A_-_EA25WBM048_SPEC_IC&E_Standards_0.2.0_DRAFT.pdf

West Basin Municipal Water District 17140 Avalon Blvd Carson, CA 90746 Phone: (310) 217-2411 www.WestBasinCA.gov

PCS Standards

INSTRUMENTATION, CONTROLS,

AND ELECTRICAL v.0.1.0

West Basin Municipal Water District

Document IC&E Standards

Revision Number 0.1.0

Effective Date 4/24/2026

Author Ethan Meeks

Reviewed by Kaylee Halliday; Alex Coker, PE

Prepared By:

9050 Irvine Center Drive Irvine, CA 92618

(949) 769-6000 www.eaintegrator.com

IC&E Standards v0.1.0 EA Project Number: EA25WBM048

17140 Avalon Blvd, Carson, CA 90746 Revision: 0.1.0 Tel 310-217-2411 Effective Date: 4/24/2026 www.WestBasinCA.Gov Page Number: 2 of 106

History Revision Date Description of Change Author Reviewed

0.1.0 4/24/2026 Draft release for review EM KH, AC

Table of Contents 1 Overview

1.1 Purpose

1.2 Facility Design Consultant Request for Proposal PCS Language

1.3 PCS Design Guidelines

1.4 PCS Responsibilities

1.5 PCS Responsibilities (Specifications Insert)

1.6 Instrumentation, Controls, and Electrical (IC&E) Standards

1.7 Physical Tagging Standard

1.8 Physical Identification Standard Specifications

2 Facility Design Consultant Request for Proposal PCS Language

2.1 Language to Insert in RFP

3 PCS Design Guidelines

3.1 PCS Overview

3.2 Instrumentation, Controls, and Electrical (IC&E) Standards

3.2.1 Equipment Control and Indication

3.2.2 PCS Panels

3.2.3 Tagging

3.2.4 Component Identification

3.3 PCS OT Infrastructure

3.4 Project Execution

3.4.1 FDC’s Design Phase Submittals

3.4.2 I/O List Development

3.4.3 Loop Drawings

3.4.4 P&IDs Development

3.4.5 Packaged System Design

3.4.6 Motor Control Schematics

3.4.7 Motor Controller Configuration

3.4.8 Development of Control Narratives

3.4.9 Development of Functional Specifications

3.4.10 Contractor’s Schedule

3.4.11 Factory Acceptance Tests (FAT)

3.4.12 Motor Starter Logic Testing

3.4.13 Commissioning

3.4.14 Site Acceptance Testing

4 PCS Responsibilities

4.1 Owner

4.2 Contract Operator

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4.3 PCS Consultant

4.3.1 General

4.3.2 Facility Design and Bidding Phases of Projects

4.3.3 Facility Construction Phase of Projects

4.4 PCS Integrator

4.4.1 General

4.4.2 Facility Construction Phase of Projects

4.5 Facility Design Consultant

4.5.1 Facility Design and Bidding Phases of Projects

4.5.2 Facility Construction Phase of Projects

4.6 Construction Contractor

5 PCS Responsibilities (Specifications Insert)

5.1 General Language to Insert into Construction Bid Documents

6 Instrumentation, Controls, and Electrical (IC&E) Standards

6.1 Input/Output (I/O) Interface Standards

6.1.1 Digital Inputs (DIs)

6.1.2 Digital Outputs (DOs)

6.1.3 Analog Inputs (AIs)

6.1.4 Analog Outputs (AOs)

6.1.5 Thermocouples and Resistance Temperature Detectors (RTD)

6.2 Intrinsically Safe Relays/Barriers

6.3 PLC Standards

6.4 UL vs. ITS

6.5 IEC vs. NEMA Components

6.6 Motor Starter Design Considerations

6.6.1 Terminology

6.6.2 Manufacturer

6.6.3 Interface to PCS

6.6.4 Full Voltage Non-Reversing (FVNR) Type

6.6.5 Reduced Voltage Soft-Start (RVSS) Type

6.6.6 Variable Frequency Drive (VFD) Type

6.6.7 Bypass Contactors on RVSS and VFD Units

6.6.8 User Interface

6.6.9 Motor Starter Logic Design

6.6.10 Motor Local Control Stations

6.6.11 Motor Control Center Considerations

6.6.12 Motor Starter PCS Inputs/Outputs (I/O)

6.7 Valve Actuator Design Considerations

6.7.1 Manufacturer

6.7.2 Open/Close Valve Actuators

6.7.3 Positioning Valve Actuators

6.7.4 Hydraulic Valves

6.7.5 Valve Local Control Stations

6.7.6 Valve Interlocks

6.8 Instrumentation Design Considerations

6.8.1 Flow Meters

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6.8.2 Pressure Transmitters

6.8.3 Level Transmitters

6.8.4 Chemical Analyzers

6.9 Other Equipment Design Considerations

6.9.1 Generator/Transfer Switch/Disconnect Switch Design Considerations

6.10 [Site Type] Design Considerations

6.10.1 PCS Inputs

6.10.2 PCS Outputs

6.11 Indicator Lights

6.11.1 Type

6.11.2 Test Function

6.11.3 Specific Indicator Lights

6.11.4 Colors

6.12 Discrete Control Buttons/Switches

6.12.1 Type

6.12.2 Motors

6.12.3 Valves

6.12.4 Emergency Stop

6.13 Field Wire and Cable

6.14 Equipment Identification

6.15 Panel Design Considerations

6.15.1 Control Panel Construction Specification

6.15.2 Power Components Specification

6.15.3 PLC Components Specification

6.15.4 Ethernet and Networking Components Specification

6.15.5 Telemetry Components Specification

6.16 Panel Installation Considerations

6.16.1 General

6.16.2 Electrical Requirements

6.16.3 Conduit Entry

7 Physical Tagging Standard

7.1 Introduction

7.2 Terminology

7.2.1 International Society of Automation (ISA)

7.2.2 ANSI/ISA-5.1-2024

7.3 Tag Structure

7.3.1 General

7.3.2 Prefix

7.3.3 Process Area Number

7.3.4 Loop Number

7.3.5 Unit/Sub-Unit Number

7.3.6 Clarifying Abbreviation

7.3.7 Example

7.4 Tables

7.4.1 Equipment Prefixes

7.4.2 ANSI/ISA-5.1-2024 Prefix Letters

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7.4.3 Process Area Numbers

8 Physical Identification Standard Specifications

8.1 Sample Electrical Identification

8.2 Sample Component Identification

Appendix A – Example P&ID www.WestBasinCA.Gov Page Number: 6 of 106

Acronyms and Terms For the remainder of the document the following acronyms will be used.

Term Description

FAT Factory Acceptance Test

FDC Facility Design Consultant

HMI Human Machine Interface

