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Synthetic Rubber Indonesia

U3 Project
Control Philosophy.
Client Work No: U3 14122-VD-U1-UTL-LGD-AYCM001-0119 Classification : D3

CLASS AREA DIS TYP REQ NO SEQ SHEET REV. PO No:14122-AYCM001


IKPT Work No:14122
VD U1 UTL LGD AYCM001 0119 - 1 Date : 01-June-2016
Vendor Work No:
320PRJ1501001
Vendor Own No : 320PRJ1501001-05-701 Page : 1

Synthetic Rubber Indonesia


U3 Project

Purchase Order No: 14122-AYCM001


Control Philosophy
For Review

AP APPROVED
AN APPROVED AS NOTED
RE NOT APPROVED (Re-Submit)
RV REVIEWED
RN REVIEWED WITH NOTES
NR NOT BE RETURNED
RETURN DATE

PROJECT ORIGINATOR
RECEIVED DATE

System No. Equipment No. FWBS/AWBS

6491 PA6491.01

1 01-June-16 Issued for Review HSP HSP VKV VKV

0 29-April-16 Issued for Review HSP HSP VKV VKV

DATE
Rev ISSUE PURPOSE PREPARE CHECKED APPROVED AUTHORIZED
ISSUED

PROJECT 320PRJ1501001
TITLE Control Philosophy
DOC. No. 320PRJ1501001-05-701
Synthetic Rubber Indonesia
U3 Project
Control Philosophy.
Client Work No: U3 14122-VD-U1-UTL-LGD-AYCM001-0119 Classification : D3

CLASS AREA DIS TYP REQ NO SEQ SHEET REV. PO No:14122-AYCM001


IKPT Work No:14122
VD U1 UTL LGD AYCM001 0119 - 1 Date : 01-June-2016
Vendor Work No:
320PRJ1501001
Vendor Own No : 320PRJ1501001-05-701 Page : 2

Revision History
First Issue
Second Issue
DATE 01-June-2016

Control Philosophy REV. NO. 1

PAGE. No 1 of 27

DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Contents
1.0 GENERAL......................................................................................................... 2
1.1 Scope................................................................................................................ 2
1.2 Demineralization Unit........................................................................................ 2
1.3 References ....................................................................................................... 4
1.4 Definition & Glossary of Terms ......................................................................... 4
2.0 Units of Measurements ..................................................................................... 4
3.0 Design Overview............................................................................................... 5
3.1 General ............................................................................................................. 5
3.2 Power supplies & distribution ............................................................................ 6
3.3 PLC panel & PLC system ................................................................................. 6
3.4 Motor starting concept ...................................................................................... 7
3.5 Instrument Junction Boxes.............................................................................. 10
3.6 Instrument Transmitters .................................................................................. 10
3.7 Pneumatic Instruments ................................................................................... 10
3.8 On/Off Valves / Modulating control valve ........................................................ 10
4.0 Instruments Utility Supplies, Cabling Systems And Earthing .......................... 11
4.1 Air Supply ....................................................................................................... 11
4.2 Cable Routine ................................................................................................. 11
4.3 Cables:............................................................................................................ 12
5.0 PROCESS CONTROL DESCRIPTION .......................................................... 13
5.1 Sand Filter (S6491.01 A/B/C) ......................................................................... 13
5.2 Activated Carbon Filter (S6491.06 A/B) .......................................................... 17
5.3 Cation Resin filter (S6491.02A/B) & Anion Resin filter (S6491.03A/B) ........... 21
5.4 Neutralization system (M6491.05) .................................................................. 25
Annexure-A System Control
Annexure-B Flow chart Sand Filter
Annexure-C Flow chart ACF
Annexure-D Flow chart SBA & SAC
Annexure-E Flow chart Neutralization
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

1.0 GENERAL

1.1 SCOPE

The purpose of this document is to describe Demineralization Unit and its operational
philosophy.

1.2 DEMINERALIZATION UNIT

The purpose of this proposed plant is to treat clean water to produce required product water
as per design basis.
In order to demineralized; water is passed through a series of Sand Filter, Activated Carbon
Filter (ACF), Cation Resin Filter, CO2 Stripper and Anion Resin Filter.
Raw water is first passed through Sand Filter to remove suspended matter and turbidity in
raw water then outlet of Sand Filter is passed to activated Carbon Filter where removal of
soluble organic or residual chlorine removal is accomplished after that the outlet of ACF goes
to Demineralization Plant which mainly consists of Cation Resin Filter, CO2 Stripper and
Anion Resin Filter. The cation and anion units are designed for counter-current regeneration.
The Cation Resin Filter contains Strong Acid Cation resin for reduce cations and total
hardness.
The Atmospheric CO2 Stripper is used for removing carbon dioxide before it reaches the
anion resins in the Anion Resin Filter. It will reduce NaOH chemical consumption for
regeneration.
The Anion Resin Filter contains Strong Base Anion resin for reduce virtually all anions and
silica.
Demineralized water from plant is stored in Demin Water Tank (T6491.01) (By Client).

Following is process flow path provided to demineralize the Raw water.


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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Raw water from Booster Pump (By others)

Sand Filter

Utility Water Tank (By others)


Utility Water for
General use

Activated Carbon Filter


Utility Water for
Potable Water

Cation Resin Filter

CO2 Stripper
Stripper Tank

Anion Resin Filter

Demin Water Tank (By others)

Acid Regeneration System is provided which consists of Acid Daily Dosing Vessel, and
Acid Dosing System and mixing tee for dilution.
Alkali Regeneration System is provided which consists of Soda Dossing Vessel, Soda
Dosing Pump and mixing tee for dilution.
Neutralization System consists of Neutralization Pit & Mixing pump (Neutralization
disposal pump) with Air scouring blower.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

1.3 REFERENCES

Piping & Instrument Diagram for Demin Package


- 14122-VD-6491-PRS-PID-0009 to 0015
Process Calculation and Equipment Sizing
- 14122-VD-U1-UTL-CAL-AYCM001-0005
Process Flow Diagram for Demineralization Package.
- 14122-VD-U1-UTL-PFD-AYCM001-0004
Process Description
- 14122-VD-U1-UTL-AYCM001-DOC-0006

1.4 DEFINITION & GLOSSARY OF TERMS

DC Direct Current
HDG Hot dip galvanized
I/O Input / Output
MCC Motor control station
PB Pushbutton
P&ID Piping & instrumentation diagram
PLC Programmable Logic Controller
HMI Human Machine Interface
AC Alternating Current
LCS Local Control Station
VFD Variable Frequency Drive
SBA Strong Base Anion
SAC Strong Acid Cation

2.0 UNITS OF MEASUREMENTS

Instrumentation will generally use the International System (SI) units of Measurement.
Instrument tubing, impulse lines and fittings shall use inch sizes.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

3.0 DESIGN OVERVIEW

3.1 GENERAL

The entire package provided by Metito is monitored & controlled from Metito supplied
PLC based system. The PLC is housed in a control panel supplied by Metito.
A Operating/Engineering station with having one 24 is provided for operation initiation,
process monitoring & engineering.
The PLC is interfaced to DCS system on a Modbus communication using TCP/IP protocol.
Status & monitoring & handshake, Command signals are interfaced between the Metito
supplied PLC & DCS. The communication cable from Metito PLC to DCS is provided by
others.
The PLC and SCADA is completely programmed by Metito as per the requirements of
P&ID, Process description & Control Philosophy. Valve sequence charts are described in the
Process Description.

Field instruments comprising of sensors and SMART HART based transmitters are supplied
by Metito. All pneumatic automatic On-off and the modulating valves for the above packages
are supplied by Metito. The plant is located in a safe area, instruments / solenoid valves &
limit switches are supplied suitable for safe area, general purpose weatherproof.

The transmitters, pneumatic valves & its accessories like limit switches, solenoid valves,
position transmitter, I/P converters are wired up to suitably located Junction boxes on or near
to the skids by Metito. Relevant on-skid tubing is also done by Metito.
Loose tubing, fitting, cable, cable glands, trays, accessories (if required) are also supplied by
Metito for out-off skid located Metito supplied valve / instrument. This material will be used by
others to tube / cable up the relevant equipment and to the appropriate JB.

Cabling and cable trays with accessories from the JB to control panel is provided as
by others & installed at site by others. All automatic on-off valves in Metito packages are
pneumatic valves provided with open & close limit switches. Also the modulating control
valve is pneumatically actuated.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Drives of this package which are rated to 660VAC are powered from MCC supplied by
others. While the drives which are rated to 380VAC are powered from field mounted
Local MCC supplied by Metito. VFD panel for Stripped pump are provided by Metito.
The control panel & VFD are located in air conditioned control room.

A brief description of the different E&I related equipments follows.

3.2 POWER SUPPLIES & DISTRIBUTION

All motors of the complete package are powered from the MCC provided by others on 660V /
3pH / 50Hz. Power cable, control cable for LCS and interface cable between MCC and PLC
are provided & laid & terminated by others at site.
Metito control panel is powered from UPS supply of 110 VAC / 1pH / 50 Hz by others.

All the transmitters are two wire transmitters powered on 24 VDC through Metito PLC panel.
Solenoid valves are powered on 24 VDC.
Electromagnetic Flow transmitter is four wire instruments and powered on 24 VDC from
Control panel.
Instruments & control cabling of the package instruments from JB to instruments is provided
by Metito.

3.3 PLC PANEL & PLC SYSTEM

(PLC IP address as : 192.168.11.79, speed 100 MBPS)


The PLC system comprises of standalone processors, simplex I/O racks, simplex I/O,
standalone power supply, internal communication & one engineering/operating work station.
A communication between PLC & DCS is established & that is based on Modbus protocol
with TCP/IP connectivity.
The Siemens PLC is housed in a control panel. The control panel is located in a control room
provided by others. Control panel shall be made of sheet steel to a shade of RAL 7035
outside. Cable entries for the panel shall be from the bottom. Control panel shall be of double
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

front type and with the door in the front and rear.
Metito shall develop the PLC application program and the SCADA screens for these
packages.
For detailed PLC configuration please refer to drawing titled
PLC configuration drawing (14122-VD-U1-UTL-SCD-AYCM001-0136) &
Data sheet for Local Control Panel (14122-VD-U1-UTL-DAT-AYCM001-0134).

