WTP Manual

OPERATION, MAINTENANCE
&
TROUBLESHOOTING
MANUAL
CLIENT
A/C
PROJECT
Ref.
M/S DELTA ENGINEERING CORPORATION

M/S KBK CHEM-ENGINEERING (P) LTD;
D M & SOFTENING PLANT
Job No: 225064
Thermax LTD., (Water & Waste Solutions)

Sai - Chambers, Mumbai Pune Road,
Wakadewadi, PUNE- 4110 03.
Tel: 020-25511010
Fax: 020-25511236.
Improving Your Business Is Our Business

On Thermax Group:
Thermaxs vision is to be a globally respected high performance company offering sustainable
solutions in energy and environment.
The Thermax Group provides business to business solutions in the areas of heating, cooling,
captive power, water treatment, air pollution control, waste management & resource recovery,
and chemicals to a wide range of industry in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power
and waste heat recovery. It also offers a range of heating equipment; energy efficient chillers and
customized products such as waste heat and exhaust gas boilers. Thermaxs integrated
expertise in energy has made GE to choose it as the vendor on first call for its global Combined
Heating Power and Cooling (CHPC) projects...
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of
solid fuels including biomass. The Groups Joint Venture, Thermax Babcock & Wilcox (TBW) has
emerged as a leading and reliable project management company with installations the world
over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries.
Leveraging its leadership position in electricity saving vapor absorption technology, it offers
process industries and commercial establishments like hotels, shopping malls and offices vapor
absorption chillers a boon in power-starved areas. These Eco-friendly, energy efficient
equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch,
Panasonic, Henry Ford Museum.
In the environment area Thermax offers waste management expertise for solid, liquid and air
pollution. Thermax provides solutions from pre-treatment to waste water treatment and chemical
conditioning of water for boiler and cooling water systems. Water recycling is a thrust area for
Thermax. Hi-grade resins from Thermax have found niche customers in US and Japanese
markets.
Thermax has an extensive international marketing network. Headquartered in Pune (Western
India), Thermax's eleven international offices are located in South East Asia, Middle East, Africa,
Russia, UK and the US. Thermaxs 4 overseas subsidiaries play a significant role in generating
business in the International market: Thermax (Rus) Ltd., Thermax (Europe) Ltd., Thermax Inc.,
USA and ME Engineering, UK. Around 20 per cent of the groups turnover comes from exports
to the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS
countries.
The Thermax groups manufacturing facilities. Spread over 14 plants, measuring a covered area
of over 65,000 sq. Mts., are ISO 9000 and ISO 14001 accredited. Thermax manufactures to
international standards like ASME, BS, DIN, and GOST. The facilities have been inspected by
Lloyds, Bureau Veritas, SGS, and TUV.
Thermaxs business is inspired by the conviction that Improving your business is our business.
Water & Waste Solutions

MAKING INDUSTRY GREEN AND COMPETITIVE
Cost competitive and Environment friendly technology innovated and developed through
continuous research to keep industry green and competitive. Excellence in Technology
and stringent quality control measures are the hallmarks in all projects undertaken by
Thermax Water & Waste Solutions Division. Thermax Water & Waste solutions division
takes on Retrofitting and Revamping orders to extend life of all aging plants. Our
comprehensive service program is the first of its kind in India. It is a program that
evaluates and then enhances the economical performance of all water & waste treatment
plants.
Thermax Water & Waste Solution Divisions wide spectrum of products and technology
covers
Pretreatment
Process Water Treatment
Ion Exchange Resins
Reverse Osmosis and Electrodialysis
Condensate Polishing
Thermal Desalination
Waste Water Treatment
Sewage Treatment
Recycling of water
Range of Cooling Water Chemicals
Range of Polyelectrolytes
Incinerators.
TABLE OF CONTENTS
CHAPTER
PAGE NO.
DESCRIPTION
1] Water Treatment: Fundamentals

05 to 11
1.1
WATER TREATMENT GENERAL WRITE-UP 06 to 08
1.2
BASIC WATER CHEMISTRY 08 to 09
1.3
PRINCIPLES OF WATER CLARIFICATIONS . 10 to 18
1.3
DEMINERALIZATION .. 19 to 20
2] PLANT CONFIGURATION & DETAILS.... 21 to 28
PRE-TREATMENT / DM PLANT
2.0
PROCESS DESCRIPTION .... 22 - 24
2.1
PLANT DETAILS ....... 24
2.2
UNIT DETAILS .. 25 - 26
2.3
INSTRUMENT DETAILS .. 27
2.4
RAW WATER QUALITY .. 27
2.5
TREATED WATER QUALITY .. 28
2.6
OUR TERMINATION POINTS . 28
3] Operation & Maintenance For "HRSCC UNIT"
29 to 47
4] Operation & Maintenance For "VERSA-FILTERS"
48 to 80
5] Operation & Maintenance For "Demineralizers"

5.1
Strong Acid Cation (SAC): Operations ...
5.2
Strong Base Anion (SBA): Operations
5.3
Mixed Bed Unit (MB): Operations ..
81 to 141
82 to 100
101 to 118
119 to 141
6] Operation & Maintenance For "FLEXI-DF" .. 142 to 173

7] General Maintenance: DM Plant ....... 175 to 190
7.1
Chemical Specifications (HCl / NaOH /NaCl) ..... 191 to 195
7.2
Chemical Safety ... 196 to 200
8] Laboratory Analysis....... 201 to 246
DAILY LOG SHEET / RESIN DATA / P & ID.. 247 to 268
PAGE NO: 04
THERMAXLTD|WATER&WASTESOLUTIONS
Chapter01
WaterTreatment:Fundamentals
WATERTREATMENTGENERALWRITEUP
BASICWATERCHEMISTRY
PRINCIPLESOFWATERCLARIFICATION
DEMINERLIZATION
M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064
1.1 WATERTREATMENTGENERALWRITEUP
INTRODUCTION
The natural water contains solid, liquid and gaseous impurities and therefore, this water
cannot be used for the generation of steam in the boilers. The impurities present in the
water should be removed before its use in steam generation. The necessity for reducing
the corrosive nature & quantity of dissolved and suspended solids in feed water has
become increasingly important with the advent of high pressure, critical & supercritical
boilers.
IMPURITIES IN WATER
The impurities present in the feed water are classified as given below 1.
2.
3.
4.
Undissolved and suspended solid materials.

Dissolved salts and minerals.
Dissolved gases.
Other materials (as Oil, Acid) either in mixed or unmixed forms.
1. Undissolved and suspended solid materials.

a. Turbidity and Sediment: Turbidity in the water is suspended insoluble matter
including coarse particles, (mud, sediment, sand etc.) that settle rapidly on standing.
Amounts ranges from almost zero in most ground waters and 60,000 ppm in muddy
and turbulent river water. The turbidity of feed water should not exceed 5 ppm.
Settling, coagulation and filtration can remove these materials. Their presence is
undesirable because heating or evaporation produces hard stony scale deposits on
the heating surface & clog fluid system.
Both are objectionable as they cause
damage to the Boiler system. A standard amount of measurement of hardness is
taken as being the amount of Calcium Carbonate (CaCO3) in the water and is
referred to in part per million (ppm) or grains per gallon (grains/gallon * 17.1 = ppm).
b. Sodium and Potassium Salts: These are extremely soluble in water and do not
deposit unless highly concentrated. Their presence is troublesome as they are
alkaline in nature and accelerate the corrosion.
c. Chlorides: Majority of the chlorides causes increased corrosive action of water.
d. Iron: Most common soluble iron in water is ferrous bicarbonate. The water
containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of
ferric hydroxide if exposed to air. Majority of ground surface water contains less than
5 ppm but even 0.3 ppm can create trouble in the feed water system by soft scale
formation and accelerating the corrosion.
e. Manganese: It also occurs in similar form as iron & it is also equally troublesome.
f. Silica: Most natural water contains silica ranging from 1 to 100 ppm. Its presence is
highly objectionable as it forms very hard scale in Boilers and forms insoluble
deposits on turbine blades. In modern high pressure Boilers its presence is reduced
as low as 10-50 ppb.
g. Microbiological Growth: Various growths occur in surface water (lake & river). The
microorganisms include diatoms, molds, bacterial slimes, algae, manganese &
Sulphate reducing bacteria and many others. These can cause coating on Heat
Exchanger and clog the flow passages and reduce the heat transfer rates.
h. Colour: Surface waters from swampy areas become highly coloured due to
decaying vegetation. Colour of feed water is objectionable as it causes foaming in

Boilers and may interfere with treatment processes. It is generally removed by
chlorination or adsorption by activated carbon.
2. Dissolved Salts and Minerals

a) Calcium and Magnesium Salts: The Calcium and Magnesium salts present in the
water in the form of carbonates, bicarbonates, and sulfates and chlorides.
The
presence of these salts is recognized by the hardness of the water (hardness of water
is tested by soap Test). The hardness of water is classified as temporary and
permanent hardness. The temporary hardness is caused by the bicarbonates of
calcium and magnesium and can be removed by boiling. The boiling converts the
soluble bicarbonates into less soluble carbonates, which can be removed by simple
blow down method. The presence of chlorides, sulfates and nitrates of calcium and
magnesium cause the permanent hardness of the water and they can not be removed
just by boiling because they form a hard scale on heating surfaces.
3. Dissolved Gases
a) Oxygen: It presents in surface water in dissolved form with variable percentage
depending upon the water temperature and other solid contents in water. Its presence
is highly objectionable, as it is corrosive to iron, zinc, brass and other metals. It
causes corrosion and pitting of water lines, boiler exchangers. Its effect is further
accelerated at high temperatures.
b) Carbon Dioxide: The river water contains 50 ppm and well water contains 2 to 50
ppm of CO2. It also causes the corrosion of stream, water and condensate lines. It
also helps to accelerate the corrosive action of oxygen. The other gases are H2S,
CH4, N2 and many others but their percentages are negligible, therefore, their effects
are not discussed here.
4. Other Materials
a) Free Mineral Acid: Usually present as sulfuric or hydrochloric acid and causes
corrosion. The presence is reduced by neutralization with alkali.
b) Oil: Generally, the lubricating oil is carried with steam into the condenser and through
the feed system to the Boiler.
It causes sludge, scale and foaming in Boilers.
Strainers and baffle separators generally remove it. The effects of all the impurities
present in the water are the scale formation on the different parts of the Boiler System
and corrosion. The scale formation reduces the heat transfer rates and clogs the
flow passage and endangers the life of the equipment by increasing the temperature
above safe limit. The corrosion phenomenon reduces the life of the Plant rapidly.
Therefore, it is absolutely necessary to reduce the impurities below a safe limit for the
proper working of the power plant.
1.2 BASICWATERCHEMISTRY
RAW WATER AND IMPURITIES
Water as it occurs in nature "pure", and whatever be the source, always contains
impurities either in solution or in suspension. The determination of these impurities
makes analysis of water necessary and removal and control of these impurities make
water treatment essential.
SOURCES
The various sources of water can be broadly classified as:
a)
Rain water
b)
Surface water (Rivers, Streams, Ponds, Lakes, and Reservoirs)
c)
Ground water (springs, Shallow Wells and Deep Wells)
Of the above, logically, rain water is the purest but even this collects and dissolves
atmospheric gases. Further, once in contact with the earth's crust, the rainwater will
gradually dissolve various materials.
IMPURITIES
The major impurities of waters can be classified in three main groups:
1) Non-ionic and Undissolved
2) Ionic and Dissolved
3) Gaseous
1. NON-IONIC IMPURITIES: These are mainly turbidity, salt, mud, dirt and other
suspended matter; microorganisms, bacteria and other organic matter, oil and
corrosion products. It goes without saying that drinking water and most industrial
water supplies should be clear and organic-free.
2. IONIC AND DISSOLVED IMPURITIES: Any salt, which dissolves in water and gives
positively charged Cations and negatively charged Anions, is called electrolyte. Some
of the most common cations in water are Calcium, Magnesium, and Sodium and Iron
rarely Ammonium Manganese.
These Cations are associated with Anions like
Bicarbonates, Carbonates, Hydroxides (the sum of which is termed as Alkalinity),
Sulfates and Chlorides. Presence of Nitrates and Phosphates is normally not very
common. In the water treatment field, the preferred method of expression of these
dissolved impurities is in terms of Equivalent Calcium Carbonate, abbreviated to "as
CaCO3". This is because Calcium Carbonate is a good common denominator as it
has a molecular weight of 100, which facilitates calculations.
3. GASEOUS IMPURITIES
Of the atmospheric gases found in naturally occurring waters, only two, Carbon Dioxide
and Oxygen are the main causes of many corrosion problems.
REMOVAL OF IMPURITIES
Our major concern is industrial water treatment, whereby, water used directly or
indirectly in an industrial process is made suitable for that particular application. The
use of water in boilers for steam generation is an obvious industrial use. Depending on
the process, varying degrees of purity of treated water are required. For example, a
textile processing unit will require soft and clear water for process use; a chemical plant
or electronic components manufacturing unit will require ultra-pure water containing total
dissolved impurities not exceeding 0.5mg/litre or less.
1.3 PrinciplesofWaterClarification
Sedimentation is the process of removing particulate solids from a carrier liquid by the
effects of gravity. This can either provide for higher density solids to be removed from
water through settling or for lower density solids to be removed from water through
flotation. In either case, two basic conditions must be met:
1. The solids to be removed must have a settling velocity (or rise velocity), which
allows for separation in a reasonable time period.
2. A period of quiescent flow is provided to allow separation of the solids from the
liquid phase.
The settling velocity of a particle in a suspension is dependent on a number of factors
as defined by Stoke's Law. Table 1 shows the settling time for various size particles.
Table 1- Particle Size versus Settling Time
Particle Size, mm
Order of Size
1.0
Coarse Sand
0.1
Fine Sand
0.01
Silt
0.001
Bacteria
0.0001
Colloidal
0.00001
Colloidal
Time to Settle
3 Seconds
38 Seconds
33 Minutes
55 Hours
230 Days
6.3 Years
The data in Table 1 shows a strong relationship between particle size and settling rate.
From Stoke's Law, the settling rate of a particle is related to the square of the diameter
of the particle. This means that a particle twice as large will settle four times as fast.
Other characteristics of Stoke's Law are:
The greater the density of the particles relative to the liquid, the faster the settling
velocity.
The larger the diameter of a particle, the higher the settling velocity.
The higher the viscosity of the liquid, the slower the settling velocity.
In practice, suspended solids will typically range in size from coarse sand (1,000 micron
diameter) down to bacteria (1.0 micron diameter) and further to colloidal substances
(0.01 micron diameter).
The settling velocity for particles is greatly affected by the diameter of the particles. As
particle size drops to 10-micron diameter or less, the time required to settle is so long
that it is not feasible to construct a settling area large enough to allow the particles timeto-settle by gravity alone.
Another primary consideration is the viscosity of the liquid, which varies with liquid
temperature. If water temperature changes from 16 C in the summer months to 4 C in
10
the winter months, the water viscosity increases from 1.117 cps to 1.568 cps, which
slows the rate of settling by 30 % or more.
At the same time, the density of the water increases as the temperature drops. Although
this change is minor compared to the change in viscosity, it can still be felt in a settling
basin.
The addition of warmer water to a basin, which contains cooler water leads to short
circuiting as the warmer water flow rises to the surface and reaches the discharge in a
fraction of the normal hydraulic retention time. In contrast, when cooler water enters a
warmer basin, the cooler water is dropped to the bottom of the basin, flows along the
bottom and rises at the basin outlet.
Although a temperature difference of only 2 C seems minor, in a basin containing 1
million gallons of water this is a difference of about 1.6 tons.
To remove dense, readily settleable particles from a suspension, a quiet settling period
can be used to allow the separation to take place. This process can be achieved using a
horizontal, rectangular settling basin as shown by Figure 1 that is used for primary
clarification for raw water clarification, oil and grease removal and other applications.
Figure 1 Rectangular Clarifier
This type of sedimentation basin is comprised of four operating zones.
Inlet Zone
Settling Zone
Sludge Zone
Outlet Zone
The inlet zone of a basin provides energy dissipation and flow distribution by means of
baffles. This provides for laminar flow through the settling zone and allows the solids to
separate from the water. The settling zone is designed to have a long enough hydraulic
retention time to permit solids to travel from the top of the water to the sludge zone
before the flow leaves the settling zone.
11
The sludge zone provides for concentration and removal of the separated solids. As the
flow leaves the settling zone, it enters the outlet zone, which typically consists of an
arrangement of v-notch weirs that provide uniform collection of the water.
A common variation of this rectangular clarifier is the circular sedimentation basin as
shown by Figure 2. Typically, they are fed from the center and the flow then radiates
outward to the periphery for discharge. In a circular basin the influent zone often
consists of a circular baffle or "center well" around the influent feed pipe that dissipates
flow velocity and directs the flow downward and outward through the settling zone.
12
Figure 2 Circular Clarifier
The sludge zone at the bottom of the unit contains a circular scraper mechanism, which
drives the solids to the center sludge hopper for discharge.
The outlet zone usually consists of a series of v-notch weirs around the outside edge of
the basin. Multiple weir launders and serpentine weirs are used on larger basins to
increase weir length.
In the case of solids, which are denser than water and are of sufficient particle diameter,
they will settle to the bottom of the basin as sludge. If the solids are less dense than
water, they will have a "negative settling velocity" and will rise to the surface due to their
buoyancy and form a "scum" or "float" layer. Typically, a scraper mechanism is provided
to remove this layer. This is the primary mechanism behind many oil and grease
removal basins, as well as flotation processes.
Some basins are designed to remove both settleable and floatable solids from the same
quiescent water flow, providing both a bottom sludge zone and a surface float zone for
removal of separated solids.
Coagulation and Flocculation
Once particle size decreases to 10 micron in diameter or less, it is very difficult to
remove the particles by direct sedimentation in a reasonable amount of time. And, as
Stoke's Law indicates, there are only three ways to increase a particle's settleability:
Increase the density of the particle relative to the water

Reduce the viscosity of the water
Increase the effective size of the particles.
13
The density of the particles is not typically a variable, and the density of water changes
only slightly due to temperature changes. Therefore, this is not usually a workable
option.
The viscosity of the water will affect the rate of sedimentation and is normally a seasonal
change caused by water temperature fluctuations. Even when it is feasible to artificially
adjust the water temperature to reduce the viscosity of the water, the rate of settling for
very small particles is minimal.
Fortunately, it is possible to increase the effective size of the particle through the
mechanisms of coagulation and flocculation. There is a direct correlation between
particle diameter and settling velocity. In fact, since the settling rate increases by the
square of the particle diameter, an increase in the particle diameter by a factor of 10 will
increase the settling velocity by a factor of 100. This process can occur through the
forces acting on a suspension of particles in water.
First, the earth's gravity attracts the particles toward the bottom of the container.
However, if the particle size is sufficiently small, this force is not able to bring about
particle separation.
Secondly, the natural forces of mass attraction will attract the particles toward each
other. This force is weak and it decreases to the square of the diameter between
particles. This means that if the distance between particles is reduced in half, the
attractive force increases fourfold. Also, because of this mutual attraction, if the particles
touch each other, they will stick together thereby increasing their effective diameter.
Thirdly, the most naturally occurring suspended particles carry an anionic surface
charge. This charge is strong enough to overcome the mutually attractive force of the
particles, dispersing them and preventing the interparticle contact, which would allow
them to stick together and increase their effective size.
Therefore, a typical suspension of solids which are not large enough to settle by way of
sedimentation are also seen to be held in suspension by mutual charge dispersion and
is known as a stabilized suspension.
The processes of coagulation and flocculation cause the stabilized particles to come
together and form masses, which are large enough to settle readily. In order for this to
occur, there must be a reduction in the surface ionic charge of the particles, which is
preventing the particles from contacting each other. The mechanism of reducing the
surface charge is called charge neutralization.
The particle charge can be visualized as producing a "bubble of charge" which
corresponds to the strength of the charge. The greater the anionic charge on the
particle, the larger the bubble size or charge radius. When the charge radius is large
enough, the repellent force of the charged particles is greater than the mutual force of
attraction, which would attract the particles to each other.
If a cationic material is added to this suspension, the cationic species will adsorb onto
the surface of the particle and cancel a portion of the anionic charge. This will shrink the
"charge bubble" and reduce the charge radius to the point that the repellent force is now
14
less than the mutual force of attraction allowing the particles to join together upon
contact.
The degree of charge neutralization is a function of the amount of cationic charge, which
is added. Typically, total eliminate the surface charge does not occur on the particles to
bring about particle contact. In fact, the potential of adding too much cationic charge will
result in cationic charge dispersion and re-stabilization of the particle suspension.
Therefore, coagulation is the process of adding sufficient cationic charge to bring about
a level of particle destabilization, which will allow the particles to contact each other
forming small aggregates known as microfloc. As the microflocs continue to contact
each other, their size increases until they become large, settleable flocs and can be
removed through sedimentation. This process is flocculation.
The efficiency of these processes is very much dependent on the amount of mixing that
is provided. This mixing should be of two varieties:
High energy mixing for coagulation
Low energy mixing for flocculation
Because the particles in a stabilized suspension are dispersed through the water, the
cationic charge, which is added for charge neutralization must also be well dispersed
into the water to allow it to react with the particles uniformly. This requires rapid, high
energy
mixing.
Also, to bring about the initial interparticle contact that leads to microfloc formation
requires rapid mixing because the particles are initially very far apart. Rapid mixing
assures a high rate of interparticle collisions.
Once microfloc formation is achieved the mixing energy must be reduced to promote
flocculation. Low energy mixing is then provided to allow continued interparticle contact,
which will cause floc size to increase. This must be low energy mixing because the floc
is fragile. As the floc grows, it becomes susceptible to shear forces, which would break it
into smaller floc particles.
To assure enough particle contact under low energy mixing conditions, the length of the
low energy mixing period is extended. While a rapid mix period may range from 30
seconds to 3 minutes for coagulation, the low energy mix period may last up to two
hours for flocculation.
To summarize, the following is a synopsis of the stages of coagulation and flocculation:
1. A cationic material is rapidly dispersed throughout a stabilized suspension of fine
particles.
2. The anionic particle charge is reduced through the adsorption of cationic material
to the surface of the particles.
3. With the particles de-stabilized, the rapid mixing brings about interparticle contact,
which begins the formation of microflocs.
4. The period of low energy mixing begins as slow, gentle mixing allows the
microflocs to build into large settleable flocs.
15
5. The large flocs are allowed to settle in a sedimentation basin, leaving clarified
water to pass on.
A cationic material, which is added to a stabilized suspension for charge neutralization is
known as a primary coagulant. Primary coagulants are available as inorganic or
organic chemicals. Inorganic primary coagulants are usually metal salts such as
aluminum sulfate, aluminum chloride, ferric sulfate or ferric chloride.
In solution, these salts ionize to a strongly cationic metal ion of trivalent aluminum or
trivalent iron. This provides a very strong cationic species for charge neutralization. Also,
the metal salts react with the alkalinity in the water to form an insoluble metal hydroxide.
This has two advantages:
1. The addition of metal hydroxide adds to the amount of solids in the water,
increasing the number of interparticle contacts.
2. As the metal hydroxide forms, it can entrap much of the fine solids into a
gelatinous precipitate.
The inorganic primary coagulants are also very effective for the removal of soluble and
colloidal color as they can chemically precipitate the color bodies.
Optimum use of metal salts requires the control of pH and alkalinity. The metal salts are
quite acidic and will decrease the pH as they react with the water. Both aluminum and
iron based primary coagulants have an optimum pH for insolubility of precipitated
hydroxides ranging from pH 5.5 to 7.5. If the pH is much lower than 5.5, the aluminum or
iron remains soluble and does not add the gelatinous hydroxide solids. Also, the soluble
aluminum or iron will not be removed from the water and will carry through the process.
Alkalinity control is normally accomplished through the addition of caustic soda or lime to
maintain the desirable pH and replace lost alkalinity.
Organic primary coagulants are cationic polymers. Polymers are long chain organic
molecules, which are soluble in water. Because they are charged molecules they are
called polyelectrolytes. The polymers used as primary coagulants are normally low
molecular weight, highly charged compounds. Because they are highly charged, they
are very good for charge neutralization. In addition, their molecular chain length allows
for bridging of the destabilized particles together into a strong, tight floc. Because the
molecular length of the polymer allows for bridging, a polymer can often form a floc with
a lesser degree of charge neutralization than without the bridging effect.
A polymer will not react with the alkalinity of the water, therefore it will not alter the pH or
form a hydroxide precipitate. Although this means a polymer will not add solids to the
water to enhance particle contact, it also means that a polymer will not increase the
amount of sludge generated.
The bridging action of a polymer can be very beneficial to forming a large dense floc,
which is more shear resistant and settles quite readily. In many instances, it is desirable
to add a polymer strictly for bridging together microflocs, whether they were formed by
an inorganic or an organic primary coagulant. A polymer added for this purpose is a
coagulant aid.
16
For optimum bridging effect, a high molecular weight polymer can be used, which may
be cationic, nonionic or anionic in charge. The high molecular weight polymer is best
added after the primary coagulant has reacted to form the initial microflocs. If added too
early, the polymer will begin to tie up the particles before a sufficient microfloc nucleus is
formed and the resulting floc size and capture will be poor. Typically, a coagulant aid will
be added following the rapid mix period and prior to the flocculation period. The optimum
feed point in relation to the primary coagulant addition point can be determined through
jar testing.
Chemical Precipitation
A special case of coagulation and flocculation is encountered when the solids to be
removed from the liquid are in solution in the liquid. To remove the dissolved solids from
the liquid they must be "prepared" by either chemical or biochemical means.
1. Chemical precipitation typically revolves around adjustment to provide an
optimum pH for insolubility of a specific compound. Many dissolved metals are
amenable to this method. For example, dissolved iron can be precipitated at a pH
of 8.5 to 9.5. In some cases the pH range is narrow and the compounds can resolubilize at a higher or lower pH.
Another chemical method involves co-precipitation. For example, silica removal
can be accomplished by pH adjustment in the presence of magnesium hydroxide.
This is also the mechanism for the removal of colloidal and dissolved organic
color bodies. A combination of pH adjustment and the presence of aluminum or
iron salts cause the partially hydrolyzed metal to react with an acidic group on the
organic color molecule forming an insoluble precipitate.
2. Biochemical precipitation is used to remove dissolved organic nutrients from
liquid. A population of microorganisms uses the soluble compounds as food
source, which metabolize them into their biomass. The organisms are then
removed as settleable solids taking the metabolized organics with them.
Filtration
Filtration is the passage of a solid/liquid suspension through a porous medium to
physically remove the solids from the suspension. In water purification, the solids may
include silt, clay, colloids and microorganisms.
The most widely used filters are rapid sand filters in which the filtration media is held in
place by gravity and the flow direction is downward. The filter medium is supported on a
gravel bed below, which is an underdrain system to collect the filtered water.
The gravel bed is built up from several layers ranging from coarse stone at the bottom to
0.1- inch diameter gravel at the top. This is designed to support the sand bed to prevent
it from passing downward and out of the bed during filtration, and to spread the upward
flow uniformly during backwashing. Filter bed media typically consists of silica sand,
garnet sand or crushed anthracite.
17
Floc particle size and strength are important to the filtration process. The pore openings
on the surface of the sand bed range from 0.1 to 0.5 mm diameter preventing large floc
particles from passing through the filter by capturing the large floc on the surface of the
sand filter. However, much of the smaller floc will pass into the bed and lodge within it.
Unless the flocs are strong, those that lodge in the bed initially will break down as the
hydraulic gradient increases. The floc passes into the filter bed through thousands of
openings per square foot and by the end of a filter run, builds-up within the first one to
four inches of the bed depth.
When a cleaned filter bed is placed in service, most of the flocs pass into the bed. As the
solids lodges between the sand grains below the surface, the free void area is reduced
and the bed offers resistance to the flow of water. If floc is very strong and sand particle
size is small, most of the solids may be captured at the surface of the filter. This leads to
rapid flow loss through the filter and the length of a filter run is short. Longer filter runs
are obtained when the flocs penetrate into the bed making greater use of the filter
matrix.
As the accumulation of solids in the bed increases, the flow rate through the filter
decreases due to the reduction of the available water channels. When flow diminishes to
a low rate, the filter is taken out of service. It is then backwashed by forcing water
upwards through the bed to rinse the solids out of the pore spaces, leaving cleaned
sand
behind.
In practice, the factors limiting the rate of filtration through sand filters are:
1. The concentration of solids to be removed by the filters. As the amount of solids
increases, the time required filling up the void spaces decreases. Once the void
spaces are full, the flow rate decreases and the filter must be backwashed.
2. The size of the particles influences whether they will be trapped at the surface of
the filter bed or pass on into the filter bed.
3. The strength of the particles determines whether the flocs will break down to
smaller particles as the f low gradient increases. If the floc is weak, it may not
stay captured in the filter bed and will pass through the bed as "turbidity
breakthrough."
4. Particle charge is important as it affects the ability of particles to be adsorbed to
the filter media. If the particles carry a high charge and are dispersed, they will
have less of a tendency to be adsorbed to the surface of the sand particles.
5. Water temperature affects both the water viscosity and the friction of the water as
it passes over the filter media surface. Cold water will filter more slowly than
warmer water due to the friction loss.
18
1.4 DEMINERALIZATION(DEIONISATION)
Demineralization or deionization is the process of removing mineral salts from water by

using the ion exchange process. With most natural water sources it is possible to use
demineralization and produce water of a higher quality than conventional distillation.
Demineralization involves two ion exchange reactions. Initially, the CATION such as
calcium magnesium & sodium are removed by HYDROGEN ion (H+). The salts thus
converted into their respective acids by this exchange. The acidic water is then passed
through an ANION exchange where the anions such as sulfates chlorides etc, are
removed by HYROXYL (OH-) ions.
Ion exchange is an equilibrium reaction, which is reversible. In the Hydrogen Cation
exchange resins the cation group shows a greater affinity for other Cations in preference
to Hydrogen ions. This is reversed when the resin bed gets exhausted of Hydrogen ions
& is regenerated with a strong acid the reverse process taking place because of
Hydrogen ions being present in high concentration in the regenerant acid (either HCl or
H2SO4).
The ANION exchange resin contains active amine groups & the OH radical replaces the
anions like SO4 & Cl. There are two types of ANION exchange resins, namely strong
basic (SBA) & weakly basic (WBA).
The strong basic anion exchange resin is regenerated with Sodium Hydroxide (Caustic
Soda) & weakly basic anion exchange resin is regenerated with Sodium Carbonate
(Soda Ash) or Caustic Soda.
The following equations will give an indication of the reaction involved during service
cycle.
Hydrogen Cation Exchange
R-SO3H + NaCl R-SO3Na + HCl
2R-SO3H + CaSO4 (R-SO3)2 Ca + H2SO4
Weak Basic Anion Exchange
R-(NH3)2 OH + HCl R-(NH3)2 Cl + H2O
Strong Basic Anion Exchange
R-(NH3)3OH + H2SiO2 R-(NH3)3 HSiO2 + H2O
19
When the supply of exchangeable ions within the resin is exhausted the treated water
quality deteriorates & the resin requires regeneration i.e. re-conversion into the
operating form.
The CATION exchange resins with mineral acid such as Hydrochloric Acid or Sulfuric
acid. The strongly basic ANION exchange resins are regenerated with Sodium
Hydroxide (Caustic Soda) & the Weakly Basic Resins with either Caustic Soda or
Sodium Carbonate; the processes are as below:
R-Na + HCl R-H + NaCl
R2 -Mg + H2SO4 2R-SO3H + MgSO4
R-Cl + NaOH R-OH + NaCl
R-HCl + NaOH R-NaCl + H2O
20
THERMAXLTD | WATER&WASTESOLUTIONS
CHAPTER - 02
PLANT CONFIGURATION & DETAILS
2.0 PROCESS DESCRIPTION
2.1 PLANT DETAILS
2.2 UNIT DETAILS
2.3 INSTRUMENT DETAILS
2.4 RAW WATER QUALITY
2.5 TREATED WATER QUALITY
2.6 OUR TERMINATION POINTS
21
2.0 PROCESS DESCRIPTION

