document acid recovery system

8/3/2019 Document Acid Recovery System

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INSTRUCTION MANUAL

Serial number 08199


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CONDOROIL IMPIANTI Instruction Manual - 2 -

Manufacturing company:

CONDOROIL IMPIANTI SRLAddress: Via Galliani, 50

21020 CASALE LITTA (VA) Italy

e-mail [email protected]

Customer:

VIRAJ PROFILES LIMITED

Specification:Object: RESIBED UNIT

Plant: EXISTING PICKLING LINE

Location: TamaMUMBAI - INDIA

Manufacturing: September 2008


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INDEX

SECTION 1: GENERAL INFORMATION...........................................................................................51.1INSTRUCTIONS .................................................................................................................................. 51.2CUSTOMERDUTIES ............................................................................................................................ 51.3TECHNICALASSISTANCE ...................................................................................................................... 51.4RESTRICTIONS .................................................................................................................................. 5

SECTION 2: HANDLING AND TRANSPORTATION..........................................................................62.1HANDLING SKID ................................................................................................................................. 6

SECTION 3: POSITIONING............................................................................................................7

SECTION 4: INSTALLATION .......................................................................................................... 84.1HYDRAULIC CONNECTIONS ...................................................................................................................84.2PNEUMATIC CONNECTIONS ...................................................................................................................8

4.3ELECTRICAL CONNECTIONS...................................................................................................................94.3.1 Electrical connections check...................................................................................................... 94.4PLANT INTERCONNECTIONS ................................................................................................................ 10

4.4.1 First treatment skid ................................................................................................................ 104.4.2 Multimedia filter ..................................................................................................................... 104.4.3 Skid for cartridge filter............................................................................................................ 104.4.4 Resibed ................................................................................................................................. 114.4.5 Resibed auxiliary skid ............................................................................................................. 11

SECTION 5: SAFETY INSTRUCTION .......................................................................................125.1GENERAL SAFETYINSTRUCTIONS ......................................................................................................... 12

5.1.1Active Safety Measures .......................................................................................................... 125.1.2Passive safety measures......................................................................................................... 125.1.3Other dangers ....................................................................................................................... 135.1.4Environmental Danger............................................................................................................ 135.1.5Noise .................................................................................................................................... 13

SECTION 6: PROCESS DESCRIPTION.....................................................................................146.1PRETREATMENT.......................................................................................................................... 14

6.1.a Feeding pickling solution........................................................................................................ 146.1.b Sludge separation ................................................................................................................. 146.1.c Filtration ................................................................................................................................ 14

6.2RESINSECTION ........................................................................................................................... 176.2.a Phase 1: water purging .......................................................................................................... 176.2.b Phase 2: salts discharge ........................................................................................................ 19

6.2.c Phase 3: pickling solution removal .......................................................................................... 216.2.d Phase 4: pickling solution recovery......................................................................................... 236.2.e Waiting time ......................................................................................................................... 25

6.3DRAWINGS..................................................................................................................................... 256.4COMPONENTS LIST........................................................................................................................... 26

6.4.1 Pre treatment ........................................................................................................................ 266.4.2 Resibed Section ..................................................................................................................... 28

SECTION 7: SET POINT ...............................................................................................................307.1PRESSURE ...................................................................................................................................... 30


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SECTION 8: WORKING PROCEDURES .........................................................................................318.1FIRST START UP .............................................................................................................................. 318.2START UP ...................................................................................................................................... 32

8.2.1 Equipment............................................................................................................................. 328.2.3 Control panel ......................................................................................................................... 32

SECTION 9: CONTROL PANEL......................................................................................................33

SECTION 10: PLANT STOP...........................................................................................................3810.1 EMERGENCY STOP.......................................................................................................................... 3810.2NORMAL STOP ............................................................................................................................... 38

SECTION 11: MAINTENANCE........................................................................................................3911.1GENERAL RULES ............................................................................................................................ 39

11.1.1 Individual protections ........................................................................................................... 3911.2PROGRAMMED MAINTENANCE............................................................................................................ 3911.3LOADING FILTERSF101 .................................................................................................................. 42

11.3.1 Loading Multimedia filter FS101 ........................................................................................... 4211.3.2 FS Maintenance data ......................................................................................................... 43

11.4CARTRIDGE FILTERFC101 ............................................................................................................... 4311.4.1 Loading cartridge in FC101 ................................................................................................... 43

11.5RESIN BED RB101 ......................................................................................................................... 4411.5.1 Changing the filter nets ........................................................................................................ 4411.5.2 Loading resins on RB101 ...................................................................................................... 45

SECTION 12: TROUBLE SHOOTING............................................................................................4612.1INSTRUCTIONS .............................................................................................................................. 46

SECTION 13: ALARMS ................................................................................................................4813.1IN CASE OF ALARM.......................................................................................................................... 48


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Section 1: General Information

1.1 Instructions

This assembly instruction manual provides the Customer with the information about theassembly of the ACID RETARDATION UNIT.This manual must always be handed over to new owners, till the final dismantling of theinstallation.

