Flow Chart for 1954 Final1
Transcript of Flow Chart for 1954 Final1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 1 & 51
START
SELECT THE SECTION
PRESS MODE SELECTION KEY
SWITCH ON MAIN AND PLC
“WELCOME TO DOSHION” “D.M. + U.F. PLANT
”
“ENTER THE”“PASSWORD _ _ _ _”
D.,M. PLANTU.F. PLANT 3. ACID / CAUSTIC UNLOADING 4. N-PIT TANK OPERATION
D.M PLANT
1.1 SERVICE MODEACF SERVICESAC SERVICESBA SERVICEMB SERVICE1.2 BACKWASH/REGN. MODE1.2.1 ACF B/W1.2.2 SAC B/W1.2.3 SBA B/W1.2.4 MB B/W
POST UF
2.1 SERVICE MODE
2.2 UF B/W
ACID / CAUSTIC UNLOADING
3.1 PUMP ON / OFF
4. N-PIT TANK OPERATION
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
PLC STARTUP OPERATIONAL LOGICS FOR ACF :
OPERATIONAL CHECKS STEPS REMARKS1 COPM. AIR PR > 5 Kg/cm2 LOCAL GAUGE ON AIR
COMP.
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSED CHECK ANY ONE SAC IN
SERVICE MODE, SELECT ANY ONE PUMP FROM ANY THREE PUMP.
SELECT ACF SERVICE CYCLE MODEA. SERVICE WITH AIR VENT (IF ACF-1001A SELECTED)
A1 TIMER TA START AUTO (START + 0 SEC)
A2V – 1102 OPEN
AUTO (START + 0 SEC)V – 1108 OPEN 61,62
A3
CWP – 1001A/B/C ANY ONE SELECTED
START 1,2,(3&4),12,5
AUTO (STEP A2 + 10 SECS)
STEP A2
NO
YES SERVICE WITH AIR VENT COMPLETE
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SYSTEM START UP- NORMAL ACF SERVICE
I-1
AUTO MODE
START SYSTEM
SELECT ONE ACF OR TWO ACF FROM ACF –
1001A/B/C
TWO ACF 1001A /B SELECTED
A2
IS ELAPSED TIME = TA ?
A1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
B. PRESERVICE RINSEB1 TIMER T(B) START AUTO (TA + 0 SEC)
B2V – 1102 OPEN
AUTO (TA + 0 SEC)V – 1107 OPEN 61,62
B3 V – 1108 CLOSE AUTO (STEP B2 + 3 SECS)
STEP B2
NO
YES
PRE SERVICE RINSE COMPLETEC. SERVICE CYCLE
C1 TIMER TC START AUTO (TB + 0 SEC)
C2V-1102 OPEN AUTO (TB + 0 SEC) V – 1106 OPEN
C3 V – 1107 CLOSE AUTO (STEP C2 + 3 SECS) STEP C2
NO
YES
SERVICE CYCLE COMPLETE IF OPERATOR WANTS TO TAKE IN REG. THEN ABLE TO TAKE
After completion of service cycle all valves will be closed after the time (TC+3) seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any ACF first service with air – vent done and then service cycle .In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves.”
Page 3 & 51
IS ELAPSED TIME = TB ?
IS ELAPSED TIME = TC ?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 4 & 51
DATA ACQUISITION & EVENT LOGGED
A1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
NOTE : 1)IF ACF 1001B OR 1001C SELECTED THEN VALVE SERIES OF 2101 … & 3101 COME 2) IF IF ACF 1001C OR 1001A SELECTED THEN VALVE SERIES OF 3101 … & 1101 COME
3) IF IF ACF 1001B OR 1001A SELECTED THEN VALVE SERIES OF 2101 … & 1101 COME 4) CHECK THE SELECTD PUMP RUN CONFIRM FEEDBACK FROM MCC PANEL. IF NOT AVAILABLE THEN MESSAGE COME “RUN CONFIRM MISSING CWP-1001 A/B/C” (AS PER SELECTED PUMP A/B/C) FOR EVERY CYCLE OF ACF –SERVICE & ACF BACKWASH 5) IF ACF 1001B AND 1001C SELECTED THEN VALVE SERIES OF 2101 … & 3101 COME
6) IF ACF 1001C AND 1001A SELECTED THEN VALVE SERIES OF 1101 … & 3101 COME
7) MAXIMUM TIME REQUIRED FOR ANY AUTO VALVE(IN WHOLE SYSTEM) OPEN / CLOSE FEED BACK AFTER OPEN / CLOSE COMMAND IS 7 SEC (FIXED) IF NOT RECEIVED WITHIN THE SET TIME AN OPERATOR ALARM WILL RAISED AND SERVICE / REGNERATION / BACKWASH CYCLE WILL PAUSE. An OVER RIDE SOFT BUTTON WILL BE PROVIDED FOR THE OPERATOR TO RESET THE ALARM AND CONTINUE WITH THE CYCLE IF HE WANTS 8) IN SAC SERVICE CYCLE SELECT DGT – 1001A/B IF DGT-1001A SELECTED THEN V-5012 VALVE OPEN AND ANY ONE SELECTED BLOWER DGB – 1001 A/B/C START IF DGT-1001B SELECTED THEN V-5016 VALVE OPEN AND ANY OEN SELECTED BLOWER DGB-1001 A/B/C START. IF TWO SAC IS IN SERVICE THEN TWO DGT-1001 A/B START AND BOTH VALVE V-5012 & V-5016 OPEN AND ANY TWO SELECTED DGB -1001A/B/C START 9) HOLD SOFT BUTTON WILL BE PROVIDED TO PROLONG THE CURRENT STEP FOR EVERY CYCLE OF ACF / SAC /SBA /MB AND UF SYSTEM AT OPERATOR DISCRETION. 10) IN WHOLE SYSTEM FOR EVERY PUMP BEFORE STARTING THE PUMP CHEK STATUS OF O/L FEED BACK. IF NOT HEALTHY THEN ALARY COME AND OPERATOR RESET ALARM AND THEN ABLE TO START THE PUMP. 11) IN OUR SYSTEM ALL PUMP AND DOSING PUMP IF WORKING PUMP IS TRIP FOR ANY INTERLOCK THEN STAND BY PUMP WILL START IN AUTO.
