Es0153-75350100-Dbr-0001 - R6 Etp

DESIGN BASIS REPORT
FOR EFFLUENT
TREATMENT PLANT
Revised as per Desein

06 31.12.19 J. Parimelazhagan GK GK
comment’s dated 06.06.19
Initial submission for
approval
Rev No Date Description Prepared Verified Approved
PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT
GACL-NALCO ALKALIES & CHEMICALS PVT

CUSTOMER
LIMITED
CONSULTANT DESEIN PRIVATE LIMITED CONSULTING
ENGINEERS
EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.
Date 31.12.19
DOCUMENT NO ES0153-75350100-DBR-0001 Rev 06
No. of pages 71
DESIGN BASIS REPORT –EFFLUENT TREATMENT PLANT
DOCUMENT ID ES0153-75350100-DBR-0001 REVISION : 06

ITEM CODE DBR0001 QUANTITY :-
DESCRIPTION DESIGN BASIS REPORT
CONTENTS
S.NO. DESCRIPTION
INTRODUCTION
1.
PROJECT DETAILS & SITE DATA
2. DESIGN BASIS FOR EFFLUENT TREATMENT PLANT
PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153
OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

CONSULTANT DESEIN PRIVATE LIMITED CONSULTING ENGINEERS SHEET : 2 of 4

01.00.00 INTRODUCTION
The intent of this “DBR” is to cover the basic design criteria for the ETP Plant of subjected POWER
plant is to be engineered, designed, supplied, erected & commissioned by M/s. ISGEC Heavy
Engineering Ltd. A brief description and salient feature of the various sub systems are defined here
for the basis of design. However, the detailed specification requirement as described in the
contract/technical specification shall be met under individual package in totality
01.01.00 PROJECT DETAILS & SITE DATA
S.No. Description Unit
A Site details
2 x 65 MW Captive Cogeneration Power Plant
1. Project Title
(CCPP) at Dahej, Gujarat, India
2. Client GACL- NALCO Alkalies & chemicals Pvt Ltd
3. EPC contractor M/s. Isgec Heavy Engineering Limited

Desein private limited,
Desein house,
4. Owner’s Consultant
Greater Kailash II
New Delhi 110 048
Village Dahej, Dist. Bharuch, Gujarat,
5. Plant Location Latitude - 21° 43’ 06.24” N
Longitude -72o 41’33.42” E
6. Power Plant Capacity MW 2x 65
7. Seismic Co-efficient zone Zone – III as per IS 1893 - 2002
8. Design Wind Velocity m/s As per IS 875, Part 3 – 47 m/s
9. Wind Direction SW-NE
10. Area classification Safe , Non- hazardous & Non- Corrosive
B Meteorological data
Ambient Temperature:
11. °C 11 / 45 /27 (Design & Performance)
(Min. / Max. / Average)
Relative Humidity :
12. % 32 / 89/70 (Design & Performance)
(Min. / Max. / Average)
Wet Bulb Temperature :
13. °C 28
(design)
Design Temperature for
14. °C 50
Electrical equipments
15. Average annual rainfall mm 710


S.No. Description Unit

Mm/h
16. Rainfall intensity 50
r
Plant Elevation above Mean
17. 7m
Sea Level
10 km from dahej railway station & 40 Km from
18. Nearest Railway Station
bharuch railway station with broad gauge line
19. Nearest Airport Domestic - Baroda (~140 kms)
20. Nearest town Bharuch– 50 KM
21. Nearest harbor Magdalla, Surat(~110 kms)

DESIGN BASIS REPORT – EFFLUENT TREATMENT PLANT
DESIGN BASIS REPORT

FOR
EFFLUENT TREATMENT PLANT

LIST OF CONTENTS
SECTION DESCRIPTION
1. DESIGN BASIS
2. EQUIPMENT SIZING CALCULATIONS
3. TECHNICAL DATA SHEET
4. CONTROL & OPERATION PHILOSOPHY
5. ELECTRICAL
6. UF & RO PROJECTION
7. ANTISCALANT PROJECTIONS

SECTION – 1
DESIGN BASIS – ETP

DESIGN BASIS – EFFLUENT TREATMENT PLANT (ETP)
(A) DESIGN PARAMETERS FOR EFFLUENT TRE ATMENT PLANT:

EFFLUENT QUANTITY AND QUALITY – CASE 1 – AS PER WATER BALANCE DIAGRAM
Opera
Effluent Qty tion/G Qty./ TSS Magnes Bicarbo Sulph Silica TDS
Sr. chlorid Sodium Calcium
Generation (m3/ enerat Day in ium as nate as ate as as (mg/ltr Remarks
No e as CL as Na as Ca
Stream hr) ion (m3) ppm Mg HCO3 SO4 SiO2 )
Hours
1 N pit reject 22.5 24 539.9 293 2959.6 190.75 1395.19 276.24 66.38 81.5 168.82 5138.5 Refer Table 1
2 Boiler Blow Down 16 24 384 Nil 10.0 0 10 0 0 0 2.5 150
Cooling Tower COC considered
3 151.2 24 3628.8 100 142.0 80 150 116 175 35 72.5 1500
Blow down as 5
Waste from caustic
4 15 24 360 Nil 15869.4 331.5 9320 468.4 0 0 0 27000 Refer Table 2
soda plant
Condenser waste
5 4 24 96.0 100 28.4 16.0 30 23.2 151.2 7.0 14.5 280
water
ESP area waste Service water
6 2 24 48 100 28.4 16.0 30 23.2 151.2 7.0 14.5 280
water quality considered
Ash silo area
7 2 24 48 100 28.4 16.0 30 23.2 151.2 7.0 14.5 280
waste water
circulating water
SSF back wash 1020
8 0.4 24 10 142 80 150 116 175 35 72.5 1500 considered for
waste 0
back wash
DMF back wash
9 5.0 24 120.0 125.6 1532.2 101.0 911.9 145.5 137.2 33.8 70.1 3531.7
waste ETP Same as ETP
UF back wash feed water quality
10 6.4 24 153.6 125.6 1532.2 101.0 911.9 145.5 137.2 33.8 70.1 3531.7
waste from ETP
Effluent
parameters to be
224.5 5395.5 125.6 1532.2 101.0 911.9 145.5 137.2 33.8 70.1 3531.7
considered for
ETP design

Note:
1. All other parameter not mentioned in the above are considered to be NIL for designing of the
system.
2. Coal pile run off flow of 60 m3/hr shall be intermittent in nature and the same shall be recycled
for CHP dust suppression.
3. Treated water flow of 10 m3/hr from Oil water separator shall be intermittent in nature and the
same shall be utilized for gardening in the nearby area.

TABLE 1 - DM PLANT EFFLUENT – QUALITY & QUANTITY
S. No. Description Unit Regeneration / Back wash waste per day

1. Pressure Sand filter m3 / day 156.00
2. Activated Carbon filter m3 / day 81.00
3. Strong Acid Cation exchanger m3 / day 156.3
4. Strong Base Anion exchanger m3 / day 131.1
5. Mixed Bed exchanger m3 / day 15.50
Total waste from DM plant m3 / day 539.9
From
Regeneration Chemical
Waste KG due
ppm as MB (KGs)
Output KG as water to Total ppm
Parameters ions in I E Unit for output
(M3) such SAC/SBA from Filter (in kgs) as such
Raw water of
(KGs) Filter B/W waste
3 x 14000
m3
Ca 23.2 SAC 6191.1 143.63 237.00 5.50 149.13 276.24
Mg 16.0 SAC 6191.1 99.18 237.00 3.80 102.98 190.75
Na 30.0 SAC 6191.1 185.73 530.96 29.42 237.00 7.11 753.22 1395.19
Cl 36.5 SBA 6048.6 220.77 1320.02 48.39 237.00 8.65 1597.83 2959.66
SO4 7.0 SBA 6048.6 42.34 237.00 1.66 44.00 81.50
SiO2 14.5 SBA 6048.6 87.70 237.00 3.44 91.14 168.82
HCO3 151.2 DG 0 0 0 0 237.00 35.84 35.84 66.38
TDS 5138.53

TABLE 2 – CAUSTIC SODA EFFLUENT QUALITY

S. No. Description Wt in % In ppm Na ppm Cl ppm Ca ppm Mg ppm Sr ppm
1 TDS 27000
2 NaCl 2.33% 23300 9320 13980 0 0 0
3 H2O 97.39% 973900
4 CaCl2 0.13% 1300 0 831.48 468.39 0 0
5 MgCl2 0.13% 1300 0 968.5 0 331.5 0
6 SrCl2 0.02% 200 0 89.4 0 0 110.54
7 HCl 0% 0 0 0 0 0 0
8 Caustic Soda Effluent Quality 9320 15869.38 468.39 331.5 110.54

S. NO DESCRIPTION UNIT Value REMARKS

As per Case – 1 above,
1. waste water flow at the inlet m3/hr 224.5
of ETP shall be
Case 2:
2. As per MOM dated 26th September 2017, RO shall be designed for a capacity
of 2 x 82 m3/hr with 75% recovery.
Total Permeate flow from 2
a. m3/hr 164.0
nos. of RO skids
b. Recovery in RO system % 75
Total Feed flow to RO
c. m3/hr 218.67
system
d. Recovery in UF system % 97.17
e. Total feed flow to UF system m3/hr 225
f. Back wash waste from DMF m3/day 96.0
g. DMF inlet flow m3/hr 229.0
h. Sludge loss in clarifier m3/hr 12.1
i. Clarifier feed flow m3/hr 241.1

Hence as per Case – 2,
Effluent treatment plant shall
3. m3/hr 241.1
be designed for an inlet flow
of

