Operation and Maintenance Manual

for
Desalination Unit
Type MEP-4-200

Our reference:
M-000201
M-000202

Customer:
Fincantieri

Operation & Maintenance Manual, MEP-4-200, Rev.00 1

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement of
this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval Company.

Published by: Alfa Laval Copenhagen A/S

Maskinvej 5
DK-2860 Søborg
Denmark

© Copyright Alfa Laval Copenhagen A/S.

This document and its content must not be copied, reproduced, transmitted or dis-
closed to any third party without consent of Alfa Laval Copenhagen A/S.

Operation & Maintenance Manual, MEP-4-200, Rev.00 2

0. Introduction..........................................................................................................7

1. Safety Instructions and Warnings........................................................................8

1.1. Safety Instructions and Warnings......................................................................8
1.2. General Safety Precautions...............................................................................9
1.2.1. Electric Equipment...........................................................................................9
1.2.2. Transportation................................................................................................10

2. Nominal Plant Data............................................................................................11

3. Operating Requirements...................................................................................12
3.1. Sea water.........................................................................................................12
3.1.1. Harmful Substances.......................................................................................12
3.1.2. Free Chlorine................................................................................................. 12
3.1.3. Filtration System............................................................................................ 12
3.1.4. TDS................................................................................................................12
3.1.5. Brine...............................................................................................................12
3.1.6. Temperature...................................................................................................12
3.2. Heating sources: Hot water and/or steam........................................................12
3.3. Compressed air for control valves...................................................................13
3.4. Electrical power............................................................................................... 13

4. MEP Process Circuits........................................................................................14

4.1. Sea water / feed water circuit...........................................................................14
4.2. Vapour circuit (2nd effect and subsequent effects)...........................................14
4.3. Distillate Circuit................................................................................................15
4.4. Brine Circuit..................................................................................................... 15
4.5. Vacuum Circuit................................................................................................ 15
4.6. Heat supply circuit............................................................................................15
4.7. Thermal efficiency............................................................................................15
4.8. MEP Process Control Systems........................................................................16
4.8.1. Condenser flow control.................................................................................. 16
4.8.2. Heat control....................................................................................................16
4.8.3. Use in Part Load Situations............................................................................17

5. Electrical Systems.............................................................................................18
5.1. Local control panel (LCP)................................................................................18
5.1.1. LCP Layout.................................................................................................... 18
5.1.2. Power Circuits................................................................................................18
5.1.3. Control Circuits...............................................................................................18
5.1.4. PLC system....................................................................................................18
5.1.5. Operator Panel (HMI).....................................................................................18
5.1.5.1. HMI Screens.................................................................................................19
5.1.5.2. Common to all screens.................................................................................19
5.1.5.3. Flow diagram................................................................................................19
5.2. Process & Sequence Control and Alarms........................................................21
5.2.1. Process Control Systems...............................................................................21
5.2.2. Control Interlock and Alarm Circuits...............................................................21
5.2.2.1. Feed Water System......................................................................................22
5.2.2.2. Distillate System...........................................................................................22
5.2.2.3. Brine System................................................................................................22
5.2.2.4. Steam (Heat) System...................................................................................22
Operation & Maintenance Manual, MEP-4-200, Rev.00 3
5.2.2.5. Evaporator Vessel........................................................................................23
5.2.3. Failure Actions............................................................................................... 23
5.2.4. Shutdown Alarms...........................................................................................23
5.2.5. Signals available for Remote Monitoring........................................................23
5.3. Earthing........................................................................................................... 23

6. Operation...........................................................................................................24
6.1. Preparation for Operation................................................................................24
6.1.1. Installation Check List....................................................................................24
6.1.2. Filling Condenser and Ejector System with Seawater....................................25
6.1.3. Filling Evaporator Seawater Area...................................................................26
6.1.4. Filling Evaporator Distillate Area....................................................................27
6.1.5. Filling the Tank of the Anti-scale Dosing Station............................................27
6.2. First Start-up....................................................................................................28
6.2.1. Starting the Vacuum System..........................................................................28
6.2.2. Starting the Feed Water Flow and Brine Pump..............................................29
6.2.3. Starting the Distillate Pump............................................................................29
6.2.4. Starting the Distillate Production....................................................................30
6.3. Normal Start-up............................................................................................... 31
6.3.1. Preparation for Starting..................................................................................32
6.3.2. Line Up of Valves...........................................................................................32
6.3.3. Starting Procedure.........................................................................................32
6.4. Normal Shut-Down...........................................................................................35
6.4.1. Normal Shut-Down in Automatic Conditions..................................................35
6.4.2. Normal Shut-Down in Manual Conditions......................................................36
6.5. Emergency Shut-Down....................................................................................37
6.6. Prolonged Shut-Down......................................................................................37
6.6.1. Shut Down For Several Days.........................................................................38
6.6.2. Permanent Shut Down...................................................................................38
6.7. Feed Water Treatment.....................................................................................39
6.7.1. Prevention of Scaling.....................................................................................39
6.7.1.1. Feed Water Ratio.........................................................................................39
6.7.1.2. Evaporation Temperature.............................................................................40
6.7.1.3. Chemical Dosing.......................................................................................... 40
6.7.2. Anti-scale Dosing...........................................................................................40
6.7.2.1. Chemical/Physical Properties.......................................................................41
6.7.2.2. Safety Precautions with use of ALTREAT 400.............................................41
6.7.3. Equipment......................................................................................................42
6.7.4. Dosing Ratio...................................................................................................42
6.7.5. Preparation of Solution...................................................................................42
6.7.6. Dosing............................................................................................................43
6.8. Operational Notes............................................................................................43
6.8.1. Normal Operation Conditions.........................................................................43
6.8.2. Maintaining Distillate Output..........................................................................44
6.9. Trouble Shooting Table....................................................................................46

7. Maintenance......................................................................................................52
7.1. Evaporator heat surfaces (plates)....................................................................52
7.2. Demisters.........................................................................................................53
7.3. Pre heater........................................................................................................53
7.4. Retubing.......................................................................................................... 54
7.4.1. Removing Tubes Supporting Distance Tubes................................................54

Operation & Maintenance Manual, MEP-4-200, Rev.00 4

7.4.2. Retubing Tubes NOT Supporting Distance Tubes.........................................57
7.5. Cleaning Condenser........................................................................................58
7.5.1. Cleaning Condenser Tubes...........................................................................58
7.6. Leak Testing.................................................................................................... 58
7.6.1. External Leaks - Vacuum Tests.....................................................................58
7.6.2. Internal Leaks.................................................................................................59
7.6.3. Internal Access...............................................................................................60
7.7. Cleaning the Unit and Components.................................................................60
7.7.1. Acid Cleaning of Evaporator..........................................................................60
7.7.2. Preparation for Cleaning................................................................................61
7.7.3. System Preparation........................................................................................61
7.8. Periodic Routine Maintenance.........................................................................63
7.9. Control Settings and Alarm Adjustments.........................................................65
7.10. Maintenance Notes for PLC based Control Systems.......................................65
7.11. Maintenance for other Equipment and Components........................................65

8. Extent of Delivery.............................................................................................. 66

9. Drawings & Lists................................................................................................67

9.1. Drawings..........................................................................................................67
9.2. Lists (standard)................................................................................................67

10. Spare Parts........................................................................................................68

10.1. Ordering Spare Parts.......................................................................................68
10.2. Alfa Laval Service............................................................................................68
10.3. Spare Parts for Evaporator..............................................................................68
10.4. Spare Part Lists............................................................................................... 69

11. Operation/Maintenance of Boosters/Plate Heat Exchangers............................70

11.1. Steam Equipment / PHE’s...............................................................................70
11.2. Evaporator plates.............................................................................................70

12. Operation/Maintenance of Control Panel...........................................................71

12.1. Control panel drawings:...................................................................................71
12.2. Warning........................................................................................................... 71

13. Operation/Maintenance of Instruments..............................................................72

14. Operation/Maintenance of Valves.....................................................................73

15. Operation/Maintenance of Pumps and Motors..................................................74

15.1. Pump & Motor Data.........................................................................................74
15.2. Warning........................................................................................................... 74

16. Operation/Maintenance of Chemical Dosing Units............................................75

16.1. Anti-scale Chemical Dosing Unit......................................................................75

17. Operation/Maintenance of CIP (Cleaning in Place) Unit....................................76

18. Operation/Maintenance of Various Equipment..................................................77

18.1. Pre heater........................................................................................................77

Operation & Maintenance Manual, MEP-4-200, Rev.00 5

18.2. Demisters.........................................................................................................77
18.3. Vacuum Ejector............................................................................................... 77
18.4. Steam Trap......................................................................................................77

19. Operation/Maintenance of Filters......................................................................78

19.1. Feed Water Filters...........................................................................................78

20. Operation/Maintenance of Frequency Controllers.............................................79

20.1. VFD for Sea Cooling Water Pump Motor.........................................................79

Operation & Maintenance Manual, MEP-4-200, Rev.00 6

0. Introduction
We are pleased to welcome you as a user of Alfa Laval MEP Desalination
Plants.

Your MEP-4-200 unit is a product of careful engineering research and skilled

workmanship. It has been thoroughly inspected and tested to give you efficient
trouble-free service, provided proper care is taken in its installation, operation
and maintenance.

Your desalination plant works on a simple principle, but for reliable and efficient
operation it is essential that the instructions contained herein be fully understood
and carried out. Only personnel capable of understanding the function and
operation of the equipment should service the unit.

We suggest that all personnel responsible for installation, operation and mainte-
nance of the unit read this manual carefully, and keep it on hand for future
reference. Observance of these instructions will enable you to obtain optimum
performance from your MEP-4-200 unit.

These units are designed for fully automatic continuous operation and semi auto-
matic start-up and shutdown. The capacity can be varied between 40% and
100% output. The use of standardised components and high quality construction
material has resulted in good economy and high corrosion resistance.

Operation & Maintenance Manual, MEP-4-200, Rev.00 7

1. Safety Instructions and Warnings
Should you need further clarification regarding this manual, do not hesitate to
contact your local Alfa Laval representative - or call Alfa Laval Copenhagen
A/S directly.

Telephone +45 (for Denmark) 39 53 60 00

Telefax +45 (for Denmark) 39 53 65 66

1.1. Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your
attention is needed and your safety is involved.

WARNING

This symbol is used to indicate the presence of a hazard, which can

or will cause severe personal injury, if the warning is ignored.

Caution

Certain passages of the text will be marked with a caution mark.

This mark indicates the presence of hazard, which will or can cause
property damage if the instructions are not observed.

Note

This type of instruction indicates a situation, which, if not avoided,

could result in damage to the equipment.

It is the owner’s and operator’s responsibility to see that any person involved with
the use or operation of this equipment follow all safety instructions and that
personnel are fully trained.

Read all safety instructions carefully and insist that those working with you and
for you follow them.

Not following the instructions may cause severe personal injury or damage the
equipment beyond repair.

Do not allow this equipment to be used if it is faulty or the operator does not
understand the proper use.

Operation & Maintenance Manual, MEP-4-200, Rev.00 8

 WARNING

The desalination plant is not to be operated in polluted water.

Distillate must not be produced from polluted water, as the produced water can
be unsuitable for human consumption.

WARNING

Noise hazards
 Use ear protection in noisy environments.

Crush hazards
 Use correct lifting tools.
Do not work under hanging load.

Burn hazard
 Wear gloves to avoid burns by hot surfaces.

Cut hazards
 Wear gloves to avoid cuts by sharp edges when handling
machined parts.
 Wear helmet to avoid cuts by sharp edges when maintaining the
machine.

Note

 Max. ambient temperature for freshwater generator is 50°C

(122°F).
 Min. ambient temperature for freshwater generator is 0°C (32°F)

1.2. General Safety Precautions

Always handle the equipment with great care. Make sure not to damage the
parts during transportation or installation.

During erection all inlets and outlets must be covered to be protected from dirt
and particles.

1.2.1. Electric Equipment

A professional electrician must carry out all electric installations in full
accordance with local regulations.

Before initial start-up:

Operation & Maintenance Manual, MEP-4-200, Rev.00 9

 WARNING

Check that your main supply cable size, voltages, frequency and
maximum error current agrees with the electrical specifications.

WARNING

Check that all connections are properly earthened (grounded) in

accordance with local regulations, and properly insulated.

1.2.2. Transportation
All transportation of the equipment must be in accordance with local regulations.

If the desalination equipment is delivered with a lifting bracket, be sure only lift
the equipment with this bracket. The MEP must be lifted using the lifting points
indicated on the unit, hooked where the following label is placed:

WARNING

The equipment is very heavy. Lifting may be hazardous to

personnel.

