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DESIGN QUALIFICATION Revision No.

:
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Document No.:

DESIGN QUALIFICATION
REPORT

ON

WATER TREATMENT
PLANT

FOR

PEGASUS FARMACO INDIA


PRIVATE LIMITED
DESIGN QUALIFICATION Revision No.:
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Document No.:

BY

HYALINE AQUA SOLUTIONS


PRIVATE LTD.

D/Q

This document is prepared by the Documentation team of Hyaline Aqua Solutions Pvt. Ltd
the treatment of water for M/s. PEGASUS FARMACO INDIA PVT. LTD. Hence, this
document before being effective shall be approved by Pegasus Farmaco Pvt. Ltd
Document Prepared: M/s. Hyaline Aqua Solutions Pvt. Ltd.

Name Designation Signature & Date


Prepared By Hari Prasad Design Engineer

Reviewed By T.Naresh Reddy Director Technical

Approved By M. Jaywant Reddy Managing Director

Document Approved by: M/s. Pegasus Farmaco India Pvt. Ltd.

Name Designation Signature & Date


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Document No.:

Checked By

Reviewed By

Approved By

TABLE OF CONTENTS

S. No. Description Page No.


01 INTRODUCTION 03
02 OVER VIEW 03 - 04
03 RESPOSIBILITY 05
04 GENERAL ASPECTS OF WATER TREATMENT 06 - 08
05 BASIS OF DESIGN 13
06 PROCESS CALCULATION 15
07 EQUIPMENT SPECIFICATION 16
08 TECHNICAL DATA 24
09 SYSTEM CONTROL 29
10 MATERIAL OF CONSTRUCTION 31
11 SUPPLIER 34
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12 DOCUMENTATION 34
13 ABBREAVIATIONS 34
14 ANNEXURES 35
15 REFERENCE DRAWINGS 35

INTRODUCTION:
This document written by Hyaline Aqua Solutions defines the complete design of the
water treatment system requested by Pegasus Farmaco India Pvt. Ltd as out lined in
Pegasus Farmaco Purchase Order No. :
The design qualification also acts as a reference for the programming & subsequent
testing of the system as well as basic document for the validation activity.
OVER VIEW
General Guidelines
Objective
To design the system in conjunction with the design data in order to provide
basis for the vendor and the supplier to design and fabricate the system
(Equipment and Components) to meet design intend to ensure that user
requirement specifications are achieved.
References
This project shell be executed in accordance with the guidelines laid down in
cGMP.
Purpose
To design the Water Treatment system considering that it should treat the Bore
well water with a TDS of not more than 1500 ppm..
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The Water treatment system shall be designed and constructed to meet all
requirements of current GOOD Manufacturing Practices (cGMP’s)
Acceptance Criteria
The out put water from Demineralizing Treatment design shell confirm to
ordered specification.
All the parameters must be proved & sustained by documents or conformed
by appropriate tests.
All the documents supplied by Hyaline Aqua Solutions.

Safety
Upon loss of electrical power, all the components fall into “SAFE” position.
Upon restoration of electrical power, Ambient Air Supply & Distribution and
Exhaust shall not start automatically. An input from the operator shell be
required to restart the system. No additional action shell be required for full
recovery after an electrical failure.
cGMP Compliance
Following basic features should be incorporated in the system design to make it
cGMP complaint.
1. Primary Treatment:
1. Microbial should be < 100 cfu/ml.
2. Residual chlorine content – Nil
3. Turbidity <2NTU
4. Water PH in between 5 – 7.
2. DM Water Treatment:
1. Microbial should be : NMT 100 cfu/ml.
2. Residual chlorine content – Nil
3. Turbidity – Nil
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4. Total Organic Carbon: NMT 0.5 PPM


5. Conductivity: NMT 0.5 Micro Siemens / Cm.
5. Water PH in between 6 – 7.
RESPONSIBILITY
In order to achieve the above objective for the Water treatment system, following
shell be the responsibility of Hyaline Aqua Solutions Pvt. Ltd and M/s. Pegasus
Farmaco India Pvt. Ltd

M/s. Hyaline Aqua Solutions Pvt. Ltd


3.1.1. The complete system is designed as per the agreed technical specification, and
user requirement specifications.
Technical specification of all the equipment, Instruments, Valves etc. are as per the
offer or better than and the purchase order.
General Arrangement, Lay out, Equipment drawings, P & I routing along with sizes
and technical specifications etc. As per requirements will be prepared and submitted
to M/s. Pegasus Farmaco India Pvt. Ltd.
M/s. Hyaline Aqua Solutions Pvt. Ltd shall provide Operating and Maintenance
manual and Standard test procedures for the complete system.
Test certificates/compliance certificates for the various items used for the system
along with Calibration certificates for critical instruments shall be provided. For non –
critical vendors standard test certificates/compliance certificates shall be provided.
Installation qualification and Operational qualification shell be submitted as part of
the qualification documents for the complete system.
M/s. Hyaline Aqua Solutions Pvt. Ltd
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Preparation and approval of qualification documents shall be on Aquatron systems be half


shall be the responsibility of following:

Name Designation Signature & Date


Design
Prepared By Hari Prasad
Engineer
Reviewed By T.Naresh Reddy D.T

Approved By M. Jaywant Reddy M.D

M/s. Pegasus Farmaco India Pvt. Ltd.

