WATER TREATMENT PLANT

The water treatment plant located in Renata PLC, Rajendrapur site is designed upon P&ID (Piping and
Instrumentation Diagram); which is basically a technical drawing that shows the interconnection among
piping, equipment, and controls for a process system. The 2D Design in AUTOCAD is the blueprint of the
whole water treatment plant.

Figure 1: Pre- Treatment System (2D Drawing)

Figure 2: Generation System (2D Drawing)

 Figure 3: Distribution System (2D Drawing)Pre-Treatment System.

The whole water treatment process is conducted in 3 sub-systems which are:

A. Pre-Treatment System
B. Generation System
C. Distribution System
These primary steps include some basic steps to keep the treatment process running. The internal system is
built in such a way that it goes through a continuity of valve, flow, treatment and tank.

Pre-
Generation Distribution
Treatment
System System System

(1) Pre-Treatment System:

The pre-treatment system is the first and essential step in the Purified Water (PW) generation process. It
prepares raw water by removing suspended solids, organic matter, chlorine, hardness, and microorganisms
—protecting downstream systems like Reverse Osmosis (RO) and ensuring long-term performance.
 Figure 4: Pre-Treatment System.

Flow Diagram:

Chlorine Dosing

Multi Media Filter

Pre-Filter 25 Micron

Break Tank Storage

Feed Water Pumps

Duplex Water Softeners

Pre-Filter 5 micron

Activated Carbon Filter

Antiscalant Dosing

Cooling Heat Exchanger

Pre-Treatment System Process:
a) Chlorine Dosing: Chlorine dosing is the process of adding controlled amounts of chlorine (usually
as sodium hypochlorite or chlorine gas) to water to disinfect it by killing bacteria, viruses, and other
microorganisms.
b) Multi Media Filter: It has primary filtering elements such as pebbles, stones, silica.
c) Pre-Filter 25 Micron: The pores of this filter are at the size of 25 micron. No particle molecule can
pass through over the size of 25 micron.
d) Break Tank Storage: This is used as a storage reservoir after these filtrations.
e) Feed Water Pumps: These pumps change/ replace water after each definite period of time by
piping.
f) Duplex Water Softeners: The resin in the Duplex Water Softeners attracts the water cations (Mg ++,
Ca++)
g) Pre-Filter 5 micron: The pores of this filter are at the size of 5 micron. No particle molecule can
pass through over the size of 5 micron.
h) Hardness Monitor: It measures and monitors the amount of hardness or the amount of Mg ++, Ca++ in
a definite range. Less presence of cations indicates soft water.
i) Activated Carbon Filter: A black carbon structure extracts all unwanted particles of water.

Figure 5: Activated Carbon Filter

j) Antiscalant Dosing: A chemical that creates a layer over the RO (Reverse Osmosis) Membrane to
protect from the damage of hard water cations and particles.
k) Flow Totaliser: Measures the total flow of the filtered water.
l) Cooling Heat Exchanger: This is a parallel plate heat exchanger. This has several pipes between
parallel plates carrying cold water. The heat is then absorbed through plates and purified hot water is
passed through by pipes.
(2) Generation System:

A PW Generation System is designed to produce high-purity water free from chemical, physical, and
microbial impurities. It follows a series of purification steps to meet pharmaceutical standards

Figure 6: Generation System.

 Flow Diagram:

Particulate filter1 Micron

Booster Pump

Reverse Osmosis Units

Degasser Unit

Continuous Electro-deioniser

UV Sterilizer

Gas separator

Generation System Process:

a) Particulate filter1 Micron: The pores of this filter are at the size of 1 micron. No particle molecule
can pass through over the size of 1 micron.
b) Booster Pump: Filtered water is pumped through booster pump.
c) Reverse Osmosis Units: This unit uses a semi-permeable membrane to remove impurities from
water. It reduces the density of water.
 Figure 6: RO Unit.

d) Degasser Unit: It removes water gas bubbles.

e) Continuous Electro-deioniser: It rigorously omits out the hard water ions, micro-organisms and
particles.
f) UV Sterilizer: It kills micro-organisms by applying UV rays. Eventually, purified water is obtained
and then stored in reservoir tanks ready to be distributed.

