performance guarantee test procedure

Performance Guarantee Test Procedure|

Performance Guarantee Test Procedure


P135/CMWSSB – Nemmeli Desalination Plant

Contract No: CNT/WSS/ICB/GOI/DESAL/005/2008-09


Client

Chennai Metropolitan Water Supply and Sewage Board

No:1, Pumping Station Road, Chintadripet, Chennai-600 002, Tamil Nadu


Consultant

MECON Limited

No. 89,south end road , Basavangudi Bangalore -560004 , India


Contractor

VATECH WABAG Ltd

Wabag House, 200 Feet MMRT Road, Chennai-600 117

Contents: Page Nos.


1.0. Over view. 4

1.1. Scope. 4

1.2. Guarantee Values. 4

1.3. Reference Documents and codes. 5

1.3.1. Documents. 5


1.3.2. Codes and standards. 5

2.0. Test Organization and responsibilities. 5

3.0. Test Procedure. 6

3.1. Conduction of Test. 6

3.2. Selected Main Equipment Test and Preliminary Checks 6


3.3. Preliminary Tests and Adjustments. 6

3.4. Conditions for test and duration. 6

3.5. Frequency of readings and samplings. 8

3.6. Accuracy of the instruments. 10

3.7. Test Data Collection and submission. 10


3.8. Validation of the test 11

3.9. Test Report 11

4.0. Test results and Calculations 12

4.1. Total Permeate production 12

4.2. Total Power Consumption 12


4.3.Specific Power Consumption 12

4.4 Recovery 12

4.5. Net product water quantity 13

Appendices:


LOG SHEETS1. Intake Area: (i) Intake system parameters log sheet

(ii) Sea water Analysis report (iii) Intake system pumps parameters report

2. Pretreatment area :(i) Pretreatment system Parameters log sheet


(ii) Individual UF skid quality parameters (iii) Individual UF skids performance parameters

3. RO system Area : (i) RO system parameters log sheet (ii) RO feed and permeate water analysis (iii) Cartridge filter feed pumps log sheet(iv) High Pressure pumps log sheet (v) Booster pump log sheet


(vi) RO individual skids performance sheet (vii) ERD Performance log sheet.

4. Post treatment area : (i) Post treatment Section log sheet (ii) Potable water Analysis (iii) Post treatment pumps performance

5. Reject and UF Backwash Area : (i) Reject &UF backwash log sheet


(ii) Reject and UF Backwash pump performance sheet

6. Chemical Area : (i) Chemical consumption log sheet

7. Specific Power consumption log sheet

CHECKLISTSa. Instrument checklist.


Annexures

i) Organogram for activity wise manpower allocation.(to be included)ii) Additional resources / instruments to be procured for Performance testing.(to

be included)1.0. Over view:

1.1 Scope:


The scope of this document is to define the performance guarantee testing procedure for the 100 MLD Nemmeli Desalination Plant.

1.2 Guarantee Values:(As per Cl.11.6.1 of Chap -1 of Vol IIA of contract specification )

Table-1

Sl.No Description Unit Value inclusive of design


Manufacture and all other tolerances including measurement uncertainty

1 Permeate Water quality & quantity at the outlet of SWRO skids at 41900 ppm inlet TDS and 32 deg.C

a) Boron ppm as B

Max. 1

b) TDS ppm ≤375


Net permeate flow from each UF Skid

m3 / hr ≥ 315

c) Net permeate quantity for12 Skids

m3/hr ≥ 4200

d) Recovery % ≥ 45.4%2 Potable water after post treatmenta) Potable water quality

parametersIS 10500 as per table -2


b) Langelier Saturation Index (LSI)

positive

c) Residual chlorine ppm 1d) Net product water quantity m3 / hr ≥ 41673 Pretreated water qualitya) SDI of ultra filter permeate <3b) Min. recovery in UF skids 90%


Net permeate flow from each UF Skid

m3 / hr ≥ 315

c) Net UF permeate quantity for 30 Skids

m3/hr ≥ 9255

d) Chlorine inlet at RO Nil4 For the complete desalination plant

a) Specific power KW/m3 3.83


consumption for complete Plant at sea water TDS 41900 ppm. 32°C at fifth year of operation

b) Noise level of rotating equipment in Desalination plant

dbA < 85


1.3 Reference Documents and codes:

1.3.1. Documents:

Contract Document Volume I and II A, IIB 1of 2 & IIB 2 of 2.

