SOP Sample Gate and SbyC Operating Instruction for Lower Monumental Juvenile Facility

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Standard Operating Procedure
Subject:
Sample Gate and SbyC Operating Instructions for Lower Monumental Juvenile Facility
Author:
Troy Humphrey
Approved by:
Don Warf

Contents

Objective

The Objective of this SOP is to give site personnel a working knowledge of the various functions available to them for entering sample rates and controlling slide gates.

Scope

This SOP is for site personnel responsible for entering sample rates and strictly pertains to Lower Monumental Juvenile Facility. The sample gates and slide gates are controlled by a Programmable Logic Controller located near the separator. Commonly referred to as a PLC, this device is accessed by a 10" Red Lion HMI (Human Machine Interface) located in the Separator Shack. The HMI took the place of a device referred to as a PV600. The HMI acts as a menu driven operator interface to the PLC. All functions of the sample gates are set by HMI operator inputs and control switches mounted on the panel located next to B Slide Gate.

Responsibilities

The personnel responsible for entering sample rates are determined by the site biologist.

Procedure

Overview

  1. Through out this manual the following formatting shall apply:
    • PAGE TITLE , PARAMETER HEADING or SCREEN NAVIGATION.
      • Used to indicate the current graphic being displayed or what the value below the heading represents or what screen will appear if the box on the screen is touched.
    • ‘PARAMETER’
      • A user settable value such as ‘SAMPLE PERCENT’ or a PLC generated value such as ‘TIME REMAINING’.
    • Switch or SWITCH SETTING.
      • User settable switches that effect gate and sample functionality such as: The A Gate is set to OFF .
  2. The HMI is a touch screen operator interface. The user can simply touch certain areas on the screen to perform specific tasks. The screens have different colored boxes and text that will help the user identify their functionality.
    • Yellow text numbers are values produced by the PLC and are dependent on parameters entered by the user.
    • Blue boxes with white text are screen push buttons that allow the user to navigate to different screens or to open data entry screens.
      • Once a data entry screen is open a numeric pad will pop up on the screen and is to be used to enter in values.
  3. The date and time is displayed above the navigation buttons on each display.
  4. Touch anywhere on the screen if the screen is black due to the screen saver being on.
    • The main menu screen will appear and look similar to the screen displayed below.
    • If a screen other than the one below appears press the MENU Button on lower left of the panel.



Image:LMJ_SAMPLE_HMI_MAIN.jpg



  • In the left hand column A Sample Gate’s times are displayed. In the right hand column B Sample Gate’s times are displayed.
  • The current ‘SAMPLE PERCENT’ for the A or B Sample Gate will be displayed in their respective column in the box below the heading of SAMPLE PERCENT. This can be set by touching the SET PERCENT button on the lower left section of the screen. Setting the ‘SAMPLE PERCENT’ is explained in detail further on in this document.
  • The current ‘OPENINGS PER HOUR’ for the A or B Sample Gate will be displayed in their respective column in the box below the heading of OPENINGS PER HOUR. This can be set by pressing the SET OPENINGS button on the lower right section of the screen. Setting the ‘OPENINGS PER HOUR’ is explained in detail further on in this document.
  • If the A or B Sample Gate is in sample, the ‘SAMPLE TIME REMAINING’ for the A or B Sample Gate will be displayed in their respective column in the box below the heading of SAMPLE REMAINING. The ‘TIME TO NEXT SAMPLE’ will be display in the box below the heading of TIME TO NEXT.




Changing the Sample Percent

From the MAIN menu touch the box with the text SET PERCENTS and the following screen will appear.

