Draft_Specs_40_90_00B_Instru_and_Control_for_Process_Systems_4.pdf

DRAFT

PW\JA\D3167666\4\42 INSTRUMENTATION AND CONTROL

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SECTION 40 90 00

INSTRUMENTATION AND CONTROL

FOR PROCESS SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. This section gives general requirements for Process Instrumentation and Control (PIC). The following PIC subsections expand on requirements of this section:

1. Section 26 05 02, Basic Electrical Requirements.

2. Section 26 05 04, Basic Electrical Materials and Methods.

3. Section 26 05 05, Conductors.

4. Section 26 05 10, Network Communication System

5. Section 40 91 00, Instrumentation and Control Components.

6. Section 40 92 01, Control Panels.

7. Section 40 96 00, Application Software.

8. Section 40 99 90, Package Control Systems.

B. Major Work Items: Includes but is not limited to engineering, furnishing, installing, calibrating, adjusting, testing, documenting, starting up, and training for complete PIC.

1. Process instrumentation including primary elements, transmitters, control devices, and control panels.

2. Programmable logic controllers.

3. Computers, servers and networks for Human Machine Interface (HMI) and Alarm Notification.

4. Control Panels.

5. Network Components.

6. Application Software:

a. Provided by Contractor for PLCs, HMI, and network components.

Work related to supporting this activity may include:

1) Coordination of all the networked (Ethernet) signals between the field devices and control system.

2) Configuration and programming PLC, HMI, and network equipment at a staging site.

3) Demonstration testing at staging site.

4) Assistance with onsite checkout of applications software.

C. Work Does Not Include :

1. SCADA Software.

2. Wifi router and equipment.

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3. Fire Alarm Control Panels.

4. Security System.

5. Telephone System.

1.02 REFERENCES

A. The following is a list of standards which may be referenced in this section and other PIC subsections:

1. ACIO-2020-002: Cybersecurity of Building Automation and Control Systems within NPS Facilities.

2. American National Standards Institute (ANSI).

3. ASTM International (ASTM):

a. A182/A182M, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service.

b. A276, Standard Specification for Stainless Steel Bars and Shapes.

c. A312/A312M, Standard Specification for Seamless, Welded, and

Heavily Cold Worked Austenitic Stainless Steel Pipes.

d. B32, Standard Specification for Solder Metal.

e. B88, Standard Specification for Seamless Copper Water Tube.

4. Deutsche Industrie-Norm (DIN): VDE 0611, Specification for modular terminal blocks for connection of copper conductors up to 1,000V ac and up to 1,200V dc.

5. Institute of Electrical and Electronics Engineers, Inc. (IEEE): C62.41, Recommended Practice on Surge Voltages in Low-Voltage AC Power Circuits.

6. International Society of Automation (ISA):

a. RP12.06.01, Recommended Practice for Wiring Methods for

Hazardous (Classified) Locations Instrumentation Part 1: Intrinsic Safety.

b. S5.1, Instrumentation Symbols and Identification.

c. S5.4, Instrument Loop Diagrams.

d. S50.1, Compatibility of Analog Signals for Electronic Industrial

Process Instruments.

e. TR20.00.01, Specification Forms for Process Measurement and

Control Instruments, Part 1: General.

f. ISA 101 Human Machine Interfaces for Process Automation

Systems.

g. ISA 18.2 Management of Alarm Systems for the Process

Industries.

7. International Conference on Energy Conversion and Application

(ICECA).

8. National Electrical Code (NEC).

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9. National Electrical Manufacturers Association (NEMA):

a. 250, Enclosures for Electrical Equipment (1,000 Volts

Maximum).

b. ICS 1, Industrial Control and Systems General Requirements.

10. National Fire Protection Association (NFPA): 820, Standard for Fire Protection in Wastewater Treatment and Collection Facilities.

11. NSF International (NSF):

a. NSF/ANSI 61, Drinking Water System Components - Health

Effects.

b. NSF/ANSI 372, Drinking Water System Components - Lead

Content.

12. UL: 508A, Standard for Safety, Industrial Control Panels.

13. HDR Instrument and Design Controls Standards: Memo Dated April 25, 2024.

1.03 DEFINITIONS

A. Abbreviations:

1. FDT: Factory Demonstration Test.

2. HMI: Human-Machine Interface.

3. HVAC: Heating, Ventilating, and Air Conditioning.

4. I&C: Instrumentation and Control.

5. I/O: Input and Output.

6. O&M: Operation and Maintenance.

7. OIT: Operator Interface Terminal.

8. P&ID: Process and Instrument Diagram.

9. PC: Personal Computer.

10. PIC: Process Instrumentation and Control.

11. PLC: Programmable Logic Controller.

12. RTU: Remote Terminal Unit.

13. SCADA: Supervisory Control and Data Acquisition.

14. SI: System Integrator.

15. SLDC: Single Loop Digital Controller.

16. SSDT: Staging Site Demonstration Test.

17. VFD: Variable Frequency Drive.

B. Application Software: Application Software will be provided and program by NPS’s selected SI.

C. Enclosure: Control panel, console, cabinet, or instrument housing.

D. Instructor Day: 8 hours of actual instruction time.

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E. Rising/Falling: Define action of discrete devices about their setpoint.

1. Rising: Contacts close when an increasing process variable rises through setpoint.

2. Falling: Contacts close when a decreasing process variable falls through setpoint.

F. Signal Types:

1. Analog Signal, Current Type:

a. 4 mA dc to 20 mA dc signals conforming to ISA S50.1.

b. Unless otherwise indicated for specific PIC subsection components, use the following ISA S50.1 options.

1) Transmitter Type: Number 2, two-wire.

2) Transmitter Load Resistance Capacity: Class L.

3) Fully isolated transmitters and receivers.

