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TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 1 OF 24

OPERATION AND CONTROL PHILOSOPHY


FOR
PLC -SCADA SYSTEM
TALCHER PROJECT

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 2 OF 24

SCHEME BACKGROUND
Execution of Rural Piped Water Supply Scheme to the mining affected villages of Talcher Kanhia
pertaining to Angul district of RWS&S Div. against bid Id No.-EIC/RWSS/17/18-19 In the state of Odisha.
(Pkg-II).

This package includes a Water Supply Scheme which covers:

 Intake Pumping Station (common for both packages i.e. Talcher and Chhendipada project)
 49.72 MLD Water Treatment Plant
 Clear Water Pumping Station
 Intermediate Booster Pumping Station- 3 Nos.
 Overhead Water Reservoir – 29 Nos.

The Instrumentation-Control Sub-System consists of providing PLC Based Control System and Field
Instruments at the Intake Pumping Station, Water Treatment Plant, Clear Water Pumping Station,
Intermediate Booster Pumping Station (IBS) and OHRs.

There is an Overall Water Management SCADA system, the Master Control Center (MCC) Facility of which
is located at Water treatment Plant.

The Water treatment Plant cum MCC has a PC based Operator system located in its control room.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 3 OF 24

1. General Description
A. PLC Control Panels at Intake, WTP, CWPS and IBS.
 The Main PLC System cabinet housing the PLC system with Input output modules will be of
suitably size with Front access type.
 The PLC Control Panel will be CNC pre-fabricated, modular in construction with multi-fold frame
structure, long life polyurethane foam rubber gasket, and special 3-point locking mechanism,
painted in an ultra-modern automated paint shop with Epoxy powder coating. The enclosures
will be IP-54 degree protected and the Colour shade will be RAL 7035 as per manufacturer
Standard. The Gland plate will be 3 mm while the doors and frame will be of 2mm and the side
panels will be 1.5 mm as per manufacturer Standard. An ISMC 100 base channel is provided at
the bottom with a 15 mm thick anti vibration pad sandwich between the main cubicle structure
and the base channel.
 All the components in panel will be mounted on DIN Rail. DIN rail will be fixed on specially
designed vertical section inside the panel.
 PLC modules will be installed on insulated DIN rail channel.
 Panel internal wiring will be done using prefab cable.
 Computerized printed ferruling will be done in PLC panel.
 Cable ways of field and internal wiring will be provided separately.
 All PLC panel will be provided with 2 nos. isolated separate earth tinned copper bus bar i.e. 1 for
Electrical and 1 for Instrument earthing (on insulator).
 The PLC system will be provided with SMPS AC to DC Converters / Power Supply of Suitable rating
which will provide all the interrogation and loop power for the I/Os. These converters will receive
230 VACS from the UPS system.
 All Digital outputs will be provided with interposing relays.
 Panel will be provided with Exhaust FAN, Tube light, Drawing pocket and Laptop charging socket
as standard.
 All Analog input wiring will be done for both type of field instruments i.e. 2 wire and 4 wire
instruments.
 For panel internal wiring distribution special tinned copper bus block will be used for easy
maintenance and troubleshooting.
 All field cable will be terminated directly on Intermediate termination boards for ease of
maintenance and troubleshooting.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 4 OF 24

