Control Philosophy & Interlock Description - 9650-11-PCP-00-0002 R-04

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PROJECT
50 MTPD CAPACITY (Cl2

BASIS) CHLOR ALKALI
PLANT
SOCIÉTÉ CHÉRIFIENNE D'ENGRAIS ET
NUBERG ENGINEERING LTD.
DE PRODUITS CHIMIQUES
CONTROL PHILOSOPHY & INTERLOCK

DESCRIPTION
PROJECT: 50 MPTD (Cl2 BASIS) CHLOR ALKALI

PLANT - 9650
Rev. Date Description Originator Reviewer Approver

00 23.01.2019 Issue for Review DH S.K.S V.G
01 02.05.2019 Revised As Marked A.L S.K.S V.G
04 09.04.2021 Revised As Marked SM S.K.S V.G
Project : 9650 Page 1 of 79 Author: Shivam Mishra
Client: SCE, Morocco Doc. No.: 9650-11-PCP-00-0002 Revision: 04

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-001
BRINE RE-SATURATOR AREA
1. The flow of saturated brine from saturated pump P-01 A/B is maintained and controlled by
flow control valve 001-FCV-01 as per set point of 001-FICA-01. When the flow increases
above the set point control valve opening will decrease.
2. The flow transmitter 001-FI-01 gives alarm when it becomes either High (H) or Low (L).
3. Interlock (5)
When level indication 001-LI-01 of 001-T-02 becomes Low-Low (LL), the Saturated
brine pump (001-P-01 A/B) shall trip. (With interlock by pass switch)
4. The level indication 001-LI-01 of 001-T-02 gives alarm when it becomes either High (H) or
Low (L).
5. Motor/Drive provision of Start and Stop from DCS shall be provided.
001-P-01 A/B - STOP & START
6. All Interlocks should have Bypass switch available on common DCS screen. And the
indication of Bypass switch activated or deactivated should be available on each Interlock
number on each screen.

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0002( 1 OF 2 )
PRIMARY BRINE TREATMENT
1. The level indication 002-LI-060 of the Flocculants Tank D-060 gives alarm when it becomes either
High – High (HH) or High (H) or Low – Low (LL) or Low (L).
2. Interlock (I-060)
When level indication LI-060 of the Flocculants Tank D-060 becomes Low-Low (LL), the
Agitator A-062 shall trip.
3. The temperature indication 002-TI-01 gives alarm when it becomes either High (H) or Low (L).
4. The temperature Indication 002-TI-02 gives alarm when it becomes either High (H) or Low (L).
A-062 - STOP AND START

002-A-01 - STOP AND START (Emergency Power)
002-A-02 - STOP AND START (Emergency Power)
9. The flow of 18% Caustic soda is maintained & controlled by Flow control valve 002-FCV-05 as per
the set point of 002-FICA-05.
10. All Interlocks should have Bypass switch available on common DCS screen. And the indication of
Bypass switch activated or deactivated should be available on each Interlock number on each screen.

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0002 (2 of 2)
PRIMARY BRINE TREATMENT
1. The level indication 002-LI-01 of the Treated Brine Tank 002-T-04 gives alarm when it becomes
either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
2. Interlock (6)
When level indication 002-LI-01 of the Treated Brine Tank 002-T-04 becomes Low-Low (LL),
the Treated Brine Pump 002-P-02A/B shall trip.
3. The temperature indication 002-TI-03 (for water) of the Clarifier gives alarm when it becomes
either High – High (HH) or High (H).
4. The temperature indication 002-TI-04 (for brine) of the Clarifier gives alarm when it becomes either
High – High (HH) or High (H).
5. Differential Temperature indication DTI-03 measures the differential temperature of the brine
clarifier. The median of 002-TI-03 & 002-TI-04 value is taken as the measured value.
When Pressure indication 0026-PI-090 of the Filter press F-090 feed line High-High (HH), the
Brine settler mud Pump 002-P-01A/B shall trip.
7. The Flow transmitter 002-FI-04 gives alarm when it becomes either High (H) or Low (L).
8. Interlock (7)
When level switch 002-LS-05 of settler mud tank 002-T-05 becomes Low (L) the Brine settler
mud Pump 002-P-01A/B as well as Agitator 002-A-05 shall trip.
002-P-01A/B - STOP & START

002-A-03 - STOP & START (EMERGENCY)
002-P-02A/B - STOP & START
Bypass switch activated or deactivated should be available on each Interlock number on each
screen.

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0003(1OF 3)
BRINE FILTER
1. The level indication 003-LI-01 of the Filtered Brine Tank 003-T-01 gives Alarm when it becomes
2. Interlock (9)
When level indication 003-LI-01 of the Filtered Brine Tank 003-T-01 becomes Low-Low (LL),
the Filtered Brine Pump 003-P-01A/B shall trip and the flow control valve FV-1401A/B of
running Polish filter (F-140A/B) shall close.
3. The level in the Filtered Brine Tank 003-T-01 is maintained by controlling the Flow of brine by Flow
Control Valve 003-FV-01 as per the set point of 003-LICA-01 or as per the set point of 003-FICA-01.
When flow increases above set point valve opening will reduce.( through selector switch on DCS)
Selector Switch
The flow shall change within minimum & maximum range as per the se point of 003-LICA-01.
Flow Controller (003-FICA-01) - When flow increases above set point the valve opening will reduce.
Level Controller (003-LICA-01) - When level increases above set point, the valve opening will
reduce.
4. The flow of brine through Filter is controlled by Flow control valve 003-FCV-01 as per the set point
of 003-FICA-01. When flow increases above set point valve opening will reduce.
5. The flow transmitter 003-FIA-01 gives alarm when it becomes either High (H) or Low (L).
6. The flow of process water during back wash of Filter is controlled by Flow control valve 003-FCV-02
as per the set point of 003-FICA-02. When flow increases above set point valve opening will reduce.
7. The flow transmitter 003-FIA-02 gives alarm when it becomes either High (H) or Low (L).
8. Differential pressure indicatior 003-DPIA-01A/B gives alarm when it become High (H) & Low (L).
003-P-01A/B - START & STOP (EMERGENCY)

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PLANT
Bypass switch activated or deactivated should be available on each Interlock number on each screen.
For the first time fill the filter 003-F-01A with water by selecting the switch is to manual mode open the
following valve –
003-XV-05A ,003-XV-02A and 003-FV-01 to set point 18 m3/hr for 30 min.
Settling Of anthracite:-
After 60 min close valve 003-XV-05, 003-XV-02 and 003-FV-02 for 5 min.
Resetting:-
After 5 min open the valve 003-XV-01, 003-XV-06 and 003-FCV-01 to set value 18 m3/hr. for 10 min and
open the manual valve to 009-T-01.
Preparation Prior to operation:-
After 10 min check the gpl. If it is greater than 280 open block valve to clarified brine tank for 05 min.
Operation:-
Condition check: The filter will check, No back wash/ Backwash complete, switch is stop.
After 01 min open valve 003-XV-07 and close 003-XV-06 and filter will come into operation. 003-F-01A will
be in operation and keep 003-F-01B in standby. Select switch A (O)-B(S) and put the whole operation into
auto mode in which A will be in operation and B will be in standby.
After 24 hrs or turbidity greater than 2 whichever is earlier, it will generate an alarm for filter A time
exhaust. Select switch B (O)-A(S)
Then 003-XV-01, 003-XV-07 will open and remain open, 003-XV-01 and 003-XV-07 will remain open for
120sec after 120 sec 003-XV-14 and 003-XV-13 will open, 003-XV-01, 003-XV-07 will close.
Back wash of 003-F-01A:-
Condition check: The filter should not be in operation (inlet outlet valve should be close).
Select switch start only when 003-LS-145 is low (operator decision)
1. Brine Draining:-
003-XV-03, 003-XV-06 will open and brine will drain to 002-T-04 for 300 sec.
2. Preparation for backwash. :-

After 300 sec. 003-XV-03, 003-XV-06 will close and 003-XV-05, 003-XV-02 will open for 30 sec.
3. Backwash:-

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PLANT
After 30 sec 003-XV-04 will open and 003-FCV-02 will open at set point 18 m3/hr (set value can be changed
if required) and other valve 003-XV-02 and 003-XV-05 will remain open for 30 min.
4. Settling of anthracite:
After 30 min 003-XV-04, 003-XV-05 and 003-XV-02 will close and 003-FCV-02 will close with a ‘0’ set value
for 300 sec.
5. Resetting:-
After 300Sec 003-XV-01 and 003-XV-06 will open for 600sec
6. Backwash finish:-
After 600sec check the gpl manually and if it is greater than 280 then select backwash finish then 003-XV-
01, 003-XV-06 will close.
After 24 hours of backwash finish it will generate alarm for filter B time exhaust Select switch A (O)-B(S)
(operator decision)
Back wash of 003-F-01B:-
Condition check: The filter should not be in operation (inlet outlet valve should be close).
Select switch start only when 003-LS-145 is low (operator decision)
1. Brine Draining:-
003-XV-10, 003-XV-13 will open and brine will drain to 002-T-04 for 300 sec.
2. Preparation for backwash. :-

After 300 sec. 003-XV-10, 003-XV-13 will close and 003-XV-12, 003-XV-09 will open for 30 sec.
3. Backwash:-
After 30 sec 003-XV-11 will open and 003-FCV-02 will open at set point 18 m3/hr (set value can be changed
if required) and other valve 003-XV-09 and 003-XV-12 will remain open for 30 min.
4. Settling of anthracite:
After 30 min 003-XV-11, 003-XV-12 and 003-XV-09 will close and 003-FCV-02 will close with a ‘0’ set value
for 300 sec.
5. Resetting:-
After 300Sec 003-XV-08 and 003-XV-13 will open for 600sec

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BASIS) CHLOR ALKALI
PLANT
6. Backwash finish:-
After 600sec check the gpl and if it is greater than 280 then select backwash finish then 003-XV-08, 003-XV-
13 will close.
After 24 hours of backwash finish it will generate alarm for filter B time exhaust Select switch A (O)-B(S)
(operator decision)
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 back wash is selected for the filter .it should start back wash from step 1 till step 6
3. All timings should be adjustable from the screen.
11. The following documents are to be referred for Polish brine Filter Sequence operation.
Sl. NO Description Annexure No

1. LOGIC TIME CHART Annexure-E
2. SEQUENCE OPERATION Annexure-F

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0003(2 OF 3)
BRINE FILTRATION
(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) and the following step.
• Liquid Filling 1 (Step No.102)
• Over Flow (Step No.103)
• Liquid Filling 2 (Step No.104)
• Precoat 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. (See terms E. 2. (4)
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 Filtered Brine pump (003-P-01A/B) by manual before Recirculation step (Step No.309).
d) After F-140A Brine Filter is in filtration process Step No.401）,set F-140B Operation switch turn
“RUN” position.
F-140B Brine filter advances each step, automatically as per the Following. Stand-by mode :

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BASIS) CHLOR ALKALI
PLANT
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 and return to preparation of precoat 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 and 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 precoat 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, and restart the operation from precoat preparation (Step
No.101) process.
3. PROCESS DESCRIPTION FOR BRINE FILTER UNIT

(I) The operation process can be mainly divided into four (4) processes.
Normally, the following operation in performed, in turn, namely,
Preparation of precoat  Precoat  Filtration  Washing  Preparation of precoat 
Precoat  Filtration  Washing ……. (in this repetition )

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a) Preparation of precoat
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. α-cellulose
in the required quantity is dosed into precoat tank.
When “PRECOAT AID PREPARATION FINISH” button has been pushed and the required
time has passed, filtered brine is filled into precoat tank and the agitation starts.
b) Precoat
Filtered Brine mixed with α-cellulose is sent into filter vessel α-cellulose powder is
attached evenly on the surface of filter elements, the precoat 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 precoat 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 and Filtration.
d) Washing
The impurities attached and α-cellulose on the surface of filter elements are removed and
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 and level switch
number of F-1401B filter, replace A with B.
a) Preparation of precoat
-1. Preparation of process (Step No.101)
Filter wash pump (003-P-03) is started before a Liquid filling process start.
• Setting time: 10 sec.
-2. Liquid filling 1 (Step No.102)

To secure precoat liquid, filtrate brine is filled into filter up to the required level. Filter wash pump
(003-P-03) is started, Washing brine inlet valve (XV-1406A), Upstream air vent valve (XV-
1411A, XV-1416A, XV-1417A), drain valve (XV-1415) are opened, and the liquid
is filled into filter vessel until its level (LS-1402-A) 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 (XV-1411A, XV-1416A, XV-1417A) and Upstream drain valve (XV-1415)
are Closed, Washing brine inlet valve (XV-1406A), Downstream air vent valve (XV-1408A) is
opened, and then liquid is filled into filter vessel until its level (LS-1401-A)reaches “HH” for 5 sec.
-5. Precoat tank liquid filling (Step No.105)

Filter wash pump (003-P-03) remains running after 5 sec. XV-1413 open and XV-1406 A closed
and XV-1408 remains open , Precoat tank supply valve (XV-1413) is opened, and the liquid filled
into precoat tank until its level (LIA-120) reaches “H”. When level (LIA-120) has reached “H”,
Precoat tank supply valve (XV-1413) is closed, Filter wash pump (003-P-03) is stopped, and the
precoat tank filling of liquid is completed. Downstream air vent valve (XV-1408A) closes.
-6. Precoat aid dosage

Dose precoat aid（α-cellulose）into the Precoat tank and push the “PRECOAT AID
PREPARATION FINISH” button.
-7. Agitation (Step No.106)

Precoat tank agitator (A-122) .
• Setting time : 10 min A-122 keeps running.
b) Preperation of precoating
-1. Agitation (Step No.301)
Precoat tank agitator (A-122) is started.

