ACID SOAKING OF CATION BEDS AT STAGE 1 DM PLANT

The acid soaking (with about 10 % acid strength ) of the weak & the strong cation beds may to bed done incase of repeatedly encountering of problems of high conductivity at strong anion O/L problem ( due to sodium slip from cation beds) or hardness at the strong cation O/L during the service of the stream or iron fouling of cation beds etc. Check the availability of the Filter water pump, Filter water sump ,ACF , regeneration system Effluent disposal system ,safety devices i.e goggles, face mask, eyewasher/drench shower proposed to be taken service during regeneration. Draw the required quantity of acid (2.0 MT of approx. 32 % HcL ) from the acid storage tank which is to be taken suction to the acid measuring tanks as follows Open the Feed valve of the selected acid measuring tank .Check that level gauge isolation valves are open & also the breather water supply valve is open & all other valves of this tank are closed. Open the drawing valve of the selected acid storage tank .Observe the level indicator of the acid measuring tank .When the level shows around 66 cms close the drawing valve of acid storage tank Allow the acid in the connected line to go to acid measuring tank. By now the level shows around 37 cms which is nearly equal to 2 MT of the acid .Close the feed valve of acid measuring tank . Line up selected regeneration pump to a available DM water storage tank having at least a level >2.0 mtr. Check that the power supply Cation exchanger operation switch is in position 1 (ON).Now press the group ON button of the corresponding cations. Close the manual isolation valve at the I/L of the weak cation bed .Put the cation exchanger operation selector switch to position 6 . Press the weak extra rinse ON button .Check at local for opening of valve V1 & V5 of the weak cation bed . Open the air vent line (manual) valve also.Allow the weak cation bed to drain completely . After the completion of weak cation bed draining .Put the cation exchanger operation selector switch to position O & then to position 6 . Press the strong cation extra rinse ON button. Ensure for the opening of the valves V1 & V2 of the weak cation bed & V1 & V5 of the strong cation bed.Open the air vent line (manual) valve also. Allow the strong cation bed to drain completely& then close the air vent line manual valve. Keep the cation exchanger operation selector switch to position O .Ensure that all valves at the local get closed. Close the manual isolation valve before V8 (downflow auto valve) ,the anual isolation valve at the strong cation service O/L & manual valve before V5 of weak cation bed. Keep the Cation exchanger operation selector switch to position 4(regeneration).For the operation of Acid metering pump and Regeneration pump following 3 modes are available : For auto start /stopping of the pump corresponding to need in the required step as per the set logic. Keep the Auto/Manual selector switch to position 1 (Auto) & the Local/Remote selector switch to position 2 ( Remote).

For start /stopping of the pump corresponding to need in the required step from the control panel. Keep the Auto/Manual selector switch to position 2 (Manual) & the Local/Remote selector switch to position 2 ( Remote).To start the pump press the start button & to stop press the stop button. For start /stopping of the corresponding to need in the required steps from the Local. Keep the Auto/Manual selector switch to position 2 (Manual) & the Local/Remote selector switch to position 1 ( Local).To start the pump press the start button & to stop press the stop button at the Local. For convenience the regeneration pump may be kept in Auto/ Remote operation & acid metering pumps at Manual /local mode. Line up the acid metering pump for dosing by opening the suction valve of the acid measuring tank containing the drawn acid .Open the suction & discharge valve of the selected acid metering pump. Open the acid dosing (cation ) dilution mixing T valve.Keep the acid metering pump stroke at 70 %. Keep the regeneration mode selector switch to position 1 (manual) & the manual step control selector switch to position 4 (Acid injection). Ensure for the opening of the valves V8(Down flow),V11(Injection valve), V12 (laterals inter connection),V15(dilution water valve) and V1 & V5 of Weak cation bed. Ensure the running of the regeneration pump & dilution water flow of 6 to 7.5 M3/Hr. Start the acid metering pump .Check for leaks & stop the dosing incase of any leak . Inform to shift chemist & coordinate with ma intenance group to rectify it. Observe the pressure of the weak & strong cation bed ( < 0.5 Kg/cm2) Incase no leak is there , open the cation acid injection sampling valve & check the acid strength being dosed with hydrometer .It is to be 1.09 to 1.1 for acid strength of around 10 % . If any variance from the above is noticed adjust the pump stroke accordingly. Incase the required strength is not obtained using one acid metering pump .Stop the dosing Open the suction & discharge valve of the other acid me tering pump also .Keep the stroke of both the pumps to around 50 % & start both the pumps. Repeat the above step . Monitor the strength of the acid dosing , the dilution water flow & the pressure of the cation beds . When the effluent starts coming out of the weak cation bed air vent line .Stop the acid dosing. Close suction valve of the acid measuring tank, suction / discharge valves of the acid metering pump(s). Keep the manual step control selector switch to position 1(Off). Keep the regeneration mode selector switch to position 2(Auto)& the Cation exchanger operation selector switch to position O(off). Press the group OFF button of the cation .Ensure for closing of all the connected auto valves & stopping of the regeneration pump. Open the acid metering pumps flushing I/L & O/L valves & flush thoroughly. After flushing close these valves. Allow the weak & strong cation beds to be under acid soaking for 24 hours. After 24 hours open the manual isolation valve at the weak cation I/L , before the V5 valve of the weak cation.

