PLC_Specs.docx

REFEERNCE DOCUMENT ONLY FOR ABL-15229

SEAWATER SYSTEM CONTROLS:

PART 1 - GENERAL:

1.1 SCOPE:

A. The contractor shall replace the three Allen Bradley SLC500 5/05 PLC’s and PanelView input/output panels at the Ted Stevens Marine Research Institute to provide seawater control systems for the seawater delivery, filtration, reservoir level, pumps, automatic backwash cycles, post treatment systems, and coordination of the controls and monitoring interface to the WebCtrl Direct Digital Control (DDC) system.

1.2 SEAWATER SYSTEM CONTROLS:

A. The control system actuators, sensors, and infrastructure are in place. The seawater controls contractor shall furnish logic control system, operator input/output panels, and all materials, including all computer hardware and software to replace the three currently installed Allen Bradley SLC 500 5/05 PLC’s and PanelView input/output panels in the Post-Treatment Control Pane l in the basement, the Wet Well Pump house Control Panel, and the Filter Building Control Panel. Currently installed automation sensors and controls, and wiring will be reutilized unless they are not compatible with the new system. It will be the controls contractor’s responsibility to determine compatibility based upon review of the as built drawings, specifications, and site visit. The seawater controls contractor shall be responsible for the design, installation, supervision and labor services, calibration, all software programming, and checkout necessary for a complete and fully operational system. The seawater controls contractor shall include training requirements. Also, the seawater controls contractor shall include developing system graphics for the new input/output panels.

B. The control system is to be set up and adjusted to achieve optimum operation of the seawater system. This includes sequencing, timing and readjustment as required, and programming of the variable frequency drives to achieve automated control. Modifications to the sequence of operation will not be considered as extra to the Contract. These modifications to continue through the commissioning period and warranty period as required to achieve optimum operation of the mechanical system.

C. Supervisory control and data acquisition (SCADA) monitoring is accomplished through the WebCtrl DDC. The seawater control system shall become an extension of the DDC through the three local control panels located in the Wet well pump house, the Filter Building, and the Post-Treatment Control Panel located in the basement. Programming shall be provided by the Seawater Control Contractor and shall include the licensing of all software needed for integration with the DDC system.

D. This Section is a performance specification clarified in certain sections to establish minimum standard of equipment, installation or level of control. The specification describes the basic functions required but not all of the installation details or components. This Trade is expected to have sufficient experience to be able to design and estimate the cost of an appropriate control system. Materials and work necessary to achieve a satisfactory result will not be considered extra to the contract.

E. The contractor shall review all contract documents and visit the site if possible prior to submission of a quotation.

F. The control system shall be a modular, and flexible. The seawater controls shall be fully commissioned and will be witnessed.

Ted Stevens Marine Research Institute

Lena Point, Juneau, Alaska

Ted Stevens Marine Research Institute

Lena Point, Juneau, Alaska

Seawater System Controls

Seawater System Controls

1.3 SEAWATER CONTROL SYSTEM/BUILDING HVAC DDC SYSTEM INTERFACE:

A. The purpose of this interface is to allow for building maintenance personnel to view and monitor the seawater control system through the facility WebCtrl DDC operator workstations and make changes to operational parameters as needed.

B. The supplier of the seawater control system is responsible for the installation, configuration, programming, start-up, and testing of the seawater controls system to meet the sequence of operation described in this section. The seawater system supplier shall also provide all licensing, hardware, and software required to program the WebCtrl direct digital control (DDC) system interface.

C. The supplier of the seawater control system is responsible to coordinate all equipment, interface and power requirements with the government’s (DDC) contractor prior to development of submittals or purchase of any equipment.

D. Communication between system components shall be via a standard communication protocol. The choice of protocol shall be coordinated between the supplier of the seawater control system and the government’s DDC contractor to ensure that it is compatible with the WebCtrl DDC system already installed. Any additional hardware required for establishing communications is the responsibility of the seawater control system supplier.

E. The seawater controls shall directly communicate with the facility DDC system. The facility DDC system shall communicate with the seawater equipment to read the information, monitor the control setpoints and alarms, and change setpoints as needed as shown in the interface points list of this specification section.

