04_140R2024R0017_Part2_of_18_0004.pdf

Sack Dam Fish Passage Central Valley Project, California Specifications No. 20-C0936

Process Control System Description

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SECTION 40 61 96

PROCESS CONTROL SYSTEM DESCRIPTION

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Payment: Include in the lump sum price offered in the Price Schedule for Process Control System.

1.02 REFERENCE STANDARDS

A. National Fire Protection Association, Inc. (NFPA)

1. NFPA 70-2023 National Electrical Code (NEC)

B. National Institute of Standards and Technology (NIST)

1. NIST SP 800-82 Rev2-2015 Guide to Industrial Control Systems (ICS) Security

1.03 DEFINITIONS

A. AI: Analog Input.

B. AO: Analog Output.

C. DI: Discrete Input.

D. DO: Discrete Output.

E. I/O: Input/Output

F. FCS: Facility Control System

G. O&M Building: Operation and Maintenance Building.

H. OIT: Operator Interface Terminal.

I. PLC: Programmable Logic Controller.

J. SCADA: Supervisory Control and Data Acquisition.

1.04 GENERAL REQUIREMENTS y

A. Provide an overall Facility Control System (FCS) for Sack Dam headwork structure, fish screen, and O&M building. The system shall be the primary control, monitoring, and

40 61 96 - 2 automation system for the gates, fish screen air burst system, manufacturer supplied brush cleaning system PLC, instruments, and associated equipment.

1. Control, data, and monitoring requirements:

a. Identified in these Specifications and supplied drawings.

b. Render complete, and functional, system which meets, at minimum the functional intent and requirements stated herein.

c. Provide safe and reliable operation of facility components under all conditions.

d. Incorporate, at a minimum:

1) Control and monitoring of the slide gates identified in Section 35 22 11 – Multi Disc Slide Gates and Fish Ramp Sill Plates.

2) Control and monitoring of the overshot gates identified in Section 35 22 10 - Overshot Gates.

3) Control and monitoring of the fish screen cleaner system as identified in Section 35 21 63 - Fish Screen Brush Cleaning System.

4) Control and monitoring of the fish screen air burst system as identified in Section 22 15 50 – Air Burst Cleaning System.

5) Monitoring of level and flow sensors as identified in Section 33 09 16 -Water Level Measuring Devices.

6) Hardwired and Datapoint I/O as defined in Section 40 61 93 – Process Control System Input/Output List.

7) Control and monitoring equipment as required in Section 40 63 00

– Process Control System Equipment and Section 40 67 00 – Process Control System Equipment Panels and Racks.

8) General facility monitoring, including, but not limited to, engine generator status, loss of power status, panel intrusion switches, door switches, and general alarms.

e. Interface with control components supplied with packaged systems, like the Fish Screen Brush Cleaning System and gate actuators to implement required control functions

2. Fully integrated startup, shutdown, and online control system.

B. Provide configuration and programming activities required for a complete and functional system.

C. Capability for remote control and monitoring from an external SCADA system.

Government will furnish and install all remote communication equipment upon successful installation of the control system as demonstrated in the site acceptance test as per Section 01 91 13 - Commissioning.

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D. Facility Control System shall act as primary control system for contractor-supplied components.

E. Interface with systems and control components through hardwired I/O signals or serial datalinks as required.

F. Fully integrated system, include the following minimum features:

1. Processing units, I/O components, network and communication components, power supplies and other miscellaneous control components.

2. Operator and engineering interface.

G. Provide system software and hardware components not explicitly listed but essential for system to meet functional requirements of these Specifications.

1.05 DESIGN REQUIREMENTS

A. Equipment Communication Links:

1. Use of routable communication protocols, including Ethernet, is prohibited.

2. Use serial communications, such as Modbus RTU, for interconnecting equipment digital control components to Facility Control System.

B. Develop system architecture, arrangements, and layout of system components.

C. Program/configure control software required to make a fully functional system.

D. Provide I/O list, data-point list and alarm points list:

1. Refer to Section 40 61 93 – Process Control System Input/Output List, for initial information from which to develop final I/O lists, data-points lists and alarm points lists.

E. Provide control system programming, control logic, and control program macros:

1. Includes logic diagrams, schematics, OIT displays, and site component interface modifications.

2. Provided documentation and descriptions of final control system program configuration to include descriptions for each rung, block, or line of ladder diagrams, and function block diagrams and structured text logic.

F. Develop interface design schematics, datalinks, and other applicable items required for interfaces between components.

1.06 SYSTEM DESCRIPTION

A. Control Modes:

1. Local/Remote Control:

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a. Provide a soft local/remote switch viewable and selectable on the control system OIT.

b. When in ‘Local’ mode:

1) Control accomplished at the OITs.

2) Allows operator to change settings and send control commands to components from the OITs.

3) Maintains ability to perform automated control of components where possible.

4) All remote-control signals from external systems are disabled.

c. When in ‘Remote’ mode:

1) Allows control system to be controlled from external remote systems located outside of the facility.

2) Control interface to future Government SCADA system.

3) Operators shall still be able to navigate through the graphic display on the OIT for system indication and status information.

d. Designed to provide bumpless transfer between ‘Local’ and ‘Remote’ mode without the need for operator action or interruption of equipment operation.

2. Automatic/Manual Control:

a. These control modes shall be available for the following features:

1) Headwork structure slide gates and overshot gates.

2) Fish screen cleaner system.

b. Automatic:

1) Designed to eliminate the need for operator action except for set point changes, biasing, and similar actions during normal operation.

2) If a component, or system, is incapable of full automatic operation due to lack of electronic control interfaces with physical components, or operating concerns for a specific piece of equipment, the system shall be automated to the extent possible.

