40 95 33 Process Control Network Overview.pdf

40 95 33 – PROCESS CONTROL NETWORK OVERVIEW

Herbert, Rowland & Grubic, Inc. 40 95 33-1 005153.0436

SECTION 40 95 33 – PROCESS CONTROL NETWORK OVERVIEW

PART 1 – GENERAL

1.1 SUMMARY

A. Section Includes:

1. General requirements for the Systems Integrator (SI), Operator Interface Units

(OIU), Programmable Logic Controller (PLC) including but not limited to software, hardware, as well as Control Concepts.

1.2 REFERENCES

A. The publications listed below form a part of this specification to the extent referenced.

The publications are referred to in the text by the basic designation only.

B. American National Standards Institute (ANSI):

1. ANSI/ISA S5.5 Graphic Symbols for Process Displays.

2. ANSI X3.154 (1997) Office Machines and Supplies – Alphanumeric Machines-

Keyboard Arrangement.

C. Electronic Industries Association (EIA):

1. ANSI/TIA/EIA-232-F(2002) Interface Between Data Terminal Equipment and

Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange.

D. Institute of Electrical and Electronics Engineers (IEEE):

1. IEEE Std 142 (2007) IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems.

2. IEEE Std 8802-3 (2021) Local and Metropolitan Area Network: Carrier Sense

Multiple Access with Collision Detection (CSMA/CD) Access Method and Physical

Layer Specifications.

E. National Fire Protection Association (NFPA):

1. NFPA 70 National Electrical Code

1.3 SYSTEM DESCRIPTION

A. The system includes the installation of a complete operating system at the Skytop Lodge

WWTP. The Systems Integrator will be responsible for installing the entire system with new PLC’s, hardware and a graphical user interface software as detailed herein.

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1. The Systems Integrator will be responsible for coordinating with the Owner and other vendors providing control panels (including those with PLC’s) in order to provide a complete and operable system as described herein and as shown on the contract drawings.

B. The operating system will be the responsibility of the Systems Integrator to provide and program the Operator Interface Units (OIU) and Programmable Logic Controllers (PLC) that are not being provided by an equipment supplier.

C. It is the Systems Integrator’s responsibility to coordinate with all necessary vendors under this contract and to provide all necessary peripheral equipment to make this a complete working system as specified.

D. In general, the Systems Integrator (SI) will be responsible for providing the OIU and all associated software and peripherals for this system.

E. Without limiting the scope of work the SI is responsible for providing equipment designated on the system architecture and providing all equipment required according to all sections of Division 27 and 40 at a minimum as well as all associated instrumentation:

1.4 SUBMITTALS

A. Submit in accordance with contract requirements:

1. Specific equipment list, which identifies the manufacturer, part number, model number and quantity.

2. Manufacturer's specification sheet for each proposed item of the system.

3. Letter indicating compliance with the Bid Package with any exceptions documented and submitted with the bid.

B. Shop Drawings: Submittal shall include point to point diagrams of all connected devices, of sufficient detail to adequately communicate that equipment meets system requirements, including:

1. OIU screens shall be submitted for Engineer and Owner comment prior to

Factory Acceptance Test.

2. System device locations on architectural floor plans.

3. Schematic wiring information for all devices. Wiring information shall include cable type, conductor routings, quantities, and connection details at devices.

C. System Description:

1. System description, indicating how equipment will operate as a system to meet the performance requirements of the WWTP.

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D. Contract Close-out Submittals:

1. Operating instructions.

2. Parts list, including: wiring and connection diagrams.

F. Submit the following with the O & M manuals.

1. Color prints of OIU screens on 8 1/2 x 11 inch paper.

2. OIU Database on 8 1/2 x 11 inch paper.

3. Scripts developed for the screen displays.

4. Diagram showing how screens are linked together.

1.5 QUALITY ASSURANCE

A. Equipment suppliers for the Programmable Logic Controllers (PLCs):

1. In order to provide the Owner with a PLC for this project the manufacturer of the PLC must have at least two (2) active Systems Integrators within a 100 mile radius of the project site who have utilized the product for similar installations.

2. The equipment supplier must maintain an adequate supply of the components provided for the project (ie Processors, I/O cards, communications cards, etc).

B. System Integrator:

1. Minimum of 10 years of experience in performing work of this size (Inputs and

Outputs as well as construction cost) has specialized in the installation of water treatment facilities similar to that required for this project, and be CSIA certified.

2. Have at least one technician trained by the manufacturer and located within a

250 mile radius of the facilities in question.

3. Maintain adequate supply of replacement parts for system components provided.

4. Have at least one (1) technician trained by the manufacturer and can be onsite in under eight (8) hours of receiving notice from the Owner or operator in an emergency situation.

