Wet Well: Design, Process and Automation

Control

Gabriel Greco, Electrical Engineering Technologist Student

gabejgreco@gmail.com
737 Charlotte St.
Sudbury, Ontario
P3R 4R1

March 29, 2022

Tom Fahey
Professor Electrical Engineering Technology
Cambrian College
1400 Barrydowne Road
Sudbury, Ontario
P3A 3V8

Dear Tom.

I am submitting my technical report entitled “Wet Well: Design, Process, and Automation
Control” to meet the requirements of TEC3601.

This report analyzes the design criteria concerning wet wells, as well, autonomous control and
monitoring equipment governing wet well process. The report also outlines the PLC program,
SCADA, and HMI programs for the well.

If you have any questions or comments regarding my report, I encourage you to contact me at
(647) 469-6503 or via email at A00201829@mycambrian.ca

Yours Sincerely,

Gabriel Greco
Electrical Engineering Technologist Student
737 Charlotte St.
Sudbury, Ontario
P3R 4R1

March 29, 2022

Tom Fahey
Professor Electrical Engineering Technology
Cambrian College
1400 Barrydowne Road
Sudbury, Ontario
P3A 3V8

Dear Tom.

I am declaring that I am the sole author of this technical report entitled “Wet Well: Design,
Process, and Automation Control”.

All the information collected from primary and secondary sources has been recorded, and
contributors have been acknowledged.

If you have any questions, I encourage you to contact me at (647) 469-6503 or via email at
A00201829@mycambrian.ca

Yours Sincerely,

Gabriel Greco
Electrical Engineering Technologist Student
Wet Well: Design, Process and Automation
Control

Prepared For:
Tom Fahey

Professor of Electrical Engineering Technology

Cambrian College of Applied Arts and Technology

Prepared By:
Gabriel Greco
A00201829

Electrical Engineering Technology Student

Cambrian College of Applied Arts and Technology

Date:
March 29, 2022
 Technical Summary

A wet-well functions as a designated storage tank designed to receive and hold sewage until it is
pumped out. Municipal wastewater utilizes gravity to travel down the municipal sewage line
until it connects with a larger collection system. When there is a low point in the system and
wastewater can no longer flow by gravity, the wastewater collects in a large chamber called a
wet-well. Wet-wells are a type of lift system where pumps are submerged in wastewater within
the wet-well. Sensing devices such as mass-flow meters, float switches, and pressure sensors are
connected inside the wet-well. These devices collect real-time information about the process
inside the wet-well and communicate them via a PLC (programmable logic controller). When
parameters are reached within the wet-well, the pumps active and transport the wastewater to a
higher elevation so that it may continue to flow. Wet-wells can vary in shape and size but serve
only one function- to transport wastewater to a higher elevation so that it may continue to flow.

This report covers all design and programming aspect for simulating the process occurring inside
a wet well. Instrumentation devices such as ultrasonic levels and float switches are utilizes to
monitor process variables such as level and pressure. As well, an HMI and PLC program have
been integrated into the system to provide remote monitoring and control of the process.
AutoCAD wiring diagrams have been provided for the PLC hardware and HMI, along with
wiring schematics for all electrical devices, and data sheets of all devices used in the project.
Table of Contents
1.0 Introduction 1
1.1 Purpose 1
1.2 Background 1
1.3 Scope 2
1.4 Limitations 2
2.0 Overview 2
2.1 Glossary of Terms2
2.2 Conclusion 4
2.3 Recommendations 4
3.0 As Found Drawings 5
3.1 Drawings 400’s 5
4.0 As Built Drawings 5
4.1 Drawings 5
4.1.1 PLC 100’s 5
4.1.2 Layout 200’s 5
4.1.3 Wiring 300’s 5
4.1.4 Terminal Blocks 500’s 5
4.1.5 Control Panel 600’s 5
5.0 PLC Program 6
5.1 PLC Program 6
5.2 Unity Pro XL Program Sequence of Operations 6
5.3 Long Comments 9
6.0 HMI/SCADA 12
6.1 HMI 12
6.2 SCADA 20
7.0 Equipment 26
7.1 Bill of Materials 26
8.0 Data Sheets 29
8.1 Specification Sheets 29
9.0 Resources 29
9.1 References 29

Appendices
Appendix A - Drawings 1
A.1 PLC 100’s 2
A.2 Layout 200’s 2
A.3 Wiring 300’s 2
A.4 As Found 400’s 2
A.5 Terminal Block 500’s 2
A.6 Control Panel 600’s 2
Appendix B – PLC Program 4
B.1 Alarm Network 5
B.2 Pump Control/Reset Network 2
B.3 Analog Dial Network 2
B.4 Pump Network 2
B.5 HMI Network 2
 B.6 Johnny Ball Lockout Network 2
B.6 Pressure Lockout Network 2
Appendix C - Graphics 4
C.1 HMI Graphics 2
C.2 SCADA Graphics 2
Appendix D – Specification Sheets 4
Appendix E – Wet Well Requirements and Change Orders 4
E.1 Wet Well Requirements 2
E.2 Change Orders 2

List of Figures
List of Illustrations 4
Figure 1: HMI Home Page 2
Figure 2: Control Status Popup 2
Figure 3: Home Page Alarm – No Faults 2
Figure 4: Event Logger with Faults 2
Figure 5: HMI Trend Page 2
Figure 6: HMI Fault Finder Page 2
Figure 7: Active Faults 2
Figure 8: SCADA Home Page – System OFF 2
Figure 9: SCADA Home Page – System ON 2
Figure 10: SCADA Fault Finder Page – No Faults 2
Figure 11: SCADA Fault Finger Page – Active Faults 2
Figure 12: SCADA Control Status Popup 2
Figure 13: SCADA Alarm Page – No Alarms 2
Figure 14: SCADA Alarm Page – Active Alarms 2
Figure 15: SCADA Process Analyst 2

iii
 Wet Well: Design, Process, and Automation Control

1.0 Introduction

1.1 Purpose
This report describes aspects of construction, programming, and design for a wet well/pump
station project for the city of Greater Sudbury, ON.

The project will integrate computer technology and automation instruments such as a PLC
program (programmable logic controllers), mechanical design considerations, autonomous
equipment sensors and instrumentation devices, as well, electrical design.

This report provides an overview of a wet well pumping station to be installed in the city of
Greater Sudbury. Included is a breakdown of the project, the process used to complete the
project, equipment and resources used, as well, a reference page. Equipment specification sheets
are also included, as well, a breakdown of the PLC program, a description of the HMI program,
and AutoCAD drawings for wire terminations and device dimensions.

1.2 Background

This report is a required component of the Electrical Engineering Technologist program at

Cambrian College. My interest in the topic of automation and process control came about during
my studies at Cambrian College. This topic is also of interest to me since I believe many
mundane or difficult and dangerous jobs may be subject to autonomous control.
 1.3 Scope

The following topics are discussed in this report:

 Design guidelines for municipal wet well/lift stations

 Achieving autonomous process control using instrumentation devices
 A full description and breakdown of the PLC program implemented for process control
of the well
 A full description and breakdown of the HMI program implemented
 Equipment specification sheets and AutoCAD drawings for electrical wiring terminations

1.4 Limitations
Due to the lack of equipment at my disposal, I was unable to physically build a wet well. Instead,
I simulated the process which would occur inside of a wet well and used sensor devices and a
PLC program to autonomously control and monitor the process. I was also unable to find a
technical advisor for my project.

2.0 Overview

2.1 Glossary of Terms, Abbreviations, and Acronyms

“A” Contacts: Represents a normally open (N.O.) contact.

ACI 030: Analog Input Module – A PLC analog input module which accepts mixed current and
voltage inputs.
ACO 020: Analog Output Module – The analog output module controls and monitors current in
4-20mA loops.
“B” Contacts: Represents a normally closed (N.C.) contact.
Control Relay: An electrically operated switching mechanism; magnetic devices that are used to
remotely switch loads.
CPS 114: Power Supply Module – Power supplies are used to supply system power to modules
inserted into the PLC rack.

