WAHANG SARAN CO.

Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Reverse Osmosis PLANT

FOR
BAFT Steel Complex
Capacity: 190m3/hr(2*95m3/hr)
Project no.: 93-0901-2

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

1. INTRODUCTION

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

This proposal is prepared for installation of two skids of Reverse osmosis

plant with all accessories and including permeate water pumps and feed
pumps and sand filtration, carbon filter with back wash pumps and air blower
and all chemical dosing system required as in P&ID document. This proposal
prepared based on data collected by customer and it is confirmed that
motioned water analysis valid and SDI is less than 3. The Design recovery
of system is based on 75%.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.GENERAL SUPPLY AND CONDITIONS

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Subject : WATER TREATMENT PLANT

Item Content

INDEX

2. General Supply and Conditions

2.1 Design condition

2.2 Scope of Work
2.3 Exclusion
2.4 Attention

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.1 Design Condition

2.1.1 Raw Water Analysis

a) Raw water physical– chemical analysis

Design. TDS mg/l : 391

The design of the plant is based on the following raw water analysis :

Raw water parameters units Value

-Total Dissolved Solids [mg/l] 275

+
-Sodium as Na [mg/l] 55
2+
- Magnesium as Mg [mg/l] 9.6
-Calcium hardness [mg/l] 22
-Potassium as K+ [mg/l] 1.5
-Chlorides [mg/l] 10.7
-Sulphates [mg/l] 52.5
conductivity µS/cm 430
PH 7.8
Total Hardness as CaCo3 mg/l 95
Turbidity(as Koolin) NTU ≤3
Silica as SiO2 mg/l 0
M-Alkalinity as CaCo3 mg/l -

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.1.2 Treated Water Quality

* The permeate water quality requirement of the plant is as follows:

Permeate water parameters units Value
( Low Pressure Water)
- pH - 7-8
-TDS [Mg/l] 18.36
-Calcium as Ca [Mg/l] 0.47
-Sodium as Na [Mg/l] 6.02
-Chloride Cl [Mg/l] 6.92
-Sulphates as SO4 [Mg/l] 3.1
-Bicarbonate as HCO3 [Mg/l] 1.66
-Silica as SiO2 [Mg/l] 0.17
-Hardness max as(CaCO3) [Mg/l] 5
-Conductivity (max) µS/cm 30

Permeate water parameters units Value

(Steam Drum)
- pH - 9
-TDS [Mg/l] 18.36
-Calcium as Ca [Mg/l] 0.47
-Sodium as Na [Mg/l] 6.02
-Chloride Cl [Mg/l] 6.92
-Sulphates as SO4 [Mg/l] 3.1
-Bicarbonate as HCO3 [Mg/l] 1.66
-Silica as SiO2 [Mg/l] 0.17
-Hardness max as(CaCO3) [Mg/l] 5
-Conductivity (max) µS/cm 30

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Permeate water parameters units Value

( High Pressure Water)
- pH - 7-8
-TDS [Mg/l] 18.36
-Calcium as Ca [Mg/l] 0.47
-Sodium as Na [Mg/l] 6.02
-Chloride Cl [Mg/l] 6.92
-Sulphates as SO4 [Mg/l] 3.1
-Bicarbonate as HCO3 [Mg/l] 1.66
-Silica as SiO2 [Mg/l] 0.17
-Hardness max as(CaCO3) [Mg/l] 5
-Conductivity (max) µS/cm 30

Permeate water parameters units Value

( Potable Water)
- pH - 6.5-8.5
-Turbidity NTU ≤1
-Free Chlorine Cl2 [mg/l] 0.5-0.8
-Hardness max as(CaCO3) [mg/l] 75
-TDS (max) [mg/l] 500

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.2 Scope of Work

Scope of work in general is consisted of:

1. Basic and detail engineering of the plant including: process design, mechanical piping, electrical,
instrumentation, and civil information according P&ID and scope of supply.
2. Supply of material, procurement and manufacturing and erection and installation of plant equipment
according to the prepared P&I diagram, electrical single line, wiring, circuit diagram equipment data
sheet.
3. Inspection and shop testing of equipment (as per client approval).
4. Guarantee of the system for 36 month after delivery of equipment to site or 18 month after
installation whichever soon.
6. Supply of spares and spare parts for two years operation and start-up and first filling .
7. Supply of piping materials, control cables and cable trays in the battery limit
8. Preparation and supply of detail design documents and drawings as per item 1, erection,
commissioning, operation and maintenance instructions.
9. All necessary field instruments, as per instrument data sheet and P&I diagram.
10. Civil detail design.
12. Supply of chemicals for commissioning (one week) operation.
14. Supply of all the pipes, fittings and valves for the system and all instruments, and equipment
mentioned in this proposal as shown in P&ID .
15. Issue of all drawings mentioned in item 1.
16. HVAC sizing for W.T.P. Hall and air conditioner split sizing for chemical room , operator
control room .
17.Design of lighting , earthing and fire fighting and fire detection.
18.Control and automation will be siemens step 7, 300 series and Cpu 315 (2DP) with one extra
profibus card
19. PLC will be siemens brand.
20. Two pieces industrial computer for monitoring and engineering .
21. Electrical panel will be withdraw able type.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.3 Exclusion

