Red Sea Utility Assets and Infrastructure Project

ELECTRO-CHLORINATION SYSTEM
Classroom Training in Tiejun Site
 Contents
1
Safety Precautions
2 System Description

4 Process Flow Diagram

5 Main Equipment

6 Operation procedures

7 Shut Down Procedure

8 Maintenance & Precaution

3
9 Trouble Shooting
 SAFETY PRECUATION

Symbols and Signs

 SAFETY PRECUATION

Symbols and Signs

Corrosive

Hazard of corrosive substances.

Personal injury and property damage as consequence.

Irritant

Hazard of irritant substances.

Minor personal injury as a consequence.

High Pressure

Pressurized liquids and gases.

Personal injury and property damage as consequence.
 SAFETY PRECUATION

Symbols and Signs

Fire Hazard

Hazard by combustible agents.

Personal injury and property damage

Respiratory Mask

As a protection against toxic gases or dusts.

Prevention of respiratory injuries.

Goggles
As a protection against hazardous substances and strong
effects of light.
Prevention of eye injuries and blinding.
 SAFETY PRECUATION

Symbols and Signs

Safety Boots
As a protection against falling-down parts, sharp objects
and hazardous substances.
Prevention of foot injuries.
Wear it unconditionally!
Face Protection
As a protection against hazardous substances and strong
effects of light.
Prevention of eye and face injuries and blinding.
Wear it unconditionally!
 SAFETY PRECUATION

Listed below are the specific system precautions that shall be ensure that
personnel do not suffer any physical injury during operation

1 Permit to work should be taken before any activity.

2 There is a routine inspection every 2 hours at least.

3 Power off the supply when inspect the equipment.

4 Energize the motor, so wear insulation shoes and gloves.

5 Irrelevant personnel shall be prohibited from entering.

6 Lighting shall provide for safe operating conditions.

7 Check shaft temperature and vibration are in normal range.

8 Valves to be check for operating correctly.

 SYSTEM DESCRIPTION

System Description

Desalination membranes are very sensitive, and pre-treatment filters out most of the
suspended matter and colloids occurring naturally in seawater, such as silt, algae,
bacteria, and plankton. Water quality is crucial for ensuring steady operation, long
membrane life and reduced cleaning requirements. An elaborate pre-treatment system
functions to remove the colloidal, particulate content in the feed sea water to ensure
feed is suitable for continuous reverse osmosis operation. However, the biological
content, that grows exponentially, and could potentially lead to blockages in the intake
pipeline and subsequent plant disruption, is treated with sporadic bursts of sodium
hypochlorite (shock dosing).

Electro-chlorination system is provided to generate Sodium Hypochlorite. Sea Water

Electro chlorination can produce up to 0.18-0.2% (1800 to 2000 mg/l) of NaOCl.
Generated Sodium Hypochlorite will be dosed into the seawater intake pipeline to
protect against bio fouling of intake structures and equipment. The onsite generation
of sodium hypochlorite from seawater is performed by electrochemical process by
partial electrolysis of sodium chloride contained in seawater as it flows through the
DC operated electrolysers. The system consists of the following sections per stream.
 SYSTEM DESCRIPTION

The system consists of the following sections per stream.

Sea Water Booster Pumps

Sea Water Filters
Sea Water feed to Electrolyzes
Sea Water feed to Electrolyzes
Sodium Hypochlorite Storage and Hydrogen Dilution System
Electrical conversion Units
Hypo Chlorite-Dosing System
Acid cleaning system

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 SYSTEM DESCRIPTION

System Description
Sea Water Booster Pumps

The sea water booster pumps 31QCJ10AP001/ 31QCJ20AP001 (one working and
one standby) ensures the desired seawater flow rate to the electro-chlorination
system.

Sea Water Filters

The self-cleaning filters (31QCJ40AT001 & 31QCJ50AT001) remove the

suspended solids from seawater and automatically eject the collected material to
the drainage without interrupting the main flow of filtered seawater. This filtered
seawater is fed to the electrolyser.