I/O Input and Output

IC&E Instrumentation, Control, and Electrical

MCC Motor Control Center

OIT Operator Interface Terminal

P&ID Piping and Instrumentation Diagram

PDR Preliminary Design Report

PLC Programmable Logic Controller

RFP Request for Proposal

ACP Area Control Panel

SAT Site Acceptance Test

PCS Process Control System

IT Information Technology

OT Operational Technology

WBMWD, the District

West Basin Municipal Water District

ECLWRF, ECL Edward C. Little Water Recycling Facility

HSEPS, Hyperion Hyperion Secondary Effluent Pump Station

CNTP, Chevron Chevron Nitrification Treatment Plant

JMMCRWRP,

Carson

Juanita Millender-McDonald Carson Regional Water Recycling Plant

TRWRP, Torrance Torrance Regional Water Recycling Plant www.WestBasinCA.Gov Page Number: 7 of 106

1 Overview

1.1 Purpose

As part of the West Basin Municipal Water District’s (the District) effort to modernize their Process Control System (PCS), Enterprise Automation (EA) has prepared a set of instrumentation, control, and electrical (IC&E) standards. For new equipment, these standards shall be followed fully. Where legacy equipment is involved, these standards should be followed as closely as possible. It is understood that the District may have to assess the feasibility and value of fully complying with these standards in certain cases.

This information is provided to the organization acting as the Facility Design Consultant (FDC) for their use in preparing the project construction documents (drawings and specifications) for a capital project or preparing internal work orders for efforts performed in house by the District. The standard is divided into the major sections detailed below.

1.2 Facility Design Consultant Request for Proposal PCS Language This section contains language that should be included in the Request for Proposal (RFP) for a Facility Design Consultant (FDC), the purpose of which is to explain to the FDC the District’s implementation philosophy and the responsibilities of the FDC as it relates to the District’s PCS.

This language is generally applicable to any project in which the FDC is preparing construction documents for facility modifications or additions that require changes to equipment connected to the District’s PCS.

1.3 PCS Design Guidelines

This section outlines the design guidelines and project execution methodology that the Facility Design Consultant (FDC) should follow when designing a project so that (1) the project’s integration with the District’s PCS is as effective as possible and (2) the project implements the District’s standards for certain instrumentation, controls, and electrical work. This information is provided to the FDC for their use in preparing the construction documents for a capital improvement project. This section should be distributed to the FDC prior to their development of a project proposal so that they understand their responsibilities surrounding the components that must integrate with the PCS.

1.4 PCS Responsibilities

This section provides a complete description of project participants (Owner, PCS Consultant, PCS Integrator, Facility Design Consultant, and Construction Contractor) and is intended for use by the

FDC.

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1.5 PCS Responsibilities (Specifications Insert)

This section is a trimmed down version of the previous section that provides the general language that should be included in the Construction Bid Documents for a project that will impact the District’s PCS. This language provides a general description of the District’s PCS implementation philosophy and the responsibilities of the Construction Contractor and the PCS Integrator. The Facility Design Consultant (FDC) shall determine how this language will best fit into their specifications and use terminology and specification section references that match their specifications.

1.6 Instrumentation, Controls, and Electrical (IC&E) Standards This section establishes standards for instrumentation, controls, and electrical (IC&E) work on the District’s projects.

1.7 Physical Tagging Standard

This section describes the process for creating structured abbreviations called “tags” for the various physical components of the process (process equipment, instrumentation, controllers and control panels, and electrical equipment), as well as input and output (I/O) signals associated with the District’s PCS.

1.8 Physical Identification Standard Specifications

The two sample specifications that make up this section describe the physical identification (that is, nameplates and labels and their type, content, materials, and installation requirements) of the various components of the process (process equipment, instrumentation, controllers and control panels, and electrical equipment), as well as raceway system components (conduit, pull boxes, etc.) and wire and cable.

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2 Facility Design Consultant Request for Proposal PCS Language This section contains language that should be included in the Request for Proposal (RFP) for a Facility Design Consultant (FDC), the purpose of which is to explain to the FDC the District’s implementation philosophy and the responsibilities of the FDC as it relates to the District’s PCS.

This language is generally applicable to any project in which the FDC is preparing construction documents for facility modifications or additions that will also require changes to the District’s

PCS.

