Sequence_of_Operation.pdf

Sequence Of Operation

St. Stephen Fish Lift St. Stephen, South Carolina

January 17, 2014 (Final)

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1. FUNCTIONAL CONTROL DESCRIPTION OF OPERATION

A. General

1) Abbreviations

CV ‐ Control Variable (PID Controller Output)

ETM ‐ Elapsed Time Meter

FCV ‐ Flow Control Valve

HIM ‐ Human Interface Module (VFD)

HMI ‐ Human Machine Interface

PLC ‐ Programmable Logic Controller

H‐O‐A ‐ Hand‐Off‐Auto Selector switch

MCC ‐ Motor Control Center

MCP ‐ Main Control Panel (PLC)

PCS ‐ Process Control System

PID ‐ Proportional Integral Derivative

VFD ‐ Variable Frequency Drive

GPM ‐ Gallon Per Minute

2) Plant Operating Interface: To accommodate the operational requirements and all other control, display, and monitoring requirements, this control system employs a Human Machine Interface (HMI) for access to plant controls. The HMI communicates with the Programmable Logic Controller (PLC) which in turn controls the plant.

Screen Color Coding: The color‐coded status indicates whether the device is either, running in automatic, running in manual, running locally, etc.

Table 1.1:

HMI Color Code Devices Chart

Color Valve Motor Mode

Green Open On Auto

Red Closed Off Off

Yellow Failure Failure Manual

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3) Uniform Control Modes

All motors, valves, and other controlled devices shall have the following control modes available for selection in the PCS.

“Auto” (Software) Automatic Mode. The PCS has full control of the device. This mode requires that the motor disconnect switch (If Applicable) local to the device is in normal/operated position and the H‐O‐A switch (If Applicable) local to the device is in the “Auto “ green position. Green “AUTO” text will appear next to the device shown on the HMI graphical screens. The PCS is intended to run all equipment in Automatic Mode of operation, Software Manual Mode or Local Mode of operation is only intended to be used in the case of maintenance or an emergency under the condition that the automatic mode of control has failed due to either initiate or shutdown a specific piece of equipment.

“Manual” (Software) Manual mode. The on/off and speed control of the device is strictly manual from the PCS HMI. The Operations personnel can start, stop, and manually adjust the speed of the device from the PCS HMI. The device will remain in manual control mode and operate as set by the Operations personnel until it is changed back to automatic (AUTO) mode from the PCS HMI. Manual mode incorporates all safety interlocks and should be used with caution. Flashing yellow “MAN” text will appear next to the device shown on the HMI graphical screens.

“Hand” (Hardware) Hand mode. Switching the device’s field mounted H‐O‐A switch to the “HAND” position will remove the device from PCS control and give control to the Operations personnel at the Main Control Panel. “HAND” position incorporates all safety interlocks and should only be used for maintenance or repair purposes. Hand control is only possible when the motor disconnect switch (if applicable) local to the device is in normal/operate position. Flashing red “HAND” text will appear on the HMI graphical screens next to the devices with H‐O‐A switches.

4) Anytime a field mounted H‐O‐A switch is moved out of the “AUTO” position, an alarm will annunciate on the PCS and flashing red “NOT IN AUTO” text will appear next to the device shown on the HMI graphical screens.

5) A device is considered “available” for automatic control by the PCS when all of the following conditions are true (where applicable):

The motor disconnect switch, local to the device, if in normal/operate position.

E‐Stop conditions are satisfied.

The H‐O‐A switch is in “Auto” position.

The device in not faulted.

The device is in “automatic” (AUTO) control mode from the SCADA system (software)

If any of these conditions are false, the MCP considers the device “unavailable” for automatic control.

6) Device “Resetting”: All motors that have failed or faulted due to a “Failed to run alarm” can be reset by the operator at the HMI screen. If the fault condition persists, then a “Hard” reset will be required at the motor respective VFD or Motor Starter. All motors, pumps, valves, and other controlled devices that have failed or faulted due to heat, overload, pressure, flow, electric, etc.

