Attachment___4_Specifications4.pdf

Leadville Mine Treatment Plant and Facilities Water Treatment Plant Replacement Leadville Mine Drainage Tunnel Project, Colorado Solicitation No. 140R4023R0011

Utility Potholing Reports

51 33 05 - 1

SECTION 51 33 05

UTILITY POTHOLING REPORTS

PART 1 GENERAL

1.01 REPORT

A. May 2022 Reports: Pothole Data Reports by Diversified Underground, Inc, Diversified Job Number 22H-90535AF, dated May 16, 2022, May 17, 2022, and May 18, 2022.

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PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

Not Used

END OF SECTION

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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

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

51 46 43 - 2

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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

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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

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

CONTRACT ISSUER DISCIPLINE PRODUCT PHASE TYPE CHRONO

509335 WTS AU SYS EN13 SG 001

SUEZ WTS

CONTROLLED DOCUMENT

WATER TECHNOLOGIES & SOLUTIONS

C Revised per Comments JAM JAM CAB 04-OCT-22 B Revised per Comments JAM KH CAB 22-JUL-22 A Issued for Information JAM JAM NA 29-APR-22

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DOCUMENT TYPE: SUEZ DOCUMENT NUMBER: 509335-WTS-AU-SYS-EN23-PH-001

CP

CONTRACT ISSUER DISCIPLINE PRODUCT PHASE TYPE CHRONO

509335 WTS AU SYS EN23 PH 001

Leadville

Drainage Tunnel Project, CO

Control Philosophy DensaDeg A & B

509335- WTS-AU-SYS-EN23-PH-001

Leadville

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Table of Contents 1 Introduction

1.1 Process Areas

1.2 Definitions and Acronyms

2 HMI Graphics

2.1 HMI Power-up

2.2 Security & Passwords Access & Privileges

2.2.1 Security Login

2.2.2 Security Passwords

2.2.3 Security Access

2.3 HMI Navigation

2.4 Status and color Schemes

2.5 Date and Time Synchronization

2.6 Triggers & Alarms

2.6.1 Triggers

2.6.2 Alarms

2.6.3 Alarm Banner

2.6.4 Alarm Summary

2.6.5 Alarm History

2.6.6 Alarm Light

2.7 HMI Trending

2.8 Buttons

3 Device Control

3.1 Device Status

3.2 Device Status and Modes

3.2.1 Device Status

3.2.2 Device Modes

4 Operator Operations

4.1 Power Interruption/Power Up

4.2 System Stop

4.2.1 Start-Up Sequence

5 Communication

5.1 Loss of Communication Alarm with Plant PLC

5.2 Plant PLC to DensaDeg PLC Necessary Communication

Leadville

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5.3 DensaDeg PLC to Plant PLC Necessary Communication

6 Analog Control

6.1 Proportional Control

6.2 PID Control Loop

6.3 Step Control

6.4 Totalizer

7 DensaDeg

7.1 Process Modes

7.1.1 AUTO Mode

7.1.2 OFF Mode

7.2 Process States

7.2.1 State Interlocks

7.2.2 Off

7.2.3 Standby

7.2.4 Start-Up

7.2.5 Production

7.3 Analog Control

7.3.1 Reactor Turbine

7.3.2 Clarifier Scraper

7.3.3 Sludge Recirculation Pump

7.3.4 Sludge Blowdown Pump

8 Technical Support

Leadville

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1 INTRODUCTION

This system consists of two identical DensaDeg trains, each with its own reactor tank, clarifier tank, sludge recirculation skid, and sludge blowdown skid. The following control descriptions apply to each train and its associated equipment. The trains are designated ‘A’ and ‘B’ so all tags will be shown with an ‘x’ replacing the train designation. For example the reactor turbine tag will be shown as 04-M-300x, representing both 04-M-300A and 04-M-300B.

The Leadville Mine Drainage Tunnel Project uses a DensaDeg solids contact clarifier system consisting of two identical trains. The trains are fed by Rapid Mixers operated by the plant. The trains consist of Reactor Tanks, Clarifier Tanks, Sludge Recirculation Pumps, and Sludge Blowdown Pumps. There is also a polymer feed from the plant to the Reactor Tank.

Mine water enters the DensaDeg reactor tank from the plant’s rapid mix tank. The water is transferred into the reaction zone and introduced through the base of the reactor basin and discharged beneath an axial flow impeller. Inside this draft tube, polymer is injected through a distribution ring to aid in the flocculation and settling ability of the coagulated particles. Recycled solids from the clarifier are introduced into the reactor to aid in flocculation. The internal recycling of previously formed solids enhances the solids contact process and increases the speed of the reactions.

