O&M Irrigation Control System

Operation and Maintenance Manual
CP16 Irrigation RTU & PLC Control

System
Operation and Maintenance Manual CP16

Irrigation RTU & PLC Control System
Gulf automation System Building No.16, Zone - 24, Street - 830,Al Muntazah Commercial, Rawdat Alkhail,
Hiteen Street, Building 2, Fourth Floor, Office No.6, PO BOX: 39352Doha, State of Qatar.
T: +974 44326630 DD: +974 70455994 E: Hariprashanna.ks@gulfautomations.com
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Contents
1 Introduction .................................................................................................................................................................................................. 6
1.1 Purpose and Scope ...................................................................................................................................................................... 6
1.2 Hazards, Warning and Cautions........................................................................................................................................... 6
1.2.1 A hazard situation ............................................................................................................................................................... 6
1.2.2 Warnings ..................................................................................................................................................................................... 6
1.3 Safety Hazards ............................................................................................................................................................................... 7
1.3.1 Precautions ................................................................................................................................................................................ 7
1.3.2 Electrical Equipment Items ................................................................................................................................................ 7
1.3.3 Portable Equipment ............................................................................................................................................................... 8
1.3.4 Training of Personnel ............................................................................................................................................................ 8
1.3.5 Personal Protective Equipment ....................................................................................................................................... 9
2 Introduction ............................................................................................................................................................................................... 11
2.1. Overall purpose on the design intent for the installed equipment or system ........................................... 11
3 Equipment Schedule and Part number with COO ................................................................................................................ 22
4 Recommended Spares ........................................................................................................................................................................ 26
5 Testing and Commissioning Data ................................................................................................................................................. 30
5.1. TESTING AND COMMISSIONING DATA ............................................................................................................................ 30
5.2. CAUSE AND EFFECT MATRIX ................................................................................................................................................. 30
5.3. SYSTEM FAILURE AND RECOVERY DETAILS (DOOMSDAY TESTS) ....................................................................... 30
6 Operation .................................................................................................................................................................................................... 33
6.1. Operator HMI View .................................................................................................................................................................... 33
6.2. Sequence of Operation Check Manual Operation ................................................................................................ 35
6.3. Sequence of Operation Check Auto Operation ...................................................................................................... 35
7 MAINTENANCE ......................................................................................................................................................................................... 38
7.1. INTRODUCTION ........................................................................................................................................................................... 38
7.2. Special Tools ................................................................................................................................................................................. 38
7.3. Preventive Maintenance Activities ................................................................................................................................... 39
7.4. Corrective Maintenance Activities .................................................................................................................................... 41
7.5. Routine Maintenance .............................................................................................................................................................. 41
7.5.1 Periodic Inspections ............................................................................................................................................................ 41
7.5.2 The Cleaning Process ......................................................................................................................................................... 42
7.6. Recommended Maintenance Schedules ...................................................................................................................... 42
7.7. Fault Finding Table .................................................................................................................................................................... 43
8 MODIFICATION INFORMATION ......................................................................................................................................................... 45
9 DISPOSAL INSTRUCTIONS .................................................................................................................................................................. 47
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9.1. KNOWN HAZARDS ..................................................................................................................................................................... 47

9.2. SAFE DISPOSAL............................................................................................................................................................................ 48
10 NAMES & ADDRESSES OF MANUFACTURER, SUPPLIER, LOCAL AGENT ............................................................... 50
11 Manufacturer Operation Recommendation ..................................................................................................................... 52
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SECTION 1
Introduction
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System
1 Introduction
1.1 Purpose and Scope

The purpose of the document is to provide an Operation Manual to understand the
Components, Troubleshoot, Emergency Operating Procedure and Safety Precaution of ABB
PLC / T BOX RTU/ Field Instrument system for Utility Tunnel Control Centre and VIP
Building Irrigation Pump Control System. This document describes the equipment and
functionality of the proposed system for the Utility Tunnel Control Centre and VIP Building
Irrigation Control System
1.2 Hazards, Warning and Cautions

1.2.1 A hazard situation
Health and Safety procedures by the Main contractor, Electrical contractor & ELV contractor
will be implemented for this job. The responsible safety officer as per procedure will conduct
a routine safety inspection in conjunction with the main contractor.
1.2.2 Warnings
Warning notices indicate three levels of danger signified by the signal word.
DANGER
WARNING
CAUTION
1. Before operation on the unit for repair or maintenance make sure power is cut off.
2. Before resetting the unit or the device that resulted the tripping and stopped the unit
operation, make sure that the reason of the trip no longer exists.
3. Wear personnel protective equipment always when doing any equipment repair or
maintenance.
4. Do not touch the equipment when in operation to avoid possible burn or injuries.
5. Do not put your hands or any tool into the equipment after the equipment has been
connected to the electricity supply, unless the equipment has been switched off by
removing the fuses or switching off the mains switch. It must be ensured that the
electricity supply cannot be accidentally switched on.
6. De-energize all power circuits before installation or servicing and maintenance.
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7. Chemicals must be stored away from heat, protected from temperature extremes
and powders kept dry. Normal safe handling procedures must be used.
8. Turn off hot and cold-water supplies before beginning any maintenance work.
9. Relieve system pressure prior to servicing.
1.3 Safety Hazards

