NEORSD

Process Control and Automation System

Design Standards

Process Control Narratives

Revision 0.0
October, 2013
NEORSD CONTROL SYSTEM DESIGN STANDARDS
PROCESS CONTROL NARRATIVES

Revision History

Version Date Authors Description of Revisions

0.0 October 2013 P. Gauche, C. Galka Original Version

1.0
1.1

1.2

1.3

1.4

Contents
I. INTRODUCTION ........................................................................................................................................ 3
II. PROCESS CONTROL MODES ....................................................................................................................... 5
A. TERMINOLOGY ..................................................................................................................................... 5
B. CONTROL MODE DEFINITIONS ................................................................................................................ 6
C. CONTROL STRATEGY DETERMINATION AND DESIGN ................................................................................... 7
III. PROCESS CONTROL NARRATIVE DOCUMENT CONTENT AND STRUCTURE .......................................................... 9
A. GENERAL REQUIREMENTS ...................................................................................................................... 9
B. PCN DOCUMENT STRUCTURE AND CONTENT .......................................................................................... 10
IV. APPENDICES TO THE PROCESS CONTROL NARRATIVE DESIGN STANDARD ....................................................... 13
A. APPENDIX A - EXAMPLE PROCESS CONTROL NARRATIVE......................................................................... 13
B. APPENDIX B GLOSSARY OF PROCESS CONTROL ABBREVIATIONS AND ACRONYMS ....................................... 23

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 NEORSD Design Standard

Process Control Narratives

I. Introduction

A process control narrative, or PCN, is a functional statement describing how device-mounted

controls, panel mounted controls, PLCs, HMIs, and other processor-based process control system
components should be configured and programmed to control and monitor a particular process,
process area or facility. PCNs are sometimes referred to as control strategies, control narratives,
sequence descriptions, and by other similar names. A PCN is the essential link between process
design and control system design. It also forms an integral part of the final control system
documentation, providing in the most concise but descriptive form, a statement that ties together
process operation, process equipment, instrumentation, control philosophy, available control modes
and control loops, as well as documenting control logic settings such as setpoints, computed values,
alarm limits, normal operating limits, trips, interlocks, and other key parameters.

Process Control Narratives serve several purposes:

• During the Preliminary Design phase of a project PCNs are used to describe the process
control and monitoring concepts based on the conceptual process design. The PCNs
document preliminary equipment and operational requirements. At the start of this stage the
document may be a Process Narrative or Process Description. At the completion of the
Preliminary Design phase the document should be a well-developed Process Control
Narrative (PCN) that is about 90% complete.
• During the Detailed Design phase, PCNs are used to refine process control design
requirements such as:
o Selection and location of instrumentation and control devices
o Hardwired interlocks and permissives
o Data archiving and reporting requirements
o Trend parameters
o Alarm settings
o Operator prompts and messages
o Other functions and parameters associated with the process.
A PCN provides the instrumentation and control system engineer with a guideline for
development of the overall design.
• During construction and start-up, the PCNs, in conjunction with supporting drawings, control
system lists, equipment specifications and instrumenttion information, must be the controlling
documents used by integrators and programmers for developing the process control logic and
system configuration. The PCNs describe the system functionality that must be installed and
tested. Site and Factory Aceptance Test checklists can, in part, be developed from the
descriptive material in the PCNs.
• Following the construction testing phase, the as-built PCNs become key reference documents,
operation and maintenance manual components, and training materials to provide current,
updatable documentation for the technical and operations personnel at the facilities. The
design documents should require contractors and integrators to submit as-built documents in
NEORSD CONTROL SYSTEM DESIGN STANDARDS
PROCESS CONTROL NARRATIVES

digital format for transpotability, accessibility and ease of use on the business network,
portable maintenance PCs, and on-line within the control system.
A draft process narrative must be prepared during the process conceptual design stage of projects.
The PCN must form a part of any process design report and its preparation must precede detailed
design. This will ensure that the process design can be accommodated within the District’s control
hierarchy and philosophy. Appendix A contains a sample PCN that depicts the expected style and
content.

In summary, the purpose of a PCN is to ensure that the process control system is programmed and
configured to support the intended operation of the process. The PCNs must convey to control
logic programmers and control system configuration specialists how the logic must work, how the
process data must be handled, and how the operator must be able to interact with the process
equipment.

To achieve this functionality, process control narrative development must be an integral component
of the process design phase of each project. As such, it requires the participation of both process
designers and control system designers. To help establish an ownership role and operator
acceptance of the process control system and its capabilities, and to provide designers with greater
insight into operators needs and potential issues under operating conditions, the end users should be
involved in PCN development and review during the design process, and refinement and testing
during implementation.

It is essential that all designers understand and utilize the District’s instrumentation, control and
electrical standards, and apply the standards to all control system design products including the
PCNs. The District’s standard formats, content requirements and terminology must be used rather
than alternate terminology that may be more commonly used by a particular designer or design
firm. The District will provide its designers and contractors with access to design, configuration
and programming standards that are relevant to each project.

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II. Process Control Modes

A. Terminology
Standard NEORSD Control Modes are identified by terms that are combinations of the
location from which control actions originate and the level of control being activated through
selection of a given control mode. There are several possible location descriptions and several
possible levels of control that, in combination, form a control hierarchy, from simple manual
starting and stopping of single devices to complex automation of process areas and facilities.

For interpretation of abbreviations and terminology used in this NEORSD Design Standard as
well as additional process control system terms that may be useful, refer to Appendix B –
Glossary of Process Control Abbreviations and Acronyms.
To help standardize the content of PCNs developed for NEORSD under all projects, including
in-house system modification and development, and out-sourced design, integration and
technical assitance projects, the following process control mode definitions and conventions
must be employed:

Control Location definitions:

• LOCAL Local controls are those that are nearest to, and typically in the
immediate area of, the controlled device. In some cases local controls
are integrated with a device’s actuator or adjacent electrical disconnect
panel. An example would be a valve actuator with “Open”, “Close”
and “Stop” buttons or switches, and in most cases a “Remote/Local”
selector switch that enables operation from either the local pushbuttons
or a remote control signal source. However, in cases where a gate,
valve, blower, or other controllable device is located in an inaccessible
or hazardous location, the local controls may be in an auxiliary control
station that is mounted in a safe, accessible location, some distance
from the device.
• REMOTE A control station location that is not in the immediate vicinity of the
controlled device, or, if there is more than one tier of remote control
for a device, a control location that is remotely located from a lower
tier control station.
• PLC/PAC or RTU Control actuated via the process control system through remotely
located HMIs, OITs, control processor logic, or other interface
devices.