Next, the densely structured precipitate is transitioned from the reactor basin through a piston flocculation zone to the clarification and thickening zone. As the water flows under the baffle and upwards into the tubes, the solids downward momentum carries them to the bottom of the clarifier basin. Here the solids are allowed to thicken with the aid of a slowly rotating scraper mechanism that pushes the sludge into a sludge hopper located at the bottom of the clarifier basin. The thickened sludge is periodically discharged from the hopper by the blowdown pump.

A part of the sludge inventory is recycled back to the reactor basin, improving the performance of the process as described above. Clarified water proceeds beneath the aforementioned baffle into the clarification zone. Additional solids removal is achieved by the use of tubes incorporated into the top of the clarification zone. Moving through the tubes, finished water is collected through a series of launders or laterals which discharge treated water into the effluent trough. Effluent water flows out of the DensaDeg for further treatment by the plant.

The reader should refer to the Piping and Instrumentation Diagrams (P&ID’s), and the Control Logic & Sequence Chart (CLSC) for a complete understanding of the plant control scheme as described below.

This CLSC contains the following tabs: Legend, Device Controls, Train Sequence Chart (SC), Control Logic Chart (CLC), Control Loop, and Communication.

Details of the control logic, setpoints, etc. that are required to operate the plant are given in the CLSC.

In the documentation, the Programmable Logic Controller is referred to as the PLC. The PLC provides automated control of the DensaDeg equipment. All the programming for the control of the DensaDeg plant is stored in the PLC.

The PLC follows specific steps to automatically control valves, pumps, etc. during the operating states of the treatment plant. These steps are listed and described in the SC.

Setpoints, alarms, calculated parameters, etc., have assigned tags in the PLC code. When tags are used in the Control Philosophy, they are identified by an alpha-numeric label, for example.

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States are a series of steps the train follows to perform operations, such as a production. A specific state discussed in this document is shown in capital letters, such as STANDBY.

1.1 PROCESS AREAS

This document covers a general description of the controls by SUEZ for the following unit processes:

DensaDeg

Sludge Pumps

1.2 DEFINITIONS AND ACRONYMS

ACF Activated Carbon Filter

Alarm An alert displayed 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)

Command Every action made on the PLC that produces a change in equipment status

CP Control Philosophy

CLSC Control Logic & Sequence Charts

CV Control Variable, sometimes called the manipulated variable

DO Dissolved Oxygen

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

FCE Final Control Element, Equipment that physically controls a desired output variable

Floc Colloids and fine particles come out of suspension and floc together to form floc

Flocculation Process where coagulated clumps join to form a cloud and then precipitate out

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

I/O Inputs and Outputs of the PLC

Interlock In place to prevent undesired actions/situations from occurring

LCP Local Control Panel

Loop A management system to regulate a process

MCC Motor Control Center

P&ID Process and Instrumentation Diagram

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

PFD Process Flow Diagram, Chart to show the flow of the system/plant

Remote/Local These controls are set via the Hand-Off-Auto (HOA) switch in the plant, usually on a piece of equipment. The Auto position allows Remote control by the PLC.

The Hand position only allows Local controls to be used

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

PLC Programmable Logic Controller

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)

Soft Controls These controls are operated via the HMI

Sequence Order of specific tasks or steps of process

SC Sequence Chart

Signal The communication between the user and the control system

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

SS, TSS Suspended Solids, Total Suspended Solid

State Sequence of automated steps (OFF, STANDBY, STARTUP, PRODUCTION)

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

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

VFD Variable-Frequency Drive

2 HMI GRAPHICS

A PLC is provided to control and monitor the system operation remotely. The system is designed to communicate with the customer’s PLC. Throughout this document the PLC controlling the DensaDeg will be referred to as the Suez PLC or just PLC. The customer’s PLC is referred to as the Plant PLC.

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

The state, step and duration remaining in the step is displayed on the train screen at the HMI.

The HMI function and graphic descriptions in the following sections are to provide directions to the operators on how to use the HMI.

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2.1 HMI POWER-UP

The HMI will power-up showing the Main graphics screen. From there operators will be able to navigate to other pages.

2.2 SECURITY & PASSWORDS ACCESS & PRIVILEGES

Alarms will activate a light on the control panel. The ability to reset alarms requires a password.

Additional capabilities for each security level are listed in section 2.2.2 below.

2.2.1 Security Login

To be able to access control functions of the HMI, the user must first login. The login screen is accessed by pressing the Security Status button at the bottom of the screen.

2.2.2 Security Passwords

There are three levels of password protection; Operator, Supervisor, & Administrator, which is the SUEZ standard. To gain access to make changes on the HMI, the operator is required to enter the correct password. There is no limit to the number of times another password can be attempted.

The system is designed with the following initial User Names and Passwords.

