DQ for Purified Water System
NAME OF THE SYSTEM : PRETREATMENT & PURIFIED WATER GENERATION SYSTEM
TABLE OF CONTENTS
SR. NO. | STAGE |
1 | OBJECTIVE & SCOPE |
2 | ACCEPTANCE CRITERIA |
3 | RESPONSIBILITY |
4 | SYSTEM DESCRIPTION (SYSTEM AND SUB-SYSTEM) |
5 | BASIS OF DESIGN AND ASSUMPTION |
6 | TECHNICAL SPECIFICATIONS |
7 | DRAWINGS REQUIRED |
8 | SUPPORTING UTILITIES |
9 | PRE-QUALIFICATION CHECKLIST |
10 | LIST OF DOCUMENTS REQUIRED |
11 | DESIGN QUALIFICATION REPORT APPROVAL |
12 | ABBREVIATIONS |
- OBJECTIVE AND SCOPE
- OBJECTIVE
- To prepare detailed specification for all major components of Equipment / instrument to ensure that the User Requirement Specification and functional requirement specification are achieved.
- To design the equipment / instrument in conjunction with the design data in order to provide basis for vendor, manufacturer & / or the design engineer for designing the system when the project begins.
- SCOPE
Application to any equipment, system, facility, process & software programs.
- When subjected for new installation
- When the existing system is replaced with the new system.
- When the existing system is subjected for up-gradation or modification.
All URS and FRS shall be defined by the user department in consultation with the engineering department, which should be finalized and mutually discussed with the system supplier, vendor & or manufacturer.
The design qualification is essential part of the qualification mechanism and will serve as a basic document for the Validation Activity.
- ACCEPTANCE CRITERIA
- A) PURIFIED WATER GENERATION SYSTEM
A.1 Equipment / Utility system shall confirm to specifications which are as per the user requirements/as per USP 39.
A.2 The Equipment / Utility / system shall confirm to the predetermined requirements and a certificate is issued by the projects / Engineering Department.
DESIGN BASIS
RAW WATER ANALYSIS
Sr. No. | Water Parameters | Actual Parameters | Design Consideration |
1 | Colour | < 5 CTU | < 5 CTU |
2 | pH | 7.5 | 6.5 – 8.5 |
3 | Conductivity (us/cm) | 900 | 1200 |
4 | Turbidity | 1.8 | Less than 5 |
5 | SDI | Not check | < 3 assumed |
6 | Total Dissolved Solids | 750 ppm | 900 ppm |
7 | Total Alkalinity | 120 ppm | 120 ppm |
8 | Total Hardness | 300 ppm | 350 ppm |
9 | Calcium as CaCO3 | 100 ppm | 125 ppm |
10 | Magnesium as CaCO3 | 200 ppm | 225 ppm |
11 | Sodium as Na | 36.11 ppm | 50 ppm |
12 | Potassium as K | 0.975ppm | 5 ppm |
13 | Sulphate as SO4 | 43.68 ppm | 50 ppm |
14 | Nitrates as NO3 | 2.3 ppm | 10 ppm |
15 | Chlorides as Cl | 92.3 ppm | 100 ppm |
16 | Flouride | 0.7 ppm | 1 ppm |
17 | Colloidal Silica | 5.6 ppm | 10 ppm |
18 | Reactive Silica | 5.6 ppm | 10 ppm |
19 | TOC | 1000 ppb | 1000 ppb |
20 | Total Plate Count | 79 CFU/ml | 1000 CFU/ml |
(Note. 1. Feed Water is free from pathogens like E- Coli, Pseudonymous, Salmonella)
- B) PRETREATMENT & PURIFIED WATER GENERATION SYSTEM
FOR PRESSURE QUARTZ FILTER
END USE : SOFTENER
QUANTITY OF WATER : 7 m3/hr
TYPE OF OPERATION : MANUAL OPERATION
FOR SOFTENER
END USE : PURIFIED WATER GENERATION SYSTEM
QUANTITY : 3.8 m3/hr
OBR : 76 m3
NO OF HRS : 20 hrs
TYPE OF OPERATION : MANUAL OPERATION
FIRST PASS RO SYSTEM (Hot Water Sanitizable)
FEED FLOWRATE : 3800 LPH
REJECT FLOWRATE : 1100 LPH
PERMEATE FLOWRATE : 2700 LPH
OVER ALL RECOVERY : 70 %
TYPE OF OPERATION : FULLY AUTO & MANUAL OPERATION
SECOND PASS RO SYSTEM (Hot Water Sanitizable)
FEED FLOWRATE : 2700 LPH
REJECT RECYCLE FLOWRATE : 500 LPH
PERMEATE FLOWRATE : 2200 LPH
OVER ALL RECOVERY : 80 %
TYPE OF OPERATION : FULLY AUTO & MANUAL OPERATION
FOR EDI SYSTEM
FEED FLOWRATE : 2200 LPH
PERMEATE FLOWRATE : 2000 LPH
REJECT FLOWRATE : 200 LPH
TYPE OF OPERATION : FULLY AUTO & MANUAL OPERATION
OVERALL RECOVERY : 90 %
TREATED WATER QUALITY
STAGE WISE TREATED WATER QUALITY AFETR RO:
(On basis of maximum feed water limiting condition)
Sr. No. | Water Parameter | Outlet of Multi Grade Filter | Outlet of Softener | Outlet of RO Pass I | Outlet of RO Pass II |
1. | Ph | 6 to 8.5 | 6 to 8.5 | 5 – 6 | 5 – 6 |
TSS | < 5 ppm | < 5 ppm | Nil | Nil | |
2. | TDS / Conductivity | 1920 us/cm | 1920 us/cm | 200 us/cm | 25 us/cm |
3. | Total Hardness ( in ppm) | 350 ppm | Less than 5 ppm | Nil | Nil |
4. | SDI | < 3 | 3.0 max | Nil | Nil |
5. | TOC | 1000 ppb | 1000 ppb | 500 ppb | 200 ppb |
6. | TVC | 1000 CFU/ml | 1000 CFU/ml | 100 CFU/ml | 50 CFU/ml |
TREATED WATER QUALITY AFTER UF : ( as per ‘Design Limits’)
(PURIFIED WATER AS PER USP 39 std.)
Sr.
No. |
Water Parameters | USP 39 | Action
Limit |
Alert Limit | Design
Limit |
1. | Conductivity | 1.25 µs/cm | 1.0 µs/cm | 0.8 µs/cm | 0.7 µs/cm |
2. | TOC in PPB | 500 ppb | 300 ppb | 200 ppb | 100 ppb |
3. | TVC / TBC
Microbial Count |
100 CFU/ml | 90 CFU/ml | 70 CFU/ml | 40 CFU/ml |
Note: With the change in the incoming water parameters, the treated water quantity & quality may get affected at different stages of the plant.
- RESPONSIBILTY
User Dept : For providing user requirement (Technical and cGMP)
Head-Operations : To review the specification from installation and Maintenance aspects.
Head-Quality : To review the specification from GMP Aspects
Vendor : To review and agree upon the requirements.
- SYSTEM DESCRIPTION (SYSTEM AND SUB-SYSTEM)
The Fully Automated PLC based Purified Water Generation system generate 2 m3/hr. of Purified water as Per USP 39 Standards.