Setting time : 5 min
-2. Preparation of process (Step No.302)
Precoat pump (P-124) is started before a Mixing process start.

Setting time : 10 sec
-1. After 10 sec. of precot 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 precoat tank” and “The brine in
filter vessel” circulate concentration. Precoat inlet valve (XV-1403A), FV-1401A with set point ,
Upstream air vent valve (XV-1411A, 1416A, 1417A), Precoat return valve (XV-1414) are opened,

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and the liquid mixed with α-cellulose, which left Precoat tank (D-120), is returned again into the
Precoat tank, via filter vessel upstream side by Precoat pump (P-124).
• Setting flow rate: 33 ㎥/hr.

• Setting time: 10 min.
-3. Precoating (Step No.304)

After 10 min. XV-1402 A will open and upstream air vent valve (XV-1411A ,1416 A ,XV-1417A, XV-
1403.XV-1414) will closed.
• Setting flow rate : 33 ㎥/hr.
• Setting time : 30 min.
-4. Flow rate change (Step No.305)

Proceed to Precoat (2) (Step No.10) from Precoat (1) (Step No.9) process. Precoat liquid is returned
into Precoat tank（D-120）through filter element, letting precoat layer of α-cellulose form on the
surface of filter element. Change the flow rate from precoat flow rate (33 ㎥/hr.) to design filtration
flow rate (26 ㎥/hr.) by flow control system (FIC-140A)
• A will Stop
Avoid as possible a flow stop or sudden flow change in this process which affect precoat layer,
inducing clogging of filter element.
-5. Overlapping (Step No.306)

After 5 min XV-1412 open and all the valve will remain as it is.
Overlapping process opens the valve before and behind a process change simultaneously in order
not to stop the flow of liquid.
• Setting time : 5sec.
-6. Precoat tank liquid discharge (Step No.307)

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

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not to stop the flow of liquid. Change the flow rate from design filtration flow rate (26㎥/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 26 m3/hr.)
• Setting time: 5sec.
-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 (XV-1401A) open, and Precoat inlet valve (XV-1403A) and
Precoat pump (P-124) stop and rest valve remain as it is .
• Setting flow rate: F ㎥/hr.
• Setting time : 5 min

If 003-LIA-02 is less than high then XV-1404 A will open for 5 sec otherwise all the valves will
remain as it is till 003-LIA-02 becomes Less than high
not to stop the flow of liquid.
• Setting flow rate: F ㎥/hr.
• Setting time: 5sec.
c) Filtration
-1. Filtration (Step No.401)
When overlapping has been completed, Brine inlet valve (XV-1401A) and Filtered brine outlet
valve (XV-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 fiteration finish F-140 B then XV-1408 will open and XV-1401B ,XV-1404 B and FV-1401 B
will close.
-3. Conditions of Recirculation (Step No.411) during filtration
When finish filtered brine tank level (003-LIA-02) has reached “H”. But, when another operating
filter is in one of “Preparation of Precoat”, “Precoat” or “Washing” process, the filter in Filtration
process cannot enter this Recirculation process.
-4. Conditions that recirculation return to filtration

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When finish filtered brine tank level (003-LIA-02) is less than “H”.
d) Washing
Normally, washing process is repeated in 4 times, and the washing steps to be made each time are
as follows.
Three Upstream air vent valves (XV-1416A, XV-1417A, XV-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 XV-1408 A will remain open and XV-1411 A, XV-1416A, XV 1417-A and XV-1415
will open for 60 sec.
• Filling:-Valve 1411 A, XV-1416A ,XV-1417A and XV-1415 will remains open till the LS1402A
becomes H after that Valve XV-1411 A, XV-1416A KV 1417-A and XV-1415 will closed and valve
XV-1406 A remains open and pump 003-P-03 will started till LS1401 A becomes HH. When LS
1401A becomes HH Pump 003-P-03 will stop and XV-1406 A and XV-1408 A will closed.
• Pressurization:-Valve XV-1407A will open for 10 Sec.
• Flash Washing:-Valve XV-1405A will open for 5 sec.
• Discharge:-XV-1405 A will remains open and valve XV-1408 A will open after 5 Sec for 180 sec. After
180 sec. XV-1405 A will closed.
→ Pressurization → Flash washing → Discharge 2

→ Air vent → Preparation of process
→ Liquid filling 1 (XV-1411A) → Over flow (XV-1411A)
→ Liquid filling 2
2nd Washing:
• Filling:-Valve 1411 A, XV-1416A ,XV 1417 A and XV-1415 will remains open till the LS1402 A
becomes H after that Valve XV-1411 A, XV-1416A XV 1417-A and XV-1415 will closed and valve
1401A becomes HH Pump 003-P-03 will stop and XV-1406 A and XV-1408 A will closed.
• Discharge:-XV-1405 A will remains open and valve XV-1408 A will open after 5 Sec for 180 sec. After

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→Pressurization → Flash washing →Discharge 2

→ Liquid filling 2
3rd Washing:
1401A becomes HH Pump 003-P-03 will stop and XV-1406 A and XV-1408 A will closed
• Discharge:-XV-1405 A will remains open and valve XV-1408 A will open after 5 Sec for 180 sec.After
→Pressurization → Flash washing → Discharge 2

→ Liquid filling
4th Washing:
1401A becomes HH Pump 003-P-03 will stop and XV-1406 A and XV-1408 A will closed
• Discharge:-XV-1405 A will remains open and valve XV-1408 A will open after 5 Sec for 180 sec.
After 180 sec. XV-1405 A will closed.
• Filling:-After 180 sec. valve XV-1406 A will open and pump 003-P-03 will started till LS1401 A
becomes HH.
→Pressurization → Flash washing →Discharge 2

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


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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 (XV-1408A) and Precoat outlet valve (XV-1402A)
is opened.
-3. Pressurization (Step No.503)

Precoat outlet valve (XV-1402A), Downstream air vent valve (XV-1408A) close, and Air
pressurization valve (XV-1407A) opens.
• Setting condition : Timer 5sec. and pressure 4.5 kg/cm2g.
-4. Flash Washing (Step No.504)

Air pressurization valve (XV-1407A) is closed and Mud discharge valve (XV-1405A) is opened to
perform the flush washing.
• Setting time : 10 sec.
At the initial start, the full opening time of Mud discharge valve (XV-1405A) must be set at 3 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 (XV-1408A) is opened, and the residual in filter is discharge
-6. Air vent (Step No.506)
Mud discharge valve (XV-1405A) closes, and the air is discharged from downstream air vent valve
(XV-146A).
• Setting time : 10 sec.
When 4th washing has been completed. step jumps to the said Liquid filling (Step
No.101), preparation of precoat.

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BASIS) CHLOR ALKALI
PLANT

Washing brine inlet valve (XV-1406A) and Upstream air vent valve (1st time=XV-1411A,
2nd time=XV-1416A, 3rd time=XV-1417A), Drain valve (XV-1415) are opened, and filtered
brine is filled into filter until its level (LS-1402-A) reaches “H”.
-8. Over flow (Step No.509)

Washing brine is overflow from Upstream air vent valve (1st time=XV-1411A, 2nd time=XV-1416A,
3rd time=XV-1417A), and the filter cake accumulated under perforated plate is washed away.
When Upstream air vent valve (1st time=XV-1411A, 2nd time=XV-1416A, 3rd
time=XV-1417A) and Drain valve (XV-1415) close, Downstream air vent valve (XV-1408A)
opens. Washing brine is filled into the filter until the level (LS-1401-A) reaches “HH”.
When the Liquid filling (2) is completed, Washing brine inlet valve (XV-1406A) closes.
4. The level indication LI-120 of the Precoat Tank D-120 gives alarm when it becomes either High –
High (HH), High (H), Low – Low (LL), Low (L).
When level indication LI-120 of the Precoat Tank D-120 becomes Low-Low (LL), the Precoat
Pump P-124 as well as Agitator A-122 shall trip.
6. The level indication LI-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).
When level indication LI-130 of the Body Feed Tank D-130 becomes Low-Low (LL), the Body
Feed Pumps P-134A/B as well as Agitator A-132 shall trip.
8. The level switch LS-145 of the Filter Slurry Pit PI-145 gives Alarm when it becomes either high (H)
or Low (L) or Low – Low (LL).
When level switch LS-145 of the Filter Slurry Pit PI-145 becomes Low-Low (LL), the Filter
Slurry Pumps P-144 as well as Agitator A-142A/B shall trip.
10. The level indication 003-LI-02 of the Polished Brine Tank 003-T-02 gives Alarm when it becomes

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BASIS) CHLOR ALKALI
PLANT
11. Interlock (10)

The level indication 003-LI-02 of the Polished Brine Tank 003-T-02 becomes Low-Low (LL),
the Polished Brine Pumps 003-P-02A/B and Filter Wash Pumps (003-P-03) shall trip.
12. The Flow of brine from Filtered brine pump (003-P-01A/B) to brine polishing filter (F-140 A) is
controlled by FV-1401 A as per the set point of FIC-1401 A. when flow increases above set point
valve opening will reduce.
13. The Flow of brine from Filtered brine pump (003-P-01A/B) to brine polishing filter (F-140 B) is
controlled by FV-1401 B as per the set point of FIC-1401 B. when flow increases above set point
valve opening will reduce.
14. The flow indication FI-1401 A of the Brine Polish filter F-140A gives alarm when it becomes either
High – High (HH) or High (H) or Low – Low (LL) or Low (L.
15. The flow indication FI-1401 B of the Brine Polish filter F-140B gives alarm when it becomes either
16. The level of Polished Brine Tank 003-T-02 is controlled by Flow Control Valve FV-1401 A/B as per
the set point of 003-LI-02.The flow shall change within maximum & minimum flow range as per the
set point of level. (optional)
17. Motor/Drive provision of Start and Stop from DCS shall be provided
A-122 - START & STOP

P-124 - START & STOP
A-132 - START & STOP
P-134 A/B - START & STOP
A-142 A/B - START & STOP
18. All Interlocks should have bypass switch available on common DCS screen. And the indication of
by pass switch activated or deactivated should be available on each interlock number on each
screen.

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BASIS) CHLOR ALKALI
PLANT
19. The following documents are to be referred for Polish brine Filter Sequence operation.

OPERATING TIME CHART FOR BRINE
1. Annexure-A
FILTER UNIT
2. FLOW CONTROL LOGIC Annexure-B
20 All Interlocks should have Bypass switch available on common DCS screen. And the indication of
Bypass switch activated or deactivated should be available on each Interlock number on each
screen.