St. Stephen Fish Lift P a g e | 3 are considered “unavailable” for automatic control by the MCP. The MCP and PCS will not resume normal operational of the faulted/failed device until it is manually “Reset” at the device respective VFD or Motor Starter. Once reset, the PCS will immediately put the device in manual (MAN) mode and the off or closed position. The Operations personnel must the put the device back into automatic (AUTO) mode from the HMI. For all motors, the PCS will record faults for a failed to run condition, moisture warning faults, motor overload faults, and VFD faults.

Additional fault data for motors controlled by VFD’s will displayed at the VFD drive HIM module.

7) Elapsed Runtime Meters (ETM): Each piece of equipment that has “Run Status” available in the PCS shall have an ETM. The ETM will display total equipment runtime hours XXX.X. The HMI will provide a means of reset for each ETM.

8) Volume Totalizers: Volume Totalizers shall be programmed in the PCS for all flow meters. The totalized flow data will be displayed and logged, and reported at the HMI. The HMI will provide a means of reset for each flow meters totalized flow.

9) Digital Alarms: Digital Alarms shall be programmed in the PCS for all Digital Devices. The Digital Alarms will be programmed in the MCP, displayed, logged, and reported at the PCS. Adjustable alarm timers (for authorized individuals) will be provided at the PCS HMI the PCS HMI will also log the time and date all alarm set point changes. Example Digital alarms are as follows:

ZAO ‐ Gate Failed to Open

ZAC ‐ Gate Failed to Close

LAH ‐ Brail Hoist High Level

LAHH ‐ Brail Hoist High High Level

10) Analog Level Alarms: Level Alarms shall be programmed in the PCS for all Analog Level Devices.

The Level Alarms will be programmed in the MCP, displayed, logged, and reported at the PCS.

Adjustable alarm set points (for authorized individuals) will be provided at the PCS HMI the PCS HMI will also log the time and date all alarm set point changes. Analog level alarms are as follows:

LALL‐ Level Alarm Low‐Low (A separate level switch may be used in place of this alarm)

LAL‐ Level Alarm Low

LAH‐ Level Alarm High

LAHH‐ Level Alarm High‐High (A separate level switch may be used in place of this alarm)

2. P & ID Sheet I‐001: Weir Gate Operation / Attraction Flow

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1) The attraction flow (Ft. /sec) will be set by using the flow readings from LIT‐001, LIT‐1100, and LIT‐1200. The flow rate shall have an adjustable setpoint (XX.X Ft. /sec) from the PCS. The weir gates will be adjusted automatically based on the entered setpoint via two PID loops (LIC‐1100, LIC‐1200). These flows will assist in attracting the fish into the Entrance Channel. Weir gates 700 and 800 are used when fish are grouped near the discharge of the dam.

2) Wing Wall Level Transmitter (LIT‐001)

An ultrasonic level sensing device (LIT‐001) will measure the level of the dams discharge.

The value will be used to calculate a rate of flow using open channel algorithms in the flow transmitter. This level signal will be programmed in the MCP, displayed, logged, and reported at the PCS HMI.

A High Flow Alarm (FAH‐001) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Low Flow Alarm (FAL‐001) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

Table 2.1

Wing Wall Level Transmitter Elevation Table

Description Elevation In Ft. Tag Notes

Discharge Level xxx.x’ LIT‐001

Transmitter: Flow High Alarm xxx.x Ft./sec FAH‐100

Adjustable by Authorized

Personnel (SCADA Password)

Transmitter: Low Flow Alarm xxx.x Ft./sec FAL‐100

Adjustable by Authorized

Personnel (SCADA Password)

3) Weir Gate 1100 (M‐1100) & Level Transmitter (LIT‐1100)

An ultrasonic level sensing device (LIT‐1100) will measure the level of the entrance channel. The value will be used to calculate a rate of flow using open channel algorithms in the flow transmitter. This flow signal will be programmed in the MCP, displayed, logged, and reported at the PCS HMI.

