Control Philos

THESE DOCUMENTS/ DRAWINGS ARE "CONFIDENTIAL INFORMATION" RELATING TO DAMOH MULTI VILLAGE RURAL WATER SUPPLY SCHEME (28
MLD WTP), MP. THESE SHALL BE

USED TO THE EXTENT NECESSARY FOR THIS PROJECT AND SHALL NOT BE USED OR DISCLOSED FOR ANY OTHER PURPOSE WITHOUT THE CONSENT OF L&T `
CLIENT
MADHYA PRADESH JAL NIGAM MARYADIT
PROJECT
BYARMA (JABERA - TENDUKHEDA) MULTI VILLAGE RURAL
WATER SUPPLY SCHEME, DISTRICT DAMOH
(28 MLD WTP), MP
L & T CONSTRUCTION
WATER & EFFLUENT TREATMENT IC
MOUNT POONAMALLE ROAD,
MANAPAKKAM, CHENNAI – 600089
PROJECT: DOCUMENT TITLE: DATE:

19.02.2020
BYARMA (JABERA - TENDUKHEDA) OPERATION & CONTROL PHILOSOPHY
L&T Construction MULTI VILLAGE RURAL WATER
Water & Effluent Treatment IC. SUPPLY SCHEME, DISTRICT
DAMOH (28 MLD WTP), MP DOC. NO: LE181250-I-WS-CW-OC-5005 REV: A
Sensitivity: LNT Construction Internal Use
Page 1 of 52
THESE DOCUMENTS/ DRAWINGS ARE "CONFIDENTIAL INFORMATION" RELATING TO DAMOH MULTI VILLAGE RURAL WATER SUPPLY SCHEME (28 MLD WTP), MP. THESE SHALL BE
`
OPERATION & CONTROL PHILOSOPHY
USED TO THE EXTENT NECESSARY FOR THIS PROJECT AND SHALL NOT BE USED OR DISCLOSED FOR ANY OTHER PURPOSE WITHOUT THE CONSENT OF L&T
FOR THE FOLLOWING SYSTEMS
1. RAW WATER PUMPING STATION
2. WATER TREATMENT PLANT (28 MLD)
3. CLEAR WATER PUMPING STATION
4. MASTER BALANCING RESERVOIRS (04 Nos.)
5. INTERMEDIATE BOOSTER PUMPING STATION (03 Nos.)
6. OVERHEAD SERVICE RESERVOIRS (80 Nos.)
7. VILLAGE TRANSFER CHAMBERS (231 Nos.)

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INDEX
S.NO DESCRIPTION PAGE NO
1 INTRODUCTION 04
2 PROJECT FLOW DIAGRAM 07
3 LAYOUT OVERVIEW 07
4 SCOPE OF WORK 08
5 FIELD INSTRUMENTS 14
6 DETAILS OF PLC & SCADA 18
7 OPERATION AND CONTROL PHILOSOPHY 21
8 MODE OF OPERATION AND INTERFACING SIGNALS 46
9 PLC - CONTROL AND OPERATIONS 49

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1. INTRODUCTION
This document describes the general control philosophy on Pumping stations,
Water treatment plant & Distribution system of the Multi village rural water supply
Scheme for 231 villages with necessary process inter-locking & Automation for the entire
system of 28 MLD treated water from Satdharu dam near Harduwa village, comprising
integration of Civil, Mechanical, electrical & Instrumentation.
A water treatment plant with output capacity of 28 MLD is proposed to be
constructed and will be automated with PLC/SCADA system.
All the pumping station shall be monitored and controlled from respective WTP/
Pumping station of ICA panel using computer terminal/SCADA which displays the current
status of the plant including key process parameters, various steps of the operation, and
various alarms in the plant.
The ICA panel provided at the WTP & each pumping station shall acquire field
instruments data, process data, drive & motor operated valve status from field and MCC
breakers. The SCADA station displays the current status of the plant including key process
parameters, various steps of the operation, and various alarms, trends to implement the
control philosophy of the plant.
This is achieved using combination of Programmable Logic Controller (PLC),
SCADA (Supervisory control and data acquisition system) software, field instruments,
actuators, drives, switches which are electrically interfaced with each other.
This document specifies the norms for integrating all elements and important steps
to be taken while developing program/coding for PLC and SCADA.
ACRONYMS
• ICA - Instrumentation control and Automation panel
• PLC - Programmable logic controller
• SCADA - Supervisory Control and Data Acquisition system
• MCC – Motor Control center

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• DI - Digital Input
• DO - Digital Output
• AI - Analog Input
• AO - Analog Output
• UPS - Uninterruptable Power Supply unit
• DPM - Digital panel meter
• NTU – Turbidity Analyzer
• RCL – Residual Chlorine Analyzer
• FIQ - Flow indicator cum totalizer
• CPG – Compound pressure gauge
• PG – Pressure gauge
• PT- Pressure transmitter
• PS – Pressure Switch
• EFM – Electromagnetic flow meter
• UFM – Ultrasonic Flow meter
• ULT – Ultrasonic level transmitter
• MBFV- Motorized butterfly valve
• MSV – Motorized sluice valve
• LIT – Level Indicating Transmitter
• LS – Level Switch
• LI – Level indicator

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REFERENCE DOCUMENTS
Instrument List for Intake well cum Raw water Pumping

LE181250-I-WS-RW-IL-5006
system
PLC IO List for Intake well cum Raw water Pumping

LE181250-I-WS-RW-IO-5011
system
Instrument List for Water Treatment Plant LE181250-I-WS-WT-IL-5007
PLC IO List for Water Treatment Plant LE180730-I-WS-WT-IO-5012
Instrument List for Clear water Reservoir cum Pump

LE181250-I-WS-CW-IL-5020
House at WTP
PLC IO List for Clear water Reservoir cum Pump House at

LE181250-I-WS-CW-IO-5021
WTP
Instrument List for Over head Service Reservoirs LE181250-I-WS-CW-IL-5009
RTU IO List for Over head Service Reservoirs LE181250-I-WS-CW-IO-5014
LE181250-P-WS-WT-PI-2006
LE181250-P-WS-WT-PI-2007
Piping & Instrumentation diagram for WTP LE181250-P-WS-WT-PI-2008
LE181250-P-WS-WT-PI-2009
LE181250-P-WS-WT-PI-2010
Control & Interlock Details for WTP System LE181250-I-WS-WT-ID-5001
Automation System Architecture LE181250-I-WS-WT-SA-5002

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2. PROJECT FLOW DIAGRAM
3. LAYOUT OVERVIEW
Main PLC at Admin Building
Filter Consoles for

Filter Bed 01 to 10
CWPH PLC RIO
Intake PLC

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4. SCOPE OF WORK
The scope of this project includes Instrumentation, control and SCADA works at the
following pumping locations.
1. Intake cum Raw water pumping station (RWPS)
2. Water Treatment Plant – 28 MLD (WTP)
3. Clear water pumping station (CWPS)
4. Intermediate Booster Pumping stations-1, 2, 3 (IBPS)
5. Master Balancing Reservoirs – 1, 2, 3 & 4 (MBR)
6. Over Head Service Reservoirs – 80 Nos (OHSR)
7. Village Transfer Chambers (VTC)
4.1 Intake cum Raw water pumping station
The raw water will be supplied from river Byarma, by the submergence of raw
water Intake pumps & through MS pipes where 04 Nos. of Vertical Turbine (VT) pump (2W
+ 2S) will be provided in the Intake well for Conveying approx. 37 MLD of Raw water to
Water Treatment Plant (WTP) with the length of 0.2 Kms.
Raw water Pumping station is Monitored & controlled by the respective RWPH
PLC by acquiring the data from filed instruments, Motor operated valves & MCC breakers.
The SCADA station displays the current status of the plant including all the key
parameters, operations & alarm signals.
4.2 Water Treatment Plant
The Water treatment plant (WTP) shall be hydraulically designed for continuous
operation to produce net output of 28 MLD in 23 hours with 20% overloading operation of
treated water to specified quality standard. The required water treatment plant broadly
consists of Cascade aerator, Parshall flume, Flash mixer, Clariflocculator, Rapid gravity
sand filters, Pre & Post chlorination system, Chemical dosing system and sludge handling
systems.

