WTP I&C Conceptual and Basic Design: I.P.D.C. Roject: Shirvan Gas Turbine Power Plant

IRAN POWER DEVELOPMENT COMPANY
MINISTRY OF ENERGY
-1-
I.P.D.C.
ROJECT : SHIRVAN GAS TURBINE POWER PLANT
WTP I&C CONCEPTUAL AND BASIC DESIGN
IN-HOUSE REVISIONS
D C B MAPNA ACo. Second Issue 0 The First Issue M.A. Sh.I.
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DOCUMENT REVISIONS
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A 0
Second Issue The First Issue
M.A. Sh.I.
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Doc. No.: MP-SVG-30IE-28-ZG3-001
Rev. A
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(PRIVATE JOINT STOCK) IRAN POWER PLANT PROJECTS MANAGEMENT Co.
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Remarks C D E F G
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References:
WTP SYSTEM P&ID DIAGRAM (MP-SVG-30IE-02-ZG0-001) WTP SYSTEM DESCRIPTION (MP-SVG-30IE-04-ZG0-001) RAW WATER P&ID DIAGRAM (MP-SVG-58IE-02-ZA0-001) RAW WATER SYSTEM DESCRIPTION (MP-SVG-58IE-04-ZA0-001) POTABLE WATER SYSTEM P&ID DIAGRAM (MP-SVG-27IE-02-UP0-001) POTABLE WATER SYSTEM DESCRIPTION (MP-SVG-27IE-04-UP0-001) WTP CONTROL PHILOSOPHY (MP-SVG-30IE-04-ZGY-001)
MAPNA Co.
Content
Doc. No.: MP-SVG-30IE-28-ZG3-001 Rev. A
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1. Introduction 2. Codes and standards 3. Site condition 4. WTP System instrument and control concept design 4.1. 4.2. 4.3. 4.3.1. 4.3.2. 4.3.3. General notes for field instruments WTP feed Pumps Chlorination package Chlorination package mixer Chlorination dosing pump for raw water reservoir Chlorination dosing pump for potable water reservoir Sand filters Activated carbon filter filtered water storage tank Softening unit 4.7.1. 4.7.2. 4.7.3. 4.7.4. 4.8. 4.9. 4.9.1. 4.9.2.
MAPNA Co.
4.4. 4.5. 4.6. 4.7.
Softeners Soft water Tank Soft Water Transfer Pump Backwash & Regeneration Pumps Sodium Bicarbonate Dosing Package Reverse Osmosis System R.O Feed Pumps Antiscalant Dosing pump Cartridge Filters High Pressure Pumps R.O's
4.9.3. 4.9.4. 4.9.5.
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4.9.6. 4.9.7. 4.10. 4.11. 4.12. 4.13. 4.14.
Washing & Flushing Tank and Pumps Permeate water tank AUX. Boiler Make-up Water Pumps Make-up Water Pumps For CCCW Potable water blending tank potable water pumps Elevated water tank
5. Control Panel Description 5.1. Panel Front Mounted instrument & devices
MAPNA Co.
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1. Introduction This document describes the I&C basic design requirements for water treatment plant (WTP) and potable water system in Shirvan Gas Turbine Power Plant. The control system for WTP includes all the required field instruments and a control panel for operation, supervision and protection of the a.m. system. Water treatment plant is including the following units: 1. 2. 3. 4. Filtration unit Softening unit Reverse osmosis unit Potable water system
2. Codes and standards Control and instrumentation of W.T.P and potable system will be designed according to the following international codes and standards: BS ISA API NFPA IEC 3. Site condition Site Location Road Site Elevation Max. Ambient Air Temperature Min. Ambient Air Temperature Design Ambient Temperature Relative Humidity Design wind velocity 9 km east of Shirvan in the Ghotbabad 1115 m above sea level 42.3C - 30C 15C 56% 144 km/hr British Standard Institute Instrument Society of America American Petroleum Institute National Fire Protection Association International Electrical Code
4. WTP System instrument and control concept design 4.1. General notes for field instruments
MAPNA Co.The
following type of field instruments will be provided for the system: Pressure & Diff. Pressure Gauges
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Pressure and Level Switches Analyzer (PH, Conductivity, Cl2) Transmitters Flow meters The instruments will be generally weather proof (IP55 for gauges and IP65 for field switches and transmitters) with wetted parts of stainless steel or bronze. For other specification of instruments please refer to instrument data sheet for water treatment plant, document no. MP-SVG 30IE 11 ZI0 - 001 . 4.2. W.T.P feed pumps In order to transfer of raw water from fire raw water tank fighting water reservoir to water treatment plant, 2X100% pumps have been foreseen in Water Treatment Plant (WTP) that are located in f/f pump house. The mentioned pumps discharge line will be equipped with a motorized valve, which its start & stop command will be used for liquid chlorine dosing system. The mentioned interlocks will be explained in the related paragraphs. Very Low level from raw water reservoir will trip the pump. Normally one pump operates while the other pump is on stand-by. 4.3. Chlorination package One chlorination package is foreseen for chlorination of raw water (water in fire water reservoir) and potable water. This package includes: Calcium hypochlorite preparation tank and mixer Calcium hypochlorite solution tank Calcium hypochlorite dosing pumps One dosing pump will be used for injection of solution to raw water reservoir and the other one injects the solution to potable water. 4.3.1. Chlorination Package Mixer
The operation (Start Stop) of mixer will be manually done by start/stop push-buttons located on WTP MIMIC panel.
