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

CO2 Stripper and Anion Resin Filter. In order to demineralized.0 GENERAL 1.2 DEMINERALIZATION UNIT The purpose of this proposed plant is to treat clean water to produce required product water as per design basis.01) (By Client). Cation Resin Filter. The Cation Resin Filter contains Strong Acid Cation resin for reduce cations and total hardness. NO. The cation and anion units are designed for counter-current regeneration.1 SCOPE The purpose of this document is to describe ‘Demineralization Unit’ and its operational philosophy. The Anion Resin Filter contains Strong Base Anion resin for reduce virtually all anions and silica. It will reduce NaOH chemical consumption for regeneration. CO2 Stripper and Anion Resin Filter. Demineralized water from plant is stored in Demin Water Tank (T6491. No. DATE 29-Apr-2016 Control Philosophy REV.: 14122-VD-U1-UTL-LGD-AYCM001-0119 1. 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. 1. Following is process flow path provided to demineralize the Raw water. The Atmospheric CO2 Stripper is used for removing carbon dioxide before it reaches the anion resins in the Anion Resin Filter. Activated Carbon Filter (ACF). water is passed through a series of Sand Filter. No 2 of 27 DOC. 0 PAGE. .

DATE 29-Apr-2016 Control Philosophy REV. 0 PAGE.: 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. Soda Dosing Pump and mixing tee for dilution. NO. No 3 of 27 DOC. . No.  Neutralization System consists of Neutralization Pit & Mixing pump (Neutralization disposal pump) with Air scouring blower.  Alkali Regeneration System is provided which consists of Soda Dossing Vessel.

: 14122-VD-U1-UTL-LGD-AYCM001-0119 1. impulse lines and fittings shall use inch sizes. DATE 29-Apr-2016 Control Philosophy REV.3 REFERENCES  Piping & Instrument Diagram for Demin Package .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 2.14122-VD-6491-PRS-PID-0009 to 0015  Process Calculation and Equipment Sizing .14122-VD-U1-UTL-AYCM001-DOC-0006 1. NO. No. .14122-VD-U1-UTL-PFD-AYCM001-0004  Process Description . No 4 of 27 DOC.14122-VD-U1-UTL-CAL-AYCM001-0005  Process Flow Diagram for Demineralization Package.0 UNITS OF MEASUREMENTS Instrumentation will generally use the International System (SI) units of Measurement. 0 PAGE. . Instrument tubing.

0 DESIGN OVERVIEW 3. I/P converters are wired up to suitably located Junction boxes on or near to the skids by Metito. Valve sequence charts are described in the Process Description. Status & monitoring & handshake. NO. cable glands. Command signals are interfaced between the Metito supplied PLC & DCS. solenoid valves. The PLC and SCADA is completely programmed by Metito as per the requirements of P&ID. . Loose tubing. The plant is located in a safe area. instruments / solenoid valves & limit switches are supplied suitable for safe area. accessories (if required) are also supplied by Metito for out-off skid located Metito supplied valve / instrument. The communication cable from Metito PLC to DCS is provided by others. No 5 of 27 DOC. Also the modulating control valve is pneumatically actuated. pneumatic valves & its accessories like limit switches. cable. fitting. This material will be used by others to tube / cable up the relevant equipment and to the appropriate JB. Field instruments comprising of sensors and SMART HART based transmitters are supplied by Metito. The PLC is housed in a control panel supplied by Metito. trays.: 14122-VD-U1-UTL-LGD-AYCM001-0119 3. The transmitters. DATE 29-Apr-2016 Control Philosophy REV. A Operating/Engineering station with having one 24” is provided for operation initiation. The PLC is interfaced to DCS system on a Modbus communication using TCP/IP protocol. No. 0 PAGE. Process description & Control Philosophy. All automatic on-off valves in Metito packages are pneumatic valves provided with open & close limit switches. position transmitter. process monitoring & engineering.1 GENERAL The entire package provided by Metito is monitored & controlled from Metito supplied PLC based system. Cabling and cable trays with accessories from the JB to control panel is provided as by others & installed at site by others. general purpose weatherproof. Relevant on-skid tubing is also done by Metito. All pneumatic automatic On-off and the modulating valves for the above packages are supplied by Metito.

speed 100 MBPS) The PLC system comprises of standalone processors. A communication between PLC & DCS is established & that is based on Modbus protocol with TCP/IP connectivity. DATE 29-Apr-2016 Control Philosophy REV. Electromagnetic Flow transmitter is four wire instruments and powered on 24 VDC from Control panel. NO.11. While the drives which are rated to 380VAC are powered from field mounted Local MCC supplied by Metito. Metito control panel is powered from UPS supply of 110 VAC / 1pH / 50 Hz by others. No. Control panel shall be made of sheet steel to a shade of RAL 7035 outside. Instruments & control cabling of the package instruments from JB to instruments is provided by Metito. The control panel & VFD are located in air conditioned control room. control cable for LCS and interface cable between MCC and PLC are provided & laid & terminated by others at site.2 POWER SUPPLIES & DISTRIBUTION All motors of the complete package are powered from the MCC provided by others on 660V / 3pH / 50Hz. simplex I/O racks. 3. internal communication & one engineering/operating work station. 0 PAGE. VFD panel for Stripped pump are provided by Metito. Solenoid valves are powered on 24 VDC. The control panel is located in a control room provided by others. simplex I/O. No 6 of 27 DOC.3 PLC PANEL & PLC SYSTEM (PLC IP address as : 192. Control panel shall be of double . A brief description of the different E&I related equipment’s follows. The Siemens PLC is housed in a control panel. Power cable. 3.79. Cable entries for the panel shall be from the bottom.: 14122-VD-U1-UTL-LGD-AYCM001-0119 Drives of this package which are rated to 660VAC are powered from MCC supplied by others. All the transmitters are two wire transmitters powered on 24 VDC through Metito PLC panel.168. standalone power supply.

B6491. The details are covered in the Table1.01A/B: Air Fan – A/B . P6491. P6491. P6491. P6491. DATE 29-Apr-2016 Control Philosophy REV. 0 PAGE.15A/B: DEMIN Water Pump – A/B d.09A/B: Backwash Pump – A/B b. P6491.: 14122-VD-U1-UTL-LGD-AYCM001-0119 front type and with the door in the front and rear. P6491. B6491. P6491.4 MOTOR STARTING CONCEPT All three phase motors of demineralization package are started on DOL except Stripped Water Pump A/B (P6491.14A/B: Mixing Pump – A/B ii. but need to be controlled as per the process requirements.19A/B/C: Utility Pump –A/B/C e. There are also some drives which are not in Metito Scope of supply. Start shall be a positive (high) going pulse & stop shall be a negative (low) going pulse.22A/B: Soda Dosing Pump – A/B f. Metito supplied pumps or blowers Client (Others) supplied pumps a.21A/B: Acid Dosing Pump – A/B iv. NO.12A/B) which are VFD starting. 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). No 7 of 27 DOC. No. Start and stop commands shall be issued from the Metito PLC panel. Metito shall develop the PLC application program and the SCADA screens for these packages.08A/B: Booster Pump – A/B c.12A/B: Stripped Water Pump – A/B i. P6491. Run/Stop and Fault feedback is made available to the PLC panel as digital inputs for following table1. 3.02A/B: Air Scouring Blower – A/B iii.

