3-Division 40 - Process Integration.pdf

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 1

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Level Instruments

B. Miscellaneous Instruments

1.02 RELATED REQUIREMENTS

A. Division 26 – ELECTRICAL

1.03 SUBMITTALS

A. Instrument supplier shall review the Contract drawings to verify suitability of the supplied instrument for the intended application prior to submittal process.

1. Provide verification of this review process by instrument and application.

B. Product Data: For each type of product.

1. Include construction details, material descriptions, dimensions of individual components and profiles, and finishes for transfer switches.

2. Include rated capacities, operating characteristics, electrical characteristics, and accessories.

C. Shop Drawings:

1. Catalog Cutsheets.

2. Field wiring diagrams.

3. Construction drawings and engineering data defining materials of construction, dimensions, weights and sizes.

D. Field quality-control reports.

E. Operation and Maintenance Data: For each type of product to include in emergency, operation, and maintenance manuals.

1. In addition to items specified in Section 01 78 00 - Closeout Submittals, include the following:

a. Features and operating sequences, both automatic and manual.

b. List of all factory settings of relays; provide relay-setting and calibration instructions, including software, where applicable.

F. Operation and Maintenance Manual:

1. Submit complete bound manuals for all hardware and software components assembled into 3 ring binders.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 2

2. Include:

a. Shop Drawing information

b. Calibration information

c. Configuration of each device, as configured at time of Maintenance Training.

d. Flash Drive copies of all custom programs incorporated.

1.04 WARRANTY

A. Manufacturer's Warranty: Manufacturer agrees to repair or replace equipment or components that fail in materials or workmanship within specified warranty period.

1. Warranty Period: 12 months from date of Substantial Completion

PART 2 - PRODUCTS

2.01 PERFORMANCE REQUIREMENTS

A. Contractor

1. The Contractor shall be responsible for the complete supply and installation of process instrumentation and control systems furnished by a single company regularly engaged in the manufacture of process instrumentation systems.

2. Functional system data is described herein and is augmented by accompanying product specifications. All elements shall be provided as shown and/or required. Additional elements such as power supplies, current repeaters, and other such elements as may be required to complete the system shall be provided even though not shown.

3. All material shall be new, free from defects, and of the quality specified or shown. Each type of material shall be of the same manufacturer throughout the work. All material shall be the product of established, reputable manufacturers normally engaged in the production of the particular item being furnished.

B. Instrumentation Supplier

1. All instrumentation equipment, panels, sensors, transmitters and other system components shall be supplied by one instrumentation manufacturer who shall be responsible for total system design, integration and functioning of the system and all components, including those items manufactured by others but furnished by the instrumentation supplier.

2. The instrumentation supplier must have the proven skill, experience, ability, facilities, and qualified personnel necessary to successfully, timely and properly complete the involved work. During the bid evaluation period, any proposed instrumentation supplier will be evaluated to consider their ability to satisfy the foregoing requirements.

3. The instrumentation supplier must assign sufficient qualified personnel to the project to assure the timely and proper completion of the work. Full, continuous, and detailed supervision of the work will be required.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 3

C. Equipment Requirements

1. The product Specifications include description of instrumentation items used in systems. In certain instances, this description is followed by at least one brand name (and/or model number) and an "or equal" provision. Each product submitted under the "or equal" provision will be reviewed as to whether it is acceptable as an equal.

2. In conducting such a review, the Engineer shall consider the comparability of the specifically named products with the "or equal" products, including specifically their relative performances. Such review shall be based both on the product individually and its interrelationship with all other aspects of the instrumentation system.

2.02 PRODUCT IDENTIFICATION

A. All the equipment shall have a stainless steel name plate permanently affixed in a conspicuous place on which is plainly marked the manufacturer's name, address, model number, and loop number as stated in the Specifications and shown on the Drawings. The nameplate of a distributing agent only is not acceptable.

2.03 LEVEL INSTRUMENTS

A. Backup Float Controller

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Primex Controls; PRIMEX DPC-4F.

b. Approved Equal.

2. Functional Description:

a. Multi-functional pump controller designed to operate two pumps. Controller can be configured to operate as duplex backup controller or as a duplex controller.

3. Features:

a. Green LED indicators for Power On and Pump Call-To-Run

b. Red LED indicator for Alarm and Backup Mode.

c. Amber LED indicators for Float Status.

d. Float out of sequence detection.

e. HIGH level relay directly operated by FLOAT 4, independent of microcontroller.

f. 12 VDC power to float switches Relay Outputs: Pump Call-To-Run (2), Low, High, Horn/Backup

g. UL Listed.

h. 2-year limited warranty.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 4

4. Electrical:

a. Input Voltage: 100 ~ 250 VAC (50/60 Hz).

b. Float switch inputs: 12 VDC, 26 mA each.

c. Relay rating 5 A maximum at 240 VAC.

5. Construction / Design:

a. Consult user manual for proper installation instructions.

B. Float Switch (LS)

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. MJK model 7030.

b. Approved Equal.

