Al-Yamama Co.

Princess Nora Bint Abdul Rahman University

QA/QC Department

RO Plant (7.21.0)
Standard Operating Procedures
1.0 INTRODUCTION
This document describes the control philosophy for the 5,284m3/d
BWRO plant supplied to Princes Nora University for Women. The
information contained in this document should be read in conjunction
with the associated Process and Instrumentation Diagrams

• 12509-PID-001-1/SHT-1 Rev 07 – Submersible Bore Well Pumps Package

• 12509-PID-001-1/SHT-1 Rev 07 – Cooling Towers Package
• 12509-PID-001-1/SHT-1 Rev 07 – Media Filters Feed Pumps
• 12509-PID-001-1/SHT-1 Rev 07 – Acid Dilution / Dosing System
• 12509-PID-001-1/SHT-2 Rev 07 – Multi Media Filters
• 12509-PID-001-1/SHT-2 Rev 07 – Multi Media Backwash System
• 12509-PID-001-1/SHT-2 Rev 07 – Multi Media Air Blower Scouring system
• 12509-PID-001-1/SHT-3 Rev 07 – 5 Micron Cartridge Filters
• 12509-PID-001-1/SHT-3 Rev 07 – High Pressure RO Pumping Systems (HPP)
• 12509-PID-001-1/SHT-4 Rev 07 – RO Membranes Arrangement & Control System
• 12509-PID-001-1/SHT-4 Rev 07 – Drinking Water Blending System
• 12509-PID-001-1/SHT-5 Rev 07 – Chemical Cleaning System
• 12509-PID-001-1/SHT-5 Rev 07 – Drinking Water Transfer System
• 12509-PID-001-1/SHT-5 Rev 07 – Flushing Water System
• 12509-PID-001-1/SHT-5 Rev 07 – Service Water Pumping System
• 12509-PID-001-1/SHT-5 Rev 07 – Delivery Water Transfer Pumps
• 12509-PID-001-1/SHT-5 Rev 07 – Blending Water System
• 12509-PID-001-1/SHT-6 Rev 07 – Anti-scalant Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – SBS Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – Pre-Chlorination Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – Post Chlorination Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – Sulphuric Acid Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – Coagulant Dosing System
• 12509-PID-001-1/SHT-6 Rev 07 – Caustic Soda Dosing System

Control of the entire process will be via a programmable logic controller

(PLC), which is accessed by the operator via a SCADA system. Certain
proprietary equipment will be directly controlled from local control panels
with any required data fed to and from the main PLC.

Most instrumentation will have local indication in addition to that shown on

the SCADA screens.

Standard Operating Issued Date

Rev# 3 Page 1
Procedure 25/12/2018
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QA/QC Department

The water treatment system comprises the following process steps.

• A self-contained bore wells pumping system comprising 2x50% bore well pumps, Variable
Frequency Drives, Transformers, MCC and associated instrumentation, all controlled by a
local control panel, which is in communication with the main SCADA. The bore well pumps
are interlocked with the equalization tanks level transmitters and they will start and stop as
per the level in the equalisation tanks. Pumps operation control philosophy is explained in
appendix A. The system compromises the followings:

2 x Pressure indicators
2 x Pressure indicator transmitters
2 x Flow indicator / transmitter
1 x diversion actuated valve (bore well headers)

• A Pre-chlorination dosing system comprising 2 sets hypochlorite dosing skids each with
2x100% dosing pumps (standby/duty), common dosing tank, common storage tanks and
level controller. Each set is dedicated to dose into one bore well discharge header. PLC
controlled via operator adjustable set points at the SCADA. The system compromises:

2 x 100% dosing pumps (for bore well-1 discharge header)

2 x 100% dosing pumps (for bore well-2 discharge header)
1 x 100% built-In level switch – Low
1 x Hypochlorite storage tank bund level switch (contact - type)
1 x hypochlorite daily dosing tank
1 x Hypochlorite bulk storage tank
1 x flow switch
An induced air cooling system compromising 4 duty cooling towers installed on the top of
the equalization tanks. The cooling towers fans are of fixed speed and each provided with
vibration sensors. The cooling towers are self-contained package with dedicated control
panel. Associated instruments such as temperature transmitters are provided for
temperature monitoring purposes. The system compromises the followings:

4 x 25% cooling units (self-contained package)

2 x Pressure indicator transmitter at the bore wells main header (one
transmitter per header – cooling tower inlet)
2 x Temperature transmitter at the bore wells main header (one transmitter per
header – cooling tower inlet)
2 x equalization tanks
2 x level transmitter (one transmitter per equalization tank)
2 x level switch - High (one switch per equalization tank)
2 x level switch - Low (one switch per equalization tank)
2 x Isolation penstocks – one per tank
4 x actuated inlet isolation valves.

x 50% Brackish water forwarding pumps (filter feed pumps) - (Variable speed drives)
operating in rotation (change over) mode by the PLC as indicated by the number of online
streams. The pumps will be interlocked with the level transmitters of the equalization tank
and the pressure transmitter at the main filter feed pumps discharge header (MMF Inlet).
The system compromises;

Standard Operating Issued Date

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Procedure 25/12/2018
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QA/QC Department

3 x 50% Filter feed pumps

3 Variable Frequency Drives (VFD)
1 x temperature transmitter at FFP suction.
1 x pressure indicator transmitter at the main feed pumps discharge header.

An acid dosing system (Not used as per chemical supplier) comprising 2 x 100% acid
dosing pumps complete with daily dosing tank, bulk storage tank, mixing Tee, flow switch,
motive water pump level controller, flow meters and temperature transmitter. The motive
water pump will be interlocked with the equalisation tank level transmitter, and the dosing
pumps, where the dosing pumps will be interlocked with the flow switch, the temperature
transmitter and the flow meter. Fully PLC controlled. The system compromises:

2 x 100% Acid dosing pumps

1 x Motive water pump
1 x Flow switch
1 x Flow indicator transmitter
1 x Temperature Indicator Transmitter
1 x Acid daily dosing tank
1 x Acid bulk storage tank
1 x built-In level switch – Low
1 x Acid storage tank bund level switch (contact - type)
1 x flow switch

A coagulant dosing system including 2 x 100% ferric chloride dosing pumps complete with
dosing tank, bulk storage tank and level controller. PLC controlled via operator adjustable
set points at the SCADA. The duty pump will be interlocked with the cartridge filters (RO
modules) inlet flow meter which will control the dosing quantity. PLC controlled via operator
adjustable set points at the SCADA. The system compromises:

2 x 100% Coagulant dosing pumps

1 x Coagulant daily dosing tank
1 x Coagulant bulk storage tank
1 x built-In level switch – Low
1 x Coagulant storage tank bund level switch (contact - type)
1 x flow switch

5 x 25% Self- contained multimedia filters each with individual set of automatic operating
valves. The operation of the valves is automatic from the SCADA. All the filters operation is
typical. Filters’ operation will be initiated from the PLC during the normal start-up of the
system. In any case all the filters will be working and the will be backwashed daily (time
based) or every each certain hours decided by the operator. At the same time the filtered
will be backwashed as per the differential pressure (pressure based) if the differential
pressure through the main filters inlet and outlet headers reaches a certain level. The filters
will be interlocked with the pressure transmitters located at their main inlet and out let
headers. Limit switches will communicate with the PLC to show valves status. Operation
philosophy of the multimedia filters and their backwash sequence is mentioned in details in
appendix B. The system compromises:

1 x conductivity analyzer at the MMF main header inlet (monitoring)

5 x Automatic media filters each associated with a set of 6 valves.
1 x Backwash water Reject Flow indicator transmitter (monitoring)
5 x Solenoid / motorized valve (for air venting), one per vessel.

Standard Operating Issued Date

Rev# 3 Page 3
Procedure 25/12/2018
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QA/QC Department

• MMF backwashing system including

1 x Backwash water storage tank T-1/A.
1 x Backwash tank level switch - Low
1 x Backwash tank level switch - High
2 x 100% backwash water pumps
1 x Pressure switch - Low (backwash pump discharge header)
1 x Backwash tank feed inlet motorized valve.
1 x backwash header automatic drain valve

• Air Blowers backwashing system including

2 x 100% Air blowers - FMS
2 x Pressure switch – High (One per blower )
1 x Flow switch at the main discharge header.

• An anti-scalant dosing system including 2 x 100% antiscalant dosing pumps complete with
dosing tank, bulk storage tank and level controller. PLC controlled via operator adjustable
set points at the SCADA. The duty pump will be interlocked with the cartridge filters (RO
modules) inlet flow meter which will control the dosing quantity. PLC controlled as per the
flow meter reading. The system compromises:

2 x 100% antiscalant dosing pumps

1 x anti-scalant daily dosing tank
1 x anti-scalant bulk storage tank
1 x anti-scalant daily dosing tank level switch – Low
1 x anti-scalant storage tank bund level switch (contact - type)
1 x flow switch

• x 50% Cartridge filters, the filtration system compromises:

1 x Oxidation Reduction Potentiometer (ORP) at the main filters feed header

1 x PH analyzer at the main filters feed header
1 x Flow meter at the main filters feed header.
1 x Oxidation Reduction Potentiometer (ORP) at the main filters discharge header

• A SBS dosing system including 3 x 100% SBS dosing pumps complete with dosing tank,
bulk storage tank and level controller. PLC controlled via operator adjustable set points at
the SCADA. Two of the three dosing pumps will be duty pumps and one for the flushing
pumps to be activated manually. The SBS membranes flushing pump will be interlocked with
the flow switch located at the discharge line close to the SBS injection dosing point. The
SBS dosing pumps will be interlocked with the cartridge filters inlet flow meter flow reading
where dosing of the SBS will be proportional to the water flow rate. In case of the flushing
dosing point, any SBS dosing pump, when operated, should be adjusted automatically by
the PLC to dose a certain set quantity (set value) of chemicals. The system compromises:

3 x 100% SBS dosing pumps (duty distribution described above)

1 x SBS daily dosing tank
1 x SBS bulk storage tank
1 x built-In level switch – Low
1 x SBS storage tank bund level switch (contact - type)
1 x Flow switch

Standard Operating Issued Date

Rev# 3 Page 4
Procedure 25/12/2018
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QA/QC Department

• x 50% Reverse Osmosis high pressure pumps (Membranes feed pumps) - (Variable speed
drives), one pump dedicated for each lane with a standby pump for both lanes. The pumps
will be interlocked with their associated pressure transmitter at the discharge header. The
system compromises:

3 x 50% high pressure membranes feed pumps

3 Variable Frequency Drives (VFD)
3 x pressure indicator transmitters (High), one at each pump discharge
header.
3 x low pressure HPP inlet isolation valves
3 x pressure indicator transmitters (low), one at each pump suction header.
2 x Automatic valve (duty/standby pumps change over).
2 x pressure indicator transmitters (high) on per membrane inlet header.