1.3.2. Codes and standards:

Following standards will be followed during the performance test:


ASTM D 4195 –Standard guide for water analysis for Reverse Osmosis Applications

ASTM D 3739 – Calculation and adjustment of the Langelier Saturation Index (LSI) for RO

ASTM D 4189 – Silt Density (SDI) of water. ASTM D4194-Operating Characteristics of R.O.Devices.


ASTM D4516-Standardising R.O.PerformanceData. ( Hydranautic’s normalization program)

ASTM D4582-Calculation and adjustment of the Stiff and Davis stability index for R.O.

ASTM D4692-Calculation and Adjustment of Sulfate Scaling Salts for R.O. ASTM D4993-Calculation and Adjustment of Silica scaling for RO.


2.0. Test Organization and responsibilities:

The test organization shall bein scope of contractor( Field Test Coordinator- FTC)

The FTC will be responsible for the following:


- To make preliminary test run and set the parameters.- To organize the test team- To verify all necessary testing instruments are in place and to check their correct

installation and functionality- To finalize the testing date and intimate to client through consultant- To direct the test- To prepare the checklist and log sheets for recording the data


- To collect all test data as Electronic reports from DCS or as log sheet entry.- Compilation & Submission of test data and reports to client/consultant for

approval

2.1 Manpower resourceutilization - Organogram: The manpower to be engaged in the performance guarantee testing activity along with their responsibilities is provided in the Organogram chart.


3.0. Test Procedure:

3.1 Conduction of Test:

The test procedure in this document shall consider the performance of the plant as a whole unit. Individual equipment performance guarantee tests stipulated in the contract agreement shall be carried out separately based on the approved test schedule


and test procedure (separate test procedure) from the client. At the end of the test, the data will be consolidated by the contractorand the test results will be compiled in the form of reports for submission and approval from client/consultant.


3.2 Selected Main EquipmentTest and Preliminary Checks:

Prior to start of the performance test for the plant as a whole unit,individual performance test on the main equipment such as seawater pumps, raw water pumps&, cartridge filter feed pumps willbe performed to checkand ascertain theirfield performance data as stipulated in the technical specification of the contract agreement chapter 2, vol-IIA.


In case the individual equipment site performance guarantee test cannot be carried out due to requirement for uninterrupted drinking water supply to the city, a prior approval from the client shall be obtained in writing for this exemption.However, the contractor shall seek prior permission from the client in writing indicating the schedule of testing and also providing the time period required for testing of the individual equipment along with the corresponding anticipated reduction in production capacity during testing.


Further, prior to start of PG test for the plant as a whole unit, satisfactory working status of instruments will be confirmed as per the Instrument checklist and clearance from client/consultant shall be obtained by the contractor in writing to proceed with the test.

Performance testing procedure for the whole plant therein comprises performance testing ofonshore & offshore intake system, UF system, RO system ,Pressure


Exchangers system,High pressure and booster pumping system, post treatment systemfor assessing the performance of the plant as a whole for the performance guarantee parameters specified in cl. 1.2 above. The test procedure includes the details of -normalizationprocedure for providing the normalized performance data considering the membrane age and sea water TDS of 41900 ppm. Considering that Hydranautics make, SWC5 max RO membranes are used in the plant, the normalization curves for Hydranautics make available in the contract agreement


vol.IIA, chapter-II shall be used for evaluating the plant performance w.r.t RO permeate quality, feed pressure ,sea water temperature,sp. Power consumption and noise level.As the plant has been producing and supplying drinking water to the city since 23.02.13, the membrane age for normalization shall be considered for PGT test as 2nd year of operation.


