Project Title CFS-61 Controls

Project Location
Project Number

1. CONTROLS

A. Acceptable manufacturers, subject to compliance with the specifications:

1. Critical Fuel Systems
2. Allen Bradley Compact Logix
3. Siemens S7
Due to the wide range of control capabilities and functions that are involved with these
systems a different set of paragraphs are provided below, please select the ones that
are appropriate for your application and design. For help please consult the factory.
When considering PLC/HMI based controls the CFS standard equipment is Automation
Direct equipment. If your client requests a particular PLC manufacturer, please consult
with the factory. A particular brand that is selected often is Allen Bradley for example.
B. Simple Relay Based Pump Set Controls.
1. Simple relay-based controls are typically found in boiler pump set
applications. Operation is to turn on the pump set when the boilers
need to run on fuel oil. This is done with a “Hand” operated switch to
start the pump. The pump will run as long as the unit is in “Hand”. The
other position is “Off” where the pump is deactivated. In “Auto” the
pump will run based on a “call for oil” signal from the boiler(s) or any
devices requiring fuel oil.
2. The controls will monitor the flow switch and if no flow is detected after
a set number of seconds the lag pump is started. The lead pump is
selected by a switch on the front panel. The lead pump will be
deactivated.
3. The controls will monitor a base pan leak switch for the pump set, if a
leak is detected the pump will stop.
4. All relay logic is based on 120VAC as developed from the power
transformer, control panels voltages are based on the power
requirements of the pumps.
C. Advanced Relay Bases Control Panels
This is usually referred to as a “Y” system. Also, every system will have a Y control
component, but may have additional more advanced control requirements.
1. Provide relay-based control systems for boiler or day tank control
systems. All controls are provided by relays. The control system is
usually broken into a high voltage section that provides power to the
pumps/motors that make up the system. The other section is a 24-volt
based relay control system.
2. All sensors are powered by 24VDC and are brought into relay logic
that is documented with ladder type diagrams.
3. Provide pump sets system with Hand - Off - Auto stations to controls
the operation of the pump(s). If shown on the schedule disconnects for
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each pump shall be provided. A power on light shall be provided. A

pump run light for each pump shall be provided. Level switches shall
be shown via lights on the front of the panel.
4. For duplex pump sets provide a lead lag switch to select the lead
pump, provide a switch to allow switching of the lead pump with each
call for operation.
5. In automatic operation the lead pump shall be called for by a “call for
fuel input”, or the logic can interface to level switches to cause the
pumps to come on to fill a generator day tank as required.
6. Controls also include a base pan leak detector, a inlet strainer DP
switch to alarm on a clogged strainer. A flow switch is used to indicate
proper flow and if not achieved the lag pump will start and the lead
pump will shut off.
D. Advanced PLC Based Control Panels
This is usually referred to as a “Z” system. Also, every system will have a Y control
component, but may have additional more advanced control requirements.
1. Provide a PLC based control system making use of commercially
available PLC components. No proprietary controls are to be used.
2. Provide PLC Control Cabinets as show on the contract documents.
Each Control Cabinet shall be completely pre-wired, and factory
programmed. To ensure job site reliability and rapid commissioning,
each cabinet shall be tested both individually and also communicating
with all other Fuel System distributed PLC’s, HMI’s and Tank Gauges.
All distributed control cabinets in this section shall be the product of
one manufacturer for single source responsibility. Cabinet to be
approved by a nationally recognized independent testing laboratory,
per standard UL- 508A. Provide a factory assembled NEMA 4 rated
steel enclosure.
3. To the extent possible, all Fuel System PLC’s shall use identical
hardware. Provide spare parts list with one spare PLC module for each
PLC module type supplied (power supply, CPU, Inputs, Outputs,
communications, etc.)
4. Provide color touchscreen operator interface terminals (HMI) where
shown on the contract drawings. As a minimum provide two HMI’s
located on the duplex pump set and in the vicinity of the day tanks. All
HMI’s shall use the same hardware and the same screen
configuration. An Operator shall be able to monitor and control any
PLC on that network from any HMI connected to any PLC.
5. Where applicable, alarm status shall be displayed on the HMI
generated process pictorials. In addition, all alarms shall be logged in
an alarm and event log. The alarm log shall indicate the time at which
the alarm occurred, the time at which the alarm was acknowledged
and the time at which the value returned to normal status. In addition to
alarm conditions, this log shall also document status changes such as
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a transfer from automatic to manual, a setpoint change, etc. so that the