3.4 MOTOR STARTING CONCEPT

All three phase motors of demineralization package are started on DOL except Stripped
Water Pump A/B (P6491.12A/B) which are VFD starting. Start and stop commands shall be
issued from the Metito PLC panel. Start shall be a positive (high) going pulse & stop shall be
a negative (low) going pulse.
Run/Stop and Fault feedback is made available to the PLC panel as digital inputs for
following table1. There are also some drives which are not in Metito Scope of supply, but
need to be controlled as per the process requirements. The details are covered in the Table1.

Metito supplied pumps or blowers Client (Others) supplied pumps


a. P6491.12A/B: Stripped Water Pump A/B i. P6491.09A/B: Backwash Pump A/B
b. P6491.14A/B: Mixing Pump A/B ii. P6491.08A/B: Booster Pump A/B
c. B6491.02A/B: Air Scouring Blower A/B iii. P6491.15A/B: DEMIN Water Pump A/B
d. P6491.21A/B: Acid Dosing Pump A/B iv. P6491.19A/B/C: Utility Pump A/B/C
e. P6491.22A/B: Soda Dosing Pump A/B
f. B6491.01A/B: Air Fan A/B
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

TABLE 1

Sr. Powered from / Starter Voltage Control Control


Drive details
No. type / Location (VAC) by Method

P6491.12A: Stripped Water Metito VFD Panel / VFD Metito


1 660 Note 1
Pump - A / Client MCC Room PLC

P6491.12B: Stripped Water Metito VFD Panel / VFD Metito


2 660 Note 1
Pump - B / Client MCC Room PLC

P6491.14A: Mixing Pump - Client MCC / DOL / Metito


3 660 Note 2
A Client MCC Room PLC

P6491.14B: Mixing Pump - Client MCC / DOL / Metito


4 660 Note 2
B Client MCC Room PLC

B6491.02A: Air Scouring Client MCC / DOL / Metito


5 660 Note 2
Blower - A Client MCC Room PLC

B6491.02B: Air Scouring Client MCC / DOL / Metito


6 660 Note 2
Blower - B Client MCC Room PLC

P6491.21A: Acid Dosing Metito MCC / DOL / Metito


7 380 Note 3
Pump - A Field PLC

P6491.21B: Acid Dosing Metito MCC / DOL / Metito


8 380 Note 3
Pump - B Field PLC

P6491.22A: Soda Dosing Metito MCC / DOL / Metito


9 380 Note 3
Pump - A Field PLC

P6491.22B: Soda Dosing Metito MCC / DOL / Metito


10 380 Note 3
Pump - B Field PLC

Metito MCC / DOL / Metito


11 B6491.01A: Air Fan - A 380 Note 3
Field PLC

Metito MCC / DOL / Metito


12 B6491.01B: Air Fan - B 380 Note 3
Field PLC

P6491.09A: Backwash Client MCC / DOL / Metito


13 660 Note 5
Pump - A (Note 4) Client MCC Room PLC
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

P6491.09B: Backwash Client MCC / DOL / Metito


14 660 Note 5
Pump - B (Note 4) Client MCC Room PLC

P6491.08A: Booster Pump - Client MCC / DOL / IKPT


15 660 Note 6
A (Note 4) Client MCC Room DCS

P6491.08B: Booster Pump - Client MCC / DOL / IKPT


16 660 Note 6
B (Note 4) Client MCC Room DCS

P6491.15A: DEMIN Water Client MCC / DOL / IKPT


17 660 Note 6
Pump - A (Note 4) Client MCC Room DCS

P6491.15B: DEMIN Water Client MCC / DOL / IKPT


18 660 Note 6
Pump - B (Note 4) Client MCC Room DCS

P6491.19A: Utility Pump A Client MCC / DOL / IKPT


19 660 Note 6
(Note 4) Client MCC Room DCS

P6491.19B: Utility Pump B Client MCC / DOL / IKPT


20 660 Note 6
(Note 4) Client MCC Room DCS

P6491.19C: Utility Pump C Client MCC / DOL / IKPT


21 660 Note 6
(Note 4) Client MCC Room DCS

Note 1: Hardwired connection between Metito VFD panel & Metito PLC Panel. Control Signals by
Metito PLC

Note 2: Hardwired connection between Client MCC & Metito PLC Panels. Control Signals by
Metito PLC

Note 3: Hardwired connection between Local (field mounted) MCC provided by Metito & Metito
PLC Panel. Control Signals by Metito PLC

Note 4: These Pumps/Motors are supplied by Others. Starter for these motors are assumed to be
DOL

Note 5: Profibus Communication between Client MCC & Client DCS. Communication through
Modbus, control Signals sent by Metito PLC to Client DCS for operating these pumps as per
process requirement

Note 6: Profibus Communication between Client MCC & Client DCS. Communication through
Modbus, Status Signals monitored by Metito PLC to generate Permissive in the Metito PLC
program sequence.

Local control stations along with required types of cables for all Motors of the package
are provided by others.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

3.5 INSTRUMENT JUNCTION BOXES

Field mounted instrument junction boxes which act as interface terminal point between
the various field instruments, transmitters, limit switches & solenoid valves and PLC
Panel.
Instrument junction boxes in this package are classified as described below,
Instrument junction boxes for 4 20 mA Analogue signals to & from PLC Panel.
Instrument junction boxes for digital signals (i.e. for limit switches and solenoid valve
to PLC Panel.

3.6 INSTRUMENT TRANSMITTERS

All instruments except Mag Flow transmitter are 2 Wire, 4-20 mA SMART HART, loop
powered type. Analysers are 4 Wire, 4-20mA with HART, 24VDC powered.

3.7 PNEUMATIC INSTRUMENTS

Pneumatically actuated On-Off valves and modulating flow control valve are part of this
package.

3.8 ON/OFF VALVES / MODULATING CONTROL VALVE

All on-off valves are pneumatically operated. Each on-off valve is provided with one open and
one close limit switch & a solenoid valve. Common Air filter regulator on each skid is
provided by Metito. Limit switches are enclosed in the enclosure. Solenoid valves are
operated on 24 VDC and are IP 65 degree of protection. Modulating control valve is provided
with Positioner with air filter regulator.
The tube used for pneumatic signal air supply tubing size 1/4 OD, SS 316 tube.
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Most of the valves are located on skids and these have been pre-tubed to air header by
Metito. Valves located out of skid have to be tubed to at site by others (if any). Relevant
pneumatic tubing & fittings will be provided as loose supply by Metito.
Each On Off valve is also provided with the following soft selectors & PB / indications on the
SCADA screen to test the functionality & carryout maintenance of individual valve.
Open PB and Close PB.
Open & Close indication.

4.0 INSTRUMENTS UTILITY SUPPLIES, CABLING SYSTEMS AND EARTHING

4.1 AIR SUPPLY

For demineralization system,


Instrument air is required for operation of On-Off and modulating control valves.

4.2 CABLE ROUTING

All Main cables for Instrument, control, & power are routed through overhead Hot-Dipped
galvanized, perforated steel cable trays. These cables & trays are provided by others & also
laid by others.

The branch cables on the skids from instruments to the junction boxes which are mounted on
the same skids, are prewired through the Hot-dipped galvanized perforated cable trays as
part of skid assembly.

While the cables & trays which laid to connect the instruments out of skid or from different
skids, are provided by Metito but needs to be done at site by others.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

4.3 CABLES:

Generally all the instrument & control branch cables shall be Flame retardant, 300/500V
grade, stranded conductors, PVC insulated. The cable types used from different purposes is
explained in the following sections

Analog signals for transmitters: 1Px1.25 sq.mm, circular Stranded copper conductor,
braided screened cable, PVC insulated.
Digital signals for Limit switches: 2P x 1.25 sq.mm, circular Stranded copper conductor,
braided screened cable, PVC insulated
Digital signals for Solenoid valves: 2C X 1.5 sq.mm, circular Stranded copper
conductor, braided screened cable, PVC insulated respectively.

Other than skid and inter skid mounted instrument cabling shall be provided by Metito and
done at site.
While the home run cables (Instrument & control cables from Junction Box to PLC Panel) &
the all the Power cable from MCC to Motors are supplied by others.
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5.0 PROCESS CONTROL DESCRIPTION

5.1 SAND FILTER (S6491.01 A/B/C)

Two working + One Standby Sand Filters are provided.

In normal operation, Sand Filter will receive raw water from Booster pump (By others,
P6491.08A/B).
Each filter is designed for backwash once in every 24 hours of operation. Backwash is
carried out by Backwash Pump (by others, P6491.09A/B).

The conditions for Permissive are described in table 2.


TABLE 2

Sr.
Activity Permissive Condition Source
No.

a. Sand Filter Service Timer less than set hours (24 hrs.) Metito PLC

b. Sand Filter is not under backwash sequence Metito PLC


1 Sand Filter Service
c. Booster (P6491.08A/B) Pump RUN status is received. Client DCS

d. Utility Water Tank Level (LT2-T6491.02)not High Client DCS

a. No other Sand Filter is under backwash sequence Metito PLC


Sand Filter
b. No other ACF is under backwash sequence Metito PLC
2 Backwash
c. Backwash Pump (P6491.09A/B) not in "RUN" condition. Client DCS

d. Air scouring blower (B6491.02A/B) is in ready mode Client DCS

The operation of these Sand Filter (S6491.01A/B/C) is carried out through the HMI (SCADA)
with the help of dedicated operation & control screen. These screens shall have dedicated
soft buttons.

Each Sand Filter (S6491.01A/B/C) can be operated individually as a separate entity.


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All the Sand Filter (S6491.01 A/B/C) are designed to operate through PLC with different
modes of operation as mentioned below,

Auto Mode.
Semi-Auto Mode.
Manual Mode.
Off Mode.

The system is also equipped with the facility of


Step Hold: Used to Hold Step Timer at the point of activation & make the system to
Run continuously & hold other sequences from the occurrence.
Step Advance: Used to skip particular step which may not be necessarily required.
This facility is available only in Semi-Auto mode during Backwash sequence

The different modes are selected by selecting respective soft selector switch provided on the
SCADA screen. The Sand Filter shall remain in the Off Mode when Off Mode is selected
deliberately. This mode can be used to prevent any operation to be carried out in case of any
breakdown.

Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, Sand Filter
(S6491.01 A/B/C) shall start it operation.
The following operation sequences are performed automatically.

a. Service.
b. Backwash.

Service Operation of Filters:

With selection of above operation, the Sand Filter (S6491.01 A/B/C) will perform the specific
selected operation automatically. Out of three Sand Filter (S6491.01 A/B/C), the two which
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

are selected for the operation shall for the set of two working filter & the third once selected
will become the stand by.

The PLC is programed to check the Permissive conditions & once they are satisfied, system
as per the Process Description: valve sequence chart (ANNEXURE-I).

With the operation is being performed the service timer starts tickling & also monitors the
differential pressure across the common inlet & common outlet headers with the help of Diff
Pressure Transmitter (PDT51-S6491-01).
System also monitors the Utility Water Tank level (LT2-T6491.02) (By others) measured by
DCS through Modbus communication. In case when the level in the tank reaches H1 level,
Sand Filter Service shall be under HOLD. When this level drops below the H2 level HOLD
on Service shall be removed.

In case when service timer value reaches to its set point or differential pressure reaches its
set point (which ever earlier), service operation of Sand Filters shall be suspended, the
standby Sand Filter shall be taken to the service. The backwash sequence shall start
automatically to the suspended Sand filter.

The backwash cycle shall be lasting for the set cycle time. Once the cycle timer value is
reached, Sand filter which was backwashed will remain stand by for the next operation cycle.
The Service timer of that filter shall get Reset by the program.

At times if there is requirement of backwash for two filters appearing simultaneously, then
backwash sequence shall be performed based on the Service time counted by PLC.
For further details refer the flow chart Annexure-A System Control & Annexure-B Sand
Filter

Backwash of Filters:

Backwash of filters will be done automatically based on the following condition.


Completion of 24 hours service cycle.
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Whenever Differential pressure is higher than 1 bar (g), backwash of filters shall be
start sequentially. Differential pressure can be determined from the provided pressure
differential transmitter (PDT51-S6491.01).
For further details refer the flow chart Annexure-B Sand Filter

Semi-Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, any of the Sand
Filter (S6491.01 A/B/C) shall be ready to operate in Semi-Auto mode.
In this mode, following operation can be performed

a. Service Start/Stop.
b. Backwash Start/Stop.

To perform Service or Backwash to particular filter, the operator is required to press


Service start or Backwash Start soft buttons respectively on the SCADA screen. These
buttons shall be enabled in Semi-Auto mode only.

Based on the option selected i.e. Service start is pressed or Backwash start is pressed, PLC
checks the Permissive conditions & once they are satisfied, system as per the Process
Description: valve sequence chart (ANNEXURE-I).
For further details refer the flow chart Annexure-B Sand Filter

Manual mode:
This mode is selected, using the soft selection on SCADA screen,
In manual mode each valve can be opened and closed from PLC. Drives listed in Table 1
can be started and stopped from PLC. This mode is useful for testing & for maintenance
purpose.

For further details refer the flow chart Annexure-B Sand Filter
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5.2 ACTIVATED CARBON FILTER (S6491.06 A/B)

One working+ One Standby Activated Carbon Filters are provided.

Activated Carbon Filter receives utility water from Sand Filters (S6491.01A/B/C). Activated
carbon media adsorbs organic matter and the residual chlorine and traces of suspended
particles from utility water. Filtered water from activated carbon filter shall be fed to Cation
Resin Filter.

The conditions for Permissives are described in table 3.


TABLE 3

Sr.
Activity Permissive Condition Source
No.

a. ACF Service Timer less than set hours (24 hrs.) Metito PLC

b. ACF is not under backwash sequence Metito PLC


Activated Carbon
1
Filter Service c. Utility Water Pump (P6491.19A/B/C) RUN status is
Client DCS
received.
d. Utility Water Tank Level not Low Client DCS

a. No other Sand Filter is under backwash sequence Metito PLC


Activated Carbon
b. No other ACF is under backwash sequence Metito PLC
2 Filter Backwash
c. Backwash Pump (P6491.09A/B) not in "RUN" condition. Client DCS

The operation of these Activated Carbon (S6491.06A/B) is carried out through the HMI
(SCADA) with the help of dedicated operation & control screen. These screens shall have
dedicated soft buttons.

Each Activated Carbon Filter (S6491.06A/B) can be operated individually as a separate


entity.
Both the Activated Carbon Filter (S6491.06A/B) are designed to operate through PLC with
different modes of operation as mentioned below,

Auto Mode.
Semi-Auto Mode.
Manual Mode.
Off Mode.
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The system is also equipped with the facility of


Step Hold: Used to Hold Step Timer at the point of activation & make the system to
Run continuously & hold other sequences from the occurrence.
Step Advance: Used to skip particular step which may not be necessarily required.
This facility is available only in Semi-Auto mode during Backwash sequence

The different modes are selected by selecting respective soft selector switch provided on the
SCADA screen. The Sand Filter shall remain in the Off Mode when Off Mode is selected
deliberately. This mode can be used to prevent any operation to be carried out in case of any
breakdown.

Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, Activated Carbon
Filter (S6491.06A/B) shall start operation.
The following operation sequences are performed automatically.

a. Service.
b. Backwash.

Service Operation of Filters:

With selection of above operation, the Activated Carbon (S6491.06A/B) will perform the
specific selected operation automatically. Out of the two filters, the one which are selected for
the operation shall become working filter & other selected later will become the stand by.

The PLC is programed to check the Permissive conditions & once they are satisfied, system
as per the Process Description: valve sequence chart (ANNEXURE-II).

With the operation is being performed the service timer starts tickling & also monitors the
differential pressure across the common inlet & common outlet headers with the help of Diff
Pressure Transmitter (PDT51-S6491-06).
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

System also monitors the Utility Water Tank level (By others) measured by DCS through
Modbus communication. In case when the level in the tank reaches L1 level, ACF Service
shall be stop. When this level rises above the H1 level HOLD on Service shall be removed.

In case when service timer value reaches to its set point or differential pressure reaches its
set point (which ever earlier), service operation of ACF shall be suspended, the standby ACF
shall be taken to the service. The backwash sequence shall start automatically to the
suspended ACF.

The backwash cycle shall be lasting for the set cycle time. Once the cycle timer value is
reached, ACF which was backwashed will remain stand by for the next operation cycle.
The Service timer of that filter shall get Reset by the program.

For further details refer the flow chart Annexure-A System Control & Annexure-C Flow
chart ACF

Backwash of Filters:

Backwash of filters will be done automatically based on the following condition.


Completion of 24 hours service cycle.
Whenever Differential pressure is higher than 1 bar (g), backwash of filters shall be
start sequentially. Differential pressure can be determined from the provided pressure
differential transmitter (PDT51-S6491.06).

For further details refer the flow chart Annexure-C Flow chart ACF

Semi-Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, any of the Activated
Carbon Filter (S6491.06 A/B) shall be ready to operate in Semi-Auto mode.
In this mode, following operation can be performed
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

a. Service Start/Stop.
b. Backwash Start/Stop.

To perform Service or Backwash to particular filter, the operator is required to press


Service start or Backwash Start soft buttons respectively on the SCADA screen. These
buttons shall be enabled in Semi-Auto mode only.

Based on the option selected i.e. Service start is pressed or Backwash start is pressed, PLC
checks the Permissive conditions & once they are satisfied, system as per the Process
Description: valve sequence chart (ANNEXURE-II).
For further details refer the flow chart Annexure-C Flow chart ACF

Manual mode:
This mode is selected, using the soft selection on SCADA screen.
In manual mode each valve can be opened and closed from PLC. Drives listed in Table 1
can be started and stopped from PLC. This mode is useful in start-up and for testing & for
maintenance purpose.

For further details refer the flow chart Annexure-C Flow chart ACF
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

5.3 CATION RESIN FILTER (S6491.02A/B) & ANION RESIN FILTER (S6491.03A/B)

These filters are also provided as One working+ One Standby, however they are designed to
work as a Trend i.e. (One Cation Resin Filter A or B shall be operated with corresponding
Anion Resin Filter A or B.

Thus is Cation Resin Filter-A (S6491.02A) is selected for the operation then Anion Filter-A
(S6491.03A) shall get selected for the operation. Similarly for Cation Filter-B (S6491.02B)
and Anion Resin Filter-B (S6491.03B)

The set of Cation Resin Filter (S6491.02A/B) and Anion Resin Filter (S6491.03A/B) shall
remove cations (Ca, Mg, Na, K & NH4) & alkalinity, Cl, SO4, NO3 & CO2) from the fed water.

The conditions for Permissives are described in table 4.


TABLE 4

Sr.
Activity Permissive Condition Source
No.

a. Service Timer less than set hours (12 hrs.), SBA o/l
Metito PLC
Conductivity is not High, Totalized Flow not achieved.
b. Filter is not under Regeneration sequence Metito PLC
SAC & SBA
1
Service
c. Utility Pump (P6491.19A/B/C)RUN status is received. Client DCS

d. Demin Tank Level (LT1-T6491.01) not High Client DCS

a. Neutralization Pit Level (LT51-M6491.05) not High Metito PLC


SAC & SBA b. Acid/Soda Dosing vessel Level (LT51-V6491.05/06) not
Metito PLC
2 Regeneration Low
c. Demin Pump (P6491.15A/B) not in "RUN" condition. Client DCS

d. Air scouring blower (B6491.02A/B) is in ready mode Client DCS

The operation of these Cation Resin Filter (S6491.02A/B) & Anion Resin Filter
(S6491.03A/B) is carried out through the HMI (SCADA) with the help of dedicated operation
& control screen. This operation is not as individual entity but as a Trend. These screens
shall have dedicated soft buttons.

