Detailed Operating Procedures for Chemical Water Treatment

4.3 Operation of the activated carbon filter 4.3.1 Starting up the activated carbon filter a. Open the main clean water valve for the new system, or the connection valve between the new and old systems. b. Open the main water inlet valve of the activated carbon filter, as well as the exhaust and water inlet valves. c. After water begins to flow out of the exhaust valve, open the normal washing drain valve, close the exhaust valve, and perform normal washing on the activated carbon filter. d. Adjust the opening degree of the inlet valve so that the cleaning intensity is 1~1.5 L/m2·s (or the cleaning flow rate is 40~50 t/h). e. If the wastewater from the forward washing stage is colorless and transparent with a turbidity of 100 μg/L, and if the SiO2 concentration in the effluent from the anion exchange bed is >100 μg/L or the conductivity is >5 μs/cm, then it is determined that this bed has failed. f. In the event of a failure of the exchanger, it should be taken out of service immediately, and a backup bed should be activated; water of substandard quality must not be fed into the desalination tank. At the same time, the water quality in the desalination tank should be tested (the test parameters include Na+, SiO2, and conductivity); if the water quality exceeds the specified limits, it must be discharged and shall not be fed into the boiler. g. Once the anion bed in the old system fails, it should be regenerated immediately and not left stored. h. During operation, the water levels in the intermediate water tank and the desalination water tank must be closely monitored; the output of the relevant equipment should be adjusted accordingly based on the water levels in these tanks, in order to prevent overflow or water shortage. i. Half an hour after the restarted suspended equipment, a comprehensive analysis of the water quality from each switch should be carried out using the standard analysis methods, to prevent any deterioration in the water quality due to potential failures during the period when the equipment was not in use. 4.4.4 Regeneration of ion exchangers 4.4.4.1 Preparations before regeneration a. Check that the acid and alkali systems are in operational condition, and that there is sufficient amount of acid and alkali solutions. b. Check that the inlet and outlet valves of the bed to be regenerated are properly closed. c. Check the valves for feeding regenerant fluid to each operating or standby bed; the valves for feeding compressed air should be tightly closed. d. Other equipment was operating normally before regeneration, and there was sufficient desalinated water for regeneration. e. Check the regeneration system and compressed air system to confirm that the conditions for regeneration are met. f. Close the water inlet valve of the online continuous monitoring instruments for the regenerative bed. 4.4.4.2 Regeneration Operation 4.4.4.2.1 Cation bed regeneration operation Sequence Regeneration procedure Operating method Key points Operational technical requirements 1 Light backwash a. Open the drain valve for cation bed backwash, and slowly open the inlet valve for light backwash. b. Adjust the opening degrees of the small backwash inlet and outlet valves so that the small backwash flow rate for the anion exchange resins in the old system is 30~50 t/h, and that for the new system it is 40~80 t/h. c. Once the backwash drain water is clear, close the small backwash inlet valve and the backwash drain valve, allowing the resin to settle naturally. a. The small backwash inlet valve should not be opened too quickly or too forcefully. b. The backwash flow rate should be sufficient to fully loosen the fat layer. c. The backwash flow rate should be well controlled, such that the backwash wastewater does not carry away the resin containing normal particles. d. A minor backwash should be performed before a major backwash. e. The short backwash time is generally 15 minutes. The broken resin and debris in the fat suppression layer have been thoroughly rinsed away, and the rinse water is clear and transparent. 2 Release water: a. Open the exhaust valves of the anion bed. b. Open the middle drain valve. c. When no water flows out of the intermediate drain valve, close the exhaust valve and the intermediate drain valve. a. After a minor backwash, water should not be released immediately; the resin should be allowed to settle naturally for 5–10 minutes to ensure that the surface of the resin in the fat-pressure layer is flat. Keep the pressure-sensitive resin in an anhydrous state. 3 Top pressure a. Open the air outlet valve of the air storage tank. b. Open the air supply valve at the top of the anode bed, and supply compressed air from the top of the anode bed to maintain the air pressure at 0.03~0.05 MPa. a. The top pressure should be applied before acid is introduced. b. The backpressure air pressure should be maintained stably at 0.03~0.05 MPa, and must not be lower than 0.03 MPa; otherwise, the resin layers will become disordered when acid is introduced. The maximum backpressure air pressure shall not exceed 0.07 MPa, otherwise it will be difficult for the acid solution to enter the anion exchange bed. c. During the processes of top pressure application, pre-injection, acid introduction, and backwashing, the air pressure must remain stable, and the air supply must not be interrupted. a. The gas supply pressure should be stabilized at 0.4~0.5 MPa. b. Maintain the air pressure inside the anion bed at 0.03~0.05 MPa. 4 Pre-injection a: Open the acid inlet valve and the intermediate drain valve of the anion bed. b. Open the water inlet valve of the acid injector (for new systems, first open the main valve for the demineralized water used for regeneration); slowly open the water inlet valve of the rotameter, and close the pressure relief valve. c. Adjusting the regeneration flow rate: the flow rate for the anion exchange resins in the old system was 17 t/h, while it is 30 t/h in the new system; pre-injection is carried out. d. Open the sampling door of the new system acid concentration meter and start the meter in operation. a. The inlet valve of the rotor flowmeter should be opened slowly; it must not be opened too quickly or forcefully. b. The injector flow rate should be stable. c. The flow rate of the injector must not exceed the water discharge volume from the anion exchange bed. d. The middle row of doors should be fully open to ensure smooth drainage, with no back pressure. If drainage is poor, it will cause the resin layers to become disordered. e. The water level inside the bed should remain stable, with no upward or downward fluctuations. There should be no disturbance in the resin inside the bed. f. The fat suppression layer above the middle row should remain dry and must not be filled with water. The values from b to f above should be maintained until the backwashing is completed. a. Controlling and stabilizing the regeneration flow rate: 17 t/h for the anion exchange resins in the old system, 30 t/h for those in the new system. b. The resin does not layer up randomly. c. No large resin particles shall flow out from the middle discharge. d. The water vapor and water mixture discharged from the middle is uniform, with no turbulence. 5. Add acid: a. Open the outlet door of the acid metering tank and the inlet door of the acid injector. b. Adjust the concentration of the regenerated acid solution to 3% (1.9 Bˊe). a. Acid should be added only after the head pressure and flow rate have stabilized for 2–3 minutes. b. The regeneration flow rate and acid concentration should be checked and adjusted at all times. c. The liquid level under the metering tank must not go to zero; no air should be allowed to enter the resin layer. a. The concentration of the regenerated acid solution is maintained at around 3% (1.9 Bˊe). b. The acid feed volume to the cation exchanger in the old system is 100 cm, while it is 165 cm in the new system. 6 Backwashing a. After the acid has been fed in, close the outlet door of the acid metering tank as well as the inlet door of the injector for acid. b. With the positions of the other valves unchanged, reverse flow cleaning is carried out while maintaining the original injector flow rate and head pressure. c. After backwashing until the acidity of the discharged water is < 10 mmol/L, close the inlet valve of the ejector and the inlet valve of the rotameter (for new systems, close the main valve for the regeneration brine); also close the acid inlet valve for the anion exchange bed, the overhead pressure air valve, and the intermediate drain valve. d. Open the pressure relief valve of the rotameter. e. Close the sampling door of the new system’s acid concentration meter and stop its operation. a. The injector maintains its original flow rate, and the back pressure remains at its original level. b. After backwashing is successful, the injector should be stopped first, followed by the overhead pressure air; the order cannot be reversed to avoid layer disruption. c. The backwashing time is generally 30 to 40 minutes. The acidity of the water discharged from the anion exchange bed is < 10 mmol/L. 7 Minor Cleaning a. Open the exhaust valve of the anion bed to release the pressure inside the regenerator. b. Open the water inlet valve of the bed; once water starts to flow out from the exhaust valve, open the middle drain valve and close the exhaust valve. c. Adjust the opening degree of the inlet valve for the filter or regenerator bed to achieve an appropriate flow rate for the minor backwash, continuing the process until no residual acid regeneration liquid is present in the effluent. a. A minor backwash should be performed only after the air in the bed has been completely exhausted. b. The short cleaning time is about 20 minutes. c. Small backwash flow rate: 50–70 t/h for the anion exchange resins in the old system, 80–100 t/h for those in the new system; no residual acid in the water discharged from the middle stage. 8. Backwash: a. After the small backwash is complete, open the backwash drain valve and close the middle drain valve, then proceed to the large backwash. b. Adjust the opening degrees of the inlet and outlet valves so that the flow rate during backwashing is: 60–80 t/h for the anion exchange resins in the old system, and 80–120 t/h for those in the new system. c. After backwashing is complete, close the inlet valve and the backwashing outlet valve to put the anion exchange resins into standby mode; or open the outlet valve and close the backwashing outlet valve to put the resins back into operation. a. If, after more than 1 hour of normal washing, the water quality still does not meet the requirements, it can be determined that regeneration has failed, and regeneration must be carried out again (a minor backwash step may not be necessary). b. If the anion bed has been drained for maintenance or other reasons, the backwashing should be carried out slowly with a low flow rate of water; once the bed is filled with water, then a higher flow rate can be used for backwashing, in order to avoid damaging the middle drain device. Discharged Na+ ≤ 100μg/L 4.4.4.2.2 Anion bed regeneration procedures Sequence Regeneration process Operation method Key points Operational requirements 1 Light backwash a. Open the drain valve for anion bed backwash, and slowly open the inlet valve for light backwash. b. Adjust the opening degrees of the small backwash inlet and outlet valves so that the flow rate for small backwashing is: 40~70 t/h for the anion exchange resins in the old system, and 40~80 t/h for those in the new system. c. Once the backwash wastewater becomes clear, close the small backwash inlet valve and the backwash outlet valve, allowing the resin to settle naturally. a. The small backwash inlet valve should not be opened too forcefully or too quickly. b. The backwash flow rate should be sufficient to fully loosen the fat layer. c. The backwash flow rate should be well controlled, such that the backwash wastewater does not carry away the resin containing normal particles. d. A minor backwash should be performed before a major backwash. e. The short backwash time is generally 15 minutes. The broken resin and debris in the fat suppression layer have been thoroughly rinsed away, and the rinse water is clear and transparent. 