F. The seawater controls contractor shall provide all hardware and software necessary to integrate the seawater controls with the DDC system.

1.4 QUALIFICATIONS:

A. The seawater control system shall be installed by an industrial controls contractor licensed to install and program Automated Logic control systems, and should have a minimum of four years’ experience installing Industrial automation and PLC systems.

B. The seawater controls contractor shall provide proof of experience with integration of the type outlined in this specification.

C. The supplier shall provide individuals experienced with the installation and startup of equipment relating to integration.

1.5 SUBMITTALS:

A. Provide complete seawater controls submittal data for coordination of the seawater system with the Automated Logic DDC system interface.

B. Product Data: Provide product data for all manufactured products, control devices, components, panels, hardware, software, surge and transient protection, and assemblies required for this project. Include product description and manufactures standard model number C. Shop drawings shall include:

1. Control center layouts.

2. Manufacturer's descriptive technical literature for all equipment and devices.

3. Interconnection schematics.

4. Wiring and piping diagrams.

5. One-line diagram from sensor and control points to Field Interface device and/or standalone panel including all components and cables.

6. Terminal cabinets, including termination listing.

7. Written description indicating sequence of operation. Shop drawings will be rejected if the written description is not included with the submission. Sequences should reference English descriptors and labels for each point described.

8. All input/output points which shall include the following information associated with each point:

a. Sensing element type and location.

b. Details of associated field wiring schematics and schedules.

c. Software and programming details.

9. Detailed block diagrams of transmission trunk routing and configuration.

10. Copies of all system graphics complete with system specific point labels.

D. Performance Testing and Commissioning Plan: Provide a detailed seawater control system start-up plan and checklist that verifies each point, sensor, device, and panel connection. System start-up plan shall include a final performance test plan that verifies the execution of all Sequences of Operation. The start-up and final performance testing shall be in conjunction with Section 15610 - Seawater System Start-up, Commissioning and Testing.

1.6 CLOSEOUT SUBMITTALS:

A. Submit operation and maintenance data.

B. The maintenance manual data is intended to cover the operation and maintenance of all control systems and equipment installed. Forward 3 copies of the Controls and Instrumentation section of the operating and maintenance manuals to ensure the binding and format of material are compatible. Ensure sufficient time has been given for the compiling of Deadline. One complete manual shall be furnished prior to the time that equipment tests are performed.

C. The manuals shall include the name, address and telephone number of the control subcontractor installing the systems if appropriate, and a list of emergency numbers for service personnel.

D. Manuals shall be furnished which provide full and complete coverage of the following subjects:

1. Operational Requirements: This document shall describe, in concise English terms, all the functional and operational requirements for the system and its functions that have been established.

2. System Operation: Complete guidance and procedures for operation of the system.

3. Functional Description: Detailed documentation, in language readily understandable to engineering personnel, of the theory of operation and specific functions of the system.

4. Software: Documentation of the theory, design, interface requirements, and functions of all software modules and systems for all digital processors.

5. Maintenance: Documentation of all maintenance on all system components including inspection, periodic preventive maintenance, fault diagnosis, and repair or replacement of defective units. Include calibration, maintenance, and repair of all sensors and controls, plus diagnosis and repair or replacement of all system hardware.

1.7 WARRANTY:

A. Submit manufacturer warranty and ensure forms have been completed in Owner's name and registered with manufacturer.

B. The system including all hardware and software components shall be warranted for a period of one year following the date of final acceptance. Any manufacturing defects arising during this warranty period shall be corrected without cost to the Government.

PART 2 - PRODUCTS:

2.1 PROGRAMABLE LOGIC CONTROLLERS (PLC or similar logic control) EQUIPMENT A. Programmable Logic Controllers (PLC) – The three main control panels, which include the Wet well Control Panel, Filter House Control Panel and Post-Treatment Control Panel shall all use the same basic components. The system will be replacing the Allen Bradley SLC 500 systems that are currently installed. See the As Built drawings for the configuration of the current system. The replacement must meet or exceed the functionality provided by the SLC 500 system.

B. All Control Panels shall each be equipped with an operator Interface. The current Panel View Plus 600 Operator Interface is to be replaced with a 10 inch touch screen panel or equivalent ruggedized control panel that provides graphic based menus and remote access through the facilities network.

