Nandipur 425MW CCPP Chemical Operation Manual

NANDIPUR 425MW CCPP CHEMICAL OPERATION MANUAL
1
Preface
This manual is edited on the basis of provisions and relevant drawings

from manufacturer and design institute, only for chemical system operation
of Pakistan Nandipur 425MW Combined Cycle Power Plant. With the
progress of the project, the manual will be supplemented and improved.
1
Abbreviation
Abbreviation Full Title
DM Demineralize
ACF Active Carbon Filter
SSR Self-sealing System
DCS Distributed Control System
C.W Close Circle Water
PLC Programmable Logic Controller
LED Light Emitting Diode
2
Contents
Abbreviation .............................................................................................. 2
1Raw Water Pre-treatment System ......................................................... 1

1.1 Function Description ..................................................................................... 1
1.2 System Parameters ........................................................................................ 1
1.2.1Clarified Water Tank, Firefighting Water Tank ..................................... 1
1.2.2 Mechanical accelerated clarifier .......................................................... 1
1.2.3 Filter ..................................................................................................... 1
1.2.4 Service Water Tank .............................................................................. 2
1.2.5 DM Water Tank .................................................................................... 2
1.2.6 Potable Water Tank .............................................................................. 2
1.3 Deep Well Pump House ................................................................................ 2
1.3.1Deep Well Pump House ........................................................................ 2
1.3.2 The Main Principle of Control ............................................................. 2
1.3.3 The requirement of deep well control and monitor. ............................. 3
1.3.4 Water Intake System Pre-start Inspections........................................... 3
1.3.5 Water Intake Pump and Vacuum Pump Manually Operations............. 3
1.3.6Water Intake Pump Manual Stop .......................................................... 4
1.3.7Fault Handling for Water Intake Pump Station ..................................... 4
1.4 Mechanical Accelerated Clarifier System ..................................................... 4
1.4.1 General ................................................................................................. 4
1.4.2 Daily Maintenance ............................................................................... 6
1.4.3 In-Service Operations .......................................................................... 6
1.4.4 Out of Service Operations .................................................................... 7
1.4.5 Sedimentation Basin Sludge Discharging Operations ......................... 7
1.4.7 Sedimentation Local Sludge Discharging Operations ......................... 8
1.4.8 Sludge Pump Auto Control .................................................................. 9
1.4.9 Sludge Pump Manual Operation .......................................................... 9
1.4.10 Sedimentation Basin System Operation and Maintenance .............. 10
1.4.11Sedimentation Basin System Trouble-shooting ................................ 10
1.5 Scrubbing Pressure Type Air Filter ............................................................. 12
1.5.1 Overview ............................................................................................ 12
1.5.2 Operation Sequence ........................................................................... 12
1.5.3 Backwash steps .................................................................................. 12
2Boiler Makeup Water System .............................................................. 13
2.1 Boiler Makeup Water System Control Overview ....................................... 13
2.2 Filtration System Control ............................................................................ 15
2.2.1Active Carbon Filter (ACF) Startup and Shutdown ........................... 15
2.2.2 Back flushing of ACF ........................................................................ 16
3
2.3 Primary Demineralized water System Startup and Shutdown .................... 16
2.3.1 Manually put cation bed, anion bed and mixed bed into operation ... 17
2.3.2 Manually stop cation bed, anion bed and mixed bed ......................... 17
2.3.3Regeneration of Primary Demineralized water System...................... 17
2.3.4 Preparation before cation bed regeneration ....................................... 18
2.3.5 Cation bed regeneration steps ............................................................ 18
2.3.6 Preparation before anion bed regeneration ........................................ 19
2.3.7 Anion bed regeneration steps ............................................................. 19
2.4 Secondary Demineralized water System Startup and Shutdown ................ 19
2.4.1Regeneration of Secondary Demineralized water System .................. 20
2.4.2 The principle of mixed ion exchanger ............................................... 21
2.4.3 Regeneration method ......................................................................... 21
2.4.4 Preparation before mixed bed regeneration ....................................... 22
2.4.5 Mixed bed regeneration ..................................................................... 22
2.4.6 Acid and alkali operation and regeneration precautions .................... 24
2.5 Acid & Alkali System Neutralization Basin Operation .............................. 25
2.5.1Acid & alkali Unloading ..................................................................... 25
2.5.2Tank Truck Acid and alkali Unloading ............................................... 25
2.5.3Metering Tank Acid/alkali Filling ....................................................... 26
2.5.4Operation of Neutralization Basin ...................................................... 27
2.6 Precautions for Acid & Alkali Unloading Work ......................................... 27
2.7 Applications of Rotation Equipments ......................................................... 28
2.7.1Pre-start Inspections ............................................................................ 28
2.7.2Pump Startup Operations .................................................................... 28
2.7.3Pump Shutdown Operations................................................................ 28
2.7.4Precautions for Use ............................................................................. 28
2.8 Ejector Use and Precautions ....................................................................... 29
2.8.1Usage ................................................................................................... 29
2.8.2Precautions and attentions ................................................................... 29
2.9 Ion Exchange and Demineralized water System Product Water Deterioration
Causes and Solutions......................................................................................... 29
2.10Water Treatment Equipment Faults and Solutions ..................................... 30
2.11Rotary Equipment Faults and Solutions ..................................................... 30
3 Chemical Dosing System ..................................................................... 31
3.1 System Overview ........................................................................................ 31
3.2 Operations of Dosing Equipments .............................................................. 32
3.2.1Operations of Phosphate Dosing Equipments .................................... 32
3.2.2Operations of Ammonia Dosing Equipments ..................................... 32
3.2.3Hydrazine Dosing Equipment Operations .......................................... 33
4
3.3 Operation of the Auxiliary Boiler Dosing Device ...................................... 33
3.3.1Operations of Phosphate Dosing Equipments .................................... 33
3.3.2Operations of Ammonia Dosing Equipments ..................................... 34
4Steam & Water Sampling System........................................................ 34
4.1 System Configurations ................................................................................ 34
4.2 System Functions ........................................................................................ 35
4.3 Operations of Steam & Water Sampling Devices ....................................... 35
4.3.1Pre-service Inspections ....................................................................... 35
4.3.2Cooling Water into Service ................................................................. 35
4.3.3High Pressure and High Temperature System into Service ................ 36
4.3.4Supervision during Operating ............................................................. 37
5 Plant Waste Water Treatment System ............................................... 37
5.1The Waste Water Treatment System mainly comprises: .............................. 37
5.1.1 Industrial Wastewater Treatment System ........................................... 37
5.1.2 Industrial Waste Water Treatment System Startup ............................. 40
5.1.3 Operation Principle of the Equipment ............................................... 40
5.1.4 Operation of the system equipments: ................................................. 43
5.2 Sanitary Sewage Treatment System ............................................................ 45
5.2.1Process flow of the sanitary sewage treatment system: ...................... 45
5.2.2Technical Data ..................................................................................... 46
5.2.3Main Technical Specification .............................................................. 46
5.2.4 Operation of the system ..................................................................... 47
5.2.5 Manual Operation Status .................................................................... 48
5.2.6 Auto Work Status................................................................................ 48
5.2.7 Cautions.............................................................................................. 48
5.3 Oil & Water Separator Operations .............................................................. 49
5.3.1 Oily Wastewater Treatment System ................................................... 49
5.3.2 Design of the System ......................................................................... 49
5.3.3 Water quality ...................................................................................... 49
5.3.4 Treatment System for Turbine House Area ........................................ 50
5.3.5 Treatment System for Fuel Oil Tank Area ......................................... 51
5.3.6 Startup and Outage of Oil Depot Area Oil Water Separation System 55
6 Chemical System Operation Manuals ............................................... 59
6.1 Water Treatment System ............................................................................. 59
6.1.1WTP Process Flow .............................................................................. 59
6.1.2 System Control Overview .................................................................. 59
6.2 Operation of Rotary Equipments ................................................................ 59
6.2.1Operation of Centrifugal Pump ........................................................... 59
6.2.2Operation of Piston Metering Pump ................................................... 61
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6.2.3Operation of Roots Blowers................................................................ 62
6.3 Thermal Equipment Steam & Water Supervision Provisions ..................... 63
6.3.1Overview ............................................................................................. 63
6.3.2Chemical Supervision during Unit Startup ......................................... 63
6.3.3Chemical Supervision during Unit Normal Operation ....................... 66
6.3.4Chemical Supervision during Unit Outage ......................................... 68
6.3.5Unit Sampling Point Setting and Analysis Items ................................ 68
6.3.6Operations of Water & Steam Sampling Devices ............................... 69
6.3.7Solutions of Water & Steam Quality Deterioration ............................ 71
6.3.8Operations of Ammonia System ......................................................... 75
6.3.9Operations of Feedwater Hydrazine Dosing System .......................... 76
6.3.10Operations of Phosphate Dosing System .......................................... 78
6.3.11Chemical Supervision of Startup Boiler ........................................... 79
6.3.12Operations of Outage Boiler Maintenance ....................................... 80
6.4 Trouble Shooting ......................................................................................... 81
6.4.1Trouble Shooting of ACF .................................................................... 81
6.4.2Trouble Shooting of Demineralized water Equipments...................... 81
6.4.3Trouble Shooting of Power Faults ...................................................... 84
6.4.4Abnormality Handling of Pump Rotation Equipments ...................... 84
6.4.5 Leakage Handling of Acid & Alkali System ..................................... 86
6.5 Oil & Water Index Control .......................................................................... 86
6.5.1Control Index of Incoming Fuel oil .................................................... 86
6.5.2Control Index of After-treated Heavy Oil ........................................... 88
6.5.3 Control Index of gas turbine inlet fuel oil .......................................... 88
6.5.4Waste Water Discharge Index ............................................................. 89
7Water & Steam Sample Collecting and Determination .................... 89
7.1 Overview ..................................................................................................... 89
7.2 Alkalinity Determination ............................................................................ 90
7.2.1Principles of determination ................................................................. 90
7.2.2Analytical reagent ............................................................................... 91
7.2.3Steps for determination ....................................................................... 91
7.2.4Calculation .......................................................................................... 91
7.3 Acidity Determination ................................................................................. 91
7.3.4Calculation .......................................................................................... 92
7.4 Concentration Determination of Hydrochloric Acid .................................. 92
6
7.4.4Calculation .......................................................................................... 93
7.5 Concentration Determination of Sodium Hydroxide .................................. 93
7.5.1Priciples of determination ................................................................... 93
7.5.3Measurement Procedures .................................................................... 93
7.5.4Calculation .......................................................................................... 93
7.6 Determination of Hardness ......................................................................... 93
7.7 Determination of Ammonia ........................................................................ 95
7.7.3Measurement Procedure ...................................................................... 95
7.7.4Calculation .......................................................................................... 96
7.8 Determination of Hydrazine........................................................................ 96
7.8.4Calculation .......................................................................................... 97
7.9 Determination of Phosphate Radical .......................................................... 97
7.9.3Measurement Procedure ...................................................................... 97
7.9.4 Calculation ......................................................................................... 98
7.10Determination of Dissolved Oxygen.......................................................... 98
7.10.1Priciples of determination ................................................................. 98
7.10.2Analyzer Reagent and Containers ..................................................... 99
7.10.3Measurement Procedures .................................................................. 99
7.11Determination of Silicon Dioxide ............................................................ 100
7.11.1 Principles of determination ............................................................ 100
7.11.2Analytical reagent ........................................................................... 100
7.11.3Measurement Procedures ................................................................ 100
7.12Determination of Ferric ............................................................................ 100
7.12.1Priciples of determination ............................................................... 100
7.12.2 Analytical reagent .......................................................................... 101
7.12.3Measurement Procedures ................................................................ 101
8. Operation of oil analysis instrument ............................................... 102
8.1 101 Series Electric Blast Oven Manual .................................................... 102
8.1.1 Use.................................................................................................... 102
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8.1.2 structural characteristics ................................................................... 102
8.1.3 major technical indicators ................................................................ 103
8.1.4 use of methods.................................................................................. 103
8.1.5 Pay attention to maintenance issues and repairs .............................. 103
8.2 ZHK302 Open Cup Flash Point Automatic Tester ................................... 104
8.2.1Working Theory ................................................................................ 104
8.2.2Structure Characteristics ................................................................... 104
8.2.3Operation instruction......................................................................... 106
8.3ZHB202 Closed-Cup Flash Point Auto-Tester ........................................... 111
8.3.1Working Theory ................................................................................. 111
8.3.2Structure Characteristics .................................................................... 111
8.3.3Operation Instructions ........................................................................112
8.3.4Testing Sample ...................................................................................116
8.3.5 Points of Attention ............................................................................117
8.4 ZHR401 Spontaneous Combustion Point Automatic Tester ......................118
8.4.1 Working Theory ................................................................................118
8.4.2 Operation instruction.........................................................................118
8.4.3 Points of Attention ........................................................................... 120
8.5 ZHSZ601 Petroleum Products Acid Automatic Tester ............................. 121
8.5.1Operation Instruction ........................................................................ 121
8.5.2 Points of Attention ........................................................................... 127
8.6 GAS CHROMATOGRAPH GC-900-SD ................................................. 127
8.6.1 Switch on .......................................................................................... 127
8.6.2 Switch off ......................................................................................... 128
8.7 ZHQ701 Multi-functional Automatic Oscillator ...................................... 129
8.7.1Structure Characteristics (Chart 1) .................................................... 129
8.7.2Operation Instruction ........................................................................ 129
8.7.3 The Use of Thermometer ................................................................. 133
8.7.4 Points for Attention .......................................................................... 133
8.8 KY-101 Coulomb Sulfur Tester ................................................................ 133
8.8.1Structure and Operating Principles ................................................... 133
8.8.2Analysis and Operation Procedures .................................................. 136
8.8.3Daily Operation ................................................................................. 137
8.8.4Common Failure Analysis ................................................................. 137
8.9 ZHL1301 Solidifying Point of Petroleum Products Tester ....................... 141
8.9.1Working Theory ................................................................................ 141
8.9.2Structure Characteristics ................................................................... 141
8.9.3Operation instruction......................................................................... 142
8.9.4Self-checkout..................................................................................... 146
8.9.5Points of Attention ............................................................................ 146
8.10 ZHN1502 Kinematic Viscometer for Petroleum Products ..................... 147
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8.10.1Structure Characteristics ................................................................. 147
8.10.2Testing of sample ............................................................................ 152
8.10.3Points of Attention .......................................................................... 155
8.11 ZHNY1801 Insulating Oil Dielectric Strength Automatic Tester ........... 156
8.11.1Working Theory............................................................................... 156
8.11.2 Operation instruction ...................................................................... 157
8.11.3Testing procedure ............................................................................ 157
8.11.4 Points of Attention.......................................................................... 159
8.11.5Regular Malfunctions ...................................................................... 160
8.12 ZHY901 Lubricating Oil Foaming Characteristics Automatic Tester .... 160
8.12.1 Summarization ............................................................................... 160
8.12.2 Technical Specification .................................................................. 160
8.12.3 Operation Instruction ..................................................................... 161
8.12.4 Sample Testing ............................................................................... 164
8.12.5 Points for Attention ........................................................................ 165
8.13Spectroil M Oil Analysis Spectrometers .................................................. 166
8.13.1Theory of Operation ........................................................................ 166
8.13.2General Operating Requirements .................................................... 166
8.13.3Daily Operator Maintenance ........................................................... 169
9 Use of Water Analysis Instruments .................................................. 171
9.1SX Series Box-type resistance furnace manual ......................................... 171
9.1.1 Structural characteristics .................................................................. 171
9.1.2Four, How to Use .............................................................................. 171
9.1.3Maintenance and Attention ............................................................... 172
9.2 Model DDB-11A Portable Conductivity Meter ........................................ 172
9.2.1 Instructions to the Meter: ................................................................. 173
9.2.2 Operation Keys................................................................................. 173
9.2.3Conductivity measuring .................................................................... 174
9.2.4 Considerations .................................................................................. 178
9.3 Model PHB-4 Portable PH Meter ............................................................. 179
9.3.1 Brief Introduction:............................................................................ 179
9.3.2 Technical Parameter: ........................................................................ 180
9.3.3 Meters Operation: ........................................................................... 180
9.3.4 Considerations:................................................................................. 182
9.3.5 Other Functions for Meter: .............................................................. 184
9.3.6 Adaptation kit for the meter: ............................................................ 185
9.4 OX-12B Type Portable oxygen analyzer .................................................. 185
9.4.1Principle ............................................................................................ 185
9.4.2 Operation As..................................................................................... 185
9.4.3 Terms of Use and maintenance ........................................................ 186
9.5 OIL-2 Type Oil Copy Concentrated Degree Meter Manual ..................... 187
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9.5.1The Working Principle ...................................................................... 187
9.5.2 Instrument Structure ......................................................................... 190
9.5.3 Equipment installation and Use ....................................................... 190
9.5.4 Normal maintenance and precautions .............................................. 193
9.6 Manual Semi-Automatic Gas Analyzer .................................................... 194
9.6.1Principles and Characteristics ........................................................... 194
9.6.2 How to Use ....................................................................................... 194
10 The Safe Use of Chemical Reagent................................................. 197
10.1 Classification of the safety performance of chemical reagents .............. 197
10.1.1 Flammable and explosive chemical reagents ................................. 197
10.1.2 Toxic chemical reagents ................................................................. 197
10.1.3 Corrosive chemical reagent ............................................................ 198
10.1.4 Strongly oxidizing chemical reagents ............................................ 198
10.2 Notes to the use of several chemical reagents ........................................ 198
10.3 Storage and Safe Keeping of Chemicals ................................................. 199
Appendix 1 Fuel Oil Component Analysis Report ......................................... 201
Appendix 2 Canal Water Quality Report ........................................................ 203
10
1Raw Water Pre-treatment System

In Nandipur 425MW Combined Cycle Power Plant, the raw water treatment
capacity is 250m3/h. The water from the once through cooling system branch pipe
to settling water tank, the clarified basin, filter, dosing equipment, water tank and
pumps. All the buried pressure steel pipe will be protected by cathodic protection.
1.1 Function Description
The raw water treatment plant is supply the service water DM water potable
water firefighting water by the clarified, filter, disinfection treated.
1.1.1 Mechanical accelerated clarifierusing the agitator machine finish the mud and
ash return he coagulate reaction, make the particle in raw water contact,
adsorption, settling, and the bigger particle can separate water as soon as possible.
1.1.2 Filterfiltering the outlet of the clarifier water and make it using for the boiler
make up water and potable water.
1.1.3 Water tankusing for store the service water, DM water, and potable water.
1.1.4 Dosing roomprovide the PAM and PAC to raw water treatment plant.
1.2 System Parameters
1.2.1Clarified Water Tank, Firefighting Water Tank
Clarified water tank, firefighting water tank
The canal water clarifier filter potable water tank booster pump terminal
point Dosing sludge disinfection treated
1.2.2 Mechanical accelerated clarifier
Design treated water quantity: 320m3/h
Inlet water content of sand: less than 3kg/m3
Outlet water suspended quantity less than 20mg/l
1.2.3 Filter
Design treated water quantity of one filter: 75m3/h

1
Total treated water quantity: 150m3/h
Inlet water turbidity: less than 20ppm
Outlet water turbidity: less than 5ppm.
1.2.4 Service Water Tank
The service water tank capacity is 700m3, the dimension of tank is

14.8mx14.8m, and depth is 3.5m.
1.2.5 DM Water Tank
The DM water tank capacity is 400m3, the dimension of tank is 16mx8m, and
depth is 3.5m.
1.2.6 Potable Water Tank
The potable water tank capacity is 200m3, the dimension of tank is 7.8mx7.8m,
and depth is 3.5m.
1.3 Deep Well Pump House
1.3.1Deep Well Pump House
The deep well pump house is installed at east of the spill way, total is four
buildings, each pump house equipping one set of deep well.
The main parameter of deep well as flow:
Type: 350JC/K320-65
Design capacity: 320m3/h
Head: 65m
The motor main parameter
Power: 90kW
Voltage: 400V
The total sets: four sets
1.3.2 The Main Principle of Control
1.3.2.1 The deep well pump house in outside of plant is operator on duty;
2
1.3.2.2 Realize the controlling and operating action showing in the control room.
1.3.2.3 The deep well pumps is four, three work one standby.
1.3.2.4 The local button will install the deep well pump.
1.3.3 The requirement of deep well control and monitor.
1.3.3.1 The deep well operating showing and monitor in control room:
a. Pump operating condition.
b. Pump outlet pressure (local display).
1.3.3.2When the power voltage reducing data of normal voltage, extending 315
second, the pump cannot be start.
1.3.3.3 Motor shall be equipped the over current protect facility, when the motor over
load the facility can shut off the loop.
1.3.4 Water Intake System Pre-start Inspections
1.3.4.1 Coupler hood of water intake pump is of good condition, anchor bolts are
complete and fixed firmly, and in addition, the cable and terminal box are in
normal condition.
1.3.4.2 Motors of intake pump and vacuum pump are well insulated.
1.3.4.3 Control box power supply of water intake pump is normal.
1.3.5 Water Intake Pump and Vacuum Pump Manually Operations
1.3.5.1 Water Intake Pump Manual Start
1.3.5.1.1Put vacuum pump AUTO/STOP/MANUAL switch to MANUAL mode on

PLC local panel.
1.3.5.1.2Put water intake pump AUTO/STOP/MANUAL switch to MANUAL mode

on PLC local panel.
1.3.5.1.3Start water intake pump from control panel and open the pump outlet butterfly
valve after 5s when pump outlet pressure above 0.22Mpa.
1.3.5.1.4Check to ensure water intake pump outlet pressure, sealing and vibration are in
normal conditions and maintain pump outlet pressure no less than 0.2Mpa.
1.3.5.1.5Check the pipelines and keep proper records.
3
1.3.6Water Intake Pump Manual Stop
1.3.6.1 Stop the water intake pump.
1.3.6.2 Check pump and pipelines and keep proper records.
1.3.7Fault Handling for Water Intake Pump Station
1.3.7.1 Report to shift leader under the following conditions, if adjustment becomes
useless, stop the pump and start the standby pump.
aAbnormal motor noise.

bBearing temp of pump or motor above 60.
cSerious water leakage from pump flange connection and out of control.
dPump motor over current.
eBearing vibration over 0.1mm/h.
1.3.7.2 Press emergency button to stop the fault pump under the following cases, while
the standby pump must be normally started via interlock, otherwise, start the
standby pump from local and report to the shift leader.
aPersonal safety endangered.
bBearing emits smoke or motor sparks.
cLeakage water endangers motor or equipment submerged.
dSerious vibration up more than 0.16mm.
eBearing temperature up to 80 and handling becomes invalid.
1.4 Mechanical Accelerated Clarifier System
1.4.1 General
The mechanical accelerating clarifier incorporates coagulating reaction and

clarification process together and uses the suspended slurry as the contact
medium to increase the chances for collision among the particles and improve the
coagulation efficiency. The working principle is as following:
The raw water after being dosed flows to the triangle water distribution tank
and then flows through the adjust crevice at the bottom to primary reaction
chamber, while the air in the water will be discharged from the blow down pipe
4
extended out of the water surface at the top of the triangle tank; the water in the
primary reaction chamber is then agitated and lifted to the secondary reaction
chamber where further coagulating reaction is carried out to conglomerate bigger
particles, then water flows to the flow guide chamber from the edges and then to
the separation chamber; the abrupt increase of the section area of water in the
separation chamber will decrease the flow velocity abruptly resulting in the
settlement of slurry and upper flow of clean water through the water collection
tank; the settled slurry backflows through the backflow crevice to the primary
reaction chamber and then mix with the raw water from the triangle weir. Inside
the separation chamber, part of the slurry will be treated by the slurry
concentrating funnel and removed periodically; the sludge drain valve at the tank
bottom is used to adjust the content of the slurry. The lifted and circulated return
water flow is 3 5 times that of the treatment capacity; after a period of
circulation process, the sludge amount will increase and shall be discharged as per
requirement to ensure the specified settle ratio.
The structure of the clarifier is shown in following sketch
1. Primary reaction chamber; 2.Secondary reaction chamber
3. Agitator; 4.Sludge scraper
5. Separation chamber; 6.Packing layer
7. Water collection tank; 8.Adjust wheel
9. Sludge funnel; 10.Pre-embedded sludge discharge pipe

5
1.4.2 Daily Maintenance
1.4.2.1Frequent inspection of the equipment to ensure proper condition and all the
connecting parts are firmly fixed;
1.4.2.2Check the oil level of the speed reducer regularly to ensure the oil level reaches
the level scale; after 3 months of operation, the oil shall be replaced;
1.4.2.3It is suggested to check and maintain the underwater parts once every half year or
as per the actual operation conditions.
1.4.3 In-Service Operations
1.4.3.1Open sedimentation basin sludge scraper bearing lubricating valve and
Differential pressure transmitter water valve
1.4.3.2 Open the basin manual water inlet valve to fill water inside.
1.4.3.3When sedimentation basin is full, start the sludge scrapper via panel. Then check
running conditions of scrapper and other in-operation devices.
1.4.3.4Start the stirrer:
a) Put the stirrer local panel switch to MANUAL mode, then press LOW SPEED
button to start the stirrer with no load.
b) When motor of stirrer runs normally, put the power switch on speed regulation
panel to ON position and slowly turn the speed adjusting knob along
clockwise direction to regulate the speed to 1-8 rpm.
c) Start lime dosing system to fill into sedimentation basin.
d) Take sample from top of secondary reaction chamber and ensure the PH value
up to above 10, then put polymeric ferric sulfate into the sedimentation basin.
e) Open manual flushing valve of sludge discharging pipe, manual sludge

discharging valve and intermediate sludge discharging valve.
f) Put the sludge discharging to auto mode from master panel and set the
accumulated discharging flow. (Initial startup stage, the setting accumulated
flow is 1-4 times of the sedimentation basin inlet flow.)
g) Put switch of sludge discharging local panel to REMOTE position, and

switches of all pneumatic valves to AUTO mode.
h) Open the following valves as sludge basin outlet valve, sludge pump cooling
6
water valve, sludge pump inlet and outlet valves, flushing water manual valve
and sludge discharging pipe outlet valve.
i) Put sludge pump start/stop switch to auto mode from master panel.
1.4.4 Out of Service Operations
1.4.4.1Stop lime dosing and poly ferric sulfate dosing.
1.4.4.2 Close sedimentation basin inlet manual valve.
1.4.4.3Stirrer shutdown
a) Slowly turn the stirrer adjusting knob along the counter clockwise
b) Put the power switch to OPENING position, direction to decrease its speed to
zero.
c) Select the panel switch to OPENING position and stop the stirrer.
d) Manually discharge sludge via the master panel till clear water comes out, then
press STOP button from local panel and stop sludge scrapper, close scrapper
lubrication water valve.
e) Remove auto sludge discharging program from master panel.
f) Close sedimentation manual sludge discharging valve, manual flushing valve

and intermediate sludge discharging valve.
g) When sludge basin level is low, stop sludge pump via putting the master control
switch to OPENING position.
h) Close sludge discharging outlet valve, sludge pump inlet and outlet valve,
manual flushing valve and sludge basin outlet valve.
1.4.4.4If the sedimentation basin is out of operation for no more than 3 days, just keep
the sludge scrappers running, otherwise, stop the scrapper and prepare for
sludge discharging.
1.4.5 Sedimentation Basin Sludge Discharging Operations
1.4.5.1 Main Sludge Discharging Button and Displays
aSludge discharging control of master panel has two buttons P1 & P2
Functions of P1:
Select/ON/OFF/Setting
7
Functions of P2:
bDisplay functions
Digitals in part 1 shows the sedimentation basin No. and P means sludge
discharging.
Digitals in part 2 have 4 digits, the first means the discharging step and other
3 digits mean execution time.
1.4.6 Sludge Discharging Button Operations and Displays
SELECTION: press P1 for 1s can select any sedimentation to perform sludge

discharging process and the P will not flash on display.
AUTO: press P2 and hold for 3s, when number inside and letter P doesnt flash
the sludge discharging mode changed to AUTO.
MANUAL: press P2 and hold for 3 s, when number inside flashes but P doesnt,
the sludge discharging mode changed to MANUAL.
SETTING: press P1 and hold for 3s, the letter P flashes and accumulated
sedimentation flow shows up, the program is of sludge discharging setting. If
press P1 and hold for 3s again, the program back to the original one.
ACCUMULATION: for the setting program, press P2 to increase/decrease the

accumulation flow displayed till up to the required value.
Sludge Discharging: press P1 for 1s, the display shows progress and time used,
the programmed discharging begins.
MAINTAIN: during discharging, press P2 for 1s, if the display execution step
and time will not change, the discharging process is maintained.
JUMP: during MAINTAIN step, press P2 for 1s to release the maintain mode,
the program will conduct the next step.
1.4.7 Sedimentation Local Sludge Discharging Operations
1.4.7.1 Release auto sedimentation sludge discharging program from master panel.
1.4.7.2 Select LOCAL from local panel
1.4.7.3 Open pneumatic valve V9 to discharge sludge.
1.4.7.4 Open pneumatic valve V11 for sludge pipe flushing.
1.4.7.5 Close V9 & V11 after the above flushing step.

8
1.4.7.6 Switch the mode from local panel to REMOTE
1.4.7.7 Put sludge discharging program to AUTO from master panel.
1.4.8 Sludge Pump Auto Control
1.4.8.1 Put the sludge pump switch on master panel to AUTO.
1.4.8.2 When sludge basin level up to low level electrode, the low level indication lamp
turns on.
1.4.8.3 When sludge basin level up to high level electrode, the high level indication
lamp turns on, and sludge pump starts.
1.4.8.4 When sludge basin level up to the over high level electrode, the over high level
indication lamp flashes and alarms, the sedimentation sludge discharging stops.
1.4.8.5 When the sludge basin level drops to the high level, alarm releases. High level
indication lamp stops flashing and keeps on.
1.4.8.6 When sludge basin level drops lower than high level, the high level indication
lamp turns off, while if the level drops lower than low level electrode, the low
level indication lamp turns off and flushing water pneumatic valve opens.
1.4.8.7 After 3 minutes flushing, the flushing water pneumatic valve closes and sludge
pump stops.
1.4.9 Sludge Pump Manual Operation
When pump needs maintenance and sludge pump manual operation becomes
necessary, follow operations below:
1.4.9.1 Put sludge pump mode on the master panel to MANUAL and start the pump.
1.4.9.2 When sludge basin level low, put local panel selection switch to LOCAL and
open circulating pneumatic valve for circulation.
1.4.9.3 When the level rises, close the circulating valve.
1.4.9.4 If pump shutdown needed, open the pump flushing water pneumatic valve for 3
minutes flushing, then close the flushing valve and put the pump mode to
REMOTE.
1.4.9.5 According to the operating conditions, turns the sludge selection switch to
AUTO or OFF position.
9
1.4.10 Sedimentation Basin System Operation and Maintenance
1.4.10.1Auto sedimentation basin inlet flow control
In calm water tank and filter inlet there will be configured with one Troll
level meter respectively send the level signal to comparator. After that, the more
intensive 0.02-0.1mPa signal is sent to control butterfly valve V3 opening,
making inlet flow varies according to the tank level.
The sedimentation inlet pipe will be equipped with one orifice plate. The
differential signal from orifice will collected by differential sensor and root
abstractor, then outputting one 4-20mA signal to control PFS and lime dosing
quantity making which form direct proportion with sedimentation flow.
1.4.10.2 The setting of sedimentation sludge discharging accumulation value must be

adjusted as the basin working conditions.
aAt the sedimentation basin initial startup stage, accumulation value of

sludge discharging must 2-3 times of the basin inlet flow, which will
facilitate the sludge formation.
bWhen top and bottom sludge concentration difference in primary reaction

chamber is within 10-30%, the accumulated sludge discharging must be
between 1.5 to 2times of the sedimentation inlet flow.
cWhen sedimentation basin in operation and the primary reaction chamber

top and bottom concentration more than 30% or less than 10% or
concentration of separation section over high or over low, it must
properly increase or decrease sludge discharging amount under the
original accumulation value setting.
1.4.10.3Measurement of sedimentation basin differential sludge concentration
aUse graduated cylinder to take sludge sample about 100ml from the
sampling pipe.
bKeep sample still for 10minutes.
cMeasure the depositing height in cylinder and records in percentage.
1.4.11Sedimentation Basin System Trouble-shooting

No. Symptoms Potential Causes Solutions
Deteriorated Over load operation Adjust the load within allowable
1
basin outlet Sharp load variation range.
10
water Over high sludge Stop load regulation and never

layer regulate the load till load becomes
Improper/Insufficie stable.
nt chemical dosing Increase sludge discharging or
High raw water increase chemical dosing
turbidity and small Adjust or increase chemical dosing.
particles Reduce load or dose more flocculant.
Low inlet water Reduce load and dose more
temp. flocculant, shorten flushing time or
Over low raw water fill with slurry.
turbidity
Improper stiring Adjust impeller speed till water
Poor caused abnormal becomes clear, then restore to the
sedimentati circulation; former speed. If the water quality
on High raw water deteriorated again, it can be judged
circulation, turbidity, low speed as too high speed impeller and too
2
the sludge impeller and much circulation or sometimes it
flow and accumulated sludge also too low impeller speed and poor
sludge layer at circulation stirring. Then adjust speed to remove
disordered. portion. the concentrated or accumulated
portion.
Too big flow during Control the output within range of
initial startup; 30-40%;
Sudden load up Balance adjustment;
during operating; Control chemical dosing amount;
Too much chemical Adjust the stirrer speed;
Sedimentati dosing; Reduce output for 1-1.5 hrs, and then
on basin Two high stirrer back to the normal running state.
3 alum floc speed Control for normal sludge
floating Sudden temperature discharging;
upward drop. Close the backflush valve.
Insufficient sludge
discharging;
Sludge pipe
backflush valve still
open.
Sedimentati Too much chemical Adjust the dosing amount;
on basin dosing; Control the sludge discharging
4
water turns Too much sluge amount.
white color discharging.
Sludge discharging Close the sludge discharging valve
Sedimentati
valve leaks or did or repair;
on output
5 not closed; Check and adjust inlet water
capacity
Too low inlet water pressure.
reduced.
pressure.
11
1.5 Scrubbing Pressure Type Air Filter
Design treated water quantity of one filter: 75m3/h
Total treated water quantity: 150m3/h
Inlet water turbidity: less than 20ppm
Outlet water turbidity: less than 5ppm.
1.5.1 Overview
1.5.1.1 Plant raw water by automatic water purifier water into the middle basin, the
middle water pump into the gravity type air scrubbing Filter tank,
1.5.1.2 Swab pressure type air filter water by gravity, gravity in uniform into the
equipment by the water distribution device, from top to bottom by the uniform
water through the filter layer under the cap to the perforated plate of watershed,
natural filtering.
1.5.1.3 Filtration through the drainage pipe after the water flows into the clear water
tank storage device, when the box is full of water, water overflows from exports,
into the water tank.
1.5.1.4 When the filter pressure difference is bigger or slightly higher than normal water
turbidity, can use air scrubbing function, and make the back flush thoroughly,
indeed Effluent water quality.
1.5.2 Operation Sequence
1.5.2.1 Before running to check all electric control equipment, valves are in normal
condition;
1.5.2.2 A1 inlet valve open A1 device; A1, emptying is wash valve.
1.5.2.3 About 10 ~ 20 min water clear, namely, open water unicom valve no. A1, close
No. A1 vent is wash valve; A1 scrubbing air filter into the running state.
1.5.3 Backwash steps
Equipment operation for a period of time, due to intercept raw water

impurities filtration chamber increasing resistance, after former filter differential
pressure is more and more big, filter before pressure caused by impurities
mandatory wear filter layer, the effluent turbidity increased; At this time should
be timely Back flush filter material layer, using air scrubbing process, is the
12
intercept at the bottom of the impurities completely cleared away. The filter the
best resuming intercept impurities, the operation steps are as follows.
1.5.3.1 A2 inlet valve open A2 device, close no. A1 equipment A1 fill valve, water
unicom valve no. A1.
1.5.3.2 Open A2 emptying valve, about 10 ~ 20 min water clear, namely, open Unicom
A2water valve, close no. A2 vent valve. A2 scrubbing air filters into the running
state.
1.5.3.3 Open A1, backwash water valve, A1, intake valve
1.5.3.4 Start fan (A1, A2 two turbine running state: one with a case, fan outlet manual
valve should be keeping in the open State).
1.5.3.5 About 10 ~ 20 min closing A1 inlet valve and fan, open A1 back flush inlet valve
and start the backwash water pump (A1, A2 two pumps running status: one with
a case, import and export pump manual valve should be kept in 4-5 min/open)
Times;
1.5.3.6 About 4-5min, close the backwash water pump, A1, backwash water valve, A1,
backwash water valve (electric); A1, scrubbing air filter backwash end to enter
standby mode.
2Boiler Makeup Water System
2.1 Boiler Makeup Water System Control Overview
System operation and regeneration are controlled by program with pneumatic

operating valves, manual isolation valves and maintenance service valves. The
primary desalination system controls conductivity for output water via anion bed
outlet, and the mixed bed also be controlled by the conductivity at its outlet. The
waste water treatment system applies automatic operation mode.
Equipment Specification
Item Equipment Name Specification QTY
1 Raw Water Tank =500m3 1
2 Raw Water Pump KH125/160--22/2 2
Q=150 m3/h P=0.3MPa N=22kW
3 Back Wash Water KH150/250B--11/4 2
Pump Q=150 m3/h P=0,3MPa N=11kW
4 Activated Carbon Filter 322812 2
H=2500mm
5 Double Fluidized Bed 222410 HRCv=800mm 2
Cation Exchanger HRCs=800mm
13
6 Decarbonator 20168 HLDG=2000m 1

