Control Philosophy

1-Variable speed Pumps:-

The pumps are to be controlled in order to control the pressure at the

delivery header and meeting the flow demand. When running under
automatic discharge pressure control , the pumps shall be started and
stopped based on the analogue pressure and flow signals from the delivery
header pressure transmitter inside the pump house and rising main flow
meter.

The pumps are equipped with variable frequency drives (VFD’s)and

configured four duty/ one stand by and one maintenance operation .

The VFDs (pumps) shall be controlled using a PID controller. The

proportional P integral (I) and derivative (D)terms of the controller shall be
configured via the SCADA system and the process variable PV shall be the
delivery header pressure on the rising mains.

The pumps shall operate to achieve a pressure set point (for pressure set
point details see “ pressure set point below”

The initial starting of the pumping station can be either manual or

automatic, the operator has the facility to start the pumps in manual mode
at control desk and then switch the pumps to auto mode and the auto
sequence will take over alternatively starting the pumping station in auto
mode.

If the operator confirms their initial starting of the pump station in auto
mode the PLC shall fully open the rising main control valve and then start
the 1st duty pump to their minimum speed of 600 RPM(for pump suction
and discharge valves control, see ‘Motorized valves control’ . when the 1st
duty pump reaches the minimum speed it shall switched to PID pressure
control based on the active pressure set point calculated by PLC and the
delivery header pressure feedback signal.

The PID parameters will have different values for different values of
delivery header pressure: i.e. when the pressure is less than pressure set
point 1, the parameters will be slow to prevent rapid increase in speed and
allow slow and safe pressurization of the network . at every pressure
increase to pressure increment, the parameters will be changed to make
the PID faster and so on until required pressure set point (active_ pressure
_SP) is reached (all PID parameters, limits and pressure set point are
adjustable from SCADA)

2- pump starting sequence

If the rising main flow exceeds the maximum flow set point for 1- pump
operation after time delay Q1max =f (pump _ speed), the 1st duty pump’s
drive speed shall be reduce to the min speed first and then the 2nd duty
pump shall be started to the minimum speed , once the two pumps have
reached the minimum speed , they shall be control together by the
pressure control PID with their speeds being increased or decreased
together in order to achieve the desired pressure.

Also during one pump operation if pressure set point not reached and even
flow did not reach Q1 max , then the duty pump’s speed shall be reduced
to the minimum speed first and then the 2nd duty pump shall be started to
the minimum speed once all running pumps have reached the min speed
they shall be controlled together by the pressure control PID with their
speed being increased or decreased together in order to achieve the
desired pressure.
3-Throttling on Qmax

During n pump operation (all duty pumps), if the rising main flow exceeds
the maximum flow set point for n pump operation{(Qn max = f(Pump_
speed)} after time delay and alarm describing the situation shall be
triggered on SCADA and the throttling valves (RM1-MOV -YYY & RM2- MOV
-YYY on rising mains (see motorized value control ) is to be throttled to
maintain the flow below Qn max. pressure shall be frozen at the last
reading (Qn max) before throttling.

The position of the throttling valve shall be controlled using a PID

controller, which is called as the throttling PID. The proportional (P),
integral (I) and derivative(D) terms of the throttling shall be configured via
SCADA system. In this throttling PID, the process variable (PV) shall be the
rising main flow, throttling/ opening shall be done in steps (to be set during
commissioning based on network condition.)

Based on throttling PID, the valve shall close/open to achieve a flow set
point Qt (Qt=Qn max- ΔQt is adjustable from SCAD), so when Qn max alarm
is declared , the throttling PID is activated. So the valve is to be throttled
first , until the flow is reduced to Qt set point or the valve reaches the
minimum throttling valve opening allowed (adjustable from SCADA), then
the valve will be stopped.

When the flow demand decreases , the valve shall start opening to keep
the flow at Qt set point throttling ends when the throttling valve reaches
the fully opened position, the throttling PID shall then be deactivated and
the Qn max alarm cleared.