AUTO OPERATION STEPS REMARKS
Page 5 & 51
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
START : ALL AUTO VALVES ARE CLOSEDSELECT ANY TWO ACF SERVICE CYCLE (ACF-1001A& B)
ANY TWO SAC IN SERVICE MODE SELECTED
A. SERVICE WITH AIR VENT FIRST SELECT ANY TWO PUMP FROM ANY THREE PUMP
A1 TIMER TA1 START AUTO (START + 0 SEC)
A2V – 1102 , 2102 OPEN
AUTO (START + 0 SEC)V – 1108 , 2108 OPEN 61,62
A3
CWP – 1001A/B/C ANY TWO SELECTED
START 1,2,(3&4),12,5
AUTO (STEP A2 + 10 SECS)
STEP A2
NO
YES SERVICE WITH AIR VENT COMPLETEB. PRESERVICE RINSE
B1 TIMER T(B1) START AUTO (TA1 + 0 SEC)
B2V – 1102 , 2102 OPEN
AUTO (TA1 + 0 SEC)V – 1107 , 2107 OPEN 61,62
B3 V – 1108 , 2108 CLOSE AUTO (STEP B2 + 3 SECS)
STEP B2
NO
YES
PRE SERVICE RINSE COMPLETEC. SERVICE CYCLE
C1 TIMER TC1 START AUTO (TB1 + 0 SEC)
C2V-1102 , 2102 OPEN AUTO (TB1 + 0 SEC) V – 1106 , 2106 OPEN
C3 V – 1107 , 2107 CLOSE AUTO (STEP C2 + 3 SECS) STEP C2
NO
YES
SERVICE CYCLE COMPLETE IF OPERATOR WANTS TO TAKE IN REG. THEN ABLE TO TAKE
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IS ELAPSED TIME = TA1 ?
IS ELAPSED TIME = TB1 ?
IS ELAPSED TIME = TC1 ?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
After completion of service cycle all valves will be closed the time (TC+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any ACF first service with air – vent done and then service cycle .In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves.”
Page 7 & 51
A2
DATA ACQUISITION & EVENT LOGGED
IS ELAPSED TIME = TC ?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
OPERATIONAL CHECKS STEPS REMARKS1 COPM. AIR PR > 5 Kg/cm2
Page 8 & 51
Starting condition for ACF B/W cycle :- 1) Either of pumps CWP – 1101 A/B/C/ in running condition. 12) Check Interlock 61 & 62 High level at N-pit tank.3) Check no ANY OTHER ACF IN B/W MODE AT A TIME ONLY SINGLE ACF IN B/W
CYCLE.4) IF ACF -1001A SELECTED THEN GO WITH VALVE SERIES –V1105, IF ACF-1001B SELECTED THEN GO WITH VALVE SERIES V-2105, IF ACF-1001C SELECTED THEN GO WITH VALVE SERIES V-3105.
ACF B/W CYCLEAUTO MODE
I-2
START SYSTEM
SELECT ONE ACF – 1001A/B/CFOR B/W
C1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
AUTO OPERATION STEPS REMARKSLS-5011 &LS-5012 (61 & 62) (STARTUP
CONDITION)SELECT ANY ONE ACF FROM ACF-1001A/B/C
A. ACF BACKWASHA1 TIMER TD START AUTO (START + 0 SEC)A2 V-1105 OPEN AUTO (START + 0 SEC)
V-1103 OPEN 61,62A3 CWP-1001A/B/C
ANY ONESTART 1,2,(3&4),5 AUTO (STEPA2+7 SECS)
STEP A2
NO
YESB.RINSE :
B1 TIMER TE START AUTO (TD + 0 SEC)B2 V - 1102 OPEN AUTO (TD+ 0 SEC )
V-1107 OPEN 61,62B3 V -1105 CLOSE AUTO (STEP B2 + 3 SEC)
V – 1103 CLOSE
STEP B2
NO
YESSELECTED ACF BACKWASH COMPLETEDAfter completion of cycle all valves will be closed the time (TE+3)seconds.All timers are settable and operator can set the time.If backwash cycle timer stopped due to any reason service cycle timer will pause but not reset.An over ride soft button will be provided for the Operator to reset the alarm and continue with the cycle if he wants In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 9 & 51
DATA ACQUISITION AND EVENT LOGGED
IS ELAPSED TIME = TD?
IS ELAPSED TIME = TE?
C1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
SAC OPERATION :
OPERATIONAL CHECKS STEPS REMARKS1 COPM. AIR PR > 5 Kg/cm2
Page 10 & 51
I-3
START SYSTEM
SELECT ONE SAC OR TWO SAC FROM SAC –
1001A/B/C
TWO SAC A/B /C SLECTED
D2
SYSTEM START UP- NORMAL SAC SERVICE
AUTO MODE
START UP CONDITION : 1) CLARIFIED PUMP CPW-1001A/B/C SELECTED IN AUTO MODE2) DEGASSER STORAGE TANK LEVEL NOT BE HIGH – 12(LT-5001)3) ANY ONE ACF TO BE IN SERVICE MODE.
D1
ONE SAC A/B/C SLECTED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSEDSELECT ANY ONE SAC SERVICE CYCLE CHEK ANY ONE ACF IN
SERVICEA. SERVICE WITH AIR RELEASE (AIR VENT)
A1 TIMER TF START AUTO (START + 0 SEC)
A2V – 1110 OPEN
AUTO (START + 0 SEC)V – 1120 OPEN 61,62
A3
CWP – 1001A/B/C ANY ONE SELECTED
ON 1,2,(3&4),12,5
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TG START AUTO (TF + 0 SEC)
B2V-1110 OPEN AUTO (TF + 0 SEC) V -1119 OPEN 61,62
B3 V-1120 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLE SELECT DGT-1001 A/B C1 TIMER TH START AUTO (TG + 0 SEC)
C2
V-1110 OPEN AUTO (TG + 0 SEC)
(SELECT ANY DGT-1001A/B)
V-1118 OPEN D3,12V-5012 or V-5016 OPEN D3,12DGB-1001A/B/C ANY SELECTED
ON D3,12
C3 V-1119 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2 NO
YES
SERVICE CYCLE COMPLETE MESSAGE COME REGNERATION REQUIRE GOTO E1
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IS ELAPSED TIME= TF?
IS ELAPSED TIME= TG?
IS ELAPSED TIME= TH?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
After completion of cycle all valves will be closed the time (TH+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any SAC first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves”.