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The Hydraulics of the treatment plant is designed in such a way that water flows by
gravity from the Cascade aerator to the pure water sump and the sludge generated from
the Clariflocculators flows by gravity to the Sludge drying beds.
Broadly, the flow scheme comprises the following process units:
a. Cascade Aerator (Including Launder)
b. Inlet Chamber
c. Raw water Channel & Parshall Flume
d. Flash Mixers
e. Clariflocculator & Sludge Valve pits
f. Clariflocculator bypass channel & Filter bypass arrangement
g. Clarified water channels
h. Rapid Gravity sand filters (6 No’s)
i. Backwash water overhead tank (on top of filter house)
j. Filtered water channel
k. Air Blowers & Air Compressors
l. Backwash Pumps
m. Clear water reservoir & Pump house
n. Sludge drying beds & Inspection chambers
o. Chemical House
p. Alum & Lime dosing pumps
q. Sludge sump
r. Wash water recovery sump
s. SDB Filtrate transfer pumps
t. Settled sludge transfer pumps
u. Backwash recycle pumps
v. Sludge transfer pumps
w. Filter Annexure Building
x. Chlorination Building
y. Administration Building

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4.3 Clear Water pumping station
The clear water from the Clear water pump house is supplied to 3No’s of IBPS & 04
Nos. of Master Balancing Reservoirs (MBR-01, 02, 03 & 4) and Overhead Service Reservoirs
(OHSR) before distributing to the Villages. The Clear water pump house is located inside
the WTP area. The treated water from the WTP is stored in a reservoir with two
compartments having capacity of 1228 KL for certain period of time. It is then pumped
through MS pipes by 04 Nos. of Horizontal Split case (HSC) (2W+2S) in the clear water
pump house to 3No’s of IBPS & MBR 01, 02, 03 & 04 and 80 Nos. of OHSR’s.
Clear water Pumping station is Monitored & controlled by the Main WTP PLC by
acquiring the data from CWPH PLC RIO which collects dasta from CWPH field
instruments, Motor operated valves & MCC breakers. The SCADA station located at WTP
displays the current status of the plant including all the key parameters, operations & alarm
signals.
4.4 Intermediate Booster Pumping stations & Master Balancing Reservoirs (MBR – 01, 02,
03 & 04)
The clear water from Clear water Reservoir & Pump house at WTP is pumped to
3No’s of IBPS & 04 Nos. of Master Balancing Reservoirs & from there it is distributed to 80
Nos. of Overhead Service Reservoirs as given in the table below.
PUMPING TO
MBR LOCATION
(NO. OF OHSR’s)
MBR 1 RAJAPATEN 8 Nos.
MBR 2 TIPNI 45 Nos.
MBR 3 SALIWADAMBAL 9 Nos.
MBR 4 BAISAGHAT 18 Nos.
Intermediate Booster Pumping station is provided with PLC Panel & Master
Balancing Reservoirs (MBR) are Monitored & controlled by the respective MBR PLC RTU
with 7” HMI by acquiring the data from filed instruments & Motor operated valves. The
data from the MBR PLC RTU is communicated to the Main WTP PLC through GSM/GPRS

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communication. The SCADA station displays the current status of the Reservoir including
all the key parameters, operations & alarm signals.
4.5 Over Head Service Reservoirs (80 Nos.)
Clear water From the OHT’s are distributed to the Village transfer chambers (VTC)
by gravity.
Overhead tank signals are Monitored & controlled by the respective RTU by
acquiring the data from the field instruments & Motor operated valves. The data from the
RTU is communicated to the Main WTP PLC through GSM/GPRS communication. The
SCADA station located at WTP displays the current status of the OHT including all the key
parameters, operations & alarm signals.
The scope of work also includes providing power backup in the form of battery at OHT for
operating the flow meters uninterruptedly and for providing illumination in the campus.
4.6 Village Transfer Chambers: (231 Nos.)
The Water Distribution comprises of (VTC’s) and these VTC’s will supply water
from OHT’s to the House Service Connections by Gravity. Each VTC’s comprise of a
Woltmann type Flow Meter to measure the clear water distributed to each of the villages.
The major components in the Pumping station & Reservoirs are as listed below:
1. PLC with standalone processors cum Instrument control & automation Panel (ICA) &
SCADA station with all required accessories at Intake well cum Pump house and Water
Treatment Plant
2. Remote terminal unit (RTU) for automation process at remote location & communicate
the data to main PLC.
3. Standalone UPS system with 1 Hour battery backup.
4. Full Bore Electromagnetic Flowmeters along with indicators and totalizers.
5. Ultrasonic level meter with sensors and transmitters.
6. Float & board level Indicator for the local indication of level.

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7. Compound Pressure gauges & Pressure Gauges for the local Indications of Pressure
measurements.
8. Pressure measurements for remote monitoring with sensors, transmitters & switches.
9. Residual chlorine & Turbidity analyzers with sensors, transmitters for continuously
monitoring the characteristics of clear water.
10. Raw water & Clear water pumps feedbacks & commands from MCC for Pump
operations.
11. Motor operated valves feedback & commands for the valve operations.
12. Woltmann Flow meter
13. Instrumentation multi-core control cables & multi-pair signal cables.
14. All necessary glands & lugs for cable termination.
15. Required perforated cable trays, and accessories.
16. Hook-up materials for installation of field instruments.
17. GPRS trans-receiver modem for remote communication with WTP main control room
located at the administration building.
The major Field instruments located in the WTP process plant are interfaced with PLC for
monitoring and control process.
1. The raw water Inlet channel is installed with 01 no. pH meter and 01 no. Turbidity
meter (NTU), for continuous monitoring of inlet characteristics of raw water for local
and remote indication.
2. One no. Ultrasonic type flow transmitter is provided in the upstream of the Parshall
flume to measure the flow rate & for field and remote indication.
3. The clarified water channel is installed with 01 no. Residual chlorine analyzer (RCL)
meter for continuously monitoring the characteristics of clear water for local and
remote indication & generate alarm.
4. Each of the filter beds are provided with the Rate of flow Transmitter (ROFT) for
measuring the instantaneous rate of filtered water flow for local and remote indication.

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5. Each of the filter beds are provided with DP type Loss of Head Transmitter (LOHT) to
identify the clogging of filter bed and indication to start back wash for local and remote
indication.
6. Bourdon type Pressure gauges at delivery side of the each pump (Backwash pumps/air
blowers/ Air compressors) for local indication.
7. Diaphragm type Pressure switch is provided with the low pressure set point at the
Common discharge header of backwash pumps and Air blower to trip the pump on
low pressure & for local and remote indication.
8. Diaphragm type Pressure Transmitter is provided at the Common discharge header of
Air Compressors for field and remote indication.
9. Rotameter type flow meter will be provided at the Air blower discharge header for
online local indication.
10. One no. Ultrasonic type level transmitter is provided in Backwash overhead tank for
field and remote indication.
11. In the Back wash over head tank, 01 no. Float & Board level Indicator will be provided
for local indication
12. Full bore Electro-Magnetic flow meter with transmitter and Digital flow Indicator
& flow Integrator is provided in the outlet of back wash pipe line for field and remote
indication.
13. Diaphragm type pressure gauge at delivery side of each pump (sludge transfer
pumps/sludge delivery beds/Supernatant recycle pumps/filter backwash sludge
transfer pumps/ lime dosing pumps/ alum dosing pumps) for local indication.
14. One no. Conductivity type Level switch with LOW level set-point is provided in each of
the Wash water collection Sump, Sludge sump, Sludge drying bed, Filter water outlet
channel and Dosing tanks is to trip the pumps & for local and remote indication.
15. The filtered water outlet channel is installed with 01 no. pH meter, 01 no. Turbidity
meter, for continuous monitoring of Filter water for local and remote indication.
16. Full bore Electro-Magnetic flow meter with transmitter and Digital flow Indicator &
flow Integrator is provided in the common discharge header of Alum & Lime dosing
pumps for field and remote indication.