(B) DESIGN BASIS FOR OILY EFFLUENT AT INLET OF OIL WATER

SEPARATORS
Sl. No. Description Unit Parameter

1. Oil concentration ppm 1000
2. Suspended solids ppm 300
Note:
1. Oil at the inlet of separator has been considered as 100% in free and floating
form.
(C) TRE ATED WATER PAR AM ETERS FOR EFFLUENT TREATM ENT PL ANT:
Sl. No. Description Unit Parameter

At the outlet of RO system:
1. TDS ppm < 200
At TPI separator outlet:
1. Oil concentration ppm < 10
2. Suspended solids ppm < 100

SECTION – 2
EQUIPMENT SIZING
CALCULATIONS

EQUIPMENT SIZING CALCULATIONS
1. Coagulant dosing system

Design flow at clarifier inlet 241.1 m3/hr
Dosage rate 50 mg/l
Dosing concentration 10%
Specific gravity of ferric chloride 1.1
Quantity of dosing pumps 2 nos. (1W+1S)
Margin considered on dosing pumps capacity 20%
Capacity of each dosing pump required 133.5 LPH
Dosing pump capacity provided 150.0 LPH
Quantity of dosing tanks 2.00 nos.
Retention time to be considered for arriving
24 hrs
total volume of dosing tanks
Margin considered on dosing tanks capacity 20%
Total effective capacity of tanks 3202.8 litres
Capacity of each dosing tank required 1601.4 litres
Capacity of each dosing tank provided 2500.0 litres
Dead level considered in tank 0.1 m
Free board considered in tank 0.3 m
Effective liquid depth 1.7 M
1.4 m Dia x 2.1
Tank size provided
m hos
2. Poly dosing system

Dosage rate 1 mg/l
Dosing concentration 0.5%
Specific gravity of polyelectrolyte 1.02
Margin considered on dosing pump capacity 20%
24 hrs
Margin considered on dosing tank capacity 20%

Total effective capacity of tanks 1361.5 litres

Capacity of each dosing tank required 680.8 litres
Capacity of each dosing tank provided 1500.0 litres
1.2 m Dia x 1.8
Tank size provided
m hos
3. Lime dosing system

Dosage rate 10 mg/l
Specific gravity of lime solution 1.04
Capacity of each dosing pump provided 60 LPH
24 hrs
Total effective capacity of tanks 1300 litres
Capacity of each dosing tank required 700 litres
Capacity of each dosing tank provided 1500 litres
1.2 m Dia x 1.8
Tank size provided
m hos
4. Chlorine Dosing System

Design flow at clarifier outlet 241.1 m3/hr
Dosage rate 5 mg/l
Specific gravity 1.202


Capacity of each dosing pump 10.0 LPH
Retention time for dosing tank 24 hrs
Capacity of dosing tank required 240.7 litres
Capacity of dosing tank provided 300.0 litres
0.7 m Dia x 1.2
Tank size provided
m hos
5. Acid measuring tank for CMB

Quantity 1 no.
Vertical
Type cylindrical with
flat bottom
Acid measuring tank capacity required as per
1000 Litres
tender
1.2 m Dia x 1.4
Tank size provided
m hos
6. Caustic measuring tank for CMB

Quantity 1 no.
Vertical
Type cylindrical with
flat bottom
Caustic measuring tank capacity required as
1000 Litres
per tender


1.2 m Dia x 1.4
Tank size provided
m hos
7. Central Monitoring Basin (CMB)

Quantity 1.0 no.
Under ground
Type atmospheric
tank
MOC RCC
Number of compartments 2.0 nos.
Effective Capacity required as per tender for 800 m3 or 4 hrs
each compartment storage
Inlet flow of effluent to CMB 224.5 M3/hr
CMB capacity required considering 4 hrs
898.0 m3
storage for each compartment
Capacity provided for each compartment 950.0 m3
Side water depth considered 3.15 m
Area required 301.58 m2
Length of each compartment required 20.0 m
Width of each compartment required 15.2 m
Free board provided 0.8 m
8. Overflow sump in CMB

Quantity 1 no.
Under ground
Type atmospheric
tank
MOC RCC
Effective Capacity required as per tender 250.0 m3
Effective Side water depth considered 3.15 m
Free board considered 0.8 m
Width required 5.0 m
Length required 16.5 m
9. Clarified water storage tank

Quantity 1.0 no.

Above ground
covered
Type
atmospheric
tank
MOC RCC
Number of compartments provided 2.0 nos.
Effective Capacity required as per tender for
250.0 m3
each compartment
Capacity provided for each compartment 250.0 m3
Dead level provided 0.3 m
Total HOS considered in the tank 3.2 m
10. Sludge sump

Quantity 1.0 no.
Under ground
Type atmospheric
tank
RCC with 5 mm
thick coal tar
MOC
epoxy screed
lining
Number of compartment 1.0 no.
Capacity provided 300.0 m3
11. Dual Media Filter (DMF)

Quantity 3 nos. (2W+1S)
Vertical
Type
cylindrical

Gross flow per unit 114.5 m3/hr

Design flow rate considered per unit in line
120.0 m3/hr
with tender
Surface flow rate 10 m3/m2/hr
Diameter required 3.91 m
Diameter provided 3.91 m
Total media height 1200 mm
Supporting media 100 mm
Sand 550 mm
Anthracite 550 mm
Free board required 75 %
Total height of DMF vessel required 2100.0 mm
Total height of DMF vessel provided 2100.0 mm
DMF back wash velocity considered 24.0 m/hr
DMF back wash flow required 288.0 m3/hr
DMF back wash pump capacity considered 317.0 m3/hr
DMF back wash pump head considered 25.0 mwc
Quantity of DMF back wash pumps 2 nos. (1W+1S)
12. DMF Air Blowers

Type Rotary twin lobe
DMF Vessel dia provided 3.91 m
Air scour velocity required for DMF 36 m/hr
Size of DMF air blower required 432 m3/hr
Size of DMF air blower provided 475 m3/hr
Head of DMF air blower provided 4.5 mwc
13. Filtered water tank (FWT)

Quantity 1.0 no.
Vertical
cylindrical
Type
atmospheric
tank
MOC MSEP
Capacity (as per tender) 100.0 m3


Diameter of tank required 5.0 m
Diameter of tank provided 5.1 m
14. UF membrane calculations

No. of UF skids 2 nos.
Recovery considered in UF system 97.35%
Net Permeate required from UF system from
218.67 m3/hr
both skids
Area per membrane 105 m2
Net flux to be considered in UF system 49.69 lmh
Instantaneous feed flow required per skid 130.4 m3/hr
Quantity of UF membranes required per skid
25 nos.
considering instantaneous feed flow
Hence, Quantity of UF membranes considered
25 nos.
per skid
15. UF CEB - Hypochlorite dosing

Flow 105.4 m3/hr
Dosage rate 200 mg/l
Capacity of each dosing pump provided 180.0 LPH
Quantity of dosing tank 1.0 no.
Volume of sodium hypo chlorite required per
3.4 Litres
MC as per UF projection
Hence Capacity of each dosing tank provided 100.0 litres
Effective liquid depth 0.6 m
0.6 m Dia x 1.0
Tank dimension
m hos

16. UF CEB - Acid dosing

Flow 105.4 m3/hr
Capacity of each dosing pump required 532 LPH
Capacity of each dosing pump provided 535 LPH
Volume of acid required per MC 9.5 litres
0.6 m Dia x 1.0
Tank dimension
m hos
17. UF CEB - Alkali dosing

Back wash flow 105.4 m3/hr
Capacity of each dosing pump provided 335.0 LPH
Volume of caustic to be used per MC 5.96 litres
0.6 m Dia x 1.0
Tank dimension
m hos

18. UF Recovery cleaning pump

Horizontal
Type
centrifugal
UF CIP pump capacity required 105.4 nos
UF CIP pump capacity provided 116.0 m3/hr
Head required for each pumps 25 mwc
19. UF Recovery Cleaning tank

Quantity 1 no.
Vertical
Type cylindrical
atmospheric
Capacity of chemical cleaning tank provided 4.8 m3
2.0 m Dia x 2.0
Tank dimension
m hos
20. UF product water storage tank

Quantity 1.0 no.
Above ground
fully covered
Type
atmospheric
tank
RCC with acrylic
reinforced
cementitous,
MOC flexible water
proof coating
confirming to BS
1881 Pt5 1983


21. UF Air Blowers

Type Rotary twin lobe
Size of UF air blower required 304 m3/hr
Size of UF air blower provided 335 m3/hr
Head of UF air blower provided 7.0 mwc
22. SMBS Dosing System

Design flow at RO inlet 218.7 m3/hr
Dosage rate 4 mg/l
1.2 m Dia x 1.4
Tank size provided
m hos
23. Antiscalant Dosing System

Dosage rate 4 mg/l


1.2 m Dia x 1.4
Tank size provided
m hos
24. Acid Dosing System

Dosage rate 6.5 mg/l
Capacity of dosing tank required 100 litres
Capacity of dosing tank provided 1000 litres
1.2 m Dia x 1.4
Tank size provided
m hos
25. Reverse Osmosis System

No. of RO skids 2 Nos.
Recovery considered in RO system 75%
Net Permeate required from each RO skid 82 M3/hr
Area per membrane 400 ft2
Average flux rate < 16 lmh
No. of stages 2 Nos.

No. of pressure vessels in stage 1 14 Nos.

