9455 11 PCP 0 0001 - Process Control Philosophy R1

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70 MTPD CAUSTIC SODA &

AL GHAITH CHEMICAL
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CONTROL PHILOSOPHY
&
INTERLOCK DESCRIPTION
Rev. Date Description Originator Reviewer Approver
00 25.01.2023 Issued for Review & Comments S.S N.K S.K.S
01 12.12.2023 Revised as Highlighted S.S N.K S.K.S
This document or pertinent or attached documents remain the property of Nuberg Industries Ltd. or shall neither be partly or fully a reproduced, nor
revealed or brought to the knowledge of others (including competitors) without the written approval of NBIL.
Project: 9455 Page: 1 of 75 Author: Salil Sharma

Client: Al Ghaith Chemical
Doc. No.: 9455-11-PCP-0-0001 Revision: 01
Industrial LLC, Oman
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9455-11-PID-0-0001 (Sheet 1 of 1) REV:04

BRINE SATURATOR AREA (PRIMARY BRINE PURIFICATION AREA)
1. The flow of saturated brine from saturated pump P‐014 A/B is maintained or controlled by
flow control valve FCV‐010 as per set point of FICA‐010. When the level increases above the
set point, control valve opening will increase.
2. The flow transmitter FICA ‐010 gives alarm when it becomes either High (H) or Low (L), an
immediate investigation or preventive action to be taken accordingly.
3. Interlock (I-010)
IF a Low-Low (LL) level detected by LIA-010 in salt saturator.
THEN a motor STOP signal will be sent to salt saturator pump P-014A AND P-014B & it
will stop,
AND a CLOSE signal will be sent to flow control valve FCV-010 & it will close.
4. The level indicator LIA‐010 in D‐011 A/B gives alarm when it becomes either High – High
(HH) or High (H) or Low – Low (LL) or Low (L) an immediate investigation or preventive
action to be taken accordingly.
5. Motor/Drive provision of Start or Stop from DCS shall be provided.

P‐014 A/B ‐ STOP
6. All motors/drives status of running/stop/trip is provided in DCS.
All Interlocks should have bypass switch available on common DCS screen. Or the indicator of by-pass
switch activated or deactivated should be available on each interlock number on each screen.

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9455-11-PID-0-0002 (Sheet 1 of 1) REV: 03

RETURN BRINE (PRIMARY BRINE PURIFICATION AREA)
1. The level indicator LICA‐080 in the Return Brine Tank D‐080 gives alarm when it becomes
either High – High (HH) or High (H) or Low – Low (LL) or Low (L) or an immediate
investigation or preventive action to be taken accordingly.
IF a LOW-LOW (LL) level detected by LICA-080 in return brine tank.
THEN a motor STOP signal will be sent to return brine pump P-084 A AND P-084 B &
it will stop.
IF a motor STOP signal is detected by on both return brine pump P-084 A AND P-084
B.
THEN a CLOSE signal will be sent to steam control valve TCV-083 & it will close.
4. The temperature of the Return Brine is controlled by steam inlet control valve, TCV‐083
which regulates the steam Flow to Return Brine Heater E‐083 as per the set point of TICA‐
083. When temperature increases above set point, valve opening will reduce.
5. The temperature indicator TICA‐083 gives alarm when it becomes either High – High (HH) or
High (H) or Low – Low (LL) or Low (L), an immediate investigation or preventive action to be
taken accordingly.
6. The level of Return Brine Tank D‐080 is maintained by controlling the Flow of Process
Water by Level Control Valve LCV‐080 as per the set point of LICA‐080. When level
increases above set point, valve opening will reduce.
7. The flow transmitter FIA‐080 in return brine line gives alarm when it becomes either High –
High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate investigation or
preventive action to be taken accordingly.
8. The flow transmitter FIA‐081 of DM water line gives alarm when it becomes either High (H)
or Low (L), an immediate investigation or preventive action to be taken accordingly.
9. The flow of return brine to Salt Saturator is controlled by FCV‐080 as per the set point of
either FIC‐ 080 or LIC‐010 (through selector switch)
Flow Controller (FIC‐ 080) ‐ When flow increases above set point the valve opening will reduce.
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Level Controller (LIC‐010) ‐ When level increases above set point, the valve opening will
reduce.
10. The ORP meter AICA-294 gives alarm when it becomes either High - High (HH) or High (H), an

All Interlocks should have bypass switch available on common DCS screen. Or the indicator of by-
pass switch activated or deactivated should be available on each interlock number on each screen.

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9455-11-PID-0-0003 (Sheet 1 of 1) REV: 04

CHEMICAL DOSING (PRIMARY BRINE PURIFICATION AREA)
1. The level indicator LIA‐050 in the Barium Carbonate Tank D‐050 gives alarm when it
becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate
IF a LOW-LOW (LL) level is detected by LIA-050 in Barium Carbonate tank.
THEN a motor STOP signal will be sent to barium carbonate dosing pump P-054 A AND P-
054 B & it will stop,
AND a motor STOP signal will be sent to barium carbonate tank agitator A-052 & it will
stop.
3. The level indicator LIA‐070 in the Soda Ash Tank D‐070 gives alarm when it becomes High –
High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate investigation or
IF a LOW-LOW (LL) level is detected by LIA-070 in soda ash tank.
THEN a motor STOP signal will be sent to soda ash dosing pump P-074 A AND P-074 B &
it will stop,
AND a motor STOP signal will be sent to soda ash tank agitator A-072 & it will stop.

A‐052 ‐ STOP
A‐072 ‐ STOP

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9455-11-PID-0-0004 (Sheet 1 of 1) REV: 03

REACTOR OR FLOCCULANT DOSING
1. The level indicator LIA‐060 in the Flocculants Tank D‐060 gives alarm when it becomes either
High – High (HH) or High (H) or Low (L) or Low - Low (LL) an immediate investigation or
preventive action has to be taken accordingly.
IF a LOW-LOW (LL) signal is detected by LIA-060 in flocculant tank.
THEN a motor STOP signal will be sent to flocculant tank agitator A-062 & it will stop.
3. The temperature indicator TIA‐020 gives alarm when it becomes either High (H) or Low (L)
an immediate investigation or preventive action has to be taken accordingly.

A‐062 ‐ STOP
A‐022 A/B ‐ START & STOP (EMERGENCY POWER)

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9455-11-PID-0-0005 (Sheet 1 of 1) REV: 03

BRINE CLARIFIER (PRIMARY BRINE PURIFICATION AREA)
1. The level indicator LIA‐040 in the Clarified Brine Tank D‐040 gives alarm when it becomes
either High – High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate investigation
or preventive action has to be taken accordingly.
IF a LOW-LOW (LL) signal is detected by LIA-040 in clarified brine tank D-040.
THEN a motor STOP signal will be sent to clarified brine pump P-044 A AND P-044 B & it
will stop.
3. The temperature indicator TIA‐030 A (for water) of the Clarifier gives alarm when it becomes
either High (H) or Low (L) an immediate investigation or preventive action has to be taken
accordingly.
4. The temperature indicator TIA‐030 B (for brine) of the Clarifier gives alarm when it becomes
either High (H) or Low (L) an immediate investigation or preventive action has to be taken
accordingly.
5. Differential Temperature indicator DT‐030 measures the differential temperature of the brine
clarifier. The median of TIA‐030 A & TIA‐030 B value is taken as the measured value.
IF a LOW (L) signal is detected by LSA-030 in clarifier sludge pit PT-030.
THEN a motor STOP signal will be sent to clarifier slurry pump P-033 A AND P-033 B & it
will stop.

A‐032 ‐ START & STOP (EMERGENCY POWER)
switch activated or deactivated should be available on each interlock number on each screen

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9455-11-PID-0-0006 (Sheet 1 of 1) REV: 03

ANTHRACITE FILTER (PRIMARY BRINE PURIFICATION)
1. The level indicator LIA‐110 in the Filtered Brine Tank D‐110 gives Alarm when it becomes
either High – High (HH) or High (H) or Low – Low (LL) or Low (L) or an immediate investigation
or preventive action has to be taken accordingly.
IF a LOW-LOW (LL) level is detected by LIA-110 in filter brine tank D-110.
THEN a motor STOP signal will be sent to filtered brine pump P-114 A AND P-114 B & it
will stop,
AND a CLOSE signal will be sent to polish brine feed control valve FCV-140 A AND FCV-
140 B & it will close.
3. The level in the Filtered Brine Tank D‐110 is maintained by controlling the Flow of brine by
Flow Control Valve FCV‐100 as per the set point of LIA‐110 or as per the set point of FICA‐100.
When flow increases above set point, valve opening will reduce. (through selector switch on
DCS)
Level Control
The flow shall change within minimum & maximum range as per the se point of LIA‐110.
Flow Controller (FICA‐ 100) ‐ When flow increases above set point the valve opening will
reduce. Level Controller (LIA‐110) ‐ When level increases above set point, the valve opening
will reduce.
4. The flow of brine through Filter is controlled by Flow control valve FCV‐100 as per the set
point of FICA‐100. When flow increases above set point valve opening will reduce.
5. The flow transmitter FICA‐100 gives alarm when it becomes either High (H) or Low (L), an
6. The flow of process water / Polish Brine during back wash of Filter is controlled by Flow control
valve FCV‐101 as per the set point of FICA‐101. When flow increases above set point valve
opening will reduce.
7. The flow transmitter FICA‐101 gives alarm when it becomes either High (H) or Low (L), an
8. Differential pressure indicator DPIA-100 A/B gives alarm when it becomes either High- High
(HH) or High (H).

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P‐114 A/B ‐ START & STOP (EMERGENCY POWER)
11. The following documents are to be referred for Anthracite filter backwash & normal running
operation:-
S.NO. Description Annexure No.

1. SEQUENCE LOGIC OPERATION Annexure-1
2. LOGIC TIME CHART Annexure-2
Note:-
1. Every step should have a skip selector so that if it is selected it will skip to the next step.
2. Manual mode if backwash is selected for the filter. It should start backwash from step 1 till step
4.
3. All timings should be adjustable from the screen.

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ANNEXURE-I
Rev. Date Description Originator Reviewer Approver
0 25.01.2023 Issued for Engineering S.S S.K.S S.K.S
This document and pertinent or attached documents remain the property of Nuberg Industries Ltd. and shall neither be partly or fully a
reproduced, nor revealed or brought to the knowledge of others (including competitors) without the written approval of NBIL.

Industrial LLC, Oman Doc. No.: ANNEXURE-1 Revision: 00
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ANTHRACITE FILTER SEQUENCE LOGIC

1.0 FUNCTION AND GENERAL FEATURES
The Sequence of Anthracite filter operation is DCS based.
There are two anthracite filter F-100 A/B. At any time 1 filter are in operation. A particular filter is
backwashed after 24 hours of service. The operation time of the filter concerned is shown in the
DCS graphics.
The filter can be backwashed in the “AUTO” mode or “MANUAL” mode. In the “AUTO” mode, the
operator initiates the backwash, upon which the various operations proceeds automatically, and
finally the operator is given the option to end the operation or repeat the operation. In the
“MANUAL” mode, the operator can open and close each on-off valve are required.
In “AUTO” mode, the backwash of filters follows the order A B. ie. After filter A, filter B is
backwash.
There shall be an indication in the DCS all the time which was the last filter backwashed. For
example “LAST FILTER BACKWASHED-A”.
Precondition for starting the sequence in “AUTO” mode is the level in Polish Brine Tank D-150 - LI-
150 is higher than “H”, indication in DCS “BACKWASH ENABLED”.
The sequence consist of 5 Steps as below:
Isolation
Backwash
Recycle
Normal Operation
Fail Step

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2.0 DESCRIPTION OF PARTICULAR STEPS
The steps are described below in detail for Filter “A”
2.1 Isolation (Step 1)
“Filter A ON BACKWASH” indication appears in the DCS after the filter was selected for
backwashing.
The valve XV 100 A at the inlet closes first. Then after few secs (0-10 sec) valve XV 106 A at
the outlet closes.
The filter is now off line and isolated.
Display will appear on DCS “Start Backwash Pump”. Pump is manually started in field.
Backwash pump will start only if level in Polish brine tank (LI-150) is > H
The program now proceeds to the next step.
2.2 Backwash (Step 2)
On confirmation of pump start from running indication, a watchdog timer T0 (T0 =

adjustable 0-50 min) is started.
This step will proceed only if the Filter wash pump P-141 is running.
The Backwash inlet valve XV 104 A opens after a time delay o 5 seconds. After few secs (0
to 10 secs) of opening XV 104 A, the backwash outlet valve XV 101 A & air inlet valve XV
103 A opens.
Opening of XV 101A starts timer T2 (adjustable 0-30 min).

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After time T2 has elapsed, XV 104 A will close and subsequently XV 101 A & XV 103 A will
also close (after few secs (0 to 10 secs) of XV 104 A closes) and the backwash pump will be
stopped.
Timer T2 is reset to zero.
The program now proceeds to the next step.
If during this step, the backwash pump trips, the program goes to “FAIL” position.
2.3 Recycle (Step 3)
After the Step 2 is over, a small delay is introduced by a timer T3 (adjustable 0-60 secs). At
the end of this time delay, valve XV 105 A on the recycle line opens. Then main inlet valve
XV 100 A gets open after few secs (0 to 10 secs).
This initiates the timer T4 (adjustable 0-10 min).
After this, the indication “CHECK BRINE QUALITY” appears on the screen. The control
room operator has to get confirmation from the field operator on the quality of the brine
at the filter outlet.
When T4 has timed out, valve XV 100 A closes and the valve XV 105 A closes after few
seconds (0 to 10 secs). Now timer T3 & T4 are reset to zero.
In the field operator does not acknowledge a good quality of brine by means of the push
button *******, a new indication “DO YOU WANT TO REPEAT BACKWASH” appears in the
DCS.
If the control room operator answer this “YES”, then the program goes back to Step 2 and
is repeated.

