Managing Water for Life

REPORT NO.:

DARVILL WASTE WATER TREATMENT WORKS:

FATS, OIL, GREASE & SCUM PUMPS

FUNCTIONAL DESIGN SPECIFICATION:

B9366-FDS-2.3 (FOGS DIGESTER FEED PUMPS)

Incorporating:
1. FOGS DIGESTER FEED PUMPS

Compiled by: DESMOND KOPKE

Company Details: ELECTRON TECHNOLOGIES
Umgeni Water Project Number:
Contributors:
Date: 24.07.2018
Revision: 01
Status: DOCUMENT REVISED FOR APPROVAL

DOCUMENT APPROVAL
NAME COMPANY DESIGNATION SIGNATURE DATE

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 DOCUMENT CONTROL

AUTHOR Desmond Kopke

FILE NAME B9366-FDS-2.3 – FOGS Digester Feeds Pumps
PATH
CREATED 27.01.2015
LAST ACCESSED 24.07.2018
NUMBER OF PAGES

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

00 27.10.2015 Document Creation Desmond Kopke
01 24.07.2018 Document Revised Desmond Kopke
02
03

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

SOURCE DOCUMENTATION
H121642-002-75-031-0002-001, Rev.0

RELATED DOCUMENTS
Include all documents referenced within or the reader may need to refer to
NO. DOCUMENT DOCUMENT HATCH UMGENI PUBLISHER DATE REV
DESCRIPTION NUMBER DOCUMENT DOCUMENT
NUMBER NUMBER
1 MCC 11Wiring B9366-2 Electron TBA TBA
Schematics
2 MCC 11 - Settled B9366-2SLD Electron TBA TBA
Sewage P. Station
Single Line Diagrams
3 MCC 11 – Cable Block B9366-2CBD Electron TBA TBA
Diagram
4 Primary Sludge H121642-002- Hatch Goba TBA TBA
Thickening P&ID 75-031-0001-
001

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Section Description Page
Number
1 Purpose 4
2 Definitions 4
3 Control and Operating Philosophy 5
3.1 Process Overview 5
3.2 Scope and Limits of Supply 7
3.3 Pre-Defined Setpoints 7
3.4 Modes of Operation 7
3.5 Sequences 7
3.5.1 Remote Auto – Operation of FOGS Digester Feed Pumps 1 & 2 8
3.5.2 Remote Manual – Operation of FOGS Digester Feed Pumps 1 & 2 9
3.5.3 Local Manual – Operation of FOGS Digester Feed Pumps 1 & 2 10
4 Interlocks 11
5 Alarms 12
5.1 Alarm Categories 12
5.2 Alarm Allocations 12
6 Operator Interfaces 13
7 System Data 14
8 Trends 15
9 Output Reports 16
10 Test Factors 17
11 Other Information 18

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1 PURPOSE
The purpose of this document is to define the Functional Design Specification for FOGS Digester
Feed Pump installation, at Darvill Waste Water Treatment Works.

2 DEFINITIONS
Include all abbreviations used in the document.
NO. KEY DESCRIPTION
1 PLC 11 Programmable Logic Controller – Settled Sewage P. Station PLC
2 PLC 18 Programmable Logic Controller – Digester PLC
3 MCC Motor Control Centre
4 DB Distribution Board
5 SCADA Supervisory Control and Data Acquisition
6 FOGS Fats, Oil, Grease & Sludge
7 FT Flow Transmitter
LT Level Transmitter

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 3 CONTROL AND OPERATING PHILOSOPHY

