Control Philosophy

Water Treatment Plants

Document control

Revisio Reviewe
Date Prepared Approved Issue Purchase
n d
A 20/10/12 Preliminary
B 17/11/12 Issued for PLC Programming

Table of Contents

1General..........................................................................................................................................4
1.1Introduction..............................................................................................................................4
1.2 Objective.................................................................................................................................5
1.3General Notes..........................................................................................................................5
2General Process Description......................................................................................................6
2.1.1Sites:..................................................................................................................................6
2.1.2Objective............................................................................................................................6
2.1.3Functional Description.......................................................................................................6
2.1.4Objective............................................................................................................................7
2.1.5Functional Description.......................................................................................................7
2.1.6Objective............................................................................................................................7
2.1.7Functional Description.......................................................................................................7
2.1.8Objective............................................................................................................................8
2.1.9Functional Description.......................................................................................................8
2.1.10Objective........................................................................................................................10
 2.1.11Functional Description...................................................................................................10
2.1.12Objective........................................................................................................................11
2.1.13Functional Description...................................................................................................11
2.1.14Sites:..............................................................................................................................11
2.1.15Objective........................................................................................................................11
2.1.16Functional Description...................................................................................................11
2.1.17Sites:..............................................................................................................................12
2.1.18Objective........................................................................................................................12
2.1.19Functional Description...................................................................................................12
2.1.20Objective........................................................................................................................12
2.1.21Functional Description...................................................................................................12
2.1.22Objective........................................................................................................................13
2.1.23Functional Description...................................................................................................13
3Detailed Control Narratives.......................................................................................................14
3.1Control Zones.........................................................................................................................14
3.1.1Objective..........................................................................................................................14
3.1.2Functional Description.....................................................................................................14
3.1.3Operation Aspects...........................................................................................................14
3.2Fire Water Tanks Level Controllers LIC-0101/LIC-0102........................................................16
3.2.1Objective..........................................................................................................................16
3.2.2Applicability......................................................................................................................16
3.2.3Functional Description.....................................................................................................16
3.2.4Operation Aspects...........................................................................................................16
3.3Raw Water Tanks Level Controllers LIC-01031/LIC-01042...................................................18
3.3.1Objective..........................................................................................................................18
3.3.2Applicability......................................................................................................................18
3.3.3Functional Description.....................................................................................................18
3.3.4 Operation Aspects..........................................................................................................18
3.4Coagulant Feed Logic Sequence...........................................................................................20
3.4.1Objective..........................................................................................................................20
3.4.2Applicability......................................................................................................................20
3.4.3Functional Description.....................................................................................................20
3.4.4Operation Aspects...........................................................................................................20
3.5Screen Filters Logic Sequence..............................................................................................21
3.5.1Objective..........................................................................................................................21
3.5.2Functional Description.....................................................................................................21
3.5.3Operation Aspects...........................................................................................................22
3.6Raw Water Feed Pumps Logic Sequence.............................................................................23
3.6.1Objective..........................................................................................................................23
3.6.2Functional Description.....................................................................................................23
3.6.3Operation Aspects...........................................................................................................23
3.8Flow Controller FIC-0201.......................................................................................................25
3.8.1Objective..........................................................................................................................25
3.8.2Functional Description.....................................................................................................25
3.8.3Operation Aspects...........................................................................................................25
3.9Feed Turbidity Meter AIC-0201..............................................................................................26
3.9.1Objective..........................................................................................................................26

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3.9.2Applicability......................................................................................................................26
3.9.3Functional Description.....................................................................................................26
3.9.4Operation Aspects...........................................................................................................26
3.10Coagulation Vessel Drain Valve (AV-0201).........................................................................27
3.10.1Objective........................................................................................................................27
3.10.2Applicability....................................................................................................................27
3.10.3Functional Description...................................................................................................27
3.10.4Operation Aspects.........................................................................................................27
3.11Membrane Filter Logic Sequence........................................................................................28
3.11.1Objective........................................................................................................................28
3.11.2Functional Description...................................................................................................28
3.11.3Operation Aspects.........................................................................................................57
3.12Membrane Transmembrane Pressure Controller DPIC-0301 / DPIC-0401.........................59
3.12.1Objective........................................................................................................................59
3.12.2Functional Description...................................................................................................59
3.12.3Operation Aspects.........................................................................................................59
3.13Granulated Activated Carbon Filters (FV-0501, 0502 and 0503) Logic Sequence..............59
3.13.1Objective........................................................................................................................59
3.13.2Applicability....................................................................................................................60
3.13.3Functional Description...................................................................................................60
3.13.4Operation Aspects.........................................................................................................61
3.14Potable Water Tank Level Controller LIC-0601....................................................................61
3.14.1Objective........................................................................................................................61
3.14.2Functional Description...................................................................................................62
3.14.3 Operation Aspects........................................................................................................62
3.15Potable Water Booster Pumps Logic Sequence (Burrendong)............................................62
3.15.1Objective........................................................................................................................62
3.15.2Applicability....................................................................................................................63
3.15.3Functional Description...................................................................................................63
3.15.4Operation Aspects.........................................................................................................63
3.16Potable Water Booster Pump Logic Sequence (Mookerawa and Glenbawn)......................64
3.16.1Objective........................................................................................................................64
3.16.2Applicability....................................................................................................................64
3.16.3Functional Description...................................................................................................64
3.16.4Operation Aspects.........................................................................................................64
3.17Potable Water Recirculation Valve (AV-0601).....................................................................65
3.17.1Objective........................................................................................................................65
3.17.2Applicability....................................................................................................................65
3.17.3Functional Description...................................................................................................65
3.17.4Operation Aspects.........................................................................................................65
3.18Potable Water Hypochlorite Dose Rate Controller AIC-0602...............................................66
3.18.1Objective........................................................................................................................66
3.18.2Applicability....................................................................................................................66
3.18.3Functional Description...................................................................................................66
3.18.4Operation Aspects.........................................................................................................66
3.19Potable Turbidity Meter AIC-0603........................................................................................68
3.19.1Objective........................................................................................................................68
3.19.2Applicability....................................................................................................................68
3.19.3Functional Description...................................................................................................68

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 3.19.4Operation Aspects.........................................................................................................68
3.20Potable Water pH Meter AIC-0601......................................................................................69
3.20.1Objective........................................................................................................................69
3.20.2Applicability....................................................................................................................69
3.20.3Functional Description...................................................................................................69
3.20.4Operation Aspects.........................................................................................................69
3.21Flow Recorder FQ-0602.......................................................................................................70
3.21.1Objective........................................................................................................................70
3.21.2Applicability....................................................................................................................70
3.21.3Functional Description...................................................................................................70
3.21.4Operation Aspects.........................................................................................................70
3.22Waste Pump PP-0702..........................................................................................................71
3.22.1Objective........................................................................................................................71
3.22.2Applicability....................................................................................................................71
3.22.3Functional Description...................................................................................................71
3.22.4Operation Aspects.........................................................................................................71
3.23Pressure Switch PS-1001....................................................................................................73
3.23.1Objective........................................................................................................................73
3.23.2Functional Description...................................................................................................73
3.23.3Operation Aspects.........................................................................................................73
...................................................................................................................................................73

1 General

1.1 Introduction

This document provides a process operation overview of the Water Treatment Plant (WTP) as
part of the WTP Upgrade Project at three separate holiday parks. It details the operating
procedures for each item of equipment and describes the process control function.

The primary objective of the WTP is to treat raw water to create 250,000 to 350,000 litres per day
(Depending on the site) of treated water meeting supplied specifications including Australian
Drinking Water Guidelines (ADWG).

The WTP is controlled by a local PLC and is fully automated with no operator action required
under normal operation. Process alarms will be sent to the project control system indicating a
need for maintenance.

1.2 Objective

This Control Philosophy is for the WTP to be installed at three holiday parks.

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The WTP utilises coagulation, filtration and disinfection to meet ADWG. The unit operations used
to achieve this are:

 Coagulant dosing equipment at Site 1.

 A screen filter to protect the membranes from large particles or high particulate loadings.

 2 x 50% Membrane filter units to remove suspended solids.

 Granular Activated Carbon (GAC) pressure vessels.

 Hypochlorite dosing for disinfection.

 Various types and formations of pumps for flow and pressure control through the plant.

 Instrumentation for the monitoring of flow, pressure, turbidity, pH and free chlorine.

These various processes are discussed in Section General Process Description – General
Process Description whilst Section Detailed Control Narratives – Detailed Control Narratives
explains how these processes are to be controlled.

1.3 General Notes

 In general instrument warning and alarms are not to be used for switching/controlling
points.

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2 General Process Description

Raw Water Pumping

Raw water is pumped to the raw water storage / fire tanks via the client. The control of the raw
water pumps is via existing level switches in the raw water storage tanks (TK-02A/B). Flow to the
WTP may be up to 24 hours per day producing a maximum treated water of 250KL/day. Raw
water enters the WTP at a flange on the raw water supply line and is the beginning of the Scope
of Work & Supply.

Coagulant Dosing System

Refer to P&ID 528-PID-01

2.1.1 Sites:

The coagulant dosing system is present at Site 1.

2.1.2 Objective

To destabalise colloids to improve removal efficiencies during filtration.

2.1.3 Functional Description

Raw water is pumped from the raw water balance tanks (TK-02A/B) via raw water feed pumps
(PP-0201A/B) and the automatic screen filter (SF-0201) to the coagulation vessel (PV-0201). The
coagulant dose rate will be operater input following jar testing for the correct ratio.

A single 200L coagulant tank provides an estimated minimum of ~3 months chemical storage at
maximum feed flow rate from which duty-standby dosing pumps DP-0903A/B feed to the inlet of a
static mixer (SM-0201) which ensures adequate mixing such that coagulation efficiency is
improved. The coagulated water is passed through a coagulation vessel (PV-0201) to allow
sufficient residence time for the coagulant to interact with the colloids present.

Filling of the chemical storage tank will be via manually controlled air operated pump from an IBC
(by others) to visual quantification. Level switches LS-0901 provide low and low-low alarms.

Raw Water Feed Pumps

Refer to P&ID 528-PID-01

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2.1.4 Objective

To feed the raw water from the raw water storage tanks through the screen filter, membrane filter
and granulated activated carbon (GAC) filter to the potable water storage tanks.

2.1.5 Functional Description

Under normal operation raw water is pumped via the raw water feed pumps (PP-0201A/B) to the
screen filter (SF-0201). The raw water feed pump flow rate is controlled by restriction orifices and
monitored by a flow transmitter (FIT-0201). During normal operation one (1) of the membrane feed
pumps is in operation while the other one (1) remain in standby mode.

When the screen filter enters flush mode, one pump continues to operate to provide sufficient flow
and pressure for cleaning. The other pump remains in standby.

