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HomeMy WebLinkAboutWQ0003626_Upgrade_20100726July 27, 2010 WASTEWATER TREATMENT CONTROL UPGRADE FUNCTIONAL SPECIFICATION VERSION 2.0 PROJECT NO. I46195 Prepared For: Campbell Soup Company One Campbell Place Box 204 Camden, NJ 08103-1799 Prepared. By: Matrix Technol�gies®, Inc. 1760° Indian Wood Circle Maumee, Ohio 43537 Matrix Technologies® INCORPORATED WASTEWATER TREATMENT CONTROL UPGRADE FUNCTIONAL SPECIFICATION VERSION 1.0 VERSION 2.0 July 8, 2010: FOR REVIEW July 27, 2010 FOR APPROVAL CONFIDENTIAL This Functional Specification is a complete and accurate description of the Wastewater Treatment Control Upgrade project developed for Campbell Soup. This scopesupersedes all previous descriptions. This scope has been reviewed and accepted by those signed below. Campbell Soup, Approval Matrix Technologies, Inc., Approval Mr. Tony Phillips Date Project Engineer Mr. Mike Schalk Project Manager Date Matrix Technologies°,.I1 TABLE_OF:CONTENTS 1.0 DOCUMENT INFORMATION- • Wastewater Treatment Control Upgrade Functional Specification 1 2.0 SYSTEM OVERVIEW 2 .+ 2.1 What the System will do 2 3.0 CONTROL. AND OPERATION_OF THE SYSTEM 3.1 System Control.Philosophy = 3.2 Spray Field Control 3• » 3, 3 3.2.1 Process. Functions and Operations 3 3.2.2 Operating Mode's r .-. 5 3.2.3 Data Collection Monitoring; and .Processing.Requirements 5 3.2.4 Equipment Requirements 3.3 .Waste Water.Supply Pump Control 6 3.3.1 Process Functions and Operations 6 4.0 OPERATOR, INTERFACE 7 4.1 Operator Terminals andLocations - 7 4.2 Screen Content 7 4.2.1 Common Guidelines for All Screens - 7 4.2.2 MAX FIELDS 8 4.2:3 Rotary Field Screens 9 4.2.4 Field. Status Indicators on the Status HMI Screen -10 5:0 DATA.COLLECTION, MONITORING, AND. PROCESSING 12 51.' Sensors. and. Input Devices 12 5:2 Information. Storage. and Retrieval 12 6.0 CONTROL AND DISPLAY PANELS 13 6.1 - Pump. House PLC 13 6:2 Pump,House HMI 13 6.3 Compressor Building PLC 13.. 6.4 Valley BaseStation2.#1 13' 6.5 ; 'Valley,BaseStation2 #2 13 6.6 Valley Pro2 lrrigation_Control_Panel = 13 6.7 Isolation Relay and Metering Panels 14 6.8 Valve Vault Terminal Box 14 6.9 Festo Solenoid Panel 14 7.0 APPENDIX 15 5 Project No.-I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev: 6, 05/08/0] 46195_Fnespc_100727 00008 Ver2.Doc Matrix Technologies®, Inc. _ 1.0 DOCUMENT INFORMATION• This document will be based on the information sources described in the Project Plan. Wastewater Treatment Control Upgrade Functional Specification Any changes from previous versions of this Functional Specification are briefly listed in the following table. Functional Specification Revision History. Version Date , , :,,, Purpose Changes 1.0 For Review Initial Version 2.0 July 27, 2010 For Approval Updated based on conference call with Tony Phillips and Bob Zimmerman July 26, 2010 Project No. 146195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195__Fncspc_100727_00008_Ver2.Doc Page 1 Matrix Technologies°, Inc. 2.0 " .SYSTEM OVERVIEW 2.1 What the. System will do Wastewater Treatment Control Upgrade Functional Specification The HMI in the pump house will allow the operatorto select . and prioritize .fields. An automatic field prioritization based on the field run time hours (rth) is also used to prioritize field irrigation. The selection of the fields will follow the automatic sequencing of fields based on the automatic prioritization unless otherwisedirected to do so by the operator at the HMI. Both priority lists will be displayed next to each other on the HMI. Each field can be placed in or out of service at each field through the Valley BaseStation2 system. The BaseStation2 will also allow for the selection of certain sections of a field to be avoided by the pivot spray system with the use of a GPS located on each pivot arm. The BaseStation2 will collect and display the accumulated flow meter data for each field and totalize the discharged waste water. The Valley system will inform 'the ControlLogix PLC system which fields are available and indicate whether there is a request for water at the current section of field where the pivot head is at: The PLC system will use that information to determine which field(s) to