2
CPU: The component of a computer system that performs the basic operations of (processing
data) of the system.
CPU 434: Concept Processor – A digitally operated electronic system, which uses a
programmable memory for the internal storage of user instruction.
DAI 540: Discrete Input Module – A module that accepts 115 VAC inputs.
DDO 353: Discrete Output Module – The DC output 24 VDC source module switches 24 VDC
powered loads and is for use with shared output common wired to 0 V.
DRA 840: Discrete Output Module – Used to switch a voltage source using 16 relays with
normally open contacts.
FBD: Function Block Diagram – A graphical language used for PLC design.
HMI: Human Machine Interface – The hardware or software through which an operator interacts
with a controller.
Johnny Balls: Float Switch – A type of level sensor used to detect the level of liquid in a tank.
Level: A horizontal plane or line with respect to the distance above or below a given point.
LD: Ladder Diagram – A graphical language used for PLC design.
Lockout: Isolating of energy from a system which physically locks the system into a safe mode.
Logic: The basis of electronic systems such as PLC’s. It works on 0’s and 1’s, and involves
addition, subtraction, multiplication, and division of zeros and ones.
Motor: A machine designed to convert one or more forms of energy into mechanical energy.
Network: A network is a section in a PLC program in which ladder logic may be applied with
the purpose of providing the PLC with logic.
PLC Card NOE 771: Ethernet network TCP/IP module

PLC: Programmable Logic Controller – An industrial solid-state computer that monitors inputs
and outputs and makes logic-based decisions for automated processes or machines.
Pump: A device that raises, transfers, delivers, or compresses fluids or that attenuates gases by
suction, pressure, or both.
Pressure: The amount of force applied perpendicular to the surface of an object per unit area.
Process: A collective term for sensors incorporated into measuring instruments used for
indicating, measuring, and recording physical quantities.
Process Variable: A physical or chemical quantity which is usually measured and controlled in
the operation of a system.
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PSI: Pounds per Square Inch - A unit of pressure expressed in pounds of force per square inch of
area.
Signal Generator: A class of electronic devices that generates electronic signals with set
properties of amplitude, frequency, and wave shape.
SCADA: Supervisory Control and Data Acquisition – A control system designed to collect,
analyse, and visualize data from industrial equipment.
Sonac: A control device that measure level using ultrasonic frequencies.
Ultrasonic: Soundwaves with frequencies higher than the upper audible limit of human hearing.
Variables: In the context of PLC’s a variable is a container that holds information.
Wet Well: A chamber in a pumping station, including submersible pump station, where waster
water is collected.

2.2 Conclusion

The process in a wet well undergoes many changes over time due to many factors such as rates
of flow, environmental factors, sedimentary build-up in pipes and in equipment, as well, time of
day. All these factors play an integral role in monitoring the process variables in the wet well.
Environmental factors influence the amount of drain water entering a system, sedimentary build-
up influences the rate of flow, and time of day influence the level in the well due to peek water
usage. All these variables influence the process occurring in a wet well and as a result require
various means of measuring and monitoring equipment if the process is to be monitored and
manipulated.

2.3 Recommendation

Upon completion of this technical report, I recommend that the report be reviewed by an
electrical engineer to determine its validity. I also recommend that the following be done:

 Create documentation and wiring schematics for any maintenance or updates that occurs
to the well
 Perform regularly scheduled cleanings and maintenance on a routine basis
 Have a back-up pump on site for emergency situations
 Test the alarm systems frequently

4
3.0 As Found Drawings

3.1 Drawings 400’s

“As Found” drawings contain all the components found on the wiring boards in room 1807A in
their as found condition.

Reference Appendix A for the “As Found” AutoCAD schematics.

4.0 As Built Drawings

“As Built” drawing are the updated versions of the “As Found” drawings. Any wirings changes
that have occurred over the course of the project have been documented in the “As Built”
drawings.

4.1 Drawings

Reference Appendix A for the “As Built” AutoCAD schematics.

4.1.1 PLC 100’s

Reference Appendix A – A.1 for the “PLC 100s” AutoCAD schematics.

4.1.2 Layout 200’s

Reference Appendix A – A.2 for the “Layout 200’s” AutoCAD schematics.

4.1.3 Wiring 300’s

Reference Appendix A – A.3 for the “Wiring 300’s” AutoCAD schematics.

4.1.4 Terminal Blocks 500’s

Reference Appendix A – A.5 for the “Terminal Blocks 500’s” AutoCAD schematics.

4.1.5 Control Panel 600’s

Reference Appendix A – A.6 for the “Control Panel 600’s” AutoCAD schematics.

5
5.0 PLC Program

5.1 PLC Program

The PLC program designed for the wet well project is meant to work in collaboration with an
interface medium (HMI) to monitor and control the system process. Primarily programmed in
user friendly languages LD and FBD, the PLC program provides remote control over a
process. The program uses several networks to monitor the process variables, initiate alarms,
and control devices, provide interlocking means for the pumps and will also lock out pumps.
Section 5.2 provides a full breakdown of all the networks that are in the PLC program.

5.2 Unity Pro XL Program Sequence of Operations

The process in the wet well can be monitored and manipulated by the accompanying PLC
program. The PLC program was designed to monitor the dynamic level and pressure in the
well, as well, indicate to the operator any fault conditions that are occurring in real time, or
that have occurred in the past. Found below is a sequence of operations for the PLC
program.

Reference Appendix B for full network designs

It is important to note that the level in the wet well is scaled to a value of 0-100% and the
pressure is scaled to a value of 0-1000PSI.

The analog dial network controls the scaling parameters for level and pressure in the wet
well. Programmed in FBD, the analog input ACI 030 card, and the analog output ACO 020
card send logic to an I_Scale function block and converts the data into a scaled engineering
value. These values are displayed on the signal generator.

The wet well operates as a storage tank for sewage. The concept is simple, when the level of
sewage in the tank reaches a certain point, pumps will be energized and will pump the
sewage out of the tank. However, before the pumps are energized certain conditions must be
met.

6
To energize the pumps the operator must ensure that all the valves are in the open position,
thereby allowing fluid to flow through the system. As well, the pumps must be primed to the
optimal pressure range (600PSI). The operator should also check for any tripped overloads
that would prevent the pumps from energizing. Another factor in the starting operation of the
pumps is the level in the well. The level in the well must be at least 65% for the lead pump to
turn on.

Prior to energizing the pump, the operator shall designate one pump as the “lead” pump and
one pump as the “lag” pump by using the Lead/Lag selector switch. When all criteria are met
the operator may press the start button and energize the pump. The lead pump will be the
first to initiate when the level in the tank is 65%. As the level in the tank increases to 75%
the lag pump will initiate and assist in lowering the level. When the level in the well drops
below 75% the lag pump will de-energize, similarly, when the level drops below 65% the
lead pump will stop. Stopping the motors is also achieved by pressing the stop button. It is
important to note that there is a 5 second time-interlock between the pumps. This avoids both
pumps from energizing simultaneously and drawing a large in-rush current.

The level in the well is monitored by two devices, a Sonac (ultrasonic sensor) and johnny
balls (float switches). The Sonac is the primary sensing element which detects the level in
the well; however, if the Sonic fails then the johnny balls become the primary level sensor. A
Sonac fail condition occurs when the level in the well is less than 10%, when this occurs the
johnny balls become the primary sensing element. The operator may confirm a Sonac fail
has occurred by referencing the “Faults” and “Alarms” tabs on the HMI.

When the johnny balls become the primary sensing element, they will monitor the level in
the well and initiate the pumps at the appropriate level. There are 5 johnny balls that monitor
their own respective levels, these levels are 20%, 45%, 65%, 75% and 90%. The lead pump
will still energize when the level in the tank is 65%, and the lag pump will still start when the
level in the tank is 75% - both pumps will de-energize when the level in the tank reaches
65% or by pressing the stop button. If all johnny balls are working correctly, when the

7
johnny balls close, a corresponding light is turned on at the DAI 540 plc card– indicating
that the johnny balls are working. When a johnny ball fails to close with rising level after 10
seconds, a johnny ball light will begin to flash on the DAI 540 plc card. Similarly, as the
tank level falls each johnny ball should drop and open the switch. If a johnny ball does not
open and is stuck, after 10 seconds a light will flash to indicate that there is an issue with the
johnny ball.