Image:LMJ_SAMPLE_HMI_SET_PERCENT.jpg



  1. To set the ‘SAMPLE PERCENT’ for an individual gate, touch the box to the right of the gate you wish to set the ‘SAMPLE PERCENT’ for. If you would like to set the ‘SAMPLE PERCENT’ for both gates to the same value touch the box to the right of the text SET BOTH.
  2. A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any percent between 00.001% and 99.999% and press the enter button. This will enter the new ‘SAMPLE PERCENT’.
  3. Once the new ‘SAMPLE PERCENT’ is entered the new sample cycle will start. The cycle will start with the gate in the closed (not sampling) part of the cycle.
    • If you decide not to enter a new ‘SAMPLE PERCENT’ press the EXIT button on the numeric keypad.
  4. It should be noted that the PLC looks for a change in the ‘SAMPLE PERCENT’ before it re-calculates the time; so it is important to enter in a ‘SAMPLE PERCENT’ value that is different than what is currently being displayed.
    • An example of this is when the user wishes to sync the sample with the top of the hour but not change the Sample Rate.
    • To do this the user will have to enter in a ‘SAMPLE PERCENT’ that is different than what is currently being used. Do this just prior to the top of the hour. Then at the top of the hour the user will enter in the original ‘SAMPLE PERCENT’.
  5. The ‘TIME TO NEXT SAMPLE’ and ‘SAMPLE TIME REMAINING’ for the A and B Sample Gate will be displayed to the right of each ‘SAMPLE PERCENT’.
  6. Press the box with the text MAIN to return to the MAIN screen.
  7. Press the box with the text SET TIME to go to the SET TIME screen.
  8. Press the box with the text SET OPENINGS to go the the OPENINGS PER HOUR screen.



Changing the Openings Per Hour

From the MAIN menu touch the box with the text SET OPENINGS and the following screen will appear.

Image:LMJ_SAMPLE_HMI_SET_OPENINGS.jpg



  1. To set the ‘OPENINGS PER HOUR’ for an individual gate touch the box to the right of the gate you wish to set the ‘OPENINGS PER HOUR’ for. If you would like to set the ‘OPENINGS PER HOUR’ for both gates to the same value touch the box to the right of the text SET BOTH.
  2. A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any number of ‘OPENINGS PER HOUR’ between 1 and 12 and press the enter button. This will enter the new ‘OPENINGS PER HOUR’.
  3. Once the ‘OPENINGS PER HOUR’ is entered the new sample cycle will start. The cycle will start with the gate in the closed (not sampling) part of the cycle.
    • If you decide not to enter a new openings per hour press the EXIT button on the numeric keypad.
  4. It should be noted that the PLC looks for a change in the ‘OPENINGS PER HOUR’ before it re-calculates the time; so it is important to enter in a ‘OPENINGS PER HOUR’ value that is different than what is currently being displayed.
    • An example of this is when the user wishes to sync the sample with the top of the hour but not change the Sample Rate.
    • To do this the user will have to enter in a ‘OPENINGS PER HOUR’ that is different than what is currently being used. Do this just prior to the top of the hour. Then at the top of the hour the user will enter in the original ‘OPENINGS PER HOUR’.
  5. Press the box with the text MAIN to return to the MAIN screen.
  6. Press the box with the text SET TIME to go to the SET TIME screen.
  7. Press the box with the text SET PERCENT to go the the SAMPLE PERCENT screen.



Changing the TIME

From the MAIN menu touch the box with the text SET OPENINGS or SET PERCENT. From either screen you will then have the option to go to the SET TIME page by pressing the box with the text SET TIME. Press the box and the following screen will appear.

Image:LMJ_SAMPLE_HMI_SET_TIME.jpg



  1. To set the ‘MONTH’ touch the box to the right of the text MONTH.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any month using any number between 1 and 12 and press the enter button. This will enter the new ‘MONTH’.
  2. To set the ‘DAY’ touch the box to the right of the text DAY.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any day using any number between 1 and 31 and press the enter button. This will enter the new ‘DAY’.
  3. To set the ‘YEAR’ touch the box to the right of the text YEAR.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any year using any number between 2010 and 2099 and press the enter button. This will enter the new ‘YEAR’.
  4. To set the ‘HOUR’ touch the box to the right of the text HOUR.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any hour using any number between 1 and 23 and press the enter button. This will enter the new ‘HOUR’.
  5. To set the ‘MINUTE’ touch the box to the right of the text MINUTE.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any minute using any number between 1 and 59 and press the enter button. This will enter the new ‘MINUTE’.
  6. To set the ‘SECOND’ touch the box to the right of the text SECOND.
    • A display box will appear over the screen with a numeric keypad. Use the numeric keypad to enter any second using any number between 1 and 59 and press the enter button. This will enter the new ‘SECOND’.
  7. Press the box with the text MAIN to return to the MAIN screen.
  8. Press the box with the text SET PERCENT to go to the SAMPLE PERCENT screen.
  9. Press the box with the text SET OPENINGS to go the the OPENINGS PER HOUR screen.