B. PLC System Details for Intake, WTP, CWPS and IBS (3 Nos.)

 The PLC control system will be Hot Redundant CPU, Power Supply and Communication Modules
with simplex type IOs at WTP Main PLC System.
 The PLC Control System will be Standalone CPU with 10” HMI and Redundant Power Supply
System with Simplex type IOs at CWPS and IBS.
 The PLC Control System will be Standalone CPU with 1 No. PC Based SCAD System and Redundant
Power Supply System with Simplex type IOs at Intake (common between Talcher and
Chhendipada project)
 Standalone Micro PLC will be provided for Chemical House, Chlorination, WTP Sub Station and
Clariflocculator System.
 Standalone Micro PLC with 7-HMI will be provided for Filter bed console. Individual Filter bed
console will be all Filter beds i.e. Total 8 Nos.
 1 Nos. PC Based Operator Work Station and 1 No. Engineering work station (Laptop) will be
provided Master Control Center (MCC) at WTP.
 Multifunction Power Meter (MFPM) of Incomer, Outgoing, Motor Feeders, DG Set and Battery
Charger will be connected through Modbus RS-485 with respective PLC system.
 Intake PLC, IBS PLC, Clariflocculator PLC System will be connected using GPRS communication
with WTP Master Control System
 CWPS, Filter Bed Console PLC and Other WTP PLC system will be connected using Fiber optic /
Ethernet communication with WTP Master control system
 At OHRs GPRS Modem with Analog Input Modules will be provided and same will be connected
with WTP Master control System through GPRS communication.
 3 KVA UPS with 3 Hours battery backup with LASMF batteries will be provided for Intake and
WTP.
 1 KVA UPS with 1 Hours battery backup with LASMF batteries will be provided for Intake and
WTP.
 0.5 KVA UPS with 1 Hours battery backup with LASMF batteries will be provided for Intake and
WTP.
 Computer table and Revolving Chairs will be provided at Intake, WTP and IBS.
 Make of PLC and SCADA is Schneider Electric. Details of the same is provided in System
configuration and Bill of material.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 5 OF 24

2. System Description

1. Intake Raw Pumping Station (Common for Talcher and Chhendipada Project)
 Intake Raw Water Pumping Station consist of
 6 Nos. Vertical turbine pump (VT) i.e. 3 Pumps for Talcher Project and 3 for Chhendipada project.
 1 No. Motor operated buttery fly valve at each Pump Discharge and common header.
 Intake well level Measurement
 Common Discharge header Pressure measurement
 Pressure switch on each pump discharge for pump tripping on high pressure.
 Common Discharge Header outlet flow measurement using Electromagnetic Flow Meter
 Motor Winding and Bearing Temperature measurement
 Motor Electrical Signal Monitoring (Motor Feeder MFPM will be interfaced with PLC Panel).
 Stand-alone PLC System with 1 No. PC Based SCAD System, A4 BW laser Printer, 4G GPRS modem
and Redundant Power Supply System with Simplex type IOs.
 Control panel will be provided with Annunciation system with hooter, Indicators for pressure and
level monitoring and Temperature scanners.
 Computer table and revolving Chairs.
 3 KVA UPS System with 3 hours battery backup with LASMF batteries.
 Intake Pumping Station will be communicated with both WTP i.e. Talcher and Chhendipada WTP
SCADA System using GPRS Communication.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
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TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 6 OF 24

Control and Interlocks: -

Signals of Intake Raw water pumping station are acquired through PLC Control panel this panel will
communicate with PC Based SCADA System over Modbus TCP/IP network.
Local/Remote operation selection can be made through Selector switch provided on MCC panel.

 A minimum water level has to be maintained in the Intake well.


 When raw water sump level reaches at Very Low level then working pump will be tripped in auto
mode from the PLC/HMI system. Very low set point can be changed from SCADA system. Set
point display will be password protected.
 The Pressure switch provided at the Pump Discharge line will enable alarm at High pressure to
trip the working pump.
 Motor Winding Temperature signals can be monitored from Panel Mounted Temperature
Scanner local SCADA system and Pump will be tripped in case of very high temperature. Alarm
and Trip set point can be changed from HMI system. Set point display will be password
protected.
 Raw water pumps will be started with their respective discharge motor operated BFV in closed
condition as the pump start, the respective discharge BFV shall be opened after a preset time
interval.
If power failure occurred at WTP (signals will be received through GPRS communication) working
pump will be tripped in auto mode from the PLC/HMI system.