If flow demand does not decrease to normal levels for a certain time

i.e., throttling continues for a certain time (adjustable from SCADA) or if

the throttling valve’s position reaches the min throttling valve opening
allowable (adjustable from SCADA), the running pumps speeds shall be
decreased to the minimum speed and then stopped and then the valve
shall be fully opened and another alarm declared on SCADA (Qn max trip)

4. no stand by pump:-

During one pump operation, if the rising main flow exceeds the maximum
flow set point for m pump operation Qm max after time delay, and if no

other pump is available for operation ,an alarm describing the same

situation shall be triggered on SCADA( Qm max Alarm) and

throttling is to be performed in the same manner described above

with the exception of using the formula Qt= Qm max - ΔQt instead of
Qt=Qn max- ΔQt to calculate the flow set point.

If the flow demand does not drop back after a certain time( adjustable from
SCADA) of throttling valve’s position reaches the minimum throttling valve
opening allowed , the running pump’s speed shall be decreased to
minimum speed and stopped and then the valve will be fully opened and
another alarm shall be declared on SCADA ( Qm max trip- requires a reset)

5. pump stopping sequence.

During m-pump operation , if the rising main flow goes below the min flow
set point for m – pump operation (Qm min= f(pump_ speed) after time
delay, least duty pump’s speed and then stopped. The other duty pump
remains under pressure control to maintain the pressure point.

Also during m- pump operation if the rising main flow is settled for long
time( adjustable from SCADA), with value between Q m-1 max and Qm min
and so demand can be managed by m-1 pump, Hence mth duty pump’s
speed shall be decreased to minimum speed and then stopped. the
remaining running pumps remains under pressure control to maintain the
pressure set point.

Notes:-

1) There should be only one auto/manual selector switch for the m

pumps and their valves .
2) “interlock details for Muaither Station” for precondition to start and
condition to trip for the operation from control desk (local mode)
and SCADA control mode( auto mode) to be submitted separately.
3) The pumps should not stop when switching from manual mode
(SCADA) to auto mode (SCADA) or from auto mode to manual mode
except in the case n pumps are running on local , the mode switched
to auto and only three pumps are needed by the auto sequence the
least duty pump will be stopped.

6-pressure set point

The active pressure set point is divided into two:

A) Manual pressure Set point( Manual_ pressure_ Set point- constant) is

adjustable from SCADA.(this is during start up as well as fixed
pressure operation)
B) Auto pressure set point (Auto _ pressure _ set point – variable)is
calculated every several minutes from the rising main flow reading
based on the following equation

Active _ Pressure_ SP = C1+C2* ,

(calculation_ period and Equation_ constant C1& C2 are adjustable from

SCADA and are to be set during commissioning based on network
conditions).
The set point shall never exceed the max possible pressure which is defined
by the pump operation range (maximum_ Pressure _ set point is adjustable
from SCADA).

The operator should also have the option to change the active pressure set
point from the auto pressure set point to the manual pressure set point.

7. VSP duty / stand by configuration (SCADA auto mode)

The duty sequence of the variable speed pumps can be selected from
SCADA as follows:

VSP Pumps (VSPX) (below will change according to number of duty pumps)

1- VSP 1,2,3,4,
2- VSP 2,3,4,1
3- VSP 3,4,1,2
4- VSP 4,1,2,3
5- VSPA (Auto)

If the automatic duty changeover mode is selected from SCADA (selection /

VSPA) the duty/ standby configuration of the pumps shall depend on the
pump running hrs. the available pump with the least running hrs is
automatically assigned as the 1st duty and so on. Duty changeover occurs
only on stopped pumps, i.e. no running pump shall be stopped because of
duty changeover except if a pump reaches the maximum number of hrs
under continues operation (adjustable from SCADA), in this case the pump
will be stopped on the next midnight time and the next duty pump will
start.

