MPAWT_PLC5_Upgrade_Scope.docx

Bay County AWWTF PLC Upgrades

Project No.:

April 16, 2026 Bay County Advanced Waste Water Treatment Facility (AWWTF) PLC Upgrades Scope of Work and Technical Specifications (Revised: 4/16/26)

PART 1 — GENERAL

1.01 PLC Components Replacement Scope

A. Work includes: Furnish and install new PLC and associated I/O modules and power supplies for each location identified herein.

B. For each PLC replacement, Contractor shall:

a. Download and review existing program.

b. Provide all programming required to develop program for new PLC to completely match the function of the existing PLC.

c. Perform all testing to verify complete functionality of new program prior to installation.

d. Duplicate or develop new tag numbers as required for complete compatibility with existing systems that are not being replaced.

e. Perform "Factory Acceptance Test" as required to validate all programming. Owner shall be notified of test a minimum of 7 days in advance and provide the opportunity to attend in person or virtually.

f. Provide demonstration test on site prior to "cutover" from existing PLC to new PLC and associated components.

g. Coordinate schedule for cutover with Owner. Maximum downtime on process shall be 12 hours.

h. Provide all updated documentation for new PLC and associated components. This documentation shall include all drawings in CAD and PDF format, software program in digital format acceptable to the Owner, O&M manuals for all components, model numbers of all components for Owner's records.

i. New program shall be provided as version 36.

C. For each panel/location, Contractor shall furnish the replacement PLC (Allen-Bradley CompactLogix 5380 series).

D. Contractor shall also furnish and install replacement power supply and I/O modules as identified herein.

E. PLC Replacement panels/locations include:

a. BNR PLC

1. Replace Allen-Bradley PLC-5/30A PLC with Allen-Bradley CompactLogix 5380 Series PLC.

2. Replace existing power supply with power supply compatible with new PLC.

3. Replace 3 Analog Input Modules with Discrete Input Modules compatible with new PLC.

4. Replace 2 Analog Output Modules with Discrete Output Modules compatible with new PLC.

b. PLC 1

1. Replace Allen-Bradley PLC-5/30A PLC with Allen-Bradley CompactLogix 5380 Series PLC.

2. Replace existing power supply with power supply compatible with new PLC.

3. Replace 7 Discrete Input Modules with Discrete Input Modules compatible with new PLC.

4. Replace 1 Discrete Output Modules with Discrete Output Modules compatible with new PLC.

5. Replace 2 Analog Input Modules with new Analog Input Modules compatible with new PLC.

6. Replace 2 Analog Output Module with new Analog Output Module compatible with new PLC.

Sub b. Replace associated remote I/O

1. Replace existing power supply compatible with new PLC.

2. Replace 2 Discrete Input Modules with Discrete Input Modules compatible with new PLC.

3. Replace 1 Discrete Output Modules with Discrete Output Modules compatible with new PLC.

4. Replace 1 Analog Input Modules with new Analog Input Modules compatible with new PLC.

5. Replace 2 Analog Output Module with new Analog Output Module compatible with new PLC.

c. Effluent PLC

1. Replace Allen-Bradley SLC 5/05 PLC with Allen-Bradley CompactLogix 5380 Series PLC.

2. Replace existing power supply with power supply compatible with new PLC.

3. Replace 4 Discrete Input Modules with Discrete Input Modules compatible with new PLC.

4. Replace 2 Discrete Output Modules with Discrete Output Modules compatible with new PLC.

5. Replace 4 Analog Input Modules with new Analog Input Modules compatible with new PLC.

6. Replace 2 Analog Output Module with new Analog Output Module compatible with new PLC.

1.02 RELATED WORK

A. The following listing of related sections may also apply and be required for proper performance of this work.

a. Section 16010 — General Provisions, Electrical

b. Section 16075 — Electrical Identification

c. Section 16123 — Wire and Cable

d. Section 16131 — Conduit

e. Section 16138 — Boxes

f. Section 16139 — Cabinets and Enclosures

1.03 REFERENCE STANDARDS

A. NFPA 70 — National Electrical Code (NEC) B. ISA-55.4 — Instrumentation Society of America (ISA) C. UL-508A — Underwriters Laboratory Industrial Control Panel Certification D. UL-698A — Underwriters Laboratory Industrial Control Panel Certification

1.04 QUALITY ASSURANCE

A. The modification to the existing PLC Control panels as specified in this section shall be integrated systems and shall be provided by a single supplier that is responsible for the proper operation of the entire system.