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Level of Control definitions:

• MANUAL Human, hands-on, control of equipment functions via an enabled

manual control station; e.g. switches, pushbuttons, dials, manual
loading stations, OITs, HMIs.
• AUTO Automatic equipment operation executed for a circuit or control loop
following predefined procedures. Occasional interaction (e.g. setpoint
changes) by an operator may be needed as process conditions change.
• SUPERVISORY Multiple process control loops or more complex algorithms are
operated autonomously by the control system with limited, infrequent
human interaction. Typical supervisory control in wastewater
collection and treatment processes involves simultaneous control of
multiple control loops based on strategic operator-entered or
programmed settings, cascaded control loops, and automated process
management strategies dependent on, and that automatically respond
to, information acquired from other processes or remote locations.

B. Control Mode Definitions

Control mode definitions for NEORSD wastewater collection and treatment facilities, arranged
in hierarchical order by combinations of control location (Section II.B) and level of control at
the location (Section II.C), include:
LOCAL
LOCAL Manual control via devices located at or near the controlled equipment
MANUAL Examples:
• Valve open and close pushbuttons on an actuator a local control station/local
control panel (LCS or LCP).
• Motor start and stop pushbuttons on a motor drive or electrical switch enclosure
near the motor.
• Motor variable speed adjustment potentiometer at a motor drive or on a power
panel.
Note: in some cases the local controls may be mounted an extended distance from the
device for safety and accessibility.
LOCAL Automatic control implemented at a local control panel in the area of the controlled
AUTO device.
Examples:
• Panel-mounted single-loop flow controllers with manual setpoint adjustment
• Pump on/off control based on local level signal settings or float switches
• Timers that cycle sludge pumping
• Other similar controls that require limited or no operator interaction.

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REMOTE
MANUAL Manually entered control exercised at a location that is not in the vicinity of
(REMOTE) the controlled device(s).
Examples:
• Stop/Start, manual adjustments and Open/Close commands entered at
remote pushbuttons or non-HMI/OIT operator interfaces
• Manually adjusted variable speed control at a VFD panel
• Any control actions that are manually initiated from a remote panel in a
process area that are not routed through a PLC.
AUTO (REMOTE) Automatic control without frequent manual intervention or process control
system interaction.
Examples:
• Automatic speed modulation by panel-mounted loop controllers
• Automatic start/stop or open/close control processed by field mounted
device controllers, limit switches, timers, etc.
PLC
MANUAL (PLC) Manually entered adjustments and commands via HMIs or OITs such as
start/stop, open/close, increase/decrease, etc. emulating LOCAL MANUAL
but processed through the PLC system.
AUTO (PLC) Automatic control actions generated by computers and PLCs in response to
inputs to the SCADA system such as monitored level, flow, density, on/off
status of equipment, etc..
Examples:
• PLC-based closed or open loop controllers with operator entered or
computed setpoints or output values
• Cascaded PID control algorithms
• Computer or PLC-based supervisory control of multiple loops, cascaded
loops and more complex flow distribution algorithms, chemical feed rate
based on ongoing computations, and level control algorithms. These
algorithms may or may not require regular operator intervention such as
ratio adjustments, setpoint adjustments, lab generated data, etc.

NOTE: Not all control modes will be implemented for every process under every project.
Available control modes will depend on design and operational factors such as whether a
location is normally staffed or unstaffed, the type of process being designed or modified, whether
vendor-provided, pre-packaged and pre-programmed PLCs and panels are provided with the
equipment, and the degree of automation desired by the District. The designer must prepare
PCNs that are relevant and appropriately aligned with each project’s conceptual design and
operational constraints.

C. Control Strategy Determination and Design

For any given process and associated control location, the appropriate control modes must be
identified and designed into the instrumentation, control devices, panels, control logic and
operator interfaces. This should be a collaborative process involving workshops that bring
together process engineering, operations, instrumentation and control system engineering,
electrical and hydraulic design and other stakeholders whose input is essential. The workshops
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should help the designer achieve a clear understanding of the existing control system structure
and functionality, as well as the District’s desired level of process control and monitoring
capabilities to be achieved under the project.
At the treatment plants, sections of the Main Control Panels (MCPs) typically house the PLCs,
and will accommodate panel mounted OITs, so the need for the MCP level of manual control
that currently exists is less critical than in the original plant process control designs, but should
be evaluated under the Failure Mode and Effects Analysis process for all new projects involving
process controls. If local manual backup controls are not critical, MCP level control can
typically be provided through an OIT with the same or greater functionality, and unused local
control panels or sections of panels can be eliminated.
The District may determine for a given project that control stations will be needed in cases
where the operators must have clusters of manual controls to maintain control of critical process
equipment if a PLC is out of service. If any, these must be identified during the detailed design.
Such control stations will need to be hardwired into process and equipment control circuits to
provide adequate functionality independent of the PLC when needed.
By properly configuring and programming the control system so the PLC maintains control of
the local process if there is a network failure, process equipment status should not be adversely
affected if a PLC fails. Hard-wired, panel-mounted controls that require additional panel space,
expense and maintenance may not be required in many cases.
Designers should not propose to eliminate any manual control at existing local device panels.
However, where the project scope permits, designers should include specification requirements
to eliminate abandoned, unused conduit, electrical and signal wiring, and abandoned control and
communications enclosures and panels. The goal is to reduce control ambiguity, simplify
maintenance and expansion, improve esthetics and make efficient use of available space.

