Attachment_03_00_00_01_Specifications_3of9_LeadvilleWTP-B3_11-07-2023_1.pdf

Leadville Mine Treatment Plant and Facilities Water Treatment Plant Replacement Leadville Mine Drainage Tunnel Project, Colorado Solicitation No. 140R6024R0009

Solid Contact Clarifiers (SCC) Supply Contract Approval Drawings and Data

51 46 43 - 1

SECTION 51 46 43

SOLIDS CONTACT CLARIFIERS (SCC)

SUPPLY CONTRACT APPROVAL DRAWINGS AND DATA

PART 1 GENERAL

1.01 APPROVED SUBMITTAL

A. Attached following this End of Section. This specification is a total of 1,378 pages.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

Not Used

END OF SECTION

Leadville Mine Treatment Plant and Facilities Water Treatment Plant Replacement Leadville Mine Drainage Tunnel Project, Colorado Solicitation No. 140R6024R0009

Solid Contact Clarifiers (SCC) Supply Contract Approval Drawings and Data

51 46 43 - 2

This page intentionally left blank.

IN REPLY REFER TO:

United States Department of the Interior

BUREAU OF RECLAMATION

Missouri Basin Regional Office

P.O. Box 36900 Billings, MT 59107-6900

MB-2600

1.3.11

SENT VIA ELECTRONIC MAIL ONLY

Mr. Dennis Gutierrez GSE Construction Company, Inc 7633 Southfront Rd STE 160 Livermore, CA 94551-8211

Subject: RSN 464353-1 � Solids Contact Clarifier (SCC) Equipment (Approval Drawings and Data), Contract No. 140R6022C0006, Supply of Solids Contact Clarifier Equipment, Leadville Mine Treatment Plant and Facilities, Leadville Mine Drainage Tunnel Project, Colorado (Your Transmittal Dated October 21, 2022)

Dear Mr. Gutierrez:

Your submittal has been reviewed and is approved.

RSN 464353-1 is complete.

Sincerely, Kurt Anderson Alt. Contracting Officer�s Representative

GSE Construction Co. Inc.

Project: 825 Leadville Supply Solids Contract Clarifier Equipment

749 North Highway 91 Leadville, Colorado 80461

Submittal #RSN 46 43 53-1-R1.2 - Approval Drawings and Data

RSN 46 43 53-1 -

Revision 2 Submittal Manager Joseph Henry (GSE Construction Co.)

Status Open Date Created Oct 11, 2022

Issue Date Oct 11, 2022 Spec Section RSN 46 43 53-1 -

Responsible Contractor

GSE Construction Co. Received From Joseph Henry (GSE Construction Co.)

Received Date Oct 21, 2022 Submit By

Final Due Date Lead Time

Cost Code

Location Type Product Information

Approvers

Ball in Court Joseph Henry (GSE Construction Co.)

Distribution Mario Lozano (GSE Construction Co.), Joseph Henry (GSE Construction Co.)

Description Please see attached Submittal & clarifications as they relate to Spec section RSN 46 43 53-1 Approval Drawings and Data Rev 02.

Contract Number: 140R6022C0006 Responsibility Code: COR

**GSE has reviewed Submittal for completion and compliance with Specification Section RSN464353-1**

Submittal Workflow

Name Sent Date Due Date Returned Date Response Attachments

General Information Attachments

Joseph Henry Pending

GSE Construction Co. Inc. Page 1 of 1 Printed On: Oct 21, 2022 07:51 AM MDT

WATER TECHNOLOGIES & SOLUTIONS

C REVISED PER SUBMITTAL COMMENTS CB MT CB 04-Oct-22 B REVISED PER SUBMITTAL COMMENTS JH CB CB 21-July-22

A ISSUED FOR INFORMATION CB AN AN 20-May-22

REV DESCRIPTION WRITTEN

BY

CHECKED

BY

APPROVED

BY

DATE

DD-MMM-YY

DOCUMENT TYPE :

CONTRACT ISSUER DISCIPLINE PRODUCT PHASE TYPE CHRONO

BUREAU OF RECLAMATION

LEADVILLE MINE

LEADVILLE, CO

509335 - RSN 46 43 53-2

Approval Drawings and Data

SUEZ WTS

CONTROLLED DOCUMENT

See notes added by BOR today.

Highlighted comments represent Suez’s Reponses.

• Factory Inspection and Test Procedures – Where are the procedures included in the submittal? Further discussions needed. Not all procedures are available at this time.

Suez: Per contract adjustment, Factory Inspection and Test Procedures have not been included in this submittal.

Factory Inspection and Test Procedures that were included in previous revisions have been removed per contract modification P-00002.

• Schematic and Wiring Diagrams

• Conductor Sizes – Where are these shown? Provided on notes sheet. BOR to review. It has been noted that the notes sheet includes one size of conductors. The team is expecting to have multiple sizes based on the different component needs. Example area of concern – the VFD is expected to have different conductor sizes than stated in the notes sheet. Does the single conductor size stated cover all components?

Suez: Electrical Schematics 509335-WTS-EL-MAT-ELEC-DI-001 have been updated to display current conductor

(Wiring) sizes for wires that are not the standard 16-gauge control wire. Page 116 on the Submittal show wire

0300, 0300A, 0305 and 0310 as #12 Gauge. Sludge recirculation and blowdown electrical schematics do not include any wires outside the 16-gauge wiring. The power wiring is assumed to be a different size, however it is not the scope of Suez to supply these as it will run directly from the VFD to the Motor. All wiring is 16 gauge unless otherwise shown.

• Communication Protocol – What is the protocol? Plan is to include Ethernet I/P in the submittal and the architecture. This information is being developed earlier in the process than normal for Suez which places coordination of the communications at risk. As this project is the first out the gate the plan is to have Suez include the communications they would use.