MAPNA Co.Also
the status of motor (on off - failure) will be indicated on WTP MIMIC panel by indication lights.
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4.3.2.
Chlorination dosing pump for raw water reservoir
When raw water MOV opens, this pump will be started and injects the calcium hypochlorite solution to raw water tank. In case of receiving low level signal from CL2 tank, pump will be stopped.
4.3.3.
Chlorination dosing potable water
pump
for
When the inlet electrical valves of potable water blending tank opens, this pump will be started and after a certain time which is necessary to dose the specified volume of solution, this pump will be stopped. In case of receiving low level signal from Cl2 tank, pump will be stopped. Type of instruments 1. Pressure gauges On outlet line of each dosing pump one pressure gauge is considered for local indication of pump outlet pressure. level switches One low level switch is considered on hypochlorite solution tank for dry protection of dosing pumps. 4.4. Sand Filters The water from WTP feed pumps is passed through the filter containing sand gravel for removal of particulate organic and colloidal matters. Two sand filters will be provided. Each filter shall have a inlet solenoid valve to select the service line. In normal operation one filter is in service line. In case of one filter being under backwash the other filter will be in service line. In general the backwash process of each filter will be 30 minutes. Type of instruments: 1. Flow indicator transmitter
MAPNA Co.Inlet
of sand filters one flow indicator transmitter will be installed to view and transmit raw water flow to W.T.P control panel. The flow will be totalized in W.T.P local control panel.
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2. Pressure indicator Inlet of sand filters one pressure indicator will be installed to view pressure of water. 3. Pressure differential indicator and switch (High) When pressure differential exceeds from a predefined set point it means that filter needs backwash. Local monitoring of pressure differential indicator will also available. 4.5. Activated carbon filter One carbon filter is foreseen for removal of residual chlorine from raw water. One electric solenoid valve is considered on inlet line of carbon filter. This valve will be controlled by level of soft water tank. Type of instruments
1. Pressure
differential indicator switch
When differential pressure exceeds from set point, it means that the filter needs to be backwashed. The backwash of carbon filter is manually. 2. Residual chlorine analyzer transmitter One residual chlorine analyzer transmitter is foreseen for analyzing and transmitting of amount of residual chlorine in filtered water. In case of excess concentration of residual chlorine in filtered water, an alarm will be activated in W.T.P local panel. 4.6. filtered water storage tank The level of this tank will be controlled by opening/closing of inlet solenoid valve. Location of this tank is in WTP building. The level of water in filtered water tank will be saved in a limit to protect of all user pumps (here filtered water pump) from dry running. The capacity of this tank is 12 m3. Type of instruments:
1. Level switches (Very High, High, Low, MAPNA Co.When level of filtered water reaches
Very Low)
to set points, it means that inlet solenoid valve should be opened/closed. These switches will be float type.
Rev. A
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4.7.
