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PLC Motor Control Fundamentals and SafetyFeatures; A Case Study
1Computer Science Department, Texas Southern University, Houston, TX.
2PLC Automation, Louisville, KY.
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*Corresponding author: Khaled Kamel, Computer Science Department, Texas Southern University, Houston, TX, USA; E-mail:
@
Received: October 20, 2018; Accepted: November 1, 2018; Published: November 26, 2018
Citation: Khaled K, Eman K (2018) PLC Motor Control Fundamentals and Safety Features; A Case Study. J Comp Sci Appl Inform Technol. 3(3): 1-8. DOI: 10.15226/2474-9257/3/3/00138
Abstract
Electric motors are the most used final control elements / actuators in process control and automation. This include DC, Synchronous, and ACinduction motors. Squirrel cage three phase induction motors are the most popular in industry as they only require one AC source, self-started,and exhibit a high degree of ruggedness. The motor speed is typically regulated using a PLC microprocessor based variable speed / frequencydrives, which greatly reduce energy consumption when adequately utilized in the control. All industrial motor starters must at least contain fuses,disconnect switch, and thermal overload protective relays. They can also include protection against over load / torque and other failures or upnormal conditions, which might damage the motor. PLC software must account for additional protections and adheres to all safety standards.This paper uses a case study extracted from an actual process control implemented project to highlight PLC motor control safety and fundamentals.Real time control used in a waste water treatment facility for the processing of high flow storm rain water using the Allen Bradley (AB) SLC 500Programmable Logic Controller (PLC). The rain water is channeled to two large wet wells, the east wet well and the west wet well. The water ispumped to the river from the two connected wells at constant rate using a predefined process sequence control. Two motor derived constant speedimmersed pumps are used, one in the east wet well and one in the west wet well. Each pump is equipped with an overload alarm switch, which isused to trigger any unusual conditions such as over temperature or over load. The motors provide an input discrete signal indicating if the motor isrunning or not. The motors can also start by activating the Push Button located on the local panel if the AUTO/MAN switch is in Manual.Three float switches are used to provide an accurate indication of the water level at three pre- specified critical east / west wet well. TheLow-Level Float switch triggers the stopping of the running pump. The High-level Float switch triggers the starting of the scheduled pump. If thescheduled pump fails to start within 5 seconds, the second pump is selected and started. An alarm must be issued to alert the operator of any motorfailure. The Very High-level float switch triggers the starting of both pumps. If either of the two pumps fails to start the corresponding alarm isactivated by the control. Failure of both pumps shuts down the system.Pumps are scheduled to run according to pre-defined calendar. This input is expected in hours of accumulated total pump run time. The twopumps must alternate while the water level is below the Very High Level and above the Low Level. The two pumps run at levels above the VeryHigh Level and cascaded timers are not altered during this condition. This paper shows the design and implementation of the process control usingan abbreviated version of the typical original system used in waste water facilities with secondary treatment and separate rain water processing.
Wet well water pumps are driven by a sophisticated inductionmotor. They are designed to safely operate in and aroundwater. Their secure sealing, rugged construction, and mountedprotective safety monitoring instrumentation provide pumpequipment long life and safe operation. In wet pit applications,submersible pump relies on the liquid in which it is submergedto dissipate the heat from the frame. If pump runs on dry or lowlevel well, the shaft and impeller spin at extremely fast rates. Withno water to transfer their rotational energy to, that energy isreleased as heat instead. Its moving parts will become extremelyhot, causing severe damage to the pump over time and greatlylimiting its service life. Also, if the pump pressure becomes toohigh, it can put excess stress on the sealed casing and pipes,potentially causing them to crack or even burst. Float switchesused to monitor wet well level can fail or get stuck on causingpump to run dry, which will burn out the pump prematurely.All potential failures are prevented by utilizing mounted pump/ motor safety features and the. redundant PLC implementedprecautions discussed next.
The first step in the design of a PLC control application is thetranslation of the process specification to actual input / outputresources. This is known as the PLC Input / Output (I/O) map.This important step lists all I/O tags, assigned PLC addresses, anddescription. Figure 1 lists the wet wells pump control systemdiscrete inputs and the corresponding PLC input tags. Figure 2shows the same process for the PLC symbol editor screen. Figure3 and Figure 4 repeat the same process for the control systemdiscrete outputs. Notice that none of the real analog inputs /outputs for this control process is listed. We only limited our casestudy to ON / OFF control based on water level simulated analogreal time measurements relative to user defined set point for thewet wells.
The PLC processor supports subroutines that allow an efficientprogram structure. File 2 (main file) define the structure of theprogram. Subroutine (SUB3) contains the code that correspondsFigure 4: Pump Station PLC System Outputs Tagsto specific tasks or combinations of parameters. Each subroutinef provides a set of input and Output parameters for sharing datawith the calling file. Figure 5 shows the subroutines designedand implemented for the wet well Pumping station control in theProject View. Figure 6 shows the same in the PLC Ladder View.
Figure 5: Pump Station System PLC Subroutines (Project View)
Figure 6: Pump Station PLC Subroutines (Ladder View)
C. Pumping Station Ladder Implementation
The Initialization Block “INITIATE” is shown in Figure 7. Aone-shot cause this rung to execute once when selector switchAUTO/MANUAL is in AUTO.
The Pump Alarm Subroutine will include, eight Rungs, (Figure8 through 10). One common alarm is dedicated for the east wetwell and the other for the West wet well. A common Alarm istriggered from east pump motor fail to start, west pump motorfail to start, or emergency shutdown.
  • The East Pump fail to Start is ON, If Motor running input isnot received within 5 seconds from the initiation of the rungcommand.
  • An alarm is issued once the selected pump fails to start. Theoperator is expected to attend to this failure and clear the causeto allow and enforce the pump alteration calendar. Having asituation where both pumps failing to start can constitute anemergency condition and must be eliminated. A third standby pump and the manual control system can eliminate thisproblem. The latch for the fail to start is used because the samecondition is used to allow the pump output.
  • West pump Fail to start is ON if the Motor running input isnot received within 5 seconds from the West Pump motor runoutput command. The latch for the fail to start is used becausethe same condition is used to allow the pump output.
  • The Common Alarm goes ON if either of the East Pump fail toStart or the west pump fail to start or Emergency Shutdown(ESD) is triggered.

