EXAMPLE CONTROL NARRATIVE

PUMP STATION
 Example – Control Narrative 2016

Table of Contents
Table of Contents ......................................................................................................................................... 2
1 Introduction .......................................................................................................................................... 3
2 PLC Hardware ........................................................................................................................................ 3
3 Control Narrative .................................................................................................................................. 4
3.1 Pump Station Control.................................................................................................................... 4
3.1.1 Run Conditions ...................................................................................................................... 6
3.1.2 Set point ramping.................................................................................................................. 6
3.1.3 Timers.................................................................................................................................... 7
3.1.4 Pump Selector Switch ........................................................................................................... 7
3.1.5 Shutdown Key ....................................................................................................................... 8
3.1.6 Modbus Communications ..................................................................................................... 8
4 Human Machine Interface (HMI) .......................................................................................................... 9
4.1 Overview ....................................................................................................................................... 9
4.1.1 Control .................................................................................................................................. 9
4.1.2 Trends ................................................................................................................................. 10
4.1.3 Alarm Banner ...................................................................................................................... 10
4.1.4 Configuration ...................................................................................................................... 11
4.2 Timers.......................................................................................................................................... 13
4.3 Rates............................................................................................................................................ 14
4.4 Logins .......................................................................................................................................... 14
4.5 Datalog & Alarm Log ................................................................................................................... 15

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1 Introduction
This document provides a functional description of the pump station controls and operation. This
includes a high-level description of functionality, PID control loops, HMI interface and related hardware.
The focus of this document is to define how the actual system operates and is programmed.

2 PLC Hardware
The PLC hardware is manufactured by Horner consisting of a XL6 PLC that has an embedded 6” HMI with
touch screen capabilities. The PLC also has built-in capabilities for data logging and serial based
communications via multiple communication protocols.

Horner PLC Hardware Description QTY I/O Points

HE-XL105BB PLC with Embedded 6” HMI, 2 Serial, USB, MicroSD, 1 12 DI
XL6 105 CANBUS, 24VDC 12 DO
2 AI
2 AQ

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3 Control Narrative
This narrative contains two basic sections, the first will describe the overall functionality of the system,
and the second contains a control description at the I/O device level. Where the function each device
connected to the system is briefly described in table form. Devices are grouped by their I/O type in
order of card slot & channel number.

3.1 Pump Station Control

This system works primarily on pressure control using two pumps. The controller will operate these two
pumps to accurately maintain a pressure set point. The output from the pressure control PID is
considered pump demand speed. Where the PID output regulates the running pump speed. Because
each pump has different capacity a staged sequence is used when choosing which pump will be running.
Initially only one pump will run at a time and as demand increases the pumps will turn on and off to
meet demand. Only at maximum demand will both pumps operate simultaneously. Pump #1 being the
smaller pump will operate primarily, and once its capacity is reached and it is no longer able to maintain
pressure, the bigger pump #2 will take over to maintain the pressure set point and pump #1 will shut
down. If pump #2 is running at 100% and pressure falls below a pressure offset then pump #1 will start
and run parallel with pump #2.

RUN
Pump #1 AT MIN
YES
(150 gpm) SPEED
Pressure 0-100% Speed
PID PUMP #1
0-100% CAPACITY
HOLDING
RUN YES
Pump #2
NO PUMP #2
(250 gpm) CAPACITY
0-100% Speed HOLDING

NO

Dual Pumps
Start Pump #1

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NORMAL PUMP OPERATION SETPOINTS PID SET POINTS
Normal Run Pressure Set point (PSI) Pressure Set Point (PSI)
Minimum Pump Speed (Hz) Proportional (Kp)
Pump #2 Start at Low Pressure Set point (PSI) Integral (Ki)
Pump #2 Start Delay Time (sec)
Pump #2 Stop Speed (Hz) Pump Transition Set Points
Pump #2 Stop Delay (sec) Pump #2 Max Start Speed

DUAL PUMP SETPOINTS

Below Pressure Offset (PSI)
Start Pump #1 Delay Time (Sec)

Example:
 Normal Run Pressure Set point: 60 PSI
 Minimum Pump Speed: 35 Hz
 Pump #2 Start at Low Pressure Set point: 45 PSI
 Pump #2 Start Delay Time: 120 sec
 Pump #2 Stop Speed: 40 Hz
 Pump #2 Stop Delay: 15 sec
 Dual Pumps Pump #1 Start Pressure Offset: 10 PSI
 Dual Pumps Pump #1 Start Delay: 15 sec