Suez: Communication protocol has been updated in 509335-WTS-AU-SYS-EN23-PH-001 “Control Philosophy” on page 64 of submittal. Page 75 represents the update. Document 509335-WTS-EL-SYS-EN13-DN-001 “Network

Architecture” has been created and added to this revision on page 104. The Control Philosophy will note that

Ethernet/IP is the communication protocol and that messaging is typically used as the method of communication.

• Secondary containment with access using removable grating Suez asked if the BOR has any preferences.

No known preferences at this time. This information was planned to be part of a separate submittal and has not been progressed in detail. Suez to inform team on estimated schedule. Further discussions expected on moving forward with incorporating this information once schedule is known. Those parts that fall under RSN 055130-1 do not need to be included in this submittal.

Suez: Per discussion with the Bureau, this will be included in our platform submittal at a later date.

• Contractor’s submittal pdf pages 603-604 show each SCC train with ladder connection tabs up the sidewall of the Reactor Tank. TSC requests the Contractor replace the ladder with reinforcement to support a walkway (by others) and connect the Contractor’s grating system to the future concrete mezzanine level. TSC requests the Contractor provide two connection points at the top of the Reactor

Tank wall where the ladder was located for W12x35 beams spaced at 4 feet on center for the following unfactored loads: Dead = 600 lb, Live = 1650 lb, Horizontal Seismic = 290 lb, Vertical Seismic = 40 lb.

[Repeat Comment from RSN 46 43 53-1 dated May 18, 2022] Suez unable to design the attachment points but can apply the loads to their structure and include in their structural analysis.

Suez: Drawings 509335-WTS-ME-555-0100-DA-001 (page 658-661) have been updated to show future structural locations into the mezzanine and the loads such as Dead, Live, Horizontal and Vertical Seismic have been considered and will be incorporated into our final structural platform. Per discussion with the Bureau the connection detail should be provided by others.

Here are the previous notes in full provided by BOR

Contract Requirements Discussions

• Level switches – Where have these been added to the submittal? Not included, will be included next submittal.

o Manufacturer's data – Page 514 o I/O List - Page 249 o Instrument list – Page 257 o P&IDs – Page 1164 & 1165

Suez: Level switches have been added to all associated documentation and manufacture data can be found under

“Instrumentation vendor Information” on page 514.

• Spare Parts – Where was the spare parts list added to the submittal? Not included, will be included next submittal.

Suez: Spare parts list has been generated under drawing 509335-WTS-OM-T02-8541-LI-001 on page 259 of submittal.

• Layout Drawings o Junction Boxes – Where are these shown? Not included, will be included in the next submittal.

Suez: Junction box have been added to the sludge recirculation and blowdown general arrangement drawings

Document 509335-WTS-ME-000-2000-DA-001 and Document 509335-WTS-ME-000-2010-DA-001 on page 567 -

571.

• Factory Inspection and Test Procedures – Where are the procedures included in the submittal? Further discussions needed. Not all procedures are available at this time.

Suez: Per contract adjustment, Factory Inspection and Test Procedures have not been included into this submittal.

Factory Inspection and Test Procedures that were included in previous revisions have been removed per contract modification P-00002.

• Schematic and Wiring Diagrams o Conductor Sizes – Where are these shown? Provided on notes sheet. BOR to review.

Suez: Electrical Schematics 509335-WTS-EL-MAT-ELEC-DI-001 have been updated to display current conductor

(Wiring) sizes for wires that are not the standard 16-gauge control wire. Page 116 on the Submittal show wire

0300, 0300A, 0305 and 0310 as #12 Gauge. Sludge recirculation and blowdown electrical schematics do not include any wires outside the 16-gauge wiring. The power wiring is assumed to be a different size, however it is not the scope of Suez to supply these. All wiring is 16 gauge unless otherwise shown.

• Communication Link to government's PLC o Data Points – One train noted, where are the other train’s data points? Not included, will be included next submittal.

• I/O List

• Address Locations

• Empty Fields in tables – why are these empty? Some are spares, others are internal. Will be clarified on next submittal.

o Communication Protocol – What is the protocol? Plan is to include Ethernet I/P in the submittal and the architecture. This information is being developed earlier in the process than normal for

Suez which places coordination of the communications at risk. As this project is the first out the gate the plan is to have Suez include the communications they would use.

Suez: Communication protocol has been updated in 509335-WTS-AU-SYS-EN23-PH-001 “Control Philosophy” on page 64 of this submittal. Page 75 represents the update. Document 509335-WTS-EL-SYS-EN13-DN-001 “Network

Architecture” has been created and added to this revision on page 104. The Control Philosophy will note that

Ethernet/IP is the communication protocol and that messaging is typically used as the method of communication.

• Reactor Tank Mixer – Does the manufacturer’s data include the following information? Not included, will be included next submittal.

o Wetted parts materials of construction - 304/304L stainless steel.

o Motor enclosure - Totally Enclosed Fan Cooled (TEFC).

o Motor - rated for inverter duty.

o Mixer shaft or impeller: number of blades, dimensions, if shaft couplings will be required o Secondary containment with access using removable grating Suez asked if the BOR has any preferences. No known preferences at this time. This information was planned to be part of a separate submittal and has not been progressed in detail. Suez to inform team on estimated schedule. Further discussions expected on moving forward with incorporating this information once schedule is known.

Suez: Document 509335-WTS-ME-555-0113-DB-620 “Impeller & Shaft Assembly” have been added to show impeller material and dimensions. This can be found on page 699 on the submittal. Documents 509335-WTS-ME-

555-0102-SD-003 on page 666 has also been revised to show the motor being provided with the reactor assembly will include a TEFC enclosure and will be inverter duty rated. Suez cannot provide exact motor name plate data at this time, however we reaffirm that the motor will match specifications.