WARNING

The improper use of this installation as well as inappropriate maintenance work mayharm people and damage things. The Operator and the Skilled Technician have to knowall the rules of this manual, before the installation. The procedures reported in thismanual can be applied to this installation only for the allowed purposes. If the Customeruses it for other purposes, he/she becomes automatically liable if people get hurt,because of lack of safety.

1.2 Customer Duties

If not otherwise specified in the contract, the Customer has to arrange:

The plant positioning.The connection of the plant to the working tanks.The power supply of the control station.The supply of compressed air.The water supply and connection to the unit.

The lifting and handling machines for the assembly.

WARNING

CONDOROIL IMPIANTI S.r.l. is not liable for damages or injuries due to an improperGROUNDING or that is not in

compliance with the rules of the country where the installation is installed.

1.3 Technical Assistance

For technical assistance, please contact CONDOROIL IMPIANTI S.r.l.

1.4 Restrictions

The installation or its components cant be modified without the written consent of CONDOROILIMPIANTI S.r.l.; not allowed modifications may alter the original functions and lead to the expiryof the warranty on the whole supply.


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Section 2: Handling and Transportation

The plant has to be handled by qualified people with a proper and suitable lift truck, and, for theheaviest components, a grane. Before moving the plant, please make sure the tanks are emptyand unplug the installation from utilities (power supply, compressed air, inlet and outlet pipes).

For transportation no special instructions are required, beside to make sure to handle with care.

The plant consists of five different parts:

FIRST TREATMENT SKID Dry Weight approx. 1400 Kg

MULTIMEDIA FILTER Dry Weight approx. 2900 Kg

SKID FOR CARTRIDGE FILTER Dry Weight approx. 670 Kg

RESIBED AUXILIARY SKID Dry Weight approx 2000 Kg

RESIBED Dry Weight approx 4000 Kg

WARNING

Never cling to or press pipes or other devices because the structure of the installation may give way.

2.1 Handling skid

The plant must be handled by means of a bridge crane using special lifting rings or a lift truck.Lifting must be gradual and uniform without brisk movements and sudden interruptions that can

cause strong oscillations.The installation can be lifted from the bottom frame. Then try to position it in such a waythat the weight is balanced.


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Section 3: Positioning

The parts of the plant have to be positioned as showed on the Drawing n. 55022_rev06 GeneralLayout and as Drawing Viraj India Layout.

A: FIRST TREATMENT SKID

This skid has to be positioned next to the picklng line in front of tank n. 3.The battery limit consisting of the valves withdrawing from the pickling tanks facing thepickling line;The panel control on the opposite side.

B: MULTIMEDIA FILTER AND SKID FOR CARTRIDGE FILTER

These parts are connected and have to be positioned in front of pickling tanks n. 4 and n.5

The Multimedia Filter in front of pickling tank n.4 (closer to First treatment skid)The connections to skid n.1 First Treatment skid facing it.The cartridge filter on the right, with the blower side facing the pickling line, and theconnections to the Multimedia Filter facing it.

C: RESIBED AUXILIARY SKID

This skid will be positioned in front of pickling tank n. 6.The battery limit consisting of the valves sending the solution back to the pickling tanksfacing the pickling line;

The electrical panel on the opposite side.

D: RESIBED

This unit will be positioned with the support of a bridge crane in front of pickling tank n. 7.The longer side facing the pickling line.Exact position must be 120 mm off compared to skid n. 3 Resibed Auxilairy skid: the backside must be in line with the back side of skid n. 3.


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Section 4: Installation

To install the unit just follow the instruction on connections as described; the equipment must beconnected to the working tanks using PP pipes, with bigger or equal diameters to the ones alreadyassembled on the units.Installation of the plant is limited to the following connections described in the followingparagraphs.

4.1 Hydraulic Connections

The unit requires the below mentioned hydraulic connections to clients utilities, or discharge:

SKID N. 1 FIRST TREATMENTInlet from pickling tanks n. 8 Butt welded d40 PPWater inlet Flanged DN50Sludge Discharge Flanged DN50Overfill back to pickling tanks Flanged DN50

SKID N. 2 SKID FOR CARTRIDGE FILTERDischarge Butt welded d32 PP

MULTIMEDIA FILTERDischarge (SIDE) Butt welded d63 PPDischarge (BOTTOM) Thread d63 PP

SKID N. 3 RESIBED AUXILIARY SKIDWater inlet Butt welded d40 PPOutlet to pickling tanks n. 8 Butt welded d40 PPConcentrated salts outlet Butt welded d40 PP

Piping is provided with butt welded connections, furthermore piping is supplied with tagsidentifying the conducted fluid.

