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Control system design of the pumping station

To cite this article: Ke Li et al 2018 IOP Conf. Ser.: Mater. Sci. Eng. 394 032129

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ACMME 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 394 (2018) 032129 doi:10.1088/1757-899X/394/3/032129
1234567890‘’“”

Control system design of the pumping station

Ke Li1, Yanping Wang*, Xiujuan Fan

1
Beijing Institute of Fashion Technology, School of Information Engineering,
Graduate student, China.

*Corresponding author e-mail: 395140317qq.com

Abstract. This paper describes the design process of the pump station control system.
Aiming at the general characteristics of the operation of the pumping station's
automatic control system, an application program using the ABB AC500 series
programmable controller in the pumping station monitoring system was proposed. The
cost of scheme is low and the management, maintenance and operation is simple. As
the engineering practice shows, using ABB AC500 PLC to form project can get high
reliability, high performance and high performance-price ratio etc., and has good
economic benefit. And PC interface is made with the WINCCV6 of Siemens
Company. The excellent openness of WINCC makes it particularly outstanding in
distributed system. In PC dynamic display design compares two different methods to
make dynamic display effect to achieve the best.

Key words: Plc, Winch, Opt, Abby, Ac500, Siemens.

1. Introduction
With the rapid development of science and technology, the "centralized management, decentralized
control" model of the control system has become a new demand in the field of automation and control.
This requires us to establish an advanced, reliable, efficient and easy to further expand the set of
process control, monitoring and computer scheduling management in one and have a good open
monitoring system to complete the entire process and all production equipment monitoring. Pumping
station control is just like this.
The use of a collection and distribution system for the control of multiple pumps and related
equipment can greatly increase the working efficiency of the staff. Our task is to set up a collection
and distribution system for pump station control to efficiently control the pumping station equipment
and monitor and protect it in real time.

2. Process Requirements Of The Control System

Based on the "centralized management, decentralized control" model, in the field control room, PLC
remote monitoring of the pump station's high and low voltage distribution cabinets, electrical cabinets.

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ACMME 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 394 (2018) 032129 doi:10.1088/1757-899X/394/3/032129
1234567890‘’“”

Figure 1. Control Charts

The pump is required to have temperature protection. When the high temperature limit is reached,
the motor must be stopped. It has low water level protection, high water level alarm and continuous
water level measurement function during pump startup and operation.
The water pump control system is divided into electric cabinet control, communication control,
water level temperature control, and monitoring feedback control.
When the water level of the suction tank is too low, in order to prevent the pump motor from idling,
the static pump should be operated; when the pressure level of the pressure tank is too high, there
should be an alarm; when the temperature of the main pressure change is too high, there should be an
alarm. The electrical cabinet control includes the electrical cabinet control system; the communication
control system; the water level treatment control system; the temperature treatment control system;
Sound and light alarm control system.

Figure 2. Motor Cabinet out of control detection part of the flow chart.

3. System Hardware Design

A: Hardware Devices
Control equipment: primary power receiving cabinet, secondary power receiving cabinet, seven
motors, main transformer, AC500 PLC.
One power-receiving cabinet: equivalent to one switch, controlling the main transformer's on and
off states.
Secondary receiving cabinet: Equivalent to a switch to control the opening and closing status of the
following circuit.
Main Transformer: The 10 KV voltage received from the wire is converted to 6 KV for later use.

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ACMME 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 394 (2018) 032129 doi:10.1088/1757-899X/394/3/032129
1234567890‘’“”

Seven electric cabinets: Control the opening and closing of seven pump motors, measure the
voltage, current, and active/reactive power. Send these measured values to the PLC via MODBUS
communication.
Seven Motor: In normal operation, the water in the suction tank is pumped into the pressure tank.
B: Other operating equipment
Computer (IPC)
UPS (Uninterrupted Power Supply)
Water Level Meter Three: JYB-K0-LAG 5 Meter Range 10 Meter Cable
PT100 two models: WZP-298 (12mm*150) and WZP-296 (10mm*30)
UPS is the English abbreviation of uninterruptible power system. It is an important external device
that can provide continuous, stable and uninterrupted power supply. In this pump control system, the
main role is: When suddenly encountered power failure, UPS can also provide computer and PLC
cabinet power supply for about 1 hour, to facilitate the user to save information in a timely manner to
prevent sudden power failure to damage the computer hardware
The main transformer has Pt100 thermal resistance, which is converted into a 4~20mA current
signal through the signal converter and sent to the AI module of the PLC. When the temperature of the
main transformer is too high, the primary power receiving cabinet is circuited.
PLC selection and hardware design
The selection of hardware equipment was based on the requirements of the control process, the
amount of data processed by the program, and the communication requirements. At the same time, the
AC500 series PM581-ETH PLC of ABB was selected in consideration of the cost. Because the pump
control system program has relatively little processing data and ABB's automation products have high
performance, high flexibility, and high availability, the pump control system can meet the conditions
required for program operation. In the control system of the pump station, the DC522 module is
selected for the digital input/output module, and there are 16 24 V DC digital inputs/outputs for the
group (2.0-2.7 and 4.0-4.7).The analogy input module selects AI523 and the two groups have 16
programmable analogy inputs (1.0-2.7 and 3.0-4.7).