1.3.1 Precautions
1. All the manufacturers safety instructions must be thoroughly read, understood and
strictly followed. All applicable safety regulations must be observed.
2. Before performing any work, turn off all power supplying the equipment and check
the voltage of incoming line terminals to positively ascertain that the equipment is
totally de-energized.
3. Always assume circuit is live until it has been checked with a voltmeter, or similar
approved means; check your instruments with a known live source before using
them for testing.
4. Check wiring. Improper wiring may cause damage to the equipment.
5. Only qualified persons are permitted to assemble, operate or maintain this
equipment. Follow all the safety instructions. Failure to do so could result in serious
injury or death.
6. Do not attempt to act unless you are sure that you know exactly what is to be done.
If you are in doubt, consult somebody who knows, or contact the related
Manufacturers Representative.
7. Never allow an untrained person to work on the equipment.
1.3.2 Electrical Equipment Items

ABB Redundant PLC Control
T BOX Irrigation Controller
HMI
Field Instruments
o Level Transmitter
o Pressure Transmitter
o Flow Transmitter
o Pressure Switch
o Level Switch
o Differential Pressure Transmitter
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o Decoder
1.3.3 Portable Equipment

Not Applicable
1.3.4 Training of Personnel

1.3.4.1 Information provided to trainees
The information contained within this document is particularly for the CP-16 Irrigation
System for. The document is provided for the purposes of identifying Demonstration
& Training for (Irrigation PLC System). The Demonstration & Training Manual will
cover the following:
1. Equipment and system descriptions, including specific section on the design intent.
2. Equipment start-up, operation in normal and emergency modes, shutdown
procedures, seasonal changeover, and manual/automatic control.
3. Planned Preventive Maintenance including frequency and checklist/ instructions.
4. Operational requirements to maintain Warranties and guarantees including Dont
Dos to prevent guarantee or warranty invalidation.
5. Common troubleshooting problems that might arise, with description of possible
causes and corrective measures.
6. Essential adjustment information.
7. Relevant health and safety issues and concerns with a dedicated section on specific
emergency procedures.
8. Special list of tools needed and a recommended spare parts inventory stipulating
fast-medium-slow moving items and quantities of each.
9. Energy Management and Control System operation and programming
10. Control sequence and strategies
11. When and how-to re-commission the system to ensure future re-commissioning,
testing can be completed during different seasonal periods or at times of differing
load demand.
12. The information contained in the operating manuals and the location of all plans and
manuals in the facility.
13. Relevant commissioning report documents
14. On-site inspections and practical training.
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15. Acceptable tolerances for system adjustments in all operating modes including
procedures for dealing with abnormal conditions and emergency situations for which
there is a specified system response.
16. Soft copy of training documentation provided (PDF and PPT format).
17. Soft copy of recorded training will be provided.
1.3.4.2 The Qualification of the trainee to be trained

The attending trainee, who is to be trained, should fulfil following basics:
Familiar with his trade and its working (M, E, or P etc.).
Familiar with general tools and tackles used in his trade.
Familiar with Machinery / Equipments which are used to fulfil the functional
requirements of his trade (M, E, or P etc.).
1.3.4.3 Skills requirement of the trainee to be trained

The trainee must have good knowledge of irrigation Automation Control Systems.
1.3.4.4 Pre-requisite skills of the trainee in order to catch up on any missed training
The training shall be attended by all Operators / Supervisors / Managers related to
Facility Management team of Trade, Machinery, and Equipments.
No training shall be repeated unless otherwise, non-availability of Operators /
Supervisors / Managers is justified.
It is the responsibility of Operators / Supervisors / Managers whom so ever wants the
repeat given / delivered training, to forward request in writing through proper
documentation and channel.
Otherwise Operators / Supervisors / Managers can go through the provided training
manual, which gives the information as listed in section 1.3.4.1 above.
1.3.5 Personal Protective Equipment
Ensure that adequate protective clothing is available for use during normal maintenance
tasks and for possible emergencies. It should be of the correct size and be readily available
for new staff and where necessary to visitors.
Items required may include:
Overalls of sufficient quality.

Hard Hats, dependent upon location and site conditions prevailing where equipment
is located.
Adequate protective boots or shoes.
Insulated working gloves.
Eye Protection.
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SECTION 2
Brief Description
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2 Introduction
2.1. Overall purpose on the design intent for the installed

equipment or system
GENERAL
The ABB PLC / T Box RTU for CP -16 have been specifically designed for Utility Tunnel
Control Centre and VIP Building Irrigation Pump Control in accordance with Project
Specification Section 28 Part 5 Instrumentation, Control and Automation. The purpose of
this manual is to provide specific technical information and general guidelines for operation
and maintenance practices to ensure the systems perform as intended and are maintained
in a satisfactory condition to ensure long life & proper operation.
SYSTEM DESCRIPTION
A. The system Architecture

B. AC 500 PM573 PLC
C. Field Instruments
Differential Pressure Transmitter
Flow Transmitter
Level Transmitter
Pressure Switch
Pressure Transmitter
D. T BOX Irrigation RTU
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A. The system Architecture

