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INTRODUCTION
This document presents a detailed description of the Water Treatment and Make-up Water System
for the 215 MW Bauang Power Plant. This includes the functions, criteria requirements, details of
system components, controls and instrumentation, operating modes, safety precautions, and
maintenance requirements of the system.
1.1
System Functions
The Water Treatment and Make-up Water System (Circuit 17) provides the water requirements of
Low Temperature Cooling System (Circuit 19), High Temperature Water Circuit (Circuit 21), Fuel
Valve Cooling Water (Circuit 22), Steam Productions Feed, Fuel Treatment operating and sealing,
and soot cleaning of exhaust gas boiler. The system is shown in Schematic Diagram in Appendix
7.1.
1.2
Criteria Requirements
The system equipment, components, and controls are designed in accordance with the
manufacturer's codes and standards and has passed the trial operation and confirmation test plan at
site and/or at shop. Tank materials shall be ASTM A283 Grade C and structural shape shall be
ASTM-A36. The raw water must be essentially free from solid matter so that a 50 micron filter has
to be mounted before the water softener.
As a nominal guide for the desired softened water quality the following values should be used:
Hardness
Contents of chlorides and sulfates
pH Value
1.3
3 to 10 odH
100 mg/liter maximum
8 to 9
b.
c.
d.
BPPC/SDD-17
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e.
f.
g.
Instruments and indicators are also provided to support the efficient and reliable operations of the
system.
The water contained in the buffer tank, 0-16V6-0, of the Raw Water System can be treated either by
softening or by distillation. The Softening Skid, 0-17S1-0, mainly consists of an ion exchange
softener with salt regeneration has a capacity of 10 m3/hr. This is used for the first make-up water
requirement and when water consumption is temporarily important. The softened water skid feeds
the softened water tank, 0-17V5-0.
From the tank 0-17V5-0, softened water is distributed to each sector of the power plant via the high
pressure skids 0-17S2A/B/C-0. Each skid is fitted with two high pressure pumps (one running, the
second one on stand by). The pump which is in service automatically starts and stops in relation
with the water pressure at the outlet. At the outlet of each skid a high pressure tank works as an
accumulator/buffer.
Softened water is also fed by the high pressure booster skid to the lube oil and fuel oil treatment
units and to the soot cleaning system of the exhaust gas boiler. However, in the soot cleaning of the
exhaust gas boiler, water washing should be carried out while engine has been stopped and the
economizer is as hot as possible.
After starting the power plant and getting enough steam products, only then that the distillation skid
can be used.
The distillation skid 0-17S3-0, mainly consists of a fresh water distiller (evaporator/condenser) and
salt regeneration tank. The unit is used for continuous refilling of the system. It is heated with
steam coming from the steam network of the power plant. The distillation skid with a capacity of 5
tons of water per day feeds the distilled water tank, 0-17V4-0. The hot water system of the
distillation skid can be fed by any of the three high pressure booster skids.
The system also feeds treated water to the following expansion tanks through the line 0-17-001-501/2/3 via manual valves :
a.
b.
c.
d.
The line 0-17-001-50-1/2/3 also feeds the steam system feed water
BPPC/SDD-17
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tank.
The filling lines for systems of the sector is fitted with chemicals dosing unit. This equipment
consists a receiver, a dosing pump and a flowmeter. Dosing of water treatment products thus
depends on % Speed and % Stroke setting of the dosing pump.
The Condensate from Charge Air System (Circuit 13) enables condensate from the charge air cooler
of each engine unit to be recovered and directed to a recovery tank (0-13V1-1/2/3). At a certain
level, the recovery tank pump draws the accumulated condensate from the tank and pump it to the
distilled water tank, 0-17V4-0.