No. of pressure vessels in stage 2 6 Nos.
No. of membranes in each pressure vessel 7 Nos.
Total no. of membranes per skid 140 Nos.
26. DG Tower dia calculation

Quantity 2 nos.
Vertical
Type
cylindrical
Flow per unit 82 m3/hr
Surface flow rate 60 m3/m2/hr
Diameter required 1.3 m
Diameter provided 1.3 m
Packing media type Pall rings
MOC of packing media PP
Media depth 1.8 m
Height of shell provided 3.3 m
27. DG Air Blowers

Type Centrifugal
DG tower dia provided 1.3 m
Air scour velocity required 20 m/min
Size of air blower required 1592 m3/hr
Size of air blower provided 1751 m3/hr
Head of air blower provided 100.0 mmwc
28. RO permeate water storage tank

Quantity 1.0 no.
Above ground
fully covered
Type
atmospheric
tank
RCC with epoxy
MOC painting of DFT
500 microns


29. RO reject collection tank

Quantity 1.0 no.
Above ground
Type atmospheric
tank
RCC with epoxy
MOC painting of DFT
500 microns
Total reject from both the RO system 54.6 m3/hr
Capacity of RO reject collection tank provided
(1 hour retention time as per clause 5.0, in 96.0 m3
chapter 4, section 1 of contract document)
Capacity of RO reject transfer pumps
90.0 m3/hr
considered with 10% margin
30. RO chemical cleaning tank

Quantity 1 no.
Vertical
Type cylindrical
atmospheric
Dia of RO pressure tube - 7 membrane 0.21

Length of RO pressure tube - 7 membrane 7.598 m

Hold up volume of each RO pressure tube 0.263 m3
No. of RO pressure tube in stage 1 14 nos.
Capacity of chemical cleaning tank required
considering 20% additional hold up volume for 4.42 m3
interconnecting pipelines
Capacity of chemical cleaning tank provided 4.50 m3
1.8 m Dia x 2.2
Tank dimension
m hos
31. RO chemical cleaning pumps

Horizontal
Type
centrifugal
Cleaning flow required per RO pressure tube 9.0 m3/hr
No. of RO pressure tube in stage 1 14 nos.
RO chemical cleaning pumps capacity
126 m3/hr
required
RO chemical cleaning pumps capacity
139 m3/hr
provided
Head required for each pumps 35 mwc

SECTION – 3
TECHNICAL DATA SHEET

TECHNICAL DATA SHEET
S. NO. PARAMETERS UNIT VALUE

CENTRAL MONITORING BASIN
1.
(CMB)
Quantity No. 1 (With twin compartment)
Type Underground atmospheric tank
Capacity m3 950 (each compartment)
MOC RCC
Inlet arrangement Inlet chamber with isolation gate
2. OVER FLOW SUMP IN CMB
Quantity No. 1
Type Underground atmospheric tank
Capacity m3 250
MOC RCC
3. CLARIFIER FEED PUMPS
Quantity Nos. 2 nos. (1W+1S)
Liquid Handled Effluent water
Type Vertical turbine
Design flow at clarifier inlet M3 / Hr 241.1
Capacity considered with 10%
M3 / Hr 266
margin
Head Mwc 15
MOC of Casing 2.5% Ni cast iron IS 210 FG 260
MOC of impeller CF8M
MOC of Shaft SS 304
MOC of shaft sleeve SS 316
Shaft Seal arrangement Gland Packing
Speed rpm 1450
FERRIC CHLORIDE DOSING
4.
SYSTEM
Chemical Dosage Level ppm 50
Chemical Concentration % 10
Dosing Tank Quantity 2 nos.
Dosing Tank capacity Litres 2500
Dosing Tank MOC MSRL
Vertical Cylindrical –
Dosing Tank Type
Atmospheric
Dosing Pumps Quantity Nos. 2 nos. (1W+1S)


Positive Displacement /
Type
Diaphragm Electronic Type
Pump Capacity LPH 150
Pump MOC PP
Motorized with SS 304 shaft &
Agitator
impeller
5. POLY DOSING SYSTEM
Chemical Concentration % 0.5
Dosing Tank Type
Atmospheric
Dosing Pump Quantity 2 nos. (1W+1S)
Type
Pump MOC SS 316
Agitator
impeller
6. LIME DOSING SYSTEM
Dosing Tank capacity (each) m3 1.5
Dosing Tank MOC MSEP
Dosing Tank Type Atmospheric
Type Screw pumps
Casing – 2% Ni CI &
Pump MOC
Rotor – SS 316
Motorized with MS shaft &
Agitator
impeller
7. HRSCC
Feed flow rate M3 / Hr 241.1
Operating Hours Hrs 24
Quantity 1 no.
Overflow loading rate M3/Hr/ 1.5


M2
Dimensions M To suit process requirement
Side Water depth M 4.0
Free Board M 0.3
HRSCC Internals - MOC MSEP
MOC of Shell RCC
8. CHLORINE DOSING SYSTEM
Dosing Tank 1 no.
Dosing Tank MOC MS ebonite lined
Type
Atmospheric
Type
Pump MOC PP
9. SLUDGE SUMP
Quantity No. 1
Capacity M3 300
Type Below ground sump
RCC; outdoor location with 5
MOC mm thick coal tar epoxy screed
lining
10. SLUDGE TRANSFER PUMPS
Type Vertical (non clog, sump pumps)
Sludge flow from clarifier M3 / Hr 12.1
M3 / Hr 13.5
margin
Head Mwc 30
MOC of Shaft SS 304
CLARIFIED WATER STORAGE
11.
TANK


Quantity 1 no. (with twin compartments)
Capacity of each compartment M3 250.0
Type Above ground, covered tank
Tank MOC RCC
12. FILTER FEED PUMPS
Quantity Nos 3 nos. (2W+1S)
Liquid Handled Clarified water
Type Horizontal centrifugal
Instantaneous flow required at
M3 / Hr 130.4
the inlet of UF
M3 / Hr 145
margin
Head Mwc 50
MOC of Shaft SS 410
13. DUAL MEDIA FILTER
Design feed flow rate considered
M3 / Hr 120.0
in line with tender
Qty Nos. 3 nos. (2W+1S)
Vessel design standard IS 2825
Type Vertical filter.
Surface Velocity - Service M3/Hr/M2 10
Surface Velocity - Backwash M3/Hr/M2 24
Sand and anthracite with
Filtering Medium
supporting media
Min Bed Depth mm 1200
Min free board 75 % of bed depth
MOC of shell IS 2062
MOC of dished ends IS 2002, Gr. I / SA515 Gr. 70
Filter Feed pump shut off head
Design pressure Kg / Cm2 or 3.5 Kg/cm2, whichever is
higher
Hydrostatic test pressure Kg / Cm2 1.5 Times of Design Pressure
Operating Mode Semi Automatic
Three coats of chlorinated
External painting
rubber paint DFT 150 microns
Internal painting Two coats of high build epoxy


zinc phosphate DFT 150
microns.
AIR SCOURING BLOWERS
14.
FOR DMF
MOC CI
Type Twin Lobe
M3 / Hr
Air scouring Velocity 36
/M2
Head Kg /cm2 0.45
15. FILTER WATER TANK
Tank Quantity No 1.0
Tank capacity M3 100
Tank MOC MSEP
Vertical Cylindrical -
Type
Atmospheric
16. FILTER BACK WASH PUMPS
Type Horizontal, Centrifugal
Liquid Handled Filtered water
Capacity M3 / Hr 317.0
Head mwc 25
2.0% Ni cast iron IS 210 FG 260
MOC of Casing & Impeller
& CF8M
MOC of Shaft & Shaft Sleeve SS410 & SS 316
Speed Rpm 1450
Shaft seal arrangement Gland packing
17. BASKET FILTER FOR UF
Quantity 2 nos.
Material of Construction SS - 316
Operating pressure Kg/cm2 2.5
Micron rating Microns 100 Microns
18. ULTRA FILTRATION SYSTEM
Quantity 2 nos.
Recovery % 97.35
Daily total feed volume M3/day 2694
Daily net filtrate volume M3/day 2623
MOC (Housing) PVC
MOC (Membrane) PVDF


Filtration Mode Dead end
Molecular Weight Cut Off Daltons 100000 MWCO
Operating Flux LMH 49.69
Operating Mode Automatic
UF piping headers SS 316
UF skid MOC MSEP
UF PRODUCT WATER
19.
STORAGE TANK
Quantity 1 no.
Capacity M3 200
Type Above ground, covered tank
RCC with acrylic reinforced
cementitous, flexible water proof
Tank MOC
coating conforming to BS 1881
pt 5 1983
20. UF CEB -1 NaOH Common for both streams
As per Manufacturer
Chemical Dosage Level ppm
recommendations
Chemical Concentration % NaOH – 30
Dosing Tank Quantity No. 1 no.
Type
Atmospheric
Dosing Pump Nos. 2 nos. (1W+1S)
Type
Pump MOC PP
Agitator
impeller
21. UF CEB -2 ( Acid) Common for both Streams
As per Manufacturer
Dosage Level ppm
recommendation
Dosing Tank Quantity Nos 1 no.
Dosing Tank MOC FRP
Type
Atmospheric


Dosing Pump Quantity Nos. 2 nos. (1W+1S)
Type
Pump MOC PP
22. UF CEB -3 ( NaOCl) Common for both Streams
As per Manufacturer
Dosage Level ppm
recommendation
Dosing Tank MOC MS ebonite lined
Type
Atmospheric
Type
Pump MOC PP
UF RECOVERY CLEANING
23.
TANK
Quantity Nos 1 no.
Capacity Litres 4800
MOC MSRL
Design Standard IS 803
Type Vertical cylindrical atmospheric
UF RECOVERY CLEANING
24.
PUMPS
Type Horizontal Centrifugal
M3 / Hr 116
margin
Head Mwc 25
MOC of Casing / Impeller CF8M
MOC of Shaft & Shaft Sleeve SS 316
Speed rpm 1450
Shaft Seal arrangement Mechanical Seal
UF CHEMICAL CLEANING
25.
MICRON CARTRIDGE FILTER
Quantity No 1 no.