Remember to lift at all lifting points indicated simultaneously to

ensure an even load.

Ensure that safe working load of the strops is sufficient to lift the unit
in the empty condition.

Operation & Maintenance Manual, MEP-4-200, Rev.00 10

2. Nominal Plant Data
Distillate
Flow rate: 33,3 t/h
Pressure at unit outlet: 2.0 bar(a)
Maximum salinity: 5 ppm
Temperature max.: 37 °C

Heating Hot Water

Flow rate: 428 t/h
Inlet temperature FWG: 89 °C
Outlet temperature FWG: 77 °C

Heating Steam
Flow rate: 9,2 t/h
Nominal pressure: 10 bar(g)
Temperature: 180 °C

Condensate
Flow rate: 9,2 t/h
Temperature: ~100 °C

Seawater
Flow rate max: 575 t/h
Pressure unit inlet, min.: 0.8 bar(g)
Temperature, max.: 32.0 °C

Brine/Seawater Blow down

Flow rate: 90 t/h
Pressure at unit outlet: 1.5 bar(g), max. back pressure
Temperature: ~47 °C

Instrument Air
Supply pressure: 7.0 bar(g)
Temperature: Ambient
Quality: Dry & clean

Electricity
Voltage: 3 x 690 V
Frequency: 60 Hz

Chemicals Consumption
Scale Inhibiting Additive: 4.0 g/m3 feed water

Overall Dimensions
For the overall dimensions see General arrangement drawing No. 9680 036143.

Operation & Maintenance Manual, MEP-4-200, Rev.00 11

3. Operating Requirements
For the operation of the evaporator, the following utilities must be available:
 Sea water
 Hot water and/or steam
 Compressed air for control valves (or electrical valves on request)
 Electrical power.

3.1. Sea water

3.1.1. Harmful Substances
The seawater/feed water is expected to be free of all harmful substances (i.e.
Ammonia, oil suspensions & oil emulsions, organic volatile compounds, toxic
components, sand etc.) usually not contained in normal seawater.

3.1.2. Free Chlorine

The residual free chlorine content of the seawater at the evaporator inlet is not to
exceed 0.5 ppm at normal conditions. If chock chlorination of the sea water
intake system is applied, a de-chlorination system must be used to ensure less
than 0.5 ppm free chlorine at the inlet of the evaporator.

3.1.3. Filtration System

The sea water inlet filter to the sea chest of the cruise vessel is typically 3- 5 mm
mesh size. The size of any suspended solids must not to be larger than 0.5 mm
when entering the evaporator plate heat surfaces and the amount must not
exceed 8 ppm (TSS).

3.1.4. TDS
The total dissolved solids (TDS) design point of the evaporator is 35,000 ppm,
which is considered as “standard” sea water. If the evaporator has to be regular
operated at higher TDS values > 43,000 ppm, the feed water ratio has to be
adjusted initially.

3.1.5. Brine
During operation the conductivity of the brine must be observed. The conductivity
must not exceed a certain threshold value of approx. 60,000 ppm. An increase in
the conductivity not related to the sea water indicates problems (fouling) in the
feed water system.

3.1.6. Temperature
The sea water design temperature is min. 0°C and max 35°C.
Exceeding the above values will cause reduced life time of the evaporator,
increased fouling of the evaporator heat surfaces and all together a reduced
performance.

3.2. Heating sources: Hot water and/or steam

The evaporator can only be operated if a heat source is available. The heating
medium can either be hot water or steam or a combination thereof.
On board a cruise liner both heat sources are available: typically the HT-Jacket
cooling water (HT-JCW) loop of the diesel engines is used as the main heat
Operation & Maintenance Manual, MEP-4-200, Rev.00 12
 source while steam produced by the Exhaust Gas Economizers (EGE) or from
auxiliary boilers as back-up.
The HT-JCW water quality must follow the diesel engine manufacturer guidelines
and if a separate hot water loop is applied, the hot water must follow general
applied requirements e.g. must be inhibited etc. Heat transfer to the evaporator
may be reduced by fouling if proper hot water quality is not kept.

3.3. Compressed air for control valves

The Alfa Laval standard valve control system is based on pneumatic actuated
valves.
The design air pressure is 7 bar(g) and the air must be clean and dry (dew point:
-40°C). Insufficient air quality may lead to malfunction of valves and thereby poor
performance of the evaporator and in severe cases may lead to failure or even
damage.
Electrically driven valves can be used, however their returning to fail-safe
position in the event of a black-out must be guaranteed.

3.4. Electrical power

Voltage: The main power supply voltage to motor driven components must not
vary more than ±10%.
Frequency: Frequency variation must remain within ±2% on the frequency.
The control circuits of 110VDC and 24VDC are derived from the main power
source by transformers located in the control panel of the evaporator.

Operation & Maintenance Manual, MEP-4-200, Rev.00 13

4. MEP Process Circuits

4.1. Sea water / feed water circuit

The inlet pressure of the filtered seawater entering the evaporator is sufficient to
feed the evaporator which is normally installed below the water line.
The sea water is pumped, via the sea cooling water pump, to the condenser.
Inside the condenser the seawater is heated to a temperature of approx. 40 -
45°C. The major portion of the seawater – preheated after having been used for
cooling purposes only - is lead back to the sea.
The remaining portion of the preheated seawater is used as feed water after
having passed the feed water filter (mesh size 0.5 mm).
In order to keep the concentration factor of the brine in the evaporator below
approx. 1.6, the feed water flow is kept constant.
After pre-treatment with anti-scale chemical (ALTREAT400), the feed water is
fed, in parallel, to each effect of the evaporator, where an optimised feeding
system distributes the seawater uniformly over the plate surfaces.
The first effect, designed for heat recovery, is based on rising film technology.
The sub-sequent effects are based on the falling film principle, always
maintaining a homogeneous liquid film on the surfaces of the plates.

Caution

At sea water temperatures <10°C the condenser flow is less than

the required feed water flow.
At these conditions brine re-circulation is necessary but for
operational safety reasons, brine re-circulation is maintained for all
sea water temperatures.

4.2. Vapour circuit (2nd effect and subsequent effects)

The plates are heated from one side by condensing vapours. The released heat
of condensation is transported - driven by the temperature difference - through
the plate walls and causes partial evaporation of the falling liquid film on the
seawater side of the plates. Due to the very low heat flux the evaporation takes
place on the surface of the liquid film only, without formation of vapour bubbles
inside the liquid film. By this, the danger of scale formation due to local dry-outs
and, as a consequence, local precipitation of scale-forming water compounds, is
reduced to a minimum and the amount of anti-scale chemicals to be injected can
be minimised.

The generated vapours leave the plates through openings on both sides of the
plate packets. Afterwards, vapours pass via mist eliminators - demisters - being
integrated in the evaporator vessels in order to separate entrained seawater
droplets.
Vapours are transported inside the evaporator vessel to the next effect where
they condense. The vapours produced in effect 1 heat effect 2, the vapours
produced in effect 2 heat effect 3, and so on. The vapours produced in the last
effect are led to the condenser.

Operation & Maintenance Manual, MEP-4-200, Rev.00 14

4.3. Distillate Circuit
The produced distillates of the all effects flow via transfer pipes and flash pots
from effect to effect. The collected distillates, together with the condensate from
the final condenser, are discharged by the distillate pump. The distillate level in
the final distillate chamber of the evaporator is controlled to prevent the distillate
pump from cavitating.

4.4. Brine Circuit

The evaporation of the seawater increases the salinity. The highly concentrated
sea water, called brine, is collected at bottom of the vessel.
The brine flows via siphon pipes from effect to effect. The brine pump discharges
the brine (blow-down) from the last effect. The brine level is controlled to prevent
the brine pump from cavitating.
A small portion of the brine is constantly recirculated to the feed water line to
ensure rated feed water flow at all sea water temperatures.

4.5. Vacuum Circuit

The boiling point of (sea) water is depending on the pressure i.e. the lower the
pressure the lower the boiling point. To avoid scale formation and to reduce the
energy requirements, the operation of the desalination units is taking place in
vacuum conditions typically between 0.1 bar(a) and 0.5 bar(a).
The non-condensable gases are sucked at each effect and led to the condenser,
where all non-condensable gases are extracted by a water-driven ejector
system. While most of the vapours are immediately condensed, the non-
condensable gases are compressed to atmospheric pressure before entering the
seawater return line, where the gases are released.

4.6. Heat supply circuit

The first effect of the evaporator is used for recovery of the waste heat. On one
side of the plate stack, the HT-JW or hot water is circulated thus heating up a
part of the feed water on the other side to the point of evaporation.
A steam booster heater, to be used as back-up when HT-JCW heat is insufficient
or not available, is positioned in the hot water loop upstream the evaporator.

4.7. Thermal efficiency

An advantage of the MEP evaporator is that it utilises all the available waste
heat, independently of the load of the diesel engines. Distillate production can be
automatically maintained down to 30% design rate.
The thermal efficiency or specific heat consumption of the evaporator, often
expressed in thermal kWh/m³, is closely related to the number of effects.
The more the effects there are, the more efficient the unit is. Better efficiency
also means lower operational costs but investment cost is unfortunately higher
due to the more complex design, the larger size and the increased heat surface.
MEP evaporators can be designed to as low as 130 kWh/m³ (6-effect unit with
feed water pre-heaters). Therefore by using more efficient units, the distillate
capacity can be maintained in a larger MCR range.

Operation & Maintenance Manual, MEP-4-200, Rev.00 15

4.8. MEP Process Control Systems
MEP control system typically consists of the following loops:
 Condenser flow control
 Feed water flow control
 Heat control (steam control to steam booster)
 Brine level control
 Distillate level control

With respect to waste heat integration, only condenser and steam flow control
have an impact, as the feed water ratio is kept constant at all capacities to
ensure sufficient wetting of the heated surfaces.

4.8.1. Condenser flow control

The sea water flow to the condenser varies as the sea water (SW) temperature
varies seasonally from summer to winter, and location where the ship is
operating and due to different load situations.
In order to ensure a constant feed water temperature, the sea water temperature
at the condenser outlet is kept constant by means of closed loop control. The
temperature is measured by temperature transmitter TT105 at the condenser
outlet and compared with the temperature set point which can be adjusted at the
HMI-panel. The sea water pump is equipped with a frequency converter which is
controlled by the output signal from the temperature control loop. If the
condenser outlet temperature is too low, the rotational speed of the sea water
pump and thus the sea water flow is decreased and vice versa.
A pressure control loop ensures a constant sea water pressure at the condenser
outlet (i.e. feed water). The pressure is measured by pressure transmitter PT101
and controlled by actuator TCV105.

By adjusting the set point of the temperature transmitter (flow), the boiling
process (temperatures) can be controlled. This causes an increasing or
decreasing of the overall temperature difference inside the evaporator thus
influencing the return temperature of the HT-JCW ensuring full utilisation of the
waste heat. The latter is currently only a manual function, but an automatic
function can be implemented.

4.8.2. Heat control

At partial load, the amount of generated vapour is reduced. Due to the reduced
vapour flow, the temperature and pressure of the first effect drops. As the
evaporation temperature in the condenser is kept constant (see above), the
overall temperature difference of the evaporator decreases and - with a certain
delay - the output of the unit also decreases. Each operation point in partial load
is not controlled at fixed values because the evaporator adapts automatically to
the conditions of the heat source, i.e. no operator intervention is necessary.

MEP evaporators using Hot Water (HW) as heat source will utilise all available
waste heat and production rate will be accordingly.
The available waste heat is limited by the outlet and return temperature of the
HT-JCW of the diesel engine (return must not drop below a certain the minimum
temperature).

Operation & Maintenance Manual, MEP-4-200, Rev.00 16

4.8.3. Use in Part Load Situations
In diesel engines part load operations less waste heat is available, and the HT-
JCW inlet temperature to the evaporator drops. The steam valve controlled by
the HT-JCW inlet temperature will then start opening to maintain the pre-set inlet
temperature.
The steam valve (can be a separate valve) is also controlled by the steam
pressure upstream the steam valve. At low steam pressure, e.g. less than 2
bar(g), the valve remains closed independent of the HT-JCW inlet temperature.
This avoids unnecessary use of the OFB’s and ensures a longer operation on
HT-JCW alone.
In order for this to function properly, the evaporator must be efficient in
maintaining the relative high production ratio.