PRE-TREATMENT
RAW WATER LIME ADDITIONCHLORINATION COAGULANT +
POLYELECTROLYTE DOSING HRSCC CLEAR WATER STORAGE.
CHLORINATION +
ALUM & POLY. DOSING
LIME DOSING
RAW WATER INLET
HRSCC
CLEAR WATER
STORAGE TANK (CWT)
Raw water storage tank (by client) with service pumps (PWR-1/2 of 90.0 M3/Hr flow
capacity) are provided. In the clarification system, raw water is added with milk-of-lime
prior to entry of HRSCC. In the HRSCC (central well) SODIUM HYPOCHLORITE
(NaOCl) DOSING is implemented to minimize organic matters & dissolved iron. For
chlorination, dosing pump (CDP1) & dosing tank (CDT1) are provided. As per chlorine
demand (TOC reduction & Iron removal), the chlorination is set.
Raw water is then added with coagulants such as alum (or FeCl3) & polyelectrolyte for
better floc formation & clarification. Ferric chloride dosing is implemented in the
HRSCC. FeCl3 solution preparations tank (CADT) with stirrer is provided. Ferric
Chloride dosing pump (CADP) is provided. For Polyelectrolyte solution preparation,
dosing tank (TPE) is provided with stirrer. Dosing of polyelectrolyte is managed through
dosing pump, PPE.
Raw water then passes through HRSCC where turbidity &
suspended matters are removed. Clear water is delivered through HRSCC service
operations. Clear water is stored in the Clarified Water Storage Tank (CWT).
Clear water is filtered through Dual Media Filter (DMF) & Activated Carbon Filter
(ACF) prior to using for DM Plant & other utilities. Media filter removes turbidity from
the water while Activated Carbon Filter removes organic matters & residual chlorine
from the feed. Feed pump, DMFP is provided to service DMF-ACF.
22
DM PLANT
Plant Configuration is described below:
CLEAR WATER [DMF][ACF][SAC][DGT][SBA][MB]Utility
WHERE, [DMF] DUAL MEDIA FILTER, [ACF] ACTIVATED CARBON FILTER, [SAC]
STRONG ACID CATION, [DGT] DEGASSER TOWER, [SBA] STRONG BASE ANION,
[MB] MIXED BED UNIT
CLEAR WATER INLET
DGT
DMF
ACF
SAC
SBA
MB
SDG
DM WATER UTILITY
TO 'SOFTENER'
& OTHER UTILITY
Clear water is to be used as feed for DM Plant operation. Clear water feed pumps
(DMFP-1/2) are provided by client. Clear water first passes through VERSA-DMF to
remove turbidity. Filtered water then passes through VERSA-ACF where residual
chlorine is removed by adsorption. De-chlorinated feed then passes through STRONG
ACID CATION where all cations such as Ca++, Mg++, Na+, K+ and Fe++ etc. are
removed/ exchanged for H+ from the CATION resin (here T42H). Upon exhaustion,
the resin is regenerated using 5% HCl. This unit is CCR type in which the regeneration
is taken in counter current direction (i.e. from top to bottom of the vessel).
The decationized water then passes through DEGASSER TOWER for stripping off
CO2. The elimination of the carbon dioxide reduces the anionic load in the subsequent
anion exchangers. Thus Degasser tower is crucial in the demineralizer. Ideally CO2
level in dissolved condition shall not be more than 10 PPM at the outlet of DGT.
Decarbonated water is stored in the Degasser Water Storage Tank (SDG).
Water from SDG is fed to the next units by feed pumps, PDG. Decationized water
passes through STRONG BASE ANION where bicarbonates traces, free mineral
acidity (SO4, Cl & NO3) & silica is exchanged for hydroxyl (OH) ions. At the outlet of
SBA, water with conductivity < 30.0 micro-S/cm & is expected.
Strong base Anion resin is regenerated using caustic (NaOH). The regeneration takes
place in counter current direction (i.e. opposite to that of service flow).
23
For further polishing, water passes through Mixed Bed unit. Mixed bed typically
contains CATION & ANION exchange resins in the mixed form. Ionic traces are
removed in the MB. Mixed Bed outlet water with < 1.0 S/cm conductivity is expected.
DM Water pH is corrected with suitable alkali prior to boiler feed makeup.
SOFTENING UNIT
In the softening plant (independent unit) water passes through softener (FLEXI-DF) to
remove hardness (Ca+Mg) from the feed water. During service cycle < 5 ppm hardness
is maintained in the treated water. Hardness components (Ca & Mg) are exchanged for
sodium ion (Na). Upon exhaustion, the resin is regenerated using 13% NaCl solution.
During the regenerated cycle, concentrated Na+ ions replace Ca++ & Mg++ ions on the
resin link. Regeneration takes place in the same direction to that of service flow rate.
The softener unit is down-flow type. During the service cycle soft water with < 5 ppm
hardness is expected.
FILTERED WATER: Filtered water @ 48.0 m3/hr is used for other utilities.
2.1
UNIT
MARK
NOS.
PLANT DETAILS (D.M. PLANT)

TREATMENT BETWEEN
FLOWS
REGN.
MA
X.
NORMAL
CHEMICAL
CAP
TIME
CONSUMPTION
PER REGN.
M3
---
Hour
-
100%
--
LITERS
-1035 LTRS. T40
Na
1116 LTRS T42H
(ACTIVE)
79 LTRS T42H
(INERT)
1355 LTRS- A23CL
(ACTIVE)
133 LTRS. A23CL
(INERT)
90 LTRS T42
136 LTRS A23
M3/Hr
-
SOFTENER -
29.0
166 kg NaCl
SAC
13.0
260
20
79 kg HCl
SBA
13.0
260
20
104 kgs NaOH
MB
13.0
1820
140
7.2 kgs HCL

9.5 kgs NaOH
DMF1
ACF1
RESINS
24
2.2
UNIT DETAILS
Sr.
No
DESCRIPTION
CDT
CAP: 100 LTRS,
CDP
0-4 LPH @ 3.5 KG
ASIA LMI
CADT
CAP.:- 500 LTRS
MS
CADP
0-30 LPH @ 3.5 KG 1
ASIA LMI
CHLORINE DOSING
TANK
CHLORINE DOSING
PUMP
COAGULANT
DOSING TANK.
(ALUM) (WITH
AGITATOR)
COAGULANT
DOSING PUMP
(ALUM)
LIME DOSING TANK
Nos
.
Off.
1
TLM
CAP.:- 500 LTRS
MS
LIME DOSING PUMP
PLM
0.5 M3 @ 3.5 KG
POLY
ELECTROLYTE
DOSING TANK
(WITH AGITATOR)
POLY ELECTROLYTE
DOSING PUMP
HIGH RATE SOILD
CONTACT
CALARIFIER
HRSCC INTERNALS
SET FLOW
90M3/HR
CLARIFIED WATER
STORAGE TANK
DUAL MEDIA FILTER
(WITH MnO2 LAYER)
ACTIVATED CARBON
FILTER
STRONG ACID
CATION
EXCHANGERCOUNTER CURRENT
TPE
CAP.:- 500 LTRS
CICENTRIFU
GAL
MS
PPE
0-30 LPH @ 3.5 KG 1
ASIA LMI
HRSCC
8.0 M DIA X 3.8 M

SWD
RCC BY
CLIENT
HRSCC
INT
SUITABLE FOR
ABOVE
MS
CWT
VERSADMF 2000 DIA X 2000

HOS
VERSAACF 2000 DIA X 2000
HOS
SAC
1000 DIA X 2500
HOS
RCC BY
CLIENT
MSEP
MSEP
MSRL
1
2
3
8
9
10
11
12
13
14
MARK.
SIZE/ CAP.
REMARKS
MS
25
CONTUNIT DETAILS
Sr
.
N
o
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
DESCRIPTION
ACID MEASURING
TANK (SAC)
DEGASSER TOWER
MARK.
SIZE/ CAP.
Nos
.
Off.
REMARKS
MHL 1
CAP.:- 300 LTRS
MSRL
DGT
600 DIA X 2500

HIGH
CAP.:- 4 M3
MSRL
MSRL
DEGASSED WATER
STORAGE TANK
DEGASSER AIR
BLOWER
DEGASSED WATER
TRANSFER PUMP
SS316
STRONG BASE
ANION EXCHANGER
COUNTER
CURRENT
ALKALI MEASURING
TANK (SBA)
SDG
BDG
PDG
305 M3/HR @ 100

1
MMWC
13 M3/HR @ 35MWC 1
CI
SS 316
KSB
SBA
1200 DIA X 2500

HOS
MSRL
MAK 1
CAP.:- 350 LTRS
MS
MIXED BED
EXCHANGER
ACID MEASURING
TANK MB
ALKALI MEASURING
TANK MB
MB
600 DIA X 1600 HOS
MSRL
MHL 2
CAP.:- 100 LTRS
MSRL
MAK 2
CAP.:- 100 LTRS
MS
MIXED BED
BLOWER
PH DOSING PUMP
PH DOSING TANK
SOFTNER
(DOWNFLOW)
BRINE MEASURING
TANK
BMB
31.1 M3/HR @ 0.45

KG /CM2
0-6 LPH @ 3.5 KG
CAP.:- 100 LTRS
1100 DIA X 2500
HOS
CAP.:- 800 LTRS
CI
1
1
1
ASIA LMI
MS
MS
MSEP
PHP
PHT
SOFTNER
MBR
26
2.3 INSTRUMENT DETAILS

MARK
DESCRIPTION
NOS
MAKE
CI
PHI
PI
FI
LG
-
CONDUCTIVITY INDICATOR
PH INDICATOR
PRESSURE INDICATOR
FLOW INDICATOR
LEVEL GAUGES
INSTRUMENT PANEL
INSTRUMENT CABLES WITHIN THE
BATTERY LIMIT
2
1
15
4
2
1
LOT
ASTER
ASTER
GLUCK
ASTER / EUREKA
TECHTROL
THERMAX APPD.
THERMAX APPD.
2.4 RAW WATER ANALYSIS

BICARBONATE ALKALINITY (as CaCO3)
TOTAL ALKALINITY (as CaCO3)
M. ALKALINITY (as CaCO3)
P. ALKALINITY
CALCIUM (as Ca)
CHLORIDE (as Cl)
COLOUR (AOOARENT)
CONDUCTIVITY
IRON (as Fe)
MAGNESIUM (as Mg)
NITRATE (as NO2)
ODOR
PH @ 160 C
POTASSIUM (K)
SILICA (as SiO2)
SODIUM (as Na)
SULPHATE (as SO4)
TOTAL DISSOLVED SOLIDS
TOTAL SUSPENDED SOLID
TURBIDITY (NTU)
163.3
163.3
163.3
ND
19.78
4.37
4
359
10.35
10.35
1.4
7.27
7.7
70
24.26
97.63
25.3
4.6
-
27
2.5 TREATED WATER QUALITY

TREATED WATER QUALITY (HRSCC O/L)
SUSPENDED SOLIDS
TURBIDITY
<25 PPM
< 25 NTU
TREATED WATER QUALITY (DMF O/L)

SUSPENDED SOLIDS
< 5 PPM
TREATED WATER QUALITY (ACF O/L)

TURBIDITY
< 5 NTU
TREATED WATER QUALITY (SBA O/L)

PH
TDS
7.5 8.5
< 20 PPM
TREATED WATER QUALITY (MB O/L)

T.D.S.
PH
PH
CONDUCTIVITY
SILICA
TOTAL IRON
< 1.0 PPM

6.2 7.2 BEFORE CORRECTION
8.8 9.2 AFTER CORRECTION
< 1MICROSIEMENS / CM
< 0.02 PPM
< 0.01 PPM (MAX)
TREATED WATER QUALITY (SOFTENER O/L)

TDS
HARDNESS
2.6
MARK
A
B
C
D
E
F
G
SAME AS FEED WATER

COMMERCIAL ZERO.
OUR TREMINATION POINTS

DESCRIPTION
SIZE
NB
125
80
125
50
HRSCC INLET
HRSCC DRAIN
DMF INLET
MB OUTLET TO
SERVICE
SOFTENET
65
OUTLET
ACF OUTLET
100
TO PROCESS
HRSCC OUTLET 200
FLOW
M3/hr
90.0
2-3
90.0
13.0
PRESSURE
Kg/cm2
1.0
ATM
3.5
1.0
29.0
1.0
48.0
2.0
90.0
1.0
CONN.
STD
ALL FLANGES
BS
10TD
SOFF & ONLY
TERMINATION
OR
MATCHING
ANSI B 16.5
150 # RATING
NOTE: - MOTORS SHOULD BE SUITABLE FOR 60HZ.
28
SECTION - CLARIFICATION
CHAPTER - 03
O & M MANU
AL FOR HIGH RATE SOLID CONTACT CLARIFIER
A) ERECTION INSTRUCTIONS REACTIVATOR

B) OPERATION INSTRUCTIONS FOR REACTIVATOR & MAINTENANCE
C) CHEMICAL DOSING IN THE CLARIFIER
29
A) ERECTION INSTRUCTIONS REACTIVATOR

General:
1.
IMPORTANT - Use care in unloading and handling the equipment, as failure to do so many
result in bending or otherwise damaging the equipment, thereby causing trouble and added
expense in erection.
2.
BEFORE STARTING ERECTION - It is important that all drawings and Instructions furnished be
carefully studied as they show the correct location and arrangement of all parts as well as the
roper order of erection. A clear understanding of all drawings and instructions is essential to
produce a satisfactory job and timely erection of the equipment.
3.
Before opening boxes and crates, consult the packing lists which describe the contents in
detail. Open only as required for erection in order to prevent loss.
4.
During the erection of the machine, the correction of minor misfits and a reasonable amount of
reaming of holes or cutting is considered a legitimate part of the erection. Any error which
prevents the proper assembling and fitting up of parts by the moderate use of drift pins or a
moderate amount of reaming and slight chipping or cutting should be immediately reported to
us for approval of the method of correction.
We do not supply and are not responsible for the design. However we will furnish the concrete
of general drawing which will show all necessary dimensions and bolt sizes required for
installation of mechanism purchased.
FOUNDATION
1.
In designing, the customer should make provision for necessary discharge cone and underflow
piping; also sufficient clearance should be left at the center to permit bolting the cone to the
bottom of tanks.
2.
Provide high pressure water connections to a Valve Assembly, or other underflow arrangement,
to permit flushing out the discharge cone and the piping to the pump.
The bridge center segment is shipped completely assembled.

1.
Assemble the two side segments to make the full bridge cum walkway.
2.
Level support at center using shims under feet at outer ends.
3.
Weld the bridge ends to the anchor plates on the RCC tank.
4.
Assemble the two sets of side supports to the bridge at 90 degrees.
30
5.
Bolt the eight rolled channels to the under members of the bridge and the side supports, to get
an uniform circular ring. Join the eight splices.
6.
Place the twelve outlet channels (radial launders) in position, one end of each resting on the
opening provided in the RCC launder and the other end hanging from the hanger bolts
suspended from the eight rolled channels. Level the top of these twelve channels to suit the
liquid discharge level.
DETENTION HOOD - Assemble the FRP panels over the hoods ring frames individually on the ground.
For bolting the sheets to the frames, matching holes need to be punched on the FRP sheets. Join all
the frames to make the round hood and suspend from the bridge as shown in the G.A. drawing.
DRIVEHEAD VERTICAL SHAFT
1.
Assemble the adapter to the Polypick gear and bearing housing, using the same fasteners that
hold them together.
2.
Place intermediate vertical solid shaft in tank and bolt to the top solid stub shaft.
7.
Now, hoist the Impeller shaft from the bottom and bolt to the bottom of the adapter using the
six high tensile bolts provided. This shaft should over circumscribe the solid scraper shaft.
8.
Fix the bottom stub shaft of the Scraper to the flanged end of the intermediate solid shaft.
9.
Adjust the drive heads for levelness using a sensitive machinist level placed across the
machined buttons on the worm gear spokes. If additional shims are required to level the drive
head and to get firm hearing under all feet, cut shims from thin, sheet metal to shape as the
shims furnished with the machines. After tightening bolts, check again for level.
10. If the drive heads have been carefully leveled, the vertical shaft will be plumb. Check to see
that the vertical shaft is centered in the discharge cone. If the shaft is more than 12mm cut of
center, adjustment should be made by shifting the mechanism support in which slotted holes
are provided at each end for this purpose.
RAKE ARM ASSEMBLY, IMPELLER AND CENTRE SCRAPER
1.
2.
For machines with pipe shafts the tie rod spider and arm spider usually are integral with the
shaft and the spacer is not required.
Attach rake arms to spiders or lugs on vertical shaft as shown on the general drawing. Where
four arms are used, be sure that the two long arms are opposite to each other.
31
3.
Where the rake blades have been shipped separately, attach the blades to the rake arms
according to the erection Diagram provided. Peen ends of bolts or prick-punch the threads to
prevent backing off.
4. Bolt center scraper to rake arms and either peen ends of bolts or prick-punch the threads to
prevent nuts from backing off.
5. Fix the draft tube to the bridge bottom using the four draft tube suspension hanger pipes and fix
the bearing holders and bearings in position, to hold the impeller shaft loosely. This should not
be tightened at all; just functions as a guide. Fix the impeller to the impeller shaft flange keeping
a distance of approximately 25 mm over the draft tube base, uniformly. Brace the draft tube to
the tank wall using the turn buckles and tie rods.
DRIVE UNITS
1.
2.
3.
The drive units may now be installed on the mechanism support as shown on the General
Drawing. Install sprockets on gear motor or reducer and on worm shafts. Do not drive
sprockets on shafts as damage may result to the bearings. Before securing large sprockets,
turn worm shaft in direction indicated on the General Drawing until the worm gear starts to
move showing that all slack has been taken up between end of shaft and overload alarm. Set
sprocket so that the hub clears the end of the worm housing by 25 mm to give room for
endwise movement of the shaft as the shaft as the overload mechanism operates. Line up the
small sprocket with a straight edge so that is 6 mm inside (toward the center line of the gear)
the driven sprocket. (In the present case this adjustment for both the drives have been
completed at our works itself.)
Connect wiring to the motors and overload switches in accordance with the Wiring Diagram.
Make sure that the heater units of the proper rating are in the starter.
Do not revolve mechanism in the reverse direction as the set collar on the worm shaft will
probably be forced out of place.
32
LUBRICATION
1.
2.
3.
4.
Lubricate drive head worm and worm gear by removing worm gear and filling with SAF-140
lubricating oil in summer and SAE-90 in winter until oil flows from overflow elbow in the side of
the housing. Be sure that elbow points downward. After the worm gear has made several
revolutions enabling the oil to work around the gear, the oil level should be checked again. The
grade of oil specified is suitable for all but extreme temperature and climatic conditions which
may necessitate the use of a lighter or heavier grade of lubricant. Grease worm shaft bearings
through alemite fittings provided using No.2 cup grease.
Electric motors, gear motors and speed reducers should be lubricated in accordance with the
manufacturers instructions attached to the unit at the time of shipment. Particular care should
be paid to the manufacturers instructions as damage may result from over greasing and overoiling of the units. If such instructions are not found, they may be obtained directly from the
manufacturer.
Lubrication of motorized lifting device worm assembly is accomplished by removing the cover
over the worm and filling with SAE-140 oil in summer and SAE-90 in winter to the center line of
the worm shaft. Lubricate slip ring assembly with No.2 cup grease through alemite fitting
provided.
Lubricate roller chain with SAE-140 oil in summer and SAE-90 in winter.
FINAL ADJUSTMENTS:
1.
2.
3.
4.
Check the vertical adjustment of the rake arms and the alignment of the blades thereon, in order
to ensure that each arm will rake the same load. This check may be accomplished by the
following method :
a. Adjust one arm as closely as possible to the specified slope. At a point about halfway
out on the arm, measure the vertical height from the point on the arm to a point on the
tank floor. Rotate machine until the opposite arm is over the same point on the tank
floor and adjust arm until the vertical height measured as before, is the same as that
obtained for the first arm. Repeat this procedure at third or quarter points of the tanks.
Both arms should then sweep through the same path. The adjustment of additional
arms should be similarly checked.
b. The blade alignment on each arm should be checked. Minor variations are permissible
but if any blade will obviously dig in more than the others, it should be adjusted or
trimmed if no adjustment is possible.
Operate the machine through a complete revolution watching, closely for any binding or
interference. Before filling tank, run the machine continuously for several hours and check
carefully for indications of overhearing in bearings and drive unit.
Check to make sure that all wiring is properly secured and protected and that all belt and chain
guards are in place.
Before filling tank for initial operation, carefully study the Operation Instructions provided.
33
CHECK LIST BEFORE OPERATION:a) The entire drive system was assembled and tested at our works. We had already checked the
concentricity of the two vertical shafts (within + / - 0.50 mm), the vertical alignment (right angle
within + / - 0.50 mm) of the two shafts with respect to the drive head base, Chain / Sprocket
alignments of both the drives, Lovejoy couplings alignments of both the drives, Bearings set up
etc. The output adapter is fixed to the impeller drive transmission plus main bearing housing
securely. Since this entire drive system has been dispatched duly assembled itself, there is no need
to recheck this part of the equipment.
b) The bridge needs to be erected in water level of + / - 2 mm at both the ends.
c) The vertical suspension of the impeller shaft can be checked with a plumb - bop on all four
directions and should measure within + / - 0.50 mm for every 300 mm.
d) The scraper shaft being guided at the impeller shaft bottom bearing and fixed to the stub shaft at
the top will automatically straighten along with the impeller shaft.
e) The split Poly-pick bush guiding the impeller shaft over the SS liner should have a minimum and
uniform gap of 0.50 mm between them. This may go up to 2 mm. This has been pre-machined
accordingly in our works. However if the gap needs to be increased at site, shims can be inserted
between the two halves of the split housing. At no time the bush can be tight over the shaft liner as
it will throttle the shaft while running.
f) Point 'e' to be repeated for the bearing bush under the impeller, guiding the scraper shaft.
g) The gap between the impeller bottom face and the draft tube bottom plate should be uniform at all
points and the gap should be between 5 mm and 25 mm.
h) The rubber seal between the cone and the draft tube should be fixed without gaps. The two items
should have a gap of above 25 mm between them as a safety measure. The gap distance is not
important as long as the sealing is full and they do not foul while rotating.
i) Other normal Clarifier procedures need be applied.
34
B) OPERATION INSTRUCTIONS FOR REACTIVATOR

PURPOSE:
The Clarifier is installed for the purpose of continuously removing substantially all settle-able solids
from a flow of water or trade waste.
For water treatment, the Clarifier is installed in water treatment plants to remove precipitate after
chemical treatment before sand filtration and is also used for pre-sedimentation of turbid waters.
The effluent Launder should be absolutely level in order to overflow a steady uniform sheet of liquid.
Any irregularity in Launder level will cause a convergence of flow at these low points, the velocity of
which will carry fine solids which have been caught in the current.
The effluent channel preferably should slope toward the outlet or outlets which must be of sufficient
capacity to take care of maximum flow conditions.
Chemical Additions in the clarifier: In the HRSCC Operations to achieve better clarity in
the effluents (feed water) various coagulants are used. Primarily ferric chloride (FeCl3) is used as a
coagulant. Lime dosing is used to maintain pH of effluent. Polyelectrolyte is used to get better floc size
and solid separation.
For appropriate dosing of the alum Jar Test must be taken along with the polyelectrolyte solution.
The combination could be as below:
Alum + Lime + Polyelectrolyte
Alum + Polyelectrolyte
Determine the best results achieved in the Jar Tests and implement the dosages on plant scale.
Sodium Hypo Chlorite Dosing (NaOCl) is fixed as per the chlorine demand of the feed (to be
determined in the laboratory to minimize COD/BOD). The same must be scaled up on plant level.
35
RAKING MECHANISM:
The raking mechanism collects the solids as fast as they settle the rake blades roll and squeeze liquid
from the solids during their travel to the center of the Clarifier. The speed of the raking mechanism has
been set for this particular machine and should not be changed without consulting us.
STARTING OPERATION:
It is assumed that the machine has been properly installed and thoroughly lubricated, all parts are in
alignment and proper clearance exists between the mechanism and concrete at all points.
The bottom of the tank has been screeded in and arms adjusted so that there is proper clearance
between blades and the tank bottom at all points throughout the complete revolution of the raking
mechanism.
If squeezes have been furnished for scraping the tank bottom to prevent septic action of sludge there
should be minimum clearance between each squeezee and the tank bottom at all times during a
complete revolution of the raking mechanism. The clearance between the tank bottom and the
squeezes should not exceed 30mm over any appreciable area.
The mechanism should be run before allowing any feed to enter the Clarifier and any discrepancies
noted and correct.
After operating the mechanism in the dry tank for several hours, the flow may be admitted. Sludge
should be withdrawn at frequent intervals at first, until a definite schedule of removal can be made.
Such sludge removal schedule should call for withdrawal at least twice every twenty four hours, and in
some cases, four or more times per twenty four hours. Do not try to discharge the sludge too thick as
this may over load the mechanism and cause septic action.
A depth of sludge of 300mm to 600mm depending on the size of the Clarifier should be kept in the
tank over the point of discharge at all times. (Telescopic type sludge disposal system is leveled
accordingly)
The sludge forms a seal over the discharge trench and sludge outlet pipe and ensures as uniform and
low moisture content sludge being removed as practical.
The mechanism must operate continuously so that the sludge is kept in constant motion toward the
discharge cone.
Sludge must be removed from the Clarifier several times daily to prevent the accumulation of heavy
rake loads. A regular schedule of pumping should be made up and strictly adhered to. The quantity of
grit in the incoming flow is very important, if it is present in appreciable quantities, more frequent
intervals of pumping will be necessary. If grit is present in large quantities, some provision for its
removal should be made prior to its entering the Clarifier.
If foreign objects, such as rocks, tools etc. are dropped into the Clarifier the mechanism should be
stopped immediately and not started again until such objects are removed.
36
UNDERFLOW LINE BECOMES PLUGGED:

If sludge is allowed to become too thick, it may plug the discharge line, also some foreign material may
have gotten into the line to cause the plugging. To correct this, turn high pressure water back through
the underflow line until the line is cleared.
OVERLOAD ALARM RINGS BELL OR STOPS MOTOR.
(For Large sized Reactivators only)
There may be an accumulation of sludge in the tank which has been gradually building up due to the
sludge being discharged at an average rate less than the rate of introduction of solids with the feed.
Immediately by-pass the feed and open up the discharge line to eliminate the accumulation of sludge
allowing the mechanism to continue running, if possible. If the overload is so heavy that the cutout
switch continues to stop the machine, it will be necessary to drain the tank and sluice out the sludge.
Some foreign object may have dropped into the tank accidentally. Stop the mechanism and see if the
object can be fished out. If not successful within a short time it will be necessary to cut off the
influent to prevent too great an accumulation of sludge. If the object cannot be removed with the tank
filled, it will be necessary to drain the tank and remove it before operating the machine.
DO NOT ATTEMPT TO KEEP ON RUNNING WHEN AN OVERLOAD IS INDICATED.
FIND THE TROUBLE AND REMOVE IT
DO NOT START UP WITH A LOAD OF SLUDGE IN THE TANK
DO NOT TAMPER WITH THE OVERLOAD ALARM SWITCH ADJUSTMENT IN AN ATTEMPT TO KEEP
THE MACHINE RUNNING UNDER OVERLOAD CONDITIONS.
ATTENTION:
1.
2.
3.
4.
5.
6.
All bolts and nuts should be kept tight and original alignments maintained. Inspections should
be made at regular intervals.
Wherever possible, examine gears and all wearing parts periodically to determine whether
excessive wear is taking place.
Test the overload alarm at least once a week to make sure that the mechanism is protected.
If the power is shut-off, or if the mechanism is stopped for any reason for longer than an hour,
bypass the flow until the machine is again started.
Keep the machine and surroundings clean and touch up all rust spots with paint frequently.
The entire mechanism above and below the water line should be painted once every year.
LUBRICATION:
The lubrication of the Center Mechanism and Drive Unit is covered in detail in a supplement attached to
this instruction.
37
OPERATING INSTRUCTIONS FOR WORM GEAR DRIVE HEAD
DESCRIPTION:
The Drive Head is shown on the Assembly Drawing and consists of a cast housing, mounted on the
mechanism support, carrying at its periphery an annular ball bearing on which rotates the worm gear
that supports the entire submerged mechanism. Meshing with the worm gear is a worm driven by a
chain or V-Belt drive from a motor or reducer. The balls ride on replaceable hardened steel strips set
into grooves in the worm gear and housing.
LUBRICATION:
Systematic lubrication will lengthen the trouble-free life of these Drive Heads. The oil-bath should be
inspected regularly to check the level and body of oil. It is good practice at these inspections to
remove the drain plug on the underside of the housing at the worm and draw off a small quantity of oil
to remove any accumulated water or foreign matter.
Summer grades of oil listed below should be used except when prevailing temperature goes below 5C
in which case winter grades should be used.
WORM, WORM GAR, & WORM GEAR BEARING
The proper oil level in the worm gear housing is determined by the plugged
Overflow elbow at the side of the worm sump. To fill the housing, remove the worm cover and the
overflow plug (making certain elbow is turned downward) and pour in oil until it starts to come out
through the overflow elbow. Pour slowly to allow oil to flow around peripheral balls. Before replacing
plug in overflow elbow rotate the machine through at least one complete revolution to dispel any
excess oil. The recommended oils are:
Summer Grade SAE-140.
Winter Grade: SAE- 90.
COUNTERSHAFT BEARINGS
The countershaft bearings are lubricated through Fittings in the top of the housing. Apply a good a
good grade of No. 2 cup grease at regular intervals depending on operating conditions, but
approximately as follows:
Bronze Bushings: Daily
Thrust Bearings: Weekly
Grease should be applied in small quantities. The use of high-pressure gun and excessive greasing
should be avoided.
38
ROLLER CHAIN
In some applications where V-Belt drives are used, the following instructions do not apply.
For roller chains in semi-enclosed guard apply the following recommended lubricant directly to chain
daily with brush or swab :
No. 2 Cup Grease
For roller chains in oil-tight guard pour the following recommended oil through the inspection opening
until the lowest part of chain just dips in pool :
Summer Grade - SAE 60. Winter Grade - SAE-140.
39
LUBRICATION INSTRUCTIONS
Proper lubrication of any equipment is an important factor in obtaining good performance and long
service life. Lubricants designed to withstand various conditions of operation are essential to assure
maximum efficiency. The products listed are for general lubrication of the mechanisms other than
electric motor or commercial speed reducers and will provide good dependable lubrication to satisfy
the various requirements.
Grit is always present and if allowed to penetrate may quickly ruin the best made bearings and gears. It
is desirable to take precautions in this regard to keep abrasive material away from points where it may
do harm. Fittings should be wiped clean before the grease gun is applied and other points of
application should be kept free of dirt. Tooth surfaces of open gears should be cleaned before they are
re-lubricated. All drums and containers should preferably be stored in a clean closed room and covers
kept tight.
Plain sleeve bearings without grease seals should be pumped completely full until some of the old
grease shows at the bearing ends. This practice forces out the old grease and seals the bearings
against penetration of foreign matter. Anti-friction bearings (Ball or Roller) should be lubricated
sparingly and housing should not be filled more than full. A full bearing will over-heat and is likely to
result in failure, if in doubt about grease level, remove the fittings or filler plug and let the machine run
for a few minutes so that excess grease may escape. Level indicators are provided to determine the
proper oil level for both lubricated gears and bearings. Electric motors and commercial speed reducers
should be lubricated according to instructions furnished by the manufacture.
Regular intervals of grease application are essential. Operating conditions will largely determine how
often each part must be serviced but in general frequent application of lubricant in small quantity is
always better than heavy dosage at longer or irregular intervals. Oil baths should be inspected at
regular intervals for proper oil level and to see that the oil remains clean and of good body. At each
inspection it is important to drain of a small quantity of oil in order to eliminate any water which may
have accumulated through leakage or condensation. The proper interval for changing oil will depend
upon amount and severity of service, but in no case should exceed a year. If the mechanism is
unprotected and subject to cold winter temperatures, the grade of lubricant should be changed with the
season. However, if regular inspections reveal the presence of grit or lack of body and oiliness, the oil
should be promptly changed.
EXPLANATION OF CHART GROUPINGS
Group-1
Enclosed bath lubricated worm gears and combinations including worm gears.
Group-2
Enclosed bath lubricated gears and combinations not included worm gears bath
lubricated chains.
Group-3
Turntable without gears
Group-4
Open gears and chains
Group-5
Plain sleeve bearings
Group-6
Commercial ball and roller bearings
Group-7
Underwater metallic bearings
Group-8
Underwater non-metallic bearings and underwater chains.
40
Oils in Group-1 should be changed to winter grade when prevailing temperatures go below 5 oC. For
other groups summer lubricants may be used safely all year round in districts where temperatures do
not go below 0 oC. Where only one product is shown it is suitable for all climates. Lubricants should
be renewed in any case as recommended in the instructions.
All lubricants listed have not been tested and are not guaranteed by us. However, they comprise the
best recommendation of the oil companies after careful joint considerations of the applications and
study of the specifications. Substitutions are practical in many cases but should be made only at the
advice of qualified Lubrication Engineer.
.
THESE LUBRICANTS HAVE BEEN PROVEN SATISFACTORY FOR USE UNDER NORMALCONDITIONS. ABNORMAL
CONDITIONS, EXTREMELY HIGH OR LOW TEMPERATURES MAY REQUIRE A SPECIAL APPLICATION. IN WHICHCASE,
CONSULT AN INDUSTRIAL LUBRICATION ENGINEER
LUBRICANTS LISTED UNDER THE GROUP HEARINGS ARE NOT IDENTICAL PRODUCTS. THEY ARE EQUIVALENT, ONLY
WITHIN A SAFE MARGIN, FOR USE IN OUR EQUIPMENT.
Group
Caltex
Bharat
Petroleum
Group-1
Meropa
Lubricant
No.5
Regal Oil
C (B&O)
Bharat
Amocam
Oil-460
Bharat
Hydrol 68
Group-3
Regal Oil F
(R&O)
Bharat
Hydrol 150
Enklo 65
Group-4
Regal Oil
G (R&O)
Bharat
Hydrol 220
Enklo 85
Group-5
Meropa
Lubricant
No.6
Regal Oil
Bharat
Amocam
Oil 460
Bharat
Hydrol 220
Gervil EP6
Group-2
Group-6
Group-7
Grease
EPI
Group-8
Multifax
No.2
ESSO
Hindustan
Petroleum
Cyndol TC140
Turbinol 52
Enklo 120
Limaplex-1
Bharat MP
Grease 2
HP Multi
Purpose
Grease
Gulf
Indian Oil
Others
Gulf Senate
Servomesh SP460 or Servocyl

C-460
Servo System 68
SAE-140
Servo System
150
SAE-40
Servo System
220
SAE-50
Servo System
SP 680
SAE-140
Servo System
320
SAE-60 or 90
Servogem EP1
NLGI
Grade-1
Servogem-2
NLGI
Grade-2
Gulf
Harmony 69
Oil
Gulf
Harmony 53
Oil
Gulf
Harmony 88
Oil
Gulf EP
Lubricant
145
Gulf
Harmony
121 Oil
Gulf Crown
Grease EP
No.1
Gulf Crown
Grease No.2
SAE-20
41
C) CHEMICAL DOSING IN THE CALRIFIER

Lime Dosing
Milk of lime dosing is to be adjusted as per the Jar Test only. Specific pH range
(guideline is to taken from Jar Tests) offers excellent clarification in combination of ferric
chlorite / alum & polyelectrolyte dosing. Lime dosing is to be scaled-up as given below:
Step-01
Step-02
Step-03
Step-04
Step-05
Determine lime dosing on Jar Test to maintain specific pH

Determine lime qty. required for specific flow rate
(90.0 m3/hr ), 30 gm/m3 x 90.0 m3 per hour
Milk of lime required for 08 hour daily operation.
Take about 2200 liters of potable grade water in the
solution tank, TLM1
Dissolve lime in the water & start mixer to make
homogeneous solution (milk of lime). Then stop mixer.
Milk of lime is to be prepared in the LIME
PREPARATION TANK (TLM1)
- Volume of tank ~ 3000 liters.
- Potable water taken = 2200 liters.
- Dissolve 22.0 kg lime in tank & start mixer.
- Prepare milk of lime.
Say 30 ppm
= 2.7 kg per
hour
~ 22.0 kg
1% milk of lime
Dosing milk of lime

- Transfer milk of lime to TLM2 (capacity 500
liters)
- Adjust the dosing pump rate to finish the solution
in 08 hours.
- 0-500 LPH dosing pump is to be adjusted @ 275
LPH
Note: Dosing solution could be prepared for 8 hours operation. For fixed rate of dosing,
prepare solution accordingly.
Dosing required as per Jar

Test
Qty. of lime to be added in 2200 lit.

(in TLM1)
10 ppm
7.34 kg
15 ppm
11 kg
30 ppm
22 kg
40 ppm
~ 30 kg
Note: calculate dead volume of the tank & mix extra lime initially (proportionately) then
follow the above method to prepare shift wise milk-of-lime.
42
CHLORINE DOSING (Dosing by trial & error method)

Chlorine dosing in the RAW water is to be estimated by first checking TOC & iron
contents in the raw water. Chlorine dosing should be adjusted to minimize TOC & iron
contents from the raw water. Check inlet & outlet TOC (KMnO4 value) after dosing
chlorine in the raw water. Keep records for TOC / iron removal & corresponding chlorine
dosing. Keep < 0.5 ppm residual chlorine in the clear water. Therefore_
Chlorine dosing (ppm) = chlorine demand (to reduce TOC & Iron) + 0.5 ppm residual
chlorine
Chlorinator (NaOCl Dosing) is to be adjusted such that the TOC contents in the clarified
water should be NOT DETECTABLE.
43
Sodium Hypochlorite Dosing

Dose fixing: NaOCl consumed by raw water for the reduction of organic matters (or
oxidation of ferrous salts to ferric) is determined on laboratory tests. The dose of NaOCl
is determined in mg/L (or ppm) on lab tests and the same shall be scaled up on plant
level.
Following steps shall be taken for NaOCl dosing:
Step-1
Laboratory test
Dosages recommended on lab test
Say, 2 ppm
(Or ppm)
Step-2
Scale-up dosages on actual flows
For 90.0 m3/hr flow rate the qty. of NaOCl required
180 gm /hr
Therefore, for 24 hrs the qty. of NaOCl required
4.3 kg / day
Step-3
Solution preparation
If 10% NaOCl solution is available, then qty. required would
be
Take about 28 liters of fresh water in the tank, CDT1.
Add the measured qty. of NaOCl and prepare homogenous
solution
~44 liters
~ 72 liters
Step-4
Step-5
Dosing NaOCl in the raw water

First adjust the flow rate of the dosing pump (75% stroke will
give desired output)
Start dosing pump and measure the flow (by marking tank
levels). About 9 liters solution shall be injected in three
Test potable water for residual chlorine, TOC after dosing
hypo-solution.
Ensure residual chlorine should be minimum at the point of
use (of potable water)
~ 3 lph
44
Alum Dosing (FeCl3).

Ferric Chloride / Alum dosing is to be fixed as per the Jar Test. The dosing on plant
level is to scaled up as given below:
Step-01
Determine coagulant (alum) dosing on Jar Test
Step-02
Determine coagulant qty. required for specific flow

rate
(90.0 m3/hr ) 90 x 10 gm per hour
Say 10 ppm
= 0.9 kg per hour
= 22 kg
Step-03
Prepare coagulant solution for 24 hour (DAILY)

operation.
Take ferric Chloride OR alum qty.
- Take about 310 liters of potable grade water in the
This will be ~ 3.6 %
solution tank, CADT
- Dissolve alum 11.0 kg in the water & start mixer to solution
make homogeneous solution. Then stop mixer.
Step-04
Dosing alum solution

- Adjust the dosing pump rate to finish the solution
in 12 hours.
- 0-30 LPH dosing pump is to be adjusted
@ 25 LPH i.e. 85% strokes
Qty of FeCl3 required to be dissolved in 310 liters of water (for 90 m3/hr

flow)
Alum Dosing
Qty. required for 12 hours
(As per Jar Tests)
operation
5 ppm
10 ppm
15 ppm
20 ppm
5.5 kg
11.0 kg
16.5 kg
22.0 kg
45
Polyelectrolyte Dosing
Dosing of Polyelectrolytes enhances bigger floc size & improves settling. Dosing rate
must be set as per method given below by Jar Tests guidelines.
Step-01
Determine Polyelectrolyte dosing on Jar Test
Step-02
Determine Poly. qty. required for specific flow rate

(90.0 m3/hr )
0.25 x 90 gm per hour
Step-03
Prepare poly. solution for 24 hour (daily) operation.

Take polyelectrolyte qty.
- For 24 hrs the qty. of polyelectrolyte required
- Take about 310 liters of potable grade water in the
solution tank, TPE
- Dissolve poly. in the water & start mixer to make
homogeneous solution. Avoid lumps formation in case
of power form polyelectrolyte. Then stop mixer.
Step-04
Say 0.25 ppm

= 22.5 gm per
hour
= 540 gm
= 270 gm
Dosing polyelectrolyte solution

- Adjust the dosing pump rate to finish the solution in 12
hours.
- 0-30 LPH dosing pump is to be adjusted @ 25 LPH i.e.
85% strokes
Note: the solution could be prepared for 08 hr shift as
explain above.
Qty. of polyelectrolyte to be dissolved in 310 lit. of water. (For 90.0 m3/hr

flow) For 12 hrs dosing
Polyelectolyte Dosing (As per Jar Qty. required for 20 hours
Tests)
opeation
0.25 ppm
0.5 ppm
1.0 ppm
270 gm
540 gm
1080 gm
Take guideline from Polyelectrolyte manufacturer to prepare % of solutions. Then

scale-up dosing as explain above. In case of powder form of polyelectrolyte, check
viscosity of the solution. Divide the dosages in 8 hours shift, if the high % of
polyelectrolyte solution becomes highly viscous.
46
HRSCC OPERATIONS
Raw water is stored in the storage tank (RWT). Through service pumps, PWR-1/2, raw
water is led to HRSCC (Central Well). In the inlet line, milk-of-lime dosing is done (as per
recommended by Jar Tests / Lab Tests requirements).
In the central well of the HRSCC water enters from the bottom zone & rises upwards.
Ferric chloride dosing & polyelectrolyte dosing is done in the central well to facilitate floc
formation. From the central well the water flows towards top & overflows. Water current
moves towards bottom & also had lateral movements due to scraper movements.
Incoming water comes in contact with the bottom sludge (already settling sludge). This
hastens floc formation. The water moves upwards towards clarification zone. The heavy
flocs are retained in the lower zone, while clear water flows upwards. Clear water is
collected in the collection troughs. From collection troughs clear water is collected &
stored in the storage tank, CWT.
Inlet Parameters control:
-
Measure inlet water turbidity (NTU).

Conduct Jar Tests & determine Lime + Alum + Poly dosing
Scale-up dosing system as per laboratory guidelines.
Check TOC & set hypochlorite dosing.
Outlet Parameters to check:

-
Clear water turbidity (NTU)

Clear water TOC (KMnO4 value)
Residual Chlorine in the clear water.
47
THERMAX LTD | WATER & WASTE SOLUTIONS
CHAPTER - 04
Operation & Maintenance Manual For

DMF/ ACF FILTER
48
PROCESS (Dual Media Filter)
The VERSA DMF filter has a special anthracite media above the conventional sand media. The
anthracite media has special surface properties due to which the small colloidal particles get attached
to the surface.
Due to this property the VERSA DMF filter is widely used in pretreatment of Reverse Osmosis systems
where fine colloidal particles needs to be removed. Particle size trapped by VERSA DMF filter is far too
smaller than the conventional sand filters or Multimedia Filters. The performance of VERSA DMF filter
further improves with coagulant dosing at the inlet. Great SDI reduction has been observed after
employing VERSA DMF in Reverse Osmosis plants, and great reduction in fouling of RO membranes
has been observed.
The VERSA DMF Filter is designed for a MAXIMUM load of 50 NTU turbidity to produce outlet water of
less than 5 NTU turbidity. The VERSA DMF Filter removes particulate turbidity of > 30 microns.
However, should the turbidity increase more than 50 NTU at the inlet of the filter, OR particulate size
required is less than 30 microns, coagulant chemicals will have to be added prior to VERSA DMF unit
with sufficient retention time.
INSTALLATION
1. UNIT LOCATION
The location of the unit assembly should be as close to the disposal drain point as possible. The
floor and foundation of the units, should be perfectly leveled and to take care of the load of the unit
assembly, when in service.
Civil foundation should be made and checked as per civil foundation drawing. Particularly, check
the slope of the drain trenches, which should be downwards towards the final disposal point. This
will ensure that there is no stagnation of water in the DRAIN SUMP. If this slope is not downwards
from beginning from drain sump to the final point of disposal, the stagnation of water will cause the
operator to misread the flow on the V-notch board provided in the Drain Sump.
Enough access should be provided for operator to carry out operation and move about freely.
On the outlet of the filter, provide water meter or flow indicator if desired at the inlet of the filter to
check the treated water flows.
49
2.
PRECAUTION
Ensure that all fittings are as per Packing List and Intact, without damage done in the transit.
3.
PIPING
Place the vessel on foundation and ensure that it is aliened and plumbed, with respect to
interconnecting piping elevations if any.
Ensure that all the flange joints are made with rubber gaskets in between. The joints should be
tightened evenly with fasteners provided for the purpose.
Ensure that screwed joints for pressure gauge connections are made leak proof by using Teflon
tape or fit tight compound or o-ring.
Connect hoses provided for sample tubing to sample points.
Ensure that Air release and drain piping are properly pointing in drain sump.
If provided, fix the v-notch board which is to measure the back wash and rinse flow rates, in the
groove provided in the drain sump.
Complete the interconnecting pipe work (In Purchasers scope of supply) from our termination
points Inlet to the VERSA DMF and Outlet of the VERSA DMF to raw water main and to service
respectively.
4. FLUSHING & HYDROTESTING
Open RINSE outlet valve V31 fully. Open AIR RELEASE valve V-12 fully. Now Open INLET valve V-1
to start flushing the piping and vessel from inside. This shall remove any dirt or debris from the
system.
Now close RINSE Valve V-6 fully. Let the AIR RELEASE valve V-12 be fully open. All the air trapped
in the vessel shall now be removed and water will start coming out FULL BORE from the AIR
RELEASE valve V-12. Now Close valve V-12. The unit shall now get pressurized to full pressure.
Check the vessel flanges and piping for any leakage's. Tighten the joints nut bolts to stop the
leakages. This completes the Hydro- testing.
50
5. MEDIA CHARGING
Put a match mark with paint on the top manhole flange and vessel flange (This will ensure that while
refixing no mismatch is observed) remove the top manhole of the vessel. Inspect the vessel from inside
for any debris etc.
Make paint marks from bottom of the vessel as indicated in the INT. ARRENGEMENT FOR VERSA
DMF FILTER drawing. Make first mark on 100 mm from bottom of the vessel. Make other marks
according to the Drg.
It is recommended to pre wash the filter media with water before loading. Hence, wash the media
type one by one and then charge inside the vessel. Especially, the sand and garnet media should
be washed outside in a tank or so, this will remove the dust and powder.
Load the media by slowly pouring the Highest sized pebbles (40-25 size pebbles) first up to the
100 mm mark. Make the layer even by hand.
After this charge the other media one by one up to the chalk mark and every time making the layer
even by the hand. This will ensure proper laying of the media and avoid any media mix up later.
After all the media is charged, it is now timed to give Open backwash. Let the top manhole of the
vessel be open. Open BACKWASH valve V-3 slowly till water starts coming out of the top manhole.
Slowly increase the BACKWASH flow rate such that media does not come out of the top manhole.
Continue this step till clear water is observed coming out of the vessel. Close BACKWASH valve V3.
Now close the top manhole cover. Open AIR RELEASE Valve V-12 fully. Open INLET Valve V-1
fully till all the air is released from the vessel. After this close AIR RELEASE valve V-12.
Now give rinse to the vessel by opening Valve V-6 (RINSE Outlet Valve). Continue this operation till
clear water is observed. (Should you observe unclear water, give backwash to the vessel as
described in the OPERATION section till clear water is observed.) Now close Valve V-6. Now the
vessel is ready for the SERVICE.
51
CAUTION
Before CHARGING Filter media inspect the gap between collection box and bottom dish. This gap
should be 5 mm evenly throughout the circumference. In case this gap is found more than 5 mm or
uneven on the circumference, please adjust the nut/bolts to maintain the gap at 5 mm, as otherwise
there are chances of filter media leaking during operation. If unable to adjust, please call local
Thermax Representative. The Drg. below indicates the location of the gap_
THE GAP SHOULD BE 5 MM
COLLECTION
BOX
53
OPERATIONS
DMF OPERATION: FLOWS
Sr. No.
Operation
Time (minutes)
REFILL
Valves V-1 & V-12 FULLY OPEN
--
RINSE
Valves V-1 FULLY OPEN, V-6 PARTIAL OPEN
--
SERVICE
20 Hrs
AIR RELEASE
Valves, V-12 FULLY OPEN
BACKWASH STEP NO.01 DRAIN DOWN

-3 MIN.
BACKWASH - STEP NO.02 BACKWASH

15 MIN.
Vales V3 FULLY & V4 PARTIAL open.

BACKWASH - STEP NO. 03 REFILL
Valve V1 & V12 FULLY OPEN. CLOSE V12 WHEN FULL BORE WATER
STARTS FLOWING OUT.
BACKWASH STEP NO.04 RINSE FAST
Open valve V1 fully & then adjust V31 for RINSE FAST =
SERVICE FLOW
BACKWASH STEP NO.05 OFF
03 MIN
05 MIN.
--
All valves remain closed.
TECHNICAL DATA (DMF)
MODEL
VERSA
DMF
DIA
Mm
HOS
Mm
DMF24
FIG:
2000 2000
MAX
WORK
PRESS
Kg/cm2
3.5
MIN
WORK
PRESS
Kg/cm2
2.0
AVG
FLOW
M3/hr
MAX
FLOW
M3/hr
90.0
94.3
BACK
WASH
FLOW
M3/hr
62.8
RINSE
FLOW
M3/hr
90.0
54
OPERATING CONDITIONS
1.
Inlet water pressure should not exceed 3.5 kg/cm2. Minimum Operating pressure: 2.0
kg/cm2. Do not exceed the Max Operating Flow rate as this may deteriorate the quality of
outlet water.
2.
Inlet water temperature should not be more than 50 Deg. C
3.
Analyze Inlet water for Suspended Solids content every week, if found consistently more than
the design limit, consult Thermax representative as this may call for additional dosing and/or
equipment prior to the VERSA DMF Filter.
4.
Inlet water should be free of oil and grease.
5.
Inspect the vessel, piping externally once in a year for damage to the painting. Repaint as
necessary.
6.
Inspect vessel internally once in a year for any damaged or peeled off paint or rubber lining as
may be applicable. In case of internally painted vessels, paint the vessels every year as
described in Maintenance section. Repair the rubber lining if found damaged.
7.
Inspect the Filter media every year, and replace if required.
8.
Give extended backwash to the filter once in a week for 45 minutes.
9.
Give Air Scouring to the filter media once in six months or if the filter is found heavily choked,
as described in Maintenance section.
10.
Use Genuine Thermax Spares.
63
Sr.
No.
1.
2.
3.
4.
5.
TROUBLESHOOTING (DMF)
Defect
Cause
Remedy
Treated Water quality not a. Filter not back-washed

a. Backwash filter regularly
up to the standard
b. Inlet Suspended Solids load b. Check inlet water quality.
increased
You may have to increase
c. Excessive Flow Rate
backwash frequency. Also
d. Channeling
Consult Thermax.
Collection/distribution
c. Please do not cross unit
e. Disturbed media layers.
max service flow rate.
d. Check and ensure sufficient
pressure.
e. Check and ensure proper
segregated media layers
Backwash
Frequency a. Inlet Suspended Solids load a. Check inlet water quality.
Required is high
increased
Consult Thermax.
Unit Rinse takes long a. Flow rate too low
a. Adjust the flow rate to the
time
normal
b. Improper Backwash
b. Give proper backwash as
given in OPERATION section
till clear water is observed.
Pressure Drop across a. No or Insufficient backwash a. Backwash filter regularly.
bed is increasing day by b. Inlet Suspended Solids load b. Check inlet water quality.
increased
day
Consult Thermax.
Media comes out from a. Improper media charging at a. Remove and recharge media
bottom outlet
the time of erection
properly
b. Too much excessive
backwash flow
b. Always maintain backwash
rate/Pressure
flow rate as indicated. Too
c. The gap in collection box
much backwash flow rate/
and dish is more than 5
Pressure can disturb media
mm. ( This should have
layers.
been checked before
c. Remove the entire media,
installation)
adjust the gap to 5 mm,
segregate the media by type
and recharge the media.
64
MAINTENANCE (DMF)
The routine maintenance of the filters should include the following _

1. VALVES
At periodic intervals (say one month) open out the valves and check seating, gate, etc. Attend
to gland packing. Replace if necessary, do routine lubrication of spindle.
2. EXTENDED BACKWASH
Once in a week extend the backwash operation to at least 45 minutes to keep the bed clean.
3. AIR SCOURING AND CLEANING OF THE FILTER MEDIA
Once in six months, open the manhole and examine the condition of the media. Throw away
any lumps formed on the top of the bed. On units where no regular air scouring facilities are
provided, air scouring should be done as follows
a. If compressed air supply is available, take a temporary tapping (say 1 hose). Attach the
hose to a M.S. pipe about 1 M long with water level inside vessel about 3above the level of
the bed, insert the pipe into the bed till it is about halfway through. The media will be seen
getting violently agitated. Move the pipe all over the bed. Carry out the air scour for a period
of about 10 minutes.
b. After the air scour do an extended backwash till wash water is clear.
c. Drain the water till the surface of the bed and scrape off any fine dust.
d. Close the manhole.
DOS AND DONTS
Never exceed the filter service flow

Never Run the filter at higher than designed inlet Turbidity
Analyses Inlet water for Turbidity regularly
Always check Inlet water for Oil & Grease content. Dont allow such water to pass through
the filter.
Inlet Water Temp should not exceed 50 Deg. C.
Do periodical Maintenance as described in the Manual
Do annual Media Check up and replacement as required.
Backwash the filter regularly as per Manual
Never allow corrosive liquids to pass through the Filter.
65
VERSA-ACF: OPERATIONS ALONG WITH DMF
PROCESS (Activated Carbon Filter)
VERSA ACF has Activated Carbon, one of the most widely used media for absorption of impurities.
The Activated carbon is employed for_
Dechlorination
Removal of Organics
Removal of Odour
The residual chlorine in the water, where chlorination is used for organics removal, is absorbed by
Activated Carbon Filter. Chlorination of water is widely used in Drinking Water Plants, Pretreatment of
DM plant and Ro plants and effluent treatment plants. The VERSA ACF removes almost all of the
residual chlorine in the water. The VERSA ACF also helps in removal of Organic matter from the
water. It is used in treatment plants for Drinking water as polisher unit at the outlet of the plant and
removes objectionable odors. The Activated carbon media has finite capacity of absorption and shall
exhaust on prolonged usage depending upon the inlet impurity load.
66
OPERATIONS: VERSA-ACF
ACF OPERATION: FLOWS
Sr. No.
Operation
Time
(minutes)
REFILL
--
RINSE
--
SERVICE
20 Hrs
AIR RELEASE
Valves, V-12 FULLY OPEN
BACKWASH STEP NO.01 DRAIN DOWN

-3 MIN.
BACKWASH - STEP NO.02 BACKWASH

15 MIN.
Vales V3 FULLY & V4 PARTIAL open.

BACKWASH - STEP NO. 03 REFILL
Valve V1 & V12 FULLY OPEN. CLOSE V12 WHEN FULL BORE WATER
STARTS FLOWING OUT.
BACKWASH STEP NO.04 RINSE FAST
Open valve V1 fully & then adjust V31 for RINSE FAST =
SERVICE FLOW
BACKWASH STEP NO.05 OFF
03 MIN
05 MIN.
--
All valves remain closed.

TECHNICAL DATA
MODEL
VERSA-
DIAMETER
MM
HOS
MM
AVG
FLOW
M3/hr
RINSE
FLOW
M3/hr
Kg/cm2
MIN
WORK
PRESS
Kg/cm2
BACK
WASH
FLOW
M3/hr
3.5
2.0
90.0
90.0
25.1
MAX
WORK
PRESS
ACF
2000
2000
68
VALVE OPENING CHART

Valves V1
UNIT
OPERATION
DMF
AIR RELEASE
RINSE
SERVICE
BACKWASH
BACKWASH
RINSE
ACF
AIR RELEASE
RINSE
SERVICE
BACKWASH
BACKWASH
RINSE
X
X
X
V2
VERSA-DMF
V3
V4
V6
V1
V2
VERSA-ACF
V3
V4
V6
V12
X
X
X
X
X
X
X
X
X
V12
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTE: INLET PUMP, PWR REMAIN ON DURING FILTER OPERATIONS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
OPERATING CONDITIONS
Inlet water pressure should not exceed 3.5 kg/cm2. Min Operating pressure: 2.0 kg/cm2. Do
not exceed the Max Operating Flow rate as this may deteriorate the quality of outlet water.
Analyze Inlet water for Residual Chlorine content every day, if found consistently more than
the design limit, arrange to control the same in the earlier process as this will exhaust the
activated carbon media faster.
Inlet water should be free of oil and grease. Suspended solids content should be less than 2
NTU. In case of higher turbidity, install a filter prior to the VERSA ACF.
Inspect the vessel, piping externally once in a year for damage to the painting. Repaint as
necessary.
Inspect vessel internally once six months for any damaged or peeled off paint or rubber lining
as may be applicable. In case of internally painted vessels, paint the vessels every year as
described in Maintenance section.
Inspect the Activated Carbon media and replace if required. Activated carbon media must
definitely be replaced with a new charge on its exhaustion as otherwise the increased
Chlorine leakage may severely affect the downstream process.
Give extended backwash to the filter once in a week for 45 minutes. This may not be required
if the VERSA ACF is installed after a filter.
69
MAINTENANCE & TROUBLESHOOTING: VERSA-ACF
Sr.
No.
1.
2.
3.
4.
TROUBLESHOOTING (ACF)
Defect
Cause
Remedy
Treated Water quality a. Inlet Residual Chlorine a. Check inlet water quality. You
not up to the standard.
load has increased
may have to increase backwash
Chlorine observed in b. Excessive Flow Rate
frequency. Also Consult
the outlet water.
c. Channeling
Thermax.
Collection/distribution
b. Do not cross unit max service
d. Disturbed media layers.
flow rate.
c. Check and ensure sufficient
pressure.
d. Check and ensure proper
segregated media layers
Backwash Frequency a. Inlet Suspended Solids a. Check inlet water quality. Inlet
Required is high
load increased
water Turbidity should not be
more than 2 NTU. Install filter
prior to the VERSA ACF.
a. Adjust the flow rate to the normal
Unit Rinse takes long a. Flow rate too low
time
b. Improper Backwash
b. Give proper backwash as given in
OPERATION section till clear
water is observed.
Media comes out from a. Improper media charging a. Remove and recharge media
bottom outlet
at the time of erection
properly
b. Too much excessive
b. Always maintain backwash flow
backwash flow
rate as indicated. Too much
rate/Pressure
backwash flow rate/ Pressure
c. The gap in collection box
can disturb media layers.
and dish is more than 5
c. Remove the entire media, adjust
mm. (This should have
the gap to 5 mm, segregate the
been checked before
media by type and recharge
installation)
the media.
78
MAINTENANCE (ACF)
Analyze Raw Water periodically to ensure that there is no increase in Inlet Residual Chlorine,
Turbidity more than the design limit. Ensure that inlet Turbidity is not more than 2 NTU. Ensure
that the inlet water is free of oil, grease.
Every six months _

1. Check the diaphragm and butterfly valves for any leakages. Repair/ Replace the diaphragm or
seats as required.
2. Calibrate the inlet and outlet Pressure Gauges.
3. Inspect the unit externally including connecting pipe work and valves. Chip away any loose
paintwork and scale and make good with fresh paint. Inspect the unit internal surface after
removing the Activated Carbon media and supporting media. Carry out internal painting by
with Black Bituminous paint after proper wire brushing. Recharge the supporting media and
Activated Carbon.
4. Carry out an extended BACKWASH with the manhole cover off and observe the bed
performance. The water should breakthrough evenly. If it breaks through from one side of the
vessel and floods over the bed surface, or the bed breaks into lumps (indicating packing and
channeling) backwash at fastest possible flow rate without bringing Activated Carbon over.
STEAMING OF ACF MEDIA

Steaming is given to ACF media to restore capacity of the activated carbon to absorb free chlorine,
Organics. This operation is also done once in a week or 15 days to sanitize the media.
1. Steaming to be done when the vessel is full of water. Attain the temperature of 80 deg C
Within 2-3 hours of steaming.
2. Slowly allow the ACF unit to cool down for 2-3 hours to room temperature naturally.
3. Start the backwash procedure as explained above with slow flow rate to avoid media cracking
due to thermal shocks.
4. Take out the fines generated through backwash with the extended time.
5. Please avoid dry steaming of carbon media when the vessel is empty (without water), as this
will create more fines due to thermal shock in the media.
79
DOS AND DONTS
Never exceed the filter service flow
Never exceed the Backwash flow
Never Run the filter with inlet Turbidity content more than 2 NTU.
Analyse Inlet water for Residual Chlorine, Organics regularly
Always check Inlet water for Oil & Grease content. Dont allow such water to pass through the
filter.
Do annual Media Check up and replacement as required.
Backwash the filter regularly as per Manual
Never allow corrosive liquids to pass through the Filter.
80
Chapter- 05
Operation & Maintenance manual For "Demineralizers"
5.1 Strong Acid Cation: Operations
(DEGASSER TOWER OPERATIONS)
5.2 Strong Base Anion: Operations

5.3 Mixed Bed Unit: Operations
M/S KBK CHEM-ENGINEERING (P) LTD; / OC NO: 225064
81
5.1 Unit Operation: Strong Acid Cation

PLANT START-UP: REFILL/RINSE/SERVICE/AIR RELEASE
DMF & ACF must be in service during DM Plant operation. Feed water quality, such as
turbidity, TOC & residual chlorine after filters is to be maintained during SERVICE.
REFILL
Open Air Release Valve V-12 fully.

