Control philosophy
Supervisory system (IFIX)1 requirements
Hardware and wiring design standards
PLC and IFIX application software standards
The discussions addressed past and present approaches used by the WG at their
facilities. Though some of these approaches differed significantly from one another,
consensus was reached with respect to future practices.
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Volume 1
Chapter 1 establishes the basic control system philosophy. The entire control system is
classified by five levels of control. These levels are defined according to the function
from an operations and maintenance standpoint of the different components of a control
loop and their configuration. Automatic control is normally accomplished using a PLC.
If control is accomplished using a single loop system or any means other than a PLC,
Automated Planning Team (APT) approval must be obtained prior to design.
Chapter 2 describes the design approaches that are to be used on WG projects. The
deliverables during and at the end of each design phase, preliminary design, and final
design are defined. Design criteria are specified for wiring design, interface with MCCs
and package systems, control panel design, and so on.
Appendix A example of an Instrumentation & Control Process Narrative
Appendix B example of an Instrumentation Data Sheet
Appendix C Training Guidelines
Appendix D Deliverable Matrix
Appendix E Revision Proposal Submittal Form
Drawing Figures Drawings referenced throughout this Manual.
Volume 2
Section 16010 covers general electrical standards that are applicable for all
electrical and instrument design, construction and installation for the City of
Portland, Bureau of Environmental Services, Wastewater Group, including the
Columbia Blvd. Wastewater Treatment Plant, Tryon Creek Wastewater Treatment
Plant and the Wastewater Pump Stations maintained by the Group.
Section 16050 covers Basic Electrical Materials and Methods
Section 16150 refers to Motors
Section 16400 refers to Service and Distribution
Section 16480 refers to Motor Control
Section 16500 refers to Lighting
Section 16660 refers to Power Generation
Section 16700 refers to Communications
Section 16910 refers to Controls
Section 17100 refers to Instrumentation
Volume 3 contains the Scada (Supervisory Control and Data Acquisition) IFIX software
design standards.
Volume 4 contains Drawings and drawing numbering standards. (Future)
Volume 5 contains O&M Manual Development Guide. (Future)
Volume 6 contains PLC Programming Guide
Volume 7 contains the Facilities Guide (Future)
Volume 8 contains the Wastewater Pump Station Design Manual. (Future)
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TABLE OF CONTENTS
Volume 1 Acronyms and Definitions .1
Chapter 1 CONTROL SYSTEM PHILOSOPHY.. .........2
1.1 Introduction..............................................................................................2
1.2 Levels of Control .............................................................................................2
Table 1-1 Levels of Control Primary Functions..3
1.2.1 Equipment Control Level...........................................................4
1.2.2 Local Control Level.. .....................................................................4
1.2.3 Programmable Logic Control (PLC)..................................4
1.2.4 System Process Control .........................................................4
1.2.5 Plant Control Level ....................................................................5
1.3 Operating Philosophy...................................................................................5
1.3.1 System Process Control Failure .............................................6
1.3.2 Programmable Logic Control (PLC) Failure .....................6
1.3.3 Local Control Panels..................................................6
1.3.3.1 Loop Control...................................................................6
1.3.3.2 Sequence Control ........................................................7
Chapter 2 CONTROL SYSTEM DESIGN GUIDELINES ........8
2.1 Design Phase.........................................................8
2.1.1 Introduction....................................................................... ........8
2.1.2 Documentation................................................... ........... ........8
2.1.2.1 Process and Instrumentation Diagrams (P&IDs)..........9