The Johnny Ball Lockout network contains a series of alarm circuits corresponding to
various tank levels. For example, if the 20% johnny ball gets stuck in the open or closed
position the 20% johnny ball alarm will initiate. This will happen for all respective johnny
balls in the tank. Each alarm circuit is composed of the same elements for their respective
levels. When a johnny ball is stuck in the open or closed position for longer than 10 seconds,
that johnny ball will initiate a flashing alarm light. This flashing light is meant to inform the
operator that a johnny ball is stuck and needs maintenance. After the johnny ball is serviced,
the operator must press the acknowledge button for the johnny ball to function.

If the level rises above 90% a high-level alarm circuit will initiate. When the level in the tank
is above +90% an amber alarm light will begin to flash. If the level drops below 90% within
10 seconds, then the light will stop flashing and become solid. The solid light informs the
operator that a high level has occurred in the well. The light will turn off when the operator
presses the acknowledge button. If the level is +90% for more than 10 seconds, then a horn
will begin to sound along with the flashing light. If the level drops below 90% than
acknowledging the high-level condition will turn off the horn and turn off the light.

Pressure is another factor that plays a pertinent role in the operation of the pumps. For the
pumps to start, the pumps must be primed to 600PSI. A broken line occurs when the system
pressure is less than 200PSI. If a broken line occurs, then the pumps will be unable to start
until the system pressure reaches 600PSI. A blocked line occurs when the system pressure
increases to 1000PSI and maintains that system pressure for longer than 5 seconds. If a
blocked line occurs than both pumps will be de-energized until the system pressure drops to
800PSI, at which point both pumps will re-energize.

8
 High-pressure lockout occurs when the system pressure has reached 1000PSI three times
within a span of one minute. When this happens, the pumps will be locked out and will be
unable to start even if the pressure has dropped to 800PSI. To restart the pumps, the system
pressure must be 700PSI or below, at which point the operator may acknowledge the alarm
by pressing the acknowledge button, and finally pressing the start button. When a high-
pressure lockout occurs a light on the DDO plc card will change from solid to flashing.
Pressing the acknowledge button will change the flashing light back to a solid light.

5.3 Long Comments

Alarm Network

The alarm circuit is activated when the level in the tank rises above 90%. When the tank level
reaches +90% the johnny ball 90 (jb90) contact will close and pass logic to an oscillator setup
which will oscillate an alarm light (AlarmLight). If the acknowledge button is pressed withing 10
seconds of the level reaching 90% then the flashing light will turn solid until the level drops
below 90% in the tank. If the alarm light is not acknowledged withing 10 seconds logic will be
passed to a to a horn coil (horn) and initiate a real-world horn. The horn will continue to sound
until the acknowledge button is pressed.

Pumpcontrol_Reset Network

The Pump Control and Reset Network performs several functions. In the top of the network there
is a section for valve control. If valve 1 or valve 6 is closed, then both pumps will turn off. If
valve 2 or valve 3 is closed then pump 1 will shut off, similarly, if valve 4 or valve 5 is closed
pump 2 will shut off – all valves must be open for the pumps to start.

Start and stop of pumps section presents all the logic that would prohibit the pumps from
starting, such as a broken line, blocked line, or closed valves. All pump starting conditions must
be met for both pumps to start. When all conditions are met logic will pass through the rung and
energize the PumpsOffCoil. When the PumpsOffCoil is energized it will change the states of all
its associated contacts, in this case when PumpsOffCoil receives logic and is energized, it will
pass logic to the Pump network allowing the pumps to start.

9
Selection of Leading and Lagging Pump section allows the operator to choose which pump will
function as the lead pump and the lag pump.

Broken Line Shutdown and Reset section monitors the pressure occurring in the process. If the
pressure in the well is less than 200 PSI then Pressure200Coil will be energized and pass logic to
a BrokenLine set coil which will shut down the pumps. The pumps cannot start until the pressure
in the well reaches 600 PSI. When 600 PSI is achieved in the well Pressure600Coil will energize
and pass logic to a BrokenLine reset coil which will reset the BrokenLine set coil and allow the
pumps to start.

Broken Line Shutdown and Reset section will stop the pump if the pressure in the well is greater
than 1000 PSI for 5 seconds – indicating that there is a blocked line in the well. The motors will
be unable to restart unless the pressure in the well drops to 800 PSI. If pressure in the well is
greater than 1000 PSI for 5 seconds, Pressure1000Coil will close and pass logic to a 5 second
ON timer. After 5 seconds has elapsed and the pressure has not dropped below 1000 PSI then
logic will be passed to a BlockedLine set coil and will shut down both pumps. When the pressure
in the well drops to 800 PSI, Pressure800Coil will close and pass logic to the BlockedLine reset
coil, which will allow the BlockedLine set coil to revert to its normal state and allow the pumps
to start.

Motor Reset section contains the logic to allow the lead and lag pumps to continue operating
until the level in the well has dropped to 45%.

Sonac Control section contains the logic that informs the operator once a low level (10%)
condition in the well occurs. When the level drops to 10% or less Coil10 will close and pass
logic to a Sonac_Warning_Light coil, indicating that a low level has occurred in the tank.

10
 AnalogDial Network

The analog dial network controls the scaling parameters for level and pressure in the wet well.
Programmed in FBD, the analog input ACI 030 card, and the analog output ACO 020 card send
logic to an I_Scale function block and scales the data into an engineering value. The level in the
wet well is scaled to a value of 0-100% and the pressure is scaled to a value of 0-1000PSI.

The Sonac Control/ Pressure Control section of this network is responsible for receiving the
scaled engineering values for pressure and level and relays the logic to greater and less than
function blocks. Depending on which function block receives logic will determine which coils
are energized as outputs. These outputs simulate pressure and level in the tank of the wet well.

Pump Network

Pump1 Motor Circuit and Pump2 Motor circuit sections perform the same function just for
different pumps. When the PumpsOffCoil receives logic from the Pump Control network, it will
pass logic to the Pump network allowing pump 1 and pump 2 to start.

5 Second Motor Delay section contains the logic to provide a timed-interlock of 5 seconds
between the lead pump start and lag pump start.

HMI Network

The HMI network is responsible for passing information from the PLC to the HMI, allowing the
process in the wet well to be monitored.

Johnny_Ball_Lockout Network

The Johnny Ball Lockout Network communicates to the operator if there are any failures with
the johnny balls in the tank when the level is increasing or decreasing. If the level in the tank is
increasing and a johnny ball fails to close, after 10 seconds an alarm light will begin to flash. If
the tank is full and all the johnny balls are working properly the lights will be solid. When the
level in the tank decreases and a johnny ball does not open for 10 seconds then a light will flash
indicating that there is an issue with the johnny balls.

11
6.0 HMI/SCADA

6.1 HMI

Reference Appendix C for a full image of the program.

A Human-Machine Interface (HMI) is an interface that enables an operator to observe and

manipulate a process in a machine, system, or device. In industrial settings, an HMI may be
used to visually display data, track trends and tags, provide remote system monitoring and
monitor inputs and outputs. HMIs are similar to SCADA systems and are commonly used
simultaneously within an industrial control system. However, there are a few key differences.
HMIs are primarily used to display process data to the operator to supervise an industrial
process, and do not allow trends to be stored. SCADA systems have a higher data acquisition
capacity and are used to monitor and control multiple large scale control systems.

Before an HMI may be integrated into a system it must first be coupled with a PLC. The PLC
acts as the CPU and takes information from inputs and creates outputs based on the PLC
logic. In the context of this project, the HMI is the interface medium between the operator and
the wet well and provides the operator with real time information occurring in the system. It
allows the operator to monitor and observe the systems process variables, alerts the operator
when a fault condition has occurred and maintains an event log. Below is a breakdown of the
operating features that were programmed into the HMI.

