KARBALA REFINERY PROJECT

UTILITY PROCESS TRAINING - BASIC

(Course Code : ETI-PR-03B)

UNIT 34 – Drinking Water Unit

CONTENTS Page : 2 / 32

Before Start..
Please follow below rules!

1. 50 minutes class, 10 minutes break

2. Please don’t use your mobile phone. If you need, use at the
out of this class room.
3. If you have question, please ask at the end of the class
4. Please be quite during the class
5. 12:00~13:00 is lunch time
CONTENTS Page : 3 / 32

1. INTRODUCTION
1) Introduction of Training Course Contents
2) Introduction of Training Schedule

2. PROCESS OVERVIEW
1) Process Principle
2) Basis of Design
3) Process Description

3. PROCESS FLOW AND CONTROL

1) Process Variables
2) Major Equipment
3) Complex Control Logic

4. START-UP AND SHUTDOWN

1) Startup Sequence
2) Shutdown Sequence
1. INTRODUCTION Page : 4 / 32

Expected Training
JV/Vendor Unit Unit Description Training Class
Duration

30 Raw Water Treatment Unit 2 days

1
51 Waste Water Treatment Plant 2 days

31 Firewater Unit 2 1 day

33 Cooling Water Unit

34 Drinking Water Unit 3 2 days

SK-PR
43 Caustic Soda Unit

35 Condensate Collection and Treatment Unit

4 2 days
36 BFW and Steam Generation Unit

37 Power Generation Unit 5 3 days

41 Instrument and Plant Air Unit 6 1 day

42 Nitrogen Generation Unit 6 1 day

1. INTRODUCTION (Continued) Page : 5 / 32

– Purpose

• The system provides drinking water to Buildings for refinery and distribution depot, and

Emergency eyewash and showers located inside refinery and distribution depot.

– Feed

• Ultra-filtered Raw Water (From Unit 30)

• 1st Reverse Osmosis Permeate (From Unit 30)

– Product

• Drinking Water Loop Supply

2. PROCESS OVERVIEW Page : 6 / 32

Process Principle

• Chlorination
Water chlorination is the process of adding hypochlorite to water.
This method is used to kill certain bacteria and other microbes in water as chlorine is highly
toxic. In particular, chlorination is used to prevent the spread of waterborne diseases such
as cholera, dysentery, typhoid, etc.

• UV Radiation
In water, UV generates ozone in situ and thus has many of the advantages of ozone
disinfection.
However, ultraviolet germicidal irradiation alone (as well as chlorination alone) will not
remove toxins from bacteria, pesticides, heavy metals, etc. from water.
2. PROCESS OVERVIEW (Continued) Page : 7 / 32

Basis of Design

– Capacity
• System Capacity : 4000 m3 (Two Storage Tanks, 48 hours hold-up)
* Drinking Water demand : 0.4 m3/day per person
* Expected number of operator : 5000
* Resulting average drinking water make-up : 84 m3/h (2000 m3/day)

Target of TDS control = 365 ppm (max)

– Drinking Water Make-up Blending Ratio

 CASE FILTERED WATER TREATED WATER TDS

NORMAL CASE 35% (29 m3/h) 65% (55 m3/h) 1000 ppm

DESIGN CASE 14% (12 m3/h) 86% (72 m3/h) 2500 ppm

30-AT-5003A 30-AT-5019
2. PROCESS OVERVIEW (Continued) Page : 8 / 32

Basis of Design
From Raw Water Treatment Unit (1) Filtered Water
(UNIT 30)

From Raw Water Treatment Unit (2) Treated Water DRINKING (4) Drinking Water Drinking Water Loop Supply
(UNIT 30) WATER UNIT

Drinking Water Loop Return (3) Drinking Water

(recycle)

Major Feed (m3/h) Major Feed (m3/h)

CASE
1 2 3 Total 4 Total

NORMAL 29 55 78 162 162 162

DESIGN 12 72 78 162 162 162

2. PROCESS OVERVIEW (Continued) Page : 9 / 32

Simplified PFD 1 operating

1 stand by
Sodium Hypochl. Tank volume :
Sol’n Static Mixer 4000m3
Filtered Water Drinking
35 ºC Drinking Water Water
Storage Tank Loop Supply
Ultraviolet
Sterilizer 35 ºC
Drinking Water 4.0 kg/cm2g
Treated Water Storage Tank
35 ºC Mixing Eductors
Drinking Water
Chlorination
Package