4.2 Pneumatic Connections

The unit has only one pneumatic feeding with the following characteristics:

Compressed air inlet to SKID n. 1 Compressed air inlet to SKID n. 3 Piping type P.E.Minimum required pressure 5 bar

Pneumatic connections from skid n.1 (all ) to the following pneumatic valves on FS101 FC101:

EV 107EV110EV111

EV112


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4.3 Electrical Connections

The unit has

N.1 ELECTRICAL FEEDING on SKID N. 1 FIRST TREATMENT with followingcharacteristics:

Feeding power 415 V 50 Hz Three phase WNInstalled power 10 kW

Control panel is provided with proper connection terminals. The electrical feeding is then suppliedto the users according to attached electrical diagrams.

WARNING

Before plugging in the installation make sure that both power supply and frequency comply with what iswritten on the plate inside the control panel. Remember that the plant NEEDS AN ELECTRIC SUPPLY 415 V50 Hz, THREE PHASES WITH NEUTRAL.

Make sure that there is an interlocked outlet between the electric line and the plant, in order to isolate themachine from the rest of the plant.

Check if the earth plate complies with the rules in force and that the section of the supply cable and ofthe external disconnecting switch is sized for MAXIMUM ABSORBTION.To plug in the plant, connect the supply cable to the terminals:I. R-S-T-N (if any) and EARTH installed inside the power panel.II. After connection, it is necessary to CHECK MOTORS ROTATION DIRECTION

4.3.1 Electrical connections check

If the plant is operated in manual, you just need to turn on engine pump for one second and lookat the rotation direction of the rear cooling impeller. It has to comply with what is written on theengine itself.If that is not the case, you have to change the position of the supply cables, by changing twophases (e.g. to exchange the position of the cable in the connecting terminal R with that of theconnecting terminal S).

DANGER

As you work inside the panel, before acting, before any operation, please check if the power supply isunplugged.


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4.4 Plant Interconnections

The ACID RETARDATION PLANT consists of five parts connected:

a. First treatment skid (n.1)b. Skid for Cartridge filter (n.2)c. Multimedia filterd. Resibed auxiliary skid (n.3)e. Resibed

Please follow the following interconnections

4.4.1 First treatment skid

OUT

From skid n.1 (Pre-treatment) to

multimedia filter FS 101 - BOTTOMd 63 Head welded

From skid n.1 (Pre-treatment) tomultimedia filter FS 101 - SIDE

d 40 Head welded

4.4.2 Multimedia filter

IN OUT

From skid n.1 (Pre-treatment) to multimediafilter FS 101 BOTTOM

Butt welded d63

From skid n.1 (Pre-treatment) to multimediafilter FS 101 - SIDE

Head welded d40

From sand filter FS101 toSkid n. 2 (cartridge filter)

Head welded d40 *

From sand filter FS101 toSkid n. 2 (cartridge filter -blower)

Thread d40 *

* Parts are provided, they need to be connected

4.4.3 Skid for cartridge filter

IN OUT

From sand filter FS101 toSkid n. 2 (cartridge filter)

Head welded d40

From skid n. 2 to skid n.3 (Resibed auxiliary) intotank n. 201

Head welded d40


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4.4.4 Resibed

IN OUT

From skid n. 3 to Resibed TOPand viceversa

Butt welded d40 same

From skid n. 3 to Resibed

BOTTOMand viceversa Butt welded d40 same

4.4.5 Resibed auxiliary skid

IN OUT

From Resibed - TOPto skid n. 3


From Resibed - BOTTOMto skid n. 3



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Section 5: Safety Instruction

In order to highlight the safety instructions of this manual, the following terms were used:

DANGERThis word is employed in the safety instructions or written on plates, to highlight how to prevent a

dangerous situation that would lead to peoples injury or death, if not.The safety directions also describe which measures are to be taken in order to avoid a dangeroussituation.By not complying with these precautions, the plant may be seriously damaged.

WARNINGThis word is employed in the safety instructions or written on plates, to highlight how to prevent adangerous situation that would lead to peoples injury and/or cause small damages.This word may also be used to describe dangerous situations which may damage only the plant.

IMPORTANTThis word refers to precautions to take in order to prevent the installation from lasting less than

expected.

NOTEThis word is used to provide or highlight useful information concerning the operation in process.

When this plant is operated in compliance with all the safety measures, neither the operator, northe people around it will ever be hurt, nor there will ever be a risk of damaging the plant.For further information about safety directions, please contact CONDOROIL IMPIANTI s.r.l..

5.1 General Safety Instructions

5.1.1 Active Safety Measures

In order to protect operators and maintenance personnel and to deactivate the plant in case ofdangerous component failure, the following safety measures have to be taken:

Safety switch (IG) on the panel door access to powered devices and controls is possibleonly without power supply, that is when the switch is on 0 (OFF).Emergency button when this button is pressed, the installation is immediately unplugged.Level controllers stop the cycle in case of abnormal conditions.Pressure switches - control the pressure inside the circuits and turn on when the calibrationSet-Points are exceeded.Air pressure switch stopping the unit, if the compressed air operating the pneumatic valves

falls below the Set-Point.

