Modular UV sterilisation unit for process water, 2 m³/h
I am designing a modular UV sterilisation unit for process water, 2 m³/h, for a food plant. The unit is assembled and tested at the factory, so on site installation takes 1 day and commissioning 1 day.
Input data
| Capacity | 2 m³/h |
|---|---|
| Storage tank | 2 m³ |
| Water | from a borehole, for floor washing in the production area |
| Format | skid module 1700 × 700 × 1850 mm: assembled and tested at the factory |
| On-site installation and commissioning (plan) | 1 working day each |
| My role | lead project engineer: process scheme and P&ID, equipment selection, 3D layout, design and automation specifications, manual; installation supervision and commissioning |
Engineering challenge
Borehole water is used to wash floors in the production area. Untreated water must not reach production if the lamp fails, if power is lost, or after pauses in demand. Work on site has to take as little time as possible.
Solution
A modular unit: pumps, filters, UV reactor, valves and control panel on one skid. It is tested at the factory and arrives ready; on site only the tank, water and power need connecting. The scheme below shows how it works.
Result
| P&ID and 3D model | issued |
|---|---|
| Detailed design: frame, installation, electrical, bill of materials | issued |
| Unit manual | issued in Russian and English |
| Factory fabrication and testing | in progress |
Step by step: from the tank to production
- 01
Storage
2 m³
Tank topped up from the borehole by level switches. The low switch protects the pumps from running dry.
- 02
Pump group
duty + standby
28 m head, pumps alternate every 24 h. Flow is set on a rotameter.
- 03
Pre-filtration
90 µm
A backwashable screen filter protects the lamp quartz sleeve.
- 04
UV disinfection
90 W · UV sensor
Intensity sensor: below 50 % the water goes to drain and the line to production closes.
- 05
Guard filter and supply
30 µm
Catches sleeve fragments after a failure. Water goes to production or back to the tank.
Safety
All solenoid valves are normally closed: without power the line to production is shut. On a UV alarm the unit flushes to drain and stops the pump. The UV bypass is padlocked. Siemens LOGO! controller; the emergency stop cuts pumps and valves in hardware.
Speed of start-up
The module is assembled, piped and tested at the factory. On site the plan is 1 working day for installation and 1 for commissioning.
My role
Lead project engineer. Process scheme and P&ID, equipment selection, 3D module layout, detailed design and automation specifications, manual in Russian and English. Installation supervision and commissioning.
Interactive 3D model
The module layout in 3D: pumps, filters, UV reactor, valves and cable trays. Switch views with the buttons at the bottom.