A PRESENTATION ON ELECTRICS,

INSTRUMENTATION & AUTOMATION OF

DEMINERALIZATION PLANT OF CAPACITY
3X89 CuM/Hr. AT TSL-KPO

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 Use of DM Plant
• The centralized DM plant will supply the DM
quality water to the following areas:

• In CPP-1 for Cycle Make up of Captive Power Plant.

• Coke Dry Quenching Steam Generator of Coke Oven Plant.
• Make-up for Process Stream Requirement to CDQ boilers
and CPP-1.
• Closed Loop Cooling System of Blast Furnace.

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 Plant Data of DM Plant
PLANT DETAILS:
1. Number of Streams Three + One Future
2. Number of Streams under Normal Operation Three + One Future
3. Design Capacity of each stream of DM system 143M3/Hr.
(DMF/ACF/SAC/SBA-I/SBA-II/MB)
4. Operating Time (DMF/ACF/SAC/SBA-I/SBA-II) 18 Hrs.
5. Operating Time (Mixed Bed) 126 Hrs.
6. Design Capacity of each stream of UF system 89 M3/Hr.
considering 267M3/Hr of DM water production
7. Operating Time of Ultra Filtration system 24 Hrs.
8. Recovery across Ultra Filtration system 93%
9. Net output between Regeneration per stream 2574 M3
(DMF/ACF/SAC/SBA-I/SBA-II)
10. Net output between Regeneration per stream 18018 M3
(Mixed Bed)

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 Design Water Analysis-Clarified Water
Sl. No. Parameter Unit Value
1 Aluminum as Al Mg/Lit 4.96
2 Bi-carbonate Alkalinity Mg/Lit 53.85
3 Calcium as CaCO3 Mg/Lit 58
4 Carbonate Alkalinity as CaCO3 Mg/Lit 56.08
5 Chloride as Cl Mg/Lit 30

6 Colloidal Silica Mg/Lit 0.84-16

7 Conductivity Micros/cm 300

8 Copper as Cu Mg/Lit 0.01

9 Dissolved Oxygen Mg/Lit 9.8

10 Fluorine as F Mg/Lit 0.67

11 Iron as Fe Mg/Lit 0.1

12 M alkalinity as CaCO3 Mg/Lit 75

13 Magnesium as CaCo3 Mg/Lit 24

14 Manganese as Mn Mg/Lit 0.13

15 Nitrates as NO3 Mg/Lit 8.92

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 Design Water Analysis-Clarified Water
Sl. No. Parameter Unit Value
16 pH at 25 Degree C 8.76

17 Potassium as K Mg/Lit 9.86

18 Reactive Silica as SiO2 Mg/Lit 79.09

19 Sodium as Na Mg/Lit 22

20 Sulphates as SO4 Mg/Lit 60

21 TDS Mg/Lit 180

22 Turbidity NTU 20

23 Zinc as Zn Mg/Lit 0.11

Note: The above parameter indicates the quality of clarified water, considered for design of DM Plant.

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 Treated Water Quality
Sl No. Outlet Parameter Unit Value
1 At DMF Outlet Turbidity NTU <2
2 At ACF Outlet Residual Chlorine ------- Not detectable
3 At SAC Outlet Sodium as CaCO3 ppm ≤1
Total Hardness -------- NIL
4 At Degasser Outlet Carbon dioxide as CO2 ppm ≤5
5 At SBA-II Outlet Reactive Sillica as SiO2 ppm 0.1
Carbon dioxide as CO2 Ppm Nil
Conductivity @ 25 deg C µS/cm ≤6
6 At MB outlet Conductivity @ 25 deg C µS/cm ≤0.1
pH ---------- 6.8-7.2
Reactive Sillica as SiO2 ppm ≤0.01
Total Hardness ppm NIL
Turbidity NTU ≤0.1
Chloride ppm NIL
Iron as Fe ppm NIL
TDS ppm <0.05
7 At UF outlet Colloidal Sillica as SiO2 ppm 0.0017
TOC ppm 0.05

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Water Balance Diagram-DM Plant

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 Various units DM Plant
2. DM Plant 4. Activated
1. Clarified Water 3. Dual Media
Supply Pumps Carbon Filter
Storage Tank Filter (3W)
(3W+2S) (3W)

8. Strong Base 7. Degassed 5. Strong Acidic

Anion Stage – I 6. Degasser
Water Storage Cation Exchanger
(3W) Tower (3W)
Tank (3W) (3W)

9. Strong Base
10. Mixed Bed 12. UF Feed
Anion Stage – II 11. UF Feed Tank UF Feed Tank
(3W) Pump (3W+2S)
(3W)

13. Pre UF Strainer

14. De-mineralized
and Ultra Filtration
Water
System (3W)

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1. Clarified Water Storage Tank
Purpose:
 The main purpose of Clarified Water Storage Tank is to store
the Clarified Water being supplied from Raw Water Treatment
Plant for further de-mineralization process.