operate in order to distribute the waste water in the pump house sump. The PLC in the pump house will monitor the level of water in the pump pit and cycle the field valves open/closed and pumps on/off. When the level in the pump pit rises enough to require a field to be irrigated, the field valve(s) will open based on the priority list and field run hours, the discharge pump(s) will start based on the number of pumps required for the level and pump(s) with the least amount of run time hours (RTH). Once a minimum pressure is reached at the "open field",. the Valley pivot will walk. A GPS unit mounted on each pivot will send the pivot's position to the BaseStation2, and upon entering an area defined earlier to be avoided, would request the field valve to be closed, another field be selected, and the pivot continue to walk until it leaves the avoided area. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_100727_00008_Ver2.Doc Page 2 Matrix Technologies®, Inc. 3.0 CONTROL AND OPERATION OF THE SYSTEM This section describes the functional requirements arid necessary capabilities of the system. The requirements of each process operation are described here for each of its operating modes. 3.1 System Control Philosophy Wastewater Treatment Control Upgrade Functional Specification There are three (3) PLC inputs received from the Valley system for each field. These are an available status; water request and walking input. The available input is interlocked with a Valley system alarm status bit that will indicate whether the system has been placed "in service". Typically, the system will be placed "out of service" with a system alarm or if the operator has placed the system "out of service". If the system is "in service", the Valley system will monitor the field to determine whether there is a water request for the section of field that the pivot head is located. If the water request is on, the Valley system will monitor the system pressure to determine if there is enough water pressure to initiate the pivot head to start "walking" around the field. This is indicated by the walking input that is transferred from the Valley system PLC and the pump house PLC control system. There is one (1) PLC output that is transferred from the pump house PLC system to the Valley system. This is a start/stop signal. This output is connected to the remote start input of the Valley system. It is yet to be determined whether this input is required to start the valley system. 3.2 Sprav Field 'Control 3.2.1 Process Functions and Operations There are two methods for controlling the priority list of the spray fields. The first method is based on a field usage time. The second method is based on theoperator being able to set a priority list on the HMI screen. The operator will be able to enter this priority list and accept the order that each field, is sequenced. This second method will override any automatic sequencing that is determined in the first method. The second method will be accepted for thirty (30) hours and then go back to the default priority list unless reaccepted on the HMI screen. The first method of prioritizing watering the spray fields is listed below. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_100727_00008 Ver2.Doc Page 3 Matrix Tcchnologies®, Inc. Wastewater Treatment Control Upgrade Functional Specification 3.2.1.1 "J" field has the.highest priority to run, but only one (1) "J" Field section should rim at a time. 3.2.1.2 The .pivot fields (A, ' C, D, E, F, G, and H)have the next highest priority to run iii normalrunning mode. 3:2.1.3 "I" field'has the lowest priority to run in "normal funning.mode. 3.2.1.4 With thesepriorities in mind, the field with the Most rest starts first. 3.2.1.5 With these priorities in mind,.the field with the most run-time stops first. 3.2:1.6 Field GPM capacities are estimated for maximum field usage to calculate how many fields must run for the pumps required. 3.2.1.7 A high alarm level'setpoint is an indication that "B" field may flood, and will trigger the phone dialer. 3.2.1.8 The goal is to .maintain fifty (50) to seventy-five (75) PSI of pressure at the discharge of the pumps. 3.2.1.9 If all fields have equal rest time hours, the start order is J1414-A-C- D-E-F=G-H-II through I11. 