2.1.2.2 Digital System Block Diagram.. ........... ........... ........9
2.1.2.3 Process Narratives..................................... ........... ........9
2.1.2.4 Electrical Drawings....................... ........... ......10
2.1.2.5 Control Panel Design ........................ ........... ......10
2.1.2.6 Installation Details ........................ ........... ......11
2.1.2.7 Interconnection Diagrams and Listings....12
2.1.2.8 Digital System Block Diagrams............ ........... ......12
2.1.2.9 Functional Descriptions.. ...................... ........... ......12
2.1.2.10 Instrument Data Sheets.... ..................... .12
2.1.2.11 I/O Data Base ................................................ ........... ......12
2.1.2.12 Instrument Lists..................................... ........... ......12
2.1.2.13 Conduit and Cable Schedules ........... ........... ......13
2.1.2.14 Equipment / Loop Numbers and MCC Space........... ......13
2.1.2.15 Elect. System Load Calc. & Coordination Study.13
2.1.2.16 Specifications................................................ ........... ......14
TABLES
2-1 External Alarm Lighting Standards
2-2 Acceptable Manufacturers
2-3 ISA Identification Letters
2-4 Typical Interconnection Listing
2-5 Conduit and Cable Schedule
APPENDIX A
Instrumentation & Control Process Narrative
APPENDIX B
Example of Instrumentation Data Sheet
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APPENDIX C
Training Guidelines
APPENDIX D
Deliverable Matrix
APPENDIX E
Revision Proposal submittal form
AutoCAD Figures
1-1
Schematic--Levels of Control
1-2
Schematic--Levels of Control
2-1
P&ID Legend
2-2
P&ID Process Symbols
2-3
P&ID example (Level Instrumentation & Pump Control)
2-4
PLC System Block Diagram
2-5
I/O Point List
2-6
Wire Number & Device Number
2-7
Typical Power Source
2-7A Power Source
2-8
Typical Power Source Wiring Diagram
2-9
Cables, Instr.and Control (Typical Interconnecting Wiring Diagram)
2-10 Control Panel Enclosure Layout
2-11 Control Panel Power Distribution
2-12 Conduit Numbering System
2-13 See Table 2-4
2-14 Detailed Discrete Outputs Wiring Schematic
2-15 Detailed Discrete Inputs Wiring Schematic
2-16 See Table 2-5
2-17A Pump Station Motor Current Loop 9997
2-17B Removed
2-17C Pretend Dry Pit Exhaust Fan Flow Loop 9996
2-17D Pretend Level Loop 9999
2-17E Pretend Flow Loop 9998
2-18 Pressure Gauge Mounting Detail
2-19 Typical FVC & VFD Motor Control Electrical Schematic
2-20 24VDC Power Distribution Wiring Schematic
2-21 Instrument Field Device Installation
Volume 2
Section 16010 General Electrical Standards ....1 17
Example: Equipment Tag(s)..........18 - 20
Section 16050 Basic Electrical Materials and Methods....1 23
Section 16150 Motors1 6
Example: Motor Specification data sheet .7
Section 16400 Service and Distribution ....1 5
Section 16480 Motor Control ...1 14
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ACRONYMS / DEFINITIONS
APT
COMA
CMU1
DRAWINGS
HOA
HOR
I/O
IFIX2
ISA
LCP
MCC
NEC
NEMA
OCA
P & ID
PC
PID
PLC
PMC
RTU
SCADA3
SCADA NODE
SPC
SS
TJB
UL
UPS
VAC
VDC
VFD
VIEW NODE
WG
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CHAPTER 1
CONTROL SYSTEM PHILOSOPHY
1.1 INTRODUCTION
This chapter discusses the control system philosophy adopted by the WG for the operation of
its treatment plants and pump stations. Designers shall follow this document when designing
a control system.
A primary function of this chapter is to establish basic definitions of some of the terms. For
example: Section 1.2 of this chapter defines different levels of control and their
corresponding functions. A level refers to a function from an Operation and/or Maintenance
standpoint. Five levels of items are defined based on whether the function of the device is for
maintenance, manual, automatic, or supervisory control of several unit processes.
Section 1.3 provides more detail about Operation philosophy under different failure modes, as
well as discussion of Backup Operator Interface devices.
The control system at Wastewater Group (WG) facilities is distributed. Modicon2
programmable logic controllers (PLCs) serve as the distributed processors and an IFIX
supervisory system serves as the Operator Interface. Control panels are provided for manual
backup purposes. At Columbia Boulevard and Tryon treatment plants, Modicon PLC's shall
be used to allow networking with their Ethernet ports. Stand-alone PLC's may be Modicon,
PLC's without Ethernet ports.
