25_00_01_-_Automation_Control_System_Amend_0004_0004.pdf

Folsom Warehouse – Bridge Crane Replacement Amendment No. 0004 American River Division Solicitation No. 140R2026R0017 Folsom Unit - Central Valley Project, California Specifications No. 20-C0942

Automation Control System

Revised 25 00 01 - 1

SECTION 25 00 01

AUTOMATION CONTROL SYSTEM

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Furnish, Install, Test and Deliver New Crane Automation Control System:

1. Payment: Lump sum price offered in the Price Schedule.

B. Provide Automation Control System Support:

1. Payment: Lump sum price offered in the Price Schedule.

a. Includes onsite testing and commissioning support trips for control system startup.

C. Spare Parts for Automation Control System:

1. Payment: Lump sum price offered in the Price Schedule.

1.02 REFERENCE STANDARDS

A. Code of Federal Regulations (CFR)

1. 29 CFR 1910 - 2022 Occupational Safety and Health Standards

B. Facilities Instructions, Standards and Techniques (FIST)

1. FIST 3-8 - 2021 Facility Instructions and Standard

Techniques (FIST) – Operation, Maintenance, and Field Test Procedures for Protective Relays and Associated Circuits.

2. FIST 4-1b – 2022 Maintenance Scheduling for Electrical Equipment

C. International Electrotechnical Commission (IEC)

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

Programming Languages

2. IEC 61000-4-5(2014) Electromagnetic compatibility (EMC) Part

4-5, Testing and measurement techniques – Surge Immunity Test

3. IEC 61000-4-11(2005) Electromagnetic compatibility (EMC) Part 4-11, Testing and measurement techniques – Voltage dips, short interruptions, and voltage variations immunity tests

Revised 25 00 01 - 2

4. IEC 62443-2020 Industrial Communication Networks – Network and System Security

D. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 519-2022 IEEE Recommended Practice and

Requirements for Harmonic Control In Electrical Power Systems

2. IEEE 754-2019 Floating Point Arithmetic

3. IEEE 802.3-2022 Ethernet

4. IEEE C37.90-2011 Standard for relays and relay systems associated with electric power apparatus

5. IEEE 1046-1996 Distribution Digital Control and Monitoring for Power Plants.

6. IEEE 1249 – 2013 Guide for Computer-Based Control for

Hydroelectric Power Plant Automation

7. IEEE 1613 – 2009 Standard for Environmental and Testing

Requirements for Communications Networking Devices in Electric Power Substations.

8. IEEE 1615 – 2019 Recommended Practice for Network Communication in Electric Power Substations

9. IEEE C37.1-2008 Standard for SCADA and Automation Systems

10. IEEE C37.2-2022 Electrical Power System Device Function Numbers, Acronyms, and Contact Designation

E. International Society of Automation (ISA)

1. ISA 101.01-2015 Human Machine Interfaces for Process

Automation Systems

2. ISA 61511-1-(2017) Functional Safety – Safety Instrumented

Systems for the Process Industry Sector Part 1: Framework, Definitions, System, Hardware and Application Programming Requirements

3. ISA 62381 -2011 Automation Systems in the Process Industry

– Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT)

Revised 25 00 01 - 3

4. ISA 62382-2012 Automation Systems in the Process Industry

– Electrical and Instrumentation Loop Check

5. ISA 62443-1-1(99.01.01)-2007 Security for Industrial Automation and Control Systems Part 1-1: Terminology, Concepts, and Models

F. National Electrical Manufacturers Association (NEMA)

1. NEMA ICS 1-2022 Industrial Control and Systems General

Requirements

2. NEMA ICS 5-2017 Control Circuit and Pilot Devices

3. NEMA ICS 7-2020 Adjustable-Speed Drives

4. NEMA ICS 8-2019 Application Guide for Industrial Control

Systems Crane and Hoist Controllers

5. NEMA ICS 16 – 2001 Motion/Position Control Motors, Controls, and Feedback Devices

G. International Electrical Testing Association, Inc. (NETA)

1. NETA ATS-2021 Acceptance Testing Specifications

2. NETA ECS-2020 Standard for Electrical Commissioning

Specifications for Electrical Power Equipment and Systems

H. National Fire Protection Association (NFPA)

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

Deleted

1.03 DEFINITIONS

A. Automation Control: Application of technology to monitor and control processes.

B. Class II Controller: controllers intended for use with CMAA crane services class A and B.

C. Control system diagram: conceptual diagram of the functional interrelationship of subsystems, usually in block form.

D. CPU: Central Processing Unit.

E. Dielectric test: tests made to determine ability of insulating materials and spacings to withstand specified overvoltages for a specified time without flashover or puncture.

F. DRAM: Dynamic Random-Access Memory.

Revised 25 00 01 - 4

G. Drift: as applied to devices such as pressure switches, temperature switches etc., a change in operating characteristics over a specified number of operations or time and specified environmental conditions.

H. Dynamic braking: control function that brakes the drive by dissipating its stored energy in a resistor. A method of controlling speed by using the motor as a generator.

I. Electric motor controller: device or group of devices that serves to govern in some predetermined manner the electric power delivered to the motor.

J. HMI: Human Machine Interface.

K. Hoist: A motor machinery unit that used for lifting and lowering a load.

L. I/O: Input/Output.

M. IP: Internet Protocol.

N. Gbps: Gigabits per second

O. Layer 1: Physical layer of networking. The lowest and most physical layer of the models including physical wires. Data at this layer is bits sent across a wire as 0’s and 1’s.

P. Layer 2: Data Link Layer. Layer involved in transmitting data from one specific node to another through VLAN, WAN or MAN containing source addresses and destination addresses. Equipment can include switches, bridges and network cards.

