PCS 7 Water Unit

Template - Seawater
Desalination by
Reverse Osmosis
Siemens
SIMATIC PCS 7 V9.0 SP1 Industry
Online
[Link] Support
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Table of contents

Table of contents
Legal information ......................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Principle of operation............................................................................ 5
1.3 Used hardware and software components........................................... 7
2 Preparation and commissioning ...................................................................... 8
2.1 Preparation ........................................................................................... 8
2.2 Commissioning ..................................................................................... 9
2.3 Components of process visualization ................................................. 10
2.4 Operating the application ................................................................... 11
2.4.1 Overview............................................................................................. 11
2.4.2 Scenario A - Reverse osmosis without multi-variable controller ........ 11
2.4.3 Scenario B - Reverse osmosis with multi-variable controller ............. 15
3 Integration of unit template into a user project ............................................ 18
3.1 Preparation ......................................................................................... 18
3.2 Copying templates .............................................................................. 18
3.3 Copying a plant section ...................................................................... 19
3.4 Customizing the OS project................................................................ 20
4 Engineering ...................................................................................................... 22
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4.1 Control module types ......................................................................... 22

4.1.1 WCMT_MonAnalog ............................................................................ 23
4.1.2 WCMT_MotSpdCon ........................................................................... 24
4.1.3 WCMT_PIDConL ................................................................................ 25
4.1.4 CtrlMPC .............................................................................................. 26
4.2 Equipment Modules and Control Modules ......................................... 27
4.2.1 Inflow (Feed) ...................................................................................... 27
4.2.2 Recirculation ....................................................................................... 31
4.2.3 Permeate ............................................................................................ 35
4.2.4 Brine ................................................................................................... 38
4.2.5 Salinity and flow rate (desalination) ................................................... 40
4.2.6 Process simulation (simulation) ......................................................... 42
4.2.7 Sequential Function Chart .................................................................. 46
5 Basics ............................................................................................................... 48
5.1 P&I diagram ........................................................................................ 48
5.2 Project structure ................................................................................. 48
5.2.1 Naming conventions ........................................................................... 48
5.2.2 Plant view ........................................................................................... 49
5.3 Components of Unit Template ........................................................... 51
5.4 Connect Control Modules ................................................................... 53
6 Appendix .......................................................................................................... 55
6.1 Service and support ........................................................................... 55
6.2 Links and literature ............................................................................. 56
6.3 Change documentation ...................................................................... 56

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1 Introduction

1 Introduction
1.1 Overview
Almost 97 percent of the water on earth is saline and cannot be used as drinking
water or for irrigation purposes. Desalination of seawater offers an opportunity to
obtain additional drinking or process water for people, industry and agriculture.
Efficient automation solutions are required to ensure the supply of fresh water,
especially in dry areas.
There are two types of processes for the desalination of seawater:
 Thermal processes such as multi-stage flash distillation (MSF)
 membrane processes such as reverse osmosis
The processes for desalinating seawater are very energy-intensive. In direct
comparison, pressure-driven membrane processes generally require slightly less
energy than thermal processes.
Seawater desalination based on reverse osmosis uses semipermeable membranes
to filter the dissolved salt from the seawater. For this purpose, the salt water is
pressed through the membranes at a higher pressure than the osmotic pressure of
the salt water. The high energy input is necessary to generate the high pressure in
front of the membrane.
A seawater desalination plant contains several sub-processes, which are shown
schematically in the following figure.
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Seawater intake Pre-treatment 1 Desalination Process 2 Post-treatment 3

1. Pre-treatment:
The salt water is cleaned of dirt and sand by mechanical filtration and
ultrafiltration. In addition, the pH value is balanced and bacteria is killed by
adding chlorine.
2. Desalination process:
In the actual desalination process, the salt water is pressed at high pressure
into a filter system containing a large number of osmosis membranes.
The osmotic pressure of the sea water must be overcome (reverse osmosis).
The product is purified water and the by-product brine.

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1 Introduction

3. Post-treatment:
Finally, the pH value is regulated again and the drinking water is enriched with
minerals.
Detailed information on the application background can be found in \3\.

1.2 Principle of operation

Only the central desalination process is covered in this application example.
A high-pressure pump (1) is used to lift the pressure of the pre-purified seawater to
a level that significantly exceeds the osmotic pressure of seawater (approx. 30
bar). The filter membranes (2) allow only the water molecules to pass through and
retain the dissolved salt. This separates seawater into water with a very low salinity
(permeate) and water with a very high salinity (retentate).
The still very high pressure at the retentate outlet can be recovered to a very large
extent with a pressure exchanger (3). Together with the booster pump (4) a part of
the fresh sea water is lifted to the pressure level of the high pressure side. In this
way, a large part of the energy consumed by the high-pressure pump at the inflow
is saved.
The PID controls for the high-pressure pump and the booster pump are supplied
with their respective setpoints by a superimposed multi-variable controller. This
enables a constant production quantity and product quality, as fluctuations are
automatically compensated without operator intervention.
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1 2

4 3

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1 Introduction

Overview picture
This process picture contains a schematic representation of a seawater
desalination plant. The components of the schematic representation are described
in section 1.1 "Overview".
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Process picture
The reverse osmosis process picture shows all process tags, drives and controllers
required for operation of the plant unit.
The majority of the process tags are analog value displays, which show the
(simulated) process values as well as violations of specified upper or lower limits.
The displayed block symbols and faceplates are part of the PCS 7 Advanced
Process Library.

Note Further information can be found in the manual "SIMATIC Process Control
System PCS 7 Advanced Process Library":
[Link]

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1 Introduction

Control concept
A multi-variable controller (MPC) is used to control flow rate and salinity (salt
concentration) of water. This controller manipulates the process via setpoint values
for the pressure at the membrane and the flow rate in recirculation.
In the MPC, the different target values are weighted differently. Product quality
(salinity) has the highest priority but remains within its dead zone during normal
operation. The controller only has to intervene if the salinity should be higher than
permitted. Therefore, the main controlled variable in normal operation is the
production output (permeate flow).
The electrical power consumption of high-pressure pump and booster pump are
low-priority controlled variables. The target values correspond to the operating
points with optimum pump efficiency.
PID controllers "PIDConL" of the APL are used for the flow of recirculation and
pressure at the membrane, which are slave controllers for the MPC master
controller.