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III. Process Control Narrative Document Content and Structure

A. General Requirements
1. The PCN developer should always bear in mind that the PCNs for a project are the
primary source of information used by the programmers for developing process control
logic and minimizing Requests for Information. The PCN should be clear, cover normal
and abnormal operation, and should elaborate on the interactions between operators and
the control system.
2. When developed within capital design, technical services, integration or construction
projects, PCNs should be prepared, submitted and reviewed under the same submittal
process as that employed for other portions of the project.
3. Under design projects involving more than process control and monitoring and requiring
a design report, the preliminary draft PCNs should be included in an appendix to the
Design Report. For projects that predominantly involve the process control system, the
PCNs should be submitted in a stand-alone document accompanied by supporting
documentation referenced in the PCN.
4. PCNs should not include project or process documentation that is otherwise available for
reference. For example, I/O lists, instrument lists, and lists of calibration settings should
not be included, but should be referenced. To avoid conflicts, ambiguities, and the need
to maintain multiple versions of the same information, never include process control and
instrumentation information that is available elsewhere. Future updates to PCNs should
be based on the latest system documentation and not on outdated information that may be
embedded in the PCN itself.
5. Process narratives must be written in accordance with all relevant District Standards (e.g.
Standard HMI and OIT objects, standard PLC/PAC AOI objects, control hierarchy,
philosophy, software development techniques, general requirements, etc.), and must
reflect the requirements of the standards. Wherever possible, references must be made to
the relevant section of the standard rather than repeating the requirements.
6. The primary author of the PCN should be the process control system engineer. However,
the PCN must be developed in cooperation with and with input from the process designer
and the District’s Operation and Engineering staff. The intent of this is to ensure that the
control system reflects not only District Standards, but the specific operational needs and
requirements of each process and facility.
7. The conceptual or draft process narrative must be updated during detailed design to
reflect the final control arrangements documented in the contract drawings and
specifications. Updated process narratives must form the basis of contract negotiations
for software development.
8. It is important to define in the PCN which settings, limits and other parameters may be
changed by the operator and which may only be modified by supervisors or others with
higher level clearance. It should also be clear which settings can be accessed and
changed through the HMIs or OITs and which require a control logic programming
change.
9. The designer should specify that the Contractor may be required to modify some initial
settings after a period of operational familiarization as part of Post-Commissioning
Services (refer to NEORSD Standards Library for standard specification for Post-
Commissioning Services).

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10. The PCN author should reference actual point tags when necessary to avoid ambiguity.
For example, it may be better to state “Shut down and inhibit starting Pump 2 if wet well
level switch S02_L002A is in a low alarm condition” than to simply refer to a low level
condition if there are multiple level switches with similar but separate functions.
11. During project implementation, it is imperative that the process narrative is updated to
reflect process/field changes. Every attempt must be made to identify changes prior to
completion of shop and site testing. Following software development and testing,
commissioning and acceptance, the final process narrative must be prepared and issued to
reflect the as-constructed situation.
B. PCN Document Structure and Content
The following standardized PCN document outline must be used to provide the District with
uniformly structured process control documentation.
The PCN for each controlled and/or monitored process must include the following
components:
Part 1. Basic Information – Document Title, Project No., Process Area
Part 2. Revision History – Version, Date, Author, Version or Change Description
Part 3. A reference list of specific relevant drawings and schedules that augment
understanding of the process control and monitoring described by the PCN,
including, as appropriate:
 Site and Equipment Location Drawings
 Network Architecture (Control System and project specific architectures)
 Electrical Drawings
 Process Piping and Process Flow Diagrams
 Process and Instrumentation Diagrams (P&IDs)
 Loop Diagrams
 I/O Lists
 Instrument Lists
 O&M and Vendor-furnished Manuals
The references should not be general, but should list specific drawing numbers
and document titles from within overall design packages. New drawings
produced under the project, as well as existing drawings that are used to augment
the design documents, should be listed if relevant.

Part 4. A description of the process or facility that clearly explains what equipment and
treatment is involved, how the process or facility should operate under various
conditions, and its relationship to parallel, upstream and downstream processes.

Part 5. A general description of process control strategies and control modes that are
available for each process unit, the major hardwired and virtual process
variables, and the types of data collected by instrumentation in the area.

Part 6. Detailed descriptions of the control algorithms and strategies that must be
programmed in the PLC, PAC or RTU control logic (e.g. pump duties,
equipment sequencing, process control loops, etc.) This section should describe

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all relevant control philosophies, interlocks, settings, limits, levels and modes,
e.g.:
 Control Settings
 Operator Security Restrictions and Permissions
 Local and Remote, Auto and Manual Control Modes
 Specific Device Control Characteristics
 Interlocks (Process, Emergency, Safety)
 Permissives/Trips
 Manually Entered Points
 Virtual And Computed Points
 Handling of bus-connected devices and associated controlled and monitored
points (DeviceNet, Modbus and other types of device communication links)
 Control Strategy Activation And Initialization
 System Generated Operator Messages and Action Prompts
 Control Mode Transference
 Failsafe Mode and Actions
 Communications
 PID Loops and Advanced Control Algorithms
 Alarms/Alarm Priorities

Part 7. Locations and Identifiers for Associated Processors, HMIs, OITs, Control
Panels, Control Rooms and Communication Cabinets

Part 8. HMI and OIT Display Descriptions

 Overviews
 Area
 Equipment Detail
 Tabular Data
 Control System Status
 Electrical System Status
 Other (weather, informational, video monitoring)

Part 9. Trend Display Details

 New Trend Menu/Index Items
 Descriptive Information for each Trend to be Developed
o Database points included in each trend
o Time scale/span
o Axis labels
o Links to other trends or displays

Part 10. Process, Power and System Alarms

 Specify alarm priorities where possible for the programmers’ use in
constructing alarm tables, displays and reports

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Part 11. Report Descriptions

 On-Demand Reports
 Scheduled, Automatically Activated Reports

Additional sections may be included as deemed necessary by the designer to fully describe
the process control strategy, control logic details, displays, trends and other operational
requirements.

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IV. Appendices to the Process Control Narrative Design Standard

A. APPENDIX A - Example Process Control Narrative

The following example is based on an actual wastewater treatment plant process scenario but
has been modified to remove references to actual facilities, projects and documents.

