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ENGINEER'S STAMP

CONTRACTOR'S STAMP

B FOR APPROVAL AS PER EH-DH-R-0009


A FOR APPROVAL
DESCRIPTION

REV.

H.H.KIM

I.S.SONG

02-Feb-12

H.H.KIM

I.S.SONG

15-Nov-10

PREPARED CHECKED

DATE

SALINE WATER CONVERSION CORPORATION


KINGDOM OF SAUDI ARABIA
Ras Al Khair Power and Desalination Plant - Phase 1

CONTRACTOR
(CONSORTIUM LEADER)

Project No
LOCATION

TITLE

31002
Ras Al Khair
SCALE

CONTRACTOR
(CONSORTIUM MEMBER)

SYSTEM DESCRIPTION AND OPERATION PHILOSOPHY FOR MSF PLANT


DOCUMENT No
REV. B
7

SUBCONTRACTOR
SHEET 1 OF 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

CONTENTS

1.

Seawater / Cooling water Supply System

2.

Thermal Desalination Plant (MSF islands)

3.

Chemical Dosing System

4.

Ball Cleaning System

5.

Acid Cleaning System

This document covers the operation and control on the following


systems in Ras Al Khair Desalination Plant - Phase 1:
-

Seawater / cooling water supply system


MSF islands
Centrailized chemical dosing system
Ball cleaning system for MSF evaporator
Acid cleaning system for MSF evaporator

Page 2 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

1. Seawater / Cooling water Supply System


1.1 Purpose
The purpose of the Seawater Supply System is to take the seawater, free of debris, from
intake pumping station and to deliver large quantities of cooling water to MSF Plant, RO
Plant and Power Plant.

1.2 General Description


The Seawater Supply System includes mainly Seawater Supply Pumps, Seawater
Screening facilities, Seawater chlorination Plant and all necessary instrumentations in
order to supply the whole of the seawater demands in Ras Al Khair Phase I Plant.
a)

There are totally twenty-four (24) Seawater Supply Pumps (SSPs) including stand-by
pumps in seawater intake pumping station. The SSPs are assigned as below:
Seawater Supply Pumps

Operating flow at

No. of

No. of

full production

Stand by

Operation

31,363

14,424

16,911

431

3,000

(ton/h)
Seawater supply pumps for MSF
plant
Seawater supply pumps for RO
plant
Seawater supply pumps for Power
plant (dump condensers)
B

Aux. cooling water pumps (for


Initial filling and Seawater
chlorination plant)
Seawater supply pumps for
Maaden
b)

Nine (9) SSPs are assigned for MSF units and these pumps are connected to a
common seawater supply header. Each SSP is operating to supply the cooling water
to one MSF unit. In case that one SSP is tripped, the stand-by pump will start

Page 3 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

automatically to maintain the plant operation without production loss. The common
seawater supply header is divided by two sections with double isolation valves.
c)

Six (6) SSPs are assigned for Power plant and these pumps are connected to a
common seawater supply header. Each SSP is operating to supply the cooling water
to one Power block, which is used for dump condenser and closed circuit cooling
water system. Also, the stand-by pump will start automatically if one operating pump
is tripped. The seawater supply header is divided by two sections with double
isolation valves.

d)

Four (4) SSPs are assigned for RO plant and these pumps are connected to a
common seawater supply header. The redundancy of these pumps are 4 x 33%.
Also, the standby pump will start auctomatically if one operating pump has failure.
The seawater supply header is divided by two sections with double isolation valves.

e)

Two (2) Auxiliary Cooling Water Pumps are assigned for seawater chlorination plant
and initial filling to seawater supply headers. One pump is used as stand-by one. For
the initial seawater filling to the seawater supply headers before start-up of main
seawater supply pumps, the auxiliary cooling water pump can supply the seawater to
each section, which is divided by double isolation valves, at the seawater supply
header of MSF plant, RO plant and Power plant respectively.

f)
B

Three (3) SSPs for Madden are assigned to supply the required amount of cooling
water, 6,000 ton/hr, 4 barG at terminal point. Also one pump is used as stand-by
one.

g)

One combined shut-off/non-return valve (Hydraulic operating valve) is mounted at


the discharge side of each SSP. This valve is combined with stop and non-return
functions with variable closing characteristics which can be adjusted to suit the
hydraulic system. The hydraulic type discharge valve will be operated either through
DCS at the CCR or through Local control panel near the valve.

h)

The start-up of the Seawater Supply Pumps is initiated from the Central Control
Room by manual operation via Visual Display Unit (VDU). These pumps will be
prevented from operation if all the interlocks and protection are not fully satisfied in

Page 4 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

the DCS.
i)

In order to obtain the qualified cooling water for MSF plant, the chlorine injection is
continuously performed into the seawater intake channels as well as shock dosing.
Seawater chlorination Plant will be controlled and supervised from the Local Control
Panel located in the Seawater chlorination Building. Some selected important signals
which need to be monitored from CCR will be interfaced with main DCS of the Plant.

j)

The Screen facilities mainly consist of thirteen (13) Bar screen and Travelling band
screens, stop logs, two (2) spray water pumps, and their necessary instrumentation.
One complete channel including a bar screen and travelling band screen is used as
stand-by. There are two (2) dam boards at the fore bay before entering the pump
chambers. The dam boards separate the pump chambers into two parts; MSF &
Power plant and RO plant. This system will be controlled and supervised from the
DCS in the Central Control Room.

1.3 Operation and Control Philosophy


1.3.1 General
The start-up and shutdown operation of the seawater supply system is initiated,
automatically or manually, from the related visual display unit (VDU) in the central control
room CCR.
The preparation activity for startup, after a long shutdown of the pump or plant, shall be
performed locally.
The mimic display (Man-Machine Interface Pictograph) of the seawater supply system on
the VDU (Visual Display Unit / Monitor) provides the control room operating personnel
with the necessary process information to operate the seawater supply pumps from the
CCR, and to ensure a safe operation of the MSF plant. For the MSF plant, the operator
can start a total of nine (9) seawater supply pumps while the remaining one pump (1) is on
standby. Any of the nine (9) pumps can be in standby mode.

Page 5 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The seawater supply system is monitored and controlled by the distributed control system
(DCS) from the CCR. The DCS provides open loop control, closed loop control and the
monitoring functions of process values as well as the plant equipment condition. Required
indications, controls, recording and alarms are provided within the DCS and these are
monitored and controlled from the DCS, VDUs in the CCR.
1.3.2 Seawater Supply Pumps
1.3.2.1 Open Loop Control
1.3.2.1.1 Drive control
-

Seawater supply pump motor,

Auxiliary cooling water pump motor,

Combined shut-off/non-return valve,

Each unit isolation valve


for MSF unit, RO plant, Power block and Seawater chlorination plant,

The seawater supply pumps can be manually started and shutdown from the VDU, in the
CCR. When the AUTO operation mode is selected, the pump will START and STOP and
the combined shut-off/non-return valve will OPEN and CLOSE as described under subparagraph (1.3.2.1.3), Starting Logic.
1.3.2.1.2 Starting Permissive Conditions
The seawater supply pump for MSF unit can be started after satisfying the following
starting permissive conditions:
-

Combined shut-off/non-return valve and pump control mode: GROUP CONTROL


POSITION

Standby pump control mode: MANUAL CONTROL POSITION

Pump/Motor lube and cooling system all valves: OPEN

Heat rejection discharge valve, 20% ~ 30% OPEN

SSP suction chamber level transmitter, NOT LOW

Page 6 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

1.3.2.1.3 Starting Logic


When the starting permissive conditions are satisfied, the seawater supply pump can be
started manually (MANUAL mode) or automatically (AUTO mode) from the CCR.
When the AUTO operation mode is selected, the pump will startup and shutdown, and the
shut-off/non-return valve will OPEN and CLOSE as follows:
z

Start pushbutton of seawater supply pump is activated.

The combined shut-off/non-return valve is open by sequential logic procedure to the


intermediate position after operating the pump.

When the pressure of the header reaches 2.0 barg, the combined shut-off/non-return
valve is opened again to the FULLY OPEN position.

At the same time (within 20-30 seconds), the isolation valve of the MSF unit, which the
operator wants to operate, shall be opened, in order to maintain the header pressure
and to prevent possible water hammering.

The other seawater supply pumps are operated in the same manner.

NOTE: During start-up, the operator can manually switch the pumps on and off,
depending on the overall demand for cooling water.
In MANUAL mode, the combined shut-off/non-return valve can be opened and closed by
using the DCS VDU in the CCR.
1.3.2.1.4 Normal Shutdown
The seawater supply pump is shutdown as follows:
z

The seawater supply pump STOP button at the control desk in the CCR is pressed.

The associated combined shut-off/non-return valve located at the discharge line starts
to close.

When the valve is fully closed, the seawater supply pump is switched off.

1.3.2.1.5 Emergency Shutdown

Page 7 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

An EMERGENCY stop push button is provided, locally, to shutdown manually the


seawater supply pump. At the same time, the combined shut-off/non-return valve is
closed, in accordance with the closing characteristics.
1.3.2.1.6 Protection Trip Condition
A protective OFF or TRIP command will be issued to shutdown the operating pump and
start the standby pump, in any one of the following cases:
Table 1.1 - Protection Trip Conditions
Instruments

Protection
PUMP SUCTION CHAMBER LEVEL

Level transmitter,

LOW LOW
PUMP DISCHARGE PRESSURE HIGH

Pressure transmitter,

HIGH, LOW LOW


MOTOR UPPER BEARING

Temperature(RTD),

TEMPERATURE HIGH HIGH


MOTOR BOTTOM BEARING

Temperature (RTD),

TEMPERATURE HIGH HIGH


MOTOR STATOR WINDING

Temperature (RTD),

TEMPERATURE HIGH HIGH


PUMP THRUST BEARING

Temperature (RTD)

TEMPERATURE HIGH HIGH


PUMP RADIAL BEARING

Temperature(RTD),

TEMPERATURE HIGH HIGH

Vibration detectors,

PUMP VIBRATION LEVEL HIGH HIGH

1.3.2.2 Signal Conditioninng


Various instruments are provided to monitor and control the seawater supply system via
DCS. They include every sensor in the pumps and associated piping, pump motors, and
in other components of the desalination unit.