3.1 PROCESS OVERVIEW

No. Description Contractor Consultant Client

Check Check Check

1 FOGS Digester Feed Pumps are designed to operate on a duty/standby

arrangement. The duty pump shall be defined by the chute position proximity
switch ZS-1026 and ZS-1027.
 When 11-ZS-1027 is high, this shall indicate the FOGS Pump 1, 11-
M-1061 is duty and FOGS Pump 2, 11-M-1063, shall be duty.
 When 11-ZS-1026 is high, this shall indicate the FOGS Pump 2, 11-
M-1063 is duty and FOGS Pump 1, 11-M-1061, shall be duty.
2  Chute Selector valve 11-XV-1103, shall change the duty FOGS
Pump on weekly basis.
 The chute selector drive, 11-XV-1103, shall also change over the
duty FOGS Pump to the Standby FOGS Pump should the duty pump
fail for any reason.
 Changeover from duty to standby, as a result of a failure, shall only
occur if the standby machine is in a completely healthy state.
 Delivery valves, 11-M-1067 and 11-M-1068 respectively, shall form
part of the healthy pump set.
 An alarm shall be raised on the PLC should the selected FOGS
pump not be healthy.
3 The level in hopper 1 and hopper 2 shall be monitored by means of an
ultrasonic level transmitter, 11-LT-1025 and 11-LT-1026 respectively.
 When 11-LT-1025 HH or 11-LT-1026 HH Level has been reached a
high level interlock is used to inhibit the operation of the FOGS
Separator conveyor, 11-M-1103, as well as the FOGS Separator
Trolley drive 11-M-1101, as there is no more capacity to accept
further product.
 The Scum and FOG could then build up in the boat structure, and
possibly spill over the weir, this is a pinch point for discussion.
4 When the sludge feed batch is started, as determined by the level in the
Thickened sludge sump, 18-LIT-1804, (Refer to FDS B9366-FDS-7.8 &
B9366-FDS-7.9 for further information), a pump call is sent by PLC 18
(Digester) to PLC 11 (Settled Sewage P. Station). Upon receipt of a pump
call from PLC 18 the following shall occur…
 Confirm duty pump hopper level 11-LT-1025 H, xx%, or 11-LT-1026
H, xx%, level has been reached.
 Confirm at least one Digester Feed Valve 18-XV-1801, or 18-XV-
1814, or 18-XV-1823 or 18-XV-1827 is open.
 Should the above two conditions be met, the duty discharge valve
11-M-1067, or 11-M-1068 shall open.
 Once the duty discharge valve 11-M-1067 or 11-M-1068 is fully open
the duty FOGS Digester Feed Pump 11-M-1061 or 11-M-1063 shall
start and run until 11-LT-1025L, xx%, or 11-LT-1026L, xx%, as the
case may be, is reached. The pumps shall then stop, and continue to
operate on an on/off basis, as long as at least 1 digester feed valve,
18-XV-1801, or 18-XV-1814, or 18-XV-1823 or 18-XV-1827 is open
and 1 digester feed pump 18 –M-1824 or 18-M-1825 is running.
Feed to digesters shall be on a batch process, as monitored by 18-FIT-1801,

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which shall be adjustable from SCADA (Refer to FDS B9366-FDS-7.8 &
B9366-FDS-7.9 for further information). Once a batch to a digester has been
completed, the inlet valve of the following on-line digester shall open. Once
this inlet valve is open the inlet valve of the previous digester shall close,
maintaining at least 1 open valve at all times. This process shall be
controlled by PLC 18, but is relevant to the understanding required to run the
Digester Feed Pumps.

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 3.2 SCOPE AND LIMITS OF SUPPLY
To fulfil the requirements of the Control Philosophy with the required interface between PLC10,
PLC11 PLC 18 and SCADA system.

3.3 PRE-DEFINED SET POINTS

Process operating parameters and equipment/instrument set points applicable to the FOGS
Digester Feed pumps are listed here.

DESCRIPTION SET POINT LOOP NUMBER

FOGS Pump 1 Hopper Level Low Low 10% DVL_11_LT_1025LL
FOGS Pump 1 Hopper Level Low 30% DVL_11_LT_1025L
FOGS Pump 1 Hopper Level High 70% DVL_11_LT_1025H
FOGS Pump 1 Hopper Level High High 95% DVL_11_LT_1025HH
FOGS Pump 2 Hopper Level Low Low 10% DVL_11_LT_1026LL
FOGS Pump 2 Hopper Level Low 30% DVL_11_LT_1026L
FOGS Pump 2 Hopper Level High 70% DVL_11_LT_1026H
FOGS Pump 2 Hopper Level High High 95% DVL_11_LT_1026HH
Distribution Chute FOGS P1 Position N/A DVL_11_ZS_1027
Distribution Chute FOGS P2 Position N/A DVL_11_ZS_1026
FOGS Digester Feed P1 Stator Protector Temp 60 Deg. C DVL_11_TIT_1061
FOGS Digester Feed P2 Stator Protector Temp 60 Deg. C DVL_11_TIT_1061

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 Formatted Table

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.