Control Tag No. Maintains constant: By adjusting:

FC-SW-01 Feed water temperature Sea water flow through condenser

TCV105 Sea water pressure Position of control valve

FCV152 Feed water flow to evaporator Position of control valve

LCV200 Evaporator brine level Brine flow

LCV400 Evaporator distillate level Distillate flow

TCV501 Distillate production Steam flow (if applied)

Operation & Maintenance Manual, MEP-4-200, Rev.00 17

5. Electrical Systems

5.1. Local control panel (LCP)

The electrical system of the unit is concentrated in the local control panel and
consist essentially of two types of circuits:
 Power Circuits (690V, 3 phase, 60Hz), containing the power supply to feed
the motor-driven components and auxiliaries, and
 Control Circuits (110VDC), power control circuits enabling surveillance and
small consumers, both manual and automatic, of all operating equipment and
conditions. Transformed from the control voltage is the 24VDC used for
lamps, transmitters and auxiliary relays.

5.1.1. LCP Layout

The cabinet is divided into two separate sections:
 MCC section for motor control circuits and motor cables.
 Instrument and PLC section for signal circuits and cables.
The cabinet includes a fan and heater for ventilation and prevention of water
condensation. Internal lighting is provided for maintenance.

5.1.2. Power Circuits

In the power circuits, the power supply is fed through the main isolator switch to
the motor control circuits.

Power supply for motors and auxiliaries include circuit breakers and contactors.
Each contactor is provided with a thermal over current relay.

5.1.3. Control Circuits

A transformation from 690V to 110VDC provides power for the control circuits
and other accessories.

The 110VDC power supply is used for motor contactors.

5.1.4. PLC system

The plant control, including the above controllers and monitoring system, is
implemented in a Programmable Logic Controller. The control system consists of
a PLC with a permanent program memory module (EEPROM).
The PLC controls and monitors all plant signals. The program performs logic and
sequential control of the plant and will alert the operator to any plant upset by
displaying warning alarms. In critical situations the plant will be automatically
shutdown and display a shutdown alarm.

5.1.5. Operator Panel (HMI)

A touch screen HMI (Human Machine Interface) provides the operator with a
control panel presented as individual function screens.
For detailed information please see document “OPERATOR PANEL,
OPERATING INSTRUCTIONS” in “Operation/Maintenance of Control Panel”.

Operation & Maintenance Manual, MEP-4-200, Rev.00 18

5.1.5.1. HMI Screens
Screens visualize the progress of processes and display specified process
values. A screen contains logically related process data and operating elements,
which can both be displayed and modified by operating the individual objects.
The operator panel is equipped with a touch screen. All operating elements such
as push buttons and alphanumeric input-/output fields, required for operation and
monitoring of the plant are displayed on the touch screen once the HMI-device is
in operation.
The operating elements are touch-sensitive. Touch objects are basically
operated in the same way as mechanical keys. You activate operating elements
by touching them lightly with your finger.
The screens have a uniform design. Each screen is partitioned into 3 sections.
There is a fixed window both at the top and at the bottom of the screen. The
content of these fixed windows is the same on all screens. The centre area is
individual for each screen.

5.1.5.2. Common to all screens

The fixed window at the top displays from left to right: date and time, logged in
user, screen name, operational state of plant and present sequence step. The
alarm indicator appears in the top right corner whenever a fault occurs.

The main centre area contains screen objects for operating and monitoring the
plant.

The fixed window at the bottom of the screen contains push buttons, which have
been assigned global functions. They initiate the same function, regardless of the
screen currently open.

5.1.5.3. Flow diagram

This screen is a simplified graphical presentation of the plant and provides a
quick overview of plant operation by indicating the operational state of motors
and valves as well as displaying actual measuring values and position of control
valves.

The symbols for motors and valves change colour according to their operational
state:
Green: stopped/ closed (ready for operation)
Red: in operation/ open
Yellow (blinking): fault, unacknowledged
Yellow (steady): fault, acknowledged

Operation & Maintenance Manual, MEP-4-200, Rev.00 19

 The different symbols are touch-sensitive. When pressed, a pop-up screen
(faceplate) belonging to the actual object opens and gives access to operation
and monitoring.

For each motor the following information is displayed on the HMI-panel:

 Operation mode (automatic or manual)
 Operational state (stopped, in operation or fault)
 Operation hours

Change between automatic and manual operation mode by pressing the button
“AUTO”, resp. “MANUAL”. In manual operation mode a motor can be started and
stopped by pressing the buttons “START”, resp. “STOP”.

Operation & Maintenance Manual, MEP-4-200, Rev.00 20

5.2. Process & Sequence Control and Alarms
The process control system is simple in design and operation. It is based on fully
automatic operation conditions and highest safety for plant and operators.

5.2.1. Process Control Systems

Process equilibrium condition is automatically maintained constant by several
pre-set, closed loop, controllers operating the control valves.

1. The brine level LT200 in the evaporator is maintained at its pre-set level by
the control valve LCV200.
2. The distillate level LT400 in the evaporator is maintained at its pre-set level
by the control valve LCV400.
3. The condenser outlet (feed water) temperature, TT105, is maintained at the
pre-set temperature by sea water pump frequency converter.
4. The sea water pressure at the condenser outlet, PT101, is maintained at the
pre-set pressure by the control valve TCV105.
5. The Feed water flow, FT152 is maintained by the action of control valve
FCV152.
6. The hot water inlet temperature, TT501, is maintained at the pre-set
temperature by the control valve TCV501.

5.2.2. Control Interlock and Alarm Circuits

Refer to functions chart, draw. no. 9680 021619.

The functions chart describes the automatic operation and alarm functions of the
desalination plant.
The plant is started up, respectively shut down by means of sequential, stepwise
control, where the proceeding from one step to the next is dependent on step
enabling conditions. The sequence proceeds from one step to the next, when
both the step enabling conditions are fulfilled and the waiting time has elapsed.

Alarms are grouped into warning and shutdown alarms. Warnings inform the
operator of plant conditions when operating outside normal set conditions. In the
event of a warning the operator shall rectify its cause. If operator action is not
taken and the condition worsens the plant will be automatically shutdown. The
shutdown alarm will report which condition caused the plant to trip.

The Desalination Unit can be started or stopped either from the HMI-panel, by
push buttons in the front of the control panel or remotely.
The plant is normally operated fully automatically.
Furthermore, each motor and valve can be put into manual operation mode and
started or stopped individually.

Process interlock and alarm circuits are installed on the following systems:
1. Feed water system
2. Distillate system
3. Brine system
4. Steam system
5. Evaporator Vessel

The settings of these alarm devices are determined during commissioning.

Operation & Maintenance Manual, MEP-4-200, Rev.00 21

5.2.2.1. Feed Water System
The feed water temperature is kept constant by the seawater temperature
controller adjusting the seawater flow through the condenser.
The feed water flow is indicated by the flow transmitter. Insufficient feed water
flow (Low Low) will actuate an alarm and shut down the unit. This protects the
evaporator plates from insufficient water coverage and resulting scale formation.
This interlock is active both in manual and in automatic. A firm aware timer gives
a 10 second delay to allow feed water control opening.

5.2.2.2. Distillate System

The distillate level on the evaporator is controlled by a level control valve (control
valve distillate) in response to level transmitter. This transmitter has also control
and alarm settings:
 Distillate pump start level. A minimum level is required for allowing the pump
to start.
 Distillate pump stop level. Below a minimum level, the pump will stop to
protect the pump from cavitating.
 Distillate high and low level alarms.

A conductivity meter monitors the distillate purity. If the distillate conductivity is

too high, an alarm will be actuated and the distillate flow will be diverted to the
brine line.

5.2.2.3. Brine System

The brine level for in the evaporator is controlled by a level control valve (control
valve brine), in response to level transmitter. This transmitter has also control
and alarm settings:
 Brine pump start level. A minimum level is required for allowing the pump to
start
 Brine pump stop level. Below a minimum level, the pump will stop to protect
the pump from cavitating.
 Brine high and low level alarms.
 Brine high-high shutdown alarm.

A conductivity meter monitors the brine. If the brine conductivity is too high, an
alarm will be actuated and the cause must be investigated carefully.

5.2.2.4. Steam (Heat) System

Note: A steam system might not be included in your scope of supply (see point 3
below)!

An applied steam system will be equipped with a steam control valve to regulate
the steam flow to the steam booster if a combined hot water and steam system is
supplied (1), or to the evaporator itself if only steam is used as heating medium
(2).

1. The inlet temperature of the hot water (heating medium) to the evaporator is
kept constant by adjusting steam flow to the steam booster. The flow is
controlled by a temperature transmitter which has the following control and alarm
settings:
 High hot water temperature alarm.
 High-High hot water temperature alarm and automatic closure of steam valve.

Operation & Maintenance Manual, MEP-4-200, Rev.00 22

 2. The inlet pressure of the steam to the evaporator is kept constant by adjusting
the steam flow. The flow is controlled by a pressure transmitter which has the
following control and alarms settings:
 High pressure alarm.
 High-High pressure alarm and automatic closure of steam valve.
3. If the evaporator is only operated on hot water e.g. HT-JW, the distillate
production will automatically follow the available heat provided i.e. no control
system is provided.

Heat supply to the evaporator is only possible after feed water and brine systems
are in operation to ensure water on the heat surfaces.

5.2.2.5. Evaporator Vessel

The evaporator vessel is equipped with a mechanical check valve for the
protection of the vessel against overpressure (>1 bar(a)).
A vacuum breaker valve respond to signals from the PLC control.

Monitoring vessel overpressure PT310 the high-high evaporator pressure alarm

will, when the unit is in production (feed water valve open and vacuum breaker
valve closed) give a shutdown alarm and stop the unit.

5.2.3. Failure Actions

In the case of air failure, automatic valves have failure close actions with the
exception of the vacuum breaker valve and the distillate reject valve. The
vacuum breaker valve will fail to its open position and the distillate valve will fail
to its reject position.

5.2.4. Shutdown Alarms

The following events give shutdown alarms and result in desalination unit shut
down and opening the vacuum breaker valve:
 Brine level > HH set point
 Sea water pressure < LL limit value
 Evaporator pressure > HH limit value (during production)
 Feed water flow < LL limit value
 Motor overload (any single motor)
 Emergency stop

5.2.5. Signals available for Remote Monitoring

Distillate Flow: 4-20mA
Salinity: 4-20mA
Plant running indication: Voltage free contacts NO & NC
Common Alarm Voltage free contacts NO & NC
Emergency stop indication Voltage free contacts NO & NC

5.3. Earthing
The necessary earthing equipment is the contractor’s responsibility. The earthing
ring has to be equipped with several lugs. The connection between the
equipment (delivered by Alfa Laval) and the lugs has to be done via insulated
copper wires.
All paint traces are carefully removed at the point of connection. Brass screws
and nuts are prohibited.

Operation & Maintenance Manual, MEP-4-200, Rev.00 23

6. Operation
The operation of the unit shall only be performed by trained personnel.

6.1. Preparation for Operation

6.1.1. Installation Check List

Note

Not all mentioned equipment might be included in your scope of

supply.

The following is a checklist to ensure that the installation has been properly
completed and the unit is ready for start-up procedures.
 Service overhead crane is installed if provided.
 Evaporator is secured to the base frame.
 Loose supply e.g. steam booster and hot water heat exchangers are secured
to the base frame.
 All utility lines are completely flushed before connected to the desalination
unit.

Caution

Incomplete flushing of the utility lines might result in clogging up the

heat surface of the desalination unit i.e. the rated production cannot
be achieved. Complete manual cleaning of all heat surfaces is then
necessary.

 Utility lines are connected to supply system and sufficient feed pressures are
provided at the unit inlet.
 Brine disposal line is connected.
 Distillate lines are connected to the different consuming devices.

Note

If the distillate has a high conductivity it will be discharged through a

separate dumping line into the brine line.

 Steam line is connected to the steam booster.

 Condensate line is connected to the steam booster.
 Hot water lines are connected to the heat exchanger.
 Feed treatment system is installed, including piping and electricity.
Operation & Maintenance Manual, MEP-4-200, Rev.00 24
  All the piping is connected between the base frame, condenser and
evaporator.
 Adequate electrical supply and earthing (grounding) is provided and
connected to the main switch of the unit.
 All equipment for measuring and indication are installed.
 All the motor couplings have been disconnected and reconnected after
checking for:
1. correct direction of rotation, and
2. alignment of shafts and couplings.
 Oil levels in all pumps (brine, distillate and vacuum) have been checked.
 Turn ON the main switch.

Note

On powering up, the low voltage alarm and other alarms will be
generated. Press the alarm-reset button and interrogate the alarm
panel. Remove alarm causes.
Prior to starting up, the unit status shall be reviewed for a no alarm
condition. All causes for shutdown alarms shall be removed before
operating the unit.

In the field:
 Check that manual valves are correctly lined-up.
 Check that the chemical pump is turned on.