3) Includes automatic start/stop capability to automatically start and stop components, including proper sequencing of component operation to prevent damage or premature aging of the equipment.

c. Manual:

1) Allows the operator to step through system operating sequence.

2) Allows the operator to individually control each component controlled by the control system.

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d. Designed to provide bumpless transfer between automatic and manual operation without the need for operator action or interruption of equipment operation.

B. Monitoring and Alarming:

1. Where monitoring or alarming are required include at a minimum:

a. Monitoring:

1) Display information received from end devices on graphic displays. Display information in units of process measurement where applicable.

2) At a minimum display information listed in the I/O lists and in the provided Specifications.

b. Alarming: Provide for levels that would indicate pre-trip and trip conditions in the process system. For example, include Low, Low-Low, High, and High-High alarm conditions as applicable.

c. This does not preclude additional functionality required by other requirements in Specifications or required system functionality.

C. Monitor and provide alarming for all instruments and devices shown interfacing with control system on supplied Piping and Instrumentation Diagram drawings, schematic and connections diagrams, I/O lists, and where Specification’s reference interfaces with PLCs or control systems and the following additional equipment:

1. Status alarms for control system equipment.

2. DC and UPS power system equipment.

D. Instrumentation:

1. Where redundant instrumentation, or feedback on the same process variable exists implement automatic fail over to operate the control system based on the feedback from the alternate instrument in the event of instrument or feedback failure.

2. Alarm when redundant feedback from instrumentation on the same process variable varies from each other more that an operator settable range.

E. Controls:

1. Designed to aid the operator over the complete operating range of the facility while the controlled equipment is in service. Incorporate all available and configurable parameters used to control the equipment within manufacturer’s equipment limitations and enhance equipment life into the design.

2. Provide modifiable setpoints and control variables, including operator adjustable setpoint deadbands, delays, alarm setpoints, and control setpoints that are modifiable by operator in the graphic displays:

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a. Include sufficient setpoints to allow operator adjustment of system through desired facility operating range.

b. All values referred to as ‘setpoints’ in these Specifications: Modifiable from the graphic displays.

3. Provide control logic to detect and mitigate bad quality or out of range signals.

Logic shall drive devices to a safe state, substitute a value, or hold last value as appropriate for application.

4. Upon initial system power up or system power restoration, all systems shall be in manual with outputs in “off” or fail-safe mode.

5. Implement safety interlocks to prevent or stop operation outside of the control system component and gate limits.

6. Monitor equipment operating status and alarm on equipment failures and failures to operate or maintain setpoint levels.

7. Include a system of interlocks to:

a. Minimize required operator intervention to prevent improper and hazardous system actions.

b. Incorporate interlocks to prevent equipment from operating in unsafe or potentially damaging conditions.

c. Incorporate permissive controls which ensure that the necessary conditions for safe operation are met prior to allowing the equipment to start, open, or close, as appropriate.

d. Provide maximum flexibility of system operation, maintenance, testing, and calibration while ensuring safe operating conditions.

8. Provide a manual mode to allow step-by-step manual control of all gate actuators and fish screen cleaning equipment.

9. Fault checking shall be included and generate appropriate control system response, component change over, and alarm upon detecting a system fault.

10. Gate Control

a. The control system shall not move more than two gates simultaneously.

In the event of loss of primary power, multiple gates shall not move simultaneously.

b. Include appropriate deadbands and other control techniques to minimize hunting and excessive gate operation from continuous small adjustments.

c. If the gate cannot be moved to a setpoint within the operator set time period, the control system should move the gate in the opposite direction one-tenth of a foot, then make another attempt to reach the setpoint. If setpoint is not reached then assert a gate fail alarm.

d. For the following gates, provide manual and automatic control listed below.

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1) Automatic control including implementing Upstream Water Surface Elevation (WSEL) Control.

2) Manual control shall include:

a) Position setpoint control to allow incremental control of the gate’s position to 0.5% the gate’s range of operation.

b) Gate control shall also include the following position options:

i. Full Close – The control system fully closes the chosen gate.

ii. Full Open – The control system fully opens the chosen gate.

3) Gates include:

a) 001-OG-310

b) 001-SG-320

c) 001-SG-330

d) 001-SG-340

e) 001-SG-350

f) 001-SG-360

g) 001-SG-370

h) 001-OG-380

e. For the following gates, provide manual control listed below.

1) Manual control shall include:

a) Position setpoint control to allow incremental control of the gate’s position to 0.5% the gate’s range of operation.

b) Gate control shall also include the following position options:

i. Full Close – The control system fully closes the chosen gate.

ii. Full Open – The control system fully opens the chosen gate.

2) Gates include:

a) 001-SG-410

b) 001-SG-420

c) 001-SG-430

d) 001-SG-440

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f. Upstream Water Surface Elevation (WSEL) Control:

1) Provide automatic control to maintain the water surface elevation upstream of Sack Dam Headworks Structure within an operator adjustable setpoint range. Control shall utilize the gates listed below to maintain this setpoint:

a) 001-OG-310

b) 001-SG-320

c) 001-SG-330

d) 001-SG-340

e) 001-SG-350

f) 001-SG-360

g) 001-SG-370

h) 001-OG-380

2) Upstream WSEL Control setpoint and feedback from associated level transmitters shall be displayed on the OITs using the same reference elevation coordinate system used on the drawings, ex. El 4175 feet, etc.

3) No features from the Fish Ramp, including the four Fish Ramp gates, shall be used for this level control.

4) WSEL Setpoint Control shall allow incremental control of the level to within an accuracy of plus or minus 0.1 foot over the upstream operating range.

5) Calculate the appropriate gate pulse to use to adjust the gates in water level control using pulse width modulation (PWM) to adjust the pulse width between maximum and minimum pulse setpoints.

