I&C (BOP) Area Report

Su bmitted by: S AR M AD RIAZ (T rainee Engineer)

Su bmitted to : M r. AL I N AW AZ (T eam Leader E& I)

1
 T AB L E OF CO NT ENT S

T opic s P a ge

1 . Ba la n c e of Pl an t 06
1 .1 . Ra w W a te r Inta ke 06
1 .1 .1 .1 .1 . C o n tro l S yste m of S cree n S yste m 07
1 .1 .1 .2 . In s tru me n t Ai r 07
1 .1 .1 .3 . Fi re Fi g h tin g S yste m 07
1 .2 . PR E TR E A TME N T 08
1 .2 .1 . S e ttli n g Ba si n 08
1 .2 .2 . C l a rifi e r 08
1 .2 .2 .1 . C h e m i cal Do s in g i n Cl a rifi e r 08
1 .2 .3 . C l e a r W e ll 08
1 .2 .4 . Fi l te r W a te r B a si n 09
1 .2 .5 . D u a l Me d ia Fil te rs 09
1 .3 . W A TE R TR E A TMEN T
1 .3 .1 . Mu l ti me d ia Fil te rs 09
1 .3 .2 . R e v e rs e Osmo si s Syste m 09
1.3.2.1. C h e m i cal Do s in g i n R O S yste m 09
1 .3 .2 .1 .1 . S o di u m bi sul p h a te 09
1 .3 .2 .1 .2 . S u lp h u ri c a c id (4 % ) 09
1 .3 .2 .1 .3 . A n ti -sc al a n t 09

1 .3 .3 . D e mi n e ral i za tio n T ra i n s 09
1 .3 .3 .1 . P ro ce ss D e s cri p ti o n 10
1 .3 .3 .2 . R e g e n e ratio n o f De mi ne ra li ze r T ra i n s 10
1 .4 . CO OL IN G TOW E R S 12
1 .4 .1 . Te c h n i ca l S p e cifi ca ti o n 12
1 .4 .2 . C o o li n g To we r 12
1 .4 .3 . Fa n s 13
1 .4 .4 . C h e m i cal Do s in g i n th e Ci rcu l atin g W a te r 13
1.4.4.1. NALCO 23212 13
1 .4 .4 .2 . S u lp h u ri c A c id 13
1 .4 .4 .3 . D i sp e rsa n t 13
1 .4 .4 .4 . C h l o rin e (Hyp o C h l o rite ) 13
1 .4 .4 .5 . TR A S A R s ys te m o f N A L C O 14
1 .5 . Ci rc u l a ti n g W a te r P u m p s 14
1 .5 .1 .1 . P re -ch e cks & S ta rti n g p ro c e du re fo r Ci rc W a te r Pu m p 1 4
1 .5 .1 .2 . S ta rti ng o f Ci rc W a te r P u m p 14
1 .5 .1 .3 . V e rifi c a ti o n 14
1 .5 .1 .4 . S to p p i ng C i rc W a te r Pu mp 15
1 .5 .1 .5 . C ri ti cal In stru m e nts 15
1.5.1.5.1. C o o li n g To we r B a s i n Lev el Tra n s mi tte rs 15
1.5.1.5.2. C o o li n g To we r B a s i n Ma ke u p Fl o w C o n tro l V alv e
(FC V ) 15
1.5.1.5.3. C W P u mp s W in di n g Te mp e ra tu re S e n so rs 15
1.5.1.5.4. L u b e W ate r Fl o w i n d i c ato r a nd S wi tc h f o r C W P 1 5
1 .5 .1 .5 .5 . C W P u mp s Lu b e W ate r P u m p s Co m mo n Di sc h a rg e
P re ss u re S wi tch 15
1 .6 . HYD R OGE N GE N E R A TION S YS TE M 15
1 .6 .1 . R e cti fi e r 15
1 .6 .1 .1 . Te c h n i ca l S p e cifi ca ti o n s 16

2
 1 .6 .2 . E l e c tro l yti c Ce ll s 16
1 .6 .3 . Fe e d W a te r 16
1 .6 .4 . H yd ro g e n m i st el i m in a to r 16
1 .6 .5 . H yd ro g e n Ga s H o l d e r 16
1 .6 .6 . H yd ro g e n C o m p re ss o r S yste m 17
1 .6 .7 . H yd ro g e n P u rifi c a ti o n S yste m 17
1 .6 .8 . C a ta l yti c pu ri fi e r 17
1 .6 .9 . A f te rco ol e r 17
1 .6 .1 0 . S to ra g e Ro o m 18
1 .6 .1 1 . S af e ty P re ca u ti o n s fo r wo rk i n g in the H yd ro g e n
B u il d i ng 18

2 . INS TR U ME N TA TI ON i n th e B OP A rea 19
2 .1 . PR E S S U RE ME A S UR E ME N T 19
2 .1 .1 . Me ch a n i cal Pre ssu re Se n si n g E le m e n t 19
2 .1 .2 . P R E S SU R E GAU GE S 20
2 .1 .2 .1 . P re ss u re Ga u g e s i n th e BOP A re a 21
2 .1 .2 .2 . P M a n d C a li b ra ti o n 21
2 .1 .3 . E l e c tri ca l P re s su re Se n sin g E le me n ts 21
2 .1 .4 . P i e zo re si s tiv e (S trai n Ga u ge ) S e n so rs 21
2 .1 .5 . P R E S SU R E TR A NS MITTE R S 22
2 .1 .5 .1 . P re ss u re tra n s mi tte rs i n th e B OP A rea 22
2 .1 .5 .2 . P M a n d C a li b ra ti o n 22
2 .1 .6 . P R E S SU R E SW ITC H 23
2 .1 .6 .1 .1 . P re ss u re S wi tch e s in th e B OP A re a 23
2 .1 .6 .1 .2 . H 2 C o mp re sso r In le t P re ss u re S wi tch 23
2 .1 .6 .1 .3 . C W P L ub e W a te r P u m p s C o m mo n Di s ch a rg e
P re ss u re S wi tch 23
2 .1 .6 .1 .4 . P M a n d C a li b ra ti o n 23
2 .2 . DIFE R E N TIA L P R ES S U R E INS TR U MEN T S 24
2 .2 .1 .1 . V a lv e Ma n if ol d fo r D iff e re n tia l P re s su re In stru me n ts 24
2 .2 .1 .2 . D P Ga u g e s in the B OP A re a 24
2 .2 .1 .3 . D P S wi tch e s in th e B OP A re a 24
2 .2 .1 .4 . P M a n d C a li b ra ti o n 25
2 .3 . L E V EL ME A S U RE ME N T 25
2 .3 .1 . L E V EL GA U GE S 25
2 .3 .2 . L E V EL SW ITC H E S 25
2 .3 .2 .1 .1 . Ma g n e ti c R e ed S wi tch e s 26
2 .3 .2 .1 .2 . D i e se l Ta n k L ev el S wi tch 26
2 .3 .2 .1 .3 . S to ra g e Ta n k Ga u ge a nd Le ve l S wi tch 26
2 .3 .2 .1 .4 . Ma i n te n a n ce 27
2 .3 .2 .2 . P M o f L eve l S wi tch e s 27
2 .3 .3 . L E V EL TR A N S MITTE R S 27
2 .3 .3 .1 . H yd ro sta ti c Pre s su re 28
2 .3 .3 .2 . B u b b l e r S yste ms 28
2 .3 .3 .3 . L ev el Tra n s mi tte rs i n B OP A re a 29
2 .3 .3 .4 . P M a n d C a li b ra ti o n of L ev el T ra n sm i tte rs 29
2 .3 .4 . U l tra so ni c L e ve l De te cto rs 30
2 .3 .4 .1 . Op e ra ti n g P ri n ci p l e 30
2 .3 .4 .2 . U l tra so ni c W a v e s 30
2 .3 .4 .3 . U l tra so ni c L e ve l In stru me n ts 31
2 .3 .4 .4 . U l tra so ni c L e ve l De v i ce s a t B OP 31
2 .3 .4 .5 . U l tra so ni c L e ve l S wi tc h 32
2 .3 .4 .6 . U l tra so ni c L e ve l Tra n sm i tte rs 32

3
 2 .3 .4 .7 . P ro g ra m mi n g (Ca l ib ra tin g ) a Si e me n s U l tra s o ni c L eve l
D e v i ce 32
2 .3 .4 .8 . P ro g ra m mi n g (Ca l ib ra tin g ) a P ro son i c FM U 8 6 0 Lev el
Tra n sm i tte r 32
2 .3 .4 .9 . N o te 32
2 .3 .4 .1 0 . Mo u n ti n g In stru c tio n s 32
2 .3 .4 .1 1 . Troubleshooting 32
2 .4 . FL OW ME A S U RE ME NT 33
2 .4 .1 . FL OW SW ITC H E S 33
2 .4 .2 . FL OW TR A N SMITTE R S 33
2 .4 .2 .1 . Tu rb i n e Typ e Fl o w T ra n s mi tte rs 33
2 .4 .2 .2 . P M o f a Tu rbi n e Typ e Fl o w Me te r 34
2 .4 .2 .3 . D P Typ e Fl o w Me te rs 35
2 .4 .2 .4 . P M a n d C a li b ra ti o n of D P Typ e Fl o w Tra n s mi tte rs 35
2 .5 . TE MP E R A TUR E MEA S U R E ME N T 36
2 .5 .1 . R TD 36
2.5.2. Wheatstone Bridge Circuits 37
2.5.3. PM and Calibration of Temperature Sensors 37

2 .6 . AN A L YTIC A L ME A SU R E ME N T 37
2 .6 .1 . p H & ORP 37
2 .6 .1 .1 . p H 37
2 .6 .1 .2 . ORP ( Oxi d a ti on -R e d u c ti on P o te n ti al ) 39
2.6.1.3. Temperature and pH 39
2 .6 .1 .4 . Me a su ri n g p H an d OR P 39
2 .6 .1 .5 . p H a n d OR P R ef e re n ce El e c tro de s 38
2 .6 .1 .6 . p H Me a su re me n t E le ctro d e s 39
2 .6 .1 .7 . ORP Me a s u re me n t E le ctro d e 39
2 .6 .1 .8 . p H A n al yze rs a t B OP 39
2 .6 .1 .8 .1 . P re v e n ti ve Ma i n te n a n ce 40
2 .6 .1 .8 .2 . C a l ib ra tio n P ro ce d u re 40
2 .7 . Co n d u ctiv i ty 41
2 .7 .1 .1 . C o n d u ctiv i ty Me a su re me n t 41
2 .7 .1 .2 . C o n d u ctiv i ty P ro b e s 42
2 .7 .1 .3 . E l e c tro d e p rob e 42
2 .7 .1 .4 . C e l l Co n s tan t 42
2 .7 .1 .5 . In d u ctiv e p ro b e s 43
2 .7 .1 .6 . C o n d u ctiv i ty Me te rs i n th e B OP A re a 43
2 .8 . HYD R OGE N GA S MON ITO R 43
2 .8 .1 . B e a c on 4 1 0 Ga s Mo n i to r 44

3 . FINA L C ON TR OL E L E ME N TS 45
3 .1 . CON T R OL V A L V ES 45
3 .1 .1 . I/P C o nv e rte rs 46
3 .1 .2 . V a lv e P o si ti o ne r 46
3 .1 .3 . C o n tro l Va l ve s a t B OP 46
3 .1 .4 . P M o f Co n trol V alv e 47
3 .2 . ON - OF F VA L VE S 47
3 .2 .1 . On - Off V al v e s i n th e B OP A re a 48
3 .2 .2 . P M o f th e On -Off Va l ve s 48
3 .3 . SOL E N OID V A L V E S (S OV s ) 48
3 .4 . ST ROK E C ON TR OL L E RS 48
3 .4 .1 . N e p tu n e S tro ke C on tro ll e r 49
3 .4 .2 . P M o f Stro k e C on tro ll e rs 49
3 .4 .3 . S af e ty No te 49

4
4. CO NT R OL S YSTE M 51

4.1.1. D CS 51
4.1.2. W ATER TR EA T ME NT PLC 51
4.1.2.1. Manu fa c turer 51
4.1.2.2. Proc ess ors 51
4.1.2.3. Proc ess or Spec ific ations 51
4.1.2.4. Po we r Suppl y 51

4.1.2.5. Spec ific a ti on 52

4.1.2.6. Bac kup C o mmunic ation Module 52
4.1.2.7. R e mote I/O Adapter Modu le 52
4.1.2.8. C o mmuni c ation with Operator Stat ion 52
4.1.2.9. Op erator Stations 52
4.1.2.10. Troubles ho oting 52
4.1.3. H ydrogen Ge nerati on PLC S ys te m 53
4.1.3.1. N ote 54
4.1.3.2. C o mmis s ioning of the H 2 Generation P LC 54
S ys te m 54
4.1.3.3. S ys te m Spec ific ations 54
4.1.3.4. I/Os 54
4.1.3.5. Proc ess or 54
4.1.3.6. D igital Input Modul e 54
4.1.3.7. Analog Input Mod ule 54

5
 C h ap ter 1: BAL AN C E O F PL A NT

Th e B OP A re a p rov i de s ma n y se rv i ce s to th e p o we r p l a n t, so m e of wh i ch a re
Ø D e mi n e ral i ze d W a te r fo r S te a m Ge n e ra ti on
Ø C h e m i cal l y Tre a te d W a te r f o r C o ol in g (C on d e n se r)
Ø W a s te W a te r D i s p o sa l (Ne utra li za ti on a n d B l o wd o wn Ba si n )
Ø H yd ro g e n Ge n e ra ti o n (fo r co o l in g o f Ge n era to r)

Fro m o p e ra tio n al pe rs p e c tiv e th e B OP a re a i s d i vi de d i n to th e f ol lo wi n g

se cti on s:
· R a w W a te r Inta ke (C a na l In ta ke )
· P re -Tre a tm e n t
· W a te r Tre a tmen t
o R e v e rs e Osmo si s
o D e mi n e ral i za tio n
· C o o li n g To we r
· H yd ro g e n Ge n e ra ti o n S ys te m

R AW WAT ER I NT A KE

A t A E S L al Pi r Th e rm a l Po we r S ta ti o n the re a re two so u rc e s o f ra w wa te r.

1 . C a n a l W ate r
2 . W el l W a te r

C a n a l wa te r i s th e p ri m a ry so u rc e & W e ll wa te r i s th e s e co nd a ry so u rce .
C a n a l W a te r i s u se d wh e n th e re i s suffi ci e n t wa te r d u ri n g su mm e r (A p ril to
Octo b e r). W h en C a n a l W a te r i s n o t a v a il a b l e the ra w wa te r re q u i re m e n t i s
f ulfi l le d f ro m su b -s u rf a ce W e ll W a te r.

Th e re a re two (2 ) C a n a l W a te r P u m p s i n sta ll e d a t ea c h un i t, o n e se rv i ce a n d
th e o th e r sta n db y. Th e re a re si x (6 ) W e ll W a te r P u mp s i n s ta ll ed a t ea ch u ni t,
fiv e se rv i ce an d on e s ta n d b y.

C a n a l W a te r f ro m C a n al su ctio n p i t pa s se s th ro ug h B a r S c r ee n wh o se
p ri m a ry p u rp o se i s to re m o v e th e la rg e so li d f ra g me n ts tha t c a n ch o ke fl o w.
Th e n the c a na l wa te r p a s se s th ro u g h th e T ra ve ling B a nd S c re e n(T BS ),
h av in g 2 2 b a sk e ts wh i ch c o n ti n uo u s l y re v o lv e in s u ch wa y th a t wa te r h a s to
p a s s th rou g h th ei r ce n tre , th e tra v el in g ba n d s cre en h a s the m e sh si ze of 1
m m a n d i t c a n b l o ck m u c h sm a ll e r i m p u ri ti e s a s c o mp a red to th e B a r S c re en .
Th e S cre e n i s wa sh e d wi th sp ra y wa te r f ro m th e S p ra y W a te r P u mp . Th e
so li d d e b ri s i s c o ll e cte d i n the wa ste co l l e cti n g p i t a nd i s p u m p ed b a ck to th e
ca n al . The ra w wa te r i s th e n p u mp ed to th e Se ttl in g B a si n wi th th e h e lp of
ca n al wa te r p u mp .

System Spe cificatio n s:

C a n a l W ate r P u m p Ca p a ci ty 1 2 0 0 m3 /h r (1 1 0 kW )
C a n a l W ate r P u m p L u be W a te r P u m p 1 .5 kW
C a n a l W ate r P u m p L u be W a te r Ta n k 2 m3
W el l W a te r P u m p C ap a c ity 2 4 0 m3 /h r (3 0 kW )
B a r S cre e n 1 5 0 0 mm x1 0 0 0 m m (1 2 0 0 m3 /h r)

6
Tra v e l in g Ba n d S cre e n 1 2 0 0 mm x3 5 0 0 (1 20 0 m3 /h r)
S p ra y W ate r P u m p 1 0 m 3 /h r (3 .7 kW )
S e ttli n g Ba si n 1 0 0 0 m3

C o ntro l System o f Screen System :

Th e B a r S c re en , Trav el in g Ba n d S cre e n an d the S p ra y W a te r P u m p a re

co n tro ll ed b y R e l a y L o g i c C o n trol . Th e con tro l pa n e l s a re i n stal le d on site .

In stru m en t Air:

T wo A i r C o mp re sso rs a re i n s tal le d a t the C a n a l In ta ke to su p pl y co o l e d , d ry

a i r to d iffe re n t i n s tru me n ts.

F ire F ig h tin g System:

A l o c al Fi re P an e l i s p re s e n t a t th e C a n a l In ta ke Are a. A F i re A l a rm
Tra n s mi s si on s ys te m i s i n sta l l e d a t th e Ca n al In ta ke A rea . In ca se of a Fi re
A l a rm a t th e C an al in ta ke A re a , the S E AB OA RD R a d i o Fi re Al a rm
Tra n s mi tte r wi l l tra n smi t an Al a rm si g na l th a t wi l l b e re ce iv e d a n d d e co d e d
b y a SE A B OA RD Re ce iv e r/De cod e r pl a ce d i n th e C C R. Th e R e ce iv e r wi l l
th e n ra i se the a l a rm ov e r the Fi re Al a rm A n n un cia tio n P a ne l i n s tall e d in th e
L a l Pi r C C R .