During membrane recirculation step, one (1) pump operates while the remaining pump is in
standby.

During the membrane flush cycle, a short period of high flow flush water is required to flush solids
from the membrane system. One (1) pump operates to flush all the material to waste. The other
pump remains in standby.

Screen Filter
Refer to P&ID 528-PID-01

2.1.6 Objective

To remove any coarse particles from the raw water prior to the membrane filter.

2.1.7 Functional Description

Raw water is pumped via the raw water feed pumps (PP-0201A/B) to the screen filter (SF-0201).
The treated effluent flow from the screen filter flows to the membrane systems (UF-01A/B). The
screen filter automatically self cleans once differential pressure across the unit exceeds a preset
value (Nominally 40-50kPa). For a cleaning cycle the integral pressure switch sends signal to the
PLC to initiate a cleaning cycle for the screen filter. A diaphragm valve inside the screen filter
opens to allow the clarified feed water to jet into the screen cleaning the filter cake to the sump via
solenoid valve (SV-0201). A manual bag filter is provided as a standby unit when the screen filter
is offline for maintenance.

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Membrane System
Refer to P&ID 528-PID-01

2.1.8 Objective

To remove fine particulate from the feed via a semi-permeable membrane.

2.1.9 Functional Description

Screened water from the screen filters is pumped via the raw water feed pumps (PP-0201A/B) to
the membrane systems (UF-01A/B). The treated filtrate from the membrane filters flows to the
GAC filters (FV-0501 / FV-0502 / FV-0503). The membrane system has seven (7) different modes
of operation available depending on the state of the membrane filter and surrounding equipment.
Each of the two (2) UF trains are able to enter any of the operation modes independantly. The
modes are:

• Standby: The membrane system is idle and ready to run provided that no warnings or
alarms are triggered. The standby mode is used when the WTP is not operating due to
alarms or system faults.

• Filtration: Water is pumped to the membrane feed via the screen filter by the raw water
feed pumps. If the CIP makeup tank is not full, the filtrate from the membranes is sent to
the CIP makeup tank, otherwise the filtrate from the membranes is sent to the GAC
(facilitated by 2 on/off control valves per train). The system continues to operate in filtration
mode until the plant enters into a different mode from one of the various triggers.

• Backwash: After a pre-determined period of time (nominally 30 minutes, to be checked and

set during commissioning), or a measured increase in transmembrane pressure (TMP –
measured between PIT-0301 and PIT-0302 for UF-01A or PIT-0401 and PIT-0402 for UF-
01B), backwash mode is initiated. Once the backwash mode is initiated the raw water feed
pump flow is stopped to the train being backwashed via a control valve (AV-0301 for UF-
01A or AV-0401 for UF-01B). The backwash mode utilises a short burst (15 seconds
nominal) of low pressure compressed air on the feed side followed by a short burst (15
seconds nominal) of high pressure compressed air on the filtrate side and low pressure
compressed air on the feed side to force filtrate back through the membrane pores to
waste. Following the high pressure compressed air burst an extended (60 seconds
nominal) air scour using low pressure compressed air on the feed side of the membrane to

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further remove accumulated particulate to waste. Next the raw water feed pump is brought
back on-line with the low pressure compressed air running (10 seconds nominal) and finally
the system is flushed with the feed pump to waste (25 seconds nominal). All durations for
the backwash sequence will be able to be adjusted during commissioning.

• Pressure Decay Test: The pressure decay test is also known as the integrety test. The
pressure decay test determines the integrety of the membrane fibres by draining the filtrate
from the membrane modules and then pressurising the system with compressed air at
100kPa. The rate at which the pressure decays across the membranes to waste indicates if
the membranes are damaged. The pressure decay test is to be conducted automatically.

• Draindown: Removes water within the filter modules to allow maintenance to occur.

• Maintenance Wash (MW) and Clean in Place (CIP): The membrane cleaning cycles are an
automated process using filtered water stored in the local CIP makeup tank combined with
cleaning chemicals to make a chemical solution which is recirculated through the
membrane treatment system. An air diaphragm CIP dosing pump is provided for batch
dosing of chemical solution from the chemical storage tank to the inline dosing point. The
system features the following chemical cleans, the frequency of the clean can be manually
changed in commissioning set points, typical frequency shown below:

 Sodium hypochlorite MW – weekly

 Sodium hypochlorite CIP – monthly

 Citric Acid MW – weekly

 Citric acid CIP – monthly

The CIP pump is operated by controlling the flow rate of air to the CIP pump using solenoid valve
SV-1001 for sodium hypochlorite and SV-1002 for citric acid. A pressure regulator (PRV-1001 for
sodium hypochlorite or PRV-1002 for citric acid) is used to control the air pressure (and
subsequently air flow) and by opening the solenoid valve for a pre-determined length of time a
calculated volume of air is provided to the CIP pump which then doses a calculated volume of
chemical to the dosing point. All of the durations of the CIP / MW dosing steps will be able to be
changed during commissioning.

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Before a CIP or MW can begin, the system must check that all resources are available, i.e. CIP
Makeup Tank level is full, and the corresponding chemical storage tank is not reading low or
empty. The membrane MW and CIP cycles require a backwash cycle before beginning.

A high warning and high high alarm are provided for TMP. The high high alarm will initiate a
backwash cycle.

The turbidity of the feed water is measured by turbidity sensor AIT-0201. The feed turbidity sensor
has a high warning to alert operators of changed process conditions or possible problems with
upstream equipment.

Granulated Activated Carbon Filter, FV-0501, FV-0502, FV-0503

Refer to P&ID 528-PID-01

2.1.10 Objective

To remove colour, odour and other volatile compounds to meet the water quality guidelines.

2.1.11 Functional Description

Water flows into the top of the GAC filter where it is evenly distributed via a diffuser. The water
flows through the media bed as a plug flow and out the bottom of the vessel before flowing to the
potable water tank (TK-03). Media consists of (from bottom to top) heavy gravel, light gravel and
granulated activated carbon.

A backwash sequence is manually triggered by an operator. The backwash sequence is required

to redistribute the carbon bed to ensure that channelling is not occuring keeping GAC filter
removal efficiency high.

The GAC backwash pump PP-0701 is sized for optimal bed expansion. Water is delivered to the
GAC backwash pumps from the Backwash / CIP Tank and backwash waste is recycled to the
Raw Water Tanks.

The backwash is a semi-automatic sequence with prompts on the HMI. As the operator continues
through the prompts each step has a button to acknowledge when valves have been positioned in
the correct orientation and then the PLC will complete the step until the next operator interaction is
required.

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Potable Water Storage Tank, TK-03

Refer to P&ID 528-PID-01

2.1.12 Objective

To store potable water until required for consumption.

2.1.13 Functional Description

Potable water is fed from the GAC filters (FV-0501, FV-0502, FV-0503) to the potable water tank
(TK-03). The level in the potable water tank is monitored via a level transmitter (LIT-0601) and
controlled by feed of potable water from the WTP upstream. When the potable water tanks are full
the WTP will stop producing clean water. The WTP will not initiate producing more clean water
until the level in the potable water tanks decreases to a user defined value.

Potable Water Discharge Pumping, PP-0601A/B/C/D

Refer to P&ID 528-PID-01

2.1.14 Sites:

The potable water discharge pumping system is present at Site 1 only.

2.1.15 Objective

To transfer the stored potable water to the existing potable water network (by others).

2.1.16 Functional Description

A separate package control system is provided with this pump skid. A fault output to the PLC and
a run input to the pump controller must be provided for.

The duty/duty/duty/standby potable water discharge pumps transfer clean potable water from the
potable water tank (TK-03) to client. The potable water feed pumps act under VSD control to
maintain a constant outlet pressure. The flow from the discharge of the potable water feed pumps
is measured by a flow transmitter (FIT-0602).

The water quality on the discharge of the potable water feed pumps is constantly measured for
free Cl (AIT-0602), pH (AIT-0601) and turbidity (AIT-0603). All three water quality meters have
high and low warnings and high high and low low alarms. The water to these meters is piped
through an orifice plate to regulate the flow and then sent to the sump after analysis.

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Potable Water Recirculation Pump, PP-0601
Refer to P&ID 528-PID-01

2.1.17 Sites:

The potable water recirculation pump is present at twosites only.

2.1.18 Objective

To mix the stored potable water and provide water for analysis and WTP sink and safety shower.

2.1.19 Functional Description

A duty pump with pressure tank is utilised for the potable water recirculation pump. A pressure
switch will be utilised to control when the potable water recirculation pump is required to run.

The water quality on the discharge of the potable water recirculation pump is constantly measured
for free Cl (AIT-0602), pH (AIT-0601) and turbidity (AIT-0603). All three water quality meters have
high and low warnings and high high and low low alarms. The water to these meters is piped
through an orifice plate to regulate the flow and then sent to the sump after analysis.

Hypochlorite Disinfection System

Refer to P&ID 528-PID-01

2.1.20 Objective

Disinfection of the stored potable water to ensure compliance with required water quality (1-2ppm
free chlorine).

2.1.21 Functional Description

Two calculations are used for chlorine dosing flow rate.

The first is measurement of influent flow to the potable water tank (Flow measured at FIT-0601)
and utilising a combination of flow paced dosing in conjunction with PID loop regulation. This
method for controlling the chlorine dosing is to be used when flow is entering the potable water
tank.

The second is a maintenance dosing regimen utilising a PID loop to keep the free chlorine at the
setpoint. This method for controlling the chlorine dosing is to be utilised when flow is not entering
the potable water tank.

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Underground Sump, TK-05

Refer to P&ID 528-PID-01

2.1.22 Objective

Temporary storage of waste streams prior to pumping to sewerage.

2.1.23 Functional Description

The sump accepts waste streams from the raw water analysis (AIT-0201), potable water analysis,
coagulation vessel (PV-0201), screen filter (SF-0201) and membrane filters (UF-01A/B). The level
in the sump is monitored by a level transmitter (LT-0702). When the level is above a user
specified value (nominally XX%) a submersible pump (PP-0702) activates and pumps water to
sewer, until the water level reduces to a user specified low value (XX%) at which time the
submersible pump stops.

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3 Detailed Control Narratives

3.1 Control Zones

Refer to P&ID 528-PID-01

3.1.1 Objective

The WTP is segregated into two (4) separate control zones to allow a section of the plant to be
taken off-line for maintenance while the other section remains operational.

3.1.2 Functional Description

The four control zones are:

1. The main water treatment plant up to the potable water tanks including the compressed air
system, raw water storage, ultrafiltration, activated carbon filtration, sump and all chemical
dosing excluding the sodium hypochlorite disinfection dosing.

2. From the potable water tanks through to the discharge to the client. This system includes
the potable water pumps, the sodium hypochlorite disinfection system and the water quality
measuring system.