Open Inlet Valve V-1 fully. Start inlet flow (@ 13.0 m3/hr).
When full bore water flows through air release valve, change over operation to rinse
mode.
RINSE
Open Inlet Valve V-1 fully (as continued from the previous step).
Open Rinse Outlet valve V-6 partially and simultaneously close V-12 fully. Continue
this step for 5 minutes with 13.0 M3/hr flow rate & then put up into service mode.
NOTE: (1) If unit is idle for long duration, then during Rinse, FMA must be checked
and duration of rinsing shall be increased further for another 10 minutes.
SERVICE
Open Inlet Valve V-1 fully.

Open Outlet Valve V-2 partially (by simultaneously closing V-6) and maintain service
flow of 13.0 M3/hr.
Continue Service Cycle for 20 hours.
Check sodium slip at the end of service cycle.
Unit to be cut off from Service after 20 hours of Service Cycle or when 'Sodium slip'
increases above desired values whichever occurs first.
Then put up the unit for regeneration.
82
AIR RELEASE
During Service run or in between Rinse step (anytime) ensure air released completely.
Air Release valve V-12 should be opened. After full bore water flows, close Air Release
VALVE.
BACKWASH (OPTIONAL) FLOW 6.3 M3/hr: TIME 10 MINUTES

NOTE: Strong Acid Cation unit is with counter-current regeneration. So occasional
backwash, after 6 to 7 service cycles MUST be taken or whenever Delta P across the
resin bed exceeds 0.8 kg/cm2. After every backwash, double quantity of regenerant to
be used.
Before starting up Backwash / Regeneration, ensure acid quantity being taken in
Measuring Tank (MHL) up to the marked level.
ACID SOLUTION PREPARATIONS FOR SAC regeneration.
SAC Regenerant calculations (1:5 ratio of Injection)

Description
HCl recommended on 100% concentration
Therefore 30% HCL required
Therefore 30% HCL required (volume)
Power water @ 1:5 injection ratio
For 30 minutes injection, the rate of power water would be
Acid injection flow
qty
79
263.33
229.18
1.15
2.29
2.75
units
kgs
kgs
Liters
m3
m3/hr
m3/hr
83
STRONG ACID CATION: REGENERATION (Counter Current)
STEP
Note: Decationised water through PDG pumps is taken as Power Water for
regeneration. Inlet valve V-25 & outlet valve V-26 of pump, PDG are open fully.
1
2
3
4
OPERATION
MIDDLE COLLECTOR
WASH
SETTLE BED
REGENERATION:
REFILL
REGENERATION:
POWER WATER
VALVE OPERATIONS
First establish down flow 2.75 M3/hour by

opening V1 partially & V-14 fully.
Then Valve V-7 is fully open & V-32 partially.

3
Here the power water flow = 2.29 m /hr
Down Flow 2.75 M3/hour is adjusted as

earlier using V-1.
Now open ACID INJECTION valve (MHL1)
and allow acid flow in.
The flow shall be 2.75 m3/hr.
Valves V-7, V-14, FULLY OPEN,
V-32and V-1 of MHL-1 ejector inlet will open.
The total flow = 5.5 M3/hour
Down Flow 2.75 M3/hour.
Power Water 2.75 M3/hour. (adjusted)
Valves V-7, V-14, fully open, V-32 and V-1
will partially open to adjust rinse.
6
7
8
9
10
REGENERATION:
ACID INJECTION
REGENERATION:
ACID RINSE (S)
REGENERATION:
SETTLE BED
REGENERATION:
REFILL
REGENERATION:
FAST RINSE
OFF
Valves V-4 fully open and V-13 partially open.

Flow 6.3 M3/hour.
All valves will remain closed.
Valves fully V-1, V-12 partially open.
Flow 13.0 M3/hour
TIME
6 min.
2 min.
1 min.
2 min.
20 min.
30 min.
1 min.
V-1 fully open, V-12 partially open.
1 min.

Flow 13.0 M3/hour.
10 min.
Regeneration completed. All valves will

remain closed.
--
89
FIG:
90
DEGASSIFIER SYSTEM
REMOVAL OF CO2:
The product water is sprayed in fine particles & distribution uniformly from the top of the
tower filled with Raschig / Pall rings. A powerful stream of air is created by a fan/ blower
flows counter currently to it, when balance sets up between the dissolved CO2 in air &
water. Thus making it possible to obtain CO2 concentration very close to equilibrium. Major
portion of CO2 dissolved in the water passes in to the air. The airflow of about 50 times
the flow of water ensures desirable stripping of the CO2 gas.
OPERATION:
Start Degasser Blower BDG.
After checking water level in the Degassed Water storage tank (SDG), take SBA in
to service. Check outlet CO2 in the Degasser outlet water.
DEGASSER SYSTEM: OPERATION
Filters & SAC are in SERVICE.

Keep DGT inlet open.
Start Degasser Blower (BDG).
Check water level in Degassed Water Storage Tank.
Check CO2 at the outlet of SDG.
NOTE:
Start the pump and observe Pressure Gauge reading. It should shut-off within a
minute of full speed (stop the pump in case suction is not flooded to avoid dry running of
Pump).
DEGASSER TOWER: MAINTENANCE

Every six months examine the Degasser Tower externally including connecting pipe works
and valves.
Remove any loose paintwork and scale and make good with fresh paint.
Periodically (once a year or as service experience dictates) shut down or by-pass the
Degasser Tower and carry out an internal inspection.
Stop the duty Degasser Blower or Gas Extraction Pump on Vacuum-Type Towers (and break
the vacuum), then drain the tower.
Remove the manhole covers on the Tower and examine the lining. If the lining is damaged,
shows signs of bubbling or lifting, or is suspect, carry out a spark test and rectify.
Clean away any packing debris that may have accumulated in the bottom dish of the vacuum
tower (or in the Degassed Water Sump) and examine all internal fitments for security.
Replace the manhole covers and return the tower to service.
Note: Some Atmospheric Degasser Towers are constructed of reinforced concrete with no
available access. Inspection of this type of tower should consist of an external examination to
check for leakage at joints, etc.
100
5.2 Unit Operation: Strong Base Anion

PLANT START-UP: REFILL/RINSE/SERVICE/AIR RELEASE
REFILL
To ensure Vessel is totally air released, Refill Step is to be followed before Rinse.
Open Air Release Valve V12 fully.

Open Inlet Valve V1 fully.
Ensure PDG Pump is in Service and sufficient water level in SDG.
Start PDG; continue the Step till full bore water flows through SBA. Then
changeover to Rinse Step.
RINSE
Open Inlet Valve V-1 fully (as continued from the previous step).
Open Rinse Outlet valve V-6 partially and simultaneously close V-12 fully. Continue
this step for 5 minutes with 13.0 M3/hr flow rate & then put up into service mode.
SERVICE

Open Outlet Valve V-2 partially.
Flow shall be 13.0 M3/hour after Outlet Valve V-2 is set up.
Measure conductivity at the outlet of STRONG BASE ANION. When conductivity &
silica exceeds the desired limits, close SERVICE and take unit for regeneration.
Note: When strong base exhausts, chlorides slip starts first resulting increase in the
conductivity.
AIR RELEASE
During Service Run or in between Rinse Step, any time, ensure complete Air is released. Open
Air Release Valve SBA V12 till full bore water flows, then close.
BACKWASH (optional/ before regeneration) - FLOW 6.8 M3/hour - TIME 10

MINUTES
While taking backwash, PDG must be in service. Control inlet backwash valve V3 while
outlet valve V4 must be fully open. Ensure backwash effluent is clear.
Every time whenever SBA is given backwash, it should be regenerated with double the
quantity of Alkali (NaOH).
Normally, backwash is done once after six cycles or
whenever Delta P across the SBA increases above 0.8 kg/cm2.
101
Alkali solution preparation for SBA regeneration.
SBA Regenerant calculations (1:5ratio of Injection)

Description
NaOH recommended on 100% concentration
Therefore 48% NaOH required
Therefore 48% NaOH required (volume)
To make 30% alkali dilution add decationised water
Therefore 30% alkali volume after dilution
Alkali injection flow
qty
104
216.67
145.41
87.25
232.66
1.16
2.33
2.79
units
kgs
kgs
Liters
Liters
Liters
m3
m3/hr
m3/hr
107
STRONG BASE ANION: REGENERATION (Counter-Current)
STEP
Note: Decationised water through PDG pumps is taken as Power Water for
regeneration. Inlet valve V-25 & outlet valve V-26 of pump, PDG are open fully.
OPERATION
MIDDLE
COLLECTOR
Valves V-4 fully open and V-13 partially open.

PDG, in service. Flow 6.8 M3/hour.
6 min.
SETTLE BED
2 min.
REGENERATION:
REFILL
Valves fully V-1, V-12 partially open.

Flow 13.0 M3/hour
1 min.
First establish down flow 2.79 M3/hour by

opening V1 partially & V-14 fully.
Then Valve V-9 is fully open & V-32 partially.

3
Here the power water flow = 2.33 m /hr
Down Flow 2.79 M3/hour is adjusted as earlier

using V-1.
Now open ALKALI INJECTION valve (MAK1)
and allow alkali flow in.
30 min.
The flow shall be 2.79 m3/hr.
Valves V-9, V-14, FULLY OPEN,
V-32 and V-1 of MAK-1 ejector inlet will open.
The total flow = 5.58 M3/hour
Down Flow 2.79 M3/hour.
Power Water 2.79 M3/hour.
30 min.
Valves V-9, V-14, fully open, V-32 and V-1 will
partially open to adjust rinse.
REGENERATION:
POWER WATER
VALVE OPERATIONS
REGENERATION:
ALKALI INJECTION
TIME
2 min.
REGENERATION:
ALKALI RINSE (S)
SETTLE BED
1 min.
REGENERATION:
REFILL
1 min.
REGENERATION:
FAST RINSE

Flow 13.0 M3/hour.
10 min.
10
OFF
Regeneration completed. All valves will remain

closed.
--
108
5.3 MIXED BED MB

There must be sufficient water level in SDG for Mixed Bed operations.
Mixed Bed Polisher Principles:

In very high-pressure boiler operations, even trace contaminants are extremely
detrimental. Demineralized water requirements are more stringent than can be produced
by the two-bed unit or RO permeate. To cope with these specifications, many operations
follow the RO Process with a mixed-bed polisher.
The mixed bed polisher consists of a special vessel into which are loaded both strong
base anion and strong acid cation resins. The cation resin, being denser, is always on
the bottom of the vessel after backwashing.
The regenerant piping is designed so that caustic enters the top of the vessel,
flows down through and regenerates the strong base anion resin, and exits the
side of the vessel near the interface between the anion and cation resins.
Similarly, the hydrochloric acid enters from the bottom of the vessel travels
upwards through cation resin, regenerates it, and flows out of the middle collector
of the vessel to the drainage. Prior to the addition of the caustic, the vessel is filled
with water and kept under pressure (blocking flow) to insure that no caustic
channels down to the cation resin before it leaves the waste line at the resin
interface.
After regeneration, air is scored to the bottom of the vessel by opening the vent.
This is called air mix and serves to mix the resins in a random fashion. As the
anion and cation resins mix, the result is a vessel filled with small two-bed
demineralizer. Each cation resin bead and its companion anion resin bead function
as a two bed unit. The combinations on the top that receive the water first are
successful in removing a great percentage of the contaminants entering the unit.
Each pair below removes, in succession, a high percentage of the contaminants in
the water passing the adjacent pair of resin beads. Extremely high-quality effluent
water is possible with this arrangement. The water generally contains silica and
sodium in the parts per billion ranges.
119
INTERNAL ARRANGEMENT
FOR MIXED BED UNITS
(500 DIA. TO 1000 DIA.)
AIR
RELEASE
INVERTED
BELL MOUTH
SERVICE INLET
INVERTED
ALKALI
INLET
SHELL
BEND
TOP OF ANION
RESIN
INSPECTION WINDOW
SHORT STRAINERS
MIDDLE
COLLECTOR
ACID OUTLET
ALK. OUTLET
TOP OF CATION
RESIN
INSPECTION WINDOW
RESIN OUTLET.
STRAINERS
2 NOS. GASKETS.
COLLECTING PLATE.
WATER OUTLET.
ACID INLET
Fig: MB Internals
120
Mixed Bed: Operations

START UP REFILL / RINSE / SERVICE OF- MB
1. REFILL
Open Air Release Valve V-12 fully.

Ensure SBA in service.
When full bore water starts flowing through air release, change over operation to
Rinse.
2. RINSE

Open Rinse Outlet valve V-6 partially and maintain a flow (M3/hour) = service flow.
Put into service on line conductivity once conductivity reduced below 0.5 micro
siemens (note initially conductivity of MB water in rinse will be more during shut
down/ regeneration).
3. SERVICE

Open Outlet Valve V-2 partially and maintain a flow (M3/hour) = SERVICE FLOW.
Put up pH and Silica Analyzer into service once flow is stabilized.
Check on line conductivity / pH / Silica and ensure valves are within set limit.
Ensure DM water Storage Tank inlet valve is open.
NOTE: for better performance of Mixed Bed it should be run continuously keeping in
mind following
1. It should not be run more than stipulated service cycle time of RATED hours or
stipulated conductivity.
2. Silica crosses high limits after rechecking laboratory results.
3. Before taking out of service in between before exhaustion to avoid resin bed
disturbance put into rinse and then to off.
4. If only one stream is in service, Mixed Bed to be continued with next stream of SAC /
SBA after first stream exhaustion.
4. AIR RELEASE
During service /before regeneration / during rinse step, ensure completely air is released.
Open air release V-12. Ensure full water flows through air release. Then close valve V-12.
121
(Regeneration steps: CATION & ANION simultaneous regeneration)

STEP - 01 / Middle Collector Wash
Open fully V-4.

Open V-13 partially & allow water to wash Middle Collector. The flow =
Backwash Flow.
STEP 02 / Back Wash
V-4 is open as earlier.

Open V-3 and allow water to backwash mixed bed. The flow = 6 x Cross
section area of the vessel. (M3/hr)
STEP 03 / Settle Bed
All valves remain closed. The resin bed (which is separated) gets settled.
STEP 04 / Power Water / ACID & ALKALI
Open Middle Collector Outlet valve, V10 fully.

Open power water inlet valves V32 (both) on MHL-1 & MAK-1 lines.
Start SBA service operation.
Establish power water 0.19 m3/hr each for both the lines (MHL-1 & MAK-1).
Observe drainage mark for appropriate settings.
STEP 05 / ACID & ALKALI INJECTION
Power water for CATION resin regeneration is established since earlier step.
Power water for ANION resin regeneration is set since earlier step.
Now open slowly V2 (MAK-1) & V2 (MHL-1) simultaneously & allow injection of
Alkali & Acids simultaneously.
Continue injection for about 15 to 20 minutes until full regenerants gets
consumed.
STEP 06 / ACID / ALKALI SLOW RINSE
When ACID & ALKALI get finished, increase power water flow & equals it to
regeneration flow rates
Continue slow rinsing for about 25 minutes. This completes regenerant
distribution through resin beds.
Stop inlet flow of rinsing water & allow the resin beds to settle.
STEP 07 / Drain Down
Open V-12 & V-4 fully.

Now open V-6 partially so as to drain water up to 100 mm above resin level.
Then air scouring shall be started.
STEP 08 / Blower Start
Valves, V-12, V-4 & V-31 are fully open.

Allow air to flow through drain.
126
STEP 09 / Air Mixing Resins
Valves, V-12, V-4 & V-11 are fully open.

Allow air to flow through resin beds to mix cation & anion resins.
STEP 10 / REFILL
V-1, V-12 remains fully open.

Open V-6 partially. Start inlet flow from SBA unit to refill the vessel.
STEP 11 / Fast RINSE (or FINAL RINSE)
Valve V-1 is fully open, Then open V-6 partially (flow = 13.0 m3/hr service flow) for
fast rinse. After 5 minutes check conductivity of the rinse outlet water.
127
REGENERATION SOLUTION PREPARATION: MB

For Mixed Bed Unit
Description
HCl recommended on 100% concentration
Therefore 30% HCL required
Therefore 30% HCL required (volume)
To make 10% acid dilution add decationised water
Therefore 10% acid volume after dilution
Acid injection flow
ANION Regeneration with NaOH
NaOH recommended on 100% concentration
Therefore 48% NaOH required
Therefore 48% NaOH required (volume)
To make 10% alkali dilution add decationised water
Therefore 10% alkali volume after dilution
Alkali injection flow
qty
7.2
24.00
20.89
41.78
62.66
0.063
0.19
0.38
units
kgs
kgs
Liters
Liters
Liters
m3
m3/hr
m3/hr
9.5
19.79
13.28
50.48
63.76
0.064
0.19
0.38
kgs
kgs
Liters
Liters
Liters
m3
m3/hr
m3/hr
128
MB OPERATIONS & REGENERATION FLOWS

MB OPERATION: FLOWS (Simultaneous Regeneration)
Sr.
Operation
No.
1 REFILL
2 RINSE
Flow M3/hr
FULL
BORE
13
3 SERVICE
13
4 AIR REALEASE
Time (minutes)
Refer Drgs.
REFILL
As required
RINSE
--
refer designed
HOURS
As required
AIR REALEASE
5 Middle Collector Wash
2.54
Step-1
6 Back Wash
2.54
10
Step-2
Step-3
8 Power Water ACID/ALK.
0.19
Step-4
9 ACID/ ALK. Injection
0.38
20
Step-5
0.38
25
Step-6
11 Drain Down
--
Step-7
12 Blower Start
--
Step-8
13 Air Mix (Resin)
--
10
Step-9
14 Refill
13
Step-10
15 Fast Rinse
13
10
Step-11
7 Settle Bed (Regeneration)
10 ACID/ ALK. Rinse (Slow)

Settle Bed (Regeneration)
SERVICE
129
PH Correction
Dosing chemical for pH correction: The acidic nature of permeate (OR MB outlet
water) is corrected using caustic soda (Morpholine or Hydrazine if used for boiler feed).
Following steps shall be taken for correction of pH.

Step_1
Measure the pH of permeate

6.8
e.g. permeate is acidic
Say, 15 ppm
Take jar test to determine base required to adjust the
pH. (Say 9.5 pH is required to be maintained using
Morpholine for boiler feed water)
Step_2
Step_3
Scale-up dosages on plant level

For 13 m3/hr permeate flow the qty. of base required
would be
195 gm/hr
(On 100%
chemical
concentration)
For 20 hours the qty. of base required
3.9 kg/day
Preparation of base solution

Take 60 liters of permeate in the dosing tank, PHT.
Add measured qty. of base & prepare homogenous
solution.
Step_4
Dosing base for pH correction

~ 3.0 lph
Adjust pump dosing rates (50% of 6 LPH dosing
pump)
Start dosing & measure the flow rates
Step_5
Lab tests
Measure pHs of permeate after chemical dosing.

Note: Dosing could be split for per shift operations (8 hours).
141
CHAPTER 06
Operation & Maintenance Manual
For
FLEXI SOFTENERS
142
TABLE OF CONTENTS
a) INSTALLATION
b) SOFTENER OPERATIONS
c) OPERATIING CONDITIONS / DOS & DONTS
d) TROUBLESHOOTING
e) MAINTENANCE
f) DAILY LOG-SHEET
143
A)INSTALLATION
UNIT LOCATION
- The location of the unit assembly should be as close to the disposal drain point as
possible. The floor should be perfectly leveled and firm to withstand the load of the
unit assembly.
- Civil foundation should be made and checked as per civil foundation drawing.
Particularly, check the slope of the drain trenches, which should be downwards
towards the final disposal point. This will ensure that there is no stagnation of water
in the DRAIN SUMP. If this slope is not downwards from beginning from drain sump
to the final point of disposal, the stagnation of water will cause the operator to
misread the flow on the V-notch board provided in the Drain Sump.
- Enough access should be provided for the operator to move about freely.
- On the outlet of the Softener provide water meter if so desired along with a rotameter
(flowmeter) at the inlet of the filter. The water meter if provided should be as close to
the outlet termination point as possible.
PRECAUTION
- Ensure that all fittings as shown on the P&I diagram and Packing List are intact and
there is no damage done in the transit.
PIPING
- Place the vessel on the foundation and ensure that it is plumbed.
- Ensure that all the flange joints are made with rubber gaskets in between. The joints
should be tightened evenly with fasteners provided for the purpose.
- Ensure that the screwed joints for the pressure gauge connections are made leak
proof by using Teflon tape or fit tight compound or o-ring.
- Connect the hoses provided for sample tubing to the sample points.
- Ensure that the Air release and drain piping are properly pointing in the drain sump.
144
- Fix the v-notch board which is provided to measure the flow, in the groove
provided in the drain sump.
- Complete the interconnecting pipe work (In Purchasers scope of supply) from our
termination points Inlet to the SOFTENER and Outlet of the SOFTENER to raw
water main and to service respectively.
FLUSHING & HYDROTESTING
- Open RINSE outlet valve V6 fully. Open AIR RELEASE valve V-12 fully. Now Open
INLET valve V-1 to start flushing the piping and vessel from inside. This shall remove
any dirt or debris from the system.
- Now close RINSE Valve V6 fully. Let the AIR RELEASE valve V-12 be fully open. All
the air trapped in the vessel shall now be removed and water will start coming out
FULL BORE from the AIR RELEASE valve V-12. Now Close valve V-12. The unit shall
now get pressurized to full pressure. Check the vessel flanges and piping for any
leakages. Tighten the joints nut bolts to stop the leakages. This completes the
Hydrotesting.
145
SUPPORTING MEDIA CHARGING

Put a match mark with paint on the top manhole flange and vessel flange (This will ensure that while
refixing no mismatch is observed) Remove the top manhole of the vessel. Inspect the vessel from
inside for any debris etc.
Make paint marks from bottom of the vessel as indicated in the INT. ARRENGEMENT FOR FLEXI
DF SOFTENER drawing . Make first mark on 100 mm from bottom of the vessel. Make other
marks according to the Drg.
It is recommended to pre wash the supporting media with water before loading. Hence, wash the
media type one by one and then charge inside the vessel.
Load the media by slowly pouring the Highest sized pebbles (40-25 size pebbles) first upto the 100
mm mark. Make the layer even by hand.
After this charge the other supporting media one by one upto the chalk mark and everytime making
the layer even by the hand. This will ensure proper laying of the media and avoid any media mix up
later.
After all the supporting media is charged, it is now time to give Open backwash. Let the top
manhole of the vessel be open. Open BACKWASH valve V-3 slowly till water starts coming out of
the top manhole. Slowly increase the BACKWASH flow rate such that media does not come out of
the top manhole. Continue this step till clear water is observed coming out of the vessel. Close
BACKWASH valve V-3.
147
CAUTION
Before CHARGING Supporting media, inspect the gap between collection box and bottom dish. This
gap should be 5 mm evenly throughout the circumference. In case this gap is found more than 5 mm
or uneven on the circumference, please adjust the nut/bolts to maintain the gap at 5 mm, as otherwise
there are chances of supporting media leaking during operation. If unable to adjust, please call local
Thermax Representative. The Drg. below indicates the location of the gap_
THE GAP SHOULD BE 5 MM
COLLECTION
BOX
148
RESIN CHARGING
After ALL the supporting media has been charged as indicated in Drawing INT. ARRANGEMENT FOR
BE and having washed the supporting media by Open Backwash it is time to charge resin.
Let all the valves be closed. The top manhole is open from previous step. Make a mark at XX
meters from bottom, on inside of the shell. Slowly open Inlet Valve V-1 and pour water into the
vessel till it is filled up to the chalk mark.
Now slowly pour the resin into the vessel from top manhole. The water filled up inside the vessel
will help the resin get distributed evenly inside the vessel. Take care that resin does not spill outside
the vessel while pouring.
Complete the operation by pouring all the resin into the vessel. At any stage, if required pour water
into the vessel from Valve V-1 to help resin get spread evenly across the vessel.
Now close the top manhole cover. Open AIR RELEASE Valve V-12 fully. Open Inlet Valve V-1 till
water starts coming out FULL BORE from Valve V-12. After this close Valves V-12 and V-1. This
completes the Resin charging operation.
149
B) SOFTENER: OPERATIONS
TECHNICAL DATA
MODEL DIAMETER FRONTAL
FLEXImm
PIPING
DF
DIA
mm
02
1100
65
MIN
SERVICE
FLOW,
M3/hr
9.5
MAX
BACKWASERVICE SH FLOW
FLOW
M3/hr
3
M /hr
29.0
6.6
FAST
RINSE
FLOW
M3/hr
29.0
MIN
RESIN
QTY
Ltrs
570
MAX
RESIN
QTY
Ltrs
1662
Base Exchanger (BE) service cycle is operated in following sequence.

REFILL
- Open BE Inlet Valve V-1 fully.
- Open Air Release Valve V-12 fully. Filter (ACF) remain in SERVICE.
- After full bore water flows from Air Release, change over to Rinse operation by
closing Air Release Valve V-12.
RINSE
-
BE Inlet Valve V-1 open fully since previous step.

Open BE Rinse Outlet Valve V-6, partially.
Flow should be 29.0 M3/hour.
Check outlet hardness before taking into service. It should be <5 ppm as CaCO3.
SERVICE
-
Open BE inlet Valve V-1 fully.

Open BE outlet Valve V-2 partially.
Maintain flow of 29.0 M3/hour.
Check inlet / outlet pressure.
AIR RELEASE
- Air release during Service Run to release air trapped in the unit is achieved by
operating Air Release Valve V-12.
- Open Air Release Valve V-12 fully.
- Ensure full bore water flows from unit. Then close Air Release Valve V-12.
150
SERVICE RUN
-
Normally Base Exchanger is in operation with 29.0 M3/hour. Flow to be maintained

by throttling outlet valve V-2
Flow through unit is achieved i.e. __ M3/OBR. (changes as per feed hardness)
___ hours service cycle achieved.
When Hardness in the outlet exceeds 5 ppm then cut-off unit from service as
indicated in normal shut down operation.
NORMAL SHUT DOWN

-
Put individual unit from service to Rinse Sequence.