N ote : A u n i q u e p rob le m a ro s e wi th th e S E AB OA R D R a d i o Fi re Al a rm
Tra n s mi s si on sys te m. Th e p ro b l e m wa s th a t th e Tra n s mi tte r wa s tra n sm i tti ng
a n al a rm to th e C C R a l th o ug h the re wa s n o f i re al a rm i n th e C an a l In ta ke
M CC l o ca l fi re p an el . Af te r e xh a u stiv e fau l t fi n di ng a n d tro u bl e sh o oti n g , the
p ro b l e m wa s re so l v e d wh e n we a p p li ed i n s ul a ti on tap e o n th e scre ws wi th
wh i c h th e bo a rd wa s a tta ch e d to the p a n el .

PR ET R E AT MENT

W a te r f ro m ca na l p u m p s th rou g h th ei r re s p e ctiv e li ne [P a kGe n /L a l pi r) co m e s

to th e th re e (3 ) se ttl in g b a si n s h a vi n g c omm o n h e a d e r wi th th e p ro vi s io n of
fi lli n g a n y se ttli ng b a si n, a n d b y p a ss li ne to co ol i n g to we r.

S e ttling B a s in:

S e ttli n g b a sin s p rov id e p ri ma ry s e ttl in g zo n e fo r l a rge su s pe n d e d pa rti cl e s,

sa n d a n d sil t i n ca n al wa te r h e n ce red u cin g th e c o st o f co a g u la tio n i n
cl a rifi e r, l oa d o n fi l te rs a n d p rov i d in g p ro p e r su cti on fo r cl a rifi e r su p p l y
p u m p . Fro m the s e ttli n g b a si n s, th e ra w ca n a l wa te r i s fe d to an i n le t
d i s trib u ti o n b o x b y cl a rif ie r su p pl y p u mp s.

N ote :

7
D u ri n g W el l se a son P re -tre a tme n t sys te m i s b yp a ss e d .

C larifier:

Fro m In l e t D i strib u ti o n B o x ra w wa te r i s d i s tri b u te d to Cl a rifi e rs (A , B , C).

Th e p u rp o se of wa te r tre a tm e n t i n the Cl a rif ie r i s to re mo v e th e su s pe n d e d
so li d s f ro m wa te r. E a c h cl a rifi e r o p e ra tes a t n o rma l fl o w ra te o f 10 2 3 m 3 /h r
a n d ma xi m u m fl o w ra te of 12 5 0 m3 /h r. Th e efflu e n t f ro m c la rifi e r g o e s to
cl e a r we l l (1 0 0 m 3 s to ra g e ca p a ci ti e s ).

S u s p en d e d so l i d s i n can al o r we l l wa t e r re q u i re i ni tia l tre a tme n t wi th a

ch e mi c al hav in g stro ng io n i c p rop e rtie s, su c h a s a ci d , li m e , al u m , o r f e rri c
su lf a te . Th e l a tte r t wo wi l l p re cip ita te at n e u tra l pH an d p ro d u ce a
g e l a tin o u s, fl o ccu le n t stru ctu re wh i c h f u rth e r h e l p s co ll e ct e xtre m el y sm a l l
p a rti cl e s. T hi s p h e no m e n o n i s k n o wn a s Co a g ul a ti on .

C he mic a l D os ing in C la r ifie r:

C oa gula n t D os ing :
Fe rri c s u lf a te i s u s e d a s co ag ul a nt i n the C l a rifi e r. It i s i nj e cte d a t th e ra te of
2 0 -3 0 ppm.

P oly m e r D os in g:
P o l yme r i s a l s o d o se d in th e C la rifi e r to e n h a n ce th e c o ag u l a ti on a n d h e lp
th e s u sp e nd e d p a rti cl e s se ttl e do wn . P o l yme r d o s a g e i s ca rri e d o u t a t a ra te
o f 1 -2 p p m.

C le a r We ll:
E ffl ue n t f ro m th e cl a rifi e rs co m e s to the C l e a r W e l l .

D ua l M e dia Filte r s :
Th e D u al Me d ia Fi l te rs o r D MF u se S a n d an d A n th ra ci te a s th e Fi l tra ti on
Me d i a . Th e Du al Me d i a Fil te rs re m o ve ca rr yo v e r su s p en d ed m a te ri a l s a nd
tu rb i d i ty. E a ch fil te r i s d e si g n to tre a t 2 5 6 m3 /h r o f wa te r. T o ta l f o u r
C e n trif ug al typ e p u mp s a re u se d f ro m wh i ch two a re u sed f o r se rvi ce , 3 rd i s
f o r ba c k wa s h a n d fo u rth o n e i s u til i ze d a s a s ta nd b y sp a re .

Th e c la rifi e d a n d fi l te re d wa te r i s d i re c ted to fil te r wa te r b a si n , an d coo l i ng

to we r b a s i n .

N ote : Du ri n g W e ll S ea s o n the we l l wa te r i s se n t di re ctl y to th e Fil te r W ate r

B a s in a nd C o o li n g To we r Ba si n .

Func tiona l S pe c ific a tions :

8
S e ttli n g ba s in s 1 0 0 0 m3
S e ttli n g ba s in wa sh p u mp 5 0 m 3 /h r (3 0 kW )
S e ttli n g ba s in sl u d ge p u mp 5 0 m 3 /h r (3 .7 kW )
C l a rifi e r s u pp l y p u m p 1 1 0 0 m3 /h r (9 0 kW )
In l e t di stri bu tio n bo x 3 0 4 8 × 1 82 8 mm (1 0 23 m 3 /h r)
C l a rifi e r 2 4 0 0 m3
C l a rifi e r U n de rfl o w p u m p s 2 3 m 3 /h r
C l e a r we l l 1 6 5 m3
C l e a r we l l 6 .3 m D 6 .4 5 m H
C o a g u l a nt Ta n k 15 m3
P o l yme r Ta n k 10m3
D MF P u m p s 5 6 7 m3 /h r (5 6 kW )
D MF B l o we rs 1 3 6 0 m3 /h r (3 0 kW )

Filte r Wa te r B a s in:

P re -tre a te d wa te r i s se n t to th e Fi l te r W ate r B a si n & C o o li ng To we r. S e rv i ce

wa te r p u m p s & Fi l te r wa te r p u m p s ta k e s su cti on f ro m th e Fil te r W a te r B a si n
& su p pl y to pl a n t se rv i ce s & D e m i ne ra li za ti o n wa te r s ys te m re sp e ctiv el y. A i r
H e a te r wa sh i n g pu m p s, Fi re P u mp s a n d FGD p u mp s a l so ta k e s u cti o n f ro m
Fi l te r wa te r B a si n .

WAT ER T R E AT ME NT

Th e d e mi n e rali za ti o n s ys te m i s de s ig n ed to p ro du c e de mi ne ra li ze d , tre a ted

wa te r wi th a c o n d u ctiv i ty of le s s tha n 0 .1 m mhos /c m a n d s i li c a co n ten t of
l e s s tha n 0 .0 1 m g/L.

Mu ltim ed ia F ilters:

P re -tre a te d wa te r f ro m th e fi lte re d wa te r b a s i n i s d i re cte d to t wo (2 ) Mu l ti -

Me d i a Fil te rs wh i ch re m o ve re si d ua l tu rbid i ty a n d su spe n de d so li d s f ro m the
wa te r. Fo l l o wi n g m u l ti me di a fil tra tio n , th e wa te r i s i n je cte d wi th s o di u m
b i s ul ph a te to re m o ve tra ce qu a n ti ti e s o f f ree c h lo ri n e . Mu l ti -Me d i a fi l te r
b a c k wa s h a n d rin se wa te r i s d i re cte d to th e i n le t di strib u ti o n b o x .
A p o rti o n of the m ul ti -m e di a fi l te re d wa te r i s d i re c te d to th e p o ta bl e wa te r
ta n k .

W a te r af te r Mu l ti Me d i a Fi lte r i s se n t to th e B a g Filte r . B a g Fi l te r re m ov e s
su sp e n d e d p a rti cl e s to mi cro n le ve l s .

Th e mu l ti -me d i a f il te re d wa te r i s di re cte d to the re v e rse o sm o s i s s ys te m.

E a c h mu l ti -me d i a fi l te r i s d e si g ne d to tre a t ma x i mu m o f 9 7 m3 /hr of p re -
tre a te d wa te r. W i th o n e (I) f il te r i n se rvi ce a n d th e o th e r i n b a c kwa s h , a
se co n d fi l te r f ee d p u mp wi l l b e a ctiv a te d. Tre a te d wa te r i s f e d to th e rev e rse
o s mo s i s s yste m wh e n a h ig h to tal di s so lv e d so l id s ra w wa te r i s u ti li ze d .

R eve rs e Osm o sis System :

9
R e v e rs e Os mo s i s i s a p ro c e ss wh e re w a te r i s d e mi n e ra li ze d u si n g a se mi
p e rm e a bl e me m b ra n e a t hi g h p re ss u re . Exte rn a l p re ss u re a rou n d 1 5 kg /cm 2
i s e x e rte d to m ov e wa te r f ro m h i g h e r co n ce n tra ti on to lo we r co n ce n tra ti on
a re a . R O s ys te m a t A E S L a l P i r co n si s ts o f two R O b a n k s. W a te r f ro m 5
m i cro n fi l te rs e n te rs th e fi rs t ba n k. R eje ct f ro m th e f i rst b a n k e n te rs th e
se co n d b a n k. R .O. syste m p ro d u ct wa te r i s c oll e cted i n th e R .O. p e rm e a te
ta n k . The fl o w o f wa te r f ro m th e mul ti me d i a fil te rs to th e R .O. pe rm e a te ta n k
i s c o n trol l e d b y th e ta n k le v e l co n trol le r.

N ote : If th e so u rc e o f wa te r i s C a n a l th e n R O S yste m i s n o t u se d a n d
i n s tea d wa te r f ro m th e Mu l ti me d i a Fi l te rs i s d i re cted to th e R O P e rm e a te
Ta n k.

C he mic a l D os ing in R O S y s te m : Th e fo llo wi n g th re e typ e s of c h e mi cal s a re

d o s e d i n th e R O s ys te m

S odium b is ulpha te :

It i s i nj e c ted in to th e mul ti m e di a fi l te r effl u e n t at a co n sta n t, m a n ua l l y se t

ra te to re m ov e chl o ri ne tra ce s f ro m th e R O f e e d. In ca s e c hl o ri n e i s n o t
i nj e cted i n Se ttli ng B a si n S od iu m B i s ulp h a te i s n o t a dd e d to th e s ys te m.
P re se n ce of C hl o rin e in RO Fe e d W a ter d a m a g e s th e me m b ra ne s o f th e
syste m . A f l o w s wi tch wi l l co n trol th e sta rt/sto p o p e ra ti o n o f th e b i su lp h a te
p u m p s.

S ulphur ic a c id (4 % ):

H 2 SO 4 i s in je c te d in to th e rev e rse o s mo si s f ee d wa te r to l o we r th e p H . Th e
a c i d ta n k fi lli n g i s au to m a ti c al l y i n i ti a ted b a se d o n the lev el in th e a cid ta n k.
R e fi ll i s a c co m pl i sh e d wi th th e a ctiv a ti on o f a di lu tio n wa te r p u mp , a n a c id
p u m p an d th e o p en in g of th e m i xe d b e d d il u ti o n wa te r v a l v e a nd the R .O.
a c i d ta n k i nl e t v a lv e . Th e fil l i ng of R .O. aci d tan k c a n a l so be d on e m an u all y.
Th e R .O. a c id tan k re fi ll seq u en ce i s i n te rl o c ke d wi th the C a ti o n a nd mi xe d
b e d re g en e ra ti o n se q u en c e s to p re v e n t re fil l i ng th e ta n k du ri n g re g e n e ra ti on
o f ei th e r p ri ma ry o r mi xe d b e d tra i n s .

A nti-s c a la nt:

Th e A n ti -sca l an t so lu ti o n i s a l s o i nj e cted i n to th e re v e rse o sm o si s f ee d wa te r

a t a c on sta nt ra te . In th e au to ma ti c m od e , the a ci d a n d a n ti -sca la n t fe e d
p u m p s a re sta rte d a n d sto p pe d a u to ma ti call y wi th th e re v e rse o s mo s i s
b o o ste r pu m p s . Re fi ll of the a n ti -sc a la n t ta n k i s d o ne ma nu al l y.

N ote : Th e d o si n g ra te of a ll th e se ch e m i ca l s i s co n tro ll ed b y S tro ke

C o n tro ll e rs. To in cre a s e o r d e c re a se th e ch e mi c al d o si ng ra te we i n cre a s e o r
d e c re a se th e stro k e l en g th f ro m th e C on tro l R oo m.

A ll th e c h e mi ca l d o si ng p u mp s h av e re d u n d a n cy i .e . o n e p u m p i s al wa ys
a v a il ab le a s a sta nd b y.

D em in eraliz atio n T rain s:

T wo De mi n e ra li za ti o n tra i n s e a c h c o m p risi n g a C a tio n u n i t, A ni o n u n i t a n d

Mi xe d B e d u ni t, p ro du ce tre a te d wa te r th a t i s f e d to th e de m i ne ra li ze d wa te r
sto ra g e ta n k s. A D e c a rbo n a to r to we r/c l e a rwe l l a n d De ca rbo n a to r W a te r

10
Fo r wa rd i n g Pu mp s a re co mmo n to b o th tra i n s. A l ev e l tran s mi tte r i n stall e d i n
th e de c a rb on a to r cl ea r we l l co n tro l s th e o p e ra ti o n o f th e d e c a rbo n ato r i n le t
m o d u la ti n g co n tro l v alv e . L e v el co n trol s i n th e d e min e ra l i ze d wa te r s to ra g e
ta n k co n tro l th e op e ra ti on o f th e D e m in e ra li ze r tra i n s .

P r oc e ss De s c r iptio n:

W a te r f lo ws th ro u g h th e i o n e xc ha n g e r’s wa te r i n l e t a n d i n to th e di ffu se r.
Th e d iffu se r sp re a d s th e wa te r o v e r th e re si n b e d . A s th e wa te r f l o ws
th ro u g h th e re si n be d , i o n s a re re mo ve d f ro m th e wa te r a n d e x ch an g ed wi th
th e h yd ro g en io n s (Ca ti o n u ni t) o r h yd ro x yl i o n s (A ni on u ni t) o cc up yi n g th e
si te s o n th e re s in b e a d s . Th e efflu e n t o f a C a ti on e xch a n ge r i s ge ne ra ll y
a c i di c, b e cau se th e h yd ro g e n i o n s p re se nt i n th e wa te r f o rm a ci d s. H o we v e r,
a fte r th e e ffl u en t f ro m a C a ti o n e xc ha n g er fl o ws th ro u g h a n io n e xch a ng e r, it
i s a l mo st pu re wa te r.

Th e a n i on effl ue n t i s the n di re c ted to mi xe d b ed p o li sh i n g u ni ts . The mi x ed

b e d un i ts con tai n b o th a n i o n a n d ca ti on re s i n s wh i ch e xc h a n ge re si d u al
ca ti on i c a n d a n i o ni c i o n s fo r th e h yd ro g en a n d h yd ro x yl i o n s. The m i xed b ed
e fflu e n t wi l l h av e a co nd u c ti vi ty of l es s th a n 0 .1 mm h o s/c m a n d si li ca
co n te nt of l e s s th an 0 .0 1 m g /l . E a ch m i xe d b e d un i t i s d e sig n ed to p ro d u ce
6 5 m 3 /h r o f tre a ted wa te r. Mi xe d be d tre a ted wa te r i s d i re cte d to th e
d e m i ne ra li ze d wa te r sto ra g e tan ks . Th e ca ti on , a n io n an d mi xe d b e d wa ste
re g e n e ran t sol u ti o n s a re di re c te d to th e n e u tral i za tio n p i t, n eu tra l i ze d wi th
e i th e r su lf u ri c a ci d o r sod iu m h yd ro xi d e , a n d th e n d i sch a rge d to th e p l an t
d ra i n sys te m.

R eg en eratio n o f D em in eraliz er T rains

Th e re si n b e ad s u se d fo r i o n e x ch an g e r ha v e th ou sa nd s of s i te s av ail a bl e fo r
e x ch a n g in g i on s . H o we v e r, on ce th e h yd ro g e n o r h yd ro xyl i o n s h av e b e e n
d e p l e ted , th e b ea d s a re no l on g e r u se fu l f o r i on e xc h a n g e . In th e e x ha u s te d
sta te , th e re si n b e d ca n no t re mov e io n s fro m th e i n co mi ng wa te r. Th e re a re
t wo p a ra m e te rs to m o ni to r re si n e xh au stio n , si li c a mo n ito ri ng & C o n d u ctiv i ty
m o n i to ri n g . D e mi ne ra li za ti on tra in s a re e xh a u ste d afte r cl e a ni ng p a rti c u la r
a m o u n t of wa te r. Th e y a re re g e n e ra te d wi th i n j e cti n g f re sh i o n s of H yd ro g e n
& h yd ro xyl .

R e g e n e ratio n i s i n i ti a te d m an u a ll y. In i ti a ti o n of a p ri ma ry tra i n re g en e ra ti o n
se q u en c e wi l l a u to ma ti cal l y re g e n e ra te a C a ti o n u n i t a nd i ts co rre s p on d i n g
a n i o n u n it co n c u rre n tl y. Fo l l o wi n g re g e ne ra ti on of a p ri m a ry tra i n a nd /o r a
m i xe d b ed u ni t, th e u n i ts a re pl a ce d i n sta n d b y a n d re tu rn to se rv i ce i s
p u s h bu tto n in i ti a te d . Th e s tan d b y re g e n e ra te d trai n ma y b e pl a ce d i n se rvi ce
d u ri n g th e re g e ne ra tio n p ro c e d u re wh e n i n the s e mi -au to mod e . Bo th trai n s
m a y b e p l a ce d i n se rv i ce tog e th e r o n l y i n th e se mi -a u to mo d e . Du ri ng n o rm a l
o p e ra ti o n, o n e trai n wi l l be i n se rv i ce an d o n e tra i n in sta n d b y. D u ri n g th e
re g e n e ra ti on of a D e mi n e ra li ze r tra i n , th e o th e r trai n wi l l be in s ta nd b y.

