03122-OM - Operating and Maintenance Procedures

Job 3122 Title O & M MANUAL Prepared by RVR Doc.
No 3122-OM
Client: IIT MADRAS Checked by ARI Rev No 00
Project 10 m/day Solar LTF - MED Desalination Plant Approved by GHK Year 2016
DESALINATION PLANT
10 m/day Solar LTF - MED
O&M MANUAL
GB SALINE WATER SOLUTIONS PVT LTD

D-99, DEVELOPED PLOTS ESTATE,
THUVAKUDY, TRICHY 620015
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Job 3122 Title O & M MANUAL Prepared by RVR Doc.No 3122-OM
OPERATING & MAINTENANCE PROCEDURES
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Table of Contents
DESALINATION PLANT..........................................................................................................1
I. PRE-COMMISSIONING..............................................................................................................4
1. Introduction.......................................................................................................................4
2. Reference Documentation...............................................................................................4
3. General Notes for Pre-Commissioning & Commissioning...............................................4
3.1 Pre-Commissioning.................................................................................................................. 4
3.2 Commissioning......................................................................................................................... 5
4. Pre-Commissioning & Commissioning Sequence.....................................................5
4.1 Pre- Commissioning................................................................................................................. 5
4.2 Commissioning......................................................................................................................... 8
II. OPERATING MANUAL..........................................................................................................9
1. Introduction....................................................................................................................9
2. Operating Principle of a MED Unit...................................................................................9
3 Description of Desalination Unit..................................................................................10
3.1 Evaporator...................................................................................................................... 10
3.2 Final condenser...................................................................................................................... 11
3.3 Distillate Pumps : Model No: To be provided by IITM.............................................................12
3.4 Brine Pumps: : Model No: To be provided by IITM...............................................................12
3.5 Seawater pumps : : Model No: To be provided by IITM.......................................................13
3.6 Anti-Scalant System.............................................................................................................. 13
3.7 Acid Cleaning System...........................................................................................................13
4. Characteristic of MED Unit...........................................................................................14
5. OPERATION SEQUENCE FOR MED PLANT NTPC, Simhadri..............................15
6. Normal Operating Procedure.........................................................................................16
6.1 General recommendations.....................................................................................................16
6.2 General Procedures at steady operation................................................................................17
6.3 Operational limits.................................................................................................................... 17
6.3 Emergency Shutdown............................................................................................................. 17
II. MAINTENANCE MANUAL...................................................................................................20
1. Routine and Preventive Maintenance...........................................................................20
1.1 Foreword................................................................................................................................ 20
1.2 Routine Inspection..................................................................................................................20
1.3 Routine Maintenance.............................................................................................................. 20
1.4 Preventive Programmed Maintenance....................................................................................21
2. Plant Preservation........................................................................................................21
2.1 Outage period shorter than 24 hours......................................................................................22
2.2 Outage period between 24 and 72 hours................................................................................23
2.3 Outage period above 72 hours...............................................................................................23
3. Evaporator Acid Cleaning Procedure............................................................................24
4. Special Maintenance.....................................................................................................26
4.1 Evaporator.............................................................................................................................. 26
4.2 Associated Equipments......................................................................................................26
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I. PRE-COMMISSIONING
1. Introduction
The following procedure outlines the preliminary operations and checks normally
required before starting-up the plant, in order to operate in safe conditions.
The pre-commissioning operations follow the mechanical completion and precede the
start-up activities, that is to be carried out after erection completion but before
insulation works.
2. Reference Documentation
1. Process Drawings
2. Equipment Drawings
3. General Notes for Pre-Commissioning & Commissioning
3.1 Pre-Commissioning
Scope of the pre-commissioning is to ensure that each system included in the scope of
supply has been manufactured and erected/assembled as per the last revision of the
applicable drawings.
All the checks should be carried out by the erection supervisor and should be recorded
and available to the GB Saline Engineers.
However the final inspection and documentation checking must be jointly carried out by
GB Saline Engineers and Client Representative.
When the Pre-commissioning completion certificate has been issued and signed by
parties, the commissioning can start.
All the pre-commissioning activities will be considered over once all the stated checks
have been completed and the relevant certificates filled up, signed and collected into
commissioning file.
Once the pre-commissioning has been completed and the desalination mechanical
completion certificate issued, the commissioning phase can be started
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3.2 Commissioning
This phase begins when powered systems and components within the battery limits of
the MED has been energized.
During Desalination commissioning, all desalination operating sequences, protections,

alarms and trips will be checked and tested.
4. Pre-Commissioning & Commissioning Sequence
4.1 Pre- Commissioning
4.1.1 Issue of Erection Completion Certificate
1. Hot water suction and delivery piping

2. Seawater piping
3. Brine piping
4. Distillate piping
5. NCG piping
6. Siphon piping
7. Vapour piping
8. Structural & Piping supports
4.1.2 Issue of Auxiliaries Erection Completion Certificate
1. Pumps
2. Manual Valves
3. Instruments with Calibration certificates
4. Cabling & Earthing (Electrical & Instruments)
5. Identification Tags for Equipments
6. Identification (Ferrules) for cables.
General notes:
1. Cable must be well supported and isolated from any possible heat source during
desalination operation
2. Control cables and power cables must be wired into separated and segregated cable
trays
3. Cables terminals must be properly installed and fixed
4. Final cables fixing to any termination board must be accurate and tight
5. Any component in desalination area must be wired to earthing system for equipment
and personnel protection even if not included into desalination scope supply.
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4.1.3 Evaporator Internal Inspection
1. Open the manholes. Check that inside the evaporator there are no foreign materials.
2. Make a visual inspection on the tube sheet and grommets.
3. Make a visual inspection on the tube bundle. The tubes must be correctly supported
as per drawings.
4. After evaporator inspection close all the manholes
5. Manholes shall be fit properly, gasket must be in good condition and properly
installed.
6. Manholes should be bolted closed in order to achieve the correct tightness.
4.1.4 Piping
1. Verify all valves are installed in the right flow direction.