Process Control Narrative PCN-22A

THICKENED SLUDGE PUMPING

Project: Contract No. 2013-001 - CWWTP Solids Processing Improvements Project

Facility: Central Wastewater Treatment Plant
Process Area: Solids Thickening, Blending and Storage

REVISION HISTORY

Version Date Author Description of Revisions

Ver. 0.0 July 1, 2000 S. Ample Conceptual Draft – Pre-design
Ver. 0.1 Dec. 10, 2003 L. Adders Final revision – programming tested and completed
Ver. 1.0 Aug. 5, 2010 D. Arnitall Modified wet well logic to accommodate control of new
third pump.

Reference Documents:

Site Drawings
• A-005 Project Site Drawing – Solids Processing Area
Network Drawing
• I-N-001 Central Plant Process Network Overview
• I-N-005 Solids Area Process Network Drawing
P&IDs
• I-P-123 Thickened Sludge Pumping Wet Well No. 2 Pumps 1, 2 and
• I-P-124 Thickened Sludge Pumping Wet Well No. 1 Pumps 4, 5 and 6
• I-P-125 Thickened Sludge Pumping Wet Well No. 3 Pumps 7, 8 and 9
• I-P-136 Thickened Sludge Wet Wells & Pumps No. 1-9 I/O Tables
Loop Diagrams
• I-C-011 Loop Diagram – Solids Area Control Panel ICP-S1
• I-C-012 Loop Diagram – Solids Area Control Panel ICP-S2
I/O Lists
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• Solids Area I/O Database

Instrument Lists
• Solids Area Instrument List
O&M and Vendor Manuals
• Variable Frequency Drive Programming and Operating Manual
• Level Sensor Hart Protocol Configuration Manual

Process Description
The thickened sludge discharged from the Plant’s eight Pre-digestion Centrifuges flows by gravity to
three existing thickened sludge wet wells containing four mixers each. Nine new pumps, one set of three
new pumps per each of the three wet wells, will transfer the thickened sludge to the Plant’s 4 sludge
digesters. Each wet well will normally have two pumps of its three pumps in service and one pump on
standby.
• Centrifuges #1 through #6 empty into Thickened Sludge Wet Well #1 (SC - south central) served by
new Thickened Sludge Transfer Pumps 4 - 6.
• Centrifuges #7 through #10 empty into Thickened Sludge Wet Well #2 (SS – south) served by new
Thickened Sludge Transfer Pumps 1 - 3.
• Centrifuges #11 through #16 empty into Thickened Sludge Wet Well #3 (NC north central) served by
new Thickened Sludge Transfer Pumps 7 - 9.
Sluice gates have been installed in the walls between Wet Well #1 and Wet Well #2, and between Wet
Well #2 and Wet Well #3. By manually opening the sluice gates (normal operating position), the three
wet well sections operate as a single wet well.
Adjacent to the three thickened sludge wet wells, there is also a sludge holding tank (location NN – north-
north) designated Tank #4. Tank #4 does not contain mixers and does not interconnect with the adjacent
three wet wells. Two existing High Pressure Thickened Sludge Transfer Pumps withdraw sludge from
Tank #4 and pump it to the digester sludge holding tanks. The two pumps operate in local manual mode
only and will be monitored, but will not be controlled, by the PLC.
New level indicating transmitters (LITs) are being provided for each of the three Thickened Sludge Wet
Wells.
The thickened sludge wet wells and sludge holding tanks are located outdoors, below grade elevation,
west of the Pre-digestion Centrifuge Building.
After the thickened sludge is blended in the three Thickened Sludge Wet Wells, the associated new
Thickened Sludge Transfer Pumps withdraw the sludge and discharge to 12” diameter headers.
Thickened Sludge Transfer Pumps #1 through #6 share one 12” common header, and Thickened Sludge
Transfer Pumps #7 through #9 share another 12” common header. These headers, and a 12” line from the
sludge holding tank (Tank #4), are each equipped with magnetic flow meters. The three lines combine
into a single 16” line downstream from the flow meters. The 16” thickened sludge line serves as the main
thickened sludge feed to the new Sludge Blending Tank (former Sludge Holding Tank No. 9). The sludge
will typically be thickened to a concentration of 5% to 7% solids.

Control Descriptions
PLC Operation of Process Equipment

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NEORSD CONTROL SYSTEM DESIGN STANDARDS
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Local and PLC monitoring of the three Thickened Sludge Wet Wells shall be provided. Also, PLC-
AUTO, PLC-MANUAL and LOCAL-MANUAL control of the nine new Thickened Sludge Pumps shall
be provided.
The PLC logic shall provide automatic wet well level control of the pumping system as described herein.
Data Collected by Instruments
Hardwired inputs and outputs – All input and outpoint points needed for monitoring the wet well levels
and monitoring and control of the pumps are shown on drawings IC-51-23, IC-51-24, IC-51-25, & IC-51-
36.
Soft inputs and outputs – This control logic does not require soft inputs and outputs from, or for, other
process area functions.

Control Algorithms

Wet Well Monitoring

The PLC monitors the sludge level in each of the three wet wells by level indicating transmitters (LITs).

Each wet well may be tagged OUT-OF-SERVICE via the HMI, wherein its associated instruments shall
not used by the PLC for control. However, monitoring and display of the data via the PLC and HMI shall
continue.

Software low level switches derived from each wet well’s LIT signal shall act as soft pump permissives
when the pumps are in the PLC control mode. For each wet well, the low level switch shall prevent the
Thickened Sludge Transfer Pumps associated with that wet well from starting, or shall stop all associated
running pumps whenever the sludge level drops below the setting of the low level switch. The soft Low
Level Limit for Wet Well No. 1 shall be a permissive/trip for Pumps 4, 5 and 6; similarly, Wet Well No.
2’s limit applies to Pumps 1, 2 and 3, and Wet Well No. 3’s limit applies to Pumps 7, 8 and 9. The
switches should be set at elevations higher than the mixer blades in each wet well (blade top heights are at
approximately 4.25 ft. elevation and switches normally set to 6.25 ft).

The wet well level signals shall be the controlling parameters for the automatic level control strategy
described in the PLC-AUTO subsection below.

A soft High Alarm Limit switch shall also be derived from each LIT signal and shall be set 0.5 ft.
(adjustable by authorized user) below the design high water level of each tank.

