Professional Documents
Culture Documents
CONTRACTOR'S STAMP
REV.
H.H.KIM
I.S.SONG
02-Feb-12
H.H.KIM
I.S.SONG
15-Nov-10
PREPARED CHECKED
DATE
CONTRACTOR
(CONSORTIUM LEADER)
Project No
LOCATION
TITLE
31002
Ras Al Khair
SCALE
CONTRACTOR
(CONSORTIUM MEMBER)
SUBCONTRACTOR
SHEET 1 OF 71
Rev. : B
Date : 2011.01.20
CONTENTS
1.
2.
3.
4.
5.
Page 2 / 71
Rev. : B
Date : 2011.01.20
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
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
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)
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
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.
Page 5 / 71
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
-
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:
-
Page 6 / 71
Rev. : B
Date : 2011.01.20
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.
Page 7 / 71
Rev. : B
Date : 2011.01.20
Protection
PUMP SUCTION CHAMBER LEVEL
Level transmitter,
LOW LOW
PUMP DISCHARGE PRESSURE HIGH
Pressure transmitter,
Temperature(RTD),
Temperature (RTD),
Temperature (RTD),
Temperature (RTD)
Temperature(RTD),
Vibration detectors,
Page 8 / 71
Rev. : B
Date : 2011.01.20
Pressure transmitter, provided in the discharge line of the Pump to indicate the
discharge pressure,
Temperature detectors are provided in each of the three windings of the motor stator
to protect against overheating,
Conductivity analyzer
Oil analyzer
pH analyzer
Turbidity analyzer
Page 9 / 71
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
-
in Pump Motor
-
Page 10 / 71
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
Rev. : B
Date : 2011.01.20
Page 12 / 71
Rev. : B
Date : 2011.01.20
Page 13 / 71
Rev. : B
Date : 2011.01.20
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
Rev. : B
Date : 2011.01.20
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
3
m /day
3
m /day
kg/
2326
kJ
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
Rev. : B
Date : 2011.01.20
S/N
Load Cases
Unit
Gross distillate
production for Each
MSF unit
3
m /day
3
m /day
kg/
2326
kJ
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
ton/h
412.0
414.2
415.1
412.3
410.6
437.1
ton/h
8.0
8.0
8.0
8.0
8.0
8.0
ton/h
34,700
36,300
35,700
34,000
33,500
36,600
ton/h
11,260
11,377
11,335
11,198
11,147
11,403
10
ton/h
7,372
7,491
7,448
7,313
7,260
7,514
Page 16 / 71
Rev. : B
Date : 2011.01.20
2.
3.
Fault Analysis.
2.
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
Rev. : B
Date : 2011.01.20
Therefore, it is necessary to press the release button to execute the following commands:
2.
3.
4.
5.
6.
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
Rev. : B
Date : 2011.01.20
Page 19 / 71
Rev. : B
Date : 2011.01.20
Page 20 / 71
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
Page 21 / 71
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.
b.
c.
d.
e.
f.
g.
h.
Page 22 / 71
c.
d.
e.
f.
g.
h.
Rev. : B
Date : 2011.01.20
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
Rev. : B
Date : 2011.01.20
a.
b.
c.
d.
e.
f.
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
Rev. : B
Date : 2011.01.20
2.
3.
4.
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
System Description
Page 25 / 71
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).
Page 26 / 71
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
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:
The various instruments provided to interface the brine recirculation system with the DCS
through closed loop control are:
Page 28 / 71
Rev. : B
Date : 2011.01.20
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:
Page 29 / 71
Rev. : B
Date : 2011.01.20
a.
b.
c.
d.
e.
Page 30 / 71
Rev. : B
Date : 2011.01.20
a.
b.
c.
d.
Page 31 / 71
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.
Page 32 / 71
Rev. : B
Date : 2011.01.20
Page 33 / 71
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.
Page 34 / 71
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
Page 35 / 71
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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2.
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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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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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.
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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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a.
b.
c.
d.
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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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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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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.
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a.
b.
c.
d.
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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the pump are supported by the thrust bearing motor. The motor is mounted on an
individual steel fabricated motor base.
. RO tempering system,
. Distillate system(1/2),
. Distillate system(2/2),
. Distillate pump/motor,
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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.
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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.
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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.
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
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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.
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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.
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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.
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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
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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.
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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)
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)
e)
Watering Timer
b)
c)
d)
e)
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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.
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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.
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)
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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
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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. .
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.
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a.
b.
c.
b.
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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.
a.
b.
And then, start the acid feed pump. Check pH to be around pH=2.
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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.
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5.4.2.3
a.
Rev. : B
Date : 2011.01.20
b.
B
Drain the neutralised water in the circuit through all the drain valves in the circuit
to seawater discharge line.
Fill the circuit with distillate and starting the cooling water recycle pump . During
filling, all the vent valves shall be open.
b.
c.
Drain the rinsing water in the circuit through all the drain valves in the circuit
to seawater discharge line.
System Preparation
(Piping & Cable connection)
Valve Preparation
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Continuously inject
If pH < 2 at outlet
NO
YES
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NO
YES
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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
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Rev. : B
Date : 2011.01.20
a.
b.
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.
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.
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