• x 50% (BWRO) Reverse Osmosis Trains. Each train PLC controlled and brought on line
according to demand decided by the operation manager.

Each SWRO train comprising the following components –

• x 50% (2 lanes) RO membrane arrays consisting of RO pressure vessels in parallel with

feed, permeate and concentrate manifolds. Each array including various control
instrumentation and control valves as detailed later in this document. Each RO module
compromises the followings:

A set of RO modules
1 x pressure transmitter (High) at the membranes reject header.
1 x automatic by pass flushing valve – reject header
1 x manual pressure control valve
1 x flow indication transmitter – Reject flow - discharge port
1 x flow indication transmitter – permeate flow - discharge port
1 x conductivity (TDS) analyzer – permeate discharge header

• A predominantly manual RO membrane cleaning facility with various hardwired

safety devices. The main components being -
1 x 100% Chemical Makeup and Recirculation Tank T-
2. 1 x level switch – Low
1 x pH meter.
2 x 100% Chemical Cleaning Recirculation Pump.
1 x 100% 5 microns Guard filter.

1 x 100% product water tank, with two compartments, the water flow from the RO system and
filtered blending line will be diverted into the first (blending) compartment of the product water
tank. The water from the blending compartment will over flow into the second compartment.
The reason for having two compartments is to maintain a certain volume of water in the first
compartment for flushing purposes. The service water booster pumps and the membranes
flushing pumps system will suck water from blending compartment which will maintain high water
level at all the time. the associated equipments and instrument with the product tank are:

1 x 100% product water tank with two equal compartments.

1 x ultra-sonic level transmitter
2 x level switches – low
1 x level switch – Low-Low

Standard Operating Issued Date

Rev# 3 Page 5
Procedure 25/12/2018
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QA/QC Department

1 x electromagnetic flow meter located at the filtered blending water line

1 x automatic flow control modulating valve located at the filtered blending water line

• Service Water Pumping system will pump the water to the service network from the
product water tank (blending compartment). The system will include:
2 x 100% service water pumps
1 x pressure booster vessel
1 x pressure switch

• RO membranes flushing system will provide clean flushing water from the membranes; it will
use water from newly installed flushing tank. The system will include:
2 x 100% Flushing water pumps
1 x pressure switch
1 x flushing tank

• Product water pumping system and it associated instruments. This system will pump
the product blended water from the product water tank to the irrigation tank. The
system compromises:
3 x 100% product water delivery pumps
1 x pressure switch
1 x Flow indicator transmitter
1 x chlorine analyzer
1 x PH analyzer
1 x Conductivity analyzer.

• A caustic soda dosing system (not usable) comprising 2 caustic soda dosing pumps
complete with storage tanks and associated instruments. The dosing flow (quantity)
proportional to the product water flow rate. Fully PLC controlled.
2 x 100% caustic soda dosing pumps
1 x caustic soda daily dosing tank
1 x caustic soda bulk storage tank
1 x built-In level switch – Low
1 x SBS bulk storage tank bund level switch (contact - type)

• A Post Chlorination dosing system comprising 2 hypochlorite dosing pumps complete with
storage tanks and associated instruments. The dosing flow (quantity) proportional to the
product water flow rate. Fully PLC controlled.
2 x 100% hypochlorite dosing pumps
1 x hypochlorite daily dosing tank
1 x hypochlorite bulk storage tank
1 x built-In level switch – Low
1 x hypochlorite bulk storage tank bund level switch (contact – type)

Standard Operating Issued Date

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Procedure 25/12/2018
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QA/QC Department

2.0 PRINCIPLE OF OPERATION

The feed water for the RO system will be provided from deep wells by means of bore hole
submersible pumps. Brackish well water at approximately 60 degrees Celsius will be pumped by
new submersible pumps directly into two pairs of Water Cooling Towers located on the top of the
Equalization Tank Compartments A and B. The Water Cooling Tower Fans operate continuously
whenever pumped flow enters. From the Water Cooling Towers, the water will flow into
collection tanks where it will overflow into the Equalization Tank Compartments.

Cooled water from the Equalization Tank Compartments A and B, will be pumped by
means Filter Feed Pumps into a set of Automatic Multi Media Filters. The Media Filters are
designed as one system that will serve both RO Trains. This gives more flexibility and
provides enough surface area during the backwash cleaning sequence for any of the filters.

From the Media Filters, and under the pressure of the Filter Feed Pumps, the water will
be separated into three streams.

The first stream will bypass the RO modules via a Flow Control Valve and mix directly
with the RO Permeate water.

The second stream will automatically maintain the level of the backwash tank, via level
control using an actuated valve and tank level High and Low Level switches. This
provides backwash water for the Media Filters.

The third stream will be the feed for the RO Trains where it will be separated into two
equal streams. This will initially pass through a separate set of 5-microns Cartridge
Filters. Each part will pass into one separate cartridge filter that is the last protection
barrier for the High Pressure Pump and thus, the Membranes.

Upstream of the 5-microns Cartridge Filters, the feed water will be injected with anti-scalant in
order to reduce the fouling within the membranes, mainly hydroxide and sulphate fouling.

Water from the Cartridge Filters and still under the pressure of the Filter Feed Pumps,
will exit into the High Pressure Pump suction port; at this step, it will be injected with SBS
(Sodium Bisulphite) to remove any Chlorine that might exist in the feed water due to
earlier Pre-Chlorination process.

The High Pressure Pump will then provide the force necessary to drive the Feed
Water through the Pressure

The Vessel and RO Membrane Element will produce the required flow of water at a
recovery rate of about 77%.

Standard Operating Issued Date

Rev# 3 Page 7
Procedure 25/12/2018
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Princess Nora Bint Abdul Rahman University

QA/QC Department

The RO Membrane system has been designed as two separate systems named as
RO Trains. Each RO Train can be operated and controlled individually from the RO
Control Panel.

RO Bypass Line Flow Control

The RO system will produce 5,280m3/day of desalinated water where it will be blended with
filtered raw ground water via the RO Bypass Line to produce 7,080m3/day of blended water at
a maximum TDS of less than 700ppm. The Bypass Line consists of a Flow Control Valve and
a Flow meter that ensures that the correct amount of water is fed to the RO Trains with the
remaining bypassing the RO. The TDS value of the blended water being measured after the
desalinated and raw filtered water has been mixed via the Local Product Tank.

At the SCADA the operator will select the number of RO Trains to operate as well as
the minimum flow rates through the RO Trains.

The Raw Water TDS as well as the Permeate TDS from each operating RO Train is
measured and transmitted to the PLC with the Flow rate and TDS levels being entered on
the SCADA and will be set up at the time of commissioning.

Drinking Water Line Flow Control

The RO system will produce up to 600m3/day of desalinated drinking water to be passed

forward to the Drinking Water Plant. The Drinking Water Line consists of a Flow Control
Valve, pH Monitor and Flow meter to ensure the correct amount of desalinated water is fed
to the Drinking Water Plant. At the SCADA the operator will select the Flow rate (up to a
maximum of 600m3/day to be passed forward to the Drinking Water Plant.

3.0 SYSTEM CONTROLS, INDICATIONS and ALARMS System Controls

and Indications
The system is controlled using an Allen Bradley PLC which is interfaced with a SCADA
which provide control and monitoring of the Plant and displays a graphical representation of
the Plant.

This section of the document is designed to assist the Software Engineer meet all
the requirements for the following:

1. Programming of the Allen Bradley PLC

2. Programming of the Allen Bradley desk mounted SCADA unit

Standard Operating Issued Date

Rev# 3 Page 8
Procedure 25/12/2018
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Princess Nora Bint Abdul Rahman University

QA/QC Department

This document is used to provide the Software Engineer with a working knowledge of
the Plant at PNUFW.

SCADA Controls

Controls and indications on the Control Panel are displayed on the SCADA, with the
following exceptions:

• System Reset Push Button

• Control Panel Emergency Stop Push Button
• Audible Alarm
The primary control position for the RO Plant is from the desk mounted SCADA fitted next
to the Control Panel. The screens programmed into the SCADA gives the operator full
automatic and manual control of the entire plant. The SCADA screens are designed to
minimize the number of key inputs required for the operator to access information. Also via
the use of pop up screens at least two key strokes are required for the operator to change
the status of any item of plant. This design gives the operator confidence to navigate
through the screens and prevents inadvertent starting or stopping of any plant equipment.

Access to screens from which system parameter (Borehole Pump Output Levels, PID
Loop Set Points, etc.) is controlled by password. Operators and Maintenance staff log in
using preset passwords from the Screen Select page.

The Automatic Start sequence is identical for Local Automatic and Remote Automatic
modes, however the Local SCADA Start / Stop Pushbuttons are inhibited when in Remote
Automatic mode and similarly the Remote Start/Stop signals are inhibited when in Remote
Automatic mode.

Emergency Stops are operable in both Local and Remote modes.

Prior to starting the Plant in Automatic mode, the following checks shall be undertaken on
the plant and equipment.

i. Both Borehole Pumps VFD Panels are healthy and ready to run and Duty 1/Duty 2
selected as well as the number of Pumps to run has been selected on the SCADA
ii. Cooling Water Towers Fans selector switches are selected to Auto on the
SCADA and at the MCC

iii. RO Train1/Train 2 has been selected Duty 1/Duty 2 as well as number of RO

Trains to run has been selected on the SCADA
iv. Filter Feed Pumps P1-A/B/C selector switches are switched to Auto on the
SCADA and at the MCC and Duty 1/Duty 2 has been selected on the SCADA

Standard Operating Issued Date

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QA/QC Department

v. H P Pumps P-2A/B/C selector switches are selected to Auto on the SCADA and at
the MCC and Duty 1 and Duty 2 has been selected on the SCADA (HPP-2B is
always standby)

vi. Pre-Chlorine Dosing Pumps DP-1A/B selector switches are switched to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA. Set
the dosage quantity required as PPM (SP)
vii. Pre-Chlorine Pumps DP-2A/B selector switches are switched to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA. Set
the dosage quantity required as PPM (SP).
viii. Post-Chlorine Pumps DP-8A/B selector switches are switched to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA. Set
the dosage quantity required as PPM (SP).
ix. Acid Dosing Pumps DP-3A/B selector switches are switched to Auto on the SCADA
and at the MCC and Duty/Standby has been selected on the SCADA. Set the
dosage quantity required as PPM (SP).
x. Coagulant Dosing Pumps DP-4A/B selector switches are switched to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA. Set
the dosage quantity required as PPM (SP).
xi. Anti-scalant Dosing Pumps DP-6A/B selector switches are selected to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA Set
the dosage quantity required as PPM (SP).
xii. SBS Dosing Pumps DP-7A/B/C selector switches are selected to Auto on the
SCADA and at the MCC and Duty/Standby has been selected on the SCADA. Set
the dosage quantity required as PPM (SP).
xiii. Backwash Pumps P-7A/B selector switches are selected to Auto on the SCADA
and at the MCC and Duty/Standby has been selected on the SCADA
xiv. Backwash Blowers B-1A/B selector switches are selected to Auto on the SCADA
and at the MCC and Duty/Standby has been selected on the SCADA
xv. Delivery Pumps P-3A/B/C selector switches are selected to Auto on the SCADA
and at the MCC and Duty/Standby has been selected on the SCADA

xvi. Multi Media Filters MMF-1/2/...5 selector switches are selected to Auto on the
SCADA.