DATE 29-Apr-2016 Control Philosophy REV.21A: Acid Dosing Metito MCC / DOL / Metito 7 380 Note 3 Pump .B Field PLC Metito MCC / DOL / Metito 11 B6491.14B: Mixing Pump .02A: Air Scouring Client MCC / DOL / Metito 5 660 Note 2 Blower .A Client MCC Room PLC B6491. Client MCC / DOL / Metito 4 660 Note 2 B Client MCC Room PLC B6491.01B: Air Fan .B Field PLC P6491.B / Client MCC Room PLC P6491.12A: Stripped Water Metito VFD Panel / VFD Metito 1 660 Note 1 Pump . NO.22B: Soda Dosing Metito MCC / DOL / Metito 10 380 Note 3 Pump .A Field PLC P6491.A / Client MCC Room PLC P6491.14A: Mixing Pump . type / Location (VAC) by Method P6491. No.B 380 Note 3 Field PLC P6491.A (Note 4) Client MCC Room PLC .12B: Stripped Water Metito VFD Panel / VFD Metito 2 660 Note 1 Pump . No 8 of 27 DOC.21B: Acid Dosing Metito MCC / DOL / Metito 8 380 Note 3 Pump .A 380 Note 3 Field PLC Metito MCC / DOL / Metito 12 B6491. Client MCC / DOL / Metito 3 660 Note 2 A Client MCC Room PLC P6491.B Client MCC Room PLC P6491.A Field PLC P6491.01A: Air Fan .: 14122-VD-U1-UTL-LGD-AYCM001-0119 TABLE 1 Sr. 0 PAGE.02B: Air Scouring Client MCC / DOL / Metito 6 660 Note 2 Blower .09A: Backwash Client MCC / DOL / Metito 13 660 Note 5 Pump . Powered from / Starter Voltage Control Control Drive details No.22A: Soda Dosing Metito MCC / DOL / Metito 9 380 Note 3 Pump .

09B: Backwash Client MCC / DOL / Metito 14 660 Note 5 Pump . Control Signals by Metito PLC Note 3: Hardwired connection between Local (field mounted) MCC provided by Metito & Metito PLC Panel.15A: DEMIN Water Client MCC / DOL / IKPT 17 660 Note 6 Pump . Control Signals by Metito PLC Note 2: Hardwired connection between Client MCC & Metito PLC Panels. Starter for these motors are assumed to be DOL Note 5: Profibus Communication between Client MCC & Client DCS. Control Signals by Metito PLC Note 4: These Pumps/Motors are supplied by Others. Client MCC / DOL / IKPT 16 660 Note 6 B (Note 4) Client MCC Room DCS P6491. Communication through Modbus. NO. No 9 of 27 DOC. .19B: Utility Pump –B Client MCC / DOL / IKPT 20 660 Note 6 (Note 4) Client MCC Room DCS P6491.A (Note 4) Client MCC Room DCS P6491. Communication through Modbus. Status Signals monitored by Metito PLC to generate Permissive in the Metito PLC program sequence. 0 PAGE.08B: Booster Pump .15B: DEMIN Water Client MCC / DOL / IKPT 18 660 Note 6 Pump . DATE 29-Apr-2016 Control Philosophy REV. Local control stations along with required types of cables for all Motors of the package are provided by others. No.08A: Booster Pump .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.19A: Utility Pump –A Client MCC / DOL / IKPT 19 660 Note 6 (Note 4) Client MCC Room DCS P6491. 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.B (Note 4) Client MCC Room PLC P6491.: 14122-VD-U1-UTL-LGD-AYCM001-0119 P6491. Client MCC / DOL / IKPT 15 660 Note 6 A (Note 4) Client MCC Room DCS P6491.B (Note 4) Client MCC Room DCS P6491.

3. NO. 24VDC powered. limit switches & solenoid valves and PLC Panel. Modulating control valve is provided with Positioner with air filter regulator.: 14122-VD-U1-UTL-LGD-AYCM001-0119 3. transmitters.e. 3. SS 316 tube. Instrument junction boxes in this package are classified as described below. Analysers are 4 Wire. . 4-20 mA SMART HART.6 INSTRUMENT TRANSMITTERS All instruments except Mag Flow transmitter are 2 Wire. No 10 of 27 DOC. The tube used for pneumatic signal air supply tubing size – 1/4” OD.8 ON/OFF VALVES / MODULATING CONTROL VALVE All on-off valves are pneumatically operated. Solenoid valves are operated on 24 VDC and are IP 65 degree of protection. 3. 0 PAGE. loop powered type. DATE 29-Apr-2016 Control Philosophy REV. 4-20mA with HART. No. Each on-off valve is provided with one open and one close limit switch & a solenoid valve.7 PNEUMATIC INSTRUMENTS Pneumatically actuated On-Off valves and modulating flow control valve are part of this package.  Instrument junction boxes for digital signals (i.  Instrument junction boxes for 4 – 20 mA Analogue signals to & from PLC Panel.5 INSTRUMENT JUNCTION BOXES Field mounted instrument junction boxes which act as interface terminal point between the various field instruments. for limit switches and solenoid valve to PLC Panel. Common Air filter regulator on each skid is provided by Metito. Limit switches are enclosed in the enclosure.

Instrument air is required for operation of On-Off and modulating control valves.1 AIR SUPPLY For demineralization system. NO.: 14122-VD-U1-UTL-LGD-AYCM001-0119 Most of the valves are located on skids and these have been pre-tubed to air header by Metito. These cables & trays are provided by others & also laid by others. are provided by Metito but needs to be done at site by others. No. 4. 0 PAGE. Valves located out of skid have to be tubed to at site by others (if any).0 INSTRUMENTS UTILITY SUPPLIES. Relevant pneumatic tubing & fittings will be provided as loose supply by Metito. 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. & power are routed through overhead Hot-Dipped galvanized. control. No 11 of 27 DOC.  Open PB and Close PB. CABLING SYSTEMS AND EARTHING 4. DATE 29-Apr-2016 Control Philosophy REV. perforated steel cable trays.  Open & Close indication. While the cables & trays which laid to connect the instruments out of skid or from different skids.2 CABLE ROUTING All Main cables for Instrument. 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. 4.

