CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS

MAHAGENCO FOR DEMINERALISATION

PLANT
DOCUMENT CONTROL SHEET

PROJECT 2 X 500 MW BHUSAWAL THERMAL POWER STATION

CLIENT MAHARASHTRA STATE POWER GENERATION CO. LTD.

DOCUMENT TITLE CONTROL PHILOSOPHY FOR DEMINERALISATION

PLANT

CONSULTANT TCE, BANGALORE

IEIL DOCUMENT NO : A4–A20154-12-304 B

REV.NO : p1

ENDORSEMENTS

P1 20/05/2010 Revised as per VDT 96 MBS RY NPD

P0 22.09.2009 First Submission MBS RY NPD

REV. PREP. BY REVW. BY APPRVD BY
DATE DESCRIPTION
NO. SIGN.(INITIAL) SIGN.(INITIAL) SIGN.(INITIAL)

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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT

CONTROL PHILOSOPHY FOR DEMINERALISING PLANT

The Control philosophy for Demineralization Plant consist of following section

listed below

 Reference Drawings
 General Description

 Brief Description of Plant/Various Units

 Pre Service & Service Flow
 Regenerant Unloading & Storage
 Regeneration
 Backwash & Air Scouring
 Neutralizing Pit

 Control & Monitoring philosophy for DM plant from DM-PLC

 Control Philosophy for Electrical Motor Drive – 415 V
 Control Philosophy for Motorized Valves.
 Control Philosophy for Pneumatic Auto Valve
 Control Philosophy for the Electrical System (LT Panels)

REFERANCE DRAWINGS:

P & I diagrams & Layouts for the reference are listed below.

Sr No Revision
Drawing Title P & ID Number
No
01 P & ID for DM Water Plant A1-A20154-01-06 Rev –R3
02 P & ID for DM Regeneration A1-A20154-01-07 Rev - R2
System
03 P & ID for DM Water Tank System A1-A20154-01-08 Rev -R3
04 Equipment Layout for DM Plant A1-A20154-02-02 Rev -R5
05 Legend Sheet A1-A20154-01-13 Rev - P0

General Description for De-mineralization Plant:

The De-mineralization plant is a three-stream plant having a net output capacity

of 100 m3/hr per stream. The system is suitable for semiautomatic operation
The de-mineralizing chain comprises of following units.

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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT

SR QUANTITY
TAG NO DESCRIPTION
NO in Nos.
1 ACF–A/B/C Activated carbon filter 3 nos.
2 LBC-A/B/C Layered Bed Cation Exchanger 3 nos.
3 DGT-A/B/C Degasser Tower 3 nos.
4 B2-A to F Degasser Blower 6 nos.
5 DGWT-A/B/C Degassed water storage tank 3 nos.
6 P11-A/B/C Degassed Water Pump 3 nos.
7 LBA-A/B/C Layered Bed Anion Exchanger 3nos.
8 MB-A/B/C Mixed bed Exchanger 3 nos.
9 B3-A/B/C Air Blower for MB 3 nos.
10 DMWT-A/B/C DM water storage tank 3 nos.
11 MDT Morpholine Dosing tank 1 no.
12 P16-A/B/C DM Water Transfer pump 3 nos.
13 RTV Resin Transfer Vessel 1 no

Apart from above, regeneration area comprises storage & dosing tanks for
regeneration of the exchanger unit’s .The regeneration area comprises the
following tanks.

SR QUANTITY in
TAG NO DESCRIPTION
NO Nos.
1 BAT-A/B/C Bulk acid storage tank 3 nos.
2 ATT-A Acid transfer tank 1 no
3 AMT-A Acid measuring tank for LBC 1 no
4 P12-A/B Acid Unloading pump 2 nos.
5 AMT-B Acid measuring tank for MB 1 no
6 AMT-C Acid measuring tank for N. Pit 1 no
7 P13-A/B Alkali Unloading pump 2 nos.
8 BCT-A/B/C Bulk Alkali storage tank 3 nos.
9 CMT-A Alkali measuring tank for LBA 1 no.
10 CMT-B Alkali measuring tank for MB 1 no
11 CMT-C Alkali measuring tank for N Pit 1 no.
12 DMRT DM Water Regeneration tank 1 no.
13 P15-A/B DM Water regeneration pump 2 nos
14 P14-A/B DM Plant Waste water pump 2 nos.
15 NP Neutralization Pit 1 no.