To further increase the capacity of the Water Treatment Plant and to ensure the continuous and
reliable supply of treated water to the plant sectors, a 20 gpm-Demineralized Plant is constructed
beside the cistern. The Demi-Plant consist raw water pump, cation unit, degasifier with surge tank,
degasifier pump, anion unit, D.M. water pump, backwash unit, and regeneration tanks. The DemiPlant supplies the distilled water tank, 0-17V4-0.
2.0
2.1
Components
2.1.1
0-17S3-0
BPPC/SDD-17
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Type
Capacity
Jacket Water Flow
Jacket Water Inlet Temp.
Jacket Water Outlet Temp.
Press. Drop at Evaporator Section
Cooling Water Flow
Cooling Water Temperature, Inlet
Cooling Water Temperature, Outlet
Pressure Drop at Condenser Section
JWP-16-C40
5 tons/day
7.4 m3/h
85 oC
66 0C
24 KPa
11.7 m3/h
30 oC (max.)
40.3 oC
61 KPa
separator vessel
2.
evaporator section
3.
condenser section
4.
combined brine/air
ejector
5.
6.
7.
salinometer
8.
control panel
Salinometer
contains starters
for the electric motors and
terminals for the salinometer.
BPPC/SDD-17
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The system is provided with a salinometer to continuously check the salt content of
the produced distilled water.
Technical Data
Type
Supply Voltage
Frequency
Power Consumption
Salinity Display
Temp. Correction
Alarm Level
Test
Fuses
External Met. Output Max. Ambient Temp. Protection Degree
NOTE: *
2.
NS10-M2
100,110,127,220VAC 10%
50/60 Hz 5%
Salinometer 5 m VA; solenoid valve,max.
45VA
0-19.9 ppm (digital display)*
Automatic in the range 5-85 oC
Can be set to any value bet. 0-19.9 ppm
can be checked by the test switch
F1=3A, for solenoid valve and buzzer,
F2=0.2A for mains input
full scale DC .2V
55 oC
IP 54
30 oC
11.7 m3/h
>0 bar
4 bar
3460 rpm
4.9 KW
53%
Horizontal
Mechanical
40 mm.
40 mm.
~ 20 m.
Material:
Impeller
Shaft
Casing
Drive
Type
Supplier
RG10
-
Bronze
AISI 316
Motor, direct couple
Ejector Pump,CNL 40-40/200
Alfa Laval
BPPC/SDD-17
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3.
4.
45 oC
42 kg
-
8.5 KW
3490 rpm
6.9
2.25
90%
F
80 oC, class B
460 10%
3
60 Hz.
14.4 A
0.91
85.5%
0.014 kg m2
IP55
MBT 132 SA
ABB
Alfa Laval
~ 42 oC
1000 kg/m3
2 ppm
450 lit./hr
0.25 bar
2.5 bar
2.25 bar
3360 rpm
0.2 kW
56%
20 mm.
20 mm.
~ 20 m.
-
RG9
AISI 316
BPPC/SDD-17
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Casing
Drive
Type
Manufacturer
Supplier
5.
RG5
-
6.
45 oC
4.5 kg
-
0.32 KW
3360 rpm
3.75
2.1
90%
F
80 oC, class B
460 V 10%
3
60 Hz
0.8A
0.78
67%
18x10-5 kg m2
IP 55
MT 63 B
ABB
Alfa Laval
85 oC
10,000 kg/m3
7
7.4 m3/hr.
1.6 bar
3490 rpm
0.75 KW
43%
65 mm.
65 mm.
~ 20 m.
BPPC/SDD-17
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Material:
Impellers
Shaft
Casing
Drive
Weight of the Set
Type
Supplier
7.
GG 20
-
AISI 316
AISI 316
45 oC
16 kg
-
2.5 KW
3460 tr/min.
6.8
2.4
2.1.2
90%
F
80 oC, class B
460 10% V
3
60 Hz
4.7 A
0.87
80%
2.14x10-3 kg m2
IP55
MT90
ABB
Alfa Laval
BPPC/SDD-17
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2.
3.