Our proposal dose not include:

1. Supply of auxiliary steam.
2. Cathodic protection (not required.)
3. Power supply
4. Any civil , fire-fighting ,lighting and earthing activity

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

2.4 Attention

1-The main power include the levels of 400V/ 3 phase, 50 Hz which is supplied by the
client at the incoming of plant space.
2-In this proposal assumes environment of site is non-hazardous area.
3- The IP of all electro motors will be IP55
.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

3.TECHNICAL AND PROCESS DESCRIPTION

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Subject : WATER TREATMENT PLANT

Item Content

3 Technical and Process Description for Reverse Osmosis system

3.1. Plant Description

1) Pre treatment :

a) Sand Filters :
In order to control the SDI of raw water, two horizontal filters
with low rate filtration considered.
b) Carbon Filter :
To control the amount of Iron in the feed water, two carbon filter
with enough EBCT considered.
2) Reverse Osmosis :

a)SBS dosing station

Injection of sodium bisulfate to the incoming water, for removing of residual chlorine
have been anticipated. Any residual free chlorine in the feed water to membranes will
destroy them in short time. Monitoring of residual chlorine content should be done by
operators daily.

b)Antiscalant dosing station

To avoid any precipitation of any hardness salts (i.e. Calcium, Magnesium,
Barium, and strontium ) antiscalant must be dosed.
When a scale inhibitor is used, it react with potential ions and form a complex
which is easily could be rejected by the concentrate flow. Since we are using new
antiscalant based on poly phosphonate , injection of any acid is not required.
c) Cartridge filters
We have selected two cartridge filter for total capacity of minimum 280m3/hr .

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

After chemical injection the water passes through cartridge filters and suspended
solids larger than 5 micron size are removed. At the outlet of cartridge filters pH
and free chlorine of feed water will be measured.
At the inlet and outlet of cartridge filters, one pressure indicator is considered.

f) High pressure pumps

The pressurized feed water to R.O is supplyed by high pressure RO feed pump.one
pump (P-601)(P-701) at about 21 bar pressure with capasity of 130m3/h,
supply water two each R.O unit.

g) R.O. SYSTEM:
Two R.O. Skids with a total capacity of 180 m3/hr as permeate water with
the recovery of 75 % has been foreseen.

h) Washing & Flushing system:

Beside of the RO skid, there is one central flushing/ washing tank with 5000 lit
capacity.
During plant operations this tank is always full of permeate water with the help of float
valve.
In case of any plant shut down, permeate water from the flushing tank will be
flowed into RO membranes by washing & flushing pump automatically. This
permeate flow will flush out the concentrate water outside the modules.
Periodically, three to four times per year, RO plant should be washed by cleaning
solutions like acidic or alkaline and biocide chemicals. Cleaning chemicals will
be prepared in the washing tank and re circulate via main cartridge filter through
the RO system.

3) Post Treatment

j) pH adjustment system :
In order to remove CO2 gas from permeate water , one chemical injection system has
been considered to raise pH.
h) Chlorine injection system

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

4. Chemical consumption table for 180m3/hr

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Type of chemical Dose (mg/lit) Daily

consumption(Kg/d)
Sodium Hypochlorite 1.5 17
Polyelectrolyte 1.5 10
SBS 3 23
Antiscalant(LF) 2 12.5

Soda (pH from 6.9 to 7.5) 10 43

Yearly consumption (Kg/year)

Basic chemical(G703) 3% 450Kg
Acidic (G37) 2% 450Kg
BIOCIDE 1% 50Kg

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5. PARTS AND EQUIPMENT

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Subject : WATER TREATMENT PLANT

INDEX

Item Content

5.1 RO Feed pump

5.2 Sodium Hypochlorite Dosing station

5.3 Polyelectrolyte Dosing System

5.4 Sand filters

5.5 Back wash pump

5.6 Backwash Blower

5.7 Carbon Filter

5.8 SBS dosing station

5.9 Antiscalant Dosing Station

5.10 Cartridge Filters

5.11 High Pressure Pump Station

5.12 Reverse Osmosis System

5.13 Membrane Chemical Cleaning System/flushing system

5.14 pH adjustment dosing station

5.15 Permeate water pump –High pressure

5.16 Permeate water pump- Low pressure

5.17 Potable water pump

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.1 RO FEED Pumps

Three complete pump station comprising pump, motor, suction-/ discharge header, isolating
valves, check valve(s), manometer(s) and accessories as described below:

Designation : RO FEED pumps

Quantity unit(s) : 3(2+1)
Type : Horizontal, centrifugal
Standard : ISO/DIN
Manufacturer : Grundfos Or Equal
Characteristic (each):
Pump:
Capacity m³/h : 134
Head M : 30
Absorbed power kW : -
Speed Rpm : 2936
Suction branch : Horizontal
Suction size DN : 80
Discharge branch : Horizontal
Discharge size DN : 65
Medium : Filtered water
Daily operation h/d : 24
Material of pump Body : Cast Iron
Material of impeller : Cast Iron
Material of shaft : SS

Motor:
Rated power kW : 15
Speed Rpm : 2936
Voltage/Frequency V/Hz : 380/50
Insulation class -

Accessories:
Manual isolating valves
Check valves
Manometer cocks
Piping
Bolts/ nuts/ washers
Controls(each)
two Manometer, 0-10bar, discharge

Location:
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Near to filtered water tank(feed water tank)

5.2 Sodium Hypochlorite Dosing station
One complete dosing station comprising pump, tank, mixer, suction line with integrated foot
valve, overflow valve, isolating valve, level switch and accessories as described below:

Designation : Sodium Hypochlorite dosing station

Quantity (dosing pumps) unit(s) : two (1+1)
Type : Diaphragm pump
Standard : ISO/DIN
Manufacturer : Jesco, Aldose , Prominent,lutz Or Equal
Characteristic:
a) Pump:
Capacity l/h : 10
Max. Back pressure Bar : 6
Daily operation h/d : 24
Materials:
Head : PVC
Diaphragm : EPDM
drive:
Rated power kW : 0.05
Voltage/Frequency V/Hz : 230/50
b) Tank:
Quantity unit(s) : Two
Type : Cylindrical
Material : PE
Volume L : 500

c) Mixer:
Type : Manual
Material, shaft : SS
Material, propeller : SS
Power KW : 0.25
Rotation Speed Rpm : -
Impeller diameter Mm : -
Shaft length mm : -
Manufacturer
Standard : ISO/DIN
Medium:
Type : Sodium Hypochlorite
Concentration % : 10

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

d) Accessories:
Isolating valve, PVC , discharge
Suction line with level switch
Nozzle injection assembly
Overflow valve, PVC, spring type
Location: : Chemical dosing station area

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.3 Polyelectrolyte Dosing station

One complete dosing station comprising pumps, tank, mixer, suction line overflow valve, isolating
valve, level switch and accessories as described below:

Designation : Polyelectrolyte dosing station

Quantity (dosing pumps) unit(s) : Two (1+1)
Type : Screw pump
Standard : ISO/DIN
Manufacturer : Wangen Pumpen Or Equal
Characteristic:
a) Pump:
Capacity l/h : 10
Max. Back pressure Bar : 6
Daily operation h/d : 24
Materials:
Head : PVC
Diaphragm : EPDM
drive:
Rated power kW : 0.55
Voltage/Frequency V/Hz : 400/50
b) Tank:
Quantity unit(s) : One
Type : Cylindrical
Material : HDPE
Volume L : 1000

c) Mixer:
Type : Manual
Material, shaft : SS
Material, propeller : SS
Power KW : 0.18
Rotation Speed Rpm : -
Impeller diameter Mm : -
Shaft length mm : -
Manufacturer
Standard : ISO/DIN
Medium:
Type : Polyelectrolyte
Concentration % : -

d) Accessories:
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Isolating valve, PVC , discharge

Suction line with level switch
Nozzle injection assembly
Overflow valve, PVC, spring type
Location: : Chemical dosing station area

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.4 Sand Filters

Two complete Horizontal sand filters comprising vessel(s), front piping, filter media, isolating
valves, sampling valve(s), manometer(s), flow meter(s), as described below:

Designation : Sand filter

Design standard) : DIN
Quantity unit(s) : 2
Operation / Stand by unit(s) : 2/0
Type : Horizontal pressure, automatic
Manufacturer : WAHANGSARAN Co.
Characteristic (each):
Medium flow m3/h : 140
Max. Flow m3/h : 160
Filtration rate m/h : 10
Max. pressure drop bar : 1
Backwash:
Max. water flow m3/h : 400
Max. duration of backwashing min : 30
Max. air flow m3/h : 600
Body:
Diameter mm : 2450
Side sheet length mm : 6500
Total length mm : -
Wall thickness mm : -
Type of formed ends : Deep dished end
Dish thickness mm : -
Operating pressure bar 4
Design pressure bar : 6
Material : RST37-2
Connections:
2 Manhole(s) DN : -
Inlet / outlet of filter(s) DN : -
Inlet / outlet of wash water DN : -
Air vent DN : -
Corrosion protection:
Inside : Epoxy resin on sand blast SA ½

Outside : Prime and top coat on sand blast

Accessories (each):
4 set Automatic isolating valves, DN 150, 200,80 pneumatic controlled
1 pc(s) Automatic air vent, PVC, ball type

1 set Front piping, Carbon Steel , DN 150, and DN 200

1 pc(s) Frame for fixing the front piping, steel corrosion protected
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