: 14122-VD-U1-UTL-LGD-AYCM001-0119 4.5 sq.25 sq.mm. circular Stranded copper conductor. PVC insulated respectively. circular Stranded copper conductor. 300/500V grade. Other than skid and inter skid mounted instrument cabling shall be provided by Metito and done at site. PVC insulated.mm. . The cable types used from different purposes is explained in the following sections  Analog signals for transmitters: 1Px1. No. braided screened cable. 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. stranded conductors.3 CABLES: Generally all the instrument & control branch cables shall be Flame retardant. No 12 of 27 DOC. DATE 29-Apr-2016 Control Philosophy REV.  Digital signals for Limit switches: 2P x 1. braided screened cable. PVC insulated.25 sq.mm. braided screened cable. 0 PAGE. PVC insulated  Digital signals for Solenoid valves: 2C X 1. NO. circular Stranded copper conductor.

Air scouring blower (B6491. Client DCS d. 0 PAGE. P6491. These screens shall have dedicated soft buttons. No 13 of 27 DOC.02A/B) is in ready mode Client DCS The operation of these Sand Filter (S6491. No other ACF is under backwash sequence Metito PLC 2 Backwash c.09A/B).08A/B) Pump RUN status is received. The conditions for Permissive are described in table 2. No other Sand Filter is under backwash sequence Metito PLC Sand Filter b. Each Sand Filter (S6491. NO.0 PROCESS CONTROL DESCRIPTION 5.01 A/B/C) Two working + One Standby Sand Filters are provided. Each filter is designed for backwash once in every 24 hours of operation.09A/B) not in "RUN" condition. Backwash is carried out by Backwash Pump (by others. DATE 29-Apr-2016 Control Philosophy REV. Backwash Pump (P6491. Sand Filter Service Timer less than set hours (24 hrs. TABLE 2 Sr. Sand Filter will receive raw water from Booster pump (By others. Sand Filter is not under backwash sequence Metito PLC 1 Sand Filter Service c. No.02)not High Client DCS a.08A/B). . P6491. Activity Permissive Condition Source No. In normal operation. a. Client DCS d.) Metito PLC b.01A/B/C) is carried out through the HMI (SCADA) with the help of dedicated operation & control screen. Booster (P6491. Utility Water Tank Level (LT2-T6491.1 SAND FILTER (S6491.01A/B/C) can be operated individually as a separate entity.: 14122-VD-U1-UTL-LGD-AYCM001-0119 5.

: 14122-VD-U1-UTL-LGD-AYCM001-0119 All the Sand Filter (S6491. This mode can be used to prevent any operation to be carried out in case of any breakdown. DATE 29-Apr-2016 Control Philosophy REV. the two which . Sand Filter (S6491. Auto Mode: When this mode is selected. 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.  Step Advance: Used to skip particular step which may not be necessarily required.  Auto Mode. using the soft selection on SCADA screen. The following operation sequences are performed automatically. NO. a.01 A/B/C). Backwash. b.  Semi-Auto Mode. Out of three Sand Filter (S6491. Service Operation of Filters: With selection of above operation.01 A/B/C) will perform the specific selected operation automatically. the Sand Filter (S6491.  Manual Mode. No 14 of 27 DOC.  Off Mode. No.01 A/B/C) are designed to operate through PLC with different modes of operation as mentioned below. The Sand Filter shall remain in the ‘Off Mode’ when ‘Off Mode’ is selected deliberately.01 A/B/C) shall start it operation. 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. 0 PAGE. Service.

No 15 of 27 DOC. . the standby Sand Filter shall be taken to the service. Sand Filter Service shall be under HOLD. then backwash sequence shall be performed based on the Service time counted by PLC. In case when service timer value reaches to its set point or differential pressure reaches its set point (which ever earlier). In case when the level in the tank reaches “H1” level. 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). The backwash cycle shall be lasting for the set cycle time. System also monitors the Utility Water Tank level (LT2-T6491. DATE 29-Apr-2016 Control Philosophy REV. Sand filter which was backwashed will remain stand by for the next operation cycle.: 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. 0 PAGE. No. The PLC is programed to check the Permissive conditions & once they are satisfied. NO. Once the cycle timer value is reached. system as per the “Process Description: valve sequence chart (ANNEXURE-I)”. The Service timer of that filter shall get Reset by the program. service operation of Sand Filters shall be suspended. 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.02) (By others) measured by DCS through Modbus communication. At times if there is requirement of backwash for two filters appearing simultaneously. When this level drops below the “H2” level HOLD on Service shall be removed. The backwash sequence shall start automatically to the suspended Sand filter.

DATE 29-Apr-2016

Control Philosophy REV. NO. 0

PAGE. No 16 of 27

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

 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”

DATE 29-Apr-2016

Control Philosophy REV. NO. 0

PAGE. No 17 of 27

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

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.

DATE 29-Apr-2016

Control Philosophy REV. NO. 0

PAGE. No 18 of 27

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

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).

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. following operation can be performed . ACF Service shall be stop. No. In case when service timer value reaches to its set point or differential pressure reaches its set point (which ever earlier). NO. The backwash cycle shall be lasting for the set cycle time. any of the Activated Carbon Filter (S6491. In case when the level in the tank reaches “L1” level. When this level rises above the “H1” level HOLD on Service shall be removed. service operation of ACF shall be suspended. Differential pressure can be determined from the provided pressure differential transmitter (PDT51-S6491.06). No 19 of 27 DOC. 0 PAGE. DATE 29-Apr-2016 Control Philosophy REV.: 14122-VD-U1-UTL-LGD-AYCM001-0119 System also monitors the Utility Water Tank level (By others) measured by DCS through Modbus communication. the standby ACF shall be taken to the service. For further details refer the flow chart “Annexure-C Flow chart ACF” Semi-Auto Mode: When this mode is selected. In this mode. The backwash sequence shall start automatically to the suspended ACF. using the soft selection on SCADA screen. Once the cycle timer value is reached.  Completion of 24 hours service cycle. backwash of filters shall be start sequentially.06 A/B) shall be ready to operate in Semi-Auto mode. ACF which was backwashed will remain stand by for the next operation cycle.  Whenever Differential pressure is higher than 1 bar (g). The Service timer of that filter shall get ‘Reset’ by the program.

DATE 29-Apr-2016 Control Philosophy REV. Backwash Start/Stop. NO. For further details refer the flow chart “Annexure-C Flow chart ACF” . Drives listed in Table 1 can be started and stopped from PLC. using the soft selection on SCADA screen. Based on the option selected i. Service Start/Stop. These buttons shall be enabled in Semi-Auto mode only.e. PLC checks the Permissive conditions & once they are satisfied. the operator is required to press ‘Service start’ or ‘Backwash Start’ soft buttons respectively on the SCADA screen. To perform ‘Service’ or ‘Backwash’ to particular filter.: 14122-VD-U1-UTL-LGD-AYCM001-0119 a. system as per the “Process Description: valve sequence chart (ANNEXURE-II)”. b. This mode is useful in start-up and for testing & for maintenance purpose. In manual mode each valve can be opened and closed from PLC. 0 PAGE. No. No 20 of 27 DOC. Service start is pressed or Backwash start is pressed. For further details refer the flow chart “Annexure-C Flow chart ACF” Manual mode: This mode is selected.

