THERMAXLTD | WATER&WASTESOLUTIONS

DM PLANT
Plant Configuration is described below:

CLEAR WATER Æ[DMF]Æ[ACF]Æ[SAC]Æ[DGT]Æ[SBA]Æ[MB]ÆUtility

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 SAC MB
ACF SBA

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).

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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 µS/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 PLANT DETAILS (D.M. PLANT)

TREATMENT BETWEEN CHEMICAL
UNIT FLOWS REGN. CONSUMPTION
RESINS
MARK MA NORMAL CAP TIME PER REGN.
NOS. X.
M3/Hr M3 Hour 100% LITERS
DMF1 - - -- - -- --
ACF1 - - -- - - -

SOFTENER - 29.0 - - 166 kg – NaCl 1035 LTRS. – T40

Na
SAC - 13.0 260 20 79 kg – HCl 1116 LTRS – T42H
(ACTIVE)
79 LTRS – T42H
(INERT)
SBA - 13.0 260 20 104 kgs NaOH 1355 LTRS- A23CL
(ACTIVE)
133 LTRS. – A23CL
(INERT)
MB - 13.0 1820 140 7.2 kgs HCL 90 LTRS – T42
9.5 kgs NaOH 136 LTRS – A23

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2.2 UNIT DETAILS

Sr. DESCRIPTION MARK. SIZE/ CAP. Nos
No . REMARKS
Off.
1 CHLORINE DOSING CDT CAP: 100 LTRS, 1 MS
TANK
2 CHLORINE DOSING CDP 0-4 LPH @ 3.5 KG 1 ASIA LMI
PUMP
3 COAGULANT CADT CAP.:- 500 LTRS 1 MS
DOSING TANK.
(ALUM) (WITH
AGITATOR)
4 COAGULANT CADP 0-30 LPH @ 3.5 KG 1 ASIA LMI
DOSING PUMP
(ALUM)
5 LIME DOSING TANK TLM CAP.:- 500 LTRS 1 MS

6 LIME DOSING PUMP PLM 0.5 M3 @ 3.5 KG 1 CI-

CENTRIFU
GAL
7 POLY – TPE CAP.:- 500 LTRS 1 MS
ELECTROLYTE
DOSING TANK
(WITH AGITATOR)
8 POLY ELECTROLYTE PPE 0-30 LPH @ 3.5 KG 1 ASIA LMI
DOSING PUMP
9 HIGH RATE SOILD HRSCC 8.0 M DIA X 3.8 M 1 RCC – BY
CONTACT SWD CLIENT
CALARIFIER
10 HRSCC INTERNALS HRSCC – SUITABLE FOR 1 MS
SET – FLOW INT ABOVE
90M3/HR
11 CLARIFIED WATER CWT - 1 RCC – BY
STORAGE TANK CLIENT
12 DUAL MEDIA FILTER VERSADMF 2000 DIA X 2000 1 MSEP
(WITH MnO2 LAYER) HOS
13 ACTIVATED CARBON VERSAACF 2000 DIA X 2000 1 MSEP
FILTER HOS
14 STRONG ACID SAC 1000 DIA X 2500 1 MSRL
CATION HOS
EXCHANGER-
COUNTER CURRENT

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CONT…………UNIT DETAILS

Sr DESCRIPTION MARK. SIZE/ CAP. Nos

. . REMARKS
N Off.
o
15 ACID MEASURING MHL 1 CAP.:- 300 LTRS 1 MSRL
TANK (SAC)
16 DEGASSER TOWER DGT 600 DIA X 2500 1 MSRL
HIGH
17 DEGASSED WATER SDG CAP.:- 4 M3 1 MSRL
STORAGE TANK
18 DEGASSER AIR BDG 305 M3/HR @ 100 1 CI
BLOWER MMWC
19 DEGASSED WATER PDG 13 M3/HR @ 35MWC 1 SS – 316 –
TRANSFER PUMP – KSB
SS316
20 STRONG BASE SBA 1200 DIA X 2500 1 MSRL
ANION EXCHANGER HOS
– COUNTER
CURRENT
21 ALKALI MEASURING MAK 1 CAP.:- 350 LTRS 1 MS
TANK (SBA)

