Prepared by –

B.V.P. Sitarama Sarma

Chemistry Dept.

1
 2
INDEX PAGE
NAME OF THE SYSTEM PAGE NO. OTHER AREAS 40 - 44

OVERVIEW OF WATER TREATMENT PLANT 3-4 SANITARY SEWAGE TREATEMENT PLANT 40 - 41

FLOW DIAGRAMS 6 - 15 STATOR COOLING WATER SYSTEM 42

FLOW DIAGRAM OF PT PLANT 6 HYDROGEN METHODOLOGY 43

FLOW DIAGRAM OF DM PLANT 7-8 COAL WASTE WATER TREATMENT PLANT 44

ZERO WATER DISCHARGE FLOW CHART 9 - 10

WATER BALANCE DIAGRAM 11 - 14

STEAM CYCLE, EXTRACTIONS 15, 16

PRE TREATMENT PLANT ( PTP) 18 - 23 FILTRATION SYSTEMS PAGE NO.

CHLORINATION BOOSTER PUMP HOUSE 19 INTAKE-WELL 46 - 48

COMPLEX WATER PUMP HOUSE 20 RESERVOIRS 49 - 50

POTABLE WATER TREATMENT PLANT 21 HRSCC 52 - 54

PTP SLUDGE DEWATERING STATION 22 CHLORINATION 55

CHLORINATION BUILDING AREA 23 - 24 SLUDGE THICKENER 56

CT BLOWDOWN SYSTEM 25 SLUDGE TRANSFER PUMP 57

DM PLANT 27 - 33 DECANTER CENTRIFUGE 58 - 59

FILTER WATER PUMP HOUSE 27 MULTI GRADE FILTERS 60 – 61

UF & RO WATER PUMP HOUSE 28 ACTIVATED CARBON FILTERS 62 - 63

UF & RO CHEMICAL DOSING ROOM 29 - 30

JANJGIR-CHAMPA
CATION & ANION REGENERATION SYSTEM 31 SELF CLEANING AUTO FILTERS 64 - 65
BALODA
AKALTARA

ACID & CAUSTIC UNLOADING AREA 32 MEMBRANE FILTRATION 66

ETP SLUDGE DEWATERING STATION 33 CROSS FLOW FILTRATION 67

SHAKTI
AKALTARA

AKALTARA
AKALTARA BAMHA
BOILER AREA 35 - 38 ULTRA FILTRATION 68 - 69 AKALTA
NIDIH

CPU 35 MICRON CARTRIDGE FILTERS 70

NAWAGARH
AKALTARA

CPU REGENERATION SYSTEM 36 REVERSE OSMOSIS 71 - 72 MALKHARODA

AKALTARA

PAMGARH
AKALTA

BOILER CHEMICAL DOSING ROOM 37 ION EXCHANGE RESINS 73 - 74 JAIJAIPUR

AKALTA

AKALTARA
DABHRA
CHEMICAL DOSING & BLOWDOWN LOCATIONS 38
2
 3

Reservoir 1 Reservoir 2 Reservoir 3

Raw water pump house

KSK Office
Road

OVER VIEW
OF
WATER TREATMENT PLANT

SEPCO Office
Cooling Tower CT Pump House Cooling Tower

3
 Pre Treatment Plant (PTP) Post Treatment Plant (DMP) 4

Sludge Pond High Rate Solid Contact Clarifier (HRSCC) Sewage Treatment Plant (STP) Guard Pond
Middle Pond

ETP Sludge Thickener

Chemical Dosing ETP Sludge Dehydration Station
Pump House
Chlorination Booster Acid Storage Tank Caustic Storage Tank
Pump House Mixed Bed (MB)
Service air
tanks

Fire Fighting
Clarified Water Storage Tank Strong Base
(CWST)

Complex Water Pump House

Anion (SBA)

Station

ETP Clarifiers
N-PIT Tanks
Sludge Thickener

DMP Pump
Clarifying
Water Tanks Strong Acid

House
Cation (SAC)

DM Water Storage Tanks (DMST)

Filter Water
Tanks
CT Make Up + Service Resin Transfer
Water Pump House Vessel (RTV)

RO Tanks
Cation & Anion

UF Tanks
HRSCC Sludge
Potable Water System
Dehydration Station

UF & RO Pump Chemical Dosing

House Room Multi Grade
Filters (MGF)
PLC

Potable Water Storage Tanks Reverse Osmosis (RO) Ultra Filtration (UF) DM Plant Office
PTP PLC Room & Pumps System System Building

4
 5

Flow Diagrams

5
 PRE TREATMENT PLANT (PTP) 6

Raw Water Pumps (6 x 1800 m3/hr) High Rate Solid Contact Clarifier (HRSCC), 5 x 2250 m3/hr

8237 m3/hr

Sludge Pond Sludge (617 m3/hr)

(2 x 4,500 m3)

Chemical Dosing Room

Middle Pond
(2 x 2,500 m3) Chlorination Booster Clarified water
Pump House (8188 m3/hr) Fire Fighting
Station
Clarified Water Storage Tanks
(CWST), 2 x 18,000 m3 Complex Water Pump
4 House

3
Sludge Thickener
(4 x 580 m3/hr) CT make up (7760 m3/hr)

2
Service Water
(218 m3/hr)
1 HRSCC Sludge
Dehydration Station
153 m3/hr

Sludge Balance
Pond (200 m3) (2*1100 m3)
150 m3/hr Colony 130 m3/hr
PTP PLC Room Potable Water Plant 20 m3/hr
System

50 m3/hr Washing water for Potable Water Storage

Solid waste to trucks automobiles (2 m3/hr) Tank & Pumps
6
 POST TREATMENT PLANT (DMP) 7
(SEE NEXT PAGE)

ETP SLUDGE ETP SLUDGE DEHYDRATION BULK ACID & CAUSTIC Acid 12th
THICKENER STATION STORAGE AREA Regenerat

Mixed Bed (MB)

ion Area

Anion (SBA)
Strong Base
N-PIT 1 3
Tanks 2
3 4 Caustic 2
Regenerat
2nd 3 1
ion Area
1st

Vessel (RTV) Cation

Clarifying Water 11th
stage

Cation (SAC)
(CF) Tanks

Strong Acid
3

Resin Transfer

(+) & Anion (-)

3rd -
1 2 ETP Clarifiers Filter
Pump 2
+
Filter Water Tanks House 1
4th
DM Water Storage Tanks
2 1
(DMST)
13th
2 4
2 2

Dual Media Filters

10th

Dual Media Filters

14th

(DMF) 1-7

(DMF) 8-14
5th
RO Tanks UF Tanks
1 3
1 1

9th
8th
7th

UF & RO Pump House Chemical Dosing Room Self Cleaning

Filters
6th
RO

UF

DMP PLC Stairs

Stairs

Reverse Osmosis (RO) System Ultra Filtration (UF) System DM Plant Office Building 7
 DM PLANT FLOW DIAGRAM (240 m3/hr) 8

Raw water Pump House CWST

Reservoirs (3 Nos) Cooling Tower
(6*1800 m3/hr) (2*18,000 m3) (16 *6 cells)
(2*3,00,000 m3, 1*6,00,000 m3) HRSCC (5*2250 m3/hr) CHP

