Joan Olesa Vallespí

Implementation of a HMI system for a

Waste Water Treatment Plant

Dissertation in Electrical and Computer Engineering

15/02/2016
DEPARTAMENTO DE ENGENHARIA ELECTROTÉCNICA E DE COMPUTADORES

MAESTRADO EM ENGENHARIA ELECTROTÉCNICA E DE COMPUTADORES

Implementation of a HMI system for a

Waste Water Treatment Plant

Joan Olesa Vallespí

President of the jury: António Paulo Mendes Breda Dias Coimbra

Orientadores: Manuel Marques Crisóstomo

Lino José Forte Marques

Vogais: João Filipe de Castro Cardoso Ferreira

15/02/2015

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ABSTRACT

The objective of this thesis is the automation and simulation of the operation of a Waste Water
Treatment Plant (WWTP). Almost all the project will be based on simulations, but one
demonstration will be performed in a real device.

This study has been done because the water treatment is a good process to develop an
automation system, but the important point of this thesis is the automation system more than the
process in itself.

The first part is to introduce the lector in the treatment of wastewaters subject and the second
part is to explain the development of the programs and the functioning of each one of them.

The way followed to make this thesis have been divided in seven goals:

1. Understand the functioning of a waste water treatment plant.

2. Design the implementation of the different device that will be necessary to accomplish
each process. It means, to choose the type of devices that we will put in every process of
the plant.
3. Design all the variables that each device will need. The variables for the PLC and the
variables for the HMI.
4. Design a complex program to control entire sensors and actuators that the plant has, using
a simulated PLC (Programmable Logic Controller).
5. Design a HMI (Human Machine Interface) system to control all the devices in the
simulated plant. The HMI system also serves to get information from the plant.
6. Do a final simulation to confirm the right functioning of the different simulated systems
together.
7. Finally, develop a control in real devices. A PLC and HMI program will be designed to
control an electric motor.

After the development of the thesis, the principal conclusion is the knowledge acquired in the
PLC and HMI systems, above all in the programming.

KEY WORDS: W.W.T.P., automation, control, simulation, SIEMENS, S7-300, S7-1200, TP

1500 Basic, KTP600 Basic.

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 INDEX

FIGURE LIST .............................................................................................................................................. 6

TABLE LIST ................................................................................................................................................ 6
ABBREVIATIONS LIST ................................................................................................................................ 6
EQUATIONS LIST ....................................................................................................................................... 6
i. INTRODUCTION .................................................................................................................................... 7
i.i Objectives and significance of project. ................................................................................................. 7
i.ii Definition and characteristics of waste water ..................................................................................... 8
i.ii.i Characteristics of waste water ...................................................................................................... 8
i.ii.ii Chemical substances ..................................................................................................................... 8
i.ii.iii Bacteriological substances ........................................................................................................... 9
i.ii.iv Suspended matter and dissolved matter ..................................................................................... 9
i.ii.v Principal parameters ................................................................................................................... 10
ii. OPERATION OF A WASTE WATER TREATMENT PLANT ...................................................................... 11
ii.i Preliminary stage ............................................................................................................................... 11
ii.ii Primary stage .................................................................................................................................... 13
ii.iii Secondary stage ............................................................................................................................... 14
ii.iv Tertiary stage ................................................................................................................................... 16
iii. SOFTWARE.......................................................................................................................................... 17
iv. HARDWARE......................................................................................................................................... 18
v. PLC PROGRAM .................................................................................................................................... 20
v.i Program blocks. ................................................................................................................................. 20
v.i.i S7-300 Organization Blocks (OB) ................................................................................................. 20
v.i.ii S7-300 Function (FC) ................................................................................................................... 21
v.i.iii S7-300 Function Block (FB) ........................................................................................................ 23
v.i.iv S7-300 Data Block (DB) ............................................................................................................. 24
v.i.v S7-1200 Organization Blocks (OB) .............................................................................................. 24
v.i.vi S7-1200 Function (FC) ................................................................................................................ 24
v.ii PLC S7-300 Variables......................................................................................................................... 25
v.iii PLC S7-1200 Variables...................................................................................................................... 32
vi. HMI PROGRAM ................................................................................................................................... 33
vi.i Program of TP1500 Basic HMI .......................................................................................................... 33
vi.ii Variables of TP1500 Basic HMI ........................................................................................................ 33
vi.iii Identification colors of TP1500 Basic HMI ...................................................................................... 34

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 vi.ii Program of KTP600 Basic HMI ......................................................................................................... 35
vii. POSSIBLE IMPROVEMENTS............................................................................................................. 36
viii. CONCLUSIONS ................................................................................................................................ 37
BIBLIOGRAPHY ............................................................................................................................................ 38
ANNEX i....................................................................................................................................................... 39
i.i Element (group) A............................................................................................................................... 39
i.ii Element (group) B .............................................................................................................................. 44
i.iii Element (group) C ............................................................................................................................. 47
i.iv Element (group) D............................................................................................................................. 52
i.v Element (group) E .............................................................................................................................. 57
i.vi Element (group) F ............................................................................................................................. 64
i.vii Element (group) G............................................................................................................................ 69
i.viii Element (group) H ........................................................................................................................... 74
i.ix Element (group) I .............................................................................................................................. 79
ANNEX ii...................................................................................................................................................... 82
ii.i PID [FB1] ............................................................................................................................................ 82
ii.ii Time Counter [FB2] ........................................................................................................................... 83
ii.iii Height simulator [FB3] ..................................................................................................................... 85
i.iv Mud/Fat simulator [FB4] .................................................................................................................. 87
ANNEX iii ..................................................................................................................................................... 88
iii.i Principal Menu .................................................................................................................................. 88
iii.ii Pretreatment 1 ................................................................................................................................ 89
iii.iii Pretreatment 2................................................................................................................................ 90
iii.iv Pretreatment 3................................................................................................................................ 92
iii.v Primary treatment 1 ........................................................................................................................ 94
iii.vi Secondary treatment 1 ................................................................................................................... 96
iii.vii Secondary treatment 2 .................................................................................................................. 98
iii.viii Tertiary treatment....................................................................................................................... 100
iii.ix Visor of curves FCV1/FCV2 ............................................................................................................ 102
iii.x Visor of curves FCV3/FCV4 ............................................................................................................. 103
iii.xi Visor of curves FCV5/FCV6 ............................................................................................................ 104
iii.xii Visor of curves FCV7/FCV8 ........................................................................................................... 105
iii.xiii Information ................................................................................................................................. 106
ANNEX iv ................................................................................................................................................... 107
ANNEX v.................................................................................................................................................... 108

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FIGURE LIST

Figure i. Motor to remove big solids in the preliminary stage. .................................................... 11

Figure ii. Bottom of the first tank where the muds are settled...................................................... 12
Figure iii. Metal blades of the first tank to remove the fats.......................................................... 12
Figure iv. First decantation tank. ................................................................................................. 13
Figure v. Generation of muds. ...................................................................................................... 14
Figure vi. Oxygen injectors. ......................................................................................................... 14
Figure vii. Secondary decantation tank. ....................................................................................... 15
Figure viii. Clean water returning to the Mondego River. ........................................................... 16
Figure ix. PLC SIEMENS S7-300................................................................................................. 18
Figure x. HMI SIEMENS TP1500 Basic. ..................................................................................... 18
Figure xi. Diagram of signal direction. ........................................................................................ 26

TABLE LIST

Table i. Elements list of the project .............................................................................................. 26

Table ii. First group variables. ..................................................................................................... 27
Table iii. Second group variables. ................................................................................................ 28
Table iv. Third group variables. ................................................................................................... 28
Table v. Fourth group variables................................................................................................... 29
Table vi. Fifth group variables. .................................................................................................... 29
Table vii. Sixth group variables. .................................................................................................. 30
Table viii. Seventh group variables. ............................................................................................. 31
Table ix. Eighth group variables. ................................................................................................. 31
Table x. Ninth group variables. .................................................................................................... 32
Table xi. Variables used in the S7-1200 program. ....................................................................... 32

ABBREVIATIONS LIST

WWTP: Waste Water Treatment Plant.

PLC: Programmable Logic Controller.

HMI: Human Machine Interface

EQUATIONS LIST

Equation 1. Mathematic function used along the project. ........................................................... 82

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 i. INTRODUCTION

i.i Objectives and significance of project.

The waste water treatment is fundamental to reduce environment wastes that coming from the
population or industry and to avoid the incontrollable discharge of waste in our own
environment.

In the past, when population of the earth was relatively low, the waste water was directly
returned to their riverbed. At that time they did not have chemicals and knowledge about waste
water treatments like nowadays.

When the earth population started to grow exponentially because of the industrialization, the
waste of water began to be a very big problem to the environment. Then, is when the WWTP
appeared, because without this kind of plants our environment could not support the pollution.

The water is one of the most important resources that we have in this planet, is the base of the
life, if we want to continue living in this planet we must be careful with our water.

The objective of this thesis, as discussed above, is to make automation and simulation of control
on a WWTP. To do this, it is necessary to understand the process very well. That way, it is easier
to make a good PLC’s program for the plant control.

To make the program, it is indispensable to know all the devices that will be used and their own
functioning in order to create the essential variables. The devices (motors, sensors and pumps
basically) will be defined after.