R e g e n e ratio n o f th e De min e ra l i ze r s yste m i s n o rma l l y p e rf o rme d on a “tra i n ”

b a s i s b y re g e n e ra ti ng th e C a ti o n an d a n i on u ni ts o f th e sa m e trai n
co n cu rre n tl y o r a mi x e d b e d un i t. In te rlo cks a re p ro v id e d to e n s u re tha t o n l y
o n e trai n o r a m i xe d b e d un i t ca n b e re g e ne ra te d a t a n y g iv en ti me . Th e
C a ti on a nd a n i on u n i ts a re reg e ne ra te d i n a s p li t fl o w c o u n te r c u rre n t ma n n e r
a n d the re f o re wi l l no t b e giv e n a fu ll ba c k wa sh e v e ry re g e n e ra ti o n . W h e n
th e s e un its a re b a ck wa sh e d (a p p ro xi m a te l y ev e ry 2 0 re g e ne ra ti o n s), a

11
d o u bl e ch e m i ca l i n j e cti o n wi l l b e a u to ma ti c all y p ro v id e d to re co n d i ti o n th e
re si n a t th e b o tto m o f the be d .

P ro vi s io n s h av e b ee n ma d e to ov e rri d e the re ge n e ra ti on if n e c e ss a ry;

h o we v e r, u nd e r n o rm a l o p e ra ti n g c on di tio n s th e re ge n e ra ti on c ycl e s sh o u ld
b e all o we d to ti m e ou t a n d se qu e n ce th ro u g h to co mpl e ti o n . Di l u ti on wa te r
f o r th e a ci d an d ca u sti c re g e ne ra te so l u ti on s i s d e m in e ra l i ze d wa te r
d e l iv e red b y th e d i lu e n ts wa te r p u m p s. Inte rl o ck s a re p rov i d ed to e n su re tha t
th e a c id a n d ca u s ti c re g e n e ra te sol u ti o ns a re d e l i ve re d a t th e co rre ct fl o w
ra te s a n d c h e m i ca l s tre n gth . A h e at e x ch a n ge r i s p ro vi d e d to h e a t the
d il u ti o n wa te r d u ri n g p re h ea t c a u s ti c i nj e cti o n a n d di s pl a c e me n t ste p s of th e
a n i o n a n d mi x e d b ed re g e n e ra ti o n p roce d u re . In te rl o ck s a re p ro vi de d to
e n s u re th at th e min i m u m a n i on d il u tio n wa te r te mp e ra tu re i s a t 3 5 o C a nd
th e m i xed b ed d il uti o n wa te r i s a t 4 9 o C . D i l u ti on wa te r fl o w i s c o n tro l l e d b y
ra te se t va lv e s p rovi d e d fo r C a tio n a ci d d i l u ti o n , mi xe d b ed a cid di lu tio n ,
a n i o n ca u sti c d il uti o n an d mi xe d b e d ca u sti c d i lu ti o n .

C OO L ING T O WER S

A t LalPir/ PakG en Coolin g T ow ers are m ainly used t o conden se s team

com ing f rom t he low pressure t urbine to c re at e v acuu m and henc e act as
drivin g forc e for st eam . Cooling Tow er is design ed to prov ide 692 Hg of
V acuu m in t he c ondens er. In it ially i t w as a seve n cell Ind uced draf t
Cooling T ow er but now aft er modific at ion in 20 08, eight h c ell has been
adde d.

T ech n ical Spe cification

C o olin g T ow er

T ype Mec hanic al Induc ed Draft C ounter

F lo w
C irc W a te r F low 35,000 m³/hr for two pu mps
H ot (Inle t) w ater Te mp 41.0 °C
C old (Outlet) W ater Temp 30.0 °C
D rift Los s % of Circ water flo w 0.10% max .
N u mber of Cel l s 8 c ell s per u nit
F an per c ell 1
Total no. of fans 8 s ets pe r unit
N o mina l c e ll di mens i on (Lx W ) 15.8 m x 19.2 m
F an s tac k height 3.8 m
Ov era ll tower height 14.8 m

F an s

T ype & Mode l Ax ial F low Prope ller Fan (Pitc h-

-adj us table)
Manu fa c turer H uds on Produc ts C orpora ti on
D ia meter 9.76 m
N u mber of Bl ades 10 Blades /fan
F an Speed R PM 114 R P M

12
Tip s pee d 58.2 m/s ec
Air Deliv ery/fan 754.0 m³/Sec
F an s tatic Effic ie nc y 64%

C h em ical Do sin g in th e C ircu latin g Wate r:

To c o n trol th e ch e mi stry o f co o li n g wa te r, d iffe re n t c he mi cal s a re d o s ed in

th e c oo li n g wa te r. Th e s to ra ge ta n ks fo r th e se che mi ca l s a re si tua te d in th e
C W Ch e m i cal S ki d . Th e fo ll o wi n g ch e m i ca l s a re d o se d i n th e co ol in g to we r

NALCO 23212:
N a l co 23 21 2 i s u s ed a s a sc a le i n hi bi to r in th e C oo li ng To we r. It i s co m mo n l y
kn o wn a s p h o sp h a te tre a tm en t. A s th e p H of th e ci rcu l a ti n g wa te r i s ke p t l o w
so th e re a re le ss c h a n ce s o f co rro s i o n fo rm a ti o n in th e syste m . Th e v a lu e o f
p h o sph a te in c i rcul a ti ng wa te r i s ma in tai ne d a t 1 .5 -2 .2 p p m

S ulphur ic A c id:

S u lp h u ri c a c id i s a dd e d to re du c e the p h o f th e ci rcu l a ti n g wa te r & to re d u ce

M.Al ka l in i ty. Th e ph of th e Co o li ng To we r i s m a in tai n ed a t a bo u t 8.2 .

D is pe r s a nt:

Th e sc a le f o rme d ten d s to s ta y su sp e n de d lo n g e n o u g h to b e re mov e d b y

e i th e r th e b lo wd o wn o r a f il tra tio n syste m . Di s p e rsa n t i s a d d e d to re mo v e the
sc a l e f ro m th e C o o l in g To we r B a s i n . It d o e s n o t a l l o w th e sc a le to s e ttl e
d o wn to th e b o tto m of th e co o li n g To we r.

C hlor ine (H y po C hlorite ):

C h l o rin e i s d o s ed i n th e c o oli n g wa te r a s a bi o ci d e to co n trol b i o lo gi c al

a c tivi ty a n d f o u li ng . C h l o rin e i s u s ua ll y a d d ed a s a sh o ck d o se , u su a ll y a t
n i g h t. It c a n be a d de d a s C l 2 o r a s h yp o ch l o ri te d ep e n d in g up o n the si ze o f
th e s ys te m. Th e h yp o ch l o ri te sho u l d be s o d iu m a s o p p o s ed to ca l ciu m (HT H)
a s th e ca l ci u m wo u l d a d d to th e syste m 's s ca l in g p o ten ti al .

A t L al Pi r C h lo ri ne D o sin g h a s be en re p l ace d b y S o d i u m H yp o C h lo ri te d ue to
sa fe ty p ri o ri ty. A t P a k Ge n C h l o ri n e i s still b ei n g u se d & i s to b e re pl a ce d till
D e ce mb e r 2 0 0 9 . C hl o ri n e i s ma in tai n ed i n th e C i rcul a ti ng wa te r s ys te m o n
re si d ua l b a si s. Th e a mou n t of chl o ri ne p re se n t i n Ci rcu la tin g wa te r i s
m a i n tai n e d a t m a xi m u m of 0 .5 p p m.

T RAS AR system o f NAL CO :

N ALC O is one of the major s upplie rs of c hemic als to AE S L al Pi r.

N ALC O has ins talle d its online moni toring s ys tem na med TR AS AR for
moni torin g the c he mis try of c oolin g water. The TR AS AR s ys te m
moni tors the c hemis tr y of c o oling wa te r.

13
No te: TR ASA R s ys te m is a N AL CO pro duc t and it is operated and
mai ntained b y N AL CO . The I&C d e part ment does not operate or
mai ntain TR AS AR .

C irc ulatin g Wate r Pu m p s

P re -c hecks & S tar ting proc edure for Circ W ater P um p

· Ma in breaker s hould be in close posit io n and me te ri ng modu le
sho win g 11 KV.
· Pump d ischa rg e MO V b rea ker shou ld be in c lose po sit ion.
· Pump d ischa rg e MO V s hould be close wit h g ree n LED li t u p.
· Disch arge line v ent valv e should be open .
· MO V selec t or s wit ch sho uld be on rem ote.
· Bearing c ooling w at er f low should be norm al 30~40m 3 /h and
dif ferentia l pressu re a cross t he st rainers of c ooling pumps should
be be low t h an 0. 2 bar.
· Cooling to wer lev el sho uld be great er t ha n 400mm and ma ximu m
w hen st arting aft er out age.
· Bearing lu be oil sh ould be no rm al.
· S pace heat ers breaker should be open.

Startin g o f C irc Wate r Pu m p

· BCW pumps f or c ooling of circ. W at er pum ps st art .

· If t he lube wat er flow is 1 5m3/ h tha n t he circ. W ate r pu mp w ill st art
· Disch arge valv e wi ll st art open u p t o 40 % w it h in f irst 40 s econd.
· Disch arge valv e wi ll open f rom 4 0% t o 100% .

Verificatio n

· Disch arge valv e int ermediate posit ion LED is lit up an d valv e opens
in gradu al even ly spa ced perc ent age increment s , halt s m oment arily
at 40% and t hen c omplet e s t he rest of the t ravel. The red LED is
t hen lit u p.
· Disch arge valv e must st art opening aft er 30 sec.
· O bserve f or any abnorm al sound and vib ra ti on.
· Disch arge pressu re s hould be clos e t o 1 bar.
· T he be ari ng t empe rat ure should be close t o 500C.
· Chec k mot or phas e current s are approxim at ely eq ual i. e. 76~80
A mps . This f igure s hould be below 88 Amps .
· S ee t hat t here s hould b e no alarm on t he motor opera t ion
ma nageme nt re lay ad jacent t o t he m ult ilan e-met ering m odule.

S top pin g Cir c W ater Pum p

T he MOV begin s t o clos e and at a p re set minimum fl ow t he pump st ops

and MOV co mplet es it t ra vel.

14
C ritical In stru m en ts:

Th e CW P i s a ve ry cri ti c a l syste m . If a CW P trip s a nd the s ta nd b y C W P do e s

n o t c u t i n th e u ni t wi l l s ta rt re d u ci ng l o ad (ru n b a ck). Th e f oll o wi n g
i n s tru me n ts i n s ta ll ed on th e CW Pu mp s a re ve ry cri ti c a l i n n a tu re a nd
e x tre me c a re sh ou ld b e ta ke n d u ri n g th ei r ma i n te n a n ce .

C ooling T owe r B a s in Le ve l T ra ns m itte rs : If th e l ev el tra n s mitte rs d i spl a y

i n a ccu ra te l ev e l re ad in g o r if the re i s a su d d en d ro p i n cu rre n t o utp u t of the
tra n s mi tte r it c a n b e v e ry c o stl y.

C ooling T o we r B a s in M ak e up Flow C ontrol V a lve ( FCV ): If th e m a ke up

FC V g e ts s tu ck o r d o e s n o t o p e ra te a n d b l o ck s th e fl o w, th e l ev e l of th e
co o li ng to we r b a si n s wi l l go do wn . A s a re su l t th e re wo u l d b e a ch a n ce th a t a
C W P mi g h t trip .

C W P um ps Wi nding T e m pe ra ture S e ns or s : Th e s e sen so rs m e a s u re an d

tra n s mi t the wi n d in g te mp e ra tu re d a ta of th e CW P mo to rs. Th e y a re v e ry
cri ti c al an d th e re i s n o roo m fo r e rro r i n th e i r mai n ten an ce .

Lube Wa te r Flow indic a tor a nd Sw itc h for C WP : Th i s d ev i ce in d i ca te s th a t

th e l u be (a n d co o l in g ) wa te r f o r the CW Pu mp s i s av a il ab le . If th i s swi tch
d o e s no t i n di c a te fl o w we wi l l n o t g e t p e rm i ss i on to s ta rt th e CW P .

C W P um ps Lube Wa te r P umps Co m mon D is c ha rge Pre s s ure Sw itc h: Th i s

s wi tc h i n di ca te s th a t th e d i sch a rg e p re ssu re o f th e p u mp s sup pl yi n g L u b e
wa te r to th e CW Pu mp s i s n o rm a l .

H YDR OG E N G E N ER AT ION SY ST EM

H yd ro g e n g a s i s u s ed a s a coo la n t fo r th e c oo li n g o f Ge ne ra to r. H yd ro g e n
g e n e ra ti on s ys te m i s d e s i g n ed to p ro d u c e 5 n o rm a l c u b i c m e te rs o f h yd ro g e n
( wh e n m e a s u re d a t 0 de g re e ce n ti g ra de an d 7 6 0 mm of H g ). It c a n co mp re s s
a n d pu rif y 5 n o rma l cu b i c me te rs of h yd ro g e n to a p re s su re o f 1 7 5 kg /cm 2 .

R e c tifie r

H yd ro g e n Ga s Ge n e ra ti n g S ys te m co n s i sts o f A i r Co o le d Sil i co n R e c tifi e r,

Tra n s f o rme r, an d Si x S tu a rt El e ctrol yti c C e ll s co n n e cte d in Se ri e s .

T ec hnic a l S pe c ific a tions

R a te d Po we r 3 0 KW
R a te d A C Vo l ta ge 3 8 0 +/- 10 V ol ts
R a te d A C C u rre n t 58 Amps
R a te d Fre q ue n c y 5 0 + /- 5 % H z
N u mb e r of P ha s e s 3
R a te d D C V ol tag e 1 5 V o l ts

15
R a te d D C C u rre n t 0 – 2000 A
P e rce n t R ip pl e 5 %
P e rce n t R e gu la ti o n 1 %
A mb i en t Te m p e ra tu re 50 0C

A C p o we r a t 3 8 0 v ol ts , 3 p h a se , a n d 50 h e rtz i s su p p l i ed f ro m th e p o we r
f ee d e r p a ne l th ro u gh ci rcu i t b re a k e r to re cti fi e r a nd tra n sfo rm e r. Ci rc u i t
b re a k e r i s p ro v i de d fo r sh o rt c i rcui t p ro te c tio n . In re cti fie r, vo l ta g e i s
re d u c e d b y a re c tif ie r tra n sf o rme r a n d c o n ve rte d to a D i re c t C u rre n t a t
V o l ta g e u p to 14 v ol ts. D C p o we r f ro m R e cti fi e r i s s up pl i e d to e le ctro l yti c
ce ll s th ro u g h co p p e r bu s ba r.

E le c tr oly tic C e lls :

Th e S tu a rt e l e ctrol yti c c e ll s a re o f th e uni -p o l a r ta n k typ e . Th e c e ll i s k no wn

a s a 3 -p la te ce ll , h avi n g o n e n i cke l -pl a te d i ro n a n o d e p la te s a n d two i ro n
ca th o de pl ate . Th e a n o d e s a re s u rro un d e d b y cl o th di ap h ra g ms wh i ch
p re v e n t mi x in g of th e h yd ro g e n a n d o x yg e n g a se s f o rm e d i n th e c el l. Th e
e l e ctrol yte i s a 2 5 % s o l u tio n of p o ta s siu m h yd ro x i d e (a l so re fe rre d to a s
‘ c a u sti c po ta s h ” o r “K OH ”) i n wa te r.

Fe e d Wa te r :

W h e n op e ra ti n g a t f u l l ca pa ci ty e a ch o f the ga s ge n e ra ti ng syste m wi l l
co n su m e a pp ro x i ma te l y 7 .5 li tte r of wa te r p e r h o u r. Fe e d wa te r to th e ce l l s
m u st b e hi g h p u ri ty d e mi n e ra li ze d o r di s til le d wa te r. S p e cif i c co n du cta n ce of
th e wa te r sh o u ld be l e ss th a n 5 mi cro oh m /cm . Fe e d wa te r f o r th e ce l l s i s
sto re d i n a 5 0 li tte r p ol ye th yl e n e ta n k f rom wh i c h i t fl o ws b y g ra vi ty to e a ch
o f th e g a s g e n e ra ti n g s ys te m. Th e tan k i s f itte d wi th a fl o a t v al v e to
a u to ma ti c al l y m a i n ta in a nd d e si re d wa te r l e v el a nd le v el s wi tc h to s to p th e
re cti f ie r if th e l e v el i n th e ta n k i s to o lo w.

H y dr oge n m is t e limina t or :

Th e h yd ro g e n g a s l e av i ng th e cel l s ca rri e s o ff s o me o f th e K OH e l e ctrol yte i n

th e f o rm of a n e n tra in e d mi s t. Mo s t of thi s e n tra in me n t i s re mo v ed i n the c el l
g a s co o l e r an d i s re tu rn ed to th e ce ll s . So me i s re mo v e d a t wa te r se a l . T h e
re m a i n de r i s re mo v ed i n the m i st el i mi na to r.

H y dr oge n Ga s H olde r :

Th e h yd ro g en ga s afte r pa s si n g th ro ug h th e wa te r s e a l e n te rs th e g a s
h o l d e r. Th e h yd ro g e n g a sho ld e r i s a we t-se a l typ e g a sh o l d e r wi th a n o mi n al
v o l u me o f 3 0 m 3 . The o p e ra ti ng p re s su re wi l l b e a p p ro xi ma tel y 1 2 5 m m wa te r
co l u mn . Th e g a sh o ld e r i s f i tte d wi th f o u r l ev e l s wi tch e s fo r co n tro l o f th e H 2
co mp re s so rs .

H y dr oge n C om pr e s s or S y s te m:

W h e n a n y of the c o mp re sso rs i s s ta rte d ei th e r on au to o r ma n u al m o de it wi l l

co n tin u e ru n ni n g f o r 3 0 m i nu te s (p rov id e d l i mi t swi tc h n o t to u ch e d mi n ) an d
th e n i t wi l l sto p re g a rdl e ss o f the lev el of g a s h ol de r. Th e c o mp re sso rs a re
u s e d to c o mp re ss th e Hyd ro g e n g a s to a p re s su re of 1 7 5 kg /cm 2 .

16
H y dr oge n P ur ific a tion S y s te m :

Th e h yd ro g e n a t the di sc h a rge o f th e oil lu b ri ca te d co mp re s so rs con ta i n th e

f oll o wi n g i m p u ri tie s

· Ox yg e n g a s , ap p ro x 0 .2 p e rce n t b y vo lu me

· W a te r v ap o u r, 1 0 0 p e rc e n t rel a tiv e h u mid ity a t o p e ra tin g c on d i ti o n s .