• Clarifier Tank Scraper - Does the manufacturer’s data include the following information? Not included, will be included next submittal.

Bearing life - L-10, 100,000 hours

Suez: Suez is reaffirming that we will provide a bearing to match specifications as we have provided bearings with a life of L-10, 100,000 hours in the past. Bearing Life is calculated by the manufacturer after all loads have been finalized. Specific calculations to be provide after buy out.

Preferences

1. Contractor’s submittal pdf page 589 shows most of the proposed nozzle locations and the location of the

Sludge Recirculation Skid. TSC requests modifying select nozzle locations as shown in Attachment 1 and summarized as follows:

a. N18 Relocate as indicated. OK

b. Shift the Sludge Recirculation Skids to within 3 feet, 6 inches of the Clarifier / Reactor Tank intersection. OK

c. Provide 3 feet of clearance from SCC control panel to the Sludge Waste Pump Skid Pad. OK with some concerns around moving outside of the available footprint. Unknown at this time.

d. <<RSN 464353-1 - Approval Drawings and Data (2022-07-25) Attachment 1.pdf>>

Suez: All requests above have been incorporated into the clarifier layout and are shown on the following documents 509335-WTS-ME-555-0100-DA-001 on page 659-662 of the submittal package.

2. Contractor’s submittal pdf pages 603-604 show each SCC train with ladder connection tabs up the sidewall of the Reactor Tank. TSC requests the Contractor replace the ladder with reinforcement to support a walkway (by others) and connect the Contractor’s grating system to the future concrete mezzanine level. TSC requests the Contractor provide two connection points at the top of the Reactor

Tank wall where the ladder was located for W12x35 beams spaced at 4 feet on center for the following unfactored loads: Dead = 600 lb, Live = 1650 lb, Horizontal Seismic = 290 lb, Vertical Seismic = 40 lb.

[Repeat Comment from RSN 46 43 53-1 dated May 18, 2022] Suez unable to design the attachment points but can apply the loads to their structure and include in their structural analysis.

Suez: Drawings 509335-WTS-ME-555-0100-DA-001 (Page 658-671) have been updated to show future structural locations into the mezzanine and the loads such as Dead, Live, Horizontal and Vertical Seismic have been considered and will be incorporated into our final structural platform. Per discussion with the Bureau the connection detail should be provided by others.

3. Submittal pdf page 1059 shows an Automated Valve List indicating eight pneumatic valves. TSC requests the Contractor provide the compressed air demand requirements of volume, pressure, duration, and quality for each valve. OK, Suez progressing. Clarified for the purposes of sizing the new WTP air compressor.

Suez: Automated Valve list (Page 1125) has been updated to include a note based on duration and volume of

Cylinder. Pressures can range per the valve actuator, please see the coordinating data sheets for each actuator for more information. It is Suez design standards at this size to size a compressor for 1 SCFM per valve at 80 PSI.

4. Submittal pdf page 134 (among others) shows each SCC train’s Clarifier Tank being provided with a turbidity analyzer: Endress+Hauser CUS52D-AA1AA3 sensor with CM442-AAM1A2F011A analyzer. Final design of the Water Treatment Plant determined the turbidity analyzers are not necessary. TSC requests deleting each train’s turbidity analyzer for a total of two. Suez agrees, will remove.

Suez: All turbidity analyzers have been removed for the project documents and the scope of supply. The turbidity meters that were included in previous revisions have been marked out on page 257.

Technical Reference Information

Contract Requirements:

1. Contractor’s submittal pdf page 4 of 1336 states, “Level switches have been added to each of the reactors to conform to specification section 46 43 53 paragraph 2.03 D 5 c.” Contractor’s submittal pdf page 129 of 1336 provides an I/O list that does not show level switches as required in specifications Section 01 33

00, Submittals, paragraph 1.04 D 1 d. Contractor’s submittal pdf page 134 of 1336 provides an instrument list. The instrument list does not show level switches and has the same revision number and date (“A” dated 7-Apr-22) as the previous submittal. Contractor’s submittal pdf pages 1271-1272 of 1336 provides a Piping and Instrumentation Diagram for each train however neither drawing shows a level switch in the reactors. TSC reviewers could not find manufacturer, model, or cutsheet information on the proposed level switches.

Suez: Level switches have been added to all associated documentation and manufacture data can be found under

“Instrumentation vendor Information” on page 514.

2. The Contractor did not include the spare parts in the submittal’s bill of materials on Contractor’s submittal pdf pages 97-98, 115, 123, 962-963, and 978-979 as required in specifications Section 46 43 53, Solids

Contact Clarifier Equipment (SCC), paragraph 1.04 B 3 c, and in accordance with specifications Section 26

24 20, Electrical and Control Panels, paragraph 1.06 and specifications Section 46 43 53, paragraph 1.09 A.

[Repeat Comment from RSN 46 43 53-1 dated May 18, 2022]

a. Contractor indicated in their responses that a spare parts list had been added to the resubmittal.

However, there did not appear to be a spare parts list added to the resubmittal. As a reminder the spare parts list is required to include the components included in the specification sections referenced in the comment above.

Suez: Spare parts list has been generated under drawing 509335-WTS-OM-T02-8541-LI-001 on page 259 of submittal.

3. The Contractor does not show the Junction Boxes on the submittal layout drawings as required in specifications Section 46 43 53, paragraph 1.04 B 3 a. [Repeat Comment from RSN 46 43 53-1, dated May

18, 2022]

Suez: Junction box have been added to the sludge recirculation and blowdown general arrangement drawings

Document 509335-WTS-ME-000-2000-DA-001 and Document 509335-WTS-ME-000-2010-DA-001 on page 567 -

571.