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 3.5.1 Remote Auto – Operation of FOGS Digester Feed Pumps 1&2

3.5.1.1 Purpose
To start the FOGS Digester Feed Pumps 1 & 2 in Remote Auto from the control building

3.5.1.2 Initiation of Sequence

Initiation of blended sludge batch feed process, initiates the FOGS Digester Feed Pumps.

3.5.1.3 Sequence Steps

STEP ACTION TRANSITION LOCATION BY

NO
1 Ensure FOGS Digester Feed pumps, 11-M- All motors are in Auto MCC Operator
1061 or 11-M-1063 are switched into PLC
mode.
2 Check the alarm status of the duty/standby All faults are checked SCADA Operator
motors by clicking on the motor
3 Reset any Present alarm conditions All faults are cleared SCADA Operator
4 Confirm FOGS Hopper Level LT1025/1026 is of 11-LT-1025 or 11-LT-1026 shall PLC PLC
sufficient level be greater than 11-LT-1025L or
11-LT-1026L setpoints
5 Confirm at least 1 digester inlet valve is open PLC 11 to cross reference with PLC PLC
18-XV-1801, or 18-XV-1814, or 18-XV-1823 or PLC 18.
18-XV-1827
6 Open duty FOGS Digester Feed Pump delivery Wait for duty valve to confirm PLC PLC
valve 11-M-1067 or 11-M-1068 fully open
7 Start FOGS digester feed pumps Pumps start, provided all PLC PLC
interlocks are healthy
8 Digester feed pumps continue to run, until … Continue to pump provided all of PLC PLC
 11-LT-1025L ##%, or 11-LT-1026L the mentioned interlocks are
##% is reached. healthy
 There is no longer a Digester Feed
Valve 18-XV-1801, or 18-XV-1814, or
18-XV-1823 or 18-XV-1827 open.
 FOGS Digester Feed Pump Delivery
Valve 11-M-1067 or 11-M-1068 is no
longer open.
9 Digester feed pumps are stopped by Hopper FOGS Digester feed Pumps 11- PLC PLC
Low Level 11-LT-1025L ##%, or 11-LT-1026L M-1061 or 11-M-1063 are
##%. allowed to restart should the
level in the duty hopper reach
11-LT-1025H or 11-LT-1026 as
the case may be.
10 Duty FOGS Digester Feed Pump Delivery Batch feed totalizer as measured PLC PLC
Valve 11-M-1067 or 11-M-1068 shall remain by 18-FIT-1801, shall stop the
open until the batch feed process has stopped, batch once the batch quantity
and the pump call from PLC 18 is removed. has been reached, and PLC 18
shall then remove the pump call
to PLC 11.

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 3.5.2 Remote Manual – Start Up/Shut Down of FOGS Digester Feed Pumps

3.5.2.1 Purpose
To start the FOGS Digester Feed 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 FOGS Digester Feed pumps, 11- All motors are in Auto MCC Operator
M-1061 or 11-M-1063 are switched into
PLC mode.
2 Check the alarm status of the All faults are checked SCADA Operator
duty/standby motors by clicking on the
motor
3 Reset any Present alarm conditions All faults are cleared SCADA Operator
4 Confirm FOGS Hopper Level 11-LT-1025 or 11-LT-1026 shall be SCADA Operator
LT1025/1026 is of sufficient level greater than 11-LT-1025L or 11-LT-
1026L setpoints.
5 Confirm at least 1 digester inlet valve is PLC 11 to cross reference with PLC 18. SCADA Operator
open, 18-XV-1801, or 18-XV-1814, or
18-XV-1823 or 18-XV-1827
6 Open duty FOGS Digester Feed Pump Wait for duty valve to confirm fully open PLC PLC
delivery valve 11-M-1067 or 11-M-1068
7 Start FOGS digester feed pumps, either This is done manually by the operator SCADA Operator
11-M-1061 or 11-M-1063 from the SCADA,
8 Digester feed pumps continue to run, Continue to pump provided all of the PLC PLC
until … mentioned interlocks are healthy
 11-LT-1025L ##%, or 11-LT-
1026L ##% is reached.
 There is no longer a Digester
Feed Valve 18-XV-1801, or 18-
XV-1814, or 18-XV-1823 or 18-
XV-1827 open.
 FOGS Digester Feed Pump
Delivery Valve 11-M-1067 or 11-
M-1068 is no longer open.
9 Digester feed pumps are stopped by FOGS Digester feed Pumps 11-M-1061 PLC PLC
Hopper Low Level 11-LT-1025L ##% or or 11-M-1063 will not restart, should 11-
11-LT-1026L ##%. LT-1025H ##% or 11-LT-1026H ##% be
reached.

