MUK-62-MGT-AIC-09004 Rev A WTP Install. & Erec. Proc. 110314

ERECTION AND INSTALLATION MANUAL
WATER TREATMENT PLANT – PHASE 2
PROJECT DOCUMENT NO:

MUK-62-MGT-AIC-09004
ERECTION AND INSTALLATION PROCEDURE

WATER TREATMENT PLANT - PHASE 2
OCCIDENTAL MUKHAIZNA LLC

MUKHAIZNA FACILITIES DEVELOPMENT
DOCUMENT REVISION HISTORY

Rev Date Remarks Originated by Checked by Approved by
A 1/7/2011 First Issue DMH SJG DSR
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Rev A
WTP Erection and Installation Procedure
WATER TREATMENT PLANT PHASE 2
TABLE OF CONTENTS
1. HEALTH AND SAFETY
1.1 TYPICAL STANDARDS UTILIZED

1.2 GENERAL PLANT SAFETY PROVISIONS
1.3 STORAGE AND HANDLING OF WATER TREATMENT CHEMICALS
1.4 SPILLS AND LEAKAGES
1.5 FIRST AID
1.6 CONTACT WITH THE EYES
1.7 ELECTRICAL SAFETY
1.8 CONCLUSION
2. MATERIAL RECEIPT AND STORAGE
2.1 TOOLS REQUIRED

2.2 INSPECTION OF MATERIALS RECEIVED
2.3 HANDLING AND STORAGE REQUIREMENTS
2.4 STORAGE AND PRESERVATION PROCEDURES
A. EPOXY LINED VESSELS
B. PIPING
C. VALVES
D. PUMPS AND FACE PIPING SKIDS
E. ELECTRIC MOTORS
F. LOCAL JUNCTIION/SOLENOID BOXES
G. BOXES/CARTONS/CRATES
H. WALNUT SHELL MEDIA, MIXED BED MEDIA AND CATION RESINS
I. STEEL PLATES
2.5 UNLOADING, LIFTING, RIGGING AND INSTALLATION REQUIREMENTS AND
INSTRUCTIONS
3. GENERAL INSTALLATION INSTRUCTIONS
3.1 MECHANICAL EQUIPMENT LIST

3.2 INSTALLATION SEQUENCE
3.3 INSTALLATION PROCEDURE
4. MECHANICAL INSTALLATION
4.1 INSTALLATION OF MAJOR EQUIPMENT

4.2 PROCEDURES FOR INSTALLATION OF MAJOR EQUIPMENT
A. TOOLS REQUIRED
B. FACE PIPING SKIDS
C. PUMP SKIDS
D. VESSELS AND PRESSURE VESSELS
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E. CHEMICAL STORAGE TANKS AND ATMOSPHERIC TANKS

F. FIELD CONSTRUCTED VESSELS
5. INSTALLATION OF INTERCONNECTING PIPING
5.1 PIPE FITTING TOOLS REQUIRED

5.2 PIPING
A. METALLIC PIPING
B. PLASTIC PIPING
5.3 INSPECTION AND TESTING OF PIPING
5.4 FLUSHING OF PIPE LINES
5.5 INSTALLATION OF TUBING
5.6 INSTALLATION OF PIPE SUPPORTS
6. MEDIA AND RESIN LOADING PROCEDURE
6.1 STRAINER NOZZLES

6.2 WALNUT SHELL AND MEDIA LOADING PROCEDURE
A. PIPELINE AND VESSEL FLUSHING
B. PREREQUISITES FOR WALNUT SHELL AND MEDIA FILTER LOADING
C. PRE-CHECKS
D. WALNUT SHELL AND MEDIA LOADING
E. MEDIA LOADING QUANTITIES
6.3 RESIN LOADING PROCEDURE
B. PREREQUISITES FOR RESIN LOADING
C. PRE-CHECKS
D. RESIN LOADING FOR CATION UNITS
E. RESIN LOADING QUANTITIES
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1. HEALTH AND SAFETY

The ultimate goal of safety is the complete prevention of injury, loss of life, and/or the destruction of
property as a result of accidents, fires, explosions, or other hazardous situations. Unfortunately, the
technical principles and practices in many fields are insufficiently established for valid evaluation of all
calculated risks, thus leaving to the individual owner-operator the sole responsibility for adequate safety.
Therefore, Aquatech International cannot accept any responsibility for the Owners/Operators in
regards to safety and related issues. Aquatech supports and promotes safety education for users of
process equipment. Various agencies have developed standards for safety in the workplace and
Aquatech advises its clients to broadly apply these codes and to conform specifically to any local
regulations. Typical examples of safety codes are shown in table below:
1.1 TYPICAL STANDARDS UTILIZED
Codes Description
SBC Standard Building Code
NEC National Electric Code
AGA American Gas Association
ANSI American National Standards Institute
ASTM American Society of Testing Material
NFPA National Fire Protection Association
ASHRAE American Society of Heating, Refrigeration & Air Conditioning Engineers
OSHA Occupational Safety and Health Association
SPC Standard Plumbing Code
SGC Standard Gas Code
SMC Standard Mechanical Code
ASME American Society of Mechanical Engineers
CFR Code of Federal Regulations
API American Petroleum Institute
1.2 GENERAL PLANT SAFETY PROVISIONS

Certain safety requirements are common to all industrial plants and process installations.
Many of these are set by local legislation, such as building and plumbing codes, or insurance
restrictions. Others follow generally acceptable experiences and practices. Multi-story buildings,
building roofs, and elevated open structures are frequently used to support, house, or service
process equipment. Alternate means of escape from elevated areas such as buildings or
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structures can be by stairway, ladder or chute. In some installations, ropes and slide poles are
acceptable. Escape routes that lead personnel into a single area are unacceptable. An additional
escape route from an elevated area is usually considered necessary for distances in excess of 40
feet from an elevator, stairway, or ladder. In a similar manner, escape doors on the ground floor
of a fully enclosed building are customarily spaced so that no worker must travel more than 40
feet to an exit.
Handling facilities should be provided to lift all equipment which must be handled during
maintenance operations. Mobile equipment should be used for this purpose whenever possible
and access ways should be arranged to facilitate access.
Suitable guards are necessary for all rotating equipment, belt drives, chain drives, and
powered conveyors. Personnel entry into process equipment is permitted only when all flow is
positively and completely shut off by block valves with intervening vents or by blind flanges or
double-disk valves with vents between seats. Valve motor operators should be disconnected or
interlocked and hand valves red tagged, locked, or guarded by personnel. Operators and workers
must be protected against contact with hot piping, or vessels.
1.3 STORAGE AND HANDLING OF WATER TREATMENT CHEMICALS

The safe storage and handling of hazardous materials requires a thorough knowledge of
chemical properties for positive containment and avoidance of leakage. Materials of construction for
storage tanks, piping, valves and pumps must be selected for adequate resistance to rapid corrosion
or other deterioration (such as caustic embrittlement, etc.) that can lead to structural failure. Dikes or
low walls should be provided around all storage tanks. Chlorine and similar toxic gases are
preferably stored in exterior locations and under sunshades to permit dissipation of minor leakage
and to minimize corrosion and pressure rise. Hazardous storage areas should be fenced in so as to
assure against entry by no one other than assigned personnel. Hazardous materials are handled
more safely in closed systems. When drum shipments are unavoidable, personnel should be fully
protected by suitable personal protective clothing, gloves, and masks. Leakages must be avoided so
as to prevent cross mixing of lethal or other extremely hazardous materials.
Emergency showers and eyewash stations must be provided in all areas where the storage,
handling, transfer, and processing of materials harmful to human tissue takes place. Emergency
facilities should be operable in all types of weather and should be simple and reliable to ensure that
an injured man (evenly if temporarily blinded) can operate them.
1.4 SPILLS AND LEAKAGES