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If the field operator acknowledges a good quality of brine by means of the push button
***** on field, then the program hold in Step 3 and indication “DO YOU WANT TO TAKE
FILTER ‘A’ IN LINE” appears on the DCS.
If the operator answer “YES”, the program proceeds to Step 4.
If the answer is “NO” or if 1 minute time elapses, then the program hold in Step 3 and
“FILTER A BACKWASH OVER” indication appears on the DCS.
On closing of valve XV 105 A watchdog timer T0 is reset. If the watchdog timer runs to
completion, an alarm is initiated and the program goes to “FAIL” position.
2.4 Normal Operation (Step 4)
This step can be initiated by answering “YES” to the question “DO YOU WANT TO TAKE
FILTER IN LINE” at the end of the previous step.
Normally however, the backwashed filter is kept ready to be taken in line when another
filter becomes due for backwash. This is indicated by audio- visual alarm.
For example, in this case an alarm message “DO YOU WANT TO BACK WASH FILTER B”
appears on the screen.
When the operator is answering YES, Step 4 gets underway. In this step, the backwashed
filter (filter A in the example) is first taken in line and then the operating filter (filter B in
the example) is taken off the line.
Taking filter A in line is started with an additional recycle of the filter to ensure a proper
operation of the filter.
First valve XV 105 A on the recycle line opens. After few secs (0 to 10 secs) from this valve
open, the main inlet valve XV 100 A.

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This initiates the timer T4 (adjustable 0-10 min).
After this, the indication “CHECK BRINE QUALITY” appears on the screen. The control
room operator has to get confirmation from the field operator on the quality of brine at
the filter outlet.
When T4 has timed out, valve XV 100 A closes after few sec (0 to 10 secs), valve XV 105 A
closes. Timer T4 is reset to zero.
If the field operator does not acknowledge a good quality of brine by means of the push
button ********, a new indication “DO YOU WANT TP REPEAT BACKWASH” appears in
the DCS.
If the control room operator answer this “YES”, then the program goes back to Step 2 and
is repeated.
If the field operator acknowledges a good quality of brine by means of the push button
******, then the program holds in Step 4 and indication “DO YOU WANT TO TAKE FILTER
A IN LINE” appears on the DCS.
2.4.1 Normal Operation taking the filter in line (Step 4.1)
If the operator answer “YES”, then the valve XV 106 A at the main outlet opens first and
after few secs, the main inlet valve XV 100 A opens. “DO YOU WANT TO TAKE FILTER AIN
LINE” display is cleared. The on-line time counter TS is first reset to zero and then started.
The steps 1 to 4 get underway for Filter B “FILTER B ON BACKWASH” indication comes in
control room.
2.4.2 Normal Operation failure while taking the filter in line (Step 4.2)
If the answer is “NO” or 1 minute time elapses, then the program holds in Step 4 and
“FILTER A RECYCLE OVER” indication appears on the DCS.
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On closing of valve XV 100 A, watchdog timer T0 is reset. If the watchdog timer runs to
completion, an alarm is initiated and the program goes to “FAIL” position.
3.0 INTERLOCK
The program can go to “FAIL” position in “AUTO” mode under the following cases:
Backwash pump or Filter wash pump P-141 trips during Step 2
Watchdog timer T0 runs out before completion of the sequence
If the main power fails
In the FAIL position, all the valves associated with the filter being backwashed go to close
position. An audio- visual alarm sis also initiated.
On acknowledge, “DO YOU WANT TO RESTART” comes. If the answer is “YES”, the program goes
back to the beginning of the step under execution.

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9455-11-PID-0-0007 (Sheet 1 of 2)
CANDLE FILTER (PRIMARY BRINE PURIFICATION AREA)
(Option for Manual & Automatic Operation on DCS Screen)
1. METHOD OF INITIAL START-UP

a) Set F‐140A Operation switch turn “RUN” position. F‐140A Brine filter advances each
step automatically, in turn, from Preparation of Process (Step No.101) or the
following step.
 Liquid Filling 1 (Step No.102)
 Over Flow (Step No.103)
 Liquid Filling 2 (Step No.104)
 Pre-coat tank liquid filling (Step No.105)
The indicator lamp “PRECOAT AID PREPARATION” is indicated. Dose α‐cellulose into pre‐
coat tank Push “PRECOAT AID PREPARATION FINISH” Button Pre‐coat tank carries out
the following steps automatically.
The indicator lamp “BODY FEED AID DOSING” is indicated. Dose α‐cellulose into body feed
tank.
Push “BODY FEED AID DOSED COMPLETION” Button.
 Agitation (Step No.106)
b) After that, F‐140A carries out the following steps automatically.

 Agitation (Step No.301)
 Preparation of Process (Step No.302)
 Mixing (Step No.303)
 Pre‐coating (Step No.304)
 Flow rate change (Step No.305)
 Overlapping (Step No.306)
 Pre‐coat tank liquid discharge (Step No.307)
 Recirculation (Step No.309)
c) Start Feed Brine pump (P‐114 A/B) by manual before Recirculation step (Step No.309).
After F‐140A Brine Filter is in filtration process Step No.401）,

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Set F‐140B Operation switch turn “RUN” position.

F‐140B Brine filter advances each step, automatically as per the Following. Stop‐by mode: F‐
140B keep on the Waiting process (Step No.200) until F‐140A satisfy the filtration finish
condition.
e) When F‐140A satisfy the filtration finish conditions (as follow).
 When the filtration time has reached the setting time.

 When the differential pressure in filtration has reached 2.0 kg/cm2.
 When “FILTRATION FINISH” button has been pushed.
F‐140A advances the washing process or return to preparation of pre-coat process
(Step No.101 ~ 105). Such an operation is repeated in turn.
2. METHOD OF OPERATION STOP

a) Don’t dose α‐cellulose into pre‐coat tank, even if the indicator lamp “PRECOAT
AID PREPARATION” is indicated, after filtration process.
Don’t push “PRECOAT AID PREPARATION FINISH” button.
b) F‐140A advances washing process or return to preparation of pre‐coat process.

After preparation of pre‐coat process, F‐140A keep on waiting process.
c) Set F‐140A Operation switch turn “STOP” position.
d) In an emergency, Operation switch turn “STOP” position immediately. When you start the
operation again, please advance steps to washing process by “MANUAL STEP ADVANCE”
button. In this case, please check that liquid are filled into the filter vessel.
e) If power outage occurs the filter unit simultaneously stops. The filter might cause the
following malfunctions due to the power outage.
 Falling or peeling of pre-coat layer
 Occurrence of clogging of element in serial use after the power recovery
 Deterioration of filtration
Out of the above reasons, when the power is recovered, skip the process with the “MANUAL
STEP ADVANCE” button, perform cleaning, or restart the operation from pre-coat preparation
(Step No.101) process.
3. PROCESS DESCRIPTION FOR BRINE FILTER UNIT
(I) The operation process can be mainly divided into four (4) processes.

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Normally, the following operation in performed, in turn, namely,

Preparation of pre-coat pre-coat Filtration Washing
a) Preparation of pre-coat
Filtrate Brine in the required quantity is filled into filter vessel. This process is
performed immediately after the completion of washing process except for the initial
start. Alfa cellulose in the required quantity is dosed into pre-coat tank.
When “PRECOAT AID PREPARATION FINISH” button has been pushed or the required
time has passed, filtered brine is filled into pre-coat tank or the agitation starts.
b) Pre-coat
Filtered Brine mixed with α‐cellulose is sent into filter vessel. α‐cellulose
powder is attached evenly on the surface of filter elements, the pre-coat layers
with α‐cellulose are formed. The layers contribute to achieve a fine filtration
quality by Preventing filter elements from blinding. The washing efficiency of
filter elements is also increased.
c) Filtration
When saturated brine has passed through pre-coat layers formed on the surface of filter
elements, from upstream side to downstream side, the fine impurities are body feed is
performed during (Step No.309) Recirculation or Filtration.
d) Washing
The impurities attached on α‐cellulose on the surface of filter elements are removed or
washed by sending the clean brine through filter elements from inside to outside
quickly. By washing, filter elements can be restored to the state before the use.
(II) DETAILED PROCESS DESCRIPTION

The explanation about F‐140A Filter is described blow. So, for automatic valve or level switch
number of F‐140B filter, replace A with B.
a) Preparation of pre-coat
1. Preparation of process (Step No.101)
Filter wash pump (P‐141) is started before a Liquid filling process start.
 Setting time: 10 sec.
2. Liquid filling 1 (Step No.102)

To secure pre-coat liquid, filtrate brine is filled into filter up to the required level. Filter wash
pump (P‐141) is started, Washing brine inlet valve (KV‐1406A), Upstream air vent valve (KV‐
1418A, KV 1416A, KV‐1417A), drain valve (KV‐1415) are opened, or the liquid is filled into
filter vessel until its level (LS‐140C) reaches “H”.

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3. Over flow (Step No.103)

Vent the air under the condition of Liquid filling 1 (Step No.102) process.

Upstream air vent valve (KV‐1418A, KV‐1416A, KV‐1417A) or Upstream drain valve (KV‐1415)
are Closed, Washing brine inlet valve (KV‐1406A), Downstream air vent valve (KV‐1408A) is
opened, or THEN liquid is filled into filter vessel until its level (LS‐140A)reaches “HH” for 5 sec.
5. Pre-coat tank liquid filling (Step No.105)

Filter wash pump (P‐141) remains running after 5 sec. KV‐1413 open, KV‐1406 A closed, KV‐
1408 remains open, Pre-coat tank supply valve (KV‐1413) is opened, the liquid filled into
pre-coat tank until its level (LIA‐120) reaches “H”. When level (LIA‐120) has reached “H”,
Pre-coat tank supply valve (KV‐1413) is closed, Filter wash pump (P‐141) is stopped, or the
pre-coat tank filling of liquid is completed. Downstream air vent valve (KV‐1408A) closes.
6. Pre-coat aid dosage

Dose pre-coat aid (α‐cellulose) into the Pre-coat tank or push the “PRECOAT AID
PREPARATION FINISH” button.
7. Agitation (Step No.106)

Pre-coat tank agitator (A‐122)
 Setting time: 10 min A‐122 keeps running.
b) Preparation of pre-coating
1. After 10 sec. of pre-coat preparation, P‐124 will start automatically for 10 sec
2. Mixing (Step No.303)

The mixing aims at making “The liquid mixed with α‐cellulose in pre-coat tank” or “The brine in
filter vessel” circulate concentration. Pre-coat inlet valve (KV‐1403A), FV‐140A with set point ,
Upstream air vent valve (KV‐1418A, 1416A, 1417A), Pre-coat return valve (KV‐1414) are
opened, or the liquid mixed with α‐cellulose, which left Pre-coat tank (D‐120), is returned again
into the Pre-coat tank, via filter vessel upstream side by Pre-coat pump (P‐124).
 Setting flow rate: 35 ㎥/hr.
 Setting time: 10 min.
3. Pre-coating (Step No.304)

After 10 min, KV‐1402 A will open, upstream air vent valve (KV‐1418A, 1416 A, KV‐1417A) will
closed.

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4. Flow rate change (Step No.305)

Pre-coat liquid is returned into Pre-coat tank（D‐120）through filter element, letting pre-
coat layer of α‐cellulose form on the surface of filter element. Change the flow rate from pre-
coat flow rate (35 ㎥/hr.) to design filtration flow rate (27 ㎥/hr.) by flow control system
(FIC‐140A)
Avoid as possible a flow stop or sudden flow change in this process which affect pre-coat layer,
inducing clogging of filter element.
5. Overlapping (Step No.306)

After 5 min KV‐1412 open, rest all the valve in will remain as it is. Overlapping process opens
the valve before or behind a process change simultaneously in order not to stop the flow of
liquid.
 Setting time: 5sec.
6. Pre-coat tank liquid discharge (Step No.307)

In order to retrieve the residual liquid in pre-coat tank (D‐120), open Brine recycle valve (KV‐
1412), close Pre-coat return valve (KV‐1414) in 5 seconds. The residual liquid in the tank is
returned into primary purified brine tank until pre-coat tank level (LIA‐120) lowers below “L”
after LIA‐120 becomes “L”, KV‐1401 will open.

Overlapping process opens the valve before or behind a process change simultaneously in
order not to stop the flow of liquid. Change the flow rate from design filtration flow rate (27㎥
/hr.) to calculated filtration flow rate (F ㎥/hr.) by flow control system (FIC‐140A)
 Setting flow rate: F ㎥/hr. (As required change it or will remain 27 m3/hr.)
8. Recirculation (Step No.309)

With filtrate rather unstable at the beginning of filtration, filtered brine is returned into Feed
brine tank (D‐040). Feed brine inlet valve (KV‐1401A) open, Pre-coat inlet valve (KV‐1403A) &
Pre-coat pump (P‐124) stop, rest valves remain as it is.
 Setting flow rate: F ㎥/hr.
 Setting time : 5 min

If LIA‐150 is less than high then KV‐1404 A will open for 5 sec, otherwise all the valves will
remain as it is till LIA‐150 becomes less than high.
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Overlapping process opens the valve before or behind a process change simultaneously in
order not to stop the flow of liquid.
 Setting flow rate: F ㎥/hr.
c) Filtration
1. Filtration (Step No.401)
When overlapping has been completed, Brine inlet valve (KV‐1401A) and Filtered brine
outlet valve (KV‐1404A) remain open and proceed to filtration process.
2. Conditions of filtration finish

 When the filtration time has reached 48 hours.
 When the differential pressure in filtration has reached 2.0 kg/cm2.
 When “Filtration finish” button has been pushed.
Press filtration finish F‐140 B then KV‐1408 will open, KV‐1401B, KV‐1404 B and8+8 FV‐1401
B will close.
3. Conditions of Recirculation (Step No.411) during filtration

When finish filtered brine tank level (LIA‐150) has reached “H”. But, when another operating
filter is in one of “Preparation of Pre-coat”, “Pre-coat” or “Washing” process, the filter in
Filtration process cannot enter this Recirculation process.
4. Conditions that recirculation return to filtration.