Page 8 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

1.3.2.2.1 Typical measurements in Pump


The following instruments are provided to protect the pumps through the signal
conditioning :
-

Pump thrust bearing temperature transmitter,

Pump radial bearing temperature transmitter,

Pressure transmitter, provided in the discharge line of the Pump to indicate the
discharge pressure,

Pump vibration detectors (X,Y,Z),

1.3.2.2.2 Typical measurements in Pump Motor


-

Temperature detectors are provided in each of the three windings of the motor stator
to protect against overheating,

Motor upper bearing temperature transmitter,

Motor bottom bearing temperature transmitter,

1.3.2.2.3 Seawater Supply Headers


There are three (3)seawater supply headers in seawater intake pumping sation. The first
common header provides seawater with MFS units. The second one provides cooling
water with power block (dump condensers, CCCW system). The third one provides
seawater with RO plant. Each seawater supply header has double isolation valves. These
valves are closed for maintenance work while the repaire work on a part of header is
required. Pressure transmitters are provided to indicate the pressure of each common
header.
The online monitoring measurements to analyze the seawater quality are provided at
common header for RO plant:
-

Conductivity analyzer

Oil analyzer

Residual chlorine analyzer

pH analyzer

Turbidity analyzer

Page 9 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Samples shall be taken every day at the analyzer skid and be analyzed in in-house
laboratory. The sampling point is provided inside the analyzer skid.
1.3.2.2.4 Suction Chamber
Level transmitter is provided in the pump suction chamber to check the level of the
seawater. When the level is below the LOW permissive level, the startup of the pump will
be inhibited. When the level drops below the LOW - LOW level, the pump motor will be
tripped.
1.3.2.3 Local Indicating Instruments
The following instruments are also provided for local indication:
in Pump
-

Pressure indicator is provided in the pump discharge lines,

Pump lube oil temperature,

Pump thrust bearing temperature,

Pump radial bearing temperature,

Pump lube oil level,

in Pump Motor
-

Motor inside air temperature hot,

Motor inside air temperature cold,

Motor bearing temperature upper,

Motor bearing temperature bottom,

1.3.3 Combined Shut-off / Non-Return Valve


This valve is automatically opened/closed in accordance with the combination of seawater
supply pump and common header pressure. When the initial pump starts to run, and the
header pressure is lower than the pre-set value (2.0 barg), the valve is opened upto an
intermediate position. The opening position is approx. 15%. However the final value will
be adjusted during the commissioning. When the pump is running and the header
pressure is higher than 2.0 barg, the valve is fully opened. After several seconds following

Page 10 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

the 2nd pump startup, this valve is fully open. When the pump trips, the valve is
automatically closed upto intermediate position quickly and then fully closed slowly, to
minimize the pressure surge initiated during the transient condition.
If the power source, applied to the combined shut-off/non-return valve or the hydraulic
system operating the valve fails, the associated pump is automatically tripped.
1.3.4 Double Isolation Valves in Common Header
These valves are manually opened/closed from the field. The valve is normally in the open
state, and are only closed in the event that isolation is required.
1.3.5 Unit Isolation Valve
MSF unit isolation valve
This valve is manually opened/closed from CCR. The operator controls the OPEN/CLOSE
state of the valve, according to the demand of the related MSF unit.
Power block isolation valves
This is manually opened/closed from CCR. The operator controls the OPEN/CLOSE state
of the valve, according to the demand of the related Power block.
RO plant isolation valves
This is manually opened/closed from CCR. The operator controls the OPEN/CLOSE state
of the valve, according to the demand of the related RO plant.
Seawater chlorination plant isolation valve
This is manually opened/closed from CCR. The operator controls the OPEN/CLOSE state
of the valve when the isolation of Seawater chlorination plant is required.

Page 11 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

1.4 Reference Drawings


. Seawater and Product water balance in Desalination Plant,
Dwg No. 70-GD-MFB-003
. Symbols and identification system (1/2)
Dwg No. 70-GD-MFB-004
. Symbols and identification system (2/2)
Dwg No. 70-GD-MFB-005

. Seawater supply system (1/2),

Dwg No. 70-GAF-MFB-001

. Seawater supply system (2/2),

Dwg No. 70-GAF-MFB-002

. Seawater supply pump/motor for MSF plant,

Dwg No. 70-GAF-MFB-003

. Seawater supply pump/motor for Powr plant,

Dwg No. 70-GAF-MFB-004

. Seawater supply pump/motor for RO plant,

Dwg No. 70-GAF-MFB-005

. Auxiliary cooling water pump/motor,

Dwg No. 70-GAF-MFB-006

. Seawater supply pump/motor for Maaden,

Dwg No. 70-GAF-MFB-007

Page 12 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2. Thermal Desalination Plant (MSF islands)


2.1 General Description
Ras Al Khair Desalination Plant Phase I consists of thermal desalination plant and
SWRO plant with Post treatment plant to produce 1,025,000 m3/day of potable water. The
net design capacity of thermal desalination plant and SWRO plant will be 717,500 m3/day
and 307,500 m3/day respectively.
The thermal desalination plant consists of eight (8) identical multi-stage flash units with
their common facilities. A "cross tube multi-stage flash (MSF) evaporator with brine
recirculation is selected for the MSF process of this plant.
At 100% of design rating, each MSF unit produces 92,582 m3 (gross) of distillate per day,
containing less than 25 parts per million (ppm) total dissolved solids, with performance
ratio of 9.5 kg distillate/2326 kJ, 108 oC top brine temperature (TBT) at seawater
temperature 30 oC.
Each MSF unit is comprised of the following equipment and systems:
1. One (1) multi-stage evaporator, complete with water boxes, condenser bundles and
miscellaneous auxiliary equipment.
2. One (1) LP steam and brine heater condensate system, complete with:
a. One (1) brine heater,
b. Two (2) brine heater condensate pumps,
c. Two (2) desuperheaters,
d. One (1) sample cooler,
e. All necessary auxiliaries.
3. One (1) brine recirculation system, complete with two (2) brine recirculation pumps,
including an emergency blowdown system.
4. One (1) brine blowdown system, complete with one (1) brine blowdown pump.
5. One (1) intermediate pressure (IP) steam venting and vacuum system consisting of:

a. One (1) Starting air ejector,


b. One (1) Starting ejector silencer,

Page 13 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

c. Two (2) 1st stage ejectors,


d. Two (2) 2nd stage ejectors,
e. One (1) Pre-condenser,
f. One (1) Inter-condenser,
g. One (1) After-condenser.
6. One (1) seawater cooling and make-up water system consisting of:

a. Seawater cooling supply piping,


b. One (1) deaerator with all internals and auxiliary equipment,
c. One (1) sample extraction pump.
7. One (1) distillate system consisting of two (2) distillate pumps.
8. Two (2) ball cleaning systems for Brine heater and Heat recovery section, Heat
rejection section.
B

9. Two (2) control valves for RO tempering at the downstream of heat rejection section.
10. All necessary control and monitoring equipment.
Each evaporator unit consists of a single deck rectangular module of twenty three (23)
stages in one (1) pass configuration. Each stage is provided with cross tube condensing
bundles.
The eight (8) MSF units with their corresponding evaporators are installed in a parallel
path configuration.
In the brine recirculating system, the stage condensers of an evaporator are divided into a
heat rejection section, comprised of three (3) stages (Stages 21 thru 23), and a heat
recovery section, comprised of twenty (20) stages (Stages 1 thru 20).

Page 14 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.2 Overall Performance data of Thermal Desalination Units


2.2.1 Operating Data for Thermal Desalination Units, Eight (8) MSF units

S/N

Load Cases

Unit

Design

A/E/F
RSC

B
SSC

C
ASC

D
WSC

G
RSCFouled

740,655

740,655

740,655

740,655

740,655

740,655

717,500

717,500

717,500

717,500

717,500

717,500

9.5

9.5

9.5

9.5

9.5

9.1

Total gross distillate


production for MSF
plant

3
m /day

Total net distillate


production for MSF
plant

3
m /day

Performance Ratio (PR)

kg/
2326
kJ

Top Brine Temperature

108.0

112.0

110.5

106.8

106.0

112.0

Seawater Temperature

30

38

35

27

18

38

Seawater Salinity

g/kg

45

45

45

45

45

45

Condensate return
temperature

113

117

115

112

111

118

Total LP-Steam
consumption @ 2.8 bar
/ 140 C

MWth

2,074

2,070

2,079

2,080

2,074

2,175

Total IP-Steam
consumption @ 18bar /
230 C

ton/h

64.0

64.0

64.0

64.0

64.0

64.0

Page 15 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.2.2 Operating Data for Each MSF unit

S/N

Load Cases

Unit

Gross distillate
production for Each
MSF unit

3
m /day

Net distillate production


for Each MSF unit

3
m /day

Performance Ratio (PR)

kg/
2326
kJ

Top Brine Temperature

A/E/F

(RSC)

(SSC)

(ASC)

(WSC)

Design

G
(RSCFouled)

92,582

92,582

92,582

92,582

92,582

92,582

89,690

89,690

89,690

89,690

89,690

89,690

9.5

9.5

9.5

9.5

9.5

9.1

108.0

112.0

110.5

106.8

106.0

112.0

Seawater Temperature

30

38

35

27

18

38

LP-Steam Flow to Each


Unit

ton/h

412.0

414.2

415.1

412.3

410.6

437.1

IP-Steam Flow to Each


Unit

ton/h

8.0

8.0

8.0

8.0

8.0

8.0

Brine Recycle Flow

ton/h

34,700

36,300

35,700

34,000

33,500

36,600

Make up seawater Flow

ton/h

11,260

11,377

11,335

11,198

11,147

11,403

10

Brine Blowdown Flow

ton/h

7,372

7,491

7,448

7,313

7,260

7,514

Page 16 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.3 Overview of Operation and Control Philosophy


The philosophy of the unit operation is based on controlling and monitoring the major
equipment and operation from the unit-related section in the central control room (CCR),
including loading-up and loading-down.
DCS carries out the process control and process information task, and the functions are
made available to the operator via a uniform user interface (Man Machine Interface-MMI).
The MMI is a window to the process; through the MMI an access to the process by the
operation personnel, is possible and thermal desalination plant common system.
The MMI for the thermal desalination Plant covers eight (8) MSF units and Post treatment
Plant.
The process control by DCS in the CCR, provides process operation and monitoring
functions related to the following:
1.

Startup and Shut-down,

2.

Analog and binary signal conditioning,

3.

Fault Analysis.

In addition, the process information, by DCS, provides information management system


functions, such as reporting, data storage, and documentation. They are as follows:
1.

Long term archiving,

2.

Incident review documentation,

3.

Characteristic value.

The operator functions and the necessary functions in MMI are performed hierarchically.
The operators interactions with the process are provided by color visual display units
(VDUs), mouse and keyboard. The dialogue via mouse on virtual keys in the header is
performed at the bottom line of the VDU and the object windows.
Control operations are performed in two-step actions. First, the objects target status is
selected, followed by pushing a command release button to execute the command.

Page 17 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Therefore, it is necessary to press the release button to execute the following commands:

a. START and STOP of equipment,


b. OPEN and CLOSE of pnuematic, hydraulic and electric motor actuated valves,
c. Change operation MODE of controller.
The following six major control loops are used to monitor and control the MSF unit
operation:
1.

LP steam and BH condensate system control,

2.

Brine recirculation system control,

3.

Brine blowdown system control,

4.

IP steam, venting and vacuum system control,

5.

Seawater cooling and make-up water system control,

6.

Distillate system control.

2.4 MSF Evaporator


The evaporator consists of the following components:
1. Twenty-three (23) flashing stages with walls between the successive stages,
2. Brine inlet distribution header,
3. Brine outlet sump,
4. Brine blowdown sump,
5. Distillate outlet.
The evaporator shell is a rectangular vessel with thermal insulation for the recovery
B

stages above the surface temperature of 60 and above. Sliding bearings are provided
between the support beams of the evaporator bottom and the shell structure, to allow for
free thermal expansion of the evaporator.
The first twenty (20) stages represent the heat recovery section, while the last three (3)
stages represent the heat rejection section.
Each stage contains a single bundle of condenser tubes, with water boxes at each end.
The water box is specially shaped to provide a good hydraulic flow pattern and favorable
distribution of flow to the tubes. Each water box has a manhole for tubes inspection.