1.3 Used hardware and software components

This application example was created with the following hardware and software
components:
Component Note
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SIMATIC PCS 7 ES/OS IPC547G W7 For the PCS 7 V9.0 SP1 example project
SIMATIC PCS 7 V9.0 SP1 Part of SIMATIC PCS 7 ES/OS IPC547G
W7
S7 PLCSIM Not a part of SIMATIC PCS°7 V9.0 SP1,
additional licenses required
APL V9.0 SP1 Part of SIMATIC PCS 7 V9.0 SP1

Note If the hardware is different, observe the minimum requirements for installing the
software components. The minimum requirements can be found in the PCS 7
Readme at the following link:
[Link]

This application example consists of the following components:

Component Note
109741119_WUT_SeawaterDesalination_PROJ_PCS7V90SP1.zip PCS 7 V9.0 SP1
example project
109741119_WUT_SeawaterDesalination_DOC_PCS7V90SP1_en.pdf This document

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2 Preparation and commissioning

2 Preparation and commissioning

2.1 Preparation
The following instructions describe the commissioning of the Unit Template, in
which the controller is simulated with the program "S7-PLCSIM". If a real controller
is available, you must configure the hardware components in the HW configuration.
1. Copy the file
"109741119_WUT_SeawaterDesalination_PROJ_PCS7V90SP1.zip" into any
folder on the configuration computer and then open the SIMATIC Manager.
2. Click on "File > Retrieve" in the menu bar and select the file
"109741119_WUT_SeawaterDesalination_PROJ_PCS7V90SP1.zip". Then
confirm by clicking on "Open".
3. Select the folder in which the project is to be saved and confirm with "OK".
The project is retrieved.
4. Confirm the "Retrieve" dialog with "OK" and then click "Yes" in the dialog to
open the project.
5. Right-click on "Desalination_OS > OS01 > WinCC Appl. > OS" and click on the
menu command "Open object".
6. Confirm the dialog "Configured server not available" with "OK".
7. Right-click the properties of your computer in the WinCC Explorer and click on
the button "Use Local Computer Name" in the opened properties dialog.
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8. Confirm the message "Change computer name" with "OK".

9. Click on "File > Exit" in the WinCC Explorer and select "Exit WinCC Explorer"
in the following dialog.
10. Then confirm with "OK".
11. Open the WinCC Explorer again, as described in step 5.
12. Open the "Tag Management" by double-clicking it.
13. Right-click in the WinCC Configuration Studio on "Tag Management >
SIMATIC S7 Protocol Suite > TCP/IP" and select the menu command "System
parameters".
14. Check the specified "Logical device name" in the tab "Unit". If the "S7-PLCSIM"
program is used, "PLCSIM(TCP/IP)" is selected as the device name.
The program must be restarted after changing the device name. Open the
WinCC Explorer again, as described in step 5.

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2.2 Commissioning
The following instructions describe how to initialize the Unit Template. The project
contains an SFC which drives the system automatically to a predefined operating
point after starting.
For commissioning it is assumed that the SIMATIC Manager has already been
opened and the Unit Template is selected in the component view.

Starting the simulation (S7 PLCSIM)

To start the simulation, proceed as follows:
1. Select "Options > Simulate Modules" from the menu.
The "S7-PLCSIM" dialog window opens.
2. In the dialog "Open project", select the "Open project from file" option.
3. Select the file "[Link]" from the path
<Project path>\Desalina\Desa_MP\[Link]>.
4. In the menu, change "PLCSIM(MPI)" to "PLCSIM(TCP/IP)".
5. In the menu, select "Run > key switch position > RUN-P".
6. Switch to the component view of the SIMATIC Manager and select
"Desalination_AS > AS01".
7. Click on "PLC > Download" in the menu bar and confirm the dialog "Download"
with "Yes".
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8. Confirm the dialog "Stop Target Modules" with "OK" and then the dialog
"Download" with "Yes".

Activate OS (WinCC runtime)

Proceed as follows to activate the OS:
1. Right-click "Desalination_OS > OS01 > WinCC Appl. > OS" and select the
"Open Object" menu.
2. To activate the OS (WinCC Runtime), select the menu item "File > Activate" in
the WinCC Explorer.
3. In the dialog "System Login", enter the user "Unit" as "Login" and "Template"
as the password; then confirm with "OK".
4. Select "RevOsmosis" in the picture tree area.

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2.3 Components of process visualization

5
1

2
4
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The process screen consists of the following main components:

1. Inflow (Feed)
2. Recirculation (abbreviation: Recirc)
3. Permeate
4. Brine
5. MPC

Function Description
Feed The temperature and flow rate of the salt water from the pre-treatment
and the pressure control by means of a high-pressure pump are
displayed at the inlet.
Recirc In the recirculation loop, the water pressure is displayed and the flow
rate is controlled by means of a booster pump (to increase the
pressure).
Permeate Contains Control Modules to display the flow rate and quality of the
purified water.
Brine Contains Control Modules to display the pressure and flow rate of the
brine discharged.
MPC Contains the Control Module of the multi-variable controller

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2.4 Operating the application

2.4.1 Overview

All components of reverse osmosis can be operated and monitored via the process
picture. In addition, the plant operator receives information (KPIs: Key Performance
Indicators) on the current process state.

Note Please note that after starting the program (PLCSIM) it takes approx. 2 minutes
until the reverse osmosis is at the operating point. During the running production
operation, all controllers are released for operation. You can recognize this state
for example in the SFC, if it has successfully processed all process steps.

The following two scenarios show different approaches for the compensation of
fouling at the filter membranes by comparing:
 Reverse osmosis without multi-variable controller
 Reverse osmosis with multi-variable controller

2.4.2 Scenario A - Reverse osmosis without multi-variable controller

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In this scenario the process of reverse osmosis is simulated. Pre-purified seawater

is forced through the filter membranes at high pressure. The filter membranes allow
only the carrier liquid to pass through and retain the dissolved salt. This leads to
fouling of the filter membranes, which in turn reduces the quality and quantity of
drinking water produced. In order to compensate for this effect, the setpoints of the
inflow and recirculation control must be adjusted again and again. In this scenario,
the setpoint adjustments must be performed manually by the operator.
1. Switch to the reverse osmosis process screen.

2. Left click the “On/Off” button in the “Tag names” field to display the block
names.

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3. Click on the block symbol of the "RO-PIC Feed" block and select "Internal" for
"Setpoint". Confirm your entry by clicking on "OK".

4. Enter the setpoint "57.24" in the faceplate of the "RO-PIC feed" module and
confirm the entry by clicking on "OK".
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5. Repeat steps 3 and 4 for the PID controller "RO-FIC-Recirc" and enter the
setpoint "728.59".
6. Switch to the simulation process screen.

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7. Click on the block symbol of the "Reset_Fouling" block.

The corresponding faceplate will be opened.
8. Select the command "On" and confirm your entry with "OK".

9. Switch to the reverse osmosis process screen.

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10. Click on the "Retrieve/Compile trend groups" button and select the "Overview"
trend display.
11. Open the trend display by clicking on "Display".

12. Wait 2 minutes and enter a new setpoint of "57.54" for RO-PIC feed.
13. Wait another 1 minute and enter a new setpoint of "57.84".
14. Wait another 2 minutes and enter a new setpoint of "58.24".
15. Wait 2 minutes and enter a new setpoint of "740" for RO-FIC-Recirc.
16. Wait another 3 minutes and click on the "Start/Stop" icon to evaluate the rule
result.