4. The Contractor did not include the factory inspection and test procedures as required in specifications

Section 46 43 53, paragraph 1.04 B 7 and in accordance with specifications Section 26 24 20, paragraph

2.16. [Repeat Comment from RSN 46 43 53-1, dated May 18, 2022]

a. There does not appear to be any modifications made to the submittal to address the deficiencies listed in the comment above and submitted test procedures still do not include the testing required in specifications Section 26 24 20, paragraph 2.16.

Suez: Per contract adjustment, Factory Inspection and Test Procedures have not been included into this submittal.

Existing Factory inspection and test procedures included in previous revisions have been removed per contract modifications P-00002.

5. The Contractor did not include conductor sizes on the submittal’s schematic and wiring diagrams as required in specifications Section 46 43 53, paragraph 1.04 B 6 f 1. [Repeat Comment from RSN 46 43 53-

1, dated May 18, 2022]

Suez: Electrical Schematics 509335-WTS-EL-MAT-ELEC-DI-001 have been updated to display current conductor

(Wiring) sizes for wires that are not the standard 16-gauge control wire. Page 116 on the Submittal show wire

0300, 0300A, 0305 and 0310 as #12 Gauge. Sludge recirculation and blowdown electrical schematics do not include any wires outside the 16-gauge wiring. The power wiring is assumed to be a different size, however it is not the scope of Suez to supply these. All wiring is 16 gauge unless otherwise shown.

6. The Contractor does not provide datapoints for the programmable controller in the submittal’s I/O list, including the address locations for the datapoints and complete empty fields on the tables included in the

Contractor’s submittal required to set up the communication link to the Government’s programmable controller, as required in specifications Section 46 43 53, paragraph 1.04 B 6 d. [Repeat Comment from

RSN 46 43 53-1, dated May 18, 2022]

a. The datapoints for only one of the trains was included. Include the other half of the datapoints or indicate in the description of the list that it is for both trains and that the datapoint addresses are accurate for both trains. Fill out the empty fields in the tables supplied with the RSN.

Suez: All data points for Densadeg B have been included in this revision and can be found on page 253.

7. The Contractor does not include information on the communication protocol used for the communication to the Government’s PLC as required in specifications Section 46 43 53, paragraph 1.04 B 6 d. [Repeat

Comment from RSN 46 43 53-1, dated May 18, 2022]

a. The Contractor’s responses in the submittal indicated that this information was added to Section 5 in the control philosophy document, but this doesn’t appear to be listed in Section 5.

Suez: Communication protocol has been updated in 509335-WTS-AU-SYS-EN23-PH-001 “Control Philosophy” on page 64. Page 75 represents the update. Document 509335-WTS-EL-SYS-EN13-DN-001 “Network Architecture” has been created and added to this revision on page 104. The Control Philosophy will note that Ethernet/IP is the communication protocol and that messaging is typically used as the method of communication.

Contractor Reminders

1. The Contractor is reminded that they must meet the requirements of specifications Section 01 33 00, Submittals, paragraph 1.05 E. Reviewed crossing out items that do not apply and marking changes on resubmittals.

2. The Contractor shall provide documentation indicating the proposed Reactor Tank mixer (referenced in the submittal as the “reactor drive”) includes the following components, in accordance with specifications

Section 46 43 53, Solids Contact Clarifiers, paragraph 1.04 B 1, and to confirm compliance with the requirements of specifications Section 46 43 53, paragraph 2.03 D 4:

a. Wetted parts materials of construction will be 304/304L stainless steel.

b. Motor enclosure will be Totally Enclosed Fan Cooled (TEFC).

c. Motor will be rated for inverter duty.

d. Reactor Tank mixer information is provided on submittal pdf page 591 and possibly on 818-858 and 868-

1047 (the Contractor’s submittal is unclear if the gear reducer information applies to the reactor drive).

e. Information on the wetted parts materials of construction, motor enclosure, and motor inverter duty rating was not located in the submittal.

f. The submittal does not provide information on the mixer shaft or impeller: number of blades, dimensions, if shaft couplings will be required, etc. [Repeat Comment from RSN 46 43 53-1, dated May 18, 2022]

Suez: Document 509335-WTS-ME-555-0113-DB-620 “Impeller & Shaft Assembly” have been added to show impeller material and dimensions. This can be found on page 699 on the submittal. Documents 509335-WTS-ME-

555-0102-SD-003 (page 666) has also been revised to show the motor being provided with the reactor assembly will include a TEFC enclosure and will be inverter duty rated. Suez cannot provide exact motor name plate data at this time, however we reaffirm that the motor will match specifications.

3. The Contractor does not provide information on the proposed Clarifier Tank Scraper in accordance with specifications Section 46 43 53, paragraph 1.04 B 1 to confirm compliance with the requirements of specifications Section 46 43 53, paragraph 2.03 E 4 d. Scraper information was provided in the

Contractor’s submittal pdf pages 604 and 760-858. Complete submittal information was not found, e.g., if the bearings have an L-10 life of 100,000 hours, which is the number of hours in service that 90 percent of the bearings will survive. Submittal pdf page 767 appears to show two bearings in the AD2A adapter assembly and that each bearing is a DBS Manufacturing part number 134-207PP, however, the bearing life information could not be located. [Repeat Comment from RSN 46 43 53-1, dated May 18, 2022]

The Contractor does not provide details of the secondary containment for changing mixer oil with access using removable grating as required in specifications Section 46 43 53, paragraph 2.03 D 4 b, however the Contractor acknowledged the need for secondary containment and indicated details will be provided in future, final fabrication drawings. The concern is that the future main WTP construction contractor may need the mixer oil secondary containment configuration information to adequately bid its installation scope of work, where its bidding effort will be well before installation

Suez: Per discussion with the Bureau, this will be included in our platform submittal at a later date.