Both the Cation Resin Filter (S6491.02A/B) & Anion Resin Filter (S6491.03A/B) are designed
to operate through PLC with different modes of operation as mentioned below,
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Auto Mode.
Semi-Auto Mode.
Manual Mode.
Off Mode.
The system is also equipped with the facility of
Step Hold: Used to Hold Step Timer at the point of activation & make the system to
Run continuously & hold other sequences from the occurrence.
Step Advance: Used to skip particular step which may not be necessarily required.
This facility is available only in Semi-Auto mode during Backwash sequence

The different modes are selected by selecting respective soft selector switch provided on the
SCADA screen. The Filters shall remain in the Off Mode when Off Mode is selected
deliberately. This mode can be used to prevent any operation to be carried out in case of any
breakdown.

Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, Cation Resin Filter
(S6491.02A/B) & Anion Resin Filter (S6491.03A/B) shall start sequential operation.
The following operations sequence are performed automatically.

a. Service.
b. Regeneration.

Service Operation of Filters:

With selection of above operation, the Cation Resin Filter (S6491.02A/B) & Anion Resin Filter
(S6491.03A/B) will perform the specific selected operation automatically. Out of the set two
filters (set A or set B), the one which are selected for the operation shall become working
filters set & other selected later will become the stand by.

The PLC is programed to check the Permissive conditions & once they are satisfied, system
as per the Process Description: valve sequence chart (ANNEXURE-III & IV).
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

With the operation is being performed the service timer starts tickling & also monitors the
Conductivity at the respective outlet of Anion Resin Filter (S6491.03 A / B) with the help of
Conductivity Analyzer AT51-S6491-03A/B & Totalized flow at the common outlet headers of
Anion Resin Filter (S6491.03 A / B) with the help of Flow Transmitter (FT51-S6491-03).
System also monitors the Demin Tank level (LT1-T6491.01) (By others) measured by DCS
through Modbus communication. In case when the level in the tank reaches H1 level,
Service shall be under HOLD. When this level rises above the L1 level HOLD on Service
shall be removed.

In case when the any of the Filter set gets exhausted, the Service operation of that Filter set
shall be suspended, the standby Set of Filters shall be taken to the service. The
Regeneration sequence shall start automatically to the suspended set of Filters.

The Reaeration cycle shall be lasting for the set cycle time. Once the cycle timer value is
reached, the set of Filters will remain stand by for the next operation cycle.
The Service timer of that filter set shall get Reset by the program.

For further details refer the flow chart Annexure-D Flow chart SBA & SAC

Regeneration of Filters:

Regeneration of filters will be done automatically based on the following condition.


Completion of 12 hours service cycle.
Whenever the Outlet conductivity of particular Anion Resin Filter (S6491.03A/B) is
higher than 10 micro S/Cm2,
Totalized flow at the common outlet of Anion Resin Filter (S6491.03A/B) is higher than
856 m3.

For further details refer the flow chart Annexure-D Flow chart SBA & SAC
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Semi-Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, any of the Set of
Resin Filters (Cation & Anion) be ready to operate in Semi-Auto mode.
In this mode, following operation can be performed

a. Service Start/Stop.
b. Regeneration Start/Stop.

To perform Service or Regeneration to particular filter set, the operator is required to press
Service start or Regeneration Start soft buttons respectively on the SCADA screen. These
buttons shall be enabled in Semi-Auto mode only.

Based on the option selected i.e. Service start is pressed or Regeneration start is pressed,
PLC checks the Permissive conditions & once they are satisfied, system as per the Process
Description: valve sequence chart (ANNEXURE-III & IV).
For further details refer the flow chart Annexure-D Flow chart SBA & SAC

Manual mode:
This mode is selected, using the soft selection on SCADA screen.
In manual mode each valve can be opened and closed from PLC. Drives listed in Table 1
can be started and stopped from PLC. This mode is useful in for testing & for maintenance
purpose.

For further details refer the flow chart Annexure-D Flow chart SBA & SAC
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

5.4 NEUTRALIZATION SYSTEM (M6491.05)

Neutralization Pit (M6491.05) is provided to collect regeneration waste water from cation
resin filter and anion resin filter along with drain and overflow from chemical dosing area.

This Neutralization Pit being a separate entity, is operate independently.

The conditions for Permissive are described in table 5.


TABLE 5

Sr.
Activity Permissive Condition Source
No.

a. Neutralization Pit Level not Low Metito PLC

b. Acid Dosing Vessel Level not Low Metito PLC


Neutralization
1
Recirculation c. Soda Dosing Vessel Level not Low Client DCS

d. Air scouring blower is in ready required as per valve


sequence chart

a. pH (AT51-P6491.14) Value is between (6 9) Metito PLC


Neutralization
b. Air scouring blower (B6491.02A/B) is in ready mode Client DCS
2 Disposal
c. Suction Basin 2 Level (LS51-M6486.24) not High High" Client DCS

The Neutralization operation (M6491.05) is carried out through the HMI (SCADA) with the
help of dedicated operation & control screen. These screens shall have dedicated soft
buttons.

The Neutralization system is designed to operate through PLC with different modes of
operation as mentioned below,

Auto Mode.
Semi-Auto Mode.
Manual Mode.
Off Mode.
The different modes are selected by selecting respective soft selector switch provided on the
SCADA screen. The Neutralization system shall remain in the Off Mode when Off Mode is
selected deliberately. This mode can be used to prevent any operation to be carried out in
case of any breakdown.
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, Neutralization shall
start operation.
The following operations sequences are performed automatically.

a. Recirculation.
b. Disposal.

Recirculation Operation:

With selection of above operation, Neutralization system will perform the specific selected
operation automatically.

The PLC is programed to check the Permissive conditions & once they are satisfied, system
as per the Process Description: valve sequence chart (ANNEXURE-V).

With the operation is being performed the system shall monitor different set cycle timer &
parameters & executes the different sequences.

In case when the set parameters are achieved, the Disposal sequence shall start
automatically.

For further details refer the flow chart Annexure-E Flow chart Neutralization

Disposal Cycle:

Disposal activity will be done automatically based on the following condition.


Completion of Recirculation cycle timer.
Maintain pH (AT51-P6491-14 ) within set parameters
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DOC. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119

For further details refer the flow chart Annexure-E Flow chart Neutralization

Semi-Auto Mode:
When this mode is selected, using the soft selection on SCADA screen, Neutralization
system shall be ready to operate in Semi-Auto mode.
In this mode, following operation can be performed

a. Recirculation Start/Stop.
b. Disposal Start/Stop.

To perform particular operation, the operator is required to press corresponding soft buttons
on the SCADA screen. These buttons shall be enabled in Semi-Auto mode only.

Based on the option selected i.e. Recirculation start is pressed or Disposal start is pressed,
PLC checks the Permissive conditions & once they are satisfied, system as per the Process
Description: valve sequence chart (ANNEXURE-V).
For further details refer the flow chart Annexure-E Flow chart Neutralization

Manual mode:
This mode is selected, using the soft selection on SCADA screen.
In manual mode each valve can be opened and closed from PLC. Drives listed in Table 1
can be started and stopped from PLC. This mode is useful in start-up and for testing & for
maintenance purpose.

For further details refer the flow chart Annexure-E Flow chart Neutralization

--------------------------------------END OF DOCUMENT-----------------------------------
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-A System Control

System Control Distribution (Annexure-A)

System (I)
Sand Filters
Annexure-B

System (II)
Carbon Filter
Annexure-C
START

System (III)
Cation/Anion Resin Filter
Annexure-D

System (IV)
Neutralization System
Annexure-E
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 1 of 7

System (I)
Sand Filter (S6491.01 A/B/C) [Annexure-B]

Service
Sand Filter (S6491.01 A/B/C)

Select train
A, B or C.

Semi Auto Select Mode A-S-M-O #


Mode M=1 All Pumps/Motors &
1
(Page 3/7) Pneumatic valves in this
S =1
system are to be
If mode operated in manual mode
selected is by individual Pushbuttons
O=1 A=1
/ Switches on HMI.
No Level interlock shall
Operation of remain applicable
Sand Filter

A S3
1

Check Start ALARM


Permissive & NO Operation

Permissive = 1 (OK)
Permissive = 0 (not OK)

X11
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 2 of 7

X11

Pre-
Open XV51-S6491-01A/B/C {SF Service inlet valve SOV}, & service
Open XV56-S6491-01A/B/C {Rinse outlet valve SOV}, Rinse

Step Timer 5 min Note 9,


If Timer= not Dn.
10, 11

Check Step Timer

If Timer= Dn.

Open XV51-S6491-01A/B/C {Service inlet valve SOV},


Open XV52-S6491-01A/B/C {Service outlet valve SOV}, After a Delay of 5
Sec,
XV55-S6491-01A/B/C {Air vent valve SOV}, shall remain open (Note 8) Service

Level = H
NO Operation,
Message on HMI Utility Tank
Utility Tank Level (T6491.02) Level
High Note 5 Note 9,
Level < H 10, 11

Step Timer 24 hrs

If WDT= not Dn. OR


PDT < SP

Check Timer
OR
PDT51-S6491-01 If WDT=Dn. OR
PDT = SP
Semi Auto
mode Auto
System stops Mode
Message on HMI
Sand Filter Start Backwash
Filter Exhausted
Mode =? cycle
need Backwash
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 3 of 7

Semi-Auto Mode
Operations

System Step System Step Service Backwash


Advance Button Hold Button Sand Filter-A/B/C Sand Filter-A/B/C
Start/Stop Start/Stop