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Evaluation
The figure shows the trend curves of reverse osmosis.

Pressure at the membrane

Upper limit of salinity Salinity after the membrane

Flow rate after the

Flow rate set point
membrane

Recirculation flow rate

Fouling

Due to fouling of the filter membranes, the flow resistance of the membrane
increases. This leads to a deterioration of the quality and reduction of the amount
of drinking water produced. In order to compensate for the deterioration of product
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properties, the operator must manually increase the setpoint for the PID control
loop of the high-pressure pump. By increasing the pressure on the filter
membranes in several steps, the fouling effect can be compensated for about 10
minutes. After 10 minutes, the control loop of the inflow reaches the manipulated
variable limits and cleaning of the membrane becomes necessary.

Note Cleaning of the membrane is not a part of this application example. In the
simulation, only the degree of fouling is reset.

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2.4.3 Scenario B - Reverse osmosis with multi-variable controller

In this scenario, the process of reverse osmosis is simulated in the same way as in
scenario A. In order to compensate for the fouling effects of the filter membranes,
the setpoints of inflow and recirculation control must be adapted. In this scenario,
these interventions are not carried out manually by the operator, but automatically
by the multi-variable master controller.
1. Switch to the reverse osmosis process screen.
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2. Left click the “On/Off” button in the “Process tag name” field to display the
block names.
3. Click on the block symbol of the SFC "Startup" and click "Start" in the menu
bar. Confirm your entry by clicking on "OK".

The sequencer set the PID controllers back to automatic mode and to setpoint
input from the MPC.
4. Switch to the simulation process screen.

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5. Click on the block symbol of the "Reset_Fouling" block.

The corresponding faceplate will be opened.
6. Click Command on the faceplate and select "On". Confirm your entry by
clicking on "OK".
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7. Switch to the process screen of reverse osmosis

8. Click on the "Retrieve/Compile trend groups" button and select the "Overview"
trend display.
9. Open the trend display by clicking on "Display".

10. Wait approx. 10 minutes and click on the "Start/Stop" icon to evaluate the rule
result.

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2 Preparation and commissioning

Evaluation
The figure shows the trend curves of reverse osmosis.

Pressure at the membrane

Upper limit of salinity Salinity after the membrane

Flow rate after the

Flow rate set point
membrane

Recirculation flow rate

Fouling

Due to fouling of filter membranes, the flow resistance of the membrane increases.
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This leads to a deterioration of the quality and reduction of the amount of drinking
water produced. As long as salinity after the membrane is lower than the specified
upper limit, the multi-variable master controller regulates the flow rate after the
membrane. As soon as salinity after the membrane exceeds the limit, salinity is
primarily controlled. By increasing the pressure on the filter membranes, the effect
of fouling on production can be compensated for about 10 minutes. After 10
minutes, the control loop reaches the manipulated variable limits and cleaning of
the membrane becomes necessary.

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3 Integration of unit template into a user project

3 Integration of unit template into a user

project
3.1 Preparation
1. Copy the file
"109741119_WUT_SeawaterDesalination_PROJ_PCS7V90SP1.zip" to the
configuration computer and then open the SIMATIC Manager.
2. Click on "File > Retrieve" in the menu bar and select the file
"109741119_WUT_SeawaterDesalination_PROJ_PCS7V90SP1.zip". Then
confirm by clicking on "Open".
3. Select the folder in which the project will be saved and confirm with the "OK"
button.
The project will be extracted.
4. In the "Retrieve" dialog, click on the "OK" button and then click on "Yes" in the
dialog to open the project.
5. Switch to the "Plant view".
6. In parallel open the project in which the unit template must be integrated.

3.2 Copying templates

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Note If you have already worked with CMTs in your existing project, then check for
equality before the following steps, as this can lead to errors in your existing
project or the unit template to be integrated.

1. Switch to the plant view.

2. Copy the CMTs from the master data library and paste them into the target
project.

3. Copy the enumerations from the master data library and paste them into the
target project.

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3.3 Copying a plant section

1. Copy the hierarchy folder "Desalination" from the AS project of the unit
template into the plant hierarchy of the target project.

Note The hierarchy folders of the plant sections "Overview" and "Simulation" are not
necessary for operation. If you want to operate your system without simulation,
you do not have to copy them.
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2. Copy the process screen "RevOsmosis" from the OS project of the unit
template into the plant hierarchy of the target project. If necessary, also copy
the pictures "Simulation" and "Overview".

Note When copying the process screens, make sure that you copy the screens to the
hierarchy level of the target project that is parameterized as the OS area.

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3.4 Customizing the OS project

In order to be able to change the colors in the reverse osmosis process picture at a
central location, a central color palette was created in the OS project of the Unit
Template. You must import the central color palette so that these colors are also
displayed in the process screen of your own project.
1. Select the "OS" in WinCC Explorer and choose "project properties" in the
context menu.
2. Choose the "Interface and Design" tab and click the "Edit" button.
3. Import the palette with the "Overwrite" option into your own project. The color
palette is in the project folder under the path:
"<Project path>\Desalina\Desalina\wincproj\OS\GraCS\[Link]>". All
existing colors will be replaced.
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Note When you export or import the colors, all color tables are always taken into
account. It is not possible to export individual color tables.

If you have created your own color tables in your project, you can also export these
and merge the tables with an editor in the XML file. Alternatively, create a new
color table in your project and define the colors individually. Also make sure that
the color index does not change, otherwise you would have to adjust the color
settings of the objects in the process picture. Of course, it is up to you to change
the colors according to your requirements.

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Color HTML Code RGB Code

R G B
3296B9 50 150 185

247087 36 112 135

50BED7 80 190 215

3D93A5 61 147 165

005F87 0 95 135

003C55 0 60 85

00646E 0 100 110

0F8287 15 130 135

494949 73 73 73

6D6D6D 109 109 109

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The following figure shows a simplified representation of how the colors are used in
the process picture.

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4 Engineering

4 Engineering
4.1 Control module types
In this unit template the following Control Module Types from the library "SWL
PCS7 V90 SP1" are used.