M/s. Pegasus Farmaco India Pvt. Ltd is responsible for the following:

To check and verify all the documents submitted as per above are in line with agreed
specifications, scope, and shell approve all the documents to signify that the vendor
has complied with his commitment.
To provide the necessary site clearance and complete the site activities covered in
M/s. Hyaline Aqua Solutions Pvt. Ltd.
Ensure that all the utilities and material required for the commissioning of system as specified
by Hyaline Aqua Solutions Pvt. Ltd in design qualification and other documents are made
available.
Carry out validation activities after the plant is certified for intended operations.
M/s. Pegasus Farmaco India Pvt. Ltd
On behalf of M/s. Pegasus Farmaco India Pvt. Ltd, following team is authorized to
approve all the qualification protocols. Such approval of qualification documents shall be
deemed acceptable by M/s. Hyaline Aqua Solutions Pvt. Ltd and shall be considered as
suppliers complying with his commitment of contract obligations.
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Name Designation Signature & Date

Checked By

Reviewed By

Approved By

GENERAL ASPECTS OF WATER TREATMENT

RAW WATER AND IMPURITIES

Water as it occurs in nature “pure” and whatever be the source, always contains
impurities either in solution or in suspension. The determination of these impurities
makes analysis of water necessary and removal and control of these impurities
make water treatment essential.

Water Sources

The various sources of water can be broadly classified as :

a) Rain Water

b) Surface water (Rivers, Streams, Ponds, Lakes and Reservoirs)

c) Ground water (Springs, Shallow Wells and Deep Wells).

Of the above, logically, rain water is the purest but even this collects and dissolves
atmospheric gases and impurities in air. Further, once in contact with the earth’s
crust, the rain water will gradually dissolve various materials.

Various (Major) Impurities


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The major impurities of waters can be classified in three main groups:

1) Non-ionic and Undissolved


2) Ionic and Dissolved
3) Gaseous

1) Non-ionic Impurities

These are mainly turbidity, salt, mud, dirt and other suspended matter; micro-
organisms, bacteria and other organic matter, oil and
corrosion products. It goes without saying that drinking water and most
industrial water supplies should be clear and organic - free.

2) Ionic and Dissolved Impurities

Any salt which dissolves in water disassociates into positively charged ions called
Cations and negatively charged ions called Anions. Since these permit the water to
conduct electricity, these salts are called electrolytes.

Some of the most common Cations in water are :

Calcium, Magnesium, Sodium and Iron, and rarely Ammonium, Potassium and
Manganese. These Cations are associated with Anions like Bicarbonates,
Carbonates, Hydroxides (the sum of which is termed as Alkalinity), Sulfates and
Chlorides. Presence of Nitrates and Phosphates is normally not very common. In
the water treatment field, the preferred method of expression of these dissolved
impurities is in terms of Equivalent Calcium Carbonate, abbreviated to “as CaCO3”.
This is because Calcium Carbonate is a good common denominator as it has a
molecular weight of 100, which facilitates calculations.

Moreover, in this form of analysis, the sum of Cations or total Cation always equals
the total Anions. Quantitatively, these are expressed in parts per million or
milligrams/litre. One part per million equals one ten thousandth of one percent
(0.0001%).

One part per million means one part in a million parts, for example, one litre in a
million litres of water or one Kg. in a million Kgs. of water.
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Of all the dissolved impurities, Hardness is perhaps the most troublesome.


Hardness is due to compounds of Calcium and Magnesium. On heating water
containing these salts, Carbon Dioxide is released from solution and the
Bicarbonates are converted into Carbonates which are insoluble and form scales
and deposits. Other salts of Calcium and Magnesium like Sulfates and Chlorides
have lower solubility than Sodium salts and precipitated out at high temperatures.
Bicarbonates of Calcium and Magnesium are known as the Alkaline Hardness or
Temporary Hardness and chlorides, Sulfates, Nitrates etc., of Calcium and
Magnesium are known as neutral or Permanent Hardness. Sodium salts are highly
soluble but can be corrosive if present in large quantities such as Sodium Chloride or
Sodium Bicarbonate.

Dissolved Silica is another troublesome impurity, especially in waters fed to Boilers


of very high temperatures and pressures. Even in lower pressure boilers, it could
form a very hard type of scale by acting as a binding agent.