1. Your submittal includes proprietary and confidential information statements and are in conflict with specifications section 013300, Article 1.02. Remove these statements.

Suez: All proprietary and confidential statements have been removed from this submittal package.

2. Your submittal includes a mechanical warranty on equipment for 608 days from delivery and does not the requirements of contract clause 52.246-18 ALT IV Warranty of supplies of a complex nature.

Suez: Warranty has been adjusted to 2 years and can be found on document 509335-WTS-GE-SYS-EN50-LT-001 –

“Warranty” on page 1371 of the submittal.

3. Your submittal does not show junction boxes as required by Section 464353, Paragraph 1.04 B.3.a

Suez: Junction box have been added to the sludge recirculation and blowdown general arrangement drawings

Document 509335-WTS-ME-0100 on page 567 - 571.

4. Your Submittal does not strike through items that do not apply as required by section 013300, Paragraph 1.04

D.1.d

Suez: All items that are not applicable to this submittal have been stroked out as per specification section 01300, Paragraph 1.04 D.1.d.

AUTOMATION SECTION

1. HMI GUIDANCE MANUAL

2. CONTROL PHILOSOPHY

3. CONTROL LOGIC & SEQUENCE CHARTS

509335-WTS-AU-SYS-EN13-SG-001

HMI Guidance Manual

Machine Edition

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A Issued for Information AG JJ DM 25-FEB-22

REV DESCRIPTION WRITTEN

BY

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BY

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DOCUMENT TYPE: SUEZ DOCUMENT NUMBER: 509335-WTS-AU-SYS-EN13-SG-001

509335 WTS AU SYS EN13 SG 001

SUEZ WTS

CONTROLLED DOCUMENT

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Table of Contents 1 Introduction

1.1 Definitions and Acronyms

2 Human Machine Interface

2.1 HMI Power-up

2.2 HMI Navigation

2.2.1 Graphics Index

2.2.2 Overview

2.2.3 Connector Arrows

2.3 Setpoints

2.4 Legend

2.5 Security & Privileges

2.5.1 Security Login

2.5.2 Security Privileges

2.5.3 Modifying Security Access

2.6 Date and Time Synchronization

3 Analog Inputs

3.1 Totalizer

4 Triggers & Alarms

4.1 Triggers

4.2 Alarms

4.2.1 Alarm Banner

4.2.2 Alarm Summary

4.2.3 Alarm History

4.2.4 Alarm Horn/Light

5 HMI Trending

6 Train Control

6.1 Mode Controls

6.2 Production Info

7 Device Control & Graphics

7.1 Device Status and Modes

7.1.1 Device Modes

7.1.2 Device Status

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7.2 Valve Control

7.3 Motor Control

7.4 Motor Lead Rotation

8 System Stop and Power Up

8.1 Power Interruption/Power Up

8.1.1 Start-Up Sequence

9 Analog Control

9.1 Proportional Control

9.2 PID Control Loop

9.3 Step Control

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1 INTRODUCTION

This document contains instructions on how to navigate and use the Human Machine Interface (HMI) provided by SUEZ that is used to operate the plant.

An overview of the plant controls is provided in the CP (Control Philosophy). Details of the control logic, setpoints, etc. that are required to operate the plant are given in the CLSC (Control Logic and

Sequence Charts).

The design of Suez HMI displays is highly inspired by ISA 101 Human Machine Interfaces and the High

Performance HMI Handbook design principles. These principles have guided design choices such as color usage, navigation, and object animation.

1.1 DEFINITIONS AND ACRONYMS

Alarm An alert activated on the HMI when there is a system disruption or condition failed.

There are different alarms for different severity of faults (Ex: Critical Alarm when tank is overflowing)

CLSC Control Logic & Sequence Charts

CLC Control Logic Charts

CV Control Variable, sometimes called the manipulated variable

Faceplate Used in the HMI to display dynamic process variables. Often, the faceplate is a pop-up and controls/modes can be selected on it.

HMI Human Machine Interface, screen used by plant personnel to view/display/control real-time/dynamic process data

Interlock An alarm or condition in place that prevents actions/situations that are undesirable or incompatible with the current state from occurring

Loop A management system to regulate a process

MCC Motor Control Center

ME Machine Edition

P&ID Process and Instrumentation Diagram

Permissive Conditions or pre-requisite steps that must be met in order to continue / progress further in process scheme

Remote/Local These controls are set via the Hand-Off-Auto (HOA) switch in the plant, usually on a piece of equipment

PID Proportional Integral Derivative control. This type of control is used to handle changes in process such as varying flow, etc.

PLC Programmable Logic Controller

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Proportional This control is used to adapt to process changes (not predictive, but reactive) (Ex:

injecting a quantity of chemical based on current flow values)

PV Process Variable, Variable being measured in a control loop (compared to the set point)

Sequence Order of specific tasks or steps of process

SC Sequence Chart

SCADA Supervisory Control and Data Acquisition

SE Site Edition

Signal The communication between the user and the control system

SP Set Point, The target value for a variable in the process

State Sequence of automated steps (PRODUCTION, STANDBY, BACKPULSE, ETC.)

System Mode Placement of complete system (AUTO, SEMI-AUTO, and OFF).

Unit Operations A basic step in a process, functional box (Ex: train)

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2 HUMAN MACHINE INTERFACE

An HMI (Human Machine Interface) is provided to control and monitor the system operation remotely.

See the network architecture drawing for the specifics of the PLC, HMI and software.

2.1 HMI POWER-UP

The HMI will power-up to a display of the Main graphics screen. All HMI screen captures in this section are samples for explaining HMI navigation and functions. The displays corresponding to the plant are accessed through the Graphics Index button in the bottom left of all displays.