Drinking Water
Loop Return

Sodium Hypochl.
Sol’n Static Mixer

1 operating
1 stand by
Discharge P :
Drinking
6.8 kg/cm2g
Water Pumps
2. PROCESS OVERVIEW (Continued) Page : 10 / 32

- Overall Plot plan

2. PROCESS OVERVIEW (Continued) Page : 11 / 32

- Area Plot plan (5D)

2. PROCESS OVERVIEW (Continued) Page : 12 / 32

- 3D model
2. PROCESS OVERVIEW (Continued) Page : 13 / 32

- Process Description
Filtered Water from Ultrafiltration (30-PK-007) is blended with permeate from first Reverse
Osmosis (30-PK-001) to reduce salt concentration and comply with Iraqi standards for “Drinking
Water” (mainly Calcium). A conductivity analyzer (34-AT-0003) is provided on ultra-filtered water
for monitoring and blending ratio adjustment.
2. PROCESS OVERVIEW (Continued) Page : 14 / 32

- Process Description (Continued)

Blending is facilitated by Drinking Water static

mixer (34-PK-003-MX-001) based on make-up
flow rate and residual clorination where Sodium
Hypochlorite solution is injected to avoid
bacteriological growth maintaining a residual
free chlorine concentration.
2. PROCESS OVERVIEW (Continued) Page : 15 / 32

- Process Description (Continued)

Blended and chlorinated water is sent to drinking water storage tanks (34-TK-001A/B). Tanks are
under level control acting as master controller on filtered water and treated water flow controls via
ratio controller (34-FFIC-0003).
Each Tank is provided with an eductors (34-J-001 A/B) connected to drinking water loop return line
to facilitate drinking water temperature and composition homogenization. Both tanks are operating
normally.
2. PROCESS OVERVIEW (Continued) Page : 16 / 32

- Process Description (Continued)

Drinking Water stream is under a residual chlorine analyzer (34-AI-0002) installed in the discharge
line of drinking water pumps.

The value can be low if the make-up flow rate low.

In this case, shock dosing is required on recycle loop to increase the value.
3. PROCESS FLOW AND CONTROL Page : 17 / 32

- Process Variable

The most important and critical variables for the Drinking water Unit are:
 Water level inside the drinking water tank
 The correct water level inside the drinking water tank is essential:
 to maintain the drinking water circuit filled
 to avoid to damage the drinking water pumps
 Drinking water tank level (34-LI-0002/0004) working range is 20 % (Low) to 80 % (High)

 Ultra-Filtered water conductivity

 Conductivity range at Feed water is 375 ~ 570 μS/cm (240~265 ppm)

 Chlorine concentration
 Free chlorine (34-AI-0002) control range at drinking water supply is 0.2 ~ 0.5 ppmv.
 Free chlorine (34-AI-0001) at make-up water could be adjusted appropriately to meet the
control range of 34-AI-0002 with stroke control of 34-PK-003.
3. PROCESS FLOW AND CONTROL (Continued) Page : 18 / 32

- Major Equipment

Drinking Water Storage Tanks (34-TK-001A/B)

 Drinking water storage tanks are designed based on the followings.
 Two (2) Drinking water storage tanks (34-TK-001 A/B) are provided.
 Each tank working volume is sized for 24 hours hold-up (2000 m3) for an overall storage capacity
of 48 hours (4000 m3).
 Tanks are fixed roof atmospheric type.
 To reduce heat picked-up from the ambient, the storage tank is provided with insulation.
 Tank maximum operating temperature is 35°C.
 Maximum drinking water make-up temperature is 35°C considering Euphrates river water
temperature.