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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT

Brief description of plant / various units is as below.

The plant consists of three de-mineralizing streams. The logic of operation is 2

stream working + 1 stream stand-by. Each stream is designed to produce 100
m3/H treated water.

At any particular point of time, the operator shall take up only one stream for
the regeneration. Operator shall bring any unit into service only after the unit is
regenerated (the same shall not be put automatically). The operator shall
initiate service operation from the MMI control scheme for that particular unit. A
set of pneumatically operated butterfly valves and pneumatically operated
diaphragm valves are provided on ACF and LBC /LBA/MB units respectively to
enable semi automatic operation of the system

Filter / Ion exchange unit shall be isolated from the system as follows –

Activated carbon filter - On reaching preset output through the bed. Or

exceeding pressure drop across the bed whichever comes earlier

Layered Bed Cation – On reaching preset output (m3) of treated water Or

reaching preset pressure drop across the bed or exceeding sodium leakage at
outlet

Layered Bed Anion – On reaching preset output through the bed. Or reaching
preset conductivity value whichever comes earlier.

Mixed Bed Unit– On reaching preset output through the bed. Or reaching preset
conductivity value, or preset silica value whichever comes earlier.

The plant is designed for semi-automatic operation. This is achieved thro’ a PLC
based control system wherein automatic sequential control is manually initiated.
The procedure of regeneration can be `sequential ‘in nature depending upon
the pre-determined set of operation from the PLC or a set-wise execution of the
same operation, each step being initiated by manual intervention of the
operator. The sequential operation is broadly based on the valve sequence
chart which explains the status of the valves and rotary equipment at different
stages of service or regeneration operation.

The operator will initiate the operation of backwashing/regeneration/rinsing of a

particular filter/ion-exchange unit, and the change from one step of the
sequence to the next will be automatic.

During automatic progress of the sequence, indication of opening and closing of

different valves is available in MMI.

Manual over-ride is provided for each filter / exchanger to facilitate operation in

“manual” mode only.

PLC system has the provision of both working on “Auto” and “manual” mode.
When the system is in “auto” mode, the process will be operated on the logic /
sequence developed in the PLC and sequential operation will occur in a step-
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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT
wise manner, as specified. Operator has to initiate service or regeneration
mode, accordingly sequential operation will be performed.

On exhaustion of unit, an alarm status will be displayed on the MMI for the
particular filter/exchanger. Operator intervention is required for isolating the filter
/ exchanger.

Soft navigators are configured on the MMI station for selecting particular
Filter/Ion Exchanger units. Each solenoid – operated valve open/close status
will be available on the MMI.
The sequential operation of the plant is broadly based on the valve sequence
chart, which explains the status of valves & rotary equipment at stages of
service or regeneration operation.

The MMI dynamic graphic screens shall indicate status of all filters, exchanger
units, and rotary equipments in the plant, and open / close condition of all auto
valves during service, regeneration process or stand-by mode of the unit.
Moreover, display of analog values for all parameters in the plant are available
on these screens.

When unit is brought into service, the sequence of opening & closing of the
valves shall be as per the valve sequence charts.

Pre service and service flow:

Feed water to DM plant shall be fed from Filter Water storage tank (FWST-B)
through DM feed pump (P2-A/B/C).

Water is passed through Activated Carbon Filter (ACF-A/B/C) to Degasser

Tower (DGT A/B/C) through Layered Bed Cation exchanger (LBC-A/B/C) and
store in Degassed water storage tank (DGWT-A/B/C).