SCHEME:
PRETREATMENT & PURIFIED WATER GENERATION SYSTEM:
PRE TREATMENT: (3800 LPH)
- Pre Sodium Hypo Chlorite Dosing System
- Raw Water Pumps
- Multi Grade Filter
- Softener Unit
FIRST PASS REVERSE OSMOSIS (HOT WATER SANITIZABLE) SYSTEM:
- SMBS Dosing System
- Antiscalent Dosing System
- pH Correction System
- 5 – Micron Cartridge Filter
- ORP Analyzer and pH sensor along with auto Dumping Valve
- RO High Pressure Pump
- Reverse Osmosis Membranes along with High Pressure Housing
- Conductivity Meter with Alarm
SECOND PASS REVERSE OSMOSIS (HOT WATER SANITIZABLE) SYSTEM:
- RO High Pressure Pump
- Reverse Osmosis Membranes along with High Pressure Housing
- Conductivity meter with Alarm
POST TREATMENT:
- Hot Water Sanitizable Electro – Deionization Unit
- Conductivity meter with Alarm
- SYSTEM DESCRIPTION:
Raw water before Raw Water Tank is dosed with Sodium Hypochlorite 1 – 2 ppm. Raw water feed pump will feed raw water from the raw water storage tank to Multi Grade Filter @ 7000 LPH.
Multi Grade Filter is a vertical down flow vessel containing pure graded silex quartz as a filtering media. The vessel is fabricated in FRP. The water generated at the outlet of Multi Grade Filter will have suspended solids less than 5 ppm. Multi Grade Filter is provided with Manual Backwash. We have provided manual ball valves of for change over from normal operation to Backwash operation.
(Note that the inlet suspended solid load should not be more than 50 ppm).
The water from Multi Grade Filter is passed through Softener. Hardness after softener is less than 5 ppm. Soft Water after Softener unit is fed to Purified Water Generation System.
Sodium Metabisulphite (Na2S2O5) is then dosed in the chlorinated water to neutralize the free chlorine (excess chlorine) present in the filtered water.
Antiscalent Dosing System is then dosed in the soft water to avoid scale formation on the RO Membranes.
pH Correction Dosing System is provided to adjust the feed pH of RO feed water as 6.5 – 8.5. The treated water is then passed through 5 micron Cartridge Filter to trap the suspended solids. This will avoid chocking of RO membranes due to suspended solids.
ORP Analyzer is provided so as to check the absence/presence of chlorine in the feed water to the RO System. If free chlorine is sensed in the feed water it will give an indication on the panel & open the dumping valve and dump the high ORP water for 300 secs. & Even if the ORP value is not below the set point it will trip the system.
This soft water is then fed to the Reverse Osmosis First pass System by means of a High Pressure Vertical multistage Pump with SS 304 wettable parts of M/s. Grundfos, Denmark. The First pass Reverse Osmosis System will generate 2700 liters/hr water with an overall recovery of 70 %. The generated water will have total dissolved solids less than 150 ppm. The semi-permeable reverse osmosis membrane has molecular weight cut off less than 150 MWCO. The Reveres Osmosis membrane acts as positive barrier to remove dissolved solids, organic compounds & bacteria.
The Reverse Osmosis System consists of thin film composite type Reverse Osmosis membrane of DOW. The material of construction of the RO membrane is Polyamide. The RO membrane is housed in the High Pressure SS 316L Wettable Parts Housing having TC end connection.
The outlet water of RO pass one is feed to RO pass two system. The Second pass Reverse Osmosis System will generate 2200 liters/hr of water with an overall recovery of 80%. The generated water will have total dissolved solids less than 15-20 ppm.
The Reverse Osmosis System consists of thin film composite type Reverse Osmosis membrane of DOW. The material of construction of the RO membrane is Polyamide. The RO membrane is housed in the High Pressure SS 316L Wettable Parts Housing having TC end connection.
The Permeate water from RO system will be fed to the Electro Deionization Unit (EDI) having designed capacity of 2000 LPH. The EDI system has a recovery of 90%.
The water generated from the outlet of EDI will be as per USP 39 Standards for Purified Water.
- BASIS OF DESIGN AND ASSUMPTION
- FEED WATER SAMPLE:
The system design is based on the feed water analysis provided by the customer as per Annexure -A.
- PRODUCT WATER QUALITY:
STAGE WISE TREATED WATER PARAMETER:
(On basis of maximum feed water limiting condition)
Sr. No. | Water Parameter | Outlet of Multi Grade Filter | Outlet of Softener | Outlet of RO Pass I | Outlet of RO Pass II |
1. | Ph | 6 to 8.5 | 6 to 8.5 | 5 – 6 | 5 – 6 |
TSS | < 5 ppm | < 5 ppm | Nil | Nil | |
2. | TDS / Conductivity | 1920 us/cm | 1920 us/cm | 200 us/cm | 25 us/cm |
3. | Total Hardness ( in ppm) | 350 ppm | Less than 5 ppm | Nil | Nil |
4. | SDI | < 3 | 3.0 max | Nil | Nil |
5. | TOC | 1000 ppb | 1000 ppb | 500 ppb | 200 ppb |
6. | TVC | 1000 CFU/ml | 1000 CFU/ml | 100 CFU/ml | 50 CFU/ml |
TREATED WATER QUALITY AFTER UF: (as per ‘Design Limits’) (PURIFIED WATER AS PER USP 39 std.)
Sr.
No. |
Water Parameters | USP 34 | Action
Limit |
Alert Limit | Design
Limit |
1. | Conductivity | 1.25 µs/cm | 1.0 µs/cm | 0.8 µs/cm | 0.7 µs/cm |
2. | TOC in PPB | 500 ppb | 300 ppb | 200 ppb | 100 ppb |
3. | TVC / TBC
Microbial Count |
100 CFU/ml | 90 CFU/ml | 70 CFU/ml | 40 CFU/ml |
Note: With the change in the incoming water parameters, the treated water quantity & quality may get affected at different stages of the plant.
5.3 FACILITY OPERATION:
The plant operation will be for 20 hrs/day,6 days/week,48 weeks/year
ANNEXURE – A
Sr. No. | Water Parameters | Actual Parameters | Design Consideration |
1 | Colour | < 5 CTU | < 5 CTU |
2 | pH | 7.5 | 6.5 – 8.5 |
3 | SDI | 900 | 1200 |
4 | Total Dissolved Solids | 1.8 | Less than 5 |
5 | Total Alkalinity | Not check | < 3 assumed |
6 | Total Suspended Solids | 750 ppm | 900 ppm |
7 | Total Hardness | 120 ppm | 120 ppm |
8 | Calcium as CaCO3 | 300 ppm | 350 ppm |
9 | Magnesium as CaCO3 | 100 ppm | 125 ppm |
10 | Sulphate as SO4 | 200 ppm | 225 ppm |
11 | Nitrates as NO3 | 36.11 ppm | 50 ppm |
12 | Chlorides as Cl | 0.975ppm | 5 ppm |
13 | Silica as SiO2 | 43.68 ppm | 50 ppm |
14 | Colloidal Silica | 2.3 ppm | 10 ppm |
15 | Reactive Silica | 92.3 ppm | 100 ppm |
16 | Total Chloride as CaCO3 | 0.7 ppm | 1 ppm |
17 | Sulphate as CaCO3 | 5.6 ppm | 10 ppm |
18 | TOC | 5.6 ppm | 10 ppm |