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5. FIELD INSTRUMENTS
5.1 LEVEL MEASUREMENT SYSTEM
Ultrasonic type Level Transmitter:
Ultrasonic type level transmitter will be provided for measurement of proportional
level of water. Ultrasonic level sensors work by the "time of flight" principle using the
speed of sound. The sensor emits a high-frequency pulse, generally in the 20 kHz to 200
kHz range, and then listens for the echo. The pulse is transmitted in a cone, usually about
6° at the apex. The time period between transmission and reception of the pulses is directly
proportional to the distance between the transducer and surface & measures the ‘Level’ in
the unit of Meters.
Float & Board Level Indicator:
Float & Board level indicator consists of a float connected to a pointer through a rope
via a set of pulleys. The pointer with nylon roller guides smoothly over a calibrated gauge
board, positioned parallel to the tank. The float accurately follows liquid level variations in
vertical direction. The horizontal float movement is restricted by two guide wires firmly
anchored to tank bottom. As such, the pointer is in `TOP POSITION' when tank is `EMPTY'
and in `BOTTOM POSITION' when `FULL'. Pointer indicates 'Level' in the unit of Meters.
Conductive type Level switch
The ability of a liquid to conduct electricity is a function of the number of charged
ions in that solution. De-ionized pure water has very high resistance, but liquids such as
sewage water, sea water and city water are quite conductive. If an electric circuit is closed
by the substance surrounding the tip of the probe, the resulting current flow will be much
higher when the probe is submerged in the water. The sensitivity of the switch is adjusted
to match the conductivity of the process liquid. Set point for the Switch is set in the units of
Meters.
Loss of Head transmitter:

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The capacitance formed by the sensing probe and the water is measured which is
directly proportional to the level of water known as head. By measuring heads at two
points called the high head and the low head, a difference can be calculated. This difference
is loss of head. Level in measured in the units of Meters.
5.2 PRESSURE MEASUREMENT SYSTEM
Bourdon type Pressure Gauges:
Glycerin filled dial & Bourdon-tube type Pressure gauge with the dial size of
150mm will be provided at discharge of each pump for local indication of pump discharge
pressure in the unit of Kg/Cm².
Diaphragm type Pressure Transmitter:
Diaphragm type Pressure transmitter with integral LCD display is provided on the
discharge line of each pumps for Remote Pressure measurement. The transmitter will
provide 4-20mA DC output proportional to the pressure. These pressure transmitter signals
will be used to generate high pressure alarms & display on SCADA screen as well as DPM
provided on ICA panel. Where the Pressure is measured in the unit of Kg/Cm².
5.3 FLOW MEASUREMENT SYSTEM
Electromagnetic Flow meter:
The Electromagnetic flow meter works on Faraday’s law of electro-magnetic
induction principle. The flow meter consists of a flow tube and a flow transmitter. The flow
tube has coils for magnetic field generation and electrodes for pickup of the induced EMF
wired up the junction box on the flow tube. The flow tube will be provided with IP-68
protection. The flow transmitter is a microprocessor based unit which generates the
required voltage for magnetic field coils, amplifies the induced EMF and provides 4-20mA
dc output proportional to the flow. The flow transmitter has integral digital display for
local indication of the current flow rate as well as totalized flow. The transmitter will be
suitable for working on 230VAC 50 Hz and the 4-20mA dc output will be wired to the PLC
system. Where the Flow is measured in the units of M³/hr.

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Ultrasonic flow Transmitter/ Rate of Flow Transmitter:
A pair of ultrasonic transceivers are placed diagonally parallel to the fluid pipe. Both
the transceivers will transmit and receive the signal at the same time. The signal travelling
in the direction of the flow will take less time to travel and the signal travelling against the
direction of travel will take more time to travel. So based on this time difference between
the two signals, flow rate can be calculated. Where the Flow is measured in the units of
M³/hr.
Online type Rotameter
Differential pressure is created in the main Flow by providing an Orifice plate in the
main pipeline. Because of this pressure, a branch of flow moves through By-Pass line
provided across the orifice plate from upstream side to downstream side of the Orifice
Plate. Additional Range Orifice plate is provided in the By-Pass line which is designed such
that flow through range Orifice plate flows in proportion with the flow through main
orifice plate. Hence by measuring the flow from By Pass line we can estimate the flow from
Main Pipe line. Where the Flow is measured in the units of M³/hr.
Woltman type Flow meter:
The Woltman flow meter works on Mechanical principle. Woltman meters measure
the velocity of the water flowing through the meter with the help of a turbine. The volume
is mechanically calculated, through the known section area and indicated with the roller
counters in cubic meters. The unique form of the “paddle wheels” enables the Woltman
meters to cover a very large measuring range with especially low head loss. The flow is
measured in the units of M³/hr.
5.4 ANALYZER SYSTEM
Residual chlorine Analyzer:
The concentration of free chlorine is determined according to the amperometric
measuring principle. The hypochlorous acid (HOCl) contained in the medium diffuses
through the sensor membrane and is reduced to chloride ions (Cl-) on the gold cathode. On
the silver anode, silver is oxidized to silver chloride. The electron release of the gold

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cathode and electron acceptance on the silver anode result in a current flow which is
proportional to the free chlorine concentration in the medium under constant conditions.
The concentration of hypochlorous acid in the medium depends on the pH value. This
dependence can be compensated by measuring the pH value in the flow assembly. The
transmitter transforms the current signal into the measuring unit of Mg/l.
Turbidity Analyzer:
The Nephlometeric turbidity meter measures turbidity by directing a strong beam
of collimated light from the sensor head assembly down into the sample in the turbid meter
body. Light scattered at 90° relative to the center line of incident light by suspended
particles in the sample is detected by the submerged photocell. The amount of light
scattered is proportional to the turbidity of the sample. If the turbidity of the sample is
negligible, little light will be scattered and detected by the photocell and the turbidity
reading will be low. High turbidity, on the other hand, will cause a high level of light
scattering and result in a high reading. This is measured in the unit of NTU.
pH Analyzer:
It is a scientific instrument that measures the hydrogen-ion activity in water based
solutions, indicating its acidity or alkalinity expressed as pH. The pH meter measures the
difference in the potential between a pH electrode and a reference electrode, so the pH
meter is sometimes referred to as a potentiometric pH meter.
On immersion in the solution to be tested, hydrogen ions in the test solution
exchange for other positively charged ions on the glass bulb, creating an electrochemical
potential across the bulb. The electronic amplifier detects the difference in electrical
potential between the two electrodes generated and converts the potential difference to pH
units.

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6. DETAILS OF PLC & SCADA
6.1 PROGRAMMABLE LOGIC CONTROLLER (PLC):
PLC is used to perform following basic operations
➢ Acquiring Feedback & Providing commands to various drives, actuators on the
predefined sequence of operation, fulfilment of safety interlocks to optimize the
operation.
➢ Read the values of different process parameters from field instruments, Multi-
function meters etc. installed in the plant.
➢ Communicate with PC based SCADA software to achieve functionality of HMI, Data
Storage and Reporting.
➢ The PLC capacity is defined in terms of capacity to handle number of Digital Inputs,
Digital Outputs, Analog Inputs, Analog Outputs, Communication ports and
protocol, Memory capacity and processing speed.
➢ For appropriate operation of the system, norms are defined considering various
devices to be connected to PLC.
➢ PLC input output considerations for drives, field instruments shall be as per P&ID.
6.2 SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA):
The WTP & pumping station SCADA System shall consist of industrial grade PC
server cum operator station and SCADA software package. The SCADA system shall be
interfaced with the PLC control system for the data acquisition and control of the entire
plant. The SCADA System shall be provided with Microsoft Windows based SCADA
software. The software shall be of dual- redundant configuration and installed at the
administration building.
The SCADA System has the following facilities:

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SCADA diagram with animation to show the status of equipment and process of the
respective section.
➢ System allows operator to issue commands to change system parameters, start &
stop equipment, provide configuration tools and operate diagnostic facilities from
Operator Work stations (OWS) after successful log-on by security password.
➢ Facility to Pop –up alarms as they occur in the pumping station.
➢ Facility to accept and reset the alarms.
➢ Facility to display & print Alarm history with real time stamp.
➢ Facility to display and print trends for key process parameters like, Level, Flow,
pressure data with real time stamp.
➢ Facility to display and print periodic process reports, operating time of all key
equipment.
➢ The work station will store all the data which will be retrieved by operation
terminals for purpose of display of reports and trends.
Thus the complete automation system is defined with following parameters:
1) Display of Status of the pumping station and operation of pumping station from
SCADA screen.
2) Display and processing of alarms & reports.
3) Sequential operation or logic of operation of the pumping station.
6.3 LOG IN AND SECURITY
The system has 3 levels of password facility for operation of the pumping station.
Unless logged in the system will not respond to any operation.
Following is the description of levels of protection.
Level 1: Operator Level which enables operator to operate any device in Auto or manual
Mode or check and print the trends, reports.