however they are designed to work as a Trend i.e.02A/B) & Anion Resin Filter (S6491. Both the Cation Resin Filter (S6491.). No 21 of 27 DOC.03A/B) are designed to operate through PLC with different modes of operation as mentioned below.02A/B) is in ready mode Client DCS The operation of these Cation Resin Filter (S6491. The conditions for Permissives are described in table 4.03A/B) is carried out through the HMI (SCADA) with the help of dedicated operation & control screen.05) not High Metito PLC SAC & SBA b. b.02A) is selected for the operation then Anion Filter-A (S6491.15A/B) not in "RUN" condition.03A/B) shall remove cations (Ca.03B) The set of Cation Resin Filter (S6491.19A/B/C)RUN status is received. Thus is Cation Resin Filter-A (S6491. Cl.02B) and Anion Resin Filter-B (S6491. Service Timer less than set hours (12 hrs. Mg. This operation is not as individual entity but as a Trend. SO4. No. Client DCS d.02A/B) & ANION RESIN FILTER (S6491. Demin Pump (P6491. a. These screens shall have dedicated soft buttons. K & NH4) & alkalinity. NO. (One Cation Resin Filter A or B shall be operated with corresponding Anion Resin Filter A or B. Acid/Soda Dosing vessel Level (LT51-V6491.01) not High Client DCS a.03A) shall get selected for the operation. 0 PAGE. DATE 29-Apr-2016 Control Philosophy REV. Totalized Flow not achieved. Filter is not under Regeneration sequence Metito PLC SAC & SBA 1 Service c.02A/B) & Anion Resin Filter (S6491.03A/B) These filters are also provided as One working+ One Standby.3 CATION RESIN FILTER (S6491. TABLE 4 Sr. Air scouring blower (B6491. NO3 & CO2) from the fed water. Client DCS d. SBA o/l Metito PLC Conductivity is not High. Similarly for Cation Filter-B (S6491. Activity Permissive Condition Source No. Na.: 14122-VD-U1-UTL-LGD-AYCM001-0119 5. Neutralization Pit Level (LT51-M6491. Utility Pump (P6491.05/06) not Metito PLC 2 Regeneration Low c.02A/B) and Anion Resin Filter (S6491. Demin Tank Level (LT1-T6491. .

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. DATE 29-Apr-2016 Control Philosophy REV. the one which are selected for the operation shall become working filters set & other selected later will become the stand by. 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.: 14122-VD-U1-UTL-LGD-AYCM001-0119  Auto Mode. b. Cation Resin Filter (S6491. The following operations sequence are performed automatically. 0 PAGE. Service Operation of Filters: With selection of above operation. Out of the set two filters (set A or set B).02A/B) & Anion Resin Filter (S6491. a. This mode can be used to prevent any operation to be carried out in case of any breakdown. Service.  Step Advance: Used to skip particular step which may not be necessarily required. system as per the “Process Description: valve sequence chart (ANNEXURE-III & IV)”. No 22 of 27 DOC. Auto Mode: When this mode is selected.03A/B) will perform the specific selected operation automatically. .  Semi-Auto Mode. using the soft selection on SCADA screen. No.  Manual Mode. Regeneration. the Cation Resin Filter (S6491. NO.03A/B) shall start sequential operation.02A/B) & Anion Resin Filter (S6491. The Filters shall remain in the ‘Off Mode’ when ‘Off Mode’ is selected deliberately. The PLC is programed to check the Permissive conditions & once they are satisfied.  Off Mode.

NO.  Completion of 12 hours service cycle. For further details refer the flow chart “Annexure-D Flow chart SBA & SAC” .03A/B) is higher than 856 m3. No 23 of 27 DOC. The Reaeration cycle shall be lasting for the set cycle time. When this level rises above the “L1” level HOLD on Service shall be removed. 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. the set of Filters will remain stand by for the next operation cycle. 0 PAGE.03A/B) is higher than 10 micro S/Cm2.03 A / B) with the help of Flow Transmitter (FT51-S6491-03). Once the cycle timer value is reached. No. The Service timer of that filter set shall get ‘Reset’ by the program. System also monitors the Demin Tank level (LT1-T6491. the standby Set of Filters shall be taken to the service. In case when the level in the tank reaches “H1” level. The Regeneration sequence shall start automatically to the suspended set of Filters.01) (By others) measured by DCS through Modbus communication.  Whenever the Outlet conductivity of particular Anion Resin Filter (S6491.: 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. In case when the any of the Filter set gets exhausted. the Service operation of that Filter set shall be suspended. DATE 29-Apr-2016 Control Philosophy REV.  Totalized flow at the common outlet of Anion Resin Filter (S6491. Service shall be under HOLD.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.

PLC checks the Permissive conditions & once they are satisfied. This mode is useful in for testing & for maintenance purpose. No 24 of 27 DOC. No. These buttons shall be enabled in Semi-Auto mode only. Regeneration Start/Stop.: 14122-VD-U1-UTL-LGD-AYCM001-0119 Semi-Auto Mode: When this mode is selected. any of the Set of Resin Filters (Cation & Anion) be ready to operate in Semi-Auto mode. system as per the “Process Description: valve sequence chart (ANNEXURE-III & IV)”. Service start is pressed or Regeneration start is pressed. b. To perform ‘Service’ or ‘Regeneration’ to particular filter set. For further details refer the flow chart “Annexure-D Flow chart SBA & SAC” Manual mode: This mode is selected. In manual mode each valve can be opened and closed from PLC. the operator is required to press ‘Service start’ or ‘Regeneration Start’ soft buttons respectively on the SCADA screen. Drives listed in Table 1 can be started and stopped from PLC. following operation can be performed a. For further details refer the flow chart “Annexure-D Flow chart SBA & SAC” . DATE 29-Apr-2016 Control Philosophy REV. In this mode. 0 PAGE. Based on the option selected i. Service Start/Stop. NO. using the soft selection on SCADA screen.e. using the soft selection on SCADA screen.

The Neutralization system is designed to operate through PLC with different modes of operation as mentioned below. DATE 29-Apr-2016 Control Philosophy REV. a. Acid Dosing Vessel Level not Low Metito PLC Neutralization 1 Recirculation c. The different modes are selected by selecting respective soft selector switch provided on the SCADA screen.05) is carried out through the HMI (SCADA) with the help of dedicated operation & control screen. No.14) Value is between (6 – 9) Metito PLC Neutralization b. TABLE 5 Sr.: 14122-VD-U1-UTL-LGD-AYCM001-0119 5.4 NEUTRALIZATION SYSTEM (M6491.02A/B) is in ready mode Client DCS 2 Disposal c. These screens shall have dedicated soft buttons.  Off Mode. Suction Basin 2 Level (LS51-M6486.24) not High High" Client DCS The Neutralization operation (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. Air scouring blower is in ready required as per valve sequence chart a.  Auto Mode. Soda Dosing Vessel Level not Low Client DCS d. pH (AT51-P6491. . This Neutralization Pit being a separate entity. No 25 of 27 DOC. is operate independently. The conditions for Permissive are described in table 5. This mode can be used to prevent any operation to be carried out in case of any breakdown. The Neutralization system shall remain in the ‘Off Mode’ when ‘Off Mode’ is selected deliberately. Neutralization Pit Level not Low Metito PLC b.  Semi-Auto Mode. 0 PAGE.  Manual Mode. NO. Air scouring blower (B6491.05) Neutralization Pit (M6491. Activity Permissive Condition Source No.