6) Gates shall operate in master-slave configuration with operator settable master-slave gate sequence.

a) Gates shall operate by opening the gates in sequence with the primary gate opening first, followed by the secondary gate, through the sequence of gates.

b) Operator shall be able to set and adjust the sequence that the gates open in the OIT.

7) Automated WSEL level setpoint control use with feedback from the upstream Headworks Structure level sensors, LE-302 and LE-

305. Provide operator adjustable level setpoints, deadbands and time delays.

8) Provide a level setpoint failure warning and alarm if the level setpoint cannot be reached within the operator set time delays.

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9) If a gate fails, system shall automatically move to next gate in sequence. If the last gate in the sequence fails, provide a level setpoint failure warning and alarm.

10) Automatically adjust control system operation to accommodate gate failure or gates taken out of service. Any gates taken out of service, failed, or set to manual control shall be skipped in the gate sequence, but the control system shall continue to operate through the remaining gates in the gate sequence.

11) Minimum and Maximum Gate Openings

a) Each gate used in WSEL control Gates shall have gate minimum and maximum opening setpoints. These setpoints shall be in addition to the gate limit switch feedback from the gate actuators and shall be adjustable from the OIT.

b) Gates in WSEL control can be fully closed, but when open must be in a position between the maximum and minimum gate openings.

c) Gates control shall still include interlocks to the gate limit switches to automatically stop attempting to open or close the gate when the limit switches indicate that the gate is Full Open or Full Close.

11. Fish Screen:

a. Provide user adjustable setpoints for alarms for WSE differential across the fish screen .

1) Start Sweeping Setpoint: Set within a range between 0 and two feet.

2) Sweeper Differential High Alarm: Set within a range between 0 and two feet.

3) Sweeper Differential High Alarm: Set within a range between 0 and two feet.

4) Sweeper Differential Trip: Set within a range between 0 and two feet.

b. Utilize fish screen level sensors LE-102, LE-103, LE-105, and LE-106 as required by 33 09 16 – Water Level Measuring Devices to calculate WSE differential for the fish screen.

c. Provide a signal to the fish screen brush cleaner control panel to initiate an emergency brush cleaning for a high water differential across the fish

40 61 96 - 10 screen. Provide operator adjustable setpoints and time delays for high water differential setpoints.

1) Setpoints shall include separate setpoints to start brushing and stop brushing.

2) Control system shall output a ‘run’ output to the fish screen brush cleaner control panel.

d. Provide operator adjustable setpoints and time delay for high water differential alarms.

e. Display monitoring and alarm points identified in Section 35 21 63 – Fish Screen Brush Cleaning System.

f. Send a lockout signal to fish screen brush cleaner control panel to immediately stop brush cleaner. Lockout shall be able to be set by the operators on the OIT.

F. Emergency Stop:

1. HS-004 on the O&M control panel 001-CP-001:

a. Immediately stops and holds all of the facility gates in place until the E- Stop is reset.

b. Sends a lockout signal to the fish screen brush cleaner control panel.

2. HS-104 on the Fish Screen Control Panel:

a. Sends a lockout signal to the fish screen brush cleaner control panel.

3. HS-304 on the Headworks Structure Control Panel 001-CP-301:

a. Immediately stops and holds all of the facility gates in place until the E- Stop is reset.

4. Sends alarm to Main facility PLC upon activating.

G. Lockout/Tagout:

1. Lockout/Tagout shall provide the operator with the ability to lockout all individual gates and fish screen components.

2. Upon application of a lockout/tagout command, system shall automatically stop, or remove from service the selected component or system. This operation shall be performed regardless of control mode that system is in.

1.07 SUBMITTALS

A. Submit in accordance with Section 01 33 00 – Submittals and 01 33 26 – Electrical Drawings and Data.

A. RSN 40 61 96 -1, System Description Documentation:

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1. Describe and document the proposed control system, its features, and limitations, compliance with the requirements, operation, software algorithms, display screens, and software configuration.

2. Provide River Bypass gate automation description. Description to include general operation, interlocks, and system response to faults or gates being taken out of service.

3. Provide a description of hardware, software, control functions, interfaces, and general data flow associated with entire system.

B. RSN 40 61 96 -2, Approval Data - Software Development Documentation:

1. Data flow chart including variables.

2. Graphic display drawings (proposed LCD display and OIT touch panel) for each screen provided as part of OIT.

3. OIT graphical screenshots.

4. Logic diagrams: Functional and binary logic drawings for the control system.

C. RSN 40 61 96 -3, Approval Data - Final Drawings and Documentation:

1. Include:

a. Final drawings of all approval layouts, schematic diagrams, and wiring diagrams including “as-built” changes.

b. Final I/O List.

c. Final Datapoint List.

d. Final Master Alarm List.

e. Final version of approved software documentation including “as-built” changes.

1.08 EXTRA MATERIALS

A. Set of special tools and accessories required for installation, normal operation, and maintenance for each facility. Include:

1. Contractor and manufacturer recommended tools and accessories.

2. Tools and accessories for field maintenance and those designed to aid in the diagnosis, maintenance, repair, and replacement of supplied equipment.

B. Spare parts for each facility:

1. I/O Cards: Minimum of 25 percent spare of each type used, no less than two of each size and type used.

2. PLCs: Fully redundant spare set of automation controllers.

3. Back planes: Minimum of one spare of each type of control system component.

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4. Communications Converters: Minimum of one spare of each type of communications converter used.

5. Operator Interface Terminal (OIT): One spare of each type.

6. Miscellaneous Components:

a. Includes all other components supplied that were not individually listed above, excluding enclosures.

b. Minimum of one spare of each type of control system component.