5.1.2 Passive safety measures

Passive safety measures refer to safety measures taken during the design phase, which protectthe operator from electric or mechanical danger:

Timing case covering electromechanical devices.IP 55 (minimum) protection of the whole electrical equipment.Use of electrical low voltage componentsInterception valves to isolate each component and to prevent liquids from spilling.

Oversized resistors of some components as compared with the actual operating pressure.


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5.1.3 Other dangers

The installation works with pressurized pipes. That is why you should wear protecting cloths andglasses. Same attention may be paid when handling products for cleaning whose data productbulletins and MSDS. Before doing any maintenance work, pipes have to be washed and then

washed again at the end of that work.If liquids come out, especially under pressure, you have to be well protected when approachingthe installation.Furthermore, when working manually, not all the alarms and safety devices are activated, so youshould be careful to avoid damages to the plant and overflow of liquids with negativeconsequences on people.

5.1.4 Environmental Danger

In view of the plant functioning and disposal of the drains, no risks for the environment are

estimated.

DANGER

It should be remebered that the treated waste waters are contaminated withchemical agents and other chemical products are used for cleaning. These productscan be accidentally spilled on the pavement or come into contact with operatingpersonnel.In such case product technical and safety data sheets should be consulted.

5.1.5 Noise

The only installation components producing noise are the pumps, certified by the manufacturer.CONDOROIL IMPIANTI S.r.l. declares that the noise produced by the plant is below 82 dB(A).


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Section 6: Process Description

6.1 PRE TREATMENT

6.1.a Feeding pickling solution

The unit withdraws the pickling solution from one pickling tank at a time, according to the cycle asset in the PLC (some tanks can be excluded, if needed).For example the EV100A (incoming from the first tank) and EV200A (outgoing to the first tank)valves open at the same time and remain open for a certain number of cycles that can be set onthe PLC.The unit cycle starts by opening the EV101 valve and starting the PM101 pneumatic valve: thepickling solution is sent to the lamellae sedimentation unit.

6.1.b Sludge separation

The solution is then fed to the lamellae sedimentation unit, where the heavy particles precipitateat the bottom of the hopper.In this unit turbolence of the incoming fluid is reduced inside the first sector and distributed allover the tank widthby going through the flow distribution frame.When the fluid falls through the lamellae, the sedimentable material aggregates, concentrates,precipitates and accumulates into the hopper, because of the increased mass. The clarifiedsolution is then stocked by overfall into tank SS101.Periodically (according to time set on the PLC) the sludge is discharged and the piping connectedis then rinsed:

A first timer opens the EV103 for a fixed period (that can be set on the PLC), A second timer opens EV104 for a different fixed period (that can also be set on the PLC)

After these periods the two valves close and the timers are reset.

6.1.c Filtration

Multimedia filter

When the liquid level in SS101 is high and the liquid level in SS201 is low (LT101 and LT201) thesystem withdraws the solution from SS101 by opening EV105, EV106, EV107 and starting thepump PC102: this way the solution is filtered in the multimedia filter and then the cartridge filter,where the particles with dimensions higher than xx microns cant go through.It is possible that the filters get obstructed because dirty: the differential pressure controldPT(101-102) is set so that when needed the system auytomatically start a discharge backflush flush cycle on the multimedia filter.

DISCHARGEThe pump PC102 stops, the valves EV105 and EV106 are closed and the valve EV110 is opened:air is blown into the filter and the solution already in the filter is pushed in the piping to the

cartridge filter.


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BACKFLUSH FLUSH DISCHARGEThe valves EV108 - 109 111 open and the pump PC103 starts.After a fixed period (can be set on the PLC) the two valves EV109 and EV111 close and EV112 andEV113 open so the system starts rinsing according to the flow line. After the dedicated timerreaches its value, the EV108 and EV113 valves close and then the the valve EV110 is opened toblow air into the filter as before; after a given period the blower turns off, the EV110 is closed and

then the EV112 is closed.After that with a little delay the EV105, EV106 and EV107 opens again and the cycle is reset.

Cartridge Filter

The FC101 cartridge filter is monitored by the Pressure Transducer PT102:

The high setting (PTH) states that the filter is dirty while the extra high setting (PTHH) states thatthe filter is blocked and stops the unit giving an alarm signal.


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6.2 RESIN SECTION

6.2.a Phase 1: water purging

During this phase the water that is stocked in the resin bed is sent back to the SS202 tank: afterchecking the level controls, the system opens the EV202, EV204 and EV210 valves and starts thePC202 pump. At this point also the controls on the flowrate (FT201) and the pressure difference(dP 201-202) are activated.


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6.2.b Phase 2: salts discharge

During this phase the salts trapped in the resin bed are sent to discharge: the system closes theEV210 valve and open the Ev205 valve.