Size microns 5
MOC - Housing SS 316
MOC - Cartridge PP
26. RO FEED PUMPS Common for both Streams
Type Horizontal, Centrifugal
Liquid Handled UF Product water
M3 / Hr 120
margin
Head mwc 25
2.5% Ni cast iron IS 210 FG 260
MOC of Casing / Impeller
& CF8M
MOC of Shaft & Shaft Sleeve SS410 & SS 316
Speed rpm 1450
27. SMBS DOSING SYSTEM Common for both streams
Chemical Dosing Concentration % 10
Dosing Tank MOC SS 316
Type
Atmospheric
Type
Pump Capacity LPH 0 - 10
Pump MOC SS 316
Agitator
impeller
ANTI SCALENT DOSING
28. Common for both streams
SYSTEM
Dosing Tank MOC SS 316
Type
Atmospheric


Type
Pump Capacity LPH 0 - 10
Pump MOC SS 316
Agitator
impeller
29. ACID Common for both streams
Chemical Dosage Level ppm 6.5
Dosing Tank MOC FRP
Type
Atmospheric
Type
Pump Capacity LPH 8
Pump MOC SS 316
30. MICRON FILTER- RO
Size microns 5
MOC - Housing SS 316
MOC - Cartridge PP
31. RO HIGH PRESSURE PUMPS
Liquid Handled UF Product water
Type Vertical multi stage centrifugal
M3 / Hr 120
margin
Head Mwc 163
MOC of Casing / Impeller / Shaft CF8M
Speed rpm 2900
32. RO SYSTEM
Feed flow rate M3 / Hr 109.3
Permeate flow per skid M3 / Hr 82.0
Qty Nos. 2 nos.


Recovery % 75
Flux LMH <16
Membrane Housing MOC FRP
MOC (Membrane) Polyamide thin-film composite.
Type Spiral wound
Operating Mode Semi Automatic
RO CHEMICAL CLEANING
33.
TANK
Quantity No. 1 no.
Capacity Litres 4500
MOC SS 316
34.
PUMPS
M3 / Hr 139
margin
Head Kg/cm2 3.5
Speed rpm 1450
35.
MICRON CARTRIDGE FILTER
Quantity No. 1 no.
Capacity M3 / Hr 126
MOC SS 316
36. DEGASSER TOWER
Flow rate M3 / Hr 82.0
Quantity Nos. 2 nos.
MOC MSRL
Fill Media PP Rasching Rings
Design Pressure Atmospheric
Type Cylindrical – Vertical
Air flow Forced draft, Counter flow
External painting Three coats of chlorinated


rubber paint DFT 150 microns.
37. DG AIR BLOWERS
Type Centrifugal
MOC MS
100% requirement of one DG
Capacity M3/min
tower
Head mmwc 100
38. DG WATER STORAGE TANK Common for both streams
Quantity No. 1
Capacity M3 600
RCC with epoxy painting of DFT
MOC
500 microns
RO PERMEATE WATER
39.
TRANSFER PUMPS
M3 / Hr 90
margin
Head Kg/cm2 3.5
Speed rpm 1450
RO REJECT COLLECTION
40. Common for both streams
TANK
Quantity No. 1
Capacity M3 96.0
MOC RCC
RO REJECT TRANSFER
41.
PUMPS
M3 / Hr 90
margin
Head Kg/cm2 3.0


Speed rpm 1450
42. API SEPARATOR
Quantity No. 1
Type Cross flow
Capacity M3/hr 10
Design standard As per API 412
MOC of body RCC
Oil skimmer Provided.
43. TPI SEPARATOR
Quantity No. 1
Plate or tube with counter flow /
Type
cross flow
Capacity M3/hr 10
Angle of inclination Deg 60
MOC of body Carbon steel
MOC of plates UV inhibited virgin PVC
Oil skimmer Slotted pipe skimmer
Qty - 1 no.
Slop oil tank MOC – HDPE
Capacity – 5 m3
Note: Vendor documents for API and TPI separator shall be submitted
separately.
WASTE WATER FROM FUEL
44. OIL PUMP HOUSE AND
UNLOADING AREA SUMP PIT
Quantity No. 1
Underground rectangular with
Type
flat bottom
Capacity M3 25
MOC RCC
FUEL OIL AREA WASTE
45.
TRANSFER PUMPS
Capacity M3 / Hr 10
Head Kg/cm2 As per system requirement
Type Vertical screw pumps
MOC of Casing / Impeller 2% Ni CI to IS 21 FG 260
MOC of Rotor and shaft SS 316


46. FUEL OIL WASTE SUMP PIT
Quantity No. 1
Underground rectangular with
Type
flat bottom
Capacity M3 30
MOC RCC
FUEL OILY WASTE SUMP
47.
TRANSFER PUMPS
Capacity M3 / Hr 10
Type Vertical screw pumps
MOC of Casing / Impeller 2% Ni CI to IS 21 FG 260
MOC of Rotor and shaft SS 316
48. TREATED WATER SUMP
Quantity No. 1
Type Underground rectangular
Capacity M3 50
MOC RCC
TREATED WATER DISPOSAL
49.
PUMPS
Capacity M3 / Hr 50
2% Ni CI to IS 21 FG 260 /
MOC of Casing / Impeller
CF8M
MOC of Shaft & Shaft Sleeve SS 304 & SS 316
50. COAL SETTLING POND
Quantity No. 1
Type Underground
Effective Capacity M3 500
MOC RCC
COAL SETTLING POND
51.
OVERFLOW SUMP
Quantity No. 1 in two compartments
MOC RCC
SETTLING POND TRANSFER
52.
PUMPS


Capacity M3 / Hr 60
Head Mwc As per system requirement
MOC of Shaft SS 304
Speed rpm 1450
53. ASH SILO AREA WATER SUMP
Quantity No. 1
Type Underground
MOC RCC
ASH SILO AREA WASH
54.
WATER TRANSFER PUMPS
Capacity M3 / Hr 10
Head Mwc As per process requirement
MOC of Shaft SS 304
Speed rpm 1450
55. PIPING
Water discharge lines ( velocity) m/s 2.5 max.
Water suction lines ( Velocity) m/s 1.0 max.
For pipe line under gravity m/s < 1.0 max.
For compressed air line m/s 15 max.
HRSCC Inlet to Clarified water
MSEP
storage tank
Filters Frontal Piping MSEP
UF Skid piping SS316
RO High pressure line ( Skid
SS316
Piping)
Low pressure piping in RO
CPVC
system
MOC of piping for all chemical &
CPVC
chemical solution lines


MOC of piping for air line GI
Note:
1. Pump head calculation shall be submitted as a separate document.

SECTION – 4
OPERATION & CONTROL

PHILOSOPHY

CONTROL & OPERATION PHILOSOPHY
GENERAL:-
Microprocessor based PLC system shall be provided for packages mentioned below
covering the total functional requirements of modulating control, sequence control,
interlocks & protection, monitoring, alarm, data logging etc.
1. Effluent Treatment Plant and Sewage treatment Plant.
The Hot Redundancy for PLC shall be considered for Controllers, communication
modules, data highway, power supply modules, IO Modules (As mentioned in
Schedule IV, Section-IV A Chapter 4 & Annex. B: Drive Control Philosophy).
Make and Model of PLC shall be same for all packages provided for subjected plant
as mentioned in schedule IV, section IVA, Ch-4.
UPS system with ACDB & batteries, associated furniture, and erection hardware for
said areas shall be provided as per contract technical specification.
All relevant design standards and design criteria shall also be included in the design
Memorandum as per Technical specification, Schedule IV, Section IV-A, Ch 1 to 8.
MICROPROCESSOR BASED PLC SYSTEM:-
The design of the control system and related equipment will adhere to the principle
of “fail safe” operation at all system levels and provide reliable and efficient
operation of the plant under dynamic conditions and attainment of maximum station
availability.
The system shall execute all control functions with the help of a set of pre-
programmed functions resident in controllers.
The system shall provide inherent safe operation under all plant disturbances and
component failures so that under no circumstance safety of the plant personnel or
equipment is risked.

The I/O panel shall be powered from redundant feeders of UPS source of
respective unit. The unit enclosure shall be of weather proof, dust tight and water
proof.
Suitable rating of UPS shall be provided to Feed IO PLC Panels, OWS / EWS all
field instruments (Through PLC), SOV (Through PLC), HW annunciation panel etc.
2 Nos. temperature elements/sensors in each units control room shall be provided

for monitoring the room temperature.
The control system shall be structured in accordance with a well-defined control

hierarchy to permit operator intervention at appropriate levels during abnormal
modes of operation.
The control and monitoring shall be performed from control room by means
of OWS/KB operation interface mounted on unit control desk, through a
microprocessor based PLC.
Permissive conditions for an equipment start shall be provided based on Switchgear

& Process Requirement.
Selection of standby equipment and starting the equipment automatically on the

tripping of running equipment and/or desired process parameter conditions (say
loss of discharge pressure or low level in the discharge tank etc.).
Isolation of the tripped equipment from the main process.
The following minimum protection shall be provided for the various

equipment/system as applicable to trip the equipment.
(a) Any condition which endangers the safety of the plant personnel.
(b) Any of the permissive conditions becoming abnormal thereby producing a
dangerous condition in operating the equipment.
(c) The conditions from process such as dry flow conditions, flashing conditions or
any other conditions that may create cavitation.
Man Machine Interface (MMI) shall be provided through Operator’s station along
with its peripherals like LED monitor, printer, mouse. Engineering functions shall
normally be carried out from dedicated workstation or operating station. In case a
dedicated engineering station is provided, EWS shall also be worked as operating
station through password / Hardware lock.
The Operator’s station shall perform the following minimum requirements.