Sea Water feed to Electrolyzes

The Sea water booster pump 31QCJ10AP001/31QCJ20AP001 VFD control the

constant feed flow by adjusting frequency with respect to required follow in flow
transmitter 31QCJ45CF001
 SYSTEM DESCRIPTION

System Description

z Sodium hypochlorite generating Electrolysers

2 x 100% Sodium hypochlorite generators (31QCJ46BB001 & 31QCJ47BB001)

are provided, one operating and one standby. Each generator comprises of one
Parallel Plate Bipolar Electrolyser. Each bipolar electrolyser consists of
electrolytic cells of modular construction, connected in electrical and hydraulic
series. The electrode assembly is placed inside an electrolyser body. The modular
cells are bipolar in design. Seawater is fed to the electrolyser through Sea Water
Booster pump after filtering the debris with automated self-cleaning filter. As
seawater flows through the Electrolyser DC current is applied with Thyristor
controlled Rectifier.

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 SYSTEM DESCRIPTION

System Description

Sodium Hypochlorite Storage and Hydrogen Dilution System

The seawater with generated Sodium hypochlorite, coming from the Bipolar
electrolyser flows to the Gas separator (31QCO75BB001) which allows
disengagement of hydrogen gas from the liquid phase at the upper part of the
separator. After separation, the liquid flows to the storage tank. The gas
separator is flushed by a continuous stream of air with the help of air blower
(31QFD61AN001, 31QFD62AN001) in order to keep the hydrogen content
inside the header, separator, and vent pipes at about 1% by volume.

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 SYSTEM DESCRIPTION

System Description
Electrical conversion Units

The Electrolyser system will have a Transformer Rectifier (T-R) Unit. The T-R
provides direct current to electrolyser, which helps to generate sodium
hypochlorite solution. Two independent Transformer Rectifiers are provided
one for each Sodium hypochlorite generator comprising of one bipolar
electrolyser. Each Transformer Rectifier is designed to relevant Sodium
Hypochlorite generator with DC current which can be continuously and
automatically controlled.

Hypo Chlorite-Dosing System

The Hypo dosing pumps (31QCO25AP001, 31QCO26AP001,

31QCO27AP001) are used to inject the hypochlorite solution from NaOCl
storage tank (31QCO15BB001) into seawater circuits. The system is designed
to perform shock dosing at an interval of 12 hours for a duration of 30 minutes.

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 SYSTEM DESCRIPTION

System Description

Acid cleaning system

The products generated by the side reaction during the electrolysis process get
accumulated on the electrodes. The fouling takes place due to the presence of
Calcium and Magnesium salts in seawater. The precipitation is periodically
removed by dissolving it in a solution of diluted hydrochloric acid. The cleaning
does not require any dismantling and done by circulating dilute Hydrochloric acid
through the Electrolyser. The acid cleaning system consists of an acid preparation
tank (31QCS55BB001) and acid circulation pump (31QCS50AP001,
31QCS60AP001).

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PROCESS FLOW
CHEMICAL REACTION
 Main Equipment's

Main equipment

No. Equipment KKS code

1 SEPARATOR 31QCO75BB001
Rotary Screw Compressor – Hydrogen Dilution 31QFD61AN001
2
Blower 31QFD62AN001
31QFD61AT001
31QFD62AT001
3 Filters
31QCJ05AT001
31QCJ15AT001
31QCJ46BB001
4 Electrolyzes – 2 No (1W + 1S)
31QCJ47BB001
31QCJ40AT001
5 Self-Cleaning Filters – 2Nos (1W + 1S)
31QCJ50AT001
31QCJ10AP001
6 Sea Water Booster Pump - 2Nos (1W + 1S)
31QCJ20AP001
31QCO25AA001
7 NaOCl Shock Dosing Pump - 3 (2W + 1S) 31QCO26AA001
31QCO27AA001
8 NaOCl STORAGE TANK - V = 12 m3 31QCO15BB001
9 ACID TANK - V = 500 ltr 31QCS55BB001
31QCS50AP001
10 Acid Re-Circulation Pump - 2 (1W + 1S)
31QCS60AP001
 OPERATION PROCEDURE

SYSTEM START-UP

Electro chlorination is a fully automated process, which is initiated from the HMI. The
master routine handles the production request from the operator, checks the available
equipment and reports the feasible production target back to the operator. The operator
interacts with the master routine using the plant recipe, where the operator enters the
request, receives the plant feedback, and executes the basic commands.