PART 3 - EXECUTION:

3.1 SEQUENCE OF OPERATIONS:

A. The proposed sequence of operation of the seawater system is as described herein.

B. Wet Well Pump House:

1. The pump house is configured with four SW pumps. In the final configuration the system will be configured with two pumps in the South Well (Pump 401 and 403), and two pumps in the North Well (Pump 402 and 404). Each seawater supply pump has a capacity of 800 gpm (50 l/s). The availability of a pump will be manually selected through a buss transfer switch for each well. Each pair of pumps will operate in a lead/lag configuration. The unselected pumps will be manually available for operation in standby. The pumps will include a Variable Frequency Drive to control the output (flow rate) of each pump. The contractor will be responsible for programming the VFD to interface with the logic controller to set the pump frequency.

2. The lead and lag pumps shall alternate to equalize runtime. The pump with the least runtime shall be evaluated on a weekly basis and shall be switched to the lead pumps, the pumps with the most runtime shall be manually selected for stand-by.

3. A magnetic flow meter is installed in each of the duplex raw seawater main lines to the filter house. When power is available, the lead seawater pump shall start. The combined output from the magnetic flow meter will be used to regulate the lead and lag seawater pumps Variable Frequency Drives and thus control the seawater delivery flow rates to maintain the seawater level of the active filter house FSW reservoir to within 10cm of the active reservoir level set point.

a. If the lead pump is at 100% speed and the active FSW reservoir cannot maintain its level set point the lag pump shall start and both pumps shall operate in unison to maintain the reservoir level set point.

b. If the reservoir is at set point and both pumps are operating at or below 45% speed for a time interval of 15 minutes the lag pump shall stop. This system of control will match the flow rate of the main seawater supply pumps to the actual system flow demand.

c. The SW control system shall have a Maximum SW Flow setting that can be changed from the local operator interface attached to each PLC, and through the WebCtrl interface. The Maximum SW Flow Setting will be used to limit VFD speed of the online pump(s) so that the maximum SW Flow setting is not exceeded.

4. A SW pressure sensor will be installed at the bottom of each wet well. These will be configured to calculate the SW level within the wet well based on the density of SW for display on the operator interface and for control of SW pumps.

a. In the event the SW level in a wet well drops below a predetermined point, an override signal will be sent to the VFD for the pump that is operating in that wet well, and an alarm will be created that is delivered to the DDC. The VFD speed will be adjusted to reduce the flow of water from the wet well to maintain the level of the wet well at or above the predetermined level.

b. If the water level in the wet well rises above the predetermined level, the system shall return to normal operation with the VFD speed controlled by reservoir level.

c. If the water level in the wet well continues to drop below a safe operating level, then the controller shall shut down the pump and an audible and visual alarm shall be activated.

5. All motor controls are the HOA (Hand-Off-Automatic) type that will allow any pump pair to be manually operated at the controller.

6. Two VFD units will be installed to control the SW pump frequencies. Each VFD will be connected to two SW pumps through a manual buss transfer switch. In this way one VFD will provide power to the pumps in the north wet well, and one will be providing power to the south wet well. The system will be programmed so that the seawater level sensor (pressure transducer) will be associated with the VFD that services that wet well. The transfer switch shall have an internal switching mechanism connected to the selector switch that will tell the PLC which pump is selected for hours computation and lead/lag status.

7. Two vacuum sensors shall be installed on the SW Siphon Lines. These will be used to monitor the status of the siphon. If the vacuum is lost, the siphon will not function. These sensors may be used at a future time to control the vacuum blowers to reestablish the siphon when it drops below a pre-determined point.

C. Main Filter House:

1. Low level, and low low level alarms are installed for the FSW reservoirs. A low level alarm condition will signify that the demand of unfiltered seawater exceeds the filtered seawater supply capability. An alarm will be announced and monitored. This will also create a “Backwash Inhibited” condition that will prevent the backwash of dirty filters.

2. There is a single backwash supply pump that provides filtered seawater for backwashing the gravity sand filters. The on-off operation of this pump is controlled by the backwash controller that cycles the backwash procedure of each gravity sand filter.