2 Release water: a. Open the exhaust valves of the anion bed. b. Open the middle drain valve. c. When no water flows out of the intermediate drain valve, close the exhaust valve and the intermediate drain valve. After a minor backwash, water should not be released immediately; instead, the resin should be allowed to settle naturally for 5–10 minutes to ensure that the surface of the resin in the fat-pressure layer is flat. Keep the pressure-sensitive resin in an anhydrous state. 3 Top pressure a. Open the air outlet valve of the air storage tank. b. Open the top pressure air valve of the anode bed, and supply compressed air from the top of the anode bed to maintain the air pressure at 0.03~0.05 MPa. d. The top pressure should be applied before adding the alkali. e. The backpressure air pressure should be maintained stably at 0.03~0.05 MPa, and must not be lower than 0.03 MPa; otherwise, the resin layers will become disordered when the alkali solution is introduced. The backpressure air pressure shall not exceed 0.07 MPa, otherwise it will be difficult for the alkali to enter the anion exchange bed. f. During top pressure application, pre-injection, alkali injection, and backwashing, the air pressure must remain stable, and the air supply must not be interrupted. c. The air supply pressure should be stabilized at 0.4~0.5 MPa. d. Maintain the air pressure inside the anion bed at 0.03~0.05 MPa. 4 Pre-injection a: Open the alkali inlet valve and the intermediate drainage valve of the anion bed. b. Open the water inlet valve of the alkali injector (for new systems, open the main valve for regenerated demineralized water first), slowly open the water inlet valve of the rotameter, and close the pressure relief valve. c. Adjusting the regeneration flow rate: The anion bed in the old system has a capacity of 27 t/h, while that in the new system is 32 t/h; pre-injection is carried out. d. Open the sampling door of the new system alkali concentration meter and start the meter in operation. a. The inlet valve of the rotor flowmeter should be opened slowly; it must not be opened too quickly or forcefully. b. The injector flow rate should be stable. c. The flow rate of the injector must not exceed the water discharge volume from the anion bed. d. The middle row of doors should be fully open to ensure smooth drainage, with no back pressure. If drainage is poor, it will cause the resin layers to become disordered. e. The water level inside the bed should remain stable, with no upward or downward fluctuations. There should be no disturbance in the resin inside the bed. f. The fat suppression layer above the middle row should remain dry and must not be filled with water. The values from b to f above should be maintained until the backwashing is completed. a. Controlling and stabilizing the regeneration flow rate: 27 t/h for the anion bed in the old system, 32 t/h for the anion bed in the new system. b. The resin does not layer up randomly. c. No large resin particles shall flow out from the middle discharge. d. The water vapor and water mixture discharged from the middle is uniform, with no turbulence. 5 Add alkali: a. Open the outlet door of the alkali metering tank and the inlet door of the alkali injector. b. Adjust the concentration of the regenerated alkali solution to 2.5% (3.7 Bˊe). a. Wait 2–3 minutes for the head pressure and flow rate to stabilize before adding the alkali. b. The regeneration flow rate and alkali concentration should be checked and adjusted at all times. c. The liquid level under the metering tank must not go to zero; no air should be allowed to enter the resin layer. a. The concentration of the regenerated alkali solution is maintained at around 2.5% (3.7 Bˊe). b. The alkali feed amount for the old anion exchange bed is 80 cm, while it is 110 cm for the anion exchange bed in the new system. 6 Backwashing a. After adding the alkali, close the outlet door of the metering tank and the alkali inlet door of the injector. b. With the positions of the other valves unchanged, reverse flow cleaning is carried out while maintaining the original injector flow rate and head pressure. c. After backwashing until the alkalinity of the discharged water is < 10 mmol/L and the conductivity is < 100 μs/cm, the backwashing is completed; the inlet valve for the injector and the inlet valve of the rotameter are closed (in the new system, the main valve for the regeneration brine is also closed), as well as the valve for feeding alkali to the anion exchange bed, the valve for supplying pressurized air, and the intermediate drainage valve. d. Open the pressure relief valve of the rotameter. e. Close the sampling door of the new system’s alkali concentration meter to stop its operation. a. The injector maintains its original flow rate, and the back pressure remains at its original level. b. After backwashing is successful, the injector should be stopped first, followed by the overhead pressure air; the order cannot be reversed to avoid layer disruption. c. The backwashing time is generally 30 to 40 minutes. The alkalinity of the water discharged from the anion exchange bed is < 10 mmol/L. Conductivity < 100μs/cm: 7 minutes of positive flushing. a. Open the exhaust valve of the anion bed to release pressure from within the reactor. b. Open the water inlet valve of the anaerobic bed; once water starts to flow out from the exhaust valve, open the middle drain valve and close the exhaust valve. c. Adjust the flow rate for a light backwash until no residual alkaline regeneration solution is present in the effluent. a. A minor backwash should be performed only after the air in the bed has been completely exhausted. b. Adjust the flow rate of water leaving the anion bed to be equal to that of water entering the cathion bed, and adjust the opening degrees of the inlet and outlet valves of the intermediate water pump in the old system (the intermediate water pump in the new system operates via frequency control) to maintain a stable water level in the intermediate water tank. c. The short wash time is about 20 minutes. d. Small backwash flow rate: 50–70 t/h for the anion bed in the old system, 60–80 t/h for the anion bed in the new system; no residual alkali in the water discharged from the middle stage. 8. Backwash: a. After the small backwash is complete, open the backwash drain valve and close the middle drain valve, then proceed to large backwash. b. Adjust the normal washing flow rate to: 70–100 t/h for the anion bed in the old system, and 80–120 t/h for the anion bed in the new system. c. After the normal washing is complete, close the water inlet valve and the washing drain valve, putting the anion bed into standby mode; or open the water outlet valve and close the washing drain valve to put the anion bed back into operation. a. If, after more than 1 hour of normal washing, the water quality still does not meet the requirements, it can be determined that regeneration has failed, and regeneration must be carried out again (a minor backwash step may not be necessary). b. If the anion bed has been drained for maintenance or other reasons, the backwashing should be carried out slowly with a low flow rate of water; once the bed is filled with water, then backwashing can be done at a higher flow rate to avoid damaging the middle drain device. c. During the light cleaning and normal cleaning phases, samples of the effluent from the cation exchange resin bed should be taken every 20 minutes for analysis, in order to prevent failures in the cation exchange resin bed from affecting the regeneration process of the anion exchange resin bed. Discharged water: SiO2 ≤ 100μg/L, conductivity ≤ 5μs/cm

4.4.4.3 Large backwash operation of cation and anion exchangers: a. When the exchanger has been in operation for 10 cycles or when the pressure difference across the resin is too high (large backwash should also be considered if the effluent water becomes too turbid during regular small backwashes of the cation bed), large backwash must be carried out before regeneration； b. A minor backwash should be carried out before a major backwash; the purpose of this is to loosen the resin layer and remove any suspended particles from it, so as to prevent the compacted resin from being suddenly displaced and damaging the middle drainage mechanism. It also helps to stop dirt such as sediment from the resin layer from flowing back into the lower layers of resin, thereby reducing the time required for the major backwash ； c. Before starting the heavy backwash, open the exhaust valve of the exchanger and the drain valve for normal washing, and drain the water in the bed to the 1/2 level indicated by the sight glass. Then slowly open the backwash air valve and supply compressed air from the bottom of the resin layer; after the resin layer has loosened over 3–5 minutes, close the backwash air valve and open the backwash drain valve. Once all the air in the bed has been drained, close the exhaust valve. d. Heavy backwashing operation: Slowly open the inlet valve for heavy backwashing (open it by 1/2 turn at a time, then pause for 2–3 minutes). Once the resin layer becomes loose, gradually increase the backwashing flow rate, until an appropriate level is reached. The goal is to keep the resin layer at about 1/2 of the height indicated on the sight glass, with the condition that the backwash water does not displace the resin. Backwash until the effluent is colorless and transparent, with no broken resin or suspended solids present. e. After the large-scale backwashing is completed, close the inlet valve for large-scale backwashing and the drainage valve for backwashing, and allow the resin to settle naturally for 5–10 minutes to maintain a flat surface of the resin in the bed. f. After the large-scale backwash, carry out regeneration following the normal procedures; the amount of regenerating solution used should be 1.5 to 2.0 times the normal amount – that is, 150 cm³ of hydrochloric acid for the cation exchangers in the old system, and 250 cm³ for those in the new system; 120 cm³ of alkali for the anion exchangers in the old system, and 180 cm³ for those in the new system. g. During the large-scale backwash of the exchangers, operators must not leave the site and must closely monitor to ensure that no resin leaks out with the water from the backwash process. 4.4.4.4 Precautions for regeneration operation: a. During pre-injection, regeneration fluid injection, and backwashing, the backpressure should be maintained at 0.03~0.05 MPa ； b. It is prohibited to increase the head pressure by closing the intermediate drain valves ； c. During the regeneration process, it is necessary to monitor the quality of the water exiting the operating bed, in order to prevent the regeneration liquid from leaking into the operating bed due to improper operations or poorly sealed valves. If the acidity of the water exiting the cation exchange bed or the conductivity of the water exiting the anion exchange bed suddenly increases, it indicates that there is a leak in the valve allowing regenerant to enter the operating bed or a leak in the valve allowing water to exit the regenerating bed. In such cases, regeneration should be stopped immediately for maintenance purposes. d. It is necessary to regularly check the rotameter, the liquid level in the metering tank, and the readings of the pH meter. If backflow due to a malfunction in the ejector causes the liquid level in the metering tank to rise, the outlet valve of the metering tank should be closed immediately; after identifying the cause, appropriate action should be taken. 