2. Operate manual valves to check their free operation.
3. Remove all devices that can hold dirtiness or that can be damaged during flushing.
4. Check all bolts of flanged connection are tight.
5. Check all temporary pipe supports have been removed.
4.1.5 Electrical motors
1. Verify wiring connection

2. Verify Motor rated voltage and frequencies are in accordance with the main supply
voltage and frequency, within the specified tolerance.
3. Check bearings are properly lubrificated.
4. Check Ventilation circuits are not obstructed.
5. Correct direction of rotation.
6. Check the correct installation of instrumentation
7. Refer to vendor manual for detailed information.
4.1.6 Pumps
Before the pump start-up the following checks shall be carried out:
1. Check alignment of the pump and motor.

2. Check motor rotation sense.
3. Check all bolt tightness.
4. Check protection guard of the coupling are installed.
5. Check bearing lubrification system is ready for operation.
6. Refer to vendor manual for detailed information.
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4.1.7 Control & Instrumentation
Furnished below some general rules for instrumentation pre-commissioning
Refer to vendor manual for detailed information
1. Check the correspondence between the field instrumentation and the relevant
datasheet.
2. Proceed then with the instrumentations calibration
4.1.8 Manual Valves
1. Verify free operation.

2. Check manually the free operation of the valves.
3. Verify the flow direction of the NRV valves
4.1.9 Level gauges, Temperature and Pressure gauges
1. Before starting the flushing operations, all field instruments must be isolated.
4.1.10 VFD Panel
1. Verify power supply system and relevant distribution

2. Verify the signal between field and the panels.
4.1.11 Blank Tests
Before proceeding with the hot commissioning operations it will be necessary to test
the sequences and the plant protection, with particular care for the following
1. Failure start of the seawater pump

2. High temperature in the first effect.
4.1.12 Piping Flushing
Following paragraphs are to describe the activities to be carried out on the desalination
unit before the plant is put in operation.
Before starting with hot commissioning, the following system shall be ready for
operation
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- Seawater/Feed water system, Brine system, Distillate system, Hot water suction and
delivery system.
- Vacuum system
It is essential that each system to be cleaned is identified. For this scope it is

suggested to prepared schemes to define the system and the lines to be cleaned.
These schemes have to identify each part of a line, the blind ends, the recirculation
branches, instatements connections etc.
4.2 Commissioning
4.2.1 Vacuum Test
The operations to be carried out are as follows:
1. Make sure that all the circuits to be tested are empty.

2. Get confirmation that power supply is available.
3. Isolate, the complete desalination system from the atmospheric pressure by tightly
closing all the outlet vales and manholes.
4. Check the water jet ejector and tightened the fasteners and open the NCG
evacuation line valve after the start-up of pump.
5. When the pressure decreases to the value of 0.12 bar (a), stop the pump and close
its suction valve
6. If the result of the test is not positive, find and eliminate the air leakage and repeat
the test.
4.2.2 Passivation
Aerated service water is to be circulated in the MED by using the brine pump. Water
should be continuously circulated until the tube surface has lost its shine uniformly. This could
take up to 2 days.
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II. OPERATING MANUAL
1. Introduction
The following Chapter outlines the operating principle of the Desalination Plant
installed at Vivekananda kendra, Kanyakumari.
- The plant in subject is based on the Flash Chamber - Multi-Effect Distillation. The
paragraph is intended to allow the reader to gain a general physical understanding of
the operating features of the desalination plant.
- The subsequent documents will provide more details on the characteristics of the
various equipments and auxiliaries involved in the operation of the desalination
plant. In this document, the aspects related to the functional purpose of each
component are emphasized. In order to provide adequate reference data to the
operator, a summary of plant design operating parameters is furnished.
2. Operating Principle of a MED Unit
The principle of Multi Effect Desalination (effects) consists in the utilization of the latent
heat released by condensation of the vapour produced in each effect for the
evaporation of seawater in the following effect. Each effect is formed by a horizontally-
arranged tube bundle, an array of seawater spray nozzles, four vapour-distillate boxes
and a vapour transfer duct, which includes the demister section.
In the first (higher temperature) effect, seawater is sprayed externally to the tube
bundle and, forms a thin film around each tube and partially evaporates. The heat
necessary to phase change is supplied by the vapour supplied by the flash chamber
into the heat-exchange tubes, where condensation occurs. At the same time, the
amount of vapour produced from the evaporation of sprayed sea water (which is
roughly of the same amount than the flow rate of inlet vapour) flows through the
demisters and then into the tubes of the following effect.
The process of vapour condensation - seawater evaporation is then repeated in each