2.1 Language to Insert in RFP

West Basin Municipal Water District (the District) desires to maintain consistent control system design and implementation across all its owned facilities, which it achieves through direct involvement of District staff (“Owner”), the Contract Operator, and/or an Owner’s Engineer (“PCS Consultant”) in all phases of a project. Additionally, the District maintains a prequalified list of On- Call PCS Integrators to perform control system integration and maintenance across all facilities, which are preferred to be used for all integration work, and may even be contracted early to provide Design Phase input and deliverables. Because of this implementation strategy, it is important for the firm selected for the Project to understand their role and responsibilities regarding modifications to the District's PCS as a result of facility modifications for which they are preparing construction documents.

The District's staff, Contract Operator, PCS Consultant, and/or PCS Integrator will be active participants in the Design and Construction Phases of the Project, including attendance at key Design Phase meetings (Kickoff Meeting, Control Strategy Meetings, Review Meetings, etc.). All parties will also review and provide comments on the Facility Design Consultant's construction document submittals.

During the Construction Phase of the project, the PCS Integrator will design PCS panel drawings;

develop detailed PCS supervisory control logic, HMI screens, reports, etc.; program PCS software and PLCs; conduct Factory and Site Acceptance Testing and PCS related start-up activities.

Included as a reference is a "PCS Responsibilities" document that summarizes the roles of the District, Contract Operator, PCS Consultant, PCS Integrator, Facility Design Consultant, and Construction Contractor. Also included as a reference is a “PCS Design Guidelines” document that summarizes the design guidelines and project execution methodology that the Facility Design Consultant should follow.

[Section 3 “PCS Design Guidelines” should be included within the RFP as a reference]

[Section 4 “PCS Responsibilities” should be included within the RFP as a reference]

Commented [AC1]: West Basin: Read this very closely to ensure it lines up with your expectations for how the system will be upgraded/maintained going forward.

Alex Aquino Arcadis

Alex Aquino Arcadis

AND SUBMIT FOR APPROVAL

Alex Aquino Arcadis

Alex Aquino Arcadis

INSTALL AND CALIBRATE INSTRUMENTS

John Venner West Basin Municipal Water District WB Response: This is the preferred method, however please add language about the district maybe having the contractor procure a PCS Integrator sub - e.g. “The District may also choose instead to have the PCS Integrator provided by the Construction Contractor as a subcontractor.”

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3 PCS Design Guidelines This section outlines the design guidelines and project execution methodology that the Facility Design Consultant (FDC) should follow when designing a project so that (1) the project’s integration with the District’s PCS is as effective as possible and (2) the project implements the District’s standards for certain instrumentation, controls, and electrical work. This information is provided to the FDC for their use in preparing the construction documents for a capital improvement project. This section should be distributed to the FDC prior to their development of a project proposal so that they understand their responsibilities surrounding the components that must integrate with the PCS.

3.1 PCS Overview

The District’s PCS is a distributed, multi-facility system with centralized monitoring and control located at the District’s main treatment facility, ECLWRF, and secondarily at the District’s four satellite facilities (HSEPS, CNTP, JMMCRWRP, TRWRP).

To maintain consistent controls system design and implementation across its facilities, the District requires designers and contractors performing work on equipment connected to its PCS to follow a set of defined instrumentation, control, electrical, PLC, and PCS standards. The PCS Integrator performing work on the system will be required to work within the District’s Schneider Electric Modicon, AVEVA System Platform, and AVEVA PI System based PCS platform. Standards have been established for graphics, objects, page layouts, and tag structures that must be used as a basis for programming by the PCS Integrator. Projects requiring PLC programming will need to use established PLC code standards regarding code templates, program structure, commenting, and tagging. Projects will also need to account for additions/modifications to the historian and operational reports as necessary.

3.2 Instrumentation, Controls, and Electrical (IC&E) Standards The District has established certain standards regarding instrumentation, controls, and electrical (IC&E) work on their projects. The IC&E standards are summarized below and described in more detail in section 6.

3.2.1 Equipment Control and Indication

The District has established standards that describe the control and indication signals (I/O) required for equipment that interfaces with the PCS. This includes discrete and analog instrumentation, motor controllers, valve controllers, and general site-level I/O. Also included are standards on local equipment control (switches and push buttons) and indicator lights.

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3.2.2 PCS Panels

Field equipment is connected to Area Control Panels (ACPs) that read inputs and send control outputs. The District has established certain standards regarding the fabrication and installation of these panels as summarized below and described in more detail in section 6.

In addition to the installation of new ACPs, the project may require modifications to existing ACPs. The PCS Integrator will be responsible for providing work orders to the Construction Contractor for modifications to be made to existing panels. In some cases, existing panels may be converted to Field Terminal Cabinets (FTCs), with the I/O associated with these panels extended to new ACPs.

3.2.2.1 Area Control Panels (ACP)

Typically, at least one ACP will be required on a project, whether new or existing. More than one may be required depending on the number of I/O points or proximity to the I/O. This will be determined as the design progresses. Exact dimensions and placement for each ACP will be determined during the design phase.

3.2.2.2 Local Control Panels (LCPs):

If required for the project, an LCP is a custom designed and fabricated electrical panel typically equipped with switches, lights, relays, and other control components (but not a PLC) installed on or in a hinged cover NEMA enclosure. As a stand-alone component, LCPs typically require fabrication drawings showing the layout of equipment inside the enclosure and on the face of the enclosure as well as an electrical schematic (relay ladder diagram).