Thickened Sludge Transfer Pump Control

The control mode of each pump shall be selectable through the LOCAL-OFF-PLC (LOD) mode selector
switch located on the pump VSD controllers that are mounted on the walkway overlooking the pumps. In
LOCAL mode, the pump shall be controllable via hardwired devices on the VSD controller. In PLC
Mode, the DCU shall control the pump via the HMI and DCU control logic.

For each pump the PLC shall monitor, as hardwired inputs to the PLC, all three positions of the LOD
switch, pump RUNNING status, pump SPEED and the PUMP FAIL signal from the VSD controller. The
PLC effects control over the pumps through START, STOP and SPEED PLC outputs hardwired to the
VSD controllers.

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The PLC incorporates a START/STOP contact output for each pump and a 4-20 mA analog output to
adjust pump SPEED.

A soft OUT-OF-SERVICE/PLC-MANUAL/PLC-AUTO selector switch shall be available on the HMI

for each pump. Soft START and STOP switches for each pump shall be used to start and stop the pump
in PLC-MANUAL. In PLC-AUTO, each pump is assigned a role as LEAD, LAG or STANDBY via the
HMI, either selected by the user/Operator, or automatically by the PLC under certain conditions as
described herein.

A pump shall automatically be disabled from PLC control when the pump is designated as OUT-OF-
SERVICE via the HMI. A pump’s availability for service is restored by selecting PLC-MANUAL or
PLC-AUTO via the HMI, provided the appropriate pump permissives are satisfied.

The HMI shall indicate that each pump is READY or NOT READY to operate in PLC-MANUAL and
PLC-AUTO modes based on whether the respective pump permissives are satisfied or not satisfied.

In PLC mode, the PLC shall prevent a pump from starting, or shall stop a running pump and generate a
pump failure alarm under the following conditions:

• Activation of the PUMP FAIL alarm from the VSD controller (pump NOT READY condition, or
FAIL TO START alarm or RUN FAIL alarm in addition to VSD FAIL alarm)

• Pump RUNNING status from the VSD controller is not activated within three seconds following
a pump START command (FAIL TO START alarm)

• Pump RUNNING status from the VSD controller is deactivated while the pump is running (RUN
FAIL alarm)

• High discharge pressure switch (PSH) trips the pump VSD (RUN FAIL alarm)*

• Low suction pressure switch (PSL) trips the pump VSD (RUN FAIL alarm)*

* Pump suction and discharge pressure switches for this area are interlocks to each
pump VSD and are not monitored by the PLC.
Pump failures that occur while a pump is in PLC mode shall cause the PLC to set the STOP output for the
pump and designate the pump as OUT-OF-SERVICE, locking out the pump from restarting in PLC mode
until the permissives are restored and the operator selects PLC MANUAL or PLC-AUTO mode to resume
PLC control of the pump.

The minimum time between consecutive pump restarts, regardless of the condition that stopped the pump
(command or failure), is 15 minutes (adjustable by authorized users). The PLC shall inhibit any attempted
PLC-commanded restart until the restart timer expires. The PLC shall reset a pump’s restart timer for a
pump each time the pump stops. The timer value shall be accessible for change from the HMI, subject to
password authentication of an authorized user.

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PLC-MANUAL Control Mode

For any pump in PLC-MANUAL control mode, the operator shall be able to manually start and stop the
pump and adjust pump speed via control faceplates at the HMIs. Pump permissives associated with PLC-
MANUAL control must be satisfied.

PLC-AUTO Control Mode

Pump Roles

The Contractor’s PLC Supplier shall develop a scheme for PLC-AUTO operation based on PID setpoint
control of wet well level, with automatic pump selection based on operator-entered running order, or
dictated by accumulated running hours as described below. The PLC supplier shall utilize the District’s
standard HMI faceplates for selection and control of the schemes or develop new faceplates if needed to
fully implement the strategy.

For each of the three wet wells, whether operating interconnected or separated in any combination, there
shall be a LEAD, LAG and STANDBY pump for the PLC-AUTO mode of operation. The role for each
pump shall be selectable by an operator through the HMI workstations. The pump control scheme for
each wet well when the pumps are in PLC-AUTO mode is described in the table below:

PUMP ROLE PUMP ON PUMP OFF

LEAD Whenever pumping is required and All pumps for the wet well are taken out
sludge level in wet well is greater than of PLC-AUTO mode. (Pumps may be
L0 inches for at least T0 minutes taken out of PLC-AUTO mode by
operator or PLC)
or
See PLC-Auto Permissives section for When sludge level in wet well is less than
explanation of level (L_) and time (T_) limit
codes
the wet well’s soft Low Level Limit for at
least T0 minutes
LAG The LEAD pump is above 97% of The combined LEAD and LAG pump
maximum speed over a pre-set time of sludge flow rate is 97% of the LEAD
T1 minutes pump maximum flow (based on pump
or curve) or less over a pre-set time interval
of T3 minutes
The wet well level exceeds an adjustable
limit (L1) greater than setpoint for a time or
period of T2 minutes The LEAD pump and LAG pump are at
minimum speed and the wet well level is
L2 inches or more below setpoint over a
time period of T4 minutes
STANDBY STANDBY pump automatically assumes role of a failed LEAD or LAG pump

Note: The time delay and setpoint values in the table above shall be updated during
commissioning and shall be based on the design criteria or determined by the ENGINEER. The
delay and setpoint values shall be accessible for change via the HMI, subject to password
authentication of an authorized user.

Pump Alternation - To implement the control scheme described in the Automatic Level Control
subsection below, the PLC Supplier shall create all necessary DCU logic and operator interface features

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to designate the order of operation of the pumps. The LEAD-LAG-STANDBY pump selection criteria
described below shall apply to each of the groups of three pumps associated with each of the three wet
wells. Two options shall be available: fixed start sequence and elapsed-time based alternating.

• Under the fixed start sequence the LEAD, LAG and STANDBY pump designations assigned by
the operator shall determine the order of pump operation for each wet well.

• Under the elapsed-time strategy the PLC shall designate the order of pump operation based on
each pump’s total running time within the group of three pumps for each wet well.

Only pumps that are selected for PLC-AUTO mode and available for operation shall be included in either
scheme.