Page 18 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Each evaporator stage contains:

a. Internally adjustable brine orifices,


b. Demisters,
c. Distillate duct with an adjustable distillate orifices.
The brine flows from one stage to the next stage through the inter-stage orifices, which
are set to achieve a self-regulation of the brine level in each stage. Therefore, the stages
are water-sealed from each other to prevent pressure equalisation between the stages.
A demister is fitted in the upper part of the flash chamber to intercept brine droplets
entrained with the vapor, and prevent them from being carried over into the condenser
tube bundle. The vapor condensing on the tubes is collected in the distillate tray and flows
to the next stage. An adjustable orifice, to maintain the interstage pressure differential, is
provided at each stage inlet, in the distillate duct. The accumulated distillate flows to the
distillate duct and is extracted by the distillate pump.
Each tube bundle has a vent section where non-condensable gases can accumulate for
extraction. Most of the stages are vented through an orifice to the next stage. The brine
heater and the 1st to 4th stage are vented directly to the inter-condenser. The vent from
5th to 11th stage is cascaded and extracted to the pre-condenser from 11th stage. Also, The
vents from the stages 12 through 23 are vented to the pre-condenser.
Venting is necessary to remove non-condensable gases from the evaporator chamber. If
these gases accumulate in the tube bundle, they will insulate the condenser tube surfaces
and adversely affect the transfer of heat and hence the evaporator performance. Each
stage is accessible through a manhole for inspection and maintenance. The distillate duct
also has manhole at each stage.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.5 LP Steam and Brine Heater Condensate System


2.5.1 Introduction
The purpose of the LP steam and brine heater condensate system is to heat the
recirculating brine up to the required top brine temperature and to return the condensate
to the power plant.
This system comprises of the following items:
1. Brine heater,
2. Brine heater condensate extraction pumps,
3. Desuperheaters,
The two brine heater condensate pumps (2 x 100%) are located under the brine heater.
The desuperheaters are located at the upstream of the brine heater. The LP steam for the
brine heater is supplied via common header from the power plant.
Each MSF unit is designed for a base load with top brine temperature (TBT) of 112 C.
The desuperheater is designed to provide temperature controls when the temperature is
controlled within 10 C from the saturation temperature of LP steam to Brine Heater.
2.5.2 System Description
Low pressure (LP) steam from the By-pass reducing station and/or Steam turbine flows to
the brine heater shell side. Before entering the brine heater, LP steam passes through the
pressure control valve and desuperheater for reducing its pressure and temperature.
The steam is used in the brine heater as heating source for the brine recirculation, which
is pre-heated through the tubes of the heat recovery section up to the required top brine
temperature.
The top brine temperature is controlled by regulating the steam pressure control valve at
the brine heater inlet, thereby increasing or decreasing the steam pressure at the brine

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

heater to automatically or manually maintain the set point temperature of the brine at the
brine heater outlet.
After releasing its latent heat to the brine, the LP steam condenses on the outside
surfaces of the tubes and drops into the hot well of the brine heater. The condensate is
returned to the feed water tanks in the Power plant by using the condensate extraction
pump. One (1) of the condensate extraction pumps, is in operation, while the other pump
is on stand-by.
A small quantity of the discharged condensate is supplied to the desuperheater which
atomizes the cooling condensate over the LP steam flow, at the brine heater inlet (for
reducing its temperature). The desuperheater is activated to control the temperature of LP
steam to the brine heater by a signal from the temperature transmitters installed at the
brine heater inlet.
The balance of the discharged condensate is also directed to the condensate sample
cooler prior to the conductivity analysis. The condensate conductivity analyzer is installed
on the condensate line. If the condensate conductivity is not acceptable, the condensate
will be dumped automatically to the seawater outfall channel through the seawater
discharge pipe line, by activating the condensate dump on/off valve in the condensate
line. However, when the measured conductivity is recovered within acceptable limit, the
condensate dump on/off valve will manually close after obtaining the confirmation on the
conductivity level, while the condensate on/off valve will allow the condensate to be
returned to the power plant.
2.5.3 Operation and Control Philosophy
2.5.3.1 Operation
All instrumentation for safe and satisfactory operation and supervision of the brine heater
system is provided and controlled from the central control room (CCR).
The condensate extraction pumps are started in the MANUAL mode. The duty pump is
selected and the AUTO/MANUAL mode switch then turned to AUTO. The selected pump

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

can be started manually in CCR when the brine heater condensate level is above the low
setpoint. The standby pump starts automatically if the duty pump trips.
2.5.3.2 Closed Loop Control
The closed loop controller of the LP steam and brine heater condensate system performs
the monitoring and control functions in DCS, to regulate the temperature of LP steam to
the brine heater and the condensate level in brine heater hotwell.
The closed loop control of the LP steam and brine heater condensate system controls the
following components:

a. LP steam control valve,


b. Brine heater condensate level control valve,
c. Desuperheaters,
The various instruments provided to interface the LP steam and brine heater condensate
system are:

a.
b.
c.
d.
e.
f.
g.
h.

LP steam to brine heater pressure transmitter,


Brine Heater inside LP steam pressure transmitters,
LP steam temperature transmitter downstream of the desuperheaters,
Condensate level transmitters,
Condensate flow transmitter,
Condensate pressure transmitter to desuperheater,
Condensate conductivity analyzer,
Condensate temperature transmitter,

LP steam pressure control


The LP steam control valve is regulated by the cascade pressure control loop. The input
parameters to the loop are: top brine temperature, brine heater steam side pressure.
Safety system for LP steam
A) The CLOSED conditions of LP steam pressure control valve to protect the evaporator
are as follows:

a. Both brine recirculation pumps, OFF.


b. LP steam temperature to the Brine heater, HIGH HIGH

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

c.
d.
e.
f.
g.
h.

Rev. : B
Date : 2011.01.20

Brine heater pressure, HIGH HIGH


Brine heater condensate level, HIGH HIGH
Both brine heater condensate pumps, OFF.
Brine recirculating flow rate, LOW LOW
Anti scalant flow, LOW LOW
MSF manual trip from the control desk pushbutton.

B) Safety measure
The pressure in the LP process steam piping will be controlled by the IP turbine control
valves. In case of bypass operation, the IP bypass station will control the pressure.
Downstream of the IP turbine 2 out of 3 pressure measurements are placed. If the
pressure higher the set pressure, the 2 out of 3 pressure measurements will close the IP
turbine stop valves. The IP turbine stop valves act as safety shut-off valves. Also, the
safety valves of the LP process steam piping system are designed to limit the system
pressure of the allowable working pressure.
Condensate level control
The condensate level control valve is throttled by the brine heater condensate level.
Condensate conductivity control
When the brine heater condensate conductivity reaches HIGH HIGH, the condensate is
dumped automatically by opening the condensate dump on/off valve in the condensate
dumping line. This valve is maintained normally CLOSED during NORMAL mode of
operation.
LP steam temperature control
The temperature of the steam to the brine heater is controlled by the desuperheater,
which sprays condensate in the LP steam flow by the temperature set point.
2.5.3.3 Open Loop Control
The open loop controllers of the LP steam and brine heater condensate system performs
the valve OPEN and CLOSE function, NORMAL operation modes and EMERGENCY
function of the equipment comprising this system.

Page 23 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The open loop controls the following components:


1. LP steam inlet MOV,
2. Brine heater condensate pumps,
3. Brine heater condensate min. flow control valve
4. Condensate on/off valve
5. Condensate dump on/off valve
The LP steam inlet MOV will CLOSE in the event that the low pressure steam control
valve is in the FULLY CLOSED position.
The brine heater condensate pumps are 2 100% capacity. In the event that one (1)
condensate pump trips, the other condensate pump is automatically started in the AUTO
operation mode. In the event of a LOW LOW level in the brine heater hotwell, the brine
heater condensate pump is tripped for pump protection.
Condensate Extraction Pump (CEP)
The following instruments are provided to protect the condensate extraction pumps
through the open loop:

a.
b.
c.
d.
e.
f.

CEP bearing (coupling side) temperature transmitter,


CEP bearing (opposite coupling side) temperature transmitter,
CEP vibration detectors,
CEP motor bearing (power side) temperature transmitter,
CEP motor bearing (opposite power side) temperature transmitter,
CEP motor winding temperature transmitters

The condensate minimum flow control valve is controlled by the condensate water flow.
This valve is closed during normal operation. When the condensate water flow reaches
the preset LOW flow, this valve immediately opens. If the flow returns to NORMAL, this
valve closes.

Page 24 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.6 Brine Recirculation and Blowdown System


2.6.1 Introduction
The purpose of the brine recirculation system is to maintain the circulating flow and at the
same time to produce the distillate, when operating at the basic process with top brine
temperature.
The purpose of the brine blowdown system is to maintain the designed value,
concentration factor, of salinity of the brine recirculation stream.
The brine recirculation system includes the following equipment:
1.

Brine recirculation pumps,

2.

Brine recirculation control valves,

3.

Brine differential pressure control valve,

4.

Emergency brine blowdown control valve,

The brine blowdown system includes the brine blowdown pump and brine blowdown level
control valve.
The brine recirculation stream is a mixture consisting of approximately 70% brine
blowdown, at about 61,030 ppm TDS, and 30 % make-up feed, at about 45,000 ppm TDS.
The salinity of the brine recirculation stream is designed to be maintained the desired
value or less by adjusting make-up water and brine blowdown flow.
The brine blowdown pump has a capacity of 7,514 ton/hr at 14 m head. Each brine
B

recirculation pump is capable of re-circulating 65 % of the maximum flow.


2.6.2

System Description

2.6.2.1 Brine Recirculation System


In the brine recirculation system, the stage condensers of the evaporator are divided into
the heat rejection section and the heat recovery section.

Page 25 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Concentrated brine is collected in the evaporator last stage (stage 23) brine sump. As it
flows to the suction side of the two (2) brine recirculation pumps concentrated brine is
mixed with make-up seawater from the deaerator in order to dilute it to the design value.
This diluted brine is recirculated by the brine recirculation pumps through the condenser
tubes of the heat recovery section, where the brine acts as cooling water. Before entering
B

stage 20 of the heat recovery section, the brine is injected with anti-scale for scale control
at the top brine temperature of 112 C. Sodium sulphite chemicals are also dosed into the
brine as oxygen scavenger. Recirculating brine passes through the condenser tubes of
the heat recovery section from stage 20 to stage 1, for final heating and then enters the
brine heater.
The top brine temperature (TBT) of the brine leaving the brine heater is controlled by the
LP steam control valve on the LP steam pipe to the brine heater inlet. Therefore, the
adjustment of the steam control valve is governed by the TBT, in order to automatically or
manually maintain the set point temperature of the brine, at the brine heater outlet by the
temperature measurement.
The brine pressure to the heat recovery section is automatically or manually controlled by
the brine recirculation control valves. These control valves are controlled from the central
control room (CCR). In order to protect the brine heater tubes and piping of the brine
heater against the adverse effects of boiling brine caused by the drop in the brine
pressure, a brine differential pressure control valve is provided located between the brine
heater outlet and the inlet to the evaporator recirculation distribution box; the valve is
actuated based upon a logic control. A differential pressure controller is installed to
monitor the pressure difference across this valve with set point (0.2 bar).
This controller is set to override the flow controller if the pressure at the inlet falls within
the required value of the outlet.
Recirculating brine, leaving the brine heater, is cascaded through the 23 stages of the
evaporator, providing distillate production. Distillate at each stage is collected and flows to
22nd stage (before last stage).

