Project: KADEN Road Phase-I

Multi Drive /Multi-Pumps -Booster

Control System for Potable Water
Pumping Station [ PWPS]
Sequence of operation

Revision Date Reason

1 10-11-2021 Preliminary for Review

2 31-1-2022 Preliminary for Review

3 27-3-2022 for Approval

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Introduction
The aim of the booster control is to maintain the desired pressure at the outlet of the pumps header
according to the demand. A dedicated motor control centre and PLC panels are provided for this
purpose.

Process philosophy in this project is based on four Variable Speed Pumps. Maintaining system pressure at its
target is obtained by managing the velocity of the variable speed pumps and staging / de-staging of pumps .

System Description

Below system components are designed to serve potable water process Control requirements in Riyadh
township:

Boaster Pumps(PWP-01,02,03,04):
4 no's (3-duty,1-standby).each pump is equipped with:
 1 no Variable frequency drive (VFD): Variable frequency drives (VFD) is provided to control pump
operation and flow rate as desired (varying the frequency and voltage of its power supply).
The VFD will also control the ramp-up and ramp-down Of the motor during start or stop, respectively
 1 no motorized butterfly valve(MOV) -regulated type with positioner at discharge line.
 2 no's flow switches(FS) (1no at discharge line, 1no at suction line).Flow switch at suction line
is used for low suction pressure protection.
 2 no's pressure indicator transmitters(PIT) (1 on discharge line, 1 no at suction line).
 1 no pressure switch(PS) at discharge line

Water Storage Tanks(PWT-01,02):

2 no's . each tank is equipped with:
 2 no's level indicator transmitter(LIT).[Any alarm, action will be taken by comparing which
reading of the two LIT's reach the related setpoint first]
 1 no temperature indicator transmitter(TIT).
 2 no's ON/OFF motorized butterfly valves(MOV) (1no at tank inlet line,1no at tank outlet line).
 1 no float switch to achieve dry run protection with MCC

Drainage System:
consists of:
Pumps(DP-01,02): (1-duty,1-standby).each pump is equipped with:
 1 no pressure indicator transmitter(PIT) at discharge line.
 1 no pressure switch(PS) at discharge line
Tank: 1 no . it is equipped with:
 1 no level indicator transmitter(LIT).

Common Pipeline Headers:

Suction line(common in): equipped with:
 1 no chlorine analyzer(AIT)
 1 no ON/OFF motorized butterfly valve(MOV).
 1 no flow indicator transmitter(FIT)
Discharge line( common out): equipped with:
 1 no chlorine analyzer(AIT)
  1 no ON/OFF motorized butterfly valve(MOV)
 1 no flow indicator transmitter(FIT).
 1 no pressure indicator transmitter(PIT).
 1 no flow switch(FS).

Surge System:
consists of:
 Compressors(2 no's).
 Surge Tank.
 Inlet Valve.
the following signals are sent from Surge system control panel to SCADA:
 Compressor.1 run status
 Compressor.2 run status.
 Compressors common fault.
 Phase Failure alarm.
 Surge Tank HH level alarm
 Surge Tank LL level alarm
 Tank Level reading
 Surge Tank Pressure

To automate the control mechanism for pump station, SCADA and HMI are designed. and accordingly, all
controllable Equipments (as pumps and valves etc...) will be controlled through RTU's (PLC units).

Sequence of Operation

Pressure transmitters (PIT) at water discharge line / header monitor and measure the distribution
network pressure and send signals to PLC unit to modulate the booster pumps operation (start / stop).

All pumps are interlocked and configured in such a way that at a time 3-pumps operate and the 4th one is
stand-by unless, it is on manual mode. Additionally, a predefined sequence subroutine is implemented to
optimize the duty hours of each pump and accordingly, each pump will be on stand-by position after a pre-
defined duty period.

Three pumps are operating in lead, lag1 and lag2 mode and the fourth pump will be the standby pump.

The system is equipped with a dedicated RTU(PLC) panel for cycling /controlling pumps/their speed in an
automatic manner as following:

a) when the system started, PLC reads header pressure and compare it with the target
(adjustable setpoint) based on PID algorithm( proportional, integral, derivative control).if pressure
found below the set value ,the lead pump starts first and the related VFD ramps its speed up to
achieve and maintain the header pressure at its target. The ramp up time is adjustable by the operator
via VFD. PLC PID algorithm modulates the pump speed to maintain header pressure setpoint,

b) in case of demand increase and If the speed of the lead pump reaches 90%, the lag1 pump starts.
meanwhile the lead pump ramps down to 45% and lag1 pump ramps up to 45%. Once both pumps
reach 45% speed, regulation of their speed starts together as per demand request.