Ensure a extra supply of around 90 M3/Hr. of clarified water for rinsing of the cation beds. Check & line up connected / any available ACF & FWP. Start the DM plant roof top exhaust fans. Keep the Cation exchanger operation selector switch to position 6 (extra rinse). Press the cation group ON button .Now press the weak cation extra rinse ON button .Ensure for the opening of valves V1 & V5 . Take any available lined up ACF in service along with filtered water pump .Set the rinsing flow around ( 80 to 90 M3/Hr.) .Close the air vent line manual valve of the weak cation bed & rinse for about 45 minutes. Keep the Cation exchanger operation selector switch to position O ( Off) & then to position 6 ( extra rinse) . Now press the strong cation extra rinse ON button .Ensure for the opening of valves V1 & V2 of the weak cation bed and valves V1 & V5 of the strong cation bed. Open the air vent line manual valve of the strong cation bed & close it after 2 to 3 minutes. Allow the rinsing of the strong cation bed for about 1 hour. After completion of the rinsing. Stop the FWP , set the clarified water flow as per requirement.Cut off the ACF from service .Put the cation exchanger operation selector switch to position O ( Off) & then press the cation group OFF button. Ensure for the closing of all the auto valves. Open the manual isolation valve before V8 of weak cation & that at the service O/L of the strong cation bed. Dispose off the effluent .Stop the DM plant roof top exhaust fans . Record the cation acid soaking details i.e the beds soaked, acid consumed ,demineralised water consumed with date.

ACID SOAKING OF CATION BEDS AT STAGE 2

DM

PLANT:

The acid soaking (with about 10 % acid strength ) of the weak & the strong cation beds are to bed done once in a year or incase of repeatedly encountering of problems of high conductivity at strong anion O/L ( due to sodium slip from cation beds) or hardness at the strong cation O/L during the service of the stream. The procedure of the acid soaking treatment is as follows : Check the availability of the Filter water pump, Filter water sump ,ACF , regeneration system Effluent disposal system ,safety devices i.e goggles, face mask, eyewasher/drench shower proposed to be taken service during regeneration. Draw the required quantity of acid (3.2 MT of approx. 32 % HcL ) from the acid storage tank which is to be taken suction to the acid measuring tanks as follows: Open the Feed valve of the selected acid measuring tank .Check that level gauge isolation valves are open & all other valves of this tank are closed. Open the drawing valve of the selected acid storage tank .Observe the level indicator of the acid measuring tank .When the level shows around 79 cms close the drawing v alve of acid storage tank Allow the acid in the connected line to go to acid measuring tank. By now the level shows around 80 cms which is nearly equal to 3.2 MT of the acid Close the feed valve of acid measuring tank . Keep the regeneration pump selector mode in position T at the MCC panel . Start the regeneration (of cation only) in either step by step or semiauto mode & override the starting steps to reach the acid injection step. Ensure for the opening of