2.2 HMI NAVIGATION

When the HMI is powered up, the main screen is shown. Screen access buttons are located on the bottom of the Main, Overview and Unit screens. These include the Graphics Index and Setpoints.

There are three ways to navigate through the HMI Screens, which are the Overview, the Graphics

Index and the process arrows.

2.2.1 Buttons

Buttons are used to navigate the HMI, as well as connector arrows, which are described in Section

2.2.4. When buttons are not clickable, they will be greyed out, as shown in Figure 2 Non-clickable

Button Example

Figure 2 Non-clickable Button Example

Figure 1 Main Screen

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This will occur depending on user access level. Shown above is a graphic for a device faceplate for a

Guest User, so the controls are greyed out and inaccessible. Accessible buttons, like in Figure 3

Graphics Index Button, have black contents and stand out more. A list of user access levels can be found in Section2.5.2 Security Privileges.

2.2.2 Graphics Index

All process displays can be accessed by clicking on the ‘Graphics Index’ button in the bottom left corner. All process displays as well as the Main Screen, Overview and Legend can be accessed through the graphics index.

Figure 3 Graphics Index Button

Figure 4 Graphics Index Display

2.2.3 Overview

Reference the Overview screen (Figure 5 System Overview, RO Example, Figure 6 Overview, UF example) to show process flow through the system. The overview screen can be used to select different process areas, as well as displaying the status of the trains and other devices.

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Figure 5 System Overview, RO Example

Figure 6 Overview, UF example

2.2.4 Connector Arrows

The third way that the process screens can be accessed is by pressing an upstream/downstream off-screen connector arrow located on the process piping takes the used to the next screen. Note that arrows with a black tip will take the user to the labelled screen when selected, and arrows with a gray tip do not lead anywhere. See P&ID for more detailed information on process flow.

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Figure 7 Navigation Arrow

2.3 SETPOINTS

Setpoint screens can be accessed by using the setpoint buttons located on device screens. These setpoints are device specific and can only be modified by specific user access levels, which is detailed in Section 2.5 Security and Privileges.

Setpoint screens can also be accessed by selecting the Setpoints button beside the Graphics index button.

Figure 8 Setpoint Button

Figure 9 Setpoint Menu Display

Within the Setpoints screens, displays can vary. They typically show lists of devices or process areas and key setpoints belonging to those areas that can be modified depending on security level. The setpoints depicted in Figure 10 Process Setpoints Display (UF example) are common setpoints that are shared between multiple trains.

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Figure 10 Process Setpoints Display (UF example)

The setpoints depicted in Figure 11 Train Setpoint Faceplate Display (UF example) are individual train setpoints, meaning that they are specific to each train.

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Figure 11 Train Setpoint Faceplate Display (UF example)

Device control (ex. Valves, Pumps) pop-up screens can be accessed by pressing the object of the device to adjust the setpoints for this device. You can find more information about this in Section 7.2.

The setpoints for transmitters are displayed by selecting the transmitter. See Section 3 Analog Inputs for more information on Transmitters.

2.4 LEGEND

Through the Graphics Index, the Legend can be located. The Legend contains information on how to read the status and type of device that is being displayed, as well as how to read some of the symbols on the device menu.

The HMI Legend screen describes many important graphics used in the HMI. These graphics are user configurable, and the ‘running’ status of devices can either be green or red, while stopped devices are grey.

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Figure 12 HMI Legend

2.5 SECURITY & PRIVILEGES

The HMI uses password protected user accounts to prevent unauthorized access or accidental changes to the operations of the plant by unqualified individuals.

The ability to de-energize the “general alarm” output (e.g. for a horn) and acknowledge alarms does not require a password, but alarms cannot be reset by a guest user.

To be able to access control functions of the HMI, the user must first login.

2.5.1 Security Login

The login screen is accessed by pressing the Security Status button at the bottom of the screen.

Figure 13 Security Status Screen

When this button is pressed, the Security Access screen is displayed.

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After logging in, the Security access screen is display.

Figure 14 Security Access Screen

To login, the user presses the Security Key button. This will bring up the Login screen. The user enters their Username and Password then presses the Enter button.

Figure 15 Login Screen

If an authorized Username and Password are entered, the login screen will disappear, and the Security

Level and Username will be displayed in the Security Status. If an incorrect entry is made, a “User

Authentication Failed” message will appear, and the User will need to re-enter their login information.

There is no limit to the number of times another password can be attempted.

To prevent unauthorized access, users should logout after control actions are complete. To logout, the user opens the Security Access screen and presses the Security Lock button. This action will reset security to the default guest level. The system will also automatically reset the security after 60 minutes of screen inactivity.

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2.5.2 Security Privileges

There are three levels of password protection; Operator, Supervisor, & Administrator.

The initial Usernames and Passwords will be provided at the time of design.

Access by unauthorized users may be a potential risk to correct and safe equipment operation. The end user is encouraged to modify these initial usernames and passwords after commissioning and acceptance of the system.

The Guest access, no username or password required, is permitted the following actions:

• Access to major screens.

• Silence horn and acknowledge alarms.

• No access to Alarm Reset button.

The Operator access is permitted the following actions:

• Access to view all screens.

• Access only to view setpoints.

• Access to view and adjust train operational modes.

• Access to view and adjust train operational states.

• Resetting of all alarms.

• Access to operate pumps and valves.

• Access to view alarm setpoints, discrete/analog simulations, alarm enable and disable, and interlock bypass.

• Access to operate and configure PID controllers, except for PID tuning parameters.

The Supervisor access is permitted the following actions:

• All operator permissions.

• Access to adjust setpoints.

• Access to operate and configure PID controllers, including PID tuning parameters.

• Access to enable/disable discrete/analog simulation.

• Access to enable/disable alarms.

• Access to bypass interlocks.