Put individual unit from Rinse Sequence to Off position.
Now exhausted stream can be taken for regeneration.
REGENERATION OF THE SOFTENER

-
REGENERANT SOLUTION PREPARATION
It is essential that specified quantity of salt is injected into the softener. This is ensured
by preparing saturated solution of the salt in the BRINE TANK. Approximately solution of
26 % concentration is prepared in the tank. The volume of water to be added to salt shall
depend on quantity of salt.
Regenerant dilution & flows: Calculations
Quantity of NaCl recommended
166 kg
Recommended concentration of brine
26%
Therefore, water addition required for dilution
166 /0.26 166 kg
Therefore, water addition (by volume)
~475 liters
Check sp. gravity of the brine after dilution of the salt
Sp. gravity of 26% brine solution (at 15 0C)
1.2016
Brine injection ration
1:1
Power water quantity
0.475 M3
Power water flow rate (assuming 30 min injection) 0.95 m3/hr
In the brine tank (MBR) take measured quantity of water & mark level on the tank for
convenience. Add NaCl (measured QTY.) and prepare homogenous solution ready for
injection.
155
REGENERANTION STEPS
STEP_01 - DRAIN DOWN (TIME: 3-4 Minutes)

- OPEN Wash Outlet Valve V-4 Fully.
- OPEN air vent valve V12 fully.
- Drain down water from the resin bed (up to 100 mm above top level).
STEP_02 BACKWASH (TIME: 10 MINUTES)
- OPEN Wash Outlet Valve V-4 Fully.
- VERY SLOWLY, OPEN Wash Inlet Valve V-3 and ADJUST it such that
level of water in the drain sump is up to the WASH marker. (6.6 M3/HR)
- After 10 minutes or when the water is clearer (same as that of inlet
water), CLOSE WASH Inlet Valve V-3 Fully.
- This completes Backwash operation.
STEP_03 - SETTLE BED (TIME: 2 Minutes)
- Allow resin to settle condition before starting regeneration.
- Ensure vessel is filled up with water. By refill step operation, open Air
Release Valve V-12 and water inlet valve, V-1.
- After full bore water flow from air release, close Valves V-12 and V-1.
- Now start regeneration
STEP_04 - POWER WATER (TIME: 2 Minutes)
- Open Rinse outlet valve V-6 partially.
- Open Brine Power Water Valve V-32 partially and adjust flow to 0.95
M3/hour.
- Allow stabilizing power water flow for 2 minutes.
STEP_05 - BRINE INJECTION (TIME: 30 Minutes)
- Rinse outlet valve V-6, Brine Power Water Valve V-32, are open since
previous step.
- Open brine outlet valve V2 (MBR) and allow brine injection in. Flow shall
be 1.9 m3/hour
- After full brine solution is used for regeneration, close Valve V-2.
156
STEP_06 - SLOW RINSE (TIME: 30 Minutes)

- All valves are open as per earlier step, except V2 is closed.
- Adjust slow rinse flow by partially opening V6 for flows = brine injection
flows (i.e. 1.9 m3/hour)
- Continue slow rinse for 30 minutes until all the spent brine (containing
hardness) remaining in the bed displaces out.
STEP_07 - SETTLE BED (TIME: 02 Minutes)
- All valves are closed & the resin bed is allowed to settle for some time.
STEP_08 - FAST RINSE (TIME: 10 15 MINUTES)
- Open rinse outlet valve V6 partially.
- Open inlet valve V1 fully & allow flow in. Open air release valve V12 and
release air.
- Adjust outlet valve V6 for fast rinse flow = 29.0 m3/hour
- Close air vent valve V12 & continue for 10 minutes.
- Measure total hardness (TH) at the outlet of rinse.
- The unit is ready for SERVICE.
157
C) OPERATING CONDITIONS
Inlet water pressure should not exceed 3.5 kg/cm2. Min Operating
pressure: 2.0 kg/cm2. Do not exceed the Max Operating Flow rate as this
may deteriorate the quality of outlet water.
Analyze Inlet water for Total Hardness and Total DISSOLVED SOLIDS
(TDS) content every week, if found consistently more than 10 % of the
design limit, consult Thermax representative.
Inlet water should be free of oil and grease, iron and other heavy metals.
Inlet water Suspended Solids should not be more than 2 ppm.
Inspect the vessel, piping externally once in a year for damage to the
painting. Repaint as necessary.
Inspect vessel internally once in a year for any damaged or peeled off
paint or rubber lining as may be applicable. In case of internally painted
vessels, paint the vessels every year as described in Maintenance
section.
Inspect the Resin every year, and remove the fines (Refer
MAINTENANCE section of this manual). Add make up quantity of resin
for the fines removed.
Give extended backwash to the Softener once in a week for 45 minutes
to remove any suspended solids accumulated. This may not be
necessary if the softener is installed after a filter.
Maintain Log-Book of operation, as this shall be required while lodging a
complaint.
166
DOS AND DONTS
Analyse Inlet water for Total Hardness and TDS regularly.
Always check Inlet water for Oil & Grease and Iron content. Dont
allow such water to pass through the softener.
Inlet water Turbidity should never exceed 2 ppm. Install filter prior to
the softener if required.
Do annual Resin Check up and replacement as required.
Backwash the softener regularly as per Manual
Always use clean and dirt free common salt.
Never exceed the softener service flow
Never Run the softener more than the rated capacity (Output between
two regenerations)
Never allow corrosive liquids to pass through the Softener
167
D) TROUBLESHOOTING
Sr. Defect
No.
Cause
Remedy
1.
Resin over exhausted
Check and give double regeneration
Backwash Valve V-3 is passing
Check and close fully if open or passing
Unit idle for long time
Check and give sufficient FAST RINSE.
Excessive or Low flow rate
Adjust Service flow rate between Minimum and

Maximum.
Check and ensure sufficient pressure.
Treated Water
quality not up to
the standard
Channeling Collection/Distribution
Decrease in
capacity Between
two successive
regenerations
Resin fouled
Check iron in water. Give chemical wash to

remove fouling. This should be done in
THERMAX representatives presence.
Resin Deteriorated
Check and replace
Inlet water Hardness and TDS has

increased
Increase in inlet Total Hardness
Analyse water. If found increased, consult

THERMAX
Check by raw water analysis
Insufficient chemical (Brine) used.
Check and ensure proper quantity
Resin Dirty
Check raw water Turbidity. Check quality of

Common salt for suspended solid content.
Avoid this
Plant being used intermittently

Resin fouled
3.
4.
Unit Rinse takes

long time
Pressure Drop
across bed is
increasing day by
day
Resin Deteriorated
Check Iron in water. Give chemical wash to

resin in presence of THERMAX representative.
Check and replace
Resin quantity insufficient in the unit
Check and add resin if required.
Flow rate too low
Increase RINSE Flow
Resin Bed choked due to Turbidity
Clean Resin and if required install filter
Resin Fines
Remove resin fines.
168
SR. Defect
No.
Cause
Remedy
5.
Low Inlet pressure
Check and adjust
Resin fouled with turbidity
Clean Resin
Resin fines on top
Remove resin fines to improve flows
Low POWER WATER suction pressure
Check and adjust Minimum required pressure

( 2.0 Kg/cm2)
Ejector Nozzle may be choked
Open ejector assembly carefully and remove

any dirt by blowing out with air.
Ejector nozzle may be broken
Check and replace
The Vessel is pressurized
Check and open RINSE OUTLET valve V6 fully.
Resin Fouled with Turbidity
Check and clean
Improper supporting media charging at the

time of erection
Remove and recharge supporting media

properly
Too much excessive backwash flow

rate/Pressure
Always maintain backwash flow rate as

indicated. Too much backwash flow rate/
Pressure can disturb media layers.
The gap in collection box and dish is more

than 5 mm. ( This should have been
checked before installation)
Remove the entire resin and supporting media,

adjust the gap to 5 mm, segregate the media
by type and recharge the media and resin.
6.
7.
Flow rate too less
Brine Injection Not

taking Place
Media comes out

from bottom outlet
169
E) SOFTENER MAINTAINANCE
-
Use good quality salt containing at least 95 % NaCl.

Analyse Raw Water periodically to ensure that there is no increase in total Hardness and
TDS.
Every six months _
Check the diaphragm and butterfly valves for any leakages. Repair/ Replace the diaphragm
or seats as required.
Open and check/Clean Ejector assembly. Remove any clogging.
Clean the Brine Measuring tank thoroughly.
Calibrate the inlet and outlet Pressure Gauges.
Inspect the unit externally including connecting pipe work and valves. Chip away any loose
paintwork and scale and make good with fresh paint. Inspect the unit internal surface after
removing the resin and supporting media. Carry out internal painting by with Black
Bituminous paint after proper wire brushing. Recharge the supporting media and resin.
1. Carry out an extended BACKWASH with the manhole cover off and observe the bed performance.
The water should breakthrough evenly. If it breaks through from one side of the vessel and floods
over the bed surface, or the bed breaks into lumps (indicating packing and channeling) backwash
at fastest possible flow rate without bringing resin over, and stir with a stout rod until the bed is
level and of a consistent density. Remove any fines etc by skimming the top surface and then
shoveling out.
2. After backwashing, drain the unit down and then note and record the bed level relative to some
convenient point. Compare this measurement with the last recorded level as a check for resin loss.
Note that in order to obtain an accurate bed measurement; the level must always be taken
immediately following a backwashing operation. If the condition or performance of resin is suspect,
take samples (approximately 30 gms sample) at a depth of 150 mm and again 450 mm and
arrange for the samples to be analyzed.
170
RESIN REPLACEMENT
1.
2.
3.
4.
Open the unit WASH INLET valve until the unit is th full of water.
Pour in the correct type and quantity of resin.
Check the resin BED DEPTH .
Replace manhole cover and regenerate unit as stated in the Operation Section.
AIR SCOUR AND EXTENDED BACKWASH

1.
INTRODUCTION
Due to prolonged use under varying pressure and flow conditions, the ion exchange resin tends
to break up. Normal annual loss, known as attrition loss, is about 5 to 10 %. The particles thus
formed are known as fines. These fines if allowed to remain in the resin bed, tend to choke up
the bed thus increasing the pressure drop across the bed and reducing the flow through it.
Some of these particles thus formed are normally eliminated during backwash but those which
go down deep into the resin bed are not removed. Hence it is advisable to remove these fines.
THIS IS RECOMMENDED TO BE DONE ATLEAST ONCE IN A YEAR.
2.
EQUIPMENT
a) An air hose of sufficient length to reach bottom of resin bed. The hose should be weighed at
end to facilitate its reaching the bottom of the resin bed.
b) Air supply at 0.5 kg/cm2.
c) A bucket to remove the fines.
3.
METHOD
A) Ensure that the vessel is filled fully with water.
B) Open the manhole
C) Open Rinse Outlet valve (V6) till the water is drained such that the level of water is 300 mm
above the resin bed. Close Rinse Outlet Valve.
D) Insert the air hose halfway into the resin bed taking care to see that it does not reach bottom
and disturb the under bed.
E) Connect the hose to air supply and start the air.
F) Move the hose throughout the resin.
G) Continue the operation for 15 minutes.
H) Cut off air supply and remove the hose.
I) Open Backwash Outlet Valve V-4 fully and slowly open Backwash Inlet valve V-3 , taking care
that good resin is not lost in the Backwash effluent.
J) After the backwashing is over, close the Backwash Inlet valve and the Backwash Outlet valve.
K) Open Rinse Outlet Valve and drain the water to slightly below the resin bed level.
L) Scrape off 6 mm (1/4) layer from the top of the resin bed and discard this.
M) Close the manhole cover.
The unit is now ready for further use.
171
RESIN STORAGE
The dry ion exchange resins have tendency to swell and break when put into water. Hence it is
necessary that the resin, whether in vessel or during storage, should always be kept in moist condition.
The ion exchange resin must never be allowed to dry.
Resins are normally supplied in polyethylene lined M.S. drums or carboys. They are always supplied in
moist condition.
1. Check the condition of the drums
2. Open the top cover and polyethylene bag.
3. Feel the resin by hand, if not moist then, add clean water (preferably D.M. Water), roll the drum
after closing. Check the resin. Repeat the procedure till the resin is in moist condition.
4. Keep the resin drums under the shed.
5. Check the condition of the resin frequently. If the resin is to be stored for a long time, store it in
exhausted form in moist condition.
DOS AND DONTS

-
Never exceed the softener service flow

Never Run the softener more than the rated capacity (Output between two regenerations)
Analyse Inlet water for Total Hardness and TDS regularly.
Always check Inlet water for Oil & Grease and Iron content. Dont allow such water to pass
through the softener.
Inlet water Turbidity should never exceed 2 ppm. Install filter prior to the softener if
required.
Do annual Resin Check up and replacement as required.
Backwash the softener regularly as per Manual
Never allow corrosive liquids to pass through the Softener
Always use clean and dirt free common salt.
172
F) FORMAT FOR OPERATION LOG SHEET

DUAL MEDIA FILTER
SR
Date
Time
DMF inlet
Pressure
Kg/cm2
DMF
outlet
Pressure
Kg/cm2
Flow
M3/hr
Total
Flow
M3
INLET
TURBIDITY,
NTU
OUTLET
TURBIDITY,
NTU
Inlet*
Water
TOC
(KMnO4
Value)
ACTIVATED CARBON FILTER

SR
Date
Time
ACF inlet
Pressure
Kg/cm2
ACF
outlet
Pressure
Kg/cm2
Flow
M3/hr
Total
Flow
M3
INLET
RESIDUAL
CHLORINE
/ TOC
NTU
OUTLET
RESIDUAL
CHLORINE
/ TOC
Inlet*
Water
TOC
(KMnO4
Value)
Time
Softener
inlet
Pressure
Kg/cm2
Softener
outlet
Pressure
Kg/cm2
Flow
M3/hr
Total
Flow
M3
Outlet
Total
Hardness,
ppm
Inlet
Water
Hardness,
ppm**
Inlet
Water
TDS,
ppm**
SOFTENER
Sr. Date
No.
** Analyse Inlet Water Total Hardness and TDS once in a week.

* If raw water is chlorinated, then measure residual chlorine at the outlet of DMF.
173
CHAPTER - 07
DM PLANT: GENERAL MAINTENANCE
General Maintenance
Chemicals Specification
Chemical Safety
174
M/S KBK CHEM-ENGINEERING (P) LTD; / 225064
General Maintenance
General maintenance: DM Plant
Thermax Water Treatment Plant should be inspected externally every six months
and any damaged paint work on vessels, pipe work and valves renewed. An annual
internal inspection of vessels is also recommended.
In case of any visible external damage, consider possibilities of corrosion, due to
underlying causes such as a damaged lining in a vessel or a pipe carrying acid or
alkali. Consequently, when removing scale on such items (e.g. chemical storage
tanks, measuring and dilution tanks) exercise caution. If there is any possibility of a
breakthrough, consult the Water Treatment Plant Chemist or Engineer.
In addition to the items specifically mentioned in the MAINTENANCE section, rectify
leaking valves and joints immediately by tightening loosened nuts and bolts or
changing sealing joints (gaskets). Replace gland packing when required DON'T LET
LEAKS PERSIST. KEEP THE WATER TREATMENT PLANT DRY AND WELL
SWEPT.
If it is necessary for maintenance personnel to enter any of the treatment units,
rubber or soft soled shoes must be worn and great care taken to avoid damage to
any rubber lining and internal lateral systems. The feet should be placed on the
lateral clamping bars, not on the laterals themselves and every effort taken to avoid
standing on the small plastic strainers. Entry into the vessels should be discouraged,
but if unavoidable, must be carried out under the supervision of the Water Treatment
Plant Chemist or Engineer.
On Demineralising and Mixed Bed units where treatment units, internal studs, nuts,
bolts and washers are made of high grade stainless steel, it is essential that only the
right quality replacements are used. The stainless steels are virtually non-magnetic
and therefore the quality of a replacement can easily be confirmed with a magnet.
Any items showing magnetic properties must be rejected. Whenever a bolt or nut
bolts against rubber, use the special rectangular plate washers. When tightening
down on these washers ensure that friction between the nut (or bolt head) and the
washer does not cause the washer to rotate and bite into the rubber lining.
Valves should be inspected regularly and gland packing where used should be
replaced regularly. Valves of the plug type and some diaphragm type, which require
lubrication, should be attended regularly.
Refer to the auxiliary manuals for maintenance instructions on other equipment that
may be supplied such as pumps, blowers and instrumentation.
175
RESIN UNITS
Inspection all units externally every 6 months including connecting pipe work and
valves. Chip away any loose paintwork and scale, and make good with fresh paint.
When the unit has been removed from service for internal inspection, close the
manual inlet and outlet isolating valves as a safety measure and then open the AIR
RELEASE valve and DRAIN valves. Remove the manhole cover and examine the
internal linings in the unit. If the lining is damaged, shows sings of bubbling or lifting,
or is suspect, carry out a spark test and rectifies. Check procedures involved with
your maintenance department or refer the matter to this Company. If the condition of
the lining below the level of the resin is suspect, the resin will have to be siphoned
out as described in the MAINTENANCE sheet entitled RESIN REMOVAL AND
REPLACEMENT.
Carry out an extended backwash with the manhole cover off and observe the bed
performance. The water should break through evenly. If it breaks through from one
side of the vessel and floods over the bed surface, or the bed breaks into lumps,
(indicating packing and channelling) then backwash at fastest possible flow rate but
avoiding resin overflow. Simultaneously stir with a stout rod until the bed is level and
of a consistent density. Remove any fines, etc. by skimming the top surface and
then shovelling out.
After backwashing, drain the unit down and then note and record the bed level
relative to some convenient point. Refer to the MAINTENANCE sheet entitled BED
DEPTH. Compare this measurement with the last recorded level as a check for resin
loss. Note that in order to obtain an accurate bed measurement; the level must
always be taken immediately following a backwashing operation. If the condition or
performance of the resin is suspect, take samples (approximately 30 gm samples) at
a depth of 150 mm and again 450 mm and arrange for the samples to be analysed.
Refill the cation or anion unit by backwashing and double-check bed performance,
then refit the manhole covers.
On Mixed Bed units, carry out an air mix operation as follows:
Mixed Bed DRAIN DOWN valve shall open, and allow the unit to fill with water until it
starts to flow out of this valve, then stop the backwash water. When the water
ceases to flow out of the DRAIN DOWN valve close the valve and start the air mix
operation, (see relevant sections in the OPERATION section) and observe the
surface of the bed. The whole of the top water and resin should be in a fairly
vigorous boiling stage.
When the Mixed Bed unit has been re-mixed, replace the manhole cover and open
the AIR RELEASE valve. Fill the unit through the inlet valve and when water free of
air flows from the AIR RELEASE valve, close the AIR RELEASE valve.
176
DEGASSER TOWER
Every six months examine the Degasser Tower externally including connecting pipe works and
valves. Remove any loose paintwork and scale and make good with fresh paint.
Periodically (once a year or as service experience dictates) shut down or by-pass the Degasser
Tower and carry out an internal inspection. Stop the duty Degasser Blower or Gas Extraction Pump
on Vacuum-Type Towers (and break the vacuum), and then drain the tower.
Remove the manhole covers on the Tower and examine the lining. If the lining is damaged, shows
signs of bubbling or lifting, or is suspect, carry out a spark test and rectify.
Clean away any packing debris that may have accumulated in the bottom dish of the vacuum tower
(or in the Degassed Water Sump) and examine all internal fitments for security. Replace the
manhole covers and return the tower to service.
Note:
Some Atmospheric Degasser Towers are constructed of reinforced concrete with no available
access. Inspection of this type of tower should consist of an external examination to check for
leakage at joints, etc.
177
RESIN SAMPLING
A.
For Softeners - Cation, Anion Exchange Units

1.
Equipment
a) A pipe (25mm diameter) of sufficient length. With stopper or cork at one end to dip
at least 500 mm into the resin bed.
b) Polyethylene bag to hold approximately 300 gms of resin.
2.
Procedure
a) Do a normal backwash of the unit.
b) Allow the resin bed to settle under gravity for 3.5 minutes.
c) Open the manhole.
d) Open RINSE OUTLET valve and allow the water to drain slowly down to the resin
bed (5-10 minutes).
e) Insert the pipe piece corked at one end into the resin bed. The pipe piece should
go into the bed to a depth of about 500 mm (IMPORTANT - SEE NOTE 2)
f) Release the cork for a minute or so. Then re-cork the pipe.
g) Quickly withdraw the pipe and hold the polyethylene bag at the open end, i.e.,
the end which was dipped inside the resin bed.
h) Release the cork and tap the pipe.
i) If no resin falls into the bag, blow into the pipe from the other end.
j) See that the resin sample so collected is about 300 gms.
k) Drain water, if any, from the bag and seal the bag so that the resin is kept in a
moist condition.
l) Close the manhole and use the unit as per requirement.
B.
For Mixed Bed Units

1. Equipment
a) Polyethylene bag to hold 300 gms of sample.
b) A 500 ml beaker.
c) String or tongs to lower the beaker into the unit.
178
2. Method
a)
b)
c)
Open the manhole.

Open the DRAIN DOWN valve and proceed to do the AIR MIX as stated under OPERATION.
After 5 minutes of mixing, and while air mixing is going on lower the beaker and withdraw it
after it is full of resin.
Transfer about 300 gms of resin into the polyethylene bag.
d)
After samples have been taken, the units should be filled up with an up-flow of water. This should be
done very slowly, especially in units where plastic distribution systems are employed. Ensure that the
water rises up through the resin bed evenly; the dry resin bed should not rise up in a mass.
C.
Despatching Samples
Pack the samples securely and despatch it to our Water Treatment Division at Pune, labelled
with the following particulars. Please note that the RESIN SAMPLE SHOULD ALWAYS BE SENT
IN A MOIST CONDITION.
1.
2.
3.
4.
5.
6.
Note:
Our Contract No. (See note).

Senders name and address to which analysis report is to be sent.
Type of resin (See note).
Unit from which resin was drawn.
State of resin, i.e., exhausted or regenerated, etc.
Total quantity of water passed through the resin since use, and number of regenerations
carried out.
1. Contract No. and type of resin, etc., can be checked from the Operation Manual.
2. Important
Some treatment units such as ones operating on Counterflow regeneration have a collecting
system near the resin surface. Extreme care should be taken when inserting the pipe so that no
damage is done to this. Care is required to see that no damage is done to any rubber - covered
and plastic items.
179
MAINTENANCE: Resins
RESIN REMOVAL AND REPLACEMENT

The performance of the ion exchange resins used in the treatment units will gradually deteriorate, and
therefore, will need to be replaced at varying intervals depending upon service conditions and the type
of resin being used. When it becomes necessary to remove a resin bed, either for replacement or to
gain access to the vessel for repair purposes, the following general procedure should be adopted.
A.
Necessary Equipment
The resins can best be removed by siphoning out into hessian sacks (gunny bags), and
therefore, the following items will be required beforehand.
1. Sufficient Hessian sacks to contain the resins. These must be quite clean and without any
torn areas.
2. A length of 25 mm or 50 mm dia. Hose (the size dependent on the volume of resin to be
siphoned) long enough to reach the bottom of the unit and at the same time, give easy
handling to fill the sacks.
3. A length of 25 mm by 25 mm clean wood, sufficiently long enough to reach the bottom of
the bed when inserted from the top of the vessel.
4. A length of rubber hose that will fit over the nearest sample valve and provide a means of
back filling the siphon hose.
5. Several meters of strong cord.
6. A change of replacement resin (if required).
To prepare the siphon, first of all ascertain whether or not the resin bed rests upon a layer of SILEX
(crushed flint and pebbles), or simply rests upon a flat bottom plate. If the former, lash the siphon
hose to the length of wood so that the wood projects approximately 50 mm beyond the hose. This will
prevent the siphon drawing up the crushed flint. If the resins rest upon a flat bed plate and there is no
under bed media, e.g., Mixed Bed Units, lash the hose to the wood so that the hose projects 50 mm
beyond the wood. This will allow the end of the hose to be pushed between the laterals of the bottom
collecting system.
Note:
Check with your maintenance department to confirm presence of SILEX and the type of collecting
system employed.
180
B. Resin Removal
1. Open the vessel Air Release valve.
2. Open the Drain Valve (RINSE OUTLET) and allow the unit to partly drain down, and then
close the Valve.
3. Remove the manhole cover.
Caution:
McNeil type manhole covers can easily be dropped into the unit (with possible damage to
the internal fittings). Attach a strong cord/rope to one of the studs below the clamp, then
slacken the nuts and knock the door in with a hammer. Rotate the clamps and lower the
cover into the unit and then turn it and lift it out of the unit.
4. Adjust the water level so that it is about 150 mm above the surface of the resin bed.
5. Push the hose with its wood stiffener down through the resin. Take care that the wood is
guided between the laterals of the collecting system in the case of Mixed Bed and some
other types of units. Most laterals are made of PVC and can be damaged.
6. Back fill the siphon from any convenient sample point.
7. Lower the end of the hose into one of the sacks, and providing that the hose has been
correctly filled, the resin will be siphoned out of the unit.
8. Ensure that the resin bed is kept in a fluid state by opening and closing the WASH INLET
valve. For large diameter units, move the hose around the bottom of the unit to ensure that
all the resin has been siphoned out.
Opportunity may be taken at this stage to thoroughly inspect the vessel, internal fittings and
necessary repairs may be carried out.
C.
Resin Replacement
1. Open the unit WASH INLET valve until the unit is 3/4th full of water. The water level should
be several cms above the highest collector system. This is necessary because the weight
of the resin falling directly on the laterals might bend them.
2. Pour in the correct quantity and type of resin.
3. Check the resin BED DEPTH (refer separate Maintenance Sheet)
4. Replace manhole cover and regenerate unit as stated in the Operation Manual.
Note:
Some cation resins are supplied in the Sodium form. If they are required in the Hydrogen form, it
will be necessary to regenerate the resin 3-4 times in succession to complete the conversion.
BED DEPTH
An ion exchange plant is designed to give a specified treated water quality when run on particular raw
water, the analysis of which has been used for the design. An economical quantity of resin required is
decided upon and also an economical quantity of regenerant to achieve the required quality of treated
water and capacity between regenerations. The resin volume is a very important factor. If this is less,
then a reduced capacity is obtained. A procedure is given below for measuring the ion exchange resin
bed depth form which, by knowing the cross-sectional area of the pressure vessel, the resin volume
can be computed.
181
Items required - A scale long enough to measure the distance from the bottom of the unit to the top
flange of the manhole. A length of 25 mm by 25 mm wood may be used, alternatively a length of
PVC, GI or MS Pipe.
Note:
For rubber-lined units, GI or MS pipes should not be used as they might cause damage to the lining or
to the collecting systems. If a pipe or length of wood is used, a separate scale is required to measure
distances.
a) Open top manhole.
b) Open WASH OUTLET then slowly open WASH INLET valves. This will fluidise the resin bed.
c) After 3-5 minutes, carefully insert the measuring pipe in the unit through the resin, until it
reaches the bottom.
Note:
1. Where a SILEX under bed is employed, the pipe is to be inserted down to this level.
2. Where no SILEX is used, the collecting system may be one of several types - header and
lateral, strainers on plate - in both cases polypropylene strainers are employed, therefore care
should be taken to see that no damage occurs to these or other components. This pipe should
be carefully manoeuvred that it reaches the bottom plate.
3. Hold the pipe vertical and mark off the distance to a convenient reference point such as the
manhole flange.
4. Remove the pipe and repeat procedure to check the depths at 2 other points, than remove pipe.
5. Measure the distance marked off on the pipe (A).
6. Continue backwashing for 10 minutes then close WASH INLET valve. This results in the resin
settling down under gravity.
7. After 5 minutes of settlement, slowly open the RINSE OUTLET valve and let unit drain slowly
over a period of 10-15 minutes.
8. When the water drains down to the resin bed level, close the RINSE OUTLET valve.
9. Re-insert the measuring pipe through the manhole down to the bed surface and mark off the
depth up to the same reference point as in para 3. Repeat this at two other points.
10. Remove pipe and measure this distance (B).
11. Measure the distance between the bottom of the REGENERANT DISTRIBUTOR to the resin
bed surface (C)
12. Open the WASH INLET valve slowly and allow the unit to fill up. Close the manhole cover.
13. Knowing the cross-sectional area of the pressure vessel and the depth of resin (A-B), calculate
the resin volume and check that it is as per the TECHNICAL DATA SHEET.
182
CHEMICAL TANKS
Every six months inspect all measuring tanks externally, including connecting pipe work and valves.
Remove any loose paintwork and scale and make good with fresh paint.
If the internal condition of the tank is suspect the tank cover must be removed under the
supervision of the Water Treatment Plant Chemist and the interior inspected and cleaned. Whilst
the cover is removed, ensure that any sludge in the bottom of the measuring tanks is removed. On
automatic plants, a possible cause of a slow acid is sludge in the bottom of the tank forming a
permanent circuit between the earth and the low level electrode.
When scraping out sludge in the acid measuring tanks use a wooden spatula or a piece of hard
polythene to avoid damage to any lining. The level indicator glasses should also be cleaned
periodically with clean rags and hot water.
The lining material in the acid measuring tanks is normally rubber when hydrochloric acid is used.
Tanks for concentrated sulphuric acid are unlined. The caustic soda measuring tanks are normally
unlined.
Note;
If at any time the unlined pipe work to and from the acid measuring tanks are flushed out with water
for cleaning purposes, it is essential that the pipes are thoroughly dried out before concentrated
acid is again passed through them, otherwise the local dilution of the acid by the residual water on
the walls of the pipe will result in corrosion.
CHEMICAL STORAGE TANKS
Every six months inspect both tanks externally including connecting pipe work and valves. Remove
any loose paintwork and scale and make good with fresh paint.
If the internal condition of the tank is suspect, provision will have to be made for draining the
tank and any residual liquor and sludge dilute and neutralised.
WARNING:
THIS MUST BE CARRIED OUT UNDER THE SUPERVISION OF THE WATER TREATMENT PLANT
CHEMIST. EXTREME CAUTION MUST BE EXERCISED WHEN HANDLING STRONG ACID AND
CAUSTIC SODA. CORROSIVE SOLUTIONS SUCH AS THESE WILL CAUSE SEVERE AND
PAINFUL INJURIES IF THEY COME INTO CONTACT WITH HUMAN TISSUE. REFER TO THE
SAFETY SECTION.
Note:
Although reference has been made to various types of equipment the sections on DESCRIPTION and
TECHNICAL DATA SHEET and the Flow Diagram will detail the actual equipment supplied.
183
MAINTENANCE: PRESSURE FILTERS (SAND, ANTHRACITE & CARBON

FILTERS)
The routine maintenance of the filters should include the following:
1. VALVES
At periodic intervals (say one month) open out the valves and check seating, gate, etc. Attend
to gland packing. Replace if necessary, do routine lubrication of the spindle.
2. EXTENDED BACKWASH
Once in a week extend the backwash operation to at least 45 minutes to keep the bed clean.
3. AIR SCOURING AND CLEANING OF THE FILTER MEDIA
This applies only to sand and anthracite filters. Once in six months, open the manhole and
examine the condition of the media. Throw away any lumps formed on the top of the bed. On
units where no regular air scouring facilities are provided air scouring should be done as
follows:
a. If compressed air supply is available, take a temporary tapping (say 1 hose). Attach the
hose to a M.S. pipe about 1 M long with water level inside vessel about 3 above the level
of the bed, insert the pipe into the bed till it is about halfway through. The media will be
seen getting violently agitated. Move the pipe all over the bed. Carry out the air scour for a
period of about 10 minutes.
b. After the air scour do an extended backwash till wash water is clear.
c. Drain the water till the surface of the bed and scrape off any fine dust.
d. Close the manhole.
Once in a year, check the condition of paint inside the unit. If any signs of corrosion are noticed,
remove the media, clean the surface and apply 2 coats of anticorrosive bitumistic paint in case of
sand/ anthracite/permiron filters and epoxy paint in the case of carbon filters.
184
MAINTENANCE: filters
AIR SCOUR & EXTENDED BACKWASH

1. INTRODUCTION
Due to prolonged use under varying pressure and flow conditions, the ion exchange resin tends to
break up. Normal annual loss, known as attrition loss, is about 5%. The particles thus formed are
known as fines. These fines if allowed to remain in the resin bed tend to choke up the bed thus
increasing the pressure drop across the bed and reducing the flow through it. Some of these
particles thus formed are normally eliminated during backwash but those which go down deep into
the resin bed are not removed. Hence it is advisable to remove these fines. THIS RECOMMENDED
TO BE DONE AT LEAST ONCE A YEAR.
2. EQUIPMENT
a) An air hose of sufficient length to reach the bottom of the resin bed. The hose should be
weighed-at-end to facilitate its reaching the bottom of the resin bed.
b) Air supply at 0.5 kg/cm2.
c) A bucket to remove the fines.
3. METHOD
a) Open the BACKWASH OUTLET valve.
b) Open the manhole
c) Close the backwash OUTLET valve and open the RESIN OUTLET valve.
d) Drain the water till level is about 300 mm (1 ft) above the resin bed.
e) Insert the air hose halfway into the resin bed taking care to see it does not reach the bottom of
the bed and disturb the under bed, if any.
f) Connect the hose to air supply and start the air.
g) Move the hose throughout the resin.
h) Continue this operation for 15 minutes.
i) Cut off air supply and remove the air hose.
j) Open BACKWASH OUTLET valve and slowly open BACKWASH INLET valve, taking care that the
effluent water does not carry good resin beds.
k) After the backwashing is over, close the BACKWASH INLET valve and the BACKWASH OUTLET
valve.
l) Open RINSE OUTLET valve and drain the water to slightly below the resin bed level.
m) Scrape off 6 mm (1/4) layer from the top of the resin bed and discard this (see note).
n) Close the manhole cover.
The unit is now ready for further use, i.e., for removal of organic cowling or for regeneration, etc.
Note:
In case a ladder is to be used for reaching the resin bed, care should be taken that there is no damage
to rubber lining if the vessel is rubber lined.
185
MAINTENANCE: Resin Treatment
The dry ion exchange resins have tendency to swell and break when put into water. Therefore, it is
necessary that the resin, whether in column or during storage should be always kept in moist
condition. The ion exchange must never be allowed to dry.
Resins are normally supplied in polyethylene lined M.S. drums. They are always supplied in moist
condition.
1. Check the condition of drums.
2. Open the top cover and the polyethylene bag.
3. Feel the resin by hand, if not moist, then:
Cation Resin
Add clean water, roll the drum after closing. Check the resin. Repeat the procedure till the resin
is in moist condition.
Anion Resin
Use decationized, soft or D.M water in place of raw water and carry out the conditioning as for
cation resin.
Close the polyethylene bag and fix the cover.
Keep the resin drum under shade, preferably in shed
Check the condition of resin frequently, when the resin is to be stored for long time. Where the
demineralising unit is to be kept out of operation for long time, keep the resin in the exhausted form
ensuring that it is always wet.
186
ALKALINE BRINE TREATMENT TO SBA/WBA

The following is the procedure of Alkaline Brine
Treatment given to SBA / WBA Units.
Prepare solution of 10% NaCl and 2% NaOH making 3 bed volumes (RESIN
VOLUMES) of WBA and SBA RESINS.
For example,
SBA Resin - A 27 MP
1751 litres
WBA Resin - A-12 X
3493 litres
3 Bed volume of both resins = 15732 litres.