Control module type Description

WCMT_MonAnalog Monitoring of an analog measuring point
WCMT_MotSpdCon Control of a motor via a frequency converter (FU) with
infinitely variable speed variation and two directions of
rotation
WCMT_PIDConL PID controller with continuous output signal (output
value)
A detailed description of the Control Module Types can be found in the paper
"Standard PCS 7 and S7 Water Templates for the Water Industry" at
[Link]
In addition to the Control Module Types from the "SWL PCS7 V90 SP1" library, the
Control Module Type "CtrlMPC" from the BMC library is also used.
Control module type Description
CtrlMPC MPC multi-variable controller
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A detailed description of the Control Module Types can be found in the paper
"Equipment Modules for SIMATIC PCS 7 using the example of the Chemical
Industry" at [Link]

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4 Engineering

4.1.1 WCMT_MonAnalog

The Control Module Type "WCMT_MonAnalog" is used to monitor an analog

measurement tag.
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In the application example, from the optional variants, only "MonAnIn" is used. The
optional variants "PMonAnalog" and "SelFp" require the PCS 7 Industry Library.
The following Control Modules are of type "WCMT_MonAnalog":
 TI-Feed  PI-Recirc
 FI-Feed  PI-Reject
 JI-Feed  JI-Recirc
 FI-Permeate  PI-Brine
 PI-Permeate  FI-Brine
 QI-Permeate

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4.1.2 WCMT_MotSpdCon

The Control Module Type "WCMT_MotSpdCon" is used to control a motor via

frequency converter with variable speed and two directions of rotation.
 Siemens AG 2018 All rights reserved

In the application example, the variants "OutFwd", "FbkFwd", "OutSpd" and

"RbkSpd" are parameterized at the instances. Only one direction of rotation is
required.
The following drives are of type "WCMT_MotSpdCon":
 NI-Feed
 NI-Recirc

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4.1.3 WCMT_PIDConL

The Control Module Type "WCMT_PIDConL" is a PID controller with continuous

output signal (manipulated variable). The PID controller can be used for fixed-
value, cascade, ratio, split-range, Smith predictor and override control.
 Siemens AG 2018 All rights reserved

The controller is used in the Unit Template to control the pressure at the membrane
and the flow of recirculation. No options are activated at the type instances used.
The following controllers are of type "WCMT_PIDConL":
 PIC-Feed
 FIC-Recirc

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4.1.4 CtrlMPC

The CMT "CtrlMPC" is used for multi-variable control. In contrast to the "Ctrl", the
multi-variable controller can handle up to four dependent manipulated and
controlled variables. MPC is short for "Model Predictive Control".
 Siemens AG 2018 All rights reserved

The multi-variable controller is used in the Unit Template to directly control the
target values permeate flow and salinity of the permeate, thus compensating for
the effect of "fouling" at the membrane. The following options are activated for the
type instances used:
 Opt_Ctrl_1
 Opt_Ctrl_2
 Opt_Ctrl_3
 Opt_Ctrl_4
The controller "XC_Desalination" is of type "CtrlMPC":

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4.2 Equipment Modules and Control Modules

The Equipment Modules are described in detail in the following section. The basis
for programming the AS are predefined Control Module Types from the water
industry. The description of the used Control Module Types can be found in section
4.1
4.2.1 Inflow (Feed)

The pre-cleaned sea water from the ultrafiltration is transported via the inflow to
reverse osmosis unit. In order to exploit the existing pressure of the retentate, part
of the fresh sea water is passed through the pressure exchanger (energy recovery
device). The high-pressure pump generates the required pressure at the
membrane. The pressure level is specified as the setpoint at the controller.

Setup

PIC
Feed

TI FI NI JI
Feed Feed Feed Feed

Membrane
Pre-Treatment
 Siemens AG 2018 All rights reserved

Pressure
Exchange

The following Control Modules are used in the "Feed" area of the plant section:
Control module Control module type Variants Description
RO-FI-Feed WCMT_MonAnalog MonAnIn Flow measurement (m³/h)
RO-TI-Feed WCMT_MonAnalog MonAnIn Temperature measurement (°C)
RO-JI-Feed WCMT_MonAnalog MonAnIn Power measurement (kW)
RO-NI-Feed WCMT_MotSpdCon OutFwd Variable speed drive
OutSpeed
FbkFwd
RbkSpeed
RO-PIC-Feed WCMT_PIDConL PV_In Pressure controller

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Parameter assignment
RO-FI-Feed
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 2000 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1349 Unit of measurement of the Control
Module (m³/h)
I PV_WL_Lim 300.0 Warning low limit
PV_AL_Lim 200.0 Alarm Low limit
PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

The following connections have been added in addition to the standard connection:
Block Connection Target Description
 Siemens AG 2018 All rights reserved

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the

simulation
SimPV_In SIM_FI_Feed.SIM_VAL Simulated process value
I MsgLock SFC "Start-up” Message lock during start-up
PV_Out SIM_Feed+Reci.In1 Calculation for the simulation

RO-TI-Feed
The following parameters were changed from the default values during project
planning:

Block Parameters Value Description

MonAnIn [Link] 80 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1001 Unit of measurement of the Control
Module (°C)
I PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

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The following connections have been added in addition to the standard connection:

Block Connection Target Description

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_TI_Feed.Out Simulated process value

RO-JI-Feed
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 1300.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1190 Unit of measurement of the Control
Module (kW)
I PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
 Siemens AG 2018 All rights reserved

GradHDnEn 0 Gradient High Alarm downwards

(Off)

The following connections have been added in addition to the standard connection:

Block Connection Target Description

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_JI_Feed.Out Simulated process value
to_MPC ReStru1 C.PV_Out Merge connection to MPC
BoStru1 [Link]
BoStru2 [Link]
Int1 MonAnIn.PV_OutUnit
Scale1 [Link]
Out XC_Desalination\from_CV3.In Connection to MPC

RO-NI-Feed
All parameters were used with the default values.

These connections have been added in addition to the standard:

Block Connection Target Description
FbkFwd SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_NI_Feed.FbkFwd_Out Simulated process value
RbkSpeed SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_NI_Feed.Spd_Out Simulated process value

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Block Connection Target Description

N Fwd SIM_NI_Feed.CmdFwd Start signal for the simulation
SP_Out SIM_NI_Feed.SP_SPD Target value for simulation
SP_Ext RO-PIC-Feed\[Link] Control value of the controller
ModLiOp SFC "Start-up” A detailed description of the
AutModLi SFC "Start-up” SFC can be found in the
section:4.2.7
ManModLi SFC "Start-up”
SP_LiOp SFC "Start-up”
SP_ExtLi SFC "Start-up”
FbkFwdOut SFC "Start-up”
AutAct SFC "Start-up”
SP_ExtAct SFC "Start-up”

RO-PIC-Feed
The following parameters were changed from the default values during project
planning:

Block Parameters Value Description

C Gain 0.6 Controller gain
TI 8 Controller delay time
 Siemens AG 2018 All rights reserved

SP_Int 57.24 Internal setpoint

PV_AH_Lim 80 Alarm high limit
PV_WH_LIM 75 Warning high limit
PV_WL_Lim 55 Warning low limit
PV_AL_Lim 50 Alarm Low limit
SP_InHiLim 100 Set point range corresponding to the
measuring range of the Control Module
SP_InLoLim 0
PV_In PV_InUnit 1137 Unit of measurement of the process value
(bar)

The following connections were added to the standard:

