go Plonh THERMAX THERMAX COGEN (AIC SHREE POWER] eUENT PROJECT RO PLANT [TITLE [OPERATION & CONTROL PHILOSOPHY, REVO. [DATE DESCRIPTION PREP [CRKD [APP BY By ley O_[180402 [i [SSUED FORINFORMATION.| AMA Sif REVISED AS PER COGENS woh of 1 _| 02-05-02 feouments-on tHe voaic | AMA | ye REFERENCE DRG - PE TDIAGRAN DRE NO- 7201 (B07 REV-OF DRG NO - 720131004 REV.OT 7 2__|LOGIc DIAGRAMS. 3 VALVE OPENING SEQUENCE DRG NO- 7201W3B003 REV-02 Hthermax Ltd. Water & Waste Solutions, [Client ‘THERMAX-COGEN Pune -411 003 |Consuttant :SBP PC reoiwatoo7 | 4 s0NOS { JOC. No. : 7204 Project 2K 18 MW CAPTIVE POWER GENERATION pLaNT_| POC NO Rev. | TOTAL SHEETS COGEN DRG NO-PP 17 vi45 20 CPP SPEC NO-PP O17 MT 45.4OPERATION & CONTROL PHILOSOPHY : SYSTEM DESCRIPTION The RO plant consists of a coagulant dosing system to dose coagulant into the raw water line inlet to reservior. This helps in coagulation of the suspended solids in the raw water. The raw water is: pumped into the dual media filter ( DMF-1 )_to remove the suspended. solids. The filtered water is then dosed with acid to adjust the pH & ther’ with antiscalant solution which will prevent the scale fromation. The water is then passed into cartridge filters to remove the fine suspended particles. The water is then pimped into the RO blocks using high pressure pumps. The reject water from the first stage is the feed water to the second stage RO block. The final permeate water is passed through the degasser tower and finally stored in the permeate water storage tank. ‘The various control requirements of the various equipments are as follows COAGULANT DOSING SYSTEM The coagulant dosing is nét a continuous and frequent operation . The same shall be done depending on the inlet raw water quality. The stroke adjustment is set manually from field using the stroke adjustment knob provided on the pumps. The coagulant dosing system consists of a coagulant dosing tank ( CDT ) & 2 nos. Coagulant dosing pumps ( PCD-1/2 ) & 1 no, Motorised agitator on CDT tank. The pumps are single phase pumps and the same will be operated either from field or from control room using the Remote / Local soft switch configured on the DOS. To establish the pry Between two pumpsCManval- 1 Auto provided on the DCS as a soft switch. The standby pump will automatically start incase of tripping of the working pump. Incase the pumps ere to be operated from the control room select the pump in to Remote mode and the pump can be operated from the push buttons configured on the DCS, Incase the pumps are to be operated from the local_ select the pump in to Local mode and the pump can be operated from the local push buttons provided near the dtive. : The agitator will be operated cither from field or from control room using the Remote / Local soft switch configured on the DCS. Incase the agitator is to be operated from the control room select the agitator in to Remote mode and the agitator can be operated from the push buttons configured on the DCS. PAGE 1 OF 10 THERMAXOPERATION & CONTROL PHILOSOPHY 4 Incase the agitaior jis, to be operated from the local select the agitator in to Local mode and the agitator can be operated from the local push buttons provided near the drive. The coagulant dosing pumps and the motorised agitator shall trip in case of low (evel in the coagulant dosing tank ( sensed by LSL-502 ). The coaguiant pumps aiso trips incase of Raw Water pump tripping or incase of High DP across the RO block ( sensed by DPIS-511), The following indications are available on the DCS for the dosing pumps 4. Pump running / not running 2. Local stop push button pressed The following indications are available on the DCS for the motorised agitator 4. Agitator running / not running 2. Motor over load 3. Local stop push button pressed FILTER AIR BLOWER ~ 1/2:- 2 nos, of filter air blowers ( 1W + 1S ) are provided for air scouring operation during filter backwash. The blowers are provided with the following ‘selections on the DCS — WORKING / STAND BY & AUTO / MANUAL / LOCAL. Incase the blowers are selected in "AUTO" mode, the blowers will start and stop as per the valve opening sequence. Incase the blowers are selected in “MANUAL” mode, the blowers can be operated using the push butions configured on the DCS. Incase the blowers are selected in "LOCAL" mode, the blowers can be operated from the Loca! Push Button Stations. The standby blower will automatically start incase of tripping of the working blower. The following indications are available on the DCS. 4. Blower running / not running 2. Motor overload trip 3. Local stop push button pressed ACID DOSING SYSTEM :- ‘ The acid dosing system consists of 1 nos of acid dosing tank (ADT ) & 2 nos. of acid dosing pumps (ADP-1/2). ‘These pumps are provided with the following selections - REMOTE / LOCAL. To establish the priority between two pumps Manual / Auto switch is provided on the DCS as a soft switch. The standby pump will automatically start incase of tripping of the working pump. PAGE 2.0F 10 THERMAXOPERATION & CONTROL PHILOSOPHY Incase the pumps are selected in "REMOTE" mode, the pumps can be operated from the push buttons configured on the DCS. Incase the pumps are selected in “LOCAL" rode, the pumps can be operated from the Local Push Button Stations provided near the drives The dosing pumps-shall trip “incase of low level in acid dosing tank (sensed by LSL-504 ). The acid dosing pumps shall trip in case the raw water pump trips or if the pH of the feed water goes below the set point ( sensed by AAL-504 ) The folowing indications are available on the DCS for the dosing pumps 1, Pump running / not running 2. Motor over load 3. Local stop push button pressed In case of high alarm of pH , operator should attend the RO plant. If pH is of water is more than the desired vaue.the operator should adjust the stroke length of dosing pump to get the desired value.( This is done once in @ while and not frequently). ANTISCALANT DOSING SYSTEM. The antiscalant dosing system consists of 1 nos of antiscalant dosing tank ( SOT) & 2 nos. of antiscalant dosing pumps.( SOP-W2|——————— i@ pumps are single phase pumps and the same will be operated either from field or from control room using the Remote / Local soft switch configured on the DCS. To establish the priority between two pumps Manual / Auto switch is provided on the DCS as a soft switch. The standby pump will automatically start incase of tripping of the working pump. ee Incase the pumps are to be operated from the control room select the pump in to Remote mode and the pump can be operated from the push buttons configured on the DCS. Incase the pumps are to be operated from the local_select the pump in to Local mode and the pump can be operated from the local push buttons provided near the drive. The agitator will be operated either from field or from control room using the Remote / Local soft switch configured on the DCS. Inease the agitator is to be operated from the contrél room select the agitator in to Remote mode and the agitator can be operated from the push buttons configured on the DCS. Incase the agitator is to be operated from the local select the agitator in to Local mode and the agitator can be operated from the local push buttons provided near the drive. The dosing pumps and the agitator shall trip incase of low level in antiscalant dosing tank. ( sensed by LSL-506 ) PAGE 3 OF 10 T THERMAX \OPERATION & CONTRO: PHILOSOPHY a + TRERMAK The dosing pump trips incase of High Pressure Pump tripping The following indications are available on the DCS for the dosing pumps 4. Pump running / not running 2, Local’ stop’push button pressed The following-indications are available on the DCS for the motorised agitator. 