· Oi l V ap o u r a n d oi l d ro pl ets pi c ke d u p i n th e oi l lu b ri ca te d co m p re ss o rs

· Mo i stu re c o n de n se d o ut of th e h yd ro g e n ga s a s a re s ul t of the
i n c re a se in p re s su re

Th e m o i s tu re , oi l d ro pl e ts a n d o i l v ap ou r a re re m o ve d i n a s e ri e s o f fi l te r.

T wo b a n ks o f th e se f il te rs a re su pp li ed s o th a t o n e b a n k ca n be in se rv i ce

wh i l e the oth e r ba n k i s b e i n g sta n d b y. Th e pu rif ie r i s f i tte d wi th in le t a n d

o u tl e t te mp e ra tu re g au g e s, a s we l l as h i g h a n d coa le sc i ng hi g h h i gh
te m p e ra tu re s wi tch e s.

C a ta ly tic pur ifie r :-

Th e c a ta l yti c p u rifi e r i s u se d to re mo v e o xyg e n i m pu ri ty f ro m th e h yd ro g e n

g a s b y c a u si ng th e o xyg e n to ca ta l yti c al l y c o mb i ne wi th h yd ro g e n to fo rm
wa te r v a p o r. W he n o p e ra ti n g p ro pe rl y th e p u ri fi e r sho u l d re mo ve o x yg e n to a
re si d ua l i m p u ri ty o f l e s s th a n te n p a rts p er mi l li on

A fte rc oole r :-

Th e af te r co o l e r i s s u p pli e d to c o ol th e h o t h yd ro g e n l eav i n g th e c a tal yti c

p u rifi e r, b e fo re i t e n te rs th e d e si c can t d rye r. If th e h yd ro g e n i s n ot
su ffi ci e n tl y c o o le d th e de si cca n t d rye r co u l d b e ov e rlo a de d , wi th h a rm fu l
e ffe c ts on the e xi t d e w p o i n t.

Th e Af te rcoo l e r i s a she ll an d tu b e typ e h ea t e x ch a n ge r, wi th h yd ro g e n

fl o wi n g o n th e tub e si de a nd co o li n g wa te r f l o wi n g o n th e sh el l si de .
Te m p e ra tu re Ga u g e at th e Af te rc oo l e r o u tl e t i n di c a te s h yd ro g e n
te m p e ra tu re .

Fro m a f te r c o ol e r the h yd ro g en ga s g o e s to H yd ro g e n sto rag e b o ttl e s

th ro u g h co a l e sci n g fi l te rs.

17
S tor a ge R oom :

In H yd ro g e n S to ra ge B u i ld in g , th e re are a to tal o f si x sto ra g e b o ttl e s

a rra n g e d i n t wo b a n ks .

S a fe ty P r ec a u tion s for w or king in the H y dr oge n B uilding:

H yd ro g e n g a s i s a v e ry d a n ge ro u s ga s a s i t c an f o rm a n e x p lo s ive mi xtu re
a n d th e re i s a l wa ys a n e xp lo s iv e ha za rd p re se n t in th e H yd ro g e n B uil d i n g.
Th e fo ll o wi n g p re ca u tio n s a re n e c e ssa ry wh i l e wo rk i n g i n the H yd ro g e n
b u i l di ng :

· R a d i o a nd c el l p h o n e s m u s t b e po we re d off .

· S p a rk -l e ss T oo l s m u s t b e u se d .

· C a re mu st b e ta k en th a t n o su ch a c tiv i ty is p e rfo rm e d th a t mi g h t re su l t
i n a sp a rk .

· L e a v e th e b ui ld in g i m me d ia tel y a f te r co mp l e ti ng yo u r wo rk.

18
 Ch ap ter 2: INST R UME NT AT ION in th e B OP A rea

Meas urement ins tru ments hav e been ins ta lled in the BOP area to
meas ure th e fo llo win g proc ess parame ters

Pres s ure
Lev el
F low
Te mpe rature
pH
C onduc tiv ity

The follo w ing final c o ntrol el e ments are being us ed in the BO P are a

C ontro l Val v es
On -O ff Valv es
Solenoid O perated Va lv es (SOVs )
Stro ke Con troll ers

PR E SS U RE ME A SUR EME NT

Mech an ical Pressu re Sen sin g Elem en ts:

Me ch a n i cal p re ssu re -se n si n g e le me n ts i nc l u de th e be llow s , th e d ia phr a gm,

a n d th e bour don tu be . E a ch o f the s e dev i ce s co nv e rts a fl ui d p re ss u re i n to
a fo rce . If u n re s tra in e d, th e n a tu ral e las ti c p ro p e rti e s of th e e l e me n t wi l l
p ro d u ce a m o ti o n p ro p o rti o na l to th e ap p l ie d p re s su re .
Th e se el e m e nts a re mo s tl y u se d i n Pre ss u re Ga u g e s a s th e p re ss u re
se n sin g el e m en t.

Th e wo rk i n g o f a p re ss u re g a u g e i n c o rpo ra ti n g a C -Typ e Bo u rd on Tu be i s
i ll u stra te d b e lo w

19
A ll th e se el e men ts ca n a l so b e u s ed to s en s e the di ff e re ntia l p re ss u re .

PR E SS U RE G A U G ES

P re ss u re g a ug e s a re u se d f o r c o n ti n uo u s f lu id p re ss u re me a su re m en t.
Ga u g e s di sp l a y th e i n stan tan e ou s p re ss ure of the fl u i d i n a p ro c e ss a nd a re
u s e d to ta k e l o ca l rea d i n g s fro m th e fi el d .

20
 P re s s ure Ga uge

P r e s s ure Ga uge s in the B OP A r e a :

W e h ave mo re th a n hu n d red p re ssu re g a u ge s i n s ta ll ed i n th e B OP A re a .

Th e se g a u ge s h a ve diff e ren t ra n ge s a n d th e y u s e d iff e ren t s e n si ng
te c h n ol o g ie s to me a su re p re ss u re . Mo st of th e p re s su re g a u g e s u se a C-
Typ e B o u rd o n Tub e a s th e p re ssu re sen sin g e l e me n t.

P M a nd Ca libra tio n:

The maintenanc e of pre s s ure ga uges is c arried out d urin g the annual
outage. The maintenanc e inv olv es the c leaning and c alib ration of
gauges . Press ure gauges are c alibrated on the C a libration W orkbenc h
in E& I W orks hop.

Electrical Pressu re Sen sin g Elem en ts:

Fo r e l e ctro ni c P re ss u re o r D iff e re n ti al P re ss u re Tra n smi tte rs we n e e d a

m e ch a n i sm wh e re we ca n c onv e rt th e Fl ui d P re ssu re in to a n e l e ctri ca l
si g na l . Thi s ca n b e a cco mp li s he d b y e l e ctri ca l p re s su re se n si n g e l e me n ts,
so me o f wh i ch a re d i scu ss e d b el o w:

Piez o resistive (St rain G au ge ) Sen so rs:

P i e zo re si s tiv e me a n s “p re ssu re -s e n s itive re si s ta n ce ,” o r a re si s ta n ce th a t

ch a n ge s v al u e wi th a p pl ie d p re ss u re . The stra in g a u ge i s a cla s si c e x a m pl e
o f a p i e zo re si stiv e e l e me n t:

A s th e te st sp e ci m e n i s s tre tch e d o r c o mp re ss e d b y th e a p pl i ca ti o n o f fo rce ,

th e co n d u c to rs o f th e strai n g a ug e a re si m il a rl y d efo rm e d . El e ctri c al
re si sta n c e (R) o f a n y co n d u cto r i s p rop o rti o na l to th e ra ti o of le n g th (L ) o v e r
cro s s-se cti o n al a re a (A ), wh i ch me a n s t h a t te n si le d ef o rm a ti o n (stre tch i n g )
wi l l i n cre a se el e c tri ca l re si s ta n ce b y si mu l ta ne ou s l y i n cre a si ng l e n g th a nd
d e c re a si n g cro ss -se c ti on al a re a wh i l e co m p re s siv e d e fo rma ti o n (s q u i sh in g )
wi l l de c re a se e l e ctri ca l re s i sta n ce b y s i mu l ta ne ou sl y d e cre a si n g l en g th a nd
i n c re a si n g cro s s-se cti o n a l a re a .

21
A tta ch i n g a s tra in ga u g e to a di a p h ra g m, re s u l ts i n a d evi c e th a t c ha n g e s
re si sta n c e wi th a p pl ie d p re ssu re . P re s sure f o rc e s the di a p h ra g m to de f o rm,
wh i c h i n tu rn ca u se s th e s tra in g a ug e to ch a n ge re si sta n ce . B y m e a s u ri n g
th i s ch a n g e i n re si sta n ce , we c a n i nfe r the a mo u n t of p re s su re a p pli e d to th e
d i a p h ra g m .

Oth e r co m mo n a n d wi d e l y u se d e l e ctri c p re ss u re se n si n g el e m e n ts a re
· D i ffe re n ti a l C ap a c ita n c e S en s o rs
· R e so n a nt El e m e n t S e n so r

PR E SSU RE T R ANS MIT T ER S

P re ss u re tra n sm i tte rs a re d e vi c e s d e si gn e d to me a s u re f lu id p re ss u re a n d
tra n s mi t th a t inf o rm a tio n vi a e l e ctri ca l sig n al s su ch a s the 4 -20 mA a na lo g
sta n d a rd , o r in di gi ta l f o rm s u ch a s H A RT.

P r e s s ure tr a ns m itte r s in the BOP A re a :

Th e p re ss u re tra n smi tte rs i n stal l e d i n th e B OP A re a a re of th e fo l l o wi n g typ e

Ma n u f a c tu re r: H o n e y we l l
Mo d e l : S TG9 4 L
S e n si n g Te ch n o l og y: Pi e zo re s i sti v e S train Ga u g e

P M a nd Ca libra tio n:

Th e P M o f p re s su re tran s mi tte rs i s c a rri ed o u t d u ri n g th e a nn u a l o u tag e . Th e

f oll o wi n g to ol s a re re q u i red f o r th e P M a n d C al ib ra ti o n o f p re s su re
tra n s mi tte rs :

· S ta n d a rd To ol ki t
· D i g i ta l Mu l ti me te r
· D i g i ta l Te st P re s su re Ga ug e
· H o n e y we l l S ma rt F i el d C o m mu n i ca to r (S FC )

Th e P M o f th e p re ssu re tra n sm i tte r i nv o lve s th e fo ll o wi n g s te p s

· Ob ta i n a wo rk p e rm i t f o r th e P M o f Pre ssu re Tra n sm i tte r.

· Inf o rm th e a rea op e ra ti o n e n g i ne e r a b o u t th e j o b .
· C o n n e ct th e p re ssu re so u rc e to the p re ssu re se n si n g p o rt of th e
p re s su re tra n smi tte r.
· C o n n e ct th e d ig i ta l m ul ti m e te r to th e Tra nsm i tte r o u tp u ts.
· A t a 0 % p re ss u re i n pu t of th e cu rre n t o u tp u t sh o u ld m e 4 m A.
· A t a 10 0 % p re s su re in p u t th e cu rre n t o u tpu t sh ou ld b e 2 0 m A .
· Th e p re ss u re an d cu rre n t v a l u e s sho u l d be c h e c ked wi th re f e re n ce to
th e f o ll o wi n g ta bl e .

In p u t P re s su re (%) Ou tp u t C u rre n t (m A)
0 04
25 08
50 12
75 16
100 20

22
If th e re i s a n y d i sc rep a n c y i n th e me a s u re d va lu e s the n c on n e ct th e
H o n e y we l l S FC to the P re s su re Tra n s mi tte r a n d e n te r th e Lo w R a n g e V a l ue
(L R V ) a n d U p pe r R a n g e V al u e (UR V ).

PRE SS UR E SWIT C H

P re ss u re S wi tch e s a re u se d fo r a u to ma ti c o pe ra tio n a nd p ro te c ti on of
e q u i p me nt. Th e s wi tch a ctu a te s wh e n th e f lu id p re s su re re a ch e s the
p re d e fi n ed se t-p o i n t. P re ssu re s wi tch e s u se D i a ph ra g ms , B el lo ws a n d C-
Typ e B o u rd o n Tub e a s p re s su re s en si n g e l e men ts.

P r e s s ure Sw itc hes in th e B OP A r e a : Ma n y d iff e re n t typ e s of p re ss u re

s wi tc h e s a re in stal le d i n th e B OP A re a . T wo o f the mo st i mp o rta n t p re ss u re
s wi tc h e s a re d i scu ss e d b e l o w:

H 2 Co m pre s s or Inle t P re s s ure Sw itc h (CIP Sw itc h):

A p re s su re s wi tch i s i n sta l l ed a t th e i nl e t o f th e H yd ro g e n C o m p re ss o rs. It

a c tu a te s a nd tri p s th e H 2 Co m p re ss o rs wh e n th e i nl e t g a s p re ssu re i s l o w.

Th e C IP swi tc h u se s a b o u rd o n tu be a s th e p re s su re -s e n s in g e le me n t, a nd a
g l a ss bu lb p a rti al l y fi ll e d wi th me rc u ry a s th e e le c tri cal s wi tch i ng el e m e n t.
W h e n a pp l i ed p re s su re c au s e s the b ou rdo n tub e to fl e x suff i ci e n tl y, th e g la s s
b u l b til ts fa r e no u gh to cau se th e m e rcu ry to fa ll a ga in s t a pa i r of e le ctro d e s,
th u s co m pl e ti ng a n e le ctri c al ci rc u i t.

A d va nta g e s o f m e rcu ry ti l t s wi tch e s in cl ud e i mm u ni ty to s wi tc h co n ta ct

d e g ra da tio n f ro m h a rmf ul a tm o sp h e re s (o i l m i st, d i rt, d u st, c o rro si on ) a s we l l
a s s a fe ty in e x plos ive a t mos ph e re s (si n c e a s pa rk co n ta i n ed wi th i n a
h e rm e ti ca ll y se a le d g la s s b u lb can n ot to u ch off a n e xp lo sio n i n the
su rro u n d in g a tmo sp he re ).

D is a dva n ta ge s in c lu d e th e p o s si b i li ty of i n te rmi tte n t e le c tri c al con ta ct

re su l ti n g f ro m me c ha n i cal v ib ra tio n , a s we ll a s se n si ti vi ty to mo u n ti n g a ng le

N ote : Th e C IP s wi tc h h a s b e e n ca u si n g p ro b le m s f o r s o me ti me . W h e n o n e
co mp re s so r i s ru nn i n g a n d the o th e r sta rts, th e CIP s wi tc h a ctua te s d u e to
e x ce s siv e me ch an i cal vi b ra ti on o f i ts mo u n ti n g sta nd . The i ss u e i s be in g
re so lv e d a nd ei the r th e m o un ti n g sta n d o r th e s wi tch wi l l b e rep la c e d .

C WP L ube Wa te r P um ps C o m mo n Dis c ha r ge P re s s ur e Sw itc h:

Th i s i s a v e ry c ri ti cal s wi tch b e ca u se i ts actu a tio n ca n re su l t i n th e trip pi n g

o f CW P .

P M a nd Ca libra tio n:
Th e i r P M i s c a rri e d o u t d u rin g th e ou ta g e a n d th e y a re ca li b ra te d wh e n
re q u i re d .

Th e i r c al ib ra tio n p ro c e d u re in vo l ve s the fo ll o wi n g ste p s

· A p pl y a p re s su re s o u rce to th e s e n si n g po rt of th e p re ss u re swi tc h .

23
 · U si n g a di g i tal mu lti me te r, ch e c k wh e th e r th e swi tc h co n ta cts a re o p e n
o r cl o se .
· Gra d u a l l y i n c rea se the p re s su re a n d ma rk th e po in ts wh e re th e s wi tc h
a c tu a te s a nd wh e re i t re se ts .
· If th e a ctu a ti o n an d de a c tiv a ti o n p oi n ts a re d iffe re n t f ro m th e d e s ig n
se tti ng s , u se th e a dj u s tme n t scre ws to a dj u st th e s wi tch .
· A g ai n ap pl y p re s su re a n d a sk the c o n trol ro o m e n g i n ee r to v e rif y
wh e th e r th e s wi tc h i s b e hav i n g a s i t sh o uld o r n o t.

D IF ERE NT I AL PR ES SUR E I N ST R UME NT S

On e of the mos t c ommon, and mos t us eful, press ure meas uring
ins truments in indus tr y is th e differen ti al pres s ure trans mitter. This
dev ic e s ens es the d ifferenc e in press ure between t wo p orts and
outputs a s ignal repres e nting that press ure i n relation to a c alibrated
range. DP ins tru ments us e the s ame s ens ing ele ments to meas ure the
differenc e in pres s ure as the press ure ins truments .

Val ve Man ifo ld fo r Differen tial P ress u re In stru m en ts:

An i mportan t ac c es s ory to the differe ntial p res s ure trans mi tter is the
three-v alv e manifo l d. Th is dev ic e inc orpo rates three manual v alv es to
is ol ate and equalize pres s ure fro m th e proc ess to the trans mi tter, for
mai ntenanc e and c al ibra ti on purpos es .

D P G au g es in th e B OP Area:

D P gau ges are ins talled on fil te rs an d s tra iners to meas ure the ex ten t
of their c loggin g and c hokin g. The ir P M and c alibration proc edure is
s imilar to tha t of Pres s ure gauges .

D P Sw itch es in th e BO P A rea:

D P S w itc hes are ins tal led on the follo w ing equip me nt
Mix ed Be d Pol i s her Unit

24
MMF
C W P Lube W ater Strainer
C W P Suc tion Strainer
D MF

PM an d Ca lib ratio n:

Their P M is done ann uall y during the o utage. Their c al ibra ti on

proc edure is s imilar to the Pre s s ure Switc h.

L EVEL ME AS U RE ME NT

A wi d e v a ri ety o f te ch n ol og i e s e xi st to m ea s u re th e le ve l o f sub s ta n ce s in a
v e sse l , e a ch e xp l oi tin g a diff e re n t p rin ci p le of p h ys i cs.

L EVEL G A UG E S

Th e l e ve l ga u g e o r si gh t-g la ss i s a v e ry s i mp l e a n d eff e c tiv e te ch n ol og y f o r

d i re c t vi s u al i n d i ca ti on of p ro c e ss l ev e l . In i ts si mpl e st f o rm, a l eve l g au g e i s
n o th i n g m o re th a n a c l ea r tu b e th ro u gh wh i c h p ro ce ss li q ui d m a y b e s e en . A
f un c tio na l d ia g ra m of a si g ht-g l a ss sh o ws h o w i t v i su a l l y re p re se n ts th e le v e l
o f li q u id in sid e a ve s sel s u ch a s a s to ra ge ta n k:

L ev el Ga u g e s a re in stal l e d o n m a n y ta n ks to p rov id e a v i su al re a di n g to
co mp l e men t th e el e c tro ni c l ev e l me a su rem e n t d e vi c e s.

