Atch_15_-_40_95_00.pdf

CHPP REPAIR ASH HANDLING CONTROL SYSTEM SECTION 40 95 00

FTQW 12-1008

SECTION TABLE OF CONTENTS

DIVISION 40 - PROCESS INTERCONNECTIONS

SECTION 40 94 43

PLC CONTROL SYSTEM

10/07

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 SUBMITTALS

PART 2 PRODUCTS

2.1 PLC SYSTEM

2.2 I/O MODULES

2.3 LOCAL GRAPHIC OPERATOR INTERFACE (HMI)

2.4 CONTROL PANELS AND HARDWARE SPECIFICATIONS

2.4.1 Contractor shall provide the following:

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

3.2 OPERATIONAL TEST

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SECTION 40 94 43

PLC CONTROL SYSTEM

10/07

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This Section covers the selection, construction, and installation of bulk material valves.

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

SD-02 Shop Drawings

Placement Plan; G

SD-03 Product Data

PLC System; G

I/O Modules; G

Local Graphic Operator Interface (HMI); G

Control Panels and Hardware Specifications; G

Catalog cuts and selection for equipment and accessory items.

General Arrangement drawings and details indicating dimensions.

Materials of construction.

SD-06 Test Reports

ICC ES Evaluation Report

PART 2 PRODUCTS

2.1 PLC SYSTEM

Support redundant controllers and power supplies to provide a high level of reliability.

Ability to expand control equipment, i.e. add I/O modules and capability to integrate into plantwide network.

Capable of supporting ethernet data communication for processor, operator HMI, remote I/O and networking.

Processors shall support simultaneous on-line programming and continuous

SECTION 40 95 00 Page 2 data acquisition and control.

Controller system shall be of modular design with plug-in processing unit, input/output frames or assemblies, and plug-in peripherals. Components shall be serviced and supported by same company.

Programming shall employ modular techniques.

Programming software: Provide all software and licenses to configure PLC for technical staff upon project completion.

2.2 I/O MODULES

In addition to I/O quantities shown in I/O List, provide 20% spare installed, wired and termination ready I/O points of each type.

Discrete input:

a. Capacity: 16-point.

b. Voltage: 120-volt ac.

Discrete output:

a. Capacity: 16-point.

b. Voltage: 120-volt ac.

Relay contact output:

a. Capacity: 16-point or 8-point.

b. Voltage: 120-volt ac.

c. Loading: 2 amperes maximum per point.

d. Grouping: Individually isolated.

Analog input:

a. Capacity: 16-point single ended or 8-point isolated.

b. Current: 4-20 mA.

c. Resolution: 12-bit min.

2.3 LOCAL GRAPHIC OPERATOR INTERFACE (HMI)

Menu driven graphics display(s) capable of accessing information from the

PLC.

At a minimum, all graphic displays from existing bottom ash and fly ash HMI's will be accessible on the new HMI's.

Interactive capability to allow operator to control I/O devices and acknowledge alarms from graphics display. Operator shall be able to change modes between manual and automatic control and change device states between on and off, enter control setpoints, timer and counter settings, process variables, and loop information by 1 or 2 keystroke action.

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DISA STIG compliance will be applied to the HMI computers and they are required to have the plant standard antivirus software installed.

Security levels shall be accessible by user-defined passwords. Levels shall include engineering configuration of graphic displays and setting system parameters, operator control functions only, and process monitoring only.

Mount HMI interface in front door of the panel to be accessed by the operator.

Failure of graphic operator interface processor shall in no way affect programmable controller functions.

Processor shall have sufficient memory for storage, display, and execution of graphic screens as specified, with excess memory of 30% available for future programming needs, minimum 8 GB.

Control program and display configuration shall be retained to allow reloading after power failure.

HMI shall perform continuous diagnostic scans to detect data communication status and programmable controller status.

Nominal screen size: 21 inches.