The master routine and electro-chlorination system routines, have a master/slave

configuration, where the master routine is the master, and the electro-chlorination system is
the slave. Based on the production requirements, and the sodium hypochlorite solution
requirements for the intermittent shock dose, the master calculates the individual slave
targets. The slaves report the number of available units back to the master.

According to the start-up, normal or shutdown procedure, the master gives the command for
the operation of the electro-chlorination system. The slave, electro-chlorination system,
reports back which units are in operation and the actual flow output.
 OPERATION PROCEDURE

SYSTEM START-UP

Master routine will send two signals to the hypochlorite dosing

system:

 To start the Hypochlorite dosing system, 2 minutes after the start of the SBS dosing
system. If the signal is 0 then the hypochlorite system will stop and after a delay
the SBS dosing will stop.

 During the shock treatment, required MG/L of hypochlorite & dosing timer.

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 OPERATION PROCEDURE

General Start-Up Sequence

Starting the electro-chlorination system is manual from the HMI, however, the
operator can change the process set values on the screens by dictating
parameters (such as the time between shock dosing, timers and set values of the
acid wash program). The normal operating mode of the electro chlorination is auto
mode.
The following sequences are involved in operation of the electro-chlorination
system:
1. On-off valve 31QCJ01AA121 opening – manual from the HMI by operator or
automatic by clock counter set point.
2. Start-up of sea water booster pump: 31QCJ10AP001 or 31QCJ20AP001.
3. Start-up of filters 31QCJ40AT001 or 31QCJ50AT001.
4. Start-up of hydrogen dilution blower 31QFD61AN001 or 31QFD21AN001.
5. Start-up of the working electrolyser: 31QCJ46BB001 or 31QCJ47BB001.
6. Start-up of hypochlorite dosing pumps: 31QCO25AP001 or 31QCO26AP001 or
31QCO27AP001.
 OPERATION PROCEDURE

General Start-Up Sequence

At the beginning of each operating cycle, the operator will select

the following from the HMI.

1. The working sea water booster pump: 31QCJ10AP001 or 31QCJ20AP001.

The working self-cleaning filter: 31QCJ40AT001 or 31QCJ50AT001 with the
corresponding on off valve: 31QCJ40AA121 or 31QCJ50AA121.
2. The working electrolyser: 31QCJ46BB001 or 31QCJ47BB001 with the
corresponding on-off valve: 31QCJ46AA101 or 31QCJ47AA101.
3. The working blower: 31QFD61AN001 or 31QFD21AN001.
4. The two working hypochlorite dosing pumps: 31QCO25AP001 or
31QCO26AP001 or 31QCO27AP001.
5. The on-off valve which will correspond to the desired injection point:
31QCO31AA121 or 31QCO32AA121
 OPERATION PROCEDURE

Permissive Startup

Per missives for Start-Up In order to start-up de electro-

chlorination system, the following shall be checked

1. The electrolyser (31QCJ46BB001 / 31QCJ47BB001) cannot be started without

the hydrogen dilution air blower in operation (31QFD61AN001 /
31QFD62AN001).
2. Before opening the on-off valve 31QCJ01AA121 (the entering to the electro-
chlorination system) the flow in the line shall be checked with the aid of FIT-
31GAF40CF001 in order to protect the sea water booster pumps
31QCJ10AP001 / 31QCJ20AP001.
3. Before opening the electro-chlorination system, it shall be also verified the
SBS dosing system to be opened in order not to damage the membranes.
 OPERATION PROCEDURE

Permissive Startup
Sea water Booster Pumps

Once the operator starts the electro-chlorination system manual from HMI, they
shall also select the route and the equipment involved in the process.
The sea water booster pumps 31QCJ10AP001/ 31QCJ20AP001 starts
automatically once the following preconditions are met: 1.
1. The flow transmitter FIT-31GAF40CF001 is indicating the desired flow.

