand.
Have your module’s model and serial numbers at hand. This information can be found on the module end plate on
the plumbing end
NOTE: Refer to manufacturer O&M for troubleshooting flow chart.
PROBLEM CAUSE SOLUTION

Module has loosened during
shipment, movement, or Contact Ionpure Technical support
Module leaks operation
Module is faulty Contact your Local Service Provider
Plumbing leaks Module adapters are loose Tighten adapters (See Figure 3-4)
Operating current too low or too Measure feed conductivity and CO2.
high Recalculate current according to Section
4 and adjust as necessary.
Poor water quality with DC
power ON Confirm correct DC+ and DC-
connections (check product and reject
Incorrect module electrical conductivity)
connection polarity Note: Incorrect polarity can cause
permanent damage
Module is fouled, scaled, or See Troubleshooting flow chart at the end

oxidized of this section.
Check if a downstream valve is

Obstruction downstream inadvertently closed.
Loss of flow and/or increase in
feed pressure
System is plugged with See Troubleshooting Flow Chart at the
particulate matter or fouled end of this section.


MANUAL
1. Check if an upstream valve is

inadvertently closed.
Loss of feed flow 2. Check for leaks or if an upstream bypass
valve is inadvertently open.
3. Check feed source output (for example, a
pump).


MANUAL
OPERATION
TYPICAL VNX MODULE LOG SHEET
Site Name: Module Serial Number:
DATE
TIME OF DAY
Feed water temperature °C
Feed water total hardness ppm

as CaCO3
Feed water total chlorine ppm
as Cl2
Feed water carbon dioxide ppm as
CO2
Feed water conductivity µS/cm
Product water resistivity MΩ-cm
DC potential volts
DC current amps
Module resistance (volts/amps) ohms
Product flow rate gpm (or m3/h)
Reject flow rate gpm (or m3/h)

Dilute inlet pressure psig
(or bar)
Dilute outlet pressure psig (or bar)
Product ΔP (Dilutein – Diluteout) psig

(or bar)
Concentrate inlet pressure psig
(or bar)
Concentrate outlet pressure psig
(or bar)
Concentrate ΔP (Concin - Concout) psig
(or bar)
COMMENTS:
Project: FIRST SOLAR DMT-2 UPW System Page 22


MANUAL
NOTE: Items in Bold must be recorded daily to maintain CEDI module warranty Good operating
data is critical to system troubleshooting
4.3 UPW Polishing Loop
4.3.1 OVERVIEW
UPW loop provide further treatment and polishing of CEDI product water in order to produce
UPW water quality with flow and pressure compliance with production floor requirement.
UPW loop consist of following components.

(a) UPW Tanks (TK-102 A/B/C)
(b) UPW Feed Pump (P-103 A/B/C)
(c) UPW Inline Booster Pump (P-104 A/B/C)
(d) UV Sterilizer (UV-101A/B)
(e) Heat Exchanger (HEX-101)
(f) Polishing Mixed Bed (MB-101A/B/C)
(g) Resin Trap (RT-101A/B/C)
(h) Final Filter (FLT-101A/B/C)
The UPW loop is design to have two UPW supply and return loop. Each of the UPW supply line is
equipped with individual flow sensor and isolation for flow control. Both loop of UPW water will
return to UPW Tanks.
UPW Feed pump (P103A/B/C) transfer water from UPW tank (TK102A/B/C) to UV Sterilizer, Heat
Exchanger, polishing mixed bed and resin trap, followed by UPW Inline Booster Pump
(P104A/B/C) to further increased supply pressure passing through the final filter before
production floor.
Water pass through two unit of UV sterilizer, UV radiation killed or damaging DNA of any
microorganisms or bacteria present in UPW.
Heat exchanger is used to regulate UPW to desirable temperature of 24C. An temperature

regulator valves is installed at the process chilled water pipe line to regulate the amount of chilled
water passing through heat exchanger.
Three unit of polishing mixed bed is located at the downstream of heat exchanger. Nuclear Grade
resin is use to further polished UPW water to quality of > 18mohm/cm. Resin trap is installed
down stream of mixed bed to trapped any resin escaped from going into UPW loop.
UPW feed pump and UPW Inline Booster Pump running frequency is controlled by Variable
Speed Controller (VFD) with pipe line pressure. PIT102A/B and PIT103A/B provide pressure
feedback to PLC and VFD hence increase or decrease running frequency until inline pressure is
matched.
Final Filter (FLT-101A/B/C) equipped with 0.1-micron absolute cartridge to filter off any possible
suspended solid or particle before supply to production floor.


MANUAL
4.3.2 UPW FEED PUMP (P103A/B/C)
The UPW water feed pump is used to transfer UPW water to the UPW polishing loop. The system
is designed in such a way that it has another make up or standby pump for each train to support
the system in case of pump failure. The pump is running in 2 running and 1 stand-by mode. Auto
changeover of pump for every 24 operating hours.
UPW Feed Pump and UPW Inline Booster Pump both design to run in 2 running 1 standby mode.
Timer for each running pump to changeover is 48 hours. Whenever the running pump stops
before the changeover time, pump will be changed to standby with the timer reset to 0. The other
pump which initially in Standby will start when there is request for pump to run signal. The timer
will count until the next changeover time.
Each UPW feed pump have installed 01 dry run sensor (FS-103A, FS-103B, FS103C). Once
individual dry run sensor alarm trigger, individual pump will stop.
Changeover sequence:
1. Changeover timer counter expire.

