SOP on Operation of Purified Water Generation and Distribution System

Rahul Kashyap
0

Purpose
To describe the procedure operation of Purified water generation and distribution system.
Procedure:
Operation of Pre Treatment Unit
  • The purified water system can be operated in both Auto as well as in Manual mode.
  • Check & ensure that all dosing chemical solutions are prepared in respective tanks
  • Check and Set the dosing of Sodium Hypochlorite before raw water storage tank, It
  • Shall be 22% stroke at Dosing pump.
  • Raw water storage tank solenoid valve operates with level sensor and Naocl dosing pump will start when solenoid valve gets open.
  • Check the value of chlorine at sampling point , it shall be in between 1 to 3 PPM.
  • Select and set the pre-treatment section in Auto mode from the form HMI.

Operation of Multi grade Filter
  • Ensure that Multiport valve of MGF shall be in Service Mode (Filtration) & Inlet / Outlet Valve of respective pumps shall be in open position.
  • Switch On the MGF Inlet pump & maintain the flow to  through flowmeter.
  • Check the inlet / outlet Water Pressure of MGF. The DP between Inlet & Outlet shall not be more than 0.3 Kg/Cm2.
  • Backwash is required once in a day or in case the DP across Inlet / Outlet increases more than 0.3 Kg/Cm2.

Backwash of MGF
  • Ensure that Multiport valve of MGF shall be in Backwash Mode & Inlet / Outlet Valve of respective pumps shall be in open position.
  • Switch On the MGF Inlet pump & maintain the flow through flowmeter.
  • Backwash shall be carried out for 10 min & after backwash multiport valve shall be turned to Rinse position.
  • Rinse shall be carried out for 5 min. After completion of rinse multiport valve shall be turned to Service mode. (Filtration Mode)

Operation of Activated Carbon Filter
  • Ensure that Multiport valve of ACF shall be in Service Mode (Filtration) & Inlet / Outlet Valve of respective pumps shall be in open position.
  • Switch On the MGF Inlet pump & maintain the flow  through flowmeter.
  • Ensure that MGF Shall be in Service Mode.
  • Check the inlet / outlet Water Pressure of ACF. The DP between Inlet & Outlet shall not be than 0.3 Kg/Cm2.
  • Backwash is required once in a day or in case the DP across Inlet / Outlet increases more than 0.3 Kg/Cm2.

Backwash of ACF
  • Ensure that Multiport valve of ACF shall be in Backwash Mode & Inlet / Outlet Valve of respective pumps shall be in open position.
  • Switch On the MGF Inlet pump & maintain the flow  through flowmeter.
  • Backwash shall be carried out for 10 min & after backwash multiport valve shall be turned to Rinse position.
  • Rinse shall be carried out for 5 min. after completion of rinse multiport valve shall be turned to Service mode. (Filtration Mode)
  • Check the pH and TDS of MGF/ACF inlet / outlet sampling point.

Operation of Ultra Filtration Unit
  • Ensure that Compressed air pressure should be between 4 to 6 Kg/Cm2
  • Ensure that sufficient potable water in Potable water storage tank No. 1
  • Open the inlet / outlet valve of Pump PMP 06 & ensure the flow rate shall be in maintain.
  • Select the Ultra Filtration mode from HMI and press service mode to ON,
  • In Service mode the UF will forward flush for 60 Sec. Maintain the feed flow to through Flowmeter  Maintain the same flow in service mode. Maintain the reject flow to through Flow meter 
  • During forward flushing pneumatic valve get Open.
  • After forward flushing the UF will automatically get in service mode for 1 Hr.
  • After service mode of 1 Hr, the system shall operate in backwash mode for 60 sec. This cycle repeats continuously. Maintain the backwash flow  through UF backwash pump and same time open pneumatic valve After completion of backwash step, Pump  stops and pneumatic valve will get close, UF section automatically gets in to Service Mode.
  • .In service mode the Pneumatic shall open and UF permeate water shall feed to UF permeate water storage tank. If the water level in the UF permeate water storage tank goes high, UF shall stop. UF shall re-operate if water level goes to medium level.
  • Maintain the inlet pressure of UF Membrane, it should be NMT 1.0 Kg/ cm2.  If the pressure increases more than 1.0 Kg/ cm2, CIP shall be carried out with Sodium Hypo chloride & Citric Acid.
  • If after CIP UF permeate flow and pressure are not maintaining than replaced the UF membrane & maintain the replacement records.
  • Water sample of UF inlet water shall be collected from Sampling Point  and filter/product water f