2. Contact System shall be a Microswitch with a minimum of 2x10^7 operations.

3. Output shall be dry contact with max load rating of (AC: 250V @16A or DC:220V@.5A or 24V@16A).

4. The operating temperature shall be between -20 ºF to 60 ºF.

5. The cable shall be made highly flexible oil resistant material and having adequate tensile strength.

6. The float housing material shall be made of Polypropylene.

7. All floats shall be provide with counter weights.

C. Submersible Level Transducer and Transmitters (LT)

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Keller

b. Sigma Controls, Inc.; Model 6000MP Transducer.

c. Precision Digital Corporation; Model PD660 Digital Panel Meter.

d. Approved Equal.

2. Material: 316 Stainless Steel.

3. Electrical:

a. Input: 15 - 45 VDC.

MARCH 2026

40 91 13 - Process Instrumentation

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KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 5

b. Output: 4 – 20 mADC/digital.

4. Electrical Connection: Attached four wire 20GA shielded cable.

5. Ranges: 0-16 feet.

6. Temperature Limits: -40 ºF to 248 ºF.

7. Accuracy: +/- 0.1%.

8. Diameter: 1.25 inch.

9. Weight: 8 oz.

10. Loop powered digital panel meter.

11. Display: Dual Line, 0.7" & 0.4" High, 5 & 8 Digits, Decimal, LCD.

2.04 MISCELLANEOUS INSTRUMENTS

A. RAIN GAUGE

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Rainwise (Basis-of-Design)

2. Functional Description:

a. Unit shall be designated to gauge the amount of rainfall and communicate that data through a wired connection which sends a 4-20mA signal to the autodialer.

3. Features:

a. Self-emptying 8" Diameter Rain Bucket.

b. Meets NWS Specifications.

4. Construction / Design:

a. Consult user manual for proper installation instructions.

PART 3 - EXECUTION

3.01 INSTALLATION

A. Description of Work

1. Provide all labor, material and necessary equipment to install instrumentation and control systems and be responsible for the satisfactory operation of the entire system as specified herein and as shown on the drawings.

2. Work includes supplying erecting, testing and placing in operation the system specified.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 6

3. Work includes the supply and installation of all process measuring elements, transmitters interconnecting wiring and process taps as specified herein and indicated on the drawings.

4. Work includes the provision and connection of all wiring to and from every electrical device furnished under this Section including 120 volt power wiring and all instrumentation and control wiring.

a. All wiring shall be in accordance with Section NEC A1 requirements.

b. Instrumentation and Control Wiring noted within this Specification Section includes:

1) Circuits used to carry analog signals

2) Circuits used to start and stop equipment

3) Circuits used to key a control function or serve as an interlock

4) Circuits used to indicate equipment operating status

5) Circuits used to actuate alarms.

c. Work includes the provision and installation of and all piping, manual shut-off valves, and mounting hardware (e.g. nuts, bolts, washers, pipe stands, or cinch anchors) associated with connecting or mounting the instrumentation, as described herein.

B. General

1. Equipment shall be located so that it will be readily accessible for operation and maintenance.

2. The Contractor shall examine the Contract Drawings and shop drawings for the various equipment in order to determine the best arrangement for the work as a whole, and shall use personnel skilled in the applicable trade for the erection of the various materials and interconnections.

C. Equipment Mounting and Support

1. Field instruments shall be mounted in the areas specified or otherwise noted.

2. Instruments attached directly to concrete shall be spaced out from the mounting surface not less than 1/2 inch by use of phenolic spacers or framing channel.

3. Expansion shields or cast-in-place inserts shall be used for securing equipment or supports to concrete surfaces.

4. Unless otherwise noted, field instruments shall be mounted between 48 inches and 60 inches above the floor or work platform.

D. Transmitters

1. Flow and pressure transmitters shall be connected to the process piping with nipples, fittings and/or tubing of material compatible with the process fluid.

2. Where transmitters are supported from process piping, leveling saddles shall be provided.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 7

3. Transmitters shall be oriented such that output indicators are readily visible.

4. Electrical connections to transmitters and elements mounted on process piping or equipment shall be made through liquid-tight flexible conduit.

5. The fitting materials shall be compatible with the process fluid.

3.02 ELECTRICAL WORK

A. Signal wiring shall be carried in raceways or conduit provided in accordance with other sections of this Division of the Specifications.

1. Shielded twisted pairs carrying 4-20 mA and other low level signals shall be run in conduits or raceways separate from all other control and power wiring.

a. All analog circuits shall be run as twisted pairs or triads.

b. In no case shall a circuit be made up using conductors from different pairs or triads.

c. Triads shall be used wherever three (3) wire circuits are required.

d. Triads shall not be formed by using two (2) pairs.

2. Terminal blocks shall be provided at all instrument cable junctions, and all circuits shall be identified at such junctions.

3. Signal circuits shall, in general, be run without splices between instruments, terminal boxes or panels.

B. Shields shall, in general, be bonded to the ground bus at the control panel and isolated at all other locations.

1. Terminal blocks shall be provided for interconnecting shield drain wires at all junction boxes.

C. Alternating current power supply connections for panel mounted equipment shall be by cord and plug where practicable.

1. Field mounted units shall be wired in solid and provided with a power disconnect switch either internally or adjacent to the unit.