19 | TVC | 1000 ppb | 1000 ppb |
(Note. 1. Feed Water is free from pathogens like E- Coli, Pseudonymous, Salmonella)
- TECHNICAL SPECIFICATIONS
6.A MAJOR EQUIPMENTS OF PRETREATMENT & PURIFIED WATER GENERATION SYSTEM:
6.A.1 PRE SODIUM HYPOCHLORITE DOSING SYSTEM
TAG NO: NaOCl (DT-01 / DP-01) |
EQUIPMENT NAME: Pre Sodium Hypo Chlorite Dosing system |
EQUIPMENT LOCATION: After Bore Well Pump |
FUNCTION: For Bacterial Disinfection in raw water. These will inhibit the bacterial growth. Sodium Hypo chlorite dosed up to 2 ppm for disinfection. |
TECHNICAL SPECIFICATION:
Quantity : One Type : Positive Displacement Pump Pump Capacity : 0.4 to 4 LPH Max. Working Pressure : 5.5 kg/cm2 MOC of Dosing Tank : HDPE Dosing Tank : 50 Liters Provided Low Level Switch : Provided Make : Milton Roy Model : UC 11 |
DOSING CALCULATION:
Dosage required : 2 ppm Feed Flow rate : 7 m3/hr Conc. of Solution : 1 % Dosing Pump flow rate : 1.4 LPH Amount of dosing solution = 1.4 x 24 = 33.6 Ltrs. |
6.A.2 RAW WATER PUMPS (1W + 1SB):
TAG NO: RWP-01 / 02 |
EQUIPMENT NAME: Raw Water Pumps |
EQUIPMENT LOCATION: After Raw Water Storage Tank |
FUNCTION: For pumping of Raw water to Pretreatment @ 7 m3/hr. |
TECHNICAL SPECIFICATION:
Quantity : Two (1W + 1SB) Type : Horizontal Multistage pump Flow rate : 7 m3/hr (7000 liter/hr) Head : 35 mWC Material of Construction : SS 304 Make : Nanfang |
6.A.3 MULTI GRADE FILTER:
TAG NO: MGF-01 |
EQUIPMENT NAME: Multi Grade Filter |
EQUIPMENT LOCATION: After Sodium Hypo-chlorite Dosing System, Piping and Raw Water Tank. |
FUNCTION: It filters the suspended solids in the Raw water up to 5 ppm with the help of Multi Grade Filter in the vessel, the inlet suspended solids should be less than 50 ppm. |
TECHNICAL SPECIFICATION:
Quantity : One Flow rate : 7 m3/hr Max. Working Pressure : 3.5 kg/cm2 Max. Pressure Drop : 0.5 kg/cm2 Diameter : 600 mm Height : 1800 mm Specific Velocity of Filtration : 25 m/hr. Back Wash Time Required : 10-15 min. Filter media : Pure Graded Silex Quartz of 1.5 to 2 mm Particle size. Valve Type : Ball valve MOC of Pressure Vessel : Fiber Reinforced Plastic (FRP) Make of Pressure Vessel : M/s. Wave Cyber, USA / Pentair Frontal Pipe Size : 38.1 mm Pressure gauge : 100 mm Dial ( Inlet /Outlet ) MOC Piping : UPVC Make of Piping : FIP MOC of Valves : UPVC Make of Valves : FIP Inlet, Outlet, Drain Connection : 1.5” BSPF union ends |
Operation:
1. Normal Operation 2. Back Wash Operation 3. Rinse Operation 1. Normal Operation: Since MGF is a Vertical Down Flow Vessel the Suspended Solids are removed by passing through Filtering Media which is been 60% filled. For normal operation position of Ball valves which are mounted on MGF should be (In Open Position: BV-05 & BV-06) (In Close Position: BV-07, BV-08 & BV-09) 2. Back Wash Operation: WHEN & WHY BACKWASH Back Wash is used to remove the Suspended Matter which is entrapped in the filter Media Top Layer during Normal Operation. Back Wash is done after 20 hr OR if the differential pressure across the filter is more than 0.5 kg/cm2. For changing from normal operation to backwash operation, the position of the Ball Valves should be (In Open Position: BV-07 & BV-08) (In Close Position: BV-05, BV-06 & BV-09) 3. Rinse Operation: WHEN & WHY BACKWASH Rinse Operation is done after Back Wash. Rinse is done to remove the Suspended Solid which is entrapped in the Filter Media during Backwash Operation. For changing from Back Wash operation to Rinse operation, the position of the Ball Valves should be (In Open Position: BV-05 & BV-09) (In Close Position: BV-06, BV-07 & BV-08) |
6.A.4 SOFTENER:
TAG NO: SF-01 |
EQUIPMENT NAME: Softener Unit-01 |
EQUIPMENT LOCATION: After Multi Grade Filter |
FUNCTION: It will replace the hardness causing Ca & Mg ions with Na ions. This will soften the raw water and will avoid scale formation. Treated Water at the outlet of softener-II will have hardness less than 5 ppm. Flow totalizer will be provided at the outlet of softener unit to indicate the amount of soft water generated and give indication after pre define quantity of soft water is generated. |
TECHNICAL SPECIFICATION:
Quantity : One Type : Vertical Up Flow Flow rate : 3.8 m3/hr Max. Working Pressure : 4 kg/cm2 Max. Pressure Drop : 0.5 kg/cm2 Diameter : 600 mm Height on straight : 1800 mm Regeneration Time Required : 20-30 min. Fast Rinse : 5-10 Minutes Resin Quantity : 450 ltrs. Make of Resin : M/s. Lenxess Model of Resin : C 249 Regenerator (NaCl) : 72 Kgs. Reg. Tank Capacity : 300 lts. MOC of Reg .tank : HDPE MOC of Softener : Fiber Reinforced Plastic (FRP) Make of Vessel : M/s. Wave Cyber, USA / Pentair Frontal Pipe Size : 38.1 mm Valve : Ball valve Pressure gauge : 100 mm Dial ( Inlet /Outlet ) Frontal Piping : UPVC Make of Piping : FIP Make of Valves : FIP |
Operation:
1. Normal Operation: Since Softener is a Vertical UP Flow Vessel the Hardness causing Ions are removed by passing through Resin Media (Cation and Anion) which is been 92% filled of the Total Volume. For normal operation the position of the Ball valves should be: (In Open position: BV-10, BV-11) & (In Close position: BV-12/13/14/15) After 12 hrs of operation of the softening plant OR after 72 m3 of OBR the softener should go under regeneration mode or the hardness does not get maintain within its limit.. 2. Regeneration Operation: WHEN & WHY REGENERATION Regeneration is used to recharge the Resin to regain its absorbing properties of hardness. Regeneration is done if the Hardness at the Outlet of Softener Unit is above 5 ppm OR after 72 m3 OBR / 12 hrs of Operation of plant whichever is earlier. Flow Totalizer will be provided at the outlet of each softener unit to indicate the amount of soft water generated and give indication of Regeneration after pre define quantity of soft water generation. For changing from normal operation to regeneration mode, the valve position should be (In Open position: BV-12/13/14) & (In Close position: BV-10/11/15) Allow the softener to backwash completely. Allow the brine solution to get completely charged in the softener. 3. Slow Rinse Operation: Slow Rinse is used to get properly mix up with Salts & Resins. (In Open position: BV-12/14) & (In Close position: BV-10/11/13/15) 4 Fast Rinse Operation: Fast Rinse is used to remove excess Salts from the resins. (In Open position: BV-10/15) & (In Close position: BV-11/12/13/14) |