If one of the manual duty selection modes is selected from the SCADA
selector switch ( VSPX from the above selection), the duty/ standby
configuration of the pumps shall follow the duty sequence selector switch.
In both duty selection modes (auto & manual), if a running pump becomes
unavailable , it shall be stopped and it’s duty assigned to the next available
pump, which shall be started to the min speed while the other running
pump slowed down to the min speed. When all pumps have reached the
min speed , they shall be switched to PID control and their speed being
increased or decreased together in order to achieve the desired pressure. If
the unavailable pump becomes available again, it shall not be started again
until stand by pump is stopped as per the system requirements (no running
pump shall be stopped to switch the duty order)

At any condition if the stand by pump is not available and the stopped
pump became available again the minimum stop time should be 10 minutes
before the stopped pump started again.

8. Fail Safe Procedure:

In the case of failure of any instrument that is critical to auto operation

such as rising main flow meter or rising main pressure transducer, all
running pumps speed will be brought down to the minimum speed then
stopped and suitable alarm declared on SCADA.

9. Motorized Valves Control:

The following valves are to be controlled automatically:

1. Pump’s suction valves

2. Pump’s discharge valves
 3. Rising main valves

The pumps suction and delivery valves are controlled automatically during
automatic pump starting. The status of the pump suction and discharge
valves shall be checked by the control system before starting the pumps. If
either of the valves is not fully open, the PLC will give it a command to open
and when it’s fully opened, it will start the pump. If the valves fail to open,
the control system shall generate an alarm and the pump shall not be
started until the cause of failure has been rectified. (Note: this is different
from manual and control desk modes, where the operator can start the
pump if the discharge valve is partially open).

a) Rising main valves

The status of rising main valves (throttling valve) shall be checked by the
control system before starting the pumps , if the valve is not open fully, the
PLC will give it a command to open and when it is fully open, it will start the
pump. The other throttling valve operation shall be as described above for
Q2 max and Q1 max throttling PID.

The rest of the motorized valves that have remote/ manual control
provision (if available) are to be controlled manually by the operator from
SCADA or local.

Note:- All the set point will be clarified and finalized at site during testing

b) Recirculation valve

During 1-pump operation, if the Rising Main flow goes below the Minimum
Flow Set-point for 1-Pump Operation (Q1_Min =f (Pump_ Speed), after a
configurable time delay, and alarm shall be raised to SCADA
(Q1_MIN_ALARM) indicating insufficient flow to the network.
The Recirculation Valve for the affected Rising Main will modulate until the
pressure in the Rising Main pressure reduces to reach the Recirculation
Pressure Set-Point for 1-Pump Operation (Rp).

The recirculation pressure set point (Rp) equal to the actual triggered
pressure in the time of starting recirculation process - ( adjustable from
SCADA)

The speed of the DUTY Pump will be frozen at the last reading (Q1_Min)
before opening either of the Recirculation Valves. The effect of the
pressure set-point for the DUTY Pump will also be frozen during the
recirculation process.

The position of each of the recirculation valves shall be controlled using a

PID controller, which is called the Recirculation PID. The Proportional (P),
Integral (I) and Derivative (D) terms of the controller shall be configured via
the SCADA system and the process variable (PV) shall be the effected Rising
Main Pressure reading.

The recirculation valves will open/close to achieve the pressure set-point

Rp.

When Q1min is reached and the recirculation valves PID is activated, each
recirculation valve will start to modulate until pressure is reduced to the Rp
set-point or the valve reaches the Minimum Recirculation Pressure Set-
point (Rp_Min). The Q1_MIN_ALARM will remain active during the
recirculation process.
When the pressure in the affected Rising Main decreases to a level at or
below the Minimum Recirculation Pressure Set-point (Rp_Min) for a
configurable time delay, the Recirculation Valve for that Rising Main will
start to close and the Q1_MIN_ALARM cleared.

If flow demand does not decrease and the Recirculation Valve (s), , remain
at the Maximum Recirculation Pressure Set-point (Rp_Max) for a
configurable time delay, the DUTY Pump's speed shall be decreased to
minimum speed and then stopped whereupon the Throttling Valve(s) of the
affected Rising Main (for Rising Mains 1 & 2, respectively) shall be fully
closed and an alarm raised to SCADA indicating NO-FLOW to the respective
network (Q1_MIN_TRIP)

10.Reservoir Inlet Valves Control Philosophy

The reservoirs’ inlet valves are to be controlled automatically by the PLC

when they are selected to operate in Local SCADA Automatic Control
Mode. In general, the reservoirs’ inlet motorized valves will operate
between two adjustable set levels in six time interval steps. The level
switches will be back up (the HI HI level setpoint will be slightly lower than
the HI HI switch, and the HI level setpoint will be slightly higher than the HI
level switch).