4.0 EMERGENCY STOP

Standard Operating Issued Date

Rev# 3 Page 10
Procedure 25/12/2018
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Princess Nora Bint Abdul Rahman University

QA/QC Department

The following Red, Mushroom Headed, Stay Put, Twist to Release. Emergency
Stop Pushbuttons are located at the following locations

a. Control Panel
b. Motor Control Centre
c. Customer Emergency Stop Signal d) RO Train 1 Area
d. RO Train 2 Area
e. Borehole Pump 1A VSD Panel g) Borehole Pump 1B VSD Panel
f. Chemical Dosing Area – See Note below:

IF AN EMERGENCY STOP PUSHBUTTON IS OPERATED THE ASSOCIATED

SYSTEM IMMEDIATELY SHUTS DOWN WITHOUT ANY DELAY.

In addition each Pump Motor has a local Emergency Stop Pushbutton installed near to
the associated Pump Motor, which, when activated will stop the particular
Pump/Blower Motor only.

Note:

The Dosing Pumps have 3 no Emergency Stops installed within the Chemical Dosing Area.

5.0 INSTRUMENTS & VALVES

Prior to starting the RO system, the followings check should be made.

• All instruments should indicate healthy.

• All instruments to alarm for fault
• All valves to alarm upon fault or non-confirmation signal.

6.0 – AUTOMATIC OPERATION

6.1 Borehole Pumps and Equalization Tank Level Control

The bore well pumps will be allowed to run if the cooling tower inlet valves satisfy
the condition in the below table (Bore well pumps operating matrix).

NOTE:

• Never run more than one BHP if only one cooling tower is in operation while the
other three cooling towers inlet valves confirm close.
• Never run two bore hole well pumps if one cooling is in operation. At least two
cooling towers will be available to take the flow of the two bore well pumps.

Standard Operating Issued Date

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Procedure 25/12/2018
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QA/QC Department

In any case, the pressure (PIT-1A/B) at the inlet of the cooling towers should
never cross SP-6.1.1. The BHP’s speed should be reduced then.

By Pass Valve CTF-01A CTF-01B CTF-01C CTF-01D BHP-01A BHP-01B

V-12AB V-1 V-2 V-3 V-4 ALLOW TO RUN
CLOSED OPEN OPEN YES NO
CLOSED OPEN CLOSED YES NO

CLOSED CLOSED OPEN YES NO

CLOSED CLOSED CLOSED OFF NO

CLOSED OPEN OPEN NO YES

CLOSED CLOSED OPEN NO YES
CLOSED OPEN CLOSED NO YES
CLOSED CLOSED CLOSED NO NO

OPEN AT LEAST ONE OF FOUR VALVE IS OPEN YES NO

OPEN AT LEAST ONE OF FOUR VALVE IS OPEN NO YES
OPEN AT LEAST ONE OF FOUR VALVE IS OPEN YES YES
OPEN CLOSED CLOSED CLOSED CLOSED NO NO
OPEN OPEN OPEN OPEN OPEN YES YES

Bore Well Pumps Operating Matrix

i. The selected Duty 1 &/or 2 Borehole Pumps start, depending on the available
cooling tower (see below cooling towers valves matrix.
ii. The SCADA Borehole Pump Status Lamp will indicate ‘BOREHOLE
PUMP ½ RUNNING’ – (As Allowed).
iii. If the feed water temperature TIT-1A/B reaches SP-6.1.8, a Control Shutdown
of the BHP’s should be initiated after a delay of 30 minutes.

Standard Operating Issued Date

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QA/QC Department

The selected Borehole Pump(s) operate as per the below description.

Pumps BHP-01A/B will operate as duty/duty to pump the water to the

equalization tank via the cooling towers.

Operation

Borehole Pumps, BHP01A/B will operate as Duty1 and Duty2, where both pumps will
operate to meet the combined output of 9,578.4m3/d. These Pumps will be controlled
by Variable Frequency Drives and the speed will be set to deliver the required Raw
Water flow and pressure at the Water Cooling Towers. The Pumps starting and
stopping will be automatically controlled via the PLC in the RO Control Panel, and will
largely operate independently of the RO Plant so that sufficient Raw Water is available
at all times to feed the RO Plant via the Filter Feed Pumps P-1A/B/C.

The pressure at the Water Cooling Tower is crucial to the safe and efficient running
of the Cooling Towers and the RO Plant. To avoid over pressure from the Borehole
Pumps, Pressure Transmitters PIT-1A/B are installed in the respective pipelines for
monitoring purpose.

Level Transmitters, LIT-1A and LIT-1B in the Equalization Tank Compartments will
monitor the Raw Water Level and control the starting and stopping of the BH
Pumps according to the Tank Level Set points on the SCADA. There are also High
and Low Level Switches in each Tank Compartment as a backup to the Level
Transmitter in the event of its failure.

The Operator will set Duty1 and Duty2 Pump Start and Stop Levels and also a
Tank Set point

Levels:

The BHP’s will be interlocked with the RO filter feed pumps to maintain level in
the equalization tank without the need to continuously start / stop or reduce the
BHP’s speed.

The BHP’s starting point is SP-6.1.2, at or less than this point both BHP’s will start.
The BHP’s stopping point is SP-6.1.3, at this point both BHP’s will stop.

Both BHP’s will restart at set point SP-6.1.4. Both BHP will be working. Above
SP-6.1.4, the BHP’s speed will match FFP speed.

Above SP-6.1.5, if only one FFP is working then reduce both BHP’s speed to match
the FFP speed/flow (considering the minimum allowed BHP’s speed SP-6.1.7).

Standard Operating Issued Date

Rev# 3 Page 13
Procedure 25/12/2018
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At SP-6.1.6, stop one BHP and adjust the running BHP speed to match the FFP speed or
reduce its speed to minimum SP-6.1.7 until it reaches SP-6.1.3 where it stops.

Interlocks

The bore-hole pumps interlock with:

• LSH-17A/B, hard weird to stop the pumps at high level SP-7.1.3.

• LIT-1A/B2, Equalization water tank Ultrasonic level transmitter.
• TIT1A/B, to stop the pumps at SP-7.1.8, with delay.
• PIT-1A/B, to inhibit the pumps at SP-7.1.1.
• V-1/2/3/4 as per the above operating matrix table
Alarms,

• LSH-17A/B, Equalization Tank Level High.

• TIT1A/B, Well Water Temperature Above allowed level.
• PIT-1A/B, Pressure at cooling tower inlet is high
• V-1/2/3/4 additional cooling tower required to be in duty.

6.2 Start Sequence

Starting the RO train/s:

From SCADA, the operator will select to operate the system in Automatic or
Manual mode.

Note: To operate a single RO Train or both trains at the same time, the same start
up procedure to be followed as follows.

If both trains are off line and need to run, then both lanes will start at the same time
as one train, Provided that the Equalization tank/s have enough water (above 60%);

Since both trains are off line, the by-pass blending valve (V-98) should be closed
and will not open until the first RO train is completely running. If the operator select
the system in Auto Mode.

The SCADA System Status Lamp will change to ‘STARTING WATER TREATMENT
PLANT “DUTY 1/2 RO TRAIN” or “DUTY 1 RO & DUTY 2 RO TRAINS”’ when starting in
auto mode (as per product tank level), the PLC should give the operator a period of 5
second to switch to manual mode before starting the execution of the auto mode.

Sequence in starting (1) one R.O. Train or both R.O. Trains at the same.

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i. The PLC will check product tank water level. Three conditions should be satisfied
as follows in order to allow for running the RO train/s (see Delivery pumps
sequence section 9).
a. If level in product tank is more than SP-6.6.7, then two trains to be prepared
to run at the same time.
b. If level in product tank is more than SP-6.6.6, then one train to be prepared
to run,
c. If level in product water tank is SP-6.6.5, none of the trains will be allowed to
start.
Upon confirmation that one or two trains can be run, then the PLC will proceed as follows:

ii. Set all MMF selected Process Operation Valves are opened in the ‘Service
Position’ See Appendix 1 Multimedia Filter Valves Sequence Positions for correct
sequence of valves operation and see the MMF sequence operation.
iii. Start the product water tank sequence with its associated post treatment dosing
if possible (see Delivery pumps sequence, section: 9).
iv. Start the SBS dosing sequence of the train/s to run (see SBS sequence).
v. The filter feed pump/s speed will start at low speed as well (simultaneously) high
pressure pump suction valve/s (V-74 & V-76). If one train to run then the
associated feed pump and HPP suction valve of the running train to open.
vi. Confirm that the flushing valve/s of the associated train to run (valve/s V255 or/& V-
256) is closed.
vii. Upon flushing valve close confirmation, the anti-scalant sequence should start
(see anti-scalant sequence).
viii. The feed pump speed should ramp up at a rate of SP-6.2.12.
ix. The feed pump speed should increase to full speed SP-6.2.4.
x. When the HPP suction pressure is at SP-6.6.10 (lower range) the HPP will start
ramping till it reaches its maximum speed SP-6.2.5. (The HPP speed could start
ramping up at the same time with the feed pump but never reaches it maximum
speed while the feed pump is still ramping up. The HPP ramping up speed is as
per SP-6.2.10.
xi. If the suction pressure does not attain within SP-6.4.4 then the FFP will shut down
(CSD).
xii. Start the coagulant dosing sequence after a preset time delay time SP-6.2.7
(see coagulant sequence).
Now the system (one or both trains) are running.

xiv. After a preset delay start SP-6.2.8 the blending sequence.

Interlocks:

• During the start-up sequence of a single or both RO trains, the PLC should never
execute any backwash sequence of the multimedia filters. In case that the media filter

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backwash is needed (time or pressure base) then the backwash sequence should be
kept on hold until the RO trains are in complete running mode and the blending
sequence is executed.

Sequence to start one Train while the other RO Train is running.