At the HMI:
 Review for no alarm condition.
 Review and check alarm settings
 Review and check control settings
 Review and check that all controllers are set in their automatic
mode.
 Reset any shut down alarms

6.1.2. Filling Condenser and Ejector System with Seawater

Before the first start-up of the unit the condenser, pumps and pipes have to be
filled with water. So the following activities have to be done:
 Close all drains in the seawater areas.
 Close the feed water valve FCV152.
 Open the vacuum breaker valve XCV301 to release the air during the filling
procedure.
 Open the condenser flow control valve TCV105 partially.
 Open the valve VA-EC-05 to the ejector water line of the evacuation system.
 Open the valves VA-SW-14 & VA-SW-15 and close the valve VA-SW-16 of
the distillate cooler system.
 Open the sea water inlet valve to the evaporator (VA-SW-01 if provided by
Alfa Laval) partially to let the seawater enter very slowly.

Operation & Maintenance Manual, MEP-4-200, Rev.00 25

 Note

The filling procedure needs some time to fill the total volume. Be
careful during the filling that the salty water do not flow out of open
drain valves or open flange connections and soil the evaporator
shell. If seawater comes out of valves or flanges close the seawater
supply quickly and close the leakages. Afterwards start the filling
again.

 Open the sea water inlet valve to the evaporator (VA-SW-01) fully. The sea
water pressure must be minimum 0.8 bar(g).
 If the condenser is completely filled, close TCV105 and close (VA-SW-01)
nearly.

Note

Normally the sea water level in the tank will now increase. To prepare normal
start conditions wait until the level reaches minimum the high value on the
level indicator.

 Remove air pockets from the ejector pump if necessary.

Note

The seawater supply and evacuation system now should be ready

for operation. Before starting the plant in automatic mode the
following procedures have to be performed to protect the system
against undefined conditions.

6.1.3. Filling Evaporator Seawater Area

Before the first start-up of the unit the evaporator and the pumps and pipes
should be filled with sea water. The filling procedure in Sec. 6.1.2 has to be
completed before. So the following activities have to be done:
 Make sure that the vacuum breaker valve XCV301 is open to let out the air
during the filling.
 Open the feed water valve FCV152 partially.

Note

After opening the valve FCV152 the seawater fills the seawater
areas in all effects of the unit if the supply pressure is sufficient. The
brine level indicator will indicate the rise of the level. If the level does
not increase, open the sea water inlet valve (VA-SW-01 if supplied
by Alfa Laval)

Operation & Maintenance Manual, MEP-4-200, Rev.00 26

  Open the drain valve VA-BR-10 until water flows out and close afterwards.

Note

Normally the brine level will now increase. To prepare normal start
conditions wait until the brine level reaches a value between low and
high on the brine level indicator.

 Remove air pockets from the brine pumps if necessary.

 Close the condenser flow control valve TCV105.
 Close the sea water inlet valve (VA-SW-01).

6.1.4. Filling Evaporator Distillate Area

Before the first start-up of the unit the distillate area in the evaporator should be
filled with distillate or clean process water. This procedure includes the following
activities:
 A hose connected to the drinking water line or other fresh water reservoirs
has to be installed up to the plant.
 Open the valve at the drinking water line and clean the inside of the hose.
 Make sure that there are no dirty residuals inside the hose.
 Close the drinking water valve after cleaning.
 Connect the hose at valve VA-DI-10.
 Open valve VA-DI-10.
 Open the valve at the drinking water line.

Note

The distillate area will now be filled with clean water. The rise of the
level will be shown at the level indicator. When the distillate reaches
the normal level, stop the fresh water flow.

 Close the valve VA-DI-10.

 Close the valve at the drinking water line.
 Disconnect the hose at ball valve VA-DI-10.
 Remove air pockets from the distillate pumps if necessary.

6.1.5. Filling the Tank of the Anti-scale Dosing Station

For the first filling of the anti-scale dosing tank, use a hose connected to a fresh
water line. Fill the tank up to the signed level and mix the fresh water with the
chemicals used for this dosing. The special information about chemicals and
mixture is found in “6.7 Feed Water Treatment”.

Operation & Maintenance Manual, MEP-4-200, Rev.00 27

6.2. First Start-up
Before the first start-up of the unit the procedures described in “6.1 Preparation
for Operation” have to be followed carefully and step by step. If you prepare the
conditions for the start-up exactly according to this manual you will get optimum
performance from your desalination unit.
The first start-up of the unit will be done in MANUAL operation conditions to
check and make sure that all equipment will be in optimum conditions and
functions.

WARNING

To prevent unintentional starting of the equipment local rules and

procedures for maintenance work must be followed.

6.2.1. Starting the Vacuum System

Before starting the vacuum system please make sure that sufficient pressure is
supplied to the seawater line.
The procedure to start the evacuation will be carried out as follows:
 Check that all of the valves are closed which could break the vacuum in the
system.
 Check that the feed water valve FCV152 is in OFF mode at the switch.
 Open the manual sea water inlet valve (VA-SW-01).
 Check the valve VA-EC-05 is open in the ejector motive water line.
 Check all piping around the evacuation system.

Note

The vacuum system is now ready for operation. To get sufficient

pressure of sea water the valve (VA-SW-01) must be fully open.

 Switch on the ejector motive pump PU-EC-01 on the panel.

 Make sure that the pump is not cavitating.

Note

Now the vacuum system evacuates the desalination plant. During

the evacuation, the sea water flow through the condenser may also
vary because the controller and the temperature transmitter TT105
try to reach the rated values. So make sure that the controllers are in
automatic conditions.

Operation & Maintenance Manual, MEP-4-200, Rev.00 28

6.2.2. Starting the Feed Water Flow and Brine Pump
If the vacuum system is in operation, the plant is ready to start the feed water.
For these activities execute the following instructions:
 Check that all controllers are in their closed loop (Auto) mode or set for
correct manual output setting. Select as required at the PID screen.
 Check that all control valves are enabled for operation. Select as required at
the control screen.
 Open feed water control valve FCV152 / FT152.

Note

Now the seawater starts flowing into the evaporator. During this time
check all connections at piping and vessel. If there are any leakages
stop the filling and evacuation and tight the located water rinse.

 If the brine level is near or higher than the rated level, start the brine pump
PU-BR-01 at the control screen. If a stand-by pump is provided, make a
pump selection.

Note

If a stand-by pump is provided, make sure that the corresponding

manual pump isolating valves are open or closed accordingly. The
valves of the pump not in operation must be closed.

 Switch on the anti-scale dosing station on the panel by turning the switch to
ON position and start the chemical pump at the control screen.

Note

Now all circuits are in operation, except the distillate pump.

The feed water pressure controller FT152 regulates the rated
pressure by means of the control valve FCV152.
The level controller LT200 regulates the rated brine level.
The temperature controller TT105 regulates the condenser flow, by
means of the control valve TCV105.
The ejector motive pump with the ejector is still sucking vacuum in
the evaporator and condenser.

6.2.3. Starting the Distillate Pump

The distillate system shall be started in preparation for the distillate production
that will occur after heat has entered the flashing chamber. If the distillate
reaches the high level at transmitter LT400, execute the following instructions to
start the distillate pump:
 Make sure that the level control is switched to automatic mode and enabled.

Operation & Maintenance Manual, MEP-4-200, Rev.00 29

  Start the distillate pump PU-DI-01 at the control screen. If a stand-by pump is
provided, make a pump selection.

Note

If a stand-by pump is provided, make sure that the corresponding

manual pump isolating valves are open or closed accordingly. The
valves of the pump not in operation must be closed.

6.2.4. Starting the Distillate Production

If the upper described procedures are done, the unit is ready to operate and start
the distillate of its first distillate.
The last condition for operation is sufficient heat flow to the heat exchangers and
the circulation of the hot water. If all other above described procedures are
performed the system has to be started as follows:
 Check the line up of hot water valves external to unit.
 Check the line up of steam and condensate valves external to unit.
 Check that the hot water loop by-pass valve VA-HW-09 is closed.
 Open the valves VA-HW-91 and VA-HW-92.

Note

If the desalination unit is only to be operated on diesel engine gen.

set, close any isolation valves of the steam system (if provided).

 Start the hot water pump PU-HW-01.

Note

If a stand-by pump is provided, make sure that the corresponding

manual pump isolating valves are open or closed accordingly. The
valves of the pump not in operation must be closed.

Note

The hot water is now in circulation and the desalination process is

ready for the heat input.

Operation & Maintenance Manual, MEP-4-200, Rev.00 30

 Note

Now the temperature of the hot water is increasing and the plant is
starting to produce its first distillate. It is important to monitor the
distillate production with the resulting start of the distillate pump and
level control of the distillate valve.

Note

The unit is now producing its first distillate. Normally the purity of the
first distillate is in bad conditions, because of dirty residuals at the
inside of the plates and evaporator shell. The impure distillate is
automatically discharged with the distillate rejection valves. The
purity normally will get to its rated values after max. one hour. If the
conductivity meter indicates pure distillate the distillate is
automatically switched over to the normal distillate line.

 Check now all conditions around the plant.

Note

The manual start has only been necessary to check all equipment
during the first start after erection or maintenance works.
With all systems filled and functions checked the unit shall be
switched to AUTOMATIC mode for normal start up and production.

To proceed to the normal automatic start-up the unit shall be

stopped according to instruction Normal Shut-Down in Manual
Conditions.

Note

If all parameters of the unit are in normal conditions, all pumps,

valves etc. should be switched to AUTOMATIC mode on the panel.
The normal operation shall always be done in automatic conditions.
The manual start has only been necessary to check all equipment
during the first start after erection or maintenance works.

6.3. Normal Start-up

The normal start-up shall always be by AUTOMATIC sequencing in the
automatic mode. If the operator decided to start-up the unit manually, he must
perform the whole start-up procedure in these conditions (MANUAL). The start-
up procedure in MANUAL is described in “6.2 First Start-up”.
The start-up procedure in AUTOMATIC is found find in the following description.

Operation & Maintenance Manual, MEP-4-200, Rev.00 31

6.3.1. Preparation for Starting
Before every start-up of the desalination plant, several checks must be done to
make sure the equipment is ready for start-up:
 Check that the anti-scale tank is filled (prepared in accordance with “6.7 Feed
Water Treatment”).
 Check oil levels in the pumps and top up with proper oil, if necessary.
 Check all connections at the limit of the plant.
 Check conditions and values of additional plants you need for operation of
the desalination plant.

WARNING

To prevent unintentional starting of the equipment local rules and

procedures for maintenance work must be followed.

6.3.2. Line Up of Valves

Check the position of valves in the feed, distillate, brine and air removal lines.
The position of the valves before the start-up must be as indicated in the valve
checklist, Table I.

Note

Shut-off valves for all instrumentation, such as gauges, level

indicators, etc., should be open unless otherwise indicated.

6.3.3. Starting Procedure

 Turn ON the main switch.

Operation & Maintenance Manual, MEP-4-200, Rev.00 32

 Note

On powering up, the low voltage alarm and other alarms will be
generated. Press the alarm-reset button and interrogate the alarm
panel. Remove alarm causes.
Prior to a start up the unit status shall be reviewed for a no alarm
condition. All causes for shutdown alarms shall be removed before
operating the unit.

In the field:
 Check that manual valves are correctly lined-up.
 Check that the chemical pump is turned on

At the HMI-panel:
 Review for no alarm condition.
 Review and check alarm settings
 Review and check control settings
 Review and check that all controllers are set in their automatic
mode.
 Reset any shut down alarms

Hot water / steam systems (if applied)

 Prior to starting the hot water system check that hot water and
steam conditions for availability at required temperatures,
pressures and quantities.
 Check that external isolation valves in the hot water system, for
feed and return, are open.
 Check that external isolation valves in the steam system, for feed
and condensate, are open.

 Set all control valves in their automatic closed loop control mode.
 Press the push button “AUTO START”.

Note

The plant now will perform the start-up procedure by its own. During
the start-up the operator is responsible to take care that the steps of
the start-up and the values of levels, pressures, etc., are correct.

The steps of the start-up in AUTOMATIC are described in the following

summary: Refer to the function chart or operator panel description for further
details.

Operation & Maintenance Manual, MEP-4-200, Rev.00 33

  The vacuum breaker valve XCV301 and the drain valve XCV311 close
 The vessel pressure is monitored
 Start of sea water pump
 Start of sea water temperature control and sea water filter
 Start of ejector pump
 Start of feed water flow control and feed water filter (if automatic)
 The chemical dosing is started (enabled)
 The brine pump PU-BR-01 starts (enabled) and level control valve LCV200 is
enabled for control.
 The distillate pump PU-DI-01 starts (enabled) and level control valve LCV400
is enabled for control.
 Distillate salinity monitoring is activated
 The hot water pump PU-HW-01 starts
 The on/off steam valve VA-ST-91 open (if steam pressure is above a pre-set
point)
 The steam regulation valve TCV501 starts to open the steam supply (if
supplied)

Note

Now all pumps, controllers and safety devices are in operation or

active and the production of the unit rises to the rated value. The
operator is requested to monitor & check the operation conditions of
the unit and record on logging sheets all operating values at least
twice a shift to recognise irregular conditions and to be able to react
quickly to prevent production upsets and to protect equipment. Only
work in sense of responsibility will give optimum performance and
availability of the desalination unit.

