Process Control Philosophy-Rev-1

ALTERED: SS REV DATE ALTERED:
REV DATE
CHECKED:
The information on this document is the property of BHEL / TiTaN it must not be used directly or indirectly in any way detrimental to the interest of the company
01 10.02.10
CHECKED: GM
STATUS:
CONTRACT
TITAN JOB NO:
TLTD 008
PROCESS CONTROL PHILOSOPHY
FOR
3 x 31 kg/hr SEAWATER BASED ELECTROCHLORINATION PLANT
2010.02.
13
BHARAT HEAVY ELECTRICALS LTD
PROJECT ENGINEERING MANAGEMENT.
This approval status shall be interpreted as laid down in the

contract and it shall not relieve the contractor from the
contractual obligation.
APPROVAL CATEGORY AWARDED = IV
13:51:07
CAT I - Approved
CAT II - Approved With Comments as Noted
CAT III - Not Approved
`COPY RIGHT D CONFIDENTIAL
CAT IV - Reference Drawing

DEPARTMENT MECHANICAL AUXILIARY
GSPC PIPAVAV POWER COMPANY

NAME:
LIMITED
FALGUNI SAHA
+05'30'
TCE Consulting Engineers Limited
700 MW CCPP AT KOVAYA, PIPAVAV, GUJARAT
BHARAT HEAVY ELECTRICALS LIMITED
PROJECTS ENGINEERING MANAGEMENT, NOIDA
TITANIUM TANTALUM PRODUCTS LTD.
86/1, VENGAIVASAL MAIN ROAD, CHENNAI - 600073, INDIA

DEPT CODE
SCALE WEIGHT (KG) REF DRG. ITEM
- - - -
NAME SIGN DATE
PROCESS CONTROL PHILOSOPHY PREP S.Subashini SS 10.02.10

FOR
CHKD G.Murugan GM 10.02.10
ELECTRO CHLORINATION PLANT
APPD G.Murugan GM 10.02.10
BHEL Doc No:
PE-VO-292-174-A001 – ANNEXURE -1
FOR INFORMATION TiTaN Doc No: REV: 01
TTPL/TLTD008/ENG/PD/100000076/101
ANNEXURE -1
DOCUMENT CATEGORY NO OF SHEETS 21 EXCLUDING COVER PAGE
13/02/10 Page 1 of 22
TITANIUM TANTALUM PRODUCTS LTD Doc.No: TTPL/TLSD005/ENG/PD/100000076/101
CHENNAI - 73 SHEET NO: 2 of 2
Rev : 01
Project : 2 x 350 MW CCPP
Client: BHARAT HEAVY ELECTRICALS LIMITED GSPC Pipavav Power Company Ltd.,
Contract No : PW/PE/MM/PIP/P-763/09 TiTaN Job No: TLTD 008
CONTENTS
PAGE NO
1.0 INTRODUCTION 3
2.0 PURPOSE 4
3.0 ELECTROCHLORINATION PLANT 5
4.0 OPERATIONAL & CONTROL OVERVIEW 6
5.0 INSTRUMENTATION & CONTROL PHILOSOPHY 8
6.0 OPERATION AND CONTROL DESCRIPTION 12
7.0 REFERENCE DOCUMENTS 22
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1.0 INTRODUCTION:
Titanium Tantalum Products Ltd (TiTaN), India has been awarded with a contract for design, engineering,
procurement and supply of Electro chlorination Plant by BHARAT HEAVY ELECTRICALS LIMITED for 700 MW (2 x
350 MW) CCPP near Pipavav, Kovaya village, Gujarat. The Electro chlorination plant is designed to prevent bio –
fouling in the condenser, cooling tower and other facilities like Seawater intake, Pretreatment Plant, CW system and
Potable water system. Sodium hypochlorite solution is used for the chlorination / disinfection of the seawater circuit to
prevent bio fouling growth of marine organisms in the seawater facilities.
This document describes the operation and control philosophy of the Electro chlorination Plant.
Electro chlorination plant will be able to generate 3 x 31 kg/h available chlorine in the form of sodium hypochlorite.
Type of plant : Seawater – Skid mounted
Design capacity of the plant : 3 x 31.0 kg/h

3
Operating seawater flow to plant : 29.0 m /h
No of electrolyzer stream in the plant : 3 Nos (3 x 50%)
No of cell in each electrolyzer stream : 1 No
Design hypochlorite production concentration : 1068 mg/L or ppm
Flow rate to be treated : 53,948 m3/h
This hypochlorite generation plant will be designed to generate and deliver to the injection points, at the following
rates.
1. Hypochlorite product as chlorine equivalent based on 1.0 ppm (mg/l) continuous chlorine dosage at
3
i. At Seawater intake for flow rate of : 3552 m /hr
3
ii. CW System for a flow rate : 46780 m /hr
2. Hypochlorite product as chlorine equivalent based on
i. 2.0 ppm (mg/l) continuous chlorine dosage for