Guard Pond
Filter Water Tanks (2*500 m3)
Clarifying Water CT blow down
Tank tank

(2*1100 m3) 2*9000 m3

FILTER WATER PUMPS Multi Grade Filters ( 14*95 m3/hr) CLARIFIED WATER PUMPS BLOWDOWN WATER TRANSFER
ETP Clarifiers
(2*480, 2*420 m3/hr) (4*580 m3/hr) PUMPS (4*600 m3/hr)
4*380 m3/hr

RO water storage
tanks (2*500 m3)

UF WATER PUMPS RO HIGH PRESSURE

UF water storage (4*200 m3/hr) PUMPS (6*200 m3/hr)
Ultra Filtration tanks (2*500 m3) Reverse Osmosis RO WATER PUMPS
(6*220 m3/hr) (6*150 m3) (4*180 m3/hr)

DM TRANSFER PUMPS
(5*170 m3/hr) MB (3*240 m3/hr) SBA (3*240 m3/hr) SAC (3*240 m3/hr)

CST (6*800 m3) DMST (4*1600 m3)

Note: 1m3 = 1000 litres 8
 9
“ZERO WATER DISCHARGE” - FLOW DIAGRAM
Basantpur (Intake well, Mahanadi River) Seorinarayan Pamgarh Reservoirs Raw Water Pump
House
Complex Water Pump House Clarified Water Storage HRSCC
Tank (CWST)
Chlorination Booster
Pumps (Cl2)
Potable Water System Service Water Pumps Coagulant Dosing
(Drinking Water) Fire Fighting CT Make-up Pumps Pumps (PAC)
Pumps Flocculent Dosing
Potable Water CT Fore Bay Boiler Blow Down Pumps (PAM)
Storage Tank Utilized for fire Cooling Basin
fighting
Evaporation loss &
Cooling Tower Sludge Pond
Drift loss Sludge Thickener

Colony Plant site (Sludge

Cooling Water Blow Down Tank Drain)
Middle Pond
Sewage
(Drainage water) Sludge Balance Pond
Coal Waste Water
Guard Pond
Treatment Plant ETP Clarifier
Sewage Treatment Centrifuge Sludge Feed Pumps
Plant
Clarifying Water Metering Pumps
Ash Handling Sludge Dehydration
Reused water Tank (for dosing PAM)
Plant (AHP) Station
tank Storage Electric Mud Bucket
Spray water for Tank Clarified Water
Green Belt & Pumps
roads Electric Mud Solid Waste discharge to
Coal Handling
Bucket trucks
Night Sludge/ Night Plant (CHP)
Soil (for Plantation) N-PIT DM PLANT Reclaimed Water Tank
(Regeneration waste) (see next page ) (Flushing Water )
RO reject 9
 Clarified Water Pumps Service Water Pumps
Turbine Condenser
10
Cooling Tower Multi Grade Filters (MGF)
Main Steam (MS)
Filter Back Wash Pumps
Blow Down Drain Filtered Water Tanks Platen Super Heated Steam
Tank
Clarifying water Divisional Super
tank Filtered Water Pumps Heated Steam Low Temperature Super
Heated Steam (LTSH)
ETP Clarifier Self Cleaning Filters (Amiad)
Saturated Steam
Reclaimed Water Ultra Filtration (UF)
Transfer Pumps Boiler Drum Blow down
UF Backwash Pumps
UF Storage Tanks tank
Economizer (Feed)
Reclaimed Water UF feed Pumps Micron Cartridge Filters
Tank High Pressure (HP) heaters
RO High Pressure Pumps
(Overflow) Boiler Feed Pump(BFP)
Reverse Osmosis (RO) RO Flushing Pumps
Guard Pond Deaerator
RO Storage Tank CW Back Water Pumps

Drain Low Pressure (LP) heaters

CHP
AHP RO Water Pumps
(RO reject water)
(non return) Acid Injection
Gland Seal Condenser (GSC)
Strong Acid Cation (SAC)
Coal N-PIT Transfer Pump Caustic Injection
Waste Water Condensate Polishing Unit (CPU)
Treatment Plant Strong Base Anion (SBA)

Neutralization Pit Caustic Injection

Hot Well
(N-PIT) Mixed Bed (MB)
Storage Tank Drain Acid Injection Condensate Makeup
DM Water Storage Tank (DMST) Condensate Storage Tank (CST) Pump 10
 PRE TREATMENT PLANT WATER BALANCE DIAGRAM 11
(BASED ON WBD)

Mahanadi River (387 m3/hr), Water for DMP Before the

first unit start-up
Clarifying Water
Evaporation and (8257 m3/hr ) (CF) Tank
Percolation Loss
(210 m3/hr), Need when DM is out of Running Boiler Blow Down
(20 m3/hr ) Induced Draft Cooling Basin
Cooling Tower Water for UNNORMAL
Raw Water Reservoirs (see next page) Operating Condition
(567 m3/hr) Floor washing water
(8237 m3/hr) for Main Building
(7760 m3/hr)
(8188 m3/hr) (5 m3/hr)
(218 m3/hr) (65 m3/hr) (29 m3/hr)
HRSCC Clarified Water
Reservoir (CWST) (36 m3/hr) (24 m3/hr)
(617 m3/hr)
(153 m3/hr) Make-up water for Evaporation Cooling
(568 m3/hr)
Air Conditioners water for Blocks
(1 m3/hr)
Sludge Treatment Potable Water Treatment Plant (36 m3/hr) (24 m3/hr)
System
(150 m3/hr)

(50 m3/hr) (2 m3/hr)

Guard Pond (5 m3/hr)
Potable Water Tank Washing water
(see next page)
for Automobiles
(130 m3/hr) (20 m3/hr)
(2 m3/hr)

(15 m3/hr) (16 m3/hr) Reused Water

Potable Water Potable Water Sewage Water Tank
For Colony For Plant Site Treatment Plant (16 m3/hr)
(130 m3/hr) (5 m3/hr) (1 m3/hr)
Spray Water for
Green Belt & Road
(16 m3/hr)
11
 COOLING TOWER & DM PLANT WATER BALANCE DIAGRAM 12
(BASED ON WBD)

Drift Loss Evaporation Loss

(246 m3/hr) (6192 m3/hr)

Clarified Water (62 m3/hr)

(7760 m3/hr) Induced Draft (629 m3/hr) Boiler Blow Down
Reservoir (CWST)
Cooling Tower Cooling Basin
(567+62=629) (567 m3/hr)
(494726 m3/hr) (see previous page) [357+210=567]
(496677 m3/hr)

(494726 m3/hr) (1951 m3/hr) Service water from CWST (210 m3/hr)
Cooling Tower (Need when DMP is out of
(476126 m3/hr) (18600 m3/hr) running)
Blow Down Tank
Condensers Auxiliary
Coolers
(4 m3/hr) (955 m3/hr) (992 m3/hr)
Clarifying Water

(357 m3/hr)
(992 m3/hr)
Washing Water for (See next page) ETP Clarifiers (CF) Tank
Air Preheater
(790 m3/hr) (992 m3/hr)
(4 m3/hr)
Drainage (9 m3/hr) (248 m3/hr)
Neutralized Pond Guard Pond UF & RO
(5+4=9) (790+248+15+9+4=1066)
(387 m3/hr)
Backwash (4 m3/hr) (15 m3/hr)
(5 m3/hr) Water for CPU DM Plant
(4 m3/hr) (372 m3/hr)

(256 m3/hr) (33 m3/hr) (12 m3/hr) (62 m3/hr)