3.2.2.3 Local Control Station (LCSs):

If required for the project, an LCS is typically an off-the-shelf electrical enclosure specifically designed to accommodate NEMA-style indicator lights and pushbutton and selector switches.

The enclosure for an off-the-shelf LCS is specified by the number of standard NEMA devices that will be installed in the enclosure, with holes for the devices pre-punched. An HOA selector switch mounted in a single-device enclosure is a common example of an LCS. Local control stations are typically associated with a motor starter or valve actuator with the components associated with an LCS shown on the electrical schematic (relay ladder diagram) of the associated equipment.

3.2.3 Tagging

The District has established a standard that describes the process for creating structured abbreviations called “tags” for the various physical components of the process (process equipment, instrumentation, controllers, control panels, and electrical equipment), as well as I/O signals associated with the District’s PCS, that will be shown on P&IDs.

"PCS Integrator will be responsible for coordinating with the..."

Might be my own ignorance here, but I’m struggling to see the difference here between an LCS and an LCP other than the LCP is custom fabricated. Can we make a clear delineation here between which cabinets will be referred to as LCPs or LCS’.

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3.2.4 Component Identification

The District has established standards that describe the physical identification (that is, nameplates and labels and their type, content, materials, and installation requirements) of the various components of the process (process equipment, instrumentation, controllers, control panels, and electrical equipment), as well as raceway system components (conduit, pull boxes, etc.) and wire and cable. Specifically, the District has developed two sample specifications:

1. A sample Section 16195 Electrical Identification specification describing identification of instrumentation, controls, and electrical (IC&E) components (Division 13 and 16 components).

2. A sample specification section for other major components (valves, slide gates, pumps, motors, etc.).

3.3 PCS OT Infrastructure

The project may require new PCS networking, workstation, or server hardware and associated software, collectively referred to as Operational Technology (OT) infrastructure. The District (through its IT department), the Contract Operator (through its OT maintenance staff), and optionally the PCS Consultant are responsible for maintaining standards regarding this infrastructure. This ensures tight integration with existing PCS components (important for the distributed nature of the PCS) and implementation of cybersecurity best practices and regulatory requirements following District policy. The FDC and PCS Integrator should plan to review design decisions, equipment selections, and device configurations with the District, Contract Operator, and/or PCS Consultant for final approval before procurement, configuration, or installation of any OT equipment begins.

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3.4 Project Execution

The following sections detail the typical execution steps of a project involving the PCS, the associated parties, and their responsibilities during each step, as well as expectations for the content of deliverables developed during design projects. The execution steps outlined below are primarily concerned with PCS and IC&E design but will extend to the entire FDC team. Depending on exact project details, not all steps may be applicable.

3.4.1 FDC’s Design Phase Submittals

3.4.1.1 Preliminary Design Report (PDR) / 30% Design Submittal

1. Design criteria.

2. Alternatives analysis.

3. Project recommendations.

4. Cost estimate.

5. Schedule:

a. Anticipated construction schedule and duration.

b. Key sequencing and constraints.

6. Major equipment selection:

a. Sole source recommendations.

b. Package system recommendations.

7. IC&E Considerations:

a. Control Narratives for new equipment.

b. Preliminary I/O list drafted.

i. New I/O identified.

ii. Legacy I/O identified and noted for reuse or demolition.

c. Space planning and initial sequencing considerations for any new, large IC&E equipment (MCCs, ACPs, etc.).

d. Electrical load considerations for new MCCs and major loads.

e. Package system recommendations.

f. Table indicating where existing valve actuators, motor control, local control panels, etc. deviate from the standards described in section 6.

Commented [AC2]: West Basin: Review this carefully as this is our standard language, it should align with your intended process.

Add to end of (f): "with recommendations on whether upgrades or replacements will be required with this design."

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g. List of required motor control schematics.

i. For each motor, include ISA tag name and descriptive name, motor horsepower, and the type of motor starter (FVNR, FVR, RVSS, VFD). For motors with VFDs, indicate whether a bypass contactor is required.

ii. Group motors to show which ones share motor control schematics.

iii. Include complete information for existing motors.

iv. For new motors include as much detail as is known and indicate which elements will be developed during 60% design.

8. Drawings:

a. Drawing list developed.

b. Key sheets developed.

c. Tagging complete.

d. P&IDs drafted.

e. One complete motor control schematic including the following devices at a minimum, as applicable:

i. Hand-Off-Remote switch at the MCC.

ii. Hand-Off-Auto switch at the local control station.

iii. Reset button.

iv. Indicator lights on the MCC for running, call to run, overload and/or pump fail.

9. Specs:

a. Specification table of contents www.WestBasinCA.Gov Page Number: 15 of 106

3.4.1.2 60% Design Submittal

1. 30% Review Comments:

a. Address and resolve review comments on 30% design submission.

b. Provide comment resolution report.

2. P&ID and Control Drawings:

a. Continue developing P&IDs. Identify any interlocks required including flow meter positive zero return (PZR) as detailed in section 6.8.1.1.

b. Verify location of control panels and sizes for physical conflicts and accessibility for operations staff.

c. Show panel sizing and locations.

d. List of required motor control schematics from PDR, updated with complete information.

e. Show a representative set of motor control schematics including FVNR starter, FVR starter, VFD, and RVSS as applicable.

f. Show any devices and control logic needed to accommodate load shedding.

g. Provide draft control narratives.

3. Drawings:

a. Majority of sheets developed.

b. Key details developed.

