Specs.pdf

NAVAL AIR SYSTEMS COMMAND 4.4.6.5

PROPULSIONS SYSTEMS EVALUATION FACILITY

Technical Requirements for Propulsions Systems Evaluation Facility Rotor Spin Facility

Distributed Control System

Andrasik, Donald Anthony CTR AD

9/14/2017

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Project Description ………………….………………………………………………….. 01

General Scope…….……………………………………………………………………… 01

Scope of Work – DCS –Cost Breakout.………………………………………………… 03

Codes and Standards…………………………………………………………………….. 05

General Information…………………………………………………………………….. 06

Facility Description……………………………………………………………………… 06

Party Definitions………….…………………………………………………………….. 07

Owner/ Buyer Project Contacts……………………………………………………….. 07

Definitions ………………………………………………………………………………... 07

General Requirements …………………………………………………………………... 10

Engineering ……………………………………………………………………………… 11

Environmental…………………………………………………………………………… 12

Power……………………………………………………………………………………… 13

Data Collection History and Monitoring ……………………………………………… 14

I/O……………………………………………………………………………………...….. 14

Control Processors……………………………………………………………………….. 16

Control Configuration and Programming…………………………………………….. 17

User Interfaces……………………………………………………………………………. 20

Display Graphics and Trending………………………………………………………… 21

Alarming………………………………………………………………………………….. 22

IT, IT Security…………………………………………………………………………….. 23

Service-ability……………………………………………………………………..……... 23

Warranty …………………………………………………………………………

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Vendor Exceptions………………………………………………………………………. 24

Schedule ………………………………………………………………………………… 24

Documentation Requirements……………………………………..………………….. 24

Technical Scope of Deliverables “Single” DCS………………….……………………. 25

DCS Scale-ability Capabilities of Hardware and Function…………………………. 26

Bidders Proposal Requirements…………………………………………………………29

Attachment 1 – Separate Listing Options Costs..…………………………………….. 30

Attachment 2 – Simplified P&ID – Speed Control.…………………………………… 31

Page 1 of 31 DCS - Technical Requirements, Budg_Proposal_Req DAA 09/14/2017

1. Project Description:

This project is for the replacement of an existing compressed air, bi-directional, turbine speed control systems in a combustion turbine Rotor Spin Facility (RSF). The

Distributed Control System (DCS) supplier shall deliver the hardware, software, documentation and instructions for a system meeting the technical requirements as presented within this specification. Cabinets, including card and module enclosures, are not part of this project. Project Management, Installation, I/O configuration, Continuous Control Configuration, Sequential Control Configuration, Supervisory

Control Configuration, logic and graphic development to be performed by the buyer.

2. General Scope:

2.1. This specification covers the design, integration, testing, and delivery FOB destination, of a complete Distributed Control System as described henceforth.

2.2. Certain technologies are identified as mandated. However, generally this specification is a full performance and functional description of the DCS. It defines the system performance and functional requirements necessary to ensure the following:

2.2.1. Delivery of an open, interoperable system on the Workstation level that is capable of digital communication to other systems over Ethernet.

2.2.2. Delivery of a fully serviceable system where the owner “owns” the system. Such that a delivered system does not require the vendor for maintenance, or configuring control functions, and does not require periodic licensing fee.

2.2.3. Delivery of a system with full functionality and performance with incorporated system security requirements as defined by Owner’s

Information Technology (IT) department.

2.2.4. Inhibits vendor closed proprietary system elements in regards to buyer use of control configuration implementation, historian data utilization etc.

2.2.4.1. Ensures the DCS Supplier delivers a working system in which the owner/ purchaser has all of the instruction, software, and tools to perform their own: application engineering, control configuration, control implementation, graphic implantation, control configuration backup, DCS - Technical Requirements, Budg_Proposal_Req DAA 09/14/2017 workstation backup, as well as maintenance module replacement, and service.

2.2.5. Provides for competitive bidding on the initial delivery of the system as well as future service contracts.

3. Scope of Work – DCS -Cost Breakout

3.1. Vendor shall supply all material, software, system configuration and documentation to deliver a fully operational system as described in this specification:

3.2. Bidder may provide optional suggestions and costs as a separate listing.

3.3. Bidder shall provide firm price proposal for project with breakout cost of sections as listed:

3.3.1. Software Cost:

3.3.1.1. All licensed conveyed software installed, to include functions as described with specification.

3.3.2. Hardware Cost of:

3.3.2.1. Operator Workstation

3.3.2.2. Engineer Workstation

3.3.2.3. AC Power switching for Workstations.

3.3.2.4. One (1) pair Fault Tolerant Controlling Processors w/ licensing.

3.3.2.5. Minimum of 3 pulse inputs for speed measurement, on three separate modules or cards (1 pulse input per card or module).

3.3.2.6. Minimum of 56 Analog Inputs with user selectable 0.0 to 20.0 ma or 4.0 to 20.0 milliamperes signal ranges.

3.3.2.7. Minimum of 8 Analog Inputs 0.0 to 10.0 VDC

3.3.2.8. Minimum of 8 Analog Outputs with user selectable

0.0 to 20.0 ma or 4.0 to 20.0 milliamperes outputs.

3.3.2.9. Minimum of 8 Discrete Outputs rated for 120 VAC

capable of at least 5 amperes, or 24 VDC at 3 amperes.

3.3.2.10. Minimum 8 Discrete Inputs Voltage Sense for

120VAC.

3.3.2.11. All necessary and redundant power supplies for

control processors and I/O.

3.3.2.12. All mounting back planes, mounting plates.

3.3.2.13. All interconnection cables for fully operational

system.

3.4. System Configuration:

3.4.1. System Configuration shall include cost of factory and site setup hours.

3.4.1.1. Site Setup: Site Setup in this case includes: Powering all DCS sub-systems, verifying full communication to all sub-systems, verification of system functionality as called for in this specification. Note: All hardware to be installed, and all AC power will be readily available at location by buyer prior to this function. Schedule to be determined after delivery of DCS.

