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


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

Page 2 & 51

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


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 ?


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

Page 4 & 51

DATA ACQUISITION & EVENT LOGGED

A1


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


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


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

Page 6 & 51

IS ELAPSED TIME = TA1 ?

IS ELAPSED TIME = TB1 ?

IS ELAPSED TIME = TC1 ?


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 ?


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


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


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

SAC OPERATION :


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


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


A3


ON 1,2,(3&4),12,5


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

Page 11 & 51

IS ELAPSED TIME= TF?

IS ELAPSED TIME= TG?

IS ELAPSED TIME= TH?


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


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

Page 13 & 51

D1

C11



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.


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

SAC REGENERATION

Page 15 & 51

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


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


A3


ON 1,2,(3&4),12,5


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

Page 16 & 51

IS ELAPSED TIME= TJ?

IS ELAPSED TIME =TI?

IS ELAPSED TIME= TK?

E2

E3


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


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?



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


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?


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

Page 20 & 51


C11


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

SBA OPERATION


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


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


STEP A2

NO


B1 TIMER TQ START AUTO (TP + 0 SEC)

B2V-1122 OPEN AUTO (TP + 0 SEC) V -1131 OPEN 61,62


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?


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


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



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


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


A3

DGWTPP – 1101A/B/C ANY ONE SELECTED

ON 13,(14&15),12,16,34


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


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


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

STEP C2 NO NO

YES


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


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)


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


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


STEP A2

NO


B1 TIMER TB2 START AUTO (TA2 + 0 SEC)

B2V-1122, 2122 OPEN AUTO (TA2 + 0 SEC) V -1131, 2131 OPEN 61,62


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?



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


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

MB OPERATION

Page 31 & 51


F2

SYSTEM START UP- NORMAL MB SERVICE

AUTO MODE

G11


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


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


B1 TIMER TB START AUTO (TA + 0 SEC)

B2V-1134 OPEN AUTO (TA + 0 SEC) V -1144 OPEN 61,62


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?



RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

Page 34 & 51

J11



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.


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


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


A3

DGWTPP – 1101A/B/C ANY ONE SELECTED

ON 13,(14&15),12,16,34


STEP A2

NO

YESSERVICE WITH AIR VENT COMPLETEB. BACKWASH


B2V-1141 OPEN AUTO (TA + 0 SEC) V -1135 OPEN 61,62


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


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 =TA?


J2

J3


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


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)


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


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)


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


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


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


STEP A2

NO



B2V-1134, 2134 OPEN AUTO (TA + 0 SEC) V -1144, 2144 OPEN 61,62


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?




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


J11


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




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



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)



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


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



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)

Page 49 & 51

IS ELAPSED TIME=TH1?

IS ELAPSED TIME=TD?

IS ELAPSED TIME=TC?

U3

U3


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

Page 50 & 51


RAJ WEST POWER LTD.

DOCUMENT NO.

ISSUE.DT 23.03.2008

REV.NO R0

Amit Prajapati Riapl ModiProject Engineer Asst. Manager AGM-Projects

Page 51 & 51

Documents

Flow Chart for 1954 Final1