2. PLC will observe motor operating frequency of Duty pump and maintain the
pressure set point.
3. Standby pump will start until it matches the motor running frequency of the Duty
pump, while set point is still maintained by Duty Pump.
4. After a 30 seconds delay, and Duty/Standby share the same motor frequency,
Standby pump will takeover to maintain the pressure set point as Duty pump.
5. Initial Duty pump will ramp down to stop and standby for next changeover.
START UP PROCEDURE
To start the UPW feed pumps:
1. Fill the pump with water, to prevent pump cavitation during start up. (Refer Pump
vendor’s operation manual)
2. Fully open the valve on the suction side of the pump and close the discharge valve when
starting the pump.
4. Select switch for UPW feed pumps “LOCAL” position on the control panel.
5. Slowly open the discharge valve.
7. If the pump is pressurized, open the discharge valve sufficiently to reach the duty point.
8. Switch the pump to “REMOTE” on control panel and “AUTO” Mode on HMI to run in auto
mode after testing.


MANUAL
Refer to Control Philosophy for operational sequence.

For the maintenance of UPW feed pump, please refer their respective manufacturer manual.
valve.
Wrong direction of rotation. Interchange two phases in the electricity
replenish.
with.
by impurities.
defective seal.
necessary.
Pump runs over the dimensioned Set the duty point in accordance with the
has tripped out. higher than specified when discharge side or install a more powerful
Pump makes pipe work section are complied with.
too much noise. Vent the suction pipe or the pump and
Pump runs replenish.
unevenly and Counter-pressure is lower than Set the duty point in accordance with the
vibrates. specified. data sheet.
Increase the liquid level on the suction side
Pump draws in air due to low
and keep it
liquid level.


MANUAL

impeller blades).
Support the pipes.
Leakage in housing or connections).
pump housing Defective pump housing gaskets Replace the pump housing gaskets or
or in or gaskets in connections. connection gaskets.
connections. Mechanical shaft seal dirty or
Check and clean the mechanical shaft seal.
Leakage in stuck together.
mechanical Mechanical shaft seal defective. Replace the mechanical shaft seal.
shaft seal. Retighten the stuffing box, repair or replace
Leakage in the stuffing
stuffing box. Replace the shaft or the shaft sleeve.
Replace the packing
defective.
replenish.
with
Too high
temperature in Replenish, reduce or replace the lubricant.
too much or unsuitable lubricant.
pump or motor.
by the pipe work.
the coupling.


MANUAL
4.3.3 UV STERILIZER (UV101A/B)

The purpose of the Aquafine UV units is to disinfect the influent or effluent waters within the
system against bacterial, pathogenic, and parasitic blooms. The high wavelength ultraviolet rays
(254 nm) penetrate through the body of the organisms of concern, disrupting the synthesis of
RNA and DNA processes, thereby the organisms are made unable to reproduce.
The UV units that are used have 316L stainless steel housing with a quartz type lenses and bulb
generating a beam with a wavelength of 254 nm .
START UP PROCEDURE
Receiving
Inspect the containment chamber for fissures, cracks, chips, and dents. Check the equipment
type and size against the shipping documents and Aquafine documents.
Storage
These units are very delicate; be extra cautious in the transportation of the equipment form
location to location. Ensure that the unit is kept at ambient temperatures at all times.
NEVER open the closed unit unless you are a competent operating or maintenance technician
who is full trained on the Ultraviolet Equipment.
NEVER touch the element (ARC TUBE and QUARTZ LENSE) with you bare hand; always wear
protective gloves, i.e., lint free cotton gloves.
NEVER attempt to operate the unit outside the treatment chamber, since this will cause
damaging effects to both skin and eyes.
Arc-tubes shall be stored in their original packaging until required for use.


MANUAL
Start Up
Allow the unit to warm for 2 minutes to achieve full power; allow the unit to cool down before
commencing service work.
Avoid the ingress of water and dirt into the quartz chamber, as this will cause the burn out of the
equipment.
The equipment must be grounded by means of a suitable earthing conductor of adequate cross-
section: minimum of 4mm 2.
The operating units can contains ozone; in the event of ozone release, evacuate to a safe
distance of at least 100 yards and ventilate the facility. DO NOT attempt to reseal the chamber.
The ozone is a very volatile substance that in high concentration can be fatal to humans. The
equipment is labelled to identify this potential safety hazard.
Voltages in excess of 2000 volts may be present within the power supply cabinets and arc-tube
head, extra caution should be exercised when in the vicinity of the unit. All high voltage
capacitors within the power supply are fitted with discharge resistors to dissipate the charge, an
interval of one minute must be allowed between isolating and opening a cabinet containing the
power source for the UV-unit. The equipment is labelled to identify this potential safety hazard.
If the unit is dropped, never open the containment chamber; there is a risk of mercury poisoning.
Ensure that the equipment is properly labelled so to identify the potential safety hazard.
Old arc-tubes must be carefully re-packed and returned to the manufacturer for safe disposal;
mercury contamination is of concern.
Sequence of Procedure Comments

1. Select the UV unit to start.
2. Ensure water is flowing through the unit.
3. Ensure the UV inlet valve and the outlet
valve are open. Slowly open the inlet
valve after opening the outlet.
4. Ensure that the unit is flooded by venting
the outlet high point vent.
5. Allow water to flow through the unit for at This will ensure there are no
least one (1) hour prior to initiating power. leaks around the quartz
sleeve prior to energization.
6. Under normal operating conditions UV
units will operate when the DI system is in
service.