4. System Software Design

The software design of this system includes PLC programming and HMI PC programming, ABB
programming software Co-De-Sys V2.3 adopted by PLC, and WINCC V6 configuration software used
by HMI.
PLC control system programming
1. The main program consists of electric cabinet control, communication control, water level
processing, and temperature processing, sound and light alarm.
The electrical cabinet control includes the main program of the electrical cabinet control group
program, out of control detection, and excitation detection. The control of the motor cabinet must be
closed at one power receiving cabinet and the second power receiving cabinet. The pump has no high
temperature alarm and runs out of control. The water level of the suction tank is not lower than the
lower limit. The motor cabinet can only be controlled by the upper computer. Any item is not satisfied.
Sub-gate treatment. Out of control detection is that the PLC did not perform the PLC sent the
command after 2 second and reported an out-of-control failure. Excitation detection is when the motor
is not energized after the normal closing of the motor, an excitation fault is sent.
2. There are two types of communication objects in the communication section. One is to read the
pump temperature, and the other is to read the measured value of the comprehensive protector. The
two types of communication methods are the same, but the number of read measurement values is not
the same, and COM1 and COM2 ports are used for communication respectively. The communication
part is executed once every second. After the communication is completed, the measured value is
transferred to the address specified in the PLC for display on the upper computer and PLC processing.

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ACMME 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 394 (2018) 032129 doi:10.1088/1757-899X/394/3/032129
1234567890‘’“”

3. The water level treatment is that the water level measurement value is directly read by the AI
module and compared with the set value of the host computer. If the limit value is exceeded, an alarm
signal is sent out.
4. Temperature treatment refers to the temperature of the water pump. There are 16 pump
temperature values. The maximum value is first determined, then the maximum value is compared
with the corresponding upper limit. If the upper limit is exceeded, an alarm signal is sent out.
5. Sound and light alarm means that if there is any fault, the integrated fault will be set. If the bell is
not muted, sound and light alarm will be performed. When all the faults are cleared, 0 is set and the
bell is muted.
HMI software system design
1. HMI programming
The upper computer uses Siemens WINCC V6 configuration software to produce. HMI is the
abbreviation of Human Machine Interface, also called human-machine interface. WINCC is used to
visualize the process and develop a graphical user interface for the operator. Open the SIMATIC
WINCC click the Graphics Designer to create the new screen.
Specific functions as follows:
Monitor the motor's current, voltage, power, and primary current, voltage, power, etc.
Controls the motor's split/closing, primary/secondary panel power transmission.
Real-time display of motor temperature point and transformer temperature, real-time alarm.
Real-time display of the actual value of the 3 water level meters, real-time alarm.
2. PC and PLC OPC settings
The full name of OPC is OLE for Process Control, and its appearance has bridged the gap between
Windows-based applications and on-site process control applications. Through DCOM technology and
OPC standards, it is entirely possible to create an open, interoperable control system software, to
achieve very important communication, OPC communication between the host computer interface and
the PLC, the information inside the PLC can be completed after the communication Display on the
interface, and reflect the operation on the interface to the PLC.
Open ABB OPC CONFIG and check PULIC Group for set the OPC server. Then click on server
and right click on Append PLC. Click the Edit button on the right to set the communication parameters.
The settings are the same as those in the PLC programming software.
Open Co-De-Sys. OPC.02 Press "Browse Server" for set the OPC in the PC, then select the desired
read-write PLC variable. After selecting the variable, add the prefix and suffix for the variable, and
select Add Location to add it. Open "Variable Manager->OPC->OPC Groups->CoDeSys_opc_02".
The upper computer can read and write the variables in the PLC through the OPC server. Then we will
assign these variables to the corresponding object in the upper computer.

5. Conclusion
With the rapid development of control technology, the field of automatic control requires the control
system to be safer, more efficient, and more humane. This article takes the pump station control
system as an example to introduce the design and implementation process of the distribution system.
The system host computer development uses the world's most open PC development software WINCC.
The "centralized management, decentralized control" model of this system has greatly improved the
efficiency of the operator. The operator can monitor and control multiple devices in real time, which
not only enables the device to operate more safely, but also greatly extends the life of the device.

Acknowledgment
This work is supported by the research and practice project of structural adjustment and professional
development of electronic information engineering. (No.ZDJG-1606).
NHFZ20180087/006 Promoting the Connotation Development Quotient of Colleges and
Universities.

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ACMME 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 394 (2018) 032129 doi:10.1088/1757-899X/394/3/032129
1234567890‘’“”

References
[1] WINCC Information System from the Siemens Company.
[2] Simple to understand Siemens WINCC V-6 [M] Beijing University of Aeronautics and
Astronautics Press ,2004 :7-81077-492-1.
[3] AC500 training materials from the ABB Company.
[4] PLC main product sample -201004xx from the ABB Company.
[5] S500 Switch Module from the ABB Company.