SECTION 40 61 13 PROCESS CONTROL SYSTEM GENERAL PROVISIONS

SECTION 40 61 13

PROCESS CONTROL SYSTEM GENERAL PROVISIONS 

PART 1 – GENERAL

1.1 DESCRIPTION

A. Scope:

1. CONTRACTOR shall provide all labor, materials, equipment, and incidentals as shown, specified, and required to furnish, install, calibrate, test, start-up and place in satisfactory operation the components of the Monitoring and Control System (MCS) that are associated with the Primary Treatment Improvements Project as required for a fully functioning system as specified and shown on the Drawings.

2. CONTRACTOR is responsible for obtaining the services of ALL SUPPLIERS. The term “SUPPLIERS” includes SYSTEM INTEGRATORS, MANUFACTURER’S REPRESENTATIVES, vendors, and all other personnel required for a complete MCS and the requirements listed or implied in the Contract Documents.

3. The MCS Work includes, but is not limited to, the following:

a. Panels and panel-mounted instruments and devices. b. Field-mounted instruments and devices.

c. Programmable automation controllers (PAC) and software (formerly known as programmable logic controllers (PLC).

d. Operator Interface Terminals (OIT).

e. Personal computers and human-machine interface (HMI) hardware and software.

f. Local area network hardware and software. g. Uninterruptible power supply.

h. All interconnecting wires and cables

i. Field device network communication hardware and software required for interfacing various systems to provide a fully-integrated system.

j. Modbus RTU network communication hardware and software required for monitoring various field instruments and sensors.

4. CONTRACTOR shall program the PACs, OITs and Human machine Interfaces (HMI) as required for complete control and monitoring of the Primary Settling Tank processes, including interlocks and data transfer. The control description of the systems and associated equipment are included in Section 40 61 96 and shall be the basis for the PAC, OIT, and HMI programming along with the process and instrumentation diagrams.

5. CONTRACTOR shall provide the HMI software developer licenses for Work on the project. The OWNER already is in possession of the HMI runtime licenses.

B. MCS shall monitor, store, display, and log process and equipment operating information; perform various process control functions; and generate various reports.

C. The Contract Documents describe the required MCS and MCS functions and operational requirements.

D. Coordination:

1. Instrumentation and Controls:

a. CONTRACTOR shall coordinate installation of panels and equipment that interfaces with the Monitoring and Control system and that are furnished under other Specification Sections under this Contract. Coordinate with SUPPLIERS of these panels and equipment to provide fully functional system in accordance with the Contract Documents.

b. CONTRACTOR shall provide PAC input/output lists to identify inputs and outputs for all PACs.

c. CONTRACTOR shall coordinate and provide PAC register lists to identify all soft inputs and outputs being communicated to/from all PACs. This information shall be in the format required by Section 40

61 93.

2. With CONTRACTOR, SUPPLIERS shall assume the responsibility for adequacy and performance of materials and equipment provided under this Section.

3. Provide I&C materials and equipment from a single manufacturer.

4. CONTRACTOR’s Responsibilities:

a. Hiring SUPPLIER’s (including SYSTEMS INTEGRATORS) to provide the technical expertise to perform relevant tasks listed below and in the Contract documents.

b. Preparing all process control equipment submittals in accordance with the Contract Documents.

c. Proper interfacing of instrumentation and control equipment with field equipment, instruments, devices, and panels, including required interfacing with packaged control systems furnished by SUPPLIERS, and required interfacing with the Site’s electrical system.

d. Review and coordination with manufacturers, SUPPLIERS, and other contracts of Shop Drawings and submittals for equipment, valves, piping, and appurtenances for ensuring proper interfacing of hardware, and locations and installation requirements of inline devices and instrument taps.

e. Direct, detailed oversight of installation of instruments, panels, consoles, cabinets, wiring and other components, and related wiring and piping connections.

f. Calibrating, source quality control, field quality control, and start-up of the system.

g. Responsibility for correction period obligations for the MCS.

h. Training operations and maintenance personnel in operation and maintenance (including calibration and troubleshooting) of the MCS.

E. Related Sections:

1. Division 26.

2. Division 40.

1.2 REFERENCES

A. Standards referenced in this Section are:

1. American National Standards Institute, (ANSI).

2. The International Society of Automation, (ISA).

3. Underwriters’ Laboratories, Inc., (UL).

4. National Fire Protection Association, (NFPA).

5. American Water Works Association, (AWWA).

6. National Electrical Manufacturer’s Association, (NEMA).

7. Occupational Safety and Health Administration, (OSHA).

8. Institute of Electrical and Electronic Engineers, (IEEE).

9. National Electrical Code, (NEC).

10. Factory Mutual, (FM).

_{1.3 QUALITY ASSURANCE}

A. General:

1. Each major component system of the MCS as specified shall be furnished by a SUPPLIER who shall assume responsibility for providing a complete packaged system.

2. Coordination of all SUPPLIERS, and the overall MCS, shall be the responsibility of the CONTRACTOR, who shall assume responsibility for providing the complete MCS.

3. All equipment, components, and materials required for each major system shall be furnished by a single SUPPLIER who shall assume the responsi- bility for adequacy and performance of all items.

B. SUPPLIER qualifications:

1. Be a financially sound firm having at least five years continuous experience in designing, implementing, supplying, and supporting instrumentation and control systems that are comparable in complexity to the hardware and software of the MCS.

2. Have in existence at the time of bid advertisement, an experienced engineering and technical staff capable of designing, implementing, supplying and supporting the controls and monitoring, and handling submittal and training requirements for the respective major equipment.

3. Have a minimum of five years experience in hardware application and programming of microprocessor based controllers and data highway systems, including DeviceNet, Ethernet, and Modbus.