The performance of plant units for the integrated PGT will be evaluated for its design capacity & product quality as per the following:

a) -Intake system – i) capacity - 11060 m3/hr to produce net UF permeate >= 9255 m3/hr. The same will

be evaluated by measurement of intake chamber sump level at 11060 m 3/hr of sea water pumping and comparing with design water levels anticipated

Amir Basha K. Syed, 06/02/14,

The pump flow need to be tested along with pump performance test. The actual flow required for 100 MLD production will be measured during PGT


ii) Performance of sodium hypochlorite dosing system at offshore sea water intake shall be evaluated by measurement of free residual chlorine at the intake chamber. No sodium hypochlorite dosing shall be carried at the intake chamber.

iii) Measurement of sea water quality parameters.

b) Pretreatment system


This can be tested separately when the new sodium hypo line is installed. The present line has leakage. New lines are ready availting anchor blocks supply expected in one week.


i) The net permeate capacity of individual UF units >= 315 m3/hr and the total net permeate quantity >= 9255 shall be evaluated by measuring the per day total UF permeate production and the UF permeate utilization for chemical cleaning and backwashing of UF membranes.

ii) The UF permeate recovery shall be evaluated by measuring the per day total feed flow to the UF membranes and the total net UF permeate production.


iii) The UF permeate water quality shall be evaluated by the measurement of Silt density Index of the UF permeate water.

c) RO system


Measurement of turbidity is recommended instead of SDI due to inadequate pressure available for SDI measurement


i) The RO recovery shall be evaluated by measuring the per day total feed flow to the RO membranes and the total net RO permeate production i.e>= 4200 m3/hr for 12 skids.

ii) The feed and RO permeate water quality shall be evaluated by the measurement of TDS and lab analysis for its constituents including boron concentration.

iii) RO inlet chlorine, feed pressure and temperature


iv) Pressure exchanger (PX) performance for salinity increase @membranes (2.7%)/@PX (5%), volumetric mixing (6%), lubrication flow/array (7m3/hr), PX overall efficiency (95.9%)/PX net transfer efficiency (95.7%), noise < 85 db at 1 m distance.

v) Normalisation curves

Post Treatment


The volumetric mixing can be proved only if CMWSSB gives permission to clean all the PX before PGTR. If shutdown is not provided for Px cleaning even the Px performance will be affected.


i) Net product water quantity after excluding internal consumption >=4167 m3/hr.

ii) Potable water quality as per IS-10500 for its constituents through lab analysis, residual chlorine (1 ppm), positive Langlier saturation index (LSI)

Reject Disposal System:


1) TDS of reject at the disposal point in the sea for measurement towards compliance to brine dispersion as approved by MOEF.

Complete desalination plant: 1. Plant Specific power consumption after normalization for feed TDS,

temperature and membrane age.2. Noise level


3. Daily Chemical consumption w.r.t to sodium hypochlorite, sulphuric acid, sodium bi sulphite, antiscalant, caustic soda & limestone

3.3 Preliminary Tests and Necessary settings:

Prior to resumption of test contractor will make preliminary runs with the purpose of


- Ascertaining plant’s suitability for the performance test. This shall include the checking and ascertaining of plant & equipment installation to the requirements contract agreement and specification. Apart from the compliance of defect lists/balance jobs as mentioned in VATEC letter no. P135/VATWS/NEMMEL/523 A and in particular full compliance to defects pertaining to nylon net at the intake, Plant rejects disposal including RO rejects, UF and disc filter backwash waste through reject outfall pipeline and pumping system,rectification of outfall


pipeline,PX acoustics and field and control room instrumentation and controls including wireless communication system shall be necessarily provided.