7. Contractor or manufacturer recommended spare parts.

8. Replace spare parts used during installation, testing, and commissioning process.

C. One copy of software and associated programming/configuration needed to meet performance requirements:

1. Final version of furnished software.

2. Installation software tools required to re-install software needed for the system to function properly, for each facility.

PART 2 PRODUCTS

2.01 GENERAL REQUIREMENTS

A. Provide components essential for system to meet functional requirements of these Specifications in accordance with Section 40 63 00 - Process Control System Equipment and Section 40 67 00 - Process Control System Equipment Panels and Racks.

PART 3 EXECUTION

3.01 INSTALLATION

A. In accordance with manufacturer’s recommendations.

B. Incorporate into the control system, at a minimum, the instrumentation and control I/O points identified in Section 40 61 93 – Process Control System Input/Output List.

C. Provide all software and associated programming/configuration required to meet performance requirements of Contract Documents:

1. At substantial completion of Project:

a. Turn current licenses for all software over to Government in Bureau of Reclamation’s name and install latest version, upgrade or service pack for all software.

2. Provide respective software supplier’s Comprehensive Support Contract for all software covering full one year warranty period following substantial completion

40 61 96 - 13 which shall provide no cost software upgrades, service packs and tech support from software supplier.

END OF SECTION

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Process Control System Equipment

40 63 00 - 1

SECTION 40 63 00

PROCESS CONTROL SYSTEM EQUIPMENT

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Payment: Include in the lump sum price offered in the Price Schedule for Process Control System.

1.02 REFERENCE STANDARDS

A. Electrotechnical Commission (IEC)

1. IEC 61131-3-2013 Programmable Controllers - Part 3:

Programming Languages

B. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 1100-2005 Recommended Practice for Powering and Grounding Electrical Equipment

2. IEEE C2-2017 National Electric Safety Code (NESC)

3. IEEE C62.42-2005 Guide for the Application of Component Surge – Protective Devices for Use in Low- Voltage [Equal to or Less than 1,000 V (ac) or 1,200 V (dc)] Circuits

4. IEEE C62.43-2005 Guide for the Application of Surge Protectors Used in Low-Voltage (Equal to or Less than 1,000 Vrms or 1,200 Vdc) Data, Communications, and Signaling Circuits

5. IEEE C62.72-2016 Guide for the Application of Surge- Protective Devices for Low-Voltage (1,000 V or Less) AC Power Circuits

C. International Society of Automation (ISA)

1. ANSI/ISA 18.2-2016 Management of Alarm Systems for the Process Industries

2. ANSI/ISA 101.01-2015 Human Machine Interfaces for Process Automation Systems

D. National Fire Protection Association, Inc. (NFPA)

1. NFPA 70-2023 National Electrical Code (NEC)

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1.03 DEFINITIONS AND ACRONYMS

A. EPIC: Edge Programmable Industrial Controller.

B. HDMI: High-Definition Multimedia Interface.

C. Faceplate: A display, part of a display, or popup used for monitoring and/or direct operation of a single control loop, device, sequence, or other entity.

D. I/O: Input/Output.

E. OIT: Operator Interface Terminal.

1.04 GENERAL REQUIREMENTS

A. Graphic Displays:

1. Provide graphic displays for the control system with a minimum level of functionality in accordance with requirements and recommendations in ANSI/ISA 101.01, and requirements in this Specification.

2. Spare capacity for an increase of up to 20 percent in the number of graphic pages.

3. Designed to support user situational awareness, intuitive navigation, and intuitive system status and condition information.

4. Designed to support all types of tasks and activities required of the operator.

5. Use consistent design philosophy across graphic displays. Specific functions desired for the individual screens may require unique arrangements of graphics and information.

6. Alarms:

a. Design alarm display and interface in accordance with ANSI/ISA 18.2.

B. Provide graphic displays viewable on the Operator Interface Terminal (OIT). Graphic displays shall include control and monitoring interface for contractor supplied components. Include sub-displays as required in this Section.

1. Primary location for operators to receive system status and perform control operations for fish screen, gates, and other contractor supplied equipment.

2. OITs shall allow operators full control and monitoring of the Facility Control System.

3. Modify all setpoints and other operator adjustable values accessible from facility graphic displays.

4. Control functions associated with the alarms, including suppressing, accepting, and modifying alarm settings.

5. Show status of all components and system processes controlled by the control system.

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1.05 GRAPHIC DISPLAYS

A. Provide graphic displays for the control system in accordance with requirements and recommendations in ISA 101.01. ISA 101.01 recommendation and requirement in addition to requirements included in this Specification represent minimum level of functionality for graphic displays.

B. Graphic displays shall incorporate a hierarchy of displays that provide a progressive exposure to detail. The following list provides a general guideline for the hierarchy of displays:

1. Highest level display shall show entire system within operator’s control. This display is intended to act as an overall indicator as to how the site is running, by tracking key performance indicators.

2. Overall display for the dam, including gate position and facility water levels.

3. Gate sequencing display allowing the operator to update the gate sequence and associated setpoints.

4. Individual displays for each gate, displaying monitoring data and allowing operator to update setpoints associated with that gate.

5. Control system display.

6. Alarm display

7. Displays shall show detail information about system operations.

C. User interaction techniques shall be developed in accordance with the following guidelines:

1. Clear, with graphics that are consistent in the method that they present similar information.

2. Graphic functions: Standardized, intuitive, straight forward with minimal user manipulation.

3. Error tolerance in user interaction for critical devices shall be included, with simple notification of error and effective methods for recovery.

D. Develop a color scheme for graphic displays:

1. Grey backgrounds for graphics, with minimal use of color in graphics.

2. Utilize color very specifically and consistently.

3. Color alone shall not be the sole differentiator of an important condition or status.

E. Include analog representation of important measurements, indicating their value relative to normal, abnormal and alarm conditions.

