Activated Carbon Filter PDF

THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION, MAINTENANCE
&
TROUBLESHOOTING
MANUAL
CLIENT
IFFCO PHULPUR
PROJECT
ACTIVATED CARBON FILTER

FOR AMMONIA & POWER PLANT
PLANT
CONDENSATE POLISHING UNIT
CAPACITY
150M3/HR
REFERENCE
OC NO 200134
Thermax Limited, (C&W Service & Solutions Group)

Thermax House, Mumbai Pune Road,
Shivaji Nagar, Pune - 411005
Tel. : 020-25511010, Fax. : 020-25511236.
WATER TREATMENT PLANT
OPERATION&MAINTENANCEMANUAL
FORACTIVATEDCARBONUNITCONDENSATEPOLISHINGUNIT
ImprovingYourBusinessIsOurBusinessOnThermaxGroup:
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ThermaxWater&WasteSolutionDivisionswidespectrumofproductsandtechnologycovers
Pretreatment
ProcessWaterTreatment
IonExchangeResins
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Recyclingofwater
RangeofCoolingWaterChemicals
RangeofPolyelectrolyte
Incinerators.
TABLE OF CONTENTS
1 : Water Treatment Fundamentals .... 6
1.1 : Water treatment general write up & Basic water chemistry .6
1.2 : Importance of Water Analysis .....7
2 : Plant Configuration and Details ...13
2.1 : System Details ......13
3 : Control Philosophy 15
3.1 : System Description ......15
3.2 : Process .....16
4 : Operation & Maintenance of "ACF Filter" .....17
4.1 : System operation for ACF ....17
4.2 : Process flow diagram ...35
4.3 : Operation Conditions checks for ACF..36