Wherever hazardous chemicals are stored, unloaded, handled, or used, an abundant supply
of water should be made available for emergency use in dissolving, diluting, or flushing away the
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spilled chemicals. The Owner/Operator must ensure that all clean-up activities comply with local,
state and federal regulations.
1.5 FIRST AID

Knowledge of first aid is of prime importance in any situation where hazardous chemicals
have come in contact with eyes or skin. At the first instant of exposure to hazardous chemicals, the
affected area should be thoroughly rinsed with large quantities of water.
1.6 CONTACT WITH THE EYES

If even minute quantities of hazardous chemicals enter the eyes, they should be immediately
irrigated with plenty of running water for at least 15 minutes. The eyelids should be held apart during
the irrigation to ensure that all the tissues of the eyes and lids are continuously flushed with water. If
a physician is not immediately available, the eye irrigation should be continued for another 15
minutes. No oils, ointments or other medications should be placed into the eye, unless ordered by a
physician. Equipment, instruments and piping for corrosive or toxic materials should be installed in
such a manner to minimize accidental discharge. Special guards, lockouts and well-defined
operating precautions can minimize the possibility of such occurrence. All authorized individuals who
have access to operate and/or perform maintenance on this equipment must be properly trained in
regard to the hazards, care, use, handling and storing of acid and caustic chemicals.
When handling or using chemicals, it is recommended that operators and maintenance
personnel wear proper personal protective equipment (PPE) such as rubber boots, gloves, aprons,
safety helmets, safety glasses and goggles to prevent personnel from being severely burned, should
an accidental spilling or splashing of chemicals occur. All employees should be made familiar with
the Material Safety Data Sheets (MSDS) and other "Right to Know" safety issues prior to operating
the process equipment.
1.7 ELECTRICAL SAFETY

Designated, qualified personnel should do all electrical work. Fatalities and serious injuries
have occurred many times while maintenance work was being performed when the source of power
had been inadvertently turned on before this work was completed. The only sure method to isolate
electricity is to lock out the appropriate disconnect switch in the "off" position before beginning any
electrical maintenance work. Whenever possible, it is also advisable to remove the fuses. Some
electrical equipment is provided with built-in key locking devices; however, if such devices are not
installed, a padlock lockout safety procedure may be designed to meet individual requirements.
The following is a suggested electrical lockout procedure; it is not meant to be a complete
procedure, or to supersede existing satisfactory methods.
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1. Key-operated padlocks are preferred, because supervisors can better exercise control over
keys than combination locks.
2. Locks should be issued to designated, qualified employees who work on electrical
equipment and the locks should be identified by the name or number of the employees to
whom they are issued.
3. Each lock should be issued with only one key. The spare key should be kept in a locked,
catalogued cabinet in the maintenance supervisor's office.
A work permit and close supervision are recommended for anyone working on the
electrical system. All employees’ actively engaged in maintenance activities especially those who
are engaged in electrical maintenance activities, should work on the “buddy” principle.
1.8 CONCLUSIONS
Effective plant safety and fire protection extend to every phase of engineering, operation,
and maintenance. At a minimum, the design of structures and equipment should reflect industry
standards in reducing all safety risks as far as possible and with full awareness and careful
assessment of special situations for which average industry practices may not be adequate.
Proper safety equipment and individual safety plans must be strictly adhered to not only for
normal service but also for emergency situations to avoid any failures, which would impair
recovery from a plant mishap.
Aquatech International Corporation will assume no responsibility for any injury in

connection with the handling of chemicals and associated utilities and components/equipment.
The owner/operators will not hold Aquatech International Corporation, its associates and
employees responsible for any injury or death should any occur during the installation and/or
operation of this equipment.
2. MATERIAL RECEIPT AND STORAGE
2.1 TOOLS REQUIRED
a. Cranes, Cherry Pickers, Man Lifts, Fork Trucks
d. Variety of Spreader Bars
c. Cable Chokers, Cloth Chokers
d. Come-along, Chain Falls
e. Crow Bars
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f. Any other rigging equipment that may be required
g. Water Proof Tarps
2.2 INSPECTION OF MATERIALS RECEIVED

The unloading equipment used shall be sized to handle the equipment weights.
a. Upon delivery, check that the equipment is in good condition; in particular check the
equipment for any damage that may have occurred during handling operations
(dents, paint scratches, etc.).
b. The packing lists must be retained for record. Make sure no parts are missing by
checking the parts delivered against the packing list and parts list. Any missing
parts must be recorded and reported to Aquatech.
c. Positive identification of equipment is imperative prior to placement and installation.
Many of the pieces of equipment look identical.
d. Media packaging, such as walnut shells, cation resin and mixed bed media shall be
checked visually without unpacking each container.
2.3 HANDLING AND STORAGE REQUIREMENTS

The shipping packaging is designed to prevent shipping damage that may be caused by truck and
sea transportation. External parts are coated with final painting and machined parts are coated with a
strippable coating. If the original shipping material is damaged, opened, or stored for several months,
then additional precautions apply as detailed below.
2.4 STORAGE AND PRESERVATION PROCEDURES

These guidelines are to be used for the storage of Aquatech equipment at the job site, prior to start
up. All Aquatech equipment should be stored indoors protected from the weather. The storage area
should be clean, roofed and the floor should be covered with a compacted non-dust-forming floor.
Periodic inspection shall be possible without undue handling.
A. EPOXY LINED VESSELS

No Welding should be performed on the exterior of any lined vessel as damage to the lining
will result. Care should be taken not to damage the lining. Care should also be taken to prevent any
objects from dropping on the lining. Here again, during cold weather, a blow to the exterior of the
vessel would cause cracking of the lining on the interior. The interior temperature of the vessel
should not be allowed to exceed the temperature specified in the lining manufacturer's
recommendations. .
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B. PIPING
Piping should be observed regularly for rust formation. The faces of plastic fittings should
be inspected to assure that no scratches or other damage is present. All pieces should be
inspected to assure that the protective plugs are in position. Any loss or damage to protective
coverings should be replaced or repaired.
The piping and valves are skid mounted, the skid assemblies (if stored outdoors) should
be kept under waterproof tarpaulin covers to protect the equipment from exposure to the
extremes of climatic variations.
C. VALVES
Valves should be examined regularly for rust formation, especially on unpainted surfaces.
The valves should be kept in a cool dry area away from sunlight since moisture will affect the
diaphragm material and also cause damage to the parts that require lubrication. In no case may the
valves be handled using the hand wheel or be dragged across the floor or ground.
D. PUMPS AND FACE PIPING SKIDS

In general, skids should be covered and stored out of the weather. All machined parts that
are exposed should be checked regularly for rust formation.
E. ELECTRIC MOTORS
All electric motors shall be stored in a clean dry place. Cable outlets must be closed up.
Unpainted parts should be checked regularly for the formation of rust.
In order to prevent damage to the bearings, motors should be stored away from bumps and
vibrations from operating machinery.
If the storage is for long duration, care should be taken to rotate the shaft at least once
every fortnight (2 weeks).
F. LOCAL JUNCTION/SOLENOID BOXES

Local panels contain tubing, pressure regulators and terminal strips. When the equipment is
going to be stored outside, they should be protected with a plastic covering since they also
contain electrical components and could be severely damaged by the weather.
G. BOXES/CARTONS/CRATES
All boxes, cartons, etc. must be stored indoors or in a sheltered area to avoid damaging the
equipment or the packaging
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Reinforced polyethylene tarpaulins in excellent condition must be used if indoor storage is

not possible. Some of the equipment will be damaged immediately if rain is allowed to contact the
equipment.
H. WALNUT SHELL MEDIA, MIXED BED MEDIA AND CATION RESINS