3. There is a rotary air blower that is used to scour the gravity sand filter beds prior to backwashing them with filtered seawater. The on-off operation of this air blower is controlled by the backwash controller as for the backwash pump.

4. All motor controls shall be the HOA ( Hand-Off-Automatic ) type that will allow any pump to be manually operated.

5. Each sand filter will have several electrically operated valves on the various piping connections to the filter, as follows:

a. Seawater Filter Valve 1a- on the north unfiltered seawater supply line.

b. Seawater Filter Valve 1b- on the south unfiltered seawater supply line.

c. Seawater Filter Valve 1c - on the filtered waste seawater discharge

d. Sea water Filter Valve 1d - on the backwash waste line

e. Seawater Filter Valve 1e - on the backwash water supply line from the domestic water system

f. These valve designations repeat for filters 2, thru 4 D. Sand Filter Modes of Operation. The sand filter modes of operation are to be modified to provide for better management of the system. Operating modes will be selectable via the local control console as well as remotely through the WebCtrl interface. Mode control and valve control where appropriate will be in parallel so that a valve opened on one panel can be closed on another panel.

E.

1. Manual Mode. The local control interface will be modified to provide local manual control for each filter.

a. In manual mode valves will be manually controlled by selection of valve position on the local or remote interface panel.

b. Overfill protections will be in place to secure inlet valves and prevent over-fill even in manual mode.

2. Semi-automatic Mode. (This represents the current mode of operations)

a. When enabled, the two inlet valves and outlet valve are fully open and remain open unless filter is disabled or scheduled for backwash.

b. Overfill protections will be in place to secure inlet valves and prevent over-fill even in manual mode.

3. Full-automatic Mode.

a. In this mode the outlet valve would be modulated to maintain the level of water in the sand filter a minimum of 10cm above the sand media. The contractor will be responsible for modification of the outlet valve, or timing operations to modulate the valve to achieve this.

b. The filter inlet valves will also be modulated so that water is distributed between the online filters. i.e. all the water will not be dumped into the first filter in the bank, but it will be evenly distributed in order to ensure all the online filters are utilized. The contractor will be responsible for modification of the inlet valves to modulate the valve to achieve this.

F. Gravity Sand Filter Backwash Control Sequence:

1. Each of the six gravity sand filters will be backwashed on a regular basis. The frequency of automatic backwashing each filter cell will be determined by the experience of the seawater system operating staff. The frequency of backwashing will vary seasonally.

a. The backwashing procedures may be initiated by a time clock controller which will use a calendar to schedule regular back wash sequences during normal working hours.

b. There will be an overriding ultrasonic level controller in the filter cells that will initiate the backwash cycle in the event that the time clock controller does not initiate the backwash cycle prior to the filters becoming dirty or clogged, requiring backwashing.

c. The ultrasonic level controller in the filter cells will also be used to inhibit the backwash of a filter that does NOT have water above a minimum of 10 cm above the sand. (water must be present for air scouring to commence)

d. The automatic backwash control system shall include manual override features to allow the backwash cycles to be manually controlled.

e. The control system shall include all electrically operated control valves and equipment and all interconnecting piping and electrical wiring, as required.

2. Each filter is supplied with unfiltered seawater from the main seawater supply pumps. There are two supply lines which can be lined up so that both provide UFSW or so that one will be in use with the other purged with fresh water to control the build-up of marine fouling organisms in the pipelines or drained.

3. A typical backwash sequence will be as follows:

a. SWFV 1a and 1b will close ( SWFV 1b will close if the line B is in use ).

b. SWFV 1c will close.

c. SWFV 1d will open. This line is connected to the backwash discharge sump.

d. SWFV 1f will open.

4. The air blower will be started and the filter will be purged with air for a few minutes and then the air blower will be shut-off.

a. SWFV 1f will be closed.

b. SWFV 1e will be opened.

5. The backwash supply pump will be started. The filter will be backwashed for a pre-set period of time. This time will be variable and will be in the order of between 3 and 8 minutes. The backwash pump will then be shut off.

a. SWFV 1e will be closed.

b. SWFV 1d will be closed.

c. SWFV 1a ( and/or 1b as the case may be ) will be opened.

d. SWFV 1c will be opened when the water level is a minimum of 10 cm above the sand bed.

