Sadelmi Philosophy

PHILOSOPHY OF OPERATION

SADELMI – DEMIN PLANT

HOFUF

2
SECTION ‐ 1
FILTERATION SYSTEM

The plant can be categorized into following four phases.

1. Filtration system
2. First Stage RO
3. Second Stage RO
4. DEMIN

1. FILTRATION SYSTEM:

Description:

In filtration system, there are three filter feed pumps and an Automatic Media
filter.

General operation philosophy of Filtration system:

The pumps feed the filter and the treated water through the filter will flow
towards the first stage RO that is split into two even streams.

The filtration system is comprised of the following.

1. Filter Feed Pumps
2. Automatic Media Filter
3. Filter Backwash Pumps
4. Air Blower
5. Dosing Pump

3
1.1 FILTER FEED PUMPS

There are three Filter‐feed pumps as follows.

Filter Feed pump – 1 / P1001

Filter feed pumps operate in two modes:

1.1‐A Automatic Mode:

The selector switch of each pump on the local control panel should be in Remote
position and HMI Auto position.

Filter feed pumps in Auto mode will be running in two cases.

CASE – I

Filter Feed pumps will run in 2 Duty/ 1 Standby fashion when both the RO first
stage streams are in operation (Service Mode). In case of single stream operation,
there will be 1 filter feed pump duty and the other two will be standby.

Feed pump P1001 is designated for Stream A operation whereas Feed pump 1002
shall be designated for Stream B operation.

Incase of failure of pump for any respective stream, the third pump P1003 will
take over and there will be a trip indication for the faulty pump.

CASE – II

When a filter undergoes backwash, the feed pump 1003 shall be running during
Rinsing.

Interlocks:

a) All filter‐feed pumps will be interlocked with a low level switch in the Raw
Water Tank to keep from dry – running.
b) All filter‐feed pumps will be interlocked with overload signal, as in case of
overload the pump must stop immediately.

4
1.1‐B Manual Mode:

There are two cases in manual mode.

CASE‐I

The pumps can be operated manually either from the control room or the local
station.

From Control Room:

The selector switch is in Remote position on the control panel. The selector
switch for the same pump in the HMI will be in manual. The pump will operate as
long as the switch remains in manual. Incase of overload or low level in the tank,
the pump will stop.

From Local Station:

The selector switch will be in Local position in the control room, and the pump
will operate with start/stop pushbuttons on the local station near by.

TIP: The HMI will sense the operation of the pump in Manual as described above
through the feedback signal to the PLC.

FAULTS AND ALARMS ACKNOWLEDGEMENTS:

1. In case of pump failure during operation for any stream due to overload,
the respective standby pump will automatically take over without stopping
the plant and there will only be a trip indication on the local panel in the
control room. The alarm will be logged.

2. In case, when both streams are continuingly running in auto mode and
more than one pump fails, the fault lamp should be lit and alarm must
annunciate. The system will shutdown, all the valves will close.

5
1.2 AUTOMATIC FILTER

The HMI shall include a separate screen for the filter operation that will have two
modes of operation for the filter.

1.2‐A Automatic Operation:

For Automatic Operation, the filter should be put in Automatic mode from the
HMI Filters Screen with the selector (soft) switch. This will allow the two streams
of 1st Stage RO to operate in complete Auto mode. For any stream, Filter feed
pump and high‐pressure pump should also be in Auto position from the HMI and
Remote position from the MCC.

1.2‐B Manual Operation (From HMI):

For the manual operation of the Filter, the HMI screen for the Automatic Media
filter shall have soft push buttons for each mode of operation of the filter with
respect to treatment.

In Manual Operation, the filter will be set in Manual mode from the HMI with the
soft switch and the desired function will be initiated e.g. Backwash, service, rinse,
air scour from the soft push buttons.

1.2‐C Modes of Operation

Automatic Filter has six motorized valves:
1. Service Inlet Valve (SIV) VM1001
2. Service Outlet Valve (SOV) VM1002
3. Backwash Inlet Valve (BIV) VM1003
4. Backwash Outlet Valve (BOV) VM1004
5. Rinse Valve (RNV) VM1006
6. Air Scour Valve (ASV) VM1005

6

We can divide the operation sequence of filter into two modes. This automatic
sequence will be applicable only when the soft switch in the HMI screen for the
Automatic Media Filter will be in Automatic operation position.

