2.7 Operation of LCP and SCADA 16-02-22

SEMANGAR NEW INTAKE
LCP & SCADA

OPERATIONAL AND FUNCTIONAL
DESCRIPTION

CADANGAN PEMBINAAN STRUKTUR MUKASAUK BARU DI LOJI
RAWATAN AIR SEMANGAR, KOTA TINGGI JOHOR.
NO.CONTRACT: PAAB/J070/J/K/05/20

Table of Contents
1. LCP Panel Operation ......................................................................................... 1

1.1 Layout ........................................................................................................... 4
2. Touch Panel Operation ..................................................................................... 7
2.1 Layout ........................................................................................................... 7
2.2 Components .................................................................................................. 8
2.2.1 Analog values ......................................................................................... 8
2.2.2 Equipment Status Display....................................................................... 8
2.3 Touch Screen Pages ..................................................................................... 9
2.3.1 Monitoring pages .................................................................................... 9
2.3.2 Manual Control Pages .......................................................................... 11
2.3.3 Plant Operation Control Page ............................................................... 13
2.3.4 Alarm Page ........................................................................................... 15
2.4 Sand Ejector Operation ............................................................................... 16
2.4.1 Sand Ejector System Auto Sequence ................................................... 24
2.5 Archimedean Operation .............................................................................. 25
2.5.1 Archimedean System Auto Sequence .................................................. 25


1. Introduction
1.1 System Architecture
The objective of this document is as a descriptive manual for operation and
monitoring functions of the SCADA and control system of Semangar New Intake
Plant.
System configuration between PLC, SCADA, and HMI devices in Semangar New
Intake Plant:
New SCADA PC
To existing SCADA
New PLC system
Location IP address
PLC 192.168.1.210
LCP HMI 192.168.1.211
Remote HMI 192.168.1.212
SCADA 192.168.1.220
2.7 Operation of LCP and SCADA 16-02-22 Page 1 of 25


1.2 PLC Control System
The PLC is used to control, obtain data, and communicate with various other devices
for control and monitoring purposes. The PLC and its components used in Semangar
New Intake Plant are as below:
Item Brand/Model
Power Supply Module BMXCPS2000
CPU BMXP342020
Digital Input Module BMXDDI3202K
Digital Output Module BMXDDO3202K
Analog Input Module BMXAMI0810
1.3 SCADA System

Real time data from the plant are gathered and displayed at the SCADA PC. User
can get to know all the status of all the instruments, analyzers readings, and level
readings in the water treatment plant. Historical alarms/events, trend data, and other
relevant data are logged for future usage. Beside monitoring, authorized users may
also control equipment and configure the plant parameters and setpoints from the
SCADA system. For the SCADA system in Semangar New Intake plant, specification
of workstation and software used are as below:
Item Brand/Model
Workstation Model Dell Precision 3650
Monitor Model Dell P2722H
Processor Intel i5-11500, 6 core
Storage 1TB SATA HDD 7200rpm
Optical Disk Drive Yes
Graphics Card Nvidia Quadro P620, 2GB
RAM 16GB (2x8GB)
Operating System Windows 10 Pro
SCADA Software Citect SCADA 2018 R2


1.4 HMI Touch Screen
Two Schneider touch panels are used, 15” touch panel in the Existing Raw Water
Intake Control Room, and 12” touch panel in the New Intake Electrical Room. These
touch panels contain the mimic drawing, equipment status and control, parameter
settings, and alarms.


2. LCP Panel Operation
2.1 Layout
Touch panel for
monitoring and control
Sand Ejector No. 1 Sand Ejector No. 2
Pump status and control Pump status and control
Sand Ejector No. 1 Sand Ejector No. 2
Valve status and control Valve status and control
Sand Ejector System LCP Panel
Auto/Manual Status Accept Alarm/Reset
and Selector Alarm/Lamp Test Button
Figure 2.1: Overview of LCP Panel operation area layout


CONTROL AVAILABLE
STATUS (WHITE) TRIPPED STATUS
(AMBER)
RUNNING STATUS
(RED) STOPPED STATUS
(GREEN)
MANUAL START MANUAL STOP
BUTTON BUTTON
Figure 2.2: Close-up of pump status and operation button
CONTROL AVAILABLE
STATUS (WHITE) FAILED STATUS
(AMBER)
FULLY OPEN
STATUS (RED) FULLY CLOSE
STATUS (GREEN)
MANUAL OPEN/CLOSE
SELECTOR SWITCH
Figure 2.3: Close-up of Valve status and operation switch