Q. Layer 3: Network Transport Layer. Including communication protocols and OSI level models. Coordination of data transfer between end systems and hosts, data rates.

R. OSI: Open Systems Interconnect model

S. PLC: Programmable Logic Controller.

T. RTD: Resistance Temperature Detector

U. SCADA: Supervisory Control and Data Acquisition.

V. SFP: Small Form-factor Pluggable

W. SNMP: Simple Network Management Protocol

X. SPAN: Switch Port Analyzer.

Y. System Integrator: A specialized technician engaged in the detail design, component selection and procurement, fabrication, wiring, assembly, programming and testing process control and communication systems. The System Integrator will provide the programming, licensing and software development for the PLC and HMI automation control system for this project.

Revised 25 00 01 - 5

Z. VDC: Volts Direct Current

AA. VDAN: Virtual Doubly Attached Node.

BB. VFD: Variable-frequency drive motor controller

CC. VLAN: Virtual Local Area Network.

1.04 SUBMITTALS

A. Submit the following in accordance with Sections 01 33 00 - Submittals and 01 33 26 – Electrical Drawings and Data:

B. RSN 25 00 01-1, Qualifications:

1. Documentation of inspector’s, engineer’s, and technician’s experience and certifications.

C. RSN 25 00 01-2, Approval Drawings and Data (Government Format):

1. Includes all items and systems in Part 2 Products, Section 25 12 10 –

Programmable Logic Controller.

2. Includes all products in Part 2 Products, Section 41 22 15 – Bridge Crane

Electrical Components.

3. Update all facility drawings impacted by modifications.

4. Drawings: Provide 30, 60 and 90 percent design drawings in coordination with

Section 41 22 14 – Bridge Crane.

5. Supply layout drawings showing the location of all Contractor supplied equipment for automation, communication, controls and monitoring.

a. Show device locations, wireway, connection and support points and grounding locations.

6. Supply layout drawings showing the location of all Contractor supplied devices, including, but not limited to PLC assembly, HMI’s, Input/Output devices, communication interface, cables, switches, patch panels, network components, power supplies, mounting hardware, connectors, relays, telecommunication cables, surge protection devices and auxiliary devices.

7. Spare parts list.

8. Catalog or product data for equipment and devices furnished.

a. Model or catalog number.

b. Manufacturer’s technical data.

c. Equipment capabilities.

d. Electrical characteristics.

e. Connection requirements and capabilities.

Revised 25 00 01 - 6

9. Component lifecycle support information:

a. Include meantime between failure and any end of life or end of support announcements for the following components:

1) Programmable Logic Controller (PLC).

2) I/O components.

3) HMI.

10. Bill of materials.

D. RSN 25 00 01-3, Installation Plan and Procedures:

1. Provide a narrative including details for installation plan and procedures for new communications equipment.

2. Detailed instructions identifying new and existing cables or wiring runs necessary for installation of new automation equipment.

3. Detailed instructions for initial inspection of new equipment, including wiring, commissioning, and testing plans.

4. Detailed instructions for throughput functional testing of communications and automation devices prior to commissioning.

E. RSN 25 00 01-4, Software Development Documentation: Automation Control Systems:

1. I/O List, including the following minimum information:

a. Point designation.

b. Card location.

c. Type and rating information.

d. Termination data.

2. Include:

a. I/O points database.

b. All variables.

c. All logic.

d. Digital processor high-level logic.

e. Functional block diagrams.

f. Modbus listing.

g. Narrative description of software operation.

h. HMI screen graphics for each screen.

1) Screen graphics shall be submitted in color.

i. Description of Alarm Log Reporting.

j. Description of Trending Capabilities.

Revised 25 00 01 - 7

3. Master Alarm List, including the minimum following information for each alarm:

a. Alarm Identifier.

b. Alarm priority.

c. Alarm group.

d. Alarm Setpoints.

4. System Overview:

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

b. Include software block diagram of entire system.

F. RSN 25 00 01-5, Factory Acceptance Test Procedure:

1. Describe mock functional test for Government witness to demonstrate how automation controls meet these specifications.

2. Describe the methods used to simulate I/O feeds to PLCs and VFDs where required for full testing and demonstration purposes.

3. Describe the methods, software, and testing metrics used to demonstrate network connectivity, network packet captures, throughput bandwidth measurements, and network locations where these measurements will take place.

4. Include new network diagrams, in accordance with Section 01 33 26 – Electrical Drawings and Data, showing all network connections and device connections for all equipment.

G. RSN 25 00 01-6, Factory Acceptance Test Report Automation Control System:

1. Certification of performance and result of system control and monitoring testing, including the following:

a. Results for all network communication paths and network failure scenario testing.

b. Results for all tests approved by the Government in the Factory

Acceptance Testing Procedure.

c. Results for any other tests performed during the Factory Acceptance Test.

2. Provide the network diagram, in accordance with Section 01 33 26 – Electrical Drawings and Data, showing all network connections and device connections for all equipment, including test equipment not being furnished and installed as a part of this contract.

a. Highlight any changes from the approved network drawings and diagrams.

3. Provide the network packet capture files for all locations for which those captures took place.

a. Uniquely name the files so that the file contents correspond to, and can be identified, using the network diagram provided in this submittal.

Revised 25 00 01 - 8

H. RSN 25 00 01-7, Pre-Start Checkout Test Procedure Automation Control System:

1. A written procedure for the new automation controls system describing how each device will be tested following the installation at site and prior to final commissioning test to verify proper performance.

I. RSN 25 00 01-8, Pre-Start Checkout Test Report Automation Control System:

1. Certification of performance and result of Pre-Start Checkout Tests.

2. Document any changes that were made during tests to either contractor wiring and equipment or Government wiring and equipment.