2. The on-off valve 31QCJ01AA121 from the inlet of electro-chlorination system is

opened.

Sea Water Filters

The Self-Cleaning Filters (31QCJ40AT001 & 31QCJ50AT001) starts automatically

once the following preconditions are met: 1.
1. The sea water booster pump 31QCJ10AP001 or 31QCJ20AP001 is working,
2. The corresponding on-off valve 31QCJ40AA121 or 31QCJ50AA121 of the
chosen filter is open
 OPERATION PROCEDURE

Permissive Startup
Electrolysers
After the first sequence when operator has chosen the involved equipment's, in
this case the working electrolyser: 31QCJ46BB001 or 31QCJ47BB001, the unit
starts automatically once the following preconditions are met:
1. Sea water booster pump is available & ready for operation.
2. Self-Cleaning filter is available & ready for operation.
3. Flow indicator and control (31QCJ45CF001)indicate the set value.
4. One of the hydrogen dilution blowers 31QFD61AN001 or 31QFD21AN001 is
available and ready for operation
5. The on-off valves (31QCJ46AA101 and 31QCJ46AA102) for the electrolyser
31QCJ46BB001 are opened:
6. The acid cleaning solution inlet valve 31QCS15AA102, outlet valve
31QCS57AA102 and the on off valve 31QCS56AA102 are closed position
when the electrolyser 31QCJ47BB001 is online. Similarly, the acid cleaning
solution inlet valve 31QCS15AA101, outlet valve 31QCS57AA101 and on-off
valve 31QCS56AA101 are closed position when the electrolyser
31QCJ46BB001 is used.
 OPERATION PROCEDURE

Permissive Startup
7. On-off valve 31QCO15AA001 on the header from the separator
31QCO75BB001 and the sodium hypochlorite storage tank 31QCO15BB001 shall
be opened.
8. Level indicator LIT-31QCO15CL002/31QCO16CL002 from the sodium
hypochlorite storage tank is not indicating High (H or HH) levels in the tank.

Sodium Hypochlorite Dosing System

The hypochlorite dosing system starts automatically once the following

preconditions are met: 1.
1. Level Indicator (31QCO15CL002/31QCO16CL002) from the sodium
hypochlorite storage tank (31QCO15BB001/31QCO16BB001) indicate the set
value for normal operation. 2.
2. Two hypo dosing pumps from 31QCO25AP001, 31QCO26AP001,
31QCO27AP001 are available and ready for operation. 3.
3. The on-off valve 31QCO31AA121 or 31QCO32AA121 corresponding to the
injection points is opened.
 OPERATION PROCEDURE

Permissive Startup
Acid cleaning system

The acid cleaning starts automatically once the following preconditions are met:
1. Level Indicator (31QCS55CL001) from the Acid Tank (31QCS55BB001) indicate
the set value for normal operation. 2.
2. One of the acid recirculation pumps 31QCS50AP001 or 31QCS60AP001 is
available and ready for operation. 3.
3. The acid cleaning solution inlet valve 31QCS15AA102 and outlet valve
31QCS57AA102 are in open position and the on-off valve 31QCS56AA102 is in
closed position when the electrolyser 31QCJ47BB001 is in the washing
sequence. The on-off valves 31QCJ47AA101 and 31QCJ47AA102 shall be in
closed position. Similarly, the acid cleaning solution inlet valve 31QCS15AA101
and outlet valve 31QCS57AA101 are in open position and the on-off
valve31QCS56AA101 when the electrolyser 31QCJ46BB001 is in the washing
sequence and the on off valves 31QCJ46AA101 and 31QCJ46AA102 shall be
in closed position. When the washing sequence of the electrolyser is over the
on-off valves 31QCS56AA101 or 31QCS56AA102 will be opened in order to
direct the acid from the system to the neutralization pit.
 OPERATION PROCEDURE

NORMAL OPERATION
 Prior to the electro-chlorination system operation, the operator shall select the
route, to set the valves in the plant and to set the route in the HMI. Only after
meeting the required permissive, the seawater booster pump will start, and the
production of sodium hypochlorite will occur. The electro-chlorination system is
fully automated. The normal operating mode is auto mode.

