UGD Control

System
AITZAZ HUSSAIN

Agenda

Process Sequence

Allen Bradley PLC 5/20

Instruments

Process Diagram

Basis for design

NOx Reduction consumption

2*56 m 3/h

Design Flow Rate of UGD

System Design Temp

30 C

Minimum Design Pressure

6 bar

Throughput Cycle

Regeneration

172.3 m 3/h

10 hours
2 hours

ACF

Backwash

t= 10 min

Shut Sevi

Open BWO

Open BWI

Start Filtered Water Pumps

Settle

t= 5 mins

Stop Pumps; Close All valves

CONTD.

Rinse

t= 2 mins

Start 1 filtered water pump

Open FRO valve

Open SEVI

Standby

Stop Filtered Water Pump

Close All valves

Pre-Service Rinse

t= 2 mins

Open FRO

Open SEVI

Start 1 Filter Water Pump

Service

time = Until DP reaches 500 mbar

Close FRO

Open SEVO

Regeneration of Anion & Cation

Cation Compaction

Open CWI/ DAI Valve of Cation

Open WWO Valve

Open CWI for SAC

Start Regen Water Pump

1.5% Acid Injection

t = 25 min

Close CW-SAC of Acid Regen.

Open BBI & BBO

Close BBD Valve

Start one Acid Regen Pumps

3% Acid Injection

t = 25 mins

Acid Regen pump automatically rapms up to 3% requirement

Contd.

Cation Displacement

t = 19 mins

Stop Acid Regen Pump

Close BBI and BBO valves of Acid Regen

Open BBD Valve of Acid Regen

Cation Settlement/ Anion Compaction

Open CWI of anion exchanger

Open WWO Valve for anion

Open CWI-SBA

Modulate Dilution Water Inlet of Caustic Regen

Modulate the Temperature Control Valve of Caustic Regen

Cation Standby/ 4% Caustic Injection

t = 7 min

Close CWI of Caustic Regen

Open BBI and BBO valves of Caustic Regen

Close BBD valve of Caustic Regen

Start 1 Caustic Regen Pump

Cont

Cation Rinse / 4% Caustic Inject

Open SEVI and FRO of Cation

Start filtered water supply pump

Cation Standby / 4% Caustic Inject

t = 20 mins

Stop Filtered water supply

Close SEVI & FRO on Cation ex.

Cation Standby/ Anion Displacement

t = 21 mins

Stop Caustic Regen pump

Close BBI, BBO

Open BBD valve of caustic regen

Cont.

Cation Standby / Anion Settle

t = 10 min

Stop Regeneration water pump

CWI/DCI and WWO valves of anion

Cation Service/ Anion Rinse

t= 4 mins

ACF, Cation and degasifier set up for service

Open SEVI and FRO valves on anion

Start Filtered Water Pump

Start Degasified Water Pump

Cation Standby / Anion Standby

Stop Filtered Water Pump Supply

Stop Degasified Water Transfer Pump

Close All Valves on Cation & Anion

Contd

Cation Service / Anion Preservice Rinse

Approx 5 mins

Open SEVI and SEVO on cation

Open SEVI and FRO on Anion

Open Conductivity Solenoid Valve on Anion

Start 1 Filtered Water Supply Pump

Start 1 Degasified Water Transfer Pump

Trains rinse down until conductivity drops to 5 uS/cm for 45 consecutive

secs.

