This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.
SECTION 13320
GENERAL INSTRUMENTATION AND CONTROL SYSTEM
PART 1 GENERAL
1.1 WORK DESCRIPTION
A. This section covers work necessary for the design, documentation, assembly, test, installation, field testing, PLC Configuration, LCP HMI Configuration, Workstation configuration, startup, training, and final documentation for a Supervisory Control and Data Acquisition (SCADA) system upgrade for the DES PLAINES RIVER WRF PHASES 2B & 3 IMPROVEMENTS project.
B. This section covers work necessary for the design, documentation, assembly, test, installation, field testing, startup, training, and final documentation for the Instrumentation and Control system for the DES PLAINES RIVER WRF PHASES 2B & 3 IMPROVEMENTS project.
C. When "SCADA" is used in the specifications it means Supervisory Control and Data Acquisition System as well as Instrumentation and Control System.
D. When "Instrumentation and Control System" is used in the specifications it means Instrumentation and Control System as well as Supervisory Control and Data Acquisition System.
E. The upgraded SCADA system will monitor and provide supervisory control for the entire Wastewater Reclamation facility and interface with the devices on the existing SCADA system not replaced in this upgrade.
F. The SCADA system provider shall be responsible for providing and integrating systems specified in this section and the following sections:
1. Section 13321: SCADA COMPUTERS AND SOFTWARE
2. Section 13322: PLC SYSTEMS
3. Section 13323: HMI SYSTEMS
4. Section 13324: SOFTWARE CONFIGURATION AND TESTING REQUIREMENTS
5. Section 13325: CONTROL PANEL ENCLOSURE CONSTRUCTION
6. Section 13326: CONTROL PANEL MOUNTED INSTRUMENTS AND DEVICES
7. Section 13327: FIELD MOUNTED INSTRUMENTS AND DEVICES
G. Major components of this system shall include the specified software, materials, equipment, and installation required to implement a complete and operational SCADA system along with any associated electrical enclosures, field mounted instrumentation and associated electrical work.
H. In order to achieve standardization for appearance, operation, maintenance, spare parts and manufacturer's service, to the greatest extent possible, like items of equipment provided hereunder shall be the end products of one (1) manufacturer.
I. Requirements for the electrical work associated with the installation of the system and associated instrumentation and control equipment are as specified in Division 16000 ELECTRICAL.
1.2 APPROVED SYSTEMS INTEGRATORS (Base Bid Named Suppliers)
A. Wunderlich Malec, Minnetonka, MN
B. Altronex - L.W. Allen, Inc., Madison, WI
C. Instrument Control Systems, Inc. - Plymouth, MN
D. Allan ICS – East Troy, WI
1.3 RESPONSIBILITY FOR COMPLETE SYSTEM
A. Systems integrator shall be the fabricator of the control panels.
B. The Systems Integrator shall be responsible for and shall provide for the design, supply, delivery, installation, certification, calibration, adjustment, software configuration, testing, startup, owner training, warranty and routine future field services, of a complete coordinated SCADA system which shall perform the specified functions.
C. The Systems Integrator shall coordinate all signal and electrical interfaces to the SCADA system for all Division 11000, Division 13000, Division 14000, Division 15000 and Division 16000 equipment vendors. Contractor shall be responsible for keeping the Systems Integrator informed.
1.4 COMPUTER SYSTEM ARCHITECTURE AND NETWORK CONFIGURATION
A. The existing SCADA system utilizes a networked PLC architecture for the plant control system. Allen Bradley PLC hardware is used to incorporate I/O signals in each process area. An HMI system, utilizing Wonderware software package, provides the operator interface for the plant processes and remote pump stations. PLCs and the HMI system are connected via network communication. A Hardware dialer provides alarm notification for process alarms at the plant.
B. Provide new fiber optic network to replace the existing DH+ and Ethernet radio based network. The existing SCADA network will be maintained until the new fiber network has been installed, tested and accepted by the engineer and owner.
C. See drawings 09-I-26 and 09-I-33 through 09-I-37 for the new fiber optic network. Provide, install and commission the new network as shown on this drawing and as specified.
D. Provide Process Communication Panels (PCPs) as part of the new fiber optic network in each of the following buildings:
1.