Details:

Normal operation:
- The PLC will monitor each reservoir’s level transmitter reading, and
when the level of a reservoir reaches the HI HI level setpoint as set in
the transmitter’s faceplate on SCADA (after adjustable time delay),
the corresponding inlet valve will start to close.
 - Valve Closing: First, the valve shall close to reach 50% (adjustable
from SCADA), and then after a time delay (adjustable from SCADA), it
will close gradually by 10% decrements (adjustable from SCADA) with
the same time delay after every decrement until it reaches the fully
closed position as indicated by the valve’s limit switch.

- When the level in the reservoir decreases and reaches the HI level
setpoint as set in the transmitter’s faceplate on SCADA (after
adjustable delay), the corresponding inlet valve will start to open.

- Valve Opening: The valve will open by 10% increments separated by

time delay, until its position reaches 50%, and after that the valve
shall fully open (same adjustable setpoints of the closing procedure).

Level switches backup operation:

- The level switches will be backups for the transmitter; so, if the HI HI
level switch is detected (after delay), the valve will close as described
in ‘Valve Closing’ above even if the level reading from transmitter did
not reach the HI HI setpoint. Also, if HI level switch becomes not
detected, the valve will open as described in ‘Valve Opening’ above
even if the level reading from the transmitter is still above its HI level
setpoint for some reason.
Note: this applies regardless if the transmitter is detected to
be faulty or not.

High level switch failure:

- If the water reaches above the HI level switch and it fails to give a
signal, and then the water reaches the HI HI level setpoint on the
transmitter, the valve will not close as the PLC cannot decide at this
point that the switch is failed, and so it gives it priority and keeps the
valve open as mentioned in the previous point.

- However, if the water reaches the HI HI level switch and the PLC
detects its signal while the HI level switch signal is still not detected,
then this is an indicator to the PLC that the HI level switch is failed,
and so it declares a suitable alarm on SCADA and deactivates the HI
level switch priority.
 So, the valve will close due to reaching HI HI level switch, and then it
will open again when the HI level is reached as detected by the level
transmitter.
The HI level switch failed alarm will be latched in the PLC/SCADA and
will require a reset from the operator before it can be considered in
the valve’s auto operation again.

- If both the HI level switch and the level transmitter of a reservoir fail,
then the corresponding inlet valve will be closed (in the same steps
mentioned in ‘Valve Closing’ above) and a corresponding alarm will
be declared on SCADA. The valve automatic operation will not be
activated again until either the HI Level Switch Failed alarm is reset
by the operator/maintenance personnel (depending on the
authorization setup), or the transmitter becomes healthy again.

- It will be possible to change the valve to manual mode and open it

manually even if the alarms from the previous point are active.

Notes:

- The above logic applies to individual reservoir inlet valve, where each
valve’s control is independent from the other valves, and is based
only on the High, High High level switches and level transmitter of its
corresponding reservoir. Each valve can be selected in auto or
manual mode individually.

- The reservoirs’ inlet motorized valves don’t actually have analog

position feedback signals, so the position of the valve will actually be
calculated according to the period of time for which the open and
close commands are given in comparison with the time required for
the valve to move from the fully closed position to the fully opened
position according to the following equation:

Where:
o ValveVirtualPosition is the calculated position of the reservoir
inlet motorized valve.
o OpenCmdTime is the accumulated period of time for which the
valve has been given the open command(adjustable from
SCADA)
o CloseCmdTime is the accumulated period of time for which the
valve has been given the close command.(adjustable from
SCADA)
o ClosedToOpenedTime is the period of time required for the
valve to move from the fully closed position to the fully opened
position. (adjustable from SCADA)