4.5 Operation of the compressed air system 4.5.1 Under normal conditions, the compressed air used for water treatment is obtained directly from the air compressor room in the boiler; the system schematic is as follows: In standby mode: Valves 02, 03, and 04 are open ； Valves 01, 05, 06 are closed. The operation method is as follows: 1. As shown in the diagram, open boiler gas supply valve 01, and also open the drain valve at the bottom of the separator 03 and the drain valve at the bottom of the gas storage tank 04 to remove the water from the separator and the gas storage tank; once all the water has been removed, close these two valves. 2. Open the corresponding air valve for the old and new systems, 05 or 06, to carry out filter backwashing and regeneration of the anion and cation beds. 3. After the gas is used up, close the boiler gas supply valve 01, and open the drain valve at the bottom of the separator 03 as well as the drain valve at the bottom of the gas storage tank 04, to return it to a standby state. 4.5.2 When the air supply is interrupted due to the shutdown or failure of the boiler air compressor, it can be obtained by starting an auxiliary oil-free lubricated air compressor. The operation of the air compression system is as follows: 4.5.2.1 Process flow: Air → Air filter → Air compressor → Aftercooler → Separator → Air storage tank 4.5.2.2 Checks before startup a. Ensure that there is sufficient lubricating oil; the oil level in the tank should reach half of the indicated level (above the oil filter). Inject an adequate amount of oil into the friction surfaces of the drive components inside the crankcase, as well as into the crosshead and bearing shells. The lubricating oil should be of the HJ-50 grade specified in GB443-64; other grades of oil that meet the requirements can also be used as substitutes. Lubricants of different grades must not be mixed together. b. Check that the device connectors are secure and there is no looseness. c. The valves and pipes of each pressure gauge should be open, and the oil pressure gauge, air pressure gauge, ammeter, alarm devices, etc. should be complete and accurate. d. Open the drain valves of the intercooler, aftercooler, separator, air tank, etc. Drain the water until there is none left, then turn it off. e. Check that the following valves should be open: the exhaust valve of the aftercooler, the intake valve of the separator, and the valve on the pipeline from the air tank to the pressure regulator. f. Check that there is sufficient cooling water, that all water pipes are unobstructed, and that the cooling water pressure and flow rate are normal. g. When manually rotating the compressor flywheel, there should be no abnormalities such as sticking or rubbing. h. Check whether the electrical system is functioning properly. i. Ensure that the area around the compressor is clean and free of debris. 4.5.2.3 Starting of the air compressor: a. Open the inlet and outlet valves for cooling water; the cooling water flow must be unobstructed. b. After the power is turned on, the oil pressure indicated by the oil pressure gauge should be above 0.15 MPa. The compressor should operate with normal sounds, without any knocking or noise, and no other abnormalities present, before it can be put into operation. 4.5.2.4 Maintenance and management during compressor operation a. Always keep the oil level in the oil tank of the compressor within the specified range. b. Continuously monitor and check the readings of the pressure gauges as well as the temperatures in various locations; these values should be within the following ranges: b.1 For primary pressure gauges: 0.2 MPa, with a maximum of not more than 0.22 MPa and a minimum of not less than 0.18 MPa. b.2 Secondary pressure gauge: Used for pressures not exceeding 0.7 MPa. b.3 Oil pressure gauge: 0.15~0.25MPa, with a minimum of not less than 0.1MPa. b.4 The exhaust temperature at all stages shall not exceed 160°C (when the exhaust temperature at stage 1 is ≤ 40°C). b.5 The oil temperature in the engine’s oil sump shall not exceed 60°C. b.6 The cooling water discharge temperature generally does not exceed 40°C. c. When the air compressor is running continuously, the intercooler, aftercooler, and separator should have their water drained every 4 hours, while the air storage tank should have its water drained every 8 hours. In humid weather, the frequency of hydrophobic treatment should be increased appropriately. d. The air filter should be kept clean; on the 1st of each month, the filter element should be removed by the day shift, washed with 10% hot soda water, and then rinsed thoroughly with hot water. e. Pay attention to whether the sound of the machine is normal, and check if the intake valve cover is overheating. f. The cooling water must not be intermittent or contain bubbles. g. Pressure regulators and safety valves should be sensitive and reliable, and tested regularly. 4.5.2.5 The machine shall be stopped immediately under the following conditions: a) When the temperature readings of the compressor exceed the specified values, or when the pressure gauge readings are outside the specified range and fluctuate irregularly. b. The compressor has severe air leakage, or there is water leakage from the cylinders or cooler. c. In the event of a sudden interruption in the cooling water supply, the inlet valve should be closed immediately after stopping the machine, to prevent cooling water from entering the hot cylinders. Cooling water can be supplied again only after the cylinders have cooled down on their own, at which point the machine can be restarted. d. The compressor or motor emits abnormal noises. e. The ammeter reading suddenly increases (indicating a sudden increase in the motor load). 4.5.2.6 Shutdown of the air compressor: a. Close the unloading valve to keep the air compressor running without load (this step may be skipped in emergency situations). b. Turn off the power supply to stop the air compressor from operating. c. Close the cooling water inlet valve and drain the cooling water from all channels; this step is not necessary for a temporary shutdown. d. Drain the residual condensate from the intermediate cooler, aftercooler, and separator. 4.5.2.7 Fault Handling for Air Compressors Serial Number Fault Type Possible Causes Resolution Methods 1 Insufficient compressor discharge volume or pressure drop a. Leakage due to improper installation of the intake and exhaust valves. b. The piston ring is crushed in the piston groove due to improper clearance selection. c. The piston rings are severely worn. d. The valve discs and spring plates of the intake and exhaust valves are damaged or have lost their elasticity. e. The consumption of compressed gas is greater than the volume of gas delivered by the compressor. a. Reinstall and temper the gasket. b. Readjust the gap. c. Replace the piston rings. d. Replace the valve disc or spring plate. e. Re-select. 2 Low oil pressure: a. The oil pump’s return valve is malfunctioning, causing oil to flow back into the aircraft’s oil tank. b. The oil level in the engine compartment is too low, so the oil pump cannot draw in oil. c. Oil suction pipe is leaking. d. The filter screen of the oil filter box or oil filter is clogged. e. The oil pump pipeline is blocked or damaged. f. The connections in the oil pipeline are not tight. g. Wear of the oil pump gears, with excessive axial clearance. h. Excessive friction in the frictional parts of the motion mechanism (such as the bearing shells at the ends of the connecting rods) leads to an increased gap and excessive oil leakage. a. Inspect the return valve or spring. b. Fill to the specified height. c. Check and eliminate. d. Cleaning. e. Inspection and repair. f. Tighten the nut or add a gasket. g. Inspect and adjust the clearance. h. Maintenance. 3 The piston comes into contact with or collides with the cylinder. a. The support ring is excessively worn and loses its supporting function. b. The piston rod is loose in connection with the crosshead, or the piston rod is loose in connection with the piston. c. Missing guide ring. a. Replace the support ring. b. Adjust or tighten the fixation. c. Install the guide ring. 4 The compressor makes abnormal noises. a. A hard metal piece has fallen between the piston and the cylinder block or cylinder seat. b. The piston rod and piston are loose. c. The rod pin rubs against the inner top of the crosshead. d. The connection between the piston rod and the crosshead is loose. e. The intake and exhaust valves are loose. f. There is water remaining in the cylinder. g. Wear of the connecting rod bushing, excessive clearance, or loose connecting rod bolts. h. The gap between the crosshead and the fuselage slide is too large. i. The journal ellipticity is too large. a. Inspect, eliminate, replace. b. Tighten the nut. c. Eliminate friction. d. Tighten the nut. e. Install firmly. f. Drainage. g. Replace the bushing, adjust the clearance, and tighten the nut. h. Adjust the clearance. i. Reinstall. 5 The exhaust gases are impure, containing oil droplets; there is dirt at the oil-scraping rings and gaskets. b. The oil-scraping ring and piston rod are severely worn. c. Wear of the packing ring. a. Check and clear. b. Replace with a new ring, finely grind the piston rod, or replace it. c. Replace. 6 Failure or jamming of the safety valve, relief valve, and load regulator: a. Rust or contamination causing impaired operation. b. The spring force is too high. a. Remove rust and grind the sealing surface, then apply silicone oil to it. b. Adjust to meet the requirements. 7 Excessively high exhaust temperature a. Improper installation of the partition rings in the stuffing box. b. The tension spring of the stuffing box is too loose. c. The sealing surface of the stuffing box is severely worn. d. Poor contact between the packing box and the friction pair of the piston rod. a. Reinstall. b. Adjust the tension force. c. Replace the stuffing box. d. Adjust and modify the internal fitting of friction force. Excessively high temperature of the 8-axis bearing shells: a. The clearance between the bearing shells and the shaft is too small. b、 The lubricant viscosity is incorrect, the oil is dirty, or it has lost its functionality. c. Poor assembly, with inadequate contact surfaces. d. The bearing is fixed too loosely or too tightly. a. Adjust to an appropriate gap. b. Replace with new oil. c. Re-calibrate after inspection. d. Tighten to the appropriate level. 9 Safety valve leakage: a. The spring is not tightened properly or its elasticity has been lost. b. There are dirt and impurities between the valve plug and the valve seat. c. The seal surfaces between the valve plug and the valve seat are not tight. a. Adjust or replace with a new spring. b. Blowing and cleaning. c. Adjust or grind the sealing surface. 10 Bubbles in the cooling water discharge: a. The cooling tubes are not properly tightened to the tube sheet. b. The gasket between the cylinder head and the cylinder is damaged. c. The screws connecting the cylinder to the cylinder head are loose. a. Re-expand the tube. b. Replace the gasket. c. Tighten the nut. 11 Abnormal primary exhaust pressure: a. High primary exhaust pressure, due to a leak or damage in the secondary intake valve. b. The primary exhaust pressure is low due to leakage or damage in the primary intake and exhaust valves. a. Grind or replace the secondary air valve. b. Grind or replace the primary air valve. 12 The secondary exhaust pressure does not reach the specified value; the secondary exhaust valve has severe leakage or is damaged. Grind or replace the new air valve.