10-PCP
Building 10 – Administration Building
2.
15-PCP
Building 15 – Control Building
3.
20-PCP
Building 20 – Raw Wastewater Pumping Station (Battery A)
4.
22-PCP
Building 22 – Raw Wastewater Pumping Station (Battery B)
5.
25-PCP
Building 25 – Grit Removal Building
6.
35-PCP
Building 35 – Blower Building
7.
45-PCP
Building 45 – RAS/WAS Building
8.
50-PCP
Building 50 – Filter Building
9.
55-PCP
Building 55 – Sand Filter Building
10.
60-PCP
Building 60 – Dryer Building
11.
75-PCP
Building 75 – Dechlorination Building
12.
80-PCP
Building 80 – Sludge Storage and Fermentation Building
13.
90-PCP
Building 90 – Sludge Dewatering Building
14.
99-PCP
Building 99 - Pekara Water Pump Station
E. All fiber optic cables which run between buildings shall be terminated in Fiber Optic Interconnection Centers (FOICs) within the PCPs as shown on the drawings and specified herein. All fibers in each fiber optic cable shall be terminated and tested with ST type connectors at the Interconnection Centers. Spare Fibers are to be tested, numbered and labeled as spares. See specification Section 16483 for fiber optic network requirments.
F. See drawing 09-I-25 for the existing SCADA systems network layout. After the new network is commissioned, operating and providing communications for the SCADA system all components designated for removal shall be removed and turned over to the owner.
G. Provide new PLCs for the WWTP as shown on the P&IDs and as shown on Network Diagrams. The existing SCADA system MicroLogix and CompactLogix PLCs will be maintained. The existing SCADA system SLC-500 PLCs will be replaced with new Compact Logix PLCs. See drawings 09-I-27 through 09-I-32 and drawings 09-I-35 through 09-I-37 for SLC-500 PLC removals and replacements with Compact Logix PLCs.
H. Provide new Allen Bradley CompactLogix control panels (LCPs) as part of the SCADA system at each of the following locations:
1. 50-LCP-5-2
2. 60-LCP-11-2
3. 80-LCP-7-2
4. 90-LCP-8-18
5. 90-LCP-8-19
I. Replace existing SLC-500 PLCs with new Allen Bradley CompactLogix PLCs at each of the following locations:
1. 10-LCP-1-1 formerly 10-RTU-1 and MAIN SCADA
2. 20-LCP-1-8 formerly 20-RTU-2
3. 20-LCP-AFD
4. 20-LCP-AFD
5. 35-LCP-3-6 formerly 35-RTU-4
6. 35-LCP-7-4
7. 45-LCP-4-7
8. 50-LCP-5-5
9. 50-LCP-6-3
10. 75-LCP-6-1
11. 90-LCP-8-16
12. 90-LCP-5-18 formerly 90-RTU-6
The existing PLCs will be maintained until the new PLCs has been installed, tested and accepted by the engineer and owner.
J. The following PLC based Local Control Panels (LCPs) are to be added to the plants new fiber optic SCADA Network as packaged control panels which are provided as part of the equipment specified under division 11000, 13000, 14000 and 15000 specifications as follows:
1. 25-LCP-2-1
2. 50-LCP-5-17
3. 50-LCP-5-18
4. 50-LCP-5-19
5. 60-LCP-11-1
6. 60-LCP-11-3
7. 60-LCP-11-17
8. 60-LCP-11-20
9. 60-LCP-12-6
K. Fiber Optics shall be utilized as the communications medium between all buildings containing PLCs; new, upgraded, and existing.
L. Provide all equipment necessary to interface the new Fiber Optic System Network to the new, upgraded and existing PLC. Required equipment includes but is not limited to PLC processor additions, Remote I/O Rack additions, media converters, switches, etc.
1.5 UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM
A. A UPS system shall be supplied for each PCP and LCP.
B. The UPS shall be sized to power the entire system for one hour.
C. UPSs shall be located within PCPs and LCPs.
D. All PCPs and LCPs shall be powered by UPS systems.
1.6 SUBMITTALS
A. Hardware Submittals:
1. Before any components are fabricated, and/or integrated into assemblies or shipped to the job site, furnish to the Engineer for their review submittal documents in accordance with Section 01330. Submittals shall include full details, shop drawings, catalog cuts and such other descriptive matter and documentation as may be required to fully describe the equipment and to
demonstrate its conformity to these specifications. Specifically, the Contractor shall submit the following materials:
2. Provide block diagrams and operational descriptions of the system showing all major components and their interconnections and interrelationships. Label each diagram and specify all external power and communications interfaces. All diagrams shall be in an 11 by 17 format.