3) Gaseous Impurities

Of the atmospheric gases found in naturally occurring waters, only two, Carbon
Dioxide and Oxygen, are the main causes of many corrosion related problems.

IMPORTANCE OF REMOVAL OF IMPURITIES

The major concern in industrial water treatment, where the water used directly or
indirectly in an industrial process, is to treat the water to be suitable for that particular
application/process. Depending on the process, varying degrees of purity of treated
water are required. For example, a textile processing unit will require soft and clear
water for process use; a chemical plant will require pure water for process not
exceeding 1.0 mg/litre of dissolved impurities or electronic components
manufacturing unit require ultra-pure water containing total dissolved impurities not
exceeding 0.5 mg/litre or less. So depending upon the requirement, various water
treatment processes are adopted to treat the water, to make the water suitable for
that particular application. The details of the processes are as follows:

FILTRATION

Filtration is the process of passing a liquid containing suspended matter through a


suitable porous material (filtering medium) to effectively remove the suspended
matter in the liquid. This is basically a physical treatment of water.
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Filtration is employed in the treatment of industrial water in order to remove or


reduce suspended solids and turbidity. This is of special importance in process and
boiler feed water as otherwise there will be formation of sludge and silt deposits./
These will restrict flow, cause overheating and consequent failure of water wall
tubes. Further, in combination with hardness, these sludge and silt deposits will add
to the volume and has the insulating effect of scale deposits.

1. Filtration is employed as a pre-treatment to softening or demineralising plants to


protect the resins in them. It is also employed for treating potable waters.
.
There are basically two types of Filters - Gravity type, and pressure type. For
industrial applications the latter are preferred; they can be linked into the mains as
they work under pressure and used in conjunction with other water treating
equipment like softeners, demineralisers without recourse to re-pumping. Also,
Pressure Filters are easier to install and operate, require less space and minimal civil
work.

Filter media commonly employed are graded and washed sand of effective size 0.35
mm to 0.50 mm resting on a supporting under bed of crushed gravel and pebbles of
four varying sizes, with the coarsest size at the bottom of the bed. The sand depth
is 500mm and the under bed depth also being 500mm.

The major components of a Pressure Filter are a steel pressure vessel with dished
ends (normally vertical and cylindrical, though for larger flows horizontal and
cylindrical vessels are employed); internals comprising raw water distributor and
filtered water collector-cum-backwash water distributor; external pipe work and
valves; filter media and instruments like pressure gauges, flow indicator etc.,

Backwashing of the filter bed has to be carried out periodically (normally once in 24
hours, more frequently if the pressure drop across the bed exceeds 0.7 Kg/cm and
which indicates accumulation of dirt in the bed) with filtered water at a minimum head
of 10 MWC. For large filtration flow rates air agitation facilities are provided then the
backwash rate can be reduced. The normal backwash time is 5-6 minutes and the
scour time 2-3 minutes.

Normally Filters should not be fed with water carrying suspended matter and
turbidity content of more than 30 to 50 NTU. Above these limits the water should be
settled and clarified before Filtration. Also to increase the efficiency of Filtration and
to ensure that even fine Suspensions are removed, the usual practice is to dose
Coagulant Chemicals like alum, ferrous sulfates or sodium aluminates at the inlet to
the filter by means of a mechanical type doser or a metering pump. in the case of a
hot lime softener plant effluent. Activated Carbon is used as a filtering Medium when
oil/chlorine removal, etc., are required. A layer of processed Manganese Dioxide is
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incorporated in sand Filters for Iron Removal. A layer of anthracite once the sand
bed enhances the filtering capacity by providing in-depth filtration. When anthracite
is used for filter can handle turbidities of up to 100 NTU.

ACTIVATED CARBON FILTER

The activated carbon has a broad spectrum of adsorptive activity, as most


Organic molecules are retained on the surface ; hardest to retain are the shorter
molecules (especially those containing less than three atoms of carbon: ordinary
alcohols, primary organic acids) and the least polar. However , heavier molecules,
aromatic compounds, substituted hydrocarbons. Etc are firmly retained. Activated
carbon eliminates hard detergents, micropolutants, and pesticides to traces.
Another widely exploited property of activated carbon is its catalytic action
particularly on the oxidation of water by free chlorine.