4. Provide standard course offerings in general process control applications and in operation, programming and maintenance of the control system and

equipment at a facility specifically utilized for training purposes. The facility shall have been in operation continuously for the last two years.

5. Have a thorough working knowledge of wastewater treatment processes and control philosophy in accordance with standard practices of the wastewater treatment industry.

6. Have a UL-approved panel shop.

7. Submit for approval documentation demonstrating compliance with the above requirements.

8. Possess and maintain a documented program of failure analysis.

C. SYSTEMS INTEGRATOR qualifications shall be in accordance with Paragraph

1.3.B. above. If the SYSTEMS INTEGRATOR is not frabicating any control panels, then Paragraph 1.3.B.6 shall not apply to the SYSTEMS INTEGRATOR. In addition, the SYSTEMS INTEGRATOR shall meet the following requirements:

1. Shall be a Rockwell listed and certified Solution Provider (preferred), or a

Rockwell-listed System Integrator.

2. Shall have ISO 9001 certification. If lacking the 9001 certification, the OWNER reserves the right to review the quality management procedures and perform a quality management audit prior to the preconstruction conference.

3. Preferred certified by the Control System Integrator Association (CSIA).

4. SYSTEM INTEGRATOR shall be Wonderware endorsed or certified in Wonderware System Platform 3 or current version of System Platform. Personnel selected for the Contract must demonstrate recent System Platform 3 (or current version) programming experience.

5. The SYSTEMS INTEGRATOR shall have an office fully staffed with project personnel within 250 miles of the Cleveland, Ohio project location.

D. Manufacturers:

1. Manufacturers of instrumentation and control equipment furnished for the MCS shall be experienced producing similar equipment and shall have the following qualifications:

a. Shall manufacture instrumentation and control system components that are fully-developed, field-proven, and of standardized designs.

b. Shall have system of traceability of manufactured unit through production and testing in accordance with ANSI/ASQ Z1.4.

c. Shall have guaranteed availability clause (99.99 percent, minimum for one year) for microprocessor-based components and appurtenances.

d. Shall have documented product safety policy relevant to materials and equipment proposed for the Work.

E. CONTRACTOR Responsibility:

1. CONTRACTOR shall retain the SUPPLIERS (which includes SYSTEMS INTEGRATOR and related personnel) to undertake the responsibilities specified below. However, execution of these specified duties by the

SUPPLIERS shall not relieve CONTRACTOR of the ultimate responsibility for the components and full functionality of the MCS.

a. Design, fabrication, implementation and applications programming of the PAC panels, OITs, and HMIs and all subsystems in accordance with the Contract Documents and all referenced standards and codes.

b. Preparation, assembly and correction of all control panel submittals in accordance with the Contract Documents.

c. Proper interfacing of all hardware, software, field devices, and panels, including required interfacing with packaged control systems furnished by other SUPPLIERS, and with the plant electrical system.

d. Detailed configuration, loop checks, testing, troubleshooting, commissioning of instruments.

e. Supervision of the installation of all instruments, panels, consoles, cabinets, wiring and other components required.

f. Calibration, testing and start-up of all control panels.

g. Training of OWNER’s personnel in operation and maintenance of the

MCS.

h. Responsibility for all warranty obligations for the control system components.

i. Maintenance of two reproducible copies of the respective system documents at the SUPPLIER's facilities for the duration of the warranty period.

j. Programming of the PACs, HMIs, and associated OITs used in the MCS in accordance with the Drawings and Specifications included in the Contract Documents.

1.4 PROGRESS AND COORDINATION MEETINGS

A. CONTRACTOR shall be responsible for scheduling and coordinating the MCS installation with regard to all other Work on the Site and in accordance with the provisions of the General Conditions. Said coordination shall be documented on the Project Schedule.

B. Routine progress and coordination meetings will be scheduled by ENGINEER.

CONTRACTOR and a representative of the SYSTEM INTEGRATOR and SUPPLIERS shall be required to attend scheduled meetings each month during active work periods (shop drawing preparation, construction, and startup).

C. The purpose of the meetings shall be to review the progress of the Work involving the MCS and associated control equipment and provide coordination for installation of the equipment to ensure Project Schedule is met.

D. Representative at the meetings shall have the competence and authority to make any and all necessary decisions. Decisions and statements made at the meetings shall commit CONTRACTOR and SUPPLIERS to agreed procedures and schedules.

E. Pre-submittal Conference

1. Schedule and conduct a pre-submittal conference for the MCS within 90 days after the Contract Times commence running.

2. Required Attendance for Pre-submittal Conference: CONTRACTOR, SYSTEM INTEGRATOR, SUPPLIERS, ENGINEER, and OWNER. Pre- submittal conference will be 8 hours. Conference will be held at the Project Site.

3. Purpose of pre-submittal conference is to review manner in which the CONTRACTOR intends to comply with requirements of the Contract Documents before submittals are prepared. CONTRACTOR shall also provide for review at the pre-submittal conference standard testing and verification procedures in advance of the formal submittal.

4. Bring to pre-submittal conference list of proposed personnel committed to assignment to the Project. List shall include SYSTEM INTEGRATOR project manager, project engineer, field representative, local service representative, and sales representative(s); and similar personnel for the SUPPLIER. Indicate addresses of personnel not based at SYSTEM INTEGRATOR’s and SUPPLIER's office nearest to the Site.