When finish filtered brine tank level (LIA‐150) is less than “H”.
d) Washing
Normally, washing process is repeated in 4 times, or the washing steps to be made each time
are as follows.
Three Upstream air vent valves (KV‐1416A, KV‐1417A, and KV‐1411A) are mounted at the
intervals of 120 degrees. During overflow in 3 times, three valves are opened, one by one, in
turn, at each overflow in order to wash evenly the surface under perforated plate.
1st Washing: Discharge 1
 Draining: ‐Valve KV‐1408 A will remain open or KV‐1418 A, KV‐1416A, KV 1417‐A & KV‐
1415 will open for 60 sec.
 Filling:‐Valve 1418 A, KV‐1416A ,KV 1417 A & KV‐1415 will remains open till the LS140A
becomes H after that Valve KV‐1418 A, KV‐1416A KV 1417‐A & KV‐1415 will closed & valve
KV‐1406 A remains open or pump P‐141 will started till LS140A becomes HH. When LS 140A

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becomes HH Pump P‐141 will stop & KV‐1406 A & KV‐1408 A will closed
 Pressurization: ‐Valve KV‐1407A will open for 10 Sec.
 Flash Washing: ‐Valve KV‐1405A will open for 5 sec.
 Discharge: ‐KV‐1405 A will remains open & valve KV‐1408 A will open after 5 Sec for 180
sec. After 180 sec. KV‐1405 A will closed.
→ Pressurization → Flash washing → Discharge 2

→ Air vent → Preparation of process
→ Liquid filling 1 (KV‐1411A) → over flow (KV‐1411A)
→ Liquid filling 2
2nd Washing:
 Filling:‐Valve 1418 A, KV‐1416A ,KV 1417 A & KV‐1415 will remains open till the LS140C
becomes H after that Valve KV‐1418 A, KV‐1416A KV 1417A & KV‐1415 will closed & valve
KV‐1406 A remains open & pump P‐141 will started till LS140A becomes HH. When LS 140A
Pressurization → Flash washing →Discharge 2

→ Liquid filling 1 (KV‐1416A) → over flow (KV‐1416A)
→ Liquid filling 2
3rd Washing:
becomes H after that Valve KV‐1418 A, KV‐1416A, KV 1417A & KV‐1415 will closed & valve
KV‐1406 A remains open & pump P‐141 will started till LS140A becomes HH. When LS 140A
 Discharge: ‐KV‐1405 A will remains open or valve KV‐1408 A will open after 5 Sec for 180
Pressurization → Flash washing → Discharge 2

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→ Liquid filling 1 (KV-1417A) → over flow (KV-1417A)

→ Liquid filling
4th Washing:
becomes H after that Valve KV‐1418 A, KV‐1416A KV 1417‐A & KV‐1415 will closed & valve
KV‐1406 A remains open & pump P‐141 will start & KV‐1408 A will closed
 Filling: ‐After 180 sec. valve KV‐1406 A will open or pump P‐141 will started till
LS140A becomes HH.
Pressurization → Flash washing →Discharge 2→ Air vent

When Air vent (Step No.506) has been completed, the step
skips to Preparation of Pre-coat
1. Filtration Finish (Step No.501)

This process checks Filter slurry tank level (LS‐145).
When tank level (LS‐145) is over "H", it does not step next process.
2. Discharge (Step No.502)

The liquid is discharged from filter vessel outlet in order to secure a required air zone for
pressurization. Downstream air vent valve (KV‐1408A) or Pre-coat outlet valve (KV‐
1402A) is opened.
3. Pressurization (Step No.503)
Pre-coat outlet valve (KV‐1402A), downstream air vent valve (KV‐1408A) close, or Air
pressurization valve (KV‐1407A) opens.
Air pressurization valve (KV‐145A) Closes.
 Setting condition: Timer 5sec. or pressure 4.5 kg/cm2G.
4. Flash Washing (Step No.504)

Air pressurization valve (KV‐1407A) is closed & Mud discharge valve (KV‐1405A) is opened to
perform the flush washing.
At the initial start, the full opening time of Mud discharge valve (KV‐1405A) must be set at 3
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second by the speed controller attached on the valve. In the normal operation, the full
opening time of this valve must also be kept at 3 second.
5. Discharge 2 (Step No.505)

Downstream air vent valve (KV‐1408A) is opened, or the residual in filter is discharge
6. Air vent (Step No.506)

Mud discharge valve (KV‐1405A) closes, or the air is discharged from downstream air vent
valve (KV‐146A).
When 4th washing has been completed. Step jumps to the said Liquid filling (Step No.101),
preparation of precoat.
Washing brine inlet valve (KV‐1406A) & Upstream air vent valve (1st time=KV‐1418A,
2nd time=KV‐1416A, 3rd time=KV‐1417A), Drain valve (KV‐1415) are opened, or
filtered brine is filled into filter until its level (LS‐140A) reaches “H”.
8. Over flow (Step No.509)

Washing brine is overflow from Upstream air vent valve (1st time=KV‐1418A, 2nd time=KV‐
1416A, 3rd time=KV‐1417A), & the filter cake accumulated under perforated plate is washed
away.

When Upstream air vent valve (1st time=KV‐1418A, 2nd time=KV‐1416A, 3rd
time=KV‐1417A) & Drain valve (KV‐1415) close, Downstream air vent valve (KV‐
1408A) opens. Washing brine is filled into the filter until the level (LS‐140A) reaches
“HH”. When the Liquid filling (2) is completed, Washing brine inlet valve (KV‐1406A)
closes.
4. The level indicator LIA‐120 of the Pre-coat Tank D‐120 gives alarm when it becomes either
High – High (HH), High (H), Low – Low (LL), Low (L)
IF a LOW-LOW (LL) level is detected by LIA-120 in pre-coat tank.
THEN a motor STOP signal will be sent to pre-coat pump P-124 & it will stop,
AND a motor STOP signal will be sent to pre-coat tank agitator A-122 & it will stop.

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6. The level indicator LIA‐130 of the Body Feed Tank D‐130 gives alarm when it becomes either
High – High (HH) or High (H) or Low – Low (LL) or Low (L) or an immediate preventive
action has to be taken accordingly.
IF a LOW-LOW (LL) level is detected by LIA-130 in body feed tank.
THEN a motor STOP signal will be sent to body feed pump P-134 A AND P-134 B & it will
stop,
AND a motor STOP signal will be sent to body feed tank agitator A-132 & it will stop.
8. The level switch LA‐145 of the Filter Slurry Pit PT‐145 gives Alarm when it becomes either High
– High (HH) or High (H) or Low (L) or Low – Low (LL) or an immediate preventive action has to
be taken accordingly.
IF a LOW (L) level signal is detected by LA-145 in filter pit.
THEN a motor stop signal will be sent to filter slurry pump P-144 & it will stop.
AND a motor STOP signal will be sent to filter pit agitator A-142 A AND A-142 B & it will
stop.
10. The Flow of brine from Filtered brine pump P‐114 A/B to brine polishing filter F‐140 A is
controlled by FCV‐140 A as per the set point of FICA‐140 A. when flow increases above set
point valve opening will reduce.
11. The Flow of brine from Filtered brine pump P‐114 A/B to brine polishing filter F‐140 B is
controlled by FCV‐140 B as per the set point of FICA‐140 B. when flow increases above set
point valve opening will reduce.
12. The flow indicator FICA‐140 A of the Brine Polish filter F‐140 A gives alarm when it becomes
investigation & preventive action has to be taken accordingly.
13. The flow indicator FICA‐140 B of the Brine Polish filter F‐140 B gives alarm when it becomes
14. The Differential pressure indicator DPIA-140 A/B gives alarm when it becomes either High- High
(HH) or High (H).
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A‐122 ‐ START & STOP
P‐124 ‐ START & STOP
A‐132 ‐ START & STOP
P-134 A/B - START & STOP
P‐144 - START & STOP
A‐142 A/B ‐ STOP
17. The following documents are to be referred for Polish brine Filter Sequence operation.
SR. NO Description Annexure No

OPERATING TIME CHART FOR CANDLE
1. Annexure‐3
FILTER UNIT

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9455-11-PID-0-0007 (Sheet 2 of 2) REV: 04

CANDLE FILTER (PRIMARY BRINE PURIFICATION AREA)
1. The level indicator LIA‐150 in the Polished Brine Tank D‐150 gives Alarm when it becomes
2. The temperature of the Polished Brine is controlled by steam inlet control valve, TCV‐160
which regulates the steam Flow to Polished Brine Heater E‐153 as per the set point of TICA‐
160, when temperature increased above set point valve opening will reduce.
3. The HCl flow indicator FICA‐150 A gives alarm when it becomes either High (H) or Low (L) or
an immediate investigation & preventive action has to be taken accordingly.
4. The Caustic flow indicator FICA‐150 B gives alarm when it becomes either High (H) or Low (L)
or an immediate investigation & preventive action has to be taken accordingly.
5. The pH of inlet Polish Brine to Polish Brine Tank is controlled by addition of HCl by pH control
valve PHV-150 A as per the set point of PHIC-150 or by FICA-150 A through selector switch (ON
DCS),
Flow Control- When flow increases above set point valve opening will decrease.
pH Control- When flow increases above set point valve opening will decrease.
6. The pH of Polish Brine to Ion exchange Tower is controlled by addition of Caustic Soda by pH
control valve PHV-150 B as per the set point of PHIC-151 or by FICA-150 B through selector
switch (ON DCS),
Flow Control- When flow increases above set point valve opening will decrease.
pH Control- When flow increases above set point valve opening will decrease.
7. The pH indicator PHIC-150 of inlet Polish Brine to Polish Brine Tank gives alarm when it
becomes either High (H) or Low (L) or an immediate investigation & preventive action has to
8. The flow indicator FICA-150 E of filtered brine after mixing HCl gives alarm when it becomes
either High (H) or Low (L) or an immediate investigation & preventive action has to be taken
accordingly.
9. The pH indicator PHIC-152 of polish brine to waste alkali tank D-160 gives alarm when it
10. The flow indicator FICA-150 D of polish brine to waste alkali tank D-160 gives alarm when it
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11. The pH indicator PHIC-151 of polish brine to waste alkali tank D-160 gives alarm when it
12. The flow indicator FICA-150 C of polish brine to waste alkali tank D-160 gives alarm when it
13. The pH of Polish Brine to Ion exchange Tower PHIC-151 gives alarm when it becomes either
High (H) or Low (L) or an immediate investigation & preventive action has to be taken
accordingly.
14. The level indicator LIA‐150 of the Polished Brine Tank D‐150 gives Alarm when it becomes

IF a LOW-LOW (LL) signal is detected by LIA-150 in polish brine tank D-150.
THEN a motor STOP signal will be sent to polish brine pump P-154 A AND P-154 B & it will
stop,
AND a CLOSE signal will be sent to steam control valve TCV-160 & it will close.

IF a motor STOP signal is detected by both polish brine pump P-154 A AND P-154 B.
THEN a CLOSE signal will be sent to HCl addition control valve PHV-150 A & it will close.
AND a CLOSE signal will be sent to caustic addition control valve PHV-150 B & it will close.
These valve remain interlock till any one of the pump will start.

P‐141 ‐ START & STOP
P-144 - STOP
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9455-11-PID-0-0008 (SHEET 1 of 1)
ION EXCHANGE PURIFICATION (SECONDARY BRINE PURIFICATION AREA)
1. The Temperature Indicator TICA‐160 of Brine from Filtered Brine Pump P‐154 A/B to Ion
Exchange column T‐160 A/B/C gives alarm when it becomes either High (H) or Low (L) or an
immediate investigation & preventive action has to be taken accordingly.
2. The Flow Indicator FICA‐160 of Brine from Polished Brine Pump P‐154 A/B to Ion exchange
column T‐160 A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate
3. The Flow of polished brine from Polish Brine Pump P‐154 A/B to Ion exchange column T‐160
A/B/C is controlled by FCV‐160 as per the set point of FICA‐160. When flow increase above set
point, the valve opening shall reduce.
4. The Flow indicator FIA‐163 of brine from Polished Brine Pumps P‐154 A/B to Ion exchange
columnT‐160 A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate
5. The Flow indicator FICA‐164 of DM water from DM water header to Ion exchange column T‐
160 A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate
6. The Flow indicator FICA‐169 of 32% caustic from P-315 A/B to Ion exchange column T‐160
A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate investigation
& preventive action has to be taken accordingly.
7. The Flow indicator FICA‐162 of 18% HCL from P-834 A/B to Ion exchange column T‐160
A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate investigation
& preventive action has to be taken accordingly.
8. The flow of DM water from DM water Header to Ion Exchange column T‐160 A/B/C is
controlled by flow control valve FCV‐164 as per the set point of FICA‐164, when flow increases
above set point valve opening will reduce.
9. The Flow Indicator FIA‐161 of Brine from Purified Brine Pump P‐174 A/B to Ion Exchange
column T‐160 A/B/C gives alarm when it becomes either High (H) or Low (L) or an immediate
10. The level indicator LICA‐170 of the Purified Brine Tank D‐170 gives alarm when it becomes
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11. The level indicator LICA‐160 of the Waste Alkali Tank D‐160 gives alarm when it becomes
12. The flow of 18% HCl control by Flow control valve FCV‐162 as per the set point of FICA‐162.
When flow increases above set point valve opening will reduce.
13. The flow of 18% Caustic control by Flow control valve FCV‐169 as per the set point of FICA‐
169. When flow increases above set point valve opening will reduce.
14. The flow of polish brine is controlled by FCV‐160 as per the set point of FICA‐160 or by LICA‐
170 through selector switch.
Flow Control When flow increase above set point valve opening will reduce.
Level Control When Level increase above set point valve opening will reduce.

IF a LOW-LOW (LL) level is detected by LICA-160 in waste alkali tank D-160.
THEN a motor STOP signal will be sent to waste alkali transfer pump P-164 & it will stop.