4.4 : Troubleshooting Guide (ACF) ....37
4.5 : Maintenance (ACF) ..38
5 : Laboratory Details ..39
5.1 : Laboratory Analysis ...39
5.2 : Daily Log- Sheet ....................72
6: P & I Drawings ........73
7: Valves Operating procedure...75
8 : Whom to Contact .......76
(for support In case of problem)
Note: For operation and maintenance of individual equipments like pumps, blowers, motors,
instruments etc please refer to the instruction manual of the respective equipments.
INTRODUCTION
TheOperation&MaintenanceManualgivesabriefintroductiontothetotalsystemsupplied
andgivesinstructionsandguidelinesforsmooth,longlastingandtroublefreeoperationofthe
plant. The O&M manual is prepared to make the operator familiar with the system/plant
supplied(ACFunit)anditsoperationandmaintenanceofthePlant.
ThechapterChemicalControldescribesthevariouslaboratorytestsandtheirprocedures,tobe
carried out in the laboratory to understand quality of feed water to the plant and quality of
product water. The regular analysis also helps in analyzing individual units' performance and
totalplantperformancevisvisoutputwaterproducedandchemicalsconsumed.
Themaintenanceofvariousequipmentingeneralandresinunitsinparticulararedetailedin
thisO&Mmanualalongwithdetailsoftroubleshooting,safetyprecautions,etc.Itisalsotobe
noted that this O&M manual covers all areas relevant to the system supplied in general and
certainproblematicareas,inparticular,withrespecttooperationandmaintenance,basedon
ourexperience,asfaraspossible.Incaseofproblems,whicharenotcovered,andpeculiar,the
samecanbereferredtousorthevariousmanufacturersasandwhentheyarise.
1.WATERTREATMENTFUNDAMENTALS
1.1WATERTREATMENTGENERALWRITEUP&BASICWATERCHEMISTRY:
INTRODUCTION:
Thenaturalwatercontainssolid,liquidandgaseousimpuritiesandtherefore,thiswatercannot
beusedforthegenerationofsteamintheboilers.Theimpuritiespresentinthewatershould
beremovedbeforeitsuseinsteamgenerationThenecessityforreducingthecorrosivenature
&quantityofdissolvedandsuspendedsolidsinfeedwaterhasbecomeincreasinglyimportant
withtheadventofhighpressure,critical&supercriticalboilers.
IMPURITIESINWATER:
Theimpuritiespresentinthefeedwaterareclassifiedasgivenbelow
Undissolvedandsuspendedsolidmaterials.
Dissolvedsaltsandminerals.
Dissolvedgases.
Othermaterials(asOil,Acid)eitherinmixedorUnmixedforms.
Undissolvedandsuspendedsolidmaterials.
a)TurbidityandSediment
Turbidityinthewaterissuspendedinsolublematterincludingcoarseparticles(mud,sediment,
sandetc.)Thatsettlesrapidlyonstanding.Amountsrangesfromalmostzeroinmostground
watersand60,000ppminmuddyandturbulentriverwater.TheTurbidityoffeedwatershould
notexceed5ppm.Thesematerialscanberemovedbysettling,coagulationandfiltration.Their
presenceisundesirablebecauseheatingorevaporationproduceshardstonyscaledepositson
the heating surface & clog fluid system. Both are objectionable as they cause damage to the
Boilersystemstandardamountofmeasurementofhardnessistakenasbeingtheamountof
CalciumCarbonate(CaCO3)inthewaterandisreferredtoinpartpermillion(ppm)orgrains
pergallon(grains/gallon*17.1=ppm).
b)SodiumandPotassiumSalts
Theseareextremelysolubleinwateranddonotdepositunlesshighlyconcentrated.
Theirpresenceistroublesomeastheyarealkalineinnatureandacceleratethecorrosion.
c)Chlorides
Majorityofthechloridecausesincreasedcorrosiveactionofwater.
d)Iron
Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous
bicarbonatedepositsbecomesyellowishandreddishsedimentofferrichydroxideifexposedto
air. Majority of ground surface water contains less than 5 ppm but even 0.3 ppm can create
troubleinthefeedwatersystembysoftscaleformationandacceleratingthecorrosion.
e)Manganese
Italsooccursinsimilarformasiron&itisalsoequallytroublesome.
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.InmodernhighpressureBoilersitspresenceisreducedaslowas1050ppb.
g)MicrobiologicalGrowth
Various growths occur in surface water (lake & river). The microorganisms include diatons,
moulds, 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
transferrates.
h)Colour
Surfacewatersfromswampyareasbecomehighlycolouredduetodecayingvegetation.Colour
offeedwaterisobjectionableasitcausesfoaminginBoilersandmayinterferewithtreatment
processes.Itisgenerallyremovedbychlorinationoradsorptionbyactivatedcarbon.
DissolvedSaltsandMinerals
CalciumandMagnesiumSalts
TheCalciumandMagnesiumsaltspresentinthewaterintheformofcarbonates,bicarbonates,
andsulphatesandchlorides.Thepresenceofthesesaltsisrecognizedbythehardnessofthe
water (hardness of water is tested by soap Test). The hardness of water is classified as
temporaryandpermanenthardness.Thetemporaryhardnessiscausedbythebicarbonatesof
calciumandmagnesiumandcanberemovedbyboiling.
The boiling converts the soluble bicarbonates into less soluble carbonates, which can be
removedbysimpleblowdownmethod.Thepermanenthardnessofthewateriscausedbythe
presenceofchlorides,sulphatesandnitratesofcalciumandmagnesiumandtheycannotbe
removedjustbyboilingbecausetheyformahardscaleonheatingsurfaces.
DissolvedGases
Oxygen
It presents in surface water in dissolved form with variable percentage depending upon the
watertemperatureandothersolidcontentsinwater.Itspresenceishighlyobjectionable,asit
iscorrosivetoiron,zinc,brassandothermetals.Itcausescorrosionandpittingofwaterlines,
boilerexchangers.Itseffectisfurtheracceleratedathightemperatures.
b)CarbonDioxide
Theriverwatercontains50ppmandwellwatercontains2to50ppmofCO2.Italsocausesthe
corrosionofstream,waterandcondenseslines.Italsohelpstoacceleratethecorrosiveaction
of oxygen. The other gases are H2S, CH4, N2 and many others but their percentages are
negligible,therefore,theireffectsarenotdiscussedhere.
4.OtherMaterials
FreeMineralAcid
Usuallypresentassulphuricorhydrochloricacidandcausescorrosion.Thepresenceisreduced
byneutralizationwithalkalis.
b)Oil
Generally, the lubricating oil is carried with steam into the condenser and through the feed
systemtotheBoiler.Itcausessludge,scaleandfoaminginBoilers.Itisgenerallyremovedby
strainersandbaffleseparators.
Theeffectsofalltheimpuritiespresentinthewaterarethescaleformationonthedifferent
partsoftheBoilerSystemandcorrosion.Thescaleformationsreducestheheattransferrates
and clog the flow passage and endanger the life of the equipments by increasing the
temperatureabovesafelimit.ThecorrosionphenomenonreducesthelifeofthePlantrapidly.
Therefore,itisabsolutelynecessarytoreducetheimpuritiesbelowasafelimitfortheproper
workingofthepowerplant.
1.2ImportanceofWaterAnalysis
Wateranalysis
Theprocessofdetermininghowmuchofvarioussubstances(impurities)arepresentingiven
sampleofwaterisknownasWaterAnalysis.
NeedforWaterAnalysis
Wateranalysisisessentialforthefollowingreasons:
a)Rawwatersourceselection.
b)Analysisofrawwaterdeterminesthetypeoftreatmentandunitsize.
c)Treatedwateranalysisindicatestheefficienciesofvariousunitsofwatertreatment.
d)Designingofmosteconomicalwatertreatmentplant.
Todesignawatertreatmentplantknowingtheimpuritiespresentinthewatertobetreatedis
needed. Complete analysis helps in determining the degree of pretreatment required in Ion
Exchangeandotherprocesslikereverseosmosisetc.
Minorconstituentlikesilicaisveryimportantsinceitmayhaveinfluenceontheregeneration
techniqueusedandcanaffectthecapacitiesthatcanbeobtained.
AnalysisofIronandchlorineisimportantforreverseosmosisdesign.
Definitionusedinwateranalysis
pH:
ItiscommonpracticetoexpresshydrogenionconcentrationintermsofpH.Bydefinitionthe
pHisthenegativelogarithmofhydrogenionconcentrationtothebaseofl0.
pH=log10(H+)=log(1/H+)
IonicproductofwaterKwhasavalueof1x1014andinneutralwaterH+concentrationis
equaltoOHconcentration.
Kw=H+xOH=1x1014(1)
Forneutralwater=(H+)=(OH)=1x107
Theequilibriumrepresentedbyequation(1)occursuniversallyinaqueoussolutionregardless
oftheequilibriumorthesolutespresent.Henceequation(1)shouldalwaysbesatisfied.
ThusthetermspHexpressestheacidityorbasicityofwater.
NeutralwaterhasapHof7.pHlowerthan7indicatesacidityandgreaterthan7isalkaline.
Alkalinity:
AsmentionedearlieralkalinityinwaterisduetopresenceofHCO3.CO3andOHions.Inraw
wateralkalinityismostlyduetoHCO3,butinsomecasesCO3ionsalsomaybepresent.Itis
importanttonotethatoutofthethreeionsonlytwoionscanexistinanysystem.ThatisHCO
3, CO3 or OH can exist alone or in combination with one more ion. Any water analysis
reportingthepresenceofallthreeionsshouldbediscarded.
Alkalinityofwaterisdeterminedbytitrationwithphenolpthaleinandmethylorangeindicator.
TheresultoftitrationwithmethylorangeindicatoriscalledTotalAlkalinityorMAlkalinity.
M.Alk.=TotalAlk=HCO3+CO3+OH.
TheresultoftitrationwithphenolpthaleinindicatoriscalledPAlkalinity.
P.Alk=OH+1/2CO3.
Hardness
CalciumandMagnesiumsaltsimparthardnesstowater.Hardwaterisdefinedasawaterwhich
does not lather or foam with soap easily. The salt of calcium and magnesium which causes
hardnessisdividedintwoparts.
1.Temporaryhardnessorcarbonatehardness.
2.Permanenthardnessornoncarbonatehardness.
ThesumoftemporaryandpermanenthardnessiscalledTotalHardness.
TotalHardness=Carbonatehardness+NonCarbonatehardness
CarbonateHardness
ItismainlyduetopresenceofbicarbonatesofCalciumandMagnesium.
Alkalinity in raw water is normally due to bicarbonate ions. Therefore, carbonate hardness
(Alkalinity)plusNonCarbonatehardnessisequaltototalhardness.
1)Carbonatehardness=Alkalinity,whenalkalinityislessthantotalhardness.
2)Carbonatehardness=Totalhardness,whenalkalinityisgreaterorequaltototalhardness.
Conductivity:
Theconductivityofwaterisdependentontheioniccontentofwater,specificallyontheability
of ionic impurities in the water to conduct electricity. Ionic impurities have the ability to
conduct electric current and thus there is direct linear relationship between ionic impurities
andconductivitywhichhelpindeterminingtheionicimpuritiesinwater.
10
ConductivityisalsorelatedtoTDSempirically=Conductivityx0.65=TDS.
TotalDissolvedSolids
Thisrepresentsallthesolubleinorganicsolidsinwaterexpressedinppm.
TotalSolids
TotalsolidisdefinedasSUMofsolubleandinsolublesolids.
Electrolytes
This is total ionizable dissolved solids in water. Total electrolyte is numerically equal to total
cationortotalanions(notsumofboth).TotalelectrolytedoesnotincludeCO2andsilica.
TotalCations
Sumofcalcium,magnesium,sodiumandpotassiumallmeasuredinthesameunit.
TotalAnions
Sumofalkalinity(HCO3+CO3+OH)+Cl+SO4+NO3allmeasuredinthesameunit.
TotalCation=TotalAnion=TotalElectrolyte
EquivalentMineralAcidity(EMA)
The equivalent mineral acidity, EMA is equal to the sum of equivalent concentration of
sulphates,chlorideandnitrate.ItisalsocalledsometimesasTotalMineralAcidity.
FreeMineralAcidity(FMA)
Freemineralacidityisequalto(EMASodiumleakage).
EMASodiumleakage=FMA
EMAFMA=Sodiumleakage.
Methodofreportingwateranalysis
There are various ways of reporting water analysis, but in general four methods which are
commonlyusedare,
1.Asppmionormg/litre.
2.EPMorM.Eq./litre(Millequivalentperlitre)
3.ppmasCaCo3.
4.GrainspergallonasCaCo3.
11
WateranalysisReport
Wateranalysiscanbereportedinmanywaysbutmostlaboratoriesgiveintheformatasgiven
below.
WATERTREATMENTPLANT
FormatforReportingwaterAnalysis
Physical
pH
ColourHazenUnit
TasteandOdour
TurbidityNTU
Conductivitymhosormillimhos
Chemical
SuspendedSolidsinppm
CalciumasppmCaCO3.*
MagnesiumasppmCaCO3.*
HardnessasppmCaCO3.*
M.AlkalinityasppmCaCO3.*
P.AlkalinityasppmCaCO3.*
Chlorideasppmormg./litre.
Sulphateasppmormg./litre.
Nitrateasppmormg./litre.
Silicaasppmormg./litre.
Ironasppmormg./litre.
TDSasppm
CO2asppm
*SometimescalciumandMagnesiumcanbereportedasinppmasCaorMg.
12
2.PLANTCONFIGURATIONANDDETAILS
2.1SYSTEMDETAILSPLANTDATA
DESIGNDATA
S.No
Description
DesignValue
UnitName
ActivatedCarbonFilter
NoofStream
01
DesignFlowrate
150M3/Hr
Specification
4MDia&2.6HOS
Designpressure
12.5Kg/cm2
Designtemperature
80C
OPERATINGDATA
S.No
Description
DesignValue
UnitName
ActivatedCarbonFilter
NoofStream
01
Flowrate
150M3/Hr
OperatingTime
20Hrs
Operatingpressure
911Kg/cm2
Operatingtemperature
60C
OperationMode
Manual
BackwashTime
30min
FeedWater
Condensateoutletwater
10
Differentialpressureinvessel
0.6Kg/cm2
11
DifferentialpressureinBasketfilter
1.5Kg/cm2
12
BlowerforACF
600m3/Hrat0.4Kg/cm2
13
ANALYSISDATA
S.No
Description
Inletparameters
Outletparameters
Ph
9.09.5
9.09.5
Conductivity
30S/Cm
30S/Cm
Oil&Grease
<1.0ppm
NIL
Turbidity
<1.0NTU
<1.0NTU
Silica
<0.02ppm
<0.02ppm
EQUIPMENTDATA
S.No TAGNO
Description
QTY
SPECIFICATION
MOC
ACF
ACFVESSEL
1NOS
4MDia&2.6HOS
MSEP
BS
BASKETSTRAINER
2NOS
FOR150M3/HRCAP
SS
ACFB1
ACFAIRBLOWER
1NO
600m3/Hrat0.4Kg/cm2
CI
DPT351,
DIFFERENTIALPRESSURE
DPT352
TRANSMITTER
2NOS
ACROSSVESSEL&BS
FT401
FLOWTRANSMITTER
1NO
DPTYPEININLET
FI
FLOWINDICATOR
1NO
ROTAMETERININLET
PRESSUREGAUGE
3NOS
BOURDENTYPE
PG101,
7
PG102,
PG103
14
3.CONTROLPHILOSPHY
3.1SYSTEMDESCRPTION:
ACTIVATEDCARBONFILTERBASICS
ActivatedCarbonworksbyattractingandholdingcertainchemicalsaswaterpassesthroughit.
BecauseACisahighlyporousmaterial,ithasanextremelyhighsurfaceareaforcontaminant
adsorption.Thecontaminantismorelikelytodiffuseintoaporeandbecomeadsorbed.
The two principal mechanisms by which activated carbon removes contaminants from water
are adsorption and catalytic reduction. Organics are removed by adsorption and residual
disinfectantsareremovedbycatalyticreduction.
Activated carbon is proven technology for the removal of naturally occurring organics and
residualdisinfectants.Activatedcarbonfiltersareusinggranularactivatedcarbonasmedia.
Activated carbon filtration is most effective in removing organic contaminants from water.
Organic substances are composed of two basic elements, carbon and hydrogen. Because
organicchemicalsareoftenresponsiblefortaste,odor,andcolorproblems.
ACfiltrationcangenerallybeusedtoimproveaestheticallyobjectionablewater.ACfiltration
will also remove chlorine. AC filtration is recognized by the Water Quality Association as an
acceptable method to maintain certain drinking water contaminants within the limits of the
EPANationalDrinkingWaterStandards.
Overallthisstudyshowedthatactivatedcarbonfiltersareextremelyeffectiveasprimaryfilters
and have the added benefit of organics reduction resulting in cost savings with reduced
chlorine demand and safer water with reduced THM formation and cleaner distribution
systems.
Activatedcarbonbedsarefiltersandneedtobebackwashedperiodically.
15
3.2PROCESS(ACF)
TheACFfilterhasaActivatedCarbonMedia,oneofthemostwidelyusedmediaforadsorption
ofimpurities.
TheActivatedcarbonisemployedfor_
Dechlorination
RemovalofOrganics
RemovalofOdour
The residual chlorine in the water, where chlorination is used for Organics removal, as
adsorbed by Activated Carbon Filter. Chlorination of water is widely used in Drinking Water
Plants,PretreatmentofDMplantandRoplantsandeffluenttreatmentplants.TheVERSAACF
removesalmostalloftheresidualchlorineinthewater.
TheVERSAACFalsohelpsinremovalofOrganicmatterfromthewater.Itisusedintreatment
plantsforDrinkingwateraspolisherunitattheoutletoftheplantandremovesobjectionable
odours. The Activated carbon media has finite capacity of absorption and shall exhaust on
prolongedusagedependingupontheinletimpurityload.
16
4.OPERATIONANDMAINTENANCEOFACFFILTER
4.1SYSTEMOPERATIONFORACTIVATEDCARBONFILTER(ACF)
TheACFunitformanualoperationshallbedividedintothefollowingoperations:
1.SERVICEcycleofACFunit
2.BACKWASHoperationofACFunit
3.AIRRELEASEoperationofACFunit
SERVICECYCLEOFACFUNIT:
EnsurethattheACFfilterisbackwashedandisreadyforservice.
Ensurefeedwaterisavailableinratedquantity/qualityandpressure.
In the service mode Service Inlet Valve VM1 and the service outlet valve VM2 remain
open.
TheservicecycleofACFis20hoursordifferentialpressureacrossthefilter0.6kg/cm2.
SERVICESTEPS
1.RINSE
2.REFILL
3.SERVICE
1. RINSE:
InthisstepServiceinletvalveVM1andRinseoutletvalveVM6remainsopen.Thestepis
carriedoutwiththecondensateoutletwaterfor5minutesattheflowrateis150m3/Hr.
17
18
2. REFILL:
InthissteptheserviceinletvalveVM1andairreleasevalveVM12remainopen.Allthe
othervalvesareinclosedcondition.Refilliscarriedoutattheserviceflowratetillfullbore
ofaircomesfromtheairreleaseline.Thetimesetforrefillis2minutes.
19
20
3. SERVICE:
Theunitistakenintoservice.Itremainsinserviceforacycleof1200 min.Afterthisitis
taken into regeneration mode. Service inlet valve VM1 and Service outlet valve VM2
remainopen.
21
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BACKWASHINGOFACF
After completion of design service run hours (20 hours) or depending up on the differential
pressureacrossthefilteri.eDifferencebetweeninletandoutletpressuregaugereadingsof0.6
kg/cm2,thevesselistakeninbackwashmode.
BACKWASHHIMPORTANCE:
Thewastewashwaterdrainsshouldbekeptfreeofcloggingorsediment.Therequisiteupflow
velocityofbackwashwatershouldbemaintainedatthedesignrateforpropercleaningofthe
media.
Backwashing of filters should not be based on arbitrarily fixed time scheduled but the
frequency should be in accordance with the filtrate quality and head loss measurement.
Durationofcleaningshouldbedependentupontheturbidityofthewastedwater.
For better performance, carry out extended backwash for 3045 minutes once in a week or till
backwasheffluentisclear.
BACKWASHSTEPS
Backwashstepsareasfollows,
1. DRAIN
2. AIRSCOURING
3. STEAM
4. BACKWASH
5. SETTLEBED
6. RINSESTEP
23
BACKWASHSTEPS
1. DRAIN:
Thebackwashmodeisinitiatedwiththedrainstep.InthisstepBackwashOutletValve(VM
4) and drain outlet valve or rinse outlet valve (VM6) remains open. All the other valves
remainclosed.Thedrainstepisforaperiodof5minutes.
24
25
2. AIRSCOURING:
Air scouring step starts and is done through ACF Blower (ACFB1). Backwash outlet valve
(VM4), Air Inlet valve(VM5) and Air releasevalve (VM12) remain open in thisstep. The
stepiscarriedfor5minutes.
26
27
3. STEAM:
Steam scouring step starts and is done through steam inlet line. Backwash outlet valve
(VM4),SteamInletvalve(VM30)andAirreleasevalve(VM12)remainopeninthisstep.
Thestepiscarriedfor10minutes.
28
29
4. BACKWASH:
In this step the Backwash Inlet Valve (VM3) and Backwash Outlet Valve (VM4) remain
open.ThebackwashisdonethroughtheCondensateoutletvalve.Thebackwashiscarried
outataflowrateof150m3/hrfor10minutes.
30
31
5.SETTLEBED:
Inthisstepthebedisallowedtosettleforaperiodof2min.Allthevalvesremainclosedinthis
step.
6.RINSESTEP:
TherinsestepofACFinbackwashmodeiscarriedoutwiththecondensateoutletwater.Inthis
stepVM1ofACFremainsopen&rinsewaterisdrainedoutthroughtherinseoutletvalveVM
6ofACF.Therinsestepiscarriedoutfor5minutesattheflowrateof150m3/hr.
32
33
AIRRELEASEOPERATION:
Airreleaseoperationisanindependentoperationcarriedouttoreleasetheentrappedairfrom
withinthevessel.Thissingleoperation;whenopenedtheAirreleasevalveVM12in2minand
theairreleasevalvealsogetsclosedmanuallyafter2mins.
BASKETSTRAINERIMPORTANCE:
TheFiltered/TreatedWaterisfirstpassedtoBasketFilter.Thisunitisprovidedforremovalof
finesuspendedparticles. Thisisa SSvesselhousingwiththeSSscreenFilterelementswhich
prevents micron size particles up to 100 . If the differential pressure on the inlet to Basket
StrainersensedbyDPT352ishighvaluealarmis1.5Kg/cm2.ACFfeedwatervalveclose/tripsin
thiscase.
ACFOUTLETFILTERED/TREATEDWATER
AfterFiltered/TreatedwaterofACFoutletwaterissentdirectlytomakeupwaterdaytankof
thepowerplantforBFWmakeupinboilerthroughdeaerator.
AfterFiltered/TreatedwaterofACFoutletwaterissentdirectlytomakeupwaterdaytankof
theammoniaplantforBFWmakeupinwasteheatboilerthroughdeaerator.
34
4.2PROCESSFLOWDIAGRAM
SCHEMATICDIAGRAMFORACTIVATEDCARBONFILTERUNIT
SURFACE
CONDENSER
CONDENSATE
WATERINLETBASKETFILTER1
ACF
TREATEDWATEROUTLET
BASKETFILTER2
TODEAERATOR
PROCESSSTEPS:
Processcondensatewaterfromsurfacecondenseroutlettodeaerator.
SURFACECONDENSERACFBASKETFILTERDEAERATOR.
35
4.3OPERATINGCONDITIONCHECKSFORACFYNIT
PREREQUISITECONDITIONOPERATION(MANUAL)ACFUNIT
ChecktheallmanuallyoperatedvalvesopenorcloseconditionsuchasVM1,VM2,VM3,
VM4,VM5,VM12,VM30&VM26.
Ensure all Pressure Gauge isolation valve (VM41) are open for all the Units & of Rotary
equipments.
Ensure all Flow Indicators / Flow transmitter DP transmitter isolation valves (VM46) are
openforalltheUnits.
WhileinserviceCondensateoutletheadervalveandACFoutletheadervalveisopen.
Inletwaterpressureshouldnotexceed12kg/cm2.DonotexceedtheMaxOperatingFlow
rateof150m3/hr,asthismaydeterioratethequalityofoutletwater.
Inletwatertemperatureshouldnotbemorethan80Deg.C
Checkthedifferentialpressureacrossthevessel&acrossthebasketfilterbeforestartup
theunit.
NowACFunitisreadytotakeintooperation.
MAINTENANCECHECKS:
Analyzeinlet/outletwaterinperiodicallyi.e.,hourly,shiftbasis,daily,weeklybasis.
EnsureAirbloweraresufficientlylubricatedandcontinuedoillevelersarefilledup.
Inspectthevessel,pipingexternallyonceinyearfordamagetothepainting.
Inspectthefiltermediaeveryyear,andreplacedifrequired.
Give extended backwash to the filter once in a week for more than 45 min or till clear
water.
Give air scouring to the filter media once in six months or if the filter is found heavily
chocked,asdescribedinmaintenancesection.
Usegenuinespares(THERMAXSPARES).
Repaintasnecessary.
Inspect vessel internally once in a year for any damaged in internals system or not. And
repairtheinternalsiffounddamaged.
Iffoundconsistentlymorethanthedesignlimit,consultTHERMAXrepresentatives.
36
4.4 TROUBLESHOOTING GUIDE (ACF)

