Ultra Filtration Module Reverse Osmosis Plant Skid Arrangement Modification-An Engineering Case Study in RO plant with Cost Effectiveness.

How to recover water wastage by UF Skid Module with lifting arrangement. A Case Study for waste water conservation in Reverse Osmosis (RO) treatment plant. Mechwix Technology

Vision &Mission: Finding out Potential improvement by implementation of daily experiences to make our world cost efficient through sustainable development. This case study was conducted to recover leakage water through UF Skid Module-A &B Lifting.

 

Abstract: The DM Plant of a 500MW thermal power plant is equipped with Reverse Osmosis (RO) Filtration unit. It was commissioned & in service from 2018. In the RO Plant there are two no. UF Skids for ultra filtration of clarified water. Then filtered water is fed to RO system to generate DM water. The rated flow through UF skid 200 m3/Hrs. per chain.

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Principally Ultra filtration (UF) involves pressure-driven separation of materials from a feed solution. The technology is used to remove particulate and microbial contaminants. UF plants are automated and have low operational labour requirements. These systems, however, can require frequent cleaning. UF membranes have a service life of three to five years or longer, which is comparable to reverse osmosis membranes. UF membranes reject solutes ranging in size from 0.03 microns and larger. There are four connections on each module. The flow enters the module through the side port located on the bottom end cap. Feed begins on the outside of the fiber. The air feed is located on the bottom of the end cap and is used for air scouring on the outside of the fiber during cleaning by back flushing.

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Since erection of the RO Plant, the bottom clearance of this UF Skid module was 100 mm which was insufficient for maintenance of the bottom portion. Few UF Skid interconnected tube was damaged (i.e. leakage developed) which was not rectified due to insufficient bottom clearance, water was drained due to UF skid interconnected tube leakage so these UF Module was isolated. Subsequently flow through UF skid reduced to 130 m3/Hrs. per chain.

                                   

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To arrest these potential losses it was decided to lift the Skid Module for maintenance approach. Presently the UF skid module has been lifted up to 675 mm from the basement & lower portion for maintenance of the Skid bottom portion. All UF skid interconnected damage tube replacement has been done and previously drained water is being recovered to the main stream flow. After all, flow through UF skid improved up to 200m3/Hrs. per chain.

Cost Effectiveness: Step by step calculation

Total rated flow per chain=200 m3/hr.

Before Skid module Base Modification Total Flow per Chain=130 m3/hr.

After Skid module Base modification Total Flow per Chain=200 m3/hr.

So Total water flow Recovery per chain= (200-130) m3/hr.=70 m3/hr.

In this system a Pump handled 400 m3/hr. flow with 90 KW power rating.

So energy equivalent of 70 m3/hr. flow equals to 15.75 KWH electric Power.

So energy savings per day=15.75*RS 4.00*24=Rs 1512.00 (Considering unit Price RS 4.00)

Total expenditure for the modification job per chain=Rs 130882.00 So Payback period=130882/1512 Day=87 Days (Approx.)

Author & Team Member: Md Kamaluddin

Team Member: 1) Er. Manishankar Bepari, Senior Manager, Turbine Maintenance. 2) Er. Debanjan Majumdar, Manager Turbine Maintenance. 3) Er. Arup Kumar Roy, Manager, TMD.

Special Thanks to : M/S P. C. Joseph Engineering & Contractors, Raghunathgunj, Murshidabad.

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