2. Where multiple field mounted units are fed from a single circuit breaker, each field mounted unit shall be protected by individual draw-out fuses.

3.03 FIELD QUALITY CONTROL

A. Factory Tests

1. Testing of Individual Components

a. Each item of equipment shall be fully factory inspected and tested for function, operation and continuity of circuits.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 8

b. Each instrument shall be factory calibrated. Calibration sheets verifying instrument accuracy shall be supplied.

2. Full System Tests

a. An operation check of the entire system shall be performed by the instrumentation supplier at his factory. Power and manually adjustable measurement and control circuits shall be connected to the central control for simulating the functions specified within the Specification section.

b. The Owner shall be notified at least ten days in advance of any factory systems tests and reserves the right to have its representatives in attendance.

B. Analog Instrument Calibration

1. All analog instruments shall be installed such that taps and parts, etc. are available for in-place calibration and test without removal. For those instruments where such in situ calibrations are not feasible (e.g. pH immersion electrodes, etc.), other calibration methods shall be provided subject to review by the County.

2. Field calibration shall be achieved using a minimum of five points (0, 25, 50, 75, and 100 percent) for calibration. Additional points may be required by the Owner for non-linear instruments.

3. Receiving elements such as controllers, final operators, etc. shall be observed and readings documented during transmitter exercising to demonstrate correct operation of entire control loop.

4. Other elements such as controllers, final operators, etc. shall be exercised to demonstrate correct operation.

C. Pretesting:

1. After installation, align, adjust, and balance system and perform complete pretesting to determine compliance of system with requirements in the Contract Documents.

2. Correct deficiencies observed in pretesting.

3. Replace malfunctioning or damaged items with new ones and retest until satisfactory performance and conditions are achieved.

4. Prepare forms for systematic recording of acceptance test results.

5. After pretesting is complete, provide a letter certifying that installation is complete and fully operable; include names and titles of witnesses to preliminary tests.

D. Operational Tests

1. An operation check of the entire system shall be performed by the instrumentation supplier after installation to verify operation.

2. Schedule tests after pretesting has been successfully completed.

3. Test all modes of system operation at each device.

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 9

4. Power and manually adjustable measurement and control circuits shall be connected to the control system to verify the functions specified within the Specification section.

5. Inspection: Verify that units and controls are properly labeled and interconnecting wires and terminals are identified.

6. Electrical Tests: Minimum required tests are as follows:

a. Verify the absence of unwanted voltages between circuit conductors and ground.

b. Test all conductors for short circuits using an insulation-testing device.

c. With each circuit pair, short circuit at the far end of circuit and measure circuit resistance with an ohmmeter. Record circuit resistance of each circuit.

7. All conditions of operation shall be simulated to demonstrate that each system operates properly.

8. Test each initiating and indicating device for operation and proper response at local control stations, PLC panel and supervisory control station.

E. Report of Tests and Inspections:

1. Prepare a written record of tests, inspections, and detailed test results in the form of a test log.

2. Tag all equipment, stations, and other components for which tests have been satisfactorily completed.

F. Acceptance

1. The system will not be accepted until all equipment satisfies the acceptance test requirements. The complete system shall operate continuously during an acceptance test period of not less than thirty days with no down-time of the complete system resulting from failure of hardware. Downtime of the system or portions of the system resulting from the following causes will not be considered system failures:

a. Downtime resulting from an outage of the main power supply provided that automatic shutdown and restart of the system satisfies the requirements of these Specifications.

b. Downtime of a portion of the system resulting from failure of a communications channel provided that the system operated as specified under this condition.

c. Downtime caused by operator error.

3.04 START-UP

A. Installation Assistance

1. Provide the services of a qualified factory engineer to supervise the installation, to test and make any adjustments required, and to place the completed system in operation.

B. System Operation Training

MARCH 2026

40 91 13 - Process Instrumentation

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 91 13 - 10

1. The Contractor shall have the instrumentation supplier provide a factory trained engineer to instruct the County's operating personnel in the use, operation, care, and maintenance of the process control instrumentation.

2. The training shall be conducted on-site and be presented in a manner to impart thorough understanding of the systems and equipment provided.

3. The training shall be given to the personnel designated by the Owner who will be responsible for operation during each work shift. The personnel shall sign a certificate presented by the Contractor that they have been trained on the plant equipment and they thoroughly understand the operation, care and maintenance of the equipment.

4. The Owner will notify the Contractor when their personnel is ready to be trained. The Contractor will then ensure that the manufacturer's representatives are available on-site to conduct the required training.

3.05 EXPENDABLES

A. One (1) year's supply of expendables shall be provided as noted within this section.

Expendables (charts, ink, test chemicals, etc.) used during calibration and checkout prior to plant acceptance shall be replenished at the Contractor's expense to insure a full year supply at the time of plant acceptance.

3.06 MAINTENANCE

A. Corrective maintenance shall be performed only by a factory trained service technician specifically trained for servicing the types of equipment furnished under this Contract.