6.A.5 SODIUM META BISULPHITE DOSING SYSTEM:
TAG NO: SMBS (DT-02 / DP-02) |
EQUIPMENT NAME: Sodium Meta Bisulphate Dosing system |
EQUIPMENT LOCATION: After Softener Unit |
FUNCTION: 1 ppm of chlorine needs 2 ppm SMBS dosing. We have considered 2 ppm of chlorine so we have assumed 4 ppm of SMBS dosing. 6 ppm SMBS is dosed in soft water to neutralize the free chlorine in soft water. (Note: ORP analyzer is provide with dumping valve to check & dump the high chlorinated water) |
TECHNICAL SPECIFICATION:
Quantity : One Type : Positive Displacement Pump Pump Capacity : 0.4 to 4 LPH Max. Working Pressure : 5.5 kg/cm2 MOC of Dosing Tank : SS 304 Dosing Tank : 25 Liters Provided Low Level Switch : Provided Make : Milton Roy Model : UC 11 |
DOSING CALCULATION:
Dosage required : 4 ppm Feed Flow rate : 3.8 m3/hr Conc. of Solution : 1 % Dosing Pump flow rate: 1.52 LPH If we consider 3 shifts of 8 hrs. = 8 x 3 = 24 hrs. Amount of dosing solution = 1.52 x 24 = 36.48 Ltrs. |
6.A.6 ANTISCALENT DOSING SYSTEM:
TAG NO: ADS (DT-03 / DP-03) |
EQUIPMENT NAME: Anti Scalent Dosing System |
EQUIPMENT LOCATION: After SMBS Dosing System |
FUNCTION: ADS (5 ppm) is dosed in soft water to avoid scaling in RO membrane. |
TECHNICAL SPECIFICATION:
Quantity : One Type : Positive Displacement Pump Pump Capacity : 0.4 to 4 LPH Max. Working Pressure : 5.5 kg/cm2 MOC of Dosing Tank : SS 304 Dosing Tank : 25 Liters Provided Low Level Switch : Provided Make : Milton Roy Model : UC 11 |
DOSING CALCULATION:
Dosage required : 5 ppm Feed Flow rate : 3.8 m3/hr Conc. of Solution : 2 % Dosing Pump flow rate: 0.95 LPH If we consider 3 shifts of 8 hrs. = 8 x 3 = 24 hrs. Amount of dosing solution = 0.95 x 24 = 22.8 Ltrs. |
6.A.7 pH CORRECTION DOSING SYSTEM:
TAG NO: pHC (DT-04 / DP-04) |
EQUIPMENT NAME: pH Correction Dosing System |
EQUIPMENT LOCATION: After Anti-scalent dosing system |
FUNCTION: To boost up the pH of RO feed water so as to convert the dissolved CO2 into alkalinity and which can be rejected in RO Pass I. |
TECHNICAL SPECIFICATION:
Quantity : One Type : Positive Displacement Pump Pump Capacity : 0.4 to 4 LPH Max. Working Pressure : 5.5 kg/cm2 MOC of Dosing Tank : SS 304 Dosing Tank : 25 Liters Provided Low Level Switch : Provided Make : Milton Roy Model : UC 11 pH Correction Chemical : NaOH or Na2CO3 |
6.A.8 5-MICRON CARTRIDGE FILTER:
TAG NO: CF – 01 |
EQUIPMENT NAME: 5 – Micron Cartridge Filter |
EQUIPMENT LOCATION: After SMBS / ADS / pHC Dosing Systems |
FUNCTION: It filter all the suspended solids in water greater than 5 – micron thus avoid chocking in RO membrane. |
TECHNICAL SPECIFICATION:
No. of Unit : One Type of Cartridge : Spun Bounded Type Rating : 5 micron Flow rate : 3800 LPH No. of Cartridge : 2 nos. 20” long MOC of Cartridge Housing : SS 304 MOC of Cartridge : PP ( Polypropylene) Make of Cartridge : Kumar/Pratham Make of Housing : HydroPure Systems Surface Finish of Housing : Internally – < 0.4 Ra Externally – mirror up to 180 grit Type of Filter : Double open end filter |
6.A.9 REVERSE OSMOSIS HIGH PRESSURE PUMP-I:
TAG NO: ROHP – I |
EQUIPMENT NAME: Reverse Osmosis High Pressure Pump- I |
EQUIPMENT LOCATION: After 5-micron Cartridge Filter |
FUNCTION: For pumping of water to RO pass-I system. @ 3.8 m3/hr |
TECHNICAL SPECIFICATION:
Quantity : One Type : Vertical Multistage Pump Flow rate : 3.8 m3/hr (3800 liter/hr) Pressure : 12 kg / cm2 Material of Construction : SS 304 Wettable parts Voltage Requirement : 415 Volts Make : Grundfos |
6.A.10 REVERSE OSMOSIS MEMBRANES:
EQUIPMENT NAME: Reverse Osmosis Membranes |
EQUIPMENT LOCATION: Within the RO System |
FUNCTION: RO membranes reduce the TDS & microbial load in the water. The semi-permeable reverse osmosis membrane has molecular weight cut off less than 150 MWCO. The Reveres Osmosis membrane acts as positive barrier to remove dissolved solids, organic compounds & bacteria. Membranes consist of thin film composite type. It will bring down the conductivity less than 200 μs/cm. |
TECHNICAL SPECIFICATION:
No. of Membrane : 4 Nos. Size of Membrane : 8” Dia. & 40” Long Type of Membrane : Thin Film Composite Type of Sanitization : Hot Water Sanitizable Material of Construction : Polyamide Make of Membrane : DOW. Model : HSRO-390FF Operating Temperature : 450 C Recovery : 70 % Feed Water Flow Rate : 3800 m3/hr Permeate Flow Rate : 2700 m3/hr Reject Water Flow Rate : 1100 m3/hr Sanitization Temp. : 850 C |
6.A.11 REVERSE OSMOSIS HOUSING:
TAG NO: RO PASS – I |
EQUIPMENT NAME: Reverse Osmosis Housing |
EQUIPMENT LOCATION: After RO High Pressure – I |
FUNCTION: RO membranes are housed in the housing. |
TECHNICAL SPECIFICATION:
No. of Housing : One No. of Membranes in RO Housing : 4 Nos. Make of Housing : HydroPure Systems Material of Construction : SS 304 Diameter : 204 mm Length : 4060 mm Thickness : 2.5 mm Surface Finish of RO Housing : Internally – < 0.4 Ra Externally – mirror up to 180 grit Maximum Flow rate for housing : 4000 LPH Permeate flow rate from RO Pass I is 2.7 m3/hr. |
6.A.12 REVERSE OSMOSIS HIGH PRESSURE PUMP-II:
TAG NO: ROHP – II |
EQUIPMENT NAME: RO High Pressure Pump – II |
EQUIPMENT LOCATION: After RO pass – I |
FUNCTION: For pumping of water to RO pass – II system. |
TECHNICAL SPECIFICATION:
Quantity : One Type : Vertical Multistage Pump Flow rate : 2.7 m3/hr (2700 LPH) Pressure : 9 kg/cm2 Material of Construction : SS 316 wettable parts Voltage Requirement : 415 volts Make : Grundfos |
6.A.13 REVERSE OSMOSIS MEMBRANES:
EQUIPMENT NAME: Reverse Osmosis Membranes |
EQUIPMENT LOCATION: Within the RO Housing |
FUNCTION: RO membranes reduce the TDS & microbial load in the water. The semi-permeable reverse osmosis membrane has molecular weight cut off less than 150 MWCO. The Reveres Osmosis membrane acts as positive barrier to remove dissolved solids, organic compounds & bacteria. Membranes consist of thin film composite type. This will bring down the conductivity less than 25 μs/cm. |
TECHNICAL SPECIFICATION:
No. of Membrane : 2 Nos. Size of Membrane : 8” Dia. & 40” Long Type of Membrane : Thin Film Composite Type of sanitization : Hot water Temperature of sanitization : 850 C Material of Construction : Polyamide Make of Membrane : DOW. Model : HSRO-390FF Operating Temperature : 450 C Recovery : 80-85 % Feed Water Flow Rate : 2.7 m3/hr Permeate Flow Rate : 2.2 m3/hr |