Page 12 & 51
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 13 & 51
D1
C11
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
NO YES
Page 14 & 51
CHECK : CONDUCTIVITY DIFFERENCE VALUE EXCEEDS THE SET VALUE FOR MORE THAN 5 MINUTES. CA-1104(6), CA-1103(7), CA-2104(8), CA-2103(9), CA-3104(10), CA-3103(11)
YES
E1
C11
D3
GO TO INTERLOCK 6,7,8,9,10,11 STOP SAC SERVICE CYCLE AND PARTICULAR SAC COME IN
ISOLATION MODE – ALL CYCLE STOP MESSAGE COME SAC-1001A/B/C REGNERATION REQUIRE.
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
SAC REGENERATION
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PRE CONDITIONS FOR SAC REGANERATION:1)At least any one DGWTP should be running (Healthy Condition) 122)The other SAC should not be in regeneration mode.3) At least one ACF- 1001A/B/C should be in service. In case if one stream in service then both ACF-1001A/B/C should be in service.4) Both N-Pit level should not be high. LS-5011(61), LS-5012(62)5)Selected SAC AMT level should be high. LS-5001(63 & 64), LS-5002(65 & 66)
E1
SELECT ONLY ONE SAC FROM 1001 A/B/C
E2
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
REMARKS
START : ALL AUTO VALVES ARE CLOSEDSELECT SAC RGENERATION Atleast any one ACF should be in
service.A. AIR RELEASE (AIR VENT)
A1 TIMER TI START AUTO (START + 0 SEC)
A2V – 1110 OPEN
AUTO (START + 0 SEC)V – 1120 OPEN 61,62
A3
CWP – 1001A/B/C ANY ONE SELECTED
ON 1,2,(3&4),12,5
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETE
B. BACKWASH (OPTIONAL) OPERATOR ABLE TO BYPASS THIS OPTION IF HE WANTS
B1 TIMER TJ START AUTO (TI + 0 SEC)
B2V-1116 OPEN AUTO (TI + 0 SEC) V -1111 OPEN 61,62
B3V-1110 CLOSE AUTO (STEP B2 + 3 SEC)V-1120 CLOSE
STEP B2
NO
YES BACKWASH COMPLETEC. MIDDLE COLLECTOR FLUSHC1 TIMER TK START AUTO (TJ + 0 SEC)
C2V-1114 OPEN AUTO (TJ + 0 SEC) V-1111 OPEN 61,62
C3 V-1116 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2 NO NO
YES
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IS ELAPSED TIME= TJ?
IS ELAPSED TIME =TI?
IS ELAPSED TIME= TK?
E2
E3
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
MIDDLE COLLECTOR FLUSH COMPLETE
D. ACID PRE INJECTION SELECT AMT-1001A/B FOR ACID PRE INJ.
D1 TIMER TL START AUTO (TK + 0 SEC)
D2
V-1115 OPEN 61,62
AUTO (TK + 0 SEC)V-5071 OR 5072 OPENV-1117 OPENV-1112 OPEN
D3V-1114 CLOSE
AUTO (STEP D2 + 3 SEC)V-1111 CLOSE
D4DGWTP – 1001A/B/C ANY ONE SELECTED ON13,14,15,16 AUTO (STEP D2 + 7 SEC)
STEP D2
NO YESACID PRE INJECTION COMPLETEE. ACID INJECTIONE1 TIMER TM START AUTO (TL + 0 SEC)
E2
V-1115 OPEN 61,62
AUTO (TL + 0 SEC)V-5071 OR 5072 OPEN 63,65V-1117 OPENV-1112 OPENV-5075 OR 5076 OPEN 63,65
STEP E2
NO
YES
Page 17 & 51
IS ELAPSED TIME=TL?
IS ELAPSED TIME=TM? OR LOW LEVEL IN AMT-1001A/B 63 OR 65 WHICH IS EARLIEST
E3
E4
E4
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
ACID INJECTION COMPLETE
STEP F2
F. SLOW RINSEF1 TIMER TN START AUTO (TM + 0 SEC)
F2
V-1115 OPEN 61,62
AUTO (TM + 0 SEC)V-5071 OR 5072 OPENV-1117 OPENV-1112 OPEN
F3 V-5325 OR 5326 CLOSE AUTO (STEP F2 + 3 SEC)
NO
YES
SLOW RINSE COMPLETEFAST RINSEG1 TIMER TO START AUTO (TN + 0 SEC)
G2V-1110 OPEN
AUTO (TN + 0 SEC)V-1119 OPEN 61,62
G3
V-1115 CLOSE AUTO (STEP G2 + 3 SEC)
V-5071 OR 5072 CLOSEV-1117 CLOSEV-1112 CLOSE
G4 DGWTP – 1001A/B/C OFF AUTO (TN + 0 SEC)HERE FACILITY WILL BE PROVIDED FOR OPERATOR TO GO FOR REPEATED FAST RINSE CYCLES BY SELECTING EXTRA FAST RINSE BY SOFT BUTTONS.After completion of cycle all valves will be closed time (TIMER PERTICULAR +3)seconds.All timers are settable and operator can set the time.If regeneration cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually. In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valvesMESSAGE COME “ SAC -1001 A/B/C REGNERATION COMPLETED “
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSEDSELECT SAC SERVICE CYCLE (FOR TWO SAC-1001A/B SELECTED)
ANY TWO ACF IN SERVICE MODE SELECTED
Page 18 & 51
IS ELAPSED TIME=TN?
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
A. SERVICE WITH AIR RELEASE (AIR VENT)A1 TIMER TF1 START AUTO (START + 0 SEC)
A2V – 1110, 2110 OPEN
AUTO (START + 0 SEC)V – 1120, 2120 OPEN 61,62
A3CWP – 1001A/B/C ANY TWO SELECTED
ON 1,2,(3&4),12,5AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TG1 START AUTO (TF1 + 0 SEC)
B2V-1110, 2110 OPEN AUTO (TF1 + 0 SEC) V -1119, 2119 OPEN
B3 V-1120, 2120 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLE SELECT BOTH DGT-1001A &BC1 TIMER TH1 START AUTO (TG1 + 0 SEC)
C2
V-1110,2110 OPEN
AUTO (TG1 + 0 SEC)
V-1118,2118 OPEN D3,12V-5016 OPEND3,12V-5012 OPEN D3,12DGB – 1001A/B/C ANY TWO SELECTED
ON D3,12
C3 V-1119,2119 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2
NO
YES
SERVICE CYCLE COMPLETE. MESSAGE COME “REGNERATION REQUIRE GO TO E1”After completion of cycle all valves will be closed the time (TH1+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any SAC first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 19 & 51D2
IS ELAPSED TIME= TF1?
