Commissioning Manual ENG for LOrealv10English.docx
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CommissioningManualENGforLOrealv10English
PactEnvironmentalTechnology（Shanghai）Co.Ltd.
5/FNo.700LuBanRoad
Shanghai200023
China
Tel.+86（0）2153019081
Fax+86（0）2153018771
e-mailpact@
L’orealBeautyCosWWTPProject
CommissioningManual
For
L’orealBeautyCosInternationalCo.,Ltd
Copyright2006byPactEnvironmentalTechnologyCo.Ltd.Allrightsreserved.
Nopartofthisdocumentmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,foranypurpose,withoutthepriorwrittenpermissionofPactEnvironmentalTechnologyCo.Ltd.
ProjectInformation
Projectname
L’orealBeautyCosWWTPProject
Client
L’orealBeautyCosInternationalCo.,Ltd
Contactperson
Telephone
Fax
Supplier
PactEnvironmentalTechnology（Shanghai）Co.Ltd.
5/FNo.700LuBanRoad
Shanghai200023
China
Contactperson
Telephone
+86（0）2153019081
Fax
+86（0）2153018771
Contractnumber
Writtenby
CHENPENG
Checkedby
JIMING
Date
Jul-20-2006
Reference
Version
1.0
Catalog
1.CommissioningDescription5
1.1Aim5
1.2CommissioningCondition5
1.3CommissioningProcedure5
1.4CommissioningScope5
2.ProcessDescription6
2.1ProcessSummary6
2.2DescriptionofProcessandOperation8
3.EquipmentSpecification22
3.1WastewaterStorageTankandAppendage22
3.2DAFSystemandAppendage24
3.3AerationTankandAppendage28
3.4ClarifierandAppendage28
3.5Sumps,PumpsandAppendage30
3.6SludgesStorageandDewateringsystemandAppendage33
3.7ChemicalStorageandAppendage34
3.8Instrumentationandautomaticvalves40
4.SettingofWastewaterPumpFlowRate44
4.1SystemDesignFlowRate44
4.2Settingofwastewaterpumpflowrate44
4.3Calibrationmethodforflowrate46
5.CommissioningofMainConstructionandEquipmentandSystemInterlockOperation（withcitywater）48
5.1ConfirmationandPreparationbeforCommissioning48
5.2CommissioningofSingleEquipment49
5.3Interlockcommissioningofinstrumentationanddevice50
5.4SystemInterlockOperation56
6.CommissioningofBiologicalProcess57
6.1InoculationofAerobicActivatedSludge57
6.2CultivationandDomestication58
6.3TestItemsinCultivationandDomestication58
7.OperationandMaintenance60
7.1RoutineInspectionCycle60
7.2RoutineInspectionofDevices60
7.3OperationofDAF61
7.4OperationofBiologicalProcess62
7.5OperationofSludeDewateringSystem66
7.6Others66
8.CommissioningRecord66
Beginvandetekst
1.CommissioningDescription
1.1Aim
Testsystemcapacityandperformance,andconfirmthatsystemautomaticalcontrolfunctionwell,eachparametermeetsrequirementofprocessbycommissioning.Thenputbiologicalaerationsystemintoservice,dischargequalifiedtreatedwater.
1.2CommissioningCondition
1.2.1Passconstructionandinstallationacceptancetestingafterfinishingsystemerection
1.2.2Availabilityofwaterresourceforsystemcommissioning（Industrywastewaterandmunicipalwaterforactivatedsludgecultivationanddomestication）
1.2.3Wellfunctionofallequipmentswithincommissioningscope
1.2.4Clientsshoulddispatchrelatedpersonalforcoordination
1.3CommissioningProcedure
1.3.1Commissioningofsingleequipment（Onlymanuallystartelectricaldeviceshortly）
1.3.2Commissioningofsystemwithcitywater（Systeminterlockoperatioinwithcitywater）
1.3.3Commissioningofsystemproduction（Biologicalprocesscommissioningwithwastewater）；
1.3.4Commissioningofsystemauto-controlprogram
1.4CommissioningScope
Including:
constructions,pumps,mixers,blowers,andrelatedinstruments,auto-controlprogram,etc.
2.
ProcessDescription
2.1ProcessSummary
BEAUTYCOSINTERNATIONALCo.,LTD,acompanyincorporatedinthePeople’sRepublicofChinahasrecentlybeenschedulingfortheconstructionofanexpendedfacilitytomanufacturehigh-valuecosmeticsproducts.
Theindustrialwastewatermainlycomesfromcleaningoperationsoftheindustrialequipment,storagevessels,rawmaterialandbulktransferequipment,watertreatmentprocessingandcleaningareas.
Thepretreatmentsystemincludingchemicalcoagulationandflocculation,DissolvedAirFlotation（DAF）canremovemostofSS,oil,greaseandheavymetalsinthewastewater.Biologicalprocesscandegradatetheorgnicmattersinthewastewater,whichcanfacilitatethefunctionofposttreatmentsystem,includingmultimediafilterandcarbonfilter.
ThetreatedeffluentisdischargedaftermeetingthetakeupstandardofthewastewatertreatmentplantinSUZHOUINDUSTRYPARK.
2.1.1FlowCapacity
Thedesigncapacityforthewastewatertreatmentplantis300m3/day.
Thesystemcanbeextendedtocapacityof540m3/dayinthefuturebyaddingadditionalaerationtanksandequipment.
2.1.2RawWastewaterCharacteristic
Table3-1RawWastewaterCharacteristic
Item
Unit
Max.
Average
Min.