F. Include visual indication if an Operator input field, or other operator-initiated control function, has been disabled.

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G. Response time requirements for the graphic displays:

1. Graphic displays shall take no longer than five seconds to appear when called up.

2. Update live information on display every two seconds unless critical nature of process information displayed requires more frequent updating.

H. Provide graph feedback when an action had been completed or an action has failed to complete.

I. Component Depiction:

1. Use standard shapes for components.

a. Shapes should be simple and avoid unnecessary detail.

2. Show status of components clearly and consistently.

3. Include operating hour tally for each gate actuator.

4. Process Lines: Limited number of line types and line thickness.

5. Process Controllers:

a. Depicted as a physical entity on the graphics, with key values like set point, output, and control mode displayed.

b. Provide faceplate type display of detailed information and user input fields for the process controller.

J. Text and Values:

1. Do not display leading zeros when depicting values unless the value is between -1 and 1.

2. Differentiate live values from static text, for example by depicting live values with a color. Units of measure should not be depicted as a live value.

3. Provide faceplates for live values with additional details, including point name.

4. Date and time display:

a. Display date in form of “YYYY-MM-DD”.

b. Display time of day in form “hours:minutes:seconds.” Update time display automatically once every second.

5. Page title: Each format shall have appropriate page title.

K. Provide visual display of lockout/tagout application.

L. Provide faceplates for sequences, including automatic startup and shutdown.

M. Provide dynamic permissive and interlock (first-out) lists accessible directly from control faceplates. Annunciate all active trip conditions on the graphic.

N. Alarm and Events:

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1. Allow for alarm monitoring for all discrete and analog inputs/outputs and communication links.

2. Alarms and indications of abnormal situations shall be clear, prominent, and consistently distinguishable.

3. Displays shall provide the Operator the ability to:

a. Acknowledge alarms.

b. Place alarms out of service.

c. Modify alarm settings.

4. Document the following for each alarm:

a. Alarm type.

b. Alarm setpoint.

5. Indicate acknowledged alarms, unacknowledged alarms, and unacknowledged alarms which have returned to normal.

6. Document Time stamped logs for alarm history, event history, diagnostic and audit history for the alarm management system.

O. No animation except for specific alarm related graphics.

P. Implement the System Use Notification banner furnished by the Government on all technically feasible display components.

1.06 SUBMITTALS

A. RSN 40 63 00-1, Component Data:

1. Manufacturer’s technical data and catalog sheets.

2. Model or catalog number, equipment capabilities, and electrical characteristics.

B. RSN 40 63 00-2, Approval Data:

1. Graphic Display page layout and color scheme.

PART 2 PRODUCTS

2.01 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A. Government shall provide the OPT022 EPIC PR1. See Attachment 12 for complete details.

2.02 INPUT/OUTPUT (I/O) MODULES

A. Provide I/O as required to meet specified functionality as listed in Section 40 61 93 – Process Control System Input/Output List.

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B. Provide at a minimum, 10 percent spare installed I/O points of each size and type.

C. Provide capability to install 20 percent additional future I/O cards at each I/O location.

Includes connection capability, space on backplanes and sufficient margin in power and operating capacity for a true ‘plug and play’ installation of additional I/O cards.

2.03 OPERATOR INTERFACE TERMINAL (OIT)

A. Monitor: SuperLogics SL-LCD-17A-PCAPTOUCH-RK, or equal, with the following essential characteristics:

1. Minimum 17-inch projected capacitive touchscreen.

2. Rated NEMA 4/4X/12, sealed to IP65/66 standards.

3. HDMI video input interface.

4. USB touch interface.

5. Resolution: 1280 x 1024 at 60Hz.

B. Locations:

1. 001-CP-001: Front panel mounted, accessible from outside of the enclosure.

2. 001-CP-101: Swing panel mounted, not accessible from the outside of the enclosure.

3. 001-CP-301: Swing panel mounted, not accessible from the outside of the enclosure.

C. Show full color graphic displays of system status and alarms.

D. Provide required adapters to interface with the EPIC controller.

E. Function:

1. the following minimum functions:

a. OITs shall include all requirements for ‘Graphic Displays.’

b. Access Controlled Function:

1) Operate facility.

2) Modify all setpoints and other operator adjustable values accessible from facility graphic displays

3) Control functions associated with the alarms, including suppressing, accepting, and modifying alarm settings.

c. Non-Access Controlled Functions

1) View only system data. This includes, at a minimum:

a) System and component status, configuration, and setpoints, as well as overall system operation.

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b) Alarm information.

F. Locations:

1. 001-CP-001.

2. 001-CP-101.

3. 001-CP-301.

2.04 CONTROL LOGIC SOFTWARE

A. Program control logic in the control system using Pac Control. Utilize the following programming methods:

1. Flowchart.

2. Optoscript.

B. Emphasize readability and maintainability in the control logic implementation.

PART 3 EXECUTION

3.01 INSTALLATION

A. In accordance with manufacturer’s recommendations.

B. Perform installation in accordance with NFPA 70.

C. Provide grounding in accordance with Section 26 05 26 – Grounding and Bonding, NFPA 70 and IEEE 1100.

D. PLCs and OITs shall be installed in enclosures in accordance with Section 40 67 00 – Process Control System Equipment Panels and Racks.

E. For connections to the programmable controller which run outside the O&M building surge suppression is required, including digital, discrete, and analog I/O.

F. Cable and Wiring: Provide cable and wiring in accordance with Sections 26 05 20 – Conductors and Cables and 26 05 02 – Basic Electrical Materials and Methods.

G. All connections shall be made to place the control system into operation.

H. Installation shall look complete and professionally done, all damage to enclosures or installation area shall be repaired and left in a finished condition.