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B.AC 500 PM573 PLC Brief Description
A full line of feature rich operator panels for use with AC500 PLC and it has excellent
scalability, flexibility based on a common automation platform with large communication
capacity. The below are salient features of AC500 PLC,
For small, medium and large applications with memory from 64 Kbyte up to 4 Mbyte
User flash disk 4GB (PM592)
Easy to configure by software
With powerful diagnosis, onboard
With different interfaces for easy communication
For central and distributed system concepts
All programmable with same software
Apart from the salient features the CPU has got below diagnostics and interface features,
LED for status indication
Integrated Onboard I/O
Integrated Ethernet (CPU ETH)
COM1 for online access, ASCII, Modbus RTU or CS31 bus
Run / Stop switch (program execution)
Expandable with up to 10 local I/O modules

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The CPU overview and configuration display and front

elements are briefly as shown below,
LCD-Display for
Diagnosis and error codes
Bus address setting
Square displays: status of fieldbus or device

written beside.
Triangle indicates the selected device to be read

or configured
Figure 1 PLC CPU
LEDs for status indication of
PWR: power on
RUN: program execution
ERR: error detection
Keypad for local operation:
RUN: to start and stop a program
VAL: for information about time settings, battery and firmware version (from FW
2.0.6)
ESC: to exit menu without saving
OK: to exit menu with saving
DIAG: for diagnosis of error codes
CFG: to set address local for Ethernet, ARCNET and Field Bus Plug
In case of an error the error, class and error number are displayed
Example indication:
E3 008
E3= error class = light error 008 = error code= empty / missing
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By use of the DIAG button up to four levels d1.d4 with detailed error
information are displayed; Various diagnostics information are explained
concisely as below,
d1
001
Figure 2 CPU DISPLAY
d1 indicates the defective component (CPU, COM1, FBP, IO-Bus, etc.)
d2 defines the defective device within the component
d3 defines the part of the module with an error (slot)
d4 defines the defective channel within the module
The add on SD memory card feature is available in the AC500 PLCs which is like
an auxiliary disk drive and has the following applications,
For data transfer between a PC with SD card reader and AC500
C. Field Instruments
DPT: Differential Pressure Transmitter Brief Description
Digital LCD Integral Display

The L1 " Digital LCD Integral Display" is connected to the electronics. The in-built key-pad
allows both display and transmitter configuration. In addition, diagnostic information is
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provided. The highest priority message will be displayed first followed by the next message
in order of priority.
Here is a list of self-explanatory errors and warning messages: "Electronic Fail", "Sensor
Elec. Fail", "Sensor Fail", "DAC Out of Range", "Sensor Invalid", "PV out of Limit", "Sensor
T Out Limit", "Electr. T Out Limit", "Current Out Saturn", "Current Out Fixed, Config.
Error", "Tot. Config Error", "Over range", "Consistency Check"
For additional details see the Transmitter Diagnostics section of this manual.
Navigate the Digital LCD Integral Display the Digital LCD Integral Display offers you an
extensive range of functions, which are grouped into menus: to access the menu, press
the button below the display indication (the bottom right icons on the Display). to select
the menu or submenus press the key close to the Select display indication (bottom right
position on the Display) to exit the menu or submenus press the key close to the Exit
display indication (bottom left position on the Display) to come back one step in the menu
or submenus press the key close to the Back display indication. to scroll through the
menu (up and down in the list on the display) or submenus use two keys in the middle
Digital LCD Integral Display list of menu and submenu functions The Digital LCD Integral
Display menu has been designed to offer self-diagnostics when used by a skilled operator.
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FIT: Flow Transmitter Brief Description
Water Master delivers speed, simplicity and ease of use at every stage of the products
lifecycle. In fact, Water Master doesnt just plug the gaps left by competitive products, it is
simply the best flow metering solution available today.
Superior control through advanced sensor design Innovative octagonal sensor design
improves flow profile and reduces up and down stream piping requirements for the most
commonly installed sizes: 40 to 200 mm (1 8). Flowmeters with traditional sensor
designs remain available to over two meters in size.
Using a higher excitation frequency combined with advanced filtering, Water Master
improves measurement accuracy by reducing fluid and electrode noise
Detailed diagnostics for rapid decision-making Water Master is proven to be robust and
reliable, with unmatched diagnostic capabilities providing the right information to keep the
process up and running. In accordance with NAMUR NE107, alarms and warnings are
classified as with the status of maintenance required, check function, failure and outside
of specification. Water Master is type approved to MID and OIML R49 type P requirements
to ensure the highest accuracy and long-term performance of the system by continuously
self-checking the sensor and transmitter in the field.
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LIT: Level Transmitter Brief Description
LST400 works on the non-contact principle of ultrasonic. A pulse of energy emits from the
transducer at the speed of sound and is detected upon its return. The transmitter can
distinguish the difference between a correct echo and other ambient noise. When the signal
returns, LST400 measures the time and then knowing the speed of sound, it can accurately
calculate the distance from the material level and open channel flow.
to the transducer. The LST400 can measure in distance mode the LST400 measures
distance from the transducer. This means the 20mA will be the furthest point and the 4mA
will be the closest point. In level mode the LST400 measures level in a tank. This means at
the furthest point or when the tank is empty, the instrument will read 4mA. At the closest
point the tank will be full, and the instrument will read 20mA. A microprocessor then controls
the output functions of the relays, display and the analogue output signals.
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PS: Pressure Switch Brief Description
The process pressure acting upon the metallic process isolating diaphragm of the sensor is
transmitted to a resistance bridge via a fluid. The change in the output voltage of the bridge
is proportional to the pressure and can be measured directly
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PIT: Pressure Transmitter Brief Description
Digital pressure transmitters are communication-ready field devices with microprocessor-