Operation of Reverse Osmosis System
  • Ensure that compressed air pressure should be in between 4 to 6 kg/cm2
  • Ensure that compressed air pressure should be in between 4 to 6 kg/cm2.
  • Check and ensure that the UF permeate water available in UF permeate water storage tank.
  • Open the RO Feed inlet / outlet valve of RO Feed Pump before starting RO system.
  • Open the RO Feed inlet / outlet valve of RO Feed Pump before starting RO system.
  • Select the Reverse Osmosis service mode from HMI and press service mode to ON,
  • upon selecting service mode, the RO will start with RO Feed Pump and also chemical dosing pump of Sodium Meta BI Sulphite, Antiscalant, NaOH will gets start.
  • Set the dosing pump at RO feed stroke at 22 % (3 liter /Hr.) from adjusting knobs of
  • respective pumps. Maintain the MCF inlet flow at flow meter 2400 to 2500 LPH through Diaphragm valve.
  • Ensure that the ORP value at outlet of MCF should not be more than 150Mv. If ORP value increases more than 150 mV water shall dump before RO Feed through dumping valve automatically. If Chlorine value does not get maintain within 30 secs the RO system will raise alarm and tripping shall happen.
  • Check and maintain the MCF inlet pressure 3.0 to 3.5 kg/cm2 at pressure gauge. If MCF inlet pressure reaches more than 3.5 kg/cm2 replace the 5 Micron Cartridge Filter or replace the Micron Cartridge Filter After every two months. 
  • Check and note the pH value of sample point MCF inlet PTG-05 and MCF outlet
  • PTG-06, it should be between 7.0 to 8.0.
  • RO 1s flush for 60 Sec on starting of RO a and RO 2 flush 60 sec during start and pneumatic valve open, RO-1St
  • Permeate gets into RO 2nd Feed and RO 2 Permeate gets feed into FEDI inlet.
  • 13.Maintain the RO-1st reject flow . Maintain the feed pressure NMT 10Kg/Cm2 through High Pressure Pump for 1st pass RO.
  • Maintain the RO-2nd reject flow . Maintain the feed pressure NMT 10Kg/Cm2 through High Pressure Pump for 2nd pass RO.
  • Permeate water of RO 2nd shall feed to FEDI. Maintain the Feed flow to FEDI , FEDI concentrate to 120 – 150 LPH & Rinse to 70 – 80 LPH.
  • Check the conductivity of first Pass RO in conductivity meter, it shall be NMT 20 µS/Cm, for 2nd pass RO Conductivity shall be NMT 10 µS/Cm and FEDI Conductivity shall be NMT 1.3 µS/Cm.
  • Periodical Chemical cleaning of first pass RO shall be carried out quarterly as per SOP No PAL/ENG/0/010 & for Second pass RO & FEDI sanitization shall be carried out monthly.
  • CIP of FEDI shall be carried out on quarterly basis or as and when permeate water conductivity goes above 1.3 µS/Cm .
  • FEDI permeate water feed into mother loop storage and distribution tank of capacity
  • 4000 Ltrs.