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The unflashed concentrated brine is again returned to the brine sump. Brine conductivity
indicating, recording and alarm instrumentation are provided for the brine recirculation
line.
An emergency brine blowdown line is connected to the seawater outfall channel through
the seawater discharge pipe. This line is provided with a emergency brine blowdown
control valve which opens when the blowdown pump trips, and blowdown is extracted
using brine recirculation pumps and maintaining the last stage brine level.
A brine recirculating flow is controlled by the brine recirculation control valves to meet the
preset value.
An on-load ball cleaning system is provided to inject balls in the brine recirculation stream
in order to minimize scale and sludge formation on the inner tube surfaces of both heat
recovery section and brine heater.
An off-load acid cleaning system is provided for cleaning of the heat recovery section and
brine heater tubes in order to remove hard scale.
2.6.2.2 Brine Blowdown System
In order to maintain the recirculating brine concentration constantly, the make-up
seawater flow rate must be higher than the distillate produced. Therefore, the excess of
this flow rate displaced by a part of the brine is discharged as brine blowdown, to the
seawater outfall channel.
The brine blowdown is removed from the last heat rejection stage (stage 23) by the
blowdown pump under level control from the last stage, and is discharged to the outfall
channel. Brine blowdown is controlled to maintain a constant brine level in the evaporator
and is achieved by the blowdown control valve. The control signal for this valve is
provided by brine level controllers within stage 23 of the evaporator.
In case of failure or outage of the blowdown pump, an emergency blowdown control valve
opens automatically to maintain the system operation and to dump the brine into the
outfall channel, via the brine blowdown discharge line, utilizing the brine recirculation

Page 27 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

pumps. However, the brine recirculation flow control shall be shifted to manual mode to
protect the brine recirculation pumps from overload and shall reduce the brine
recirculation flow considering the emergency brine blowdown flow rate.
2.6.3 Operation and Control Philosophy
2.6.3.1 Normal Operation
The brine recirculation and brine blowdown systems are controlled from the MSF unitrelated section in the central control room (CCR)
The brine recirculation control valves are operated to maintain the circulating flow to the
set value, and are throttled by the differential pressure control valve.
In the event of tripping of the blowdown pump, the emergency brine blowdown control
valve is open.
2.6.3.2 Closed Loop Control
2.6.3.2.1 Brine Recirculation System
The closed loop controller of the brine recirculation performs the monitoring functions of
the brine recirculation system and the brine recirculation pumps and provides conditioned
signals to the open loop controller.
This group performs the following control functions:

Brine differential pressure control valve (brine heater to evaporator),

Brine recirculation control valves,

Emergency brine blowdown control valve

The various instruments provided to interface the brine recirculation system with the DCS
through closed loop control are:

Brine differential pressure transmitter,

Brine recirculation flow transmitter,

Brine recirculation temperature transmitter,

Page 28 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Top brine temperature transmitters (2 ouf of 3 instrumentation),

Brine recirculation pressure transmitter,

Rev. : B
Date : 2011.01.20

Brine Differential Pressure Control


The brine differential pressure control valve will be throttled by the pressure differential
controller and brine recirculation pressure transmitter. In NORMAL mode of operation, this
valve will be throttled by the pressure differential controller.
When the brine recirculation pressure transmitter alarm becomes LOW, which is located
at the outlet of brine heater, this valve will be regulated.
Emergency Brine Blowdown Control
The emergency brine blowdown control valve will be maintained normally CLOSED during
NORMAL mode of operation.
This valve will be open when the brine blowdown pump stops during brine recirculation
pumps are running.
Brine Recirculation Control
The brine recirculation control valves will be throttled by the brine recirculation flow set
point, which is corresponded to Top Brine Temperature.
2.6.3.2.2 Brine Blowdown System
The closed loop controller of the brine blowdown system maintains a constant brine level
in the evaporator provides conditioned signals to the open loop control.
This group performs the following control functions:

Brine blowdown flow control, by using the level control valve,

Brine blowdown minimum flow control, by using the ON/OFF control valve,

Various instruments are provided to interface the brine blowdown system with the DCS
through the closed loop control:

23rd stage brine level transmitters,

Brine blowdown flow transmitter,

Page 29 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Brine blowdown pump discharge pressure transmitter

Brine Level Control


The brine blowdown control valve is reculated by the 23rd stage brine level transmitters.
2.6.3.3 Open Loop Control
2.6.3.3.1 Brine Recirculation System
The open loop controls the brine recirculation pumps, START and STOP, valve OPEN
and CLOSE functions, NORMAL operating modes and TRIP function of the equipment
comprising the brine recirculation system.
The open loop controls the following equipment:

a. Brine recirculation pumps,


b. Brine recirculation pump discharge MOVs,
The brine recirculation pump suction valves must be opened before the pump starts.
Within 10 seconds from the start of BRP, the brine recirculation pump discharge MOV will
start to OPEN.
The MSF unit is not capable to produce the distillate with only one Brine recirculation
pump and must be shut down in case of one Brine recirculation pump trips.
Brine Recirculation Pump (BRP)
The following instruments are provided to protect the brine recirculation pump through
closed loop control:

a.
b.
c.
d.
e.

BRP motor bearing (upper and bottom) temperature transmitters,


BRP motor winding temperature transmitters,
BRP vibration detectors,
BRP thrust bearing temperature transmitter,
BRP radial bearing temperature transmitter,

Page 30 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.6.3.3.2 Brine Blowdown System


The open loop control also performs the control function of the blowdown pump START
and STOP, valve OPEN and CLOSE, normal operating modes and emergency functions
of the equipment comprising the blowdown system.
The open loop controls the following equipment:

a. Brine blowdown pump,


b. Brine blowdown pump discharge MOV,
The brine blowdown pump suction valve must be opened before the pump starts. The
brine blowdown discharge MOV will start to open within 10 seconds after the brine
blowdown pump starts.
The brine blowdown minimum flow control valve is closed during normal operation and
opens when the brine blowdown flow goes LOW less than the set value. When the brine
blowdown flow is not LOW, the valve is closed. And this valve will be in the close position
during the pump no-operation.
Brine Blowdown Pump (BBDP)
The following instruments are provided to protect the blowdown pump through closed loop
control:

a.
b.
c.
d.

BBDP motor bearing (upper and bottom) temperature transmitters,


BBDP motor winding temperature transmitters,
BBDP vibration detectors,
BBDP thrust bearing temperature transmitter,

2.6.4 Equipment Description


2.6.4.1 Brine Recirculation Pump Description
Two (2) brine recirculation pumps are located adjacent to the last stage of the evaporator.
Both pumps are used for the recirculation of brine through the tubes of the evaporator

Page 31 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

heat recovery stages and the brine heater. The brine is extracted by these brine
recirculation pumps from the brine sump below the last stage of the evaporator. Two (2)
duty pumps are provided for each evaporator unit.
The brine recirculation pump, having 2100 mm suction and 1350 mm discharge bore, are
of the vertical dry pit type with a barrel.
The motor is mounted on a steel fabricated motor stool and it is connected with the pump
by gear coupling. The pump rotating direction is clockwise when viewed from the top.
Sealing water from the CCCW system is fed to the pump mechanical seal to prevent air
suction from atmosphere. The sealing water flow condition is checked by a pressure
switch.
2.6.4.2 Brine Blowdown Pump Description
One (1) duty brine blowdown pump is located adjacent to the last stage of the evaporator.
The brine blowdown is pumped from the brine sump below the last stage of the
evaporator to the outfall channel.
The brine blowdown pump, having an 1400 mm suction and an 900 mm discharge bore, is
vertical dry pit type with barrel. The hydraulic axial thrust and the rotor weight of the pump
are supported by the thrust bearing. The motor is mounted on an individual steel
fabricated motor stool.
Sealing water from the service water system is fed to the pump mechanical seal to
prevent air suction from atmosphere during initial start-up only. The sealing water flow
condition is checked by a pressure switch.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.7 Intermediate Pressure Steam, Venting and Vacuum Systems


2.7.1 Introduction
The Intermediate pressure (IP) steam, venting and vacuum system creates and sustains
the vacuum condition in the evaporator and deaerator, by removing non-condensable
gases which enter the MSF unit either with the make-up seawater, or through leakage into
the vacuum vessels.
Each of the eight (8) MSF units is equipped with its own, dedicated, vacuum system
consisting of two-stage ejector sets with associated surface type condensers (tubular
type), as follows:
1. Pre-condenser, 1 100%
2. Intercondenser, 1 100%
3. After condenser, 1 100%
4. First stage ejector, 2 100%
5. Second stage ejector, 2 100%
6. Startup (Hogging) ejector, 1 100%
7. Startup ejector silencer, 1 100%
The operation of each system is independent of the operation of the other systems.
Each vacuum system is located above the evaporator and deaerator, on a self-supporting
structure, which provides sufficient height for the operation of the condensers and
ejectors.
The first and second stage ejectors are mounted horizontally, with the discharge flange
mounted downwards to the condensers.
All condensers, except for pre-condenser, are mounted at an elevation of over 10 meters
from the discharge level, in order to allow for a barometric discharge into the collecting pit
or evaporator chamber.
The hogging or startup ejector is mounted horizontally, and discharges to the atmosphere
through a silencer.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The capacity of the vacuum system with only one (1) of the two (2) ejectors operated per
stage, is capable of providing 100% of the respective nominal duty required.
During the startup of the MSF unit, the air from the evaporator stages and the deaerator
are evacuated by the starting ejector. Motive steam for the ejectors is supplied through the
IP steam header from the HP/IP reducing station in Power plant.
Cooling water for the vacuum system is taken from the seawater supply stream line.
2.7.2 System Description
From the intermediate pressure steam line of the power plant, motive steam at a pressure
of min. 18 bara is admitted to a pressure control valve.
Five (5) IP lines from power blocks provide IP steam with the eight (8) MSF units.
The motive steam for the first and second stage ejectors passes first through the pressure
control valve, so that they may be shutdown by the DCS in case of any failure in the
cooling water supply.
From the IP steam header, the steam is fed to each of the two (2) pairs of ejectors,
B

through the ejector inlet isolation valve. Cooling water is fed to the vacuum condensers
from the seawater supply pumps, through the seawater supply line. The maximum
temperature of cooling water leaving the vacuum condenser is 48C when seawater
temperature is 38C.
The cooling water flow rate of 2,200 ton/h, through the condensers, is monitored by the
flow transmitter.
Water vapor and non-condensable gases are delivered through large diameter piping from
the evaporator stage 23 and the deaerator to the precondenser.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The non-condensable gases are removed from the pre-condenser by the first stage
ejector, and discharged at a higher pressure into the inter-condenser. The motive steam
from the first stage ejector flows to the inter condenser.
The non-condensable gases are removed from the intercondenser by the second stage
ejector, and discharged at a slightly above atmospheric pressure into the aftercondenser.
The motive steam from the second stage ejector flows to the aftercondenser, and the noncondensable gases including CO2 gas are delivered to the booster vacuum pump from
after-condenser to the post treatment plant during normal operation. When the booster
vacuum pump is not operated, these non-condensable gases are discharged into the
atmopshere automatically.
In this way, the two-stage ejector system operates like a single vacuum pump, sustaining
high vacuum in the evaporator and removing the non-condensable gases.
The pre-condenser, inter-condenser and after-condenser are all of the surface type. The
condensers condense the incoming vapor and motive steam by means of heat exchange
with the cooling water, which flows in the tubes.
During operation, condensate from the inter-condenser and after-condenser is discharged
to the collecting pit and liquid from pre-condenser is delivered to the distillate duct or brine
chamber by gravity.
The single stage startup ejector is provided for rapid evacuation of air, from the evaporator
and the deaerator, during the startup of each MSF unit. The suction side of the startup
ejector is directly connected to the vent pipe.
The starting ejector is directly discharged to the atmosphere through a silencer, in order to
minimise the noise produced during the operation.
The starting ejector is capable of producing an initial vacuum of below 240 mbar in the
evaporator, within one and half hour. Then, the evacuation is continued by the steam jet
air ejector system.
2.7.3 Operation and Control Philosophy

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.7.3.1 Startup
The venting and vacuum system is started by the DCS, in the central control room (CCR)
and the preparation of start-up and duty ejector operation shall be done manually from
field.
When starting from atmospheric temperature and pressure, the startup air ejector is used
to evacuate the system piping, the evaporator and the deaerator to get vacuum condition
quickly, down to 240 mbar.
This process takes approximately one and half hour, during which time all the pipe-work,
vessels, and operating ejectors will be purged of most of their non-condensable gases.
While the startup ejector is hogging down the pressure in the evaporator, the cooling
water to the three (3) condensers is turned on by opening the isolation valve allowing the
flow rates to reach at design flow rate and to stabilise.
When the pressure has reached to 240mbar, the duty ejector system shall start operation.
At first, check the condenser cooling water flow is stable and the flow rate is indicated at
design condition (2,200 ton/hr). When it is satisfactory, start from the 2nd ejector and then
the 1st ejector.
When the last stage pressure reaches 0.15 bara or less, the startup ejector shall be
shutdown, startup ejector suction valve is closed, and then the motive steam isolation
valve shall be closed.
2.7.3.2 Normal Operation
During the normal operation of the plant, the after-condenser shell side will be at a
pressure of 1.013 bara. The inter-condenser shell side pressure will be 0.152 bara. The
pre-condenser shell side pressure will be 0.076 bara or less.
Once the system is operating and all pressures have been established inside evaporator,
it may be necessary to adjust the flow rates of the cooling water to 2,200 ton/h, in order to