controlled electronics. For bidirectional communication, an FSK signal is superimposed on
the 4 20 mA output signals via the HART protocol. The graphic user interface (DTM) can
be used to configure, poll, and test the pressure transmitter on a PC. Handheld terminals
also support communication. For local operation, a button is available on the system
electronics for setting the lower and upper range values. In combination with an optionally
installed LCD indicator, a complete external configuration and parameter setting of the
transmitter can be performed via the four local pushbutton controls.
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SECTION 3
EQUIPMENT SCHEDULE AND PARTNUMBER WITH COO
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3 Equipment Schedule and Part number with COO
LIST OF MATERIALS WITH COUNTRY OF ORIGIN PLC &

INSTRUMENTS
S.No MATERIALS MAKE PART NO ORIGIN
Processor Rack
TB521-ETH:AC500,Terminal
1 ABB 1SAP112100R0270 Germany
Base,2slots
PM583-
2 ETH:AC500,Prog.Log.Controller ABB 1SAP140300R0271 Germany
1MB
CM577-ETH:AC500,Com.Module
ETHERNET
4 MC502:SD- Memory Card 2GB ABB 1SAP180100R0001 Germany
TA521:AC500 Lithium Battery
for data buffering
Communication & I/O
Modules
CI590-CS31-HA:S500,Bus
Module 16DC,2xCS3
TU551-CS31:S500,Bus Terminal
Unit, Screw
TU515:S500,I/O Terminal
Unit,24VDC,Screw
AX522:S500,Analog
I/O.Mod.8AI/8AO,U/I/RT
DI524:S500,Digital Input
Module,32DI
DC523:S500,Digital
Config.I/O.Mod.24DC
Network Components
1 Ethernet Switch 6 Port Harting 24030060000 Germany
HMI & Software

PS501:AC500, Programming SW
Control V2.2.0
System
CP650,color-
2 ABB 1SAP550100R0001 Italy
touch,10.4",800x600
3 PB610 Panel Builder ABB 1SAP500900R0001 Germany
TK681 Communication cable
RS232: CP600-AC500
Instruments
1 Pressure transmitter ABB 261GS- U.K.T.N.T.1 L1.B2 Italy
2 Float level switch Nivelco NLP -1- 05 - 1 Hungary
LST
3 Ultrasonic level transmitter ABB China
400.Y0.S15.N1.P3.A1.H1
SGV-F-2-4BM
4 Pressure Gauge/ Indicator Dwyer USA
(Range - 0-10kg/cm2)
5 Pressure switch E&H PTP-31-A4B13P1DD1A Europe
266DSH
6 Pressure differential transmitter ABB Italy
H.S.S.A.2.B.7L9.B1
FEV121.080.V1.S.4.S2.B.1
7 Magnetic flow transmitter ABB .A.1.2.A.3.A.1.A.1...M5.V3. UK
CWA.T3
Panel and Switchgears
Eletra/
1 Control Enclosure 047-SBX-148030 UAE
Reputed
2 Power Supply Weildmuller 1469480000 China
3 Plug-In Relay 24VDC with Base ABB CR-P Series Europe
4 Push Button ABB CP1-1 Series Europe
5 Indication Lamps - 230VAC ABB CL-500 Series Europe
6 Selector Switch ABB C3-SS1 Series Europe

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LIST OF MATERIALS WITH COUNTRY OF ORIGIN IRRIGATION

CONTROL SYSTEM
S.No MATERIALS MAKE PART NO ORIGIN
Irrigation Controller
1 Telecontrol Gateway Semaphore TG2 Belgium
Tonick
2 Decoder Adaptor/Interface BT2 BT2 Hungary
Watering
3 Power Supply Semaphore PS-AC-30W Belgium
4 24VAC Transformer Shin-Star YOBS24001300A Taiwan
Field Decoders
Irrigation Decoder (For Solenoid Tonick

1 TW-TK-DC-1 Hungary
Valve Interface) Watering
Flow Meter Contact Closure
Tonick
2 Counter Decoder( For Flow TK-FLO-CC Hungary
Watering
Meter Interface)
Volumetric Water Content