Once the program is done, we will proceed with the design of the HMI to have a graphic control
and data acquisition of the different variables of the plant devices.

The procedure is the following:

1. Introduction about the different processes that are part of the waste water treatment.
2. Automation with PLC program of all different process that are part of the waste water
treatment.
3. Human Machine Interface of all different process that are part of the waste water
treatment.

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i.ii Definition and characteristics of waste water

The waste waters are all type of waters whose quality has been affected negatively by human
influence. The waste water includes:

o Domestic and urban waters.

o Mining or industrial waters.
o Natural waters mixed with the two previous types.

Treating this water is essential for our society; without treatment, pollution problems would be
insupportable for the environment. For this reason piping and treatment systems to clean this
kind of waters are essential. In big industrialized cities of developed countries they are very
common. Also, some industries have their own WWTP.

i.ii.i Characteristics of waste water

All natural water sources contain some other substances, at different concentrations. Rain water
has few mg/L of these substances and the sea water has, normally, around 35mg/L of water.
Depending of the physical state of the substances we can differentiate these types:

o Suspended substance in the water

o Colloid substance in the water.
o Dissolved substance in the water.

i.ii.ii Chemical substances

Normally, the waste water is composed by 99% of current water and 1% of suspended or
dissolved solids. These solids can be classified into inorganic or organic solids:

o The inorganic solids are composed by: Nitrogen, phosphorus, chlorides, sulphates,
carbonates, bicarbonates, arsenic, cyanide, cadmium, chromium, copper, mercury, lead
and zinc.

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 o The organic solids, can be classified in:
 Nitrogenous (that is contains nitrogen in its molecules): proteins, urea, amines and
amino acids.
 Non-nitrogenous: cellulose, fats and soaps.

i.ii.iii Bacteriological substances

One of the most important reasons to treat the waste waters is the elimination of the pathogenic
agents arising from people that are present in excrements, in order to avoid biological
contamination. Between these agents we can found:

o Fecal coliform.
o Salmonellas.
o Virus.

i.ii.iv Suspended matter and dissolved matter

Thinking about waste water, we can distinguish between divided in suspended and dissolved
matter.

o To extract the suspended matter of the waste water, the most common methods are the
physicochemical treatments, mainly, sedimentation and decantation. Normally, the muds
that the water contains are extracted by sedimentation, because are denser, and the fats
and oils, are extracted by decantation.
o To extract the dissolved matter of the waste water, the most common method is the
oxygenation of water to get muds formed from biological components plus organic
waste. Then using the decantation, these muds are moved away.

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i.ii.v Principal parameters

According to the European Directive, the most important parameters to analyze water waste are:

o Temperature.
o Potential of hydrogen (pH).
o Total Solids in suspension.
o Organic matter.
o Kjeldahl method.
o Ammonias and Nitrates.

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 ii. OPERATION OF A WASTE WATER TREATMENT PLANT

The functioning of a Waste Water Treatment Plant will be explained in this section. The WWTP
is divided into different stages; in this specific case, the WWTP will be divided in four stages
that will be explained below:

ii.i Preliminary stage

In this stage, the most important thing is to remove the big (more than 2mm) solids to get the
correct functioning of the machines along the process. Objects commonly removed during
preliminary stage include trash, tree limbs, leaves, branches, and other large objects.

The first part of this preliminary stage is composed by three filters with their metal blades and
their respective motors. The first filter picks up the big solid waste, the second, the medium solid
waste, and the last one, the little solid particles (less than 2 cm).

In the next image the tools used to remove the solids are shown in the first part of preliminary
stage in Figueira da Foz (Portugal) WWTP:

Figure i. Motor to remove big solids in the preliminary stage.

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The second part of this preliminary stage is composed by one Compressor Pump (CP) to stir the
water and separate the muds and the fats dissolved in it. Then, to remove this waste; there are
two pumps, one for the muds and the other one for the fats.
In the next figures, the tank where the first physical separation is done is shown.

Figure ii. Bottom of the first tank where the muds are settled.

Figure iii. Metal blades of the first tank to remove the fats.

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ii.ii Primary stage

The aim of this stage is to remove the suspended matter in the water. In this case, the first
process is the simple decantation by gravity. To do that, a tank where water arrives from the
preliminary stage is needed. Normally, in this decantation, 70% of suspended matter is removed.
In a normal situation, this process goes in between one or two hours but in this project the
process is simulated just during 20 seconds.

Then, to remove this mud, there is one pump. In the next image, first decantation tank is shown
in Figueira da Foz WWTP:

Figure iv. First decantation tank.

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ii.iii Secondary stage

This stage is very important in the process; the aim of the secondary stage is to remove the
biological matter dissolved in the water by an oxidation process, followed by sedimentation.

This biological process is a natural control process. It consists in the injection of oxygen to the
water. This way the microorganisms can be feed with the organic matter that the water contains.
To do that, it has a Side Channel Blower (SCB). During this process the microorganisms grow a
lot and create dense lumps. In the next images the tank and the muds generated because of the
oxygen injection are shown:

Figure v. Generation of muds.

And the tank empty where it can see the oxygen injectors:

Figure vi. Oxygen injectors.

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Because of the density of the lumps generated, the lumps go to the bottom of the secondary
decantation tank; these lumps receive the name of secondary muds. Then, the secondary muds
are picked up by one pump. In the next images, we can see the second decantation tank empty,
different parts that compose this system are detailed:

Figure vii. Secondary decantation tank.

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ii.iv Tertiary stage

The tertiary stage consists in depurate the water for consume. There are several ways to clean the
water, but every process has the same purpose, to reduce the ionization of the water before
sending it back to the river, to the settlement or to the industry.

Normally, this treatment is based on the cleaning of the rests of detergents, colorants, solvents,
odors and tastes. In this case, the process consists in adding chloride in the water before sending
it back to the river. To do that, a Chlorine Dispenser Pump (CDP) injects chlorine in the water.
In the next image, we can see the clean water returning to the river:

Figure viii. Clean water returning to the Mondego River.

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 iii. SOFTWARE

To accomplish this project, it has been necessary to use specific software from the SIEMENS
Company. This software gets the acronym of TIA (Totally integrated Automation), with this
software, different types of PLC and HMI from Siemens can be programmed. The TIA software
includes:

o Totally Integrated Automation Portal: this software is the base of TIA, it is used to
update the new software, include the licenses, and make projects with PLC, HMI or
SCADA.
o STEP 7 Professional: this software is used to make the PLC program. In this project we
will use the professional version that allows programming all the SIEMENS PLC's.
o WinCC Basic: this software is used to make the HMI program. We could just download
just the Basic version because the Professional version it was not available. With the
Basic version we can just make a HMI program and that is the reason why this project is
made with HMI and not with an SCADA interface.
o S7-PLCSIM: this software is used to simulate the programs done with STEP 7 and
WinCC. With this version it is not possible to simulate PLC S7-1200/1500.

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 iv. HARDWARE

All the hardware used in the thesis has been simulated for different reasons. Firstly we tried to
make some simulations with the PLC S7-1200 of SIEMENS, but the simulations with this devise
were not available in our software versions. Then, the PLC chosen was S7-300 whose
simulations were easier and faster.

To perform the simulations, the CPU 314C-2 PN/DP has been chosen for two reasons, the first is
that this CPU have a PROFINET interface to connect with the other hardware devices and the
other, is the protocol transport is TCP/IP.

Figure ix. PLC SIEMENS S7-300

The HMI screen selected was TP1500 Basic; there are three reasons to choose this screen. The
first, because is the biggest in the program (WinCC Basic) and it is better to see the actuators,
sensors and their controllers. Another reason is because this device does not have buttons, and
the screen is bigger, and finally, it has a PROFINET interface to connect with the PLC chosen.

Figure x. HMI SIEMENS TP1500 Basic.

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The PLC that the DEEC laboratory has is the S7-1200. This PLC is really used in industry and
will be a positive opportunity to work with it. The CPU of this PLC is 1214C AC/DC/Rly whose
main characteristics are:

o 14 Digital Inputs (DI) at 24 V.

o 10 Digital Outputs (DO).
o 2 Analogic Inputs (AI).
o 1 Analogic Output (AO)
o PROFINET interface.

Figure xi. PLC SIEMENS S7-1200.

The HMI that we can be found in the DEEC laboratory is KTP600 Basic color PN Portrait, this
HMI is really used in industry too. The main characters of this device are:

o 5.7” screen.
o 240 x 320 pixels, 256 colors.
o PROFINET interface.

Figure xii. HMI KTP600 Basic PN Portrait.

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 v. PLC PROGRAM

In this part of the statement, the distribution of the principal PLC program will be explained. The
STEP7 has several program blocks. In these blocks is where the program code is written. In this
case, all programs have been written in KOP language. All the Programs in S7-300 will be
simulated and the program in S7-1200 will be used in a real device.

The program of this thesis is composed by a combination of different program blocks explained
below. In Annex i and Annex ii, we will explain concretely each different program block used to
do the simulation, in Annex iv the programs used to do the real implementation. Now, we will
explain each program block used in the thesis.

v.i Program blocks.