4, Agitator’tupning / not running : 2. Motor ogéload 3. Local stejs push button pressed | HIGH PRESSURE PUMPS (HPP-1/2 on the D&S REMOTE / LOCAL. To establish the priority between two pumps Manual / Auto switch is provided on the DCS as a soft switch. The standby pump wili-automatically start incase of tripping of the working pump. The standby pump will automatically start incase of tripping of the working pump. ep ww Inease the pumps are’selected in “ REMOTE " mode, the High pressure ~ pumps can-be operated using the push buttons configured on thie DCS. Incase the pumps’ are selected in” LOCAL " mode, the pumps can be operated from the Local Push Button Stations. The standby pump will automatically start incase of tripping of the worki pump. The following indications are available on the DCS 1, Pump running / not running 2. Motor overload trip 3. Local stop push button pressed The high pressure pump-1 shall trip incase of low pressure in the suction of HPP-1 ( sensed by PSL-510A ). The high pressure pump-2 shall trip incase of low pressure. in the suction of HPP-2 ( sensed by PSL-510B ) The running high pressure pumps shall trip incase of following conditions. 1. PH of feedwater goes below the setpoint ( AAL-504 ) * 2. None of the acid dosing pumps are running or the dosing pump trips during the opefation (a time delay of 10 secs is given before tripping the high pressure pump so that time is given for the standby dosing pump to start). 3. None of the anti scalent dosing pumps are running or trips during the operation (a time delay of 10 secs is given before tripping the high pressure pump so that time is given for the standby dosing pump to start ) 4. DP across RO Block is high ( Sensed by DPIS-511) 5. DP across DMF-1 is very high ( Sensed by DPIS-501), 6. Raw water pump trips. PAGE 4 OF 10OPERATION & CONTROL PHILOSOPHY CLEANING SYSTEM :- The.cleaning system consists of 1 no. of cleaning tank & 1 no. of cleaning pump. The cleaning pump is provided with REMOTE / LOCAL selection on the Dcs. Incase the pump is selected in “REMOTE” mode, the pump can be operated from the push buttons configured on the DCS. Incase the pump is selected in “LOCAL” mode, the pump can be operated from the Local Push Button Station provided near the drives. The cleaning tank agitator is provided with REMOTE / LOCAL selection on the ocs. Incase the agitator is selected in "REMOTE" mode, the agitator can be operated from the push buttons configured on the DCS. Incase the agitator is selected in "LOCAL" mode, the agitator can be operated from the Local Push Button Stations provided near the drive. The cleaning pump and the cleaning tank agitator shall trip incase of low level in cleaning tank ( sensed by LSL-512 ). The following indications are available on the DCS for the cleaning pump and the agitator. 4. Pump running / not running 2. Motor overload trip 3. Local stop push button pressed DEGASSER AIR BLOWER :- ‘The degasser air blower:1/2 is provided with REMOTE / LOCAL selection ‘on the DCS. Incase the blowers are selected in “REMOTE” mode, the blowers can be operated from the push buttons configured on the DCS. Incase the blowers are selected in "LOCAL" mode, the blowers can be operated from the Local Push Button Stations provided near the drives. . Autostandby operation of the second blower is not provided. The following indications are available on the DCS for the degasser air blower. 4. Pump running / not running. 2. Motor overload trip 3. Local stop push button pressed. PAGE 5 OF 102 2A OPERATION & CONTROL PHILOSOPHY THERMAK PH DOSING SYSTEM :- The p-H Dosing system is provided to correct the pH of the CT make up water. It consists of a automatic pH dosing system consisting of a pH sensor / p H transmitter / dosing controller configured on the DCS The p H dosing system consists of 1 nos of pH dosing tank ( DPH ) & 2 nos. of p H dosing pumps ( PPH-1/2 } ! These pumps are provided with the following selections — REMOTE / LOCAL To establish the priority between two pumps Manual / Auto switch is provided on i the DCS as a soft switch. The standby pump will automatically start incase of tripping of the working pump. | Incase the pumps are selected in “REMOTE” mode, the pumps can be operated from the push buttons: configured on the DCS. Incase the pumps are selected in "LOCAL" midde, the pumps can be. operated from the Local Push Button Stations provided near the drives.The standby pump starts automatically in case the working pump trips . | The dosing pumps shall trip incase of low level in pH dosing tank.