Purified Water Generation, Purpose:
Purified Water Generation, The purpose of this SOP is to define the Maintenance procedure of Purified Water Generation and Distribution System manufactured by Watertown in order to ensure its smooth & trouble-free operation and generation of qualified purified water.
Purified Water Generation, Scope:
This Standard Operating Procedure applies to the PW Generation and Distribution systems manufactured by Watertown. The Generation system of purified water is located at the utility area (roof top).
Definitions / Abbreviation:
[][]SOP: Standard Operating Procedure.
[][]PW: Purified Water.
[][]HMI: Human Machine Interface.
[][]RO: Reverse Osmosis.
[][]EDI: Electro De Ionizer.
[][]ACF: Activated Carbon Filter.
[][]MGF: Multi Grade Filter.
Responsibilities:
[][]The roles and responsibilities are as follows:
Engineering (Validation) Department
[][]Preparing the SOP and revise it when necessary.
Engineering (Maintenance) Department
[][]To provide necessary support for maintenance of the system.
[][]To ensure that the operators are responsible to carry out the maintenance tasks and fill up the logbooks.
Operators
[][]To perform the maintenance of the system according to the SOP.
[][]To fill up the logbooks.
Manager, Engineering
[][]To ensure that the maintenance of PW plant are done properly.
Manager, Quality Assurance
[][]To approve the SOP.
[][]To ensure overall implementation of this SOP.
Procedure:
Precautions:
[][]All operation work must be done safely in accordance with the requirements of the Plant Safety Statement and the safety notices around the plant. Specific attention must be paid to the following:
[][]Use Personal Protective Equipment during handling of any kind of chemical.
[][]Be careful about the hot water and steam line.
[][]Ensure all the utilities before doing any operation.
[][]Hang the Maintenance tag prior to any maintenance activity.
System Description:
[][]The PW is produced from feed water through various processes. In pretreatment portion the feed water is passed through the MGF, ACF, softener and 5 micron cartridge filter. Then the pretreated water is passed through 1st and 2nd stage RO and finally through EDI. In RD/EDI section there is another 5 micron cartridge filter after 1st RO.
[][] There are four chemical dosing systems in PW Generation system such as chlorine dosing, SMBS dosing, Anti Scalant dosing and pH correction dosing. There is a PW storage tank of capacity 5000L in Solid Block.
[][]Also, there is a PW Distribution loop in the Liquid Block which contains a 3000L PW storage tank. There is a user point in the PW distribution loop system of Solid to supply the PW in the PW storage tank of Liquid Block.
Maintenance Procedure:
[][]Filter Cleaning procedure: The cartridge filter is cleaned when the filter is blocked and the pressure rises. Normally, an alarm is generated on the PLC due to high pressure (greater than 0.3MPa).
The cartridge filter is dismantled from the filter housing. Then wash the filter by passing the normal water through the filter in backward direction.
[][]Sanitize the ACF after every 14 days according to the SOP.
[][]Sanitize the 1st RO, 2nd RO and EDI after 6 months according to the SOP.
[][]Sanitize the PW distribution system after every 14 days according to the SOP.
[][]Clean the dosing tanks on every 2 weeks. At first, empty the dosing tank and wash it by PW.
[][]The maintenance schedule of PW Generation and Distribution system is given below:
[][]Daily maintenance
>>Check for any leakage.
[][]Bi monthly
>>Clean the dosing tanks.
[][]Monthly
>>Shoot clean for panel board.
[][]Yearly
>>Tighten all the nuts and bolts.
>>Check all electrical connections.
[][]After two years
>>Change the gasket of the valves.
>>Check the pneumatic pipes and change if it is necessary.
>>High pressure (greater than 0.3 MPa) across the cartridge pre filter
>>Wash the cartridge pre filter.
Annexure:
Annexure – I: Maintenance Log Sheet of PW Generation and Distribution system