6.A.14 REVERSE OSMOSIS HOUSING:
TAG NO: PWG-RO PASS II |
EQUIPMENT NAME: Reverse Osmosis Housing |
EQUIPMENT LOCATION: After RO High Pressure – II |
FUNCTION: RO membranes are housed in the housing. |
TECHNICAL SPECIFICATION:
No. of Housing : One Make of Housing : HydroPure Systems Material of Construction : SS 316L Diameter : 204 mm Length : 2040 mm Thickness : 2.5 mm Surface Finish of RO Housing : Internally – < 0.4 Ra Externally – mirror up to 180 grit Max Feed Flow rate : 3000 LPH |
6.A.15 ELECTRO DEIONIZATION UNIT:
TAG NO: EDI – 01 |
EQUIPMENT NAME: Electro De-Ionization System |
EQUIPMENT LOCATION: After RO pass II |
FUNCTION: EDI bring down the conductivity of RO treated water. The water generated from the outlet of EDI will be as per USP 34. |
TECHNICAL SPECIFICATION:
No. of Unit : One Type : Hot Water Sanitizable Model No. : IP – LXM 24 – HI-3 Minimum Flow rate : 1400 ltrs/hr Maximum Flow rate : 4200 Ltrs/hr Normal Flow rate : 2800 ltrs/hr End Connection : 1” TC Operating Voltage DC : 150 – 250 V DC Maximum Voltage : 300 V Operating Current : 1 – 3 Amps Maximum Current : 5 – 6 Amps. Concentrate Flow rate (Reject) : 250 LPH Pressure Drop across concentrate : 0.5 kg/cm2 Max. Working Pressure : 2.5 kg/cm2 Make of EDI : M/s. Ion Pure EDI, USA Material of Construction of different parts: Dilute Spacer : Polysulfone Concentrate Spacer : Polysulfone End Block : Polypropylene Resin compartment O-rings : FDA-grade silicon Anion exchange resin 1 : Styrene / DVB, strong base, type I Anion exchange resin 2 : Styrene / DVB, strong base, type II Cation exchange resin : Styrene / DVB, strong acid Anion exchange membrane : Heterogeneous PE/AER Cation exchange membrane : Heterogeneous PE/CER Anode : Platinized Titanium Cathode : SS 316 |
6.A.16 CIP TANK
TAG NO: CIP-ST |
EQUIPMENT NAME: CIP Tank |
EQUIPMENT LOCATION: Before CIP feed pump |
FUNCTION: For Sanitization. |
TECHNICAL SPECIFICATION:
Quantity : One Make : Hydro pure Type : Plain Tank Working Capacity : 200 Liters Gross Capacity : 220 Liters Tank Dia ID : 600 mm Shell Height : 750 mm Design Pressure & Tempe. : 3.5 Kg/cm2 & 120oC Design Code : cGMP Top & Bottom : Torispherical Dished end M.O.C. of Shell : SS 316 L Nozzles : Triclover end Surface Finish : Internally electro polished to <0.4 micron Ra. Externally buffed to mirror finish |
6.A.17 CIP FEED PUMP:
TAG NO: CIP – CIPFP |
EQUIPMENT NAME: CIP Feed Pump |
EQUIPMENT LOCATION: Trolley Mounted |
FUNCTION: Pumps Purified water to RO system @ 2.5 m3/hr |
TECHNICAL SPECIFICATION:
Quantity : One Type : Horizontal Multistage Pump Flow rate : 2.5 m3/hr (2500 liter/hr) Pressure : 2.9 kg / cm2 Material of Construction : SS 316 wettable parts Voltage Requirement : 3 Phase, 415 volts Make : Grundfos |
6.B INSTRUMENTATION & OTHER ITEMS
6.B.1.1 PRESSURE GUAGES:
TAG NO: PG-01 / 02 / 03 |
INSTRUMENT NAME: Pressure Gauges |
LOCATION: 1) Inlet of Multi Grade Filter
2) Outlet of Multi Grade Filter 3) Outlet of Softener |
FUNCTION: To check the line pressure |
TECHNICAL SPECIFICATION:
Make : Waaree Size of Gauge : 100 mm Dial Range : 0-7 kg/cm2 End Connection : 3/8” BSP (M) MOC : SS Body with SS internals |
6.B.1.2 PRESSURE GUAGES:
TAG NO: PG – 04 / 05 / 10 |
INSTRUMENT NAME: Pressure Gauges |
LOCATION: 1) Inlet of 5 micron Cartridge Filter
2) Outlet of 5 micron Cartridge Filter 3) Inlet line of EDI System |
FUNCTION: To check the line pressure. |
TECHNICAL SPECIFICATION:
Make : Waaree Size of Gauge : 63 mm Dial Range : 0 – 7 kg/cm2 End Connection : ¼” BSP (M) MOC : SS Body with SS internals Damping Liquid : Glycerin Accuracy : ± 1.6 % of FS |
6.B.1.3 PRESSURE GUAGES:
TAG NO: PG – 06 / 07 / 08 / 09 |
INSTRUMENT NAME: Pressure Gauges |
LOCATION: FOR TWO PASS RO-EDI SYSTEM
1) Feed line of RO pass – I 2) Reject line of RO pass – I 3) Feed line of RO pass – II 4) Reject line of RO pass – II |
FUNCTION: To check the line pressure |
TECHNICAL SPECIFICATION:
Make : Waaree Size of Gauge : 63 mm Dial Range : 0 – 21 kg/cm2 End Connection : 1/4” BSP (M) MOC : SS Body with SS internals Damping Liquid : Glycerin Accuracy : ± 1.6 % of FS |
6.B.1.3 PRESSURE GUAGES:
TAG NO: CIP-PG |
INSTRUMENT NAME: Pressure Gauges |
LOCATION: Discharge line of CIP Feed Pump-1 |
FUNCTION: To check the line pressure. |
TECHNICAL SPECIFICATION:
Make : Waaree Size of Gauge : 63 mm Dial Range : 0 – 7 kg/cm2 End Connection : ¼” BSP (M) MOC : SS Body with SS internals Damping Liquid : Glycerin Accuracy : ± 1.6 % of FS |
6.B.2 ROTAMETER:
TAG NO: RM-01 / 02 / 03 / 04 / 05 / 06 |
INSTRUMENT NAME: Rotameter |
LOCATION: 1) Inlet line of Multi Grade Filter (1000 – 10000 LPH)
2) Potable Water Line (500 – 5000 LPH) 3) RO First Pass reject line (200 – 2000 LPH) 4) RO Second Pass reject line (100 – 1000 LPH) 5) EDI Feed line (400 – 4000 LPH) 6) Concentrate line of EDI – I (30 – 300 LPH) |
FUNCTION: To check the line flow rate. |
TECHNICAL SPECIFICATION:
Make : George Fischer End Connection : Tri Clover end Type : Variable Area Model : SK MOC of float : SS 316 MOC of Measuring Tube : SS MOC of end connection : Nylon 6 Accuracy class : 2.5 |
6.B.3 FLOW INDICATOR TOTALIZER:
TAG NO: FIT-01 |
INSTRUMENT NAME: Flow Indicator Totalizer |
LOCATION: Outlet of Softeners |
FUNCTION: To check the total line flow rate. |
TECHNICAL SPECIFICATION:
Make : Aster Technology Model : FT-650 Line Size : 38 mm Type : Turbine Type End Connection : Threaded |
6.B.4 FLOATY LEVEL SWITCH:
TAG NO: FLS-01 |
INSTRUMENT NAME: Floaty Level Switches |
LOCATION: Raw Water Tank |
FUNCTION: To check the Level in the tank. If the level in the tank is below the desired level the system will give indication on the panel & will trip the system. |
TECHNICAL SPECIFICATION:
Make : Innovative Technologies Quantity : One Type : Floaty type MOC : PVC |
6.B.5 LOW LEVEL SWITCH:
TAG NO: LLS-01 / 02 / 03 / 04 / 05 |
INSTRUMENT NAME: Low Level Switches |
LOCATION:
1) NaOCl-01 Dosing Tank 2) Raw Water Tank 3) SMBS dosing system 4) ADS dosing system 5) pH correction system |
FUNCTION: To check the Level in the dosing tank. If the level in the tank is below the desired level the system will give hooter & after settable time will trip the system. |
TECHNICAL SPECIFICATION:
Make : Innovative Technology Quantity : 05 Nos. Type : Magnetic MOC : PP |