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Level 2: Supervisor level, which allows supervisor to change the process parameters and set
points within specified limits.
Level 3: Designer Level, which allows the commissioning engineer to change equipment
related variables, which should not be changed once the plant is put in to operation.
6.4 DISPLAY STATUS OF PLANT AND OPERATION OF PLANT FROM SCREEN
The SCADA screen will display the status of the plant as per the P&I Diagram with same
method of tagging the equipment.
The colour code for this display is based on standard prevailing practice.
6.5 PROCESS PARAMETERS
The process parameters are indicated in the SCADA screen will have the tag
number and the actual values with appropriate units. Since all the equipment’s / parts may
not be accommodated in one screen, the plant or section of plant can be divided in to sub
screen and navigation keys to switch the screen are provided on each screen.
6.7 BUTTONS AND DATA ENTRY
For operation of any equipment, soft button is provided on each equipment in
transparent mode at SCADA screen. So that a pop window is generated for operation or
data entry once operator clicks the mouse on the equipment.
6.8 ALARMS
All incoming and PLC internal generated alarms must immediately be indicated at
the SCADA. This should help operators to overcome critical situations of any equipment or
of the plant.
6.9 REPORTING
Daily process report generated by SCADA will be available in the work station. On
the same line weekly monthly reports are generated & the alarm Report is generated for
any pre‐defined interval.

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7. OPERATION AND CONTROL PHILOSOPHY
7.1 INTAKE WELL CUM RAW WATER PUMP HOUSE
LT
PLC
INTAKE
WELL
PT PT PT PT
EFM
1. One No. of Radar type level indicating transmitter is considered for continuous
reservoir level measurement, which is interlock to trip the pump & to enable alarm,
when the reservoir level is LOW.
2. One No. of Pressure gauge with the line size of 400 mm on discharge side of each of
the two pumps for measuring and display of the individual pump pressure locally.
3. One No. of Pressure gauge with the line size of 400 mm on discharge side of each of
the other two pumps for measuring and display of the individual pump pressure
locally.

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4. One No. of Pressure Indicating Transmitter provided on discharge side of each
pump which is interlocked to trip the pump & to enable alarm when the discharge
pressure goes HIGH.
5. One No. of Pressure Indicating Transmitter provided on common discharge side of
pump for monitoring the discharge line pressure & to enable alarm when the
discharge pressure goes HIGH.
6. One No. of Electromagnetic flow meter on common discharge side of pump for
monitoring the total discharge flow rate.
7. Four No’s of VT pumps (2 Working + 2 Standby) at Raw water pump house Which
is interlocked with the Level & Pressure transmitters for the system control
operations.
8. One No. of motor operated butterfly valve is provided on discharge side of each
pump which is interlocked with the respective VT pumps, to start the pump & for
control operation.
7.2 RAW WATER CONTROL SYSTEM EQUIPMENT’S:
WIRELESS
10” HMI GPRS COMMUNICATION
UPS & BATTERY

PLC
FIELD INSTRUMENTS
PUMPS / MOV’S

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1. PLC based control system consisting of Standalone processor, Memory unit,
communication module and non-redundant Input/output Modules with necessary
PLC Hardware and Software will be provided in the Pumping station control room
to monitor & control operation as shown the above picture.
2. One No. of Instrument control panel will be provided in raw water pumping station
with the necessary Panel meter & Alarm Annunciators to display the Critical
Parameters of Level, Pressure & Flow measurements with RS 485 for PLC interface.
3. 10” HMI with touch screen – 01
4. Ethernet Switch
5. GPRS MODEM
6. UPS System of required 230V AC input supply providing 1 hour battery backup for
Intake instrumentation system.
7.3 WATER TREATMENT PLANT:
A water treatment plant with output capacity of 23.45 MLD in 23 hours is proposed
to be constructed. Broadly, the flow scheme comprises the following process units.
1. Cascade Aerator (CA-01) - 1 no.
2. Inlet Chamber (IC-01) – 1 no.
3. Raw water Channel with Parshall Flume (PF- 01) - 1 no.
4. Flash Mixers (FM-01) - 1 no.
5. Clariflocculators and Clarified Water Channel (CF-01 & CF-02) - 2 nos.
6. Sludge Valve pit (SVP-01) – 1 no.
7. Rapid Gravity sand filters (RGSF-01 to RGSF-06) - 06 nos.
8. Backwash Overhead tank (BWOHT-01) - 1 no.
9. Air Blowers (WT-AB-04A, 04B) – 2 nos.
10. Air Compressors (WT-AC-05A, WT-AC-05B) – 2 nos.
11. Backwash Pumps (WT-P-03A & 03B) – 2 nos.
12. Alum dosing tanks (ADT-01, ADT-02 ) – 2 nos.
13. Agitators for Alum dosing Tanks (AG-05A, AG-05B) – 2 nos.
14. Alum dosing pumps (AL-P-01, AL-P-02) – 2 nos.

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15. Lime dosing tanks (LDT-01, LDT-02) – 2 nos.
16. Agitators for Lime dosing Tanks (AG-06A, AG-06B) – 2 nos.
17. Lime dosing pumps (LM-P-01, LM-P-02) – 2 nos.
18. Wash Water Recovery Sump (WWRS-01) – 1 no.
19. Settled sludge transfer pumps (WT-P-06A, WT-P-06B) – 2 nos.
20. Backwash Recycle pumps (WT-P-07A, WT-P-07B) – 2 nos.
21. Sludge drying beds (SDB-01 to SDB-08) -08 nos.
22. Sludge Sump (SS-01) – 1 no.
23. Sludge transfer pumps (WT-P-08A, WT-P-08B) – 2 nos.
24. Sludge Drying Bed filtrate Sump (SDBSF – 01) – 1 no.
25. Sludge drying bed filtrate transfer pumps (WT-P-09A, WT-P-09B) – 2nos.
Broadly the process scheme for the WTP is described below:
Cascade Aerator (CA-01)
The raw water is pumped to the inlet of the water treatment plant i.e. the raw water
enters the cascade aerator through a pipeline using raw water pump. The cascade aerator is
designed as a circular type aerator.
The cascade aerator is provided mainly to reduce the iron content in the raw water.
In the cascade aerator, while the raw water cascade down the steps provided, it absorbs the
atmospheric oxygen, there by the iron content in the raw water which are in the ferrous
form are converted to ferric form. The ferric form of the iron can be easily settled in the
downstream settling unit.
Inlet Chamber (IC-01)
Raw water will be delivered to the inlet chamber within proposed WTP through
raw water main. The inlet chamber shall be of RCC and designed for future phase. The
feed flow of raw water in the inlet pipe can be turbulent. Inlet chamber is provided to
ensure laminar feed water flow. The velocity of flow is broken in this inlet chamber.
Chlorine shall be injected by bottom mounted diffuser disc/pipes. The residual head at the
end of pumping main will be 2m, which may be kept, is consideration during the design.

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Raw Water Measuring Channel & Parshall Flume (PF-01)
Water from inlet chamber flows through a R.C.C. channel installed with Parshall
flume of standard design as per IS 14371 (latest) where an Ultrasonic flow transmitter
(20GAC000FT001) is installed to monitor the flow through the channel which is hardwired
to the PLC for continuous monitoring of inlet characteristics of raw water.
The Raw water Inlet is also installed with 01 No. of pH analyzer (20GAC001pH001)
and 01 No. of Turbidity analyzer (20GAC001TU001) which are hardwired to PLC for
continuous monitoring of inlet characteristics of raw water.
Flash Mixer (FM-01)
The raw water from the Parshall Flume enters into Flash Mixing unit for dispersion
of the coagulant chemical. Flash mixer (FM-01) of RCC construction designed for 45
seconds retention time are provided. The tank is installed with motorized agitator (AG-01)
to achieve intimate mixing of raw water with Alum.
Flash mixer Agitator will be interlocked with incoming raw water flow rate (WTP
inlet Parshall flume) for avoiding the dry running condition. Agitator Run/ Trip feedback
signals are taken from MCC feeder and are displayed in Operators station by means of
color change in SCADA Graphics.
Clariflocculators & Clarified Water Channel (CF-01)
The Clariflocculator with the rotating bridge arrangement is based on a central feed,
flocculation and clarification. Clariflocculator is provided with 4 no’s agitators (AG-
02A/02B/02C & 02D), a central platform and a radial scrapper system in each of the units.
The outlet pipe from flash mixer will feed into the central flocculation part. The
Clariflocculators are provided for the removal of suspended matter, organic etc. It has a
central area for coagulation and flocculation and an outer area for settling. The flocculation
zone is designed for a detention time of 30 minutes. The clarified water flows through
launders fitted with weir plates and through clarified water channels, reach the filter feed
channel.
The turbidity achieved at the outlet (over flow) of Clarifier shall not exceed 15 NTU.

