Managing Water for Life

REPORT NO.:

DARVILL WASTE WATER TREATMENT WORKS:

DIGESTER PLANT

FUNCTIONAL DESIGN SPECIFICATION:

B9366-FDS-7.1 (PRIMARY SLUDGE P.STATION)

Incorporating:
1. Primary Sludge Pumps

Compiled by: DESMOND KOPKE

Company Details: ELECTRON TECHNOLOGIES
Umgeni Water Project Number:
Contributors:
Date: 10.05.2017
Revision: 01
Status: FDS Design Review Meeting

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 18.04.2017 Document Creation Desmond Kopke
01 10.05.2017 FDS Design Review Meeting Desmond Kopke
02
03

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

SOURCE DOCUMENTATION
H121642-002-75-031-0002-001 Rev. 3

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 18 Digester Wiring B9366-7 Electron
Schematics
2 MCC 18 Digester Plant Single B9366-7SLD Electron
Line Diagrams
3 MCC 18 Digester Plant Loop B9366-7L Electron
Diagrams
4 MCC 18 Digester Plant B9366-7IH Electron
Instrument Hook Up Diagrams
5 MCC 18 Digester Plant Cable B9366-7CBD Electron
Block Diagrams
6 Primary Sludge Thickening H121642-002- Hatch Goba
P&ID 75-031-0002-
001 Rev.3

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 INSERT CONTENTS PAGE HERE

1 PURPOSE
The purpose of this document is to define the Functional Design Specification for Primary Sludge
Pump Installation, 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

No. Description Consultant Check Client Check
1 Primary sludge sump is made up of two half’s, those being A and B.
Separation between sump A & B is achieved with the use of a knife
gate valve monitored with limits ZSC-1803 and ZSO-1803.
2 When ZSC-1803 is not closed, indicating a common sump, which
shall be the normal mode of operation, the PLC shall use the average
of the two levels LIT-1803A and 1803B, as the level on which control
is based.
3 If there is a difference of more than 5%, for time period xx sec, in the
two readings, and alarm shall be raised and the operator can then
chose which level to use.
4 In the common sump mode of operation…
1. Primary Sludge Pumps M-1817/18 shall operate on a
Duty/Standby set up.
2. FIT-1819 shall be used to protect the operational pump
against a no flow scenario.
3. Pump speed shall be controlled via a PID control loop , that
shall achieve and maintain a certain level, which shall always
be below the PST inlet invert.
5 In the separate sump mode of operation…
1. The Primary Sludge pumps shall be controlled based on their
sump specific level controller.
2. M-1817 shall be controlled on level LIT-1803A
3. M-1818 shall be controlled on level LIT-1803B
4. There shall always only be one PID controller, the output of
which shall be used for control of both loops.
6 Primary Sludge Pumps shall not be allowed to run simultaneously.

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 It is understood that while operating in the separate sump mode of
operation, PST underflow shall only be allowed to fill one half of the
sump at a time. This is an operator responsibility.

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 Course
Screens are listed here.

DESCRIPTION SET POINT LOOP NUMBER ConsultantCheck Client Check

Primary Sludge Sump A Level High 18-LIT-1803A

Primary Sludge Sump B Level High 18-LIT-1803B
Primary Sludge Discharge Flow Low 18-FIT-1819

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 – Primary Sludge Pumps

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 3.5.1.1 Purpose
To start the Primary Sludge Pumps in Remote Auto from the control building

3.5.1.2 Initiation of Sequence

Primary Sludge Pump Sump Level High

3.5.1.3 Sequence Steps

STEP ACTION TRANSITION LOCATION BY Consultant Client

NO Check Check
1 Ensure pumps are switched into PLC MCC Operator
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 common or single sump mode PLC PLC
of operation.
5 When level LIT-1803 increases to LAH PLC PLC
30% then engage PID Control loop and
start duty pump
6 Pump at rate controlled by PID controller PLC PLC
in an effort to achieve and maintain a
level set point that shall be below inlet
invert
7 If level LIT-1803 drops below 10%, dis- PLC PLC
engage PID control loop and stop pump.
8 Once pumping has started wait 30 sec, PLC PLC
and verify flow with flow meter FIT-1819.
If flow is less than XXm3/hr then stop
pump and start standby pump.

3.5.2 Remote Manual – Start/Stop Thickened Sludge Pumps in Remote/Manual Mode

3.5.2.1 Purpose
To start the Thickened Sludge 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 Consultant Client

NO Check Check
1 Ensure pumps are switched into PLC MCC Operator
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

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 4 Confirm common or single sump mode PLC PLC
of operation.
5 Pumping started by operator SCADA Operator

6 Pump at rate controlled by PID controller PLC PLC

in an effort to achieve and maintain a
level set point that shall be below inlet
invert
7 If level LIT-1803 drops below 10%, dis- PLC PLC
engage PID control loop and stop pump.
8 Once pumping has started wait 30 sec, PLC PLC
and verify flow with flow meter FIT-1819.
If flow is less than XXm3/hr then stop
pump and start duty pump.

3.5.3 Local Manual – Start Up/Shut Down of Thickened Sludge Pumps

3.5.3.1 Purpose
Starting the Thickened Sludge Pumps 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 Consultant Client

NO Check Check
1 Ensure pumps are switched into Local MCC Operator
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 sufficient level in the sludge Field Operator
sump
5 Select pumping speed MCC Operator

6 Start Primary Sludge pump Field Operator

7 Stop Primary Sludge Pump Field Operator

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

Tag Description Safety / Consultant Client

Process Check Check
Interlock
Primary Sludge Pump X START = FAILED if Pump X Isolator = OFF, Safety
Emergency Stop = OFF, Motor Tripped Circuit = ON
Primary Sludge Pump X START = FAILED if Primary Sludge Sump Process
Level not high, FIT-1819 = Low, Sister Primary Sludge pump already

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 running

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 RED, to
confirm, 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- ACTION ALARM Consultant Client

CONDITION CATEGORY Check Check
DVL_17_LIT-1803A/B Primary Sludge Investigate 2
Sump High cause
DVL_17_FIT-1819 Delivery Flow Investigate 2
Low Cause

6 OPERATOR INTERFACES

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

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 DISPLAY NAME AREA COVERED REF DRAWING
Digester Plant – Displays the Screening Channels mimic. Active elements include valve status,
Primary Sludge (Open. Closed, % position), Motor Status, (Running, Stopped, Tripped, Run
Pump Station Hours), and also displays related instrumentation process values and trends,
(Flows, Levels, Pressures)
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.
17-LIT-1803A/B Primary Sludge Sump Level 1 sec 30 days
17-FIT-1819 Primary Sludge Discharge 1 sec 30 days
Flow

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

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.

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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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