3.4.1.2. Estimated time (during normal business hours) and

the cost for on-site setup of hardware including travel and lodging.

3.4.1.3. Site setup cost shall not include application or control configuration engineering or development.

3.5. Documentation:

3.6. Shipping:

4. Codes and Standards:

4.1. All Alternating Current (AC) power and grounding shall comply with the national Electrical Code (NEC).

4.2. ANSI/ISA-5.1-2009, (American National Standards Institute)/ International

Society of Automation) Instrumentation Symbols and Identification.

4.2.1. Standard shall be utilized if optional control application configuration is requested by buyer.

4.3. ISA-TR5.1.01/ISA-TR77.40.01-2012 (R2016), Functional Diagram Usage

4.3.1. Technical report is to provide advice and guidance in documenting application software through functional diagrams, and shall be utilized if optional control application configuration is requested by buyer.

4.4. Control Processors sub-system and related power supplies shall comply, as applicable and called out in:

4.4.1. International Electrotechnical Commission (IEC) 61326-1, Ed 2.0

(EN61326-1:2013) Class A Emissions and Industrial Immunity Levels inclusive of:

4.4.1.1. International Special Committee on Radio Interference

(CISPR); Industrial, Scientific, and Medical Equipment

– Radio-Frequency Disturbance Characteristics –

Limits and Methods of Measurement CISPR 11

4.4.1.2. IEC 61000-4-2; Electrostatic Discharge, ESD Immunity

4.4.1.3. IEC 61000-4-3; Radiated Field Immunity

4.4.1.4. IEC 61000-4-4; Electrical Fast Transient/Burst

Immunity

4.4.1.5. IEC 61000-4-5; Surge Immunity on I/O and

communications lines

4.4.1.6. IEC 61000-4-6; Immunity to Conducted Disturbances

induced by Radio-frequency Fields DC power and communication lines

4.4.1.7. IEC 61000-4-8; Power Frequency Magnetic Field

Immunity

5. General Information:

5.1. Facility Location

5.1.1. Patuxent River Naval Air Station, Saint Mary’s County, Maryland

5.2. Mail Address:

Propulsion Systems Evaluation Facility Building 2360 Unit 4 22229 Elmer Road Patuxent River, MD 20670

6. Facility Description

6.1. Propulsion Systems Evaluation Facility (PSEF) is a facility owned and utilized by the United States Navy for various system, sub-system, and component testing, primarily, but not limited to fleet aircraft. Test articles include Navy, Marines, Air Force, Army as well as a variety of Commercial entities systems. In performing such tests data is collected and analyzed for determining performance, life cycle, and failure cause modes. Testing requires manual and automation of test article manipulation which include:

Continuous Regulatory Control, Sequence Control, Supervisory Control, Discrete Logic Control, etc.

6.2. Rotor Spin Facility (RSF) is one of several testing services within PSEF. RSF evaluates the structural and material aspects of gas turbine engine rotors under simulated conditions. RSF physical testing units consists of 4 vertical vacuum chambers, with 106”, 59”, 45” and 24” inside diameters located in adjacent rooms. A detached central control room houses the data acquisition systems, the control systems, tests engineers, and operator technicians for each of the respective chambers. Each chamber is fitted with compressed air driven turbines of various sizes that spin rotor stages and components of gas turbine engines. Automated sequences are performed for checking low cycle fatigue, and high cycle fatigue of various mechanisms. Complex mission cycles, and thousands of unmanned cycles may be run with rotational speed exceeding 100,000 Rotations Per Minute (RPM). See

Attachment #3 Simplified P&ID.

7. Party Definitions:

7.1. Owner/ Buyer: Department of the Navy, Naval Air Systems Command

4.4.6.5 Propulsions Systems Evaluation Facility (PSEF)

7.2. Vendor: The successful company who is awarded the contract, and who has accepted the Owner’s term and conditions.

7.3. Bidder: Those companies submitting bids for fulfilling the requirements of this project.

8. Owner/ Buyer Project Contacts:

8.1. Technical Point of Contact: Alex Merriweather, Phone: 301.757.3402

Donald Andrasik, Phone: 301.757.3412

9. Definitions:

9.1. Alarm: Notification of an abnormal condition.

9.2. Algorithm: A logical procedure for solving a recurrent mathematical problem.

9.3. Alternating Current (AC): Voltage in which the charge carriers in a conductor or semiconductor periodically reverse their direction of movement at a relative pre-defined period.

9.4. Analog: Continuous signal of data. In the case of this requirement a continuous signal of data measurement, or data output.

9.5. Analog to Digital Conversion (A to D, A-D): Method of measuring continuous signal in time and converting value into a digital measurement form.

9.6. Application Engineering: The engineering as related to configure control logic, sequences, and continuous control designs from available software algorithms to produce desired process results. This is performed by utilizing primary measuring devices and instrumentation, with physical output manipulation of end elements.

9.7. Binary: A two-state measurement and/ or computational system information is represented by on/ off, true/ false, or 0/ 1 etc.

9.8. Control Processor (CP): The digital processor running programs utilizing instrument data measurements, running algorithms, Boolean logic, and manipulating end element outputs for desired process responses.

9.9. Common Mode Rejection Ratio (CMRR): Rating of common mode noise rejection ratio; |Adm/Acm|, where Adm is gain differential mode, and Acm is gain common mode. Described in decibels (Db) as Db=20log10(Adm/Acm).

9.10. Compact Disk (CD): Optical digital storage medium in shape as a disc.

9.11. Data Acquisition System (DAS or DAQ): A system comprised of the necessary components for the capturing of analog and/ or discrete information from instrumented physical test articles. Information is inputted into the DAS in the form (in any combination) of analog electrical, discrete electrical, and electronic frequency. For the purposes of this specification the DAS will be of a digital computer type – digitizing, presenting and saving all inputted information as collected. The DAS is a separate system from DCS. However, the DAS and DCS shall share instrumentation data primarily through 4 to 20 milliamp loops.