0 PAGE. Neutralization system will perform the specific selected operation automatically. DATE 29-Apr-2016 Control Philosophy REV. Disposal. using the soft selection on SCADA screen. Recirculation. No 26 of 27 DOC. the Disposal sequence shall start automatically. The PLC is programed to check the Permissive conditions & once they are satisfied. b. NO. Recirculation Operation: With selection of above operation. 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. The following operations sequences are performed automatically. Neutralization shall start operation. No.: 14122-VD-U1-UTL-LGD-AYCM001-0119 Auto Mode: When this mode is selected. 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.  Maintain pH (AT51-P6491-14 ) within set parameters .  Completion of Recirculation cycle timer. a. In case when the set parameters are achieved.

Neutralization system shall be ready to operate in Semi-Auto mode. b.: 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. 0 PAGE. No 27 of 27 DOC. the operator is required to press ‘corresponding soft buttons on the SCADA screen. For further details refer the flow chart “Annexure-E Flow chart Neutralization” Manual mode: This mode is selected. Disposal Start/Stop. system as per the “Process Description: valve sequence chart (ANNEXURE-V)”. To perform particular operation. Recirculation Start/Stop. This mode is useful in start-up and for testing & for maintenance purpose. Drives listed in Table 1 can be started and stopped from PLC. following operation can be performed a. using the soft selection on SCADA screen. Recirculation start is pressed or Disposal start is pressed. DATE 29-Apr-2016 Control Philosophy REV. In manual mode each valve can be opened and closed from PLC. In this mode. using the soft selection on SCADA screen. NO. PLC checks the Permissive conditions & once they are satisfied.e. No. For further details refer the flow chart “Annexure-E Flow chart Neutralization” --------------------------------------END OF DOCUMENT----------------------------------- . These buttons shall be enabled in Semi-Auto mode only. Based on the option selected i.

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 .

01 A/B/C) [Annexure-B] Service Sand Filter (S6491. 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.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) Select train A. 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 .

Rinse Step Timer 5 min Note 9. Message on HMI Utility Tank “Utility Tank Level (T6491.  XV55-S6491-01A/B/C {Air vent valve SOV}. OR PDT = SP Semi Auto mode Auto System stops Mode Message on HMI Sand Filter Start Backwash “Filter Exhausted Mode =? cycle need Backwash” .02) Level High” Note 5 Note 9.  Open XV51-S6491-01A/B/C {Service inlet valve SOV}. 11 Step Timer 24 hrs If WDT= not Dn. OR PDT < SP Check Timer OR PDT51-S6491-01 If WDT=Dn. 10. shall remain open (Note 8) Service Level = H NO Operation. & service  Open XV56-S6491-01A/B/C {Rinse outlet valve SOV}.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}.  Open XV52-S6491-01A/B/C {Service outlet valve SOV}. Level < H 10. 11 Check Step Timer If Timer= Dn. After a Delay of 5 Sec. If Timer= not Dn.

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

Utility Water Tank Message on HMI (T6491. 1 S2 Check 1 Timer If WDT= Dn. 1 Check Timer If WDT= Dn. X12 .02) Level “Utility Tank Level Low” Level > SP Drain  Open XV55-S6491-01A/B/C {Air vent valve SOV}.  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. 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}.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.02A/B) Note 9 S1 & 11 Step Timer 5 min If WDT= not Dn. After delay of 5 sec  Start Duty Air scouring Blower (B6491. Backwashing Pump Wait till system is engage =? available Available Level <= L NO Operation.

X13 . Settle  All the valves remain close. 1 Check Timer If WDT= Dn. & 11 1 Check Timer If WDT= Dn.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. System is Standstill S1 Step Timer 5 min 1 S2 Note 9 If WDT= not Dn.

&  Open XV56-S6491-01A/B/C {Rinse outlet valve SOV}. & 11 1 Check Timer If WDT= Dn. If Mode = Auto A Sand Filter Mode =? If Mode = Semi Auto Stop Backwash System shall remain Idle . Rinse S1 Step Timer 5 min 1 Note 9 S2 If WDT= not Dn.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}.

Air Scouring Blower-A A:Alarm 2 N/A N/A 5 Sec B6491.02 Utility Water Tank Level (From DCS) 5 Sec Level not High or Low 2 YB1-P6491. Tag Number Description Delay Time Condition No 1 LI2-T6491.02 A Fault Status Stop Blower XA51.08A/B) Status 2 Sec Running (Not Stopped or No Fault) 3 YB1-P6491.01A/B/C H 1 bar B: Start backwash cycle SAND FILTER 1 MIN S6491. Number Value PDT51. Diff Pressure TX Across 1 30 Sec A: Alarm S6491-01 Sand Filter S6491. Air Scouring Blower-B A:Alarm 3 N/A N/A 5 Sec B6491.01A/B/C XA51.09A/B) Status 2 Sec Stopped (Not Running or No Fault) Alarms Sr.02 B Fault Status Stop Blower .08A/B Booster Pump (P6491.09A/B Backwashing Pump (P6491.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-B Flow chart Sand Filter Page 7 of 7 Start Permissive Sr. Tag Set Description Alarm DELAY ACTION No.

” Permissive = 0 (not OK) Permissive = 1 (OK) X11 .06 A/B) [Annexure-C] Service ACF (S6491. 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.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.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-C Flow chart ACF Page 1 of 6 System (II) Activated Carbon Filter (S6491.

&7 Check Step Timer If Timer= Dn.02) Level High” Note 5 Level < SP &7 Note 1 Step Timer 24 hrs If WDT= not Dn. & service  Open XV56-S6491-06A/B {Rinse outlet valve SOV}. Message on HMI Utility Tank “Utility Tank Level (T6491. Rinse Step Timer 5 min Note 5 If Timer= not Dn. Level > SP NO Operation.  Open XV51-S6491-06A/B {Service inlet valve SOV}. After a Delay of 5 Sec.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}. OR PDT < SP Check Timer OR PDT51-S6491-06 If WDT=Dn.  XV54-S6491-06A/B {Air vent valve SOV}. shall remain open (Note 4) Service  Close XV56-S6491-06A/B {Rinse outlet valve SOV}. OR PDT = SP Semi Auto mode Auto System stops Mode Message on HMI ACF Start Backwash “Filter Exhausted Mode =? cycle need Backwash” .  Open XV52-S6491-06A/B {Service outlet valve SOV}.

