OPERATION & MAINTENANCE MANUAL
1.1 Introduction WATERTRAK STANDARD WATER TREATMENT SYSTEM
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH AQUATECH INTERNATIONAL INTERNATIONAL CORPORATION AQUATECH AQUATECH PROJECT #P-00101
1.1 Introduction
Introduction
Congratulations on purchasing one of the best-engineered and manufactured water purification systems available. Aquatech International is a privately held Pennsylvania Corporation located in suburban Pittsburgh. At this eight (8) acre location, we own and operate a 30,000 square foot manufacturing facility with railroad accessibility. The administrative and engineering personnel reside in a 10,000 square foot building that allows excellent interdepartmental interface and proximity to the factory to ensure a high degree of quality control for compliance to customer specification. We specialize in the manufacture and construction of Custom Engineered Water and Waste Water Treatm Treatment Systems for Semiconductor Manufactur Manufacturers, ers, Generating Generating Stat Stations, ions, Chemical, ical, Pulp, Paper Paper and Steel Mills, Electronic, Fertilizer, Petroleum and Petrochemical Industries. These systems include the following equipment:
a.
Pretreatment and Chemical Feed Systems.
b.
Coagulation, Precipitation Systems including Clarifiers and Lime Softeners.
c.
Filtration Systems including Gravity Filters, Vertical and Horizontal Pressure Filters with Sand, Activated Carbon and Mi Mixed Medi Media.
d.
Carbon Filters and Carbon Adsorption Columns.
e.
Zeolite Water Softeners, Chloride Dealkalizers, Split Stream Dealkalizers.
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH AQUATECH INTERNATIONAL INTERNATIONAL CORPORATION AQUATECH AQUATECH PROJECT #P-00101
1.1 Introduction
Introduction
Congratulations on purchasing one of the best-engineered and manufactured water purification systems available. Aquatech International is a privately held Pennsylvania Corporation located in suburban Pittsburgh. At this eight (8) acre location, we own and operate a 30,000 square foot manufacturing facility with railroad accessibility. The administrative and engineering personnel reside in a 10,000 square foot building that allows excellent interdepartmental interface and proximity to the factory to ensure a high degree of quality control for compliance to customer specification. We specialize in the manufacture and construction of Custom Engineered Water and Waste Water Treatm Treatment Systems for Semiconductor Manufactur Manufacturers, ers, Generating Generating Stat Stations, ions, Chemical, ical, Pulp, Paper Paper and Steel Mills, Electronic, Fertilizer, Petroleum and Petrochemical Industries. These systems include the following equipment:
a.
Pretreatment and Chemical Feed Systems.
b.
Coagulation, Precipitation Systems including Clarifiers and Lime Softeners.
c.
Filtration Systems including Gravity Filters, Vertical and Horizontal Pressure Filters with Sand, Activated Carbon and Mi Mixed Medi Media.
d.
Carbon Filters and Carbon Adsorption Columns.
e.
Zeolite Water Softeners, Chloride Dealkalizers, Split Stream Dealkalizers.