Softening unit
4.7.1. Softeners Two softeners are provided. In normal operation one softener is in service and the other one is standby. After softening of a predetermined amount of water the softener shall be regenerated. So the softener shall be stopped and the standby softener shall come in service. Each softener has an inlet electrical solenoid valve and a local flow indicator. At outlet header of softener, one flow indicator transmitter is located. PLC calculates the total flow passed from the operating softener and after a predetermined amount of flow the solenoid valve of operating softener will be closed and the inlet solenoid valve of other softener will be opened. There is interlock between the close/open of the solenoid valve and the total flow calculated by PLC. Also there is interlock between the close/open of the solenoid valve and the level of soft water in the soft water tank. After predefined time or quantity of soft water production, softeners shall be regenerated. For regeneration, PLC will close the solenoid valve of the softener which needs regeneration and regeneration will be done manually by operator. According to process calculations, each softener will be in operation for 9.7 hours. The approximate duration of backwash and regeneration process of each softener will be as follows: - Backwashing - Regeneration - Slow rinse - Fast rinse 15 min. 60 min. 30 min. 30 min.
Type of instrument: 1. Local flow indicator Local flow indicator shows flow of water passing through output line of each softener.
2.
Flow indicator transmitter
The flow rate in basic line shall be indicated and transmitted by a Flow indicator transmitter. Total flow shall be calculated by PLC.
MAPNA Co. 4.7.2.
Soft water Tank
Rev. A
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This tank contains soft water and level switch of tank has interlock with solenoid valve of softeners to prevent tank from emptying and overflowing also has interlock with inlet solenoid valve of carbon filter. The capacity of this tank is 12 m3. Type of instruments:
1.
level switches (Very High, High, Low, Very Low)
Level of soft water controls state the open/close position of softeners and carbon filter solenoid valves. These switches will be float type. 4.7.3. Soft Water Transfer Pump This pump transfers soft water to AUX. Boiler and there is interlock between start/stop of this pump and level of soft water tank also with AUX. Boiler make-up water tank level. Type of instruments: Pressure indicator One pressure indicator shall be installed after pump to view pressure locally. 4.7.4. Backwash & Regeneration Pumps Backwash water is supplied by two pumps, one of them is in service and the other one is stand by. Required water for backwash of filters is stored in soft water storage tank. Also they have interlock with level of soft water storage tank to prevent pumps from dry running. Type of instruments:
1-
Pressure indicators
Two pressure indicators shall be installed after pumps to view pressure locally. 2- Flow indicator The flow rate in common line of backwashing shall be indicated by a local flow meter.
MAPNA Co. 4.8.
Sodium Bicarbonate Dosing Package

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One Sodium Bicarbonate Dosing Package is foreseen for PH adjustment of boiler make-up water/CCCW make-up water and potable water. This package includes one solution preparation tank with mixer and two dosing pumps. One dosing pump injects the Sodium Bicarbonate to boiler and CCCW make-up water and the other one injects Sodium Bicarbonate to potable water blending tank. Soft water will be used for preparation of Sodium Bicarbonate solution. Type of instruments: 1. Pressure indicator One pressure indicator shall be installed after pumps to view pressure locally. 2. Level switch (Low) One Low level switch has been provided to protect the dosing pump from dry running. This switch will be float type. 4.9. Reverse Osmosis System 4.9.1. R.O Feed Pumps
There are two pumps that in normal operation one of them is in service and the other one reserves as standby. These pumps feed soft water to R.O's and there is interlock between start/stop of these pumps and level of permeate water tank. Type of instruments: 1. Pressure indicators Two pressure indicators shall be installed after pumps to view pressure locally. 4.9.2. Antiscalant Dosing package
For protection of membranes of R.O package one antiscalant dosing package is foreseen. This package includes preparation tank and one dosing MAPNA pump.
Co.
The antiscalant solution will be injected to inlet of R.O cartridge filters.
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Antiscalant solution will be prepared with permeate water. Type of instruments: 1. Pressure indicator One pressure indicator shall be installed after pump to view pressure locally. 2. Level switch (Low) One low level switch has been provided to protect the dosing pump from dry running. This switch will be float type. 4.9.3. Cartridge Filters
There are two cartridge filters that will be equipped with two Pressure differential indicators. Normal pressure differential indicates plugged cartridge filter. Type of instruments: 1. Pressure differential indicator Pressure differential indicator, indicates pressure differential of cartridge filters to operators locally. 2. Flow indicator The flow rate in basic line shall be indicated by a Flow indicator to view correct direction and normal amount of flow locally. 3. Temperature indicator Temperature of water in basic line must be in ambient range and shall be indicated by a temperature indicator to view locally. 4.9.4. High Pressure Pumps
It is considered two units of stainless steel high-pressure pumps, one in operation and one as stand by.
MAPNA valves are open. Before high-pressure pumps there is Co.unit, which is pressure switch for measuring the min.