12
HMI Home Page

Figure 1 - HMI Home Page

The home page interface provides the operator a means of starting and stopping the system,
viewing the fault conditions of the system, acknowledging any fault conditions that have
occurred, as well, displays real-time information on the process variables being monitored
(level and pressure). Tank level and pressure are display in the bottom left corner; level is
expressed as a percentage (%) while pressure is represented by pounds per square inch (PSI).
A tank with a variable level feature simulates what the process in the wet well would look
like. Fitted on top of the tank is a Sonac (ultrasonic sensor) to measure the level with
ultrasonic frequencies. If the Sonac fails, the Sonac Working light will turn from green to red
to indicate to the operator that there has been a Sonac failure. Beside the tank is a level scale.
As the level in the tank increases so will the corresponding lights.

13
When the start button is pressed the system process will initiate and when the stop button is
pressed the system will stop. Faults that have occurred during the process may be observed in
the Fault Finder page; however. There is a control status button on the home page which
initiates a popup for quick access to the control devices status while staying on the home
page.

Figure 2 - Control Status Popup

An acknowledge button has been added to clear and reset faults. The status of the valves is
also displayed. Closed valves are displayed in grey and open valves are displayed as green.
Likewise, when the pumps are not energized, they are displayed as grey and when the pumps
are energized, they are displayed as green. When a device experiences a fault then that piece
of equipment will be displayed as red. The operator can access the different HMI pages by
clicking the tabs at the top of the home page. A colour index button has been added to the
bottom left of the page. When clicked, a popup appears with a legend of the color functions in
the program.

14
HMI Alarm Page
Figure 3 - Alarms Home Page – No Faults

The alarm page contains an event logger that records and stores faults and trips that have
occurred in the system. For example, if the level in the tank is less than 10% than the event
will immediately be displayed in the alarm logger, along with a time stamp and the date at
which the fault occurred. Faults that remain active in the system are display in the alarm
logger as red. When the fault has been acknowledged and fixed by the operator the status of
the fault will be displayed in green. Tab selection is accessible at the top of the alarm page.
System control and status buttons have been added to the bottom of the alarm page. The
system control button initiates a pop-up window which provides the operator a means of
starting and stopping the system, as well, acknowledge faults. The status button initiates a
pop-up window which displays the status of control devices such as valves and johnny balls
and displays the status of the pumps and overloads.

15
The figure below demonstrates the faults being displayed in the events logger. The logger
displays a message regarding the fault, the date of occurrence, the time, and the status of the
fault. Active faults are displayed as red with a status of “ACTIVE”, similarly, faults that have
been acknowledged are displayed as green with a status of “RTN”.

Figure 4 – Event Logger with Faults

16
HMI Trends Page

Figure 5 – HMI Trends Page

The trends page provides visual displays of the process variables in the form of trend graphs.
The level trend graph is located on the left side of the page and displays the level (%) in the
tank in the forms of a line graph. The tank level (%) is also expressed on a scale located below
the line graph. The pressure gauge is located on the right side of the page and displays the
system pressure (PSI). The graphs will display their respective process variables when the
system is operational. A numerical representation for tank level (%) and pressure (%) can be
found at the bottom of the page. System control and status buttons have been added to the
17
trends page to provide quick access to start and stop the system, as well, check the condition
of control valves and johnny balls.

HMI Fault Finder Page

Figure 6 - HMI Fault Finder Page

The fault finder page provides an efficient means of locating and correcting faults in the
system. The page displays the operational status for all means of control for the system.
Alarm conditions are programmed into the PLC program, if a process variable breeches an
alarm condition a system fault will occur. When a fault condition occurs the colour display for
that fault will turn from green to red, similarly, when a fault is cleared the colour display will
change from red to green. A green status symbol denotes that there are no faults in the system,
while a red status symbol denotes that a fault has occurred.

18
Fault conditions are broken down into sections, such as tank level alarms, pressure alarms,
valve alarms, and float switch alarms. These sections house their respective alarm symbols.
The faults page also displays the status of both pumps and their respective overloads. Faults
that have occurred will be logged in the alarm page along with the date and time which they
occurred. A system control and status button have been added at the bottom of the page to
provide a quick means of system control.

The figure below demonstrates the occurrence of a fault. In this case, the overloads for both
pumps must be reset, there is a broken line due to low pressure, the level in the tank is above
90%, and the valves are in the closed position. To correct this, the overloads must be reset, the
valves must be in the open position, and the pumps must then be primed to 600PSI. Initiating
the pumps will lower the level in the tank and clear the high-level fault, this will also cause
the horn alarm to cease. Alarms displayed as red indicate that a fault has occurred, while
alarms displayed as green indicate that no alarm is active.
Figure 7 – Active Faults

19
6.2 SCADA

Reference Appendix C for a full image of the program.

SCADA systems are essential for monitoring and controlling industrial processes. They assist
in maintaining system efficiency and production efficiency, as well, process data to improve
to help mitigate downtime. SCADA (Supervisory control and data acquisition) is a software
system which allows industrial organizations to:

 Control a process locally or remotely

 Monitor and gather real-time process data
 Interact with instrumentation devices such as sensors, pumps, valves, motors, and
more through HMI software.
 Logs events into a database

The PLC is the communication medium between the HMI and sensing devices, and the
SCADA software. Information from the HMI and sensors in the wet well will be sent to the
PLC module. Once received, the PLC will communicate that information to computers with
SCADA software. SCADA software will process the information from the PLC and convert it
into a display for the operator.

The SCADA system for the wet well project has been created with Citect Studio and has been
designed to work in conjunction with the PLC hardware. The information from the PLC is
transferred to the HMI which provide remote monitoring and control of the pumps and
sensing devices inside the well. The SCADA system has also been programmed to display
alarms and trends. Trend graphs are visual representations of industrial processes in real-time.
These trend graphs may be used to monitor an active process, or to analyze process variables
to improve system efficiencies. Trends may also be stored into an event logger for future
reference. Alarms inform the operator that proves variables have breeched the operational
conditions of the system. For example, a low level (-10%) in the wet well indicates that there
is a Sonac failure. When this event takes place and alarm will be displayed in the program to
inform the operator of a breech of system conditions. Alarms may also be recorded in an
event logger for future reference.

Below is a breakdown of the sections created in the SCADA program. These sections provide
real-time information to the operator on the condition of sensing devices and pumps used in
the wet well. The sections are broken down into 4 parts – home page, fault finder, trends, and
alarms.

20
SCADA Home Page

Figure 8 – SCADA Home Page – System OFF

The home page is displayed when the operator runs the active program in Citect Studio. The
home page is a visual representation or the active process in the wet well. The home page is
furnished with basic system controls such as start, stop, and acknowledge. The start button will
energize the pumps, the stop button will de-energize the pumps, and the acknowledge button
clears faults that have occurred. Along with the control features, a control status button has been
added to the home page. Pressing this button will engage a popup window displaying the
operating status of devices such as overloads, valves, pumps, and johnny balls. A pressure and
level gauge have been added to the bottom left of the screen. These gauges display their
respective process variable in real-time, they also display the process variables as numerical
values underneath the gauges.

A visual representation of valves and pumps may be found in the middle of the home page. The
colour grey denotes devices such as valves, johnny balls and pumps are in the closed/de-
energized state, whereas green denotes devices are open/energized. If a fault occurs on a piece of
equipment that item will be displayed as red – denotes that a fault has occurred. All valves must
be in the open position for the system to start. If valve #1 and valve #6 are closed, then both
pumps will be de-energized. If valve #2 and valve #4 are closed than pump #1 will be de-
energized, similarly, if valve #3 and valve #5 are closed than pump #2 will be de-energized.

The tank icon provides a visual representation of the level in the wet well tank. It uses a variable
graph to display the dynamic level in the tank in real-time. On top of the tank is the Sonac
(ultrasonic measuring device). The Sonac is the primary level sensor for the system and monitors

21
the level inside the well. The function status of the Sonac is displayed at the top of the tank –
green denotes that the Sonac is functional, and red denotes that the Sonac has failed. If the Sonac
fails, the johnny balls take over as the primary level sensor.