The flow rate value will be used to adjust weir gate, M‐1100, to maintain the desired attraction flow in the entrance channel for proper attraction.

A High Flow Alarm (FAH‐1100) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

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A Low Flow Alarm (FAL‐1100) will provide feedback regarding a deviation outside the logged, and reported at the PCS HMI.

Table 2.2

Weir Gate 1100 Level Transmitter Elevation Table

Description Elevation In Ft. Tag Notes

Discharge Level xxx.x’ LIT‐1100

Transmitter: Flow High Alarm xxx.x Ft./sec FAH‐1100

Adjustable by Authorized

Personnel (SCADA Password)

Transmitter: Low Flow Alarm xxx.x Ft./sec FAL‐1100

Adjustable by Authorized

4) Weir Gate 1200 (M‐1200) & Level Transmitter (LIT‐1200)

An ultrasonic level sensing device (LIT‐1200) will measure the level of the entrance channel. The value will be used to calculate a rate of flow using open channel algorithms in the flow transmitter. This flow signal will be programmed in the MCP, displayed, logged, and reported at the PCS HMI.

The flow rate value will be used to adjust weir gate 1200, M‐1200, to maintain the desired attraction flow in the entrance channel for proper attraction.

A High Flow Alarm (FAH‐1200) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Low Flow Alarm (FAL‐1200) will provide feedback regarding a deviation outside the logged, and reported at the PCS HMI.

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Table 2.3

Weir Gate 1200 Level Transmitter Elevation Table

Description Elevation In Ft. Tag Notes

Discharge Level xxx.x’ LIT‐1200

Transmitter: Flow High Alarm xxx.x Ft./sec FAH‐1200

Adjustable by Authorized

Personnel (SCADA Password)

Transmitter: Low Flow Alarm xxx.x Ft./sec FAL‐1200

Adjustable by Authorized

5) Weir Gate 700 (SV‐700)

Gate 700 shall be lowered to full open position to allow fish to enter Crowder area from entrance channels. This “Fully Opened” signal will be programmed in the MCP and displayed.

A Gate Failed to Open Alarm (ZAO‐700) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐700) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

6) Weir Gate 800 (SV‐800)

Gate 800 shall be lowered to full open position to allow fish to enter from dam discharge. This gate will only be lowered when Enabled from the MCP and Gate 700 is fully closed. This “Fully Opened” signal will be programmed in the MCP and displayed.

A Gate Failed to Open Alarm (ZAO‐800) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐800) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

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3. P & ID Sheet I‐001: Crowder Gate Operation

1. The Crowder Gate (SV‐600) is utilized to “Crowd” the fish toward Entry Gate 100 (SV‐100) in order to maximize the number of fish collected in the brail hoist. The Crowder gate moves from a downstream position switch (ZSD‐600) to an upstream switch (ZSU‐600) to indicate full travel. A position feedback device (ZI‐600) provides information on current position of the gate. The gate is interlocked with gate 100’s position.

2. Crowder Gate (SV‐600)

Gate 600 is initially downstream and “Fully Opened” to allow fish to enter Crowder area.

Upon verification of Gate 100 “Fully Opened” and a time delay (Modifiable from PCS) the gate will begin to close.

Gate 600 will begin to close when time delay expires. A Gate 600 “Fully Closed” status will be displayed on the HMI. Upon closure of Gate 600 the Crowder will begin to move Upstream to push the fish through Gate 100.

Gate 600 will remain at the Upstream location until Gate 100 is confirmed “Fully Closed” on HMI.

Upon Gate 100 fully closed, Gate 600 will move downstream and fully open.