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Drives (Agitators & Clariflocculator motor) will be controlled from the LCP &
locally from the Start/ Stop LPBS provided near the motor (hard wired to respective
feeder). Necessary feedbacks (On/ Off/ Trip & Local/ Remote) will be taken from Clarifier
LCP which is located at clarifier unit to PLC for monitoring.
Sludge Valve Pit (SVP-01)
The sludge collected at the bottom of clarified is connected to the Sludge Valve pits
(SVP-01) and is carried to the nearest drain through electrically operated Knife gate valves.
This valve operation is controlled automatically on intermittent basis.
Rapid Gravity Sand Filters (RGSF-01 to 06)
The clarified water is fed into the 06 Nos. of rapid gravity sand filters (twin beds)
with (Constant head & constant flow type with the top covered) arranged in two rows.
Each filter bed shall be designed for a filtration rate of 5.5m3/m2/hr. Two nos. (1W +1S) of
Air Blowers (WT-AB-04A/ 04B) of 1690 m3/hr. capacity, Air Compressor (WT-AC-05A /
05B) & Backwash water pumps (WT-P-03A /03B) of 230 m3/hr. for air & water backwashing
sequence shall be provided.
Filtration shall be by gravity downwards through a bed of filter sand supported by
a layer of suitable graded filter gravel. The filtered water is collected through the under
drain system and flows into an outlet chamber and into the common treated water channel.
The turbidity achieved at outlet of filter will be < 1 NTU.
Each filter are of twin bed provided with Ultrasonic type Rate of flow transmitter
(ROFT) & Differential Pressure type Loss of head transmitter. The instantaneous filtered
water flow value & loss of head value is measured. The measured values are displayed
locally and the output (4-20mA DC analog signal) are connected to PLC for indicating the
instantaneous values in SCADA and further used for interlocking purpose such as
Backwash sequence.
The filtered water is collected through the under drain system and flows into an
outlet chamber and into common filtered water channel. The Filtered water outlet pipeline
is also provided with online pH meter (20GAC206pH002) & Turbidity meter

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(20GAC206TU002) which is hardwired to PLC for continuous monitoring of characteristics
of filtered water.
• Pneumatic operated Valves/Gates in Rapid gravity sand filters (Typical)
Each rapid gravity sand filter consists of twin bed with 5 nos. of Pneumatic valves/gates
viz:
1. Inlet gate from filter feed RCC channel – 1 no.
2. Air scouring valves - 1 no.
3. Dirty backwash outlet channel gate – 1 no.
4. Backwash filling water inlet valves - 1 no.
5. Filtered Water Outlet valve - 1no.
• Working Operation (Rapid gravity sand filter in working mode)
1. Inlet gate from filter feed channel from Clariflocculator open position
2. Air scouring valve close position
3. Dirty back wash water Outlet channel gate for further treatment in close position.
4. Backwash water inlet valve close position
5. Filtered water Outlet valve open position
• Backwash operation (Rapid gravity sand filter selected in Backwash mode)
1. High Head loss signal from Loss of Head transmitter (LOHT) & Low flow rate signal
from Rate of flow transmitter (ROFT) in filter outlet.
2. Inlet Gate of filter feed channel close position.
3. Filtered water outlet valve close position (After completion of preset time)
4. Dirty backwash outlet channel gate in open position
5. Air scouring valve open position (After completion of preset time)
6. Working blower is started
7. Working blower is stopped (After completion of preset time)
8. Air scouring valve close position (After completion of preset time of air scouring and
water)
9. Backwash tank outlet valve open position (at preset condition)
10. Backwash filling water inlet valve in open position
11. Backwash tank outlet valve (Fully opened) in open position.

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12. Backwash water inlet valve in close position (After completion of preset time)
13. Dirty backwash outlet channel gate in close position (After completion of preset time).
14. Inlet gate from Filter feed channel in open position
15. Filtered water outlet valve in open position
• Backwash sequence
Back wash sequence of rapid gravity filters is possible only if
1. Low flow rate signal from Rate of flow transmitter (ROFT) in filter outlet.
2. Backwash water tank level at Middle/High
3. Recycling tank level not high
Once it’s back washed, the Backwash Outlet Gate to dirty back wash water channel
is closed and the filter goes to working mode explained above. Backwashing operation will
be possible for only one filter bed at a time.
• Steps involved for backwash operation for each of the Rapid Gravity Sand Filters
RAPID GRAVITY SAND FILTERS (RGSF-01):-
1. To close the Inlet gate (SG-201) from filter feed channel.
2. To close Filtered water Outlet valve 20GDB055BFV208 (After completion of preset time)
3. To Open Dirty backwash outlet channel gate (SG-202)
4. To open Air scouring valve 20GDB074BFV214 (After completion of preset time)
5. To start 1 no of blowers WT-AB-04A/B
6. To stop the working Blower WT-AB-04A/B (After completion of preset time)
7. To close the Air scouring valve (20GDB074BFV214)
8. To Open Backwash water inlet valve (20GDB037BFV202).
9. To close Backwash water inlet valve 20GDB037BFV202 (After completion of preset time)
10. To Close Dirty backwash outlet channel gate SG-202 (After completion of preset time)
11. To Open the Inlet gate (SG-201) from filter feed channel
12. To Open Filtered water Outlet valve (20GDB055BFV208)

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6. To stop working Blower WT-AB-01A/B (After completion of preset time)
8. To Open Backwash water inlet valve (20GDB040BFV203)
9. To close Backwash water inlet valve 20GDB040BFV203 (After completion of preset
time)
6. To stop working Blower WT-AB-01A/B(After completion of preset time)
9. To close Backwash water inlet valve 20GDB043BFV204 (After completion of preset time)

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time)
time)

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time)
Air Compressors (WT-AC-05A/05B)
Air compressors are used for the air delivery for scour of the filter bed valves. The
air compressors are provided with one no. Pressure Gauges (20GDB110PG005,
20GDB111PG006) at each of the delivery side for local indication. One number Pressure
Transmitter (20GDB112PT001) is provided at the common delivery header for pressure
monitoring.
Air Blowers (WT-AB-04A/04B)
Blowers are used for the air delivery for scour of the filter beds. Provision for air
blowing is done such that all the air is released from the system at the end of the scour
before the backwash commences. The air blowers are provided with one no. Pressure
Gauges (20GDB069PG003, 20GDB070PG004) at each of the delivery side for local
indication. Bulk Flow Rotameter 1no (20GDB071RM001) is provided for local monitoring of
pressure and flow of the air from the Blower. One number pressure Switch
(20GDB073PS002) is provided at the common delivery header to trip the pumps in case of
low pressure.

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Backwash Pump (WT-P-03A/03B)
When the filter head loss increases due to clogging of the bed, the filters shall be
taken on back washing using air & water. Two backwash pumps (1W+1S) (WT-P-03A/ 03B)
are installed in the Clear water pump house. Two number of pressure gauge
(20GDK026PG001/ 20GDK027PG002) are provided at each of the discharge side of the
Backwash pumps and a pressure switch (20GDK028PS01) is provided at the common
discharge header of the pumps for local and remote monitoring of the pressure.
Blowers & Backwash pumps Run/Trip feedback signals are taken from the
respective MCC feeders and wired to the PLC. The status of above equipment’s is
displayed in Operator’s work station by means of color changes in blower symbols in
SCADA Graphics.
Backwash Tank (BWOHT-01)
One number BackWash OverHead Tank is provided on the top of filter Gallery to
supply water & to meet the requirement of filter backwash. Overhead Backwash tank shall
be designed for two filter backwash volume plus 10% margin. Backwash filling pump (WT-
P-03A/ 03B) [1W + 1S] will take water from the Filtered water channel for filling the
Backwash tank (BWOHT- 01). Water backwash of 10 minutes is considered. As per the
requirement backwash rate shall be 24 m3/m2 per hour.
One no. of Float and Board type Level Indicator (20GKB000LI001) and an Ultrasonic
type Level Indicating Transmitter (20GKB000LT001) for monitoring of water level,
continuous measurement, trending of data and initiations of Low, Medium & High alarm
is provided in the Back wash tank for interlocking with Backwash pumps.
All the indications are linked to the PLC. Run/Trip feedback signals of each of the
pumps are taken from the respective MCC feeders and are displayed in Operator’s station
by means of color changes in Pump symbols in SCADA Graphics.