Cl 2 +H2O 2HCl + ½ O2

This is the method used for dechlorination of water subjected to excess chlorination
treatment

Cation Exchanger:

Cations are ions that carry a positive electric charge, typical Cations are Calcium,
Magnesium, Sodium, Iron, Copper,, Gold, Hydrogen etc
As water passes through the Cation exchanger it encounters millions of resin beads
each of which contains a large number of negatively charged exchange sites in the
pores and microscopic paths of it structure when the resin is in the regenerated state
each exchange site is occupied by a positively charged hydrogen ions as the
positively charged Cations in the water contact the beads they are attached to the
negative exchange sites. Since they are stronger in their positive charge then the
positive hydrogen ions they drive off the hydrogen ions and attach to the exchange
sites by doing, they maintain the balance between the positive and negative charges.
Since the hydrogen ions are acidic this exchange can also be described as
displacement of acid ions. The water at the outlet of Cations is dilute mineral acid.

Cation resin is generally produced from styrene and divinylbenzine containing


sulfonic acid groups these synthetic organic resins are designed to remove specific
or all Cations from water, depending on the concentration of free mineral acidity of
the raw water the effluent ph will be 2 and 4.
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Anion Exchanger

Anions are ions that carry a negative electrical charge, typical anions are chlorides,
sulphate, nitrates, carbonates Bio-carbonates, hydroxides etc.
The anion exchange process is similar to the Cation exchange process, The anion
resin is made of resin beads which have positive exchange sites and when
regenerated with NaOH are occupies by negative Hydroxide ions (OH) as the
negatively charges are the non-metallic anions contact the beads the same
attraction-repulsion process takes place and the negative hydroxide ions are
dislodged and replaced by the stronger negative non-metallic ions.
Anion resin is produced from the styrene and divinylbenzine but contains quaternary
ammonium groups these synthetic organic resins are designed to exchange or
adsorb specific or all anions from water including silica and carbon dioxide. The PH
will be typically between 7.2 and 9.

Mixed Bed

Mixed bed differ from the individual Cation and anion bed system as mentioned
above the Cation and anion resins are used separately in their respective vessels
whereas in the mixed bed the two resins namely Cation and anion are arranged side
by side in a single vessel and are intimately mixed by agitation with the help of
compressed air, the whole bed behaves like an infinite number of anion and Cation
exchangers in series.

To carry out regeneration the two resins are separated by decompacting them with a
stream of water. As the anion resin is lighter, it rises to the top while the heavier
Cation resin falls to the bottom.

After separation each of them is regenerated separately the anion portion with
caustic soda and the Cation with a strong acid. The resins are washed and remixed
with compressed air

The water obtained is of very high purity and remains constant throughout the cycle.
The pH is almost neutral the rinsing water consumption is very low . The mixed bed
has a very low exchange capacity and hence this should always precede after the
anion unit . The inlet water to Mixed Bed should be less than 30 micro siemen / cm.

Disinfection by ultra violet radiation.


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The final mixed water before use in any industry is disinfected and for this purpose
ultra violet system is used .

The ultra violet radiation is emitted by very low pressure mercury vapour lamps, the
power rating of which may be as much as 200 watts and whose average life is 3000
hours. The wave length lie in the 200 – 300 nm range [ 2000 – 3000 angstrom units]
with a maximum microbicidal action around 250nm.

The water to be treated is usually pressurized and filtered for removal of suspended
impurities or turbid matter that can take place due to reagents used for regeneration
of exchangers. The presence of turbid matter or suspended solids reduces the
transmittance and hence the water should be perfectly clean.

The water is made to flow through a pipe at the center of which is located a quartz
tube accommodating the radiation source. In this way the thin layer of water is
exposed to the germicidal action of the rays

5 Micron filter:
In this process, the water passes through 5 Micron Cartridge to avoid impurities NLT
5 micron in size.

0.2 Micron filter:


In this process, the water passes through 0.2 Micron Cartridge to avoid impurities
NLT 0.2 micron in size.

Scheme: PROCESS based on USER REQUIREMENT

The user requires 30,000 liters of De- mineralized water with a conductivity less than
1 micro Siemens/ cm. The source of water is from the Bore well

The Bore well Water Characteristics, as furnished by the user M/s Alkaloids pvt ltd,
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Total Dissolved Solids : 1782 ppm

Total Hardness : 1045 ppm as CaCO3

M. Alkalinity : 200 ppm as CaCO3

Na : 285 ppm as CaCo3

Silica : 19.36 ppm as SiO2

Cl : 110 ppm as CaCO3

Turbidity & Total Suspended Solids : 2.00

The Treated water quality at various stages shall be as mentioned below:

At the outlet of R.O system:

TDS : < 150 ppm

At the outlet of SBA:

pH : 6.5 - 9.5
Conductivity : < 30 Micro Siemens/cm
Silica : < 0.5 ppm as SiO2

At the outlet of Mixed Bed

pH : 6.5 - 7.5
Conductivity : < 0.5 Micro Siemens/cm
Silica : < 0.1 ppm as SiO2
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The process Scheme

BORE WELL WATER (Pegasus Supply)

STORAGE TANK (Pegasus Supply )