It must be paid attention that in operation mode, all pump inlet and outlet min. pressure control pressure via PLC. If a pre adjusted min. pressure is not available at the inlet of high-pressure pumps, there will be alarm and automatic plant shut down. Main reason for
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a low-pressure switch plant shut down signal might be plugged filters (cartridge filters) and/or closed valves in up stream of the low-pressure switch. At the outlet of high-pressure pumps there is a pressure-measuring sensor for alarm and plant shut down at any high pressure, more than the required pressure. Type of instruments: 1. Pressure switch (Low) The pressure switch will be used for pressure dropping alarm. 2. Pressure indicators Two pressure indicators shall be installed before and after of each high pressure pump to view the pressure of service line. Pressure switch (High) Pressure in outlet of pumps shall be at set point, if the pressure is high, PLC will turn off the high pressure pumps.
3. 4.9.5.
R.O's
There are two trains of R.O. system which one train is in service and one train is as standby. Each train has its own isolating valves as a complete unit independently. Concentrate water from two R.O. trains will be equipped with flow and pressure measuring instruments. On the common outlet permeate there are instruments for measuring the flow, pressure and conductivity. In each train there are 2 R.O. modules (sets of pressure vessels), each train will be equipped with sampling valve, showing the situation of each module from process view point. In case of any plant shut down, permeate water from the flushing tank will be conducted into R.O. trains by flushing pumps automatically. This permeate flow will wash out the concentrate water. Type of instruments: 1. Pressure indicators Pressure of inlet water to RO, injected water and outlet permeate water shall be indicated. Four pressure indicators will be needed.
MAPNA Co.
2. Flow indicator
Rev. A
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Flow of chemical drain shall be monitored locally. 3. Conductivity indicator and transmitter Conductivity of permeate water shall be displayed locally and transmitted to PLC. 4. Pressure Switch (High) Pressure of permeate water shall be in range of set point. Pressure switch will make high alarm when pressure is high. 5. Flow indicator / totalizer and transmitter Flow of permeate water shall be in set point range. Flow rate shall be indicated and transmitted to PLC. Washing Pumps & Flushing Tank and
4.9.6.
Washing and flushing skid includes one tank & one pump. The washing & flushing water will be permeate water. Type of instruments: 1. Pressure indicator One pressure indicator shall be installed after pump to view pressure locally.
2.
Level switch (Low)
One level switch has been considered in flushing tank for dry protection of washing pump. 4.9.7. Permeate water tank
One storage tank is foreseen for permeate water tank. This tank will be equipped with level switches. Suction lines of following users are branched from this tank:
MAPNA Co.
Auxiliary boiler make-up water tank CCCW & compressor washing pumps
Type of instruments:
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1.
Level switches (Very Low, Low, High , Very High)
Low & high level switches will be used for start and stop of high pressure pumps. Very Low level switch will be used for dry protection of boiler and CCCW make-up pumps. Very High alarm will be used for alarm to prevent loss of permeate water from overflow of tank. 4.10. AUX. Boiler Make-up Water Pumps There are two pumps that in normal operation one of them is in service and the other one reserves as standby. Type of instruments: 1. Pressure indicators Two pressure indicators shall be installed after pumps to view pressure locally.
2.
PH analyzer indicator and switch (High)
PH of permeate water in outlet of this pumps shall be indicated locally by PH analizer indicator. If PH is high, analizer switch will send alarm to PLC. 4.11. Make-up Water Pumps For CCCW There are two pumps that in normal operation one of them is in service and the other one reserves as standby. These pumps will send permeate water to accumulator and to CCCW. Type of instruments: 1. Pressure indicators Two pressure indicators shall be installed after pumps to view pressure locally.
2.
PH analyzer indicator and switch (High) of this pumps shall be indicated locally by PH analizer switch will send alarm to PLC.
MAPNA of permeate water in outlet PH Co. analizer indicator. If PH is high,
3. Pressure indicator and switch (High, low)

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If line pressure after pumps reaches a low or high level , this instrument will start/stop the CCCW make-up pumps. Potable water blending tank
4.12.
One potable water blending tank is foreseen for blending of filtered water and permeate water with a certain ratio. When the level of water in this tank reaches to low level the inlet permeate & filtered water solenoid valve will be opened and after a predetermined time (which may be different for each valve) these valves will be closed. Hypochlorite dosing pumps will be also started with low level signal and will be stopped after dosing a predetermined volume of hypochlorite solution. Type of instruments:
1.