3
Pre treatment Plant : 3552 m /hr
ii. 2.0 ppm (mg/l) shock dosage at Seawater intake

3
for 30 min after every 8 hours for a flow rate : 3552 m /hr
iii. 2.0 ppm (mg/l) shock dosage at CW System

3
for 90 min after every 22.5 hours for a flow rate : 46780 m /hr
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2.0 PURPOSE:
The purpose of this document is to explain the Operation and Control Philosophy of the electrochlorination plant. This
document defines the Instrumentation, Control and interlocks provided for safe and effective operation of the plant.
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3.0 ELECTROCHLORINATION PLANT
The electro chlorination plant consists of the following sections: -
a) Seawater inlet: 2 x 100 % seawater booster pumps of horizontal centrifugal type.
b) Seawater filtration: 2 x 100% automatic self-cleaning type seawater filters.
c) AC to DC conversion: 3 x 50% Transformer-rectifiers for providing DC current.
d) Sodium hypochlorite generation: 3 x 50% sodium hypochlorite generators.
e) Sodium hypochlorite storage and H2 dilution system: 2 Nos. hypochlorite storage cum degassing tanks and 2
Nos 2x100% dilution air blowers for hydrogen dilution.
f) Sodium hypochlorite dosing: 8 Nos horizontal centrifugal pumps and 2 positive displacement pumps.
g) Electrolyser cleaning system: 1 x 100% Bulk acid storage tank, 1 x 100% Acid cleaning tank, 2 x 100% Acid
transfer pumps, 2 x 100% Acid Cleaning pump.
h) 2 x 100% Common pit pump is also provided for pumping the drain water to RO-DM Plant.
i) PLC based Local Control Panel.
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4.0 OPERATIONAL & CONTROL OVERVIEW
4.1 Process Description
The chlorination system delivers hypochlorite solution obtained by seawater electrolysis process. The process phases
can be summarized as follows:
• Seawater supply & filtering.
• Electric conversion AC to DC.
• Seawater electrolysis process.
• Hypochlorite storage and dosing.
The seawater is fed to the electrochlorination plant at a pressure of 2.5 – 7.5 kg/cm2 g. If the seawater supply
pressure is 2.5 kg/cm2 g, then the water is pumped by means of seawater booster pumps (1 operating + 1 standby) to
self-cleaning filters at a pressure of 4.0 kg/cm2 g.
This seawater passes through self cleaning filters (1 operating + 1 standby) where all suspended solids with size
bigger than 0.5 mm are filtered.
The flow control valves provided at inlet to each Electrolyser unit will control seawater flow rate.
The filtered seawater is fed to the Electrolyser unit. There are 3 Nos. electrolyser stream having chlorine production
capacity of 31.0 kg/hr (maximum) each. Two-generator unit is continuously in operation and one is standby.
Each Electrolyser stream will have individual transformer-rectifier which will supply DC power to electrolyser in order
to produce sodium hypochlorite from seawater. The DC current from the transformer - rectifier is transferred through
cables / bus bars to the Electrolysers.
The Electrolyser will generate hypochlorite and hydrogen consuming the sodium chloride present in the seawater
when applying DC power.
The active hypochlorite solution is collected in the Sodium Hypochlorite storage cum degassing tank where the
liberated hydrogen gets vented out with air dilution.
This hypochlorite solution is pumped to the hypochlorite solution dosing area by horizontal centrifugal pumps.
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The hydrogen generated with the hypochlorite gets separated in the hypochlorite-storage cum degassing tank. The
dilution air blowers (2 Duty + 2 Standby) are provided in order to dilute the hydrogen stream with air, so as to get a
non-flammable mixture (25% of LEL).
In case of failure of one blower, the other one will start automatically. An automatic interlock will shutdown the rectifier
if both the blowers fail.
.Sampling valves will be provided at the outlet of the electrolyser to take sample for testing the electrolyser
performance.
The side reaction products of the electrolysis process after long periods of operation can accumulate on the
electrodes. They shall be removed dissolving them in a solution of diluted hydrochloric acid that shall be circulated
through the Electrolyser.
The acid cleaning system consists of a bulk storage tank, acid cleaning tank, 2 Nos acid transfer pump and two Nos
acid cleaning pumps, which are hooked up to the Electrolyser units for cleaning.
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5.0 INSTRUMENTATION & CONTROL PHILOSOPHY
5.1 General
The electro chlorination plant is designed to operate continuously at design capacity. The unit will be suitable to
operate satisfactorily between 20% and 100% of design capacity. The unit is controlled through a PLC based control
system.
All controls will be incorporated into a PLC panel. All ON/OFF valves will be equipped with limit switches. This
information will be sent to PLC.
The PLC includes the required D.C power supplies, the alarm systems, a set of control and selector switches and
signalling lamps to fulfil the process control requirements.
5.2 Process Instrumentation Control and Interlocks
Self actuated pressure control provided at seawater supply line of plant inlet will control the downstream pressure in
the range of 3.5 to 4.0 kg/cm2.g (when seawater booster pump is not running) in case of very high seawater supply
pressure. During normal seawater supply pressure (2.5 Kg/cm2.g), this pressure control valve shall be bypassed.
Pressure indicator transmitter provided at the seawater inlet line will deliver alarm in case of high seawater supply
pressure (around 3.5 Kg/cm2.g) which will be an indication for the operator to stop the running seawater booster pump
and open the booster pumps bypass line and simultaneously self actuated pressure control valve shall be taken in