S.No
DEFECT
CAUSE
REMEDY
Condensatewater
a.Filternotbackwashed
a.Backwashfilterregularly
qualitynotupto
b. Inlet Suspended Solids load b.Checkinletwaterquality.
thestandard
increased
You may have to increase backwash
c.ExcessiveFlowRate
frequency.AlsoConsultThermax.
d.ChannelingCollection/distribution
c.Pleasedonotcrossunitmaxservice
e.Disturbedmedialayers.
flowrate.
d. Check and ensure sufficient
pressure.
e.
Check
and
ensure
proper
segregatedmedialayers
2
BackwashFrequency
a. Inlet Suspended Solids load a.Checkinletwaterquality.Youmay
Requiredishigh
increased
havetoincreasebackwashfrequency.
AlsoConsultThermax.
UnitRinsetakeslongtime a.Flowratetoolow
a.Adjusttheflowratetothenormal
b.ImproperBackwash
b. Give proper backwash as given in

OPERATION section till clear water is
observed.
PressureDropacrossbed a.NoorInsufficientbackwash
isincreasingdaybyday
b. Inlet Suspended Solids load b.Checkinletwaterquality.
increased
You may have to increase backwash

frequency.AlsoConsultThermax.
a.Backwashfilterregularly.
Mediacomesout
a.Impropermediachargingat
a. Remove and recharge media
frombottomoutlet
thetimeoferection
properly
b. Too much excessive backwash b. Always maintain backwash flow.

flowrate/Pressure
Too much backwash flow rate/
c.Thegapincollectionboxanddish Pressurecandisturbmedialayers.
is more than 5 mm. ( This should c. Remove the entire media, adjust
have
been
checked
installation)
before thegapto5mm,segregatethemedia
bytypeandrechargethemedia.
TREATMENT PLANT
37
4.5MAINTENANCE(ACF)
Theroutinemaintenanceofthefiltersshouldincludethefollowing_
VALVES
Atperiodicintervals(sayonemonth)openoutthevalvesandcheckseating,gate,etc.Attend
toglandpacking.Replaceifnecessary,doroutinelubricationofspindle.
EXTENDEDBACKWASH
Onceinaweekextendthebackwashoperationtoatleast45minutestokeepthebedclean.
AIRSCOURINGANDCLEANINGOFTHEFILTERMEDIA
Onceinsixmonths,openthemanholeandexaminetheconditionofthemedia.Throwaway
anylumpsformedonthetopofthebed.Onunitswherenoregularairscouringfacilitiesare
provided,airscouringshouldbedoneasfollows
a.Ifcompressedairsupplyisavailable,takeatemporarytapping(say1hose).
AttachthehosetoaM.S.pipeabout1Mlongwithwaterlevelinsidevesselabout3abovethe
levelofthebed,insertthepipeintothebedtillitisabouthalfwaythrough.Themediawillbe
seen getting violently agitated. Move the pipe all over the bed. Carry out the air scour for a
periodofabout10minutes.
b.Drainthewatertillthesurfaceofthebedandscrapeoffanyfinedust.
c.Closethemanhole.
TREATMENTPLANT
DOSANDDONTS
Neverexceedthefilterserviceflow
AnalysesInletwaterforTurbidityregularly
AlwayscheckInletwaterforOil&Greasecontent.Dontallowexceedthelimit.
InletWaterTempshouldnotexceed80Deg.C
DoannualMediaCheckupandreplacementasrequired.
BackwashthefilterregularlyasperManual
NeverallowcorrosiveliquidstopassthroughtheFilter.
38
5. LABORATORY DETAILS
5.1 LABORATORY ANALYSIS
CONTENTS
1. pH
2. TURBIDITY
3. COLOUR
4. ELECTRICAL CONDUCTANCE
5. TOTAL DISSOLVED SOLIDS
6. SUSPENDED MATTERS
7. HARDNESS
8. SILICA
9. CHLORIDE
10. OILS AND GREASE
11. RESIDUAL CHLORINE
12. REAGENTS
39
1.pH:
ItiscommonpracticetoexpresshydrogenionconcentrationintermsofpH.Bydefinitionthe
pHisthenegativelogarithmofhydrogenionconcentrationtothebaseofl0.
pH=log10(H+)=log(1/H+)
IonicproductofwaterKwhasavalueof1x1014andinneutralwaterH+concentrationis
equaltoOHconcentration.
Kw=H+xOH=1x1014(1)
Forneutralwater=(H+)=(OH)=1x107
WATERTREATMENTPLANT
Theequilibriumrepresentedbyequation(1)occursuniversallyinaqueoussolutionregardless
oftheequilibriumorthesolutespresent.Henceequation(1)shouldalwaysbesatisfied.
ThusthetermspHexpressestheacidityorbasicityofwater.NeutralwaterhasapHof7.pH
lowerthan7indicatesacidityandgreaterthan7isalkaline.
METHOD A pH Indicator:
ApH indicatoris ahalochromicchemical compoundthat is added in small amounts to