PUMP

QUARTZ SAND FILTER

ACTIVATED CARBON FILTER

ANTISCALENT DOSING

5 MICRON ON LINE FILTER

REVERSE OSMOSIS PLANT

R.O PERMEATEWATER STORAGE TANK

PUMP

CATION

DEGASSER STORAGE TANK


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ANION

MIXED BED

TO SS STORAGE TANK

PROCESS CALCULATION

Since 30,000 liters of D.M. Water is required Net at the outlet of Mixed bed unit:

CALCULATION OF OUTPUT FROM CATION UNIT

30 M3 net output +2 M3 for cation regeneration +2 M3 for Anion bed regeneration + 2


M3 for Mixed bed regeneration = 36M3

considering an exchange capacity of 45 g Caco3/l This is arrived based on Raw


water analysis considering all ionic parameters, ratios, dearating factors etc

For 18 M3 output of Cation then the calculation shall be

36 x 75
= 60 liters of Cation resin is required.Actual quantity used is 100 Liters.
45

The resin manufacturers suggest a minimum bed depth of 700 mm for all
exchangers to get sufficient contact time and effective performance.

Considering surface flow rate and velocities we have selected 330 diameter vessel
with 1250 mm height so as to accommodate the above resin . The volume of the
above vessel shall be 106.8 liters, the cation resin expansion is 7% and hence the
cation unit shall be filled with 99.3 liters of Duolite C-20 H as the unit is a packed
bed.
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CALCULATION OF OUTPUT FROM ANION UNIT

considering an exchange capacity of 28 g Caco3/l This is arrived based on Raw


water analysis considering all ionic parameters, slippage of carbon dioxide from the
degasser, ratios, deairating factors etc

For 34 M3 output of Anion then the calculation shall be

34 x 75
= 91 liters of Anion resin is required.
28

The volume of the above vessel shall be 106.8 liters, the Anion resin expansion is
12% and hence the Anion unit shall be filled with 94 liters of Duolite A-116 resin as
the unit is a packed bed.

CALCULATION OF OUTPUT FROM MIXED BED UNIT

For the calculation of Mixed bed unit preceding packed bed cation and Anion the
velocity should not exceed 50 m/hr as the flow required is 3 M3/hr and a maximum
flow of 5 M3 the calculation would be

2 M3/hr
= 0.07 M2 The diameter of 300 mm vessel is suitable since the
50 M/hr surface area is 0.07065 M2

Consultants prefer to derate the Cation by 30 % and the Anion resin by 20 %.


The 300 diameter Mixed bed unit with 35 liters each of Cation and Anion resin will
produce 48 M3 considering the silica leakage of 2 ppm from SBA.

The average bed depth should be 500 mm in general the ratio of Cation to anion is
1:1 or 1:1.5 etc in our case the ratio is 1;1 due to few factors and considering the pH.
The Mixed bed unit is an polishing unit and brings the pH to neutral The Mixed bed
regeneration is slightly complicated and has to be regenerated carefully. The unit
has to be regenerated only once in 7 days and if the silica slippage is less than the
above the unit will produce much more than the rated output. To monitor the M.B unit
an on line conductivity measurement at the outlet is the best solution hence an on
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line conductivity meter should be provided with a range of 0 to 4 Micro siemen/cm.


Usually the conductivity at the outlet of Mixed bed shall be less than 1.0 Micro
siemen / cm. For the process industries and should be regenerated if the
conductivity exceeds 1.0 Micro siemen / cm.

EQUIPMENT SPECIFICATION:

MULTI MEDIA FILTER


TECHNICAL DATA

MODEL : MMF

MOC : FRP

Diameter – mm : 330

Maximum Service Flow - M3/Hr. : 2.0

Minimum Service Flow - M3/Hr. : 1.0

Min. Operating Pressure - Kg/cm2: 2.0

Max. Operating Pressure - Kg/cm2: 3.5

Max. feed water turbidity – NTU : 5.0

Max. Treated water Turbidity NTU: 2.0

Backwash flow - M3/Hr. : 2.0


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Duration of Back Wash – Minutes: 10

Back Wash Frequency, under


normal conditions : Once in a Day

ACTIVATED CARBON FILTER


TECHNICAL DATA

MODEL : HACF

MOC - : FRP

Diameter – mm : 330

Maximum Service Flow - M3/Hr. : 2.0

Minimum Service Flow - M3/Hr. : 1.0

Min. Operating Pressure - Kg/cm2: 2.0

Max. Operating Pressure - Kg/cm2: 3.5

Max. feed water turbidity – NTU : 2.0

Max. Treated water Turbidity NTU: 1.0

Backwash flow - M3/Hr. : 2.0

Duration of Back Wash – Minutes : 10


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Back Wash Frequency, under


normal conditions : Once in a Day

On -Line Filter - 5 Micron Rating


TECHNICAL DATA

Model : AOF-5

Max. Total Flow Rate : 2,500 LPH

M O C of Housing : Food grade


plastic

Cartridge Material : ……..do………

REVERSE OSMOSIS MODULE


TECHNICAL DATA

Maximum Total Feed Flow - Liters/Hr : 1,000

Maximum Permeate Flow - Liters/Hr : 500

Concentrate recirculation Flow - Liters/Hr : 100

Reject Flow - Liters/Hr : 400

Total system Recovery Percentage : 60 %


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MOC of Pressure Tube : FRP

Maximum Pressure Tube Rating : 225 psi

No. of Membranes : 2

Size of Membrane Dia : 4 Inch .