CAUTION: Prior to starting the second lane, the blending sequence (valve) V-98
should be halted. It is very important that the blending valve V-98 does not undergo
and adjustment (close/open) during the start-up of the second lane while the first
train is running. It should be maintained at its current position until the second train
is completely running.

i. Check that the product water tank level is not higher than SP-6.6.5, otherwise
the train start-up will be inhibit to run.
ii. Confirm that the flushing valve/s of the associated train to run (valve/s V255 or V-
256) is closed.
iii. Upon flushing valve close confirmation the HPP inlet suction valve and the filter
feed pump of the associated train to operate should start simultaneously and
the feed pump speed should ramp at a rate of SP-6.2.12.
iv. Feed pumps speed to ramp up to full speed SP-6.2.4.
v. SBS dosing sequence to adjust its flow according to the new feed flow. vi.
Adjust the anti-scalant dosing according to the new flow.
vi. When the HPP suction pressure is at SP-6.6.10 (lower range) the HPP can
start ram pump up to its full speed SP-6.2.5. (The HPP can ramp up with the
FFP providing that the HPP never reaches its full speed while the FFP is still
ramping up).
vii. After a preset delay time SP-6.2.6 adjust the acid dosing according to the
new feed flow.
viii. Adjust the coagulant dosing according to the new feed flow after a preset
time delay time SP-6.2.7 (starting from the acid adjustment step viii).
Now the system (one or both trains) are running

ix. After a preset delay start SP-6.2.8 the blending sequence can start adjusting.

Interlocks:

Any of the flushing valves should never open if the associated HPP is running and
/or if the FFP speed is at SP-6.2.4
HPP inlet valves V-74/75&76 should never close if the associated HPP is ON.

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HPP inlet valves V-74/75&76 should give a feedback confirmation within SP-
6.4.4 from the starting time of the FFP, otherwise the FFP will shut down.
Any running train to inhibit if:

1. Anti-scalant dosing FS-9 in not confirmed, after a delay time SP-6.4. – CSD
2. SBS dosing flow switch FS-10 is not confirmed without any delay – TRIP (delay
start-up of the system).
3. If the ORP-2 above SP-6.1.9, immediate CSD
4. Acid FS-6 is not confirmed, after a delay SP-6.4.3 - CSD

RO Blending Sequence

The RO Blending system will be continuously under adjustment from the PLC by
modulating the blending valve V-98 until the SP-6.2.11 is attained as per the
below blending TDS equation:

Blended TDS Calculations

FIT-3 = {SP-6.2.11 } x {[(FIT-3 + FIT-4 + FIT-5)-(FIT-10)]} - {(Cl-4 x [(FIT-4 + FIT-5)

– (FIT-10)])]} / {Cl-1} Not3:

Note: In the above equation, CI means conductivity NOT chlorine.

FIT-3 reads the flow through the modulating valve V-98. This valve will be actuated
by the PLC.

The valve is 4-20mA, thus, when the valve is completely closed (zero flow) this will
be 4 mA, and when the valve is at maximum opening it will be at 20mA.

Therefore the valve will start opening at a rate of SP-6.2.9 while the PLC will
start executing the equation until the equation is satisfied.

Interlocks:

• In case that the one or both plant are starting up, the blending sequence should
be executed after a complete start up on the lanes.
• If the another train is to start while a train is already running, the blending valve V-
98 should hold its current position (not to adjust – hold its position) until the second
train starts and confirm a complete running, then the blending valve can complete
its tuning sequence according to the new permeate flow.
• The blending valve should be adjusted (including close and open) slowly at slow
rate SP-6.2.9

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6.3 Controlled Shutdown of Complete Water Treatment Plant Sequence – (two

trains running)
In case of automatic shutdown of the system (PLC command), or in case of
manual shutdown by pressing the SCADA ‘Water Treatment Plant Stop’ Button,
the Water Treatment Plant will perform a complete shutdown and the following
procedure shall be followed if both train to shut down together.

Both trains shutting down simultaneously – CSD.

i. The Duty Coagulant Sequence stops.

ii. Close the blending valve slowly SP-6.2.9 until it is completely close. Accordingly
the FFP should adjust their speed to match their operating sequence.
iii. The operating RO Train HP Pumps stop – ramping down at the same ramping
up rate, Simultaneously,
iv. The Duty Anti-scalant and Acid Dosing Pump stops v. Reduce the filter
feed pumps speed to SP-6.2.2.
v. Open the associated Flushing Valves** of the shutting down RO trains for a
period of SP-6.2.3
vi. After a pre-set time SP-6.2.3 the associated flushing valve should closed and
simultaneously the associated feed pump (at reduced speed) should ramp
down slowly SP-6.3.1 until it stops and confirms stopping.
vii. The flushing valves should confirm closed.
viii. Stop the SBS sequence; simultaneously close the shutting down RO Trains
Inlet valves V-74 / V-75 / V-76.
ix. Close the Duty MMF Inlet Valves (See Appendix-1 Multimedia Filter
Valves Sequence Positions for correct sequence of valve operation)
x. The SCADA System Status Lamp will indicate ‘WATER TREATMENT
PLANT STOPPED’
xi. The operational Borehole Pumps will complete to operate as per their
operating sequence.

xii. The product water pumps will complete to operate as per their
operating sequence.

Note:

Any backwashing activities can continue when the Water Treatment

Plant Shutdown signal is activated.

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** Opening of the flushing valves (flushing step) will take place only during
(safe) CSD. In case of immediate (emergency) shut down due to a trip or else,
then the flushing step should not take place.

6.4 RO Train Shutdown Sequence

One train is shutting down while the other is still running. (CSD)

On pressing the SCADA RO Train (either 1 or 2) (manual mode) Stop Button or in

case of auto shut down due to product water tank level, or due to trip that leads to
normal shutdown, the particular RO Train will perform a complete shutdown and
the following procedure shall be followed.

i. The HPP of the RO Train to shutdown stops – ramp down at the same ramping
up rate SP.6.2.10.
ii. The Filter Feed Pump of the shutting down train ramp down its speed to SP-
6.2.2,simultaneously the blending valve V-98 should adjust accordingly
(throttle) at SP-6.4.1 to adjust to the new feed flow (TDS calculations), thus
maintaining SP-6.2.11.
iii. Simultaneously with the feed pump speed ramping down, the Duty Coagulant,
acid and anti-scalant Dosing Pumps flow rates should adjusted according to the
new feed flow rate (see the coagulant, acid & anti-scalant dosing sections).
iv. The filter feed pump of the train that is still in duty should adjust automatically
to the new specification if required (flow & pressure at the HPP inlet)
v. The Flushing Valve opens for a preset time SP-6.2.3
vi. After a pre-set time SP-6.2.3 the operating the operating RO Flushing
Valves closes and simultaneously Filter Feed Pumps should complete
ramping down slowly SP-6.3.1 and. The FFP should keep ramping down
until it stops and confirms stopping.
vii. The flushing valves should confirm closed.
viii. The SBS dosing should adjust to the new feed flow.
ix. The RO Trains Inlet valve of the associated shutting down trains V-74 / V-75 /
V-76 should close and should confirm closing by the PLC.
x. The SCADA System Status Lamp will indicate ‘WATER TREATMENT PLANT
RO TRAIN (1 or 2) TRIPPED or STOPPED’
xi. The operational Borehole Pumps will complete their operation as per their
sequence.
xii. The product water pumps will complete to operate as per their
operating sequence

Caution:

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Upon starting one RO train while the other is still running, the filter feed pump of
the running train should adjust to provide the required flow and pressure for the
running train as per the filter feed pump sequence of operation.

Caution:

The flushing step of the RO train during shut down is only executable during CSD.
In case of interlock trip or any other trip, the shutdown will be immediate without
any flushing step. In this case alarm should be raised that the plant is stopped
without flushing.

6.5 One train is shutting down while the other is OFF.

On pressing the SCADA RO Train (either 1 or 2) Stop Button or in the event of

a single RO product tank level or when there is a CSD, the RO Train will
perform a complete shutdown and the following procedure shall be followed.

i. Close the blending valve slowly SP-6.2.9 until it is completely close.

Accordingly automatically the FFP should adjust their speed to match their
operating sequence (the pressure / flow at the inlet of the HPP suction port.
ii. The Duty Coagulant Sequence stops.
iii. The operating RO Train HP Pumps stop – ramping down at the same ramping
up rate SP-6.2.10.
iv. The Duty Anti-scalant and Acid Dosing Pump stop.
v. Reduce the filter feed pumps speed to SP-6.2.2. Simultaneously the
blending valve should close completely (incrementally).
vi. Open the operating RO Flushing Valve of the associated train since it is a CSD.
vii. After a pre-set time SP-6.2.3 the operating Filter Feed Pumps should ramp
down slowly SP-6.3.1 and simultaneously the operating RO Flushing Valves
close. The FFP should ramp down until it stops and confirms stopping
viii. The flushing valves should confirm closed.
ix. Stop the SBS sequence; simultaneously close the RO Trains Inlet valves V-74 /
V-75 / V-76.
x. Close the Duty MMF Inlet Valves (See Appendix-1 Multimedia Filter
Valves Sequence.

Correct sequence of valve operation.

xi. The operational Borehole Pumps will complete to operate as per their
operating sequence.

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xii. The product water pumps will complete to operate as per their
operating sequence.

Note:

Any backwashing activities can continue when the Water Treatment Plant
Shutdown is in progress.

6.6 Filter Feed Pumps Sequence - FFP

Pumps P-1A/B/C is of VFD type will operate as duty/duty/standby to pump the

water to the multimedia filters.

Operation

The filter feed pumps will run automatically as per the water level in the product
water tank controlled by the level transmitters’ LIT-1A/1B, and upon demand from
the PLC (Product water tank level) to run the RO trains.

Any or both duty feed pumps will be able to run as long as the water level in
the tank/s is at or above SP-6.6.1.

If the water level in the tank becomes at SP-6.6.2 and decreasing, alarm should be
given that feed tank level is low. If the level reached SP-6.6.3 and decreasing, one
of the systems should go into control shut down. If the level reaches SP-6.6.4 and
decreasing, the second system should go into a control shut down.

(RO trains) will be allowed to run if the Feed water tanks level is at LS-18A/B.

The feed pumps, thus the RO system, will work as per the product water tank level
as follows,

• If the product tank level is at SP-6.6.5, both RO lanes should stop.

• If product tank level is more than SP-6.6.6, then one feed pump should stop,
thus, one train only is allowed to run.
• If product tank level is less than SP-6.6.7, then both feed pump should run, thus, both
trains are running.
Interlocks

The feed pumps interlock with:

• LSL-18A/18B, hard weird to stop the pumps at low level; dry run protection.LIT-
1A/1B, Equalization / Feed water tanks Ultrasonic level transmitters, to control the
pumps operation
• TIT-2, inhibit the feed water temperature (RO FEED) is above SP 6.1.9 - CSD.

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•
PIT-1, to inhibit the pumps at SP-6.6.8 – CSD.
•
Inhibit the feed pump/s if the associated motorized Valves V-74/75/76 is in
closed position.
• HPP inlet valves V-74/75&76 should give a feedback confirmation within SP-
6.4.4 from the starting time of the FFP otherwise the FFP will shut down.
• (PLC) PIT-8/9/10, to ramp up or down the feed pump speed to match the
required suction pressure at the HPP suction pressure within SP-6.6.10.
• Filter feed pump if not in remote
• Instrument failure (pressure / level / Temperature)
Alarms,

• LSL-18A/18B, “Feed Water Tank Level Low-Low”.