line.
Pressure indicator transmitter provided at the seawater inlet line will deliver alarm in case of high high seawater supply
pressure (around 5.0 Kg/cm2.g) and trip the running electrolysers and close the inlet shutdown valve XSDV 001.
Differential pressure transmitter provided across the self-cleaning strainers will start backwashing at high differential
pressure and deliver alarm in case of high high differential Pressure across the strainers.
Pressure indicator transmitter provided at the each seawater booster pump discharge line will continuously monitor
the seawater booster pump discharge pressure.
Standby seawater booster pump starts in case of running pump trips.
The flow control station provided at the inlet of each Electrolyzer stream will control seawater flow through
Electrolyzers at a preset value. In case of high flow, alarm will be delivered.
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Flow switch provided at the inlet of each Electrolyzer stream will deliver alarm and trip the respective Electrolyzer
stream in case of low flow and close the respective upstream ON-OFF valves with time delay.
Differential pressure indicator transmitter provided across each Electrolyzer stream will deliver alarm and trip the
respective Electrolyzer stream in case of high differential pressure across the Electrolyzer stream and close the
respective upstream ON-OFF valves with time delay.
Temperature indicator transmitter provided at the common seawater supply header after strainers will deliver alarm in
case of high seawater temperature and trip the running Electrolyzer streams, seawater booster pumps and close the
XSDV 001 valve.
Temperature indicator transmitter provided at the outlet of each Electrolyzer stream will deliver alarm in case of higher
temperature than preset value and trip the respective Electrolyzer stream and close the respective upstream ON-OFF
valves with time delay.
Flow transmitter provided at the common discharge header of dilution blowers (B-1001 A/B & B-1002 A/B) will
continuously monitor the airflow. It will deliver alarm in case of low flow and start the standby dilution air blower and
trip the complete plant in case of low airflow persists.
Spare blowers will automatically start when running blower trips.
Hydrogen detector provided near the electrolyzer unit and hypochlorite storage cum degassing tank area, ensure that
the hydrogen concentration in the atmosphere does not cross-allowable limits (25% of LEL). If the preset value is
reached, the whole plant will shutdown automatically.
Flow control station provided at each sets of hypochlorite dosing pump common discharge line will control the dosing
flow continuously as per preset value.
Flow transmitters provided at each sets of hypochlorite dosing pump common discharge line will deliver alarm in case
of low hypochlorite flow or high hypochlorite flow. It will trip the respective running pump in case of low low
hypochlorite flow.
In case of automatic shutdown of the unit, a timer will delay the shutdown of the air dilution blowers.
In case of Low level in the hypochlorite storage cum degassing tank, level transmitter will deliver alarm.
High high level in both hypochlorite storage cum degassing tanks will automatically trip the Electrolyzer streams and
stop the seawater supply.
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Low low level in both the hypo storage cum degassing tanks will automatically stop the sodium hypochlorite dosing
pumps (P-1002A/B/C, P-1003A/B, P-1004A/B/C).
Level transmitter provided in the bulk acid storage tank will deliver alarm in case of low or high level in the tank. Incase
of low low level the running acid transfer pump trips.
Level transmitter provided in the Acid cleaning tank will deliver alarm in case of low or high level in the tank. Incase of
low low level the running acid transfer pump trips.
Rectifier current can be adjusted by the operator for controlling hypochlorite solution concentration by potentiometer
provided in the panel or by setting the value through PLC panel. Rectifier is provided with local indication for Current
and Voltage.
In general while starting the hypochlorite unit the trip interlocks will be bypassed.
The following conditions are incorporated towards automatic stop / trip of the individual stream of electrolysers and its
associated equipments
.
High high seawater inlet pressure
High seawater supply pressure
Low seawater flow at the inlet of Electrolyzer stream
High differential pressure across electrolyser stream
High high solution temperature at the outlet of Electrolyzer stream
Seawater booster pumps trip
Low flow on the blower discharge header line occurs continuously.
High High Level in hypochlorite storage cum degassing tanks.
Loss of power, Transformer trip, Rectifier Failure
The following conditions are incorporated towards automatic shutdown of the complete plant.
H2 is 2.0% near hypochlorite storage cum degassing tanks and Electrolyzers.
Motor failure / stop of both the Air dilution blowers
Emergency plant shutdown by push button.
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The following events shall follow the shutdown of the complete plant as minimum events:
Transformer rectifier switching off
Seawater booster pumps switching off if it is running
Seawater inlet isolation valve (XSDV 001) closing
Running hypochlorite dosing pumps switching off
Dilution Air blowers switching off with time delay
Controls for the hypochlorite dosing pumps will include logic for the pump “tripped” feature to alarm in the event of
pump failure and start the stand by pump automatically.
All the operation of the equipments and drivers will be controlled from the PLC control panel.
5.3 HSE Impact of Design Features

