16967_N18_Deluge_Pump_Station_final.pdf

USCG Kodiak 16967 Deluge Pump Station Local Telemetry Panel (PSCP400) Modification Telemetry Upgrade 1 Mar 13

SECTION 16967

DELUGE PUMP STATION CONTROL PANEL (PSCP400) AND FRESHWATER

TREATMENT PLANT CONTROL PANEL (PCP-23) MODIFICATIONS

PART 1 – GENERAL

1.01 SUMMARY

A. Work and materials specified in this section include modifying an existing electrical control panel at a pump station and at the freshwater treatment plant to use both a telephone modem as well as an existing cable modem to communicate with each other. This shall require integration services, startup services, testing, training, and commissioning as required for a Local Control Panel (PSCP400) and for a Plant Control Panel (PCP-23). The site contains equipment and instrumentation. The company supplying PSCP and PCP equipment and services shall be the same company as that used in related sections and shall be referred to as the “Integrator”.

1.02 RELATED SECTIONS

Related sections include the following:

Title Specification 1 Reporting 16961 2 HMI at N2 and N38 16962 3 Aviation Hill Reservoir Local Telemetry Panel

(LTP700)

16963

4 Aviation Hill Pump Station Control Panel

(PSCP300)

16964

5 Nemetz Reservoir Local Telemetry Panel (LTP600) 16965 6 Old Womans Reservoir Local Telemetry Panel

(LTP500)

16966

7 Deluge Pump Station Control Panel (PSCP400) 16967 8 Freshwater Treatment Plant Control Panel (PCP200) 16968

1.03 RESPONSIBILITY OF INTEGRATOR

A. The Integrator shall be fully and completely responsible for the assembly, modification, and installation of the systems as specified herein and shall be enjoined by the Owner as a Contractor.

B. The Integrator should note the requirement for successful testing of the telemetry system prior to substantial completion.

C. The Integrator shall be fully and completely responsible for the programming, telemetry, configuration, coordination, startup, training, and commissioning of the systems.

1.04 INTEGRATOR REQUIREMENTS

A. The Integrator shall meet the following requirements:

1. The Integrator shall have a minimum of five (5) years of experience providing telemetry for water systems. The Integrator must provide a minimum of three (3) project examples with references within a 100 mile radius of this facility to the Engineer on jobs of similar scope and complexity.

2. The Integrator’s PLC programmer must meet minimum criteria. Any replacement for this programmer shall be subject to the same criteria. The PLC programmer must meet one of the following criteria:

a) Certification from an independent agency, i.e. Certified Control

System Technician (ISA) or Control Systems Engineer (state).

b) Submit resume of PLC programmer to the Engineer for approval.

3. The Integrator must agree that all drawings, documentation, applications software (logic), and configuration files provided and/or used by the Integrator shall be the property of the Owner. A revocable use agreement will not be acceptable. Application software, documentation, and all programming provided by the Integrator shall not be copyrighted, encrypted, nor coded. The Integrator shall maintain and archive a copy of all PLC and HMI programs as a backup, available to the Owner for the life of the system. The Owner shall be given three CDs containing all PLC logic, configurations, drawings, and documentation.

B. The Integrator shall be able to provide emergency control system testing, troubleshooting, and repairs within 48 hours of notification of a problem.

C. The Owner reserves the right to disqualify Integrators with insufficient experience, poor references, or unqualified personnel.

1.05 INTEGRATOR RESPONSIBILITIES

Install telephone telemetry between the Freshwater Treatment Plant and the Pump Station Control Panel to operate in addition to the existing cable telemetry.

A. The work related to the local control panel shall include, but not be limited to the following:

1. Modify an existing pump station control panel (PSCP) consisting of a programmable logic controller (PLC), Ethernet switch, hardware, and cable modem. The control components shall be modified to be an integrated system that includes all accessories necessary for operation.