S1 S2 S3 S4
1 1 1 1

Note 12 Note 12

Note:-
1. Metito supplied Pumps & blowers with suffix as A shall become Duty pump & blowers while pumps & blowers with
suffix as B shall be stand-by pump & blowers,
2. During normal operation, if Duty pump is unavailable for operation, then Stand-by pump shall take over automatically,
operator shall be made aware by message displayed in Status window on Operation & Control Screen of HMI.
3. If both Duty & Stand-by pumps are unavailable during normal operation, system shall raise Alarm & shall shutdown.
4. After every stoppage of pump operation, Duty and Stand-by role shall be swapped.
5. System shall temporarily Halt Auto operation when High levels signal of Utility Tank received by PLC from SRI DCS.
And if level reaches low level, system shall start its operation. Step timer shall hold when system is halt.
6. System shall stop Backwash cycle when Low level signal of Utility Tank received by PLC from SRI DCS.
7. Proper Delay Timers shall be introduce where ever possible, to make system operation smooth & bump free.
8. Valve shall get closed after the delay time of 60 Sec. Actual timer setting to be done on site based on the Filter
performance.
9. System shall monitor the Alarm signals (Dedicated alarm message shall be shown on HMI). In case if any alarm is
encountered, then system shall halt the sequence which is under operation, step timer of particular step will remain
Hold till alarm gets cleared/reset.
10. System shall stop its operation in case if there is Command received from DCS to stop the Sand Filter operation.
This command shall suspend the operation of sand filter in Service or Backwash cycle irrespective of the mode to which
it is running (All on-off valves shall be closed by DCS stop signal. Continue the operation mode to which it is running
after reset of the signal).
11. System shall monitor the valve operation during the corresponding sequence (Dedicated alarm message shall be shown
on HMI). Any abnormality in the valve open & close positions feedback during operation transaction or standstill state
shall be considered as valve fault & thus shall generate system alarm & suspend the operation of that particular system.
12. System shall have facility for Step Hold & Step Adv. These are active during backwash operation in Semi-Auto modes.
Step Hold when activated shall hold all the Step timer from further counting step timing, that particular step shall
continue as long as Step Hold is active.
Step Adv when activated, system shall skip the particular step & jump to the next sequence. This is to save the
operation time by skipping particular step if not necessary from operation point of view.
13. Abbreviations: A=Auto, S=Semi-Auto, M=Manual, O=Off, DN=Done (Complete), WDT=Watch Dog/Step Timer, SP=Set
point.
14. In the Flow chart, only those valves which are to be opened by system are described, While the valves which are not
mentioned shall remain close.
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 4 of 7

Start Backwash

Engage S4
1
No Operation.
Backwashing Pump
Wait till system is
engage =?
available
Available
Level <= L

NO Operation,
Utility Water Tank
Message on HMI
(T6491.02) Level
Utility Tank Level Low
Level > SP

Drain Open XV55-S6491-01A/B/C {Air vent valve SOV},


Open XV56-S6491-01A/B/C {Rinse outlet valve SOV}

S1
Step Timer 5 min
1
Note 9 S2
& 11 If WDT= not Dn.
1
Check
Timer If WDT= Dn.

Open XV55-S6491-01A/B/C {Air vent valve SOV},


Air
Open XV54-S6491-01A/B/C {Air inlet valve SOV}
Scouring
Open XV57-S6491-01A/B/C {Backwash outlet valve SOV}
After delay of 5 sec
Close XV51-B6491-02 {Blower Drain valve SOV}, After delay of 5 sec
Start Duty Air scouring Blower (B6491.02A/B)

Note 9 S1
& 11 Step Timer 5 min
If WDT= not Dn.
1
S2

Check 1
Timer
If WDT= Dn.

X12
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 5 of 7

X12

Open XV57-S6491-01A/B/C {Backwash outlet valve SOV}


After delay of 5 sec
Backwash Open XV53-S6491-01A/B/C {Backwash inlet valve SOV}

S1
Step Timer 10 min 1
Note 9 S2
& 11 If WDT= not Dn.
1
Check
Timer

If WDT= Dn.

Settle All the valves remain close, System is Standstill

S1
Step Timer 5 min
1
S2
Note 9 If WDT= not Dn.
& 11 1
Check
Timer

If WDT= Dn.

X13
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 6 of 7

X13

Open XV51-S6491-01A/B/C {SF Service inlet valve SOV}, &


Open XV56-S6491-01A/B/C {Rinse outlet valve SOV},
Rinse

S1
Step Timer 5 min
1
Note 9 S2
If WDT= not Dn.
& 11 1
Check
Timer

If WDT= Dn.

If Mode = Auto

A Sand Filter
Mode =?

If Mode = Semi Auto

Stop Backwash
System shall remain Idle
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-B Flow chart Sand Filter Page 7 of 7

Start Permissive
Sr. Tag Number Description Delay Time Condition
No
1 LI2-T6491.02 Utility Water Tank Level (From DCS) 5 Sec Level not High or Low

2 YB1-P6491.08A/B Booster Pump (P6491.08A/B) Status 2 Sec Running


(Not Stopped or No Fault)
3 YB1-P6491.09A/B Backwashing Pump (P6491.09A/B) Status 2 Sec Stopped
(Not Running or No Fault)

Alarms
Sr. Tag Set
Description Alarm DELAY ACTION
No. Number Value
PDT51- Diff Pressure TX Across
1 30 Sec A: Alarm
S6491-01 Sand Filter S6491.01A/B/C
H 1 bar
B: Start backwash cycle SAND FILTER
1 MIN
S6491.01A/B/C

XA51- Air Scouring Blower-A A:Alarm


2 N/A N/A 5 Sec
B6491.02 A Fault Status Stop Blower
XA51- Air Scouring Blower-B A:Alarm
3 N/A N/A 5 Sec
B6491.02 B Fault Status Stop Blower
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 1 of 6

System (II)
Activated Carbon Filter (S6491.06 A/B) [Annexure-C]

Service
ACF (S6491.06 A/B)

Select Duty
train

Select Mode A-S-M-O #


Semi Auto
1
Mode M=1 All Pumps/Motors &
(Page 3/6) Pneumatic valves in this
S =1
system are to be
If mode operated in manual mode
selected is by individual Pushbuttons
O=1 A=1
/ Switches on HMI.
No Level interlock shall
Operation of remain applicable
ACF

A S3
1
HMI message Check Start ALARM
Potable water will Permissive & NO Operation
not be available
when ACF is OFF. Permissive = 0 (not OK)

Permissive = 1 (OK)

X11
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 2 of 6

X11

Pre-
Open XV51-S6491-06A/B {Service inlet valve SOV}, & service
Open XV56-S6491-06A/B {Rinse outlet valve SOV}, Rinse

Step Timer 5 min Note 5


If Timer= not Dn.
&7

Check Step Timer


If Timer= Dn.

Open XV51-S6491-06A/B {Service inlet valve SOV},


Open XV52-S6491-06A/B {Service outlet valve SOV}, After a Delay of 5
Sec,
XV54-S6491-06A/B {Air vent valve SOV}, shall remain open (Note 4) Service
Close XV56-S6491-06A/B {Rinse outlet valve SOV}.

Level > SP
NO Operation,
Message on HMI Utility Tank
Utility Tank Level (T6491.02) Level
High Note 5
Level < SP &7

Note 1
Step Timer 24 hrs

If WDT= not Dn. OR


PDT < SP

Check Timer
OR
PDT51-S6491-06 If WDT=Dn. OR
PDT = SP
Semi Auto
mode Auto
System stops Mode
Message on HMI
ACF Start Backwash
Filter Exhausted
Mode =? cycle
need Backwash
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 3 of 6

Semi-Auto Mode
Operations

System Step System Step Service Backwash


Advance Button Hold Button Sand Filter-A/B/C Sand Filter-A/B/C
Start/Stop Start/Stop

S1 S2 S3 S4
1 1 1 1

Note 8 Note 8

Note:-
1. System shall temporarily Halt Auto operation when High levels signal of Utility Tank received by PLC from SRI DCS
during Service mode.
2. System shall stop Backwash cycle when Low level signal of Utility Tank received by PLC from SRI DCS.
3. Proper Delay Timers shall be introduce where ever possible, to make system operation smooth & bump free.
4. Valve shall get closed after the delay time of 60 Sec. Actual timer setting to be done on site based on the Filter
performance.
5. System shall monitor the Alarm signals (Dedicated alarm message shall be shown on HMI). In case if any alarm is
encountered, then system shall halt the sequence which is under operation, step timer of particular step will remain
Hold till alarm gets cleared/reset.
6. System shall stop its operation in case if there is Command received from DCS to stop the Activated Carbon Filter
operation. This command shall suspend the operation of sand filter in Service or Backwash cycle irrespective of the
mode to which it is running (All on-off valves shall be closed by DCS stop signal. Continue the operation mode to which
it is running after reset of the signal).
7. System shall monitor the valve operation during the corresponding sequence. Any abnormality (Dedicated alarm
message shall be shown on HMI) in the valve open & close positions feedback during operation transaction or standstill
state shall be considered as valve fault & thus shall generate system alarm & suspend the operation of that particular
system.
8. System shall have facility for Step Hold & Step Adv. These are active during backwash operation in Semi-Auto modes.
Step Hold when activated shall hold all the Step timer from further counting step timing, that particular step shall
continue as long as Step Hold is active.
Step Adv when activated, system shall skip the particular step & jump to the next sequence. This is to save the
operation time by skipping particular step if not necessary from operation point of view.
9. Abbreviations: A=Auto, S=Semi-Auto, M=Manual, O=Off, DN=Done (Complete), WDT=Watch Dog/Step Timer, SP=Set
point.
10. In the Flow chart, only those valves which are to be opened by system are described, While the valves which are not
mentioned shall remain close.
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 4 of 6

Start Backwash

Engage S4
1
No Operation.
Backwash Pump
Wait till system is
engage =?
available
Available
Level <= L

NO Operation,
Utility Tank
Message on HMI
(T6491.02) Level
Utility Tank Level Low
Level > SP

Open XV55-S6491-06A/B {Backwash outlet valve SOV}


After delay of 5 sec
Backwash Open XV53-S6491-01A/B {Backwash inlet valve SOV}

S1
Step Timer 10 min 1
Note 5 S2
&7 If WDT= not Dn.
1
Check
Timer

If WDT= Dn.

Settle All the valves remain close, System is Standstill

S1
Step Timer 5 min
1
S2
If WDT= not Dn.
Note 5
1
&7
Check
Timer

If WDT= Dn.

X12
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 5 of 6

X12

Open XV51-S6491-06A/B {Service inlet valve SOV}, &


Rinse Open XV56-S6491-06A/B {Rinse outlet valve SOV},

S1
Step Timer 5 min 1
S2
Note 5 If WDT= not Dn.
1
&7
Check
Timer

If WDT= Dn.

If Mode = Auto

A ACF
Mode =?