3. Drawings of equipment to be supplied shall include, as a minimum: overall dimension details for each panel, console, etc., including internal and external arrangements and door mounted operator devices with nameplate designations. Wiring diagrams of equipment including field device connections shall be included and specific installation/wiring requirements identified.
4. Operational Description shall include the principal functions/capabilities of the personal computers and PLC’s as provided and configured /programmed. Included shall be a description of system communications.
5. Provide a detailed Bill of Materials along with descriptive literature identifying component name, manufacturer, model number, and quantity supplied.
B. Software Submittals:
1. Provide complete user manuals for all supplier configured software and firmware. For ancillary software such as operating systems, spreadsheets, etc. being supplied under this contract, only a listing of the manuals which will be included with the Operations and Maintenance documentation is required.
2. Sample communication and control database programs for project in hardcopy form. As a minimum, hardcopy form shall be fully documented, including code, comments, addressing data and cross-references, etc. Every line or section of code shall be accompanied by a comment describing its function.
3. Provide initial graphic display and report format layouts as described later in this specification. List and briefly describe all operator interface functions provided at the PC, including: alarm annunciation and acknowledgment, status displays, control capabilities, report generation, event logging, charting and trending, etc.
C. Additional PLC Replacement Submittals:
1. For each LCP listed for PLC replacement, before any PLC components are added or removed, identify all existing I/O on existing PLC(s) and furnish a list to the Engineer and Owner for their review.
2. In LCPs listed for PLC replacement, before any PLC components are added or removed , compare I/O list to PLC program and the main plant SCADA HMI database. Furnish list to the Engineer and Owner for their review.
3. In LCPs listed for PLC replacement, before any PLC components are added or removed, provide a written change-out procedure for each to the Engineer and Owner for their review.
D. Test Outlines and Procedures Submittals
1. Test descriptions shall be in sufficient detail to fully describe the specific tests to be conducted to demonstrate conformance with this specification.
E. Spares and Expendable Recommendations
1. The Contractor shall provide a list of recommended spares and expendable items. The list shall be exclusive of any spares furnished under this Contract. A total
purchase cost for the recommended list shall be provided in addition to the unit cost for each item.
1.7 ON SITE SUPERVISION
A. The Contractor shall provide experienced personnel to supervise, perform, and coordinate the installation, adjustment, testing, and startup of the system. The personnel shall be present on-site as required to affect a complete and operating system.
1.8 TESTING AND STARTUP
A. All elements of the SCADA system shall be tested to demonstrate that the total system satisfies all of the requirements of this Specification. All special testing materials and equipment shall be provided by the Contractor. The Contractor shall coordinate and schedule all of his testing and startup work with the Owner. As a minimum, the testing shall include both a factory test and a field test. Testing requirements are as follows:
1. Factory Tests
a. The Computer System with peripherals, PLC’s and all other associated hardware shall be tested at the factory, prior to shipment, so as to demonstrate that each component is operational and meets the requirements of these specifications. Test results shall be certified, with written documentation provided to the Owner and Engineer upon test completion. Owner and Engineer shall be notified at least two weeks in advance of Factory Testing. Factory Test may be witnessed by Owner and/or Engineer.
2. Field Tests
a. All system components shall be checked to verify that they have been installed properly and that all terminations have been made correctly. Witnessed field tests shall be performed on the complete system. Each function shall be demonstrated to the satisfaction of the Owner and Engineer on a paragraph-by-paragraph basis.
b. Each test shall be witnessed and signed off by the Contractor and the Engineer upon satisfactory completion. The Contractor shall notify the Owner at least two (2) weeks prior to the commencement date of the field tests.
