Commissioning Manual ENG for LOrealv10English.docx

1、Commissioning Manual ENG for LOrealv10EnglishPact Environmental Technology (Shanghai) Co. Ltd.5/F No. 700 LuBan RoadShanghai 200023ChinaTel. +86 (0)21 53 01 90 81Fax +86 (0)21 53 01 87 71e-mail pactLoreal BeautyCos WWTP ProjectCommissioning ManualFor Loreal BeautyCos International Co.,LtdCopyright 2

2、006 by Pact Environmental Technology Co.Ltd. All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, for any purpose, without the prior written permission

3、of Pact Environmental Technology Co.Ltd.Project InformationProject nameLoreal BeautyCos WWTP ProjectClientLoreal BeautyCos International Co., LtdContact personTelephoneFaxSupplierPact Environmental Technology (Shanghai) Co. Ltd.5/F No. 700 LuBan RoadShanghai 200023ChinaContact personTelephone+ 86 (0

4、)21 53 01 90 81Fax+ 86 (0)21 53 01 87 71Contract numberWritten byCHEN PENGChecked byJI MINGDateJul-20-2006ReferenceVersion1.0Catalog1. Commissioning Description 51.1 Aim 51.2 Commissioning Condition 51.3 Commissioning Procedure 51.4 Commissioning Scope 52. Process Description 62.1 Process Summary 62

5、.2 Description of Process and Operation 83. Equipment Specification 223.1 Wastewater Storage Tank and Appendage 223.2 DAF System and Appendage 243.3 Aeration Tank and Appendage 283.4 Clarifier and Appendage 283.5 Sumps, Pumps and Appendage 303.6 Sludges Storage and Dewatering system and Appendage 33

6、3.7 Chemical Storage and Appendage 343.8 Instrumentation and automatic valves 404. Setting of Wastewater Pump Flow Rate 444.1 System Design Flow Rate 444.2 Setting of wastewater pump flow rate 444.3 Calibration method for flow rate 465. Commissioning of Main Construction and Equipment and System Int

7、erlock Operation（with city water） 485.1 Confirmation and Preparation befor Commissioning 485.2 Commissioning of Single Equipment 495.3 Interlock commissioning of instrumentation and device 505.4 System Interlock Operation 566. Commissioning of Biological Process 576.1 Inoculation of Aerobic Activate

8、d Sludge 576.2 Cultivation and Domestication 586.3 Test Items in Cultivation and Domestication 587. Operation and Maintenance 607.1 Routine Inspection Cycle 607.2 Routine Inspection of Devices 607.3 Operation of DAF 617.4 Operation of Biological Process 627.5 Operation of Slude Dewatering System 667

9、.6 Others 668. Commissioning Record 66Begin van de tekst1. Commissioning Description1.1 AimTest system capacity and performance, and confirm that system automatical control function well, each parameter meets requirement of process by commissioning. Then put biological aeration system into service,

10、discharge qualified treated water. 1.2 Commissioning Condition 1.2.1 Pass construction and installation acceptance testing after finishing system erection 1.2.2 Availability of water resource for system commissioning (Industry wastewater and municipal water for activated sludge cultivation and domes

11、tication) 1.2.3 Well function of all equipments within commissioning scope1.2.4 Clients should dispatch related personal for coordination 1.3 Commissioning Procedure 1.3.1 Commissioning of single equipment（Only manually start electrical device shortly）1.3.2 Commissioning of system with city water（Sy

12、stem interlock operatioin with city water）1.3.3 Commissioning of system production（Biological process commissioning with wastewater）；1.3.4 Commissioning of system auto-control program1.4 Commissioning Scope Including: constructions, pumps, mixers, blowers, and related instruments, auto-controlprogra

13、m, etc.2. Process Description2.1 Process SummaryBEAUTYCOS INTERNATIONAL Co., LTD, a company incorporated in the Peoples Republic of China has recently been scheduling for the construction of an expended facility to manufacture high-value cosmetics products.The industrial wastewater mainly comes from

14、 cleaning operations of the industrial equipment, storage vessels, raw material and bulk transfer equipment, water treatment processing and cleaning areas. The pretreatment system including chemical coagulation and flocculation, Dissolved Air Flotation (DAF) can remove most of SS, oil, grease and he

15、avy metals in the wastewater. Biological process can degradate the orgnic matters in the wastewater, which can facilitate the function of post treatment system, including multimedia filter and carbon filter. The treated effluent is discharged after meeting the take up standard of the wastewater trea

16、tment plant in SUZHOU INDUSTRY PARK.2.1.1 Flow Capacity The design capacity for the wastewater treatment plant is 300 m3/day. The system can be extended to capacity of 540 m3/day in the future by adding additional aeration tanks and equipment.2.1.2 Raw Wastewater Characteristic Table 3-1 Raw Wastewa

