CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS

MAHAGENCO EFFLUENT TREATMENT PLANT

DOCUMENT CONTROL SHEET

PROJECT 2 X 500 MW BHUSAWAL THERMAL POWER STATION

CLIENT MAHARASTRA STATE POWER GENERATION CO. LTD..

CONSULTANT: TCE, BANGALORE.

DOCUMENT TITLE: CONTROL PHILOSOPHY FOR

EFFLUENT TREATMENT PLANT SECTION

IEIL DOCUMENT NO. : A4-A20154-12-304 D

REV.NO : P0

ENDORSEMENTS

P1

P0 20/05/2010 First Submission MBS RY NPD

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

CONTROL PHILOSOPHY

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A4-A20154-12-304 D Rev: P0
 CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS
MAHAGENCO EFFLUENT TREATMENT PLANT

FOR
EFFLUENT TREATMENT PLANT

The Control Philosophy for the Effluent treatment has following sections listed
below

 Reference Drawings.
 General Description for Effluent treatment Plant
 General Description for Sludge Handling System.
 Control & Monitoring philosophy for ETP from DM-PLC
 Electrical Motor Drive Control Philosophy – 415 V

REFERANCE DRAWINGS:

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

Sr.No Revision
Drawing Title P & ID Number
No
01 P & ID for Effluent Treatment plant A1-A20154-01-12 Rev – R0
06 Equipment Layout for Effluent Treatment A1-A20154-02-04 Rev - 4b
plant
07 Legend Sheet A1-A20154-01-13 Rev - 0

General Description for Pretreatment Plant – Non DM service:

Equipment List :-

SR QUANTITY
Tag Nos. DESCRIPTION
NO in Nos.
1 EQT Waste water collection & equalization tank. 1 no
2 P18 A/B Waste equalization pumps 2 nos
3 P19 A/B HRSCC feed pumps 2 nos
4 HRSCC High rate solid contact clarifier 1 no
5 CWST Clear water storage tank 1 no
6 CFT Centrifuge feed tank 1 no
7 P20 A/B Centrifuge feed pumps 2 nos
8 CENT-4 Centrifuge 1 no
9 TFT TPI feed tank 1 no.
10 P21A/B TPI Feed pump 2 nos
11 TPI Tilted plate interceptor 1 no.

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 CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS
MAHAGENCO EFFLUENT TREATMENT PLANT

12 DT4-C Alum Solution preparation Tank 1 no

DT-3D Polyelectrolyte Solution preparation Tank 1 no
13
14 DT-3E Polyelectrolyte Solution preparation Tank 1 no
15 DP5-A/B Alum Solution Dosing Pumps 2 nos
16 DP6 – A/B Polyelectrolyte Dosing Pumps 2 nos
17 DP7-A/B Polyelectrolyte Dosing Pumps 2 nos

Effluent treatment system is designed to treat maximum influent flow of 427.2 m3/hr of
effluent water from Coal decanter, CT blow down, Boiler blow down, DM /SF/CPU waste,
Brine filter backwash floor washing and miscellaneous services and it is suitable for
manual operation.

ETP plant consist one waste collection cum equalization tank (EQT) ,High rate solid
contact clarifier (HRSCC), Clear water storage tank (CSW), Centrifuge feed tank (CFT) ,
Dewatering centrifuge (CENT), TPI Feed Tank (TFT) Tilted plate Interceptor (TPI)
Chemical dosing system is also provided for dosing of Alum and Polyelectrolyte in HRSCC

The Effluents from various streams (Coal decanter, CT blow down, Boiler blow down,
DM/SF/CPU waste, Brine filter backwash floor washing and miscellaneous services ) is
collected in Compartment –I of EQT, after collection, Effluent is transferred to
Compartment –II of EQT by means of waste equalization pump (P18-A/B).to get uniform
quality of collected effluent, than it get transferred to HRSCC with the help of HRSCC feed
pump ( P19 A/B ). Level switches LS 1204, LS 1205 are for High alarm and low tripping
of respective pumps (P18 A/B, P19 A/B) , Two separate level indicators (LIFB-1201/1202)
are also provided for local monitoring of level in Comp-I & II respectively. Air agitation is
also carried out in both compartments with the help of air blower (B-6 A/B/C)

Effluent from Comp-II of EQT is pumped to HRSCC by means of HRSCC feed pump
(P19A/B). One local flow indicator is provided (FI 1201) at inlet pipe of HRSCC to measure
the flow. The HRSCC is designed for operation with normal rated input of 861.7 m3/hr,
Coagulation and flocculation are the basic process that occurs in HRSCC. Suspended
impurities will get removed from water during the process. Consists of speed reduction
gear drive operated central propeller & agitator to ensure effective coagulation, flocculation
& clarification.