Water & Closed DM HVAC Water

Boiler Blow
Steam Loss Water Loss Loss
Down Water
(256 m3/hr) (33 m3/hr) (12 m3/hr)
12
 COOLING TOWER BLOWDOWN TANK WATER BALANCE DIAGRAM 13
(BASED ON WBD)

Induced Draft Cooling Tower

(see previous page)
(496677 m3/hr)

(494726 m3/hr) (1951 m3/hr)

Cooling Tower
Condensers &
Blow Down Tank
Auxiliary Coolers
(see pervious page)

(4 m3/hr) (992 m3/hr)

Washing Water for ETP Clarifiers (955 m3/hr)

Air Preheater (see previous page)
(see previous page)

(1 m3/hr) (790 m3/hr) (164 m3/hr)

Washing Water for Guard Pond Water tank for Coal (43 m3/hr)
Oil Area (see previous two pages) Convey System

(1 m3/hr) (207 m3/hr)

Oil contained waste

(65 m3/hr) (81 m3/hr) (61 m3/hr)
water treatment station
(1 m3/hr)
Spray water for Spray water for coal Washing water for
Equipment's & Pipes coal storage yard convey system Dedust coal convey structures
drainage when checked
(3 m3/hr) (4 m3/hr) (65 m3/hr) (81 m3/hr) (61 m3/hr)

Coal contaminated waste

water treatment system
(18 m3/hr)

13
 GUARD POND WATER BALANCE DIAGRAM 14
(BASED ON WBD)

Cooling Tower Floor washing water Backwash Water Equipment's & Pipes
Blow Down Tank for Main Building for CPU drainage when checked
Drainage (4 m3/hr)
(790 m3/hr) (5 m3/hr)
Neutralized Pond

DM Plant
Oil contained waste
water treatment station
(1 m3/hr) Guard Pond (248 m3/hr)
[Capacity= 3300 m3] UF & RO

(1075 m3/hr)

(391 m3/hr) (24 m3/hr) (660 m3/hr)

Water for Bottom Ash Water for Mill Reject Water for Fly Ash
Handling System Handling System Handling System
(969 m3/hr)
(1360 m3/hr) (660 m3/hr)
(24 m3/hr)
Bottom Ash Yard Fly Ash Yard
(1384 m3/hr) (660 m3/hr)

(415 m3/hr) (660 m3/hr)

(Evaporation Loss) (Evaporation Loss)

14
 STEAM CYCLE 15
(Based On Heat Balance Diagram & Boiler Operational Manual)
(541⁰C/16.67 Mpa) (358.5⁰C)
(1.021 Mpa)
CST
FINAL SUPER HEATER HP IP LP LP CYCLE MAKE-
(25⁰C) UP ( approx
56 m3/hr)
(499⁰C) (327.8⁰C/
3.853 MPa) (46.7⁰C) HOTWELL
Return Condensate
PLATEN SUPER HEATER (541⁰C) (approx 1140 m3/hr)
(46.7⁰C)
(3.468 MPa)

(443⁰C) GLAND SEAL

REHEATER
CONDENSER
DIVISIONAL SUPER HEATER CEP sample point
Main Steam sample point
(47.3⁰C)
(404⁰C)
LP HEATER# 08
LOW TEMPERATURE
SUPER HEATER (83.7⁰C)

LP HEATER # 07
(394⁰C)

RADIANT ROOF (100.9⁰C)

SUPER HEATER
LP HEATER # 06
Saturated Steam sample point
(>361⁰C) (118.9⁰C)
BOILER DRUM Boiler Drum sample point
(190 kg/cm2) LP HEATER # 05
Deaerator sample point
Economizer or Feed water
sample point (137.4⁰C)
(323⁰C)

ECONOMIZER HP HEATER # 01 HP HEATER # 02 HP HEATER # 03 DEAERATOR

(10 kg/cm2)
(277.3⁰C) (246.3⁰C) (215.7⁰C) (178.6⁰C)
* NOTE: Only Temperature Rising Zones Are Mentioned Here
* NOTE: Feed water quality effected by temperature and pressure
 16
STEAM EXTRACTIONS
Steam Extractions are used for various purposes, one of the most important is to
raise the temperature of feed water. Heaters are used to increase the feed water
temperature. Heaters are internally having shell and tubes for heat transfer. See the
image showing the internal design of an heat exchanger.

DEAERATOR: Gases are easily dissolved in cold water and slightly dissolved in hot
water. Pressure also plays a vital role in dissolution. If a liquid is under high pressure
and low temperatures, than the liquid contains more dissolved gases in it and vice
versa. If a liquid reaches boiling point then there is no dissolved gases present in it.
In Deaerator water is under opposite pressure with temperatures crossing the
boiling point, which removes all dissolved gases present in it.

HP TURBINE IP TURBINE LP TURBINE

(STEAM EXTRACTIONS) (STEAM EXTRACTIONS) (STEAM EXTRACTIONS)

391.8⁰C 327.8⁰C 470.1⁰C 358.5⁰C 245.4⁰C 186.7⁰C 129.2⁰C 87.8⁰C

(277.3⁰C) (46.7⁰C)
HP HP HP LP LP LP LP HOTWELL
HEATER#01 HEATER#02 HEATER#03 HEATER#05 HEATER#06 HEATER#07 HEATER#08

DEAERATOR
251.9⁰C 221.3⁰C 187.3⁰C 187.3⁰C 106.5⁰C 89.3⁰C 52.9⁰C
 17

PRE TREATMENT
PLANT

17
 PUMP DETAILS OF PRE TREATMENT PLANT 18

1 2 3 4 5 6

Sludge Ponds Raw water pumps (6*1800 m3/hr) Chemical Dosing Room

PAM Dosing Pumps (650 LPH)

SLUDGE TRANSFER PUMPS
(Enhanced Self-Priming Centrifugal HRSC HRSC HRSC Mixers
C#1 C#2 C#3 PAM (2*15 m3)
Pumps-3*340 m3/hr) HRSCC#1

HRSCC#2
Sludge Drain Line
HRSCC#3
HRSC HRSC
SLUDGE POND C#5 C#4
HRSCC#4
(2*4500 m3)
HRSCC#5

Sludge tr. Pump discharge line Stairs

Level Gauge
REFLUX PUMPS
(Vertically Long Axle Pumps- HRSCC#1
2*1040 m3/hr)
HRSCC#2

HRSCC#3
MIDDLE POND HRSCC#4
(2*2500 m3)
HRSCC#5
PAC (2*15 m3)
PAC Dosing Pumps (732 LPH)

18
 19
CHLORINATION BOOSTER PUMP HOUSE

HRSCC HRSCC HRSCC

#1 #2 #3
Chlorination Booster Pump House

HRSCC HRSCC
HRSCC#1 (Chlorine Dosing: 7 LPH) #5 #4

HRSCC#2 (Chlorine Dosing: 7 LPH)

Injectors and HRSCC#3 (Chlorine Dosing: 7 LPH)

Control Valves
HRSCC#4 (Chlorine Dosing: 7 LPH) Chlorination Booster Pumps for
Chlorinated Potable water system (20 m3/hr)
water HRSCC#5 (Chlorine Dosing: 7 LPH)

Chlorination Booster Pump for

HRSCC (100 m3/hr)

Chlorine Gas Automatic Self-Cleaning Filters

Raw water line from

HRSCC # 4&5 Outlet
Potable System
(Chlorine Dosing: 2 LPH) Raw water line from CT
Make up Pump

LPH = Liters Per Hour

19
 20
Diesel Driven Spray pump
(1*410m3/hr)

Motor Driven Spray pump

Inter connection (1*410 m3/hr)
Fire fighting station

Diesel Driven Hydrant pumps

(2*410 m3/hr)

COMPLEX WATER PUMP HOUSE

Motor Driven Hydrant pumps
Clarified Water Storage Tank (CWST)

(2*410 m3/hr)
Fire fighting station:
Jockey pumps (2*60 m3/hr) Jockey pump runs continuously to maintain the pressure in
the line. If pressure dropped below the set-point, then the
second jockey pump starts automatically to maintain the
pressure. Even though the pressure is not maintaining, then the
hydrant pump will start automatically to maintain the pressure in
Hydropneumatic tank the line.
(1*220 Nm3/min) High pressure drop in the line indicates that there is an
emergency situation. After completion of work again pressure
build-up and hydrant pump will stop automatically.
Diesel pumps are ready to handle the emergency situation
CT make up pump house

when there is no power supply.