Thus15,732 litres of 10% NaCl and 2% NaOH shall be prepared.
Initially the units were backwashed thoroughly and the alkali brine prepared was injected
into SBA, letting the effluent coming out of SBA drain outlet. After 10 minutes the
Alkaline Brine is injected into WBA thoroughfare SBAs without any power water and the
effluent will come out from WBA and is drained.
One-bed volume 5244 litres (one third of the total solution prepared) is let to pass
through SBA and WBA (thoroughfare) and allowed to drain out through rinse outlet of
WBA.
The second bed volume (5244 litres) of alkaline brine solution is allowed to pass through
both SBA and WBA units and when the units are full with the solution, the injection is
stopped and units with resin and alkali brine solution are allowed to soak for 12 hours.
After soaking the units with alkaline brine solution for 12 hours, drain down the vessels
and final part of the alkaline brine solution is injected through both SBA and WBA. After
completing the injection of the alkaline brine solution, the units WBA and SBA were
rinsed thoroughly at normal rinse flow rate till the chlorides in the effluent are nil. Then
the units WBA/SBA were given double regeneration (with double the quantities of
regenerant chemicals).
ALKALINE BRINE Wash to be given to anion (STRONG BASE AND WEAK Base)
resins for removal of ORGANIC FOULING.
Normally, ONCE IN A YEAR
RECOMMENDED FOR better performance of the resins.
187
ALKALINE BRINE TREATMENT PROCEDURE FOR MB
PREPARE SOLUTION of 10% NaCl and 2% NaOH making 3 BED volumes (RESIN
VOLUMES) OF MB ANION RESIN.
For example,
MB Resin - A 27 MP
3 Volumes of Anion Resin
2660 Litres
7980 litres
Thus, 7980 litres of 10% NaCl and 2% NaOH is prepared.

First the MB unit is backwashed thoroughly & first batch (1/3rd of total solution prepared 2660 LITRES) to be injected thorough alkali inlet distribution header letting the effluent
to come out through RINSE outlet (V-6). The second batch of ALKALINE brine solution
(2660 litres) is against injected into the MB unit & is allowed to soak for 12 hours. After
soaking the unit for 12 hours, The vessel is drained and the final batch of alkaline brine
solution is injected. After that the unit should be rinsed thoroughly till the effluent coming
out contains nil chlorides. The MB unit should be given TRIPPLE regeneration after the
alkaline brine treatment.
188
TROUBLESHOOTING
PROBLEM
INDICATOR
PROBLEM CAUSE
A) LOSS OF
EXCHANGE
CAPACITY OF
RESIN
Shorter service cycle
Change in raw water

composition
Quality deterioration &

premature break
through of solids in
the treated water
Channeling of resin
bed and improper
distribution / collection
of water / regenerant
chemicals
Inefficient or insufficient
regeneration
Improper injection
strength of regenerant
chemical
Excessive regenerant
consumption
Excessive service flow

Frequent interruptions
in service cycle
Insufficient quantity of
resin
Resin fouling
B) LOSS OF RESIN
DURING
BACKWASH
Resin in wash water
Excessive backwash
flow
CHECKS / REMEDIAL
MEASURES
Analyse raw water every month
and monitor the quality
Internal distribution and
collection systems for any loose
laterals, loose strainer buttons,
choking of strainer buttons and
alignment
Check above and ensure proper
quality of regenerant
Check ejector, power flow rate,
strength of regenerant in Storage
/ Measuring / Dilution Tanks by
sampling
Monitor flow by throttling valves
with the help of flow meters/
water meters
Avoid
Check resin bed depth
periodically for loss of resins.
Makeup losses in time
Analyse resin samples. Contact
manufacturer for further advice
Ensure flow rates are maintained
as specified
189
PROBLEM
INDICATOR
PROBLEM CAUSE
Air entrainment
Faulty collectors
(Checking of strainers)
Excessive fines
C) FOULING OF
RESIN
Long rinse time

Deterioration in
quality of treated
water
D) EXCESSIVE
VIBRATIONS
Delay in quality
coming to
acceptable limits
CHECKS / REMEDIAL
MEASURES
Ensure proper air release
See A-2 above
Operate plant at parameters

designed and with proper
injection strengths of
regenerants to minimize
formation of fines
Oil contamination
Check raw water supply and
avoid mixing of lubricants in
stream
Contaminants in
Ensure proper quality of
regenerant
regenerants
Turbidity and organics in Check raw water quality. Provide
feed water
additional pretreatment facility if
required
Iron in feed water
-- do -Resin bed not kept clean Inspect units periodically and
avoid mixing of foreign
Resin fouling
Avoid fouling / contamination of
resin
Improper distribution /
collection
Channeling & formation
of chemical pockets in
resin bed
Flow rate too low
Check internals periodically

-- do -Maintain proper flow rates as
specified
190
CHEMICAL SPECIFICATIONS
HYDROCHLORIC ACID (recommended for regeneration)
HYDROCHLORIC ACID FORMULA HCl

MOLECULAR WEIGHT
36.5
SPECIFICATIONS FOR TECHNICAL GRADE HCl
Specific Gravity
1.145
HCl as HCl
30.0 min.
Residue on ignition, (% by weight)
0.1 max.
Sulphate as H2SO4, (% by weight)
0.1 max.
Iron as Fe, (% by weight)
0.02 max.
Free chlorine as Cl
0.02 max.
Lead as Pb, (% by weight)
-Sulphate as SO2, (% by weight)
0.05 max.
191
SPECIFIC GRAVITY CHART

HYDROCHLORIC ACID
(AQUEOUS HYDROCHLORIC ACID SOLUTION)
BOUMI
0.5
1.2
2.6
3.9
5.8
6.6
7.9
9.2
10.4
11.7
12.9
14.2
15.4
16.6
17.7
18.8
19.9
21.0
22.0
23.0
24.0
SPECIFIC GRAVITY
1.0032
1.0082
1.0181
1.0279
1.0376
1.0474
1.0574
1.0675
1.0776
1.0878
1.0980
1.1083
1.1187
1.1290
1.1392
1.1493
1.1593
1.1691
1.1789
1.1885
1.1980
PERCENTAGE HCL
1
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
192
SODIUM HYDROXIDE (recommended for regeneration)
SODIUM HYDROXIDE
NaOH
MOLECULAR WEIGHT
40.0
SPECIFICATIONS FOR PURE GRADE NaOH
NaOH as NaOH
99.5% min.
Carbonate as Na2CO3, (% by weight) 0.4 max.
Chlorides as NaCl
0.1% max.
Sulphate as Na2SO4, (% by weight)
0.1 max.
Silicates as SiO2
0.02% max.
Fe
20.0 ppm
Cu
2.0 ppm
Mn
1.0 ppm
total hardness
5.0 ppm
193
SPECIFIC GRAVITY CHART

SODIUM HYDROXIDE (NaOH)
BOUMI
SPECIFIC GRAVITY
PERCENTAGE NaOH
1.4
2.9
4.5
6.0
7.4
8.8
10.2
11.6
12.9
14.2
16.8
19.2
21.6
23.9
26.1
28.2
30.2
32.1
34.0
35.8
37.5
39.1
40.7
42.2
43.6
45.0
46.3
47.5
48.8
49.9
1.0095
1.0207
1.0318
1.0428
1.0538
1.0648
1.0758
1.0869
1.0979
1.1059
1.1309
1.1530
1.1751
1.1972
1.2191
1.2411
1.2629
1.2848
1.3064
1.3279
1.3490
1.3696
1.3900
1.4101
1.4300
1.4494
1.4083
1.4873
1.5065
1.5251
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
194
SODIUM CHLORIDE (NaCl)

SODIUM CHLORIDE SOLUTIONS: CALCULATED FROM GERLACHS TABLES
PERCENT
NaCl OF
GRAMS
PER 100
GRAMS OF
SOLUTIONS
SPECIFIC
GRAVITY AT
15 C
--------------
15 C
R 59 F
59 F
BAUME AT
15 C OR
59 F
PERCENT NaCl
OF GRAMS
PER 100
GRAMS OF
SOLUTIONS
SPECIFIC
GRAVITY AT
15 C
--------------
15 C
R 59 F
59 F
BAUME AT
15 C OR
59 F
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
1.0073
1.0165
1.0217
1.0290
1.0302
1.0437
1.0511
1.0585
1.0655
1.0734
1.0810
1.0886
1.0962
1.1038
1.0
2.0
3.1
4.1
5.1
6.1
7.1
8.0
9.0
9.9
10.9
11.8
12.7
13.5
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
26.0
26.4
1.1115
1.1194
1.1273
1.1352
1.1432
1.1511
1.1593
1.1676
1.1758
1.1840
1.1923
1.2016
1.2043
14.5
15.5
16.4
17.3
18.2
19.0
19.9
20.8
21.7
22.5
23.4
24.3
24.6
195
CHEMICAL SAFETY
SAFETY PRECAUTIONS
Chlorine gas is known as potential danger to health in its manufacture and industrial
use. Chlorine gas itself is a pungent, greenish-yellow gas that is more than twice as
heavy as air. The handling & use of both liquid & gaseous chlorine require close
attention to safety precautions & practices.
Chlorine is notably irritating to mucous membranes of eyes, nose, throat & lungs
because it reacts with the body moisture to form dangerous acids. In fact the first
symptom of exposure to it is smarting & burning of the eyes, nose & throat. Continued
exposure can cause intense coughing, chest pain & vomiting. If breathed long enough,
high concentrations of chlorine can cause muscle cramping of throat & swell the linings
of air passage, resulting in suffocation.
Liquid chlorine produces gas instantly, if spilled. Either the liquid or the concentrated gas
can severely burn the skin or eyes. Freeze burns can also be caused by the rapid
vaporization of the liquid. Persons, who for any reasons have to enter an area
containing a high concentration of chlorine, or where accidental spillage could occur,
should wear protective clothing & gloves & use a full-face airline respirator. If you find
that the air you are breathing is contaminated with chlorine, hold your breath until you
get the nearest emergency mask on. If you have to breathe before you can the mask on,
take very shallow breaths.
If even a little chlorine gets into your eyes or if they are stretched to strong
concentrations of gas, flush them out immediately with lots of water at the face spray.
See the plant doctor afterwards. If liquid chlorine gets on the skin anywhere wash the
area with lots of running water. You can use a mild soap, but dont put on an ointment or
any medicine until the doctor tells you to.
To protect against low-level exposure any person who develops chlorance, continuous
headaches, or feelings or general indisposition, anxiety or suffocation should report to
the plant nurse or doctor immediately. Each employee must be aware of hazards to
health resulting from working with chlorine & how he can best reduce the hazards
through safe work practices & safety precautions.
196
In addition the employee should:

1.
2.
3.
4.
5.
Avoid skin & eye contact with chlorine.

Know where emergency equipment is kept in his area & how to use it.
Know his job, his equipment, & what he should do in case of emergency.
Be prepared to assist other persons near him in case of emergency.
Make sure ventilation systems are functioning during work periods.
Tell his supervisor about anything unusual concerning the use of chlorine gas or
liquid in his area.
6. Report to the plant nurse or doctor any unusual or chronic symptoms that he feels
could be related to exposure to chlorine.
SAFETY PRECAUTIONS FOR ACID USERS
Whenever corrosive acids are used, consideration must be given to the provision of
suitable protection for personnel working with them.
The chief hazards are splashes in eyes, burns & damage to clothing. In some instances
obnoxious fumes are evolved. In order to minimize the risk of these hazards, certain
precautions must be taken, and accordingly recommendation of precautions and
suitable equipment are described below.
SAFETY MEASURES:
There are a number of precautionary measures, which are common to all acids. These
are as follows:
1. Personnel should be aware of the character of the acids & their hazards.
2. Avoid contact with the eyes, skin & clothing.
3. Goggles must always be worn during the handling of corrosive acids.
4. Protective clothing should be worn; rubber boots or clogs for the feet, aprons for the
body, & gauntlets or gloves for the hands.
5. A plentiful supply of water must always be available. A bath or shower of water
adjacent to the working area is an advantage. Tepid water should be supplied so
that any possibility of shock is reduced to a minimum. The shower must be equipped
with foolproof & easily operated valve.
6. An eyewash bottle, containing clean water, should be readily available.
7. Smoking or naked lights should be prohibited in the vicinity of vessels containing
acid.
8. Acid supplied in mild steel drums may liberate Hydrogen. The bung should,
therefore, be done on receipt & after that at frequent intervals or at any time when
bulging of the drum is noticeable.
9. Do not discharge drums or carboys by the application of pressure to the containers.
Discharge by pouring, siphoning or by means of an approved discharge device.
SPILLAGE
197
Protective clothing, but preferably with face shields instead of eye goggles must be worn
when dealing with spillage. Any person not engaged in clearing the spillage should be
kept away from the area.
The most satisfactory method removing any acid, which has been spilled, is to hose it
down with water. The stream should be directed to the edges of the spillage & not to the
center. The diluted acid solutions are corrosive & if necessary, may be neutralized with
hydrated Lime or Soda Ash.
It is dangerous to add water to Oleum & Chlorosulphonic Acids & reference should be
made to the special precaution on handling these acids.
ACIDS AND SPECIAL PRECAUTIONS IN THEIR HANDLING.

SULPHURIC ACID
Sulphuric acid is highly corrosive. It reacts violently with water, and the heat developed
may be sufficient to raise the solution to the boil. When diluting always add acid to the
water slowly & carefully, stirring throughout addition. Water must NOT be added to
strong Sulphuric Acid.
The acid attacks organic matter & when concentrated will cause charring, sufficient heat
sometimes being developed to cause ignition. Dilute acid will weaken fabric, rope etc.,
which will ultimately disintegrate.
HYDROCHLORIC ACID
Hydrochloric Acid is highly corrosive. It is highly soluble in water, & the commercial
product is the solution of gas in water. Very little heat is evolved on dilution & boiling
does not occur.
FIRST AID
In case of contact or spillage, drench water. For eyes, give prolonged irrigation with
water & get medical attention immediately. The contents of this Safety Sheet are given
in a good faith but without warranty.
CAUSTIC SODA SOLUTION
PROTECTIVE CLOTHING
When handling Caustic Soda solutions, care should be taken to prevent splashing or
contact with the skin. It is particularly necessary to protect the eyes by wearing of
comfortable goggles or eye shields which should be insisted on during all stages in the
discharge of road, rail tankers into bulk storage vessels, the subsequent handling & use
of liquor. Wool is readily acted by Caustic Soda, so cotton clothes should be worn.
Rubber gloves & Wellington Boots worn inside the sleeves & legs of overalls, give good
protection to hands & feet.
198
FIRST AID TREATMENT FOR CAUSTIC BURNS

Whenever there is a risk of caustic burns occurring by spillage, splashing, spurting or
any other means, 5% solution of Ammonium Chloride (Sal-Ammoniac ) should be
readily available in such quantities that the skin or clothing can be immediately drenched
with it . If this action is taken without delay, it is unlikely that serious damage will occur.
The Ammonium Chloride solution is stored most effectively in a vessel holding 5 gallons.
The vessel has a bottom outlet & is fitted with a length of rubber tubing & a pinchcock.
If there has been such delay in the application of the solution that some destruction of
the epidermis has taken place & there is actually a burn, the part affected should be
drenched with Ammonium Chloride for 10-15 minutes & then washed continuously with
running water or Saline /Boracic Lotion for a period of an hour. The burn should then be
dressed with a four -fold pad of lint soaked in Bonnys Blue Paint.
This dressing should be left undisturbed until it drops off without aid, then the burns will
be found to have healed completely. No infection can possibly take place if the tissues
have been thoroughly died by the Blue Paint.
CAUSTIC SODA IN EYES
If the Caustic Soda gains access to the eye, the eye should be washed immediately with
complete contents of one eyewash bottle (8-16 oz) of 5% Ammonium Chloride solution.
Such bottles should be placed conspicuously in boxes in the Plant, so as to be
immediately available when needed. This treatment should be carried out on the spot by
one of the mans mates.
The individual should then be removed to the works surgery or other convenient place &
the eye irrigated with running Saline /Boracic Lotion, or failing this, clear water preferably
at body temperature, continuously for one hour taking special care that the Lotion
reaches the corners of the lower sulcus. This prolonged irrigation is of extreme
importance & must be done at once. If such a case is sent to hospital without this
preliminary irrigation, irreparable damage will have been done. This can only be
prevented at the time of the accident by the procedure.
199
An alternative first-aid treatment for eye burns which is less painful than the application
of 5% of Ammonium Chloride solution is as follows:
The eye should be immediately washed out with the complete contents of one eyewash
bottle (8-16 oz) of a buffered first-aid solution made by the following formulae:
Potassium Dihydrogen Phosphate
( KH2PO4)
Dibasic Sodium Phosphate (Na2HPO4, 12H2O)
Distilled Water
Brilliant Green
27.22 gm
71.63 gm
1.00 Ltrs.
00.01 gm
This treatment must be followed by the prolonged irrigation treatment with

Saline/Boracic Lotion as described above, under medical supervision. In order to
prevent eye burns, the most satisfactory precaution is to insist on use of efficient
goggles.
NOTE:
1. Saline / Boracic Lotion is made up in double strength as follows Sodium Chloride
Boric Acid
Distilled water
45 gm
50 gm
2.5 Ltrs.
The double strength lotion should be stored in Winchester bottles. At the time of
using , it should be diluted with an equal volume of warm water in a wash bottle to
make a lotion at about body temperature. The temperature is correct when a little
of the lotion poured on the back of the hand feels just warm and no more.
2. Bonnys Blue Paint.
Blue Paint is prepared by dissolving Crystal Violet or Brilliant Green, 0.15% of each in
equal parts of alcohol and water. (Se Martindale, the Extra-pharmacopoeia, 1952, 23rd
Edition, 1242 Pigmentum Tinctorium). The contents of this Safety sheet are given in
good faith but without warranty.
200
CHAPTER - 08
Laboratory Analysis / Daily Log Sheets
P & I Drawings
201
CONTENTS
1. TURBIDITY ________________________________________________ 203
2. COLOUR __________________________________________________ 204
3. ELECTRICAL CONDUCTANCE ________________________________ 207
4. TOTAL DISSOLVED SOLIDS _________________________________ 209
5. SUSPENDED MATTERS _____________________________________ 210
6. EQUIVALENT MINERAL ACIDITY ______________________________ 211
7. ACIDITY___________________________________________________ 212
8. ALKALINITY _______________________________________________ 213
9. FREE CARBON DIOXIDE _____________________________________ 215
10. RESIDUAL CO2 IN CATION EXCHANGER TREATED WATER ______ 216
11. SODIUM BY FLAME PHOTOMETRY ____________________________ 217
12. HARDNESS ________________________________________________ 219
13. CALCIUM HARDNESS _______________________________________ 221
14. IRON _____________________________________________________ 222
15. SILICA ____________________________________________________ 224
16. SULPHITE _________________________________________________ 228
17. SULPHATE ________________________________________________ 229
18. CHLORIDE ________________________________________________ 230
19. PHOSPHATE_______________________________________________ 233
20. OXYGEN CONSUMED FROM PERMANGANATE SOLUTION________ 234
21. OILS AND GREASE _________________________________________ 235
22. RESIDUAL CHLORINE _______________________________________ 238
23. REAGENTS ________________________________________________ 240
202
1) TURBIDITY
OUTLINE OF THE METHOD
The sample is matched against standard suspensions of fullers earth in water.
TERMINOLOGY
For the purpose of this test, the following definition shall apply. Scale Unit - Turbidity imparted
by 1 mg of fullers earth when suspended in 1000 ml of distilled water.
PREPARATION OF TURBIDITY STANDARDS
Mix slowly with constant stirring 5.000 g of fullers earth previously dried and shifted through
75 micron IS Sieve with distilled water and dilute it to 1000 ml. Agitate intermittently for one
hour and then allow to stand for 24 hours. Withdraw the supernatant liquid without disturbing the
sediment. Vaporate about 50 ml of the removed liquid, dry the residue at 105 + 2 Deg. C and
weigh the residue to determine the amount of clay in suspension. Prepare turbidity standards
with this standardised stock suspension with distilled water. A drop of saturated mercuric
chloride solution may be added as preservative. The standards are stable for three months.
PROCEDURE
Pour the sample after thorough shaking into a clear glass bottle of suitable capacity, say, one
litre. Compare it with the turbidity standards contained in similar bottles, holding them against
a suitable background and using a source of light which illuminates them equally and is placed
so that no rays reach the eye directly. The sample and the standards shall be shaken
simultaneously immediately before comparison. If the sample has turbidity over 100 units,
dilute it with distilled water before testing and multiply the result with an appropriate
factor.
NOTE
Comparison of turbidity may also be done with the help of suitable instruments.
203
2) COLOUR
The colour of the sample is matched against a series of standards containing potassium
chloroplatinate and cobalt chloride.
TERMINOLOGY
For the purpose of this test, the following definitions shall apply :
True Colour
Apparent Colour
Hazen Unit
Colour due to substances in solution, after removal of

suspended matter.
Colour due to substances which are in solution as well as in
suspension.
Colour obtained in a mixture containing either on milligram
of Patinum or 2.49 mg of potassium chloroplatinate along
with 2 mg of cobalt chloride (CoCl2.6H2O) in 1 litre of the
solution.
APPARATUS
Nessler Tubes - Flat-bottom tube of thin colourless glass. Two types of tubes are required. The
longer tubes shall be 45 cm tall and 2.5 cm in internal diameter. The shorter tubes shall be 30
cm tall and 1.7 cm in internal diameter. Tubes of any one type shall be identical in shape, and
the depth measured internally from the graduation mark to the bottom shall not vary by more
than 2 mm in the tubes used.
REAGENTS
Platinum or Potassium Chloroplatinate Aqua Regia - prepared by mixing one part by
volume of concentrated nitric acid (conforming to IS:264-1950) with three parts by volume
of concentrated hydrochloric acid (conforming to IS:265-1962). Cobalt Chloride-Crystalline,
with the molecular composition CoCl2.6H2).
204
PROCEDURE
PREPARATION OF COLOUR STANDARDS
Dissolve 0.500 g of metallic platinum in aqua regia and remove nitric acid by repeated
evaporation to dryness on water bath after addition of excess of concentrated hydrochloric acid
(conforming to IS:265-1962). Dissolve the residue with 1.0 g of cobalt chloride in 100 ml of
concentrated hydrochloric acid to obtain a bright solution, if necessary by warming. Dilute the
solution to 1000 ml with distilled water. This stock solution has a colour of 500 Hazen units.
A more convenient way of preparing the same solution is by dissolving 1.245 g of potassium
chloroplatinate and 1.0 g of cobalt chloride in distilled water and diluting to 1 litre. Prepare a
set of colour standards having colour 5, 10, 15, 20, 25, 30, 35, 40, 50, 60 and 70 Hazen units by
diluting the stock solution with water. Protect these colour standards from evaporation and
contamination when not in use. The colour standards shall be freshly prepared for each
determination. But in routine practice, they may be used repeatedly, provided they are
protected against evaporation and contamination when not in use.
PROCEDURE FOR CLEAR SAMPLES
For samples having turbidity under 5 mg/l, match the colour of the sample against the standard
colours in the longer Nessler Tubes. Fill the tubes to mark and compare the colour by looking
vertically downwards against a pure white surface. If the colour is found to exceed 70 units,
dilute the sample with distilled water before comparison and multiply the result by appropriate
factor. As matching is very difficult when the colour of the sample is below 5 Hazen units, report
the colour as less than 5 Hazen units in such cases. When the colour of the sample exceeds 30
Hazen units, the comparison may, if desired, be made in the shorter Nessler tubes.
PROCEDURE FOR TURBID SAMPLES
If the sample has turbidity over 5 mg/l it becomes impossible to measure the true colour
accurately by the method prescribed in PROCEDURE for clear samples and if an attempt is
made, the value found shall be reported as "apparent colour". In the presence of turbidity, the
true colour shall be determined after centrifuging. The sample shall be centrifuged until the
supernate liquid is clear. The centrifuged clear sample shall be compared by the method
prescribed in PROCEDURE for clear samples.
NOTE
For estimating true colour, filter paper shall not be used since that leads to erroneous results.
REPORT
The results of colour determination shall be excess in whole numbers and shall be recorded as
follows :
205
Hazen Units
Less than 5
5 to 50
51 to 100
101 to 250
251 to 500
Report as "Less than 5 Hazen Units"

Report to the nearest 1 Hazen Unit
NOTE
The colour determination shall be made as early as possible after the collection of samples as
certain biological change occurring in storage may affect the colour.
206
3) ELECTRICAL CONDUCTANCE
GENERAL
The unit of conductance is the mho or reciprocal ohm. Specific conductivity is the
conductance at a specified temperature across a column of a liquid 1 cm2 in area and 1 cm
long, and is expressed mhos per centimetre. This is an inconveniently large unit for water
testing and it is usual to use the micromho per centimetre known as the "dionic unit", which is
one-millionth part of a mho per centimetre.
APPARATUS
Several kinds of apparatus are available. They generally consist of two parts.
CONDUCTIVITY CELL
Containing a pair of electrodes. The sample to be tested is poured into this cell. There are
many forms of cell. One of the most convenient types is provided with a funnel for filling,
a drain for emptying, and an overflow for maintaining constant level. Electrodes for use with
samples having very low dissolved solids (such as condensates) should not be coated with
platinum black. Platinum black which has been heated to redness until it is grey is suitable.
Bright platinum or gold or heavily gold plated electrodes may be used. Some instruments are
designed to work with particular form of conductivity cell, and are then calibrated directly in
conductivity units. Other instruments, primarily introduced for more general application, are
calibrated on conductance units and their readings require multiplication by a factor known
as the "cell-constant" which shall be determined by experiment. Measuring Instrument - For
measuring the electrical conductance (or the resistance which is the inverse of
conductance) between the electrodes of the cell. There are several satisfactory commercial
models. Operators, less they have adequate facilities, would be well advised to purchase a
ready made instrument.
207
PROCEDURE
Determine the cell constant if necessary, either directly with a standard potassium chloride
solution (say 0.002 N) or by comparison with a cell the constant of which is known
accurately. (In the latter case, the concentration and nature of the electrolytes in the liquid
which is used for the comparison should be the same and should be similar respectively
to those of the liquids with which the cell is likely to be used in practice). Use some of the
samples to wash out the conductivity cell thoroughly. Fill the conductivity cell with the
sample. Measure the conductivity in accordance with the instructions of the instrument
manufacturer.
Calculations
FOR INSTRUMENT READING RESISTANCE :
1 x 106
Electrical conductance, in dionic units
=
(or micromhos per centimetre)
rk
Where r = Resistance in ohms, and k = Cell constant

FOR INSTRUMENT READING CONDUCTANCE :
Electrical conductance, in dionic units
(or micromhos per centimetre)
= ck
Where c = conductance in micromhos, and k = cell constant
CORRELATION OF ELECTRICAL CONDUCTANCE TO TOTAL DISSOLVED
SOLIDS
For water containing a given mixture of mineral salts, the electrical conductance is closely
proportional to the dissolved solids. When the samples are known to be free from wide
fluctuation in mineral content, the electrical conductance offers a quick means of computing the
total dissolved solids. However, this PROCEDURE may be used only after ascertaining the
appropriate conversion factor for a particular series of samples.
Electrical conductance
Dissolved Solids
208
4) TOTAL DISSOLVED SOLIDS (TDS)

A well mixed filtered sample is evaporated in a weighed dish and dried to constant weight in an
oven at 103 to 105 Deg. C. The increase in weight over that of the empty dish represents the
total residue.
APPARATUS
1.
2.
3.
Silica or porcelain dish of 100 ml capacity

Desicator
Oven
PROCEDURE
Ignite the clean evaporating dish at 550 + 50 Deg. C for 1 hour. Cool, desiccate and weigh.
Transfer the measured sample to the preweighed dish and evaporate to dryness on a steam
bath. Choose a sample volume that will yield a minimum residue of 25 mg to 250 mg. If
necessary, add successive portions of sample to the same dish. Dry the evaporated sample for
atleast 1 hour at 103 to 105 Deg. C. Cool the dish in a desiccator and weigh. Repeat the cycle
of drying, cooling and weighing until a constant weight is obtained.
Calculations
Total dissolved solid, mg/L =
Wt of residue x 1000
ml. of sample taken
209
5) SUSPENDED MATTERS
Suspended matter is the material retained on filter after filtration of a well mixed sample of
water. The residue is dried at 103 to 105 Deg. C.
APPARATUS
1.
2.
3.
4.
5.
Gooch crucible
Silica or porcelain evaporating dish of 100 ml capacity
Desiccator
Oven adjustable to constant temp of 103 - 105 Deg. C.
Water batch
PROCEDURE
Prepare a gooch crucible with asbestos (20 to 30 ml of 0.5% suspension of gooch asbestos
added and washed under suction), dry and ignite at 500 Deg. C for atleast 30 minutes, cool and
weigh. Filter a suitable volume of the well mixed sample through the crucible. Wash with
distilled water, dry at 105 Deg. C for one hour. Weigh.
Calculations
Suspended matters in mg/L =
W x 106
V
Where,
w = wt. in g of the suspended matter
V = vol. in ml. of the sample taken for filteration
NOTE
If Gooch Crucible is not available, standard "Whatman" filter paper may be used.
210
6) EQUIVALENT MINERAL ACIDITY

All the chlorides, sulfates, nitrates of Ca, Mg, Na. etc. are converted to corresponding mineral
acids when they come into contact with strongly acidic cation exchanger like Tulsion-42. When
the Performance of the cation unit is satisfactory the EMA and free mineral acidity (FMA) will
be one and the same. Therefore, to have thorough control over the cation unit, EMA test is
necessary.
PRINCIPLE
Some quantity of the water is allowed to pass through a cation exchanger Tulsion - 42 in
hydrogen form, the effluent is collected and titrated against standard alkali and EMA is
expressed as CaCO3.
Ca
R.H. + Mg
Na
} Cl
} SO4
} HCO3
Ca
----- R. Mg
Na
} Cl
+ H } SO4
} HCO3
REAGENTS
1.
2.
3.
Strongly acidic cation exchanger Tulsion - 42 in H+ form.