FlowCapacity
m3/d
360
220
Temperature
℃
38
20
Color
times
PH
10.6
9
7.1
CODCR
mg/l
11000
7500
BOD5
mg/l
4400
3000
SS
mg/l
2000
1000
Mineraloilsandgreases
mg/l
10
10
Animalandplantoils
mg/l
10
10
Totaloilsandgreases
mg/l
850
Volatilephenols
mg/l
10
10
KjeldahlNitrogen
mg/l
130
85
NH4-N
mg/l
90
45
Totalphosphate
mg/l
3
3
LAS
mg/l
1
Copper
mg/l
0.05
Zinc
mg/l
0.4
Totallead
mg/l
1
1
Totalarsenic
mg/l
0.5
0.5
Totalsilver
mg/l
0.5
0.5
Totalberyllium
mg/l
0.01
0.01
Totalnickel
mg/l
1
1
1、TheWWTPhasthecapacityoftreating300m3/dayofthewastewater,andhastheextendedcapacitytoreach540m3/daycapacity.
2、FortheMax.,Average,Min.,refertoSpecificationsEffluentTreatmentintheCONTRACTpage28of73.
3、TheamountsofTotaloilsandgreases,LAS,Copper,Zincarenotindicatedinthecontract.AmountsofTotaloilsandgreases（850mg/l）andLAS（1mg/l）intheabovetablearetestedresultsfromjartests.And,amountsofCopper,Zincarereferringtothecorrespondingfiguresintheenvironmentalimpactassessmentreport.
2.1.3WASTEWATERDISCHARGELIMIT
Thetreatedeffluentmust,atalltimes,complywithClassIIIstandardsoftheIntegratedWastewaterDischargeStandards（GB8978-1996）andDischargestandardformunicipalwastewater（CJ3082-1999）.ThedischargelimitofpollutantcoppermeetstherequirementofClassIIoftheIntegratedWastewaterDischargeStandards.
Someofthemainitemsareprovidedforreference:
Table3-2WastewaterDischargeLimit
Item
Unit
DischargeLimit
FlowCapacity
m3/d
300
Temperature
℃
38
Color
times
PH
6-9
CODCR
Mg/l
≤425
BOD5
Mg/l
≤30
SS
Mg/l
≤68
Mineraloilsandgreases
Mg/l
≤17
Animalandplantoils
Mg/l
≤85
Totaloilsandgreases
Mg/l
≤17
Volatilephenols
Mg/l
≤1.7
NH4-N
Mg/l
≤29.75
Phosphate
Mg/l
≤5
LAS
Mg/l
≤17
Copper
Mg/l
≤1
Zinc
Mg/l
≤5
Totallead
Mg/l
≤0.85
Totalarsenic
Mg/l
≤0.43
Totalsilver
Mg/l
≤0.43
Totalberyllium
Mg/l
≤0.0043
苯并荜
Mg/l
≤0.0000225
Totalnickel
Mg/l
≤0.85
2.2DescriptionofProcessandOperation
RefertoP&IDforthedetailprocess.Sectionsbellowedwillgivebriefintroductionstomainequipment.Automaticcontrolsaredescriptedsimplyhere,formoredetailinformationrefertoFunctionalSpecificationControlSystemVersion2.0.
2.2.1Air-to-watercooler
Function:
Cooltherawwastewatertotheappropriaterangeoftemperature
Components:
CoolingTower（CT01）,TemperatureTransmitter（TT0101）,etc.
Theclienthasanexistingair-to-watercoolerforthewastewaterapplication.Itisinstalledintheinletpipeline,havingthreesetsfan.Thetemperaturetransmitterwilldetectthetemperatureofinletrawwater,thensendingthecorrespondingsignaltocontrolcoolingfanrunning,reducingpowerconsumeatutmost.
TheparametersoftemperaturetransmittercanbesetviaHMI.
2.2.2WastewaterStorageTank
Function:
equalizethewastewaterfully
Components:
Two
（2）existingtanks（200m3each,T01A/B）,Anew-built400m3tank（T01C）,Leveltransmitterandswitch,mixer,etc.
Two
（2）existingtanks（200m3each）willbeutilizedaswastewaterstoragetanks.Thesetwotankswillhavecommunicatinglevelasonetank,byaddingtwo
（2）interconnectingpipingatthebottom.Theexistingverticalmixers（A01A/B）willbeusedformixingpurpose.One
（1）circulationpump（P01F）willbeinstalledtoallowcirculationbetweenthetanks.
Athird400m3tank（T01C）willbebuilt.The400m3tankwillbeconstructedofconcretewithFRPcoatedinsideinside.Thedesignandconstructionofthe400m3tankwillallowtheprovisionofaddingofthecoverinthefuture.Recirculationpumps（P01G/H）aredesignedinthe400m3tanktoprovidethestirringofthewatertopreventsmell.FrequencyconversioncontrolisemployedtoP01G/H,regulatingaccordingtothelevelinthetank.Eight（8）Liquidjetmixingnozzles（G3/4”）willbeinstalledinthetanktoassistthemixingeffort.
Thetwoexistingtanks（T01A/B）areusedintermittentlywiththethirdtank（T01C）byturns.PneumaticON/OFFvalvesaredesignedattheinletofeachtank.WhenPneumaticvalve（PV01A/B）open,Pneumaticvalve（PV01C）close,Supplypump（P01A/B/C）stop,meansthatT01A/Barefillingwithrawwastewater,supplypump（P01D/E）running,T01Cissupplyingrawwastewatertothedownstream.WhenPneumaticvalve（PV01A/B）close,Pneumaticvalve（PV01C）open,Supplypump（P01A/B/C）runs,meansthatT01A/Baresupplyingrawwastewatertothedownstream,supplypump（P01D/E）stop,T01Cisfillingwithrawwastewater.
Wastewatermaycontainoil,wh
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