The Wastewater Group Process Control Software Standards are as follows (2003)3:
Due to the cost of software upkeep and training costs, all proposed equipment must be
compatible with the above mentioned software or it is not approved for installation.
1.2 LEVELS OF CONTROL
As a general operations philosophy, all plants will have five different functional levels of
control (shown schematically in Figures 1-1 and 1-2):
Equipment control
Local control
Programmable Logic Controller (PLC) control
System Process control
Plant Monitoring/Control
2
3
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Defining these levels of control helps communicate WG's operation philosophy, which is
broken down into five subtopics. Each of these subtopics is discussed separately with a
statement of its purpose, WG's needs and requirements, as well as some guidelines to meet
these requirements. This classification tries to group the components of a Loop by their
function. This should help designers in deciding whether a component is necessary, and, if so,
how the Loop shall be configured. Table 1-1 provides a summary of these classifications.
Table 1-1
Levels of Control Primary Functions
Level of
Control
Primary Function
Remarks
Plant
Monitoring/
Control
System
Process
Control
PLC
Automatic Control
Local
Equipment
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The Local Control Panel (LCP) will have annunciators and status lights mounted on it.
Critical alarms shall be hardwired, with other alarms PLC-driven or hardwired, as necessary.
Examples of critical alarms are: high digester gas pressure, lower explosion limit detection,
and chlorine leak(s).
1.3.1 SYSTEM PROCESS CONTROL FAILURE
In the event of an operator interface failure at the SPC level, control will be possible at the
plant control level operator interface or the LCP.
1.3.2 PROGRAMMABLE LOGIC CONTROLLER FAILURE
As a backup against PLC failure, LCPS will be provided. These LCPS will have
open-close-auto (OCA), hand-off-auto (HOA) switches, status lights, and possible PID
controllers as needed to allow manual operation of the plant or pump station in the event of a
PLC failure.
All switches, lights, and other devices required for manual operation of a process will be
located on one panel, or adjacent panels, so that manual operation can be carried out from one
location. For example, all the valve controls, status lights, sequence indicators, and other
devices required for manually operating the Effluent Pumps will be located on the same panel.
1.3.3 LOCAL CONTROL PANELS
The LCPS shall have devices mounted on them that allow operation of the Process if the
supervisory system or PLC fails. The LCPS shall have devices that, under normal operation,
facilitate loop control, sequence control, or any other control necessary to operate one or more
unit processes. Shown below are examples of two different types of loop and sequence
control with associated panel mounted devices.
1.3.3.1 Loop Control
Loop control refers to a case where an analog variable needs to be maintained at a given set
point. This is achieved by using a (PID) control algorithm. A PID controller will have an
analog input (the process variable), an analog output (the manipulated variable), and a set
point. The set point may be either operator entered, or the output of another PID loop
(Cascade Control).
In the case of critical loops, which need to remain operational even if the PLC fails,
stand-alone loop controllers shall be used. These loop controllers may also be used for noncritical loops. These loop controllers shall be mounted on the LCP and shall have a digital link
to the PLC so that set points and tuning parameters can be communicated to and from the
PLC. Process variable and loop output information will be communicated to the PLC. The
PLC will also be able to monitor and change the mode of operation (e.g., manual or
automatic) of the loop controllers. The loop controllers will be programmable so that default
settings can be chosen in the event of a PLC failure. Chlorination is an example of critical
loops.
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Chapter 2
CONTROL SYSTEM DESIGN GUIDELINES
This chapter provides guidelines for design phases and the deliverables that the WG
expects at the end of each phase. Outline all5 deviations from these standards for approval by
the APT.
2.1 DESIGN PHASE
2.1.1 INTRODUCTION
The design phase involves a conceptual design of the control system. This phase considers
technical process requirements, as well as operations and maintenance issues. All design
effort will employ Volume 2, Electrical and Instrumentation Construction Standards. The
design referred to in this section is distinct from similar phases of the "IFIX and PLC
programming" effort. "PLC Program Design" commences at, or near, the completion of the
process and hardware design. Refer to Volumes 3 and 6 for IFIX and PLC programming
design guidelines.
