UNITED CEMENT INDUSTRIAL COMPANY (5000t/d)

PROJECT TRAINING

Water & Fire-fighting System

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 Contents

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 Ⅰ Design principle for water & fire fighting system

1. Flow sheet for water & fire fighting system

2. Raw water treatment system

3. Process water system

4. Potable water system

5. Fire fighting system

6. Waste water treatment system

7. Water pipe routing

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 1. Flow sheet for water & fire fighting system

Circulation cooling water flow

9834.3m3/d
Make-up water for circulation water system
49.2m3/d

Consumption of spraying water

540.0m3/d
(219.8m3/d is from treated waste water)

Consumption of potable water

300.0m3/d

Consumption of process water for power plant

100.0m3/d

Make-up water for fire fighting Max.

325.0m3/d
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Raw water requirement
 2. Raw water treatment system

a. Raw water tanks

 7×2000m3
 Every tank can independently work through long rod valve
 Every tank can be cleaned independently through movable submersible pump

b. Raw water treatment

 Raw water quality ‘approximate to seawater & brine’
TDS 14000mg/L, Total hardness 8400mg/L
 Treatment process

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  Treatment capacity
• Product water flow: 60m3/h, 1440m3/d.
• recovery of RO: 50%.
• ratio of desalinization: ≥98%.
• Product water quality: TDS ＜ 500mg/L, Total hardness (as CaCO3) ＜ 200mg/L, PH=7-
8.

c. Treated water tank

1000m3
Two pumps, one use, one standby. Run in power frequency.
Pump draws water from this water tank and supplies water to all water tanks (including
potable water tank, fire fighting water tank, spray water tank, circulation cold water
tank, circulation warm water tank, fire fighting water tank for HFO tanks). The pump
will start and supply water When water level of whichever tank reaches replenishing
water level (starting pump water level) . The pump will stop when water levels of all
tanks reach max. water level.

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 3. Process water system

a. Circulation cooling water system

One circulation water tank, cold. 500m3
Three pumps, two use, one standby. Run in power frequency.
Pumps draw water from this cold water tank and supply cold water to the equipment
which are required cooling water. Temperature of the cold water go up and cold water
became warm water after cold water exchange heat with equipment. Warm water flow into
circulation warm water tank in residual pressure.
Set one auto-cleaning filter in rising water pipe of pumps group in order to keep water
cleaning.
Dosing NaCLO into the cold water tank in order to prevent breeding bacteria and alga.
Dosing water quality stabilizer into the cold water tank in order to prevent scale
formation.

One circulation water tank, warm. 500m3

Three pumps, two use, one standby. Run in power frequency.
Pumps draw water from this warm water tank and supply warm water to heat exchanger
in chiller station. Temperature of the warm water go down and warm water became cool
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 water after warm water exchange heat with chilled water. cool water flow into circulation
cold water tank in residual pressure.
 Set one auto-cleaning filter in rising water pipe of pumps group in order to keep water
cleaning.
 Dosing NaCLO into the warm water tank in order to prevent breeding bacteria and alga.
 Dosing water quality stabilizer into the cold water tank in order to prevent scale formation.

b. Spraying water system

One spraying water tank, 500m3
Two pumps, one use, one standby. One pressure vessel. Pump Runs in frequency conversion &
constant pressure.
 Pumps draw water from this water tank and supply water to water tanks which are in the
spraying water location. Pump runs uninterruptedly in 24 hours.
 Dosing NaCLO into the spraying water tank in order to prevent breeding bacteria and alga.

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 4. Potable water system

One potable water tank, 500m3

Three pumps, one use or two use or three use. One pressure vessel. Pumps Run in
frequency conversion & constant pressure.
Pumps draw water from this water tank and supply potable water to all use points in
cement plant & power plant and colony & housing. Pumps run uninterruptedly in 24
hours.
Dosing NaCLO into the potable water tank in order to prevent breeding bacteria and
alga.

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 5. Fire fighting system

a. Fire fighting water system for the whole plant

One fire fighting water tank, divided into two, every one can independently work,
2×500m3.
Two diesel engine driven fire pumps, one use, one standby. Two jockey pumps, one use,
one standby. One pressure vessel.
Loop pipe net for supplying water to indoor & outdoor hydrants.
Workshops installed indoor hydrant ‘cement packing, central laboratory, fire brigade’.
Pumps draw water from this water tank and supply fire fighting water to all use points
in the whole plant. Jockey pump runs uninterruptedly in normal times in 24 hours and
keep pressure of fire fighting pipe net at 13bar. Fire fighting main pump – diesel pump
will start when the pressure goes down to 11.5bar or fire alarm appears.
Dosing NaCLO into the fire fighting water tank in order to prevent breeding bacteria
and alga.