Salt Rejection % : 95 %

Max. Feed Water TDS : 1000 ppm

Permeate Water TDS : <100 ppm

No. of Systems Offered : ONE

Chemical Dosing Required : Anti-Scalant at


7.0ppm Dosage
Rate
R.O. Feed Water Pump - High Pressure Pump

Max. Flow Rate - Liters/Hr. : 1,200

Discharge Head - Mtrs. : 120

Feed Pressure : 2.5 bar


No. of Units : 1 No.

PRESSURE VESSELS CATION AND ANION


TECHNICAL DATA

MODEL : HSAC
DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Page No.:23 of 37
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MOC - : FRP

Diameter – mm : 330

Numbers : Each One

Material of Construction : FRP

Design Pressure : 5Kg/Cm2

Test Pressure : 1.5 times of design


pressure

Maximum Service Flow - M3/Hr. : 2.0

Minimum Service Flow - M3/Hr. : 1.0

Min. Operating Pressure - Kg/cm2 : 2.0

Max. Operating Pressure - Kg/cm2 : 3.5

Guarantee through put : 30 M3

Number : Each One

MIXED BED PRESSURE VESSEL TECHNICAL DATA

Make : Hyaline

Size : 300x2000

Type : Vertical, Cylindrical with dish ends

Numbers : ONE

Material of Construction : Mild steel rubber lined

Design Code : ASME 2825

Design Pressure : 5Kg/Cm2


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Test Pressure : 1.5 times of design pressure

I/O Distributors : Polypropylene

Strainer Material : Polypropylene

No. of strainers : 10 @ 80 triangular pitch

Rubber lining : As per IS 4682 Part-I

Lining thickness : 3mm

Spark Test : 5KV/mm =15KV

Shore hardness : 65 Degrees

Adhesion Test : Peel off Test

Aging Test : Respective Medium

Inlet / Outlet Connections : 25NB

Design Flow : 2 M3r / Hour

Max Flow : 1 M3/ Hour

Guarantee through put : 30 M3/ Day

BODY GASKETS FOR ALL PRESSURE VESSELS:

Vessel Body Gaskets : 6mm Thickness Neoprene

Numbers : 3 numbers for Mixed Bed

VALVES FOR MIXED BED:

Type : Diaphragm
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Make : Experts / Flow way / BDK

M.O.C : Cast Iron Ebonite Lined

Body : C.I- IS 210-FG260

Bonnet : C.I- IS 210-FG260

Compressor : C.I- IS 210-FG260

Hand Wheel : C.I- IS 210-FG260

Diaphragm : Neoprene

Spindle : SS-410

Spindle Bush : SGI

No. Of Valves : 25 NB Valves 10Nos & 20NB 4Nos

ALL PIPES FOR MIXED BED

Frontal and interconnecting: MSRL

Size : 25NB

M.O.C : Mild Steel

Quality : IS 1239 Medium Duty

Internal Lining : Rubber 3 mm Thickness

Table : BS Table 10-D

FILLING MEDIA FOR PREASSURE SAND FILTER:

Filter Media : Quartz sand

Supplier : Hyaline
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Particle Density

Effective Size : 16/32

Uniform Coefficient

Nozzle for media removal : 4”

Quality : Filtered Water / Inlet Source

Back wash flow : 13 mtr

Design surface flow rate : 153 mtr/Hr/Sq.mtr

FILLING MEDIA FOR ACTIVATED CARBON FILTER:

Filter Media : Activated carbon

Supplier : Global Adsorbents

Bulk Density : 0.52

Hardness Number : 98

Effective Size : 8x16


\
Moisture Content : 5 % Max

Total surface : 950

Iodine number : 950

Carbon Tetrachloride Absorption: 50 % min

Ash content : 3% Max

Nozzle for media removal : 4”

Back washing : 10 minutes

Quality : Filtered Water / Inlet Source


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Back wash flow : 2M3

Design surface flow rate : 15 M3Hr/M2

FILLING MEDIA FOR STONG ACID CATION EXCHANGER

CATION RESIN:

Name of the product : CATION

Resin Quantity max : 98.5 Ltr

Resin Type : Duolite C-20H

Batch No. : As per Mfg

Resin Matrix : Cross-linked Polystyrene

Physical form : Amber Translucent Beads

Shipping / Ionic Form : Hydrogen

Shipping Weight (Gms / Ltr) : 770-810

T.E.C Meq / Ml in H form : Min 1.80

% Moisture in H Form : 47 – 53

Specific Gravity : 1.21-1.27

Effective Size : 0.45-0.55

Uniformity Coefficient : Max 1.80


DESIGN QUALIFICATION Revision No.:
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Particle Size : 0.3-1.2

Operating PH Range : 0-14

Regenerant : HCL

Quality of Regenerant : HCL Technical Grade :IS265

Quantity of Regenerant : 8 Kgs as 100% & 26.4 as 30%

Injection Strength : 5%

Preparation : 10%

Method of Regeneration : Ejector


FILLING MEDIA FOR STONG BASE ANION EXCHANGER

ANION RESIN:

Name of the product : ANION

Resin Quantity : 100 Ltr

Resin Type : Duolite A- 116

Batch No. : As per Mfg

Resin Matrix : cross-linked Polystyrene

Physical form : Amber Translucent Beads

Shipping / Ionic Form : Chloride

Shipping Weight (Gms / Ltr) : 680-750

T.E.C Meq / Ml in c l form : Min 1.30

% Moisture in chloride Form : 47 – 53

Specific Gravity : 1.04-1.14

Effective Size : 0.45-0.55


DESIGN QUALIFICATION Revision No.:
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Page No.:29 of 37
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Uniformity Coefficient : Max 1.80

Particle Size : 0.3-1.2

Operating PH Range : 0-14

Regenerant : NaOH

Quality of Regenerant : NaOH Technical Grade :IS252

Quantity of Regenerant : 8 Kgs

Injection Strength : 5%

Preparation : 10%

Method of Regeneration : Ejector

FILLING MEDIA FOR MIXED BED EXCHANGER

Mixed bed unit contains both Anion Resin and Cation Resin
CATION RESIN:
Name of the product : CATION

Resin Quantity : 35 Ltr

Resin Type : Duolite C-20H

Batch No. : As per Mfg

Resin Matrix : cross-linked Polystyrene

Physical form : Amber Translucent Beads

Shipping / Ionic Form : Hydrogen

Shipping Weight (Gms / Ltr) : 770-810

T.E.C Meq / Ml in H form : Min 1.80

% Moisture in H Form : 47 – 53
DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Page No.:30 of 37
BHONGIR, NALGONDA DIST.

Document No.:

Specific Gravity : 1.21-1.27

Effective Size : 0.45-0.55

Uniformity Coefficient : Max 1.80

Particle Size : 0.3-1.2

Operating PH Range : 0-14

Regenerant : HCL

Quality of Regenerant : HCL Technical Grade :IS265

Quantity of Regenerant : 3 Kg

Injection Strength : 5%

Preparation : 10%

Method of Regeneration : Ejector

ANION RESIN:

Name of the product : ANION

Resin Type : Duolite A-113

Resin Quantity : 35 ltrs

Batch No. : As per Mfg

Resin Matrix : cross-linked Polystyrene

Physical form : Amber Translucent Beads

Shipping / Ionic Form : Chloride

Shipping Weight (Gms / Ltr) : 680-750

T.E.C Meq / Ml in clform : Min 1.30

% Moisture in chloride Form : 47 – 52


DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Page No.:31 of 37
BHONGIR, NALGONDA DIST.

Document No.:

Specific Gravity : 1.04-1.14

Effective Size : 0.45-0.55

Uniformity Coefficient : Max 1.80

Particle Size : 0.3-1.2

Operating PH Range : 0-14

Regenerant : NaOH

Quality of Regenerant : NaOH Technical Grade :IS252

Quantity of Regenerant : 3 Kg

Injection Strength : 5%

Preparation : 10%

Method of Regeneration : Ejector

EJECTORS FOR REGENERATION OF MIXED BED CATION AND ANION

Make : Hyaline

Ejector Ratio : 1:1

Material of Construction : Mild Steel Ebonite Lined

End Connections : 20x20x20

Spark Test : 15KV

Hydro Test : 10Kg/Cm2

Hardness : 95-98 Degrees Shore A

Nozzle Bore : 4mm

Throat Bore : 10mm


DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Page No.:32 of 37
BHONGIR, NALGONDA DIST.