effect, at lower temperature and pressure. The distillate collected in the distillate box is
discharged, via a suitable duct, to the following effect. The remaining part of vapour
produced is led to an external distillate condenser,(Final condenser) consisting in a
tube-bundle heat exchanger cooled by fresh seawater flowing in tube side; the whole
distillate stream is collected in this condenser, then extracted with a pump and
delivered to storage.
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The concentrated brine from the first effect is, similar to the distillate, cascaded to the
4th effect and then it is returned to the sea or recirculated from the heat balance point
of view, the heat input to the system is given by the solar flat plate collector; and heat is
released in the Final condenser, with a corresponding increase in temperature of the
cooling seawater at condenser outlet. The seawater preheated in this way is
subsequently utilized as feed water to each effect.
The non-condensable gases released from feed seawater (dissolved air and CO2
formed from carbonates breakdown) are flowing from each effect by a suitable vent
system collected from the final condenser and finally purged to atmosphere by the
vacuum pumps.
The main advantage of MED technology derives from the low operating temperature,
which significantly reduces scale formation phenomena and contributes to prevent
major corrosion risks.
3 Description of Desalination Unit
3.1 Evaporator
Reference Drawings: 1623122-1-L-55-01-0070_REV. 01
The process of vapour condensation and seawater evaporation is effected in the Multi-
Effect Evaporator, which is the basic equipment of the Desalination Plant. The
Evaporator is formed by a cylindrical vessel and is divided in four effects, The
Evaporator shell is fabricated in SA240 UNS32304 plates.
Each effect of the evaporator is composed by a bundle of straight Titanium tubes (SB
338 Gr. 2 and Al 6061 Tubes) fixed with EPDM grommets between two tube-sheets
made in SA240 UN SS 32304 plates. At each tube end a distillate section, is provided,
for the purpose of collecting the distillate formed within the tubes. Each effect and
distillate box is equipped with manholes, in order to allow for easy access to each tube-
sheet for inspection.
One row of spray nozzles is placed above each tube bank, each row equipped with one
nozzle, in such a manner to allow for an uniform wetting of all the tubes. The spray
nozzles installation is made by a flanged coupling and is such that they can be easily
dismantled from the external platform for inspection and cleaning.
The demisters installed in the Evaporator are of the horizontal, wire-mesh type made in
Stainless Steel 316. They are composed by pads having dimensions, such that they
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can be easily handled and passed through the evaporator manholes. The demister
pads are installed in horizontal frames placed within the evaporator, in such a manner
that they can be accessible and, if necessary, removable for cleaning. The demister
filters the entrained water particles from the vapour stream to be condensed in the
subsequent effect.
The individual evaporator vessel / overall assembly have the following dimensions:
1. Shell outside diameter x Thickness = 1800 mm x 6 mm

2. Length of Evaporator = 6696 mm
The tube bundle of each effect has the following characteristics:
1. Number of tubes = 4 x (893 AL 6061 + 47 Titanium SB 338 Gr 2) = 3760

2. Tube OD = 25.4 mm
3. Tube length = 936 mm for Titanium and 936mm for Aluminium
3.2 Final condenser
Reference Drawings: 1623122-2-F-55-0034_REV. 01
It is a shell-and-tube heat exchanger with horizontal axis, whose function is to condense

the part of the vapour produced in the last effect of the Evaporator by the cooling
seawater, flowing within the tubes. Vapour is condensed in the shell side of the
exchanger thus forming distillate, which is collected at the bottom of the vessel, where
also the distillate produced in the Evaporator is discharged through adequate siphon.
The distillate is extracted from the vessel, where a constant level is maintained, by the
distillate pump.
The non-condensable gases released from the seawater sprayed in the Evaporator are
cascaded through the effects and finally collected in the final condenser, from where they
are led, mixed with vapour, to the suction nozzle of the water jet pump.
The tube bundle of the Distillate Condenser is subdivided in eight passes and is formed
by straight Titanium Tubes SB 338 Gr2 fixed with grommets at each end in UNS 32304
tube-sheets. The water-boxes are closed by bolted covers, which can be removed for
access to the tube-sheet.
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The details of the Final Condenser are as follows:
1. Shell outside diameter : 700 mm X 6 mm thickness.

2. Shell length : 2000 mm
3. Overall length : 2752 mm
4. Number of tubes : 92
5. Tube diameter : OD 25.4 X 0.4 mm thickness, SB 338 Gr.2
6. Tube length : 2052 mm
3.8 Distillate Pumps : Model No: To be provided by IITM
One full duty, centrifugal, end-suction pumps are installed. The pump in operation
continuously extracts distillate from the Final Condenser.
The main characteristics of the Distillate Pumps are as follows:
Duty Flow Rate : IITM

Head at Design Condition : IITM
Motor Power /speed : IITM
Since the distillate at pump suction is in saturation condition (i.e., it is in equilibrium with
vapour phase), it is important to keep enough suction head in order to prevent the
occurrence of cavitations, with consequent damage of the impeller. For this reason, the
distillate suction level is kept at a pre-set value by level guage acting on distillate pump's
VFD motor.
3.10 Brine Pumps: : Model No: To be provided by IITM
The purpose of the Brine Recirculation Pumps is to recirculate a portion of brine to

evaporator to mix with make-up sea water and spray through nozzles in the MED effects
and to blowdown the remaining brine to the battery limit.
One full duty centrifugal, end-suction pumps are installed.
The main characteristics of the Brine Recirculation Pumps are as follows