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH AQUATECH INTERNATIONAL INTERNATIONAL CORPORATION AQUATECH AQUATECH PROJECT #P-00101
1.1 Introduction
Water and Hazardous Waste Treatment faci facililitities. es. Aquatech prefers to to supply supply the the customer customer a "systems-approach" to meet the desired water quality standards. This includes design, manufacture, construction, startup and annual certification. This unique ability has been developed over the last 17 years and Aquatech has the full-time in-house professionals to meet project needs. This operation and maintenance manual should be kept near the workplace and plant engineering office. Periodically, it needs to be updated to reflect modifications, additions, and deletions or other changes affecting the original design concept. Prior Prior to to design changes, changes, Aquatech strongly strongly recommends the owner owner contact our Customer/Fi Customer/Field eld Support representative for review and comments or issues of spare parts, field service and documentation, please direct your inquiry to:
Aquatech Aquatech Internationa Internationall Corporation Corporation Manager, Customer and Field Support P. O. Box 150 1 Four Coins Drive Canonsburg, Pa Pa 15317 Phone:
724 746-5300
OPERATION & MAINTENANCE MANUAL
1.2 Safety WATERTRAK STANDARD
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.2 Safety First
Safety First The ultimate goal of safety is the complete prevention of personnel injury, loss of life, destruction of property as a result of accidents, fires, explosions, or other hazardous situations. While this goal may seem illusionary, adequate safety and fire prevention emphasizes the prevention of accidents and failures. Unfortunately, the technical principles and practices in many fields are insufficiently established for valid evaluation of all calculated risks, thus leaving to the individual owner-operator the sole responsibility for adequate safety. Therefore, Aquatech International cannot accept any responsibility for the Owners/ Operators in regards to safety and related issues. Aquatech supports and promotes safety education for users of process equipment. Various agencies have developed standards for safety and Aquatech advises its clients to broadly apply these codes and to conform specifically to local regulation. Typical examples of safety codes are shown in table below:
Codes SBC NEC AGA ANSI ASTM NFPA AHSRAE
Typical Standards Utilized Description Standard Building Code National Electric Code American Gas Association American National Standards Institute American Society of Testing Material National Fire Protection Association American Society of Heating, Refrigeration and Air Conditioning Engineers
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.2 Safety First
provided around all platforms and all uncovered sumps or pits. Ladders serving platforms more than 12 feet above grade should be provided with cages extending down 8 feet above grade or platform. Handling facilities should be provided to lift all equipment which must be handled during maintenance operations. Mobile equipment should be used for this purpose whenever possible and accessways should be arranged to facilitate this. Items not accessible with mobile equipment should be serviced by portable equipment. Davits should be provided for manway covers, exchanger bonnets, and relief valves. Elevated equipment not accessible to mobile equipment which requires servicing and involves weight in excess of 1000 pounds should be provided with permanent handling facilities. Trolley beams or cranes should be provided for servicing large compressors or drivers. Suitable guards are necessary for all rotating equipment, belt drives, and chain drives, and powered conveyors. Screening devices, dryers, packaging, and similar equipment should also be provided on process equipment undergoing servicing or maintenance while the alternate equipment is in use. Personnel entry into the process equipment is permitted only when all flow is positively and completely shut off by doubleblock valves with intervening vents or by blind flanges or double-disk valves with vents between seats. Valve motor operators should be disconnected or interlocked and hand valve red tagged, locked, or guarded by personnel. Operators and workers must be protected against contact with hot piping, or vessels. Storage and Handling The safe storage and handling of hazardous material requires a thorough knowledge of chemical properties for positive containment and avoidance of leakage. Storage tanks, piping, valving and pump material must be selected for resistances to rapid corrosion or other deteriorate (caustic
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.2 Safety First
Sodium Hydroxide Sodium Hydroxide (NaOH) or caustic soda can cause severe burns on contact with skin or eyes or when taken internally. Great care should be take when handling the anhydrous material or when preparing or handling caustic soda solutions.