1 set Bolts/ nuts/ washers, galvanised steel

1 set Gaskets, EPDM, DN 150 - DN 200

Controls (each):
1 pc(s) Manometer, 0 - 10 bar, inlet header
1 pc(s) Manometer, 0 - 10bar, outlet

Distribution system (each):

Type of distribution : Lateral
Top distributor : Adjustable channel
Bottom distributor : With S 40 air scour nozzles
Nozzel plate thickness mm -
Filter bed(Two Layers)
Effective size mm : 0,6
Uniformity coefficient : 1,47
Supporting gravel, bed depth mm : 250
Operation: Automatic and manual operation via PLC

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.5 Back wash Pumps

One complete pump station comprising pump, motor, suction-/ discharge header, isolating valves,
check valve(s), manometer(s) and accessories as described below:

Designation : Back Wash pumps

Quantity unit(s) : 2
Operation / Stand by unit(s) : 1/1
Type : Horizontal, centrifugal
Model : -
Manufacturer : Grundfoss/Atura Or Equal
Characteristic (each):
Pump:
Capacity m³/h : 400
Head m : 10
Speed Rpm : 1470
Suction branch : Horizontal
Suction size DN : 200
Discharge branch : Vertical
Discharge size DN : 150
Impeller size mm :
Medium : Filtered water
Daily operation h/d : 24
Materials:
Casing : Cast iron
Shaft : S.S
Impeller : Cast iron
Motor:
Rated power kW : 18.5
Speed rpm : 1470
Speed control Yes/No : No
Number of poles : 4
Voltage/Frequency V/Hz : 400/50
Rated current at 380V A : 29.7
Protection : IP 55
Insulation class : F
Temperature rise : B

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Accessories:
4 pc(s) Manual isolating valves, DN 150 – DN200
2 pc(s) Check valves, DN 200
1 set Piping, DN 200 - DN 150
2 pc(s) Common base frame for pumps
1 pc(s) Sampling valve
1 set Bolts/ nuts/ washers, galvanized steel
1 set Gaskets, EPDM
Controls:
2 pc(s) Manometer, 0 - 4 bar, discharge

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.6 Back wash Air Blower

Two complete air blower station(s) each comprising blower, motor, silencer(s) isolating valve(s),
safety valve, manometer(s), flow indicator(s) and accessories as described below:

Designation : Air scour

Quantity unit(s) : 2(1/1)
Manufacturer : AERZEN Or Equal
Characteristic (each):
Blower block:
Capacity m³/h : 600
Pressure increase mbar : 500
Power consumption kW : -
Speed rpm : 2930
Temperature at suction °C : 25
Discharge size : -
Type of drive : Belt
Motor:
Model : ACC. to Manufacturer
Manufacturer : VEM,ABB Or Equal
Rated power kW : 15
Speed rpm : 2930
Speed control Yes/No : No
Number of poles :
Voltage/Frequency V/Hz : 400/50
Rated current at 400V A : -
Cos φ : -
Protection : IP 55
Insulation class : F
Temperature rise : B
Materials:
Casing : Cast iron
Rotor : Forged carbon steel
Accessories (each):
1 pc(s) Silencer, C-steel
1 pc(s) Manual isolating valve, CI, DN 100
1 set Check valve, CI, DN 100, wafer type
1 pc(s) Safety valve, CI, DN 80, spring type
1 pc(s) Frame for fixing the front piping, steel corrosion protected
1 set Bolts/ nuts/ washers, galvanized steel
1 set Gaskets, EPDM
1 pc(s) Base frame
1 pc(s) Belt protection casing
Controls:
1 pc(s) Manometer, steel, 0 - 1 bar,

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.7 Carbon Filter

One complete vertical carbon filter comprising vessel(s), front piping, filter media, isolating
valves, sampling valve(s), manometer(s), flow meter(s), as described below:

Designation : carbon filter

Design standard) : DIN
Quantity unit(s) : 2
Operation / Stand by unit(s) : 2/0
Type : Vertical pressure, automatic
Manufacturer : WAHANGSARAN Co.
Characteristic (each):
Medium flow m3/h : 140
Max. Flow m3/h : -
Filtration rate m/h : 26
Max. pressure drop Bar : 1
EBCT min : 5

Body:
Diameter mm : 2600
Side sheet length mm : 3500
Total length mm : -
Wall thickness mm : -
Type of formed ends : Deep dished end
Dish thickness mm : -
Operating pressure bar 3
Design pressure bar : 4
Material : RST 37-2
Connections:
2 Manhole(s) DN : 600
Inlet / outlet of filter(s) DN : 150
Inlet / outlet of wash water DN : 150
Air vent DN : 40
Corrosion protection:
Inside : Epoxy resin on sand blast SA ½

Outside : Prime and top coat on sand blast

Accessories (each):
4 set Automatic isolating valves, DN 150, 200,80 pneumatic controlled
1 pc(s) Automatic air vent, PVC, ball type

1 set Front piping, Carbon Steel , DN 150, and DN 200

1 pc(s) Frame for fixing the front piping, steel corrosion protected
1 set Bolts/ nuts/ washers, galvanised steel
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