 When hypochlorite dosing is required, the on-off valve 31QCJ01AA001 will be

opened by the operator from HMI. A flowrate of 2 m3 /h will go through one of the
sea water booster pumps 31QCJ10AP001 / 31QCJ10AP001 to the self-cleaning
filter 31QCJ40AT001 or 31QCJ50AT001 previously chosen by the operator from
HMI. Differential Pressure switch (PDIT-31QCJ40CP001 PDIT-31QCJ50CP001)
provided across self-cleaning filter (31QCJ40AT001 / 31QCJ50AT001 ) will
continuously monitor the differential pressure and it will initiate cleaning if it
reaches pre-set value.

 The flow indicator and control (FIT-31QCJ45CF001) installed on the discharge line
of the sea water booster pump, keeps constant flowrate to the electrolyser
31QCJ46BB001 / 31QCJ47BB001 by adjusting the sea water booster pump
speed. The operating electrolyser is also chosen previously by the operator from
the HMI.
 OPERATION PROCEDURE

NORMAL OPERATION
• The temperature in the electrolyser is kept under control with the aid of
temperature indication and control TT-31QCJ46CT001 respectively TT-
31QCJ47CT001 in order to limit the formation of the bromine and bromate salts.

• The sodium hypochlorite solution output from the electrolyser is fed into the
hydrogen de-gassing tank 31QCO75BB001 where the product is held for sufficient
time to allow the hydrogen to disperse from the hypochlorite.

• One essential aspect is that the air blowers (31QFD61AN001 / 31QFD61AN001)

have to be opened before the electrolyser, and in the event of failure of the
operating blower the other will start automatically. Auto tripping of the Transformer-
Rectifier unit in the event of failure of both the air blowers is recommended.

• Sodium hypochlorite prepared is stored in the storage tank 31QCO15BB001.

Three VFD shock dosing pumps 31QCO25AP001 / 31QCO26AP001/
31QCO27AP001 are used to inject the hypochlorite solution into seawater circuits.
The flowrate sent to the injection points is controlled by flow indication and control
FIC-31QCO30CF001. The system is designed to perform shock dosing at an
interval of 12 hours for a duration of 30 minutes.
 OPERATION PROCEDURE

Set Points

Set Points The hypo dosing skid will use mg/l to calculate the desired
dosing rate based on the strength of the solution & intake flow. Operator will
have option to set and adjust mg/l in the HMI. Tabulated below, are the
initial set points for the hypochlorite dosing skid. These values are
adjustable on HMI screen and can be changed by the operator as per the
requirement of the plant.

Description HMI Variables (can be modified

by operator on HMI screen)
Hypo Dosing Rate during shock Mode 10 MG/L
Duration of shock treatment 30 min

HMI Variables for Start-Up – Electro-chlorination System

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 SHUTDOWN PROCEDURE

System Shutdown
Shock Chlorination is a timer based operation and shall be done once or twice a day
for 30 mints. Shut down can be executed automatic through interlock:
1. Booster Pump VFD & Flow transmitter (FIC-31QCJ45CF001) provided at the
inlet of the Electrolyzes unit will control the seawater flow rate. In case of low
flow, it will generate an alarm and stop the running electrolyzes
(31QCJ46BB001 / 31QCJ47BB001)
2. Electrolyzes (31QCJ46BB001 /31QCJ47BB001) outlet temperature High
Alarm (TT- 31QCJ46CT001 / TT-31QCJ47CT001 ) and Trip - and stop the
running electrolyzes.
3. Transformer rectifier Voltage and Current Alarms / Trip - stop the running
electrolyzes.
4. The storage tank 31QCO15BB001 is equipped with a level indicator
transmitter (LIT 31QCO15CL002/31QCO16CL002) that stops the dosing
pumps (31QCO25AP001 / 31QCO27AP001 / 31QCO25AP001) when the tank
level drops to the minimum level set point.
 SHUTDOWN PROCEDURE

System Shutdown

5. A High-high level alarm at Hypo tank (31QCO15BB001/31QCO16CL002)

will automatically trip the system – including stop the running electrolyzes.