7 Decarbonator Blower CQ21--J Q=3600 m3/h 1
P=1.5Kpa N=4kW
3
8 Intermediate Water V=10 m 282010 1
Tank
9 Intermediate Water KH125/200A 2
3
Pump Q=150 m /h P=0.45MPa N=30kW
10 Double Fluidized Bed 222410 HRAv=1200mm 2
Anion Exchanger HRAs=800mm
11 Mixed Ion Exchanger 202410 HANION=1000mm 2
HCATJON=500mm
12 Resin Trap 426 6
3
13 Dm Water Tank V=500 m 9562 H=8927mm 2
N=22kW
14 Dm Water Pump (To KH100/200--22/2 N=18.5kW 2
Matn Building) Q=100 m3/h P=0.45MPa
15 Service Dm Water KH100/200A--18.5/2 2
Pump Q=70 m3/h P=0.45MPa N=3.0kW
16 Acid Unlorage Pump IHF65--50--125 2
Q=25 m3/h P=0.2MPa
17 Acid Storage Tank 3228 V=50 m3 2
18 Acid Metering Pump Q=3.0 m3/h 2
(For Cation Exchanger) P=0.4MPa N=1.1kW
19 Acid Metering Pump Q=1.0 m3/h 2
(For Moxed-Ion P=0.4MPa N=1.1kW
Exchanger)
20 Acid Fume Absorber 500 2
21 Caustic Unloading KH65/125--4/2 2
3
Pump Q=25 m /h P=0.2Mpa N=4.0kW
22 Caustic Storage Tank 3228 V=50 m3 2
23 Caustic Metering Pump Q=3.0 m3/h P=0.4Mpa N=1.1kW 2
(For Anion Exchanger)
24 Caustic Metering Pump Q=1.0 m3/h P=0.4Mpa N=1.1kW 2
(For Moxed-Ion
Exchanger)
25 Roots Blower BK6008 Q=10N m3/min 2
P=0.06MPa N=18.5 KW
26 Air Storage Tank V=7 m3 16168 P=0.8MPa 2
27 Waste Water Basin V=200 m3 2
28 Waste Water Pump 100FZB--30L 4
3
Q=100 m /h P=0.3MPa N=22kW
29 Cation Resine Cleaning 222410 1
Vessel
30 Anion Resine Cleaning 222410 1
Vessel
14
31 Hydrazine Suction Q=100L/min P=0.05MPa 1

Pump
32 Hydrazine Metering 800 V=0.05MPa 1
Tank
33 Hydrazine Metring Q=15L/h P=1.0MPa 2
Pump (Make Up
Water)
34 Caustic Metering Tank V=2 m3 13126mm 1
(For Anion Exchanger)
35 Caustic Metering Tank V=1 m3 10126mm 1
(For Mixed Ion
Exchanger)
36 Acid Metering Tank V=2 m3 13126mm 1
(For Cation Exchanger)
37 Acid Metering Tank V=1 m3 10126mm 1
(For Mixed Ion
Exchanger)
38 Dm Water Pump KH65/200--7.5/2 2
3
(To Oil Area) Q=30 m /h P=0.45MPa N=7.5kW
2.2 Filtration System Control
2.2.1Active Carbon Filter (ACF) Startup and Shutdown
Two sets of ACFs (one in operation, the other one standby) are equipped with
pneumatic diaphragm valves for equipment inlet, outlet, back-flushing inlet,
back-flushing outlet and air ventilation. Each ACF is configured with flowmeter at
inlet and differential pressure for inlet and outlet. Processes for ACF as operation
and back flushing can all realize automatical control. The job siteis arranged with
operating panel, so operation of the equipments can be from the local panel, and the
relevant parameters will send to the central control computer for control room
supervision. The jobsite panel can realize auto or manual operation via the
AUTO/MANUAL switch. The ACF back flushing are doubly controlled by
accumulated output water flow (adjustable) and inlet & outlet differential pressure
(adjustable). When the above flow and differential pressure up to the setting value
on computer for 10minutes, the ACF must be stopped and be prepared for back
flushing, simultaneously, the other filter starts.
2.2.1.1 Startup of active carbon filter
a. Water filling: Open inlet valve and exhaust valve, and start raw water pump.
b. Rinse: After the exhaust valve outlets water, open the conventional flushing drain
valve and close the exhaust valve to flush until the outlet water is clear.
15
c. Put into operation: open the outlet valve, and close the conventional flushing
drain valve.
2.2.1.2 Active carbon filter outage
a. Stop raw water pump.
b. Close filter inlet and outlet valves.
2.2.2 Back flushing of ACF
Conditions of ACF back flushing:
a. When accumulated flow up to 2000 m3, auto flushing begins.
b. When inlet and outlet water differential pressure up to 0.05MPa, auto flushing
starts.
c. Precondition for back flushing: the clear water tank must have sufficient water
for back flushing, and the back flushing pump is of normal condition for use.
2.3 Primary Demineralized water System Startup and Shutdown
During normal water production, the cation and anion beds will run or stop
simultaneously. During auto mode operating, the intermediate water tank level
controls cation exchanger startup and shutdown. When the tank level below the
high level, cation exchanger starts for water production, while when tank level is
high, the exchanger stops. Simultaneously, during operation, intermediate water
tank level and demineralized water tank level both control the anion bed operation,
when intermediate tank level above low level and demineralized water tank below
high level, anion exchanger begins to produce water; while, when intermediate tank
level drops to low level and demineralized water tank level above high level, the
anion exchanger stops.
16
2.3.1 Manually put cation bed, anion bed and mixed bed into operation
2.3.1.1 Open cation bed inlet valve, exhaust valve and active carbon filter outlet valve.
2.3.1.2 After cation bed exhaust valve outlets water, open the conventional flushing
drain valve and close exhaust valve.
2.3.1.3 After the cation bed outlets water normally, start up the carbon removal fan,
open cation bed outlet valve and close cation bed conventional flushing drain
valve.
2.3.1.4 After the water level of the middle tank reaches more than 2/3, open anion bed
inlet valve and exhaust valve.
2.3.1.5 After anion bed exhaust valve outlets water, open the conventional flushing
drain valve and close exhaust valve.
2.3.1.6 After anion bed outlets water normally, open mixed bed inlet valve and exhaust
valve, open anion bed outlet valve and close anion bed conventional flushing
drain valve.
2.3.1.7 After mixed bed exhaust valve outlets water, open the mixed bed conventional
flushing drain valve and close exhaust valve.
2.3.1.8 When the mixed bed water conductivity is less than 0.2s/cm or SiO2 is less than
20g / L, open the mixed bed outlet valve, close mixed bed conventional
flushing valve, and restrict the water into the desalination water tank.
2.3.2 Manually stop cation bed, anion bed and mixed bed
2.3.2.1 Stop raw water pump, and close cation bed inlet and outlet valves.
2.3.2.2 Stop intermediate water pump, and close anion bed inlet and outlet valves.
2.3.2.3 Close mixed bed inlet and outlet valves.
2.3.3Regeneration of Primary Demineralized water System
The cation and anion exchangers are of two lines, one line in operation and the
other standby, regeneration of which depends on anion outlet water conductivity.
When anoin outlet water conductivity more than 10us/cm for 10minutes, the cation
and aion exchangers of this line are exhausted and to be regenerated, then the other
line are activated for operation. Regeneration conditions: regeneration process
needed or not depends on the anion bed outlet conductivity. When conductivity is
up to setting value, regeneration process begins. While, if any one of preconditions
17
for regeneration as neutralization basin not up to high level, regeneration pump not
in operation, acid & alkali metering tank not drop to low level is met, regeneration
process cannot proceeds.
2.3.4 Preparation before cation bed regeneration
2.3.4.1 When the acid reserves are sufficient, open the manual outlet valve of the acid
storage tank that is ready to run.
2.3.4.2 Cation bed regeneration system, compressed air system and waste water
disposal system are in standby mode, and air tank pressure is normal.
2.3.4.3 Open the manual inlet valve of the cation bed regeneration pump.
2.3.4.4 Check and make sure the cation bed regeneration system is normal.
2.3.5 Cation bed regeneration steps
2.3.5.1. Back flushing
Open the outlet valve of the acid storage tank, open the inlet acid valve of the
cation acid metering tank, make the acid reach the mark in the metering tank.
2.3.5.2. Charge regeneration solution
Open equipment regeneration solution inlet valve (fully open), back flushing
drainage valve and then ejector inlet valve, regulate the flow to 19 - 27T / H and
maintain it for three minutes, and then open the concentrated acid valve. The first
step: regulate regeneration solution concentration to 0.6% (specific gravity 1.003),
and maintain it for 50 minutes. The second step: regulate regeneration solution
concentration to 1.0%, and maintain it for 30 minutes. The third step: regulate
regeneration solution concentration to 2.0%, and maintain it for 50 minutes.
2.3.5.3. Replacement
After the charging of acid is completed, close concentrated acid valve, and
leave the remaining valves unchanged. The flow is 36T / H. Continue to flush for
60 minutes.
2.3.5.4. Conventional flushing
After the replacement is completed, close all valves, open exhaust valve,
conventional flushing drainage valve and inlet valve, and close the exhaust valve
after the exhaust valve outlets water. The flushing flow is about 60 - 70T / H. Flush
until the outlet water has no hardness, and the acidity stable sodium is <100g / L.
18
Then it is qualified standby.
2.3.6 Preparation before anion bed regeneration
2.3.6.1 When the alkali reserves are sufficient, open the manual outlet valve of the alkali
storage tank that is ready to run.
2.3.6.2 Anion bed regeneration system, compressed air system and waste water disposal
system are in standby mode, and air tank pressure is normal.
2.3.6.3 Open the manual inlet valve of the anion bed regeneration pump.
2.3.6.4 Check and make sure the regeneration system is normal.
2.3.7 Anion bed regeneration steps
2.3.7.1. Back flushing
Open outlet valve of the alkali storage tank, open inlet alkali valve of the
anion bed, make the alkali reach the mark in the metering tank.
2.3.7.2. Charge regeneration solution
Open equipment regeneration solution inlet valve (fully open), back flushing
drainage valve and then ejector inlet valve, regulate the flow to 15---23T/H and
maintain it for three minutes, and then open the concentrated alkali valve. The first
step: regulate regeneration solution concentration to 0.6% (specific gravity 1.003),
and maintain it for 50 minutes. The second step: regulate regeneration solution
concentration to 1.0%, and maintain it for 30 minutes. The third step: regulate
regeneration solution concentration to 2.0%, and maintain it for 50 minutes.
2.3.7.3. Replacement
After the charging of alkali is completed, close concentrated alkali valve, and
leave the remaining valves unchanged. The flow is 15---23T/H. Continue to flush
for 60 minutes.
2.3.7.4. Conventional flushing
After the replacement is completed, close all valves, open exhaust valve,
conventional flushing drainage valve and inlet valve, and close the exhaust valve
after the exhaust valve outlets water. The flushing flow is about 60--80T/H. Flush
until the water conductivity is 10S/cm and SiO2 is 100ug / L. Then it is
qualified standby.
2.4 Secondary Demineralized water System Startup and Shutdown

19
Mixed bed and demineralized water pump are of synchronous operation mode.
Startup and shutdown of the two equipments are subjected to the demineralized
water tank level and refined water (anion bed outgoing water) tank level. When
level is low, mixed bed starts and when level high, mixed bed and demineralized
water pump stops. While, if the demineralized water tank level is above low level
and refined water level below high level, the bed and pump begins to produce water;
if demineralized water tank level is below low level and refined water level high,
the pump and mixed bed shuts down. During completely automatic operation,
startup and shutdown of demineralized water pump and mixed bed are subjected to
demineralized water tank and refined water tank level. when the demineralized
water tank level is above low level and refined water level below high level, the bed
and pump begins to produce water; when demineralized water tank level is below
low level and refined water level high, the pump and mixed bed shuts down.
2.4.1Regeneration of Secondary Demineralized water System
The plant is configured with 2 sets of mixed bed, one in operation and the
other one as standby. Regeneration of the bed is controlled by anion outlet water
silicon leakage rate and conductivity two factors. When the two factors out of limits
for 10 minutes, the bed resin become exhausted and bed enters into regeneration
mode, while, the other bed activates for service.
20
Mixed Exchanger Schematic Figure
2.4.2 The principle of mixed ion exchanger
The mixed bed is filled with anion and cation exchange resins. Put anion and
cation exchange resins in the same exchanger, and mix them evenly before running.
Mixed ion exchanger can be regarded as a multi-stage double-bed. The salt
containing anions and cations in water are exchanged by resins via this exchanger
and then produce high-purity water. In the mixed bed, anions and cations are mixed
with each other evenly, so anions and cations exchange and reaction are almost
simultaneous. Or put it in another way. The water cations and anions exchange is
repeatedly staggered, the H + generated by H type exchange and the OH- generated
by OH type exchange cannot accumulate, which basically eliminates the effect of
counter-ions, and ensures thorough exchange.
The primary pure water that enters the mixed bed is good and the exchanger
load is small, so the resin exchange capacity is exhausted after a long time.
2.4.3 Regeneration method
The mixed bed adopts internal regeneration, which means, making use of the
21
different specific gravities of two kinds of resins, adopting back flushing to make
cations and anions exchange resins completely separated (cation resins deposit,
while anion resins float), and enabling cation resins to regenerate through acid and
anion resins to generate via caustic soda.
2.4.4 Preparation before mixed bed regeneration
3.4.4.1 When the acid and alkali reserves are sufficient, open the manual outlet valve
of the acid and alkali storage tank that is ready to run.
3.4.4.2 Mixed bed regeneration system, compressed air system and waste water
disposal system are in standby mode, and air tank pressure is normal.
3.4.4.3 Open the manual inlet valve of the mixed bed regeneration pump.
3.4.4.4 Check and make sure the regeneration system is normal.
2.4.5 Mixed bed regeneration
2.4.5.1 Open acid unloading valve and alkali unloading valve of PH metering box, fill
acid and alkali liquid separately to the mark of liquid level meter of the PH
metering box, and make the preparations before mixed bed regeneration. It is
recommended to carry out regeneration while the mixed bed is re-put into
operation.
2.4.5.2 Back flushing and stratification
2.4.5.3 Open mixed bed back flushing drain valve, exhaust valve and back flushing
inlet valve, regulate the back flushing flow via the middle pump outlet water,
check whether there is resin and flush until the outlet water is colorless and
transparent.
2.4.5.4 Still stratification
After the back flushing is completed, stop the middle pump, and close mixed
bed back flushing inlet valve, drain valve and exhaust valve. Let it still for 20
minutes. If the anion and cation resin interface is unclear, repeat the back flushing
stratification steps.
2.4.5.5 Drainage
Open conventional flushing outlet valve and outlet water for about nine
minutes or so. Outlet water until the water level reaches the mark that is 200mm
above the anion resin surface. Close conventional flushing outlet valve.
22
2.4.5.6 Charge regeneration solution
Open acid and alkali ejector inlet valve, middle outlet valve, mixed bed acid
inlet valve and alkali inlet valve, open desalted water to mixed bed acid inlet and
alkali inlet valves, start the regeneration pump and carry out pre-ejection for 3-5
minutes. Then open the injector acid inlet and alkali inlet valves to carry out
regeneration for 25-30 minutes. Acid concentration is 3-5% and alkali
concentration is 2-3%. Acid concentration and alkali concentration can be
regulated via the manual diaphragm valve at the outlet of the PH metering box. The
rate of the regeneration solution that passes through the mixed bed is controlled at
4m / h.
2.4.5.7 Replacement
After the charging of regeneration solution is completed, close acid and alkali
ejectors acid inlet valve and alkali inlet valve, and continue to open the
regeneration pump to charge water into the mixed bed to carry out replacement.
The replacement time is 30-40 minutes.
2.4.5.8 Conventional flushing of anion resins
Stop regeneration pump, close acid and alkali ejector inlet valve, and close
mixed bed middle outlet valve, acid inlet and alkali inlet valves. Open mixed bed
inlet valve to fill water into the mixed bed. After the mixed bed is filled full with
water, open the middle outlet valve, close exhaust valve and carry out conventional
flushing of anion resins. The conventional flushing time is 20-30 minutes.
2.4.5.9 Conventional flushing of cation resins
Open conventional flushing outlet valve, and close middle outlet valve after
the valve is in place, to carry out conventional flushing of cation resins. The
conventional flushing time is 20-30 minutes.
2.4.5.10 Mixing of anion and cation resins
Open mixed bed conventional flushing outlet valve, exhaust valve, back
flushing outlet valve, drain water of the mixed bed for eight minutes, and close the
conventional flushing outlet valve until the water level reaches the mark that is
200mm above anion resin surface. After water drainage is completed, open air
storage tank outlet valve and compressed air inlet door, and carry out resin mixing
for 3-5 minutes. After the mixing of resins is completed, close the air storage tank
outlet valve and compressed air inlet valve. Observe through the peephole to see
whether the resins are mixed evenly; otherwise repeat resin mixing steps.
23
2.4.5.11 Drainage
After the resin mixing is completed, close mixed bed air intake valve, quickly
open conventional drainage valve to drain water for 30-60S. Close conventional
flushing drainage valve and back flushing drainage valve until the water level
reaches resin surface.
2.4.5.12 Conventional flushing
Open mixed bed inlet valve and exhaust valve, fill water into the mixed bed.
After the mixed bed is filled full with water, open the conventional flushing
drainage valve, open conductivity meter valve and silicon meter valve to put
conductivity meter and silicon meter into operation, close the exhaust valve and
carry out conventional flushing of resins. The conventional flushing time is
20-30min.
2.4.5.14 Standby:
When the conventional flushing outlet water is under the state with SiO2
20g / L and DD 0.2S/cm, close the inlet valve, conventional flushing drainage
valve, conductivity meter valve and silicon meter valve to stop conductivity meter
and silicon meter, and close inlet and outlet manual valves. Then, the mixed bed is
switched to standby state.
2.4.6 Acid and alkali operation and regeneration precautions
2.4.6.1 Acid and alkali operation precautions
2.4.6.2 All acid and alkali devices on site should be marked with warning signs.
2.4.6.3 The operator should wear acid and alkali protective articles while working.
There should be emergency medicine and industrial sources on site.
2.4.6.4 If any acid or alkali is found leaked to the ground or outside of the container,
promptly rinse with water.
2.4.6.5 Mixed bed regeneration precautions
2.4.6.6 Before acid and alkali are filled into the mixed bed, they must be thoroughly
stratified with clear boundaries; otherwise anion and cation resins cannot
completely regenerate, which will affect the quality of the outlet water.
2.4.6.7 After mixed bed regeneration is completed, make sure the cation and anion
resins are mixed evenly; otherwise the conventional flushing time may be
prolonged or the conductance cannot be washed out after a long time. When
24
such phenomenon appears, fill water again to mix and carry out conventional
flushing again. If the conventional flushing still fails, repeat the regeneration.
Firstly eject, and repeat the regeneration at the time about one minute after the
regeneration pump outlet water enters the mixed bed through the ejector. Time
and other parameters are subject to the debugging data.
2.5 Acid & Alkali System Neutralization Basin Operation
2.5.1Acid & alkali Unloading
Preparations
2.5.1.1 Ensure that acid/alkali tank truck/train is ready for unloading, acid/alkali
reservoir tank level is low and the unloading pump is in standby, in addition, all
valves are closed and free of leakage, the pump seal water line is unblocked.
2.5.1.2 Timely take samples from acid/alkali tank truck/train for lab analysis. Ensure
the sample quality is good and keep a proper record, if which cannot meet the
requirements, never unload and report to the relevant dept.
2.5.1.3Inspect to ensure the siphon hose and siphon tank are of good condition and
connected tightly.
2.5.1.4 High elevation acid/alkali tank reservoirs are in standby.
2.5.1.5 Open acid mist absorber inlet valve to put the absorber into service.
2.5.1.6Special rubber hose for acid/alkali unloading is free of breakage, otherwise
repair or replace.
2.5.1.7Completed with necessary tools as iron wire, pincer pliers, spanner, wincher, etc.
2.5.1.8 Pressure of emergency flushing source water must be sufficient, and if clear
water pump stops, the emergency flushing must be activated.
2.5.2Tank Truck Acid and alkali Unloading
2.5.2.1Connect the special rubber hose to the truck tank flange, for which must paymore
attention to do not connect wrongly. Open tank acid/alkali outlet valve,
emergency acid or alkali pump inlet valve, pump sealing water inlet valve, high
elevation acid/alkali reservoir tank inlet and emergency pump vent valve. When
acid or alkali overflows from the emergency pump vent valve, close the valve.
Open emergency flushing pipe outlet valve to flush the overflowed or pump
25
leaked acid or alkali.
2.5.2.2Start emergency acid/alkali unloading pump. When the pressure up to 0.3Mpa,

slowly open emergency pump outlet valve and regulate outlet pressure to
0.2Mpa to filling acid/alkali to the reservoir tank.
2.5.2.3Check to ensure acid/alkali already flows into the high elevation tank, otherwise,
check and restart unloading pump again.
2.5.2.4During unloading, strictly check and supervise to avoid leakage and environment
pollution.
2.5.2.5When pressure of unloading pump suddenly drops or gauge indicator pin swings
sharply, it means the truck tank empties, then stop the unloading pump and close
the pump inlet and outlet valve as well as high elevation reservoir tank inlet.
2.5.2.6 Sign on laboratory report and rinse the jobsite with clear water. Record the
acid/alkali reservoir tank level and keep a good record.
2.5.3Metering Tank Acid/alkali Filling
2.5.3.1Jog operation
Click to enter display F5 Primary Demineralized water System (if mixed, enter F6).
Select equipment to be regenerated with JOG mode. Open primary and

secondary valves at acid/alkali reservation tank outlet and open inlet valve of
acid/alkali metering tank (mixed bed regeneration will have acid and alkali two
metering tanks). When the level of metering tank is up to the need height, close
inlet valve of metering tank, and then close primary and secondary valves at high
elevation acid/alkali reservoir tank outlet.
2.5.3.2 Step mode operation
Click to enter display F5 Primary Demineralized water System (if mixed, enter F6).
Select equipment to be regenerated with SEQUENCE mode. Open primary

and secondary valves at acid/alkali reservation tank outlet, then click regeneration
button and Regeneration Agent Preparation button. The system will automatically
fill acid/alkali to the metering tank. When metering tank level up to the required
value, click standby button and the system automatically close metering tank inlet
valve to interrupt the filling.
26
2.5.4Operation of Neutralization Basin
2.5.4.1 Pre-start Inspections
a) Ensure NO. 1# OR 2# basin level is high, simultaneously, acid inlet S7 and

alkali inlet J7 are closed, high elevation acid/alkali neutralization basin outlet
manual valve is closed and neutralization pump outlet and recirculating valve
are closed.
b) Source control air is of normal state, and solenoid valve panel is already
supplied with air and energized. All valves can open/close freely, reliably and
the meters can normally indicate.
c) Ensure IPC of PLC is running and already switches to F7 Neutralization Basin

System display.
d) Neutralization pump and stirrer as well as the on-line meters are in standby.
2.5.4.2 Jog mode operation
a) Mechanical stirring.
Start 1# (2#) stirrer for mechanical stirring.
b) Cycling stirring with pump.
Startup neutralization pump 1# (2#), open neutralization pump circulating

valve F1 (F3) for cycle stirring. Put on-line meters into service after 30 min.
c) pH adjustment
If basin ph<6, open neutralization basin alkali filling valve J7 or J8,

otherwise if ph>9, open the acid inlet valve S7 or S8. Relevantly, open the acid
or alkali outlet valve of the reservoir tank and continue the cycling stirring.
When 6pH9, the PH of neutralization basin is proper. Then close the
filling-in valve J7 (S7) or J8 (S8).
d) Waste water rejection
Open neutralization pump outlet F2 (F4) and close F1(F3), the waste
water is rejected into underground sewer. When neutralization basin level is at
low-level, stop the neutralization pump and close the pump outlet F2 (F4).
2.6 Precautions for Acid & Alkali Unloading Work
2.6.1 All acid & alkali equipments must be hanged with warning plates.
27
2.6.2 Workers must wear protective apparatus; in addition, the jobsite must be prepared
with first-aid medicine and relevant industrial facilities.
2.6.3 Timely rising the leaked acid or alkali on ground or at container external.
2.7 Applications of Rotation Equipments
2.7.1Pre-start Inspections
2.7.1.1Inspect to ensure oil level must be between +/-2mm of oil lens centerline.
2.7.1.2Check to ensure correct motor rotation direction. (Pump must be rotates in

clockwise direction looking from motor side).
2.7.1.3Ensure that pump inlet valve is open and empty the air in pump during the initial
startup.
2.7.1.4 Rotate the pump before startup to guarantee flexible rotation.
2.7.1.5 Pump should start with its outlet valve closed to avoid motor overload, so that it
must ensure the pump outlet valve is closed before startup.
2.7.1.6Ensure power of pump is available and relevant signals are correct.
2.7.2Pump Startup Operations
Press START button and slowly open the outlet valve, anyhow the running
time with outlet valve closed should not exceeds 3 min. Continuously adjust pump
outlet valve till the pressure and flow up to the proper state.
2.7.3Pump Shutdown Operations
2.7.3.1 Close the pump outlet valve.
2.7.3.2 Press SHUTDOWN button.
2.7.3.3 Keep a good record.
2.7.4Precautions for Use
2.7.4.1 When the pump is out of operation for a long time, if the restart need, firstly
rotate the pump to guarantee a flexible running, and then run it after electrical
insulation met the code requirements.
2.7.4.2Never adjusts flowrate via intake water valve in case of cavitation erosion.
2.7.4.3The pump should run within high efficiency operating range.
28
2.7.4.4If abnormal symptom appears on the pump, handle with it timely.
2.8 Ejector Use and Precautions
2.8.1Usage
Open pipeline valves before and after ejector to make pumped regeneration
water enters into the ejector. Open chemical solution inlet valve and regulate the
flow making concentration of ejector outlet solution up to the required value. The
performance of ejector is adjustable by changing thickness of gasket to adjust
distance between nozzle and mixing portion.
2.8.2Precautions and attentions
2.8.2.1Hydraulic test must be performed after installation. To guarantee a good

installation effect, the regeneration pump outlet pressure must be within
0.196-0.392Mpa.
2.8.2.2No special maintenance for ejector needed, but which must be avoid long-term
exposure to sunshine, rain or strike/break by sharp objects.
2.8.2.3Inner diameter of the connecting pipe with ejector must be no less than nominal
diameter of the ejector. Moreover, the flange gasket inner diameter must be
bigger than the flange inner diameter.
2.9 Ion Exchange and Demineralized water System Product Water Deterioration
Causes and Solutions

No Symptoms General Causes Solutions
Back flushing inlet not Close the back flushing
totally closed valve tightly.
High SiO2 Broken acid and alkali Contact maintenance for
content after distributor forms bias flow handling.
regeneration, resulting in partial poor Improve the acid &
1
which cannot regeneration. alkali quality.
drops by Bad quality of acid & alkali Guarantee the solution
direct-flushing solution. amount or concentration
Insufficient regeneration within the required
solution or low concentration range.
High acidity of Resin exhausted or anion Stop regeneration
2
mixed bed resin reduced. process and fill with
29
output water Mixed bed regeneration and anion resin to the

the acid inlet valve not tightly required proportion.
closed. Tightly close the acid
inlet valve.
Bad intermediate tank water Improve the water
quality making mixed bed quality.
resin exhausted. Tightly close the acid
Acid or alkali inlet valve not inlet valve and open the
tightly closed, or acid & acid discharging valve.
Deterioration
alkali for the other bed Tightly close mixed bed
of
3 regenerating enters into the outlet valve.
demineralized
operating bed.
tank water
Regeneration solution enters
into demineralized water
system due to not closed or
not tightly closed bed outlet
valve
2.10Water Treatment Equipment Faults and Solutions

Resin flushed Too much flushing flow. Adjust the inlet valve
away during ion opening of back flushing
1
exchanger back and control the flow.
flushing
Mixed bed resin Output water cap Contact the maintenance to
2 missing during damaged or dropped off replace.
operation
Too short ion Resin aged or polluted, Replace the aged resin.
exchanger cycle making ion exchanging Revive the polluted resin
time capacity drops. Resin Thoroughly flush the resin
3 caking, bias current, the Enhance regeneration
regeneration efficiency efficiency.
drops, or resin damaged, Make up resin to the
insufficient resin height. stipulated height
2.11Rotary Equipment Faults and Solutions

1 Pump Impeller, bearing broken stop pump and contact
30
abnormal or other rotation maintenance for handling.

noise components get loosed Stop pump and contact
Foreign sundries enters maintenance to remove the
into pump sundries inside.
Overload operation
Step by step close the outlet valv
e until the load become normal.
Inlet valve closed. Open the inlet valve.
Low tank level or tank Stop pump and increase the tank
emptied. level
Air is sucked into the Stop pump and replace air inside
pump the pump, then start again.
No
Blocked inlet pipe or pump Stop pump and contact
2 pumping
wheel maintenance to remove the
water
Air leaked from suction sundries inside.
side. Stop pump and contact
Reverse motor rotation maintenance for handling
direction. Stop pump and contact electrical
to reconnect the wire.
Pump inhaled with air or Empty inside air and open the
too small outlet opening outlet valve widely.
Anchor bolts loosened or Tighten the screw and well
improper coupling connect the coupling.
connection Stop and contact maintenance for
Serious
Motor and shaft imbalance handling.
rotary
3 centerline and rotation
component
components seriously
s vibration
abraded
Rotation components
loosened or damaged.
Fan blade corroded or
dropped off
Motor over temperature. Stop motor and contact
Motor emits smoke (burnt maintenance for handling.
Motor smell) or catches fire.
4
faults Auto tripping.
Motor shutdown failed
Phase loss
3 Chemical Dosing System
3.1 System Overview
Chemical dosing system consists of devices for boiler phosphate dosing, boiler
feedwater ammonia dosing, hydrazine dosing. Each unit is equipped with one set of
chemical dosing system for plant water quality control. Dilute hydrazine dosing is
31
to remove the dissolved oxygen in feedwater and control the PH value; while,
concentrated hydrazine dosing is to protect boiler inner shell from rust formation
during long-time outage. The ammonia dosing is to control the feedwater PH value
and phosphate dosing is to drop the residual boiler water hardness. Finally, closed
demineralized water chemical dosing is to avoid corrosion during equipment
cooling.
3.2 Operations of Dosing Equipments
3.2.1Operations of Phosphate Dosing Equipments
3.2.1.1 Solution preparation.
Open solution cover to fill the specified amount of phosphate into the solution
tank, and then start the blender for 20min forming 1-5% phosphate solution.
3.2.1.2 Operation.
a) After boiler firing, shift lead to open primary and secondary drum chemical
dosing valves.
b) When boiler pressure rises up, analyze boiler water quality and properly dosing
chemicals accordingly.
c) Open phosphate solution tank outlet valve and metering pump outlet valve as
well as main dosing valve.
d) Start dosing pump and adjust pump stoke as boiler water PO43 content
e) Observe phosphate dosing pump pressure and output capacity; never leave
before everything including pump rotation and sound turns normal.
3.2.2Operations of Ammonia Dosing Equipments
3.2.2.1 Solution preparation
Ammonia solution preparation: use barrel pump to transfer the concentrated

ammonia water into the solution tank where equipped with motor-operated blender,
then make 1-2.5% ammonia solution.
3.2.2.2 Operation
a) When deaerator process circulating heating, inform shift lead to open the
primary valve for deaerator downcomer chemical dosing.
b) Open ammonia solution tank outlet valve, ammonia dosing pump outlet and inlet
32
valves and main dosing valve.
c) Start relevant ammonia dosing pump, adjust feedwater PH by varying dosing

amount and put the on-line PH meters into service. Observe dosing pump
pressure and output, never leave before everything including rotation,
temperature and sounds of the pump turns normal.
d) When the operating pump or regulator faults, manually put the standby pump
into operation and switch over corresponding control signals.
3.2.3Hydrazine Dosing Equipment Operations
Startup the infusion pump to fill the pure hydrazine into metering tank, then
open outlet valve of the metering tank and transfer the hydrazine inside solution
tank, when finish filling a certain amount hydrazine, close the metering tank outlet
valve. Finally, start the blender motor for 20min to dilute the solution to 0.1-0.5%.
3.2.3.2 Operation
b) Open hydrazine solution tank outlet valve.
c) Start dosing pump and adjust pump stoke as feedwater hydrazine content.
d) Observe dosing pump pressure and output, never leave before everything
including rotation, temperature and sounds of the pump turns normal.
3.3 Operation of the Auxiliary Boiler Dosing Device
3.3.1Operations of Phosphate Dosing Equipments
3.3.1.1 Solution preparation.
Open solution cover to fill the specified amount of phosphate into the solution
tank, and then start the blender for 20min forming 1-5% phosphate solution.
3.3.1.2 Operation.
a) After boiler firing, shift lead to open primary and secondary drum chemical
dosing valves.
b) When boiler pressure rises up, analyze boiler water quality and properly dosing
33
chemicals accordingly.
c) Open phosphate solution tank outlet valve and metering pump outlet valve as
well as main dosing valve.
d) Start dosing pump and adjust pump stoke as boiler water PO43 content
e) Observe phosphate dosing pump pressure and output capacity; never leave
before everything including pump rotation and sound turns normal.
3.3.2Operations of Ammonia Dosing Equipments
Ammonia solution preparation: use barrel pump to transfer the concentrated

ammonia water into the solution tank where equipped with motor-operated blender,
then make 1-2.5% ammonia solution.
3.3.2.2 Operation
b) Open ammonia solution tank outlet valve, ammonia dosing pump outlet and inlet
valves and main dosing valve.
c) Start relevant ammonia dosing pump, adjust feedwater PH by varying dosing

amount and put the on-line PH meters into service. Observe dosing pump
pressure and output, never leave before everything including rotation,
temperature and sounds of the pump turns normal.
d) When the operating pump or regulator faults, manually put the standby pump
into operation and switch over corresponding control signals.
4Steam & Water Sampling System
4.1 System Configurations
Steam & water sampling system consists of HT & HP framework, instrument

rack and manual sampling frame. The HT & HP framework is equipped with
sample cooler and pressure & temperature reducer; the instrument rack is
composed of thermostat, over temperature protection and chemical analysis
instruments; the manual sampling frame is mainly to perform manual chemical
analysis to the sample water. At last, the microcomputer processing system
34
includes data acquisition system, instrument over limit signal transmission and
instrument output system.
4.2 System Functions
4.2.1The system can provide continuous steam & water sample of generator set, and
which also can realize on-line analysis and manual sample analysis.
4.2.2The system also have steam & water monitoring and data acquisition functions,
which can accurately analyze and show the relevant steam & water parameters, in
addition, alarm for the abnormal working conditions.
4.2.3The device has protection functions for sample water over temperature and cooling
water interruption problems and along with acousto-optic alarms.
4.3 Operations of Steam & Water Sampling Devices
4.3.1Pre-service Inspections
4.3.1.1Acknowledge positions and functions of sampling rack components according to

the steam & water sampling system drawing.
4.3.1.2Regulate upper and lower pressure limit of cooling water electrical contact
pressure gaug and check to ensure the alarm system is of good condition. The
upper limit setting of cooling water inlet pipe electrical contact pressure meter is
0.8MPa, and lower is 0.1MPa.
4.3.1.3The lower limit setting of cooling water outlet pipe electrical contact pressure
gauge is 0MPa. (Monitored pressure difference with inlet0.2MPa)
4.3.1.4Energize the patrol-check device, set sampling cycle and upper and lower alarm
of all sampling points according to the stipulated instructions. Set upper limit for
alarm about 40-45 and lower limit 0.
4.3.1.5Inspect to ensure components of sampling rack as flexible joint, seal parts,

fixings free of loose and all of valves closed.
4.3.1.6Sampling system valves are all closed and all pressure reducing valve stroke to
1/31/2.
4.3.2Cooling Water into Service
4.3.2.1Cooling water inlet and outlet global valves for all sampling points are opened.
4.3.2.2Open cooling water main inlet and outlet valves. The inlet and outlet pressure
35
difference of cooling pipe 0.2MPa is normal, for which must be no less than
0.1MPa, and cooling water must no more than 35.
4.3.2.3Check to ensure normal alarm: regulate upper limit of cooling water inlet pipe
electrical contact pressure gauge less than actual water pressure, if it alarms, the
upper limit alarm is normal. Then restore the pressure to 0.8MPa. Regulate
again to change the lower limit bigger than the actual pressure value, if it alarms,
the lower limit alarm is of normal state. Then restore the valve back to 0.1MPa.
After testing the alarm, regulate and stabilize the inlet and outlet differential
pressure above 0.2MPa.
4.3.2.4Open all global valves for coolers to ensure cooling water for sampling system
with normal conditions, for which the pressure and flow must be within the
required range.
4.3.3High Pressure and High Temperature System into Service
Only when cooling system under normal condition, the HT & HP system can run.
4.3.3.1Open all manual sampling valves and flowmeter knobs on LT area.
4.3.3.2Primary and secondary water sample inlet valves, blowdown valves and flow
control valves are all closed.
4.3.3.3Slowly open primary valve of one sampling points on the rack, observe the filter,
secondary valve and blowdown valve joints for leakage inspection, if it leakage
exists, tight with special spanner.(Note: wear gloves and avoid scald)
4.3.3.4If the primary water sample inlet valve, blowdown valve and filter are free of
leakages, then open blowdown valve till full opening to drain all deposit water
out, and when water temp rises up and becomes stable, quick close the
blowdown valve. Repeat open & close the blowdown valve for about 3 times,
blowdown process is finished.
4.3.3.5Slowly open secondary water sample inlet valve to make water flow into
temperature and pressure reducing container, if which exists leakage, close the
primary inlet valve for handling.
4.3.3.6Slowly open flow control valve and observe the floater of flowmeter rising, if
which is about 1500ml/min, the flow is proper. Its better the floater is between
60 and 90.
4.3.3.7Open and regulate the sample inlet control valve and flow-throttling valve to
provide the meter needed amoint, then regulate manually sampling flow is about
36
200-400ml/min, otherwise, adjust the flow control valve and flow-throttling

valve till which is up to standard.
4.3.4Supervision during Operating
4.3.4.1The on-duty operator must inspect and adjust sampling device working
conditions at any time, including patrol inspection to all sample water flow &
temperature, cooling water flow, thermostat device level, temperature and
compressor, all on-line meter indications and exchange column operating
conditions.
4.3.4.2When adjusting the flow, it must balance opening of manual sampling valve and
water sample inlet valve. While, when adjusting instrument water sample flow,
it should adjust instrument sample water inlet valve, never use flowmeter inlet
and outlet valves as the regulation medium.
4.3.4.3If on-line meters become abnormal or ion exchange column exhausted, timely
inform the instrument maintenance for handling.
4.3.4.4 During operating, if cooling water is interrupted, immediately close sampling

rack primary valve. If fail to cut-off the sample water, contact with shift leader
to close the primary and secondary valve from jobsite.
5 Plant Waste Water Treatment System