(a) Selection of Auto / Manual, Open / Close operation, start / stop operation etc.
(b) Dynamic Mimic display detecting the entire process for control monitoring
purpose.
(c) Alarm monitoring, report generation, logs, calculations and printing of logs,
reports, trends etc.
(d) Online / historical trending, historical storage and retrieval of data.
A Shift/daily log shall be provided to furnish data for routine analysis of plant
performance. This log can be printed on demand at any time. The primary objective
of the Visual Annunciation System shall be to draw operator’s attention to
abnormalities in plant status and parametric values enabling him to take corrective
measures to avoid emergency/Plant trip out conditions or decrease in plant output.
HW annunciation system shall be driven by Digital output.
Sequence of annunciation for the control desk mounted facia windows shall
be as below:-
Sr. No. Condition Visual Audible

1. Normal OFF OFF
2. Alarm Flash ON
3. Return To Normal
ON
a) Before Acknowledge ON
(Different tone)
b) After Acknowledge OFF OFF
4. Alarm Acknowledge
a) Before Return To Normal Steady ON OFF
ON
b) After Return To Normal Slow Flashing
(Different tone)
5. Reset OFF OFF
6. Test Flash ON

Control & Operation From Interface

Sr. Control Local with Plant
System Remarks
No. System Control CCR DDCMIS
Room
H/W and a) PLC with one no. OWS &
soft link one no. Operating cum
Interface of engineering station and with
PLC with Redundant hot standby
DDCMIS for processor with one no. A4
monitoring size B/W LJP. Remote I/O
only. panels shall also be provided
HW signals for
(If Required).
equipment
(Redundant
status/abnormal
bi-directional b) Relay based local control
condition, and
Effluent OPC link panel with colored Mimic,
critical process
Treatm with H.W. Annunciator, P.B.,
parameters etc.
ent Ethernet Indicators, indication Lamps
shall be provided
Plant & Based and Ammeters shall be
PLC Applicabl to plant
1. Sewag TCP/IP provided for ETP misc. sumps
Based e DDCMIS.
e Protocol for with pumps, which are located
Other non-
Treatm soft link more than 100 meters from
critical signals
ent interfacing) ETP plant PLC control room.
thru soft link for
Plant. Each Control panel shall have
complete
the hardwired interfacing with
Monitoring shall
PLC for signal transfer like
be provided to
status of pumps and status of
Plant DDCMIS.
process parameters.
d) Also the running/stopped

feedbacks shall be connected
to nearby BOP PLCs for
monitoring and the locations
& PLCs to be assigned.

Local Control Room(s) is envisaged for this project.

The control room consists of the following:
(a) PLC based system cabinets.

(b) Marshalling/termination cabinets.
(c) Operator work stations.
(d) Operating cum Engineering work station
(e) Printers
(f) Local control desk shall be provided with Hard wired Annunciation system,
Ammeters, Parameter Indicators, LED Based indication Lamps etc.
(g) Location: Safe area.
(h) UPS system

SECTION – 5
ELECTRICAL
GACL_25.0C_3.0Y_7
5.0R_1-31-2019.pdf

ELECTRICAL
SYSTEM PARAMETERS AND VARIATIONS:
S. No Description 415V System 240 V System
1 Nominal Voltage 415 V 240 V
2 Highest System Voltage 433 V 264 V
3 Number of Phases Three (3) One (1)
4 Frequency 50 Hz 50 Hz
5 Voltage Variation + 10% + 10%
6 Frequency Variation + 5% + 5%
Combined Voltage &
7 10 % 10 %
Frequency Variation
8 Neutral Earthing Solidly Grounded Solidly Grounded
9 Fault Level 50 kA for 1 sec 9 kA
Note: $$ denotes fault level at DCDB level shall be 25kA while at DLDB level fault level
shall be 9kA.

SECTION – 6
UF & RO PROJECTION

HYDRAcap MAX 80 Summary
Project Details
Project Title GACL Nalco (2) (1)
Application RO Pretreatment
Client Name GACL
Prepared By mjoshi@hydranautics.com
1. Feed water quality
Source Waste Water - Industrial (Chemical)
Minimum Temperature 27 °C
Turbidity 1 NTU
Total suspended solids 2 ppm
Total dissolved solids 3000 ppm
COD 50 ppm
BOD5 20 ppm
TOC 10 ppm
pH 7.5
Fe 0.2 mg/L as Fe
Mn 0.02 mg/L as Mn
Al 0.05 mg/L as Al
Alkalinity 100 mg/L as CaCO3
Ca 100 mg/L as CaCO3
Total Hardness 250 mg/L as CaCO3
LSI* -0.498
* If LSI is negative, there is little to no potential for scale in the form of CaCO3; if LSI is positive, there is potential for scale in the form of CaCO3.
1 A. Expected permeate water quality
Turbidity < 0.2 NTU
TSS < 0.5 ppm
SDI 3
* These values are general values based on any feed water characteristics.
2. Main Operating Parameters
Filtration time 34 min
Air Scour Sequence Duration 4.131 min
Cycle Duration 38.13 min
Number of cycles per day 37.76 #
Number of cycles per day without MC 34.76 #
Number of cycles per day with MC 3 #
Design Basis Constant Flux
Enhanced Solids Removal
Accelerated Drain
Use of concentrate?
Concentrate % 0.00 %
Concentrate Bleed % 0.00 %
Maintenance Clean Solution Make Up Water Filtrate Water
Chemical for MC1 and RC1 NaOCl
Chemical for MC3 and RC3 Hydrochloric Acid and Hydrochloric Acid
MC1 frequency 0 #/rack/day
MC1 + 2 Frequency 2 #/rack/day
RC1 frequency 0.017 #/rack/day
MIT frequency 0.0333 #/rack/day
Confidential
Product performance calculations are based on nominal element performance when operated on a feed water of acceptable quality. The results shown on the printouts produced by this program are estimates of product
performance. No guarantee of product or system performance is expressed or implied unless provided in a separate warranty statement signed by an authorized Hydranautics representative. Calculations for chemical
consumption are provided for convenience and are based on various assumptions concerning water quality and composition. As the actual amount of chemical needed for pH adjustment is feedwater dependent and not
membrane dependent, Hydranautics does not warrant chemical consumption. If a product or system warranty is required,please contact your Hydranautics representative. on-standard or extended warranties may result in
different pricing than previously quoted.
3. System Design Overview
Number of modules per rack 25
Number of duty racks 1
Number of standby racks 0
Total number of racks 1
Total Rack footprint size* 14.97 m2
Single Rack Length 4 m
Single Rack Width 1.8 m
Single Rack footprint size* 7.047 m2
Number of valves/rack** 8
Total number of valves*** 11
Module type HYDRAcap MAX 80
Membrane material PVDF
Membrane area per module 105 m2
Total number of duty modules 25
Total number of standby modules 0
Total number of modules 25
Number of duty feed pumps 1
Number of duty air scour blowers 1
Number of duty chemical dosing systems 1
Daily Total Feed Volume 2694 m3/d

Daily Net Filtrate Volume 2623 m3/d
Daily Gross Filtrate Volume 2630 m3/d
Total Waste water volume 71.46 m3/d
Total Chemical-free Waste water volume 57.06 m3/d
Total Chemical Waste water volume 14.35 m3/d
Total concentrate volume 0 m3/d
Total concentrate volume 0 m3/h
Total concentrate bleed volume 0 m3/d
Total concentrate bleed volume 0 m3/h
Average Recovery 97.35 %
Operation Time 24 h/24

System production time with n racks in service 20.16 h
System production time with n-1 racks in service 0 h
Per rack production time with n-1 racks in service 0 h
* Total rack footprint sizes assumes a gap between each rack of 2 m (~7 ft). **Assumes there are automatic and manual valves for all major valves (i.e. feed,
filtrate, concentrate, etc.). Also, includes either feed chemical injection points for chlorine, caustic, and acid if required by design. ***Assumes three extra valves
for common chemical injection points for RC's.
Confidential
N RACKS IN SERVICE
Instantaneous total feed flow 130.4 m3/h
Instantaneous individual rack feed flow 130.4 m3/h
Instantaneous total filtrate flow 130.4 m3/h
Instantaneous individual rack filtrate flow 130.4 m3/h
Instantaneous total concentrate 0 m3/h
Instantaneous individual rack concentrate 0 m3/h
Instantaneous total concentrate bleed flow 0 m3/h
Instantaneous individual rack concentrate bleed flow 0 m3/h
Instantaneous rack flux 49.69 LMH
Temperature corrected instantaneous flux 49.69 LMH
N-1 RACKS IN SERVICE
Instantaneous total feed flow 0 m3/h
Instantaneous individual rack feed flow 0 m3/h
Instantaneous total filtrate flow 0 m3/h
Instantaneous individual rack filtrate flow 0 m3/h
Instantaneous rack flux 0 LMH
Temperature corrected instantaneous flux 0 LMH
Average gross flux 49.69 LMH

Temperature correction factor 1
Temperature corrected average gross flux 49.69 LMH
Confidential
4. Cleaning Occurrence and Time Consumption
Duration Total Plant Occurrence Total Plant Time Consumed for Cleaning per
Sequence
(min) / day Day (min)
AS 4.131 34.76 143.6
MC1 28.71 0 0
MC2 0 0 0
MC3 28.71 1 28.71
MC1 + 2 28.71 2 57.42
MIT 11.73 0.033 0.391
RC1 121.1 0.017 2.011
RC2 121.1 0.017 2.011
RC3 121.1 0.017 2.011
Total per day (min) 230.1
Non production time per 230.1
rack (min)
5. Waste water production
Total waste
Chemical-free waste Chemical waste Waste
Occurrence water
Sequence water volume / water volume / water
/ day volume /
3 3 %
sequence (m ) sequence (m )
day (m3)
Concentrate Bleed 0.0 0 0
AS 1.508 ~ 34.76 52.43 73.37
MC1 0 0 0 0 0
MC2 0 0 0 0 0
MC3 1.544 4.784 1 6.327 8.854
MC1 + 2 1.544 4.784 2 12.65 17.71
MIT 1.508 0 0.033 0.05 0.088
RC1 6.474
RC2 6.474
RC3 6.474
Total per day 71.46
Chemical-free wastewater total 57.06
per day
Chemical wastewater total per 14.35
day
6. Major Equipment Specification Summary
Equipment Detail Units Value Notes