- EB planned shutdown in the testing period- Making settings as required with or without plant shutdown.- UF/RO Membrane and PX cleaning if required. Intake pipe cleaning if found to be

essential. Necessary shutdown to be provided by the client.- Checking instruments and equipment status.


This is essential as CMWSSB has not given specific maintenance shutdown periodically, when requested, since 8th Jan 2014.


TNEB shutdown to be arranged by CMWSSB . If required we request this to be conducted after 72 hours test, as a continuation to PGTR ,to avoid discontinuity in the test


This is not part of PGT. This may please be removed as separate discussions are parallelly going on


- Familiarizing the personnel nominated for the test.- Checking and ensuring the availability of spares.

3.4. Conditions for test and duration:

The Plant test will be conducted by contractor in the presence of Consultant &Client.


The OEM representatives for Sea water and raw water pumps, Disc filters , UF membranes , Cartridge filter feed pumps, reject transfer pumps, RO membranes , High pressure and booster pumps, Pressure exchangers , shall be made available during the test for witnessing the performance of the respective equipment/units. The test record of the relevant units/equipment are to be vetted by the manufacturer for its site performance.


Readiness for the performance test will be intimated by contractorin writing to the Client and the Consultant atleast 15 days in advance along with their compliance report mentioned in clause 3.3 above. The compliance report shall be backed by joint certificate from the consultants & contractor to ascertain that the defect lists/balance jobs have been attended for acceptance. Only on receipt of the above, the client & consultant will indicate their consent for the suitable mutually agreed date of test. The plant shall be operated at product water


Since compliance report is being discussed at highest level this may please be removed as it does not form part of PGT


capacity of 100 MLD. The test for the stabilized performance of the complete system for72 hours uninterrupted test duration shall be carried out. Field and control room data will be logged during this test duration, at the frequency in the log format forming a part of this document.

All installed instruments used for test data measurements shall have a valid calibration certificate on the date of test.. All the external and master instruments required for PGT shall be of adequate accuracy limits and possess –valid


After start of summer Some times in a day we have experienced 5 trips. Hence, 72 hours of cumulative stabilized operation shall be considered in case of TNEB trips/power failure discarding the hours of interruption.


calibration certificate from approved independent agency/reputed laboratory/institute (NABL accredited) . In case of new instruments manufacturer’s certificate shall be provided with valid date. Should the PG test of SWRO plant be affected or interrupted for reasons including Force Majeures related to reliability or performance of equipment, the test shall be stopped and repeated in full when faults have been remedied by implementing adequate solutions.


In continuation to comment above, PGT to be allowed to be continued for rest of the period for which PGT is yet to be completed ,once the plant stabilizes on restarting after the force majeure.


In the event that the plant fails to meet the performance criteria, the tests shall be re-run after the requirednecessary corrective action has been taken.

Should the results of the performance test show that the equipmenthas failed to meet the specified guarantees, the contractor shall carry out the modification, at his own cost to meet the guaranteed values. In such a case, the performance & guarantee test shall be repeated by the contractor as soon as the equipment is ready after corrective actions. The corrective actions and the


performance, tests shall be carried out till the specified guarantee parameters are achieved.

(TO BE INCLUDED IN INDIVIDUAL EQUIPMENT PGT )Current, voltage, bearing/motor winding temperature, Vibration and noise level of pumps shall be recorded and demonstrated atsite as a part of Performance guarantee test.

All interlocks and protections relating to the pumps, motors and motorized valves & pneumatic operated valves shall be demonstrated /tested as per control logic.


Normally take once during the PGTR period as SWRO is a base load operating unit and there will not be any change


The methodology to demonstrate the interlocks and protections for the above equipment shall be provided as a part of the PGT procedure.