2 NHCl
Standard 0.02 N sodium hydroxide solution
PROCEDURE
A. REGENERATION OF RESIN COLUMN
1.
2.
3.
4.
Fill up the column with about 50 ml. of cation resin uniformly and soak it in DM
water. Remove any air bubbles.
Regenerate with 200 ml of 2 N HCl at the rate of 5 ml/min.
Rinse it thoroughly with distilled water till the effluent becomes neutral.
Always keep some amount of distilled water over the column.
B. DETERMINATION
1.
2.
3.
Add the water to be tested slowly and pass through the column at the rate of 5
ml/min.
Discard the first 50 ml portion of the effluent and collect the rest in flask.
Pipette out 50 ml from it and add 2 drops of mixed indicator. Titrate against
standard 0.02 N NaOH.
Calculations
EMA as CaCO3, mg/L =
ml. of titrant x 1000

ml. of sample taken
211
7) ACIDITY
The acidity of a water may be caused by the presence of uncombined (free) carbon dioxide
mineral acids and salts of strong acids and weak bases. The test is based on the titration of
a sample with a standard solution of a strong base. Titration to the methyl orange end point (pH
4.5) is arbitrarily defined as "free acidity". It measures the relatively strong acids such as
mineral acids. Titration to phenolphthalein end point pH 8.3 is defined as "total acidity" and it
includes also the weak acids, acid salts, and some acidity due to hydrolysis.
REAGENTS
1. 0.02 N Sodium hydroxide.
2. Phenolphthalein indicator solution
3. Methyl orange indicator solution.
PROCEDURE
a) Phenolphthalein acidity (total acidity).
Take 50 ml or 100 ml of sample in an Erlenmeyer flask, add 0.15 to 0.5 ml (3 to 10 drops) of
phenolphthalein indicator and titrate with standard 0.02 N NaOH to the same colour as that of
the pH 8.3 NaHCO3, colour standard.
Calculations
Mg/L of phenolphthalein OR total acidity as CaCO3
ml. of 0.02N NaOH x 1000

ml. of sample taken
b) Methyl Orange or Mineral Acidity.

Take 50 or 100 ml of sample in an Erlenmeyer flask. Add 2 drops of methyl orange
indicator to the sample and titrate with standard 0.02 N.NaOH to the very faint orange colour
characteristic to pH 4.5.
Calculations
Mg/L of methyl orange OR total mineral acidity as CaCO3
ml. of 0.02N NaOH x 1000

ml. of sample taken
NOTE
If residual chlorine is present it is removed by addition of small amount (0.05 to 0.1 ml) of
0.1 N.Na2S2O3 to avoid interference with methyl orange colour change.
212
8) ALKALINITY
The alkalinity of a natural water is mainly due to the presence of carbonates, bicarbonates
and hydroxides, and less frequently to borates, silicates and phosphates. Alkalinity is determined
by titration with a standard solution of strong acid to certain end points as given by indicator
solutions. Phenolphthalein contributed by hydroxide and carbonate and methyl orange or
screened methyl orange is used for the second point (approximately pH 4-5) contributed by the
bicarbonates.
REAGENTS
1. 0.02 N sulphuric acid.
3. Methyl orange indicator or SMO solution
PROCEDURE
a) Phenolphthalein alkalinity
Take 50 ml or 100 ml of sample in an Erlenmeyer flask, add 2 drops of phenolphthalein
indicator, and titrate over a white surface with 0.02 N H2SO4 until the pink coloration just
disappears.
Calculations:
Mg/L of phenolphthalein alkalinity as CaCO3
ml. of 0.02N H2SO4 x 1000

ml. of sample taken
b) Total or methyl orange alkalinity

Take 50 ml or 100 ml of the sample. Add 2 drops of methyl orange indicator, and titrate
with 0.02 N H2SO4 until the colour changes from yellow to faint orange.
Calculations :
Mg/L of total OR methyl orange alkalinity as CaCO3
ml. of 0.02N H2SO4 x 1000

ml. of sample taken
213
Calculations of Hydroxide, Carbonate, Bicarbonate and total Alkalinity:

The different types of alkalinities are determined by using separately phenolphthalein and
methyl orange as indicator for titration. The relative quantities of bicarbonate, carbonate,
hydroxide and total alkalinity can be obtained from the following table :
Value of P &
M Alkalinity
P = zero
P < 1/2 M
P = 1/2 M
P > 1/2 M
P=M
Bicarbonate
Alkalinity
M
M - 2P
Nil
Nil
Nil
Carbonate
Alkalinity
Nil
2P
2P
2(M-P)
Nil
Hydroxide
Alkalinity
Nil
Nil
Nil
2P - M
P
Total
Alkalinity
M
M
M
M
M
NOTE
1. If water is prechlorinated, add 2 drops of 0.1 N sodium thiosulphate solution, before
addition of methyl orange indicator.
2. In the presence of alkali phosphates :
3. In the presence of phosphate treatment and where the phosphate is present as a trisodium
salt, part of the alkalinity to phenolphthalein will be due to the alkalinity combined with
the phosphate (PO4). If the phosphate content (as PO4) is expressed as mg/l; the effect
on P will be equal to one half of the content in mg/l of phosphate and this shall be
subtracted from P reading before using the above table. The alkalinity to
phenolphthalein after addition of BaCl2 is not affected by the presence of phosphate.
PROCEDURE
To 100 ml of sample add a crystal of sodium sulphate and 10 of 10% BaCl2 solution. Mix well
for 2 minutes and titrate using phenolphthalein as indicator.
Calculations
ml of 0.02 N H2SO4 x 1000
ml of sample
=
mg/lit of P (BaCl2) Value
214
9) FREE CARBON DIOXIDE

Free carbon dioxide is the term used to designate carbon dioxide gas dissolved in water. The
designation "free" carbon dioxide is used to differentiate a solution of carbon dioxide gas from
combined carbon dioxide present in the form of bicarbonate and carbonate ions. The CO2
content often is the sole contributor to the acidity of the sample.
REAGENTS
1. Standard 0.02 N NaOH solution
PROCEDURE
Collect the water sample in a glass bottle by allowing the water to flow from the bottom
through a rubber tube connected to the source. Allow the water to overflow 2 to 3 times the
capacity of the bottle and close. In the laboratory syphon the sample into 100 ml graduated
cylinder and allow some over flow to take place. Quickly adjust the sample volume to 100 ml
and add 0.25 - 0.5 ml (5 to 10 drops) phenolphthalein indicator. If the sample remains
colourless titrate rapidly with standard NaOH to the colour of pH 8.3 NaHCO3 colour
standard resting along side in an identical graduated cylinder. Repeat the determination on
a second sample by adding full alkali volume of the first titration and if the sample remains
colourless complete the titration. Accept the second titration as the more reliable results.
Calculations
CO2 as CO2 mg/L
Titrant x N of NaOH x 1000 x 44

ml. of sample taken
215
10) RESIDUAL CO2 IN CATION EXCHANGER TREATED WATER

Residual carbon dioxide is normally checked in cation exchanger treated water or degasser
outlet to check total anionic load on anion exchanger.
REAGENTS
1. 0.02 N standard sodium hydroxide solution
3. Methyl orange indicator solution
PROCEDURE
Collect the sample by means of rubber tubing discharging at the bottom of a graduated cylinder
or nessler tube. Allow the sample to overflow for a few minutes and withdraw the tubing while
the sample is flowing. Flick the cylinder to throw off excess sample above the 100 ml mark. To
this 100 ml add methyl orange indicator and titrate against standard sodium hydroxide. To the
second sample add enolphthalein indicator, and titrate against standard sodium hydroxide.
Calculations
Residual CO2 in decationized water mg of CO2 per litre =
(B A) x 1000 x 0.88
100
Where B = ml of standard sodium hydroxide required for

phenolphthalein end point
A = ml of standard sodium hydroxide required for
methyl orange end point
NOTE
1. The standard sodium hydroxide is rendered carbonate free by passing the solution through
a strongly basic anion exchanger, Tulsion A-27 in the OH form.
2. Where the free carbon dioxide content of the water sample is high, some loss of CO2 occurs.
216
11) SODIUM BY FLAME PHOTOMETRY

Flame Photometry is concerned with the emission of characteristic radiation in flames by
individual elements and the co-relation of the emission intensity with the concentration of
the elements.
A small volume of the solution of the sample is placed in a cup of an atomiser. Air or oxygen
and a combustible gas are fed to the atomiser at controlled rates of flow and the solution is
vaporised in a special burner. At the high temperature of the flame, the salts vaporise and
dissociate into the constituent atoms or radicals. The vapours of the metal atoms are then
excited atoms radiate their characteristic special line, the intensity of which is a relative
measure of the metal in solution. This intensity is measured by suitable instruments.
REAGENTS
1. Standard Sodium Solutions for Calibration Curves :
Dissolve 2.5418 g of A.R. sodium chloride in 1 lit of distilled water in a volumetric flask.
This solution contains the equivalent of 1.0 mg Na per ml. Dilute this stock solution to give
four solutions containing 10, 5, 3 and 1 ppm sodium ions.
2.
Standard Potassium Solution for Calibration Curves :

Dissolve 1.9090 g of A.R. potassium chloride in 1 lit of distilled water in a volumetric
flask. This solution contains the equivalent of 1.0 mg/ per ml. Dilute this stock solution
to give four solutions containing 10, 5, 3 and 1 ppm potassium ions.
217
PROCEDURE
The operating manual supplied with the instruments should be read before attempting any
work. A general approach is described :
1.
2.
3.
4.
5.
Adjust the sensitivity control to the minimum value.

Turn the gas supply and light the gas at the burner.
Adjust the air supply till a blue flame is obtained.
Charge the small sample beaker with distilled water and place it in position.
Fine adjustment of air supply so that the blue cone of the flame just forms ten separate
cones, one to each burner hole.
6. Place the appropriate filter in position.
7. Spray standard solution containing the ion to be determined and by means of the
calibrated potentiometer, adjust the galvanometer to read approximately full scale
deflection.
8. Spray distilled water and adjust the galvanometer spot to read zero by means of the zero
control.
9. Spray standard solution again and readjust the sensitivity control for full scale deflection of
the galvanometer.
10. Check the zero by spraying with distilled water.
11. Spray solutions of known concentration but less than that of the standard solution, and
note the galvanometer reading at each concentration. Plot the galvanometer reading
against the concentration, expressed say as ppm and thus prepare a calibration curve for each
element.
12. Spray the unknown solution in the flame. Note the galvanometer deflection and
evaluate the concentration from the calibration curve.
NOTE
If it is known that the solution contains a sufficient concentration of an interfering
substance to affect the reading it will be necessary to employ standard solutions which also
contain approximately the same concentration of the interfering substance as is present in the
sample. The ideal method of removing interferences is to separate the element being
determined by chemical means, but this procedure is not always practicable.
218
12) HARDNESS
Hardness in water is due to the presence of bicarbonates, chlorides and sulphates of calcium
and magnesium. Temporary hardness is due to the presence of bicarbonates and permanent
hardness due to the presence of chlorides and sulphates. Sometimes, hardness may include
iron, aluminium, zinc, manganese, etc.
METHOD A
COMPLEXAMETRIC METHOD (EDTA METHOD )
EDTA forms a chelated soluble complex when added to a solution of certain metal ions. If a
small amount of EBT is added to an aqueous solution containing calcium and magnesium ions
at pH of 10.0 + 0.1, the solution will become red wine. If EDTA is then added as a titrant, the
calcium and magnesium will be complexed. After sufficient EDTA has been added to
complex all the calcium and magnesium, the solution will turn blue from red wine.
REAGENTS
1. Ammonia buffer of pH 10.
2. M solution of disodium salt of ethylenediamine tetra acetic acid.
3. Eriochrome black T indicator solution.
PROCEDURE
Take 50 ml of sample in an Erlenmeyer flask, add 4 to 6 drops of Eriochrome black T indicator
solution. Add 1 ml of buffer solution and mix. Titrate immediately with EDTA solution till the
colour changes from red to blue.
Calculations:
Total hardness as CaCO3 mg/lit
= Vol. of 0.01 M EDTA soln. x 1000

ml of sample
NOTE
For checking hardness in soft water use 500 ml of the sample into 750 ml evaporating dish and
add 3 ml of buffer solution followed by 10-12 drops of indicator solution.
219
METHOD B
SOAP SOLUTION METHOD FOR HARDNESS TESTING
This is a quick method for checking hardness of treated water or an accurate determination of the
hardness of treated water, EDTA method for hardness should be used.
REAGENTS
1. B soap solution
2. 40 ml shaking bottle
PROCEDURE
Take water sample upto 40 ml mark in shaking bottle. Add 10 drops of the "B" soap solution.
Shake vigorously. If a lather is obtained which will last for 1 to 2 minutes, the water is soft.
If no lather is obtained, or if the lather does not last, the water is hard.
NOTE
1. Rinse the shaking bottle clean with soft water thoroughly.
2. The soap solution bottle should be kept tightly stoppered. It will otherwise evaporate and
give false reading.
220
13) CALCIUM HARDNESS

The water sample is titrated against EDTA solution using Murexide indicator (ammonium
purpurate) in highly alkaline medium.
REAGENTS
1. Approximately 1 N sodium hydroxide solution
2. 0.01 M standard EDTA solution
3. Murexide indicator
PROCEDURE
Prepare a colour comparison blank in a white porcelain basin by stirring 2.0 ml of 1 N. NaOH,
0.2 g solid indicator mixture (or 4 to 6 drops of indicator solution) into 50 ml of distilled water
and sufficient EDTA titrant (0.05 to 0.1 ml) to produce an unchaning purple colour. Pipette into
a similar basin 50 ml. of sample, neutralize the alkalinity with 0.02 N. HCl, boil for 2 to 3
minutes to expel the CO2 and cool to room temperature. Add 2.0 ml 1 N NaOH, or a volume
sufficient to produce a pH of 12 to 13 and mix. Add 0.2 g of powdered indicator. Stirring
constantly titrate with standard EDTA solution to the colour of comparison blank. Check the
end point by adding 1 or 2 drops of titrant in excess to be sure that no further deepening of the
purple colour takes place.
Calculations
Calcium, as CaCO3, mg/L
(A - ) x C x 1000
ml of Sample
Where A = ml of EDTA required for titration of sample

B = ml of EDTA required for blank
C = mg of CaCO3 equivalent to 1.0 ml of EDTA
NOTE
The only serious interference with the EDTA titrant of calcium is that of orthophosphate ion.
If the calcium hardness exceeds about 60 ppm CaCO3, and the concentration of
orthophosphate is 10 ppm, or more, calcium phosphate is precipitated when the pH is raised
to 12, giving low results. Phosphate, if present, can be removed by ion exchange.
221
14) I R O N
Iron is frequently found in natural waters. In addition to the "natural" iron content of a water,
iron is passed into solution when the corrosion of iron and steel surface occur.
METHOD A
O-PHENANTHROLINE METHOD
The calorimetric estimation of iron is based on the formation of the orange red phenanthroline
complex (C12 H2 N2)3 Fe++ in the pH range 2-9. Below pH 2 the colour develops slowly and
is much weaker. Since this complex is formed with ferrous iron Hydroxylamine,
hydrochloride is the most satisfactory reducing agent (for the reduction of ferric iron). Certain
divalent metals such as Cd, Hg and Zn form slightly soluble complexes with the reagent and
reduce the intensity of the iron colour, but, this interference may be minimised by adding a large
excess of reagent. Phosphorous may be present upto 20 ppm. Fluoride (500 ppm) does not
interfere if the pH is kept above 4.0.
REAGENTS
1.
2.
3.
4.
Standard iron solution

1-10 phenanthroline monohydrate REAGENTS
Ammonium acetate buffer solution
Hydroxylamine hydrochloride
PROCEDURE
For total iron use well mixed sample. For determination of dissolved iron if precipitated iron
is present, decant a sample allow to settle down the precipitations and filter. If precipitated iron
is present, use the filtrate. Prepare a series of visual standards/photometric calibration curve by
measuring the following amounts of standard iron solutions into beakers, 0.01, 0.02, 0.03, 0.04,
0.05 upto 0.1 mg. Dilute the solution to 50 ml. To the sample, blank and the standards add 2 ml
conc. HCl, 1 ml hydroxylamine solution, glass beads and boil until the volume is reduce to
15 to 20 ml. Transfer the solution to Nessler tubes if visual comparison is to be made or to 50
or 100 ml volumetric flasks if spectrophotometric method is used. Add 10 ml ammonium acetate
buffer and 5 ml 1-10 phenanthroline reagent, dilute to the mark with distilled water, and mix
well. After 10 to 15 minutes compare the colour visually or measure the absorbance at 510
mm. The colour forms in the range of pH 2-9 and is very stable.
Calculation
Iron as Fe, mg/L
mg of Fe x 1000
ml of Sample
222
METHOD B
IRON BY THIOGLYCOLLIC ACID METHOD
In ammoniacal medium, mercaptoacetate (as the ammonium salt HSCH2 COONH4) reacts
with iron to yield the soluble red purple product Fe (OH) (SCH2COO)2 containing iron in the
ferric state. Ferrous iron reacts to give the same complex by air oxidation. In the absence of
oxygen, the colour slowly fades as a result of the reduction of ferric iron to ferrous and
oxidation of mercaptoacetate to the disulphide - O2 CCH2 SSCH2CO2. The air oxidation of
ferrous iron in the system is very rapid and usually under analytical conditions, more than the
pace of the reduction so that a stable coloration is obtained. The reaction must be carried out in
basic medium, precipitation of metal hydroxides may be prevented by adding citrate. Certain
metals among them Cu (21 mg), Arsenic +3 (> 100 mg), Tin+2, Zinc (> 10 mg) and cadmium
black, the iron colour, although this effect can be diminished by the addition of more reagent.
Very high concentration of salts of alkali metals decrease the colour intensity somewhat. On the
other hand anions have but a slight effect on the colour.
As much as 5000 ppm
chloride, fluoride, orthophosphate, tartrate, oxalate and citrate do not interfere. The
colour is fairly stable (atleast 6 hours in diffuse light).
REAGENTS
1. Thioglycolic acid (80%)
2. Ammonia solution (sp. gr. 0.91)
PROCEDURE
Take 100 ml of water sample into a 250 ml beaker. Add 2.5 ml of thioglycollic acid reagent.
After stirring evaporate in sand or water bath to 5 ml (not less), then allow to cool. Add 5.0 ml
of ammonia solution, shake and pour into the 25 ml measuring flask. Make upto the mark.
Measure optical density at 540 mm using 5 cms cell. Reagent blank and standard to be carried
simultaneously.
Calculations
Iron as Fe, mg/L
mg of Fe x 1000
ml of Sample
223
15) SILICA
The silica content of natural water will vary to a considerable extent depending on the locality.
The presence of silica is particularly objectionable in water used for boiler feed purpose as it may
lead to the formation of hard dense scale. In addition, a very serious problem encountered in high
pressure operations is the deposition of siliceous materials on turbine blades & superheaters.
The gravimetric method is the standard applicable above 20 mg / lit SiO2 content . This method
should be followed for standardisation of standard silicate solution used in colometric methods.
The heteropoly blue colometric method is adaptable for the range of 0 to 2 mg / lit SiO2 &
yellow molyb silicate method in the range of 0 to 20 mg / lit . Reagent blank should always be
used in all the three methods.
METHOD A
GRAVIMETRIC METHOD
PROCEDURE
Take a sample to contain atleast 10 mg of SiO2 . If necessary clarify by filtration. Acidify with 2
or 3 ml of conc. Hcl & evaporate to dryness in a platinum dish on a water bath . At regular
intervals add 2 or more portions of 2 to 3 ml of conc. HCl as additional quantities of sample is
added to the dish. Bake the evaporated residue in an oven ad 110 Deg. C for about an hour. Add 5
ml. of conc. Hcl warm & add 50 ml distilled water. Loosen the clinging residue from the sides &
the bottom of the dish & filter collecting the filtrate. Wash the dish & residue with hot 1 : 50
HCl & finally with distilled water until the washings are free from chloride. Return the filterate
& washings to the platinum dish & again evaporate to dryness. Repeat as previously, collecting
the residue in another filter paper. Dry the two filter papers with residue ,burn, ignite at 10001200 Deg C in a platinum crucible & weigh . Moisten the residue with a few drops of distilled
water , add 2 drops of H2SO4 & 10 ml. 48% HF . Cautiously evaporate to dryness on a steam
bath in a fume cupboard . Again ignite at 1000-1200 Deg. C. Cool & weigh. Carry out a blank.
224
Calculations
SiO2 , as SIO2 mg / lit
( A - B ) - ( C - D ) x 1000
ml of sample
Where A = Weight of crucible & sample residue in mg. after first ignition
B = Weight of crucible & sample residue in mg. after HF treatment &
second ignition.
C = Weight of crucible & blank residue in mg. after first ignition
D = Weight of crucible & blank residue in mg. after HF treatment &
second ignition.
METHOD B
REACTIVE SILICA
COLOMETRIC ESTIMATION OF SILICA
Ammonium molybdate at approximately pH 1.2 reacts with silica & any phosphate present to
produce hteropoly acids. Oxalic acid is added to destroy the molybdophosphoric acid but not the
molybdosilicic acid . Even if phosphate is known to be absent , the addition of oxalic acid is
highly desirable & is a mandatory step . The intensity of the yellow colour is proportional to the
concentration of molybdate- reactive silica. The yellow molybdosilicic acid is reduced by means
of 1 amino - 2- naphthol - 4 - sulphonic acid to heteropoly- blue. The blue colour is more intense
than the yellow colour & provides increased sensitivity. In atleast one of its forms , silica does
not react with molybdate even though it is capable of passing through filter paper & is not
noticeable turbid. The presence of such a molybdate unreactive silica is undesirable in raw water
.It will not be removed in the water treatment plant & will find its way to highly pressure stream
system , where it will be converted to " molybdate-reactive " silica. Such increase in silica
content will give rise to scale problem .
Chromate & large amounts of fe, PO4, sulphide, tannin, colour & turbidity are potential
interferences. Oxalic acid treatment suppresses PO4 & reduces tannin interference. Inorganic
sulphide can be removed by boiling an acidified sample. The addition of 1 ml. of 1% EDTA
solution after molybdate reagent overcomes high Fe & Ca concentrations.
225
COLOMETRIC ESTIMATION OF SILICA - 0- 20 PPM SiO2

REAGENTS
1.
2.
3.
4.
Ammonium molybdate solution

2 N sulphuric acid.
10 % oxalic acid.
Lovibond comparator with standard silica disc.
PROCEDURE
1. Fill one of the Nessler tubes to the 50 ml. mark with sample & place in the left hand
compartment of Lovibond comparator.
2. Fill the other Nessler tube with 50 ml. of sample at 25 - 30 Deg. C . Add 2 ml. of acidified
ammonium molybdate solution . Mix thoroughly, add 4 ml. of oxalic acid & again mix
thoroughly. Place in the right hand compartment & allow to stand for 10 minutes.
3. Stand the comparator facing a uniform source of light, compare the colour of the sample in
the disc. Rotate the disc until the colours are matched.
Calculations
SiO2 in mg / lit as SiO2 = Disc reading
x 20
NOTES
1. Should the colour in the test solution be deeper than the deepest standard , a fresh test should
be carried out using a smaller quantity of sample & diluting to 50 ml. with distilled water
before adding the REAGENTS.
2. Silica free water :
3. Distilled water from an all - metal "Still " or water which has been passed successively
through a mixed bed deionisation unit & strongly basic anion exchanger such as Tulsion
A27MP unit regenerated with a regeneration level of 320 gm per litre NaOH has been found
to be suitable. Prepare & store in a polyethylene bottle a large batch of water containing not
more than 0.005 ppm SiO2 , determine the silica content of water by treating it as a sample .
This water is used to prepare reagents & standards , & to dilute samples when necessary .
COLOMETRIC ESTIMATION OF SILICA 0-2 PPM SiO2
REAGENTS
1.
2.
3.
4.
Acidified ammonium molybdate solution.

10 % oxalic acid.
Amino - naphthol reducing agent.
Lovibond comparator with standard silica disc or spectrophotometer suitable for measurement
at 815 microsiemens wave length .
226
PROCEDURE
1. Fill one of Nessler tubes to the 50 ml . mark with sample, & place in the left hand
compartment of Lovibond comparator.
2. Fill the other Nessler tube with 50 ml. of sample, at 25 -30 Deg.C. Add 2 ml. of acidified
ammonium molybdate solution . Mix thoroughly, stand for 5 minutes . Add 4 ml of oxalic
acid & mix well . Then 2 ml. of reducing agent, mix well compared with that of a blank
comprising the same water without reagents, using Lovibond comparator or read the
absorbance using a spectrophotometer (wave length 815 microsiemens). Compute the silica
content from the standard graph prepared from the standard silica solution.
METHOD C :
DETERMINATION OF TOTAL SILICA (MOLYBDATE REACTIVE & UNREACTIVE
SILICA )
The molybdate unreactive silica is converted to the reactive form or state by digesting the sample
with sodium bicarbonate.
REAGENTS
1.
2.
3.
Sodium bicarbonate .
1 N sulphuric acid.
Other reagents as per previous method.
PROCEDURE
Take 100 ml. of sample or lesser quantity ( 20 - 100 micrograms SiO2 ) but made upto 100 ml.
distilled water in a platinum dish. add 200 mg. silica free sodium bicarbonate & digest on a
stream bath for one hour . Cool & add slowly , with stirring , 2.5 ml. sulphuric acid ( 1 N ) . Do
not interrupt the analysis but proceed at once with the remaining steps . Transfer quantitatively
into a plastic container. For development of colour & CALCULATIONS refer the previous
procedure.
227
16) SULPHITE
The determination of sulphite usually is made only on boiler water. Generally speaking, sulphite
is not present in natural water. In boiler, feed water sodium sulphite is fed to remove dissolved
oxygen .
REAGENTS
1. Hydrochloric acid 1 + 1
2. Starch Indicator Solution :
Dissolve 5 gms of starch & 0.01 gms. of mercuric iodide with 30 ml. cold distilled water &
slowly pour it with constant stirring in to 1 lit. of boiling distilled water. Boil for 3 minutes.
Allow to cool & decant off supernatant clear liquid .
3. Standard Potassium Iodate - Iodine Solution :
Weigh accurately 0.713 gms. of potassium iodate & dissolve in about 150 ml. of distilled
water. Add 7 gms of potassium iodide & 0.5 gms. of sodium bicarbonate. When dissolved,
dilute the solution to exactly 1 litre.
PROCEDURE
Place 10 ml. of 1 +1 HCl in a 250 ml. flask. Rapidly add 100 ml sample, submerging the pipette
tip below the acid surface to minimise air exposure . After adding 1 ml. starch indicator solution
titrate with standard iodate - iodide ( KIO3 ) solution ,to the first appearance of persistent blue
colour. Determine the blank titration by taking 100 ml. distilled water .
Calculations
Sulphite as SO3 , mg / lit = ( A - B ) x 100
Where , A = ml of titrant for sample .
B = ml of titrant for blank .
STANDARD IODATE- IODIDE SOLUTION
Weigh accurately 0.713 g of potassium iodate & dissolve in about 150 ml of distilled water. Add
7 g of potassium iodide & 0.5 g of sodium bicarbonate when dissolved dilute the solution to
exactly 1 lit.
228
17) SULPHATE
METHOD A
GRAVEMETRIC METHOD
The sulphate is precipitated as barium sulphate by the addition of barium chloride to a slightly
acidified solution of the sample at the boiling temperature. The precipitate is ignited and the
residue is weighed as barium sulphate. The presence of silica and other non-volatile suspended
matter cause high results. Sulphites and iron should also be present.
REAGENTS
1. Hydrochloric Acid 1:1
2. Methyl Red Indicator solution
3. Barium Chloride solution
PROCEDURE
Take sample to contain approx. 50 mg sulphate. Dilute to 250 ml. Adjust the acidity with HCL to
Ph 4.5 to 5.0, using methyl red indicator . Then add an additional 1 to 2 ml. of HCL. Heat the
solution to boiling and stir gently then add warm Bacl2 solution slowly until precipitation appears
to be complete then add about 2 ml. in excess. Digest the precipitate on a water bath at 80 to 90
deg C, not less than 2 hours. Filter through a filter paper or through gooch crucible and wash
with hot distilled water until washings are free from chlorides. Dry the filter paper and
precipitate and ignite at 800 deg. C for 1 hr. Do not let the filter paper flame. Cool in a desicator
and weigh.
Calculation
Sulphate as SO4 mg/lit =
mg BaSO4 * 411.5
ml. of sample
METHOD B
EDTA METHOD
A measured excess of standard barium chloride solution is added to the sample & the excess
barium chloride estimated by titration against standard EDTA solution.
REAGENTS
1. Approx. 1N nitric acid
2. Standard barium chloride solution.
3. pH-10 buffer solution.
229
4. EBT indicator.
5. 0.01 M EDTA solution
PROCEDURE
Neutralise 100 ml. of the sample with dilute nitric acid, adding a slight excess , & boil off to
expel carbon dioxide. Add 10 ml. or more if required, of standard barium chloridesolution to
boiling solution & allow it to cool. Dilute to 200 ml. mix & allow precipitate to settle. Withdraw
50 ml. of the supernatant liquid, add 0.5 ml. to 1.0 ml. of buffer & several drops of indicator
solution. Titrate with standard EDTA solution to a blue colour which does not change on
addition of further drops of EDTA solution.
Calculations
sulphates, as SO4, mg/lit = 9.6 (0.1A +B - 4C )
where:
A = Total hardness of sample (as CaCO3 mg/lit )
B = Volume in ml. of standard barium chloride solution added
C = Volume in ml. of standard EDTA solution required for titration
NOTE
1. It is very difficult to judge the endpoint of titration of barium against EDTA using EBT as
indicator. It is preferable to use standard MgCl2 solution along with BaCl2 for Bacl2
standardisation ( or use a mixture of BaCl2 + MgCl2 solutions, instead of BaCl2 solution for
precipitate of sulphate ion ).
2. It is also desirable to add MgCl2 solution, whenever, sample is low in Mg ions as in the case
of decationized water.
18) CHLORIDE
METHOD A
SILVER NITRATE METHOD
Chloride is determined by titration with std. silver nitrate solution in the presence of potassium
chromate indicator at neutral Ph. Silver chloride is precipitated and at the end point red silver
chromate is formed.
REAGENTS
1.
2.
3.
4.
5.
N Std. silver nitrate solution