Valve shall get closed after the delay time of 60 Sec. 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. 5. then system shall halt the sequence which is under operation. 10. System shall monitor the Alarm signals (Dedicated alarm message shall be shown on HMI). DN=Done (Complete). 8. System shall temporarily Halt Auto operation when High levels signal of Utility Tank received by PLC from SRI DCS during Service mode. 6. In case if any alarm is encountered. WDT=Watch Dog/Step Timer. O=Off. In the Flow chart. to make system operation smooth & bump free. 9. only those valves which are to be opened by system are described. Proper Delay Timers shall be introduce where ever possible. System shall have facility for Step Hold & Step Adv. 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. This is to save the operation time by skipping particular step if not necessary from operation point of view. Abbreviations: A=Auto. step timer of particular step will remain ‘Hold’ till alarm gets cleared/reset. 4. While the valves which are not mentioned shall remain close. . Continue the operation mode to which it is running after reset of the signal). 7. 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. Actual timer setting to be done on site based on the Filter performance. system shall skip the particular step & jump to the next sequence. System shall monitor the valve operation during the corresponding sequence. Step Adv when activated. System shall stop Backwash cycle when Low level signal of Utility Tank received by PLC from SRI DCS. M=Manual. 3. SP=Set point. These are active during backwash operation in Semi-Auto modes. System shall stop its operation in case if there is Command received from DCS to stop the Activated Carbon Filter operation. 2. S=Semi-Auto.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.

X12 . 1 Check Timer If WDT= Dn. Utility Tank Message on HMI (T6491.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-C Flow chart ACF Page 4 of 6 Start Backwash Engage S4 1 No Operation. System is Standstill S1 Step Timer 5 min 1 S2 If WDT= not Dn.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. Backwash Pump Wait till system is engage =? available Available Level <= L NO Operation. Note 5 1 &7 Check Timer If WDT= Dn. Settle  All the valves remain close.

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}. S1 Step Timer 5 min 1 S2 Note 5 If WDT= not Dn. & Rinse  Open XV56-S6491-06A/B {Rinse outlet valve SOV}. 1 &7 Check Timer If WDT= Dn. If Mode = Auto A ACF Mode =? If Mode = Semi Auto Stop Backwash System shall remain Idle .

5 bar 30 Sec S6491.06B B: Shut down service cycle ACF HH 1. Diff Pressure TX Across 2 H 1 bar 30 Sec A: Alarm S6491-06A Strainer of ACF S6491. Number Value PDT51.06A/B PDT51. Tag Set Description Alarm DELAY ACTION No.19A/B/C) 2 Sec Running Status (Not Stopped or No Fault) 3 YB1-P6491.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-C Flow chart ACF Page 6 of 6 Start Permissive Sr.06A/B B: Start backwash cycle ACF 1 MIN S6491.06A B: Shut down service cycle ACF HH 1. Diff Pressure TX Across 3 H 1 bar 30 Sec A: Alarm S6491-06B Strainer of ACF S6491.19A/B/C Utility Water Pump (P6491. Diff Pressure TX Across 1 H 1 bar 30 Sec A: Alarm S6491-06 ACF S6491.09A/B) Status 2 Sec Stopped (Not Running or No Fault) Alarms Sr.5 bar 30 Sec S6491.06A PDT51.06B .02 Utility Water Tank Level (From DCS) 5 Sec Level not High or Low 2 YB1-P6491.09A/B Backwashing Pump (P6491. Tag Number Description Delay Time Condition No 1 LI2-T6491.

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.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 1 of 19 System (III) Cation + Anion Resin Filter (S6491. 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 (T6491.02 A/B & .

Note 5  Open XV57-S6491-02A/B {SAC Rinse outlet valve SOV}. Rinse for After delay of 5 sec SAC & SBA  Open XV52-P6491-12A/B {Stripper pump inlet valve SOV}. service  Open XV56-S6491-03A/B {SBA Rinse outlet valve SOV}. Note 5 &7 Check Step Timer If Timer= Dn. After delay of 5 sec  Duty Stripper pump P6491-12A/B. Check Step Timer If Timer= Dn.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}. Check Pre- service Step Timer 5 min Rinse for SAC & SBA Check Conductivity (AT51-S6491-03A/B)=? If Timer= not Dn. X18 X19 X12 Y01 . starts running. &7 Step Timer 10 min If Timer= not Dn.  Open XV58-S6491-02A/B {SAC Rinse inlet valve SOV}.

 Open XV52-S6491-02A/B {Service outlet valve SOV}. shall remain open (Note 4) After a Delay of 5 Sec.01A/B) Starts running Level < SP LV51-S6491-02 +/. SAC Service Level > SP Step Timer 12 hrs Timer = not Dn. + LT51- (% valve opening) T6491-07 Modulation . 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 .  Duty Air-Fan (B6491.  XV56-S6491-02A/B {Air vent valve SOV}. & Note 5 Totalizes Flow < SP & &7 Conductivity < SP Step Timer OR FT51-S6491-03 OR AT51-S6491-03A/B Timer =Dn.07) Level Level < SP  Open XV51-S6491-02A/B {Service inlet valve SOV}. Level > SP Message on HMI “Stripper Tank Stripper Tank Level High” (T6491.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-C Flow chart SAC+SBA Page 3 of 19 X12 NO Operation.

After delay of 5 sec  Duty Stripper pump P6491-12A/B. Flow < SP LC51-T6491-01 +/. 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 .  Open XV52-S6491-03A/B {Service outlet valve SOV}. starts running. & Totalizes Flow < SP & Note 5 Conductivity < SP &7 Step Timer OR FT51-S6491-03 OR AT51-S6491-03A/B Timer =Dn.  XV55-S6491-02A/B {Air vent valve SOV}. shall remain open (Note 4) After a Delay of 5 Sec.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. + FT51- (% VFD opening) S6491-03 Modulation .01) Level Level High” Level < SP  Open XV51-S6491-03A/B {Service inlet valve SOV}.  Open XV52-P6491-12A/B {Stripper pump inlet valve SOV}. SBA Service Flow > SP Step Timer 12 hrs Timer = not Dn.

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. 9. Actual timer setting to be done on site based on the Filter performance. only those valves which are to be opened by system are described. These are active during regeneration operation in Semi-Auto modes. SP=Set point. In case if any alarm is encountered. System shall have facility for Step Hold & Step Adv. then system shall halt the sequence which is under operation. Abbreviations: A=Auto. System shall temporarily Hold Regeneration cycle when level in Neutralization Pit is High & resume when level drops to or below low Level. that particular step shall continue as long as Step Hold is active. This is to save the operation time by skipping particular step if not necessary from operation point of view. In the Flow chart. to make system operation smooth & bump free. 11. System shall stop Regeneration cycle when Low level signal of Utility Tank received by PLC from SRI DCS. 4. System shall monitor the valve operation during the corresponding sequence. WDT=Watch Dog/Step Timer. Proper Delay Timers shall be introduce where ever possible. 5.14122-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. Step Hold when activated shall hold all the Step timer from further counting step timing. . System shall stop its operation in case if there is Command received from DCS to stop the Sand Filter operation. System shall temporarily Halt Auto operation when Low levels signal of Utility Tank received by PLC from SRI DCS. system shall skip the particular step & jump to the next 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. System shall monitor the Alarm signals (Dedicated alarm message shall be shown on HMI). Continue the operation mode to which it is running after reset of the signal). 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. 6. O=Off. Step Adv when activated. 10. 7. Valve shall get closed after the delay time of 60 Sec. step timer of particular step will remain ‘Hold’ till alarm gets cleared/reset. M=Manual. 2. while the valves which are not mentioned shall remain close. S=Semi-Auto. DN=Done (Complete). 3. 8.