5. System Integrator and Panel Shop shall be housed at the same location. Panel shop must be UL508 and UL698 listed

C. Regulatory Requirements: Installed products shall meet standards of a recognized testing laboratory (UL. or comparable).

1.6 WARRANTY

A. All components supplied and installed by the Contractor shall be warranted against defects in material and workmanship for a period of at least 12 months, commencing upon the date of acceptance by the Owner. Warranty service shall be provided by a

Herbert, Rowland & Grubic, Inc. 40 95 33-4 005153.0436 qualified factory-trained service representative. The warranty is in addition to, and not a limitation of, other rights Owner may have under the Contract Documents.

PART 2 – PRODUCTS

2.1 Operator Interface Unit (OIU):

A. The OIU shall be used to monitor and control the operation of process equipment through the control system provided by the PLC. The OIU shall provide for operator interaction, overall control, system supervision, and process equipment control and monitoring. The Contractor shall provide hardware configured and sized to support expansion as specified and shown on the drawings.

B. The Systems Integrator shall provide good quality renditions with significant enhancements to provide a working representation of the process equipment. Screens shots are to be submitted to the Engineer and Owner for review and comment early in the project so that a working product can be utilized during start-up. After start-up the

Engineer and Owner will provide a final set of comments to address the graphical representation of the process equipment.

C. The following is a brief description of the minimum requirements on each screen.

General color scheme for equipment is as follows: Running (Red), not Running (Green), Alarm/Failure (Yellow). The Systems Integrator shall utilize the I/O List for the data points:

1. Main Menu:

a. The Main Menu is to include “buttons” to navigate to all of the various screens.

2. WWTP Overview:

a. Influent Screen Status.

b. EQ Tank Status.

c. Recirculation Wet Well Status.

d. Secondary Clarifier & Post Aeration Tank Status.

e. Generator & ATS Status.

f. Switchgear Status.

3. Monitor Screen.

4. Influent Screen:

a. Influent Channel Level.

b. Influent Channel Flow.

c. Solenoid Valve positions.

d. Auger Motor Status.

e. Integrated PLC status.

f. Alarms.

5. EQ Tank:

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a. Level status.

b. Float Switch status.

c. Submersible Pump status.

d. Blower status.

e. Alarms.

6. Recirculation Wet Well:

a. Level status.

b. Float switch status.

c. Submersible Pump status.

d. Local Control Station status.

7. Secondary Clarifier & Post-Aeration:

a. Level status.

b. Float switch status.

c. Submersible Pump status.

d. Blower status.

e. D.O. Level.

f. Local Control Station status.

8. Timers & 24Hr Clock, User Settable:

a. User settable timers are to be available to the user as a pop-up or on a separate screen to allow the operator to make changes.

b. 24Hr clock shall allow the user to set operating windows on a hourly/daily/weekly basis.

9. Trending Screen:

a. Show Active as well as Historical for all analog points listed in the I/O

List.

b. Trends shall be accessible through a “TRENDS” button where all trends will be grouped. The Owner and Engineer will provide input for grouping trends, however in general trends for monitoring a particular process shall be grouped.

c. Retrieving historical data should utilize combo boxes to select the files based on month and year. If the file is stored externally, the system should allow the user to select the external file (from external hard drive).

10. Report Screens:

a. Reports are to be automatically generated each day/month or when selected with data as directed by owner and as detailed in the Control

Concepts listed below.

11. Alarm Screen:

a. Current Alarms – alarm indication without further notification until alarm resets.

b. Alarm History – With an option to print.

12. Event Logger:

Herbert, Rowland & Grubic, Inc. 40 95 33-6 005153.0436

a. Provide an event logger to document all setpoint changes, alarm limits, and analog ranges such that the user can go back through the log to find previous values and determine the exact value, time, and date that it was changed.

13. Analog Set-up Screen (One screen to do all of the following unless directed otherwise):

a. Provide zero and span ranges for all analog signals so that the ranges can be changed at a later date if equipment is changed or calibrations dictate a change in ranges.

b. The change should not only correct the OIU display but correct any scaling which occurs at the PLC level.

c. All analog devices to have a user settable Low and High alarm setpoint.

This setpoint shall also be able to be inhibited by the user should they deem it an unessential alarm.

14. Security – Passwords/Access Privileges:

a. The ability to silence the horn and acknowledge alarms does not require a password, but alarms cannot be reset. To gain access to make changes on the OIU, the operator will be required to enter the correct password. After a set amount of time of inactivity the user will be prompted to re-enter their password.

b. In order to access the control screens, the individual must enter a correct password then press Enter. The operator password should be set to “Operator, and not changeable by the Operator. The Supervisor, Engineer, and Administrator password can be modified from the OIU.