CT make up pumps
(4*2600 m3/hr)
Hydro Pneumatic Tank

Capacity: 22.6 m3
Design Pressure: 15 kg/cm2
Service water pumps Operating Pressure: 0.7 kg/cm2
(3*290 m3/hr) Design temp: 100’C
Vessel Height: 6520 mm
Water: 1300 mm

Potable water pumps (3*75 m3/hr) 20

 CLARIFIED WATER STORAGE TANK (CWST) Complex Water Pump House
Service 21
water line

Potable Water Pumps

POTABLE WATER/DRINKING WATER (3*75 m3/hr)
TREATMENT PLANT Tapping from
Service water line

(150 m3/hr)
Chlorination Line from Booster Pump House
(2 Litres Per Hour/100 Pounds Per Day)
Potable Water
Storage Tank
(2*1100 m3)
To Plant & Colony

Activated Carbon
Filters (3*75 m3/hr)
Chlorine Analyser
ACF ACF ACF

Dual Media Filters

(3*75 m3/hr) DMF DMF
DMF
Backwash Water
to Sludge Pond
(1 m3/hr)
CWST
Air Line for Backwash

Filter Blowers
(2*23.6N m3/min)
21
Potable Backwash Pumps (2*450 m3/hr)
 22
PT PLANT BUILDING (PTP SLUDGE DEWATERING STATION) Top Floor

Horizontal Decanter Centrifuges (5*100 m3/hr)

Extracted Water PRE TREATMENT
to HRSCC
PLANT PLC ROOM

Sludge Screw Conveyor (30 m3/hr)

Concentrated
Sludge discharged Sludge Mud Bucket
to Mud Buckets (20 m3/hr),
discharged to Truck s

PAM Dosing To Decanter

Dehydration Coagulant
Sludge water

Dissolved Tanks (2*144 m3)

Centrifuges
To Decanter Centrifuges

PAM Dosing Pumps (5*6791 LPH)

Sludge Transfer Pumps (5*100 m3/hr)

Sludge Balance Pond (200 m3), Underground

Drained Sludge from Sludge Thickeners Ground Floor

enters into Sludge Balance Pond 22
 23
CHLORINATION BUILDING AREA
Chlorination Booster Pump Cooling
House For Cooling Water Towers
CW Booster 8 Blowers, 8 Chlorine
Leak Chlorine

Waste Pit
Pumps 4*80 Leak Detectors
Cylinder
m3/hr (Set Point-0.5 ppm,
Alarm-0.3 ppm

Automatic Self
Chlorine
Cleaning Filters Caustic
Line BA Set, PPE’s and
Chlorinated water Solution Ammonia Torch
to Forebay Tank (10%) Caustic Spray location
#5
CHLORINATOR ROOM
#4 Scale Inhibitor
*CW Chlorinators (5 Nos) Safety
#3 Dosing Pumps
200 Litres Per Hour/10000 Shower
(3*249 LPH)
#2
Pounds Per Day
#1 Acid Dosing
*RW Chlorinators (2 Nos)
#2 Pumps (3*249
62.5 LPH/3000 PPD
#1 LPH)
*Potable Water Chlorinators #2
(2 Nos), 2 LPH/100 PPD #1 Chlorine Total 52
Tonners Cylinders Sulfuric Acid Bulk

Lime Bags for acid Neutralization

EVAPORATOR ROOM Storage Tank#3
Total (50 Tons)
Weight-
Evaporators For Raw
1600 kgs
Water/Potable Water (80°C-84°C)
Empty Sulfuric Acid Bulk
Evaporators For Cooling Weight- Storage Tank#2
Water (80°C-84°C) 700kgs
(50 Tons)

Sulfuric Acid Bulk

PLC ROOM Chlorine Absorption Tank#2 Chlorine Absorption Tank#1 Storage Tank#1
(20% Caustic Solution) (20% Caustic Solution) (50 Tons)

Recirculation
Pumps (100 m3/hr)
Sulfuric Acid Unloading
Pumps (2*25 m3/hr)
Blowers
23
 24

CHLORINATION FLOW DIAGRAM

Rota Meter
Chlorine Injector
Gaseous Chlorine Hot Water Bath showing flow
Contains 900 kgs of
chlorine with 8 Liquid Chlorine
kg/cm2 pressure

COOLING
BOOSTER PUMP
TOWER
FOREBAY
CHLORINE TONNER Chlorinated
EVAPORATOR (84⁰C) water
CHLORINATOR (62.5 kg/hr)

COOLING TOWER MAKE-UP WATER LINE COOLING TOWER

24
 25
COOLING TOWER BLOWDOWN SYSTEM

GUARD POND
CHP

ETP

CT BLOWDOWN PUMPS
(4*600 m3/hr)
COOLING WATER LINE FROM
CONDENSER OF EACH UNIT

COOLING TOWER BLOWDOWN TANK

1*9000 m3 1*9000 m3

TO COOLING TOWER
FOREBAY
 26

DM PLANT

26
 27
FILTER WATER PUMP HOUSE (DMP)

FILTER WATER PUMPS (2*480, 2*420 m3/hr) FILTER BACK WASH PUMPS (3*340 m3/hr)

Filter water UF system Filter water For Filter

storage tank storage tank backwash

FILTER BLOWERS (3*6.6 1N m3/min) CLARIFIED WATER PUMPS (4*580 m3/hr)

DM Plant
Atmospheric For Filter (DMF) Clarifying water Dual Media
Air backwash storage tank Filters

For
For Anion
Cation
MB#3 MB#2 MB#1
1 2 3 4 5 6 7 Resin
Resin

DUAL MEDIA FILTERS (1-7) RESIN TRANSFER VESSEL (RTV) MIXED BED (MB)

SAC#1 SAC#2 SAC#3 SBA#1 SBA#2 SBA#3

8 9 10 11 12 13 14

DUAL MEDIA FILTERS (8-14) STRONG ACID CATION (SAC) STRONG BASE ANION (SBA)

27
 28
UF & RO WATER PUMP HOUSE (DMP)
MB REGENERATION DM TRANSFER PUMPS RO WATER PUMPS CW BACK WATER PUMPS RO FLUSHING PUMPS
PUMPS (2*50 m3/hr) (5*170 m3/hr) (4*180 m3/hr) (3*180 m3/hr) (2*200 m3/hr)

DM water MB DM water CST RO water SAC RO water Boiler Blow RO water For RO
Storage Tank Storage Tank storage tank storage tank down tank storage tank Flushing

