SOFCON INDIA PVT. LTD.

(CONFIDENTIAL-FOR INTERNAL USE ONLY)

Project Manual
June 2013

Table of Contents
This document is a Manual for the PLC-SCADA Project

Steps of Project

1: HMI Development for respective project by P & ID

2: Logic Development for respective project

3: Simulation of project

4: Factory Acceptance Test

Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

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Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

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Pump-Sump (Project 1)
Overview
A new pump is to be installed into a sump. Its purpose is to empty the sump
of water once the level becomes too great. In the sump are two level
switches, high and low, to allow control of the valve. To ensure no water
washes back into the sump through the pump output a valve isolates the
pump and ensures enough pressure is built up by the pump before this
isolation is removed.

Pump P01 Control

Inputs
1. Running (RG)
2. In auto (UA)
3. Fail (YA)
Outputs
1. Start (ST)
2. Speed (SC)
Control
When the PLC requests the pump to run the Start output shall be set. Pump
symbol turns green.
When the PLC requests the pump to stop the Start output shall be cleared.
Pump symbol turns red.
The Pump can only be requested to start when the pump is available
(Unavailable input is set) and healthy (Failed input is set and no software
generated alarms).
All buttons, for example "Auto/Start/Stop", are displayed on the HMI
screen.

Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

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Speed Control using PID

PID controls the pump speed. All PID loop parameters are trended. HMI screen graphically
displays Setpoint (SP), Process Variable (PV), and Control Variable (CV).
PV is the flow
SP is the flow setpoint
CV is the pump % speed
E=SP - PV

Software Generated Alarms

Given table shows the set, reset and action conditions for pump related
alarms.

Alarm
Description

Set

Pump fail to
start

Pump not in
auto

Action

Reset

When the pump is

requested to start
and running
confirmation is
missing for 5
seconds.

Places pump
into manualstop mode.

When the pump is

placed into auto or
manual-start.

When there is no
pump available to
run in auto.

Places pump
into manualstop mode.

When the pump is

placed into auto or
manual-start.

Flow FS01 Control

The flow value controls the pump speed through PID loop. A flow setpoint
may also be entered manually on the HMI. The flow will be in gallons per
minute.

Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

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Tag

Setpoint

Set

Action

Reset

FSL-01

9 gpm

When the pump is

running and flow is
at or below the
setpoint for 6
seconds.

The pump
shall be
requested to
manual-stop

When flow is greater

than the setpoint for
5 seconds

The pump
shall be
requested to
manual-start

When flow is less

than the setpoint for
5 seconds

FSH-01

95 gpm

When flow is at or
above the setpoint
for 6 seconds.

Valve V01 Control

Outputs
1. Output (OP)
Control
When the PLC requests the valve to open the Opened output shall be set.
When the PLC requests the valve to close the closed output shall be set.
When the valve is neither Opened nor Closed it is travelling. Part green and
part white.
The Valve can only be requested to open when the valve is available
(Unavailable input is set) and healthy (Failed input is set and no software
generated alarms).
"Auto/Open/Close buttons for valve controlling is displayed on the HMI
screen.

Level LS01 Control

Water is directed to the sump, as the level increases the flow demand
decreases causing the valve to close. As the Sump level decreases the flow
demand increases, causing the valve to open. The level can be measured in
inches.
Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

Page 6

Tag

Setpoint

Set

Action

Reset

LSL-01

5 in.

When level is at or
below the setpoint
for 3 seconds.

The valve shall

be requested
to start

When level is greater

than the setpoint for
5 seconds

LSH-01

95 in.

When level is at or
above the setpoint
for 3 seconds.

The valve shall

be requested
to stop

When level is less

than the setpoint for
5 seconds

Specific Control Philosophy

Upon a low level input becoming set by the low level switch (LSL-01) the
valve shall be requested to open. Level low shall be indicated on HMI.
Once the valve is opened the PLC shall wait 15 seconds before requesting
the pump to open.
Upon a high level switch input (LSH-01) becoming set the valve shall be
requested to close. Once the valve is closed the pump shall be requested to
start. Level high shall be indicated on HMI.
All timers shall be settable from the HMI, including Device Failed and Process
Timers.

Device Color Coding

The HMI uses the color-coding shown below:

Color

Valve

Pump

Green

Open

On

Red

Closed

Of

Yellow

Failure

Failure

A device placed in MANUAL control will have MAN displayed over or beside
the device.
Project Lab Manual

Sofcon India Pvt. Ltd.(Confidential-For Internal Use Only)

Page 7