1.9 GENERAL TRAINING
A. The training program shall educate operators, maintenance, engineering, and management personnel with the required levels of system familiarity to provide a common working knowledge concerning all significant aspects of the system being supplied. The training program shall consist of five 8-hour days. Both classroom-type and field site sessions shall be provided. At least two weeks prior to the requested start of the program, the proposed dates of training shall be submitted to the Owner and the Engineer for approval. The training shall be specific to the instrumentation being provided and shall be specific to topics required by the Owner.
B. The supplier shall provide all instructional course material, equipment and manuals to conduct the training program. Owner shall provide facilities for the training.
1.10 ALLEN BRADLEY FACTORY TRAINING
A. A week long Allen-Bradley Compact Logix PLC training course shall be provided for 3 of the owners SCADA maintenance personnel. Integrator shall provide location options to owner. Integrator shall pay all travel and lodging expenses for the owners personnel training.
B. A week long Wonderware training course shall be provided for 3 of the owners SCADA maintenance. Integrator shall provide location options to owner. Integrator shall pay all travel and lodging expenses for the owner personnel training.
C. A 3 day Allen-Bradley Panelview Plus training course shall be provided for 3 of the owners SCADA maintenance. Integrator shall provide location options to owner. Integrator shall pay all travel and lodging expenses for the owner personnel training.
1.11 OPERATION AND MAINTENANCE MANUALS
A. The Contractor shall provide (4) complete sets of hard-covered ring bound loose-leaf O&M manuals. In addition to “as-built” system drawings, the manuals shall include internal wiring diagrams and operating and maintenance literature for all components provided under this section. Drawings to be updated after acceptance of testing and O&M Manual updates provided to owner. Also provide AutoCAD files for all drawings on compact disk.
B. The submitted literature shall be in sufficient detail to facilitate the operation, removal, installation, programming and configuration, adjustment, calibration, testing and maintenance of each component and/or instrument.
C. Operation and Maintenance manuals shall include hard copies of all PLC and HMI programs written to accomplish the monitoring control and testing functions specified. Programs shall be updated after testing is complete, with the program(s) provided to the Owner on Compact Disk and flash memory stick or SE card. Four (4) copies to be provided.
D. The contents of the O&M manuals shall be generally organized as follows:
1. System Hardware/Installation
2. System Software
3. Operation
4. Maintenance and Troubleshooting
1.12 DEFINITION OF ACCEPTANCE
A. System acceptance shall be defined as that point in time when the following requirements have been fulfilled:
1. All O&M documentation has been submitted, reviewed and approved.
2. The complete SCADA system has been successfully completed with all testing requirements completed.
3. All Owner's staff personnel training programs have been completed.
4. Owner/Engineer sign a document indicating the SCADA system has formally been accepted.
PART 2 PRODUCTS
2.1 GENERAL
A. The functions and features specified herewith are the minimum acceptable requirements for the Instrumentation and Control system. The provided system shall equal or exceed each requirement.
B. In some cases, the specifications may allow the accomplishing of certain functions by means of more than one hardware/firmware/software approach. Any approach that is proposed shall equal or exceed all functional, operational, convenience and maintenance aspects of the one described.
C. Major equipment, component and software items are specified; however the Contractor shall, at no additional cost, provide all appurtenant items, whether specifically referenced herein or not, but which may be required for operation as hereinafter specified.
PART 3 EXECUTION
3.1 GENERAL
A. Coordinate all work with the engineer/owner to avoid conflicts, errors, delays and unnecessary interference with operation of the existing system during installation, testing, cutover and startup.
B. Install all new equipment in accordance with the manufacturer's instructions and approved submittals.
END OF SECTION
SECTION 13321
SCADA COMPUTERS AND SOFTWARE
PART 1 GENERAL
1.1 This specification covers the technical requirements for the fabrication, engineering, wiring and installation for the SCADA computer and SCADA software system.
1.2 SUBMITTALS
A. Submittals shall be as specified in the following specification sections:
1. General Conditions
2. Section 13320: GENERAL INSTRUMENTATION AND CONTROL SYSTEM
PART 2 PRODUCTS
2.1 SCADA COMPUTER HARDWARE
A. Computers and Peripherals
1. Provide (6) new computer systems to function as workstations for SCADA monitoring and control system for the locations as listed below:
a. Administration Building 10 Control Room
b. Administration Building 10 Conference Room
c. Raw Wastewater Pumping Station Building 20 Electrical Room
d. Filter Building 50 Electrical Room
e. Dryer Building 60 Electrical Room
f. Sludge Dewatering Building 90 Electrical Room
2. Each computer hardware system shall consist of a CPU, minimum 2 TB SATA hard disk drive, Optical disk drive that supports DVD+/- RW, and a telephone modem.