If above is true, start rinsing mix bed

Normal Operation transferring water into Demin Tank

Regeneration of Mix Bed

Backwash : 10 mins

Settle : 5 mins

Blocking Flow/ Preheat : 13 mins

4% Caustic Inject / 4% Acid Inject : 31 mins

Acid Displacement / 4% Caustic Inject : 21 mins

Acid Displacement / Caustic Displacement : 13 mins

Acid Displacement / Caustic Rinse : 17 mins

Drain Down : 10 mins

Air Mix : 15 mins

Refill : 8 mins

Rinse : 7 mins

Preservice Rinse : 5 mins

Service

Neutralization System

To neutralize demineralization waste within allowable limits

Recycle initiates when pH is high or MMI command

If pH ranges from 6-9 : Blow down

If pH > 9 : Acid Regen Valve Open & Start 1 Acid feed pump

If pH < 6 : Caustic Regen Valve Open & Start 1 Caustic feed

pump

PLC Allen Bradley 5/20

AB PLC 5/20

16K Words memory

512 I/Os (Any mix) or 512 I/Ps and 512 O/Ps (complementary)

Two Channels

Serial Comm.

Fundamentals

HMI : Merely Interactive Display

Dynamic display status of assigned address

Takes user input

HMI

PLC : Brain

Fetch, decode, execute, store

PLC

FIELD
Devices

HMI @ Rousch

AB PLC 5/20

PLC Cycle
START

Housekeeping
Internal checks on
memory, speed and
operation. Service
any communication
requests, etc.

Output Scan
The Output Image data
is transferred to the
external output
circuits, turning the
output devices ON or
OFF.

Input Scan
The status of external inputs
(terminal block voltage) is written
to the Input image (Input file).

Program Scan
Each ladder rung is scanned
using the data in the Input file.
The resulting status (Logic
being solved) is written to the
Output file (Output Image).

Contd.

Selector Switch

Remote

Program

Run

DIP Switches

Always
Of

I/O Modules

Rack Selection

Memory

Rom

Preprogramed with OS

RAM

Contains user program being executed

Fresh Copies of updates

Current Status

Generally battery back-up for storage of retentive data

EEPROM

Back-up program

Program loaded from EEPROM if RAM is cleared or compromised

Number Systems - Revisit

PLC At Rousch

2 Channels

4 Racks (0-3)

8 Slots Per Rack

16 pt I/O modules

8 Points I/O Modules

for Analog Outputs

Memory Addressing

Idea is to inform the processor where the input or output point is

Image Table

Three Types in PLC-5

2 Slot Addressing

1 Slot Addressing

Slot Addressing

2 Slot Addressing

Physically 2 Slots of I/O Module comprises of 1 Group

16 Bits Per two slots or 8 bits per 1 slot per input or output
module

Complementary I/Os

16 point I/O modules can only be used if they complement

i.e if slot 0 is input, slot 1 must be output

2 * 8-point I/O module can be used in any order

1 * 16 point module if need to be used in order that does not

complements then adjacent slot needs to be empty

Assigns one I/O Rack Number to 8 I/O groups

1 Slot Addressing

One group corresponds to one physical slot

Each slot in chassis corresponds to 16 bit in input image

table and 16 bit in output image table

16 Point I/O Modules can be used in any combination

32 Point I/O module can only be used as complementary

pair

8 Point Module would result in fewer I/Os

Assign one I/O rack number to eight I/O Groups

 Slot Addressing

Utilizes Maximum I/Os

2 Words (32 Bits) Corresponds to 1 slot

Therefore, 32 pt I/O Modules can be connected in any order

Assigns 1 Rack number to 4 slots

Usage of 16 & 8 pt I/Os makes it under-utilized

Addressing Summary

1 Slot Addressing is used at Rousch

Instruments

Silica Analyzer

Principally an optical instrument

Sample tube is placed between light source & photodector

Acidic Molybdate is reacted with Silica sample

The absorption spectrum is observed & compared with a sample

of molybdate silica solution with 0 ug/L silica

Samples are compared on basis of absorption and concentration

is estimated

Conductivity Analyzer

Distilled water has low conductivity (0.5- 3uS/cm)

Electrodes with fixed distance

RTD

Electrodes swap charges

pH Probes

pH sensitive part is a glass bulb fused to glass tube

Bufered KCl at pH 7

Silver Chloride wire

Potential is measured between reference &

sample