IS ELAPSED TIME= TG1?
IS ELAPSED TIME= TC?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 20 & 51
DATA ACQUISITION AND EVENT LOGGED
C11
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
SBA OPERATION
OPERATIONAL CHECKS STEPS REMARKS1 COPM. AIR PR > 5 Kg/cm2
AUTO OPERATION STEPS REMARKS
Page 21 & 51
I-4
START SYSTEM
SELECT ONE SBA OR TWO SBA FROM SAC –
1001A/B/C
TWO SBA 1001- A/B/C SLECTED
F2
SYSTEM START UP- NORMAL SBA SERVICE
AUTO MODE
START UP CONDITION : 1) SELECTED DGWTP-1001A/B/C SHOULD BE IN AUTO MODE2) DEGASSER STORAGE TANK DGWST-1001 LEVEL NOT BE LOW – 12(LT-5001)3) ANY ONE MB-1001A/B/C TO BE IN SERVICE MODE.4) SELECTED DGWTP-1001A/B/C IN AUTO MODE
F1
ONE SBA-1001 A/B/C SLECTED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
START : ALL AUTO VALVES ARE CLOSEDSELECT SBA SERVICE CYCLE ANY ONE MB SHOULD BE
SELECTED (I5)A. SERVICE WITH AIR RELEASE (AIR VENT)
A1 TIMER TP START AUTO (START + 0 SEC)
A2V – 1122 OPEN
AUTO (START + 0 SEC)V – 1132 OPEN
A3
DGWTP – 1101A/B/C ANY ONE SELECTED
ON 13,(14&15),12,16,34
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TQ START AUTO (TP + 0 SEC)
B2V-1122 OPEN AUTO (TP + 0 SEC) V -1131 OPEN 61,62
B3 V-1132 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLEC1 TIMER TR START AUTO (TQ + 0 SEC)
C2V-1122 OPEN AUTO (TQ + 0 SEC) V-1130 OPEN F3
C3 V-1131 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2
NO
YES
SERVICE CYCLE COMPLETEMESSAGE COME REGNERATION REQUIRE SBA-1001A/B/C GO TO F3
Page 22 & 51
IS ELAPSED TIME= TP?
IS ELAPSED TIME= TQ?
IS ELAPSED TIME= TR?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
After completion of cycle all valves will be closed the time (TR+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any SBA first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 23 & 51
F1
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 24 & 51
CHECK : (1)SBA CONDUCTIVITY EXCEEDS THE SET VALUECT-1101(17), CT-2101(18), CT-3101(19), CHECK (2) SBA SILICA EXCEEDS THE SET VALUE SIA-1101(20), SIA-2101(21), SIA-3101(22)
YES
G11
G1
G11
F3
GO TO INTRLOCK : - 17,18,19,20,21,22 STOP SERVICE SYSLE AND PARTICULAR SBA COME IN ISOLATION
– ALL CYCLE OPERATION STOPE. MESSAGE COME SAC-1001A/B/C REGNERATION REQUIRE.
NO
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
SBA REGENERATION
Page 25 & 51
PRE CONDITIONS FOR SBA REGANERATION:1)Selected DGWTP-1001A/B/C should be in Auto mode.2)The other SBA should not be in regeneration mode.3) Both N-Pit level should not be high. LS-5011(61), LS-5012(62)4)Selected SBA CDT-1001A/B level should be high. LS-5007(72), LS-5008(74)5)Only One SBA should be in Regeneration.6)Regeneration Pump RWP – 1001A/B should be in Auto mode.7)Another SBA-1001 and not any MB – 1001A/B/C should be in regeneration.
G1
SELECT ONLY ONE SBA FROM SBA-1001 A/B/C
G2
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
REMARKS
START : ALL AUTO VALVES ARE CLOSEDSELECT SBA REGENERATION A. AIR RELEASE (AIR VENT)
A1 TIMER TS START AUTO (START + 0 SEC)
A2V – 1122 OPEN
AUTO (START + 0 SEC)V – 1132 OPEN 61,62
A3
DGWTPP – 1101A/B/C ANY ONE SELECTED
ON 13,(14&15),12,16,34
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETE
B. BACKWASH (OPTIONAL) OPERATOR ABLE TO BYPASS THIS OPTION IF HE WANTS
B1 TIMER TT START AUTO (TS + 0 SEC)
B2V-1128 OPEN AUTO (TS + 0 SEC) V -1123 OPEN 61,62
B3V-1122 CLOSE AUTO (STEP B2 + 3 SEC)V-1132 CLOSE
STEP B2
NO
YES BACKWASH COMPLETEC. MIDDLE COLLECTOR FLUSHC1 TIMER TU START AUTO (TT + 0 SEC)
C2V-1126 OPEN AUTO (TT + 0 SEC) V-1123 OPEN 61,62
C3 V-1128 CLOSE AUTO (STEP C2 + 3 SEC)
Page 26 & 51
IS ELAPSED TIME= TT?
IS ELAPSED TIME =TS?
G2
G3
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
STEP C2 NO NO
YES
MIDDLE COLLECTOR FLUSH COMPLETE
D. CAUSTIC PRE INJECTION SELECT CDT-1001A/B FOR CAUSTIC PRE INJ.
D1 TIMER TV START AUTO (TU + 0 SEC)
D2
V-1127 OPEN 61,62
AUTO (TU + 0 SEC)V-5070 OR 5071 OPENV-1129 OPENV-1125 OPEN
D3V-1126 CLOSE
AUTO (STEP D2 + 3 SEC)V-1123 CLOSE
D4RWP – 1001A/B ANY ONE SELECTED
ON56,57,58 AUTO (STEP D2 + 7 SEC)
STEPD2 NO YES
YESCAUSTIC PRE INJECTION COMPLETEE. CAUSTIC INJECTIONE1 TIMER TW START AUTO (TV + 0 SEC)
E2
V-1127 OPEN 61,62
AUTO (TV + 0 SEC)V-5070 OR 5071 OPEN 71,73V-1129 OPENV-1125 OPENV-5150 OR 5155 OPEN 71,73
STEP E2 NO
YES
Page 27 & 51
IS ELAPSED TIME= TU?
IS ELAPSED TIME=TV?