2. Analog Signal, Voltage Type: 1V dc to 5V dc within panel where common high precision dropping resistor is used.

3. Discrete signals, two-state logic signals using dc or 120V ac sources as indicated.

4. Pulse Frequency Signals:

a. Direct-current pulses whose repetition rate is linearly proportional to process variable.

b. Pulses generated by contact closures or solid state switches.

c. Power source less than 30V dc.

5. Special Signals: Other types of signals used to transmit analog and digital information between field elements, transmitters, receivers, controllers, and digital devices.

G. Standard Software: Software packages that are independent of Project on which they are used. Standard software includes system software, supervisory control, and data acquisition (SCADA) software.

1. System Software: Application independent (non-project specific) software developed by digital equipment manufacturers and software companies. Includes, but is not limited to, operating systems; network support, programming languages (C, C++, Visual C++, BASIC, Visual Basic); Office Suites (word processor, spreadsheet, database); e-mail;

security (firewall, antivirus; spam, spyware) debugging aids; and diagnostics.

2. Controller Programming Software: Software packages for the configuring of PLCs, RTUs, SLDC, and network devices.

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1.04 SYSTEM DESCRIPTION

A. Design Requirements:

1. Complete detailed design of PIC components and PIC drawings.

2. Provide consistent hardware and software functions for PIC. For example, provide functions in control logic, sequence controls, and display layouts in same or similar manner.

3. PIC design as shown and specified includes:

a. Functional requirements, performance requirements, and component specifications.

b. P&IDs, block diagrams, and network diagrams.

4. Typical drawings for installation details, control panel layouts, control panel schedules, PLC I/O module wiring, panel power, and control diagrams.

B. Use a qualified PIC System Integrator for at least the following work:

1. For PIC Equipment and Ancillaries:

a. Completing detail design.

b. Configuring network switches.

c. Submittals.

d. Equipment, enclosures, and ancillaries.

e. Instructions, details, and recommendations to, and coordination with Contractor for Certificate of Proper Installation.

f. Verify readiness for operation.

g. Verify correctness of final power and signal connections (lugging and connecting).

h. Adjusting and calibrating.

i. Starting up.

j. Testing and coordination of testing.

k. Training.

2. Verify following Work not by PIC System Integrator is provided:

a. Correct type, size, and number of signal wires with their raceways.

b. Correct electrical power circuits and raceways.

c. Correct size, type, and number of PIC-related pipes, valves, fittings, and tubes.

d. Correct size, type, materials, and connections of process mechanical piping for in-line primary elements.

3. Non-PIC Equipment Directly Connected to PIC Equipment:

a. Obtain from Contractor, manufacturers’ information on installation, interface, function, and adjustment.

b. Coordinate with Contractor and relevant subcontractors to allow required interface and operation with PIC.

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c. For operation and control, verify installations, interfacing signal terminations, and adjustments have been completed in accordance with manufacturer’s recommendations.

d. Test to demonstrate required interfaces and operation with PIC.

e. Examples of items in this category, but not limited to the following:

1) Valve operators, position switches, and controls.

2) Chemical feed pump and feeder speed/stroke controls.

3) Automatic samplers.

4) Motor control centers.

5) Adjustable speed and adjustable frequency drive systems.

f. Examples of items not in this category:

1) Internal portions of equipment provided under Division 26, Electrical, that are not directly connected to PIC equipment.

2) Internal portions of package system instrumentation and controls that are not directly connected to PIC equipment.

1.05 SUBMITTALS

A. General Format:

1. Submittal Format:

a. Electronic Copies: Required, unless otherwise noted for specific items.

1) Manufacturers’ Standard Documents: Adobe Acrobat PDF.

2) Documents created specifically for Project:

a) Text and Graphics: Microsoft Word.

b) Lists: Microsoft Excel, unless otherwise noted for specific items.

c) Drawings: AutoCAD.

B. Action Submittals:

1. Bill of Materials: List of required equipment.

a. Group equipment items by enclosure and field, and within an enclosure, as follows:

1) PIC Components: By component identification code.

2) Other Equipment: By equipment type.

b. Data Included:

1) Equipment tag number.

2) Description.

3) Manufacturer, complete model number and all options not defined by model number.

4) Quantity supplied.

5) Component identification code where applicable.

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6) For panels, include panel reference number and name plate inscription.

c. Formats: Hard copy and Microsoft Excel.

2. Catalog Cuts:

a. I&C Components, Electrical Devices, and Mechanical Devices:

1) Catalog information, marked to identify proposed items and options.

2) Descriptive literature.

3) External power and signal connections.

4) Scaled drawings showing exterior dimensions and locations of electrical and mechanical interfaces and installation details.

3. Instrument List:

a. Initial Instrument List is provided as a supplement to this section.

Data from this may be used as starting point for creating final Instrument List and Component Data Sheets.

b. Applicable fields to be completed include, but are not limited to:

Instrument List Characteristics

Item

Tag Number

Loop Number

Description

Manufacturer and complete model number

Size and scale range

Setpoints

Reference P&IDs, Electrical, Mechanical, Interconnection Drawings and Installation Details Drawings

Instrument detail number

c. Submit updated version of Instrument List in Microsoft Excel.

4. Component Data Sheets: Data sheets for I&C components.

a. Format:

1) Similar to ISA TR20.00.01.

2) Microsoft Excel, one component per data sheet.

3) Submit proposed format for Component Data Sheets before completing data sheets for individual components.

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b. Content:

1) Specific features and configuration data for each component, including but not limited to:

a) Tag Number.

b) Component type identification code and description.

c) Location or service.

d) Service conditions.

e) Manufacturer and complete model number.

f) Size and scale range.

g) Setpoints.

h) Materials of construction.

i) Options included.

j) Power requirements.

k) Signal interfaces.

l) Name, address, and telephone number of manufacturer’s local office, representative, distributor, or service facility.

c. Electronic Copies: Microsoft Excel.