B. For standardization and quality purposes the following System Suppliers are pre-approved for the hardware integration portion: 1.) Vyper Automation; Greg Kumpula; (407) 335-0311.

C. The following criteria must be met by the System Integrator.

a. A minimum of Ten (10) years' experience performing similar work for municipalities. A list of references shall be provided with submittal.

b. Shall have been in business a minimum of Ten (10) years operating under the same company name.

c. Be advanced certified on VTScada.

D. Provide or supply all hardware and software specified herein. Provide all required and specified collateral services in connection with the system such as testing, calibration, startup, operation and maintenance manuals, and operator training without additional cost to the OWNER.

E. The System Supplier shall be responsible for coordinating with the CONTRACTOR to obtain all necessary data from individual manufacturers to determine the necessary transition for operation, control and/or monitoring from the manufacturer's equipment.

F. All materials, equipment sizes, and capacities shall conform to the requirements of the NEC, the National Electric Manufacturer's Association, and to applicable regulations of the local electric codes.

G. All materials and equipment must be UL listed and Control Panels must be UL-508A certified or UL-698A certified for and all control panels with intrinsic safety barriers or hazardous locations.

1.05 RESPONSIBILITY FOR COMPLETE SYSTEM

A. The System Supplier shall be responsible for and shall provide for the design, supply, delivery, installation, certification, calibration and adjustment, software configuration, testing and start-up, of a complete, coordinated system. A single supplier shall provide the PLC System upgrades including software.

B. The System Supplier shall design and furnish a complete, integrated, and functionally operational system, warranted to perform the intended functions as herein specified.

1.06 SUBMITTALS

A. Submit shop drawings and product data in accordance with Owner's requirements.

B. Submit full technical data complete with manufacturer's published data.

C. Submit manufacturer's descriptive literature, operating instructions, and maintenance and repair data with an Equipment Data Sheet showing the exact part or model number with descriptive break down of the model number. All pertinent information shall be included on the Equipment Data Sheet.

D. Submit manufacturer's schematics and system layout drawings which shall include the following:

E. Hardware Submittals:

a. Provide a block diagram and description of the system configuration showing all components and their interconnections etc. Label each diagram and specify all external power and communications interfaces. All diagrams shall be 11x17 format and be developed in latest version of AutoCAD in DWG file format.

b. Provide an equipment list with descriptive literature identifying component name, manufacturer, model number, a description of the operation, quantity supplied and any special characteristics.

c. Drawings of equipment to be supplied shall include, as a minimum, overall dimension detail for each panel, console, etc., including internal and external arrangements and door mounted operator devices with nameplate

d. designations. Elementary and wiring diagrams of equipment including field device connections shall be included with specific installation/wiring requirements identified. Provide detailed bills of materials with spare parts provided.

F. PLC Submittals:

a. PLC System Diagram: Provide a diagram showing all PLC and network components. Show the exact PLC rack layout with details of the actual modules used and filler plates for spare slots. Identify components by manufacturer and model number. Show interconnecting cables with pin out details or model numbers of PLC manufacturers cables.

b. Bill of Materials: A list of all components. Group components by type and include:

1. Component manufacturer, model number and part number.

2. Component description.

3. Quantity supplied.

4. Reference to tag on drawings.

c. Descriptive Information: Provide catalog information, descriptive literature, performance specifications, internal wiring diagrams, power and grounding requirements, power consumption, and heat dissipation for all the equipment. Clearly mark all options and features proposed for this project.

d. Interconnecting Wiring Diagrams: Provide diagrams that shall show all PLC and control panel components, their interconnecting cables, wiring terminations, and terminations to all interacting elements and subsystems. Terminations shall be numbered.

e. Outline Drawings: Provide equipment drawings showing external dimensions, enclosure materials, conduit connections, and installation requirements.

f. Installation Details: Provide any modifications or further details as may be required to supplement the Contract Documents and adequately define the installation of the PLC.

g. Input/output List: Provide for each I/O point list point type, tag number of the source or final control element, equipment description, PLC number, terminal identification, and address.

1.07 PLC OPERATION & MAINTENANCE MANUALS

A. Provide complete Operation and Maintenance Manuals for the PLC in an open software format. At a minimum the O&M shall include:

B. Component Manufacturers' O & M Manuals: Include manuals to cover installation, operations, maintenance, troubleshooting, and calibration.

C. Operating instructions shall incorporate a functional description of the entire system, including the system schematics that reflect "as-built" drawings.