Main function of the Waste Water Treatment System is to collect and treat
waste water produced in the course of daily life and production activities in the
Power Plant. All the waste water is treated to satisfy the Standards of Discharge and
then discharged or reused.
5.1The Waste Water Treatment System mainly comprises:
Industrial Wastewater Treatment System
Sanitary Sewage Treatment System
Oily wastewater treatment system
5.1.1 Industrial Wastewater Treatment System
The treatment capacity of the industrial waste water treatment system of

Pakistan Gas Turbine Combined Cycle Power Plant Project is Q= 50m3/h and the
maximum treatment capacity is Q=60m3/h. The industrial waste water treatment
system is applied to dispose the oily wastewater and industrial wastewater from
37
power plant with the water quality after treatment meeting the design requirements
for the treatment of industrial wastewater.
The turbidity of the inlet water is 1500mg/L and the turbidity of inlet water
within short time shall be no more than 5000mg/L. The oil content of the inlet water
shall be less than 500mg/L.
The system is furnished with manual and automatic control functions. The
local manual control cabinets of the equipment will be provided by our company.
All the fault and operational status of all the equipments may be displayed in the
control room and give alarming accordingly. The automatic control of the system
shall be performed by the PLC provided by the buyer.
This system is to collect and treat all the Industrial Wastewater produced in the
Power Plant. The industrial waste water will be collected into the Industrial
Wastewater Regulating Pond by gravity and then pumped to the Industrial
Wastewater Treatment Equipment by the Booster Pumps installed in the Industrial
Wastewater Booster Pump House.
Equipment Specification:
No Description Qty Technical Specification Re.
Type XJYCQ-50
Size 25004800mm
Treatment capacity Q=50m3/h
Short-term maximum processing volume
Suspended Q=60m3/h
1 substance 1set
Turbidity of inlet water 1500mg/l Short time
clarifier
Max.5000mg/l
Turbidity of outlet water 50 mg/L
Working pressure Ambient pressure
Material Q235
Type XJYQF-50
Short-term maximum processing volume
Q=60m3/h
Air-handing
1set Size 38003500mm
unit
Oil content of inlet water 500mg/l
2 Oil content of outlet water 1mg/l
Working pressure A mbient pressure
Material Q235
Output Head Rotate Power Vol
Type
air dissolved m3/h m rpm KW V
1set
water pump ISG60
23 44 2900 7.5 400
-200
38
Air
pressur
capacit Rotate Power Vol
Type e
Air y rpm KW V
1set Mpa
compressor m3/min
V-0.2
0.28 0.8 1450 2.2 400
8/8
Type XJYSX-20
Intermediate Size 320028002250mm
1set
tank Equipment capacity 20m3/h
Material Q235
3
Type
Intermediate m3/h m rpm KW V
2set
water pump ISG65
50 20 2900 5.5 400
-125
Type XJYCBL-50
Anti-wash intensity 1215L/m2s
Size 1800H4500mm -
No Valve
4 2set Turbidity of inlet water 50100mg/l
Filter
Turbidity of outlet water 5mg/l
Average filtering speed 1 m/h
Material Q235
Type XJY-JN-5
Collection
1set Size 240015001500
basins
Material Q235
5 Output Head Rotate Power Vol
Sludge Type
m3/h m rpm KW V
pump 2set
25QW
upgrade 8 22 2900 1.1 400
8-22
Type XJYWN-15
Sludge
6 1set Size 2600H4800mm
Thickener
Material Q235
Output Device Size Power Vol
Type
m3/h mm KW V
Centrifuge 1set
1780101070
D2LL 0-5 10.5 380
7 9mm
Sludge Type
2set m3/h m rpm KW V
pump
G30-1 5 60 960 2.2 400
Coagulant Dosing Device
Dosing
8 1set Equipment material PE
Device
Agitator tank size 13501600mm 1
39
set
Solution tank size 13501600mm 1
set
Working temperature 545
Agitator Stainless steel Motor
Power: 0.55KW
Magnetic floating board level meter : furnished with
high and low1 points switch value distance signal
output
Coagulant Aids Dosing Device
Equipment material PE
Agitator tank size 10501300mm 1 set
Solution tank size 10501300mm 1 set
Working temperature 545
Agitator Stainless steel Motor Power: 0.55KW
Magnetic floating board level meter : furnished with
high and low 1 points switch value distance signal
output
5.1.2 Industrial Waste Water Treatment System Startup
Whole treatment system will be automatically running and auto-controlled

according to the water quality required at the outlet of the system. Detail
requirements will be shown on the manufacturers running manual.
Industrial Wastewater Booster Pumps will be interlocked with level of

Industrial Wastewater Regulating Pond, and low water level (-5.85)interlock with
pump stoppage. Normal water level-5.25start pump, high water level
-4.85start the second pump. High water level -3.70start the standby pump
and alarm.
5.1.3 Operation Principle of the Equipment
5.1.3.1Suspended substance clarifier:
Suspended substance clarifier is a kind of new type steel structured waste

water treatment equipment with coagulation, reaction and sedimentation combined
together, which is applied for speedy separation of the suspended substances. The
system has been widely applied in the treatment of high turbidity industrial water.
The influent industrial wastewater will enter the first reaction chamber of the
suspended substance clarifier after mixed with the injected chemicals, where
40
complete reaction will occur through spiral flow, then the waste water flows in
reverse direction to the second reaction chamber where the suspended solids will
conglomerate to big flocks and then goes to the clarification separation area where
the flocks will fall into the sludge hopper after the wastewater is in contact with the
filling, while the clarified water will rise to the upper part of the equipment and then
overflows from the overflow groove and flows to the subsequent oil dispose unit.
Setting the sludge draining time and drain the sludge automatically in static
pressure as per site conditions, then the sludge will self drains to the sludge
thickener equipment.
The industrial wastewater treatment system includes suspended solids

clarification systems and the artery water inlet pipe is provided with pipe mixer and
one chemical inlet. The injected coagulant solution will be prepared by the dosing
unit.
5.1.3.2 Oil Dispose Unit:
With the application of superficial layer floatation separation principle, the oil
dispose unit features large treatment capacity, small size and stable operation. The
traditional air floatation process adopts the approach of static water inlet and
dynamic water outlet, while the oil dispose unit adopts the dynamic water inlet and
static water outlet approach.
The influent water in the oil dispose unit will firstly mix with the injected
chemicals and then mix with the filled air-dissolved water to produce large amount
of small bubbles which will adhere to the flocculated solids making the gravity of
the flocks less than 1. Then the suspended substance will swiftly floats to the water
surface as per flotation principle resulting in the separation of solids and water.
Then the selfly-rotary pollutant removal unit will collect the floating oil and
discharge to the central motionless pollutant collection area and then self flows to
the oil collection tank. The scrapping board connected to the water distributor will
scrape the sludge at the tank bottom to the sludge tank for disposal.
The walking device and the scum scrapper are driven by the speed reducing
motor and powered by the central slip ring.
The water inlet pipe of the oil dispose unit is provided with pipe mixer and one
chemical inlet and the used coagulant solution is prepared by the dosing unit.
5.1.3.3Filter:
With both automatic filtering and backwashing functions, the filter features
41
automatic operation and no energy consumption, which is a kind of energy-saving

filtering equipment.
After the treatment of previous oil dispose unit, the industrial wastewater
flows to intermediate water tank and then lifted to the filter by the intermediate
water pump. The industrial waste water will then be filtered when flowing through
the filtering layer from top to bottom, the clean water flows to the clean water tank
at the top of the filter tank through the flow guide tube. After the water tank gets full,
the clean water will flow to the clean water pond through the water collection
groove and water outlet pipe.
The continuous interception of the suspended solids by the filtering layer

during the operation of the filter will slowly increase the resistance of the filtering
layer, which will keep rising the water level inside the siphon rising pipe. When the
water level rises to the siphon auxiliary pipe, the water will fall from the siphon
auxiliary pipe and will bring away the air inside the siphon decline pipe by the
exhaust pipe, then when the vacuum reaches certain level, the siphon effect will
occur bringing the water in the water tank flow upward through the filtering layer
from bottom to top to backwash the filtering layer. When the water level of the
washing water tank declines to the level of the siphon breaking pipe nozzle, the air
will enter the siphon pipe to terminate the siphon effect and brings end to the
backwashing of the filtering tank, then the filtering tank goes to the next round of
operation.
In order to shorten the time for backwashing, forcing siphon breaking pipe is
furnished, which will help the buyer to terminate the siphon backwashing during
the backwashing process and make the system quickly restored to the operation
state.
During the operation of the filtering tank, the actions of filtering

backwashing termination of backwashing restored to the next round of
filtering are automatically conducted by water force with no requirement for
operator management.
5.1.3.4 Sludge Thickener
Sludge Thickener: Set coagulation, reaction, sedimentation separated in one

of the new steel water enrichment processing equipment for waste water sludge
containing a high concentration of the enrichment processing, in order to reduce the
volume of sludge. Sludge Thickener into the water moisture content of 99 ~ 99.8%
more than the devices treated by the soil moisture content can be reduced to 95%
Sludge Thickener using vertical-flow circular structure, the water by

42
coagulation Dosing Chilodonella fill through the sludge layer has been further after
the settlement, so that separation of water have been clarified.
Concentrated pool of sludge into the water to set coagulant dosing port 1, the
added coagulant liquid dosing device from
5.1.3.5 Chemical dosing equipments
Chemical dosing equipments comprise coagulant dosing system and

coagulant aid dosing system the parameters of chemical dosing system are as
follows
Chemical type of Aluminum chloride
Chemical type of coagulant aid
Coagulant dosing density15~50mg/l
Coagulant aid dosing density 3mg/l
5.1.4 Operation of the system equipments:
5.1.4.1 Inspection prior to the start-up:
(1) Check to make sure that the liquid level of the water tank meets the requirement,
the inlet and outlet valves of all water pumps are in opening state, no converse
rotation of the pump, motor is in good condition, the earthing line is properly
connected, the grounding bolts of the pump are securely fixed, the coupler is
flexible without any blockage, suitable amount of lubricant in the oil chamber
with proper lubrication.
(2) The floor of the waste water treatment room is flat and clean without any
foreign objects to affect the moving.
(3) The connecting pipe of equipment shall be inspected of the sealing state and
shall be ensured in good standby state.
(4) Check whether the incoming voltage is right and whether the connecting cables
between the electric control cabinet and electric equipment are in good
conditions.
(5) Check to make sure that all the valves of the industrial waste water treatment
system are installed in right places listed as following:
No Description Qty Valve Name Position Remarks
Suspended Solenoid valve for inlet
1 1sets Open
substance water
43
clarifier Electric valve for sludge

Close Time start
drain
Solenoid valve for
Close Time start
backwashing
Sampling valve Close Manual
Chemical inlet valve Open Manual
Water inlet valve of oil
Open Manual
dispose unit
Regulating valve of
Manual
outlet water of Open
adjust
air-dissolved tank
Inlet valve of
air-dissolved water Open Manual
Oil dispose pump
2 1sets
unit Outlet valve of
air-dissolved water Open Manual
pump
Outlet valve of air
Open Manual
compressor
Mud solenoid Close Time start
Chemical inlet valve Open Manual
Water inlet valve Open Manual
Forcing siphon breaking
Close Manual
valve
3 Filter 2sets
Forcing siphon pressure
Close Manual
water inlet valve
Emptying valve Close Manual
Intermediate
1sets Emptying valve Close Manual
tank
4
Intermediate Water inlet valve Open Manual
2sets
water pump Water outlet valve Open Manual
Collection
1sets Emptying valve Close Manual
basins
5 Sludge Water inlet valve Open Manual
pump 2sets
Water outlet valve Open Manual
upgrade
Sludge Chemical inlet valve Open Manual
6 1sets
Thickener Sampling valve Close Manual
Water inlet valve Open Manual
Sludge Water outlet valve Open Manual
7 2sets
pump Sludge pump outlet port
Open Manual
valve dosing
Backwash Valve Close Manual
8 Centrifuge 1sets
44
5.1.4.2 System Startup
a. Reform blast aeration to the waste water reservoir and preliminarily adjust PH
value as chemical analysis.
b. Start up lift pump to transfer the waste water into coagulation-reaction basin
and dose flocculant and coagulant, and then fill acid or alkali according to the
PH value.
cStart stirrer when sedimentation level is high making flocculating constituent

formed.
dAfter waste water enters into sedimentation basin, regulate the flow and
chemical dosing amount according to the water quality.
eIf too many alumen flocs appear in water, properly reduce dosing amount and
conduct blowdown.
fDuring operation, pay attention to supervise output water quality of auto back
flushing filter, if the PH cannot up to standard, transfer the outlet water back to
waste water reservoir.
gare fully observe the back flushing effect during operating and properly make
adjustment accordingly.
hAvoid basin overflow during operation.
iDuring sedimentation basin blowdown process, pay attention to the normal

operation of blowdown screw pump
5.2 Sanitary Sewage Treatment System
Function of this system is to collect and treat all the sanitary sewage produced
in the Power Plant. The sanitary sewage is collected into a Sanitary Sewage
Regulating Pond by gravity through pipe and then the sewage is pumped into the
Sanitary Sewage Treatment Equipment by the booster pumps installed in the
Regulating Pond. By the Sanitary Sewage Treatment Equipment, suspended solid,
colloidal substance, soluble organic matter will be removed to an acceptable
content and the pathogenic bacteria will be eliminated. After treatment, the water
will pump to greening water system.
5.2.1Process flow of the sanitary sewage treatment system:
Regulate wastewater tank. The primary settling tank oxygenContact

oxidation pool (min 2)
45
Chlorination
Secondary sedimentation tankThe middle of the pool

disinfectionFreshpond biofilter water.
5.2.2Technical Data
5.2.2.1Treatment capacity of the sanitary sewage treatment system Q=10m3/h;
5.2.2.2 Inlet water quality:BOD5200ppmSS250ppmAmmonia nitrogen 50ppm,

total phosphor 5ppm, oil content 150ppm;
5.2.2.3Equipment, water quality to meet the "Wastewater Reclamation and Reuse

Project design specifications" GB50335-2002 in the town of miscellaneous indicators
of water quality control requirements. Main indicators:, BOD5 5ppm, water NTU
10 mg / L., ammonia nitrogen 5ppm, equipment, total chlorine in water after 30min
exposure greater than or equal 1.0mg / L, total coliform number of 3 Ge / L. PH value
6 ~ 9,If the equipment runs under the condition of following data for long time
CODcr100ppmthe outlet water will surely meet the requirement.
BOD550ppm
SS100ppm
5.2.2.4 Electric supply
The buyer is responsible for connecting the power supply to the local control
cabinet of the seller;
(1)Incoming power: 380/220V AC 50Hz
(2)Overall power of the equipment: N =26.7KW
(3) Max. operating power: N =16.5KW
(4)Overall power of clo2: N=0.6KW
5.2.3Main Technical Specification

Qty
No Description Technical specification Re.
(Set)
Type XJY-WSZ -10
Sanitary Size 950030003000mm-1
sewage tanks
1 1
treatment 650030003000mm-1 tanks
equipment Material Q235
Treatment capacity: Q=210m3/h
46
Volta
Outpu Head Rotation Power
Type ge
Sludge t m3/h m rpm KW
2 2 V
lifting pump
WQ10
10 10 2900 1 380
-10-1
Outpu Head Rotation Power Volta
Intermediat Type
t m3/h m rpm KW ge V
3 e water 2
WQ15
pump 15 10 3900 1.5 380
-10-1.5
Type
Clean water t m3/h m rpm KW ge V
4 2
lifting pump WQ15
15 20 2900 2.2 380
-20-2.2
Type
Backwash t m3/h m rpm KW ge V
5 1
water pump WQ45
45 18 2900 5.5 380
-18-5.5
Flow Press
Rotation Power Volta
Type m3/mi ure
rpm KW ge V
6 Air blower 2 n mm
HC-80
3.45 4000 500 5.5 380
S
5.2.4 Operation of the system
5.2.4.1 Inspection prior to start-up:
a. Check to make sure that the tank water level is normal, outlet valves of each
water pump and air blower are opened, no converse rotation, electric motor in
good condition, complete earthing lines, pump and air blower fixed by
grounding screws with flexible rotation and no blockage, and the oil chamber has
suitable amount of lube greaser with proper lubrication;
b. Check to make sure that the ground floor of the sewage treatment station is flat
and clean with no objects affecting the operation;
c. Check to make sure that the sealing of the connecting pipelines is in good
conditions;
d. Check to make sure the incoming power voltage is right and the connecting
cable between the electric control cabinet and the electric devices are in good
condition;
47
5.2.5 Manual Operation Status
When the sludge lifting pump, air blower, intermediate water pump, clean
water pump and backwash water pump are in manual working state, all the electric
devices shall be in continuous running state with alternative running not allowed;
5.2.6 Auto Work Status
Enhancing sludge pumps, fans, intermediate pumps, clear water pumps,

backwash pumps installed in remote control state. Run automatically, all the
equipment running status, fault alarm and so on, through the local operator to
connect the signal box Yingjie points to the buyer to achieve remote automatic
control system PLC
A. Sludge lifting pump: the sludge lifting pump works discontinuously at set time;
during the operation of the equipment, the pump will drain the sludge once
every 68 hours for about 34min; 2 sludge drain pump work alternatively;
B. Air blower: 2 air blowers are in operation and all 3 air blowers are time
controlled and automatically switch; 2 running air blower are also under the
control of the sewage lifting pump of the buyers equalization tank; so the
start-up of the sewage lifting pump of the equalization tank will also actuate 2
air blowers; when the sewage lifting pump of the equalization tank is stopped,
the air blowers will work discontinuously automatically, that is to say, the air
blower will be on for 20minutes and off for 40minutes to ensure no shortage of
oxygen in the oxidization tank;
C. Intermediate water pump: interlock with the liquid level switch of the
intermediate water tank; one pump runs at middle liquid level, 2 pumps run at
high level and the pump stops at low liquid level;
D. Backwash water pump: Interlock with the turbidity meter; when the turbidity of
outlet water is bigger than 10mg/l, the backwash water pump will be actuated,
after 45 minutes, the pump stops and the equipment is put to normal
operation;
E. Clean water pump: Interlock with the liquid level of the clean water tank, one
pump runs at high level and the pump stops at low liquid level;
5.2.7 Cautions
1) Regularly check of the operation conditions of each electric device of the control
system and ensure timely solution for any found problems;
48
2) The air blower shall be filled with lube oil regularly during the operation; pay
attention to any vibration and temperature rise of the electric motor and the
temperature and humidity inside the air blower house as well as the noise from
the air blower, if there is any wrong, shut down the system immediately to repair;
3) Keep frequent inspection of the aeration conditions of the oxidization tank and
sludge tank and the packing fixing conditions inside the oxidization tank, take
immediate actions for any found troubles;
4) Irregular inspection of the working conditions of water pump and the motor of
the air blowers, if there is any abnormal noises, timely repair is required and
replace the easily worn parts;
5) The pump and air blower shall be subject to regular care;
5.3 Oil & Water Separator Operations
5.3.1 Oily Wastewater Treatment System
Function of this system is to collect oil polluted wastewater produced in the

turbine house and fuel oil tank area. Separately two sets of oily waste water
treatments are installed to disposal the wastewater. The oily waste water firstly
shall be collected into a Regulating Pond by gravity through pipelines and then
pumped into the Treatment Equipment by the booster pumps installed in the
Regulating Pond. After treated, the water will be discharged into the treated water
tank.
5.3.2 Design of the System
Two set of oily wastewater treatment equipment is adopted for this project is
for the turbine house area with capacity of 10m3/h, the other is for the fuel oil tank
area with capacity of 15m3/h.
5.3.3 Water quality
Water quality at the inlet of the treatment system of fuel oil tank area: oil2%,
SS5%;
Water quality at the inlet of the treatment system of fuel oil tank area:
oil2000ppm, SS100mg/L;
49
5.3.4 Treatment System for Turbine House Area
5.3.4.1 oil separating pond
Dimension of pond: 4500x4800x7000mmLxWxH
Valid volume 80m
Material Concrete
Quantity 1
5.3.4.2 Waste water intake pond
Material Concrete
Quantity 1
5.3.4.3 Oil connecting pond
Valid volume 24m
Material Concrete
Quantity 1
5.3.4.4 Oily waste water pump
Type ZWII50-15-30
Flow 15 m/h
Head 30m
Power 3KW
Quantity 2 sets
5.3.4.5 Oil separator
Type ZWII50-15-30
Diameter 1.5m
Valid volume 5m
Surface load: q =5.66m3/(m2h)
50
Quantity 1
5.3.4.6 Oil pump
Type 3GR42x4A
Flow 4.8m/h
Head 100m
Power 4KW
Quantity 1set
Voltage400V
5.3.4.7 Working process
5.3.5 Treatment System for Fuel Oil Tank Area

5.3.5.1 Oil separating pond
Valid volume 100m
Material Concrete
Quantity 2
5.3.5.2 Waste water intake pond
Material Concrete
Valid volume 130m
Quantity 1
51
5.3.5.3 Oil connecting pond
Valid volume 50m
Material Concrete
Quantity 1
5.3.5.4 Clean water pond
Valid volume 65m
Material Concrete
Quantity 1
5.3.5.5 Oil separator
Type ZWII50-15-30
Diameter 2.4m
Valid volume8m
Surface loadq =3.18m3/(m2h)
Quantity 1
5.3.5.6 First lifting pump
Type ZWII65-20-30
Flow 20m/h
Head 30m
Power 5.5KW
Quantity2 sets
5.3.5.7 Second lifting pump
Type 65ZX25-50
Flow 20m/h
Head 50m
Power 7.5KW
Quantity 2 sets
52
5.3.5.8 Air dissolved equipments
Size0.8m3.86m
Valid volume1.5m
Flow density 859m3/(m2d)
Design/working pressure: 0.60/0.45Mpa.
Ratio of liquid/air: 1005.
Quantity1set.
5.3.5.9 Floatation equipments
Size3.0m/2.4m4.6m
Valid volume6.35m
Surface load3.18m3/ (m2h)
Quantity 1set
5.3.5.10 Filter pump
TypeKQWH65-160B
Flow 21.6m/h
Head 24m
Power 3KW
Quantity 2 sets
5.3.5.11 Filter & backwash pumps
Filter Size1.84.08m
Filter valid volume6.35m
Backwash pumps capacity,Q=30 m3/h; H=18m N=4KW;
Totally 1 filter and 2 sets of backwash pumps shall be installed
5.3.5.12 Clean water lifting pumps
TypeZWII65-30-18
Flow 20m/h
Head 30m
Power 5.5KW
53
Quantity 2 sets
5.3.5.13 Oil pumps
Type3GR42x4A
Flow 4.8m/h
Head 100m
Power 4KW
Quantity 2 sets
5.3.5.14 Oil residue tank
Filter Size6.0 m1.8m2.8m
Filter valid volume27m
Materials steel
Quantity 1set
5.3.5.15 Oil residue pumps
TypeZWII50-20-15
Flow 20m/h
Head 15m
Power 2.2KW
Quantity 2sets
5.3.5.16 Chemical dosing equipments
One set of NaOH dosing system
One set of PAC dosing system
One set of PAM dosing system
Four sets of chemical mixer.
5.3.5.17Working process
54
5.3.6 Startup and Outage of Oil Depot Area Oil Water Separation System
5.3.6.1 Preparation before startup
1. View whether there is enough liquid in #1, #2 and 3 # agent mixing boxes. If
not, be sure to prepare the liquid first.
2. Check whether the automatic control system is normal. Preliminarily set

various automatic control parameters.
3. Check whether the gas supply and pressure are normal.
4. Check whether the level in #1 oil separator has risen to certain height or set
height, and confirm the wastewater influent is normal.
5. Open the main piping valves of oil water separator, dissolved air unit, efficient
air flotation unit, etc. according to specified order, to ensure the whole process
smooth.
6. Fill corresponding pump (only refer to self-priming pump) chamber with water.
5.3.6.2 Startup
a. When the level in #1 oil separator reaches a high level, open the inlet valve
of the primary pump, start the primary pump, then slowly open the outlet
valve of the primary pump. When the outlet pressure reaches and stays
55
stably at rated pressure, slowly open the outlet valve of the primary pump, to
ensure the outlet pressure meter of the primary pump indicates within 0.2 ~
0.25Mpa range. When the primary pump switches to the "Auto" control
mode, adjust the liquid level of #1 oil separator on the centralized control
display panel while the primary pump is started up, and the liquid level of #1
oil separator while the primary pump is stopped.
b. Open the inlet air filling valve (i.e., aerated solenoid valve) of oil water
separator. When the oil water separator aerated solenoid valve switches to
"Auto" operating mode, oil water separator aerated solenoid valve and the
primary pump are interlocked: i.e., when the primary pump is started, oil
water separator aerated solenoid valve opens; when the primary pump is
stopped, oil water separator aerated solenoid valve closes.
c. Adjust the opening degree of oil water separator inlet valve, and control 1#
mixing reactor operating pressure within 0.20 ~ 0.25MPa.
d. Observe the surface wastewater of oil water separator, adjust the air filling
quantity (adjust the gas flow meter knob) of mixing reactor; when there are
tiny dense air bubbles in the surface wastewater, it indicates that the air
filling quantity is appropriate. General air filling quantity is about 2-5% of
treated water volume. The air filling quantity of mixing reactor can be
indicated by air flow meter. The air filling quantity of mixing reactor can be
changed by adjusting the knob on air flow meter.
e. Observe the surface oil spill of oil water separator, and correct the oil layer
height of fluid conditioner during action. When the fluid conditioner
switches to "Auto" control mode, adjust the oil layer height of fluid
conditioner on the centralized control display panel while it is started up, and
the oil layer height while the fluid conditioner is stopped. When the fluid
conditioner "Auto" control mode fails, switch the fluid conditioner to
"manual" control mode. At this moment, select either one of "continuous /
intermittent" working modes. When continuous working mode is selected,
the fluid conditioner is open all the time; when intermittent working mode is
selected, the opening time and closing time of fluid conditioner can be set.
f. Before starting up the secondary pump, open the inlet valve and outlet valve of
#1, #2 and 3 # agent dosing pumps, and open #1, #2 and 3 # agent dosing
pumps. (#1 agent can be fed only when wastewater influent PH value is less
than 6.8).
g. When water intake pool liquid reaches high level, start the secondary pump,
56
and then slowly open the outlet valve of the primary pump. When the outlet
pressure reaches and stays stably at rated pressure, slowly open the outlet
valve of the secondary pump to ensure the secondary pump outlet pressure
meter indicates within 0.3 ~ 0.4Mpa range. The display valve of
electromagnetic flowmeter can be adjusted by adjusting the opening of the
valve behind electromagnetic flowmeter (the designed flow is 15m3 / h, i.e.
the instantaneous flow shown on electromagnetic flowmeter). When the
secondary pump switches to "Auto" control mode, adjust the liquid level of
water intake pool on the centralized control display panel while the
secondary pump is started up, and the liquid level of water intake pool while
the secondary pump is stopped.
h. Open the inlet air filling valve of dissolved air unit (i.e., aerated solenoid
valve). When dissolved air unit aerated solenoid valve switches to "Auto"
operating mode, the dissolved air unit solenoid valve and secondary pump
are interlocked: i.e., when secondary pump is started up, dissolved air unit
aerated solenoid valve opens; when secondary pump is stopped, dissolved air
unit aerated solenoid valve closes.
i. Adjust the opening of the outlet valve of the dissolved air unit, and control
dissolved air unit working pressure within 0.25-0.35MPa. Adjust the liquid
level on centralized control display panel when the dissolved air unit exhaust
valve is open and the liquid level when the exhaust valve is closed. When
dissolved air unit exhaust valve switches to "Auto" control mode, adjust the
liquid level of dissolved air unit on the centralized control display panel
when the dissolved air unit exhaust valve is open, and the liquid level when
the exhaust valve is closed.
j. Adjust the air filling quantity of # 2 agent via the online PH meter at the outlet
of the dissolved air unit. Generally the PH value is controlled within 7~9.
The specific values can be determined based on the actual water quality. The
PH meter and the # agent dosing pump have formed interlocking. The
operator can set the PH value of PH meter according to the specific water
quality and the scum condition of efficient air flotation unit. At this moment,
the system will automatically adjust the dosage quantity of the #2 agent
dosing pump, to ensure the PH value of PH meter reaches a set value.
k. When #2 agent dosing pump and PH meter interlocking is selected "Yes",

the PH value can be set, to ensure the system automatically adjust the dosage
quantity of the #2 agent dosing pump.
l. Open the scraper of efficient air flotation unit. Adjust the fluid conditioner of
57
efficient air flotation unit, and control the liquid level of the surface oil
residue of efficient air flotation unit. When the press filter pump switches to
"Auto" control mode, adjust the liquid level of efficient air flotation unit on
the centralized control display panel when the press filter pump is started up,
and the liquid level when the press filter pump is stopped.
m. Adjust the various parameters of the filter system to make them more
reasonable. The filter system adopts PLC fully-automatic control.
n. When the liquid level of clean water pool reaches high level, start the clean
water pump, and then slowly open the outlet valve of clean water pump.
When outlet pressure reaches and stays stably at rate pressure, then slowly
open the clean water pump outlet valve. When the clean water pump
switches to the "Auto" control mode, adjust the liquid level of clean water
pool on the centralized control display panel when the clean water pump is
started up, and the liquid level when the clean water pump is stopped.
o. When the oil reservoir level reaches the high level, open the outlet valve
(remember) of oil delivery pump and then start the oil delivery pump.
When the oil delivery pump switches to "Auto" control mode, adjust the
liquid level of oil collecting sump on the centralized control display panel
when the oil delivery pump is started up, and the liquid level when the oil
delivery pump is stopped.
p. When the liquid level of oil residue box reaches high level, start oil residue
box mixer, open residue delivery pump inlet valve, and start residue delivery
pump. When outlet pressure reaches and stays stable at rate pressure, then
slowly open the residue delivery pump outlet valve. When the residue
delivery pump switches to "Auto" control mode, adjust the liquid level of oil
residue box on the centralized control display panel when the residue
delivery pump is started up, and the liquid level when the residue delivery
pump is stopped.
5.3.6.3 Shutdown
a. When the liquid level in #1 oil separator drops to low level, stop the
primary pump and close the inlet air filling valve (i.e., aerated solenoid
valve) of oil water separator.
b. When the liquid level in water intake pool drops to low level, stop the
secondary pump and close the inlet air filling valve (i.e., aerated solenoid
valve) of dissolved air unit, and stop #1, #2 and 3 # agent dosing pumps.
58
c. Stop efficient air flotation unit scraper.
d. When the liquid level of efficient air flotation unit drops to low level, stop
the press filter pump.
e. When the liquid level in clean water pool drops to low level, stop the clean
water pump. When the liquid level in oil reservoir drops to low level, stop
the oil delivery pump. When the liquid level in oil residue box drops to low
level, stop the residue delivery pump and the mixer.
f. If an equipment is outage for a long time, open the vent valve to discharge
the water inside, and open the drainage valve to discharge the liquid inside
the pump.
6 Chemical System Operation Manuals
6.1 Water Treatment System
6.1.1WTP Process Flow
Raw water tank to raw water pump, the activated carbon filter cation
exchangercarbon removal devicethe middle water tank the middle water pump
toanion exchanger, ion exchanger, Yin and Yang are theof the mixed bedin
addition to salt water tank in addition to salt water pump to the user
6.1.2 System Control Overview
System operation and regeneration are controlled by program with pneumatic

operating valves, manual isolation valves and maintenance service valves. The
primary desalination system controls conductivity for output water via anion bed
outlet, and the mixed bed also be controlled by the conductivity at its outlet. The
waste water treatment system applies automatic operation mode.
6.2 Operation of Rotary Equipments
6.2.1Operation of Centrifugal Pump
6.2.1.1Pre-start inspection
a) Area around pump and motor must be clean without any sundries influencing
operation.
b) Coupler can rotate freely without jam, and the coupler hood and anchor bolts
are firmly fixed.
59
c) Lube oil level is 3mm above centerline, and the oil level meter is of good
condition.
d) Motor wire connections and earthing are of good condition, control panel are
supplied with power and air.
e) All meters and gauges are of good condition and in standby.
f) To-be-transferred liquid is sufficient and its reservation container outlet valve

