Doc. No.

: SOP/001/PS08/1
ZAMBIA SUGAR Plc
Page 1 of 4
STARTING AND STOPPING OF BULK WATER Revision No.:
PUMPA PS 8 Revision Date:
Issue No.:
Issue Date: 25/03/2024

ISSUED BY: APPROVED BY:

``
1. OBJECTIVE

To carry out a safe start and stop of Pump Units according to a standard procedure.

2. RESPONSIBILITY

2.1 Pump Station Attendant *

3. SAFETY/HEALTH/ENVIRONMENT

3.1 Safety

a) Be alert of hazards around the station

3.2 Health

Not applicable

3.3 Environment

Not applicable

4. SCOPE

Bulk Pump Station No. 8

5. PROCEDURE

A safe operation of the Pump Units at Pump Station No. 8 will include:

5.1 Starting of the Unit from the ABB HMI

5.1.1 The relay (REX640) to be set into Local mode from the top right icon on the HMI
screen and to ensure the actuator valve is closed.

5.1.2 Confirm Local mode display on the HMI screen.

 Doc. No.: SOP/001/PS08/1
ZAMBIA SUGAR Plc
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5.1.3 Click on the Home button and navigate to the Single Line Diagram page.

5.1.4 Click on the Breaker Icon (QBB1) on the Single Line Diagram.

5.1.5 Click on the Green Close Breaker Icon to close the breaker to start the motor.
(NEVER STOP THE MOTOR FROM THE SCREEN)

5.1.6 Click “YES” on the pop up asking to confirm action of the Breaker.
 Doc. No.: SOP/001/PS08/1
ZAMBIA SUGAR Plc
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5.1.8 Immediately after closing of the breaker manually open the Valve from the actuator.

5.2 Manual Stopping of the Unit when started from the ABB HMI

5.2.1 Ensure the actuator is selected to Local mode.

5.2.2 Manually close the valve from the actuator and wait for the breaker to operate under
undercurrent to stop the unit. (if motor continues running after closing of the
valve operate the estop/emergency button.)

5.3 Manual Start of the Unit from ABB TNC Switch

5.3.1 Ensure the PLC is selected to manual mode on the PLC by clicking on the MAINT
on the HMI, the manual icon will show with M on the valve.

5.3.2 Ensure the ABB REX 640 is selected to Remote Mode, relay will show the icon ‘R”.

5.3.2 Operate the TNC switch to start the motor with Valve closed.

5.3.2 Manually open the valve from the actuator.

 Doc. No.: SOP/001/PS08/1
ZAMBIA SUGAR Plc
Page 4 of 4

5.4 Manual Stopping of the Unit when started from the TNC Switch

5.4.1 Ensure the actuator is selected to Local mode.

5.4.2 Manually close the valve from the actuator and wait for the breaker to operate under
undercurrent to stop the unit. (if motor continues running after closing of the
valve operate the estop/emergency button.)

5.5 Starting and Stopping of the Unit from the PLC HMI (AUTO MODE)

5.5.1 Select the Auto mode on the PLC HMI and select the Valve to auto by clicking the
valve icon and click on the Dot icon from the pop UP to select automatic.

5.5.2 Ensure the actuator and the ABB REX 640 relay are selected to Remote.

5.5.2 To start the unit click on the “Auto Start” icon on the HMI.

5.5.2 To stop the unit click on the “Auto Stop” icon on the HMI.
 Doc. No.: SOP/001/PS08/1
ZAMBIA SUGAR Plc
Page 5 of 4