Electrical Control Systems Technology

Control Design
Elec 508

CONTROL DESIGN
ELEC 503

JJD Rev1

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10/11/2005

Electrical Control Systems Technology

Control Design
Elec 508

Table of contents
Course project overview
Process and Instrument Diagram
Bill of Material
Power and Control schematic diagrams
PLC/HMI wiring Diagram
Control panel arrangement

Item
P&ID
BOM
Power and Control Diagram
PLC/HMI wiring Diagram
Control Panel arrangement
Mid term Test
Final Test

JJD Rev1

Week due
3
6
9
12
15

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Grade
10%
10%
10%
10%
10%
25%
25%
100%

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Electrical Control Systems Technology

Control Design
Elec 508

Course project overview

Prepare the engineering design drawings and documentation for the
temperature control of a cooling water system.
The cooling water system consists of two (2) hydraulic loops using a single
tank with a baffle to separate the hot side from the cold side.
In the first loop, warm water is taken from the hot side of a Tower Tank and
is cooled by the cooling towers, the cooled water is returned to the cold side
of the Tower Tank.
In the second loop, Process pumps take cooling water from the cold side of
the Tower Tank and deliver it to the plant where the water is heated by the
process and returned to the hot side of the Tower Tank.
The process water temperature and pressure is monitored by a PLC.
The PLC is programmed to stop and start the pumps and fans to maintain the
process water in the cold side of the Tower Tank at the desired temperature.
The Process water pumps are also controlled by the PLC, which is
programmed to stop and start the Process pumps to maintain the process
water at the desired pressure.
The PLC is to be located inside the electrical control panel together with the
motor starters fuses and other associated hardware
The operator is able to monitor the process by a HMI located in the door of
the electrical control panel.
Each pump and motor will have a selector switch so that the operator can
manually control the pumps and fans.

JJD Rev1

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Electrical Control Systems Technology

Control Design
Elec 508

P&ID OF THE COOLING WATER SYSTEM.

Cooling Water loop
The cooling water system consist of four (4) cooling towers, each with a 2
speed fan. Warm water is taken from the hot side of the tower tank and
delivered to each tower by a tower pump.
The process water temperature is measured by a transducer and the PLC is
programmed to maintain the process water temperature at setpoint.
The first stage of cooling is created by the flow of water through the cooling
tower, If the temperature of the process water is above the setpoint due to a
higher process load the PLC will call more tower pumps.
When all of the pumps are running and the temperature is above the setpoint
due to the process demand being greater than the supply, the second stage of
cooling is initiated and the tower fans are started in sequence and running at
low speed.
When all of the tower fans are running at low speed and the temperature is
above the setpoint, the third stage of cooling is initiated and the fans are each
run at high speed.
When the process load falls the process is reversed.
The amount of cooling required is determined by the process load. The
number of tower pumps and fans running at any given time must always
meet the process demand so that the process water is always at setpoint.
Process Water loop
Cooling water is taken from the cold side of the tower tank and delivered to
the plant by four (4) process pumps. The warm process water is returned to
the hot side of the tower tank.
The process water pressure must remain at the setpoint. A transducer
measures the process pressure and the PLC will stop and start the process
pumps to maintain the pressure.

JJD Rev1

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Electrical Control Systems Technology

Control Design
Elec 508

Procedure.
a)
Submit a sketch of the P&ID for approval.
The sketch must have appropriate identification.
(ie title, name, date etc).
b)
Draw the approved P&ID to engineering standards on A size paper
(8 x 11) with appropriate border and individual title block.
Use appropriate cross references if more than one drawing is required
to illustrate the whole process.
No scale is required except that the drawing must contain all of the
relevant process, instrumentation and pump information, it must be
clear and easily read.
Use the Romans font for text.
Layers must be correctly named
Line and text colors can be chosen by the designer.

See appendix for typical process symbols.