5. CONTRACTOR shall prepare items listed below for presentation at

pre-submittal conference. Submit information to ENGINEER two weeks prior to pre-submittal conference.

a. List of materials and equipment required for MCS, and manufacturer and model proposed for each item.

b. List of currently-known requests for interpretations of which

CONTRACTOR is currently aware.

c. List of proposed exceptions to the Contract Documents along with brief explanation of each. Approval shall be subject to a formal submittal.

d. Proposed MCS network architecture diagram.

e. Sample of each type of process control submittal required by the Contract Documents. These may be submittals prepared for other projects.

f. List of proposed submittals. See Specification Section 01 33 00,

Submittal Procedures, for general submittal requirements.

g. CPM type schedule for all control related activities from pre-submittal conference through start-up and training. Particular emphasis shall be given to dates relative to submittals, design, fabrication, programming, factory testing, deliveries, installation, and field-testing. The schedule shall be subdivided to show activities relative to each major item or group of items when everything in a given group is on the same schedule.

h. General outlines of types of tests to be performed to verify that all sensors and transducers, instruments, and digital processing equipment are functioning properly.

i. Sample drawings

j. Sample OIT and HMI graphics

k. Sample programming documentation.

1.5 MANDATORY COORDINATION WORKSHOPS

A. Standards Workshops: The OWNER desires HMI and OIT systems that meet the District Standards and that and similar in “look and feel” to the District-wide HMI systems. To that end, the CONTRACTOR is required to attend and implement results from multiple workshops with the OWNER. The purpose of the workshops will be to review the District Automation Standards and discuss their specific application to this project. The District makes available PAC, OIT, and HMI

object libraries (for use in their respective programming software) which shall be the basis for all of the new and modified MCS content. The following workshops will be held, attended by the CONTRACTOR and OWNER and OWNER REPRESENTATIVE(S) to further define and detail to the CONTRACTOR the District Standards and method of display and control. Each workshop shall be for at least four (4) hours and no more than eight (8) hours. The workshops will be scheduled by the OWNER and OWNER’s PROGRAM MANAGER and will be scheduled prior to the first Factory Test. The CONTRACTOR, SYSTEMS INTEGRATOR, and applicable SUPPLIERS shall be required to attend. Where the OWNER has defined standards, examples and templates will be distributed at the workshops. (Note: The following list is intended to provide the CONTRACTOR with an indication of the number and content of each workshop. The OWNER reserves the right to change the order, add to or modify the content of any workshop as required.)

1. Standards Workshop 1: PAC Programming:

a. Tag Standards (Review with OWNER the method of tagging different types of I/O, specific to the project)

b. Documentation Standards (Review with OWNER the requirements for documenting logic development and annotating program), including electronic and paper documentation.

c. Logic Development Standards (Review with OWNER which logic shall be developed in ladder logic and which shall be developed in structured text)

d. Structured subroutines

e. PAC programs shall require the use of extensive and detailed rung, module, and procedure comments. I/O tags with a description shall be used in the program. District Automation standards are published which document programming requirements and shall be followed.

2. Standards Workshop 2: OIT Configuration

a. Graphic Standards (Review with OWNER color, faceplate, display requirements for local OITs)

b. Event and Alarming requirements (Review with OWNER methods to displaying alarms at local OITs)

c. Control Function requirements (Review with OWNER hierarchy of control, format for local/remote/manual controls capabilities)

d. Standard screen layout

e. CONTRACTOR shall submit sketches of proposed graphic screens to ENGINEER and OWNER two weeks before workshop, for ample time to review and comment on the direction of the design effort

3. Standards Workshop 3: HMI Graphics Configuration Part I

a. Graphic Template (Review with OWNER the template for screen display, location of global/local information), HMI server application.

b. Hierarchy (Review with OWNER the hierarchy for system linking on the project, including overviews, main menus, sub menus, context sensitive menus, etc.)

c. Graphic Display Wizards/Galaxies (Review with OWNER required symbols to be used for field devices/equipment, and how different status/alarms would be displayed)

d. Colors (Review with OWNER color requirements for systems/processes)

4. Standards Workshop 4: HMI Graphics Configuration Part II

a. Alarm and Event Handling (Review with OWNER the escalation and display requirements for events and alarms, including grouping, priorities, and method of annunciation.)

b. Security Access Levels (Review with OWNER the security login function that will be configured, including access levels, rights and privileges.) Implement OWNER specific requirements for network security items, including hardware and software configuration, passwords, security levels, boot requirements, etc.

5. Standards Workshop 5: Historical Information

a. Process Trending (Review with OWNER the required data to be trended, and the frequency of collection for MCS data)

b. Alarm and Event Capture (Review with OWNER the required alarms and events to captured within the MCS Historian)

6. Standards Workshop 6: Regulatory Items

a. Review with OWNER the specific requirements for regulatory

systems, including alarm handling for regulatory alarms, data handling for regulatory systems, formats of reports, etc.)

B. Project Workshops: The OWNER desires to review and comment on each HMI system graphic and bring together Operations and Maintenance staff to review use and application of the MCS HMI. To that end, the CONTRACTOR is required to demonstrate (either in person or over the internet via remote shared desktop/meeting capability) each control strategy and its related HMI graphics. The purpose of the workshops will be to allow OWNER stakeholders to review and comment on the representation of process equipment, process flows, information requirements, placement of objects on the screen, etc. All comments will be compiled and the CONTRACTOR shall be expected to respond to and implement changes. For each system defined below, the CONTRACTOR is expected to provide a (4)-hour First Demonstration, and (2) hour Second Demonstration, and a (2) hour Final Demonstration. At the meeting, the SYSTEMS INTEGRATOR, as well as the respective SUPPLIER, shall attend. There will be Control Strategy/Graphic Reviews for the following systems:

(Note: The following list is intended to provide the CONTRACTOR with an indication of the number and content of each workshop. The OWNER reserves the right to change the order, add to or modify the content of any workshop as required.)

1. Primary Settling Tanks (PST) 1 through 6

1.6 SYSTEMS INTEGRATOR PROJECT PERSONNEL

A. CONTRACTOR shall provide the following project personnel:

1. Project Manager:

a. The CONTRACTOR shall appoint a Project Manager who shall coordinate and schedule all the Work and assure that the Project Schedule is met.

b. The Project Manager shall act as the liaison with CONTRACTOR for the installation of the MCS equipment and shall assist in all matters required for proper coordination and interfacing of the equipment and processes.