Motor Power/ rpm : IITM
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Since the brine at pump suction is in saturation condition (i.e., it is in equilibrium with
vapour phase), it is important to keep enough suction head in order to prevent the
occurrence of cavitations, with consequent damage of the impeller.
3.11 Seawater pumps : : Model No: To be provided by IITM
The pump in continuous operation allow the sea water to run forward inside the
Finalcondenser tubes
The main characteristics of the Sea water Pumps are as follows:

Motor Power/ speed : IITM
3.14 Anti-Scalant System
The Chemical Injection has the purpose of dosing continuously into feed water the
chemical additives necessary for proper operation of the Desalination Plant, namely:
- Anti-scale additive, necessary to reduce the amount of scale formation on heat

exchange tubes external surface due to alkaline precipitation in seawater;
The commercial products of anti-scale and anti-foam have to be diluted with water in the
tanks.
Each group is composed by:

- Tanks made of HDPE with a volume of 500 liters
- Pumps of metering type.
- interconnecting piping and isolation valves.
3.15 Acid Cleaning System
The purpose of this chemical injection package is to allow the periodical, off-line
cleaning of the external surfaces of the exchanger tubes of the evaporator effects from
the alkaline scale deposits (the time interval between two acid cleaning will be within the
range 6 - 12 months).
The system is composed by:

1. Tanks made of HDPE with a volume of 2000 liters
2. One pump with the flow rate of 100 LPH
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3. Pressure= 2.5 kg/cm2; MOC = PTFE

4. Local instruments (level gauge and pressure gauge).
5. Interconnecting piping and isolation valves.
4. Characteristic of MED Unit
This chapter defines the functional characteristics for the operation of the MED unit
Operating Parameters
S.No Description Parameters
Desalinated Water Production :
1 Production 10 m/day
2 Delivery Temperature at Battery limit 41 C
3 Delivery Pressure at Battery limit 2 .8 bar (a)
4 Conductivity 10 S/cm
Steam Inlet
5 Pressure at Battery limit 0.16 bar(a)
6 Temperature at Battery limit 55.4 C
7 Total Maximum Consumption 357 kg/hr
Seawater Inlet
8 Flow Rate at Battery limit 27,407 kg/hr
9 Temperature range at Battery limit 30 C
10 Total Dissolved Solids 1866 ppm
11 Delivery Pressure 2.5 bar (a)
Brine Outlet
12 Brine Outlet Flow Rate 1781 kg/hr
13 Delivery temperature 43.6 C
14 Delivery Pressure 3 bar (a)
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5. OPERATION SEQUENCE FOR MED PLANT Vivekananda Kendra, Kanyakumari
Ensure following before start up

a. A-01 is closed
b. Sea water is available at battery limit
c. Level in flash chamber is high and hot water generator is flooded.
d. FCV-01 is fully open
e. B-13 is closed
f. Decide which pumps are going to be switched on A/B and open the corresponding suc-
tion and discharge valves.
g. Dosing Tank is filled up.
Start up Sequence:
1. Switch on sea water pump.

2. Put FCV-01 in regulation and maintain flow rate (FT-11) at 60000 kg/hour or higher
3. After stabilization of flow, open B-13 manually until FT-14 reads 10000 kg/hr
4. After level in LT-26 reaches high level, LCV-01 will be regulate level as per set point in
LT-26.
5. Set VFD of Brine pump to ensure FT-25 reads 15000 kg/hr
6. At this point, the level in LT-26 may continue increasing since no production is avail-
able. To take care of this, regulate B-13 until FT-14 is less than or equal to FT-24 and
maintain position.
7. Switch on vacuum pumps and let the pressure in PT-10 and PT-03 reach less than 100
mbar(a). This will take 1-2 hours. During this step, water level will increase in effect 1
and is normal.
8. Switch on the hot water pump and circulate water through the hot water generator.
Open guillotine gates and switch on the ID fan. When hot water reaches 90 deg C,
open A-01. Switch on dosing system.
9. Due to maintenance activity, if A-01 is not opened, close guillotine gates and
switch off ID fan.
10. Flashing will reduce the temperature of hot water to 72 deg C or lesser. Continue
steady state until MED warms up and starts production.
11. When LT-30 level reads high, switch on distillate pump and control level in LT-30
through LCV-02. Once production starts, increase flow in FT-14 by opening B-13 grad-
ually.
Shutdown Mode
1. Close guillotine gates and switch off ID fan.

2. Regulate B-13 manually until level in brine tank is steady.
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3. Distillate pump will switch off on low level.