J. RSN 25 00 01-9, Check Prints (Government Format):

1. As-shipped drawings.

K. RSN 25 00 01-10, Site Acceptance Test Procedure Automation Control System:

1. Test procedure shall include but not limited to the following:

a. Detailed written step-by-step procedures of field tests for the Site Acceptance Testing.

b. Describe the functional test for the Government to witness to demonstrate how the Automation Control System and network devices will meet these specifications.

c. Describe the methods for I/O verification and PLCs logic verification.

1) For each I/O point, provide a detailed list of steps to include unique identifiers for each conductor and test point that will be used for I/O verification and PLC logic verification.

L. RSN 25 00 01-11, Site Acceptance Test Report Automation Control System:

1. Certification of performance and throughput results for Automation Control

System includes the following:

a. Results for all tests approved by the Government in the Site Acceptance

Testing Procedure.

b. Results for any other tests performed during the Site Acceptance Test and not covered in other test reports submitted for Government approval.

2. Provide written description of results for each test performed.

3. Include indication of pass, fail or out of range results.

4. Provide updated network diagrams and automation control drawings in accordance with Section 01 33 26 – Electrical Drawings and Data, reflecting the state of the network at the conclusion of acceptance testing.

a. Show all testing equipment connections prior to their removal from the network.

Revised 25 00 01 - 9

M. RSN 25 00 01-12, Commissioning of Electrical Equipment – Automation Control System:

1. Provide completed and signed electrical commissioning forms.

N. RSN 25 00 01-13, Final As-Built Drawings (Government Format), Final Software File and Documentation Automation Control System:

1. Full set of user’s manuals, guides, and tutorials for software packages.

2. Categorized licensing information to be turned over to the Government for record keeping.

3. Provide a copy of all software files containing final versions of all PLC and HMI programs.

4. Provide copy of all final software files including a record of all setting and logic values installed.

5. Electronic copies of Final As-Built Drawings and diagrams submitted in the

O&M Manual in AutoCAD (*.dwg) format.

O. RSN 25 00 01-14, Operation and Maintenance Manual; Crane Automation Control System:

1. Include in main volume of Operation and Maintenance Manual.

2. Comply with requirements in Section 01 78 30 – Project Record Documents.

3. Content:

a. Network diagrams, schematics and wiring diagrams.

b. Furnishing software, hardware and communications protocols necessary to modify programming in programmable devices.

1) Include version numbers for all software and firmware.

c. Spare parts list corresponding to bill of materials for a complete system.

1.05 AUTOMATION CONTROL SYSTEM DESCRIPTION

A. The Automation Control System includes the complete integration of programmable logic controllers, variable frequency drive motor controllers, human machine interfaces, control enclosures, and related equipment. The automation control system shall include but not limited to power supplies, input modules, output modules, sensors, feedback devices, communications devices and any other required equipment to provide a fully functional system. The PLC automation system will receive discrete input signals, and through the use of control algorithms to coordinate the overall operation of the crane motors.

B. Provide design, labor, equipment, materials and supervision to furnish, install, program, calibrate, adjust, document, test and commission the total system as required herein, as shown on the drawings and required for the complete integration of the Automation Control System.

Revised 25 00 01 - 10

C. The contractor shall place the completed system in operation, including programming, tuning loops, testing and adjusting parameters, and final adjustments during crane system start-up. The Contractor shall provide the services of trained and qualified technicians for these services.

D. Automation Control and Monitoring.

1. The Automation Control System shall interface with VFDs to enable precise control of motor speed and torque, control all electrically operated equipment, monitor all processes and annunciate statuses and alarms.

2. The system incorporates a range of sensors and feedback devices to monitor and provide real-time information about various parameters such as position, speed, load and safety conditions. These sensors include limit switches, encoders, load cells and proximity sensors. The data from these devices is fed back to the PLC, enabling accurate control and monitoring of the crane motors.

3. Speed and Position Control:

a. A combination of AC static stepless control and VFD vector control using the pendant control station as the primary interface between the operator and crane motor control. The pendant provides precise command input to the controllers, enabling the operator to control the crane’s motions.

1.06 RELATED WORK

A. Coordinate features of the automation control system to be compatible with the following Sections:

1. Section 25 12 10 – Programmable Logic Controller

2. Section 41 22 14 – Bridge Crane

3. Section 41 22 15 – Bridge Crane Electrical Components

4. Deleted

1.07 AUTOMATION CONTROL SYSTEM DESIGN AND PERFORMANCE

REQUIREMENTS

A. General requirements:

1. Failure of PLC, I/O hardware, power supplies, or network communication link must be fail-safe and alarmed.

2. In accordance with IEEE 802.3 and IEEE 1249.

B. Control System and Network:

1. The Contractor shall provide all equipment, including software and hardware, necessary for testing, installation, communication, troubleshooting all systems provided with the crane.

Revised 25 00 01 - 11

2. The crane Automation Control System shall be programmed and operate according to the descriptions in this specification. This description indicates minimum system requirements. The Contractor shall provide all required coordination for a complete and functional Automation Control System. Field adjustments or additional features added during startup and commissioning shall be included in the bid price.

3. The Contractor shall provide all crane specific operational software files including ladder logic and functional block programming for their associated systems.

a. Provide software development and programming including PLC’s, instrumentation, VFD’s, HMI and crane control system.

b. Provide additional system accessories as required for a complete and operational control system.

4. Provide complete system startup, configure, program, function test and commission of the complete Automation Control System and other process control equipment.

5. A single common networked design shall not be used for the automation control system. A failure of individual functions shall not affect any other function except as defined for specific safety interlocks.