2. Field Engineer:

a. The CONTRACTOR shall appoint a Field Engineer with responsibilities as follows:

1) Provide advice and technical consultation relative to installation techniques and procedures for equipment furnished.

2) Installed system checkout, calibration, adjustment, and start-up, including tuning of every control loop.

3) Maintenance services during availability demonstration.

4) Involvement in the on-site system training of plant personnel.

5) Resolving of control problems encountered during initial start-up and testing of all MCS equipment.

b. The Field Engineer shall have a minimum of five years experience in systems engineering and start-up and shall have a thorough working knowledge of both the hardware and software supplied.

3. Training Personnel:

a. Comply with requirements of Section 40 61 26, Process Control System Training, and Section 01 79 00, Instruction of Operations and Maintenance Personnel. Training can be segmented by major systems and common systems.

_{1.7 SUBMITTALS}

A. Action Submittals: Submit the following:

1. Shop Drawings:

a. General:

1) Shop Drawings preparation shall not commence until after the pre- submittal conference specified below.

2) Manufacture of a part of the MCS shall not commence until related submittals have been approved by ENGINEER.

3) Shop Drawings shall be submitted in complete packages grouped to permit review of related items as generally outlined in Paragraph 1.7.A.3, below.

4) Review of Shop Drawings will be for conformance with Contract

Documents and with regard to functions specified to be provided.

5) Incomplete or non-project specific submittals will be rejected.

6) Written testing and verification procedures for system performance, including acceptance criteria for OWNER review and approval prior to testing.

b. Pre-Submittal Conference: CONTRACTOR shall prepare the items listed below for presentation at the Pre-Submittal Conference. The information shall be submitted to ENGINEER three weeks prior to the date of the conference.

1) List of equipment and materials required for the MCS and the brand and model, which CONTRACTOR proposes to use for each item.

2) List of proposed exceptions to the Contract Documents along with a brief explanation of each. Approval shall be subject to a formal submittal.

3) Sample of each type of submittal specified herein. The samples may be submittals prepared for other projects.

4) A flow chart showing the steps to be taken in preparing and coordinating each control system submittal to ENGINEER, and a list of proposed submittals.

5) CPM schedule for all control related activities from the

pre-submittal conference through start-up and training. Particular emphasis shall be given to dates relative to submittals, design, fabrication, programming, factory testing, deliveries, installation, and field-testing. The schedule shall be subdivided to show activities relative to each major item or group of items when everything in a given group is on the same schedule.

6) General outlines of the type of tests to be performed to verify that all sensors/transducers, instruments, and digital processing equip- ment are functioning properly.

c. Field Instruments, Solenoid Valves, Valves, and other Actuator- Controlled Devices:

1) Manufacturer’s product name and complete model number of devices proposed for use, including manufacturer’s name and address.

2) Instrument tag number in accordance with the Contract

Documents.

3) Functional name.

4) Manufacturers standard catalog product data.

a) Catalog information shall be tailored for this project by indicating all options and accessories provided or deleting or crossing out all non-applicable options or information.

b) Provide electronic editable copies (MS Word, Excel) and paper data sheets conforming to the latest revision of ISA TR20 specification sheets for review and approval. For all instrumentation, provide completely filled out ISA TR20 sheets. Incomplete sheets or sheets not filled out using the latest TR20 forms shall be returned without review and unapproved.

c) CONTRACTOR shall include on ISA TR20 data sheets for all elements including:

i. Failure position for actuator controlled devices

ii. Indicating defined failure position for power failure iii. Indicating failure position for loss of control signal iv. Valve failure is defined as loss of power or loss of

signal.

v. Instrument failure position and signal response.

5) Description of construction features.

6) Performance and operation data.

7) Installation, mounting, and calibration details; instructions and recommendations.

8) Service requirements.

9) Dimensions of instruments and details of mating flanges and locations of closed tanks, pipe sizes for insertion instruments, and upstream/downstream straight run pipe lengths required.

10) Range of each device and calibration information

11) Descriptions of materials of construction

12) NEMA ratings for equipment.

13) Classified (hazardous) area ratings d. Panels, Consoles, and Cabinets:

1) Layout drawings that include:

a) Front, rear, and internal panel views to scale. b) Dimensional information.

c) Tag number and functional name of components mounted in and on panel, console, or cabinet, as applicable.

d) Product information on panel components.

e) Nameplate location and legend including text, letter size and colors to be used.

f) Location of anchorage connections.

g) Location of external wiring and piping connections.

h) Mounting and installation details, coordinated with actual application.

i) Proposed layouts and sizes of operator interface graphic display panels.

j) Calculations substantiating panel heating and cooling provisions proposed. List and utilize the following parameters in the calculations:

i) Enclosure dimensions.

ii) Minimum and maximum temperature outside the enclosure based upon the environmental conditions given in Article 2.1.B.

iii) Minimum and maximum desired temperature inside the enclosure based upon the manufacturer’s stated operating temperature range of the panel components.

iv) Internal heat load.

k) Subpanel layouts and mounting details for items located inside control panels.

2) Panel Wiring Diagrams: Drawings shall be in accordance with

IEEE standards and shall include the following information:

a) Name of each panel, console, or cabinet. b) Wire sizes and types.

c) Pipe sizes and types.

d) Terminal strip and terminal numbers. e) Wire color coding.

f) Functional name and manufacturer’s designation for components to which wiring and piping are connected.

3) Control schematics shall be in accordance with convention indicated in Annex D of NFPA 79. Standardized wiring diagrams that do not accurately reflect actual wiring to be furnished are unacceptable. Tables or charts for describing wire numbers are unacceptable.