Table 1 Default User Names and Passwords

Security Level User Name Password Guest Default n/a Operator oper 1111 Supervisor super 2222 Administrator admin water

Access by unauthorized users may be a potential risk to correct equipment operation. The end user is encouraged to modify these initial user names 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.

Acknowledge alarms.

No access to Alarm Reset button.

A screensaver blanks the screen after a set amount of time of inactivity, typically 60 minutes. The screen is reactivated by a single touch. Reactivation cannot select a device or operating sequence. The password must be re-entered for Operator/Supervisor/Administrator access.

The Operator access is permitted the following actions:

Access to view all screens.

Access only to view setpoints.

Access to view and adjust of all train operational modes.

Access to view and selection of train state button views.

Resetting of all alarms.

Access to operate pumps and valves.

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

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 constants.

HMI Administrator access is permitted the following actions:

All Supervisor permissions.

Access to view and adjust for equipment operation.

Access to installation options for the design.

Add or delete users.

Permission to exit the runtime application.

2.2.3 Security Access

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.

The end user when logged in as administrator is able to add and delete individual users if so desired.

The end user is encouraged to customize the default user names and default passwords shown above.

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

2.3 HMI NAVIGATION

When 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 Overview, Graphics Index and Setpoints.

2.4 STATUS AND COLOR SCHEMES

Table 2 HMI Color Code for Devices Chart

Color Valve Pump

Grey Closed Off

Green Open On

Red Border Alarm Alarm

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2.5 DATE AND TIME SYNCHRONIZATION

The HMI date and time is 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.

2.6 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 by the operator at the HMI.

If there is no value for Range Min. or Range Max. the setpoint is not adjustable by the operator at the

HMI.

Setpoints for transmitters are dedicated to the transmitter.

2.6.1 Triggers

A trigger is a normal event that can clear an alarm or be one of several points in a sequence of events.

These triggers are listed in the CLC as “Trigger” under the Type column.

2.6.2 Alarms

Alarms are used to identify a problem with the system.

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

2.6.2.1 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 - Delay step 30 or the Fault - Shutdown step 31. Most alarms will put the system in Fault - Delay, which stops blowdown but otherwise continues the process. If the system is in this step for the duration of the delay timer, it will proceed to Fault - Shutdown.

If there is a failure alarm, a VFD fault, or a high-high torque alarm from the Clarifier Scraper, then the system will proceed immediately to Fault Shutdown.

The operator can reset a critical alarm by pressing the System or Unit Alarm Reset button on the HMI.

This button resets the alarm, and the unit will resume operation by proceeding to step 1 of the current state.

2.6.2.2 Warning Alarm

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

2.6.3 Alarm Banner

When alarms are triggered, an alarm banner will be shown at the top of HMI screen. Operators can Acknowledge alarm or Clear alarm by pressing pushbutton in alarm banner. The alarm banner is closed by pressing the Exit button.

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2.6.4 Alarm Summary

When an alarm occurs, the user should check the current alarms from 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.

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.

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.

2.6.5 Alarm History

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.

2.6.6 Alarm Light

Activation of any alarm will energize a PLC output for an alarm light. The alarm light will remain lit until all alarms are cleared, and no active alarms are present.

2.7 HMI TRENDING

Instrument values are trended for a 10-minute duration. The HMI device interface graphically displays the value over time.

The value is shown on the graph as a percentage of the maximum instrument range.

2.8 BUTTONS

HMI button presses are momentary. After a button is pressed at the HMI, it is reset after one scan time.

3 DEVICE CONTROL

3.1 DEVICE STATUS

Reference the HMI Legend screen for device icon samples and status indication definitions.

3.2 DEVICE STATUS AND MODES

3.2.1 Device Status

Device statuses describe conditions that will change how the device responds to commands.

Interlocked – An Interlock is a condition external to the device that disables it from operating.

Specific Interlock states and descriptions are described in the device interface in the HMI.

Remote – A device is considered to be in Remote when it is able to be controlled by the PLC rather than controls local to the device on in the MCC. When a device is not in Remote Auto

C

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(MCC local) control "L" in an orange square is displayed beside the device. On the device

Faceplate the home symbol is orange.

Ready – A device is Ready when it is not interlocked, not in manual, and not in alarm. The

Ready status indicates that it is able to be commanded by automatic process controls from the

PLC.

3.2.2 Device Modes

Most devices are able to be operated in either Auto or Manual mode, as described below:

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.

4 OPERATOR OPERATIONS

4.1 POWER INTERRUPTION/POWER UP

The SUEZ PLC monitors the plant control power supply. On loss of plant control power supply, the

SUEZ PLC:

All automatic valves will move to their fail positions, All tank motors will continue running as long as they are able, All pump motors will stop, The DensaDeg proceeds immediately to the Faulted step of the current state and waits for power to resume.