Activated Carbon Filter (ACF-A/B/C) is provided with an inlet flow indicator (FI-
601 – FI 603) and pressure gauge (PI-601 to 606) at the service inlet & outlet
line for local indication. Differential Pressure switch-high (DPSH-601 to DPSH-
603) is provided across the ACF to measure pressure drop across bed, alarm
for high pressure drop is provided. Operator interference is required for further
process. Pneumatic auto valve for each vessel (ACF-V601 to ACF-V607and
ACF-V609, eight nos) are provided for respective ACF (A/B/C)

Layered Bed Cation exchanger (LBC – A/B/C) is provided with flow indicator
(FI-604, FI-606 and FI-608) at the service inlet and Flow indicating transmitter
(FIT-605, FIT-607, FIT-609) at the service outlet along with pressure gauge (PI-
606 – PI-612), for local indication. Flow indicating transmitter provides an alarm,
if output exceeds the preset value. Also, differential pressure switch-high
(DPSH-604/605/606) is provided across the Resin Trap to provide high alarm.
Sodium analyzer AIT603 (common for LBC-A/B/C) is provided for monitoring
and alarm for sodium content in water. Operator intervention is required for
isolating LBC from service, if required.
Water from LBC-A/B/C shall be passed through degasser tower (DGT A/B/C)
further to the Degassed Water Storage Tank (DGWT-A/B/C) through control
valves (DGT-V602) which control by level transmitters (LT-601 to LT-603) in
DGWT. Degassed water storage tank is also provided with level switches (LS-
601 to LS-609) for high, low alarm and low-low tripping of degassed water
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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT
transfer pump (P11-A/B/C).

Water from degassed water transfer pump (P11-A/B/C) is feed to the Layered
Bed Anion (LBA – A/B/C) and this pump is provided with pressure gauge (PI
628 – PI-630) for local indication. Pressure switch (PS-601 to PS-603) is
provided to trip the pump on high pressure or to start sand by pump on low
pressure. Alarm for low and high pressure will be generated in PLC. On high
pressure, recirculation valve (DGWT-V604) of each degasser will open to
facilitate recirculation.

Layered Bed Anion Exchanger (LBA-A/B/C) is provided with local flow meter
(FI610, FI-612 and FI-614) at the service inlet and pressure indication (PI-613 to
PI-618) at both the inlet and outlet of exchanger. Flow transmitter (FT-611, FT-
613 and FT-615) is provided at service outlet for preset output high alarm, as
required for isolation. Each exchanger is provided across Resin Trap (RT) with
differential pressure switch (DPSH-607/608/609) is provided across the Resin
Trap to provide high alarm. Conductivity analyzer (AIT-604,606,608) is provided
at service outlet to monitor the conductivity value and alarm is generated in the
PLC to isolate the vessel by operator intervention. Conductivity analyzer is also
provided (AIT-605, 607,609) at rinse outlet to monitor the conductivity value and
alarm is generated in the PLC to stop the rinse.

Mixed Bed Exchanger (MB-A/B/C) is provided with local flow meter (FI616, FI-
618 and FI-620) at the service inlet and pressure indication (PI-619 to PI-624) at
both the inlet and outlet of exchanger. Flow transmitter (FT-617, FT-619 and FT-
621) is provided at service outlet for preset output high alarm, as required for
isolation. Conductivity & pH analyzer (AIT(cond.)-612,615,618) (AIT(pH)-
610,613,616) is provided at service outlet to monitor the conductivity / pH value
and alarm is generated in the PLC to isolate the vessel by operator intervention.
Conductivity analyzer is also provided (AIT-611, 614,615) at rinse outlet to
monitor the conductivity value and alarm is generated in the PLC to stop the
rinse. Common silica analyzer (AT-619, three channels) is provided for
monitoring the silica content (high alarm) in the discharge of Mixed Bed
Exchanger for operator intervention.

De-mineralized water from Mixed Bed exchanger (MB-A/B/C) will be stored in

DM water storage tank (DMWT-A/B/C), which is provided with Level Transmitter
(LT-801/802/803) for monitoring and Level Indicator (LI-801/802/803) for local
indication. Level Switches (LS-802 to LS-810) are provided on DM water
storage tanks for high, low alarm and low-low tripping of the DM transfer pump
(P-16-A/B/C). The morpholine tank with agitator (MDT-AG-801) is provided for
the addition of morpholine to the suction of DM water transfer pump by
morpholine dosing pump (MDP-A/B).The low level switch (LS- 801) is
interlocked to trip the morpholine dosing pump (MDP-A/B) and the agitator. The
level indicator (LI-804) is also provided for local indication.