Level switches (Very Low, Low, High, Very High)
Very Low level switch will be used for dry protection of potable water pumps. Low level switch will be used for opening of inlet solenoid valve. High level switch will be used for closing of inlet solenoid valve. Very High level switch will be used to make an alarm for operator action to prevent loss of water from overflow. 4.13. potable water pumps Two potable water pumps are provided for pumping potable water to elevated tank. Type of instruments: 1. Pressure indicators: Two pressure indicators shall be installed after pumps to view pressure locally. 2. Flow indicator transmitter:
MAPNA flow indicator transmitter is provided One Co. pumps for local indication & transmission of
on discharge line of potable potable water flow to control
panel of W.T.P.
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3.
conductivity & PH & Cl2 analyzer
These analyzer transmitters are provided for monitoring of potable water quality. In case of exceeding any of these parameters from a predetermined valve an alarm will be activated in local panel of W.T.P. 4.14. Elevated water tank Level of elevated tank will be controlled with start/stop of potable water pump. This tank should be protected from empting of water and over flow. Exceed from both of these condition should announce to the operator. The capacity of elevated tank is 15 m3. Type of instruments: 1. Level Transmitter One level Transmitter will be considered for sending signal to local control panel in order to control panel monitoring. The transmitter will be equipped with local indication facilities.
2.
Level switches (Very High , High, Low, Very Low)
These switches will consider for tank water level controlling due to interlock with potable water pumps. These switches will be float type. Control Panel Description The control panel is a conventional free standing type, which to be installed in the WTP building. The panel will be weather proof IP41 and to be installed in safe (non-hazardous) area. The panel will be equipped with thermostat and internal lighting powered by 220 VAC, 50 Hz. 5.1. Panel Front Mounted Instruments & Devices The control panel front mounted instruments and devices will as following:
MAPNA Co.Annunciator
5.
with 4 X 7 or other approved alarm windows, buzzer, acknowledge, reset and test push buttons. The Alarm sequence will be based on ISA sequence and alarm conditions will be as following:
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* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
Sand Filter-1 DP High Sand Filter-2 DP High Activated Carbon Filter DP High Filtered Water Storage Tank Level Too High Filtered Water Storage Tank Level High Filtered Water Storage Tank Level Low Filtered Water Storage Tank Level Too Low Calcium Hypochlorite Solution Tank Level Low Carbon Filter Outlet Residual Chlorine High Antiscalant Preparation Tank Level Low Soft Water Storage Tank Level Too High Soft Water Storage Tank Level High Soft Water Storage Tank Level Low Soft Water Storage Tank Level Too Low Cartridge Filter-1 Outlet Pressure Low Cartridge Filter-2 Outlet Pressure Low H.P. Pump-1 Outlet Pressure High H.P. Pump-2 Outlet Pressure High RO Outlet Pressure High RO Outlet Conductivity High Sodium Bicarbonate Solution Tank Level Low Washing & Flushing Tank Level Low Permeate Water Storage Tank Level Too High Permeate Water Storage Tank Level High Permeate Water Storage Tank Level Low Permeate Water Storage Tank Level Too Low Potable Water Blending Tank Level Too High Potable Water Blending Tank Level High Potable Water Blending Tank Level Low Potable Water Blending Tank Level Too Low Potable Water Pump Outlet pH High Potable Water Pump Outlet Conductivity High Potable Water Pump Outlet Cl2 High Make up Water Pump outlet pH High Aux. Boiler Make up Water Pump Outlet pH High PLC Failure Control Power Supply Failure
MIMIC panel showing WTP.

MAPNA The status of pumps (ON, OFF, FAILURE) Co.panel by indication lights. Also the START
will be provided on the MIMIC & STOP push buttons for each pump and mixer will be provided on MIMIC panel.
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For coupled pumps (stand-by, duty) one selector switch will be considered on the MIMIC panel for selecting the duty pump. One selector switch on MIMIC panel will be considered for selecting of auto/manual mode of WTP. Digital indicators for quantities indicated in Project P&I Diagram will be provided on the MIMIC panel. Lamp test push button will be considered on the MIMIC panel. Note: one unit of LCD touch control work station is under study as an alternative for substitution of mimic and alarm panel. The selection of one of above mentioned display alternatives will be made before finalization of the panel arrangement.
MAPNA Co.
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WTP I&C Conceptual and Basic Design: I.P.D.C. Roject: Shirvan Gas Turbine Power Plant

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