MANUAL
START UP PROCEDURE
PROBLEM CAUSE CORRECTION

UV Lamp(s) will not • Check input voltage if below or • Have a qualified electrician:
light above requirement • Install a voltage regulator
• Line cord disconnected or outlet • Check and replace
defective • Replace
• Defective UV Lamp • Check output voltage. Must
• Defective lamp ballast be 480v-580v across lamp
• Blown Fuse connections. If not, replace
• Loose open circuit wire ballast.
• Check fuses and
disconnect.
• Trace out and repair
Leak at Quartz • Defective or cracked 0-ring • Replace
Nipple • O-ring not seated properly
• Quartz jacket cracked
NOTE: For detailed Trouble Shooting please refer to the manufacturer’s data.
General Preventative Maintenance
The lamps should be replaced every 8,000 hours of operation or when the intensity falls below
60%.
4.3.4 HEAT EXCHANGER (HEX101)

A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to
another. The UPW water and PCW water is separated by a solid wall to prevent mixing. For
efficiency, heat exchangers are designed to maximize the surface area of the wall between the
two fluids, while minimizing resistance to fluid flow through the exchanger.
Temperature sensor located after hex exchanger outlet to monitor UPW supply temperature to
distribution loop. Signal will send to PLC and reading displayed at HMI. PLC then sends the
signal to PID temperature controller to be analyzed. PID temperature controller control PCW
valve opening percentage. Hence, achieved desirable temperature for DIW.
START UP PROCEDURE
1. Ensure temperature sensor & PID temperature controller functioning well
2. Ensure all DIW incoming and downstream isolation valve are in open position
3. Check the functioning of PCW supply valve controlled by PID temperature controller


MANUAL
4.3.5 NON-REGENERABLE POLISHING COLUMNS (MB101-A/B/C)

Ultra Pure Resin which consists of mixed cation exchange resin and anion exchange resin is
used in this UPW polishing loop. To obtain a higher degree of purity, water from MB system is
further demineralized by the Polishing Columns. In this last stage of treatment, the water passes
through a bed of thoroughly mixed cation and anion exchange resins which are ultra-pure resins.
START UP PROCEDURE
1. Ensure MB Flushing Valve are open
2. Slowly open the MB Inlet Valve to filled the column.
3. Release excess air in the column
4. Flush resin for 10 to 15 minutes to WWTP
5. Slowly open the MB Outlet valve and close flushing valve
6. Check product water resistivity on the outlet resistivity sensor
OPERATION DATA
Volumetric flow rate 23.3 m3/hr per column
Volume 750L of resin/per column
Resin UP6040
4.3.6 RESIN TRAP (RT101-A/B/C)

The resin trap filter is used for trap any escaped resin from the mixed bed column. The guard
filter will filter particles 1 micron an above.
Water enters the filter through an “inlet” and passes through the coarse screen that functions as a
“first stop” for rough particles. Water then reaches the fine screen, which further purifies the flow
by separating smaller particles from the water. As more water flows through, impurities build up
on the fine screen. As impurities on the screen accumulate, a pressure imbalance is built up
between the internal section of the fine screen and its external section.
When the Difference in pressure reaches the preset value on the Differential pressure indicator, a
series of events is triggered while water continuous to flow to the system units. Refer
manufacturer’s manual for cleaning and service maintenance.
START UP PROCEDURE
1. Make sure all isolation valves are opened.
2. Filter starts to function when feed flow in.

For the maintenance of trap filter, please refer their respective manufacturer manual. (Attached
documents)


MANUAL
4.3.7 UPW INLINE BOOSTER PUMP (P104A/B/C)
DIW booster pumps transfer water the UPW supply loop. Centrifugal pumps use rotational
velocity to create this pressure. Multistage centrifugal pumps perform this task with greater
energy efficiency.
The pump materials of construction must be compatible with the DIW water. Stainless steel 316
material is normally fine. The pump must be sized for the maximum usage possible at the
minimum pressure required by the equipment, with sufficient flow left over so as to create
turbulent conditions that will assist in reducing the biological activity on the pipe surfaces.
This DIW Booster pumps are equipped with variable speed drive. The pump is running in 2
running and 1 stand-by mode. Auto changeover of pump for every 24 operating hours.
1. Changeover timer counter expire.

2. PLC will observe motor operating frequency of Duty pump and maintain the
pressure set point.
START UP PROCEDURE
To start the UPW Inline Booster pumps:
1. Fill the pump with water, to prevent pump cavitation during start up. (Refer Pump
vendor’s operation manual)
2. Fully open the valve on the suction side of the pump and close the discharge
valve when starting the pump.
4. Select switch for UPW feed pumps “LOCAL” position on the control panel.
5. Slowly open the discharge valve.
7. If the pump is pressurized, open the discharge valve sufficiently to reach the duty
point.
8. Switch the pump to “REMOTE” on control panel and “AUTO” Mode on HMI to run
in auto mode after testing.


MANUAL
Refer to Control Philosophy for operational sequence.

For the maintenance of UPW Inline Booster pump, please refer their respective manufacturer
manual.
valve.
Wrong direction of rotation. Interchange two phases in the electricity
replenish.
with.
by impurities.
defective seal.
necessary.
Pump runs over the dimensioned Set the duty point in accordance with the
has tripped out. higher than specified when discharge side or install a more powerful
Pump makes suction pipe. Make sure that all conditions in
too much noise. pipe work section are complied with.
Pump runs Vent the suction pipe or the pump and
unevenly and replenish.
vibrates. Counter-pressure is lower than Set the duty point in accordance with the
specified. data sheet.


MANUAL
liquid level. and keep it

impeller blades).
Support the pipes.
Leakage in housing or connections).
pump housing Defective pump housing gaskets Replace the pump housing gaskets or
or in or gaskets in connections. connection gaskets.
connections. Mechanical shaft seal dirty or
Check and clean the mechanical shaft seal.
Leakage in stuck together.
mechanical Mechanical shaft seal defective. Replace the mechanical shaft seal.
shaft seal. Retighten the stuffing box, repair or replace
Leakage in the stuffing
stuffing box. Replace the shaft or the shaft sleeve.
Replace the packing
defective.
replenish.
with
Too high
temperature in Replenish, reduce or replace the lubricant.
too much or unsuitable lubricant.
pump or motor.
by the pipe work.
the coupling.