3.2.1.10 If all fields have equal run time hours, the stop order is I11. through I1-H-G-F-E-D=C-A-J 14-J 1. 3.2.1.11 Minimum delay tunes between field starts will be determined during commissioning. This may or may not be a concern. Note: Preventative measures will be needed to avoid saturation of field B. Currently field B" isused as an overflow field. If the level in the sump area is requesting five pumps, the pump house control system needs programmed so five pumps are running regardless of field conditions. This preventative measure will supersede any of the aboveconditions that would prevent the desired number of pumps from running. This may require the field to distribute water even if that section of field isn't requesting water. Project No. I46195, July 27, 2010, Version 2.0 [D=04-02, Funcspec.doc,.Rev. 6, 05/08/03] 46195. Fncspc_100727_00008 Ver2.Doc Page 4 Matrix Technologies°, Inc. 3.2.2 Operating Modes Wastewater Treatment Control Upgrade Functional Specification The field system is designed to run in an automatic mode of operation. A password protected screen will be installed to bypass this automatic mode to open valves manually.. This manual screen will be used only during commissioning with the possibility . of keeping it for maintenance/ troubleshooting capabilities. This will be determined during commissioning. The pumps have auto/hand plc inputs. While the selector switch is selected to hand, the pump will run regardless, unless there is a high pump discharge pressure alarm. While the selector switch is in automatic mode, the pump will start/stop based on requests from the field. 3.2.3 Data Collection, Monitoring, and Processing Requirements Wonderware trending will be set up to view real time and historical data. Data collected will be pump on/off times, pump house discharge pressures, valve open/close status, and weather information. New trend screens will be developed to view this data. Historical data will be retained for seven (7) • days, and can be expanded to retain data for longer periods of time. 3.2.4 Equipment Requirements This section describes the spray field equipment requirements. 3.2:4.1 A flow meter for each 'field will send data directly to the Valley system. 3.2.4.2 Each of ,the pivot fields (A, C, D, E, F, G, and H) will have a water valve controlled by the PLC. 3.2.4.3 Each of the "I" and "J" fields will have a bank of solenoid valves for control of individual sections of that field. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_100727_00008 Ver2.Doc Page 5 Wastewater Treatment Control Upgrade Matrix Technologles®, Inc. Functional Specification 3.3 Waste.Water. Supply Pump.Control 3.3.1 Process Functions aiid.Op'erations The Waste Water is delivered from the : main plant to a sump in thepump house. From there up to six (6) sump pumps can be used to deliver enough water to the spray fields in order to lower the sump level. A setup screen will have entries for one (1) pump level, two (2) pump level, three (3) pump level, four (4) pump level, five (5) punp level and six (6) pump level. The pumps will be started/stopped based on deadband 'control: The PLC will 'determine which pump(s) to run based on the following criteria: 3.3.1.1 If the sump pit level is below the low -low level then all pumps are disabled. 3.3.1.2 An alarm level will indicate that B field may flood, and will trigger the phone dialer. 3.3.1.3 The pump that has the most rest time will start first, regardless of when it is stopped. 3.3.1.4 The pump that has the most run time will stop first, regardless of when it is started. 3.3.1.5 If all pumps have equal rest time hoiirs, then the start order is 1-2-3- 4-5-6. 3.3.1.6 If all pumps have equal run time hours, then the start order is 6-5-4- 3-2-1. 3.3.1.7 There is a minimum ten (10) second delay between pump starts. 3.3.1.8 There is a minimum ten (10) "second delay between pump stops. 