Start Permissive for VT Pumps


 Sump level is normal.
 Motor is not tripped/fault.
 Motor Winding and Bearing Temperature is normal.
 Motor feeder should be available for remote operation.
 Discharge valve BFV should be closed condition
 Discharge valve should be available for remote operation.
 Common discharge header valve should be in open condition.
 Pump should be selected as working pump.
 Water demand signal should be available from WTP.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 7 OF 24

Trip Conditions for VT Pumps


 Discharge valve BFV is closed when pump is running.
 Discharge valve fail to open during pump startup
 Sump level is Very low.
 Motor Tripped due to electrical fault from HT panel.
 Winding Temperature is very High
 Pump discharge pressure high.
 WTP Power failure.

Auto Start Condition for Standby Pump


 Motor tripped due to overload.
 Working pump discharge valve fails to open.
 Discharge valve BFV is closed when pump is running.

Following alarms will be assigned in Local SCADA system.


 Motor Tripped on over load (for each pump)
 Pumps fail to Start/Stop.
 Discharge Valves fail to open/close.
 Discharge Valve position feedback
 UPS Failure.
 PLC trouble
 Low/Very Low level in Sump
 High/Very High level in Sump.
 Pump discharge pressure High
 Power fails at WTP.
 Motor Winding/Bearing Temperature is high and very high
 Power Feeders MCCB Tripping
 DG Set Failure
 Others as per IO List

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 8 OF 24

Following parameter will be transmitted to Master Control Station using GPRS communication.

 Pump and Discharge valve Status i.e. Pump (ON, OFF, Trip and Remote FB).
 Valve (Open, Close and Remote FB, Position FB)
 Pump Run Hours
 Sump Level
 DG Set Data
 Motor Winding and Bearing Temperature
 Common header pressure
 Motor Electrical Parameter such as Voltage, Current, Frequency, Power Factor and Active Power
 Outlet Flow and Totalized Value.
 And other parameters as per IO list.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 9 OF 24

2. 49.72 MLD Water Treatment Plant

Water Treatment Plant consist of


 Inlet Flow measurement using open channel flow meter
 Inlet Water pH, Turbidity and Residual Chlorine measurement.
 pH, Turbidity and Residual Chlorine measurement at Clear Water Outlet
 Backwash Tank Level Measurement
 Filter bed Loss of Head and Rate of Flow measurement
 Level switch for Alum Dosing Tank, Lime Dosing tank and Filter Beds.
 Hot Redundant PLC System, Power Supply and Communication Modules with simplex type IOs at
WTP Main PLC System
 Standalone Micro PLC will be provided for Chemical House, Chlorination, WTP Sub Station and
Clariflocculator System.
 Standalone Micro PLC with 7-HMI and Push buttons for valve operation will be provided for Filter
bed console. Individual Filter bed console will be all Filter beds
 Control Panels will be provided with Annunciation with Hooters, Indicators for Level, Pressure,
Loss of head and rate of flow on respective panels.
 1 Nos. PC Based Operator Work Station ,1 No. Engineering work station (Laptop), A3 Black and
white Printer will be provided Master Control Center (MCC) at WTP.
 Computer table and revolving type chairs
 3 KVA UPS System with 3 hours battery backup with LASMF batteries.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 10 OF 24

Inlet Chamber
Raw water enters the plant through Raw Water Inlet channel.
 1 No. Ultrasonic type open channel flow meter is provided at Raw Water Inlet Channel to
monitor the flow rate of raw water in the Raw Water Channel which produces 4-20 mA DC
analog output corresponding to instantaneous flow. It will give total flow of raw water entering
into 8 Filter beds as well as existing 6 Filter beds. The flow meter is provided with Flow totaliser
 1 No. pH, Turbidity and Residual Chlorine Analyzers will be installed at Raw Water Channel to
monitor Raw water quality and signals of the same will be interfaced with PLC/SCADA System.
Flash Mixer
 The water from the outlet of Raw Water Inlet enters the distribution Chamber from where it is
further passed on to the Flash Mixer portion through a Manual Gate.
 The water received at the flash mixer is thoroughly mixed with the Alum and Lime dosing
solution.
 The aggressive agitation results in instantaneous and effective mixing of chemicals.
 Flash Mixer Motor can be started manually through the soft pushbutton provided on the SCADA.
 Flash Mixer motor will start automatically when open channel flow reaches to start level (user
selectable from SCADA screen, password protected).
 Flash Mixer motor will stop automatically when open channel flow reaches to stop level (user
selectable from SCADA screen, password protected).
Clariflocculator
 The raw water after mixing enters flocculation zone of Clariflocculator.
 Clariflocculator PLC will be installed on the bridge. Panel will be suitable for outdoor installation
i.e. with double front door panel will be provided
 Clariflocculator PLC is connected with SCADA system through GPRS communication. Controlling
of Clariflocculator PLC can be done from WTP SCADA system.
 Flocculator motor of a particular flocculator tank can be started manually through the soft
pushbutton provided on the SCADA
 Clariflocculator motor will start automatically when open channel flow reaches to start level (user
selectable from SCADA screen, password protected).
 Clariflocculator motor will stop automatically when open channel flow reaches to stop level (user
selectable from SCADA screen, password protected).