LE V E L S WIT C H E S

25
A l ev e l s wi tch i s u se d to d e te ct th e fl u i d (o r s o l i d ) l ev el i n a v e sse l o r ta n k.
L ev el s wi tch e s a ctu a te a t p re def in e d se t-p o in ts to p e rf o rm so m e c o n trol
a c ti on .

Ma n y d i ffe re n t typ e s o f L ev el S wi tch e s a re b e in g u se d i n th e B OP Are a . A

f e w o f the lev e l s wi tch e s a re d i scu sse d be l o w:

Mag n etic R eed Sw itch es:

S p e ci al typ e s of s wi tc h e s a re u se d i f th e l iq ui d to b e me a su re d i s a
h a za rd o u s c h e mi ca l o r if i t i s a t h ig h te m p e ra tu re o r hi g h p re s su re . Th e
fi g u re b el o w s h o ws a m e th o d o f s wi tch i n g i n su ch c a se s . E a ch re e d s wi tch i s
n o rm a ll y o p e n . W he n th e fl o ati n g ma g n et o u tsi d e th e tu b e co m e s n ea r th e
s wi tc h , i t attra c ts the ma gn e ti c p o le pi e ce in the swi tch . Th i s a cti o n cl o s e s
th e swi tch u n til th e fl oa ti n g m ag ne t mo ve s a wa y. N o fo ll o we r m a g n e t i s
n e e de d i n si d e th e tu be .

Ma g n e ti c re e d s wi tc h e s ca n b e se rv i ced f ro m th e top of th e tub e . Th e se

s wi tc h e s a re n o t s e a l ed i n the tu b e , an d th e y n e v e r co m e i n to co n ta ct wi th
th e l iq ui d i n th e tan k.

D ie s e l T a nk Le ve l S w itc h:

Th e l e ve l swi tc h e s i n stall e d o n the D i e se l Ta n k (Fi re Fi gh ti n g Pu m p H o u se )

a re Ma g n e ti c Re ed S wi tc h e s, h av i n g a si n g l e s wi tch i n g p oi n t (lo w l e ve l ).
Th e se s wi tch e s d o n o t h av e th e o p ti o n o f ad ju stin g th ei r s wi tch i ng p oi nt.
Th e y a re v e ry re l i ab le an d hav e l o ng o p e ra ti o n al l iv e s.

Storag e T an k Gau g e an d L evel Sw itch :

Th e s ys te m sh o wn i n the fi g u re i s ca ll ed a s to ra ge -ta n k ga u ge . It h a s a fl o a t
th a t ri se s a n d f all s wi th th e su rf a c e o f th e l i qu id . A pe rfo ra te d ta p e
co n n e c te d to the fl o a t p a ss e s th ro u g h the ta n k to p a n d i nto th e g a u ge h e ad .
A sp ri n g mo to r ke ep s th e ta p e tau t a nd ex e rts a c o n sta n t ten si o n a t th e f lo a t.
A sp ro c ke t wh e e l d riv e s a sh af t, wh i ch in tu rn d riv e s a co u n te r m e c h an i s m.
Th e co un te r ca n be c ali b ra ted to sh o w th e vo lu me of wa te r i n th e ta n k
i n s tea d of th e d e pth . The s i ze a n d sh a pe of the ta n k d e te rmi n e ho w ma n y

26
g a l l on s (o r l i te rs, o r cu b i c f ee t) o f wa te r a re i n th e ta n k f o r e v e ry u n i t of
d e p th.

M a inte na nce :

Th e m o s t co m mo n m ai n te n an c e p rob l e ms wi th fl o a t-a c tu a te d l ev e l ga u g e s
o fte n o cc u r wh e re th e p ro ce ss li q u i d co n ta cts th e fl oa t. The g u i de c a bl e s
so me ti m e s b re a k o r b e co m e co rro d ed , an d th e ta p e a tta ch e d to th e fl o a t c a n
b re a k o r b e co me twi ste d . A l s o , co rro s i on c a n c a u se h ol e s i n th e fl o a t.
Op e n i n g th e s wi tch a n d re wi n d in g the re el a nd tap e i s a ve ry te d i o u s a n d
ti m e co n su m i ng a c tiv ity.

F l e xi b l e t ap e an d p l u mb - b ob

Th i s typ e of L eve l S wi tch i s i n stal le d o n th e B lo wd o wn B a si n a n d Fi lte r

W a te r Ba sin .

C a p a c i ta n c e (C o n d u c tiv ity T yp e L ev e l S wi tch )

P M of Le ve l S w itc h es :

Th e P M o f L ev e l S wi tc h e s i s pe rfo rm e d d u ri n g th e a n nu al o u ta g e . Th e P M
i nv olv e s di s ma n tl in g a n d th o ro ug h cl ea n in g of th e s wi tch . Th e s wi tch i s th e n
o p e ra ted an d i ts a c tu a ti o n a n d re se t po in ts a re ve rifi e d .

L EVEL T RA N SMIT T ER S

Lev el Trans mitters are us ed for c ontinuous meas ure of the lev el of a
v es s el or tank. Lev el Trans mitters operate on man y different princ ip les .
T wo of th e mos t c ommonl y us e d types are disc u ss ed below:

27
Hyd ro static Pressu re:

A v ertic al c olumn of flui d e x erts a pres s ure due to the c olumn’s weight .
The relations hip bet ween c olu mn h e ight a nd flui d pres s ure at the
botto m of the colu mn is c ons tant for any partic ular fluid (dens ity)
regardless of v ess el width or s hape.
This princ ipl e ma kes it pos s ib le to inf er the height of li qu id in a v es s el
by meas uring the press ure generated at the botto m.

D ifferen ti al pres s ure trans mitters are the mos t c o mmon pres s u re-
s ens ing dev ic e us ed in this c ap ac ity to infer liquid lev e l within a v ess el.
In the h ypothetic a l c ase of a n oi l v es sel, the trans mitter wou ld c onnec t
to the v es s e l i n thi s manner (w ith the high s ide toward th e p roc ess and
the lo w s ide v ented to atmos phere) :

C onnec ted as s uc h, the differential press ure tra ns mitter func tions as a
gauge press u re trans mitter, res ponding to h ydros tatic press ure
exc eeding ambient (at mos pheric ) press ure. As liquid l ev el inc re as es ,
the hydros tatic pres s ure applie d to the “hig h” s ide of the differential
press ure trans mitter als o inc reas es , driv ing the trans mitter’s output
s igna l higher.

In this wa y th e DP Trans mi tte r c an be c alib rated to ac t as a lev el

trans mi tter b y c alc ulating the press ure ex erted by d iffe rent height of
liquid c olu mn.

B u bb ler System s:

A n i n te re s tin g v a ri atio n o n thi s th e me o f d i re ct h yd ro s ta ti c p re ss u re

m e a su re me n t, d i scu sse d a bo v e , i s th e u se of a pu rg e g a s to me a s u re
h yd ro sta ti c p re ss u re i n a li qu id -c o n tai n i ng v e s se l . Thi s e li mi na te s the n e e d
f o r d i re c t co n ta ct of th e p ro ce s s l iq ui d a g a i n st th e p re ss u re -se n si n g e le m e n t,
wh i c h c a n b e a d va n ta g e ou s if th e p ro ce ss l iq ui d i s c o rro siv e . Su ch syste m s

28
a re of te n ca ll ed b u bb le tu be o r d ip tu be s ys te ms , th e f o rme r n a m e b e i ng
a p p ro p ri a tel y d e sc ri ptive f o r th e wa y p u r g e g a s b u bb le s ou t th e e nd of the
tu b e a s i t i s su b me rg e d in p ro c e ss l iq u i d . A k e y d e ta i l of a b u b bl e tu b e
syste m i s to p ro vi d e a me a n s of l i mi tin g g a s fl o w th ro u g h th e tu b e , so th e
p u rg e g a s b a c kp re s su re p ro p e rl y re fl e c ts h yd ro sta ti c p re ss u re a t th e e n d of
th e tu b e wi th n o a d di ti o n al p re ss u re d ue to f ri c ti o na l l o s se s of p u rg e fl o w
th ro u g h th e l e n g th o f th e tub e . Mo s t b u b bl e tu b e s ys te ms , th e re fo re , a re
p ro v i de d wi th s o me me a n s o f mo n i to ri ng p u rge g a s f lo w, typ i ca l l y wi th a
ro ta m e te r o r wi th a s ig h tfe e d b ub bl e r:

If the p u rge g a s fl o w i s n o t to o g re a t, g a s p re ss u re me a su re d an ywh e re i n

th e tu b e syste m d o wn stre a m o f th e ne e dl e v a lv e wi l l b e e qu a l to the
h yd ro sta ti c p re ssu re o f th e p ro c e ss li q u id a t th e b otto m of the tu b e wh e re
th e g a s e sca p e s . In o th e r wo rd s, th e p u rg e g a s a cts to tran sm i t th e li q ui d ’ s
h yd ro sta ti c p re ssu re to so m e re m o te p o in t wh e re a p re ssu re -s e n s i ng
i n s tru me n t i s l o cate d . A g en e ra l ru l e -of -th u m b i s to l i mi t p u rge g a s flo w to
th e p oi n t wh e re yo u ca n e a s i l y co u n t i nd iv i d ua l bu b bl e s e xi ti n g the b u b b le
tu b e (o r i n sid e th e si g h tfe e d b ub b l e r if o ne i s p rov i de d on the s ys te m).

It ma y b e n o te d tha t i n bo th th e ca se s, Bu b bl e r syste m a n d H yd ro sta ti c typ e

L ev el tra n sm i tte rs, we a re a c tu a ll y m e a su ri n g the p re ssu re e x e rte d d u e to
th e fl ui d he ig h t a n d u sin g i t to in f e r the lev el of th e flu id .

Le ve l T ra ns mitte r s in B OP A r e a :

B o th Bu b bl e r Typ e a nd Hyd ro sta ti c typ e of l ev el tran s mi tte rs a re i n s ta ll ed in

th e B OP a re a . In a d di ti o n to the s e oth e r typ e s o f L ev el tra n s mi tte rs a re al s o
i n s tall e d i n th e B OP a re a th a t a re
· Fl o a t Typ e L ev e l Tra n sm i tte r
· D i a p h ra g m Typ e L e v el Tra n sm i tte r

Ma ke : H o n e ywe l l
Mo d e l : S TD 9 24
Typ e : B u b b l e r

P M a nd Ca libra tio n of Le ve l T r a ns m itte rs :

29
Th e P M o f L e v el Tra n smi tte rs i s c a rrie d ou t d u rin g th e a n n u al o u ta ge .

Th e P M o f p re s su re tran s mi tte rs i s c a rri ed o u t d u ri n g th e a nn u a l o u tag e . Th e

f oll o wi n g to ol s a re re q u i red f o r th e P M a n d C al ib ra tio n o f p re s su re
tra n s mi tte rs :

· S ta n d a rd To ol ki t
· D i g i ta l Mu l ti me te r
· D i g i ta l Te st P re s su re Ga ug e
· H o n e y we l l S ma rt F i el d C o m mu n i ca to r (S FC )

Th e P M o f th e l ev el tra n sm i tte r i nv olv e s th e f ol l o wi n g s te p s

· Ob ta i n a wo rk p e rm i t f o r th e P M o f L eve l Tra n s mi tte r.

· Inf o rm th e a rea op e ra ti o n e n g i ne e r a b o u t th e j o b .
· C o n n e ct th e p re ssu re so u rc e to the h yd ro s ta ti c p re ssu re se n si ng p o rt
o f th e l eve l tra n sm i tte r.
· C o n n e ct th e d ig i ta l m ul ti m e te r to th e transm i tte r o u tp u ts.
· A t a 0 % p re ss u re i n pu t of th e cu rre n t o u tp u t sh o u ld m e 4 m A.
· A t a 10 0 % p re s su re in p u t th e cu rre n t o u tpu t sh ou ld b e 2 0 m A .
· Th e p re ss u re an d cu rre n t v a l u e s sho u l d be c h e c ked wi th re f e re n ce to
th e f o ll o wi n g ta bl e .

In p u t P re s su re (%) Ou tp u t C u rre n t (m A)
0 04
25 08
50 12
75 16
100 20

If th e re i s a n y d i sc rep a n c y i n th e me a s u re d va l u e s the n c on n e ct th e
H o n e y we l l S FC to th e L ev e l Tra n s mitte r a n d en te r th e L o w Ra n g e V a l u e
(L R V ) a n d U p pe r R a n g e V al u e (UR V ) o f hyd ro sta ti c p re s su re .

N ote :
Th e p e rso n do in g the c a li b ra ti o n mu s t h av e th e d a ta th a t sh o ws th e re l a ti o n
b e twe e n l ev el a nd p re ss u re fo r th a t sp e cifi c d e vi ce .

Ult raso n ic Le vel Detecto rs

Ope r a ting P rinc iple :

A n o th e r wa y o f m ea s u ri ng l iq ui d l e v el in v e ss el s i s to b o u n ce a trave l i ng
wa v e o ff th e su rf a ce of th e li q ui d – typ i ca l l y f ro m a lo ca ti o n a t the to p of th e
v e sse l – u si n g th e ti me -o f-fl i g h t f o r th e wa v e s a s a n i nd i c ato r of d i sta n ce ,
a n d th e re fo re a n i nd i ca to r of l i qu id h ei g h t in sid e th e v e s se l . Th i s fo rm of
m e a su re me n t i s ca l le d Ti me D o ma i n R e fle c to me try.

U ltra s onic Wa ve s :

30
U l tra so ni c so u n d wa v e s wi th f req u en c ie s of 1 to 5 me g a h e rtz (M H z) c a n b e
u s e d to d e te ct li q u i d o r s o li d l ev el s. B asi c a ll y, u l tra son i c wa v e s a re so u n d
wa v e s, b u t a re a t h i gh e r f re qu e n ci e s th an ca n b e d e te c te d b y th e hu m a n e a r
(u su a ll y u p to 2 0 ki lo h e rtz m a xi m u m).

Th e mo st co m mo n ki n d of u l tra so n i c tra n sd u ce r co n s i sts of a pi e zo e le c tri c

cr ysta l (su ch a s q ua rtz). W h e n a v ol ta g e i s a p p li e d to th e p la te s , th e
p i e zo el e ctri c c rysta l e xp a n d s o r co n tra cts. If th e v o l tag e i s al te rn a ti n g a t a n
u l tra s on i c f re q u e n cy, th e c rysta l e xp an d s an d co n tra cts a t th e sa m e
u l tra s on i c f re qu e n c y. Th e cr ys ta l vi b ra te s, a n d th e se v i b ra ti o n s ca n b e
tra n s fe rre d to a d i a ph ra g m to p ro d u ce ul tra so ni c s o un d wa v e s.

U ltra s onic Le ve l Ins tr u me nts :

U l tra so ni c lev el in s tru me n ts mea s u re th e di s tan c e fro m th e tra n s mi tte r

(l o c a ted a t s o me hi gh p oi nt) to th e s u rfa ce of a p ro c e ss m a te ria l l o c a te d
f u rthe r b el o w. Th e ti me -o f-f li gh t fo r a so u n d p ul se in d i ca te s th i s d i sta n ce ,
a n d i s in te rp re te d b y th e tran smi tte r e le c tro n i cs a s p ro c e ss l ev e l . The se
tra n s mi tte rs m a y o u tp u t a s i g n a l c o rre sp o n di n g e i the r to th e fu ll ne s s o f the
v e sse l (filla ge ) o r th e a m o un t of e mp ty sp a ce re mai n i ng at the top o f a
v e sse l (ulla ge ).

U l l ag e i s the “n a tu ral ” mo d e of me a su re me n t f o r th i s so rt o f l ev el i n stru m e n t,

b e c a u se th e so u nd wa v e ’ s ti m e -of -fli g h t i s a d i re c t fu n c ti o n of h o w mu ch
e m p ty sp a c e e xi s ts b e twe e n th e li qu id su rf a ce a nd th e to p of th e v e ss el .
To ta l ta n k h ei g ht wi l l al wa ys b e th e su m o f fil la g e an d ul la g e , th o ug h . If the
u l tra s on i c le ve l tra n sm itte r i s p ro g ra m me d wi th th e ve s se l’ s to tal h ei g h t, i t
m a y c a l cu l a te fi ll a g e vi a si m p le s u b tra cti on :

Filla ge = T ota l he ight − U lla ge

Ultraso n ic L evel De vices at B O P:

T wo t yp e s o f u l tra so n i c le v el d e vi c e s a re b e in g u se d a t the B OP a re a
1 . U l tra so ni c L e ve l S wi tc h
2 . U l tra so ni c L e ve l Tra n sm i tte r

31
U ltra s onic Le ve l S w itc h:

Ma n u f a c tu re r: S i e me n s Mi l itro ni cs
Mo d e l : P OIN TE K U L S 2 00

Th i s swi tc h i s to b e in sta l le d o n the ne w S o di u m Hyp o c h l o ri te Ta n k. Thi s

s wi tc h i s p ro g ra mm e d u si ng th e S ie me n s Infra re d H a n d P rogr a m me r .

U ltra s onic Le ve l T r a ns mitte r s :

Ma n u f a c tu re r: S i e me n s Mi l itro ni cs
Mo d e l : S ITR A N S Pro b e L U

Ma n u f a c tu re r: E n d re s s & Ha u se r
Mo d e l : P ro s o ni c F MU 8 6 0

P r ogra m ming (C a libr a ting ) a S ie m e ns U ltra s onic Le ve l D e vic e :

Th e Mi l i tron i cs u l tra so ni c le ve l tra n smi tter o r s wi tch i s p ro g ra mme d b y th e

S ie me ns H a nd P r ogra mme r.
To c a li b ra te th e lev el tra n s mi tte r we n e e d to e n te r th e e x a ct v al ue s of
d iffe re n t pa ra m e te rs s u ch a s Ta n k H ei gh t a n d Ma xi m u m Li q ui d He i gh t i n th e
d ev i ce .

