PLC 5 BIOTOWERS SCADA SYSTEM OPERATION MANUAL Revision 1.0 May 15, 2006
PLC 5 BIOTOWERS SCADA SYSTEM OPERATION MANUAL Revision 1.0 May 15, 2006 Table of Contents 1 Introduction... 4 2 Revision History... 4 3 PLC System Overview... 4 4 Conventions... 6 4.1 Set Points and Process Values... 6 4.2 Equipment Colors... 6 4.3 Line sizes and colors... 6 4.4 Instrument Bubbles... 7 5 Sample SCADA Screens... 8 5.1 BIOTOWER Overview... 9 5.2 Individual BIOTOWER... 10 5.3 BIOTOWER Fan Pop up Screen... 11 5.4 Rotary Distributor Pop up Screen... 12 5.5 BIOTOWER Pump Station... 13 5.6 BIOTOWER Pump Pop up Screen... 14 5.7 BIOTOWER Pump Station Control Set Points... 15 5.8 BIOTOWER Pump Station Alarm Set Points... 16 6 Sample Panel View (OIT) Screens... 17 6.1 BIOTOWER-4 Screen... 18 6.2 BIOTOWER-5 Screen... 19 6.3 BIOTOWER-6 Screen... 20 6.4 BIOTOWER-4 Rotary Distributor Screen... 21 6.5 BIOTOWER-5 Rotary Distributor Screen... 22 May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 2 of 23
6.6 BIOTOWER-6 Rotary Distributor Screen... 23 May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 3 of 23
PLC 5 BIOTOWERS SCADA SYSTEM OPERATION MANUAL Revision 1.0 May 15, 2006 1 Introduction This document presents the operational logic and sample SCADA and OIT (local operator interface terminal) screens for the BIOTOWERS at the Stockton Regional Wastewater Control Facility. 2 Revision History The table below shows the history of revisions to this document. Rev. Description By Date 1.0 Issued for customer training Max Hanson/ May 15, 2006 Imran Saeed 3 PLC System Overview PLC#5 is an existing PLC with a Panelview operator interface. The functions available at the Panelview terminal have been duplicated in the SCADA system screens. The PLC#5 program has been enhanced to control the new adjustable-speed rotary distributors. Some other program modifications are made to allow the SCADA system access to Panelview set points. A new Ethernet network communication card has been added to PLC#5 for communication to the plant main SCADA system over the fiber optic Ethernet network. The PLC#5 operation block diagram is shown in Fig-1 below. An Operator Interface Terminal (OIT) is connected to the RIO network channel on the main PLC rack, for allowing the plant operator to monitor and control the process locally. The same RIO network channel on the main PLC rack is also communicating to a remote I/O rack through a RIO adapter. The variable frequency drives for the mechanical rotary distributors are connected to a second remote I/O channel on the PLC, providing direct control and data transfer over RIO. Process instrumentation such as pressure, level and flow transmitters are wired to the I/O and communication channels of the PLC. The PLC monitors the process values from its analogue and digital input channels. When the control mode is in AUTO, the PLC determines the necessary May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 4 of 23
control outputs for achieving the desired process conditions according to the process set points entered by the operator. In Manual mode the plant operator can control the process by manually entering the values through OIT. PLC#5 operation is further explained by the block diagram below (Fig-1). OIT (Operator Interface Terminal) RIO Network RIO Network Third Rack in Main Enclosure (Allen Bradley PLC5 - Remote I/O Rack) Second Rack in Main Enclosure (Allen Bradley PLC5 - Remote I/O Rack) PLC#5 BIOTOWER System (Allen Bradley PLC5 - Main PLC Rack) RIO Network RIO Communication Adapter Digital Output Channels Analogue I/O Channels RIO Communication Adapter Digital Input Channels Digital Input Channels CPU (Control Logic Processing) Ethernet Network Communication. CH RIO1 RIO2 RIO Network RIO Network RIO Network Ethernet FC Fiber/Copper Converter Fiber optic To other VFDs RIO Network RIO Network RIO Network FC Fiber/Copper Converter VFD VFD VFD VFD VFD VFD Ethernet Plant Central SCADA Fig-1; PLC-5 Operation Block Diagram May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 5 of 23
4 Conventions 4.1 Set Points and Process Values Set points appear with a black background inset field and white text. Process values will show an inset field with a white background and blue text. Status indicators also have the white inset field, but the foreground color may change depending upon the conditions and the background will turn yellow for abnormal situations. Status Indicator Text Colors: Text Background Meaning Dark Red White Not called, inactive, off Dark Green White Called, active, on Gray White Not ready, unavailable for PLC control Black Yellow Alarm, abnormal condition 4.2 Equipment Colors Symbols for motor-driven equipment are animated with colors to reflect status. Valves symbols are also color-coded. Foreground Red Green Gray Yellow Foreground Red Green Gray Yellow Meaning Not called, inactive, off Called, active, on Not ready, unavailable for PLC control Alarm, abnormal condition Meaning Closed Opened (or called to open if no feedback) Not ready, unavailable for PLC control Alarm, abnormal condition 4.3 Line sizes and colors Where appropriate, major process lines are shown with 3D pipe symbols and are animated to show when fluid is flowing. Minor process lines are shown with a dark gray background and an animated foreground color. Minor process lines do not have 3D appearance and are smaller. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 6 of 23
Foreground Gray Blue Cyan Yellow Light Green Magenta Pink Light Brown Teal White Dark Brown Meaning No flow is present Plant water Miscellaneous minor process (e.g., scrubbant) Sulfur dioxide Chlorine or sodium hypochlorite Ferric Chloride Polymer Wastewater Storm water Air Sludge 4.4 Instrument Bubbles Many screens will be arranged to show process flow similar to a Process and Instrumentation Diagram (P&ID). Instrument bubbles will show tag names and will have the relevant process value displayed. These bubbles are animated and will turn yellow when an alarm is present at the instrument represented by the bubble. Clicking on the instrument bubble will open the appropriate pop-up screen (note that these symbols are not used for some existing instruments as the PLC logic does not include all the features necessary to support the pop up screen). May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 7 of 23