A. Fixed Start Sequence

The operator shall be prompted at the HMI to designate a role for each available pump as LEAD or
LAG pump, with the DCU designating the remaining pump as STANDBY if available. The pumps
shall be automatically operated in that order by the PLC, as needed, per the wet well level control
logic described in subsequent sections. The PLC shall inhibit selection and sequence assignment of
any pump that is not in PLC-AUTO mode, is designated OUT-OF-SERVICE, or is otherwise
unavailable due to alarms of any type.

B. Elapsed-Time Based Alternating

This alternating scheme shall be based on the recorded pump elapsed run time. The elapsed runtime
for each pump shall be tracked by the PLC. Initial elapsed runtime shall be set by the operator based
on the existing hardwired elapsed runtime meters or known use of the pumps prior to the
implementation of the PLC elapsed runtime monitoring. For each wet well, the PLC-AUTO available
pump with the least running hours shall be selected by the PLC as the LEAD pump, with the LAG
and STANDBY pumps assigned in order of increasing total running time and availability for PLC-
AUTO service.

Reassignment of Pump Roles for PLC-AUTO Level Control

• Reassignment of pump LEAD, LAG, and STANDBY roles shall take place without interruption to
the process.
• The PLC shall not allow reassignment of pump roles to occur between a pump that is currently
running and one that is not currently running.
Under Fixed Start Sequence:
o An operator shall be allowed to switch the roles of any two running pumps or any two
stopped pumps.
o To switch the role of a running pump with a non-running pump the operator must take
manual control of the two pumps, removing them from the PLC-AUTO scheme and
performing any needed speed changes and pump starts and stops to balance the system.
When the two pumps to be switched are either both running or both not running, the PLC
shall allow the operator to switch their roles.

Under Time-based Alternation:

o The PLC shall only automatically alter or swap the roles of pumps based on total elapsed
running time when the pumps are stopped. Changes shall only occur between pumps with a

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difference of greater than 24 hours of accumulated running time. Any automatic change in
roles shall generate an event message at the HMI and in the event log.

The PLC shall allow an authorized user to reset or correct the elapsed runtime for each pump from the
PLC in the event a pump or its motor is replaced or overhauled.

PLC-AUTO Level Control Strategy

This PLC-AUTO control strategy is intended to provide wet well level control for the three wet wells
individually or when interconnecting gates are opened to form one or two wet wells. Level control shall
be implemented using PID algorithms. All level control operating limits and PID controller process
variable feedback values shall originate from the three wet well level indicating transmitters.

The PLC shall have soft points, manually switchable by the operator, that represent the OPENED and
CLOSED positions of the two unmonitored interconnecting sluice gates between the wet wells (1-2 and
2-3). The manually-entered OPENED/CLOSED status shall be displayed as part of the workstation
display displays and will be used in the PLC-AUTO control logic in the DCU.

The PLC shall automatically configure PLC-AUTO level control for the three wet wells as follows based
on the operator-entered interconnecting gate positions:

• If the two sluice gates are OPENED so that the three wet wells are interconnected to form a single
wet well, the PID control shall obtain its feedback from the designated PRIMARY wet well level
sensor. (The PLC shall prompt the operator to select a PRIMARY sensor when needed.)

• If one gate is CLOSED, forming two effective wet wells, the PLC shall control the isolated wet
well’s level based on that wet well’s level sensor signal and shall control the two interconnected
wet wells based on the PRIMARY wet well level sensor signal.

• If both gates are CLOSED, forming three separate wet wells, the PLC shall control each wet
well’s level based on the individual level sensors.

• If any wet well sensor currently assigned as a PID loop feedback fails, is deactivated, is out of
range, or otherwise changes to bad signal quality, the PLC shall deactivate the wet well level
control algorithm and prompt the operator via the HMI to take action (possibly assigning an
alternate sensor as PRIMARY, leaving control in PLC-MANUAL mode, or taking local control
action as appropriate).

Automatic level control shall operate as follows:

• The PLC Supplier shall create an operator workstation faceplate that enables the PRIMARY wet
well selection. The operator may at any time change the selected PRIMARY wet well level
sensor, if wet wells are interconnected, to another valid level sensor. The PID controller shall
recognize the new sensor as the process feedback for the control loop of the interconnected wet
wells. All operating procedures listed in the above table shall apply to all LEAD, LAG and
STANDBY pumps for all wet wells.

• When the three wet wells are divided into two (two interconnected, one separate), the PLC shall
control the single, separate wet well using that wet well’s level sensor as a separate PID controller
process feedback, and the two connected wet wells using the PRIMARY level sensor as PID
controller feedback.

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• The PLC shall automatically start any pump designated as LEAD at minimum speed if not
running, when the level is sustained at greater than L0 (see above table), the LEAD pump START
setting for the wet well, for T0 minutes, and if all other permissives are met (see Permissives
below.)

• The PLC shall stop any running pump when the level falls below the Low Level Limit for that
pump for a preset time. Pumps designated as LEAD shall automatically restart as noted in the
preceding step when level rises.

• To avoid situations where multiple pumps start and stop simultaneously, settings for the start and
stop levels noted in the table in this section shall be offset between wet wells. Initially the L0,
L1, and L2 settings for pumps associated with Wet Well 1 shall be less than those associated with
Wet Well 2 by a small adjustable amount (initially 2% of sensor range), and a similar difference
shall also be implemented between Wet Well 2 and Wet Well 3 pumps. The PLC shall rotate the
offsets between wet wells periodically to help equalize pump usage.

Thickened Sludge Transfer Pump PLC-AUTO Mode Permissives

The following pump permissive conditions are required for PLC-AUTO start of a pump:

• Pump LOD mode selector switch on the LCP is set for PLC
• Soft OUT-OF-SERVICE/PLC-AUTO/PLC-MANUAL mode selector on HMI is set for
PLC-AUTO mode
• The wet well level is greater than the soft low level switch setting
• Pump VSD is not in FAIL alarm condition.

If all the permissives are met, the LEAD pump shall start when commanded by the DPU. The PLC shall
adjust LEAD pump speed, and shall start, stop and adjust the speed of the LAG pump as stated below to
maintain the level in the wet well at the operator entered setpoint.

The PLC shall adjust LEAD pump speed, and shall start, stop and adjust the speed of the LAG pump as
stated below to maintain the discharge header pressure at setpoint.