Contractor shall demonstrate the guaranteed Specific Power Consumption furnished in the guaranteed values on day basis.The guaranteed specific power consumption is furnished in the contract for sea water Design TDS of 41,900 ppm at 32°C at the end of the fifth year operation for 100 MLD (4167 m3/hr) product


This test has already been done with ABB. If required it shall be conducted separately as it will call for interruption of PGT


water having quality as per IS – 10500 indicated in table-2. In case of lower or higher TDS & temperature during the performance guarantee test run, the Specific power consumption shall be suitably corrected and modified by extrapolating & Normalizing based on the normalizing TDS & temperature correcting graphs furnished along with the contract.

The successful performance test run shall be for a minimum of uninterrupted 72 Hours operation of the complete plant. Any equipment, instruments , tools and

AMJAD-INSTRUMENT, 06/02/14,

Ultrasonic flow meter can be measured for SS and HDPE line ( only if min pipe line length required 5D/2D is available and Pipe line size above 4 inch)


tackles required for the test would be provided by contractor. The test shall also include measurement of vibration, noise level and bearing temperature rise for pumps and motors.

Noise measurement shall be done as per Hydraulic Institute Standard(HIS). The tests shall be carried out with the machine operating at therated Speed. Correction for background noise shall be applied in line with HIS .


Vibration and noise level are normally take once during the PGTR period as SWRO is a base load operating unit and there will not be any change


3.5. Frequency of readings and samplings:

During the test the following readings will be taken in the logsheets from field instruments as well as from the control room DCS as per the frequency indicated.The tag nos. for the installed field instruments to be providedfrom which the following readings are obtained. The sampling locations / provisions for tappings shall be identified and indicated in the procedure.


a) Intake Area :

(i) Sea water quality parameter analysis shall be carried out at every 8 hrs. The parameters to be analysed is provided in Sea water Analysis report (Report no. )


(ii) Sea water conductivity , TDS (calculated), pH, turbidity , FRC, sea water chamber sump level , shall be recorded from the DCS at every 2 hour interval and the sea water TOC at every 4 hour interval.

(iii) Sea water sample for TSS measurement shall be collected at every 8 hours and will be analysed in the laboratory.


Online TOC failure during recent TNEB power failure due to very high voltage fluctuation


Sensors not available in field nor connected to DCS


(iv) Raw water pH, conductivity , TDS( calculated) ,turbidity , FRC shall be recorded from the DCS at every 2 hour interval and Raw water TSS measurement shall be carried out in the lab at every 8 hour interval.

(v) The performance parameters for intake system pumps in operation , i.e., Sea water pumps , Raw water pumps and Dirty water transfer pumps will be recorded as per the following.


FRC sensor relocated to UF common permeate outlet and connected to DCS


Sensors not available in field nor connected to DCS


- Pumps discharge pressure& Discharge flow @ 2hrs interval , speed of rotation , vibration , motor winding temperature, Noise level at every 4 hours interval shall be recorded in the field using field instruments.


Pumps vibrations using potable meter can be taken for Once in a shift ( Difficult to take every 2 hrs – 12points/equipments


Can be taken from the local readings available


- Pump sump level, Motor Amps, Voltage ,Motor KW shall be recorded in the DCS/Control room (for electrical parameters)at every 2 hour interval.

b) Pretreatment Area


(i) For individual UF skids (30 nos.) - The feed pH, Feed turbidity, Feed TSS, Feed FRC , permeate pH, Permeate turbidity ,Permeate SDI, Permeate FRC shall be carried out once in a day by sample collection and lab analysis. The individual skid performance parameters including feed flow , permeate flow, feed inlet pressure , permeate pressure , TMP, permeability , flux and recovery shall be recorded for every 2 hours from the DCS.


TSS and SDI to be taken at common inlet as it will be same


(ii) The SDI , FRC, pH, for the common UF permeate shall be recorded at every two hours from the lab .The turbidity of the common UF permeate at every 2 hours is recorded from the DCS.

(iii) The total UF feed flow, UF permeate flow and the Total Backwash flow will be recorded on a per day basis from the DCS.