PLANT AUTO/MANUAL
SELECTOR SWITCH
Figure 2.4: Close-up of plant Auto/Manual status and selector switch


3. Touch Panel Operation
3.1 Layout
Page Title Date and Time
Navigation button
Figure 3.1: Overview of touch panel layout


3.2 Components
3.2.1 Analog values
Figure 3.2: Analog value display
Figure 3.3: Analog value setpoint settings
3.2.2 Equipment Status Display
Figure 3.4: Equipment status display
Status display for equipment is displayed by the circle beside the equipment. Status
is displayed by colour of the circle as below:
Status Colour
No signal
Running/ Fully
Opened
Stopped/Fully Closed
Tripped/Failed


3.3 Touch Screen Pages
3.3.1 Monitoring pages
These pages are only for illustrating and monitoring the plant values and equipment
status. No controls are in these pages.
Figure 3.5: New Intake Plan View Page


For changing
between pump 1/2
Figure 3.6: New Intake Side View Page
Figure 3.7: Electrical MCCB Status Page


3.3.2 Manual Control Pages
In the control pages, the status pilot lights and control buttons are of the equipment
are displayed.
Figure 3.8: Archimedean Pump Control Page


Figure 3.9: Sand Ejector Pump and Valves Control Page
Figure 3.10: Exhaust and Ventilation Fan Control Page


Graphic Description
Control Available (White)
Running/Fully Opened
(Red)
Stopped/Fully Closed
(Green)
Tripped/Failed (Amber)
Start/Open button
(Green)
Stop/Close button (Red)
3.3.3 Plant Operation Control Page
A
C
F
B E
D G
Figure 3.11: Plant Auto Controls & Settings Page


A) LCP Auto/Manual mode selector switch mode
B) Archimedean System Auto Mode status and Start/Stop push button
C) Archimedean Pumps Running Time and Duty Amount (based on level)
D) Archimedean Pumps Operation Time and Level setpoint for Auto Mode
E) Sand Ejector System Auto Mode status and Start/Stop push button
F) Sand Ejector Pumps Running Time
G) Sand Ejector Pumps Duration Time and Cycle Time setpoint for Auto Mode


3.3.4 Alarm Page
Figure 3.12: Alarm Annunciator Page

This page shows the alarm annunciator of the New Intake plant.
Graphic Description
Accepts the active alarms to stop the siren.
Resets the active alarms.


4. SCADA Operation
4.1 General Layout
1 3
2
5
4
6
Figure 4.1: General Layout of SCADA Pages
1) Menu
 Menu dropdown for page navigation
2) Page title
3) Alarm page buttons

 Navigate to alarms & events page.
4) Page quick navigation buttons

 Previous page
 Next page
 Back to last page
 First page (menu page)
5) Last active alarm display
6) Current logged in user


4.2 SCADA Equipment Status Description
In the mimic pages, the equipment such as pumps, ventilation fans, and circuit
breakers are colour coded to indicate their status as below.
No signal Running Stopped Tripped
Motors
Fans
Circuit
Breakers
For valves, there will be an indicator lamp beside the valve to indicate their status as
below:
Opened Closed
For EF/OC, and ELR, the same indicating lamp beside them to indicate their status
as below:
Tripped Normal


4.3 General Pages
4.3.1 Menu Page
Figure 4.2: Menu Page

User login, navigation to all pages is accessible here.
Other pages are accessible only after user logged in.