4.6 Operation of Acid-Base Systems 4.6.1 Operation of Acid Systems 4.6.1.1 Old Acid System a. System flow: Vacuum pump creates negative pressure → Acid tank in the vehicle → Low-level acid storage tank (20 m3) → Acid metering tank → Acid injector → Anion exchange resin bed b. Acid transfer: Insert the acid outlet hose from the vehicle’s acid tank into the inlet of the low-level acid storage tank (20 m3), open the valve on the vehicle’s acid tank, and allow the acid to flow automatically into the low-level acid storage tank (20 m3). c. Acid addition (adding acid to the metering tank): c.1 Open the water inlet valve of the acid mist absorber. c.2 Open the inlet valve of the vacuum pump to create a negative pressure in the acid metering tank, allowing the hydrochloric acid in the low-level acid storage tank (20 m3) to flow into the metering tank under atmospheric pressure. c.3 After acid extraction is complete, close the water inlet valve of the vacuum pump and the water inlet valve of the acid mist absorber. 4.6.1.2 New acid system a, System flow _______________________ Vacuum pump creates negative pressure ↓ | ↑ Car acid tank → Low-level acid discharge tank → Acid discharge pump → High-level acid storage tank → Acid metering tank → (2.5 m3) | ↑ Acid injector → Anion exchange resin bed b. Acid discharge: b.1 Insert the acid outlet hose from the car acid tank into the inlet of the low-level acid discharge tank (2.5 m3), open the valve on the car acid tank to allow the acid to flow into the low-level acid discharge tank (2.5 m3). b.2 Open the liquid discharge valve of the low-level acid storage tank (2.5 m3) as well as the inlet and outlet valves of the acid transfer pump, and open the acid inlet valve of the high-level acid storage tank. Once the liquid level in the low-level acid storage tank (2.5 m3) reaches above 100 cm, start the acid transfer pump to pump hydrochloric acid into the high-level acid storage tank. If the liquid level in the low-level acid unloading tank (2.5 m3) falls below 40 cm, the acid unloading pump should be stopped immediately, and it should be restarted only after the liquid level rises again. b.3 After the acid unloading is complete, stop the acid pump, close the inlet valve of the high-level acid storage tank, as well as the outlet valve of the low-level acid unloading tank (2.5 m3), and the inlet and outlet valves of the acid pump. b.4 Note: Before starting the acid discharge pump, it is necessary to first open the discharge valve of the low-level acid storage tank (2.5 m3), as well as the inlet and outlet valves of the acid discharge pump, and the inlet valve of the high-level acid storage tank. The acid discharge pump may be started only after the liquid level in the low-level acid storage tank (2.5 m3) reaches the required level. It is strictly prohibited to start the acid discharge pump with no load or under pressure. During the acid discharge process, close attention must be paid to the liquid level indicator in the low-level acid storage tank (2.5 m3); if the level drops below 40 cm, the acid discharge pump should be stopped immediately. It is also prohibited to allow the low-level acid storage tank (2.5 m3) to become empty or to operate the acid discharge pump with no load. Adding acid to the C acid metering tank: c.1 Gravity-fed acid addition: Open the outlet valve of the high-level acid storage tank and the inlet valve of the acid metering tank; also open the water inlet valve of the acid mist absorber in the metering tank, so that hydrochloric acid flows into the metering tank by gravity. c.2 Applying negative pressure to introduce acid: If the rate of acid introduction due to gravity is slow, the inlet valve of the vacuum pump in the acid metering tank can be opened to create a negative pressure in the tank, thereby allowing hydrochloric acid to enter more quickly. c.3 Acid pumping: If the acid injection rate using the above two methods is not satisfactory, an acid discharge pump can be used to increase the pressure of the acid solution. The procedure is as follows: first, close the vacuum water inlet valve and the acid inlet valve of the high-level acid storage tank. Then, open the drain outlet valve of the high-level acid storage tank as well as the connection valve between the high-level acid storage tank and the low-level acid discharge tank, so that the acid from the high-level acid storage tank can flow into the low-level acid discharge tank. Once the liquid level in the low-level acid discharge tank reaches above 100 cm, open the liquid outlet valve of this tank, the inlet valve of the acid pump, the outlet valve of the acid pump, and the connection valve between the acid pump and the metering tank. Start the acid discharge pump to push the hydrochloric acid into the metering tank. c.4 After acid addition is complete, turn off the relevant equipment and close all valves. 4.6.2 Operation of the alkali system 4.6.2.1 Process of the alkali system a. Old system: Truck-mounted alkali tank → Alkali transfer pump → High-level alkali storage tank → Alkali metering tank → Alkali injector → Anion exchange resin bed b. New system: ___________ Vacuum pump creates negative pressure ↓ | ↑ Truck-mounted alkali tank → Alkali transfer pump → High-level alkali storage tank → Alkali metering tank → Alkali injector → Anion exchange resin bed 4.6.2.2 Transferring alkali Connect the discharge hose from the truck-mounted alkali tank to the inlet pipe of the alkali transfer pump. First, open the inlet valve of the alkali transfer pump, as well as the discharge valve of the truck-mounted alkali tank and the inlet valve of the high-level alkali storage tank. Once the pipeline ahead of the alkali transfer pump’s inlet is filled with alkali solution, start the pump to pump the alkali directly into the high-level alkali storage tank. After the transfer is complete, stop the pump and close the inlet valve of the pump as well as the inlet valve of the high-level alkali storage tank. 4.6.2.3 Adding alkali to the alkali metering tank a – Old system: Open the outlet valve of the high-level alkali storage tank and the inlet valve of the alkali metering tank, allowing the alkali solution to flow into the metering tank by gravity; once the desired level is reached, close the outlet valve of the high-level alkali storage tank and the inlet valve of the alkali metering tank. b. New system: b.1 Gravity feeding of alkali: Open the inlet door of the alkali metering tank, the connection door between the high-level alkali storage tank and the metering tank, and the outlet door of the high-level alkali storage tank, so that the alkali solution can flow into the metering tank by gravity. b.2 Applying negative pressure to the alkali: If the rate at which alkali is fed by gravity is slow, the inlet valve of the vacuum pump in the alkali dosing tank can be opened to create a vacuum in that tank, thereby increasing the flow rate of the alkali solution. b.3 Pressurizing the alkali with a desalkalization pump: If the rate of alkali addition using the above two methods is not satisfactory, a desalkalization pump can be used to apply pressure to the alkali solution. The procedure is as follows: first, close the water inlet valve of the vacuum pump, the alkali outlet valve of the high-level alkali storage tank, and the connection valve between the high-level alkali storage tank and the metering tank. Then, open the sewage discharge valve of the high-level alkali storage tank, the connection valve between the high-level alkali storage tank and the alkali transfer pump, and the connection valve between the alkali transfer pump and the alkali metering tank. Start the alkali transfer pump to pump the alkali into the alkali metering tank. After the alkali addition is complete, stop the relevant equipment and close all valves. 4.6.3 Precautions for operating acid-base systems: a. When the acid (alkali) transport vehicle arrives, the water treatment duty personnel should check the relevant order sheet to understand the details, in order to prevent incorrect unloading of acid (alkali). Notify the day shift in the laboratory to take samples for testing; unloading of the acid (alkali) can only proceed if its quality meets the standards. b. Operators should wear the necessary protective equipment and have a backup water source for flushing. c. In the event of acid (alkali) leakage on the ground, storage tanks, or other equipment, it should be washed clean with water promptly. d. After the operation of the acid (alkali) system is completed, stop the acid (alkali) pump or vacuum pump, and close all relevant valves. However, the acid mist absorber should be kept in operation at all times; the water inlet valve should be opened wide when discharging acid, and kept closed under normal conditions. e. Acid (alkali) dumping operators are strictly prohibited from leaving the site to prevent acid (alkali) from spilling.