3. Sump pump

4. Air Compressors

3.1.3 Operation Aspects

Operation modes

Any control zone can be individually placed into maintenance mode while the remaining areas of
the WTP in automatic mode. Care will have to be taken to ensure that problems do not occur at
the interfaces between the control zones when the entire WTP is not in AUTO mode from low or
high tank levels.

Start-up

There are no special start-up requirements.

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Fallback Strategy

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

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3.2 Fire Water Tanks Level Controllers LIC-0101/LIC-0102

Refer to P&ID 528-PID-01

3.2.1 Objective

The level in the fire water tanks is monitored, but not controlled.

3.2.2 Applicability

The firewater tank level controllers are utilised at all sites. Site 3 has two (2) fire tanks (TK-01A/B)
each with a level transmitter (LIT-0103 & LIT-0104). Site 1 has one (1) fire tank (TK-01A) with a
level transmitter (LIT-0103). Site 2 has one (1) fire tank (TK-01A), but no level transmitter
installed.

3.2.3 Functional Description

The level in each fire water tank (TK-01A/B) is measured by the level transmitter (LIT-0103 & LIT-
0104) respectively. The signal from the level transmitters is sent to LIC-0101 and LIC-0102. The
difference between the level transmitters is to be monitored and an alarm raised if the difference
between them exceeds a user input value. High, high high, low and low low alarms are to be
rasied on tank levels.

3.2.4 Operation Aspects

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Failure of one level Raise alarm on the HMI and Alarm on HMI will remain until the
transmitter (LIT- continue operation. Set ALARM RESET handswitch in the PLC is
0103 OR LIT-0104) remining transmitter as duty. activated.
Failure of second Raise alarm on the HMI and Alarm on HMI will remain until the
level transmitter continue operation. ALARM RESET handswitch in the PLC is
(LIT-0103 OR LIT- activated.

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0104)

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

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3.3 Raw Water Tanks Level Controllers LIC-0101/LIC-0102

Refer to P&ID 528-PID-01

3.3.1 Objective

The level in the raw water balance tanks is controlled via the feed control valves to the two
ultrafiltration trains (AV-0301 and AV-0401) coupled with raw water feed pump (PP-0201A/B).

3.3.2 Applicability

The raw water tank level controllers are utilised at all sites.

3.3.3 Functional Description

The level in each raw water balance tank (TK-02A/B) is measured by the level transmitter (LIT-
0101 & LIT-0102) respectively. The signal from the level transmitters is sent to LIC-0101 and LIC-
0102 and the combined signal from the two controllers is used to determine the operation of the
feed and discharge from the raw water balance tanks. One transmitter is to be duty and the other
to be standby in normal operation, with either able to be manually disabled via the HMI. The
difference between the level transmitters is to be monitored and an alarm raised if the difference
between them exceeds a user input value. High, high high, low and low low alarms are to be
rasied on tank levels.

If the duty level transmitter level below X%, the ultrafiltration trains will enter standby mode and
PP-0201A/B will stop and raw water will cease to be fed into the WTP. If the combined level in the
tanks rises above X%, the ultrafiltration trains will be available to enter filtration mode again when
required.

3.3.4 Operation Aspects

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

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 Control Philosophy

Failure of one level Raise alarm on the HMI and Alarm on HMI will remain until the
transmitter (LT- continue operation. Set ALARM RESET handswitch in the PLC is
0101 OR LT-0102) remining transmitter as duty. activated.
Failure of second
Alarm on HMI will remain until the
level transmitter Raise alarm on the HMI and
ALARM RESET handswitch in the PLC is
(LT-0101 OR LT- shut down WTP
activated.
0102)

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

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3.4 Coagulant Feed Logic Sequence

Refer to P&ID 528-PID-01.

3.4.1 Objective

To control the feed of coagulant to the raw water for optimal particle and colour removal in the
ultrafiltration system.

3.4.2 Applicability

The coagulant dosing systems are only utilised at Site 2.

3.4.3 Functional Description

A PLC soft hand switch is used to select the plant into AUTO or OFF mode. An additional PLC
soft hand switch is used to place the plant into MAINTENANCE mode. In AUTO mode, the feed
will flow from the coagulant dosing pumps (DP-0903A/B) into the screen filter filtrate, through the
static mixer (SM-0201) and into the coagulation vessel. The rate of coagulant feed is flowpaced
based on an operator desiginated setpoint and the flow measured by FIT-0201.

3.4.4 Operation Aspects

Operation modes

This logic block is required to be AUTO in all normal operational modes.

Start-up

Sequence will start when flow is detected through FIT-0102.

Fallback Strategy

Malfunction Automatic Action Operator Action

Low low level (LS-0901) Coagulant pump (DP-0903A/B) will Operator Reset required
reported in coagulant dosing stop. An alarm will be displayed on once fault condition is
tank (TK-08) the HMI. removed

Shutdown/Abnormal Conditions

There are no abnormal conditions.

Page 20 of 73
 Control Philosophy

3.5 Screen Filters Logic Sequence

Refer to P&ID 528-PID-01.

3.5.1 Objective

To control the operation of Screen Filter SF-0201.

3.5.2 Functional Description

One screen filter (Filtaworx FW080) is provided as pre-treatment prior to the membrane system.
The system filters feed water until the backwashing sequence of the screen filter is triggered either
by the expiration of a timer, a signal from an integral differential pressure switch across the filter or
the membrane unit initiates a cleaning cycle.

During normal filtration mode the setting of the valves are as follows:

Table 1: Screen filter control valve positions during different filtration modes

Mode Mode Mode Mode

Valve / Equipment
1 2 3 4

Close Close
AV-0301 Open Open
d d
Close Close
AV-0401 Open Open
d d
Close Close Close
SV-0201 Open
d d d
Membrane Feed Pump (PP-
On On On On
0201A/B)

Where:

 Mode 1: Treatment plant in Filtration mode

 Mode 2: Screen filter back wash initiated, raw water is used to backwash the screen. The
screen filter actuated outlet valve is closed forcing the pump pressure to ramp up

Page 21 of 73
  Mode 3: The solenoid valve is opened forcing the cleaning of the screen filter, all wastes
drain away.

 Mode 4: After user inputted delay, the backwash is complete and the system returns to
mode 1 (Filtration mode).

3.5.3 Operation Aspects

Operation modes

This logic block is required to be AUTO in all normal operational modes.

Start-up

No special start-up sequence required.

Fallback Strategy

Malfunction Automatic Action Operator Action

Shutdown/Abnormal Conditions

If the differential pressure switch input remains on following a backwash sequence the system will attempt
to complete another backwash immediately. A user adjustable set-point will be available to determine how
many attempts can be made prior to the system shutting down.

Page 22 of 73
 Control Philosophy

3.6 Raw Water Feed Pumps Logic Sequence

Refer to P&ID 528-PID-01

3.6.1 Objective

The raw water feed pumps (PP-0201A/B) supply the raw water to the water treatment plant for
processing.

3.6.2 Functional Description

Duty/standby selection: One of PP-0201A/B is nominated as the duty pump by a PLC soft hand
switch. Duty pump is defined as the pump that is selected to run. The other pump therefore
becomes the standby. Change of duty selection is by this same manual PLC soft hand switch.

In AUTO mode, PP-0201A/B flow is monitored by FIT-0201 flow meter.

In AUTO mode the pump will turn on when signalled by a decreased level in the potable water
storage tank (TK-03) is triggered (Via LIT-0601 user set point). Raw water feed pump, PP-
0201A/B will turn off when the potable water tank level transmitter LIT-0601 reaches a user
setpoint level condition.

If raw water feed pump, PP-0201A/B is called to run and no flow is detected through flow meter
FIT-0201 after X seconds, then the pump will switch off and an alarm will be displayed on the HMI.

The pump logic is contolled via the following setpoints adjustable on the HMI.

Table 2: HMI process setpoints

Adjustable
Setpoint Units Function
Value
The time that FIT-0201 detects no flow
Zero Flow Delay Second
1 - 10 before it switches off Backwash PP-
Timer s
0201A/B/C.
3.6.3 Operation Aspects

Operation modes

The membrane feed pump logic control is required to be AUTO in all normal operational modes.

Start-up

Refer to section 3.7.2

Page 23 of 73
Fallback Strategy

Malfunction Automatic Action Operator Action

Input signal from Raw
Switch off Raw Water Feed
Water Tank (LOW-LOW)
Pumps PP-0201A/B raise No operator intervention required.
or Potable Water Tank
alarm on HMI
(HIGH-HIGH)
If the standby pump starts
Switch off Duty Backwash successfully then continue operation
No flow after X Seconds Pump PP-0201A/B raise and raise alarm on the HMI.
of start command being alarm on HMI, switch over If both pumps fail then automatic
sent to the standby pump and re- operation will not commence until the
commence ALARM RESET handswitch in the
PLC is activated.

Shutdown/Abnormal Conditions

Stop pumps on signal from Raw Water Tank low level and Potable Water Tank high level.

3.7 Flow Controller FIC-0201

Refer to P&ID 528-PID-01

3.7.1 Objective

Flow Controller FIC-0201 is used to measure the flow rate out of the raw water feed pumps PP-
0201A/B.

3.7.2 Functional Description

This is a monitoring device only.:

3.7.3 Operation Aspects

Page 24 of 73
 Control Philosophy

Operation modes

Flow controller FIC-0201 is required to be in AUTO during all normal operating modes. The flow
transmitter provides flow indication and high/low alarms for flow in the screen filter discharge line.

Start-up

There is no special start-up sequence.

Fallback Strategy

Refer to Section Error: Reference source not found1

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

Page 25 of 73
3.8 Feed Turbidity Meter AIC-0201

Refer to P&ID 528-PID-01

3.8.1 Objective

AIC-0201 is used to detect turbidity in the raw water feed line.

3.8.2 Applicability

The feed turbidity meter is present at all sites.

3.8.3 Functional Description

Turbidity Meter AIC-0201 will raise a plant alarm if high turbidity is detected. A high-high turbidity
alarm will shut down the water treatment plant.

3.8.4 Operation Aspects

Operation modes

Turbidity Meter AIC-0201 will raise a high turbidity warning and high-high turbidity alarm if high
turbidity is detected.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Turbidity
Raise alarm on the HMI. Alarm on HMI will remain until the ALARM
Transmitter AIC-
Shut down WTP. RESET handswitch in the PLC is activated
0201 (Bad PV)

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

Page 26 of 73
 Control Philosophy

3.9 Coagulation Vessel Drain Valve (AV-0201)

Refer to P&ID 528-PID-01

3.9.1 Objective

The coagulation vessel drain valve (AV-0201) allows for the coagulation vessel to be drained if
solids have settled out during periods of plant inactivity.

3.9.2 Applicability

The coagulation vessel drain valve is present at Site 1 only.