If the level control LT202 is above the low setting, the system starts Phase 3.


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6.2.c Phase 3: pickling solution removal

During this phase the pickling solution trapped in the resin bed is sent to tank SS201: the systemcloses the EV202, EV204 and EV205 valves and open the EV206, EV207 and EV208 valves.

When the level control LT202 is on the low setting, the system open the EV201 valve, until the leelcontrol reaches the high setting.


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6.2.d Phase 4: pickling solution recovery

During this phase the pickling solution regenerated is sent to the pickling tanks: the system closesthe EV208 and opens the EV209 valve.


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6.2.e Waiting time

The unit is in stand by for a fixed time (it can be set on the control panel).

During these phases the system monitores the following unit controls:

Pressure transducers PT201 and PT202 if the tranducers reach the high setting (maximum pressure on the resin

bed), the system shuts down

Differential pressure control dP201-202 to check if the resins are plugged (during phase 3and 4)

if the level reaches the high setting the system shuts down

Flow transducer FT201 if the flowrate is below the low setting the unit shows a pre-alarm

if the flowrate is above the high setting the unit shows a pre-alarm

6.3 Drawings

Drawing Number Description

55021 Rev07 P&ID Resibed Unit

55022-1 Rev02 Layout Part 1





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6.4 Components List

6.4.1 Pre treatment

ITEM DESCRIPTION CODE QTY SPECIFICATION

EV100Membrane Valve 2-ways

AUT PP NC d40 VN0066 8 11/4" PP PTFE weld

PM101Membrane pump PVDF/

150PM0026 1 150 l/m - PVDF

SL101BLADE TECH 6/0,5/20/60

PPDT0003 1 dis n. 55026 rev01

SS101 1000 l PE tank KT0034 1 1.000 l - D 990 x h 1.470

Deep load 2" Flanged KA0044 1 OR - Viton

Connection Viton 2" KA0042 1 Flanged DN50

Connection PP DN32 KA0043 1 Gas - MA - Viton

PC102Horizontal centrifugal

pump PE 160PC0076 2 6mch - 26m - 3 kW

SF01 Blower 1.5 kW PT0005 2 100 mch Pdiff: 200 mbar

Manifold PI0012 2 For blower PT0005

Filter E 5 PI0010 1 For blower PT0005

Safety valve PI0015 600 For blower PT0005

Cartridge PI0011 2 For blower PT0005

Pressur Indicator 0-600 PI0004 2 For blower PT0005

Connection E 5 PI0014 1 For blower PT0005

Flexible connection E 5 PI0013 1 For blower PT0005

No return valve PI0016 1 For blower PT0005




AUT PP NC d32 VN0008 1 1" PP PTFE weld

EV103

Membrane Valve 2-ways

AUT PP NC d63 VN0009 1 2"PP PTFE weld


AUT PP NC d32 VN0008 1 1" PP PTFE weld








AUT PP d63 VN0074 1 2"PP EPDM weld



EV111 Membrane Valve 2-waysAUT PP NC d63

VN0009 1 2"PP PTFE weld


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EV113 Membrane Valve 2-waysAUT PP NC d40 VN0066 8 11/4" PP PTFE weld