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 c) If the speed of the two pumps (lead & lag 1) drops below 40% due to demand decrease, lag1 pump
stops first and the speed of the lead pump will be ramped up to 80% . once pump speed reaches 80%,
PLC PID algorithm controls back header pressure to maintain it at the set value.

d) If the lead and lag1 pumps are running and their speeds exceed 90% due to demand increase, lag2
pump starts and the speed of lead&lag1 pumps will be ramped down to 30% whereas the speed of the
lag2 pump will be ramped up to 30%. Once all three pumps(lead,lag1,lag2) speed reaches 30%,PLC
PID algorithm controls back header pressure to maintain it at the set value.
The three pumps speeds are regulated together so that they will have the same speed during
regulation

e) If the speed of the three working pumps reduced to 27% due to demand decrease, the lag2 pump
stops and the speed of the lead & lag 1 pumps will be ramped up to 40% . once the two pumps speed
reaches 40%, PLC PID algorithm controls back header pressure to maintain it at the set value
The two pumps speeds are regulated together so that they will have the same speed during regulation.

in case of further demand decease, sequence in point c( above) will be applied

Pumps Change Over/Cycling

The duty assignment for lead/lag1/lag2 for the pumps can be either done manually by operator via a selection
(from SCADA HMI) or automatically based on predefined set change over time inside PLC. (adjustable at
SCADA HMI ).this ensures the optimization and equalization of the duty hours of each pump.

During operation; at any point of time; if any one of the duty pumps (lead, lag1, and lag2) fails, the changeover
function is immediately activated so that the standby pump will take its position.

Any of the following faults stops the respective duty pump and calls for the standby one to run:
i. VFD Starter fault.
ii. High bearing temperature alarm.
iii. High winding temperature alarm.
iv. Discharge line closed valve( fail to open).
v. High discharge pressure by PS or PIT.
vi. Low discharge pressure by PIT.
vii. Low suction pressure by PIT.

The following alarms call for all pumps to stop (system shutdown):
i. Low Low (LL) level of PWT (Dry run).
ii. closed valve at the line up tank outlet MOV.
iii. closed valve at main discharge common header.
iv. High discharge pressure on common header

Potable Water Tanks Level Control

Water storage tanks are equipped with Level indicator transmitters to measure the level in these tanks.
the signals are sent to PLC panel to control the opening / closing of tank's inlet valves(MOV's).

Moreover, a Low Low level setpoint(LL) (adjustable at SCADA HMI ) will be compared with tank level
to ensure dry run protection for the pumps.

The operation for the level indicator control is adjusted (at SCADA HMI) as follows in perspective to set the
sequence of operation:
  High High(HH) setpoint: if any of the two LIT's reaches this setpoint, PLC will close tank's
inlet motorized valve (MOV)
 High(H) Setpoint: if any of the two LIT's reaches this setpoint, PLC will open tank's inlet
motorized valve (MOV)
 Booster pump operate in duty/standby fashion potable / fire water services
 Low( L) setpoint: if any of the two LIT's reaches this setpoint, booster pump (PWP) will be
stopped for potable services
 Low fire (LF) setpoint: in case of fire alarm, booster pumps operate for fire services
 Low Low(LL) setpoint: if any of the two LIT's reaches this setpoint, all pumps stop (dry run protection).
Additionally, Each tank has also a separate 1no float switch to achieve dry run protection
independently from PLC

Drainage system:
Drainage tank is equipped with Level indicator transmitter to measure its level. the signal is sent
to PLC panel to control the operation of pumps (starting/stopping) in order to drain the cumulated water
to storm network.

the pumps are interlocked and configured in such a way that at a time 1 pump operate and 1 pump is
stand-by unless, it is on manual mode or requested for assistant

a predefined sequence subroutine is implemented to optimize the duty hours of each pump.

The operation for the level indicator control is adjusted(at SCADA HMI) as follows in perspective to set the
sequence of operation:

 High High(HH) setpoint: PLC starts lag pump in an assist fashion.

 High(H) setpoint: PLC starts 1 pump in lead/Lag fashion (based on time or fault changeover)
 Low(L) setpoint: all pumps stop (dry run protection)