3.9.3 Functional Description

In AUTO mode, AV-0201 will open for XX seconds upon starting of the WTP if there has been no
flow through FIT-0201 for longer than XXX minutes.

In AUTO mode while valve AV-0201 is open PP-0201A/B are not able to run.

In MAINTENANCE mode, AV-0201 can be open and closed via soft hand switches on the HMI.

3.9.4 Operation Aspects

Operation modes

The potable water pump logic control is required to be AUTO in all normal operational modes.

Start-up

Refer to section 3.2.2

Fallback Strategy

Malfunction Automatic Action Operator Action

AV-0201 failed to Alarm on HMI will remain until the
Raise alarm on HMI. Shut
open/closed or limit ALARM RESET handswitch in the
down WTP
switch failure PLC is activated

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

Page 27 of 73
3.10 Membrane Filter Logic Sequence

Refer to P&IDs 528-PID-01

3.10.1 Objective

To automatically control the membrane filtration unit and associated equipment to allow optimal
performance of the unit with minimal cleaning cycles.

3.10.2 Functional Description

Under normal conditions the membrane filtration unit undergoes six (6) different modes of
operation. The majority of operation time should be spent in filtration mode, where the feed water
is actively passing through the membrane material to produce clean filtrate. The modes are:

Standby (UF Mode 1):

In standby mode the membrane filtration unit is ready to operate but not currently performing any
actions. Standby mode is the default mode when the WTP is not running.

Table 3: Membrane filter control valve positions during standby mode UF-01A

Valve / UF Mode
Equipment 1
AV-0301 Closed
AV-0302 Closed
AV-0303 Closed
AV-0304 Closed
SV-1004 Closed
SV-1006 Closed

Table 4: Membrane filter control valve positions during standby mode UF-01B

Valve / UF Mode
Equipment 1
AV-0401 Closed
AV-0402 Closed
AV-0403 Closed
AV-0404 Closed
SV-1005 Closed
SV-1007 Closed

Page 28 of 73
 Control Philosophy

Filtration (UF Mode 2):

In filtration mode the membrane filtration unit is actively producing filtrate. Filtration mode is the
default mode when the WTP is running.

Table 5: Membrane filter control valve positions during filtration mode UF-01A

Step Step Step Step

Valve / Equipment
1 2 3 4

Close Open Open Open

AV-0301
d
Close Open Close Close
AV-0302
d d d
Close Close Close Open
AV-0303
d d d
Close Close Open Close
AV-0304
d d d
Close Close Close Close
SV-0201
d d d d
Close Close Close Close
SV-1004
d d d d
Close Close Close Close
SV-1006
d d d d
Raw Water Feed Pump (PP- On On On
Off
0201A/B)
Step 1: Standby mode

Step 2: Flush mode. Flush mode is to be enabled if the UF train has been in standby mode for
more than XX minutes.

Step 3: Initial filtration with the filtrate produced filling the CIP make-up tank. Once fill to (User
adjusted) level on level transmitter (LIT-0701) is tripped step 4 is initiated.

Step 4: Filtration with filtrate proceeding to downstream processes. Step 3 is the usual filtration
mode.

Page 29 of 73
Table 6: Membrane filter control valve positions during filtration mode UF-01B

Step Step Step Step

Valve / Equipment
1 2 3 4

Close Open Open Open

AV-0401
d
Close Open Close Close
AV-0402
d d d
Close Close Close Open
AV-0403
d d d
Close Close Open Close
AV-0404
d d d
Close Close Close Close
SV-0201
d d d d
Close Close Close Close
SV-1005
d d d d
Close Close Close Close
SV-1007
d d d d
Raw Water Feed Pump (PP- On On On
Off
0201A/B)
Step 1: Standby mode

Step 2: Flush mode. Flush mode is to be enabled if the UF train has been in standby mode for
more than XX minutes.

Step 3: Initial filtration with the filtrate produced filling the CIP make-up tank. Once fill to (User
adjusted) level on level transmitter (LIT-0701) is tripped step 4 is initiated.

Step 4: Filtration with filtrate proceeding to downstream processes. Step 3 is the usual filtration
mode.

Membrane Backwash (UF Mode 3):

In membrane backwash mode the membrane filtration unit is cleaning material accumulated via
filtration from the membrane fibres. Membrane backwash mode is controlled via timer with an
override if transmembrane pressure (TMP) exceeds a user inputted value. Transmembrane
pressure is calculated via:

TMP = Filtrate Pressure (PIT-0302) – Feed Pressure (PIT-0301) for UF-01A

Page 30 of 73
 Control Philosophy

TMP = Filtrate Pressure (PIT-0402) – Feed Pressure (PIT-0401) for UF-01B

The duration of each step in the backwash sequence shall be able to be manually inputted via the
HMI.

Table 7: Membrane filter control valve positions during membrane backwash mode (UF-01A)

Step Step Step Step Step Step Step

Valve / Equipment
1 2 3 4 5 6 7

Close Close Close Close Close Close Close

AV-0201
d d d d d d d
Open Close Close Close Open Open
AV-0301 Open
d d d
Close Close Open Open Close
AV-0302 Open Open
d d d
Open Close Close Close Close Close Open
AV-0303
d d d d d
Close Close Close Close Close Close Close
AV-0304
d d d d d d d
Close Close Close Close Close Close Close
SV-0201
d d d d d d d
Close Close Open Close Close Close Close
SV-1004
d d d d d d
Close Close Open Open Close Close
SV-1006 Open
d d d d
Raw Water Feed Pump (PP- On Off On On
Off Off On
0201A/B)
Step 1: Filtration mode

Step 2: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation
for the backwash cycle

Step 3: Filtrate back flush using compressed air and low pressure aeration air scour for XXX
seconds

Step 4: The back flush stops but the extended aeration continues for XXX seconds

Step 5: The feed water pumps are used in conjunction with the low pressure air scour to flush all
the wastes from the system by opening up the waste outlet valve and pumping water for XXX
seconds.

Page 31 of 73
Step 6: Continued flush, no aeration for XXX seconds.

Step 7: After expiration of flush timer, resume filtration mode

Table 8: Membrane filter control valve positions during membrane backwash mode (UF-01B)

Step Step Step Step Step Step Step

Valve / Equipment
1 2 3 4 5 6 7

Close Close Close Close Close Close Close

AV-0201
d d d d d d d
Open Close Close Close Open Open
AV-0401 Open
d d d
Close Close Open Open Close
AV-0402 Open Open
d d d
Open Close Close Close Close Close Open
AV-0403
d d d d d
Close Close Close Close Close Close Close
AV-0404
d d d d d d d
Close Close Close Close Close Close Close
SV-0201
d d d d d d d
Close Close Open Close Close Close Close
SV-1005
d d d d d d
Close Close Open Open Close Close
SV-1007 Open
d d d d
Raw Water Feed Pump (PP- On Off On On
Off Off On
0201A/B)
Step 1: Filtration mode

Step 2: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation
for the backwash cycle

Step 3: Filtrate back flush using compressed air and low pressure aeration air scour for XXX
seconds

Step 4: The back flush stops but the extended aeration continues for XXX seconds

Step 5: The feed water pumps are used in conjunction with the low pressure air scour to flush all
the wastes from the system by opening up the waste outlet valve and pumping water for XXX
seconds.

Page 32 of 73
 Control Philosophy

Step 6: Continued flush, no aeration for XXX seconds.

Step 7: After expiration of flush timer, resume filtration mode

Membrane Cleaning / Maintenance Wash (UF Mode 4 / 5):

The membrane cleaning cycles are an automated process that are conducted periodically to
remove waste materials that a normal backwash is unable to remove. The membrane cleaning
cycles utilise filtered water stored in the local CIP make-up tank combined with cleaning chemicals
to create a chemical solution which is recirculated through the membrane filtration system.

Two (2) air diaphragm dosing pumps (DP-0803 for citric acid and DP-0801 for sodium
hypochlorite) are provided for batch dosing of chemical solution from the chemical bulk storage
tank to the inline dosing point. The membrane system features the following chemical cleaning
cycles with estimated frequency of operation, the frequency of the cleaning cycles can be
manually changed during commissioning.

• Sodium Hypochlorite Maintenance Wash (MW) – Weekly

• Sodium Hypochlorite Clean in Place (CIP) – Manually initiated with an automatic override 2
monthly

• Citric Acid Maintenance Wash – On demand

• Citric Acid Clean in Place – Manually initiated with an automatic override 2 monthly

Before a CIP or MW can begin, the system must check that all required resources are available.
Specifically CIP Make-up tank level transmitter (LIT-0701) must be above a user input value and
the required chemical storage tank (LS-0802 for citic acid or LS-0801 for sodium hypochlorite) can
not read low or low-low.

Each CIP pump is operated by controlling the flow rate of air to the CIP pump using solenoid valve
SV-1001 for sodium hypochlorite and SV-1002 for citric acid. A pressure regulator is used to
control the air pressure (and subsequently air flow) and by opening the solenoid valve for a pre-
determined length of time a calculated volume of air is provided to the CIP pump which then
doses a calculated volume of chemical to the dosing point.

The duration of each step in the backwash sequence shall be able to be manually inputted via the
HMI.

Page 33 of 73
If a CIP or MW is initiated and the temperature from CIP / backwash tank temperature transmitter
(TIT-0701) is below a user defined value (nominally 20oC) then the CIP tank heater (HE-0701) is
to be enabled until the tank temperature is brought above the user defined value. Once the tank
temperature transmitter is above the setpoint for x minutes a prompt is raised on the HMI that the
CIP / MW can proceed (The heater remains on and the plant stays in normal filtration / backwash /
standby modes as required). Once the prompt is acknowledged the CIP / MW cycle runs.

The control system will include safeguards against excessive amounts of MW/CIP chemicals
entering the treated water storage tank. Essentially, once chemicals have been dosed the current
sequence needs to be completed or the system flushed prior to allowing the plant to re-enter
filtration mode.