Block Connection Target Description

C SP to_Master.ReStru1 Merge connection to
MPC
SP_InHiOut to_Master.ReStru2
SP_InLoOut to_Master.ReStru3
PV_Out to_Master.ReStru4
CasaCut to_Master.BoStru1
LockAct to_Master.BoStru3
SP_Ext from_Master.Restruc1 Disconnect wiring
from MPC
ModLiOp SFC "Start-up” A detailed
AutModLi description of the
SFC can be found in
ManModLi the section:4.2.7
SP_LiOp
SP_ExtLi

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Block Connection Target Description

SP_IntLi
AutAct
SP_ExtAct
SP
PV_WH_Ac
OosAct Out to_Master.BoStru2 Merge connection to
MPC
PV_In PV_In.PV_OutUnit to_Master.Int1
PV_In.ScaleOut to_Master.Scale1
to_Master Out XC_Desalination\from_Ctrl1.In Connection to MPC
from_Master In XC_Desalination\to_Ctrl1.Out Connection from
MPC

4.2.2 Recirculation

The fresh sea water, which has been lifted to a higher pressure level by the
pressure exchanger, is pumped to the membrane by the booster pump. The flow
rate to be pumped is specified as the flow setpoint at the controller:

Setup
Membrane
 Siemens AG 2018 All rights reserved

Pre-Treatment

PI
Recirc
FIC
Recirc
NI JI
Recirc Recirc

Pressure
Exchange

The following Control Modules are used in the "Recirc" plant section area:
Control module Control module type Variants Description
RO-PI-Recirc WCMT_MonAnalog MonAnIn Pressure measurement (bar)
RO-JI-Recirc WCMT_MonAnalog MonAnIn Power measurement (kW)
RO-NI-Recirc WCMT_MotSpdCon OutFwd Variable speed drive
OutSpeed
FbkFwd
RbkSpeed
RO-FIC-Recirc WCMT_PIDConL PV_In Flow controller

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Parameter assignment
RO-PI-Recirc
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 90.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1137 Unit of measurement of the Control
Module (bar)
I PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

The following connections have been added in addition to the standard connection:
Block Connection Target Description
 Siemens AG 2018 All rights reserved

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the

simulation
SimPV_In SIM_PI-[Link] Simulated process value
I MsgLock SFC "Start-up” Message lock during start-up

RO-JI-Recirc
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 140.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1190 Unit of measurement of the Control
Module (kW)
I PV_AH_En 0 High alarm (Off)
PV_WH_En 0 High warning (Off)
PV_AL_En 0 Low alarm (Off)
PV_WL_En 0 Low Warning (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

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The following connections have been added in addition to the standard connection:

Block Connection Target Description

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_JI_Feed.Out Simulated process value
to_MPC ReStru1 C.PV_Out Merge connection to MPC
BoStru1 [Link]
BoStru2 [Link]
Int1 MonAnIn.PV_OutUnit
Scale1 [Link]
Out XC_Desalination\from_CV4.In Connection to MPC

RO-NI-Recirc
All parameters were used with the default values.

These connections have been added in addition to the standard

Block Connection Target Description
FbkFwd SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
 Siemens AG 2018 All rights reserved

SimPV_In SIM_NI_Recric.FbkFwd_Out Simulated process value

RbkSpeed SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_NI_Recirc.Spd_Out Simulated process value
N Fwd SIM_NI_Recirc.CmdFwd Start signal for the simulation
SP_Out SIM_NI_Recirc.SP_SPD Target value for simulation
SP_Ext RO-FIC-Recirc\[Link] Control value of the controller
ModLiOp SFC "Start-up” A detailed description of the
AutModLi SFC "Start-up” SFC can be found in the
section:4.2.7
ManModLi SFC "Start-up”
SP_LiOp SFC "Start-up”
SP_ExtLi SFC "Start-up”
FbkFwdOut SFC "Start-up”
AutAct SFC "Start-up”
SP_ExtAct SFC "Start-up”

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RO-FIC-Recirc
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
C Gain 0.16 Controller gain
TI 4.7 Controller delay time
SP_Int 728.6 Internal setpoint
PV_AH_En 80 Alarm High (Off)
PV_WH_En 75 Warning High (Off)
PV_WL_En 55 Alarm Low (Off)
PV_AL_Em 50 Warning Low (Off)
SP_InHiLim 900 Set point range corresponding to the
measuring range of the Control Module
SP_InLoLim 0
PV_In PV_InUnit 1349 Unit of measurement of the process value
(m³/h)
The following connections were added to the standard:
Block Connection Target Description
C SP to_Master.ReStru1 Merge connection to
MPC
SP_InHiOut to_Master.ReStru2
 Siemens AG 2018 All rights reserved

SP_InLoOut to_Master.ReStru3
PV_Out to_Master.ReStru4
CasaCut to_Master.BoStru1
LockAct to_Master.BoStru3
SP_Ext from_Master.Restruc1 Disconnect wiring from
MPC
ModLiOp SFC "Start-up” A detailed description of
AutModLi the SFC can be found in
the section:4.2.7
ManModLi
SP_LiOp
SP_ExtLi
SP_IntLi
AutAct
SP_ExtAct
SP
PV_WH_Ac
OosAct Out to_Master.BoStru2 Merge connection to
PV_In PV_OutUnit to_Master.Int1 MPC

ScaleOut to_Master.Scale1
to_Master Out XC_Desalination\from_Ctrl2.In Connection to MPC
from_Master In XC_Desalination\to_Ctrl2.Out Connection from MPC

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4.2.3 Permeate

Here, the residual salinity and the quantity of desalinated seawater are recorded.

Setup
PI FI
Permeate Permeate

Membrane
Permeate

QI
Permeate

The following Control Modules are used in the "Permeate" plant section:
Control module Control module type Variants Description
RO-FI-Permeate WCMT_MonAnalog MonAnIn Flow measurement (m³/h)
RO-PI-Permeate WCMT_MonAnalog MonAnIn Pressure measurement (bar)
RO-QI-Permeate WCMT_MonAnalog MonAnIn Measurement of conductivity
(µS/cm)
In addition to conductivity, the quality of the product can also be represented by
salinity. For this purpose, the salinity is calculated in simplified form using the
following linear conversion factor:
 Siemens AG 2018 All rights reserved

g µS
1 = ̂ 1226.1
L cm
Conductivity 𝑆 is usually measured at a real plant. However, the conversion into
salinity must be carried out individually. Conductivity depends, for example, on salt
composition, pressure and temperature.