IS ELAPSED TIME=TW? OR LOE LEVEL IN CDT-1001A/B 71,73 WHICH IS EARLIER
G3
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
CAUSTIC INJECTION COMPLETE STEP F2
F. SLOW RINSEF1 TIMER TX START AUTO (TW + 0 SEC)
F2
V-1127 OPEN 61,62
AUTO (TW + 0 SEC)V-5070 OR 5071 OPENV-1129 OPENV-1125 OPEN
F3 V-5150 OR 5155 CLOSE AUTO (STEP F2 + 3 SEC)
NO
YES STEPG2
SLOW RINSE COMPLETEG. FAST RINSEG1 TIMER TY START AUTO (TX + 0 SEC)
G2V-1122 OPEN
AUTO (TX + 0 SEC)V-1131 61,62 OPEN
G3
V-1127 CLOSEAUTO (STEP G2 + 3 SEC)
V-5070 OR 5071 CLOSEV-1129 CLOSEV-1125 CLOSE
G4 RWP – 1001A/B/C OFF AUTO (TX + 0 SEC)
NO
YES
FAST RINSE COMPLETEAfter completion of cycle all valves will be closed the time (TY+3)seconds.All timers are settable and operator can set the time.If regeneration cycle timer stopped due to any reason reganeration cycle timer will pause but not reset.Operator has to reset Manually. In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 28 & 51
IS ELAPSED TIME=TX?
IS ELAPSED TIME=TY?
G4
G4
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSEDSELECT SBA SERVICE CYCLE (FOR TWO SBA SELECTED)A. SERVICE WITH AIR RELEASE (AIR VENT)
A1 TIMER TA2 START AUTO (START + 0 SEC)
A2V – 1122, 2122 OPEN
AUTO (START + 0 SEC)V – 1132, 2132 OPEN
A3
DGWTP – 1101A/B/C ANY TWO SELECTED
ON 13,(14&15),12,16,34
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TB2 START AUTO (TA2 + 0 SEC)
B2V-1122, 2122 OPEN AUTO (TA2 + 0 SEC) V -1131, 2131 OPEN 61,62
B3 V-1132, 2132 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLEC1 TIMER TC2 START AUTO (TB2 + 0 SEC)
C2V-1122, 2122 OPEN AUTO (TB2 + 0 SEC) V-1130, 2130 OPEN
C3 V-1132, 2132 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2
NO
YES
SERVICE CYCLE COMPLETEMESSAGE COME “ SBA REGNERATION REQUIRE”
Page 29 & 51
IS ELAPSED TIME= TA2?
IS ELAPSED TIME= TB2?
IS ELAPSED TIME= TC2?
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
After completion of cycle all valves will be closed the time (TC2+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any SBA first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 30 & 51
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
MB OPERATION
Page 31 & 51
DATA ACQUISITION AND EVENT LOGGED
F2
SYSTEM START UP- NORMAL MB SERVICE
AUTO MODE
G11
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
OPERATIONAL CHECKS STEPS REMARKS1 COPM. AIR PR > 5 Kg/cm2 LOCAL GAUGE
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSEDSELECT MB SERVICE CYCLE ANY ONE SBA-1001A/B/C SHOULD
BE SELECTED INSERVICE CYCLEA. SERVICE WITH AIR RELEASE (AIR VENT)
A1 TIMER TA START AUTO (START + 0 SEC)V – 1134 OPEN AUTO (START + 0 SEC)
Page 32 & 51
I-5
START SYSTEM
SELECT ONE MB OR TWO MB FROM
MB – 1001A/B/C
TWO MB -1001A/B/C SLECTED
H2
START UP CONDITION : 1) SELECTED DGWTP-1001A/B/C SHOULD BE IN AUTO MODE2) DEGASSER STORAGE TANK DGWST-1001 LEVEL NOT BE LOW – 12(LT-
5001)3) ANY ONE SBA-1001A/B/C TO BE IN SERVICE MODE.4) IDMWST TANK, SELECTED IN FILLING MODE, LEVEL NOT HIGH
H1
ONE MB A/B/C SLECTED FOR OPERATION
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
A2 V – 1145 OPEN
A3DGWTP – 1101A/B/C ANY ONE SELECTED
ON 13,(14&15),12,16,34AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TB START AUTO (TA + 0 SEC)
B2V-1134 OPEN AUTO (TA + 0 SEC) V -1144 OPEN 61,62
B3 V-1145 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLEC1 TIMER TC START AUTO (TB + 0 SEC)
C2
V-1134 OPEN
AUTO (TB + 0 SEC) V-1143 OPEN H3V-5197 OPEN 35V-5243 /5244/5245 (SELECT DMWST-1001A/B/C TANK)
OPEN 35,56,57,58
C3 V-1144 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2
NO
YESSERVICE CYCLE COMPLETEAfter completion of cycle all valves will be closed the time (TC+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any MB first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves”
Page 33 & 51
H1
IS ELAPSED TIME= TA?
IS ELAPSED TIME= TB?
IS ELAPSED TIME= TB?
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Page 34 & 51
J11
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
NO
Page 35 & 51
CHECK : (1)TOTALISED FLOW THRU MB EXCEEDS THE PRESET VALUE. FT-1101(23), FT-2101(24), FT-3101(25)(2)MB OUTLET SILICA EXCEEDS THE PRESET LIMIT. SIA-1101-1(32), SIA-1101-1(33), SIA-1101-1(34)(2)MB OUTLET CONDUCTIVITY EXCEEDS THE PRESET LIMIT. CA-1102(29), CA-2102(30), CA-3102(31)
J1
J11
H3
GO TO INTERLOCK 23,24,25,32,33,34,29,30,31 STOP MB-1001A/B/C SERVICE CYCLE AND PARTICULAR MB-
1001A/B/C COME IN ISOLATION MODE – ALL CYCLE OPERATION STOP.
MESSAGE COME MB-1001A/B/C REGNERATION REQUIRE.
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
MB REGENERATION
REMARKS
Page 36 & 51
PRE CONDITIONS FOR MB REGANERATION:1)Degasser water storage tank level should not be low. LT-5001 (12)
2)Degasser water pumps should be in auto.3)Regeneration pumps should be in auto4) Both N-Pit level should not be high. LS-5011(61), LS-5012(62)5)Selected MB-1001A/B/C CDT – 2001A/B level should be high LS-5009 (76) , LS-5010 (78)
6)Selected MB AMT -2001A/B level should be high LS-5003 (68) , LS-5004 (70)
5) One SBA -1001A/B/C should be in service. Incase one stream is in operation then both SBAs should be in service.7)Another MB shold not be in regeneration.