Page 34 of 73
Table 9: Membrane filter control valve positions during citric acid maintenance wash mode (UF-01A)

Step Step Step Step Step Step Step Step Step Step
Valve / Equipment Step 4 Step 5
1 3 6 7 8 9 10 11 11 12
Close Close Closed Close Close Close Close Closed Closed Closed Closed
AV-0201 Closed
d d d d d d
Close Close Closed Close Close Close Close Open Closed Open Open
AV-0301 Closed
d d d d d d
Close Open Close Close Open Open Closed Closed Closed
AV-0302 Open Closed Open
d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
AV-0303 Closed
d d d d d d
Close Close Closed Open Closed Closed Open Open
AV-0304 Open Open Open Open
d d
Close Close Closed Close Close Close Open Closed Closed Open Closed
AV-0701 Closed
d d d d d
Close Close Open Open Close Close Closed Closed Closed Closed
AV-0702 Open Open
d d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
SV-1001 Closed
d d d d d d
Close Close Closed Open Close Close Close Closed Closed Closed Closed
SV-1002 Closed
d d d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
SV-1004 Closed
d d d d d d
Close Open Close Close Close Close Closed Closed Closed Closed
SV-1006 Open Closed
d d d d d
Raw Water Feed
Pump (PP- Off Off Off Off Off Off Off Off On Off On On
0201A/B)
Citric Acid CIP Off Off Off Off On Off Off Off Off Off Off Off
Pump (DP-0803)
CIP / Backwash
Off Off On Off On On On Off Off Off Off Off
Pump (PP-0701)
Sump Pump (PP-
Off Off Off On
0702)
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The CIP pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by opening
up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 6, SV-1002 is energised and DP-0803 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8: Cleaning solution is flushed to waste until CIP make-up tank user input level (LIT-0701) is reached.

Step 9: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 10: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 11: After step 10 a prompt is to appear on the screen instructing the operator to adjust HV-0711 to be adjusted to recirculate
flow in the sump and add sodium hydroxide to the sump manually. Once aknowledged on the HMI the sump pump (PP-0702) is run
for XX minutes. Following the run time another prompt is displayed on the HMI instructing the operator to adjust HV-0711 to
discharge to sewer. Once aknowledged step 12 is initiated.

Step 12: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 13: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 10: Membrane filter control valve positions during citric acid maintenance wash mode (UF-01B)

Step Step Step Step Step Step Step Step Step Step
Valve / Equipment Step 4 Step 5
1 3 6 7 8 9 10 11 12 13
Close Close Closed Close Close Close Close Closed Closed Closed Closed
AV-0201 Closed
d d d d d d
Close Close Closed Close Close Close Close Open Closed Open Open
AV-0401 Closed
d d d d d d
Close Open Close Close Open Open Closed Closed Closed
AV-0402 Open Closed Open
d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
AV-0403 Closed
d d d d d d
Close Close Closed Open Closed Closed Open Open
AV-0404 Open Open Open Open
d d
Close Close Closed Close Close Close Open Closed Closed Open Closed
AV-0701 Closed
d d d d d
Close Close Open Open Close Close Closed Closed Closed Closed
AV-0703 Open Open
d d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
SV-1001 Closed
d d d d d d
Close Close Closed Open Close Close Close Closed Closed Closed Closed
SV-1002 Closed
d d d d d
Close Close Closed Close Close Close Close Closed Closed Closed Closed
SV-1005 Closed
d d d d d d
Close Open Close Close Close Close Closed Closed Closed Closed
SV-1007 Open Closed
d d d d d
Raw Water Feed
Pump (PP- Off Off Off Off Off Off Off Off On Off On On
0201A/B)
Citric Acid CIP Off Off Off Off On Off Off Off Off Off Off Off
Pump (DP-0803)
CIP / Backwash
Off Off On Off On On On Off Off Off Off Off
Pump (PP-0701)
Sump Pump (PP-
Off Off Off On
0702)
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The CIP pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by opening
up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 6, SV-1002 is energised and DP-0803 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8: Cleaning solution is flushed to waste until CIP make-up tank user input level (LIT-0701) is reached.

Step 9: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 10: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 11: After step 10 a prompt is to appear on the screen instructing the operator to adjust HV-0711 to be adjusted to recirculate
flow in the sump and add sodium hydroxide to the sump manually. Once aknowledged on the HMI the sump pump (PP-0702) is run
for XX minutes. Following the run time another prompt is displayed on the HMI instructing the operator to adjust HV-0711 to
discharge to sewer. Once aknowledged step 12 is initiated.

Step 12: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 13: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 11: Membrane filter control valve positions during sodium hypochlorite maintenance wash mode (UF-01A)

Valve /
Step Step Step Step Step Step Step
Equipm Step 1 Step 2 Step 8A Step 9 Step 10 Step 12
3 4 5 6 7 8B 11
ent
AV- Closed Close Close Close Close Close Close Closed Closed Closed
Closed Closed Closed
0201 d d d d d d
AV- Closed Close Close Close Close Close Close Open Open Open
Closed Closed Closed
0301 d d d d d d
AV- Open Open Close Close Close Open Open Closed Closed
Closed Open Open ?
0302 d d d
AV- Closed Close Close Close Close Close Close Closed Closed Closed
Closed Closed Closed
0303 d d d d d d
AV- Closed Close Close Open Closed Open Open
Closed Open Open Open Open ?
0304 d d
AV- Closed Close Close Close Close Close Open Closed Open Closed
Closed Closed Closed
0701 d d d d d
AV- Closed Close Open Open Close Closed Closed Closed
Closed Open Open Closed Closed
0702 d d
SV- Closed Close Close Close Open Close Close Closed Closed Closed
Closed Closed Closed
1001 d d d d d
SV- Closed Close Close Close Close Close Close Closed Closed Closed
Closed Closed Open
1003 d d d d d d
SV- Open Close Close Close Close Close Close Closed Closed Closed
Closed Closed Closed
1004 d d d d d d
SV- Open Open Close Close Close Close Closed Closed Closed
Closed Open Closed Closed
1006 d d d d
Raw
Water Off Off Off Off Off Off Off Off Off Off On On On
Feed
Pump
(PP-
0201A/
B)
Hypo
CIP
Pump Off Off Off Off Off On Off Off Off Off Off Off Off
(DP-
0801)
SMBS
Pump
Off Off Off Off Off Off Off Off On Off Off Off Off
(DP-
0901)
CIP /
Backwa
sh
Off Off Off On Off On On On ? Off Off Off Off
Pump
(PP-
0701)
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 5, SV-1001 is energised and DP-0801 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8A: Cleaning solution is flushed to waste until CIP make-up tank user input level (LIT-0701) is reached.

Step 8B: SMBS is dosed into the tundish to drain to the sump for XX seconds. This step is to run XX seconds after step 8A is
initiated. It can finish before or after Step 8A, if Step 8A finishes prior to step 8B step 9 is initiated. If step 8B finishes prior to step
8A the system will wait for step 8A to finish prior to starting step 9.

Step 9: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 10: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 11: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 12: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 12: Membrane filter control valve positions during sodium hypochlorite maintenance wash mode (UF-01B)

Valve /
Step Step Step Step Step
Equipm Step 1 Step 2 Step 7 Step 8A Step 8B Step 9 Step 10 Step 12
3 4 5 6 11
ent
AV- Closed Close Close Close Clos Closed Closed Closed Closed
Closed Closed Closed Closed
0201 d d d ed
AV- Closed Close Close Close Clos Closed Open Open Open
Closed Closed Closed Closed
0401 d d d ed
AV- Open Open Close Clos Open Open Closed Closed
Closed Open Closed Open ?
0402 d ed
AV- Closed Close Close Close Clos Closed Closed Closed Closed
Closed Closed Closed Closed
0403 d d d ed
AV- Closed Close Close Ope Open Closed Open Open
Closed Open Open Open ?
0404 d d n
AV- Closed Close Close Close Clos Open Closed Open Closed
Closed Closed Closed Closed
0701 d d d ed
AV- Closed Close Open Ope Closed Closed Closed Closed
Closed Open Open Closed Closed
0703 d n
SV- Closed Close Close Close Ope Closed Closed Closed Closed
Closed Closed Closed Closed
1001 d d d n
SV- Closed Close Close Close Clos Closed Closed Closed Closed
Closed Closed Closed Open
1003 d d d ed
SV- Open Close Close Close Clos Closed Closed Closed Closed
Closed Closed Closed Closed
1005 d d d ed
SV- Open Open Close Clos Closed Closed Closed Closed
Closed Open Closed Closed Closed
1007 d ed
Raw
Water Off Off Off Off Off Off Off Off Off Off On On On
Feed
Pump
(PP-
0201A/
B)
Hypo
CIP
Pump Off Off Off Off Off On Off Off Off Off Off Off Off
(DP-
0801)
SMBS
Pump
Off Off Off Off Off Off Off Off On Off Off Off Off
(DP-
0901)
CIP /
Backwa
sh
Off Off Off On Off On On On ? Off Off Off Off
Pump
(PP-
0701)
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 5, SV-1001 is energised and DP-0801 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8A: Cleaning solution is flushed to waste until CIP make-up tank user input level (LIT-0701) is reached.

Step 8B: SMBS is dosed into the tundish to drain to the sump for XX seconds. This step is to run XX seconds after step 8A is
initiated. It can finish before or after Step 8A, if Step 8A finishes prior to step 8B step 9 is initiated. If step 8B finishes prior to step
8A the system will wait for step 8A to finish prior to starting step 9.

Step 9: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 10: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 11: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 12: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 13: Membrane filter control valve positions during citric acid CIP mode (UF-01A)

St Ste
Valve / Step Step Step Step Step Step
ep Step 2 Step 8 p Step 11 Step 12 Step 14 Step 15
Equipment 3 4 5 6 7 13
1 10
Cl Closed Close Closed Closed Close Closed Closed
Close Close Close Close Clo
AV-0201 os d Closed d
d d d d sed
ed
Cl Closed Close Closed Open Close Open Open
Close Close Close Close Clo
AV-0301 os d Closed d
d d d d sed
ed
Cl Open Open Open Open Close Closed Closed
Close Close Close Op
AV-0302 os Open Closed d
d d d en
ed
Cl Closed Close Closed Closed Close Closed Closed
Close Close Close Close Clo
AV-0303 os d Closed d
d d d d sed
ed
Cl Closed Close Open Closed Close Open Open
Close Op
AV-0304 os d Open Open Open Closed d
d en
ed
Cl Closed Close Close Open Closed Close Open Closed
Close Close Close Clo
AV-0701 os d d Closed d
d d d sed
ed
Cl Closed Open Open Closed Closed Close Closed Closed
Close Clo
AV-0702 os Open Open Closed d
d sed
ed
SV-1001 Cl Closed Close Close Close Close Close Closed Clo Closed Closed Close Closed Closed
os d d d d d sed d
 ed
Cl Closed Close Open Closed Closed Close Closed Closed
Close Close Close Clo
SV-1002 os d Closed d
d d d sed
ed
Cl Open Close Close Closed Closed Close Closed Closed
Close Close Close Clo
SV-1004 os d d Closed d
d d d sed
ed
Cl Open Open Close Closed Closed Close Closed Closed
Close Close Clo
SV-1006 os Open d Closed d
d d sed
ed
PP- Of
Off Off Off Off Off Off Off Off Off On Off On On
0201A/B f
Citric Acid
Of
CIP Pump Off Off Off Off On Off Off Off Off Off Off Off Off
f
(DP-0803)
Of
PP-0701 Off Off On Off On On Off On Off Off Off Off Off
f
PP-0702 Off Off Off On
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 5, SV-1002 is energised and DP-0903 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.
Step 8: The membranes are allowed to soak in the chemical solution for programmed length of time.