MANUAL
4.3.8 FINAL FILTER

Filtration is often used after UV units to remove living and dead bacteria, as well as particles that
may have originated in upstream equipment. Submicron filters will remove most of the bacteria
and particles.
UPW Final filter rating used in this supply loop is rated at 0.1 micron absolute accordingly. The
flow rate of the service water determines the length and number of filter elements required.
Filter elements are held between two plates inside the filter vessel. Water enters the vessel, flows
through the filter elements into the hollow core and collected by the lower filter element plate
before leaving the filter vessel.
Pressure drop across the cartridge filter system will determine the time for cartridge changing.
When the filter elements become clogged with impurities, the dirty filter elements are removed
and replaced by new elements. After the vessel is closed, service water is used to rinse the new
filter elements and remove any external dirt. Rinse water enters the vessel through the service
inlet and drains out through a drain valve at the bottom of the vessel.
Final filter should be replaced at least once a year, or when the pressure differential across the
filters exceeds 10 psi.
START UP PROCEDURE
Before installing/changing the filter, please check the followings:

1. Do not use cover lifting device unless filter housing is firmly anchored and pipe in place
2. Ensure that inlet and outlet connections are properly identified to prevent reverse hookup.
Clean and sludge chamber drains are provided at the bottom of the filter vessel and
should be accessible for drainage.
3. Ensure that the proper type and quantity of filter elements are on site
CARTRIDGE CHANGEOUT
1. Close inlet valve to the housing which need to change/install the filter elements.
2. Wait for 2 – 3 minutes, then close the outlet valve of the housing which need to
change/install the filter elements
3. Open drain valve located at the side of filter vessel to drain remaining water inside filter
housing.
4. Open vent valve to break vacuum so that the housing can drain thoroughly
5. Remove clamp of the selected housing, raise top cover to open
6. Remove hold down plate from the top of the filter cartridges
7. Remove dirty (spent filter cartridges)
8. Check seal assemblies for damage, replace if necessary
9. Examine the pedestals at bottom of housing for damage
10. Install new filter cartridges
11. Re-install the seal assemblies on each filter cartridge
12. Re-place the filter housing top cover
13. Tighten clamp until o-ring is fully compressed
14. Close the drain valve on the selected vessel


MANUAL
15. Follow step of filter housing start-up

HOUSING START UP
1. Ensure vent valve is opened to purge out air from filter housing
2. Partially open service inlet valve to fill up the housing slowly. This is to eliminate shock on
the filter element
3. Wait 3 to 4 minutes for cartridge to soak and air within cartridge ventilated through the
vent valve located on top of housing
4. Close vent valve when water flow out from vent valve. Air has been removed from filter
housing
5. Open the drain valve on the selected filter vessel
6. Fully open the service inlet valve
7. Rinse the new filter cartridges thoroughly until there is no sign of bubble in the rinse water
drained out from drain valve.
8. Open service outlet valve slowly to fully open position. Slow and gradual opening will
prevents sudden pressure drop.
9. Now the filter is fully on-line. Verify there are no water leaks from filter housing.


MANUAL
5.0 ELECTRICAL CONTROL PANEL
• Quantity : 1 no of control panel and 1 no of PLC panel
• Accessories : c/w electrical wiring, system
Interlocking, PLC and HMI
Control panels shall be equipped with all motor starters, HMI for flowmeter, resistivity
monitors, level switch interface, selector switches. It shall also come with pumps auto/manual
control, indicator lights, relays, circuit breakers and safety cut-off c/w light indication. All
proper control of the whole system, switches and indicators shall be clearly labeled and
arranged to facilitate ease of operation.

OPERATION & MAINTENANCE Rev : Date : 01 March

MANUAL 2 2019
6.0 SYSTEM SEQUENCE CONTROL
Power supply from upstream received by UPW Main Control Panel located at DMT02 before
distributed to pumps, equipment & instrument, local control panel, main PLC panel, remote IO panel
and VFD panel.
6.1 General Control Philosophy
6.1.1 Pump Controls
Motor starters for pumps are housed in the Main Control Panel which located at DMT02. At the Main
control panel, that’s a LOCAL/OFF/REMOTE selector switch. Pumps can be operated in Remote
(Auto) mode or Local (Manual) mode by changing the Off-Remote-Local hand switch at Main Control
Panel.
When the pump is set in Auto (Remote) mode, the pump operation is commanded by PLC and HMI
- On starting of the pump, the PLC program checks the run feedback signal, if the run signal is
not received within five seconds of start command then the pump is displayed as Fail to Run
mode at HMI.
- Pump is displayed as (Run) at HMI when pump is running
- Pump is displayed as (Stop) at HMI when pump is stop
- Pump can be manual override at HMI to Start / Stop the pump
- When manual override at HMI to Start the pump but the pump cannot be started, it is
displayed as Fail to Start mode at HMI
- When manual override at HMI to Stop the pump but the pump cannot be stopped, it is
displayed as Fail to Stop mode at HMI
- When the running pump is trip, trip signal received by PLC and pump is displayed as (Trip) at
HMI.
- When running pump is tripped, it is auto changeover to initiate the standby pump to run.
- If pump trip due to current overload at MCC, pump can be reset by switching the hand switch
Off, then Remote position. PLC will initiate Auto start up.
- If pump trip due to power supply failure, the pump is reset by PLC when power supply is
available. PLC will initiate Auto start up.
- If pump trip due to process parameter control (such as low suction pressure, dry run alarm),
operator needs to acknowledge alarm and reset the pump at HMI. PLC will initiate Auto start
up.
- Pump changeover from Duty to Standby and vice versa at a pre-set time. In case pre-set
time is reached when unit operation is running, changeover pump will be postponed to take
place at the next unit operation start up, except UPW Feed Pump and UPW Inline Booster
Pump changeover sequence will be elaborated in Section 1.4.
- For all failure mode and trip mode, operator needs to acknowledge alarm and reset the pump
to Auto at HMI after investigating the failure cause.