17、ter Characteristic ItemUnitMax.AverageMin.Flow Capacitym3/d360220Temperature3820ColortimesPH10.697.1CODCRmg/l110007500BOD5mg/l44003000SSmg/l20001000Mineral oils and greasesmg/l1010Animal and plant oilsmg/l1010Total oils and greasesmg/l850Volatile phenolsmg/l1010Kjeldahl Nitrogen mg/l13085NH4-Nmg/l90

18、45Total phosphatemg/l33LASmg/l1Coppermg/l0.05Zincmg/l0.4Total leadmg/l11Total arsenicmg/l0.50.5Total silvermg/l0.50.5Total berylliummg/l0.010.01Total nickelmg/l111、The WWTP has the capacity of treating 300 m3/day of the wastewater, and has the extended capacity to reach 540 m3/day capacity.2、For the

19、 Max., Average, Min., refer to Specifications Effluent Treatment in the CONTRACT page 28 of 73.3、The amounts of Total oils and greases , LAS, Copper, Zinc are not indicated in the contract. Amounts of Total oils and greases (850mg/l) and LAS(1mg/l) in the above table are tested results from jar test

20、s. And, amounts of Copper, Zinc are referring to the corresponding figures in the environmental impact assessment report. 2.1.3 WASTEWATER DISCHARGE LIMIT The treated effluent must, at all times, comply with Class III standards of the Integrated Wastewater Discharge Standards (GB 8978-1996) and Disc

21、harge standard for municipal wastewater (CJ3082-1999). The discharge limit of pollutant copper meets the requirement of Class II of the Integrated Wastewater Discharge Standards. Some of the main items are provided for reference: Table3-2 Wastewater Discharge LimitItemUnitDischarge LimitFlow Capacit

22、ym3/d300Temperature38ColortimesPH6-9CODCRMg/l425BOD5Mg/l30SSMg/l68Mineral oils and greasesMg/l17Animal and plant oilsMg/l85Total oils and greasesMg/l17Volatile phenolsMg/l1.7NH4-NMg/l29.75PhosphateMg/l5LASMg/l17CopperMg/l1ZincMg/l5Total leadMg/l0.85Total arsenicMg/l0.43Total silverMg/l0.43Total bery

23、lliumMg/l0.0043苯并荜Mg/l0.0000225Total nickelMg/l0.852.2 Description of Process and Operation Refer to P&ID for the detail process. Sections bellowed will give brief introductions to main equipment. Automatic controls are descripted simply here, for more detail information refer to Functional Specific

24、ation Control System Version 2.0. 2.2.1 Air-to-water coolerFunction: Cool the raw wastewater to the appropriate range of temperature Components: Cooling Tower (CT01), Temperature Transmitter (TT0101), etc. The client has an existing air-to-water cooler for the wastewater application. It is installed

25、 in the inlet pipeline, having three sets fan. The temperature transmitter will detect the temperature of inlet raw water, then sending the corresponding signal to control cooling fan running, reducing power consume at utmost. The parameters of temperature transmitter can be set via HMI. 2.2.2 Waste

26、water Storage TankFunction: equalize the wastewater fully Components: Two (2) existing tanks (200 m3 each, T01A/B), A new-built 400 m3 tank(T01C), Level transmitter and switch, mixer, etc.Two (2) existing tanks (200 m3 each) will be utilized as wastewater storage tanks. These two tanks will have com

27、municating level as one tank, by adding two (2) interconnecting piping at the bottom. The existing vertical mixers (A01A/B) will be used for mixing purpose. One (1) circulation pump (P01F) will be installed to allow circulation between the tanks. A third 400 m3 tank (T01C) will be built. The 400 m3

28、tank will be constructed of concrete with FRP coated inside inside. The design and construction of the 400 m3 tank will allow the provision of adding of the cover in the future. Recirculation pumps (P01G/H) are designed in the 400 m3 tank to provide the stirring of the water to prevent smell. Freque

29、ncy conversion control is employed to P01G/H, regulating according to the level in the tank. Eight (8) Liquid jet mixing nozzles (G3/4”) will be installed in the tank to assist the mixing effort. The two existing tanks (T01A/B) are used intermittently with the third tank (T01C) by turns. Pneumatic O

30、N/OFF valves are designed at the inlet of each tank. When Pneumatic valve (PV01A/B) open, Pneumatic valve (PV01C) close, Supply pump (P01A/B/C) stop, means that T01A/B are filling with raw wastewater, supply pump(P01D/E) running, T01C is supplying raw wastewater to the downstream. When Pneumatic valve (PV01A/B) close, Pneumatic valve (PV01C) open, Supply pump (P01A/B/C) runs, means that T01A/B are supplying raw wastewater to the downstream, supply pump(P01D/E) stop, T01C is filling with raw wastewater. Wastewater may contain oil, wh