Operation & Maintenance Manual, MEP-4-200, Rev.00 34

 TABLE I: PRE-START POSITION OF VALVES
Circuit Valve Service Position
Tag No.
Feed VA-SW-01 Sea water inlet for evaporator Open
TCV105 Condenser flow control Auto & closed
FCV152 Feed water control Auto & closed
Brine VA-BR-10 CIP line (unit drain) Closed
LCV200 Brine level control Auto & closed
VA-CI-10 CIP line Closed
Distillate VA-DI-10 Distillate drain Closed
LCV400 Distillate level control Auto & closed
CCV403 Distillate reject 3-way valve Auto & reject
VA-DI-32 Distillate cooler by-pass Closed
VA-DI-30 Distillate cooler inlet Open
VA-DI-31 Distillate cooler outlet Open
Ejector VA-EC-05 Ejector sea water main line Open
VA-SW-14 Distillate cooler inlet Open
VA-SW-15 Distillate cooler outlet Open
VA-SW-16 Distillate cooler by-pass Closed
Hot VA-HW-09 Hot water by-pass Closed
water VA-HW-91 Hot water inlet Open
VA-HW-92 Hot water outlet Open
VA-HW-05 Booster inlet Open
VA-HW-06 Booster by-pass Closed
VA-HW-07 Booster outlet Open
Steam TVC501 Steam flow control Auto & closed
VA-ST-91 On/off steam Auto & closed
Conden VA-CS-91 Condensate outlet Open
sate

6.4. Normal Shut-Down

The normal shutdown procedure will be done in automatic conditions. If the
operator decided to shut down the unit in manual conditions both procedures are
described in the following sections.

6.4.1. Normal Shut-Down in Automatic Conditions

The unit itself will perform the normal shutdown procedure in automatic
conditions after pushing the AUTOMATIC STOP button. During the shutdown the
operator is responsible to monitor the steps of the shutdown and the values of
levels, pressures, etc., are correct.
The steps of the shutdown in automatic are described in the following summary:
 Steam valve is closing
 Hot water pump is stopped
 Close hot water inlet and outlet valves (if installed)
 Ejector pump is stopped
 The vacuum breaker XCV301 is opened
 The system cools down for a period of time.
Operation & Maintenance Manual, MEP-4-200, Rev.00 35
  Sea water pump is stopped
 Sea water temperature control disabled
 Stop of automatic control sea and feed water filters (if supplied)
 Feed water flow control valve is closing
 Stop of chemicals dosing
 The vessel levels are drained for a period of time.
 The brine pump PU-BR-01 is stopped on low level (level control still enabled)
 The brine valve LCV200 closes (level control still enabled)
 The distillate pump PU-DI-01 is stopped (level control still enabled)
 The distillate valve LCV400 closes (level control still enabled)

Note

The unit has now completely stopped, but be careful of the vacuum
inside of the unit.

6.4.2. Normal Shut-Down in Manual Conditions

The normal shutdown manually will be performed by the operator step by step in
the following manner,

Note

If the panel is in AUTO a change of the selector switch from AUTO

to MAN will automatically shut down the unit in one step and a
shutdown alarm generated.

Caution

Prior to a shutdown co-ordinate the shutdown with steam and hot

water plant operators to prevent system upsets.

 The panel is in MAN.

 Close the steam booster valve TCV501 by disabling the valve at the control
screen.
 Stop the hot water pump PU-HW-01
 Stop the ejector pump PU-EC-01
 Open the vacuum breaker XCV301
 Close the feed water valve FCV152
 Stop the chemical pump PU-CD-01
 Stop the sea water pump PU-SW-01
 Close the manual seawater valve VA-SW-01
 Stop the brine pump PU-BR-01
 Close brine valve LCV200
Operation & Maintenance Manual, MEP-4-200, Rev.00 36
  Stop the distillate pump PU-DI-01
 Close distillate valve LCV400

Note

The unit has now completely stopped, but be careful of the vacuum
inside of the unit.

Caution

If you stop the unit for a longer time, that means more than 48 hours,
it is necessary to flush the unit with distillate or drinking water to
avoid corrosion. Salinity, oxygen and moisture are mainly
responsible for damages at mechanical seals etc. and corrosion at
unit’s equipment. It is a must to study and follow the section 6.6
about PROLONGED SHUTDOWN.

6.5. Emergency Shut-Down

If an emergency requires shutting down the unit as rapidly as possible, proceed
as follows:
 Press the red EMERGENCY STOP button on the panel.
 Close all valves which are possible to close.
 Review the alarm panel
 Check the reason of emergency.
 Take care that all equipment will be in safe conditions.
 Inform all responsible persons of the shutdown.
 Turn OFF main switch if the situation requires complete electrical isolation.

WARNING

Do not unlock the EMERGENCY STOP button before having

switched off the main switch and locating the reason of emergency.
The EMERGENCY STOP should be avoided if not necessary.

6.6. Prolonged Shut-Down

If the unit is to remain shut down for a longer time, the operator must perform
additional steps for preservation of the equipment. Please find below two
different descriptions of procedures for temporary shut down (several days) and
permanent shut down. It is also necessary to follow “7.5 Leak Testing” (Cleaning
the Unit and Components) before you prepare a prolonged Shut-Down.

Operation & Maintenance Manual, MEP-4-200, Rev.00 37

6.6.1. Shut Down For Several Days
If the unit is to remain shut down for several days, that means not longer than
one week, additional steps must be performed by the operator for preservation of
the equipment, as follows:
 Isolate the unit by closing all valves to the utilities.
 Drain the brine from the evaporator.
 Connect fresh water or tap water to the sea water inlet.
 Open the feed water valve FCV152.
 Now the condenser and sea water inlet/outlet piping and all equipment in
contact with sea water will be flushed (flushing water will be drained by the
brine pump - manually operated or if enabled (auto)).
 Drain the whole unit including brine siphons from liquids.
 Drain and flush the anti-scale tank with fresh water. Temporarily disconnect
the discharge tubing of the dosing pumps and operate the pumps on fresh
water for at least 15 minutes.
 Turn OFF main switch.

Note

Procedure of flushing with fresh water or distillate is a must to save

the equipment against corrosion. If scale or other residuals are
recognised on plates or shell, a procedure of acid cleaning is
necessary to perform before preservation of the unit. The acid
cleaning will be done in accordance to “7.6 Cleaning the Unit and
Components”

Caution
Do not apply a “stop & start” operational philosophy based on stand-
still up to 48 hours.
This will seriously harm the lifetime of your unit!
Continuously operation will ensure maximum lifetime of your
equipment.

6.6.2. Permanent Shut Down

If the unit has to be shut down for more than one week, additional steps must be
performed by the operator for preservation of the equipment. The above
described procedures have to be carried out in strong accordance of the
respective rules. The permanent shut down needs extended preservations to
keep out salinity, moisture and oxygen.

Additional steps must be performed by the operating personnel as specified

below:
 Make sure that there is no salinity residual rest in the whole equipment of the
unit.
 Make sure that there are no residual liquids in the whole equipment of the
unit.
Operation & Maintenance Manual, MEP-4-200, Rev.00 38
  If there are several rests of liquids, drain the fluids to keep everything dry.
 It might be necessary to loosen or disconnect certain flanges for complete
drain of piping.

Note

For continuation of preservation procedure for a long time the unit

has to be cleaned and dried completely. Scale or other plugs of dirt
on plates or shell and moisture at joint packings will promote crevice
corrosion in connection to oxygen.

 Close all drains at pipes, pumps, evaporator, condenser, etc.

 Close all valves at the battery limit of the desalination unit.

6.7. Feed Water Treatment

6.7.1. Prevention of Scaling
During the evaporation of seawater there is always a risk of scaling on the
heating surfaces. This will lead to a reduction of the k-values of the heating
surface and decreasing distillate production and reduction of plant efficiency.

In order to effectively prevent scaling the operators must be aware of the factors
influencing the scale formation:
 Feed water ratio
 Evaporation temperature
 Chemical dosing.

6.7.1.1. Feed Water Ratio

The feed water ratio is an extremely important factor. It is defined by the relation-
ship between the feed water amount fed into the plant and the produced amount
of distillate.

For your Alfa Laval desalination unit, the ratio has been optimised to ~4.

If the feed water ratio is reduced, the concentration will rise in the plant resulting
in scale formation.

Two things may shift the feed water ratio: first of all direct adjustment of the feed
water system, and secondly exceeding the maximum distillate production laid out
for the plant. The operators must observe the following rules at all times.

Caution

DO NOT exceed maximum plant capacity.

Be careful if adjusting the feed water system.

Operation & Maintenance Manual, MEP-4-200, Rev.00 39

6.7.1.2. Evaporation Temperature
Another factor influencing scale formation is the heating medium temperature.
Temperatures higher than laid out by Alfa Laval will increase the scaling risk.

If the plant is steam driven, be sure that the steam is saturated.

Caution

DO NOT exceed prescribed heating media temperatures.

6.7.1.3. Chemical Dosing

In order to control scale formations on the heating surfaces and continuously
ensure long operation periods without acid cleaning the plant, it is absolutely
necessary to dose scale control additives to the feed water. The operators must
follow the instructions for chemical dosing given by Alfa Laval very carefully.

Caution

DO NOT operate the desalination unit without recommended

chemicals.

6.7.2. Anti-scale Dosing

Alfa Laval recommends ALTREAT 400 for anti-scale dosing. Alfa Laval has had
many years of experience with this distillate, and we have achieved excellent
results, when the dosing was carried out correctly.

If it is not possible to have this brand, ask the supplier of a similar type, and
follow his recommendations.

Note

Never use chemicals containing anti foam as this destroy the heat
transfer and thereby affect the distillate production.

Caution

Your rights under the warranty might be affected if ALTREAT400 is

not used.
Alfa Laval cannot and will not recommend any other anti-scale
chemical.

Operation & Maintenance Manual, MEP-4-200, Rev.00 40

6.7.2.1. Chemical/Physical Properties
ALTREAT 400 is a neutral solution of synthetic polymer. The active reagent of
Sodium salts derives from a distillate based on hydrolysed polymaleic anhydride.

The properties are listed below:

Physical form Liquid
Solid content 41.5 – 46.5%
pH-value 7.5 - 8
Density (DIN 51757, 23°C) 1.24 – 1.28 g/cm3
Viscosity ≤ 600 mPa
(23°C, Brookfield, 60 rpm)

6.7.2.2. Safety Precautions with use of ALTREAT 400

WARNING

1. USE eye protection and gloves. Avoid skin contact, eye contact
or contact with clothes.

2. CLEAN empty tanks before disposal.

3. If chemicals are spilled on clothes, rinse with water and

dispose off clothes.

4. If chemicals are spilled on the floor, rinse with water and suck
remaining chemicals off with sand. Clean the spot immediately
afterwards.

5. ALTREAT 400 is hazardous, if consumed in a concentrated

solution. If consumed by mistake:
IMMEDIATELY SEEK MEDICAL ATTENTION.

6. If eyes get in contact with the chemicals, rinse for least 20

minutes.
IMMEDIATELY SEEK MEDICAL ATTENTION.

WARNING

For handling of chemical drums do follow local safety instructions.

Risk of personnel injuries due to handling and heavy lifts. Handling
tools must be made locally.

Operation & Maintenance Manual, MEP-4-200, Rev.00 41

6.7.3. Equipment
The following standard equipment is delivered:
 1 Chemical tank
 1 Flow indicator, 0 - 2.5 l/h
 1 Hand mixer
 1 Level alarm
 1 Chemical dosing pump

The chemical tank has a capacity of 140 l, each 20 l are clearly marked. Use the
hand mixer on top after refilling to ensure a homogenous mixture of chemicals
and water. The level alarm gives an external alarm, when the level in the tank
falls below approx. 60 l.

The dosing pump is a membrane pump type, maximum counter pressure 10 bar.
The pump is furnished with a safety valve.
When the pre-set safety valve of 10 bar is exceeded, the pump will automatically
stop, until the backpressure is covered.

NEVER adjust the pump capacity during stand still.

6.7.4. Dosing Ratio

The amount of ALTREAT 400 to be continuously added to the unit is calculated
in relation to the amount of feed water.