Adequate pressure not available to take SDI values.


c) RO Area

(i) The RO common feed water and Permeate quality parameter analysis shall be carried out at every 8 hour interval by Lab.


(ii) The RO common feed water pH, conductivity , TDS(calculated), FRC, ORP ,SDI and temperature shall be recorded at every 2 hour interval from DCS. The RO feed TOC shall be monitored at every 4 hour interval from DCS.

(iii) The total RO feed flow rate and the total RO permeate flow rate shall be recorded on a per day basis from the DCS.


(iv) The RO individual skids (12 nos.) performance data shall be recorded at every 2 hours from the DCS.

(v) The performance data for individual equipment Pressure Exchanger units shall be recorded as per the following


- For cartridge filter feed pumps –Suction Pressure ,Total discharge flow , Current , Voltage , KW is recorded from DCS /Control room (for electrical parameters) and Discharge Pressure from field at every 2 hours , rpm ,vibration ,winding temperature, noise level from field at every 4 hour interval.


- For High pressure pumps & Booster pumps, Individual operating pumps suction ,discharge pressures , discharge flows ,rpm, motor current , Voltage ,KW shall be recorded from DCS/ Control room (for electrical parameters) at 2 hr interval and vibration , Winding temperature, and noise level at every 4 hour interval from field measurement.


12 readings for each pump cannot be taken at this interval. One stabilized reading can be taken per pump


- For individual operating Pressure Exchanger devices the performance data will be recorded from the DCS. The sound level measurement shall be carried out from the field at every 4 hour interval.

d) Post treatment Section


Normally take once during the PGTR period as SWRO is a base load operating unit and there will not be any change


(i) Potable water quality parameter analysis shall be carried out by lab at every 8 hrs.

(ii) The performance parameters for pumps in the post treatment area are recorded as follows.

- The pump performance parameters of Recarbonation tower feed pumps ,absorber feed booster pumps, and service water pumps for


3 inch pipe line Flow cannot be measured with Ultrasonic flow meter


Pump not in use. Hence parameter measuring could be waived


Parameters that can be measured in lab alone can be taken, which is listed in Table 2.


suction/discharge pressures&flow at every 2 hour interval , speed of rotation , vibration , noise level , winding temperature shall be recorded at every 4 hours interval at field . The pump performance parameters for Current, voltage, KW shall be recorded from the DCS /Control room (for electrical parameters) for every 2 hour interval.


Current, Voltage, kw connection not available in field nor DCS not connected


Winding temperature sensor not available.


12 readings for each pump cannot be taken at this interval. One stabilized reading can be taken per pump


(iii) The potable water quantity generated shall be recorded on per day basis from DCS. Complete inorganic analyses (Ionic concentrations). Conductivity, pH, Turbidity, TDS, Organics and residual chlorine, langlier saturation Index (LSI) as per the parameters (Table 2 below.) and their specified range stated from IS-10500: 1991