The johnny balls are the secondary level sensors in the system and are placed beside the tank.
The johnny balls will close at tank levels 20%, 45%, 65%, 75% and 90%. There are two lights
beside each johnny ball; the lights under the heading “Stuck” will turn red when a johnny ball is
stuck, while the other light indicates the functional status of the johnny ball. A grey light denotes
that the johnny ball is not closed, while a green light denotes that a johnny ball is closed.

Figure 9 – SCADA Home Page – System ON

22
SCADA Fault Finder

Figure 10 – SCADA Fault Finder Page – No Faults

The fault finder page provides a visual depiction of faults that have occurred in the process. For
example, if float switch 45% failed to close then the 45% float switch fail light would turn from
green to red. A green light beside a status indicates that the device is operational and has no
faults. A red light beside a status indicates that the device has experienced a fault or has
malfunctioned. When a system fault occurs, the fault will show up on the fault finder page and
the alarm section.
The fault finder is categorized according to device groupings. This means all float switch alarms
will be grouped together, likewise, all pressure alarms will be grouped together, and so on. Any
fault that occurs within the system will result in the respective alarm light switching from green
to red – red indicating a fault, green indicates no fault. Several alarm groups are indicated on the
fault finder page. These alarm groups are float switch alarms, valve alarms, tank level alarms,
pressure alarms, pump alarms, and tripped overloads.

A start, stop, acknowledge, and control status button have been added to the bottom left of the
fault finder page. The start and stop buttons allow the operator to initiate the process from the
fault page. The acknowledge button will allow the operator to clear and acknowledge faults that
have occurred, and the control status button will initiate a popup showing the status of control
devices.

23
The figure below illustrates that a fault has occurred for “High Tank Level +90%”, “Horn
Alarm”, “Blocked Line” and “Tripped O/L”.

Figure 11 – SCADA Fault Finder Page – Active Faults

SCADA Alarms Page

The SCADA alarm page constantly monitors equipment and alerts the operator of any equipment
issues or alarm conditions. In the wet well project defined alarms are the primary alarm
objective. Defined alarms report fault conditions or unexpected issues in an industrial process,
these alarms must be configured manually by the operator. Digital alarms are a category of
defined alarms and are used throughout the program. Digital alarms activate in response to the
state of a digital variable. When a variables binary state changes from a 0 to 1 the alarm is
triggered, and a notification will occur.

Alarms can be viewed in the in the drop-down menu on the right side of the home page. Clicking
the alarms section will open another drop-down menu where active alarms may be viewed.
Alarms are also displayed at the top of the home page. When an alarm condition is activated, it
will be logged in the alarm page under active alarm section. The date, time, tag, name, and state
of the alarm will be displayed in the active alarm page.

The figure below depicts the SCADA alarm page without any active faults.

24
 Figure 13 – SCADA Alarm Page – No Alarms
Figure 14 – SCADA Alarm Page – Active Faults

SCADA Process Analyst

The SCADA process analyst is an Active X control designed to display trend data from a
SCADA trend server, and alarm tags from the SCADA alarm server. It is capable of displaying
every trend type and alarm data in the same window. The process analyst provides a visual
means to analyze and compare trend data.

Figure 15 – SCADA Trends Page

7.0 Equipment

7.1 Bill of Materials

Below lists of all the components found on the wiring boards in room 1807A. A brief description
is given for each device.

AIPhone - AT-406 – Provides communication between the local operator and remote operator.
Allan-Bradley – Amber LED Indicator Light 800L- 18L10A – Amber LED indicating light that
informs the operator a high-level condition has occurred in the wet well.

Allan-Bradley – Green Pushbutton 800T-A1D1 – Flushed green pushbutton used to start the
lead pump.

Allan-Bradley – Green LED Indicator Light 800L-30L10G - Green LED indicating light that
informs the operator that both pump motors are ON.

25
Allan-Bradley – Red LED Indicator Light 800L-30L10R – Red LED indicator light that informs
the operator that pump motors are stopped.

Allan-Bradley – Red Pushbutton 800T-B6A4 – Flushed red pushbutton used to stop both pump
motors

APG – Cable Float Switch FT-100A, FT-100B – Not a real device used in project

APG - Pump Control Ultrasonic Level Sensor DST-1002-CL10 - Not a real device used in
project.

Automation Direct – DIN Rail, Slotted DN-R35S1-2 – Slotted DIN rail for mounting terminal
blocks

Automation Direct – Selector Switch HT8JAH3A – 3 position selector switch – 1 switch is

used for lead/lag pump selection, the second switch is used to force start the lag pump.

Drok – Drok Signal Generator 300482 – 4-20mA signal generator – 1 signal generator is used
for displaying the level in the wet well tank, the other signal generator is used to display the
pressure in the tank.

Eaton – Heavy Duty Safety Switch 1HD361 – 600V fused main disconnect – provides a safety
means for isolating the supply from the electrical circuit.

Eaton – JKS Fast-Acting Class J Fuse JKS-10 – Class J fast-acting fuse for the main disconnect.

Ferraz Shawmut - Time Delay Fuse ATDR1 – Time delay fuse for the fused disconnect in the
enclosure.
Rockwell Automation – Limit Switch NEMA Type 4 802T-ATP – Limit switch used in pump
#2 enclosure to prevent the circuit from energizing while the door is open.

Rockwell Automation – NEMA Industrial Control Relay 700-P400A1 – Control relays CR1
supplies power to pump #1 and CR2 supplies power to pump #2.

Schneider Electric – Combination Starter Class 8538 – Fusible Disconnect Switch Type – An
electrical enclosure fitted with a 600V, 3-phase disconnect, and a combination starter. There is a
combination starter for each pump.

Schneider Electric – 100VA Control Transformer 9070TF100D5 – Each enclosure has a

100VA control transformer to provide the control circuit with the required 120V.

Schneider Electric – HMI Base Unit, Harmony GTU HMIG3U – The power supply for the
HMI screen display.

26
Schneider Electric – HMI Touch Panel Screen HMIST6600 – The touchscreen user interface
that allows operators to control and monitor the wet well process.

Schneider Electric – Mounting Plate NSYMM64WH – Steel mounting plate for the inside of
the electrical enclosures. Allows heavy electrical components to be mounted inside of the
electrical panel.

Schneider Electric – Modicon ConneXium Ethernet Switch TCSESU083FN0 -

Schneider Electric – Modicon Quantum Racks – 10 Slot 140XBP01000 -

Schneider Electric – PLC Card ACI 030 Analog Input Module – A PLC analog input module
which accepts mixed current and voltage inputs.

Schneider Electric – PLC Card AC0 020 Analog Output Module – The analog output module
controls and monitors current in 4-20mA loops.

Schneider Electric – PLC Card CPS 114 Power Supply Module 140 CPS114 20 - Power
supplies are used to supply system power to modules inserted into the PLC rack.

Schneider Electric – PLC Card CPU 434 Concept Processor 140 CPU434 12A - A digitally
operated electronic system, which uses a programmable memory for the internal storage of user
instruction.

Schneider Electric – PLC Card DAI 540 Discrete Input Module 140 DAI5 400 00 - A module
that accepts 115 VAC inputs.

Schneider Electric – PLC Card DDO 353 Discrete Output Module 140 DD0353 00 - The DC
output 24 VDC source module switches 24 VDC powered loads and is for use with shared output
common wired to 0 V.

Schneider Electric – PLC Card DRA 840 Discrete Output Module 140 DRA840 00 - Used to
switch a voltage source using 16 relays with normally open contacts.

Schneider Electric – PLC Card NOE 771 Ethernet Network 140NOE77111 - Ethernet network
TCP/IP module

Schneider Electric – 24VDC Power Supply ABL8MEM24006 - Supplies power to the PLC
card CPS 114.

Schneider Electric – Terminal Block 9080GME6 – Grey terminal blocks 30A/600V, connects
to a 35mm DIN rail. The terminal blocks are a neutral meeting spot for electrical conductors that
supply power to different parts of the electrical circuit.