Step 9: (Not shown in table) Repeat steps 7 and 8 programmed number of times.

Step 10: Cleaning solution is flushed to waste until CIP make-up tank low level (LIT-0701) is reached.

Step 11: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 12: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 13: After step 12 a prompt is to appear on the screen instructing the operator to adjust HV-0711 to be adjusted to recirculate
flow in the sump and add sodium hydroxide to the sump manually. Once aknowledged on the HMI the sump pump (PP-0702) is run
for XX minutes. Following the run time another prompt is displayed on the HMI instructing the operator to adjust HV-0711 to
discharge to sewer. Once aknowledged step 14 is initiated.

Step 14: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 15: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 14: Membrane filter control valve positions during citric acid CIP mode (UF-01B)

St Ste
Valve / Step Step Step Step Step Step
ep Step 2 Step 8 p Step 11 Step 12 Step 14 Step 15
Equipment 3 4 5 6 7 13
1 10
Cl Closed Close Closed Closed Close Closed Closed
Close Close Close Close Clo
AV-0201 os d Closed d
d d d d sed
ed
Cl Closed Close Closed Open Close Open Open
Close Close Close Close Clo
AV-0401 os d Closed d
d d d d sed
ed
Cl Open Open Open Open Close Closed Closed
Close Close Close Op
AV-0402 os Open Closed d
d d d en
ed
Cl Closed Close Closed Closed Close Closed Closed
Close Close Close Close Clo
AV-0403 os d Closed d
d d d d sed
ed
Cl Closed Close Open Closed Close Open Open
Close Op
AV-0404 os d Open Open Open Closed d
d en
ed
Cl Closed Close Close Open Closed Close Open Closed
Close Close Close Clo
AV-0701 os d d Closed d
d d d sed
ed
Cl Closed Open Open Closed Closed Close Closed Closed
Close Clo
AV-0703 os Open Open Closed d
d sed
ed
SV-1001 Cl Closed Close Close Close Close Close Closed Clo Closed Closed Close Closed Closed
os d d d d d sed d
 ed
Cl Closed Close Open Closed Closed Close Closed Closed
Close Close Close Clo
SV-1002 os d Closed d
d d d sed
ed
Cl Open Close Close Closed Closed Close Closed Closed
Close Close Close Clo
SV-1005 os d d Closed d
d d d sed
ed
Cl Open Open Close Closed Closed Close Closed Closed
Close Close Clo
SV-1007 os Open d Closed d
d d sed
ed
PP- Of
Off Off Off Off Off Off Off Off Off On Off On On
0201A/B f
Citric Acid
Of
CIP Pump Off Off Off Off On Off Off Off Off Off Off Off Off
f
(DP-0803)
Of
PP-0701 Off Off On Off On On Off On Off Off Off Off Off
f
PP-0702 Off Off Off On
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 5, SV-1002 is energised and DP-0803 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.
Step 8: The membranes are allowed to soak in the chemical solution for programmed length of time.

Step 9: (Not shown in table) Repeat steps 7 and 8 programmed number of times.

Step 10: Cleaning solution is flushed to waste until CIP make-up tank low level (LIT-0701) is reached.

Step 11: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 12: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 13: After step 12 a prompt is to appear on the screen instructing the operator to adjust HV-0711 to be adjusted to recirculate
flow in the sump and add sodium hydroxide to the sump manually. Once aknowledged on the HMI the sump pump (PP-0702) is run
for XX minutes. Following the run time another prompt is displayed on the HMI instructing the operator to adjust HV-0711 to
discharge to sewer. Once aknowledged step 14 is initiated.

Step 14: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 15: Normal filtration mode resumes with filling of the now empty CIP make-up tank
Table 15: Membrane filter control valve positions during sodium hypochlorite CIP mode (UF-01A)

St
Valve / Step Ste Step Step Step Step Step Step Step
ep Step 3 Step 5 Step 6 Step 8
Equipment 1 p4 7 10A 10B 11 12 13 14
2
Cl Clo Close Close Close Close
Close Close Clos Close
AV-0201 os Closed sed Closed Closed Closed d d d d
d d ed d
ed
Cl Clo Close Open Open Open
Close Close Clos Close
AV-0301 os Closed sed Closed Closed Closed d
d d ed d
ed
O Op Open Open Close Close
Close Close Clos
AV-0302 pe Open en Closed Closed Open ? d d
d d ed
n
Cl Clo Close Close Close Close
Close Close Clos Close
AV-0303 os Closed sed Closed Closed Closed d d d d
d d ed d
ed
Cl Clo Open Close Open Open
Close
AV-0304 os Closed sed Open Open Open Closed Open ? d
d
ed
Cl Clo Closed Open Close Open Close
Close Close Clos Close
AV-0701 os Closed sed Closed Closed d d
d d ed d
ed
Cl Op Open Close Close Close Close
Close Close
AV-0702 os Closed en Open Open Closed Closed d d d d
d d
ed
SV-1001 Close Cl Closed Clo Close Open Clos Closed Closed Close Close Close Close Close
d os sed d ed d d d d d
 ed
Cl Clo Closed Close Close Close Close
Close Close Clos
SV-1003 os Closed sed Closed Closed Open d d d d
d d ed
ed
O Clo Closed Close Close Close Close
Close Close Clos Close
SV-1004 pe Closed sed Closed Closed d d d d
d d ed d
n
O Op Closed Close Close Close Close
Close Close Clos Close
SV-1006 pe Open en Closed Closed d d d d
d d ed d
n
PP- Of
Off Off Off Off Off Off Off Off Off Off On On On
0201A/B f
Hypo CIP
Of
Pump (DP- Off Off Off Off On Off Off Off Off Off Off Off Off
f
0801)
SMBS
Of
Pump (DP- Off Off Off Off Off Off Off Off On Off Off Off Off
f
0901)
Of
PP-0701 Off Off On Off On On Off On ? Off Off Off Off
f
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds

Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 6, SV-1001 is energised and DP-0801 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8: The membranes are allowed to soak in the chemical solution for programmed length of time.

Step 9: (Not shown in table) Repeat steps 8 and 9 programmed number of times.

Step 10A: Cleaning solution is flushed to waste until CIP make-up tank low level (LIT-0701) is reached.

Step 10B: SMBS is dosed into the tundish to drain to the sump for XX seconds. This step is to run XX seconds after step 10A is
initiated. It can finish before or after Step 10A, if Step 10A finishes prior to step 10B step 11 is initiated. If step 10B finishes prior to
step 10A the system will wait for step 10A to finish prior to starting step 11.

Step 11: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 12: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 13: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 14: Normal filtration mode resumes with filling of the now empty CIP make-up tank.

Table 16: Membrane filter control valve positions during sodium hypochlorite CIP mode (UF-01B)

Valve / Step Step Step Step Step Step Step Step Step Step Step Step Step Step
Equipment 1 2 3 4 5 6 7 8 10A 10B 11 12 13 14
Close Close Close Close Close Close Close Close Close Close Close Close Close Close
AV-0201
d d d d d d d d d d d d d d
Close Close Close Close Close Close Close Close Close Close Close Open Open Open
AV-0401
d d d d d d d d d d d
Close Open Open Close Close Close Close Open Open Close Close
AV-0402 Open Open ?
d d d d d d d
AV-0403 Close Close Close Close Close Close Close Close Close Close Close Close Close Close
 d d d d d d d d d d d d d d
Close Close Close Close Close Open Close Open Open
AV-0404 Open Open Open Open ?
d d d d d d
Close Close Close Close Close Close Close Close Close Close Open Close Open Close
AV-0701
d d d d d d d d d d d d
Close Close Close Open Open Close Close Close Close Close Close Close
AV-0703 Open Open
d d d d d d d d d d
Close Close Close Close Close Open Close Close Close Close Close Close Close Close
SV-1001
d d d d d d d d d d d d d
Close Close Close Close Close Close Close Close Close Close Close Close Close
SV-1003 Open
d d d d d d d d d d d d d
Close Open Close Close Close Close Close Close Close Close Close Close Close Close
SV-1005
d d d d d d d d d d d d d
Close Open Open Close Close Close Close Close Close Close Close Close Close
SV-1007 Open
d d d d d d d d d d d
PP-
Off Off Off Off Off Off Off Off Off Off Off On On On
0201A/B
Hypo CIP
Pump (DP- Off Off Off Off Off On Off Off Off Off Off Off Off Off
0801)
SMBS
Pump (DP- Off Off Off Off Off Off Off Off Off On Off Off Off Off
0901)
PP-0701 Off Off Off On Off On On Off On ? Off Off Off Off
Step 1: Once a backwash is initiated, the feed pump stops and all valves are closed in preparation for the backwash cycle

Step 2: Filtrate back flush using compressed air and low pressure aeration air scour for XXX seconds

Step 3: The back flush stops but the extended aeration continues for XXX seconds
Step 4: The feed water pumps are used in conjunction with the low pressure air scour to flush all the wastes from the system by
opening up the waste outlet valve and pumping recycled ultrafiltered water from the CIP make-up tank for XXX seconds.

Step 5: Valves are repositioned to accept the chemical dosing.

Step 6: Once valves have been adjusted in step 6, SV-1001 is energised and DP-0801 injects chemical for programmed duration.

Step 7: Dosed chemical solution is recirculated through the membranes for programmed duration.

Step 8: The membranes are allowed to soak in the chemical solution for programmed length of time.

Step 9: (Not shown in table) Repeat steps 8 and 9 programmed number of times.

Step 10A: Cleaning solution is flushed to waste until CIP make-up tank low level (LIT-0701) is reached.

Step 10B: SMBS is dosed into the tundish to drain to the sump for XX seconds. This step is to run XX seconds after step 10A is
initiated. It can finish before or after Step 10A, if Step 10A finishes prior to step 10B step 11 is initiated. If step 10B finishes prior to
step 10A the system will wait for step 10A to finish prior to starting step 11.

Step 11: The CIP make-up tank is gravity drained to wastes by opening AV-0701 for programmed duration.

Step 12: The membranes are flushed with feed water to wastes to remove remaining chemicals for programmed feed flow.

Step 13: The CIP make-up tank is flushed for programmed duration to wastes to ensure chemical is drained.

Step 14: Normal filtration mode resumes with filling of the now empty CIP make-up tank.
Membrane Integrity Test (UF Mode 6):

The membrane integrity test is also known as the pressure decay test. The membrane integrity
test is an automated process that is manually initiated. The membrane integrity test pressurises
the filtrate side of the membranes with compressed air to 100kPa. The compressed air is turned
off and the rate of pressure decay is used to determine the condition of the membrane fibres.

