CLIENT: KPR SUGAR MILLS LIMITED

CLIENT CONSULTANT: AVANT-GARDE SYSTEMS AND CONTROLS (P) LTD

DESCRIPTION: CONTROL PHILOSOPHY
PROJECT: 90 KLPD MOLASSES BASED MULTI PRODUCT DISTILLERY

PROJECT NO 190256 Prepared by Checked by Approved by

DOC NO 190256-CP-001 SP SP KS
Rev 0 Date 31.08.2019
UF SYSTEM CONTROL PHILOSOPHY

1.1 Modes of Operation

Control of the UF system is achieved through an Operator controlled software selection, and SCADA system, which has the following modes of control:

 AUTO
 OFFLINE
The UF system has 4 modes of operation, namely,

1) Service

2) Backwash - 1st CEB

3) Backwash - 2nd CEB

4) CIP Cleaning

Modes 1. 2 and 3 are usually automatic while 4 is manual.

Backwash frequency is adjustable depending on feed condition.

1.1.1 AUTO Mode:

When the system is set to AUTO mode:

 The particular system shall be able to operate in accordance with the preset duty sequences automatically, e.g. service, backwash, shut-down
 When the following conditions are met for its associated equipment:
1. All actuated/control valves and equipments are available
2. The system control interlocks are satisfied

When the system works under “AUTO” mode, it will be looped with operation “Service”—“Backwash”. When backwash is completed, the system will return to
Service mode and a new cyclic is initiated. The set point value of Service duration to activate a Backwash sequence can be altered anytime when the system
is running. The system will reject set point values of Service and Backwash, when the new set point is equal or less then current total operation time.

In AUTO mode, the opening and closing of valves as the UF switches from “Service” to “Backwash” will be auto. TMP and flows through UF will be monitored
and automatically adjusted by VFD through PLC.
All automatic valves are incorporated with limit switches. In the case when PLC does not receive feedback signal from the particular valve’s action for more
than 10 seconds, alarm will be initiated and operation sequence will be halted.

1.1.2 OFFLINE Mode

When the particular system is set to OFFLINE mode:

 The train shall be shutdown as per the “Shutdown Sequence”.

 All controls to the valves and instruments of the selected train are disabled.
 This allows switching off a train from any mode of operation.

When the system is in “OFFLINE” mode, the Operator is able to manually “OPEN” or “CLOSE” any of the automatic actuated valves through the HMI
workstation.

1.2 Operating Sequence Chart: Start-up Sequence

Start-up sequence will be initiated if Operator selects “AUTO” and “SERVICE” mode of operation.

The operator is to select at least 1feed pump and 1 backwash pump in HMI and then ensure the manual valves are in the correct position and all auto valves
are in “Closed” position before starting the system. Also make sure the instruments air available with sufficient pressure.

ABFV-705–Backwash

Sodium Hypo Dosing

ABFV-701 – UF Feed

Backwash top outlet

ABV-701– Reject to

Pump-P 702 A /B

Caustic Dosing
Backwash Inlet

UF - Backwash
ABFV-703– UF

ABFV-702– UF

UF feed pump
bottom Outlet

Acid Dosing
ABFV-704–

P 701 A /B
permeate
drain
Steps Description Duration

Forward Flush –
1 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

2 Backwash Top 40 sec X X X O O X OFF ON OFF OFF OFF

 ABFV-705–Backwash

Sodium Hypo Dosing

ABFV-701 – UF Feed

Backwash top outlet

ABV-701– Reject to

Pump-P 702 A /B

Caustic Dosing
Backwash Inlet

UF - Backwash
ABFV-703– UF

ABFV-702– UF

UF feed pump
bottom Outlet

Acid Dosing
ABFV-704–

P 701 A /B
permeate
drain
Steps Description Duration

Forward Flush –
3 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

4 Train in Service mode 30 min O O O X X X ON OFF OFF OFF OFF

Forward Flush –
5 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

6 Backwash Bottom 40 sec X X X O X O OFF ON OFF OFF OFF

7 Train in Service mode 30 min O O O X X X ON OFF OFF OFF OFF

Note: - O = Open (Valve open condition

X = Close (Valve close condition)
1.3 Operating Sequence Chart: Backwash 1st CEB

ABFV-705–Backwash

Sodium Hypo Dosing

ABFV-701 – UF Feed

Backwash top outlet

ABV-701– Reject to

Pump-P 702 A /B

Caustic Dosing
Backwash Inlet

UF - Backwash
ABFV-703– UF

ABFV-702– UF

UF feed pump
bottom Outlet

Acid Dosing
ABFV-704–

P 701 A /B
permeate
drain
Steps Description Duration

Forward Flush –
1 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

2 Backwash Top 60 sec X X X O O X OFF ON ON ON OFF

3 Soak 5 min X X X X X X OFF OFF OFF OFF OFF

4 Backwash Top 30 sec X X X O O X OFF ON OFF OFF OFF

Forward Flush –
5 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

6 Backwash Top 60 sec X X X O O X OFF ON OFF OFF ON

7 Soak 5 min X X X X X X OFF OFF OFF OFF OFF

Start from Step 1-7 of

8 Regular Logic

NOTE: If feedback is not received from any of the auto valves during the backwash process, the sequence will halt and alarm will be triggered.
Operator is to investigate the causes e.g. signal cabling connection, valve connection, or manual forced open/close previously.
1.4 Operating Sequence Chart: Backwash 2nd CEB