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 11 OF 24

Dosing System
 3 Nos. Alum and 3 Nos. Lime Dosing system is envisaged in scheme to control Turbidity and pH of
Water.
 Level Switch with High and Low feedback will be provided for Alum and Lime Tanks.
 The Dosing process starts as soon as Open Channel flow reaches to dosing Start Level.
 Alum and Lime Agitator can be start/stop manually through the soft pushbutton provided on the
SCADA.

Sludge System
 Clarified Sludge and Sludge Transfer Pumps and can be start/stop manually through the soft
pushbutton provided on the SCADA.

Filter Bed Automation

The settled water proceeds through the channel to the filter bed where the sand filtration takes place.
This is an intricate physical process for removal of balance turbidity, suspended solids micro-organisms
etc.

The CI gate is provided at the inlet of the filter bed, which is open and closed manually and hence we
have not envisaged any PLC interfacing with the panel.

There will be 8 filter beds each having:


 Raw Water Inlet Gate – 1 No.
 Clear Water Outlet Valve – 1 No.
 Backwash Water Inlet Valve – 1 No.
 Air Inlet Valve – 1 No.
 Dirty Water Outlet Gate– 1 No.

All the above valves are provided with motor operated actuators for automatic operation through PLC.

The filter bed gets exhausted over a period of time while filtering the settled water. It then needs back
washing to remove the clogging and make it freshly available for the process. The rate of exhaustion is
measured in terms of the loss of head.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
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TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 12 OF 24

Each filter bed is provided with Loss of Head) transmitter and ROF transmitter

The output from these transmitters (4-20 mA DC analog signals) are monitored locally and remotely at
each filter console on the panel mounted HMI, Indicators and at the PC based SCADA System.

Backwash Sequence

 The backwash overhead tank is provided with 1 no ultrasonic type level transmitter
 The backwash Overhead water tank level monitoring for starting and stopping the pumps as well
as tripping in case of very low level and operation of the two pumps with 1 working + 1 standby
and flow measurement on backwash common header line & outlet of backwash water tank shall
be monitored through PLC.
The backwash sequence shall be possible if the following conditions are prevailing:
1. Backwash overhead tank level normal.
2. All valves being in remote feedback.
3. Air blowers with remote feedback.

The backwash sequence shall start on the following conditions are prevailing:
1. Detection of high LOH and low ROF indicating the clogging of the bed.
2. Pre-defined time user selectable
3. From HMI soft pushbutton (BACKWASH START)

Filter bed clogged alarm is displayed at the PLC based SCADA system.

Followings sequence of operations happens for back washing of filter bed:


1. Drain down
2. Air scouring
3. Back-Washing
4. Rinsing
5. Service

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 13 OF 24

Backwash Operation Steps

Raw Water Air Inlet Backwash Dirty Water Clear Water


Air Blower
Inlet Valve Valve Inlet valve Outlet Valve Outlet Valve
START Close Close Close Close Close OFF
DRAIN Close Close Close Open Close OFF
AIR SCOUR Close Open Close Open Close ON
BACKWASH Close Close Open Open Close OFF
RINSING Close Close Close Open Close OFF
SERVICE Open Close Close Close Open OFF

 First of all, the valves will be closed immediately.