Operation of Purified Water Mother Loop storage and distribution system
  • Ensure that compressed air pressure should be in between 4 to 6 kg/cm2.
  • Check and ensure that water is available in storage tank, open the process loop pump inlet & outlet valve.
  • Open the HMI screen of Purified Water Mother Loop storage and distribution system and press the service mode ON.
  • Check and maintain the flow in return line it shall be NLT 4.13 M3/Hr. (velocity 1.2
  • m/Sec.)
  • Mother Loop distribution pump feed purified water to Section-1,2 and Section -3 distribution tank.
  • Mother loop distribution tank(4KL), distribution tank (Section 1,2) & distribution tank Section 3 shall be level controlled with back pressure valve & Flow Diverter valve.
  • Check and maintain the conductivity of return line Purified Water in conductivity meter, it shall be NMT -1.3 µS/Cm, if conductivity value get high HMI will raise alarm, if conductivity is not maintain in 30 secs water dumped through pneumatic valve.
  • Check and maintain UV Intensity of Mother Loop Purified Water supply line shall be
  • NLT – 40 W/m2, if value of UV intensity goes below 40W/m2 clean the UV chamber glass and if after cleaning of UV chamber glass, intensity is not maintained replace the UV Lamp or after each 7500 Burning Hrs. and maintain the replacement records.
  • Mother Loop storage and distribution system tank Electrical Vent Filter EVF-501Shall be changed in every one year and maintain the replacement of filter record.
  • Periodical Sanitization of Mother Loop storage tank shall be monthly.

Operation of Purified Water Section 1&2 Loop storage and distribution system
  • Ensure that compressed air pressure should be in between 4 to 6 kg/cm2.
  • Check and ensure that water is available in storage tank, open the process loop Pump inlet & outlet valve.
  • Open the HMI screen of Purified Water Section -1 & 2 Loop storage and distribution system and press the service mode ON.
  • Check and maintain the flow in return line it shall be NLT-4.13 M3/Hr. (Velocity NLT-1.2m/sec.).
  • Check and maintain the conductivity of return line Purified Water in conductivity meter, it shall be NMT -1.3 µS/Cm, if conductivity value get high HMI will raise alarm, if conductivity is not maintained in 30 secs water dumped through pneumatic valve
  • Check and maintain UV Intensity of Purified Water Section 1-2 supply line shall be NLT – 40 W/m2, if value of UV intensity goes below 40W/m2 clean the UV chamber glass and if after cleaning of UV chamber glass, intensity is not maintained replace the UV Lamp or after each 7500 Burning Hrs. and maintain the replacement records.
  • Section-1&2 storage tank Electrical Vent Filter EVF-301 changed every one year
  • and maintain the replacement records.
  • Periodical Sanitization of Section 1-2 storage tank shall be monthly.

Operation of Purified Water Section 3 Loop storage and distribution system.
  • Ensure that compressed air pressure should be in between 4 to 6 kg/cm2.
  • Check and ensure that water is available in storage tank, open the process loop
  • Pump inlet & outlet valve.
  • Open the HMI screen of Purified Water Section -3 Loop distribution
  • system and press the service mode ON.
  • Check and maintain the flow in return line it shall be NLT-4.13 M3/Hr. (Velocity NLT-1.2m/sec.).
  • Check and maintain the conductivity of return line Purified Water in conductivity meter, it shall be NMT -1.3 µS/Cm, if conductivity value get high HMI will raise alarm, if conductivity is not maintained in 30 secs water dumped through pneumatic valve.
  • Check and maintain UV Intensity of Purified Water Section 3 supply line shall be NLT – 40 W/m2, if value of UV intensity goes below 40W/m2 clean the UV chamber glass and if after cleaning of UV chamber glass, intensity is not maintained replace the UV Lamp or after each 7500 Burning Hrs. and maintain the replacement records.
  • Section-3 storage tank Electrical Vent Filter EVF-301 changed every one year and maintain the replacement records.
  • Periodical Sanitization of Section 3 storage tank shall be monthly



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