must be open, vent valve properly opened and level exceeds 1/2.
g) Pump outlet valve must be closed and inlet valve fully opened; the cooling
water source is sufficient and cooling water inlet is opened with unobstructed
water flow.
h) For a pump out of operation for more than half a month, it must contact
electrical to measure the motor insulation before startup.
6.2.1.2Startup
a) Click centrifugal pump icon, select START button, when bearing rotation
direction, pump outlet pressure and motor current up to normal value, slowly
open outlet valve to adjust to normal working conditions.
b) If pump works for lifting water up, the pump also need to fill full of water to
empty the air residued inside.
6.2.1.3 Operation maintenance
a) Frequently inspect pump outlet pressure, motor current, lube oil quality and
level; pay attention to the container level is at normal position avoiding idling
pump running. It is not proper if the centrifugal pump runs continuously under
30% of designed flow; otherwise, bypass or circulating pipe needs to be
installed.
b) Never keeps the centrifugal pump continuously running more than 3 if pump
outlet valve closed; or never use inlet valve to control the pump flow.
c) The running pump and motor temperature must not exceed 65 and bearing
temp must not exceed 70.
d) During running, the pump should be free of abnormal noise, if it is, contact
maintenance for handling.
e) If pump lacks of oil or oil becomes deteriorated, it must timely makeup oil or
replace.
60
f) Mechanical seal must be free of leakages and overtemperature. Packing seal

should shows continous drop state, which is properly 30 drops.
g) Switch pump over as rotary equipments switchover provisions. Before

switchover, firstly start standby pump, when standby one runs normally, stop
the running pump.
6.2.2Operation of Piston Metering Pump
6.2.2.1 Pre-start inspection
a) Area around pump and motor must be clean without any sundries.
b) Oil quality and oil level for the pump is of normal state.
c) Pump inlet and outlet valve as ell as pressure gauge isolation valve must be
open.
d) Rotate the coupler to make piston move forwards and backwards several times,
which must be free of jam.
e) Bolts for all pump components connections must be firmly fixed, the pump
body is of good condition and all control panel is energized and supplied with
air.
f) To-be-transferred liquid is sufficient and its reservation container outlet valve

must be open, vent valve properly opened and level exceeds 1/2.
g) For a pump out of operation for more than half a month, it must contact
electrical to measure the motor insulation before startup.
6.2.2.2 Startup
a) Click pump, select the popped START button and confirm, then the pump
starts.
b) Adjust pump stroke as required.
a) Frequently inspect pump outlet pressure, oil quality and oil level.
b)Pump bearing temp. must not exceeds 70 and motor temp. must not exceeds
65.
c) Running sound of pump must be in a continuous and uniform state without

noise.
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d)Pay attention to the container level is at normal position avoiding idling pump
running
e) Leakage loss of piston metering pump at packing seal point must not exceeds 15
drops, otherwise tighten the packing suppression cover.
f) When adjusting pump stroke, never in a too far too fast way, and lock it with the
adjusting components.
6.2.3Operation of Roots Blowers
6.2.3.1 Pre-start Inspection
a) Area around fan and motor must be free of sundries, anchor bolts are firmly
fixed, motor earthling is of good condition and control panel is energized.
b) Manually rotate the equipment which can rotate freely without jam; protective
hood is firmly fixed and belt is of good condition and tensioned.
c) Connection of all components are firmly jointed without looseness; lube oil
quality can meet the requirement and oil level is normal.
d) All meters are of good condition with correct indication.
e) Valve and bypass valve on Roots blower inlet and outlet pipes must be fully
opened to guarantee an unimpeded flow; cooling water is sufficient and
unblocked.
6.2.3.2 Startup
a) Open air vent valve and start roots blower for 5mins idle running.
b) After operation turns to normal state, gradually adjust blower outlet valve and
close the vent valve to regulate to normal output. Note: never run the blower
under overload.
a) Inspect motor current is no more than the rated value and running sound is
normal. If it exists any strike or friction, immediately stop the motor and restart
after trouble shooting.
b) Bearing temperature must be lower than 70 and motor temperature lower
than 65.
c) Check to ensure oil quality and oil level is of normal state.
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d) When switchover the fans, firstly start the standby one, when the standby one
runs normally, then stop the running fan.
e) During startup, never start with inlet and outlet valve closed.
f) Frequently inspect fixation of all components, which must be free of looseness.
g) Frequently inspect fixation of all components, which must be free of looseness.
6.2.3.4 Shutdown
a) Press the STOP button and fan stops.
b) Close primary and secondary fan outlet valves as well as cooling water valve.
6.3 Thermal Equipment Steam & Water Supervision Provisions
6.3.1Overview
Steam & water monitoring of thermal equipment goes throughout the whole
startup, operation and shutdown process, which is to guarantee steam and water
quality and prevent from corrosion, scaling and salification. Therefore, relevant
boiler internal and external chemical dosing must be applied, which includes
condensate ammonia dosing, feedwater ammonia dosing, feedwater hydrazine
dosing, boiler water PH adjustment and phosphate dosing, grey water anti-scaling
treatment and closed cooling water dosing, etc. Each unit is equipped with one set
of steam & water sampling system, which is configured with march-past HT & HP
rack and dry & wet mixing pan, condenser leakage detecting and sampling device
near hotwell; for the startup boiler, there is also one set of dosing system and one set
of steam & water sampling system.
6.3.2Chemical Supervision during Unit Startup
6.3.2.1 Preparations before whole set unit startup.
a) Operators ensure demineralized water tank level is above 5.5m.
b) Operator must timely regulate working conditions of makeup water treatment

system to provide enough water, and the out of operation demineralized water
system should be in standby state.
c) Check to ensure all analyzing instruments are well-calibrated, the chemicals are
complete and enough, analyzing containers are complete.
d) Well prepare for making ammonia and hydrazine solution, inspect ammonia
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dosing pump and hydrazine dosing pump are in standby state.
e) Logs or analysis report forms are complete.
f) Contact shift leader for inspection and open steam & water primary valve and
all primary dosing valves.
g) Prepare phosphate solution and sodium dioxide solution. Ensure phosphate

dosing pump is in standby state.
h) Steam & water sampling device is of good condition and all instruments are
normal; ensure cooling water of sampling device is unblocked, then open main
cooling water valve and drain water main valve.
i) Inspect to ensure all kinds of valves for steam & water sampling system
including HT & HP valve, pressure reducing valve, meter inlet water valve
closed, cooling water inlet and outlet valves of all stages opened. All cooling
water lines are unblocked with sufficient flow, and manual sampling valves of
all lines are all opened.
j) Inspect to ensure sampling device power cable, input and output signal is
correct and reliable.
k) Put the auto thermostat for samples of steam & water into service, then select
the second mode, i.e., refrigerator is at usually working state and use heater to
keep media temperature at balance control trough.
l) Sampling points, ammonia, hydrazine and phosphate dosing plant, instrument

plant and analyzing plant must be with sufficient of illumination.
m) High pure water for analyzing is sufficient.
6.3.2.2 Chemical supervision during drum water filling or circulating period
a) Timely start feedwater ammonia and hydrazing dosing pumps after receive
command of drum filling from shift leader. Contact with shift leader to open
primary ammonia and hydrazine dosing valves and regulate the PH to
8.80-9.30, hydrazine concentration 30-50g/l. Inspect cooling water entered into
HT pressure reducing rack is proper or not. Open blowdown valve of feedwater
sampling to the full opening, then open primary and secondary HP needle valve
to blowdown. After blowdown water becomes clear, open third sampling valve
and pressure reducing valve and close the blowdown valve. Regulate pressure
reducing valve opening to inspect if flow at manual sampling valve is higher
than 1500ml/min, and then reduce the flow to 350-500ml/min.
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b) After drum level can be detected, start boiler water phosphate dosing pump to
fill phosphate inside boiler for half an hour and stop the pump. Open left and
right blowdown valves for boiler water sampling to full open position, then
open primary and secondary HP needle valve for blowdown. After blowdown
water becomes clear, open third sampling valve and pressure reducing valve
and close the blowdown valve. Regulate pressure reducing valve opening to
inspect if flow at manual sampling valve is higher than 1500ml/min, and then
reduce the flow to 350-500ml/min.
c) Take samples and analyze ferric content of feedwater and boiler water. When
Fe1000g/l, drain drum water into trench to replace water; when Fe1000g/l,
reclaim water back to condenser.
d) When feedwater Fe80g/l, thoroughly analyze feedwater quality. When

feedwater DO (Dissolved Oxygen)30g/L, SiO280g/L and
H(Hardness)2.5mol/l, boiler water clear and Fe200g/l, report to shiftleader
and operator that drum water quality can meet the code requirements,
combustion system can be startup.
6.3.2.3 Chemical supervision during hot state rinsing
a) After received command for boiler firing, from shiftleader, open left and right
blowdown valves for saturated steam and superheated steam sampling to full
open positions, then open the left and right primary and secondary HP needle
valves for blowdown. After blowdown water becomes clear, open third
sampling valve and pressure reducing valve and close the blowdown valves.
Regulate pressure reducing valve opening to inspect if flows of saturated steam
and superheated steam manual sampling points are higher than 1500ml/min,
then reduce the flows to 350-500ml/min.
b) Take condensate, feedwater, boiler water, saturated steam and superheated

steam samples for analysis once 30min, then start dosing pump and regulate
pump strokes timely. Pay attention to that if put condensate water fine treatment
mixed bed into service, it need adjust ammonia dosing amount as PH value at
high speed mixed bed outlet.
c) Supervise boiler water PH must be within range of 9-10, PO23PPm, if which

can not meet the requirement, timely adjust phosphate pump stroke.
d) When boiler water Fe200PPb, saturated steam Fe50PPb, pay a repeative

analysis and report to operation and shiftleader, the boiler hot state rinsing
result meet the code requirements.
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6.3.2.4 Chemical Supervision before turbine rolling
a) After boiler hot state rinsing meet the requirement, flush and adjust left and
right superheated steam manual sampling pipe.
b) When drum pressure up to 1.5MPa, contact shift leader to put the continous
blowdown into service. Fully open blowdown primary valve and adjust
secondary valve opening; take samples of condensate water, feed water, boiler
water and saturated steam as well as superheated steam and analyze, adjust
dosing pump dosing amount as needed. If steam & water quality is not good,
timely contact with shift leader and increase frequency of periodical blowdown.
c) Take left and right superheated steam samples for analysis, when SiO260g/l
and Na20g/l, report to operator and shift leader that the steam quality can meet
the requirement and is available for turbine rolling.
6.3.2.5 Chemical supervison before sychronization
a) After rolling, strictly analyzed condensate water quality, when H5.0mol/l,

and water becomes clear, inform shift leader and operator that condensate
discharging can be stopped for recycling.
b) Before synchronization, it needs to strictly analyze left and right superheated

steam samples.
c) When superheated steam SiO230g/l & Na20g/l, inform shift leader and
operator to ready for synchronizing.
6.3.3Chemical Supervision during Unit Normal Operation
6.3.3.1 Chemical supervision during condenser operation
a) Inspect condensate temperature once every two hours and analyze pH, hardness,
silicon, sodium, ammonia and conductivity once every two hours, and
dissolved oxygen, ferrous once every four hours.
b) If condensate water indexes out of limits during operating, increase analysis

frequency and items. Or if condensate water becomes deteriorated, report to
shift leader, operator and as chemical dept, then carfully coordinate turbine to
find causes and apply trouble-shooting.
c)
condenser leakage and conduct the leaking stoppage work; while, if hardness
relevant supervisor for unit shutdown.

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6.3.3.2 Chemical supervison during deaerator running
a) Each shift must pay a jobsite inspection at least one time for inspecting
deaerator oxygen exhaust valve opening, deaerator level, pressure and
temperature and make comparison with turbine control instruments for
instrument calibration.
b) During normal operation, deaerator should maintain pressure 0.67MPa as

gauge indicated, and temp. 162, proper oxygen exhaust valve opening and
dissolved oxygen<7g/l.
c) Analyze dissolved oxygen once every two hours. When which can not meet
code requirement, timely inform turbine to find causes and conduct
adjustment; when dissolved oxygen in feedwater is more than 20g/l, and which
cannot drop within 24 hours, ask the supervisor for a emergency shutdown.
d) Thoroughly analyze chemical indexs as stipulated regulations once every two

hours, e.g. feed water hydrazine analysis once every two hours, if which is
abnormal, timely report to shift leader and operator, take measures to handle it
and adjust outputs of dosing pumps as lab reports.
e) Take feedwater samples once every four hours for ferrous analysis, and ask
CCR for parameters as feedwater flow, pressure and temp. Moreover, analyze
feedwater PH once every two hours.
f) Take boiler water samples once every two hours for thorough analysis, if which
is abnormal, contact with shift leader or operator to take measures for handling.
When
g) Take superheated steam sample and saturated steam sample once every two
hours for silicon dioxide, soudium and ferrous analysis.
h) According to steam & water quality, adjust condensate water ammonia dosing,
feedwater ammonia and hydrazine dosing as well as boiler water phosphate
dosing amount.
i) According to steam & water quality, inform boiler for periodical and continous
blowdown adjustment, for which blowdown within 0.31.0% and steam &
water normal loss2%, steam & water yield>98%.
j) Strengthening works of dosing pump inspection and maintenance, sampling

temp. & flow inspection and adjustment for prevention of on-line instrument
water interruption. Conduct patrol inspections to all equipments and systems
once every two hours and write down on-line instrument data.
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k) When steam & water quality becomes abnormal, increase analyze frequency
and sampling point, strengthen supervision works, then report to operator and
shift leader to find causes and take relevant measures for handling. When the
water quality is seriously deteriorated and cannot be restored to normal state,
ask shift leader and chemical dept. for shutdown.
6.3.4Chemical Supervision during Unit Outage
6.3.4.1After receiving shutdown command from shift leader, make relevant

preparations, if boiler needs outage and maintenance, make joint efforts and
supervision works.
6.3.4.2After unit shutdown, stop the steam & water sampling system, switch off all
power lines for instruments, close main on-line sampling valve and manual
sampling valve on panel.
6.3.4.3 After unit shutdown, stop all chemical dosing pumps and close relevant inlet and
outlet valves as well as all dosing valves. Contact shift leader to close all
primary chemical dosing valves and primary steam & water sampling valves.
6.3.4.4 Keep shutdown records including causes and time.
6.3.4.5Contact maintenance with defects which only can be handled after shutdown and
make relevant preventative measures.
6.3.5Unit Sampling Point Setting and Analysis Items
Max. Supervision Meters

Sampling Max. temp.
No. Press.
Points M DD pH O2 SiO2 PNa
MPa
Condensate
1 pump outlet 3.0 45
water
Deaerator
2 0.80 172
outlet water
Economizer
3 20.2 271
inlet water
Drum left
4 18.5 365
boiler water
Drum right
5 18.5 365
water
6 Left side 18.3 565
68
saturated
steam
Right side
7 saturated 18.3 545
steam
Left side
8 superheated 18.3 540
steam
Right side
9 superheated 18.3 540
steam
Reheater
10 3.31 540
inlet steam
HP heater
11 6.4 286
drain water
LP heater
12 0.4 146
drain water
Air heater
13 0.87 174
drain water
Closed cycle
14 0.37 33
cooling water
Generator
15 interior 0.3 40
cooling water
Note: Items with sign means measurement after ion exchangers, and items mean there
are measuring points.
6.3.6Operations of Water & Steam Sampling Devices
6.3.6.1The operation before startup
a. Cooling frame
1) All the high pressure valves need to be close.
2) All conjunctions and fasteners shouldnt be loosen and be fall off.
3) Put the pressure adjusting nut of constant pressure device at
4) Open the master valve of cooling water in-and-out parent pipesand the pressure
69
should over than 0.2MPa.
b. Artificial sampling boards, dash boards
1) Check all the conjunctions between valves and parts firmly.
2) The current-limiting valves of artificial sampling boards need.
3) Closed all the meter-sampling valves of dash boards.
6.3.6.2Device startup
a. Cooling frame
1) Open the in and out ball valves of cooling devices one by one in order.
2) The recoiling filter is on running.
3) Open the first inner door of sampling water device, and then the second one
(full), and open the blow-off door largest for draining.
4) Turn off the blow-off doors after draining.
5) Open stopped valves of constant pressure devices.
b .Artificial sampling boards
1) Open the door of artificial sampling boards.
2) Analyze the flow rate of artificial sampling.
c. Dash boards
1) Get out filter elements of each sampling water meter.
2) Take out the poles from each transmitter.
3) Open the inlet throttles of dash boards and wash pipes by 1 minute, then full
install them.
4) According to the quantity of sampling water meter, full open the outer
adjusting valves of constant pressure devices, while as to adjust the nuts for
meeting the request.
PSThe flow rate of manpower is 500ml/minDD, PH are 300ml/min, O2 meter is

500ml/min, other meters are 150ml/min
e. Stoppage devices
1) Close the sampling water inner first door and second door of cooling frame.
70
2) Close the throttle of dash boards.
3) Close the power of temperature controlling, meter and constant devices.
4) Close the cooling headwater of devices.
6.3.7Solutions of Water & Steam Quality Deterioration
6.3.7.1 Principles
a) When steam & water quality becomes deteriorated, quickly inspect if the sample
is the representative sample, analysis result is correct, analytical reagent and
analytical instrument is of normal state. Then after comprehensively analyze
steam & water quality deterioration and confirm the fact, immediately report to
shiftleader, put up with proposals and take measures to restore the steam and
water quality to the standard range.
b) When steam & water quality is deteriorated, the on-duty operator must write
down detailed notes including time, causes, solutions and result, if the on-duty
operator can not finish the trouble-shooting, then also make the detailed record
about work done, never hand over orally, simultaneously, the takeover shift must
continuously handle with the problems above and take down records with
measures and results.
c) According to steam & water deterioration degree, there are 3 kinds of

requirements for handling as bellows: Primary class: for corrosion possibly
caused by foreign matters, handle and restore to standard value within 72 hrs.
Secondary class: for corrosion must be caused by foreign matters, handle and
restore to standard value within 24 hrs. Tertiary class: for caused by undergoing
corrosion, if water quality did not turn good, shutdown unit within 4 hrs. For
abnormality handling, if which can not turns good within the stipulated time,
then apply measures for the higher class treatment.
6.3.7.2 Solutions for feedwater deterioration

Abnormal
No Analysis of Causes Solutions
Symptoms
1. Oil content in
1. Contact shiftleader, find
feedwater
causes and handles timely.
2. Initial startup and
2. Flush sampling pipes
Turbid many mechanical
1 3. Reinforce PH adjustment and
feedwater impurities.
thermal/chemical handling.
3. Serious feedwater pipe
4. Find causes and handle the
corrosion
problem timely.
4. Turbid source water
71
enters into feedwater.

1. Leakage inspection and
1. Condenser leakage. blockage.
2. Bypass of ondensate 2. Tightly close the valve and
water treatment system pay a trouble-shooting.
Improper
leakage. 3. Put mixed bed out of service,
2 feedwater
3. Mixed bed exhausted. and switchover to the standby
hardness
4. Improper drain water bed.
5. Hardness analytical
4. Reject the disqualified drain
regent polluted. water.
5. Change the analytical reagent.
1. Improper ammonia
1. Adjust ammonia dosing
dosing;
amount;
2. Ammonia dosing
Improper 2. Find causes and apply with
system faults.
3 feedwater the solutions.
3. Sampling temp
PH 3. Adjust sampling temp.
overlow or overhigh.
4. Find source acid and dispose
4. Acidic water mixes
in time.
into feedwater
1. Poor deaerator
1. Contact shift leader for
working conditions;
handling.
2. Deaerator inner defects
Dissolved 2. Repair.
3. Incorrect instrument
oxygen 3. Contact I & C maintenance to
4 indication.
out of adjust the on-line meters.
4. Analytical reagent lose
limits 4. Replace new reagent.
efficacy
5. Find leakages and apply
5. Feedwater system
sealing to it.
untight sealing
1. Stop exhausted mixed bed and
1. Mixed bed exhausted.
regenerate it.
2. Untight bypass of
2. Tightly close the bypass or
condensate water
dispose the defects.
treatment system
3. Stop recollecting and exhaust
Feedwater 3. Disqualified deaerator
into condenser.
silicon and recollecting water.
4. Find leakages and block them.
5 sodium 4. Condenser leakage.
5. Contact shift leader to adjust
out of
5. Sharp unit load
the operating conditions.
limits variation.
6. Replace qualified makeup
6. Polluted makeup
water.
water.
7. Replace the analytical reagent
7. Polluted analytical
and contact I & C maintenance to
reagent or meters failure
repair.
Feedwater
1. Hight ferrous and 1. Reinforce water replacing and
ferrous copper content during unit blowdown works.
6
and copper initial startup stage 2. Reinforce ammoniation and
out of
2. Feedwater system deoxygenization works.
72
limits corrosion. 3. Find disqualified source drain

3. High ferrous and water and reject.
copper content in drain
water
6.3.7.3 Solutions for boiler water deterioration

Abnormal
No Analysis of Causes Solutions
Symptoms
Reinforce blowdown works.
Insufficient drum
Reinforce blowdown and inner
Turbid blowdown.
1 handling, process silicon
symptom Initial boiler startup
flushing if necessary.
Tubid feedwater
Find causes and dipose.
Improve feed water quality.
High silicon and sodium
Reinforce blowdown works.
content in feedwater
Silicon Inspect quality of chemicals and
Insufficient drum
and change if neccesary.
blowdown.
2 sodium Adjust phosphate dosing amount
Impure phosphate.
out of and reinforce blowdown and
Sharp boiler load change
limits stabilize operating conditions.
Phosphate content of
Adjust phosphate dosing
boiler water out of limits.
amount.
High phosphate
concentration.
Dilute phosphate solution and
Dosing pump outlet
shorten pump stroke.
interconnection valve still
Boiler Inspect to ensure the valve is
opened.
water closed or not.
3- Sharp change of boiler
PO4 Contact to adjut boiler working
3 operating conditions and
content conditions and enhance the
high boiler water
exceeds blowdown frequency.
concentration ratio.
limit Reinforce the supervision work
Remaining phosphate
and blowdown freqence.
dissolved.
Shorten the pump stroke.
Too long dosing pump
stroke.
Low concentration of Increase pump stoke and
metering tank solution solution concentration.
Boiler Too much blowdown Reduce blowdown amount.
water Boiler working conditions Contact to stabilize boiler
3-
PO4 changed result in working conditions.
4 content temporary phosphate Improve feedwater quality.
lower than missing. Find causes and contact
standard High feedwater hardness. maintenance for handling.
value Dosing system blockage or Adjust sampling flow.
leakage. Contact maintenance for
Sampling flow is low and handling.
73
unpresentative.
Dosing pump failure.
High feedwater
conductivity;
High Find causes and dispose
Insufficient boiler
5 conductivi Reinforce blowdown work
blowdown.
ty Adjust chemcia dosing.
Too much chemical
dosing.
Adjust chemical dosing amounts
Boiler Insufficient phosphate
Adjust blowdown amount
water low dosing.
Adjust ammonia dosing amount
PH or Too much blowdown
Find acidic water source and
phenolpht Insufficient feedwater
contact relevant person to dipose
6 halein ammonia dosing.
it. Stop mixed bed and fill
alkalinity Acidic water or mixed bed
sodium dioxide into drum to
low than leaked resin enters into
adjust it.
standards boiler
Contact to adjust operating
Sharp unit load change.
conditions
6.3.7.3 Solutions for steam quality deterioration

Abnormal
No. Analysis of Causes Solutions
Symptoms
High boiler water salt
content. Inspect continuous blowdown
Resin of hydrogen ion efficiency and increase
exchange column periodical blowdown frequency.
Conductivi
exhausted Contact to replace it.
1 ty out of
Inaccurate instrument Contact maintenance to handle
limits
indication. it.
Steam & water separator Dispose after boiler shutdown
exists defect Contact shiftleader to adjust.
High drum level.
Disqualified boiler water
Refer to solutions for boiler
quality.
water deterioration.
Severe change of boiler
Contact shift leader to stabilize
operating conditions
operating conditions.
Disqualified
Improper Contact shift leader to handle.
Desuperheating water for
steam Contact maintenance to handle
boiler superheated steam
2 silicon and after boiler shutdown.
Drum steam & water
sodium Contact shift leader to dispose
separator failure or low
contents it.
efficiency.
Adjust chemical dosing amount.
High drum level.
Inspect continuous blowdown
Too much chemical
efficiency and increase
dosing.
periodical blowdown frequency.
High boiler water salt
74
content.
6.3.7.4 Solutions for condensate water deterioration

Abnormal
Symptoms
1. Reinfore supervision work,
Condenser leakage inspect leakages and block.
Mixed bed exhausted. 2. Put the exhausted mixed bed
Hardness
Too much amminia out of service for regeneration.
and
dosing 3. Adjust ammonia dosing
1 conductivit
Hydrogen ion exchange amount.
y out of
column exhausted. 4. Contact instrument for
limits
Inaccurate instrument replacement.
indications 5. Contact maintenance for
calibrations.
Poor condenser vacuum
Contact shift leader and inspect
sealing
leakages and block.
Improper Poor condensate pump
Switch condensate pump and
dissolved gland packing sealing
2 repair the defect one.
oxygen Too much makeup
Adjust and stabilize working
content water.
conditions.
Vacuum pump failure
Contact for maintenance.
and low efficiency.
6.3.8Operations of Ammonia System
6.3.8.1 Prestart inspection
a) Inspect oil level of dosing pumps, pressure gauges, regulators and level meters
are of normal state; control panel is already energized, and panel power switch
at IN OPERATION position and select switch to MANUAL, dosing pump is in
standby.
b) Put ammonia dosing pump piston stroke to ZERO position.
c) Rotate pump rotary components to inspect jam or inflexible rotation problems.
d) Inspect motor rotation direction is the same as arrow showed or not.
e) Inspect to ensure that outlet valve of ammonia solution tank and main pipe
interconnection valve are fully opened and level of solution is high.
f) Inspect to ensure inlet and outlet valves of ammonia dosing pump are fully
opened, primary dosing valve at local fully opened, relevant dosing
interconnection valve closed.
75
g) Inspect dosing pump extraction pipelines are free of leakage and pump anchor
bolts are firmly fixed.
6.3.8.2 Startup
a) Press START button to start the dosing pump.
b) Increase or decrease pump stroke via the panel buttons. Put the metering pump
into normal operation, then each pump will dose for the relevant pump.
c) After pump runs normally for 30min, take sample for analysis, if which can not
meet the requirements, timely find causes and dispose it. Conduct continous
chemical analysis till the result meet the requirements and then turns into
normal analysis stage.
d) During normal operation, only one ammonia solution tank supply solution, if
which is under low-level, switch to the other tank for service.
e) After ammonia dosing pump operation becomes stable, inspect conductivity

meter transmitter, then open relevant valves after sampling pipe is ready for
service, contact I & C to activate conductivity meter and on-line PH meters.
f) Ammonia solution tank level can be observed from jobsite, when level drop to
low level XL, alarm is activated, while, when drop to low-low level XLL,
metering pump stops automatically.
g) When running pump faults, open the inlet and outlet valves of standby one as
well as relevant outlet interconnection valve to start the standby pump and then
dispose problems existing.
6.3.8.3Shutdown
Press SHUTDOWN button to stop it, and then close pump inlet and outlet
valves and pressure gauge isolation valve, put control panel power OUT of
OPERATION position. When unit needs a long-term outage, drain out solutions in
pump and pipelines and flush with fresh water. During shutdown, it must contact
with shift leader to close primary dosing pump.
6.3.9Operations of Feedwater Hydrazine Dosing System
a) Inspect oil level of dosing pumps, pressure gauges, regulators and level meters
are of normal state; control panel is already energized, and panel power switch
at IN OPERATION position and select switch to MANUAL, dosing pump is in
76
standby.
b) Put hydrazine dosing pump piston stroke to ZERO position.
c) Rotate pump rotary components to inspect jam or inflexible rotation problems.
d) Inspect motor rotation direction is the same as arrow showed or not.
e) Inspect to ensure that outlet valve of hydrazine solution tank and main pipe
interconnection valve are fully opened and level of solution is high.
f) Inspect to ensure inlet and outlet valves of hydrazine dosing pump are fully
opened, primary dosing valve at local fully opened, relevant dosing
interconnection valve closed.
g) Inspect dosing pump extraction pipelines are free of leakage and pump anchor
6.3.9.2 Startup
a) Press START button to start the dosing pump.
b) Increase or decrease pump stroke via the panel buttons. Put the metering pump
into normal operation, then each pump will dose for the relevant pump.
c) After pump runs normally for 30min, take sample for analysis, if which cannot
meet the requirements, timely find causes and dispose it. Conduct continuous
chemical analysis till the result meet the requirements and then turns into
normal analysis stage.
d) During normal operation, only one hydrazine solution tank supplys solution, if
which is under low-level, manually switch to the other tank for service.
e) When dosing pump operates stably, inspect to ensure deaerator inlet water flow
transmitter is of normal state, then open relevant valves, put hydrazine pump
into auto operation.
f) Hydrazine solution tank level can be observed from jobsite, when level drop
to low level XL, alarm is activated, while, when drop to low-low level XLL,
g) When running pump faults, open the inlet and outlet valves of standby one as
well as relevant outlet interconnection valve to start the standby pump and then
dispose problems existing.
6.3.9.3 Shutdown
77
a) Press SHUTDOWN button to stop it, and then close pump inlet and outlet
valves and pressure gauge isolation valve, put control panel power OUT of
OPERATION position.
b) Hydrazine solution tank level can be observed from jobsite, when level drop to
low level XL, alarm is activated, while, when drop to low-low level XLL,
c) When unit needs a long-term outage, drain out solutions in pump and
pipelines and flush with fresh water.
d) During shutdown, it must contact with shift leader to close primary dosing
pump.
6.3.10Operations of Phosphate Dosing System
a) All valves of phosphate dosing system are of good conditions; pump inlet and
outlet valves as well as pressure gauge isolation valves are fully opened and
relevant dosing interconnection valve is closed
b) If the service tank level is above 1/2, the tank outlet valve and relevant main
pipe interconnection valve are fully opened, while, the standby tank outlet valve
is closed.
c) Phosphate metering pump and motor are standby and oil level is normal.
d) Set the phosphate dosing pump piston stroke to ZERO position.
e) Rotate pump rotary components to inspect jam or inflexible rotation problems.
f) Inspect motor rotation direction is the same as arrow showed or not.
g) Contact boiler to open drum primary, secondary and tertiary valves
h) Inspect dosing pump extraction pipelines are free of leakage and pump anchor
6.3.10.2 Startup
a) Press phosphate dosing pump STRAT button on control panel, and adjust pump
stoke as chemical analysis result to put the dosing pump into operation.
b) Inspect pump and motor sound, and the pressure indicated pressure shall be
high than the drum pressure.
78
c) After 30minutes operating, take boiler water samples for drum and analyze the
quality, if which cannot meet the requirement, timely adjust pump stroke.
6.3.10.3 Shutdown
a) Press dosing pump SHUTDOWN button to stop the pump.
b) If for a long time shutdown, then close pump inlet and outlet valves. After
standby pump stops, the interconnection valves must be closed too. If for a
long-term outage, the residual solution in pump and pipelines must be drained
off and flush with fresh water.
c) During unit shutdown, contact shift leader to close the primary dosing valve.
6.3.11Chemical Supervision of Startup Boiler
6.3.11.1 Chemical supervision during startup stage
a) After receive boiler filling command, contact boiler to open drum chemical
dosing valve. Then start phosphate dosing pump to fill solution into drum and
maintain boiler water PO43- within 515PPm
b) After BFP startup, starts ammonia dosing pump and open relevant valve to fill
ammonia into feedwater and maintain feedwater PH within 8.809.30.
c) After boiler firing and pressurizing, fully open primary and secondary sampling
valves, and then close cooling water valve to flush pipelines. Then 10-15min
later, open cooling water valve, the pipe flushing is over. Adjust secondary
sampling valve opening to guarantee sample water temp. 30 and flow
within 500700ml/min.
d) Contact boiler to open continuous blowdown valve and begin take steam &
water samples for analysis.
e) When analyzed steam index as Na+15PPb & SiO220PPb, inform shift

leader that steam is qualified for boiler start and it can send auxiliary steam to
steam header.
6.3.11.2 Chemical supervision during normal operation
a) Analyze startup boiler steam and water sample once every four hours, if which
is not good, quickly fined causes and contact to solve it.
b) Adjust dosing amount as steam and water qualities.
c) Reinforce dosing pump inspection and maintenance works.
79
6.3.11.3 Chemical supervision during shutdown
a) Stop relevant dosing pumps and close relevant dosing valves after receiving
startup boiler shutdown commands.
b) Close primary and secondary sampling valves and cooling water valve.
c) For long-time standby and short-time running characteristics of startup boiler,

ordinarily, it always drain all residual water out when boiler is still hot for
drying the boiler to protect with the functions of coordinated drying agents. The
only work after that is to change invalid drying agent periodically.
d) To protect boiler during a short term outage, it only need to fill NaOH &
Na3PO4 mixture solution to control the alkalinity within 5-12mmol/l.
6.3.12Operations of Outage Boiler Maintenance
6.3.12.1 Protection with pressurized and deaerated feedwater
After boiler shutdown, fill boiler with deaerated feedwater and keep a certain
pressure and flow for preventing from air leaking in.
a) Standby running boiler (Service lifetime about 7 days). After boiler shutdown,
decrease the pressure to 0.5-1.0MPa, i.e., boiler protection with pressurized
water. When temp. of superheater shell is lower than feedwater., open boiler
vent valve at the highest point to fill superheater with feedwater from back
flushing side till water overflows from air vent valve. Then after that,
maintain the pressure within 0.5-1.0MPa making feedwater overflows from
saturated steam sampling points with flow 50200L/h. Take boiler water or
saturated steam sample once every four hours and analyze dissolved oxygen
content to ensure it no more than 7ug/L, otherwise, contact boiler for
periodical blowdown.
b) Protection after maintenance (service lifetime no more than 7 days). Before

protection, ensure boiler proper is flushed clean and water from periodical
blowdown is clear and apparent. Fill boiler with qualified feedwater till water
overflows from superheater air vent valve. Open boiler superheater back
flushing valve and boiler water sampling valve and keep pressure about
0.51.0MPa and overflow 50200L/h. Take boiler water or saturated steam
sample once every four hours and analyze dissolved oxygen content to ensure
it no more than 7ug/L, otherwise, contact boiler for periodical blowdown.
6.3.12.2 Protection with hot boiler oven drying method
80
After boiler shutdown, pressure drops to stipulated value, fast drain off
residual water inside boiler and dry heating surfaces with residual temp.
a) After boiler shutdown, quickly close all dampers and furnace doors to seal the
furnace and prevent fast heat loss.
b) When drum pressure drops to 0.5-0.8MPa, quickly drain off residual water.
c) After drainage, immediately open air vent valves, steam exhaust valve and
drain valves using natural ventilation to exhaust moisture inside boiler till glass
sheet free from existing dew formation.
6.4 Trouble Shooting
6.4.1Trouble Shooting of ACF

No Abnormal
Analysis of Causes Solutions
. Symptoms
Active carbon caked. High intensity back
Water distributor failure flushing
High ACF outlet
result in bias flow Maintenance
1 water turbidity
High incoming water Guarantee high outlet
and COD
turbidity. water quality.
Poor backflushing effect Back flush again.
ACF outlet water Plated weld Loose or
mixed with cracked Stop for maintenance.
2
filtration Water distribution lay Stop for maintenance.
materials disordered.
External regeneration and
Low ACF cycle Active carbon polluted.
active carbon
3 output water Active carbon missing
replacement.
amount due to backflushing, etc.
Makeup active carbon.
6.4.2Trouble Shooting of Demineralized water Equipments

No. Abnormal Symptoms Analysis of Causes Solutions
Cation bed deeply Immediately stop for
exhausted. regeneration and dose
Cation bed outlet Cation bed back more acid.
1
water with hardness flushing valve Close the valve tightly or
leakage or untightly contact maintenance for
sealing. repair.
Contact for
Resin leakage during Water outlet defects.
maintenance.
2 cation or anion bed Quatz layer
Reload with quatz or fill
direct flushing disordered.
after screened.
81
Resin leakage from