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0003( 3 OF 3)
BRINE FILTRATION
1. The level indication 003-LI-02 of the Polished Brine Tank 003-T-02 gives Alarm when it
becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
2. The Temperature indication 003-TI-01 give alarm when it becomes High-High (HH) or High
(H).
3. The temperature of the Polished Brine is controlled by steam inlet control valve, 003-TCV-
01 which regulates the steam Flow from Brine Pre Heater 003-E-01 as per the set point of
003-TI-01.when temperature increased above set point valve opening will reduce.
4. The temperature switch 003-TSZ-03 gives alarm when it becomes either High (H) or High-
High (HH).
5. Interlock (Z-12)
If High-High (HH) temperature is detected by temperature switch 003-TSZ-03 on
Brine Heater 003-E-01.Then steam control valve 003-TCV-01 will close.
6. Interlock (10)
When the level indication 003- LI-02 of Polished Brine tank (003-T-02) becomes Low-Low
(LL), the Polished Brine Pump 003-P-02 A/B & 003-P-03 shall trip.

003-P-02 A/B - START & STOP
003-P-03 - START & STOP
8. All Interlocks should have Bypass switch available on common DCS screen. And the
indication of Bypass switch activated or deactivated should be available on each interlock
number on each screen.

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BASIS) CHLOR ALKALI
PLANT
9650-11-PID-00-0004
ION EXCHANGE PURIFICATION
1. The Flow Indication FI-160 of Brine from Polish Brine Pump 003-P-02A/B to Ion exchange column
T-160 A/B/C gives alarm when it becomes either High (H) or Low (L).
2. The Flow of brine from Polish Brine Pump 003-P-02A/B to Ion exchange column T-160 A/B/C is
controlled by FV-160 as per the set point of FIC-160. When flow increase above set point, the valve
opening shall reduce.
3. The Flow indication FI-163 of brine from Polish Brine Pumps 003-P-02A/B to Ion exchange column
T-160 A/B/C gives alarm when it becomes either High (H) or Low (L).
4. The Flow indication FI-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).
5. The Flow indication FI-169 of 32% caustic to Ion exchange column T-160 A/B/C gives alarm when
it becomes either High (H) or Low (L).
6. The Flow indication FI-162 of 18% HCL to Ion exchange column T-160 A/B/C gives alarm when it
becomes either High (H) or Low (L).
7. The flow of DM water from DM water Header to Ion Exchange column T-160 A/B/C is controlled by
flow control valve FV-164 as per the set point of FIC-164.when flow increases above set point valve
opening will reduce.
8. The Flow Indication FI-161 of Brine from Purified Brine Strong Pump 005-P-01A/B to Ion Exchange
column T-160 A/B/C gives alarm when it becomes either High (H) or Low (L).
9. The level indication 005-LI-01 of the Purified Brine Tank 005-T-01 gives alarm when it becomes
10. The level indication LI-160 of the Waste Alkali Tank D-160 gives alarm when it becomes either
11. The flow of 18% HCl control by Flow control valve FV-162 as per the set point of FICA-162. When
flow increases above set point valve opening will reduce.
12. The flow of 32% Caustic control by Flow control valve FV-169 as per the set point of FICA-169.
When flow increases above set point valve opening will reduce.

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BASIS) CHLOR ALKALI
PLANT
13. The flow of polished brine is controlled by 004-FCV-160 as per the set point of 004-FICA-160 or by
005-LI-01 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.
14. Motor/Drive provision of Start & Stop in DCS shall be provided in DCS to MCC panel

When the level indication 004- LI-160 of waste alkali tank D-160 becomes Low-Low (LL), the
Transfer Pump for Waste Alkali Tank P-164 shall trip.
16. The following documents are to be referred for Ion Exchange Column (T-160 A/B/C)
Regeneration, Time Chart and Sequence operation.

9. LOGIC TIME CHART Annexure-C
10. LOGIC TIME CHART Annexure-D
Bypass switch activated or deactivated should be available on each interlock number on each screen.

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BASIS) CHLOR ALKALI
PLANT
PURE BRINE FEED AREA

9650-11-PID-00-0005
1. The level indication 005-LI-01 of the Purified brine Stroage tank 005-T-01 gives alarm when it
2. The level indication 005-LI-03 of pure brine Top-up tank gives alarm when it becomes either Low –
Low (LL) or Low (L).
3. Interlock (Z-16)
When level indication 005-LI-01 of Purified brine tank 005-T-01 becomes Low-Low. The
Pure pumps 005-P-01A/B shall trip and Steam Heating control valve 006-TCV-01A shall close.
4. Interlock (IZ-170)
When any one of pump 005-P-01 A or B shall trip another pump will start automatically. If
following condition is normal–
• 005-LI-01 is not Low – Low (LL).
• Another Pump trip signal from MCC is not coming.
5. Interlock (Z-13)
If a motor STOP signal is detected on both of Pure brine Pump 005-P-01 A/B for certain
period (> 60 seconds to allow for auto-changeover), than On-off valve 007-XV-04 shall open
and Control valve 007-FCV-01 , 006-TCV-01A will close.
An activation signal will be sent to Interlock Z-1.
6. Motor/Drive provision of Start & Stop in DCS shall be provided.
005-P-01 A&B - START & STOP (EMERGENCY)
Bypass switch activated or deactivated should be available on each interlock number on each
screen.

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BASIS) CHLOR ALKALI
PLANT
PURE BRINE HEAT CONDITIONING

9650-11-PID-00-0006
1. The temperature of the Feed Brine is controlled by steam inlet control valve, 006-TCV-01A which
regulates the steam Flow to Feed brine heater 006-E-01 as per the set point of 006-TIC-01. When
temperature increased above set point valve opening will reduce.
2. The temperature Indicator 006-TI-01 of feed brine to electrolyser gives alarm when it either High-
High (HH) or High (H) or Low(L).
3. The changeover of heating mode & cooling mode is done manually through DCS by selector switch
in DCS & in field will be done by field operator for startup brine Heater/Cooler 006-E-01.
4. The temperature of feed brine to electrolyser is controlled by cooling water inlet control valve 006-
TCV-01B, which regulate the cooling water flow to 006-E-01 as per the set point of 006-TICA-01.
When temperature increase above set point, valve opening will increase.
5. The Flow indication 006-FI-01 of the DM Water gives alarm when it becomes either High (H) or Low
(L).
6. Interlock (Z-14)
When the temperature at the outlet of feed brine heater 006-E-01 becomes High-High (HH)
temperature control valve 006-TCV-01A shall close.
This valve will remain interlocked until the temperature drops below High.
screen.

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PLANT
CELLROOM ELECTROLYSER
9650-11-PID-00-0007
1. The Flow indication 007-FI-01 of the Feed brine to electrolyser gives alarm when it becomes either
High (H) or Low – Low (LL) or Low (L).
2. The flow of feed brine is maintained and controlled by flow control valve 007-FCV-01 as per set
point of 007-FIC-01. When the flow is increase above the set point control valve opening will reduce.
The flow setpoint is set by the plant control system, in ratio to the electrolyser running current
density (load), although there is the capability for trim this value.
The following algorithm describes the relationship between the setpoint for the pure brine feed
flow controller 007-FIC-01 and measured DC current:
Fb = 0.0151 C N P in the range 6.78 to 20.33 kA

Fb = 0.1037 N in the range 0 to 6.78 kA
Where:
Fb = Pure brine feed flowrate setpoint (m3/h)
C = Measured DC current to electrolyser (kA)
N = Number of modules in electrolyser (46 nos.)
P = Operator settable adjustment factor, limited to the range 0.9 to 1.1
3. The Flow indication 007-FI-02 of the Feed catholyte to electrolyser gives alarm when it becomes
either High (H) or Low – Low (LL) or Low (L).
4. The flow of feed catholyte is maintained and controlled by flow control valve 007-FCV-02 as per set
point of 007-FIC-02. When the flow is increase above the set point control valve opening will reduce.
The flow setpoint is set by the plant control system, in ratio to the electrolyser running current
density (load), although there is the capability for operator trim this value. This can be used to help
with temperature control.
The following algorithm describes the relationship between the setpoint for the catholyte feed flow
controller FICZ-02 and measured DC current:
Fc = 0.0151 C N P in the range 6.78 to 20.33 kA

Fc = 0.1037 N in the range 0 to 6.78 kA

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PLANT
Where:
Fc = Catholyte feed flowrate setpoint (m3/h)
C = Measured DC current to electrolyser (007-U-01) (kA)
N = Number of modules in electrolyser (0-90)
P = Operator settable adjustment factor, limited to the range 0.9 to 1.1
5. The Flow indication 007-FI-05 of the Nitrogen line to electrolyser gives alarm when it becomes
either High (H) or Low (L).
6. The Flow indication 007-FI-04 of the plant air line to electrolyser gives alarm when it becomes
7. The temperature Indicator 007-TI-02 of catholyte from electrolyser gives alarm when it either High
(H) or High – High (HH) or Low (L).
8. The PLC of Voltage Monitoring System(VMS) will give the feedback/data of individual of each cell to
DCS.
9. The temperature Indicator 007-TI-01 of anolyte from electrolyser gives alarm when it either High
(H) or Low (L).
10. The Pressure indication 007-PI-04 A/B/C of the Hydrogen gas from electrolyser gives alarm when it
11. The Pressure indication 007-PI-03 A/B/C of the Chlorine gas from electrolyser gives alarm when it
12. The Differential Pressure indication 007-DPI-01 A/B/C of the Chlorine gas & Hydrogen gas from
electrolyser gives alarm when it becomes either High – High (HH) or High (H) or Low – Low (LL) or
Low (L).
13. The Electrolyser Voltage 007-VIZ-01 gives alarm when it becomes either High – High (HH), High (H).
14. Individual Module voltage 007-VIZ-01 to 90 gives alarm when it becomes High(H) or High –
High(HH).
15. The Electrolyser Current 007-IIZ-01 gives alarm when it becomes either High – High (HH), High (H)
or Low - Low (LL) or Low (L).

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PLANT
16. Interlock (Z-1) Whole Cell room Trip
If there is a plant power failure resulting in loss of power to rectifier (007-U-01_TF)
OR a Low-Low (LL) level is detected by 005-LI-03 in Pure Brine top-up Tank (005-T-02).
OR a High-High(HH) level is detected by 008-LI-01A or 008-LI-01B in Anolyte Tank (008-T-

01).
OR a Low-Low (LL) level is detected by 008-LI-01A or 008-LI-01B in Anolyte Tank (008-T-

01).
OR a High-High (HH) level is detected by 010-LI-01 or 010-LI-02 in Catholyte Tank (010-T-01).
OR a Low-Low(LL) level is detected by 010-LI-01 or 010-LI-02 in Catholyte tank(010-T-01).
OR a Low-Low (LL) level is detected by 010-LI-04 in cathloyte top-up tank head tank (010-T-
02).
OR High-High (HH) pressure is detected by any two of three or all 007-PI-03A, 007-PI-03B,
007-PI-03C on the Cellroom Chlorine header.
OR High-High (HH) pressure is detected by any two of three or all 007-PI-04A, 007-PI-04B,
007-PI-04C on the Cellroom Hydrogen header.
OR a High-High (HH) Temperature is detected by 007-T-02 on the Catholyte header.
OR a High-High (HH) cell room differential pressure is detected by two out of three of 007-
DPI-01 A/B/C.
OR a Low-Low (LL) cell room differential pressure is detected by two out of three of 007-DPI-
01 A/B/C.
OR an emergency stop button is activated in 007-HS-01.
OR an Emergency stop switch is selected in DCS panel.
OR If there is a plant Instrument Air 038-PI-1050 pressure become Low-Low (LL).

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PLANT
OR High-High(HH) current is detected from the rectifier 007-U-01_CF.
OR Low-Low(LL) current is detected from rectifier 007-U-01_CF. (This Signal needs to be

ignored during Start-UP sequence)
OR trip/interlock 23 is activated.
OR trip/interlock Z3 is activated.
OR trip/ interlock Z-18 is activated.
OR trip/interlock 24 is activated.
OR trip/interlock Z-23 is activated.
OR Chlorine pressure control valve 016-PCV-02 is open > 10% for more than 5 minutes and
current 007-IIZ-01 is > 6.778 KA.
OR a High-High(HH) Pressure is detected by 015-PI-01 on chlorine feed to 015-C-01.
OR a motor STOP singal is detected by 015-XA-01A and 015-XA-01B on both chlorine

absorption pump 015-P-01 A&B for a sustained period of 60 Seconds ( to allow for auto
changeover).
OR a Low-Low (LL) flow is detected for a sustained period of 60 seconds by 015-FI-02 on the
circulation return to 015-C-01.
OR a Low-Low(LL) level is detected by 015-LI-02A in emergency absorber circulation tank

015-T-02A and 015-V-03A is OPEN.