1. Service Mode:
2. Backwash Mode:
a. Drain
b. Air Scour
c. Backwash
d. Rinse

1.2‐C‐1 SERVICE MODE:

In this mode, Service inlet valve and service outlet valve will open. Where as, all
other valves will be closed.
Service Backwash Backwash
Service Inlet Rinse Air Scour
Outlet Inlet Outlet
OPEN OPEN CLOSE CLOSE CLOSE CLOSE

1.2‐C‐2 BACKWASH MODE: (Total Duration: 25 Minutes)

The filters will be backwashed once the differential pressure switch closes to
confirm the difference in pressure between the filter inlet and outlet point.
Once the system is in backwash mode, the filter will further go into following four
steps.
7

Step –1

DRAIN: (Duration: 3 Minutes)

In this mode, Backwash outlet valve and rinse valve will open. Where as, all other
valves will be closed.
Outlet Inlet Outlet
CLOSE CLOSE CLOSE OPEN OPEN CLOSE

Step –2

AIR SCOUR: (Duration: 3 Minutes)

In this mode, Backwash Outlet valve and Air Scour valve will open. Where as, all
other valves will be closed. Air blower shall also run.
Outlet Inlet Outlet
CLOSE CLOSE CLOSE OPEN CLOSE OPEN
*See Air Blower.

Step – 3

BACKWASH: (Duration: 14 Minutes)

In this mode, Backwash inlet valve and Backwash outlet valve will open. Where
as, all other valves will be closed.
Outlet Inlet Outlet
CLOSE CLOSE OPEN OPEN CLOSE CLOSE
* See Filter Backwash Pumps.
Backwash pump must run in the duration of step – 3 (backwash).

8
Step – 4

RINSE: (Duration: 5 Minutes)

In this mode, Service inlet valve and Rinse valve will open. Where as, all other
valves will be closed.
Outlet Inlet Outlet
OPEN CLOSE CLOSE CLOSE OPEN CLOSE

During rinse, the filter feed pump as assigned by the present changeover
sequence will run.

As soon as Rinse finishes the filters will go back to normal (Service) mode.

1.2‐D PROVISION OF MANUAL BACKWASH FROM HMI:

The manual backwash from HMI system will be carried out as follows:

The filter should be switched to Manual mode from the soft switch in the HMI
Screen.

The soft‐switch for manual backwash in the SCADA will get the filter and RO
stream out from service mode.

There will be soft‐pushbuttons for Drain, Air scour, Backwash and rinse in SCADA.

During Rinse (Step –4) and Backwash (Step –3) in manual mode, the required
pumps will also start/stop manually from the HMI.


There is an open/close (built in limit switch) feedback fed from each valve to the
PLC. Every time the valve opens or closes, the limit switch should give feedback
within the preset time. Incase of failure of any valve there will be an alarm in the
HMI and the system will go out of service. The Alarm screen will flash the faulty
valve. The alarm must be acknowledged and cleared before the system goes back
to service again.
9
1.3 FILTER BACKWASH PUMPS

There are two Filter‐backwash pumps as follows.

Filter Backwash pump – 1 / P1004
Filter Backwash pump – 2 / P1005

Filter‐backwash pumps operate in two modes:


The selector switch of each pump on the control panel should be in Remote

Filter backwash pumps will run when the filter is in Backwash Mode (Step –3
Backwash).

Backwash pump will operate in One duty / 1 standby fashion.

Interlocks:

a. All backwash pumps will be interlocked with a low level switch in the
Backwash tank to keep from dry – running.
b. Each backwash pump will be interlocked with overload signal, as in case of



CASE‐I

station.

From Control Room:

The selector switch is in Remote position on the local control panel. The selector
10
the pump will stop.

From Local Station:

will operate with start/stop pushbuttons on the local station.



1. In case of pump failure during operation due to overload or no feedback
signal the standby pump will automatically take over without stopping the
sequence and there will only be a trip indication on the local panel in the
control room. Alarm will be logged.

11
1.4 AIR BLOWER:

There are two Air Blowers as follows.

Air Blower / AB3001

Air blower operates in two modes:

1. Automatic Mode
2. Manual Mode


The selector switch on the control panel should be in Remote position and HMI
Auto position.

Air blower will run when a filter is in Backwash Mode (Step –2 Air Scour).

In case of failure of the air blower during operation due to overload or by
emergency stop. Alarm will annunciate and the fault lamp shall be lit.

Interlocks:

a. The air blowers will be interlocked with overload signal, as in case of
overload the blower must stop immediately.



CASE‐I

The blowers can be operated manually either from the control room or the local
station.

From Control Room:

The selector switch is in Remote position on the local control panel. The selector
switch for the same blower in the HMI will be in manual. The blower will operate
as long as the switch remains in manual. Incase of overload the blower will stop.
12
From Local Station:

will operate with start/stop pushbuttons on the local station.

TIP: The HMI system will sense the operation of the blower in Manual as
described above through the feedback signal to the PLC.