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 b. Fire fighting system for HFO & diesel oil tanks
One fire fighting water tank, divided into two, every one can independently work,
2×730m3.
Three diesel engine driven fire pumps, two use, one standby. Two jockey pumps, one use,
one standby. One pressure vessel. One foam tank. Ten foam monitors. Ten foam
hydrants. Ten water hydrants. Two foam chambers for every oil tank. Two flame
detectors for every oil tank. Wrapping temperature sensitive cable around every oil tank.
Loop water pipe for supplying water to water hydrants and sprinklers.
Loop foam pipe for supplying foam to foam hydrants.
Pumps draw water from this water tank and supply fire fighting water to water hydrants
& sprinklers and the foam tank. Jockey pump runs uninterruptedly in normal times in 24
hours and keep pressure of fire fighting pipe net at 11bar. Fire fighting main pump –
diesel pump will start when the pressure goes down to 9.5bar or fire alarm appears.
Dosing NaCLO into the fire fighting water tank in order to prevent breeding bacteria
and alga.

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 c. IG541 Gas (inergen) fire fighting system for CCR
 IG541 agent is a mixture of three naturally occurring gases: Nitrogen(52%),
Argon(40%) and Carbon dioxide(8%). IG541 agent extinguishes fire by lowering the
oxygen content below 15% and above 10%, and it does no harm to people.
 The min. design concentration shall be higher than 1.3 times of extinguishing
concentration at the min. temperature. The actual extinguishing concentration shall be
less than 52% at the max. temperature. The design temperature of the system is 20℃, the
ambient temperature is 0~50℃.
 The design concentration shall achieve 95% during 48 to 60 seconds after extinguishing.
The concentration of agent must be maintained for a substantial period of time, 10
minutes is adopted for electrical equipment.
 The system shall be provided with automatic, manual and mechanical emergency
actuation.
 The volume of cylinder is 80L, the storage pressure is 15MPa. The total of cylinders 80.
 Design concentration 37.5%.

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 d. fire fighting system for ER
Portable carbon dioxide extinguisher be used for electric control cabinets in ER.
Portable dry-power extinguisher be used for cable floor in ER.

e. fire fighting system for fuel station

Setting up portable dry-power extinguisher and wheeled foam extinguisher in fuel tank
area and fuel dispenser area. Setting up automatic foam extinguisher above fuel
dispenser.

f. Other fire fighting facilities

Setting up portable dry-power extinguisher in all workshops and building except ER.
Setting up one water-foam fire engine in fire brigade (fire engine is supplied by UCIC).

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 6. Waste water treatment system

a. Waste water of RO system & Overflow of raw water tank

Overflow of raw water tank high saltness.
Waste water of RO system high saltness.
This waste water will be drained out of the plant through rain gutter.

b. Other waste water from the whole plant and colony

Waste water quality high COD, BOD, NH3-N, SS. Many bacteria.
All waste water will be collected and carried to sewage treatment through sewage pipe.
Treated water through sewage treatment will be used for spraying water system of the
plant.

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 Treatment process

Treatment capacity
• capacity: 20m3/h, 480m3/d.
• treated water quality:
turbidity(NTU) ≤3
TDS ≤1500mg/L
BOD5 ≤10mg/L
NH3-N ≤10mg/L

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7. Water pipe routing

a. Pipe category
 cooling water supply & return pipe (XJ &XH)
 spray water pipe (SJ)
 potable water pipe (J)
 fire fighting water pipe (XF)
 reclaimed water pipe (ZJ)
 sewage pipe (W)

b. Pipe material
 Pressure flow pipe (XJ, XH, SJ, J, XF, ZJ, W) ： Steel wire reinforced thermoplastics
(PE) composite pipe
 Gravity flow pipe (W) ： Metal reinforced polyethylene (PE) spiral corrugated pipe

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 c. Pipe laying method
All pipes are directly buried underground.

d. Fire hydrant & valve

 Setting up one fire hydrant every 90 meters beside the main roads. Setting up one valve
in the inlet of every fire hydrant.
 For all pressure flow pipe, setting up valves before pipe entering buildings.

e. Valve well & sewage inspection well & septic tank

 All valves in the outdoor pipelines are installed in valve wells.
 Setting up one sewage inspection well every 30~40 meters in sewage pipeline.
 Setting up septic tanks in suitable location of sewage pipeline for intercepting and
digesting excrement.