Caustic soda is supplied as a 50% liquid in Rayon grade. First Aid General first aid is of prime importance in the case of hazardous chemicals coming in contact with eyes or skin. At the first instant of exposure to hazardous chemicals, the affected area should be thoroughly rinsed with large quantities of water. Contact with Eyes If even minute quantities of hazardous chemicals enter the eyes, they should be immediately irrigated with plenty of running water for at least 15 minutes. The eyelids should be held apart during the irrigation to ensure that all the tissues of the eyes and lids are continuously in contact with water. If a physician is not immediately available, the eye irrigation should be continued for another 15 minutes. No oils, oily ointments or other medication should be placed into the eye, unless ordered by a physician. Equipment, instruments, and piping for corrosive or toxic materials should be installed in such a manner as to minimize accidental discharge. Special guards and/or locks and well-defined operation precautions can minimize the possibility of such occurrence. All authorized individuals who have access to operate and/or perform maintenance on this equipment must be properly trained in
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.2 Safety First
A work permit and close supervision are recommended for anyone working on the electrical system. Common Errors That Make A Lockout System Ineffective 1. System not enforced and properly supervised by management. 2. Failure to use the lock. 3. Locking out the incorrect disconnect. 4. Leaving the key in the lock. 5. Asking others to do the locking out. 6. Failure to use the tags. 7. Failure to check inside switch box to make sure disconnect is positive. 8. Pulling fuses and not locking out. 9. Not identifying all switches and disconnects to the equipment. 10. Assuming the equipment is inoperable. 11. Assuming the job is too small to merit locking out. Safety Instructions for Back pressure and Relief Valves • • •
•
Wear protective clothing and glasses when working with or near chemicals Refer to MSDS sheets for all chemicals being used Use only the re-placements parts from the OEM. Use of other parts may result in damage to equipment or injury Flush all components that re in contact with chemicals prior to servicing Stop the flow of sample through the system prior to working on the pump
OPERATION & MAINTENANCE MANUAL
1.3 Common Terminologies WATERTRAK STANDARD
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
Acids A large class of chemical substances whose water solutions have the ability to react with cation resins to regenerate exhausted resins which permits the resin to be used over and over again. Acids are also used to lower the pH of waste water to a desired range, (typically 7±1). Acids utilized in Aquatech processes are hydrochloric (20° Be HCl) or sulfuric 66° Be H 2SO4 technical grade. pH of acids is less than 7.0. Air Scour - Air enters bottom head of pressure vessel and flow through the strainer plate nozzles evenly distributed through the vessel’s media. Air agitates the media loosening any compacted media by breaking any crust formed due to solids. Anion An ion having a negative charge like sulfate (SO 4-), carbonate (CO 3-) hydroxide (OH-), and chloride (Cl -), etc. Alkalinity capacity of water to neutralize acids, a property imparted by the water's content of carbonate, bicarbonate, hydroxide, and on occasion borate, silicate, and phosphate. It is expressed in milligrams per liter of equivalent calcium carbonate (mg/l CaCO 3). Anti-Scalant – is a chemical agent added to the RO feed water to inhibit the precipitation or crystallization of salt compounds. Backwash - During the service cycle, the filter media bed collects some suspended impurities from the water. Some of the media particle/beads breakup into fines and the bed becomes somewhat compacted. Introducing water at calculated flow rates in the opposite direction to the service flow lifts the bed that loosens and expands into the free board provided for the
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
cubic foot of the resin when regenerated with 8 pounds of regenerant would exchange ions equivalent to 20 Kilograms of calcium carbonate providing a treated water of the selected quality Chlorination – the addition of small amounts of free chlorine to water for the purpose of killing harmful microorganisms Chemical precipitation : (1) the process of utilizing chemicals to produce a separable solid phases within a liquid medium; in analytical chemistry, precipitation is used to separate a solid phase in an aqueous solution. (2) The process of softening water by the addition of lime and soda ash as the precipitants Conductivity The property of a substance (water) that describes it ability to transfer electricity. It is the inverse of resistively. Quality of Water Obtained From Various Sources Quality (Electrical Type of Water Resistance In Terms Of Megaohms-cms.) Theoretical maximum quality (calculated) 26 Water after 28 distillations in quartz 18.3 25° C Water treated by strongly acidic-strongly based system 18 Water after three distillations in quartz 2 Water after three distillations in glass 1
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
exhausted when the active ion concentration reaches a low level and effluent has a pre-selected high leakage of un-exchanged ions, known as end point leakage. Using sodium chloride, the exhausted resin is regenerated, bringing back the level of active ion concentration. Fast Rinse After the slow rinse the resin is rinsed further at a higher flow rate. Rinsing removes excess regenerant from the resin, at the same time all the eluted ions are displaced from the resin bed, bringing the resin back to active condition, ready to be put into service. Fouling the process in which undesirable foreign matter accumulates in a bed of media, clogging pores and coating surfaces. Freeboard the vertical distance between a bed of media and the collector for backwash water. This distance is the height available for bed expansion during back washing. Freeboard is usually expressed as a percentage of bed depth. Hardness a characteristic of water, imparted by salts of calcium, magnesium, and iron, such as bicarbonates, carbonates, sulfates, chlorides, and nitrates that cause curdling of soap, deposition of scale in boilers, damage in some industrial process, and sometimes objectionable taste. It may be determined by a standard laboratory procedure or computed from the amounts of calcium and magnesium as well as iron, aluminum, manganese, barium, strontium, and zinc; expressed as equivalent parts per million of calcium carbonate. Temporary hardness is due to calcium and magnesium alkaline salts, such as magnesium