Potassium chromate indicator
Phenolthalein Indicator solution
N Nitric Acid solution
Calcium carbonate
230
PROCEDURE
Take 50 ml. or 100 ml of sample in an Erlenmeyer flask. Add five drops of phenolthalein. If the
sample turns pink, Neutralise with 0.02 N Nitric acid. If Acidic (as in the case of decationised
water) add a small amount of A.R. calcium carbonates. Add 1 ml of potassium chromate indicator
and titrate with std. silver nitrate solution with constant. stirring until there is perceptible reddish
colour. Subtract 0.2 ml. from titration fig. to allow for the excess of reagents required to form
silver chromate.
Calculation
Chloride as CaC03 mg/lit =
ml of AgN03 * 1000
ml of sample taken
NOTE
1. If sample is highly coloured , add AL(OH)3 suspension, mix then let it settle , filter and
combine filtrate and washing
2. If sulphide, sulphite and thiosulfate is present, add 1ml H2O2 and stir for 1 Min.
3. Bromide, iodide and cyanide register as Eqvt. chloride concentration.
METHOD B
Chloride ion can be titrated with mercuric nitrate because of the formation of soluble, slightly
dissociated mercuric chloride. In the Ph range 2.3 to 2.8 diphenylcarbozone indicates the end
point of this titration by formation of purple complex with excess of mercuric ions. To keep the
solution in Ph range +/- 0.1 Ph unit nickel nitrate with HNO3 is added .
REAGENTS
1. 0.02 N Mercuric nitrate Std. solution
2. Diphenyl-carbozone indicator solution
3. 4 M nickel nitrate solution
PROCEDURE
Take 50 ml. of sample , add 1 ml. of diphenylcarbozone indicator solution. Add 1 ml. of nickel
nitrate solution. Titrate against Std. mercuric nitrate solution to colour change of green to violet.
Carry out blank titration with DM Water.
Calculation
Chloride as CaCO3 mg/lit = (A - B ) * 1000
ml. of sample
where , A = ml of titrant required for sample
B = ml of titrant required for blank.
231
METHOD C
CHLOROMETRIC METHOD FOR CHLORIDE (MERCURY THIOCYNATE METHOD)

This method depends upon the displacement of thiocynate ion from mercuric thiocynate by
chloride ion. In the presence of ferric ion, a highly coloured ferric thiocynate complex is formed
and the intensity of its colour is proportional to the original chloride ion concentration.
REAGENTS
1. Mercuric thiocynate solution
2. Ferric ammonium sulphate solution
3. Std. sodium chloride solution -0.1 mgCl / ml.
PROCEDURE
Take 10-20 ml of water sample containing about 40 micrograms of chloride in a 25 ml. std. flask.
Add 2.0 ml of ferric ammonium sulphate solution, followed by 2.0 ml of mercuric thiocynate
solution. Make up to the volume. Measure the optical density at 460 microsiemens From the
calibration curve for the Std., compute the value for the sample.
Calculation
Chloride , as CL mg /lit
Microgram of chloride from graph

ml. of sample
232
19) PHOSPHATE
A neutralised sample is reacted with ammonia molybdate & stannous chloride. The blue colour
obtained is matched against that produced with a series of standard phosphate solutions, visually
or with spectrometer at 690 micro.
REAGENTS
1. Phenolphthalein Indicator solution.
2. Approximately 4 N sulphuric acid.
3. Ammonium Molybdate solution.
4. Stannous chloride solution.
5. Standard phosphate solution.
PROCEDURE
To a 50 ml. sample containing not more than 0.15 mg. of phosphate (as PO4), add one drop of
phenolphthalein indicator. If a pink colour is obtained, add dilute H2SO4 dropwise to discharge
the colour. Add, with through mixing after each addition 2.0 ml. of ammonium molybdate
solution & 0.25 ml. 5 drops of stannous chloride solution. The rate of colour development &
intensity of colour depend upon the temperature of the final solution, each 1 Deg C increase
producing about 1 percent increase in colour. hence samples & reagents should be within 2 deg .
C of one another & at a temperature between 20 to 30 deg. C. After 10 min. but before 15 min.,
measure the colour photometrically or visually in a Nessler tubes against standards prepared
simultaneously. A blank shall always be run on the reagents & distilled water.
Calculations
Phosphates as PO4 mg/lit = 1000 * w
V
where,
w
= weight in mg. of phosphate (as Po4) in sample from standard graph (or
solution).
V
= Volume in ml. of sample taken.
233
20) OXYGEN CONSUMED FROM PERMANGANATE SOLUTION

(CHEMICAL OXYGEN DEMAND)
This method is only an empirical measure of the organic matter. It gives some indication of the
nature of the oxidisable substance present in the sample since nitrates, ferrous salts or sulphides
will reduce the permanganate immediately whereas the organic matter reacts with the
permanganate only after some time.
It can be determined at room temperature by estimating the amount of standard KMnO4 solution
consumed by the sample in 4 hours or at elevated temperature for a shorter period.
REAGENTS
1.
2.
3.
N/10 standard KMnO4 solution.

N/10 standard oxalic acid solution.
(1: 3) sulphuric acid solution
PROCEDURE
Take 100 ml. of sample in conical flask. Add 10 ml. of 1:3 sulphuric acid solution & 10 ml. of
N/10 standard KMnO4 solution is added to acidified sample. The sample is then boiled for
exactly 10 min. Introduce 10 ml. of standard N/10 oxalic acid & while still hot titrate with
standard KMnO4 slightly pink colour reappears
Calculations
Oxygen as KMnO4 consumed, mg/lit = ml. of KMnO4 solution
used up * 31.6
or
Oxygen, as Oxygen mg/lit = ml. of KMnO4 solution *8.0
234
21) OILS AND GREASE

The oils & grease are extracted by an organic solvent . The solvent is distilled off & the weight of
the extracted matter is determined. Some extractable, especially unsaturated fats & fatty acids,
oxidize rapidly hence, special precautions regarding temperature & solvent vapour displacement
are necessary to minimise this effect.
SAMPLING
The most satisfactory method of sampling two - phase liquids is to use a sampling tube that is
capable of withdrawing a complete section of the water as it flows in a rectangular culvert or
trough, in most instances, however, water will have to be sampled from the outfall of the pipe or
from a stream & in these circumstances some of the water should first be collected in a large
cylindrical vessel having a capacity of 10 to 15 litres. A sectional sampling tube should be used to
withdraw the test sample from this. A sampling tube suitable for sampling water , that dont
contain highly viscous matter ( for example, tar ) consist of a heavy - gauge brass tube , 1m. long
, with an outside diameter of 40 mm. Over one end of the tube is fitted to the brass bucket made
from a piece of tube 50 mm. long & sealed at one end. The bucket has an internal diameter of
1.5 mm. greater than the outside diameter of the main tube. To the opposite sides of the bucket,
are braced two brass rods, 6mm. in diameter , which pass through guides braced to sides of the
main tube. The rods are so arranged that the top of the bucket can be withdrawn to a distance of
not less than 10 cm. from the bottom of the main tube, & they guide the bucket into a position
covering the end of the tube when it is pushed back again. A suitable spring catch is provided on
one of the guide rods so that the bucket is automatically locked into the top position when it is
raised to its highest point . The open end of the sampling tube is fitted with a rubber bung. To
take a sectional sample , the spring catch is released & the bucket is drawn as far away as
possible from the end of main tube. The rubber bung is withdrawn from the other end. The tube is
lowered vertically through the liquid to the sampled until the bottom of the bucket rest on the
bottom of the culvert or of the vessel that has been filled with the water. The main tube is then
pushed down, guided by the brass rods, to the limits of his travel, whereupon the spring catch
locks the bucket in the raised position covering the end of the tube. The rubber bung is tightly
inserted in the open end & the tube is withdrawn.
The outside of the sampler is wiped free of adhering liquid the bucket & the lower part of the
tube are inserted into a wide - mouthed bottle of suitable capacity, & the rubber bung is removed.
The sample section of the liquid will flow into the bottle leaving a small quantity of liquid in the
bucket . The tube is then tilted , so that this liquid is added to the main bulk of the sample. The
operation is repeated until sufficient quantity has been collected. At least 24 - 25 mm. of air space
should be left between the top level of the liquid & the stopper of the bottle.
STORAGE OF SAMPLE
235
Since many oils & hydrocarbons are utilised by bacteria , storage is obviously detrimental.
However, if it becomes necessary to store the sample before analysis is taken up , the samples
should be acidified with dilute sulphuric acid (1:1 ) , 5 ml / lit., of the sample, to inhibit bacterial
activity .
APPARATUS
SEPARATING FUNNELS
Of 1.5 to 2 litres capacity . The stopper or stop or stop cock should not be lubricated with matter
soluble in petroleum ether.
REAGENTS
1.
2.
Dilute Hydrochloric acid - 1 : 1

Light Petroleum ( Petroleum ether ) - boiling range 40 to 60C.
PROCEDURE
Place the sample, usually 1 litre, in a separating funnel of sufficient size to allow the addition of
acid & solvent , & still have space for proper agitation. Acidify the sample with dilute
hydrochloric acid, 5 ml /lit, of the sample. Rinse the sample bottle carefully with 15 ml. of
petroleum ether & add the ether washings to the separating funnel. Add an additional 25 ml. of
ether to the sample bottle, rotate the ether in the sample bottle & add the ether to the separating
funnel . Shake vigorously for 2 minutes. Allow the ether layer to separate. Withdraw the
aqueous portion of the sample into a clean container , & transfer the solvent layer into a clean,
tarred distilling flask capable of holding at least 3 volumes of solvents(See Note).If a clear ether
layer cannot be obtained, filter the solvent layer into tarred distilling flask through a funnel
containing an ether moistened filter paper. The filter paper should be washed with petroleum
either after folding to avoid inclusion of skin oils. Use a small funnel and filter paper as practical.
NOTE
While transferring the solvent layer from the separating funnel, a small quantity of it remains at
the stem of the separating funnel, it is advisable to wash it with a few millilitres of solvent and to
add the washings to the solvent layer. Return the aqueous portion of the sample to the separating
funnel, rinsing the container with 15 ml. of ether. Add the ether washings and additional 25 ml. of
ether to the separating funnel and agitate for about 2 Min. Allow the solvent layer to separate and
discard the aqueous phase. Add the ether washings to the tarred distilled flask . After all the ether
from the 2 extractions and the final rinsing are included wash down the funnel and filter paper
twice with fresh 5 ml. increments of the petroleum ether.
Distil of all but approx. 10 ml. of the ether extract on a water batch or an electric heating mantle,
observing necessary safety precautions and keeping the heat source at about 70 Deg c.
236
Disconnect the condenser and boil of the remaining the solvent from the tarred flask at the same
temp. Dry on a water bath or stream bath. When dry ,lay the flask on its side to facilitate the
removal of solvent vapour. Introduce Aprrox. 3 volumes of dry illuminating gas or Nitrogen into
flask to displace solvent vapour . Cool in desiccator for 30 Min. and weigh.
Calculation
Oils And grease , mg/lit =
1000 W
V
Where,
W = weight in Mg. of the residue in the flask
V = volume in ml. of the sample taken for the test.
Express the result to the nearest Mg
237
22) RESIDUAL CHLORINE

(ORTHOTOLYDINE - ARSENI METHOD)
Chlorine rapidly oxidises ortholydine (3,3-dimethybenzdine) to the corresp. hologuinone which
is intensely yellow. This provides a sensitive test for available chlorine. The test is subject to
interference by production of false colour for chlorine when nitrite ,iron or manganese is present
in the water. The false colour produced with orthotoludine by interfering substance present in the
presence of sodium arsenite but the colour due to residual chlorine does not. The test permits the
measurement of the relative amounts of free available chlorine, combined available chlorine ,and
colour due to interfering substances. The temperature of the sample should never be above 20 deg
C.
REAGENTS
1.
2.
3.
4.
Phosphate buffer solution -0.5%

Potassium dichromate solution
P-Tolydine reagent
5 % sodium arsenite solution
PROCEDURE
1. VISUAL STANDARDS
Pipette into 100 ml. Nessler cylinder 1,2,3 etc. ml of dilute chromate- dichromate solution an
dilute to 100 ml with phosphate . Protect the solutions from dust, evaporation and direct
sunlight. These Stds. correspond to residual chlorine Eqvt. of 0.01, 0.02 ,0.03.... mg/lit Resp.
2. FREE AVAILABLE CHLORINE
In a nessler tube take 0.5 ml of Toludine reagent and 9.5 ml of sample . Mix quickly and
thoroughly and add 0.5 ml of NaAS02 followed by mixing. Compare the colour with Std.
(Call this reading as A).
3. TOTAL AVAILABLE RESIDUAL CHLORINE

In a nessler tube take 0.5 ml of 0-Toludine reagent and 9.5 ml of sample, mix and compare the
colour with standards colour in similar tube after 5 Min. (Call this reading as B).
4. BLANK
Prepare a blank 9.5 ml sample and 0.5 ml NaAS02 solution and compare the colour with std.
colour immediately and after 5 Min. (Call this reading as C1 and C2).
Calculation
238
Free available residual chlorine

= Reading A - Blank C1
Combined available residual chlorine = Reading B - Blank A
Total available residual chlorine
= Reading B - Blank C2
239
23) REAGENTS
1. STANDARD 1 N HCL SOLUTION
Dilute 83 ml. of conc. HCL (about 11 N solution, specific gravity 1.174-1.189 ) to 1lit. with
distilled or deionised water . Standardise with standard sodium carbonate solution.
2. STANDARD 0.1 N HCL SOLUTION
Dilute 8.3 ml. of conc. Hcl or 100 ml. of 1 N solution to 1000 with distilled water.
Standardise with standard sodium carbonate solution.
3. STANDARD 0.02 N Hcl SOLUTION.
Dilute 200 ml. of 0.1 N standard acid to 1000 ml. with distilled water. Standardize with
standard sodium carbonate solution
4. STANDARD 1 N H2SO4 SOLUTION
Dilute 28 ml. of conc. H2SO4 (about 36 N solution, specific gravity 1.834-1.836 ) to 1lit.
with distilled or deionised water. Standardise with standard sodium carbonate solution.
5. STANDARD 0.1 N H2SO4 SOLUTION
Dilute 2.8 ml. conc. H2SO4 to 1 lit. with distilled or deionised water. Standardise with
standard sodium carbonate solution.
6. STANDARD 0.02 N H2SO4 SOLUTION
Dilute 200 ml. of 0.01 N H2SO4 to 1 lit. with distilled or deionised water. Standardise with
standard sodium carbonate solution.
7. 1.0 N HNO3 SOLUTION
Dilute 64 ml. of conc. HNO3 (about 15 N solution, specific gravity 1.409-1.418 ) to 1lit. with
distilled or de ionised water. Standardise with standard sodium carbonate solution.
8. STANDARD I.0 N NAOH SOLUTION
Dissolve 40.0 gm. of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water .
Standardise with standard acid solution.
240
9. STANDARD 0.1 N NAOH SOLUTION

Dissolve 4.0 gms of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water.
Standardise with standard acid solution.
10. STANDARD SODIUM CARBONATE SOLUTION
(Approx. 0.05 N ) Dry 3 to 5 g primary standard Na2 CO3 at 250 deg C for 4 hours & cool in
a desicator . Weigh 2.5 +/- 0.2 gms (to the nearest mg. ) Dilute to 1litre with deionised or
distilled water.
11. STANDARD 0.02 N SILVER NITRATE SOLUTION.
Dissolve 3.3927 gms. AgNO3 in distilled water & dilute to 1 lit. Standardise against 0.02 N
NaCl standard solution.
12. STANDARD 0.02 N SODIUM CHLORIDE SOLUTION
Dry 2-3 g of primary standard NaCl at 140 deg C for 4 hours & cool it in a desicator. Weigh
1.689 gms (to the nearest mg. ) Dilute to 1litre with deionised or distilled water.
13. STANDARD 0.02 N MERCURIC NITRATE SOLUTION
Dissolve 3.246 gm. mercuric nitrate in 100 ml of 5% HNO3 solution & make up to 1 lit. with
D.M. water. Standardise with standard sodium carbonate solution.
14. STANDARD MERCURIC THIOCYANATE SOLUTION
Weigh 1 gm Hg(SCN)2 & add 100 ml methanol & mix to obtain a saturated solution. store in
a amber bottle in a cool place.
15. FERRIC AMMONIUM SULPHATE
Dissolve 12 g of Fe (NH4)2(SO4) 2. 12H2O in 100 ml of 9 N HNO3 (580 ml. of conc. HNO3
in 1 lit. of water). Filter if necessary & store in a amber bottle.
16. 0.1 MG/LIT. STANDARD CHLORIDE SOLUTION
Dissolve 1. 1648 g NaCl in 1 lit. of distilled or deionised water.
241
17. AMMONIA BUFFER OH pH 10

Dissolve 16.9 g of ammonium chloride in 143 ml. conc. ammonium hydroxide (NH4OH).
Add 1.25 g of magnesium salt of EDTA. (If the magnesium salt of EDTA is unavailable
dissolve 1.179 g disodium salt of EDTA & 780 mg. MgSO4.7H2O or 644mg. MgCl2.6H2O
in 50 ml. distilled water.) & dilute to 250 ml. with distilled water.
18. STANDARD 0.01 M SOLUTION OF EDTA
Dissolve 3.723 g of disodium salt of EDTA in 1 lit. of distilled or deionised water.
Standardise with standard calcium solution.
19. STANDARD CALCIUM SOLUTION
Weigh 1 gm anhydrous calcium carbonate into a beaker, add a little at a time, dilute
Hydrochloric acid until CaCO3 has dissolved. Wash down the beaker with carbon dioxide
free water & makeup to 1 lit. 1 ml. of the solution contains 1mg of sulphate (as SO4)
20. STANDARD BARIUM CHLORIDE SOLUTION
Dissolve 2.443 g of barium chloride (BaCl2, 2H2O) in distilled water & dilute to 1 lit. 1 ml.
of this solution is equivalent to 0.36 mg. of sulphate (as SO4).
21. STANDARD POTASSIUM IODATE -IODATE SOLUTION
Weigh accurately 0.713 g of potassium iodate & dissolve in about 150 ml. of distilled water.
Add 7 g of potassium iodate & 0.5 g of sodium bicarbonate ,when dissolved, dilute the
solution to exactly 1 liy.
22. STANDARD IRON SOLUTION
Dissolve 1.404 g of ferrous ammonium sulphate Fe(NH4)2(SO4)2, 6H2O in 50 ml. distilled
water & 20 ml. conc. H2SO4. Add 0.1 N KMNO4 dropwise to impart a faint but persistent
pink colour & dilute to 1 lit. with distilled eater. Dilute 50 ml. of the above stock solution to 1
lit. with distilled water to form a standard solution containing 0.01 mg. fe/ml.
23. 1,10 PHENANTHROLINE MONOHYDRATE SOLUTION
Dissolve 0.1 g in 100 ml. distilled water containing 2 drops conc. Hcl . (Not more than 0.1
mg. Fe can be determined).
242
24. AMMONIUM ACETATE BUFFER SOLUTION

Dissolve 250 g of ammonium acetate in 150 ml. distilled water, add 700 ml. glacial acetic
acid & dilute to 1 lit.
25. AMMONIUM MOLYBDATE SOLUTION FOR SILICA ESTIMATION
75 g of ammonium molybdate is dissolved in 500 ml. of distilled water. To 322 ml. of 10 N
sulphuric acid the molybdate solution is added gradually with constant stirring. The solution
is made upto 1 lit.
26. 10% OXALIC ACID
Dissolve 10 gms. oxalic acid in 100 ml. of distilled water.
27. AMINO NAPHTHOL REDUCING AGENT
Dissolve 0.5 g of 1 amino-2-naphthol-4sulphonic acid & 1gm. of sodium sulphite (Na2SO3)
in 50 ml. distilled water, with gentle warming if necessary, add this to solution of 30 g
sodium metabisulphite (NaHSO3)in 150 ml. distilled water. Filter into plastic bottle. Dicard
the solution when it becomes dark. prolong reagent life by sorting in a refrigerator.
28. STOCK SILICA SOLUTION
Dissolve 4.73 g of sodium metasilicate nonhydrate (Na2SiO3, 9H2O) in recently boiled &
cooled water & dilute to approx. 900 ml. Analyse 100.0ml. portions by gravimetric method,
adjust the remainder of the solution to contain 1.000 mg./1SiO2. Store in a tightly stoppered
plastic bottle.
29. STANDARD SILICA SOLUTION
Dilute 10 ml. stock solution to 1 lit. with recently boiled & cooled water this solution
contains 10 mg/lit. Sio2 or 1 ml. =10 Sio2. Store in a tightly stoppered plastic bottle.
30. AMMONIUM MOLYBDATE SOLUTION FOR PHOSPHATE ESTIMATION
Dissolve 25 gms. of ammonium molybdate in 175 ml. of distilled water. In another container
add, cautiously to 400 ml. of distilled water, 310 ml. of conc. H2SO4. Cool it & add the
molybdate solution to this distilled acid & dilute the whole to 1 lit.
243
31. STANNOUS CHLORIDE SOLUTION

Dissolve 2.5 gms. of fresh supply of stannous chloride (SnCl2,2H2O) in 10 ml. of conc. Hcl
& dilute to 100 ml. with distilled or deionised water. Filter if it is turbid. Store the solution in
a cool place in a aspirator bottle having class stopcock. A 5 mm. thick layer of pure mineral
oil shall be floated over the surface of the solution to minimise oxidation. Always drain out a
little of solution out of the stopcock before use.
32. STANDARD PHOSPHATE SOLUTION
Dissolve 0.716 g of dry potassium dihydrogen phosphate (KH2PO4) in 1 lit. of distilled
water. Dilute 100 ml. of solution to 1lit. 1ml. of this solution =0.05 mg of phosphate (as PO4
).
33. STANDARD 0.1 N POTASSIUM PERMANGANATE SOLUTION
Dissolve 3.1608 g of potassium permanganate (dried at 105 deg C ) in distilled water made
upto 1 lit. This solution must be stored in the dark.
34. STANDARD 0.1 N OXALIC ACID SOLUTION
Dissolve 4.5018 g of oxalic acid in distilled water, make upto 1lit.
35. PHOSPHATE BUFFER SOLUTION O.5 M (FOR FREE CHLORINE)
Dissolve 22.68 g Na2HPO4 & 46.19 g KH2PO4 (both dried overnight at 105 deg C) &
dilute to 1 lit. with distilled water. Let this solution age for No. of days & filter if any
precipitate appears.
36. PHOSPHATE BUFFER SOLUTION 0.1 M
Dilute 200 ml. of 0.5 M filtered phosphate buffer solution to 1 lit.
37. STOCK CHROMATE- DICHROMATE SOLUTION
Dissolve 1.55 g K2Cr2O7 & 4.65 g K2CrO4 in 0.1 M phosphate buffer solution.
38. DILUTE CHROMATE DICHROMATE SOLUTION
Dilute 100 ml. stock solution to 1 lit. with 0.1 M phosphate buffer solution. On dilution of
1ml. of this solution to 100 ml. with 0.1 M phosphate buffer solution gives a very close visual
match with the yellow colour produced by 0.01 mg/lit. residual chlorine.
244
39. O-TOLUDINE REAGENT

Dissolve 1.35 g of O-toludine dihydrogen chloride in 500 ml. distilled water & add with
constant stirring to a solution of 150 ml. conc. Hcl in 350 ml. distilled water.
40. SODIUM ARSENITE SOLUTION
Dissolve 5 g of sodium meta arsenite in 1lit. distilled water.
41. PHENOLPHTHALEIN INDICATOR SOLUTION
Dissolve 0.1 g of phenolphthalein in 60 ml. of rectified spirit & dilute with distilled water to
100 ml.
42. METHYL ORANGE INDICATOR SOLUTION
Dissolve 50 mg. methyl orange powder in distilled water & dilute to 100 ml.
43. SCREENED METHYL ORANGE INDICATOR SOLUTION
Dissolve 0.2 g crystalline methyl orange in a mixture of 25 ml. of methylated spirit & 25 ml.
of deionised water. Dissolve 0.28 g xylene cyanol FF in a mixture of 25 ml. of methylated
spirit & 25 ml. deionised water. Mix the two solutions together.
44. 5% POTASSIUM DICHROMATE INDICATOR SOLUTION
Dissolve 50 g K2CrO4 in little distilled water. Add Silver Nitrate solution until a definite red
precipitate is formed. Let it stand for 12 hr. filter & dilute to 1 lit with distilled water.
45. SODIUM THIOSULPHATE 0.1 N SOLUTION
Dissolve 25 gm Na2S2O3,5H2O & dilute to 1 lit. with distilled water.
46. DIPHENYL CARBAZONE INDICATOR SOLUTION
Dissolve 0.4 g of di phenyl carbazone in 100 ml. of 95% is propanol
47. 4 M NICKEL NITRATE SOLUTION.
Dissolve 1163 gms. of nickel nitrate (Ni(NO3)2,6H2O)in 1 lit. of D.M. water.
245
48. ERIOCHROME BLACK T INDICATOR SOLUTION

a) Mix 0.5 g of sodium salts of Eriochrome Black T ( 1- hydroxy-2-naphthylazo)-5-nitro-2naphthol-4-sulphonic acid) with 4.5 gms hydroxylamine hydrochloride. Dissolve this
mixture in 100 ml. of 95% ethyl or isopropyl alcohol.
b) Mix together 0.5 g dye & 100 g NaCl to prepare a dry powder mixture.
49. MUREXIDE INDICATOR SOLUTION
a) Dissolve 150 g of Murexide (ammonium purpurate ) in 100 g of absolute ethylene
glycol. Water solution of the dye is not stable for longer than a day.
b) Mix 200 mg. of murexide with 100 gms. of solid NaCl & grinding the mixture to 40 to
50 mesh.
c) Titrate immediately after adding the indicator because it is unstable under alkaline
conditions.
50. STARCH INDICATOR SOLUTION
Dissolve 5 gms of starch & 0.01 gms of mercuric iodide with 30 ml. of cold distilled water &
slowly pour it with constant stirring into 1 lit. of boiling distilled water. Boil for 3 min &
allow it to cool then decant off the supernatant clear liquid.
51. HYDROXYLAMINE HYDROCHLORIDE SOLUTION FOR Fe
Dissolve 10 gms. NH2OH & HCl in 100 ml. distilled water.
246
RAW WATER ANALYSIS (PPM as CaCO3)

CATIONS
Ca (Calcium)
Mg (Magnesium)
Na (Sodium)
K (Potassium)
Fe (dissolved)
TDS
TURBIDITY
TSS
Conductivity
PH
ANIONS
HCO3
(Bicarbonates)
Cl (Chlorides)
SO4 (Sulfates)
NO3 (Nitrates)
SiO2 (Silica)
Mg/L
NTU
Mg/L
Micro-S/cm
Note: To get better idea about the performance of the Demineralization Plant, occasionally
check the raw water for chemical analysis (as given above.)
DAILY LOG SHEET (PRE-TREATMENT & FILTRATION)
HRSCC
Date / Time
Inlet Raw Water turbidity
(NTU)
Outlet clear water turbidity
(NTU)
Alum Dosing (ppm)
Polyelectrolyte Dosing
(ppm)
Outlet water, TDS (ppm)
Lime Dosing (ppm)
247
DAILY LOG SHEET (DM PLANT)

INLET Turbidity, NTU
OUTLET Turbidity (NTU)
DMF
Inlet Pr. (kg/cm2)

Outlet Pr. kg/cm2)
INLET TOC (KMnO4 value)
SBA
DGT
SAC
ACF
OUTLET TOC (KMnO4)

value
Inlet Pr. (kg/cm2)
Outlet Pr. kg/cm2)
Residual Chlorine at
OUTLET (ppm)
Inlet Pr. (kg/cm2)
Outlet Pr. (kg/cm2)
Inlet TH
Outlet FMA
SDG level
inlet, CO2
outlet, CO2
OUTLET CONDUCTIVITY
S/cm
OUTLET TDS (mg/L)
Inlet Pr. (kg/cm2)
Outlet Pr. kg/cm2)
OUTLET pH
MB
OUTLET SiO2 (mg/L)
PHP
SOFTENER
PH
Inlet Pr. (kg/cm2)

Outlet Pr. kg/cm2)
OUTLET pH
OUTLET SiO2 (mg/L)
OUTLET CONDUCTIVITY
S/cm
DOSING RATE (PPM)
DM WATER pH AFTER
CORRECTION
INLET Hardness (TH), ppm
OUTLET Hardness ppm
Inlet Pr. (kg/cm2)
Outlet Pr. kg/cm2)
pH at OUTLET
248

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OPERATION, MAINTENANCE

M/S DELTA ENGINEERING CORPORATION

Thermax LTD., (Water & Waste Solutions)

Improving Your Business Is Our Business

Water & Waste Solutions

1] Water Treatment: Fundamentals

4] Operation & Maintenance For "VERSA-FILTERS"

5] Operation & Maintenance For "Demineralizers"

6] Operation & Maintenance For "FLEXI-DF" .. 142 to 173

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

Undissolved and suspended solid materials.

1. Undissolved and suspended solid materials.

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

decaying vegetation. Colour of feed water is objectionable as it causes foaming in

2. Dissolved Salts and Minerals

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

This type of sedimentation basin is comprised of four operating zones.

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

Figure 2 Circular Clarifier

Increase the density of the particle relative to the water

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

Demineralization or deionization is the process of removing mineral salts from water by

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

2.0 PROCESS DESCRIPTION

RAW WATER INLET

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

PLANT DETAILS (D.M. PLANT)

104 kgs NaOH

7.2 kgs HCL

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

CAP: 100 LTRS,

0-4 LPH @ 3.5 KG

CAP.:- 500 LTRS

0-30 LPH @ 3.5 KG 1

CAP.:- 500 LTRS

LIME DOSING PUMP

CAP.:- 500 LTRS

0-30 LPH @ 3.5 KG 1

8.0 M DIA X 3.8 M

VERSADMF 2000 DIA X 2000

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

CAP.:- 300 LTRS

600 DIA X 2500

305 M3/HR @ 100

1200 DIA X 2500

CAP.:- 350 LTRS

600 DIA X 1600 HOS

CAP.:- 100 LTRS

CAP.:- 100 LTRS

31.1 M3/HR @ 0.45

M/S KBK CHEM ENGINEERING (P) LTD; / OC NO: 225064

2.3 INSTRUMENT DETAILS