6. Failure of the monitoring system shall not affect crane functions.

7. All provided hardware and software shall be currently marketed products, not currently scheduled for end of life or obsolescence.

8. Design to ensure there is no remote access capability enabled. Physically disable or remove all network devices not required for operational purposes.

9. Remove all software and services not required for operation or maintenance. If removal is not technically feasible, then disable software not required for the operation of the crane.

a. The removal of software or services shall not impede the primary function of the control system.

10. The software and services to be removed or disabled shall include, but not limited to:

a. Unused networking and communications protocols.

b. All unused data and configuration files.

c. Unused administrative utilities, diagnostics, network management and system management functions.

d. Software compilers for programming languages that are not used in the control system.

e. Messaging services, games and cameras.

f. Device drivers for components not procured.

Revised 25 00 01 - 12

C. Application Programmed Logic shall have the following capabilities:

1. Process to upload and download programs.

2. Support for program de-bugging and troubleshooting.

3. Provide support for programming languages in accordance with IEC 61131-3.

4. Provide portability of developed algorithms between devices from the same or different vendors.

5. Performance for data acquisition, processing and delivery in accordance with

IEEE C37.2.

6. Provide failure recovery mode.

7. Design with expandability.

8. Self-diagnostics.

9. Design to utilize variables placed in non-volatile memory and the means of creating the non-volatile memory.

D. Design a crane automation control system.

1. Perform the following functions:

a. Control and monitor hoist and travel motors, circuit breakers, heaters, indicating devices, sensors, VFD’s and protective devices.

b. Acquire operating data from meters, transducers, contact devices, limit switches and proximity switches.

c. Accept inputs and provide outputs as listed on applicable input/output lists and drawings.

2. Provide future expansion capability of at least 20 percent for inputs, outputs and programming logic.

E. Application Programming Control System:

1. Hoist Motor Control Modes:

a. Closed-loop speed controlled with torque limiting.

b. Single-axis positioning.

c. Master-slave torque control operation.

d. Synchronous operation.

2. Travel Motor Control Modes:

a. Open or closed-loop speed control.

b. Single-axis positioning.

c. Master-slave torque control operation.

d. Synchronous operation.

Revised 25 00 01 - 13

3. Hoist Motor Operation Modes:

a. Deleted

b. Manual.

c. Jogging.

d. Speed Controlled

e. Encoderless emergency mode.

f. Position sensing.

g. Limit switch handling.

h. High-impact load handling.

i. Anti-Shock.

4. Travel Motor Operation Modes:

a. Deleted

b. Manual.

c. Jogging.

d. Speed Controlled

e. Encoderless emergency mode.

f. Position sensing.

g. Limit switch handling.

h. Anti-Collision.

i. Anti-Sway.

5. Processor shall be able to be programmed in a high level or block diagram type language.

a. Programmed in Ladder Logic.

b. It shall support the following functions at a minimum:

1) Normally open contact.

2) Normally closed contact.

3) Relay coil.

4) Latching relay with set and reset inputs.

5) Positive triggered one-shot.

6) Negative triggered one-shot.

7) Delay on timer.

8) Delay off timer.

9) Pulse timer.

Revised 25 00 01 - 14

10) Up counter.

11) Down counter.

12) Arithmetic functions including addition, subtraction, multiplication, division, square root, and absolute value.

13) Relational functions including greater than, less than, and equal to.

14) Grouping of programming sections into subroutines.

15) Supports configurable variable names using common text of

8 characters or more.

c. Accessible via Ethernet connection or USB.

d. Software required to view and make program changes shall be provided as a part of the contract including any licenses, dongles, activation keys, etc.

as needed.

1) Compatible with Microsoft Windows versions 11.

e. Programing documentation:

1) Sufficiently documented to provide readability for technicians and engineers.

2) Add comments describing program revision level; program sections, modules and functions; variable names and directions to navigate through the code where an external module is called or a jump to another location takes place.

3) Comments written in clear, concise, English using sentence structure and proper case.

4) Comment rate should be 10 percent or more (i.e., one comment line for every 10 program lines).

6. Password protection shall prevent unauthorized changes to application program.

F. PLC ladder logic application programs and HMI screen application files shall become property of the Government and shall not contain proprietary information.

G. I/O connects to the PLC assembly as shown on the drawings and I/O list.

H. Provide the ability to replace PLC I/O cards, power supplies, and hard drives without need to disconnect or disturb plant wiring.

I. Equipment shall not be affected by operation of microwave and mobile VHF radio equipment.

J. Provide password protection for all PLC’s and HMI panels.

1. Configurable passwords.

Revised 25 00 01 - 15

2. Passwords shall be a minimum of 8 characters long including at least one of each of the following: letter, number, and special character.

K. Operating System:

1. Provide the manufacturer’s standard operating system software package.

2. Capable of maintaining a point database in its memory including all parameters, constraints and the latest value or status of all points.

3. Application programs must use the data in memory resident files.

4. Support a full complement of automation control functions.

5. Capability to restart application programming of all connected I/O functions based on detection of power failure.

L. Failure Mode:

1. Upon any failure detection, perform an orderly shutdown.

2. Force all PLC outputs to a predetermined state.

1.08 PROJECT CONDITIONS

A. Plant Layout: See Section 52 00 00 – Drawings, for informational drawings showing general plant layout and work areas.

B. Altitude: 500 feet.

C. Maximum outdoor ambient temperature: 120 degrees F.

D. Relative Humidity Range: 25 to 89 percent.

1.09 DELIVERY, STORAGE, AND HANDLING

A. Accept equipment on site in shipping containers with labeling in place.

B. Protect equipment from damage, moisture, and dust, free from contact with soil and weather.

1.10 QUALIFICATIONS

A. Qualified Professional Engineers: Demonstrated experience on crane systems on at least two separate contracts.

B. Qualified Electricians: Minimum of one licensed electrician during field wiring and critical aspects of the field work.

