Ozone plant final Presendation 2023 Aquatech.pptx

Presentation

1. Ozone Generation & Ozone Disinfection

2. Table Of Contents 2 1. Ozone Basic. A) History Of Ozone Plant B) Basic Of Ozone Plant 2. Ozone Operation. A) Ozone Generating Principle B) Ozone Plant Construction C) 3 Pillars Of Ozone Plant D) Ozone Operations 3. Ozone Plant Maintenance. A) Maintenance Basic B) Maintenance Why? C) Maintenance types and Necessity 4 ).Disinfection

3. 3 A) History Of Ozone Plant 1. Ozone Basic

4. 4 History Of Ozone Plant Copy of the LETTERS PATENT for the pulp bleaching with ozone, 1868

5. 5 Ozone drinking water treatment plant Siemens u. Halske , Berlin - 1898 History Of Ozone Plant

6. 6 Dosing Pump station for Aluminium Sulphate Rapid Filter Ozone Plant Air Ozone Sedimentation Tank Injectors Raw water Pump Clean Water Tank River Newa Capacity 2000 m³/h St. Petersburg ozone plant for drinking water disinfecting, about 1905 History Of Ozone Plant

7. 7 History Of Ozone Plant Ozone Plant St. Petersburg ozone plant for drinking water disinfecting, about 1905

8. 8 Ozone drinking water treatment plant Siemens u. Halske , Paris - 1912 History Of Ozone Plant

9. 9 B) Basic of Ozone Plant 1. Ozone Basic

10. An ozone plant is a machine! An ozone plant is an electrical equipment! An ozone plant is an electromagnetic equipment! An ozone plant is pressure vessel! Ozone plant and protective systems intended for use in potentially explosive atmosphere 10 What is an Ozone Plant? Basic of Ozone Plant

11. 11 Ozone Contact System Controlling residual ozone in water O 2 /O 3 (Alarm autom. Switch-off ozone production) Ambient air measurement Feed gas: O2 air Oxygen Ozone Generator Water to be treated Treated water Ozone Destruct Design of an Ozone Plant O 2 /O 3 Off - Gas Basic of Ozone Plant

12. 12 A) Ozone Generating Principle 2. Ozone Operation

13. 13 electrical energy + 2 O 2) O + Ozone Generating Principle

14. 14 Ozone Molecule Ozone Generating Principle

15. 15 Ozone Generating Principle

16. 16 B) Ozone Plant Construction 2. Ozone Operation

17. 17 Understanding Of Tubli Ozone Plant Main Compressor Unit Power Rating : 165 KW Max Working Pressure : 3.6 Bar R PM: 2800 M ake : Atlas Copco R refrigerant Dryer Type: BEM 05-EsEEE-35 A/29S Permissible pressure: 6.0 bar Operating temp: 0/+230 O C Make : Ultra filter     Air dryer Dryer type: HRS-L 1600 S Work. Temp. : 4 O C to 50 O C A mb. Temp. : 4 O C to 40 O C Work. pressure: 2.5 - max 6 bar Make : Ultra filter   Ozone Gas Generator   Manuf. No. – H1239 Year 2001 Capacity – 1942 L Working Pressure: 4 bar W orking Temp. : -50 to 50 °C M ake : WEDECO   PLC Control Panel Siemens SIMATIC HV Transformer Type : 606 B 2100A 1010T0 5001 Primary / Secondary Voltage : 1060V/ 5500V Primary / Secondary Current : 2062A / 382A Rated Power : 2100 kVA Make: J. Schneider Electrotechnik Gmbh       Power Supply Unit Rated Power : 700 KW Voltage : 400V P hase : 3 Phase Make : Xylum   Chiller Unit T ype : W KWS 800 Max oper . pressure : 28 bar Refrigerant : R407C Make : Heck   Air Ozone Gas Ozone Plant Construction

18. 18 Ozone Plant Construction

19. 19 Ozone Plant Construction

20. 20 EFFIZON HP Technology Ozone Plant Construction

21. 21 EFFIZON HP Technology Ozone Plant Construction

22. 22 EFFIZON HP Technology Ozone Plant Construction

23. 23 EFFIZON HP Technology Ozone Plant Construction

24. 24 C) 3 Pillars Of Ozone Plant 2. Ozone Operation

25. 25 3 Pillars Of Ozone Plant 1. Feedgas 2. Energy 3. Cooling water

26. 26 3 Pillars Of Ozone Plant Feed gas supply Feedgas alternatives: LOX  (Liquid Oxygen) Air  (Air preparation systems) Oxygen  (V)PSA-systems) Feedgas quality: dew point: < - 70 °C filtered by 0,1 µm mesh oil and fat free pressure (inlet): > 1,5 bar(g) for LOX / > 2,5 bar(g) for air Hydrocarbons: < 60 ppm Argon: > 1000 ppm Nitrogen: > 1000 ppm