5 Sample SCADA Screens Sample SCADA screens for the BIOTOWER system follow. These are the screens that will appear on the plant SCADA system. Screens with similar function are available at existing Panelview local operator interface and would be shown in section 6 of this document. Please not that no process data was present when these screens were generated. This means that process values will show zero and it is operating scenarios that are not actually possible may be shown. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 8 of 23
5.1 BIOTOWER Overview This screen presents an overview of the BIOTOWER facilities. The three active biotowers are shown as well as the abandoned trickling filters. The flow rate going to each biotower is indicated, as is the total flow rate. Pump station status is indicated in the middle of the screen. Clicking on a biotower will open a specific screen for that biotower. Clicking on the pump station will open the pump station screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 9 of 23
5.2 Individual BIOTOWER The individual biotower screen shows current status for the tower and its related equipment. Set points to control the instantaneous hydraulic application rate (SpülKraft or SK factor) are also provided. Fans are color animated to show status, as is the center of the distributor mechanism. If the distributor drive is on, the distributor will rotate slowly. Clicking on the status box for a fan will open a pop-up screen with controls for that fan. Clicking on the status box for the distributor will open a pop-up screen with its controls. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 10 of 23
5.3 BIOTOWER Fan Pop up Screen The fan pop-up screen shows detailed status and allows an operator to control the fan manually. Low airflow and failure alarms can also be disabled from this screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 11 of 23
5.4 Rotary Distributor Pop up Screen The pop-up screen for a rotary distributor is illustrated to the left. Starting and stopping of the distributors is always manually controlled. The operator simply clicks the On/Off button to toggle the desired status. Speed of the distributor may be controlled automatically (determined by the desired SK factor) or manually from this screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 12 of 23
5.5 BIOTOWER Pump Station This screen shows the status of the biotower pump station. Detailed status is shown for each pump, as are wetwell and recycle levels, weir position and bypass flow rate. The discharge pressures are shown above the pumps and the total discharge flow rate and target flow rate appear in the upper right. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 13 of 23
5.6 BIOTOWER Pump Pop up Screen The biotower pump pop-up screen shows detailed status information for the selected pump. It also allows manual start / stop control. There are many alarms associated with each pump and each alarm has an individual alarm disable button. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 14 of 23
5.7 BIOTOWER Pump Station Control Set Points This screen presents control set points for the pump station. Pumps are controlled by flow rate and speed. A desired recycle flow ratio is entered and the pump speeds will be varied to achieve that target. When the pumps have been operating at the maximum speed for the call next delay, the next pump in sequence is called. If the pumps are operating at the minimum speed for the stop last delay, the last pump called will be stopped. Set points and manual controls for the bypass weir and bypass isolation gate are also available. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 15 of 23
5.8 BIOTOWER Pump Station Alarm Set Points This screen presents alarm set points, status and disable controls for alarms that are associated with the pump station. There are level alarms for the wetwell, recycle channel and differential between the two. There are pressure alarms for the pump seal water pressures and pump discharge pressures. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 16 of 23
6 Sample Panel View (OIT) Screens Sample screens for local Panel view operator interface for the BIOTOWER system follow. Most of the existing screens are used, and their functions are duplicated into the new SCADA system. The screens for the new VFD-powered rotary distributors and navigation buttons to get to those screens are added into the local Panel view operator interface. These are the screens that will appear at the plant Operator Interface Terminal (OIT) of BIOTOWER system. Please note that no process data is present in these screens and these were generated during the offline development. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 17 of 23
6.1 BIOTOWER-4 Screen This is and existing screen and presents an overview of the BIOTOWER-4 system on the local Operator Interface Terminal (OIT). Distributor-4 navigation button is added on this screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 18 of 23
6.2 BIOTOWER-5 Screen This is and existing screen and presents an overview of the BIOTOWER-5 system on the local Operator Interface Terminal (OIT). Distributor-5 navigation button is added on this screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 19 of 23
6.3 BIOTOWER-6 Screen This is and existing screen and presents an overview of the BIOTOWER-6 system on the local Operator Interface Terminal (OIT). Distributor-6 navigation button is added on this screen. May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 20 of 23
6.4 BIOTOWER-4 Rotary Distributor Screen This is a new screen for the existing local operator interface terminal. It presents the status of the BIOTOWER-4 rotary distributor. A screen with similar functions is also configured in the new SCADA system as explained in section 5.4. Note that distributor speed is reported in minutes per revolution (MPR). May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 21 of 23
6.5 BIOTOWER-5 Rotary Distributor Screen This is a new screen for the existing local operator interface terminal. It presents the status of the BIOTOWER-5 rotary distributor. A screen with similar functions is also configured in the new SCADA system as explained in section 5.4. Note that distributor speed is reported in minutes per revolution (MPR). May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 22 of 23
6.6 BIOTOWER-6 Rotary Distributor Screen This is a new screen for the existing local operator interface terminal. It presents the status of the BIOTOWER-6 rotary distributor. A screen with similar functions is also configured in the new SCADA system as explained in section 5.4. Note that distributor speed is reported in minutes per revolution (MPR). May 15, 2006 Rev. 1.0 PLC 5 BIOTOWERS SCADA System Operation Manual Page 23 of 23