4. Close A-01
5. Shutdown Dosing system
6. Continue circulating sea water until temperature in effect 1 and final condenser shell
side reads less than 45 deg C. When temperature is less than 45 Deg C, close B-13
and let the brine pump switch off after reaching low level.
7. Switch off sea water pump.
Emergency Operations.
1. If TE-29 is greater than 67 deg C

a. Close A-01
b. Close guillotine gates
c. Switch off ID fan.
6. Normal Operating Procedure
6.1 General recommendations
As a basic rule in the operation and maintenance of the Desalination Plant, the
operators should familiarize themselves as much as possible with the operating
characteristics of the system. This can only be accomplished by observing, recording,
checking and comparing data and details. Emergency conditions resulting in
unnecessary outages and repairs can be avoided by a proper working knowledge and
attention from the operator.
Operating at conditions which exceed the design limits will shorten the life of
equipment and its components. As operating experience is gained and control
parameters are finely tuned, the characteristics of the plant and the actual operating
requirements will become evident to the operator. An indispensable and essential aid for
the early identification of potential difficulties is a well kept record of routine operations
and plant performances data, such as chemical consumption, flow rates, temperatures,
production, etc., together with careful back-up of recorded trends for late reference. At
the same time the laboratory should periodically check the analysis, instruments such as
conductivity meters with reference standard solutions used for routine determinations in
the control lab. Any other observations and remarks dealing with the plant features
should also be entered in the books.
Control room operating staff must note of any change in operating conditions. Local
operators shall patrol regularly the plant and promptly report any abnormality. Immediate
corrective actions shall be taken to avoid consequent damages and eventual shutdown.
The following list intends to highlight some of the checks that should be carried out
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periodically by the operators, in no way meaning that these are the only checks nor the
only important ones. - The operators shall be fully familiar with the correct maximum
values of the pressure, levels, temperatures, etc. at the various different measuring
points and check them at every shift.
- Annunciators shall be checked for operation, at least once per shift.

- All running equipment shall be checked for proper lubrication, vibrations, abnormal
noises, overheating of bearing, etc., on a continuous basis.
- Any possible leakage from piping and equipment shall be promptly reported.
Finally, it is essential that the O&M personnel be familiar with the technical
characteristics of all components installed, also by careful reading the relevant
instruction manuals.
6.2 General Procedures at steady operation
During the normal operation of the desalination plant, a stable distillate production is
maintained by the control system which, performs the closed-loop controls and
alarm/shutdown logic functions on main plant parameters.
In this situation, the operator shall keep under control the operating parameters of all
equipment and circuits, in order to recognize all anomalous situations and take the
adequate corrective actions before a plant shut down occurs.
In particular, at every shift a log sheet form will be filled in with the operating data
collected at control system panel and on local instruments. Periodically, samples of
seawater, distillate and brine blow-down will be collected and analyzed at chemical
laboratory for determining conductivity and pH values. Any anomalous value or trend
shall be recognized and reported to the responsible Chief Engineer.
6.3 Operational limits
This desalination plant is designed for a continuous net production of 1.25 ton/hr of
distillate under normal operation, with a top brine temperature of 45C.The temperature
of motive steam to evaporator shall not exceed 64.5C under normal operation. The
above top brine temperature cannot be exceeded because otherwise the possibility of
scaling formation would increase and the effect of the anti-scale additive would be lost.
High temperatures can be caused by excessive steam to the thermo-compressor or
excessive fouling in the heat transfer tubes.
6.3 Emergency Shutdown
In general terms, any plant parameter going out of specification to such an extent as to
cause an alarm to occur, can be said to be an emergency. However in the majority of
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cases such alarm conditions can be rectified by immediate minimal operator action. An
emergency shutdown may be caused by the following major causes:
a) Loss of seawater supply

b) Loss of steam supply
c) Loss of electric supply
d) Trip-out of equipment protective devices
The emergency shutdown operation is in a way a quick form of normal shutdown. The
procedure is practically the same except that the sequence of operation may differ
depending on which type of failure occurs.
Generally the first action required is to reduce or stop the Hot water supply from solar
panel and close the NCG evacuation valve.
7.3.1 Loss of Seawater Supply
A loss of seawater supply will cause an automatic shutdown intervention.
7.3.2 Loss of Steam Supply
A loss of steam supply will result in a gradual but fairly controlled loss of production.
Due to the abnormal operation of flash chamber, vacuum in the Evaporator will
decrease and for high level of brine will occur. As soon as the operator will recognize
this occurrence, he shall start immediately the shutdown procedure.
7.3.3 Loss of Electric Supply
If loss of electric power occurs, the control valves actuators will move to safe position.
The jet pump NCG evacuation valve should be closed.
The most alarming occurrence in this type of failure is that the remote reading instruments
may give false readings and cannot be relied upon. It is recommended therefore that if this
type of failure occurs the following procedures be adopted:
a) Continue to operate the seawater circulating system.

b) Close the steam inlet valve.
c) Stop the distillate pumps.
d) Check that no makeup seawater is flowing in the evaporator.
e) Close the brine blow-down valve.
f) Ascertain the cause of failure and attempt to rectify remembering that air failure may
render the desalination plant inoperable.
g) Check the plant to assess if any damage has occurred.
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7.3.4 Trip-out of Pumps
The trip-out or out of service of a pump should not be, in principles, a cause for total
shutdown of the plant, since the provided standby unit should be quickly started and
put into operation. However some problems could arise if the changeover operation is
not smoothly carried out, especially for the brine pump, since this could create some
unbalance in the system and a shutdown of the plant.
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II. MAINTENANCE MANUAL
1. Routine and Preventive Maintenance
1.1 Foreword
The provisions of this Maintenance Manual outline the general activities to be carried
out for a correct maintenance of the overall Desalination Unit.
1.2 Routine Inspection
It is recommended that a system of routine inspection be carried out by plant operators

whilst undergoing the normal log sheet readings. A plant defect log book should be kept
by plant operators so that maintenance crews may refer to it during periods of plant
shut down or for planning maintenance periods. Each log sheet of such book shall
contain at least the following information: technical faults, date, possible cause, and
possible remedy. The log sheet can be forwarded to GB for analysis and feedback.
All defects found by operators should be immediately related to the Desalination