Parameter assignment
RO-FI-Permeate
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 2000 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1349 Unit of measurement of the Control
Module (m³/h)
I PV_WL_Lim 100.0 Warning low limit
PV_AL_Lim 80.0 Alarm Low limit
PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

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The following connections have been added in addition to the standard connection:

Block Connection Target Description

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In F_Factor.Out Simulated process value
I MsgLock SFC "Start-up” Message lock during start-up
PV_Out SIM_FI_Brine.In2 Calculation for the simulation
to_MPC ReStru1 C.PV_Out Merge connection to MPC
BoStru1 [Link]
BoStru2 [Link]
Int1 MonAnIn.PV_OutUnit
Scale1 [Link]
Out XC_Desalination\from_CV2.In Connection to MPC

RO-PI-Permeate
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 90.0 Measuring range of the Control
 Siemens AG 2018 All rights reserved

I [Link] 0 Module
PV_InUnit 1137 Unit of measurement of the Control
Module (bar)
PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)
The following connections have been added in addition to the standard connection:
Block Connection Target Description
MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_PI-[Link] Simulated process value

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RO-QI-Feed
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 1800.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 0 Unit of measurement of the Control
Module (µS/cm)
PV_AH_Lim 1300 Alarm high limit
PV_WH_LIM 1280 Warning high limit
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

The following connections have been added in addition to the standard connection:

Block Connection Target Description

MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
 Siemens AG 2018 All rights reserved

SimPV_In SIM_JI_Feed.Out Simulated process value

to_MPC ReStru1 C.PV_Out Merge connection to MPC
BoStru1 [Link]
BoStru2 [Link]
Int1 MonAnIn.PV_OutUnit
Scale1 [Link]
Out XC_Desalination\from_CV1.In Connection to MPC

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4.2.4 Brine

In this system area, the pressure of the retentate is measured and the pressure is
transferred to the fresh seawater by the pressure exchanger. Flow of the brine is
recorded in the discharge pipe.

Setup:
Membrane

PI
Reject

PI FI
Brine Brine
Pressure
Exchange
Brine

In the Equipment Modules "Brine" the following Control Modules are used:
Control module Control module type Variants Description
RO-FI-Brine WCMT_MonAnalog MonAnIn Flow measurement (m³/h)
RO-PI-Brine WCMT_MonAnalog MonAnIn Pressure measurement (bar)
RO-PI-Reject WCMT_MonAnalog MonAnIn Pressure measurement (bar)
 Siemens AG 2018 All rights reserved

Parameter assignment
RO-FI-Brine
The following parameters were changed from the default values during project
planning:

Block Parameters Value Description

MonAnIn [Link] 1000.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1349 Unit of measurement of the Control
Module (m³/h)
I PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)

The following connections have been added in addition to the standard connection:
Block Connection Target Description
MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_FI_Brine Simulated process value
PV_Out SIM_FI_Brine.In2 Calculation for the simulation

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RO-PI-Brine
The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MonAnIn [Link] 90.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1137 Unit of measurement of the Control
Module (bar)
PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)
The following connections have been added in addition to the standard connection:
Block Connection Target Description
MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_PI-[Link] Simulated process value
 Siemens AG 2018 All rights reserved

RO-PI-Reject
The following parameters were changed from the default values during project
planning:

Block Parameters Value Description

MonAnIn [Link] 90.0 Measuring range of the Control
I [Link] 0 Module
PV_InUnit 1137 Unit of measurement of the Control
Module (bar)
PV_AH_En 0 Alarm High (Off)
PV_WH_En 0 Warning High (Off)
PV_AL_En 0 Alarm Low (Off)
PV_WL_En 0 Warning Low (Off)
GradHUpEn 0 Gradient High Alarm upwards (Off)
GradHDnEn 0 Gradient High Alarm downwards
(Off)
The following connections have been added in addition to the standard connection:
Block Connection Target Description
MonAnIn SimOn SIM_On_Off.Activate Activates/deactivates the
simulation
SimPV_In SIM_PI-[Link] Simulated process value

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4.2.5 Salinity and flow rate (desalination)

The multi-variable control system regulates flow rate and salt concentration of
water as a measure of product quality. For this purpose, the controller delivers its
output values as external setpoints to the slave controllers for feed pressure and
recirculation flow.
Product quality (salinity) has the highest priority but remains within its dead zone
during normal operation. The controller only has to intervene if the salinity should
be higher than permitted. Therefore, the main control variable in normal operation
is the production output (permeate flow).
The electrical power consumption of high-pressure pump and booster pump are
low-priority controlled variables. The target values correspond to the operating
points with optimum pump efficiency.

Setup
PIC XC
Feed Desalination

NI JI PI FI
Feed Feed Permeate Permeate

Membrane
Pre-Treatment Permeate
 Siemens AG 2018 All rights reserved

FIC
Recirc
NI JI
Recirc Recirc

Pressure
Exchange

Brine
The following Control Modules are used in the "Desalination" plant section:
Control module Control module type Variants Description
RO-XC-Desalination CtrlMPC Opt_Ctrl_1 Multi-variable controller as
Opt_Ctrl_2 master controller
Opt_Ctrl_3
Opt_Ctrl_4

Parameter assignment
RO-XC-Desalination
The Control Module contains communication blocks for connecting slave
controllers and for displaying controlled variables, and is an instance of the Control
Module Type "CtrlMPC". The communication blocks are connected to the following
variables.
CVs (Controlled Variables):
 Salinity after membrane (RO-QI-Permante)
 Flow after membrane (RO-FI-Permante)
 High-pressure pump power consumption (RO-JI feed)
 Booster pump power consumption (RO-JI-Recirc)

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MVs (Manipulated Variables, setpoint values for slave controllers):

 Feed pressure (RO-PIC feed)
 Recirculation flow rate (RO-FIC-Recirc)

The following parameters were changed from the default values during project
planning:
Block Parameters Value Description
MPC SP1 533.31 Setpoint setting for the process value
1
SP2 475.0 Setpoint setting for process value 2
SP3 913.0 Setpoint setting for process value 3
SP4 65.0 Setpoint setting for process value 4
PreFilt1 24.0 Settling time in s of setpoint filter for
setpoint SP1
PreFilt1 36.0 Settling time in s of setpoint filter for
setpoint SP2
MV1Man 55.0 Control value in manual mode
MV2Man 700.0 Control value in manual mode
DB_No 18 DB number with controller data
DeadBand_SP1 In1 606.92 Upper limit of the deadband
 Siemens AG 2018 All rights reserved

The following connections have been added in addition to the standard connection:

Block Connection Target Description

RO-XC- Dead band for set value 1
MPC SP1DeadB Desalination\Limit_Deadband.Out
RO-XC- Calculate the dead band
MPC SP1OpOut Desalination\DeadBand_SP1.In2t from the target value
RO-PIC_Feed\from_Master.In Control value for the inlet
to_Ctrl1 Out pressure
RO-FIC_Recirc\from_Master.In Control value for
to_Ctrl2 Out recirculation flow rate
RO-PIC_Feed\to_Master.Out Connection from the
Control Module Inlet
from_Ctrl1 In pressure
RO-FIC_Recirc\to_Master.Out Connection of the Control
from_Ctrl2 In Module Recirculation
from_CV1 In RO-QI-Permate\to_MPC.Out Connection of salinity
display
from_CV2 In RO-FI-Permate\to_MPC.Out Connection of flow rate
indicator
from_CV3 In RO-JI-Feed\to_MPC.Out Connection to high-
pressure pump display
from_CV4 In RO-JI-Recirc\to_MPC.Out Connection to booster
pump display

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4.2.6 Process simulation (simulation)

The task of process simulation is to understand or demonstrate the functionality of

reverse osmosis, especially with regard to the control functions of the multi-variable
controller. There is no claim of exactly reproducing the real physical behavior of a
certain desalination plant.