Note

Recommended dosing ratio is 4 ppm of feed water amount.

When dosing pump is in operation, adjust pump capacity to 1.0 l/hr by measuring
the change of level of the chemicals in the dosing tank.

The flow indicator shows if the pump is running (pulses).

Note

The dosing pump must always be adjusted to 1.0 l/h corresponding

to 24l/24h. This means that the operator has to refill the chemical
tank approx. every 5 days (24 hours of operation per day) or when
the low level alarm is activated.

To ensure that the dosage rate is correct, fill in a log with consumption of
chemicals and compare this one with the readings of the distillate. This is the
easiest way to check consumption and it will give a warning if chemical stock is
low.

6.7.5. Preparation of Solution

The solution is prepared in the mixing tank by dissolving the ALTREAT400
additive in fresh water or distillate. The maximum effective life time of the
solution is one week. Preparation of quantities of solution for longer periods is
therefore not recommended.
Operation & Maintenance Manual, MEP-4-200, Rev.00 42
  When necessary, stop the dosing pump and close their valves (not during
operation of the desalination unit).
 Fill with clean fresh water or distillate up to about ½ of the quantity of solution
specified in Table II.
 Pour into the tank the quantity of ALTREAT400 indicated in Table II, and mix
it. Add water to bring the total quantity of solution up to that specified.
 Continue mixing for at least 5 minutes or until the entire additive is completely
dissolved and the solution is clear.

TABLE II: EVAPORATOR FEED WATER TREATMENT

Distillate Quantity of Quantity of Dosing rate Capacity
Output solution chemical in of tank – 24/7
in tank tank operation

[m³/d] [litre] [litre] [litre/hr] [Days]

800 140 67 1 5.8

6.7.6. Dosing
After the solution is thoroughly dissolved:
 Open the valves of the feed dosing pump.

Note

The dosing pump or plastic discharge tubing may be damaged if

operated with closed discharge valves.

 Start the anti-scale dosing pump.

 Set the pump for the dosing rate indicated in Table II, by adjusting the flow of
the pump, as indicated in the manufacturer’s service manual.
 Check that the chemicals used per day is in according with Table II.

Note

A low dosing rate at a high frequency is recommended when using

membrane pumps to ensure a homogeneous mix in the feed water

6.8. Operational Notes

6.8.1. Normal Operation Conditions
It is important that operating personnel become familiar with normal operating
conditions so that deviations from the norm can be recognised quickly and dealt
with promptly. Table III lists the approximate readings that should be obtained
during normal operation of the unit. Most of these indications will be found on the
central instrument and control panel.

Operation & Maintenance Manual, MEP-4-200, Rev.00 43

6.8.2. Maintaining Distillate Output

The normal feed treatment will keep the scale formation of the evaporator to a
minimum, but it is not being prevented completely. Over a certain time interval,
scale will gradually accumulate.
If the temperature of the incoming sea water is held constant at the design value,
the production of the unit will gradually decrease as scale accumulates on the
surfaces of the plates.
Eventually the scale will have to be removed by acid cleaning acc. to 7.6
Cleaning the Unit and Components.

The rate of scale deposition can be predicted more or less accurately, since it
depends on many factors, including:
 Chemical composition of the feed water.
 Degree of attention to feed treatment.
 Brine concentration ratio (ratio of feed to brine flow rates).

Scaling on evaporator plates leads to an increase of the total plant temperature

difference. As general rule, the unit should be acid cleaned if only 80% of full
production can achieved for no obvious reason at 100% heat supply.

Operation & Maintenance Manual, MEP-4-200, Rev.00 44

 TABLE III: TEST SHEET
Test Sheet MEP-4-200 Plant no.: Name: Average
Date
Distillate production m³/h
Distillate production net. m³/24h
Distillate production total m³
Conductivity distillate µS/cm
Conductivity brine mS/cm
SCW temp. inlet condenser °C
Feed temp. (condenser outlet) °C
Hot water inlet temperature °C
Hot water outlet temperature °C
Steam pressure bar
Condensate temperature °C
Temperature effect 1 °C
Temperature effect 2 °C
Temperature effect 3 °C
Temperature effect 4 °C
Temperature effect 5 °C
Temperature effect 6 °C
Distillate temperature °C
Brine temperature °C
Seawater supply pressure bar(g)
Condenser outlet pressure bar(g)
Feed water pressure bar(g)
El motor ejector Amp
El motor brine Amp
El motor distillate Amp
El motor hot water Amp
El motor sea water Amp
El motor condensate Amp

6.9. Trouble Shooting Table

Operation & Maintenance Manual, MEP-4-200, Rev.00 45
Problem Cause Action

Dumping of produced Check conductivity meter alarm set point.

distillate due to high salt
content. Too low evaporation temperature in last effect.

Dumping of produced
Low distillate production.
distillate with salinity below Check inside of dumping valve.
alarm set point.

Too high level in level Malfunction of distillate pump or too high

indicators. backpressure in distillate line.

Malfunction of distillate flow

Flow meter defect. Replace flow meter.
meter.

Distillate capacity higher

Check flow meter. Check hot water/steam flow
than specified, see section
and temperature.
“Technical data”.

Increase evaporating temperature in the last

Evaporating temperature effect. Check sea cooling water temperature
High salt content in produced too low. and flow. Check salinity in each effect using
distillate. test valves.

Condenser tubes leaking. Perform leakage test (see “Pressure testing”).

Conductivity meter defect. Check conductivity meter function.

Start sea cooling water pump, open inlet valve

Seawater not available.
sea cooling water.

Faulty pressure indication. Check and/or replace pressure gauge.

Insufficient ejector pump

Impeller/wear rings worn Dismantle pump. Replace impeller/wear rings,
discharge pressure.
out if necessary.

Mechanical seal defect Replace, if seal is leaking.

Air pockets in pump Vent pump.

Ejector pump amperage Change electric cables, if rotating direction is

Rotating direction.
consumption too high. wrong.

Discharge pressure level Check backpressure. Readjust overboard

too low. valve.

Operation & Maintenance Manual, MEP-4-200, Rev.00 46

Problem Cause Action

Mechanical friction inside Dismantle, and inspect pump parts acc. to

pump. “Maintenance of pumps”.

Too low air pressure. Check function.

Too low discharge pressure

Check pump and adjust / repair.
Feed water valve does not from feed water pump.
open.

Check that sea cooling water pump is running.

Too low seawater flow to
Check strainer before sea cooling water
feed water pump.
pump.

Check feed water pump pressure gauge.

Too much or too little feed
Sea feed water system. Check feed water valve. Check pressure
water supplied.
before orifice (1.8-2.2 bar g)

Increasing evaporating Check for air leakages. Check air suction from
temperature. ejector.
Low heat transfer in heat
exchangers effects.
Adjust distillate level control valve or overhaul
Too high distillate level.
distillate pump.

Too high backpressure on Adjust brine level control valve. Check

pump. seawater/brine overboard line.

Brine pump does not extract

the brine. Impeller / wear rings Dismantle and replace impeller / wear rings.

No discharge pressure. Dismantle mechanical shaft seal and replace.

Brine pump discharge

Level control valve settings. Adjust level control valve.
pressure too high.

Check rotating direction of pump and

Rotating direction.
interchange electric cables, if wrong.
Brine pump ampere
consumption too high.
Check for mechanical friction inside pump.
Mechanical friction.
Dismantle and inspect pump parts.

Air ejector does not extract Inlet pressure ejector. Check ejector pump discharge pressure.

Operation & Maintenance Manual, MEP-4-200, Rev.00 47

Problem Cause Action

Check nozzle/diffuser dimensions; measure

Nozzle/diffuser dimensions.
and replace.

Check suction inlet valves. Remove

air/gasses (increasing Suction inlet valves.
obstructions; check the valves moves freely.
evaporating temperature).

Check discharge pipeline and remove

Too high backpressure. obstructions; clean or overhaul overboard
valve.

Vent condenser end covers by opening air

Air pockets.
valves

Check that the inlet & outlet temperatures on

Inlet and outlet
thermometers accord with values given by
Low cooling effect in temperature.
Alfa Laval service engineer during test run.
condenser (increasing
evaporating temperatures).
Check for fouling of tubes and clean with
Fouling.
brush if necessary.

Seawater flow. Check seawater flow and temperature.

Dismantle pump and inspect or replace

Impeller / wear rings.
impeller / wear rings.
Distillate pump does not
extract distillate. Increasing
level in level indicator.
Discharge pressure too
Adjust distillate level control valve settings.
high.

Check rotating direction of pump and

Rotating direction.
interchange electric cables, if wrong.
Distillate pump ampere
consumption too high.
Check for mechanical friction inside pump.
Mechanical friction.
Dismantle, and inspect pump parts.

Conductivity meter defect. See manufacturer’s instructions

Dismantle and clean. Check for correct wire

Faulty electrode units. connection from electrode unit to conductivity
Error in conductivity meter
meter according to cable connection diagram.
indication.

Water penetration into

electrode unit cable Dismantle electrode unit cover.
connections.

Operation & Maintenance Manual, MEP-4-200, Rev.00 48

Problem Cause Action

Solenoid valve malfunction. Check air inlets for obstructions.

Emptying valves do not open
when the plant is stopped.
Emptying valves clogged. Disassemble and remove obstructions.

Emptying valves do not close

Emptying valves clogged. Disassemble and remove obstructions.
when plant is started.

Too high evaporating Too low cooling water flow

Adjust sea water flow control valve settings.
temperatures. condenser.

Too low evaporating Too high sea cooling water

Adjust sea water flow control valve settings.
temperatures. flow condenser.

Failure in LCP start-up Trouble-shoot control panel according to key

Starting procedure wrong.
sequence. diagram and sequence diagram.

Failure in LCP stop Trouble-shoot control panel according to key

Stop procedure wrong.
sequence. diagram and sequence diagram.

Low level in anti-scale tank. Fill up with chemical solution.

No flow indication on flow

indicator on anti-scale dosing Needle valve closed. Open valve.
unit.

Defect check valve. Dismantle and clean.

Level alarm on anti-scale Fill up with chemical solution according to

Low level in anti-scale tank.
tank. separate instructions.

Air leakage into main Tighten bolts before start-up and under
vessel or piping. vacuum, on: flanges, end covers, valves etc.

Air leakage through loose, Tighten bolts, repair or change defective pipes
cracked or broken piping. and gaskets.

Air leakage through Check mechanical seal on brine pump and

High absolute pressure in
mechanical seal of pumps. distillate pump. Replace defective parts.
vessel.

Check if pump is running. See pump

Ejector pump malfunction. maintenance manual. Check ejector nozzle.
Check piping in the evacuation line.

Pressure control setting not For correct setting, see final settings after
correct. commissioning

Operation & Maintenance Manual, MEP-4-200, Rev.00 49

Problem Cause Action

Coupling of distillate pump

Check coupling. Replace if necessary.
is defective.

Distillate pump motor is not

Consult an electrician.
running.

High distillate level. Level control valve

Check valve and actuator.
malfunction.

Distillate pump mechanical Check and replace defective parts, if

seal is defective. necessary.

Closed valves at unit limits. Open valves at unit limits.

Same possibilities for brine

Same corrections in brine system as for
system as for distillate
distillate system, see above.
system above.
High brine level.

Feed water flow too high. Decrease feed water flow rate.

Feed supply system

Check feed system.
defective.

Defective temperature
No or insufficient feed flow.
regulation at final Check temperature control / regulation.
condenser.

Final condenser is clogged. Clean final condenser.

Check demister and change sections if

Demister is defective.
necessary.

Demister is partially
Clean (flush) demister.
clogged with scale.

High distillate conductivity. Leakage through

Check and tighten or replace, if necessary.
evaporator plate gaskets.

Leakage through final Check and tighten if possible. If not call Alfa
condenser tube-plate. Laval.

Leaking condenser tube Plug the defective tube (both ends)

Operation & Maintenance Manual, MEP-4-200, Rev.00 50

Problem Cause Action

Air leakage into system. Check and stop the unit. See point about high
pressure in vessel.

Pressure of steam supply

Distillate output decreases. Check steam source and piping.
decreases.

Scale or fouling on plates

Clean plates (CIP)
surfaces.

Defective components at
Check valves or replace if necessary.
valve moving parts.

Malfunction of pneumatic
Clogged filter at valves air
valves. Clean or replace filter.
system.

Insufficient air supply. Check instrument air system.

Alarm and/or warning light

remain on with normal Short cut or wire break Check installation.
operating conditions.

Malfunction of distillate flow Flow meter or pulse

Replace flow meter and/or pulse generator.
meter. generator defect.