C. Specialized in the design, assembly, programming, testing, installation and service of crane control and communication systems for at least the last three years. System Integrator shall be experienced with the programming and commissioning of PLC systems, operator interfaces and VFD’s.

Revised 25 00 01 - 16

1. Minimum of 3 years of experience testing and commissioning crane control systems.

2. In depth knowledge of this particular application and fully capable of troubleshooting and modifying control system hardware and software, including making modifications during on-site testing as necessary.

3. Technically qualified to supervise installation and testing work, meeting with COR approval.

4. Present or represented at work site during installation period.

5. Report, in writing to COR, work not in accordance with manufacturer’s recommendations or other conditions possibly resulting in unsatisfactory job.

6. Maintain daily log of accomplished work.

D. Manufacturer:

1. Regularly engaged in manufacture of similar items.

E. Project Designer and Project Programmer:

1. Minimum of 3 years of experience designing crane or similar systems utilizing similar components.

1.11 SPARE PARTS

A. Spare Parts:

1. Deliver spare parts in coordination with COR.

2. Furnish spare parts listed in Table 25 00 01A – Spare Parts for Automation

Control System.

Table 25 00 01A – Spare Parts for Automation Control and Monitoring

Item Description Quantity

1 Software License for PLC Application Software 1

2 Software License for HMI Application Software 1

PART 2 PRODUCTS

2.01 CONTROL LOGIC & PLC

A. Proportional Integral and Derivative control:

1. Proportional control.

2. Proportional plus integral control.

Revised 25 00 01 - 17

3. PLC Automation control equipment must be capable of functioning in an ambient temperature ranging from 20 to 120 degrees F, up to 100% relative humidity.

4. Vibration: 2g at 10 to 500 Hertz.

B. Refer to Section 25 12 10 – Programmable Logic Controller.

2.02 PLC APPLICATION PROGRAM

A. General:

1. Crane automation control programming logic shall be based on supplied drawings and descriptions of these specifications.

2. Command Priorities:

a. A scheme of priority levels must be provided to prevent interaction of a command of low priority with a command of higher priority. Override commands entered by the operator must have the priority than those emanating from the applications programs.

3. Control modes shall be provided with a mode selector control switch with the following positions:

a. MANUAL – Local manual control mode performed by operator at the crane pendant control station.

1) When the selector switch is in the MANUAL position, the speed is specified manually from the high-level controller. The hoist and travel motors are accelerated and decelerated to the set speed in such a way that the load sway has been eliminated when the set speed is reached.

2) Sway control is active in manual mode.

3) Jogging/inching/micro-speed is active in manual mode.

4) Approaching zero position for soft landing is active.

b. SAFE – Disable controls.

4. Anti-Sway, Anti-Skew, Anti-Jerk, and Anti-Collision functions:

a. Prevent damage.

b. Prevent accidents.

c. Implement programming, sensors and proximity switches into crane automation control system.

d. Continuous load damping.

5. Collision Avoidance/”No-Fly Zone” function:

Revised 25 00 01 - 18

a. Provide software functionality to create No-Fly Zones within the boundaries of the crane’s region of operation with the following characteristics:

1) Software shall utilize provided sensors as described in section 41

22 15 – Bridge Crane Electrical Components, Paragraph 2.18 “Sensors” to determine coordinate definitions.

2) Any crane entry into No-Fly Zones shall be disallowed.

3) No-Fly zones shall have several software-defined boundaries surrounding them with the following characteristics:

a) A full-stop boundary, disabling all further motion.

b) A slow-down and alarm boundary, restricting the crane to runway-end slow speeds and triggering an audible and visible alarm.

c) Boundaries shall be of equal or successively larger width around the No-Fly Zone in the order of full-stop, slow-down.

4) Each No-Fly Zone and its corresponding boundaries shall have separately defined parameters.

5) Boundary widths and No-Fly Zone locations shall be editable by site staff.

6) The software shall include an Override allowing operation in the No-Fly Zone.

a) Override shall include protection against accidental engagement.

B. Relay Function ladder operations shall consist of the following contacts and coils:

1. Normally Open Contact.

2. Normally Closed Contact.

3. Coil.

4. Negated Coil.

5. Retentive Coil.

6. Negated Retentive Coil.

7. Positive Transition Coil.

8. Negative Transition Coil.

9. Set Coil (Latch).

10. Reset Coil (Unlatch)

11. Retentive Set Coil.

Revised 25 00 01 - 19

12. Retentive Reset Coil.

13. Positive Transition Contact – leading edge one-shot coil.

14. Negative Transition Contact – trailing edge one-shot coil.

C. Adjustable Parameters:

1. Provide parameter input and display directly, in the correct engineering units, through a series of keystrokes on a front panel display with decimal point and polarity indication. Provide display in metric English units.

2. Provide a password protected configuration screen on the HMI to adjust automation control parameters.

3. Include the following items at a minimum:

a. PLC control timer setpoints.

b. VFD parameter setpoints.

c. Acceleration and Deceleration parameters.

d. No-Fly Zone and Boundary definitions per 2.02.A.5.

e. Adjustable Analog and Digital input threshold setpoints including but not limited to:

1) Setpoint calculation for motion control.

2) Crane controller signaling system.

3) Closed-loop speed control.

4) Open-loop speed control.

5) Coordinate transformation.

6) Hoist motor RTD.

7) Travel motor RTD.