5. Sizing and Selection Calculations:

a. Primary Elements:

1) Complete calculations plus process data used. Example for

Flow Elements:

a) Minimum and maximum values, permanent head loss, and assumptions made.

b. Controller, Computing, and Function Generating Modules: Actual scaling factors with units and how they were computed.

c. Electronic Copies: Microsoft Excel, one file for each group of components with identical sizing calculations.

6. Preliminary Panel Elevation Drawings:

a. Provide prior to submitting Panel Construction Drawings:

1) Scale Drawings: Show dimensions and location of front of panel devices.

2) Panel Legend (Bill of Material): List front of panel devices by tag number. Include nameplate inscriptions, service legends, and annunciator inscriptions.

3) Submit electronic copies of Drawings.

7. Panel Construction Drawings:

a. Scale Drawings: Show dimensions and locations of panel-mounted devices, doors, louvers, subpanels, internal and external.

b. Panel Legend (Bill of Material): List front of panel devices by tag numbers, nameplate inscriptions, service legends, and annunciator inscriptions.

c. Bill of Materials: List devices mounted within panel that are not listed in panel legend. Include tag number, description, manufacturer, and model number.

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d. Construction Details: NEMA rating, materials, material thickness, structural stiffeners and brackets, lifting lugs, mounting brackets and tabs, door hinges and latches, and welding and other connection callouts and details.

e. Construction Notes: Finishes, wire color schemes, wire ratings, wire, terminal block numbering, and labeling scheme.

f. Submit electronic copies of Drawings.

8. Diagrams:

a. Detailed Wiring Diagrams:

1) Diagrams including:

a) Panel Wiring Diagrams for discrete control and power circuits.

b) Loop Wiring Diagrams showing individual wiring diagram for each analog or pulse frequency loop.

c) Interconnecting Wiring Diagrams showing electrical connections between equipment, consoles, panels, terminal junction boxes, and field-mounted components.

2) Prepare as-built redline markup of detailed wiring diagrams.

Show terminal numbers on switch blocks, relays, and internal components.

3) Submit electronic copies of Drawings.

b. Panel Wiring Diagrams:

1) Cover wiring within a panel including, but not limited to, instrumentation, control, power, and communications, and digital networks.

2) Objectives: For use in wiring panels, making panel connections, and future panel trouble shooting.

c. Diagram Type:

1) Ladder diagrams where applicable. Include devices that are mounted in or on the panel that require electrical connections. Show unique rung numbers on left side of each rung.

2) Schematic drawings for wiring of circuits that cannot be well represented by ladder diagrams.

d. Item Identification: Identify each item with attributes listed.

1) Wires: Wire number and color. Cable number if part of multiconductor cable.

2) Terminals: Location (enclosure number, terminal junction box number, or MCC number), terminal strip number, and terminal block number.

3) Components:

a) Tag number, terminal numbers, and location

(“FIELD”, enclosure number, or MCC number).

b) Switching action (open or close on rising or falling process variable), setpoint value and units, and

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process variable description (for example, Sump Level High).

4) I/O Points: PLC unit number, I/O tag number, I/O address, terminal numbers, and terminal strip numbers.

5) Relay Coils:

a) Tag number and its function.

b) On right side of run where coil is located, list contact location by ladder number and sheet number.

Underline normally closed contacts.

6) Relay Contacts: Coil tag number, function, and coil location (ladder rung number and sheet number).

7) Communications and Networks: Network type, address or node identification, port or channel number, and type of connector.

8) Show each circuit individually. No “typical” diagrams or “typical” wire lists will be allowed.

9) Ground wires, surge protectors, and connections.

10) Wire and Cable Names: Show names and wire color corresponding to Circuit and Raceway Schedule for circuits entering and leaving a panel. Refer to Division 26, Electrical.

e. Loop Wiring Diagrams: Individual, end-to-end wiring diagram for each analog and discrete or equipment loop.

1) Conform to the minimum requirements of ISA S5.4.

2) Under Paragraph 5.3 of ISA S5.4, include the information listed under Subparagraphs 2 and 6.

3) Show loop components within a panel and identify each component, component terminals, and panel terminals.

4) If a loop connects to panels or devices not provided under this section and its subsections, such as control valves, motor control centers, package system panels, variable speed drives, include the following information:

a) Show the first component connected to within the panel or device that is not provided under this section and its subsections.

b) Identify the component by tag and description.

c) Identify panel and component terminal numbers.

5) Drawing Size: Individual 11-inch by 17-inch sheet for each loop.

6) Divide each loop diagram into areas for panel face, back-of-panel, field, and PLC.

7) One Drawing Per Loop: Show each loop individually. No “typical” loop diagrams will be allowed.

8) Show:

a) Terminal numbers, location of dc power supply, and location of common dropping resistors.

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b) Switching contacts in analog loops and output contacts of analog devices. Reference specific control diagrams where functions of these contacts are shown.

c) Tabular summary on each analog loop diagram:

(1) Transmitting Instruments: Output capability.

(2) Receiving Instruments: Input impedance.

(3) Loop Wiring Impedance: Estimate based on wire sizes and lengths shown.

(4) Total loop impedance.

(5) Reserve output capacity.

d) Circuit and raceway schedule names.

f. Communications and Digital Networks Diagrams:

1) Scope: Includes connections to Ethernet network, SCADA servers, and packaged vendor systems.

2) Format: Network schematic diagrams for each different type of network.

3) Show:

a) Interconnected devices, both passive and active.

b) Device names and numbers.

c) Terminal numbers.

d) Communication Media: Type of cable.

e) Connection Type: Type of connector.

f) Node and device address numbers.

g) Wire and cable numbers and colors.

g. Panel Plumbing Diagrams:

1) For each panel containing piping and tubing. Show type and size for:

a) Pipes and Tubes: Thickness, pressure rating, and materials.

b) Components: Valves, regulators, and filters.

c) Connections to panel-mounted devices.

d) Panel interface connections.

e) Submit electronic copies of Drawings.