This post was last edited by Benbenxuan on 2009-10-19 at 10:35. 4.8 Explanation of the operation mode of the water treatment system 4.8.1 Desalination water tanks 4.8.1.1 The main operation involves tanks #1 and #2 for desalination; they are switched over during the weekday shift on Mondays. Before the switchover, use up all the water stored in the desalination water tanks 1# and 2# of the old system, and then fill them with water as a backup. 4.8.1.2 Under normal conditions, the water level in the backup desalination tank should be at the full mark, and the water level in the operating tank should be no less than 3m at the time of shift handover. 4.8.2 The main desalination water pumps are #2 and #3 desalination water pumps, which operate in a variable-frequency mode and are switched over once a week. To prevent pump #1 from becoming corroded due to prolonged idling, it is switched on during the last week of each month; after operating for one week, it is switched back to pump #2 or #3. 4.8.3 Desalination System 4.8.3.1 Under normal conditions, the old and new desalination systems operate independently of each other; the connection valves for the effluent from the filters, the cation exchange resins, and the anion exchange resins between the two systems are kept in a closed state. 4.8.3.2 Under normal conditions, after the new system operates continuously for three cycles in single column mode, the old system is switched in; then, each of the desalination units in the old system operates for one cycle before the new system is switched back in. 4.8.3.3 During the first two cycles of continuous operation of the new system, once the exchanger fails, it should be regenerated immediately without being stored; once regenerated, it shall be put into use. During the third cycle, if one exchanger fails, the entire system shuts down and the old system is brought online; the failed exchangers (including both the failed beds and those that have not failed) are regenerated during the day shift. 4.8.3.4 In the old system, the two columns of desalination equipment are used in rotation for one cycle; once one exchanger in either column fails, the old system is shut down. During operation of the old system, the anion bed was regenerated during the day shift, while the cation bed was regenerated during the current shift. 4.8.3.5 When the external steam supply is large or a large amount of water needs to be added in an emergency situation, the two desalination units in the old system can be combined into one unit for operation. This is done by connecting the three filters that are operated in series together, and placing this combined unit in parallel with the other two filters in series. Similarly, the two cation exchange resins, the two intermediate water pumps, and the two anion exchange resins are also operated in parallel. 4.8.3.6 When the old and new systems cannot operate independently due to equipment failures or other reasons, the relevant interconnection valves between the two systems can be opened to switch to a master control mode of operation. 5 Common System Failures and Solutions 5.1 Unacceptable System Performance Metrics 5.1.1 Deterioration of the quality of the water output Sequence Number Phenomena of water quality deterioration Possible causes Solutions 1 Excess turbidity in the water output from mechanical filters and activated carbon filters a. High turbidity of the incoming water. b. The filter layer is dirty. c. Insufficient filter media. a. Notify the water plant to adjust the equipment. b. Backwash filter. c. Add supplementary filter media. 2 The residual chlorine in the water exiting the activated carbon filter is above the standard; a. The residual chlorine in the incoming water is high. b. Activated carbon has become ineffective. c. Backwash door leakage. a. Reduce the water inflow volume and inform the water treatment plant to reduce chlorine addition. b. Replace or regenerate activated carbon. c. Inspect the backwash door. 3 The water output from the cation exchange resin bed has high hardness or a high Na+ level. a. There is a leak in the backwash valve of the cation exchange resin bed. b. Insufficient amount of acid added or incorrect acid concentration. c、 Poor quality of hydrochloric acid. d. Disorderly layering or deviation in regeneration. e. Failure of the regeneration system. f. Significant loss of cation resins. a. Check the backwash door and repair it properly. b. Increase the amount of acid added or adjust the acid concentration. c. Use qualified hydrochloric acid. d. Identify the cause and regenerate again. e. Inspect and maintain the regeneration system. f. Add cation resin. 4 Sudden increase in acidity of the water exiting the solar water heater: a. Regenerated acid solution has leaked in. b. The quality of the fresh water changes, with an increase in salt content. a. Close tightly the acid inlet valve for the operating cation bed and the outlet valve for the regenerated cation bed; if the valves fail, stop the regeneration process. b. Identify the reasons for changes in the quality of the clean water, and contact the water treatment plant to take action. 5 High CO2 content in the water entering the anaerobic tank: a. The carbon dioxide removal fan is shut down. b. The output of the carbon dioxide remover fan decreases. c. The drip pipe of the carbon dioxide remover has fallen off. d. The water inflow is too high. a. Check and restart after processing. b. Contact to service the internal devices. c. Contact to service the internal devices. d. Adjust the water inflow properly. 6 The conductivity of the water exiting the anion bed is high; a. The forward washing of the cation bed was not successful. b. Failure of the sunbed depth. c. Failure of the anion bed regeneration system. d. Leakage at the large backwash door of the anion bed. e. Regenerated alkali solution has leaked in. f. Loss of anionic resin. g. The anion resin is contaminated. a. Continue to wash the cation bed until it meets the standards; if it fails to do so, it is considered ineffective. b. Shut down the deactivated cation exchange resin bed. c. Maintain and regenerate the system. d. Inspect the large backwash door and repair it properly. e. Close tightly the alkali inlet valve of the operating bed and the effluent valve of the regeneration bed; if the valves fail, stop the regeneration process. f. Add supplementary anionic resin. g. Clean the anionic resin. 7 The SiO2 level in the effluent from the anoxic bed is not up to standard; a. The regeneration is incomplete. b、 The quality of the regenerated alkali solution is poor. c. Regeneration system failure. d. The quartz sand cushion in the anodic bed has a high SiO2 leaching rate. a. Regenerate again. b. Use qualified alkaline solution. c. Inspect and maintain the regeneration system. d. Test, clean, or replace the quartz sand cushion. 8 The water quality in the desalination tank is not up to standard: a. The water quality of the effluent from the anion exchange bed and cation exchange bed is not satisfactory. b. Failure of meters or expiration of medications leads to equipment failure going unnoticed in a timely manner. c. Raw water flows into the desalination tank. d. During the regeneration of the anion bed and cation bed, if the outlet valve is not closed properly or leaks, the acid and alkali regeneration fluids leak into the desalination water tank. e. Due to inadequate chemical monitoring, the cation and anion resins were not shut down in a timely manner after they failed. a. Handle it in accordance with the method mentioned in the previous paragraph. b. Repair the meters and replace the medications. c. Check the source of raw water and cut off the raw water supply. d. During regeneration, it is necessary to strengthen the inspection of the backwash valve, outlet valve, and connection valves of the exchanger to prevent acids and alkalis from leaking into the desalination water tank. e. Strengthen chemical monitoring, especially when the exchanger is approaching failure. f. Once it is detected that the water quality in the desalinated water tank has deteriorated, it should be removed promptly and replaced with qualified desalinated water. If some of the degraded demineralized water has already been fed into the boiler, enhanced monitoring of water and steam conditions should be carried out, along with appropriate treatment measures inside the boiler. 5.1.2 Reduced system output Serial Number Common faults Possible causes Solutions 1 Short operating cycle of the anion exchange resin, reduced exchange capacity a. Deterioration in the performance of the anion resin. b. Loss of cation resin. c. Fault in the solar water heater equipment. d. Improper regeneration operation. e. The quality of the regenerated acid solution is poor. a. Test the cation resin; revive or replace it. b. Add cation resin. c. Inspect the cation exchange resin equipment and repair it. d. Adjust the regeneration conditions. e. Purchase qualified recycled acid solution. 2 The operating cycle of the anion bed is short, resulting in a reduced exchange capacity; a) the performance of the anion bed resin deteriorates. b. The anion resin is contaminated by organic substances and iron. c. Fault in the anode bed equipment. d. Loss of anion resin. e. The efficiency of the carbon dioxide remover decreases. f. Improper regeneration operation or failure of the regeneration system. a. Test the anion resin; revive or replace it. b. Use appropriate chemical agents to revive, treat, or replace the anion resin. c. Eliminate anion bed failures. d. Add resin. e. Check the carbon dioxide remover packing and fan. f. Adjust the regeneration conditions and eliminate failures in the regeneration system. 5.1.3 Reduction in operational economic indicators, fault phenomena, possible causes, and solutions: High consumption of regenerant – a) Deterioration in resin performance. b、 The quality of the regenerant is poor. c. Resin loss. d. The regeneration distribution device inside the equipment is damaged. e. Improper regeneration operation. f. Significant changes in the quality of the incoming water. g. The resin layer is uneven, causing misalignment of the flow. a. Resin restoration or replacement. b. Use qualified regenerants. c. Add resin to identify and seal off the leakage path. d. Repair the distribution device. e. Improve the regeneration conditions. f. Analyze the quality of the incoming water and determine the regeneration ratio anew. g. Investigate the cause of the offset current and identify countermeasures.