D. The PLC shall accept the following functions from the hoist and travel motor controllers:

1. Master Switch Signals:

a. Setpoint.

b. Control enable.

2. Ramp-function generator

a. Series-connected ramp-function generator with adjustable ramps to form the speed setpoint.

3. Speed Controller:

a. Coordinated with ramp-function to form the control loop.

4. Start Pulse:

Revised 25 00 01 - 20

a. Start command activates hoisting direction of rotation immediately after power up to prevent the load from dropping on start-up.

5. Sequencer:

a. For switching through rotor stages and activates reversing.

6. Standstill monitoring:

a. Integral zero-speed monitoring with electrical brakes.

E. Inputs and Outputs:

1. Automation controls shall collect electrical power and process data from digital inputs for the following values:

a. Hoist and Travel Motor voltage, current, frequency.

b. Motor field voltage and current.

c. Motor position.

d. Two Speed changer setpoint.

1) First Speed: Microspeed. High or low frequency setting.

2) Second Speed: Normal speed.

Deleted

e. Upper Limit switch #1.

f. Upper Limit switch #2.

g. Lower Limit switch #1.

h. Deleted

i. End Travel Limit Switch #1.

j. End Travel Limit Switch #2.

F. Control Functions:

1. Proportional, integral, derivative PID controller.

2. Bumpless transfer between control modes.

3. Tracking of set point, process variable and equipment status (LIFT, LOWER, FOREWARD, REVERSE, HOLD).

2.03 HOIST MOTOR CONTROL LOOP

A. Control Logic Description:

1. Monitors load conditions to match motor torque and speed for LIFT and LOWER operation.

B. Process Control Signals:

Revised 25 00 01 - 21

1. Command output signal sent to the hoist motor from PLC.

2. Feedback for position.

3. Upper and lower limit switches.

C. Operation Sequence:

1. Hoist motor “Start of Run Motor Check”:

a. The start-up check shall check the motor torque at the beginning of each lift.

1) A “Torque-Proving” function shall be programmed on a power up cycle. The VFD will test the motor at the default torque test value.

2) Once the first check has successfully completed the VFD will check the motor at the torque required for the suspended load.

3) If no load is suspended the VFD will check the motor torque at the minimum torque check value. The hoist may rotate slightly in the lift direction due to a buildup of starting torque, this is normal.

4) During the hoist motor start, the VFD shall check to ensure the motor has produced sufficient torque before releasing the brakes.

5) If the hoist motor fails to generate sufficient torque during start-up, the VFD will trip with an error. Brakes shall not be released.

6) The automation controller will use PID control to maintain the level to user defined set point.

2. Hoist motor “Load Float”:

a. The load float utilizes the encoder feedback to hold the load at zero speed without setting the motor brakes. This allows for precise movement of a load.

b. Once the motor brakes have been released and motion commands have been completely released, the VFD shall decelerate to zero speed. The float load will trigger a timer.

c. If a motion command is issued before the timer has expired the load float timer will reset.

d. Once the load float timer has expired, the VFD shall apply the motor brakes and start the “End of Run Motor Brake Check”.

e. Load float timer shall be set to a minimum of 2 seconds, unless otherwise designed by the crane manufacturer.

3. Hoist motor brakes delay:

a. Program a delay for a minimum of 0.3 seconds, unless otherwise designed by the crane manufacturer.

Revised 25 00 01 - 22

b. Delay shall allow for the motor brakes to fully release before accepting a frequency command as well as allowing for the motor brakes to fully set before starting the “End of Run Motor Brake Check”.

c. Design to prevent the hoist motor from running through the brakes or prematurely slip.

4. Hoist motor “End of Run Motor Brake Check”:

a. Program to check for motor brake slip and the end of each lift cycle.

b. Once the load float timer expires, the PLC shall lockout the directional commands.

c. The VFD will apply the motor brakes and wait until the delay timer has expired. Once the timer expires, the VFD shall reduce the motor torque to 0 percent.

d. If motion is detected during the “End of Run Motor Brake Check” the VFD shall restore full torque to the motor and trigger the fault condition signal from and output relay.

1) The lift and speed commands shall be locked out.

2) The PLC shall wait until a LOWER command is given and then proceed to lower the load in low speed. If the LOWER command is removed, the VFD will start the “End of Run Motor Brake Check” again.

e. Once the load is safely placed on the ground and the “End of Run Motor Brake Check” passes, the VFD shall restore all motion and speed commands. The fault condition signal shall be deactivated.

5. All operation sequences shall be displayed and alarmed on HMI.

D. MANUAL:

1. Autospeed.

a. After a time delay (setpoint), feedback signal is sent to PLC if there is a fail-to-lift or fail-to-lower condition.

1) Motor brakes will be automatically applied

2) Alarmed to HMI.

b. The autospeed feature shall automatically increase the high speed frequency to the preset value when the lifting torque percentage or current at the high speed frequency is less than the Autospeed output torque threshold.

1) The output current must not exceed the motor full load current or the VFD full load current while in Autospeed.

2) The output torque must not exceed 225 percent.

3) Autospeed frequency shall not be set above 90 Hz.

Revised 25 00 01 - 23

2. Automation Control with loss of power:

a. Apply mechanical brakes.

b. Display alarm on HMI.

3. Control Loop – Temperature Alarms:

a. Alarms: Motor High Temperature detected.

b. Alarms: Smoke detected in machine room.

c. Display on HMI’s.

4. Control Loop – Power:

a. Monitor main power circuit for undervoltage.

b. Operation Sequence:

1) PLC Initiate application of motor brakes.

2) PLC Initiate transfer switch to engine generator (if available).