Square D – Circuit Breaker Disconnect Mechanism 9422RQ1 – 3-phase circuit breaker for each
electrical panel.

27
Square D – NEMA Motor Starter 8536SC03V02S – A combination starter (relay and overload)
that controls the pumps.

Square D – Molded Case Motor Circuit Protector HLL36030M71 – 30A, 600VAC molded case
circuit breaker. Used in the electrical enclosure for pump #2.

WEG – General Purpose Motor 00112ET3H145T-W22 – 1HP, 60Hz, 575V, 3-phase squirrel
cage induction motor. There are two motors that start each pump respectively.

Weidmuller – Terminal Block End Plate AP 100 BK – Terminal block end plates.

8.0 Data Sheets

8.1 Specification Sheets

Please reference Appendix D for a full list of specification sheets used in the wet well project.

9.0 Resources

9.1 Specification Sheet References

AIPhone – (2022) AT-406 – https://www.supplyworks.com/Sku/312933340/aiphone-at-406-series-surface-mount-

1-channel-audio-intercom-with-one-at-206b-master-station-one-at-306b-sub-station-gray-840067650639-at-406b-
a#specifications-link
Allan-Bradley – (2022) Amber LED Indicator Light 800L- 18L10A - https://www.lumen.ca/en/products/12-
control-automation/09-pilot-devices/03-indicator-pilot-lights/06-specialty/p-QUxMODAwTDE4TDEwQQ==-
all800l18l10a-800l-p-l-18-mm-indicator-light-amber-120-vac-indicator

Allan-Bradley – (2022) Green Pushbutton 800T-A1D1 - https://www.westburne.ca/cwr/Category/Motor-Control-

%26-Automation/Motor-Control/Pushbuttons%2C-Pilot-Lights%2C-Selector-Switches/30-5MM-Pushbuttons-Pilot-
Lights-%26-Illum-Operators/800T-A1D1-PUSHBUTTON-UNIT-GREEN/p/ALB800TA1D1-WG

Allan-Bradley – (2022) Green LED Indicator Light 800L-30L10G -

https://www.westburne.ca/cwr/Category/Motor-Control-%26-Automation/Motor-Control/Pushbuttons%2C-Pilot-
Lights%2C-Selector-Switches/18MM-Pushbuttons%2C-Pilot-Lights-%26-Illum-Operators/800L-30L10G-
INDICATOR-LIGHT-PLASTIC-30/p/ALB800L30L10G-WG

Allan-Bradley – (2022) Red LED Indicator Light 800L-30L10R -

https://www.platt.com/platt-electric-supply/Indicator-Lights-Operator-Only/Allen-Bradley/800L-30L10R/
product.aspx?zpid=1057491

Allan-Bradley – (2022) Red Pushbutton 800T-B6A4 - https://www.westburne.ca/cwr/Category/Motor-Control-

%26-Automation/Motor-Control/Pushbuttons%2C-Pilot-Lights%2C-Selector-Switches/30-5MM-Pushbuttons-Pilot-
Lights-%26-Illum-Operators/800T-B6A4-A-B-PUSH-BUTTON-UNIT/p/ALB800TB6A4-WJ

28
Anixter - (2022) #14AWG Black Conductor 6G-1401-02-500 - https://objects.eanixter.com/PD372195-AN.PDF
Anixter - (2022) #14AWG Red Conductor 6F-1401-03-500 - https://objects.eanixter.com/PD372195-AN.PDF
APG – (2022) Cable Float Switch FT-100A, FT-100B -
https://alpscontrols.com/prod_data//docs/APG_SENSORS/FT-100-FT-300.pdf?

APG - (2022) Pump Control Ultrasonic Level Sensor DST-1002-CL10 -

https://www.apgsensors.com/sites/default/files/datasheets/DCR.pdf

Automation Direct – (2022) DIN Rail, Slotted DN-R35S1-2 -

https://cdn.automationdirect.com/static/specs/dinrailscb.pdf

Automation Direct – (2022) Selector Switch HT8JAH3A -

https://cdn.automationdirect.com/static/specs/eaton30mm2select.pdf

Drok – (2022) Drok Signal Generator 300482 - https://www.droking.com/Adjustable-Current-Voltage-Analog-

Simulator-0-20mA-Signal-Generator-for-signal-sources-valve-adjustment-inverter-control-PLC-etc

Eaton – (2022) Heavy Duty Safety Switch 1HD361 - https://www.dixonelectric.ca/products/20-power-

distribution/03-disconnect-safety-switches/01-fusible-safety-switches/05-heavy-duty-safety-switches/p-
Q1VIMUhEMzYx-heavy-duty-fusible-single-throw-safety-switch-30-a-600-vac-250-vdc-3-p-painted-steel-nema-1-
indoor

Eaton – (2022) JKS Fast-Acting Class J Fuse JKS-10 - https://www.eaton.com/us/en-us/skuPage.JKS-

10.specifications.html

Ferraz Shawmut - (2022) Time Delay Fuse ATDR1 - https://ferrazshawmutsales.com/pdfs/ATDR.pdf

Phoenix Contact – (2022) Power Supply Unit 2866776 - https://www.phoenixcontact.com/en-ca/products/power-

supply-quint-ps1ac24dc20-2866776

Rockwell Automation – (2022) Limit Switch NEMA Type 4 802T-ATP -

https://www.westburne.ca/cwr/Category/Motor-Control-%26-Automation/Automation-Products/Proximity%2C-
Limit%2C-Level-Sensors/Limit-Switches/802T-ATP-LIMIT-SWITCH/p/ALB802TATP-WG

Rockwell Automation – (2022) NEMA Industrial Control Relay 700-P400A1 -

https://www.westburne.ca/cwr/Category/Motor-Control-%26-Automation/Motor-Control/Monitoring-Relays/
Industrial-Control-Relays/700-P400A1-CONTROL-RELAY-120V-AC/p/ALB700P400A1-WG

Schneider Electric – (2022) HMI Base Unit, Harmony GTU HMIG3U -

https://www.se.com/ww/en/product/HMIG3U/base-unit-harmony-gtu-premium-box-for-universal-panel/

Schneider Electric – (2022) HMI Touch Panel Screen HMIST6600 -

https://www.se.com/ww/en/product/HMIST6600/touch-panel-screen-harmony-st6-12w-display-2com-2ethernet-
usb-host-device-24-vdc/

Schneider Electric – (2022) Combination Starter Class 8538 – Fusible Disconnect Switch Type -
https://download.schneider-electric.com/files?
p_File_Name=8538SCA24V86CFF4H30P2T_DATASHEET_CA_en-
CA.pdf&p_Reference=8538SCA24V86CFF4H30P2T_DATASHEET

Schneider Electric – (2022) 100VA Control Transformer 9070TF100D5 -

https://www.se.com/ca/en/product/9070TF100D5/transformer-type-tf-industrial-control-100-va-600-vac-primary-
120-vac-secondary-1-phase-50-60-hz-55-c-rise/

29
Schneider Electric – (2022) Mounting Plate NSYMM64WH -
https://www.se.com/ca/en/product/NSYMM64WH/mounting-plate-enclosure-h600xw400mm-polyester-powder-
over-galvanised-sheet/

Schneider Electric – (2022) Modicon ConneXium Ethernet Switch TCSESU083FN0 -

https://www.se.com/ww/en/product/TCSESU083FN0/connexium-unmanaged-switch-8-ports-for-copper/

Schneider Electric – (2022) Modicon Quantum Racks – 10 Slot 140XBP01000 -

https://www.se.com/ca/en/product/140XBP01000/modicon-quantum-racks-backplanes-10-slots/

Schneider Electric – (2022) PLC Card ACI 030 Analog Input Module 140ACI03000 -
https://www.se.com/ca/en/product/140ACI03000/analog-input-module-modicon-quantum-8-i-multirange/

Schneider Electric –(2022) PLC Card CPS 114 Power Supply Module 140CPS11420 -
https://www.se.com/ca/en/product/140CPS11420/power-supply-module-modicon-quantum-115-v-230-v-ac-
summable-or-standalone/