Intermediate drain
3 Intermediate drain Contact for maintenance
pipe defect
pipe
Running bed Sudden Valve leakage of
Close the valve tightly or
4 conductivity, PH and acid or alkali
repair the valve.
acidity rise regeneration system
The should-open
valve did not open
or too small
Open relevant valve or
opening.
adjust valve opening.
During cation/ anion Acid or alkali
Stop for maintenance.
bed regeneration ejector damaged.
Open relevant valve
period, acid/ alkali Insufficient pressure
5 widely.
cannot be filled in or of ejector
Reduce the back
acid/alkali metering pressurized water
pressure.
tank leves rises High back pressure
Fastening and eliminate
of regenerating bed.
the leakage.
Acid or alkali
absorbing pipe
leakage
Wrong content
High CO2 content of
analysis. Reanalyze.
6 decarbonator outlet
Imbalance water Adjust.
water
and air intake.
Insufficient cation
bed flushing before
Shutdown to flush again.
bed in service
Anion bed outlet Find cause and dispose
Cation bed water
7 water with hardness timely.
leakage to
and SiO2 content rises Replace with new
intermediate tank
solution.
Impure alkali
solution.
Anion bed outlet
water conductiviy Anion bed
drops and then rise exhausted. Process regeneration.
8
again. (without Poor anion bed Regenerate again.
phenolphthalein regeneration effect
alkalinity)
Cation bed outlet
water conductiviy Cation bed Process cation bed
drops and then rise exhausted. regeneration.
9
again. (with Cation bed sodium Stop and try to find
phenolphthalein leakage causes.
alkalinity)
Anion bed SiO2 Chemicals for Replace the analysis
10
seriously exhausted, analysis lose chemicals.
82
While the parameter efficacy. Heat to 30

normaly decreased. Water sample lower Calibrate the meter
than 10
Silica-meter failure.
Too much flocculant
dosing.
Adjust pre-treatment
Poor regeneration
dosing amount.
effect
Regenerate again.
Resin lay caked and
Intensive backflushing
Too short cation bed flow bias
11 Maintenance.
cycle time Inlet and outlet
Change with qualified
water device defect
solution.
and flow bias
Resin regeneration or
Poor acid solution
replace.
Resin aged, polluted
or oxidized.
Too much flocculant
dosing. Adjust dosing amount.
Too less anion resin. Make up with new resins
Poor regeneration Find causes and
effect. regenerate it again.
Inlet and outlet Contact for maintenance
Too short anion bed water device defect Find causes and dispose.
12
cycle time. Poor decarbonating Replace with qualified
effect alkali.
Poor alkali quality Resin regeneration or
Resin aged, polluted replace.
or oxidized. Intensively back flush
Unflatness of resin and grind the resin flat.
surface.
Incorrect meter
Early mixed bed Calibrate meters
indication.
13 conductivity out of Inspect and dispose
Water leaks into
limits transmitter problems.
transmitter.
Chemicals for
analysis lose Replace the analysis
Early mixed bed SiO2 efficacy. chemicals.
14
out of limits Water sample low Heat to 30
than 10 Calibrate the meter
Silica-meter failure.
Outlet water cap
Resin exists in mixed
15 come-off or Stop for maintenance
bed resin catcher
damaged.
Mixed bed big Tightly close relevant
Demineralized tank
16 backflushing water valve or contact for
water deteriorated.
valve or acid/alkali maintenance.
83
valve was not tightly Find causes, and then

closed or valve process regeneration.
leaked. Regerate again.
Primary Regenerate or replace
demineralized water resin. When desalinated
system exhausted to water is polluted, isolate
affect mixed bed demineralized water
outlet water. tank, and replace tank
Mixed bed water under cases not
regeneration effect influencing water
is not good or resin supply.
lose efficacy.
Resin polluted and
aged.
6.4.3Trouble Shooting of Power Faults

No. Abnormal Symptoms Analysis of Causes Solutions
Contact shift leader and
electrical maintenance to
find causes and supply
power as soon as
possible.
Put the in-use instrument
power to OFF position
Put all switches for
Sudden rotary rotary equipments to
equipment shutdown STOP position, close all
and illumination pump outlet valves, and
lamps turn off. Power loss of WTP inlet and outlet valves of
1
Instrument power transformer all water treatment
source interruption. equipments.
Voltmeter indication After powered on, put
drops to ZERO. the water treatment
equipments into service
sequentially and
reinforce the water
quality supervision, if
during regeneration
period, and regenerate
again as the procedure
required.
6.4.4Abnormality Handling of Pump Rotation Equipments
6.4.4.1Trouble shooting for centrifugal pumps
84
Abnormal
Symptoms
Insufficient pump water
Stop pump and refill
filling before pump startup
water to replace air
or pump exists air inside.
inside.
Wrong wire connection
Contact for
and pump reverse rotation.
maintenance.
Pump inlet valve still
Open the inlet valve or
closed or valve core
repair.
come-off.
Contact for
No water or Water impeller come-off or
maintenance.
1 solution be blockage by impurities.
Enhance the level and
pumped out Water or solution tank
vent the air inside pump
level low.
out.
Water lines blocked by
Clear the sundries
foreigh matters.
away.
Motor running with phase
Contact electrical for
missing.
handling.
Serious mechanical sealing
Contact maintenance
wear caused severe water
for handling.
leakage.
Stop pump and vent air
out.
Pump inhales air Tighten the bolts.
Anchor bolts looseness. Stop pump for
Bearing wear. maintenance.
Obvious Friction between rotary Stop pump for
pump components. maintenance.
2
vibration and Pump intake with foreign Stop pump for
noise matters. maintenance.
Coupler misalignment. Stop pump for
Suction head over high or maintenance.
insufficient drawing water Reduce the head and
fill pump with enough
drawing water
Bearing lack of oil or oil
level low, or poor oil Adjust oil level or
quality. replace with new oil.
Improper bearing Stop pump for repair or
Pump bearing installation. reinstall the pump.
3 overtemperat Bearing broken. Contact for
ure Friction between rotation replacement.
components and fixation Contact maintenance
part. for adjustment.
Pump shaft deflection or Contact for alignment.
coupler disalignment.
85
Before pump startup, Re-start as provisions

Motor outlet valve still open. Contact for
overheated Fuse for one phase blown. maintenance
4
and Rotary parts friction or Contact for handling
overcurrent jam. Restore to normal
Overload running. working condition.
6.4.5 Leakage Handling of Acid & Alkali System
6.4.5.1Quickly find leaking point. For cases of strong acid mist smell or irritation,
everyone must wear protective mask, rubber gloves, rubber shoes and
acid-proof clothes. Pay attention to put trousers outside boots and flush with
fresh water before enter jobsite.
6.4.5.2If pipe leakage occurs, immediately cut off acid or alkali source, close outlet
valves of acid and alkali reservation tanks and outlet valves of acid or alkali
metering tanks, then inform shift leader and operator for handling timely.
6.4.5.3If acid or alkali reservation tank seriously leaks, start emergency acid or alkali
pump to transfer the residual acid or alkali to other tanks. If the leakage is not
serious, immediately contact maintenance to take temporary measures and
prevent from leakage extension. Then report to relevant dept. for arranging rush
repair.
6.4.5.4When acid or alkali metering tank leaks use the residual acid or alkali for
regeneration process, if no regeneration needed, the early regeneration can be
arranged, then contact maintenance for handling.
6.4.5.5If there is acid or alkali leakage, conform to Electricity Industry Safety Work
Rules to dispose the problem.
6.5 Oil & Water Index Control
6.5.1Control Index of Incoming Fuel oil

Standards
No Items Unit Test Method
Light oil Heavy oil
1 Chroma (ISO) 1.5 GB6540
0#0.85 Static
Specific Non-stan 0.98 ASTM
2 gravity dard oil GB1884
Eccentrici D1298
(15.6) as
ty0.96
reference
86
Standards
Light oil Heavy oil
Viscosity
3.0~8.0
20
Viscosity ASTM
3 cst 180 GB265
50 D445
Viscosity
13
98.9
4 Flow point 30 GB3535
ASTM D97
Solidifying
5 0 GB510
point
Flash point
65 GB261 ASTM D93
(open cup)
6
Flash point
90 GB267 ASTM D92
(closed cup)
Carbon
ASTM
residue (10% wt.% 0.25
D524
distilment)
7 Carbon GB268
residue100% wt.% 10
sample
8 Cetane value 45 GB386
9 H % 12 11
Moisture
10 wt.% 0.5 GB260 ASTM D95
content
ASTM
11 Ash content ppm 50 400 GB508
D482
wt.% 0.5 GB380
12 S
1.5 GB387
Cleanliness ASTM
13 Level 2
(Stability) D1661
MIL-S-831
14 Na+K ppm 0.5 50
29A
MIL-S-831
15 V ppm 0.5 40
29A
MIL-S-831
16 Ca ppm 2.0 10
29A
MIL-S-831
17 Pb ppm 1.0 1.0
29A
MIL-S-831
18 Ni ppm 30
29A
19 Low heating Cal/g 10260 9800 GB384 ASTM
87
Standards
Light oil Heavy oil
value D240
G-YX-ZD
Separating
20 ok S-RH-YFX
test
-02
G-YX-ZD
N-heptane
21 5 S-RH-YFX
undissolved
-04
6.5.2Control Index of After-treated Heavy Oil

Heavy Oil
No Items Unit Remark
Standards
Viscosity50 cst 180
1
Viscosity98.9 cst 13
2 Solidifying point 30
3 Flashing point 90
4 S wt.% 1.5
5 Na+K ppm 0.7
6 V ppm 40
7 Ca ppm 10
8 Pb ppm 1.0
9 Low heating value Cal/g 9800
6.5.3 Control Index of gas turbine inlet fuel oil

Standards
Light oil Heavy oil
1 Chroma (ISO) 1.5
2 Specificgravity(15.6 0.85 0.96
)
3 Viscosity20 cst 3.0~8.0
Viscosity50 cst 180
Viscosity98.9 13
4 Flow point 30
88
Standards
Light oil Heavy oil
5 Solidifying point 0
6 Flash point (open cup) 65
Flash point (closed cup) 90
7 Carbon residue (10% wt.% 0.25
distilment)
Carbon residue 100% wt.% 10
sample
8 Cetane value 45
9 H % 12 11
10 Moisture content wt.% trace 0.5
11 Ash content ppm 50 400
12 S wt.% 0.5
1.5
13 Cleanliness (Stability) grade 2
14 Na+K ppm 0.5 1.0
15 V ppm 0.5 40
16 Ca ppm 2.0 10
17 Pb ppm 1.0 1.0
18 Ni ppm 30
19 Low heating value Cal/g 10260 9800
6.5.4Waste Water Discharge Index

No Items Unit Standards Remark
1 PH value 6~9
2 Petrolem mg/L 10
3 Suspended solids mg/l 100
7Water & Steam Sample Collecting and Determination
7.1 Overview
Sampling of steam & water is one distinctive important step to guarantee the
89
accuracy of analysis result. To take required sample, it must use proper sampling
device and take sample from the representative point, morever, strictly conform to
relevant provisions for sampling, transportation and reservation.
a) Periodically flush the sampling pipe (at least once a week). Before system
inspection, flush relevant pipe and properly prolong the flushing time. Then
adjust flow to 500-700ml/min after flushing, and till flow becomes stable then
take sample.
b) When taking sample where with sample cooler, adjust sampling valve opening
to regulate water flow about 500-700ml/min, then maintain the flowrate and
simultaneously regulate cooling water flow to keep sample water temp. about
3040. For steam sampling must as designed flowrate.
c) For sampling of feedwater, boiler water and steam, it must maintain the
constant flowrate.
d) Water container must be of glass or plastic products, while, container for silicon
or other constituent analysis must be of plastic material.
e) Before taking sample, thoroughly clean sampling bottle and flush it with
sample water for three times, and then take sample.
f) For sampling on raw water pipe, the sampling point should be arranged at raw
water pump outlet or somewhere with flowing raw water.
g) The amount of new samples must be sufficient for test and re-check. The
sample for total analysis should be no less than 5L. If the water sample is turbid,
divide the samples into two bottles. Whereas, the water sample for single item
analysis must not be less than 300ml.
h) Ordinarily, it use fixed sampling bottle to take sample which is used to monitor
and control test sample.
i) After sampling, timely analyze samples and never store the samples. If
anything wrong, it must take and analyze sample again.
7.2 Alkalinity Determination
7.2.1Principles of determination
Water alkalinity means amount of substance which can take in hydrogen ion. It
is classified with phenolphthalein alkalinity and total alkalinity. Phenolphthalein
alkalinity means substance amount is determined by using phenolphthalein as
90
indicator with end PH is 8.3. Total alkalinity means substance amount is measured
by using methyl orange as indicator with end PH 4.2. If alkalinity0.5mg/l, it is
better use methyl red-methylene blue as indicator for the total alkalinity
determination with the end PH is 5.0.
7.2.2Analytical reagent
a) 1% phenolphthalein indicator
b) 0.5% methyl orange
c) Methyl red/methylene blue
d) 0.1N, 0.05N and 0.01N sulfuric acid solution
7.2.3Steps for determination
a) Fill 100ml transparent water sample into triangle beaker, then drip with 2-3
drops phenolphthalein indicator, if which turns into red, drip standard sulfuric
acid solution 0.1 or 0.5N into the beaker till the water back to colorless; if
solution with a low alkalinity, select micro burette and drip with 0.01N standard
sulfuric acid solution till the water turns to colorless, record volume of acid
consumption as a.
b) Then drip with Methyl red/methylene blue 2 drops (or methyl orange),
continuous drip sulfuric solution till shows purple or orange color, record the
acid volume consumption as b.
7.2.4Calculation
Phenolphthalein alkalinity= N.a/V103mmol/l
Total alkalinity= N.(a+ b)/V103mmol/l
Among the equation above: N means normal concentration of standard sulfuric acid
solution, a & b means volumes of standard sulfuric acid consumption for alkalinity
titration.
7.3 Acidity Determination
Water acidity means amount of substance which can take in hydroxide ion. It
takes methyl orange as indicator, i.e., drip methyl orange into sodium hydroxide
91
solution till the solution color turns into orange color (pH about 4.2). Determination
range is only limit to strong acid, normally inorganic acid, for which the acidity is
called methyl orange acidity. The method above is applicable for acidity
determination of cation bed outlet water.
a) 0.1% methyl orange indicator
b) 0.1N Standard NaOH solution
Fill 100ml transparent water sample into triangle beaker, drip two drops
methyl orange into the water, and drip 0.1N NaOH till shows orange color and
record the alkali consumption volume as a.
7.3.4Calculation
Acidity= N.a/V103mmol/l
Among the equation above: a means consumption volume (ml) of standard NaOH
for titration; N means normal concentration of NaOH solution; V means sample
water volume (ml).
7.4 Concentration Determination of Hydrochloric Acid
Take methylene red-methylene blue as indicator, drip into standard NaOH

solution till the color turns purple and finally turns into green (pH 4.2).
Methyl Red-Methylene Blue Indicator
0.1N Standard NaOH solution
a) Use pipette (5ml or 10ml) to intake sample water 1ml to conical flask (250ml)
which is already clean by silica-free water, then dilute sample water to 100 ml.
b) Drip 2 drops methylene red-methylene blue indicator, then use 0.1MNaOH for
92
titration till the color turns into green from purple, fininally record the NaOH
consumption as b.
7.4.4Calculation
HCL% = M.b36.5/(V1000) 100 = 0.365b
Among the equation above: M means molar concentration of standard NaOH

solution; N means volume of sample water as ml; b means volume of NaOH
solution consumption as ml; 36.5 means molecular weight of HCL.
7.5 Concentration Determination of Sodium Hydroxide
7.5.1Priciples of determination
Take the Methyl Red-Methylene Blue as indicator and the terminal PH is

about 5.0, and the color changes from green into red purple.
Methyl Red-Methylene Blue Indicator
0.1M, 0.05M, 0.01M sulfuric acid solution
7.5.3Measurement Procedures
a) Measure 1.0ml water sample precisely with pipette and put into 250 ml conical
flask, and dilute to 100ml with silica-free water.
b) Put in 2 drops of Methyl Red-Methylene Blue indicator, titrate with 0.1MH2SO4

to make the solution change from green into red purple and then record the
consumed volume a (ml).
7.5.4Calculation
NaOH% = Ma40/V1000100 = 0.40a
In the equation, M-molar concentration of standard surfuric acid solution
V- Water sample volume,
ml a-consumed surfuric acid solution volume during titration,
ml 40-molecular weight of NaOH.
7.6 Determination of Hardness

93
In the buffer solution of PH=100.1, eriochrome black T is used as indicator,

titrate ethylene diamine tetraacetic acid disodium salt (short for EDTA) stand
solution till the solution is pure blue. Based on the consumed volume of EDTA, the
sodium and magnesium content in the water can be calculated.
Ethylene diamine tetraacetic acid disodium salt (EDTA) 0.01N standard

solution 0.5%eriochrome black T indicator (1+4) triethanolamine
solution %LCysteamine hydrochloride 0.5% Acid chrome blue K indicator
Ammonia - ammonium chloride buffer solution
When hardness of the water sample is over 0.5mmol/l:
a) Take 100ml clear water sample and put into 250ml clean Erlenmeyer flask.
b) Add in 5 ml Ammonia - ammonium chloride buffer solution, put 2 drops of

0.5%eriochrome black T indicator, shake constently, titrate with 0.01NEDTA
standard solution to make the solution change from red into blue, and record the
volume of the consumed EDTA standard solution.
c) Calculation YD= Na/V10 3= 0.2a (mmol/l)
In the equation, N- concentration of EDTA standard solution
a-the sonsumed EDTA standard solution volume, ml
V- volume of water sample, ml
When hardness of the water sample is within 1500mol/l:
a) Take 100ml water sample and put into 250ml clean Erlenmeyer flask.
b) Fill in 2 ml 1%LCysteamine hydrochloride and 2 ml triethanolamine solution

(1+4), shake 1min and then fill in 5ml amonia - ammonium chloride buffer
solution and two drops of 0.5% acid chrome blue k indicator.
c) Shake constantly, use the micro burette to titrate with 0.01MEDTA standard
solution to make the solution change from tiny red into blue-violet, and then
record the consumed dard solution volume a.
d) Calculate YD= Ma/V10 6 (mol/l)

94
In the equation, M- the concentration of EDTA standard solution
a-The consumed EDTA standard solution during titrarion, ml
V- volume of the water sample, ml
7.7 Determination of Ammonia
In alkalinity solutions, ammonia and Nessler's reagent reacts and produces

yellow complex. The intensity of the color depends on the ammonia contents, as a
result, it can be compared with standard color grader to get the ammonia content in
the sample.
This method is adaptable for ammonia content measurement in demineralized

water, condensate and steam, within the measurement range of 0.12.5mg/l.
Nessler ' s reagent
10% potassium sodium tartrate solution
1ml = 0.01mgNH3 working solution
7.7.3Measurement Procedure
a) Take a group of working solution based on the following table, and inject in a
group of 10ml color comparison tubes, dilute to the scale.
Preparation of Stand Ammonia Solution

No. 1 2 3 4 5 6 7 8
Ammonia working
0 0.01 0.03 0.06 1.0 1.5 2.0 25
solution (ml)
NH2 content
corresponding to water
0 0.01 0.03 0.06 1.0 1.5 2.0 25
sample after dilution
mg/l
b) Fill 10ml water sample into another color comparison tube.
c) Fill in 0.5 ml (10 drops) 10% potassium sodium tartrate solution and 0.2ml (4
drops) Nessler ' s reagent respectively, shake evenly and stand 2 min for color
95
comparison. The concentration of ammonia is the concentration of the standard

working solution with the same color to the water sample color.
7.7.4Calculation
NH3 = 0.01a/V100 = 0.01a/101000 = a(mg/l)
In the equation, V10ml, a-the ammonia working solution to be added, ml, and
0.01-concentration of ammonia working solution (1ml = 0.01mg/1NH3)
7.8 Determination of Hydrazine
In the acid solution, hydrazine and paradime thylamino benzaldehyde reacts

and produces lemon yellow azo-compound. This method is adaptable to measure
the hydrauzine content in Feedwater and steam, within the range of
3100g/1N2H4.
Paradime thylamino benzaldehyde-surfuric acid solution
Hydrazine solution (1ml/gN2H4)
a) Take the standard solution as the table below, and inject into 500ml color
comparison tube, dilute with demineralized water to the scale, at the same time,
take 50ml water sample into 50ml color comparasion tubes.
Preparation of Hydrazine Standard Solution

No. 1 2 3 4 5 6 7 8 9
Standard solution
0.1 0.3 0.5 1.0 1.5 2.5 3.0 4.0 5.0
volune to be added ml
N2H41g/l
corresponding to water 2 6 10 20 30 50 60 80 100
sample after dilution
b) Inject 50ml water sample in another color comparison tube.
c) Fill in paradime thylamino benzaldehyde-surfuric acid solution to the above

color comparison tubes, mix evenly and stand for 3 minutes for color
comparison. The concentration of the hydrazine in the water sample is the
96
concentration of standard working solution of the same color.
7.8.4Calculation
N2H4=a1/501000 = 20ag/l
In the equation, a-filling amount of the working hydrazine solution, ml
1-Concentration of hydrazine solution, g/ml
Note: when hydrauzine content in the sample is over100g/l, dilute and then
analyze.
7.9 Determination of Phosphate Radical
Under the acidity of 0.6NH2SO4, phosphate and ammonium molybdate produces

molybdophosphoric heteropoly acid. Reduce it with stannous chloride and the
phosphomolybdenum blue will be produced. The compare with the standard color
prepared at the same time. The reaction is as the follos:
PO43- + 12M0O42- + 27H+H3[PMO3O104+( molybdophosphoric heteropoly acid)

12H2O[PMO3O104]3+ + 4Sn2+H3[PMO3O94] (phosphomolybdenum blue) + 4Sn2+
Ammonium molybdate-sulfuric acid mixed solution
1% Stannous chloride glycerin solution
1ml=0.1mgPO43 phosphate solution
7.9.3Measurement Procedure
a) Preparations of Phosphate Standard Grader
Take phosphate solution sampling with micro burette, inject into a group of
25ml colorimetric tubes with grinding plug, dilute with silica-free water to
20ml, shake evenly and then add 2.5ml ammonium molybdate-sulfuric acid
mixed solution to the scale and shake evenly, then add two or three drops of 1%
Stannous chloride glycerin solution, shake evenly and stand 2mins for clolor
comparison.
Preparation of Standard Phosphate Solution
97
No. 1 2 3 4 5 6 7 8 9 10
Standard solution
volumeto be 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 5.0 0.60
added ml
Corresponding
PO43-mg/l content
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 10.0 12.0
in water sampling
after dilution
b) Take 5.0 ml water sample and inject into 25 ml color comparison tube and other
chemical injection same as 7.9.1.
c) Compare the water sample color with the standard phosphate solution.
7.9.4 Calculation
Water sample PO43- = 0.01a/V1000 = 2a(mg/l)

In this equation, a-phoshate solution volume filled into the standard color same to
the water sample color, ml.
V-volume of water sample, ml
Note:
a Color comparison of the water sample and the standared should be prepared
at the same time.
b If the water sample is muddy, measure after filtration.
c In winter, temperature is low, so compare the color 5mins later after

chemical injection.
d The water sampling amount can be increased and decreased based on the
phosphate content.
7.10Determination of Dissolved Oxygen
Under the condition of PH 8.5, ammonia indigo carmine (Ammonia carmine)

is reduced into light yellow complex by zinc amalgam (zinc granule). When it
meets with the dissolved oxygen in water, it will be oxidated into blue, while the
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color intensity is related with oxygen content in the water. This method is
adaptable for condensate and feedwater whose dissolved oxygen content is within
Amonia-ammonium chloride buffer solution 2100g/l, with sensitivity of 2g/l.
7.10.2Analyzer Reagent and Containers
Acid blue disulfonic acid sodium stock solution
Ammonia indigo carmine solution: take 50ml stock solution, add 8ml buffer
solutio, dilute with demineralized water to 100ml. The PH of the solution is 8.5,
and it cannot stand for 8h, otherwise, prepare the solution once again.
Amalgam zinc burettes
Specialized oxygen bottle, clear bottles with tight grinding port plug (250ml).
Sampling barrel: the height is 150mm higher than the oxygen bottle, if using
overflow sampling method, the sampling barrel can be omitted.
Reductive indigo two sulfonic acid sodium solution: inject a small amount of
ammonia indigo carmine buffer solution into the burette filled with amalgam
zinc to wash the amalgam zinc, then reduce the burette with ammonia indigo
carmine (do not make the amalgam zinc have air bubbles), stand for several
minutes, and it can be used when the solution changes from blue into yellow.
The higher the temperature, the higher solution reduction rate, however, the
temperature cannot exceed 40.
a) Clean the sampling barrel and oxygen bottle first and then put the sampling
tube at the bottom of oxygen bottle inside the sampling barrel, to make the
water overflow for 3mins at least, but the water temperature cannot exceed
35 (it s better to be 1-3 lower than the ambient temperature).
b) Put the zinc reduction burette into the oxygen bottle slowly, gently take the
sampling tube out, and then add reductive indigo two sulfonic acid sodium
solution immediately about 1.5 ml.
c) Gently take the burette out and plug the bottle tightly, and mix evenly under
water and stand for 2mins to ensure thorough reaction.
d) Take the oxygen bottle out from the sampling barrel, compare with the
standards immediately in the natural light or under the day light lamp taking
white as background.
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7.11Determination of Silicon Dioxide
7.11.1 Principles of determination
Under the condition of PH within 1.1-1.3, the dissolved silicon in the water
and the ammonium molybdate can produce the yellow silicomolybdate complex,
and then the silicomolybdate complex can be reduced into silicomolybdenum blue
by 1- amino-2- naphthol-4- sulfoacid, then measure the silica content with silicate
analyzer.
Add tartaric acid or oxalic acid to avoid the interference of the phosphate and
small amount of ferric ion in the water sample.
Sulfuric acid - ammonium molybdate solution
10% tartaric acid solution
10% ammonium molybdate solution
1-2-4 acid reducing agent
1.5mol/L sulfuric acid solution
According to the instrument introduction requirements, adjust the

superscripts and subscripts and lower silicate analyzer and then start measuring.
Take 100ml water sample and pour in a plastic bottle washed with high purity
water, add 3 ml acid - ammonium molybdate solution, mix evenly and stand for
5min, then add 3ml tartaric acid solution, mix evenly and stand for 1 min; then add
2 ml 1-2-4 acid reducing agent, mix evenly and stand for 8mins, then measure
according to the operation requirements of the silicate analyzer. The indication of
instrument is the silica content of the water sample. When the silica content in the
sample is higher than 200ppb, dilute based on the condition and then start
measuring.
7.12Determination of Ferric
Boil the water sample to make the ferrum of every status to be decomposed
100
in ionized state, and then reduct the ferric iron by hydroxylamine hydrochloride.
Under the condition of PH within 4-5, the ferrous reacts with phenanthroline and
produces light red complex, compare the color with the standard color, the
intensity of the color depends on ferric content.
7.12.2 Analytical reagent
Hydrochloric acid (Class G.R)
Stronger ammonia (Class G.R)
10% hydroxylamine hydrochloride
0.1% phenanthroline solution
Acetic acid-ammonium acetate buffer solution
Ferric standard solution
a) Take a series of ferric working solution and inject in color comparison tube of
50 ml, and then dilute with Class I reagent water to the scale.
Preparation of ferric standard solution
No. 1 2 3 4 5 6 7 8 9
Ferric working
0 0.25 0.50 1.0 2.0 4.0 6.0 8.0 10.0
solution (ml)
Corresponding ferric
contant in water after 0 5 10 20 40 80 120 160 200
dilution ppb
b) Put water sample of 50 ml into 250ml breaker, which is washed by

demineralized water, then add 2 ml hydrochloric acid (1+1), heat and
concentrate to its volume less than 25 ml. When cooled down to 30, add 1 ml
hydroxylamine hydrochloride solution, shake evenly and stand for 5 mins, then
add in 5ml 0.1% phenanthroline, shake evenly and put a small piece of congo
red test paper in the breaker, add dropwise hydrazine slowly to make the test
paper change from blue into purple. At this moment, the PH value is within
3.8-4.1. Then, add 5 ml acetic acid-ammonium acetate buffer solution, shake
evenly and put into a 50ml volumetric flask washed by class I reagent water,
dilute with the class I reagent water to the scale. Shake evenly and compare the
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color of the sample with the color of ferric standard solution.
8. Operation of oil analysis instrument
8.1 101 Series Electric Blast Oven Manual
8.1.1 Use
Electric drying oven for laboratory and scientific research units to do baking,
melt, sterilization purposes.
8.1.2 structural characteristics
101 electric drying oven is convection ventilation structure, the cold air from
the bottom of the hole into the wind, hot air escaping from the roof top of the wind.
Cold air through the bottom of the heater, the side holes directly through the floor
into the room, take the left side of the chamber board through hole into the chamber,
as electric fans to promote indoor air mechanical convection heat to room
temperature uniformity compared with non-blast style more uniform drying.
The drying cabinet is made from the steel surface, painting; insulation filling
enough, good insulation properties, branded external decorative parts is plated.
Oven with double door for easy observation of objects test case of electrical
components installed on the box on the left space, easy maintenance, reliable
operation, heater divided into four groups.
102
8.1.3 major technical indicators
1. Using temperature: 60-300
2. The temperature fluctuation: 1
3. The temperature uniformity of Tolerance: The maximum temperature is not

greater than 2.5%
4. The working power supply, AC 220V 22V 50 1HZ
8.1.4 use of methods
1. When the goods against payment box, will be outside the glass door and they
shut and the air box on top of an appropriate unscrew the top valve.
2. Power on, open the selected temperature switch, the grade is generally used, the
use temperature is below 100 to open a file or two files.
3. Open the blower switch, the blower working.
4. The thermostat knob clockwise rotation to the desired temperature setting

(adjusting the scale on the scale card for reference only) two yellow lights that
heat off when the yellow light, green light both indicate that the heating to stop
and wait yellow, green automatically following the interest rate that temperature,
depending on the wind the top level of the thermometer temperature controller
repeatedly adjusted to the required temperature.
8.1.5 Pay attention to maintenance issues and repairs
1. The box line voltage AC 220V, 50HZ before use should be noted that the power
supply voltage is consistent with the use of power outlets must be ground level
required for effective grounding.
2. The power to use, remember touch the electrical box on the left part of space or
wiping with a damp cloth and wash with water, repair the power supply should
be cut off.
3. The power cord is not wrapped in metal, cannot be placed in hot or humid place
to prevent the rubber aging and leakage.
4. Place objects in the box not too crowded, have to stay out of natural convection
of air space, so that moist air can escape in the wind on top speed.
5. Should regularly check the temperature regulator of the silver contacts are hairy
103
or grievances, if any, can be used to contact sand flat sand cloth after use, and
will often wipe with a clean cloth to make good contact (attention to the need to
cut off power supply) room thermostat should not impact the metal tube so as not
to affect the sensitivity.
6. No proof of this drying device, do not prevent entry of flammable materials.
7. After each use, shall supply all off, kept clean both inside and outside boxes.
8. When using high temperature, they should pay attention to burn care.
8.2 ZHK302 Open Cup Flash Point Automatic Tester
8.2.1Working Theory
The instrument is heating according to the temperature curve stipulated by the

method of ASTMD92-IP 36GB/T 267-1988. The heating is controlled by CPU.
The status, temperature and pre-set data are displayed on blue LCD monitor. When
the specimen temperature approaches the flash point, the CPU will control the
electric indignation system to ignite automatically. When the flash point appears, it
is locked and displays the flash point. The temperature keeps rising until the fire
point appears which is locked. The monitor displays the flash point and the fire
point results, the sound alerts. In the meantime, the cooling system will cool the
heater automatically.
8.2.2Structure Characteristics
8.2.2.1 Obverse chart (chart 1)
1. Blue LCD monitor
2. Igniting rod cover
3. Igniting rod
4. Testing head
5. Lid
6. Heater
7. Temperature transducer
8. Flash point detector
9. Power switch
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10. Button
11. Fire point detector
12. Printer
(2)Reverse Chart (chart 2)
13. Standard RS232
14. Signal Output
15. AC Power (240V) Output
16. AC Power (240V) Input
17. AC Power Fuse Holder
18. AC Power Input
19. Signal Input
105
8.2.3Operation instruction
8.2.3.1Installation environment
ZHK302 Open Cup Flash Point Automatic Tester is installed on a workbench

with convective air and without direct sunlight. ( It can be installed in a ventilated
closet. The fan does not work while testing.)
8.2.3.2Requirement for AC power
Single-phase AC power (240V, 50Hz) is applied. The voltage fluctuation must

not exceed 5%. AC regulator (1000W) may be used.
8.2.3.3Lift the green handle of the printer and load the printing paper. Press down the
green handle and install the printing paper on the shelf. Switch on the power.
Operation Switch on the power, blue LCD monitor displays,
Press any key, it displays, Main menu
106
Press , , Enter key to select.

Method
D92: International Standard

GB: National Standard
Pre-test: The flash point of a sample is not known. The igniting rod starts
working while the sample is heated.
Press Enter, blue LCD monitor displays:
Test fire point: After testing the flash point, it keeps heating until getting
the result of fire point.
Only test flash point: fire point is not tested.
Press Enter to select.
Preset temperature
107
Press , , Enter key to set flash point of sample.

Test flash point
Press Enter, monitor displays,
Sample is under the status of testing. Press Select twice, testing stops.
Date set
Press , , Enter key to set the date. The set is restored in the
instrument.
Air pressure
108
Press , , Enter key to set the air pressure.

Historic data
Press , , Enter key to check the historic data.

Press Enter, back to main menu.
Calibration
Press , , Enter key to select checking items. The selected item

acts while selecting.
After setting, select Back, press Enter.
Remarks:
The contents of parameter cannot changed randomly, otherwise the
testing result may be affected.
After each setting, status should be the original status. (Press
Enter one more time).
Printer set
109
Press , , and press Enter key after selection.

Testing
1. Ensure that Switch on the back cover is on the position of Testing.
2. Set method.
Select Method, press Enter to choose method, and also select whether
measuring fire point or not.
3. Preset temperature.
Press Enter, back to Main Menu to select Preset Temperature. Press
Enter, back to Main Menu after setting.
4. Printer set. Press Enter, back to Main Menu after setting.
5. Put sample into the sample cup, to the up reticle while temperature is less
than 210, to the down reticle while temperature is over 210. Put the
sample cup on the heater.
6. Select Test flash point on Main Menu, press Enter, testing head touches
down to the sample cup. It starts heating. While flash point appears, testing
head rises automatically, flash point is displayed, the sound alerts and testing
result is printed. If Test fire point is selected, it keeps heating. While fire
point appears, testing head rises, igniting rod returns to left side, the lid covers
the cup automatically, heating stops. Flash point and fire point are displayed,
the sound alerts and testing results are printed.
Points of attention & Maintenance
A Points of attention
1 The instrument has igniting equipment. Testing would be better taken in
ventilated closet ( fan is not working), in case error might be produced by
outer airflow.
2.Temprature transducer is made of glass. Do not collide with other objects.
3.Before changing sample, sample cup should be cleaned. Sample cup and the
heater must not be obstructed, so that the heat transmission can keep in good
condition.
4.Do not use hand or other objects to press or raise heating head. Do not push
or pull igniting rod. In case, mechanical damnifications are caused.
110
5. When the instrument cannot work normally, firstly check if signal wire is
connect, then select Calibration for self-inspection. Do not dismantle and
repair the instrument by yourselves.
B Maintenance
1.Being used for a long period, the flash point transducer is coved with dirt,
affecting testing accuracy. Clean the transducer with gasoline or petroleum
aether. Be much careful for the cleaning.
2.When the instrument is not used, please take out sample cup.
8.3ZHB202 Closed-Cup Flash Point Auto-Tester
8.3.1Working Theory
The instrument is heating according to the temperature curve stipulated by the

method of ASTM D93 and GB261-83. For gas ignition, when the sample
temperature approaches the flash point, the microcomputer will control the air
course system to open the gas valve and ignite automatically. When the flash point
appears, the instrument will lock, display and print the testing result. In the
meantime, the cooling system will cool the heater automatically. For electric
ignition, gas supplier and air course will not be used.
The instrument structure is as the charts.

