Defects | Causes | Remedies |
Decrease in capacity between two successive regenerations |
a. Increase in ionic load
b. Flow recorder defective
c. Insufficient chemicals used
d. Resin dirty
e. Plant being used intermittently
f. Channelling in bed
g. Resin fouled
h. Resin deteriorated
i. Resin quantity insufficient in unit
|
Check by analysis
Check
Check
Give prolonged backwash
Avoid this
Check and ensure uniform distribution /collection
If
cation, give HCl wash; if anion, resin give alkaline brine
treatment
Check and replace charge
Check and top up
|
Treated quality not upto the standard |
a. Cation exhausted
b. Anion exhausted
c. Mixed bed exhausted
d. MB resin not in uniform mixed state
e. Some valves like backwash leaking
f. Na slip from cation high
g. SiO2 slip from anion high h. Unit idle
i. Unit not sufficiently rinsed
j. Excessive/low flow rate
k. Channelling l. Resin fouled
m. Resin deteriorated
|
Check
Check
Check
Repeat air mix and rinse
Check
Check raw water analysis; change in Na/TA and SiO2/TA ratio; use
more chemicals
Check raw water analysis; change in Na/TA and SiO2/TA ratio; use
more chemicals
Check
Rinse to satisfactory quality
Adjust to between unit min/max flow rate
Check and ensure uniform collection/distribution
Check resin and give alkaline brine/ HCL treatment
Check resin and
replace
|
Mixed bed quality not good |
a.
Resin not separated during backwash properly
b. Air mix not proper
c.
Final rinse not proper
d. Some valves may be leaking
and contaminating the treated water
|
Give extended backwash after exhausting the bed
Repeat
Repeat
Check and examine
|
High residual CO2 from degasser |
a.
It can be due to choked suction filter of degasser air blower
b.
Improper air flow to the degasser
c. Degasser blower not in operation
d.
Air seal not fitted/broken resulting in short circulating of
air
|
Check and clean filter
Check damper, speed of blower, discharge pressure
Check and operate blower
Check and replace
fitting
|
Unit rinse takes long time |
a. Flow rate too high
b. Unit exhausted
c. Backwash valve passing
d. Anion resin organically fouled
e. MB air mix not satisfactory
f. Acid/alkali pockets formed
in unit
|
Increase flow rate
Regenerate unit
Check and rectify
Give alkaline brine treatment
Carry out air mix once again
Faulty design check and rectify.
Temporarily backwash (followed by air scour if MB) and rinse
again
|
Flow rate too less |
a. Choked valve and suction strainer of pump
b. Cavitation in the pump
c. Low inlet pressure
d. Distribution or collecting system choked
e. Resin trap at outlet choked
f. Control valve shut due to
low off-take
|
Check
Check
Check-pump
Check
Check and clean
Increase off-take
|
Pressure drop across the bed increasing day by day |
a. Defective valves
b. Packed resin bed and resin fines present
c. Collecting system choked
d. Pressure gauge
defective
|
Check
Give extended backwash with open manhole and scrap off fines from
top surface of the resin
Check, repeat backwash
Check and rectify/
replace
|
Flooding in degasser |
a.
Very high air flow rate
b. Packed tower chocked due to dirt or broken packing material |
Reduce air flow rate by adjusting damper
Open and check
|
Resin being lost |
a. Excessive backwash pressure
b. Faulty collecting system
c. Inlet strainer
damaged
|
Check inlet pressure and reduce if necessary
Examine same for breakage
Check and replace
|
Ejector not working |
a. Low power water pressure
b. Air lock in the unit
c. Choked or defective valves
d. Ejector nozzle may be choked
e. Too much back pressure from the unit
f. Bulge in pipe lining |
Check
Backwash & open air release
Examine and rectify
Check
Check for chokage of collecting system; passage of inlet/outlet
valves
Check and rectify
|
Incorrect reading rota-meters |
a. Chocked orifice lines/orifice
b. Dirty glass and
float
|
Check and clean
check and
clean
|
Improper reading from flow recorder integrator |
a.
Choked impulse lines/orifice
b.
DP transmitter requires recalibration
c.
Leakage in signal tube between transmitter and panel
d. Low air pressure for DP
transmitter or recorder
|
Check and clean
Recalibrate
Check
Check
|
Level electrodes system for measuring and dilution tank not functioning properly |
a.
Improper contact between electrodes and control
cabling
b.
Shorting of the two electrodes due to moisture or
any foreign material
c. Improper working of the level
controllers
|
Check contact and rectify
Check and dry the contacts of moisture
and dirt
Check
|
Leakage from acid injection/unloading/transfer pumps |
a.
Improper adjustment of the mechanical seal
b. Low strength of sulphuric and
presence of ferrous sulphate
|
Check and adjust
Check concentration and take
appropriate action
|
Corrosion in concentrated acid tanks and lines |
a. Low concentration of sulphuric acid
b. Lining of HCl tank/pipe
line damaged
|
Check silica gel breather in acid storage tank and replace silica
gel charge if exhausted
Rectify
|
Improper opening and closing of pneumatically operated valves |
a.
Defective solenoid valves
b.
Leakage in airline from solenoid valve to the respective control
valve.
c.
Improper contact of micro switch giving false indication to
panel
d. Fused mimic lamp giving false
indication to the panel
|
Check
Check
Check
Check
|
Improper operation of a certain regeneration cycle | a. Defective relays in the control circuit | Check and replace relays |
Solid state programme not functioning properly |
a.
The controller can be kept in "hold" due to the reasons explained under
operation
b.
Improper operation of the controls for the controller
c. Defect in the inside of the
controller
|
Remove conditions which cause "hold" of controller
Press test switch & check the complete cycle
Check the instruments thoroughly
from inside. Meanwhile, operation may be continued by using bypass
toggle switches
|
Dedicated and thanks to Greenko group CEO &; MD Shri Chalamalasetty Sir and Shri Mahesh Koli SIr, AM Green Ammonia (India) management Shri Gautam Reddy, Shri GVS ANAND, Shri K.Pradeep Mahadev, Shri VIJAY KUMAR (Site Incharge), Shri G.B.Rao, Shri PVSN Raju, Dr. V. Sunny John, Shri V. Parmekar ,Smt .Vani Tulsi,Shri B. B.K Uma Maheswar Rao, Shri T. Govind Babu, Shri P. Rajachand, Shri B.V Rao, Shri. LVV RAO ,Shri P.Srinivaslu Promotion- EHSQL-by Dr. A.N.GIRI- 27.9 Lakhs Viewed Thanks to NFCL.
Sunday 2 March 2014
Troubleshooting of DM plant
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