In case the softener is exhausted and the controller indication is at Marche (Service), press
Manuel (Manual) and wait for 2 minutes. The light indicator will change from Marche
(Service) to Phase I (Backwash). From there it will automatically go through Phase II and
Phase III after completing the preset time. After Phase III, it will return to Marche (Service).
a.
Water Softener
Maximum Operating Temperature
Maximum Operating Pressure -
b.
50 oC
10.5 bar
c.
45 oC max.
1 kg/m3
>7
5 m3/hr.
0.3 bar
5 bar
1 m. CL
2900 rpm
1.5 KW
60%
Vertical
1 1/4"
1 1/4"
~ 20 m.
motor, direct couple
CNR4
Grace
1.5KW max.,1.1KW
min.
2900 rpm
40
45 oC
90% max.
F
460 10%
BPPC/SDD-17
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Phase
Frequency
Protection Class
Manufacturer
Supplier
2.1.3
3
60 Hz
IP55
Grundfos
Grace
b.
0-17P4A/B/C/D/E/F-0
6 (2 per skid)
45 oC max.
10 m3/hr.
0.2 bar
3 bar
3 bar
4 m.CL
3600 rpm
62%
Vertical
2 1/2"
2 1/2"
~ 20m.
Ft20
-
PPOM
Z30C13
GMi64
KSB
6 (2 per skid)
0.8 KW
3600 rpm
20
1.1 KW
BPPC/SDD-17
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Nominal Speed
Voltage
Phase
Frequency
Nominal Current
Power Factor
Protection Class
Manufacturer
Supplier
2.1.4
3600 rpm
460 10% V
3
60 Hz
2.1 A
0.77
IP55
KSB
KSB
2.
7 lit./min.
45 min.
20 gpm
15 min. or until acceptable quality is
reached.
fast rinse/service
Flow rate
Time
b.
7 lit./min.
128 kg
5%
45 min.
slow rinse
Flow rate
Time
3.
BPPC/SDD-17
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Flow rate
Kgs. of NaOH (45%) Concentration
Time
2.
slow rinse
Flow rate
Time
3.
7 lit./min.
44 kgs
4%
60 min.
7 lit./min.
60 min.
20 gpm
15 min. or until acceptable quality is
reached
fast rinse/recycling
Flow rate
Time
To maintain the efficiency of the cation and anion units, backwashing of the service vessels
are undertaken from time to time specially when the differential pressure between inlet and
outlet is more than 10 psi or when there is an observed fouling of cation or anion resins.
Backwashing of service vessels have three phases namely:
a.
2.
Backwashing of resin
Flow rate
Time
3.
b.
20 gpm
20 min.
2.
Backwashing of resin
Time
3.
20 min.
BPPC/SDD-17
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a.
Cation Unit
Technical Data
Flow Rate
No. of Vessel
Type of Resin
Vol. of Resin
Regeneration level
Regenerant
Regenerant Concentration
Regenerant Required/cycle
Vessel Dia.
Cylindrical Height
No. of PPN Strainers
Material of construction
No. of Valves
b.
20 GPM
1
Amberpack 120
300 li.
55 gms/li.
Hydrochloric Acid
5%
345 li.
500 mm
1800 mm
24 pcs.
mild steel with rubber lining
6
Anion Unit
Technical Data
Flow Rate
No. of Vessel
Type of Resin
Vol. of Resin
Regeneration level
Regenerant
Regenerant Concentration
Regenerant Required/cycle
Vessel Dia.
Cylindrical Height
No. of PPN Strainers
Material of construction
No. of Valves
c.
20 GPM
1
Amberpack 420
180 li.
90 gms/li.
Sodium Hydroxide
4%
435 li.
400 mm
1850 mm
24 pcs.
mild steel with rubber lining
6
Degasifier Unit
Technical Data
Dia.
Cylindrical Height
Vol. of Rachis kings
Flooded Capacity
Material of construction
388 mm
2850 mm
200 li.