4) Stock list or bill of materials for each panel including tag number, functional name, manufacturer’s name, model number and quantity for components mounted in or on the panel or enclosure.

e. Field wiring and piping diagrams, include the following:

1) Wire and pipe sizes and types.

2) Terminal numbers at field devices and in panels.

3) Fiber optic termination designations in the field and in panels.

4) Color coding.

5) Conduit numbers in which wiring will be located.

6) Locations, functional names, and manufacturer’s designations of items to which wiring or piping are connected.

7) Point to point wiring diagrams shall include all interconnections between field devices, panels, control stations, lighting panels, and motor starters.

f. Proposed Operator Interface and Human Machine Interface graphic layouts. Each graphic display and process report layout will be subject to modification from CONTRACTOR’s submitted format within limits of software package used for development. Implement such modifications in accordance with ENGINEER’s written comments on the submittal. There shall be a minimum of three review cycles for OIT and HMI graphics during the submittal phase. There is no maximum to the number of reviews of the graphics, if the graphics are not being implemented as required or do not work as designed.

g. Programmable Control System Information:

1) System Description and documentation:

a) Detailed block diagram showing system hardware configura- tion and identifying model numbers of system components.

b) Software listings for operating system, applications, and HMI. c) Software language and organization.

d) Format, protocol and procedures for data highway communications and local communications with input/output modules and peripheral devices.

e) HMI interfacing details, licensing structure, and included functions.

f) Control and failure modes.

g) Online and offline capabilities for programming, system utilities, and diagnostics.

h) Complete Input/output point listing with I/O module cross- reference identification for each programmable controller, in accordance with the requirements of Section 40 61 93.

i) Database listing, including all I/O points, hard and soft (calculated) points. Database shall be submitted in an electronically editable version for review by the OWNER.

j) Suggested detailed format and configuration of log reports, alarm summaries, printer outputs, displays, and graphics.

k) List of spare parts and test equipment.

2) Equipment Hardware:

a) Layout drawings showing front, rear, end, and plan views to scale of equipment, I/O components, power supplies, and peripheral devices.

b) Construction details, features and procedures.

c) Interconnection diagrams, including termination details, cable identification list, and cable length.

d) Drawings showing equipment layout.

e) Installation requirements, instructions, and recommendations.

3) Software Description:

a) Licensing agreement with name of licensee, renewal requirements, release and versions, expiration dates (if any) and upcoming releases scheduled before Project completion. When upcoming releases are expected, provide descriptions, when available, of features that differ from the proposed release.

b) Provide information of number of run, client, and development licenses as well as I/O point count limit per license.

c) Standard technical and instructional documentation covering software for utility, system support, system documentation, display, communications, data logging and storage and diagnostic functions. Submit this information as electronic files.

d) Standard technical documentation covering all aspects of the computer system software functions and capabilities, including instruction set description and programming procedures related to monitoring, display, logging, reporting and alarming functions.

e) Detailed functional descriptions of application programs explaining control, display, logging and alarming features to be provided and functions to be performed.

4) Documentation describing memory type, size and structure and listing size of system memory, I/O and data table memory and size of memory available for control programs. Also define estimated control program memory requirements and processor execution times and program scan times.

5) Description of on-line diagnostic tests and off-line tests.

6) Dimensional data of equipment.

7) Hardware manuals.

8) Manufacturer’s installation instructions for grounding and power conditioning requirements.

9) Description of how faults are detected, isolated, and corrected.

10) System I/O Loop Wiring Diagrams: Prepare Shop Drawings on module-by-module basis and include the following information: a) Rack numbers, module type and slot number, and module

terminal point numbers. Include location and identification of intermediate panel and field terminal blocks and terminal numbers to which I/O wiring and power supply wiring is connected. Identify power supply circuits with designation numbers and ratings.

b) Wiring sizes, types, wire numbers, and color coding.

c) Designation of conduits in which field I/O wiring will be installed.

d) Location, functional name, tag numbers and manufacturer’s module numbers of panel and field devices and instruments to which I/O wiring will be connected. For discrete I/O devices use NFPA 79 electrical symbols tagged with designation as shown.

e) Prepare loop wiring diagrams in accordance with ISA 5.4, Figure 6 showing loop diagram, shared display and control, minimum required items plus all optional items.

f) Addressing card and system layout, including special configuration rules and limitations.

g) Interface and cable data.

h) Indicated modularity of I/O modules.

h. Complete point-to-point interconnection wiring diagrams of field wiring associated with the system. Diagrams shall include the following:

1) Field wiring between each equipment item, panel, instruments, and other devices, and wiring to control stations, panelboards, and

motor starters. Some of this equipment may be specified in other Divisions. CONTRACTOR is responsible for providing complete point-to-point interconnection wiring diagrams for control and monitoring of that equipment.

2) Numbered terminal block and terminal identification for each wire termination.

3) Identification of assigned wire numbers for interconnections.

Assign each wire a unique number.

4) Schedule showing the wiring numbers and the conduit number in which the numbered wire is installed.

5) Junction and pull boxes through which wiring will be routed.

6) Identification of equipment in accordance with the Contract

Documents.

7) Instrument tag numbers from Contract Documents.

8) Manufacturer’s model, product, or catalog number for each item.

9) Location of each item.

10) Signal type and calibrated range, scale, and set point for each item, as applicable.

11) Transmitter output drive and receiver input impedances. Show total loop impedance and reserve.

12) Identification of all loop and instrument energy sources.

3. Samples:

a. Color charts for finish paint for metallic panels. Provide full range of paint manufacturer’s standard and custom colors. Color selection will be by ENGINEER.

b. Color charts for fiberglass-reinforced panels. Provide full range of panel manufacturer’s standard and custom colors. Color selection will be by ENGINEER.