9.12. Decibel A-weighted (dBA, dBa): Expression of the relative loudness of sounds in air as perceived by the human ear.

9.13. Decibel (Db, db, dB): A logarithmic unit used to express the ratio of two values. In the case of this specification Db is the ratio of voltage amplitude as expressed as Db=20log10(V1/V2).

9.14. Digital: A quantized measurement or output of a signal at a specific moment in time.

9.15. Discrete: A signal input or output usually utilized for on/ off control, or detection of on/ off (open/ close) action.

9.16. Distributed Control System (DCS): A digital control system for a process or plant, in which autonomous controllers are physically and functionally distributed, have I/O that can be physically and functionally distributed, and have an integrated engineering and operator interface.

9.17. Direct Current (DC): Voltage in which the charge carriers in a conductor or semiconductor flow in one continuous direction.

9.18. Digital Versatile Disc (DVD): Optical digital storage medium with higher storage capability as compared to a CD.

9.19. Sequence of Events (SOE) Recording: A combination of hardware and software capable of monitoring inputs and outputs providing time stamps of changes within a defined time resolution.

9.20. Graphical User Interface (GUI): A monitor, visual subset of operator interfaces.

9.21. Ground: An electrical connection to earth. Purpose is for electrical safety, and for instrument measurement reference.

9.22. Highway Addressable Remote Transduce (HART): Digital hybrid communication protocol utilized with 2 wire, 4 to 20 milliamp instruments.

9.23. Human Machine Interface (HMI),(GUI – Graphical User Interface): A graphical, object-oriented method by which an operator is capable of communicating with the system. The Human-Machine interface allows the operator to manage, control, monitor, and configure the system.

9.24. Hysteresis: The phenomenon in which a measurement, or final element position lags, or does not respond to, a change in the measured media or position demand, and is influenced by the previous measurement, or movement of the device.

9.25. Input/ Output (I/O): Designation for measured inputs and driven outputs of: analog voltage, current, and discrete forms.

9.26. Interoperable Open System: A digital computer system that has ability to communicate, execute programs, or transfer data via standard protocols to one or more other digital computer systems.

9.27. Inter-Range Instrumentation Group time codes (IRIG): Standard formats for transferring timing information.

9.28. Linearity: The measure of the extent to which a certain response is directly proportional to the applied measured media changes. This applies to an input measurement, and to demand changes to a final element.

9.29. MODBUS: Serial communications protocol originally published by Modicon in 1979 for use with its programmable logic controllers (PLC).

Utilizes American Standard Code for Information Interchange (ASCII) or Remote Terminal Unit (RTU) modes. Serial communication to only one device is by Recommended Standard (RS-232). Serial communication to multiple devices is by RS-422 or RS-485. Ethernet communication is also available with Transmission Control Protocol (TCP).

9.30. Operating System (OS): Software which controls the execution of computer programs.

9.31. Operator Interface: A device combination of hardware and software, personal computer (PC), workstation, laptop or display terminal, which provides access to the Distributed Control System. Can be used for:

configuration, network management, diagnostics, data manipulation, data analysis etc. in real time or in displaying previously collected historical data.

9.32. Peripheral: External devices used for communication to and from a computer. Peripherals include CRT, printer, hard drives, disk drives, modems, etc.

9.33. Piping and Instrument Diagram (P&ID): Graphical drawing depicting process piping connections and related instrumentation.

9.34. Portable Document Format (PDF) (pdf): File format which presents documents in a manner independent of application software, hardware, and operating systems.

9.35. Precision Time Protocol (PTP): A protocol utilized to synchronize clocks on multiple computers or data collection modules.

9.36. Random Access Memory (RAM): Temporary working storage for computer processors in running various programs.

9.37. Resistive Temperature Detectors (RTD): A sensor for measuring temperature, by the device resistance changing as temperature changes.

9.38. Scientific Apparatus Makers Association (SAMA) Symbols. Developed for the functional diagramming of instrument and control systems, used by control system designers and engineers. Adapted in ANSI/ISA-5.1.

American National Standards Institute/ International Society of Automation (Formerly the Instrument Society of America).

9.39. Sensor: Device capable of measuring the condition or value of a physical variable including but not limited to: magnetic, electromagnetic, electrical, pressure, temperature etc.

9.40. Software: Programs and routines used to extend the capabilities of computers hardware.

9.41. Thermocouple: A sensor for measuring temperature, by the device utilizing two dissimilar metals join together to produce DC voltage, which changes as temperature changes.

9.42. Time Synchronization: Algorithm to assure multiple data points from multiple various locations are time stamped from a central clock, and the data points are actually digitized at the clock time stamp indicated.

9.43. Transducer: A device that converts one form of energy into another form.

For the case of this specification, a device that converts variations in a physical quantity into an electrical signal.

9.44. Transmitter: A device that measures a physical process and converts to an electrical signal that is amplified, and capable of scaled calibration. A transmitter may utilize a transducer, varying capacitance, strain gauge etc.

for the primary measurement before amplification.

10. General Requirements:

10.1. The Bidder shall include:

10.1.1. User lists and contacts of installed general systems and turbine speed control systems.

10.1.2. Mechanical frame work needs, grounding requirements, shielding recommendations at a minimum.

10.1.3. Description of intra communication network to include

Workstation to Control Processors, Control Processors to I/O.

10.1.4. Drawings of system internal connections, network connections, and instrumentation connections for field devices.

10.1.5. Installation instructions and recommendations.

10.1.6. Configuration tool instructions for continuous control, sequential control, and logic with description and examples.