Control Room. All defects found should be dealt with as soon as possible. Certain
defects will require complete plant shut down, but others do not require plant shutdown.
It is important that checks detailed by the manufacturers of evaporator, heat exchanger,

seawater filter, steam trap, pumps, Water jet ejector and other items of plant be
adhered to.
In addition to the normal log sheet readings it is also recommended that a system of
periodic readings shall be taken of pump bearing temperatures (by use of a touch
pyrometer/thermometer).
1.3 Routine Maintenance
A high degree of cleanliness of all equipment and surrounds will assist on the early
detection of leaks and other defects, as well as it will assist in the safe operation of the
plant.
Routine maintenance of the plant will be based on the following weekly activity roll:
a) Examine the exterior of the evaporator and all other equipments daily for signs of
leaks.
b) Where possible, move a little the valves which are normally left in the open / close
position over long periods, then put back in position.
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Note: Ensure that plant operating conditions allow this to be done.
c) Inspect all valve glands for leakage. If required repair as per Manufacturers
recommendations.
d) Blow-down all water from the magnetic flow level gauge glasses daily.
e) Inspect all fixed and sliding support of piping and equipment and ensure that the
holding-down bolts are secured and in good condition.
f) Check that pumps lubrication arrangement is correct.
g) Check that there is not excessive gland leakage from pump mechanical seals or
packed glands.
h) Check all flanges joints and gaskets for leakage.
i) Check for pump vibration. For spare pumps, if excessive vibration is found, change
over the spare pump and carry out inspection of faulty machine, replace or repair
damaged components.
j) Cleaning of the sea water strainer through back-washing shall be done whenever a
high differential pressure has been detected and the flow shall be switched to the other
(manual filter), then the filtering elements of the clogged section must be cleaned by
back-washing.
1.4 Preventive Programmed Maintenance
a) Each item of auxiliary equipment (pumps, etc.) should be dismantled for inspection
and replacement of worn parts at the intervals recommended in relevant
manufacturers instructions.
b) The Desalination Plant should be shutdown at intervals of no more that 12 months

running time. During the shutdown period all programmed and necessary special
maintenance activities are going to be carried out.
c) If plant is going to be shutdown and not re-started immediately, it should be

preserved in the manner described next Plant Preservation.
d) For acid cleaning operation refer to section 3.
2. Plant Preservation
This chapter defines the operations to be carried out in order to drain and flush with
fresh water the shell side of the Multi-Effect Evaporator and associated piping and
Sh.21 of 28
equipment after plant shut-down, in order to protect the equipment from the pitting
corrosion associated to the presence of pockets of stagnant, high-chloride content
solution. The purpose of the operations here described is to reduce the chloride
concentration inside the unit to not more than 500 mg/l.
The fresh water to be used for flushing will be product water, or anyhow water having a
TDS value less than 30 ppm and pH greater than 6.
The operations to be carried out are different according to the duration of the outage
period after plant shut-down. Three different sequences are therefore presented in this
chapter, for the following cases:
(i) Outage period shorter than 24 hours (from shut-down to re-start);

(ii) Outage period between 24 and 72 hours;
(iii) Outage period longer than 72 hours.
2.1 Outage period shorter than 24 hours
For a short term shut-down period (not longer than 24 hours), it is adequate to keep the
plant under vacuum conditions. In the case that shut down has been made because it
is necessary some kind of work or inspection that requires to break the vacuum, then
drain the evaporator shell and the heat - exchangers water boxes for maintenance.
2.2 Outage period between 24 and 72 hours
1. Carry out steps (1) to (12) as described at Section 2.3.

2. After having completed the washing and draining of the Evaporator, the plant should
be kept under vacuum conditions, using the vacuum system.
2.3 Outage period above 72 hours
The most important factor in plant preservation is the washing with fresh water to
remove salts down to a concentration of not more than 1000 S/cm2.
This is best achieved by draining the plant off brine as completely as possible, then
filling the Evaporator with fresh water and circulating it through the evaporator to
ensure that all surfaces are washed.
The method employed for filling the evaporator with fresh water is the following:
1. All the manual and on-off valves must be closed.

2. Put all the pumps in manual mode.
Sh.22 of 28
3. Open the feedwater manual valve in Eff 1 to 6

4. Open manual valves in the services line
5. When the water level inside the Evaporator vessels, measured through the level
transmitter on the 6th effect has reached the high value, start the brine
pump.
6. Keep fresh water circulating for one hour.
7. Take samples of the water in the evaporator and check the conductivity, with
portable instrument
8. The procedure shall continue until the conductivity will reach approximately the
value of 1000 S/cm2
9. if not, repeat the steps from (6) to (12) until the above condition has been
reached. Then drain the plant completely via the brine pump and the plant drains.
3. Evaporator Acid Cleaning Procedure
The acid cleaning operation shall be carried out every year at the end of the
programmed shutdown, before re-starting the plant. If this operation is not carried out
within this recommended interval; the (GOR) Gained Output Ratio may be decreased
to such a point that the plant performance may not be maintained any more.
Before every acid cleaning procedure starts the following checks shall be done:
1. The Desalination Plant is shut down.