RO HIGH PRESSURE PUMPS (6*200 m3/hr) UF BACKWASH PUMPS (2*440, 1*480 m3/hr) UF WATER PUMPS (4*200 m3/hr)

UF water pumps RO System UF water For UF UF water RO high pressure

storage tank backwash storage tank pumps

DM Plant

28
REVERSE OSMOSIS (RO) ULTRAFILTRATION (UF) SELF CLEANING AUTO FILTERS
 29
UF & RO CHEMICAL DOSING ROOM

SCALE INHIBITOR DOSING TANK (2 m3) NaHSO3 DOSING TANK (2 m3) ACID DOSING TANK (2 m3) ALKALI DOSING TANK
(2 m3)
DM Plant

Scale Inhibitor Dosing Sodium Bi-Sulfite Dosing UF ACID Dosing RO ACID Dosing UF Alkali Dosing RO Alkali Dosing
Pumps (2*85 LPH) Pumps (2*115 LPH) Pumps (2*115 LPH) Pumps (2*946 LPH) Pumps (2*235 LPH) Pumps (2*946 LPH)

RO SKID UF SKID
Return line Return line

Recirculation line Recirculation line

Drain

Drain
MF Filter

MF Filter
RO CLEANING UF CLEANING
TANK (5 m3) TANK (5 m3)
Heaters

Heaters

RO Cleaning Pumps (2*210 m3/hr) UF Cleaning Pumps (2*176 m3/hr)

Reclaimed Tank (Under ground, 300 m3) CONTINUE……… 29

 30
UF & RO CHEMICAL DOSING ROOM

Coagulant
DM Plant
Preparation
Tank (5 m3)
HYPO Dosing HYPO Dosing
Tank (5 m3) Tank (5 m3)

Coagulant
Dosing Tank (5 HYPO Dosing Pumps HYPO Dosing Pumps
m3) (2*946 LPH) for UF (5*25 LPH) for ETP

To ETP Clarifier

Coagulant
Dosing Tank (5 Reclaimed water Pumps
(2*145 m3/hr)
m3)
ETP 1
UF Feed line

ETP 2

Over flow water

to N-Pit tank
ETP 3

ETP 4

Reclaimed Tank (Under ground, 300 m3) 30

 31

5% HCL sol
CATION & ANION
REGENERATION SYSTEM
SAC

DM Water Line 5% HCL solution

Ejector
DM Plant
33% Acid, For SAC N-Pit
from Bulk Acid (1.8 m3) For MB 5% NaOH sol
storage tank 33% HCL (1.2 m3)
33% HCL

Acid Regeneration Area

SBA

Alkali Regeneration Area

DM Water Line

N-Pit
For SBA For MB
48% Caustic, (1.8 m3) (1.8 m3)
from Bulk Caustic 30% NaOH Ejectors 30% NaOH 5% NaOH sol GUARD POND
storage tank

MB
MB

DM Water Line 5% NaOH solution N-PIT

5% HCL N-Pit
sol
31
 CPU Regeneration
32
Waste
ACID & CAUSTIC UNLOADING AREA,
N-PIT AND GUARD POND AREA Guard Pond
(3300 m3)

CT Blow RO Reject Waste water

Down water tr. Pumps
(3*400 m3/hr)
ACID STORAGE TANKS (2*20 m3) SOLID ALKALI ALKALI STORAGE TANKS (2*20 m3)
DISSOLVED TANK N-Pit water

30-35% 30-35% 45-48% 45-48%

HCl HCl NaOH SSTP
ALKALI UNLOADING
NaOH
ACID UNLOADING
PUMPS (2*15 m3/hr) PUMPS (2*15 m3/hr)

Alkali Dosing Pump

Compressed Air Tanks

Acid Dosing Pump

ROOT BLOWERS
(2*7.3 1N m3/min) N-PIT

(2*12.5 N m3)
DMP
ETP

TOWARDS GUARD
POND
N-PIT: NEURTALIZATION-PIT
(2*320 m3)
Acid waste from Cation bed
after acid regeneration and
Alkali waste from Anion bed Acid waste + Alkali waste = Salty
after caustic regeneration N-PIT WATER TRANSFER water (Acid+Caustic=Salt + water).
mixed and neutralized by each PUMPS (2*150 m3/hr)
other.
Regeneration waste from SAC, SBA &
MB after regeneration
32
 33
ETP SLUDGE DEWATERING STATION
Top Floor

Horizontal Solid-Bowl Decanter

Centrifuges (2*50 m3/hr) ETP#2 ETP#1
Extracted Water to ETP
Clarifier through Reclaimed
Water Basin

ETP#3 ETP#4

Concentrated
Sludge
ETP
Sludge

PAM Dosing

Sludge water
Tank ETP
Water Mixer
PAM
Mixer
Sludge
Thickener
PAM Powder Overflow Overflow

Drain Drain

PAM Dosing Pumps for Centrifuge (2*946 LPH) PAM Dosing Pumps for ETP (5*235 LPH)

ETP Sludge tr. Pumps

(2*50 m3/hr)

Ground Floor 33
 34

BOILER AREA

34
 CONDENSATE POLISHING UNIT (CPU) 35

• The Condensate Polishing Units (CPU) consists of

Deep Mixed Bed Service Vessel with external
Condenser Cooling Water (In & Out) regeneration system.
• CPU is an Auxiliary System of Boiler, and works
like Kidneys in human being. Which continuously
Chances of contamination TURBINE filters the impurities without any disturbance.
takes place • Each MB consists of Cation & Anion resin.
• Cation Exchange Resin is Purolite D001 & Anion
Hot well DM Water make-up Exchange Resin is Purolite D201.
(From DM Plant)

BOILER
1500 m3/hr

750 m3/hr 750 m3/hr

Condensate Extraction Pumps

(CEP), 2*1640 m3/hr
MB-B 12.7 m3
MB-A MB-C

BENEFITS:
* Improvement in the quality of condensate and
"cycle" clean up.
* Reduced blow down and make up
requirements Resin Resin Resin
Trap Trap Trap
* Quick start up and as a result, full load
conditions are reached early giving economics
benefits.
* Orderly shutdown possible in case of
condenser tube leak conditions.
* Improvement in quality of steam which results
in enhanced turbine life. Recirculation Pump Ammonia
(468 m3/hr) Hydrazine 35
 CPU REGNERATION SYSTEM (External) 36
*CPU regeneration system is an external
system, where mixed resin from CPU Beds
collected through pipeline.
*Mixed resin collected in Resin Separator
Vessel, where stage wise backwash
RESIN SEPARATOR
(25.6 m3) conducted to remove the “CRUD” and
CATION
REGENERATION separate the Cation and Anion resins in two
RESIN HOLDING ANION
HEATER (8 m3)
TANK (13.6 m3) TANK (15.6 m3) REGENERATION separate layers.
TANK (9.16 m3) RESIN TRAP *Later Cation resin transferred to Cation
100⁰C
regeneration unit and Anion resin to Anion
regeneration unit. After that regeneration
done by separately.