STEP 7 has four types of program blocks:

o Organization Blocks (OB): these blocks can control the execution of the program. OB
can react in front of cyclic events, events controlled by time and, finally, events
controlled by alarms too.
o Function Blocks (FB): Function blocks are logical blocks that deposited their values
permanently in instance data blocks, so that they remain available after processing block.
o Function (FC): The Functions are logical blocks, without memory. Is more renowned as
subroutine.
o Data Block (DB): The Data blocks serve to save different program data.

v.i.i S7-300 Organization Blocks (OB)

In this PLC program, three different OBs will be used:

o Main [OB01]: This OB is the principal Block in the program, it is generated

automatically when it creates a project, and it is used to make a cyclic execution of the
rest of the blocks that are in the program.

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 o CYC_INT5 [OB35]: This OB serves to do a cyclic execution, independent of OB01.
That is used to do a PID regulation, because the regulation could have a faster cycle than
the OB01. Always that it is necessary to use a closed loop process in the program. In this
case, eight PID controllers will be used.
o COMPLETE RESTART [OB100]: The function of this OB is to send an initial value,
to a determinate variable, when the CPU switches on. In this case, is necessary to send an
initial value to the SET POINT and PROCESS VALUE every time that the PID
regulation starts.

v.i.ii S7-300 Function (FC)

This program has twenty nine FC, not all of the FCs has a different code inside it. In some cases,
the actuators are copies of others, with different variables, of course.

Here is a list of the different FCs on S7-300:

o MDC5 [FC31]: The function of this FC, is to control the functioning of the Motor Direct
Current 5 (MDC5). This motor is used to move up the metal blade in order to pick up the
solid waste in the first filter.
o MDC1 [FC8]: The function of this FC is to control the functioning of the Motor Direct
Current 1 (MDC1). This motor is used to move up the metal blade to pick up the solid
waste in the second filter.
o MDC2 [FC7]: The function of this FC is to control the functioning of the Motor Direct
Current 2 (MDC2). This motor is used to move up the metal blade to pick up the solid
waste in the third filter.
o FCV1/FM1 CONTROL [FC2]: The function of this FC is to control the regulation of
the Flow Control Valve 1 (FCV1) and Flow Meter 1 (FM1). This actuator is the fourth
that can be found in the project, it is used to regulate the water flow between the third
filter and physical separation of muds and fats.
o CP1 [FC5]: The function of this FC is to control the Centrifugal Pump 1 (CP1). This
pump is used to inject air in the first tank, doing the first separation between muds and
fats.
o FCV2/FM2 CONTROL [FC3]: The function of this FC is to control the regulation of
the Flow Control Valve 2 (FCV2) and Flow Meter 2 (FM2). This actuator is to regulate
the air flow that CP1 injects in the first tank.

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o MP1 [FC4]: The function of this FC is to control the Mud Pump 1 (MP1). This pump is
used to pick up the muds settled at the bottom of the first tank.
o FP1 [FC9]: The function of this FC is to control the Fat Pump 1 (FP1). This pump is
used to pick up the fats settled on the surface of the first tank.
o FCV3/FM3 CONTROL [FC6]: The function of this FC is to control the regulation of
the Flow Control Valve 3 (FCV3) and Flow Meter 3 (FM3). This actuator is to regulate
the water flow between the first air tank and the second tank (first decantation).
o MDC3 [FC10]: The function of this FC is to control the functioning of the Motor Direct
Current 3 (MDC3). This motor is used to move the structure that helps to settle the muds
in the bottom of the second tank (first decantation tank).
o MP2 [FC11]: The function of this FC is to control the Mud Pump 2 (MP2). This pump is
used to pick up the muds settled at the bottom of the second tank (first decantation tank).
o FCV4/FM4 CONTROL [FC12]: The function of this FC is to control the regulation of
the Flow Control Valve 4 (FCV4) and Flow Meter 4 (FM4). This actuator is to regulate
the water flow between the second tank and the oxygenize tank (third tank).
o SCB1 [FC13]: The function of this FC is to control the regulation of the Side Channel
Blower 1 (SCB1). The function of this actuator is to inject oxygen to the water to
accomplish the secondary stage.
o FCV5/FM5 CONTROL [FC14]: The function of this FC is to control the regulation of
the Flow Control Valve 5 (FCV5) and Flow Meter 5 (FM5). This actuator is to regulate
the flow oxygen that SCB1 injects in the oxygenize tank.
o FCV6/FM6 CONTROL [FC15]: The function of this FC is to control the regulation of
the Flow Control Valve 6 (FCV6) and Flow Meter 6 (FM6). This actuator is to regulate
the water flow between the third tank (oxygenize tank) and the next one (second
decantation tank).
o MP3 [FC16]: The function of this FC is to control the Mud Pump 3 (MP3). This pump is
used to pick up the muds settled at the bottom of the fourth tank (second decantation
tank).
o MDC4 [FC18]: The function of this FC is to control the functioning of the Motor Direct
Current 4 (MDC4). This motor is used to move the structure that helps to settle the muds
in the bottom of the fourth tank (second decantation tank).
o FCV7/FM7 CONTROL [FC19]: The function of this FC is to control the regulation of
the Flow Control Valve 7 (FCV7) and Flow Meter 7 (FM7). This actuator is to regulate
the water flow between the fourth tank (second decantation tank) and the next one
(chlorine tank).
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 o CDP1 [17]: The function of this FC is to control the regulation of the Chlorine Dispenser
Pump 1 (CDP1). The function of this actuator is to inject chlorine to the water to
accomplish the tertiary stage.
o FCV8/FM8 CONTROL [FC29]: The function of this FC is to control the regulation of
the Flow Control Valve 8 (FCV8) and Flow Meter 8 (FM8). This actuator is to regulate
the chlorine flow that CDP1 injects in the fifth tank (chlorine tank).
o FM9 [FC20]: The function of this FC is to control the Flow Meter 9 (FM9). The last
Flow Meter serves to know the quantity of water that come back to the river.

v.i.iii S7-300 Function Block (FB)

This project has four different FBs. The FBs have been used to do different simulations for the
different actuators that it can found in the process:

o HEIGH SIMULATOR [FB3]: This function block serves to simulate a distance sensor
for the MDC1, MDC2 and MDC5, because these actuators are working in function of the
distance that is generated by FB3.
o MUD & FAT SIMULATION [FB4]: This function block serves to simulate the level of
mud and fat that it have in each process. This FB is used in MP1, MP2, MP3 and FP1.
o PID [FB1]: This function block serves to simulate a real input. This real input will be a
simulation of a water/oxygen/chlorine flow. To do that, a mathematic function to
generate this real number has been used. This FB is used in FCV1, FCV2, FCV3, FCV4,
FCV5, FCV6, FCV7 and FCV8.
o TIME COUNTER [FB2]: This function block is a time counter to control how many
time the actuators are in the running state. The actuators with “running state” are MDC1,
MDC2, MDC3, MDC4, MDC5, MP1, MP2, MP3, FS1, CP1, SCB1 and CDP1.

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v.i.iv S7-300 Data Block (DB)

Data block could be created when the FB is used in a FC or in an OB, but it is possible to
generate a DB to save variables to do whatever. As FB can be used infinite times, it is necessary
to create a different data every time that one FB is used. This project has twenty eight DBs,
twenty seven are simulating a FB and one is just to input some necessary variables. The DBs
used in the project are listed below:

o DBs generated from PID [FB1]: PID_1 [DB8], PID_2 [DB14], PID_3 [DB25], PID_4
[DB10], PID_5 [DB28], PID_6 [DB30], PID_7 [DB31], PID_8 [DB24].
o DBs generated from the MUD & FAT SIMULATION [FB4]: SIMULATION MP1
[DB3], SIMULATION MP2 [DB9], SIMULATION MP3 [DB19], SIMULATION
FP1[DB11].
o DBs generated from the HEIGH SIMULATOR [FB3]: SIMULATION MDC1 [DB2],
SIMULATION MDC2[DB5], SIMULATION MDC3[DB1].
o DBs generated from the TIME COUNTER [FB2]: TIME CP1 [DB36], TIME MDC1
[DB44], TIME MDC2 [DB7], TIME MDC5 [DB18], TIME MP1 [DB37], TIME
MP2 [DB20], TIME MP3 [DB22], TIME CDP1 [DB4], TIME SCB1 [DB6], TIME
FP1 [DB38], TIME MDC3 [DB39], TIME MDC4 [DB21].

v.i.v S7-1200 Organization Blocks (OB)

The PLC program on S7-1200 only has one OB:

o Main [OB01]: This OB is the principal Block in the program, it is generated

automatically when it creates a project and it is used to make a cyclic execution of the
rest of the blocks that are in the program. Also, we have a little program to count the rpm
of the electric motor.

v.i.vi S7-1200 Function (FC)

The program to control the motors just has one Function:

o MOTOR [FC1]: This Function Block serves to make a control on a real motor. Thought
the HMI we can input a percentage value to control the tension of the motor.
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v.ii PLC S7-300 Variables

In this part of the project we will see the process used to create the different variables that will be
used along of the simulated project. To make the variables, firstly, it is indispensable to divide all
the actuators and sensors in different types. The next table will show the classification elements:

ELEMENTS LIST
Number Element (name) Element (type) Element (group) Description
1 MDC1 MDC (1) A Motor Direct Current
2 MDC2 MDC (1) A Motor Direct Current
3 MDC3 MDC (2) B Motor Direct Current
4 MDC4 MDC (2) B Motor Direct Current
5 MDC5 MDC (1) A Motor Direct Current
6 PS1 PS (3) A Position Sensor
7 PS2 PS (3) A Position Sensor
8 PS5 PS (3) A Position Sensor
9 FCV1 FCV (4) C Flow Control Valve
10 FCV2 FCV (4) D, G Flow Control Valve
11 FCV3 FCV (4) C Flow Control Valve
12 FCV4 FCV (4) C Flow Control Valve
13 FCV5 FCV (4) E, H Flow Control Valve
14 FCV6 FCV(4) C Flow Control Valve
15 FCV7 FCV (4) C Flow Control Valve
16 FCV8 FCV (4) D, G Flow Control Valve
17 FM1 FM (5) C Flow Meter
18 FM2 FM (5) G Flow Meter
19 FM3 FM (5) C Flow Meter
20 FM4 FM (5) C Flow Meter
21 FM5 FM (5) H Flow Meter
22 FM6 FM (5) C Flow Meter
23 FM7 FM (5) C Flow Meter
24 FM8 FM (5) G Flow Meter
25 FM9 FM (5) C Flow Meter
26 MP1 MP (6) F Mud Pump
27 MP2 MP (6) F Mud Pump
28 MP3 MP (6) F Mud Pump
29 FP1 FP (6) F Fat Pump
30 MS1 MS (3) F Mud Sensor
31 MS2 MS (3) F Mud Sensor
32 MS3 MS (3) F Mud Sensor
33 FS1 FS (3) F Fat Sensor
34 CP1 CP (7) D Centrifugal Pump
35 SCB1 SCB (8) E Side Channel Blower

25
 36 OS1 OS (3) H Oxygen Sensor
37 CDP1 CDP (7) D Chlorine Dispenser Pump
38 CS1 CS (3) D Chlorine Sensor
39 PID1 – PID8 PID (9) I PID controller to FCVs

Table i. Elements list of the project

The Data type signals are divided in X, Y, E and C, followed by the identifying and then, doing
the Variable (name):

o X: signal which comes from the plant.

o Y: Orders from the PLC to the plant.
o E: States of the elements.
o C: Command or orders from HMI to PLC.

In this image we show how the signals system works:

E
X E
PLANT PLC HMI
Y C
Figure xiii. Diagram of signal direction.

To classify all the variables, the order will be always the same:

Element (name) +_+ Variable (name)

For example: MDC1 (Element)_E_SERVICE (Variable)

In the superior table we can see the column “Element (type)”, this “type” means the type of
variable group that it has in the project; in this case, it has 9 different groups of variables for the
different actuators and sensors.

26
The first element group includes the actuators MDC1, MDC2 and MDC5:

ELEMENTS TYPE 1
Number Variable (name) Variable (type) Description
1 XRUNNING BOOL Running input signal
2 XALARM BOOL Alarm input signal
3 C_SERVICE BOOL Service command
4 C_OSERVICE BOOL Out of service command
5 C_RESET BOOL Reset command
6 C_MANUAL BOOL Manual Command
7 C_AUTOMATIC BOOL Automatic Command
8 C_START_AUTO BOOL Start in Automatic mode command
9 C_STOP BOOL Stop in Manual mode command
10 C_STOP_AUTO BOOL Stop in Automatic mode command
11 C_UP BOOL Up command (manual state)
12 C_DOWN BOOL Down command (manual state)
13 C_ RESET_COUNT BOOL Reset of counter command
14 E_RUNNING BOOL Running state
15 E_SERVICE BOOL Service state
16 E_MANUAL BOOL Manual state
17 E_OSERVICE BOOL Out of service state
18 E_ALARM BOOL Alarm state
19 E_AUTOMATIC BOOL Automatic state
20 SECONDS INT Seconds running
21 MINUTES INT Minutes running
22 HOURS INT Hours running

Table ii. First group variables.

The second element group includes the actuators MDC3 and MDC4:

ELEMENTS TYPE 2
Number Variable (name) Variable (type) Description
1 YSTART BOOL Start output signal
2 XRUNNING BOOL Running input signal
3 XALARM BOOL Alarm input signal
4 C_SERVICE BOOL Service command
5 C_OSERVICE BOOL Out of service command
6 C_START BOOL Start command
7 C_RESET BOOL Reset command
8 C_STOP BOOL Stop command
9 C_ RESET_COUNT BOOL Reset of counter command

27
 10 E_RUNNING BOOL Running state
11 E_SERVICE BOOL Service state
12 E_OSERVICE BOOL Out of service state
13 E_ALARM BOOL Alarm state
14 SECONDS INT Seconds running
15 MINUTES INT Minutes running
16 HOURS INT Hours running

Table iii. Second group variables.

The third group of elements includes the sensors PS1, PS2, PS5, MS1, MS2, MS3, FS1, OS1 and
CS1. The third group will be divided into five different subgroups, the Position group (PS), the
Mud group (MS), the Fat group (FS), the Oxygen group (OS) and the Chlorine group (CS).
Below, five tables with the three different subgroups:

ELEMENTS TYPE 3
Subgroup 1: POSITION GROUP
Number Variable (name) Variable (type) Description
1 HEIGH REAL Position of the blade.
Subgroup 2: MUD GROUP
Number Variable (name) Variable (type) Description
1 MUD_QUANTITY REAL Quantity of muds (kg)
Subgroup 3: FAT GROUP
Number Variable (name) Variable (type) Description
1 FAT_QUANTITY REAL Quantity of fats (l)
Subgroup 4: OXYGEN GROUP
Number Variable (name) Variable (type) Description
1 OXYGEN_QUANTITY REAL Quantity of oxygen (ppm)
Subgroup 5: CHLORINE GROUP
Number Variable (name) Variable (type) Description
1 CHLORINE_QUANTITY REAL Quantity of chlorine (ppm)

Table iv. Third group variables.

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The fourth element group includes the actuators since FCV1 to FCV8:

ELEMENTS TYPE 4
Number Variable (name) Variable (type) Description
1 XALARM BOOL Alarm input signal
2 C_AUTOMATIC BOOL Automatic command
3 C_MANUAL BOOL Manual command
4 C_ SERVICE BOOL Service command
5 C_RESET_ALARM BOOL Reset command
6 C_OSERVICE BOOL Out of service command
7 E_ALARM BOOL Alarm state
8 E_AUTOMATIC BOOL Automatic state
9 E_OSERVICE BOOL Out of service state
10 E_MANUAL BOOL Manual state
11 E_SERVICE BOOL Service state

Table v. Fourth group variables.

* Note: FCV2, FCV5 and FCV8, do not have the Variables C_MANUAL and C_AUTOMATIC, because it is not necessary, the
E_MANUAL and E_AUTOMATIC states will be controlled by CP1, SCB1 and CDP1, respectively.

The fifth element group includes the actuators from FM1 to FM9:

ELEMENTS TYPE 5
Number Variable (name) Variable (type) Description
1 XALARM BOOL Alarm input signal
2 E_ALARM BOOL Alarm state
3 XMINS REAL Real input value
4 MINS REAL Real value in the program

Table vi. Fifth group variables.

The sixth element group includes the actuators MP1, MP2, MP3 and FS1:

ELEMENTS TYPE 6
Number Variable (name) Variable (type) Description
1 YSTOP BOOL Stop output signal
2 YSTART BOOL Start output signal
3 XRUNNING BOOL Running input signal
4 XALARM BOOL Alarm input signal
5 C_SERVICE BOOL Service command

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 6 C_RESET BOOL Reset command
7 C_OSERVICE BOOL Out of service command
8 C_MANUAL BOOL Manual command
9 C_AUTOMATIC BOOL Automatic command
10 C_START BOOL Start in manual mode command
11 C_STOP_AUTO BOOL Stop in automatic mode command
12 C_START_AUTO BOOL Start in automatic mode command
13 C_STOP BOOL Stop in manual mode command
14 C_RESET_COUNT BOOL Reset of counter command
15 E_RUNNING BOOL Running state
16 E_SERVICE BOOL Service state
17 E_MANUAL BOOL Manual state
18 E_AUTOMATIC BOOL Automatic state
19 E_OSERVICE BOOL Out of service state
20 E_ALARM BOOL Alarm state
21 SECONDS INT Seconds running
22 MINUTES INT Minutes running
23 HOURS INT Hours running

Table vii. Sixth group variables.

The seventh element group includes the actuators CP1 and CDP1:

ELEMENTS TYPE 7
Number Variable (name) Variable (type) Description
1 YSTART BOOL Start output signal
2 XRUNNING BOOL Running input signal
3 XALARM BOOL Alarm input signal
4 C_SERVICE BOOL Service command
5 C_OSERVICE BOOL Out of service command
6 C_MANUAL BOOL Manual command
7 C_AUTOMATIC BOOL Automatic command
8 C_START BOOL Start in manual mode command
9 C_STOP BOOL Stop in manual mode command
10 C_START_AUTO BOOL Start in automatic mode command
11 C_STOP_AUTO BOOL Stop in automatic mode command
12 C_RESET BOOL Reset command
13 C_RESET_COUNT BOOL Reset of counter command
14 E_ALARM BOOL Alarm state
15 E_SERVICE BOOL Service state
16 E_OSERVICE BOOL Out of service state
17 E_MANUAL BOOL Manual state
18 E_AUTOMATIC BOOL Automatic state
19 E_RUNNING BOOL Running state
20 SECONDS INT Seconds running
30
 21 MINUTES INT Minutes running
22 HOURS INT Hours running

Table viii. Seventh group variables.