D. Provide system architecture diagram showing network communications including but not limited to all PC's, PLC's, switches, cables, etc.

E. List of spare parts and expendables provided.

F. Panel equipment, field devices, and instruments data sheets, including complete "bill of materials" of PLC's, control panel devices, computers, printers, software, field equipment, etc.

G. Communication Network Cable Testing documentation with the actual tests of each fiber after terminations. All cable data shall be included on the form including but not limited to cable manufacturer, part number, cable tag and location, fiber number and color, testing procedures, test equipment utilized, actual readings and results, and personnel name with time and date the testing was performed.

H. Digital copy of final configuration files, backups of system files and PLC programs.

I. Complete operator instructions for all PLC components including download instructions with details for functions and data entry.

J. Point lists for PLC inputs/outputs. Identify point number (tag), point description, point type, range in engineering units (if analog point), PLC number, rack and slot number, and point address.

K. The complete electronic O&M shall be provided with an easy-to-use index and bookmarks for CAD drawings, Equipment Data Sheets, software or equipment manufacturers O&M literature, etc. Clicking on an item on the index shall immediately display the Equipment Data Sheet and software or equipment manufacturers O&M for the item. Likewise clicking on a drawing shown on the index shall display the drawing. Other functions at a minimum shall include search, zoom and print page or selection features. All contents of the O&M may also be displayed with thumbnails. Clicking on the thumbnail shall immediately display the item, i.e. drawing, Equipment Data Sheet, instruction literature, etc.

1.08 PLC PROGRAMS, AUTOCAD DRAWINGS AND DOCUMENTATION

A. All programs and configuration files developed and utilized for the project shall be owned by the end user. All programs and configuration files shall be provided to the OWNER in their documented form and in their native file format. This includes but is not limited to: PLC components.

B. Provide all drawings in native (DWG) and PDF file formats.

C. Provide all PLC I/O lists in Excel file format.

1.09 SOFTWARE LICENSES

A. Purchase any required software packages (PLC Programming or other) required for the system in the name of the authorized end user. All software shall be delivered to the OWNER with original disks and in its original box.

1.10 FACTORY TESTING BY A QUALIFIED PROFESSIONAL

A. The factory testing will be observed and certified by a qualified professional that is a full-time employee of the System Supplier.

B. Develop and submit a test plan, testing documentation and QA/QC check lists specific to the project requirements and each control panel or PLC. Test all specific functions, I/O and control loops, etc. Test all specific functions including, but not limited to, the following:

a. Failure mode and backup procedures: power failure, auto restart, disk backup and reload, retentive outputs.

b. All network communications.

c. Operator Interface Terminal (OIT), all functions.

d. Completely simulate all possible field conditions and run in fully automatic and manual.

e. Simulate all existing systems being interfaced to with new programs and configurations. The System supplier must own or acquire all hardware required for the simulation.

f. Provide certified factory testing documents showing all tests performed and results achieved.

C. Submit the completed certified factory testing documents showing all tests performed and results achieved plus all QA/QC check lists prior to shipment of the system, control panels and or PLC. The documents shall be signed by the qualified professional. The certified documents must be approved prior to shipment.

D. Invite the CONTRACTOR and OWNER to observe the factory testing of the system. A two-week notice of the testing date shall be provided.

1.11 PROCESS CONTROL STRATEGY DESIGN MEETING AND SUBMITTALS

A. A video conference process control strategy design meeting shall be held with the OWNER's personnel to discuss specific details of the control strategies, HMI graphics, trends, I/O and SCADA System functions that are to be developed for the system.

B. Prior to the meeting the System Supplier shall submit a detailed narrative for each of the proposed control strategies to the OWNER for review.

C. A follow up video conference process control strategy design meeting shall be held with the OWNER's personnel within two weeks of the first one to review the final control strategy and demonstration of the HMI graphics.

1.12 OPERATIONS, HARDWARE & SOFTWARE MAINTENANCE TRAINING

A. After the project substantial completion, provide two instructor days of onsite for the OWNER's personnel in the operation of the System and software and hardware training for the OWNER's maintenance technicians in the maintenance of the system hardware and software. Training shall include:

a. Standard operational features of HMI, OIT and PLC equipment provided.

b. Operation of each function or mode: For example, AUTO/MANUAL control, control set point settings, control mode selection, alarm acknowledgment and Constant Speed modes.

c. Interfaces with other controls and systems.

d. Standard hardware features of the HMI, PLC, OIT and field instrumentation, etc.

e. Specific training for the actual hardware configuration provided.

f. Test, adjustment, and calibration procedures.

g. Hardware troubleshooting, component removal and replacement, and periodic

h. maintenance.

i. Standard software features of all software provided, including but not limited to HMI, PLC and OIT programming software.

j. Software troubleshooting, backups, restores, loading software and periodic maintenance.

k. Software O&M functions and features.