IF a LOW-LOW (LL) level is detected by LIA-170 in pure brine tank D-170.
THEN a motor STOP signal will be sent to pure brine feed pump P-174 A AND P-174 B &
it will stop.

P‐174 A/B - START & STOP (EMERGENCY POWER)
P‐164 - STOP
19. The following documents are to be referred for Ion Exchange Column (T-160 A/B/C)
Regeneration, Time Chart or Sequence operation.
Sl. NO Description Annexure No

1. LOGIC TIME CHART Annexure‐4

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9455-11-PID-0-0009 (SHEET 1 of 1) REV: 04

BRINE MUD FILTER
 REFER VENDOR DOCUMENT FOR ROTARY VACUUM DRUM FILTER.

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9455-11-PID-0-0010 (SHEET 1 of 1) REV: 04

PURIFIED BRINE AREA-ELECTROLYZER AREA
1. The flow indicator FICA-200 of the DM water to pure brine gives alarm when it becomes either
High (H) or Low (L) or an immediate preventive action has to be taken accordingly.
2. The flow of DM water from DM water line to Brine Line going to Electrolyser R-230 A/B is
controlled by flow control valve FCV-235 as per the set point of FICA-200.when flow increases
above set point valve opening will reduce. FICA-200 will take set point from Ratio Controller
FRC-200 as per Doc. No. ML290-I52. (Logic Diagram For Electrolyser)
3. The Pressure indicator PICA-234 of DM water line gives alarm when it becomes High (H), an
4. The pressure of DM water to pure brine header is controlled & maintained by PCV-234 as per
the set of PICA-234, when the pressure increases above the set point the valve opening will
increase.
5. The level indicator LIA-245 of the Brine Head Tank D-245 gives alarm when it becomes either
Low (L) or Low-Low (LL) or an immediate investigation & preventive action has to be taken
accordingly.
6. The flow indicator FICA-221 of the DM water line gives alarm when it becomes either High (H)
or Low (L) or an immediate preventive action has to be taken accordingly.
7. The flow of DM water to 32% Caustic Line going to Electrolyser R-230 A/B is controlled by flow
control valve FCV-221 as per the set point of FICA-221, when flow increases above set point
valve opening will reduce. FICA-221 will take set point from Ration Controller FUNC-221 as per
Doc. No. ML290-I52. (Logic Diagram For Electrolyser)
8. The Temperature Indicator TICA-200 of pure brine from Purified Brine Pump P-174 A/B to
Electrolyser R-230A/B gives alarm when it becomes either High (H) or Low (L) or an immediate
9. The Chlorine Gas Detector AT-230 near Electrolyser R-230A/B gives alarm when it becomes
High (H) or High-High (HH) an immediate investigation & preventive action has to be taken
accordingly.
10. The following documents are to be referred for Cell House Interlocks -

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DOCUMENT /
SL. NO DESCRIPTION REMARK
DRAWING NO
LOGIC DIAGRAM FOR
1. ML-290-I52-REV-0
ELECTROLYSER
2. INTERLOCK DIAGRAM ML386-I50-001-REV-0

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9455-11-PID-0-0011 (SHEET 1 of 1) REV: 04

ELECTROLYSER – ELECTROLYSIS AREA
1. The Pressure indicator PdCA-228 of Hydrogen gas header gives alarm when it becomes High-
High (HH), an immediate investigation or preventive action to be taken accordingly.
2. The Pressure indicator PICA-227 of Hydrogen gas header gives alarm when it becomes either
High – High (HH) or High (H), an immediate investigation or preventive action to be taken
accordingly.
3. The Pressure indicator PICA-216 of Chlorine Gas header gives alarm when it becomes High-High
(HH), an immediate investigation or preventive action to be taken accordingly.
4. The Pressure indicator PICA-215 of Chlorine gas header gives alarm when it becomes High –
High (HH) or High (H), an immediate investigation or preventive action to be taken accordingly.
5. The Pressure of Hydrogen Gas header is controlled by pressure control valve PCV-227 as per
the set point of PICA-227, when pressure increases above set point valve opening will increase.
PICA-227 will take set point from FUNC-227 as per Doc. No. ML290-I52. (Logic Diagram For
Electrolyser)
6. The Pressure of Chlorine Gas header is controlled by pressure control valve PCV-215 as per the
set point of PICA-215, when pressure increases above set point valve opening will increase.
7. Differential pressure indicator PdIA-229 measure the differential pressure of the main cell room
gas header. The difference of PICA-227 & PICA-215 value is taken as the measured value.
8. The Pressure indicator PIA-231 of Oil Pressure unit gives alarm when it becomes Low (L), an
9. The Pressure indicator PICA-217 of N2 gas to N2 seal pots SP-231 /232 /233 gives alarm when it
becomes High (H) or Low (L), an immediate investigation or preventive action to be taken
accordingly.
10. The pressure of N2 gas is controlled & maintained by PCV-233 as per the set point of PICA-217,
when the pressure increases above the set point the valve opening will increase.

Z-239 - START & STOP (EMWRGENCY POWER)

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DOCUMENT /
DRAWING NO
LOGIC DIAGRAM FOR
1 ML-290-I52-REV-0
ELECTROLYSER
2 INTERLOCK DIAGRAM ML386-I50-001-REV-0

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9455-11-PID-0-0012(A) (SHEET 1 of 1) REV: 04

ELECTROLYSIS-A
1. The flow indicator FICAZ-231 A of the pure brine gives alarm when it becomes either High (H) or
Low - Low (LL) or Low (L) or an immediate preventive action has to be taken accordingly.
2. The flow of Pure Brine to Electrolyser R-230 A is controlled by flow control valve FCV-231 A as
per the set point of FICAZ-231 A, when flow increases above set point valve opening will reduce.
The set point shall be as per selector switch for auto & cascade mode. In auto mode the set point
shall be given by DCS operator & for cascade mode refer Doc. No. ML290-I52. (Logic Diagram for
Electrolyser).
3. The flow indicator FICA-230 A of the Hydrochloric acid line gives alarm when it becomes either
4. The flow of Hydrochloric acid going to Electrolyser R-230 A is controlled by flow control valve
FCV-230 A as per the set point of FICA-230 A , when flow increases above set point valve
opening will reduce. The set point shall be as per selector switch for auto & cascade mode. In
auto mode the set point shall be given by DCS operator & for cascade mode refer Doc. No.
ML290-I52. (Logic Diagram for Electrolyser).
5. The flow indicator FIAZ-233 A of dilute caustic to electrolyser R-230 A gives alarm when it
becomes either High – High (HH) or High (H) or Low (L) or Low – Low (LL), an immediate
6. The flow of dilute Caustic Line going to Electrolyser R-230 A is controlled by flow control valve
FCV-233 A as per the set point of FIAZ-233 A , when flow increases above set point valve opening
will reduce. The set point shall be as per selector switch for auto & cascade mode. In auto mode
the set point shall be given by DCS operator & for cascade mode refer Doc. No. Doc. No. ML290-
I52. (Logic Diagram for Electrolyser).
7. The flow indicator FIA-235 A of DM water to catholyte header gives alarm when it becomes
either High (H) or Low (L), an immediate investigation or preventive action to be taken
accordingly.
8. The flow indicator FIA-232 A of DM water to pure brine header of electrolyser R-230 A gives
alarm when it becomes either High (H) or Low (L), an immediate investigation or preventive

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9. The Temperature Indicator TIA-213 A of Anolyte Brine from E-213 A gives alarm when it
becomes High (H), an immediate investigation or preventive action has to be taken accordingly.
10. The pH indicator PHIA-213 A gives alarm when it becomes High (H) or Low (L), an immediate
11. Differential pressure indicator PdIZ-230 A measure the differential pressure of the Hydrogen
Gas & Chlorine gas line, gives alarm when it becomes either High – High (HH), High (H) or Low -
Low (LL) or Low (L). The difference of PIA-220 A & PIA-210 A value is taken as the measured
value.
12. The Pressure indicator of Chlorine gas PIA-210 A gives alarm when it becomes High-High (HH),
13. The Pressure indicator of Hydrogen gas PIA-220 A gives alarm when it becomes High-High (HH),
14. The temperature indicator of Exit caustic TIA-220 A gives alarm when it becomes High (H), an
immediate investigation or preventive action has to be taken accordingly.
15. The Electrolyser Voltage EI-2301 A-2370 A gives alarm when it becomes either High – High
(HH), High (H) or Low - Low (LL) or Low (L). An immediate investigation or preventive action
has to be taken accordingly.
16. The Electrolyser Current AIA-230 A gives alarm when it becomes either High – High (HH), High
(H) or Low - Low (LL). An immediate investigation or preventive action has to be taken
accordingly.
17. The Electrolyser Differential voltage EdIZ-230 A gives alarm when it becomes either High – High
DOCUMENT /
DRAWING NO
LOGIC DIAGRAM FOR
1 ML-290-I52-REV-0
ELECTROLYSER

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9455-11-PID-0-0012(B) (SHEET 1 of 1) REV: 04

ELECTROLYSIS-B
1. The flow indicator FICAZ-231 B of the pure brine gives alarm when it becomes either High (H)
or Low - Low (LL) or Low (L) or an immediate preventive action has to be taken accordingly.
2. The flow of Pure Brine to Electrolyser R-230 B is controlled by flow control valve FCV-231 B as
per the set point of FICAZ-231 B, when flow increases above set point valve opening will reduce.
The set point shall be as per selector switch for auto & cascade mode. In auto mode the set point
shall be given by DCS operator & for cascade mode refer Doc. No. ML290-I52. (Logic Diagram for
Electrolyser).
3. The flow indicator FICA-230 B of the Hydrochloric acid line gives alarm when it becomes either
4. The flow of Hydrochloric acid going to Electrolyser R-230 B is controlled by flow control valve
FCV-230 A as per the set point of FICA-230 B , when flow increases above set point valve
auto mode the set point shall be given by DCS operator & for cascade mode refer Doc. No.
ML290-I52. (Logic Diagram for Electrolyser).
5. The flow indicator FIAZ-233 B of dilute caustic to electrolyser R-230 B gives alarm when it
6. The flow of dilute Caustic Line going to Electrolyser R-230 B is controlled by flow control valve
FCV-233 B as per the set point of FIAZ-233 B, when flow increases above set point valve
auto mode the set point shall be given by DCS operator & for cascade mode refer Doc. No. Doc.
No. ML290-I52. (Logic Diagram for Electrolyser).
7. The flow indicator FIA-235 B of DM water to catholyte header gives alarm when it becomes
accordingly.
8. The flow indicator FIA-232 B of DM water to pure brine header of electrolyser R-230 B gives
alarm when it becomes either High (H) or Low (L), an immediate investigation or preventive

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9. The Temperature Indicator TIA-213 B of Anolyte Brine from E-213 B gives alarm when it
becomes High (H), an immediate investigation or preventive action has to be taken accordingly.
10. The pH indicator PHIA-213 B gives alarm when it becomes High (H) or Low (L), an immediate
11. Differential pressure indicator PdIZ-230 B measure the differential pressure of the Hydrogen
Gas & Chlorine gas line, gives alarm when it becomes either High – High (HH), High (H) or Low -
Low (LL) or Low (L). The difference of PIA-220 B & PIA-210 B value is taken as the measured
value.
12. The Pressure indicator of Chlorine gas PIA-210 B gives alarm when it becomes High-High (HH),
13. The Pressure indicator of Hydrogen gas PIA-220 B gives alarm when it becomes High-High
(HH), an immediate investigation or preventive action has to be taken accordingly.
14. The temperature indicator of Exit caustic TIA-220 B gives alarm when it becomes High (H), an
immediate investigation or preventive action has to be taken accordingly.
15. The Electrolyser R-230B Voltage EI-2301 B-2370 B gives alarm when it becomes either High –
High (HH), High (H) or Low - Low (LL) or Low (L). An immediate investigation or preventive
action has to be taken accordingly.
16. The Electrolyser Current AIA-230 B gives alarm when it becomes either High – High (HH), High
(H) or Low - Low (LL). An immediate investigation or preventive action has to be taken
accordingly.
17. The Electrolyser Differential voltage EdIZ-230 B gives alarm when it becomes either High – High
DOCUMENT /
DRAWING NO
LOGIC DIAGRAM FOR
1 ML-290-I52-REV-0
ELECTROLYSER

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LOGIC DIAGRAM FOR ELECTROLYZER
27 Apr 23
TOTAL 14 SHEETS
Y. KADO H. HIRATA T. YAMAGUCHI
27 Apr 23 27 Apr 23 27 Apr 23
NO. DESCRIPTION DATE DRAWN APPROVED CHECKED DRAWN
FOR JOB NO.
Al Ghaith Chemical Industries LLC ML-386 / 9455

JOB NAME DOC. NO.
Al Ghaith Oman Project – 70TPD Caustic Soda Plant ML290 -I52 REV. 0
ASAHI KASEI CORPORATION
TITLE
CONTENTS
Page
1 BRINE FEED CONTROL 3
2 HYDROCHLORIC FEED CONTROL 5
3 DEPLETED BRINE RECYCLE FLOW CONTROL 7
4 CATHOLYTE DILUTION FLOW CONTROL 9
5 GAS DIFFERENTIAL PRESSURE CONTROL 10
6 P-234 AUTO START/STOP 11
7 P-264A/B AUTO START/STOP 12
8 P-274A/B AUTO START/STOP 13
9 PURIFIED BRINE DILUTION CONTROL 14
2/14 ASAHI KASEI CORPORATION

BRINE FEED CONTROL
SV FUNC 231 X: PV 1 ( RECT. I )
FUNC FUNC 231 :

SV1 = 4.55 (m3/h)
SV2 = C x A x X (m3/h)
PV FICZA-231 MV X = Rect. I
PID C = 0.9 -1.1
A = 16.9 / 14.9 = 1.14

(m3/h) (KA)
The following data shall be changeable on the DCS

by some operators.:
C, A
FIT-231 FCV-231
Applicable instruments : FICZA-231 A to B