PART 4 - INSTRUMENT LIST

4.01 INSTRUMENT TAGGING/LOCATION:

TAG DESCRIPTION LOCATION

LT12 LEVEL TRANSMITTER WET WELL

FS12 HIGH ALARM WET WELL

FS22 LAG PUMP ON WET WELL

FS32 PUMP ON WET WELL

FS42 PUMP OFF WET WELL

FS52 LOW ALARM WET WELL

MARCH 2026

40 94 43 - Programmable Logic Controllers For Process Systems

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 94 43 - 1

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Programmable Logic Controllers.

B. Operator Interface Terminals.

1.02 REFERENCE STANDARDS

A. IEEE C37.90 - IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus; 2005 (Reaffirmed 2011).

B. UL 508 - Industrial Control Equipment; Current Edition, Including All Revisions.

1.03 SCOPE OF WORK

A. Provide all programmable logic controllers, operator interface terminals, and all equipment for a complete and functional PLC control panel in each area of the plant as indicated in the contract drawings.

B. Coordinate with Section 40 95 13 - Process Control Panels and Hardware for additional control panel hardware and control panel enclosures.

1.04 SUBMITTALS

A. Submit catalog cuts, shop drawings, and O&M manuals for all equipment in conformance with the requirements of Section 40 95 13 - Process Control Panels and Hardware.

1.05 WARRANTY

A. Conform with all Contract Warranty requirements specified in the General Conditions and General Requirements.

B. Provide an extended manufacturer’s warranty on all products and equipment to remain in effect for not less than one year after the successful completion of the reliability acceptance tests.

PART 2 - PRODUCTS

2.01 PROGRAMMABLE LOGIC CONTROLLERS (PLC)

A. In order to minimize training requirements, provide a uniform look and feel, and provide better support and administration, the Owner has standardized on a single Control System software package and PLC manufacturer. Therefore, no substitutes will be accepted for the specified products.

B. The Programmable Logic Controllers shall be an Allen Bradley 1769 CompactLogix Series controller with power supplies, processors and network interface modules.

1. The standardized equipment is listed below:

a. CPU, Catalog No. 1769-L30ER, with integrated Ethernet IP port.

MARCH 2026

40 94 43 - Programmable Logic Controllers For Process Systems

CALN TOWNSHIP MUNICIPAL AUTHORITY

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MARCH 2026 40 94 43 - 2

b. 16pt 24VDC DI Module, Catalog No. 1769-IQ32.

c. 16pt 24VDC DO Module, Catalog No. 1769-OB16.

d. 8pt AI Module, Catalog No. 1769-IF8.

e. 8pt AO Module, Catalog No. 1769-OF8C.

f. Expansion Module Catalog No. 1769-CRR1.

g. Right End Cap, Catalog No. 1769-ECR.

h. Left End Cap, Catalog No. 1769-ECL.

i. 24V DC Power Supply, Catalog No. 1769-PB4.

2.02 OPERATOR INTERFACE TERMINALS (OIT)

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Automation direct model CM5-T15W.

2. Approved Equal.

B. Graphic Panel Touch Screen shall be Fully graphical touchscreen display with serial port configured for communication to local PLC.

C. General Requirements:

1. 15 inch color TFT LCD, 1366x768

2. I/O: (3) Serial Ports, (1) Ethernet Port, (2) Memory Card Slots (4) USB A Port (1) USB B Port.

3. Supports Modbus TCP Communication.

4. 24V DC Powered.

5. Built-in Ethernet 10/100 TCP/IP for programming.

D. Programming Software:

1. The OIT programming software shall be Automation Direct model CM5-PGMSW version 8.0 or later, or approved equal.

2.03 SPARE PARTS

A. Provide the following spare PLC equipment:

1. 1 (one) spare Power Supply

2. 1 (one) spare PLC

3. 1 (one) spare DI I/O Modules

MARCH 2026

40 94 43 - Programmable Logic Controllers For Process Systems

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KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 94 43 - 3

4. 1 (one) spare DO I/O Modules

5. 1 (one) spare AI Modules

6. 1 (one) spare AO Modules

PART 3 - EXECUTION

3.01 CONFIGURATION AND PROGRAMMING

A. Configure each new programmable logic controller (PLC) for all inputs and outputs.

B. Configure and program the new programmable logic controllers to allow monitoring and control from the control system.

C. Configure the new PLC to communicate with the control system I/O servers via Ethernet connections.

D. Coordinate and document PLC LAN Node numbering and IP addresses with Plant personnel before installation.

E. Qualified representatives of the PLC manufacturer or a qualified systems integrator shall perform all configuration and programming.

F. Completely configure and program each PLC as required outlined in Section 40 96 00 - Process Control Software.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 1

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Equipment enclosures.

B. Control panel components.

C. Power supplies and UPS.

1.02 RELATED REQUIREMENTS

A. Section 40 94 43 - Programmable Logic Controllers For Process Systems.

B. Section 40 95 33 - Process Control Networks.

C. Section 40 96 00 - Process Control Software.

1.03 REFERENCE STANDARDS

A. NEMA EN 10250 - Enclosures for Electrical Equipment (1000 Volts Maximum); 2024.

B. NFPA 79 - Electrical Standard for Industrial Machinery; 2021.

C. UL 508A - Industrial Control Panels; Current Edition, Including All Revisions.

1.04 SCOPE OF WORK

A. Design, Supply and Install all hardware and software products required to provide a complete and fully functional control system as shown on the Contract Drawings and/or herein specified.