HMI Administrator access is permitted the following actions:

• All Supervisor permissions.

• Access to view and adjust advanced settings for equipment operation.

• Access to re-configure installation options for the design.

• Permission to exit the runtime application.

Typical builds also include a Programmer level of access with opportunity to adjust configuration settings and other similar content. A username and password for this level can be made available on customer request. If required, this level of access can be removed from the design and would become unavailable to all users including Suez personnel. If retained, this level of access should be allowed only to personnel that are authorized for edits to the PLC logic. Opportunity to remove or restore this level of access is accessible to the administrator level of access.

2.5.2.1 Override Features

A feature that is available is the ability to enable/disable the system override features. Override features are allowed for Input Simulation, Alarm Disable, and Interlock Bypass. Once an individual

Page : 15 / 51 override feature is enabled by a supervisor, they can then be utilized on devices by supervisor and admin users. The individual override features will not be visible unless visibility is enabled by a supervisor. If ivisibility is enabled, it is displayed with orange background in the upper left corner under the Suez logo, as seen in Figure 16.

Figure 16 Override Features Button, not active

Figure 17 Override Features Button, active

Figure 18 Override Features Display, operator view

The operator can Hide/Disallow these items but not able to display/allow them, as indicated by the text on Figure 18.

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Figure 19 Override Features Display, supervisor view

Figure 20 Override Features Button, Active with Icons

Once individual override features are allowed by the supervisor, they will appear with icons on the button face, with the display still shown as Figure 18 to operators. The features that are allowed will be displayed as icons on the Override Features button as shown in Figure 20.

In device faceplates in Figure 21, Figure 22, and Figure 23, a display on the bottom of the settings tab will show a slider on the bottom with ‘No’ and ‘Yes’ options under ‘Allow Alarm/Control Disable’ or the allowed feature on its respective screen. Once ‘Yes’ is selected by the supervisor, the Enable/Disable

Bell icon can be selected on the right of the desired alarm. The Simulation input can be specified, or the interlock to be bypassed can be selected. These features cannot be changed by operators, only supervisors, administrators and programmers.

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Figure 21 Simulation Input Enabled

Figure 22 Alarm/Control Enabled

Figure 23 Interlock Bypass Enabled

2.5.3 Modifying Security Access

The end user, when logged in as administrator, can add and delete individual users if so desired. The end user is encouraged to customize the default user names and default passwords.

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Figure 24 Security Access Administrator

Select the Change Password button, which displays the following screen.

Figure 25 Change User Password

On the Security Access screen select the Add User button to display the following screen. FactoryTalk

Security User is the typical user required.

Figure 26 Add User/Group Account

On the Security Access screen select the Delete User button to display the following screen.

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Figure 27 Delete User/Group Account

2.6 DATE AND TIME SYNCHRONIZATION

The HMI date and time are displayed in the top right corner of every screen. The HMI date/time is synchronized to the PLC Date/Time. The Clock Synchronization screen can be accessed by pressing this display. The HMI clock will be continually updated from the PLC clock and will be displayed on the

HMI screen.

Figure 28 Clock Button

Figure 29 Clock Synchronization

To change the HMI/PLC clock, the HMI Clock must be configured to Master. Select the “HMI Clock

Configured to Master” check box to bring up the clock change buttons.

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Figure 30 Clock Synchronization HMI Master

To change the HMI time/date, press the Change HMI Date & time Button. This will bring up numeric entry setpoints. Enter in the current date/time and hit Accept. The HMI date/time will now be updated, but different than the PLC Date/Time. To change the PLC clock, press the Sync PLC to HMI Clock.

Figure 31 HMI Time and Date Buttons

3 ANALOG INPUTS

Analog Inputs are communicated from transmitters in the plant. These devices are displayed in the HMI with the value that they are transmitting. These are displayed on the HMI as a box with the value inside, and the tag of the indicating instrument labelling the box, as seen in Figure 38.

Select the transmitter button on the HMI to display the transmitter Faceplate. The different tabs of the

Faceplate are displayed by selecting the top row symbols, which represent, going from left to right, Home, Alarm Settings, Trending, Transmitter Settings, Setpoint & Delay Limits, and Trigger

Descriptions.

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Some project have a Placement tab as well, which lets the user move the faceplate to a new location on the HMI, which will show once the Faceplate is closed and re-opened, as seen in Figure 57.

Figure 32 Transmitter Faceplate, Home

Figure 33 Transmitter Faceplate, Alarm Settings

Figure 34 Transmitter Faceplate, Trending

Figure 35 Transmitter Faceplate, Transmitter Settings

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Figure 36 Setpoints and Delay Limits for Level Transmitter

Figure 37 Level Triggers Display on Transmitter Faceplate

Figure 38 Transmitter with Simulation PV

Figure 39 Transmitter Faceplate with Simulation PV

Figure 38 and Figure 39 display a transmitter faceplate with a simulation process variable instead of a calculated value. This is used during testing to ensure that the program functions with a simulation of the real process rather than a static calculated value.

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3.1 TOTALIZER

Some of the system flow signals are totalized. The PLC monitors the flow rate and summates both a running flow total and a flow total for today. At midnight, the flow total is captured as a daily total and the today total is reset to 0. A 7-day total history is recorded.

The running total can be reset by pressing the Reset button, which captures the current running total as

Previous Running Total and resets the running total. The reset is time stamped and the reset date and time are displayed.

Figure 40 Totalizer Display

Figure 41 Totalizer Faceplate

Figure 42 Totalizer Faceplate, History

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Figure 43 Totalizer Faceplate, Settings

Figure 44 Totalizer Faceplace, Position

4 TRIGGERS & ALARMS

Alarms are displayed on the HMI using the text shown in the CLC Tag/Mnemonic and Description cells.