4. Specifications:

a. Draft technical specifications.

b. Provide draft sequencing and constraints spec.

c. Coordination with manufacturers and suppliers for pricing and review.

d. Budgetary estimates for any sole source equipment.

5. Other:

a. Submit updated I/O list.

b. Equipment Tagging Crosswalk: Prepare a crosswalk document that lists all existing equipment to remain with its existing tag and its new tag per section 6.14.

Replace "on" with "from" for all these clauses. Removes confusion about whether this is requiring a re-submit of the previous dwgs or just addressing the comments in the new dwgs

Is this for physical, PCS, IO tags, or all of the above?

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3.4.1.3 Interim Submittal for IC&E only

1. 60% Review Comments:

a. Address and resolve review comments on 60% design submission on IC&E.

b. Provide comment resolution report.

2. P&ID and Control Drawings:

a. Submit any P&IDs that have changed.

b. Submit all motor control schematics and LCP wiring schematics.

3. Control Narrative:

a. Further develop the control narrative.

b. Attend up to two meetings to review control narrative.

4. Other:

a. Submit updated I/O list.

b. Submit list of any existing I/O that will be abandoned or demolished.

c. Submit updated Equipment Tagging Crosswalk.

3.4.1.4 90% Design Submittal

1. 60% Review Comments:

a. Address and resolve review comments on 60% design submission.

b. Provide comment resolution report.

2. P&ID and Control Drawings:

a. Finalize P&IDs.

b. Finalize schematics.

c. Finalize control narrative.

3. Drawings:

a. Majority of sheets developed.

b. Key details developed.

4. Specifications:

a. Draft front ends, including bid form and Contractor qualifications.

b. Technical specifications:

i. Draft Measurement and Payment.

c. Updated budgetary estimates for any sole source.

5. Other:

a. Submit final I/O List.

John Venner West Basin Municipal Water District

John Venner West Basin Municipal Water District What’s the purpose of this interim submittal? Why not just go from 60% to 90%? Also, my understanding was that this whole section was just for IC&E? If not the case, additional docs (e.g. civil or mech) may be required - if it is the case, no need to state “for IC&E only”

John Venner West Basin Municipal Water District

John Venner West Basin Municipal Water District Remove "up to two" - for complex projects this could be higher

Add an "estimated construction timeline" document to 90% and 100% submittals www.WestBasinCA.Gov Page Number: 17 of 106

b. Submit final abandoned/demolished I/O list.

c. Submit final Equipment Tagging Crosswalk.

3.4.1.5 100% Design Submittal

1. 90% Review Comments:

a. Address and resolve review comments on 90% design submission.

b. Provide comment resolution report.

2. Finalize front end details, including bidding timeline, bid form

3.4.2 I/O List Development

1. Develop a list of I/O connected to the PCS either through ACPs or Ethernet in spreadsheet format for review and use by the District and the PCS Integrator. This process can be simplified if the I/O tags shown on the P&IDs are developed as attributes within the AutoCAD (or equivalent) drawings, which will allow them to be directly exported in spreadsheet format. The I/O list, at a minimum, should include basic information: type (DI, DO, AI, and AO), ISA tag name, description, I/O voltage/characteristics, scale, units (for analogs), and memory address (for Ethernet).

2. In addition to the installation of new ACPs, it is possible that existing ACPs will need to be converted to Field Terminal Cabinets (FTCs). If a large number of I/O has been routed from equipment that will not be replaced on the project to an ACP that will be replaced on the project, converting the existing ACP to an FTC and extending the I/O from there to the new ACP may be more cost-effective than installing new conductor to each I/O point. As part of design, the FDC shall discuss such opportunities with the District to determine the most effective solution.

3. For any existing I/O that will be abandoned or demolished, maintain a complete list in spreadsheet format such that the District and PCS Integrator may use it for analysis and modification of existing tagging, PLC code, HMI graphics, historian configuration, and reports related to the I/O points.

3.4.3 Loop Drawings

1. The FDC shall require the Contractor to prepare ISA loop drawings for all control loops being installed or modified by the contactor.

2. Loop drawings shall show the following at a minimum:

a. Device terminations for all signals including terminal numbers.

b. Connections to power supplies including polarity.

c. Grounding terminations for shielded cable.

d. Wire and cable numbers.

e. Indicate PLC rack, slot, and channel, as well as panel terminal numbers.

Alex Aquino Arcadis

RECOMMEND ADDING THE FOLLOWING:

- The I/Os shall be identified by the location of the card (slot no.) and input/output point number.

-In addition to the active I/O's, the list shall also include the implemented spare I/O's and the available I/O's remaining on the I/O board.

Alex Aquino Arcadis

RECOMMEND ADDING THE FOLLOWING:

-Functional name of each loop -Reference name, drawing, and loop diagram numbers for any signal continuing off the wiring diagram sheet.

-MCC panel, circuit, and breaker numbers for power feeds to the loops and instrumentation.

Should this spreadsheet include all IO associated with the PCS being touched? Or just new/modified IO? If the former, data should be in spreadsheet e.g. "existing - no modification/ existing - modification/ new"

John Venner West Basin Municipal Water District Add in here that: "where possible, an existing IO spreadsheet will be provided by the District"

As-Built drawings shall be provided both as standalone project versions and integrated into the District’s existing facility record drawings www.WestBasinCA.Gov Page Number: 18 of 106

3.4.4 P&IDs Development

1. The P&IDs shall show every new and existing I/O point in the I/O list. Likewise, every point shown on the P&IDs shall be included in the I/O list.