PC103Horizontal Centrifugal

pump AISI 316PC0080 2

9mch 20m CER/CARB/FPM1,5kW

PT101-102 Pressure Transducer 0/6 ST0002 2 0-6 BAR

PT101-102 Separator d20 1/2" SM0018 2 1/2" G F/F

PI101-102Pressure Indicator 0-6 bar

DN 63SM0008 2 1/4" GAS AISI 316

PT101-102 Ball valve PP G+F d20 VP0014 1 DN15 PP/FPM T/T INS 20

LT101Pressure Transducer

0/200

ST0010 1 0-200 mbar

LT101 Separator d20 1/2" SM0018 1 1/2" G F/F

LT101 Ball Valve PP G+F d20 VP0014 2 DN15 PP/FPM T/T INS 20

V101 Ball valve PP G+F d40 VP0040 1 DN32 PP/FPM Head weld

Ball valve PP G+F d40 VP0040 1 DN32 PP/FPM Head weld

VR101 Ball valve PP G+F d40 VP0040 1 DN32 PP/FPM Head weld

VBP102 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32

V103 Butterfly valve PP-H d63 VP0048 1 DN50


V106 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32


VR103 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32



V106-107 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32


VSF101 Rielief valve GF d32 VP0049 1 d32

VSF102 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32

VBP101 Ball valve PP G+F d63 VP0012 1 DN50 PP/FPM T/T INS 63


V110 Butterfly valve PP-H d63 VP0048 1 DN50


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6.4.2 Resibed Section

ITEM DESCRIPTION CODE QTY SPECIFICATION

SS201 3000 l PE tank KT0035 1 2.850 l - D 1.470 x 1.940 h

Deep load DN32 KA0045 1 OR - Viton

PP DN32 connection KA0043 1 MA - Viton

PP 1/2" connection KA0007 1 MA - Viton

SS202 3000 l PE tank KT0035 1 2.850 l - D 1.470 x 1.940 h



PP DN32 connection KA0043 1 MA - Viton

PP 1/2" connection KA0007 1 MA - Viton

LT201-202Pressure Transducer

0/200ST0010 2 0-200 mbar

LT201-202 Separator d20 1/2" SM0018 2 1/2" G F/F

PP ball valve G+F d20 VP0014 2 DN15 PP/FPM T/T INS 20

PC202Horizontal centrifugal

pump PE 160PC0075 1 6mch - 18m - 2,2 kW

RB201 Condores anionic strong HR0009 600 1.3eq/l size 0.150 -0.300mm

XT201-202 Conductivity sensor SC0015 2 0 microS - 2 S

XT201-202 Conductivity meter - field SC0036 2 24V Inductive 2x20mA

EV201Membrane Valve 2-waysAUT PP d50 Flan NC

VN0073 1 1 1/2" PP EPDM - Flang








AUT PP NC d40

VN0066 1 11/4" PP PTFE weld











VR201 Ball valve PP G+F d32 VP0013 1 DN25 PP/FPM T/T INS 32



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PT201-202 Pressure transducer 0/6 ST0002 2 0-6 BAR

PT201-202 Separator d20 1/2" SM0018 2 1/2" G F/F

PI201-202Pressure Indicator 0-6 bar

DN 63SM0008 2 1/4" GAS AISI 316

V206-207 Ball valve PP G+F d20 VP0014 2 DN15 PP/FPM T/T INS 20

Pressure transducer SD0005 1 DN15-100

FT201Fitting for pressure

transducerSD0006 1 x SD0005 DN32



Filter nets 1650 JX0019 2 100% PP

Filter nets support 1650 JX0020 2 100% PP

Gasket for filter nets 1780 JX0021 2 D 1780 d 1530


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Section 8: Working Procedures

8.1 First Start Up

The following operations should be performed before the plant start up:

a. Make sure that the lines to the unit are free and manual valves (if any) forindustrial water are open.

b. The following valves must be open: V101, V102, V103, V104, V105, V107, V108, V110, V112, V201,

V202, V203, V204, V205;c. The following valves will be set during start up:

VR101, VR102, VR103, VR104, VR105, VR201, VBP101, VBP102;d. Make sure that the discharge and relief valves on the filters are closed;e. Check all the electrical connections and the direction of motor rotation;f. Verify that all the hydraulic connections have been connected:

Connections to and from Pickling tanks:EV100 A inlet from first tank (to be treated)EV200A outlet fo first tank (to be treated)

Industrial waterConcentrate OutletDischarge from skid n.1n. 2 Discharges from FS101

FILTERING SECTION

FS101

Make sure that filters FS101 has been filled first with proper material (for technical informationabout it, please contact CONDOROIL IMPIANTI personnel). If necessary the filter is to be loadedas follow (in case its decided to substitute filtering elements follow the indications of Chapters11.3 of the present manual).

Cover the nozzles uniformly using the lateral manhole; Close the lateral and bottom manhole. Carefully clean the flanges before positioning

relative gaskets screw the bolts. Fill the filtering column from the upper manhole taking care to distribute the sand

uniformly;

Fill the tank with water and pressurize it up to 3 bar to check tightness.


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FC101

Make sure that the filtering cartridges have been installed in accordance with the followingprocedure:

Open the housing locking flange;

Replace n. 30 30 5 micron cartridges in each filter. Close the housing. Close drain valve VS102; Open pressure relief valve; Wait for the complete filling of the housing and when the liquid starts overflowing

close the pressure relief valve.

INSTRUMENTS

It is necessary to check that all the instruments are in good serviceable conditions. In case any ofthe instruments are not calibrated or not operable proceed with routine maintenance as indicatedin chapters 8.2.1 and 8.2.2

8.2 Start Up

8.2.1 Equipment

It is recommended to have available the following instruments and materials:

Safety glasses when working with chemicals; Spare elements; Bottles for water samples.

8.2.3 Control panel

Supply the electric board with electric power. Open the valves for compressed air to the distributing lines and all the pilots that control

the pneumatic valves and pneumatic pumps (air pressure 6 bar); Make sure to open the valves to Level controls and Pressure transducers (LT101, LT201,

LT202, PT101, PT102, PT201, PT202);

Reset all active alarms by pressing the button RESET on the control panel. Acknowledge all the alarms visualized on the display of PANEL VIEW pressing the

pushbutton ACK. Set the work parameters from the panel to the page SET POINT SONDS Verify the correct addressing of all hydraulic and electric connections on the page

MANUAL CONTROLS Push the button START for operation.


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Section 9: Control Panel

TANKS PROGRAM: the operator can choose the tanks to treat and how many cycles to perform


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UNIT: the operator can check the unit state

RESINS: the operator can set the time for each phase.