Drinking Water Pumps (34-P-001A/B)

 2 X 100% Drinking Water Pumps (34-P-001 A/B) are provided
 Drinking Water maximum flowrate is 260 m3/h according to the sum of the following:
 Drinking Water Peak Demand = Avg. Consumption * Peak Factor (PF) + 2 Safety
Shower/Eyewash simultaneous operating = 84*2 +14 = 182 m3/h
 Drinking Water Loop continuous recirculation: 78 m3/h.
 Drinking Water Pumps are designed to supply 2.5 kg/cm2(g) at grade minimum at furthest
Refinery Drinking water user (building tie-in, safety shower, etc.), 3.5 kg/cm2(g) minimum at
Karbala depot users.
3. PROCESS FLOW AND CONTROL (Continued) Page : 19 / 32

- Major Equipment (Continued)

Drinking Water Chlorination Package (34-PK-003)

Drinking Water dosing pumps are automatically operated to allow residual free chlorine at the
Drinking Water distribution between 0.2 ppm and 0.5 ppm max and residual free chlorine on water
make-up to drinking water tanks of 0.5 ppm.

 One continuous and one batch sodium hypochlorite solution injections are provided to maintain
the above required residual free chlorine concentration:
 Drinking Water Make-Up line to Drinking Water Tanks by static mixer (34-PK-003-MX-001),
Hypochlorite is dosed at 3 ppm maximum.
 Shock batch dosage through Sodium Hypochlorite Solution Static Mixer (34-PK-003-MX-002)
which motive fluid is Drinking Water return loop. Hypochlorite is dosed at 1 ppm on whole
drinking water storage volume (4032 m3) in a period of 10 hours once per week.
 Sodium Hypochlorite solution concentration is 12% minimum.
 Sodium Hypochlorite storage is for 7 days hold-up (1.5 m3 working volume).
 Sodium Hypochlorite solution is supplied in drums.
3. PROCESS FLOW AND CONTROL (Continued) Page : 20 / 32

- Major Equipment (Continued)

Drinking Water Distribution line

The distribution system consist of a main ring routed along the main process units and buildings
B.L. to allow continuous recirculation avoiding stagnant conditions; continuous recycle flow back to
the storage tank at a normal rate of 78 m3/h.
 The potable water lines will be installed underground to minimize temperature gain from solar
radiation.
 A single sub-header will be provided to supply drinking water to each process unit block/building.
 A single sub-header will be provided to supply drinking water to Karbala Depot.

Drinking Water Blending and Drinking water storage tanks

Level of Drinking Water Storage Tanks (34-TK-001A/B) is controlled using Cascade Level Control.
34-HS-0002 is provided to select Level input signal from either of two Drinking Water Storage Tanks
(34-TK-001AorB) which cascades ratio controller (34-FFIC-0003) from DCS by operator.

Level Controller (34-LIC-0005) acts as the master controller to control the level of Drinking Water
Storage Tank (34-TK-001AorB) by controlling the flow of Filtered Water by regulating 34-FV-0003
and flow of Treated Water by regulating 34-FV-0002. Ratio Controller 34-FFIC-0003 controls the
ratio of Filtered Water by regulating 34-FV-0003 and Treated Water by regulating 34-FV-0002.
3. PROCESS FLOW AND CONTROL (Continued) Page : 21 / 32

- Complex Control (1) - Drinking Water Blending

Manual input = 365 ppm

0-90 m3/h

0-50 m3/h
(25)
Input = 1000 ppm

0-80 m3/h
Input = 94 ppm (59)
3. PROCESS FLOW AND CONTROL (Continued) Page : 22 / 32

- Complex Control (1) - Drinking Water Blending

The pre-set ratio will be adjusted depending on actual water quality. Target quantity of TDS in
drinking water make-up is 365 ppm max. produced as follow;

Analyzer detects conductivity in microS/cm. but it cannot be converted to total dissolved solution..
- 30-SC-5001 for Raw(River) water in ppm TDS (30-AT-5003A/B)
- 30-SC-5033 for RO permeate water in ppm TDS (30-AT-5019)

Generally, 1 microS/cm = 0.640 ppm TDS (for quick reference purpose only).

Residual free chlorine at required concentration at the Drinking Water distribution is maintained by
adjusting the Sodium Hypochlorite Dosing Pumps stroke in Drinking Water Chlorination Package
(34-PK-003).

Chlorine analyzer 34-AE-0001 analyses the residual free chlorine concentration and sends the
signal to 34-AIC-0001A. 34-AIC-0001A will send the signal to multiplication block 34-AY-0001.