P r ogra m ming (C a libr a ting ) a P r os onic FM U 8 6 0 Le ve l T r a ns m itte r :

Th e P r os onic FM U 8 60 ul tra so ni c l e v el tra n sm i tte r i s p ro g ra mm e d b y u si n g

th e b u tto n s a nd d i spl a y g iv en o n th e tran smi tte r b o d y. To ca li b ra te th e l e ve l
tra n s mi tte r we n e e d to e n te r the e x a ct v a lu e s of d iffe re n t p a ra m e te rs s u ch a s
Ta n k H e ig h t a n d Ma xi m u m L i q ui d He ig h t in th e d ev i ce .

N ote :

W h e n we i n sta ll e d S ITR A N S P ro be L U a t R O 4 % A ci d Ta n k (PA K GE N ) th e

o p e ra ti o n p e rso nn el co m pl a i n ed th a t the re s p o n se of th e L ev el Tra n sm i tte r
wa s v e ry s l o w. To i n c re a se th e re sp o n se ti me , we c h a n g e d th e v al ue of
p a ra m e te r P 00 3 [Re sp o n se Ti me ], f ro m slo w to m e d i u m. Thi s re ctifi e d the
p ro b l e m.

M o unting Ins tru c tions :

1 . It sh o ul d b e e n s u re d th a t th e so u nd pa th re ma i n s p e rp en di cul a r to th e
m a te ri al b e i ng s en se d .

2 . Id e a l l y, m o u n t S ITR A N S P ro be L U so th a t th e f a ce of th e tran sd u ce r i s
a t le a st 30 0 mm (1 f t) a bo v e the hi gh e s t an ti ci p a te d l eve l .

T r ouble s ho otin g:

If p ro p e r c o m mu ni ca ti o n i s n o t b ei n g e stab li sh ed wi th th e d evi c e

32
1 . C h e c k the f oll o wi n g :
• Th e re i s po we r a t th e un i t
• Th e L C D sh o ws th e re l ev a n t d a ta
• Th e d e vi c e can be p ro g ra mm e d u s in g the h a nd p ro g ra mm e r
2 . V e rif y th a t th e wi ri n g co n n e cti on s a re co rre c t.

In c a se o f a n y o the r e rro r o r f au l t, n o te the f a ul t co d e a n d co n s ul t th e d ev i c e

i n s tru cti o n man u al fo r fu rth e r a cti on .

F L OW MEA S UR E ME NT

Th e me a su re m e n t of f lu i d f lo w i s v e ry i mp o rta n t in p ro ce ss co n tro l . Flo w

m e te rs te l l u s a b o u t th e to ta l f lu id b e i ng co n s u m e d in th e syste m a n d a t
d iffe re n t po in ts.

F L OW S WIT CH ES

A flo w s witc h is detec ts the flow o f s ome f luid through a p ipe. Fl o w

s witc hes often us e “p addles ” as the flow-s ens ing el e ment, the motion o f
wh ic h ac tuates one or more s wi tc h c ontac ts .

F low s witc hes are us ed main l y for the pro te c tion of p u mps . The y
indic ate the flow of Lube (an d c oo ling) water. If th ere is not s uffic ient
flo w of lube wa te r the pu mp (e.g. C W P) wi ll not s tart.

The P M of flo w s wi tc hes is done ann uall y.

F L O W T R AN S MIT T ERS

F low Trans mitters are ins talle d at v arious points in the BO P area to
prov ide a c ontinuous data regarding the flo w ra te and tota l flo w
(v olume) of the proc ess fluid. Thes e tra ns mitters prov ide the flow data
to the D CS or PLC depen ding o n the c ontrol loop o f whic h they are a
part.
There are t wo t ype s of F low meas ure ment dev ic es being c urrently us ed
in the BOP area

· Turbine T ype F lo w Trans mitters

· D P T yp e Fl o w Trans mi tters

T u rb in e T yp e F low T ran sm itters:

Tu rb i n e typ e fl o w me te rs a re v ol u m e tri c-flo w m e a su re me n t d evi c e s. Th e y

i nf e r th e fl o w ra te o f th e fl ui d f ro m the fl u id ve lo ci ty. Th e fi g u re b el o w sh o ws
a tu rb i n e typ e fl o w me te r. Its o p e ra tio n i s d e s cri b ed be lo w

33
 C uta w a y Im a ge of a T ur bine T y pe Flow M e te r

Fl u i d e n te rs th e m e te r f ro m lef t, pa ss i ng th ro u g h the flo w s trai g h te ne r. Th e

stra i g h te n e r d a m p e n s th e tu rb ul e n ce in th e f lu id . The f lu id th en stri k e s th e
ro to r sm o o th l y, ca u si ng i t to sp in . The ra te at wh i c h the ro to r spi n s,
so me ti m e s refe rre d to a s ro ta tio n a l ve loci ty, i s d i re ctl y p ro p o rti on a l to the
v e l o ci ty o f th e fl ui d pa ss i ng th ro u g h the m e te r. A s th e ro to r s pi n s , i ts bl a d e s
ca u se a p u l sa tin g el e c tri cal si g n al to be p ro d u ce d i n th e pi ck up u ni t. The
p i c kup u ni t i s mo u n te d i n l i ne wi th th e ro to r. E a ch ti m e a bl a d e
p a s se s th e h e ad o f th e p i cku p u ni t, i ts pre s e n c e i s sen se d an d a v ol tag e i s
p ro d u ced . A s th e b l a d e mov e s p a st th e pi c kup h e a d , th e vo l tag e d e cre a s e s
u n ti l a n o th e r bl a de mov e s i n to p o si ti o n.

· Th e v el o c ity o f fl ui d fl o wi n g th ro ug h th e me te r i s p ro p o rtio n al to
v o l u me tri c f lo w ra te .
· Th e ro ta ti o na l ve lo city o f th e ro to r i s p ro po rti o na l to fl u i d v e l o ci ty.
· Th e fre q ue n c y o f th e e le c tri cal si g na l p rod u c e d b y th e m a g ne ti c pi c ku p
u n i t i s p ro p o rti o na l to the ro to r’ s sp e ed (rp m).

In thi s wa y b y co m p u ti n g th e f req u en c y o f th e el e ctri c al s ig n al p rod u c ed b y

th e m a gn e ti c p i cku p u ni t we c a n i n fe r th e v o l u me tri c f lo w ra te o f th e flu id .

P M of a T urbine T y pe Flow M e te r:

Th e P M o f Tu rbi ne Typ e fl o w tra n s mi tte rs i s d o n e d u rin g the an n ua l o u ta g e .

Th e P M o f th e tu rb i ne typ e tra n s mi tte r in vo lv e s th e fo ll o wi n g ste p s:

· A p pl y f o r Liv e wo rk P e rm i t
· Iso l a te the pi pe o n wh i ch F T i s i n s tall e d
· N o te th e p o si ti o n of th e tu rbi ne me te r b e fo re ta k in g i t ou t of th e p i p e
· Op e n th e co n n e cto r c o nn e cti n g th e Tu rbi n e Fl o w Me te r to th e p i p e a n d
ta k e ou t the tu rbi n e e le me n t f ro m th e pi pe a n d i m me di a tel y cl o se th e
i s ol a ti n g va lv e .
· C l e a n th e Tu rb in e El e m en t
· R o ta te th e el e m en t an d se e wh e th e r th e Fl o w Me te r sh o ws a ccu ra te
re a d i n g ; th e fl o w me te r s h o u l d sho w ze ro wh e n th e tu rbi ne el e m e n t
sto p s ro ta ti ng
· In s e rt th e tu rb in e e le m e n t i n th e pi p e i n th e sa m e p o s itio n a s b efo re .
· S cre w th e Fl o w Me te r i n to p ro p e r p l a ce

34
N ote : Th e a n gl e of th e e le m e n t sh o ul d n ot b e c ha n g e d o r i t wi l l re sul t in
i n a ccu ra te re ad in g .

D P T yp e F low Meters:

The relations h ip bet ween the D elta P a nd F low is non linear. F low is
direc tly p ropo rtiona l to the s quare roo t of the differenc e in pre ss ure.

Q = k √ ((P 1 -P 2 )/ρ)

PM an d Ca lib ratio n o f DP T yp e F low T ran sm itters:

Th e P M o f Fl o w tra n smi tte rs i s c a rri e d o u t d u ri ng th e a nn u al o u ta g e .

Th e fo l lo wi n g to o l s a re re q ui re d fo r th e ca l ib ra tio n of D P Typ e fl o w
tra n s mi tte rs

S ta n d a rd To ol ki t
P re ss u re S o u rc e
Mu l ti me te r

Fo l l o w th e f ol lo wi n g ste p s to c ali b ra te a DP Typ e F l o w Tra n sm i tte r.

· Ob ta i n a wo rk p e rm i t f o r th e P M o f Fl o w Me te r.
· Inf o rm th e a rea op e ra ti o n e n g i ne e r a b o u t th e j o b .
· C l o se bo th th e Hi g h P re ss u re Si d e a nd L o w P re s su re s i d e v al ve s.
· Op e n th e e q ua li zi n g va l v e.
· C l o se th e eq u ali zi n g v alv e af te r so m e ti me a n d c o nn e ct the p re ss u re
so u rce to th e hi gh p re ss u re si d e .
· C o n n e ct th e d ig i ta l m ul ti m e te r to th e Tra nsm i tte r o u tp u ts.

35
 · A t a m in i mu m p re s su re i np u t o f 0 mm H2 0 th e c u rre n t o u tpu t sho u l d m e
4 mA.
· A t a m a xi m u m p re ssu re in p ut o f 3 0 00 mm H 2 O th e c u rre n t o u tp u t
sh o ul d b e 20 m A .
· Th e p re ss u re an d cu rre n t v a l u e s sho u l d be c h e c ked wi th re f e re n ce to
th e f o ll o wi n g ta bl e .

P e rce n tag e DP C u rre n t

% (m mH 2 0 ) (m A )
0 0 4
25 750 12
50 1500 1 5 .3 14
75 2250 1 7 .8 6
100 3000 20

If th e re i s a d i s cre p a n cy b e twe e n th e ta bl e va lu e s an d th e m e a su re d v a l ue s
th e n :
· R e a d j u st the Up pe r R a n g e V a l u e (U R V) a n d L o w R a n g e V al ue (L R V ) of
th e tra n smi tte r b y u s i ng th e H one yw e ll SFC o r H AR T C om m unic a tor .
· C l o se th e co ve r of th e tra n sm i tte r af te r rec o n n e c ti ng th e su p p l y a n d
si g na l wi re s .

Th e v al u e s g iv e n ab ov e h av e b ee n c al cu la te d b y u s i n g th e fo rmu l a th a t
re l a te s Fl o w R a te to Diff e re ntia l P re s su re.

Q = k√ ((P 1 -P 2 ) /ρ)

N ote : Th e 0 -3 0 0 0 m m H 2 0 p re s su re ra n ge h a s b e e n ta ke n a s a n e xa mp l e ,
th e a ctu al ra n ge o f th e Fl o w T ra n s mi tte r m a y b e d iff e ren t.

T EMN PER AT UR E ME A S UR EMENT

Th e m e a su re me n t of te mp e ra tu re of d iffe re n t e q u i p me n ts a nd p ro c e sse s i s
e s se n ti al f o r p ro c e ss co n trol . Th e re a re rel a tiv el y f e w te mp e ra tu re
tra n s mi tte rs an d sen so rs in sta l le d i n th e B OP A re a . Ho we v e r R TDs h a v e
b e e n i n s tall e d to d e te ct th e wi n d i n g tem p e ra tu re of the mo to rs of CW P .
R TD s a re a l so u se d to m e a s u re th e te mpe ra tu re of C oo li n g To we r Fa n s.

R T D:

Th e e le c tri cal re si s ta n ce of ce rta in m e ta l s ch an ge s a s th e a mb i en t

te m p e ra tu re ch an g e s. T hi s c ha ra c te ri stic i s th e b a si s fo r a te m pe ra tu re -
m e a su ri n g i n stru m e nt ca ll e d a n R TD , o r R e si s ta n ce -Te mp e ra tu re De te cto r.
Th e RT D i s a ki n d of tra n s d u ce r. R TD s co n v e rt te m pe ra tu re ch a ng e s to
v o l tag e si g na l s (u su al l y mi ll v ol ts, o r mV ) b y m e a s u ri n g re si sta n ce .

Th e m a te ri al s u sed i n the R TD m u st b e e xtre me l y p u re , o f u n if o rm q u a l i ty,

sta b le wi th i n a spe cifi c te mp e ra tu re ra ng e , a n d a bl e to giv e rep ro d u ci bl e
re si sta n c e -te m p e ra tu re re a d i ng s. On l y a f e w m e ta l s h a v e the se p ro pe rti e s—
f o r e xa m pl e , p l a ti nu m, c o p p e r, a n d n i ck el . Th e re l a tio n sh i p b et we e n
re si sta n c e a nd te mp e ra tu re i s li n ea r f o r a c e rta in ra ng e of te m pe ra tu re s . Th e

36
ra te a t wh i c h th e re si stan c e in c re a se s a s te m p e ra tu re in cre a s e s d e p e nd s o n
th e s pe c ifi c c h a ra cte ri sti c s of th e m e ta l .

Wh eatsto ne B ridg e C ircu its:

Th e e le ctri c al ci rc ui t co m mo n l y u s e d wi th a p l a ti nu m R TD i s re f e rre d to a s a
W h e a tsto n e b ri d ge . Th e b ri dg e co nv e rts th e R TD ’ s ch a ng e i n re si s ta n c e to a
v o l tag e o u tp u t. Th i s ci rc ui t u se s fo u r se p a ra te e l e ctri ca l re s i sto rs , o ne of
wh i c h i s th e R TD . T h e b ri d g e i s i ni tia l l y b a la n ced , wi th v ol tag e o u tp u t e q u al
to ze ro , b e ca u s e al l fo u r re si sto rs a re e q u al . A s th e re si sta n ce of th e RTD
ch a n ge s , d ue to a te mp e ratu re c h an g e , th e b ri dg e b e co me s u nb al a n c ed ,
re su l ti n g in a v o l ta g e ou tp u t o th e r th a n ze ro .

R e si st a n c e o f R TD ch an g i n g d u e t o Te mp e ra t u re

P M a nd Ca libra tio n of T e mpe r a tur e S e ns ors :

Th e P M o f R TD s i s ca rri e d o u t du ri ng the a n n ua l o u ta g e . A Te m p e ra tu re
C a l ib ra to r (S i m ul a to r) i s u se d to ca li b ra te th e R TDs .

N ote :

Th e wi ri n g strip s of th e R TD s i n sta ll e d on th e CW P (U n i t 2 ) we re ch a n g e d
d u ri n g P a kGe n o u tag e . Th e R TD s we re c a li b ra ted a n d the i r re ad in g s we re
v e ri fie d f ro m the C o n trol R o o m.

A NA L YT IC AL MEA S UR E ME NT

p H & O R P Se ns ors

p H:

A meas ure of the ac i dity of a proc es s li quid as determined b y the

nu mb er of h ydrog en ions ; the negativ e c ommon l ogarith m of the
hyd rogen i on c onc entration in an aq ueous s olu ti on.

The pH v alue of an aqueous (water c ontaini ng) liquid i s an

indic ation of pos itiv e hydrogen ion (H+) ac tiv ity. Read ings of pH i n non-
aqueou s liquids are not me as ures of hydrogen ion a c tiv ity, but are
us eful i n s pec ific s ituations . The mo l ec ules that ma ke up a liquid,

37
whether water alone or wa ter with anot her c hemic al dis s olv ed in it, c an
be partiall y b ro ken do wn i nto s mal ler p artic les referred to as ions .
So me of the mol ec ules in water (H 2O break do wn into t wo different
kin ds of ions , H + (h ydrog en) an d OH - (hydrox yl) .

OR P (O xid ation -R ed u ction Po tential)

OR P is a meas ure o f the ratio of ions th at o x idize to thos e th at reduc e

other c hemic als ; the v alu e (on a lo garith mic s c ale) i n mil l v olts (mV) of
a liquid ’s ox idation o r reduc tion p otential.

T em p eratu re an d p H:

Te mpe rature has a s i gnific ant effec t on pH . Pure water has a pH of 7

only at 25°C (7 7°F ) , wh ic h is referred to as th e s tan dard temp erature.
The dis s oc i ation c ons tant c h anges with c hanges in temperature. This
c aus es the ratio of H+ to O H - ions , and thus the p H v alue , to c hange as
we ll.

pH Anal y zers normal l y inc l ude a temp era tu re detec tor and are c apable
of c alc ulating the pH, by means of a temperature c orrec tion fac tor, as if
the te mperature ac tual ly were 25°C .

Effe ct o f T em peratu re o n p H
valu e
Te mperature, 0 C Neutral pH
0 7.47
25 7.00
50 6.63
75 6.35
100 6.13

Meas urin g p H an d OR P

p H and O RP R eferen ce Elect ro d es

A p H p ro be i s ma d e up of t wo se p a ra te el e ctro de s , a s i s a n ORP p ro b e . Th e
re fe re n ce e le ctro d e i s th e s a me fo r bo th p H a nd ORP p ro b e s, b u t th e
me a su re me n t e l e ctro de s a re di ffe re n t. Th e re fe re n ce e l e ctro d e i s d e si g n e d
to p ro vi de a con sta n t v ol ta g e po te nti al d e sp i te ch a ng e s i n p H o r
te m p e ra tu re . Th i s el e c trod e i s u se d to m o n i to r a n y ch a n ge i n th e to ta l li q u id
p o te ntia l .

38
Th e le a d wi re i s i n an in n e r tu b e th at c o n ta i n s si lve r m e ta l a n d si lve r
ch l o rid e p a ste . Th i s pa s te i s in co n ta ct wi th a sa tu ra te d so l u tio n of
p o ta ssi u m chl o rid e (K CI), wh i ch a c ts a s a n el e ctri ca l b ri d g e to th e so lu tio n
b e i n g mea su re d . Th e p ote n ti a l o f th e re fe re n ce el e ctro de d e p en d s o n
te m p e ra tu re a n d o n th e K C I co n c e ntra tio n.