The Integrator shall assemble the system to provide both telephone and cable communications to the Freshwater Treatment Plant Control Panel (PCP-23). The Integrator modifying PSCP400 shall also provide the As- Built drawings of the PSCP as supplied by the panel fabricator to reflect the changes.

2. Modify an existing Freshwater Treatment Plant Control Panel (PCP) consisting of a PLC, Ethernet switch, hardware, and cable modem. The components shall be modified to be an integrated system that includes all accessories necessary for operation. The Integrator shall assemble the system to provide both telephone and cable communications to the Deluge Pump Station Control Panel (PSCP-400). The Integrator modifying PCP- 23 shall also provide the As-Built drawings of the PCP as supplied by the panel fabricator to reflect the changes.

3. Provide control system configuration services. This shall include development of all configurations for all equipment required by this specification. This shall include but not be limited to the following:

a) Configuration of new telephone Telemetry services

b) Coordination of new telephone Telemetry services

c) Continued operability of existing cable modem.

4. Provide startup services.

5. Provide system commissioning.

6. Provide complete training on the system to operations staff.

1.06 PUMPSTATION CONTROL PANEL OPERATION SCOPE

The current control panel (PSCP400) currently consists of a cable modem that is used to communicate between this facility and the Fresh Water Treatment Plant. Due to the lack of reliability of this system throughout the year, a plan has been devised to determine if a telephone modem is more reliable in this situation. The integrator is to modify the existing panel by providing a separate telephone modem with communications to the FWTP in addition to the existing cable modem.

A. The pump station control panel shall support the following:

1. Deluge Pump Station.

B. The modifications to the local control panel shall not affect the existing controls or telemetry of the panel. The Integrator is specifically prohibited from adversely affecting the existing controls in PSCP400.

C. The Integrator shall configure all systems required for communications. This shall include but not be limited to:

1. The Telemetry System as required for communications between the Fresh

Water Treatment Plant and Deluge Pump Station.

1.07 FRESHWATER TREATMENT PLANT CONTROL PANEL OPERATION SCOPE

The current control panel (PCP-23) currently consists of a cable modem that is used to communicate between the Fresh Water Treatment Plant and Deluge Pump Station. Due to the lack of reliability of this system throughout the year, a plan has been devised to determine if a telephone modem is more reliable in this situation. The integrator is to modify the existing panel by providing a separate telephone modem with communications to the FWTP in addition to the existing cable modem.

A. The freshwater treatment plant control panel shall support the following:

1. Freshwater treatment plant.

B. The modifications to the local control panel shall not affect the existing controls or telemetry of the panel. The Integrator is specifically prohibited from adversely affecting the existing controls in PCP-23.

C. The Integrator shall configure all systems required for communications. This shall include but not be limited to:

1. The Telemetry System as required for communications between the Fresh

Water Treatment Plant and Deluge Pump Station.

1.08 STANDARDS AND CODES

A. All equipment and materials shall conform to the latest revised editions of applicable standards published by the following organizations:

1. American National Standards Institute (ANSI)

2. Institute of Electrical Manufacturers Association (IEMA)

3. National Electrical Manufacturers Association (NEMA)

4. Underwriters Laboratories Inc. (UL)

5. International Society of Automation (ISA)

6. National Fire Protection Association (NFPA 70)

B. All electrical equipment and materials, and the design, construction, installation, and application thereof shall comply with all applicable provisions of the National Electrical Code (NEC), the Occupational Safety and Health Act (OSHA), and any applicable Federal, State, and local ordinances, rules and regulations.

C. All materials and equipment specified herein shall be approved by the Underwriters Laboratories Inc. for the purpose for which they are used and shall bear the testing agencies’ label. The control panel shall bear a UL label for the completed, assembled panel.

1.09 INTEGRATION WITH OTHER EQUIPMENT AND DEVICES

A. Compatibility responsibility

1. The Integrator shall be completely responsible for the integration of the local control panel with all instrumentation, equipment and devices as indicated and implied by the plans and these specifications. The Integrator shall define specific electrical control characteristics of all equipment and devices, shall define requirements for and furnish all interfacing devices, and shall define specific requirements for interconnecting wiring.