B. Design the control panels and field wiring interfaces required to implement the control equipment.

1. All control panels shall be designed and manufactured in accordance with UL 508A, Standard for Industrial Control Panels, and NFPA 79, Electrical Standard for Industrial Machinery.

2. All components shall be UL recognized.

C. Connect and test all input and output field wiring to and from the control equipment.

D. Provide all manufacturer's services required for installation, startup, calibration, inspection, and training.

E. Provide all coordination required for system integrator's services as specified in Section 40 96 00 - Process Control Software.

F. Provide all equipment specified elsewhere for a complete and operable system.

1.05 SUBMITTALS

A. Submit the following information involving proposed hardware for the control system:

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 2

1. A detailed written description of the control system outlining the purpose and capabilities of each component.

2. Catalog information, shop drawings, and descriptive literature for each component of the control system.

3. Shop drawings and catalog cuts for all panels and enclosures.

B. Submit complete detailed shop drawings, working drawings and descriptive literature for control panel equipment, cabinets, and components. As a minimum the shop drawings and working drawings shall include the following:

1. Bill of Materials

2. Power load calculations verifying capacity of power supplies and UPS units to carry the panel load.

a. Provide a minimum of 20% spare capacity on DC power supplies.

b. Provide 10 minutes of no power operation on UPS units.

3. Heat rise calculation of each enclosure.

4. Front panel, back panel and panel schematic wiring diagrams.

a. Submit detailed drawings showing proposed arrangement of equipment within each enclosure, proposed locations of all equipment and enclosures, and proposed arrangement of all conduits and conductors that will enter each enclosure.

b. Provide a minimum of 20%, but no less than two (2), installed spare I/O for each type of I/O present in the panel. All I/O are to be factory wired out to field terminal strips in the panel. These spare I/O are to be in addition to the material to be supplied under the Spare Parts section of this specification.

c. Provide a minimum of 20%, but no less than two (2), spare (open) module slots on the controller I/O back plane.

5. Interconnection wiring diagrams showing all component and panel terminal board identification numbers and external wire numbers, including existing equipment and equipment furnished by others.

6. Provide field wiring diagrams showing the connection of the wiring out to all new and existing monitored and controlled field devices. Field wiring diagrams include:

a. Point-to-Point Field Interconnection Diagrams.

1.06 WARRANTY

A. Conform with all Contract Warranty requirements specified in the General Conditions and General Requirements.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 3

B. Provide an extended manufacturer’s warranty on all products and equipment to remain in effect for not less than one year after the successful completion of the reliability acceptance tests.

PART 2 - PRODUCTS

2.01 EQUIPMENT ENCLOSURES

A. Wall Mounted Enclosures

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Hoffman; Bulletin A12-series.

b. Approved Equal.

2. UL 508A listed, wall mount, single door, hinged with quick-release latch enclosures with minimum dimensions as indicated on the drawings.

3. Provide enclosures at installed locations with the following environmental ratings.

a. Indoor, Dry and Clean Locations: NEMA EN 10250, Type 12.

b. Indoor, Damp or Wet Locations: NEMA EN 10250, Type 4.

c. Indoor, Subject to Corrosive Liquids or Gases: NEMA EN 10250, Type 4X, 316 stainless steel.

d. Outdoor Locations: NEMA EN 10250, Type 4X.

2.02 CONTROL POWER TRANSFORMERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Square D; a brand of Schneider Electric

2. Siemens.

3. Eaton Electrical Inc.: Cutler Hammer Business Unit.

4. Approved Equal.

B. The control panel shall be provided with a single voltage feed. Provide a control power transformer(s) as required for each voltage in the control panel.

C. Primary voltage shall be the primary voltage of the system. Secondary voltage shall be as required for the equipment being powered.

D. Transformer VA rating shall be as required for the system being provided.

E. Provide fused primary and secondary, and bond unfused leg of secondary to enclosure.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 4

F. Transformer shall be UL listed.

2.03 UNINTERRUPTIBLE POWER SUPPLY (UPS)

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Square D; a brand of Schneider Electric

2. PULS Dimension.

3. Approved Equal.

B. 24VDC Din Rail Mount UPS:

1. Output: 12VDC, 5A and 24VDC, 10A.

2. Input Voltage: 24VDC.

3. Temperature Range: -10 ºF to 120 ºF.

4. Output Power Capacity: 360W in Normal Mode, 240W in Buffer Mode.

C. UPS shall be UL 508 Listed.

D. Warranty: 3 years.

E. Provide 12VDC battery, sized appropriately per backup requirements.

1. Allowed Batteries: 3.9Ah to 40Ah VRLA Lead Acid.

2.04 DC POWER SUPPLY

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. PULS Dimension.

2. SOLA Hevi-Duty.

3. Approved Equal.

B. Din Rail mounted power supply housed in rugged narrow metal case with large, rugged, accessible, multiple connection screw terminations.