4.3.2 SCADA Configuration Page
Figure 4.3: SCADA Configuration and Layout Page

SCADA Configuration Page shows the network configuration of the New Intake
System. The location of SCADA PC, touch panels, PLC, and other devices are
shown here.
4.3.3 Existing Intake Pump Data Page
Figure 4.4: Existing Raw Water Pump Data Page


4.4 Mimic Pages
4.4.1 New Intake Overview Page
Figure 4.5: Overview Page of New Intake

4.4.2 New Intake Side View Page
1
2
Figure 4.6: Side View of New Intake Plant


1) Switch to Plan View Page
2) Switch between Pump 1 & Pump 2

4.4.3 New Intake Plan View Page
1
2
Figure 4.7: Plan View of New Intake Plant
1) Switch to Side View Page
2) Manual controls for Pumps and Valves


4.4.4 New Intake MSB Power Supply Page
Figure 4.8: MSB Single Line Diagram of New Intake Plant

New MSB Single Line Diagram for all MCCB.
4.5 Control Pages
4.5.1 Fan Controls Page
Figure 4.9: Ventilation and Exhaust Fan Control Page


Plant Operation Controls Page
1
2
5
3
6 7
4
Figure 4.10: New Intake Plant Operation Control Page

This page is for starting/stopping auto mode for Archimedean and Sand Ejector
Systems.
The relevant timers, signals, and parameters required for auto sequence are also
available for monitoring and setting here.
1) LCP Auto/Manual mode selector switch mode
2) Archimedean System Auto Mode status and Start/Stop push button
3) Archimedean Pumps Running Time and Operation Time setpoint
4) Archimedean Pumps Level setpoint, Current River Level and Pump Duty
Amount
5) Sand Ejector System Auto Mode status and Start/Stop push button
6) Sand Ejector Pumps Running Time
7) Sand Ejector Pumps Duration Time and Cycle Time setpoint for Auto Mode


5. Sand Ejector Operation
The Sand Ejector System is operated by the LCP panel buttons or by the touch
screen. The Sand Ejector System depends on the Auto/Manual mode selector
switch provided on the LCP.
In Manual mode (i.e. selector switch in left position), the Sand Ejector Pumps and
Valves can be operated manually by the buttons/switch on the LCP panel, MCC
panel, or remote push buttons.
In Auto mode (i.e. selector switch in right position), the Sand Ejector Pumps and
Valves can be operated separated by the touch screen (Figure 3.9), or Sand Ejector
System fully auto start when “Auto Start” button is pressed in the touch screen
(Figure 3.11, E).
Every time the Auto/Manual selector switch is turned from Auto->Manual or Manual-
>Auto, all pumps will be stopped, and all valves will be closed as a safety measure.
5.1 Sand Ejector System Auto Sequence
1) Make sure All Sand Ejector Pumps and Valves are not in operation.
2) Set the Operation Time and Cycle Time for the Sand Ejector System from
the touch screen (Figure 3.11, G).
3) Press the “Auto Start” push button to start the Sand Ejector Auto System.
4) The Sand Ejector Pump 1 will Start, and the Sand Ejector Valve 1 will Open.
5) Sand Ejector Pump 1 will run for the half of set Operation Time, then Sand
Ejector Pump 1 will Stop, and the Sand Ejector Valve 1 will Close.
6) The Sand Ejector Pump 2 will Start, and the Sand Ejector Valve 2 will Open.
7) Sand Ejector Pump 2 will run for the half of set Operation Time, then Sand
Ejector Pump 2 will Stop, and the Sand Ejector Valve 2 will Close.
8) The Sand Ejector System operation will complete, and the system will wait
until set Cycle Time elapsed before starting again at Step 3.


6. Archimedean Operation
The Archimedean System is operated by the touch screen only. The Archimedean
System depends on the Auto/Manual mode selector switch provided on the LCP.
In Manual mode (i.e. selector switch in left position), the Archimedean Pumps can
only be operated manually by the MCC panel or remote push buttons.
In Auto mode (i.e. selector switch in right position), Archimedean Sand Ejector
Pumps can be operated manually by the touch screen (Figure 3.8), or Archimedean
System fully auto start when “Auto Start” button is pressed in the touch screen
(Figure 3.11, B).
Every time the Auto/Manual selector switch is turned from Auto->Manual or Manual-
>Auto, all pumps will be stopped as a safety measure.
6.1 Archimedean System Auto Sequence
1) Make sure All Archimedean Pumps are not in operation.
2) Set the Level Setpoints and Operation Time for the Archimedean System
from the touch screen (Figure 3.11, D).
3) Press the “Auto Start” push button to start the Archimedean Auto System.
4) The previous running pump will be the duty pump. Else, the default duty pump
is Pump 1.
5) Depending on the current river level and setpoints, the set number of pumps
will run based on:
a. Above High Setpoint: 0 pump duty
b. Between High and Low Setpoint: 1 pump duty
c. Between Low and Low-Low Setpoint: 2 pump duty
d. Below Low Setpoint: 0 pump duty
6) During 1 pump duty, if the pump has run for set Operation Time, or the pump
has tripped, the pump will stop and changeover to the other pump.