If Mode = Semi Auto

Stop Backwash
System shall remain Idle
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart ACF Page 6 of 6

Start Permissive
Sr. Tag Number Description Delay Time Condition
No
1 LI2-T6491.02 Utility Water Tank Level (From DCS) 5 Sec Level not High or Low

2 YB1-P6491.19A/B/C Utility Water Pump (P6491.19A/B/C) 2 Sec Running


Status (Not Stopped or No Fault)
3 YB1-P6491.09A/B Backwashing Pump (P6491.09A/B) Status 2 Sec Stopped
(Not Running or No Fault)

Alarms
Sr. Tag Set
Description Alarm DELAY ACTION
No. Number Value
PDT51- Diff Pressure TX Across
1 H 1 bar 30 Sec A: Alarm
S6491-06 ACF S6491.06A/B
B: Start backwash cycle ACF
1 MIN
S6491.06A/B
PDT51- Diff Pressure TX Across
2 H 1 bar 30 Sec A: Alarm
S6491-06A Strainer of ACF S6491.06A
B: Shut down service cycle ACF
HH 1.5 bar 30 Sec
S6491.06A
PDT51- Diff Pressure TX Across
3 H 1 bar 30 Sec A: Alarm
S6491-06B Strainer of ACF S6491.06B
B: Shut down service cycle ACF
HH 1.5 bar 30 Sec
S6491.06B
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 1 of 19

System (III)
Cation + Anion Resin Filter (S6491.02 A/B & .03 A/B) [Annexure-D]

Service
SAC /SBA

Select Duty
train
Semi Auto Select Mode A-S-M-O #
Mode M=1 All Pumps/Motors &
1
(Page 5/19) Pneumatic valves in this
S =1
system are to be
If mode operated in manual mode
selected is by individual Pushbuttons
O=1 A=1
/ Switches on HMI.
No Level interlock shall
Operation of remain applicable
ACF

A S3
1
Check Start ALARM
Permissive & NO Operation

Permissive = 1 (OK)
Permissive = 0 (not OK)

Open XV51-P6491-15
Buffer Tank
{Demin water makeup
(T6491.04)
valve SOV}
Level

LT51-T6491-
LT51-T6491-
04 >= SP
04 < SP

X11
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 2 of 19

X11

Pre-
Open XV51-S6491-03A/B {SBA Service inlet valve SOV}, service
Open XV56-S6491-03A/B {SBA Rinse outlet valve SOV}, Rinse for
After delay of 5 sec SAC &
SBA

Open XV52-P6491-12A/B {Stripper pump inlet valve SOV},


After delay of 5 sec
Duty Stripper pump P6491-12A/B, starts running.

Open XV58-S6491-02A/B {SAC Rinse inlet valve SOV}, Note 5


Open XV57-S6491-02A/B {SAC Rinse outlet valve SOV}, &7

Step Timer 10 min


If Timer= not Dn.

Check Step Timer


If Timer= Dn.
Check
Pre-
service
Step Timer 5 min Rinse for
SAC &
SBA
Check Conductivity
(AT51-S6491-03A/B)=?

If Timer= not Dn.


Note 5
&7
Check Step Timer
If Timer= Dn.

X18

X19
X12 Y01
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 3 of 19

X12

NO Operation, Level > SP


Message on HMI
Stripper Tank Stripper Tank
Level High (T6491.07) Level

Level < SP

Open XV51-S6491-02A/B {Service inlet valve SOV},


Open XV52-S6491-02A/B {Service outlet valve SOV},
XV56-S6491-02A/B {Air vent valve SOV}, shall remain open (Note 4)
After a Delay of 5 Sec,
Duty Air-Fan (B6491.01A/B) Starts running

Level < SP
LV51-S6491-02
+/- + LT51-
(% valve opening) T6491-07
Modulation - SAC
Service

Level > SP
Step Timer 12 hrs

Timer = not Dn. & Note 5


Totalizes Flow < SP & &7
Conductivity < SP Step Timer
OR
FT51-S6491-03
OR
AT51-S6491-03A/B Timer =Dn. OR
Totalizes Flow >= SP OR
Conductivity >= SP

System stops
Message on HMI Start SAC
SAC/SBA Regeneration
SAC Exhausted
Mode =? Sequence
need Regeneration
Semi Auto Auto
mode Mode
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 4 of 19
Y01

Level > SP
NO Operation,
Message on HMI Demin Water Tank
Demin Water Tank (T6491.01) Level
Level High
Level < SP

Open XV51-S6491-03A/B {Service inlet valve SOV},


Open XV52-S6491-03A/B {Service outlet valve SOV},
XV55-S6491-02A/B {Air vent valve SOV}, shall remain open
(Note 4) After a Delay of 5 Sec,
Open XV52-P6491-12A/B {Stripper pump inlet valve SOV},
After delay of 5 sec
Duty Stripper pump P6491-12A/B, starts running.

Flow < SP
LC51-T6491-01
+/- + FT51-
(% VFD opening) S6491-03
Modulation - SBA
Service

Flow > SP
Step Timer 12 hrs

Timer = not Dn. &


Totalizes Flow < SP & Note 5
Conductivity < SP &7
Step Timer
OR
FT51-S6491-03
OR
AT51-S6491-03A/B
Timer =Dn. OR
Totalizes Flow >= SP OR
Conductivity >= SP

System stops
Message on HMI Start SBA
SAC/SBA Regeneration
SBA Exhausted
Mode =? Sequence
need Regeneration
Semi Auto Auto
mode Mode
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 5 of 19

Semi-Auto Mode
Operations

System Step System Step Service Regen.


Advance Button Hold Button SBA/SAC-A/B SBA/SAC-A/B
Start/Stop Start/Stop

S1 S2 S3 S4
1 1 1 1

Note 8 Note 8

Note:-
1. System shall temporarily Halt Auto operation when Low levels signal of Utility Tank received by PLC from SRI DCS.
2. System shall stop Regeneration cycle when Low level signal of Utility Tank received by PLC from SRI DCS.
3. Proper Delay Timers shall be introduce where ever possible, to make system operation smooth & bump free.
4. Valve shall get closed after the delay time of 60 Sec. Actual timer setting to be done on site based on the Filter
performance.
5. System shall monitor the Alarm signals (Dedicated alarm message shall be shown on HMI). In case if any alarm is
encountered, then system shall halt the sequence which is under operation, step timer of particular step will remain
Hold till alarm gets cleared/reset.
6. System shall stop its operation in case if there is Command received from DCS to stop the Sand Filter operation.
This command shall suspend the operation of sand filter in Service or Regeneration cycle irrespective of the mode to
which it is running (All on-off valves shall be closed by DCS stop signal. Continue the operation mode to which it is
running after reset of the signal).
7. System shall monitor the valve operation during the corresponding sequence. Any abnormality (Dedicated alarm
message shall be shown on HMI) in the valve open & close positions feedback during operation transaction or standstill
state shall be considered as valve fault & thus shall generate system alarm & suspend the operation of that particular
system.
8. System shall have facility for Step Hold & Step Adv. These are active during regeneration operation in Semi-Auto
modes. Step Hold when activated shall hold all the Step timer from further counting step timing, that particular step
shall continue as long as Step Hold is active.
Step Adv when activated, system shall skip the particular step & jump to the next sequence. This is to save the
operation time by skipping particular step if not necessary from operation point of view.
9. Abbreviations: A=Auto, S=Semi-Auto, M=Manual, O=Off, DN=Done (Complete), WDT=Watch Dog/Step Timer, SP=Set
point.
10. System shall temporarily Hold Regeneration cycle when level in Neutralization Pit is High & resume when level drops to
or below low Level.
11. In the Flow chart, only those valves which are to be opened by system are described, while the valves which are not
mentioned shall remain close.
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 6 of 19

Start SAC Regeneration

S4
Yes
1
No Operation.
Other Exchanger in
Wait till system is
Regeneration =?
available
No

Open XV53-S6491-02A/B {Compaction inlet valve SOV}


Open XV55-S6491-02A/B {Compaction outlet valve SOV} ,
After delay 2 Sec
SAC
Open LV51-S6491-02 {SAC Inlet Control valve}
Compaction

S1
Step Timer 3 min
1
S2

Note 5 1
&7 Check
Timer
Timer= not Dn.
Timer = Dn.

X13
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 7 of 19

X13

Open XV55-S6491-02A/B { Compaction outlet valve SOV} ,


Open XV54-S6491-02A/B {Acid inlet valve SOV}
After delay 2 Sec
Open XV52-P6491-21 {Demin Water Pump dis to mixing Tee
valve SOV}
After delay of 2 Sec
Flow < SP
Acid
Injection FV51-P6491-15
@ 1.5% +/- + FT51-
(% valve opening) P6491-15
Modulation -

Flow > SP
Note 5
&7 Open XV51-P6491-21 {Acid dosing pump discharge valve
SOV}
After delay 2 Sec
Duty Acid Dosing pump P6491-21A/B starts running with set
strokes control signal (for Acid concentration of 1.5 %)

S1
Step Timer 678 sec 1
S2 Timer =
not Dn.
1
Check
Timer

If WDT= Dn.

X14
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 8 of 19

X14

Open XV55-S6491-02A/B { Compaction outlet valve SOV} ,


Open XV54-S6491-02A/B {Acid inlet valve SOV}
After delay 2 Sec
Open XV52-P6491-21 {Demin Water Pump dis to mixing Tee
valve SOV}
After delay of 2 Sec
Flow < SP
Acid
Injection FV51-P6491-15
@ 3% +/- + FT51-
(% valve opening) P6491-15
Modulation -

Flow > SP
Note 5
&7 Open XV51-P6491-21 {Acid dosing pump discharge valve
SOV}
After delay 2 Sec
Duty Acid Dosing pump P6491-21A/B starts running with set
strokes control signal (for Acid concentration of 3 %)

S1
Step Timer 345 Sec 1
S2 Timer =
not Dn.
1
Check
Timer

If WDT= Dn.