All media shall be stored indoors in a cool, dry location. If stored outdoors, the containers
must be covered and kept from getting wet. Wetted media is difficult to handle, which will make
vessel loading considerably more difficult. Media must also be kept from freezing as this can
damage the media, create fines and reduce its effectiveness.
I. STEEL PLATES
Cut and rolled steel plates for the field fabricated vessels shall be unloaded and stored in a
dry location in such a way as to maintain the shape of the steel plates.
2.5 UNLOADING, LIFTING, RIGGING AND INSTALLATION REQUIREMENTS AND

INSTRUCTIONS
Rigging, erection and installation as defined herein will be performed by the site contractor.
Rigging refers to unloading, transport to destination, setting, etc.
Installation means placement of equipment in the respective location, aligning with the other
related equipment and anchoring the installed equipment. Anchoring and final grouting of
vessels, pumps, tanks, face piping skids, pump skids, pipe rack and pipe supports should be
performed only after completing the interconnecting piping installation.
REFER TO THE GENERAL ASSEMBLY DRAWINGS BEFORE ATTEMPTING TO LIFT ANY

EQUIPMENT!
When a vessel arrives on a truck, please inspect the vessel carefully both inside and outside
for possible damage incurred during shipment. This inspection should take place prior to
unloading or handling the vessel. Should damage exist, please make a notation to this respect on
the bill of lading and notify Aquatech representative immediately. Unless the damage is severe, it
is satisfactory to remove the vessel from the trailer but do not set the vessel up vertically, as
damaged areas are much more difficult to reach on an erected vessel.
When ordering a crane, inform the rigger of the weight of the vessel and of the distance the
vessel is to be moved by a stationary crane. Do not select the capacity of the crane merely in
accordance with the weight of the vessel, as the crane is rated with its boom in a near vertical
position and the rating reduces as the boom moves toward a horizontal position. The crane
should have either a three-way sling or three chokers. The chokers should be at least the
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diameter of the vessel in length and should be of sufficient tensile strength to accommodate the
load.
The vessel will arrive with lifting lugs or channels equally spaced at the top of the vessel with
one of them located at the twelve o’clock position. There will be another lug or channel at the
bottom of the vessel also at the twelve o’clock position. To unload the vessel, attach the slings or
chokers of the load line to the top lugs with the whip line attached to the bottom lug. To remove
the vessel, lift it by both the load line and the whip line maintaining the horizontal position. Do not
attempt to move the vessel to a vertical position at this point, as the bottom of the vessel will be
pulled forward along the bottom of the trailer. It is also possible that the rear of the vessel would
be pushed into the drop of the trailer. After the vessel has been elevated sufficiently to clear the
trailer, move it laterally several feet. The vessel may now be carefully brought into a vertical
position by reducing the load line and slackening the whip line. As the vessel becomes vertical
the top lug at twelve o’clock position will assume an equal load to the remaining top lugs with the
bottom lug becoming ineffective. The whip line can be disconnected at this point. The vessel can
now be moved to set upon the pad. Refer to Rigging Drawing that illustrates the above
instructions.
All interconnecting piping break points are identified in the drawings provided. Pipe connections
from this point to the equipment are supplied loose and are to be installed at site.
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INSTALLATION MANUAL
3. General Installation Instructions

3.1 MECHANICAL EQUIPMENT LIST
Tag
No. Description Numbers Qty Shipping Philosophy
(62-)
Vessel with internals on Flat Bed
WALNUT SHELL FILTER UNIT V-09005 4
1 Face Piping Skid on Flat Bed
WITH FACE PIPING SKID A/B/C/D Skids
Loose Components
WARM LIME SOFTENING CLARIFIER
2 V-09000 1 System
(WLSC)
WLSC - Carbon Steel Plate for
3 Containerized Knocked Down Steel Plate
Tank Walls
4 WLSC - Stairs to Platform Containerized
WLSC - Bridge, Mechanism, Containerized Prefabricated Components, Bridge Shipped in
5
Ladders & Platforms Pre-Assembled Components and 4 Large Sections
6 WLSC - Drive Containerized with item 5
PRIMARY STRONG ACID CATION V-09003
7 4 Shipped with Saddles on Flat Bed Truck
UNITS A/B/C/D
V-09005
8 POLISHING STRONG ACID CATION UNITS 4 Shipped with Saddles on Flat Bed Truck
A/B/C/D
9 FILTERED WATER TANK T-09000 1 Containerized Knock Down Steel Plate
V-09002
10 MEDIA FILTER UNITS 4 Shipped with Saddles on Flat Bed Truck
A/B/C/D
11 SULFURIC ACID STORAGE TANK T-09007 1 Shipped with Saddles on Flat Bed Truck
12 SKID - MEDIA FILTERS 4 Shipped on Flat Bed Truck
SKID - SAC PRIMARY & POLISHING
13 4 Shipped on Flat Bed Truck
UNITS
P-09003
14 SKID MOUNTING - SLUDGE PUMPS 1 Shipped on Flat Bed Truck
A/B
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WTP Installation Manual
Tag
(62-)
SKID MOUNTING - BRINE TRANSFER P-09011
PUMPS A/B
SKID MOUNTING - BRINE P-09012
REGENERATION PUMPS A/B
SKID MOUNTING SURFACTANT P-09017
DOSING A/B
T-09001
18 SOFT WATER TANK 2 FRP Tank w/Ladder & Platform on Flat Bed Truck
A/B
19 BRINE STORAGE TANK T-09005 1 FRP Tank w/Ladder & Platform on Flat Bed Truck
20 COAGULANT STORAGE TANK T-09006 1 FRP Tank w/Ladder & Platform on Flat Bed Truck
21 SURFACTANT FEED/STORAGE TANK T-09014 1 FRP Tank w/Ladder & Platform on Flat Bed Truck
T-09004
22 BRINE SATURATOR TANK 2 FRP Tank w/Ladder & Platform on Flat Bed Truck
A/B
T-09004
23 BRINE SATURATOR TANK INTERNALS 2 Containerized
A/B
24 SODA ASH SILO AND SYSTEM
24.1 SODA ASH SILO PLATE MATERIAL V-09002 Knock Down Steel Shipped on Flat Bed Trucks
SODA ASH ACCESSORIES
1 Container for Skid (combined with Item 25.2 Skid)
INCLUDING DILUTION TANK, PUMP
1 Container for Loose Ship Items (combined with Item 25.2
24.2 SKID, SCREW FEEDER, DUAL CONE 1 Lot
Loose Ship Items)
BOTTOM, DUST COLLECTOR, FILL
1 Loose Shipment (Dual Cone)
LINE, GATE VALVES & BINACTIVATOR
25 DOLOMITE LIME SILO AND SYSTEM
HYDRATED DOLOMITE LIME SILO
25.1 V-09028 Knock Down Steel Shipped on Flat Bed Trucks
PLATE MATERIAL
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Tag
(62-)
HYDRATED DOLOMITE LIME
ACCESSORIES 1 Container for Skid (combined with Item 24.2 Skid)
INCLUDING DILUTION TANK, PUMP 1 Container for Loose Ship Items (combined with Item 24.2
25.2 1 Lot
SKID, SCREW FEEDER, DUAL CONE Loose Ship Items)
BOTTOM, DUST COLLECTOR, FILL 1 Loose Shipment (Dual Cone)
LINE, GATE VALVES & BINACTIVATOR
A-09001
26 DEWATERING FILTER PRESS 2 Loose Shipped on Flat Bed Trucks
A/B
P-09000
27 RAW WATER PUMPS (PLINTH MOUNTED) A/B/C/D/ 6 Containerized
E/F
BACKWASH WASTEWATER TRANSFER P-09001
28 2 Containerized
PUMP (PLINTH MOUNTED) A/B
OILY WASTE WATER PUMP (PLINTH P-09018
29 2 Containerized
MOUNTED) A/B
FILTRATE TRANSFER PUMPS (PLINTH P-09019
30 2 Containerized
MOUNTED) A/B
MEDIA FILTER FEED PUMPS (PLINTH P-09004
31 4 Containerized
MOUNTED) A/B/C/D
FILTER BACKWASH PUMPS (PLINTH P-09005
32 3 Containerized
MOUNTED) A/B/C
DILUTION WATER PUMPS (PLINTH P-09006
33 2 Containerized
MOUNTED) A/B
COAGULANT DOSING SKID (2 PUMPS - P-09013
34 1 Containerized
TAG# P-09013A/B) A/B
ACID DOSING SKID FOR CLARIFIER (2 P-09014
35 1 Containerized
PUMPS - TAG# P-09014A/B) A/B
POLYMER DOSING SKID (CLARIFIER) (2 P-09015
36 1 Containerized
PUMPS - TAG# P-09015A/B) A/B
POLYMER DOSING SKID (DEWATERING P-09016
37 1 Containerized
PRESS) (2 PUMPS - TAG# P-09016A/B) A/B
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Tag
(62-)
38 COMPRESSED AIR SYSTEM
K-09000
38.1 INSTRUMENT AIR COMPRESSOR 2 Shipped on Flat Bed Trucks
A/B
D-09000
38.2 AIR DRYER 2 Shipped on Flat Bed Trucks
A/B
V-09010
38.3 AIR RECEIVER (2 Dry & 2 Wet) 4 Shipped on Flat Bed Trucks
V-10010
39 TRANSFORMERS – MV - 2 Shipped on Flat Bed Trucks
40 TRANSFORMERS – LV - 6 Shipped on Flat Bed Trucks
41 SWITCHGEARS - 4 Shipped on Flat Bed Trucks
42 AC/DC – UPS - 1 Shipped on Flat Bed Trucks
43 CONTROL PANEL - 1 Shipped on Flat Bed Trucks
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INSTALLATION MANUAL
3.2 INSTALLATION SEQUENCE