solutionsothatthepH(acidityorbasicity)ofthesolutioncanbedeterminedvisually.Hencea
pH indicator is achemicaldetector forhydroniumions (H3O+) or hydrogen ions (H+) in
theArrhenius model. Normally, the indicator causes thecolourof the solution to change
dependingonthepH.
Thesecommercialindicators(e.g.,universalindicatorandHydrionpapers)areusedwhenonly
roughknowledgeofpHisnecessary.
METHODBPHCELL(pHMeter):
ApH meteris an electronic device used for measuring thepH(acidityoralkalinity) of a liquid
(though special probes are sometimes used to measure the pH of semisolid substances). A
typical pH meter consists of a special measuring probe (aglass electrode) connected to an
electronicmeterthatmeasuresanddisplaysthepHreading.
Thisiscontainingapairofelectrodes.Thesampletobetestedispouredintothiscell.Thereare
manyformsofcell.
Thereareseveralsatisfactorycommercialmodels.Operators,lesstheyhaveadequatefacilities,
wouldbewelladvisedtopurchaseareadymadeinstrument.
40
2.TURBIDITY
OUTLINEOFTHEMETHOD
Thesampleismatchedagainststandardsuspensionsoffullersearthinwater.
TERMINOLOGY
Forthepurposeofthistest,thefollowingdefinitionshallapply.ScaleUnitTurbidityimparted
by1mgoffullersearthwhensuspendedin1000mlofdistilledwater.
PREPARATIONOFTURBIDITYSTANDARDS
Mixslowlywithconstantstirring5.000goffullersearthpreviouslydriedandshiftedthrough75
micronISSievewithdistilledwateranddiluteitto1000ml.Agitateintermittentlyforonehour
andthenallowtostandfor24hours.Withdrawthesupernatantliquidwithoutdisturbingthe
sediment.Vaporateabout50mloftheremovedliquid,drytheresidueat105+2Deg.Cand
weightheresiduetodeterminetheamountofclayinsuspension.Prepareturbiditystandards
with this standardized stock suspension with distilled water. A drop of saturated mercuric
chloridesolutionmaybeaddedaspreservative.Thestandardsarestableforthreemonths.
PROCEDURE
Pourthesampleafterthoroughshakingintoaclearglassbottleofsuitablecapacity,say1lit.
Compare it with the turbidity standards contained in similar bottles, holding them against a
suitablebackgroundandusingasourceoflightwhichilluminatesthemequallyandisplacedso
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,
diluteitwithdistilledwaterbeforetestingandmultiplytheresultwithanappropriatefactor.
NOTEComparisonofturbiditymayalsobedonewiththehelpofsuitableinstruments.
41

3.COLOUR
OUTLINEOFTHEMETHOD
The colour of the sample is matched against a series of standards containing potassium
chloroplatinateandcobaltchloride.
TERMINOLOGY
Forthepurposeofthistest,thefollowingdefinitionsshallapply:
TrueColour
Colourduetosubstancesinsolution,afterremovalofsuspendedmatter.
ApparentColour
Colourduetosubstanceswhichareinsolutionaswellasinsuspension.
ColourobtainedinamixturecontainingeitheronmilligramofPatinumor
HazenUnit
2.49 mg of potassium chloroplatinate along with 2 mg of cobalt chloride

(CoCl2.6H2O)in1litreofthesolution.
APPARATUS
NesslerTubesFlatbottomtubeofthincolourlessglass.Twotypesoftubesarerequired.The
longertubesshallbe45cmtalland2.5cmininternaldiameter.Theshortertubesshallbe30
cmtalland1.7cmininternaldiameter.Tubesofanyonetypeshallbeidenticalinshape,and
thedepthmeasuredinternallyfromthegraduationmarktothebottomshallnotvarybymore
than2mminthetubesused.
REAGENTS
PlatinumorPotassiumChloroplatinateAquaRegiapreparedbymixingonepartbyvolumeof
concentrated nitric acid (conforming to IS: 2641950) with three parts by volume of
concentratedhydrochloricacid(conformingtoIS:2651962).CobaltChlorideCrystalline,with
themolecularcompositionCoCl2.6H2).
TREATMENTPLANT
42

PROCEDURE
PREPARATIONOFCOLOURSTANDARDS
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(conformingtoIS:2651962).Dissolvetheresiduewith1.0gofcobaltchloridein100mlof
concentratedhydrochloricacidtoobtainabrightsolution,ifnecessarybywarming.Dilutethe
solutionto1000mlwithdistilledwater.Thisstocksolutionhasacolourof500Hazenunits.A
more convenient way of preparing the same solution is by dissolving 1.245 g of potassium
chloroplatinateand1.0gofcobaltchlorideindistilledwateranddilutingto1litre.Preparea
setofcolourstandardshavingcolour5,10,15,20,25,30,35,40,50,60and70Hazenunitsby
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
protectedagainstevaporationandcontaminationwhennotinuse.
PROCEDUREFORCLEARSAMPLES
Forsampleshavingturbidityunder5mg/l,matchthecolourofthesampleagainstthestandard
coloursinthelongerNesslerTubes.Fillthetubestomarkandcomparethecolourbylooking
vertically downwards against a pure white surface. If the colour is found to exceed 70 units,
dilutethesamplewithdistilledwaterbeforecomparisonandmultiplytheresultbyappropriate
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
exceeds30Hazenunits,thecomparisonmay,ifdesired,bemadeintheshorterNesslertubes.
TREATMENTPLANT
PROCEDUREFORTURBIDSAMPLES
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,thevaluefoundshallbereportedas"apparentcolour".Inthepresenceofturbidity,the
true colour shall be determined after centrifuging. The sample shall be centrifuged until the
supernatant liquid is clear. The centrifuged clear sample shall be compared by the method
prescribedinPROCEDUREforclearsamples.
43

NOTE
Forestimatingtruecolour,filterpapershallnotbeusedsincethatleadstoerroneousresults.
REPORT
Theresultsofcolourdeterminationshallbeexcessinwholenumbersandshallberecordedas
follows:
HazenUnits
Lessthan5Reportsas"Lessthan5HazenUnits"
5to50Reportstothenearest1HazenUnit
NOTE
Thecolourdeterminationshallbemadeasearlyaspossibleafterthecollectionofsamplesas
certainbiologicalchangeoccurringinstoragemayaffectthecolour.
44

4.ELECTRICALCONDUCTANCE
GENERAL
Theunitofconductanceisthemhoorreciprocalohm.Specificconductivityistheconductance
at a specified temperature across a column of a liquid 1 cm2 in area and 1 cm long, and is
expressedmhospercentimeter.Thisisaninconvenientlylargeunitforwatertestinganditis
usualtousethemicromhopercentimeterknownasthe"dionicunit",whichisonemillionth
partofamhopercentimeter.
APPARATUS
Severalkindsofapparatusareavailable.Theygenerallyconsistoftwoparts.
CONDUCTIVITYCELL
Thisiscontainingapairofelectrodes.Thesampletobetestedispouredintothiscell.Thereare
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.
Brightplatinumorgoldorheavilygoldplatedelectrodesmaybeused.Someinstrumentsare
designed to work with particular form of conductivity cell, and are then calibrated directly in
conductivityunits.
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"whichshallbedeterminedbyexperiment.MeasuringInstrumentFormeasuringthe
electrical conductance (or the resistance which is the inverse of conductance) between the
electrodesofthecell.Thereareseveralsatisfactorycommercialmodels.Operators,lessthey
haveadequatefacilities,wouldbewelladvisedtopurchaseareadymadeinstrument.
TREATMENTPLANT
45

PROCEDURE
Determine the cell constant if necessary, either directly with a standard potassium chloride
solution(say0.002N)orbycomparisonwithacelltheconstantofwhichisknownaccurately.
(Inthelattercase,theconcentrationandnatureoftheelectrolytesintheliquidwhichisused
for the comparison should be the same and should be similar respectively to those of the
liquidswithwhichthecellislikelytobeusedinpractice).Usesomeofthesamplestowashout
theconductivitycellthoroughly.Filltheconductivitycellwiththesample.
Calculations
FORINSTRUMENTREADINGRESISTANCE:
1x106
Electricalconductance,indionicunits(ormicromhospercentimetre)=
rk
Wherer=Resistanceinohms,andk=Cellconstant
FORINSTRUMENTREADINGCONDUCTANCE:
Electricalconductance,indionicunits(ormicromhospercentimetre)=ck
Where
c=conductanceinmicromhos,andk=cellconstant
CORRELATIONOFELECTRICALCONDUCTANCETOTOTALDISSOLVEDSOLIDS
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
thetotaldissolvedsolids.
Electricalconductance
DissolvedSolids
TREATMENTPLANT
46