X15
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 9 of 19

X15

Open XV55-S6491-02A/B { Compaction outlet valve SOV} ,


Open XV54-S6491-02A/B {Acid inlet valve SOV}
After delay 2 Sec
Open XV52-P6491-21 { Demin Water Pump dis to mixing Tee
valve SOV}
After delay of 2 Sec
Flow < SP
Acid
Injection FV51-P6491-15
@ 4.5% +/- + FT51-
(% valve opening) P6491-15
Modulation -

Flow > SP
Note 5
&7 Open XV51-P6491-21 {Acid dosing pump discharge valve
SOV}
After delay 2 Sec
Duty Acid Dosing pump P6491-21A/B starts running with set
strokes control signal (for Acid concentration of 4.5 %)

S1
Step Timer 345 sec 1
S2 Timer =
not Dn.
1
Check
Timer

If WDT= Dn.

X16
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 10 of 19

X16

Open XV55-S6491-02A/B { Compaction outlet valve SOV},


Open XV53-S6491-02A/B { Compaction inlet valve SOV}
After delay 2 Sec
Acid Open XV52-P6491-21 {Demin Water Pump dis to mixing Tee valve
displaceme SOV}
nt After delay of 2 Sec
Flow < SP

FV51-P6491-15
+/- + FT51- Timer =
not Dn.
(% valve opening) P6491-15
Modulation -
Note 5
&7
Flow > SP
S1
Step Timer 978 sec 1
S2
1
Check
Timer
Timer = Dn.

Resin Bed
Settling All the valves remain close, System is Standstill

S1
Step Timer 10 min Timer
1 = not
S2 Dn.
1
Check
Note 5 Timer
&7 Timer = Dn.

X17
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 11 of 19

Start SBA Regeneration

S4
Yes
1
No Operation.
Other Exchanger in
Wait till system is
Regeneration =?
available
No

Open XV54-S6491-03A/B {Compaction outlet valve SOV},


Open XV53-S6491-03A/B { Compaction inlet valve SOV}
After delay 2 Sec

Flow < SP
Note 5
FV51-P6491-15
&7
+/- + FT51-
(% valve opening) P6491-15
Modulation -

SBA Flow > SP


Compaction S1
Step Timer 3 min
1
S2
1
Check
Timer
Timer= not Dn.
Timer = Dn.

Y02
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 12 of 19

Y02

Open XV53-S6491-03A/B { Compaction outlet valve SOV} ,


Open XV57-S6491-03A/B {Regn. Outlet to Neut. valve SOV}
After delay 2 Sec
Open XV52-P6491-22 {Demin Water Pump dis to mixing Tee valve
SOV}
After delay of 2 Sec
Flow < SP
Soda
Injection FV51-P6491-15
@ 4% +/- + FT51-
(% valve opening) P6491-15
Modulation -

Flow > SP
Note 5
&7 Open XV51-P6491-22 {Soda dosing pump discharge valve SOV}
After delay 2 Sec
Duty Soda Dosing pump P6491-22A/B starts running with set
strokes control signal (for Soda concentration of 4 %)

S1
Step Timer 50 min 1
S2 Timer =
not Dn.
1
Check
Timer

If WDT= Dn.

Y03
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 13 of 19

Y03

Open XV53-S6491-03A/B { Compaction outlet valve SOV} ,


Open XV57-S6491-03A/B {Regn. Outlet to Neut. valve SOV}
After delay 2 Sec
Soda Open XV52-P6491-22 {Demin Water Pump dis to mixing Tee valve
displacement SOV}
After delay of 2 Sec
Flow < SP

FV51-P6491-15
+/- + FT51-
(% valve opening) P6491-15
Note 5
Modulation -
&7

Flow > SP
S1
Step Timer 47 min 1
S2 Timer =
not Dn.
1
Check
Timer
If WDT= Dn.

Resin Bed
Settling All the valves remain close, System is Standstill

S1
Step Timer 10 min Timer =
1 not Dn.
S2
1
Check
Note 5 Timer
&7 Timer = Dn.

Y04
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 14 of 19

X17 Y04

Rinse
Recycling Open XV51-S6491-03A/B {SBA Service inlet valve SOV},
for SAC & Open XV56-S6491-03A/B {SBA Rinse outlet valve SOV},
SBA After delay of 5 sec

Open XV51-P6491-12A/B {Stripper pump inlet valve SOV},


After delay of 5 sec
Duty Stripper pump P6491-12A/B, starts running.

Note 5 Open XV58-S6491-02A/B {SAC Rinse inlet valve SOV},


&7 Open XV57-S6491-02A/B {SAC Rinse outlet valve SOV},

S1 Timer= not
Step Timer 30 min 1 Dn.
S2
1
Check Step Timer
If Timer= Dn.

Cond > SP

Delay Check Conductivity


1 min (AT51-S6491-03A/B)=?

Cond <= SP

X18 Delay 1 min

X19
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 15 of 19

X18

Extended
Rinse XV51-S6491-03A/B {SBA Service inlet valve SOV} remains open,
Recycling XV56-S6491-03A/B {SBA Rinse outlet valve SOV} remains open
for SAC & XV51-P6491-12A/B {Stripper pump inlet valve SOV} remains open
SBA

Duty Stripper pump P6491-12A/B, continuous running.

XV58-S6491-02A/B {SAC Rinse inlet valve SOV} remains open,


Note 5 XV57-S6491-02A/B {SAC Rinse outlet valve SOV} remains open,
&7

S1 Timer= not
Step Timer 5 min Dn.
1
S2

Check Step Timer 1


If Timer= Dn.

Cond > SP

Delay Check Conductivity


1 min (AT51-S6491-03A/B)=?

Alarm Cond <= SP


Regeneration Fault
System shall remain Idle Delay 1 min

X20
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 16 of 19

X19 X20

End of
Regenerat
ion Open XV53-P6491-12A/B {Rinse recycle to CO2 stripper valve SOV}
After Delay of 2 sec
Open XV51-P6491-12A/B {SBA Service inlet valve SOV},
After delay of 5 sec
Duty Stripper pump P6491-12A/B, starts running.

Step Timer 10 min


Level > L &
Note 5 Timer = not DN
&7
Check Step Timer
OR
(LT51-T6491.04)
Level < L OR
Timer = DN

Stop Duty Stripper pump P6491-12A/B, after 5 sec delay


Close XV53-P6491-12A/B {Rinse recycle to CO2 stripper valve SOV}
Close XV51-P6491-12A/B {SBA Service inlet valve SOV},

System stops
Message on HMI
SAC/SBA A
Regeneration
Mode =?
Complete
Semi Auto Auto
mode Mode
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 17 of 19

Auto Selection

Level >= H
Acid
Filling
LT51-V6491-05 Text Message
Acid Vessel Full
Level < L

Note 5
&7 Open XV51-V6491-05 {Acid Dosing
Vessel valve SOV}

Auto Selection

Level >= H
Soda
Filling
LT51-V6491-06 Text Message
Soda Vessel Full
Level < L
Note 5
&7 Open XV51-V6491-06 {Soda Dosing
Vessel valve SOV}
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 18 of 19

Start Permissive
Sr. Tag Number Description Delay Time Condition
No
1 LI1-T6491-01 Demin Water Tank Level (From DCS) 5 Sec Level not High

2 YB1-P6491.19A/B Utility Water Pump (P6491.19A/B/C) Status 2 Sec Running


(Not Stopped or No Fault)
3 YB1-P6491.15A/B Demin Water Pump (P6491.15A/B) Status 2 Sec Running
(Not Stopped or No Fault)

Alarms
Sr. Tag Set
Description Alarm DELAY ACTION
No. Number Value
PDT51- Diff Pressure TX Across
1 H 1 bar 30 Sec A: Alarm
S6491-02A Strainer of SAC S6491.02A
B: Shut down service cycle SAC
HH 1.5 bar 30 Sec
S6491.03A
PDT51- Diff Pressure TX Across
2 H 1 bar 30 Sec A: Alarm
S6491-02B Strainer of SAC S6491.02B
B: Shut down service cycle SAC
HH 1.5 bar 30 Sec
S6491.03B
PDT51- Diff Pressure TX Across
3 H 1 bar 30 Sec A: Alarm
S6491-03A Strainer of SBA S6491.03A
B: Shut down service cycle SBA
HH 1.5 bar 30 Sec
S6491.03A
PDT51- Diff Pressure TX Across
4 H 1 bar 30 Sec A: Alarm
S6491-03B Strainer of SBA S6491.03B
B: Shut down service cycle SBA
HH 1.5 bar 30 Sec
S6491.03B
LT51- Stripper Tank (T6491.07) 400 A: Alarm, Start Air Fan & Stop Stripper
5 L 30 Sec
T6491-07 Level Transmitter. mm water Pump
1400
H 30 Sec A: Alarm, Stop Air Fan.
mm
LT51- Buffer Tank (T6491.04) 380 A: Alarm & Stop Stripper water Pump
6 L 30 Sec
T6491-04 Level Transmitter. mm P6491.12 A/B
2200 A: Alarm & Start Stripper water Pump
H 30 Sec
mm P6491.12 A/B
LT51- Acid Dosing Vessel 140 A: Alarm, Open Acid inlet valve (XV51-
7 L 30 Sec
V6491-05 (V6491.05) Level TX. mm V6491-05) & Stop Acid Dosing Pump
1050 A: Alarm, Close acid inlet valve (XV51-
H 30 Sec
mm V6491-05)
A: Alarm, Open caustic inlet valve
LT51- Soda Dosing Vessel 125
8 L 30 Sec (XV51-V6491-06) & Stop caustic dosing
V6491-06 (V6491.06) Level TX. mm
pump
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-C Flow chart SAC+SBA Page 19 of 19