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Filtered Water Channel
Filtered water flows through a R.C.C. channel. The Filter water outlet pipeline is
provided with online pH meter (20GAC206pH002) & Turbidity meter (20GAC206TU002)
which is hardwired to PLC for continuous monitoring of inlet characteristics of raw water.
Chlorination Building
The chlorination building houses the following facilities:
a) Pre-Chlorination system for chlorine injection in Raw water at the inlet chamber
b) Post chlorination system for chlorine injection in Chlorination chamber on Clear
water channel.
c) Chlorine Tonner Storage Area for storage of Chlorine toners for both Pre & Post
Chlorination systems
d) Common Control Panel for Pre & Post Chlorination systems
e) Chlorine Leak Detection System
Chlorination System Description:
Electro chlorination system consists of Relay based starter cum control panel with
system selector switch which can be operated either in Manual mode or Automatic mode.
The control & operation of the system are based on vendor scope.
a) The pre-chlorination systems consist of following units:
Two nos. of Booster pumps one working and other standby with pressure gauge
on individual discharges. The booster pumps pump the water through the
ejectors to enable the injection of Chlorine by vacuum suction through
chlorinator units.
b) The post-chlorination systems consist of following units:
Two nos. of Booster pumps one working and other standby with pressure gauge
on individual discharges. The booster pumps pump the water through the
ejectors to enable the injection of Chlorine by vacuum suction through
chlorinator units.

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Pneumatic Operated Valves in Filter Beds
Each Pneumatically operated valves will be provided with one selector switch
(Local / Remote) in actuator.
‘Remote’ position means the valve is selected for Auto operation. In this mode the
valves are closed / opened based on the PLC logic.
The ‘Local’ position of selector switch is for manually closing or opening the valves
for maintenance purpose.
Valve Close/Open Status will be displayed by change of colors in SCADA graphics
in control room and through indication lamps on control desk.
FILTER CONTROL DESK - PLC BASED panel at each filter bed gallery with following
instrumentation / control systems equipment’s facilities and indications: (FCD-PLC RIO 1
to 6)
• Start filter wash cycle – Key operated push button
• Manual/automatic- Key operated selector switch
• Filter water holding tank full
• Open/close Illuminated push buttons for 03 Nos. of Valves & 02 Nos. of gates.
• Filter ready for wash
• Filter washing
• Filter out of service
• Filter in service
• Wash water pump 1, 2 tripped
• Air scour blower 1,2 tripped
• Air Compressor 1, 2 tripped
• HMI touch screen is provided for parameter monitoring and control operation.
Necessary communication interface is considered between these filter control desks and
main WTP PLC control panel through Fiber Optic cables.
Wash Water Recovery Sump (WWRS-01)
The dirty backwash water from the filter bed is lead into the wash water recovery
sump, where the supernatant water from the sump is pumped through the Backwash
recycle pumps (WT-P-07A, WT-P-07B) to the raw water parshall fume. The Sludge left is

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transferred by the Settled Sludge Transfer pumps (WT-P-06A, WT-P-06B) to the Sludge
Drying beds. One No. of Pressure gauge (20GDS159PG011, 20GDS160PG012,
20GDS162PG013, 20GDS163PG014) is provided at each pump discharge header. One No. of
Level Switch is provided (20GDS000LS006) to trip the Backwash recycle Pumps in case of
Low level & trip the Settled sludge transfer pumps in case of Low Low level.
Sludge Sump (SS-01)
The Sludge from the Clariflocculator is sent to the Sludge sump, from where it is
transferred to the Sludge drying beds by the use of Sludge transfer pumps (WT-P-06A, WT-
P-06B). Each pump is provided with a Pressure gauge (20GDS268PG015, 20GDS239PG016)
at the discharge header. A level Switch (20GDS000LS009) [Set point: L-2.6 - Refer
Instrument list] is provided to monitor the level of the sludge sump for low level tripping.
Sludge Drying Beds (SDB)
The Sludge from Filter backwash Sludge transfer pumps and the Sludge Sump will
be transferred to the Sludge Drying beds followed by the Inspection chamber. 08 number of
Sludge Drying beds (SDB-01 to SDB-08) and 08 number of Inspection chambers (IC-01 to
IC-08) are provided to dry the Sludge and send the Filtered water to the Sludge Drying bed
filtrate sump.
Chemical Dosing System
The chemical house is included to provide necessary space for the storage of
chemicals, unloading etc.
The following chemical dosing systems of adequate capacity dosing tanks with agitators
and dosing pumps as per tender requirement are provided as part of the treatment scheme.
a) Alum Dosing System:

Alum is used as a coagulant aid in the removal of raw water turbidity. Dosage of
Alum is considered as 60 mg/L at 10 % strength of solution and 90 days storage capacity.
Alum dosing system consists of 02 nos. Alum dosing tanks (ADT-01, ADT-02) each

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provided with 1 no. dosing mixer (agitators AG-03A/ 03B) and 2 nos. alum dosing pumps
[1W + 1S] (AL-P-01/ 02).
All the Alum dosing tanks are connected by one common header and all alum
dosing pumps are connected to this header & it flows to the Parshall Flume of the WTP. A
dual low level switch (20GDN000LS002/003 for detecting low level for interlocking with
pump/Agitator operation & Alarm in PLC. Low level at the Level switch will trip all the
pumps of the Chemical dosing system and the respective agitator. Level Indicators
(20GDN000LI002, 20GDN000LI003) are also provided at each tanks for local indication of
the tank level. Pressure gauges (20GDN124PG007/ 20GDN126PG008) provided at the
delivery side of each pumps.
The operator shall select the working and standby option provided in the graphics
SCADA screen. On selection, PLC shall check for process interlocks for start the dosing
pumps. If the three tanks are detected for low level, no alum dosing pump can be started.
In other words any one alum dosing pump will run only if level switches are in normal
position for tanks (low level not activated).
Any pump or agitator can be either stared from the SCADA graphics through PLC
by software toggle push button or from the local Start/Stop PB provided near each motor.
The start/stop of pump from local start/Stop PB (near the motor) is possible only if the
respective pump is selected in local mode through the local/remote selector switch
provided on respective pump MCC feeder.
Pump Running & Pump trip indication will be displayed in Operator’s work station
by means of color changes in Pump symbols in Graphics (details to be furnished during
detailed Eng.). These signals will be taken from the respective MCC feeders.
Each pump is provided with one selector switch for selecting the pump normal/standby
operations. Pumps selected will run under following conditions
a) Raw water flow rate (at WTP inlet Parshall flume) is normal
b) Alum dosing tank levels are normal (not low level) for running dosing pumps.
If any of the level switch in Alum dosing tank is activated due to low level the Agitator
installed in that tank is prevented from starting.

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b) Lime Dosing System:
Three nos. dosing tanks (LDT-01/02) are provided. Electrically driven mechanical
agitators (AG-04A/04B) are provided for continuous stirring of the solution in the tanks.
The control of the flow (outlet) shall be regulated automatically through modulation of
stroke length on the basis of inflow rate of raw water and the quality (turbidity value) of
the water.
There are 2 no’s (1W +1S) dosing pumps provided for dosing lime at the dosing
point. Each tank is equipped with one level switch (20GDN000LS004, 20GDN000LS005) for
detecting low level for interlocking with pump/Agitator operation & Alarm in PLC. Level
Indicators (20GDN000LI004, 20GDN000LI005) are also provided at each tanks for local
indication of the tank level. Pressure gauges (20GDN138PG009/20GDN140PG010) shall be
provided at the delivery side of each pumps.
The operator shall select the working and standby option provided in the graphics
SCADA screen. On selection, PLC shall check for process interlocks for start the dosing
pumps. If both the tanks are detected for low level, no lime pre saturator dosing pump can
be started. In other words any one of lime dosing pump will run only if level switches are
in normal position for any tanks (low level not activated).
Any pump or agitator shall run only manually through PLC by software toggle push
button or from the local Start/Stop PB provided near each motor. The start/stop of pump
from local start/Stop PB (near the motor) is possible only if the respective pump is selected
in local mode through the local/remote selector switch provided on respective pump MCC
feeder.
Pump Running & Pump trip indication will be displayed in Operator’s work station
by means of color changes in Pump symbols in Graphics (details to be furnished during
detailed Eng.). These signals will be taken from the respective MCC feeders.
Each pump is provided with one selector switch for selecting the pump normal/standby
operations. Pumps selected will run under following conditions
a) Flash Mixer Agitator is running
b) Raw water flow rate (at WTP inlet parshall flume) is normal
c) Any lime pre saturator tank levels are normal (not low level) for any one dosing pumps
running.