The Flow-transmitters (FT-801, 802) is provided on the common header of the

DM water transfer pump, which goes to the condensate storage tanks. It
provides input to the PLC regarding the flow through the DM water transfer
pump. This flow is totalized in the PLC and a high alarm signal is generated for
recalculating the water through auto valve (P6-V815). Pressure switch (PS-801
and PS-802) is provided in the common header of the pump for tripping the
pump at low pressure.
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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT
REGENERANT UNLOADING & STORAGE:

During regeneration, the progress of different sequence/sub-process shall be

displayed on MMI in the form of step description, which is in progress. Failure in
any operation will also be indicated. Once a filter/exchanger has been
regenerated it will not be put back into service automatically, but operator will
have to manually put back into service through a soft selection switch.
The LBC exchangers are regenerated by hydrochloric acid and LBA exchangers
are regenerated by sodium hydroxide solution. As the MB exchanger contains
Anion as well as Cation resin, both the regenerants are passed through the unit
during regeneration.

For unloading of hydrochloric acid into Bulk Acid storage Tank, Acid-unloading
pump (P12-A/B) shall be used. It is provided with pressure indicator (PI-701,
702) in the discharge line. For unloading of Sodium hydroxide into Bulk Alkali
storage tank, Alkali unloading pump (P13- A/B) shall be used. It is also provided
with pressure indicator (PI-704, 705) in the discharge line. Unloading operation
is controlled manually thro’ local push button station (LPBS) provided near each
motor.

The alternate provision for storing acid in Acid transfer Tank (ATT) is facilitated ,
acid can be transfer to acid measuring tanks by applying air pressure in ATT.
Pressure gauge ( PG-703) and level gauges ( LG-710/711/712/731) are
provided for local monitoring of pressure and level respectively. P
1

Filling operation of the bulk tanks to measuring tanks is by gravity. Unloading of

acid/alkali will be manually operated from the field. All drive status / indications
(including Pumps, Agitators) will be available on the PLC by means of
ON/OFF/TRIP indication

Hydrochloric acid is transferred from the Bulk Acid Storage tank (BAT-A/B/C) to
the acid measuring tanks (AMT-A/B for LBC & MB respectively) by means of
gravity. Ejector is provided to mix water with acid to get it in dilute form, which
will be used for regeneration.

Flow indicator (FI-701, 702) is provided to monitor the flow at water inlet line to
acid ejector. Also the density indicator (DI-701, 702) is provided on the
discharge line of the ejector to measure the dilution of acid. The level indicator
(LI – 713 & LI - 714) is provided for local indication and the level switches (LS-
701 & LS - 702) for low-low, low & high alarm, also to maintain the level in
measuring tank through opening / closing of auto valve at outlet (AMTV04A/B)
at the inlet (AMTV01A/B) of the tank.

Alkali is transferred from the Bulk Alkali Storage tank (BCT-A/B/C) alkali
measuring tanks (CMT – A/B for LBA & MB respectively) by means of gravity.
Ejector is provided to mix water with alkali to get it in dilute form, which will be
used for regeneration

Agitators are provided for Alkali measuring tank (CMT A-AG-701& CMT B-AG-
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MAHAGENCO FOR DEMINERALISATION
PLANT
701) for proper mixing of the alkali. Flow indicator (FI-703, 704) is provided to
monitor the flow at water inlet line to alkali ejector. Also the density indicator (DI-
703, 704) is provided on the discharge line of the ejector to measure the dilution
of alkali. The level indicator (LI – 724, LI - 725) is provided for local indication
and the level switches (LS-703 & LS - 704) for low-low, low & high alarm, also to
maintain the level in measuring tank through opening / closing of auto valve at
outlet (CMTV04A/B) & at the inlet (CMTV01A/B) of the tank.