22 MIXED BED MB 600 DIA X 1600 HOS 1 MSRL

EXCHANGER
23 ACID MEASURING MHL 2 CAP.:- 100 LTRS 1 MSRL
TANK – MB
24 ALKALI MEASURING MAK 2 CAP.:- 100 LTRS 1 MS
TANK – MB

25 MIXED BED BMB 31.1 M3/HR @ 0.45 1 CI

BLOWER KG /CM2
26 PH DOSING PUMP PHP 0-6 LPH @ 3.5 KG 1 ASIA LMI
27 PH DOSING TANK PHT CAP.:- 100 LTRS 1 MS
28 SOFTNER SOFTNER 1100 DIA X 2500 1 MS
(DOWNFLOW) HOS
29 BRINE MEASURING MBR CAP.:- 800 LTRS 1 MSEP
TANK

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2.3 INSTRUMENT DETAILS

MARK DESCRIPTION NOS MAKE

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

2.4 RAW WATER ANALYSIS

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

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2.5 TREATED WATER QUALITY

TREATED WATER QUALITY (HRSCC O/L)

SUSPENDED SOLIDS <25 PPM
TURBIDITY < 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 7.5 – 8.5
TDS < 20 PPM
TREATED WATER QUALITY (MB O/L)
T.D.S. < 1.0 PPM
PH 6.2 – 7.2 BEFORE CORRECTION
PH 8.8 – 9.2 AFTER CORRECTION
CONDUCTIVITY < 1MICROSIEMENS / CM
SILICA < 0.02 PPM
TOTAL IRON < 0.01 PPM (MAX)
TREATED WATER QUALITY (SOFTENER O/L)
TDS SAME AS FEED WATER
HARDNESS COMMERCIAL ZERO.

2.6 OUR TREMINATION POINTS

MARK DESCRIPTION SIZE FLOW PRESSURE CONN.

NB M3/hr Kg/cm2 STD
A HRSCC INLET 125 90.0 1.0 ALL FLANGES
B HRSCC DRAIN 80 2-3 ATM BS 10TD
C DMF INLET 125 90.0 3.5 SOFF & ONLY
D MB OUTLET TO 50 13.0 1.0 TERMINATION
SERVICE OR
E SOFTENET 65 29.0 1.0 MATCHING
OUTLET ANSI B 16.5
F ACF OUTLET 100 48.0 2.0 150 # RATING
TO PROCESS
G HRSCC OUTLET 200 90.0 1.0

NOTE: - MOTORS SHOULD BE SUITABLE FOR 60HZ.

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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

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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.

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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 hood’s 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. For machines with pipe shafts the tie rod spider and arm spider usually are integral with the
shaft and the spacer is not required.
2. 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.

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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. 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.)
2. 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.
3. Do not revolve mechanism in the reverse direction as the set collar on the worm shaft will
probably be forced out of place.

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LUBRICATION

1. 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.
2. Electric motors, gear motors and speed reducers should be lubricated in accordance with the
manufacturer’s instructions attached to the unit at the time of shipment. Particular care should
be paid to the manufacturer’s instructions as damage may result from over greasing and over-
oiling of the units. If such instructions are not found, they may be obtained directly from the
manufacturer.
3. 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.
4. Lubricate roller chain with SAE-140 oil in summer and SAE-90 in winter.

FINAL ADJUSTMENTS:

1. 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.
2. 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.
3. Check to make sure that all wiring is properly secured and protected and that all belt and chain
guards are in place.
4. Before filling tank for initial operation, carefully study the Operation Instructions provided.

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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.

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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:

i Alum + Lime + Polyelectrolyte

9 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.

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