3.3.1.9 If a pump tries to run and does not start in five (5) seconds, analarm is set. Reset to run pump. Note: Preventative measures may be required to maintain pump house discharge pressure between fifty (50) and seventy-five (75) PSI as a normal operating range. If this pressure is exceeded, an additional field may be opened to relieve this pressure or it may require the field to distribute water even if that section of field isn't requesting water. If fifty (50) PSI is not maintained, it may be necessary to turn on an additional pump to boost -this pressure in order for the valley system pivot field to rotate. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195 Fncspc_100727_00008 Ver2.Doc Page 6 Matrix Technologies®, 4:0 OPERATOR INTERFACE This section describes the typesand locations cif the terminals used in this system: It also describes the content of the computer screens provided to the operators. Wastewater Treatment Control Upgrade Functional Specification 4.1 Operator Terminals and Locations The requirements for operator terminals 'are described in the following table. IDa° hype ' ,Location, Access Level % ' : Passvvord F Required? 1 Touchscreen Pump House 4.2.. Screen Content This section describes the content of the computer screens provided to the operators. 4.2.1 Common Guidelines for All Screens The HMI application exists and much of its functionality will remain intact. It will be modified as follows for this project. Project No. I46195, July 27, 2010, Version2.0 [D-04-02, Funcspec:doc, Rev, 6, 05/08/03], 46195_Fncspc_100727_00008_Ver2.Doc Page 7 Matrix Technologies®, Inc. 4.2.2 MAX FIELDS RESET NOW, FIELD FIELD STATUS WATER REQUEST AVAILABLE° NOT REEQUESTING° AVAILABLE° REQUESTING° NOT AVAILABLE° NOT REQUESTING° AVAILABLE° REQUESTINGO AVAILABLE° REQUESTINGO NOT AVAILABLE° NOT REQUEESTING° NOT AVAILABLE° NOT REQUESTING° NOT AVAILABLE° NOT REQUESTING° NOT AVAILABLE° MOT REQUESTING° PUMP HOUSE PRESSURE 0 PSIG Wastewater Treatment Control Upgrade .Functional Specification PUMP STATUS The.changes to this screen are as follows: 4.2.2.1 ' White indication is for available and upon receiving a water request. 4.2.2.2 Gray indication is for not available and when riot receiving a water request. 4.2.2.3 Inner ring of spray field will display available status and, follow color code above. 4.2.2.4 Outer ring of spray field will display water request status and follow :color code above. - 4.2.2.5 , Perpendicular line on spray field represents when field iswalking and will rotate in a clockwise direction with line- color changing from yellow to green. 4.2.2.6 Sump level will be display on right side of screen and show percent level. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195 Fncspc_100727_00008 Ver2.Doc Page 8 Matrix Technologies®, Inc. 4.2.3 Rotary Field Screens Wastewater Treatment Control Upgrade Functional Specification 7/27/2010 CAMPBELL SOUP SUPPLY A FIELD 11:05:54 AM -VALLEY.;CONTROL STATUS• FIELD IS'- AVAILABLE FIELD I5" NOT 'REQUESTING 'WATER FIELD I5 NOT WALKING OVERVIEW. . PUMPS STATUS LOGIN, tNrM NL H HELP TREND The changes to this screen are as follows: 4.2.3.1 Valley system status will be displayed on this screen 4.2.3.2 Field status animation displayed on this screen. Project No. I46195, July 27; 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195.Fncspc_100727_00008 Ver2.Doc Page 9 Matrix Technologies®, Inc. ZONE Wastewater Treatment Control Upgrade Functional Specification 4.2.4 Field Status Indicators on the Status HMI Screen RUOME ;:REST "-AUTO.µ, ;MANUAL" HOURS,TIME,. ISEQUENCESEQUENCI ,IRTIO;-$-HOURS' IµNUMBER',I NUMBER,. RUN TIME yHOORSt*t REST'- AUTO'< TIME'" s SEQUENCE HOURS' NUMBER° OUT OF SERVICE REASON -" MANUAL,; WEEKLY a SEQUENCE. USAGE TOUT OF SERVICE REASON: NUMBER IENTRY'1 ,'$� _ 'TATUS.. AUTO 1 MANUAL,; SEQUENCE SEOUENCEq OUT OFESEEIWICE .NUMBER'4-NUMBER, ., - 101 ' ' ' 0.00 102.: O.UU _ 0.001 103 0.00 0 '0.00 114" "-- . 0.00 SEQUENCE;`' SELECTION:.:`'_ =MANUAL. ,AUTOMATIC SEQUENCE -",.°',SEQUENCE SELECTION ' SELECTION" 4.2.4.1 'RUN TIME HOURS' is the accumulated field run time hours: Increments while the field is runnings 4.2.4.2 'REST TIME HOURS' is the accumulated field rest time hours. Increments while the field is off. 4.2.4.3 Auto Sequence Number is a priority list for the "fields to be irrigated, starting, With one (1) being the highest priority. This list Will continually be updated based on highest rest time. 4.2.4.4 " Manual Sequence Number is manually entered by the operator as the fields that have highest priority.' 