Installation sequence to be developed by Installation Contractor based on recommendations
from Aquatech, refer to Attachment 1 – Installation Sequence, material receipt at site dates,
personnel at the job site and work flow of the job site.
3.3 INSTALLATION PROCEDURE

Steps to be taken for the installation of all equipment:
1. Review all drawings and documents associated with the equipment that is being installed. A
reference list of documents and drawings, refer to document number MUK-62-MGT-AIC-
00003 - Mukhaizna Phase II Equipment Document Reference, will be provided by Aquatech
for each piece of equipment, this list should be used as reference and not for a complete list
of documents needed for the installation of the equipment. Example: P&ID, GA Drawing, Civil
Drawings, Rigging Drawings, Vendor Installation Procedures, Vendor Packages and
Fabrication drawings.
2. The drawings and or documents will reference the piece markings needed to install the
equipment and its associated components. Example: Tag Number, Material Number, Spool
Number and/or Piece Marking.
3. Installation Contractor needs to retrieve all needed material for equipment being installed
from their storage facility. Aquatech will provide a Master Shipping List, refer to document
number MUK-62-MGT-AIC-00004 – Master Shipping List, showing most of the markings
explained in Item 2 on the list. Installation Contractor should to use this list and their material
receiving reports to identify where the material is located in their storage yard.
4. Drawings and Documents mentioned in Item 1 will give guidance on how the equipment is to
be installed and in what sequence. If this detail is not provided in such documents or
drawings, it is the responsibility of the Installation Contractor to develop such procures with
recommendations and assistance from Aquatech when requested.
4. MECHANICAL INSTALLATION
4.1 INSTALLATION OF MAJOR EQUIPMENT

Section 3 provides a list of major equipment supplied by Aquatech. The Warm Lime Softening
Clarifier, Filtered Water Tank, Soda Ash and Dolomite Lime Silos will be provided as knocked down
steel and will require field fabrication and erection. The Walnut Shell Filters, Primary and Polishing
Strong Acid Cation Units and Media Filter Vessels will be supplied as assembled units with finished
linings and coatings. Pressure vessel face piping will be supplied as assembled skids, including valves
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WTP Installation Manual
and instruments, local panel boxes, etc. Interconnecting piping will be provided loose, along with piping
supports for field assembly.
Dosing pumps will be mounted on a skid. Balance of all pumps and equipment will be supplied
loose and will be installed at site.
4.2 PROCEDURE FOR INSTALLATION OF MAJOR EQUIPMENT

A. TOOLS REQUIRED
a. Level Gun
b. Hilti Gun
c. Hilti Anchors
d. High strength carbon steel shims
e. Levels
f. Plumb bobs
g. Pneumatic Hammer or Bushing Tool
B. FACE PIPING SKIDS

Following is the sequence of erection of a face piping assemblies:
1. Check Civil Foundations.
2. Mark the location of the supports
3. Surface Preparation.
4. Install the support on the Marked Location.
5. Align and Level the support
6. Provide shims as required.
7. Anchor the support.
8. Check Piping for Plumbness.
9. Grouting of Face piping supports.
1. Check Civil Foundations

Face piping skids are designed to be placed on the concrete plinths, which will be
provided by the civil contractor. Proper Inspection of Civil Foundations with reference to the
Elevations shown in the General Arrangement drawing and also Civil Foundation drawings
will show the installation of the skid. Due to inconsistencies in the concrete, some shimming
and leveling will be required. An allowance of 1 inch is generally considered for this
adjustment.
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2. Mark the location of the Skid as per General Arrangement drawing

Identification of the correct location of the skids as per General Arrangement
drawing and its orientation is very important prior to installation. Mark the coordinates of the
skids as shown in the General Arrangement drawing.
3. Surface Preparation
The area of the face-piping skid, as located on the General Arrangement drawing, is
to be roughed or bushed using pneumatic hammer or bushing equipment. This is done to
remove the smoothness on the concrete plinths surface for better bonding of grout material
with the concrete.
4. Install the Skids on the Marked Location

Face piping skids are provided with four lifting lugs located on the lower portion of the skids.
All four lifting points must be used for lifting.
Usage of spreader bars will avoid damage to skid mounted equipment.
CAUTION: In no case should you attach slings to branch pipes or flanges on skids to
manoeuvre them. This may result in damage of the piping or breakage of valves.
5. Align and Level the Skid

Align the face piping skid to the marking made on the concrete plinths and check
the level of the skid using a spirit level. Shims are to be provided to make necessary
adjustments and an allowance of 1 inch is generally considered for this adjustment.
6. Provide shims as required

Generally, high strength carbon steel shims of size 2” X 2” square, and of thickness
as required or as observed after leveling the skid is to be provided beneath the face piping
skid frame at appropriate intervals. The span between shims is decided based on the size
of the skid.
7. Anchor the Skid

After shimming is completed, the skid shall be anchored down using the Anchor
clips & Anchors. These clips will be installed as per the details on the General Arrangement
Drawing.
Anchoring will be completed after interconnecting piping has been installed.
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8. Check Piping Levels for Plumbness

Face piping assembly is to be checked for plumpness before further connections
to check for misalignments, if any, due to transportation or mishandling.
9. Grouting of Face piping skid

After anchoring is complete, the gaps between the skids and the concrete pad
should be grouted and the surface should be finished smooth. For a better finish, proper
formwork is made surrounding the skid and a 45-degree chamfer is provided upon
completion of grout pouring. This procedure is to be followed for all face piping skid-
mounted equipment.
C. PUMP SKIDS
Pump skids are an assembly of piping and the valves associated with the pumps.
Following is the Sequence of Erection of a Pump Skid and described below:
2. Mark the location of the Skid.
4. Install the Skid on the Marked Location.
5. Align and Level the Skid.
7. Anchor the Skid.
8. Check Pump Suction & Discharge Piping for Pipe Stresses on Pump.
9. Grouting of Pump Skid.
10. Pump Alignment Checks