27. 27 3 Pillars Of Ozone Plant ENERGY SUPPLY The present state of technology reaches specific energy values of: 6 – 15 kWh/kgO3 depending on operating conditions! Power supply requirement: Main supply 400V / 50Hz / 3 Phase Main electrical network TN-C-Net / TN-S-Net Different power supply can be accepted after clarification

28. 28 3 Pillars Of Ozone Plant COOLING WATER SUPPLY Cooling Water quality/requirement: temperature in, design 2 - 32 °C quantity, 1,5 – 6,5 m³/kgO 3 temperature rise 3 - 5 K normal operating pressure 1 - 2 bar(g) contents of Iron < 0,3 mg/l contents of Manganese < 0,05mg/l contents of Chlorides < 100 mg/l pH 6 – 8 carbonate hardness < 8 degree german standard conductivity < 600 µs/cm free of suspended solids and aggressive compounds.

29. 29 3 Pillars Of Ozone Plant

30. 30 3 Pillars Of Ozone Plant

31. 31 D) Ozone operations 2. Ozone Operation

32. OZONE PLANT START UP PROCEDURE Ensure process water lifting flow going on Ensure cooling water pump delivery manual valve opened Ensure compressor cooling water pump manual valve opened Ensure desiccant dryer inlet and outlet air flow manual valves & cooling water manual valves opened Ensure cooling water & chilled water manual valves open in chillers Ensure ozone dosing manual valves are opened Ensure cod blowers suction manual valves are opened Ensure ozone generator air inlet & ozone outlet air manual valves & cooling water outlet manual valves opened Ensure all the equipment have been kept in auto control mode from main plc and set dosing and process water flow set points in main plc Switch on the generator from their local plc switch as per the production requirement Ensure all the equipment of that respective line of the switched on generators are in enabled condition from main plc [accept only converters disabled] Provide the start (ON) command to main plc Closely follow the process parameters like cooling water flow, air flow, air pressure & dew points After achieving dew point of dryers switch on the converters 32 Ozone operations

33. OZONE PLANT STOPPING PROCEDURE Ensure all the equipment are running in Auto control mode Provide [OFF] command to main plc & wait until all cooling water pumps are stopped Switch off all the generators from their local plc For complete isolation of each equipment close all the process manual valves of all equipment 33 Ozone operations

34. 34 A) Maintenance Basic 3. Ozone Plant Maintenance

35. 35 Maintenance Basic MAINTENANCE DEFINITION The Maintenance Of All Technical And Associated Administrative Actions Intended To Retain An Item In, Or Restore It To, A State In Which It Can Perform Its Required Function (Stated Condition). The Engineering Decisions And Associated Actions Necessary And Sufficient For The Optimization Of Specified Capabilities [Capability Is The Ability To Perform A Specific Action Within A Range Of Performance Level.]

36. 36 Maintenance Basic WHAT IS TO BE MAINTAINED? The list of Electrical equipment, location wise which needs to be maintained . sub-station electrical equipment ht / lt ( pcc /mcc) panels transformers (power/distribution/lighting) lighting/service boards ups and battery chargers battery banks control panels for specific equipment process interlocks annunciation panel ecs panels emergency dg sets junction boxes in fields

37. 37 Maintenance Basic WHAT IS TO BE MAINTAINED? b. a/c plant and pressurization c. emergency dg set d. field electrical equipment- motors and local control stations movs eot crane specific equipment power/lighting panels lighting fixtures panels for hydro jetting m/c connection welding recepticles single phase power points hand lamp connections fire alarm mcp junction boxes for fire alarm/ neumann communication

38. 38 Maintenance Basic WHAT IS TO BE MAINTAINED? D . Electrical Equipment In Control Room Panel For Fire Alarm Panel For Neumann Exchange Control Panels For Specific Equipment Power Cable End Termination In Inst. Panels Control Cable End Termination In Fir Lighting Fixture Including Emergency Lighting Lighting/Power Panels/Points E. Cabling Power Cables Control Cables End Terminations Straight Through Joints

39. 39 B) Maintenance Why? 3. Ozone Plant Maintenance

40. 40 Maintenance Why ? To improve / enhance Performance Life of equipment Reliability To save time and money To reduce / eliminate breakdown

41. 41 C) Maintenance Types and Necessity 3. Ozone Plant Maintenance

42. 42 Maintenance Types and Necessity MAINTENANCE TYPES Proactive maintenance Predictive maintenance Preventive maintenance(PPM) Breakdown maintenance Reliability Centered Maintenance (RCM)