A “Gate Failed to Open” Alarm (ZAO‐600) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A “Gate Failed to Close” Alarm (ZAC‐600) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

Gate 600 “Crowder Not at Downstream position” Alarm will be programmed in the MCP, displayed, logged, and reported at the PCS.

Gate 600 “Crowder Not at Upstream position” Alarm will be programmed in the MCP, displayed, logged, and reported at the PCS.

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4. P & ID Sheet I‐001: Brail Hoist / Fill Chamber Operation

1. The Fill chamber consists of Gate 100 (Entry Gate), Gate 200 (Exit Channel Gate), Gate 300 (Fill Valve), Gate 400 (Empty valve), Chamber Level (LIT‐100) and a Brail Hoist basket. The fish enter the fill chamber thru Gate 100 and are grouped within the Brail hoist. Gate 100 is closed and Gate 300 opens to begin filling the chamber to the exit channel level. The Brail hoist is then slowly raised and the elevation is provided via an encoder (ZI‐100). The position is given in elevation (Ft.). After the fill chamber reaches the same level as the exit channel level Gate 200 lowers. The basket continues to elevation of 65.0 Ft. to allow all the fish to exit the brail basket. The brail hoist and Gate 200 continue to move together until a high operating limit is reached. Once this point is achieved Gate 400 is opened to allow the chamber to drain down to the entrance channel level. As the fill chamber is emptied, the brail basket is lowered to its starting position. Gate 100 is then “Fully opened”.

2. Entry Gate 100 (SV‐100)

Gate 100 is initially in a fully open position to allow fish to enter from the Crowder area into the fill chamber. The gate “Fully opened” signal will be programmed in the MCP and displayed.

Gate 100 will begin closing once the Crowder gate (SV‐600) is at its upstream position.

The gate will fully close to begin raising the water level in the chamber. The gate “Fully closed” signal will be programmed in the MCP and displayed. The fully closed signal will be interlocked with Gate 300 (Fill valve).

A Gate Failed to Open Alarm (ZAO‐100) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐100) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

3. Exit Gate 200 (SV‐200)

Gate 200 is initially in a fully closed position to allow filling of the chamber and keep exit channel water from entering the chamber. The gate “Fully closed” signal will be programmed in the MCP and displayed. The fully closed signal will be interlocked with Gate 300 (Fill valve).

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Gate 200 will begin opening once the fill chamber level (xxx.x Ft) has been achieved.

The gate will continue to open as the brail hoist moves up the fill chamber. This will allow the fish to swim into the exit channel. The gate “Fully opened” signal will be programmed in the MCP and displayed.

The Brail basket will stop for XXX.X seconds to allow fish to leave chamber. Gate 200 and brail basket rise at the same time to remove all fish from the lift chamber.

A “PAUSE” button located in the Control Room can be pressed to allow the Brail Hoist to stay at its current position and allow the fish more time to exit the hoist. (This affects only the operation of the hoist system).

A Gate Failed to Open Alarm (ZAO‐200) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐200) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

4. Fill Valve 300 (SV‐300)

Gate 300 is initially in a fully closed position until Gate 100 has fully closed. The fill valve “Fully closed” signal will be programmed in the MCP and displayed. The fully closed signal will be interlocked with Gate 100 and Gate 200 (Fill valve).

Gate 300 will begin opening once Gate 100 has fully closed. The gate will begin to open to a given position to slowly fill the chamber to allow the brail basket to be elevated.

Gate 300 will move to a fully opened position once a given fill chamber level has been achieved. The gate “Fully opened” signal will be programmed in the MCP and displayed.

A Gate Failed to Open Alarm (ZAO‐300) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐300) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

5. Discharge Valve 400 (SV‐400)

Gate 400 is initially in a fully closed position until Gate 200 has fully opened and the brail basket is fully raised. The discharge valve “Fully closed” signal will be programmed in the MCP and displayed. The fully closed signal will be interlocked with Gate 200 and Brail hoist position.