The eighth element group includes just the actuator SCB1:

ELEMENTS TYPE 8
Number Variable (name) Variable (type) Description
1 YSTART BOOL Start output signal
2 YCOOL BOOL Cool ok output signal
3 YOIL BOOL Oil ok output signal
4 XALARM BOOL Alarm input signal
5 XRUNNING BOOL Running input signal
6 XCOOL BOOL Cool input signal
7 XOIL BOOL Oil input signal
8 C_SERVICE BOOL Service command
9 C_OSERVICE BOOL Out of service command
10 C_MANUAL BOOL Manual command
11 C_AUTOMATIC BOOL Automatic command
12 C_START BOOL Start in manual mode command
13 C_STOP BOOL Stop in manual mode command
14 C_START_AUTO BOOL Start in automatic mode command
15 C_STOP_AUTO BOOL Stop in automatic mode command
16 C_COOL BOOL Cool ok (manual mode) command
17 C_OIL BOOL Oil ok (manual mode) command
18 C_READY BOOL Ready (automatic mode) command
19 C_RESET BOOL Reset command
20 C_RESET_COUNT BOOL Reset of counter command
21 E_ALARM BOOL Alarm state
22 E_SERVICE BOOL Service state
23 E_OSERVICE BOOL Out of service state
24 E_MANUAL BOOL Manual state
25 E_AUTOMATIC BOOL Automatic state
26 E_RUNNING BOOL Running state
27 E_OILOK BOOL Oil ok state
28 E_COOLOK BOOL Cool ok state
29 E_READY BOOL Ready state
30 SECONDS INT Seconds running
31 MINUTES INT Minutes running
32 HOURS INT Hours running

Table ix. Eighth group variables.

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Finally, it has another group of variables to control the opening percentage of every Flow
Control Valve (FCV).

ELEMENT TYPE 9
Number Variable (name) Variable (type) Description
1 POSITION REAL FCV opening percentage

Table x. Ninth group variables.

The simulated program has a total of 452 different variables among states, commands, integer
tags, inputs, outputs and internal tags to control all the system.

v.iii PLC S7-1200 Variables

In this part of the project, the variables used in the program of S7-1200 will be explained. To
control the Motor, we just needed few variables. It is not necessary to do a complex division of
variables.

Number Variable (name) Variable (type) Description

1 START BOOL Start command
2 STOP BOOL Stop command
3 INPUT SIGNAL REAL Input Percentage of velocity
4 REAL VALUE REAL Internal tag to escalation
5 OUTPUT SIGNAL INT Output tension value to the motor
6 FORWARD BOOL Command forward direction
7 REVERSE BOOL Command reverse direction

Table xi. Variables used in the S7-1200 program.

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 vi. HMI PROGRAM

To accomplish the programs of the HMIs will be used the WinCC software explained in the third
point of the memory.

vi.i Program of TP1500 Basic HMI

The HMI program to control the TP1500 Basic is divided in thirteen images:

o Principal Menu (1): This is the menu, from this image the user can go to the
others images.
o Process images (7): In these images the different parts of the process are shown.
To explain the preliminary stage three images have been used, for the primary
stage, just one image, for the secondary stage, two more images, and finally, to
show the tertiary stage, one more.
o Visor of curves images (4): In these images the graphic elements are shown to
follow the PIDs development. To show these evolutions there are four images, the
first shows the development of PID1 and PID2, the second shows the
development of PID 3 and PID4, the third shows the development of PID5 and
PID6, and finally, the fourth image, shows the development of PID 7 and PID8.
o Information (1): In this image, it is shown the information about the project and
about the author.

In the Annex iii, it will be explained concretely each part of each different image of the HMI
simulated program.

vi.ii Variables of TP1500 Basic HMI

To do the HMI program, three kinds of variables were needed. In the Figure xiii, we can see that
the variables which interact with PLC are states (E) or commands (C), but there is another type,
the integer tags to control the working of the different actuators.

o States (E): In the HMI images, the control panels are shown, every control panel
has the states of the actuator. Every “E variable” is equivalent to a state
(E_SERVICE, C_OSERVICE and etcetera).

33
 o Commands (C): In the HMI images, the control panels can be seen, every control
panel has buttons with names, and every button serves to connect or disconnect
the relay associated to a Command (C_SERVICE, C_OSERVICE and etcetera).
o Integer tags: In the HMI images, different real inputs can be seen to show
different variables of the program (sensors and meters).

vi.iii Identification colors of TP1500 Basic HMI

The HMI interface has been created with different colors to identify the different states of each
actuator or quantities of each meter by graphic way.

Every actuator (it considers actuators FCVs, MPs, MDCs, FP, CP, CDP and SCB) of the
process has an “identification state color”, the classification of these colors is the following:

o Grey: When the actuator is “OSERVICE” state (“Out of service”) or is off.

o Green: When the actuator is on “SERVICE” state, or if it has, “RUNNING”
state, the square in the actuator put it on green.
o Red: When the actuator is on “Alarm state”, in this case, the square is flicking.

Every flow meter in the process (from FM1 to FM9) has an “identification flow quantity”, the
unit used for the FMs is l/s, could be another, but in metric system is the most common. The
colors classification in function of the flow is:

o Orange: When the flow is between 0 and 20 l/s.

o Green: When the flow is between 21 and 80 l/s.
o Red: When the flow is between 81-100 l/s.

*Note: This identification is completely arbitrary, could be another different, this project is focused in automation, not in the
accuracy of the specific processes.

34
vi.ii Program of KTP600 Basic HMI

The HMI program to control the KTP600 Basic has only two images:

o Principal Menu (1): This is the menu image, from this we can go to the control motor.
o Control Motor (2): In this image we can found the different buttons and inputs to control
the motor.

35
 vii. POSSIBLE IMPROVEMENTS

To improve this project, there are several things that could have been changed. The principal
change that I could have done is the development of a SCADA system to control the system, but
unfortunately, we did not have the suitable software to make it. Anyway, the WinCC software
allows a Human Machine Interface and a basic control system can be done. Actually, the HMI is
like an SCADA but more limited because the presentation and the formats are simpler.

Another thing that could be different in this project is the PLC program application, I would like
to test more programs in a real PLC but the time I had was limited. Also, I could use more
Function Blocks [FB] instead of Functions [FC], in fact, when we use the FB, the memory used
is less and the SCAN time is smaller, but I was not accustomed to use the FB and I decided to
accomplish most of the PLC program with subroutines (FC).

Also, I could have done a simulation on the "treatment muds" stage, but I thought that it was too
redundant. I thought that was not necessary and I decided to invest the time doing another things.

In general, I am a beginner in the automation world but I thing that thesis is sufficiently complex
to be a beginner.

36
 viii. CONCLUSIONS

After the realization of this thesis I have obtained some conclusions. I have been working in this
project during five month approximately and during this time I learned a lot of things that will be
important in my professional career.

The first and most important conclusion is the self-learning in the programming of automatic
devices. I have never been working with this software before and it was completely new for me.
The TIA Portal use blocks to design programs, which are new for me.

Another conclusion would be the necessity that sometimes we have to find information. As a
beginner in this world, I had some problems that I repaired searching for information, and above
all, spending time treat with the different software used. I have needed to read some manuals of
SIEMENS to understand some blocks that the program has. I learned that when you spend the
enough time trying to solve a problem, finally you get the solution, perhaps seems unimportant,
but for me has been a really relevant thing.

The visual part of the thesis has been made with a HMI system. The program developed by me,
would be better in a SCADA, is a pity because with HMI you cannot see all the potential of the
program made, anyway the result has been successful.

The conclusion that I obtained during the last weeks of the thesis is related with the
communications between the different real devices used. When the real devices are used, you
realize of the importance of this part in the automation world. The knowledge of the PROFINET
interface will be really useful for me in the future.

For me, make the thesis in English have been a really big achievement too, because I do not used
this language too much. Right now, with the Bologna plan, we need to do some credits in
English to get the tittle.

As a general conclusion I can say that the development of this thesis has been really useful for
me, because I want to focus my professional degree in something related with automatic
systems, doing projects with PLC and developing visual control system like HMI or SCADAs.