I. All accounts that are not needed for normal or maintenance operation shall be removed or disabled prior to delivery of the system to the Government.

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Process Control System Equipment Panels and Racks

40 67 00 - 1

SECTION 40 67 00

PROCESS CONTROL SYSTEM EQUIPMENT PANELS AND RACKS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Payment: Include in the lump sum price offered in the Price Schedule for Process Control System.

1.02 REFERENCE STANDARDS

A. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 1100-2005 Recommended Practice for Powering and Grounding Electrical Equipment

B. International Organization for Standardization (ISO)

1. ISO 13850-2015 Safety of machinery - Emergency stop function - Principles for design

C. International Code Council (ICC)

1. IBC-2018 International Building Code

D. National Electrical Manufacturers Association (NEMA)

1. NEMA 250-2020 Enclosures for Electrical Equipment (1,000-Volts Maximum)

2. NEMA ICS 1-00(R2015) Industrial Control and Systems: General Requirements

E. National Fire Protection Association, Inc. (NFPA)

1. NFPA 70-2023 National Electrical Code (NEC)

2. NFPA 79-2021 Electrical Standard for Industrial Machinery

1.03 DEFINITIONS AND ACRONYMS

A. I/O: Input/Output.

B. OIT: Operator Interface Terminal.

C. PLC: Programmable Logic Controller.

D. UPS: Uninterruptible Power Supply.

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1.04 GENERAL REQUIREMENTS

A. Provide power distribution to all control system components to support full operation of the system.

1. Include analog loop power supplies and contact interrogation voltages for dry contact inputs where required.

2. Provide all fuses, circuit breakers, power supplies, transformers, etc., required to supply and transform power feeds at the desired voltage.

3. Provide DIN rail disconnect for each 120-volt circuit entering enclosure.

B. Provide Uninterruptible Power Supply (UPS) system for the Programmable Logic Controller (PLC) with a minimum of 60-minute run time for 150 percent of the load.

1. Maintain power to all inputs in the event of a utility power outage.

2. Provide power supply failure or “on backup power” alarm.

C. Provide all fuses, circuit breakers, power supplies, transformers, etc., required to supply and transform power feeds at the desired voltage.

D. Provide DIN rail disconnect for each 120-volt circuit entering enclosure.

1. Determine size and ratings of the following:

a. Fuses.

b. Power supplies.

c. Surge suppression devices.

1.05 SUBMITTALS

A. RSN 40 67 00-1, Component Data:

1. Manufacturer’s technical data and catalog sheets for Items in Part 2.

2. Model or catalog number, equipment capabilities, and electrical characteristics.

PART 2 PRODUCTS

2.01 ENCLOSURES

A. In accordance with NEMA 250. Corrosion resistant, minimum Type 12 enclosures for indoor installations and Type 3R enclosures for outdoor installations.

B. Provide additional enclosures as necessary to meet functional requirements of these Specifications.

C. Sized to adequately house equipment for that location plus 25 percent. Include sufficient space for mounting an additional PLC, similar in size to Contractor supplied PLC(s).

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D. Provide thermostatically controlled cabinet space heaters to control condensation in all cabinets not in a temperature controlled environment or subject to condensation.

E. Enclosures design shall allow free and easy access to internal components.

F. Enclosures shall have louvers, or ventilation, as required to maintain the temperature of the equipment within manufacturer recommended range.

1. Fans or other forced ventilation devices shall be provided as redundant pairs and shall be provided with temperature alarms.

2. Louvers and openings shall be equipped with screens and changeable filter material to prevent the entrance of dust, insects and rodents.

G. All doors shall be lockable.

H. Finishes:

1. Manufacturer’s standard finishes, unless part of an existing cabinet, or control enclosure lineup in which case the existing colors should be matched.

I. Wire Duct:

1. Provide wiring duct system with removable covers for performing wiring within enclosure.

2. Install with wiring duct covers accessible for removal and replacement.

3. Do not attach wiring to duct system covers.

4. Wiring within ducts shall be accessible for operation, maintenance, removal, and replacement.

5. Design wiring duct system with capacity to wire all devices, present and future that can practically be mounted in enclosure.

J. Wiring inside switchboards, control panels, etc., not intended for use extending outside of the enclosure.

K. Enclosure wiring for power, control, instrumentation, or telecommunication shall maintain characteristics of those cable types.

L. Wire Connections:

1. Make connections at device terminals or terminal blocks. Maximum two wires per termination point.

2. Install incoming 120-volt branch circuits on adjacent terminal block terminals.

2.02 EMERGENCY STOP PUSHBUTTON

A. In accordance with ISO 13850.

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B. Immediately stop all equipment operation and hold in place, regardless of the control mode that the system is in. This includes:

1. Stops all facility gates.

2. Locks out the brush cleaner.

C. Type:

1. Maintained push, twist to release.

2. NEMA 4X or IP65 Rated.

D. Size: 30 mm.

E. Install stops in locations where easily accessible for operation, with a guard to reduce inadvertent operation of the device.

F. Equipment will be locked out from automatic restarting.

G. Locations:

1. 001-CP-001 mounted on the front of the control enclosure.

2. 001-CP-101 mounted on a swing-out panel inside control enclosure.

3. 001-CP-301 mounted on a swing-out panel inside control enclosure.

2.03 DC POWER SUPPLY

A. Provides connections for primary and backup input power sources. Automatically transfers to backup power source on loss of power on the primary source.

B. Type:

1. Switch-mode power supply.

2. Din-Rail mountable.

C. Input Voltage: 100-240 volts AC.

D. Output Voltage: 24 volts DC plus-and-minus 1 percent.

E. Output Current: 20-amps, minimum.

F. Connection Type: Screw clamp.

2.04 DC UNINTERRUPTIBLE POWER SUPPLY (UPS)

A. Type: Industrial.

B. Provide UPS systems with battery backups at the following locations:

1. 001-CP-001,

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2. 001-CP-101, and

3. 001-CP-301.