1. Power supply shall be enclosed and completely finger safe. Open power supplies shall not be acceptable.

2. Input: Auto Select 115/230 VAC, 50/60 Hz single phase.

3. Adjustable Voltage Output: 24 Vdc – 28 Vdc.

4. Temperature Range: -10 ºF to 120 ºF operation without derating.

5. Indefinite short circuit, overvoltage and overtemperature protection.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

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KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 5

6. Highly efficient greater than 90% switching technology.

7. Power supply shall be UL 508 listed.

8. Warranty: 3 years.

2.05 SELECTOR SWITCHES, PILOT LIGHTS, ILLUMINATED PUSHBUTTONS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Square D, 9001 Series;

2. Allen Bradley, 800 Series;

3. Approved Equal.

B. Selector switches, pushbuttons and indicator lights unless otherwise noted shall be round style, 30mm, heavy-duty, oil-tight type and shall have nameplate lettering as noted on the Drawings.

1. Miniature style units shall not be acceptable unless otherwise noted on the Drawings.

C. Operator mechanism including locking ring and legend plate shall be a corrosion resistant material.

D. Switch contacts shall be arranged for the configuration and duty as indicated, and operating handles shall be easily operated by hand without the use of tools.

E. Pushbuttons shall be momentary or maintained contact type as indicated.

F. Switches and pushbuttons located remotely from the controller shall be provided with lockout features.

G. Indicator light lenses shall be polycarbonate type with color as noted.

H. Indicator lights shall be LED type and push-to-test.

I. Lamp replacement shall require removal of the front mounted lens cap only.

2.06 SIGNAL SPLITTERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Acromag.

2. Approved Equal.

B. Single 2-wire or 4-wire input, two identical isolated outputs.

C. 24VDC powered with built in isolated excitation supply with short circuit protection that can drive up to two field 2-wire process loops.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 6

D. Full isolation between input channel, both output channels, the excitation supply and power input.

2.07 SIGNAL ISOLATORS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Action Instruments.

2. Allen Bradley.

3. Approved Equal.

B. Signal conditioner with AC powered re-transmitter.

C. Single or Dual channel DC input, as required for the application.

D. Signal Isolation: 2000VAC isolation between Input, Output and Power.

2.08 RELAYS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Square D.

2. Allen Bradley.

3. Approved Equal.

B. Interposing Relays:

1. Miniature plugin relay with Din rail mounting socket.

2. 10A resistive rating.

3. Double throw C-Form contact output.

4. UL Listed.

5. Coil Voltage and contact count as required for the application.

6. LED indicating light for energized state.

7. Mechanical override lever.

C. Power-On Relay:

1. Miniature plugin relay with Din rail mounting socket.

2. 10A resistive rating.

3. Double pole, double throw C-Form contact output.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 7

4. UL Listed.

5. Coil Voltage: Equal to panel incoming power.

6. Coil to be wired to panel incoming power.

7. Contact output to be wired to receiving device as indicated in other section of these specifications or as shown on the drawings.

8. LED indicating light for energized state.

9. Mechanical override lever.

2.09 TERMINAL BLOCKS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Allen Bradley; 1492 Series Terminal Blocks.

2. Approved Equal.

B. Terminal blocks shall be one-piece molded plastic blocks with screw type terminals and barriers rated for 300 volts.

C. Terminals shall be double sided and supplied with removable covers to prevent accidental contact with live circuits.

D. Terminals shall have permanent, legible identification, clearly visible with the protective cover removed.

E. Terminal blocks shall be fused type where indicated on the drawings.

F. Analog signals shall be terminated on modular narrow form factor terminal blocks intended for the protection of a floating double conductor (4-20 mA analog) signal.

G. Two-stage surge protection for one operated floating double conductor.

H. Disconnect knife on both signal paths.

I. Separate ground connection.

J. Screw terminal connections.

K. Nominal voltage: 24 V DC.

2.10 POWER DISCONNECTS

A. Panel disconnects

1. Provide NEC compliant panel disconnects. Disconnect and shall be interlocked to the control panel door handle.

2.11 MISCELLANEOUS EQUIPMENT

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 8

A. Wiring

1. All wiring shall be in accordance with the applicable requirements of Division 26.

B. Nameplates and Name Tags

1. Panel mounted tags shall be plastic; field mounted tags shall be stamped stainless steel.

2. Nameplate shall be engraved, rigid, laminated plastic type with adhesive back. Unless otherwise noted, color shall be black with white letters and letter height shall be 3/16 inch.

2.12 SPARE PARTS

A. Terminal Blocks: Provide 20% spare blocks of each type used, installed

B. Fuses: Provide 10% spares for all types used (no less than one each).

C. Panel Lights: Provide 10% spares for all types used (no less than one each).

PART 3 - EXECUTION

3.01 DISCONNECTION AND REMOVALS

A. All power, control and instrumentation wiring associated with equipment, panels, devices, etc. to be removed and replaced shall be identified, marked and then disconnected to facilitate their replacement and any related work.

B. All materials no longer used shall be removed unless otherwise directed by the Engineer.

Affected surfaces shall be repaired to confirm to the type, quality, and finish of the surrounding surface in a neat and workmanlike manner.