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 3.5.3 Local Manual – Start Up/Shut Down of FOGS Digester Feed Pumps 1 & 2

3.5.3.1 Purpose
Starting the FOGS Digester feed pump 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 FOGS Digester Feed pumps, 11- All motors are in local MCC Operator
M-1061 or 11-M-1063 are switched into
Local mode.
2 Ensure 11-LT-1025 or 11-LT-1026 is Level readings available from local SCADA Operator
above the low low level setpoint, 11-LT- display.
1025LL ##% or 11-LT-1026LL##%.
3 Start/stop FOGS digester feed pumps Via push buttons located in the field Field Operator
11-M-1061 or 11-M-1063 as required.

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

Tag Description Safety /

Process
Interlock
11-M-1061 & 11- FOGS Digester Feed Pump X START = FAILED if Pump X Isolator = Safety
M-1063 OFF, Emergency Stop = OFF, Electronic Relay Fault = HIGH, Motor
Tripped Circuit = ON
11-M-1061 & 11- FOGS Digester Feed Pump X START = FAILED if FOGS Hopper Level Process
M-1063 = Low Level, at least 1 x Digester 5, 6, 7 or 8 inlet valve, 18-XV-1801, or
18-XV-1814, or 18-XV-1823 or 18-XV-1827 not = open, FOGS Digester
Feed Pump Delivery valve 11-M-1067 or 11-M-1068 not = open

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 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 NOT APPLICABLE
(NOTIFICATION)
LEVEL 1 NOT APPLICABLE
(FAILURE)
LEVEL 2 An alarm condition that warns the Senior Operator of impending
(CRITICAL FAILURE) negative impact on process performance, plant integrity, personnel
safety or environmental safety. This alarm is generated and
indicated on the screen until 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_11_LT_1025 Level FOGS Digester Feed Pumps Alarm High High and 2
running Alarm Low Low
DVL_11_LT_1026 Level FOGS Digester Feed Pumps Alarm High High and 2
running Alarm Low Low

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 6 OPERATOR INTERFACES

LOCAL INTERFACE LOCATION REF DRAWING

Local/PLC Selector Switch MCC Panel Door B9366-2
Local Start Stop Push Button Field B9366-2
Delivery Valves Operations Filed B9366-2
Local Reset Push Button MCC Panel Door B9366-2

DISPLAY NAME AREA COVERED REF DRAWING

Oil Separator Displays the FOGS Pumps 1 & 2 mimic along with the boat structure and Refer to O&M
relevant machines. Active elements include valve status, (Inlet valves, De- for SCADA
sludge valves), Motor Status, (Running, Stopped, Tripped, Run Hours, Image
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 Refer to O&M
interrogated here. for SCADA
Image

Instrument Pop Instrument process settings are read here, Trends are displayed and Refer to O&M
Up’s Process Calibration Values set. for SCADA
Image

Valve Pop Up’s Auto/Manual Selection is done here. Open/close is selected here when Refer to O&M
operating in Manual for SCADA
Image

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7 SYSTEM DATA

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

 Current draws (per phase if possible)

 Run hours
 Availability
 Kilowatts / kWh
 Trips
 Historic trips

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 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_11_LT-1025 FOGS P1 Hopper Level 60 sec SCADA & 30 Days
Sequal
DVL_11_LT_1026 FOGS P2 Hopper Level 60 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.

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9 REPORT OUTPUTS

Reports originate from the Sequal database.

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10 TEST FACTORS

Test Factors include:

1. FDS review.
2. Site Acceptance Testing (SAT) on completion of commissioning to demonstrate the
system operates pre-handover.
3. QCP Verification and sign-off

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11 OTHER INFORMATION

Refer to Operation and Maintenance Manual.

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