MANUAL 2 2019
- Pump status will also be displayed by pilot light at Main control panel: green for run, red for
stop, amber for trip.
When the pump is set in Manual (Local) mode, the operator has full control of the pump. The pump
can only be start/stop using the local ON/OFF switch regardless of the startup sequence and
interlocking.
To start a pump, either in Remote or Manual, Switch the local ON/OFF switch to “ON”. To stop the
pump, switch the local ON/OFF switch to “OFF”.
6.1.2 Pumps Variable Frequency Drive (VFD ) Control
Pumps VFD is controlled by mean of Pressure Indicator Transmitter (PIT).
Pressure Indicator Transmitter (PIT) send the pressure reading to Remote IO Panel or Main PLC.
PLC send the pressure reading to Pumps VFD which set in Auto (remote) mode. VFD analyzed
reading and send signal to control pumps operating frequency.
When the pump is set in Manual (Local) at Main control panel, the operator has full control of the
pump. The pump can only be start/stop using the local ON/OFF switch regardless of the startup
sequence, VFD setting and interlocking.
For unit operations with PIT in redundancy, average pressure reading is taken for VFD control.
6.1.3 Tank Level Controls
Tank level is controlled by mean of Level Indicator Transmitter.
Tank level indicator transmitter sends the tank levels to PLC. PLC and HMI command the equipment
which is set in Auto (remote) mode in operation to maintain the tank levels, namely RO Water Tank
level and UPW Tank level. Tank level set points are set at HMI for:
- Low Low Level to cut off running pump

- High Level to turn off inlet valve or/and upstream system operation
- High High Level Alarm
- Each level set point with deadband
For unit operations with tanks in redundancy, level sensor reading for tank on “DUTY” mode are
taken for PLC control.
Hydrostatic Level Sensor reading is taken for PLC control and alarm. Ultrasonic Level Sensor
reading is taken for alarm.

MANUAL 2 2019
6.1.4 EDI Controls Power supply received by EDI Rectifier Panel from Main Control Panel
before distribute to EDI module. One set of LOCAL/OFF/REMOTE selector switch located at
UPW main control panel. There’s another set of ON/OFF selector switch located at EDI
Rectifier Panel as Local Switch.
Interlocking of EDI Pumps and EDI Product Flow Switch control the ON/OFF of EDI units.
In the condition when one unit of EDI product flow switch alarm triggered, EDI rectifier for the
individual unit will automatically off.
CEDI Feed pump speed (control by VFD) interlocked with quantity of CEDI module running in
Remote mode.
If 4 EDI module is running, the EDI feed pump will auto run at 50 Hz to achieve operating flowrate of
44 m3/hr
33 m3/hr
22 m3/hr
18.5 m3/hr
If select EDI feed pump in Manual Mode in HMI, operator can manually adjust the pump speed.
Minimum pump speed: 35Hz
Two unit of dry run sensor (FS-102) are installed at 2 the suction of 2 CEDI pumps, once individual
dry run sensor alarm triggered, individual CEDI feed pump stop.
6.2 UV Sterilizer Controls
Power supply distribute to UV Sterilizer from UPW main control panel. LOCAL/OFF/REMOTE
selector switch at the UPW main control panel, and AUTO/MANUAL button on HMI. Two unit of UV
sterilizer interlock with UPW Feed Pump (P-103A/B/C). IF UPW Feed pump Stop, UV will stop
automatically. Under condition when UPW Feed Pump start and run, UV will run automatically.
6.3 Pump Auto Changeover for UPW Feed Pump & UPW Inline Booster Pump
UPW Feed Pump and UPW Inline Booster Pump both design to run in 2 running 1 standby mode.
Timer for each running pump to changeover is 48 hours. Whenever the running pump stops before
the changeover time, pump will be changed to standby with the timer reset to 0. The other pump
which initially in Standby will start when there is request for pump to run signal. The timer will count
until the next changeover time.

MANUAL 2 2019
1. Changeover timer counter expire. PLC will observe motor operating frequency of
Duty pump and maintain the pressure set point.
6.4 Alarms
Table below shows the general action required for alarm:
No Description HMI & Main Control Panel
1 Pump fail to run alarm (for 3 phase Acknowledge Alarm

pump and 1 phase pump) Reset Pump
2 Pump fail to stop alarm (for 3 phase Acknowledge Alarm
pump and 1 phase pump) Reset Pump
3 Pump trip alarm (for 3 phase pump Acknowledge Alarm
only) Reset pump
4 Analogue Instrument for monitoring Acknowledge Alarm
(4-20mA) setpoint alarm Reset pump
(Flow, Tank Level, Pressure,
Resistivity, Temperature, TOC, Na)
instrument set point only activate when the upstream unit operation is running.
6.5 Control and Operation - RO Transfer System

Control of RO transfer system involves DMT-2 UPW Main Control Panel, RO Transfer
System local control panel and HMI.
Equipment and Instrument List for RO Transfer System
Equipment/Instruments Tagging Type Running Mode
RO Transfer Pump P-101A/B Pump 1 running, 1 standby

DMT-2 RO Tank Level Sensor LIT-101A/B Hydrostatic Level All reading in HMI, PLC
sensor control with “DUTY” mode
tank level sensor
RO Transfer Pump Dry Run FS-101A, Dry Run Sensor
Sensor FS101B
RO Transfer Pump Flow FIT-101 Flow Sensor Reading show on HMI
Sensor and Totalizer