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Rev. : B
Date : 2011.01.20

compensate the fluctuations in the amount of non-condensable gases being produced in


the evaporator and deaerator.
It is also possible to change over from a duty ejector to the standby ejector, while the plant
is in operation, without disturbing the pressure or temperatures in the plant.
2.7.3.3 Shutdown
The normal shutdown of this system is usually performed manually. An emergency
shutdown of the system can be initiated by the DCS, by turning off the motive steam, in
the event of failure of the cooling seawater supply. However the shutdown still has to be
completed manually. When the plant has cooled sufficiently, the cooling water flow to the
condensers is turned off, by closing the condensers inlet isolation valve.
If the shutdown is to be of a extended duration, it is required that the entire vacuum
condenser with pipings shall be drained of water, to prevent corrosion damage and
possible fouling, due to evaporation.
2.7.3.4 Closed Loop Control
2.7.3.4.1 IP Steam Pressure Control
The closed loop controller of the IP steam, venting and vacuum system performs the inlet
IP steam pressure control through DCS.
1. IP steam inlet control valve,.
The following instruments perform signal conditioning through DCS :
1. IP steam inlet flow transmitter,
2. IP steam inlet pressure transmitter,
3. IP steam inlet temperature transmitter,
4. Cooling water flow transmitter,
5. Cooling water temperature transmitter,
6. Gas to post treatment plant flow transmitter,
The IP steam inlet control valve close condition is as follows:

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

1. Cooling water to vacuum system flow, LOW-LOW


2. Cooling water to vacuum system temperature, HIGH-HIGH
3. IP steam temperature, HIGH-HIGH
The pressure, temperature, flow rate of the motive steam and the flowrate of noncondensable gases including carbon dioxide are monitored from the DCS by pressure,
temperature and flow transmitters, located at strategic points in the systems. The IP
steam flow rate will be compensated by the temperature and pressure. These pressures
and temperatures are also monitored from the DCS.
The temperature and flow rates of the cooling seawater is also monitored from the DCS,
through temperature and flow transmitters in the cooling water discharge piping. This
information is used to shut off the motive steam, at the IP steam inlet isolation valve.
2.7.3.5 Open Loop Control
The open loop controller performs the OPEN and CLOSING functions of the following
valves via DCS:
1.

IP steam inlet MOV,

The IP steam inlet MOV can be operated manually in CCR.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.8 Seawater Cooling and Make-up Water System


2.8.1 Introduction
The seawater cooling and make-up water system is provided in order to supply cooling
water to the MSF unit, the condensers of the vacuum system and the heat rejection
section (stages 21 to 23). The system also supplies make-up water to the brine
recirculation system, for compensating the distillate produced and the brine discharged
through the brine blowdown system.
The seawater is pumped to the thermal desalination units from the intake pumping station,
through a distribution common header.
Most of the cooling seawater heated in the heat rejection section returns to the sea. Only
a fraction of the flow is tapped off as make-up water for the MSF unit. The remaining
cooling seawater will be discharged to the outfall channel.
The seawater cooling and make-up water system includes the following items:
1.

Seawater supply and discharge lines,

2.

Deaerator to eliminate the dissolved gases entering with the seawater.

3.

Make-up water sampling system, with a sample pump and DO2 analyzer for
continuous monitoring of the dissolved oxygen content in the make-up seawater.

The make-up seawater flows to the evaporator through the deaerator integrated with
stage 23, in order to reduce its dissolved oxygen content. The dissolved oxygen effluent
from the deaerator shall not be greater than 20 ppb. The salinity of the make-up seawater
is 45 g/kg, at design condition.
The make-up seawater is dosed with anti-foam chemical to prevent the formation of foam
in the deaerator and evaporator. The dosing rate will be controlled by the make-up flow
rate proportionally.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The cooling water flow to the vacuum condensers is taken from the main cooling water
supply pipe near to the cold end of the heat rejection section. The make-up water to the
deaerator is taken from the cooling water dischare pipe.
2.8.2 System Description
2.8.2.1 Seawater Cooling Supply and Distribution System
The cooling seawater is pumped by the seawater supply pumps through the main cooling
water header to the condensing tubes of the heat rejection section of the evaporator. A
part of the flow is diverted to the condensers of the vacuum system, from where it flows
down into the seawater outfall channel. Some amount of seawater is also provided for
quick filling the heat recovery section during the start-up.
Cooling seawater flows through the tube side of the heat rejection section and absorbs
heat from the flashing vapor within the corresponding flashing chambers. In this way, the
vapor condenses and collects in the distillate tray.
The pressure of the cooling water passing through the heat rejection section is monitored
by the pressure transmitter.
After cooling the heat rejection stages of the evaporator, a part of the warmed seawater
flows through the deaerator, as make-up water supply for the brine recirculation system.
The flow rate of this make-up water is controlled automatically or manually from the
central control room (CCR) by the flow control valve and measured by the flow meter in
order to maintain the concentration ratio within design limit. During AUTOMATIC control,
the make-up flow is controlled as a ratio of distillate flow. The ratio may be manually
adjusted by the operator. The seawater, which is in surplus to the make-up water flow
requirements, is discharged into the seawater discharge channel, carrying the excess
heat with it.
The temperature of the cooling seawater discharge is controlled by the seawater
discahrge control valve automatically.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Before entering the deaerator, the make-up water is first dosed with the anti-foam agent to
prevent the formation of foam during startup or at any time after startup, depending upon
the presence of surface active material. It is then sprayed into the evacuation chamber of
the deaerator, where it is met by an upward flow of stripping steam, supplied from the first
stage of the heat rejection section (21st stage). The stripping steam flow drives the
majority of the dissolved gases, and carries them towards the outlet of the venting and
vacuum system.
The deaerated water flows, by gravity, to the last stage in order to be mixed with the brine,
in the brine sump. After leaving the deaerator, the make-up water is mixed with brine and
then is dosed with anti-scale agent, to prevent the build-up of scale in the brine
recirculation system. It is mixed with sodium sulphite to remove the remaining dissolved
oxygen.
A make-up water sampling pump is provided to continuously extract a small flow of water,
for continuous monitoring of the dissolved oxygen content in the make-up water.
The make-up water is delivered into the last stage, where it is mixed with the brine, by the
action of the brine recirculation pump. This pump draws continuously brine and seawater
mixture out of the brine sump, in order to homogeneously mix the contents of the brine
sump.
In case that the seawater temperature is below 25 C , the cooling water recycle pump will
be running to increase the inlet temperature of the cooling water to the heat reject section.
The design flow rate of cooling water recycle pump will be considered at lowest seawater
temperature, 14 C.
An on-load ball cleaning system is provided to inject balls in the cooling water supply
stream in order to remove sludge formation on the inner tube surfaces of heat rejection
section.

2.8.2.2 RO Tempering System


Most of the heated seawater from the heat rejection section returns to the outfall channel
during summer operation. However, during winter season, this discharged cooling water is

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

used as the temperature tempering water for RO plant in order to increase the
temperature of RO feed water more than 22C.
The heated seawater is transferred to the seawater supply system for RO plant, of which
connection point is located at the inlet of DAF system.
There are two (2) stream lines with control valves; one (1) is connected to the downstream
of heat rejection section, the other is connected to the discharge of vacuum condensers.
In order to maintaine the MSF operation smoothly during the tempering period, there are
two (2) control valves that are located at the downstream of heat rejection section and the
discharge side of vacuum condensers respectively:
One (1) control valve controls the temperature of heat rejection discharge because the
functionality of this control valve is the same as the one of heat rejection discharge control
valve.
One (1) control valve controls the flow rate of vacuum condenser cooling water because
the functionality of this control valve is the same as the one of vacuum condenser cooling
water control valve.
All tempering lines from each MSF are combined one (1) common header, which is
connected to the inlet of RO plant. Before connecting a common header to RO feed water
supply line, one (1) temperature control valve is existing to adjust the inlet temperature of
RO plant.
2.8.3 Operation and Control Philosophy
The seawater cooling and make-up water system is operated and controlled by the DCS,
from the central control room (CCR).
2.8.3.1 Closed Loop Control
The closed loop controller of the seawater cooling and make-up water system performs a
make-up water flow control, seawater discharge flow control through DCS.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The following drives are related to three control performance.


This group performs the control function to regulate the following valves:

a. Heat rejection cooing water discharge control valve,


b. Make-up seawater control valve,
The following instruments are adapted to perform a signal conditioning through DCS.

a.
b.
c.
d.

Seawater discharge temperature transmitter,


Make-up seawater flow transmitter,
Heat rejection cooling water discharge flow transmitter,
Dissolved O2 analyser in deaerator

Heat rejection cooling water discharge flow control


The heat rejection cooling water discharge control valve is regulated by the cooling water
discharge temperature according to the pre-set value.
Make-up seawater flow control
The supply of make-up seawater is controlled by make-up seawater flow control valve to
give a flow rate which is proportional to the outflow of distillate from the 22nd stage of the
evaporator. The set point for the make-up flow controller is equal to the distillate flow
multiplied by a ratio selected by the operator.
2.8.3.2 Open Loop Control
The open loop control of the seawater cooling system controls the open and close
function of the following valves:

a. Seawater inlet to evaporator MOV by the operator manually.


d. The Start and Stop of sample extraction pump can be initiated from CCR.
2.8.4 Equipment Description
2.8.4.1 Deaerator

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The deaerator is used to release dissolved gas from the make-up seawater before it is
added to the brine recirculation flow.
The deaerator vessel integrated with the last stage of heat rejection section consists of
duplex stainless steel shell and maintained at an extremely low pressure by the venting
and vacuum system. In order to withstand the forces generated by the internal vacuum,
the shell, top and bottom of the vessel are reinforced with rectangular stiffeners. The
spray pipes, distributors, packing support, and stripping steam spray bars are fabricated
from stainless steel.
The incoming seawater is distributed to four (4) spray pipes, each provided with thirty two
(32) spray nozzles, to ensure a uniform flow over the whole area of the packed bed. The
packed bed consists of a layer of polypropylene pall rings.
Stripping steam is introduced below the packed bed, and flows upwards through the bed
and the falling curtains of water droplets. Dissolved gasses driven off by the stripping
steam are carried away through the vent outlets to the venting and vacuum system.
After percolating through the packed bed, the make-up seawater is collected at the bottom
of the deaerator from where it is conducted by gravity to the last stage of heat rejection
section.
2.8.4.2 Sample Extraction Pump (SEP)
The sample extraction pump is an horizontal axis, sealed, single stage, single entry
centrifugal pump with back pull out type with space coupling volute casing with integrally
casted axial suction nozzle and top discharge nozzle.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