BRINE FEED CONTROL
If 0 < Rect. I < 4.05 KA,

BRINE FLOW CONTROL Set SV=SV1
If 4.05 =< Rect. I =< 16.2 KA,
18.0
Set SV=SV2
16.0
14.0 X= Rect. I
BRINE FLOW RATE
12.0 SV2 =C x A x X
A= 16.9 / 14.9 = 1.14

(m3/h)
10.0 Flow
(m3/h) (KA)
C= 0.9 - 1.1
8.0
SV1 = 4.55 (m3/h)
6.0
4.0 NOTE :
Rect current 4.05 is equivalent
2.0 to current density 1.5KA/m2
0.0
0 2 4 6 8 10 12 14 16
RECTIFIER CURRENT
(KA)

HYDROCHLORIC ACID FEED CONTROL
SV FUNC 230 X: PV 1 ( RECT. I )
FUNC
SV1 = 77.50 (L/hr)

( CE = 96% )
SV1 = 155 (L/hr)
PV 2 FICZA-230 MV ( CE = 93.5% )
SV2 = C x A x X (L/hr)
PID
X = Rect. I
C = 0.9 -1.1
CE = 96% A = 288.0 / 14.9 = 19.394

(L/hr) (KA)
CE = 93.5% A = 576 / 14.9 = 38.788
(L/hr) (KA)
FIT-230 FCV-230 The following data shall be changeable on the DCS

by some operators.:
C, A
Applicable instruments : FICZA-230 A to B

HYDROCHLORIC ACID FEED CONTROL
If 0 < Rect. I < 4.05 KA,

Set SV=SV1=0
If 4.05 =< Rect. I =< 16.2 KA,
HCL FLOW CONTROL Set SV=SV2
700
X= Rect. I
600
SV2 =C x A x X
500 A = 288.0 / 14.9 = 19.394
HCL FLOW RATE
( CE = 96% )
A = 576 / 14.9 = 38.788
( L/hr.)
400
( CE = 93.5% )
300 C= 0.9 - 1.1

CE =
93.5% SV1 = 77 (L/hr)
200 ( CE = 96% )
SV1 = 155 (L/hr)
( CE = 93.5% )
100
NOTE :
Rect current 4.05 is equivalent
0 to current density 1.5KA/m2
0 5 10 15 20
RECTIFIER CURRENT
(KA)

DEP. BRINE RECYCLE FLOW CONTROL
SV FUNC 241 X : Total Current
FUNC
PV FICZA-241 MV
PID SV = C x A x X (m3/h)
X = Total Current
C = 0.9 -1.1
A = 4.1 / 29.7 = 0.138

(m3/h) (KA)
FIT-241 FCV-241

by some operators.:
FICZA-241 C, A


4.5
4.0
DEP. BRINE RECYCLE FLOW RATE
3.5 X= Total Recti
3.0 SV = C x A x X (m3/h)
A= 4.1 / 29.7 = 0.138

(m3/h)
2.5
(m3/h) (KA)
C= 0.9 - 1.1
2.0
Flow
1.5
1.0
0.5
0.0
0 5 10 15 20 25 30 35
RECTIFIER CURRENT
(KA)

CATHOLYTE DILUTION FLOW CONTROL
SV FUNC 221 X : ( TOTAL RECT. I )
FUNC
PV FICZA-221 MV
SV = C x A x X (m3/h)
PID
X = TOTAL Rect. I
C = 0.9 -1.1
A = 2.5 / 29.7 = 0.084

(m3/h) (KA)
FIT-221 FCV-221

by some operators.:
FICZA-221 C, A

GAS DEF. PRESSURE CONTROL
FUNC227 PIT-215
SV SV= PIT-215+0.04 kg/cm2
PV PICZA-227 MV
PID
PIT-227 PV-227
PICZA-227

P-234AUT START_STOP
BEGINNING
Local P.B Station

MAN Motor Control Unit
P-234
AUT/MAN
AUT
P-234 P.B P-234 P.B

ON OFF
P-234 PUMP P-234 PUMP

START STOP
Hi Low
LIAS-230
Level

START STOP
END

P-264AUT START_STOP
BEGINNING
Local P.B Station

P-264
AUT/MAN
AUT
P-264 P.B P-264 P.B

ON OFF

START STOP
Hi Low
LIAS-260
Level

START STOP
END

P-274AUT START_STOP
BEGINNING
Local P.B Station

P-274
AUT/MAN
AUT
P-274 P.B P-274 P.B

ON OFF

START STOP
Hi Low
LIAS-270
Level

START STOP
END

PURIFIED BRINE DILUTION CONTROL
FUNC 200 FIT-200
Ratio
SV SV= FIT-200 x 0.5
PV FICA-234 MV
PID
FIT-234 FCV-234
FICA-234

SIGNAL CONDITION
Tag No Service Device DCS I/O Contact

VALVE OPEN
ZV-231A-B When the vavle is opened, close the contact LS of Open side Di
VALVE CLOSE
When the vavle is closed, close the contact LS of Close side Di
VALVE OPEN
When the SOV is no-energized, close the valve SOV Do
VALVE CLOSE
VALVE OPEN
VALVE CLOSE
VALVE CLOSE
When the SOV is no-energized, open the valve SOV Do
VALVE OPEN
VALVE OPEN
ZV-255 When the vavle is opened, close the contact LS of Open side Di
VALVE CLOSE
VALVE CLOSE
When the SOV is no-energized, open the valve SOV Do
VALVE OPEN
VALVE OPEN
VALVE CLOSE
VALVE OPEN
When the SOV is no-energized, close the valve SOV Do
VALVE CLOSE
Emergency
When the SW is opened, Emergency act Push Button Di
Stop Button Action
CANCEL
Cancel Sw When the SW is closed, the interlock is canceled. Select switch Di
1/2
SIGNAL CONDITION FROM/TO ELECTRICAL
Item Service Device DCS I/O Contact

When the Recti is started, close the contact and when the RUN
Main Rectifier On/Off State Di
Recti stopped, open the same contact STOP
START
Start / Stop command On/Off State Do
STOP
CLOSE
DCDS The DCDS is opened, open the contact On/Off State Di
OPEN
OPEN
Open command On-Momentary Do
Close command Off-Momentary Do

CLOSE
2/2
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9455-11-PID-0-0013 (SHEET 1 of 1) REV: 04

DEPLETED BRINE & CATHOLYTE AREA
1. The level indicator LICA-240 of Depleted Brine Tank D-240 gives alarm when it becomes either
High – High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate investigation or
2. The level of Depleted Brine Tank D-240 is maintained by controlling the Flow of Depleted brine
by Level Control Valve LCV-240 as per the set point of LICA-240, when level increases above set
point valve opening will increase
3. The Temperature Indicator TIA-240 of Depleted brine tank D-240 gives alarm when it becomes
either High (H) or Low (L), an immediate investigation & preventive action has to be taken
accordingly.
4. The flow indicator FICA-240 of the depleted brine to pure brine header gives alarm when it
becomes either High (H) or Low (L) or an immediate preventive action has to be taken
accordingly.
5. The Flow of Depleted Brine is maintained by controlling the Flow of Depleted brine by flow
Control Valve FCV-240 as per the set point of FICA-240 when flow increases above set point
valve opening will reduce. The set point shall be as per selector switch in auto mode or in
cascade mode. In auto mode set point is to be given by DCS operator & for cascade mode refer
Doc. No. ML290-I52. (Logic Diagram for Electrolyser).
6. The Temperature Indicator TIA-250 of Caustic Soda Tank D-250 gives alarm when it becomes
either High (H) or Low (L), an immediate investigation & preventive action has to be taken
accordingly.
7. The level indicator LICA-250 of Caustic Soda Tank D-250 gives alarm when it becomes either
8. The level of Caustic soda Tank D-250 is maintained by controlling the Flow of 32% caustic soda
by Level Control Valve LCV-250 as per the set point of LICA-250, when level increases above set
point valve opening will increase.
9. The flow indicator FICA-223 of cooling water to catholyte cooler gives alarm when it becomes
either High (H) or Low (L) or an immediate preventive action has to be taken accordingly.

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10. The flow indicator FIA-250 gives alarm when it becomes High (H).The Totalizer shall be made
on screen with set point & reset option.
11. The Temperature Indicator TIA-254 of Caustic Soda line gives alarm when it becomes either
High (H), an immediate investigation & preventive action has to be taken accordingly.
12. The level indicator LICA-255 of Caustic Soda Head Tank D-255 gives alarm when it becomes
accordingly.
13. The pressure indicator PICA-223 of caustic flow to catholyte cell header gives alarm when it
becomes either High (H) or Low (L), an immediate investigation or preventive action to be taken
accordingly.
14. The pressure of caustic to caustic cell header is controlled & maintained by PCV-223 when the
pressure increase above the set point the valve opening will increase.
15. The Temperature Indicator TICA-223 of Caustic Soda line gives alarm when it becomes either
High (H) or Low (L), an immediate investigation & preventive action has to be taken accordingly.
16. The temperature of caustic to catholyte header is controlled & maintained by TCV-223 as per the
set point of TICA-223 when the temperature increases above the set value the valve opening will
decreases.
17. The Temperature Indicator TICA-224 of Caustic Soda line gives alarm when it becomes either
High (H) or Low (L), an immediate investigation & preventive action has to be taken accordingly.
18. The temperature of caustic to catholyte header is controlled & maintained by TCV-224 as per the
set point TICA-224, when the temperature increases above the set point the valve opening will
decreases.

IF a LOW-LOW (LL) level is detected by LICA-240 in anolyte tank D-240.
THEN a Motor STOP signal will be sent to anolyte pump P-244 A AND P-244 B & it will
stop.
AND a CLOSE signal will be sent to anolyte control valve LCV-240 & it will close.

IF a HIGH-HIGH (HH) level is detected by LICA-240 in Anolyte brine tank D-240.

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THEN a motor STOP signal will be sent to pure brine tank pump P-174A AND P-174B & it
will stop.

If anyone pump P-244 A or P-244 B shall trip another pump will start automatically. If the
following condition is normal:
 LIA-240 is not Low-Low (LL)
 Another pump trip signal from MCC is not coming.

IF a LOW-LOW level is detected by LICA-250 in catholyte tank D-250.
THEN a motor STOP signal will be sent to catholyte pump P-254 A AND P-254 B & it will
stop.
AND a CLOSE signal will be sent to Caustic export control valve LCV-250 & it will close.

If anyone pump P-254 A or P-254 B shall trip another pump will start automatically. If the
following condition is normal:
 LIA-250 is not Low-Low (LL)
 Another pump trip signal from MCC is not coming.


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9455-11-PID-0-0014 (SHEET 1 of 1) REV: 04

ANOLYE & CATHOLYE BLOW DOWN ELECTROLYSIS AREA
1. The level indicator LIA-235 of wash water tank D-235 gives alarm when it becomes either High
(H) or Low (L), an immediate investigation or preventive action to be taken accordingly.
2. The level indicator LIA-260 of Anolyte blow down tank D-260 gives alarm when it becomes
accordingly.
3. The level indicator LICA-270 of Catholyte blow down tank D-270 gives alarm when it becomes
accordingly.
4. The flow indicator FIA-264 of Anolyte Blow Down to De-chlorination Tower line gives alarm
when it becomes either High (H) or Low (L) or an immediate preventive action has to be taken
accordingly.
IF a LOW (L) level is detected by LICA-235 in wash water tank.
THEN a motor STOP signal will be sent to wash water pump P-234 & it will stop.
OR
IF a HIGH (H) level is detected by LICA-235 in wash water tank.
THEN a motor START signal will be sent to wash water pump P-235 & it will start.
For Start/Stop logic refer Doc. No. ML290-I52 (Logic Diagram for Electrolyser).
IF a LOW (L) level is detected by LICA-260 in Anolyte Blown Down tank.
THEN a motor STOP signal will be sent to Anolyte Blown Down pump P-264 & it will stop.
OR
IF a HIGH (H) level is detected by LICA-260 in Anolyte Blown Down tank.
THEN a motor START signal will be sent to Anolyte Blown Down pump P-264 & it will start.
IF a LOW (L) level is detected by LICA-270 in Catholyte Blown Down tank.
THEN a motor STOP signal will be sent to Catholyte Blown Down pump P-274 & it will stop.
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OR
IF a HIGH (H) level is detected by LICA-270 in Catholyte Blown Down tank.
THEN a motor START signal will be sent to catholyte Blown Down pump P-274 & it will
start.

P‐235 - STOP (EMERGENCY POWER)

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9455-11-PID-0-0015 (SHEET 1 of 1) REV: 04

BRINE DECHLORINATION AREA
1. The level indicator LIA-300 of Caustic Dosing Tank (D-300) gives alarm when it becomes either
2. The level indicator LICA-280 of De-chlorination tower/tank (T-280) gives alarm when it
IF a LOW-LOW (LL) level is detected by LICA-280 in De-chlorination tower/tank (T-280).
THEN a motor STOP signal will be sent to both De-chlorination tower pumps P-284 A AND
P-284 B & it will stop.
AND a motor STOP signal will be sent to both Sodium Sulphite Pumps P-294 A AND P-294
B & it will stop.
AND a CLOSE signal will be sent to de-chlorination level control valve LCV-280 & it will
close.
AND a Close signal will be sent to 18% Caustic addition valve PHV-280 & it will close,
AND a Close signal will be sent to 18% HCl addition valve PHV-293 & it will close.
4. The level LICA-280 of De-chlorination tower /tank (T-280) is controlled by level control valve
(LCV-280) as per the set point of LIC-280. When level increases above set point, valve opening
will increase.
5. The pH of de-chlorinated brine is controlled by addition of 18 % caustic soda by pH control

valve PHV-280 as per the set point of AICA-280 or by FICA-300 through selector switch.
Flow Control  When flow increase above set point valve opening will decrease.
pH Control  When pH increase above set point valve opening will decrease.
6. The pH of depleted brine is controlled by addition of 18 % HCl by pH control valve PHV-293 as

per the set point of AICA-293 or by FICA-293 through selector switch.
Flow Control  When flow increase above set point valve opening will decrease.
pH Control  When pH increase above set point valve opening will increase.
7. The pH indicator AICA-293 of de-chlorinated brine from instrument cooler (E-293) gives alarm
when it becomes either High (H) or Low (L) an immediate investigation or preventive action to

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8. The Pressure indicator PICA-280 of De-chlorination Tower gives alarm when it becomes either
High (H) or Low (L), an immediate investigation or preventive action to be taken accordingly.
9. The flow transmitter FIA-293 of 18% HCl flow to de-chlorination tower inlet gives alarm when
it becomes either High (H) or Low (L), an immediate investigation or preventive action to be
taken accordingly.
10. The pH of de-chlorinate Brine AICA-280 gives alarm when it becomes either High (H) or Low
(L), an immediate investigation or preventive action to be taken accordingly.
11. The flow transmitter FICA-300 gives alarm when it becomes either High (H) or Low (L), an

IF HIGH –HIGH level is detected by LIA-300 in Caustic dosing tank.
THEN a CLOSE signal will be sent to Process water ON-OFF valve XV-300 & it will close,
AND a CLOSE signal will be sent to 32% caustic ON-OFF valve XV-301 & it will close.
13. All Motor/Drive provision of Start or Stop from DCS shall be provided.
P-284 A/B - START & STOP (EMERGENCY POWER)
C-281 A/B - START & STOP (EMERGENCY POWER)
All motors/drives status of running/stop/trip is provided in DCS.