9. Panel Power Requirements and Heat Dissipation:

a. For control panels tabulate and summarize:

1) Required voltages, currents, and phases(s).

2) Maximum heat dissipations Btu per hour.

3) Calculations.

4) Steady State Temperature Calculations: For nonventilated panels, provide heat load calculations showing the panel estimated internal steady state temperature for ambient air temperatures of 90 degrees F.

10. Installation Details: Include modifications or further details required and define installation of I&C components.

11. Spares (for instruments, IO modules), expendables (for analytical instruments) and test equipment.

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12. PLC I/O List: Submit I/O assignment and Rack/Slot/Point.

13. Identify proposed items, options, installed spares, and other provisions for future work (for example, reserved panel space; unused components, wiring, and terminals).

14. Color schedule for control panels.

15. Applications Software Documentation:

a. Complete configuration documentation for microprocessor based programmable devices.

b. For each device, include program listings and function block diagrams, as appropriate, showing:

1) Functional blocks or modules used.

2) Configuration, calibration, and tuning parameters.

3) Descriptive annotations and control narratives

c. Refer to PIC subsections for additional requirements.

16. Factory and Field Test Documentation:

a. Submit test plans prior to Factory and Field Tests.

b. Submit test reports and punch lists from the Factory and Field tests.

c. Submit final sign off documentation from the Factory and Field tests.

17. Legends and Abbreviation Lists:

a. Definition of symbols and abbreviations used; for example, engineering units, flowstreams, instruments, structures, and other process items used in nameplates, legends, data sheets, point descriptions, HMI displays, alarm/status logs, and reports.

b. Use identical abbreviations in PIC subsections.

c. Submit updated versions as they occur.

18. Shop Drawings for Changes Impacting PLC and SCADA Programming:

a. Submit details of changes required to PLC and SCADA monitoring and control resulting from installation of alternative or upgraded process equipment and instrumentation, and other causes.

C. Informational Submittals:

1. Proposed Submittal breakdown consisting of sequencing and packaging of information in accordance with Project Schedule.

2. Statements of Qualification:

a. PC System Integrator.

b. PC System Integrator’s site representative.

c. Resume for each PIC System Integrator’s onsite startup and testing team member (engineers, technicians, and software/configuring personnel).

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3. Operation and Maintenance Data:

a. In accordance with Section 01 78 23, Operation and Maintenance

Data, and in addition the following:

1) General:

a) Provide sufficient detail to allow operation, removal, installation, adjustment, calibration, maintenance and purchasing replacements for PIC components.

b) Submittal Format: Both hard copy and electronic copies for all submittals. Refer to Article Submittals, Subparagraph Submittal Format.

b. Manufacturer’s O&M Manuals for Components, Electrical Devices, and Mechanical Devices:

1) Content for Each O&M Manual:

a) Table of Contents.

b) Operations procedures.

c) Installation requirements and procedures.

d) Maintenance requirements and procedures.

e) Troubleshooting procedures.

f) Calibration procedures.

g) Internal schematic and wiring diagrams.

h) Component and I/O Module Calibration Sheets from field quality control calibrations.

2) Provide PDF file with linked index to all manuals.

c. List of spares, expendables, test equipment and tools provided.

d. List of additional recommended spares, expendables, test equipment, and tools. Include quantities, unit prices, and total costs.

4. Provide Manufacturer’s Certificate of Proper Installation where specified.

5. Testing Related Submittals:

a. Factory Demonstration Test:

1) Preliminary Test Procedures: Outline of proposed tests, forms, and checklists.

2) Final Test Procedures:

a) Proposed test procedures, forms, and checklists.

b) Capacity, Timing, and Simulation: Describe simulation and monitoring methods used to demonstrate compliance with capacity and timing requirements.

3) Test Documentation: Copy of signed off test results.

b. Staging Site Demonstration Test:

1) Preliminary Test Procedures: Outline of proposed tests, forms, and checklists.

2) Final Test Procedures: Proposed test procedures, forms, and checklists.

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3) Test Documentation: Copy of signed-off test results when tests are completed.

c. Functional Test:

1) Preliminary Test Procedures: Outline of proposed tests, forms, and checklists.

2) Final Test Procedures: Proposed test procedures, forms, and checklists.

3) Test Documentation:

a) Copy of signed-off test results.

b) Completed component calibration sheets.

d. Performance Test:

1) Preliminary Test Procedures: Outline of proposed tests, forms, and checklists.

2) Final Test Procedures: Proposed test procedures, forms, and checklists.

3) Test Documentation: Copy of signed-off test results.

6. Training Module: In accordance with Section 01 79 00, Demonstration and Training.

7. Maintenance Service Agreement: Prior to Substantial Completion, submit service agreements signed by Contracting Officer and maintenance provider for work.

8. Manufacturer Service Support for Network and SCADA Equipment:

a. Product warranty service agreement.

b. Cisco’s SMARTnet support for 1-year after final acceptance.

c. Technical Support contact numbers, days per week, hours per day.

d. Documentation showing that warranties, SMARTnet, etc., have been transferred to the Contracting Officer complete with contact information provided by the Contracting Officer.

e. Preventive maintenance schedule.

f. Software and firmware updates.

1.06 QUALITY ASSURANCE

A. Qualifications:

1. PIC System Integrator: Minimum of 10 years’ experience providing, integrating, installing, and starting up similar systems as required for this Project.

2. PIC System Integrator’s Site Representative: Minimum of 5 years’ experience installing systems similar to PIC required for this Project.

B. PIC Coordination Meetings:

1. General: Refer to Section 01 31 00, Project Management and Coordination, for PIC coordination meetings.

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2. PIC Schedule Coordination Meeting:

a. Timing: Following Contracting Officer review of PIC Schedule.

b. Purpose: Discuss Contracting Officer’s comments and resolve scheduling issues.