850 A: Alarm Close caustic inlet valve


H 30 Sec
mm (XV51-V6491-06)
Cation Resin Filter
AT51-
9 (S6491.02A/B) common L 2 30 Sec A: Alarm
S6491-02
outlet pH Analyzer
H 7 30 Sec A: Alarm
Anion Resin Filter
AT51-
10 (S6491.03A/B) common L 6.2 30 Sec A: Alarm
S6491-03
outlet pH Analyzer
H 8.2 30 Sec A: Alarm
Anion Resin Filter
AT51-
11 (S6491.03A) outlet H 8 30 Sec A: Alarm
S6491-03A
Conductivity Analyzer
HH 10 30 Sec A: Start Regeneration Sequence
Anion Resin Filter
AT51-
12 (S6491.03B) outlet H 8 30 Sec A: Alarm
S6491-03B
Conductivity Analyzer
HH 10 30 Sec A: Start Regeneration Sequence
Anion Resin Filter
FT51- A: Alarm & Start Regeneration
13 (S6491.03) outlet Flow TX H 860 30 Sec
S6491-03 Sequence
totalized Flow
FT51- Demin Water for
14 L 15.4 30 Sec A: Alarm
P6491-15 Regeneration Flow TX.
H 88.7 30 Sec A: Alarm
XA51- Stripper Pump -A Fault A:Alarm
15 N/A N/A 5 Sec
P6491.12 A Status Stop Pump
XA51- Stripper Pump -B Fault A:Alarm
16 N/A N/A 5 Sec
P6491.12 B Status Stop Pump
XA51- A:Alarm
17 Air Fan-A Fault Status N/A N/A 5 Sec
B6491.01A Stop Fan
XA51- A:Alarm
18 Air Fan-B Fault Status N/A N/A 5 Sec
B6491.01B Stop Fan
XA51- Acid Dosing Pump-A Fault A:Alarm
19 N/A N/A 5 Sec
P6491.21 A Status Stop Pump
XA51- Acid Dosing Pump-B Fault A:Alarm
20 N/A N/A 5 Sec
P6491.21 B Status Stop Pump
XA51- Soda Dosing Pump-A Fault A:Alarm
21 N/A N/A 5 Sec
P6491.22 A Status Stop Pump
XA51- Soda Dosing Pump-B Fault A:Alarm
22 N/A N/A 5 Sec
P6491.22 B Status Stop Pump
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 1 of 8

System (IV)
Neutralization System (Annexure-E)

System Start
Semi Auto
Mode
(Page 5/8) Select Required Mode of Operation
Auto-Semi-Manual All motors, pneumatic
valves in this system are to
be operated in manual
A & S = 0 (Man) mode using individual soft
Semi =1 Pushbuttons/ Switches.
Mode =? All interlock shall remain
applicable
Auto=1
S11
1

X33 Check Start ALARM


Permissive & NO Operation
1
Permissive = 0

Permissive= 1
Level < H.

Check
LT51-M6491-05=?

Level >= H.

X31
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 2 of 8

X31

Initial
recirculation
Open XV52-P6491-14 {Recirculation Line valve SOV},
Open XV52-B6491-02 {Air scouring valve SOV} after a delay of 20 Sec,
Close XV51-B6491-02 {Blower Drain valve SOV} after delay of 10 sec
Duty- Mixing pump P6491.14A/B starts running
After a delay of 5 Sec,
Duty- Air scouring blower B6491.02A/B starts running.

Check
pH (AT51-P6491-14)=?

Step Time 30min


Time = 25min If WDT= not Dn.

J1 Check
Timer=?
Timer= Dn.
pH
Checking XV52-P6491-14 {Recirculation Line valve SOV} remains open,
XV52-B6491-02 {Air scouring valve SOV} remains open,
XV51-B6491-02 {Blower Drain valve SOV} remain close
Duty- Mixing pump P6491.14A/B continues running
Duty- Air scouring blower B6491.02A/B continues running.

J2
pH >= 8.5. pH <= 5.5

Check C1
A1 pH (AT51-P6491-14)=?

pH <= 7.5 pH >= 6.5


A2 C2
6.5 =< pH <= 7.5

X32
1
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 3 of 8

J1
Acid
Dosing

A1 A2

Open XV51-M6491-05 {Acid dosing to Stop Duty-Acid dosing pump


Neut. valve SOV} P6491.21A/B,
After Delay of 5 sec After Delay of 2 sec
Duty- Acid dosing pump P6491.21A/B Close XV51-M6491-05 {Acid dosing to
starts running Neut. valve SOV}

J1

Caustic
Dosing

C1 C2

Open XV52-M6491-05 {Caustic dosing to Stop Duty-Caustic dosing pump


Neut. valve SOV} P6491.22A/B,
After Delay of 5 sec After Delay of 2 sec
Duty- Caustic dosing pump P6491.22A/B Close XV52-M6491-05 {Caustic dosing to
starts running Neut. valve SOV}
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 4 of 8

X32
1

Delay Time 2min

XV52-P6491-14 {Recirculation Line valve SOV} remains open,


Mandatory
XV52-B6491-02 {Air scouring valve SOV} remains open,
recirculation
XV51-B6491-02 {Blower Drain valve SOV} remain close
Duty- Mixing pump P6491.14A/B continues running
Duty- Air scouring blower B6491.02A/B continues running.

Step Time 30 min


Timer= not Dn.

Check
Timer=?
Timer = Dn.

9 < pH < 6

Check J2
pH (AT51-P6491-14)=?

9 > = pH > = 6
Semi Auto mode

Message on HMI
Neut.
System Ready for
Mode =?
Disposal
Auto Mode

Disposal
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 5 of 8

Disposal

S12
1

XV51-P6491-14 {Mixing Pump Discharge valve SOV} will open,


After a delay of 5 sec
XV52-P6491-14 {Recirculation Line valve SOV} gets close.
XV51-B6491-02 {Blower Drain valve SOV} remain close
Duty- Mixing pump P6491.14A/B Start if not running
Disposal

XV52-B6491-02 {Air scouring valve SOV} will get open,


XV51-B6491-02 {Blower Drain valve SOV} remain close
Duty- Air scouring blower B6491.02A/B starts if not running.
Note: 11

Level > L.

Check
LT51-M6491-05=?

Level <= L.

Auto Mode

Neut. X33
Mode =?
1
Semi Auto
mode

Disposal Stop
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 6 of 8

Semi Auto Mode


Operations

Neutralization Disposal
Start/Stop Start/Stop

S11 S12
1 1

Note:-
1. The Pumps/Blowers with suffix as A shall become Duty pump while pump with suffix as B shall be stand-by pump,
2. During normal operation, if Duty pump is unavailable for operation, then Stand-by pump shall take over automatically,
operator shall be made aware by message displayed in Status window on Operation & Control Screen of SCADA system.
3. If both Duty & Stand-by pumps are unavailable during normal operation, system shall raise Alarm & shall shutdown.
4. After every stoppage of pump operation, Duty and Stand-by role shall be swapped.
5. System can be operated only in any one mode of operation at a given time i.e. Auto or Semi-Auto or Manual mode.
6. System shall temporarily suspend Auto operation when level in Neutralization Pit drops to Low level & resume when
level rises above or equal to High Level.
7. Proper Delay Timers shall be introduce where ever possible, to make system operation smooth & bump free.
8. If any Dosing pump Trips or Stopped system shall display alarm & shall start shutdown.
9. Parameters for AT51-P6491-14 shall be monitored only when any of the mixing pump is running.
10. In the case when there is blower requirement for Air Scouring of Sand Filter then,
XV54-S6491-01A/B/C {Air inlet valve SOV} shall open & then XV52-B6491-02 {Air scouring valve SOV} will get close.
After the completion of Air scouring cycle, XV52-B6491-02 {Air scouring valve SOV} will open & then
XV54-S6491-01A/B/C {Air inlet valve SOV} shall close.
11. System shall monitor the valve operation during the corresponding sequence. Any abnormality (Dedicated alarm
message shall be shown on HMI) in the valve open & close positions feedback during operation transaction or standstill
state shall be considered as valve fault & thus shall generate system alarm & suspend the operation of that particular
system.
12. In the Flow chart, only those valves which are to be opened by system are described, While the valves which are not
mentioned shall remain close.
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 7 of 8

Start Permissive
Sr. Tag Number Description Delay Time Condition
No
1 LT51-M6491-05 Neutralization Pit Level 5 Sec Level not Low
2 LT51-V6491-05 Acid Dosing Vessel Level 5 Sec Level not Low
3 LT51-V6491-06 Soda Dosing Vessel Level 15 Sec Level not Low
4 LS51-M6486.24 Suction Basin 2 Level 15 Sec Level not High
High
5 Not Applicable Regeneration cycle 1 min Cycle is complete

Alarms
Sr. Set
Tag Number Description Alarm DELAY ACTION
No. Value

AT51-P6491-
1 Mixing Pump outlet pH A:Alarm
14
HH 8.5 2 min

B: Start Acid dosing Pump

A:Alarm
7.5 2 min
H
B: Stop Acid dosing Pump

A:Alarm
L 6.5 2 min

B: Stop Soda dosing Pump

A:Alarm
LL 6.5 2 min

B: Start Soda dosing Pump

LT51-M6491- HH 2 min
2 Neutralization Pit Level 3000 A:Alarm
05
14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy
Annexure-E Flow chart Neutralization Page 8 of 8

B: Hold Regeneration of SBA


or SAC

2 min A:Start Neutralization


H 1300
Sequence

2 min
L 400 A:Stop Duty Mixing Pump

2 min
LL 300 A:Trip Duty Mixing Pumps

B: Trip Blower if running for


Neut. Pit
Mixing Pump
FT51-P6491- A: Alarm
3 (P6491.14A/B) Discharge H 25 1 min
14
Flow TX

L 10 1 min A: Alarm

A: Alarm & Stop Mixing


LL 5 1 min
Pump (P6491.14A/B)

XA51- Acid Dosing Pump-A A:Alarm


4 N/A N/A 5 Sec
P6491.21 A Fault Status Stop Pump

XA51- Acid Dosing Pump-B Fault A:Alarm


5 N/A N/A 5 Sec
P6491.21 B Status Stop Pump

XA51- Soda Dosing Pump-A A:Alarm


6 N/A N/A 5 Sec
P6491.22 A Fault Status Stop Pump

XA51- Soda Dosing Pump-B A:Alarm


7 N/A N/A 5 Sec
P6491.22 B Fault Status Stop Pump

XA51- Mixing Pump-A Fault A:Alarm


8 N/A N/A 5 Sec
P6491.14 A Status Stop Pump

XA51- Mixing Pump-B Fault A:Alarm


9 N/A N/A 5 Sec
P6491.14 B Status Stop Pump

XA51- Air scouring Blower-A A:Alarm


10 N/A N/A 5 Sec
B6491.02 A Fault Status Stop Blower

XA51- Air scouring Blower -B A:Alarm


11 N/A N/A 5 Sec
P6491.02 B Fault Status Stop Blower