• LIT-1A/1B, Ultrasonic Level Switch will raise visual alarms as follows:
• Feed Tank Level at (SP-6.6.2) “Level is Decreasing”.
• Feed Tank Level at (SP-6.6.3) “Level is LOW, RO Train-1or2 is shutting down CSD”.
• Feed Tank Level at (SP-6.6.4) “Level is LOW-LOW, RO Train-1&2 is shutting down
- CSD”.

Product tank level at SP-6.6.6, One RO train is shutting down. Delay 1 minute.

• Product tank level at SP-6.6.5, the second RO train is shutting down. Delay 1 minute.
• SP-6.6.8 Feed pump discharge pressure is out of the set point range – CSD,
• Pump is not in remote mode.
• Pump trip.
• Instrument failure (pressure / level / Temperature)
CAUTION:

When both trains are running (if started together or consecutively), both feed
pump should be linked and work as one pump, thus, both FFP should adjust to
operate at the same speed and ramp Down/Up at the same time.

6.7 Chemical Cleaning System - Cleaning Pumps

Pumps P-6A/B is of fixed speed type will operate manually from the SCADA as
duty/standby to pump the water to the RO membranes for cleaning purpose.

Operation

The cleaning pumps will run manually by the operator from SCADA after confirming
that all the required manual cleaning valves are set to cleaning positions.

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Interlocks

The Cleaning pumps interlock with:

• LSL-5, hard weird to stop the pumps at low level (preset point), dry run protection.
• The cleaning pumps will inhibit when SP-6.7.1 of the associated train to be cleaned
is made (if the HPP running feedback signal is not confirmed)
• If not in remote position.

Alarms,

• LSL-5, “Cleaning Water Tank Level Low-Low”.

6.8 Flushing System Sequence - Flushing Pumps

Pumps P-5A/B are of fixed speed type will operate manually from SCADA as
duty/standby to pump the water to the RO membranes for flushing purpose.

Operation

The flushing pumps will run manually by the operator after confirming that all the
required manual flushing valves are set to flushing positions. However these pumps will
not run until a confirmation is received from the flushing line SBS flow switch.

Interlocks

The Flushing pumps interlock with:

•
PSL-2, will inhibit the pumps if pressure is below at SP-6.8.1.
•
Flushing pumps not in remote mode.
•
SBS flushing discharge line flow switch FS-11.
•
The flushing pumps will inhibit when SP-6.7.1 of the associated train to be flushed
is made (if the HPP running feedback signal is not confirmed)
• Pressure switches PS-2 to inhibit the pump at SP-6.8.2.
Alarms,

• PSL-2, “Low Discharge pressure”.

• FS-11, No feedback signal – Flushing pump is inhibited.
• The HPP of the train to be flushed is running – Flushing pump inhibited.
• SP-6.8.2 is made – Flushing pump discharge pressure is low.
• Pump is not in remote mode.
• Pump trip.

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6.9 Multi Media Filters

The media filters will provide a filtration media for the feed water to remove all the
suspended solids and to reduce the turbidity of the water. When both trains are to
run, all the five filters will be in duty. In case if one RO train to run then only three
filters will be called for duty and the other two filters will be idle to be called for duty
when one of the running three filters need a backwash.

Operation

The media filters when in auto mode will have the option to run in the below modes:

1. Time mode
2. Differential pressure mode.
Time Base Mode Sequence:

In time base mode, the filters will go for a backwash sequence at certain set time
duration time base (SP-6.9.1A/B/C/D/E) for MMF-1/2/3/4/5 decided by the PLC.

Differential Pressure Mode (sequential backwash):

Filters will start to be backwashed consecutively after each other when the differential
pressure PIT-1 & PIT-7 across the filters reaches SP-6.9.2. In this case, if the filters are
called by the PLC for a backwash sequence, the sequence will start by initiating the
backwash of the first filter, and when it is finished, the PLC will start backwashing the
second filter after confirming that the high level in the backwash water tank is made
LSH-7 (SP-6.9.3) and so on until all the filtered are backwashed.

In case the differential pressure does not go back to less than the set point limit SP-
6.9.4 immediately after a complete full backwash procedure (within 2 minutes from
ending the backwash procedure), or in case that the differential pressure across the
filters reached maximum level in less than SP-6.9.5 from final backwash sequence then
alarm should be raised “Change/check the filters’ media”.

Backwashing sequence of one filter is typical for all the filters, and will all undergo
the same backwash mechanism.

Backwash sequence consists of three main steps:

1. Air Scouring
2. Backwashing
3. Rinsing
4. Service

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When these three steps are executed on any of the filters, the backwashed filter will
be immediately put back into service, and the second filter is called for a
backwashing sequence.

Each of the media filter is equipped with a set of valves, these valves will be set open
or close by the PLC during the backwash sequence as per the process requirement.

1.1.1 MMF Backwashing Sequence

In Time Base Mode (base) MMF-1

When the MMF-1 is called for a backwash sequence (SP-6.9.1) (MMF-1) the
following steps will ensue:

N.B: The sequence can be displayed on separate screen, showing the

valves status positions.

1. Alarm will be given “MMF- 1 will enter a backwash sequence”.

2. After a preset time SP-6.9.13, the PLC will isolate MMF- 1 by closing valves V-
16 & V-19 and confirm to the PLC.
3. The PLC will confirm (feed-back signal from the valves) that the filter is isolated
by confirming that V-16/17/18/19/51/20/290 are closed, “MMF- 1 is isolated”.
4. The PLC will signal valves V-129 to open, “Backwash header drain valve V-129
is open” a confirmation signal should be given.
5. After opening V-129, the backwash reject valve V-17 and the backwash
header drain valve V-290 should open simultaneously. “Valves V-17 & V-290
are open” and confirm to the PLC.
SP-6.9.6 after completion of step 5, the backwash header drain valve V-129
should close and confirm to the PLC. “Backwash Water Drain Header is closed”.

6. PLC will signal the duty Blower to Start, and immediately the blower inlet valve
V-51 should open with a confirmation signal to the PLC when it is fully open
“Blower B-1A/B is running”.
7. The blower will run for SP-6.9.7.
8. After SP-6.9.7, the PLC will close valve V-51 and them immediately
(simultaneously) inhibit the running Blower, “Blower B-1A/B is inhibited”.
9. Upon confirmation that the blower is inhibited, the PLC should slip into the
backwash sequence by closing valve V-290; and opening valve V-20.
“Backwash sequence is in Progress”.
10. Soon a feed-back signal received confirming opening of valve V-20, the
duty backwash pump P-7A/B should start. “Backwash pump is running”.

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11. FIT-1 at the backwash water reject header will confirm the flow rate range. If
the flow range is not within the allowed limits SP-6.9.8 for more than SP-6.9.9,
the backwash pump will be inhibited “Backwash sequence is interrupted”. The
operator should regulate (adjust) the backwash reject water control valve
manually and re-initiate the Backwash step by confirming this order from the
SCADA.
12. If the backwash range is within the allowed limits then the backwash
sequence will be maintained for SP-6.9.10 decided in field. “Backwash
sequence is in Progress”.
13. When the backwash sequence is completed, the PLC will inhibit the backwash
pump and shift into the rinsing sequence, “backwash sequence is completed”.
14. Upon completing the backwash sequence and inhibiting the backwash pump, the
PLC will initiate the rinsing sequence immediately by closing valves V-20 & V-17
simultaneously, and then opening valves V-16 & V-18 simultaneously. “Rinsing
Sequence in Progress”. The rinsing sequence will be executed for SP-6.9.11.
15. When the rinsing sequence is completed, the product valve V-19 should
open, and feedback signal should confirm that V-19 is fully open.
16. When V-19 is confirmed open, V-18 Should close with confirmation
feedback signal. “MMF-1 is in service”.
17. Timer should start counting for SP-6.9.12 before the second media filters
starts its backwash sequence.

MMF Backwashing Sequence

In Pressure Mode Sequence (Differential Pressure) MMF-1

The initiation of the MMF while in pressure mode will take place when the difference
in the main inlet (PIT-1) and outlet (PIT-7) pressure reaches 0.7 bar (SP-6.9.2). In
this case all the multimedia filters will be backwashed in sequence starting with
MMF- 1 which will be the first to be called by the PLC.

When the MMF- # is called for a backwash sequence the following steps will ensue: N.B:
the sequence can be displayed on separate screen, showing the valves status.

1. Alarm will be given “MMF- 1 will enter a backwash sequence”.

2. The PLC will check if the High water level in the backwash tank is made SP-6.9.3.
3. After a preset time SP-6.9.13, the PLC will isolate MMF- 1 by closing valves V-16
& V-19 and confirm to the PLC.
4. The PLC will confirm (feed-back signal from the valves) that the filter is isolated
by confirming that V-16/17/18/19/51/20/290 are closed, “MMF- 1 is isolated”.
5. The PLC will signal valves V-129 to open, “Backwash header drain valve V-129
is open” a confirmation signal should be given.

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6. After opening V-129, the backwash reject valve V-17 and the backwash header
drain valve V-290 should open simultaneously. “Valves V-17 & V-290 are open”
and confirm to the PLC.
7. SP-6.9.6 after completion of step 5, the backwash header drain valve V-129
should close and confirm to the PLC. “Backwash Water Drain Header is closed”.
8. PLC will signal the duty Blower to Start and immediately open the blower inlet valve
V-51 with a confirmation after when full opening. “Blower B-1A/B is running”.
9. The blower will run for SP-6.9.7.
10. After SP-6.9.7, the PLC will close valve V-51 and them immediately
(simultaneously) inhibit the running Blower, “Blower B-1A/B is inhibited”.
11. Upon confirmation that the blower is inhibited, the PLC should slip into the
backwash sequence by closing valve V-290; and opening valve V-20. “Backwash
sequence is in Progress”.
12. Soon a feed-back signal received confirming opening of valve V-20, the
duty backwash pump P-7A/B should start. “Backwash pump is running”.
13. FIT-1 at the backwash water reject header will confirm the flow rate range. If the
flow range is not within the allowed limits SP-6.9.8 for more than SP-6.9.9, the
backwash pump will be inhibited “Backwash sequence is interrupted”. The operator
should regulate (adjust) the backwash reject water control valve manually and re-
initiate the Backwash step by confirming this order from the SCADA.
14. If the backwash range is within the allowed limits then the backwash sequence will
be maintained for SP-6.9.10 decided in field. “Backwash sequence is in Progress”.
15. When the backwash sequence is completed, the PLC will inhibit the backwash
pump and shift into the rinsing sequence, “backwash sequence is completed”.
16. Upon completing the backwash sequence and inhibiting the backwash pump, the
PLC will initiate the rinsing sequence immediately by closing valves V-20 & V-17
simultaneously, and then opening valves V-16 & V-18 simultaneously. “Rinsing
Sequence in Progress”. The rinsing sequence will be executed for SP-6.9.11.
17. When the rinsing sequence is completed, the product valve V-19 should open,
and feedback signal should confirm that V-19 is fully open.
18. When V-19 is confirmed open, V-18 Should close with confirmation feedback
signal. “MMF-1 is in service”.