J1
SELECT ONLY ONE MB FROM 1001 A/B/C
J2
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
START : ALL AUTO VALVES ARE CLOSEDSELECT MB REGENERATION A. AIR RELEASE (AIR VENT)
A1 TIMER TA START AUTO (START + 0 SEC)
A2V – 1134 OPEN
AUTO (START + 0 SEC)V – 1145 OPEN 61,62
A3
DGWTPP – 1101A/B/C ANY ONE SELECTED
ON 13,(14&15),12,16,34
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. BACKWASH
B1 TIMER TB START AUTO (TA + 0 SEC)
B2V-1141 OPEN AUTO (TA + 0 SEC) V -1135 OPEN 61,62
B3V-1134 CLOSE AUTO (STEP B2 + 3 SEC)V-1145 CLOSE
STEP B2
NO
YES BACKWASH COMPLETEC. MIDDLE COLLECTOR FLUSHC1 TIMER TC START AUTO (TB + 0 SEC)
C2V-1135 OPEN 61,62 AUTO (TB + 0 SEC) V-1138 OPEN
C3 V-1141 CLOSE AUTO (STEP C2 + 3 SEC) STEP C2 NO NO
YES
STEP E2
MIDDLE COLLECTOR FLUSH COMPLETE
D. ACID PRE INJECTIOND1 TIMER TD START AUTO (TC + 0 SEC)D2 V-1144 OPEN 61,62 AUTO (TC + 0 SEC)
Page 37 & 51
IS ELAPSED TIME= TB?
IS ELAPSED TIME =TA?
IS ELAPSED TIME= TC?
J2
J3
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
V-5073 OR 5074 OPEN (SELECTED AMT TANK2001A/B) V-1137 OPEN V-1136 OPEN
D3V-1135 CLOSE AUTO (STEP D2 + 3
SEC)V-1138 CLOSE
D4RWP – 1001A/B ANY ONE SELECTED
ON56,57,58AUTO (STEP D2 + 7 SEC)
STEP D2
NO YES
ACID PRE INJECTION COMPLETEE. ACID INJECTIONE1 TIMER TE START AUTO (TD + 0 SEC)
E2
V-1144 OPEN 61,62
AUTO (TD + 0 SEC)V-5073 OR 5074 OPEN 67,69(SEL. AMT-2001A/B)
V-1137 OPENV-1136 OPENV-5377 OR 5078 OPEN 67,69
STEP E2
NO
YES
YES
Page 38 & 51
ACID INJECTION COMPLETEF. ACID SLOW RINSE (PRE INJECTION)F1 TIMER TF START AUTO (TE + 0 SEC)
F2
V-1144 OPEN 61,62
AUTO (TE + 0 SEC)V-5073 OR 5074 OPENV-1137 OPENV-1136 OPEN
F3V-1135 CLOSE AUTO (STEP F2 + 3
SEC)V-1138 CLOSE
F4
RWP – 1001A/B ANY ONE SELECTED
ON56,57,58AUTO (STEP F2 + 7 SEC)
IS ELAPSED TIME=TE? OR LS5003 OR 5004 WHICH IS SELECTED 67 OR 69WHICH IS EARLIER
IS ELAPSED TIME=TD?
J3
J4
J4
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
STEP F2 NO
YES
STEP G2
SLOW RINSE COMPLETECAUSTIC PRE INJECTIONG1 TIMER TG START AUTO (TF + 0 SEC)
G2
V-5172 OR 5173 OPEN
AUTO (TF + 0 SEC)V-1146 OPENV-1140 OPENV-1139 OPEN 61,62
G3
V-1144 CLOSEAUTO (STEP G2 + 3 SEC)
V-5073 OR 5074 CLOSEV-1137 CLOSEV-1136 CLOSE
NO
YES
STEP H2CAUSTIC PRE INJECTION COMPLETEH.CAUSTIC INJECTIONH1 TIMER TH START AUTO (TG + 0 SEC)
Page 39 & 51
IS ELAPSED TIME=TF?
IS ELAPSED TIME=TG?
IS ELAPSED TIME=TH?
IS ELAPSED TIME=TF?
J5
J5
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
H2
V-5172 OR 5173 OPEN 71,73
AUTO (TG + 0 SEC)V-1146 OPENV-5160 OR 5165 OPEN 71,73V-1140 OPENV-1139 OPEN 61,62
NO YES STEP I2
CAUSTIC INJECTION COMPLETEI .CAUSTIC SLOW RINSEI1 TIMER TI START AUTO (TH + 0 SEC)
I2
V-5172 OR 5173 OPEN
AUTO (TH + 0 SEC)V-1146 OPENV-1140 OPENV-1139 OPEN 61,62
I3
V-1144 CLOSEAUTO (STEP H2 + 3 SEC)
V-5073 OR 5074 CLOSEV-1137 CLOSEV-1136 CLOSE
NO
YES
CAUSTIC SLOW RINSE COMPLETEJ . DRAIN DOWN MINUTESJ1 TIMER TJ START AUTO (TI + 0 SEC)
J2V-1135 OPEN 61,62
AUTO (TI + 0 SEC)V-1144 OPEN 61,62V-1145 OPEN 61,62
J3V-1146 CLOSE
AUTO (STEP J2 + 3 SEC)
V-5172 OR 5173 CLOSEV-1139 CLOSE
J4 DGWTP-1001-A/B/C OFF AUTO (TI + 0 SEC)J5 RWP-1001-A/B OFF AUTO (TI + 0 SEC)
STEP J2
NO
Page 40 & 51
IS ELAPSED TIME=TG?
IS ELAPSED TIME=TI?
IS ELAPSED TIME=TJ?
J5J5
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
YES
STEP K2 DRAIN DOWN MINUTES COMPLETEK . AIR MIXINGK1 TIMER TK START AUTO (TJ + 0 SEC)
K2V-1135 OPEN 61,62
AUTO (TJI + 0 SEC)V-1142 OPENV-1145 OPEN 61,62
K3 V-1144 CLOSEAUTO (STEP K2 + 3 SEC)
K4MBB-A/B SELECTED ONE
ONAUTO (TK + 0 SEC)
NO
YES STEP L2
AIR MIXING COMPLETEL . FINAL RINSE (FACILITY PROVIDED FOR OPERATOR TO GO FOR REPEATED RINSE CYCLE BY SELECTING EXTRA RINSE CYCLE BY SELECTING EXTRA RINSE SOFT PB.)L1 TIMER TL START AUTO (TK+ 0 SEC)
L2V-1134 OPEN
AUTO (TK + 0 SEC)V-1144 OPEN 61,62
L3V-1135 CLOSE AUTO (STEP L2 + 3
SEC)V-1145 CLOSEL4 MBB-A/B OFF AUTO (TK + 0 SEC)
NO
YES
FINAL RINSE COMPLETE
Page 41 & 51
IS ELAPSED TIME=TK?