Gate Control Switches

The panel located to the left of the PLC enclosure has six switches mounted on it.

  1. Divert During Sample
    • The top left switch is the Divert During Sample switch for A Sample Gate and the top right switch is the Divert During Sample switch for B Sample Gate. With this switch ON, PIT Tagged fish will be diverted during the sample. This will occur at any sample rate but not during BYPASS mode.
  2. Mode Switches
    • The middle left switch is the A Sample Gate Mode switch for A Sample Gate and the middle right switch is the B Sample Gate Mode switch for the B Sample Gate. Each switch has three mode positions.
      • The first position from left to right is labeled OFF for BYPASS. With the switch in this position there will be no sampling.
      • The second or middle position is labeled AUTO for NORMAL OPERATION. With the switch in this position, sampling will occur based on the ‘SAMPLE PERCENT’ and ‘OPENINGS PER HOUR’ entered.
      • The third position is labeled ON for 100% sample. With the switch in this position the sample gate will stay in the sample position.
  3. De-Water Switches
    • The lower left switch is A De-water Valve switch for A Sample Gate and the lower right switch is the B De-water Valve switch for B Sample Gate. Each switch has three positions.
      • The first position from left to right is labeled OFF. With the switch in this position the De-water valve will be closed regardless of the state of the sample gate.
      • The second or middle position is labeled AUTO for NORMAL OPERATION. With the switch in this position the De-water valve will open when there is an active sample.
      • The third position is labeled ON. With the switch in this position the De-water valve will open regardless of the state of the sample gate.
  4. Test Buttons
    • Located near each A Slide Gate is a Test A push button. Pushing this button will simulate a diversion request and open the gate IF:
      • The Divert During Sample switch for A Sample Gate is turned OFF and there is not a active sample taking place at A Sample Gate OR
      • The Divert During Sample switch is turned ON.
    • Located near each B Slide Gate is a Test B push button. Pushing this button will simulate a diversion request and open the gate IF:
      • The Divert During Sample switch for B Sample Gate is turned OFF and there is not a active sample taking place at B Sample Gate OR
      • The Divert During Sample switch is turned ON.



Gate Sensors and Trouble Light

  1. The gate sensors installed on the A and B Slide Gates will be maintained by PSMFC but provide indication to site personnel when there are problems with either the sensors or the gates.
  2. The sensors were installed to reduce or eliminate the 'double slam' that occurs during heavy fish traffic. They are also used to monitor the state of the gate and provide visual indication via a trouble light if one of the gates is stuck open or stuck closed. #*The same trouble light will be lit if one of the gate sensors is missed 3 times or stuck on 3 separate times for more than 3 seconds.
  3. If the trouble light is on there is either a problem with the gate or the sensors and possibly both. The operator will have to investigate the cause of the trouble light.
  4. When the trouble light is on, the 'double slam' logic for the gate that is experiencing trouble will be removed from the logic.
    • Example 1
      • The trouble light is on and the ALARM page on the 6" Red Lion HMI is indicating B GATE SENSOR TROUBLE.
        • The PLC will will remove the 'double slam' logic for B Gate and B Gate will work as it has in past years until the issue is resolved by PSMFC and re-set.
    • Example 2
      • The trouble light is on and a page pops up on the 10" Red Lion HMI in the separator shack and it is stating that the is B Gate Trouble and that B Gate is stuck open.
        • The PLC will remove the 'double slam' logic for B Gate and B Gate will work as it has in past years until the gate is unstuck and the alarm is reset by the operator.

IT IS IMPORTANT TO NOTE THAT SITE PERSONNEL CAN CLEAR GATE TROUBLE (STUCK OPEN, OR CLOSED) BUT PSMFC MUST CLEAR SENSOR TROUBLE.

Gate Trouble Light

To investigate a trouble light, open the enclosure that contains the switches for setting Divert During Sample and view the messages on the 6" HMI screen or take note of the pop up window on the 10" HMI screen. You should see something similar to the graphics below.