5.TOTALDISSOLVEDSOLIDS(TDS)
Awellmixedfilteredsampleisevaporatedinaweigheddishanddriedtoconstantweightinan
ovenat103to105Deg.C.Theincreaseinweightoverthatoftheemptydishrepresentsthe
totalresidue.
APPARATUS
1.Silicaorporcelaindishof100mlcapacity
2.Desicator
3.Oven
PROCEDURE
Ignite the clean evaporating dish at 550 + 50 Deg. C for 1 hour. Cool, desiccate and weigh.
Transferthemeasuredsampletothepreweigheddishandevaporatetodrynessonasteam
bath. Choose a sample volume that will yield a minimum residue of 25 mg to 250 mg. If
necessary,addsuccessiveportionsofsampletothesamedish.Drytheevaporatedsamplefor
atleast1hourat103to105Deg.C.Coolthedishinadesiccatorsandweigh.Repeatthecycle
ofdrying,coolingandweighinguntilaconstantweightisobtained.
Calculations
Wtofresiduex1000
Totaldissolvedsolid,mg/L=
ml.ofsampletaken
47

6.SUSPENDEDMATTERS
Suspended matter is the material retained on filter after filtration of a well mixed sample of
water.Theresidueisdriedat103to105Deg.C.
APPARATUS
1.Goochcrucible
2.Silicaorporcelainevaporatingdishof100mlcapacity
3.Desiccators
4.Ovenadjustabletoconstanttempof103105Deg.C.
5.Waterbatch
PROCEDURE
Prepare a gooch crucible with asbestos (20 to 30 ml of 0.5% suspension of gooch asbestos
addedandwashedundersuction),dryandigniteat500Deg.Cforatleast30minutes,cooland
weigh. Filter a suitable volume of the well mixed sample through the crucible. Wash with
distilledwater,dryat105Deg.Cforonehour.
Weigh.
Calculations
Wx106
Suspendedmattersinmg/L=
V
Where,
w=wt.ingofthesuspendedmatter
V=vol.inml.ofthesampletakenforfiltration
NOTE
IfGoochCrucibleisnotavailable,standard"Whatman"filterpapermaybeused.
48

7.HARDNESS
Hardnessinwaterisduetothepresenceofbicarbonates,chloridesandsulphatesofcalcium
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,aluminum,zinc,manganese,etc.
METHODAOMPLEXAMETRICMETHOD(EDTAMETHOD)
EDTA forms a chelated soluble complex when added to a solution of certain metal ions. If a
smallamountofEBTisaddedtoanaqueoussolutioncontainingcalciumandmagnesiumions
atpHof10.0+0.1,thesolutionwillbecomeredwine.IfEDTAisthenaddedasatitrant,the
calciumandmagnesiumwillbecomplexes.AftersufficientEDTAhasbeenaddedtocomplexall
thecalciumandmagnesium,thesolutionwillturnbluefromredwine.
REAGENTS
1.AmmoniabufferofpH10.
2.Msolutionofdisodiumsaltofethylenediaminetetraaceticacid.
3.EriochromeblackTindicatorsolution.
PROCEDURE
Take50mlofsampleinanErlenmeyerflask;add4to6dropsofEriochromeblackTindicator
solution. Add 1 ml of buffer solution and mix.Titrate immediately with EDTA solution till the
colourchangesfromredtoblue.
Calculations:
TotalhardnessasCaCO3mg/lit=Vol.of0.01MEDTAsolutionx1000mlofsample
ATERTREATMENTPLANT
NOTE
Forcheckinghardnessinsoftwateruse500mlofthesampleinto750mlevaporatingdishand
add3mlofbuffersolutionfollowedby1012dropsofindicatorsolution.
49

METHODB
SOAPSOLUTIONMETHODFORHARDNESSTESTING
Thisisaquickmethodforcheckinghardnessoftreatedwateroranaccuratedeterminationof
thehardnessoftreatedwater,EDTAmethodforhardnessshouldbeused.
REAGENTS
1.Bsoapsolution
2.40mlshakingbottle
PROCDURE
Takewatersampleupto40mlmarkinshakingbottle.Add10dropsofthe"B"soapsolution.
Shakevigorously.Iflatherisobtainedwhichwilllastfor1to2minutes,thewaterissoft.Ifno
latherisobtained,orifthelatherdoesnotlast,thewaterishard.
NOTE
1.Rinsetheshakingbottlecleanwithsoftwaterthoroughly.
2. The soap solution bottle should be kept tightly stoppered. It will otherwise evaporate and
givefalsereading.
50

CALCIUMHARDNESS
The water sample is titrated against EDTA solution using Murexide indicator (ammonium
purpurate)inhighlyalkalinemedium.
REAGENTS
1.Approximately1Nsodiumhydroxidesolution
2.0.01MstandardEDTAsolution
3.Murexideindicator
PROCEDURE:Prepareacolourcomparisonblankinawhiteporcelainbasinbystirring2.0mlof
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 unchanging purple
colour.Pipetteintoasimilarbasin50ml.ofsample,neutralizethealkalinitywith0.02N.HCl,
boilfor2to3minutestoexpeltheCO2andcooltoroomtemperature.Add2.0ml1NNaOH,or
a volume sufficient to produce a pH of 12 to 13 and mix. Add 0.2 g of powdered indicator.
StirringconstantlytitratewithstandardEDTAsolutiontothecolourofcomparisonblank.Check
theendpointbyadding1or2dropsoftitrantinexcesstobesurethatnofurtherdeepeningof
thepurplecolourtakesplace.
Calculations
Calcium,asCaCO3,mg/L=(A)xCx1000mlofSample
WhereA=mlofEDTArequiredfortitrationofsample
B=mlofEDTArequiredforblank
C=mgofCaCO3equivalentto1.0mlofEDTA
NOTE:TheonlyseriousinterferencewiththeEDTAtitrantofcalciumisthatoforthophosphate
ion. If the calcium hardness exceeds about 60 ppm CaCO3, and the concentration of
orthophosphateis10ppm,ormore,calciumphosphateisprecipitatedwhenthepHisraisedto
12,givinglowresults.
Phosphate,ifpresent,canberemovedbyionexchange.WATERTREATMENTPLANT
51

8.SILICA
Thesilicacontentofnaturalwaterwillvarytoaconsiderableextentdependingonthelocality.
The presence of silica is particularly objectionable inwater used for boiler feed purpose as it
mayleadtotheformationofharddensescale.Inaddition,averyseriousproblemencountered
inhighpressureoperationsisthedepositionofsiliceousmaterialsonturbineblades&super
heaters.Thegravimetricmethodisthestandardapplicableabove20mg/litSiO2content.This
methodshouldbefollowedforstandardizationofstandardsilicatesolutionusedincolorimetric
methods.Theheteropolybluecolorimetricmethodisadaptablefortherangeof0to2mg/lit
SiO2 & yellow molyb silicate method in the range of 0 to 20 mg / lit. Reagent blank should
alwaysbeusedinallthethreemethods.
METHODAGRAVIMETRICMETHOD
PROCEDURE
Takeasampletocontainatleast10mgofSiO2.Ifnecessaryclarifybyfiltration.Acidifywith2
or 3 ml of conc. HCl & evaporate to dryness in a platinum dish on a water bath. At regular
intervalsadd2ormoreportionsof2to3mlofconc.HClasanadditionalquantityofsampleis
addedtothedish.Baketheevaporatedresidueinanovenad110Deg.Cforaboutanhour.
Add5ml.ofconc.HClwarm&add50mldistilledwater.Loosentheclingingresiduefromthe
sides&thebottomofthedish&filtercollectingthefiltrate.Washthedish&residuewithhot
1 : 50 HCl & finally with distilled water until the washings are free from chloride. Return the
filtrate & washings to the platinum dish & again evaporate to dryness. Repeat as previously,
collectingtheresidueinanotherfilterpaper.Drythetwofilterpaperswithresidue,burn,ignite
at 10001200 Deg.C in a platinum crucible & weigh. Moisten the residue with a few drops of
distilledwater;add2drops ofH2SO4&10ml. 48%HF.Cautiouslyevaporatetodrynessona
steam bath in a fume cupboard. Again ignite at 10001200 Deg.C Cool & weigh. Carry out a
blank.
52

Calculations
(AB)(CD)x1000SiO2,asSiO2mg/lit=mlofsample
WhereA=Weightofcrucible&sampleresidueinmg.afterfirstignition
B=Weightofcrucible&sampleresidueinmg.afterHFtreatment&secondignition.
C=Weightofcrucible&blankresidueinmg.afterfirstignition
D=Weightofcrucible&blankresidueinmg.afterHFtreatment&secondignition.
METHODBREACTIVESILICA
COLOMETRICESTIMATIONOFSILICA
AmmoniummolybdateatapproximatelypH1.2reactswithsilica&anyphosphatepresentto
producehteropolyacids.Oxalicacidisaddedtodestroythemolybdophosphoricacidbutnot
themolybdosilicicacid.Evenifphosphateisknowntobeabsent,theadditionofoxalicacidis
highlydesirable&isamandatorystep.Theintensityoftheyellowcolourisproportionaltothe
concentrationofmolybdatereactivesilica.Theyellowmolybdosilicicacidisreducedbymeans
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 at least one of its forms ,
silicadoesnotreactwithmolybdateeventhoughitiscapableofpassingthroughfilterpaper&
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 molybdatereactive " silica. Such
increaseinsilicacontentwillgiverisetoscaleproblem.
PLANT
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
solutionaftermolybdatereagentovercomeshighFe&Caconcentrations.
53