the valves opening of valves 218,219, 210,250, 209, of the cation beds and valves 302A(inside regeneration room). Open all the above valve manually ( except the valve 219 ) by operating there wheel clockwise . Override the regeneration steps to reach the off position. Open the rinse O/L valves 209 & air vent valve 211 of the weak cation bed & the valve 217 (rinse O/L of strong cation bed) by local solenoid operation .Open & the manual air vent valve of the strong cation bed. Allow the cation beds to drain fully. After draining close the valves 209 & 217 by local solenoid valve operation. Also close the manual air vent valve of the strong cation bed. Open the suction valve of the acid measuring tank containing the drawn acid .Open the suction & discharge valve of any available acid metering pump .Also open the acid dilution mixing T valve. Keep the acid metering pump stroke at 80 % . Start the regeneration pump from local. Observe the dilution water flow & adjust to (4 to 5 M3/Hr.). Start the acid metering pump from local. Check for leaks & stop the dosing incase of any leak . Inform to shift chemist & coordinate with maintenance group to rectify it. Observe the pressure of the weak & strong cation bed ( < 0.5 Kg/cm2) Incase no leak is there , open the cation acid injection sampling valve & check the acid strength being dosed with hydrometer .It is to be 1.09 to 1.1 for acid strength of around 10 % If any variance from the above is noticed adjust the pump stroke accordingly. Incase the required strength is not obtained using one acid metering pump .Stop the dosing Open the suction & discharge valve of the other acid metering pump also .Keep the stroke of both the pumps to around 50 % & start both the pumps. Repeat the above . Monitor the strength of the acid dosing , the dilution water flow & the pressure of the cation beds . When the effluent starts coming out of the weak cation bed air vent line .Stop the acid dosing & the regeneration pump from local. Close suction valve of the acid measuring tank, suction / discharge valves of the acid metering pump(s) & the acid dosing mixing T valve. Put the regeneration pump mode selection to N mode in the MCC panel. Open the acid metering pumps flushing I/L & O/L valves & flush thoroughly. After flushing close these valves. Allow the weak & strong cation beds to be under acid soaking for 24 hours. Normalise the valves 218,219, 210,250 of the cation beds and valves 302A(inside regeneration room) by keeping the corresponding solenoid valves in local open position & operating the wheel anticlockwise .After n ormalising the wheel put the corresponding solenoid valves in auto position . After completion of soaking start the DM plant roof top exhaust fans.Open the valves 209,211 of the weak cation bed. Allow the beds to drain After draining open the service I/L valve 205 of the weak cation bed .Take any connected/lined up ACF bed in service by opening its service I/L & O/L valves 201 & 202 by local solenoid valve operation. Ensure a extra supply of around 110 M3/Hr. of clarified water for rinsing of the cation beds. Check & line up connected / any one of the available FWP B/C/D. Start the selected filtered water pump from local.

The rinsing of the weak cation bed starts . Close the air vent valve 211. Allow to rinsing for 45 minutes. Monitor the rinse flow (100 to 110 M3/Hr.) After completion of weak cation rinsing . Open the valves 206 of the weak cation bed ,212 & 217 of the strong cation bed ( by local solenoid valve operation) & also the manual air vent valve of the strong cation bed. Close the valve 209 of the weak cation bed by local solenoid valve operation. The rinsing of the strong cation bed starts .Close the manual air vent valve. Allow the rinsing to continue for 1 hour. After completion of the rinsing stop the FWP from local. Close the valves 201,202 of the ACF ,valve 205 & 206 of the weak cation bed & valves 212 & 217 of the strong cation bed ( by local solenoid valve operation). Stop the DM plant roof top exhaust fans. Set the clarified water flow as per the requirement. Dispose off the effluent. Record the cation acid soaking details i.e the beds soaked, acid consumed ,demineralised water consumed with date.