Managing Water for Life

REPORT NO.:

DARVILL WASTE WATER TREATMENT WORKS:

RETURN ACTIVATED SLUDGE PUMP STATION

FUNCTIONAL DESIGN SPECIFICATION:

B9366-FDS-1.8 (DRAINAGE PUMPS)

Incorporating:
1. INLET WORKS: DRAINAGE PUMPS

Compiled by: DESMOND KOPKE

Company Details: ELECTRON TECHNOLOGIES
Umgeni Water Project Number:
Contributors:
Date: 04.02.2016
Revision: 01
Status: For Review

DOCUMENT APPROVAL
NAME COMPANY DESIGNATION SIGNATURE DATE

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DOCUMENT CONTROL

AUTHOR
FILE NAME
PATH
CREATED
LAST ACCESSED
NUMBER OF PAGES

REVISION REVISION DATE REVISION DESCRIPTION AUTHOR (S) SIGN-OFF

00 27.10.2015 Document Creation Desmond Kopke
01 04.02.2016 FDS Design Review Desmond Kopke
02
03

TARGET READERSHIP
Project Team Comprising: Umgeni Water, Hatch Goba, Group 5 & relevant sub-contractors

SOURCE DOCUMENTATION
H121642-001-75-031-0001, REV.0
H121642-001-75-031-0002, REV.0

RELATED DOCUMENTS
Include all documents referenced within or the reader may need to refer to
NO DOCUMENT DESCRIPTION DOCUMENT PUBLISHER DATE REV
. NUMBER
1 MCC 10 Inlet Works Wiring B9366-1 Electron
Schematics
2 MCC 10 Inlet Works Single B9366-1SLD Electron
Line Diagrams
3 MCC 10 Inlet Works Loop B9366-1L Electron
Diagrams
4 MCC 10 Inlet Works Instrument B9366-1IH Electron
Hook Up Diagrams
5 MCC 10 Inlet Works Cable B9366-2CBD Electron
Block Diagrams
6 Inlet Works P&ID P&ID H121642-001- Hatch Goba
75-031-0001
& 0002

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 INSERT CONTENTS PAGE HERE

1 PURPOSE
The purpose of this document is to define the Functional Design Specification for the Drainage
Pumps, at Darvill Waste Water Treatment Works.

2 DEFINITIONS
Include all abbreviations used in the document.
NO. KEY DESCRIPTION
1 PLC Programmable Logic Controller
2 MCC Motor Control Centre
3 DB Distribution Board
4 SCADA Supervisory Control and Data Acquisition
5 RAS Return Activated Sludge
6 FT Flow Transmitter
7 LT Level Transmitter

3 CONTROL AND OPERATING PHILOSOPHY

3.1 PROCESS OVERVIEW

Drainage pumps shall operate on a duty/duty assist arrangement. Duty shall alternate after each
operation. When the level in the sump, as determined by LT-1027, reaches ##%, High level, the
pump shall start, and continue to pump provided there is sufficient level, and shall stop pumping
when the level reaches ##%, Low Level. When a high-high level ##% is reached, an alarm is
generated, raised on the SCADA, and the second duty assist pump is started. Both pump down
to low level and stop.

3.2 SCOPE AND LIMITS OF SUPPLY

This section of the Functional Design Specification should clearly detail the scope and limits of
the supply. The scope of supply should include a list of deliverables.

The limits of supply should list all items outside the scope of the supply but that are required by
the project. Where interfacing to 3rd party systems constraints and assumptions should be
included.

3.3 PRE-DEFINED SET POINTS

Process operating parameters and equipment/instrument set points applicable to the Drainage
Pumps are listed here.

DESCRIPTION SET POINT LOOP NUMBER

Drainage Sump Level Transmitter DVL_10_LT_1027

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 3.4 MODES OF OPERATION
All modes of operation for the system should be detailed, including Automatic/Manual, Start-
up/Shutdown, Over-rides, Emergency Shutdown, System Failure and Recovery.

3.5 SEQUENCES
A summary of the operating sequences for the processes incorporated is listed below. The
individual sequences are described in detail in subsequent sections.

SEQ. NO. SEQUENCE DESCRIPTION RISK REFERENCE

P&ID No.
3.5.1 Remote Auto – Operation PLC takes full control, no
Risk
3.5.2 Remote Manual – Start Up/Shut Down PLC has limited control, all
process interlocks still
applicable, limited risk
3.5.3 Local Manual –Start Up/Shut Down Operator takes full control
of system, maximum risk

NOTE: This system has been designed to run in Remote Automatic mode of operation. Local
Manual mode is designed for testing and commissioning only. Running in this mode is risky, and
can lead to equipment damage if not operated correctly.

3.5.1 Remote Auto – Operation of Drainage Pumps 1 & 2

3.5.1.1 Purpose
To start the Drainage Pumps 1 & 2 in Remote Auto from the control building

3.5.1.2 Initiation of Sequence

High Sump level initiates the sequence

3.5.1.3 Sequence Steps

STEP ACTION TRANSITION LOCATION BY

NO
1 Ensure Drainage pumps, are switched MCC Operator
into PLC mode.
2 Check the alarm status of the SCADA Operator
duty/standby motors by clicking on the
motor
3 Reset any Present alarm conditions SCADA Operator
4 Confirm Sump Level LT-1027 is of PLC PLC
sufficient level

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 5 Start Duty Drainage pump PLC PLC
6 Drainage pump continues to run, until a PLC PLC
low level ##% is reached

3.5.2 Remote Manual – Start Up/Shut Down of Drainage Pumps

3.5.2.1 Purpose
To start the FOGG Pumps in Remote Manual from the control building

3.5.2.2 Initiation of Sequence

The Senior Operator Initiates the Sequence

3.5.2.3 Sequence Steps

STEP ACTION TRANSITION LOCATION BY

NO
1 Ensure Drainage Pumps, are switched MCC Operator
into PLC mode.
2 Check the alarm status of the SCADA Operator
duty/standby motors by clicking on the
motor
3 Reset any Present alarm conditions SCADA Operator
4 Confirm Sump Level LT-1027 is of SCADA Operator
sufficient level
6 Start Drainage Pump SCADA Operator
7 Drainage pump continues to run until a PLC PLC
low level ##%, is reached.