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 Ⅱ Control & operation for main equipment
1. Control for main equipment
 Raw water treatment
All raw water treatment equipment in raw water treatment workshop automatically run
through control system of equipment itself. All kinds of working parameters, breakdown
signal and alarm signal is transmitted to CCR. All kinds of chemicals would be mixed
manually.
The raw water treatment system automatically starting or stopping is according to water
level of desalting water tank (treated water tank in combined pumping station workshop).
At the same time, the system starting or stopping is related to water level of raw water
tank.
 Combined pumping station
All pumps (including process water pumps, potable water pumps, fire fighting pumps and
replenishing water pumps) are controlled by CCR. All kinds of working parameters
(such as water level, pressure, flow, etc.) breakdown signal and alarm signal is
transmitted CCR. Chemicals dosed into water tanks would be mixed manually.
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 Starting pump is permitted only when water level of water tank is higher than starting
pump level. Automatically stopping pump when water level reaches the minimum level.
Fire fighting system for oil tanks
Foam monitor, foam hydrant and water hydrant will be operated manually. All other
equipment (including fire pumps, jockey pumps, foam tank, foam chambers, spray
nozzles, and etc.) automatically run through control system of equipment itself. All kinds
of working parameters, breakdown signal and alarm signal is transmitted to CCR.
Sewage treatment
All sewage treatment equipment in sewage treatment workshop automatically run through
control system of equipment itself. All kinds of working parameters, breakdown signal and
alarm signal is transmitted to CCR. All kinds of chemicals would be mixed manually.
Spray pumping station for limestone crushing
Starting or stopping spray pump for unloading pit is through driver manually operating the
control push-button.

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 2. Operation for main equipment

 Raw water treatment

Open all normally open manual valves, close all normally closed manual valves, turn control
buttons of all equipment to automatic state, then press the starting button of raw water
treatment system, raw water treatment system will automatically run according to set
procedure. Chemical cleaning online is required to operate by manual (manually start and
shop pump, and manually open and close valves). Chemical cleaning once online every
1~3 months. Normally, replace RO membranes once every three years, replace filter
media once every year.
 Combined pumping station
Starting or stopping of every pump group is controlled by operator in CCR. Before starting
pump, check manual valves whether they are in the set state, check water level of water
tank whether it reaches starting pump level. Every pump in pump group alternately runs,
working pump exchanges with standby pump once every one month. For main fire
pumps, in order to check their performance and keep them in good state, test running
once every month, duration 15 minutes every times.
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  Fire fighting system for oil tanks
When main control cabinet receives fire alarm signal (from flame detector or temperature
sense cable or manual alarm box) or pipe pressure goes down to set value, main fire pumps
will automatically start. For main fire pumps, in order to check their performance and
keep them in good state, test running once every month, duration 15 minutes every
times. Foam monitor and foam hydrant and water hydrant need be operated manually at
fire fighting. Replace foam concentrate at regular intervals according to quality
guarantee period.
 Sewage treatment
Hoist submerged pumps and check guide rail and pumps once every month. Replace filter
media once every year, replace ultrafiltration membrane once every three years. Carry
away greasy dirt and sludge cakes at regular intervals.
 Spray pumping station for limestone crushing
Starting or stopping spray pump for unloading pit is through driver manually operating the
control push-button.

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 Ⅲ Matters need attention in commissioning

1. It’s necessary to thoroughly clean water tank and piping system.

2. Check the valves on circulating cooling water pipes, to see whether it can work
normally. All valves should be able to open and close completely.
3. Check circulation pumps and constant pumps, to see whether it can meet the
requirement of design. The working pressure of single pump should be close to the
designed pressure, virtual flow should be close to the designed flow. If there is a big
difference between the working condition and the design, the pumps need repair.
Check the spray pump, fans and spray nozzles of closed cooling tower, if some of
them can not normally run, please repair or change. Check water tank of closed
cooling tower, ensure it does not leak and electronic level meter normally run.

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 4. Check the pressure gauges and thermometers in workshops. If damaged, they should
be repaired or changed according to design.
5. After completing the above work, it’s necessary to debug the circulating cooling
water system over the whole plant. Because of the different distance from the
circulating water pump room to different workshops, the inlet pressure of workshops
is different. Turn down the inlet valve of the workshops which are near to the pump
room, and open wide the inlet valve of the workshops which are distant from the
pump room, ensure cooling water flow of every equipment reach to design flow.
6. Check water meters, pressure gauges, thermometers and temperature rise of the
equipment at the same time of adjusting the valves, in order to ensure the equipment
in normal operation.

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 7. Debug all raw treatment equipment, including instrument, meter, valves, motors,
tanks, pipes and so on.
8. Debug all chemical dosing devices and chemicals.
9. Absolutely remove the packing of RO & UF membrane before installation, ensure full
of water in membrane housings after installation.
10. Trained personnel shall be needed to manage raw water treatment and circulating
cooling water system. All debugged valves should be marked and nobody could be
permitted to adjust the valves. Monitor the working condition of all equipment and
instrument constantly in the central control room. In case abnormal condition occur,
response and repair in time. Check of the equipments and pipes of raw water treatment
and circulating cooling water system regularly, and properly handle any discovered
problem.

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 姓名 Name: Xiong Zhongliang
电话 Tel:+86-22-26915256
邮箱 E-mail: [email protected]

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