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
Because a high quality scale inhibitor is available for this particular application concentration stream can have LSI up to 1.5. Anti-scalant addition will help to reduce or eliminate need for acid consumption. Oxidant a chemical agent that oxidizes. Oxidation in a broad sense oxidation is the increase in positive valence of any element in a substance. On the basis of the electron theory, oxidation is a process in which an element losses electrons. In a narrow sense, oxidation means the chemical addition of oxygen to a substance. Parts per million (ppm) the unit commonly used to represent the degree of pollutant concentration where the concentrations are small. Larger concentrations are given in percentages. 1ppm = 1mg/L. In BOD analysis, the results are expressed in ppm, whereas in the suspended solids test, the values are expressed in percents. In air, ppm is usually a volume/volume ratio; in water, ppm represents a weight/volume ratio. pH control is of critical importance in a large number of industrial operations such as in water purification. pH is a value taken to represent the acidity or alkalinity of an aqueous solution; it is defined as the logarithm of the reciprocal of the hydrogen-ion concentration of a solution:
(1) pH = Log (---------)
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
Examples Liquid
Pure water Sea water Blood Milk Soil (optimum for crops) Cola Soft Drinks
pH Value 7 7.8 - 8.2 7.3 - 7.5 6.5 - 7 6-7 2-3
In acid-base titrations, changes in pH can be detected by indicators, such as methyl orange, etc. Litmus paper can also be used as a rough indication of acidity or alkalinity. pH adjustment : a means of maintaining the optimum pH through the use of chemical additives .
Precipitate to cause a dissolved substance to form a solid particle which can be removed by settling or filtering such as the removal of dissolved iron by oxidation, precipitation and filtration. Precipitate is also used to refer to the solid formed as a result of precipitation. Reduction chemical reaction in which an atom or molecule gains an electron; decrease in positive valence; addition of hydrogen to a molecule.
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
RO Permeate – Within the RO vessel are a series of membranes. Pressurized water flows into the RO vessel and the pressure forces water through the filtering layers of the membranes and into the permeate chamber. Permeate comes out both end of the vessel from the center of the membranes. Permeate connections from each array are headered together. 85% of the feed water into the vessel becomes permeate water. Permeate will have the majority of suspended solids, organic material such as bacteria, and dissolved mineral and salts removed. RO Reject – The remaining water that does not flow into the permeate chamber is called reject or concentrate. The concentrate has ions which are too large to flow through the membranes. The concentrate from the first array flows feeds the second array. As with the first array, the pressure forces some of the concentrate through the membranes. The concentrate from the second array flows feeds the third array. As with the second array, the pressure forces some of the concentrate through the membranes. The concentrate flow leaving the third array is limited to 15% of the feed by adjusting the globe valve on the RO bank’s reject line. Recovery – is the amount of feed water recovered as permeate. It is expressed as percentage (%) recovery.
% Recovery = Permeate Flow / (Permeate Flow + Reject Flow) x 100 Scale – is a coating that forms on surface of membranes due to the precipitation or crystallization of salt compound or solids. Precipitate that forms on surfaces in contact with
Project: PERI Client: Global Management Partners, LLC Location: Punto Fijo / Puerto LaCruz
AQUATECH INTERNATIONAL CORPORATION AQUATECH PROJECT # P-00101
1.3 Common Terminologies
and air (0.00120 g/cc, or 1.29 g/l at 0 and 760 mm) for gases. The specific gravity of solids and liquids is the ratio of their density to that of water at 4° C taken as 1.0 as 1 cc of water weighs 1 gram. Thus a solid or liquid with a density of 1.5 g/cc has a specific gravity of 1.5. Since weights of liquids and gases vary with temperature, it is necessary to specify both temperatures involved, except for rough or approximate values. Suspended solids (1) solids that either floats on the surface of, or is in suspension in, water, wastewater, or other liquids, and which are largely removable by laboratory filtering. (2) The quantity of material removed from wastewater in a laboratory test, as prescribed in “Standard Methods” and referred to as non-filterable residue. Turbidity Foreign suspended particles in water imparting an unsightly appearance and will result in deposits in water lines, process equipment, etc. It is measured by a nephelometer that which senses the quantity of light transmitted through a water sample. The units are given as NTU.