Display type: Color TFT active matrix.

Min Resolution: 1200 x 800 or better.

Operator interface: Touchscreen.

Power required: 24-volt dc or 120-volt ac

Communication interface: Provide Duel Ethernet communication protocol interfacing between graphics operator interface components and to programmable controller specified.

Configuration software: Provide software and license to configure the HMI project for technical staff upon project completion.

2.4 CONTROL PANELS AND HARDWARE SPECIFICATIONS

2.4.1 Contractor shall provide the following:

Panel exterior general arrangement drawings showing location of surface and flushed mounted equipment.

Panel interior arrangement drawings including:

a. Locations and identification of terminal blocks.

b. Locations and identification of racks/chassis and equipment mounted within.

c. Arrangement of other equipment mounted inside panel identified by instrument tag number.

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Exterior panel wiring interface termination diagrams

Enclosure rating: NEMA 4.

Size: Sufficient to house terminal blocks, wireways, power supplies, racks, chassis, and instruments required for application. Provide additional space for future expansion.

Subpanels: Provide for full surface mounting of terminal blocks, wireways, power supplies, racks, chassis, and instruments.

All Enclosures will have a bulkhead connection for compressed air to keep the enclosure pressurized to mitigate dust collection inside panel. The shut off valve and regulator will be outside the panel and a dispersion device will be inside panel.

DC power supply:

a. Provide 1 or more 24-volt dc power supplies, as necessary, within each panel to power field transmitters, PLC modules and related equipment.

b. Type: Redundant.

c. Input voltage: 120VAC.

Provide separate terminal strips and wireways for 120-volt ac and 24-volt dc circuits.

Terminal block requirements:

a. Provide 1 or more 24-volt dc power supplies, as necessary, within each panel to power field transmitters, PLC modules and related equipment.

b. Type: High-density.

c. Voltage: 600-volt.

d. Wire range: 24 AWG to 12 AWG.

e. Mounting: Rail-mounted with end anchors and barriers.

f. Spare: Provide greater amount of 20% or 6 terminals per terminal strip

Terminate maximum of 2 wires on single connect point.

Install power distribution blocks to parallel feed to power control devices. Parallel wiring from instrument to instrument not acceptable.

Provide plug-in strip for ac supply power to devices requiring ac power via power cord.

Circuit protection:

a. Install individual circuit breakers for protection of control panel power supply circuits as identified.

(1) Group circuit breakers on separate terminal strip away from low-voltage instrumentation circuitry.

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(2) Provide fuses or circuit breakers for protection of individual instrumentation circuits. Instrumentation circuits for field-mounted instruments may be combined in logical groupings of no more than 10 devices/signals.

Provide internal copper grounding bus for ground connections.

Fluorescent lighting fixtures of sufficient size and quantity to provide 30 to 50 foot-candles of illumination within panel. Wire to UL-approved switch mounted inside panel.

Duplex, 120-volt ac, 3-wire grounded type convenience outlets. Provide 1 duplex receptacle per enclosure.

Provide Vortex Cooler for cabinet cooling. Utilize plant compressed air through vortex device to provide subcooled air to cabinet for pressurization and cooling. 8-35 CFM depending on cabinet cooling load.

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

Install all components to be dust tight for fly ash operation.

Locate enclosures where shown on Drawings and/or designated by Engineer.

Enclosure shall be positioned to allow doors to be fully opened for easy access to wiring and components.

Install equipment and accessories in accordance with manufacturer's recommendations.

3.2 OPERATIONAL TEST

The following field commissioning tasks shall be conducted:

a. Visual check will be performed to ensure correct equipment connection.

b. Latest revision of configuration and base level programs has been loaded.

c. Complete loop functional checks shall be performed.

d. Input signals shall be applied to each loop, and when applicable, outputs measured.

e. Input/output values will be compared to graphic operator interface values.

f. Configuration displayed on graphic operator interface will be verified.

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