34-FIC-0003 on Filtered Water Line and 34-FIC-0002 on Treated Water Line will send the signal to
the Summation Block 34-FY-0004. 34-FY-0004 will also send the summation signal to 34-AY-0001.
3. PROCESS FLOW AND CONTROL (Continued) Page : 23 / 32

- Complex Control (2) – Chlorine Analyzer Controller

3. PROCESS FLOW AND CONTROL (Continued) Page : 24 / 32

- Complex Control (2) – Chlorine Analyzer Controller

34-AY-0001 is multiplication of feedback control signal from 34-AIC-0001A and feedforward control
parameter which is calculated with signal from 34-FY-0004. Then, 34-AY-0001 gives a new set point
to 34-AIC-0001B to modulate the chemical injection pump stroke.

The chloride injection rate is proportional to the drinking water make-up flow rate. However, the
make-up flow rate is depending on tank level (34-LIC-0005 cascade with 34-FFIC-0003).

When the make-up water flow rate is changed (increased or decreased), the injection rate shall be
changed according to the change of the water flow rates.

This flow rate change is expressed as the delta (D) between process value (PV) and set point (SP)
of 34-FFIC-0003. As of the results, the injection rate is also adjusted according to the delta (D) as
shown below;

New SP of 34-AIC-0001B = (Current SP of 34-AIC-0001B) + [D x (Control range of 34-AIC-0001)]

Where, D = [(SP of 34-FFIC-0003) – (PV of 34-FFIC-0003)] / (PV of34-FFIC-0003)
AIC-0001A set point (Operator input) = 3 ppm (default)
In steady state, SP of AIC-0001B is equal to SP of 34-AIC-0001A.

Feed forward controller (34-AIC-0001B) using the delta is adjusting chemical injection rate ahead to
avoid dilution and/or enrichment by the first part of make-up water.
Pump selector (34-HS-0001) is provided for selection of injection pump (34-PK-003-P-001A/B).
3. PROCESS FLOW AND CONTROL (Continued) Page : 25 / 32

- Cause and Effect Diagram

PDF Document
4. START-UP AND SHUTDOWN Page : 26 / 32

- Start up sketch at PFD

4. START-UP AND SHUTDOWN (Continued) Page : 27 / 32

The followings shall be available for this unit start-up:

• Electric Power, Control, Telecommunication and Fire water system
• Water System (Unit 30) – UF water (30-PK-007) & 1st RO Permeate water (30-PK-001)
• Instrument Air Unit (Unit 41)
• Steam generation Unit (Unit 36) for winter season
• Waste Water Treatment (Unit 51)

1. Fill the Drinking water tank (34-TK-001A/B)

During normal operation, both tanks are in operation.
1) Check the both tanks line-up is ready to receive water.
2) Set 34-LIC-0005 output is 0.0% in manual mode
3) Make sure raw water treatment unit (Unit 30) in operation
4) Operator shall input the following data in 34-HIC-0001
 30-SC-5001 for Raw(River) water in ppm TDS
 30-SC-5033 for RO permeate water in ppm TDS
 Target TDS in ppm of drinking water
5) 34-FV-0003 and 34-FV-0002 is close in manual mode
6) Set auto mode the water flow controllers (34-FIC-0002, 34-FIC-0003 and 34-FFIC-0003), while
LIC-0005 in manual mode with the output of 1.0%
7) Check the Conductivity of 34-AI-0003
8) When tank level is 1.0%, change the output of 0.0%.
4. START-UP AND SHUTDOWN (Continued) Page : 28 / 32

2. Start the Drinking Water Chlorination Package

1) Line up dosing pump (34-PK-003-P-001 A/B) to 34-PK-003-MX-002.

2) Increase 34-LIC-0005 output signal to ensure positive flow rate (34-FY-0004).
3) Start pump (34-PK-003-P-001 A/B) with stroke set at 20% in manual mode.
4) Set 34-AIC-0001A at 2.5 ppm in auto mode and ensure 34-AIC-0001B in auto mode.
5) Change 34-PK-003-P-001 A/B in auto mode
6) Increase tank level controller (34-LIC-0005) output signal slowly monitoring pump stroke signal
(output value of 34-AIC-0001B).
7) When the chemical injection rate is stabilized then, tank level shall be increased to 50%.
4. START-UP AND SHUTDOWN (Continued) Page : 29 / 32

3. Start Drinking Water Pump

In case of initial start-up, it needs to be filled the underground drinking water header.
During the underground recirculation loop is filling, the tank level shall be maintained at 20% to
allow gravity flow. Service all eye wash stations to eliminate the air pocket in the drinking water
line.