( sensed by LSL-517 ) PH of the water after the dosing point is checked using the online pH electrode. This electrode gives a mV input to the field mounted pH transmitter. The transmitter output is given to the PH controller configured on the DCS This | controller gives a controlled output of 4-20 mA DC to the electronic stroke | controller mounted on the dosing pumps which adjusts the stroke length of the } pump automatically based on the controller output so that a constant pH is (_ maintained at the downstream of the pH dosing point The following indications are available on the DCS for the dosing pumps 1. Pump running / not running : 2. Motor over load 3. Local stop push button pressed OPERATION OF DUAL MEDIA PRESSURE FILTER-1 valve. The water passes through the filter media comprising of Anthracitetsand followed by media support i.e gravel. Due to these varied sizes of filter rhedia . depth filtration can be achieved, the coarser suspended solids being trapped in the fine sand. The filtered water is then collected by a lateral system . As the filter The raw water is led to the dual media pressure filter by opening the filter inlet PAGE 6 OF 10OPERATION & CONTROL PHILOSOPHY media starts retaining the suspended solids, the Dp across the filter media staits increasing and once it reaches a preset value the filter is to be backwashed. The filter is being provided with multiple selections on the DCS with 6 positions. The positions are - REFILL / RINSE / SERVICE / OFF / BACKWASH. 7 AIR RELEASE REFILL OPERATION OF DUAL MEDIA PRESSURE FILTER: Select to REFILL mode and press the REFILL START PB configured on the DCS. The DCS will issue 4 commnad to open the valves UV-501A & UV-501G & UV-503, The REFILL mode can be deselected by selecting the OFF mode configured RINSE OPERATION OF DUAL MEDIA FILTER Select to RINSE mode and press the RINSE START PB configured on the DCS. The DCS will issue a commnad to open the valves UV-501A & UV-S01E & UV-503. The RINSE mode can be deselected by selecting the OFF mode configured SERVICE OPERATION OF DUAL MEDIA FILTER-1 Select to SERVICE mode and press the “SERVICE START" PB provided on the control panel. The DCS will issue a command to open the valves UV-501A (service inlet valve ) & UV-501B (water outlet valve ) & valve UV-503, On receipt of "OP ACROSS FILTER HIGH * alarm on the DCS - ,the filter will be isolated by closing it's inlet and outlet valves (UV-501A&UV-501B) automatically. The operator will then manually initiate backwash operation of the DUAL MEDIA FILTER AIR RELEASE OPERATION OF DUAL MEDIA FILTE: Select to AIR RELEASE mode and press the AIR RELEASE START PB configured on the DCS. The DCS will issue a command to open the valve UV- 501G & UV-503. The AIR RELEASE mode canbe deselected by selecting the OFF mode configured, BACKWASH OPERATION OF DUAL MEDIA FILTER- The operfor can do the backwash of the filter in AUTO mode by selecting to BACKWASH mode . 4 nos. of push buttons are provided to control the backwash operation through DCS 1) START PB ~ To start the backwash operation 2) STOP PB ~ To stop the backwash operation. PAGE 7 OF 10 THERMAXOPERATION & CONTROL PHILOSOPHY 3) HOLD / RELEASE PB — Press to Hold the step & Release to proceed the next step, 4) SKIP PB — To skip the step Following are the pre requisites’ to’ start the backwash operation“ of Dual media filter-1 1) Dual media filter-1_ is selected in “BACKWASH" mode 2) Filter air biower-1/2 selected in AUTO mode 3) Filter air blower-1 is selected in "WORKING" mode and the Filter air blower-2 is selected in “STANDBY” mode or the vice versa 4) Filter oullet valve UV-501B''s in closed position ( sensed by limit switch feedback ) 5) The raw water pumps are running Note : Incase of high turbidity in the monsoon season a provision of using the