B. Training sessions shall be video recorded and provided to the OWNER. Training sessions shall be recorded in a digital media format and shall be capable of playing on any computer or tablet environment.

C. Submit a training outline and agenda of specific topics and time to be used for each topic.

1.13 PRODUCT DELIVERY, HANDLING AND STORAGE

A. Comply with manufacturers' recommendations for delivery, handling, and storage.

B. Schedule the delivery of the equipment to coordinate with the project completion schedule.

C. Equipment shall be delivered by the System Supplier or a representative shall be onsite to observe and inspect the unloading of all the equipment by the CONTRACTOR.

D. Each item of equipment shall be tagged with identifying number shown on the Shop Drawings visible after packaging.

E. General CONTRACTOR's attention is directed to the fact that equipment has delicate components and extreme care shall be taken in handling to avoid internal and/or external damages.

F. Damaged equipment will not be accepted. Damaged equipment by the GC unloading or by inadequate storage shall be replaced by the GC. Damaged equipment prior to delivery or in transient shall be replaced by the System Supplier.

G. Equipment not for immediate use shall be stored inside an environmentally controlled building with heat and air conditioning systems, with enclosures under protective coverings and shall be fully protected from moisture, extreme heat and vibration.

1.14 FIELD TERMINATIONS AND COMMUNICATION NETWORK CABLE INSTALLATION AND TESTING

A. All network wiring related conduit shall be provided and installed by the Electrical CONTRACTOR (EC). All copper and fiber network cable (i.e. Fiber Optic; CAT 6 Ethernet; CAT 5E Ethernet) shall be provided and terminated by the System Supplier.

B. The EC shall terminate all signal instrumentation cables for all field instrumentation.

C. The EC shall be responsible for properly and professionally labeling all cables and shall assist the System Supplier as needed to locate and troubleshoot the field wiring during terminations and testing.

D. All required fiber optic cable fibers shall be terminated and tested by the System Supplier. The System Supplier must provide certified training documentation for the System Supplier personnel performing the terminations and testing. Testing documentation shall be provided to prove the actual tests of each fiber after terminations. All cable data shall be included on the form including but not limited to cable manufacturer, part number, cable tag and location, fiber number and color, testing procedures, test equipment utilized, actual readings and results, and personnel name with time and date the testing was performed.

E. The completed Record Documentation shall be included in all forms of the O&M Manuals.

1.15 SERVICE REPORTS

A. Service reports shall be provided for each day that a representative of the System Supplier is on site. The service reports shall include all tasks performed, time on site, instrument tags, instrument service and etc. Instrumentation Calibration Worksheets shall be provided and attached to the associated service reports.

1.16 WARRANTY

A. Systems supplier shall furnish a one-year onsite warranty for the system, providing for a 24-hour response time in normal working hours, five days per week for the length of a one-year warranty period.

B. For any service visit during this period, provide the OWNER with a written report stating the reason for equipment failure and recommendations to prevent recurrence.

PART 2 — PRODUCTS

2.01 GENERAL

A. All equipment and materials shall be new, unused and proven by previous use of similar products to be completely suitable for the service intended.

B. All of the equipment shall be the manufacturer's latest and proven design. Specifications and drawings call attention to certain features but do not necessarily cover all details for the design of the System.

C. Mount process indicators and Operator Interface Terminals (OIT) at eye level, 60" from floor to centerline of instrument.

D. Panel wiring for all 4-20mA analog input signals shall be two-conductor, shielded cable with drain. Cable and connectors shall be Belden No. 8760, UL Style 2092, 20 AWG minimum, or equal. Single conductors shall be tinned copper with 600V insulation, gauge as required.

E. PVC wiring duct shall be provided as required and shall have removable non-slip covers. Wiring duct shall contain 50% spare space. Wiring duct must be mounted with machine grade screws. Plastic and/or aluminum rivets are not acceptable. For consistency and standardization, wiring duct shall be by Panduit Corporation, no exceptions, color gray. All wiring in control enclosures not in wiring duct shall be bound with continuous type spiral windings or neatly bound with tie wraps not less than two inches apart consistently and shall not allow the shown wires to cross each other within the bundle.