4. Factory Acceptance Test Procedure: Submit proposed procedures for factory testing required to comply with the Contract Documents. Test procedure shall include the following:

a. Visual inspection of components and assembly. b. Description of hardware operational testing.

c. Description of software demonstration.

d. Description of testing equipment to be used. e. Sign-off sheets to be used at time of testing.

B. Informational Submittals: Submit the following:

1. Documents to be submitted prior to pre-submittal conference, in accordance with Article 1.3 of this specification.

2. System Software Documentation: Submit preliminary software documentation at least four weeks prior to expected initiation of factory testing. Submittal shall be for OWNER and ENGINEER for information only and shall not be subject to formal approval. Software documentation shall include the following:

a. Complete hard copies of all ladder diagram programming. Docu- mentation shall include complete external and internal I/O coil, contact,

and signal cross-referencing, addressing, and rung numbering. Documentation shall clearly distinguish between internal and real I/O and shall also incorporate extensive English language to identify contact, coil and signal functions and for labeling and description of program, sub-program and rung purpose and action.

b. Complete listing of external and internal I/O address assignments, register assignments, and preset constant values along with functional point descriptions. Also, list all unused/undefined I/O and data table registers available.

c. Complete hard copies of all program documentation for all types of programs.

d. Detailed system memory map defining memory segments used and spare memory segments available for system memory, I/O tables, Data Tables and control program.

e. Complete database listing including listings for log, report, and alarm file setups.

f. Hard copies of all system graphic displays and formats for all logs, reports and the alarm summary.

g. User's manuals describing procedures and providing examples for use of operator's consoles, workstations and programming terminal, accessories and system utility routines to perform control, display and logging program generation, program modification, program verification, diagnostics, program documentation, loading and backup and other required system support functions.

3. Manufacturer’s Instructions:

a. Shipping, handling, storage, installation, and start-up instructions.

b. Templates for anchorage devices for materials and equipment that will be anchored to concrete or masonry.

4. Source Quality Control Submittals:

a. Results of factory testing.

5. Special Procedure Submittals:

a. Notification to OWNER and ENGINEER at least 14 days before readiness to begin system checkout at the Site. Schedule system checkout on dates acceptable to OWNER and ENGINEER.

b. Written procedure for system checkout. Submit not less than 90 days prior to starting system checkout.

c. Ninety days prior to starting system checkout submit written procedure for start-up.

6. Field Quality Control Submittals:

a. Submit the following prior to commencing system checkout and start- up.

1) Completed calibration sheets for each installed instrument showing five-point calibration (zero, 25, 50, 75, 100 percent of span), signed by factory-authorized serviceman.

b. Field calibration reports c. Field testing reports.

7. SUPPLIER’s Reports:

a. Installation inspection and check-out report.

b. Submit written report of results of each visit to Site by SUPPLIER’s service technician, including purpose and time of visit, tasks performed, and results obtained. Submit within two days of completion of visit to the Site.

8. Qualifications Statements:

a. SYSTEM INTEGRATOR. b. SUPPLIER.

c. Manufacturers, when required by ENGINEER.

C. Closeout Submittals: Submit the following:

1. Furnish Operations and Maintenance Manuals for the MCS in accordance Section 01 78 23, Operation and Maintenance Data and the supplemental requirements as follows:

a. Complete list of supplied system hardware parts with full model numbers referred to system part designations, including spare parts and test equipment provided.

b. Copy of all approved submittal information and system Shop Drawings as specified herein with corrections made to reflect actual system as tested and delivered to the site for installation. Half-size black line reproductions shall be provided for all Shop Drawings larger than 11 by

17-inches.

c. Complete up-to-date system software documentation.

d. Manufacturer's Original Copies of Hardware, Software and Installation, Assembly and Operations Manuals for the distributed control system central monitoring station and peripheral devices, and all other control system components. Manuals shall include the following information:

1) General descriptive information covering the basic features of the equipment.

2) Physical description covering layout and installation requirements and all environmental constraints.

3) Functional and operational descriptions covering the procedures for programming, operation, start-up, shutdown, and calibration of the distributed control system equipment and explaining how the various control functions are performed.

4) Principles of operation explaining the logic of operation; provide information covering operation to a component level.

5) Maintenance procedures covering checkout, troubleshooting, and servicing; checkout procedures shall provide the means to verify the satisfactory operation of equipment, troubleshooting procedures shall serve as a guide in determining faulty components and servicing procedure shall cover requirements and recommended time schedule for calibration, cleaning, lubrication and other housekeeping and preventive maintenance procedures.

6) Wiring, schematic and logic diagrams.

7) Safety considerations relating to operation and maintenance procedures.

2. Record Documentation:

a. CONTRACTOR shall revise all system Shop Drawings, submittals, and software documentation to reflect as-built conditions in accordance

with the requirements of the Section 01 78 39, Record Documents and the supplemental requirements below. CONTRACTOR shall obtain the services of the SYSTEM INTEGRATOR and other SUPPLIERS to assist with these requirements.

b. Five copies of all revised Shop Drawings and documentation shall be submitted to the ENGINEER to replace out-dated drawings and documentation contained in the System Operation and Maintenance Manuals. Half-size black line sets shall be provided for all drawings larger than 11 by17-inches. Specific instructions for out-dated drawing removal and replacement shall be provided with the Record Drawing submittal.

c. Half-size black line prints of wiring diagrams applicable to each control panel shall be placed inside a clear plastic envelope and stored in a suitable print pocket or container inside each control panel.

d. Markups shall be maintained and submitted electronically; hand drawn copies shall not be accepted.

e. Prior to commissioning, CONTRACTOR shall furnish to ENGINEER three copies of an installation inspection report certifying that all equipment has been installed correctly and is operating properly. The report shall describe the inspection and test procedure and include any repairs, modifications or other work performed during the factory test and commissioning. The format of the report shall be submitted for review and approval prior to notification of commencement of any test or loop check. CONTRACTOR shall provide two weeks notice to ENGINEER of intent to commence testing. The report shall be signed by the CONTRACTOR and the system Supplier’s authorized manufacturer’s representative.