Th e K C l slo wl y m i g ra te s f ro m th e ref e re n ce e le ctro d e to th e so l u ti on b e i n g

m e a su re d b y me a n s of a li q ui d j un c tion c o n s i sti n g of a p o ro u s ce ra m i c
m a te ri al n e a r th e bo tto m of th e e l e ctrod e . C rysta l s of so l i d K C I i n th e b o tto m
o f th e el e ctro de e n s u re tha t th e sol u ti o n sta ys sa tu ra te d . A p o rta l i s p rov i d e d
f o r re pl e ni sh m en t of th e K C I, a nd a ru bb e r sl e e ve p ro te c ts th e p o rtal f ro m
co n ta mi n a ti on .

p H Measu rem en t Electrod es

Th e p H me a su re m e n t e le c tro d e p ro d u ces a p o te n tia l , wh i ch re l a te s d i re c tl y

to the sol u tio n i n wh i ch i t i s su b me rge d . Me a su re m e n t of th e po te n tia l
re q u i re s a cu rre n t th ro u gh a v e ry h i g h imp e d a n ce a mpl ifie r a n d b a c k to the
p ro c e ss l i q ui d . E le c tri cal c o nn e c ti o n of th e m e a s u rin g ci rc u i t to th e l iq u i d i s
th ro u g h a l iq ui d j u n cti on tha t i s p a rt of the re fe re n ce e le c tro d e.

Th e p H m e a su re me n t el e c tro de h a s a th i n -wa l l e d gl a s s b u l b fi l l ed wi th a
l iq u i d of kn o wn P H, u su a ll y po ta s s iu m c hlor ide (K Cl ). A s il ve r -s il ve r
c hlor ide e l e ctrod e i s i mm e rse d in th e l iq ui d . Th e h yd ro g e n i o n s o n the
i n si d e of th e e l e ctro d e a re of a diff e re nt c o n ce n tra tio n th an the h yd ro g en
i o n s on th e o u tsi de . T h e se io n s wa n t to re a c h e q uil ib ri u m b y mi g ra ti n g
th ro u g h th e g la ss wa l l of the e l e ctro d e u nti l th e co n cen tra tio n s a re th e sa me .

Th i s mi g ra ti o n i s p re v en te d b y th e gl a s s, a n d th u s a p o te n ti al i s e sta bli s h ed .
A p o ten tia l di ffe re n ce a c ro ss th e th in bu l b wi l l o ccu r wh e n th e H + a ctiv ity
i n si d e th e e le c tro d e i s diffe re n t f ro m th e H + a ctiv i ty i n th e l i q ui d to b e
m e a su re d . Be ca u se gl a s s i s a n i n sul a to r, th e bu lb wa l l m u st b e v e ry th i n to
p e rm i t a cc u ra te v ol tag e re ad in g s.

Th e p H me a su re m e n t el e ctro d e ( wh i ch i s u sua l l y a tta ch e d to a hi g h -

i m p e da n ce v o l tme te r) re a cts to a n y ch a n g e in v o l ta g e a n d re po rts i t a s a p H
re a d i n g . Th e p H me a s u re m e n t el e c tro d e h a s a wa te rti g h t s e al a t th e top to
ke e p ou t a n y l i q u id o r m o i stu re tha t c o ul d a ff e ct th e p rob e’ s o pe ra ti o n .

OR P Measu rem en t Electro d e

Th e ORP me a su re m e n t el e ctro d e i s s i mp l y a p l a ti n u m wi re e xp o se d at i ts
b o tto m e n d to th e p ro c e ss li q ui d. Th e OR P re fe re n ce e l e ctro d e i s i d e n ti c al to
th e p H ref e re n ce e l e ctro d e . The ORP m e a s u re me n t el e c tro de re a c ts to
v a ri a ti o n s i n v ol tag e . V o l ta g e v a ri a ti o n s ca u s e d b y v a ri a ti o n s i n th e a ctiv i ty
o f th e o xi di zi n g a n d re du cin g i o n s i n the p ro c e ss li q u id a re a mpl i fi ed a nd
d i s pl a ye d a s th e OR P o f th e l iq u i d .

p H An alyz ers at BO P:

At AES Lal Pir we hav e the fol lowin g p H & OR P Sens ors ins talled in the
BOP Area .

39
Manu fa c turer: Yo kog a wa
Mode l: EX A PH 202
Input: 24 V DC
Ou tp ut: 4~2 0 mA

Manu fa c turer: D KK
Mode l: HD M -135
Input: 24V DC
Ou tp ut: 4~20 mA

Pre ven ti ve Main ten an ce:

The P M of pH meters is c arried out on a fortnightl y bas is . The pH probe

is c l eaned and the pH meter is c alib rated as part of the PM ac tiv ity.
The c ali bratio n proc es s requires the follo wing s olutions and tools

· pH 4.01 s olution
· pH 10.01 s olution
· pH 7.01 s olution
· KCL s olution
· C lean (De minerali zed) W ater b ottl e
· Tis s u e Pap er

C alibratio n Pro ced u re:

1. Ob ta in a Liv e work per mit for the P M o f pH meter.

2. Infor m the area operation engine er,
3. Put the pH meter on Standb y. [The pH reading in C CR wi ll re main
fix ed]
4. Is olate the pH meter.
5. C are fu ll y ta ke out the pH probe fro m th e pipe.
6. C hec k whether the KCL s olu ti on is pres ent in the top of elec trode
or not.
7. If KCL s ol ution is not pres ent or dimin i s hed, refill it.
8. C hec k whether the pH meter is c onfigured for a 2-po int
c ali bratio n (pH 4 & pH 10) .
9. R ins e the tip of elec trode with D e miner ali zed water.
10. C lean the tip of the elec trode with a tis s ue pape r.
11. Pres s the C alibration Button on the pH meter.

40
 12. D ip the pH el ec tro de in a pH 4.0 buffer s olutio n and gently
s tir the s olution with the elec trode .
13. W hen the dis p lay s hows N EX T, pres s the C alibration button
again.
14. Qu ic kl y rins e th e elec trode wi th De mi n e rali zed w ater and
dry it w ith a tis s ue.
15. D ip the elec trode in a pH 10.01 buffer s olution and gen tl y
s tir the s olution til l the dis play b ec o me s no rmal again.
16. Again rins e the elec trode with D e miner ali zed water and dr y
it.
17. Put the probe bac k into the pi pe.
18. R e mov e the is olation and open the v alv e to allow the pH
meter to read the ac tual pH v alue.
19. W hen the pH v alue has s tabilize d, p ut the pH meter on
nor mal mode.

C o n d uctivity

The c onduc tiv ity of a s ubs tanc e is the meas ure of its ab ility to c onduc t
elec tric c urrent. The c onduc tiv i ty o f a s ubs tanc e is th e c o nduc tanc e of
a unit length and u n it c ro ss -s ec tional are a of tha t s ubs tanc e. The
abilit y to meas ure a proc ess liquid ’s c o nduc tiv ity is ess entia l in
c ontrollin g a proc ess s ys tem.

C o nd u ctivity Measu rem en t:

To meas ure c onduc tiv ity in a liquid, you ins ert two plates in the liquid.
As s hown in th e F igu re, thes e plates (c alled elec trodes) are eac h 1 c m
s quare. The p lates mus t be pa rall el to eac h other an d s e para te d from
eac h othe r by 1 c m for c onduc tiv ity to be equal to res is tiv ity.

41
Othe r di mens ions i ntroduc e a multipl ie r, referred to as a c ell c ons tant,
into the c al c ulation. Then yo u app l y a c harge of 1 v olt ac ros s the
plates . The meas ure ment ins tru ment in dic ates the c onduc tiv i ty by
dis pl aying the a mo unt of meas ured c urrent on a meter, s c reen, or
rec order.

C o nd u ctivity Pro b es:

Sev eral kin ds of s ens ors , or probes , are us ed to meas ure the
c onduc tiv ity of a proc es s liquid. The tw o main kin ds are:

Elec trode probe

Induc tiv e (el ec trode-less ) probe.

Electro d e p rob e:

The elec trode probe ope rates by applyi ng a fix ed-amp litude , s quare-
wav e v olt age ac ross two e lec trodes of kno wn s i ze and kno wn
s eparation immers ed in the proc es s liquid (the arrangemen t in F ig. 1-
1) . If th e l iquid c ontains ions , allowing a c urrent to flow, the c u rrent is
meas ured and c onv erted to a c on duc tiv ity readi ng. An a lternating
c urrent is us ed to av oid polarizin g th e l iquid, a c onditio n th at would
ma ke a rea ding i mpos s ible. Po lariz atio n is the produc tion o f a gas eous
layer on the s urfac e of the e lec trodes .

C e ll C ons ta nt:
If the s ize of the el ec trode plates is c hanged, th e amo unt of c u rrent
flo wing bet ween the p lates c hanges . Therefore, the indic ated
c onduc tiv ity c hanges altho ugh the v oltage has not c hanged. This
proc edure is referred to as c hang ing the c ell c ons tant of an ins trument.
Eac h c ell with fix ed elec trod es has its own c ell c on s tant. C ell c o ns tants
range fro m 0.01 to 100 and v ary by mul ti ples of ten. An ins tru ment with
a c ell c ons tant of 0.01 has a ran ge of 1 to 10 mic ro-s iemens , an
ins trument with a c ell c ons tant of 0.1 has a range of 1 to 10 0 mic ro-
s iemens , and an ins trument with a c ell c ons tant of 1.0 c an meas ure 1
to 1000 mic ro-s i emens , and s o on. The lower ranges are us ed for fluids
of l o wer c onduc tiv i ty and the hi gher ranges for thos e of higher

42
c onduc tiv ity. B y c hanging the c ell c ons tant, you c an adapt an
ins trument fo r the range of c ond uc tiv ity of the liqu id you are meas uring.
A c onduc tiv ity probe mus t be mounted s o that it is in direc t c ontac t with
the proc ess liq uid at all ti mes . Eac h prob e is c onnec ted to an indic ator
or trans mitter b y a 3 to 4 wire c able . The ex tra wire(s ) are us ed for
te mperature c ompens ation.

In d u ctive pro b es:

The i nduc tiv e magnetic field p robe , als o referred to as a n elec trode-
les s probe, operates on a different pri nc iple fro m th e elec trode probe.
The induc tiv e probe is made up of two c ompletel y enc l os ed e lec tric al
c oil s . D uring ope ration , the prob e is entirely i mmers ed in the p roc es s
liquid . The probe is enc los ed in a corros ion- res is tant c oating. The
ins trument s end s an alternating c urrent through the pri mar y c oil. This
c urrent c reates an alternating magneti c field that induc es an alternating
c ur rent in the pic kup c oil. The c onduc tiv ity of the proc ess li quid affec ts
the magnetic c oupling between the coi ls . The i nduc ed c urrent in the
pic kup c oil is d irec tly proportional to th e c onduc tiv ity of the liquid .

N o d irec t c ontac t is nec es s ary betwee n the c oi ls and the s olution, thus
reduc ing potentia l maintenanc e proble ms . This s ys tem normall y
trans mi ts a 4 to 20 mA dc s ign al that is pro portio nal to the meas ured
c onduc tiv ity. To c hange the c ell c ons ta nt, yo u c hange the probe. Eac h
probe is c onnec ted to an in dic ator-trans mitter b y a c able with at leas t
s ix wires . T wo pairs of wi res are c onnec ted to the c oils . The remaining
w ire s are u s ed for temperature c ompens ation. Th e indic ator-
trans mi tter s ends a c urrent to the induc tiv e probe. It then reads the
pic kup c oil c urrent, c onv erts that c urrent to c onduc tiv ity, and dis p lays a
reading of the meas urement. The elec trode -les s probe is c orros ion and
eros ion res is tant, bu t requires hi gher c onduc tiv ities and is more
c omplex and c os tly.

C o nd u ctivity Meters in th e B OP Area :

W e are us ing the Co nduc tiv ity Meter s from Yo koga wa and D KK. The
PM of th e c onduc tiv ity meters is do ne annuall y and the y are c alibrated
when required.

H YD R OG E N G A S MO NIT O R

The H ydroge n generation p lant is a v ery c ritic al area of the pl ant. H 2

gas c a n form ex plos iv e mix ture a nd the re alwa ys a ha zard of ex p los ion
in c as e of H 2 gas l eakage. To detec t the le akage of H ydrogen i n the
H ydrogen Build ing we hav e ins talled H 2 gas detec tion s ys tem tha t
c ons is ts of the following parts :

43
H ydrogen Ga s Leak D etec tor (Sens o r)
Beac on 410 G as Moni tor

B eaco n 410 Gas Mon ito r:

Th e B e a co n 4 10 i s a h ig hl y co n fi gu ra bl e , mi cro p ro ce s so r-b a s ed , fl e xi bl e a n d
e a s y to u se 4 c h an n el ga s m o n ito r. It sim u l ta n e ou s l y d i s pl a ys th e g a s typ e ,
re a d i n g s, an d s tatu s f o r 4 ch a nn el s of g a s d e te cti on . It i s co nn e c ted to th e
H 2 se n s o r a n d i t c onv e rts the i r 4 ~20 mA a na lo g si g n al i n to a pp m re a d i ng
th a t i s sh o wn o n th e d i spl a y.

E a c h ch a nn el ha s 3 f ul l y co n fi g u ra bl e a la rm p o in ts. A bu il t-in a u di bl e a l a rm
a l e rts yo u to a l a rm c o n di ti o n s. Ea ch ch a n n e l al s o ha s 2 d e di c a te d f u ll y
co nf ig u ra b l e re la ys a n d th e re i s a b a nk o f c o mm o n re l a ys a s we l l . Th e
co mm o n re l a ys ca n o p ti on al l y b e c o nf ig u re d a s a d di ti o n a l c h an n e l re la ys
a ll o wi n g u p to 3 al a rm re la ys p e r c h a n ne l .

44
 C h ap ter 3: F INAL C O NT R OL EL E ME N T S

C O NT RO L VAL V ES

C ontr ol va l ve s a re v alv e s u s ed to c on trol c o nd i ti o n s s u ch a s fl o w, p re s su re ,

te m p e ra tu re , a n d li q u i d l ev el b y fu ll y o r p a rti all y o p e n i n g o r c l o si n g i n
re sp o n se to sig n al s re ceiv ed f ro m co n tro l le rs.

Th e c o n trol v a lv e m a ni pu la te s a fl o wi n g fl ui d , s u ch a s ga s, s te a m , wa te r, o r
ch e mi c al co m po u n d s, to co m p en s a te fo r th e l o ad di s tu rba n ce a n d ke ep the
re g u l a te d p ro ce ss v a ria bl e a s clo se a s p os si b le to th e d e si re d s e t p oi n t.

C o n tro l v alv e s a re co mp ri s e d o f two m a j o r p a rts : th e va l ve body , wh i ch

co n tai n s al l th e me ch a n i cal co m p on e n ts n e ce ssa ry to i nfl u en ce fl ui d fl o w;
a n d th e va l ve a c tua tor, wh i ch p ro vi de s th e me c ha n i cal po we r n e c e ss a ry to
m o v e th e co m p o ne n ts wi th i n the v a lv e b od y.

C ontr ol Va l ve w ith a P os itione r & I/P C on ve rte r

Th e p u rp o se of a co n tro l v a lve a ctu a to r i s to p rovi d e th e m o tiv e f o rce to

o p e ra te a v alv e me c h an i s m. B o th sl id in g -ste m a n d ro ta ry c o n tro l v alv e s
e n j o y th e s a me s e l e c ti o n of a ctu a to rs: pne uma tic , h yd ra u l i c , e le ctri c m o to r,
a n d ha nd (m a n u a l ).

P n e u ma ti c a ctua to rs u se a i r p re ssu re p u sh i n g ag a i n st ei th e r a f le xi b le
d i a p h ra g m o r a p i s to n to m ove a v alv e me c h a n i sm. Th e ai r p re s su re re q u i re d

45
to mo tiv a te a p n e u ma ti c a ctu a to r ma y c o me di re c tl y f ro m th e ou tpu t o f a
p n e u ma ti c p ro ce ss co n tro l le r, o r f ro m a s i gn al tra n sd u ce r (o r co n v e rte r)
tra n s l a ti ng a n el e ctri c al sig n al in to a n ai r p re ss u re si g n al . S u ch tra n sd u c e rs
a re c o mm o nl y kn o wn a s I/P o r “I to P” c o nv e rte rs, si n ce th e y typ i ca l l y
tra n s l a te an e l e ctri c c u rre n t si g n al (I) o f 4 to 2 0 mA D C i n to a n ai r p re s su re
si g na l (P ) of 3 to 1 5 P S I.

I/P C on ve r te r s :

I/P Co nv e rte rs a re a l so kn o wn a s E le c tro -Pn e u m a ti c Tra n s du c e rs. Th e

tra n s d u ce r re c e ive s a 4 to 2 0 mA D C i n p u t si gn al a n d tra n smi ts a
p ro p o rtio n al 0 .2 to 1 .0 ba r (3 to 1 5 ps ig) p n e u m a ti c ou tp u t p re ssu re to a
fi n a l con tro l el e m e n t (C o n tro l V a l ve ).

V a lve P os itione r :

A P o si tio n e r i s a mo tio n -co n trol dev i ce d e si g n ed to a cti v e l y co mp a re ste m

p o s i ti on a g ai n s t th e c o n trol sig n al , ad j u sti ng p re s su re to th e a c tu a to r
d i a p h ra g m o r pi s to n u n til th e co rre c t ste m p o si ti o n i s re a c h ed . In oth e r
wo rd s , a p o s i ti o n i s a se co nd a ry co n tro l s ys te m1 3 u n to i tself , a cti ng wi th i n
i ts li mi ts to ma in tai n v al v e ste m p o si ti o n i n cl o se c o rre sp o n de n c e to the
co n tro l si g n al ’ s co m ma n d :

P o s i ti on e rs e sse n ti al l y a ct a s con tro l s ys te ms wi th i n the m se lv e s: the v alv e ’ s

ste m p o s i ti on i s th e p ro ce s s v a ri a bl e (P V ), th e c o mm a n d si gn al to th e
p o s i ti on e r i s th e se tp o i nt (S P ), a nd the p o si ti o ne r’ s sig n al to th e v al v e
a c tu a to r i s th e ma n i p ul a te d va ri ab le (MV ) o r o u tp u t. Th u s, wh e n a p ro ce s s
co n tro ll e r se n d s a co m ma n d sig n al to a v a lv e e q ui pp e d wi th a p o si ti o ne r, th e
p o s i ti on e r re ce iv e s th at co m ma n d si g nal an d d oe s i ts b e s t to e n su re the
v a lv e s te m p o si tio n fo ll o ws a l o n g .

C ontr ol Va l ve s a t B OP :

A t AE S La lP ir th e I& C De pa rtme n t i s re sp o n si bl e fo r th e m a in te n a n ce of th e
va lv e a c tua tor a n d th e MMD D e p a rtm e n t i s re sp o n si bl e fo r th e ma in ten a n ce
o f va l ve b ody . N e a rl y a ll th e C o n trol Valv e s (Th ro ttl in g A c ti o n ) i n th e B OP
a re a p ne uma tic a lly ac tua te d wi th a H a nd -J a ck fo r m a nua l a c tua tion.