3. Training Coordination Meeting:

a. Timing: Following Contracting Officer review of preliminary training plan.

b. Purpose:

1) Resolve required changes to proposed training plan.

2) Identify specific Contracting Officer personnel to attend training.

1.07 DELIVERY, STORAGE, AND HANDLING

A. In accordance with Section 01 67 00, Product Requirements.

B. Prior to shipment, include corrosive inhibitive vapor capsules in shipping containers, and related equipment as recommended by capsule manufacturer.

C. Prior to installation, store items in dry indoor locations. Provide heating in storage areas for items subject to corrosion under damp conditions.

D. Cover panels and other elements that are exposed to dusty construction environments.

1.08 SEQUENCING AND SCHEDULING

A. Refer to Section 01 31 00, Project Management and Coordination, for Contractor’s scheduling requirements for applications software testing.

B. Prerequisite Activities and Lead Times:

1. Do not start following key Project activities until prerequisite activities and lead times listed below have been completed and satisfied:

a. Shop Drawing Reviews by Contracting Officer:

1) Prerequisite: Contracting Officer acceptance of Schedule of Values and Progress Schedule.

2) Schedule: In accordance with completed schedule of Shop Drawing and Sample submittals specified in Section 01 33 23, Submittal Procedures.

b. Test Prerequisite: Associated test procedures Submittals completed.

2. Training Prerequisite: Associated training plan Submittal completed.

a. PLC and HMI Configuration Training Session 1 Prerequisite:

PLC and HMI hardware and software Shop Drawings approved.

b. Staging Site Demonstration Test Prerequisite: PLC and HMI staging equipment delivered to staging site.

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c. PLC and HMI Shipment to Site:

1) General Prerequisites:

a) Approval of PIC Shop Drawings and preliminary operation and maintenance data.

b) FDT and SSDT completed.

d. PLC and HMI Installation Prerequisite: Equipment received at

Site.

e. Functional Test Part 1 Prerequisite: PLC and HMI installation complete.

f. Functional Test Part 2 Prerequisite: Functional Test Part 1 completed.

g. Performance Test Prerequisite: Functional Test Part 2 completed and facility started up.

1.09 MAINTENANCE

A. Maintenance Service Agreement:

1. Duration of 2 years, unless otherwise noted in PIC subsections.

2. Start on date of Substantial Completion.

3. Performed by factory-trained service engineers with experience on PIC systems to be maintained.

4. PIC Systems Covered: PIC components, PLC, HMI, and network equipment.

5. Materials and labor for preventive maintenance and monthly Site visits.

6. Materials and labor for demand maintenance with coverage 8:00 a.m. to

5:00 p.m. Monday through Friday.

7. Response Time: Service engineer shall be onsite within 24 hours of request by Contracting Officer.

8. Spare Parts: If not stocked onsite, delivered to Site within 24 hours from time of request.

9. Repair or replace components or software found to be faulty.

10. Replace and restock within 1 month onsite spare parts and expendables used for maintenance. Provide list of items used and replaced.

11. Submit records of inspection, maintenance, calibration, repair, and replacement within 2 weeks after each Site visit.

B. Telephone/Remote Support: As specified in PIC subsections.

C. Software Subscription: As specified in PIC subsections.

1.10 EXTRA MATERIALS

A. As specified in PIC subsections.

B. In computing spare parts quantities based on specified percentages, round up to nearest whole number.

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C. Spare Parts:

Description

Percent of Each Type and Size Used No Less Than dc power supplies 20 2

Fuses 20 5

Relays 20 3

Terminal Blocks 10 10

120V ac Isolation Transformers 10 2

Surge Suppressors 10 2

D. Expendables:

1. For following items provide manufacturer’s recommended 2-year supply, unless otherwise noted:

a. Chemicals for analyzers.

b. pH Sensor Overhaul Kits: Two.

c. Spray pump filter adhesive; Hoffman Model A-FLTAD. One pint per panel with air filters.

PART 2 PRODUCTS

2.01 GENERAL

A. Provide PIC functions shown on the Drawings and required in PIC subsections for each system and loop. Furnish equipment items required in PIC subsections. Furnish materials, equipment, and software whether indicated or not, necessary to effect required system and loop performance.

B. First Named Manufacturer: PIC design is based on first named manufacturers of equipment, materials, and software.

1. If proposed or equal items require, but not limited to, different installation, wiring, raceway, enclosures, intrinsically safe barriers, and accessories, provide such equipment and work.

C. Like Equipment Items:

1. Use products of one manufacturer and of the same series or family of models to achieve standardization for appearance, operation, maintenance, spare parts, and manufacturer’s services.

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2. Implement same or similar functions in same or similar manner. For example, control logic, sequence controls, and display layouts.

D. Components and Materials in Contact with Water for Human Consumption:

Comply with the requirements of the Safe Drinking Water Act and other applicable federal, state, and local requirements. Provide certification by manufacturer or an accredited certification organization recognized by the Authority Having Jurisdiction that components and materials comply with the maximum lead content standard in accordance with NSF/ANSI 61 and

NSF/ANSI 372.

1. Use or reuse of components and materials without a traceable certification is prohibited.

2.02 I&C COMPONENTS

A. Specifications: Refer to Section 40 91 00, Instrumentation and Control Components, for specifications for I&C components.

B. Components for Each Loop: Major components for each loop are listed Instrument Index referenced in Article Supplements. Furnish equipment that is necessary to achieve required loop performance.

C. Control Panels: Reference Control Panel Schedule in Article Supplements.

2.03 PROGRAMMABLE LOGIC CONTROLLERS

A. Reference PLC components in Section 40 91 00, Instrumentation and Control Components.

2.04 NETWORK AND HMI COMPONENTS

A. Reference Network and HMI components in Section 40 91 00, Instrumentation and Control Components.

2.05 SERVICE CONDITIONS

A. Standard Service Conditions:

1. The following defines certain types of environments. PIC subsections refer to these definitions by name to specify the service conditions for individual equipment units. Design equipment for continuous operation in these environments:

a. Server Room, Air Conditioned:

1) Temperature: 60 degrees F to 80 degrees F.