2. Existing I/O should be clearly differentiated from new I/O in the P&IDs (e.g. using grey and black coloring).

3. Ensure that PCS connections are clearly shown with the appropriate ISA symbol.

Hardwired and networked connections should both be shown and clearly differentiated.

4. Ensure that the P&IDs clearly show which I/O points are connected to the PCS by identifying which ACP they will be landed in and the type of I/O point (DI, DO, AI, and AO).

See example P&ID sheet provided in Appendix A – Example P&ID.

5. Ensure that P&IDs accurately show external electrical service requirements (24VDC, 120 VAC, 480 VAC, etc.) to process equipment, control panels, instrumentation, solenoid valves, etc. If power is furnished from a PCS panel (as might be the case with some solenoid valves), indicate the PCS panel from which the device is served.

3.4.5 Packaged System Design

1. Packaged Systems are process units that are manufactured with mechanical and controls components and with standard control programming. Typically, the control programming is specific to the internal workings of the system and does not change based on the specific application. However, there are times when the packaged system includes custom programming for the application.

2. When the FDC’s process experience suggests that a packaged system is the appropriate solution for a process element, the FDC shall identify the packaged system in the Preliminary Design Report (PDR) and discuss the system characteristics that make a package system the appropriate choice. The FDC shall also explain the degree of customization of manufacturer’s programming that will be required, the PLC brand and model and details of the control interface proposed by the standard system, and the maintenance requirements. The District prefers packaged systems to still follow all standards within this document, including use of Schneider Electric Modicon M580 PLCs with non-proprietary code (fully viewable, not password protected) and clear documentation of the control strategy and programming. This discussion will allow the District to determine if the packaged system will be purchased with an integral control system or if the control will be programmed into the District’s PCS by the PCS Integrator.

3. Packaged systems must be able to communicate via Ethernet to the District’s PCS, preferably with all tags within the PLC made available to the PCS. If not possible, at minimum they must be able to communicate running/idle status, any remote control commands or setpoints, control modes, major and minor alarm status, and E-Stop status.

Preferably, they will be able to communicate with the PCS using OPC UA, with Modbus as a secondary preference, and include a detailed and well-documented tag list. If a different protocol is required, discuss the integration details with the District.

DO YOU INTEND TO SHOW UPDATED TAGS FOR THESE EXISTING POINTS? OR LEAVE LOOPS BLANK

As-Built P&IDs shall be provided as part of both the standalone project package and integrated into the District’s existing facility record drawings www.WestBasinCA.Gov Page Number: 19 of 106

4. If the packaged system provides any OT infrastructure (computer or networking components), they will be subject to the same requirements as detailed in section 3.3 to ensure they comply with District cybersecurity policy, best practices, and regulatory requirements.

5. Often packaged system manufacturers will request remote access to the packaged system’s control components for monitoring or adjustment. It is the District’s preference not to allow any direct remote vendor access, especially via vendor provided hardware. If required, discuss the manufacturer’s requirements with the District to determine what access is required and how that access can be provided securely following District cybersecurity policy.

6. Packaged systems are still required to follow all documentation requirements detailed in this document, particularly P&IDs (section 3.4.4), Loop Drawings (3.4.3), I/O Lists 3.4.2, Motor Control Schematics (section 3.4.6), and Control Narratives (section 3.4.8).

3.4.6 Motor Control Schematics

1. The FDC’s drawings shall include control schematics for each motor starter and drive, as well as any other control to be implemented in relay ladder logic format (such as a local control panel).

2. The FDC shall ensure each device shown on a control schematic (hand switch, indicator light, instrument, etc.) is also shown on the P&ID. The device shall be identified with the same ISA tag on both the P&ID and motor control schematic.

3. The FDC shall ensure all hardwired interlock connections are clearly shown on the P&IDs.

3.4.7 Motor Controller Configuration

The PCS Integrator will configure motor management relays, VFDs, and RVSSs. The FDC shall support device configuration by providing the PCS Integrator a spreadsheet containing the following information as a part of 90% design submittal:

1. List of motors and method of control (FVNR, VFD, RVSS)

2. Nameplate data including the following:

a. Nominal voltage

b. Number of phases

c. Nominal horsepower

d. Full load current

3. Information necessary for configuring motor management relays

a. Contactor rating

b. CT ratios, PT ratios, and wiring winding count

Add “And 100% design submittal, or bid package if PCS Integrator is a subcontractor to the Facility Contractor.”

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4. Information necessary for configuring VFDs

a. Nominal frequency

b. Nominal speed in RPM

c. Maximum frequency

d. Minimum and maximum speed clamps in Hz for normal operation

e. Acceleration and deceleration times in seconds

3.4.8 Development of Control Narratives

3.4.8.1 General

1. The FDC shall develop the controls portion of the specification to clearly identify the work to be performed by the Contractor and the PCS Integrator, and Contractor’s interface with the PCS Integrator.

2. If control narratives are required for packaged systems programmed by an entity other than the PCS Integrator, the FDC shall include detailed and complete control narratives in the specifications.

3.4.8.2 Development

1. For applicable systems as identified in the I/O list, the FDC shall develop control narratives that the District, Contract Operator, PCS Consultant, and PCS Integrator will use to develop functional specifications and ultimately the control programming. The FDC shall discuss control concepts in the PDR and provide the complete control narratives with the 60% design submittal. The FDC shall update the control narratives to resolve any comments received and produce a supplemental submittal with those comments incorporated as detailed in section 3.4.1.3.