2.9 Distillate System


2.9.1 Introduction
The purpose of the distillate system is to transfer the distillate produced in each stage of
the evaporator via the distillate header into post treatment plant.
The distillate system consists of two (2) distillate pumps per MSF unit, for the transfer of
distillate from all evaporator stages to the header.
The two(2) distillate pumps are located adjacent to the last stage of the evaporator. The
distillate system includes a conductivity analyzer for measuring the contamination of the
distillate. If the measured value is above a pre-set level of 25 ppm (50 S/cm), the
distillate is dumped to the seawater outfall channel through the dishcharged seawater line.
2.9.2 System Description
The flashed vapor at each stage of the evaporator passes through demisters and enters
the tube bundle zone, where the vapor releases its latent heat to the brine or seawater,
which flows inside the tubes. The vapor condenses and then drops into the distillate tray.
The demister is provided to trap the unflashed brine during the vapor flashing process, in
order to avoid the contamination of the pure distillate.
The distillate at each stage of the evaporator is collected in a trough located below each
condenser tube bundle, and flows from 1st stage to 22nd stage. The distillate produced
from the last stage (23rd stage) is transferred to 22nd stage by level difference.
The distillate is withdrawn from the 22nd stage by the distillate pump and then pumped to
the distillate header. There are two (2) distillate headers and each one is connected from
four (4) MSF units and transfer it to the post treatment plant.
Distillate production can be adjusted manually/automatically by means of the control of
brine recirculation flow and top brine temperature.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Local level gauges are provided to observe the level of distillate in each tray. The
conductivity of the distillate is constantly monitored by the conductivity analyzer located at
the discharge line of the distillate pumps. If the distillate conductivity is 50 S/cm, a
signal will be automatically sent to the distillate on/off valve to close and simultaneously to
the distillate dump on/off valve to open, in order to direct the flow of contaminated distillate
to the outfall channel.
A distillate line is provided between the distillate on/off valve and the distillate header for
flushing the evaporator after shutdown. This line provides fresh water for the brine
chamber flushing to the discharge chamber of the evaporator The brine recirculation
pump are used for circulation of the flushing water during this operation.
2.9.3 Operation and Control Philosophy
2.9.3.1 Normal Operation
The distillate system is operated and controlled by the DCS, from the central control room
(CCR).
The two (2) distillate pumps operate on DUTY/ STANDBY mode. The selected duty pump
is used for continuous evaporator operation at full load. In the event that the duty pump is
shutdown, the standby pump starts automatically without interruption of the system in the
AUTO operation mode.
The distillate flow rate is controlled to maintain the set level of the distillate at 22nd stage of
the evaporator. The level setpoint can be adjusted by the operator in the central control
room (CCR), including HIGH and LOW levels.
2.9.3.2 Dump Operation
The distillate on/off valve and dump on/off valve, installed on the distillate line downstream
of the pumps, are controlled by the analyser which measures the distillate conductivity. If
the conductivity exceeds the pre-set value in the CCR, the dump on/off valve
automatically opens to dump the distillate to the outfall channel.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The distillate level of the system is also controlled during the dumping operation.
2.9.3.3 Closed Loop Control
The closed loop controller of the distillate system performs a distillate level control through
the following items:
1. Distillate level control valve,
The following instruments are adapted to perform a signal conditioning in the distillate
system with the DCS:

a.
b.
c.
d.
e.
f.
g.

Distillate conductivity analyser,


Distillate flow transmitter,
Distillate temperature transmitter,
Stage 22 distillate level transmitters,
Stage 22 distillate temperature transmitter
Stage 22 vapor pressure transmitter
Stage 22 vapor temperature transmitter

Distillate Level Control


The level of the distillate, at the 22nd stage of the evaporator, is controlled by the distillate
level control valve, located on the distillate discharge line.
The distillate level control valve is regulated by the 22nd stage level transmitter. Even
though the distillate conductivity is high and dump on/off valve is in open condition, it will
maintain the level of distillate in the 22nd stage distillate chamber.
2.9.3.4 Open Loop Control
The open loop controller of the distillate system performs the pump startup and shutdown,
valve open and close function, normal operating modes and emergency functions of the
following equipment:
1. Distillate pumps,
2. Distillate pump discharge MOV,
3. Distillate on/off valve,
4. Distillate dump on/off valve

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5. Distillate minimum flow control valve,


In AUTO operating mode, if the operating distillate pump trips, the standby distillate pump
will start automatically when the level of the distillate in stage 22 is not less than the LOW
set point.
Distillate Pump (DP)
The following instruments are provided to protect the distillate pump through closed loop
control:

a.
b.
c.
d.

DP motor bearing (upper and bottom) temperature transmitter,


DP motor winding temperature transmitter,
DP vibration detectors,
DP thrust bearing temperature transmitter,

Within 10l seconds after the start-up of the distillate pump, the discharge MOV will start to
open. In case that the conductivity of distillate water is High High, the dump on/off valve
will automatically open and the distillate on/off valve will be closed.
The minimum flow control valve is automatically operated by the distillate pump discharge
flow transmitter. If the flow is lower than pre-set value, the valve is automatically opened,
in order to maintain the minimum flow of the distillate pumps discharge line.
The temperature of pump bearings is monitored by temperature detectors. The motor
bearing temperature is detected by temperature detectors located in the bearing housing,
on both the power side and opposite power side of the motor. The motor winding
temperatures are also detected by temperature detectors located in the stator slots.
2.9.4 Equipment Description
2.9.4.1 Distillate Pump
The distillate pumps having a 1000 mm suction and 700 mm discharge, are of the vertical
dry pit type, with barrel. The pump is of single suction diffuser type and the pump rotation
is clockwise facing the pump coupling. The hydraulic axial thrust and the rotor weight of

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

the pump are supported by the thrust bearing motor. The motor is mounted on an
individual steel fabricated motor base.

2.10 Reference Drawings

. Mass & Heat Balance for MSF plant,


Dwg No. 70-GD-MFB-001
. Seawater and Product water balance in Desalination Plant,
Dwg No. 70-GD-MFB-003
. Symbols and identification system(1/2),
Dwg No. 70-GD-MFB-004
. Symbols and identification system(2/2),
Dwg No. 70-GD-MFB-005
. LP steam and BH condensate system(1/2),
Dwg No. 70-GDB-MFB-001
. LP steam and BH condensate system(2/2),

Dwg No. 71-GDB-MFB-001

. Condensate extraction pump/motor,

Dwg No. 71-GDB-MFB-002

. I.P steam, venting & vacuum system,

Dwg No. 71-GDH-MFB-002

. S/W cooling and make-up water system,

Dwg No. 71-GAC-MFB-001

. Cooling water recycle pump/motor,

Dwg No. 71-GAC-MFB-002

. RO tempering system,

Dwg No. 70-GAC-MFB-001

. Brine recirculation system(1/2),

Dwg No. 71-GDG-MFB-001

. Brine recirculation system(2/2),

Dwg No. 71-GDG-MFB-002

. Brine recirculation pump/motor,

Dwg No. 71-GDG-MFB-003

. Distillate system(1/2),

Dwg No. 71-GDK-MFB-001

. Distillate system(2/2),

Dwg No. 70-GDK-MFB-001

. Distillate pump/motor,

Dwg No. 71-GDK-MFB-002

. Brine blowdown system,

Dwg No. 71-GDR-MFB-001

. Brine blowdown pump/motor,

Dwg No. 71-GDR-MFB-002

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

3. Chemical Dosing System


3.1 General Description
The chemical dosing system is the system where the chemicals are prepared in solution
and supplied for injection. The eight (8) MSF units have one (1) central type chemical
dosing system. The chemical dosing pumps(2 operating and 1 standby) feed a ring main
B

from which via spur lines and the chemicals are dosed to each evaporator unit from ring
main.
Severe foaming can contaminate distillate water; scale deposits can block the tubes; and
residual oxygen in deaerated water can cause corrosion throughout the evaporator unit.
During evaporator operation, these problems are kept under control by injecting anti-foam,
anti-scale and sodium sulphite chemicals into the evaporator unit.
The dosing rate of the chemicals is automatically controlled by means of dosing pump

stroke adjustment and control valve by DCS fully. The control regulating system receive
signals from the instrumentation that measures the flow of the additive and of the make-up
water.

3.2 System Description


3.2.1 Anti-Foam Dosing
Anti-foam is required to suppress foaming in the deaerator and in the evaporator flash
chambers. Anti-foam is injected upstream of the deaerator.
The dosing rate requirement for anti-foam is dependent on foaming tendencies of the
seawater and brine. Foaming in the desalination unit is due to a variety of reasons, such
as:
1. The presence of organic compounds, their concentration and the type of
organic matter present.
2. Total dissolved solids.
3. Temperature.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

4. Insoluble matter in suspension and their surface properties.


Since foaming can result in the carryover of brine into the distillate, thus contaminating the
purified water, it must be controlled.
The recommended dosing level of anti-foam is 0.1 ppm using 5% BELLITE M8 solution.
3.2.2 Anti-Scale Dosing
Scale deposition caused by crystallization of alkaline scales, e.g. CaCO3 and Mg(OH)2.
Non-alkaline scales e.g. CaSO4 are the most common scales in MSF. Scale deposition
B

normally begin in sequence, CaCO3, Mg(OH)2 then CaSO4 as the temperature increase.
The scale precipitations inside MSF tube condenser cause a reduction in overall heat
transfer coefficient which increases the required heat transfer area (increases CAPEX)
and reduction the tube inner diameter, might block the tube and increase the pumping
power (increase OPEX).
Controlling scale deposition in Thermal desalination plants is essential in order to maintain
operating efficiency. Scale formation hinders the heat transfer process, increases
operating costs by increasing the amount of steam required to maintain TBT (top brine
temperature) and causes frequent shutdown of the plant for cleaning. At present, the most
widely used method to control scale is by the addition of chemical additives (anti-scalants)
which tend to increase the saturation limits of inorganic salts present in seawater.
The chemical BELGARD EV2030 or EV2045 is very effective in controlling alkaline scale.

In case of CaSO4 scaling is prevented by controlling the temperature and concentration


factor of the brine within the precipitation limits, that is a maximum temperature of 120
and a concentration factor of foulant and silt.
The anti-scale dosing system is designed to supply 100% solution. Anti-scale can be
injected into discharge line of the brine recirculation pump line. In case of emergency
conditions when circulating pumps are out of service, anti-scale is injected to suction line
of the brine recirculation pump under vacuum through by-pass line.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

If a failure of the anti-scale chemical supply occurs, the operator shall immediately
prepare for shutdown. If it is not possible to restore the chemical feed, the operator shall
take all necessary actions to shutdown the system.
3.2.3 Sodium Sulphite Dosing
The presence of dissolved oxygen in water is a cause of corrosion in metals. The deaerator
removes most of the dissolved oxygen, and the deaerated water will have 20 ppb or less
residual oxygen. Sodium sulphite chemical injection is used to scavenge this residual
oxygen from the deaerator water, according to the following reaction
2 Na2SO3 + O2

2 Na2SO4

The sodium sulphite dosing system is designed to supply 0.9 ppm dosing rate, using a
10 % solution.
Sodium sulphite can be injected into discharge line of the brine recirculation pump.

3.3 Operation and Control Philosophy


All equipment in chemical dosing system are controlled by DCS at CCR.
Chemical Circulating Pump
There are three (3) pumps in ring main type chemical dosing system, two (2) operation
B

and one (1) stand-by. Each pump is designed to cover 100% capacity under normal
operation of eight (8) evaporators. To prepare abnoraml operating condition, such as
when ball cleaning system sut down, anti scale doing rate increase up to 5 ppm, each
pump works 50% condition under normal operation. To decide one pump operation
flowrate, total make up water flow signal of eight (8) evaporators shall be transmitted to
the electronic capacity controller of the pump. 4 mA shall correspond to 0% flow, and 20
mA shall correspond to 100% flow.
And each evaporator injection rate can be controlled by control valve installed in injection

point by flow transmitter signal of the additive flow in each evaporator.