1) Loop/Component Inspections and Test Report: Each loop shall have a Loop Status Report to organize and track its inspection, adjustment, and calibration. These reports shall include the following information and checkoff items with spaces for signoff by the system Supplier:

a) Project Name. b) Loop Number.

c) Tag Number for each component in each loop. d) Checkoffs/signoffs for each component.

i)Tag/Identification ii)Installation iii)Termination – wiring iv)Calibration/Adjustment

2) Checkoffs/signoffs for the loop:

a) Panel interface terminations b) I/O interface terminations

c) I/O signal operation

d) Inputs/outputs operational: received/sent processed, adjusted

e) Total Loop operation

3) Summary of Functional requirements for each component: a) For indicators and recorders: Scale and chart ranges b) For transmitters/converts: Scale and chart ranges

c) For computing Elements: Function

d) For controllers: Action (direct/reverse) control modes (PID)

e) For switching elements: Unit range, differential

(FIXED/ADJUSTABLE), reset (AUTO/MANUAL)

f) For I/O Modules: Input or output

4) Calibrations:

a) For analog Devices: Required and actual inputs and outputs at 0, 25, 50, 75, and 100 percent of span, rising and falling.

b) For Discrete Devices: Required and actual trip points and reset points

c) For Controllers: Mode Settings (PID)

d) For I/O modules: Required and actual inputs or outputs for

0, 25, 50, 75, and 100 percent of span, rising and falling.

5) Space for comments

6) Space for signoff by MCS Supplier

f. CONTRACTOR shall submit to the ENGINEER certified calibration certificates for field instruments and devices specified in Section 40 70

05, Primary Sensors and Instruments, and panel mounted devices specified in Section 40 78 00, Panel Mounted Instruments and Devices, prior to start up.

1) Receipt of any calibration certificate shall in no way imply acceptance of any work or instrument.

2) The calibration certificates shall be prepared and submitted by the CONTRACTOR and shall contain the information shown on the sample calibration certificate included at the end of this section.

3) Each calibration certificate shall be signed and dated by the authorized manufacturer’s representative and the CONTRACTOR. Completed certificates shall be submitted to ENGINEER.

g. Prior to startup and commissioning, the entire installed instrument and control system shall be certified that it is ready for operation. All preliminary testing, inspection, and calibration shall be complete and documented. The system Supplier shall submit a written letter stating the system is “READY” for operation.

h. At conclusion of startup and commissioning, CONTRACTOR shall submit a written letter stating that all equipment has been commissioned correctly and is operating properly.

1) Prepare and submit record documents in accordance with Section

01 78 39, Record Documents.

2) Revise all MCS Shop Drawings to reflect as-built conditions in accordance with the following.

a) Use "as-built" updates of approved Shop Drawings and submittals in operation and maintenance manuals.

b) Half-size black line prints of wiring diagrams applicable to each control panel shall be placed in clear plastic envelopes inside a suitable print pocket or container inside each control panel.

c) Submit drawings of the point-to-point interconnection wiring diagrams updated to reflect final as-built equipment information and as-installed field installation information.

D. Maintenance Materials Submittals: Submit the following:

1. Spare Parts and Test Equipment a. General

1) Furnish the spare parts and test equipment in accordance with the Contract Documents, identical to and interchangeable with similar materials and equipment provided for the MCS as part of the Work.

2) Provide source quality control for spare parts as part of factory testing prior to shipment of process control system equipment.

3) For process sensors and other analog instruments, SUPPLIER shall submit a separate quotation for recommended list of spare parts and test equipment. Separately list and price each item recommended. Spare parts quotation shall include a statement that prices quoted

are valid for a period of one year from date of equipment installation and that SUPPLIER understands that OWNER reserves the right to purchase none, any, or all parts quoted. Upon request, SUPPLIER shall submit documentation that stock of spare parts and test equipment is obtainable within 48 hours of receipt of

OWNER’s order.

b. Furnish the following spare parts:

1) Five of each type of relay (control relay, time delay relay, and current alarm relay) for each quantity of forty or fraction thereof provided as part of the Work.

2) One of each type of PAC input/output module or card used.

3) One of each type of PAC communication module or card used.

4) One replacement power supply for each type and size provided as part of the Work.

5) One-year supply of all expendable or consumable materials.

6) One per quantity of five or fraction thereof of gauges, indicators, switches, and limit switches provided, complete with extension arms, diaphragm seals, filled and ready to use.

7) One per quantity of ten or fraction thereof provided, per range of field instruments including insertion type instruments. No spares are required for inline instruments such as magnetic flow meters and flumes or venturis that include flow tubes through which flow is conveyed.

8) One per quantity of ten or fraction thereof provided of sensors and targets including, but not limited to, all sensors and targets used in the chain and flight monitoring system.

9) Twelve of each type and size of fuse used in panels and instruments.

10) Six of each type and size of breaker used in panels and instruments. c. Furnish the following test equipment:

1) One of each set of special tools required to insert, extract, and connect internal or external connectors, including edge connectors.

3) One set of special calibration equipment required for system calibration.

d. Furnish the following communicators, drivers, and software:

1) Provide two sets of all tools including, but not limited to, communicators, remotes, and similar devices. Provide software and drivers available from the manufacturer for all instrumentation.

The software functions include, but are not limited to, configuration, communication, testing, calibration, verification, troubleshooting, diagnostics, and printing.