 In the Drain sequence, B.W outlet valve will be opened immediately.
 In the Air Scour sequence, Blower air inlet valve will be opened
 One of the air blowers is started automatically by PLC for air scouring for some time (approx. 5
min/user adjustable)
 After the time elapses the air blower is stopped followed by closing of the blower air inlet valve.
 After completion of air scouring, backwash water inlet valve is opened for some time. Time is
user adjustable. Backwash water will be taken from the backwash OHT through backwash
pumps.
 After the preset time for the backwash with filtered water, the B.W inlet valve will be closed.
 Now the filter inlet valve and filter outlet valve of the filter bed are opened for the filtration
process to continue. And the above sequence gets repeated during each back-wash cycle.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 14 OF 24

OPERATION FOR BACKWASH PUMPS

 Backwash pump can be started manually through the soft pushbutton provided on the SCADA
when the water in the Backwash overhead tank goes below 20% level and stopped when the
level goes above 90 % level.

Auto sequence for Backwash pumps:

 Select working /stand by pump from SCADA by pressing soft pushbutton.


 If the level of backwash OHT tank goes low below 20% then the working pump will be started to
fill the Backwash overhead tank.
 If the level of backwash OHT tank goes high above 90% then the working pump will be stopped
automatically in order to avoid the overflow of the Backwash overhead tank.
 If working pump trips, standby will start automatically.

CHLORINE BOOSTER PUMPS:


 4 Nos chlorine booster pumps are used. 2 pumps are used for Pre chlorination and 2 pumps are
used for Post chlorination.
 Chlorine booster pump can be start/stop manually through the soft pushbutton provided on the
SCADA.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 15 OF 24

3. Clear Water Pumping Station and Intermediate Pumping Station.

CWPS and IBS (3 Nos.) Pumping Stations consist of


 1 No. Motor operated sluice valve at each Pump suction side.
 1 No. Motor operated buttery fly valve at each Pump discharge and common header.
 Sump/Reservoir Level Measurement.
 Common Discharge header Pressure measurement
 Pressure switch on each pump discharge for pump tripping on high pressure.
 Common Discharge Header outlet flow measurement using Electromagnetic Flow Meter
 Motor Winding and Bearing Temperature measurement
 Motor Electrical Signal Monitoring (Motor Feeder MFPM will be interfaced with PLC Panel).
 Stand-alone PLC System with panel mounted 10” HMI ,4G GPRS modem and Redundant Power
Supply System with Simplex type IOs.
 Control panel will be provided with Annunciation system with hooter, Indicators for pressure and
level monitoring and Temperature scanners.
 Computer table and revolving Chairs.
 1 KVA UPS System with 1-hour battery backup with LASMF batteries.
 CWPS will be connected with WTP Master control system using Fiber optic communication and
IBS will be connected with WTP Master control system using GPRS communication.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 16 OF 24

Control and Interlocks: -

Signals of CWPS and IBS pumping station are acquired through PLC Control panel this panel will
communicate with PC Based SCADA System over Modbus TCP/IP network.
Local/Remote operation selection can be made through Selector switch provided on MCC panel.

 A minimum water level has to be maintained in the Sump/Reservoir


 When raw water sump level reaches at Very Low level then working pump will be tripped in auto
mode from the PLC/HMI system. Very low set point can be changed from SCADA system. Set
point display will be password protected.
 The Pressure switch provided at the Pump Discharge line will enable alarm at High pressure to
trip the working pump.
 Motor Winding Temperature signals can be monitored from Panel Mounted Temperature
Scanner local SCADA system and Pump will be tripped in case of very high temperature. Alarm
and Trip set point can be changed from HMI system. Set point display will be password
protected.
 Clear water pumps will be started with their respective discharge motor operated BFV in closed
condition as the pump start, the respective discharge BFV shall be opened after a preset time
interval.
If power failure occurred at upstream station (signals will be received through fiber optic/GPRS
communication) working pump will be tripped in auto mode from the PLC/HMI system.