• Normal operation will consist of starting each LEAD pump at its preset pump START level (L0)
at minimum speed, when the wet well is in its normal operating range, indicating adequate
capacity of sludge to be pumped. As noted above, the L0 level will be slightly different for each
wet well to avoid simultaneous starts.

• As the wet well level increases, the speed of each running pump shall be increased to meet level
setpoint. When the LEAD pump for a wet well has been running above 97% of maximum speed
for an adjustable time delay of T1 minutes, or the wet well level is L1 inches or more above
setpoint for a period of T2 minutes, the LAG pump shall start at minimum speed, and the speed of
each running pump shall be decreased as the LAG pump speed is increased until the all pumps
are sharing the load with equal output from the PID controller.

• As the wet well level decreases the speed of the running pumps shall be decreased to maintain
setpoint. When the flow reaches 97% of the maximum flow of a LEAD pump for an adjustable
time delay of T3 minutes, or when both pumps are running at minimum speed for an adjustable
time delay of T4 minutes and level is at L2 inches or more below setpoint, the LAG pump shall
stop and the LEAD pump shall continue to operate.

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• If the sludge level in the wet well reaches the limit of the wet well Low Level Limit Switch, the
LEAD pumps shall stop and all sludge pumps shall be inhibited from starting. The pumps will be
ready for operation when the sludge level rises to the reset level of the Low Level Limit Switch.

• The STANDBY pumps shall automatically assume the role of any failed LEAD or LAG pump.

Initial high and low operating and alarm limits shall be based on the pump design and/or determined
by the ENGINEER. Operating limits shall be updated by the PLC Supplier during commissioning as
recommended by the ENGINEER after observation of the operation of the new pumps. All limits,
timer and setpoint values shall be accessible for change via the HMI, subject to password
authentication of an authorized user.

Control Location
The control logic for this process shall reside in processors PLC-C22A, PLC-C22B, PLC-C22C and PLC-
C22D, which are located in the electrical room adjacent to the Solids Area Control Room in panels ICP-
S1 and ICP-S2.

Control Displays
All control displays shall be available locally at the Pre-Digestion/Central Heat HMI workstations. Each
HMI screen shall contain targets to other relevant displays created for the Thickened Sludge Transfer
Pumping. The HMI displays at workstations in the Central Heat Control Room shall also contain targets
to relevant main Central Control Center displays.

At least three main displays shall be developed for this site as described below. Auxiliary pop-up
displays, to serve as faceplates, data entry windows etc. shall be developed as required.

Thickened Sludge Transfer Pumping Main Screen

This main screen shall look similar to a combination of drawings IC-51-23, IC-51-24, & IC-51-25 and
contain the following objects:

• The statuses of the Wet Wells as IN-SERVICE or OUT-OF-SERVICE

• Dynamic pump symbols and discharge pipes that change colors when flow is detected, with
associated process variable values indicated where measured (Pressure. Level and Flow)

• Pumped sludge flow rate and totalized flow, and sludge line pressures

• For each wet well, Wet Well level indicator with the following alarm conditions and additional
information:

 Level high
 Average, highest and lowest level for the last 24 hours
 Average, highest and lowest level for the last 1 month
 Trend window showing the level for the last 60 minutes in graphic format.

• One OUT-OF-SERVICE/PLC-MANUAL/PLC-AUTO selector switch per sludge pump, with switch

position indication. The operator shall be able to select any of the three operating modes. In the PLC
AUTO mode, the PLC shall control the pump based on the control logic described above. In the PLC
MANUAL mode, the Operator shall be able to operate a pump if no restrictions apply and the level in

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the wet well is higher than 1.0’ above the soft Low Level Limit (this level limit shall be available for
change by an authorized user with password authentication).

Pump Detail Displays

• The following information shall be displayed for each sludge pump as a minimum:

 Pump control mode (LOCAL, PLC-MANUAL, PLC-AUTO, OUT-OF-SERVICE)

 Pump READY/NOT READY
 Pump status (RUNNING, STOPPED)
 Pump Speed (RPM and Percent)
 Alarms statuses
 Pump Role indication (LEAD, LAG, or STANDBY)
 ELAPSED PUMP RUNTIME in hours and tenths of an hour
 Number of operations (starts) for the last 24 hours, for the last 1 month and for the last 6 months

• Target to a level control setpoint and alarm level entry window. The window shall contain a list of all
current setpoints, alarm levels and adjustable time delay and control limits and their settings. If the
operator has the appropriate level of access, the values shall be available for change.

• A faceplate for manual pump control shall be available for the operator when the pump is in PLC
MANUAL mode. If the faceplate is in use by one of the PLC displays, the control of the pump from
all other HMI workstations shall be inhibited. The faceplate shall contain the following controls as a
minimum: one START pushbutton; one STOP pushbutton; one OUT-OF-SERVICE/PLC-
MANUAL/PLC-AUTO selector, PUMP SPEED INCREASE pushbutton, PUMP SPEED
DECREASE pushbutton, PUMP SPEED OUTPUT window (desired pump speed shall be accepted as
a direct input in the window) PUMP RUNNING status; PUMP SPEED indication, Pump Alarms
Statuses; and all hard and soft selector switch positions.

Alarms
Provide alarms of the same type and function as those implemented in the existing PLC, and as described
herein. Alarms shall be initiated through the PLC for the following conditions for each Thickened
Sludge Transfer Pump:

• PUMP FAIL
• FAIL TO START
• FAIL TO STOP
• RUN FAIL
• VSD FAIL
• VSD BYPASS
In addition these alarms are required for each wet well:
• HIGH WET WELL LEVEL
• LOW WET WELL LEVEL

Reporting
Daily, monthly and yearly reports for this process area shall be prepared, as described in section 40-xx-xx
of the specifications.