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Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Chemical dosing pumps are provided with an internal safety relief valve. The relief pressure
is factory set at 10% above the maximum operating pressure to protect the pump. In addition,
an external relief valves are located at the pump discharge and rin main to protect the
pipeline in case of over pressurization.
Pressure gauges are located at pump suction and discharge for monitoring purpose.
Chemical Tank Agitator
Each chemical tank will have a set of its level transmitter and agitator. To mix uniformly
chemical and water, agitator operates when filling and intermittent. However, when the
B

level in the chemical operating tank is LOW, the level transmitter shall trigger a signal to
cut off its agitatorr operation, to protect the agitator from dry run.
Chemical Tank
Level gauge are located locally at the chemical tank, to enable the operator to read the
level of chemical in the tank. In addition, a level transmitter shall transmit a signal to the
DCS.
During normal operation, only one tank shall be in operation and the other tank shall be
isolated. When the tank in use reaches LOW-LOW level, the isolation valve to the standby
tank shall be opened and that for the operating tank shall be closed.
Emergency shower and eye washer

Emergency shower and eye washer are available in the event of an emergency.
According to MSDS of each cheamical, it immediately remove contaminated clothing and
skin by using emergency shower and eye wahser if skin contact is occurred.
In case of eye contact, it rince the eye with water with eye wahser before getting medical
attention.
Emergency shower and eye washer equipment is installed neighboring districts near the
shelter of chemical dosing system to approach easily and quickly under emegency
situation.

Page 53 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

3.4 Chemical filling method to mixing tank


3.4.1 Liquid type chemical (Antiscale, Antifoam) filling method
In case of Antiscale, 100% chemical of antiscale is filled to each mixing tank by barrel
pump. The necessary antiscale amount is filled up to H level of tank with checking level
gauge.
In case of Antifoam, the necessary chemical amount is filled to mixing tank up to 5%

value by using barrel pump from drum. Operator measure 5% value of tank by level gauge
locally mounted. Then the remainder of mixing tank is filled up with service water and
agitator is operating to mix chemical with water uniformly.
3.4.2 Powder type chemical (Sodium sulphite) filling method
In case of power type (sodium sulphite), the necessary chemical is filled to mixing tank

through manhole at top of the mixing tank by using portable hopper. Operator tear the bag
of sodium sulphite, then fill in hopper with powder chemical.
After filling up to necessary amount in hopper, this hopper is moving from ground to
mixing tank by hoist installed under the roof of shelter. Then the remainder of mixing tank
is filled up with service water and agitator is operating to mix and solve sodium sulphite to
water uniformly.

3.5 Reference Drawing

. Chemical Dosing System(1/3)

Dwg No. 70-GDN-MFB-001

. Chemical Dosing System(2/3),

Dwg No. 70-GDN-MFB-002

. Chemical Dosing System(3/3),

Dwg No. 70-GDN-MFB-003

Page 54 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

4. Ball Cleaning System


4.1 General Description
The purpose of the ball cleaning system is to remove sludge and scaling from the inner
walls of the heat recovery section & the brine heater tubes, and heat rejection section
during normal operation, by using larger size sponge balls than tube ID.
It is a simple, closed, ball re-circulation loop. A non-clogging pump carries sponge rubber
B

balls out of an inline ball collector and injects them into the inlet water flow of the shell and
tube unit to be cleaned. The balls are forced through these tubes by the differential
pressure available across them. Ball strainer screen(s) located after the outlet of these
tubes remove the balls from the main cooling water flow and feeds them back to the ball
collector for re-circulation or collection.
Since the diameter of the sponge rubber ball is slightly larger than the inside diameter of

the cooling tube, the ball wipes dirt and scale from the inside surface of the tube. These
deposits are removed without disturbing the protective film on the inside tube walls. The
ball collector that is provided in the ball re-circulation line allows for the removal of the
balls from circulation when cleaning is not required or worn balls.
One ball cleaning system is located near the brine heater and the heat recovery section,
and the other is located near heat rejection section. Two independent ball cleaning
system are supplied per evaporator unit.
This system is designed in order to take below matters :
1) Ensure a constant heat transfer coefficient in the heat recovery and brine heater.
2) Ensure better thermal efficiency due to the reduction of heat consumption and
consequently less steam consumption.
3) Inhibit corrosion by eliminating the build-up of micro-organisms in the tubes.
4) Reduce use of chemical additives.
5) Extend the service life of cooling tubes.

Page 55 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

4.2 System Description


4.2.1 Ball Strainer
B

The ball strainer section separates the cleaning balls from the exiting shell and tube unit
cooling water and passes them through the tube cleaning system recirculation loop. In a
double screen ball strainer, this separation is accomplished using an inverted V screen
configuration that covers the entire pipe diameter.
Each assembly consists of a spool piece, screens on shafts, independently motor
operated actuators, flanged ball discharge ports, two differential pressure ports on either
side of the screens with isolation valves, and a differential pressure transmitter.
The actuators are provided with a hand-wheel to allow operation of the screens manually
for test and adjustment or in the event of a control failure. The screens are designed so
that when they are rotated to the open position, the flow of the water through them is
reversed. This reversal forces any debris that has accumulated on the screens to be
flushed off.
4.2.2 Differential Presusre Transmitter
B

A differential pressure transmitter continuously monitors the pressure differential across


the ball strainer screens. With an increase in differential pressure due to an accumulation
of debris, the 4-20 mA output signal to the control panel increases. Once this signal
exceeds a predetermined value (set point #1), the control system will signal the actuators
to open the screens to the normal backwash position. Prior to this operation, the ball
collector will automatically collect the balls and remove them from circulation.
The 4-20 mA signal from the transmitter has two differential pressure set points. When the
pressure drop reaches set point #1, the system will go into the normal backwash cycle. If
the pressure drop reaches the second set point, the system will go into the emergency
backwash cycle. In the emergency backwash cycle, the screens will enter into the
backwash position without collecting the balls so some or all of the balls may be lost in
this backwash situation.
Emergency backwash prevents the ball strainer screens from being damaged due to
extreme differential pressure. The DP units are field adjustable and should be set by
Operator during start-up and commissioning.

Page 56 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

4.2.3 Ball Collector


The ball collector is spherical vessel with a sight glass. This view port allows the operators
to visually monitor the flow and condition of the cleaning balls in the tube cleaning system
(clarity of cooling water permitting). As an access man hole, it allows for the removal of
the cleaning balls for replacement. The ball collector has a fixed internal screen tube that
will block the cleaning balls and prevent them from leaving during the collection
Manually operated vent and drain valves are provided on the top and bottom of the ball
collector. These valves, along with the pump skid isolation valves, allow the operator to
remove balls through the easy opening access port. Both the addition and removal of the
balls can be accomplished without affecting the condenser operation.

4.2.4 Ball Recirculating Skid including Pump


The Ball Recirculating Pump is a non-clog type Centrifugal Pump capable of handling soft
solids under suitable pressure and injects the sponge rubber balls into the points which
are indicated as below :
1) In case of Ball Cleaning System for Brine heater and Heat Recovery Section
-. Brine heater
-. Brine Heater + Heat Recovery Section
2) In case of Ball Cleaning System for Heat Rejection Section
-. Heat Rejection Section
The ball recirculation skid contains non-clogging process pump with motor, ball collector,
interconnecting piping. pump pressure gauges, isolation valves, and MOVs.
Pump configuration will move balls through the ball circulation line without damaging them
like a pump with a tighter impeller to casing tolerance would. The motor and
the coupling guard introduce a safer working environment where water and people are
present.

Page 57 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

4.2.5 Local Control Panel


The control panel is equipped with main power circuit & PLC. A Programmable Logic
Controller (PLC) regulates all operations for the tube cleaning system. The front panel
contains start-stop and function switches along with pilot lights to display the operating
function. Digital indicators are also supplied to display the differential pressure across the
screen.
The system is provided with a Local Control Panel suitable for both Manual and Automatic
Operation. The Control Panel has got a mimic at its front facia that explains the System
functioning.

4.2.6 Others
Sponge rubber balls with a special composition and size 2 mm greater than the inner
diameter of the heat exchanger tubes are injected into the Brine stream at the inlet. These
balls which have a specific gravity same as that of the Brine are carried into the heat
exchanger by the velocity of the inlet water. Cleaning balls are then pushed through the
tubes by the differential pressure existing across the heat exchanger. While passing
through the heat exchanger tubes, the balls are pressed against the walls of the tubes
thus removing all deposits on the inner surface of the tubes. A specially designed screen
arrangement called the Ball Strainer, separates the balls going from the Brine line and the
balls are collected in the Ball Collector.
A V-Piece with a sight glass enables monitoring of the circulation of Cleaning Balls.
For an even distribution of the balls in the branches at the injection points, an injection

pipe facilitates transportation of the balls into the Main Brine Recirculating water. This
assembly consists of an injection pipe and an isolation ball valve. The valve is attached to
a flanged connection placed in BRP downstream line. Piping is run from the pump skid
outlet connection to the injection nozzle for insertion of the cleaning balls.

4.3 Operation and Control Philosophy

Page 58 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

The control logic is set out to cater to the operational requirements of Ball cleaning system
under all conditions.
Ball cleaning system functions under three modes.
a) Manual Mode
b) Automatic Local
c) Automatic Remote
4.3.1 Preparation before Normal Operation- Automatic Mode
The matters described as below are under automatic mode in normal operation.
a)

Required No. of Balls per charge are in the Ball Collector.

b)

Ensure ball collector is filled with water by opening valve Sea Water Inlet Valve

manually.
c)

Open manually Ball Collector VENT VALVE to ensure venting of air entrapped if any
in the ball vessel.

d)

After ensuring both the conditions close the valves.

e)

Ready to start lamp should be illuminated.

4.3.2 Auto Start (Operation Cycle)


Selector Switch should be in "AUTO LOCAL", and the SYSTEM IN LOCAL Lamp will be
illuminated. AUTO STOP" indication lamp will be illuminated.
By pressing the AUTOMATIC START illuminated push button, the following sequence of
operations takes place.
Time table can be changed in execution stage.
a)

Watering Timer

15 Minutes (PLC timer)

b)

Ball Injection Timer

05 Minutes (PLC timer)

c)

Ball Collection Timer

23 Minutes (PLC timer)

d)

Cooling Water Cycle Timer

7 Minutes (PLC timer)

e)

System Cycle Timer (Rest)

5 minutes (PLC timer)

Page 59 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

In case of ball cleaning system for heat rejection section, the time table is different from
above table. According to temperature and scale status in heat rejection section, it might
be operated intermittent. It will be fixed during commissioning period.

4.4 Reference Drawing


. Ball cleaning system for Heat Recovery and Brine Heater (1/2)
Dwg No. 71-GDP-MFB-001

. Ball cleaning system for Heat Rejection (2/2)

Page 60 / 71

Dwg No. 71-GDP-MFB-002

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5. Acid Cleaning System


5.1 Introduction
Diluted hydrochloric acid is used for the removal of scale deposits, such as calcium
carbonate, magnesium hydroxide and other components, from the tube inner surface for
the followings:
-

Circuit 1 (brine. Heater + heat recovery section Stg #1 ~ #5, 6)

Circuit 2 (brine heater + heat recovery section)

The hydrochloric acid is normally delivered to the plant using a tank truck with unloading
B

pumps system to fill acid storage tank. The acid is transferred to the acid solution tank on
mobile skid near evaporator by transfer pump and is dosing to cleaning circuit by dosing
pump on mobile skid when acid cleaning.

5.2 System Description


A mobile skid type acid cleaning system with acid storage system is provided for off-load
B

descaling of the brine heater and heat recovery tube surfaces, using hydrochloric acid.
For cleaning the evaporator tubes, the desalination unit shall be shutdown.
Each cleaning circuit is prepared, as follows:
-

Circuit 1
(Inlet of the cleaning circuit is isolated between the brineheater recircualtion control
valve and heat recovery section stg. #5, 6 by the isolation plate.)

Circuit 2
(Inlet of the cleaning circuit is isolated by the brineheater recircualtion control valve
and outlet by the brine recirculation pump discharge flow control valves)

5.2.1 Acid Storage System


Acid storage system include acid storage tank, corrosion inhibitor tank,seal pot, transfer
pumps, structure, platform, others. Acid storage tank is filled from tank lorry truck by
unloading pump. To provent acid vapour, seal pot is connected with vent of acid storage
tank. Corrosion inhibitor tank is filled by barrel pump form durm.