Start Permissive for Pumps


 Sump/Reservoir level is normal.
 Motor is not tripped/fault.
 Motor Winding and Bearing Temperature is normal.
 Motor feeder should be available for remote operation.
 Suction Valve should be Opened condition.
 Discharge valve BFV should be closed condition.
 Discharge valve should be available for remote operation.
 Common discharge header valve should be in open condition
 Pump should be selected as working pump.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 17 OF 24

Trip Conditions for Pumps


 Suction /Discharge valve BFV is closed when pump is running.
 Discharge valve fail to open during pump startup
 Sump level is Very low.
 Motor Tripped due to electrical fault from HT panel.
 Winding Temperature is very High
 Pump discharge pressure high.
 WTP Power failure or Upstream Side Pumping Station Power Failure.

Auto Start Condition for Standby Pump


 Motor tripped due to overload.
 Working pump discharge valve fails to open.
 Discharge valve BFV is closed when pump is running.

Following alarms will be assigned in Local SCADA system.


 Motor Tripped on over load (for each pump)
 Pumps fail to Start/Stop.
 Suction Valves fail to open/close.
 Discharge Valves fail to open/close.
 UPS Failure.
 PLC trouble
 Low/Very Low level in Sump/Reservoir
 High/Very High level in Sump/Reservoir
 Pump discharge pressure High
 Power fails at WTP and Upstream Pumping Station.
 Motor Winding/Bearing Temperature is high and very high
 Power Feeders MCCB Tripping
 DG Set Failure
 Others as per IO List

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 18 OF 24

Following parameter will be transmitted to Master Control Station using FOC/GPRS


communication.

 Pump and Discharge valve Status i.e. Pump (ON, OFF, Trip and Remote FB).
 Discharge Valve (Open, Close and Remote FB, Position FB)
 Suction Valve (Open, Close and Remote FB)
 Pump Run Hours
 Sump Level
 DG Set Data
 Motor Winding and Bearing Temperature
 Common header pressure
 Motor Electrical Parameter such as Voltage, Current, Frequency, Power Factor and Active Power
 Outlet Flow and Totalized Value.
 And other parameters as per IO list.

4. Overhead Reservoir (OHRs) System

OHRs consist of
 1 No. Ultrasonic Level Transmitter for Level Measurement
 1 No. Electromagnetic Flow meter for inlet flow measurement.
 1 No. Residual Chlorine Analyzer for Chlorine Measurement.
 1 No. GPRS modem cum Analog Input module will be provided to interface with above signals.
 Signals will be transmitted to WTP Master Control System using GPRS Communication.
 Total No. of OHRs are 29 Nos.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 19 OF 24

5. SCADA SYSTEM at Master Control Center (MCC)

 1 No. PC Based SCADA system will be provided at WTP Main Control Room with advance graphics
and animation facility.
 1 No. Laptop will be provided for Engineering purpose i.e. Laptop will be loaded with PLC
Programming software, SCADA development software
 1 No. A3 Black and white printer will be provided for report printing.
 Computer Tables and Revolving chairs will be provided.
 Major SCADA displays will comprise Main Overview display, Pump parameter and control display,
Set-point display, Alarms display, Historical trends, Electrical SLD and parameter and Reports
(Daily report, Weekly report and Monthly report).

6. SCADA System Features

1. SCADA Software
 SCADA Runtime software will be installed in WTP Master control computer system.
 Data acquired from various PLCs and RTUs will be displayed on SCADA System.
 SCADA PC System will be loaded with MS office software i.e. word, excel for report generation
purpose.
 SCADA System support open database connectivity for report generation purpose.
 SCADA PC will be connected with broadband interconnection to communicate with remote
stations data transfer facility.