MANUAL 2 2019
Interlocking control are summarize as following
Equipment Interlock with Condition Auto Response Alarm

RO Transfer DMT-1 RO Tank DMT-1 RO RO Transfer NIL
Pump (P- Level Tank Low Level Pump Stop
101A/B)
DMT-2 RO Tank DMT-2 RO RO Transfer NIL
Level (LIT-101A/B) Tank Level (LIT- Pump Stop
101A/B) Pre-set
High Level
DMT-2 RO RO Transfer Acknowledge Alarm
Tank Level (LIT- Pump Start
101A/B) pre-set
Pump start level
RO Transfer Pump Dry run sensor RO Transfer Acknowledge

Suction Dry Run (FS101A, FS- Pump Stop Alarm, Troubleshoot
Sensor (FS-101A, 101B) triggered and restart pump
FS-101B)
Operating Control Procedure
1. Make sure all pumps, equipment, instruments interlocking is tested and start-up accordingly.
2. Make sure all normally valves are in open position.
3. On DMT-2 HMI, Set the pre-set pump start and pump stop level of DMT-2 RO Tank (LIT-
101A/B)
4. On DMT-2 HMI, Set the HH and LL alarm level of DMT-2 RO Tank (LIT-101A/B).
5. Select the “DUTY” tank on HMI , PLC will control accordingly to “DUTY” tank level.
6. Switch RO Transfer Pump DMT-2 RO Transfer System to “REMOTE” mode on Local Control
Panel
7. On DMT-2 HMI Pump Page, switch RO Transfer Pump P-101A/B to “AUTO”
8. RO Transfer Pump P-101A/B will run in auto mode accordingly to system interlocking.
6.6 Control and Operation - CEDI System
Control of CEDI system involves DMT-2 UPW Main Control Panel, CEDI Rectifier Panel and
HMI.
Equipment and Instrument List for CEDI System


MANUAL 2 2019
Equipment/Instruments Tagging Type Running Mode
CEDI Feed Pump P-102A/B Pump 1 running, 1 standby

CEDI Module CEDI-A/B/C/D CEDI 4 running
DMT-2 RO Tank Level LIT-101A/B Hydrostatic All reading in HMI, PLC control with
Sensor Level sensor “DUTY” mode tank level sensor
UPW Tank Level Sensor LIT-102A/B/C Hydrostatic All reading in HMI, PLC control with
Level sensor “DUTY” mode tank level sensor
CEDI Feed Pump Dry FS102A, Dry Run
Run Sensor FS102B Sensor
CEDI Feed Flow Sensor FIT-102A Flow Sensor Reading show on HMI and local
and Totalizer display
CEDI Product Flow FIT-102B Flow Sensor Reading show on HMI and local
Sensor and Totalizer display
CEDI Feed Resistivity RS-101A Resistivity Reading show on HMI and local
Sensor Sensor display
CEDI Product Resistivity RS-101B Resistivity Reading show on HMI and local
Sensor Sensor display
CEDI Sampling Point RS-101C Resistivity Reading show on HMI and local
Resistivity Sensor Sensor display
CV-101 Pneumatic
CEDI Product Diversion Control Valve
Valve (UPW Tank)
CEDI Product Diversion CV102 Pneumatic
Valve (RO Tank) Control Valve
CEDI Feed Pump RO Water Tank LIT-101A/B CEDI Feed Pump Acknowledge
(P-102A/B) Level Intermediate Level Run Alarm,
(LIT-101A/B) Troubleshoot
and restart
pump
LIT-101A/B Low CEDI Feed Pump Acknowledge
Level Stop Alarm,
Troubleshoot
and restart

MANUAL 2 2019
pump
CEDI Pump FS-102A, FS 102B CEDI Feed Pump Acknowledge

Suction Dry Run Triggered Stop Alarm,
Sensor (FS-102A, Troubleshoot
FS-102B) and restart
pump
CEDI Rectifier CEDI Module flow FS-104A Respective Acknowledge
(CEDI-A/B/C/D) switch Or Rectifier Stop Alarm,
(FS-104A/B/C/D) FS-104B Troubleshoot
Or and restart
FS-104C
Or
FS-104D
Triggered
CEDI PRODUCT CEDI Product RS-101B CV-102 Open & Acknowledge

DIVERSION Resistivity Sensor Triggered low CV-101 Close Alarm
VALVE- UPW (RS-101B) resistivity alarm
Tank (CV-101) &
CEDI PRODUCT
DIVERSION UPW Water Tank LIT-102A/B/C High CV-102 Open &
VALVE- RO Tank Level level CV-101 Close
CV-102) (LIT-102A/B/C)
UPW Water Tank LIT-102A/B/C CV-101 Open &

Level Intermediate level CV-102 Close
(LIT-102A/B/C)
3. On DMT-2 HMI, Set the pre-set pump start and pump stop level of DMT-2 RO Tank (LIT-
101A/B) & UPW Tank (LIT-102A/B/C)
4. On DMT-2 HMI, Set the HH and LL alarm level of DMT-2 RO Tank (LIT-101A/B) & UPW Tank
(LIT-102A/B/C)
6. Switch following on DMT-2 RO Transfer System to “REMOTE” mode on Local Control Panel
(b) CEDI Module (CEDI-A/B/C/D)
(c) CEDI Product Diversion Valve (CV-101 & CV-102)

MANUAL 2 2019
7. On DMT-2 HMI, switch following to “AUTO”