Pump skids are designed to be placed on the concrete plinths or localized raised
concrete pads, which will be provided by the civil contractor. Proper inspection of civil
foundations with reference to the elevations shown in the General Arrangement drawing and
also Civil Foundation drawings will show the installation of the skid. Due to inconsistencies in
the concrete, some shimming and leveling will be required. An allowance of 1 inch is
generally considered for this adjustment.
2. Mark the location of the Skid as per General Arrangement drawing
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Page 19 of 36
Identification of the right location of the skid as per General Arrangement drawing
and its orientation is very important prior to installation. Mark the coordinates of the skid as
shown in the General Arrangement drawing.
The area of the pump skid, as located in the General Arrangement drawing, is to be
roughed up or bushed using pneumatic hammer or bushing equipment. This is done to
remove the smoothness on concrete plinth’s surface for better bonding of grout material with
the concrete.
4. Install the Skid on the Marked Location

Pump Skids are provided with four lifting lugs located on the lower portion of the
skids, below the piping mounted on the skid. All four lifting points must be used for lifting.
Usage of Spreader bars will avoid damage to skid mounted equipment.
CAUTION: In no case attach slings to branch pipes or flanges on skids to maneuver

them. This may result in damage of the piping or breakage of valves.
5. Align and Level the Skid

Align the pump skid to the marking made on the concrete plinths and check the
level of the skid using a spirit level. Shims are to be provided to make necessary
adjustments. An allowance of 1 inch is generally considered for this adjustment.

as required or as observed after leveling the skid is to be provided beneath the pump skid
frame at appropriate intervals. The span between shims is decided based on the size of the
Skid.
7. Anchor the Skid

After shimming is completed, the skid shall be anchored down using the anchor
clips and anchors. These clips will be installed as per the details on the General
Arrangement drawing.
8. Check Pump Suction & Discharge Piping for Pipe Stresses on Pump
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Pump suction and discharge piping assembly is checked for pipe stresses by
loosening the suction and discharge flanges. Pipe stresses are generally due to
inadequate supports or pipe misalignments. If stresses are found, it has to be eliminated
by providing additional supports or piping modification as necessary.
9. Grouting of Pump Skid

After anchoring is complete, the gaps between the skids and the concrete pad
should be grouted and the surface should be finished smooth. For better finish a proper
formwork is made surrounding the skid, and a 45-degree chamfer is provided upon
completion of grout pouring.
10. Pump Alignment Checks

After grouting is completed, pumps are to be checked for soft foot, axial and
radial alignment. This pump alignment is done only in the case of pumps with coupled
motors. In the case of directly mounted motors, generally the flange face of the pump
where the motor is bolted is checked for squareness. In the case of vertical pumps, the
pump base and the flange face are checked for squareness before bolting the motor.
The soft foot check is done to ensure the feet of the motor is not causing any
stress on the pump.
The axial and radial alignment is done to an accuracy of 2 thousandths of an inch

or 0.05mm using various methods such as Dial Gage Alignment or Laser Alignment.
D. VESSELS AND PRESSURE VESSELS

Pressure vessels are typically supported by legs. The legs are designed to be
continuously supported on the concrete or structural steel.
The Walnut Shell Filters and Strong Acid Cation Units are vertical vessels, while the
Media Filters are horizontal vessels.
The vessels have an internal epoxy coating. The epoxy lined vessels are not supposed
to be CUT OR WELDED. as this will damage the internal lining.
The internal distribution and collection system may be one or combination of the following:
a. Distribution Headers
b. Strainer Plate with Strainers (Strainer Buttons)
Following is the sequence of erection of a vessel with descriptions below:

2. Mark the location of the Vessel.
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4. Install the Vessel on the Marked Location.
5. Align and Level the Vessel.
7. Check Squareness of Inlet/Outlet Nozzles.
8. Anchor the Vessel Legs.
9. Grouting of Vessel Legs.
10. Check Vessel Internal Lining.
11. Check Tightness of Vessel Internals

Pressure Vessels are designed to be placed on the concrete plinths or localized
raised concrete pads, which will be provided by the civil contractor. Proper inspection of civil
foundations with reference to the elevations shown in the General Arrangement drawings
and Civil Foundation drawings will indicate the installation location of the vessel. Due to
inconsistencies in the concrete, some shimming and leveling will be required. An allowance
of 1 inch is generally considered for this adjustment.
2. Mark the location of the Vessel as per General Arrangement Drawing

Identification of the correct location of the vessel as per General Arrangement
drawings and its orientation is very important prior to installation. Mark the coordinates of the
vessel as shown in the General Arrangement drawing.
The area of the vertical vessel legs (footings) that is found after locating the vessel
as shown in the General Arrangement drawing is to be roughed up or bushed using
pneumatic hammer or bushing equipment. This is done to remove the smoothness on
concrete plinth’s surface for better bonding of grout material with the concrete.
4. Install the Vessel on the Marked Location

Vessels are provided with lifting lugs and a tailing lug. Lifting lugs are provided at
the top dish end and a tailing lug at the bottom dish end in the case of vertical pressure
vessels. The tailing lug is used to make the vessel vertical during installation, along with the
lifting lugs, depending on the size of the pressure vessel. All lifting lugs must be used for
lifting.
The number of lifting lugs will vary with the size of the pressure vessel.
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In some cases, usage of spreader bars may be imminent to complete the setting of
the vessel.
CAUTION: In no case should you attach slings to vessel nozzles or flanges to

maneuver the vessels. This may result in damage of the nozzles.
5. Align and Level the Vessel

Align the vessel leg footings that are found after positioning the vessel, as indicated
in the General Arrangement drawings, to the markings made on the concrete plinths and
check the level of the vessel using a spirit level. Shims are to be provided to make
necessary adjustments and an allowance of 1 inch is generally considered acceptable for
this adjustment.

as required or as observed after leveling the vessel is provided beneath the vessel legs. A
minimum of two sets of shims under each leg is advised for proper balance.
7. Check Squareness of Inlet/Outlet Nozzles

Vessel inlet and outlet nozzles are to be checked for squareness using a plumb
and spirit level as necessary.
This is done prior to connection of face piping or any other piping.
8. Anchor the Vessel Legs

After shimming is completed, the skid is to be anchored down using the anchors.
Two anchors are typically provided to anchor each leg of the vessel. Anchoring will be
completed after interconnecting piping has been installed.
9. Grouting of Vessel Legs

After anchoring is complete, the gaps between the vessel leg bases and the
concrete pad should be grouted and the surface should be finished smooth. For better
finish, a proper formwork is made surrounding the skid and a 45-degree chamfer is
provided upon completion of grout pouring.
10. Check Vessel Internal Lining
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Internal Lining is to be checked for damages if any visible. In case of doubts a

random sponge test on lining and spark testing is done.
11. Check Tightness of Vessel Internals

The Vessel Internals may be of one or a combination of the following:
i. Internal Distribution Headers with Laterals.
ii. Strainer Plate with Strainer buttons.
i. The Internal Distribution Headers with laterals are to be checked for
a. Tightness of header flanges.
b. Usage of correct gaskets.
c. Usage of correct size hardware.
d. Usage of correct size U-bolts.
e. Tightness of laterals.
f. Damages on laterals if of PVC material.
g. Damages on lateral screens.
ii. The Internal strainer plates with strainer nozzles are to be checked for
a. Tightness of strainer nozzles (buttons).
b. Damages (cracks) on a strainer nozzle (button).
c. Usage of lock washers in strainers.
d. Check for no gap between the nozzle and plate.
E. CHEMICAL STORAGE TANKS AND ATMOSPHERIC TANKS