The electrochlorination unit is located at safe area (Non-Hazardous).
Adequate working space will be provided.
In normal operation, the dilution air blower will still run 30 minutes after unit stop as a minimum to dilute
remaining fumes of hydrogen in sodium hypochlorite storage cum degassing tank.
Hydrogen Detectors
Hydrogen Detector gives pre alarm at 38% (1.5% of H2 in Air) LEL (Low Explosive Limit) and alarm with trip at 50% of
LEL (2.0% of H2 in air).
Three nos of Hydrogen detectors are provided in this plant. One is located in the space between two sodium
hypochlorite storage cum degassing tanks and another two are located in between each electrolyzer streams to
ensure that the hydrogen concentration does not cross-allowable limit. If the preset value is reached, whole unit will
be shut automatically.
After electrical power shut-off, the Electrolyzer unit is flushed with seawater for a short period (few minutes) to remove
residual hypochlorite and previously produced hydrogen. The flushed water will be drained to common drain header.
All the drains from strainers, Hypo storage cum degassing tank over flow, drain and Bulk acid storage tank overflow
and drain, Acid cleaning tank overflow and drain, all dosing pumps, acid transfer pump and common pit pump drain
are collected in the Common Pit.
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6.0 OPERATION AND CONTROL DESCRIPTION
The electrochlorination plant basically consists of the following sections:
Seawater supply
Seawater filtration
Sodium hypochlorite generation system
Sodium hypochlorite storage and hydrogen dilution
Acid cleaning system
Sodium hypochlorite dosing system
Acid neutralization system
Description of each section is given in the following paragraphs.
6.1 Seawater Supply System
The seawater shall be taken from seawater supply header. The seawater supply pressure ranges between 2.5
kg/cm2 g to 7.5 kg/cm2 g. Seawater booster pumps will increase the pressure to 3.5 to 4. 0 kg/cm2 g when the inlet
supply pressure is 2.5 kg/cm2 g. Two nos of Sea water Booster pumps (P-1001 A/B) are provided for this purpose.
Impeller and Casing material are made of ASTM A 743 CF8M. Interlock have been provided for Auto start of the stand
by in the event of failure of the operating seawater booster pump.
When seawater supply pressure is 2.5 Kg/cm2.g, the self actuated pressure control valve shall be bypassed and
seawater booster pump bypass line shall be closed.
When seawater supply pressure increases to 3.5 Kg/cm2.g (read through the pressure indicator transmitter PIT-001),
seawater booster pump shall be stopped, pump bypass line shall be opened and self actuated pressure control valve
shall be put in line.
6.2 Seawater Filtration System
The seawater will flow through automatic self-cleaning filter with a mesh suitable to provide 500 micron filtration. The
filtering process is required to protect Electrolyzer cells from debris damage.
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6.2.1 Automatic Self-cleaning Strainers
During normal operation, approximately 58 m3/hr of seawater entering the electrochlorination unit at the pressure of
approximately 3.5 to 4.0 kg/cm2 g is delivered to the self-cleaning strainer.
Strainer vessel contains filtering elements. The filtering elements are mounted as a tube sheet, without moving
clearances. During filtration the raw seawater enters the bottom of the strainer shell and the inner tubes. Solids are
left behind on the inner walls of the filtering elements, while the seawater passes through the filtering mesh towards
the filtered seawater compartment and hence to the outlet nozzle.
As soon as the differential pressure across the clogged strainer reaches the set point of the high-pressure differential
transmitter the backwashing sequence is activated. The strainer motor starts to rotate the backwash assembly and the
backwash outlet valve is opened.
Due to the differential between the pressure in the filtered seawater compartment and the atmospheric pressure
downstream the backwash valve, a reversal flow is established across the filtering elements, so that the seawater
removes and carries the solids out of the strainer to drain.
After completion of this cycle (measured by timer) provided that pressure loss value is lower than the pre-fixed one,
the motor is deactivated and the blow-down valve is closed.
In case the differential pressure value shouldn’t be with the normal values, the cleaning will continue to re-enter
acceptable values.
Backwashing sequence can be operated also manually through switch placed on control panel.
Note: During the backwashing sequence, approximately 10 - 15% inlet flow is discharged through the flush out
valve, while the outlet pressure slightly decreases, but this will not cause any problem to the Electrolyzers because the
flow indicator and controller maintains constant seawater flow-rate to each generator.
6.2.2 Strainer not in Operation
Closing relevant inlet/outlet valves isolates strainer not in operation. The strainer will be filled with fresh water
completely then empty it in order to remove last traces of salts contained in seawater, and finally leave strainer empty
until it is placed in use.
6.2.3 Strainer Under Anomaly
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Only in case that the pressure differential across the strainer is higher than specified, and/or the backwash is not
effective, i.e. strainer anomaly alarm will be given; corrective steps are applied as follows:
A spare strainer of self-cleaning type is provided; which can be put in operation during maintenance of other
strainer.
Start the spare strainer, i.e. fill the strainer previously shut, by opening relevant valves.
Shutdown the strainer under anomaly (by closing relevant isolation valves).
Open vent and drain in order to empty said strainer for maintenance purpose.
6.3 Sodium Hypochlorite Generating System