Alum & Polyelectrolyte solution are dosed in the draft tube of HRSCC by means of dosing
pumps DP-5 A/B, DP-6-A/B respectively, in order to have proper coagulation &
flocculation. Dosing of alum & Polyelectrolyte to the system is manually controlled by
adjusting the dosing rate of the respective pumps . Alum and Polyelectrolyte dosing tanks
(DT-4C & DT-3 E) are provided with agitators to facilitate preparation and mixing of
solution. Level switch (LS 1201/1202 ) are provided on DT-4C & DT-3E for high alarm and
low level tripping of dosing pumps DP5-A/B & DP-6 A/B respectively.

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 CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS
MAHAGENCO EFFLUENT TREATMENT PLANT

The clarified water from HRSCC is allowed to flow through the channel to the Clear water
storage tank (CWST). Level switch (LS 1206) is provided in CWST for Low as well as High
alarm at PLC. One float & board type level indicator (LIFB-1203) is also provided for local
monitoring of level.

The clarified water is reused for make of service and ventilation system. Separate service
makeup and ventilation makeup pumps are provided to transfer clarified water to service
and ventilation system respectively. Some part of the clarified water is recycled to use for
dilution of chemicals like Alum and polyelectrolyte in chemical house of ETP.

Instruments like Flow totalizer (FQAH 1201), Conductivity meter (Cond-1201), Turbidity
meter (Turb-1201) & PH meter (PH-1201) are provided at discharge header of service
make up pump to monitor quality of clarified water in PLC

One separate Tilted plate interceptor system is provided for separation of oil from oily
effluent. In this system oily effluent from fuel oiling /transformer area is collected in Tilted
plate interceptor feed tank (TPI feed tank), The oily effluent is than feed to Tilted plate
interceptor (TPI) Unit with the help of TPI feed pump (P21 A/B). Level switch (LS 1208) is
provided at TPI feed tank for High alarm & low tripping of the pump `P21`. Oil separation is
carried out in TPI, the separated oil comes out from oil skimmer continuously, and the
same separated oil will be collected & disposed. Oil free water is transferred to EQT by
gravity for further processing. During separation of oil, some sludge may get separated
from effluent, the same sludge is collected & transferred to centrifuge feed tank for further
dewatering process.

General Description Sludge handling system:

Sludge disposal operation of HRSCC is operated manually. Sludge from HRSCC will be
collected in Centrifuge feed tank (CFT) by gravity through Telescopic Sludge sump (TSS-
HRSCC). CFT is provided with Level switch (LS-1207) for high & low alarm and low level
tripping of centrifuge feed pump (P20-A/B) .Collected sludge is .fed to centrifuge (CENT-4)
for dewatering by help of “centrifuge feed pump” (P20 A/B).
Polyelectrolyte solution is dosed at the inlet of centrifuge by means of dosing pumps (DP-
7-A/B), Dosing of Polyelectrolyte to the system is manually controlled by adjusting the
dosing rate of the pump. Polyelectrolyte dosing tank (DT-3D) is provided with agitator to
facilitate preparation and mixing of solution. Level switch (LS 1203) is provided on DT3-D
for high alarm and low level tripping of dosing pumps DP7-A/B.
The sludge from the centrifuge will be collected & disposed. Clarified water is recycle to
EQT for processing.

Control & Monitoring philosophy for ETP plant

The ETP plant system shall be monitor & controlled by local control panel located in ETP
plant area. As per the operation philosophy mentioned in the tender specifications, the

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A4-A20154-12-304 D Rev: P0
 CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS
MAHAGENCO EFFLUENT TREATMENT PLANT

operation of all valves in ETP system shall be operated in manual mode only.

The PLC based system considered in the philosophy mentioned above identifies control of
some drives as an interlock feature (indicated in the P & ID) and rest will be manual-
based. On/off, trip Indications for drive and instrument high, low alarm will be available on
the Local control panel.

The complete operation logic of monitoring and interlock system is incorporated in the ETP
plant PLC system. The ETP plant equipments shall be operated through the PLC based
Local control panel.

The ETP - PLC for above-mentioned system have following features.

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

communication modules ,cables & non redundant I/O’s
b) The processor shall contain program memory with read/write
capability & shall be solid state RAM with battery back up.
c) The PLC has supervisory functions like MMI which shows the
reading of all analyzer /transmitter, alarm & any abnormalities
etc. All engineering activity for ETP plant shall be carried out
through PLC & operation activity from PLC based Local control
panel in ETP Plant control room.
d) ETP plant status indication will be communicated to the DM-SF
PLC through FO (fiber optic) link. & same will be available in DCS
through DM-SF PLC.

 Electrical Motor Drive Control Philosophy For 415 V Drive –

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

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

Following signal exchange will take place between MCC & PLC.

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 CONTROL PHILOSOPHY FOR 2 X 500 MW BHUSAWAL TPS
MAHAGENCO EFFLUENT TREATMENT PLANT

1. Drive start command for 415 V drive

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

Control Philosophy for Electrical Incoming System –

The status input of relevant electrical equipment & electrical parameter

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

Following signal exchange will take place between Electrical systems – LT

Panels & PLC

a) Status Feedback of Breaker ON

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

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

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