5. HMI Indication, alarming and operator set points:

a. Hoist control mode selection and status indication.

b. Hoist Position: 0 to 100 percent.

c. In Transition.

d. Hoist Motor Fault/Trouble.

e. Motor overtemperature/overload alarm.

f. Motor disconnect Open.

g. Loss of power alarm.

h. Loss of signal alarm.

E. Inputs to start sequence checks Table 25 00 01B – Inputs to Start Sequence Checks

C = Control; P = Protection

Input Name Position Function From Description

Control mode transfer switch

43CCS MANUAL C Control Panel

Motor control mode selection

Motor disconnect breaker

42CD Closed C Control Panel

Electric motor actuator running circuit breaker

Motor starter contact

6CS Open Control Panel

Electric motor actuator starting contact

Motor overload relay

50C Normally Closed

P Control Panel

Electric motor actuator overload relays

Overtemperature protection relay

38C Normally Closed

P Control Panel

Electric motor actuator overtemperature protection device

Revised 25 00 01 - 24

2.04 TRAVEL MOTOR CONTROL LOOP

A. Control Logic Description:

1. Monitors load conditions to match motor torque and speed for FORWARD and

REVERSE operation.

B. Process Control Signals:

1. Command output signal sent to the travel motor from PLC.

2. Feedback for position.

3. Laser sensors for anti-collision and anti-sway.

4. End of travel limit switches.

C. Operation Sequence:

1. Travel motor “Start of Run Motor Check”:

a. The start-up check shall check the motor torque at the beginning of each travel.

1) During the travel motor start, the VFD shall check to ensure the motor has produced sufficient torque.

2) If the travel motor fails to generate sufficient torque during start-up, the VFD will trip with an error.

3) The automation controller will use PID control to maintain the travel position to user defined set point.

2. Travel motor time delay:

a. Program a delay for a minimum of 2 seconds, unless otherwise designed by the crane manufacturer.

Table 25 00 01B – Inputs to Start Sequence Checks C = Control; P = Protection

Input Name Position Function From Description

Limit switch #1 33ULS1 C Crane Upper Limit switch for crane operation

Limit switch #2 33LLS2 C Crane Lower Limit switch for crane operation

Motor Torque Check Value

C PLC Default or preset hoist motor torque check value

Motor Torque Check time

C PLC Preset “Start of Run Motor Check” timer.

Output Torque Threshold

C PLC Autospeed preset torque and current threshold %

Autospeed Frequency

C PLC Autospeed preset frequency threshold

Revised 25 00 01 - 25

b. Delay shall allow for the travel motor brakes to fully release before accepting a frequency command as well as allowing for the motor brakes to fully set before starting the “End of Run Motor Brake Check”.

c. Design to prevent the travel motor from running through the brakes or prematurely slip.

3. Travel motor “End of Run Motor Brake Check”:

a. Program to check for motor brake set and the end of each travel cycle.

b. The VFD will apply the motor brakes and wait until the delay timer has expired. Once the timer expires, the VFD shall reduce the motor torque to 0 percent.

c. If motion is detected during the “End of Run Motor Brake Check” the VFD shall restore full torque to the motor and trigger the fault condition signal from and output relay.

1) The FORWARD and speed commands shall be locked out.

2) The PLC shall wait until a REVERSE command is given and then proceed to REVERSE in low speed. If the REVERSE command is removed, the VFD will start the “End of Run Motor Brake Check” again.

d. Once end of travel or target position is reached and the “End of Run Motor Brake Check” passes, the VFD shall restore all motion and speed commands. The fault condition signal shall be deactivated.

4. All operation sequences shall be displayed and alarmed on HMI.

D. MANUAL:

1. Autospeed:

a. After a time delay (setpoint), feedback signal is sent to PLC if there is a fail-to-start condition.

1) Motor brakes will be automatically applied.

2) Alarmed to HMI.

b. The autospeed feature shall automatically increase the high speed frequency to the preset value when the starting torque percentage or current at the high speed frequency is less than the Autospeed output torque threshold.

1) The output current must not exceed the motor full load current or the VFD full load current while in Autospeed.

2) The output torque must not exceed 180 percent.

3) Autospeed frequency shall not be set above 90 Hz.

2. Automation Control with loss of power:

a. Travel motor brakes shall be applied.

Revised 25 00 01 - 26

b. Display alarm on HMI.

3. Control Loop – Temperature Alarms:

a. Alarms: Motor High Temperature detected.

b. Alarms: Smoke detected in machine room.

c. Display on HMI’s.

4. Control Loop – Power:

a. Monitor main power circuit for undervoltage.

b. Operation Sequence:

1) PLC Initiate application of motor brakes.

2) PLC Initiate transfer switch to engine generator (if available).

5. HMI Indication, alarming and operator set points:

a. Travel control mode selection and status indication.

b. Travel Position: 0 to 100 percent.

c. In Transition.

d. Travel Motor Fault/Trouble.

e. Motor overtemperature/overload alarm.

f. Motor disconnect Open.

g. Loss of power alarm.

h. Loss of signal alarm.

E. Inputs to start sequence checks:

Table 25 00 01C – Inputs to Start Sequence Checks

C = Control; P = Protection

Input Name Position Function From Description Control mode transfer switch

43CCS MANUAL C Control Panel

Motor control mode selection

Motor disconnect breaker

42CD Closed C Control Panel

Electric motor actuator running circuit breaker

Motor starter contact

6CS Open Control Panel

Electric motor actuator starting contact

Motor overload relay

50C Normally Closed

P Control Panel

Electric motor actuator overload relays

Overtemperature protection relay

38C Normally Closed

P Control Panel

Electric motor actuator overtemperature protection device

Limit switch #5 33TLS5 C Crane Travel Limit switch for crane operation

Limit switch #6 33TLS6 C Crane Travel Limit switch for crane operation

Revised 25 00 01 - 27

Table 25 00 01C – Inputs to Start Sequence Checks C = Control; P = Protection

Input Name Position Function From Description Motor Torque Check Value

C PLC Default or preset hoist motor torque check value

Motor Torque Check time

C PLC Preset “Start of Run Motor Check” timer.