When power is restored, the control system will power-up. The system can be configured for automatic or manual restart after power-up. In manual mode, a PLC Power Restored alarm will occur. This alarm will need to be reset by the operator for equipment to operate. In Automatic mode, the Power Restored alarm will be reset by the PLC and power-up process will start automatically. After the alarm is reset, there is an Equipment Power up delay. During power-up, the unit processes are in the fault step of the current state and locked out from operation. After the equipment power-up delay is complete, the unit fault is cleared, and the equipment will restart normally. The power up status is displayed at the bottom of the screen.

The power-up settings are accessed by pressing the PLC Panel Status button on the Main screen.

This screen also shows the status of the Power Health, Operational Stop Button, PLC Flash Load, PLC Battery and PLC Forces Enabled alarms.

4.2 SYSTEM STOP

A mechanical System Stop pushbutton is also provided at the panel to allow for the operator to immediately stop all equipment through the PLC.

When the button is pressed, an alarm occurs and:

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Page : 12 / 18 all common equipment is stopped immediately all trains transition to the Faulted step of their current state.

When the button is reset:

all trains are restarted one at a time, following the Start-Up sequence detailed in the Control Logic Chart.

When the System Stop button is pulled out and the Reset button pressed, power is restored to the outputs. When the System Stop Alarm is reset at the HMI. After the alarm is reset, there is an Equipment Power up delay. During power-up, the unit processes are in the fault step of the current state and locked out from operation. After the equipment power-up delay is complete, the unit fault is cleared, and the equipment will restart normally.

4.2.1 Start-Up Sequence

The start-up sequence is the order in which the devices in the plant are re-enabled after a power interruption or after a system stop is reset.

When re-enabled, each train proceeds according to the SC.

A delay is provided in each step to allow for devices to start before advancing to the next step. Steps are skipped for those devices which are not ready.

5 COMMUNICATION

For the SUEZ system to maintain optimal performance, information must be communicated between the plant PLC and the SUEZ PLC. Such communication will be by Ethernet I/P per customer instructions. The signals required are both analog and digital.

Operating parameters of the SUEZ system such as flow rates, pressures, train sequences, etc. are available for communication, if necessary, when the plant SCADA is required to only monitor these parameters. A list showing this information, however, is not provided in this document due to the large number of parameters available.

The SUEZ PLC and plant PLC both generate a heartbeat signal. Each “heartbeat” signal increments at a regular rate, (e.g. each second), and is monitored by the other PLC. When communication with a PLC is lost, the PLC that is monitoring the “heartbeat” signal detects that the state of the signal has not changed for a pre-set time, for example after 5 seconds, and alarms.

When the counter reaches 10,000 it restarts counting from zero.

Signals communicated from the Plant PLC to the Suez PLC, and signals communicated from the Suez PLC to the Plant PLC are listed in the CLSC Comms section.

5.1 LOSS OF COMMUNICATION ALARM WITH PLANT PLC

If there is a loss of communication with the plant the DensaDeg PLC will continue to operate in its current state. It will not initiate a new blowdown sequence, but will complete any that have already started.

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5.2 PLANT PLC TO DENSADEG PLC NECESSARY COMMUNICATION

The following data tags from the Plant PLC must be available to the DensaDeg PLC. They are essential to the clarification process. Additional communicated data tags and details of the tags are described in the CLSC Communications section.

1. Heartbeat

2. DensaDeg Start

3. Influent Flow

4. Blowdown Available

5.3 DENSADEG PLC TO PLANT PLC NECESSARY COMMUNICATION

The following data tags from the DensaDeg PLC must be available to the Plant PLC. They are essential to the clarification process. Additional communicated data tags and details of the tags are described in the CLSC Communications section.

1. Heartbeat

2. DensaDeg Critical Alarm

3. DensaDeg Warning Alarm

4. DensaDeg System Stop

5. Blowdown In Progress

6. DensaDeg State

6 ANALOG CONTROL

The following Proportional, PID, and Step controls are available. Refer to the Control Loop tab in the CLSC for details about which controllers are used for specific devices.

6.1 PROPORTIONAL CONTROL

Each Proportional Controller has an “Auto/Manual” selector switch. In the “Auto” position, the pump speed is controlled using Proportional Output to vary the speed of the metering pump based on process flow to maintain a certain dose rate (ppm). In the “Manual” position, the operator enters a value for the pump speed (%).

The Proportional Output is controlled by accessing the appropriate Dose screen. The screen displays the dose setpoint, process flow, output and AUTO/MANUAL control. The configuration screen allows access to change the proportional calculation setpoints including Pump Capacity, Chemical Concentration, Specific Gravity and Pump Stroke length.