6.B.6 FLOW SWITCHES:
TAG NO: FS-01 |
INSTRUMENT NAME: Flow Switches |
LOCATION: Raw Water inlet line |
FUNCTION: To check the line flow. |
TECHNICAL SPECIFICATION:
Make : Dag Process Quantity : One MOC : SS 316 Size : 1.5” |
6.B.7 ORP SENSOR TRANSMITTER & CONTROLLER:
TAG NO: ORP – 01 |
INSTRUMENT NAME: Oxidation Reduction Potential Analyzer |
LOCATION: Inlet of RO pass – I |
FUNCTION: ORP Analyzer is provided so as to check the absence/presence of chlorine in the feed water to the RO System. If free chlorine is sensed in the feed water it will give an indication on the panel & open the dumping valve and dump the high chlorinated water for 300 secs. & even if the ORP value is not below the set point it will trip the system. |
TECHNICAL SPECIFICATION:
Quantity : One Make : Forbes Marshall Range : +1000 to – 1000 mV End Connection : 1” TC end connection MOC of Electrode : Glass |
6.B.8.1 CONDUCTIVITY SENSOR TRANSMITTER & CONTROLLER:
TAG NO: CIC – 01/02 |
INSTRUMENT NAME: Conductivity Indicator cum Controller |
LOCATION: 1) Outlet of RO pass – I 2) Outlet of RO pass – II |
FUNCTION: To check the conductivity in the water, if the conductivity in the feed water is sensed high above a settable value then it will give an indication on the panel & open the dumping valve and dump the high conductivity water. |
TECHNICAL SPECIFICATION:
Quantity : Two Make : Emerson Range : 0 – 200 µs/cm for First Pass Permeate 0 – 100 µs/cm for Second Pass Permeate End Connection : 1 ½” TC end connection. MOC : SS 316 wettable parts |
6B.8.2 CONDUCTIVITY SENSOR TRANSMITTER & CONTROLLER:
TAG NO: CIC – 03 |
INSTRUMENT NAME: Conductivity Indicator cum Controller |
LOCATION: 1) Outlet of EDI system |
FUNCTION: To check the conductivity in the water, if the conductivity in the feed water is sensed high above a settable value then it will give an indication on the panel & open the dumping valve and dump the high conductivity water. |
TECHNICAL SPECIFICATION:
Make : Emerson Range : 0 – 10 µs/cm (EDI outlet) End Connection : 1 ½” TC end connection. MOC : SS 316 wettable parts |
- B.9 HIGH PRESSURE SWITCH:
TAG NO: HPS – 01 / 02 |
INSTRUMENT NAME: High Pressure Switch |
LOCATION: 1) Outlet of RO High Pressure – I
2) Outlet of RO High Pressure – II |
FUNCTION: To check the feed pressure to the RO system, if the line pressure in the feed water is sensed high above a settable value then it will trip the entire RO-EDI system. |
TECHNICAL SPECIFICATION:
Make : Danfoss Range : 1 to 16 bar End Connection : 3/8” BSP (M) MOC : SS wettable parts Type : Seamless Bellow type pressure switch |
B.10 LOW PRESSURE SWITCH:
TAG NO: LPS – 01 / 02 / 03 |
INSTRUMENT NAME: High Pressure Switch |
LOCATION:
1) Inlet of RO High Pressure – I 2) Inlet of RO High Pressure – II 3) Inlet of EDI unit |
FUNCTION: To check the pressure in the water, if the line pressure in the feed water is sensed low below the settable value then it will trip the entire RO-EDI system. |
TECHNICAL SPECIFICATION:
Make : Danfoss Range : 0 to 3 bar End Connection : 3/8” BSP (M) MOC : SS wettable parts Type : Seamless Bellow type pressure switch |
- B.11 LEVEL SWITCH for CIP Tank:
TAG NO: CIP – LLS |
INSTRUMENT NAME: Low Level Switch |
LOCATION: CIP Tank |
FUNCTION: To check the Level in the CIP tank. If the level in the tank is below the desired level the system will give indication on the panel & will trip the system. |
TECHNICAL SPECIFICATION:
Quantity : One Make : Mahalaxmi Model : SMT-16M 3” TC-AH MOC : SS 316 |
- B.12 TEMPERATURE INDICATOR & TRANSMITTER
TAG NO: CIP – TT |
EQUIPMENT NAME: Temperature Transmitter |
EQUIPMENT LOCATION: 1) CIP Feed Pump Discharge |
FUNCTION: To check Temperature of system during Sanitization Process |
TECHNICAL SPECIFICATION:
Make : Wika Wetted material : SS 316 Range : 0 to 2000 C Input : PT – 100 (RTD) Accuracy : + / – 0.5% of F.S. Ambient Temp : 250 C |
B.13 CONTROL VALVES
TAG NO: AV –01 / 02 / 03 / 04 / 05 / 06 |
EQUIPMENT NAME: Control Valves |
LOCATION :
1) Raw Water Inlet line 2) Before RO High Pressure – I (ORP Dump) 3) Reject line of RO pass – I (Auto Rinse Valve) 4) Permeate line of RO pass – I (CIC Dump) 5) Reject line of RO pass – II (Auto Rinse Valve) 6) Permeate line of RO pass – II (CIC Dump) |
FUNCTION: To monitor the plant operation in Auto/Semi-Auto mode as per the pre-set logic & time. |
TECHNICAL SPECIFICATION:
Make : Avcon Type : Y- type Pneumatic operated ON-OFF MOC : SS Wettable Parts End Connection : TC end Size : As per valve schedule |
B.14 FLOW DIVERTER VALVE
TAG NO: FDV – 01 |
EQUIPMENT NAME: Flow Diverter Valve |
LOCATION: Outlet of EDI unit. |
FUNCTION: To dump the high conductivity water at outlet of EDI unit. |
TECHNICAL SPECIFICATION:
Make : Kumar Process MOC : SS 316L End Connection : TC end Size : 1” |
6.B.15 SAMPLING VALVE:
EQUIPMENT NAME: SP-05 to 11 |
EQUIPMENT LOCATION: RO-EDI Distribution Piping |
FUNCTION: To take a Sample for RO Water Analysis. |
TECHNICAL SPECIFICATION:
Quantity : 07 Nos. Make : Kumar Process Type : Milipore Design Size : 8 NB M.O.C. : SS 316L |
6.B.16 VALVE SCHEDULE
Sr. No. | Location of Valve | Tag No. | Size | Type | MOC |
1 | Before Raw Water Tank | AV-01 | 32 mm | Actuated Valve (NC) | SS 304 |
2 | ORP dump valve | AV-02 | 25 mm | Actuated Valve (NC) | SS 304 |
3 | RO-I Reject line (Auto Flushing) | AV-03 | 20 mm | Actuated Valve (NC) | SS 304 |
4 | RO-I Conductivity dump valve | AV-04 | 20 mm | Actuated Valve (NC) | SS 304 |
5 | RO-II Reject line (Auto Flushing) | AV-05 | 20 mm | Actuated Valve (NC) | SS 304 |
6 | RO-II Conductivity dump valve | AV-06 | 20 mm | Actuated Valve (NC) | SS 304 |
7 | Suction line of RWP-01 | BV-01 | 1.5” NB | Manual Ball Valve | SS 304 |
8 | Discharge line of RWP-01 | BV-02 | 1.25” NB | Manual Ball Valve | SS 304 |
9 | Suction line of RWP-02 | BV-03 | 1.5” NB | Manual Ball Valve | SS 304 |
10 | Discharge line of RWP-02 | BV-04 | 1.25” NB | Manual Ball Valve | SS 304 |
11 | MGF Inlet | BV-05 | d40DN32 | Manual Ball Valve | UPVC |
12 | MGF outlet | BV-06 | d40DN32 | Manual Ball Valve | UPVC |
13 | MGF back wash inlet | BV-07 | d40DN32 | Manual Ball Valve | UPVC |
14 | MGF back wash outlet | BV-08 | d40DN32 | Manual Ball Valve | UPVC |
15 | MGF drain | BV-09 | d40DN32 | Manual Ball Valve | UPVC |
16 | Softener-01 Inlet | BV-10 | d40DN32 | Manual Ball Valve | UPVC |