10.1.7. Graphic configuration tools instructions including read and write functions for both Boolean and real values.

10.1.7.1. Configuration Examples of various P&ID graphics, machine graphics, numeric, trends, and various manual/ auto graphics, including push button graphics.

10.2. Backup software tool instructions and methodology description for both control processors, and workstations.

10.3. Identification of Control Processor level software and Operating System.

10.4. Identification of Operator and Engineer Workstation Operating System.

10.5. Bidder shall include statement of Life Cycle of proposed technology/ solution including proposed technology/ solution maturity and guaranteed future support commitment.

10.6. The Vendor shall include:

10.6.1. Project Contact/ Coordinator:

10.6.1.1. Vender shall include a single point of contact in reference to project technical, interfacing, installation questions and discussions.

10.6.1.1.1. Project Contact may reference, and refer to various subject matter experts in regards to detailed and technical type discussions.

11. Engineering:

11.1. Vendor to supply a complete Engineered System ready for installation, connection to instrumentation, for buyer test control purposes.

11.2. Vendor to supply complete engineering drawings of system internal connections, network connections, and instrumentation termination connections for field devices (module or card to I/O termination point).

11.3. Vender shall supply complete installation instructions and recommendations:

11.3.1. Instructions shall include mechanical frame work needs, grounding requirements, shielding recommendations at a minimum.

11.3.1.1. Instructions shall include configuration tools, and examples for continuous control, sequential control and logic.

11.4. Vendor shall supply complete operator and engineering instructions:

11.4.1. Instruction shall include all channel signal connections, all channel signal set-up with configuration, all trending tools, all operator interface GUI tools, all display tools, all historical data tools, etc.

11.4.1.1. Vendor shall supply examples of various P&ID graphics, machine graphics, trends, and various manual/ auto graphics, including push button graphics including graphic for control function and logic connection.

12. Environmental:

12.1. System shall meet, or exceed the following environmental limits.

12.1.1. Processors of control system and I/O sub-system shall be capable of, have no degradation of stated performance, and no reduction of warranty in the following states:

12.1.1.1. Operating.

12.1.1.2. Powered on, standby

12.1.1.3. Power off, storage

12.1.1.3.1. For all above states:

12.1.1.3.1.1. Withstand Temperature between 0 degree F. to (+)

120 degree F.

12.1.1.3.1.2. Withstand 95%, non-condensing relative humidity

12.1.1.3.1.3. Withstand Vibration of 0.5g rms - 5 to 500 Hz.

12.1.2. Workstations (Operators and Engineers) shall be capable of, have no degradation of stated performance, and no reduction of warranty in the following states:

12.1.2.1. Operating.

12.1.2.2. Powered on, standby

12.1.2.3. Power off, storage

12.1.2.3.1. For all above states:

12.1.2.3.1.1. Withstand Temperature between (+) 55 degree F. to

(+) 95 degree F..

12.1.2.3.1.2. Withstand 85%, or greater, non-condensing relative humidity

12.1.2.3.1.3. Withstand Vibration of 0.5g rms 5-300Hz, or greater.

13. Power:

13.1. DCS I/O and control processors shall utilize two (2) independent AC power inputs, such that a single AC power feed failure does not disrupt control function, or system operation. AC power @ 120VAC to be supplied by the buyer. Control processors and I/O power supplies shall be capable of:

13.1.1. 85 to 265 VAC at 55 to 63 Hz operation

13.1.1.1. Bidder shall supply AC current needs to buyer.

13.2. Total redundant DC power supplies shall be provided for processor and

I/O modules needs.

13.2.1. DC power supplies shall include capability to provide complete power for all DCS cards/modules including suppling I/O excitation power (within card/modules specification) for transmitters and transducers.

13.2.2. A single DC Power supply failure shall not disrupt control function, or system operation.

13.2.3. Individual DC power supplies shall be monitored, and alarmed upon failure.

13.2.4. Each individual DC power supply shall be accessible, and changeable by buyer.

13.2.5. Removal of a power supply, installation of a power supply, and return to full service of a power supply shall not cause any disruption of system function or control of the DCS.

13.3. DCS Workstation and Monitors:

13.3.1. All DCS workstations, monitors, and peripherals shall be powered by 120 VAC at 60 Hz.

13.3.2. DCS Workstations shall utilize two (2) independent AC power inputs, such that a single AC power feed failure does not disrupt control function, or system operation.

13.3.2.1. Bidder shall supply AC current needs to buyer.

14. Data Collection History and Monitoring:

14.1. Vendor shall supply data collection history system within DCS architecture.

14.2. History data collection system shall have capability for 100 channels, at a sample rate of 1/second minimum.

14.3. History data collection system shall be capable of storing of one hundred

(100) hours of data minimum.

14.4. All history data shall be readily trended and/ or displayed in the time domain.

15. I/O

15.1. All I/O bus communication to control processors shall be fault tolerant.

Fault tolerant is defined as ability to function with any single point of failure with the intercommunication network between the I/O and control processors. This includes any single cable disruption (disconnect), any single switch (if utilized) failure, and any single port failure.

15.1.1. Fault tolerant communication shall be a standard designed offering of the system.

15.2. All I/O cards or modules shall have the ability for change out under power “hot swappable”.

15.3. Speed Probe Measurements:

15.3.1. System shall have the capability of speed signal detection from:

15.3.1.1. Hall Effect speed probe with pulses generated by a tooth style wheel, and

15.3.1.2. External test pulse train sources (Signal Generator).

15.3.1.3. System shall be able to detect pulse amplitude from a minimum of 7 VDC to 24 or greater VDC.

15.3.1.4. System shall have all speed input pulse measurement channels galvanic isolated, channel-to-channel, and channel-to-ground.

15.3.1.4.1. Galvanic isolation shall be a minimum of 600 VAC.

15.3.1.4.1.1. Speed measurement module shall be able to

withstand 600 VAC for one (1) minute without damage.