To Guard Pond

Waste Water Tank/N-Pit

(320 m3)
[under Ground]
ROOT BLOWER
ROOT BLOWERS
(1*8.87 m3/min)
(2*8.87 m3/min)
Waste Water Pumps
PRESSUREISED AIR STORAGE (2*100 m3/hr)
TANKS (2*12.7 m3)

*After completion of regeneration,

regenerated resin transferred to Resin Caustic Metering Pumps Acid Metering Pumps
holding tank and mixed with air. (3*1617 liters) (3*2356 liters)
*The mixed resin were transferred to Caustic Storage Acid Storage
the location and taken into service. Tank (20 m3) Tank (20 m3)
*CPU resins are special resins, which are
designed to sustain in high pressures
and temperatures.
*CPU Removes suspended solids (like
turbidity etc) and dissolved impurities
Caustic Unloading Acid Unloading Pumps
from the return condensate and make-
Acid Metering Tank Pumps (2*12.5 m3/hr) (2*12.5 m3/hr)
up water. Caustic Metering Tank 36
(2200 liters) (4000 liters)
 37
BOILER CHEMICAL DOSING ROOM

Hydrazine Hydrazine Ammonia Ammonia

Metering Metering Metering Metering
Tank Tank Tank Tank
(1200 ltrs) (1200 ltrs) (1200 ltrs) (1200 ltrs)

Dosing in CPU Outlet line Dosing in Deaerator Outlet line Doing in CPU Outlet line Doing in Deaerator Outlet line
(2*97 ltrs/hr) (2*90 ltrs/hr) (2*97 ltrs/hr) (2*145 ltrs/hr)

Phosphate Caustic There are two Boiler Chemical Dosing

Metering Metering Rooms in KMPCL, one for 1,2,3 units and
Tank Tank For another for 4,5,6 units.
(1200 ltrs) Unit#1,2,3 Hydrazine, Ammonia and Phosphate
(1200 ltrs)
Dosing equipment's are three sets for
three units and Caustic Dosing system is
one for each three units.
Like wise two Dosing rooms are there.

Caustic Dosing in CCCW

Dosing in Boiler Drum for three Units
(2*56 ltrs/hr) (4*97 ltrs/hr)
37
 BOILER CHEMICAL DOSING LOCATIONS AND 38
BLOWDOWN LOCATIONS
CONDENSATE POLISHING UNIT (CPU)

MECHANICAL
DEAERATOR
MB-A MB-B MB-C

CPU OUTLET

AMMONIA (NH3) DEAERATOR

OUTLET
HYDRAZINE (N2H4)

BOILER DRUM
AMMONIA:
Ammonia is a pH booster. At high pH (9-10) boiler corrosion
is very less. But ammonia is a corrosive for yellow metals
(copper).

HYDRAZINE:
TRI SODIUM CONTINUOUS BLOW
Hydrazine Hydrate is an oxygen scavenger. Which avoids
PHOSPHATE DOWN (CBD)
serious corrosion problems. After mechanical deaeration, the
remaining dissolved oxygen (DO) was removed by hydrazine. (Na3PO4)
BCP SUCTION HEADER
PHOSPHATE:
Tri-Sodium Phosphate (TSP) is used to prevent scales in
boiler. TSP reacts with hard scale forming ions and convert
BOTTOM RING HEADER
them into loose precipitates, which were drained through
boiler blow down.
PERIODIC BLOW
Ammonia and Hydrazine are Volatile matters. They present in both water and steam, but phosphate is non-volatile matter, it can't DOWN (PBD)
distribute into steam. So it present only in water.
Ammonia and Hydrazine both are removed in Condensate Polishing Unit along with other impurities. That’s why dosing of Ammonia
and Hydrazine are required continuously.
38
 39

OTHER AREAS

39
From Sewage Water SANITARY SEWAGE TREATMENT PLANT (SSTP) 40
Pump House

ANAEROBIC TANKS CONTACT OXIDATION TANKS SEDIMENTATION TANKS

SLUDGE TANK

Mechanical Grid

Sewage Pumps
(2*25 m3/hr)
SEWAGE WATER STORAGE
BASIN (350 m3) Sludge Terminal
Carry Away

ANAEROBIC TANKS CONTACT OXIDATION TANKS SEDIMENTATION TANKS

ROAD
GUARD
POND
SSTP

ROAD
DM PLANT
Root Blowers
(4*4.32 m3/min)

Domestic Water

Auto To Rain Water Piping

Chlorinated water Backwash
Filter
(50 m3)

Intermediate Water
Basin Pumps (2*50 m3)
Purified Water Basin
Pumps (2*50 m3)

Safety Shower CHLORINE DIOXIDE INTERMEDIATE WATER BASIN PURIFIED WATER BASIN 40
GENERATOR (2*400 g/hr) (150 m3) (300 m3)
 41

SEWAGE: Sewage is the term used for wastewater that often contains faeces, urine and laundry waste.

ANAEROBIC TANKS
• Aerobic, means in the presence of air (oxygen); while anaerobic means in the absence of air (oxygen). These
two terms are directly related to the type of bacteria or microorganisms that are involved in the degradation
of organic impurities in a given wastewater.
• Therefore, aerobic Waste Water Treatment Plant processes take place in the presence of air and utilize
those microorganisms (also called aerobes), which use free oxygen to assimilate organic impurities i.e.
convert them in to carbon dioxide, water and biomass.
• The anaerobic treatment processes, on other hand take place in the absence of air (free oxygen) by those
microorganisms (also called anaerobes) which do not require air (free oxygen) to assimilate organic
impurities. The final products of organic assimilation in anaerobic Waste Water Treatment Plant are methane
and carbon dioxide gas and biomass.

CONTACT OXIDATION TANKS

• Aeration in the oxidation tank is provided by aerators fitted with variable speed drives. Dissolved oxygen (DO)
concentrations in the oxidation tank are monitored and results in optimized nitrogen removal capabilities.
• Waste activated sludge and scum is withdrawn from the oxidation tank.

SEDIMENTATION TANKS
• Waste activated sludge is pumped from the oxidation tank to the anaerobic sludge tank. Bio-solids are further
stabilized using anaerobic sludge tanks.
• Supernatant (clear water on top) from the top of sedimentation tank collected in Intermediate water basin.

41
 42
STATOR COOLING WATER SYSTEM

The major cause of problems in stator cooling systems

has not been corrosion but, rather, deposit accumulation
in critical areas. These deposits are copper oxides
released from one area of the stator coolers and pH = 7.0
deposited in another. The amount of dissolved oxygen in pH = 8.0
the system, and particularly variations in that oxygen pH = 8.5
concentration, determines when copper oxides are
released.

Low Dissolved Oxygen Regime: Copper forms Cuprous

Oxide (Cu2O) under reducing conditions (less than 50
ppb).

High Dissolved Oxygen Regime: Copper forms Cupric

Oxide (CuO) when dissolved oxygen is high (grater than
2000 ppb).

Either of these oxides can be stable and create a passive

oxide layer on the channels in the stator bars. A slightly
alkaline pH increases the stability of the oxide layer.