Number of duty pumps 1
Average feed flow rate per pump m3/h 112.3
Average feed pressure kPa 154.5
Feed pump(s) Assumed average filtrate pressure kPa 35 Feed pumps must be equipped
with VFDs
Maximum feed flow rate per pump m3/h 130.4
Maximum feed pressure* kPa 281.6
Estimated average total feed pump energy 3 0.068
consumption kWh/m
Number of duty blowers 1
Average aeration rate per rack/blower m3/h 304.2
Maximum aeration rate per rack/blower m3/h 380.3
Air scour &
Blower(s) Average Air Scour Pressure kPa 53.06
Maximum Air Scour Pressure kPa 70
Estimated average total blower energy 3 0.005
consumption kWh/m
*Does not include piping losses outside of rack. i.e. The piping to and from the rack. **Chemical for RCs can be poured and mixed directly into RC tank. In
which case, no RC dosing pump is required.
Confidential
7. Chlorine Maintenance Clean (MC1) summary
General
Makeup water for MC1s N/A
Number of MC1 per rack per day 0
Duration 28.71 minutes
Target chlorine concentration per MC 0 ppm
MC1 Chlorine Consumption Data
Assumed chemical stock concentration 0 g/L
Assumed chemical stock concentration 12 %
Volume of chlorine to be used per MC 0 L
Volume of chlorine to be used per day 0 L
MC1 Chemical Filling
Pump used for chemical solution filling N/A
MC1 chemical solution filling flowrate 0 m3/h
Chlorine dosing pump flowrate 0 L/h
Chlorine dosing pump run time 0 s
MC1 Chemical Rinsing
Pump used for chemical rinsing N/A
MC1 rinsing flow 0 m3/h
MC1 Dosing Pump Specifications
Chemical dosed into N/A
Maximum dosing pump flow rate 0 L/h
Maximum dosing pump pressure 0 kPa
8. Chlorine Recovery Clean (RC1) summary
General
Makeup water for RC1s Filtrate
Number of days between RC1 per rack 60.24 days
Target chlorine concentration per RC 1000 ppm
Target temperature of solution 40 °C
RC1 Chlorine Consumption Data
Solution concentration 133.1429 g/L
Stock Solution concentration (weight percent) 12 %
Volume of chlorine to be used per RC 17.01 L
Volume of chlorine to be used per day 0.282 L
RC1 Chemical Filling
Pump used for chemical solution filling RC Pump
RC1 filling flow 105.4 m3/h
RC1 Chemical Rinsing
Pump used for chemical rinsing Feed Pump
RC1 rinsing flow 130.4 m3/h
Confidential
9. Caustic Maintenance Clean (MC2) summary
General
Makeup water for MC2s N/A
Duration 0 minutes
Target caustic solution concentration 0 ppm
MC2 Caustic Consumption Data
Stock chemical density 0 g/mL
Stock chemical % 30 %
Volume of caustic to be used per MC 0 L
Volume of caustic to be used per day 0 L
Pump used for chemical solution filling N/A
Filling flow 0 m3/h
Caustic flow during filling 0 L/h
Caustic dosing pump running time 0 s
Pump used for chemical rinsing N/A
MC2 Rinsing flux 0 LMH
MC2 Rinsing flow 0 m3/h
Chemical dosed into N/A
Maximum dosing pump flow rate 0 L/h
10. Caustic Recovery Clean (RC2) summary
General
Target caustic concentration 3500 ppm
RC2 Caustic Consumption
Density 1.52 g/ML
% commercial solution 30 %
Volume of caustic to be used per RC 17.38 L
Volume of caustic to be used per day 0.289 L
Filling flow 105.4 m3/h
RC2 Rinsing flow 130.4 m3/h
Confidential
11. Acid Maintenance Clean (MC3) summary
General
Makeup water for MC3s Filtrate
Type of acid Hydrochloric Acid
Target acid solution concentration 1470 ppm
MC3 Acid Consumption Data
Stock chemical density 1.164 g/mL
Stock chemical % 30 %
Volume of acid to be used per MC 9.535 L
Volume of acid to be used per day 9.535 L
Acid flow during filling 443.5 L/h
Acid dosing pump running time 77.39 s
MC3 Rinsing flux 49.52 LMH
MC3 Rinsing flow 130.4 m3/h
Chemical dosed into Filtrate Line
Maximum dosing pump flow rate 443.5 L/h
12. Acid Recovery Clean (RC3) summary
General
Type of acid Hydrochloric Acid
Target acid concentration 5000 ppm
RC3 Acid Consumption
Density 1.164 g/l
% commercial solution 30 %
Volume of acid to be used per RC 32.43 L
Volume of acid to be used per day 0.538 L
RC3 Rinsing flow 130.4 m3/h
Confidential
13. Chlorine + Caustic Maintenance Clean (MC1 + 2) summary
General
Makeup water for MC1+2s Filtrate
Number of MC1+2 per rack per day 2
Target chlorine solution concentration 200 ppm
Target caustic solution concentration 1200 ppm
MC1+2 Chlorine & Caustic Consumption Data
Chlorine stock chemical concentration 133.1429 g/L
Caustic stock chemical density 1.52 g/mL
Chlorine stock chemical % 12 %
Caustic stock chemical % 30 %
Volume of chlorine to be used per MC 3.402 L
Volume of caustic to be used per MC 5.961 L
Volume of chlorine to be used per day 6.805 L
Volume of caustic to be used per day 11.92 L
MC1+2 Chemical Filling
Chlorine dosing pump flowrate 158.3 L/h
Chlorine dosing pump run time 77.39 s
Caustic dosing pump flowrate 277.3 L/h
Caustic dosing pump run time 77.39 s
MC1+2 Chemical Rinsing
MC1+2 Rinsing flux 49.52 Lmh
MC1+2 Rinsing flow 130.4 m3/h
MC1+2 Dosing Pump Specifications
Chemical dosed into Filtrate Line
Maximum dosing pump flow rate (chlorine) 158.3 L/h
Maximum dosing pump flow rate (caustic) 277.3 L/h
14. Chemical Consumption Summary
12% SODIUM HYPOCHLORITE
Sodium Hypochlorite Consumption due to MC1 0.000000 L/m3 filtrate
Sodium Hypochlorite Consumption due to MC1 + 2 0.002594 L/m3 filtrate
Sodium Hypochlorite Consumption due to RC1 0.000108 L/m3 filtrate
Total Sodium Hypochlorite Consumption 0.002702 L/m3 filtrate
Total Daily Sodium Hypochlorite Consumption 7.087 L/day
Total Annual Sodium Hypochlorite Consumption 2587 L/year
30% SODIUM HYDROXIDE
Sodium Hydroxide Consumption due to MC2 0.000000 L/m3 filtrate
Sodium Hydroxide Consumption due to MC1 + 2 0.004545 L/m3 filtrate
Sodium Hydroxide Consumption due to RC2 0.000110 L/m3 filtrate
Total Sodium Hydroxide Consumption 0.004655 L/m3 filtrate
Total Daily Sodium Hydroxide Consumption 12.21 L/day
Total Annual Sodium Hydroxide Consumption 4457 L/year
30% HYDROCHLORIC ACID & 30% HYDROCHLORIC ACID
Hydrochloric Acid Consumption due to MC3 0.003635 L/m3 filtrate
Hydrochloric Acid Consumption due to RC3 0.000205 L/m3 filtrate
Total Acid Consumption 0.003840 L/m3 filtrate
Total Daily Acid Consumption 10.07 L/day
Total Annual Acid Consumption 3677 L/year
Confidential
15. Auxiliary Equipment Recommendations
RECOMMENDATION*
Number of RC pumps 1
RC maximum pump flow 105.4 m3/h
RC maximum pump pressure 230 kPa
RC Tank Size 4.722 m3
Number of Compressors/Air Receivers/Dryers 1
Compressed Air Receiver Size** 0.138 m3
Air Volume required to do a Pressurized Drain and MIT*** 0.645 m3
Compressor Rating**** 10.42 m3/h
Dryer Rating***** 10 m3/h
*All sizes expressed in this table depend upon site requirements
*All sizes expressed correspond to working volume capacities not including piping from tank to racks or safety factors
**Assumes air in receiver is at 6 bar.Only considers volume required for air assisted chemical drain and integrity testing, which is delivered to the rack at ~1.4
bar. Does not consider requirements of any other equipment requiring compressed air for operation.
***Assumes pressure required for the modules (no piping) and a 50% safety factor.
****Assumes a 50% safety factor and that the air will be delivered within the first third air scour and chemical drain step.
*****Assumes dryer is only used for pneumatic valve operations.
16. Automatic Valves
# Valves/ Total # of Size