15.3.2. Speed channel accuracy shall be 0.01% or better, of pulse reading regardless of pulse rate.

15.3.3. System shall have capability to measure pulse train to 25 KHz with no missing pulses. (To a cycle period minimum of 40 microseconds).

15.3.3.1. System shall have capability to measure duty cycle of pulse stream including:

15.3.3.1.1. Pulse width “Hi” percentage of cycle period in time to a minimum of 16 microseconds, or a

15.3.3.1.2. Pulse valley “Lo” percentage of cycle period in time to a minimum of 16 microseconds.

15.4. DC Analog Inputs:

15.4.1. Analog accuracy shall be ±0.03% of span, or better, including linearity.

15.4.2. Analog inputs shall have capability for user selectable filtering including:

15.4.2.1. First Order Lag

15.4.2.2. Second Order Butterworth

15.4.2.3. Averaging

15.4.2.3.1. Filters shall have user adjustable settings:

15.4.2.3.1.1. Filter Order.

15.4.2.3.1.2. Filter Time.

15.4.2.3.1.3. Filters shall have ability to be low pass, high pass or band pass configured (linked in a serial manner).

15.4.3. Analog inputs shall be fully galvanic isolated.

15.4.3.1. Galvanic Isolation shall be channel-to-channel, and channel-to-ground.

15.4.3.2. Galvanic isolation shall be 600 Volts minimum.

15.4.3.2.1. System shall have capability to have 600 VAC applied continuously for one (1) minute without damage.

15.4.4. Each analog channel shall be minimally capable of:

15.4.4.1. Common Mode Rejection 100 db at 60 Hz.

15.4.4.2. Normal Mode Rejection 95 db at 60 Hz.

15.4.4.3. Analog voltage inputs shall have a minimum input

impedance of 10 Megaohm.

15.4.4.4. Analog milliamp input shall have a maximum input

impedance of 65 Ohm.

15.4.4.5. System shall have ability to supply excitation voltage with full current capability for all analog input channels for customer utilization of two wire transducers and transmitters.

15.4.4.5.1. DCS excitation capability shall not prohibit analog inputs from measurement of current from self-powered, or externally excited transducers and transmitters.

15.4.4.5.1.1. System shall have capability to mix usage, at any ratio, both system exited and externally exited transducers and transmitters.

15.5. DC Analog Outputs

15.5.1. Analog accuracy shall be ±0.05% of span, or better, including linearity.

15.5.2. Analog DC Current output shall have the capability of driving 0 to

20 milliamperes, and 4 to 20 milliamperes, into a load of 750 or greater

Ohms.

15.5.3. Analog milliamp output shall not interfere with HART

communication to a hand held device.

15.6. Discrete Inputs:

15.6.1. System shall have ability to detect voltage sense and set as logic

Boolean data.

15.6.2. System shall have capability of detecting discrete input measurement to include:

15.6.3. Voltage Detection (voltage sense)

15.6.3.1. Voltage Sense shall include ability of VAC detection.

15.6.3.1.1. 120 VAC sense capability

15.7. Discrete Outputs:

15.7.1. System shall have ability to provide discrete output.

15.7.1.1. AC output shall have capability of 120 VAC @ 5

amperes resistive load, 2.5 amperes reactive load

15.7.1.2. DC output shall have capability of 30 VDC @ 3

amperes resistive load

16. Control Processors:

16.1. Processing system shall be fault tolerant

16.1.1. Fault Tolerant is defined as two control processors, either of which control the process, and both processors running the same program, synchronized in time and values (values match).

16.1.1.1. Control Processors shall not be of a redundant style, as defined as a “hot” standby, where the standby processor is not at the same state of program (in time and values) as the main processor. That is, a hot standby, where the standby is updated after any number of steps behind the main processor will not be allowed.

16.1.1.2. Fault tolerant control processing shall be a standard designed offering of the system.

16.2. Processing system shall allow for replacement of a fault tolerant processor without disrupting control function, or system operation to include:

16.2.1. Removing of a failed processor from fault tolerant pair.

16.2.2. Replacing with new a control processor to a fault tolerant pair. This includes down loading, and synchronization to a fully fault tolerant status.

16.3. All control processors shall have the ability for change out under power

“hot swappable”.

16.4. Control Processor bus communication to I/O shall be fault tolerant.

16.5. Control Processor bus communication to Workstations (Operator and

Engineer) shall be faulty tolerant.

16.5.1. Fault tolerant communication shall be a standard designed offering of the system.

16.5.2. Fault tolerant bus communication is defined as ability for control system operation to not be effected by any single point of failure to include:

16.5.2.1. DCS intranetworking system of cable (copper or fiber optic), switch (managed or unmanaged), port, etc.

16.6. System shall continuously monitor status and health of all major components and provide alarming upon detection of any failure.

17. Control Configuration and Programming:

17.1. Programmable and configuration tools shall be provided by vendor to buyer.

17.2. Device programming and configuration tools shall be fully licensed to buyer by device and/ or software application.

17.2.1. Device programming and configuration tools shall not be licensed by time, time of use, or periodic license fee.

17.3. Control configuration shall have full capability of modification while DCS is controlling a process. Modifications, minor or major, shall not require a re-load of the control processors.

17.4. Control configuration modifications shall not require a re-synchronization of a fault tolerant control processors.

17.5. Control configuration modifications shall not require having one of the fault tolerant set to be “off-line”.

17.6. Control configuration shall have capability of user defined block (software blocks) running sequence (or order).

17.7. Control block (software blocks) shall not run by a time-slice method.

17.8. Controllers shall have a defined block (software blocks) number to timetable of run time.

17.9. Overloading of control processor by blocks (software blocks) shall not shut down the controller, or stop the controller function.

17.9.1. Controller shall have a system with ability to handle overload, while still running functions in a manner to distribute burden. (Time limitations may not be satisfied, including timing and integral action etc.)