These are generally flat-bottomed tanks and the material of construction is FRP.
As these tanks have flat bottoms, the surface must have a smooth finish, with no gravel
protruding above the surface. This may be on a raised pad, or directly on the concrete surface
provided by the civil contractor for these tanks. The civil contractor must ensure that the surface
is flat, smooth and level within +/- 1/16 inch, before setting the tanks. Grouting is not required for
the bottoms of these tanks.
Filling a FRP vertical vessel obviously places stress on the sidewall, causing it to try to
move outward. This stress is manifested to the greatest extent at the knuckle radius – the point
of junction between the bottom and the straight shell. To assure the maximum possible life of the
vessel, the tanks’ design includes a generous amount of reinforcement in the knuckle area. With
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any FRP vessel, the knuckle reinforcement will extend below the rest of the vessel bottom
causing an empty vessel to rest on its extremities only. When the vessel is filled, its bottom is
pushed downward, causing stresses in the knuckle. Emptying the vessel allows the bottom to
rise upward in the center, continuous cycling results in continuous flexing at the knuckle.
The support base for flat-bottom vertical vessels should provide full and uniform support
over the entire bottom area. The support base should be properly designed to prevent settling or
deflection under maximum design loads. The support base surface must be nonporous and free
of cracks, depressions and vertical projections. Reinforced concrete, trowel finished to American
Concrete Institute Specifications (ACI-301-72, Section 11.7.3, “Trowel Finish”) is often used as a
support base. Each flat bottom unit must be set on a cushioning pad to minimise stresses
caused by seams, shrinking distortion and/or support base irregularities. Where irregularities are
less than ½ inch (12.7mm) in depth, use layers of 30 lb. roofing felt (see the illustration on the
next page for quantity and size required). Where irregularities in the surface of the support base
are greater than ½ inch (12.7mm) in depth, an asphalt type of paving mastic can be trawled
allowed for the mastic to harden (4 hours minimum) before the first layer of roofing felt is applied.
A suitable elastomer sheet material of proper environmental resistance may be substituted for the
roofing felt.
Important: If the vessel bottom was fabricated with a core material and the bottom has concavity
more than ½” in depth, a wet concrete grout mix without rocks should be used instead of the
roofing felt illustration on the following page. Pyramid the wet grout mix from the thickest location
at the center, to a thickness of ½” toward the perimeter of the vessel.
Following is the Sequence of Erection of an Atmospheric Tank with descriptions below:

2. Mark the location of the Tank.
3. Install the Tank on the Marked Location.
4. Check Squareness of Inlet/Outlet Nozzles.
5. Anchor the Tank.
6. Grouting of Tank.
7. Check Internal Lining.
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Roofing Felt Illustration

Atmospheric tanks are designed to be placed on the concrete plinths or localized
raised concrete pads, which will be provided by the civil contractor. Proper inspection of civil
foundations with reference to the elevations shown in the general arrangement drawings
and also civil foundation drawings will indicate the location for the installation of the tank.
Any inconsistencies in the concrete should be corrected before installing the tank.
2. Mark the location of the Tank as per General Arrangement Drawings

Identification of the correct location of the tank as per General Arrangement
drawings and its orientation is very important prior to installation. Mark the coordinates of the
tank as shown in the General Arrangement drawings.
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3. Install the Tank on the Marked Location

Tanks are provided with three lifting lugs and a tailing lug. Lifting lugs are provided
near the top plate and the tailing lug near the bottom plate of the tanks. The tailing lug is
used for making the tank in the vertical position. The number of lifting lugs is dependant on
the size of the tank. Alt least three lifting lugs must be used for lifting.
Before placing FRP tanks are put into place, a felt or rubber matting should be
placed under the tank where the tank is to be installed. This is to keep the bottom of the
FRP tank from wearing out of the tank during operation of the plant. FRP tanks walls flex
during filling and drawing down operations.
In some cases usage of spreader bars will be required.
CAUTION: In no case should you attach slings to tank nozzles or flanges to maneuver
them. This may result in damage of the nozzles.
4. Check Squareness of Inlet/Outlet Nozzles

Tank inlet or outlet nozzles are to be checked for squareness using a plumb and
spirit level as necessary.
This is done prior to connection of any piping.
5. Anchor the Tank

The tank may be anchored down at anchor clips fixed on the shell of the tank using
the anchors provided.
6. Grouting of Tank
After anchoring is complete, the gaps between the tank anchor clips and the
concrete pad should be grouted and the surface should be finished smooth. For better
finish, a proper formwork is made surrounding the skid and a 45-degree chamfer is
provided upon completion of grout pouring.
7. Check Internal Lining

Internal lining is to be checked for damages. Any damage found will need to be
repaired before filling the vessel as the lining is critical in containing the chemicals and
protecting the FRP structural walls.
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F. FIELD CONSTRUCTED VESSELS
The following vessels are partially provided as cut and rolled plate and require field construction:
Warm Lime Softening Clarifier
Filtered Water Tank
Soda Ash Silo
Dolomite Lime Silo
Details for this installation should be done by the installation contractor and installed to the
Installation drawings provided by Aquatech.
5. INSTALLATION OF INTERCONNECTING PIPING

Interconnecting piping has been prefabricated to the maximum extent possible so as to minimize
installation time required. Field welds have been provided to allow flexibility for shipping and to provide
flexibility for the fabricator. Pipe spool pieces that are to be field welded have been provided with an
additional pipe length to accommodate installation of pipe. This extra length of pipe can be cut to fit as
needed by contractor. Breakpoints and field welds are shown on the piping isometric drawings. Piping
smaller than 2-1/2” and greater than 8” will be supplied at straight pipe runs and loose fittings for field
fabrication.
5.1 PIPE FITTING TOOLS REQUIRED
a. Pipe threading machine
b. Hand tools: Pipe wrenches, Crescent wrenches
c. Tubing benders
d. CPVC and PVC pipe cement
e. Welding machines
f. Pipe cutting machine
g. Grinding machines for edge preparation
h. Jack screws
i. Small capacity press

j. Hoisting and rigging equipment.
PIPING INSTALLATION
1. Cleaning of all welded joints will be done as per the owner’s requirements.
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2. To prevent rust formation, all SS welds must be top clear coated with polyurethane after acid
cleaning.
3. Pipe welding should be per ASME approved procedures.
4. All welds must be free from defects (i.e. splatters, undercuts, overlaps etc).
5.2 PIPING
Field Installed Piping generally consists of combination of the following:
A. Metallic Piping
B. Plastic Piping
A. METALLIC PIPING
Metallic Piping may be further divided into carbon steel piping or stainless steel piping,
depending on the application.
Carbon and stainless steel piping are provided with field joints to facilitate ease of
installation. In case of stainless steel piping insulating strips of rubber or equivalent material must be
placed between stainless steel piping and painted steel pipe supports or structural steel. These
insulating strips must also be placed between the galvanized U-bolts and the stainless steel.
B. PLASTIC PIPING
Plastic piping is generally site fabricated to the maximum extent possible to facilitate
flexibility for installation.
 Method of permanent joining- Solvent cements.
 Suitable for mechanical joining.
5.3 INSPECTION AND TESTING OF PIPING

Inspection and testing of all the piping (metallic and non-metallic) will be done as per the
owner’s requirements.
Major equipment such as vessels, heat exchangers, pumps, and compressors shall be
isolated from the pipeline test.
5.4 FLUSHING OF PIPING LINES
All piping (metallic and non-metallic) and tubing must be flushed thoroughly with water,
especially any threaded galvanized piping to ensure removal of filings, burrs, chips, slag, or other
foreign objects.
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5.5 INSTALLATION OF TUBING