6.3.1 Electrolyzers
Electro chlorination system consists essentially of 3 x 50% Electrolyzer streams. Each Electrolyzer stream is
connected with a dedicated transformer rectifier unit. Each electrolyser stream is having one electrolyzer cell.
Electrolyzer cells are horizontal modular fins bipolar in construction. The anodes of every bipolar assembly are
directly connected to the cathodes of the next assembly.
The Electrolyzer is connected to rectifier, by means of a set of copper D.C. cables or bus bars. The sodium
hypochlorite production can be continuously controlled, by manually pre-setting the D.C. load on rectifier control panel.
These equipments are designed to achieve the output from each electrolyser stream and match the requirement of
production for continuous and shock dosing. From the generator, sodium hypochlorite solution (and by-product
hydrogen in mixed phase) is sent through the outlet header to the sodium hypochlorite storage and degassing system.
6.3.2 Electrolyzer unit Operation
Seawater is delivered to Electrolyzer stream at a constant flow rate.
Three pneumatically actuated ON-OFF valves XSDV002, XSDV003 and XSDV004 are provided on three Electrolyzer
stream Inlet line respectively for automatic isolation purpose.
Hypochlorite production is controlled, under normal operating conditions, in a range of 20 to 100% of rated capacity.
The chlorine production can be continuously controlled, by pre-setting the D.C. current set point.
Adjustment of D.C. current load is possible, by operating either locally from the rectifier control cubicle, or remotely
from PLC control panel. The D.C. current is automatically kept stable by the rectifier control system at the pre-set
value, with an accuracy of ±2% rated full current.
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6.3.3 Electrolyzer Controls and Interlocks
i. On each Electrolyzer stream inlet, a flow control station is provided to ensure a fine control on the seawater
flow to the Electrolyzer.
ii. Seawater flow to Electrolyzer is monitored by means of a flow switch. In case, seawater flow to the generator
doesn’t remain in a pre-set time range an alarm is given and respective stream will be tripped.
iii. When starting the system, necessary by-pass of the interlock will be provided in order to restore the proper
flow-rate to Electrolyzer. On electrolyser outlet, the pressure line is approximately atmospheric, since the line
is connected to the hypochlorite storage tank, which is vented to the atmosphere.
iv. Temperature transmitter will monitor the temperature on the outlet line of the Electrolyzer; if the temperature is
higher than an adjustable pre-set value, the respective rectifier is automatically tripped.
v. In case, the transformer rectifier unit trips, due to internal faults, D.C. current feed to Electrolyzer is
consequently stopped.
6.4 Sodium Hypochlorite Storage and Hydrogen Dilution System
6.4.1 Sodium hypochlorite storage cum degassing Tank
The produced sodium hypochlorite solution, together with by-product hydrogen, is sent to the storage system.
Two storage tanks provide the storage for the produced sodium hypochlorite and, in the upper part, the
disengagement of hydrogen gas from the liquid phase.
Both these tanks are connected with each other by using a level equalizer line which will ensure the same level in both
tanks at any point of time
Dosing Pumps suction line is taken from the side of the tanks in order to avoid the heavy carry over of calcium and
magnesium deposits through dosing pumps suction line.
6.4.2 Storage Tank Alarm and Interlock
When there is level fluctuation in the tank, the Electrolyzer units are automatically started or stopped. Level transmitter
makes the regulation during normal operation. As extreme system protection, an overflow nozzle has been installed.
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A high high level in the tank will trip the running Electrolyzer. A low low level alarm in both the tanks will stop the
dosing pumps.
In case of stop of Electrolyzer, seawater feed to Electrolyzer stream is stopped, with time delay, in order to flush
hydrogen. In case of automatic shutdown of the plant, a timer will delay the shutdown of both Dilution air blowers for
approximately 30 minutes.
The H2 detector near the hypochlorite storage cum degassing tank monitors the H2 concentration, if H2 concentration
goes beyond 50% of LEL, it will trip the Electrolyzer.
6.4.1 Dilution Air Blowers
2 x 100% Dilution air blowers are supplied to dilute hydrogen in each tanks (Totally 4 nos). The hydrogen gas
disengages from the liquid phase in the upper part of the tank. One-dilution air blower is continuously operating and
second blower is selected in the standby mode. For operating blower failure, the standby blowers start automatically.
Therefore the tank is flushed by a continuous stream of air, in order to keep the hydrogen content, inside the tank and
vent pipe at about 1% by volume, i.e. well below dangerous level (Lower explosive limit = 4.0% by volume for
hydrogen).
6.4.2 Blower Controls
i. Low airflow transmitter is installed on each blower discharge header line. If the airflow rate reaches a
minimum pre-set value it allows to start the standby one and to stop the duty blower. If the low flow persists,
at the expiry of a pre-set time delay, the low airflow transmitter will trip the rectifier and alarm is given too.
Seawater booster pumps are stopped and XSDV 001 is closed.
ii. In case of motor failure / stop of the operating blower, the standby blower starts automatically. If both blowers
fail, an acoustic and visual alarm is activated, rectifiers tripped, generators tripped, seawater booster pumps
are stopped and XSDV 001 is closed.
iii. Air flow transmitters FT 008 / 009 will cut-off the DC current supply to the generating unit after the expiry of the
pre-determination delay in the event of persistent low air flow after starting the standby dilution air blowers.
6.5 Sodium Hypochlorite Dosing System
i. Eight centrifugal pumps P-1002 A/B/C of 4.0 m3/hr capacity (each), P-1003 A/B of 7.5 m3/hr capacity (each),
P-1004 A/B/C of 50 m3/hr capacity (each) are provided for continuous and shock dosing. Two nos of metering
pumps with capacity 10 LPH (each) is provided for treating potable water system. Sodium hypochlorite
solution is dosed to seawater intake system and Cooling water from storage tanks at the rate of 1.0 ppm
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during continuous dosing and 2.0 ppm during shock dosing. During continuous dosing one out of three pumps
will be running and during shock dosing two out of three pumps will be running.
ii. Sodium hypochlorite solution is dosed to pre treatment plant from tanks at the rate of 1.0 ppm during
continuous dosing .The commercial hypochlorite from its storage tank is dosed at the rate of 1 ppm to potable
water system.
iii. Hypo storage cum degassing tank level should be maintained for operating the continuous dosing pump; if the
level of the tank reaches very low in both the tanks then the running dosing pump is tripped.
iv. The stand by pump will start automatically in the event of failure of the operating one.
v. A timer starts the shock dosing pumps, automatically by logic. Timer is started for 30 minutes and after 30
minutes the shock dosing pumps are stopped. This timer is started every 8 hours of interval for Seawater
intake and CW system.
vi. Hypo storage cum degassing tank level should be maintained for operating the shock-dosing pump; if the
level of the tank reaches very low in both the storage tanks then the dosing pump is tripped.
vii. The standby pump will start automatically in the event of failure of the operating one.
viii. Auto stoke adjustment of potable water dosing pump (P-1005 A/B) based on the feed back of chlorine sensor
located at the Service water storage tank.
01
6.5.1 Pumps Regulations and Safety Interlocks
i. Hand operated valve on discharge side of pump is opened during pump start-up, shortly after the motor switch
on. Please note that during pump first start-up hand valves on discharge side must be preferably closed, in
order to prime the pump.
ii. On the contrary, before stopping the pump (for example for maintenance), the discharge valve is gradually
closed. Then the motor is switched off immediately.
iii. If operating pump fails due to motor failure, the stand-by pump is automatically started, and alarm is given to
warn the operator. Then investigation has to be done, by the operator, in order to verify the cause of the
problem.
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iv. In case of very low level in sodium hypochlorite storage cum degassing tank, all dosing pumps are stopped.
Dosing system is re-started after the investigation and after the proper level in tank has been restored.
6.6 Transformer-rectifiers
6.6.1 General
Three independent transformer-rectifier units are provided one for each electrolyser stream. Each unit is
designed to feed relevant electrolyser stream with D.C. current, which can be continuously and automatically
controlled.
Each unit consists essentially of:
One rectifier transformer;
One silicon thyristor controlled rectifier.
All the units are installed indoor.
The automatic control system allows holding the pre-set D.C. current with an accuracy of +1% rated full
current.
The cubicle incorporates a control panel, which includes alarms, trips, and metering and control equipment, to
properly protect and check the unit. One emergency stop push-button is located on each T/R cubicle.
6.6.2 Input/output signals between TR and PLC control panel
The following input/output signals are rendered to PLC control panel:

i. Cumulative fault alarm signal for rectifier and/or transformer trips to PLC
ii. Digital feedback signal of rectifier “ON or RUNNING” to PLC
iii. Digital feedback signal of rectifier “OFF or STOP” to PLC
iv. Digital signal from PLC to TR for rectifier START
v. Digital signal from PLC to TR for rectifier STOP
vi. Trip signal to rectifier from process side (from PLC;
vii. Analog signal from PLC to Rectifier for controlling the DC current.
viii. Analog signal from Rectifier to PLC for DC current feedback.
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ix. Analog signal from Rectifier to PLC for DC voltage feedback.
6.7 Electrolyzer Cleaning System
6.7.1 General Description
It is well known that the generation of active chlorine by electrolysis of seawater are fouled by precipitation on the
cathodes of hydroxides and carbonates of cations, such magnesium and calcium, present in the feed solution. The
fouling rate mainly depends on:
Cathodic current density;
Seawater chemical composition, temperature and flow-rate through the Electrolyzers;
Material and surface finishing of the cathodes.
For these reasons, the Electrolyzer units will be equipped with facilities to dissolve and remove any fouling that takes
place within the Electrolyzers.
The cleaning of the Electrolyzers does not require any dismantling and it is done by circulating through the
Electrolyzers a dilute hydrochloric acid solution (6% HCI by weight).
The system shall be acid washed on a routine basis.
The duration and frequency of acid washing is dependent on the seawater chemical composition and temperature and
on current density. The field experience will determine the best duration and frequency. Based on previous
experience, the expected cleaning frequency is about once every 3 to 4 weeks. Acid cleaning the cells frequently will
not be considered as a problem but not cleaning them can lead to problem.
Remarks
Acid washing prevents possible troubles related to progressive scaling of the electrodic package, i.e. the increase of
operating voltages, the plugging of the path between the electrodes and hence uneven distribution of flow and current
to the electrodes.
Prolonged operation under those anomalous conditions will lead to an increase of power consumption, quick damage
of anodic coating and even short circuits between anodes and cathodes.
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If acid cleaning is not performed every month, or its time (duration should be approximately one hour and half) and/or
acid concentration are not sufficient (much less than 6%), salt deposits will lead to hard scaling problems of
electrodes. Therefore, subsequent cleaning cycles could not be effective, if path between adjacent electrodes is
completely blocked.
During acid washing, HCl will reduce its concentration. The best washing efficiency obtained by using HCI between
6% and 4% (minimum) by weight, because the lower is the concentration; the longer is the time to dissolve
precipitates.
Moreover at a concentration less than 4% w/w, HCI efficiency in dissolving scales is very poor.
6.7.2 Hydrochloric Acid Cleaning Equipments
The system is mainly composed of:
One bulk acid storage tank