2) Relative Humidity: 40 percent to 60 percent.

3) NEC Classification: Nonhazardous.

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b. Inside, Air Conditioned:

1) Temperature:

a) Normal: 60 degrees F to 80 degrees F.

b) With Up to 4-Hour HVAC System Interruptions:

40 degrees F to 105 degrees F.

2) Relative Humidity:

a) Normal: 10 percent (winter) to 70 percent (summer).

b) With Up to 4-Hour HVAC System Interruption:

10 percent to 100 percent.

3) NEC Classification: Nonhazardous.

c. Inside:

1) Temperature: 20 degrees F to 104 degrees F.

2) Relative Humidity: 10 percent to 100 percent

3) NEC Classification: Nonhazardous.

d. Outside:

1) Temperature: Minus 20 degrees F to 104 degrees F.

2) Relative Humidity: 10 percent to 100 percent, rain, snow, freezing rain

3) NEC Classification: Nonhazardous.

B. Standard Service Conditions for Panels and Consoles:

1. Unless otherwise noted, in Instrument List and Control Panel Schedule located in Article Supplements at End of Section, design equipment for continuous operation in these environments:

a. Freestanding Panel and Consoles:

1) Inside, Air Conditioned: NEMA 1.

2) Inside: NEMA 12.

b. Smaller Panels and Assemblies (that are not freestanding):

1) Inside, Air Conditioned: NEMA 12.

2) All Other Locations: NEMA 4X.

c. Field Elements: Outside.

C. Special Environmental Requirements: Design following panels for continuous operation in environments listed.

2.06 NAMEPLATES AND TAGS

A. Panel Nameplates: Enclosure identification located on enclosure face.

1. Physical Characteristics:

a. Location and Inscription: Refer to Example Control Panel Layouts and Control Panel Schedule drawings.

b. Materials: Laminated plastic attached to panel with stainless steel screws.

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c. Letters: 1/2-inch high, white on black background, unless otherwise noted.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

B. Component Nameplates, Panel Face: Component identification located on panel face under or near component.

1. Physical Characteristics:

a. Location and Inscription: As shown on panel drawing.

b. Materials: Adhesive-backed, laminated plastic.

c. Letters: 3/16-inch high, white on black background, unless otherwise noted.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

C. Component Nameplates, Back of Panel: Component identification located on or near component inside of enclosure.

1. Physical Characteristics:

a. Inscription: Component tag number.

b. Materials: Adhesive-backed, laminated plastic.

c. Letters: 3/16-inch high, white on black background, unless otherwise noted.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

D. Legend Plates for Panel Mounted Pushbuttons, Lights, and Switches:

1. Physical Characteristics:

a. Inscription:

1) Refer to table under Subparagraph Standard Pushbutton Colors and Inscriptions.

2) Refer to table under Subparagraph Standard Light Colors and Inscriptions.

3) Refer to P&IDs on the Drawings.

b. Materials: Stainless steel, keyed legend plates. Secured to panel by mounting nut for pushbutton, light, or switch.

c. Letters: Black on gray or white background.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

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E. Service Legends: Component identification nameplate located on face of component.

1. Physical Characteristics:

a. Inscription: As shown on panel drawing.

b. Materials: Adhesive-backed, laminated plastic.

c. Letters: 3/16-inch high, white on black background, unless otherwise noted.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

F. Nametags: Component identification for field devices.

1. Physical Characteristics:

a. Inscription: Component tag number.

b. Materials: 16-gauge, Type 304 stainless steel.

c. Letters: 3/16-inch high, imposed.

d. Mounting: Affix to component with 16-guage or 18-gauge stainless steel wire or stainless steel screws.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

2.07 MECHANICAL SYSTEM COMPONENTS

A. Reference Section 40 91 00, Instrumentation and Control Components.

2.08 FUNCTIONAL REQUIREMENTS FOR CONTROL LOOPS

A. Shown on the Drawings, in panel control diagrams, and Process and Instrumentation Diagrams (P&ID). P&ID format and symbols are in accordance with ISA S5.1, except as specified or shown on the Drawings.

B. In Supplements that describe requirements not obvious on P&IDs or panel control diagrams.

C. Supplemented by standard functional requirements in PIC subsections.

2.09 ELECTRICAL REQUIREMENTS

A. Electrical Raceways: As specified in Section 26 05 33, Raceway and Boxes.

B. Wiring External to PIC Equipment:

1. Special Control and Communications Cable: Provided by PIC System Integrator as noted in Component Specifications and PIC subsections.

2. Other Wiring and Cable: As specified in Section 26 05 05, Conductors.

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C. I&C and electrical components, terminals, wires, and enclosures UL recognized, or UL listed.

D. Wires within Enclosures:

1. Physical Characteristics:

a. ac Circuits:

1) Type: 600-volt, Type MTW stranded copper.

2) Size: For current to be carried, but not less than 18 AWG.

b. Analog Signal Circuits:

1) Type: 600-volt stranded copper, twisted shielded pairs or triad with a 100 percent, aluminum-polyester shield, rated 60 degrees C.

2) Panels with Circuits Less Than 600 volts: Rated at 600 volts. Belden 18 AWG Type 9341, Triad Beldon No. 1121A.

3) Size: 18 AWG, minimum.

c. Other dc Circuits.

1) Type: 600-volt, Type MTW stranded copper.

2) Size: For current carried, but not less than 18 AWG.

d. Special Signal Circuits: Use manufacturer’s standard cables.

e. Wire Identification: Numbered and tagged at each termination.

1) Wire Tags: Machine printed; heat shrink.