Page 61 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

Acid and corrosion inhibitor are dosing to mobile acid cleaning unit and to demoster
cleaning system by each transfer pumps which are operated by air and consist 1
operating and 1 stand-by.
5.2.2 Mobile Acid Sleaning System
B

The mobile acid cleaning unit is connected to each evaporator with temporary piping
(flexible hoses), in order to dose acid and chemicals to discharge to the brine heater
outlet, through the tubes. When acid cleaning, mobile skid move to unloading area near
evaporator and connected. The mobile acid cleaning unit include acid solution tank, fume
scrubber, dosing pump, accessories and safety equipment.
5.2.3 Emergency Shower and Eye Washer
B

Emergency shower and eye washer are available in the event of an emergency.
According to MSDS of acid, it immediately remove contaminated clothing and skin by
using emergency shower and eye washer if skin contact is occurred.
In case of eye contact, it rinses the eye with water with eye washer before getting medical
attention.
Each emergency shower and eye washer equipment is installed neighbouring districts
near acid storage area and mobile acid skid unloading area to approach easily and
quickly under emergency situation.
The seawater/brine within the cleaning circuit will be replaced by unchlorinated distillate
from the distillate header. The distillate is circulated in the cleaning circuit in the reverse
direction of the brine flow.
B

Hydrochloric acid dose slowly into the cleaning circuit, producing an acid cleaning fluid
with a pH of not less than 2. Corrosion inhibitor which is transferred bytransfer pump to
mixing tank on mobile skid from storage tank, shall be added into the cleaning circuit
concurrently to protect the tubes from acid corrosion before dosing acid.
The scale in the tubes is dissolved according to the following formulas:
CaCl2 + H2O + CO2

CaCO3 solid + 2HCl

Page 62 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Mg (OH)2 solid + 2HCl

Rev. : B
Date : 2011.01.20

MgCl2 + 2H2O

Carbon dioxide gas will be produced and must be vented completely by the CO2 scrubber,
located on the mixing tank. Also periodical venting of the water boxes is recommended to
remove trapped gas.
Grab samples shall be taken and analysed in the laboratory. The pH-meters shall be
monitored in order to determine the progress of the cleaning procedure and the residual
activity of the acid solution. The cleaning fluid is then drained slowly into the out fall
channel.. The cleaning circuit shall be flushed thoroughly with distillate before being
disassembled and stored.
Basically, neutralisation is performed by dosing NaOH (sodium hydroxide) in the cleaning
circuit, before discharging the neutralized water to the out fall channel. .

5.3 Operation And Control Philosphy


The loading of concentrated hydrochloric acid from the acid tank lorry truck into the
storage tank and then transfer to acid solution tank on mobile skid by acid transfer pump,
B

it will be initiated in manual.


The acid cleaning procedure is performed in manual from the desalination unit. A safety
system monitors the pH of the diluted cleaning fluid, after mixing the circulating distillate
stream with concentrated acid and also after leaving the heat recovery section. Further
the safety system checks the level in acid solution tank and the flow into the circulation

circuit. The safety system shall switch off the acid transferred pump and acid dosing
pump with sound an alarm in case of any malfunction such as: LOW pH, HIGH or LOW
level of acid solution tank and rise of temperature.

5.4 Acid Cleaning Procedure


This procedure is prepared based on Circuit 2 (brine heater + heat recovery section).
There would be no problem to apply this procedure for Circuit 1 (brine heater + heat
recovery section stg. #1 ~ 5,6).
B

A detail procedure can be changed during design stage.

Page 63 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5.4.1 Pre-Start Checks


5.4.1.1 Chemical Preparation
Before the system start-up, the following chemicals shall be prepared.
<Acid Storage System>
B

a.

Hydrochloric acid (32% HCl) in the acid tank lorry truck


WARNING:
Ensure that acid storage tank is empty and no water inside, before unloading to
the acid tank lorry truck.
Fill in storage tank.

b.

Corrosion inhibitor in barrels


Fill in storage tank

c.

Check each transfer pump and service air line

<Mobile Acid Cleaning System>


a.

Check and mount mobile acid cleaning unit in unloading area

b.

Caustic Soda (30% NaOH) in barrels

5.4.1.2 Flexible Hose Preparation


The flexible hoses are connected in order to form a circuit for acid cleaning.
5.4.1.3 Power and Control Cable Preparation
Power and control cable shall be connected.
5.4.1.3 Service Air Preparation
B

Service air line shall be connected in pump.


5.4.1.4 Valve Preparation
The valves shall be pre-set before start-up.

Page 64 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5.4.1.5 Personal Protective Equipment


All the personnel engaged in the acid cleaning operation must have the following
personal protective equipments, in addition to the standard safety equipment;
- Safety goggles
- Acid resistant rubber gloves
- Respiratory masks (suitable against acid fumes)
- Acid resistant cover alls.
5.4.1.6 Emergency Shower and Eye Washer
B

Before proceeding for the work, emergency shower and eye washer in the plant
premises must be checked and identified.
5.4.1.7 First Aid
A complete first aid kit equipment with necessary medicines
Neutralizing agents for treating acid burns must be available at site.
5.4.2 Start-Up
5.4.2.1 Distillate Filling to the Circuit
a.

Drain the brine in the circuit through all the drain valves in the circuit.

b.

Fill the circuit with distillate and starting the cooling water recycle pump. During
filling, all vent valves shall be open.

c.

Circulate distillate in the circuit for about 20 minutes, in order to make stable
operation.

5.4.2.2 Chemical Injection and Acid Cleaning

a.

Inject corrosion inhibitor by barrel pump .

b.

And then, start the acid feed pump. Check pH to be around pH=2.

Page 65 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

c.

Rev. : B
Date : 2011.01.20

Once the pH reaches 2 or less than 2, this indicates tubes are cleaned and stop
acid dosing.
Important;
During acid dosing monitor the CO2 scrubber and the vents on the brine
heater and heat recovery water boxes should be open to release CO2.
Monitor pH every after 30 minutes interval from the sample point and plot the
graph time vs. pH
Monitor Cu++ when pH reaches to 3 or less after 30 minutes interval in
increases abnormally it indicates that the tubes are clean.
Plot graph time vs. Cu++

d.

Continuously monitor the pH at the cooling water recycle pump outlet pH meter.
Also it is recommended to check the pH at the brine heater inlet, that is, the acid
recirculation outlet from brine heater.

e.

Leave open partially the water box vents at brine heater water boxes and stage
#1 box, for degassing.

f.

Time to time, vent out water boxes of all other stages to remove trapped gas.

g.

Once the pH comes down 2 at recirculation pump outlet, stop the acid feeding for
some time and restart the feeding after the pH is about 3.

h.

Stop acid feeding when the pH reaches around 2~3 at both outlet cooling water
recycle pump and brine heater inlet.

i.

Flush the acid feed lines using distillate water and then dismantle all acid feed
connections.

j.

Continue circulation for about one more hour at the stable low pH (2~3) to ensure
complete cleaning.

Page 66 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

5.4.2.3
a.

Rev. : B
Date : 2011.01.20

Neutralization and Drain


Inject NaOH by the barrel pump. If the pH value keeps 5.5 through 9 for 60
minutes, stop the barrel pump (NaOH injection) and the cooling water recycle
pump .

b.
B

Drain the neutralised water in the circuit through all the drain valves in the circuit
to seawater discharge line.

5.4.2.4 Rinsing and Drain


Repeat this rinsing and drain procedure 3 times in normal.
a.

Fill the circuit with distillate and starting the cooling water recycle pump . During
filling, all the vent valves shall be open.

b.

Circulate distillate in the circuit for rinsing for 30 minutes

c.

Drain the rinsing water in the circuit through all the drain valves in the circuit
to seawater discharge line.

5.5. Flow Chart


5.5.1 Preparation for acid cleaning
Chemical Preparation
(HCl, NaOH, Corrosion Inhibitor)

System Preparation
(Piping & Cable connection)

Valve Preparation

Page 67 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5.5.2 Operation of acid cleaning


Distillate to Heat recovery &
brine heater

Cooling water recycle pump


START
Corrosion inhibitor dosing
START

Corrosion inhibitor dosing


STOP

Circulating for about 60 minutes

Acid feed pump START


B

Continuously inject

If pH < 2 at outlet

NO

YES

Acid feed pump STOP

Recirculation for 60 minutes

Page 68 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5.5.3 Neutralization & Acid draining


NaOH dosing START

Supply pH > 6.5

NO
YES

NaOH dosing STOP

Drain out neutralization water


through water box drain

Recirculation pump STOP

Line-up Brine blowdown drain

Open seawater make-up for shell


filling

Start BRP each for 2hrs

Shutdown the unit and drain

Page 69 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

5.6 Acid Cleaning System for Demisters


5.6.1 Introduction
The demister acid cleaning is required for the removal of scale deposits on the demisters
in the evaporator, using diluted hydrochloric acid. Service air is jetted from the bottom
side of the cleaning basin and the flushing basin, in order to promote the cleaning
performance, and also reduce the cleaning time.
5.6.2 System Description
The desalination unit shall be shut down in order to take out the scaled demisters from
each stage. The removed demisters are transferred to the demister acid cleaning area by
a pork lifter car, which is not supply scope of DOOSAN.
This system is designed to use diluted hydrochloric acid as cleaning material. The
B

cleaning basin is filled with service water and hydrochloric acid (32%) to make pH=2 of
dilution hydrochloric acid in general. The cleaning time is about two (2) hours in general.
Both pH value and cleaning time depend on the scale quantity, so accordingly are to be
changed. The cleaning completion is actually judged by visual checking.
The demisters are loaded into the demister carrier, which can carry a half stage amount of
demisters. The electric hoist transfers the demister carrier to the cleaning basin, the
flushing basin and the storage area.
The flushing basin is filled with service water. The flushing time is about one (1) hour in
general. The flushing completion is actually judged by visual checking.
All the used water in the cleaning basin and the flushing basin is neutralized to dose

NaOH into each basin and drain to the retention pit, and go to neutralization pit.
5.6.3 Cleaning Procedure
5.6.3.1 Cleaning

Page 70 / 71

Project : Ras Al Khair Power and Desalination Plant - Phase I


Subject : System Description and Operation Philosophy for MSF Plant
Doc. No. : 70-GD-MFB-001

Rev. : B
Date : 2011.01.20

a.

Fill the cleaning basin with service water

b.

Feed acid to make pH=2 diluted hydrochloric acid.

c.

Transfer the demister carrier into the prepared cleaning basin by the electric hoist.

d.

Service air is jetted. Keep cleaning about 2 hours in general. The cleaning
completion is actually judged by visual checking.

5.6.3.2 Flushing
a.

During the cleaning time, fill the flushing basin with service water.

b.

Transfer the demister carrier into the prepared flushing basin by the electric hoist.

c.

Service air is jetted. Keep flushing about 1 hour in general. The flushing completion
is actually judged by visual checking.

d.

Transfer the demister carrier into the storage area.

5.6.3.3 Pre-neutralization
a.

After the cleaning and the flushing each, dose NaOH into basin

b.

Inject NaOH by the barrel pump. If the pH value keeps 5.5 through 9,
stop the barrel pump (NaOH injection).

c.

Drain the neutralized water to retention pit

Neutralized water in retention pit transfer to neutralization pit in RO area.

5.7 Reference Drawing

. Acid Storage System

Dwg No. 70-GDE-MFB-001

.Mobile Acid Cleaniung System

Dwg No. 70-GDE-MFB-002

. Acid Cleaing System for Demister

Dwg No. 70-GDE-MFB-003

Page 71 / 71

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