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BASIS) CHLOR ALKALI
PLANT
OR a Low-Low(LL) level is detected by 015-LI-02B in emergency absorber circulation tank

015-T-02B and 015-V-03B is OPEN.
OR a motor STOP signal is detected by 015-XA-03A AND 015-XA-03B on both emergency

absorber Blowers 015-K-01A&B for a sustained period of 60 second ( to allow for auto change
over).
OR a Low-Low(LL) Level is detected by 015-LI_03 in 18% caustic tank 015-T-03.
OR a High-High(HH) chlorine absorption circulation temperature is detected by 015-TI-01.
OR a High-High(HH) emergency chlorine absorption column temperature is detected by 015-

TI-04.
OR Brine flow 007-FI-01 will show (-)20% deviation in flow from set point for 60 seconds.
OR Caustic flow 007-FI-02 will show (-)20% deviation in flow from set point for 60 seconds.
OR Rectifier stops (Rectifier inter logic fails).
OR HCL synthesis unit mail Interlock (Z-45) is activated. (By pass arrangement provided on
DCS screen).
THEN
A Signal will be sent to switch off rectifier and the polarizing rectifier will start
AND a signal will be sent to Plant air isolation valves 007-XV-02 and it will open.
AND a signal will be sent to Nitrogen isolation valves 007-XV-01 and it will open.
AND a signal will be sent to Pure Brine control valve 007-FCV-01 to ensure they are in AUTO
with set point = 14 m3/hr. (NOTE-1)
AND a signal will be sent to catholyte control valve 007-FCV--02 to ensure they are in AUTO
with set point = 18.9 m3/hr. (Note-1)
(NOTE-1  Flow rates of brine & caustic are for 70 installed modules. If for the modules are
added then flow rate set point must be increased Proportionally to the number of modules for
90 installed modules, the flow rate for brine is 18 m3/hr and for caustic 24.3 m3/hr.)

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PLANT
AND a signal will be sent to Anolyte HCl flow control valve 008-ACV-01 and it will close after a
delayed of 30 min.
AND a signal will be sent to Anolyte HCl flow control valve to chlorate destruction 008-FCV-02
and it will close.
AND a signal will be sent to Caustic control valve 010-LCV-01 and it will close.
AND a signal will be sent to Catholyte tank nitrogen purge valve 010-XV-02 & it will open.
AND a signal will be sent to DM water flow control valve 011-FCV-01 & it will close.
AND a signal will be sent to Chlorine pressure control valve 016-PCV-01 & it will close.
AND a signal will be sent to Chlorine pressure control valve 016-PCV-02 & it will open.
AND a signal will be sent to Hydrogen pressure control valve 020-PDCV-01 & it will close.
AND a signal will be sent to Hydrogen pressure control valve 020-PDCV-02 to ensure it is in
AUTO with a set point equal to 250 mmwc.
AND a signal will be sent to HCL synthesis unit and Z-45 will trip.
A reset of the system, once the trips have cleared, will be via operation of local button in DCS.
17. Interlock (Z-3)
IF a LOW LOW electrolyser brine flow is detected by 007-FIC-01 for a sustained period of
60 seconds.
OR a HIGH HIGH module or electrolyser voltage is detected in the voltage monitoring
system (007-VIZ-01).
THEN a signal will be sent to pure brine emergency feed valve 007-XV-04 and it will OPEN,
AND an activation signal will be sent to Z1.
AND Polarisation rectifier will STOP after 50 minutes
A reset of the system, once the trips have cleared, will be via the pressing of a button in the
control room.
18. Interlock (Z-4)

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BASIS) CHLOR ALKALI
PLANT
IF a LOW LOW electrolyser caustic flow is detected by 007-FICZ-02 for a sustained period
of 60 seconds.
OR a HIGH HIGH module or electrolyser voltage is detected in the voltage monitoring
system, 007-VIZ-01.
THEN a signal will be sent to Catholyte emergency feed valve 007-XV-05 and it will OPEN,
AND an activation signal will be sent to Z1
A reset of the system, once the trips have cleared, will be via the pressing of a button in the
control room.
19. Interlock (Z-17)
IF totalised nitrogen purge flow 007-FI-05 is >16 Nm³
THEN ENABLE polarising rectifier 007-X-02 and main rectifier 007-X-01 to electrolyser.
This interlock will remain ENABLED during aborted start-ups, as long as nitrogen purge flow
remains > 16 Nm³/h
20. Interlock (Z-37)

IF a Low-Lo(LL) Pressure is detected by two out of three of 007-PI_04 A/B/C on the cell room
Hydrogen Header.
Then a signal will be sent to Nitrogen Purge valve 014-XV-02 AND it will open.
Main Rectifier Energisation
On initial energisation of the main rectifier the l o a d to the electrolyser is slowly increased from
buttons provided in plant over view graphics screen shall be change as per Plant/DCS
operator requirement –
TAN NO. R-230 UNIT

Rectifier
Load SV 007-IIZ-01 KA
 In single press of button, valve of Rectifier load (AIC-230) will

increase to 0.1 KA.

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PLANT
 In single press of button, valve of Rectifier load (AIC-230) will

decrease to 0.1 KA.
Pressure Controller Value on plant over view graphics screen shall be change as per
Plant/DCS operator requirement –
 In single press of button, valve of controller will increase to 5 MMWC.
 In single press of button, valve of controller will decrease to 5 MMWC.
Rectifier (RE-230) Control Philosophy
First DCS give ON command to Rectifier RE-230 to SWITCH ON the rectifier and rectifier will do
their internal checking and wait for some time for getting Rectifier RE-230 ON feedback or Trip
feedback.
If Trip feedback comes then we have to troubleshoot the problem at rectifier end. If ON feedback
comes then DCS give Process Healthy Feedback to rectifier RE-230 after checking all process
interlocks healthiness and in return rectifier gives “Ready to start feedback” to DCS after checking
all its internal alarms also by putting local / remote selector switch in remote position and this
feedback will comes to DCS .
After that DCS give current set point to rectifier for taking load and in return rectifier gives current
and voltage feedback to DCS .
DCS gives current set point in step by step i.e. in Single Press 0.1 KA will increase.
If any process trip comes due to interlock IZ-230 then DCS give process trip command to rectifier
RE-230 to stop the rectifier and if any trip comes at rectifier end then it gives Rectifier trip feedback
to DCS for stopping of plant.
Signals to be shown on DCS screen
• CD_RE-230_ON  Command to Switch ON the rectifier
• FB_RE-230_ON/OFF TRIPFeedback of ON/OFF of rectifier will be shown on DCS screen.
• FB_RE-230_ TRIPFeedback of TRIP of rectifier will be shown on DCS screen.
• FB_IZ-230  Feedback of Process ready to rectifier i.e. healthy signal of Interlock IZ-230 will be
shown on DCS screen.
• FB_RE-230_READY  Rectifier ready to start feedback comes on DCS screen.


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BASIS) CHLOR ALKALI
PLANT
• FB_RE-230_L/R  Feedback of local / remote of rectifier will be shown on DCS screen.
• FB_RE-230_RUN  Feedback of rectifier running will be shown on DCS screen.
• FB_RE-230_V  Feedback of voltage (EI-230) from rectifier will be shown on DCS screen.
• FB_RE-230_C Feedback of current (AI-230) from rectifier will be shown on DCS screen.
• FB_RE-230_STOP  Stop Button on DCS screen, Emergency trip command from DCS to stop the
rectifier.
Polarization Rectifier (PR-230) Control Philosophy
Before starting of Rectifier RE-230, Polarization rectifier PR-230 must be ready and in ON condition
and put local /remote switch in remote position.
If Main Rectifier RE-230 Trip then DCS gives RUN command to polarization rectifier PR-230 and
after getting ON feedback.
It gives current set point to polarization in define ramp rate of current (ramp up will be in
polarization panel) and in return polarization gives current and voltage feedback to DCS.
Polarizer rectifier PR-230, ON command till the main rectifier RE-230 current is less than 2 KA. So
when ever main rectifier current fall below 2 KA, polarizer will start to feed current in Electrolyser
Signals to be shown on DCS screen
• FB_RE-230_L/R  Feedback of local / remote of polarization rectifier will be shown on DCS screen.
• FB_PR-230_ON/OFF/TRIP Feedback of On/Off/Trip of polarization rectifier will be shown on

DCS screen.
• FB_PR-230_RUN  Feedback of polarization rectifier running will be shown on DCS screen.
• FB_PR-230_V Feedback of voltage from polarization rectifier will be shown on DCS screen.
• FB_PR-230_C Feedback of current from polarization rectifier will be shown on DCS screen.
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
ANOLYTE HANDLING
9650-11-PID-00-0008(1of 2)
1. The PH Indicator 008-AI-01 gives alarm when it becomes either High (H) or Low (L).
2. The level indication 008-LI-01A of the Anolyte tank 008-T-01 gives alarm when it becomes either
3. The level indication 008-LI-01A of the Anolyte tank 008-T-01 gives alarm when it becomes either
4. The temperature Indicator TI-240 of Anolyte tank 008-T-01 gives alarm when it either High (H) or
Low (L).
5. The level of Anolyte tank 008-T-01 is maintained by controlling the Flow of Anolyte by Level Control
Valve 008-LCV-01 as per the set point of 008-LI-01A and 008-LI-01B .when level increases above
set point valve opening will increase.
6. The pH of Anolyte tank 008-T-01 is maintained by controlling the Flow of HCl by Control Valve 008-
ACV-01 as per the set point of 008-AIC-01.When pH increases above set point valve opening will
increase.
7. Interlock (Z-18)
When the level indication 008-LI-01A or 008-LI-01B of Anolyte tank 008-T-01 becomes High-
High(HH).
Then a signal will be sent to pure brine flow control valves 007-FCV-01 and it will close.
AND a single will be sent to pure Brine emergency feed valve 007-XV-04 and it will open.
AND HCl flow control valve 008-ACV-01 & 008-FCV-02 and they will close.
AND a motor STOP signal will be sent to 005-NO-01A and 005-NO-01B pure brine pumps 005-
P-01 A and B.
AND activation signal will be sent to Z1.
When level indication 008-LI-01A or 008-LI-01B of Anolyte tank becomes Low-Low (LL). The
Anolyte pump 008-P-01 A/B shall trip.
AND 008-FCV-02 will close.
AND 008-ACV-01 will close.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
When any one of pump 008-P-01 AorB shall trip another pump will start automatically. If
• 008-LI-01 A or 008-LI-01 B is not Low – Low (LL).
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CHLORATE DESTRUCTION
9650-11-PID-00-0008(2of 2)
1. The temperature Indicator 008-TI-03 of chlorate destruction tank 008-T-02 gives alarm when it
2. The temperature Indicator 008-TI-01 of acidic brine to chlorate destruction tank 008-T-02 gives
alarm when it either High-High (HH) or High (H) or Low (L).
3. The flow indication 008-FI-01 of Anolyte gives alarm when it becomes either High (H) or Low (L).
4. The flow indication 008-FI-02 of HCl gives alarm when it becomes either High (H) or Low (L).
5. The flow of HCl is maintained and controlled by flow control valve 008-FCV-02 as per set point of
008-FIC-02. When the flow is increase above the set point control valve opening will reduce.
6. The temperature of Acid brine to 008-T-02 is controlled by Steam inlet control valve 008-TCV-04,
which regulate the steam flow to 008-E-01 as per the set point of 008-TICA-01. When temperature
increase above set point, valve opening will reduce.
7. Interlock (Z-19)
When temperature indicator 008-T-01 becomes High-High (HH) , Steam control valve 008-
TCV-04 will close.
This valve will remain interlocked on till the temperature drops below High.
008-P-02 A&B - START & STOP
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
ANOLYTE DECHLORINATION
9650-11-PID-00-0009(1 OF 2)
1. The level indication 009-LI-03 of 18% HCL Dosing Tank (009-T-02) gives alarm when it becomes
2. The level indication 009-LI-01 of De-chlorination tower tank (009-T-280) gives alarm when it
becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L), an immediate
investigation and preventive action to be taken accordingly.
When the level of De-chlorination tower tank (009-T-280) 009-LI-01 becomes Low –Low (LL),
De- chlorination tower pumps (009-P-01A/B) & sodium sulphite Pumps (P-294 A/B)
shall trip. Caustic ON/OFF valve 012-XV-01 will close.
4. The level of De-chlorination tower tank (009-T-280) is controlled by level control valve (009-LCV-
01) as per the set point of 009-LIC-01.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