Th e c o n trol v alv e s i n th e B OP a re a h av e b e e n p rov i d e d b y th e f ol l o wi n g

m a n uf a c tu re rs:

46
 · FIS H E R
· C OP E S V U LC AN
o S e ri e s 9 5 00 , Mo d e l 9 5 01
o P n e u ma ti c , Di a ph ra g m A ctu a te d
o D i re ct o r R e v e rse A c ti n g

Th e P M o f co n trol v a l ve s i s c a rri e d o u t d uri n g o u tag e . Th e f ol lo wi n g sp a re

p a rts mu s t b e rea d i l y av ai la bl e

· D i a p h ra g m
· V a lv e P o si ti o ne r (S p a re P a rts )
· I/P C o nv e rte r (S p a re )
· In s tru me n t Ai r Tu bi n g
· P ro p e r Fi tti ng s
· N u ts a n d B ol ts

P M of C ontr ol V a lve :

Th e fo l lo wi n g to o l s a re re q ui re d fo r th e ma i n te n a n ce of C o n trol Va lv e s

· C o mp l e te To o l kit
· Mi l l ia m p e re C u rre n t So u rc e
· D i g i ta l Te st P re s su re Ga ug e

Th e P re v e ntiv e Ma i n te na n ce o f the C o n tro l Va lve in v olv e s th e f oll o wi n g

ste p s:

· Ob ta i n th e wo rk p e rm i t
· A sk th e C on tro l R oo m o p e ra to r to o p e ra te th e Va lve a n d o b se rve i ts
o p e ra ti o n
· If th e v alv e i s n o t op e ra ti n g p ro pe rl y, re a li g n th e v a lve ste m a nd
ca li b ra te th e I/P co nv e rte r a n d Va lv e P o siti o n e r
· To c a li b ra te th e I/P co nv e rte r gi v e a 4 mA cu rre n t si gn al a t i ts i n pu t
a n d ob se rv e i ts ou tp u t p re ssu re wi th th e D i g i ta l Te st P re s su re Ga u g e ;
th e p re ssu re sh o u l d b e 3 p si g
· A d ju s t the c u rre n t to 2 0 mA ; th e p re ssu re sh o u l d no w b e 1 5 p s i g
· R e p e a t th e fo ll o wi n g ste p s u n ti l th e d evi ce me e ts the a cc u ra cy
re q u i re men ts
· If th e I/P c o nve rte r i s o k a n d th e va lv e i s s ti ll no t wo rki n g p ro p e rl y
o p e n th e ca sin g of th e V a lv e Po s i ti on e r
· C l e a n th e V alv e Po si ti on e r
· A d ju s t the ze ro a n d spa n settin g s of th e va lv e p o si tio n e r
· Op e ra te a n d o b s e rv e th e co n tro l v al v e
· In c a se th e p rob le m i s no t re so lv ed b y c a li b ra ti o n , ch e ck to se e
wh e th e r a n y p a rt re q u i re s re p la c e me n t; an d re p l a ce i t
· C l e a n th e co n trol v a lv e

O N-O F F V AL VE S

47
On - Off V alv e s a re s i mil a r to co n trol v a lv e s b u t th e y a re n o t u s e d fo r
m o d u la ti n g co n tro l , th e y a re o n l y u se d f or o n -o ff c on tro l i .e . a n On -Of f v al v e
wi l l ei th e r b e op e n o r cl o se .

On- Off V a l ve s in the B OP A r e a :

Th e On -Of f v a lv e s in the B OP a re a h av e b e e n p ro v id e d b y th e f o ll o wi n g t wo
m a n uf a c tu re rs

· K e ysto n e
· ITT

P M of the On- Off V a lve s :

Th e P M o f th e se v alv e s i s d o n e o n an a n n u al b a si s . Th e f oll o wi n g p a rts a re

re q u i re d f o r the m a in te na n c e of th e s e va lv e s

· S ta n d a rd To ol ki t
· V a lv e S ea li n g Ki t
· R u b b e r s e ali n g O-ri n g s o f d iff e ren t s tan da rd s i ze s

Th e a c tu a to rs o f th e se v a lv e s a re o p e ne d a nd cl e a n ed . The d a ma g ed se a l s
a re re p l a ce d an d the v a lve i s c le an e d an d g re a s e i s a pp li ed to th e m ov in g
p a rts .

SOL E NOID V AL VES (SO Vs )

A s ole noid va l ve i s a n e le ctro m e ch an i ca l v a lv e f o r u se wi th l i q u id o r g a s.

Th e v alv e i s co n tro ll ed b y a n el e ctri c c u rre n t th rou g h a sol e n oi d co il .
S o le n oi d v a lv e s ma y h a ve t wo o r m o re p o rts: i n th e ca se of a two -p o rt v a l v e
th e f l o w i s s wi tc h e d o n o r off ; i n the c a se o f a th re e -p o rt va lv e , th e o u tf lo w i s
s wi tc h e d b e twe e n th e t wo o u tl e t p o rts. Mu l ti pl e s ol en oi d v a lve s ca n b e
p l a ce d to g e th e r o n a ma nif ol d .

In th e B OP a rea S OV s a re m o stl y u se d to co n trol the f lo w o f a i r to On -Of f

v a lv e s . Th e P M o f th e se v al v e s i s ca rri e d o u t du ri ng th e a nn u a l ou tag e .

ST RO KE CO NT R OL L ER S

S tro ke Co n trol le rs a re d ev i ce s th a t a re u se d to co n trol th e f lo w ra te o f

m e te ri n g p u mp s . S tro ke C o n tro ll e rs a re u se d wi th Po si tiv e D i sp l a ce m e n t
p u m p s th a t a re u se d fo r c h e mi cal d o si n g . S tro ke c o n troll e rs co n tro l the
stro k e s a n d h e n ce the d o si ng ra te o f th e C h e m i cal D o s in g Pu mp .

A t A E S L al Pi r we h a v e f o u r d iffe re n t typ es o f S tro k e C on tro ll e rs i n s tall e d i n

th e B OP a re a .

· N E P TUN E S tro ke Co n trol le rs

· P U L S A MA TIC S tro ke C o n tro ll e rs
· P U L S A FE E DE R S tro ke Co n troll e rs

48
 · OB L S tro ke C o n tro l le rs

N e ptune S tr ok e C ontr olle r :

Th e N e p tu ne E C 5 0 00 & E C 6 0 0 0 Ele ctro n i c S tro ke C on tro ll e r a re bi -

d i re c ti o na l , AC p o we re d , d i g i ta l el e c tro nic l i n ea r a c tu a to rs wi th b u il t-in s e rv o
a m p lif ie rs . Th e S tro ke C o n tro ll e r i s m o un te d o n a N ep tu ne 5 0 0 se rie s o r 6 0 0
se ri e s h yd ra u l i c di ap h ra g m typ e c h e mi c al me te ri ng p u m p . P u mp ca pa ci ty i s
co n tro ll ed b y th e co n tro ll e r's b ru sh l e ss ste p p e r m o to r wh i ch i s di re c tl y
co n n e c te d to th e p u m p co n tro l ro d .

OB L a re th e l a te st s tro ke c on tro ll e rs tha t h av e b e e n in stal le d on R O A ci d

Fe e d pu m p s in La l Pi r a nd Pa kGe n .

P M of S tr ok e C ontr olle r s :

Th e P M o f stro k e co n trol le rs i s ca rri e d out o n an a n n ua l b a si s d u ri n g th e

a n n ua l o u ta g e .

Th e fo l lo wi n g to o l s a n d sp a re p a rts mu s t b e o n h an d fo r th e ma i n te n a n ce o f
stro k e co n trol le rs

· S ta n d a rd To ol ki t
· C o tto n C lo th
· Mi l l i -A mp e re Cu rre n t S ou rce
· In s tru cti on Ma n u al
· E l e c tro n i c C a rd (Sp a re )

Th e fo l lo wi n g step s a re f oll o we d d u ri n g the m a i nte n a n ce of S tro ke

C o n tro ll e rs

· W o rk Pe rmi t i s ob tai n ed .
· Op e ra ti o n e n gi n e e r i s i nfo rme d ab o u t th e j o b .
· Th e c ov e r o f th e stro ke co n troll e r i s o p en e d .
· Th e e l e ctri ca l co n ne c tio n s of th e s tro ke co n tro ll e r a re re mo ve d a n d th e
wi re s a re p ro p e rl y ta g g e d .
· Th e s tro ke c on tro l l e r i s s e pa ra te d f ro m the p u mp a n d b ro u gh t to th e
wo rks h o p f o r ov e rha u l in g .
· Th e s tro ke c on tro l l e r i s di sa ss e m bl e d.
· Th e s tro ke c on tro l l e r i s di li ge n tl y cl e a ne d a n d i ts mov i n g p a rts a re
p ro p e rl y l ub ri ca te d .
· Th e s tro ke c on tro l l e r i s re a s se m bl e d a nd i ts el e c tri c wi re s a re
re co n n e c te d .
· Th e s tro ke c on tro l l e r i s c al ib ra te d .
· Fo r c a l ib ra tio n fo ll o w th e p ro ce d u re g iv e n i n th e i n s tru cti o n ma n ua l .
· A f te r ca li b ra ti on con n e ct th e stro ke co n tro ll e r to th e m e te ri n g p u m p
a n d te st the stro ke con tro l l e r b y g ivi ng a si m u la te d 4 ~20 mA cu rre n t
si g na l a t i ts in p u t.
· If th e s tro ke c o n trol l e r i s o p e ra ti ng a s pe r d e sig n th e n rej o i n th e s tro ke
co n tro ll e r to th e p u m p a n d re ma ke th e e l ectri c a l co n ne c tio n s.

S a fe ty N ote :

49
If we h a v e to go an d wo rk o n a stro k e co ntro l le r wh i l e th e pl a n t i s ru n ni ng
th e f o ll o wi n g m u s t b e ke p t i n mi n d :

· S tro ke co n trol l e rs a re c he m i cal d o si n g pum p s.

· W e s ho ul d re ad the MS D S o f th e c he m i cal b efo re wo rki n g o n th e
stro k e co n trol le r.
· If p o s sib l e , the s tro ke co n trol le r s h o ul d be ta k en o u t of se rv i ce f o r
m a i n ten a n ce .
· W e m u st b e we a ri n g f a ce sh ie ld a nd al l o th e r re q u i re d PP E s.

50
 C h ap ter 4: CO NT R OL SYST EM

D CS

A ll th e ma jo r p u mp s an d d riv e s i n th e B OP a re a a re b ei ng co n tro ll e d b y th e
D C S. F o r i n stan ce

· CWP
· C a n a l W ate r P u m p s
· C l a rifi e r S up pl y P u m p s
· S to rm W a te r Pu mp s
· D e mi n e ral i ze d W a te r Pu mp s S e rvi c e W a te r P u m p s

In a d d i ti on to th i s th e Fi re syste m i n di ca tio n s a n d tan k lev e l in di c a ti o n s a re

a l s o av ai la b l e i n th e CC R .

WAT ER T R EAT ME NT PL C

The D e minerali zati on s ys te m and the RO Sys te m are c ontrolled b y th e

W ater Trea tment PLC s ys te m. The PL C is l oc ated in the W ater
Treat ment MC C.

Man u factu rer:

The PLC s ys te m has been prov ided by ALLEN - BR A DLE Y.

Pro ces so rs:

The proc ess or ins tal led in the W ater Tre atment PL C is PLC 5/30 Ca t #
1785 L30 B/E. Th e s ys te m c ons is ts of redun dant C PU s . O ne of th e
C PU is s erv ic e and the other is s tand by. Both th e proc ess ors are
moun te d in a 4 s lot c has s is .

Pro ces so r Sp ecific atio n s:

Mode l: PLC 5/30 C at # 1 785 L30 B/E

U s er Me mor y W ords Ma x : 32K
Me mory T ypes : Batter y-bac ked s ta ti c RA M, E EPR OM pro gra m bac kup
Total I/O Max :1024
Analog I/O Max : 1024
I/O Sc an Ti me per R ac k: 1 0 ms @ 57.6 kbi t/s

Pow er Su p p ly:

51
Eac h CPU has its own indepe ndent Power Supp l y modu l e. The po wer
s uppl y module is p rov ided ex ternal AC power b y a trans former mounted
ins i de the PLC C abinet.

Sp ecific atio n:

Input Voltage: 220 V AC

Input Voltage R ange: 194-264 V AC
R eal Input Po wer Max : 56 W
Apparent Input Po wer Max : 89 VA
Trans former Load Max : 140 VA

B acku p Co m m un icatio n Mo du le:

Als o mou nted i n th e c hass is i s a Bac kup Co mmunic ation Module (BC M)
C at # 1785-BC M C . The BC Ms of both the proc ess o rs c ommunic ate
w ith ea c h othe r; in c as e the s erv ic e proc es s or goes offlin e due to any
reas on the s ys te m wi ll not be dis rupted and the s tandby proc es s or will
take ov er.

R em o te I/O Ad ap ter Mo d ule:

The I/ O Modules are ins talled in a 16 s lot c hass i s that als o has a
R e mote I/O Adapter Module. The I/Os fro m the field are c onnec ted to a
fus ed wiring ar m. The fus ed wiring a rm prov i des pro te c tion to the I/O
modu les in c as e of s hort c irc ui ti ng in the field. The Re mo te I/O Adap te r
Modu les c ommunic ate direc tly with the C PUs .

C o m m u nicatio n w ith Op erato r Statio n :

The proc ess data is s ent from the C PU s to the d is play s tations o n a
D H+ c o mmunic a ti on lin k at a s pe ed of 57.6Kb p s. The D H+ l i n k is
ins tal led in th e for m of a r ing and all t he C PUs a re c o mmun ic a ti ng with
the ring i .e . the data fro m any PL C proc ess or c an be dis p layed on any
c omputer i n the BO P C ontrol Ro o m (LalPir or Pa kG en) .

Op erato r Station s:

The proc es s p arameters are dis played on two c omputers (on eac h unit)
plac e d in the BO P Contro l roo m. Th e s oftware us ed for s u perv is ory
c ontrol is R SVIE W 32. The s oftware al lo ws operation enginee rs to v i ew
the pro c ess parameters in real ti me, c hange any s et points or c ontrol
(s tart or s top ) any equip ment. The operator s tations are pas s word
protec ted and onl y the relev ant operation engin eers c an ac c ess it.

T ro ub lesh o otin g:

I&C main te nanc e engineers c an troubles hoo t the PLC s ys te m b y us ing

R SLo gix 5. Th e troubles hooting ac tiv iti es ma y inc l ude but are not
li mi te d to :

52
 · Progra mming (to inc orporate c hang es in proc ess )
o To add a new proc e ss loop. To c hange the logic of a
proc es s etc

· F orc ing (an input) during main te nanc e or tes ting

· P ID Loop Tun ing

o To man ipu late the para me ters of a P ID c ontrol loop to
obtain the opti mu m res ults

Hyd ro g en Gen eratio n PL C Sys tem

The H ydrogen Gen eratio n Plan t is c ontrolled by a PLC s ys te m. Th e

PLC s ys te m ba s ic ally c ontrols the Re c tifier and the t wo H 2
C o mpres s ors , and it is a SLC -500 s ys te m.

The PLC at the H 2 Gene ration P lant w as rec ently upgraded during the
Pa kG en Outage.

· H ot W ork Per mit O bta ined

· Liv e W ork Per mit O bta ined
· F ire Man arranged (along w ith F ire Ex tin guis her)
· H 2 Generation Plant was is olated .
· C onnec tion drawing of the O MRO N PL C v erifi ed in the field.
· Eac h and ev ery I/O and po wer s upply w ire was c ompared with the
drawing and found o k.
· The po wer s upply w ires c onnec ted to the OMR ON PLC w ere
re mov ed , properly ta gged and their tip s c ov ered with ins ulation
tape.
· The input and ou tp ut w ires were re mov ed and their tips c ov ered
w ith ins ulation tape .
· The unnec ess ary c ab le trays we re re mov ed.
· The O MRO N PLC and its I/O Modu le were dis mantled fro m the
PLC pa nel.
· N e w drill hol es were drilled for the SL C 5/03 10 -Slot c has s is .
· The SLC 5/03 c hass is was i ns talled in the PLC panel.
· The input and o utput c ables were rerouted w ithin the c ab inet for
eas y and aes thetic wiring.
· The I/O mo dules were ins talled in the c hass is and the i nput and
output w ires were c o nnec ted in their I/O s lo ts c orres ponding to
the new s ys te m.
· Loop Tes ti ng: All the I/O c onnec tions giv en in the drawing we re
v erified phys ic all y.
· The proc es s or c ard was in s erted in its s pec ified s lot.
· The s upp ly wires were c onnec ted.
· The I/O addres s es in the logic were modi fi ed as the phys ic al
arrangement of the I/O modu les had been a ltered .

53
 · The Laptop was c onn ec ted to the CPU .
· C o mmuni c ation initiated us ing R SLinx 2 .
· Progra m do wnloaded.
· After tes ting and troubles hooting the operation engineers were
c all ed and told about the c ompletion of job.
· It wa s agreed that the ne w PL C s ys tem would b e prope rl y
c ommis s i oned.

No te:

A Triac Output C ard was giv ing s ome output v oltage ev en in the OFF
s tate, due to wh ic h ann unc iation LEDs we re alwa ys glo wing. Proble m
was s olv e d by replac ing the TR IAC out put c ard by a R ela y O utput Ca rd.

The SLC 5/03 i s programmed us i ng Ladder Logic in the s o ftware

R SLo gix 500 (v ers ion 8.1) .

The c o mmun ic atio n between L aptop an d SLC was c arried out us ing the
s oftware RSLinx ov er a R S-232 Se rial l in k.

C o m m issio nin g o f the H2 Ge ne ratio n PL C Syste m :

All the protec tions and i nterl oc ks were v erified and found to be ok and
the PLC was wor king as it s ho uld.

System Spe cificatio n s:

I/Os:

D igital Inputs : 02 (1 Di gital Input Modu le 24V D C)

Analog Inputs : 46 (3 Analog Input Mod ules 110V AC)
Analog O utputs : 34 (3 Anal og Output Modu les 110V AC)

Pro ces so r: SLC 5/03

D igital In p u t Mo du le: 8 D igital Inputs (24V) 1 746 IV-8

An alog In p u t Mo d u le: 16 Analog In pu ts 1746 OW -16

54