1. Enter key 10. Signal input socket
2. Up key 11. AC power input socket
3. Down key (connect with 14)
4. Power switch 12. AC power socket
5. Monitor 13. Fuse
6. Auto-igniter 14. AC power output socket
7. Testing head 15. Standard RS232C interface
8. Gas-adjust valve 16. Signal output socket
9. Gas inlet
111
8.3.3Operation Instructions
A Preparation
1.Connect AC power supply wire with (12) socket.
2.Connect two-end AC power supply wire with (11) and (14).
112
3.Before leaving the factory, the instrument is installed with electric ignition
method. If gas ignition method is required, connect the gas to (9). Check and
ensure no blow-by. Take off the installed igniter and replace it with spark hand
lever. Re-install the electric igniter to the original position of the spark hand lever.
Make it to face the head of the spark hand lever. Keep the 2mm distance between
the top of the electric igniter and the spark hand lever to ensure correct ignition.
Then, screw tightly the fixed bolt.
4. Connect signal wire with (10), (16), fix the bolt on the plug.
5. Take off the printer cover board. Lift the green push-brace. Insert the front of
printing paper into the black idler wheel and extend some paper out. Push down
the push-brace. Install the paper on the shelf. After the above operation, please
check if all the connection is correct. Then switch on the power.
B Testing Operation
Switch on the power, the testing head rises automatically and prompt sounds. It
displays as follows :
Press any key; it displays the main menu Choice of function.

1. Method
D93: International standard
GB261: National standard
Pre-test: The flash point of a sample is not known. It ignites while the sample
is heated.
113
Press Enter, it displays:
Method A: Gas ignition Method B: Electric ignition

Press , to select. Press Enter to back to main menu.
2. Pre-set temperature
Press , to set the temperature. Press Enter after setting.

3. Time set
Press , to set the date. Press Enter after setting.

For example: Press , to set as following:
2006(Year)

Enter

03 (Month)

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Enter
01 (Day)

Enter
01 (Hour)

10 (Minute)

Enter
4. Air pressure
Press , to set the air pressure. Press Enter after setting.

5. Historic data
Press , to set the historic data. Press Enter after setting.

6.Printer set
Press , to set the printer. Press Enter after setting.

7. Instrument checkout
115
Press , , Enter key to select. The selected item should have actions on
Status, such as the display of on, off and mechanical movement, which
demonstrates that the instrument is in standard conditions.
Remark:
The content of Parameter is already set before leaving factory. Do not

change randomly. Otherwise, the testing result may be affected. After all the above
data is set, the instrument automatically store and keep it even when power down.
8.3.4Testing Sample
A. Gas ignition (method A)
Refer to the method of 3 of (1) of Charpter 5, change the spark hand lever and
the igniter.
Connect the gas supplier and open it. Select Instrument checkout on the main
menu. Select Gas valve, press Enter to open the valve. 30 seconds later, select
Igniter, press Enter to light on the igniter. Adjust the gas valve (8) to ignite the
gas on the spark hand lever. The adjusting time cannot be too long (normally in 20
seconds). If it does not ignite, turn off the igniter (press Enter once). After 30
seconds, press Enter again to light on the igniter. Repeat the above procedure till
ignition, and then turn off the igniter. Adjust the flame to about 4 mm. Exit to the
main menu.
B. Electric ignition (method B)
The instrument is installed with electric igniting method before leaving

factory. If it has been changed method A and return electric ignition, pay attention
that the installation position of the igniter should be at the reticle. Otherwise, the
electric igniter may be damaged by collision.
C. Clean the sample cup with gasoline or petroleum aether.
Pour the sample into the cup to the reticle. Put the sample cup in the heating
hole. On the main menu, select Test flash point, press Enter. The testing head
touches down automatically. It starts heating. It displays as follows:
116
While flash point appears, testing head rises automatically, flash point is
displayed, the sound alerts and testing result is printed. If the testing needs to
terminated, press Enter twice to stop testing.
D. When the pre-set temperature is too high or the sample temperature is too high,
the instrument stops testing automatically. On Status, it displays Pre-set is
too high or Temperature is too high.
E. When the sample temperature exeeds 50 over the pre-set temperature and the
flash point does not appear; the instrument will stop testing automatically.
F. After testing, press or to back to the main menu.
8.3.5 Points of Attention
8.3.5.1 Points of attention for testing
a. The instrument has igniting equipment. Testing would be better taken in

ventilated closet (fan is not working).
b. Temperature transducer is made of glass. Do not collide with other objects.
c. Every time before changing sample, the sample cup should be cleaned. Do not
put other objects in the heating hole. Otherwise, the testing may not be
proceeded.
d. The testing head moves automatically and mechanically. Do not move it by hand
forcibly. Otherwise, mechanical damnifications are caused.
e. When the instrument cannot work normally, firstly check if signal wire is
connected, then use the self-checkout function to check the instrument. If you get
some questions, please contact with us immediately. Do not dismantle and repair
the instrument by yourselves.
8.3.5.2Maintenance
a. The transducer of the instrument is easily covered with oil stain, affecting testing
117
accuracy. Clean the transducer with gasoline or petroleum aether regularly. Be

much careful for the cleaning to avoid damages by collision.
b. Do not clean the instrument shell with corrosive detergent to avoid the damages
to the exterior lacquer. When the instrument is not used for a long time, put the
sample cup on the heating hole. On Instrument checkout item, select Testing
head, press Enter to make it touchdown.
8.4 ZHR401 Spontaneous Combustion Point Automatic Tester
8.4.1 Working Theory
The instrument meets the requirement of DL/T706-1999 Testing Method of

Spontaneous Combustion Point of Anti-fuel Oil of Power Plants. It automatically
sets the three stage temperature, automatically PID control the temperature rising of
the heating furnace. When the temperature is raised to the set three stage
temperature, the instrument indicates the sampling. When the sample combusts and
creates flame, it demonstrates that spontaneous combustion is happened. If there is
not any flame in 5 minutes, it is believed that there is no spontaneous combustion at
the temperature. The lowest temperature, at which the spontaneous combustion is
happened, is confirmed as spontaneous combustion point of the sample.
8.4.2 Operation instruction
8.4.2.1. Preparation
A. Insert three temperature sensors into 7, 8 and 9 separately. Connect them with
the corresponding wiring ends 17, 18 and 19.
B. Connect 12 and 17 with AC power wire.
C. Connect 11 and 15 with 9 core signal wire.
D. Connect printer and 13 with 25 core signal wire.
E. Connect printer and 21with power supply wire (2 core black).
F. 1 piece of trace syringe (scale 0.01ml), 1 piece of No.8 or No.9 needle
G. 1 piece of hot hair dryer
8.4.2.2. Testing
A. Connect clean borosilicate conical glass flask with furnace cover. Put it into the
heating furnace.
118
B. Connect the plug of 240V AC power supply wire with socket 16. Connect
another one with AC power input socket 10. (Socket current 20A)
C. Switch on the power (3), it prompts twice and the testing shelf (6) is raised
automatically. The monitor displays.
Spontaneous Combustion Point Automatic

Tester
Honorably Manufactured by Shandong

Zhonghui Instrument Co. Ltd.
D. Press any key, the monitor displays.
Upper temperature : xxxxx
Middle temperature : xxxxx
Lower temperature : xxxxx
Pre-set temperature : xxxxx
Status : x x
Time : xxx
E. Setting temperature.
Press Set key
119
It displays the original temperature.
Press or to change the number of temperature. Press Enter to

complete the setting of temperature and return to the main page.
(6) Setting date.
Press Set key
It displays the original date.
Press or to select year
Press Enter.
The setting of month and day is the same procedure.
F. Analysis of sample
After setting the temperature as above procedure, press Start key, the
monitor displays the main page and heating starts.
When the three stage temperature reaches the setting number, the instrument
testing end enters into the heating furnace automatically. It displays Sampling and
alerts. At this time, the operator press Start key, it displays Testing. Use the trace
syringe to inject vertically 0.05ml sample to the bottom of borosilicate conical glass
flask and remove the trace syringe quickly. If there is no spontaneous combustion
in 5 minutes, the instrument will raise the setting temperature by 10
automatically. Repeat the above testing. If there is spontaneous combustion, the
instrument will reduce the setting temperature by 3 automatically. Repeat the
above testing until there is not any spontaneous combustion. The lowest
temperature, at which the spontaneous combustion is happened, is spontaneous
combustion point of the sample. At this time, it displays the spontaneous
combustion point. In the meantime, the printer prints the testing result.
8.4.3.1 After each sampling, the testing end is raised. Hair dryer should be used to blow
the borosilicate conical glass flask for drying.
8.4.3.2 The current of AC power should be more than 20 A.

120
8.4.3.3 After each sampling, the testing end is raised. Clean paper of cloth should be
used to wipe the testing shelf. Otherwise, its sensitivity would be affected.
8.4.3.4 During sampling, pinch the needle by hand. Sample should be injected to the
bottom of borosilicate conical glass flask vertically. The needle must not touch
the testing shelf.
8.4.3.5 Pay attention to the anode and cathod when connecting temperature sensors
with the wiring ends.
8.5 ZHSZ601 Petroleum Products Acid Automatic Tester
8.5.1Operation Instruction
8.5.1.1 The instrument is put on a stable working table.
8.5.1.2 Press the CORRECT pump clip and the soft tube into CORRECT pump.
8.5.1.3 Press the titration pump clip and the soft tube into titration pump. Make sure
that the position button of the clips should be in the line of the red reticle.
8.5.1.4 Take out the titration solution, the stainless tube and the extract liquid. Add
strong liquor into the aspirator bottle. Insert the stainless tube into the titration
solution and the strong liquor separately. Replace the tube lid and the perfusion
tube of extract liquid attached with the instrument. Screw the lid tightly (as chart
2). Check and make sure that there is airtight seal of each interface.
CORRECT
Strong liquor
Extract liquid
8.5.1.5 Connect single-phase AC power with power socket. (Remark: The power socket
should have ground wire and is well connected to the ground.)
8.5.1.6 Take a certain amount of testing sample. Put the sample cup into the instrument.
8.5.1.7 Put a stirrer into the testing sample.
8.5.1.8 Switch on the power. The monitor displays:
Petroleum Products Acid Automatic Tester
121
Honorably Manufactured by Shandong Zhonghui

Instrument Co. Ltd.
Press any key to enter the working interface.
8.5.1.9 Working interface
Acid: mgKOH/g
Status: Preparation
Time: 10:58
Testing Setting Exhausting Data

Self-inspection
Press or to select the menu and press Enter.
Setting
Setting
Sample Weight Date
Sample Select Titration Speed
Printing Return
Sample Select:
122
Sample Select
Insulating Oil
Turbine Oil
Fire-resistant Oil
Insulating Oil:
Sample Select
Sample A
Sample B
Sample AB
Enter into the interface if Turbine Oil and Fire-resistant Oil as the above
method.
It can test two samples simultaneously. Choose Sample AB and save time.
Setting Date:
Date
Year 2004 Month 04 Day 18
Hour 10 Minute 01
123
Press or to change and press Enter to confirm. Time can be adjusted

through the menu. The setting time is non-volatility. It keeps timing while power is
off.
Sample Weight:
A Weight: 8.40g
B Weight: 1.76g
Setting Printing:
Printing
Print
Not Print
This menu can be used to select to print or not print the testing result. It can
be stored.
Titration Speed:
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Titration Speed
Normal Titration
Quick Titration
Press or to select titration speed. Normal Titration is selected while the

number of acid is small. Quick Titration is used while number of acid is big.
Exhausting:
Exhausting of CORRECT
Exhausting of Extract Liquid
Return
Status: Exhausting of CORRECT
Before testing, make sure that there is not any air bubble in both liquid tube. If there is
any air bubble, this menu is used to exhaust air.
Data
Data
Display Data
Delete Data
Return
125
100 groups of data can be stored and will not be lost while power is off. For the
operation of deleting data, it displays Data has been deleted to show that deletion is
completed.
Display Data
Sample A 0.036 mgKOH/g
Sample B 0.038 mgKOH/g
Sample No. No.8
Year 04 Month 02 Day 14
It displays the present data. Press or to change sample No. to view the
previous data.
Self-inspection
Position Self-inspection
Light Source Self-inspection
Stirring Self-inspection
Press or to move cursor. Press Enter to begin or exit self-inspection.
Testing
Sample A Acid: 0.038 mgKOH/g
Status: Position
Time: 10:58
Testing Setting Exhausting Data
126
Self-inspection
Press Enter, the instrument will begin testing according to the setting. It
prompts and prints the result of testing after testing is completed.
8.5.1.10After testing, insert the soft tube in CORRECT into absolute ethanol. In the
menu of Exhausting, select Exhausting of CORRECT. Clean the tube to
prevent jamming.
8.5.1.11 Switch off the power. Take out of the sample cup and clean it for the next
testing. Undo the clips of the CORRECT pump and the extract liquid.
Method: press the side button on the clip, the clip will pop out.
8.5.2.1 After each testing, undo the clips of the CORRECT pump and the extract liquid
to prevent the extrusion and distortion of the soft tube, which will affect the
following testing.
8.5.2.2 There is a position button on the pump. Make sure that the position button of the
clips should be in the line of the red reticle. Normally it has already been
adjusted before leaving the factory. Please do not adjust again randomly;
otherwise the testing result would be affected.
8.5.2.3 After testing, must clean the tube with absolute ethanol to prevent jamming.
8.5.2.4 When the soft tube is distorted and loose elasticity, please change it.
8.5.2.5 The instrument must be well grounded.
8.6 GAS CHROMATOGRAPH GC-900-SD
8.6.1 Switch on
(a) Regulated N2 of cylinder to 0.5MPa and turn the hydrogen and Air generator on.
Observe the carrier gas pressure(total 0.3MPa carrier 1 0.040.06MPa, Carrier
2 0.03MPa ).
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(b) After 1530 minutes , turn the power switch on (Green) , depress the heater
switch(Red), Monitor operation: COL---ENT CITP 60
INJ----ENT INJT 60
TCD---ENT TCDT 70
Shift---TCD/DET ENT DETT 120
Shift---INJ/ME ENT AUXT 360
If normal, push START (Blue).
If abnormal need to reset temperature: COL---60----ENT
INJ---- 60---ENT
TCD---70---ENT
Shift---TCD/DET---120---ENT
Shift---INJ/ME-------360---ENT
(c) Set TCD current, hit the CE key, turn switch on of TCD panel.
(d) When temperature of DET to 100 above ignite it (MONIT-Shift-TCD/DET),

regulated H2 pressure to 0.12MPa(2 pass), Air pressure to 0.03MPa (2 pass),
ignite it, After ignition return the Air flown to 0.07MPa.
(e) Zero the baseline by turning knobs as zero on the FID1, FID2. TCD control
panel. Channel A FID1 signal situated the below on PC monitor. Channel B
TCD and FID2 signal parallel. After baseline of A, B channel stable then
injection, the method of signal switch as follows.
Channel B signal switch: TCD shift---8-- -91 ---ENT
FID2 shift---8--- 91 ---ENT
8.6.2 Switch off
(a) Turn the switch on TCD control panel off.
(b) Turn off the heater switch.
(c) Turn off the H2 generator and Air pump.
(d) When methanizer temperature decrease to 100 below turn power switch off
(MONITShift---INJ/ME)
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(e) Wrenched off the N2 cylinder.
8.7 ZHQ701 Multi-functional Automatic Oscillator
8.7.1Structure Characteristics (Chart 1)
1. Control Panel 2 . Key
3. Key 4. Enter Key
5 . Power Socket 6 . Fuse
7. Power Switch 8 . Up-door
9 . Themometer Jack
8.7.2Operation Instruction
8.7.2.1 Connect the oscillator with the power supply, the capacitance of the power
socket, which should have good ground connection, must exceed 5A.
8.7.2.2 Different containers are used according to the different specimen.
8.7.2.3 Switch on the power, the oscillator has the prompting sound.
The monitor displays:
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Press any key to display the main page.
Example: Method 1
1) Press , , move the cursor to Method 1, then press Enter.
Press Enter
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Press Enter
This is the time of heating. It will be the oscillating time when the set temperature
is reached.
An alarm is automatically given.
2) In case to stop in the midway, press Enter. The monitor displays: Stop the
task
3) Press Enter, the heating & oscillating is stopped. The screen returns to the
display as 1). Press , back to the main page.
8.7.2.4The choice of User-defined
1) Press , , move the cursor to User-defined, then press Enter.
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Press Enter, the cursor moves to x x
Press , to set the temperature
Press Enter, Press to move the cursor to Oscillating time
Press Enter to move the cursor to x x minutes, press , to set the

oscillating time
Press Enter, Press to move the cursor to Resting time
Press Enter to move the cursor to x x minutes, press , to set the

resting time
Press Enter
Press to move the cursor to End the setting
Press Enter, the screen will display as example 1, and then go on the operation.
2) The parameters are automatically remembered and stored after the setting.
(1) The choice of main page Start
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Move the cursor to Start
Press Enter to start the oscillating
Press Enter to stop the oscillating
8.7.3 The Use of Thermometer
8.7.3.1Unscrew the sealed bolt of the thermometer jack at the up-door, insert the
thermometer at the measurement as chart 2.
8.7.3.2 Adhere the thermometer with adhesive plaster, lift a step as chart 3 and wedge
the thermometer at the jack.
8.7.4 Points for Attention
8.7.4.1 The instrument is installed on the level and solid workbench.
8.7.4.2 The instrument must not be installed in a room with corrosive gas.
8.7.4.3 The instrument must not be placed in humid environment.
8.7.4.4 The monitor screen must not be punched and collided by hands and hard articles.
8.8 KY-101 Coulomb Sulfur Tester
8.8.1Structure and Operating Principles
8.8.1.1Instrument Structure
The instrument mainly consists of mainframe, combustion furnace, stirrer,

electrolytic cell (integrated) as well as PC and printer. (See Figure 1-1)
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An Instrument structure and functions of each component
1). Stirrer: stir bar in the electrolytic cell is twirled by the revolving magnetic force
to further drive the rotation of electrolyte, which on the one hand makes SO 2
fully absorbed and on the other hand makes the iodine and bromine precipitated
on the positive pole rapidly diffuse.
2). Electrolytic cell (see figure 2-2): it contains a pair of platinum indicator
electrodes (with small surface) and a pair of platinum electrolysis electrodes
(with large surface) as well as a gas filter (glass fuse board). Its used for the
storage of electrolyte and the capture of SO2. The indicator electrodes could
indicate the electric potential change in the electrolyte and after powering up
iodine and bromine could be precipitated on the electrolysis electrodes. The gas
filter is used to disperse the gas into many minute bubbles to increase the
contact area between the gas and electrolyte to realize the sufficient absorption.
3). Drying tube: for the storage of desiccating agent (allochroic silicagel or
anhydrous calcium chloride) and dehydration. If the content of SO2 in the air is
too high the test result might be affected, therefore its necessary to add NaOH
into the drying tube.
4). Flow meter: for the control of gas flow. Air exhaust flow800ML/min
5). Electromagnetic pump: for inspiration and air exhaust, with regular inspection
of the leather cup in the pump, which should be replaced immediately once it is
cracked.
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Electrolytic Tank
Fig.2-2
1. Four electrode poles 2 Cover of electrolytic cell
3. Cup of electrolytic cell 4. Air inlet
5. Fuse board 6. Four electrode plates
7. Stir bar 8. Air outlet
Note: please refer to the following operation to open the electrolytic cell in
daily maintenance.
1. To disassemble the fork connected with the four electrode poles (write down the
order for easy reconnection);
2. To disassemble the silicone tube connecting the air inlet and air outlet;
3. To remove the electrolytic cell carefully and then add distilled water between the
cover and the mill of electrolytic cell for easy dissolution of the crystal;
4. To hold the cup of the electrolytic cell with both hands after the distilled water
has infiltrated to the mill, with thumbs up to bear the cover and it could be
opened;
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5. Please remember to add the stir bar after handling the electrode plates and fuse
board;
6. To assemble the electrolytic cell according to the disassembly order;
7. To place the electrolytic cell on the support of the stirrer and connect the silicon
tube and electrode wire.
8.8.2Analysis and Operation Procedures
8.8.2.1 Analysis Procedures
A Preparation
1) To prepare electrolyte as required
2) To connect all the cables, power lines and electrode wires (without power
supply)
3) To open the stainless steel plate of the injection port of the instrument so as to
make sample;
B. Experimental Procedures
1) To open the power supply of combustion furnace, printer, mainframe and PC;
2) To open the power supply of air pump/stirrer and pump about 300ml electrolyte
from the tap hole of the electrolytic cell. Then clamp the tap tube and adjust the
stir speed to the highest value to fog the bubbles around the fuse board of the
electrolytic cell;
3) To start the application software and get online first and then click the
Temperature Rise, the following interface will pop up:
4) The instrument will heat up automatically (it takes about 20min to

reach1150);
5) To place high-sulfur sample (about 50mg) into the combustion boat and then
add tungsten trioxide and finally click the sample injection, the instrument will
automatically analyze the sample, the following interface will pop up;
6) To make sample officially after the balance of the instrument;
7) To place the weighted sample into the combustion boat and cover with a thin
layer of tungsten trioxide and finally put the combustion boat into the quartz
boat, then click the sample injection, the instrument will automatically analyze
the sample;
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8) The instrument will automatically control the decomposition course of sample

and give real time display of sulfur content and furnace temperature, as well as
determine the terminal point of the decomposition, withdraw the sample and
show the percentage composition of sulfur automatically, then the following
interface will pop up, please input the sample information and press Confirm;
9) After the experiment, please press Cooling to discharge electrolyte and clean
the electrolytic cell before drain out the water, and finally turn off power supply
of the instrument.
10) Shutdown steps: press cooling first, then the Port Disconnection and finally
the Exit.
8.8.3Daily Operation
8.8.3.1 Daily Operation
To ensure successful experiments, please operate the instrument in accordance

with the following procedures in daily operation:
1. To open the power supply of combustion furnace, printer, mainframe and PC in

order;
2. To turn on the switch of air pump/ stirrer and pump about 300ml electrolyte
from the tap hole of the electrolytic cell. Then clamp the tap tube and adjust the
stir speed to the highest value and adjust the flow meter of air exhaust to
1000ml/min;
3. To heat up the furnace to the set temperature;
4. After the sample analysis, it will display the result automatically;
5. To turn off the switch of air pump/ stirrer and pull out the air exhaust tube of
the electrolytic cell to discharge electrolyte, then connect the air exhaust tube and
pump in distilled water. Finally turn on the switch of air pump/ stirrer and
clean the electrolytic cell before drain out the water
6. To turn off the power supply of the instrument.
8.8.4Common Failure Analysis
Common failure analysis
A. The electrolysis is overshot, and the electrolyte gets dark.
1) Electrode poles of the electrolytic cell are stained and must be cleaned with
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alcohol;
2) Poor contact of plugs in the electrolytic cell;
3) Insufficient stirring speed (it occurs at the test of high sulfur usually);
4) Invalidation of electrolyte;
B. Relatively low test result
1) Insufficient air flow;
2) Poor tightness of the gas carrier system, with leakage;
4) Fracture of quartz tube;
5) Insufficient temperature of the high temperature furnace;
6) Poor sample presentation;
7) Blockage of gas carrier system.
C. Low accuracy of test result
1) Too coarse sample granularity;
3). Blockage or leakage of gas carrier system;
4) Contamination of electrode poles;
5) Failure of the electric motor of stirrer, with unstable rotate speed;
6) With strong electromagnetic interference in the surrounding.
D. No rise in temperature in combustion furnace
1) To inspect and replace the fuse (30A) immediately once it melts;
2) To inspect and replace the 220V power line between the power socket and
silicon carbon tube once it is burned out.
3) To inspect and replace the resistance of silicon carbon tube if its too large;
4) To replace the solid-state relay immediately once it is burned out.
E. Too fast or slow temperature rise in combustion furnace
1) Too fast-- solid-state relay has short circuit and must be replaced;
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2) Too fastthe resistance of silicon carbon tube is too small and must be
replaced;
3) Too slow-- the resistance of silicon carbon tube is too large and aging and must
be replaced;
4) Too slowtoo low grid voltage;
5) If theres temperature rise in combustion furnace but the temperature indicator

doesnt change, the thermocouple is broken and must be replaced;
6) If the change of the temperature indicator is abnormal, the thermocouple must

be replaced;
F. Sample injection isnt in place
1) To replace the pushrod if its bended;
2) To adjust transmission mechanism;
3) To replace the quartz tube if its bended
G. Too little flow rate or bubbles
1) Insufficient pulling force of electromagnetic pump and the leather cup is aging
and must be replaced;
2) Theres black sediment on the 11-fuse board of serious blockage in the

electrolytic cell, and the fuse board requires cleaning;
3) Poor tightness of the system, with leakage.
H. The electrolytic cell cant be opened
1) To remove the electrolytic cell carefully and add water from the mill of the
electrolytic cell to make it slowly infiltrate into the mill;
2) To hold the cup of the electrolytic cell carefully with both hands and bear the
cover with thumbs;
3) Only water is enough for the seal of the mill of the electrolytic cell generally,
without the need of other sealing materials.
I. How to confirm whether something is wrong to the instrument or the electrolytic

cell?
1) This inspection is mainly about the electrolytic system of the instrument to

confirm if the electrolyte is too yellow (continuous electrolysis) or too white (no
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electrolysis);
2) To open only the power supply of mainframe before the inspection, with other
power supply cut off and no press of [Temperature Rise] button;
3) To disassemble No 1 and No3 fork from the electrolytic cell with NO 2 and No j
remaining according to Figure 4-1;
4) To simulate sample test but without sample injection.
5) To short connect the NO 1 and No2 forks and inspect the rapid increase of the
number at the mg/S% display window, then short connect NO 3 and No 4 forks
and inspect the immediate stop of the number at the mg/S% display window.
6) If the phenomenon is like that of 5, the instrument is normal. Then examine

according to 4.1.12, if the stir is normal but the problem still exists when making
the sample, its necessary to replace the electrolytic cell.
J. Inspection of four binding posts of the electrolytic cell and the connecting line
1) If the fork rusts, it must be polished with sand paper;
2) To fix the forks and four binding posts;
3) The correct connection is as the following figure:
Figure 4-1
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The forks and four binding posts
A pair of large platinum plates (electrolytic electrode)
A pair of small platinum plates (indicator electrode)
K Incomplete sample burning, with black color
1) To inspect the flow rate to see if the tightness is normal;
2) To inspect if the bubbles around the 11-fuse board of the electrolytic cell is
normal.
8.9 ZHL1301 Solidifying Point of Petroleum Products Tester
8.9.1Working Theory
The instrument is suitable to standard GB510-83. Controlled by CPU, the

cooling system cools the sample. Blue LCD monitor displays the status,
temperature, settings and clock. The sample is cool to the highest temperature that
cannot move (solidifying point), monitor displays solidifying point. Testing result
is printed.
8.9.2.1Obverse chart (chart 1)
1. Power switch
2. Key
3. Blue LCD monitor
4. Pouring orifice
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8.9.2.2Reverse chart (chart 2)
1.Infall of cooling water
2.Oil drain port
3.Osculum of cooling water
4.AC fuse tube holder
5.AC power supply socket
8.9.2.3Plan form Chart
1.Printer
8.9.3Operation instruction
8.9.3.1 Installation
a Carefully take the instrument out of the packing box, put it on a solid workbench.
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b Disconnect the tube which is connected to the infall and the osculum of cooling
water. Unscrew the pipe clamp. Use long tubes to connect the infall and the
osculum of cooling water separately. Screw the clamp tightly (prevent leakage).
The other end of the admitting pipe is connected and fixed to water
c The other end of excurrent pipe is connected to sewer. After connecting all the
pipes, pour water to inspect if there is leakage.
d Use one tube to connect the oil drains port. Put the other end of tube into the
jerrican.
Open the reverse cover board. Find the white latex tube which is connecting
the pouring orifice and the refrigerator. Take off the water-stop clamp. Then
cover the reverse cover board.
e Connect AC power supply wire with AC power supply socket (Remark: the
socket should have the grounded wire).
8.9.3.2Functions
1) Switch on the power, it displays:
2)Press any key, it displays:
Pre-set temperature
Press Enter, it displays:
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Press , , Enter to set the temperature. Press Enter.
Time set
Press , , Enter, it displays:
Press , , Enter to set the date and time.
Testing
Press , to select this item. Press Enter to enter the menu of Testing, it
displays:
Historic data
Select this item, press Enter to enter the menu of Historic data. Then select
Display the data, press Enter. Press , for the stored historic data.
Sample set
Press , to select this item. Press Enter to enter the menu of Sample
set, it displays:
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Oil 1: insulating oil; oil 2: fire-resistant oil; Oil 3: diesel oil; Oil 4: others.
Press , to select the testing sample. Press Enter to confirm and exit.
Printer set
-4-
Press , to select this item. Press Enter, it displays:
Press , to select whether to print the testing result. Press Enter to

confirm and exit.
8.9.3.3 Testing
1.Pre-set the solidifying point of sample.
2.Set the testing sample.
3.Select Testing menu, press Enter key to enter into the status of testing.
4. Clean the oil conduit.
Top up the pouring orifice with sample carefully. Open the vent valve. Pay
attention that there is sample in the pouring orifice at all times (normally it can
be cleaned after 2 to 3 times). Then close the vent valve.
5.Infuse the sample.
Top up the pouring orifice with sample. Open the vent valve. Observe the reticle
on the pouring orifice. When the level of oil reaches the reticle, close the pouring
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orifice.
6.Connect the cooling water.
7.Testing
Press Enter key, Status changes into Cooling. The instrument starts cooling.
When the difference between the temperature and the pre-set temperature
reaches about 20, Status changes into Testing automatically. When the
solidifying point appears, the testing result is printed. It is displayed and kept on
the monitor for about 2 minutes. Then the temperature resumes to room
temperature. When the temperature returns above 0, press Enter to repeat
the testing.
8.9.4Self-checkout
8.9.4.1Status displays: Error. Cooling stops.
Cause: Cooling water stops circulation or water pressure is too low. When
the prompt occurs, check the circulating bath part.
8.9.4.2Status displays: Error Too low temp.
Cause: The temperature of refrigerator is too low. The instrument can -5- not
enter into the status of testing. Try to resume the temperature of refrigerator above
0.
8.9.5Points of Attention
8.9.5.1The cooling water pressure must be stable. Otherwise, the repeatability of sample
may be affected.
8.9.5.2After one test, the next test should be done until the temperature is resumed
above 0.
8.9.5.3When sample is changed, before testing another sample, the oil conduit must be
cleaned by the new testing sample.
8.9.5.4The spur track must be filled full of liquid to prevent air. Otherwise, the testing
result may be affected. If the repeatability and the accuracy are not satisfied,
top up the pouring orifice with oil. Open part a to discharge oil and air
simultaneously. Then fix a.
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8.9.5.5If the testing error is relatively big, first of all, it maybe the cleaning problem.
Please re-clean it and test again. Afterwards, it maybe the problems that if the
sample is contaminated or is affected with damp.
8.9.5.6 Screw the lid on the oil conduit tightly to prevent filth.
8.10 ZHN1502 Kinematic Viscometer for Petroleum Products
8.10.1.1Obverse chart (chart 1)
1.Screen 2.Key 3.Power switch 4.Capillary pipe lid 5.Bath lid
6.Transducer 7.Bath 8.Bush 9.Cabinet base 10.Printer
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8.10.1.2Reverse chart (chart 2)
1.Signal wire clip 2.Fan 3.Serial wire socket 4.Power supply socket
5.Fuse tube 6.Signal wire clip 7.Transducer socket
8.10.1.3Function
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1) Switch on the power, blue LCD monitor displays:
2) Press any key, it displays,
3) Press , , ENTER key to select.
Testing
Normally after all the other functions and parameters are set, enter this layout for
testing sample. It displays,
When time of constant temperature is up (hum prompts 4 times), press

1, 2, 3, 4 to time four viscometers separately. Press the same number
button again, timing is stopped. Press , to select Cancel or Back.
Select Back and press ENTER, exit the layout. Select Cancel and press
ENTER, timing is stopped. Refer to part 4 of this chapter for the details of
operation and function.
Temp set
149
According to the need, press number key and ENTER to set appropriate
pre-set temperature. The temperature can be pre-set as: 20, 40, 50, 0 or
100. During the input, press CLR to clear the number which has been input if
it is needed. (In other layouts, CLR key has the same function.) If the number is
not fitted for the requirement of pre-set temperature, after ENTER is pressed,
the past stored temperature is resumed automatically. In other layouts, the
instrument has the same function.
Press , to select Times to set the number of testing (1-5).
Sample set
Sample number in every viscometer can be set. Input range is 0--99. Press
, to select viscometer. For example, if you want to the sample number
in viscometer 3 to be set as 50, press , to make cursor to Viscometer
3, input 5 and 0, then press ENTER. Press ENTERS one more time to exit
the layout.
Time set
Real time can be set. Press , to select items: Year, Month, Day,
Hour, Minute. Press the number key to input the real time. Press ENTER, the
input works. If ENTER is not pressed, the past time is resumed. Press ENTER
one more time to exit the layout.
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Printer set
Press , to select Print or Not print. Press ENTER, the setting

works. Press ENTER one more time to exit the layout.
Tube parameter
Set the parameters of each viscometer----Viscometer, Tube diameter and

Tube constant.
Press , to select the setting item. Press the number key to input the
appropriate number. Press ENTER, the input works. Viscometer can be input
as: 1, 2, 3, 4; Tube diameter can be input as: 0.4, 0.6, 0.8, 1.0, 1.2, 1.5, 2.0, 2.5, 3.0,
3.5, 4.0, 5.0, 6.0; Tube constant can be input as (4 digit): 0.000001 999.9 (mm2
/s2)
4. Function layout during testing
During testing, there are two layouts to deal with different instances.
Cancel testing
Viscometer number can be selected. There are two items to be selected.

Cancel once. It cancels the proceeding testing. If the testing is over, it cancels the
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last one. Cancel all. It cancels all the testing of the selected viscometer (all times
of testing are cancelled). Both functions take effect after the relevant viscometer
number is input. Press ENTER one more time to exit the layout and back to the
layout of Testing.
Calculate viscosity
If all the time of one group testing conforms to the error allowed, the
instrument automatically enters into the layout. If the Constant number of
viscometer is already input, press ENTERS. Viscosity of this testing is display
and printed. If the instrument is connected to a computer, the testing result can be
transmitted to the computer. If the constant number need to be changes, after
changing, press ENTER. The instrument acts as above. Press ENTER to back to
the layout of Testing. Otherwise, it automatically returns after 6 seconds.
8.10.2Testing of sample
8.10.2.1Reagent
A Petroleum aether: 60--90, analytical reagent
B Ethanol: 95%, chemically pure
8.10.2.2Preparation
A Switch on the power, according to above method, set the appropriate constant
temperature, real time, relevant parameters of viscometer, and if it needs to be
printed or not.
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B ENTER into the layout of Testing, the instrument enter into the status that
temperature is raised and controlled. In the meantime, stirrer starts working.
C Preparation of sample
(1) If sample contains water and mechanical impurity, it must bedehydrated and
filtrated. For the high viscosity lubricating oil, it can be suctioned by water
pump or other vacuum pump through ceramic filler. It also can be dehydrated
in the status that being heated to the temperature 50--100.
(2) Principle of choosing capillary pipe: choose appropriate viscometer according

to the testing temperature. The sample flowing time must be not less than
200S. For the viscometer which diameter is 0.4mm, the flowing time must
be not less than 350S.
(3)Before testing, viscometer must be cleaned by regent oil or petroleum aether.