17.10. Vendor shall supply a fully configurable system to the buyer. This includes

17.10.1. Adding/ removing I/O modules,

17.10.2. Configuring I/O modules,

17.10.2.1. Configuration of: sample rates, input scale, offset, filtering including first order, second order, averaging.

17.10.2.2. Continuous control configuration, with predefined and available controllers:

17.10.2.2.1. Proportional (P)

17.10.2.2.2. Integral (I)

17.10.2.2.3. Proportional-plus-Derivative (PD)

17.10.2.2.4. Proportional-plus-Integral (PI)

17.10.2.2.5. Proportional-plus-Integral-plus-Derivative (PID)

17.10.2.2.6. Non-Interactive PID (NIPID)

17.10.2.3. All controllers shall have predefined connections for tracking, and initialization functions. Tracking and

Initialization shall be connectable to any real value.

Tracking and Initialization Boolean input shall be connectable to any discrete Boolean, or Logic Boolean output.

17.10.2.3.1. Further, system shall have overall control back

calculation capability from any output or block (software block) for initialization and tracking, including ability to back calculate from a characterized output.

17.10.2.3.2. System shall have power up initialization capability.

17.10.2.3.3. System shall have configurable failsafe on outputs:

17.10.2.3.3.1. Configuration shall include ability for:

17.10.2.3.3.2. Last State (Boolean)

17.10.2.3.3.3. Assigned Predefined Boolean

17.10.2.3.3.4. Last Value (Real)

17.10.2.3.3.5. Assigned Predefined Real

17.10.2.3.3.6. Time delay for failsafe action

17.10.2.3.4. DCS shall have a PID controller with capability of settable gap with dead zone, or settable gain.

17.10.2.3.5. PID Controllers shall have ability for setpoint

feedforward.

17.10.2.3.6. PID Controllers shall have connectable feedforward.

17.10.2.3.7. PID Controllers shall have settable, and connectable low output clamp limits, and high output clamp limits.

17.10.2.3.8. PID Controllers with integral action shall have

integral feedback connection.

17.10.2.3.9. PID Controllers shall have configurable cycle time.

17.10.2.3.9.1. PID Controllers shall have ability to run at cycle time period of 50 milliseconds on a control processor level.

17.10.2.3.9.2. A PID controller with cycle time of 10 milliseconds shall be available. PID function may run at the I/O card or module level.

17.10.2.3.10. Control configuration shall include “higher” pre-defined functions such as: median value select, averaging, low value select, high value select, biasing, characterization, dead-time, alarming, etc.

17.10.2.4. Control Configuration shall include Boolean Logic function configuration capability

17.10.2.4.1. Boolean functions allowing utilization and interfacing all Boolean logic gates (and, or, exclusive or, nand, nor, not, flip flop, flip flop –reset dominant, timing/ clock, delay on, delay off, single shot pulse, etc.)

17.10.2.4.2. Boolean timing functions shall have programmable timing initialization.

17.10.2.4.3. Control configuration shall include Math (algebraic equation capability). To include at a minimum:

17.10.2.4.3.1. Add, Subtract, Multiply, Divide, exponent, logarithmic including antilog, exponent, trigonometry, average, median, absolute, square, square root, truncate, rounding, integer math, etc.

17.10.3. Control configuration shall have predefined algorithm sets (blocks, function blocks, software blocks, etc.) that utilized connectable inputs.

17.10.3.1. Configuring Blocks shall not be utilized by addressing to downstream block or function. That is, each block shall be configured by requiring an input connection, and not by addressing an output.

17.10.4. Display configuration tools shall be suppled and installed in DCS and include ability for buyer to:

17.10.4.1. Produce displays and graphics to include operator manual/ auto – “hand-stations”, trends, signal values, Boolean states.

17.10.5. Programming and configuration tools shall include ability for buyer to perform programming scripting on Workstation level.

18. User Interfaces:

18.1. Vendor shall supply user Interface hardware and software for an operator workstation and an engineer workstation.

18.1.1. Vender shall supply one (1) operator workstation computer, including available USB port, keyboard, mouse and two (2) 23” diagonal monitors. Workstation computer hardware shall have sufficient RAM and sufficient hard drive memory for performance of this specification.

18.1.2. Vender shall supply one (1) engineer workstation computer, including keyboard, mouse and one (1) 23” diagonal monitor.

Workstation computer hardware shall have sufficient RAM and sufficient hard drive memory for performance of this specification.

18.1.3. Vendor shall supply complete software for one (1) fully functioning

Operator workstation, and one (1) fully operational Engineering workstation.

18.1.3.1. The Operator software package shall provide the

ability to monitor: DCS health, process, control, and end elements.

18.1.3.2. The Operator software package shall provide ability for placing control loops to manual or automatic, trend analog and discrete process channels, monitor and manage process alarms, and override data points, etc.

18.1.3.3. Engineer workstation shall provide all of the

Operator Workstation ability along with: system configuration, display configuration, process alarming configuration, control logic configuration, continuous control configuration, and sequence control configuration, etc.

18.1.3.3.1. Vendor shall supply graphic configuration tools for workstations and graphic such that an operational graphic can be displayed on an engineers’ workstation, without allowing control, or manipulation of selected areas, or display picks. Display on engineers’ workstation shall be the exact display as the operators workstation with only display pick manipulation differences in this case.

18.1.4. Vender shall supply a color laser-jet printer and include software drivers such that screens can be printed from either the Operators’

Workstation or Engineers’ Workstation.

18.1.5. All system software shall be fully licensed. Software shall include original Optical Media (CD and/ or DVD) of each system.

18.1.6. Vendor shall supply a system with multiple levels of user security:

18.1.6.1. Vendor shall supply Administration, Engineering, Operator, and Technician sign-on/ password levels of security at a minimum.