Simulation of the membrane

For process simulation, a matrix of linear dynamic transfer functions is used as a
model. The process model is a 2x4 multi-variable system in which the influence of
each input variable to each output variable is simulated by a separate partial
transfer function. The model describes the temporal behavior of process deviations
from the operating point. The process simulation runs in real time, only the fouling
process runs in time-lapse, i.e. 240 times faster than real time. This means a
cleaning of the membrane is necessary after 10 minutes.
Input variables

RO-NI-Feed RO-NI-Recirc
Output variables

QI_Permeate G11 G12

FI_Permeate G21 G22

JI_Feed G31 G32

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JI_Recirc G41 G42

In the simulation plan "Sim_Membran" the process variables of the MPC are
calculated. Operating points, delays and interactions are defined for each process
variable. The dynamic model describes deviations from the operating point for the
respective process variable.

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For the transfer functions G11, G21, G31, G32, G41 and G42 a first-order delay
function (PT1 behavior) around the operating point is simulated.
1

2 3

1. Calculation of the deviation from the operating point

2. First order delay element
3. Gain

The transfer functions G12 and G22 cannot be realistically simulated by first-order
delay functions (PT1 behavior). Therefore, for these two transfer functions, the
form
1+𝑇𝑧 ∙𝑠
𝐺(𝑠) = 𝐾𝑝 ∙ is selected
(1+𝑇𝑝1 ∙𝑠)(1+𝑇𝑝1 ∙𝑠)

1
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1. Calculation of the deviation from the operating point

2. Transfer function
3. Influence of fouling
4. Conversion to conductivity

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Note The conversion of salinity to conductivity (measurable at the real plant) is carried
out for the template in simplified form with the following linear conversion factor:
g µS
1 = ̂ 1226.1
L cm
In a real plant, the actual salinity can only be calculated from the measured
conductivity. The conversion depends on salt composition, pressure and
temperature and must be calibrated individually.

Process simulation
In the simulation plan "Simulation" the process variables of the two PID controllers
are calculated. Operating points, delays and interactions are defined for each
process variable. The dynamic model describes deviations from the operating point
for the respective process variable.
1

2 3

2
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2 3

1. Simulation of a motor with two directions of rotation and variable speed

2. Scaling to the operating point
3. Simulation of the process behavior (PT1 element)

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A plan-in-plan module is used to simulate a motor with two directions of rotation

and variable speed. The following table shows the input parameters of the block.
Parameters Type Description
SP_SPD STRUCT Analog setpoint of the engine
Value: REAL
ST: BYTE
SP_Scale STRUCT Setpoint limits of the engine
High: REAL
Low: REAl
Scale STRUCT Scaling of the motor in revolutions per minute
High: REAL
Low: REAL
CmdFwd STRUCT Command to start the engine in forward direction
Value: BOOL
ST: BYTE
CmdRev STRUCT Command to start the engine in reverse direction
Value: BOOL
ST: BYTE
Kp STRUCT Engine gain factor
Value: REAL
ST: BYTE
Tv REAL Delay time of the engine (PT1 behavior)
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The following table shows the output parameters of the block.

Parameters Type Description
SPD_Out STRUCT Analog output value of the engine in percent
Value: REAL
ST: BYTE
SPDU_Out STRUCT Analog output value of the engine in revolutions
Value: REAL per minute
ST: BYTE
SP_Scale_Out STRUCT Output of the scaling of the engine in percent
High: REAL
Low: REAL
Scale_Out STRUCT Output of the scaling of the engine in revolutions
High: REAL per minute
Low: REAL
FbkFwd STRUCT Feedback of the engine in forward direction
Value: BOOL
ST: BYTE
FbkRev STRUCT Feedback of the engine in reverse direction
Value: BOOL
ST: BYTE

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4.2.7 Sequential Function Chart

After the CPU has been started, the SFC "Startup" drives the system into the
operating point. The SFC starts the drives and defines setpoints for the controllers.
The messages of the Control Modules are blocked until all process values are
within the normal range. The SFC is processed only once after the start of the
CPU.
(1) "Lock Messages":
The messages of the affected blocks are
blocked.
1
(2) "NI-Feed-Link" and "NI-Recirc-Link":
The operation of the drives is set to
automatic and the setpoint source is set to 2
external.

(3) "NI-Feed-Start” and "NI-Recirc-Start": 3

The drives are started.

(4) "PIC-Feed-Start" and "FIC-Recirc-Start":

The operation of the PID controllers is set to 4
interconnection and the setpoint source is
set to internal.
5
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(5) "Start_MPC".
Starting the MPC in manual mode and
setting the output value
6

(6) "PIC-Feed-Ext" and "FIC-Recirc-Ext":

The operation of the controllers is switched
over to the external setpoint. 7

(7) "Auto_MPC":
The MPC is given the setpoints and put into 8
automatic mode.

(8) "NI-Feed-Op" and "NI-Recirc-Op": 9

The usability of the engines is enabled
again for the operator.
10
(9) "PIC-Feed-Op" and "FIC-Recirc-Op”:
The operation of the controllers is enabled
again for the operator. 11

(10) "MPC-Op" and "FIC-Recirc-Op":

The operation of the MPC is enabled again
for the operator.

(11) "Unlock Messages":

The messages of the affected blocks are
released.

The SFC "Startup" is implemented in the folder "RevOsmosis" of the plant

hierarchy.

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4.2.8 Key Performance Indicators (KPI)

The CFC "KPI" contains key figures that inform the operator about the performance
of the process. The following key performance indicators are calculated and
displayed in the visualization:
1. Sheet: Specific energy consumption: The specific energy consumption is
calculated from the ratio of total power consumption to volume flow. The total
power is calculated by adding the power of the high-pressure pump and the
̇
booster pump. The outgoing volume flow 𝑉𝑃𝑒𝑟𝑚𝑎𝑡𝑒 corresponds to the permeate
product outflow.
𝑃Feed + 𝑃Recirc
𝑆𝐸𝐶 =
̇
𝑉Permeate

2. Sheet: Overall energy consumption (OverallEnergy): The energy consumption

describes the energy consumed since the last cleaning of the membrane and
is calculated from the time integral of the power consumption of the two
pumps.