3.02 CONTROL PANELS

A. Control panels shall be completely fabricated, instruments installed and wired in the manufacturer’s factory and tested prior to delivery to the site. The control panels shall be factory assembled with all input and output devices.

1. All wiring and equipment shall be completed and tested prior to shipment.

2. All external connections shall be by way of numbered terminal blocks.

3. Install spare terminal blocks on backpanel.

B. Panel instrumentation arrangement shall be as shown, with minor modifications as required by the particular equipment furnished. Modifications shall be subject to the approval of the Engineer.

C. All back panels shall be secured with all the appropriate zinc plated mounting hardware.

D. All devices and wiring shall be properly labeled.

1. Front panel devices shall be identified by laminated nameplates

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40 95 13 - Process Control Panels and Hardware

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MARCH 2026 40 95 13 - 9

2. Panel mounted devices and wiring shall be identified by a permanent marking system.

E. All circuit breakers, terminal strips, and related devices required to provide a complete, safe, and neat installation shall be provided.

F. Wiring

1. Wires shall be 600-volt class, PVC insulated stranded copper and shall be of the sizes required for the current to be carried, but not below 14 AWG enclosed in either sheet metal raceway or plastic wiring duct.

2. Wiring for signal circuits shall be twisted shielded pairs not smaller than No. 18 AWG, and be separated at least 6-inches from any power wiring.

3. All wires shall be identified as per the requirements of Division 26 specifications.

4. Provide wiring channels as required.

5. All interconnecting wires between panel mounted equipment and external equipment shall be brought out to numbered external wiring terminals and terminated.

6. All wires shall be numbered and identified.

G. Terminal Blocks

1. Wires shall be terminated at the terminal blocks with crimp type, pre-insulated, ring-tongue lugs.

2. Lugs shall be of the appropriate size for the terminal blocks screws and for the number and size of the wires terminated.

3. Fused terminal Block shall be used for power distribution.

H. Nameplates and Name Tags

1. All components provided under this Section, both field and panel mounted, shall be provided with permanently mounted name tags bearing the entire tag number and description of the component.

3.03 INSTALLATION

A. All items shall be installed in accordance with the manufacturer’s recommendations.

B. The Contractor shall furnish and install all material and hardware required to supply a complete and functional installation.

C. Notify Owner personnel prior to disconnect any existing signals.

3.04 TESTING

A. Test the hardware and software using simulated inputs and outputs prior to installation.

MARCH 2026

40 95 13 - Process Control Panels and Hardware

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 13 - 10

1. The Contractor shall retain the services of a system integrator to provide detailed test plans and procedures to demonstrate and document that all equipment has been properly installed and configured for a full functional system which meets all contract requirements.

2. See Section 40 96 00 - Process Control Software.

B. Test the complete installed system by demonstrating that all signals are properly received and sent and that the control system operates as intended.

3.05 CLEANING AND TOUCH-UP PAINTING

A. The premises shall be kept free from accumulation of waste material and rubbish. Upon completion of work, the Contractor shall remove materials, scraps, and debris from the site.

Scratches, scrapes, or ships in interior or exterior surfaces of devices shall be touched up with finishes matching as nearly as possible the type and color of the original finish.

B. All material, equipment, and workmanship shall be subject to inspection by the Engineer or his representatives. In the event the Engineer finds the materials or workmanship not in accordance with these Contract Documents, the work or materials shall be removed and replaced, or corrected, by and at the expense of the Contractor.

3.06 TRAINING

A. Provide all on-site and off-site training as specified in Section 40 96 00 - Process Control Software.

MARCH 2026

40 95 33 - Process Control Networks

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 33 - 1

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Communication Wiring and Materials.

B. Cellular Communication Equipment.

1.02 RELATED REQUIREMENTS

A. Section 40 95 13 - Process Control Panels and Hardware

B. Section 40 94 43 - Programmable Logic Controllers For Process Systems

1.03 REFERENCE STANDARDS

A. IEEE 802.1Q - IEEE Standard for Local and Metropolitan Area Networks – Bridges and Bridged Networks; 2022, with Amendment (2025).

B. IEEE 802.3 - IEEE Standard for Ethernet; 2022 (Corrigendum 2024).

C. IEEE 1588 - IEEE Standard for a Precision Clock Synchronization Protocol for Networked Measurement and Control Systems; 2019, with Amendment (2024).

1.04 SCOPE OF WORK

A. Provide all network equipment for a complete and functional SCADA system.

1.05 SUBMITTALS

A. Submit catalog cuts, shop drawings, and O&M manuals for all equipment in conformance with the requirements of Section 40 95 13 - Process Control Panels and Hardware.

1.06 WARRANTY

A. Conform with all Contract Warranty requirements specified in the General Conditions and General Requirements.

B. Provide an extended manufacturer’s warranty on all products and equipment to remain in effect for not less than one year after the successful completion of the reliability acceptance tests.

PART 2 - PRODUCTS

2.01 COMMUNICATION WIRING AND MATERIALS

A. For premises wiring cable see applicable sections of Division 26.

B. Category 6 Patch Cables (CAT 6)

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Belden.