2.7 Operation of LCP and SCADA 16-02-22

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SEMANGAR NEW INTAKE

LCP & SCADA

1. LCP Panel Operation ......................................................................................... 1

2.7 Operation of LCP and SCADA 16-02-22 Page 1 of 25

1.3 SCADA System

2.7 Operation of LCP and SCADA 16-02-22 Page 2 of 25

2.7 Operation of LCP and SCADA 16-02-22 Page 3 of 25

Figure 2.1: Overview of LCP Panel operation area layout

2.7 Operation of LCP and SCADA 16-02-22 Page 4 of 25

2.7 Operation of LCP and SCADA 16-02-22 Page 5 of 25

Figure 2.4: Close-up of plant Auto/Manual status and selector switch

2.7 Operation of LCP and SCADA 16-02-22 Page 6 of 25

Figure 3.1: Overview of touch panel layout

2.7 Operation of LCP and SCADA 16-02-22 Page 7 of 25

Figure 3.2: Analog value display

Figure 3.3: Analog value setpoint settings

3.2.2 Equipment Status Display

Figure 3.4: Equipment status display

2.7 Operation of LCP and SCADA 16-02-22 Page 8 of 25

Figure 3.5: New Intake Plan View Page

2.7 Operation of LCP and SCADA 16-02-22 Page 9 of 25

Figure 3.6: New Intake Side View Page

Figure 3.7: Electrical MCCB Status Page

2.7 Operation of LCP and SCADA 16-02-22 Page 10 of 25

Figure 3.8: Archimedean Pump Control Page

2.7 Operation of LCP and SCADA 16-02-22 Page 11 of 25

Figure 3.9: Sand Ejector Pump and Valves Control Page

Figure 3.10: Exhaust and Ventilation Fan Control Page

2.7 Operation of LCP and SCADA 16-02-22 Page 12 of 25

3.3.3 Plant Operation Control Page

Figure 3.11: Plant Auto Controls & Settings Page

2.7 Operation of LCP and SCADA 16-02-22 Page 13 of 25

B) Archimedean System Auto Mode status and Start/Stop push button

C) Archimedean Pumps Running Time and Duty Amount (based on level)

F) Sand Ejector Pumps Running Time

2.7 Operation of LCP and SCADA 16-02-22 Page 14 of 25

Figure 3.12: Alarm Annunciator Page

Accepts the active alarms to stop the siren.

Resets the active alarms.

2.7 Operation of LCP and SCADA 16-02-22 Page 15 of 25

Figure 4.1: General Layout of SCADA Pages

3) Alarm page buttons

4) Page quick navigation buttons

5) Last active alarm display

6) Current logged in user

2.7 Operation of LCP and SCADA 16-02-22 Page 16 of 25

2.7 Operation of LCP and SCADA 16-02-22 Page 17 of 25

Figure 4.2: Menu Page

2.7 Operation of LCP and SCADA 16-02-22 Page 18 of 25

Figure 4.3: SCADA Configuration and Layout Page

Figure 4.4: Existing Raw Water Pump Data Page

2.7 Operation of LCP and SCADA 16-02-22 Page 19 of 25

Figure 4.5: Overview Page of New Intake

Figure 4.6: Side View of New Intake Plant

2.7 Operation of LCP and SCADA 16-02-22 Page 20 of 25

2) Switch between Pump 1 & Pump 2

2) Manual controls for Pumps and Valves

2.7 Operation of LCP and SCADA 16-02-22 Page 21 of 25

Figure 4.8: MSB Single Line Diagram of New Intake Plant

Figure 4.9: Ventilation and Exhaust Fan Control Page

2.7 Operation of LCP and SCADA 16-02-22 Page 22 of 25

Figure 4.10: New Intake Plant Operation Control Page

2) Archimedean System Auto Mode status and Start/Stop push button

3) Archimedean Pumps Running Time and Operation Time setpoint