Timer = Dn. X13 .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. 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. 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} .

+ 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. 1 Check Timer If WDT= Dn. X14 .  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% +/. 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} .5 %) S1 Step Timer 678 sec 1 S2 Timer = not Dn.

 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. X15 . 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} . 1 Check Timer If WDT= Dn.

+ 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. 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} . 1 Check Timer If WDT= Dn. X16 .  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% +/.

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}. Resin Bed Settling  All the valves remain close. Timer = not Dn. + FT51. X17 . 1 Check Note 5 Timer &7 Timer = Dn. System is Standstill S1 Step Timer 10 min Timer 1 = not S2 Dn.  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 +/. (% valve opening) P6491-15 Modulation - Note 5 &7 Flow > SP S1 Step Timer 978 sec 1 S2 1 Check Timer Timer = Dn.

Y02 . Timer = Dn. 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. + FT51- (% valve opening) P6491-15 Modulation - SBA Flow > SP Compaction S1 Step Timer 3 min 1 S2 1 Check Timer Timer= not Dn.  Open XV53-S6491-03A/B { Compaction inlet valve SOV} After delay 2 Sec Flow < SP Note 5 FV51-P6491-15 &7 +/. Other Exchanger in Wait till system is Regeneration =? available No  Open XV54-S6491-03A/B {Compaction outlet valve SOV}.

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} . + 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. Outlet to Neut.  Open XV57-S6491-03A/B {Regn. Y03 . 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% +/. 1 Check Timer If WDT= Dn.

System is Standstill S1 Step Timer 10 min Timer = 1 not Dn. 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. 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. Resin Bed Settling  All the valves remain close. S2 1 Check Note 5 Timer &7 Timer = Dn. Y04 .

Note 5  Open XV58-S6491-02A/B {SAC Rinse inlet valve SOV}. S2 1 Check Step Timer If Timer= Dn.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}. S1 Timer= not Step Timer 30 min 1 Dn. 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}. Cond > SP Delay Check Conductivity 1 min (AT51-S6491-03A/B)=? Cond <= SP X18 Delay 1 min X19 . &7  Open XV57-S6491-02A/B {SAC Rinse outlet valve SOV}. After delay of 5 sec  Duty Stripper pump P6491-12A/B. starts running.

continuous running. Cond > SP Delay Check Conductivity 1 min (AT51-S6491-03A/B)=? Alarm Cond <= SP ‘Regeneration Fault’ System shall remain Idle Delay 1 min X20 . 1 S2 Check Step Timer 1 If Timer= Dn. &7 S1 Timer= not Step Timer 5 min Dn.  XV58-S6491-02A/B {SAC Rinse inlet valve SOV} remains open.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. Note 5  XV57-S6491-02A/B {SAC Rinse outlet valve SOV} remains open.

starts running. 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}. Step Timer 10 min Level > L & Note 5 Timer = not DN &7 Check Step Timer OR (LT51-T6491.14122-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.04) Level < L OR Timer = DN  Stop Duty Stripper pump P6491-12A/B. 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} .

Diff Pressure TX Across 2 H 1 bar 30 Sec A: Alarm S6491-02B Strainer of SAC S6491.15A/B) Status 2 Sec Running (Not Stopped or No Fault) Alarms 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-P6491.03A B: Shut down service cycle SBA HH 1.5 bar 30 Sec S6491.19A/B/C) Status 2 Sec Running (Not Stopped or No Fault) 3 YB1-P6491. Diff Pressure TX Across 3 H 1 bar 30 Sec A: Alarm S6491-03A Strainer of SBA S6491. Open caustic inlet valve LT51.02B B: Shut down service cycle SAC HH 1.14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-C Flow chart SAC+SBA Page 18 of 19 Start Permissive Sr. mm water Pump 1400 H 30 Sec A: Alarm. Diff Pressure TX Across 1 H 1 bar 30 Sec A: Alarm S6491-02A Strainer of SAC S6491. Diff Pressure TX Across 4 H 1 bar 30 Sec A: Alarm S6491-03B Strainer of SBA S6491. Buffer Tank (T6491.19A/B Utility Water Pump (P6491.05) Level TX.03B PDT51. Soda Dosing Vessel 125 8 L 30 Sec (XV51-V6491-06) & Stop caustic dosing V6491-06 (V6491.12 A/B 2200 A: Alarm & Start Stripper water Pump H 30 Sec mm P6491. Start Air Fan & Stop Stripper 5 L 30 Sec T6491-07 Level Transmitter.03B LT51. Acid Dosing Vessel 140 A: Alarm.12 A/B LT51. Close acid inlet valve (XV51- H 30 Sec mm V6491-05) A: Alarm. mm P6491.5 bar 30 Sec S6491.07) 400 A: Alarm. mm pump .04) 380 A: Alarm & Stop Stripper water Pump 6 L 30 Sec T6491-04 Level Transmitter.06) Level TX.03A PDT51. Tag Set Description Alarm DELAY ACTION No. Open Acid inlet valve (XV51- 7 L 30 Sec V6491-05 (V6491.5 bar 30 Sec S6491. Number Value PDT51.02A B: Shut down service cycle SAC HH 1.5 bar 30 Sec S6491. Stripper Tank (T6491.03B B: Shut down service cycle SBA HH 1. mm V6491-05) & Stop Acid Dosing Pump 1050 A: Alarm. Stop Air Fan.03A PDT51.15A/B Demin Water Pump (P6491. mm LT51.