3. A minimum of 2 serial ports and 6 USB ports or 8 USB ports with 2 USB to serial adapters shall be provided.
4. All computer hardware must be listed on the Windows 7 and Windows 8 compatibility list published by Microsoft Corporation.
5. ROHS Compliant Lead Free Motherboard and Chassis.
6. 16 GB Memory Minimum. Memory to be 1600 Mhz minimum.
7. 100 Mbps Ethernet adapter.
8. 3 Year Warranty on all computer hardware.
9. Power provided to the computer and its peripherals will be 120 VAC, 3 wire, 60 Hz. Computer shall be capable of operating satisfactorily in an ambient temperature range of 40 to 100 F with a relative humidity of 5 to 85% non- condensing.
10. Keyboard, Mouse and Speakers to match manufacturer of Computer.
11. All necessary communications and power cabling and/or cords between the PC, PCC, PLC, UPS and all peripheral equipment shall be included. Provide surge protected power bar(s) as required.
12. Tower type PC layout.
B. CPU
1. Computer shall be a 64 bit unit in an ATX configuration. CPU shall be an Intel Core i7-3.0 GHz or better. Power supply shall be at least 500 watts.
2. Included shall be an industry standard 101 key QWERTY type keyboard. Keyboard shall include 12 programmable function keys, an 18 key numeric keypad and separate cursor and screen editing keys. Indicating lights shall be included on the keyboard to indicate the current status of the Cap Lock, Num Lock and Scroll Lock functions.
3. An optical scroll mouse shall be provided to operate in conjunction with the Main Video Display to allow the selection of operational tasks, eliminating most typing functions, and saving operator time.
C. Disk System
1. Hard disk drive system shall contain as a minimum one 2 TB SATA Drive, 6Gb/s 7200 RPM.
2. DVD +/-RW disk drive shall mounted on front of computer.
D. Video Display System
1. Owner provided monitors.
E. Modem
1. Provide internal or external modem as recommended by Dialer Manufacturers.
F. Approved Manufacturers
1. Dell
2. HP
2.2 OPERATING SYSTEM
A. Operating system for computer shall be MS-Windows 8 Enterprise R2 SP1.
B. Provide Anti-Malware, antivirus software with three year license to protect the computer system. Norton internet security package or as directed by Owner.
C. Upon delivery of computer systems, each computer shall be turned over to owner for Hard Drive backup imaging. After owner has completed imaging, computers will be returned to systems integrator for Wonderware software load and SCADA system configuration.
2.3 PRINTER SYSTEM
A. Owner provided printer.
2.4 COMPUTER BACKUP SYSTEM
A. Provide one Western Digital My Passport 1TB, 7200RPM USB 3.0 external hard drive to backup each SCADA Computer.
B. Provide latest version of Symantec Ghost Backup software for the SCADA Computer to allow external hard drive to backup the computer.
2.5 SCADA SOFTWARE
A. Owner shall provide licensed copies of Wonderware InTouch for contractor loading and configuration.
B. PLC and Computer shall be programmed to recreate all existing screens, alarms, and reporting on existing SCADA Computer.
2.6 SYSTEM COMPUTER SCADA SOFTWARE
A. Load and configure owner provided license copies of Wonderware InTouch on each Workstation Computer.
B. Provide, load, and configure one licensed copy of Rockwell Win-911/Pro 2014 on Administration Building 10 Control Room Workstation Computer.
C. Provide copies of all other required software and configuration services to reproduce the Display Screens, Trends, and Reports from existing SCADA computers to new Workstations.
PART 3 EXECUTION
3.1 GENERAL
A. Coordinate all work with the engineer/owner to avoid conflicts, errors, delays and unnecessary interference with operation of the existing system during installation, testing, cutover and startup.
B. Install all new equipment in accordance with the manufacturer's instructions and approved submittals.
END OF SECTION
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