Tonick
3 Sensor Decoder (Moisture TK-VWC-VH400 Hungary
Watering
Sensor with Decoder)
Irrigation Programming
Software
Tonick
1 Decoder Programmer/Tester HW-DEC-PRG Belgium
Watering
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SECTION 4
RECOMMENDED SPARES
System
4 Recommended Spares
Recommended Spare PLC & INSTRUMENTS First Year
Installed Recommended
S.No MATERIALS MAKE PART NO Spare QTY
QTY
Re Processor Rack
TB521-
1 ETH:AC500,Terminal ABB 1SAP112100R0270 2 2
Base,2slots
PM583-ETH:AC500,
2 Prog.Log.Controller ABB 1SAP140300R0271 2 0
1MB
CM577-ETH:AC500,
3 Com. Module ABB 1SAP170700R0001 2 0
ETHERNET
MC502:SD- Memory
4 ABB 1SAP180100R0001 2
Card 2GB 0
TA521:AC500
5 Lithium Battery for ABB 1SAP180300R0001 2 0
data buffering
Communication &
I/O Modules
CI590-CS31- 0
1 HA:S500,Bus Module ABB 1SAP170700R0001 1
16DC,2xCS3
TU551- 0
2 CS31:S500,Bus ABB 1SAP221100R0001 1
Terminal Unit, Screw
TU515:S500,I/O 0
3 Terminal ABB 1SAP210600R0001 3
Unit,24VDC,Screw
AX522:S500,Analog 1
4 I/O.Mod.8AI/8AO,U/I ABB 1SAP250000R0001 1
/RT
DI524:S500,Digital 1
5 ABB 1SAP240000R0001 1
Input Module,32DI
DC523:S500,Digital
6 ABB 1SAP240500R0001 1 1
Config.I/O.Mod.24DC
Network
Components
Ethernet Switch 6
1 Harting 24030060000 1 0
Port
HMI & Software

System
PS501:AC500, 0
1 Programming SW ABB 1SAP190100R0200 1
Control V2.2.0
CP650,color- 0
2 ABB 1SAP550100R0001 1
touch,10.4",800x600
3 PB610 Panel Builder ABB 1SAP500900R0001 1 0
TK681
4 Communication cable ABB 1SAP500981R0001 1 0
RS232: CP600-AC500
Instruments
261GS- U.K.T.N.T.1
1 Pressure transmitter ABB 1 0
L1.B2
2 Float level switch Nivelco NLP -1- 05 - 1 2 0

LST
Ultrasonic level
3 ABB 400.Y0.S15.N1.P3.A 1 0
transmitter
1.H1
SGV-F-2-4BM
Pressure Gauge/
4 Dwyer (Range - 0- 7 2
Indicator
10kg/cm2)
PTP-31- 0
5 Pressure switch E&H 1
A4B13P1DD1A
Pressure differential 266DSH
6 ABB 1 0
transmitter H.S.S.A.2.B.7L9.B1
FEV121.080.V1.S.4.
Magnetic flow
7 ABB S2.B.1.A.1.2.A.3.A.1. 1 0
transmitter
A.1...M5.V3.CWA.T3
Panel and
Switchgears
Eletra/ 0
1 Control Enclosure Repute 047-SBX-148030 1
d
Weildm 0
2 Power Supply 1469480000 2
uller
Plug-In Relay 24VDC 0
3 ABB CR-P Series 16
with Base
As 0
4 Push Button ABB CP1-1 Series
required
Indication Lamps - As 0
5 ABB CL-500 Series
230VAC required
As 0
6 Selector Switch ABB C3-SS1 Series
required
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Recommended Spare IRRIGATION CONTROL SYSTEM First

Year
Installed Recommended
S.No MATERIALS MAKE PART NO QTY
QTY
Irrigation Controller
Semaphor 0
1 Telecontrol Gateway TG2 1
e
Decoder Adaptor/Interface Tonick 0
2 BT2 1
BT2 Watering
Semaphor 0
3 Power Supply PS-AC-30W 1
e
0
4 24VAC Transformer Shin-Star YOBS24001300A 1
Field Decoders
0
Irrigation Decoder (For Tonick
1 TW-TK-DC-1 4
Solenoid Valve Interface) Watering
Flow Meter Contact Closure 0

Tonick
2 Counter Decoder (For Flow TK-FLO-CC 1
Watering
Meter Interface)
Volumetric Water Content 0
Tonick
3 Sensor Decoder (Moisture TK-VWC-VH400 1
Watering
Sensor with Decoder)
Irrigation Programming
Software
Tonick 0
1 Decoder Programmer/Tester HW-DEC-PRG 1
Watering
System
SECTION 5
TESTING AND COMMISSIONING DATA
System
5 Testing and Commissioning Data
5.1. TESTING AND COMMISSIONING DATA
Submitted as Separate Document.
5.2. CAUSE AND EFFECT MATRIX

NA
5.3. SYSTEM FAILURE AND RECOVERY DETAILS

(DOOMSDAY TESTS)
The irrigation PLC System can be failed to perform under the following conditions and the
same can be rectified by carrying the recovery checks and remedial actions.
Table 1 BMS PLC System Failures and Recovery Details
System Failures Recovery Checks / Remedial Action

Check power supply input cabinet
PLC Off Check breaker or switch inside DPLC cabinet
Check if connector is correctly plugged
Check the Display with Error Code refer the
PLC Stop
diagnostic Manual
Check the Power is available to ethernet switch
Check the 24 VDC SMPS is healthy and measure
the voltage
No Communication
Check the RJ45 and Fibreoptic Port are fixed
Properly.
Ping the IP Address from Work station
Malfunction Restart the system by powering OFF and ON
Check if cable RJ45 is well connected
No value on TCP/IP interface Wait about two minutes to allow the system to
receive all serial data
For major damage (unusual breakdown) to the system/equipment, please contact the
supplier/agent (M/s Gulf Automation System).
When any component of PLC system fails, the following steps will be taken to assure
prompt resumption of service with minimal impact of operation.
System
Investigate the situation to determine the cause of the problem, the affected areas, and
estimated time to restore the PLC system service.
Notify the concern departments affected when a problem will exist for an extended
period.
Correct problem, in house, if possible and return systems to service.
Notify the FM department if the system function has been restored.
If problem cannot be repaired in house, call the outside service trades or outside
service contractor to respond to the failure and repair the affected equipment, if
possible.
After repairs are made and equipment is operating, notify affected users.
System
SECTION 6
OPERATION
System
6 Operation
The equipments monitored/controlled by automation system for irrigation water

pumping station comprises of
Pumps 2 Nos.
Level Transmitter (Ultrasonic Type) 1 No.
Float Level Switch 2 Nos.
Motorized valve 1 No.
Gate valve 1 No.
Pressure Transmitter 1 No.
Pressure Differential Transmitter 1 No.
Solenoid valve 4 No.
6.1. Operator HMI View