Since the MMF’ backwash is in differential pressure mode, the second filter MMF-2
backwashing sequence will immediately start when MMF-1 backwash ends
confirming that SP-6.9.3 is made.

Soon MMF-2 is done and SP-6.9.3 is made, then MMF-3 can be called for a
backwash and so on until all the media filters are backwashed.

Disregarding the time base mode, if the media filters are in time base mode and the
PLC detected high differential pressure, then the PLC should switch the media filters

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sequence mode into pressure mode, initiate a backwash sequence for all the filters
and then switch back again to time base mode. Alarm should show “switching to
pressure mode for a backwash is taking place”. However, after switching back to time
base mode, the PLC should not execute the next time base backwash sequence until
SP-6.9.14 is passed.

Upon calling trains 1&2 for duty, all the multimedia filters should confirm healthy for
operation and their valves are set automatically to service positions (Attached Valves
List).

If only one train is called for operation, all the filters should confirm healthy and at least
any 3 of them ready for operation provided that during backwash any of the two idle
filters that confirmed healthy and ready for operation will be put into duty when one of
the 3 operational filters go for backwash. “MMF- #/#/#/#/# in Service” - “MMF- -
#/#/#/#/# in Service”.

In case any of the valves does not confirm open or closed during any sequence of
operation, the associated filter should be isolated and alarm raised “MMF- # Out of
Service”. Backwash of this filter will be avoided (passed).

The operator should have the ability to operate / backwash or isolate any of the MMF
manually (over-ride auto mode) at any time provided that the MMF system is put in
manual mode. Alarms should be raised giving the status of each MMF System.
Operating the filter will be then the operator responsibility; however, feedback signal
from the valves should show on the SCADA.

“Media Filters in Manual Mode”

“MMF-1 in Backwash mode / isolated / service/ out of Service....”. “MMF-2 in Backwash

mode / isolated / service/ out of Service....”. “MMF-3 in Backwash mode / isolated /

service/ out of Service”. “MMF-4 in Backwash mode / isolated / service/ out of Service”.
“MMF-5 in Backwash mode / isolated / service/ out of Service”.

If for any reason the blowers did not start or the air scouring inlet valves do not open
during backwash sequence due to valve malfunction, the current backwash
sequence should continue and the next backwash sequence should not start until
the problem is solved; “Scouring sequence is inhibited”. The system can complete
its backwash sequence and then rinse and put in service.

Interlocks

• PIT-7 & PIT-1 SP-6.9.2 to check continuously the pressure difference and
confirm healthy.

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• PSL- 4 will inhibit the backwash pump at low pressure – preset value.
• LSH-7 will inhibit/close the filling valve V-58 upon high tank level.
• LSL-8 will inhibit the backwash pumps at low level – dry run protection.
• PSH-5/6 will inhibit the blowers when pressure is high.
• MMF backwash starting sequence inhibit when level switch LS-7 is not high.
• Blowers and backwash pumps are not in remote.
• FIT-1 is not healthy.
• FS-1 will inhibit the blowers when there is no flow, after SP-6.9.15.
• In case that no confirmation is given from any of the valves, the associated media
filter vessel should be isolated and put out of duty.
Alarms

• In pressure mode, PIT-7 & PIT-1 SP-6.9.2 “MMF Differential pressure High
– Backwash sequence will be initiated”.
• PSL-4, “Low backwashes pump discharge pressure”.
• LSH-7, “Valve V-58 open/close – Low/High backwash tank water level”.
• LSL-8 “backwash tank water level is low”.
• PSH-5/6 “Blower discharge pressure high”.
• FS-1 “No air flow from the blowers”.
• Backwash pumps are not in remote
• Blowers are not in remote.
• FIT-1 is not healthy
• MMF-XXX is on hold (out of duty) due to valve confirmation signal problem.

6.10 High Pressure Pumps – HPP

High Pressure Pumps P-2A/B/C are of VFD type will operate as duty/duty/standby
to pump the water at the required pressure to the RO membranes operated at full
speed SP-6.2.5. Changing the pumps from standby to duty is done manually by the
operator Via the SCADA and confirmation from the field. The standby HPP will NOT
be allowed to start immediately automatically (when any of the running HPP is
faulty/trip) until after a delay time SP-6.9.17 where field confirmation is given to start
the standby pump.

Operation

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The HPP will run automatically when the suction pressure is SP-6.6.10, controlled
by the pressure transmitter PIT-8/9/10 installed at the suction port of each pump.
This suction pressure will be provided by the filter feed pumps P-1A/B/C.

Any or both feed pumps will be able to run when called by the PLC provided
that other interlocks been made / satisfied.

The HPP P-2A/B/C run speed to maintain the pressure PIT-14 & PIT-15 SP-
6.9.18 located at the HPP discharge header / Membranes feed header.

Interlocks

The HPP pumps interlock with:

• PIT-8/9/10, to keep the HPP running providing certain suction pressure SP-6.6.10
provided by the FFP. If SP-6.6.10 is not attained within SP-6.9.25 then the HPP
will be inhibited.
• PIT-14/15, to control the HPP speed maintaining a maximum allowed pressure
(not more than) SP-6.9.19. – CSD in SP-6.9.26
• PIT-14/15, to control the HPP speed maintaining a minimum allowed pressure
(not less than) SP-7.9.27. – CSD in SP-7.9.26
• Stop the HPP (system) if ORP-2 reads above SP-7.1.9 – Immediate shut
down (TRIP) – CSD in SP-6.9.26
• PIT-11/12/13, to monitor the HPP discharges pressure. Maximum allowed
pressure SP-6.9.20.
• PIT-16/17 in conjunction with the PIT-14/15 to monitor the differential pressure across
the membranes. PIT14-16 & PIT15-17 SP-6.9.21 (both at the same set point)
– CSD in SP-6.9.26
• Valves V-74/75/76 inhibits the HPP Pumps immediately if these valves are closed.
• Flushing valves V-255/256 to inhibit the HPP immediately if these valves are open.
• Instruments and alarm failure.
• If not in remote.
• PIT-16 & PIT-17 if pressure above SP-6.9.19 - CSD in SP-6.9.26
• FIT-6 & FIT-7 flow outside SP-6.9.22 range after delay time SP-6.9.24.- CSD in
SP-6.9.26
• FIT-4 & FIT-5 if flow outside SP-6.9.23 range after delay time SP-6.9.24.- CSD in SP-
6.9.26
Alarms,

• PIT-8/9/10, “Low HPP suction pressure, increase FFP speed to reach SP-6.6.10”. If
SP-6.6.10 is not attained within SP-6.6.25 then system will go into CSD “Train 1/2
is shutting down”
• PIT-8/9/10, “High HPP suction pressure, Reduce FFP speed to maintain SP-6.6.10.

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• PIT-14/15, “Membranes Feed Pressure High / Low, HPP Ramping Up / Down”

to match SP-6.9.18.

• PIT-14/15, “High Membranes Inlet pressure High SP-6.9.19, CSD with delay SP-
6.9.26 to shut down the train if issue is not rectified “Train-1/2 is shutting down”.
• PIT-14/15, “Low Membranes Inlet pressure Low SP-6.9.27, CSD with delay SP-
6.9.26 to shut down the train if issue is not rectified “Train-1/2 is shutting down”.
DP (PIT-14-16 & PIT 15-17) (SP-6.9.21) “Membranes Differential Pressure - High”
– – CSD in SP-6.9.26 if issue not rectified.

7.0 CHEMICAL DOSING SEQUENCES

All dosing pump will dose as per the water flow rate, thus, as per the flow meter rate.

7.1 Pre-Chlorination Dosing SET-A Sequence.

The pre-chlorination chemical dosing pumps set A consist of two pumps DP-1A/B
(Standby and Duty), will dose into the discharge pipe of bore well BHP-01A.

The pre-chlorination dosing set A will start dosing when FIT-17 is reaches SP-
7.1.1 and to stop dosing when the flow is less than SP-8.1.1.(see set points
range) Upon starting, Pre-chlorination dosing set A will dose at SP-7.1.2 based
on the flow rate from FIT-17 as per the following formula

(FIT-17 x SP-7.1.2) ÷ (10 x SP-7.1.3 X SP-7.1.4) = Liter / Hour (LPH) The pump
flow range is 0-18LPH and has a 4-20mA adjustable stroke.

Therefore, at 0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow)
18LPH the pump will be at 20mA.

The PLC will execute the above formulae as per the inputs from the set points and
the flow meter.

Interlocks

• CSD if FS-4 is not made (NO FLOW) – delay time SP-7.1.23.

• BHP-01A to shutdown in SP-7.1.23.
• Pump is not in remote
• Instruments fault
Alarms

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• Pre-chlorination is not available: “BHP-01A will shut down”

• FS-4 not made; “CSD in SP-8.1.23”

7.2 Pre-Chlorination Dosing SET-B Sequence.

The pre-chlorination chemical dosing pumps set B A consist of two pumps DP8A/B
(Standby and Duty), will dose into the discharge pipe of bore well BHP-01B. The
pre-chlorination dosing set B will start dosing when FIT-18 is reaches SP-7.1.1 and
to stop dosing when the flow is less than SP-7.1.1.

Upon starting, Pre-chlorination dosing set B will dose at SP-7.1.2 based on the
flow rate from FIT-17 as per the following formula (FIT-18 x SP-7.1.2) ÷ (10 x SP-
7.1.3 X SP-7.1.4) = Liter / Hour (LPH)

The pump flow range is 0-18LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 18LPH the
pump will be at 20mA. The PLC will execute the above formulae as per the inputs
from the set points and the flow meter.

Interlocks

• CSD if FS-3 is not made (NO FLOW) – delay time SP-7.1.23.

• BHP-02A to shutdown in SP-7.1.23.
• Pump is not in remote
• Instruments fault
Alarms

• Pre-chlorination is not available: “BHP-02A will shut down”

• FS-4 not made; “CSD in SP-7.1.23”

7.3 SBS Dosing Sequence.

The SBS chemical dosing pumps set consists three dosing pumps DP-7A/B/C.
DP7A&B will be the standby and duty for the RO system and will dose as per flow
meter FIT-2. DP-7C is for the flushing system and will be operated manually. The
dosing rate of DP-7A&B will be initially at a rate of (6 X SP-8.1.2) (Six Folds) when
it is called by the PLC to start the SBS pumps.