One Acid cleaning tank;
Two hydrochloric acid circulating pumps (1 working and 1 standby);
6.7.3 Acid Cleaning Operation
Acid cleaning will be performed on one Electrolyzer unit at a time. The operation is manual. When
Electrolyzer unit is to be Acid washed, the operator should proceed as follows:
i. Isolate power from the rectifier (seawater still running) to the Electrolyzer stream.
ii. Close upstream ON-OFF valves and downstream isolation valves of the Electrolyzer stream.
iii. Flush the electrolyser using service water by opening the respective valves for at least 15 minutes
iv. Once flushing is over, Drain the electrolyser completely.
v. Check the level of HCl acid cleaning tank.
vi. Start acid cleaning pump in operation, in order to recycle HCI solution to acid tank. In this condition,
hydrochloric acid solution is well homogenized. Moreover operator should check, by chemical analysis, actual
concentration of HCI solution; in case concentration is less than 4 to 3.5% w/w, operator should renew
solution, or it should be strengthen to solution of 6% w/w, by adding concentrated hydrochloric acid.
vii. Open all manual valves from acid tank to Electrolyzer unit and back to tank.
viii. Re-circulate, by means of acid cleaning pump, 6% w/w hydrochloric acid solution through electrolyser for
approximately one and half hour.
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ix. Stop circulating HCI solution through Electrolyzer.
x. When this operation is over, stop and isolate acid system, by tightly closing hand-operated valves, and start to
flush Electrolyzer with service water again. Washing service water is discharged through drain to common pit.
xi. At the end, fill the Electrolyzer unit with seawater and prepare it for a new operating cycle.
Remarks
Before starting acid cleaning, electrical power is shut-off, the Electrolyzer is flushed with service water for a short
period (15 minutes) to remove residual hypochlorite and, more important, to flush all the previously produced
hydrogen.
Operator must verify that the interconnecting valves of hydrochloric acid system to generator skids are tightly closed,
to prevent direct contact between HCI and NaOCI that can lead to evolution of gas chlorine, which may be irritating to
eyes and mucous membranes.
6.7.4 Preparation of 6% Hydrochloric Acid Solution
Commercial grade Hydrochloric acid is pump through the pump (P-1007 A/B) to Bulk acid storage Tank (T-1003)
Required quantity of service water is filled in the Acid cleaning Tank. Then calculated quantity of commercial grade
Hydrochloric acid is drawn in to the Acid cleaning Tank (T-1002).The level in the tank is measured by the level
indicator provided in the tank. Operator should start hydrochloric acid pump, in order to recycle the 6% w/w to the
tank. At this condition hydrochloric acid solution is well homogenized.
Interlocks have been provided for both the tanks T-1002 & T-1003. Incase of low level in the tank alarm will be given.
For low low level in the tank respective pump will be tripped in order to avoid dry run of the pump.
COMMON PIT:
The gravity drain from Seawater booster pump , Hypochlorite dosing pumps and electrolyzer drain line are routed to
Common pit.The pressured drain from Sea water strainer and flushing line from electrolyzer is also collected in the
common pit.Drain from Acid transfer pump and Acid cleaning pump is also collected separately in the common pit.
The collected drain in the common pit is pumped to RO-DM PLANT N-PIT. Interlock has been provided for auto start
of standby common pit pump incase of failureof the running pump.
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Rev : 01
7.0 REFERENCE DOCUMENTS
• Process Design Basis and Sizing Calculation.
• Piping and Instrumentation Diagram
13/02/10 Page 22 of 22