(b) CEDI Module (CEDI-A/B/C/D)
(c) CEDI Product Diversion Valve (CV-101 & CV-102)
8. CEDI System will run in auto mode accordingly to system interlocking.
6.7 Control and Operation – UPW Supply Loop System
Control of UPW Supply Loop system involves DMT-2 UPW Main Control Panel, and HMI.
Equipment and Instrument List for CEDI System
Equipment/Instruments Tagging Type Running

Mode
UPW Tank Level Sensor LIT-102A/B/C Hydrostatic Level All reading in HMI,
sensor PLC control with
“DUTY” mode tank
level sensor
UPW Feed Pump P-103A/B/C Pump 2 running 1 standby
UPW Booster Pump P-104A/B/C Pump 2 running 1 standby
UV Sterilizer UV-101A/B UV 2 running
Heat Exchanger HEX-101 1 running
Polishing Mixed Bed MB-101A/B/C 3 running
Resin Trap RT-101A/B/C Filter Housing 3 running
Final Filter FLT-101A/B/C Filter Housing 3 running
UPW Feed Pump Dry Run FS-103 Sensor

Sensor
UPW Booster Pump Low LPS-101 Sensor
Pressure Switch
UPW Feed Pump Pressure PIT-101A/B Sensor Reading show on

Sensor HMI and local display
UPW Booster Pump Pressure PIT-102A/B Sensor Reading show on
Polishing Mixed Bed Feed RS-102 Sensor Reading show on
Resistivity HMI and local display

MANUAL 2 2019
Polishing Mixed Bed Product RS-103 Sensor Reading show on

UPW Loop Point of Supply RS-104 Sensor Reading show on
HEX Outlet Temperature TIT-101 Sensor Reading show on
HEX Temperature Regulating CV-103 Regulating
Valve Valve
UPW Loop Point of Supply TIT-102 Sensor
Temperature Sensor
TOC Analyzer TOC-101 Analyzer Reading show on
HMI and local display
Sodium Analyzer NA-101 Analyzer Reading show on
UPW Supply Loop 1 Flow FIT-106A Sensor Reading show on
UPW Supply Loop 2 Flow FIT-106B Sensor Reading show on
UPW Return Flow FIT-105 Sensor Reading show on
N2 Blanketing System N2- Sensor and
101/102/103 Analyzer
UPW Feed Pump UPW Tank Level LIT102A/B/C UPW Feed Pump Acknowledge
(P-103A/B/C) (LIT-102A/B/C) low level Stop Alarm,
Troubleshoot
LIT102A/B/C UPW Feed Pump
Intermediate Run
level
UV Sterilizer (UV- UPW Feed UV Sterilizer Stop
101A/B) Pump Stop
UPW Inline UPW Feed UPW Inline

Booster Pump (P- Pump Stop Booster Stop
104A/B/C)

MANUAL 2 2019
HEX Temperature HEX Outlet Temperature - CV-103 auto

Regulating Valve Temperature Set Point open/close to
(CV-103) Sensor (TIT-101) regulate UPW
temperature
CDA Pressure PLC CDA -alarm set Reading show in
(CDA-101) point HMI. Alarm
trigger as per re-
set point
3. On DMT-2 HMI, Set the pre-set pump start and pump stop level of UPW Tank (LIT-
102A/B/C)
4. On DMT-2 HMI, Set the HH and LL alarm level of UPW Tank (LIT-102A/B/C)
6. Switch following on DMT-2 RO Transfer System to “REMOTE” mode on Local Control Panel
a. UPW Feed Pump (P-103A/B/C)
b. UPW Inline Booster Pump (P-103A/B/C)
c. UV Sterilizer (UV-101A/B)
7. On DMT-2 HMI, switch following to “AUTO”
a. UPW Feed Pump (P-103A/B/C)
b. UPW Inline Booster Pump (P-103A/B/C)
c. UV Sterilizer (UV-101A/B)
8. UPW Supply Loop System will run in auto mode accordingly to system interlocking.

MANUAL 2 2019
7.0
SEQUENCE
OF
OPERATION
(SOO)

MANUAL 2 2019

MANUAL 2 2019
FIGURE 1 -RO PERMEATE PUMP AUTO SEQUENCE OF OPERATION
All Panel Power On
All Selector Switch in

Remote mode
Check DMT-02 RO
Check Existing DMT-
Permeate Tank level
01 RO Permeate
Tank level
Level ≥ High Level = Level = Level = Low

Level setting Intermediate Intermediate Level setting
Level setting Level setting
Time delay: 10secs Time delay: 10secs

Time delay: 15 secs
RO Permeate pump Alarm
stop RO Permeate pump
start
RO Permeate pump
stop
Acknowledge
Alarm &
Troubleshoot

MANUAL 2 2019
FIGURE 2 - EDI SYSTEM AUTO SEQUENCE OF OPERATION
All Panel Power On

Remote mode
Check RO
Permeate Tank DIW Tank Level Check EDI Product
level Resistivity
Acknowledge Level = Low Level > Low

Alarm & Level setting Level setting
Troubleshoot Level < High EDI Product
Level setting Level = High EDI Product
Level setting Resistivity < Resistivity >
Low set point Low set point
Time delay: 10 secs
EDI system stop Alarm

operation
EDI Diversion Valve

to RO Permeate Tank
Acknowledge Open
Alarm &
Troubleshoot EDI Feed Pump Start
Time delay: 15 secs
No Time delay: 15 secs

EDI Tank Pneumatic Valve
Individual Fully Closed
EDI stalk stop operation
EDI Tank Pneumatic
Low Flow Low Flow Valve
Alarm Not OK Low Flow Low Flow Not 4OK
Switch 1 Switch 2 Switch 3 Switch
deactivated? deactivated? deactivated? deactivated?
Time delay: 15 secs