Going directly from 4.6.3 to 4.8 – some parts are missing in between, and it hasn’t been posted completely yet. Thank you for your hard work, OP

I will keep adding more, but it’s really too long. My internet speed isn’t fast enough, so I can only post it in segments. Also, 5 questions can only be posted per section per day, so I’m sorry about that

5.2 Contamination of ion exchange resins Sequence Number Common contaminants Characteristics of contamination Preventive measures 1 Iron contamination of the resin a. The resin’s appearance turns dark brown; in severe cases, it becomes black. b. The exchange capacity decreases. c. Corrosion of equipment pipes. d. The quality of the regenerant is poor, with a high iron content. a. Reduce the iron content in the water fed into the solar bed. b. Acid-wash, soak, and clean the resin. c. Anti-corrosion treatment for equipment pipelines. d. Purchase qualified recycled reagents. 2 Oil contamination of resins: a) Decreased exchange capacity. b. The periodic water production volume decreases. a. Circulate NaOH solution to wash the resin. b. Clean the resin with an appropriate organic solvent. c. Clean using a combination of solvents and surfactants. 3 Contamination of the resin by silicon: a) Decreased exchange capacity. b. The SiO2 content in the effluent increases. a. The anion bed should be regenerated promptly once it becomes ineffective. b. Take measures to heat the regenerated alkaline solution to 35~40°C. c. Improve the parameters of the regeneration process. d. Resins severely contaminated with silicon can be cleaned by cyclic treatment with a hot 4% NaOH alkaline solution; if necessary, an appropriate amount of phosphate can be added. 4 Contamination of anionic resins by organic substances: a) The color of the resin darkens, changing from light yellow to dark brown and even black. b. The working exchange capacity of the resin decreases, and the cyclic water production volume drops. c. Organic acids leak into the effluent, increasing its conductivity. d. The pH of the effluent decreases. e. The SiO2 content in the effluent increases. f. Increased consumption of cleaning water. a. Improve the quality of the incoming water. b. Analyze the quality of the incoming water to identify the source of organic matter. c. Regenerate using high-quality NaOH regenerant. d. Improve the regeneration process by heating the alkali solution. e. Thoroughly clean the resin and carry out revival treatment. f. It is advisable to use water from an activated carbon filter as the inlet water for the solar water heater. 5.3 Equipment Failures and Handling Methods Equipment Name Fault Symptoms Possible Causes Handling Methods Mechanical filter Leaking of filter media into the effluent a. Damage to the effluent discharge device. b. Disordered layer in the quartz sand cushion. a. Check the water outlet device. b. Clean out for maintenance, then refill. Backwash drainage causes filter media to escape: a. The backwash water flow rate is too high or too intense. b. The pressure of the compressed air used for backwashing is too high. c. The filter layer is too dirty, resulting in local penetration during backwashing and excessive flow velocity. a. Stop backwashing, adjust the backwashing flow rate, and slowly open the valve. b. Adjust the compressed air pressure. c. Adjust the flow rate, backwash for sedimentation, and loosen the filter media. Activated carbon filter: Filter media leaks into the effluent. a. The water cap is loose or damaged. b. The bolts connecting the internal air pipes are loose. a. Tighten or replace the water cap. b. Tighten the bolts. Backwash drainage causes loss of filter media: a. The backwash water flow rate is too high or too intense. b. The pressure of the compressed air used for backwashing is too high. a. Stop backwashing, adjust the backwashing flow rate, and slowly open the valve. b. Adjust the compressed air pressure. In cation (anion) exchangers, during operation or backwashing, the resin leaks out; a) the quartz sand layer at the bottom becomes disordered. b. Fault of the bottom dome-shaped porous plate. Shut down for maintenance: Small (large) backwashing drainage or exhaust causes resin loss. a. The backwashing flow rate is too high or too intense. b. Resin caking, local penetration during backwashing, and excessive flow rate. a. Stop the backwashing process, wait for 15 minutes, then proceed with the operation again. Adjust the backwashing flow rate by gradually opening the valves. After performing heavy backwashing and allowing the resin to settle for 5 minutes, a 10-minute normal washing cycle is required before heavy backwashing can be carried out once more. b. During backwashing, care should be taken to adjust the flow rate, or compressed air should be introduced from the bottom of the exchanger to loosen the resin layer. Resin in the middle drainage channel a, or the middle drainage filter element or mesh pack is damaged. b. The flange bolts in the middle row are loose. c. Deformation and ring damage of the middle row device. Out of service for maintenance; large pressure difference between inlet and outlet water; a. Resin sedimentation. b. Resin fragmentation. c. The large backwash interval is too long. d. Fault in the bottom water distribution device. a. When the pressure difference exceeds 0.15 MPa, it fails; in such cases, a thorough backwash and regeneration are carried out. b. Perform a thorough backwash to wash out the broken resin. c. Perform a thorough backwash as specified. d. Notify for maintenance work. Carbon remover; water spraying at the exhaust port of the carbon remover; excessive fan airflow – adjust the opening degree of the fan’s inlet valve. Excessive fan vibration: a. Friction between the casing or air inlet and the impeller. b. The base stiffness is insufficient or not robust enough. c. Loose foundation bolts. d. There are foreign objects in the air intake filter. e. The impeller is loose or deformed, resulting in rotor imbalance. Shut down; contact the relevant parties for handling. In the acid-base system, during regeneration, acid and base cannot be added to the exchanger because a) the pressure at the top of the exchanger is high. b. The resistance of the middle row of pipe filters (filter elements) is high. c. Low water inlet pressure and flow rate of the injector. d. Jet failure. e. The valve for feeding regenerating liquid to the exchanger is not fully open. f. Fault in the acid-base valve or blockage of the acid-base pipe. g. The backup bed’s acid-base door was not closed properly. h. The resin buildup is too dense. a. Adjust the top pressure. b. Stop regeneration and perform a minor backwash. c. Adjust the flow rate. d. Notify for maintenance. e. Open the regeneration liquid inlet valve fully. f. Notify for maintenance. g. Ensure the door for bringing in acid or alkali for spare beds is tightly closed; if it cannot be closed properly, stop the regeneration process and contact maintenance. h. Perform a thorough backwash to loosen the resin. During regeneration, water flows back into metering tank A; the pressure inside the regeneration bed is too high, resulting in high backpressure. b. Jet failure. c. The acid/base inlet valve of the regenerator bed is damaged or not open. d. Leakage at the acid and alkali inlet door of the running bed. a. Adjust the top-pressure air pressure to: 0.03~0.05MPa. b. Contact maintenance for repairs. c. Open the acid and alkali inlet door; if it is damaged, contact maintenance. d. Identify leaks and notify maintenance for handling. Article 2: Regulations for Steam and Water Supervision 1 Introduction to Major Thermal Equipment and Steam-Water Flow Processes 1.1 Boiler Specifications Boiler No. Model Rated Evaporation Capacity (t/h) Superheated Steam Pressure (MPa) Superheated Steam Temperature (°C) Condensation Method Manufacturer Date of Commissioning Boiler No. 6 NG35-39/450 35 3.82 450 Mixed Hangzhou Boiler Factory December 1986 Boiler No. 7 B&WB130/3.82-M 130 3.82 450 Mixed Beijing Boiler Factory August 1988 Boiler No. 8 NG130/3.82-M 130 3.82 450 Surface-mounted Hangzhou Boiler Factory March 1989 Boiler No. 9 130/3.82-M 130 3.82 450 Surface-mounted Hangzhou Boiler Factory August 1992 Boiler No. 12 WGZ130/3.82-15 Type 130 3.82 150 Surface-mounted Wuhan Boiler Factory January 1999 1.2 Turbine Specifications Turbine No. Model Type Rated Power (KW) Inlet Steam Pressure (MPa) Inlet Steam Temperature (°C) Manufacturer Date of Commissioning Turbine No. 4 C3-35-10 Condensing type 3000 3.5 435 Qingdao Turbine Factory January 1986 Turbine No. 7 N12-35-1 Condensing type 12000 3.5 435 Nanjing Turbine Factory December 1986 Turbine No. 8 N25-35-1 Condensing type 25000 3.5 435 Wuhan Turbine Generator Factory January 1989 Turbine No. 9 N25-35-1 Condensing type 25000 3.5 435 Wuhan Turbine Generator Factory September 1988 Turbine No. 10 N25-35-1 Condensing type 25000 3.5 435 Nanjing Turbine Generator Factory July 1992 Turbine No. 11 N25-35-1 Condensing type 25000 3.5 435 Nanjing Turbine Generator Factory December 1992 1.3 Deaerators and Drain Tanks There are four deaerators in total across the plant; their operating pressure is 0.02 MPa and their operating temperature is 105°C. There are two drain tanks, used to collect the drain water from equipment and pipelines. 1.4 Vapor flow in thermal systems: The Jiangnan Power Plant uses a header system; make-up water, condensate, deaerated water, feedwater, and superheated steam are all connected through headers. The basic water vapor flow path is as follows: ┌----------------------－－┐ ↑ ↓ Chemically treated demineralized water → Demineralized water pump → Condenser → Low-pressure heater → Deaerator → Feedwater pump → High-pressure heater → Economizer → Steam drum → Superheater → Steam pipeline → Turbine → Condenser 2 Specifications for water treatment equipment in boilers 2.1 Specifications for chemical dosing pumps Serial number Name Mechanical components Motor Quantity (units) Manufacturer Model Flow rate Head Model Power KW Rotational speed r/min 1 Ammonia dosing pump for demineralized water 1DB-0.06/15 0.06 t/h 15 kgf/cm2 JO2-11-4 0.6 1380 2 Benxi Water Pump Factory 2 Ammonia dosing pump for feedwater MJA-0.1/60 60 L/h 2 Yixing Huayi Jinghuan Equipment Factory 3 Phosphate dosing pump 3DT-1/150 1 t/h 150 kgf/cm2 JO2-52-6 7.5 720 2 Baoji Water Pump Factory 2.2 Specifications for chemical dosing tanks Serial number Name Dimensions Φ×h (mm) Volume m3 Quantity (units) Remarks 1 Ammonia solution tank for demineralized water 1100×1050 1.0 2 Steel 2 Phosphate solution tank 600×900×900 0.49 1 Steel 3 Ammonia solution tank for feedwater 1.0 1 Plastic 2.3 Main laboratory instruments and meters Serial number Name Model specifications Quantity Manufacturer 1 721 spectrophotometer 721-100 6 Shanghai Third Analytical Instrument Factory 2 581-G photoelectric colorimeter 581-G 4 Shanghai Huaguang Instrument and Meter Factory 3 Precision pH meter PHS-3C 5 Shanghai Leici 4 Conductivity meter DDS-11A 5 Shanghai Leici 5 Digital sodium ion concentration meter DWS-51 5 Shanghai Leici