IS ELAPSED TIME=TL?
J6
J6
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
After completion of cycle all valves will be closed the time (TL+3)seconds.All timers are settable and operator can set the time.If regeneration cycle timer stopped due to any reason reganeration cycle timer will pause but not reset.Operator has to reset Manually. In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves”
AUTO OPERATION STEPS REMARKSSTART : ALL AUTO VALVES ARE CLOSEDSELECT MB SERVICE CYCLE (FOR TWO MB 1001 A/B /C SELECTED)
ANY TWO SBA -1001A/B /C SHOULD BE IN SERVICE
A. SERVICE WITH AIR RELEASE (AIR VENT)A1 TIMER TA START AUTO (START + 0 SEC)
A2V – 1134, 2134 OPEN
AUTO (START + 0 SEC)V – 1145, 2145 OPEN 61,62
A3
DGWTP – 1101A/B/C ANY TWO SELECTED
ON 13,(14&15),12,16,34
AUTO (STEP A2 + 7 SECS)
STEP A2
NO
YESSERVICE WITH AIR VENT COMPLETEB. PRE SERVICE RINSE (FAST RINSE)
B1 TIMER TB START AUTO (TA + 0 SEC)
B2V-1134, 2134 OPEN AUTO (TA + 0 SEC) V -1144, 2144 OPEN 61,62
B3 V-1145, 2145 CLOSE AUTO (STEP B2 + 3 SEC) STEP B2
NO
YES PRE SERVICE RINSE COMPLETE.C. SERVICE CYCLEC1 TIMER TC START AUTO (TB + 0 SEC)
C2
V-1134, 2134 OPEN
AUTO (TB + 0 SEC)
V-1143, 2143 OPEN H3V-5197 OPEN 35V-5243 / 5244/ 5245 (SELECTED DMWST – 1001A/B/C TANK)
OPEN 35,56,57,58
C3 V-1144, 2144 CLOSE AUTO (STEP C2 + 3 SEC)
Page 42 & 51
IS ELAPSED TIME= TA?
IS ELAPSED TIME= TB?
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
STEP C2
NO YESSERVICE CYCLE COMPLETEAfter completion of cycle all valves will be closed the time (TC+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually.If after tripping any MB first service with air – vent done and then service cycle . In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
Page 43 & 51
H2
IS ELAPSED TIME= TC?
J11
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
ACID AND CAUSTIC HANDLING AREA:
Page 44 & 51
AUTO MODE MANUAL MODE
START BY SOFT BUTTON
AUP-1001A/B ORCUP-1001A/B
(53,
CHECK THE LEVEL IN BCST-1001A/B AND BAST-1001A/B
LT-5008 (48,49), LT-5009 (50.51),
LT-5006 (52,53), LT-5007 (54,55),
CHECK LOW LEVEL IN BCST-1001A/B 52,54,48,50
START MANUALLY FROM DCS AUP/CUP – 1001A/B 53,55,49,51
ACID / CAUSTIC HANDLING
LEVEL LOW?
48,50,52,54
LEVEL HIGH?
49,51,53,55
DATA ACQUISITION AND EVENT LOGGED
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
FILLING OPERATION OF AMT-FOR SAC AND MB :
Page 45 & 51
CHECK THE LEVEL IN AMT FOR SAC/ MB
AMT FOR SAC-1001A/B (63,64,65,66)
AMT FOR MB-2001A/B (67,68,69,70) LEVEL STATUS WILL
COME ON DISPLAY
LEVEL LOW?
(63,65,67,69)
LEVEL HIGH?
(64,66,68,70)
START THE PUMP FROM AUP-1001A/B OR
CUP-1001A/B
DON’T START THE PUMP FROM AUP-1001A/B OR
CUP-1001A/B
MSG WILL COME ON DISPLAY FOR STARTING THE
AUP/CUP PUMPS
AUTO MODE FOR AMT 1001 1/ & AMT-2001A/B
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
FILLING OPERATION OF CDT-SBA AND MB :
Page 46 & 51
CHECK THE LEVEL IN CDT FOR SBA/ MB
CDT FOR SBA-1001A/B (71,72,73,74)
CDT FOR MB-2001A/B (75,76,77,78) LEVEL STATUS WILL
COME ON DISPLAY
LEVEL LOW?
(71,73,75,77)LEVEL HIGH?
(72,74,76,78)
ABLE TO START ACID INJECTION CYCLE FOR
PARTICULAR VESSEL BY OPENING THE ACID INLET
VALVE
STOP ACID INJECTION CYCLE FOR PARTICULAR VESSEL BY CLOSING THE
ACID INLET VALVE
AUTO MODE CDT-1001A/B & CDT-2001A/B
START FILLING FOR PARTICULAR VESSEL BY OPENING THE
PARTICULAR WATER INLET AND CAUSTIC INLET VALVE
STOP FILLING FOR PARTICULAR VESSEL BY CLOSING THE
PARTICULAR WATER INLET AND CAUSTIC INLET VALVE
START AGITATOR AND RUN IT FOR 15 MINUTES AND AFTER STOP IT.ALSO CHECK (71,73,75,77)
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
UF OPERATION :
STEP A2SELECT ANY ONE FROM UF-2101A/B FOR SERVICE CYCLEALL VALVE ARE CLOSED
IF UF-2101A SELECTED
A. INITIAL FAST FLUSHA1 TIMER TA START AUTO (START+ 0 SEC)
A2
V-5218 OPEN 92
AUTO (START + 0 SEC)V-5216 OPEN 37 (IF V-5217 38)V-5199 OPEN V-5220 OPEN
A3 UFFP-1001A/B START 36,35,56,57,58,37,38AUTO (STEP A2 + 7 SEC)
NO
Page 47 & 51
AUTO – U1
START UF NORMAL MODE
IS ELAPSED TIME=TA?
