10.0 INSTRUMENTATION AND CONTROLS 10.1 INTRODUCTION Draft Basis of Design Report
C-9 Impoundment Project


South Florida Water Management District (SFWMD)


Draft Basis of Design Report
10-1
November 2006

10.0
INSTRUMENTATION AND CONTROLS
10.1
INTRODUCTION
This section presents the basis for the design of the instrumentation and control (I & C) system
for the C-9 Impoundment Project. Each of the water control facilities within the C-9
Impoundment area will be monitored and controlled remotely through the S-509 Pump Station.
Each water control structure will have a Remote Terminal Unit (RTU) based control system.
Each pump station will have a Programmable Logic Controllers (PLC) based control system that
will interface with an RTU for remote monitoring from SFWMDs operations center over
SFWMDs Supervisory Control and Data Acquisition (SCADA) facilities. The existing telemetry
system, which is centralized at SFWMD headquarters, will be extended to include the new
facilities. Communications from the S-509 Pump Station to SWFMD Headquarters will be over
the SFWMDs Microwave Telemetry System.
10.2
PUMP STATION DESIGN BASIS
The SFWMD design standard entitled Major Pump Station Engineering Guidelines, Final
Edition dated December 1, 2005, has been utilized as a basis for developing the pump station
instrumentation and controls design.
10.2.1
Pump Station Control System Architecture
Figures 10-1 depicts the basic control system architecture for pump station applications utilizing
diesel driven pumps. For diesel type pump stations, the entire station operation will be
monitored and controlled in the control room through a personal computer (PC) based master
workstation. The workstation will incorporate an operating system that employs a Graphical
User Interface (GUI) functioning in a windows environment (e.g. Microsoft Windows). The
Windows-based GUI computer will incorporate a Human Machine Interface (HMI) that will allow
users to interact with the computer control systems. It will provide the pictures the operator
will use to monitor and control the plant processes. The graphics and nomenclature displayed
on the screens will be designed to be consistent with SFWMD standards. In addition to
providing control and monitoring functions, the proposed workstation will have the capability of
providing trending and historical data.
The main control panel monitors the operation of the diesel engine control panels (DECP), trash
rake control panel, contractor interface panel, miscellaneous systems motor control centers
(MCC), security and fire alarm systems, fuel monitoring system, potable water system, stilling
wells, local water control structures and interfaces with the RTU telemetry system for SCADA
monitoring. The main control panel will contain an Ethernet switch that will be the primary
interface point to the control room workstation. A local uninterruptible power supply (UPS) will
be provided to eliminate the transient that occurs during transfer to and from normal and
emergency power.
Each DECP will have PLC with an HMI using GUI software for local monitoring and control of
the engine, pump and associated support systems. Communications between these controllers Draft Basis of Design Report
C-9 Impoundment Project


South Florida Water Management District (SFWMD)


Draft Basis of Design Report
10-2
November 2006

and the control room workstation will be via Ethernet/IP protocol through the main control panel.
Each DECP will also have a local UPS.
A contractor interface panel, consisting of PLC with an HMI using GUI software, will be provided
to act as an interface to the water sampler, headwater level transmitter and tailwater level
transmitter. The panel will also have a local UPS.
SFWMDs remote telemetry units (RTU) utilize Motorola MOSCAD to monitor and control the
various remote operations such as gates and culverts. In pump station applications, the
MOSCAD unit serves as the interface gateway between the pump station control system and
the SCADA system at the remote operations center.
All control panels will be designed in accordance with UL 508A requirements and will carry a UL
508A label.
10.2.1.1
Master Workstation
The operation of the pump station will be monitored and controlled by a PC based work station
in the control room. If a break room is provided with the facility, a second PC based work station
will be provided that has all the same capabilities as the master workstation. Each will interface
with the station MCP through the Ethernet/IP protocol. Failure of any of the computers will not
inhibit the complete control and monitoring of the station.
In addition to the master workstation, an operator work station and printer will be furnish in the
control room for report generation, trending and historical analysis. The master workstation and
operator workstation will be furnished in a main floor mounted desk top type console. Sufficient
space will be allotted for cabling for present utilization and for future additions of up to 50
percent. The desktop console will be ergonomically designed for the Operator to visually
monitor all data points and provide control.
The HMI uses a GUI software program that works under the operating system of the PC. The
workstation PC acts as the data exchange for the HMI and the real world various PLC. The HMI
software will allow for complete remote station control, such as starting and stopping of pumps
by simply clicking the picture of the motor on the screen with the computer mouse. The HMI
will be customized for this specific project to show all system components and monitored values
in a way that represents the actual field installed arrangement and interconnections. Graphics
will be dynamic to show the status of all equipment (e.g. pumps running or alarm condition) and
display real time data parameters such as levels, pressures, temperatures and flows with this
same data trended in the historical data. Alarms will be shown to appear as real world
indicators such as colored pilot lights. Trending will be shown as charts. Master work station will
include an alarm page that the operator can control.
Work stations will utilize the latest technology available at the time the station is designed. This
will include the GUI-based operating system and all software upgraded to the latest versions.
The computers will include a 128 key keyboard, mouse, a read/writable DVD/CDROM drive,
and a 120 GB hard drive (minimum). Alarms will be printed on a wide-carriage printer. A laser
printer will be furnished for report writing. Monitors will be 19 inch flat panels (minimum). In
addition to HMI software, the computers will also include database, spreadsheet, and word
processing software that meet SFWMDs standards. Draft Basis of Design Report
C-9 Impoundment Project


South Florida Water Management District (SFWMD)


Draft Basis of Design Report
10-3
November 2006

10.2.1.2
Programmable Logic Controllers
PLC is implemented in the engine control panels, as well as the main control panel that will be
designed around the Allen-Bradley Control Logix family. Switch closures such as start-stop
pushbuttons and HOA selector switches will be digital inputs. Electrical inputs reflecting varying
process parameters (such as a 4 to 20 milliamp signal corresponding to the level from a level
transmitter) will be analog. Similarly, turning on a motor or other control operation from PLC will
be a digital output. Varying the speed of a motor drive will be an analog output. The PLC will
have a 25 percent spare capacity for each type of I/O and memory.
The DECP PLC will be furnished by the engine manufacturer as part of the pump package and
programmed to meet the requirements of the engine operation, including all control for starting,
stopping, and monitoring various fluid levels. The software will be programmed so that the
operation of the pump can continue with the MCP PLC disabled. The DECP PLC will provide
the interlock, startup, and emergency stop logic for the engines, pumps and associated support
systems. The PLC will monitor the alarm and fault status of other vendor panels.
The main control panel PLC will serve as the interface to building related systems such as the
fire alarm, intrusion detection, fuel monitoring, potable water system and miscellaneous other
monitored station points not associated with DECP.
Typical I/O points for individual devices used in a diesel driven pump station are presented in
Table 15-1. For the electric driven pump station alternative, the corresponding diesel inputs and
outputs would be deleted and replaced mainly with electric pump and motor controls, and
monitoring.
10.2.1.3
Main Control Panel
The MCP will include duplex PLC to provide the main monitoring and control for the pump
station. The duplex processors will have a bumpless transfer (i.e. either unit can take over
operation of the plant architecture without loss of data or requirement for shutdown). The MCP
acts as the main i