03) outlet Flow TX H 860 30 Sec S6491-03 Sequence totalized Flow FT51.22 B Status Stop Pump .21 B Status Stop Pump XA51.2 30 Sec A: Alarm Anion Resin Filter AT51- 11 (S6491.03A/B) common L 6.14122-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. Soda Dosing Pump-A Fault A:Alarm 21 N/A N/A 5 Sec P6491.12 B Status Stop Pump XA51. Stripper Pump -A Fault A:Alarm 15 N/A N/A 5 Sec P6491.2 30 Sec A: Alarm S6491-03 outlet pH Analyzer H 8. A:Alarm 18 Air Fan-B Fault Status N/A N/A 5 Sec B6491.02A/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. A: Alarm & Start Regeneration 13 (S6491.01A Stop Fan XA51.12 A Status Stop Pump XA51.03A) 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. A:Alarm 17 Air Fan-A Fault Status N/A N/A 5 Sec B6491.7 30 Sec A: Alarm XA51. Demin Water for 14 L 15. Acid Dosing Pump-B Fault A:Alarm 20 N/A N/A 5 Sec P6491. Acid Dosing Pump-A Fault A:Alarm 19 N/A N/A 5 Sec P6491. H 88.03B) outlet H 8 30 Sec A: Alarm S6491-03B Conductivity Analyzer HH 10 30 Sec A: Start Regeneration Sequence Anion Resin Filter FT51.21 A Status Stop Pump XA51.22 A Status Stop Pump XA51. Soda Dosing Pump-B Fault A:Alarm 22 N/A N/A 5 Sec P6491.01B Stop Fan XA51.4 30 Sec A: Alarm P6491-15 Regeneration Flow TX. Stripper Pump -B Fault A:Alarm 16 N/A N/A 5 Sec P6491.

X31 . pneumatic valves in this system are to be operated in manual A & S = 0 (Man) mode using individual soft Semi =1 Pushbuttons/ Switches.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. Check LT51-M6491-05=? Level >= H. 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 pH (AT51-P6491-14)=? Step Time 30min Time = 25min If WDT= not Dn. J2 pH >= 8.  Close XV51-B6491-02 {Blower Drain valve SOV} after delay of 10 sec  Duty.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}.Air scouring blower B6491.02A/B starts running.Mixing pump P6491. pH Checking  XV52-P6491-14 {Recirculation Line valve SOV} remains open. J1 Check Timer=? Timer= Dn.5 pH >= 6.  Open XV52-B6491-02 {Air scouring valve SOV} after a delay of 20 Sec.5 Check C1 A1 pH (AT51-P6491-14)=? pH <= 7.02A/B continues running.Air scouring blower B6491.5.Mixing pump P6491.14A/B starts running  After a delay of 5 Sec.5 =< pH <= 7. pH <= 5.14A/B continues running  Duty.5 A2 C2 6.5 X32 1 .  XV51-B6491-02 {Blower Drain valve SOV} remain close  Duty.  XV52-B6491-02 {Air scouring valve SOV} remains open.  Duty.

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} . After Delay of 5 sec After Delay of 2 sec  Duty. valve SOV} P6491.Caustic dosing pump P6491.22A/B  Close XV52-M6491-05 {Caustic dosing to starts running Neut.21A/B  Close XV51-M6491-05 {Acid dosing to starts running Neut.Acid dosing pump P6491. After Delay of 5 sec After Delay of 2 sec  Duty. valve SOV} P6491. valve SOV} J1 Caustic Dosing C1 C2  Open XV52-M6491-05 {Caustic dosing to  Stop Duty-Caustic dosing pump Neut.22A/B.21A/B.

9 < pH < 6 Check J2 pH (AT51-P6491-14)=? 9 > = pH > = 6 Semi Auto mode Message on HMI Neut.02A/B continues running.14A/B continues running  Duty. Check Timer=? Timer = Dn. recirculation  XV51-B6491-02 {Blower Drain valve SOV} remain close  Duty.Air scouring blower B6491.14122-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.Mixing pump P6491. “System Ready for Mode =? Disposal” Auto Mode Disposal . Step Time 30 min Timer= not Dn.

02A/B starts if not running. Auto Mode Neut.  XV51-B6491-02 {Blower Drain valve SOV} remain close  Duty.Air scouring blower B6491. After a delay of 5 sec  XV52-P6491-14 {Recirculation Line valve SOV} gets close. Note: 11 Level > L.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. X33 Mode =? 1 Semi Auto mode Disposal Stop .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. Check LT51-M6491-05=? Level <= L.

only those valves which are to be opened by system are described. While the valves which are not mentioned shall remain close. After the completion of Air scouring cycle. If any Dosing pump Trips or Stopped system shall display alarm & shall start shutdown. Parameters for AT51-P6491-14 shall be monitored only when any of the mixing pump is running. 11. After every stoppage of pump operation. 9. to make system operation smooth & bump free. 3. XV54-S6491-01A/B/C {Air inlet valve SOV} shall open & then XV52-B6491-02 {Air scouring valve SOV} will get close. In the Flow chart. Auto or Semi-Auto or Manual mode. 8. Proper Delay Timers shall be introduce where ever possible.e. System shall monitor the valve operation during the corresponding sequence. 4. 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. operator shall be made aware by message displayed in Status window on Operation & Control Screen of SCADA system. The Pumps/Blowers with suffix as ‘A’ shall become Duty pump while pump with suffix as ‘B’ shall be stand-by pump. During normal operation. XV52-B6491-02 {Air scouring valve SOV} will open & then XV54-S6491-01A/B/C {Air inlet valve SOV} shall close. 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.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. then Stand-by pump shall take over automatically. if Duty pump is unavailable for operation. 6. 2. 12. 7. In the case when there is blower requirement for Air Scouring of Sand Filter then. System can be operated only in any one mode of operation at a given time i. 10. If both Duty & Stand-by pumps are unavailable during normal operation. . 5. Duty and Stand-by role shall be swapped. system shall raise Alarm & shall shutdown.

14122-VD-U1-UTL-LGD-AYCM001-0119 Control Philosophy Annexure-E Flow chart Neutralization Page 7 of 8 Start Permissive 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. 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-M6486.5 2 min B: Stop Soda dosing Pump A:Alarm LL 6.5 2 min H B: Stop Acid dosing Pump A:Alarm L 6.5 2 min B: Start Soda dosing Pump LT51-M6491.24 Suction Basin 2 Level 15 Sec Level not High High 5 Not Applicable Regeneration cycle 1 min Cycle is complete Alarms Sr. HH 2 min 2 Neutralization Pit Level 3000 A:Alarm 05 .

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. Mixing Pump-A Fault A:Alarm 8 N/A N/A 5 Sec P6491. Soda Dosing Pump-A A:Alarm 6 N/A N/A 5 Sec P6491. Soda Dosing Pump-B A:Alarm 7 N/A N/A 5 Sec P6491.22 A Fault Status Stop Pump XA51.14122-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. Acid Dosing Pump-B Fault A:Alarm 5 N/A N/A 5 Sec P6491. A: Alarm 3 (P6491.14 A Status Stop Pump XA51.02 B Fault Status Stop Blower . Acid Dosing Pump-A A:Alarm 4 N/A N/A 5 Sec P6491.02 A Fault Status Stop Blower XA51. Mixing Pump-B Fault A:Alarm 9 N/A N/A 5 Sec P6491. Air scouring Blower -B A:Alarm 11 N/A N/A 5 Sec P6491.14A/B) XA51.21 B Status Stop Pump XA51. Air scouring Blower-A A:Alarm 10 N/A N/A 5 Sec B6491.21 A Fault Status Stop Pump XA51.14 B Status Stop Pump XA51. Pit Mixing Pump FT51-P6491.22 B Fault Status Stop Pump XA51.