Feed water filter vibrations Too high pressure drop on

during cleaning sequence flush outlet (max. ΔP = 3 Adjust pressure in flush outlet pipe (orifice).
(automatic filter only) bar)

Operation & Maintenance Manual, MEP-4-200, Rev.00 51

7. Maintenance

7.1. Evaporator heat surfaces (plates)

The heat surfaces of the evaporator are based on plate technology. Prior to
delivery a leakage test has been performed to check for defective plates and
gaskets.

Should, however, the distillate conductivity during operation increase for no

obvious reason a leakage test must be performed, referring to section 7.5.

If a plate leakage is detected during the test it is necessary to open the affected
plate heat exchanger.

Note

Only well trained personnel should conduct maintenance and/or

repair work on the plate heat exchangers.
It is recommended to order service assistance from Alfa Laval to
conduct such work.

Prior to open the plate heat exchangers, it is necessary to remove the demisters.
Carefully note the position of the demister sections to ease the reinstallation.

Note

After some time of operation, the demisters made of Polypropylene

(PP) tend to be brittle. Be careful upon removal and installation.
Defective demisters might result in increased conductivity of the
distillate.

WARNING

Secure that all utilities connections are closed and the heat
exchangers of the HT-JW recovery and main condenser systems
are drained before opening.
Risk of burn hazards and slippery surfaces.

WARNING

The heat exchangers of the first MEP effect (JW/HW recovery) and
main condenser (for capacities <500 m³/24h) are not equipped with
hangers for the pressure plates i.e. the pressure plates (each ~80
kg) will drop when bolts are loosened if a lifting system is not used.

Risk of severe personnel injuries due to handling and heavy lifts!!!

Operation & Maintenance Manual, MEP-4-200, Rev.00 52

7.2. Demisters
The demister requires very little, if any, maintenance work. However, some
general practices should be observed in maintaining them, as follows:
 The access to the demisters is only possible after opening the access doors.
 Over very long periods of operation, some salt or scale deposits may
accumulate on the demisters. This can be determined by inspection of the
demister sections. If necessary to clean, removal and flush with a lot of water.
If scale is existent on the demister dip in a tank of acid solution. For example
the spent acid after acid cleaning of evaporator.

The removal of demister sections will be done as follows:

 Open the door of the effect the work shall take place.
 Make sure that there is adequate ventilation in the main tank before entering.
 Enter the main tank via the access door.
 Dismantle the fixing elements of the demister (note the position to ease the
reassembly work).
 Remove the demister elements one by one.

The installation of new or cleaned demister sections will be done the opposite
way.

7.3. Pre heater

To get the correct inlet temperature of the hot water pre heater is installed. The
pre hater requires very little maintain. The pre heater is shell & tube type (EX-
HW-02). Over a period of time there may me some deposits accumulated in the
pre heater. This can be determined by inspection of the pre hater sections. If
necessary to clean, removal and flush with a lot of water is recommended.

Before opening the pre heater make sure that steam and condensate line is
closed and all operation is stopped. Make sure that TP9 and TP10 is closed
manually (steam and condensate inlet) (not in Alfa Laval supply). Depressurise
and drain the pre heater. Use the drain valve (VA-HW-10) to drain the pre
heater.

The inspection is done by opening the top cover. Then you have access to the
tubes. When closing after inspection or maintain install new top cover gaskets to
insure no leakage.

Prior to delivery a leakage test has been performed to check for defective tubes
and for the rolling of the tubes. If a tube leakage is detected, the normal
procedure is to roll tube again if the leakage is between tube and tube sheet or
plug the affected tube if the tube itself is leaking.

Approx. 10% of the tubes can be plugged without affecting the capacity. If
amount of plugging is more than 10% retubing is recommended (standard
retubing is described in next section).

Operation & Maintenance Manual, MEP-4-200, Rev.00 53

 Leaking tubes are very seldom. If several incidents are occurring, a close
investigation to find the root cause must be conducted.

7.4. Retubing
The main condenser is a shell & tube type. Prior to delivery a leakage test has
been performed to check for defective tubes and for the rolling of the tubes.

Should, however, the distillate conductivity during operation increase for no

obvious reason a leakage test must be performed. If a condenser tube leakage is
detected, the normal procedure is to roll tube again if the leakage is between
tube and tube sheet or plug the affected tube if the tube itself is leaking. Approx.
10% of the tubes can be plugged without affecting the distillate capacity.

Leaking tubes are very seldom. If several incidents are occurring, a close
investigation to find the root cause must be conducted.

For replacing tubes, the below procedure should be followed.

Caution

In order to prevent loosing tubes inside the vessel, never remove

more than one tube at a time:

One tube out - one tube in.

7.4.1. Removing Tubes Supporting Distance Tubes

These tubes would be marked with a pricking in the tube plate.

1. Use drifter or trigger to loosen the tube from the rolling zone.

Operation & Maintenance Manual, MEP-4-200, Rev.00 54

 When the tube has been pushed approx. 20 mm behind the tube plate.

2. Feel with a finger if a distance tube is mounted.

3. Insert the new tube into the tube plate.

4. Push new tube forward, while pulling old tube out.

Caution

DO NOT use the new tube to push out the old tube.

Operation & Maintenance Manual, MEP-4-200, Rev.00 55

 When the new tube is inserted correctly

5. Roll the tube in both ends with the tube expander.

Operation & Maintenance Manual, MEP-4-200, Rev.00 56

7.4.2. Retubing Tubes NOT Supporting Distance Tubes

1. Use drifter or trigger to loosen tube from rolling zone.

When the tube has been pushed approx. 20 mm behind the tube plate:

2. Feel with a finger that there is no distance tube.

3. Remove the old tube.

4. Insert new tube.

When the new tube is inserted correctly:

Operation & Maintenance Manual, MEP-4-200, Rev.00 57

 5. Roll the tube in both ends with the tube expander.

7.5. Cleaning Condenser

Caution

Always use a steel brush to clean the inside of condenser tubes.

7.5.1. Cleaning Condenser Tubes

1. Fit the brush on a rod and remove obstructions in the tubes.
2. Wash the tubes with clean seawater.
3. Clean the steel brush before storing it for future

7.6. Leak Testing

The Alfa Laval MEP Desalination Plants are low temperature distillation units
and therefore operating under vacuum conditions in the evaporator vessel and
most pipes. Any external leaks will result in air being drawn into the process, with
possible loss of vacuum and efficiency. For optimum performance of the unit
these leaks must be eliminated.

Within the evaporator vessel, however, the probability and/or significance of

internal leaks through gaskets between plates and chamber walls are minimal.
This is not only because the pressure differential is very small, but also because
the pressure on the distillate side is always higher than that on the brine side.
Thus, possibility of distillate contamination is minimised.

7.6.1. External Leaks - Vacuum Tests

The unit should always be subjected to vacuum tests following any major
disassembly, or if the unit has been idle for an extended period, or if air leaks are
even suspected. Such tests consist essentially of two parts. First, the time

Operation & Maintenance Manual, MEP-4-200, Rev.00 58

 required to build a specified vacuum is checked; then, with the unit shut off, the
rate of vacuum loss (pressure rise) is observed. Perform these tests as follows:
 Follow the normal start-up instructions, but in manual conditions.
 After starting the ejector pump, check the time required to evacuate the
vessel from atmospheric pressure to 0.1 bar(a) indicated at PT310. With a
tight system and ambient temperature in a range of 20 - 35°C, this time
should be approximately 1 hour.
 Shut off ejector pump. Check the rate of pressure rise over a period of 12
hours. If possible, select a period in which the ambient temperatures at the
start and again at the end are likely the same. The maximum allowable
pressure rise, as measured by PT310, is 0.1 bar per hour.

Note

With the unit shut down and under vacuum, leaks can usually be
detected audibly either by bubbling of air into water, or by inrush of
air into vacuum spaces.

 If the test indicates excessive air leakage, the leaks should be located and
corrected, until satisfactory vacuum tests can be achieved.

Note

It is not allowed to start up the unit if the pressure rise during the
vacuum test is more than 0.1 bar/h. Air is crucial for the efficiency of
the desalination process.

7.6.2. Internal Leaks

The location and correction of internal water leaks will usually require internal
access, which is maintaining by opening the manholes at the evaporator side.
When leakage has occurred from the seawater side it can usually be located by
opening the distillate pipes. Damaged gaskets or dirt between the flange
connections may cause leaks.

The normal way of testing for internal leaks is the following:

 Close brine outlet valve and feed water valve on the controllers.
 Fill the unit with seawater up to 300-400 mm from the bottom of the level
glass on the brine side, or by opening the feed valve with controller in
manual.
 Open the valve on the brine re-circulation / acid cleaning string.
 Start the brine pump manually.
 Let the flow run for 1 to 3 hours and inspect the condensate / distillate outlets
for leaks. If the leak is more than 0.2 litres / hour disassemble the leaking
plate stack and correct or change the leaking gasket.

Operation & Maintenance Manual, MEP-4-200, Rev.00 59

 Finding leaks in this way is done to ensure that there is no leak from the feed
water distribution system to the distillate side causing higher salinity in the
distillate.
The plate stacks can also be tested from the distillate side to ensure that there
are no leaks from condensate to evaporation side.
The leaks found in this way are limiting the loss of distillate or vapour by-pass
from one effect to the next.
 Test the effects one by one.
 Dismantle what is needed to be able to fill up the plate stacks from the
distillate pipe going out of the effect.
 Fit a blind with a valve and fill up the condensate/distillate side to just below
the shelf level of the vessel.
 Open the drain valves from the u-pipes in the bottom and check for leaks.
 If there are major leaks locate the effect leaking and correct the cause.

7.6.3. Internal Access

To reach all areas inside the unit e.g. for demister or plate maintenance, the
evaporator is equipped with access doors. An access door will open the total
area of an effect to realise an inspection of the whole inner parts of the effect.

7.7. Cleaning the Unit and Components

WARNING

Take care during handling with acids. The instructions about

handling chemicals have to be on hand and studied before starting
any activities with acids.
Do not mix more acid solution than required for the job.

7.7.1. Acid Cleaning of Evaporator

Acid cleaning is required if the full output of the unit can no more be achieved
although full heat is applied and/or a visual check confirms the presence of scale
on the evaporator plates.
The scale deposit normally consists mostly of acid-soluble carbonates, which
can easily be removed by recirculation of a solution for acid cleaning.
The cleaning is performed by pumping an acid solution via the feed water system
to the surfaces of the plates. This process will be performed as follows:

 Cleaning of the evaporator heat surfaces via the brine pump and recirculation
bypass (VA-CI-01), for the recycling of the acid solution.

Note

Scaling normally starts in the hottest effects of the system.

Operation & Maintenance Manual, MEP-4-200, Rev.00 60

7.7.2. Preparation for Cleaning
Before starting, have on hand all the material and equipment required for the
entire acid cleaning operation, which should include the following:

 An adequate quantity of acid, as determined below: Table IV

 Cleaning In Place (CIP) mobile unit with transfer pump and mixing tank,
flexible tubing and valves for mixing circuit
 Safety clothing, particularly rubber gloves and safety glasses
 pH test paper or better an electrical pH measurement
 A wooden paddle
 Plentiful supply of clean fresh water for rinsing accidental spillage on
personnel.

WARNING

Although acid cleaning powder or solution presents little hazard,

care should be exercised in handling and use. The dry powder in
contact with moist skin may cause some irritations. For this reason
safety glasses and rubber gloves should be worn while handling the
acid. Wearing a rubber apron and boots is also recommended. If
powder is spilled on the skin or clothes, it should be flushed off with
a lot of water. Dusting of the powder can irritate the nose and eyes,
particularly indoors, and should be avoided by careful handling.
Follow carefully the manufacturers recommendations!

7.7.3. System Preparation

TABLE IV - ACID CLEANING DATA
MEP-TYPE 4-200
Total quantity of acid required for each 0.5 mm scale kg 150
Distillate to mix with acid
Amount of water to fill cleaning circuit (approx.) m3 2-3
Brine level indicator mm 200 - 300
Quantity of distillate to by-pass after cleaning and
m3 6-10
flush.

Any loose flaked-off scale and/or sand accumulated in the bottom of the
evaporator tank should be removed manually prior to acid cleaning. If allowed to
remain, it will result in increased requirements for acid quantity and cleaning
time. It can also clog the distribution system and pump mechanical seal if such
substances enter the brine pump. It should therefore be swept away from the
brine pump suction connection and removed.

Isolated the sea water side of the evaporator from the utilities connections:
 Close sea water inlet valve (VA-SW-01)
 Close condenser outlet valve TCV105
Operation & Maintenance Manual, MEP-4-200, Rev.00 61
  Close brine level control valve LCV200

The lines for acid cleaning will be as follows:

 Open feed water valve FCV152
 Open bypass valve VA-CI-01.