There is to be no limit to the number of times another password can be attempted. The following is a list of access rights:

1) Operator:

(a) Access to all screens.

(b) Access only to Presets and Setpoints.

(c) Starting and stopping automatically controlled systems.

(d) Resetting of all Alarms.

(e) Auto Operation of all Pumps and Valves, not Manual.

(f) Access only to PID control setpoints & graphics.

2) Supervisor:

(a) Access to all screens.

(b) Access to and adjustment of Presets and Setpoints.

(c) Access to alarm setpoints only, no ability to change.

(d) Access to and adjustment of all operations, starting and stopping the process equipment.

(e) Resetting of all Alarms.

(f) Manual & Auto Operation of all Pumps and Valves.

(g) Manual control of PID's.

Herbert, Rowland & Grubic, Inc. 40 95 33-7 005153.0436

(h) Access to PID control setpoints & graphics, but cannot adjust PID tuning parameters.

3) Engineer:

(a) Access to all screens.

(b) Access to and adjustment of Presets and Setpoints.

(c) Access to and adjustment of alarm setpoints.

(d) Access to and adjustment of all operations, starting and stopping the process equipment.

(e) Resetting of all Alarms.

(f) Manual & Auto Operation of all Pumps and Valves.

(g) Manual control of PID's.

(h) Access to and ability to change PID control setpoints & tuning parameters.

(i) Access to set and change Operator and Supervisor password.

4) Administrator:

(a) Access to all screens.

(b) Access to and adjustment of Presets and Setpoints.

(c) Access to and adjustment of alarm setpoints.

(d) Access to and adjustment of all operations, starting and stopping the process equipment.

(e) Resetting of all Alarms.

(f) Manual & Auto Operation of all Pumps and Valves.

(g) Manual control of PID's.

(h) Access to and ability to change PID control setpoints & tuning parameters.

D. Back-up and Storage:

1. The user shall be capable of completely backing up the operating system to an external hard drive as required.

2. All historical data, alarm points, and event logging is to be stored to an external media (USB Drive) every month automatically. The Systems Integrator is to utilize scheduler software which is typical with external USB storage drives to map the locations of the points listed above in addition to the reports to automatically be stored every 30 days.

3. Back-up and storage of historical data should not stop operation of monitoring or logging current points.

E. Record Documents: Maintained as a separate hard copy set of drawings, wiring diagrams of the control system, accurately reflecting all changes and additions.

2.2 CONTROL CONCEPTS

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A. Recirculation Wet Well & Secondary Clarifier Control Panel (40-CP-400):

1. General:

a. 40-CP-400 shall house the primary PLC processor and be used to monitor and control all points associated with the recirculation wet well, secondary clarifiers, and EQ tank, as defined in the I/O list in Table

40 95 34.

b. During generator operation, the primary PLC processor shall prevent more than two (2) motors from starting simultaneously. Motor starts shall be sequenced as necessary to prevent generator overload and excessive voltage drop.

2. Recirculation Wet Well:

a. The recirculation wet well pumps (20-P-201, 202) shall be operated automatically by the PLC via the level sensor (LE-200) within the wet well. Operator adjustable setpoints shall be provided on the OIU for setting the wet well level. The PLC shall alternate operation of each pump in a duty-standby configuration. LE-200 will be the primary device for controlling the pumps. The float switches (LSL-200 & LSH-200) are provided for backup control. The Float switches shall be wired to the

PLC for indication with hardwired controls to the submersible pump

VFDs in the event of PLC failure. The PLC shall initiate a high-level alarm to 40-AD-400 if LSH-200 is tripped. A user-settable 24Hr clock with selectable days of the week, or every day, options and a minimum of four (4) time slots per day shall be provided that limits the operating windows as set by the operator. If no limits are set, no limiting of the pumps should occur. The high-level float switches shall automatically override the 24Hr clock setpoints.

b. H-O-A switches and START/STOP pushbuttons shall be provided on 40-

CP-400 for each pump. Local Control Stations (LCS) shall be provided near each pump. In HAND mode, the Operator may utilize the local

START/STOP pushbuttons or the LCS to enable the VFDs. In AUTO mode, the PLC enables the VFDs based on the conditions noted above.