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9455-11-PID-0-0015(A) (SHEET 1 of 1) REV: 04

CHLORATE DESTRUCTION
1. The Temperature indicator TICA-272 of Chlorate Destruction Tank (D-272) gives alarm when it
2. The flow indicator FICA-271 of the Depleted brine to Mixing tank D-271 gives alarm when it
3. The temperature of the Depleted brine is controlled by steam inlet control valve, TCV-272 which
regulates the steam Flow to Chlorate Destruction Tank (D-272) as per the set point of TICA-272,
when temperature increased above set point valve opening will reduce.
4. 18% HCl flow to mixing tank D-271 adjust manually in Rotameter by operator.
IF LOW-LOW (LL) flow is detected by FICA-271 of depleted brine to Mixing tank.
THEN a CLOSE signal will be sent to 18% HCl addition ON-OFF valve KV-271 & it will
close.
IF HIGH-HIGH (HH) temperature is detected by TICA-272 in chlorate destruction tank D-
272.
THEN a CLOSE signal will be sent to LP steam control valve TCV-272 & it will close.

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9455-11-PID-0-0016 (SHEET 1 of 1) REV: 03

SODIUM SULPHITE DOSING (DECHLORINATION AREA)
1. The level indicator LIA-290 of sodium sulphite tank (D-290) gives alarm when it becomes either
2. The flow of sodium sulphite to de-chlorinated brine is controlled by FCV-294 as per the set
point of either FICA-294 or by AICA-294.
 Flow Controller- When flow increases above set point, valve opening will reduce.
 ORP Controller- When ORP value increases above set point, valve opening will
increase.
3. The flow indicator FICA-294 of sodium sulphite gives alarm when it becomes either High (H) or
Low (L), an immediate investigation or preventive action to be taken accordingly.
IF the LOW-LOW (LL) level is detected by LIA-290 in sodium sulfite tank.
THEN a motor STOP signal will be sent to sodium sulphite dosing pump P-294 A AND P-
AND a motor STOP signal will be sent to sodium sulphite tank agitator A-292 & it will stop,
AND a Close signal will be sent to sodium sulphite dosing control valve FCV-294 & it will
close.

A-292 - START & STOP (EMERGENCY POWER)

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9455-11-PID-0-0017 (SHEET 1 of 1) REV: 04

CAUSTIC DISTRIBUTION & CAUSTIC SOTRAGE AREA
1. The level indicator LIA-310 of 32% caustic intermediate tank (D-310A) gives alarm when it
IF a LOW-LOW level is detected by LIA-310 in 32% caustic intermediate tank D-310.
THEN a motor STOP signal will be sent to 32% caustic intermediate pump P-314 A AND P-
AND a motor STOP signal will be sent to caustic distribution pump P-315 A AND P-315 B &
it will stop.
3. The level indicator LIA-320 A of 32% caustic soda storage tank (D-320 A) gives alarm when it
4. The level indicator LIA-320 B of 32% caustic soda storage tank (D-320 B) gives alarm when it
5. The level indicator LIA-320 C of 32% caustic soda storage tank (D-320 C) gives alarm when it
6. The level indicator LIA-320 D of 32% caustic soda storage tank (D-320 D) gives alarm when it
IF a LOW-LOW (LL) level is detected by LIA-320A in 48-50% caustic intermediate tank D-
320 A,
OR a LOW-LOW (LL) level is detected by LIA-320B in 48-50% caustic intermediate tank D-
320 B,
OR a LOW-LOW (LL) level is detected by LIA-320C in 48-50% caustic intermediate tank D-
320 C,
OR a LOW-LOW (LL) level is detected by LIA-320D in 48-50% caustic intermediate tank D-
320 D,
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THEN a motor STOP signal will be sent 48-50% caustic dispatch pump P-324 A AND P-324
B & it will stop,
AND a CLOSE signal will be sent 48-50% caustic dispatch ON-OFF valve XV-324 & it will
close.
8. The flow indicator FI-324 of the caustic soda gives alarm when it becomes either High (H) or
If a HIGH-HIGH (HH) value is detected by FIA-324 TOTALIZER in 48-50% caustic dispatch
line.
THEN a CLOSE signal will be sent to 48-50% caustic dispatch ON-OFF valve XV-324 & it will
close.
RESET OPTION REQUIRED WITH POP-UP CONFIRMATION MESSAGE

P-314 A/B - STOP
P-315 A/B - STOP
P-324 A/B - STOP

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9455-11-PID-0-0018 (Sheet 1 of 2) REV: 04

CHLORINE COOLING & CHILLING
1. The Chlorine pressure from outlet of Chlorine mist Eliminator F-424 is maintained or controlling
by Pressure control valve PCV-413A & B as per the set point of PICA-424. Chlorine pressure
increase above set point/split control. First PCV-413 A will operate as per set point if it is full
THEN PCV-413 B will operate.
2. Interlock – I-413
During a shutdown, as the cell room load is reduced, the pressure can be gradually
reduced by changing the set point of controller PICA-424.when the cell room finally
tripped PCV-413A & B will ****** (OPEN/CLOSE CONDITION WILL CONFIRMED DURING
COMMISSIONING).
I.e. after activation of IZ-230 all electrolyser trips.
3. The temperature indicator TIA-423 of chlorine gas from Chlorine cooler (E-423) gives alarm
when it becomes either High (H) or Low (L), an immediate investigation or preventive action to
4. The Pressure indicator PICA-424 gives alarm when it becomes either High – High (HH) or High
(H) or Low – Low (LL) or Low (L), an immediate investigation or preventive action to be taken
accordingly.

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9455-11-PID-0-0018 (Sheet 2 OF 2) REV: 04

HYDROGEN COOLING & CHILLING
1. The Hydrogen pressure from outlet of Hydrogen mist Eliminator F-614 is maintain or
controlling by Pressure control valve PCV-400 as per the set point of PICA-400. The Hydrogen
pressure is increase above set point control valve PCV-400 opening will increase.
2. During a shutdown, as the cell room load is reduced, the pressure can be gradually reduced by
changing the set point of controller PICA-400, when the cell room finally tripped PCV-400 will
fully open. I.e. after activation of IZ-230 all electrolyser trips.
3. The temperature indicator TIA-623 of Hydrogen gas from hydrogen cooler (E-623) gives alarm
when it becomes either High (H) or Low (L) an immediate investigation or preventive action to
4. The Pressure indicator PICA-400 gives alarm when it becomes either High – High (HH) or High
(H) or Low – Low (LL) or Low (L), an immediate investigation or preventive action to be taken
accordingly.

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9455-11-PID-0-0026 (Sheet 1 of 2) REV: 04

CHLORINE ABSORPTION
1. The level Indicator LICA-720A of chlorine absorber circulation tank D-720 gives alarm when it
2. The Flow Indicator FIA-713 of sodium hypo to chlorine absorption column gives an alarm
when it becomes either High (H) or Low – Low (LL) or Low (L), an immediate investigation or
3. The Flow Indicator FIA-714 of sodium hypo to Hypo Storage gives an alarm when it becomes
either High (H) or Low – Low (LL) or Low (L), an immediate investigation or preventive action
to be taken accordingly.
4. The Temperature Indicator TIA-713 of sodium hypo from chlorine absorber circulation chiller
E-713 gives an alarm when it becomes either High (H) or Low (L), an immediate investigation
or preventive action to be taken accordingly.
5. The Temperature Indicator TIA-710 of chlorine absorption column T-710 gives an alarm when
it becomes either High – High (HH) or High (H), an immediate investigation or preventive
6. The ORP Indicator AIA-710 of chlorine absorber circulation tank T-710 gives alarm when it
becomes either High – High (HH) or High (H) or Low (L), an immediate investigation or
7. The ORP Indicator AIA-710 of chlorine absorption column tank T-710 is normally controlled &
maintained by PHV-710A when the ORP increase above the set point the valve opening will
increase. PHV-710B will operate if PHV-710A will not maintained the ORP value.
8. The level Indicator LIA-780 of 18 % Caustic Head Tank D-780 gives an alarm when it becomes
either Low (L) or Low-Low (LL), an immediate investigation or preventive action to be taken
accordingly.
9. The Pressure Indicator PICA-731 of Wet Chlorine gas to chlorine absorption column T-710
gives an alarm when it becomes either High (H) or Low (L), an immediate investigation or
10. Interlock IZ-780

IF a motor STOP signal is detected by chlorine absorber circulation pump P-724A AND P-
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724B for a certain period of 60 sec,

OR if a motor STOP signal is detected by chlorine emergency absorber circulation pump
P-744A AND P-744B for a certain period of 60 sec,
OR a LOW-LOW (LL) flow is detected by FIA-713 of chlorine absorber circulation tank D-
720 to chlorine absorption column T-710 for a certain period of 60 sec,
OR a LOW-LOW (LL) flow is detected by FIA-733 of chlorine emergency absorber
circulation tank D-740 to chlorine emergency absorption column T-720 for a certain
period of 60 sec,
THEN an OPEN signal will be sent to caustic addition ON-OFF valve XV-780 & it will open.
As soon as any of four pump P-724A AND P-724B, P-744A AND P-744B start signal receive
or any of the flow indicator FIA-713 OR FIA-733 gives the signal above LOW (L) value
THEN the caustic addition ON-OFF valve XV-780 will close.
11. Interlock I-720

IF a LOW-LOW (LL) level is detected by LICA-720 in chlorine absorber circulation tank D-
720.
THEN a motor STOP signal will be sent to chlorine absorber circulation pump P-724A AND
P-724B & it will stop.


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9455-11-PID-0-0026 (Sheet 2 of 2) REV: 04

CHLORINE ABSORTION
1. The level Indicator LIA-740 in chlorine emergency absorber circulation tank D-740 gives alarm
when it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L), an
2. The Flow Indicator FIA-733 in sodium hypo to chlorine emergency absorption column gives
alarm when it becomes either High (H) or Low (L) or Low-Low-Low (LL), an immediate
3. The Temperature Indicator TIA-733 in sodium hypo from chlorine emergency absorber
circulation chiller E-733 gives alarm when it becomes either High (H) or Low (L), an immediate
4. The Temperature Indicator TIA-720 in chlorine emergency absorption column gives alarm
when it becomes either High – High (HH) or High (H) , an immediate investigation or preventive
5. The ORP Indicator AIA-720 in chlorine emergency absorber circulation pump line gives alarm
when it becomes either High – High (HH) or High (H), an immediate investigation or preventive
6. The Suction Pressure of Wet Chlorine gas in chlorine absorption column T-710 is controlled &
maintained by PCV-731 as per the set point of PICA-731. When Suction increases above set
point, valve opening will reduce.
7. Pressure Indicator PIA-732 in hypo blower suction gives alarm when it becomes either High (H)
or Low (L), an immediate investigation or preventive action to be taken accordingly.
8. Interlock IZ-731
IF a motor STOP signal is detected by B-731A OR B-731B any one in emergency absorber
blower.
THEN a motor START signal will be sent to another emergency absorber blower B-731A
OR B-731B & it will start.
9. Interlock I-740
IF a LOW-LOW (LL) level is detected by LIA-740 in chlorine emergency absorber
circulation tank D-740
THEN a motor STOP signal will be sent to chlorine emergency absorber circulation pump

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P-744A AND P-744B & it will stop.

B-731 A/B - START & STOP (EMERGENCY POWER)

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9455-11-PID-0-0028 (SHEET 1 of 1) REV: 04

HYPO STORAGE & DISPATCH
1. The Level Indicator LIA-790 A in Sodium Hypochlorite Storage Tank D-790 A gives alarm when
it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L) an immediate
2. The Level Indicator LI-790 B in Sodium Hypochlorite Storage Tank D-790 B gives alarm when it
3. The Level Indicator LI-790 C in Sodium Hypochlorite Storage Tank D-790 C gives alarm when it
4. The Level Indicator LI-790 D in Sodium Hypochlorite Storage Tank D-790 D gives alarm when it
5. Flow Indicator FIA-790 in Sodium Hypochlorite dispatch line gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low- Low (LL), an immediate investigation or
6. Interlock I-784
IF a LOW-LOW (LL) level is detected by LIA-790A in sodium hypochlorite storage tank,
OR a LOW-LOW (LL) level is detected by LIA-790B in sodium hypochlorite storage tank,
OR a LOW-LOW (LL) level is detected by LIA-790C in sodium hypochlorite storage tank,
OR a LOW-LOW (LL) level is detected by LIA-790D in sodium hypochlorite storage tank,
THEN a motor STOP signal will be sent to sodium hypochlorite dispatch pump P-794 & it
will stop.
IF a HIGH-HIGH (HH) value is detected by FIA-790 TOTALIZER in sodium hypochlorite
dispatch line.
THEN a CLOSE signal will be sent to sodium hypochlorite dispatch ON-OFF valve XV-784 &
it will close.