COLORIMETRICESTIMATIONOFSILICA020PPMSiO2
REAGENTS
1.Ammoniummolybdatesolution
2.2Nsulphuricacid
3.10%oxalicacid
4.Lovibondcomparatorwithstandardsilicadisc.
PROCEDURE
1.FilloneoftheNesslertubestothe50ml.markwithsample&placeinthelefthand
compartmentofLovibondcomparator.
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, adds 4 ml. of oxalic acid & again mix
thoroughly.Placeintherighthandcompartment&allowtostandfor10minutes.
3.Standthecomparatorfacingauniformsourceoflight;comparethecolourofthesamplein
thedisc.Rotatethediscuntilthecoloursarematched.
Calculations
SiO2inmg/litasSiO2=Discreadingx20
NOTES
1. Should the colour in the test solution be deeper than the deepest standard , a fresh test
shouldbecarriedoutusingasmallerquantityofsample&dilutingto50ml.withdistilledwater
beforeaddingtheREAGENTS.
TREATMENTPLANT
2.Silicafreewater:
3. Distilled water from an all metal "Still " or water which has been passed successively
throughamixedbeddeionizationunit&stronglybasicanionexchangersuchasTulsionA27MP
unit regenerated with a regeneration level of 320 gm per liter NaOH has been found to be
suitable.Prepare&storeinapolyethylenebottlealargebatchofwatercontainingnotmore
than 0.005 ppm SiO2, determine the silica content of water by treating it as a sample. This
waterisusedtopreparereagents&standards,&todilutesampleswhennecessary.
54

COLOMETRICESTIMATIONOFSILICA02PPMSiO2
REAGENTS
1.Acidifiedammoniummolybdatesolution.
2.10%oxalicacid.
3.Aminonaphtholreducingagent.
4. Lovibond comparator with standard silica disc or spectrophotometer suitable for
measurementat815microsiemenswavelength.
PROCEDURE
1. Fill one of Nessler tubes to the 50 ml. Mark with sample, & place in the left hand
compartmentofLovibondcomparator.
2. Fill the other Nessler tube with 50 ml. of sample, at 25 30 Deg.C. Add 2 ml. of acidified
ammoniummolybdatesolution.Mixthoroughly,standfor5minutes.Add4mlofoxalicacid&
mixwell.Then2ml.ofreducingagent,mixwellcomparedwiththatofablankcomprisingthe
same water without reagents, using Lovibond comparator or read the absorbance using a
spectrophotometer (wave length 815 micro siemens). Compute the silica content from the
standardgraphpreparedfromthestandardsilicasolution.
TREATMENTPLANT
55

METHODC:
DETERMINATIONOFTOTALSILICA(MOLYBDATEREACTIVE&UNREACTIVESILICA)
The molybdate unreactive silica is converted to the reactive form or state by digesting the
samplewithsodiumbicarbonate.
REAGENTS
1.Sodiumbicarbonate.
2.1Nsulphuricacid.
3.Otherreagentsasperpreviousmethod.
PROCEDURE
Take100ml.ofsampleorlesserquantity(20100microgramsSiO2 )butmadeupto100ml.
distilledwaterinaplatinumdish.Add200mg.ofsilicafreesodiumbicarbonate&digestona
streambathforonehour.Cool&addslowly,withstirring,2.5ml.sulphuricacid(1N).Donot
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.
TREATMENTPLANT
56

9.CHLORIDE
METHODASILVERNITRATEMETHOD
Chlorideisdeterminedbytitrationwithstd.silvernitratesolutioninthepresenceofpotassium
chromateindicatoratneutralPh.Silverchlorideisprecipitatedandattheendpointredsilver
chromateisformed.
REAGENTS
1.NStd.silvernitratesolution
2.Potassiumchromateindicator
3.PhenolthaleinIndicatorsolution
4.NNitricAcidsolution
5.Calciumcarbonate
PROCEDURE
Take50ml.or100mlofsampleinanErlenmeyerflask.Addfivedropsofphenolthalein.Ifthe
sample turns pink, Neutralize 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
reagentsrequiredtoformsilverchromate.
Calculation
ChlorideasCaC03mg/lit=mlofAgN03*1000mlofsampletaken
NOTE
1.Ifsampleishighlycoloured,addAl(OH)3suspension,mixthenletitsettle,filterandcombine
filtrateandwashing
2.Ifsulphide,sulphiteandthiosulfatearepresent,add1mlH2O2andstirfor1Min.
3.Bromide,iodideandcyanideregisterasEqvt.Chlorideconcentration.
WATERTREATMENTPLANT
57

METHODB
Chlorideioncanbetitratedwithmercuricnitratebecauseoftheformationofsoluble,slightly
dissociatedmercuricchloride.InthePhrange2.3to2.8diphenylcarbozoneindicatestheend
pointofthistitrationbyformationofpurplecomplexwithexcessofmercuricions.Tokeepthe
solutioninPhrange+/0.1PhunitnickelnitratewithHNO3isadded.
REAGENTS
1.0.02NMercuricnitrateStd.solution
2.Diphenylcarbozoneindicatorsolution
3.4Mnickelnitratesolution
PROCEDURE
Take50ml.ofsample,add1ml.ofdiphenylcarbozoneindicatorsolution.Add1ml.ofnickel
nitrate solution. Titrate against Std. mercuric nitrate solution to colour change of green to
violet.CarryoutblanktitrationwithDMWater.
Calculation:
ChlorideasCaCO3mg/lit=(AB)*1000ml.ofsample
Where
A=mloftitrantrequiredforsample
B=mloftitrantrequiredforblank.
58

METHODCCHLOROMETRICMETHODFORCHLORIDE(MERCURYTHIOCYNATEMETHOD)
This method depends upon the displacement of thiocynate ion from mercuric thiocynate by
chlorideion.Inthepresenceofferricion,ahighlycolouredferricthiocynatecomplexisformed
andtheintensityofitscolourisproportionaltotheoriginalchlorideionconcentration.
WATERTREATMENTPLANT
REAGENTS
1.Mercuricthiocynatesolution
2.Ferricammoniumsulphatesolution
3.Std.sodiumchloridesolution0.1mgCl/ml.
PROCEDURE
Take 1020 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
thiocynatesolution.Makeuptothevolume.Measuretheopticaldensityat460microsiemens
fromthecalibrationcurvefortheStd.,computethevalueforthesample.
Calculation
Chloride,asCLmg/lit=Microgramofchloridefromgraphml.ofsample
TREATMENTPLANT
LANT
59

10.OILSANDGREASE
OUTLINEOFTHEMETHOD
Theoils&greaseareextractedbyanorganicsolvent.Thesolventisdistilledoff&theweightof
theextractedmatterisdetermined.Someextractable,especiallyunsaturatedfats&fattyacids
Oxidize rapidly hence, special precautions regarding temperature & solvent vapour
displacementarenecessarytominimisethiseffect.
SAMPLING
Themostsatisfactorymethodofsamplingtwophaseliquidsistouseasamplingtubethatis
capableofwithdrawingacompletesectionofthewaterasitflowsinarectangularculvertor
trough,inmostinstances,however,waterwillhavetobesampledfromtheoutfallofthepipe
orfromastream&inthesecircumstancessomeofthewatershouldfirstbecollectedinalarge
cylindricalvesselhavingacapacityof10to15litres.Asectionalsamplingtubeshouldbeused
towithdrawthetestsamplefromthis.Asamplingtubesuitableforsamplingwater,thatdont
containhighlyviscousmatter(forexample,tar)consistofaheavygaugebrasstube,1m.long,
withanoutsidediameterof40mm.Overoneendofthetubeisfittedtothebrassbucketmade
fromapieceoftube50mm.long&sealedatoneend.Thebuckethasaninternaldiameterof
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
sidesofthemaintube.
Therodsaresoarrangedthatthetopofthebucketcanbewithdrawntoadistanceofnotless
than10cm.fromthebottomofthemaintube,&theyguidethebucketintoapositioncovering
theendofthetubewhenitispushedbackagain.Asuitablespringcatchisprovidedononeof
theguiderodssothatthebucketisautomaticallylockedintothetoppositionwhenitisraised
toitshighestpoint.Theopenendofthesamplingtubeisfittedwitharubberbung.Totakea
sectional sample, the spring catch is released & the bucket is drawn as far away as possible
fromtheendofmaintube.
60

Therubberbungiswithdrawnfromtheotherend.Thetubeisloweredverticallythroughthe
liquidtothesampleduntilthebottomofthebucketrestonthebottomoftheculvertANT
orofthevesselthathasbeenfilledwiththewater.Themaintubeisthenpusheddown,guided
bythebrassrods,tothelimitsofhistravel,whereuponthespringcatchlocksthebucketinthe
raisedpositioncoveringtheendofthetube.
Therubberbungistightlyinsertedintheopenend&thetubeiswithdrawn.Theoutsideofthe
sampleriswipedfreeofadheringliquidthebucket&thelowerpartofthetubeareinserted
Intoawidemouthedbottleofsuitablecapacity,&therubberbungisremoved. Thesample
sectionoftheliquidwillflowintothebottleleavingasmallquantityofliquidinthebucket.The
tubeisthentilted,sothatthisliquidisaddedtothemainbulkofthesample.Theoperationis
repeateduntilsufficientquantityhasbeencollected.Atleast2425mm.ofairspaceshouldbe
leftbetweenthetopleveloftheliquid&thestopperofthebottle.
STORAGEOFSAMPLE
Since many oils & hydrocarbons are utilised by bacteria, storage is obviously detrimental.
However,ifitbecomesnecessarytostorethesamplebeforeanalysisistakenup,thesamples
shouldbeacidifiedwithdilutesulphuricacid(1:1),5ml/lit.,ofthesample,toinhibitbacterial
activity.
APPARATUS
SEPARATINGFUNNELSOf1.5to2litrescapacity.
Thestopperorstopcockshouldnotbelubricatedwithmattersolubleinpetroleumether.
REAGENTS
1.DiluteHydrochloricacid1:1
2.LightPetroleum(Petroleumether)boilingrange40to60C.
61