2. All the equipment are switched off and set in manual mode.
3. All manual valves are closed.
4. Unit at atmospheric pressure.
5. Flexible hose ready to connect the acid to the desalination unit.
6. Acid (Formic Acid aqueous solution 85%)
7. Service water available.
8. Protective clothing available.
9. Rubber gloves available.
The following equipment shall be available for the acid cleaning
1. Acid Cleaning System

2. Formic Acid (85% Concentration)
3. Portable instrument for pH
4. Portable instrument for conductivity
Sh.23 of 28
Procedure:
1. All the manual and on-off valves must be closed.
2. Put all the pumps in manual mode.
3. Open the feedwater manual valve in Effect 1 to 6
4. Open manual valves in the services line and fill up evaporator with service water.
5. When the water level inside the Evaporator vessels, measured through the level
transmitter on the 6th effect has reached the high value, start the brine recirculation
pump.
6. Keep fresh water circulating for half an hour.
7. In order to evacuate the gases developed during the acid cleaning process, open
the manhole in order to guarantee the evacuation of gases.
8. All isolating valves of pressure gauges and transmitters must be closed.
9. Open the manual valve connecting the acid cleaning system.
10. Start to inject acid solution (formic acid and water already mixed together in the
acid tank) with the dedicated pump.
11. Run the pump for 5 minutes and then stop it while the solution is re-circulated for
half an hour. Check the pH every 10 minutes. Re-start the dosing pump (while the
solution is continuously recirculating) till to reach the recommended concentration and
the pH falls below 2 or 3. As soon as the pH value falls below 3 (in the range 2 to 3)
stop the dosing pump while recirculation the solution. The initial concentration is to be
calculated as the ratio between the fresh water batch recycling in the evaporator and
the acid to be progressively injected into it. The cleaning can proceed continuously
until the acid solution is exhausted and pH rises up.
12. Check the pH, if it is around 7, discharge the solution through the outfall channel
and, if the cleaning is not completed, repeat the acid cycle as necessary.
13. Close the manual valve connecting the acid cleaning system.
14. Stop the brine recirculation pump
15. The solution should be discharged through the neutralization and neutralized in the
waste water treatment basin. The solution shall not be absolutely neutralized inside the
evaporator.
Sh.24 of 28
16. After the discharge of the solution start the flushing of the evaporator
17. Flush the evaporator with fresh water
18. Stop the flushing when that conductivity is approx 1000 S/cm2 and pH between 6.5
and 7.5
19. Drain the evaporator
At the end of this procedure the unit is ready for the star-up, make sure that all the
necessary action before the start up is followed.
4. Special Maintenance
Generally the following special maintenance operations shall be carried out during the
programmed plant shutdown or when especially necessary.
4.1 Evaporator
Before working on the evaporator, close the manual isolated steam valve and isolate all
electrical supplies.
4.1.1 Evaporator shell
Access to all effects can be gained by means of bolted manhole doors. When all doors
have been opened, access to the demister pads is possible. These pads are fixed in
position by stainless steel fixing wires, which must be removed before the pads can be
carefully lowered. The pads should then be thoroughly examined for damage and
possible deposits of calcium carbonate or calcium sulphate which can arise through
abnormal operation of the plant. If such deposits are present these can be removed by
pickling the pads in a 5% solution of hydrochloric or sulphuric acid for the calcium
carbonate and 10% solution of ethylene diamine tetra acetic acid for the calcium
sulphate. Damaged pads should be repaired if possible or in cases of severe damage,
renewed. If pads do not require pickling they should be flushed through with clean fresh
water before re-assembly.
All visible steelworks and tubes should be carefully inspected for signs of deterioration
and, if necessary, remedial action carried out. All internal fittings and bolts checked for
tightness, pipe joints examined for possible leakage and pipe interior checked for
cleanliness. Any deposits of silt scale or rubbish which may have accumulated must be
cleaned out. If necessary the bottom of the shell will be flushed through with clean water.
Before bolting up each stage manhole ensure that all tools, rags and other debris are
removed from internals. Check that faces of stage access doors are cleaned and free
Sh.25 of 28
from obstructions and secure doors having renewed the joints.
Lightly grease bolts.
4.1.2 Tubes of the effects
Access to the tube sheets can be gained by opening both the external and internal
manholes. Tube sheets should be inspected for pitting and tube ends examined for
damage.
Any foreign bodies, which may have gained access, should be cleared from the tube
plate and removed
4.2 Associated Equipments
4.2.1 Antiscalant & Antifoam Dosing System
During periods of shutdown for maintenance carry out the following routine.
1. Drain chemical solution from all tanks and refill with clean water.
2. Open the flanged connections of dosing pipe as close to evaporator shell as possible.
3. Run each chemical injection pump on 100% delivery until a flow of good clear water
is flushed out of each open connection.
4. Drain down tanks, clean out and make good repairs as necessary. Inspect gauge
Glass fittings and Inspect all instruments.
4.2.2 Acid Cleaning System
During the plant shut-down period for maintenance, the following shall be carried out:
1. Drain acid solution from tank and refill with clean water.
2. Open the flanged connections of dosing pipe as close to evaporator shell as possible.
3. Run acid cleaning pump on 100% delivery until a flow of good clear water is flushed out
of each open connection.
4. Drain down tanks, clean out and make good repairs as necessary. Inspect gauge glass
fittings and inspect all instruments.
Sh.26 of 28
4.2.3 Sea water Spray Nozzle
The sea water spray nozzle shall be inspected for possible blockage or restriction during
major plant shutdown.
4.2.5 Final Condenser
1. Drain the sea water in the water box if the plant is in shutdown condition.
2. If there is a suspect of leakage of sea water into the shell, it can be checked by
allowing the sea water to pass into the water box and the drain valve in the distillate can
be opened and checked for any leakage.
3. On some occasion the tube ends may leak, i.e. the tubes expanded over the
tube-.plate might be leaking. In checking for leakage, water may be found to be weeping
round the tube circumference. In such cases Tube expanders could be used to seal the
leaking tube to tube sheet by removing the water box.
Note: A check should be made on the tube wall thickness and the engineer should be
satisfied that enough metal exist, before the sealing operation is started, to ensure that
individual tube walls are not excessively thinned by tube expansion operation.
4.2.7 Valves
All valves should be examined at regular intervals and leaking glands tightened carefully
or repacked as necessary.
Valves which normally function in a fixed position over long periods should be
lubricated. Any valve showing signs of seizure should be dismantled and overhauled in
accordance with the manufacturers instructions.
During periods of shut-down for maintenance, all control valves, ON/OFF valves should
be inspected and worn parts refurbished or replaced as necessary.
4.2.8 Instruments
All instrumentation should be checked and overhauled where necessary in accordance