1 set Gaskets, EPDM, DN 150 - DN 200

Controls (each):
1 pc(s) Manometer, 0 - 10 bar, inlet header
1 pc(s) Manometer, 0 - 10bar, outlet

Distribution system (each):

Type of distribution : Lateral
Top distributor : Adjustable channel
Bottom distributor : With S 40 air scour nozzles
Nozzel plate thickness mm -
Filter bed(One Layer)
Carbon height mm : 2200
Volume of carbon M3 : 10
Supporting gravel, bed depth mm : 100
Operation: Automatic and manual operation via PLC

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.8 SBS Dosing station

One complete dosing station comprising pump, tank, mixer, suction line with integrated foot
valve, overflow valve, isolating valve, level switch and accessories as described below:

Designation : SBS dosing station

Quantity (dosing pumps) unit(s) : two (1+1)
Type : Diaphragm pump
Standard : ISO/DIN
Manufacturer : Jesco, Aldose,Etatron, Doseuro Or Equal
Characteristic:
a) Pump:
Capacity l/h : 24
Max. Back pressure Bar : 4
Daily operation h/d : 24
Materials:
Head : PVC
Diaphragm : EPDM
drive:
Rated power kW : 0.12
Voltage/Frequency V/Hz : 230/50
b) Tank:
Quantity unit(s) : two
Type : Cylindrical
Material : PE
Volume L : 500

c) Mixer:
Type : Manual
Material, shaft : SS
Material, propeller : SS
Power KW : 0.18
Rotation Speed Rpm : -
Impeller diameter Mm : -
Shaft length mm : -
Manufacturer Jesco or turbo mixer

Standard : ISO/DIN
Medium:
Type : S.B.S
Concentration % : 10

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

d) Accessories:
Isolating valve, PVC , discharge
Suction line with level switch
Nozzle injection assembly
Overflow valve, PVC, spring type
Location: : Chemical dosing station area

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.9 Antiscalant Dosing Station

One complete dosing station comprising pump, tank, mixer, suction line with integrated foot
valve, overflow valve, isolating valve, level switch and accessories as described below:

Designation : Antiscalant dosing station

Quantity (dosing pumps) unit(s) : two (1+1)
Type : Diaphragm pump
Standard : ISO/DIN
Manufacturer : Jesco, Aldose,Etatron, Doseuro Or Equal
Characteristic:
a) Pump:
Capacity l/h : 24
Max. Back pressure Bar : 4
Daily operation h/d : 24
Materials:
Head : PVC
Diaphragm : EPDM
drive:
Rated power kW : 0.12
Voltage/Frequency V/Hz : 230/50
b) Tank:
Quantity unit(s) : One
Type : Cylindrical
Material : PE
Volume L : 500

c) Mixer:
Type : Manual
Material, shaft : SS
Material, propeller : SS
Power KW : 0.25
Rotation Speed Rpm : -
Impeller diameter Mm : -
Shaft length mm : -
Manufacturer Doseuro

Standard : ISO/DIN
Medium:
Type : Antiscalant
Concentration % : 1

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

d) Accessories:
Isolating valve, PVC , discharge
Suction line with level switch
Nozzle injection assembly
Overflow valve, PVC, spring type
Location: : Chemical dosing station area

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.10 Cartridge Filters

Two complete stainless steel cartridge filter(s), including, housing(s), filter element(s), inlet -
/outlet valve(s) and accessories as described below:

Designation : Two filters

Quantity unit(s) : 2(1+1)
Manufacturer :-
Model WAHANGSARAN
Characteristic (each):
Design flow m3/h : 280
Max. pressure drop Bar : 1.5
Medium to be filtered : Filtered water
Standard : ISO/DIN
Body:
Qty pcs 2
Diameter mm : 508
Total height with leg Mm : 2235
Operating pressure Bar : 3 bar
Hydraulic test pressure Bar : 14.3
Inlet/outlet size DN : 150/150
Connections:
Inlet / outlet of filter(s) inch : 6/6
Filtration degree µm : 5
Number of elements : 70
Length of elements inch : 40
Materials:
Housing :-
Manufacturer : WAHANGSARAN

Controls(each)
One Pressure gauge, inlet header
One Pressure gauge ,outlet header

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.11 High Pressure Pump Station

One complete pump station comprising pump, motor, suction-/ discharge header, isolating valves,
check valve(s), manometer(s)booster pumps, turbocharger and accessories as described below:

Designation : High pressure pumps

Quantity unit(s) : 2(1/1)
Type : Horizontal, centrifugal
Standard : ISO/DIN
Manufacturer : Grundfos, KSB Or Equal
Model -
Characteristic (each):
Pump:
Capacity m³/h : 130
Differential Head MH2O : 170
Motor power kW : 78.28

Speed Rpm : 2900

Suction branch : -
Suction size DN : -
Discharge size DN : -
Medium : Filtered water (Brackish water)
Casing material SS304
Impeller SS304