43. 43 Maintenance Types and Necessity SOURCES OF DEFECTS FAILURE Collateral damage. (bearing seizure, damaged shaft) WORKMANSHIP What they do; not what they could do. Not just skill and motivation… the system as well. (being so reactive and time-pressed so as to fail to align the pump before bringing it to line.) DESIGN Design not fitting current use, could be poor initial design. MATERIALS Defects in mfg , storage, handling and sourcing OPERATIONS Normal wear & tear, operational practices

44. 44 Maintenance Types and Necessity TYPES OF MAINTENANCE Preventive Maintenance Consists of performing regular maintenance on a time schedule. it is an expensive alternative that simply masks and delays the root causes of failure. Predictive maintenance Consists of applying early warning techniques to detect small amount of damage before they lead to catastrophic failure. expensive repairs remain imminent. Proactive maintenance Focuses on identifying the root cause of failure affecting the system. properly applied, it commissions corrective action to eliminate theirs before damage has occurred. while predictive and preventive maintenance are effective to a degree, neither focus on detecting the root cause of failure. for true expenditure control, a proactive approach is required.

45. 45 Maintenance Types and Necessity TYPES OF MAINTENANCE Breakdown maintenance Based on a “run to failure” philosophy. often results in maintenance expenditures exceeding annual profit. Reliability centered maintenance (RCM) Fix the process, not just the problem. to get other departments to adjust, to work out new, more productive arrangement that sometime cross traditional boundaries or shift territories or responsibilities and get different departments or functional groups to even accept each others idea.

46. 46 Maintenance Types and Necessity PREVENTIVE MAINTENANCE SCHEDULED/PLANNED RELAY TESTING EARTHING BONDING TESTING MOTOR PREVENTIVE MAINTENANCE UPS / BATTERY CHARGER MAINTENANCE ETC. CHANCE BASED MAINTENANCE SINGLE LINE EQUIPMENT AND CRITICAL EQUIPMENT WHICH NORMALLY CAN NOT BE RELEASED FOR MAINTENANCE .

47. 47 Maintenance Types and Necessity PREDICTIVE MAINTENANCE CONDITION MONITORING The continuous or periodic measurement and interpretation of data to indicate the condition of an item to determine the need for maintenance. The preventive maintenance initiated as a result of knowledge of the condition of an item from routine or continuous monitoring.

48. 48 Maintenance Types and Necessity PREDICTIVE MAINTENANCE CONDITIONING MONITORING IS DONE FOR THE FOLLOWING PARAMETERS Vibration Heat/temperature Alignment Wear and Tear Noise Bearing Condition Pressure Loading trend Lubricating grease/oil Power Quality Monitoring

49. 49 Maintenance Types and Necessity PREDICTIVE MAINTENANCE CHANCE BASED MAINTENANCE RELAY TESTING EARTHING / BONDING CHECKING PANEL MAINTENANCE TRANSFORMER OVERHAULING/ PREVENTIVE MAINTENANCE OVERHAULING / PM OF CRITICAL MOTORS AND SINGLE LINE EQUIPMENT BATTERY BANK MAINTENANCE UPS AND BATTERY CHARGER MAINTENANCE MAINTENANCE OF COMMUNICATION SYSTEM ETC.

50. 50 Maintenance Types and Necessity PREDICTIVE MAINTENANCE DIAGNOSTIC TESTING BDV, DGA/ CHEMICAL TESTS ON TRANSFORMER OIL MILLIVOLT DROP TESTS ON BREAKERS/ CONTACTORS CONTACT VACUUM TEST ON VACUUM BOTTLE OF VCB TAN-DELTA & CAPACITANCE TEST FOR MOTORS, TRANSFORMERS, CABLES. MCSA TEST ON RUNNING MOTORS PARTIAL DISCHARGE TEST, RATIO, POLARITY AND KNEE POINT VOLTAGE TESTS ON CT& PT . CONTACT RESISTANCE TESTS FOR THE JOINTS/TERMINATIONS. THERMOGRAPHIC SURVEY FOR HT/LT PANELS

51. 51 Maintenance Types and Necessity PREDICTIVE MAINTENANCE HISTORY/TREND MONITORING BASED ON THE HISTORY AND TREND DECISION IS TAKEN TO CARRY OUT MAINTENANCE ACTIVITY MTBF- MEAN TIME BETWEEN FAILURE IS ONE OF THE CRITERIA TO DECIDE MAINTENANCE ACTIVITY.

52. 52 Maintenance Types and Necessity PROACTIVE MAINTENANCE IMPROVES EQUIPMENT RELIABILITY INCREASES MEAN TIME BETWEEN FAILURE. IDENTIFIES IMPROPER OPERATING CONDITIONS. CORRECTS PROBLEMS WHILE STILL THEY ARE MINOR. IMPROVES THE RELIABILITY OF REPAIRS. DEVELOPS MORE EFFECTIVE EQUIPMENT SPECIFICATIONS. MAINTAINS THE ACCURACY OF SENSITIVE COMPONENTS. ALLOWS FOR ROOT CAUSE FAILURE ANALYSIS. AUTOMATICALLY PROVIDES PREDICTIVE MAINTENANCE CAPABILITIES.