If there is dirt on the viscometer, it must be cleaned by chromic acid, water,
distilled water or 95% ethanol in sequence. Then it is drying in an oven or
hot air filtered through cotton.
(4)During testing, sample is loaded in a clean, dry capillary pipe viscometer

which diameter conforms to the requirement. Before loading sample, fit
rubber pipe over branch pipe 7, use finger to block the nozzle of pipe shaft 6.
Upside down the viscometer, insert pipe shaft 1 into the sample container. Use
absorbent to suck the liquid to reticle b. Pay attention not to make bubble and
cranny of the liquid in pipe shaft 1, extension part 2 and 3. When the level of
liquid reaches reticle b, lift the viscometer from the container, make it resume
to the normal status quickly. In the meantime, wipe off the sample on pipe
shaft 1 and ektexine. Put the rubber pipe off branch pipe 7 and fit it over pipe
shaft 1 ( See chart 4).
1, 6 pipe shaft
2, 3, 5 extension part
4 capillary pipe
7 branch pipe
a,b reticle
8.10.2.3Testing Procedure
A. Observe the temperature display of instrument. When the difference between

the displayed temperature and the pre-set temperature is 0.1, fix the
153
capillary pipe which is filled with sample on the pipe shelf. Remark: At least
half of extension part 2 of the viscometer must be immerged into the liquid.
B. Adjust the viscometer upright. Plummet is used to check the upright status
from two mutual upright directions.
C. Press decimal . key, the instrument starts timing in constant temperature

automatically. When time is up (Hum prompts 4 times). The rubber pipe on
capillary pipe shaft 1 sucks sample into extension part 3, making the level of
liquid a little higher than reticle a. Pay attention not to make bubble and
cranny of the liquid in capillary pipe and extension part 3.
D. Observe the flowing status of sample in the pipe. When the level of liquid
reaches reticle a, press the key of corresponding number, timing starts. When
the level of liquid reaches reticle b, press the key again to stop timing.
E. Repeat testing until the times of testing reaches the pre-set number. The
instrument handles the testing results automatically. If the timing conforms
to the error allowed (at least there are 3 times that the difference between the
result and the arithmetic mean is less than 0.5%), the average is taken and
enter into the layout of Calculate viscosity. Refer to D operation procedure.
F. If several testing results do not conform to the error allowed, the instrument
hums three times, prompting this group of testing failed. It needs to do the
testing again.
While one viscometer is working, the others can be tested also. The method
of testing is as above.
G. Whichever viscometer is in testing, when there is testing failure for one reason,
press and to select ENTER to enter into the layout of Cancel
testing. The result of this testing or all the results of this group can be
cancelled. Refer to D operation procedure.
8.10.2.4Calculation of Kinematic Viscosity
V=C
V: Kinematic viscosity at a certain temperature, unit: mm2 / s
C: Constant number of viscometer, unit: mm2 / s2
: Average of testing time, unit: s
8.10.2.5Requirement of Accuracy
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A. Repeatability (suitable to GB/T 265-88)
For the same operator, the same sample, the difference of two repeated testing
results does not exceed the following.
Testing temperature (): 15100
Repeatability (%): 1 of arithmetic mean
B. Reproducibility (suitable to GB/T 265-88)
For different operators, the difference of two testing results from two labs does
not exceed the following.
Testing temperature (): 15100
Reproducibility (%): 2.2 of arithmetic mean
C. If the accuracy exceeds the standard, clean the viscometer again; take the
sample again to repeat the testing. In the meantime, try to reduce the
man-made error during the testing.
8.10.2.6Report
A. The result is 4-digit significant figure.
B. Take the arithmetic mean of two repeated testing results as the kinematic
viscosity of sample.
8.10.3Points of Attention
8.10.3.1 When the bath is not filled with distilled water, it is forbidden to enter into the
status of testing (Press Testing to enter into testing layout. If press Testing
imprudently, please switch off the power immediately). In case, the electric
heating tube might be burned out.
8.10.3.2 Temperature compensation
When the display of thermometer and the display of instrument have an error,
(the accuracy of thermometer is 0.1. The thermometer has been verified by
Metrological Service in the same year) the instrument can be operated to have
temperature compensation.
In the layout of Testing, press ENTER key Choices of functions,

Press , to select Set temperature, press ENTERthe layout of Set
temperature, press . twice press , to adjust the display of instrument
to conform with the thermometer press ENTER press ENTER to normal
155
testing.
8.11 ZHNY1801 Insulating Oil Dielectric Strength Automatic Tester
8.11.1Working Theory
The instrument is suitable to national standard and industry requirement.

Controlled by microcomputer, it implements to raise voltage in a stable speed.
High performance AD switcher makes quick conversion between simulation and
digital. Big blue screen display voltage. At the instant that insulating oil is
punctured, the number of instant voltage is recorded and stored. Testing result is
printed by thermal printer. Structure Characteristics
8.11.1.1 The following is the chart of instrument chart.
A. Protective cover
B. Power switch
C. Thermal printer
D .LCD monitor screen
E .Cooler fan
F. Earth-plate
G. Fuse
H. Power socket
I .Cup
156
8.11.2 Operation instruction
8.11.2.1 Preparation
A. Oil cup and electrodes must keep clean. During the period of no testing, they
ought to be filled with new transform oil for protection. After testing input
oil, they must be cleaned by impregnant gasoline or petroleum aether. They
can be used again after drying (60).
B. Oil cup and electrodes must be inspected after one-month continuous testing.
Regulator is used to measure if there is a change of electrodes spacing.
Magnifier is used to investigate if surface of electrodes gets dark. If the
phenomena occur, readjust electrodes spacing and clean electrodes with silk
cloth. This work should be also taken if the instrument is not used for a long
period. Shake sample softly, making impurity scatted well-proportioned.
Make sure there is not any air bubble. Put sample into oil cup slowly. Make
sure there is not any air bubble. Do not touch electrodes, inside of oil cup and
sample. Testing is taken in a dustproof dry place. Therefore, sample is not
contaminated.
C. Oil cup is placed horizontally. Ensure there is good contact.
D. Cover the protective cover during testing; avoid getting an electric shock by
high voltage. .Ground wire must be connected before testing (ground wire
must be thick enough), so that safety of people and instrument is guaranteed.
8.11.3Testing procedure
8.11.3.1. Switch on the power, blue LCD monitor displays,
8.11.3.2 Press any key, it displays main menu,
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Mode
Motionless time: motionless time before testing
Interval time: interval time of each testing
Speed of voltage rising: select 2kV/S or 3kV/S according to different methods
Stirring time: get rid of dissociative carbon caused by punctuations
Number of testing: 6 times
Stop-rising voltage: humidity in southern area is disadvantage to instrument,

normally set 60 kV
Stop-rising time: time need for one testing
Date
This is the real time. When power down, press , , Enter key to set
date and time.
Printer
158
Printing the result or not can be selected. For the instruments from other
producers, testing cannot be taken while there is no printing paper. This feature
ensures that testing can be proceeded while printing paper is out.
Historic data
Regular data processing is applied. 100 data can be stored. Display data
displays the punctured number and average number of previous testing results.
Delete data deletes data. When prompt occurs, data is already deleted.
Testing
Cover the protective cover, press Enter, the instrument is timing on the
basis of motionless time automatically. When motionless time is up, voltage rises
at the pre-set speed till sample is punctured. Then voltage goes down, stirs, and
stays motionless, until the number of testing reaches pre-set number. Average
comes out and is printed. During all the status except voltage going down, press
to back, press Enter to skip the present status.
8.11.4 1 Instrument must be well connected to the ground.
8.11.4.2 During the rising of voltage, protective cover must be covered.

159
8.11.4.3 The instrument is installed on the level and solid workbench.
8.11.4.4 After testing, use cloth to clean the oil on the electrodes of compression
chamber, floor and protective cover. Keep all components clean. Oil cup
should be filled with dry oil for the next testing.
8.11.4.5 Please contact with supplier for small cups.
8.11.5Regular Malfunctions
8.11.5.1 Phenomenon: After motionless time, voltage does rise. Solution: Check if
protective cover is covered.
8.11.5.2 Phenomenon: After switch on instrument, there is no display and no prompt

sound. Solution: Check if AC supply wire is connected and if fuse is in good
condition (check fuse after disconnecting AC supply wire).
8.11.5.3 Phenomenon: During the start of testing and start-up, prompt occurs. Solution:
Operate according to the prompt.
8.11.5.4 Phenomenon: Printer does not work. Solution: Check printer set if it needs to
be printed, or maybe printer is not on the line.
8.12 ZHY901 Lubricating Oil Foaming Characteristics Automatic Tester
8.12.1 Summarization
ZHY901 Lubricating Oil Foaming Characteristics Automatic Tester meets

the requirements of GB/T12579 and ASTMD892. It is applicable to test foaming
tendency and stability of the lubricating oil under the condition stipulated by the
standard. This instrument adopts digital PID automatic temperature control
system. The precision of temperature control is high. This instrument adopts big
screen LCD monitor and makes man-machine conversation straight and
convenient. With auto timing and air supply, the operation is simple and practical.
This instrument has refrigerator to ensure that 24 water bath temperature can
be controlled within the scope stipulated by the standard when it exceeds the
limit.
8.12.2 Technical Specification
Temperature Control Range: Low temperature bath 24
High temperature bath 93.5
160
Temperature Control Precision: 0.5
Monitor: Blue LCD
Temperature Range: 099
Power: 3300W
Air Flow: Flow of every air flow meter is controlled at 945ml/min.
Diameter of air diffusion head: 25.40.02mm Max diameter of

hole80m
Air Permeability of diffusion head: 3000-6000ml/min under

2.44Kpa(250mm water column) pressure.
Power Supply: AC 240V Frequency: 50Hz
Environment Temperature: 1035
Environment Humidity: 85%
Weight: 39Kg
8.12.3 Operation Instruction
8.12.3.1 Installation Environment
ZHY901 Lubricating Oil Foaming Characteristics Automatic Tester

should be installed in a clean and dry room.
8.12.3.2. Power Requirement
This instrument uses 240V/50HZ single phase AC power. Ensure that

the voltage has no big fluctuation and the instrument is well connected to
ground.
8.12.3.3Installation
a) Take the main frame and spare parts out of the package. Pay attention not
to destroy the water bath. Then check if all the parts on the packing list
are complete.
b) Hang the Drying Tower on the back board of the chassis according to the
instruction of the Complete Set Drawing and connect the silicone tube
with Air Inlet and Air Outlet.
c) According to the structure drawing, put the two water bath on the two
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base plates separately, and gently put the high and low temperature bath
electric heating tubes on the two water bath tubs separately. Handle with
care to avoid damaging the water bath. Pay attention not to misplace the
high and low temperature bath.
d) Inject distilled water from the water injecting holes of the two water
bath tubs separately. When the two 1000ml measuring cylinders
immerge in the water bath, the height from water surface to the rim of the
tub should always be kept about 50mm.
e) Connect control box with electric heating tubes by control cable.
8.12.3.4 Instrument Function
a) Turn on the current and switch on the power, the monitor displays :
Lubricating Oil Foaming Characteristics Automatic
Tester
b) Press any key to display the testing menu.
------ Testing ------
Low Temerature Bath
High Temperature Bath
Both
Select the appropriate testing. Either of low temperature bath or high

temperature bath can be tested or both can be tested simultaneously. In
addition, it has the function to open air pump solely to adjust the air flow
position of the flow meter before testing. Press Enter, then press to
open the air pump, press again to close the air pump. When opening
the air pump, the air flow of the pending test air road can be adjusted. The
air pump will be closed automatically when entering other page.
c) Low temperature bath
162
Press Enter, it displays Temp. Control The instrument begins to

control the temperature (e.g. If the water temperature of the bath is higer
than the max limit of 24.5 stipulated by the testing standard, the
refrigerator begins working to control the temperature automatically).
Temp. : 24.0
Status : Temp. Con.
Time : 00 :00
After the waterStart
bath temperature
Cancel Returnmeets the requirement, put in the
measuring cylinder which has been loaded with the testing sample.
Connect the air outlet of the main frame and the air inlet of the diffusion
head with hose. Press or to move the cursor to Start. Press
Enter, it displays immerge to keep the diffusion head at constant
temperature. Time displays the timing of this step. Five minutes later, the
buzzer sounds and air is supplied automatically. Timing starts
automatically when the first foam bursts from the measuring cylinder. Five
minutes late, the buzzer sounds. At this time, record the volume of the foam.
Precision is 5ml. Then Status displays Standing. Ten minutes
later(prompt by the sound of the buzzer), record the foam volume of the
measuring cylinder.
During the process of testing, move the cursor to Cancel, then press
Enter , the testing can be cancelled, Status displays Temp. Con. In case
of re-testing, just operate as per the above procedures. If the cursor is at
Cancel, press Enter continuously for 3 seconds, the instrument will
close temperature control.
When Status displays Immerge, press Enter, the instrument will

go to the next step : Air Supply.
When the cursor is at Start, press Enter continuously, and then press
or to increase or decrease the displayed temperature.
d) High Temperature Bath Test:
Refer to low tempeatture bath for testing procedure and method.
Temp. : 93.5
Status : Temp.Con.
163
Time : 00 :00
e) Both
After entering into this page, press Enter, both water baths start to
control temperature simultaneously. Press Enter again to enter into the
testing menu.
Temp. 24.0 93.5
L H
Status : Temp. Con. Temp.

Con.
Time : 00 :00
Start Cancel Return
Select Low Temperature Bath, testing starts from low temperature

bath. Select High Temperature Bath, testing starts from high
temperature bath. Time displays the testing time of corresponding testing
procedure. Testing procedures are similar to c) and d). The difference is :
When Status is Temp. Con., the cursor is at Cancel. Press Enter
for three seconds,both temperature control. Status displays Ready. If
it needs to be in temperature control status again, just move cursor to
Start and press Enter again.
8.12.4 Sample Testing
Please refer to testing procedure stipulated in GB/T12579.
8.12.4.1 Please load silica into the drying tower according to the loading chart of
drying tower.
8.12.4.2 Connect the silicone tube of air road. Temperature control is at 24 or

93.5 (either of both) and keep temperature constant.
8.12.4.3 Pour sample into 1000ml measuring cylinder and make the liquid level is at
190ml scale line and immerge it in 24 water bath. It should be at least at
the depth of 900ml scale line. (Sample must not be shaked or stirred
mechanically. It should be heated to 493 firstly, then be cooled at
243.)
164
8.12.4.4 Move the cursor to Start, press Enter, Status displays Immerge.
(orginally it should be Temp. Con..) Five minutes later (prompt by the
sound of the buzzer), air is supplied automatically and Status displays
Air Supply. Adjust flow meter to make air flow at 945ml/min. Make
clean dry air through air diffusion head. At this time, foam is produced in
the measuring cylinder, keep supplying air for 5minutes 3 seconds.
Record the volume of foam immediately (the volume from liquid level to
the top of forming). After standing time of 10minutes 10seconds, record
the volume of foam again. Precision is 5ml.
8.12.4.5 Pour second sample into clean 1000ml measuring cylinder and make the
liquid level is at 190ml scale line. Immerge it in 93.5 water bath. It
should be at least at the depth of 900ml scale line. When the temperature of
sample reaches 931, insert clean air diffusion head and air supply tube.
Testing is taken as the procedure 3 of Chapter 5. Record the volume of
form immediately after stopping the air and after standing time separately.
Precision is 5ml.
8.12.4.6 Remove all the foam left by 93.5 by stirring method. Put the measuring
cylinder at room temperature and make the temperature of sample below
43.5. Then immerge it in 24 water bath. When the temperature of
sample reaches the temperature of the water bath, insert clean air diffusion
head and air supply tube. Testing is taken as the procedure 3 of Chapter 5.
Record the volume of form immediately after stopping the air and after
standing time separately. Precision is 5ml.
8.12.4.7 Report
Testing result is reported as following :
Foaming tendacy Foaming stability
Foaming Volume Foaming Volume
after five minutes of supplying air after ten minutes of standing
8.12.5 Points for Attention
8.12.5.1 The power supply should be well connected to the ground.,
8.12.5.2 When there is no or little water in the water bath, do not switch on the
power for testing to avoid burning the electric heating tube.
8.12.5.3 The air diffusion head should be cleaned according to the requirement of
165
GB/T12579 to guarantee the testing precision.
8.12.5.4 When the blue color of silica in the drying tower has faded, it indicates it
has lost efficacy. New silica should be replaced.
8.13Spectroil M Oil Analysis Spectrometers
8.13.1Theory of Operation
Optical emission spectroscopy (OES) is a technique for detecting and

quantifying the presence of elements in a material. OES utilizes the fact that each
element has a unique atomic structure. When subjected to the addition of energy,
each element emits light of specific wavelengths, or colors. Since no two
elements have the same pattern of spectral lines, the elements can be dif-
ferentiated. The intensity of the emitted light is proportional to the quantity of the
element present in the sample allowing the concentration of that element to be
determined.
8.13.2General Operating Requirements
8.13.2.1Rod Electrode Sharpening
The rod electrode, along with the disc electrode, form the analytical gap
through which the oil or fuel sample are passed for analysis. An alternating
current discharge will occur between the disc and rod electrode and vaporize the
sample and the metallic components in it. This is the basis of the arc emission
technique.
The preparation of the tip of the rod electrode plays a significant role in
obtaining repeatable analytical data. The rod electrode must be cleaned prior to
inserting it into the electrode sharpener. This is accomplished by taking a clean
paper towel and removing the components of the burn residue from the previous
analysis. Remove all residue from the tip and sides of the electrode by rotating
the rod in the paper towel while applying pressure with the fingers of the opposite
hand.
NOTE: The paper towel should be laboratory grade and free of silicon.
With the spectrometer on, turn the MODE switch to OPERATE. This applies
power to J2, the electrode sharpener power connector. Momentarily press the
power switch located on the base of the electrode sharpener. The sound of the
electric motor should be heard and a slight vibration should be felt through the
motor. The motor will continue to run on a self-timed cycle for approximately 3
166
to 5 minutes. To sharpen the rod electrode, insert the rod into the rotating
electrode guide hole until it comes in contact with the cutter blade. Apply inward
pressure until approximately 1/8 to 3/16 inch (3 to 5 mm) is cut from the end of
the rod. Slightly decrease the inward pressure on the rod electrode, but still
maintain its contact with the cutter blade. This will polish the rod electrode tip.
Remove the rod electrode and visually inspect the tip. It should have a clean
cut with no apparent chipping around the circumference of the rod. The surface
should be very smooth and have a polished mirrored looking surface. If the qual-
ity of the surface is not as described, insert the rod into the sharpener and repeat
the cutting and polishing procedure. Remove the rod, inspect the surface quality
and if acceptable, place the rod electrode into the original box for storage until
ready for use. To prevent contamination of a sharpened rod electrode, do not
touch the tip or edge of the tip of the sharpened electrode with the fingers or
metallic surfaces or anything but a fresh, clean laboratory grade paper towel. Do
not use a rod electrode for analysis if the surface appears to have been damaged.
The electrode sharpener power is on a timing circuit and will turn off after
approximately 3 to 5 minutes. The electrode sharpener can also be turned off by
placing the MODE switch in the STANDBY position.
8.13.2.2 Installing the Disc Electrode
The disc electrode is the most significant contributor to the accuracy and
repeatability of the instrument. They are manufactured and then purified to strict
specifications to ensure that they do not contain unacceptable levels of trace
element contamination for the elements of interest. The care taken to properly
install the disc on the shaft will help to ensure that excitation parameters will be
kept as constant as possible, thus resulting in repeatable analytical data.
To install the disc electrode on the shaft, a laboratory grade disposable towel is
recommended. Pour out a few disc electrodes onto a clean laboratory grade paper
towel. Take a laboratory grade paper towel and double it to be sure that no
contamination from the fingers will be absorbed into the disc. If large size paper
towels are used, they should be cut with scissors into two inch squares to
facilitate easy handling. Place the towel over the disc electrodes, and with the
forefinger and thumb, grab one disc from the pile and place the disc on the shaft.
With firm pressure, push the disc electrode onto the shaft until it comes to rest
against the index shoulder of the shaft. If the disc electrode does not offer some
resistance to the shaft as it is being inserted, remove and discard this electrode
because the inner diameter has not been made to the tolerances specified.
8.13.2.3 Disposable Sample Holder

167
Installing the oil or fuel sample to be analyzed should be the last step in
loading the sample stand for analysis. When performing fluid analysis, an
important consideration which has an effect on the reproducibility of the analysis
is the quantity of the sample introduced into the analytical gap. This parameter is
one for which the instrument cannot adjust. Proper level of oil in the sample
holder is, therefore, part of any good operator technique. Standards and samples
are analyzed either in disposable plastic sample holders or a reusable sample
holder. In either case, it is recommended that the sample holder be filled level
with the top.
NOTE: An adapter may be required with some of the commercially available

disposable sample holders.
With the forefinger and thumb, pick up the sample holder and place it in the
slot at the top of the sample table. Push the sample holder towards the back of the
sample table until the sample holder comes to a stop. It is now properly
positioned in the sample table. Lift the table positioning lever, located on the
bottom of the sample table, upward until the table reaches the end of its travel.
The bottom of the disc electrode should now be immersed in the sample. The
sample is now ready for analysis. Close the door of the sample stand and press
the START button located on the operators control panel or function key 9 (F9)
on the keyboard, or the burn icon.
Upon completion of the analysis, open the sample stand door, lower the table
and remove the sample holder. Please note that proper oil disposal procedures
must be followed as dictated by local regulations and laws.
8.13.2.4 Reusable Sample Holder
The procedure is identical to the above disposable sample holder procedure

except that a clean reusable sample holder is used to hold the oil or fuel for the
analysis. The sample stand table also has a special cutout and groove to hold the
sample holder in place and to align it properly for the analysis.
Upon completion of the analysis, open the sample stand door, lower the table
and remove the sample holder. Pour the oil into a suitable container for proper
disposal and set the sample holder aside for cleaning. Please note that proper oil
disposal procedures must be followed as dictated by local regulations and laws.
The sample holder should be cleaned with an ultrasonic bath and an envi-
ronmentally acceptable cleaning solution.
8.13.2.5Cleaning the Sample Stand
168
The Spectroil M incorporates the rotating disc arc emission technique for
excitation of the fluid sample. This technique produces a fine carbon residue
which, when combined with oil droplets, produces an oil coating over the sample
stand and door area. If allowed to accumulate, this coating will collect the carbon
particles and eventually produce a lower resistance path than the analytical gap. If
this occurs, the high voltage will not discharge across the analytical gap, but will
discharge along the lower resistance path causing damage to the sample stand
components.
8.13.3Daily Operator Maintenance
This section details the maintenance actions required of the operator on a daily
basis. These maintenance actions pertain mainly to the operator accessible
assemblies such as the sample stand, the readout and control panel, and the
automatic printer. Any maintenance that is required to be performed in the
excitation source, optics, or computer electronics is strictly limited to technically
skilled personnel.
DAILY OPERATOR MAINTENANCE
CAUTION: Do not use alcohol or Chlorinated Solvents to clean plastic or

painted surfaces.
Component Required Maintenance Frequency Maintenanc
e Level
Plate, Mounting, Clean to remove oil and carbon Every 5 Operator
Sample Stand buildup especialy between disc burns
Component electrode shaft and rod electrode
holder.
Window, Quartz, Clean to remove oil and carbon Every 5 Operator
Protective splashes with isopropyl alcohol or burns
an ammonia based window cleaner.
Sensors, Sample Using a Q-tip, clean to remove oil Daily Operator
Stand and carbon splashes with isopropyl
alcohol or an ammonia based
window cleaner.
Sample Stand Clean complete sample chamber to Twice Operator
Area remove oil splashes and carbon Daily
buildup.
Door, Sample Clean complete door to remove oil Twice Operator
Stand splashes and carbon buildup. Daily
169
Electrode Rotate cutting blade to new edge. As Operator

Sharpener Required
Panel, Readout Inspect for oil splashes and carbon Daily Operator
and Control residue. If present, remove with
mild cleaning detergent.
Frame and Inspect for oil splashes and dust Daily Operator
Exterior Panels buildup. If present, remove with
mild detergent.
CAUTION: DO NOT USE ALCO-
HOL OR CHLORINATED SOL-
VENTS TO CLEAN PLASTIC OR
PAINTED SURFACES.
Printer Inspect for worn ribbon, loose cable Daily Operator
connectors, and dirt and dust build-
up. Replace worn ribbon, tighten
loose connections and clean
accordingly. Refer to printer
operation and maintenance manual.
170
9 Use of Water Analysis Instruments
9.1SX Series Box-type resistance furnace manual
9.1.1 Structural characteristics
The series resistance furnace are rectangular shape, with angle steel welded
line shell and made of thin welded steel folding. Studios - made from the refractory
furnace chamber as a whole, uniformly distributed around the furnace are sealed
hole to wear silk, heat components-Cr27A17MO2 Fe-Cr alloy wire wound into a
spiral after the wear on the wire hole. Between the furnace and the furnace shell
with high alumina refractory fiber, alumina and perlite insulation brick light brick
building as insulation. Furnace door hinge fixed through multi-level panel on the
stove, oven door closed door handle, the use of self-respect, through the leverage of
the door and close the mouth, turned up only slightly to mention the handle off the
hook after pulled out, the door can be placed on the left. In addition, mouth and
bottom of door chain fitted with safety switches, when the door opened, the furnace
will automatically cut off power supply to ensure safe operation, the furnace after
the furnace has opened a thermocouple hole, thermocouple holes from into the
furnace. Controller system made of thin steel plate. In some measure, and the
furnace power supply regulation and control of three parts, which measure and
control the temperature by the configuration instructions to complete the
instrument, electric power supply of three parts, which measure and control the
temperature by the configuration instructions to complete the instrument, electric
power supply unit by the contactor, current meter, power switch, terminal blocks
and other components, so not only can measure temperature, but also control the
temperature in a given range.
9.1.2Four, How to Use
9.1.2.1 The series resistance furnace no special installation, interior flat surface or table
(frame) can be placed on, in supporting the thermostat should be avoided by the
real shock, with placement and not too close to the furnace to prevent
overheating affect the normal operation of electronic components.
9.1.2.2 The thermocouple from the thermocouple hole in the holder into the furnace, the
thermocouple hole and the gap between the use of asbestos rope packing, and
then fixed.
9.1.2.3 Shell opened a temperature controller, press "electric resistance furnace and
temperature controller connected wiring diagram" and the back-end temperature
171
controller, power supply wiring board marked wires, electric furnace,

thermocouple, door safety switch. Connect the power supply, the phase line and
the centerline cannot be reversed, otherwise it will affect the normal working
temperature controller, and a risk of electric shock, the first pole in the power
line, subject to installation of switches to control the total supply.
Thermocouple temperature controller connected to the application of
compensation lead wire to remove the cold-side effect caused by temperature
changes, the connection cannot be reversed when the positive and negative, in
order to ensure safe operation, furnace, temperature controller shell to be
reliable grounding.
9.1.2.4 After checking correct wiring ministries can power heating.
9.1.3Maintenance and Attention
9.1.3.1 When the furnace for the first time use or long-term suspended again after use,
must be oven dried. Oven temperature and time: room temperature -2004
hour open the door to room temperature -600 4 hour
9.1.3.2 Furnace used, furnace temperature shall not exceed the rated temperature, so as
not to damage the heating element, and a ban on the direct infusion of various
fluids within the furnace and dissolved metals, often eliminating Lu furnace dust,
oxides, to ensure the furnace clean.
9.1.3.3 The series resistance furnace work applies to the following conditions: (1) Not
more than 1000 meters above sea level (2) Ambient temperature in the range of
+5 -40 . (3) The use of the region's most wet monthly average maximum
relative humidity of not more than 90%, while mean minimum temperature of
not higher than 25 . (4) Around the stove no conductive dust, explosive gas,
and can seriously damage the corrosion of metal and insulation gas. (5) no
obvious vibration and bumps.
9.1.3.4 The user to comply with the custody, use, installation, under the conditions of
transport, delivery period starting from my factory in 18 months (including the
use of not more than 12 months), the product due to poor manufacturing quality
or the event of damage does not work, I plant for free repair or replacement parts
the user.
9.2 Model DDB-11A Portable Conductivity Meter
172
9.2.1 Instructions to the Meter:
9.2.1.1 LCD Display
a. Measuring value
b. Measuring unit
c. Icon of low voltage, when the power blew 6V, appears this icon, change new
battery.
d. Manual Temperature
e. Measuring value and unit
f. Stable icon of the measuring value
g. Icon of parameter model.
9.2.2 Operation Keys
The meter have four keys
9.2.2.1 Switch and calibration button.
(a)Short-time press (time<1.5s), same as the power key.
(b)Depress (time >2s), meter can calibrate automatically.
(c)Under the parameter model, press the key means affirmance, the meter return to
measuring model.
9.2.2.2 Increase and decrease key.
173
(a)When in measuring state, press the key to increase or decrease the temperature
value. Short-time press to alter 0.1 each time, while depress, the temperature
will alter rapidly.
(b)Under the parameter to set the state, press the key to change the number or
ON/OFF state.
9.2.2.3 Function key and enter key.
(a)Function key under the measuring state, press it to enter model P1, P2, P3 and
so on.
(b)Enter key under the parameter to set the state, press the key means enter and
enter next parameter setting.
9.2.3Conductivity measuring
9.2.3.1. Preparation:
a. Short press key to power on;
b. Connect 2301-C conductivity electrode to the meter.
9.2.3.2. Electrode calibration:
a. Use thermometer to measure the temperature of standard solution,
press or to change the temperature that appears on LCD.
b. Put the conductivity electrode into purified water, wash and dry it, dip in
calibration solution of 1413S/cm, still after stir it, wait the measuring value
become stable and appears , then depress key, when the LCD
appears , you release it, the blinking 1413s/cm, after a few seconds,
the appears and return to measuring model, meanwhile the stable measuring
value appears on the LCD, if not we can repeat the steps till it stable.
9.2.3.3. Solution test:
174
a. Use thermometer to measure the temperature of the solution, adjust the
temperature on the LCD correctly by press or .
b. Wash and dry the conductivity electrode, put it into solution, still after stir it,
wait the measuring value become stable and appears then read it, is the
conductivity value of the solution.
9.2.3.4. Important specification:
a. The meter have two way measuring model: MTC (manual temperature
compensation and NTC (no temperature compensation), we can set under the
parameter setting P1 model.
(a) MTC measuring model: (chart 4-1), LCD have the temperature, temperature
compensation of the meter: 2.0/, reference temperature: 25.
(b) NTC (no temperature compensation) measuring model: (chart 4-2), LCD has
no temperature, now the meters parameter of the temperature compensation is
zero, the meter has no temperature compensation, and the measuring value is
the conductivity value under the temperature.
b. There are two ways: standard solution calibration way and constant setting way
for calibrating of conductivity electrode to the meters setting, the 4.2. Item
electrode calibration description is the standard solution calibration way, this
way can ensure the best accuracy. So we suggest this is the first choice. If the
users used to the constant setting way: means according the constant value on
the conductivity electrode to set, please doing it under parameter setting P3
(detail P7 item4.5.4.). Two ways we can choose freely, no effect to each other.
175
c. The meter have special one-point calibration function, we can make the
conductivity of the water sample and calibration solution similar to each other
as much as possible to calibrate meter, normally the calibration solution is
1413S/cm, use the accessory 2301-C conductivity electrode(K = 1 cm-1), use
1413S/cm calibration solution to calibrate, we can use for measuring range:
0.5S/cm ~100mS/cm; use 12.88 mS/cm calibration solution to calibrate, can
use for measuring range: 100mS/cm~200mS/cm. see chart (4-1) to choose.
Chart (4-1)
Measuring range 0.1~ 20S/cm 0.5S/cm ~ 200mS/cm
Electrode K=0.1cm-1 K=1.0cm-1

parameter
(flowage test)
Standard 84S/cm 84S/cm 1413S/cm 12.88 mS/cm

solution
9.2.3.5 Parameter setting:
a. The list of conductivity measuring parameter (chart (4-2))
Chart (4-2)
Icon Parameter setting item Parameter
P1 Temperature compensation choose OFF-On ( power off-on)
P2 Electrode constant choose 0.1 - 1.0 - 10
P3 Electrode constant setting
P4 Temperature unit choose /
b. Temperature compensation choose (P1)
(a)Press key, the meter enter P1 model, chart (4-3):
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(b)Press key, choose On or OFF:
On have temperature compensation
OFF no temperature compensation
(c)Press key enter next parameter setting or press key to confirm,

then return measuring model.
c. Electrode constant choose (P2)
(a)Under P1 model press key enter P2 model, chart (4-4);
(b)Press key to change constant setting: 0.11.010.0
(c)Press key enter next parameter setting or press key to

confirm, then return measuring model.
d. Electrode constant setting (P3)
(a)Under P2 model press key to enter P3 model, LCD appears the last
calibrating constant value, like: 0.96 cm-1 chart (4-5);
(b)Press or key to change the number, according the constant

value on conductivity electrode to set;
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(c)Press key enter next parameter setting or press key to

confirm, then return measuring model.
(d)If need constant calibration to the conductivity electrode beyond constant 1,

such as use the constant of conductivity electrode is 10.3, we first enter
parameter setting P2 to set constant 10, then enter P5 model set the
constant 10.3.
e. Temperature unit / choose (P4)
(a)Under P3 model press key to enter P4 model, chart (4-5).
(b)Press key to choose temperature unit.
(c) Press or to confirm then return measuring model.
9.2.4 Considerations
9.2.4.1 Before sold out the company we have already calibrated the conductivity
electrode, normally the users can directly use it;
9.2.4.2. We suggest on normal situation once a month to calibrate; new electrode and
used some time already, we should again to calibrate the conductivity
electrode;
9.2.4.3. Keep the electrode clean, before and after using the conductivity electrode, we
should use the pure water wash it and dry it.
9.2.4.4. On the surface of the 2301-C conductivity electrode sensor bar have the
platinum black, can decrease the electrode polarization, can enlarge range, so
the surface of the electrode of platinum black cannot wipe, only stir in the
water, in case of breaking the layer of the platinum black; use the warm water
with detergent can wash the organic constituent, also can use the ethyl alcohol
to wash.
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9.2.4.5. The conductivity electrode should put into pure water, in case of inerting of
platinum black, if you find the electrode with some platinum black does not
work, can dip into 10% nitric acid solution or 10% hydrochloric acid solution
about 2min, then use the pure water wash carefully then use it, if not we should
change new surface of the electrode or change a new electrode.
9.2.4.6 Temperature unit and change: press key for a few seconds can
change or .
9.2.4.7 When the LCD appears the battery icon, means the voltage is lower than we
using requires, please change the battery.
9.2.4.8 The meter can automatically power off after stopping use it 15min.
9.3 Model PHB-4 Portable PH Meter
9.3.1 Brief Introduction:
There is a microprocessor chip inside the meter and its appearance looks good
with easily operation. For notable features read as follows:
9.3.1.1 Equipped with 201B-S pH/ATC 3-in-1 combination electrode which used
special sensitive membrane formula and structure mode, not only for
measuring normal water solution, but also for measuring surface water, river
water, tap water, high purified water and acid rain and so on lower ion strength
solution that we cannot use normal PH electrode for measuring stably, have
response quick, stable display, ATC and so on features.
9.3.1.2 Three points automatically calibration for double slope which make the
meters accuracy much higher and manual temperature compensation.
9.3.1.3 Automatic display slope percentage after calibrating.
9.3.1.4 Large blue background LCD screen which can show both PH and temperature
value at the same time.
9.3.1.5 Inside of the chip has two series data of PH buffer solution, can be choose
freely.
9.3.1.6 Lower power display, power off automatically after 15 minutes.
9.3.1.7 and can be switched automatically.
9.3.1.8 Packing with special carrying case and there are standard buffer solution inside
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it.
9.3.2 Technical Parameter:
9.3.2.1 Measuring Range: pH: 0~14.00 PH mV: 1999 mV
9.3.2.2 Resolution: pH: 0.01pH mV: 1 mV
9.3.2.3 Accuracy: pH: meter0.01pH 1 digit
meter comes with electrode0.02pH 1 digit
mV: 0.1%F.S 1 digit
9.3.2.4 Input Resistance: 11012
9.3.2.5 Temperature Compensation Range: 0~80(automatic)
9.3.2.6 Power: 1pc of model 6F22 9V cell
9.3.2.7 Dimension and Weight: 168 x 43 x 26mm/170g
9.3.2.8 Working Condition: environment temperature: 5~35 . Relative moisture