Separate Acid measuring tank (AMT-C) & Alkali measuring tank (CMT-C) is
provided for adding acid and / or alkali to the neutralization pit (NP). These
tanks are provided with the level switches (LS – 710 & LS-711 respectively) for
Low & high alarm. Level indicator (LG-726, 727) is provided for local indication.

List below is the corresponding exchanger and measuring tanks:

Exchanger Measuring tank used

LBC - A/B/C AMT – A & CMT - A
MB - A/B/C AMT – B & CMT - B
N. Pit AMT-C & CMT – C

Before taking up in regeneration of a stream or an exchanger, it has to be

ensured by the operator that the respective measuring tanks are filled with
required quantity of regenerants. In case the regeneration tanks are not filled,
regeneration sequence shall not proceed further.

REGENERATION

When a filter or exchanger unit is exhausted and isolated from the system,
operator shall select the sequential operation along with the drives and
associated tanks for regeneration operation, in either auto or in Manual mode.

The unit to be regenerated will be selected by the operator from the MMI for the
regeneration steps viz., Backwash, Regeneration, and Rinse etc. in a step-wise
manner. Yet, the automatic sequence shall be interruptible at any time by the
operator and can be manually controlled from that step onwards. Moreover,
operator shall be able to prolong a given step by inputting revised timing data in
the field locations provided for the purpose. The operator shall also' be able to'
Hold, Advance or Reset a step as and when desired by means of soft-keys
provided on the MMI command screens. When the unit is in manual operation,
the operator has the flexibility of selecting and executing each and every step of
operation of the exchanger unit, one at a time. The selected step shall proceed
till operator intervention takes place.

Regeneration shall not be able to proceed, if the level is low in the selected
regenerant tanks. The steps of regeneration except chemical injection and rinse
shall be time-based.

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 CONTROL PHILOSOPHY 2 X 500 MW BHUSAWAL TPS
MAHAGENCO FOR DEMINERALISATION
PLANT

Hot water from DM Water regeneration tank will be used for caustic solution
preparation during the regeneration process.

The DM Water regeneration tank is equipped with Heater (s), temperature

switch (TSH 701), Low & High level switches (LS – 705, 706) and Pressure
switches for high alarm (PS-701) and to trip the heater. The temperature
maintained in the tank is 50 deg Celsius using the temperature switch. The hot
water will be fed as power water to alkali ejector. Pressure indicators (PI-706,
707) are provided for the local indication on the discharge line of DM
regeneration pump P15-A/B.

The low level switch (LS-705) is interlocked with the heater so that if water level
in the tank is low, the heater will trip automatically. Also the interlocking of the
pressure switch with high-pressure switch/contact is provided for switching off
the heater in case of high pressure in the vessel. The high and low level alarm
is available on the MMI.

Resin transfer is carried out using water with the air. For resin transfer, the
following vessels are provided

 DM Water Regeneration Tank (DWRT)

 DM regeneration pump (P15-A/B)
 Resin transfer Vessel (RTV

Compressed air is supplied to resin transfer vessel (RTV) from the compressed
air system for resin transfer.

NEUTRALISING PIT:

Wastewater generated during the course of regeneration is collected in the

Neutralizing Pit (NP) comprising of two compartments, each capable of handling
wastewater from regeneration of two streams at a time. Each compartment is
provided with one level switch (three contacts for high, low and low low alarm)
and interlocked with the Waste Water Transfer pump (P14-A/B) for low low level
tripping. The relevant signals shall be available on the MMI. Wastewater
recirculation is provided by means of auto valve (P14-V03) depending upon the
pH value. Operator initiates disposal of neutralized water by starting the waste
transfer Pumps P14-A/B.

pH indicator / transmitter (PHIT-701) is mounted on the discharge line of pumps

P14-A/B for continuously monitoring the pH of the waste water. An alarm is
given when the pH value deviates from a pre-set range i.e. 6.8 pH - 7.5 pH.
Based on pH value, the auto valves on the discharge and recirculation line will
be operated automatically. If the PH decreases below the set point, operator
has to intervene and manually open the value for dosing the chemicals

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MAHAGENCO FOR DEMINERALISATION
PLANT

(Acid/Alkali) to achieve the desired pH. Chemicals (Acid/Alkali) dosing tanks are
provided with Level switches (low and high alarm), which are available in the
MMI for operator intervention.