1. In case of blower failure during operation due to overload or no feedback
signal, there will only be a trip indication on the local panel in the control
room. The alarm must annunciate.

13

SECTION ‐ 2
DOSING PUMPS

2.1 Operation Modes:
Dosing pumps shall have a separate HMI screen with respective Auto off Manual
Soft switches to allow both Auto and Manual operation modes.

Dosing pumps will operate according to the following philosophy.

1. Pre‐chlorination
2. De‐chlorination
3. Acid
4. Antiscalant

2.2 Pre‐chlorination Dosing Pump:

The pre‐chlorination dosing pump in Auto mode (HMI Soft Switch) and Remote
from the dosing pump control panel will always be interlocked with the filter feed
pumps auto operation. Whereas in case feed pumps are running in manual, the
dosing pump should also be operated in manual in the same way from the HMI
soft switch.

2.3 De‐chlorination & Antiscalant dosing pumps:

Following cases shall be considered for the operation of De‐chlorination &
Antiscalant dosing pumps.

2.3‐A Case‐1

The de‐chlorination and Antiscalant dosing pumps in Auto mode (HMI Soft
Switch) and Remote from the dosing pump control panel will always be
interlocked with the high pressure pump Auto operation in the respective
stream.
14
2.3‐B Case‐2

The de‐chlorination dosing pump in Auto mode (HMI Soft Switch) and Remote
from the dosing pump control panel will always be interlocked with the Auto
operation of the filter feed pumps while the startup flushing or shutdown
flushing (details will follow in the next chapter) of the respective RO streams is
underway.

Whereas in case high pressure pumps are running in manual, the dosing pumps
should also be operated in manual in the same way from the HMI soft switch.

* For case‐II, the Antiscalant dosing pump will not be considered.

2.4 Acid dosing pumps:

Acid dosing pumps in Auto mode (HMI Soft Switch) and Remote from the dosing
pump control panel will always be interlocked with the Auto operation of the
high pressure pump of the respective stream.

Whereas in case high pressure pumps are running in manual, the dosing pumps
should also be operated in manual in the same way from the HMI soft switch.
15

SECTION – 3
FIRST PASS RO STREAMS

3.1 STAGES OF OPERATION:

The RO sequence can be broken down to three stages considering startup till
shutdown as below:

1. Startup flushing
2. Service
3. Shutdown flushing

The RO system consists of two streams and each includes following automatic
components.

1. De‐chlorination dosing Pump (As described in previous Section)
2. Antiscalant Dosing pump (As described in previous Section)
3. Acid dosing pump (As described in previous Section)
4. High Pressure Pump / P1006A , P1007B
5. Feed Motorized Valve / VM1007A, VM1010B
6. Dump Motorized Valve / VM1008A, VM1011B
7. Flush Motorized Valve / VM1009A, VM1012B
8. 1st Pass Break Tank Level Switch / LS2001

3.2 GENERAL OPERATION PHILOSOPHY OF RO SYSTEM:

For the normal operation, the Filter Feed pumps are put in auto mode (HMI SOFT
SWITCHES) and Remote position on the control panel, the High‐Pressure Pump is
also put in auto (HMI SOFT SWITCH) and remote on the control panel, Feed line
Motorized valve, Flush Line Motorized Valve are ready to receive open signal
and the unit will go in operation.
16

3.2‐A STARTUP FLUSHING

At first, startup flushing occurs for preset time duration (2 min) considering
adequate pressure built up before the system goes to service.
In startup flushing, only feed pumps run, de‐chlorination dosing pumps will inject
SBS, feed line and flush‐motorized valves are open.

3.2‐B SERVICE

After startup flushing, the unit goes into Service. High‐pressure pump starts.
Antiscalant and Acid dosing initiates whereas the de‐chlorination continuingly
remains active. Flush Motorized valve closes.

3.2‐C SHUTDOWN FLUSHING

Thus, the system in service keeps topping up the 1st Pass Break tank until the high
level is reached. At this moment when the tank is topped up fully as limited by
the level switch, the unit goes into Shutdown Flushing.

During shutdown flushing the high‐pressure pump stops. Acid and Antiscalant
dosing shall be inactive. Feed pump for the respective stream will run
continuingly whereas the flush motorized valve will open again. The unit
undergoes shutdown flushing for the preset duration (e.g. 4 minutes). After the
shutdown flushing the system is ideal until the 1st Pass Break tank (Product tank)
level goes down to a preset level.