with the manufacturers instructions.
Sh.27 of 28
Particular attention should be paid to the various flow measuring and analyzing
instruments.
All level gauge should be cleaned for possible blockage or restriction, during major plant
shut-down.
4.2.9 Pumps and electric motors
During periods of shutdown or standby carry out any required maintenance or overhauls
as recommended in relevant Manufacturers Instruction Manuals.
Sh.28 of 28

03122-OM - Operating and Maintenance Procedures

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Job 3122 Title O & M MANUAL Prepared by RVR Doc.

GB SALINE WATER SOLUTIONS PVT LTD

OPERATING & MAINTENANCE PROCEDURES

3. General Notes for Pre-Commissioning & Commissioning

During Desalination commissioning, all desalination operating sequences, protections,

4. Pre-Commissioning & Commissioning Sequence

4.1 Pre- Commissioning

4.1.1 Issue of Erection Completion Certificate

1. Hot water suction and delivery piping

4.1.2 Issue of Auxiliaries Erection Completion Certificate

4.1.3 Evaporator Internal Inspection

1. Verify all valves are installed in the right flow direction.

4.1.5 Electrical motors

1. Verify wiring connection

1. Check alignment of the pump and motor.

4.1.7 Control & Instrumentation

Furnished below some general rules for instrumentation pre-commissioning

Refer to vendor manual for detailed information

4.1.8 Manual Valves

1. Verify free operation.

4.1.9 Level gauges, Temperature and Pressure gauges

4.1.10 VFD Panel

1. Verify power supply system and relevant distribution

4.1.11 Blank Tests

1. Failure start of the seawater pump

4.1.12 Piping Flushing

It is essential that each system to be cleaned is identified. For this scope it is

4.2.1 Vacuum Test

The operations to be carried out are as follows:

1. Make sure that all the circuits to be tested are empty.

II. OPERATING MANUAL

2. Operating Principle of a MED Unit

The process of vapour condensation - seawater evaporation is then repeated in each

3 Description of Desalination Unit

Reference Drawings: 1623122-1-L-55-01-0070_REV. 01

1. Shell outside diameter x Thickness = 1800 mm x 6 mm

The tube bundle of each effect has the following characteristics:

1. Number of tubes = 4 x (893 AL 6061 + 47 Titanium SB 338 Gr 2) = 3760

3.2 Final condenser

Reference Drawings: 1623122-2-F-55-0034_REV. 01

It is a shell-and-tube heat exchanger with horizontal axis, whose function is to condense

The details of the Final Condenser are as follows:

1. Shell outside diameter : 700 mm X 6 mm thickness.

3.8 Distillate Pumps : Model No: To be provided by IITM

The main characteristics of the Distillate Pumps are as follows:

Duty Flow Rate : IITM

3.10 Brine Pumps: : Model No: To be provided by IITM

The purpose of the Brine Recirculation Pumps is to recirculate a portion of brine to

One full duty centrifugal, end-suction pumps are installed.

The main characteristics of the Brine Recirculation Pumps are as follows

Duty Flow Rate : IITM

3.11 Seawater pumps : : Model No: To be provided by IITM

The main characteristics of the Sea water Pumps are as follows:

Duty Flow Rate : IITM

3.14 Anti-Scalant System

- Anti-scale additive, necessary to reduce the amount of scale formation on heat

Each group is composed by:

3.15 Acid Cleaning System

The system is composed by:

3. Pressure= 2.5 kg/cm2; MOC = PTFE

4. Characteristic of MED Unit

S.No Description Parameters

Desalinated Water Production :