6. This sequence will complete the backwash cycle for Filter 1. The other filters will then be backwashed similarly.

G. Seawater Waste System Controls and Operation:

1. The SW Waste tanks in the basement of the lab contain level sensors which shall indicate high and low levels as outlined herein and shall be used to divert water through a three-way valve to maintain the level in the tanks.

2. The contractor shall program the 3 way valve to maintain the water level in the tanks within 10cm of the normal level with a minimum of “hunting”.

3.2 BUILDING HVAC DDC SYSTEM INTERFACE:

A. Start-Up and Check-out Procedures

1. The seawater controls system supplier shall independently start-up, check-out and test all hardware and software and verify communication between all components.

2. Verify that all control wiring is properly connected and free of all shorts and ground faults. Verify that terminations are tight.

3. Verify that all analog and binary input/output points read properly.

4. Verify alarms and interlocks.

B. Joint Commissioning - Verify operation of the integrated system.

1. Upon review of software, a point to point test of the integrated control installation shall commence. The seawater controls system supplier representative, in conjunction with the facility HVAC DDC system representative, shall test actual field operation of each control and sensing point. Compare the values read in the building control system to those indicated on the seawater control panel display.

2. When the point to point input/output testing is successfully completed, a series of hardware/software systems tests shall be performed. All groups of points that are under system control shall be tested for compliance with the sequences of operation. All commissioning procedures shall be documented in writing and submitted to the Contracting Administrator for review and approval. The tests shall include but not be limited to:

a. Control interlocks and any miscellaneous sequences shall be tested.

b. All alarm and shutdown modes shall be tested for proper operation.

3. The Contracting Administrator or his representative may elect to be present to observe and review these tests. Provide 14 ten days advance notice of the start of the interface testing procedures.

C. Interface Points List. The following points shall be included for monitoring and alarming via the seawater/ facility HVAC DDC system interface:

1. Wet Well Intake Pump House:

a. Wet Well Level (centimeters)

b. Wet Well Low Level (alarm)

c. Lead/Lag Pump Indicator (PMP-401, PMP-402, PMP-403, PMP-404)

d. PMP - 401 Seawater Pump Status (on/off)

e. PMP - 401 Seawater Pump Failure (alarm)

f. PMP - 401 Seawater Pump VFD pump speed (Hz)

g. PMP - 402 Seawater Pump Status (on/off)

h. PMP - 402 Seawater Pumps Failure (alarm)

i. PMP - 402 Seawater Pump VFD pump speed (Hz)

j. PMP - 403 Seawater Pump Status (on/off)

k. PMP - 403 Seawater Pumps Failure (alarm)

l. PMP - 403 Seawater Pump VFD pump speed (Hz)

m. PMP - 404 Seawater Pump Status (on/off)

n. PMP - 404 Seawater Pumps Failure (alarm)

o. PMP - 404 Seawater Pump VFD pump speed (Hz)

p. Flow Meters Seawater Delivery Rate (GPM)

q. Unfiltered Seawater Water Quality:

1) PH

2) Dissolved O2

3) Temperature

4) Salinity

5) Turbidity

2. Filter House:

a. Active Reservoir Selection (Reservoir #1 or #2)

b. Reservoir #1 Level (Calculated Gallons and Meters)

c. Reservoir #1 Level Setpoint (Calculated Gallons and Meters)

d. Reservoir #1 Low Level (Alarm)

e. Reservoir #1 High Level Overflow (Alarm)

f. Reservoir #2 Level (Calculated Gallons and Meters)

g. Reservoir #2 Level Setpoint (Calculated Gallons and Meters)

h. Reservoir #2 Low Level (Alarm)

i. Reservoir #2 High Level Overflow (Alarm)

j. Sand Bed Filters 1-6 level (Centimeters above the sand)

k. Sand Bed Filters 1-6 Backwash cycle status each cell (on/off)

l. All Control Valve Positions (percentage open/closed)

m. Filter backwash Control Panel Status (on/off)

n. Filter backwash Control Panel Failure (alarm)

o. PMP-301 Backwash Pump Status (on/off)

p. AB-301 Blower status (on/off)

q. AB-301 Blower delivery pressure (kPa)

r. Filtered Seawater Water Quality:

1) PH

2) Dissolved O2

3) Temperature

4) Salinity

5) Turbidity

3. Post Treatment Room:

a. Waste Seawater Tank Level (meters)

b. Waste Seawater Tank Low Level (Alarm)

c. Waste Seawater Tank High Level Overflow (Alarm)

d. Cooling Seawater Tank Level (Calculated Liters)

e. Cooling Seawater Tank Low Level (Alarm)

f. Cooling Seawater Tank High Level Overflow (Alarm)

g. Backwash Surge Tank Level (Calculated Liters)

h. Backwash Surge Tank Level Low Level (Alarm)

i. Backwash Surge Tank Level High Level Overflow (Alarm)

j. PMP-106 Pump Status (on/off)

k. PMP-107 Pump Status (on/off)

l. PMP-108 Pump Status (on/off)

m. OG-1 Ozone Generator Control (on/off)

n. OG-1 Ozone Generator Status (on/off)

o. OG-1 Ozone Generator Failure (alarm)

p. OG-2 Ozone Generator Control (on/off)

q. OG-2 Ozone Generator Status (on/off)

r. OG-2 Ozone Generator Failure (alarm)

s. OCT-1 Ozone Level Sensor (ppm)

t. OCT-1 High Ozone Level (alarm)

u. OCT-2 Ozone Level Sensor (ppm)

v. OCT-2 High Ozone Level (alarm)

w. OCT-3 Ozone Level Sensor (ppm)

x. OCT-3 High Ozone Level (alarm)

y. OCT-4 Ozone Level Sensor (ppm)

z. OCT-4 High Ozone Level (alarm)

aa. Space Ozone Detector Warning (alarm)

ab. Space Ozone Detector High Level (alarm)

ac. North Wet Well Siphon Vacuum

ad. South Wet Well Siphon Vacuum

3.3 PRESSURE SWITCHES/SENSORS:

A. Vacuum sensors shall be installed on the siphon lines for each wet well. These shall be used to monitor the state of vacuum in the siphon, and will create an alarm when the vacuum rises above a pre-determined level (loss of siphon).

B. The vacuum sensor may be used to schedule operation of the vacuum pumps at a future point to continuously monitor the level of vacuum and turn on the vacuum pumps if required.

3.4 FLOW METERS:

A. Flow Meters shall be installed on the SW discharge lines from the FSW Reservoirs and included in the graphics for the reservoir levels.

B. Flow meters shall be installed on the heat pump evaporator and condenser lines to calculate the efficiency of the heat pumps.

3.5 INSTALLATION SEQUENCING: The Contractor shall work closely with the facilities staff to sequence installation of the controls, and schedule work in such a way as to cause minimum impact.

A. Wet Well Intake/Pump House:

1. The new logic control system will be installed and tested without interrupting the flow of water to the filter building.

2. Pump control will be placed in manual and the pump will remain operational during the upgrade.

3. The contractor shall provide a means to monitor the magnetic flow meters to sound the alarm if the pump flow drops below established alarm setpoints prior to disabling the current PLC.

B. Filter Building:

1. Replacement of the filter building PLC will be scheduled to occur during the winter months. At this time the sand filters will be temporarily bypassed with the UFSW routed directly to the wet labs at TSMRI and UAF.

2. The contractor will be able to take the filter building systems offline to replace the wiring and controls without impacting the ability of the system to provide water.

3. The pump controls will be placed in manual, or programmed to maintain a pre-determined flow rate in GPM.

C. Post Treatment Room:

1. The water diverter valve will need to be operational during the replacement of the PLC. This valve maintains the water level of the waste water tank.

3.6 START-UP / DEMONSTRATION: The Contractor shall demonstrate to the satisfaction of the Contract Administrator the complete and proper operation of all Seawater systems. The demonstration shall include, but not be limited to the following:

1. Proper operation of the seawater delivery system, filtration, and post treatment system

2. Proper operation of all pumps.

3. Proper operation of all valves, specialties and accessories.

4. Verify equipment status signals, trouble alarms, seawater controls, sequences of operation, and building HVAC DDC interface.