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MANUAL: the operator can select and control each component


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LEVELS SETUP: the operator can set all the setpoint for the control instruments (level, pressure,and so on)


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SETUP TIMERS: the operator can setup the timers to manage the unit


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Section 10: Plant stop

There are three types of plant stop:

10.1 Emergency stop

All the working equipment is switched off immediately and low voltage supply line is disconnected.As soon as the plant has been stopped in emergency a red alarm lamp is lighted.

This stop can be caused by:

Pressing a red mushroom emergency button on the plant.

10.2 Normal stop

When the plant must be stopperd the operator can push the STOP button ont the Control Panel:the system ends the cycle and then all the controls and utilities are de activated (pumps, valves,etc.)When the plant is restarted it starts again from the pretreatment section and in case the levelcontrols in SS201 and SS202 are activated, also the resin cycle starts.


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Section 11: Maintenance

11.1 General Rules

The installation has to be used only by qualified, trained and authorised staff.Before using it, operators have to:

Read the whole manual.Deeply understand the functions of the various components as well as of control positionsand functions.

Before doing any maintenance work, supply sources have to be unplugged (i.e. power, hydraulicand pneumatic supply) and a notice, showing that maintenance work is being carried out, must behanged out.

11.1.1 Individual protections

Operators have to use individual protections as explained in the EEC directives (glasses, gloves,overalls, shoes, etc.) and in the laws in force concerning health and individual safety, especiallybecause potentially dangerous chemical products such as detergents, preservatives etc. areemployed in the installation.If anyone comes into contact with a chemical product, please refer to the enclosed producttechnical and safety data sheet. Please comply with the safety directions of each product, providedby the supplier himself.

11.2 Programmed Maintenance

Before doing any maintenance work, it is necessary to:

Unplug water supplyDisconnect hydraulic connectionsUnplug pneumatic supplyUnplug electrical power supply

Appropriate maintenance programme ensures safe and efficient operation of the plant andconsents to reduce stops for emergency maintenance activities.The following summary table contains the description of maintenance activities to be performedand their suggested frequency.

After the plant has been put into operation the operator can evaluate on the base of experience ifit should be necessary to render the described activities more or less frequent.In order to have a record of all the performer operations we suggest that operators should beobligated to fill in tables of programmed maintenance for each component (see Plant operatingdata).


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Table 11.0 Preventive programming maintenance

COMPONENT PARTS COMPONENTOPERATIONS SUGGES

Cleaning,regularlycheck thethightness ofsensor nut

EVERYXT 201-202

CONDUCTIVITY

METER

Sensor

Replacement SEMES

Central collector and

arms

Replacement EVERY

Fiter nozzle andexpanding bolts

Replacement EVERY

Gasket Replacement EVERY

SF 101MULTIMEDIAFILTER

Filling material Replacement EVERY

At dirtFC101 CARTRIDGE FILTER

Cartridge FA PP ReplacementMONT

Nets and gaskets Replacement WhenleakRB101 RESIN BED

Resins Replacement EVERY


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Table 11.1 Operating maintenance data Conductivity meter

Design

Operatorsignature

Date

Operating hours

CALIBRATION

CLEANING

REPLACEMENT


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11.3 Loading Filter SF101

This section contains guidelines for loading and replacement of filtering beds inside the filters.

11.3.1 Loading Multimedia filter FS101

It is recommended to totally replace filtering beds every three years except the cases ofpremature filter fouling which may require more frequent replacements. All the operations shouldbe performed only after the plant has been shut off.

The following procedure to replace filtering bed should be followed:

1. Verify that automatic valve EV107, EV109, EV11, EV113 are closed.2. Empty the filter discharging the water by opening manual valve V1103. Open the upper manhole.4. Verify with the help of an electric torch that the tank is completely empty.5.

Open the lateral manhole, unscrew all the bolts except the upper bolt.6. Rotate the blind flange using the screwed bolt as a pivot axis until the manhole is fullyopen.

7. Take out all the sand from the tank manually.8. Proceed with attention near the nozzles removing sand with a broom as not to damage

the nozzles.9. Wash nozzles and diffusion plate with water as to fully eliminate all the sand residuals.10.Open the bottom manhole.11.Wash the tank section under the diffusion plate from the bottom manhole.12.Replace the central collector with ways and filtering arms (see Fig. 8.1)13.Remove the worn nozzle from the diffusion plate.14.Install new nozzles (see fig. 8.3).15.Cover the nozzles uniformly with filling material using the lateral manhole.16.Close the lateral and bottom manhole. Carefully clean the flanges before positioning

relative gaskets, screw the bolts. Attention: gaskets must be replaced each timethe flange is opened.

17.Fill the filtering column from the upper manhole taking care.18.Close the upper manhole. Carefully clean the flanges, install the relative gaskets and screw

the bolts.Attention: gaskets must be replaced each time the flange is opened19.Fill the tank with water and pressurize it up to 3 bar to check tightness.