6. Auto tripping of the Transformer-Rectifier unit in the event of failure of both

the air blowers (31QFD61AN001 / 31QFD61AN001).

7. A Low-Low level alarm at acid tank will automatically trip the running acid
circulation pump.
 SHUTDOWN PROCEDURE

Auto-System Shutdown
The following trip conditions are incorporated towards automatic
shutdown of the system.
 Filtered Seawater flow (31QCJ45CF001) insufficient.
 High solution temperature (31QCJ46CT001, 31QCJ47CT001) at the outlet of
respective electrolyzes.
 High voltage/ current in Transformer - Rectifier.
 Loss of power, Transformer trip, Rectifier Failure
 Hydrogen Dilution Blowers stop/fault.

The following events shall follow the Shutdown of the unit as

minimum events:

 Transformer rectifier switching off.

 Sea Water Booster Pump stopping.
 Hypo Dosing pumps stopping.
 Air blowers stopping.
 SHUTDOWN PROCEDURE

Emergency Shutdown
Events that may lead to an unplanned total plant shutdown:
 Total electrical power failure.
 Emergency situation such as fire, flow, personnel safety, in which the E-stop
(emergency stop) button for total intake or total plant is pressed.
 Critical process interlock occurs.
In a shutdown caused by power failure the following activities
take place:

 All pumps and blower stop immediately.

 Electrically actuated filters are automatically shut down.
 Electrolyser system is stopped.

The use of chlorination is contingent upon sea conditions and is at the plant
manager and operator’s discretion. Free chlorine can cause irreversible damage
to the RO membranes. It is imperative to ensure that the SBS dosing system is
ready for operation before performing theLogo
Company shock treatment procedure.
 MAINTENANCE & PRECUATION

Use, Maintenance and Precautions

The proper usage and good maintenance of sodium hypochlorite generation
installations of electrolysis of sea water serve as the prerequisite of its long-term
stable operation.

As the hydrogen will be generated in the electrolysis, the good ventilation in the
chlorination generation room should be kept in the operation of the generator, and
do not conduct fire working in the workshop.

Even strength should be used on valves opening and closing, especially for UPVC
plastic valve

The corresponding valves on the pipeline should be opened before starting the
pump to make sure the pipeline unblocked, and do not conduct anhydrous
operation. 。

If any vibration or abnormal noise happens in the process of pump operation, stop
the pump immediately for inspection, and work after fault removal
 MAINTENANCE & PRECUATION

Use, Maintenance and Precautions

The rack oil tank of the sea water pump should be filled with lubricating oil as
required; ensure that the oil level is within the specified range and the oil is
replaced regularly. If any leakage happens in the pump, the cause shall be
identified. The seals should be adjusted and the worn parts shall be replaced
in time.

Sludge pumps at the bottom of tanks need to be opened regularly (at least
once a week) for sediment discharge, in case the sediments block the
pipeline and affect the normal working of the auto control instrument.

The voltage of the electrolytic bath should be monitored frequently (normal

value for a bath: 40 ~ 45 V). If the voltage difference of the bath exceeds 5 V,
the electrode of the generator should be acid-washed.

When an alarm signal appears during the operation of the device, the cause
shall be found out and the fault shall be cleared out.