System
Modes of Operation-
Manual ON
Manual OFF
Auto Mode
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6.2. Sequence of Operation Check Manual Operation

No. Test Steps Acceptance Criteria Applicability
1. After boot Enter to Navigation should happen in the HMI
Parameter Screens HMI
2. Enter the number of The total number of valve selection HMI
Valves to be operated can be entered between 1-4 only.
Set point should be in the Range of
1-4
3 Click the Manual ON Text should Appear as MANUAL HMI
Button ON SELECTED
4 Click on the apply The Number Quantity of Valves Valve Status monitored
button Entered in the Set point. Example in the Main Screen
then two Valves will be MANUAL
ON
5 Click on the Manual Text should Appear as MANUAL HMI
OFF Button OFF SELECTED
6 Click on the Apply The Number Quantity of Valves Valve Status monitored
button Entered in the Set point. Example in the Main Screen
then two Valves will be Manual
OFF.
6.3. Sequence of Operation Check Auto Operation
TIME BASED CONTROL

1. After boot Navigation should happen in the HMI HMI
Enter to
Parameter
Screens
2. CYCLE 1 CYCLE 1 can be set as per valve schedule Ex HMI
SETPOINT 6.00 AM. The valve number 1 will be on for 15
Hours and Minutes, After 15 MINUTES VALVE 2 will
Minutes switched ON and VALVE 1 will be switched
need to be OFF. Sequence of Operation will be continued
entered unit Valve 4 Operates.
3. CYCLE 2 CYCLE 2 can be set as per valve schedule Ex HMI
SETPOINT 18.00 PM. The valve number 1 will be on for
Hours and 15 Minutes, After 15 MINUTES VALVE 2 will
Minutes switched ON and VALVE 1 will be switched
need to be OFF. Sequence of Operation will be continued
entered unit Valve 4 Operates.
4. Enter the The total number of valve selection can be HMI
number of entered between 1-4 only. Set point should be
Valves to in the Range of 1-4
be operated
System

5 Click the Text should Appear as AUTOMATIC HMI
Manual ON SELECTED
Button
6 Click on the The Number Quantity of Valves Entered in the Valve Status monitored in
Apply Setpoint. will be operated on the Time 1 and the Main Screen
button Time 2 Setpoint,
WHETHER BASED CONTROL
Note:
Whether condition mode is preprogramed, and it can be tested when Communication link is available to Lusail
city main Scada. the Modbus list will be allowing to put the Irrigation in the weather based Operation once the
communication link is established.
System
SECTION 7
MAINTENANCE
System
7 MAINTENANCE
7.1. INTRODUCTION
All the equipment which is used throughout CP-16, Irrigation system VIP Building should be
strictly used, maintained and replaced when necessary, only by the manufacturers
permission and by authorized persons.
7.2. Special Tools

Standard tools Wrenches, spanner set, flat & star screwdrivers etc.
Snip Cutter Right, left and straight.
Personnel Protection Gear.
Vacuum Cleaner/Blower.
Multi-meter.
Tester.
Ladder/Scaffolding.
Drilling Machine.
Teflon Tape.
System
7.3. Preventive Maintenance Activities

Quarterly (Four (4) PPM per contractual Year) preventive maintenance during the principal period
of maintenance should be carried out by the client.
Integrated Automation System Monthly Checklist
Project Name: CP-16 Utility Tunnel Control Centre and VIP Building Irrigation Pump
Control System
Date:
Type of Maintenance:
1. Preventive Maintenance
2. Corrective Maintenance
3. Risk-Base
d Maintenance
Status
Task Case Corrective
Task
No. NOT Description Action
OK
OK
1.00 Network & Computers
Check physical status of the
1.01 workstations, Scan the hard disks for
any errors along with virus scan.
1.02 Perform Hard drive back-up for

panel and controller databases.
Check network operation, switches
1.03 and data cables by physically and
verify as per build-in drawings.
Check operation of master clock and
1.04 ensure the synchronization on among
all equipments.
1.05 Review the operation with

maintenance personnel.
2.00 ABB Software
Check tag type faceplate for all

2.01
equipments and ensure that reading
values are correct.
System
2.02 Random check of different

equipments and field devices.
Check and ensure proper
2.03 functionality using ABB specialized
software.
3.00 Panels diagnostic checks
3.01 Signs of Damages
3.02
Ensure panel fault LED's as inactive.
Check for signs of overheating of
3.03 components in the panel and internal
temperature.
Check and ensure that the UPS
3.04 system get charging and make a note
on battery healthiness.
4.00 PLC's
4.01 Check the high availability status of

each Dual-PLC.
Ensure each PLC in Panel RIOU-
4.02 CG-04 is in running mode and make
sure no errors are in active.
5.00 Field Devices
Check the Flow Meter switches
5.01 physical status and active reading via
software.
Check Transducer with differential
5.02 pressure on operation and physical
status.
Check Level Transducer physical