009-FCV-01 as per the set point of 009-AIC-01 or by 009-FIC-01 through selector switch. when pH
increases above set point, valve opening will decrease.
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. Interlock (Z-21)
IF a Low Low is detected by 009-FI-04 in air feed to dechlorination tower tank 009-T-280 for
a sustained period of 60 seconds
THEN a signal will be sent to anolyte tank level control valve 008-LCV-01 and it will close.
7. Interlock (Z-20)
IF a High-High level is detected by 009-LI-01 in dechlroniation tower tank 009-T-280.
THEN a signal will be sent to anolyte tank level control valve 008-LCV-01 and it will close.
AND a signal will be sent to caustic head tank valve 012-XV-01 and it will close after a delay of
15 minutes.
AND a signal will be sent to Sodium Sulfite flow control valve 025-FCV-02 and it will close
after a delay of 15 minutes.
These valves will remain interlocked untill the tank level falls below High-High.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
8. The Pressure indication 009-PI-01 of De-chlorination Tank gives alarm when it becomes either
9. The flow transmitter 009-FI-01 gives alarm when it becomes either High – High (HH) or High (H) or
Low – Low (LL) or Low (L ).
10. The pH transmitter 009-AI-01 gives alarm when it becomes either High (H) or Low (L).
11. The Differential Pressure indicator 009-DPI-01 gives alarm when it become High(H) or Low(L).
12. The Flow indication 009-FI-04 gives alarm when it becomes either High(H) or Low(L).

When any one of pump 009-P-01 AorB shall trip another pump will start automatically. If

When any one of Blower 009-K-01 AorB shall trip another pump will start automatically. If
009-P-01 A/B - STOP & START (EMERGENCY)

009-K-01 A/B - STOP & START (EMERGENCY)
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
LEAN BRINE STORAGE

9650-11-PID-00-0009(2 OF 2)
1. The level indication 009-LI-02 of the Lean Brine Tank 009-T-01 gives alarm when it becomes either
2. Interlock (22)
When level indication 009-LI-02 of 009-T-01 becomes Low-Low (LL), the Lean Brine Pump
(009-P-02 A/B) shall trip.
3. The level of Lean Brine Tank 009-T-01 is maintained by controlling the Flow of Process Water by
Level Control Valve 009-LCV-03 as per the set point of 009-LIC-02.when level increases above set
point valve opening will reduce.
4. The flow transmitter 009-FI-01 of 18% HCL gives alarm when it becomes either High(H) or Low(L ).
5. The flow transmitter 009-FI-01 of PW water line gives alarm when it becomes either High (H) or
Low (L).
6. The pH indicator (009-AI-01) gives alarm when it becomes either High (H) or Low (L).
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CATHOLYTE HANDLING
9650-11-PID-00-0010
1. The temperature Indicator 010-TI-01 of catholyte tank pump header gives alarm when it either
High (H) or Low (L).
2. The level indication 010-LI-02A of the Catholyte tank 010-T-01 gives alarm when it becomes either
3. The level indication 010-LI-02B of the Catholyte tank 010-T-01 gives alarm when it becomes either
4. The level of Catholyte tank 010-T-01 is maintained by controlling the Flow of Catholyte by Level
Control Valve 010-LCV-01 as per the set point of 010-LIC-02A and 010-LIC-02B.when level
increases above set point valve opening will increase.
5. The density Indicator 010-AIC-02 of 32% caustic to catholyte tank 010-T-01 gives alarm when it
6. The level indication 010-LI-04 of the Catholyte top-up tank 080-T-02 gives alarm when it becomes
either Low – Low (LL) or Low (L).
7. The flow indication 010-FI-01 of catholyte gives alarm when it becomes either High (H) or Low (L).
8. Interlock (Z-23)
If a motor STOP signal is detected on both of Catholyte pump 010-P-01Aand 010-P-01B for
certain period (> 60 seconds to allow for auto-changeover), than On-off valve 007-XV-05 shall
open and Control valve 007-FCV-02 , 011-XV-01 will close.
An activation signal will be sent to Interlock Z-1.
9. Interlock (I-23)
When level indication 010-LI-01 or 010-LI-02 of Catholyte tank becomes Low-Low (LL). The
Catholyte pump 010-P-01 A/B shall trip.
AND 011-XV-01 will close.
3

• 010-LI-01 or 010-LI-02 is not Low – Low (LL).

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CATHOLYTE HEAT CONDITIONING

9650-11-PID-00-0011
1. The temperature Indicator 011-TI-01 of catholyte to electrolyser gives alarm when it either High
(H) or Low (L).
2. The flow indication 011-FI-01 of DM water gives alarm when it becomes either High (H) or Low (L).
3. The temperature of the caustic is controlled by steam inlet control valve, 011-TCV-01A which
regulates the steam Flow to feed catholyte heater 011-E-01 as per the set point of 011-TICA-01A.
When temperature increased above set point valve opening will reduce.
4. The temperature of the caustic is controlled by cooling water inlet control valve, 011-TCV-01B
which regulates the cooling water Flow to feed catholyte heater 011-E-01 as per the set point of
011-TICA-01A. When temperature increased above set point valve opening will increase.
5. The changeover of heating mode & cooling mode is done manually through DCS by selector switch
in DCS & in field will be done by field operator for “Feed Catholyte heater/cooler 011-E-01.”
The selection of heating or cooling is via the controller which also acts on automatic islation valves
011-XV_01 and 011-XV-02 for steam/condensate or 011-XV_03 for cooling water return.The
temperature set point is set by the operator or control sequence based upon the temperature
requriments at the electrolyser.
6. The flow of DM Water is controlled by DM water control valve 011-FCV-01 as per the set point of
011-FIC-01,When flow increases above set point valve opening will reduce.
The following algorithm describes the relationship between the set point for the dilution water feed
flow controller 011-FIC-01 and measured DC current.
Fw = 0.00142*C*N*P ( C- in the range of 0 to 20.33 KA)
Where :-
Fw = Dilution water feed set point(M3/h)
C = Measured DC current to electrolyser (KA)
N = Number of modules in Electrolyser (0-90 nos)
O = Operator settable adjustment factor, limited to the range 0.8 to 1.2.
7. Interlock (Z-25)
When temperature switch 011-TSZ-03 becomes High-High (HH) , Steam shut off valve 011-XV-
01 will close

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CAUSTIC HANDLING
9650-11-PID-00-0012 (1 OF 2)
1. The level indication 012-LI-01 of 32% Caustic intermediate tank 012-T-01A gives alarm when it
becomes either High-High (HH) or High (H) or Low-Low (LL) or Low (L).
2. The level indication 012-LI-02 of 32% Caustic intermediate tank 012-T-01B gives alarm when it
3. Interlock (30)
When level indication 012-LI-01 or 012-LI-03 of 32% Caustic intermediate tank 012-T-01
A&B becomes Low-Low (LL) 012- P-01 A/B & 012-P-02 A&B shall trip.
4. Interlock(29)
If a High-High level is detected by 012-LI-01 or 012-LI-03 in 32% Caustic intermediate Tank
012-T-01 A&B.
THEN a signal will be sent to Sodium Hydroxide flow control valve 012-FCV-01 and it will
close
AND a signal will be sent to DM water flow control valve 012-FCV-02 and it will close.
5. The Flow Indication 012-FI-01 of Sodium Hydroxide gives alarm when it becomes either High (H)
or Low (L).
6. The Flow Indication 012-FI-02 of DM water gives alarm when it becomes either High (H) or Low (L).
7. The flow of Sodium Hydroxide is controlled by Sodium Hydroxide control valve 012-FCV-01 as per
the set point of 012-FIC-01,When flow increases above set point valve opening will reduce.
8. The flow of DM water is controlled by DM water control valve 012-FCV-02 as per the set point of

10. All Interlocks should have bypass switch available on common DCS screen. And the indication of
bypass switch activated or deactivated should be available on each interlock number on each
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CAUSTIC DILUTION
9650-11-PID-00-0012 (2 OF 2)
1. The level indication 012-LI-05 of 18% Caustic tank 012-T-01 gives alarm when it becomes either
High-High (HH) or High (H) or Low-Low (LL) or Low (L).
2. The level indication 012-LI-06 of 18% Caustic Head tank 012-T-04 gives alarm when it becomes
3. Interlock (33)
When level indication 012-LI-05 of 18% Caustic tank 012-T-03 becomes Low-Low (LL) 012- P-
03 A/B shall trip.
4. Interlock(34)
If a High-High level is detected by 012-LI-05 in 18% Caustic Tank 012-T-03.
THEN a signal will be sent to Caustic flow control valve 012-FCV-03 and it will close
5. The Flow Indication 012-FI-03 of Caustic gives alarm when it becomes either High (H) or Low (L).
7. The flow of Caustic is controlled by Caustic control valve 012-FCV-03 as per the set point of 012-
FIC-03,When flow increases above set point valve opening will reduce.
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CHLORINE ABSORPTION & HYPOCHLORITE PRODUCTION

9650-11-PID-00-0015 (1 OF 2)
1. The level indication 015-LI-04 of 20% Caustic tank 015-T-06A gives alarm when it becomes either
2. The level indication 015-LI-06 of 20% Caustic tank 015-T-06B gives alarm when it becomes either
3. The level indication 015-LI-03 of 18% Caustic Deluge tank 015-T-03 gives alarm when it becomes
either High (H) or Low-Low (LL) or Low (L).
4. The temperature Indicator 015-TI-04 of Chlorine Emergency Absorption(015-C-02) gives alarm

when it becomes either High (H) or Low (L).
5. The temperature Indicator 015-TI-05 of Caustic to 20% Caustic tank(015-T-06 A/B) gives alarm
6. The temperature Indicator 015-TI-03 of Sodium Hypochlorite to Chlorine emergency absorption

(015-C-02) gives alarm when it becomes either High (H) or Low (L).
7. The Pressure indicator 015-PIA-16 gives alarm when it becomes either High(H) or Low(L).
8. The Pressure indicator 015-PIA-17 gives alarm when it becomes either High(H) or Low(L) or Low-
Low(LL).
9. The Chlorine detector 015-AI-04 gives alarm when it becomes High(H).
10. Interlock (50)

When level indication 015-LI-04 of 18% caustic tank 015-T-06A beomes Low-Low (LL) than
18% caustic dilution pump 015-P-04 A/B shall trip.
11. Interlock(44)
If a High-High level is detected by 015-LI-04 or 015-LI-06 in 18% Caustic Tank 015-T-06 A/B.
THEN a signal will be sent to Caustic flow control valve 015-FCV-05 and it will close
12. The Flow Indication 015-FI-03 of Sodium Hypochlorite gives alarm when it becomes either High (H)
or Low (L).

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
13. The Flow Indication 015-FI-05 of Caustic gives alarm when it becomes either High (H) or Low (L).
15. The flow of Caustic is controlled by Caustic control valve 015-FCV-05 as per the set point of 015-
FIC-03,When flow increases above set point valve opening will reduce.