2. Functional Characteristics: None.

3. Performance Characteristics: None.

E. Terminate and identify wires entering or leaving enclosures as follows:

1. Analog and discrete signal, terminate at numbered terminal blocks.

2. Special signals terminated using manufacturer’s standard connectors.

3. Identify wiring in accordance with requirements in Section 26 05 05, Conductors.

F. Terminal Blocks for Enclosures:

1. Quantity:

a. Accommodate present and spare indicated needs.

b. Wire spare PLC I/O points to terminal blocks.

c. One wire per terminal for field wires entering enclosures.

d. Maximum of two wires per terminal for 18 AWG wire for internal enclosure wiring.

e. Spare Terminals: 20 percent of connected terminals, but not less than five per terminal block, unless otherwise shown on the Drawings.

2. Terminal Block Types: Reference Section 40 91 00, Instrumentation and Control Components, Part 2, Article Electrical Components.

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G. Grounding of Enclosures:

1. Furnish isolated copper grounding bus for signal and shield ground connections.

2. Ground this ground bus at a common signal ground point in accordance with National Electrical Code requirements.

3. Single Point Ground for Each Analog Loop:

a. Locate signal ground at dc power supply for loop.

b. Use to ground wire shields for loop.

4. Ground terminal block rails to ground bus.

H. Analog Signal Isolators:

1. Furnish signal isolation for analog signals that are sent from one enclosure to another.

2. Do not wire in series instruments on different panels, cabinets, or enclosures.

I. Intrinsic Safety System Installation:

1. Comply with NEC Article 504, Intrinsically Safe Systems.

2. Install intrinsically safe circuits in a separate wire way that:

a. Is separated from nonintrinsically safe circuits as specified by

NEC.

b. Is colored light blue and has message “Intrinsically Safe Circuits Only” on raceway cover every 6 inches.

J. Electrical Transient Protection:

1. General:

a. Function: Protect elements of PIC against damage due to electrical transients induced in interconnecting lines by lightning and nearby electrical systems.

b. Surge suppressors are not shown for external analog transmitters.

Determine quantity and location, and show in Shop Drawings.

Refer to example wiring in installation details as shown on the Drawings.

c. Provide, install, coordinate, and inspect grounding of surge suppressors at:

1) Connection of ac power to PIC equipment including panels, consoles assemblies, and field-mounted analog transmitters and receivers.

2) At the field and panel, console, or assembly connection of signal circuits that have portions of the circuit extending outside of a protective building.

2. Surge Suppressor Types: Reference Section 40 91 00, Instrumentation and Control Components, Part 2, Surge Suppressors.

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3. Installation and Grounding of Suppressors:

a. As shown. See Surge Suppressor Installation Details.

b. Grounding equipment, installation of grounding equipment, and terminations for field mounted devices are provided under Division 26, Electrical.

2.10 PANEL FABRICATION

A. General:

1. Nominal Panel Dimensions: As shown on the Drawings.

2. Instrument Arrangements: As shown on the Drawings.

3. Panel Construction and Interior Wiring: In accordance with the National

Electrical Code (NEC), state and local codes, and applicable sections of NEMA, ANSI, UL, and ICECA.

4. Fabricate panels, install instruments and wire, and plumb at PIC System Integrator’s facility. No fabrication other than correction of minor defects or minor transit damage permitted onsite.

5. UL Listing Mark for Enclosures: Mark stating “Listed Enclosed Industrial Control Panel” per UL 508A.

6. Electrical Work: In accordance with the applicable requirements of Division 26, Electrical.

B. Temperature Control:

1. Freestanding Panels:

a. Nonventilated Panels: Size to adequately dissipate heat from equipment mounted inside panel and on panel.

b. Ventilated Panels:

1) Furnish with louvers and forced ventilation as required to prevent temperature buildup from equipment mounted inside panel and on panel.

2) For panels with backs against wall, furnish louvers on top and bottom of panel sides.

3) For panels without backs against wall, furnish louvers on top and bottom of panel back.

4) Louver Construction: Stamped sheet metal.

5) Ventilation Fans:

a) Furnish where required to provide adequate cooling.

b) Create positive internal pressure within panel.

c) Fan Motor Power: 120V ac, 60-Hz, thermostatically controlled.

6) Air Filters: Washable aluminum, Hoffman Series A-FLT.

2. Smaller Panels (that are not freestanding): Size to adequately dissipate heat from equipment mounted inside panel and on panel face.

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3. Space Heaters:

a. Thermostatically controlled to maintain internal panel temperatures above dewpoint.

b. Refer to Control Panel Schedule in Article Supplements.

C. Freestanding Panel Construction:

1. Materials:

a. Sheet steel, unless otherwise noted in Control Panel Schedule in

Article Supplements.

b. Minimum Thickness: 10-gauge, unless otherwise noted.

2. Panel Front:

a. Fabricated from a single piece of sheet steel, unless otherwise shown on the Drawings.

b. No seams or bolt heads visible when viewed from front.

c. Panel Cutouts: Smoothly finished with rounded edges.

d. Stiffeners: Steel angle or plate stiffeners or both on back of panel face to prevent panel deflection under instrument loading or operation.

3. Internal Framework:

a. Structural steel for instrument support and panel bracing.

b. Permit panel lifting without racking or distortion.

4. Lifting rings to allow simple, safe rigging and lifting of panel during installation.

5. Adjacent Panels: Securely bolted together so front faces are parallel.

6. Door:

a. Full height, fully gasketed access door where shown on the Drawings.

b. Latch: Three-point, Southco Type 44.

c. Handle: “D” ring, foldable type.

d. Hinges: Full-length, continuous, piano-type, steel hinges with stainless steel pins.

e. Rear Access: Extend no further than 24 inches beyond panel when opened to 90-degree position.

f. Front and Side Access Doors: As shown on the Drawings.