85%RH
9.3.3 Meters Operation:
9.3.3.1 PH value measurement:
a. Short press key to power on.
b. Taking off the short circuit protecting cap which on the socket of meter, then
connect the PH combination electrode, put the electrode into pure water stirring
and dry it out.
c. Fix position calibration: Immerge the PH electrode into pH7.00 buffer solution,
still it after slightly stirring and when showed value is stable, then press the
calibration button for some minutes, and release it when there
show and 7.00 after many seconds, when there display icon , steady
PH calibration value and temperature value. (The value at this time will be
different during different temperature, for example, meter will display 7.00 when
temperature is 25 and it will be 7.04 when temperature is 15. All of them
are setting data inside in the chip) which shows finished calibration and data
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have been remembered by chip.
d. Slopecalibration: Take out electrode, clean it with pure water and dry it out,
and insert it into pH4.00 buffer solution, then still it after slightly stirring, and
press calibrating button after displayed value become stable. Then release
it when there show , first display twinkle 4.00 and after some
seconds, symbol, stabled PH calibrating value and temperature value are

displayed on the LCD that means calibration is finished and data is
remembering by chip. After calibrating, meter will automatically display slope
percentage of electrode in this stage.
e. Slopecalibration: Take electrode out, wash it with pure water and dry it out,
then insert it into pH10.01 buffer solution, still it for almost 10 seconds after
slightly stirring, and press calibrating button after displayed
value become stable. Then release it when there show , first display twinkle
10.01 and after some seconds, symbol, stabled PH calibrating value and
temperature value are displayed on the LCD that means calibration is finished
and data is remembering by chip. After calibrating, meter will automatically
display slope percentage of electrode in this stage.
f. Sample measurement: Immerse PH electrode into the sample solution after

washing and dry out. Still it after slightly stirring and reading data when it stable
displays that is PH value.
Note: According to the equal temperature measurement principle for PH testing,

the temperature of sample solution is the more closer to standard buffer
solutions temperature the measuring value is the much higher, user should pay
attention to obey when actual testing.
g. Specification:
There is an intelligent chip in the meter, which could choose one point, two
point and three point automatically calibration, it only needs calibrate with
pH7.00 buffer solution for one point calibration if the measuring accuracy 0.1pH.
If the measuring range is only in acidic range (pH<7.00) or alkali range (pH>7.00)
which could also use two point calibration, except pH7.00 fixed position
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calibration, you should choose pH4.00 or PH 10.01 for the second point
calibration. You should choose three point calibration if the measuring range is
wide or PH electrode is aged for has been used for a long time. But when the
electrode being used for the first time, it must be calibrated with 3 points to adjust
the slope of meter is in accordance with PH electrode. I have helped customers.
9.3.3.2. Measure mV value:
a. Press key, change the meter to mV mode.
b. Connect ORP electrode or ion electrode (need extra equip) insert it into sample
solution, still it after slightly stirring, and reading until there shows stable ORP
value or the potential of ion electrode
9.3.4 Considerations:
9.3.4.1 Calibration times for meter rely on the sample, electrode performance and
required accuracy. For high accurate measurement (0.02pH), which should
be calibrated immediately with standard buffer solution, for general accuracy
measuring (0.1pH), which can be used almost one week or long time once
be calibrated. However, the meter must be renewing calibration read as
follows:
(a) New electrode and unused one for a long time;
(b) After measuring acid (pH<2) or alkaline (pH>12) solution;
(c) After measuring solution which contains fluoride and concentrated

organic solution;
(d) The temperature of solution is much different with calibration

temperature.
9.3.4.2 There are some soak solution in the protect bottle in the front of electrode, the
electrode head soak into it for keep the glass bulb and junctions activation.
When measuring twist off the cap and expose the electrode, wash it clean with
pure water. After using, insert the electrode in and twist the cap on. Once found
there are some thickness or go moldy in the protect bottle, then the soak solution
should be replaced immediately.
9.3.4.3 Preparation of the electrode soaks solution: Take 25g analytical pure KCL,
which need be dissolved in 100ml pure water stir till dissolved completely. The
electrode should be avoid soaking into the pure water, protein solution and acid
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fluoride solution for a long time, and protect it touches with organic silicon lipid.
9.3.4.4 When the meter calibrating use PH standard buffer solution, in order to improve
the measuring accuracy, the PH value of buffer solution should be reliable. The
buffer solution should be replaced in time after being used for many times.
9.3.4.5Keeping electrode clean and dry, especially note that keep meter and connectors
high clean and dry, otherwise, which will lead the electrode inaccuracy or
invalidation. If the electrode is dirty which could be cleaned with cotton and
alcohol, then blow it try.
9.3.4.6 The sensitive glass bulb in the front of combination electrode which can not
touch with hard things, any broken and hair will make the electrode invalidity.
Before and after measuring, the electrode should be washed with pure water and
after washing should dry the electrode out and user should not polish the bulb
with paper for that will lead potential of electrode is unstable and lengthen
response time. The electrode should be washed again and again for remove the
sample stuck on the electrode, after measuring sticky sample.
9.3.4.7 An electrode which be used for a long time, or measured solution that contains a
polluting solute easily for the sensitive bubble, or a substance resulting in jam at
the junction, the electrode will be getting passivation, its sensitivity grade will
decrease and its response is getting slow, the reading are not correct. It could
adopt the following method for various cases:
(a) The glass bubble which is contaminated and aging: put the electrode into a
0.1mol/L dilute hydrochloric acid (preparation: 9ml hydrochloric acid is
diluted into 1000ml.) for 24 hours. Rinse it with pure water, then dipped it
into the electrode dipping solution for 24 hours. If it is serious passivation,
put the end of electrode into 4% HF (hydrofluoric acid) for 3 or 5 seconds,
rinsing it with pure water, then dipped it in the electrode dipping solution
for 24 hours to make it renew.
(b) Clean for contaminated glass bubble and junction: (For reference)
Contamination abluent
Inorganic metal oxide dilute acid (<1mol/L)
Organic Lipidic dilute washing
Resinic macromolecules dilute alcohol, acetone, ether
Proteinic haematocyte sediment acidic enzymatic solution (such as dried

yeast)
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Kinds of paint dilute bleacher, peroxide
The material of the electrode housing is poly-carbonate. Please pay attention

while washing, be careful while using tetrachloro-methane, trichloroethylene,
tetrahydrofuran. Because these reagents will dissolve poly-carbonate which
lead to the electrode invalidation.
9.3.4.8 PH Electrode using period is about one year, but it will be short if the using
condition is bad, or the maintenance is not well. You should replace a new
electrode in time when the electrode is aging or invalidation. The
microprocessor inside the meter has a function for inspecting electrode slope
automatically (detail see 3.1.5 and 3.1.6). If the slope is less than 85%, you
should consider performing the electrode activation (detail see 3.7.), or replace a
new electrode.
9.3.5 Other Functions for Meter:
9.3.5.1 and can be switched: Press the button to change to .
9.3.5.2 Battery must be replacing when the sign of batterys electric charge shows on
the LCD, it means the voltage lower than we using require.
9.3.5.3 Meter will power off automatically after 15 minutes in case of being unused.
9.3.5.4 Inside of the meter have two series data of PH buffer solution:
pH 6.86 series is Chinese PH standard buffer solution data: pH4.00, pH6.86

and pH9.18.
pH 7.00 series is USA PH standard buffer solution data: pH4.00, pH7.00 and
pH10.01.
In the same series solution, the meter can automatically recognize three kinds
of buffer solution. When the user need to change the series of buffer solution,
can put the electrode into pH6.86 or pH7.00 buffer solution, press for a
few seconds, when the LCD appears sign, then release the button, LCD
appears the blinking number: 6.86 or 7.00,at the moment quickly press
increase button or decrease button , can change the buffer solution

series. When the number become still it means has already finished the
adjustment to the PH buffer solution. This meter before selling out the
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company the PH buffer solution series is the pH6.86 series, if no necessary,

please do not adjust freely, in case of using wrong buffer solution can lead the
calibration of the meter wrong, during the using process, if find the error is
big difference, please check the PH buffer solution is all right first.
9.3.5.5 The meter might be locked occasionally (it cant be closed by press switch
button), then the user just need to take out battery and replaced it to battery
compartment will be working.
9.3.6 Adaptation kit for the meter:
9.3.6.1. PHB-4 portable PH meter 1set
9.3.6.2 201B-S plastic pH/ATC 3-in-1 combination electrode 1p5
9.3.6.3 pH4.00, 7.00, 10.01 buffer solution each (50ml) 1 bottle for
9.3.6.4 Model 6F22 9V cell ton kit
9.3.6.5 Carrying case for the
9.3.6.6 Instruction manual meter
9.4 OX-12B Type Portable oxygen analyzer
9.4.1Principle
Polarographic measurement of oxygen using the principle of oxygen

produced in the electrochemical sensor, Electrolysis current and oxygen
concentration is proportional to the temperature compensation system parameter
calibration temperature coefficient.
Electrode in the oxygen reduction process consumes oxygen; oxygen must

be supplied by the media continuously. Therefore, the use of instruments to
measure oxygen concentration, the media must continue to flow, to ensure accurate
measurement and reliable.
9.4.2 Operation As
9.4.2.1The role of instrument function keys:
a Tuning regulator:
Used to measure the gases oxygen and dissolved oxygen in the air
conditioning use during calibration.
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b Gas oxygen / oxygen switch:
This switch is used to measure the gases oxygen and dissolved oxygen in the
conversion. When the switch is highlighted, the in air calibration, measure the
oxygen gas; in the air after calibration switch is pressed, direct measurement of
dissolved oxygen.
c Range selector switch:
Range switches left, center or right third gear. The measurement range of
each file to determine according to customer requirements.
9.4.2.2Determination:
a Determination of oxygen gas:
1) Instrument calibration - equipment powered on, the instrument placed in%

files, oxygen electrode placed in the air, and stability (15 ~ 25) minutes, adjust
tuning regulator, the instrument showed 20.6%. Such as precision measurement
instruments, application of dry air correction was 21.0%.
2) The sample gas measured - calibrated, the oxygen electrode placed in the
measured sample gas, to be stable (1 to 2 minutes), record the reading (%),
compared to the actual oxygen concentration in sample gas.
b dissolved oxygen:
1) Instrument calibration - equipment powered on, the instrument placed in mg /

L files, oxygen electrode placed in the air, to be shown stable (2 to 3) minutes,
adjust tuning regulator, the instrument showed 20.6%; Then the gas oxygen/
dissolved oxygen measured directly after pressing the switch. Such as precision
measuring instruments, calibration data should be high and the humidity
calibration (see appendix).
2) Sample determination - instrument corrected, and put on oxygen electrode

flow cell sample into the flow cell, sample to maintain the flow rate is greater
than 10cm/sec. The gas oxygen/oxygen switch is pressed, to be shown stable
instrument (2~3) minutes, record the reading (Mg / L) dissolved oxygen shall
sample.
9.4.3 Terms of Use and maintenance
9.4.3.1 Oxygen electrode factory equipment has been installed, you can immediately
put into use. If you need to reinstall the electrode membrane, follow these steps:
(see below)
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a. The electrode into the cavity with a syringe twice re-distilled water, then rinse
with DO-100 electrolyte out of 0.2ml, to set aside part of the gap.
(For film dressing water diagram)
Add a drop of electrolyte on the electrode head, the PA-100 membrane

electrolyte rinse cycle with two, buckle slowly fill the electrode head and tightened
with a laminated ring. Water after cleaning electrodes, and then dry absorbent paper,
rotating the sheath. Oxygen electrode connected to the instrument, turn the power
24 hours before use.
9.4.3.2 Of the instrument battery voltage <8V, the LCD panel the upper left corner will
display "LOBAT", should be replaced with new batteries.
9.4.3.3 If the instrument readings and volatile, not the correct measurement. Tapping
oxygen electrode, instrument readings fluctuations> 0.5%, it is because PA-100
film movement, perforation, or rupture, should be replaced. Replacement of the
first electrode film, see this chapter. Five long open instruments, sometimes
passive phenomenon, both readings gradually reduce, due to the introduction of
surfactant electrode kit was due to the electrode surface adsorption, replace the
electrolyte, pure cotton or filter paper graze cathode ethanol surface membrane
replacement cycle; Apparatus having problems using the call asked, have
questions, please send our repair department, apparatus, do not own to open the
back cover, should be mobilized within the adjustable part, so as not to cause
trouble to repair the company. This instrument is a measurement instrument, in
order to ensure accurate use of equipment should be annually sent to the local
quality and technical inspection department for examination or inspection of the
company.
9.5 OIL-2 Type Oil Copy Concentrated Degree Meter Manual
9.5.1The Working Principle
Most petroleum substances in the infrared band at 3.4m have strong

absorption (Fig. 1a), using the corresponding absorption band on a small solvent
(Figure 1b) water and the substances extracted from the oil after Determination of
187
oil solvent absorbance or transmittance of the infrared, can be under the Lambert -
Beer law in water samples obtained copies of the concentration of oil.
According to this principle design of the OIL-2 type of oil in water

concentration meter were single beam structure, the infrared light source, and light
chopper, synchronous optical switches, testing pool, focusing lens, narrow-band
infrared filters, infrared detectors, detection circuit and power circuit of several
parts (Figure 2). OIL-2 type instrument detection beams exit the pool with a good
performance of narrow band IR filter, the filter covers the optical properties of the
International Organization for Standardization (ISO) recommended analysis
method required three absorption peaks, so as to ( ISO) method one step closer.
Light source infrared light through optical chopper after cutting through the
detection cell, the detection of oil tanks are part of solvent absorbed energy, the
remaining infrared light through IR filter and focusing lens concentrates the energy
to the infrared detector sensitive element , mid-infrared optical filter as the role of
the center wavelength of 3.4 m were outside the filter blocks the infrared radiation,
so get on the infrared detector element sensitive detection of the energy pool can
reflect changes in the concentration of oils. Optical chopper for cutting the role of
infrared detector output waveform shown in Figure Uc diagram for the oil samples
absorb infrared radiation energy, which is equivalent to 3.4m infrared light
transmittance; Ub contains infrared detector output offset voltage and the voltage
changes with environmental temperature fluctuations; Ua infrared detection energy
is reached sum; their relationship Uc = Ua-Ub; because Ub is a variable with the
temperature fluctuations, to accurately reflect the oil were detected in
concentrations of Uc Ua must first be detected accurately and Uc, then the
subtraction circuit may the Uc, Uc complete and accurate detection purposes; Uc
has been on extended range digital conversion and other processing circuits, the
final reading in the digital display directly on the concentration of oils.
188
Figure 2
189
Figure 3
9.5.2 Instrument Structure
Functional arrangement shown in Figure 4, instrument panel
Figure 4
Figure 4 Schematic diagram of instrument panel features
9.5.3 Equipment installation and Use
9.5.3.1 Preheating equipment:
Test room should check whether the power requirements, such as testing
indoor power supply voltage fluctuations than AC220V 10%, to be the instrument
power input is electronic exchange regulator. Laboratory in the vicinity can not
have welding, high frequency heat sealing machine and other large sources of
interference, equipment should be well grounded. Correct in identifying
instrumentation power after the power switch, preheat apparatus. Instrument
warm-enter the work state after 30min, when the instrument detection of low
concentration samples, the preheating time may be extended.
9.5.3.2 Standard oil, solvents and containers:
a. OCB instrument randomly mixed with standard solution of petroleum

hydrocarbons can also press the "Water and Wastewater Monitoring Analysis
Method" method described in hexadecane, isooctane and benzene as the standard
by mixing oil.
bEquipment for the oil were used in the concentration of solvent-specific carbon
190
tetrachloride, it is our use of imported raw material. Dedicated infrared

transmittance of carbon tetrachloride in the 3.4m high, and the consistency of
good FCL. However, in analyzing the samples with low concentrations of oil were
when the sample to be tested according to the number of how many will be the
number of bottles of dedicated pool of carbon tetrachloride in a dry and clean large
container and mix, then back-packing reagent bottle. The solvent can be used to
adjust instrument zero, standard solution preparation and cleaning equipment
detection system. Concentration of solvent in the oil were used in large quantities,
can be recycled for use after re-distillation.
c Analysis used in glass measuring tools and utensils must be cleaned with
washing liquid, shall not use soap, detergent and enzyme wash, clean and dry the
containers should not be a residual moisture. Measuring and utensils before use
application blank in the first flush of carbon tetrachloride.
d Preparation of calibration equipment scale (readings) with standard solution.

General election equipment range near the midpoint of the concentration of
standard solution preparation. Maximum range of the instrument 100mg / L, can be
40mg / L ~ 60mg / L choose a concentration within the preparation of standard
solution. If the measured object has a lower concentration of the samples are also
available with 40mg / L standard solution under the scale calibration of
instruments.
9.5.3.3 Adjustment and calibration of instruments
aCleaning Pipe equipments and testing pool. From the reagent bottle poured
20mL ~ 30mL of carbon tetrachloride in a small beaker blank, put on random
with a long needle syringe, draw a blank about 6mL carbon tetrachloride
injection apparatus, repeated push-pull syringe pipeline flushing and testing
equipment pool, out into the empty carbon tetrachloride discarded. Continue
cleaning by this procedure 3 to 5 times.
bSyringe draw 6mL blank carbon tetrachloride, the net emission of air bubbles in
the syringe, and then from the instrument slowly into the inlet, when the solvent
out of the overflow outlet from the apparatus, said detection equipment pool has
been filled with solvent. After 30 seconds display apparatus, to adjust equipment
"zero" button to zero the display. Repeat the above steps 2 to 3 times, such as the
instrument appears in the 0.2 range, could be that the instrument zero
adjustment is completed. Such as the instrument display more than 0.2 can be
re-adjusted "zero" button to zero the display, and confirm the continuous
injection of 2 to 3 times the readings were within 0.2 before the next step when
the instrument calibration and analysis.
191
c Calibration equipment scale (reading). Zero adjust the instrument has a future,
to take another set of syringes and needles, draw the appropriate concentration of
standard solution of about 6mL rinse tank and pipeline testing. When the second
injection of standard solutions should pay attention to the net first row of air
bubbles in the syringe, slowly inject equipment, pool and pipe to prevent the
detection of bubbles. Stable instrument reading after 30 seconds; adjust the
instrument panel on the "calibration" button, the instrument display and the
corresponding concentration of the solution injected. Three times into the
standard solution, such as the average of nearly three times the standard solution
shows the concentration values (allow 0.1mg / L ~ 0.2mg / L of error) that the
instrument calibration can be calibrated better. As three times the standard
deviation shows the average concentration value is higher, to re-adjust the
"calibration" button to display the average of nearly three times the standard
value.
After the third part of the adjustment apparatus entered the normal state into the
sample analysis can be measured. To remind the user to note: instrument into the
normal working state, the panel's "Zero" and "calibration" button cannot touch.
The event of malfunction, according to the front of the zero adjustment and
calibration methods to re-adjust the scale of the instrument, the instrument into
the normal working condition.
9.5.3.4 Specimen is water sample collection and pre-treatment, refer to the "Water and
Wastewater Monitoring Analysis Method," in relevant part. The need to
highlight a few of the instruments;
a After extraction of the oil extract of pre-injection equipment must use

anhydrous sodium sulfate for dehydration.
bEach sample prior to use in measuring the sample solution of about 6mL a test
pool and pipe cleaning. From the start the second injection of the sample
readings, three consecutive readings, and whichever is the general average of
measurement results.
c The establishment of each instrument reading time (response) slightly

different, so the reading time for each measurement requirements as consistent
as possible.
dTo ensure the measurement precision, each sample should use a syringe and
needle, this time in the measurement of low concentration samples is
particularly important. Recommendations on the number in the syringe to
prevent the mix.
192
e The detection equipment and piping in the dead pool smaller, amount of
solvent required for each measurement is also smaller, so in practical work in the
extraction fluid volume size can be reduced to 25mL, the corresponding volume
of water samples can be collected reduced. However, the calculation of
measurement results to the sample volume, extraction than the substitution of
"Water and Wastewater Monitoring Analysis Method," which stipulated
formula.
9.5.4 Normal maintenance and precautions
9.5.4.1 Water samples contain more animal or vegetable oil and fatty substances, should
refer to "Water and Wastewater Monitoring Analysis Method", in the
pre-separation step.
9.5.4.2 Direct impact on the pool bubble detection and accurate reading appears. Slowly
into the sample is the best way to prevent bubbles.
9.5.4.3 Instrument of the working environment to ensure no direct exposure to the sun
to the instrument on, place the instrument table should not feel significantly
more powerful vibration and wind.
9.5.4.4 The range of different needs of different length detection cell, the user when
ordering please specify range in scope.
9.5.4.5 Concentration of oil was dedicated exclusively for the carbon tetrachloride is
our complete production equipment, the user can contact me at any time to buy.
Special carbon tetrachloride can be re-used after distillation recycling.
9.5.4.6 After each test application blank work detection system of carbon tetrachloride
cleaning 2 to 3 times, to prevent contamination detection system, but also easy
to use to shorten the next time the zero adjustment. As a result of the net
extraction do not forget to use anhydrous sodium sulfate or detection cell
dehydration caused by contamination, the instrument will appear unstable or
unable to adjust the zero reading of the phenomenon. Then ethanol injection
equipment can be repeatedly washed detection system was then used to absorb
liquid into the mouth from ear ball repeatedly blowing smoke, the system will
remain in the detection of dry ethanol, carbon tetrachloride and then injected
into a blank check and adjust equipment, general can achieve good results. If
this cleaning is invalid, can be unloaded from the instrument testing pool return
the cleaning company.
9.5.4.7 Equipment failure, please do not disassemble the user can return the instrument
to inform my company or my company, I will send technical personnel to go as
193
soon as possible repair.
9.5.4.8 One year warranty of the equipment, the warranty period is not a man-made
damage to the company for free repair. In other cases, such as improper use of
damage, the company is also responsible for repair, but the cost of charging the
appropriate fee.
9.5.4.9 I will from time to time hold classes, but also make an appointment to the
company's separate training for customer service, welcome to contact.
9.6 Manual Semi-Automatic Gas Analyzer
9.6.1Principles and Characteristics
The apparatus in accordance with certain chemical properties of the solution

can absorb certain gaseous substance to this theory, driven by compressed air from
an automatic opening and closing of the bolt into the standard bottle of compressed
gas to drive down the standard of the bottle surface, which makes the volume
airway pressure in the tested gas in turn be absorbed into the absorption bottle, the
gas has been absorbed values as contained in the volume of a gas and then burn the
remaining gas plus oxygen, calculated according to the chemical reactions of
several other gases volume, which has the principle of this instrument reliable, high
precision, advanced structure, easy operation, easy maintenance features.
9.6.2 How to Use
9.6.2.1Preparation before use
First of all the components of the joint inspection equipment, Taps

Department are tight, flexible, and familiar with the instrument structure, the role of
the various components and relationships, and channel direction, and then adjust
the standard bottle, so that surface and volume of tracheal 100ml bottle engraved
line of liquid level at the same level.
Power on, start the motor, Taps A2 will automatically open and close, open
Taps A1, A3, A5, A6 adjust air pressure, the solution adjusted to full volume just
float the upper airway closure, and then instantly dropped to the solution 100ml (or
near) groove Department is appropriate.
According to the figure below, right-on, the various absorption solutions

were absorbed into the bottle.
The first bottle into: 30% potassium hydroxide solution to absorb carbon
194
dioxide.
The second bottle enters: potassium bromide solution and bromine solution,
or use a mixture of nickel sulfate and sulfuric acid mixture, absorption of
unsaturated hydrocarbons.
The third bottle into the: focus of gallic acid solution or by 11%
phloroglucinol solution and 19% mixed solution of potassium hydroxide to absorb
oxygen.
Into the fourth bottle: the mixture of cuprous chloride and ammonia, carbon
monoxide absorption.
Fifth bottle (attached): You can load 10% sulfuric acid solution, absorbing
play the fourth bottle of ammonia.
Sixth bottle (attached): can be used to duplicate the absorption of certain

gases.
The method uses the unit can also be arranged to their specific conditions.
9.6.2.2. Absorption:
Equivalent Tube full solution to the air immediately after the relevant oil
discharge A5 A5, (along with the beam direction) and then off A3, A4 open flush
pipe samples taken, when the flush gas to the amount taken, the relations A4, open
A3, see the amount of liquid surface immediately open up A5, equivalent full float
tube closure solution, immediately off A5, then open A4, A3 relations official
sampling, sample taken from 100ml groove, immediately off A4, A5 open zero, A5
closed, A3 B1 Open to open the sample bottle onto the V1 to absorb absorb absorb
2 to 3 times A3, note reading, and then redo the first observation is constant,
constant off after B1, in accordance with the method followed by the gas pressure
into the V2 , V3, V4 absorption bottle absorption, and residual gas pressure into the
V5 stored.
9.6.2.3 Burning:
According to theory, or situation by adding a little excess of oxygen, (make

residual gas in the H , CH combustion) to enable the measurement of oxygen by
volume after the trachea into Molotov cocktails inside, immediately closed B7,
transmission warm-about 60 seconds, this B5 absorption bottle when opened into
the amount of residual gas inside the trachea, note reading, off A1, while
re-opening A3, B7, will slowly put all the residual gas inside the combustion V7
Molotov cocktails, burned and then after the connection switches A3, 3 ~ 4 times to
195
make Molotov cocktails repeated strings within a closed fluid dynamic (note the
sealing liquid and combustion platinum gold contacts do not) make full combustion,
string, after moving off B7, A3, A1 to be red-hot platinum gold to open about 30
seconds and then cooled to open B7, After the burning of the residual amount of gas
back into the trachea, note reading, (ie post-combustion capacity) related B7, open
B1, A3, the residual pressure within the wash into the V1 absorbed back into the
volume of the trachea, the note reading.
SB9801 Albright each set of gas analyzers include the following components:
Parts names and purposes:

No. NAME MATERIAL SET USE
1 Manual bolt 1 Readings, turn the direction of a designated
90 , can be isolated from pressure
readings
2 Standard GLASS 1 Appearance of 5% sulfuric acid solution, add
bottles B40 Hard methyl red indicator
3 Volume materials 1 The volume control system better than
control reading that do not absorb the finished bottle
than the direct reading hand-held
4 Absorption 5 Were dressed in dif Were dressed in
bottle different absorbent to absorb different gases
measured fervent absorbent to absorb
different gases measured.
196
5 Molotov 1 Combustible gas for combustion

cocktails
6 Multiple 1 Costumes, silver sulfate, Nickel sulfate
bottle mixture
7 Drying tube 1 Remove impurities in the tested gas
8 Beam 1 Exhaust gas and the place to take
9 Liquid seal 1 Costumes, distilled water, from the role
bottles liquid seal
10 Control bolt 1 Automatic gas and not gas, to automatically
absorb
11 Decompress 1 Reduce the combustion air pressure
ion plug
12 Synchronou 15W 1 Rotation control bolt
s motor
13 Transformer 0-5V 1 Combustible gas for combustion
10 The Safe Use of Chemical Reagent

Prior to the use of a chemical reagent, you must have a comprehensive
understanding of its safety performance, so that, when using it, you can take some
safety precautions in a targeted way, so as to avoid laboratory personnel and
laboratory equipment hazards as a result of improper use.
10.1 Classification of the safety performance of chemical reagents
10.1.1 Flammable and explosive chemical reagents
Generally, the liquid with flashpoint <25 that is highly volatile will burn
in case of open flame. The lower the flashpoint is, the more flammable. Such as
ether, gasoline, benzene, ethyl acetate, with flashpoint < -4.
10.1.2 Toxic chemical reagents
General chemical reagents are toxic to human body. While using any toxic
chemical reagent, try to avoid large volume of intake. Be sure to wash hands after
using. The reagent that makes people poisoned by just a small volume of intake is
called highly toxic chemical reagent. LD50 the fatal dose in biological
experiments is 50mg/kg or less.
Potassium cyanide, sodium cyanide, and other cyanide and arsenic (As2O5).
Arsenic poisoning, sulfuric acid, dimethylester, etc. inadvertently caused during
semiconductor manufacturing.
197
10.1.3 Corrosive chemical reagent
Promptly clean if any chemical reagent is directly exposed onto skin, mucous
membranes, eyes or respiratory organs, especially when the chemical reagent is
highly corrosive, such as various acids and alkalis:
H2SO4, HCL, HNO3, NaOH, KOH.
10.1.4 Strongly oxidizing chemical reagents
Strongly oxidizing chemical reagents are peroxides or oxygen acids with

strong oxidation and the salts thereof, such as perchloric acid and the salts thereof,
and salts thereof, permanganic acids and the salts thereof, dichromic acids and the
salts thereof (potassium dichromate), phosphorus pentoxide. Strongly oxidizing
chemical reagents can produce oxygen explosion under appropriate conditions.
The use of such substances should be under conditions where the ambient
temperature is not higher than 30 and the ventilation is good.
10.2 Notes to the use of several chemical reagents
10.2.2 Acetone and absolute ethyl alcohol are flammable, whose vapor can form
explosive mixtures with air and can cause fire explosion when exposed to open
flame and high heat. While using, they should not be heated by electric furnace,
and the containers containing them cannot be shaken. If they are directly
exposed to eyes, rinse with water. If they are eaten inadvertently, drink enough
water, induce vomiting and seek medical treatment. If they cause a fire, use
non-fusibility foam dry powder, CO2 or sand to put out the fire.
10.2.3 Sulfuric acid
It is a strong acid and also strong oxidant. It has dramatic effect on organic
matter. It is corrosive and toxic, and has strong irritation and burning effects on
skin, mucous membranes, eyes and respiratory organs. In addition, the
preparation of lotion (for foam beaker and drop bottles) should use sulfuric
acid and potassium dichromate (both are strong oxidants). When sulfuric acid
is poured into potassium dichromate solution, the reaction is very strong, and
there are certain dangers, so when preparation, please be very careful. Stay
away from open flames and heat sources, keep good ventilation, wear
protective aprons, sleeves, and goggles, and take protective measures when
necessary. If the acid spills on the skin, use dilute alkali (or soap) to clean.
When dilution, do not pour water into sulfuric acid (the specific gravity of
water is smaller than that of sulfuric acid, so it will easily splash out). Slowly
198
pour sulfuric acid into water. Once an accident occurs, do keep calm.
10.2.4 Xylene and hydrofluoric acid (HF)
Xylene: a colorless, transparent and volatile liquid with aromatic odor,

mainly used in pharmaceutical industry, dyes, paints, and plastics, etc. It can
also be used as solvent or diluent for painting, etc. The acute poisoning
caused by it mainly includes: headache, dizziness, weakness and numbness of
the limbs after the inhalation of high concentration in a short time; severely,
coma and convulsions. Hydrofluoric acid (HF): a serious harmful chemical. If
it is directly exposed to the infected part, it will cause redness, pain and rapid
diffusion. If it is accidentally exposed onto the skin, rinse with plenty of
water first, and then immediately seek medical treatment at specified
occupational diseases hospital.
It is often used in the preparation of SiO2 corrosive liquid. Wear

protective gloves and masks while using it. Be careful when operating in a
fume hood.
10.2.5 Chlorine and chlorine compounds
Chlorine must be used when dry etching is adopted in the future. Chlorine gas
is highly toxic and choking. It can hurt throat and equipment (such as
mechanical pump of vacuum system). Do pay attention to ventilation and
exhaust, and also enhance self-protection.
10.2.6 Other commonly used chemicals
Such as NaOH (strong alkali, strongly corrosive, flammable, easily burn skin)
and H3PO4 (weak acid, flammable) which will not be detailed here. When
taking chemicals, take gently, so as to prevent collision, drag and dumping.
After use, be sure to tighten the cap, so as to avoid leakage or fall when it is
re-taken. Take the bottle in correct way (especially large bottle, such as
sulfuric acid bottle), and wear protective gloves.
10.3 Storage and Safe Keeping of Chemicals
10.3.1 Stored at special venues and special cabinets, and under the management of
designated people.
10.3.2 Such safety measures as ventilation, explosion proof, pressure relief, alarm, fire
fighting, sun proof, thermostat, static removal and so on can be set according
to the types and nature of articles.
199
10.3.3 Those dangerous chemicals that will easily burn or explode or produce toxic
gases when exposed to fire or damp should not be stored at damp, water leak
or low-lying areas and should be stored away from open flames and heat.
10.3.4 They should be stored at cool and ventilated places.
10.3.5 They should be checked and registered upon warehousing-in and should be
subject to periodic inspection.
200
Appendix 1 Fuel Oil Component Analysis Report
Furnance Oil (HSFO) Specification

TEST UNITS LIMITS TEST METHODS
Acid Number, Mg
Max. Nil ASTM D 664/D-974
Strong KOH/g
Ash %W Max. 0.10 ASTM D 482/IP-4/75
Calorific Value,
BTU/Lb Min. 18200 ASTM D-240
Gross
Carbon Residue,
%W Max. 12.0 ASTM D 189
Conradson
Flash point, PMcc Deg. C Min. 66 ASTM D 93
Potassium + sodium Ppm Max. 50 IP 228 or ASTM D 2788
Pour Point Deg. C Max. 50 ASTM D 97
Relative Density @
Deg. F Max. 0.9800 ASTM D 1298
60/60
Sediment %W Max. 0.15 ASTM D 473 or IP - 53
ASTM D 1552 or 2622
Sulphur %W Max. 3.5
or 4294
Vanadium Ppm Max. 60 ASTM D 1548 or IP 288
Calcium Ppm Max. 10 ASTM D 1548 or IP 288
Max.180
Viscosity, Kinematic Summer
cst ASTM D 445 or IP 71/75
@50 Deg. C Max.125
Winter
Water %V Max. 0.50 ASTM D 95
High Speed Diesel (HSD) Oil Specification

TEST
TEST UNITS LIMITS
METHODS
Ash %Wt Max. 0.01
Carbon Residue, Conradson %Wt Max. 0.1
Pour Point Deg.C Max. -6
Cloud Point Deg.C Max. +5
Color ASTM - Max. 2.5
Corrosion, copper strip 3h
- Max. No.1
100
Centane Number/Centane Index - Min.45
Flash point, PMcc Deg.C Min. 66
Min.0.820
Relative Density @ 60/60
Max.0.870
Sediment %Wt Max. 0.01
Sulphur %W Max. 1.0
201
Viscosity, Kinematic @37.8 cst Min. 1.6 Max. 5.5

Water %Vol Max. 0.10
Calorific Value Gross BTU/lb 18500 43.031MJ/Kg
202
Appendix 2 Canal Water Quality Report
203
Appendix 3 Well Water Quality Report
204

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NANDIPUR 425MW CCPP CHEMICAL OPERATION MANUAL

This manual is edited on the basis of provisions and relevant drawings

Abbreviation Full Title

ACF Active Carbon Filter

SSR Self-sealing System

DCS Distributed Control System

C.W Close Circle Water

PLC Programmable Logic Controller

LED Light Emitting Diode

1Raw Water Pre-treatment System ......................................................... 1

1Raw Water Pre-treatment System

1.1 Function Description

1.2 System Parameters

1.2.1Clarified Water Tank, Firefighting Water Tank

Clarified water tank, firefighting water tank

point Dosing sludge disinfection treated

1.2.2 Mechanical accelerated clarifier

Design treated water quantity: 320m3/h

Inlet water content of sand: less than 3kg/m3

Outlet water suspended quantity less than 20mg/l

Design treated water quantity of one filter: 75m3/h

Total treated water quantity: 150m3/h

Inlet water turbidity: less than 20ppm

Outlet water turbidity: less than 5ppm.

1.2.4 Service Water Tank

The service water tank capacity is 700m3, the dimension of tank is

1.2.5 DM Water Tank

1.2.6 Potable Water Tank

1.3 Deep Well Pump House

1.3.1Deep Well Pump House

The main parameter of deep well as flow:

Design capacity: 320m3/h

The motor main parameter

The total sets: four sets

1.3.2 The Main Principle of Control

1.3.3 The requirement of deep well control and monitor.

a. Pump operating condition.

b. Pump outlet pressure (local display).

1.3.4 Water Intake System Pre-start Inspections

1.3.4.3 Control box power supply of water intake pump is normal.

1.3.5 Water Intake Pump and Vacuum Pump Manually Operations

1.3.5.1 Water Intake Pump Manual Start

1.3.5.1.1Put vacuum pump AUTO/STOP/MANUAL switch to MANUAL mode on

1.3.5.1.2Put water intake pump AUTO/STOP/MANUAL switch to MANUAL mode

1.3.5.1.5Check the pipelines and keep proper records.

1.3.6Water Intake Pump Manual Stop

1.3.6.1 Stop the water intake pump.

1.3.6.2 Check pump and pipelines and keep proper records.

1.3.7Fault Handling for Water Intake Pump Station

aAbnormal motor noise.

1.4 Mechanical Accelerated Clarifier System

The mechanical accelerating clarifier incorporates coagulating reaction and

The structure of the clarifier is shown in following sketch

1. Primary reaction chamber; 2.Secondary reaction chamber

3. Agitator; 4.Sludge scraper

5. Separation chamber; 6.Packing layer

7. Water collection tank; 8.Adjust wheel

9. Sludge funnel; 10.Pre-embedded sludge discharge pipe

1.4.2 Daily Maintenance

1.4.3 In-Service Operations

1.4.3.1Open sedimentation basin sludge scraper bearing lubricating valve and

Differential pressure transmitter water valve

1.4.3.4Start the stirrer:

c) Start lime dosing system to fill into sedimentation basin.