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Max Flow : 1.73 / Hr

Overall Length : 103mm

Flange : B.S Table – 10-D

For API’s Processing Plant Distribution System:


Treated Water
Parameter Values Remarks
Temperature Ambient
Turbidity NIL
Residual Chlorine content NIL
Microbial <100 cfu/ml.
PH 5-7
TOC NMT 0.5PPM
Conductivity NMT 0.5 micri simens/Cm.
Filtration Level 0.2 micron

Basis of Design (Water Consumption)


1.
Primary Treated
S. No. Description Quantity Water Required Remarks
Lts./Day
1

2
DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Total:

SYSTEM CONTROL

Control the system by manual operating the push buttons whenever system is
required, one inter lock is provided for safety aspect.

1. Whenever distribution system storage tank volume is lesser than specified


level, the DM water plant pumps & blower is automatically on and fill the
tank with pure water with specified level.
2. Whenever distribution system storage tank volume is lesser than specified
level, the DM water plant pumps & blower is automatically on and fill the
tank with pure water with specified level at this process water conductivity
is more than
0.5 micro siemens/cm. the water return to the degassed water tank with
help of air operated activated 3 Way valve.

UTILITIES

Electrical power supply (3 Phase, 440 Volts, 50Hz)


Earthing
Air with 3 Kg. /Sq.cm. Pressure.
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ERECTION & INSTALLATION

The entire plant is erected and installed to fulfill the cGMP requirement for
Water Supply, which are mentioned in point 2.2.

Material of Construction (Equipment)


Scope of
S. No. Item MOC Quantity Remarks
Supply
Bore
01 Bore well pump 1 No. Pegasus
water
02 Raw water storage tank RCC 1 No Pegasus

03 Raw water feed pump CI 1 No. Hyaline


Pressure Quartz Filter with
04 FRP 1 No. Hyaline
Piping &Valves
Pressure Activated carbon
05 FRP 1 No. Hyaline
Filter with Piping & Valves
For
06 Proportionate Dozer PP 1 No. Hyaline
antiscalent
07 5 micron filter PP 1 No Hyaline

08 R.O.PLANT 1 No. Hyaline


Permeate storage tank for
09 HDPE 1 No. Hyaline
DM plant feed water
10 Feed pump for SAC CI 1 No. Hyaline
Strong Acid Cation
11 Pressure vessel with Piping FRP 1 No. Hyaline
& Valves
Strong Base Anion
12 pressure vessel with Piping FRP 1 No. Hyaline
& Valves
13 Mixed Bed MSRL 1 No. Hyaline
DESIGN QUALIFICATION Revision No.:
WATER TREATMENT PLANT Date:
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Page No.:35 of 37
BHONGIR, NALGONDA DIST.

Document No.:

Material of Construction (Instruments)


Scope of
S. No. Item MOC Quantity Remarks
Supply
01 Glass tube Rota meters PP 02 Hyaline

02 Pressure Gauges SS 02 Hyaline


SS 316
03 Pressure Gauges Diaphragm 02 Hyaline
type
04 Online Conductivity Meter Digital 03 Hyaline

Testing
Turbidity
Lab
Residual Chlorine
Lab
Microbial
Lab
Conductivity
On line conductivity meter
TOC
Lab
Pathogens
Lab
Motor Load
Motor load to be checked with Tong tester /Digital Multi meter.
Identification
Whole system will be tagged. The tag number will be follow the numbers
of P & I diagram.
DESIGN QUALIFICATION Revision No.:
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Page No.:36 of 37
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CLEANING

The whole system cleans by run the system 4 hours with filter water.

SUPPLIER

Refer to attached list of components, Annexure – 1, for the details of equipments and
Instruments vendors and technical specifications for the same.

DOCUMENTATION
After Design Qualification approval, Installation Qualification and Operational
Qualification will be prepared by Alkaloids pvt limited with the successful installation
and commissioning of the system. These documents will be supported with following
details.

1. P & I of the system


2. Plant layout
3. MOC & Test certificates for Filters
4. Manuals of all brought out components
5. SOP for start & Stop procedures and Test procedures

12. ABBREVIATIONS

1. DQ : Design Qualification
2. Mts. : Meters
3. NTU : Nephelometric turbidity unit
4. TOC : Total organic carbon
5. PPM : Parts per million
6. FLP : Flame Proof
7. NFLP : Non Flame Proof
DESIGN QUALIFICATION Revision No.:
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Page No.:37 of 37
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8. Cub. Mt. /Hr. : Cubic Meter per Hour


9. µM : Micro Meter
10. pH : Hydrogen ion concentration
11. Q.A : Quality Assurance

13. ANEEXURES

Annexure No. Description


S. No.
01 Annexure - 01 Technical Specifications of components

02 Annexure - 02 Raw water Analysis report

14. REFERENCE DRAWINGS

S. No. Drawing No. Description

01 GA Drawing of Primary treatment

02 GA Drawing of DM Plant

03 P & I for Primary treatment

04 P & I for DM Plant

15. REVISION HISTORY

S. No. Revision No. Date Reason for Revision


01 00 First Draft

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