340 li.
mild steel with rubber lining
BPPC/SDD-17
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d.
e.
1500 mm
1500 mm
2650 li.
mild steel with rubber lining
600 mm
1820 mm
mild steel with epoxy lining
centrifugal
30 gpm
75 ft.
2" NPT
1 1/2" NPT
cast iron
cast iron
stainless steel with mechanical seal
2 hp
220V / 440V, 3 phase
3500 rpm @ 60 Hz
centrifugal
30 gpm
52 ft.
1 1/2" NPT
1 1/4" NPT
AISI 316
stainless steel
2 hp
440V / 220V, 3 phase
3500 rpm
Backwash Unit
Technical Data
Dia.
Cylindrical Height
Material of construction
f.
g.
BPPC/SDD-17
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h.
DM Water Pump
Technical Data
Type
Capacity
TDH
Suction
Discharge
Body
Impeller
Motor
Voltage
RPM
i.
centrifugal
30 gpm
52 ft.
1 1/2" NPT
1 1/4" NPT
AISI 316
stainless steel
2 hp
440V / 220V, 3 phase
3500 rpm
Blower
Technical Data
Type
Capacity
Motor
Voltage
RPM
2.1.5
2.1.6
0-17V5-0
3,000 mm.
30 m3
atmospheric
7655-B
2.2
BPPC/SDD-17
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2.2.1
Instruments
a.
Pressure Indicator
Direct reading pressure indicators are installed at the softened water skid high
pressure pump discharge line to monitor the pump performance and efficiency.
Item Number Service Description
PI017101-0
0-10 bar
Tecnova
0-6 bar
WIKA
Technical Description:
Operating Conditions
Fluid
Upstream Pressure
Downstream Pressure
Flow
Operating Temperature
Calcul. KV/Choose KV
Diameter
Water
3 bar
0.5 to 1 bar
1 m3/hr
Ambient
0.93
ND 15 mm.
BPPC/SDD-17
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Connection
Material
Seat Material
Plug Material
Membrane Material
Pressure Set Point
Pressure Gauge Scale
Range
Mounting Accessories
Type
Supplier
2.2.2
1
/2" G
Brass
Brass
SS
CR
1 bar
0/4 bar
0.2-4 bar
Manometer
50 EM
Samson
Controls
Each skid is provided with local control panel to house the controls for the pumps.
The Water Softener Skid high pressure pump can be started by turning its control switch to
"START" position and can be stopped by turning its control switch to "STOP" position. Its
control panel is equipped with "ON-VOLTAGE" indicating light to confirm that its circuit
breaker (located on the right side of the control panel) is at "ON" position.
The Softened Water Skids (0-17S2A/B/C-0) control panels which are located beside each
softened water skid are provided with "AUTO-OFF-MANUAL" toggle switch for the
automatic or manual starting of the pumps. With water level at the softened water tank is
normal and the toggle switch placed at "MANUAL" position, the respective pump will start
right away and will only stop when the toggle switch is placed at "OFF" position. But when
the toggle switch of the pump is in "AUTO" position, starting and stopping of the pump is
based on the water pressure at the outlet.
3.0
MODES OF OPERATION
3.1
4.0
SAFETY PRECAUTIONS
BPPC/SDD-17
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It is very important that the person/persons involved with the use or operation of equipment
mentioned in this document follow all safety precautions. Read and follow all safety instructions
carefully. Not following the instructions may cause severe personal injury or damage the equipment
beyond repair. Using the equipment mentioned here should not be allowed if it is faulty or the
operator does not understand it's proper use.
5.0
MAINTENANCE
A scheduled program of testing and inspection should be maintained to ensure that all system
components and their control systems are in good working condition.
Manufacturer's recommendation for preventive and in service maintenance and inspection should be
the minimum basis.
6.0
REFERENCES
6.1
6.2
6.3
6.4
7.0
APPENDICES
7.1
7.2
7.3