Daily operation h/d : 24

Piping
Low pressure PVC-U
High Pressure Stainless Steel 304
Motor:
Rated power kW : 90
Speed Rpm : 2900
Voltage/Frequency V/Hz : 400/50
Manufacturer ABB/ Or Equal
Accessories:
Manual isolating valves,
Manometer ,pressure switch low/High
Piping,

Controls(each) Bolts/ nuts/ washers,

one Manometer, 0-10 bar, inlet(suction)
one Manometer,0-40 bar, discharge of pump

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

one Pressure switch low, suction header

one Pressure switch high, discharge header
Temperature indicator, discharge
Variable Frequency Drive for pressure control in winter and summer time

Location
on the R.O skid

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.12. Reverse Osmosis system

Two complete independent skids, mounted on one frame each comprising , pressure vessels,
membranes, isolating valves for high- and low pressure side, sampling valves, manometers, flow
meters, conductivity meter, washing connections, as described below:

Designation : RO system
Quantity Unit(s) : Two skids
Standard : ISO/DIN
Characteristic(each skid of
RO)
Nominal permeate capacity m³/hr : 99
Total daily capacity m³/d : 2280
Raw water flow m³/h : 132
Working pressure Bar : 21
Recovery % : 75
Working time H/d : 24
TDS of raw water mg/l : 275
Permeate quality, designed mg/l : <18
(TDS)

R.O. Membranes
Type : 8” Brackish water Spiral wound
Quantity(total) Unit 108
Material : Polysulfon/Polyamid
Manufacturer Filmtec-Dow Chemicals
Model BW30-400/or BR3(Oltemare)
Pressure vessels:
Type : Straight/Side port or End Port
Quantity(total) : 18
Material : Fiber glass
Pressure rating PSI 450
Manufacturer Codeline-Knappe(France), Beakart(Spain)
Piping material:
Raw water : U-PVC
Concentrate : SS304
Permeate : U-PVC

Instrumentation(each )
* Conductivity meter on permeate side : 1
* Flow meter on the permeate side of each : 1
skid

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

* Flow meter on the each raw water side : 1

* Manometers : 3
Controls: : Start up by GPS via PLC
Shut down by GPS via PLC
Location: On R.O. skid

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5. 13. Membrane chemical cleaning and Flushing system

a) One complete system for washing & flushing of the RO trains with the following specifications:

Designation : Washing/Flushing system

Quantity unit(s) : One
Standard : ISO/DIN
Model GROUNDFOS Or Equal
Characteristic:
a)Tank:
Duty : Preparation/Storage of cleaning solutions &Storage
of permeate water
Type : Vertical
Quantity unit(s) : 1
Volume L : 5000
Material : High density polyethylene
b)Mixer:
Type of mixer : Electric
Material : SS
Power kW : 0.55
C)Washing/Flushing pumps:
Number of pumps : Two
Type : Horizontal, centrifugal pump
Nom. Flow m3/h : 90
Head M : 30
Material : S.S 316
Power kW : 15
Model CRN90-2
Manufacturer : Grundfos Or Equal
d)Washing cartridge filter
Quantity Units 2
Normal flow m3/h : 90
Medium to filtered : Washing solution

Max. Pressure drop Bar : 1.0

Model GEM25/40"
Body:
Diameter mm : 355.6

Height mm : 1980

Wall thickness mm : 5
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

Operating pressure Bar : 3

Inlet/outlet size DN : 150

Material:
Hosing : Stainless Steel 304
Filter elements : PP
Filter element:
Quantity : 25
Height of cartridge inch : 40
Pressure loss Mbar : 200
Accessories:

- Easy fitting connections & hoses for cleaning

solution
- One complete set of PVC valves & fitting for
re-circulation of cleaning solution
- one float valve
Controls:

One Level switch,PE tank

Two Manometer,
discharge, cartridge
filter outlet

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.14 pH adjustment Dosing Station

One complete dosing station comprising pump, tank, mixer, suction line with integrated foot
valve, overflow valve, isolating valve, level switch and accessories and Gas scrubber as described
below:

Designation : PH adjustment dosing station

Quantity (dosing pumps) unit(s) : 2 (1+1)
Type : Diaphragm pump
Standard : ISO/DIN
Manufacturer : PROMINENT CO./Jesco/Aldose/Dosapron Or
Equal

Characteristic:
a) Pump:
Capacity l/h : 10
Max. Back pressure Bar : 4
Daily operation h/d : 24
Materials:
Head : PVC
Diaphragm : PTFE
drive:
Rated power kW : 0.05
Voltage/Frequency V/Hz : 230/50

b) Tank:
Quantity unit(s) : Two
Type : Cylindrical
Material : PE
Volume L : 100

c) Mixer:
Type : Electrical
Material, propeller : SS
Power KW : 0.18
Rotation Speed Rpm : 1000
Impeller diameter Mm : 150
Shaft length mm : -