Field installation of instruments, sampling points and analyzer instruments should be as
per Aquatech detail drawings. Any tubing between instrument, sampling points, analyzer, etc.
and the hook up point on piping or local panel are to be installed by the installation contractor.
5.6 INSTALLATION OF PIPE SUPPORTS

Pipe supports are used to secure the piping to its position during operation.
The nozzles on any tank, vessel, or pump are not designed to support piping loads alone.
If such a condition is observed, it will be necessary to fabricate additional supports so that the
load is not transferred to these nozzles. All such changes will be done after consulting with an
Aquatech representative.
The shop fabricated pipe supports are to be checked and the dimensions confirmed per
pipe support and piping drawings. Using a surveyor’s level, the support location is to be identified
and marked, with reference to the plant co-ordinate points. The pipe supports are oriented as
indicated pipe support location drawing at their pre-determined locations and installed on the
specified locations and fixed in place with anchor bolts of sizes as specified in drawing. If
required, shims may be used to maintain the proper elevation. Then the support foundation is
filled with grout.
6. MEDIA AND RESIN LOADING PROCEDURE

Prior to media loading, vessel internal inspection must be completed.
The vessel internals may be of one or a combination of the following:
1. Internal Distribution Headers with Laterals.
2. Strainer Plate with Strainer buttons.
1. The Internal Distribution Headers are to be checked for

a. Tightness of Header Flanges.
b. Usage of Correct Gaskets.
c. Usage of Correct Size Hardware.
d. Usage of Correct Size U-Bolts.
e. Tightness of Laterals.
f. Damages on Laterals.
g. Damages on Lateral Screens.
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2. The Internal Strainer Plates with Strainer Nozzles are to be checked for
a. Tightness of Strainers Nozzles (Buttons).
b. Damages (Cracks) if any on a Strainer Nozzle (button).
c. Usage of Lock Washers.
d. Check for no gap between the Nozzle and Plate.
6.1 STRAINER NOZZLES

There are two (2) parts to a strainer nozzle. The main assembly and the lock nut
arrangement. Sometimes a kynar strainer has a double nut arrangement wherein holding the nut
on the top portion and tightening the mating nut at the bottom portion tightens it. To inspect the
strainers one person has to hold the top nut by entering the vessel through the top manway,
another person has to tighten the bottom nut by entering the vessel through the access port
provided below the strainer division plate. The persons doing the above inspection and
installation should take care not to step on the strainers as they may get damaged.
The strainer plate may be a split panel type or single lined plate. In case of split panel
type, strainer plates are to be inspected for tightness, since they are bolted onto the panel
supports. Then the weir plate elevation and the launder slope is to be checked with respect to the
drawing.
Before the internals inspection, open the top manway, bottom manway and, preferably,
any other vessel nozzles. Fix a ventilation fan or a forced draft on one of the top manway
openings and exhaust the stagnant gases from the vessel by running the exhaust fan. After about
half an hour, check the oxygen level inside the vessel. If oxygen level is acceptable, fix one or
two lamps inside the vessel so that sufficient working light is available. Ensure safe working
oxygen levels and proper lighting during confined area work is being performed. Follow prevalent
safety codes for confined space entry. In absence of any, follow OSHA codes for the same. The
persons entering into the vessel should use safety belts with rope ladder only. Also ensure
persons entering into the vessel should not wear hard sole shoes as they may damage the kynar
strainers. They should not carry any sharp edge items that can cause damage to the lining.
The strainer plates also are to be inspected for tightness since they are bolted on to the
panel supports. The weir plate elevation and the launder slope is to be checked with respect to
the drawing. The sub-contractor has to conduct the necessary checks as specified by the owner’s
requirements.
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6.2 WALNUT SHELL AND MEDIA FILTER LOADING PROCEDURE

a. Remove the media trap from the bottom of the vessel. Thoroughly flush filter unit and
associated pipeline in service flow path and backwash path. Flush all piping on the
vessel.
b. Flush until the water coming out is clear and free of debris.
c. Install the media trap.
B. PREREQUISITES FOR WALNUT SHELL AND MEDIA FILTER LOADING

a. Ensure the correct type and quantity of the media is available per the table in Section E
below.
b. Install the scaffoldings near the vessel for media loading. Prepare rigid platform to store
the media bag on the top of the scaffolding.
c. Line up the media bags or jumbo sacks (as the case may be) near to the vessel.
d. Arrange forklift to lift the one by one media bags and store on the platform.
e. Feed water supply is available (either by commissioning the upstream equipment or
arranging a temporary water source of required pressure).
f. Instrument air supply is available.
g. Required tool & tackles is available.
h. Flashlight is available.
i. Chain, pulley and Bucket to load media.
C. PRE-CHECKS
Before loading the media, carry out detailed inspection of the empty vessel as follows:
a. Open the top manway, bottom manway and media removal nozzle on the vessel.
b. Allow the vessel to remain like this for at least 4 hours to ensure that any gases
entrapped are released out.
c. Connect a portable blower at the bottom manway to create a continuous draft of air in the
vessel.
d. With the help of a flashlight carry out a visual inspection of the vessel to check for any
debris or unwanted objects.
e. Keep all the valves in closed position.
f. Isolate all in-line instruments from the system.
g. Monitor the oxygen level in the vessel with the help of a portable oxygen analyzer.
h. Ensure that all the local regulations of Confined Space entry are strictly followed and then
the inspection personnel should go inside the vessel.
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i. Inspect strainer nozzles for damage, splitting of the slots and tightness. Two persons are
required to accomplish this.
j. Make sure that no construction material tools plastic sheets, debris is left inside the
vessel.
k. Close bottom manways after inspection. If manway gaskets are worn and does not seal
well, replace manway gaskets before closing manways.
D. WALNUT SHELL AND MEDIA LOADING

a. Close Media removal nozzle.
b. Close all the valves. Fulfill all regulations of confined space entry and then one person
shall go inside the vessel.
c. With forklift lift and store one bag of gravel or media on the platform. Open the bag. With
chain pulley and bucket slowly transfer the gravel or media inside the vessel. The person
in the vessel shall empty the bucket carefully. Caution must be taken care so that the
gravel or media does not fall on the nozzles from a high elevation.
d. Once the first layer of gravel or media is loaded, the person in the vessel will smooth the
top surface to a uniform height.
e. If additional layers of gravel or media are required, steps c and d are repeated until all the
required material has been added. The top surface is leveled after the person inside the
vessel has climbed out. After leveling the top media, close the top manway.
f. Open vent valve. Fill the vessel with water through Service Inlet (SEVI) valve
g. Fill the vessel with water, close all the valves and soak for 12 hrs.
h. Backwash the media for 30 minutes, according to flow rate shown on sequence chart to
remove the fines from the media. Repeat the backwash till the backwash water runs
reasonably clear of fines.
i. Carryout a slow rinse by opening Service Inlet (SEVI) valve and Fast Rinse Outlet (FRO)
valve. Observe to confirm that no large gravel or media are leaking out of the vessel. This
can be done by monitoring the water sample at the media trap blow-down valve. Initially
expect some amount of broken particles or fines, which should eventually stop. If whole
particles are continually observed then some of the nozzles in the vessel are damaged or
leaking. In such a case the media needs to be removed and vessel strainer nozzles are
to be re-checked and replaced if required.
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E. MEDIA LOADING QUANTITIES
The filter media type and loading quantities are presented in the following table:
Quantity
Vessel Material
per Vessel
Walnut Shell Filter Deep Black Walnut Shell 521 ft³
Anthracite 745 ft³
Sand 370 ft³
Media Filter Gravel #6 - #12 69 ft³
Gravel ¼ - ½” 65 ft³
Gravel 270 ft³
6.3 RESIN LOADING PROCEDURE