3 Water Vapor Sampling 3.1 Water Sample Containers The containers used to store water samples are called water sample containers (water sample bottles). Common water sample containers include colorless hard glass stoppered flasks and polyethylene bottles with lids. The former has advantages such as better corrosion resistance and ease of cleaning, but it should not be used to store water samples intended for the determination of glass-containing elements such as silicon, sodium, potassium, boron, and other trace elements ； The latter has high corrosion resistance, contains no heavy metals or inorganic components, and is lightweight and impact-resistant; it is the most commonly used container for water samples. However, since polyethylene bottles tend to absorb heavy metals, phosphates, organic substances, etc., they should be treated with a mixture of hydrochloric acid and hydrofluoric acid after being used for some time, and then reused after being rinsed thoroughly. The washing and use of all water sample containers shall comply with the provisions of relevant standards. 3.2 Water sample sampling device The device used to collect water samples is called a sampling device. The sampling devices for Furnaces 7#, 8#, and 9# are located in the sampling room next to the electrostatic precipitator of Furnace 9# ； Boiler No. 12 and the Changhai 220 t/h boiler are each equipped with a sampling system, which are located in the transmitter room of Boiler No. 12 and the sampling room inside the Changhai boiler, respectively. Except for the steam samples from Furnace No. 6, as well as the condensate water from the Jiangnan turbine and the cooling water from the Changhai generator, which require on-site sampling, all other steam and water samples can be collected in the chemical water control room of Furnace No. 12. 3.2.1 Commissioning of the sampling device: a. Open the main inlet valve for industrial water to the sampling frame, and open the inlet and outlet valves of the corresponding water sample cooler according to the operation status of the machine and boiler, to ensure smooth flow of the cooling water. b. For the full extraction sampling frame, open the primary and secondary valves as well as the drain valve; after draining for 5 minutes, open the pressure relief valve and the manual sampling valve, then close the drain valve. c. Adjust the secondary valve of the sampling frame, the pressure reducing valve, the manual sampling valve, and the water inlet valve of the cooler to ensure that the water sample flow rate is 500–700 ml/min and the water temperature is below 30°C. d. After the standby furnace has been operating stably for four hours, open the control valve of the online monitoring instrument to adjust the flow rate of the flow meter so that it meets the sampling requirements of the corresponding instrument, and then activate the operation of the instrument. 3.2.2 Shutdown of sampling devices: If the turbine and boiler unit orders a shutdown, the relevant sampling devices and instruments should be stopped from operating promptly. a. Connect the online monitoring instrument to the control valve and shut down the operation of the instrument. b. Close the primary and secondary valves of the sampling frame, as well as the pressure reducing valve; after 20 minutes, close the inlet valve of the cooler and reduce the flow rate at the main valve for industrial water used for cooling. If the cooling water inlet valve does not close properly, the cooling water outlet valve should be closed. 3.3 Requirements and precautions for water vapor sampling 3.3.1 Flushing of the sampling pipeline The sampling pipeline should be flushed at least once a week; before flushing, the online instruments must be disconnected, and flushing should continue until the water sample becomes clear and transparent. a. Each water sample pipeline should be flushed separately; it is strictly prohibited to leave the site after opening several valves at once. b. Before conducting a systematic inspection and sampling, the relevant sampling pipes should be flushed, with the flushing time being appropriately extended. c. After rinsing, adjust the flow rate of the water sample to 500–700 ml/min and keep the water temperature below 30°C; sampling should be conducted only after stability is achieved to ensure that the samples are sufficiently representative. d. Pipe flushing should be performed when starting up the furnace. If a blockage is detected in the sampling tube, it should be flushed promptly to keep the pipeline unobstructed. 3.3.2 Methods for collecting water vapor samples: a) The sampling bottle must be rinsed with the water sample to be collected at least three times before the sample can be collected (unless otherwise specified in the standards). b. Water supply, boiler water, and steam samples should, in principle, be kept in a continuous flow; when collecting other water samples, the water accumulated in the pipes must first be drained and the pipes flushed before sampling can take place. c. When measuring unstable components in water samples, sampling should generally be done on-site, with testing carried out immediately after sampling. Otherwise, preprocessing measures should be taken immediately after sampling to convert the unstable components into a stable state before sending them to the laboratory for analysis. d. The number of water samples collected should meet the requirements for testing and verification. Sample fluids that require analysis of multiple parameters should not be collected in multiple batches. 3.3.3 Precautions: a. The one-way valve on the sampling frame should not be opened and closed frequently; it should remain fully open during normal operation. The adjustment of water sample flow rate and water temperature should be carried out by operating the pressure reducing valve and the secondary valve. b. When opening the high-pressure valve on the switch sampling frame, one should stand to the side; the valve should be opened slowly, without opening it fully at once, to prevent burns from steam. c. The cooling water must not be interrupted during normal operation; the cooling water must be turned on first before the sampling device is put into use. If the cooling water supply is suddenly interrupted during operation, the sampling valve should be closed immediately, the online instrument should be shut down, and then the cause should be investigated. 4 Supervision of water and steam quality 4.1 Supervision items and quality standards for water and steam 4.1.1 Quality of water and steam during normal operation of the unit Name Supervision item Unit Quality standard Analysis frequency (hours/time) Remarks Steam Sodium μg/kg ≤15 4 When the quality of water and steam deteriorates, the analysis frequency should be increased or continuous monitoring should be carried out. Silica μg/kg ≤20 4 Iron μg/kg ≤20 Checked during daytime shifts Copper μg/kg ≤5 Checked during daytime shifts Water hardness μmol/L ≤2.0 4 Dissolved oxygen μg/L ≤15 4 Silica μg/L: It is necessary to ensure that the silica level in steam meets the standards. 4 pH (25°C): 8.8~9.2 4 Iron μg/L ≤50 Checked during daytime shifts Copper μg/L ≤10 Checked during daytime shifts Condensate water: Dissolved oxygen μg/L ≤50 4 Silica μg/L: It is necessary to ensure that the silica level in boiler water meets the standards. 4 Hardness μmol/L ≤2.0 4 Boiler water pH (25°C): 9.0~11.0 4 Phosphates mg/L: 5~15 4 Silica mg/L ≤3.0 4 Deionized water: Hardness μmol/L ≤5.0 Iron μg/L ≤50 4.1.2 Quality of water and steam when starting shut-down or standby units Name Monitoring items Unit Quality standards Analysis frequency (hours/time) Remarks Steam Silica μg/kg ≤80 Continuous monitoring The quality of steam after the boiler is started, or before steam is supplied to the turbine, must be controlled in accordance with these regulations; it should reach the standard values for normal operation within 8 hours. Sodium: μg/kg ≤50, monitored continuously; Conductivity (after hydrogen ion exchange, at 25°C): μs/cm ≤3.00, monitored continuously. Water supply hardness: μmol/L ≤10.0, monitored continuously. At the time the boiler is started, the quality of the water supply must meet these specifications, and it should reach the standard values for normal operation within 8 hours. Dissolved oxygen: μg/L ≤50; Iron: μg/L ≤150. Condensate water: Appearance – colorless and transparent. Continuous monitoring is required; the quality of condensate water begins to be monitored in accordance with these regulations once the unit starts operating. Hardness: μmol/L ≤10.0, to be monitored continuously. Silica: μg/L ≤80, to be monitored continuously. Iron: μg/L ≤80. Copper: μg/L ≤30. 4.2 Chemical monitoring during unit startup: 6 hours before the start of the turbine and boiler, the shift supervisor should inform the chemical treatment shift leader to make preparations for chemical monitoring. 4.2.1 Preparations before startup a. Check whether there is an adequate and qualified supply of demineralized water in the water treatment room. b. Check whether the lighting in the water vapor sampling room, chemical dosing room, and other sampling points is sufficient. c. The water vapor sampling device is intact and free of defects, with sufficient and unobstructed cooling water. d. Online monitoring chemical instruments, with laboratory instruments in good standby condition. e. The dosing pump ran successfully during the test, with sufficient lubricating oil and oil of qualified quality. f. The concentration and ratio of the chemical in the dosing tank are appropriate, with the liquid level above 2/3. g. Check the opening status of the devices and valves that are in communication with the main equipment, and keep records. h. There is an adequate supply of chemicals for water treatment inside the furnace (ammonia water, trisodium phosphate, dimethyloxime, etc.), and the reagents used for analysis are complete and of qualified quality. 