Display Graphics and Trending:

18.2. System shall provide for buyer/ user settable analog value (numbers), and

Boolean digital screen displays.

18.3. System graphics shall provide for buyer/ user configurable control operator hand-stations with manipulation, and operator on/ off “button” manipulation.

18.4. System graphics shall provide for buyer configurable P&ID process drawings, and physical drawings such as piping, vessels, turbines etc.

18.4.1. System graphics shall provide for dynamic process indication with process presentations to include live value updates, change of color, flashing etc.

18.5. Vendor shall supply information of the nominal time delay latency of channel signal change to graphic display update.

18.6. System shall have ability for multiple process trending:

18.6.1. Trending package shall include user settable X-axis delta, that

“slides” with time (X-axis time delta remains the same, but provides continuous time trending).

18.6.2. Trending package shall have user settable Y-axis delta with preference for auto adjusting.

18.6.3. Trending package shall have capability for a minimum of four (4) multiple traces simultaneously and multiple trends with multiple traces.

18.6.4. Trending package shall have capability of user selectable color per trace.

19. Alarming:

19.1. DCS shall include a system alarming function.

19.1.1. System alarming shall include capability to monitor complete DCS sub-systems, cards/ modules, power supplies for health status.

19.1.2. System shall alarm on health problems and failures of any of all

DCS sub-systems, cards/ modules, and power supplies.

19.2. DCS shall include a process alarming function:

19.2.1. Process alarming shall have user available configuration tools for:

19.2.1.1. Alarm priority including function and display:

19.2.1.1.1. Color, point in-alarm, and not acknowledged flashing.

19.2.1.1.2. Color, point in-alarm, acknowledged non -flashing.

19.2.1.1.3. Acknowledged alarms and not acknowledged alarm

displayed in configured priority order.

19.2.1.1.4. Capability of re-alarming based upon delta changed of measured value.

19.2.1.1.5. Capability of setting setpoint gap for alarm resetting.

19.2.1.1.6. Capability of dynamically setting alarm setpoint level.

19.2.1.1.7. Capability of storing alarm history (logging) to a minimum length of 200 alarms.

19.2.2. Alarming system shall utilize operator workstation for listing of alarms

20. IT, IT Security:

20.1. Contractor shall abide by requirements of the Buyer IT Department.

20.1.1. The DCS Workstations (Operator’s and Engineer’s) shall have the following security implements installed and functioning:

20.1.1.1. McAfee Anti-Virus Scan Version 8.8 minimum

20.2. There shall not be any connection to general (enterprise) IT network, of the CP to workstation communication or I/O subsystems network.

21. Service-ability:

21.1. Vendor shall deliver a fully functioning, complete, serviceable system.

21.2. All devices shall be fully operational, and have full communication when commissioned by buyer.

21.3. Vendor shall provide a system with complete access to all modules and components. All elements of the system, including modules, submodules, and interconnecting cables, must be accessible and serviceable by owner maintenance staff.

21.4. Vendor shall supply system in which all I/O cards or modules, and control processors are changeable under power.

21.5. Vendor shall supply system with full backup capability of both the control processors, and workstations.

21.5.1. Backup method shall be fully maintainable by buyer without assistance from vendor or outside source.

21.6. All service tools shall be included as part of the delivered system.

21.7. Vendor shall supply list of recommended spare parts.

21.8. Vendor shall include a recommended maintenance need for supplied system including all sub-system and components.

22. Warranty:

22.1.1. Vendor shall provide a full and complete system warranty for a service period of one (1) year commencing after final delivery. Bidder to supply detail of guarantee proposal.

22.1.1.1. The warranty shall provide full system functionality, parts replacement, software upgrades necessary in to ensure full system functionality during the warranty period.

23. Vendor Exceptions:

23.1. Bidder shall identify exceptions to any provisions within this specification.

23.2. Evaluation, judgment, and approval of such exceptions, and any alternative approaches rest solely upon the buyer.

24. Schedule:

24.1. Vender shall provide schedule for delivery from time of contract award to delivery of system.

24.2. The projected schedule will be consistent with PSEF internal needs. Buyer retains the right to change the schedule up to contract award.

25. Documentation Requirements:

25.1. Vendor shall supply paper drawings, and/ or electronic drawings in

[PDF] to include:

25.1.1. Mechanical layout and physical dimensions of complete DCS hardware.

25.1.2. Physical Block Diagram to include layouts, single line diagrams of internal (related to internal system) connections.

25.1.3. Functional Block Diagram of System (Workstations/ Controller/

Processor, I/O modules etc.)

25.1.4. Control Processor communication connection to Workstation.

25.1.5. I/O communication connection diagrams to control processors.

25.2. Vendor shall supply three (3) completes sets of printed manuals, and/ or electronic manuals in Word or [PDF] to include:

25.2.1. Installation detail instruction manuals.

25.2.2. System configuration, I/O card/ module configuration, continuous control configuration manuals, sequential control manuals, and logic control manual.

26. Technical Scope of Deliverables for Distributed Control System

26.1. DCS shall be delivered ready for full function as described in this specification (after supplied communication cables, modules or cards, power supplies installed by buyer).

26.2. DCS Workstations shall be delivered with all functions and software packages as described in this specification.

26.2.1. Operators’ Workstation shall have user available USB ports, keyboard, mouse, RAM to meet or exceed functional performance requirements, Hard-drive to meet or exceed functional performance requirements.

26.2.1.1. Operators’ Workstation shall be delivered with two (2) 23” diagonal monitors including interconnecting cables between workstation and monitors, and power cables.

26.2.2. Engineers’ Workstation shall have user available USB ports, a keyboard, mouse, RAM to meet or exceed functional performance requirements. Hard-drive to meet or exceed functional performance requirements.

26.2.2.1. Engineers’ Workstation shall be delivered with one (1) 23” diagonal monitors including interconnecting cables between workstation and monitors, and power cables.