Gate 400 will begin opening once Gate 200 and the brail basket have reached their final positions. The gate will begin to open to start discharging water from the fill chamber.

Gate 300 will move to a fully opened position once a given fill chamber level has been achieved. The gate “Fully opened” signal will be programmed in the MCP and displayed.

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Gate 300 will move to a fully closed position to allow dewatering of chamber.

(Dewatering will not begin until Gate 300 “Fully Closed” signal has been given).

A Gate Failed to Open Alarm (ZAO‐400) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐400) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

Table 4.1

Fill Chamber Level Transmitter and Switch Elevation Table

Description Elevation In Ft. Tag Notes

Brail Hoist Position xxx.x’

LIT‐100

Elevation of Basket

Switch: High‐High xxx.x’ LSHH‐100 Fixed Level Switch for

Alarm

Switch: High xxx.x’ LSH‐100 Fixed Level Switch for

Alarm

Transmitter: Level High Alarm xxx.x’

LIT‐100

LAH‐100

Adjustable by Authorized Personnel (SCADA Password)

Transmitter: Low Level Alarm xxx.x’

LIT‐100

LAL‐100

Adjustable by Authorized Personnel (SCADA Password)

Transmitter:

Failure Alarm

LAT‐100 Diagnostic Alarm

5. P & ID Sheet I‐001: Brail Hoist / Fill Chamber Operation

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1. The exit channel consists of Gate 200 (Exit Channel Gate), Gate 900 (Holding Pool), Gates 1000/1000A (Sampling area) and Exit Channel Level (LIT‐200). The fish enter the exit channel thru Gate 200 (See previous section on Gate 200 operation). The fish are guided past the observation windows which allow them to be viewed and counted using high speed cameras. A spooker system is also utilized to move the fish through the holding area. This system consists of a remote panel which will provide blasts of air into the channel at periodic intervals to move the fish toward the exit. The panel has manual overrides to allow an operator to cycle valves as needed. A holding pool area is also located in the exit channel. Gate 900 and Gates 1000/1000A allow fish to be “Held” in a sampling basket for further evaluation. These gates are initiated Manually by an operator. The exit channel is also monitored for dewatering and operational coordination with the brail hoist and fill chamber gates.

2. Holding Pool Gate 900 (SV‐900)

Gate 900 is initially in a fully open position to allow fish to enter the holding pool from the exit channel. The gate “Fully opened” signal will be programmed in the MCP and displayed.

Gate 900 is closed manually by the operators. The gate “Fully closed” signal will be programmed in the MCP and displayed.

A Gate Failed to Open Alarm (ZAO‐900) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐900) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

3. Holding Pool Gates 1000/1000A (SV‐1000)

Gates 1000/1000A are initially in a fully open position to allow fish to leave the holding pool. Separate feedback exist for each gate but they are operated together. The gates “Fully opened” signal will be programmed in the MCP and displayed.

Gates 1000/1000A are closed manually by the operators. The gates “Fully closed” signal will be programmed in the MCP and displayed.

A Gate Failed to Open Alarm (ZAO‐1000) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐1000) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Open Alarm (ZAO‐1000A) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

A Gate Failed to Close Alarm (ZAC‐1000A) will provide feedback regarding a deviation outside the normal operating conditions. This alarm will be programmed in the MCP displayed, logged, and reported at the PCS HMI.

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Table 5.1

Exit Channel Level Transmitter

Description Elevation In Ft. Tag Notes

Exit Chamber Level xxx.x’

LIT‐200

Water level

Transmitter: Level High Alarm xxx.x’

LIT‐200

LAH‐200

Adjustable by Authorized Personnel (SCADA Password)

Transmitter: Low Level Alarm xxx.x’

LIT‐200

LAL‐200

Adjustable by Authorized Personnel (SCADA Password)

Transmitter:

Failure Alarm

LAT‐200 Diagnostic Alarm