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P-794 - STOP

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9455-11-PID-0-0029 (SHEET 1 of 1) REV: 04

HCL DILUTION
1. The Level Indicator LIA-830 of HCL Service Tank D-830 gives alarm when it becomes either
IF a LOW-LOW (LL) level is detected by LIA-830 in HCl service tank D-830.
THEN a motor STOP signal will be sent to HCl service pump P-834A AND P834B & it will
stop.
IF a HIGH-HIGH (HH) level is detected by LIA-830 in HCl service tank D-83.
THEN a CLOSE signal will be sent DM water addition ON-OFF valve XV-830A & it will close,
AND a CLOSE signal will be sent 32% HCl addition ON-OFF valve XV-830B & it will close.

P-834 A/B - STOP

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9455-11-PID-0-0030 (SHEET 1 of 1) REV: 04

HCL SYNTHESIS UNIT
1. The Level Indicator LICA-813 in HCL Intermediate Tank D-810 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low-Low (LL) or an immediate investigation
2. The Temperature Indicator TIA-813 in HCL Intermediate Tank D-810 gives alarm when it
becomes either High-High (HH) or High (H), an immediate investigation or preventive action
to be taken accordingly.
3. The Flow Indicator FIA-811 in cooling water line to Furnace R-810 gives alarm when it
becomes Low (L) or Low-Low (LL), an immediate investigation or preventive action to be
taken accordingly.
4. The Pressure Indicator PIA-811 in Cl2 gas line to Furnace R-810 gives an alarm when it
becomes either High – High (HH) or High (H) or Low (L) or Low-Low (LL) or an immediate
5. The Temperature Indicator TIA-811 in Chlorine gas line gives alarm when it becomes High (H)
or High-High (HH) or an immediate investigation or preventive action to be taken accordingly.
6. The Flow Indicator FICA-810 in Cl2 gas line to Furnace R-810 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low-Low (LL) or an immediate investigation
7. The Cl2 flow to furnace R-810 is controlled by Flow Control Valve FCV-810 as per the set point
of FICA-810. The Cl2 flow will act as a master. When flow decreases below set point. Valve
opening will increase.
8. The Hydrogen flow is controlled with hydrogen flow ratio controller FFIC-812, the H2 ratio
control loop consist of flow Indicator FFICA-812, ratio controller FFIC-812 or the control valve
FCV-812. A signal from the Cl2 flow Indicator FICA-810 is fed to the ratio controller FFIC-812.
The ratio controller FFIC-812 will adjusts the hydrogen flow as per Cl2 flow (recommended
Cl2/H2 ratio is 1:1.2 at normal conditions.) ratio shall be adjusted from screen.
Note: Unit should not be put in ratio controller until it stabilized.
9. The Flow Indicator FICA-812 in H2 gas line to Furnace R-810 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low- Low (LL) or an immediate
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10. The Pressure Indicator PIA-812 in H2 gas to Furnace R-810 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low – Low (LL) or an immediate
11. The Temperature Indicator TIA-812 in Hydrogen gas line gives alarm when it becomes High
(H) or High-High (HH) or an immediate investigation or preventive action to be taken
accordingly.
12. As per Cl2 flow, the flow of DM water is also need to be adjusted; hence the DM water is also
controlled through a ratio control loop consisting of flow indicator FICA-815, the ratio
controller FFICA-815. A Cl2 flow signal from FICA-810 is also fed to the ratio controller FFICA-
815 to have desired quantity of DM water (Recommended Cl2/H2O ratio is 1:0.006 at normal
conditions.) ratio shall be adjusted from screen.
13. The Pressure indicator PIA-815 in DM water line to HCl furnace R-810 gives an alarm either it
become Low (LL) or Low – Low (LL) or an immediate investigation or preventive action to be
taken.
14. The Flow indicator FICA-815 in DM water line to Tail gas Tower T-820 is maintained and
controlled by Flow control valve FCV-815 as per the set point of FICA-815, when flow
increases above set point, valve opening will reduce.
15. The Pressure Indicator PIA-814 in N2 gas line gives alarm when it becomes either High – High
(HH) or High (H) or Low (L) or Low – Low (LL) or an immediate investigation or preventive
16. The Flame Indicator FFA-813 in Furnace R-813 gives alarm when the flame in burner becomes
failure or ON.
17. The Pressure Indicator PIA-813 in Combustion Chamber R-810 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low – Low (LL) or an immediate
18. The Flow Indicator FIA-813 in HCL Circulation Pumps (P-814 A/B) to Tail Gas Tower T-820
gives alarm when it becomes either High (H) or Low (L) or Low – Low (LL) or an immediate
19. The Temperature Indicator TIA-821 in Tail Gas Tower T-820 gives alarm when it becomes
High (H) or High-High (HH) or an immediate investigation or preventive action to be taken
accordingly.
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20. The Flow Indicator FIA-814 in HCL Circulation Pumps P-814A/B to HCL Storage tank gives
alarm when it becomes either High (H) or Low (L) or an immediate investigation or preventive
21. The level in HCL solution tank D-810 is controlled by LCV-813 as per the set point of LICA-813.
When level increases above set point, valve opening will increase.
22. The Pressure Switch PAH-810 of Collection Pot BD-811 gives alarm when it becomes High (H).
23. The Chlorine on-off valve XV-801, Hydrogen on-off valve XV-802 or CL2, H2 control valve FCV-
810 & FCV-812 will not open until the interlocks are healthy except H2/Cl2 flow ratio low, Cl2
flow low, flame failure & DM water flow low. However these signals are bypassed with timer
(adjustable 20 minutes) .manual bypass switches provided in DCS.

IF a LOW-LOW (LL) hydrogen pressure is detected by PIA-812 in HCL furnace hydrogen
header,
OR a HIGH-HIGH (HH) hydrogen pressure is detected by PIA-812 in HCL furnace hydrogen
header (WITH BYPASS SWITCH),
OR a LOW-LOW (LL) pressure is detected by PIA-811 in HCL furnace chlorine header,
OR a HIGH-HIGH (HH) pressure is detected by PIA-811 in HCL furnace chlorine header
(WITH BYPASS SWITCH),
OR a LOW-LOW (LL) chlorine flow is detected by FICA-810 in HCL furnace (WITH BYPASS
SWITCH),
OR a LOW-LOW (LL) hydrogen flow is detected by FICA-812 in HCL furnace (WITH BYPASS
SWITCH),
OR a Flame failure is detected by FFA-813 in HCL furnace (Start-Up bypass is provided at
DCS, adjustable 0-20 minutes),
OR a LOW-LOW (LL) cooling water flow is detected by FIA-811 in HCL furnace cooling water
header,
OR a LOW (L) DM water flow is detected by FICA-815 in HCL furnace DM water header,
OR a LOW-LOW (LL) DM water pressure is detected by PIA-815 in HCL furnace DM water
header,
OR a HIGH-HIGH (HH) combustion chamber pressure is detected by PIA-813 in HCL
furnace (WITH BYPASS SWITCH)
OR emergency trip switch is pressed by ESR-810 (IN DCS),
OR emergency trip switch is pressed by ESL-810 (IN LOCAL PANNEL),
OR a motor STOP signal is detected by both HCL circulation pump P-814A AND P-814B
(Time delay of 10 minutes),
OR a HIGH (H) pressure is detected by PAH-810 in HCL furnace collection pot, (i.e. Bursting
Disc failure),

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OR a LOW-LOW (LL) instrument air pressure is detected by PIA-1050 in Instrument air

receiver tank,
OR a HIGH-HIGH (HH) level is detected by LICA-813 in HCL intermediate tank,
OR IZ-230 Activated (WITH BYPASS SWITCH REQUIRED)
THEN an OPEN signal will be sent to Nitrogen purge ON-OFF valve XV-810 in hydrogen
header & it will open (PRESET TIME PERIOD TO PURGE NITROGEN & THEN CLOSE, PRESET
TIME ADJUSTABLE BETWEEN 0 to 5 MINUTES),
AND an OPEN signal will be sent to Nitrogen purge ON-OFF valve XV-811 in chlorine header
& it will open (PRESET TIME PERIOD TO PURGE NITROGEN & THEN CLOSE, PRESET TIME
ADJUSTABLE BETWEEN 0 to 5 MINUTES),
AND a CLOSE signal will be sent to Hydrogen gas control valve FCV-812 & it will close,
AND a Close signal will be sent to Hydrogen gas ON-OFF valve XV-802 & it will close,
AND a CLOSE signal will be sent to Chlorine gas control valve FCV-810 & it will close,
AND a CLOSE signal will be sent to Chlorine gas ON-OFF valve XV-801 & it will close,
AND a CLOSE signal will be sent to DM water control valve FICA-815 & it will close after a
time delay of 300 seconds.

IF a LOW-LOW (LL) level is detected by LICA-813 in HCL intermediate tank D-810.
THEN a motor STOP signal will be sent to HCL circulation pump P-814A AND P-814B & it
will stop.

IF a hard wired switch (in local panel) is pressed,
OR a soft switch (in DCS) is pressed.
THEN an OPEN signal will be sent to nitrogen ON-OFF valve XV-810 to H2 Header & it
will open. (PRESET TIME PERIOD TO PURGE NITROGEN & THEN CLOSE, PRESET TIME
AND an OPEN signal will be sent to nitrogen ON-OFF valve XV-811 to Cl2 Header & it will
open (PRESET TIME PERIOD TO PURGE NITROGEN & THEN CLOSE, PRESET TIME
27. Motor/Drive auto Start/Stop provision in DCS

P-814 A/B - STOP
B-801 A/B - START & STOP (EMERGENCY POWER)

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9455-11-PID-0-0031 (SHEET 1 of 2) REV: 04

HCL STORAGE & DISPATCH AREA
1. The Level Indicator LIA-840 A of HCL Storage Tank D-840 A gives alarm when it becomes either
High – High (HH) or High (H) or Low (L) or Low-Low (LL) an immediate investigation or
2. The Level Indicator LIA-840 B of HCL Storage Tank D-840 B gives alarm when it becomes either
High – High (HH) or High (H) or Low (L) or Low-Low (LL), an immediate investigation or
3. The Level Indicator LIA-840 C of HCL Storage Tank D-840 C gives alarm when it becomes either
4. The Level Indicator LIA-840 D of HCL Storage Tank D-840 D gives alarm when it becomes either
5. The Level Indicator LIA-840 E of HCL Storage Tank D-840 E gives alarm when it becomes either
6. The Level Indicator LIA-840 F of HCL Storage Tank D-840 F gives alarm when it becomes either
7. The flow Indicator FIA-844 of HCl dispatch line gives alarm when it becomes either High (H) or
IF a LOW-LOW (LL) level is detected by LIA-840A in HCL storage tank D-840A,
OR a LOW-LOW (LL) level is detected by LIA-840B in HCL storage tank D-840B,
OR a LOW-LOW (LL) level is detected by LIA-840C in HCL storage tank D-840C,
OR a LOW-LOW (LL) level is detected by LIA-840D in HCL storage tank D-840D,
OR a LOW-LOW (LL) level is detected by LIA-840E in HCL storage tank D-840E,
OR a LOW-LOW (LL) level is detected by LIA-840F in HCL storage tank D-840F.
THEN a motor STOP signal will be sent to HCL dispatch pump P-844A AND P-844B & it
will stop,
AND a CLOSE signal will be sent to HCL dispatch ON-OFF valve XV-844 & it will close.
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9. Flow Indicator FI-844 of HCl dispatch line gives alarm when it becomes either High (H) or Low
(L), an immediate investigation or preventive action to be taken accordingly.

IF a HIGH-HIGH (HH) value is detected by FIA-844 TOTALIZER in sodium hypochlorite
dispatch line.
THEN a CLOSE signal will be sent to sodium hypochlorite dispatch ON-OFF valve XV-844 &
it will close.

P-844 A/B - STOP

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9455-11-PID-0-0031 (SHEET 2 of 2) REV: 04

SCRUBBER PACKAGE FOR HCL STORAGE TANKS
1 The Level Indicator LIA-845 of HCL Fume Scrubber Tank D-845 gives alarm when it becomes
either High – High (HH) or High (H) or Low (L) or Low-Low (LL), an immediate investigation or
IF a LOW-LOW (LL) level is detected by LIA-845 in HCL fume scrubber tank.
THEN a motor STOP signal will sent to HCL fume scrubber tank pump P-845A AND P-
845B & it will stop.

P-845 A/B - STOP

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9455-11-PID-0-0032 (SHEET 1 of 1) REV: 04

PROCESS WATER SYSTEM
1. The Level Indicator LIA-1004 in Raw Water tank D-1004 gives alarm when it becomes either
2. The Level Indicator LIA-1005A in RO Water tank D-1005A gives alarm when it becomes either
3. The Level Indicator LIA-1005B in RO Water tank D-1005B gives alarm when it becomes either
4. The Level Indicator LIA-1005C in RO Water tank D-1005C gives alarm when it becomes either
5. RO water unit refer Vendor document.
IF a LOW-LOW (LL) level is detected by LIA-1005A in RO water tank D-1005A,
OR a LOW-LOW (LL) level is detected by LIA-1005B in RO water tank D-1005B,
OR a LOW-LOW (LL) level is detected by LIA-1005C in RO water tank D-1005C.
THEN a motor STOP signal will be sent to process water pump P-1004A AND P-1004B &
it will stop.
AND a motor STOP signal will be sent to DM water feed pump P-1006A AND P-1006B & it
will close.
IF a LOW-LOW (LL) is detected by LIA-1004 in raw water tank D-1004.
THEN a motor STOP signal will be sent to raw water pump P-1014A AND P-1014B & it
will stop.
IF a motor STOP signal is detected by both process water pump P-1004A AND P-1004B
for a certain period of >60 sec. (adjustable).

