PLC and HMI Programming for Pumping System
Budget: $750 – $1,500 AUD
I am looking for an experienced PLC and HMI programmer to develop the automation system for my specific pumping system. I require programming expertise in a specified system (to be specified by the client). The key functionality that I want to achieve with the programming is the automation of the system.
Ideal Skills and Experience:
- Strong programming skills in the specified PLC and HMI system (to be specified by the client)
- Experience in developing automation systems for pumping systems
- Knowledge of fault detection and alert systems
- Ability to improve the current system as needed
Brief outline is.
Inputs:
Analog 4-20mA input for level, pressure or temperature transducer
Digital inputs for backup low and high float switches, pressure switches or system enable/disable input and a low flow switch
Outputs:
1-4 pump outputs
BMS volt free output for common fault
Modbus RTU Serial RS485 connections for SCADA
Function Features
Multi pump control - Control of up to 4 pumps in any number of duty, duty assist and standby pump configurations
Pump limiting - For limiting max flow or power requirements
Duty sharing and alternation - Adjustable duty change period and Additional pumps are staged into operation to maintain setpoint and destaged when no longer required
Staggered pump start and stop - Prevents excessive current draw and reduce water surge or hammer
Manual control - Manual modes for system and pumps with 10 minute timeout to revert back to auto mode
System types - Level, pressure or flow control modes
Control directions - For emptying or filling a tank, boosting or dropping pressure.
Speed control of pumps - PID control for pressure with adjustable proportional and integral values to change VSD responsiveness
Level control mode - Controlled by 4-20mA hydrostatic level transducer and optional backup high and low level float switches, submerged in a tank or pit.
Maintain minimum level - Ensures minimum tank level is maintained (Specific to level mode, empty direction)
Pressure control mode - Controlled by 4-20mA pressure transducer and optional high and low pressure switches
Sleep assist speed minimise - When the system is at setpoint and pump speed is constant due to no demand for water, the system will slowly drop the pump speed, helping it to go to sleep sooner (Specific to pressure mode)
Sleep assist boost - When the system is nearing setpoint and there is no demand for water, the system will boost the pressure before going to sleep so it can sleep for longer, reducing pump cycling (Specific to pressure control)
Pipe fill - If the system wakes up and pressure is low, pipe fill runs a single pump to gently build pipe pressure and shuts the pump down if unable to build pressure within 10 minutes (Specific to pressure mode)
Fault Protection
Protection modes - Apply to most protections, and include alarm (alarm only), lockout (alarm and pump shutdown) and inhibit (pump shutdown only, no alarm)
High and low level, pressure or temperature protection - Alarm and/or shutdown on high and low level, pressure or temperature depending on the system type, low pressure protection features automatic restart attempts
Auxiliary tank level protection - Pump shut-down on supply tank low or destination tank full
Maximum run protection - Activates after pumps run at max speed for 30 mins, protecting the system in the event of a burst pipe, with automatic restart attempts
Pump cycle protection - Activates if system goes to sleep but wakes up within 5 seconds, 10 times in a row, due to a faulty non-return valve or similar fault preventing the system from maintaining pressure
No flow protection - Activates if a pump is running but there is no flow for 30 seconds (if using flow switch instead of low level float), with automatic restart attempts
Feedback signal fault protection - Shuts down all pumps in the event of a transducer failing
Pump VSD fault protection - VSDs feature short circuit, overload, supply phase loss, under/over voltage, earth fault and other protections to protect the pumps
Interface Features
Main screen with system status, auto/off/manual modes
Pump screens with status, logged data and auto/off/manual control
Alarms screens with mute/reset, date & time stamped historical faults
Logged data with system event & fault counts, pump starts, run hours
Analog feedback value trend graph
Streamlined, user friendly system setup process
System diagnostics for easy fault finding, factory reset
Additional Options
/BMS - With BMS volt free outputs for power on, low pressure, individual pump run, individual pump fault and common fault
/SMS - With ME-Link Module for SMS alarm/status messaging
Pumping Station Controller that can be programmed via the HMI to tell it that there is 1or 2 or 3 or 4 Pumps in the system.
Digital Inputs & Outputs
There will be Analog Inputs for Tank Level, Flow and Pressure.
Streamlined, user friendly system setup wizard
Selection of Pump via HMI for it to be in OFF state, Auto state or Manual.
HMI will show pressure, flow and level. Along with pump running change of color.
Pumps can be run via VSD. if selected.
PID control increase or decrease of level, pressure or flow.
Time and date stamped alarms, logged data and trend graph.
SMS Alarms to programmed numbers.