Design: Dissolved Oxygen (DO) = >1100 ppb

Stator Cooling Water Demineralizer Resin Quantity: 360 litres
Anion Resin: 240 ltrs
Cation Resin: 120 ltrs
 43
HYDROGEN METHODOLOGY

Electrolyte Solution: Potassium Hydroxide (KOH) or Sodium Hydroxide (NaOH) – To ensure high efficiency , hydrogen purity is
24-30% and Vanadium Pentoxide (V2O5)-0.3-0.5% generally maintained above 98%.
Although hydrogen is 14 times more efficient than air
Working Principle :- in removing heat and is the lightest of all gases, there
The amount of hydrogen and oxygen formed are directly proportional to the can be major disadvantages if not used properly.
amount of DC current.
Hydrogen can be very explosive when mixed with air,
Each cell will produce 3.750 m3 standard H2 and 1.875 m3 of standard O2.
and it will lose efficiency when its purity decreases.
5.625 = 3.750 + 1.875 (Practical) Additionally, high moisture levels in the hydrogen can
H2O = H2 + O2 lead to generator component failure.
Concentration of Electrolyte = 30 % KOH
FLAMMABLE LIMIT:
1000 m3 = 666 m3 + 334 m3 (Theoretical) LOWER: 4%, UPPER: 74%
H2O = H2 + O2
Cathode = Hydrogen, Anode = Oxygen FREEZING POINT: -259.14⁰C
BOILING POINT: -252.87⁰C

Stator cooling water DEW POINT: “Dew Point” is defined as the temperature to
for Stator Cooling which a given volume of gas must be cooled at constant
pressure and constant water vapor content in order for
saturation to occur. If the gas is cooled further, some of
the moisture will condense.
DRY HYDROGEN DEW POINT: -80⁰C
MOIST HYDROGEN DEW POINT: 20⁰C
Usual industry standard is to achieve control at -20°C, or
lower.

Hydrogen Gas for

Rotor Cooling
 COAL WASTE WATER TREATMENT PLANT 44
Coal Yard
Chemical Dosing
Tanks (1 m3)
Membrane Filters
PAC
2 1 Shion (6 m3)

Unloading Pumps
By Gravity
CAUSTIC
(6 m3)

3 HYPO
(6 m3)
Submersible Pumps
(3*35 m3/hr)
Storage Tank Coal Yard
Root Blowers

FILTER Filtered Water In First Chamber: Coal dirty water enters into the first
Storage Tank chamber. Chemicals added to lower the turbidity (coal
Overflow Line particles) and smell (organic matter).
Service In Second Chamber: Coal particles are settle down
Membrane Filter slowly. The accumulated coal particles removed by the
help of mud bucket.
In Third Chamber: With the help of blowers, chemicals
are mixed thoroughly and maintain the coal particles in
washing suspended form for further filtration.

In Service: Submersible pumps feed the coal water into

the membrane filters from bottom side, where filtration
SHION
will be taken place from bottom to top. In the upper
Fine Thick chamber filter water collects by overflowing.
Coal Slurry In Washing: From bottom to top water recirculates
(drain) through submersible pumps. By touching the membrane
filters from bottom side and collects the fine dust
particles, the dirty water enters into shion, which filter
Thick Coal Slurry 3
the fine dust. 44
(drain)
 45

GENERAL DESCRIPTION OF
“THE IMPORTANT FILTRATION
SYSTEMS USING IN KMPCL”

45
 46
RIVER INTAKEWELL

46
 47
Front View Side View
Intake Well
Intake Well Pumps

Floating Objects Floating Objects

Mahanadi River Screenings

Screenings
Basantpur

Settled Objects
23.64 kms
Settled Objects

Seorinarayan Basantpur Seorinarayan Pamgarh

22.86 kms Total Number of 03 (2W,1S) 02(1W,1S) 04 (2W,2S)

Pumps 02(1W,1S)
Flow 3*2500 m3/hr 2*5000 m3/hr 4*6000 m3/hr
2*2500 m3/hr
Distance 23.64 kms 22.86 kms 14 kms
Pamgarh
Stock One month stock for
14.0 kms total six units

Reservoirs

47
 48

Bar & Travelling Screens

Screening is the first most step of filtration starting from River Intake well. Which filters, floating objects like trees,
fishes, algae, wood pieces, leaves, stones etc in river water. They are often placed on slight inclination. Which are
moving and cleaned continuously. Coarse screens (50 mm) followed by fine screens (25mm).
48
 49
RESERVOIRS

49
 50
Mahanadi River
155.5 mts 155.5 mts 295 mts

10 mts

3,00,000 m3 3,00,000 m3 6,00,000 m3

316.5 mts 1 2 3

Inter connection Gates

Top view
Raw water pump house
HRSCC
KMPCL have 3 reservoirs with the capacities of total 12 lacks .
(3 lacks + 3 lacks + 6 lacks) m3.

The main purpose of reservoirs are to maintain the water stock for 7-15 days and secondary is storage
of raw water.

Raw water storage : There is a noticeable improvement observed in water quality by retention of
water. On retention suspended solids in the water are pulled downwards by the means of gravity. After
some duration there is a reduction in turbidity, total suspended solids (TSS), pathogenic bacteria and
river algae, while at the same time not long enough to encourage other organisms to develop.

50
 Aeration These three methods are not using in KMPCL for PT Plant 51

Aeration requires only when high amount of dissolved gases are present in
water, generally in ground water. It is the cheapest method for removing excess
amount of dissolved gases & undesirable gases (volatile organic compounds)
from water. Dissolve metals like iron & manganese are oxidized and
precipitated out. In aeration gases are absorbed or liberated from water until
equilibrium is reached.

Greensand Filters

Water containing excessive amounts of iron and manganese can stain clothes,
discolor plumbing fixtures, and sometimes add a "rusty" taste and look to the water. In
general ground water contains iron & manganese in excess compare to river water.
Greensand filters are used to remove iron and manganese from water.

Oil skimmers

Oil skimmers are used to separate oil from water. In general oils/Grease are not
found in natural water, except if any contamination occures. Mostly effluent
water contains oily substances.
In KMPCL tank type oil skimmer is using for separate oil/water in FOPH.
51
 52

High Rate Solid Contact Clarifier

(HRSCC)

Turbidity Water Clear Water

Sludge 52
 53
Mechanical High Rate Solid Contact Clarifier (HRSCC)

Clarifiers removes turbidity, color, colloids and small particles. Clarifiers works on the principle of
Stoke’s law. Coagulants, flocculants and disinfectants are used to achieve the quality.
Negatively charged colloidal particles are removed by adsorption onto the surface of coagulant (PAC),
which eventually form floc by aggregation of the smaller particles.
In presence of polyelectrolyte (PAM),
these flocs form quicker and settle
Mechanical High Rate Solid Contact Clarifier (HRSCC)
down easily. The accumulated flocs
are than collected at the bottom of
Flocculent
the clarifier. The clear water collects
from the top of the clarifier.
Turbidity meter
Chlorine Analyzer

Static Mixer
Streaming
A streaming current (SC) meter is an Current
Detector (SCD)
instrument for measuring the charge
that exists on small, suspended
particles in liquid. A streaming
Transmitter

current meter (SCM) is the only Sludge Impeller or

Flow

online instrument that can be used Pond mixer, 11KW

Scraper 2.2 KW
to measure coagulated particle Chlorine
stability for the feedback control of
PAC

Supernatant water from Middle Pond

coagulant dosage. Raw water

Chlorination Booster Pump House

53
 Big & medium 54
sized particles are
naturally settled
down by gravity in
stagnant water. This
action takes place in
reservoirs.

Tiny charged
particles, repulse
each other and not
able to settle down
easily. For this we
required chemicals
to treat the water.
This action takes
place in the
clarifiers.