4.2.4.5 'Out of Service Reason' displays the Operator and the .selected downtime reason. 4.2.4.6 The Zone coliinin indicates field name. • Project No.'I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195 Fncspc_100727_0000$ Ver2.Doc Page 10 Matrix Technologies°, Inc. Wastewater Treatment Control Upgrade Functional Specification 4.2.4.7 Sequence Selection will determine the order of sequencing for irrigation. 4.2.4.8 The "J" field limit boxes allow display and editing, of the weekly state permit quantities. "J" fields cannot run after their weekly limit is reached. Weekly limit reset after seven (7) days. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195 Fncspc_100727_00008 Ver2.Doc Page 11 Matrix Techn�logies®, Inc. Wastewater Treatment Control Upgrade Functional Specification 5.0 DATA COLLECTION, MONITORING, AND PROCESSING This section describes the information collected, monitored, and processed by this system. It also lists the printouts and reports that are available to the operators. — •To Be Determined. 5.1 Sensors and Input Devices Input data that will be used for historic fogging are as follows Pump 1-6 Auxiliary Contacts Field Valves Position (Open/Closed) Pump discharge pressure Sump Level Weather Conditions 5.2 Information Storage and Retrieval Retrieval of the stored data will be through trending. One Trending screen will be developed for the pump auxiliary contacts. One screen will be developed for the Field pump positions. One screen will be developed for the analog data (discharge pressure, sump level). One screen will be developed to display weather information. Each trending screen can display up to eight (8) tags, so additional data can be collected as needed. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_ 100727_00008_V er2.Doc Page 12 Wastewater Treatment Control Upgrade Matrix Technologies°, Inc. Functional Specification 6:0 CONTROL AND DISPLAY PANELS This section describes the required location, content, and functionality of each panel included in this system. 6.1 Pump House PLC This panel contains a ControlLogix PLC that will have the majority of the PLC code in the system. It will determine which pumps shall run as well as which fields shall run. 6.2 Pump House HMI This HMI exists now and is the only Wonderware HMI in the system. It is the primary operator interface in the pump house. 6.3 Compressor. Building PLC This PLC is connected to the F, G, and H pivot fields and I and J stationary fields. This PLC will serve mostly as a remote I/O slave to the Pump House PLC. 6.4 Valley BaseStation2.. #1 This unit will be programmed arid supplied by Valley Controls and will reside in the maintenance building near the Pump House. It will communicate wirelessly with all the Valley Pro2 and Auxiliary Link panels at the individual fields. It will receive and track water application data and determine which fields can be put into use by the pump house PLC. 6.5 Valley BaseStation2#2 This unit will be similar to the Valley BaseStation2 #1 and will reside in the M9 building at the main plant. 6.6 Valley Prot Irrigation ControlPanel One of these panels will be mounted at each of the pivot fields and will relay information to and from the pump house PLC. Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_100727_00008 Ver2.Doc Page 13 Matrix Technologies°,Inc. 6.7 Isolation Relay and -Metering Panels These panels relay the signals from the Valley Pro2 panels to the PLC and. back. There is one panel at the center of each pivot field. 6.8 Valve Vault Terminal_ Box Wastewater Treatment Control Upgrade Functional Specification This panel relays the signals from the PLC to the pivot field valves.. There is one panel near each pivot field water valve. 6.9 Festo Solenoid Panel This panel will contain blocks of fest solenoids. There will be one solenoid for each area of fields "I" and "J". Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195 Fncspc_100727_00008 Ver2.Doc Page 14 Matrix Technologies°, Inc. 7.0 APPENDIX Wastewater Treatment Control Upgrade Functional Specification Project No. I46195, July 27, 2010, Version 2.0 [D-04-02, Funcspec.doc, Rev. 6, 05/08/03] 46195_Fncspc_100727_00008 Ver2.Doc Page 15