5.03
status, operation and verify
appropriate wirings.
Check Level Switch and compare
5.04 reading on the corresponding
software.
Check Pressure sensor operation
5.05 with physical status and compare
reading with installed thermostat.
5.06 Check the Valve Decoder in the

RTU webpage Software
Engineer name & Signature: Supervisor name & Signature:

System
7.4. Corrective Maintenance Activities

Corrective Maintenance is the result of a Preventive Maintenance Inspection. The
purpose of corrective maintenance is to return the sites systems or equipment to
serviceable operation and to avoid unplanned service interruptions. When corrective
maintenance is required the technician conducting the PM shall advise the
Maintenance Coordinator who originally issued the PM that corrective maintenance is
required. The Maintenance Coordinator shall ensure that the original work ticket for
the PM is closed and gain approval from the Facility Manager (FM) for the creation of
a CM or PR work order detailing the requirements and any unfinished PM work (if
applicable) is issued.
7.5. Routine Maintenance

7.5.1 Periodic Inspections
Periodic inspection should be performed at least once every month on all Control
panels, equipments and devices, cable, connections, and other critical equipment.
Periodic inspections are extremely beneficial in reducing electrical failures by
identifying potentially dangerous conditions; such as, loose or dirty connections,
overloaded, or improperly installed equipment.
By measuring the heat imbalance relative to the environment and to surrounding

equipment, abnormal or adverse conditions can be uncovered that if left unattended
would worsen to the point of failure. Periodic inspections are very helpful in planning
the work scope of an upcoming scheduled outage. Prior to the planned maintenance,
a survey should be conducted to help identify areas that need specific and immediate
attention.
Resources can then be allocated to address these specific problems during the de
energized period. Periodic inspections are done on energized equipment and should
be conducted during peak demand periods if possible.
This will reveal the most serious problems and those that would otherwise go
undetected.
At a minimum, the loading should be at least 40% of the rated load of the equipment
being inspected.
Effective periodic inspections require specialized equipment and should be

performed only by qualified technicians. Experience and training is required to
accurately identify problem conditions and possible causes so that specific
recommendations can be made to correct the situation.
It is imperative that these recommendations be implemented in a timely manner to
benefit from an infrared inspection. Knowing a problem exists does not help avoid an
electrical failure unless corrective actions are employed.
System
7.5.2 The Cleaning Process

Cleaning the Workstation
Housekeeping and maintenance of a central workstation should include the following
o Clean and service the computer, monitor and keyboard in accordance with the
manufacturers instructions.
o Clean and service the printer in accordance with manufacturers instructions.
Cleaning the Control Panels

o Cleaning the Control Panels (DCPs) before the preliminary checks
o Remove dust from the inside using a vacuum cleaner - do not use blow cleaning as
this may cause shavings and detritus to accumulate in a live area.
o Dust the outside.
o If necessary, use a neutral dissolvent that will not damage the paint.
o Touch up paintwork if necessary.
o Check absence of foreign matter inside the panels (tools, screws and bolts) that could
prevent it from operating properly.
7.6. Recommended Maintenance Schedules
Level Maintenance Interval Maintenance operations

Check alarms for priority levels,
Level I Daily
messages, routing
As for Level, I plus
Visual inspection
Check accuracy of time clock
Level II 1 Month
Check time schedules
Review recently generated
alarms
As for level II plus
Check start-up and shut-down
routines
Level III 6 Months Check optimum-start and
optimum-stop routines
Check control loops for stability
and accuracy
As for level III plus
Level IV 1 Year Check data logging as
required
System
Level Maintenance Interval Maintenance operations

Check sequencing of
multiple plant units
Check interlocks
Check interfaces with fire
and 3rd party systems
As for level IV plus
Software back-up
Database integrity
Level V 2 Years
Software updates (if
applicable)
7.7. Fault Finding Table

Problem Probable Cause Solution / Action
No Power Incorrect wiring. Check connections and
Power supply cable
not connected. Verify if power supply is
Main Breaker is available.
switched Inspect, trace the cause.
off/tripped. Turn ON the Breaker after
Cable damage clearing the fault.
PLCs frequently switching Electro Magnetic Check connections
Offline Interference. Verify if any equipment is
Loose contact creating disturbance to
PLC network.
Isolate device by device,
module by module and
then panel by panel.
Dont switch off and switch
on the controller
frequently as there is
chance to lose the
program.
Frequent Alarms Sensor or Panel Check connections
fault Remove the digital input
Cable Fault cable from the PLC and
check the equipment
panel for fault.
System
SECTION 8
MODIFICATION INFORMATION
System
8 MODIFICATION INFORMATION
The Facilities Maintenance Team should use this Section of the manual to enter details of
any modifications undertaken during the life of the system and equipment installed.
It is recommended not to carry out any substantial modifications on the system.