Cleaning Procedure
 The unit is filled with fresh water to a level 300 mm from bottom level brine
side.
 Start the brine pump PU-BR-01.
 Prepare the acid solution in the mixing tank according to table IV. Several
batches must be made and pumped in individually acc. to below.
 Connect the flexible tubing to VA-BR-10.
 Open the acid cleaning valve VA-BR-10.
 Start the acid cleaning pump of the CIP unit.
 After the acid is mixed into the recirculating water, stop the acid pump and
close the acid valve VA-BR-10.
 Ten minutes after adding the acid, start to check the pH-value of the
recirculating solution.
 For checking the pH-value use the drain valve VA-BR-10 (disconnected CIP
unit)
 The first sample should be disposed because of the dead end of the drain
line. Only use the second sample to check the pH-value.
 If the pH rises to 3.5, neutralise the spent acid and dispose into the brine line.
 Stop the pumps and empty the system.
Note

For ecological reasons the spent acid solution must be neutralised

with a basic material, such as limestone or soda-ash, before draining
for disposal.
Carefully follow local rules and regulations.

 Clean again, following the above procedure until the evaporator plates are
clean of scale. If the pH fails to rise to 3.5, but remains at lower value for at
least an hour, it indicates that the cleaning process is completed. Always
confirm the cleanliness by visual inspection.

WARNING

As carbon dioxide (CO2) gas is generated by the acid reaction with

the scale, make sure that there is adequate ventilation in the
evaporator vessel tank before entering.

Operation & Maintenance Manual, MEP-4-200, Rev.00 62

  After the last cleaning, flush the unit with fresh sea water for 3 consecutive
hours. Check that the pH of the incoming feed water is the same as the
discharged flush water before putting the desalination unit back in operation.
 After restarting the unit, as a precaution, set the 3-way valve CCV403 to
dispose the distillate for the first 6 to 10 m³ back to the sea.
 For several days following acid cleaning, sequentially check the operation of
the brine level controller LT200. If clogged with scale particles, it will give the
control valves wrong signals. If necessary, clean the bypass tube and float.

7.8. Periodic Routine Maintenance

The operator should be familiar with the procedures for maintenance of the sub-
supplier’s equipment. For detailed instructions, refer to the sections of this
manual of the pertinent equipment.
As a guide, Table V is a general summary of routine periodic maintenance. In
many cases the frequency of maintenance procedures will depend upon severity
of actual operating conditions, and those given in the table are recommended
minimum maintenance. If actual operating and/or environmental conditions
warrant, the intervals should be shortened wherever necessary.
In particular, lubrication requirements for motor bearings can vary widely with
bearing type, size and rotational speed, especially as to frequency of greasing.
Nor it is possible to specify one greasing interval that is applicable to a given size
motor of different manufacturers. The recommendations in Table V are average
requirements; it is important to refer to manufacturer’s instructions in each
specific case.
When checking motor bearing temperatures, use a thermometer rather than rely
on feeling by hand. The thermometer bulb can be placed in contact with the
bearing frame and held in place with caulking or putty. If bearings are running
excessively hot, it may be the result of too much lubricant. If changing the
lubricant does not correct the conditions, disassemble and inspect the bearings.
To repack a bearing with grease, do not fill completely, but only between ½ and
2/3 full.

TABLE V - MAINTENANCE INTERVALS

Equipment Daily Weekly Monthly Quarterly semi-annually Annual
Distillation unit Check CIP if Check and
operating data necessary tighten all
against bolts
normal throughout
conditions unit (vessel,
piping, view
ports etc.)

Vessel Check,
internal replace and/or
tighten
sacrificial
anodes

Access doors Check and

to vessel tighten bolts

Check door
gaskets

Operation & Maintenance Manual, MEP-4-200, Rev.00 63

Equipment Daily Weekly Monthly Quarterly semi-annually Annual
Condenser Check
sacrificial
anodes in
condenser
covers

Check cover
gaskets
Pumps Check oil Check pump Change oil in Grease motor Check all
levels if oil and motor pumps (see bearings, rotating
lubricated bearing manufacturers tighten all bolts elements in
pumps are temperatures instructions) at pumps and pumps (see
used motors, check manufacturers
coupling for instructions),
alignment - clean, inspect
shim up units if and re-grease
necessary motor
bearings

Water jet Check Check nozzle

ejector function (inlet (see
& outlet manufacturers
pressure) instructions)

Dosing Check Prepare new Clean and

systems function and solutions if flush dosing
dosing rates, needed equipment with
adjust if fresh water
necessary

Level control Check Clean float and

indicators function of bypass tubes
floats

Manual valves Operate if not

in daily use

Pneumatic Check Grease Tighten all

valves function screws.

Electrical Check See Check

instruments function manufacturers calibration
instructions Tighten all
screws.

Electric Check Inspect of Tighten all

panels function any dirt screws in
inside. panel, check
Clean if all contacts of
necessary main
components,
clean to
protect
against short
circuits and
corrosion’
PLC Refer to section: Maintenance Notes for PLC based control systems.

Operation & Maintenance Manual, MEP-4-200, Rev.00 64

Equipment Daily Weekly Monthly Quarterly semi-annually Annual
Piping Check for Inspect and
leakages clean to get
out scale and
dirt

Instrument air Check Inspect and

system function clean piping
and filters

Feed water Check Clean

filter function manually, see
manufacturers
instructions

WARNING

The manufacturers instructions have to be followed independently

from the table above.

7.9. Control Settings and Alarm Adjustments

All controls have been set in the factory. Normally they do need readjustment on
site. Referring to “Operation/Maintenance of Control Panel” section for list of set
points.
Control valve tuning may be required after commissioning as conditions change.
Readjustment on site may be performed only by Alfa Laval personnel or with
Alfa Laval authorisation.
The operator shall constantly update a log of all settings.

7.10. Maintenance Notes for PLC based Control Systems

The control logic for the Desalination unit is programmed in a B&R PLC. Any
work in connection with the control system or PLC shall only be carried out by a
qualified technician.

7.11. Maintenance for other Equipment and Components

For operation and maintenance of other equipment and components of the
evaporator, referring to following “Operation/Maintenance” sections.

Operation & Maintenance Manual, MEP-4-200, Rev.00 65

8. Extent of Delivery
Alfa Laval will deliver the following equipment:

2 MEP-4-200 Hot Water, each capacity 800 m3/24h

The units delivered are skid mounted and ready for fast and direct hook-up to the
heat source.

Auxiliary:
 1 CIP (Cleaning in Place) acid cleaning unit with electrical pump.

The exact extent of the Alfa Laval delivery can be seen in the P&I diagram.

MEP-4-200, each unit:

1 Brine pump with motor

1 Ejector pump with motor

1 Distillate pump with motor

1 Hot water pump with motor

1 Sea water pump with motor (VFD controlled)

1 Steam booster incl. regulation valves and steam trap

1 Pre heater, type S&T

1 Distillate cooler

1 Ejector system water driven

1 Anti-scale dosing unit incl. pump and tank

1 HECO Feed water filter

1 USPH approved back flow preventer incl. test kit (common)

1 Local control panel incl. MCC

Operation & Maintenance Manual, MEP-4-200, Rev.00 66

9. Drawings & Lists

9.1. Drawings

General Arrangement Drawing Drawing No.: 9680 036143

PI-Diagram Drawing No.: 9680 036142

PID Legend Drawing No.: 985 18973

H&M Diagram Drawing No.: 9680 036363

Position of Equipment Drawing No.: 9680 038103

9.2. Lists (standard)

Pump List List No.: 9680 039384

Tag Number List List No.: 9680 039381

Operation & Maintenance Manual, MEP-4-200, Rev.00 67

10. Spare Parts

10.1. Ordering Spare Parts

When ordering spare parts please always state:
 Unit number
 Drawing number
 Position number
 TAG number

In order to identify TAG numbers, please refer to P & ID and other drawings, in
the “Drawing” section, and for more specific information regarding components in
the “Components” section.

When ordering parts for pumps proceed as follows:

 Find item number of the pump in the TAG number list (see “Lists”).
 Check spare parts drawing and part list to identify the item to be ordered.
(See “O/M of Pumps” section).

10.2. Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.

Do not hesitate to contact your Alfa Laval representative if you have any
questions, problems or require spare parts.

10.3. Spare Parts for Evaporator

Zink Anode, Vessel 9850006213

Iron Anode, Condenser 9851290001

Gasket Door
(ALFA LAVAL Drawing No. 985 22866)

Sight glass Ø125 9851944001

Gasket for sight glass Ø125 9851944002

Solenoid Valve 9852272801

Conductivity Sensor 9852230601

Operation & Maintenance Manual, MEP-4-200, Rev.00 68

10.4. Spare Part Lists
AMOS Lists

Operation & Maintenance Manual, MEP-4-200, Rev.00 69

11. Operation/Maintenance of Boosters/Plate Heat Exchangers

11.1. Steam Equipment / PHE’s

Distillate cooler, PHE Item No.: 30109-09912 &

30109-09913

Steam booster, S&T Item No.: 9680205584

11.2. Evaporator plates

Assembly Plate Stack, D-ECP-10 Drawing No.: 985 23025

Assembly Plate Stack, P-36 - MEP Drawing No.: 985 23149

Gasket Configurations P-36 – 0.6 MEP Drawing No.: 985 23148

Each D-ECP-10 plate stack consist of 92 plates

Each P-36 plate stack consist of 58 plates of E(S-V-D-E) type

Operation & Maintenance Manual, MEP-4-200, Rev.00 70

12. Operation/Maintenance of Control Panel

12.1. Control panel drawings:

Control Panel diagrams Drawing No.: 9680 036323

Connection diagrams Drawing No.: 9680 036360

Operator Panel, Operating Instruction Doc. No.: 9680 039798

Parts List Doc. No.: 9680 040559

12.2. Warning

WARNING

To prevent unintentional starting of the equipment local rules and

procedures for maintenance work must be followed.

WARNING

Free access to the operating position is the responsibility of other

parties. Local rules must be followed.

Operation & Maintenance Manual, MEP-4-200, Rev.00 71

13. Operation/Maintenance of Instruments

Instrument list Doc. No.: 9680 039382

Operation & Maintenance Manual, MEP-4-200, Rev.00 72

14. Operation/Maintenance of Valves

Valve list Doc. No.: 9680 039383

Operation & Maintenance Manual, MEP-4-200, Rev.00 73

15. Operation/Maintenance of Pumps and Motors

15.1. Pump & Motor Data

Pump & Motor Data Doc. No.: 9680 040512

15.2. Warning

WARNING

Due to limited service space around the pumps and components

below the vessel, risk of personnel injuries is present.
Own maintenance tools for handling must be made.
Follow carefully local working rules and procedures.

WARNING

To prevent unintentional starting of the equipment local rules and

procedures for maintenance work must be followed.

Operation & Maintenance Manual, MEP-4-200, Rev.00 74

16. Operation/Maintenance of Chemical Dosing Units

16.1. Anti-scale Chemical Dosing Unit

Anti-scale dosing unit Item No.: 9680 167185

Note: Dosing unit consist of:

 Stirrer
 Multi function valve
 Dosing tank, 50 liter
 Dosing pump BT4b 1602PPEUA000000
 Level switch
 Injection valve ½” x 6 mm

Operation & Maintenance Manual, MEP-4-200, Rev.00 75

17. Operation/Maintenance of CIP (Cleaning in Place) Unit

Acid Cleaning Unit with pneumatic motor Item No.: 9680 119524

Operation & Maintenance Manual, MEP-4-200, Rev.00 76

18. Operation/Maintenance of Various Equipment

18.1. Pre heater

Pre heater – Shell & tube Item No.: 9680 205057

18.2. Demisters
Demister Effect 1 - 3 Item No.: 9680 207478
Demister Effect 4 Item No.: 9680 207479

18.3. Vacuum Ejector

Vacuum Ejector, Körting Item No.: 9680 163219

18.4. Steam Trap

Spirax Sarco, FT43-10 Item No.: 9850 001154

Operation & Maintenance Manual, MEP-4-200, Rev.00 77

19. Operation/Maintenance of Filters

19.1. Feed Water Filters

HECO TS4-3175 Item No.: 9680 165362

Operation & Maintenance Manual, MEP-4-200, Rev.00 78

20. Operation/Maintenance of Frequency Controllers

20.1. VFD for Sea Cooling Water Pump Motor

Vacon Frequency Converter, IP54 Item No.: 9680 168270

By-pass Switch Box OT160 Item No.: 9680 168731

Operation & Maintenance Manual, MEP-4-200, Rev.00 79