a. Remove resin trap from the bottom of the vessel. Thoroughly flush the unit and
associated pipeline in service flow path and backwash path. Flush all piping on the
vessel.
b. Flush until the water coming out is clear and free of debris.
c. Install the Resin trap.
B. PREREQUISITES FOR RESIN LOADING

a. Ensure the correct type and quantity of the resin is available.
b. Line up the resin barrels or jumbo sacks (as the case may be) near to the vessel.
c. Ensure that Resin Loading Eductor is available.
d. Hoses for required lengths and size suitable for the resin eductor are available.
e. Service water supply is available (either by commissioning the upstream equipment or
arranging a temporary water source of required pressure).
f. Instrument air supply is available.
g. Required tool & tackles are available.
h. Flashlight is available.
C. PRE-CHECKS
Before loading the RESIN, carry out detailed inspection of the empty vessel as follows:
a. Open the top and bottom manway and resin removal nozzle on the vessel.
b. Allow the vessel to remain like this for at least 4 hours to ensure that any gases
entrapped are released out.
c. Connect a portable blower at the bottom manway to create a continuous draft of air in the
vessel.
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d. With the help of a flashlight carry out a visual inspection of the vessel to check for any
debris or unwanted objects.
e. Keep all the valves in closed position.
f. Isolate all in-line instruments from the system.
g. Monitor the oxygen level in the vessel with the help of a portable oxygen analyzer.
h. Ensure that all the local regulations of Confined Space entry are strictly followed and then
the inspection personnel should go inside the vessel.
i. Inspect strainer nozzles for damage, splitting of the slots and tightness. Two persons are
required to accomplish this.
j. Carefully inspect the rubber lining for damages.
k. Make sure that no construction material tools plastic sheets, debris is left inside the
vessel.
l. Close manways after inspection. If manway gaskets are worn and do not seal well
replace manway gaskets before closing manways.
D. RESIN LOADING FOR CATION UNITS

a. Close Resin removal nozzle.
b. Open service inlet valve and manual vent valve. Fill the vessel with water to 50% level to
allow settling and avoid resin damage.
c. Close all the valves. Open Resin loading nozzle and manual vent valve.
d. Prepare the resin eductor for operation. Connect a hose between the discharge end of
the eductor and the vessel’s resin fill nozzle. Connect another hose between the power
water end of the eductor and the water source. Attach a piece of PVC pipe to the suction
end of the eductor.
e. Add water in resin barrel to fluidize the resin and dip the suction pipe of the eductor into
the barrel.
f. Open the tank drain valve and start water supply to eductor. Adjust the water flow to the
optimum such that excessive water is not consumed for the operation. The resin will now
start getting sucked into the eductor and travel to the vessel. Add water in the barrel as
needed to keep the resin fluidized Load 25% of resin volume. Stop water supply and
close the tank drain valve and fill nozzle.
g. Open vent valve. Fill the vessel with water through Service Inlet (SEVI) valve.
h. Close vent valve. Carryout slow rinse by opening Service Inlet (SEVI) valve and Fast
Rinse Outlet (FRO) valve. Observe to confirm that no whole resin beads are leaking out
of the vessel. This can be done by monitoring the water sample at the resin trap blow-
down valve. Initially expect some amount of broken resin particles or fines, which should
eventually stop. If this is OK, proceed to next step. If whole resin beads are continually
observed then some of the resin nozzles in the vessel are damaged or leaking resin. In
Rev A
Page 35 of 36
such a case the resin needs to be removed and vessel strainer nozzles are to be re-
checked and replaced if required.
i. After ensuring that there is no resin leak from the vessel, load the remaining Cation resin
in the manner explained above.
j. Once resin loading is complete, close the resin fill nozzle and manual vent valve. Repeat
the backwash till the backwash water runs reasonably clear of fines.
E. RESIN LOADING QUANTITIES
The filter media type and loading quantities are presented in the following table:
Quantity
Vessel
per Vessel
Primary Strong Acid Cation 708 ft³
Polishing Strong Acid Cation 522 ft³
Rev A
Page 36 of 36

MUK-62-MGT-AIC-09004 Rev A WTP Install. & Erec. Proc. 110314

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MUK-62-MGT-AIC-09004 Rev A WTP Install. & Erec. Proc. 110314

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ERECTION AND INSTALLATION MANUAL

WATER TREATMENT PLANT – PHASE 2

PROJECT DOCUMENT NO:

ERECTION AND INSTALLATION PROCEDURE

OCCIDENTAL MUKHAIZNA LLC

DOCUMENT REVISION HISTORY

1.1 TYPICAL STANDARDS UTILIZED

2. MATERIAL RECEIPT AND STORAGE

2.1 TOOLS REQUIRED

3. GENERAL INSTALLATION INSTRUCTIONS

3.1 MECHANICAL EQUIPMENT LIST

4.1 INSTALLATION OF MAJOR EQUIPMENT

E. CHEMICAL STORAGE TANKS AND ATMOSPHERIC TANKS

5. INSTALLATION OF INTERCONNECTING PIPING

5.1 PIPE FITTING TOOLS REQUIRED

6. MEDIA AND RESIN LOADING PROCEDURE

6.1 STRAINER NOZZLES

1. HEALTH AND SAFETY

1.1 TYPICAL STANDARDS UTILIZED

1.2 GENERAL PLANT SAFETY PROVISIONS

1.3 STORAGE AND HANDLING OF WATER TREATMENT CHEMICALS

1.4 SPILLS AND LEAKAGES

1.5 FIRST AID

1.6 CONTACT WITH THE EYES

1.7 ELECTRICAL SAFETY

Aquatech International Corporation will assume no responsibility for any injury in

2. MATERIAL RECEIPT AND STORAGE

2.1 TOOLS REQUIRED

a. Cranes, Cherry Pickers, Man Lifts, Fork Trucks

d. Variety of Spreader Bars

c. Cable Chokers, Cloth Chokers

d. Come-along, Chain Falls

f. Any other rigging equipment that may be required

g. Water Proof Tarps

2.2 INSPECTION OF MATERIALS RECEIVED

2.3 HANDLING AND STORAGE REQUIREMENTS

2.4 STORAGE AND PRESERVATION PROCEDURES

A. EPOXY LINED VESSELS

D. PUMPS AND FACE PIPING SKIDS

F. LOCAL JUNCTION/SOLENOID BOXES

Reinforced polyethylene tarpaulins in excellent condition must be used if indoor storage is

H. WALNUT SHELL MEDIA, MIXED BED MEDIA AND CATION RESINS

2.5 UNLOADING, LIFTING, RIGGING AND INSTALLATION REQUIREMENTS AND

REFER TO THE GENERAL ASSEMBLY DRAWINGS BEFORE ATTEMPTING TO LIFT ANY

3. General Installation Instructions

3.2 INSTALLATION SEQUENCE

3.3 INSTALLATION PROCEDURE

4.1 INSTALLATION OF MAJOR EQUIPMENT

4.2 PROCEDURE FOR INSTALLATION OF MAJOR EQUIPMENT

B. FACE PIPING SKIDS

1. Check Civil Foundations

2. Mark the location of the Skid as per General Arrangement drawing

4. Install the Skids on the Marked Location

5. Align and Level the Skid

6. Provide shims as required

7. Anchor the Skid

8. Check Piping Levels for Plumbness

9. Grouting of Face piping skid

1. Check Civil Foundations

2. Mark the location of the Skid as per General Arrangement drawing

4. Install the Skid on the Marked Location

CAUTION: In no case attach slings to branch pipes or flanges on skids to maneuver

5. Align and Level the Skid