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MAIN WTP PLC ROOM AT ADMINISTRATION BUILDING
The Central Control Room is located at the WTP Administration Building & is
provided with various equipment for complete monitoring & control of the plant:
➢ ICA (Instrumentation, Control and Automation) panel with control PLC and SCADA
System at WTP. ICA panel consists of Redundant Controller, IO Modules, Power
Supply, Communication Interface and Dedicated monitor for Alarm Annunciation &
Process parameters. ICA shall be made for measurement of Process parameter and
monitoring & controlling the Electro-mechanical equipment to implement the plant
control philosophy.
➢ 1 No. Operator Workstation (SCADA) system with 22” display screen shall be
provided. This system will enable the operator to monitor / control the overall WTP
process from the main control room. The station also enables the operator to view
alarms and Generate alarm reports/Trends.
➢ 1 No. Engineering Work station (Laptop) shall be provided.
➢ 1 No. Color inkjet printer shall be provided for report generation.
➢ 1 No. dot matrix printer shall be provided.
➢ 1 No. UPS cum Battery is provided for backup power.
➢ GPRS/GSM communication modem- 01 No.
➢ Providing measuring instruments at WTP as indicated in the P&IDs.
7.4 Clear Water Pump House & Reservoir at WTP
Field Instruments:
1. Two Nos. of Ultrasonic type level indicating transmitter at each compartment is
considered for continuous reservoir level measurement, which is interlock to trip
the pump & to enable alarm, when the reservoir level is LOW.
2. One No. of Compound Pressure gauge on suction side of each pump for measuring
and display of the individual suction side pump pressure locally.
3. One No. of Pressure gauge on discharge side of each pump for measuring and
display of the individual pump pressure locally.
4. One No. of Pressure gauge on common discharge side of pump for measuring and
display of the discharge header pump pressure locally.

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pressure goes HIGH.
pump to monitor the pipe line pressure & to enable alarm when the discharge
pressure goes HIGH.
7. One No. of Residual Chlorine Analyzer provided at CWPH on the common
discharge side of pump to monitor the residual value & to enable alarm, when the
Residual values goes LOW or HIGH
monitoring the total discharge flow rate, which is interlocked with the Motorized
Butterfly valve to open / Close valve based on the Flow Requirement.
9. HSC pumps at the Clear water pump house are interlocked with the Level &
Pressure transmitters for the system control operations.
pump which is interlocked with the respective HSC pumps to start the pump & for
control operation.
11. One No. of motor operated butterfly valve is provided on common discharge side of
pump which is interlocked with the Flow meter, for valve open / close control
operation.

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(Typ. Drawing)
PLC
LT LT PLC
COMPARTMENT-1 COMPARTMENT-2
PT PT PT PT
EFM
7.5 Clear water Control System Equipment’s:
CWPH PLC RIO WTP MAIN PLC @ ADMIN BUILDING
FIELD INSTRUMENTS
PUMPS / MOV’S

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1. Instrument from Clear water pump house is hardwired to the PLC RIO Panel
located at Clear Water pump House Control Room & the signal is further carried to
WTP main control room with the necessary panel meter & Alarm Annunciators to
display the Critical Parameters of Level, Pressure & Flow measurements via Fiber
Optic Communication.
7.5 Intermediate Booster Pumping Station - 1
Field Instruments:
pressure goes HIGH.
pressure goes HIGH.
8. HSC pumps at the pump house are interlocked with the Level & Pressure
transmitters for the system control operations.
control operation.

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operation.
7.6 Intermediate Booster Pumping Station - 2
Field Instruments:
pressure goes HIGH.
pressure goes HIGH.
8. HSC pumps at the pump house are interlocked with the Level & Pressure
transmitters for the system control operations.
control operation.

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operation.
7.6 Master Balancing Reservoirs (MBR-01/02/03/04) Control system Equipment’s:
WIRELESS
GPRS COMMUNICATION
MBR 01/02/03/04
MBR RTU – 04 Nos.
FIELD INSTRUMENTS
MOV’S
1. Instruments from MBR-1, 2, 3 and 4 is hardwired to the RTU panel located at
respective MBR control room to display the Critical Parameters of Level & Flow
measurements & communicate the same to Main control room at WTP via GPRS
communication.

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7.7 Over Head Service Reservoirs (80 Nos.)
LT RTU
RTU RTU RTU RTU
RTU
RCL NTU
FCV PT
EFM
1. One No. of Ultrasonic type level indicating transmitter is considered for continuous
reservoir level measurement, which is interlock to open / Close the motorized
operated valve based on the level, where to close the valve when the reservoir level
is HIGH & to Open the valve when the reservoir level is LOW
2. One No. of Hydraulically Operated Flow control valve is provided on inlet side of
the OHSR which is interlocked with the level transmitter for valve open & close
operations.
3. One No. of Electromagnetic flow meter is provided on the inlet side of the OHSR to
monitor the inlet flow rate continuously & to regulate the valve based on the flow
requirement.
4. One No. of Blind type Pressure Transmitter provided on inlet side of OHSR to
monitor inlet reservoir pressure measurement
5. One No. of Residual Chlorine & Turbidity Analyzer provided at the out of OHT to
monitor the residual & Turbidity values continuously.

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`
6. Power Backup in the form of online hybrid Solar panel with battery arrangement
for Instrumentation equipment & illumination in the campus.
7.9 OHSR Control System Equipment’s:
WIRELESS
GPRS COMMUNICATION
OHSR-80 Nos.
OHSR RTU – 80 Nos.
FIELD INSTRUMENTS
FCV
1. Instrument from OHSR’s are Hardwired to the RTU which is located at respective
OHSR control room is to display the Critical Parameters of Level, Pressure, Flow
measurements, Analysers & communicate the same to Main control room at WTP
via GPRS communication.
7.10 Village transfer chamber (231 Nos.)
Field instruments & Control Equipment’s:
1. One No. of Woltmann type Flow meter is considered at each village for the
measurement of flow rate at remote location. The Flow meter is located inside the
Chamber.

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`
8. MODE OF OPERATIONS AND INTERFACING SIGNALS
8.1 DRIVE CONTROL PHILOSOPHY
Pump operation.
All pumps will be operated in the following manner.
8.2 Valve operation
All valves will be operated in the following manner.

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`
8.3 REMOTE MODE
This mode is valid only if the provided equipment of the pumping station like
Motor Drives, Pumps are healthy. Local/Remote selector switch provided in the respective
Motor control panel are selected to “Remote” position for PLC-SCADA operation and
respective position feedback will be indicated on HMI Screen. The provided SCADA
system consist of AUTO, MANUAL & TEST modes of operation
8.4 LOCAL MODE
The selector switch provided on electrical panel (MCC) is selected to LOCAL and
status of mode selection is fed to PLC and indicated on HMI Screen. In this mode the drive
can be started/ stopped from LPBS near equipment. PLC shall have the supremacy control
and will monitor the status of pump in case of any abnormal process conditions then PLC
shall trip the pump, if PLC is Online & healthy.
Signal Interface between PLC & PNEUMATIC VALVES:

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USED TO THE EXTENT NECESSARY FOR THIS PROJECT AND SHALL NOT BE USED OR DISCLOSED FOR ANY OTHER PURPOSE WITHOUT THE CONSENT OF L&T `
Signal Interface between PLC & MOV:
Signal Interface between PLC & PUMPS:
Signal Interface between PLC & MCC Breakers:

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`
9. PLC - CONTROL AND OPERATIONS
9.1 CONTROL MODES FOR THE WTP & PUMPING STATIONS
• AUTOMATIC
• MANUAL
• TEST
A Mode selection will be provided on the SCADA/HMI for operation of pump sets.
Operation of pumping station in any of the above modes is possible only when all the
pumps and their discharge valves are selected to Remote mode in the respective
valves/switchgear panel through selector switch.
9.2.1 AUTOMATIC CONTROL MODE
In this mode the pumps will be operated automatically through certain commands
from the SCADA/HMI with all protection interlocks.
• The automatic control mode will be selected by the operator positioning of mode
selector switch on the control panel. This mode selection will be accepted and
retained by the control system.
• Based on demand of water and based on the availability of the pumps operator can
able to select the combination of working – standby pumps if applicable on the
SCADA/HMI.
• The PLC system will check the status of start permissive conditions and provide a
signal for ‘Pumps ready to start’. The operator then will give a command to start
from the local SCADA/HMI.
• When pumping station start command is given from HMI/SCADA, PLC will check
the start permissive conditions and subject to satisfaction of interlocks, it will issue
start command to the pump and open discharge Butterfly valve simultaneously. On
the receipt of valve open feedback and pump running feedback continuously pump
start sequence is complete.
• The stand-by pumps will start when a working pump fails or stops during running.

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`
Pump start sequence
Permissive conditions for pump start will be
• Auto mode selection in SCADA/HMI.
• Reservoir Level not Low.
• Discharge MBFV is close
• Discharge MBFV- Actuator No Fault/trip AND Actuator in remote.
• Motor off feedback.
• Discharge Pressure Not High
• Motor not tripped/ fault.
• MCC Available
• Emergency stop push button not operated.
Start sequence for pump start will be
• Start pump drive & open discharge MOV valve simultaneously
• If duty pump fails to start or its discharge valve fails to open within set time or
discharge header pressure low, then pump starting sequence will be abandoned
and the standby pump will start automatically
• When pump starts and discharge valve opens fully, the start sequence is
completed.
Pump Trip sequence
The pump automatic mode Trip sequence will be as follows:
• Reservoir Level is Low.
• Discharge MBFV valve is closed when pump running
• Discharge pressure indicating transmitter high at each pump.
• When the pump stops and discharge valve closes, the stop sequence is complete
• The discharge valve will close after the pump has stopped. In case power supply
is not available the valve will close on resumption of power.
• In case of ‘stop pumping station’ command, the pumps will stop one by one
with a time gap as per preset time.

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`
9.2.2 MANUAL CONTROL MODE
In this mode the pumps and its associated discharge valve will be individually
operated from the SCADA/HMI as per the demand of water and based on the availability
of the pumps. All the permissive conditions and the safety interlocks will be applicable in
this mode.
Start permissive for pumps
• Reservoir Level not Low.
• Discharge MOVs- Actuator No Fault/trip AND Actuator in remote.
• Discharge Pressure Not High
• Motor off feedback.
• Motor not tripped/ fault.
• MCC Available.
Trip condition for pump
• Respective motorized discharge MSVs is closed when pump is running.
• Reservoir level low
• Pump discharge pressure switch high.
Open / Close / stop permissive for pump discharge MOV
• Corresponding Pump - On feedback AND Valve Actuator in Remote AND Valve
Actuator No Fault/trip for opening of valve.
• Based on the Feedback valve operation is done by HMI/SCADA for Open/Close of
Motorized Butterfly valve.
• Corresponding Pump- Trip feedback for closing of valve on pump running.
9.2.3 TEST CONTROL MODE
In this mode the pumps/valves will be individually operated from the SCADA/HMI
during Cold trail/testing purposes. The Test mode will be similar to the manual mode but
all the permissive conditions and safety interlocks will be bypassed in this mode.

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`
9.3 LOCAL CONTROL MODE
The starting and stopping of the pumps will be as per the operator commands. This
mode of control will normally be used for maintenance purposes or in the event of a PLC
failure. In order to start a pump in this mode, the operator set the selector switch to ‘Local’.
The pump can then be started or stopped using the start and stop buttons on the MCC
panel. Each pump can also start / stop through local push button stations (LPBS) provided
near each pump set. Valve actuators will be operated manually at the actuator by selecting
the ‘local-off-remote’ selector switch to ‘local’ and using the local controls at the valve.
9.4 CONTROL & OPERATION PHILOSOPHY FOR ELECTRICAL PANELS
Monitoring and operations of the incomers & Bus couplers will be done through a
SCADA HMI which is provided in the PLC control rooms of Pumping station. Emergency
stop push button will be provided in motor control center for tripping purpose. Providing
& installation of Energy Meters, to measure electrical power consumed, with each pump set
(≥30 KW) at all pumping station. The reading of these meters will be sent to the PLC
System for energy audit.

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Control Philos

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THESE DOCUMENTS/ DRAWINGS ARE "CONFIDENTIAL INFORMATION" RELATING TO DAMOH MULTI VILLAGE RURAL WATER SUPPLY SCHEME (28

MLD WTP), MP. THESE SHALL BE

MADHYA PRADESH JAL NIGAM MARYADIT

BYARMA (JABERA - TENDUKHEDA) MULTI VILLAGE RURAL

WATER SUPPLY SCHEME, DISTRICT DAMOH

(28 MLD WTP), MP

WATER & EFFLUENT TREATMENT IC

MOUNT POONAMALLE ROAD,

MANAPAKKAM, CHENNAI – 600089

PROJECT: DOCUMENT TITLE: DATE:

FOR THE FOLLOWING SYSTEMS

1. RAW WATER PUMPING STATION

2. WATER TREATMENT PLANT (28 MLD)

3. CLEAR WATER PUMPING STATION

4. MASTER BALANCING RESERVOIRS (04 Nos.)

5. INTERMEDIATE BOOSTER PUMPING STATION (03 Nos.)

6. OVERHEAD SERVICE RESERVOIRS (80 Nos.)

7. VILLAGE TRANSFER CHAMBERS (231 Nos.)

PROJECT: DOCUMENT TITLE: DATE:

S.NO DESCRIPTION PAGE NO

2 PROJECT FLOW DIAGRAM 07

6 DETAILS OF PLC & SCADA 18

7 OPERATION AND CONTROL PHILOSOPHY 21

8 MODE OF OPERATION AND INTERFACING SIGNALS 46

9 PLC - CONTROL AND OPERATIONS 49

PROJECT: DOCUMENT TITLE: DATE:

This document describes the general control philosophy on Pumping stations,

integration of Civil, Mechanical, electrical & Instrumentation.

A water treatment plant with output capacity of 28 MLD is proposed to be

constructed and will be automated with PLC/SCADA system.

various alarms in the plant.

control philosophy of the plant.

This is achieved using combination of Programmable Logic Controller (PLC),

to be taken while developing program/coding for PLC and SCADA.

• ICA - Instrumentation control and Automation panel

• PLC - Programmable logic controller

• SCADA - Supervisory Control and Data Acquisition system

• MCC – Motor Control center

PROJECT: DOCUMENT TITLE: DATE:

• UPS - Uninterruptable Power Supply unit

• DPM - Digital panel meter

• NTU – Turbidity Analyzer

• RCL – Residual Chlorine Analyzer

• FIQ - Flow indicator cum totalizer

• CPG – Compound pressure gauge

• PT- Pressure transmitter

• EFM – Electromagnetic flow meter

• UFM – Ultrasonic Flow meter

• ULT – Ultrasonic level transmitter

• MBFV- Motorized butterfly valve

• MSV – Motorized sluice valve

• LIT – Level Indicating Transmitter

PROJECT: DOCUMENT TITLE: DATE:

Instrument List for Intake well cum Raw water Pumping

PLC IO List for Intake well cum Raw water Pumping

Instrument List for Water Treatment Plant LE181250-I-WS-WT-IL-5007

PLC IO List for Water Treatment Plant LE180730-I-WS-WT-IO-5012

Instrument List for Clear water Reservoir cum Pump

PLC IO List for Clear water Reservoir cum Pump House at

Instrument List for Over head Service Reservoirs LE181250-I-WS-CW-IL-5009

RTU IO List for Over head Service Reservoirs LE181250-I-WS-CW-IO-5014

Control & Interlock Details for WTP System LE181250-I-WS-WT-ID-5001

Automation System Architecture LE181250-I-WS-WT-SA-5002