resultant collection of alarms and events is a true and complete log of
plant operating conditions.
E. Provide a Master Panel control panel as noted on the drawings. This master
panel will display all the data contained in the fuel oil control system to allow
system wide monitoring and control. The Master Panel will make use of a
touch screen interface that will show data as shown on the various operating
screens throughout the system in one location.
F. Provide a Remote Screen control panel as noted on the drawings. The
remote screen is to provide information that is provided at another location
within the control system.
G. Distributed Controller Locations
1. Provide a PLC for each area shown on the contract drawings. Provide
PLC-to-PLC communications as described above and as shown on the
contract drawings. For multiple generator installations, as a minimum
provide one PLC for each of the following:
a. Duplex Pump Set Control
b. Day Tank Level Control (no more than 3-day tanks per PLC)
c. Main Tank Filtration System (if specified)
d. Multiple Main Tank Selector Valves System (if specified)
e. Tank Truck Off-Loading System (If specified)
H. Redundant Distributed Control System
1. Provide a multiple PLC based distributed control system in order to
prevent fueling system failure due to a common mode controller or
communication failure.
2. Provide multiple independent PLC’s. Each PLC shall have an
independent power supply, CPU and I/O. A single (or redundant) CPU
with networked remote I/O is not acceptable.
3. To the extent possible, all Fuel System PLC’s shall use identical
hardware. Provide one spare PLC module for each PLC module type
supplied (power supply, CPU, Inputs, Outputs, communications, etc.)
4. All Fuel System PLC’s shall be interconnected via dual communication
cables and dual communication ports per PLC. The communication
ports shall be electrically isolated from ground and from PLC to PLC.
Logic shall test each communication cable at least once every 10
seconds and logic shall auto-failover to the operating cable if one cable
fails. Provide cable and PLC failure alarms to the BAS. PLC to PLC
communications shall be Master-less.
5. For systems with large numbers of generators, provide multiple
independent distributed control networks and PLC’s in order to further
prevent a common mode failure. See contract drawings for quantity
and distribution of control networks.
I. Operator Interface Terminals (HMI)
1. Provide color touchscreen operator interface terminals (HMI) where
shown on the contract drawings. As a minimum provide two HMI’s
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located on the duplex pump set and in the vicinity of the day tanks. All
HMI’s shall use the same hardware and the same screen
configuration. An Operator shall be able to monitor and control any
PLC on that network from any HMI connected to any PLC.
2. Each HMI shall include a time/date stamped Alarm and Event Log for
rapid trouble shooting, verification of filtration cycles, etc.
3. The HMI shall provide remote monitoring capability via a standard
personal computer internet browser remote via the BAS Ethernet
network, with access security provided by BAS network firewalls,
routers, VPN’s, etc.
4. Software features shall include the following: Operator interaction shall
be touch screen-based to allow for easy selection of screens, manual /
automatic status changes, start/stop functions, setpoint changes,
output changes and without any special programming skills. Screen
selection shall also be available through tactile feedback function keys.
The HMI shall provide facsimiles of the local controllers and clearly
labeled English language and engineering unit display of the control
parameters.
5. Where applicable, alarm status shall be displayed on the HMI
generated process pictorials. In addition, all alarms shall be logged in
an alarm and event log. The alarm log shall indicate the time at which
the alarm occurred, the time at which the alarm was acknowledged
and the time at which the value returned to normal status. In addition to
alarm conditions, this log shall also document status changes such as
a transfer from automatic to manual, a setpoint change, etc. so that the
resultant collection of alarms and events is a true and complete log of
plant operating conditions.
6. The HMI shall be manufactured in accordance with UL50, IEC 1010-1
and EN 61010-1: Safety requirements for electrical equipment for
measurement, control, and laboratory use, Part 1.
J. BAS Interfaces: Provide a Building Automation System Protocol Convertor
into the control panel to interface all data from the fuel oil system to a BAS
system as shown on the drawings. A tag list of available data points to be
monitored shall be provided in the O&M Manual. This tag list will provide
description of the data, its format, and its address. Protocol shall be selected
by the BAS vendor and shall be either BACnet/IP or Modbus TCP/IP. BAS
vendor to provide the Ethernet routers, switches, and backbone cabling.
K. Automatic Pump Prime, Suction Line, and Day Tank Level Switches Integrity
Safety Check Test: The control system shall include a battery backed, real
time clock and must be capable of automatically energizing the lead pump
once every day. This safety check is to verify the suction piping integrity,
pump prime, and to verify pump operation including the day tank level
switches operational readiness. Once the lead pump has proven satisfactory
operation, the lag pump shall be energized and run through the same test.
These tests shall be recorded in the controller memory with a Time/Date
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stamp for later verification or diagnosis. If either lead or lag pump fails any of
these tests, the control system shall generate an audible and visual alarm and
log the “Failed Pump” condition. The day tank return pump(s) shall be
similarly tested whereby each return pump shall be activated and return oil
back to the main tank continuing until the day tank low level switch is
activated. The return pump shall stop and the lead supply pump will restart.
The Supply pump will refill the day tank up to the 90% level, activating that
switch again. The supply pump will shut off and the return pump restart until
the day tank level has dropped to the supply pump-off level. The supply
pump will finally restart and fill the tank back to the pump-off (80%) level and
then stop. This test sequence will demonstrate that not only the supply and
return pumps, but also all level switches in the day tank are functioning
properly. If during this sequence, any pump or level switch shall prove faulty,
the control system shall generate an audible and visual alarm and log such
event as a “failure” condition.
This automatic prime test feature is an option, found on very critical applications.
L. Wiring shall be in accordance with NEC standards, using stranded copper
conductors in liquid tight conduit. Special care shall be taken to ensure the
conduit is not over capacity in accordance with NEC.
M. Approved manufacturers
1. The only manufacturers approved shall be actively involved in the
manufacturing of fuel oil equipment. The equipment shall be a Total
Fuel Management System and manufactured by Critical Fuel Systems,
a division of BFS Industries LLC or approved

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