2. Security Level
 SCADA System software will be provided with multiple level access control system.
 User access level can be configured for multiple users i.e. Operator Login, Supervisor Login,
Engineer Login, Assistant Engineer login and Executive Engineer Login.
 New user creation or deletion of any users can be done at site any time with special password
protected method.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
DOCUMENT COVER SHEET NO. OF SHEETS

TITLE OF DOCUMENT: OPERATION AND CONTROL PHILOSOPHY FOR PLC -SCADA SYSTEM PAGE 20 OF 24

3. PLC /RTU Security Level


 PLC and RTU communication port can be password protected for unauthorized access.
 PLC/RTU program can be changed or modified only after availability of proper access to user.
 Security level will be available in multiple options i.e. as follows
- Unlimited access: - In this user can modify, change, delete PLC/RTU program or
communication port settings.
- Access without configuration: - In this user can read or write RTU configuration and setpoint
parameters. However, user will not be authorized to change PLC/RTU logic diagram.
- User access for PLC/RTU parameter reading or setpoint views.
- Complete protected – in which user can be view only RTU communication port details

For More features of SCADA Software refer below SCADA Software Datasheet.

EXECUTION OF RURAL PIPED WATER SUPPLY SCHEME TO THE MINING AFFECTED VILLAGES
PROJECT NAME OF TALCHER KANHIA PERTAINING TO ANGUL DISTRICT OF RWS&S DIV. AGAINST BID ID NO.-
EIC/RWSS/17/18-19 IN THE STATE OF ODISHA.(PKG-II)
CUSTOMER ANGUL (TALCHER) RWS&S DIV. GOVERNMENT OF ODISHA
EPC CONTRACTOR NCC LIMITED, HYDERABAD
C & I CONTRACTOR SAI APPLIED TECHNOLOGIES PVT. LTD, VADODARA
SAT DOC. NO. SAT/1068/DOC/22
DATE 03.08.2021 PREP. BY JP CHECKED BY DS
PRODUCT DATASHEET

AVEVA Plant SCADA


(formerly Citect SCADA)

Commitment to operator empowerment and engineering efficiency

AVEVA Plant SCADA is a leading high-performance Supervisory Control and


Data Acquisition (SCADA) software solution for industrial process customers.
Superior operational context and built-in functionalities help consolidate,
simplify, and optimize control; empowering operators to streamline their
operations for efficiency, reliability, and safety.
Overview

AVEVA Plant SCADA is a key pillar of our monitoring What’s new


and control industrial software suite. Building on the The latest release of Plant SCADA includes a range of
developments of Citect SCADA 2018 R2 with a focus new functionality to make your data more accessible,
on integration and interoperability with the AVEVA through native HTML5 visualization for read-only access
Operations portfolio, Plant SCADA integration of to our new Industrial Graphics from a browser, tablet, or
Industrial Graphics alongside the already powerful smartphone, and improvements in communications.
native graphics capabilities, together with a focus on
communications, engineering efficiency and an ongoing AVEVA industrial graphics
commitment to Cyber Security. AVEVA Industrial Graphics provides a new thin client
solution for the delivery of HTML5 graphics to desktop
Key benefits: browsers and mobile devices. This consists of a new
y Engineering Cost Reductions with a host of modern graphics editor, new graphics technology, and
contextual improvements that simplify project design new web client runtime experience offering HTML5
and management visualization, all available alongside the existing
y Enhanced Operator Awareness with navigation Graphics Builder editor, legacy Graphics format, and
zone and alarm indicators saving valuable time in high-performance desktop runtime.
diagnosing process anomalies
Improved connectivity (IPv6, OPC-UA server)
y Increased Production Efficiency with new contextual In Plant SCADA 2020 R2, IPv6 addresses are supported
workspace that simplifies the operator experience throughout the configuration, including PC Network
and facilitates timely decision making and reduces Addresses, I/O Devices (for supported drivers), Servers
risk of downtime and Clients. In addition, Plant SCADA supports native
y Extended operational value with native integration to OPC-UA server functionality to share your plant data
our AVEVA Industrial Software portfolio throughout your organization.
y Mobile extension capabilities with Access Anywhere A new Connectivity Server component has been created
via HTML5-compliant web browsers to be the foundation of OPC-UA communications, and to
y Alignment with Abnormal Situation Management serve data updates to drive animations within our new
industry best practice guidelines HTML5 graphics.