17 | Softener-01 Outlet | BV-11 | d40DN32 | Manual Ball Valve | UPVC |
18 | Softener-01 power water | BV-12 | d25DN20 | Manual Ball Valve | UPVC |
19 | Softener-01 brine injection | BV-13 | d40DN32 | Manual Ball Valve | UPVC |
20 | Softener-01 slow Rinse outlet | BV-14 | d40DN32 | Manual Ball Valve | UPVC |
21 | Softener-01 Fast Rinse outlet | BV-15 | d40DN32 | Manual Ball Valve | UPVC |
22 | Diversion line | BV-16 | d40DN32 | Manual Ball Valve | UPVC |
23 | Discharge ROHP-01 | BV-17 | 25 mm | Manual Ball Valve | SS 304 |
24 | Discharge ROHP-02 | BV-18 | 25 mm | Manual Ball Valve | SS 304 |
25 | Discharge line of Raw Water Pump – 01 | NRV-01 | 1.25” | Non Return Valve | SS 304 |
26 | Discharge line of Raw Water Pump – 02 | NRV-02 | 1.25” | Non Return Valve | SS 304 |
27 | Conc. Inlet EDI | DV-01 | DN 20 | Diaphragm Valve | SS 316 |
28 | CIP Tank drain valve | CIP-DV-01 | DN 20 | Daiphragm Valve | SS 316 |
29 | CIP Suction Valve | CIP-DV-02 | DN 20 | Daiphragm Valve | SS 316 |
30 | CIP Discharge Valve | CIP-DV-03 | DN 20 | Diaphragm Valve | SS 316 |
31 | ORP needle valve | NV-01 | ¼ ” | Needle valve | SS 304 |
32 | Reject line RO-01 | NV-02 | 20 mm | Needle Valve | SS 304 |
33 | Reject line RO-02 | NV-03 | 20 mm | Needle Valve | SS 304 |
34 | After NaOCl-01 Dosing System | SP-01 | 8 NB | Sampling Valve | SS 304 |
35 | Inlet of Multi Grade Filter | SP-02 | 8 NB | Sampling Valve | SS 304 |
36 | Outlet of Multi Grade Filter | SP-03 | 8 NB | Sampling Valve | SS 304 |
37 | Outlet of Softener-01 | SP-04 | 8 NB | Sampling Valve | SS 304 |
38 | After SMBS dosing system | SP-05 | 8 NB | Sampling Valve | SS 316 |
39 | After ADS dosing system | SP-06 | 8 NB | Sampling Valve | SS 316 |
40 | After pHC dosing system | SP-07 | 8 NB | Sampling Valve | SS 316 |
41 | After 5-micron Cartridge Filter | SP-08 | 8 NB | Sampling Valve | SS 316 |
42 | After RO pass-I | SP-09 | 8 NB | Sampling Valve | SS 316 |
43 | After RO pass-II | SP-10 | 8 NB | Sampling Valve | SS 316 |
44 | After EDI system | SP-11 | 8 NB | Sampling Valve | SS 316 |
- C.1 PLC PANEL:
TAG NO.: PLC Panel |
INSTRUMENT NAME: MCC cum PLC panel. |
LOCATION: Mounted on the SKID |
FUNCTION: To operate all Pumps, drives, control valves and instrumentation. To operate predefined operational logic of the plant. To operate the plant with predefine interlock logic for safety and trouble free operation. To collect predefine process parameter for equipment validation. |
TECHNICAL SPECIFICATION:
MOC of Panel : SS 304 with matt finish Digital Input and Output Card Make : Mitsubishi Model : FX3G 60MR+FX2N 8ER Digital Input : 40, 24VDC input Digital Output : 28, 230VAC output Analog Input/Output Card Make : Mitsubishi Model : FX2N 8AD + 5A Analog Input : 12 Nos. Analog Output : 01 No. MMI ( Monochrome) Make : Mitsubishi Catalogue No. : E – 1043 Communication Port : RS-232 (DF1) Printer Port : RS-232 Display : Touch Screen Size : 3.5” |
6.C.2 PLC INPUT/OUTPUT DETAILS:
Sr.No | D/Input | Input Description | D/Output | Output description |
1 | X0 | RWP-01 start/stop | Y0 | NaOCl-01 |
2 | X1 | RWP-01 trip | Y1 | SMBS-01 |
3 | X2 | RWP-02 start/stop | Y2 | ADS-01 |
4 | X3 | RWP-02 trip | Y3 | PHC-01 |
5 | X4 | LLS NaOCl-01 | Y4 | RWP-01 |
6 | X5 | FS-01 | Y5 | RWP-02 |
7 | X6 | HL – Raw Water Tank | Y6 | ROHP-01 |
8 | X7 | ML – Raw Water Tank | Y7 | ROHP-02 |
9 | X10 | LL – Raw Water Tank | Y10 | EDI |
10 | X11 | ROHP 1 start/stop | Y11 | PLP-01 |
11 | X12 | ROHP 1 trip | Y12 | PLP-02 |
12 | X13 | ROHP 2 start/stop | Y13 | HIUV |
13 | X14 | ROHP 2 trip | Y14 | PWST Heater |
14 | X15 | EDI start/stop | Y15 | CIPFP |
15 | X16 | EDI trip | Y16 | CIP Heater |
16 | X17 | CIPFP start/stop | Y17 | AV-01 |
17 | X20 | CIPFP trip | Y20 | AV-02 |
18 | X21 | CIP HTR Start / Stop | Y21 | AV-03 |
19 | X22 | LLS SMBS-01 | Y22 | AV-04 |
20 | X23 | LLS ADS-01 | Y23 | AV-05 |
21 | X24 | LLS-pHC-01 | Y24 | AV-06 |
22 | X25 | LPS-01 ROHP-01 | Y25 | FDV-01 |
23 | X26 | LPS-02 ROHP-02 | Y26 | PWD-FDV-01 |
24 | X27 | LPS-03 EDI | Y27 | PWD-AV-01 |
25 | X30 | HPS-01 ROHP-01 | Y30 | VF HTR |
26 | X31 | HPS-02 ROHP-02 | Y31 | Hooter |
27 | X32 | LLS CIPT | Y32 | Spare |
28 | X33 | PLP 1 start / stop | Y33 | Spare |
29 | X34 | PLP 2 start / stop | ||
30 | X35 | PLP 1/2 trip | ||
31 | X36 | PWST Ceramic Heater | ||
32 | X37 | Auto Manu. Switch for RO-EDI | ||
33 | X40 | Auto Manu. Switch for Purified Water Distribution System | ||
34 | X41 | EMERGENCY | ||
35 | X42 | ACCEPT | ||
36 | X43 | Air Pressure Switch | ||
37 | X44 | Spare | ||
38 | X45 | Spare | ||
39 | X46 | Spare | ||
40 | X47 | Spare | ||
Sr.No | Analog Input | A/I description | Analog Output | A/O description |
1 | AI-1 | PWG – ORP 01 | AO-1 | PLP – VFD |
2 | AI-2 | PWG – CIC 01 | ||
3 | AI-3 | PWG – CIC 02 | ||
4 | AI-4 | PWG – CIC 03 | ||
5 | AI-5 | PWD – CIC 01 | ||
6 | AI-6 | PWD – FT 01 | ||
7 | AI-7 | PWD – TT 01 | ||
8 | AI-8 | PWD – LIC | ||
9 | AI-9 | CIP TIC | ||
10 | AI-10 | EDI Current |
6.C.3 System Description & Process Logics for Purified water Generation System
Sr. No. | Interlock Description | Action Taken | Indication on MMI | Audio Visual Alarm | |
1 | High Level in Raw Water Tank | Will close Actuated Valve AV-01 | YES | YES | |
2 | Medium Level in Raw Water Tank | Will open Actuated Valve AV-01 | YES | NA | |
3 | Low Level in Raw Water Tank | Will stop RWP-01 / 02 | YES | YES | |
4 | Medium Level in Raw Water Tank | Will start RWP-01 / 02 | YES | NA | |
5 | Low Level in NaOCl-01 Dosing Tank. | Will trip NaOCl-01 Dosing Pump & will close AV-01 | YES | YES | |
6 | Low flow in Raw Water inlet line | Will trip NaOCl-01 Dosing Pump & will close AV-01 | YES | YES | |
7 | High Totalized flow at outlet of softener | It Should give Alarm for Regeneration. | YES | YES | |
8 | Emergency Stop | Should Trip the System. | YES | YES | |
9 | Low level in SMBS 1 Dosing tank | RWP-01 will stop & RO-EDI System will stop. | YES | YES | |
10 | Low level in ADS Dosing tank | RWP-01 will stop & RO-EDI System will stop. | YES | YES | |
11 | Low Level in pH Correction Dosing tank | RWP-01 will stop & RO-EDI System will stop. | YES | YES | |
12 | High ORP-01 Value. | 1) Free chlorine will pass through and ORP sensor will sense free chlorine. Inturn the ORP value will increase above the set point. This will open the ORP dumping valve AV-02.