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40 95 33 - Process Control Networks

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

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b. Black Box.

c. Approved Equal.

2. Shielded twisted pair (ScTP) cables shall be high performance 4-pair cables with protective foil shielding specifically designed for Ethernet applications, verified to EIA/TIA Category 6, with snagless boot and factory installed RJ-45 connectors.

2.02 ETHERNET LAN EQUIPMENT

A. Unmanaged Ethernet Switches

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. Black Box; Heavy Duty Hardened Edge Switch with hardened power supply.

b. Pheonix Contact.

c. Approved Equal.

2. Heavy Duty, hardened, sealed steel enclosure, DIN rail mounted, copper switch.

3. Features:

a. Support VLAN tagging and spanning tree passthrough.

b. Include Link-Loss-Learn (LLL) feature for fast network recovery.

c. Auto MDI/MDI-X ports.

d. Nonblocking switching architecture with a 2K MAC address table.

4. Ports:

a. RJ-45 10/100Mbps copper ports.

b. Provide minimum of five copper ports.

5. LED Indicators:

a. Per Port: Power.

b. Per Fiber Port: LK/ACT, F/H.

c. Per Copper Port: 10/100.

6. Standards: IEEE 802.3, IEEE 802.3u, IEEE 802.1p/q.

7. CE Approved.

8. Temperature Rating:

a. Storage: -40 ºF to 185 ºF.

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40 95 33 - Process Control Networks

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b. Long-term operating: -13 ºF to 140 ºF.

9. Humidity: 5–95%, noncondensing.

2.03 CELLULAR COMMUNICATION EQUIPMENT

A. Autodialer

1. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

a. OmniSite (Basis-of-Design).

2. Functional Description:

a. Unit shall be designed to read values of the floats and motor data to provide a real time monitoring system. The unit shall use a cellular connection to send data and alerts to plant owner and plant owners operators.

3. Features:

a. Immediate alarm reporting.

b. Machinery Operational Data reporting.

c. Advanced Internet based monitor, analyzer and controller.

d. 4GLTE Cat-1/Cat-M1, OmniSite Modular Radio (OSMR).

e. Cellular Communication.

1) Provide omnidirectional antenna kit with integrated 16 ft coax cable. Include mounting bracket with screws.

4. Operating Parameters:

a. Power Input: 12VDC or 120VAC

b. 14 IO Ports.

2.04 SPARE PARTS

A. Patch Cables: Provide 10% spares for all types used (no less than one each).

PART 3 - EXECUTION

3.01 CONTROL SYSTEM COMMUNICATION COORDINATION

A. Cutover PLC data points to the SCADA monitoring system.

B. Ethernet Patch Cables

1. Provide and install copper cords to connect from patch panels to network switches, hubs, media converters, and other network devices.

MARCH 2026

40 95 33 - Process Control Networks

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 95 33 - 4

2. Coordinate and supply suitable connectors for each patch cable as required for each application.

C. Refer to Section 40 96 00 - Process Control Software for additional programming and system integration requirements.

MARCH 2026

40 96 00 - Process Control Software

CALN TOWNSHIP MUNICIPAL AUTHORITY

KINGS'S GRANT PUMP STATION UPGRADES

MARCH 2026 40 96 00 - 1

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Programming Software.

B. General Functional Descriptions.

C. System Process Functional Descriptions.

D. I/O List

1.02 RELATED REQUIREMENTS

A. Section 40 94 43 - Programmable Logic Controllers For Process Systems.

B. Section 40 95 33 - Process Control Networks.

1.03 DEFINITIONS

A. PLC: Programmable Logic Controller - Purpose built industrial control hardware that controls a process.

B. I/O: Inputs/Outputs - Analog or digital connections between the PLC and process equipment.

C. Discrete: Binary signal represented as 0/1, On/Off, etc.

D. Analog: Variable Signal representing an integer or real number value.

E. Communications: Means by which PLCs can share information digitally with each other or certain equipment. Communications can vary by protocol and media.

F. Communications Protocol: The language that a PLC communicates with other equipment. Modbus is an example of a communications protocol.

G. Serial Communications: Name given to a type of communications where data is passed in series. This type of communication can be either one to one or one to main (via daisy chained wiring). A relatively slower form of communications that utilizes a variety of protocols.

H. Ethernet: Family of wired communications that utilizes a variety of commercial and Industrial communication protocols. Relatively fast form of communications that hardwired IT networks utilizes.

I. SCADA: Supervisory Control and Data Acquisition - Control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes.

J. HOA: Hand - Off - Auto

K. OIT: Operator Interface Terminal – Touch screen terminal device located on PLC control panels or near the process. OITs allow the operator to make changes locally to the equipment.

MARCH 2026

40 96 00 - Process Control Software

CALN TOWNSHIP MUNICIPAL AUTHORITY

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L. Safety: Condition that prevents a piece of equipment from running in Hand or Auto mode. Safeties are generally alarms that could damage the equipment or create a hazard. E.g. hi pressure alarm.

M. Interlock:

1. Condition that prevents a piece of equipment from running in Auto mode. Interlocks are generally used to prevent unwanted process conditions. E.g. Hi level alarm.

2.…