The membrane integrity test is an automatic process and will run at an operator defined time
XX:XX every XX days.

A backwash (UF mode 3) must be performed prior to a membrane integrity test being conducted.
When the membrane integreity test is called the system will wait for the next backwash to be
called for that train and schedule the membrane integrity test be be conducted immediately after it.

Table 17: Membrane filter control valve positions during membrane integrity test (UF-01A)

Step Step Step Step Step

Valve / Equipment Step 6 Step 7
1 2 3 4 5
Open Close Close Close Close Open
AV-0301 Closed
d d d d
Close Close Open Open Closed
AV-0302 Open Open
d d
Open Close Close Close Close Open
AV-0303 Closed
d d d d
Close Close Close Close Close Closed
AV-0304 Open
d d d d d
Close Close Open Close Closed
SV-1004 Open Closed
d d d
Close Close Close Close Close Closed
SV-1006 Closed
d d d d d
Raw Water Feed Pump (PP- On Off Off On
Off Off Off
0201A/B)
Step 1: Filtration mode – Step 7 in backwash sequence

Step 2: All valves are closed and equipment stopped.

Step 3: Filtrate is drained with compressed air.

Step 4: Continue filling with compressed air until PIT-0302 is 100kPa.

Step 5: Compressed air supply is shut off and pressure decay over time is measured.

Step 6: After required duration AV-0304 is opened to exhaust compressed air.

Step 7: Once exhausted, resume filtration mode

Table 18: Membrane filter control valve positions during membrane integrity test (UF-01B)

Step Step Step Step Step Step Step

Valve / Equipment
1 2 3 4 5 6 7
Open Close Close Close Close Close Open
AV-0401
d d d d d
Close Close Open Open Close
AV-0402 Open Open
d d d
Open Close Close Close Close Open
AV-0403 Open
d d d d
Close Close Close Close Close Close Close
AV-0404
d d d d d d d
Close Close Open Close Close Close
SV-1005 Open
d d d d d
Close Close Close Close Close Close Close
SV-1007
d d d d d d d
Raw Water Feed Pump (PP- On Off Off On
Off Off Off
0201A/B)
Step 1: Filtration mode – Step 7 in backwash sequence

Step 2: All valves are closed and equipment stopped.

Step 3: Filtrate is drained with compressed air.

Step 4: Continue filling with compressed air until PIT-0402 is 100kPa.

Step 5: Compressed air supply is shut off and pressure decay over time is measured.

Step 6: After required duration AV-0403 is opened to exhaust compressed air.

Step 7: Once exhausted, resume filtration mode

3.10.3 Operation Aspects

Operation modes

The membrane filter is required to be in AUTO during all normal operating modes.

Start-up

As the compressed air reciever will need time to re-pressurise in-between each backwash
sequence the start-up the train A & B will be staggered based on the entered filtration time. E.g if
the filtration time is 30 minutes start-up of the second train will be staggered by 15minutes so that
a backwash is occuring every 15 minutes.

Fallback Strategy

Malfunction
Automatic Action
Operator Action
Pressure transmitter (PIT-0401 or PIT-0402), (bad PV)
Raise alarm on HMI. Shut-down membrane systems
Automatic normal operation will not commence until the ALARM RESET handswitch in the PLC is
activated.

Shutdown/Abnormal Conditions

Sump Pump (PP-0702) Interlocks:

A number of interlocks / cycle modifications are required for the sump pumps to allow the
membrane cycles to complete sucessfully. The modifications required are:

• The sump pumps are to be disabled between the start of step 10 until the start of step 13
for the citric acid CIP cycle

• The sump pumps are to be disabled between the start of step 10 until the start of step 13
for the sodium hypochlorite CIP cycle

• During CIP cycles (both citric acid and sodium hypochlorite) prior to commencing step 10
the sump must be drained to below the normal stop pump level. Backwash cycles from the
other UF train are to be inhibited until after step 13 for a citric acid CIP or step 12 for a
sodium hypochlorite CIP.

• The sump pumps are to be disabled between the start of step 8 until the start of step 11 for
the citric acid MW cycle

• The sump pumps are to be disabled between the start of step 8 until the start of step 11 for
the sodium hypochlorite MW cycle

• During MW cycles (both citric acid and sodium hypochlorite) prior to commencing step 8
the sump must be drained to below the normal stop pump level. Backwash cycles from the
other UF train are to be inhibited until after step 11 for a citric acid MW or step 10 for a
sodium hypochlorite MW.
3.11 Membrane Transmembrane Pressure Controller DPIC-0301 / DPIC-0401

Refer to P&ID 528-PID-01

3.11.1 Objective

The pressure difference between the feed and filtrate sides of the membrane in the ultrafiltration
unit (UF-01A and UF-01B) is monitored to ensure the filter is operating efficiently.

3.11.2 Functional Description

DPIC-0301 DPIC-0401 is used to monitor the transmembrane pressure (TMP) and initiate an
alarm or backwash sequence if the TMP exceeds a user inputted value.

Transmembrane pressure is calculated via:

TMP = Filtrate Pressure (PIT-0302) – Feed Pressure (PIT-0301) for UF-01A

TMP = Filtrate Pressure (PIT-0402) – Feed Pressure (PIT-0401) for UF-01B

If the TMP exceeds XXkPa an alarm is raised on the HMI. If the TMP exceeds XXkPa a backwash
sequence of the membranes is initiated.

3.11.3 Operation Aspects

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Failure of pressure Alarm on HMI will remain until the
Raise alarm on the HMI and
transmitter (PIT- ALARM RESET handswitch in the PLC is
continue operation
0301 OR PIT-0302) activated.

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

3.12 Granulated Activated Carbon Filters (FV-0501, 0502 and 0503) Logic Sequence

Refer to P&ID 528-PID-01.

3.12.1 Objective
To control the operation of granulated activated carbon filters (FV-0501, FV-0502 and FV-0503).

3.12.2 Applicability

The Granular activated carbon filters are present at all sitesSite 1 has 3 filters (FV-0501, 0502 and
0503) while Site 2 has only 2 filters (FV-0501 and 0502).

3.12.3 Functional Description

Two or three GAC filters are provided to remove volitile components, colour and odour from the
treated water. The system filters feed water via adsorption until the backwashing sequence is
manually triggered by an operator. The GAC filter will not receive feed water unless the screen
filter (SF-0201) is in filter mode and the membrane filter (UF-0301) is in filter mode.

The GAC filters have manual multiport valves attached to them that must be positioned by an
operator to complete either filtration or backwash cycles. Once a backwash is triggered the HMI
will guide the operator through the required steps to complete the backwash.

The steps to complete a backwash are:

1. Fill the CIP / Backwash tank from the normal (MW / CIP fill level) to the GAC backwash fill
level via initiating step 3 of the filtration cycle on UF-01A and UF-01B.

2. Raise a prompt on the HMI that GAC backwash is ready to proceed and prompt user to
position MPV-0501 into backwash and MPV-0502 (and MPV-0503 for Site 2) into
Winterize/Closed.

3. Once the prompt has been acknowledged AV-0703 is to open and PP-0701 is to run for XX
minutes. Run UF-01A and UF-01B in filtration mode step 3 to continue water

4. Stop PP-0701 and close AV-0703.

5. Continue filling CIP / Backwash tank to the GAC backwash fill level.

6. Raise a prompt on the HMI that GAC backwash is ready to proceed and prompt user to
position MPV-0502 into backwash and MPV-0501 (and MPV-0503 for Site 2) into
Winterize/Closed.

7. Once the prompt has been acknowledged AV-0703 is to open and PP-0701 is to run for XX
minutes. Run UF-01A and UF-01B in filtration mode step 3 to continue water

8. Stop PP-0701 and close AV-0703.

9. **** For Site 2 only for Site 1 goto step 13**** Continue filling CIP / Backwash tank to the
GAC backwash fill level.
 10. Raise a prompt on the HMI that GAC backwash is ready to proceed and prompt user to
position MPV-0502 into backwash and MPV-0501 (and MPV-0503 for Site 2) into
Winterize/Closed.

11. Once the prompt has been acknowledged AV-0703 is to open and PP-0701 is to run for XX
minutes. Run UF-01A and UF-01B in filtration mode step 3 to continue water

12. Stop PP-0701 and close AV-0703.

13. Continue filling the CIP / Backwash tank from the normal (MW / CIP fill level).

The backwash timer shall be able to be adjusted via the HMI. The backwash pump (PP-0701)
feeds ultrafiltered water through the media bed to redistribute the granulated activated carbon for
a user defined duration (Nominally 10 minutes). The flow from the GAC backwash pumps is
registered by flow switch (FS-0701). The backwash is required to remove channelling in the media
bed, ensuring the GAC filter runs at optimal efficiency.

3.12.4 Operation Aspects

Operation modes

This logic block is required to be AUTO in all normal operational modes.

Start-up

As a common tank and pump is used for the membrane CIP / MW cycles and the GAC backwash
cycles

Fallback Strategy

Malfunction Automatic Action Operator Action

Operator Reset required
Raise pump alarm.
Failure of pump to start. once fault condition is
Raise backwash incomplete alarm.
removed

Shutdown/Abnormal Conditions

No shutdown / abnormal conditions

3.13 Potable Water Tank Level Controller LIC-0601

Refer to P&ID 528-PID-01

3.13.1 Objective

The level in the potable water tank is controlled via the raw water feed pumps (PP-0201A/B) (and
the potable water booster pumps (PP-0601A/B/C/D) at Site 1 only).
3.13.2 Functional Description

The level in the potable water balance tank (TK-03) is measured by the level transmitter (LIT-
0601). The signal from the level transmitter is sent to LIC-0601 and the signal is used to determine
the operation of the feed and discharge from the potable water tanks.

If the level in the tank falls below XX%, PP-0201A/B will turn on and treated water will be fed into
the two tank from the WTP. If the combined level in the tank rises above XX%, PP-0201A/B will
turn off and treated water feed to the tank will be ceased.

***** Site 1 Only*******

If the level in the tank falls below XX%, an alarm will be raised on the HMI. If the level falls futher
to below XX%, PP-0601A/B/C/D will turn off and potable water will cease to be pumped from the
plant. If the level in the tank rises above XX%, PP-0601A/B/C/D will energise and potable water
pumping from the plant will resume.

3.13.3 Operation Aspects

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Failure of level Alarm on HMI will remain until the
Raise alarm on the HMI and
transmitter (LIT- ALARM RESET handswitch in the PLC is
stop operation
0601) activated.

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

3.14 Potable Water Booster Pumps Logic Sequence

Refer to P&ID 528-PID-01

3.14.1 Objective

A separate control system is supplied for the operation of the potable water pumps. This
sends fault outputs to thePLC and the PLC sends run signals to this system.
The potable water pumps (PP-0601A/B/C/D) operate under speed control to maintain a constant
outlet pressure over different flow rates. The duty points are achieved via VSD control of the
pumps and the ability to bring up to 3 pumps on line in parallel for high flow applications.