3.4.9 Development of Functional Specifications

3.4.9.1 Process Control Workshop

1. At the beginning of the Construction Phase of the project, the PCS Integrator will conduct an up to three-day Process Control Workshop with the District, Contract Operator, and PCS Consultant to review the process as a whole, major process equipment, and the FDC’s control narratives. The PCS Integrator will then produce and distribute meeting notes from this Workshop.

2. The FDC shall participate and require any pre-selected vendors of major process equipment to participate in the Process Control Workshop to develop process control details.

3. The FDC shall review and return comments on the Process Control Strategy Workshop meeting notes. During preparation of review comments, the FDC shall coordinate with the equipment vendors as necessary.

Commented [AC3]: West Basin: Just a note that this was a major change from our standard language, which encourages bringing the PCS Integrator into the Design Phase. This originally stated “During the 90% Design Phase…”. This section has been modified to be consistent with the rest of the document reflecting that the PCS Integrator is only brought in at the Construction Phase. Let us know if you want to discuss this further.

John Venner West Basin Municipal Water District Response to comment: This is true if the Integrator is brought on board as a sub to the prime contractor, but may not always be the case. Suggest changing language to “Once brought onboard,…” or similar to cover all eventualities

John Venner West Basin Municipal Water District

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3.4.9.2 Development

1. The PCS Integrator shall produce a Draft Functional Specification describing the anticipated PLC control programming, HMI screens, and reports based on the results of the Process Control Strategy Workshop.

2. The FDC shall review the Draft Functional Specification and submit comments highlighting areas where the control understanding does not meet the design intent or requirements.

3. The FDC shall solicit comments from equipment vendors who attended the Process Control Workshop about specific areas of the Draft Functional Specification that involve their equipment.

4. The FDC shall participate in a half-day comment review meeting for the Draft Functional Specification.

5. The FDC shall require vendors of major process equipment to review the Draft Functional Specification (or any successor version released during construction) as it relates to control of the equipment they will supply. The FDC shall require a submittal with all such equipment providing a list of concerns with the Functional Specification as written or a statement that the process equipment will function correctly under the control programming specified. In this context “major process equipment” is equipment for which control programming must be tailored. Generic equipment, such as pumps and valves, do not require this submittal.

1. Upon receipt of all comments, the PCS Integrator will progress the Functional Specification from Draft to Final, submit that specification for review, and conduct a review meeting if deemed warranted.

2. The FDC shall review and prepare comments on the Final Functional Specification.

Fix numbering www.WestBasinCA.Gov Page Number: 22 of 106

3.4.10 Contractor’s Schedule

The FDC shall include the following items, as applicable, in the requirements for the Contractor’s CPM (critical path) schedule submittal.

3.4.10.1 Motor Control Centers (MCCs)

1. MCC Submittal Preparation.

2. MCC Submittal Review Process.

3. MCC Resubmittal Preparation.

4. MCC Resubmittal Review Process.

5. Final MCC Submittal Preparation.

6. Final MCC Submittal Review Process.

7. MCC Fabrication.

8. MCC Factory Acceptance Testing (Manufacturer’s Standard).

9. MCC Shipment.

10. Motor Starter Logic Testing as described in section 3.4.12.

a. Include periods for Initial Testing, Non-Conformance Resolution and Re-Testing.

b. The FDC shall work with the District and/or the PCS Consultant during the Design Phase to define the expected schedule durations for Motor Starter Logic Testing.

11. MCC Installation.

3.4.10.2 Milestones to Support Commissioning

1. Required ACP Delivery Date (at least 8 weeks after approval of submittals).

2. ACP Installation.

3. Commissioning*:

a. Instrumentation Calibration, Configuration, and Setup. (Equipment Testing)

b. Point-to-Point Wire Testing. (Equipment Testing)

c. Loop Testing. (Equipment Testing)

d. I/O Checkout. (System Start-up)

e. Control Strategy Testing. (System Start-up)

*Note: Commissioning task terminology may vary between project specifications and should be coordinated to ensure all tasks are understood and included.

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3.4.10.3 Site Acceptance Testing

1. The FDC shall detail the number and sequence of commissioning steps needed to cutover process control operation to maintain any required operations continuity.

2. The FDC shall provide the Contractor with anticipated durations for any tasks lead by the PCS Integrator.

3. The FDC shall require the Contractor to submit instrumentation submittals a minimum of eight weeks before required ACP delivery date.

3.4.11 Factory Acceptance Tests (FAT)

The PCS Integrator and Contractor shall perform factory acceptance testing on the exact hardware being used in the project to the maximum extent possible.

1. PCS FAT: During the Construction Phase, the PCS Integrator will conduct a Factory Acceptance Test demonstrating the proper operation of the control programming.

a. The FDC shall participate in up to three full days of factory acceptance testing.

Factory acceptance testing can be conducted virtually or in person, as an option of the PCS Integrator.

b. The FDC shall ensure the Contract Documents require the participation of major process equipment vendors.

2. ACP FAT: The PCS Integrator will perform a FAT of the ACP at the panel fabricator’s facility. The test will be witnessed by the District and/or the PCS Consultant. Neither the FDC nor the Contractor have a specific role in the ACP FAT but may be present at their discretion.

3. Local Control Panel FAT: The FDC shall require the Contractor (or sub-contractor) supplying the instrumentation and local control panels to perform factory testing for any control panels or other components having custom fabrication for the project. Factory tests may be witnessed by the District and/or the PCS Consultant at their discretion.