The BES CONTROL SYSTEMS STANDARDS DELIVERABLES MATRIX outlines
the what and when of deliverables. (Appendix D)
The WG prefers to have the designer do most, if not all, of the detailed engineering.
In a control system detailed design, the designer is responsible for providing most of the
design specifications and drawings required to construct the project.
NOTE: The Wastewater Group (WG) Engineering Department will supply the Maintenance
Planners with existing drawings of facilities to be re-modeled. This will allow the Planners to
update the equipment numbers to the current standards. After the equipment numbers have
been updated, the Planners will return the drawings to Engineering for distribution.
Drawings not provided by the designer include control panel structural details, and detailed
loop wiring diagrams, which are typically provided by a contractor. Note: Loop wiring
diagrams are organized according to loop numbers and show detailed point-to-point
connections per ISA Standards.
2.1.2 DOCUMENTATION
The following narratives are provided to describe document requirements.
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General requirements for typical control schemes, alarm annunciator sequence, loop
interface requirements, analog alarms, and filtering and scaling.
Set points
Descriptions of individual control schemes, interlocks, and interactions between
different control loops.
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Clear identification of all components by name and label. These components include;
field devices, I/O cards, and operator interface devices, plus other devices such as
relays, timers, and isolators.
Identification of all termination devices (e.g., TJB's, MCC's, and I/O devices) and
termination points (e.g., terminal strips, terminal points, and I/O points).
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dimensions or provide the necessary modifications at no cost to the owner. The contractor
typically provides control panel structural details.
Control Panel Power Distribution and Wiring. Control panel power distribution design
drawings show how wiring is distributed to the various control circuits and other devices
requiring power, including fans, outlets, lights, power conditioners and analog circuits. These
designs must meet all local codes and requirements, including UL listing.
Examples of power distribution wiring diagrams are shown in figure 2-8.
Panel Elevations and Schedules. A control panel elevation gives a panel's dimensions and
shows in detail, the layout of devices on the face of the panel. A schedule identifies each
device by its component label, component specification number, nameplate inscription and
part number.
Internal Configuration. The detailed configuration of the panel interior, showing wireways,
terminal strips, and so on, may be left to the contractor. However, the design engineer shall
lay out the panel interior in sufficient detail (showing major devices such as PLC's, I/O bases,
and power supplies) to ensure that the control panel is sized correctly. The contractor must
provide detailed layouts for approval prior to construction.
Manufacturer Drawings. Manufacturer Drawing(s) shall be provided in electronic form
(AutoCAD) and their standardized drawings, when printed, shall have non-applicable portions
deleted or crossed out.
Examples of typical panel elevations, schedules, and internal configurations are shown on
Figure 2-10.
2.1.2.6 INSTALLATION DETAILS
Show details schematically. Show general installation details for instruments and their
supports as well as any special requirements, including earthquake consideration.
Installation details for all instruments primary elements shall include, where applicable:
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2.1.2.16 SPECIFICATIONS
Final specifications shall include the following as a minimum:
items.
Special submittal requirements
General testing plan requirements (see Volume 2, Electrical and Instrument design
standards for Circuit Level Testing Requirements)
Detailed equipment training-plan proposed by the consultant. Must be based on
consulting with WG personnel and using appendix C
The Process portion of the Operation & Maintenance6 (O&M) manual requirements in
electronic form. (The contractor is to provide equipment portion of the O&M
information. The design consultant to provide the final O&M manual).
Onsite startup services requirements
Technical requirements (Contractor qualifications / applicable certifications)
Requirement of a list of recommended spare parts and expendables, especially those
not stocked locally. WG maintenance will review the list for appropriate stocking
items.
Requirement that the contractor shall provide Instrument Data Sheets for each
instrument, control valve, and electrical adjustable speed devices.
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