37
BIBLIOGRAPHY

[1] SIEMENS AG, SIMATIC Programar con STEP 7 [Online]. Nuremberg, SIEMENS AG,
2006 [Data of inquiry: November 2015]. Available on:
<https://cache.industry.siemens.com/dl/files/056/18652056/att_70833/v1/S7prv54_s.pdf>

[2] SIEMENS AG, SIMATIC WinCC Basic V11.0 SP1 [Online]. Nuremberg, SIEMENS AG, 2011 [Data
of inquiry: December and January 2016]. Available on:
<http://wikifab.dimf.etsii.upm.es/wikifab/images/b/b8/WinCCBasic_v11.pdf>

[3] RODRÍGUEZ, Antonio, LETÓN, Pedro, ROSAL Roberto, DORADO Miriam, VILLAR Susana,
SANZ Juana M, Tratamientos de aguas residuales industriales [Online]. Madrid, Comunidad de Madrid,
2006 [Date of inquiry: October 2015]. Available on:
<https://www.madrimasd.org/informacionidi/biblioteca/publicacion/doc/VT/VT2_Tratamientos_avanzad
os_de_aguas_residuales_industriales.pdf>

[4] DEL VILLAR, Alberto, Guía de tratamientos avanzados de aguas residuales urbanas [Online].
Alcalá, Ministerio de Economía y Competitividad, 2011 [Date of inquiry: October 2015]. Available on:
<http://www.consolider-tragua.com/documentos/guia_tratamientos_avanzados.pdf>

38
ANNEX i

The first annex, as said in the fifth section of the memory, will explain step by step the entire
simulated program done along the dissertation. In the Table i, the different types of actuators and
sensors that it has in the programs can be seen, and how are classified. Well, the fourth column
of this table, Element (group), shows the type of subprogram that each element has. It means
that every different group have the same program structure, for this reason, explaining the eight
types (A, B, C, D, E, F, G, H, I) of subprograms that it have it will explain all the subprograms of
the thesis.

Next, each program type step by step will be detailed.

i.i Element (group) A

The first elements in the Table i are the MOTOR DIRECT CURRENT MDC1, MDC2 and
MDC5. These motors are used in the preliminary stage to pick up the solid waste in the water.
To explain the functioning of these motors the MDC1 will be used as example, but it could have
chosen any of the other two.

 The first segment is to let the MDC system in “SERVICE” state.

39
 The second segment is to choose the manual mode of MDC setting the system in
“MANUAL” state.

 The second segment is to choose the automatic mode of MDC setting the system in
“AUTOMATIC” state.

 The third segment is to send the “START_AUTO” command (when the system is in
“AUTOMATIC” state) or the “START” command (when the system is in “MANUAL”
state) to send from the plant to the PLC the “XRUNNING” signal.

40
 The fourth segment is to simulate the signal that comes from the plant (“XRUNING”
signal) to set the system in “RUNNING” state.

 The next segment is where the height level is generated (by simulation), depending of the
work mode of the system (automatic or manual) the simulator (FB3) will work different.
When the system is in “AUTOMATIC” state, the actuator will be active every 20
seconds to simulate the ascent or descent of the metal blade which picked up the waste
from the water. When the system is in "MANUAL" state, the ascent and descent of the
metal blades must be activated manually, “UP”, “DOWN” or “STOP” command can be
chosen.

41
 When the MDC sends the “OSERVICE” command or the “ALARM” state is on, the
system puts in “OSERVICE” state.

 The eighth segment is for simulate the alarm signal which comes from the plant and let
the system in “ALARM” state.

42
 The ninth segment is to put all the states of the system in reset.

 The last segment is the time counter (TIME COUNTER [FB2]) used to count how many
time the MDCs are in “RUNNING” state.

43
i.ii Element (group) B

The elements of the second group are the motors that control the tools used to accomplish the
primary and secondary decantation, which are MDC3 and MDC4. These motors do not have
manual or automatic states because it was not necessary for the function that they will do. To
explain these elements the MDC3 will be used as an example.

 The first segment is to let the MDC system in “SERVICE” state.

 The second segment is to send to the plant the “START” signal.

 The next segment is to simulate the input signal “XRUNNING” to the PLC.

44
 The fourth segment is to simulate when the input signal “XRUNNING” lets the system in
“RUNNING” state.

 When the “OSERVICE” command is sent or the “ALARM” state is ON, the system is set
on “OSERVICE” state.

 The sixth segment is to simulate the input signal “XALARM” which lets the system in
“ALARM” state.

45
 The ninth segment is to set all the states of the system in reset.

 The last segment is the time counter (TIME COUNTER [FB2]) used to count how many
time the MDCs are in “RUNNING” state.

46
i.iii Element (group) C

The elements from this group are the first type of FLOW CONTROL VALVES (FCV1, FCV3,
FCV4, FCV6 and FV7) and FLOW METERS (FM1, FM3, FM4, FM6 and FM7). The function
of these valves is to regulate the flow between the different parts in the process. The program
done to the FCV1 will be used for the explanation of the program:

 The first segment is to let the FCV system in “SERVICE” state.

 The second segment is to choose the automatic mode of FCV and to enter the position of
the valve (opening percentage).

47
 The third segment is to choose the manual mode of FCV and to enter the position of the
valve (opening percentage).

 This segment is to ensure that you will never enter a negative number to the valve.

 This segment is to ensure that you will never enter a number bigger than 100 to the valve.

48
 The sixth segment is to let the system in “OSERVICE” state when the "OSERVICE"
command is sent, when the alarm of FVC is active or when the “RESET” command is
sent.

 This segment is to send the real number generated by PID to the Flow Meter when the
system is in automatic mode.

49
 This segment is to send the set point to the Flow Meter when the system is in manual
mode.

 This segment is to simulate an alarm signal of Flow Meter that comes from the plant.

 This segment is to simulate an alarm signal of Flow Control Valve that comes from the
plant.

50
 The last segment is to let all the system in reset.

51
i.iv Element (group) D

This element is basically the program to control the Centrifugal Pump 1 (CP1) and Chlorine
Dispenser Pump 1(CDP1). To control these elements, is necessary the control of the respective
FCVs (FCV2 to CP1 and FCV8 to CDP1) and FMs (FM2 to CP1 and FM8 to CDP1).The CP1
controls the air flow that injected in the preliminary stage, and CDP1 controls the chlorine flow
injected in the tertiary stage. To show the program it will use the CP1, but it could use the CDP1

 The first segment is to let the system in service state.

 The second segment is to choose the manual mode.

52
 The third segment is to choose the automatic mode.

 The fourth segment is to let the system “OSERVICE” state and without manual or
automatic state, that happens when the command “OSERVICE” is sent or when the
“ALARM” state is set.

53
 The next segment is to simulate an alarm input from the plant.

 The sixth segment is to put send the “START” order to the plant from the PLC, in
automatic or manual mode.

 The next segments are to send the “RUNNING” order from the CP1/CDP1 (plant) to the
PLC. First the PLC sends to the CP1/CDP1 the “START” order, and then, the order from
CP1/CDP1 to PLC is sent. This segment it is just to make the simulation.

54
 When the CP1/CDP1 is in “RUNNING” state, it is necessary to set the FCV2/FCV8 in
“SERVICE” state to send the Set Point opening of the FCV2/FCV8.

 The tenth segment is to let all the system in reset.

55
 The last segment is the time counter (TIME COUNTER [FB2]) used to count how many
time the CP1/CDP1 is in “RUNNING” state.

56
i.v Element (group) E

The element E is to control the Side Channel Blower 1 (SCB1), to do that is necessary the
control of FCV5 because it will control the oxygen flow injected to the water in the secondary
stage. It is some similar with the CP1 program, but more complex.

 The first segment is to let the SCB1 system in service state.

 The second segment is to choose the manual mode of SCB1.

57
 The third segment is to choose the automatic mode of SCB1.

 The fourth segment is to let the system in “OSERVICE” state and without ”MANUAL”
or ”AUTOMATIC” states, that happens when the command “OSERVICE” is sent or
when the “ALARM” state is set.

58
 The fifth segment is to simulate the input alarm from the plant.

 This segment is to send the “oil” signal to the SCB1 in “MANUAL” or “AUTOMATIC”
(ready) state.

 The seventh and eighth segments are for simulate of the heating of the oil in SCB1. The
seventh is to simulate the time and the eighth is to simulate the signal that comes from the
plant. When the oil it is ready to work the “OILOK” state is on.

59
 This segment is to send the “COOL” signal to the SCB1 in “MANUAL” or
“AUTOMATIC” (ready) mode. When the preparation of the SCB1 is automatic, it needs
the “OILOK” state to continue with the cool process.

 The tenth and eleventh segments are for simulate the cooling process of the SCB1. The
tenth is to simulate the time and the eleventh is for simulate the signal that comes from
the plant. When the cooling system it is ready to work the “COOLOK” state is set.

60
 When the SCB1 system is in “SERVICE” state, “OILOK” state and “COOLOK” state,
the system set it in “READY” state. Now, the SCB1 can start to work correctly.

 The next segment is to send the “START” signal to the plant from the PLC, in
“AUTOMATIC” or “MANUAL” mode.

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 The next segments are to send the “START” signal from the PLC to the plant (SCB1).
Then, the SCB1 send to the PLC the “XRUNNING” signal and finally, the
“XRUNNING” signal from the PLC sets the “RUNNING” state of the SCB1.

 When the SCB1 is in “RUNNING” state, it is necessary to let the FCV5 in “SERVICE”
state to send the Set Point opening of the FCV5.

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 The seventeenth segment is to let all the system in reset.

 The last segment is the time counter (TIME COUNTER [FB2]) used to count how many
time the SCB1 is in “RUNNING” state.

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i.vi Element (group) F

This element group is composed by the Mud Pumps (MP1, MP2 and MP3) with her respective
Mud Sensors (MS1, MS2 and MS3) and by the Fat Pump (FP1) and her respective Fat Sensor
(FS1). To explain the functioning of this type of element the program of MP1 will be used.

 The first segment is to let the system in “SERVICE” state.

 The second segment is to let the system in “MANUAL” state.