26.2.3. DCS shall be delivered with all control processors, I/O modules or cards, with mounting plates, power cables, power supplies, and all communication cables.

26.2.4. DCS shall be delivered with Fault Tolerant Control Processors capable of:

26.2.4.1. running logic of greater than 100 gates at 10 times per second minimum,

26.2.4.2. a single flow control loop at 2 times per second minimum,

26.2.4.3. a supervisory set point development at 2 times per second minimum,

26.2.4.4. 5 override loops running at 5 times per second or greater.

26.2.4.5. A single loop control at 100 times per second minimum

(I/O card or module level acceptable).

26.2.5. DCS shall be delivered to provide the following I/O capability:

26.2.5.1. A minimum of 3 pulse inputs for speed measurement, on three separate modules or cards (1 pulse inputs or greater per card or module).

26.2.5.2. 56 Analog Inputs minimum with user selectable 0.0 to

20.0, or 4.0 to 20.0 milliamperes signal ranges.

26.2.5.3. 8 Analog Inputs minimum of 0.0 to 10.0 VDC.

26.2.5.4. 8 Analog Outputs minimum of 0.0 to 20.0, 4.0 to 20.0 milliamperes.

26.2.5.5. 8 Discrete Outputs minimum for 120 VAC at 5.0 amperes, or for 0 to 30 VDC at 3 amperes.

26.2.5.6. 8 Discrete Inputs minimum Voltage Sense for 120 VAC

27. DCS Scale-ability Capabilities of Hardware and Function

27.1. DCS vendor shall show future growth support to buyer.

27.1.1. DCS scalable I/O, and scalable functional software shall be in relation to the vendor proposed base DCS satisfying this specification.

27.1.1.1. Bidder shall only supply documentation of vendor

system that maintains integral DCS design, with intent of inherently being utilized on the proposed system.

27.2. Bidder shall supply documentation illustrating offered DCS capability for scale-ability in hardware.

27.2.1. Future addition of I/O including:

27.2.1.1. Pulse Inputs (2 times greater than base bid minimum)

27.2.1.2. Analog 4 to 20 milliamperes inputs (4 times greater than base bid minimum)

27.2.1.3. Analog 0 to 10 VDC inputs (4 times greater than base bid minimum)

27.2.1.4. Analog 0 to 10 VDC outputs (Minimum of 16)

27.2.1.5. Analog Thermocouple inputs

27.2.1.5.1. Type K (Minimum of 64)

27.2.1.5.2. Type J (Minimum of 32)

27.2.1.5.3. Type T (Minimum of 8)

27.2.1.5.4. Type E (Minimum of 8)

27.2.2. Analog RTD Inputs

27.2.2.1. Platinum (Minimum of 48)

27.2.2.2. Nickel (Minimum of 8)

27.2.2.3. Copper (Minimum of 8)

27.2.3. MODBUS Interface:

27.2.3.1. Capable of connectivity, communicating and

incorporating values through a serial MODBUS interface via RS-232, RS-422, or RS-485.

27.2.3.1.1. RS-485 shall be capable of communication with 32

devices (drops).

27.2.3.1.2. RS-422 shall be capable of 5 transmitters and 10

receivers.

27.2.4. HART I/O communication capability.

27.2.5. Intrinsically safe (I/O).

27.2.6. Redundant analog output (4 to 20 milliamp) capability.

27.2.7. Discrete Inputs

27.2.7.1. Contact Sense (Minimum of 24)

27.2.7.1.1. System shall have ability to supply excitation

“wetting” voltage or current to provide contact sense.

27.2.7.2. Voltage Sense, 120 VAC & 24 VDC, (Minimum of 24

each)

27.2.7.3. Discrete Outputs (16 @ 120 VAC, 16 @ 30 VDC)

27.2.8. Fiber optic network communication.

27.3. Bidder shall supply documentation illustrating offered DCS capability scalability in function.

27.3.1. Future Addition of Software and Functions:

27.3.1.1. Expansion of data history by:

27.3.1.1.1. 100 count by 4X minimum. (400 channels)

27.3.1.1.2. Storage length by 4X minimum. (4000 hours)

27.3.1.2. Advanced Controllers including self-tuning

(feedforward - feedback).

27.3.1.3. Advance Process Control (APC) functions including

Multi- Variable Model Predictive Control

27.3.1.3.1. APC available in Control Processor

27.3.1.3.2. APC available in Workstation

27.3.1.3.3. Non-linear identification

27.3.1.3.4. Non-linear optimization control

27.3.1.3.5. Real-time adaptive control

27.3.1.3.6. Process modeling

27.3.1.3.7. Neural networks

27.3.1.3.8. Fuzzy logic

27.3.1.4. Control programming support and function for SAMA

representation.

27.3.1.4.1. Control Programming shall have dynamic

SAMA object adjustment to reflect actual configuration changes as they are performed.

27.3.1.5. Time synchronization of workstations (Operator and

Engineer’s), Control Processors, and I/O Modules or cards.

27.3.1.6. Capable of input from GPS source and/ or IRIG-b time source.

27.3.1.7. Buyer defined logs of data, and timing (Hourly, change of shift, Dailey, Monthly) such as on, off of discrete outputs (devices) and operator actions.

27.3.1.8. Transient event recording with buyer settable triggers and data collection points

27.3.1.9. Sequence of Events recording (SOE) with 1 millisecond resolution.

27.3.1.10. Automatic logging of user sign-on and time.

27.3.1.10.1. System with automatic change tracking

logging of: personnel sign in, and sign out, date and time, system changes including user date and time, control system configuration changes including user date and time.

28. Bidders Proposal Requirements:

28.1. Bidder shall make known:

28.1.1. Schedule:

28.1.1.1. Time to delivery after contract award.

28.1.2. Buyer supplied AC Power service…