Valve Description Pipe Velocity (m/s) Notes
Rack Valves (mm)
1 1 Feed valve ≤2.7 150
1 1 Filtrate valve <2.7 150 Size of common filtrate pipe
section*
1 1 Concentrate valve ≤8.6 100
0 0 Concentrate return
valve
1 1 Drain valve ≤1.2 150
1 1 Air scouring inlet valve ≤0.75 kPa ∆P/30.5m 150
of pipe
1 1 Filtrate to drain valve ≤2.7 100
1 1 RC feed valve ≤2.7 150
1 1 Membrane integrity test ≤97 kPapipe
∆P/100m of 37
valve
0 0 Feed chlorine injection

valve
1 1 Filtrate chlorine
injection valve
0 0 Feed caustic injection

valve
1 1 Filtrate caustic injection

valve
0 0 Feed acid injection

valve
1 1 Filtrate acid injection

valve
*Top and Bottom Header size is 100 mm
Confidential
Product performance calculations are based on nominal element performance when operated on a feed water of acceptable quality. The results shown on the
printouts produced by this program are estimates of product performance. No guarantee of product or system performance is expressed or implied unless
provided in a separate warranty statement signed by an authorized Hydranautics representative. Calculations for chemical consumption are provided for
convenience and are based on various assumptions concerning water quality and composition. As the actual amount of chemical needed for pH adjustment is
feedwater dependent and not membrane dependent, Hydranautics does not warrant chemical consumption. If a product or system warranty is required,please
contact your Hydranautics representative. on-standard or extended warranties may result in different pricing than previously quoted.
HYDRAcap® MAX 80 Process Overview
Membrane System
Project Information Number of Racks 1
Project Title GACL Nalco (2) (1) Modules per Rack 25
Application RO Pretreatment Temperature Corrected
49.69
Average Gross Flux, LMH
Client Name GACL
Recovery, % 97.35
Prepared By mjoshi@hydranautics.com
Filtration time, min 34
Flow, m3/d 2623
RC Pump
Max Flow, m3/h 105.4
Max Pressure, kPa 230
Flow, m3/d 0
RC Tank
Volume, m3 4.722
Feed
Flow, m3/d 2694
Feed Source Waste Water - Industrial Chemical Maintenance Clean
Temp, oC 27 Stock Chemical NaOCl NaOH HCl NaOCl + NaOH
Turbidity, NTU 1 Concentration 12 % 30 % 30 % 12 % + 30 %
MCs / Rack / Day 0 0 1 2
Total, m3/d 71.46 Chem. Use, LPD 0 0 9.535 6.805 + 11.92
Chemical, m3/d 14.35 Dosing Pump Flow, LPH 158.3 277.3 443.5
Air Flow / Rack, m3/h 304.2
CONFIDENTIAL
Product performance calculations are based on nominal element performance when operated on a feed water of acceptable quality. The results shown on the printouts produced by this program are estimates of product performance. No guarantee of product or system performance is expressed
or implied unless provided in a separate warranty statement signed by an authorized Hydranautics representative. Calculations for chemical consumption are provided for convenience and are based on various assumptions concerning water quality and composition. As the actual amount of
chemical needed for pH adjustment is feedwater dependent and not membrane dependent, Hydranautics does not warrant chemical consumption. If a product or system warranty is required, please contact your Hydranautics representative. Non-standard or extended warranties may result in
Integrated Membranes Solutions Design Software, 2018
Created on: 1/31/2019 05:52:49
Permeate Throttling (Variable)

Project name GACL Nalco Page : 1/4
Calculated by MJ Permeate flow/train 82.00 m3/h
HP Pump flow 109.33 m3/h Raw water flow/train 109.33 m3/h
Feed pressure 16.2 bar Permeate recovery 75.00 %
Feed temperature 25.0 °C(77.0°F) Element age 3.0 years
Feed water pH 7.50 Flux decline %, per year 15.0
Chem dose, mg/l, 30 % 6.5 HCl Fouling factor 0.61
Specific energy 0.75 kwh/m3 SP increase, per year 10.0 %
Pass NDP 8.5 bar Inter-stage pipe loss 0.207 bar
Average flux rate 15.7 lmh
Feed type Waste MF/UF
Pass - Perm. Flow / Vessel Flux DP Flux Beta Stagewise Pressure Perm. Element Element PV# x
Stage Flow Feed Conc Max Perm. Boost Conc TDS Type Quantity Elem #
m3/h m3/h m3/h lmh bar lmh bar bar bar mg/l
1-1 62.4 7.8 3.4 17.1 0.6 20.7 1.13 3 0 15.5 78 CPA5-LD 98 14 x 7M
1-2 19.6 7.8 4.5 12.6 0.7 16.8 1.1 0 0 14.6 227.4 CPA5-LD 42 6 x 7M
Permeate
Ion (mg/l) Raw Water Feed Water Water Concentrate 1 Concentrate 2
Hardness, as CaCO3 792.13 792.13 6.355 3154.9 3154.9
Ca 148.00 148.00 1.187 343.9 589.5
Mg 103.00 103.00 0.826 239.3 410.2
Na 1050.76 1050.76 39.953 2412.5 4090.2
K 0.00 0.00 0.000 0.0 0.0
NH4 0.00 0.00 0.000 0.0 0.0
Ba 0.000 0.000 0.000 0.0 0.0
Sr 0.000 0.000 0.000 0.0 0.0
H 0.00 0.00 0.000 0.0 0.0
CO3 0.82 0.51 0.001 3.2 10.5
HCO3 147.00 144.38 9.002 325.5 543.1
SO4 34.00 34.00 0.251 79.0 135.5
Cl 2070.00 2071.90 60.667 4773.7 8119.5
F 0.00 0.00 0.000 0.0 0.0
NO3 0.00 0.00 0.000 0.0 0.0
PO4 0.00 0.00 0.000 0.0 0.0
OH 0.00 0.01 0.000 0.0 0.0
SiO2 71.00 71.00 1.957 163.7 278.6
B 0.00 0.00 0.000 0.0 0.0
CO2 3.81 5.93 5.93 5.93 5.93
TDS 3624.58 3623.55 113.85 8340.75 14177.19
pH 7.70 7.50 6.37 7.82 8.02
Saturations Raw Water Feed Water Concentrate Limits

CaSO4 / ksp * 100, % 1 1 3 400
SrSO4 / ksp * 100, % 0 0 0 1200
BaSO4 / ksp * 100, % 0 0 0 10000
SiO2 saturation, % 54 55 196 140
CaF2 / ksp * 100, % 0 0 0 50000
Ca3(PO4)2 saturation index 0.0 0.0 0.0 2.4
CCPP, mg/l 12.18 7.54 244.90
Langelier saturation index 0.39 0.18 1.82 2.5
Ionic strength 0.07 0.07 0.28
Osmotic pressure, bar 2.7 2.7 10.4
Product performance calculations are based on nominal element performance when operated on a feed water of acceptable quality. The results shown on the printouts produced by this program are
estimates of product performance. No guarantee of product or system performance is expressed or implied unless provided in a separate warranty statement signed by an authorized Hydranautics
representative. Calculations for chemical consumption are provided for convenience and are based on various assumptions concerning water quality and composition. As the actual amount of chemical
needed for pH adjustment is feedwater dependent and not membrane dependent, Hydranautics does not warrant chemical consumption. If a product or system warranty is required, please contact your
Hydranautics representative. Non-standard or extended warranties may result in different pricing than previously quoted. Version : 1.222.81 %
Email : imsd-support@hydranauticsprojections.net
Created on: 1/31/2019 05:52:50

Pass - Perm. Flow / Vessel Flux DP Flux Beta Stagewise Pressure Perm. Element Element PV# x
Stage Flow Feed Conc Max Perm. Boost Conc TDS Type Quantity Elem #
m3/h m3/h m3/h lmh bar lmh bar bar bar mg/l
1-1 62.4 7.8 3.4 17.1 0.6 20.7 1.13 3 0 15.5 78 CPA5-LD 98 14 x 7M
1-2 19.6 7.8 4.5 12.6 0.7 16.8 1.1 0 0 14.6 227.4 CPA5-LD 42 6 x 7M
Permeat Permeate
Pass - Element Feed Pressure Conc NDP e Water Water Beta Permeate (Passwise cumulative)
Stage no. Pressure Drop Osmo. Flow Flux TDS Ca Mg Na Cl
bar bar bar bar m3/h lmh
1-1 1 16.2 0.14 3 10.4 0.8 20.7 1.1 37 0.383 0.266 13.018 19.704
1-1 2 16 0.12 3.3 9.9 0.7 19.5 1.1 41.6 0.43 0.299 14.629 22.146
1-1 3 15.9 0.1 3.7 9.4 0.7 18.5 1.11 47 0.486 0.338 16.508 24.997
1-1 4 15.8 0.09 4.2 8.9 0.6 17.3 1.12 53.5 0.554 0.386 18.804 28.481
1-1 5 15.7 0.07 4.7 8.3 0.6 16.1 1.12 60.9 0.631 0.439 21.392 32.41
1-1 6 15.7 0.06 5.4 7.7 0.5 14.8 1.13 68.9 0.715 0.497 24.205 36.685
1-1 7 15.6 0.05 6.1 6.9 0.5 13.1 1.13 78 0.81 0.564 27.407 41.554
1-2 1 15.3 0.14 6.7 9 0.6 16.8 1.08 81.1 0.843 0.587 28.489 43.202
1-2 2 15.2 0.12 7.2 8.3 0.6 15.4 1.1 84.9 0.882 0.614 29.8 45.198
1-2 3 15.1 0.11 7.8 7.6 0.5 14.1 1.08 89.3 0.929 0.646 31.343 47.548
1-2 4 15 0.1 8.5 6.9 0.5 12.6 1.07 94.4 0.982 0.683 33.123 50.259
1-2 5 14.9 0.09 9.1 6.1 0.4 11 1.07 100.1 1.043 0.726 35.146 53.341
1-2 6 14.8 0.08 9.8 5.4 0.4 9.7 1.07 106.6 1.111 0.773 37.415 56.799
1-2 7 14.7 0.07 10.4 4.7 0.3 8.3 1.06 113.8 1.187 0.826 39.93 60.632
Created on: 1/31/2019 05:52:50