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The reports shall include:

• Information for each pump:

 Total elapsed runtime
 Elapsed runtime for the last running period
 Number of operations for the last 24 hours
 Number of operations for the last 1 month
 Pump status
 Pump alarm status
• Information for wet well levels:
 Wet well role (PRIMARY, IN-SERVICE/OUT-OF SERVICE)
 Current levels
 Average, highest and lowest levels for the last 24 hours
 Average, highest and lowest levels for the last 1 month
• Pumped sludge flow rate (maximum, minimum and average) for the reporting period
• Totalized hourly and daily pumped volume (daily reports)
• Totalized daily and monthly pumped volume (monthly reports)
• Totalized monthly and annual pumped volume (yearly reports)
• Pumped sludge pressures (minimum, maximum and average) for the main and bypass discharge lines
for the reporting period
• Station Alarms and Events (Daily reports - Last 24 Hour period)
*** END OF NARRATIVE ***

End of Appendix A
B. APPENDIX B Glossary of Process Control Abbreviations and Acronyms
Item Description
AC Alternating Current
ALM Alarm
AMP Amperes - Unit of measure of electrical current
ANSI American National Standards Institute
AOI Add-on Instruction
AUTO Automatic (Control Mode)
AVG Average
BKW Backwash
BLDG Building
BTL Base Template Library
BYP Bypass
CAD Computer-Aided Drafting

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Item Description
CFG Configuration
CLSD Closed
CMD Command
CMMS Computerized Maintenance Management System (see WAM)
COAX Coaxial Cable
COMP Compute/Computer/Compensate
CONC Concentration
COTS Common off-the-shelf (as applies to commercial application software)
DC Direct Current
DCS Distributed Control System
DDC Direct Digital Control
DP Differential Pressure
EMI Electromagnetic Interference
EMP Electromagnetic Pulse
ER/ES Electronic Record/Electronic Signature
ESD Electrostatic Discharge
EU Engineering Units
FAT Factory Acceptance Test
FDBK Feedback
FLT Fault, Failure
FLW Flow (or Flow Rate)
FPT Functional Performance Testing
FWD Forward
GHz Gigahertz = Billion Cycles per Second (See Hertz)
GIS Geographical Information System
GND Ground
GPM Gallons per Minute
GUI Graphical User Interface
H, HI or HIGH High Alarm Limit or Condition (Warning)
HH or HI-HI High-High Alarm Limit or Condition (Critically High)
HMI Human Machine Interface
HVAC Heating, Ventilation and Air Conditioning
Hz Hertz – Unit of measure representing frequency in cycles per second
I/O Input/Output
I/P Current to Pneumatic Signal Converter
ID Identification or an item used to verify one’s identity (e.g. user name)
IDE Integrated Development Environment
IEEE Institute of Electrical and Electronics Engineers
ILK Interlock
INST Instrument, Instantaneous
InSQL IndustrialSQL Server (Wonderware Historian)
IP Internet Protocol

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Item Description
ISA International Society for Automation
IT Information Technology
Kbps Kilobits per Second - Communication rate - Thousand bits per second
KV Kilovolts
kVA Kilovolt-amps
KW Kilowatts
Khz Kilohertz = Thousand Cycles per Second (See Hertz)
L, LO or LOW Low Alarm Limit or Condition (Warning)
LAN Local Area Network
LED Light Emitting Diode
LL or LO-LO Lo-Lo Alarm Limit or Condition (Critically Low)
LOC Local (Control Mode)
LVL Level
LWR Lower
M/C Multi-conductor
M/E Mechanical/Electrical
MAINT Maintenance
MAN Manual
MAX Maximum
MB Modbus
MBP or MB+ ModbusPlus
Mbps Megabits (Million bits) per second
MCC Motor Control Center
MCS Monitoring and Control System
MDT Mean Down Time
MHO Unit of Measure of Conductivity (electrical)
MIN Minimum
MTBF Mean Time Between Failures
MTBM Mean Time Between Maintenance
MTTM Mean Time to Maintain
MTTR Mean Time to Repair
MW Megawatts
NEC National Electrical Code (NFPA 70)
NEG Negative
NEMA National Electrical Manufacturer’s Association
NFPA National Fire Protection Association
NIST National Institute of Standards and Technology
O&M Operation and Maintenance
OIT Operator Interface Terminal
OOS Out of Service
OPER Operator
OPND Opened

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Item Description
OS Operating System
P Proportional (Used in control output algorithm)
P Pressure
P&ID Process and Instrumentation Diagram or Drawing
PAC Process Automation Controller
PB Pushbutton
PC Personal Computer
PCN Process Control Narrative
pH Chemical Acid-Base unit of measure based on hydrogen ion concentration
Ph Phase
PI Proportional – Integral (Type of control output algorithm)
PID Proportional-Integral-Derivative (Type of control output algorithm)
PLC Programmable Logic Controller
PM Preventive Maintenance
POS Position, Positive
PREP Power Reliability Enhancement Program
PSI Pressure in Pounds per Square Inch
PSIA Pressure in PSI as measured on an absolute scale
PSIG Pressure in PSI above standard atmospheric pressure or another reference
(as measured by gauge)
PSID Unit of Differential Pressure in Pounds per Square Inch
RBD Reliability Block Diagram
RCM Reliability Centered Maintenance
REM Remote (Control Mode)
REV Reverse
RF Radio Frequency
RFI Radio Frequency Interference
RGB Red Green Blue
ROC Rate of Change
RMS Root Mean Square
RPM Revolutions per Minute
RSDL Residual
RT Runtime
RTD Resistance Temperature Detector or Device
RTU Remote Terminal Unit
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition
SEC Seconds – Unit of Time
SHLD Shield
SIL Safety Integrity Level
SME Society of Manufacturing Engineers
SOP Standard Operating Procedure

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Item Description
SPD Speed
SQL Structured Query Language
STP Shielded Twisted Pair
SP Setpoint
THD Total Harmonic Distortion
TMP Temperature
TMPD Differential Temperature
TRB Turbidity
TRQ Torque
TVSS Transient Voltage Surge Suppression
UDA User-defined Attribute
UDF User-defined Function
UDT User-defined Data Type
UPR Upper
UPS Uninterruptible Power Supply
UTC Coordinated Universal Time – World Time Standard Reference
UTP Unshielded Twisted Pair
VAC Volts Alternating Current
VDC Volts Direct Current
VFD Variable Frequency Drive
VIB Vibration
VPC Volts per Cell
WAM Oracle’s Work and Asset Management Application Software
WAN Wide Area Network

END OF APPENDIX B

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