The pumps dosing rate will calculated as per the following equation.

(FIT-2 x(6 X SP-7.1.2)) ÷ (10 x SP-7.1.7 X SP-7.1.8) = Liter / Hour

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The pump flow range is 0-15LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 15LPH, the
pump will be at 20mA.

The PLC will execute the above formulae as per the inputs from the set points and
the flow meter.

The above equation will be executed only until the complete start-up of the RO
train/s i.e. when the HPP reaches its maximum speed and PLC will revert into
another mode of operation for the SBS dosing as follows
Therefore, upon completion of the start-up of the RO train/s (HPP reaches its maximum
operational speed), the PLC will monitor the ORP-1 instrument reading and

dose accordingly; if the ORP-1 reading is below SP-7.1.5 then the PLC will stop
SBS dosing (which is being executed as per the above equation). However, If ORP-
1 reads above SP-7.1.5, SBS dosing pump should start at 80% of its maximum
stroke rate (dosing pump rate) for a period of SP 7.1.6 (no equation to execute,
dose as per the instrument reading), during this time the PLC will be monitoring
ORP-2, after SP-7.1.6 the SBS dosing rate should be reduced incrementally SP-
7.1.26 until ORP-2 reaches SP-7.1.24. When SP-7.1.24 is attained the dosing rate
will be maintained. ORP-1 will be under PLC monitoring, and if ORP-1 reaches SP-
7.1.5 the SBS dosing will stop.

The SBS dosing pump flow rate is

The pump flow range is 0-15LPH and has a 4-20mA adjustable stroke.

Therefore, at 0 (zero LPH) the pump will be at 4mA (0%) and at maximum
stroke (flow) 15LPH, the pump will be at 20mA (100%).

After the HPP reaches the PLC will not execute the above formulae but it will
monitor both ORP meters and dose as per their values as described above.

The operator should have the ability to override the system and select
the DUTY/STANDBY of any of the three SBS dosing pumps.

Interlocks

• Inhibit dosing FS-10 is not made (No Flow) – immediate system shut down with
delay during start up.
• HPP to shut down if ORP-2 is above SP-7.1.9 – Immediate system shut down.
Pump is not in remote
• Instruments fault

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Alarms

• FS-10 is not made

• High ORP value (ORP-2), “IMMEDIATE PLANT SHUTDOWN”

7.4 Anti-scalant Dosing Sequence.

The anti-scalant chemical dosing pumps set consist of two pumps DP-6A/B
(Standby and Duty), will dose into the main RO module feed header.

The anti-scalant dosing set will start dosing when it is called by the PLC as per
the following formula

(FIT-2 x SP-7.1.10) ÷ (10 x SP-7.1.11 X SP-7.1.12) = Liter / Hour

The pump flow range is 0-3LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 3LPH the
pump will be at 20mA.

The PLC will execute the above formulae as per the inputs from the set points and
the flow meter.

Interlocks

• Inhibit dosing FS-9 is not made – delay during start up. Pump is not in
remote Instruments fault

Shut down of the system if FS-9 is not made (NO Flow) within SP-7.1.25

Alarms

• FS-9 is not made, “CSD”

7.5 Acid Dosing Sequence (not usable).

The acid chemical dosing pumps set consist of two pumps DP-3A/B (Standby
and Duty) that will dose into the main RO module feed header.

Prior to starting the dosing acid the followings should confirm,

The Acid Motive pump P-9 is running.

The flow switch FS-2 is confirmed.

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The flow meter FIT-11 confirms SP-7.1.14

The acid dosing set will start dosing when it is called by the PLC which will be
monitoring analyzer PH-2. The dosing quantity will be increased by the PLC until
PH-2 reaches SP-7.1.13 taking into consideration the number of trains to run.

When the acid sequence is called by the PLC, the motive water pump P-9 should
start and the FIT-11 (SP-7.1.14) and FS-2 should confirm made prior to starting
the duty acid pump.

Upon starting the acid dosing pump, the PLC will monitor the TIT-4 and maintain
its set point SP-7.1.15.

• If the temperature is above SP-7.1.15, the duty acid pump should reduce
its speed immediately until the temperature is below SP-7.1.15.
• The flow switch FS-2 is confirmed.
• The flow meter FIT-11 confirms SP-7.1.14.
If the temperature is above SP-7.1.16 then the running acid dosing pump should
stop immediately keeping the motive pump running for further 10 minutes.

The pump flow range is 0-22LPH and has a 4-20mA adjustable stroke.

Therefore, at 0 (zero LPH) (0%) the pump will be at 4mA and at maximum
stroke (flow) 22LPH the pump will be at 20mA (100%).

The PLC will inclemently start the duty acid dosing pumps from 0% and
increase inclemently at a rate of SP-7.1.29 until PH-2 reads SP-7.1.13 where
the PLC will maintain the same dosing rate continuously.

Interlocks

The following should stop the acid dosing pumps if made (attained)

• The Acid Motive pumps P-9 to confirm healthy prior to starting the acid dosing.
•
The flow switch FS-2 is confirmed made (Flow Available).(delay few
seconds)
• The flow meter FIT-11 confirms SP-7.1.14. (delay few seconds)
• Temperature transmitter TIT-4 at maximum SP-7.1.16 – Immediate stop
of acid dosing pumps)
• PH-2 is above SP-7.1.30, “CSD in SP-7.1.27” delay start up timer.
In case the acid dosing pump is off (stopped) the RO system should go into a CSD
in SP-7.1.27”

CAUTION:

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In any case if the acid blending system is stopped for any reason, the motive water
pump P-9 should be kept ON for a period of 10 minutes before it is switched off.

Alarms

• FS-2 is not made (No Flow) “Acid Dosing Pump Is Inhibited”.

• Temperature at blending Tee discharge is High (TIT-4) “Low dilution Water”.
• PH-2 is above SP-7.1.30, “CSD in SP-7.1.27”.

7.6 Coagulant Dosing Sequence.

The coagulant chemical dosing pumps set consist of two pumps DP-7A/B
(Standby and Duty), will dose into the main RO module feed header.

The coagulant dosing set will start dosing when it is called by the PLC as per
the following formula

((FIT-2 + FIT-3) x SP-7.1.17) ÷ (10 x SP-7.1.18 X SP-7.1.19) = Liter / Hour

The pump flow range is 0-4LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 4LPH the
pump will be at 20mA.

The PLC will execute the above formulae as per the inputs from the set points and
the flow meter.

Interlocks

• Inhibit dosing FS-7 is not made (No Flow) – delay during start up. Pump is not
in remote
• Instruments fault

Alarms

• FS-7 is not made “CSD in SP-7.1.27”

POST TREATMENT

7.7 Post Chlorination Dosing Sequence.

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The post chlorination chemical dosing pumps set consist of two pumps DP-
2A/B (Standby and Duty), will dose into the product water line header.

The chlorination dosing set will start dosing when it is called by the PLC. Dosing of
the hypo (post) will start when FIT-9 reaches SP-7.1.20 or above, and keep
increasing the pump dosage quantity at an increment rate of SP-7.1.31 until the
chlorine meter CL2-1 reads SP-7.1.21 taking into consideration the flow rate of one
or two trains and maintain SP-7.1.21.

The pump flow range is 0-12LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 12LPH the
pump will be at 20mA.

Interlocks

Inhibit dosing if FS-5 is not made (NO flow) in SP-7.1.28 – delay during
start up.
FS-5 is not made “Delivery pumps shut down in SP-
7.1.28” Pump is not in remote
Instruments fault

Alarms

• FS-5 is not made “Delivery pumps shut down in SP-7.1.28”

7.8 Caustic Soda Dosing Sequence – Post PH Adjustment (not usable).

The post PH chemical dosing pumps set consist of two pumps DP-5A/B (Standby
and Duty), will dose into the product water line header.

The caustic dosing set will start dosing when it is called by the PLC. Dosing of

the caustic will start when FIT-9 reaches SP-7.1.20 or above, and keep increasing
the pump dosage quantity at an increment rate of SP-7.1.32 until the PH meter PH-
4 reads SP-7.1.22 taking into consideration the flow rate of one or two trains and
maintain SP-7.1.22.

The pump flow range is 0-15LPH and has a 4-20mA adjustable stroke. Therefore, at
0 (zero LPH) the pump will be at 4mA and at maximum stroke (flow) 15LPH the
pump will be at 20mA

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Interlocks

Inhibit dosing if FS-8 is not made (NO flow) in SP-7.1.28 – delay

during start up.
FS-8 is not made “Delivery pumps shut down in SP-
7.1.28” Pump is not in remote
Instruments fault

Alarms

• FS-8 is not made “Delivery pumps shut down in SP-7.1.28”

8.0 Service Pumps

P-4A/B operates as duty standby and provides high quality blended water for
various duties around the plant room.

The pumps P-4A/B will be self-contained skid mounted pump set complete with
accumulator (pressure vessel), high / low pressure switches (differential,
Pressure indicators (gauges).

The set (system) will provide the PLC with healthy and running / stop signal.

Interlocks, alarms

• If PS-1, is made the duty service pumps will be made available and run
immediately to compensate for the pressure lose in the pipe, the pump
status (Visual alarm) should show on the SCADA “service pumps running”.
• If PS-1, is unmade the duty service pumps will be made un-available and
stop immediately, the pump status (Visual alarm) should show on the
SCADA “service pump stopped – Duty Pump Available”.
• If LS-11 (LL), is made, then the service water pump will be made available to
run at any time. The pump status on the SCADA should show “Duty Service
Pump is Available, LS-11 is made”.
• If LS-11 (LL), is unmade, then the service water pump will be made
unavailable to run. The pump status on the SCADA should show “Duty
Service Pump is Unavailable, LS-11 is unmade”.

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Flushing Pumps

Pumps P-5A/B operates as duty standby and provides the membrane with
clean water for flushing purpose.

These pumps are utterly of manual operation and they will be operated by
the operator when required.

Interlocks

• If LSL-6, to inhibit flushing pumps at low level

• If PSL-2, to inhibit the pumps at low pressure after SP-8.1.1.
• FS-11, to inhibit the pumps if SBS flow is not made.
• To inhibit the flushing pumps when the HPP of the associated train to be
flushed in running.
Alarms

• LSL-6 low Flushing pumps inhibited, “Flushing Tank Low Level”.

• If PSL-2, to inhibit the pumps at low pressure, “Low Discharge Pressure”.
• FS-11, “Flushing pumps inhibited, SBS is not available”.
• HPP is running.

9.0 Delivery pumps

Pumps P-3A/B/C will operate as duty/duty/standby to pump the water to the

irrigation tank.

Operation

The Delivery pumps will run automatically as per the water level in the product
water tank controlled by the level transmitter LIT-2.