3.2‐D FAULT SHUTDOWN

Fault shutdown occurs in the following three conditions:
a) Very Low/High Pressure

When the pressure in the system is below the low‐pressure set point or
above the high‐pressure set point the system will shutdown right away
with the fault indication and alarm without shutdown flushing. Feed
pumps, High‐pressure pump and all the dosing pumps will stop.
17

b) HIGH ORP

When the ORP value reaches the upper limit (Preset 375mV), the system
will immediately shutdown without shutdown flushing, dump motorized
valve will open whereas, feed pumps, high pressure pump and dosing
pumps will stop. The feed line Motorized valve closes. There is an alarm
with fault indication.
c) Low level Feed Tank

Incase there is low level (20 %) in the Raw Water Tank, the whole system
stops immediately without shutdown flushing with Fault Indication and
Alarm.

3.2‐E ALARM

Generated Alarm is going to be logged in the HMI system. The nature of
alarm can also be interpreted from relative parameters.
18
3.3 HIGH PRESSURE PUMP

There is one high‐pressure pump in each stream as follows.

High Pressure Pump – Stream A / P1006A
High Pressure Pump – Stream B / P1007B

High Pressure pumps operate in two modes:


The selector switch of the pump on the local control panel should be in Remote

Interlocks:

a) High Pressure pump will be interlocked with the filter feed pump
operation as the filter feed pump must be running when the high pressure
pump is in operation.
b) The high‐pressure pump will be interlocked with overload signal, as in case
of overload the pump must stop immediately.



CASE‐I

station.

From Control Room:

the pump will stop.
19
From Local Station:




a) In case of pump failure during operation for any stream due to overload,
the respective pump must immediately stop and the stream will be out of
service with alarm and fault indication.

b) The alarm must be acknowledged and Reset in order to bring the system
back in operation.
20
SECTION – 4
SECOND PASS RO STREAMS
4.1 GENERAL DESCRIPTION:

The second pass RO operates when the high‐pressure pump is in Auto mode
(HMI Soft switch) and the Flush motorized valve is ready to operate automatically
for the respective stream.

The Second pass RO consists of following automatic components.

1. High Pressure Pumps / P2001A, P2002B
2. Flush Motorized Valve / VM2001A, VM2002B
3. Mixed Bed Feed Tank Level Switch / LS3001

4.1‐A STARTUP

Every time the unit starts, the flushing motorized valve will open for 2 minutes
startup flushing where as the high pressure pump will remain stopped. After
startup flushing, flush‐motorized valve will close and the high pressure pump will
start and continue till the Mixed Bed tank is topped up and there is no low level
in the 1st pass break tank or until and unless the high pressure pump is switched
off from the Automatic operation.

4.1‐B SHUTDOWN

There will be two cases in the shutdown of the plant as follows.

CASE‐I

When the high‐pressure pump is switched from remote to off position or from
Auto to off position in the HMI, the high‐pressure pump will immediately stop
and the flush motorized opens again for 4 minutes. After 4 minutes the flush‐
motorized valve is closed and the system is ideal.

CASE‐II

The high level is reached in the Mixed bed Tank, the system will undergo the
same shutdown sequence as in Case‐I.
21

4.2 HIGH PRESSURE PUMP

There is one high‐pressure pump in each stream as follows.

High Pressure Pump – Stream A / P2001A
High Pressure Pump – Stream B / P2002B

High Pressure pumps operate in two modes:


The selector switch of the pump on the local control panel should be in Remote

Interlocks:

The high‐pressure pump will be interlocked with overload signal, as in case of



CASE‐I

station.

From Control Room:

the pump will stop.
22
From Local Station:




a) In case of pump failure during operation for any stream due to overload,
the respective pump must immediately stop and the stream will be out of
service with alarm and fault indication.

b) The alarm must be acknowledged and Reset in order to bring the system
back in operation.

4.3 FAULT SHUTDOWN

Fault shutdown occurs in the following three conditions:
a) Very Low/High Pressure

When the pressure in the system is below the low‐pressure set point or
above the high‐pressure set point the system will shutdown right away
with the fault indication and alarm without shutdown flushing. Feed
pumps, High‐pressure pump and all the dosing pumps will stop.

b) Low level Feed Tank

Incase there is low level (20 %) in the 1st Pass Break Tank, the whole
system stops immediately without shutdown flushing with Fault Indication
and Alarm.

3.2‐E ALARM

Generated Alarm is going to be logged in the HMI system. The nature of alarm
can also be interpreted from relative parameters.
23

Sadelmi Philosophy

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sadelmi Philosophy

Uploaded by

Copyright:

Available Formats

OPEN OPEN CLOSE CLOSE CLOSE CLOSE

CLOSE CLOSE CLOSE OPEN OPEN CLOSE

CLOSE CLOSE CLOSE OPEN CLOSE OPEN

CLOSE CLOSE OPEN OPEN CLOSE CLOSE

OPEN CLOSE CLOSE CLOSE OPEN CLOSE

You might also like