Construction Features:
1.It is a RCC structure of 20.35 M(L)X14.05 M (B)X 4.8 M (D) with
a storage capacity of 1000 CuM of clarified water.

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1. Clarified Water Storage Tank (Pictorial View)

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 1. Clarified Water Storage Tank- Instruments
Sl.
SSl Instrument Details Pictorial Purpose and Description
No.
1. It will indicate the water level of clarified
water storage tank.
Float and Board Type
2. It operates on float technique which is
Level Indicator,
connected to a pointer through a rope via a
Make: V. Automat &
1 Instruments (P) Ltd.,
set of pulleys. The pointer glides over a
calibrated gauge board, positioned parallel to
Indicating Range: 5 mtr.
tank. The pointer is in “TOP “ position when
Least count: 5mm
tank is empty and at “BOTTOM” position
when tank is full.

1. ULT is used to provide the clarified water level

in RCC tank to OWS. If the level of water is low
low , it will initiate trip command for DM plant
Ultrasonic Level supply pumps.
Transmitter SMART with 2. ULT is mounted on top of RCC tank and
Local indication, transmits the ultrasonic pulse at speed of
2
Make: Siemens, sound down the tank which is reflected back
Model no: 7ML5221- to transmitter from liquid surface. Transducer
2BA11-ZY15 measures the time delay between transmitted
and received echo signal. Level is calculated
by instrument using formula: Level= (Velocity
of sound X Time)/2.

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 2. DM Plant Supply Pumps (3W+2S)
Purpose:
 DM plant supply pumps is used to transfer the clarified water from CWST to Dual
Media Filter (DMF).
 There are total 5 nos. of DM Plant Supply Pumps , three in working and two in stand by.

Major Features:
1. DM Plant Supply pumps are Horizontal Centrifugal type of capacity 171 CuM/hr each
and Head 50 MLC. Other details are as below:
Make: Mather & Platt, Model No.: ET ISO NO.26, Stage: Single, Speed: 1470 RPM,
Lubrication: Grease Based, Efficiency at duty point: 72%, Wt. of bare pump: 270 KG.

2. To provide the mechanical input power to these pumps Low voltage (415 Volt) induction
motor has been used. Details of the same are as below:
Make: Bharat Bijlee Limited, Motor KW: 45 KW, Pole: 4, Mounting: B3,
Frame Size: 250M, Full Load Speed: 1470 RPM, Full Load Current (FLC): 77.2 Amp.

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2. DM Plant Supply Pumps (Pictorial View)

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 3. Dual Media Filter (DMF)
Purpose:
 The basic purpose of Dual Media Filter is to filter the turbidity associated with Clarified
Water i.e. 20 NTU (Nephelometric Turbidity Unit) as per design analysis to <2 NTU.
 For each stream of DM Plant, there is individual Dual Media Filter vessel.
Major Features:
1. Dual Media Filter vessel is having a dimension of 4.1 Mtr. Dia X 2.1 Mtr. HOS (Height of
Straight). At the bottom of vessel concreting of ratio 1:3:6 of cement, sand and
aggregates respectively is done.
2. Above that there is homogeneous layer of media of different sizes and quality which are
as follows:
At the bottom, 100 mm depth of 40-25 pebbles,
above that , 75 mm depth of 20-12 mm pebbles,
then , 75 mm depth of 12-6 mm pebbles,
75 mm depth of 10-3 mm pebbles,
75 mm depth of 6-2 mm of crushed gravel,
300 mm depth of Filtering Sand 16/32,
350 mm depth of Anthracite 0.8-2.3 mm
3. The tare weight of vessel exclusive of concrete is 8610 Kg and inclusive of concrete is
39630 Kg.

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3. Dual Media Filter (Pictorial View)

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Dual Media Filter - Valve Description
Sl. Valve Valve Function
No. Tag Details

1 VA1 Service This is a pneumatic valve

Inlet through which clarified water
will enter the vessel.
2 VA2 Service A pneumatic valve, filtered
Outlet water will come out through this
valve and will go to ACF and
Filtered Water Tank.
3 VA3 Backwash During backwashing of DMF,
Inlet potable water will enter via this
valve.
4 VA4 Backwash
Outlet

5 VA6 Rinse
Outlet

6 VA11 Air Inlet

7 VA12 Air
Release

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Dual Media Filter- Manual Operation

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Capacity of D

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FRONT VIEW OF METERING PANEL

33 kV Incomer 33 kV
Cubicle from Outgoing
tapping point feeder
cubicle

1400

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SIDE VIEW OF METERING PANEL

1900

1350

1600

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BASE FRAME OF METERING PANEL FABRICATED AT SITE

500 33 kV Incomer
cable 33 kV Outgoing
cable

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 NOTES ON METERING PANEL

1. All dimensions indicated in previous slides are in mm.

2. Width and depth of cable trench in metering room is 800 mm and 800 mm
respectively.
3. Increasing the width of cable trench we can avoid the need of base frame.
4. Provision of lighting is also to be done in metering room.
5. Earthing is also required to be done for metering panel.

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THANK YOU

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