Control & Monitoring philosophy for DM plant from DM-PLC:

The control & monitoring of DM plant will be from DM/Softening - PLC

workstation (two operator work station and one engineering station) located at
DM plant control room. Apart from DM Plant the following system also be
controlled & monitored from the DM/Softening - PLC. These systems are ---

 PT Plant PLC (with one workstation and Local Control panel installed
in PT Plant control room).
 Effluent Treatment plant PLC (with one workstation and Local Control
panel installed in ETP Plant control room).

The DM/Softening - PLC for above-mentioned system have following

features.

a) The PLC system has redundant CPU, Power supply,

communication modules ,cables & non redundant I/O’s
b) The processor shall contain program memory with read/write
capability & shall be solid state RAM with battery back up.
c) The PLC has supervisory functions like MMI which shows the
reading of all analyzer /transmitter, alarm & any abnormalities etc.
All engineering activity for DM/SF shall be carried out through PLC
in DM Plant control room.
d) DM PLC status indication will be communicated to DCS by
redundant port provided in DM PLC through OPC connectivity

P
1
A. Electrical Motor Drive Control Philosophy For 415 V Drive –
The 415 V drives, except for manually operated drives, will be operable from
remote (PLC at control room) as well as from local push button station, located
near drive. Remote manual operation (Start/Stop) of 415 V drives will be
performed in two modes. Normal mode of operation will be carried out from
PLC. Permissive & trip condition will display on MMI. Control command
Start/stop under normal mode will be generated in PLC & issued through
interposing relays mounted in respective MCC Electrical protections from the
drives will be realized form the MCC, where as process interlocks & protections
will be realized in PLC. Operation of the drive from PLC will only be possible
upon fulfillment of all process & protection interlock.

Local / Remote selection will be carried from the MCC .Local operation will be
carried out from LPBS near drive and remote operation from PLC. Emergency
stopping of drive will envisage from the local push button station. The stop push
button will be stay put type & provided with press to local & turn to release. Key
less type mechanism & will be directly wired to the MCC. Stop operation from
respective starter module in MCC has not been envisaged.

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PLANT
Following signal exchange will take place between MCC & PLC.

1. Drive start command for 415 V drive

2. Drive Stop command for 415 V drive
3. For Status feedback for 415 V drive
 On feed back
 Off feedback
 Trip Feedback
 Selector switch Remote
 CT input for Current Transducer (above 30 kW)

B. Control Philosophy for Pneumatic Auto Valve –

Pneumatic auto valve will be operated from PLC only. Power supply for the auto
valve will be feed from the PLC panel. Open/closed command is generated in
PLC and open close feedback taken to PLC from field whether valve will
operate in Auto/Manual mode. Operator can operate auto valve manually after
selecting the manual mode from PLC. However in auto mode, auto valve will be
operated as per logic & process requirement.

Following signal exchange will take place between valve & PLC.

a) Valve Open limit switch feedback

b) Valve Close limit switch feedback
c) Valve Open / Close command

Control Philosophy for Electrical Incoming System –

The status input of relevant electrical equipment & electrical parameter

mentioned below is considered as input to the PLC for displaying the electrical
status of the system.

Following signal exchange will take place between Electrical systems – LT

Panels & PLC

a) Status Feedback of Breaker ON

b) Status Feedback of Breaker OFF
c) Status Feedback for Breaker Trip
d) Status Feedback of Spring charged.
e) Status Feedback of Breaker in test mode.
f) Status Feedback of Breaker in service mode.
g) Status Feedback of Breaker trip circuit healthy.
h) ON Command - Incomers/Bus-couplers.
i) OFF command - Incomers/Bus-couplers.
j) For Metering of the LT panels. --

 Current.
 Voltage.
 Power.
The control & operation philosophy as described above is in line with the tender
specifications.

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