If the water level in the tank is above SP-9.1.1, both pumps will run together
starting consecutively. If the water level in the tank reaches SP-9.1.2 one pump
will; be stop. If the level reaches SP-9.1.3 the second Delivery pump will stop. The
pumps will run (restart) when the level reaches SP-9.1.4

Interlocks

The Delivery pumps interlock with:

• LSL-19, hard weird to stop the pumps at low level; dry run protection.
• LIT-2, Product water tank Ultrasonic level transmitter, to control the
pumps operation as per the above set points SP-9-1.1/2/3/4.

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• PSL-7, to inhibit the pumps when pressure is Low in the discharge pipe with
a delay start up.

• FS-8 to inhibit the Delivery pumps if FS-8 is not made after SP-9.1.5, with a
delay start up.
• FS-5 to inhibit the Delivery pumps if FS-5 is not made after SP-9.1.5, with a delay
start up.
Alarms,

• LSL-19, “Product Water Tank Level Low-Low”.

• LIT-2, Ultrasonic Level Switch will raise alarms as follows:
• Tank Level SP-9.1.1 “Delivery Pumps starting”.
• Tank Level Low, SP-9.1.2 “Duty Product Pump-1 is inhibited”.
• Tank Level Low-Low SP-9.1.3 “Duty Delivery pump-2 is inhibited”.
• Tank Level at SP-9.1.4 “both Delivery pump are available”.
• FS-8 is not made, “CSD after SP-9.1.5, Caustic soda dosing is not available
• FS-“5 is not made, “CSD after SP-10.1.5, Hypochlorite dosing is not available”.

10.0 Drinking water Pumps / Blending System

RO Permeate & Filtered Water blending control philosophy

Part of the RO permeate will be diverted to be used for Drinking purposes after
being blended with the existing filtered municipal water. RO permeate water
(600cum/day) with a TDS content of less than 50 ppm that does not include any
kind of added chemicals will be blended with filtered water to produce a certain
quantity of water at a TDS level of approximately 200 ppm.

RO permeate water from the main RO permeate header will be diverted into a
holding tank. From the holding water tank, transfer water pumps P-8A/B (MFS) will
pump the water into a main header where it will blend with the filtered water coming
from the existing filtration system before it is being mixed by a static mixer and
discharged into the drinking water tank.

The transfer pumps P-8A/B main discharge header will be provided with
electromagnetic flow meters and a modulating flow control valves, while the filtered
water flow rate will be provided and controlled by the VFD of the filtered water
transfer pumps P-9A/B to pass the required quantity of water enough to attain the
final required TDS level. In addition there will be a set of installed instruments to
ensure safe operation of the process.

Standard Operating Issued Date

Rev# 3 Page 40
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

The PLC will read the TDS level of the blended water after the static mixer and
accordingly adjust the filtered water transfer pumps (P-9A/B) flow rate by ramping
up or down their speed until the final blended TDS level is attained.

The RO water (pumped from the holding tank) will continuously has a fixed TDS
level as well its flow rate by means of a modulating valve that can be controlled
from the SCADA. Thus, the water flow rate from the filtration system will be
controlled automatically by the PLC to attain the final blended TDS level.

The level of water in the service drinking water tank (client tank) will be monitored
by a level transmitter and will initiate the blending process as follows:

Due to the mode of consumption of water the blending process will be a kind of
batch process otherwise if the consumption from the service tank is continuous
then the blending process will be continuous. The blending process will be inhibited
when the drinking water level is at (SP-10.1). At level (SP-10.2) the blending
process will restart.

The TDS of the RO permeate water is fixed and un-adjustable. The PLC will
consider the RO permeate water flow rate FIT-10 as fixed value SP-10.3 set at the
SCADA via valve V-273, with allowed maximum flow rate of SP-10.4.

When the PLC receives a signal from LIT-4, the modulating valve V-273 will open to
SP-10.3. Immediately (pre-adjusted via the SCADA), the UV system will be activated
and the drinking water transfer pump will start, provided that LIT-3 is above SP-10.5
and that LSL-01 is made. After receiving flow confirmation from FS-3, the filtered water
pumps will start at a minimum speed (SP-10.9) and start ramping up at a slow rate (SP-
10.7) until the blended water TDS/CL-8 reaches SP-10.6. At that level the SCADA will
fine adjust the VFD speed accordingly until the TDS/CL-8 SP-10.6

The VFD adjustment rate will be SP-10.7. If FS-3 does not give a flow confirmation
after a set delay time SP-10.8 the UV system and the transfer pump will stop and
the filtered water transfer pumps will stop, thus inhibiting the blending system
process. The total blended flow rate will be calculated from FIT-10 & FIT-12. The
SCADA will display the individual flow rates and the total blended flow, as well the
valves opening level/percentage and TDS levels.

The water will finally be processed by a UV system for sterilization purpose. The UV
system is a self-contained system and will give only a healthy signal to the PLC.

The electrical mixer at the drinking water tanks (Standby/Duty) will start automatically
when the level in the tank is above SP-10.15, 2 minutes after confirming SP-10.6, the
hypochlorite dosing system will start add executed as follows.

Standard Operating Issued Date

Rev# 3 Page 41
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

Post Chlorination Dosing Sequence.

• The chlorination chemical dosing pumps set consist of two pumps DP-A/B
(Standby and Duty), will dose into the blended water header prior to the
static mixer.
• The chlorination dosing set will start dosing when it is called by the PLC. Dosing
of the hypo (post) will start when SP-10.6 is attained /confirmed with a delay of
SP-10.11.
• The dosing of chlorine will be as per the following formulae:
[(FIT-10 + FIT-12) x SP-10.12] ÷ (10 x SP-7.1.3 X SP-7.1.4) = Liter / Hour

All other available instruments will be monitoring the process specifications

and displaying their reading on the SCADA system
Shut down

• When the below interlocks are made, the blending process will be inhibited
as follows:
• The filtration water pumps will stop inclemently until it comes to rest (zero
flow) and confirm.
• The transfer pumps will inhibit and the modulating valve V-273 will close and
confirm closed.
Interlocks

• LIT-3 will monitor the level in the holding tank and close motorized valve V-272
at high level with delay timer. As well it will stop the transfer pumps at low level.
• TDS level of (TDS/CL-8) reaches SP-10.14.
• LSL-01 will protect the pumps (Dry Run protection).
• FS-3, will inhibit the transfer pumps at no flow with a delay timer during start up.
• V-273 will open to a certain preset limit SP-10.3 from SCADA.
• Filtered water pumps speed below SP-10.9.
• LSH-29 will inhibit the blending process.
• FS-3a, after delay of SP-10.13
• Instruments are fault.
• Pumps not in remote.
• LS-03 will protect the filtered water pumps (Dry Run protection).
• FIT-12 will protect the filtered water pumps (Dry Run protection).

Alarms

• LIT-3, “High Tank Level”.

Standard Operating Issued Date

Rev# 3 Page 42
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

• LSL-01, “Low Level Tank”.

• UV system Status
• FS-3, “No flow from the transfer pumps”.
• LSH-29, “Modulating valves are inhibited”.
• “UV system is not available”.
• FS-3a is not made
• Electrical agitators / mixers Status.
• When TDS level of (TDS/CL-8) above SP-10.6 “Drinking water TDS is
above limit”.

11.0 Multimedia backwash Pumps

Pumps P-7A/B are of fixed speed type will operate as duty/standby to pump
filtered water to the multimedia filters for backwashing.

Operation

The filter backwash pumps will run upon request by the PLC to backwash the system.

Any of the backwash pumps will be able to run as long as the water level in the tank
is above Low level LS-8 or satisfy conditions mentioned later in the backwash
sequences.

The inlet Motorized valve (Backwash tank filling line) V-58 will open automatically
to maintain high water level in the tank up to LSH-7. When the tank is full the
valve (V-58) will close with a delay timer.

The pressure switch at the main backwash pumps discharge header will switch off
the pumps if the backwash pumps pressure lower than 0.7 bar (SP 1.1.21/2).

Interlocks

The backwash pumps interlock with:

• LSL-8, hard weird to inhibit the pumps at low level; dry run protection.
• Valve V-58 (backwash filling line) is interlocked with the LSH-7 to close at
high level (delay included).
• PSL-4 will switch off the pump when discharge pressure is Low.
• Interlocks with the media filter valves – Part in the MMF section.
• Pumps not in remote.

Standard Operating Issued Date

Rev# 3 Page 43
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

Alarms,

• LSH-7, “High Backwash Water Tank Level”.

• PSL-4, “Low Backwash pumps discharge”
• LSL-8, “Low Backwash Tank Level – Backwash Pumps Inhibited”.
• Pumps not in remote.
• Pump trip / fault.
• Valves failure to close or open.

12.0 Multimedia backwash Blowers – Air Scouring

Blowers B-1A/B are of fixed speed type will operate as duty/standby four scouring
the media in the filters during backwash sequence.

Operation

The air blowers will run upon request by the PLC to scour the media. Scouring
the system will be part of the backwash process.

The pressure switch will switch off the blower if pressure is high.

Standard Operating Issued Date

Rev# 3 Page 44
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

Interlocks

The blowers interlock with:

• PSH-5/6, to inhibit blowers at high pressure.

• FS-1 will inhibit the blowers if flow is not available after SP-13.1.1 preset time.
Alarms,

• PSH-5/6, “High Pressure Blower discharge – Blower Inhibited”.

• FS-1,“No air Flow – Blowers Inhibited”
• Blower Trip / fault.
9.0 Building and Basement AHU’S

Pre-Start Checks
When the system is off,
• The DX-cooling coil is disabled.
• The return air damper is closed.
• The supply fan is off.

9.1.0 System Start-up

THE AHU is operated by any of the following:
• Manually through the HOA switch.
• Automatically from the BMS by an optimum start stop 7 day
time schedule program.
• Automatically from the BMS by a low/ high space temperature
limit program.
• Manually from the BMS by an operator manually entered
command.
9.2.0 Start Sequence
The system is started in the following sequence:
• The motorized return air damper modulates to a preset
position (sensed by a limit switch).
• After a time delay, when the damper is proved open, the
supply fan starts.
• Once the fan is running, the DX cooling coil is energized.

9.3.0 System Normal Running Checks Fan Control

The current switch located at the fan starter proves airflow.

9.4.0 DX Cooling Control

The return air temperature sensor is monitored by the corresponding
AHU DCP, which in turn varies the control signal in response to the
cooling demand.

Standard Operating Issued Date

Rev# 3 Page 45
Procedure 25/12/2018
 Al-Yamama Co.
Princess Nora Bint Abdul Rahman University

QA/QC Department

9.5.0 Temperature Control

The required temperature set point is set by the DCP or at the BMS
workstation. When the supply temperature, sensed by the supply air
temperature sensor, exceeds a programmable limit, a high limit alarm
is reported to the BMS. When the supply temperature, sensed by the

Standard Operating Issued Date

Rev# 3 Page 46
Procedure 25/12/2018