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 The third segment is to let the system in “AUTOMATIC” state.

 The next segment is to send the “START” signal to the plant in “MANUAL” or
“AUTOMATIC” mode.

 The fifth segment is to send from the plant to the PLC the “RUNNING” signal in automatic or
manual mode.

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 The sixth segment is where the mud/fat level is generated (by simulation), depending of
the work mode of the system (automatic or manual) the simulator (FB4) will work
different. When the system is in “AUTOMATIC” state, the actuator will be active every
20 seconds to simulate the mud/fat removing. When the system is in "MANUAL" state,
the mud/fat removing must be activated manually.

 The eighth segment is to send the “STOP” signal to the plant in “MANUAL” or
“AUTOMATIC” mode.

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 The ninth segment is to let the system in “OSERVICE” state and without ”MANUAL” or
”AUTOMATIC” states, that happens when the command “OSERVICE” is sent or when
the “ALARM” state is set.

 The next segment is to simulate an alarm input from the plant.

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 The eleventh segment is to let all the system in reset.

 The last segment is the time counter (TIME COUNTER [FB2]) used to count how many
time the actuators (MP1, MP2, MP3 or FP1) are in “RUNNING” state.

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i.vii Element (group) G

This element group is formed by the Flow Control Valve 2 (FCV2) and Flow Control Valve 8
(FCV8) and her respective Flow Meters (FM2 and FM8). To do the explanation of this element
group, FCV2 controlled from the CP1 program will be used.

 The first segment is for let the FCV system in “SERVICE” state. To do that, it is
necessary to set the SERVICE state in the control actuator (in the case of FCV2, the CP1
and in the case of FCV8 the CDP1).

 The second segment is to choose the automatic mode of FCV and to enter the position of
the valve (opening percentage). To do that, it is necessary the “RUNNING” state of the
control actuator, the “START_AUTO” command of the control actuator and the
“AUTOMATIC” state of this actuator (in the case of FCV2, the CP1).

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 The third segment is to choose the manual mode of FCV and to enter the position of the
valve (opening percentage). To do that, it is necessary the “RUNNING” state of the
control actuator, the “START” command of the control actuator and the “MANUAL”
state of this actuator (in the case of FCV2, the CP1).

 This segment is to ensure that you will never enter a negative number to the valve.

 This segment is to ensure that it will never enter a number bigger than 100 to the valve.

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 The sixth segment is to let the system in “OSERVICE” state when the "OSERVICE"
command is sent, when the alarm of FVC is active, when the “RESET” command is sent.
when the alarm of FM is active, when the “OSERVICE” command of the controller (CP1
in the FCV2 case) is sent or when the controller is in “ALARM” state.

 This segment is to send the real number generated by PID to the Flow Meter when the
system is in “AUTOMATIC” mode.

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 This segment is to send the set point to the Flow Meter when the system is in
“MANUAL” mode.

 This segment is to simulate an alarm signal of Flow Meter that comes from the plant.

 This segment is to simulate an alarm signal of Flow Control Valve that comes from the
plant.

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 The last segment is to let all the system in reset.

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i.viii Element (group) H

In this section, the functioning of Flow Control Valve 5 (FCV5) will be explained. This element
is used in the project to control the Side Channel Blower 1 (SCB1). The Flow Meter 5 (FM5)
will be explained in this section too.

 The first segment is for let the FCV5 system in “SERVICE” state. To do that, it is
necessary the SERVICE state in the control actuator SCB1.

 The second segment is to choose the “AUTOMATIC” mode of FCV5 and to enter the
position of the valve (opening percentage). To do that, it is necessary the “RUNNING”
state, the “START_AUTO” command the “AUTOMATIC” state of the control actuator
SCB1.

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 The third segment is to choose the “MANUAL” mode of FCV5 and to enter the position
of the valve (opening percentage). To do that, it is necessary the “RUNNING” state, the
“START” command and the “MANUAL” state of the control actuator SCB1.

 This segment is to ensure that you will never enter a negative number to the valve.

 This segment is to ensure that it will never enter a number bigger than 100 to the valve.

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 The sixth segment is to let the system in “OSERVICE” state when the "OSERVICE"
command is sent, when the alarm of FVC5 is active, when the “RESET” command is
sent when the alarm of FM5 is active, when the “OSERVICE” command of the controller
SCB1 is sent or when the controller is in “ALARM” state.

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 This segment is to send the real number generated by PID to the Flow Meter when the
system is in “AUTOMATIC” mode.

 This segment is to send the set point to the Flow Meter when the system is in
“MANUAL” mode.

 This segment is to simulate an “ALARM” signal of Flow Meter that comes from the
plant.

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 This segment is to simulate an “ALARM” signal of Flow Control Valve that comes from
the plant.

 The last segment is to let all the system in reset.

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i.ix Element (group) I

This section is for explain the PID element, this element will be used to control the simulated
real input which is used to simulate a flow water. The PID 1 will be used to do the example.

 When the FCV is in “AUTOMATIC” state, the PID starts working:

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 The second segment is to generate the number that will be the flow
water/oxygen/chlorine simulation. Two comparisons to assure that the input “SET
POINT” will be always between 0 and 100 will be done.

 When the SET POINT number sent is negative, automatically, the Process Value is 0.
The Process Value is the number that simulates the flow water.

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 When the SET POINT number sent is too much bigger (more than 100.0), automatically,
the Process Value is 100.0.

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ANNEX ii

In this annex, will be explained the functioning of the different function blocks done along the
project. The Function Blocks (FB) has been really useful to do the different simulations that the
project needs. It has four different Function Blocks that will be explained now.

ii.i PID [FB1]

This FB it has done to simulate a Real number to simulate water/oxygen/chlorine flow. To do

that has been generated a first order function. The generated function is:

( )

Equation 1. Mathematic function used along the project.

Where , U is the Manipulated Variable and is the Process

Value.

 The first segment is the Mathematic function explained above.

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  The second segment is just to send to .

ii.ii Time Counter [FB2]

This Function Block is a counter to know how much time the different actuators are in
“RUNNING” state. The program is a normal counter, and then the time is divided in seconds,
minutes and hours with one Reset Counter.

 The first and second segments are used to generate a seconds pulse.

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 The third and fourth segments are used to count the seconds and let the counter at 0 when
the counter arrives at 60 seconds.

 The fifth and sixth segments are used to count the minutes and let the counter to 0 when
the counter arrives at 60 minutes.

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  The seventh segments are used to count the hours.

ii.iii Height simulator [FB3]

This Function block is used to simulate the ascent and descend of the metal blades moved by
MDC1, MDC2 and MDC3. It is a time counter until 20 seconds, it could be another cycle, but, to
realize a simulation it is a good period.

 The first and second segments are used to generate a seconds pulse.

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 The third segment is to control the UP/DOWN counter depending on the commands sent
from the HMI control.

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i.iv Mud/Fat simulator [FB4]

This Function block is used to simulate the filling and emptying of the different tanks in the
project through the MP1, MP2, MP3 and FP1. It is a time counter until 20 seconds, it could be
another cycle, every second means a kg of mud, or a fat liter.

 The first and second segments are used to generate a seconds pulse.

 The third segment is to control the UP/DOWN counter depending on the commands sent
from the HMI control.

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ANNEX iii

The third annex is to show the functioning of every part of HMI program. The program is made
of thirteen images. The project has been divided in different sections, because when the control
is make by HMI it is not possible to put all the process in the same screen (or image in our case),
to do a good organization, it has done a principal screen where is possible to go to the other
images. All the images have a place in upper right corner where it can see the time and the day.

Next, every image and the utility of each one will be explained.

iii.i Principal Menu

This image is the place where it is possible to go to the others images, that is the principal
function of the Principal Menu. It has twelve buttons, where it can read the destination of the
different processes. In the top right we find the date and time.

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iii.ii Pretreatment 1

In this image it can see the entrance of waste water to the plant; the first step is picking up the
big solids through the metal blades of MDC5. In the upper left corner we find three buttons, one
to go to the previous image, another to go to the principal menu and the other to go to the next
image.

In the MDC5 controller, we can see the states in the left part, when one of these states is set in
ON, the letters become black. In the right side we can see the command buttons, every button is
connected with a command in the PLC program.

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iii.iii Pretreatment 2

This image shows the second part of the pretreatment, there are two motors (MDC1 and MDC2)
to ascend and descend the metal blades to remove the solid waste. Then it has a Flow Control
Valve (FCV1) to control the flow before the first tank. In the upper left corner we find three
buttons, one to go to the previous image, another to go to the principal menu and the other to go
to the next image.

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In this image, we can see two controllers; the first one is to control the motors MDC1 and
MDC2, to optimize the space we have put together the states of both motors, when a states is sets
in ON, the little square next to letters, becomes black.

In the controller of FCV1 we can see the states in the left part. In the right side it has the buttons
commands and below them, the set point percentage, that is an input to send to the PLC the
opening percentage desired for the FCV1.

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iii.iv Pretreatment 3

This image shows the third part of the pretreatment. In this part, there is a tank where the fats and
the muds are separated thanks of a Compressor Pump (CP1). In this image we can see four
actuators and three sensors. The actuators are CP1, MP1, FCV1 and FP1; the sensors are FM1,
MS1 and FS1. In the upper left corner we find three buttons, one to go to the previous image,
another to go to the principal menu and the other to go to the next image.