When the chlorination generation devices are in seasonal outage, the liquid
within the exhaust equipment and pipeline should be drained
 MAINTENANCE & PRECUATION

Use, Maintenance and Precautions

In the electrolyzed chlorination generation, the electrolytic current should be strictly
controlled below 2855 A. When the operating current remains within the normal
range, and the operating voltage exceeds 10% of the initial operating voltage, and
the product concentration declines obviously (despite the fact that the accumulative
working hour does not reach 720 h), the electrolytic bath of the generator should be
acid-washed. ；

During the operation of the device, if the wiring terminals of the generator and the
joints of rectifier power electric elements suffer an over-high temperature rise
(above 60°C), the device should be stopped to check whether the terminal stud is
fastened or the contact surface is smooth;

If any leakage happens in the operation, the accurate leakage location should be
checked out. The leakage in the joint of flange can be solved through adjusting or
replacing the sheet gasket and screwing down the bolt with spanner; the leakage in
the union joint of UPVC can be stopped through adjusting or replacing the O-rings
on the sealing surface and screwing down the union joint; leakage in the bonding
joint of UPVC pipe fitting can be welded by PVC welding rod;
 TROUBLE SHOOTIING

Troubleshooting and Handling

No. Fault Reason Handling

When operating the
control cabinet, trouble Default phase in the motor To avoid disrupting operation, “standby” can be put
lamps of machines and and pump into use, and meanwhile the cause shall be
1 pumps is lit and the
emergency alarm bell Overload and jamming in identified and the fault shall be cleared out in time
rings. the motor and pump cleared out in time
Small water flow rate of Check whether the circulating water pump in the sea
sea water manifold water pump room is started.
Low sea water flow rate Insufficient opening of
2 Open relevant sea water valves fully.
alarm of generator relevant sea water valves
Insufficient output of sea
Disassemble the sea water filter for washing.
water pump
Blockage of sea water filter  
Low sea water flow rate of
Adjust the sea water flow rate to the rated value.
generator
High outlet temperature High temperature rise at Check whether the terminal stud is fastened or the
3 alarm of generator the electric terminal contact surface is smooth;
Excessive electrolysis Adjust the electrolysis current to the normal working
current range.
 TROUBLE SHOOTIING

Troubleshooting and Handling

No. Fault Reason Handling
High inlet pressure The outlet valve of the generator is not
4 alarm of generator opened.
Open the outlet valve of the generator.
High differential
Disassemble the automatic flushing filter
5 pressure of automatic Blockage of automatic flushing filter
for inspection and washing.
flushing filter
The accumulative working hour of the
generator exceeds 720 h. (if no acid Shut down the generator, conduct acid
Alarm for acid washing washing is performed and the device washing according to the “5.4 - acid
6 of generator continues to operate at this time, the washing” and the alarm will be removed
rectifier cabinet shall 8 after over 60-minute acid washing.
hours.)automatically trips

Fusing of high-speed fuse

High temperature of elements: the

ultrahigh temperature of radiator is
caused by fan stalling or other reasons.
Rectifier power fault See details at Installation and Operation
7 Fan fault: caused by short circuit of the
alarm Instruction of Electrolysis Power
fan coil or overload.
DC overcurrent: due to sudden changes
of power grid or load, the DC output
current of the rectifier exceeds the
setting value.
 TROUBLE SHOOTIING

Troubleshooting and Handling

No. Fault Reason Handling

The value displayed in the
8 electromagnetic flow meter There is no liquid in the sensor or the  
pipe is not filled with liquid.
exceeds 100%.
Too many gases in the liquid
Fluctuation in the Disturbance of electromagnetic field,
9 electromagnetic flow meter for example, the nearby electromotor
 
gets started.
started.
Extremely low current Set the current to the specified value

10 Low concentration in sodium Improper sampling time Take samples after the equipment stays
hypochlorite in stable operation for 20 minutes.
Low chloride concentration in sea
water  
Check if the sea water pipeline is
The electrolytic bath is not filled with unblocked or the sea water flow rate is
sea water.
After the rectifier cabinet is normal.
11 closed, there is only voltage
and the current is zero. Turn the “OUTPUT ADJUSTMENT”
The “OUTPUT ADJUSTMENT” knob on
the rectifier cabinet is at zero. potentiometer knob on the rectifier
cabinet.