OK OK OK OK
Time Delay: 15 secs Time Delay: 15 secs Time Delay: 15 secs Time Delay: 15 secs
EDI Diversion Valve
Start Rectifier EDI 1 Start Rectifier EDI 2 Start Rectifier EDI 3 Start Rectifier EDI 4
to RO Permeate Tank
Closed
Rectifier Rectifier Rectifier Rectifier

Yes operating operating operating operating
Alarm current higher current higher current higher current higher
than High set than High set than High set than High set
point? point? point? point?
No
Time Delay: 60 secs Acknowledge
Alarm &
Troubleshoot
No Alarm
EDI Product Resistivity
higher than Low set point?
Yes
EDI Feed Flowrate higher No Alarm

than Low set point?
Yes
EDI Product Flowrate higher No Alarm

than Low set point?
Yes
EDI system continue to

run

MANUAL 2 2019
FIGURE 3 - UPW LOOP AUTO SEQUENCE OF OPERATION
All Panel Power On
Acknowledge
Alarm &
Remote mode
Troubleshoot
Not OK.
DIW Tank Level Time delay: 10 secs
> Low Level Alarm DIW loop stop
setting? operation
OK
Time Delay: 15secs
UV Sterilizer unit Start UPW Feed Pump Start
Time Delay :10 sec

Not OK Alarm Acknowledge
Alarm &
UPW Inline Booster Pump Low Pressure Troubleshoot
Switch
UV Sterilizer unit Stop

OK
UPW Inline Booster Pump

Start
UPW Feed Pump Stop
Time Delay: 15secs
Time delay: 10 secs
Not OK
Low Pressure Switch Alarm UPW Inline Booster
OK? pump stop operation
OK
Time Delay: 180secs
UPW Feed Pump Pressure Acknowledge

No Alarm Alarm &
Troubleshoot
Yes
UPW Inline Booster Pump

No Alarm
pressure higher than Low
set point?
Yes
UPW Supply flowrate

No Alarm
Yes
UPW Return flowrate higher

No Alarm
than low set point?
Yes
UPW Supply resistivity

No Alarm
Yes
UPW Supply TOC lower

No Alarm
than High set point?
Yes
UPW Supply Temperature No Alarm

within set point range?
Yes
DI system continue to
run

MANUAL 2 2019
ANNEX 1
AS-BUILT DRAWING

MANUAL 2 2019
ANNEX 2
SPARE PART LIST

MANUAL 2 2019
ANNEX 3
PASSWORD LIST
CONTROL SET POINT

MANUAL 2 2019
ANNEX 4
TESTING & COMMISIONING
REPORT

MANUAL 2 2019
Annex 5
INSTRUMENTS
CERTIFICATE

MANUAL 2 2019
Annex 6
EQUIPMENT / INSTRUMENTS
MANUFCATURE O&M

DMT-2 UPW O&M-Rev0 - 2 - 14032019

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OPERATION MANUAL

70 m3/hr UPW WATER SYSTEM

FIRST SOLAR VIETNAM DMT2

VINSTAR (M) SDN. BHD.

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

Back to Table of Content Page 2 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

BEING A SUPPLIER OF EQUIPMENT WHICH, IF OPERATED IMPROPERLY,

BY READING THIS MANUAL AND UNDERSTANDING THE RISKS AND

IF YOU HAVE ANY QUESTIONS ON PROCEDURES SUGGESTED OR

WE TAKE YOUR SAFETY SERIOUSLY!

Back to Table of Content Page 3 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

1. PERSONNEL SAFETY INFORMATION

SAFETY NOTES AND PRECAUTIONS

Back to Table of Content Page 4 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

VESSEL OR TANK ENTRY

Use a rope ladder to climb in and out of a vessel.

Never smoke or allow anyone to smoke while inside a vessel.

Do not leave the vessel open when no one is working inside.

Back to Table of Content Page 5 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

Safety showers must be kept in good working order.

Regularly inspect terminations for tightness and proper connection.

Allow only qualified electrical personnel to troubleshoot or repair electrical system.

REMEMBER: "ELECTRICITY IS A GREAT SERVANT AND A DEADLY MASTER".

Back to Table of Content Page 6 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

No. Description Owner Initial Operation &

1. Check operation of all safety showers and eyewash [ ] [ ]

2. Post phone numbers of all emergency services in a [ ] [ ]

3. Ensure that all operators of this equipment are [ ] [ ]

5. Check that all pumps/valves and starters are [ ] [ ]

6. Ensure proper access and adequate lighting around [ ] [ ]

7. Supply all required acid/caustic protective gear (full- [ ] [ ]

9. Provide adequate ventilation where necessary. [ ] [ ]

10. Keep up to date records of operation including levels [ ] [ ]

11. Do not exceed maximum allowed working pressure [ ] [ ]

12. Obtain confined space work permit prior to tank or [ ] [ ]

13. Personal protective equipment head been identified [ ] [ ]

Back to Table of Content Page 7 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

14. Individuals shall be trained for proper selection and

SAFETY NOTES AND PRECAUTIONS FOR CHEMICAL

• Working on acid pumps

Back to Table of Content Page 8 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

• Calibrating metering pumps using suction side calibration cylinders or by Discharging

12. Vessel or tanks Entry

• Before entering a vessel, have it checked for oxygen sufficiency.

1.1.1. TOXICOLOGICAL PROPERTIES (HEALTH HAZARDS)

Back to Table of Content Page 9 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

1.1.2. FIRST AID MEASURES

1.1.3. PREVENTIVE MEASURES

Specific Engineering Controls Required: Not Applicable

Special Shipping Information: Avoid freezing

Back to Table of Content Page 10 of 57

OPERATION & MAINTENANCE Rev : 2 Date : 01 March 2019

2. SYSTEM DESIGN BASIS

Parameter Unit Value