4.2.2 Chemical supervision during boiler startup: a. Once the boiler has been successfully ignited, inform the boiler operator to open the sampling valves for feedwater, boiler water, saturated steam, superheated steam, as well as the valves for chemical dosing and continuous drainage in the drum. After the boiler operation is completed, open the cooling water valve of the sampling rack to flush each steam sampling pipeline. b. When the drum pressure rises to 0.49 MPa, phosphate dosing should be initiated; simultaneously, the PO43- content and pH value of the boiler water should be tested, and the dosage should be adjusted accordingly based on the test results. c. After the boiler is started, enhanced continuous and periodic drainage should be carried out to clarify the boiler water as quickly as possible. d. During the boiler pressure-raising process, analysis of the SiO2 content in the boiler water should be intensified, and the blowdown rate should be adjusted promptly. e. When SiO2 ≤ 80 μg/kg and Na ≤ 50 μg/kg in the superheated steam, inform the shift supervisor that it is permissible to start the turbine with steam injection. f. Once the boiler is operating properly, adjust the relevant valves on the sampling frame so that the water sample flow rate is between 500 and 700 ml/min, the water temperature remains below 30°C, and the flow rate stays stable; also install the appropriate online instruments. 4.2.3 Chemical monitoring during turbine startup: Once the turbine begins to spin up, thoroughly flush the sampling pipes and take samples of the condensate water at regular intervals to test its quality. The hardness should be ≤10.0 μmol/L, silicon dioxide levels should be ≤80 μg/L, and the condensate water should be colorless and transparent. Only when these conditions are met should the shift supervisor be informed to recover the condensate water; otherwise, it should be discharged into the drain. 4.3 Chemical supervision during unit operation 4.3.1 The quality of water and steam should be regularly monitored during unit operation. Upon discovering that the quality of the water vapor is unsatisfactory, the frequency of analysis should be increased, relevant personnel should be contacted, and the branch office and shift supervisor should be informed; the cause must be identified promptly, measures taken to restore normal conditions as soon as possible. 4.3.2 Based on the analysis of the feedwater quality, adjust the ammonia addition amount in a timely manner to maintain the feedwater pH between 8.8 and 9.2 ； When the dissolved oxygen level is not within the specified range, it should be reported to the shift supervisor, and the amount of dimethylhydroxime added should be adjusted. 4.3.3 Adjust the amount of phosphate added and the opening degree of the continuous blowdown valve based on the results of boiler water analysis; if the silica content in the boiler water is too high, the frequency of regular blowdown should also be increased. 4.3.4 When it is found that the hardness of the condensate water exceeds the specified limit, the shift supervisor should be notified immediately to locate the leak, and the frequency of analysis should be increased. 4.3.5 When the load increases sharply or when the steam temperature, pressure, and water level are unstable, it is necessary to immediately monitor the quality of the steam and keep detailed records for future reference. 4.3.6 Chemical monitoring shall ensure the representativeness of the collected water vapor samples and the accuracy of the test results. If defects are found in the water vapor sampling device, the chemical dosing and waste discharge devices, maintenance personnel should be contacted promptly to address them. 4.4 Chemical monitoring during unit shutdown 4.4.1 4 hours before the shutdown of the turbine and boiler, the shift supervisor shall inform the chemical personnel to prepare for the shutdown. 4.4.2 After the boiler is shut down and the pressure is reduced, close the corresponding dosing valves, the continuous blowdown valve and its associated primary/secondary valves, the cooling water valves, and the inlet valves for the online chemical instruments. 4.4.3 Carry out proper protection measures for the shutdown or standby of turbines and boilers in accordance with the \"Guidelines for Preventing Corrosion of Shutdown (Standby) Thermal Equipment in Thermal Power Plants\", and conduct necessary chemical monitoring. When the shutdown period of the boiler is less than 1 week, maintenance can be carried out using the method of drying with the residual heat from draining water from the hot boiler ； When the downtime exceeds 1 week, maintenance is carried out using pure octadecylamine or the “NH3–dimethylthioxime” method. 4.4.3.1 Waste heat drying method using water drainage from the hot furnace: a. After the boiler is shut down, quickly close all dampers and the furnace door to seal the furnace chamber and prevent rapid heat loss. b. When the pressure in the boiler’s drum drops to 0.3 MPa–0.5 MPa, drain all the water remaining in the drum promptly; be careful to ensure that the temperature difference between the upper and lower parts of the drum wall does not exceed the allowable value during this pressure reduction process. c. During the drying process, the air humidity inside the pot should be measured every hour, and the humidity level should be

5 Water Treatment in the Boiler 5.1 Chemical Deoxidation of Feedwater and Adjustment of pH Value 5.1.1 Overview 5.1.1.1 Principles and Objectives Chemical deoxidation of feedwater involves adding reducing chemicals to the feedwater in order to eliminate the residual dissolved oxygen that cannot be removed completely by thermal methods, thereby preventing metal oxide corrosion in the feedwater system. The adjustment of the feedwater pH is achieved by adding a certain amount of alkaline substances to control the pH level of the feedwater and prevent corrosion caused by free CO2 in the feedwater system. 5.1.1.2 Drugs: Ammonia water, dimethyl oxime 5.1.1.3 Dosage point: a. Make-up water main. b. Deaerator drain pipe. 5.1.1.4 Chemical dosing equipment: a) The chemical dosing point in the make-up water main is equipped with 2 ammonia pumps and two 1.0 m3 ammonia solution tanks. b. At the chemical dosing point of the oxygen outlet pipe, there are 2 ammonia pumps and 1 ammonia solution tank with a capacity of 1.0 m3. 5.1.1.5 Selection of dosing point: Under normal circumstances, dosing should be carried out at the deaerator drain pipe; when there is a malfunction in the dosing system at that location or for other reasons, dosing can be done at the make-up water main. 5.1.2 Ammonia–dimethylthioxime addition to make-up water 5.1.2.1 System flow: Ammonia water + dimethylthioxime → Deionized water → Jet pump → Ammonia solution tank → Ammonia pump → Make-up water main pipe 5.1.2.2 Preparation of the solution: a. Preparation of the solution begins when the liquid level in the ammonia solution tank drops to 30 cm; for each preparation, 1 bottle of ammonia water (2500 ml per bottle) and 1 pack of dimethylthioxime (1 kg per pack) are used. b. Open the water inlet valve of the ammonia solution tank, insert the ammonia absorption tube into the ammonia bottle, open the ammonia extraction valve; after extracting all the ammonia, extract the dimethylthioxime solution that has been pre-dissolved in a plastic bucket. c. After pumping out the ammonia solution and the dimethyl oxime solution, close the ammonia pump valve; continue to feed demineralized water into the ammonia solution tank, and once the glass level gauge indicates full capacity, close all valves. 5.1.2.3 Chemical dosing procedure: a. Open the outlet valve of the ammonia solution tank, as well as the inlet and outlet valves of the ammonia pump, and the dosing valve on the make-up water main. b. Start the ammonia pump; the pointer on its outlet pressure gauge should swing back and forth. If not, stop the pump for inspection. c. The operator may leave the site only after the ammonia pump is operating normally. 5.1.3 Adding ammonia–dimethylthioxime to the feed water 5.1.2.1 System flow: Ammonia water + dimethylthioxime → Ammonia solution tank → Ammonia pump → Drain pipe of the deaerator 5.1.3.2 Preparation of the solution: Pour 2.5 liters of ammonia water and 1 kg of dimethylthioxime into the ammonia solution tank; open the water inlet valve of the tank to add water. Once the liquid level reaches 90 cm, close the water inlet valve and start the mixer to stir for 5–10 minutes. 5.1.3.3 Preparatory work before dosing a. Understand the operation status of the deaerator ； b. Check the opening and closing status of each valve in the chemical dosing system ； c. Check whether the ammonia pump gasket, backup wheel, pressure gauge, etc. are in good condition. 5.1.3.4 Chemical dosing operation: a. Notify the turbine to open the main chemical dosing valve for the drain pipes of the relevant deaerators ； b. Outlet door of the ammonia solution tank, inlet and outlet doors of the ammonia pump ； c. Open the corresponding deaerator dosing door as required ； d. Start the ammonia pump and check its outlet pressure gauge; the pointer of the gauge should move back and forth, and the pressure should be above the operating pressure of the deaerator; otherwise, stop the pump for inspection. e. Check the pump body and motor for any abnormal noises; if any are detected, stop operation immediately, switch to the backup pump, and contact maintenance. f. Adjust the pump stroke to ensure an appropriate dosing flow rate. 5.1.3.5 Stop of chemical dosing: Stop the ammonia pump, close the inlet and outlet valves of the ammonia pump as well as the outlet valve of the ammonia solution tank; also close the valve for feeding chemicals into the corresponding deaerator. If the deaerator is shut down, the main dosing valve for its drain pipe should be closed. 5.2 Phosphate treatment of boiler water 5.2.1 Overview 5.2.1.1 Principle: Phosphate treatment of boiler water involves the addition of phosphate solutions to maintain a certain level of phosphates in the boiler water. Under conditions of boiling boiler water and high alkalinity, calcium ions in the boiler water react with phosphate ions to form a soft type of sludge, which is then removed through the boiler’s blowdown system, thereby preventing scaling substances from forming deposits inside the boiler. 5.2.1.2 Dosage point: Inside the boiler drum. 5.5.1.3 Chemical: Trisodium phosphate. 5.2.2 Preparation of the phosphate solution: Weigh 8.0 Kg of qualified solid trisodium phosphate and put it into a wire basket; dissolve it using deionized water, stirring continuously as it is diluted to ensure complete dissolution. Once the desired concentration is reached, close the valve for the deionized water. 5.2.3 Chemical dosing operations: a. Check that the main valve for dosing into the boiler drum is open, and that the phosphate dosing pump is in good working condition. b. Open the dosing valve of the corresponding boiler; check that the pointer of the pressure gauge should swing back and forth. If not, stop the pump and conduct an inspection. c. Stop chemical dosing: Stop the chemical dosing pump, and close the corresponding boiler chemical dosing valve as well as the outlet valve of the chemical dissolving tank.