1. Should modifications become necessary for any reason, all modifications shall
comply with the original design requirements, as indicated in the Project Specifications.
2. All manufacturer instructions shall be followed.
3. Consult the authorized manufacturers representative.
4. Modified portions and effected parts of the system must be tested and proper
operation, performance and safety verified.
5. Modification must be performed only by properly qualified and trained personnel.
System
SECTION 9
DISPOSAL INSTRUCTIONS
System
9 DISPOSAL INSTRUCTIONS
Materials used in maintenance activities and any repaired or replaced items may require
classification as to the type of waste material that they constitute.
The preferred options for disposal are:
Recycling.
Incineration with energy recovery.
Landfill.
The prospect of recycling should always be explored and exercised whenever possible.
The installed items described within this manual require no special considerations regarding
their disposal, and therefore may be disposed of as general builders waste unless
contaminated with a known hazardous material. In the event of such
contamination, local procedures must be followed during disposal.
9.1. KNOWN HAZARDS

The following hazards are associated with the disposal of the elements of this system:
Power: Units must be de-energized and electrically isolated (both power and
control voltage as applicable).
Electrocution: Electrocution can be caused as the main part is pumps which
use electrical power and they are inside the water, so special gloves should be used
to avoid it.
Pressurized system: Ensure that system pressure is reduced before
dismantling any part.
System
9.2. SAFE DISPOSAL
Debris and waste should be swept up or vacuumed and placed in strong polythene bags
(such as the bags used to package the mineral board). Dispose of at an approved waste site
suitable for building waste, observing local regulations.
Consult Doha Municipality Authority, for guidance on the proper disposal / recycling of any
equipment units.
Alternatively, refer the equipment to be disposed of to a recycling agency, or the local

representative of the manufacturer.
System
SECTION 10
Name and Address of Manufacturer, Supplier, Local Agent
System
10 NAMES & ADDRESSES OF MANUFACTURER, SUPPLIER,

LOCAL AGENT
MANUFACTURER LOCAL SUPPLIER / AGENT

PLC and Controllers IO modules
ABB Ltd Gulf Automation System
Affolternstrasse 44
Building No.16, Zone - 24, Street - 830,
CH-8050 Zurich Al Muntazah Commercial, RawdatAlkhail,
Switzerland Hiteen Street, Building 2, Fourth Floor,
Office No.6, P.O. Box: 39352
Tel. +41 (0)43 317 7111
Fax +41 (0)43 317 4420 Doha, State of Qatar.
Tel: +974 44326630
Fax: +974 44602761
URL http:/www.gulfautomations.com
System
SECTION 11
Manufacturer Operation Recommendation
System
11 Manufacturer Operation Recommendation

O&amp;M Irrigation Control System

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Operation and Maintenance Manual

CP16 Irrigation RTU & PLC Control

Operation and Maintenance Manual CP16

9.1. KNOWN HAZARDS ..................................................................................................................................................................... 47

1.1 Purpose and Scope

1.2 Hazards, Warning and Cautions

1.3 Safety Hazards

1.3.2 Electrical Equipment Items

1.3.3 Portable Equipment

1.3.4 Training of Personnel

1.3.4.2 The Qualification of the trainee to be trained

1.3.4.3 Skills requirement of the trainee to be trained

1.3.5 Personal Protective Equipment

Items required may include:

Overalls of sufficient quality.

2.1. Overall purpose on the design intent for the installed

A. The system Architecture

A. The system Architecture

B.AC 500 PM573 PLC Brief Description

User flash disk 4GB (PM592)

Easy to configure by software

With powerful diagnosis, onboard

With different interfaces for easy communication

For central and distributed system concepts

All programmable with same software

LED for status indication

Integrated Onboard I/O

Integrated Ethernet (CPU ETH)

COM1 for online access, ASCII, Modbus RTU or CS31 bus

Run / Stop switch (program execution)

Expandable with up to 10 local I/O modules

The CPU overview and configuration display and front

Diagnosis and error codes

Bus address setting

Square displays: status of fieldbus or device

Triangle indicates the selected device to be read

Figure 1 PLC CPU

LEDs for status indication of

RUN: program execution

ERR: error detection

Keypad for local operation:

RUN: to start and stop a program

ESC: to exit menu without saving

OK: to exit menu with saving

DIAG: for diagnosis of error codes

Figure 2 CPU DISPLAY

d1 indicates the defective component (CPU, COM1, FBP, IO-Bus, etc.)

d2 defines the defective device within the component

d3 defines the part of the module with an error (slot)

d4 defines the defective channel within the module

For data transfer between a PC with SD card reader and AC500

DPT: Differential Pressure Transmitter Brief Description

Digital LCD Integral Display

FIT: Flow Transmitter Brief Description

LIT: Level Transmitter Brief Description

PS: Pressure Switch Brief Description

PIT: Pressure Transmitter Brief Description

Digital pressure transmitters are communication-ready field devices with microprocessor-

3 Equipment Schedule and Part number with COO

LIST OF MATERIALS WITH COUNTRY OF ORIGIN PLC &

S.No MATERIALS MAKE PART NO ORIGIN

1 Ethernet Switch 6 Port Harting 24030060000 Germany

HMI & Software

1 Pressure transmitter ABB 261GS- U.K.T.N.T.1 L1.B2 Italy

O&M Irrigation Control System

O&M Irrigation Control System