𝐸consumption = ∫(𝑃Feed + 𝑃Recirc ) d𝑡

3. Sheet: Produced quantity (OverallProduction): The quantity produced

describes the quantity of drinking water produced since the last purification of
the membrane and is calculated from the time integral of the volume flow of the
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desalinated water.
̇
𝑉Product = ∫ 𝑉Permeate d𝑡

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5 Basics
5.1 P&I diagram
The following P&ID shows the process of reverse osmosis within a seawater
desalination plant. This process is described in more detail in this application
example.
PIC XC
Feed Desalination

TI FI NI JI PI FI
Feed Feed Feed Feed Permeate Permeate

Membrane
Pre-Treatment Permeate

PI QI
Recirc Permeate
PIC
Recirc
NI JI PI
Recirc Recirc Reject

Pressure PI FI
Exchange Brine Brine
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Brine

5.2 Project structure

5.2.1 Naming conventions

For the composition of the process tags a uniform naming convention is used,
which corresponds to the European standard EN 62424. As shown here using the
example of a process tag for pressure recording, the process tag designations in
the AS program are structured as follows:
RO-PI-Feed
Plant code: RO (Reverse Osmosis)
First letter: P-pressure
Next letter: I - indicator
Measuring point code

The following tables contain the designations used in this application example and
their meaning:

First letter Meaning

F Flow
J Power
L Level
M Moisture
N Engine

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First letter Meaning

P Pressure
Q Amount, quantity or quality
S Speed (velocity, rotational speed, frequency)
T Temperature
X Freely selectable first letter
Y Control valve

Next letter Meaning

A Alarming/Messages
C Control
F Fraction
I Indication
R Recording/Storage
S Switching function or binary control function (not safety-relevant)

5.2.2 Plant view

The SIMATIC PCS 7 project is created as a multi-project "Desalination_MP" and

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contains the following subprojects:

 Desalination_AS
Contains the hardware configuration of the AS and the AS program.
 Desalination_OS
Contains the configuration of the OS and the OS project.
 Desalination_Lib
The master data library provides all the components used.

The plant hierarchy is defined with three levels (plant, plant section and Equipment
Module) and the OS level is defined as level 2. The AS program for seawater
desalination is set up in the "RevOsmosis" plant unit.
The 'RevOsmosis' unit contains the Equipment Modules in which the CFCs are
located.
The process picture of reverse osmosis is displayed at the operator station in the
plant area "RevOsmosis". The process screen contains the Control Modules of all
Equipment Modules.

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The following figure shows the structure of the PCS 7 multi-project.

Desalination OS - Project
Overview RevOsmosis Simulation

PDL PDL PDL

Overview RevOsmosis Simulation

Desalination AS - Project

RevOsmosis

Birne

CFC CFC CFC

RO_FI_Brine RO_PI_Brine RO_PI_Reject

Feed

CFC CFC CFC CFC CFC

RO_FI_Feed RO_NI_Feed RO_JI_Feed RO_PIC_Feed RO_TI_Feed
 Siemens AG 2018 All rights reserved

Permeate

CFC CFC CFC

RO_FI_Permeate RO_PI_Permeate RO_QI_Permeate

Recirc

CFC CFC CFC

RO_JI_Recirc
RO_FI_Permeate RO_FIC_Recirc
RO_PI_Permeate RO_NI_Recirc
RO_QI_Permeate

MPC
RevOsmosis
CFC SFC CFC
RO_XC_Desalination Startup KPI

RevOsmosis

CFC CFC CFC

SIM_On_Off Simulation SIM_Membran

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5.3 Components of Unit Template

The desalination process is realized with the following components:
 High pressure pump
 Osmosis membranes
 Pressure exchanger
 Booster pump
 Control Modules for recording pressure, flow rate, performance, quality and
temperature

2 4

1
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1. Analog process tag

2. Pump drive with PID control
3. Sequential function chart "Startup"
4. MPC

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Startup
After you start the CPU, the SFC "Startup" is executed. You can check the status
of the SFC at the block symbol with the corresponding faceplate and restart the
sequencer if necessary.
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PID control
The drives "NI-Feed" and "NI-Recirc" are controlled by a PID controller. The
controller "PIC-Feed" controls the pressure "PI-Feed" at the osmosis membrane.
The controller "FIC-Recirc" regulates the flow "FI-Recirc" of fresh sea water, which
has been brought to a higher pressure level by the pressure exchanger.

The setpoints for PID control of pressure and flow are specified by the multi-
variable controller.

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5 Basics

MPC
The PID controllers "PIC-Feed" and "FIC-Recirc" receive the setpoints from a
master multi-variable controller. The multi-variable controller commands up to four
interacting manipulated and controlled variables as well as one measurable
disturbance variable. In this case, the flow rate and the quality of the product are
read and the manipulated variables for the desalination process are calculated.
 Siemens AG 2018 All rights reserved

5.4 Connect Control Modules

For the next steps, make sure that the hardware devices including peripherals are
completely configured in your project. You should parameterize all used inputs and
outputs of the periphery with symbol names. Name the symbols in the same way
as the corresponding process tag names. E.g. the following symbolic names are
used to control the high pressure pump:
Address Symbol Data type Comment
IW 516 RO-PI-Feed-In WORD Feed Pressure
IW 518 RO-NI-Feed-FBSpd WORD Feedback Speed HPP
I 0.0 RO-NI-Feed-FBFwd BOOL Feedback Run Forward HPP
QW 515 RO-NI-Feed-SPSpd WORD Setpoint Speed HPP
Q 0.0 RO-NI-Feed-Start BOOL Starting Forward HPP

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Then connect the connection "PV_In" or "PV_Out" of all driver blocks to the
process periphery.
 Siemens AG 2018 All rights reserved

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6 Appendix

6 Appendix
6.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
[Link]

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
[Link]/industry/supportrequest
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SITRAIN – Training for Industry

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
[Link]/sitrain

Service offer
Our range of services includes the following:
 Plant data services
 Spare parts services
 Repair services
 On-site and maintenance services
 Retrofitting and modernization services
 Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
[Link]

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:
[Link]

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6 Appendix

6.2 Links and literature

No. Topic
\1\ Siemens Industry Online Support
[Link]
\2\ Link to this entry page of this application example
[Link]
\3\ Whitepaper: "Optimization of Reverse Osmosis Seawater Desalination Plants by
Advanced Process Control"
[Link]
industry/en/desalination/PublishingImages/[Link]
\4\ Standard PCS 7 and S7 Water Templates for the water industry
[Link]
\5\ SIMATIC Process control system PCS 7 Advanced Process Library (V9.0 SP1)
[Link]
\6\ Controller optimization with PCS 7 PID Tuner
[Link]

6.3 Change documentation

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Version Date Modifications

V1.0 10/2018 First version

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