015-K-01 A/B - START & STOP (Emergency)
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CHLORINE ABSORPTION & HYPOCHLORITE PRODUCTION

9650-11-PID-00-0015 (2 OF 2)
1. The level indication 015-LI-01 of Chlorine Absorber Criculation tank 015-T-01 gives alarm when it
2. The level indication 015-LI-02A of Emergency Absorption circulation tank 015-T-02A gives alarm
when it becomes either High-High (HH) or High (H) or Low-Low (LL) or Low (L).
3. The level indication 015-LI-02B of Emergency Absorption circulation tank 015-T-02B gives alarm
when it becomes either High-High (HH) or High (H) or Low-Low (LL) or Low (L).
4. The temperature Indicator 015-TI-02 of Chlorine Emergency Absorption(015-C-01) gives alarm

5. The temperature Indicator 015-TI-05 of Caustic to 20% Caustic tank(015-T-06 A/B) gives alarm
6. The temperature Indicator 015-TI-01 of Sodium Hypochlortie to Chlorine emergency

absorption(015-C-01) gives alarm when it becomes either High-High (HH) or High (H) or Low (L).
7. Interlock (38)
When level indication 015-LI-01 of Chlorine Absorber circulation tank 015-T-01 beomes Low-
Low (LL) than Chlorine Absorption circulation pump 015-P-01 A/B shall trip.
8. Interlock (Z-40)
If a High-High(HH) pressure is detected by 015-PI-01 in the feed to the Chlorine Absorption
column 015-C-01.
Then a signal will be sent to the air Intake Bleed valve 015-XV-02 and it will close.
9. Interlock (Z-41)
If a motor STOP signal is detected by 015-XA-02A and 015-XA-02B on both emergency
absorption circulation pump 015-P-02 A&B for a sustained period of 60 second (to allow for
auto changeover)
OR a Low-Low(LL) flow is detected by 015-FIZ-03 on the circulation return to 015-C-02 for a
sustained period of 60 seconds.
THEN a signal will be sent to 18% caustic deluge valve 015-XV-03 and it will open.
AND an activation signal will be sent to Z1

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
10. Interlock (42)

If 015-T-02A inlet valve 015-XV-02A is not open.
OR 015-T-02A outlet valve 015-V-03A is not open.
THEN 015-T-02B inlet valve 015-XV-02B to can-not be closed.
11. Interlock(43)
If 015-T-02B inlet valve 015-XV-02B is not open.
OR 015-T-02B outlet valve 015-V-03B is not open.
THEN 015-T-02A inlet valve 015-XV-02A to can-not be closed.
12. Interlock(51)
When level indication 015-LI-02 A or B becomes Low-Low (LL) than Emergency Absorption
circulation pump 015-P-02 A or B and pump 015-P-03 will trip.
13. Interlock (52)

14. Interlock (53)

• 015-LI-02A or B is not Low – Low (LL).
15. The Pressure indicator 015-PIA-01 gives alarm when it becomes either High-High (HH) or High(H)
or Low-Low (LL) or Low(L).
16. The Flow Indication 015-FI-02 of Sodium Hypochlorite gives alarm when it becomes either High (H)
or Low (L).
015-P-01 A/B - START & STOP (EMERGENCY)

015-P-02 A/B - START & STOP (EMERGENCY)
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
CHLORINE COOLING
9650-11-PID-00-0016
1. The Pressure indication 016-PI-05 of the Chlorine gas from Wet chlorine filter gives alarm when it
2. The temperature Indicator 016-TI-01 of chlorine gas from 016-E-01 gives alarm when it either
High-High (HH) or High (H) or Low (L).
3. The Flow indicator 016-FI-01 of Chlorine wet gas gives alarm when it becomes High (H) or Low(L).
4. The Chlorine pressure indicating controller, 016-PIC-01 takes the median value from pressure
indicating controllers 007-PIC-03 A/B/C at the outlet of the electrolyser, and adjusts the pressure
using pressure control valve 016-PCV-01. The pressure setpoint is set by operator. If 016-PCV-01 is
unable the maintain the pressure at setpoint set by controller 016-PIC-02 will open automatically
having a setpoint set by controller 016-PIC-02 at 10 mbar higher than 016-PIC-01. 016-PIC-02 also
uses the median value from pressure indicating controllers 007-PIC-03 A/B/C as the measure value.
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
HYDROGEN COOLING & VENT

9650-11-PID-00-0020
1. The Pressure indication 020-PI-05 of the Hydrogen gas from Hydrogen filter gives alarm when it
2. The Temperature indication 020-TI-01 of the Hydrogen wet gas from electrolyser gives alarm when
it becomes either High (H) or Low (L).
3. The Differential pressure indicating controller, 020-PDIC-01 takes the median value from
differential pressure indicating controllers 007-DPI-01 A/B/C at the outlet of the electrolyser, and
adjusts the differential pressure using control valve 020-PDCV-01. The differential pressure
setpoint is set by the operator at 15 mbar. If 020-PDCV-01 is unable to maintain the differential
pressure at setpoint, control valve 020-PDCV-02 will open automatically having a setpoint set by
controller 020-PDIC-02 at 10 mbar higher than 020-PDIC-01. 020-PDIC-02 also uses the median
value from differential pressure indicating controllers 007-DPI-01 A/B/C as the measured value.
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
HCL SYNTHESIS UNIT

9650-11-PID-00-0023A
1. The Pressure Indication PIA-101 of Chlorine gas from Cl2 moisture separator MS-1611 gives
alarm when it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
2. The Flow Indication FICA-101 of Chlorine gas from Cl2 moisture separator MS-1611 gives alarm
when it becomes either High High (HH) or High(H) or Low (L) or Low-Low (LL).
3. The Cl2 gas flow to furnace (SU-1) is maintained and controlled by flow control valve FV-101 as
per set point of FICA-101. When the Flow is increase above the set point control valve opening
will decrease.
4. The Pressure Indication PIA-201 of Hydrogen gas from H2 moisture separator MS-1610 gives
alarm when it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
5. The Flow Indication FICA-201 of Hydrogen gas from H2 moisture separator MS-1610 gives
alarm when it becomes either High (HH) or High(H) or Low-Low (LL) or Low (L).
6. The hydrogen flow is controlled with hydrogen flow ratio controller (FFICA-102), the H2 ratio
control loop consist of flow Indication (FICA-201), ratio controller (FFICA-102) and the control
valve (FV-201) .A signal from the Cl2 flow Indication (FICA-101) is fed to the ratio controller
(FFICA-102). The ratio controller (FFICA-102) will adjusts the hydrogen flow as per Cl2 flow .
7. The hydrogen flow set-point is a direct function of HIC201 (total production in mtpd, on a 100%
HCl basis) desired from the unit. The operator is required to input the total amount of HCl that is
to be produced (in metric tons per day), on a 100% HCl basis and this is converted to a
hydrogen flow set point FIC201.
Hydrogen Flow Calculation:-
The hydrogen flow is measured with an orifice plate flow meter FIT201. This flow meter transmits a raw
value HW H2 (in Nm3/h) of the flow to the DCS. This raw value is obtained from the differential
pressure DP201 (mmH2O) seen across the plate by using the constant values of the pressure,
temperature and molar weight that have been used for the design of the orifice plate (respectively
Pdes, Tdes, Mdes).
A correction is further applied in the DCS to consider the actual pressure, temperature of the flowing
gas, measured by PIT201, TIT201 and its molar weight M.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
T and Tdes expressed in °K Tdes (°K) = Tdes(°C) +273.15
Tdes = 40 °C = 313.15°K
P and Pdes expressed in bar abs
Pdes(bar abs) = (Pdes (mmH2Og)+10330) / 10200
Pdes = 1600 mmH2O g = 1,1696 bar abs
M and Mdes expressed in kg/kmol Mdes = 3,09 kg/kmol
The effective molar weight of the gas is calculated according gas composition:
(Values from on-line analyzers can be used here)
M = VFH2H2 x 2,016 + VFH2OH2 x 18
The flow is calculated with the differential pressure DP201 and corrected from the measured
pressure PIT201 (barg) and the measured temperature TIT201 (°C).
Let us gather all the constant parameters in the K201 factor
Note : “Wet” Saturated Hydrogen Gas
When the hydrogen is saturated with water, the molecular weight M and the composition of the gas are
affected by the water content which depends from the temperature. In this case, M deviates from the
Mdes value and this will in turn also affect the calculated ratio H2/oxidizers. The mass flow will need to
be compensated to give the flow of hydrogen on a “dry basis”.
The molecular weight (and V% composition) can effectively be calculated by knowing the pressure &
temperature of the hydrogen gas as its “coolest” point after saturation and before the battery limit of the
synthesis unit.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
The hydrogen is saturated with water at the temperature of supply. This affects the molecular weight
and gas composition, which in turn will affect the calculated combustion ratio of H2 / oxidizers. The
volumic flow needs to be compensated to give the flow of hydrogen on a “dry basis”.
The molecular weight (and V% composition of H2O) is calculated by knowing the pressure &
temperature of the hydrogen gas at operating temperature.
Thus the volumic fraction of water in hydrogen feed (VFH2OH2) can be estimated based on vapor
pressure VPH2O. The water vapour pressure only depends on the temperature TIT921 according to the
equation below:
VP H2O = EXP [ 73,649 - 7258,2/ (TIT921 + 273,15) - 7,3037*LN (TIT921 + 273,15) + 4,1653E-
06*(TIT921 + 273,15)^2] (Pa abs)
The vapour fraction VF H2O H2 of water in hydrogen feed is obtained from the ratio of the water vapour
pressure which depends on the temperature only, to the total pressure given by PIT201
VF H2O H2= VP H2O / PIT201 All pressures are given in Pascal absolute
The composition used for design is

VF*H2 H2 =0.9200
VF*O2 H2 =0.0000
VF*N2 H2 =0.0000
VF*H2O H2 =0.0800
if other components such as O2 or N2 can be present in the hydrogen feed
Here, for all components except water in the composition used for design
VF*H2 H2 +VF*O2 H2 + VF*N2 H2 =K*
K* = 0.92
The sum of the volumic fraction for all components, water included, is 1.
VFH2 H2 +VFO2 H2 + VFN2 H2+ VFH2O H2 =1
The volumic fraction of other components is obtained by
VFH2 H2 = VF*H2 H2 * (1- VF H2O H2) / K*

VFO2 H2 = VF*O2 H2 *(1- VF H2O H2) / K*
VFN2 H2 = VF*N2 H2 *(1- VF H2O H2) / K*

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The water fraction and then the molar weight vary with the temperature
The molar weight is obtained as
M = (VFH2H2 * 2.016) + (VFO2H2 * 32) + (VFH2OH2 * 18.016) + (VFN2H2 * 28)
The molar weight of the gas used for design is Mdes =3.28
Any deviation from this base composition will affect the measurement, and should be
compensated for by considering a factor SQRT( Mdes /M) for Molecular weight compensation
Chlorine Flow Calculation:-
The chlorine flow is measured with an orifice plate flowmeter FIT101. This flowmeter transmits a raw
value HW FIT101 (in Nm3/h) of the flow to the DCS. This raw value is obtained from the differential
pressure DP101 (mmH2O) seen across the plate by using the constant values of the pressure,
temperature and molar weight that have been used for the design of the orifice plate (respectively Pdes,
Tdes, Mdes).
Tdes FE101B = 40 °C = 313.15°K
P and Pdes expressed in bar abs Pdes(bar abs) = (Pdes (mmH2Og)+10330) / 10200
Pdes FE101B = 1600 mmH2O g = 1.1696 bar abs
M and Mdes expressed in kg/kmol Mdes = 66,45 kg/kmol
The effective molar weight of the gas is calculated according gas composition:
(Values from on-line analyzers can be used here)

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BASIS) CHLOR ALKALI
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8. The Pressure indication PIA-501 of Process Air from header gives alarm when it becomes High
– High (HH) or High (H) or Low – Low (LL) or Low (L).
9. The Flow indication FIA-501 of Air gives alarm when it becomes High – High (HH) or High (H) or
Low – Low (LL) or Low (L).
10. As per Air flow, the flow of Cl2 is also need to be adjusted; hence air flow will be controlled by
FV-501 and the Cl2 is also controlled through a ratio control loop consisting of flow indication
(FICA-101), the ratio controller (FFICA-502), and the control valve (FV-501). A Cl2 flow signal
from FICA-101 is also fed to the ratio controller FFICA-502 to have desired quantity of air.
Ratio shall be adjusted from DCS screen.
COMBUSTION AIR FLOW CONTROL
During the start-up of the synthesis unit, air is used to generate both the auto-ignition system pilot flame
and the main flame in the burner (before chlorine is introduced). Burning the hydrogen fuel with the
oxygen present in the air generates water.
Under start-up condition, combustion air is fed to the system to generate the main synthesis flame at
the minimum turndown capacity for this unit. For this unit with the pre-set conditions as outlined in this
manual, this equates to a start-up air flow rate of 484 Nm3/hr.
Once the pilot flame is established by the CC, the hydrogen can mix with the main flow of combustion
air, and the main combustion flame is established. After allowing a short time for stabilization of the
flame, chlorine is substituted for air as the air flow is ramped down and the chlorine is ramped up.
This is done in a way as to try to maintain a constant ratio of hydrogen to oxidizers. The substitution
phase is complete when the air flow rate is reduced to “zero” and the air block valve is in the closed
position and only the chlorine feed stream is flowing (as the oxidizer).