3.5.3 Local Manual – Start Up/Shut Down of Drainage Pumps 1 & 2

3.5.3.1 Purpose
To Stat the Drainage pumps 1 & 2 from the field, in Local Mode.

3.5.3.2 Initiation of Sequence

The Senior Operator Initiates the Sequence

3.5.3.3 Sequence Steps

STEP ACTION TRANSITION LOCATION BY

NO
1 Ensure Drainage Pumps, are switched MCC Operator
into Local mode.
2 Ensure Level is above low, low set point PLC Operator
3 Start/stop Drainage pumps as required Field Operator

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 4 INTERLOCKS
Detail all interlocks in a table such as the one below.

Tag Description Safety /

Process
Interlock
Pump X START = FAILED if Pump X Isolator = OFF, Emergency Stop = Safety
OFF, Electronic Relay Fault = HIGH, Motor Tripped Circuit = ON
Pump X START = FAILED if Scum Hopper Level not = Low Level, Process

5 ALARMS

5.1 ALARM CATEGORIES

Identify each of the alarm categories proposed for the system and the level of acknowledgment
necessary eg.

CATEGORY DESCRIPTION
LEVEL 0 Where there is a change in operation status of equipment and
(NOTIFICATION) instrumentation on the plant during normal operating mode. The
alarm is generated as a line statement on the ALARM SCREEN in
BLUE print.
LEVEL 1 An alarm condition that warns the Senior Operator of impending
(FAILURE) negative impact on process performance, plant integrity, personnel
safety or environmental safety. The alarm is generated as a line
statement on the ALARM SCREEN in RED print. The text will
change to BLUE print if the ALARM CONDITION is rectified before
the Senior Operator acknowledges the alarm. The Senior Operator
must acknowledge the alarm.
LEVEL 2 An alarm condition that warns the Senior Operator of severe
(CRITICAL FAILURE) negative impact on process performance, plant integrity, personnel
safety or environmental safety. This alarm is generated as a yellow
POP-UP SCREEN that must be acknowledged by the Senior
Operator.

5.2 ALARM ALLOCATIONS

Provide a table describing each alarm as below:

TAG NO. DESCRIPTION PRE-CONDITION ACTION ALARM

CATEGORY
DVL_10_LT_1027 Drainage Sump Level = Low Drainage Pump running Stop Drainage pump 2
2

6 OPERATOR INTERFACES

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 LOCAL INTERFACE Location REF DRAWING
Local/PLC Selector Switch MCC Panel Door
Local Start Stop Push Button Field
Delivery Valves Operations Filed
Local Reset Push Button MCC Panel Door

DISPLAY NAME AREA COVERED REF DRAWING

Inlet Works – Displays the Inlet Works Drainage Pumps 1 & 2 mimic. Active elements include
FOGG Plant valve status, (Inlet valves, De-sludge valves), Motor Status, (Running, Stopped,
Tripped, Run Hours, Power, Current Drawn), and also displays related
instrumentation process values and trends, ( Levels)
Motor Pop Up’s Auto/Manual Selection is done here. Safety/Process interlocks are interrogated
here.
Instrument Pop Instrument process settings are read here, Trends are displayed and Process
Up’s Calibration Values set.
Valve Pop Up’s Auto/Manual Selection is done here. Open/close is selected here when operating
in Manual

7 SYSTEM DATA

All data gathered, generated or calculated by the system should be detailed. Where calculations
are done, these should be fully described.

8 TRENDS
Details of the tags to be trended should be included in a table.

LOG LOCATION
FREQUENCY OF DATA
TAG NO. DESCRIPTION RETENTION PERIOD
TO BE
STORED
fixed disk, length of time data is to be
floppy disk, maintained
network
path, etc.
DVL_10_LT_1027 Drainage Sump Level 1 sec 30 Days

Other aspects that should be detailed are the archiving of data (procedures for back-up) and
export facilities to other formats e.g. Excel, database programs etc.

9 REPORT OUTPUTS

The format of all reports produced by the system should be detailed. The format and explanation
of the report contents should be included.

10 TEST FACTORS

Each stage of the testing should be detailed within the FDS. This includes

1. Factory Acceptance Testing (FAT) performed at the suppliers premises

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2. Site Acceptance Testing (SAT) on completion of commissioning to demonstrate the
system operates pre-handover.

The FDS should include details of all test documentation and responsibilities for the tests.

11 OTHER INFORMATION

The following should be included in the FDS only if not supplied to Umgeni Water in
separate documents (in which case reference to these documents should be made in the
FDS):

1. System Interfaces – detail all inputs and outputs from the control system, details of
voltage, current, etc., communication interfaces between systems including protocols and
formats
2. System Attributes – availability, maintainability, installation, and training should be
discussed
3. Design Factors –any other significant factors relating to the design of the system should
be detailed.
4. Resource Requirements - should describe, if possible, the basic project team, access
required to Umgeni Water’s premises, and input and timing required by the customer into
the project.

For any further clarification please consult the FDS provided as an example in Appendix 1. Also,
it should be noted that relevant P&IDs must be included as an appendix to the FDS.

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