Table -2


S.No Parameter Units LimitSample

frequency1 Color, Max Hazen 5 Once in shift

2 Odour Unobjectionable Once in shift

3 Taste Agreeable Once in shift

4 Turbidity, Max NTU Once in shift

5 pH value 6.5 to 8.5 Once in shift

6 Total Hardness as CaCO3, mg/l 300 Once in shift


Max7 Iron as Fe, Max mg/l 0.3 Once in shift

8 Chlorides as Cl, Max mg/l 250 Once in shift

9 Residual Free Chlorine, Max mg/l 0.2 Once in shift

10 Fluoride as F, Max mg/l 1.5 Once in shift

11 Dissolved Solids, Max mg/l 500 Once in shift

12 Calcium as Ca, Max mg/l 75 Once in shift

13 Magnesium as Mg, Max mg/l 30 Once in shift


14 Copper ac Cu, Max mg/l 0.05 Once in shift

15 Manganese as Mn, Max mg/l 0.1 Once in shift

16 Sulphate as SO4, Max mg/l 200 Once in shift

17 Nitrate as NO3, Max mg/l 45 Once in shift

18 Phenolic Compounds as C6H5OH, Max

mg/l 0.001 Once in a day

19 Mercury as Hg, Max mg/l 0.001 Once in a day

20 Cadmium as Cd, Max mg/l 0.01 Once in a day


21 Arsenic as As, Max mg/l 0.01 Once in a day

22 Cyanide as CN, Max mg/l 0.05 Once in a day

23 Lead as Pb, Max mg/l 0.05 Once in a day

24 Zinc as Zn, Max mg/l 5 Once in a day

25 Chromium as Cr6+, Max mg/l 0.05 Once in a day

26 Aluminum as Al, Max mg/l 0.03 Once in a day

27 Boron as B, Max mg/l 1 Once in a day


28 Alkalinity, Max mg/l 200 Once in a day

29 Langlier Saturation Index positive Once in a day

e) UF backwash and reject area


(i) The Total UF backwash flow rate on per day basis is recorded from the DCS.

(ii) The reject concentration at disposal point (diffuser outlet ) shall be measured in line with MOEF requirements on a per day basis from the field and recorded.


(iii) The UF backwash pump parameters shall be recorded as follows

- The pump suction /discharge pressures at every 2 hour interval and motor winding temperature, noise level, vibration shall be recorded at every 4 hours from field. The performance parameters of flow , Current , speed, voltage , KW shall be recorded from DCS /Control room (for electrical parameters) at every 2 hour interval.


(iv) The reject disposal pump parameters shall be recorded as follows - The pump suction /discharge pressures, flow at every 2 hours & motor

winding temperature, noise level, vibration shall be recorded at every 4 hours from field. The performance parameters of flow , Current , speed, voltage , KW shall be recorded from DCS /Control room (for electrical parameters)at every 2 hour interval.


Pump not in use. Hence parameter measuring could be waived.


f) Chemical Area

g) The chemical consumption for Antiscalant, Sodium bisulphate, NaOH, H 2SO4, NaOCl, CO2 and limestone shall be recorded for every 8 hour interval from the DCS.Power consumption per cubic meter of product water produced. The


Can be given Manual calculation based on Level transmitter (LT level available in DCS)


Reject pump, PG, Temperature scanners are removed


readings for power consumption shall be logged from the energy meter installed at the plant.

3.6. Accuracy of the instruments:

Accuracy of Instruments to be provided by the contractor for testing shall be as follows.

Sl.No Parameters Instrument Accuracy CERTIFICATE ACCURACY


Available accuracy is given below


1 Voltage Multimeter/Clamp meter + /- 0.5% +/-0.7%+ 2 digits

Current Clamp meter + 0.5% +/-2%

2 Speed Tacho meter non- contact type

+ /- 1rpm +/-1rpm

3 Temperature Digital thermo meter +/- 0.1deg C +/-2% deg C

4 Vibration IRD 308 or Equivalent + 0.5 % NA


5 Noise Level Decibel meter +/- 2 db +/-1.5%

6 Pressure Gauge +/-0.5% +/-0.1%

Transmitter +/-0.1% +/-0.075%

7 Time Stop watch +/- 0.5% +/-0.5%

8 Flow Flow element +/-1.5% +/-1%


3.7 Test Data Collection and submission: Test data log sheetswitnessed jointly by the Consultant/Clients and

contractor/OEMSand duly signed by them will be collected& compiled by the contractor.

For instruments connected to DCS, necessaryreportshall be obtained.(Detailing)


4 copies of test reports are to be made..