F. All equipment mounted within the PLC enclosure shall be mounted on the enclosure back panel, neatly organized, labeled with a tag as shown on OWNER-approved control panel drawings and shall be in accordance with the manufacturer's recommendations.

G. All field wiring shall be mounted either at the bottom or side of the enclosure back panel, depending on where the I/O conduits penetrate the enclosure.

H. The field wiring terminals and panel wires shall be clearly labeled and identified and shown on the panel drawings.

I. Jumpers between adjacent terminal blocks shall be tinned copper jumper bars supplied by the terminal block manufacturer.

J. Interconnection drawings shall be provided along with wire numbers, terminal numbers, equipment tag numbers and panel physical layout drawings.

K. All systems and individual components, whether panel or field mounted units, that are located in different areas of the plant, one inside building to device outside of building, shall be protected from voltage and/or current surges.

L. Provide a surge protection device "SPD" for 12OVAC power entering all PLC cabinets. The SPD shall be SSI model USPT1P1DIN-21. Units shall be DIN rail mounted. Units shall be listed to UL1449 current addition.

M. Provide a surge protection device "SPD" for all analog 4-20mA signal circuits entering PLC or control cabinets. The SPD shall be SSI model CLP###AxDIN-B-21 (### equals voltage, x equals number of wires i.e. 2, 4, or 6). Units shall be listed to UL497B and shall be DIN rail mounted.

N. Control and instrumentation power supplies shall be adequately sized to provide 150% of that as required by the equipment served.

O. The input and output of each separate DC power supply shall be individually fused with easily accessible DIN-rail mounted fused switch. Provide separate fused disconnects for each PLC, OIT, each DC power supply, etc.

P. All power supplies shall be DIN Rail mounted and shall have screw terminals for all connections. Solder type connections will not be allowed. All screw terminal connections shall be finger safe.

Q. All pushbuttons, selector switches, and pilot light units shall be heavy duty, 30.5mm, NEMA type 4/4X, corrosion resistant, bulletin 800H by Allen-Bradley.

R. Terminal strips shall be mounted using DIN rails. Terminal strips shall be as manufactured by Wiedmueller, Phoenix, Entrelec, or approved equal.

S. All digital inputs shall be isolated from field wiring through terminal strips and 24 VDC, interposing mechanical relays, no exceptions.

T. All digital outputs, including spares, shall be isolated from field wiring through terminal strips and 24 VDC, interposing mechanical relays.

U. All mechanical control relays shall be DIN rail mounted. Minimum contact rating for mechanical control relays shall be 10 Amps at 250 VAC. All control and auxiliary relays shall have LED indicator and test actuators. Control relays shall be Finder series 55 with Finder series 94 Relay Base Socket.

V. Provide a main circuit breaker for power service with a through the door or dead front door handle operation. Main circuit breaker shall be by Eaton or Siemens.

W. If a control cabinet is not fed with 12OVAC available, provide a dedicated 2KVA transformer inside the control panel with circuit protection and dedicated circuit for a 12OVAC GFCI receptacle.

X. Provide Control Panel with UL-698A certification.

2.02 CONTROL PANEL ENCLOSURES

A. Provide NEMA 1 rated enclosure with 3-point locking latch. Provide enclosures as wall mounted according to drawings and based on physical characteristics and limitations. All PLC cabinets shall be dead front constructed with door in door. Enclosures shall be manufactured by Saginaw or Hoffman.

2.03 HUMAN MACHINE INTERFACE SOFTWARE (HMI)

B. As applicable, Modify the existing VTSCADA System and HMI software for all additions and provide the required process graphic screens, database tags, trending and historical data per the request of the OWNER.

PART 3 — EXECUTION

3.01 GENERAL

A. All control by the System shall be distributed to the local PLC and shall be capable of operating in an automatic mode completely independent of the OIT or SCADA HMI.

B. Where setpoints, operating limits, and other control settings are provided by the functional descriptions, these settings shall be initial settings only. The Contractor/Integrator shall utilize the existing parameters for the initial settings in the new program/PLC. All such settings shall be fully adjustable and based on actual operating conditions.

C. Provide PLC programming standardization for communications, messages and data tables for addressing all discrete, analog signals and data from all remote and local AWWTF PLC's.

END OF SECTION

PLC Upgrades - 1