2. Only equipment and devices with electrical control characteristics as defined by the Integrator of the local control panel shall be installed.

Equipment and devices with electrical control characteristics other than as defined by the Integrator shall be removed and proper equipment and devices shall be installed at no additional cost to the Owner.

B. The final selection of equipment and vendors is provided by the Integrator. The Integrator shall provide coordination of the selected equipment with the panel prior to submission of the submittal drawings to ensure panel IO, and circuitry are compatible. This coordination shall include, but not be limited, to the following:

1. Coordination of the panel and the main headquarters telemetry equipment shall be the responsibility of the Integrator.

2. Coordination of the PLC – radio modem communications shall be the responsibility of the Integrator. Existing PLC ports are as shown in Part 3.

1.10 SUBMITTALS

A. The Integrator shall develop and submit to the Engineer, for review and approval, the following within 30 days of contract award:

1. Three project examples of jobs of similar scope and complexity with references.

2. Provide examples of HMI display screens (screen shots) the Integrator has developed.

3. PLC programmer certification or resume.

B. The Integrator shall develop and submit to the Engineer, for review and approval, the following project data prior to panel modification:

1. A schedule of materials for the system, listing all equipment and components to be provided.

2. Technical data sheets for all components.

C. The Integrator shall develop and submit to the Engineer, for review and approval, the following project data prior to substantial completion:

1. Testing documentation for the performance testing.

2. O&M Manual per requirements of the O&M Specification section.

1.11 WARRANTY

A. The Integrator shall guarantee each system to be free of defects in design, materials and workmanship for a period of one (1) year following the date of acceptance, by formal action of the Owner, of all work under the contract.

B. As part of the guarantee, the Integrator shall indemnify and hold harmless the Owner, the Consultant and their officers, agents and employees against and from all claims and liability arising from all damage and injury due to defects in the control systems.

C. The Integrator shall make any and all repairs, replacements, modifications and adjustments within one (1) week of notification. Should the Integrator fail to respond within 36 hours or fail to complete the work within a timely manner, the Owner may proceed to undertake or complete the work. In such event, the Integrator shall be liable for all costs incurred by the Owner.

1.12 TESTING

A. Performance Verification Testing

1. The Integrator shall test all telemetry functions of the local control panel.

B. 7-Day Acceptance Testing

1. Following the performance verification testing and the operator training the Owner shall continuously test the local control system for a period of seven (7) days. The test shall include the requirements for complete site functionality to include all instrumentation, control, and operator interface issues. The Integrator shall not be permitted onsite during this test;

modification of any systems shall restart the 7-day acceptance test.

2. The Owner will maintain an observation log of system performance during this phase of testing. The observation log shall be reviewed with the Integrator. At the Owner’s discretion, waivers may be issued and recorded to clear specific observation if the Integrator explains how the observed behavior does not materially affect the required functionality or performance of the system.

3. All deficiencies shall be corrected and retested unless waived by the Owner.

4. Successful completion of the 7-day acceptance testing is required before the system shall be considered substantially complete.

1.13 OPERATION AND MAINTENANCE (O&M) DATA

A. The Integrator shall prepare and assemble detailed operation and maintenance (O&M) manuals. The manuals shall contain data for the panel, which shall include but not be limited to the following:

1. Preventative maintenance procedures

2. Trouble-shooting

3. Calibration

4. Testing

5. Replacement of components

6. Automatic mode operation

7. Manual mode operation

8. System schematics

9. As-built wiring diagrams

10. Catalog data and complete parts list for all equipment and control devices

11. Listing of recommended spare parts

12. Listing of recommended maintenance tools and equipment

PART 2 – PRODUCTS

2.01 TELEMETRY MODEM

A. The telemetry modem shall integrate with the PLC to provide communication with district main headquarters and other PLCs in the Freshwater Treatment System.