Context-aware workspace Library of configurable objects Alarm management enhancements

02 AVEVA Plant SCADA


Other enhancements y Seamlessly integrated Alarming, Trending, Interlocks
In addition to the keynote features mentioned above, and Control data together in a single interface,
the following enhancements are also now available across multiple monitors without the need for coding
within Plant SCADA 2020 R2: y All helping to minimize visual distractions for
operators, enabling timely decision making and
y Determine usage of Graphics Library items
helping to mitigate risk and operational downtime
throughout your project (integrated for both legacy
Graphics and new Industrial Graphics Libraries) Comprehensive equipment library
within Plant SCADA Studio IDE A wide selection of configurable symbols that follow
y Persistent GoTo Object dialog settings within industry best practice for Situational Awareness including:
Graphics Builder
y Drives y Mining objects
y Display dialogs from Graphics Builder on correct
y Valves y Polar star
monitor
y Meters y Bar graph
y Hide ‘Add’ button in Special Days view of the BACnet
Scheduler at runtime y Data and UI elements y Wind compass
y Out-of-the-box symbol library significantly reduces
Security enhancements
time building graphics while giving the flexibility to
y Reduced permissions for running Plant SCADA with
customize objects to suit your unique needs
support for running under Virtual Service Accounts
y Improvements in graphics system and new
y User Groups now able to restrict access to
workspace concept substantially reduces time
configuration files (including those on deployment
building complex layouts
server/client), as well as access to the Plant SCADA
configuration tools y Pinned windows, named animations, animated
polyline vertices to help simplify the engineering
y Enhanced IT management with support for mapping
experience
of security groups to Windows Domain groups
including security configuration for Deployment, Enhanced alarm management
support for Domain groups within Local groups, and y In-built navigation zone within Workspace providing
support for authentication of Windows users through a instant visual alarm summary, with immediate
CtAPI (so you don’t have to manage local users) focus to abnormal situations, showing the highest
y Extended encryption through to ActiveX Web Server priority alarm for a piece of equipment
connections y Alarm indicators to quickly draw operators’ attention
and help locate the source of anomalies and
associated severity
Key features: y Alarm Shelving allowing you to temporarily silence
alarms for a specific duration or until a specified time,
Context-aware workspace with the ability to re-shelve as needed
y A dedicated out-of-the-box Situational Awareness y Define up to 8 Cause(s), Response(s), and
Workspace that provides flexible, consistent, rich Consequence(s) for your alarms to give your
context for operators, as well as a new way to build operators the information they need to deal with
context-aware SCADA visualization abnormal situations
y Equipment-driven interface provides operators with
real-time, holistic situational context to help improve
efficiency and facilitate timely corrective action

03 AVEVA Plant SCADA


Seamless integration

The latest release of AVEVA Plant SCADA offers native Summary


connectivity with our industrial software suite and tight y Seamlessly weave Visualization, Alarms, Trends,
application integration with third-party hardware and Interlocks and Control together for superior
software offerings, helping to unlock and extend the operational context
value of our customers’ SCADA systems.
y Build an effective SCADA system out-of-the-box
AVEVA Plant Access Anywhere is a mobile extension faster than ever before
of AVEVA Plant SCADA that provides unprecedented y Comprehensive Library and Operational Content out-
real-time access to AVEVA applications via HTML5- of-the-box
compliant web browsers. AVEVA Plant Access
y Increase Operator effectiveness in all situations
Anywhere enables visualization, collaboration, and
execution at various levels of the organization with y Any Citect SCADA system can upgrade to embrace
zero client installation and maintenance, enabling users the new features
to securely troubleshoot plant equipment from any
location, on any device, at any time.

Context-aware workspace

© 2021 AVEVA Group plc and its subsidiaries. All rights reserved.
AVEVA and the AVEVA logo are a trademark or registered trademark of AVEVA Group plc in the U.S. and other countries.
All product names mentioned are the trademarks of their respective holders.

aveva.com

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