filtered water for the backwash is envisaged ( a tap off from CT make up pump delivery header is provided ) . In such eventuality operator to open and close the valve VM-43 & VIM-3 from the field. Ensuring the above, press push button backwash start PB, the following steps will be carried out in a sequence. STEP NO-1 DRAIN DOWN ( TIME = 2 MINS Valve UV-501D,UV-501G & UV-503 will open for 2 mins, After 2 mins the sequence will advance to the next step STEP NO-2 AIR BLOWER SERVICE ( TIME = 1 MIN.) The auto selected blower will start, valve UV-501D,UV-501G & UV-503 will continue to remain open from the previous step . After 1 minute’ the sequence will advance to the next step. STEP NO-3 AIR SCOURING TIME = 10 MINS. In this step, valve UV-501F will open , UV-503 will close . Valve UV-501D and UV-501G will continue to remain open from the previous step. Filter air blower- 1/2 will continue to run from the previous step . After 10 minutes the sequence will advance to the next step. In this step filter air blower will stop. Valve UV-501C & UV-503 will open. Valve UV-501D & UV-501G will continue to remain open from the prevoius step. After 10 minutes the sequence will advance to next step. PAGE 8 OF 10OPERATION & CONTROL PHILOSOPHY J STEP N REFILL Timi INS In this step valve UV-501C and UV-501D wilt close . Valves UV-501A. & UV: 501G will open. Vaive UV-503 will continue to remain open from the previous step. After 5 minutes, the sequence will advance to the next step. MINS. In this step valve UV-501G will close. Valve UV-501E is opened and valve UV- 501A & UV-503 will continue to remain open from the previous step. STEP NO-7 OFF TIME = 1 MIN. In this step valve UV-501A & UV-501E will close & valve UV-503-will continue to remain open from the previous step. After this step, DCS will issue an alarm Filter- backwash completed”. This alarm will remain on for 1 minute. if any of the pre requisites is not fulfilled and START PB is pressed or any of the pre requisites fails during the backwash operation, DCS will abort the programme, with an alarm “Filter backwash failed", This alarm will remain on for 1 minute. GENERAL :. All drive status ( including Pumps, Agitators) available on the DCS (by means of ON/OFF/TRIP/LOCAL STOP PB OPERATED indications configured on the DCs. Each solenoid-operated valve status will be provided on the DCS. Green indicates that the valve is open and red indicates that the valve is closed Start Up procedure for the RO Plant : + The raw water pumps is started and the water goes id the dial media fiter and reaches HP pump suction. + The acid dosing system & Antiscalant dosing system is started . The PH value of the feed water is checked using PH analyser provided ( AT-504 ) Till the required PH is reached the dump valve UV-509 is opened aind water is recirculated back in to the raw water tank, : * Once the required PH is reached the dump valve UV-509 is closed and the water is passed through the RO block, + Open the reject valve UV-511. With the HP pump motor still under stopped condition the water passes through RO system and then discharged through PAGE OF 10 THERMAXOPERATION & CONTROL PHILOSOPHY ! oF THERMAX the reject valve . ( Hand operated globe valve at the discharge of the HP Pump is suitably throttled to restrict the flow and create some resistance ). This purging operation is for 10-15 mins ( the exaci timing will be adjusted *°“uring,the commissioning ) Pee. *¥: The HP pump -122 is‘started from’ REMOTE (start édimmand.is:given by the ‘ DCS provitiéd at the interlocks for HPP are satisfied) and the discharge . valve: is. mahually adjusted to. arrive at the desired flow rate . This fixed pésition: of. the dischrge valve of the High “pressure ump will renvain undhieingad'ti'the RO block requires the cleaning operation. . * Offtdetection of High DP across RO block , Section wise cleaning of the RO ‘y system is taken up. The pump discharge globe valve is reset for the desired flow considering the section of the RO. | PAGE 10 0F 10 | | I