THE FOLLOWING PARAMETERS EXCEED RECOMMENDED DESIGN LIMITS
Concentrate saturation of SiO2 (196.13 %) is higher than limit 140 %.
The above saturations limits only apply when using effective scale inhibitor or dispersant. Without scale
inhibitor or dispersant, the saturation and precipitation limit of the contaminant should not exceed its solubility in
solution.
Created on: 1/31/2019 05:52:50

Temperature : 25.0 °C Element age, P1 : 3.0 years
Stream No. Flow (m3/h) Pressure (bar) TDS (mg/l) pH Econd (µs/cm)
1 109 0 3625 7.70 6489
2 109 16.2 3624 7.50 6492
3 109 16.2 3624 7.50 6492
4 46.9 15.5 8341 7.82 13973
5 27.3 14.6 14177 8.02 22888
6 62.4 3.00 78.0 6.21 159
7 19.6 0 227 6.66 463
8 82.0 0 114 6.37 232
SECTION – 7
ANTISCALANT PROJECTIONS

Reverse Osmosis Antiscalant Proposal
Project Information
Project Name/ Location: GNAL Project Dahej
Country of Installation: India
RO Designation: RO System
Prepared by: ISGEC
Date: 30-01-2019
Version: 2.0.0
Operating Parameters Design

Feed Flow: 2616 m3/day
Product Flow: 1962 m3/day
Reject Flow: 654 m3/day
Recovery: 75 %
Concentration Factor (CF): 3.98
Type of Application: Brackish Water
Assumed Salt Passage: 0.5 %
Temperature: 25 C
Water Chemistry Design

Ion Unit Raw Water Feed Concentrate
Aluminum ppm Al 0 0 0
Barium ppm Ba 0 0 0
Calcium ppm Ca 148 148 589.78
Iron ppm Fe 0 0 0
Magnesium ppm Mg 103 103 410.46
Manganese ppm Mn 0 0 0
Potassium ppm K 0 0 0
Silica ppm SiO2 71 71 282.94
Sodium ppm Na 1050 1050 4184.25
Orthophosphate ppm PO4 0 0 0
Bromide ppm Br 0 0 0
Chloride ppm Cl 2070 2070 8248.95
Nitrate ppm Nitrate 0 0 0
Sulfate ppm SO4 34 34 135.49
Bicarbonate ppm HCO3 147 147 581.53
Carbonate ppm CO3 0.66 0.66 4.66
Fluoride ppm F 0 0 0
Strontium ppm Sr 0 0 0
Carbon dioxide ppm CO2 3.93 3.93 5.4
pH 7.7 7.7 8.24
Ionic Strength 0.07 0.07 0.28
1
Product Dosage Recommendation and Product Usage Details – Design Case
Product Selected: PC-510T Design Conditions

Dose in feed water for scale control: 4.58 ppm
Dose in feed water for iron/aluminum/manganese control: 0 ppm
Total feed water dose: 4.58 ppm
PermaTreat PC-510T in concentrate: 18.23 ppm
Daily requirement for PermaTreat PC-510T: 11.93 kg/day
Acid/ Alkali Daily Requirement: 0 kg/day
Daily Requirement of Acid/ Alkali in ppm: 0
Scaling Indices Design

Index Name Feed Values Concentrate Values Untreated % Treated %
CaCO3 SR 1.54 37.48 3747.89 25.85
CaSO4 SR 0 0.02 1.92 0.69
BaSO4 SR 0 0 0 0
SrSO4 SR 0 0 0 0
CaF2 SR 0 0 0 0
Fe Fouling 0 0 0 0
Al Fouling 0 0 0 0
Mn Fouling 0 0 0 0
SiO2 Fouling 0.53 1.73 173.15 83.24
Ca3(PO4)2 Fouling 0 0 0 0
Design Untreated Design Treated
All queries and requests for additional information can be made to:
Nalco Company - PermaCare products
E-mail: ask@nalco.com
Web site: www.permacare.com
North America (+1) 630 305 1000, South America (+55) 11 5644 6500,
Europe (+31) 71 524 1100, Pacific (+65) 686 14011
Disclaimer: The information used in the RO Optimizer computer program is based on published data, laboratory studies and practical experience.
Since the conditions in which the PermaTreat antiscalants may be used are outside our control, We cannot warranty the results obtained.
2
Project Information
Project Name/ Location: GNAL Project Dahej
Country of Installation: India
RO Designation: RO System
Prepared by: ISGEC
Date: 30-01-2019
Version: 2.0.0
Operating Parameters Alternate

Feed Flow: 2616 m3/day
Product Flow: 1962 m3/day
Reject Flow: 654 m3/day
Recovery: 75 %
Concentration Factor (CF): 3.98
Type of Application: Brackish Water
Assumed Salt Passage: 0.5 %
Temperature: 35 C
Water Chemistry Alternate

Ion Unit Raw Water Feed Concentrate
Aluminum ppm Al 0 0 0
Barium ppm Ba 0 0 0
Calcium ppm Ca 148 148 589.78
Iron ppm Fe 0 0 0
Magnesium ppm Mg 103 103 410.46
Manganese ppm Mn 0 0 0
Potassium ppm K 0 0 0
Silica ppm SiO2 71 71 282.94
Sodium ppm Na 1050 1050 4184.25
Orthophosphate ppm PO4 0 0 0
Bromide ppm Br 0 0 0
Chloride ppm Cl 2070 2071.61 8255.36
Nitrate ppm Nitrate 0 0 0
Sulfate ppm SO4 34 34 135.49
Bicarbonate ppm HCO3 147 144.54 572.05
Carbonate ppm CO3 0.79 0.49 3.81
Fluoride ppm F 0 0 0
Strontium ppm Sr 0 0 0
Carbon dioxide ppm CO2 3.93 5.57 6.93
pH 7.7 7.5 8.08
Ionic Strength 0.07 0.07 0.28
3
Product Dosage Recommendation and Product Usage Details – Alternate Case
Product Selected: PC-510T Alternate Conditions

Dose in feed water for scale control: 3.97 ppm
Dose in feed water for iron/aluminum/manganese control: 0 ppm
Total feed water dose: 3.97 ppm
PermaTreat PC-510T in concentrate: 15.81 ppm
Daily requirement for PermaTreat PC-510T: 10.34 kg/day
HCl Daily Requirement: 4.33 kg/day
Daily Requirement of HCl in ppm: 1.65
Scaling Indices Alternate

Index Name Feed Values Concentrate Values Untreated % Treated %
CaCO3 SR 1.31 34.5 3449.57 23.79
CaSO4 SR 0 0.02 1.92 0.69
BaSO4 SR 0 0 0 0
SrSO4 SR 0 0 0 0
CaF2 SR 0 0 0 0
Fe Fouling 0 0 0 0
Al Fouling 0 0 0 0
Mn Fouling 0 0 0 0
SiO2 Fouling 0.47 1.59 159.03 76.46
Ca3(PO4)2 Fouling 0 0 0 0
Design Treated Alternate Treated
Recovery adjusted to 75 vs. 75 ; Feed pH adjusted to 7.5 vs. 7.7; Temperature adjusted to 35 vs. 25.
Savings generated by Alternate design:
Type Design Alternate Savings US$ Savings

Feed 2616 m3/day 2616 m3/day 0 m3/day 0
Reject 654 m3/day 654 m3/day 0 m3/day 0
pH 0 kg/day 4.33 kg/day -4.33 kg/day 0
PC-510T usage reduced by 1.59 kg/day.

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DESIGN BASIS REPORT

Revised as per Desein

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT

GACL-NALCO ALKALIES & CHEMICALS PVT

EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.

DOCUMENT ID ES0153-75350100-DBR-0001 REVISION : 06

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

DOCUMENT ID ES0153-75350100-DBR-0001 REVISION : 06

01.01.00 PROJECT DETAILS & SITE DATA

S.No. Description Unit

3. EPC contractor M/s. Isgec Heavy Engineering Limited

7. Seismic Co-efficient zone Zone – III as per IS 1893 - 2002

8. Design Wind Velocity m/s As per IS 875, Part 3 – 47 m/s

9. Wind Direction SW-NE

10. Area classification Safe , Non- hazardous & Non- Corrosive

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

DOCUMENT ID ES0153-75350100-DBR-0001 REVISION : 06

S.No. Description Unit

20. Nearest town Bharuch– 50 KM

21. Nearest harbor Magdalla, Surat(~110 kms)

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

DESIGN BASIS REPORT

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

2. EQUIPMENT SIZING CALCULATIONS

3. TECHNICAL DATA SHEET

4. CONTROL & OPERATION PHILOSOPHY

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

DESIGN BASIS – ETP

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

DESIGN BASIS – EFFLUENT TREATMENT PLANT (ETP)

(A) DESIGN PARAMETERS FOR EFFLUENT TRE ATMENT PLANT:

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

TABLE 1 - DM PLANT EFFLUENT – QUALITY & QUANTITY

S. No. Description Unit Regeneration / Back wash waste per day

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

TABLE 2 – CAUSTIC SODA EFFLUENT QUALITY

2 NaCl 2.33% 23300 9320 13980 0 0 0

3 H2O 97.39% 973900

4 CaCl2 0.13% 1300 0 831.48 468.39 0 0

5 MgCl2 0.13% 1300 0 968.5 0 331.5 0

6 SrCl2 0.02% 200 0 89.4 0 0 110.54

8 Caustic Soda Effluent Quality 9320 15869.38 468.39 331.5 110.54

PROJECT 2 X 65 MW COGENERATION CAPTIVE POWER PLANT PROJECT ID : ES0153

OWNER GACL-NALCO ALKALIES & CHEMICALS PVT LIMITED DATE : 31.12.19

S. NO DESCRIPTION UNIT Value REMARKS

e. Total feed flow to UF system m3/hr 225

f. Back wash waste from DMF m3/day 96.0

g. DMF inlet flow m3/hr 229.0