3.8. Validation of the test:

If during the test or during subsequent analysis or interpretation of the observed/recorded data and obvious inconsistency is found which effects the


validity of the results, the parties should be make effort to adjust or eliminate the inconsistency

3.9. Test Report:

On completion of performance test, within two weeks, contractor shall submit a test report to the Client with a copy submitted to the consultant stating:


a) Whether the system has passed or failed the performance test accompanied by sufficient data and calculations to demonstrate the level of performance attained with respect to the guaranteed parameters.

b) The level of performance achieved with respect to the desired level of performance.

The report shall include the following:


(I) Description of test procedure.(II) Standards that were used.(III) Instrumentation details and calibration(IV) Full schematic diagrams with indication of instrument test location and

identification tag numbers . (V) Test logs and summary of test readings used for performance calculations.(VI) Computation of test results


(VII) Conclusion of performance test: Test passed or not.

4.0 .Test Results and Calculations:

4 .Test Results and Calculations:

4.1. Net permeate flow from each UF Skid (m3/hr):


Net Permeate Total UF Permeate UF Backwash flow

Flow from each = Production in 24 hours - in 24 hours m3/hr

UF skids 30 (No of skids in filtration)* 24


Total UF Permeate Production in 24 hours= FIQ_UF PERM (Initial-Final Values taken from Totalizer).

UF Backwash flow in 24 hours = UF_1 to 15 BW+ UF_ 16 to 30 BW (Initial-Final Values taken from Totalizer).

4.2. Net Permeate Quantity for 12 RO Skids (m3/hr):


Net Permeate Quantity for = RO Permeate production in24 hrs.m3/hr

12 RO Skids 24

RO Permeate production in 24 hrs. = FIQ_RO PERM (Initial-Final Values taken from Totalizer).


4.3. RO Recovery (%):

RO Recovery = RO Permeate Flow in 24 hrs.* 100 %

RO Feed Flow in 24 hrs.

RO Permeate Flow in 24 hrs.=FIQ_RO PERM (Initial-Final Values taken from Totalizer).


RO Feed Flow in 24 hrs.=FIQ_CF FEED(Initial-Final Values taken from Totalizer).

4.4. Net product water quantity (m3/hr):

Net Product Water= RO Permeate Flow in 24hrs-Service Water Flow in 24 hrs

Quantity m3/hr 24


RO Permeate Flow in 24 hrs.=FIQ_RO PERM (Initial-Final Values taken from Totalizer).

Service water flow in 24 hrs. = FIQ_SER (Initial-Final Values taken from Totalizer)

4.5. Recovery in UF skids (%):

UF Skids Recovery= Net permeate flow from all UF Skid in 24 hrs


Flow meter not available nor dcs not connected. We are planning to install a mechanical flow meter.


NetUF Feed Flow in 24 hrs

Net UF Feed Flow = Gross UF Feed- (Top & Bottom Flush Flow+ Set Cross Flow)

Total UF Permeate Production in 24 hrs= FIQ_UF PERM (Initial-Final Values taken from Totalizer).

Gross UF Feed flow in 24 hrs=FIQ_UF FEED (Initial-Final Values taken from Totalizer)


Top & Bottom Flush in 24 hrs. =FIQ_UF T&B Flush (Initial-Final Values taken from Totalizer)

4.6. Specific Power Consumption:The average specific energy consumption can be obtained by means of following calculations.


Specific Energy ( ESP) = Total power consumed during the test period

Consumption Total Permeate production during the test period

ESP = ET/QT in kwh/m3

Total Power Consumption ( ET):


Plant total power consumption (ET) is given by Total kWh recorded on the 110 KV incomer of Main Receiving Substation (MRSS) meter after deducting L&T (MRSS) power feeder meter reading from the start of the test run until the completion of test run on day basis.EMRSS – kWh recorded at MRSS from start to finish of test run on day basis.E L&T – kWh recorded at L & T (MRSS) from start to finish of test run on day basis.


ET = EMRSS- E L&T in kWh

performance guarantee test procedure

Documents

erd performance log

ro system parameters

chemical consumption

reject uf backwash log

test report

log sheets1

test organization

test results