Schneider Electric – (2022) PLC Card CPU 434 Concept Processor 140CPU43412A -
https://www.se.com/ca/en/product/140CPU43412A/concept-processor-80486-modicon-quantum-1-modbus-plus-2-
modbus-rs232/

Schneider Electric –(2022) PLC Card AC0 020 Analog Output Module 140ACO02000 -
https://www.se.com/ca/en/product/140ACO02000/analog-output-module-modicon-quantum-4-o-4-20-ma-12-bits-
bipolar-current/

Schneider Electric – (2022) PLC Card DAI 540 Discrete Input Module 140DAI5400 -
https://www.se.com/ca/en/product/140DAI54000/discrete-input-module-modicon-quantum-16-i-115-v-ac-16-
channels/

Schneider Electric – (2022) PLC Card DDO 353 Discrete Output Module 140DD035300 -
https://www.se.com/ca/en/product/140DDO35300/discrete-output-module-modicon-quantum-32-o-solid-state/

Schneider Electric – (2022) PLC Card DRA 840 Discrete Output Module 140DRA84000 -
https://www.se.com/ca/en/product/140DRA84000/discrete-output-module-modicon-quantum-16-o/

Schneider Electric – (2022) PLC Card NOE 771 Ethernet Network 140NOE77111 -
https://www.se.com/ca/en/product/140NOE77111/ethernet-network-tcp-ip-module-class-c30-factorycast-
configurable/

Schneider Electric – (2022) 24VDC Power Supply ABL8MEM24006 -

https://www.se.com/ca/en/product/ABL8MEM24006/regulated-switch-power-supply-1-or-2phase-100-240v-ac-
24v-0-6-a/

Schneider Electric – (2022) Terminal Block 9080GME6 - https://www.se.com/us/en/product/9080GME6/terminal-

block-linergy-box-lug-connector-grey-colored-block-30a-600-v/

Square D – (2022) Circuit Breaker Disconnect Mechanism 9422RQ1 -

https://www.se.com/us/en/product/9422RQ1/disconnect-mechanism-circuit-breaker-variable-depth-150-250a-3-
pole-operator-only-for-powerpact-h-and-j-breakers/

Square D – (2022) NEMA Motor Starter 8536SC03V02S - https://www.se.com/us/en/product-range/1862-nema-

type-s-motor-starters-8536-8736-8606/

30
Square D – (2022) Molded Case Motor Circuit Protector HLL36030M71 -
https://www.se.com/ca/en/product/HLL36030M71/motor-circuit-protector-powerpact-h-unit-mount-30a-3-pole50-
ka-600-vac-80-rated/

WEG – (2022) General Purpose Motor 00112ET3H145T-W22 -

https://static.weg.net/medias/downloadcenter/h14/h8f/WEG-standard-stock-catalog-complete-catalog-us100-
brochure-english.pdf

Weidmuller – (2022) Terminal Block End Plate AP 100 BK - https://catalog.weidmueller.com/catalog/Start.do?

localeId=en_DE&ObjectID=1189890000

Appendix
Appendix A – Drawings
A.1 PLC 100’s
100 – 00 PLC Card-Whole Rack
100 – 01 PLC Card ACI 030 00
100 – 02 PLC Card DAI 540 00
100 – 03 PLC Card ACO 020 00
100 – 04 PLC Card CPS 114 20
100 – 05 PLC Card CPU 434 12A
100 – 06 PLC Card DAI 540 00
100 – 07 PLC Card DDO 353 00
100 – 08 PLC Card DRA 840 00
100 – 09 PLC Card NOE 771 11
A.2 Layout 200’s
200 – 01 Main Board Elevation
200 – 02 Telephone
A.3 Wiring 300’s
300 – 01 Pressure Display
300 – 02 Level Display
300 – 03 Pump #1
300 – 04 Pump #2
300 – 05 Main Disconnect
300 – 06 Control Relay #1 (CR1)
300 – 07 Control Relay #2 (CR2)
300 – 08 HMI
300 – 09 24V DC Power Supply
300 – 10 Phoenix Contact
300 – 11 Ethernet Switch
A.4 As Found 400’s
400 – 00 PLC Card 10-Slot Rack

31
 400 – 01 PLC Card ACI 030 00
400 – 02 PLC Card DAI 540 00
400 – 03 PLC Card ACO 020 00
400 – 04 PLC Card CPS 114 20
400 – 05 PLC Card CPU 434 12A
400 – 06 PLC Card DAI 540 00
400 – 07 PLC Card DDO 353 00
400 – 08 PLC Card DRA 840 00
400 – 09 PLC Card NOE 711 11
400 – 10 Pressure Display
400 – 11 Level Display
400 – 12 Pump #1 Wiring
400 – 13 Pump #2 Wiring
400 – 14 Terminal Block #1 (TB1)
400 – 15 Terminal Block #2 (TB2)
400 – 16 Terminal Block #3 (TB3)
400 – 17 Telephone
400 – 18 Phoenix Contact
400 – 19 Main Disconnect
400 – 20 24V DC Power Supply
400 – 21 HMI Wiring
400 – 22 Ethernet Switch
400 – 23 Control Relay #1 (CR1)
400 – 24 Control Relay #2 (CR2)
400 – 25 Control Panel Front View
400 – 26 Control Panel Inside View
A.5 Terminal Blocks 500’s
500 – 01 Terminal Block #1 (TB1)
500 – 02 Terminal Block #2 (TB2)
500 – 03 Terminal Block #3 (TB3)
A.6 Control Panel 600’s
600 – 01 Control Panel Front View (Outside)
600 – 02 Control Panel Back of Door (Inside)
Appendix B – PLC Program
B.1 Alarm Network
B.2 Pump Control / Reset Network
B.3 Analog Dial Network
B.4 Pump Network
B.5 HMI Network
B.6 Johnny Ball Lockout Network

32
 B.7 Pressure Lockout Network
B.8 Pump Lockout Network
Appendix C – Graphics
C.1 HMI Graphics
C.2 SCADA Graphics

Appendix D – Specification Sheets

Appendix E – Wet Well Requirements and Change Orders

E.1 Wet Well Requirements

Appendix E.1 contains the original requirements for the wet well project.

PLC Wet Well Requirements

- One selector switch to choose lead/lag pump (use 1 toggle sw.)

- One selector switch (1 toggle sw.) to choose what to display on the analog out dial, either
level or pressure.
- Start button, this must be pressed before any pump can turn on. To run program, stop
button stops program. (Use 1 toggle sw. to simulate start and stop, 2 wire control)
- Tank level is measured using an Ultra Sonic level (Sonac), represented by an analog dial
on simulator card. (Scaled 0 to 100 %)
- The Sonac controls the lead pump start, lag pump start and pumps off levels.
o Lag Pump Start – 75%
o Lead Pump Start – 65%
o Both Pumps Off – 45%
- The high, high, and low, low levels are monitored by only the Johnny balls.
- When the Sonac is working, the 45%, 65% & 75% Johnny balls do not work.
- Sonac Level failure is triggered by (a toggle sw. N.C.)
- When Sonac fails, a warning light must come on, indicating Sonac has failed.
- When Sonac fails the Johnny balls must automatically take over level sensing
- 5 Johnny balls each represented by a switch (5 Toggle sw., all N.O.)
o High, High – 90%
o Lag Pump Start – 75%

33
 o Lead Pump Start – 65%
o Both Pumps Off – 45%
o Low, Low - 20% master stop in case Ultra Sonic (U/S) Level or 45% Johnny ball
fails.
- If the high, high float is actuated (90%) it triggers a 3-stage alarm, (flashing light, then
horn, then solid light)
- As soon as the level is high a Flashing light starts, and as long as the level stays high,
then after 10 seconds the horn comes on. If level stays high and you press the
“acknowledge button”, (1 toggle sw., N.O. momentary contact, “you push and let go”)
the horn goes off and the light goes solid, (no more flashing).
- Solid light indicates that there is a high-level condition and has not dropped.
- Once the level drops, the solid light goes off.
- If level went high, flashing light starts, and then the level drops before 10 sec. the
flashing light goes out and horn does not sound. (This would indicate a Temporary High-
High level)
- Also, if high-high level is triggered, again the Alarm must latch on, (flashing light), 10
seconds later the horn comes on but if the level drops after horn starts then the light
continues to flash, and horn goes off. This is indicating that there was a high-high level
for more than 10 seconds and it cleared itself.
- Flashing light only with no horn would indicate that there was a high level for more than
10 seconds and it dropped.
- If acknowledged and the horn is off and level dropped, then flashing light goes out.
- If the low, low float (20%) is actuated it immediately shuts down all Pumps
Pressure – simulated using the second analog dial – scaled from 0-1000psi
900psi – motors time off if lasts for more than 10sec. (blocked line)
Won’t restart until 800psi is reached
600psi- motors will not start until 600psi is reached. (Pump primed after broken line)
200psi- motors shut off immediately (broken line)
201psi to 899psi is normal operating pressure.