4. Process Equipment FAT: The FDC shall determine which specialized process equipment requires factory acceptance testing and what witnessing requirements should apply.

5. MCC FAT: The FDC shall require the MCC manufacturer’s standard quality assurance test performed at their fabrication facility prior to shipment. Factory tests may be witnessed by the District and/or the PCS Consultant at their discretion.

FOR ANY WITNESSED FAT, CLARIFY WHO WILL PAY FOR FOR TRAVEL, FOOD AND LODGING

DOES THIS INCLUDE VENDOR PACKAGED SYSTEMS?

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3.4.12 Motor Starter Logic Testing

1. The specifications shall include the Contractor’s responsibilities for Motor Starter Logic Testing performed by the PCS Integrator. This testing will verify that the control logic (alarms, interlocks, etc.) for each motor starter operated correctly.

2. The Contractor shall provide:

a. 21 days written notice to the District, the PCS Consultant, and the PCS Integrator of the date that the testing period may begin.

b. Permission to perform the testing without impact to the warranty, as the equipment will still be “owned” by the Contractor at the time of testing.

c. Unlimited, unhindered access to the motor starters for the defined testing period.

d. 120 VAC, single phase, 15 A temporary power for PCS Integrator’s use to simulate test conditions.

e. A manufacturer’s representative scheduled to arrive shortly after completion of testing to address any non-conformances found.

3. Development of the test plan and execution of the testing will be performed by the PCS Integrator. Approval of the testing documentation by the District and/or the PCS Consultant is required prior to start of testing. The Contractor is not required to be present for the test but may be present at their discretion.

4. The testing shall be performed at the project site following delivery of the motor starter or MCC, but prior to the connection of any field wiring, including power. The PCS Integrator will simulate field devices per the test plan to verify motor starter operation.

5. Motor Starter Logic Testing shall be clearly distinguished from the MCC Factory Acceptance Test, which is led by the manufacturer at their fabrication facility prior to shipping to the project site.

3.4.13 Commissioning

1. After major construction and equipment installation has been completed, the Contractor shall be required to perform Instrumentation Calibration, Configuration, and Set-Up; Point-to-Point Wire Testing; Process Equipment Testing; and Loop Testing.

a. The Contractor shall develop and submit their proposed testing documentation for review by the District and/or the PCS Consultant.

b. Approval of the testing documentation is required prior to start of testing.

2. Upon completion of Loop Testing, the Contractor shall assist the PCS Integrator in performing I/O checkout.

a. The FDC shall work with the District and their PCS Consultant during design to determine an expected duration for I/O checkout and include that duration in the specifications.

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b. The Contractor shall provide 21 days written notice the District, the PCS Consultant, and the PCS Integrator of the date that the Contractor will be ready for I/O checkout.

c. I/O checkout will include the following steps:

i. The PCS Integrator will view inputs and command outputs from the ACP.

ii. The Contractor shall be responsible for activating instruments and devices to produce the required inputs (contact open, contact closed, analog values, etc.) and report outputs.

iii. The Contractor shall be responsible for troubleshooting I/O errors and correcting wiring and device problems outside the ACP.

d. The PCS Integrator shall develop and submit their proposed I/O checkout documentation for review by the District and/or the PCS Consultant prior to start of checkout.

3. Upon completion of I/O checkout, the PCS Integrator will perform Control Strategy Testing, to ensure the PCS functions as expected when connected to the process equipment.

a. The PCS Integrator shall develop and submit their proposed Control Strategy Testing documentation for review by the District and/or the PCS Consultant prior to start of testing.

4. The PCS Integrator shall also ensure that the Historian and Reporting systems are updated to function in accordance with all PCS changes.

3.4.14 Site Acceptance Testing

1. The FDC shall specify requirements for site acceptance testing to ensure the project works as an integrated system. As a minimum, include the following requirements:

a. Discuss with the District the extent of which witnessed Control Strategy Testing performed by the PCS Integrator should occur.

b. Continuous operation of the process equipment in automatic (PCS) control mode for 24 hours a day, for a period of 7 consecutive days for small sites (e.g. lift station) or 30 consecutive days for large sites (e.g. treatment process). In the event of a failure that prevents the process from being restarted within a reasonable amount of time (as determined by the District) or a reoccurring issue that prevents regular operation of the process, this period will restart. These timelines are a general requirement for each type of site, and the District should be consulted for the exact timeline required to satisfy site acceptance testing for any given site.

2. As proper operation of the PCS by the District is not the Contractor’s responsibility, include requirements to identify any failures as being the Contractor’s responsibility or the PCS Integrator’s responsibility to resolve.

3. Upon completion of commissioning, the PCS Integrator shall ensure the development environment is updated to accurately reflect the state of the production environment.

John Venner West Basin Municipal Water District

John Venner West Basin Municipal Water District Change "lift station" to "pump station"

This is the first time the dev environment is mentioned. Add a line about it to the “PCS Overview section above” www.WestBasinCA.Gov Page Number: 26 of 106

4 PCS Responsibilities This section provides a complete description of project participants (Owner, PCS Consultant, PCS Integrator, Facility Design Consultant, and Construction Contractor) and is intended for use by the

FDC.

4.1 Owner

West Basin Municipal Water District will provide strategic direction and design input to PCS-related projects and consultants as the asset owner.

4.2 Contract Operator

The District’s Contract Operator will provide operational and maintenance related design input to PCS-related projects and consultants as the asset operator.

4.3 PCS Consultant

The PCS Consultant role may be filled by either internal District staff or the…