Starting Condition : 1) Overload feed back available for UFFP :-1001A/B2) Intermediate DM water storage tank level should not be low ( LT-5002)(35)3) Selected DM water storage tank level should not be high ( LT-5003 – 56,LT-5004 – 57,LT-5005 – 58)4) Select UFFP-1001 A/B IN Manual or Auto mode and select any one pump and any one UF 5) Select any one UF-1001A/B FOR OPERATION6) Select any one BST-1001 A/B for operation
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
YES
STEP B2INITIAL FAST FLUSH COMPLETE
B. SERVICE CYCLE : SELECT ANY ONE UF -2101A/B FOR SERVICE CYCLE
SELECT DM WATER STORAGE TANK DMWST-1001A/B/C
B1 TIMER TB START AUTO (TA+ 0 SEC)
B2
V-5218 OPEN 92
AUTO (TA + 0 SEC)V-5221 OPEN 56,57,58,39(40)
V-5243OPEN 56 (if V-5244 57,IF V-5245)
B3 V-5220 CLOSE AUTO (STEP B2 + 3 SEC)
NO
YES STEP C2
SERVICE COMPLETE , GO TO UF BACKWASH CYCLE.IF FLOW IS = TOTAL FLOW THEN ALSO BACK WASH CYCLE REQUIRE
C. BACKWASH :
C1TIMER TC (UF B/W FIRST HALF CYCLE)
START AUTO (TB+0SEC)
C2V-5220 OPEN
AUTO (TB+ 0 SEC)V-5219 OPEN
C3V-5218 CLOSE
AUTO (STEP C2 + 3 SEC)V-5221 CLOSE
Page 48 & 51
IS ELAPSED TIME=TA?
IS ELAPSED TIME=TB?
U2
U2
DATA ACQUISITION AND EVENT LOGGED
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
C4 UFFP-1001A/B OFF AUTO (TB + 0 SEC)C5 UFBP-1001A/B ON 56,57,58,41 AUTO (STEP C2 + 7 SEC)
B/W FIRST HALF COMPLETED NO
YES
STEP C6B/W FIRST HALF COMPLETED
H1TIMER H1 (UF B/W SECOND HALF CYCLE)
START AUTO (TC+ 0 SEC)
C6 DP-1001A/B (SELECTED) ON 43 AUTO ( TC + 0 SEC)C7 DP-1001C/D (SELECTED) ON 44 AUTO (TC + 0 SEC)C8 DP-1001E/F (SELECTED) ON 45 AUTO (TC + 0 SEC)
NO
YES STEP D1
D. FAST FLUSHD1 TIMER TD START AUTO (TH1+ 0 SEC)
D2
V-5218 OPEN 92
AUTO (START + 0 SEC)V-5199 OPEN
V- 5216OPEN 37 (IF V-5217 38)
V-5220 OPEN
D3
V-5220 CLOSE
AUTO (D2+ 3 SEC)
V-5219 CLOSEDP-1001A/B (SELECTED) STOPEDP-1001C/D (SELECTED) STOPEDP-1001E/F (SELECTED) STOPEUFBP-1001A/B STOPE
D4 UFFP-1001A/B START 36,35,56,57,58,37,38,
AUTO (STEP D2 + 7 SEC)
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IS ELAPSED TIME=TH1?
IS ELAPSED TIME=TD?
IS ELAPSED TIME=TC?
U3
U3
CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
NO
YES
FAST FLUSH COMPLETE UF B/W CYCLE COMPLETEAfter completion of cycle all valves will be closed the time (TD+3)seconds.All timers are settable and operator can set the time.If service cycle timer stopped due to any reason service cycle timer will pause but not reset.Operator has to reset Manually. In every cycle the valves are closed as per sequence only after 3 seconds of the “opening of next cycle valves
NOTE : 1)IN DMWST-1001A/B/C TANK FOR LOW LEVEL IN SELECTED
TANK ,MESSAGE WILL COME ON DISPLAY OF SCADA FOR SELECTION CHANGE OVER TO OTHER TANK,IF CHANGE OVER SHALL BE NOT DONE WITHIN 10 MIN THEN SELECTED PUMP DGWTP-1001A/B/C(IF IMST-1001 IS HIGH) AND UFFP-1001A/B TRIP.
THIS CHANGE OVER IS MADE AUTOMATICALLY WITHIN 10 MIN.2) AT EVERY STEP CONTROL SYSTEM WILL CHECK FOR THE
REQUIRED DRIVE / VALVE FEEDBACKS. IN CASE ANY OF THE FEED BACK IS NOT RECEIVED WITHIN THE SET TIME, AN OPERATOR ALARM WILL BE RAISED AND THE SERVICE / BACKWASH / FAST FLUSH CYCLE WILL PAUSE. AN OVER RIDE SOFT BUTTON WILL BE PROVIDED FOR THE OPERATOR TO RESET THE ALARM AND CONTINUE WITH THE CYCLE.
3) IF SYSTEM TRIP DURING SERVICE CYCLE THEN SERVICE CYCLE TIMER CYCLE TIMER WILL PAUSE BUT NOT RESET AND AFTER RESTART FIRST SERVICE WITH AIR WENT DONE AND THEN SERVICE CYCLE DONE.
4) IF BACKWASH CYCLE STOPPED DUE TO ANY REASON BACKWASH CYCLE TIMER WILL PAUSE BUT NOT RESET. OPERATOR HAS TO RESET THE TIMER MANUALLY.
5) IN THIS FLOW CHART N-PIT OPERATION NOT INCLUDED.
6) IN MANUAL MODE OF WHOLE SYSTEM ALL PUMP START STOPE DONE BY MANUALLY BY SOFT BUTTON AND ALL THE INTERLOCK COME IN PICTURE.
ALL VALVE OPEN CLOSE DONE WITH ALL THE INTERLOCK BY MANUALLY.
7) IN UF -2101A CYCLE V-5218 VALVE SERIES SELECTED & IN UF-2101B CYCLE V-5223 VALVE SERIES SELECTED
8) THIS LOGIC IS SUBJECT TO SOME CHANGES AS PER SITE CONDITIONS AT TIME OF COMMISSING AND THE TIME OF TESTING.
Prepared By Checked By Approved By
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CONTROL PHILOSOPHY FOR DM+UF PLANT
RAJ WEST POWER LTD.
DOCUMENT NO.
ISSUE.DT 23.03.2008
REV.NO R0
Amit Prajapati Riapl ModiProject Engineer Asst. Manager AGM-Projects
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