Alarms are tracked on the alarm summary screen.

Alarms, Triggers, and Setpoints that have a value for Range Minimum and Range Maximum are adjustable with a supervisor login at the HMI.

If there is no value for Range Min. or Range Max, or if those values are the same. the setpoint is not adjustable by the operator at the HMI.

4.1 TRIGGERS

A trigger is a normal event that can clear an alarm or initiate one of several steps in a sequence of events. These triggers are listed in the CLC as “Trigger” under the Type column.

4.2 ALARMS

Alarms are used to identify a problem with the system.

Critical alarm: The critical alarms are used to protect equipment from damage. If a critical alarm occurs, the unit will proceed immediately to the Fault step and put associated devices in a safe state, though this does not occur for all critical alarms, just most. For example, the alarm ‘PLC Program

Loaded from Flash’ is alarm only despite being a critical alarm. The operator can reset a critical alarm by pressing the System or Unit Alarm Reset button on the HMI.

Warning alarm: Advisory alarms are used to notify the operator of an abnormal condition. The operator is expected to acknowledge an advisory alarm by pressing the Acknowledge button and correct the abnormal situation. If the problem is not corrected, production quality/quantity may be affected in the future.

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Alarms are listed in the CLC as either “Alarm – Advisory” or “Alarm – Critical” under the Type column.

4.2.1 Alarm Banner

When Alarms are triggered, an alarm banner will be shown at the top of HMI screen. Operators can

Acknowledge an alarm or Clear an alarm by pressing the pushbutton in the alarm banner. The alarm banner is closed by pressing the Exit button. If multiple alarms occur simultaneously, they will be displayed one at a time as each is acknowledged.

The alarms that are displayed here are for Machine Edition (ME) and Site Edition (SE) alarms.

Figure 45 ME Alarm Banner

Figure 46 SE Alarm Banner

4.2.2 Alarm Summary

When an alarm occurs, the user should check the current alarms from the alarm summary screen, which is accessed by pressing the Alarm Summary pushbutton at the bottom of the screen. This screen will show the Alarm Date/Time and Alarm Description of the current alarms. If an alarm has been acknowledged, this Date/Time will be shown as well.

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Figure 47 ME Alarm Summary

Figure 48 SE Alarm Summary

Based on the alarms, the operator should address the situation and fix the issue causing the alarm. If the problem is not corrected, equipment operation and production may be affected.

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Once the cause of the alarm has been addressed, the alarm can be reset by either pressing the corresponding Unit Reset button or the Reset All button. Some alarms are configured to reset automatically when the conditions causing them are cleared.

4.2.3 Alarm History

The Alarm History screen can be accessed from the Alarm Summary screen. The alarm history shows the alarm date/time, acknowledge date/time and description of all alarms that have occurred with the most recent shown first.

Figure 49 ME Alarm History

Figure 50 SE Alarm History

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4.2.4 Alarm Horn/Light

Activation of any alarm will energize PLC outputs for an alarm horn and an alarm light, if installed. The operator may press the Alarm Horn Silence button to mute the horn. Any subsequent alarms will sound the horn again. The alarm light will remain lit until all alarms are reset, and no active alarms are present.

5 HMI TRENDING

In SE, most analog inputs and key performance indicators are trended for 3 months at a time on a 5 second sample. PID variables are trended for 2 days on a 2 second sample. Trending of specific variables is unique to the needs of the plant and can be modified.

In ME, most analog inputs and key performance indicators are trended for 10 minutes at a time on a 2 second sample. PID variables are trended for the same data log as analog inputs. Capacity for trending is limited with ME applications.

Each PID controller will trend percentage of the Setpoint, Process Variable and Control Variable at the frequencies described above. The trend screen can be used to assist with tuning of the PID parameters.

6 TRAIN CONTROL

The Mode, State, Step and Time remaining in the step are displayed on the train screen at the HMI. For some systems the pending state may be shown to the right of the mode, state, step and time. Any important messages, such as demand override, train fault, or backwash required, are also displayed at the top of the display.

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Figure 51 Train Screen

6.1 MODE CONTROLS

The state and mode that an individual train is in can be modified through the Mode Controls button at the top left of the train’s display screen. This displays a menu that enables the operator to select the state and mode of the train. This menu is highly specific to the type of plant, and only stats and modes available to a train are shown. Consult the Sequence Chart for details. It also provides the option to select Demand Override. More information on states and modes can be found in the Control

Philosophy.

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Figure 52 Train State and Mode Selection

Figure 53 Train Mode Controls Button

6.2 PRODUCTION INFO

On the train display, the production info button is also available. Selecting this button will bring up a display that shows the production information such as flow, TMP and total permeate or other parameters depending on the plant.

Figure 54 Production Information (UF Example)

Figure 55 Production Info Button

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7 DEVICE CONTROL & GRAPHICS

7.1 DEVICE STATUS AND MODES

7.1.1 Device Modes

Select a device to display the pop-up controls. The pop-up will have the following pushbuttons:

Auto / Manual:

• Auto – The operator sets the device for automatic operation. The device will be prevented from operating by any active alarm interlocks, unless the interlock’s bypass is selected. The device operates as shown in the Sequence Chart or as defined in the CLC.

• Manual – The operator sets the device for manual operation. In this mode, the Start and Stop buttons are active for a pump/blower, etc. or Open and Close buttons are active for a valve. The device operates with all alarm interlocks enabled unless an interlock’s bypass is selected.

All devices controlled by the SUEZ PLC are listed in the CLSC in the Device Controls sheet, showing devices which have “Auto” and “Manual” device modes.

Some project have a Placement tab as well, which lets the user move the faceplate to a new location on the HMI, which will show once the Faceplate is closed and re-opened, as seen in Figure 57.

7.1.2 Device Status

When a…