Hardwired interlocks and ladder-logic permissive shall be implemented that prevents simultaneous operation of both pumps. In OFF mode, neither submersible pump shall operator.

c. The Operator shall have the ability to adjust each pump’s VFD output frequency via panel-mounted potentiometers. The OIU shall display each drive’s output frequency via ethernet communications to the drive. The potentiometer limits (VFD limit) should be user-settable

(maintenance mode) in the PLC. When pumps turn on, they should ramp to the set VFD frequency.

d. Externally mounted disconnect switches shall be provided with auxiliary contacts wired back to each VFD. If a disconnect is in the OFF position, the associated VFD shall not be enabled.

Herbert, Rowland & Grubic, Inc. 40 95 33-9 005153.0436

3. Secondary Clarifier:

a. Each secondary clarifier is provided with (2) submersible pumps powered by VFDs. The submersible pumps (30-P-301, 302, 303, 304) shall be operated automatically by the PLC via a user-settable 24Hr clock with a minimum of four (4) time slots per day that can be set to every day, or specific days of the week. Each clarifier is provided with (1) low-level float switch (LSL-301, 302). When the 24Hr clock setpoint is enabled, the PLC shall enable the VFDs and the pumps shall run until the operating window closes or the associated low-level limit switches open.

b. The PLC shall sequentially enable each submersible pump VFD with a user-settable, minimum 5-second, delay between each pump start. The

PLC shall prevent more than 1 pump from energizing at any given time.

The PLC shall enable both pumps associated with each clarifier in AUTO mode with the delay between the pumps as noted above.

c. If the secondary clarifier pumps are called to run while the recirculation pumps are running, the clarifier pumps shall wait until the recirculation pumps have shut off.

d. H-O-A switches, START/STOP pushbuttons, and LCS’s shall be provided and integrated similar to section 2.2 (A)(2)(b).

e. The Operator shall have the ability to adjust each pumps VFD output frequency similar to section 2.2 (A)(2)(c).

f. External mounted disconnect switches shall be provided and integrated similar to section 2.2 (A)(2)(d).

4. Secondary Clarifier (post-aeration basin):

a. The post-aeration basin is provided with (2) aeration blowers powered by across-the-line motor starters. A Dissolved Oxygen (DO) sensor shall provide DO data to the PLC. The PLC shall operate the blowers (40-B-

301, 302) in duty-standby to regulate the post-aeration DO. The desired

DO shall be settable from the OIT. The PLC shall alternate operation of each blower in a duty-standby configuration.

b. H-O-A switches, START/STOP pushbuttons, and LCS’s shall be provided and integrated similar to section 2.2 (A)(2)(b).

B. Equalization (EQ) Tank Control Panel (10-CP-102):

1. General

a. 10-CP-102 shall house the remote I/O rack(s) and communicate with the

PLC processor located in 40-CP-400. 10-CP-102 shall contain an OIU to provide all indicators and control features as described below and as listed in the I/O list in Table 40 95 34.

2. EQ Tank Submersible Pumps:

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a. The EQ tank submersible pumps (10-P-101, 101) shall be operated automatically by the PLC via the level sensor (LE-203) within the tank.

Operator adjustable setpoints shall be provided on the OIU for setting the tank level setpoints. The PLC shall alternate the operation of each pump in a duty-standby configuration. LE-103 will be the primary device for controlling the pumps. The float switches (LSL-100 & LSH-100) are provided for backup control. The Float switches shall be wired to the

PLC for indication with hardwired controls to the submersible pump

VFDs in the event of PLC failure. The PLC shall initiate a high-level alarm to 40-AD-400 if LSH-100 is tripped. A user-settable 24Hr clock shall be provided that limits the operating windows as set by the operator. The float switches shall automatically override the 24Hr clock setpoints.

b. H-O-A switches and START/STOP pushbuttons shall be provided on 10-

CP-100 for each pump. In HAND mode, the Operator may utilize the local START/STOP pushbuttons to enable the VFDs. In AUTO mode, the

PLC enables the VFDs based on the conditions noted above. Hardwired interlocks and ladder-logic permissive shall be implemented that prevents simultaneous operation of both pumps. In OFF mode, neither submersible pump shall operate.

c. The Operator shall have the ability to adjust each pumps VFD output frequency via panel-mounted potentiometers. The OIU shall display each drive’s output frequency via ethernet communications to the drive.

d. Externally mounted disconnect switches shall be provided with auxiliary contacts wired back to each VFD. If a disconnect is in the OFF position, the associated VFD shall not be enabled.

3. EQ Tank Blowers:

a. The EQ tank aeration blowers (10-B-101, 102) shall be operated automatically by the PLC Via the level sensor (LE-203) within the tank.