1.8 DELIVERY, STORAGE, AND HANDLING

A. CONTRACTOR shall make all arrangements for transportation, delivery, and storage of the equipment and materials in accordance with Section 01 60 00, Product Requirements, of the system SUPPLIER, and requirements of equipment manufacturers.

B. Prior to packaging, each manufacturer or SUPPLIER shall securely attach tag number and instructions for proper field handling and installation to each instrument.

C. MCS equipment shall be packaged at the factory, prior to shipment, to protect each item from damage during shipment and storage. Containers shall be protected against impact, abrasion, corrosion, discoloration, and other damages. Clearly label contents of each container and provide information on the required storage conditions necessary for the equipment.

D. CONTRACTOR shall make arrangements to store MCS equipment in accordance with Section 01 60 00, Product Requirements and manufacturer’s instructions and relevant organization standards. SUPPLIER shall notify CONTRACTOR, in writing, with copies to OWNER and ENGINEER of the storage requirements and recommendations for the equipment prior to shipment.

_{PART 2 – PRODUCTS}

2.1 GENERAL PROVISIONS FOR PRODUCTS

A. Power Supplies:

1. All electrically-powered equipment and devices shall be suitable for operation on 115-volt plus-or-minus 10 percent, 60 Hertz plus-or-minus two Hertz power. If different voltage or closer regulation is required, provide suitable regulator or transformer.

2. Provide appropriate power supplies for all two-wire transmitters, loops for monitoring discrete inputs and necessary outputs. Install power supplies mounted in enclosures, and install in appropriate control room or field panel.

3. Power supplies shall be suitable for minimum of 130 percent of the maximum simultaneous current draw.

4. Provide power on-off switch or air circuit breaker for each item requiring electrical power.

5. Provide isolation transformers, line voltage regulators and power distribution panels for the distributed digital portions of the MCS to eliminate electrical noise and/or transients entering on the primary power line.

B. Signal Requirements:

1. Unless otherwise shown or indicated in the Contract Documents, control system shall be furnished to use 4 to 20 mA DC analog signals with HART protocol.

2. Provide signal converters and repeaters where required. Analog inputs to distributed control system shall be through appropriate repeaters to provide signal isolation where series-looped with other devices and to allow loop to maintain integrity even when distributed control system is out of service. Power supplies shall adequate for signal converter and repeater loads.

3. Signals shall be isolated from ground.

4. Signals shall not have a transient DC voltage exceeding 300 volts over one millisecond nor a DC component over 300 volts.

5. The system and associated input/output wiring will be used in a facility environment where there can be high-energy AC fields, DC control pulses, and varying ground potentials between the sensors/transducers or input contact locations and system components. The system design shall be adequate to provide proper protection against interferences from all such possible situations.

C. Miscellaneous:

1. Instrumentation and MCS components shall be heavy-duty types, suitable for continuous service in a municipal wastewater treatment plant environment. Furnish products that are currently in production at the time products are shipped from the factory. All equipment furnished shall be of modular construction and be capable of field expansion through installation of plug-in circuit cards and additional cabinets as necessary. Logic and control loops shall be fail-safe.

2. Instrumentation and other MCS components shall return automatically to accurate measurement within 15 seconds upon restoration of power after a power failure, and when transferred to standby power supply.

3. Provide surge protection for instruments and all other MCS components that could be damaged by electrical surges.

4. Field-mounted instruments and MCS components shall be suitable for installation in humid and corrosive service conditions. Field-mounted instrument enclosures, junction boxes, and appurtenances shall comply with NEMA 4X requirements, unless otherwise shown or specified.

5. Relays with interconnections to field devices shall be wired through terminal blocks. Terminals as part of the relay base are unacceptable.

6. Panel mounted instruments, switches, and other devices shall be selected and arranged to present a pleasing coordinated appearance. Front-of-panel- mounted devices shall be of the same manufacturer and model line.

7. All components furnished, including field-mounted and rear-of-panel instruments, shall be tagged with the item number and nomenclature as shown and the instrument index in the Contract Documents.

8. Ranges and scales specified in the Contract Documents shall be coordinated to suit equipment actually furnished. Range, scale, and set point values specified in other Sections of Division 40 are for initial setting and configuration. Coordinate specified values with actual equipment furnished to implement proper and stable process action as systems are placed in operation.

9. Device circuitry shall be treated with conformal coating.

10. Field-mounted devices shall be protected from exposure to freezing temperatures.

D. Environmental Conditions:

1. MCS and its components shall be designed and constructed for continuous operation under the following temperature and humidity conditions:

a. Equipment and Devices Installed in Control Rooms:

1) Ambient Temperature: 60 degrees F to 80 degrees F normal range;

and 40 degrees F to 105 degrees F occasional maximum extremes.

2) Relative Humidity: 80 percent, normal; 95 percent maximum.

b. Equipment and devices installed at indoor locations (other than control rooms) for digital processing equipment hardware, control panels, and instruments:

1) Ambient Temperature: 40 degrees F to 120 degrees F.

2) Relative Humidity: 98 percent maximum. c. Equipment and Devices Installed Outdoors:

1) Ambient Temperature: -20 degrees F to 120 degrees F.

2) Relative Humidity: 100 percent maximum.

E. Refer to other Division 40 specifications for product requirements for materials and equipment that are part of the MCS.

PART 3 – EXECUTION

_{3.1 GENERAL PROVISIONS FOR EXECUTION}

A. Refer to other Division 40 specifications for execution requirements for the MCS.

3.2 ATTACHMENTS:

A. Refer to Appendix B of the contract for a listing of the contents of PLC PR, the Allen-Bradley PLC-5 which shall be replaced under this contract. Refer to and follow the requirements of Appendix C for the NEORSD Automation Standards and Conventions Manual, and refer to and follow the requirements of Appendix D for the NEORSD Object Library Users Manual.