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DQ for Purified Water System

DQ for Purified Water System

NAME OF THE  SYSTEM : PRETREATMENT & PURIFIED WATER GENERATION SYSTEM

TABLE OF CONTENTS

SR. NO. STAGE PAGE NO.
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

 

  1. OBJECTIVE AND SCOPE 
  • OBJECTIVE
  1. To prepare detailed specification for all major components of Equipment / instrument to ensure that the User Requirement Specification and functional requirement specification are achieved.
  2. 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.

  1. When subjected for new installation
  2. When the existing system is replaced with the new system.
  3. 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.

  1. ACCEPTANCE CRITERIA 
  1. 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) 

  1. 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.  

  1. 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.

  1. 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.

  1. 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)

  1. 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
  2. Regeneration Operation
  3. Slow Rinse Operation
  4. Fast Rinse 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

  1. 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

  1. 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 

  1. 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

 

  1. 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

  

  1. 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

 

  1. 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

 

 

  1. PRE-QUALIFICATION CHECK LIST

9.1     HYDRAULIC PRESSURE TEST

9.2     DOCUMENTATION CHECK

9.3     INTERLOCK CHECKS

9.4    OPERATIONAL CHECKS

  1. 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

 

  1. 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
  1. 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

 

For More Pharma Updates Visit –https://pharmaguidances.com

 

About Pharmaceutical Guidanace

Mr. Shiv Kumar is the Author and founder of pharmaceutical guidance, he is a pharmaceutical Professional from India having more than 14 years of rich experience in pharmaceutical field. During his career, he work in quality assurance department with multinational company’s i.e Zydus Cadila Ltd, Unichem Laboratories Ltd, Indoco remedies Ltd, Panacea Biotec Ltd, Nectar life Science Ltd. During his experience, he face may regulatory Audit i.e. USFDA, MHRA, ANVISA, MCC, TGA, EU –GMP, WHO –Geneva, ISO 9001-2008 and many ROW Regularities Audit i.e.Uganda,Kenya, Tanzania, Zimbabwe. He is currently leading a regulatory pharmaceutical company as a head Quality. You can join him by Email, Facebook, Google+, Twitter and YouTube

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