ABFV-705–Backwash

Sodium Hypo Dosing

ABFV-701 – UF Feed

Backwash top outlet

ABV-701– Reject to

Pump-P 702 A /B

Caustic Dosing
Backwash Inlet

UF - Backwash
ABFV-703– UF

ABFV-702– UF

UF feed pump
bottom Outlet

Acid Dosing
ABFV-704–

P 701 A /B
permeate
drain
Steps Description Duration

Forward Flush –
1 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

2 Backwash Bottom 60 sec X X X O X O OFF ON ON ON OFF

3 Soak 5 min X X X X X X OFF OFF OFF OFF OFF

4 Backwash Bottom 30 sec X X X O X O OFF ON OFF OFF OFF

Forward Flush –
5 Bottom 10 sec O X X X O X ON OFF OFF OFF OFF

6 Backwash Bottom 60 sec X X X O X O OFF ON OFF OFF ON

7 Soak 5 min X X X X X X OFF OFF OFF OFF OFF

Start from Step 1-7 of

8 Regular Logic

NOTE: If feedback is not received from any of the auto valves during the backwash process, the sequence will halt and alarm will be triggered.
Operator is to investigate the causes e.g. signal cabling connection, valve connection, or manual forced open/close previously.
Notes

1) All times and flow rates are estimated and adjustable during start-up, depending on required flux.

2) O = Valve Open; X = Valve Closed ; ON = Pump Running; OFF = Pump in OFF condition

3) Backwash frequency is adjustable depending on feed condition.

4) CEB is envisaged once in 12 hours. During CEB Ist and IInd the flow will be be alternated once from
bottom and once from top.

6) The timings for the above steps is effective timing after valve opening.
7) CEB flow shall be set at half the backwash flow rate.

8) During CEB , free chlorine @ 200mg/l in the form of Sodium Hypochlorite shall be injected along with
Sodium Hydroxide. The dosage of Sodium Hydroxide shall be such

9) During CEB, HCl shall be injected to maintain a pH of around 2.

REVERSE OSMOSIS SYSTEM CONTROL PHILOSOPHY

RO START STAGE-1

1. When the Operator press the RO AUTO Start.

2. Open RO Flushing Valve (ABFV-801).
3. After 5 seconds delay start Acid dosing pump (DP 905 A/B) /Antiscalant dosing pump (DP 904 A/B) / SMBS dosing pump (DP906 A/B).
4. After 5 seconds delay start RO Feed Pump (P703 A/B).
5. Check for RO Feed Line ORP normal condition (ORP 801) (i.e. value is under the nominal value).
6. If OK proceed to next step; i.e. if NOT OK open RO ORP dump valve (ABFV-801) and system trip.
7. Check for RO Low pressure switch normal condition (LPS 801 / 802) (i.e. there is Low Pressure).
8. If OK (i.e. Low Pressure exists), after 20 seconds switch ON RO High Pressure Pump (P-801 A/B).
9. Check for RO High Pressure switch (HPS-801 /802) normal condition (i.e. there is no High Pressure).
10. If OK (i.e. High Pr does not exists), proceed to next step else trip RO System.
11. After 60 seconds close RO Flushing valve (ABFV-801)

RO high Pressure Pump Suction Pressure LOW

 If RO Low pressure switch not OK (i.e., Lo pr not Exists).

 Switch off RO feed pump & close RO Flushing valve.
 After taking necessary corrective action go to RO START.

RO Feed ORP HI

 If RO Feed ORP is high than the set value;

 Open RO Dump valve.
 After taking necessary corrective action go to RO START.

Fault Conditions:

 RO High Pressure Pump Discharge pressure HI

 UF Permeate tank level LO
  Acid Dosing pump OFF
 Anti Scalant dosing pump OFF
 SMBS dosing pump OFF
 RO feed ORP value abnormal

For any of the above fault conditions;

1. After 5 seconds switch off RO High Pressure Pump

2. After 5 seconds switch off Acid dosing pump / Anti Scalant dosing pump /Anti Oxidant dosing pump / RO Feed pump.
3. After 5 seconds switch off RO Feed pump.
4. After taking necessary corrective action go to RO START.

RO AUTO VALVE CONTROL PHILOSOPHY

SL.NO TAG DESCRIPTION LOCATION AUTO VALVE LOGIC CONDITION CONTROL

LOGIC
RO System

1 ORP-801 OPR Dumping RO System ABFV-801 Dump Valve has to open if ORP Value PLC Control
exceeds 1000mV
2 RO System ABFV-802 1. When High pressure pump starts after PLC Control
30 seconds the valve has to be closed.
2. During RO shut down, after high
pressure pump stops, the valve has to
be open for 30 seconds for flushing.