HMI Pages
Main Overview, Settings, Alarms, Trend, Analog, Counters and Readings
HARDWARE OMRON
PLC CPIL-EL20DR-D
HMI NB5Q-TW01B
Analog Input CP1W-ADB21
Analog Input CP1W-AD041
Ideal Skills and Experience:
- Strong programming skills in the specified PLC and HMI system (to be specified by the client)
- Experience in developing automation systems for pumping systems
- Knowledge of fault detection and alert systems
- Ability to improve the current system as needed
Brief outline is.
Inputs:
Analog 4-20mA input for level, pressure or temperature transducer
Digital inputs for backup low and high float switches, pressure switches or system enable/disable input and a low flow switch
Outputs:
1-4 pump outputs
BMS volt free output for common fault
Modbus RTU Serial RS485 connections for SCADA
Function Features
Multi pump control - Control of up to 4 pumps in any number of duty, duty assist and standby pump configurations
Pump limiting - For limiting max flow or power requirements
Duty sharing and alternation - Adjustable duty change period and Additional pumps are staged into operation to maintain setpoint and destaged when no longer required
Staggered pump start and stop - Prevents excessive current draw and reduce water surge or hammer
Manual control - Manual modes for system and pumps with 10 minute timeout to revert back to auto mode
System types - Level, pressure or flow control modes
Control directions - For emptying or filling a tank, boosting or dropping pressure.
Speed control of pumps - PID control for pressure with adjustable proportional and integral values to change VSD responsiveness
Level control mode - Controlled by 4-20mA hydrostatic level transducer and optional backup high and low level float switches, submerged in a tank or pit.
Maintain minimum level - Ensures minimum tank level is maintained (Specific to level mode, empty direction)
Pressure control mode - Controlled by 4-20mA pressure transducer and optional high and low pressure switches
Sleep assist speed minimise - When the system is at setpoint and pump speed is constant due to no demand for water, the system will slowly drop the pump speed, helping it to go to sleep sooner (Specific to pressure mode)
Sleep assist boost - When the system is nearing setpoint and there is no demand for water, the system will boost the pressure before going to sleep so it can sleep for longer, reducing pump cycling (Specific to pressure control)
Pipe fill - If the system wakes up and pressure is low, pipe fill runs a single pump to gently build pipe pressure and shuts the pump down if unable to build pressure within 10 minutes (Specific to pressure mode)
Fault Protection
Protection modes - Apply to most protections, and include alarm (alarm only), lockout (alarm and pump shutdown) and inhibit (pump shutdown only, no alarm)
High and low level, pressure or temperature protection - Alarm and/or shutdown on high and low level, pressure or temperature depending on the system type, low pressure protection features automatic restart attempts
Auxiliary tank level protection - Pump shut-down on supply tank low or destination tank full
Maximum run protection - Activates after pumps run at max speed for 30 mins, protecting the system in the event of a burst pipe, with automatic restart attempts
Pump cycle protection - Activates if system goes to sleep but wakes up within 5 seconds, 10 times in a row, due to a faulty non-return valve or similar fault preventing the system from maintaining pressure
No flow protection - Activates if a pump is running but there is no flow for 30 seconds (if using flow switch instead of low level float), with automatic restart attempts
Feedback signal fault protection - Shuts down all pumps in the event of a transducer failing
Pump VSD fault protection - VSDs feature short circuit, overload, supply phase loss, under/over voltage, earth fault and other protections to protect the pumps
Interface Features
Main screen with system status, auto/off/manual modes
Pump screens with status, logged data and auto/off/manual control
Alarms screens with mute/reset, date & time stamped historical faults
Logged data with system event & fault counts, pump starts, run hours
Analog feedback value trend graph
Streamlined, user friendly system setup process
System diagnostics for easy fault finding, factory reset
Additional Options
/BMS - With BMS volt free outputs for power on, low pressure, individual pump run, individual pump fault and common fault
/SMS - With ME-Link Module for SMS alarm/status messaging
Pumping Station Controller that can be programmed via the HMI to tell it that there is 1or 2 or 3 or 4 Pumps in the system.
Digital Inputs & Outputs
There will be Analog Inputs for Tank Level, Flow and Pressure.
Streamlined, user friendly system setup wizard
Selection of Pump via HMI for it to be in OFF state, Auto state or Manual.
HMI will show pressure, flow and level. Along with pump running change of color.
Pumps can be run via VSD. if selected.
PID control increase or decrease of level, pressure or flow.
Time and date stamped alarms, logged data and trend graph.
SMS Alarms to programmed numbers.
HMI Pages
Main Overview, Settings, Alarms, Trend, Analog, Counters and Readings
HARDWARE OMRON
PLC CPIL-EL20DR-D
HMI NB5Q-TW01B
Analog Input CP1W-ADB21
Analog Input CP1W-AD041