54
 55

Chlorination System

Chlorine is an disinfectant. It kills the micro

organisms like bacteria, algae etc and
improves the color, taste & smell of the water.
Chlorine oxidizes iron and manganese also.
Each chlorine tonner contains 900 kgs of
liquid chlorine out of 1600 kgs of total weight. Legionnella bacteria (found in cooling
Chlorine is a gas but in high pressure gaseous water, causes lung diseases in humans)

chlorine converts into liquid chlorine and vice- Sulfate Reducing

versa. Bacteria (SRB), causes
corrosion in cooling towers
From the tonner chlorine can be collected
in two ways, gaseous chlorine from the top
side and liquid chlorine from the bottom side.
Evaporators (heaters) are used to convert
liquid to gaseous form (80-84°C) for cooling
Algae (causes severe fouling
water treatment. in cooling towers)
55
 56

Radial flow Sludge Thickener:

Gravity thickening uses the natural tendency of higher-density solids to settle out of liquid to concentrate the
solids.
Thickening is the process by which solids are condensed to produce a concentrated solids product and a
relatively solids-free supernatant. Thickening wastewater solids reduces the volume of residuals, improves
operation, and reduces costs for subsequent storage, processing, transfer, end use, or disposal. For example,
thickening liquid-solids (slurry) from 3 to 6 percent will reduce the volume by 50 percent.

The diameter of each clarifier is 20 m & height is 5.6 m. Total 4 sets (3 working, 1 standby).

SLUDGE THICKENER
OVERVIEW 56
 57

Sludge Transfer Pump

Progressive Cavity Screw Pumps

Progressive cavity (PC) pumps are commonly referred to in industry as mono-
pumps, screw pumps, eccentric screw pumps or worm pumps. All are positive displacement
pumps.
The PC pump consists of two major components, a rotor and a stator. The rotor is
helix shaped, machined from either stainless steel, hard-coated carbon steel or hard-coated
stainless steel.
PC pump is recommended for highly viscous and/or shear-sensitive liquids and
sludge. Key industries for PC pumps are pulp and paper, wastewater and oil.

57
 58

Horizontal Solid Decanter

Centrifuge

58
 59

Decanter Centrifuge
Decanters are horizontal, solids-oriented, solid-wall scroll centrifuges.

Decanter centrifuges are normally based on horizontal separation technology and work
at slower speeds. An important application is dewatering of sludge in wastewater
treatment plants. Decanter centrifuges require a centrifugal force for the separation of the
solids from the liquid.

The Horizontal Decanting centrifuge (Decanter) has a vast field of applications in

various Processes where a liquid and a solid phase have to be continuously separated.

59
 60
Multi Grade Filters

60
 Quartz Sand
61

Anthracite

Sand

Sand Anthracite
Quartz Sand

Pebbles

Gravels
Gravels Pebbles

Filter Media

61
 62

Activated Carbon
Filters (ACF)

62
 Dual Media Filter (DMF) 63

3024 mm
Dual Media Filters are used to remove
turbidity and suspended solids from water.
2470 mm

Well operated Dual Media Filters are able to

Anthracite filter the water 15-20 microns. (Ex: size of
1200 mm

human hair is 50-100 microns).

Quartz Sand

Strainers
(HDPE) Activated Carbon Filter (ACF)

Activated Carbon Filters: Coconut shell activated carbon is

used to remove Free Residual Chlorine (FRC), organic ACF
matter, oil, grease, objectionable taste, odor and
color from water.
Particularly ACF is used to remove chlorine from water.
Chlorine effects the life of RO membranes and Resins. Activated
In general ACF is not recommended for RO plants. Carbon
ACF works on the principle of Adsorption. Sand

Strainers
(HDPE)
63
 64

Self Cleaning Auto Filters

64
 65

Self cleaning auto filters are placed before

UF as a Pre Ultra Filtration (UF). These filters are
designed based on Suction Scanner Technology.

AMIAD-Filtering process:
The water enters through the inlet pipe into
the coarse screen from outside in, and through
the fine screen from inside out. The "filtration
cake” accumulates on the fine screen surface
and causes head loss to develop.

Self-cleaning process:
The filter will start the self-cleaning process when the pressure
differential across the screen reaches a pre-set value or a
predetermined lapse of time.
Suction scanner, which rotates in a spiral movement while
removing the filtration cake from the screen, and expels it out
through the exhaust valve.

65
 66

66
 67

67
 68
Ultra Filtration

68
 69

Ultrafiltration (UF) is similar to RO and NF, but is defined as a crossflow process that does not reject ions. UF rejects solutes
above 1000 daltons (molecular weight).
UF removes larger organics, colloids, bacteria, and pyrogens while allowing most ions and small organics such as sucrose to
permeate the porous structure.

Membrane Name & Specifications: Norit XIGA (SXL-225 FSFC PVC)

XIGA Dead-End filtration, inside-out flow concept developed by Norit X-Flow. Membrane is polyethersulfone (PES) having free
surface flow collector (FSFC) internals with polyvinyl chloride (PVC) housing.
Each pressure vessel have four membranes likewise, total 22 pressure vessels per one UF skid.
69
 70

Micron Cartridge Filters (MCF)

Micron Cartridge Filters (MCF) are Pre RO filters placed before RO skid.

Cartridge filters are effective in the removal of moderate amounts of particles from liquids
in the size range of 50 to 0.035 microns.

Pleated Filter Cartridges A pleated cartridge is a “surface” type filter cartridge that is effective in removing diverse
sized particles in limited quantities.
Pleated cartridges will remove particles of its micron rating with good resistance to being “blinded” by larger particles.
Pleated filter cartridges are particularly effective on surface waters from streams and rivers.
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Reverse Osmosis

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 RO Reject RO Feed RO Permeate 72

Reverse osmosis is the

newest major method of
water purification and
one of the types of cross-
flow membrane filtration.

Reverse Osmosis is a
process which removes
both dissolved organics
and salts using a
mechanism different from
ion exchange and
activated carbon.

Membrane Name & Specifications: DOW FILMTEC BW30-400

High Rejection, High Surface Area Brackish Water RO elements with Cross flow filtration.
Membrane Type: Polyamide Thin-Film Composite (TFC) membranes.
Two Stage and Single Pass RO. Each RO Skid is having 34 pressure vessels (1st stage 22+ 2nd stage 12), each pressure vessel is
having 6 membranes. So total 204 membranes in one RO skid.
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 Service flow
73

MB

SAC SBA

Regeneration
HCL NaOH NaOH
Exhaust Resin
Acid Caustic Acid &Caustic
Regeneration Regeneration Regeneration

HCL
Fresh Resin
Cation Resin Anion Resin

Ion Exchange
Resin
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 74

• Ion exchange resins are synthetic organic polymers. Most commonly used resins are gel type polystyrene resins.
• Resin beads are insoluble in water and having the size of 0.3 mm - 1.2 mm. Optimum size is 0.6 mm.
• Resins are porous. It contents 45-55 % moisture. It swells after absorption of water. Gel type resins are once wet are
never allowed to dry otherwise, resin will be cracked.
• Cross-linking increases stability of resin but decreases the exchange rate.
• Temperature limit is ≤50⁰C.

• Cation exchange resins are two types, Strong Acid Cation exchange resins (SAC) and Weak Acid
Cation exchange resins(WAC).
• Cation Resin (SAC): Tulsion: T-42 H+. (Make: Thermax)
• Anion exchange resins are two types, Strong Base Anion exchange resins (SBA) and Weak Base
Anion exchange resins (WBA).
• Anion Resin (SBA): A-23 Cl-. (Make: Thermax)

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EASY TO DRAIN, BUT
DIFFICULT TO GAIN
(Water Treatment)

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