C. UPS and batteries shall be installed in enclosures supplied in accordance with Section 40 67 00 – Process Control System Equipment Panels and Racks.

D. UPS and battery shall not impede access to other equipment within enclosure.

E. Supply the following loads from the UPS:

1. Everything inside control cabinets.

2. Power supplies.

3. OITs.

4. PLCs.

F. Sizing and locations:

1. Sized to provide 150 percent of full load current for the supplied control equipment.

a. 001-CP-001: 480-watts, minimum.

b. 001-CP-101: 480-watts, minimum.

c. 001-CP-301: 480-watts, minimum.

G. Minimum status display and output alarms to process control system:

1. Low Battery.

2. Overload/Trouble.

H. Input voltage: As Required.

I. Output voltage: As Required.

J. Batteries:

1. Leak-proof.

2. Hot-swappable, user replaceable.

3. Maintenance-free sealed Lead-Acid battery with suspended electrolyte.

4. Sized to provide at least the maximum rated load current of the UPS system for at least 60 minutes.

2.05 SURGE SUPPRESSION

A. 4-20 milli-ampere transient protection modules:

1. Triple stage hybrid protection.

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2. Surge Current (8/20 microsecond wave form): 10 kilo-ampere, minimum.

3. Clamping Voltage: 30 volts DC.

4. Response Time: Less than 5 nanoseconds.

5. Throughput Resistance: 12 ohms, maximum.

6. Automatically resets after each transient.

B. Line voltage surge protection device:

1. Rated Voltage: 120 volt, 60 Hertz.

2. Rated Current: 15 amperes.

3. Single-phase service.

4. Surge Current (8/20 microsecond wave form): 10 kilo-ampere, minimum.

5. Clamping Voltage: 270 volts.

6. Maximum Continuous Operating VAC (MCOV): 115 percent rated line voltage.

7. Response Time: Less than 5 nanoseconds.

8. Modes of Protection: L-N, L-G, N-G.

9. Automatically resets after each transient.

C. For automation equipment in outdoor enclosures, furnish surge suppression for power supply inputs and wiring leaving the enclosure, including digital I/O, analog I/O, and communication wiring.

2.06 INTERPOSING RELAYS

A. Type: General Purpose Relay.

B. Double-Pole, Double-Throw (DPDT), minimum.

C. Contact Rating: 15-amp, 120 volts AC, minimum.

D. Coil Voltage: As required for application where used.s

2.07 GROUND BUS

A. Material: Copper.

B. Size: Sufficient to attach equipment ground conductors.

C. Length: Sufficient to attach equipment ground conductors plus 20 percent spare.

D. Insulated mounting bracket.

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2.08 FUSE BLOCK AND FUSES

A. Type: Finger-Safe terminal block.

B. DIN-Rail mountable.

C. Fuse:

1. Rated for size required.

2. 250-volts, current limiting.

2.09 POWER TERMINAL BLOCKS

A. Type EB-25 as manufactured by General Electric; 1600 Series as manufactured by Marathon Special Products, Buchanan catalog Nos. B104 as manufactured by Ideal Industries, Inc.; or equal, having the following essential characteristics:

1. Molded one piece design with 3 or 4 termination points.

2. Rating: 600 volts, 15 amperes, minimum.

3. Terminals: Binding-head or washer-head screws with serrated or grooved contact surfaces suitable for use with crimped ring-type terminal connectors.

4. Full-size marking strips.

2.10 TERMINAL BLOCKS

1. Arrange terminal blocks to segregate signal types and account for spare space.

2. Mount terminal blocks at least 3-inches from panel edges and other devices.

Mount adjacent rows of terminal blocks with 12-inches separation minimum. Do not block access to front of terminal blocks.

3. Machine lettered terminal numbers on terminal block marking strips. Do not use hand lettering.

4. Power Terminals:

a. Terminal Type:

1) Binding-head or washer-head screws with serrated or grooved contact surfaces.

2) Spring-clamp type terminal blocks are not acceptable.

b. Voltage rating: 600 volts.

c. Current rating: 25 amperes minimum.

5. Control Panel Terminals:

a. Terminal Type:

b. Voltage rating: 300 volts.

c. Current rating: 20 amperes.

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6. Arrange terminal blocks to allow external cabling to be supported.

7. Access to front of terminal blocks shall be unobstructed.

8. Analog Inputs shall be of disconnecting switch type terminal blocks.

2.11 PANEL SWITCHES

A. Type: Plunger Style.

B. Voltage: 24 volts DC.

C. Locations: Inside control panel CP-001, CP-002, CP-101, and CP-301.

D. Mounting: Per manufacturer instructions.

2.12 BALANCED MAGNETIC CONTACT

A. Separate magnet housing and contacts.

B. Voltage: 24 volts DC.

C. All metal housing.

D. Locations: Inside O&M Building Control Room 101 north doors.

E. Mounting: Per manufacturer instructions.

2.13 NAMEPLATES

A. Nameplates for Enclosures and Components Mounted in Enclosures:

1. Provide nameplates for all enclosures specified in Part 3.

2. Nameplates shall have tag names on the first line, and the description of the panel on the second line.

3. Provide nameplates for all terminal blocks, fuses, and all components located in an enclosure.

4. Attach nameplates to enclosures with pan head self-tapping screws. Use of adhesives to attach nameplates is not acceptable.

a. Attach nameplates to pushbuttons, indicating lights, and selector switches in accordance with component manufacturer’s instructions. Use of self-tapping screws is not required.