Process Control Philosophy-Rev-1

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What is the purpose of the electrochlorination plant?

What is the purpose of the electrochlorination plant?

What are the main components of the electrochlorination plant?

What are the main components of the electrochlorination plant?

ALTERED: SS REV DATE ALTERED:

PROCESS CONTROL PHILOSOPHY

3 x 31 kg/hr SEAWATER BASED ELECTROCHLORINATION PLANT

This approval status shall be interpreted as laid down in the

CAT IV - Reference Drawing

GSPC PIPAVAV POWER COMPANY

BHARAT HEAVY ELECTRICALS LIMITED

PROJECTS ENGINEERING MANAGEMENT, NOIDA

TITANIUM TANTALUM PRODUCTS LTD.

86/1, VENGAIVASAL MAIN ROAD, CHENNAI - 600073, INDIA

NAME SIGN DATE

PROCESS CONTROL PHILOSOPHY PREP S.Subashini SS 10.02.10

3.0 ELECTROCHLORINATION PLANT 5

4.0 OPERATIONAL & CONTROL OVERVIEW 6

5.0 INSTRUMENTATION & CONTROL PHILOSOPHY 8

6.0 OPERATION AND CONTROL DESCRIPTION 12

7.0 REFERENCE DOCUMENTS 22

Type of plant : Seawater – Skid mounted

Design capacity of the plant : 3 x 31.0 kg/h

2. Hypochlorite product as chlorine equivalent based on

i. 2.0 ppm (mg/l) continuous chlorine dosage for

ii. 2.0 ppm (mg/l) shock dosage at Seawater intake

iii. 2.0 ppm (mg/l) shock dosage at CW System

3.0 ELECTROCHLORINATION PLANT

The electro chlorination plant consists of the following sections: -

a) Seawater inlet: 2 x 100 % seawater booster pumps of horizontal centrifugal type.

b) Seawater filtration: 2 x 100% automatic self-cleaning type seawater filters.

c) AC to DC conversion: 3 x 50% Transformer-rectifiers for providing DC current.

d) Sodium hypochlorite generation: 3 x 50% sodium hypochlorite generators.

i) PLC based Local Control Panel.

4.0 OPERATIONAL & CONTROL OVERVIEW

4.1 Process Description

• Seawater supply & filtering.

• Electric conversion AC to DC.

• Seawater electrolysis process.

• Hypochlorite storage and dosing.

5.0 INSTRUMENTATION & CONTROL PHILOSOPHY

5.2 Process Instrumentation Control and Interlocks

Standby seawater booster pump starts in case of running pump trips.

Spare blowers will automatically start when running blower trips.

High seawater supply pressure

Low seawater flow at the inlet of Electrolyzer stream

High differential pressure across electrolyser stream

High high solution temperature at the outlet of Electrolyzer stream

Seawater booster pumps trip

Low flow on the blower discharge header line occurs continuously.

High High Level in hypochlorite storage cum degassing tanks.

Loss of power, Transformer trip, Rectifier Failure

H2 is 2.0% near hypochlorite storage cum degassing tanks and Electrolyzers.

Motor failure / stop of both the Air dilution blowers

Emergency plant shutdown by push button.

Transformer rectifier switching off

Seawater booster pumps switching off if it is running

Seawater inlet isolation valve (XSDV 001) closing

Running hypochlorite dosing pumps switching off