53. 53 Maintenance Types and Necessity PROACTIVE MAINTENANCE REDUCES MAINTENANCE AND OPERATING COSTS Eliminates repeated maintenance work. Identifies potential problems prior to major overhaul Reduces spare part inventory. Improves personal efficiency. Avoid rush shipment costs. Improves maintenance procedures. Lower mandatory overtime requirements. Improves equipment operating efficiency. Reduces wasted power consumption. Reduces production loss insurance rates.

54. 54 Maintenance Types and Necessity PROACTIVE MAINTENANCE Increased production capacity less unplanned downtime. reduced quality problem and lower rejection rated extended equipment life. Reduced unit production costs increased production due to less downtime. reduced cost due to lower rejection rates. reduced cost due to start up and shutdown losses. Improved supplier performance trend seriousness and frequency of repairs performance feedbacks for equipment improvements eliminate doubt during warranty claims track performance beyond warranty period

55. 55 Maintenance Types and Necessity RELIABILITY CENTERED MAINTENANCE Form a cross-functional team to solve the problem. Widen your views to understand the cause of problem. Use brainstorming session and 5-why principles to arrive at root cause. Use p-d-c-a cycle to solve the problem.

56. 56 Planned Preventive Maintenance Service (Weekly) No. Main Air Compressor Air Service Compressors Refrigerant Dryer Desiccant Dryer Chiller 1 Check Oil Level Drain Condensate Check Filter Green/Red Check Filter Green/Red Check Oil Level Of Compressor 2 Check Readings On Display Check Dew Point Gauge Check Function Of Condensate Discharge Check For DP Of Filter Check Water Pressure 3 Check Condensate Discharge Inspect Air Filter Check Water Temperature

57. 57 Planned Preventive Maintenance Service (Monthly) No. Main Air Compressor Air Service Compressors Desiccant dryer Chiller cooling pump COD 1 Check programmed settings Inspect air filter Lubricate fan seal (oil) Check performance, noise & vibration check the function of emergency stop control device 2 Check for any leakages in compressors Check pump gland condition and tighten if necessary Check the condition of blower for noise, vibration 3 Check bearing lubrication Check for piping for any leakages

58. 58 Planned Preventive Maintenance Service (yearly) NO. PSU MF Transformer 1 Check and tighten all cable and bus bar connection to the right torque. Check Oil breakdown voltage 2 Check stacks condition Check insulation resistance 3 Check inverter and rectifier

59. 59 Planned Preventive Maintenance Service (5 years once) NO COD 1 Replace Catalyst

60. 60 Planned Preventive Maintenance Service ( Once ) NO PSU 4 1 Replacing of semi conductor stack. 2 Replacing of capacitor bank. 3 Replacing of snubber board.

61. 61 Principle Function of Equipment COD (Catalytic ozone destructor)

62. 62 (COD) Ozone destruction system OZONE CONCENTRATION

63. 63 Ozone destruction system for P&P

64. 64 How ozone disinfection works in water treatment? Ozone is a highly powerful oxidant that inactivates pesticides ,fungus , organic materials, contaminates, and viruses 4. Disinfection

65. 65 4. Disinfection 1. Ozone is an unstable molecule that rapidly decays to oxygen (O2)and releases a single oxygen atom, because of weak bond. 2. That single oxygen atom is very reactive, and reacts with the cell membrane of the bacteria and breaks it, attacks the cellular components, interrupts the cellular activity. Which causes immediate death of hazardous micro organisms. 3. Other biocides like chlorine has to pass through the cell membrane of the micro organism. Ozone is 51% stronger than chlorine and has 3.125 times faster kill rate.

66. 66 4. Disinfection

67. 67 Ozone molecule attacks glycoproteins, glycolipids and raptures the cell wall of micro organism. 4. Disinfection

68. 68 Ozone further damages DNA and enzyme synthesis by oxidation and the micro organism cell dies. 4. Disinfection

69. Advantages of ozonation in water disinfection process. 69 4. Disinfection

70. Ozone is more effective than chlorine in destroying virus and bacteria. Ozonation process uses short contact time. No harmful residual that needed to be removed from water. No regrowth of micro organisms after ozonation of water. Ozone is generated on site, so that no safety problems of shipping and handling. Ozone elevates dissolved oxygen content of the processed effluent . 70 4. Disinfection Advantages of ozonation in water disinfection process .

71. 71 Thanks for interests and cooperation ! End of training