D. Nonfreestanding Panel Construction:

1. Based on environmental design requirements, provide the following unless otherwise noted in Control Panel Schedule in Article Supplements:

a. Panels Listed as Inside, Air Conditioned:

1) Enclosure Type: NEMA 12.

2) Materials: Steel.

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b. Other Panels:

1) Enclosure Type: NEMA 4X.

2) Materials: Type 316 stainless steel.

2. Metal Thickness: 14-gauge, minimum.

3. Doors:

a. Rubber-gasketed with continuous hinge.

b. Stainless steel lockable quick-release clamps.

E. Control Panel Electrical:

1. Power Distribution within Panels:

a. Feeder Circuits:

1) One or more 120V ac, 60-Hz feeder circuits as shown on the Drawings.

2) Make provisions for feeder circuit conduit entry.

3) Furnish terminal block for termination of wires.

b. Power Panel: Furnish main circuit breaker and circuit breaker on each individual branch circuit distributed from power panel.

1) Locate to provide clear view of and access to breakers when door is open.

2) Breaker Sizes: Coordinate such that fault in branch circuit will blow only branch breaker, but not trip main breaker.

a) Branch Circuit Breakers: 15 amps at 250V ac.

3) Breaker Manufacturers and Products: Refer to Division 26, Electrical.

c. Circuit Wiring: P&IDs and Control Diagrams on the Drawings show function only. Use following rules for actual circuit wiring:

1) Devices on Single Circuit: 20, maximum.

2) Multiple Units Performing Parallel Operations: To prevent failure of any single branch circuit from shutting down entire operation, do not group all units on same branch circuit.

3) Branch Circuit Loading: 12 amperes continuous, maximum.

4) Panel Lighting and Service Outlets: Put on separate 15 amp, 120V ac branch circuit.

5) Provide 120V ac plugmold for panel components with line cords.

2. Signal Distribution:

a. Signal Wiring: Separate analog signal cables from power and control within a panel and cross at right angles where necessary.

b. Within Panels: 4 mA dc to 20 mA dc signals may be distributed as 1V dc to 5V dc.

c. Outside Panels: Isolated 4 mA dc to 20 mA dc only.

d. Signal Wiring: Twisted shielded pairs.

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e. RTD and Thermocouple Extension Cable:

1) Continuous field to panel with no intermediate junction boxes or terminations.

2) RTDs in motor windings are considered a 600-volt circuit.

3) Terminate thermocouple extension wire directly to loop instrument.

3. Signal Switching:

a. Use dry circuit type relays or switches.

b. No interruption of 4 mA to 20 mA loops during switching.

c. Switching Transients in Associated Signal Circuit:

1) 4 mA dc to 20 mA dc Signals: 0.2 mA, maximum.

2) 1V dc to 5V dc Signals: 0.05V, maximum.

4. Relay Types: Reference Section 40 91 00, Instrumentation and Control Components, Part 2, Article Electrical Components.

5. Push-to-Test Circuitry: For each push-to-test indicating light, provide a fused push-to-test circuit.

6. Internal Panel Lights for Freestanding Panels:

a. Type: Switched 100-watt incandescent back-of-panel lights.

b. Quantity: One light for every 4 feet of panel width.

c. Mounting: Inside and in the top of back-of-panel area.

d. Protective metal shield for lights.

7. Service Outlets for Freestanding Panels:

a. Type: Three-wire, 120-volt, 15-ampere, GFCI GFCI duplex receptacles.

b. Quantity:

1) Panels 4 Feet Wide and Smaller: One.

2) Panels Larger than 4 Feet Wide: One for every 4 feet of panel width, two minimum per panel.

c. Mounting: Evenly spaced along back-of-panel area.

8. Standard Pushbutton Colors and Inscriptions:

a. Use following unless otherwise noted in Instrument List:

Tag Function Inscription(s) Color

OO ON

OFF

Black Black

OC OPEN

CLOSE

Black Black

OCA OPEN

CLOSE

AUTO

Black Black Black

OOA ON

OFF

AUTO

Black Black Black

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Tag Function Inscription(s) Color

LR LOCAL

REMOTE

Black Black

SS START

STOP

Black Black

RESET RESET Black

EMERGENCY

STOP

EMERGENCY STOP Red

b. Lettering Color:

1) Black on white and yellow buttons.

2) White on black, red, and green buttons.

9. Standard Light Colors and Inscriptions:

a. Use following color code and inscriptions for service legends and lens colors for indicating lights, unless otherwise noted in Instrument List:

Tag Function Inscription(s) Color

ON ON Red

OFF OFF Green

OPENED OPENED Red

CLOSED CLOSED Green

LOW LOW Amber

FAIL FAIL Amber

HIGH HIGH Amber

AUTO AUTO White

MANUAL MANUAL Yellow

LOCAL LOCAL White

REMOTE REMOTE Yellow

b. Lettering Color:

1) Black on white and amber lenses.

2) White on red and green lenses.

F. PIC Enclosure Internal Wiring:

1. Restrain by plastic ties or ducts or metal raceways.

2. Hinge Wiring: Secure at each end so bending or twisting will be around longitudinal axis of wire. Protect bend area with sleeve.

3. Arrange wiring neatly, cut to proper length, and remove surplus wire.

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4. Provide abrasion protection for wire bundles that pass through holes or across edges of sheet metal.

5. Connections to Screw Type Terminals:

a. Locking-fork-tongue or ring-tongue lugs.

b. Use manufacturer’s recommended tool with required sized anvil to make crimp lug terminations.

c. Wires terminated in a crimp lug, maximum of one.

d. Lugs installed on a screw terminal, maximum of two.

6. Connections to Compression Clamp Type Terminals:

a. Strip, prepare, and install wires in accordance with terminal manufacturer’s recommendations.

b. Wires installed in a compression screw and clamp, maximum of one for field wires entering enclosure, otherwise maximum of two.

7.…