Medium:
Type : Base
Concentration % : 10
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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.15 High pressure permeate water transfer

One complete pump station comprising pump, motor, suction-/ discharge header, isolating valves,
check valve(s), manometer(s) and accessories as described below:

Designation : High pressure permeate water pump

Quantity unit(s) : 2(1/1)
Type : VEERTICALcentrifugal
Standard : ISO/DIN
Manufacturer : Grundfos Or Equal
Characteristic (big pump):
Pump:
Capacity m³/h : 40
Head M : 100
Absorbed power kW : -
Speed Rpm : 2950
Suction branch : -
Suction size DN : 80
Discharge branch : -
Discharge size DN : 80
Medium : Permeate water
Daily operation h/d : 24
Material of impeller : SS
Material of shaft : SS

Motor:
Rated power kW : 18.5
Speed Rpm : 2950
Voltage/Frequency V/Hz : 380/50
Insulation class IP55

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.16 Low pressure permeate water transfer

One complete pump station comprising pump, motor, suction-/ discharge header, isolating valves,
check valve(s), manometer(s) and accessories as described below:

Designation : Permeate water pump transfer

Quantity unit(s) : 2(1/1)
Type : centrifugal
Standard : ISO/DIN
Manufacturer : Grundfos Or Equal
Characteristic (big pump):
Pump:
Capacity m³/h : 140
Head M : 40
Absorbed power kW : -
Speed Rpm : 2950
Suction branch : -
Suction size DN : 80
Discharge branch : -
Discharge size DN : 65
Medium : Permeate water
Daily operation h/d : 24
Material of impeller : Cast Iron
Material of shaft : Cast Iron

Motor:
Rated power kW : 22
Speed Rpm : 2950
Voltage/Frequency V/Hz : 380/50
Insulation class : IP55

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

5.17 potable water transfer

One complete pump station comprising pump, motor, suction-/ discharge header, isolating valves,
check valve(s), manometer(s) and accessories as described below:

Designation : potable water pump

Quantity unit(s) : 2(1+1)
Type : VERTICAL centrifugal
Standard : ISO/DIN
Manufacturer : Grundfoss Or Equal
Characteristic (big pump):
Pump:
Capacity m³/h : 10
Head M : 30
Absorbed power kW : 4
Speed Rpm : 2950
Suction branch : -
Suction size DN : 40
Discharge branch : -
Discharge size DN : 40
Medium : Permeate water
Daily operation h/d : 24
Material of impeller : SS
Material of shaft : SS
Motor:
Rated power kW : 1.5
Speed Rpm : 2950
Voltage/Frequency V/Hz : 380/50
Insulation class IP55

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

6- Electrical System

6. 1. GENERAL

This proposal provides the general information which is necessary for design
and execution of electrical works.
6. 3. STANDARDS AND CODES

Material section, design, manufacturing, testing and installation of electrical

equipment will comply with IEC publications; in case of lack of any code in IEC
standard, NEC or ANSI will be. Considered as reference.
6. 4. QUALITY ASSURANCE

Wahang Saran Co. is responsible for quality of design, selection of equipment

manufacturing, installation and proper operation of system.
6.5. SUPPLY OF POWER

The main power is 400V AC, 50Hz, 3-phase, 4-wire, system solidly grounded which
is supplied by the client at the incoming terminals of our control panel.
6. 6. TERMINAL POINTS

All the incoming power lines will be received at the incoming terminal of panels in
W.T.P , i.e. the supply , installation and termination of cables between circuit
breaker of switch gear of circuit breaker of upstream panels is out of Wahang
Saran scope of work and is not foreseen in this proposal .
6. 7. ELECTRICAL EQUIPMENT

6-1) Switchgears

Electrical switchgears will be manufactured by European reliable manufacturers

using the first quality equipments available in local market all switchgears will be
withdraw able type

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-The ingress degree of panels will be:

-IP 54 for outdoor panels

-IP 42 for indoor panels

All enclosures specified for outdoor will, in addition to the above requirements, be
designed to shed rain water and prevent the accumulation of staying water on any
part of the enclosure.

Free standing enclosures will be manufactured of 2 mm sheet steel and wall

mounted enclosures, of 1.5 mm sheet steel.

Anti condensation heaters for the panels and lamp test push button will be
prepared on those panels including signal lamps.

Control panels will be equipped with internal lighting and door switches when
required. Gland plates of the panels will be removable.

All compartment doors will be interlocked to prevent opening when the isolating
switching device is in it’s “ON” position.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

6-2) Cables

All cabling in the scope of work will be supplied and mounted in the plant. The
required cables will be obtained from reliable manufacturers having standard
approval for their products.

Cables foreseen to be used installed either on trays/racks, in ducts, cleared to steel

work or laid in concrete trenches

6-3) Cable trays

Cable trays will be sized to carry the plant’s cables.

Cable trays and ladders will be supplied from reliable manufacturers. The material
will be hot galvanized sheet steel.