Pump #1 is running and controlling via the pressure PID to maintain 60 PSI while running at min speed
35 Hertz, demand increases and pump 1 slowly reaches 100% speed. (60 Hz) Pressure begins to drop as
pump capacity is exceeded, dropping to 45 PSI. After 120 Seconds, pump #2 turns on and slowly ramps
up while pump #1 ramps down. Pump #2 ramps up to ~48 hertz and holds until pump #1 finishes its
ramp down. After pump #1 shuts off, pump #2 begins controlling to pressure set point. If demand
continues to increase, eventually Pump #2 will reaches 100% speed and pressure begins to drop. 15
Seconds after the pressure reaches 50 PSI (10 psi below the setpoint) Pump #1 starts up and begins
controlling to maintain the pressure setpoint.
After time, as demand decreases and Pump #1 begins to ramp down eventually reaching min speed.
Pump #1 shuts off leaving Pump #2 running by itself. As demand decreases, Pump #2 eventually reaches
its shutdown speed of 40 Hertz (gpm flow should now be within the capacity pump #1) After 15 seconds
Pump #1 turns on and ramps up while pump #2 ramps down and turns off. Pump #1 begins controlling
to meet the pressure set point.

Pump #2 Max Start Speed setpoint is in hertz. And will limit the starting pump speed during pump
transitions. This is to prevent the starting pump from ramping up its capacity before the stopping pump
has ramped down.

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3.1.1 Run Conditions
Three run conditions exist, Normal and Easy Line Fill and Fire Safety.

Normal

During normal start-up, the pumps will start and stop based on a pressure set point offset. Pump #1 will
operate as the primary pump and maintain the pressure set point. If its capacity is exceeded, then
Pump #2 will take over until the demand return down to level that Pump #1 can deliver. At which time
Pump #2 will stop and Pump #1 will take over.

Easy Line Fill

Easy Line Fill is initiated whenever there is a power failure or if PT-1000 the pipeline pressure
transmitter faults. ELF can also be initiated manually from the HMI. When in ELF, PID control is disabled
and pump #1 runs and slowly ramping up to an ELF speed set point in Hertz. The system will remain in
ELF mode until an ELF pressure set point is reached. After reaching the ELF Pressure set point the
system will switch to normal mode enabling the PID pressure controller, and controlling to the PID
pressure set point. The ELF pressure set point can only be set to a value equal to or lower than the
running pressure set point. While ELF is in control, all shutdowns are disabled.

In addition operators can force ELF run mode at any time by using an on screen HMI button, the system
will remain in ELF until ELF pressure set point is reached.

SET POINTS
ELF Complete Pressure (PSI)
ELF Pump Speed (Hz)
ELF Manual (On)

Fire Safety

Fire Safety Mode can be enabled from the HMI by operators with the correct login. When enabled, the
larger capacity Pump #2 will start up, ramping down pump #1 and turning it off. The system pressure
setpoint is replaced with a fire safety pressure setpoint and the system PID will regulate pump #2 to
maintain pressure at the higher fire safety setpoint. The normal HI HI pressure shutdown will be
disabled and replaced with the higher fire safety HI HI pressure shutdown point.

3.1.2 Set point ramping

The normal pressure and fire safety pressure set points in the system can be changed from the HMI at
any time. Whenever there is a change between set points or a change to an active set point, a ramp
rate will control how fast the actual PID setpoint changes to match the new value.

PID RAMP SET POINTS

Pressure PID Set Point Ramp (%/sec)

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Alternatively, there is also a ramp rates for the speed demand output to each VFD which will restrict the
rate of change on each pumps speed demand signal. The output demand ramps also change depending
on conditions, when in ELF mode the output ramp use the ELF ramp rate to ramp from minimum speed
to ELF max speed, when in lead lag transition the lead/lag ramp rate is used, and when running normally
the output speed ramp is in effect.

SPEED DEMAND RAMP SET POINTS

Pump Output Speed Ramp (%/sec)
Pump Lead/Lag Transition Ramp Rate (%/sec)
ELF Speed Ramp Rate (%/sec)

3.1.3 Timers
Hour Meters
Each pump has its own hour meter which has an optional hours offset and can be reset to zero at any
time when logged in. The reset button must be held on for 5 seconds to trigger a reset.

Control Timers
Startup Alarm Delay – Upon startup this setpoint determines how long low pressure and flow
alarms are disabled.
Pressure Low Low Shutdown Delay – Shutdown has a 5-Minute debounce timer
Pressure Hi Hi Shutdown Delay – Shutdown has a 1-Minute debounce timer

Auto Restart Timer/Counter

After a low or high pressure shutdown the system will automatically startup again after 30 seconds. Set
points exist to limit how many times the system can auto-restart after a pressure shutdown. If the
number of auto restarts exceeds the operator setpoint the system will remain shutdown. Pressing reset
button will reset the auto-restart counter.