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 Once primed the pumps can run between 201 and 899 PSI with proper starting and stopping
sequences, without the need to be re-primed.
*Only after a broken line do you need to prime pumps. (Pressure must reach 600 psi)

If both pumps are running and the lead/lag switch is turned then no change in pumps until
existing sequence has been completed, level must drop to 45%.
If one pump is running and switch is changed then running pump can stop and other pump
can start.

Valves – There are 6 valves in this program, represented by the X’s. They must be open for
their respective motors to be able to run. (6 toggle sw)
2 Pump 1 3
-----------X-------------M-------------X-------- Pressure is measured here
1
------X------- -------X---------
4 Pump 2 5 6
-----------X-------------M-------------X--------

If switches 1 or 6 are turned off, then stop both pumps. If 2 or 3 switches are off stops Pump
1 if switches 4 or 5 are turned off stops Pump 2.

If both pumps are running and something causes them to stop, (a fault, valves or stop
button etc.) then both pumps cannot start at the same time when restarting pumps, lead pump
starts, lag pump follows 5 sec after. (Every time.)

NOTE: 2 pumps never start at the same time under any condition.

PROJECT REQUIREMENTS:

-Programmed in any language LL or LD or FBD or any combination of the languages for various
networks/ sections

-Use Real world inputs, Real world outputs, Virtual outputs & Analog inputs; (Level - Analog
IN1, Pressure - Analog IN2)

- Print out your “memory map”, this should include all “real” and “virtual” input & output
address and labels or names.

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- Note that you are not required to use O/L contacts for the pumps.

Details for the high, high float 3 stage alarm:

- If the high, high float is actuated (90%) it triggers a 3-stage alarm, (flashing light, then
horn, then solid light)
- As soon as the level is high a Flashing light starts, and as long as the level stays high,
then after 10 seconds the horn comes on. If level stays high and you press the
“acknowledge button”, (1 toggle sw., N.O. momentary contact, “you push and let go”)
the horn goes off and the light goes solid, (no more flashing).
- Solid light indicates that there is a high-level condition and has not dropped.
- Once the level drops, the solid light goes off.
- If level went high, flashing light starts, and then the level drops before 10 sec. the
flashing light goes out and horn does not sound. (This would indicate a Temporary High-
High level)
- Also, if high-high level is triggered, again the Alarm must latch on, (flashing light), 10
seconds later the horn comes on but if the level drops after horn starts then the light
continues to flash, and horn goes off. This is indicating that there was a high-high level
for more than 10 seconds and it cleared itself.
- Flashing light only with no horn would indicate that there was a high level for more than
10 seconds and it dropped.
- If acknowledged and the horn is off and level dropped, then flashing light goes out.

E.2 Change Orders

Appendix E.2 contains the wet well change orders and project requirements to be implemented
for the 6th semester wet well project for ELC1007 – PLC Projects and Troubleshooting.

Wet Well Change Orders and Project Requirements

1. First requirement monitors your overload for pump #1 and pump #2. And ensure they
work properly to stop the correct pump electrically and not in your program.
a. To be used in your SCADA and HMI displays. (Fault finder)

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2. First change order, If the level on the Sonac drops below 10% - fail the Sonac and switch
to Johnny Ball level control. (Remove Sonac failure switch)

3. Change order #2 during normal operation Sonac working properly.

You will monitor the Johnny balls. (Top 5 switches are for johnny balls, bottom 6 are for
valves)

So, if all Johnny balls are working correctly, when the switch is turned on a light on the
24 DC card will light up to indicate that each Johnny ball is working.

 90%
 75%
 65%
 45%
 20%

If the level is rising the 20% Johnny balls work fine light turns on.

45% Johnny ball works fine light turns on.

65% Johnny Ball fails to close with the rising level, (Johnny ball broken) after 10 sec.
65% Johnny ball light begins to flash. This alarm must latch.

 90%
 75%
 65% Flashing this will indicate that 65% Johnny Ball has failed
 45%
 20%

When level drops below the 65% level, you have to latch the 65% Johnny ball. To
indicate to the electrician which Johnny ball has failed?

If the tank is full and all the Johnny balls worked properly on the way up and all lights
are on indicating Johnny balls all working. As level falls each Johnny ball should drop
and open the switch. If a Johnny ball does not open and is stuck, after 10 sec. light will
flash indicating a problem with the Johnny balls. Each Johnny ball is monitored
individually. Once the operator washes the failed Johnny ball and the ball drops the
flashing light goes away (does not latch).

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4. #3 change order

Pump Lock-out

If Pump 1 is the lead pump and level reaches 65% Pump 1 should start. If we fail Pump 1
and it does not start, Pump 2 must start in its place. The same thing happens if Pump 2 is
lead pump and we fail Pump 2; Pump 1 must start in its place.

If the lead pump is fixed it can start to help the other pump after the reset button is
pressed.

BUT YOU CANNOT STOP THE RUNNING PUMP TO START THE REPAIRED
PUMP.

Lead Pump is locked out which means if pump is repaired it still cannot start. You must
press the reset button (or Start button) to allow pump to restart. Repaired pump can start
only if level is above 65%.

If level drops to 45% level and then rises to 65% the proper lead pump will start, and
everything is back to normal.

Change Order #4

Part 1

When pumps stop due to a high pressure, I want you to design a program that will
lockout the pumps. This lockout will occur if the system has reached a high pressure 3
times within a time span of 60 seconds.

When this lockout occurs, a light on the DDO card will begin to flash, output #8 (address
24) to indicate the pumps have lockout. Once the acknowledge button has been pressed
this light will become solid. I would also like for you to indicate this on your HMI. This
alarm light, named high-pressure lockout, will be located on the main page as well as the
fault finder page of your HMI.

Just remember these steps for the high-pressure lockout.

1. Set your high pressure to 1000psi or the maximum scalable value you can contain
with your analog dial. When this high pressure occurs, the pumps will stop after 5
seconds. This is down from the 10 seconds you had previously set in your project.
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2. Once the pumps have stopped the pressure must drop to 800psi before the pumps can
restart automatically.
3. If the pressure has reached 1000psi 3 times with the time span of a minute, the pumps
will lockout and will be unable to start even if the pressure has dropped to 800psi.
4. Once this lockout has occurred a flashing light will appear on the DDO card, as
mentioned above.
5. To restart the pumps, the pressure must be 700psi or below, you must acknowledge
the alarm which in turn will change the flashing light on the DDO card solid, and then
press the start button. Once all of this has been done the pumps will be able to restart.

Part 2

If the lead pump is running, I want to be able to force the lag pump to turn on, even if the
level in the tank is below 75%. To accomplish this, we will be using the second unused
selector switch. When the level has reached 65% and the lead pump has started, you can
put the second selector switch into the on position and 10 seconds later the lag pump can
start.

Once the level in the tank has dropped to 45% both pumps must stop even if the second
selector switch is in the on position. If you forget to switch the selector switch back to off
the pump will again restart. If you turn off the switch before the level drops to 45% the
lag pump will stop.

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