PROCEDURE
Placethesample,usually1litre,inaseparatingfunnelofsufficientsizetoallowtheadditionof
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
petroleumether&addtheetherwashingstotheseparatingfunnel.Addanadditional25ml.of
ether to the sample bottle, rotate the ether in the sample bottle & add the ether to the
separatingfunnel.Shakevigorouslyfor2minutes.Allowtheetherlayertoseparate.Withdraw
the aqueous portion of the sample into a clean container, & transferthe solvent layer into a
clean,tarreddistillingflaskcapableofholdingatleast3volumesofsolvents(SeeNote).
If a clear ether layer cannot be obtained, filter the solvent layer into tarred distilling flask
throughafunnelcontaininganethermoistenedfilterpaper.Thefilterpapershouldbewashed
withpetroleumeitherafterfoldingtoavoidinclusionofskinoils.Useasmallfunnelandfilter
paperaspractical.
NOTE
Whiletransferringthesolventlayerfromtheseparatingfunnel,asmallquantityofitremainsat
thestemoftheseparatingfunnel,itisadvisabletowashitwithafewmillilitersofsolventand
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
solventlayertoseparateanddiscardtheaqueousphase.Addtheetherwashingstothetarred
distilledflask.Afteralltheetherfromthe2extractionsandthefinalrinsingareincludedwash
downthefunnelandfilterpapertwicewithfresh5ml.incrementsofthepetroleumether.
Distil of all but approx. 10 ml. of the ether extract on a water batch or an electric heating
mantle,observingnecessarysafetyprecautionsandkeepingtheheatsourceatabout70Degc.
Disconnect the condenser and boil of the remaining the solvent from the tarred flask at the
sametemp.Dryonawaterbathorstreambath.Whendry,laytheflaskonitssidetofacilitate
theremovalofsolventvapour.IntroduceAprrox.3volumesofdryilluminatinggasorNitrogen
intoflasktodisplacesolventvapour.Coolindesiccatorfor30Min.andweigh.
TREATMENTPLANT
62

Calculation
Oilsandgrease,mg/lit=
1000W
V
Where,
W=weightinMg.oftheresidueintheflask
V=volumeinml.ofthesampletakenforthetest.
ExpresstheresulttothenearestMg
63

11.RESIDUALCHLORINE
(ORTHOTOLYDINEARSENIMETHOD)
Chlorinerapidlyoxidisesortholydine(3,3dimethybenzdine)tothecorresp.hologuinonewhich
isintenselyyellow.Thisprovidesasensitivetestforavailablechlorine.
Thetestissubjecttointerferencebyproductionoffalsecolourforchlorinewhennitrite,ironor
manganeseispresentinthewater.Thefalsecolourproducedwithorthotoludinebyinterfering
substancepresentinthepresenceofsodiumarsenitebutthecolourduetoresidualchlorine
doesnot.
Thetestpermitsthemeasurementoftherelativeamountsoffreeavailablechlorine,combined
available chlorine, and colour due to interfering substances. The temperature of the sample
shouldneverbeabove20degC.
REAGENTS
1.Phosphatebuffersolution0.5%
2.Potassiumdichromatesolution
3.PTolydinereagent
4.5%sodiumarsenitesolution
PROCEDURE
1.VISUALSTANDARDS
Pipetteinto100ml.Nesslercylinder1,2,3etc.mlofdilutechromatedichromatesolutionan
dilute to 100 ml with phosphate . Protect the solutions from dust, evaporation and direct
sunlight.TheseStds.correspondtoresidualchlorineEqvt.Of0.01,0.02,0.03....mg/litResp.
2.FREEAVAILABLECHLORINE
In a nessler tube take 0.5 ml of Toludine reagent and 9.5 ml of sample. Mix quickly and
thoroughlyandadd0.5mlofNaAS02followedbymixing.ComparethecolourwithStd.(Call
thisreadingasA).
3.TOTALAVAILABLERESIDUALCHLORINE
Inanesslertubetake0.5mlof0Toludinereagentand9.5mlofsample,mixandcomparethe
colourwithstandardscolourinsimilartubeafter5Min.(CallthisreadingasB).
64

4.BLANK
Prepareablank9.5mlsampleand0.5mlNaAS02solutionandcomparethecolourwithstd.
colourimmediatelyandafter5Min.(CallthisreadingasC1andC2).
Calculation
Freeavailableresidualchlorine=ReadingABlankC1
Combinedavailableresidualchlorine=ReadingBBlankA
Totalavailableresidualchlorine=ReadingBBlankC2
WATERTREATMENTPLANT
65

12.REAGENTS
1.STANDARD1NHCLSOLUTION
Dilute83ml.ofconc.HCL(about11Nsolution,specificgravity1.1741.189)to1lit.
Withdistilledordeionisedwater.Standardisewithstandardsodiumcarbonatesolution.
2.STANDARD0.1NHCLSOLUTION
Dilute8.3ml.ofconc.Hclor100ml.of1Nsolutionto1000withdistilledwater.
Standardizewithstandardsodiumcarbonatesolution.
3.STANDARD0.02NHclSOLUTION.
Dilute200ml.of0.1Nstandardacidto1000ml.withdistilledwater.
Standardizewithstandardsodiumcarbonatesolution
4.STANDARD1NH2SO4SOLUTION
Dilute28ml.ofconc.H2SO4(about36Nsolution,specificgravity1.8341.836)to1lit.
Withdistilledordeionisedwater.Standardisewithstandardsodiumcarbonatesolution.
5.STANDARD0.1NH2SO4SOLUTION
Dilute2.8ml.conc.H2SO4to1lit.withdistilledordeionisedwater.
6.STANDARD0.02NH2SO4SOLUTION
Dilute200ml.of0.01NH2SO4to1lit.withdistilledordeionisedwater.
7.1.0NHNO3SOLUTION
Dilute64ml.ofconc.HNO3(about15Nsolution,specificgravity1.4091.418)to1lit.
withdistilledordeionizedwater.Standardizewithstandardsodiumcarbonatesolution.
8.STANDARDI.0NNAOHSOLUTION
Dissolve 40.0 gm. of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water .
Standardizewithstandardacidsolution.
9.STANDARD0.1NNAOHSOLUTION
Dissolve4.0gmsofNAOHto1.0lit.withcarbondioxidefreedistilledordeionisedwater.
Standardisewithstandardacidsolution.
66

10.STANDARDSODIUMCARBONATESOLUTION
(Approx.0.05N)Dry3 to5 gprimarystandardNa2CO3at250degC for4hours &coolina
desicator.
Weigh2.5+/0.2gms(tothenearestmg.)Diluteto1litrewithdeionisedordistilledwater.
11.STANDARD0.02NSILVERNITRATESOLUTION.
Dissolve3.3927gms.AgNO3indistilledwater&diluteto1lit.Standardiseagainst0.02NNaCl
standardsolution.
12.STANDARD0.02NSODIUMCHLORIDESOLUTION
Dry23gofprimarystandardNaClat140degCfor4hours&coolitinadesicator.
Weigh1.689gms(tothenearestmg.)Diluteto1litrewithdeionisedordistilledwater.
13.STANDARD0.02NMERCURICNITRATESOLUTION
Dissolve3.246gm.mercuricnitratein100mlof5%HNO3solutionand
makeupto1lit.withD.M.water.Standardisewithstandardsodiumcarbonatesolution.
14.STANDARDMERCURICTHIOCYANATESOLUTION
Weigh1gmHg(SCN)2&add100mlmethanol&mixtoobtainasaturatedsolution.
Storedaamberbottleinacoolplace.
15.FERRICAMMONIUMSULPHATE
Dissolve12gofFe(NH4)2(SO4) 212H2Oin100mlof9NHNO3 (580ml.ofconc.HNO3in1lit.of
water).Filterifnecessary&storeinaamberbottle.
16.0.1MG/LIT.STANDARDCHLORIDESOLUTION
Dissolve1.1648gNaClin1lit.ofdistilledordeionisedwater.
17.AMMONIABUFFEROHpH10
Dissolve 16.9 g of ammonium chloride in 143 ml. conc. ammonium hydroxide (NH4OH). Add
1.25gofmagnesiumsaltofEDTA.(IfthemagnesiumsaltofEDTAisunavailabledissolve1.179
g disodium salt of EDTA & 780 mg. MgSO4.7H2O or 644mg. MgCl2.6H2O in 50 ml. distilled
water.)&diluteto250ml.withdistilledwater.
18.STANDARD0.01MSOLUTIONOFEDTA
Dissolve3.723gofdisodiumsaltofEDTAin1lit.ofdistilledordeionisedwater.
Standardisewithstandardcalciumsolution.
67

19.STANDARDCALCIUMSOLUTION
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&makeupto1lit.1ml.ofthesolutioncontains1mgofsulphates(asSO4)
20.STANDARDBARIUMCHLORIDESOLUTION
Dissolve2.443gofbariumchloride(BaCl2,2H2O)indistilledwater&diluteto1lit.
1ml.ofthissolutionisequivalentto0.36mg.ofsulphate(asSO4).
21.STANDARDPOTASSIUMIODATEIODATESOLUTION
Weighaccurately0.713gofpotassiumiodate&dissolveinabout150ml.ofdistilledwater.
Add7gofpotassiumiodate&0.5gofsodiumbicarbonate,whendissolved,dilutethesolution
toexactly1liy.
22.STANDARDIRONSOLUTION
Dissolve1.404gofferrousammoniumsulphateFe(NH4)2(SO4)2,6H2Oin50ml.distilledwater&
20ml.conc.H2SO4.Add0.1NKMNO4dropwisetoimpartafaintbutpersistentpinkcolour&
diluteto1lit.withdistilledeater.Dilute50ml.oftheabovestocksolutionto1lit.withdistilled
watertoformastandardsolutioncontaining0.01mg.fe/ml.
23.1,10PHENANTHROLINEMONOHYDRATESOLUTION
Dissolve0.1gin100ml.distilledwatercontaining2dropsconc.Hcl.
(Notmorethan0.1mg.Fecanbedetermined).
24.AMMONIUMACETATEBUFFERSOLUTION
Dissolve250gofammoniumacetatein150ml.distilledwater,add700ml.glacialaceticacid&
diluteto1lit.
25.AMMONIUMMOLYBDATESOLUTIONFORSILICAESTIMATION
75 g of ammonium molybdate is dissolved in 500 ml. of distilled water. To 322 ml. of 10 N
sulphuricacidthemolybdatesolutionisaddedgraduallywithconstantstirring.Thesolutionis
madeupto1lit.
26.10%OXALICACID
Dissolve10gms.oxalicacidin100ml.ofdistilledwater.
68