6" Red Lion HMI indicating trouble with B Gate Sensors




Image:LMJ_SAMPLE_HMI_SENSOR_TROUBLE.jpg

10" Red Lion HMI indication trouble with B Gate Sensors




Gate Trouble
  • The problem whether it is GATE TROUBLE or SENSOR TROUBLE will be highlighted in red.
  • If the problem is with the gate, such as indicated in the graphic below, the operator should investigate whether the gate is stuck open or stuck closed, resolve the problem and then clear the trouble light by pressing the box CLEAR TROUBLE LIGHT.


Image:LMJ_SAMPLE_HMI_GATE_TROUBLE.jpg



Sensor Trouble
  • The problem whether it is GATE TROUBLE or SENSOR TROUBLE will be highlighted in red.
  • If the problem is with a sensor, such as indicated in the graphic below, the operator should use the number provided on the screen to call PSMFC.


Image:LMJ_SAMPLE_HMI_SENSOR_TROUBLE.jpg


10" Red Lion HMI indication trouble with B Gate Sensors



  • Press RETURN TO MAIN PAGE to clear the pop up from the 10" HMI in the separator shack.
  • Press RETURN TO MAIN to return to the main screen on the 6" HMI located in the enclosure by B Gate.
6" HMI
  1. The 6" HMI is located in the enclosure to the left of the PLC.
  2. The MAIN page of this HMI can be used to quickly check the alarm status of the sensors and gates.
  3. The graphics below show what the MAIN screen will look like if there are alarms or if there are no alarms.
    • This is provided in the rare case that the pop up window on the 10" HMI was cleared and the trouble light was on long enough to burn out.



6" Red Lion HMI indicating there are unresolved alarms, press the button to view alarms.






6" Red Lion HMI indicating there are no alarms.




Frequently Asked Questions

Q: Can I damage the system?
A: No. No operator inputs can damage the system.

Q: Can I use the gate test switches at any time?
A: No. The test switches will not work during an active sample when the Divert During Sample switch is set to OFF.

Q: Can I enter an incorrect value?
A: Yes. Caution should be used when determining sample gate open time. An example would be entering 12 openings per hour with a 00.1 percent sample rate. Point one percent of an hour would be 3.6 seconds. When divided by 12 gate openings per hour the open time per opening would be .3 second. This is not enough time to fully open the gate. The same consideration should be used when using a 99.9 sample rate.

Q: Can I enter a value out of range?
A: No, the PV600 will give you a ‘value out of range’ error.

Q: When the Sample Mode is set to 100%, will PIT tagged fish be diverted from the sample?
A: No. They will only be diverted if the Divert During Sample switch is ON.

Q: With the Sample Mode switch set to AUTO (Normal Operation) and the Divert During Sample switch set to ON, will PIT tagged fish be diverted from the sample.
A: Yes, With the Divert During Sample switch set to ON, PIT tagged fish will be diverted from the sample.

Q: Can the sample be shut off?
A: Yes, when Sample Mode is set to OFF(Bypass) the sample will be shut off.

Q: How can I synchronize a new sample rate with the top of the hour?
A: When a new sample rate or new number of openings per hour is entered the new cycle starts exactly when the enter button is pushed. It should be noted that the value you are changing to synchronize with the top of the hour must be a new value. If you don’t want to change your ‘SAMPLE PERCENT’ or ‘OPENINGS PER HOUR’ but wish to synchronize at the top of the hour you must enter a different ‘SAMPLE PERCENT’ or ‘OPENINGS PER HOUR’ just prior to the top of the hour. This will cause the PLC to see a change in sample rate and re-calculate the sample times. At the top of the hour re-enter the ‘SAMPLE PERCENT’ or ‘OPENINGS PER HOUR’ you wish to run at.

Q: What will happen if a power outage occurs? Will I lose my settings?
A: No. All sample settings are stored in non-volatile memory.


References


Contact PSMFC at (509) 735-2773

Name Extension
Don Warf 1
Scott Livingston 2
Darren Chase 3
Alan Brower 4
Troy Humphrey 5
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