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To optimize the space, the controller of Compressor Pump (CP1) and Flow Control Valve 2
(FCV2) is the same, in the left part of this controller the states of CP1 can be seen and in the
right side, button to send the commands to the PLC.

The other controller of this image is to control the Mud Pump 1 (MP1) and the Fat Pump 1
(FP1). In the left side the buttons to send the commands of MP1 to the PLC can be seen. In the
middle we can see the different states of each actuator, when the state is ON, the little square
next to letters become black. Finally, in the right side, the buttons to send the commands of FP1
to the PLC can be seen.

In the lasts images, we can see the MP1 with the Mud Sensor 1 (MS1) and the Fat Pump 1 (FP1)
with his respective Fat Sensor 1 (FS1).

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iii.v Primary treatment 1

In this image we can see the first decantation of the process. To accomplish that, three actuators
were needed, a Flow Control Valve (FCV3) to control the water flow that enter in the first
decantation tank, one Motor Direct Current (MDC3) to turn the tool that help to settle the muds
in the bottom of the tank, and a Mud Pump (MP2) to remove the mud settled. In the upper left
corner we find three buttons, one to go to the previous image, another to go to the principal menu
and the other to go to the next image.

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In the controller of FCV3 we can see the states in the left part. The right side has the buttons
commands and below them, the set point percentage, that is an input to send to the PLC the
opening percentage desired for the FCV3.

The other controller of this image is to control the Motor Direct Current 3 (MDC3) and the Mud
Pump 2 (MP2). In the left side we can see the buttons to send the commands of MDC3 to the
PLC. In the middle we can see the different states of each actuator, when the state is ON, the
little square next to letters become black. Finally, in the right side are the buttons to send the
commands of MP2 to the PLC.

In the last images we can see the Motor Current Direct 3 (MDC3) and Mud Pump 2 (MP2) with
his respective Mud Sensor 2 (MS2).

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iii.vi Secondary treatment 1

The next image shows the first part of secondary treatment. This treatment consists in the
injection of oxygen into the water. To do that, it needs a Side Channel Blower (SCB1) controlled
by Flow Control Valve (FCV5). The flow that enters in the oxygenation tank is regulated by
another Flow Control Valve (FCV4). The SCB1 has a path to be ready to work, firstly it is
necessary to switch on the oil circuit (“OILOK” state) and then the refrigerate circuit
(“COOLOK” state). In the image, we can see that states (little squares) above SCB1. In the upper
left corner we find three buttons, one to go to the previous image, another to go to the principal
menu and the other to go to the next image.

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In the controller of FCV4 we can see the states in the left part. In the right side it has the buttons
commands and below them, the set point percentage, that is an input to send to the PLC the
opening percentage desired for the FCV4.

The other controller of this image is to control the Side Channel Blower 1 (SCB1) and the Flow
Control Valve 5 (FCV5). In the left side we can see the different states of each actuator, when
the state is ON, the little square next to letters lets black. Below the states indicators the Set Point
of FCV5 can be seen. In the right side, the buttons to send the commands of SCB1 and below
that, the buttons to send the commands of FCV5.

In the lasts images we can see the Side Channel Blower 1 (SCB1) with his respective Oxygen
Sensor 1 (OS1) and Flow Control Valve 5 (FCV5).

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iii.vii Secondary treatment 2

In this image we can see the second decantation of the process. To accomplish that, it needs three
actuators, a Flow Control Valve (FCV6), to control the water flow that enter in the first
decantation tank, one Motor Direct Current (MDC4) to turn the tool which helps the water to be
deposited in the bottom of the tank and a Mud Pump (MP3) to remove the mud deposited in the
bottom of the tank. In the upper left corner we find three buttons, one to go to the previous
image, another to go to the principal menu and the other to go to the next image.

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In the controller of FCV6 we can see the states in the left part. In the right side it has the buttons
commands and below them, the set point percentage, that is an input to send to the PLC the
opening percentage desired for the FCV6.

The other controller of this image is to control the Motor Direct Current 4 (MDC4) and the Mud
Pump 3 (MP3). In the left side we can see the buttons to send the commands of MDC4 to the
PLC. In the middle, the different states of each actuator, when the state is ON, the little square
next to letters become black. Finally, in the right side, we can see the buttons to send the
commands of MP3 to the PLC.

In the last images we can see the Motor Current Direct 4 (MDC4) and Mud Pump 3 (MP3) with
his respective Mud Sensor 2 (MS2).

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iii.viii Tertiary treatment

In this image we can see the last stage of this waste water treatment. To do that, it is necessary a
Flow Control Valve (FCV7) to regulate the water flow that enter in the last tank, a Chlorine
Dispenser Pump (CDP1) to inject chlorine to the water before come back to the river and his
respective Chlorine Senor (CS1), and finally, another Flow Control Valve (FCV8) to control the
quantity of chlorine injected in the water. In the upper left corner we find two buttons, one to go
to the previous image and another to go to the principal menu.

100
In the controller of FCV7 we can see the states in the left part. In the right side it has the buttons
commands and below them, the set point percentage, that is an input to send to the PLC the
opening percentage desired for the FCV7.

The last controller of the process is to control the Chlorine Dispenser Pump 1 (CDP1) and his
respective Flow Control Valve (FCV8). In the left side we can see the different states of each
actuator, when the state is ON, the little square next to letters become black. Below the states
indicators we found the Set Point of FCV8. In the right side, we can see the buttons to send the
commands of SCB1 and below that, the buttons to send the commands of FCV8.

In the lasts images we can see the Chlorine Dispenser Pump 1 (CDP1) with its respective
Chlorine Sensor 1 (CS1) and Flow Control Valve 8 (FCV8).

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iii.ix Visor of curves FCV1/FCV2

This image is just to show the evolution of the variables of Flow Control Valve 1 (FCV1) and
Flow Control Valve 2 (FCV2). In the upper left corner we find one button to go to the principal
menu. In this graphics three variables can be seen:

 SET POINT: the Set Points sent, is the white curve.

 PROCESS VALUE: The Real number simulated by the PID, is the red curve.
 MANIPULATED PROCESS: The pulse generated by CONT_C to control the Process
Value, is the blue curve.

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iii.x Visor of curves FCV3/FCV4

This image is just to show the evolution of the variables of Flow Control Valve 3 (FCV3) and
Flow Control Valve 4 (FCV4). In the upper left corner we find one button to go to the principal
menu. In this graphics three variables can be seen:

 SET POINT: the Set Points sent, is the white curve.

 PROCESS VALUE: The Real number simulated by the PID, is the red curve.
 MANIPULATED PROCESS: The pulse generated by CONT_C to control the Process
Value, is the blue curve.

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iii.xi Visor of curves FCV5/FCV6

This image is just to show the evolution of the variables of Flow Control Valve 5 (FCV5) and
Flow Control Valve 6 (FCV6). In the upper left corner we find one button to go to the principal
menu. In this graphics three variables can be seen:

 SET POINT: the Set Points sent, is the white curve.

 PROCESS VALUE: The Real number simulated by the PID, is the red curve.
 MANIPULATED PROCESS: The pulse generated by CONT_C to control the Process
Value, is the blue curve.

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iii.xii Visor of curves FCV7/FCV8

This image is just to show the evolution of the variables of Flow Control Valve 7 (FCV7) and
Flow Control Valve 8 (FCV8). In the upper left corner we find one button, one to go to the
principal menu. In this graphics three variables can be seen:

 SET POINT: the Set Points sent, is the white curve.

 PROCESS VALUE: The Real number simulated by the PID, is the red curve.
 MANIPULATED PROCESS: The pulse generated by CONT_C to control the Process
Value, is the blue curve.

105
iii.xiii Information

In the last HMI image, we can see some information about the author and the process. In the
upper left corner we find one button, one to go to the principal menu.

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ANNEX iv

In the fourth annex of the thesis, the program done for the real PLC will be explained. It is a
program to control an analogic output (velocity percentage of the motor). The Analogic output is
connected to a variable velocity drive who works between 0 and 10 V and that is connected to a
motor.

Firstly, the START order is sent from the KTP600 Basic to the PLC, the next step is to choose
the direction of the motor, FORWARD o REVERSE. When the direction is chosen, we can send
the velocity percentage and the motor starts to work.

The value (velocity) is normalized from 0% to 100% and then, escalated from 0 (0V) to 27648
(10V). The analogic output could be in tension or in current, in this case we are working in
voltage.

Finally, we have a STOP order that when is sent to the PLC, we send a 0% to the normalized
value (INPUT SIGNAL).

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ANNEX v

This annex is to explain the functioning of the Real HMI KTP600. It is a simple program to
control the Motor formed by two images. The first is a simple presentation image to go to the
motor control; the buttons F1 to F6 have no function. The entire image is a button to go to the
control motor image:

The CONTOL MOTOR image is to control the functioning of the motor, we can see five
buttons.

 Back: this button is just to come to the principal menu.

 START: This button is to send the “START” command to the PLC.
 FORWARD: To choose the Forward direction of the motor.
 REVERSE: To choose the reverse direction of the motor.
 STOP: This button s to send the “STOP” command to the PLC.

Then, we can see an input to send the velocity percentage to the PLC.

108