27.AMINONAPHTHOLREDUCINGAGENT
Dissolve0.5gof1amino2naphthol4sulphonicacid&1gm.ofsodiumsulphite(Na2SO3)in50
ml. distilled water, with gentle warming if necessary, add this to solution of 30 g sodium
metabisulphite(NaHSO3)in150ml.distilledwater.Filterintoplasticbottle.Dicardthesolution
whenitbecomesdark.prolongreagentlifebysortinginarefrigerator.
28.STOCKSILICASOLUTION
Dissolve4.73gofsodiummetasilicatenonhydrate(Na2SiO3,9H2O)inrecentlyboiled&cooled
water&dilutetoapprox.900ml.Analyse100.0ml.portionsbygravimetricmethod,adjustthe
remainderofthesolutiontocontain1.000mg./1SiO2.Storeinatightlystopperedplasticbottle.
29.STANDARDSILICASOLUTION
Dilute10ml.stocksolutionto1lit.withrecentlyboiled&cooledwaterthissolutioncontains
10mg/lit.SiO2or1ml.=10SiO2.Storeintightlystopperedplasticbottle.
30.AMMONIUMMOLYBDATESOLUTIONFORPHOSPHATEESTIMATION
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
molybdatesolutiontothisdistilledacid&dilutethewholeto1lit.
31.STANNOUSCHLORIDESOLUTION
Dissolve 2.5 gms. of fresh supply of stannous chloride (SnCl2,2H2O) in 10 ml. of conc. Hcl &
diluteto100ml.withdistilledordeionisedwater.Filterifitisturbid. Storethesolutionin a
coolplaceinaaspiratorbottlehavingclassstopcock.A5 mm.thicklayerofpuremineraloil
shallbefloatedoverthesurfaceofthesolutiontominimiseoxidation.Alwaysdrainoutalittle
ofsolutionoutofthestopcockbeforeuse.
32.STANDARDPHOSPHATESOLUTION
Dissolve 0.716 g of dry potassium dihydrogen phosphate (KH2PO4) in 1 lit. of distilled water.
Dilute100ml.ofsolutionto1lit.1ml.ofthissolution=0.05mgofphosphate(asPO4).
33.STANDARD0.1NPOTASSIUMPERMANGANATESOLUTION
Dissolve3.1608gofpotassiumpermanganate(driedat105degC)indistilledwatermadeupto
1lit.Thissolutionmustbestoredinthedark.
69

34.STANDARD0.1NOXALICACIDSOLUTION
Dissolve4.5018gofoxalicacidindistilledwater,makeupto1lit.
35.PHOSPHATEBUFFERSOLUTIONO.5M(FORFREECHLORINE)
Dissolve22.68gNa2HPO4&46.19gKH2PO4(bothdriedovernightat105degC)&diluteto1lit.
withdistilledwater.LetthissolutionageforNo.ofdays&filterifanyprecipitateappears.
36.PHOSPHATEBUFFERSOLUTION0.1M
Dilute200ml.of0.5Mfilteredphosphatebuffersolutionto1lit.
37.STOCKCHROMATEDICHROMATESOLUTION
Dissolve1.55gK2Cr2O7&4.65gK2CrO4in0.1Mphosphatebuffersolution.
38.DILUTECHROMATEDICHROMATESOLUTION
Dilute100ml.stocksolutionto1lit.with0.1Mphosphatebuffersolution.Ondilutionof1ml.
ofthissolutionto100ml.with0.1Mphosphatebuffersolutiongivesaveryclosevisualmatch
withtheyellowcolourproducedby0.01mg/lit.residualchlorine.
39.OTOLUDINEREAGENT
Dissolve1.35gofOtoludinedihydrogenchloridein500ml.distilledwater&addwithconstant
stirringtoasolutionof150ml.conc.Hclin350ml.distilledwater.
40.SODIUMARSENITESOLUTION
Dissolve5gofsodiummetaarsenitein1lit.distilledwater.
41.PHENOLPHTHALEININDICATORSOLUTION
Dissolve0.1gofphenolphthaleinin60ml.ofrectifiedspiritand
dilutewithdistilledwaterto100ml.
42.METHYLORANGEINDICATORSOLUTION
Dissolve50mg.methylorangepowderindistilledwater&diluteto100ml.
43.SCREENEDMETHYLORANGEINDICATORSOLUTION
Dissolve0.2gcrystallinemethylorangeinamixtureof25ml.ofmethylatedspirit&25ml.of
deionisedwater.Dissolve0.28gxylenecyanolFFinamixtureof25ml.ofmethylatedspirit&
25ml.deionisedwater.Mixthetwosolutionstogether.
70

44.5%POTASSIUMDICHROMATEINDICATORSOLUTION
Dissolve 50 g K2CrO4 in little distilled water. Add Silver Nitrate solution until a definite red
precipitateisformed.Letitstandfor12hr.filter&diluteto1litwithdistilledwater.
45.SODIUMTHIOSULPHATE0.1NSOLUTION
Dissolve25gmNa2S2O3,5H2O&diluteto1lit.withdistilledwater.
46.DIPHENYLCARBAZONEINDICATORSOLUTION
Dissolve0.4gofdiphenylcarbazonein100ml.of95%ispropanol
47.4MNICKELNITRATESOLUTION.
Dissolve1163gms.ofnickelnitrate(Ni(NO3)2,6H2O)in1lit.ofD.M.water.
48.ERIOCHROMEBLACKTINDICATORSOLUTION
a) Mix 0.5 g of sodium salts of Eriochrome Black T ( 1 hydroxy2naphthylazo)5 nitro2
naphthol4sulphonicacid)with4.5gmshydroxylaminehydrochloride.
Dissolvethismixturein100ml.of95%ethylorisopropylalcohol.
b)Mixtogether0.5gdye&100gNaCltoprepareadrypowdermixture.
49.MUREXIDEINDICATORSOLUTION
a)Dissolve150gofMurexide(ammoniumpurpurate)in100gofabsoluteethyleneglycol.
Watersolutionofthedyeisnotstableforlongerthanaday.
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.STARCHINDICATORSOLUTION
Dissolve 5 gms of starch & 0.01 gms of mercuric iodide with 30 ml. of cold distilled water &
slowlypouritwithconstantstirringinto1lit.ofboilingdistilledwater.Boilfor3min&allowit
tocoolthendecantoffthesupernatantclearliquid.
51.HYDROXYLAMINEHYDROCHLORIDESOLUTIONFORFe
Dissolve10gms.NH2OH&HClin100ml.distilledwater.
71
5.2DAILYLOGSHEET
S.NO
1
2
3
4
5
INLET
PARAMETERS
Pressure
Temperature
DPTacrossvessel
DPTacrossbasketfilter
FlowRate
OUTLET
S.NO
PARAMETERS
pH
Conductivity
Turbidity
Oil&Grease
Silica
Chlorides
INLET
OUTLET
72
6.P&IDFORACF
P&IDFORPOWERPLANT:
73

P&IDFORAMMONIAPLANT:
74
REFILL
RINSE
AIRBLOWER
ACFB1
CONDENSATE
WATEROUTLET
VALVE
VM
CONDENSATE
WATERINLETVALVE
NC
VM
NC
DRIVE
DRIVEDESCRPTION
TAG
VM26 BLOWERDISCHARGE
NC
STEAMINLET
AIRRELEASE
VM12
NC
VM30
RINSEOUTLET
VM6
NC
LEGEND
NC
VM4 BACKWASHOUTLET
NC
AIRINLET
BACKWASHINLET
VM3
NC
SERVICEMODE
VM5
SERVICEOUTLET
VM2
STEPNO
REFDOC:
1)PANDIDIAGRAMFOR
SOFTENERPLANTPACKAGE
DRG.NO.WTBAA00054REV03.
NC
SERVICEINLET
VM1
STEPDESCRIPTION
ACF
STEP
TIMEIN
MINS
VALVE VALVE
POSITION TAG VALVEDESCRPTION
S.NO
7.OPERATIONPROCEDUREFORACTIVATEDCARBON(ACF)
SERVICE
1200
BACKWASHMODE
DRAINDOWN
AIRSCORING
STEAM
BACKWASH
SETTLEBED
REFILL
FINALRINSE
OFF
1
2
3
4
5
6
7
8
2
5
10
10
2
2
10
AIRRELEASE
M/S.THERMAXLTD,THERMAX
HOUSE,NO.4.MUMBAIPUNE
ROAD,SHIVAJINAGAR,
PUNE.411005.
ISSUEDFOR
INFORMATION
SHEETNO.1
NCVALVEPOSITION
NORMALLYCLOSE
- VALVE OPEN CONDITION
RMOTORTORUNINPARTICULAR
STEP
CLIENT:IFFCO,PHULPURUNIT,ALLAHABAD,UTTARPRADESH.
PROJECT:ACTIVATEDCARBONFILTERUNITFORAMMONIA&POWERPLANT
75
8.TOWHOMCONTACT
ServiceManagerRegionalOffice
SOUTHERN REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET,
CHENNAI-600018 TEL : 044 - 24353831 (4LINES); FAX : 044 - 24353841;
Email : [email protected]
NORTHERN REGION
THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT
LOK, NEAR PRIYA CINEMA, NEW DELHI 110 057
TEL:011-26145319 FAX:011-26145311; Email: [email protected]
EASTERN REGION
THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7,
CAMAC STREET, KOLKATA;TEL:033-22826711/12/13; FAX:033-22826796;
Email: [email protected]
WESTERN REGION
THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE
ROAD, WAKADEWADI, PUNE 411 003. TEL:020- 25541010 FAX:020- 25542235
Email: [email protected]
Corporate Regional Manager
SOUTHERN REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET,
CHENNAI-600 018 TEL:044-24353831(4LINES) FAX:044- 24353841
Email:[email protected]
NORTHERN REGION
THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT
LOK, NEAR PRIYA CINEMA, NEW DELHI 110 057
TEL:011-26145319 FAX:011-26145311 Email:[email protected]
EASTERN REGION
THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7,
CAMAC STREET, KOLKATA. TEL:033-22826711/12/13 FAX:033-22826796
WESTERN REGION
THERMAX LIMITED, DHANRAJ MAHAL, 2ND FLOOR,
CHATRAPATI SHIVAJI MARG, NEAR REGAL CINEMA,
GATEWAY OF INDIA, COLABA, MUMBAI- 400 039 TEL:022- 22045391 FAX:022-22040859
Service Manager Head Office
THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD,
WAKADEWADI, PUNE 411 003. TEL:020- 25541010 FAX:020- 25542235 Mobile : 98230 82588
Divisional Head THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE
ROAD, WAKADEWADI, PUNE 411 003. TEL:020-25541010 FAX:020- 25542235
Formoreinformationvisitwww.thermaxindia.com.
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134