Motor and Fan specifications
Supply voltage 3 phase 575volts 60 Hz
Tower pump motors Weg OPG general purpose 15 hp 1800 rpm
Tower fan motors Weg OPG general purpose 10hp 900/1800 rpm
Process pump motors Weg OPG general purpose 30hp 1800 rpm
Transmitter information
Tower Tank cold side temperature
Tower Tank hot side water temperature
Process supply water pressure
Process return water pressure

JJD Rev1

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0-100oC RTD
0-100oC RTD
0-100 psi
0-100 psi

4-20ma
4-20ma
4-20ma
4-20ma

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Electrical Control Systems Technology

Control Design
Elec 508

Bill of Material
Prepare an excel spread sheet of all equipment required to house and control
the cooling water system.
Control Equipment to be sized and selected: Ralston Vision series Electrical Panel Nema 4 rated (size to TBA after
Control Panel arrangement is complete.
Lamacoid (engraved on 2 color plastic) Labels
ABB type OES Fused Disconnect switch
AB Power Distribution block
Ferraz Shawmut type J Motor and transformer Fuses
AB IEC Motor and Fan Contactor type 100-C
AB IEC Motor and Fan Overload device
Hammond Control transformer type PH
Touch safe terminal blocks
Hand-Off-Auto (3 position) illuminated selector switches
24vDC power supply
AB Micrologix 1500 PLC processor and base
Micrologix PLC I/O modules (c/w I/O list)
AB HMI Panelview 550 monochrome touch screen
Communications Cables
Power conductor size from CEC
All relevant information is available at the manufacturers web page
ab.com
hammondsales.com
ferrazshawmut.com
ralstonmetal.com
catalog.wegelectric.com
abb-control.com
cadresources.com
cadtoolsonline.com
Typical headings of a BOM:Item
1

Description
Contactor

JJD Rev1

Tag Manufacturer
TP1-C Allen Bradley

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Model
Dwg/line
100-C23D01 JJD1/25

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Electrical Control Systems Technology

Control Design
Elec 508

Power and Control schematic wiring diagrams

This diagram will contain the following equipment: Fused disconnect
Fuses, contactor and overload for each pump and fan
Control transformer and fuses
Control schematic for each pump and fan, includingHand-Off-Auto illuminated selector switch.
Contact for Auto operation from PLC
Auxiliary contact from each selector switch Auto position to the
PLC.
Wire size
Wire numbers
Line numbers
Terminals and terminal numbers
Cross reference details for elements on other drawings
Feeder conductor MCA (minimum conductor ampacity)

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Electrical Control Systems Technology

Control Design
Elec 508

PLC and HMI wiring diagrams

The first diagram will contain the following equipment: PLC base unit and I/O modules
HMI connections
24Vdc power supply for HMI and input signals
24Vdc Power supply loading details
Line numbers
Terminals and terminal numbers
Cross reference details for elements on other drawings

The subsequent diagrams will contain the following equipment: Base unit wiring
Module wiring
Wire numbers
PLC power supply loading details
Line numbers
Terminals and terminal numbers
Cross reference details for elements on other drawings

JJD Rev1

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Electrical Control Systems Technology

Control Design
Elec 508

Control Panel arrangement

These are scale drawings of the Control panel and should include the
following details:Standard Panel size and wall mounting arrangements
Front panel layout of HMI and selector switches c/w lamacoid labels
Front panel hole dimensions
Inner panel arrangement

JJD Rev1

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10/11/2005

Electrical Control Systems Technology

Control Design
Elec 508

JJD Rev1

Page 10 of 13

10/11/2005

Electrical Control Systems Technology

Control Design
Elec 508

JJD Rev1

Page 11 of 13

10/11/2005

Electrical Control Systems Technology

Control Design
Elec 508

JJD Rev1

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10/11/2005

Electrical Control Systems Technology

Control Design
Elec 508

JJD Rev1

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10/11/2005