DECEMBER 11, 2015 PLC-Based Waste Water Lift Station with Demo Box by Lance McParlan Advisor & Instructor: Paul Lin Outline This presentation will cover: What a Lift Station is Why they are being upgraded Design Hardware Software Testing Problems Conclusion Donohue & Associates 1
What is a Lift Station? Lift stations: Wet Well Pumps (dry or submersible) Valve Vault Control Panel Figure 1: Brookside Lift Station Equipment Reaching End of Life Existing Lift Station Panels are all over 20 years old. These components need to be upgraded This project includes: Bid Documents Construction related services Panel Drawings Demo Box Figure 2: Brookside Panel (old) Donohue & Associates 2
What is a PID? PID stands for Process and Instrumentation Diagram Shows process flow Instrumentation PLC (Programmable Logic Controller) IO HMI (Human Machine Interface) Functions Major panel components Brookside PID Site Removal & Site Plans Removal Drawings (example) Shows what is to be moved and or relocated Additional plan notes and instruction on removal and relocation Site Plans (example) Shows the location of new or relocated equipment Wiring tables Additional notes instructions for construction Donohue & Associates 3
Panel Fabrication Drawings Detailed Panel Drawings used to build the panel Usually designed by contractor during construction Allowing me to design them under a Professional Service Agreement saved the project at least 2 months of schedule Contains panel layout, power wiring, IO wiring, and bill of materials Swingout Panels Front Swingout panels PanelView HMI Graceport (outlet and Ethernet port) Breakers Pilot Lights Hand Switches Hour Meters Figure 3: Swingout Panels Donohue & Associates 4
Control Components Figure 4: Control Comp. Control Voltage side (120Vac and 24Vdc) Micro850 PLC Breakers Fuses Terminals Relays UPS 24Vdc Power supply Surge Protection Device 230v 3-phase Components 230v Components Control Power Transformer Breakers Power Distribution Block Phase Loss Monitor Surge Protection Device Nema Magnetic Motor Starters Field Terminals Figure 5: 230v Components Donohue & Associates 5
Programming The PLC and the HMI were both programmed using Connected Component Workbench Free Software from Rockwell Conglomerate of Rockwell RS software and Visual Studio The PLC and HMI programs for each station were identical for every station (except for preloads) They are able to be customized for each station using the HMI PLC Program Routine The PLC Program had 13 subroutines, 12 of which were used for this project Preloads default values in case of memory loss Main handles real time clock and simulation mode Pump_#_Device (3 pumps in total) Level_Control Alternator Alternates lead and lag pumps Read_Data Reads data sent from polling master Write_Data Moves data into an integer file to be transferred to polling master Donohue & Associates 6
HMI Program The HMI Program has 4 screens and 2 popup banners Overview Setpoints StationSetup Alarm Status Diagnostics (popup banner) Alarm Banner Very Basic animation (layering Images) Shows wetwell and pump status Wetwell Level Pump Run Indicator Pump HOA Position Estimated Run Hours Number of Pump Starts HMI Overview Donohue & Associates 7
HMI Setpoints Screen from which operator can adjust the station setpoints HMI Station Setup This is where the interface can be customized for each station (this information is also programmed into the preloads) Donohue & Associates 8
HMI Status Screen This is the information that gets sent back to the polling master to be displayed on the SCADA System (Supervisory Control and Data Acquisition) Interfacing HMI and PLC Interfacing the PLC and HMI was simple for this application List of tags matched in a table to compare the tag name of HMI to the PLC O.DS for PLC to HMI, I.DC for HMI to PLC (Discrete Status & Control) Donohue & Associates 9
Testing Factory Testing IO checkout Check every input to PLC Jump or simulate any field signals Test Simulate mode Make sure set points work Test all physical switches and inputs Problems Had a few problems with shipping and panels getting damaged PLC and HMI program didn t work on the upgraded firmware (aliasing issue in the PLC program) Problems with on UPS with a low battery (had to swap some N.O. and N.C. contacts) Donohue & Associates 10
Conclusion Project went fairly smooth Covered hardware and software Covered Design and Construction Phases Had a few issues but nothing substantial Questions? Donohue & Associates 11
Demonstration Donohue & Associates 12