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  • The two pumps alteration follows a defined calendar based onscheduled run time in hours (simulated by 60 seconds). AnON Delay Retentive timer shown in Figure 11 is configuredfor one hour Preset Value (T4: 0.ACC). The Done bit of thistimer is used to trigger an up counter, which is configured toimplement the desired pump schedule calendar Figure 12.
  • The Pump Calendar is initialized by the operator in hours,which indicate the time intervals for the two pumpsalterations. The Up counter shown in Figure 13 is used to keeptrack of the accumulated pump run time in hours. The counteris incremented every hour of operation.
  • A memory word (N7:0) as shown in Figure 13 is used to selectone of the two pumps to run and is named Increment register(INCRM).
  • The increment (INCRM) register will increment every time theuser calendar expires. The even values of this register (N7:0/0is False) will be used to select and start the East pump. The oddvalues of this register (N7:0/0 is True) will be used to selectand start the West pump. Figure 14 and Figure 15 implementthis logic.
  • If system is placed in AUTO and the Wet Will water levelexceeds the High limit, the scheduled pump will be selectedand run. If the selected pump fails to start, an alarm is issued,and the other pump is selected and started. If the water levelexceeds the High High limit, both pumps are selected andstarted regardless of the defined calendar.
  • The Override float switch ON status will override the selectionprocess and run both two available pumps, otherwise thescheduled pump will rum.
  • The Off-float switch will cause the running pump to stop whenthe switch gets activated. Pumps cannot run on empty or lawlevel well.
  • Once a pump is done with its calendar before the off switchbecomes active and while the on float goes off, the other pumpmust run to help reduce the wet level to the low value, whichtriggers the Off-float switch. This action is triggered by thedone bit shown in the first rung of the ladder.

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    This paper offers readers an insight to PLC programmingwith focus on real industrial process automation applicationsand immersible motors / pumps safety control features. RockwellAllen Bradley SLC-500 PLC hardware configuration and the ABRSLogix 500 software were used for this implementation andfinal commissioning. LogixPro 500 simulation software was alsoused initially to implement and test the required process controlbefore any need for the real PLC hardware and physical fieldinstrumentation. The case study selected for this paper can serveas a cap stone project encompassing most of the concepts coveredin PLC process control and industrial automation. The project ispart of larger waste water treatment control process, which wasimplemented by the authors several years ago and documented ina recently published text book. The abbreviated part included inthis paper deals with a common process control task in the WasteWater Treatment industry, which has to do with the pumpingstation control. The coverage in this paper is simplified to one siteand can be easily transformed to an equivalent implementationusing the Learning Pit LogixPro 500 simulation software.

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    ReferencesTop
    1. Gabor Takacs. “Electrical Submersible Pumps Manual: Design, Operations and Maintenance”, Second Edition, Gulf Professional Publishing 2017.
    2. Kamel E and Kamel K. “Waste Water Treatment Wet Wells Pump Station PLC Control”. International Journal of Science and Engineering Technology. 2015;1.
    3. Kamel K and Kamel E “Programmable Logic Controllers: Industrial Control”, McGraw-Hill Professional. ISBN: 9780071810456, 2013.
    4. LogixPro Simulator for the Allen Bradley SLC 500 programmable logic controllers, The LearningPit.com.