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BASIS) CHLOR ALKALI
PLANT
AIR FLOW CALCULATION
The air flow is measured with an orifice plate flowmeter FIT501. This flowmeter transmits a raw value
HW FIT501 (in Nm3/h) of the flow to the DCS. This raw value is obtained from the differential pressure
DP501 (mmH2O) seen across the plate by using the constant values of the pressure, temperature and
molar weight that have been used for the design of the orifice plate (respectively Pdes, Tdes, Mdes).
Tdes = 20 °C = 293.15°K
PI and Pdes expressed in bar abs Pdes(bar abs) = (Pdes (mmH2Og)+10330) / 10200
Pdes FE39951 = 2040 mmH2O g = 1.2127 bar abs
M and Mdes expressed in kg/kmol Mdes = 28.84 kg/kmol
Let us assume M = Mdes when the operating conditions are closed to design conditions.
The flow is calculated with the differential pressure DP501 and corrected from the measured pressure
PIT501 (barg) and the measured temperature TIT501 (°C).
Let us gather all the constant parameters in the K501 factor

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11. The Hydrogen gas flow to furnace (SU-1) is maintained and controlled by flow control valve
FV-201 as per set point of FICA-201. When the Flow is increase above the set point control
valve opening will decrease.
12. The Pressure Indication PIA-601 of Nitrogen from Header gives alarm when it becomes Low (L).
13. The Flow Indication FIA-601 of Nitrogen from Header gives alarm when it becomes Low (L).
14. The Flow Indication FIA-901 of Cooling Water from Header gives alarm when it becomes either
Low- Low (LL) or Low (L).
15. 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 indication (FICA-401), the ratio controller
(FFICA-402), and the control valve (FV-401). A Cl2 flow signal from FICA-101 is also fed to the
ratio controller FFICA-402 to have desired quantity of DM water Ratio shall be adjusted from
DCS screen.
16. The Flow Indication FICA-401 of DM Water from header gives alarm when it becomes either
High (H) , Low Low (LL) or Low (L).
17. The Flow Indication FICA-402 of DM Water from header gives alarm when it becomes Low (L).
18. The flow of DM Water from header is maintained and controlled by flow control valve FV-401 as
per set point of FICA-401. When the Flow is increase above the set point control valve opening
will decrease.
19. The Flow Indication FIA-310 of HCl from HCl transfer pump P-1A/B gives alarm when it
becomes Low (L).
20. The Level Indication LICA-302 of HCl transfer tank gives alarm when it becomes either High-
High (HH) or High (H) or Low-Low(LL) or Low (L).
21. The level of HCl transfer tank D-1 is maintained and controlled by flow control valve LV-302 as
per set point of LICA-302. When the Level is increase above the set point control valve opening
will increase.
22. The Level Indication LICA-302 of HCl unit catch tank CT-1 gives alarm when it becomes either
Low-Low(LL) or Low (L)
23. The Chlorine on-off valve (XV-102), Hydrogen on-off valve (XV-204) and CL2, H2 control valve
FV-101 & FV-201 will not open until the interlocks are healthy except H2/Cl2 flow ratio low, Cl2
flow low, & DM water flow low.

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PLANT
26. The density Indication AICA-301 of HCl from HCl synthesis unit (SU-1) gives alarm when it
27. The Pressure Indication PIA-601 of unabsorbed HCl from Tail gas tower (TT-1) gives alarm
when it becomes either High High (HH) or High (H).
28. The Temperature Indication TIA-801 of HCl from Tail gas tower (TT-1) gives alarm when it
becomes either High High (HH) or High (H).
29. The Temperature Indication TIA-703 of HCl synthesis unit (SU-1) gives alarm when it becomes
either High High (HH) or High (H).
30. The Pressure Indication PIA-841 of Instrument Air from Header gives alarm when it becomes
Low Low (LL).
31. Motor/Drive auto Start/Stop provision in DCS
P-1 A/B - START & STOP
32. The Pressure Indication PIA-811 of hydrogen from hydrogen header to auto ignition panel gives
alarm when it becomes Low.
33. The Flow Indication FIA-812 of hydrogen from hydrogen header to auto ignition panel gives
alarm when it becomes Low.
34. The Flow Indication FIA-822 of Nitrogen from Nitrogen header to auto ignition panel gives alarm
when it becomes Low.
35. The Flow Indication FIA-831 of Chlorine from Chlorine header to auto ignition panel gives alarm
when it becomes Low.
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Interlock Description

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Definition:
Permissive switch contact: Active means that the switch contact is made or is active for the permissive.
Wiring is done in “fail safe” meaning upon an alarm the switch contact opens or is “not made” to “0”
(bit).
Pressure, temperature and level alarms “low” mean the NO contact opens on an alarm but during the
permissive state the NO is made to “1” ( not in alarm).
Pressure, temperature, level, analyzer alarms “high” and the E-stop and rupture disc alarm mean the
NC contact opens on an alarm but during the permissive state the NC is made to “1” (not in alarm).
All the analog alarms have modifiers L, LL, H or HH. The L & H are for the first level alarms (operator
notification) and the LL and HH modifiers mean a shutdown or logic interlock. “1” is a permissive bit and
“0” is an alarm bit.
Limit Switches: Flow or position switches have only L or H modifiers which can be logic interlocks or
Permissive.
For a position limit switch, L means a closed valve (NO contact is made to “1”) and H means an open
valve (NO contact is made to “1”). A switch contact alarm and the software alarm will occur when the bit
goes to “0”.
Some PLC and DCS software suppliers provide a block valve module such that when the valve is
actuated, it waits for the valve to transfer state, and then checks both the ZSL & ZSH position.
If Table 1 (Permanent Condition) and Table 2 (Conditional conditions for start-up) condition will be
initiated then to stop the HCl Synthesis unit and should be following steps:
1. Activation by any of the E-STOP devices (field pushbuttons or DCS interaction).

2. Activation caused by a Shutdown interlock as noted in permanent conditions (TABLE 1) or in
TABLE 2 during start-up.
The Control cabinet takes the following actions automatically and simultaneously:
3. Drive the control valve outputs to 0%: the air (FV501), chlorine (FV101), and hydrogen (FV201).
4. Close the On/Off valves of Air, Chlorine and Hydrogen (respectively YV502, YV102 and YV204).
5. Start the nitrogen post purge: the nitrogen purge solenoids YV601 and YV603 will be
deenergized for a period of 4 minutes. Post purging is controlled by the Control Cabinet and is set at 4
minutes.
6. The Control Cabinet will set the Absorbing water controller, FFIC402 to LOCAL and set it to
1238 kg/h. (The absorbing water will continue to scrub off gases for the purge period but at minimal
capacity.) Set a timer for 90 seconds for the absorption water to continue to flow once the hazardous

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BASIS) CHLOR ALKALI
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shutdown is initiated. At the end of the time period, stop the flow of absorption water to the system (set
FIC401 to 0% output) and energize the solenoid YY402 to close YV402.
7. When the purge is completed, the control cabinet closes the nitrogen shut-off valves YV601 and
YV603 by energizing their solenoids.
8. Reset the E-STOP, if required, on the DCS or field push buttons by resetting the push-pull
mushroom button if the shutdown was initiated by the E-stop.
9. After acknowledgement of the alarms, disable all controllers and conditional alarms (in
preparation for a restart).
• Absorbing water flow controller, FIC401; disable FILL401
• Air flow controller, FIC501; disable FILL501.
• Chlorine controller, FIC101; disable FILL101
• Hydrogen flow controller, FIC201; disable FILL201
• Disable pilot hydrogen low flow alarm, FAL812. (FISL812)
• Disable pilot air low flow alarm, FAL831. (FISL831)
• Disable main nitrogen low flow alarm, FAL801. (FISL801)
10. Disable all other conditional alarms.

• The operator should find the cause of the emergency shut-down and make all necessary
maintenance or adjustments to the system. The system should be programmed to have a “1st
out” alarm indication to allow the operator to isolate the problem and then acknowledge it.
• The control cabinet system should then essentially return to a state of readiness and indicate
“START-UP MODE” once the system is reset.
• The HCl transfer pumps P-1A or P-1B must be stopped immediately if the shutdown was
initiated by low level interlock LAL302 or LILL302. If the shutdown was not initiated by one of
these two low level interlocks, operator can let the pump running for a duration of 30 minutes in
order to stay ready for re-start. After this 30 minutes timer, pumps must be stopped
automatically if no start-up of the unit has been initiated.

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BASIS) CHLOR ALKALI
PLANT
HCL SYNTHESIS UNIT

9650-11-PID-00-0023B
11. The Flow Indication FIA-403 of process water from header gives alarm when it becomes High
(H).
12. The Temperature Indication TIA-706 at outlet of Caustic Scrubber (51C003C) gives alarm when
it becomes either High High (HH) or High (H) or Low (L).
13. The Flow Indication FIA-700 of Caustic from P-03A/B gives alarm when it becomes Low (L).
14. The Flow Indication FIA-703 of Caustic recirculation from P-2A/B gives alarm when it becomes
Low (L).
15. The level LSH-704 of Caustic Scrubber (51C003C) gives alarm when it becomes High (H).
16. The level LSL-704 of Caustic Scrubber (51C003C) gives alarm when it becomes Low (L).
17. The Level of caustic is maintained and controlled by level control valve LV-704 as per set point
of LICA-704. When the level is increase above the set point control valve opening will increase.
Bypass switch activated or deactivated should be available on each interlock number on each screen.

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BASIS) CHLOR ALKALI
PLANT
HCL DILUTION
9650-11-PID-00-0024
1. The level indication 024-LI-01 of 18% HCl tank 024-T-01 gives alarm when it becomes either High-
High (HH) or High (H) or Low-Low (LL) or Low (L).
2. Interlock (46)
3. When level indication 024-LI-01 of 18% HCl service tank 024-T-01 becomes Low-Low (LL)
02- P-01 A/B shall trip.
4. Interlock(47)
If a High-High level is detected by 024-LI-01 in 18% HCL Tank 024-T-01.
THEN a signal will be sent to HCL flow control vavle 024-FCV-01 and it will close
AND a signal will be sent to DM water flow control vlave 024-FCV-02 and it will close.
5. The Flow Indication 024-FI-01 of HCl gives alarm when it becomes either High (H) or Low (L).
7. The flow of HCL is controlled by HCL control valve 024-FCV-01 as per the set point of 024-FIC-
01,When flow increases above set point valve opening will reduce.
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BASIS) CHLOR ALKALI
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CHEMICAL DOSING SYSTEM

9650-11-PID-00-0025(2 OF 2)
1. The level indication 025-LI-050 of the Barium Carbonate Tank 025-D-050 gives alarm when it
When level indication 025-LI-050 of the Barium Carbonate Tank 025-D-050 becomes Low-
Low (LL), the Barium Pump 025-P-054 A/B as well as Agitator 025-A–052 shall trip.
3. The level indication 025-LI-070 of the Soda Ash Tank 025-D-070 gives alarm when it becomes High
4. Interlock(I-070)
When level indication 025-LI-070 of the Soda Ash/Pumping Tank 025-D-070 becomes Low-
Low (LL), the Soda ash pump 025-P-074 A/B as well as Agitator 025-A–072 shall trip.
025-A-052 - START & STOP

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BASIS) CHLOR ALKALI
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CHEMICAL DOSING SYSTEM

9650-11-POD-00-0025(1 OF 2)
1. The level indication 025-LI-290 of sodium sulfite tank (025-D-290) gives alarm when it becomes
2. The flow of sodium sulfite to de-chlorinated brine is controlled by 025-FCV-01 as per the set point
of either 025-FIC-01 or 025-OIC-01.
Flow Controller- when flow increases above set point the valve opening will reduce.
ORP Controller- When ORP value increases above set point, valve opening will increase.
3. The flow indication 025-FI-01 of sodium sulfite gives alarm when it becomes either High – High
(HH) or High (H) or Low (L).
4. The ORP indication 025-OIA-01 of depleted brine gives alarm when it becomes either High (H) or
High-High (HH) or Low (L).
5. The pH indication 025-PHI-01 of depleted brine gives alarm when it becomes either High (H) or Low
(L).
When the level Indication 025-LI-290 of sodium sulfite tank (025-D-290) becomes Low –Low
(LL), Sodium Sulfite pumps (025-P-294 A/B) as well as Agitator (025-A-292) shall trip.