6-4) Electrical motors

Electrical motors will be supplied from European manufacturers. These motors

comply with DIN EN60 034-1 or IEC60 and DIN EN 50 347. All motors are
designed for IP55. They are suitable for use in dusty or damp surroundings. The
motors can be used in the tropics. Approx.value 60% relative humidity at CT 40'c.
Standard motors with frame sizes 63 to 450 are fitted with a radial –flow fan which
functions independently of the direction of rotation. The air is blown from the non
driven end to the drive end.

6. 8. AREA CLASSIFICATION

The water treatment plant is considered to be installed in non-hazardous area; so no

special provisions are foreseen for this purpose in this proposal.

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7. INSTRUMENTATION AND CONTROL

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Subject :WATER TREATMENT PLANT

Item Content

INDEX

7. INSTRUMENTATION AND CONTROL

7.1 General

7.2. Scope of work

7.3. Standards and codes

7.4. Quality assurance

7.5. Design criteria

7.6. Programmable logic controller (PLC, HMI, SCADA)

7.7. Input/output (I/O) modules

7.8. Control Panel

7.9. Control Cables

7.10. Alarm announciator

7.11. Measurement

7.12. Pneumatic system

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

7.1General

The control system will be provided to permit the safe and efficient operation of
water treatment plant.

Sufficient instrumentation and control will be provided to meet the R.O. water
treatment plant.

7.2 Scope of work

The scope of work comprises of detail design, supply of equipment, installation,

commissioning, guarantees, shop testing and inspection and providing of inspection
and test procedures during erection, commissioning, operation and maintenance.
Also preparation and supply of detail design documents and drawings (where
necessary), erection, commissioning, operation and maintenance instructions of all
control requirements.

7.3 Standards and Codes

The control system will be designed in accordance with the applicable portions
of the following codes and standards:

a) American National Standard Institute (ANSI)

b) Instrument Society of American (ISA)

c) International electric cods (IEC)

d) Deutsche institute for normunge (DIN)

7.4 Quality assurance

Wahang Saran Co. is responsible for quality of design, equipment manufacturing,

installation and proper operation of control system.

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7.5 Design criteria

The local control of entire process will be performed from local control panels, or
switchboards provided for this purpose.

The main control panel will be equipped with all necessary instruments and equipment
required for sequence, protection interlocks and process equipment status indication
facilities.

The remote control of the loops and monitoring will be performed by PLC .The sequences
will be implemented by a PLC located in main control panel in W.T.P.

The control system of the unit will allow:

a) Manual operation from local facilities (these facilities comprises of

electromotor for controlling valves, and local control switches for

controlling electrical consumers).

b) Fully automatic operation of R.O. system

c) All signals necessary for sequential operation will be connected to the PLC.

7.6 Programmable logic controllers (PLC)

The PLC system will be microprocessor based and will provide all functions normally by
a relay or hardware logic system.

The system software will include the main software and the application software. The
main software includes the operation system, diagnostic routines, etc.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

7.7 Input/output (I/O) modules

I/O modules will be clearly identified as their function and will be protected against
incorrect location.

The analogue modules will be 24VDC, 4-20 mA, and digital modules will be 24 VDC
voltage free contacts, otherwise will be used along with interface relays.

7.8 Control Panel

The main control panel will contain PLC system, terminal blocks, interface relays, DC
power supply electrical protective devices, recorder and alarm annunciate.

A mushroom type emergency shutdown pushbutton will be prepared on the face of panel
and protected against accidental disoperation.

Process override switches will be provided on the control panel only when specifically
requested by the process.

7.9 Control Cables

The control cables will be of annealed copper and flame retardant. The cross-sectional
area of the conductors will be as follows:

1 sq-mm, for analogue signals

1.5 sq-mm, for digital signals and solenoid valves

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

7.10 Alarm Announciator

The alarm annunciation system will be installed in control panel .

The logic sequence cards will be solid-state type. This system will consist of:

-logic sequence cards installed in cabinet.

-Lamp display at front of control panel .

-Acknowledgement pushbutton.

-Lamp-test pushbutton.

The logic sequences will be in accordance with ISA S18.1-Alarms will be divided into
two categories:

a) Those which cause trip in system (flashing in red)

b) Those which will not result a trip (flashing in white)

Each alarm card will accommodate a maximum 4 alarm inputs.

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7.11 Measurement

Measurement and control instruments, which perform similar duties, will be of uniform
type and manufacturer.

The equipment will offer a high degree of reliability.

7.12 Pneumatic System

The valve actuators will be pneumatic expect where other types of actuators needed. The
water treatment unit will be divided into zones, and each zone will be an operation section
of the process. The pneumatic actuators in each zone will be connected via air tubes to a
solenoid box in which an isolation valve and a solenoid valve is considered for each air
consumer (actuator).

There will be a pressure regulator and filter assembly at the entrance of the W.T.P. to
provide pressure control for actuators.

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Project :BAFT STEEL MAKING PLANT Project no.: 93-0901-2

8. ROSA DESIGN DATA

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