B. Nameplates shall consist of letters and numbers engraved on phenolic-type material. Size of letters and figures shall be approximately 7/16 inch for cabinet device nameplates and 1 inch for cabinet designations.

C. Refer to Section 26 05 02 – Basic Electrical Materials and Methods.

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PART 3 EXECUTION

3.01 INSTALLATION

A. Perform installation in accordance with NFPA 70 and IBC seismic requirements for installation locations.

B. Panel and Enclosures:

1. 001-CP-001:

a. Nameplate: 001-CP-001 Main Facility Control Panel.

b. Location: O&M Building Control Room 101.

c. Size: 36-inches (height) x 36-inches (width) x 12-inches (depth), minimum.

2. 001-CP-002:

a. Nameplate: 001-CP-002 Communications Panel.

b. Location: O&M Building Control Room 101.

c. Size: 36-inches (height) x 36-inches (width) x 12-inches (depth), minimum.

3. 001-CP-101:

a. Nameplate: 001-CP-101 Fish Screen Control Panel.

b. Location: Fish Screen Concrete Pad (South Pad).

c. Size: 36-inches (height) x 24-inches (width) x 12-inches (depth), minimum.

4. 001-CP-102:

a. Nameplate: 001-CP-102 Solenoid Valve Relay Enclosure.

b. Location: Fish Screen Concrete Pad (South Pad).

c. Size: 36-inches (height) x 24-inches (width) x 12-inches (depth), minimum.

5. 001-CP-103:

a. Nameplate: 001-CP-103 Fish Screen Level Sensors Enclosure.

b. Location: Fish Screen Concrete Pad (South Pad).

c. Size: 24-inches (height) x 24-inches (width) x 12-inches (depth), minimum.

6. 001-CP-301:

a. Nameplate: 001-CP-301 Headworks Structure Control Panel.

b. Location: River Bypass Concrete Pad (North Pad).

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c. Size: 36-inches (height) x 24-inches (width) x 12-inches (depth), minimum.

7. 001-CP-302:

a. Nameplate: 001-CP-302 Headworks Structure Level Sensors Enclosure.

b. Location: River Bypass Concrete Pad (North Pad).

c. Size: 24-inches (height) x 24-inches (width) x 12-inches (depth), minimum.

8. Provide additional enclosures as necessary to meet functional requirements of these Specifications.

C. Emergency Stop Pushbutton: Installed in accordance with NFPA 72 and ISO 13850.

D. Make grounding and bonding connections in accordance with Section 26 05 26 – Grounding and Bonding, NFPA 70, and IEEE 1100.

E. Terminal Blocks:

1. Arrange terminal blocks to segregate signal types and account for spare space.

2. Arrange terminal blocks to allow external cabling to be supported.

3. Mount terminal blocks at least 3-inches from panel edges and other devices.

Mount adjacent rows of terminal blocks with 12-inches separation minimum.

Access to front of terminal blocks shall be unobstructed.

4. Machine lettered terminal numbers on terminal block marking strips. Do not use hand lettering.

5. Identify vertical columns of terminal blocks with single letter such as “A”, “B”, or “C”. Vertical columns may contain more than 12 termination points.

F. Cable, Wiring and Raceway:

1. Contractor shall provide all cable, wiring and raceway required to make connections from/to control system components, IO signals and power connections. Provide all connections required to supply a fully functioning system that meets the requirements in these specifications.

2. Provide cable and wiring in accordance with Section 26 05 20 - Conductors and Cables and Section 26 05 02 - Basic Electrical Materials and Methods.

3. Wire Connections:

a. Make connections at device terminals or terminal blocks. Maximum two wires per termination point.

b. Install incoming 120-volt branch circuits on adjacent terminal block terminals.

c. Install ring tongue connectors for terminations at terminal blocks and electrical devices. Use pin-type terminal connectors where use of ring

40 67 00 - 11 tongues is not practical such as terminations at selector switches, pushbuttons, indicating lamps, and auxiliary relays.

d. Do not terminate wire without terminal connector.

e. Wire splices are not acceptable.

4. Provide raceway in accordance with Section 26 05 33 – Raceway and Boxes.

5. Make cable and conduit connections. Use watertight conduit hubs for conduit connections.

G. Cable Terminations:

1. Terminate power and control cables that run outside of enclosures at terminal blocks.

2. Segregate cable terminations by signal type and locate for ease of connections to terminations.

H. Provide nameplates for Contractor supplied equipment in accordance with Section 26 05 02 – Basic Electrical Materials and Methods.

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Overshot Gate Hoist

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SECTION 41 22 10

OVERSHOT GATE HOIST

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Overshot Gate Hoist:

1. Measurement: Number of overshot gates hoists designed, furnished, installed, and tested.

2. Payment: Unit price offered in the Price Schedule.

a. Includes cost of furnishing materials and performing work required for designing, fabricating, installing, and testing one overshot gate hoist, including associated equipment.

b. Includes cost of furnishing one-time replacement supply of lubricants for hoists and spare cotter pins for the rope sockets.

c. Includes cost of furnishing training for the operation and maintenance of the hoists.

1.02 REFERENCE STANDARDS

A. American Gear Manufacturers Association (AGMA)

1. AGMA 908-B89 Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth

2. AGMA 2001-D04 (R2010) Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth

3. AGMA 6013-A06 Industrial Enclosed Gear Drives

4. AGMA 6034-B92 (R1999) Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors

B. American Institute of Steel Construction (AISC)

1. AISC 360 – 2022 Specifications for Structural Steel Buildings

C. ASTM International (ASTM)

1. ASTM A36/A36M-19 Carbon Structural Steel

2. ASTM A148/A148M-20e1 Steel Castings, High Strength, for Structural Purposes

3. ASTM A290/A290M-16(21) Carbon and Alloy Steel…