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BASIS) CHLOR ALKALI
PLANT
BRINE MUD FILTER

9650-11-PID-00-0026
1. The pressure indication PI-090 of the slurry feed line gives alarm when it becomes either High –
High (HH) or High (H).
When Pressure PI-090 of the Filter press F-090 feed line High-High (HH), the Brine settler
mud pump (002-P-01 A/B) shall trip.
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BASIS) CHLOR ALKALI
PLANT
CAUSTIC DISTRIBUTION & STORAGE

9650-11-PID-00-0028
1. The level indication 028-LI-320 A of 50% caustic soda storage tank (028-D-320 A) gives alarm
when it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
2. The level indication 028-LI-320 B of 50% caustic soda storage tank (028-D-320 B) gives alarm when
it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
3. The level indication 028-LI-320 C of 50% caustic soda storage tank (028-D-320 C) gives alarm when
it becomes either High – High (HH) or High (H) or Low – Low (LL) or Low (L).
4. The level indication 028-LI-320 D of 50% caustic soda storage tank (028-D-320 D) gives alarm
When level Indication (028-LI-320 A/B/C/D) of all four caustic storage tank (028-D-320
A/B/C/D) becomes Low-Low (LL), the pump (028-P-324 A&B) shall trip.
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BASIS) CHLOR ALKALI
PLANT
HYPO STORAGE & SHIPPING

9650-11-PID-00-0029
1. The Level Indication 029-LI-790 A of Sodium Hypochlorite storage Tank (029-D-790 A) gives alarm
2. The Level Indication 029-LI-790 B of Sodium Hypochlorite storage Tank (029-D-790 B) gives alarm
3. The Level Indication 029-LI-790 C of Sodium Hypochlorite storage Tank (029-D-790 C) gives alarm
4. The Level Indication 029-LI-790 D of Sodium Hypochlorite storage Tank (029-D-790 D) gives alarm
5. The Level Indication 029-LI-790 E of Sodium Hypochlorite storage Tank (029-D-790 E) gives alarm
6. The Level Indication 029-LI-790 F of Sodium Hypochlorite storage Tank (029-D-790 F) gives alarm
7. The Level Indication 029-LI-790 G of Sodium Hypochlorite storage Tank (029-D-790 G) gives alarm
8. The Level Indication 029-LI-790 H of Sodium Hypochlorite storage Tank (029-D-790 H) gives alarm
9. The temperature Indicator 029-TI-790 A of Sodium Hypochlorite storage Tank (029-D-790 A) gives
alarm when it either High - High (H-H) or HIgh (H).
10. The temperature Indicator 029-TI-790 B of Sodium Hypochlorite storage Tank (029-D-790 B) gives
11. The temperature Indicator 029-TI-790 C of Sodium Hypochlorite storage Tank (029-D-790 C) gives
12. The temperature Indicator 029-TI-790 D of Sodium Hypochlorite storage Tank (029-D-790 D) gives

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BASIS) CHLOR ALKALI
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13. The temperature Indicator 029-TI-790 E of Sodium Hypochlorite storage Tank (029-D-790 E) gives
14. The temperature Indicator 029-TI-790 F of Sodium Hypochlorite storage Tank (029-D-790 F) gives
15. The temperature Indicator 029-TI-790 G of Sodium Hypochlorite storage Tank (029-D-790 G) gives
16. The temperature Indicator 029-TI-790 H of Sodium Hypochlorite storage Tank (029-D-790 H) gives

When Level Indication of all Hypo Storage Tank (029-LI-790 A/B/C/D) becomes Low-Low
(LL), the Pump (P-794) shall trip.
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BASIS) CHLOR ALKALI
PLANT
HCL STORAGE & DISPATCH

9650-11-PID-00-0030(1of 2)
1. The Level Indication 030-LI-840 A of HCL Storage Tank (030-D-840 A) gives alarm when it becomes
2. The Level Indication 030-LI-840 B of HCL Storage Tank (030-D-840 B) gives alarm when it becomes
3. The Level Indication 030-LI-840 C of HCL Storage Tank (030-D-840 C) gives alarm when it becomes
4. The Level Indication 030-LI-840 D of HCL Storage Tank (030-D-840 D) gives alarm when it becomes
5. The Level Indication 030-LI-840 E of HCL Storage Tank (030-D-840 E) gives alarm when it becomes
6. The Level Indication 030-LI-840 F of HCL Storage Tank (030-D-840 F) gives alarm when it becomes
When the level of Hcl Storage Tank (030-D-840 A/B/C/D/E/F) becomes Low- Low (LL), Hcl
Dispatch Pumps (030-P-844 A/B) shall trip.
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BASIS) CHLOR ALKALI
PLANT
DM WATER SYSTEM
9650-11-PID-00-0033
1. The Level Indication 033-LI-1020 A of DM Water tank (033-D-1020 A) gives alarm when it becomes
2. The Level Indication 033-LI-1020 B of DM Water tank (033-D-1020 B) gives alarm when it becomes
3. The Conductivity indicator 003-AI-1020 of DM water unit gives alarm when it becomes High(H).
4. Control scheme of DM water plant is provided in local control panel.
When level indication 033-LI-1020A or 033-LI-1020B of DM water tank (033-D-1020 A/B)
becomes Low-Low (LL), all the pumps (033-P-1021 A&B,033- P-1022,033- P-1023A&B & 033-
P-1024 A/B) shall trip.
When Pumps (033-P-1021 A&B) gives stop signal or trip signal for a certain time period {>4
minute (adjustable) }, the pumps connected to DM seal water (015-PI-01 A&B, 015-P-02 A&B,
015-P-03, 012-P-01 A/B, 012-P-02 A/B, 010-P-01 A/B, 009-P-01 A/B, 008-P-02 A/B, 008-P-01
A/B and 005-P-01 A/B, 012-P-03A/B, P-164, 015-P-04A/B, P-1101 A/B, P-1301A/B, P-
324A/B) shall trip.
033-P-1024 A/B - START & STOP (Emergency)

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BASIS) CHLOR ALKALI
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COOLING WATER GENERATION

9650-11-PID-00-0034
1. The Temperature Indication 034-TI-1031 of Cooling water from cooling water pumps (034-P-
1030A/B/C/D/E) gives alarm when it becomes either High (H) and High-High (HH).
2. The Pressure Switch 034-PS-1030 of cooling water from cooling water pumps (034-P-
1030A/B/C/D/E) gives alarm when it becomes Low (L).
3. The Temperature Indication 034-TI-1030 of cooling water return from process plant gives alarm
when it becomes either High (H) or High-High (HH).
034-P-1034 A/B/C/D/E - START & STOP (Emergency no. 1 pump)
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BASIS) CHLOR ALKALI
PLANT
CHILLED WATER GENERATION

9650-11-PID-00-0035
1. The Level Indication 035-LI-1040 A of Chilled Water Tank (035-D-1040) gives alarm when it
2. The Level Indication 035-LI-1040 B of Chilled Water Tank (035-D-1040) gives alarm when it
When the level of Chilled Water Tank (035-D-1040) becomes Low-Low (LL), Chilled water
recirculation Pumps (035-P-1045 A/B) as well as Pump (035-P-1044 A/B) shall trip.
4. The control scheme of 035-PCV-1040 is provided in local control panel of vapor absorption chiller
(035-U-1040).
5. The control scheme of 035-XV-1040 is provided in local control panel of vapor absorption chiller
(035-U-1040).
6. The temperature Indication 035-TI-1040 of chilled water tank (035-D-1040) gives alarm when it
becomes either High – High (HH) or High (H) or Low (L).
7. The temperature Indication 035-TI-1041 of chilled water tank (035-D-1040) gives alarm when it
becomes either High – High (HH) or High (H) or Low (L).
8. Control of Chilled water plant is provided in local control panel.
Motor/Drive provision of Start and Stop from DCS shall be provided.

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BASIS) CHLOR ALKALI
PLANT
CONDENSATE RECOVERY SYSTEM

9650-11-PID-00-0036
1. The Level Indication 036-LS-1041 of Condensate recovery tank (036-D-1041) gives alarm when it
2. The Level Indication 036-LS-1042 of waste water recovery pit (036-PIT-1042 ) gives alarm when it
When the level of Condensate recovery tank (036-D-1041)) becomes Low-Low (LL),
Condensate recovery pump (036-P-1041) shall trip. (with interlock by pass switch) & pump
(036-P-1041) start with level high switch.
When the level of waste water recovery tank (036-D-1042) becomes Low-Low (LL), Waste
water recovery pump (036-P-1042) shall trip. (with interlock by pass switch)

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BASIS) CHLOR ALKALI
PLANT
WASTE WATER TREATMENT

9650-11-PID-00-0037
When the Level Switch (037-LS-910 A or B) of waste water pit becomes Low-Low (LL), the
Pump (037-P-914 A and B) 037-A-972 will trip.
2. The Level Switch (037-LS-910) of pit gives alarm when it becomes either High (H) or Low (L) or
Low-Low(LL).
037-P-914A/B - START & STOP

screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
PSA N2 GAS PLANT WITH COMPRESSOR, PROCESS AIR & AIR DRYING UNIT
9650-11-PID-00-0038
1. The control scheme of Air Compressors (038-U-1050 A/B) is provided in local control panel.
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 Indication 038-PIA-1050 of Instrument air receiver gives alarm when it becomes
5. The Pressure Indication 038-PIA-1060 of N2 gas receiver gives alarm when it becomes either High –
6. The Pressure Indication 038-PIA-1045 of N2 gas receiver gives alarm when it becomes either High –
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
PROCESS WATER
9650-11-PID-00-0042
1. The Level Indication 042-LI-1000 of process Water Tank (042-D-1005) gives alarm when it
When the level of RO Water Tank (042-D-1005) becomes Low-Low (LL), RO water Transfer
Pumps (042-P-1005 A/B) and DM feed water pump (P-1006 A/B) shall trip. (with interlock
by pass switch)
3. Control scheme of RO system is provided in local control panel.
042-P-1004 A/B - STAR & STOP (EMERGENCY)
screen.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
STEAM BOILER
9650-11-PID-00-0043
1. The Level indication in Boiler feed water tank (043-LI-1070) gives alarm when it becomes either
When Level in Boiler Feed Water Tank becomes High 043-XV-1070 will get closed and will
open when Level becomes Low. (with interlock by pass switch)
3. The temperature indication (043-TI-1070) gives alarm when it becomes either High – High (HH) or
4. The temperature of the boiler feed water is controlled by steam inlet control valve, 043-TV-1070
which regulates the steam Flow to boiler feed water tank (043-D-1070)as per the set point of 043-
TIC-1070.when temperature increased above set point valve opening will reduce.
5. The Level indication in Fuel oil storage tank (043-LI-1072) gives alarm when it becomes either High
screen.
7. Controlling of Boiler is provided in local control panel.

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
STEAM DISTRIBUTION
9650-11-PID-00-0048
1. The Pressure Indication (048-PI-2201) of Medium pressure steam at PRS gives alarm when it
2. The Pressure Indication (048-PI-2201) of Low pressure steam at PRS gives alarm when it becomes

CLIENT: CONTRACTOR:
PROJECT

BASIS) CHLOR ALKALI
PLANT
HFO SYSTEM
9650-11-PID-00-0066
1. The Temperature Indicator (066-TI-1074) of HFO Storage Tank (D-1074) gives alarm when it
2. The level indication (066-LI-1074) of HFO Storage Tank (D-1074) gives alarm when it becomes

Control Philosophy & Interlock Description - 9650-11-PCP-00-0002 R-04

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Control Philosophy & Interlock Description - 9650-11-PCP-00-0002 R-04

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50 MTPD CAPACITY (Cl2