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THEN a motor STOP signal will be sent to salt saturator pump P-014A AND P-014B & it
will stop,
AND a motor STOP signal will be sent to return brine pump P-084A AND P-084B & it will
stop,
AND a motor STOP signal will be sent to barium carbonate dosing pump P-054A AND P-
054B & it will stop,
AND a motor STOP signal will be sent to soda ash pump P-074A AND P-074B & it will
stop,
AND a motor STOP signal will be sent to clarified brine pump P-044A AND P-044B & it
will stop,
AND a motor STOP signal will be sent to filter brine pump P-114A AND P-114B & it will
stop,
AND a motor STOP signal will be sent to pre-coat pump P-124 & it will stop,
AND a motor STOP signal will be sent to filter slurry pump P-144& it will stop,
AND a motor STOP signal will be sent to polish brine pump P-154A AND P-154B & it will
stop,
AND a motor STOP signal will be sent to filter wash pump P-141& it will stop,
AND a motor STOP signal will be sent to filtrate brine pump P-094A AND P-094B & it
will stop,
AND a motor STOP signal will be sent to sodium hypochlorite dispatch pump P-794 & it
will stop,
AND a motor STOP signal will be sent to HCL dispatch pump P-844A AND P-844B & it
will stop,

P-1004 A/B - STOP (EMERGENCY POWER 1 No.)
P-1014 A/B - STOP

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9455-11-PID-0-0033 (SHEET 1 of 2) REV: 04

DM WATER PLANT
1. The Level Indicator LIA-1020 A in DM Water tank D-1020 A gives alarm when it becomes either
High – High (HH) or High (H) or Low (L) or Low - Low (LL), an immediate investigation or
2. The Level Indicator LIA-1020 B in DM Water tank D-1020 B gives alarm when it becomes either
3. Flow Indicator FIA-1020 in DM Water from Mixed bed outlet line gives alarm when it becomes
accordingly.
IF a LOW-LOW (LL) level is detected by LIA-1020A in Demineralized water tank D-1020A,
OR a LOW-LOW (LL) level is detected by LIA-1020B in Demineralized water tank D-
1020B.
THEN a motor STOP signal will be sent to rectifier DM water make up pump P-1021 & it
will stop.
AND a motor STOP signal will be sent to DM seal water pump P-1022A AND P-1022B & it
will stop.
AND a motor STOP signal will be sent to DM water cell dosing pump P-1023A AND P-
1023B & it will stop,
AND a motor STOP signal will be sent to DM water supply pump P-1024A AND P-1024B &
it will stop.
IF a motor STOP signal is detected by both DM seal water pump P-1022A AND P-1022B
for a certain period of >60 seconds adjustable.
THEN a motor STOP signal will be sent to pure brine pump P-174A AND P-174B & it will
stop,
AND a motor STOP signal will sent to Anolyte pump P-244A AND P-244B & it will stop,
AND a motor STOP signal will be sent to Catholyte pump P-254A AND P-254B & it will
stop,
AND a motor STOP signal will be sent to Anolyte blow down pump P-264 & it will stop.
AND a motor STOP signal will be sent to De-chlorination pump P-284A AND P-284B & it
will stop,

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AND a motor STOP signal will be sent to chlorine absorption circulation pump P-724A
AND P-724B & it will stop,
AND a motor STOP signal will be sent to chlorine emergency absorption circulation pump
P-744A AND P-744B & it will stop,
AND a motor stop signal will be sent to sodium hypochlorite dispatch pump P-794 & it
will stop.

P-1021 - START & STOP (EMERGENCY POWER)

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0033 (SHEET 2 of 2) REV: 04

DM WATER PLANT
1. REFER O&M MANUAL DOCUMENT NO:

2. The pH indicator AIA-1021 of DM water outlet from mixed bed MX-2605 gives alarm
when it becomes either High (H) or Low (L).
3. The conductivity meter CDI-1020 at the outlet of mixed bed MX-2605 gives alarm ehen it
becomes High (H).


CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0034 (SHEET 1 of 1) REV: 04

COOLING WATER GENERTAION
1. The Temperature Indicator TIA-1031 of Cooling water from cooling water pumps P-
1030A/B/C/D/E) gives alarm when it becomes either High (H) and High-High (HH)
2. The Pressure Switch PS-1030 of cooling water from cooling water pumps P-1030A/B/C/D/E
gives alarm when it becomes Low (L).
3. The Temperature Indicator TIA-1030 of cooling water return from process plant gives alarm
when it becomes either High-High (HH) or High (H).
4. The Level Indicator LS-1035 of Rectifier Cooling Water Pit (PT-1035) gives alarm when it
becomes either High (H) or Low (L) or Low-Low (LL).
IF a LOW (L) pressure is detected by PSL-1030 in cooling water discharge line.
THEN a motor STOP signal will be sent to cooling water pump P-1034A & it will stop.
AND a motor STOP signal will be sent to cooling water pump P-1034B & it will stop.
AND a motor STOP signal will be sent to cooling water pump P-1034C & it will stop.
AND a motor STOP signal will be sent to cooling water pump P-1034D & it will stop.
IF a LOW (L) level switch is detected by LSA-1035 in rectifier cooling water pit.
THEN a motor STOP signal will be sent to rectifier cooling water pit pump P-1035A AND
P-1035B & it will stop.
7. Motor/Drive provision of Start and Stop from DCS shall be provided.

P-1034 A/B/C/D/E/F - START & STOP (EMERGENCY POWER 1 NO.)
F-1030 A/B - STOP
P-1035 A/B - STOP

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0035 (Sheet 1 of 1) REV: 04

CHILLED WATER SYSTEM
1. The Level Indicator LIA-1040 A of Chilled Water Tank D-1040 (HOT WELL) gives alarm when it
2. The Level Indicator LI-1040 B of Chilled Water Tank D-1040 (COLD WELL) gives alarm when it
IF a LOW-LOW level is detected by LIA-1040A in chilled water tank (HOT WELL),
OR a LOW-LOW level is detected by LIA-1040B in chilled water tank (COLD WELL).
THEN a motor STOP signal will be sent to chilled water supply pump P-1044A AND P-
AND a motor STOP signal will be sent to chilled water circulation pump P-1045A AND P-
4. The control scheme of PCV-1040 is provided in local control panel of Vapor Absorption Machine
chiller (U-1040).
5. The control scheme of XV-1040 is provided in local control panel of Vapor Absorption Machine
chiller (U-1040).
6. The temperature Indicator TIA-1040 in chilled water tank D-1040 (HOT WELL) gives alarm
7. The temperature Indicator TIA-1041 in chilled water tank D-1040 (COLD WELL) gives alarm

P-1044 A/B - STOP (EMERGENCY POWER)
P-1045 A/B - STOP (EMERGENCY POWER)

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0036 (SHEET 1 of 1) REV: 04

CONDENSATE & RECOVERY SYSTEM
1. The Level Indicator LA-1041 in Condensate recovery tank D-1041 gives alarm when it becomes
accordingly.
2. The Level Indicator LA-1042 in waste water recovery tank (D-1042) gives alarm when it
becomes either High (H) or Low (L), an immediate investigation or preventive action to be
taken accordingly.
IF a LOW (L) level is detected by LA-1041 in condensate recovery tank.
THEN a motor STOP signal will be sent to condensate recovery pump P-1041 & it will
stop.
OR
IF a HIGH (H) level is detected by LA-1041 in condensate recovery tank.
THEN a motor START signal will be sent to condensate recovery pump P-1041 & it will
start.
IF a LOW (L) level is detected by LA-1042 in waste water recovery pit.
THEN a motor STOP signal will be sent to waste water recovery pump P-1042 & it will
stop.

P-1041 - STOP
P-1042 - STOP

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0037 (Sheet 1 of 1) REV: 04

WASTE WATER TREATMENT (ETP AREA)
IF a LOW (L) level is detected by LAS-910 in effluent pit.
THEN a motor STOP signal will be sent to effluent pump P-914 A AND P-914 B & it will stop.
2. The Level Switch LS-910 of pit gives alarm when it becomes either High (H) or Low (L), an
3. The pH indicator AIA-910 gives alarm when it becomes either High (H) or Low (L), an

P-914 A/B - STOP

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0038 (Sheet 1 of 1) REV: 04

PSA N2 GAS PLANT WITH COMPRESSOR, PROCESS AIR & AIR DRYING UNIT
1. The control scheme of Air Compressors (U-1050 A/B) is provided in local control panel.
(REFER VENDOR MANUAL).
2. The control scheme of Air drying unit is provided in local control panel.
3. The control scheme of N2 generation unit is provided in local control panel.

4. The Pressure Indicator PIA-1050 of Instrument air receiver gives alarm when it becomes either
5. The Pressure Indicator PI-1060 of N2 gas receiver gives alarm when it becomes either High –
6. The Pressure Indicator PI-1062 of N2 gas receiver gives alarm when it becomes either High –
7. Interlock(I-1050)
IF a LOW-LOW (LL) pressure is detected by PIA-1050 on instrument air receiver
THEN a TRIP OR STOP signal will be sent to IZ-230 (ELECTROLYSER).

AND a TRIP OR STOP signal will be sent to I-810 (HCL FURNACE).

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
9455-11-PID-0-0043 (Sheet 1 of 1) REV: 04

BOILER SYSTEM
IF a LOW (L) level is detected by LIA-1070 in boiler feed water tank with Deaerator.
THEN a OPEN signal will be sent to make up water ON-OFF valve XV-1070 & it will open
OR
IF a HIGH (H) level is detected by LIA-1070 in boiler feed water tank with Deaerator.
THEN a CLOSE signal will be sent to make up water ON-OFF valve XV-1070 & it will close.
2. The Level indicator in Boiler feed water tank LIA-1070 gives alarm when it becomes either
High (H) or Low (L), an immediate investigation or preventive action to be taken accordingly.
3. The temperature indicator TICA-1070 gives alarm when it becomes either High – High (HH) or
High (H) or Low (L) or Low - Low (LL), an immediate investigation or preventive action to be
taken accordingly.
4. The Temperature of the boiler feed water with Deaerator is controlled by steam inlet control
valve, TCV-1070 which regulates the steam Flow to boiler feed water tank D-1070 as per the set
point of TICA-1070, when the temperature increases above set point, valve opening will reduce.

CLIENT CONTRACTOR
PROJECT

AL GHAITH CHEMICAL
CHLORINE PLANT
INDUSTRIAL LLC
PRODUCTION CALCULATION FORMULAS
1. Caustic Production:
FIA-250*1.35= ******* TPH

(Tag no. FIQ-250 in Depleted Brine & Catholyte Electrolysis)
2. Chlorine Production:
Production rate = 1.324 In η Cl2 x 1 x 10-8 TPH
I = Total electrolyser Current in Amps (Refer Tag no - AIA-230 x 1000)

n = 124
η Cl2 = % Chlorine Current Efficiency(manual entry)


9455 11 PCP 0 0001 - Process Control Philosophy R1

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9455 11 PCP 0 0001 - Process Control Philosophy R1

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CLIENT CONTRACTOR

70 MTPD CAUSTIC SODA &

Rev. Date Description Originator Reviewer Approver

00 25.01.2023 Issued for Review & Comments S.S N.K S.K.S

01 12.12.2023 Revised as Highlighted S.S N.K S.K.S

Project: 9455 Page: 1 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0001 (Sheet 1 of 1) REV:04

5. Motor/Drive provision of Start or Stop from DCS shall be provided.

6. All motors/drives status of running/stop/trip is provided in DCS.

Project: 9455 Page: 2 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0002 (Sheet 1 of 1) REV: 03

70 MTPD CAUSTIC SODA &

11. Motor/Drive provision of Start or Stop from DCS shall be provided.

12. All motors/drives status of running/stop/trip is provided in DCS.

Project: 9455 Page: 4 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0003 (Sheet 1 of 1) REV: 04

5. Motor/Drive provision of Start or Stop from DCS shall be provided.

6. All motors/drives status of running/stop/trip is provided in DCS.

Project: 9455 Page: 5 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0004 (Sheet 1 of 1) REV: 03

4. Motor/Drive provision of Start or Stop from DCS shall be provided.

5. All motors/drives status of running/stop/trip is provided in DCS.

Project: 9455 Page: 6 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0005 (Sheet 1 of 1) REV: 03

7. Motor/Drive provision of Start or Stop from DCS shall be provided.

8. All motors/drives status of running/stop/trip is provided in DCS.

Project: 9455 Page: 7 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

9455-11-PID-0-0006 (Sheet 1 of 1) REV: 03

9. Motor/Drive provision of Start or Stop from DCS shall be provided.

70 MTPD CAUSTIC SODA &

P‐114 A/B ‐ START & STOP (EMERGENCY POWER)

10. All motors/drives status of running/stop/trip is provided in DCS.

S.NO. Description Annexure No.

Project: 9455 Page: 9 of 75 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

Rev. Date Description Originator Reviewer Approver

0 25.01.2023 Issued for Engineering S.S S.K.S S.K.S

Project: 9455 Page: 1 of 7 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

ANTHRACITE FILTER SEQUENCE LOGIC

The sequence consist of 5 Steps as below:

Project: 9455 Page: 2 of 7 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

2.0 DESCRIPTION OF PARTICULAR STEPS

The steps are described below in detail for Filter “A”

2.1 Isolation (Step 1)

The filter is now off line and isolated.

The program now proceeds to the next step.

2.2 Backwash (Step 2)

On confirmation of pump start from running indication, a watchdog timer T0 (T0 =

Opening of XV 101A starts timer T2 (adjustable 0-30 min).

Project: 9455 Page: 3 of 7 Author: Salil Sharma

70 MTPD CAUSTIC SODA &

Timer T2 is reset to zero.

The program now proceeds to the next step.

2.3 Recycle (Step 3)

This initiates the timer T4 (adjustable 0-10 min).