3.1.4 Pump Selector Switch

Normal Operation will have the pump selector switches set to AUTO. In auto the pump will operate
based on system pressure and flow. The OFF position will disable the respective pump and is mainly
used for maintenance. The HAND position allows for manual on/off and speed control via the VFD
control pad. When in HAND the pump will run under control of its speed dial on the key pad. Turning it
clockwise the speed will increase, by spinning it counter clockwise the speed will decrease. The hand
switch is hard wired to close the VFD contactor and enable the forward run command on the VFD. This
operation can be VERY dangerous. All control system shutdowns are bypassed and ignored when in
HAND and the pump will run at its VFD set speed regardless of system pressure.

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3.1.5 Shutdown Key
A system shutdown is provided to describe the cause and effect of each device and alarm/shutdown
conditions and actions taken due to any condition. Please refer the shutdown key for further details on
the system shutdowns.

Should the pump #1 or pump #2 trip offline or be turned off the alternate pump will automatically take
over and operate to maintain pressure.

3.1.6 Modbus Communications

The PLC has a number communication options. The built in serial port MJ2 is configured for Modbus
RTU via RS-232. The serial port baud rate settings by default are 19200-8-N-1. Please refer to the
system Modbus Table document for details.

Other communication protocols are available and can be configured upon request. MJ2 can be
configured for RS-485 rather than RS-232 upon request as well.

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4 Human Machine Interface (HMI)

This system utilizes a 6” color touch screen as an HMI. Navigation through the system is provided using
onscreen buttons. Set points and system parameters are available after the operator has input a correct
security code, this code is independent of door security keypad. No set points can be changed without a
login. Set points always have a black background with white text.

4.1 Overview
The main overview screen is the default screen displayed on the HMI, it will indicate the current run
state of the pumps and has some operating set points along with the pressure and flow. The header
banner displays relevant run time data and is displayed on all screens. The alarm banner and navigation
buttons are always displayed. No set points can be modified unless an operator has logged on to the
system. Side screen buttons like F1 – F5 also change screens, press F5 to access the configuration
screens, while F1-F3 cycle through the main overview screens.

Screen
Header
Change
Banner

Control &
Set Points

Navigation
Buttons

Login
Alarm Reset
Button
Alarm Banner Button

4.1.1 Control
The control displays the current status of the PID control loops. PID setpoints for proportial and integral
terms are available for tuning.

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Set Points PID Set Points

4.1.2 Trends
Trending screens display an x/y trend of runtime data and will display pressure vs flow vs pump speed.

4.1.3 Alarm Banner

Two on screen alarm areas exist, an active alarm banner displays the current active alarms while an
alarm history page displays a complete history of every alarm. Each alarm is date and time stamped.
Pressing the active alarm banner will pop up an alarm control display which allows for

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acknowledgement of alarm. Pressing the reset button will reset/clear any alarm conditions which have
returned to normal. The Alarm History is found on the main config screen.

4.1.4 Configuration
Access to the configuration pages requires the input of a user access code. After entering the correct
code the operator can adjust set points for pump pressure along with other system timers and
parameters like transmitter scaling and alarm and shutdown set points. The default passcode to access
the configuration pages is 911.

4.1.4.1 Analog Input Scaling & Alarms

Analog inputs (4-20mA) have options for min/max engineering unit scaling, as well as setpoints for alarm
and shutdown limits. Setting any LoLo, Lo, Hi, HiHi, limits to a value of -555 will disable that particular
limit.

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4.1.4.2 Digital Input & Digital Output Forcing

Digital input status screen displays the raw input status of the inputs. The digital output screens not
only display the output status but allow for output forcing. An operator must first enable the force for
each channel then toggle output on/off.

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4.2 Timers
The timer configuration page contains the set point for Lead pump runtime in days. Along with a set
point for a startup delay timer which will disable certain alarms like the Low Low shutdowns for Pressure
and Flow until the pumps have been running for the specified amount of time. Pump hour meter
settings are also found here.

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4.3 Rates
Various ramp rates for setpoint changes are configurable.

4.4 Logins
When logged in using the 911 password or via the engineer account, passwords can be updated and
changed. Three users exist, two operators and one engineer. Each can be assigned a name and
password.

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4.5 Datalog & Alarm Log

By default, the system will data log the system status saving to CSV file on a MicroSD card. A new CSV
file is created every day and a sample is taken every 15 seconds. The follow variables are in the log with
a date and time stamp. The MicroSD card can be removed at any time and the CSV files can be copied
and opened on a computer with any application like Microsoft Excel. Alarm logs are also saved to CSV
automatically.

 Pipeline Pressure  Pump #1 VFD Demand

 Pump #1 Run Status  Pump #2 VFD Demand
 Pump #1 Fault  Digital Input Status’
 Pump #2 Run Status  Digital Output Status’
 Pump #2 Fault

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