3.14.2 Applicability

The potable water booster pumps are present at site1 only.

3.14.3 Functional Description

In AUTO mode, PP-0601A/B/C/D % speed is determined automatically so as to maintain a

pressure setpoint as monitored by PIT-0601 pressure transmitter. PP-0601A/B/C/D is to run
unless a low level is registered in the potable water tank (TK-03)

In MAINTENANCE mode, PP-0601A/B/C/D only responds to manual start-stop PLC soft hand
switch. In MAINTENANCE mode, the % speed is still set by the supplier control panel.

The pump logic is contolled via the following setpoints adjustable on the Supplier Control Panel
HMI.

3.14.4 Operation Aspects

Operation modes

The potable water pump logic control is required to be AUTO in all normal operational modes.

Start-up

Refer to section 3.2.2

Fallback Strategy

Malfunction Automatic Action Operator Action

Switch off potable water Automatic normal operation will
Potable Water Tank
pumps PP-0601A/B/C/D recommence when level rises past
(LOW-LOW)
raise alarm on HMI LOW set point.
Fault signal received Alarm on HMI will remain until the
from package PLC Raise alarm on the HMI ALARM RESET handswitch in the
output. PLC is activated

Shutdown/Abnormal Conditions

Stop pumps on signal from Potable Water Tank LOW LOW level.
3.15 Potable Water Booster Pump Logic Sequence

Refer to P&ID 528-PID-01

3.15.1 Objective

The potable water booster pump (PP-0601) operates in combination with a pressure tank to
maintain a constant outlet pressure.

3.15.2 Applicability

The potable water booster pump is present at site 2 only.

3.15.3 Functional Description

In AUTO mode, PP-0601 is called to run on a low pressure signal from PS-0601. PP-0601
switches off on a high pressure signal from PS-0601. PP-0601 is to be inhibited from running if a
low level is registered in the potable water tank (TK-03)

In MAINTENANCE mode, PP-0601 only responds to manual start-stop PLC soft hand switch.

3.15.4 Operation Aspects

Operation modes

The potable water pump logic control is required to be AUTO in all normal operational modes.

Start-up

Refer to section 3.2.2

Fallback Strategy

Malfunction Automatic Action Operator Action

Switch off potable water Automatic normal operation will
Potable Water Tank
pumps PP-0601 raise alarm recommence when level rises past
(LOW-LOW)
on HMI LOW set point.

Shutdown/Abnormal Conditions

Stop pump on signal from Potable Water Tank LOW LOW level.
3.16 Potable Water Recirculation Valve (AV-0601)

Refer to P&ID 528-PID-01

3.16.1 Objective

The potable water recirculation valve (AV-0601) allows for the recirculation flow in the potable
water tank (TK-03) to be enabled and disabled.

3.16.2 Applicability

The potable water recirculation valve is present at all sites.

3.16.3 Functional Description

In AUTO mode, AV-0601 switches open and closed based on timers present in the PLC. The
valve is able to be set by the operator to be open for XX.X hours and closed for XX.X hours in a
cyclic pattern.

In AUTO mode, sodium hypochlorite disifection dosing is to be disabled while AV-0601 is closed.
AV-0601 is to be forced open and dosing resumed upon a low warning for potable water free
chlorine from AIT-0602.

In AUTO mode, AV-0601 is to be forced open when flow (>XXm 3/hr) is registered by FIT-0601.
When flow ceases AV-0601 is able to actuate based on the programmed cycle.

In MAINTENANCE mode, AV-0601 can be open and closed via soft hand switches on the HMI.

3.16.4 Operation Aspects

Operation modes

The potable water pump logic control is required to be AUTO in all normal operational modes.

Start-up

Refer to section 3.2.2

Fallback Strategy

Malfunction Automatic Action Operator Action

Alarm on HMI will remain until the
Valve open/close or limit Raise alarm on HMI,
ALARM RESET handswitch in the
switch failure continue operation
PLC is activated.

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

3.17 Potable Water Hypochlorite Dose Rate Controller AIC-0602

Refer to P&ID 528-PID-01

3.17.1 Objective

Both flow rate signal from meter FIT-0601 & Free chlorine signal from meter AIT-0602 are sent to
dose rate controller AIC-0602 to calculate speed for dose pumps DP-0802A/B.

3.17.2 Applicability

The potable water hypochlorite dose rate controller is present at all sites.

3.17.3 Functional Description

The potable water hypochlorite dose rate controller consists of two separate control loops based
on the status of the water treatment plant.

When flow is actively entering the potable water tank (I.e FIT-0601 >0) a flow paced plus
proportional, integral, derivative (PID) controller is used to achieve the following:

A. The measured feed flow is used to dose a base-line Xppm into the potable water tanks.

B. The measured free chlorine is used by the PID controller to adjust this dose rate until the
target free chlorine concentration setpoint is achieved.

When flow is not entering the potable water tank (I.e. FIT-0601 = 0) a separate PID controller is
utilised to maintain the free chlorine level withing the potable water tank. Each of the PID
controllers are to be able to have their paramaters set individually.

Controller Action
PID Control (decreasing Free Chlorine should result in
AIC-0602
increased dose rate and vice versa)
3.17.4 Operation Aspects

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Free Chlorine Raise alarm on the HMI.
Alarm on HMI will remain until the ALARM
Transmitter AIT- Continue normal
RESET handswitch in the PLC is activated
0602 (Bad PV) operation. (disable the
 dosing loop that is
controlled by AIT-0602
however flow paced will
remain)
Switch off the duty
If the standby dosing pump starts successfully
selected dosing pump
then continue operation and raise alarm on the
and automatically switch
Dosing pump fault HMI.
over to the standby unit.
Alarm on HMI will remain until the ALARM
Raise alarm on the HMI
RESET handswitch in the PLC is activated.
and continue operation

Shutdown/Abnormal Conditions

There are no special shut-down requirements.

3.18 Potable Turbidity Meter AIC-0603

Refer to P&ID 528-PID-01

3.18.1 Objective

AIC-0603 is used to detect turbidity in the potable water discharge line.

3.18.2 Applicability

The potable turbidity meter is present at all sites.

3.18.3 Functional Description

Turbidity Meter AIC-0603 will raise a plant alarm if high turbidity is detected.

3.18.4 Operation Aspects

Operation modes

Turbidity Meter AIC-0603 will raise a high turbidity warning and high-high turbidity alarm if high
turbidity is detected.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Turbidity Raise alarm on the HMI.
Alarm on HMI will remain until the ALARM
Transmitter AIC- Continue normal
RESET handswitch in the PLC is activated
0603 (Bad PV) operation.

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

3.19 Potable Water pH Meter AIC-0601

Refer to P&ID 528-PID-01

3.19.1 Objective

AIC-0601 is used to detect the pH of the potable water discharge line.

3.19.2 Applicability

The potable water pH meter is present at all sites.

3.19.3 Functional Description

pH Meter AIC-0601 will raise a plant alarm if high or low pH is detected.

3.19.4 Operation Aspects

Operation modes

pH Meter AIC-0601 will raise a high pH alarm if high pH is detected.

pH Meter AIC-0601 will raise a low pH alarm if low pH is detected.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

pH Transmitter Raise alarm on the HMI.
Alarm on HMI will remain until the ALARM
AIC-0601 (Bad Continue normal
RESET handswitch in the PLC is activated
PV) operation.

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

3.20 Flow Recorder FQ-0602

Refer to P&ID 528-PID-01

3.20.1 Objective

FQ-0602 is used to data record the flows in the potable water discharge line.

3.20.2 Applicability

FQ-0602 is present at all sites.

3.20.3 Functional Description

Flow transmitter FIT-0602 measures flow of potable water from the WTP to the holiday park
reticulation. Historical data of flows from the WTP will be able to be recalled via the HMI.

3.20.4 Operation Aspects

Operation modes

Flow recorder FQ-0602 will record all flows through FIT-0602 and retain the data for X months.

Start-up

There are no special start-up requirements.

Fallback Strategy

Malfunction Automatic Action Operator Action

Flow recording will not recommence until the
Flow Transmitter Raise alarm on the HMI
ALARM RESET handswitch in the PLC is
FIT-0602 (fault) and continue operation
activated.

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions

3.21 Waste Pump PP-0702

Refer to P&ID 528-PID-01

3.21.1 Objective

The waste pump is a submersible pump used to empty the sump as required.

3.21.2 Applicability

The waste pump is present at all sites.

3.21.3 Functional Description

Level transmitter LT-0702 indicates when the level in the sump rises. When the level is above XX
% the waste pump turns on. When the level reduces to XX% or below the waste pump turns off.

3.21.4 Operation Aspects

Table 19: WTP Operation based on sump level (TK-05)

Nominal Level in
Sump Action
(adjustable)
<20% LOW – Pumps turned off

>30% Cannot trigger MW or CIP

>50% Cannot trigger GAC backwash

>60% Cannot trigger UF backwash

High – Raise warning on HMII
>80%
Cannot trigger screen filter backwash
>90% High High Alarm

Operation modes

This controller is required to be in AUTO during all normal operating modes.

Start-up

When LT-0702 exceeds Low level XX%.

The waste pump is required to operate XX minutes prior to a membrane backwash cycle
triggering. Secondary to this condition, the sump level must be below XX% before a MW or CIP
occurs.

Fallback Strategy

Malfunction Automatic Action Operator Action

 FS-0702 detects no flow
after X seconds; raise Alarm on HMI will remain until the ALARM
PP-0702 Fault
alarm and shut down the RESET handswitch in the PLC is activated
WTP.

Raise alarm on the HMI. Alarm on HMI will remain until the ALARM
LIT-0702 fault
Shut-down sump pumps RESET handswitch in the PLC is activated

Shutdown/Abnormal Conditions

LT-0702 is less than XX%.

3.22 Pressure Switch PS-1001

Refer to P&ID 528-PID-01

3.22.1 Objective

PS-1001 is used to detect pressure in the instrument compressed air line.

3.22.2 Functional Description

Pressure Switch PS-1001 will raise a plant alarm fault if low pressure is detected.

3.22.3 Operation Aspects

Operation modes

Pressure switch PS-1001 provides a low pressure alarm if low pressure is detected.

Start-up

There are no special start-up requirements.

Fallback Strategy

PS-1001 provides a digital signal when pressure is detected. Should PS-1001 be faulty, the PLC
will presume a zero pressure condition which will provide an alarm as it would if there were low
pressure. In this situation, operator intervention will be required.

Shutdown/Abnormal Conditions

There are no shutdown/abnormal conditions