Figure 7: UV Sterilizer
g) Gas separator: A gas separator removes entrained gases (like air, oxygen, or carbon dioxide) from
liquids—usually water—before the liquid moves to the next stage of a process.

PW Generation Unit (GENESYS)

The unit is made of the following components.
 Figure: PW Generation Unit (GENESYS)

a) Sensors: A variety of sensors are used to monitor and control various parameters to ensure the water
meets the required quality standards. Key sensors include conductivity, pH, turbidity, flow, pressure,
temperature, dissolved oxygen, chlorine, UV intensity, level, and TDS sensors.

(a) (b)
Figure 8: (a)Conductivity Sensor (b)Sensor Reading.

b) PLC: The PLC automates the entire process, ensuring the production of Purified Water (PW) is
efficient, meets required standards, and operates safely with real-time monitoring, alarms, and
regulatory compliance.The operating voltage is at 24V.
c) 3 Phase AC Motor: The 3 phase AC motor operates at 400V.
d) Relays and Circuit Brakers: Circuit brakers and relays are used for switching the circuits
ON/OFF.
e) Magnetic Contactor: It works just like relays but one switching can affect directly 3 phases
unlike relay.
f) Feedback System: It gives feedback which ensures the phase switching.
g) HMI: HMI (Human Machine Interference) displays the whole system controlling diagram. It
shows values of sensor information, valve ON/OFF control and builds a relation between HMI and
PLC. These are done by the
engineers.
 Figure 9: PW Generation HMI.

h) UPS: An Uninterrupted Power Supply (UPS) system in a PW (Purified Water) Generation Unit is
crucial to ensure continuous power for the entire water treatment process. The UPS ensures that the
system operates without interruption, especially during power outages or fluctuations, maintaining
the water quality and preventing any damage to the critical equipment such as pumps, sensors, and
PLCs.

(3) Distribution System:

The distribution system in a water treatment plant is the final stage where Purified Water (PW) or Water for
Injection (WFI) is stored, circulated, and delivered to various user points (like production, cleaning,
formulation areas) within the pharmaceutical facility.
 Figure 6: Distribution System.

Distribution Process:

a) Control Panel:
i. PLC: The PLC automates the entire process, ensuring the production of Purified Water (PW)
is efficient, meets required standards, and operates safely with real-time monitoring, alarms, and
regulatory compliance.The operating voltage is at 24V.
ii. HMI: HMI (Human Machine Interference) displays the whole system controlling diagram. It
shows values of sensor information, valve ON/OFF control and builds a relation between HMI and
PLC. These are done by the engineers.
 Figure 9: Distribution System HMI.

iii. Relays: Relays are used for switching the circuits ON/OFF.
iv. Magnetic Contactor: It works just like relays but one switching can affect directly 3 phases
unlike relay.

b) Solenoid Valve: A solenoid valve is an electrically controlled valve used in the distribution system
of a PW (Purified Water) system to start or stop the flow of water automatically.
c) Pneumatic Cylinder: Pneumatic cylinders are mechanical devices that generate force through
pressurized air. It can be single acting or double acting. Single acting cylinders have 1 air line which
makes the forward and reverse movement slow. Whereas double acting cylinders have 2 air lines which
make these home position movements fast.

Figure 12: Pneumatic Cylinder.

d) VFD: VFDs (Variable Frequency Drives) are usually used for controlling 3 phase AC motors. It
includes inverter circuit which causes variation in frequency that controls the speed.
e) UV Lamp: It kills micro-organisms which suitable wavelength.
f) Heat Exchanger (Shell & Tube): A shell and tube heat exchanger is a device used for efficient heat
transfer between two fluids, typically one hot and one cold. It consists of a cylindrical shell containing
multiple tubes, where one fluid flows through the tubes (tube-side fluid) and the other flows around the
tubes within the shell (shell-side fluid). Heat is transferred from the hotter fluid to the cooler one
through the tube walls. Baffles inside the shell direct the flow to enhance turbulence and improve heat
transfer efficiency. These exchangers are widely used in industries like power plants, chemical
processing, and HVAC systems due to their robustness and effectiveness in handling high temperatures
and pressures.

Figure 13: Heat Exchanger (Shell & Tube)

g) PW storage: In a water treatment plant, PW storage typically stands for Purified Water Storage
depending on the specific context.

Figure 13: PW storage.