B. The modem shall support leased telephone line operation.

C. The modem shall support the Bell 202 carrier interface protocol.

D. The modem shall support Point-to-Multipoint and Point-to-Point operation modes.

E. The modem shall have an operating temperature range of 0 to 60 degrees C or better.

F. A connection shall be provided from the existing SLC-5/05 to the telephone modem. The Contractor shall verify the cable type prior to purchase.

G. The telemetry modem shall be Data-Linc Group LLM1100 or approved equal.

The modem shall be compatible with existing headquarters modems. The telemetry modem shall be of the same make and model as used in related sections, to ensure compatibility.

PART 3 – EXECUTION

3.01 INSTALLATION

A. In accordance with the installation drawings and instructions prepared by the Integrator, the Integrator shall install the modem into the existing panel.

Technicians who are skilled and experienced in the installation of electrical systems and control panels shall perform the installation.

1. This shall include all necessary hardware and accessories as required to securely mount the modem inside the panel without adversely affecting the existing controls and equipment inside the panel.

B. Installation shall include all elements and components of the telemetry system as well as interconnecting wiring between the modem and the existing PLC. All wiring shall be labeled at both ends for ease of servicing.

1. This shall include all necessary hardware and accessories as required to securely power the modem from the panel’s existing uninterruptable power supply without adversely affecting the existing controls and equipment inside the panel.

3.02 INSPECTION AND VERIFICATION OF INSTALLATION

A. After completion of the installation of control panel, the Integrator shall inspect the installation and verify that all components and wiring are correctly installed.

The Integrator shall determine the exact scope and nature of work required to correct deficiencies and errors in the work and shall supervise the performance of such work.

3.03 CALIBRATION AND STARTUP

A. The Integrator shall calibrate all components of the panel after completion of installation. Each component shall be adjusted to be within the required range and for the specific application. Components that cannot be properly calibrated or that are found to exceed the specified range or accuracy shall be removed and replaced.

B. The Integrator shall place the modem into operation. This startup process entails verifying that the headquarters PLC can send and receive data and instructions to and from the panel PLC via either the new modem or the existing modem.

1. The two telemetry channels shall be independent of each other, so that a failure of one channel shall not negatively impact the functioning of the other channel.

2. The Integrator shall configure the PLC to track and monitor uptime for both communications channels separately, so that uptime and reliability for each channel can be compared to the other.

C. The Integrator shall be solely and completely responsible for all maintenance of the systems from time of start-up to the date of acceptance, by formal action of the Owner, of all work under the contract. The Integrator shall correct all deficiencies and defects and make any and all repairs, replacements, modifications and adjustments as malfunctions or failures occur. The Integrator shall perform all such work required to cause and maintain proper operation of the system and to properly maintain the systems.

D. The Integrator shall anticipate that the Owner may delay acceptance of all work under the contract if, in the judgment of the Owner, malfunctions or failures in operation of the control panel occur after start-up. The Integrator shall not be entitled to an extension of time or to any claim for damages because of hindrances, delays or complications caused by or resulting from delay by the Owner in accepting the work because of malfunctions or failures in operation of the panel.

3.04 OPERATION AND MAINTENANCE TRAINING

A. The Integrator shall conduct specifically organized training sessions in operation and maintenance of the control panel for personnel employed by the Owner. The training sessions shall be conducted to educate and train the personnel in maintenance and operation of all components of the panel. Training shall include, but not be limited to, the following:

1. Preventative maintenance procedures

2. Troubleshooting

3. Calibration

4. Testing

5. Replacement of components

6. Automatic mode operation

7. Manual mode operation

B. A training session of at least one (1) hour in duration shall be conducted at the site (after start-up of the systems) concerning instruction and operation of the control panel and all associated electrical equipment and devices. The Integrator shall prepare and assemble specific instruction materials for the training session and shall supply such materials to the Owner at least four (4) weeks prior to the time of the training.

END OF SECTION