1) Make sure level of tank 34-TK-001A/B is higher than 20% with auto mode.
2) Open 1-1/2” bypass valves between the pump suction and discharge lines.
Due to gravity, the water will fill the pump suction line, discharge header, Ultraviolet Sterilizer
and underground drinking water header.
3) Start 34-P-001A/B and adjust the discharge valve to appropriate pressure (34-PG-0001A)
4) Check chloride concentration of 34-AI-0002.
- Make sure Chlorine content is 0.2 ~ 0.5 mg/L by (34-AI-0002).
- Take water sample from 34-SC-0001 (34-P-001A/B Drinking Water Pumps Discharge Line)
- If required, shock dosing shall be performed
5) Start Ultraviolet sterilization
6) At the end of water filling, water make-up valves will be almost closed
7) Maintain the pump operation and open discharge valve fully
8) Put stand-by pump at remote mode for auto start by 34-PALL-0002
4. START-UP AND SHUTDOWN (Continued) Page : 30 / 32

4. Start Ultraviolet Sterilization

Each ultraviolet sterilization train is designed for 100% capacity. During normal operation, both
trains can be operated (if required), (each 50%).
Caution:
Do not operate UV system until the UV chamber is completely filled with water. Do not allow
flow through UV chamber during start-up (until warming-up)

1) UV System shall be started at local.

2) Close 34-PK-002-Z-001A inlet valve
3) Ensure that there are no alarms in the UV system of 34-PK-002-Z-001A
4) Set the UV chamber to the warming state
5) Sets the power level at 100%. When warming is complete, and no major or critical
alarms are present, the UV system: Shows “OK” on the HMI User Interface.
6) Open inlet and outlet manual butterfly valves of 34-PK-002-Z-001A to service
7) For 34-PK-002-Z-001B, repeat the above steps

Now, both 34-PK-002-Z-001A and B are operating. (Normally, 1 operating, 1 spare)

4. START-UP AND SHUTDOWN (Continued) Page : 31 / 32

- Shutdown Procedure
1) Stop the drinking water pump
a. Put 34-LIC-0005 to manual mode and set output as 0.0%.
b. Put 34-FIC-0002 and 34-FIC-0003 to manual mode and Close valves.
c. Stop pump 34-P-001A and the local/remote selector position in LOCAL for both pumps.

2) Shutdown the UV System at local

a. Stops process flow through the UV chamber by closing inlet block valve.
b. At local, the operator changes the UV system Operation Mode to LOCAL.

3) Stop the drinking water chlorination package

a. Stop the pump 34-PK-003-P-001A or B by push button at Local or DCS. (34-MHSS-
03P001A/B).
b. Ensure the local/remote selector position in LOCAL for both pumps.

4) Drain the Drinking Water Unit

a. Drain of Pump 34-P-001A/B
b. Drain of Ultraviolet sterilizer 34-PK-002-Z-001A/B
c. Drain of Drinking water storage tank 34-TK-001A/B
5. Special Procedure Page : 32 / 32

- Shock Dosing Procedure

1) Frequency
Shock dosing is required when free chlorine contents is lower than 0.2 ppm at 34-AI-0002. When
make-up flow rate is low, chlorine content at 34-AI-0002 could be lower than 0.2 ppm due to
natural extinction characteristics of residual chlorine. In this case, shot dosing is required.
Expected frequency is once a week.

2) Procedure
• Change the line up chlorine injection line from 34-PK-003-MX-001 to 34-PK-003-MX-002
• Adjust stroke of the pump to meet 2.0 l/h (30% stroke). Expected duration is 10 hours.
• If chlorine content at 34-AI-0002 is higher than 0.5 ppm, stop dosing.
• After shock dosing, line up change to 34-PK-003-MX-001 for normal operation.

For the following procedures, Refer to Unit 33

- Chemical Curbed Area Operating Procedure

- Chemical Injection Package Operating Procedure