Operator adjustable setpoints shall be available on the OIU for setting the tank level that operates the Blowers. The PLC shall alternate operation of each blower in a duty-standby configuration. LE-103 will be the primary device for controlling the blowers. Whenever the level is above the “low-level” setpoint, a single blower shall operate. Once the level drops below the “low-level” setpoint, the blower shall turn off. IF the level drops below float switch LSL-100, the blower shall turn off.

b. H-O-A switches and START/STOP pushbuttons shall be provided on 10-

CP-102 for each blower. In HAND mode, the Operator may utilize the local START/STOP pushbuttons to energize the motor starter. In AUTO mode, the PLC energizes the starter based on the conditions noted above. Hardwired interlocks and ladder-logic permissive shall be implemented that prevents simultaneous operation of both blowers. In

OFF mode, neither blower shall operator.

Herbert, Rowland & Grubic, Inc. 40 95 33-11 005153.0436

c. The PLC shall prevent the blowers from operating whenever the submersible pumps are ON.

C. Alarm Notification System:

1. Plant personnel will be automatically notified of the below alarms at the facility via the Autodialer (40-AD-400) software.

2. The PLC will initiate a timer for all major alarms (based on a list provided by the

Engineer and Owner). If the timer is not acknowledged after a user settable amount of time, initial setpoint 10 minutes, the timer will trigger the respective output which is to be connected to an autodialer. The major alarm lists are as follows:

a. EQ Tank Control Panel – System Fail

b. Secondary Clarifier – System Fail

c. EQ Tank High – Level Alarm

d. Recirculation Wet Well – High Level Alarm

e. Automatic Transfer Switch – Utility Power Failure

f. Automatic Transfer Switch – Transfer Power Failure

g. Automatic Transfer Switch – On Generator Power

h. Generator – System Fault

PART 3 – EXECUTION

3.1 EXAMINATION

A. Verification of Conditions. Prior to all work of this section, carefully inspect the installed work of all other trades and verify that all such work is complete to the point where this installation may properly commence.

B. Discrepancies. In the event any discrepancies are discovered, immediately notify the

Owner’s Representative in writing. Do not proceed with installation in areas of discrepancy until all such discrepancies have been fully resolved.

3.2 PREPARATION

A. Protection:

1. All equipment and materials shall be packed at the factory to protect each item from damage during shipment and storage.

2. Provide blocking and cushioning materials to prevent damage during shipment.

3. Panel mounted instruments and equipment to be installed inside enclosures, panels, or consoles shall be mounted and assembled at the panel manufacturer’s facility.

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B. Surface Preparation. The work shall be carefully laid out in advance. Where cutting, drilling, etc., of floors, walls, ceilings, or other surfaces is necessary, the work shall be carefully done. Any damage to building, piping, or equipment shall be repaired by skilled mechanics of the trades involved, and at no additional cost to the Owner.

3.3 FACTORY ACCEPTANCE TESTING (FAT)

A. The Systems Integrator will demonstrate to the Owner and the Engineer a fully functioning system at their facility. Coordination will be required with other equipment suppliers. The contractor will provide a minimum four weeks advanced notice of the demonstration and allow an alternate date for all applicable parties to schedule the FAT.

Up to Four (4) representatives for the client, and up to four (4) representatives from the

Engineer will be included in the FAT at the integrators facility. All travel, lodging and boarding expenses shall be paid by the Systems Integrator.

B. The Contractor will connect all PLC’s and Operator Interface units in network to simulate the design including the actual Ethernet switches and cables where feasible. The contractor will demonstrate that all programming is complete and functioning.

C. All Inputs and Outputs are to be demonstrated via switches, potentiometers, indicating lights and meters. The contractor will demonstrate as much as possible that the program works as intended while verifying the I/O.

3.4 INSTALLATION

A. General. Install equipment, as indicated, with manufacturer’s written instructions, and with recognized industry practices.

B. The Contractor shall load software required for an operational control system, including databases (for points specified and shown), operational parameters, and system, command, and application programs. The Contractor shall adjust, tune, debug, and commission all software and parameters for controlled systems to assure proper operation in accordance with the sequences of operation and database tables.

C. On Site Start-Up:

1. The Contractor will demonstrate to the Engineer and to the Owner that all points are being monitored and the system operates as designed and intended.

3.5 FIELD QUALITY CONTROL

A. Inspection. Upon completion of this portion of the work, the Contractor shall provide for the services of a qualified representative of the manufacturer to inspect and approve the installation.

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B. Tests. Upon completion of all inspections and prior to acceptance by the Owner, perform the field tests.

3.6 DEMONSTRATION

A. General. When all required tests have been performed and prior to final approval, a qualified representative of the supplier shall thoroughly demonstrate to the Owner’s personnel the operation of all items installed under this section.

END OF SECTION