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Table 11.3 Operating maintenance data of Cartridge filter

Operator

signature

Note

Date

Operating hours

FC101 REPLACING CARTRIDGE FA PP

305

11.5 Resin bed RB101

11.5.1 Changing the filter nets

The gaskets and nets must be replaced if broken and everytime the resins are replaced.

To change the gasket and nets it is necessary to:

1. Make sure all the valves to and from the unit are closed2. Open the housing locking flange.3. Remove the gasket with the filtering nets4. If it is necessary to change the bottom net:

a. Manually remove the resins and stock them if it isnt necessary to change themb. Replace the bottom filtering netsc. Replace or refill the resins until the unit is completely filled

5. Fill it with water and drain the water while open6. Set top gaskets and nets7. Close the flange8. Fill the unit with water and test it with pressure9. Open the housing lockin flange again and, after removing net and gasket complete filling

(the resins should have set)10.Set gaskets and net11.Close the flange making sure to tight all the bolts


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11.5.2 Loading resins on RB101

The resins must be replaced when dirtry and when the unit doesnt work as set..

To load the resins it is necessary to:

12.Make sure all the valves to and from the unit are closed13.Open the housing locking flange.14.Remove the gasget with the filtering nets15.Manually remove the resins16.Rinse the unit with industrial water17.Replace the resins until the unit is completely filled18.Fill it with water and drain the water while open19.Set gaskets and nets20.Close the flange21.Fill the unit with water and test it with pressure22.

Open the housing lockin flange again and, after removing net and gasket complete filling(the resins should have set)

23.Set gaskets and net24.Close the flange making sure to tight all the bolts


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Section 12: Trouble Shooting

12.1 InstructionsUse the following table to localize the problem and define remedial measures.

WARNING ALARM EQUIPMENT POSSIBLE CAUSE REMEDIAL

LACK OFCOMPRESSEDAIR

LACK OF AIRLow pressure in thecompressed air feed line to theelectric valves

Check pressure in the lineCheck eventual lacks on thefeeding line of compressed airCheck eventual lacks on using lineof compressed air

Check pressure reducer on thecompressed air line is calibrated at3.8 bar

LEVEL EXTRAHIGH SS101 SS201 SS202

MAXIMUMLEVEL SS101or SS 201 orSS202

LT101 HH

LT201 HHLT202 HH

Limit LT101 or LT201 ot LT202

set on PLC is not correct.

Inaccurate reading oftransducer.

LT101: Pneumatic valve EV101has not been closed.LT201: Pneumatic valveEV201 has not been closed.

LT101: Pneumatic valve EV105has not been opened.LT201: Pneumatic valveEV202 has not been opened

LT202: Pneumatic valveEV206 has not been opened

LT101: PC102 mulfunction.LT201 LT202: PC202mulfunction

Set the correct limit.

Check the transducer operation

Check valves operationCheck service air pressure


Check pumps operation

LEVEL EXTRALOW SS101 SS201 SS202

MINIMUMLEVEL SS101or SS 201 orSS202

LT101 LLLT201 LLLT202 LL

Limit LT101 or LT201 ot LT202set on PLC is not correct.

Inaccurate reading oftransducer.

LT101: Pneumatic valve EV101has not opened.LT201: Pneumatic valvesEV201 has not opened.

In general valves mulfunction

LT101: PC102 mulfunction.LT201 LT202: PC202mulfunction


Check the transducer operation



Check pumps operation


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WARNING ALARM EQUIPMENT POSSIBLE CAUSES REMEDIAL

FILTERFC101clogged

CARTRIDGEFILTERCLOGGED

PT102H H Filter is clogged.

Inaccurate readings oftransducers PT102.

dP limit is wrong.

Replace cartridges in accordancewith the maintenance instructions.

Check the transducers operation.


NO LIQUIDON FS101

ABSENCE OFFLUID IN PUMPPC102

PT101 LL VR103 valve completely open.

PC102 pump mulfunction

EV105-106 mulfunction.

Inaccurate reading oftransducer PT102.

Feed pipes are closed orobstructed.

Set the valve.

Manually check the pump.

Manually check the valves .

Set the correct limits

Control correct opening of valves

and piping.

RESINSRB201clogged

RESIN BEDCLOGGED

PT201-202H H Resin bed is clogged.

Inaccurate readings oftransducers PT201-202.

dP limit is wrong.

Replace resins or filtering nets inaccordance with the maintenanceinstructions.

Check the transducers operation.



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Section 13: AlarmsThe unit is equipped with an alarm system. Please note the alarms which can occur.

13.1 In case of alarm

ALARM

RED Light

- Find the alarm cause from the tables in previous chapter

After having identified the cause of the alarm and having resolved the problem with the help ofthe table given in Chapter 9.1, push the ACK button on PANEL VIEW and then the black pushbutton RESET on the control panel.

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