Output Torque Threshold

C PLC Autospeed preset torque and current threshold %

Autospeed Frequency

C PLC Autospeed preset frequency threshold

2.05 PROGRAMMABLE LOGIC CONTROLLER

A. Refer to Section 25 12 10 – Programmable Logic Controller.

2.06 COMMUNICATION MODULES

A. Refer to Section 25 12 10 – Programmable Logic Controller.

2.07 HMI AND GRAPHIC DISPLAYS

A. Refer to Section 25 12 10 – Programmable Logic Controller.

2.08 CONTROL ENCLOSURE

A. Refer to Section 41 22 15 – Bridge Crane Electrical Components.

2.09 FACTORY ACCEPTANCE TESTING

A. Coordinate factory acceptance testing of automation systems with factory testing of Crane Electrical Components and PLC assembly (Section 41 22 15 – Bridge Crane Electrical Components and Section 25 12 10 – Programmable Logic Controller)

B. Notify the Government at least 60 days before witness tests are to be conducted and as agreed by the COR.

C. Prior to Factory Acceptance Test, the Contractor shall perform burn-in test of the equipment for a minimum of 72 hours.

D. The purpose of the Factory Acceptance Test is to demonstrate the functionality, performance and stability of the hardware and software.

Revised 25 00 01 - 28

E. The test shall verify that hardware and software meet the requirements of the specifications and drawings.

F. Factory Acceptance Tests shall include point to point checks of all connections and application simulation tests that demonstrate automation controls will operate as described in these specifications.

G. Government reserves the right to request additional simulation and control algorithm tests, to demonstrate proper programming sequences.

H. Perform 100 percent I/O checkout, closed loop simulation of binary/modulating logic, and validations of all logic and displays.

1. Display of all alarms and warnings on the HMI shall be demonstrated for each I/O point.

I. Specific tests shall include but not be limited to:

1. Simulation of each discrete data point at the terminal block.

2. Simulation of each analog data signal using current or voltage source.

3. Operation of communication between PLC, Distributed I/O devices, power meters, process meters, network switches and crane automation control network.

a. Fail-safe shutdown and restart of PLC application programming.

4. HMI display screens and data display.

5. Simulation of crane motor LIFT, LOWER, FORWARD and REVERSE operation sequences in MANUAL control mode, including the ability to introduce out of sequence events to test program stability.

6. Simulation of HMI status functions in all control modes.

7. Demonstration of Maintenance Test Mode capability.

J. Government will witness first factory acceptance test and reserves the right to witness subsequent factory tests. Notify COR in writing at least 60 days prior to beginning the Factor Acceptance Tests.

1. Location: Contractor facility.

K. Do not ship equipment until the test reports for the equipment are approved.

1. Approval of factory tests shall in no way relieve the Contractor of the responsibility for furnishing equipment that meets the requirements of these specifications.

2.10 NETWORK ASSET CONFIGURATION MANAGEMENT LIST

A. Spreadsheet format.

Revised 25 00 01 - 29

a. The Network Asset Configuration Management List includes the following minimum information:

1. List of all equipment located at the facility and connected to the communication networks in the system in separate rows and in the first columns and on the same row for each piece of equipment:

a. Serial number.

1) Model number.

b. Firmware revision numbers.

1) Communication addresses.

c. Default passwords.

2. In a separate spreadsheet tab for each device, include a list of all active and inactive electronic access ports in the first column and include the following minimum information in subsequent columns, on each row, for each port:

a. Enabled or disabled status.

1) Communication protocol used on this port.

b. If the port is enabled, list the service, node, device, and/or system requiring this communication port to be enabled.

3. Spreadsheet rows shall be sortable based on any column’s contents.

2.11 SECURITY

A. Communication between Automation Controls System:

1. Approved components or systems:

a. Bridge crane automation control networks.

b. Crane HMI alarm system.

c. Intranet communications with approved, internally networked, devices are the only network connections that will be allowed.

2. Unapproved Components:

a. Components and systems are unapproved unless they are included in the list of approved components or systems.

b. Anything with a connection to the internet, Reclamation, or Contractor business network, or world wide web are unapproved.

B. All contractor owned devices, and communication paths, not being turned over to the Government, shall be removed from the system within 48 hours following the completion of a system’s Site Acceptance Testing.

b. All wireless capability must be fully disabled prior to delivery and will remain disabled prior to, during and following Site Acceptance Testing.

Revised 25 00 01 - 30

C. Access Control - Provide the following minimum access control capabilities, in

1. accordance with the recommendations in ISA 62443-1-1 and ISA 62443-2-1The

Contractor shall provide user accounts with configurable access and permissions associated with one or more organizationally defined user roles, where roles are used to include the following requirements:

a. Password length.

b. Minimum required password complexity.

1) Minimum of eight characters in length.

2) Support a maximum of 64 characters in length.

3) At least one special character.

2. Adjustments to the above requirements shall only be with the explicit written approval of the Project Manager upon receipt of a written justification.

3. PLC assemblies, VFD assemblies and Network devices:

a. Provide individual accounts for each user with customizable access privileges for each account.

b. Accounts shall be configurable into role-based functions allowing varying levels of interface.

c. Include account authentication by approved method.

4. The Contractor shall configure each component to operate using the principle of least…