2) ORP comes down within the desired limit. After 30 secs. of consistent reading, below the set value it will close the AV-02. Allow the water to feed to the RO system. The entire system will start automatically.
3) If the ORP value is high for more than 300 secs. it will trip the plant. |
YES
YES
YES |
YES
NA
YES
|
|
13
|
Low Pressure at ROHP – 01 suction | This will trip the ROHP – 01 | YES | YES | |
14 | Repeated Low Pressure at ROHP – 01 suction | After ROHP – 01 trips for 4 times in a minute. This will trip the entire plant. | YES | YES | |
15 | High Pressure at ROHP –01 discharge | RO – EDI system will trip. | YES | YES | |
16 | High Conductivity at RO pass – I outlet | 1) If the conductivity is above the set point, it will open the dumping valve AV-04.
2) After 30 secs. of consistent reading, below the set value, it will close the AV-04. Allow the water to feed to the 2nd Pass of RO system. The entire system will start automatically.
3) If the RO pass-I outlet conductivity is high for more than 300 secs. It will trip the plant. |
YES
YES
YES |
YES
NA
YES
|
|
17 | Low Pressure at ROHP – II | This will trip the ROHP – II | YES | YES | |
18 | High Pressure in ROHP – II discharge | RO – EDI system will trip. | YES | YES | |
19 | High Conductivity at RO pass – II outlet | 1) If the conductivity is above the set point, it will open the dumping valve AV-06.
2) After 30 secs. of consistent reading, below the set value, it will close the AV-06. Allow the water to feed to the EDI system. The entire system will start automatically.
3) If the RO pass-II outlet conductivity is high for more than 300 secs. it will trip the plant. |
YES
YES
YES
|
YES
NA
YES |
|
20 | Low pressure at EDI inlet | Low pressure at EDI inlet, will trip EDI unit. | YES | YES
|
|
21 | High Conductivity at EDI outlet | 1) If the conductivity is above the set point, it will open the dumping valve FDV-01.
2) After 30 secs. of consistent reading below the set value, it will close the FDV-01. Allow the water to feed to the purified water tank. The entire system will start automatically.
3) If the EDI outlet conductivity is high for more than 300 secs. it will trip the plant.
|
YES
YES
YES |
YES
NA
YES |
|
22 | Low temperature at CIP supply line | Ceramic Heater will be ON. | YES | NA | |
23 | High temperature at CIP supply line | Ceramic Heater will be OFF. | YES | NA | |
24 | Low Level in CIP Tank | Should trip the Heater & CIP Feed Pump. | YES | YES | |
25 | Emergency Stop | RO-EDI System will trip. | YES | YES |
- DRAWINGS REQUIRED
SR. NO. |
DESCRIPTION |
DRAWING NO. |
REV |
1 | P&ID for Pretreatment & Purified Water Generation & Distribution System | HPS/PR150/PWG/DR01 | 0 |
2 | Skid Drawings | HPS/PR150/PWG/DR02 | 0 |
3 | Isometric for Pretreatment System | HPS/PR150/PWG/DR03 | 0 |
4 | Isometric for RO-EDI System | HPS/PR150/PWG/DR04 | 0 |
5 | Control Panel Drawing | HPS/PR150/PWG/DR05 | 0 |
6 | CIP Tank Drawing | HPS/PR150/PWG/DR06 | 0 |
- SUPPORTING UTILITIES
SR. NO. | Equipments / Instruments | Location | Utilities | Specification | Scope |
1 | Pretreatment Plant | PW Generation Plant | Raw Water | 7000 LPH | ZCHL |
2
|
Control Panel | RO Plant Room | Power | 3 phase, 430V, 50 Hz | ZCHL
|
3 | RO Plant | RO Plant Room | Compressed Filtered regulated Air | MOC of tube is PU, Press – 6 kg/cm2 | ZCHL
|
- PRE-QUALIFICATION CHECK LIST
9.1 HYDRAULIC PRESSURE TEST
9.2 DOCUMENTATION CHECK
9.3 INTERLOCK CHECKS
9.4 OPERATIONAL CHECKS
- LIST OF DOCUMENTS REQUIRED FOR GENERATION SYSTEM
CODE | DOCUMENTS REQUIRED |
A | Manufacturer’s Manuals – Preventive Maintenance (O.M.) |
B | MOC Certificate |
C | Leak Test Reports / Hydro Test Report |
D | Sanitization Reports |
E | Cleaning / Flushing Reports |
F | Manufacturer’s Catalogue |
G | Test Certificate |
H | Guarantee / Warranty Certificate |
I | Basis of Design |
- DESIGN QUALIFICATION REPORT
APPROVAL
Approved / Not Approved
Approved By
|
Signature | |
Vendor | Executive name | |
Client
|
Engineering
|
|
Head-Operations | ||
Head-Quality |
Abbreviation
|
Description |
URS | User Required Specification |
FRS | Functional Required Specification |
cGMP | Current Good Manufacturing Practice |
QA | Quality Assurance |
USP | United States Pharmacopoeia |
WHO | World Health Organization |
ROHP | RO High Pressure Pump |
CIPFP | CIP Feed Pump |
SMBS | Sodium Meta bisulfate |
ADS | Antiscalent dosing System |
pHC | pH Correction |
CF | Cartridge Filter |
RO | Reverse Osmosis |
EDI | Electro-Deionization |
CIP | Cleaning In Place |
Ppm | Mg/Ltrs OR Parts Per Million |
NTU | Neblometric Turbidity Unit |
MWCO | Molecular Weight Cut-Off |
CFU/ml | Colony Forming Unit per ml |
TSS | Total Suspended Solids |
TDS | Total Dissolved Solids |
TOC | Total Organic Carbon |
TVC | Total Viable Count |
TBC | Total Bacterial Count |
TC | Tri Clover |
P&ID | Process Flow & Instrumentation Diagram |
LPH | Liters Per Hour |
- ABBREVIATIONS
PG | Pressure Gauge |
RM | Rotameter |
LLS | Low Level Switch |
PLC | Programmable Logical Controls |
MMI | Manual Machine Interface |
ORP | Oxidation Reduction Potential |
CIC | Conductivity Indicator cum Controller |
HPS | High Pressure Switch |
LPS | Low Pressure Switch |
MOC | Material Of Construction |
CPVC | Chlorinated Poly-Vinyl Chloride |
SS | Stainless Steel |
PP | Poly-Propylene |
FRP | Fiber Reinforced Plastic |
HDPE | High Density Poly Ethylene |
HOS | Height Of Shell |
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