Amendment 14 - 25 00 00.00 22_ASW_Control.pdf

P381 Multi-Mission Drydock #1

Portsmouth Naval Shipyard, Kittery, ME eProjects # 1604959

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PART 1 GENERAL

1.1 REFERENCES

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ASW CONTROL SPECIFICATIONS (PWD ME)

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B1 (2013) Standard Specification for

Hard-Drawn Copper Wire

ASTM B8 (2011; R 2017) Standard Specification for

Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM D709 (2017) Standard Specification for

Laminated Thermosetting Materials

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2017; Errata 1-2 2017; INT 1 2017)

National Electrical Safety Code

IEEE 100 (2000; Archived) The Authoritative

Dictionary of IEEE Standards Terms

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment

(1000 Volts Maximum)

NEMA C80.1 (1994) Rigid Steel Conduit - Zinc Coated

(GRC)

NEMA FU 1 (2012) Low Voltage Cartridge Fuses

NEMA ICS 4 (2015) Application Guideline for Terminal

Blocks

NEMA ICS 6 (1993; R 2016) Industrial Control and

Systems: Enclosures

NEMA KS 1 (2013) Enclosed and Miscellaneous

Distribution Equipment Switches (600 V

Maximum)

NEMA RN 1 (2005; R 2013) Polyvinyl-Chloride (PVC)

Externally Coated Galvanized Rigid Steel

Conduit and Intermediate Metal Conduit

NEMA TC 2 (2013) Standard for Electrical Polyvinyl

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Chloride (PVC) Conduit

NEMA TC 3 (2016) Standard for Polyvinyl Chloride

(PVC) Fittings for Use with Rigid PVC

Conduit and Tubing

NEMA Z535.4 (2011; R 2017) Product Safety Signs and

Labels

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020) National Electrical Code

NFPA 70E (2018; TIA 18-1; TIA 81-2) Standard for

Electrical Safety in the Workplace

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.147 The Control of Hazardous Energy (Lock

Out/Tag Out)

UNDERWRITERS LABORATORIES (UL)

UL 1063 (2017) UL Standard for Safety Machine-Tool

Wires and Cables

UL 198E (1988; Rev Jul 1988) Class R Fuses

UL 360 (2013; Reprint Nov 2018) UL Standard for

Safety Liquid-Tight Flexible Metal Conduit

UL 44 (2018) UL Standard for Safety

Thermoset-Insulated Wires and Cables

UL 486A-486B (2018) UL Standard for Safety Wire

Connectors

UL 489 (2016) UL Standard for Safety Molded-Case

Circuit Breakers, Molded-Case Switches and

Circuit-Breaker Enclosures

UL 506 (2017) UL Standard for Safety Specialty

Transformers

UL 508 (2018) UL Standard for Safety Industrial

Control Equipment

UL 512 (1993; Rev thru Mar 1999) Fuseholders

UL 514B (2012; Reprint Nov 2014) Conduit, Tubing and Cable Fittings

UL 514C (2014; Reprint Feb 2020) UL Standard for

Safety Nonmetallic Outlet Boxes, Flush-Device Boxes, and Covers

UL 6 (2007; Reprint Sep 2019) UL Standard for

Safety Electrical Rigid Metal Conduit-Steel

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UL 651 (2015; Reprint Nov 2018) UL Standard for

Safety Schedule 40, 80, Type EB and A

Rigid PVC Conduit and Fittings

UL 83 (2017) UL Standard for Safety

Thermoplastic-Insulated Wires and Cables

UL 870 (2016; Reprint Mar 2019) UL Standard for

Safety Wireways, Auxiliary Gutters, and

Associated Fittings

1.2 DEFINITIONS

Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, shall be as defined in

IEEE 100.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Transformers; G

Wireways; G

SD-03 Product Data

Circuit Breakers; G

Switches; G

Transformers; G

Enclosed Circuit Breakers; G

Motor Controllers; G

Motor Starters; G

Submittals shall include performance and characteristic curves

SD-06 Test Reports

600-Volt Wiring Test; G

SD-07 Certificates

Fuses; G

SD-10 Operation and Maintenance Data

Electrical Systems, Data Package 5; G

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Submit operation and maintenance data in accordance with Section 01 78 23, OPERATION AND MAINTENANCE DATA and as specified herein.

1.4 QUALITY ASSURANCE

1.4.1 Fuses

Submit coordination data as specified in paragraph, FUSES of this section.

1.4.2 Regulatory Requirements

In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction," or words of similar meaning, to mean the Contracting Officer. Equipment, materials, installation, and workmanship shall be in accordance with the mandatory and advisory provisions of NFPA 70 unless more stringent requirements are specified or indicated.

1.4.3 Standard Products

Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design, and workmanship. Products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year period shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period. Where two or more items of the same class of equipment are required, these items shall be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.

1.4.3.1 Alternative Qualifications

Products having less than a 2-year field service record will be acceptable if a certified record of satisfactory field operation for not less than

6000 hours, exclusive of the manufacturers' factory or laboratory tests, is furnished.

1.4.3.2 Material and Equipment Manufacturing Date

Products manufactured more than 3 years prior to date of delivery to site shall not be used, unless specified otherwise.

1.5 MAINTENANCE

1.5.1 Electrical Systems

Submit operation and maintenance manuals for electrical systems that provide basic data relating to the design, operation, and maintenance of the electrical distribution system for the building.

This shall include:

a. Single line diagram of the "as-built" building electrical system.

b. Schematic diagram of electrical control system.

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c. Manufacturers' operating and maintenance manuals on active electrical equipment.

d. Complete bill of materials for electrical control system.

1.6 WARRANTY

The equipment items shall be supported by service organizations which are reasonably convenient to the equipment installation to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

Materials, equipment, and devices shall, as a minimum, meet requirements of UL, where UL standards are established for those items, and requirements of NFPA 70.

2.2 CONDUIT AND FITTINGS

Shall conform to the following:

2.2.1 Rigid Metallic Conduit

Rigid, Threaded Zinc-Coated Steel Conduit, NEMA C80.1, UL 6

2.2.2 Rigid Nonmetallic Conduit

PVC Type EPC-40, and EPC-80 in accordance with NEMA TC 2, UL 651

2.2.3 Liquid-Tight Flexible Metal Conduit, Steel

UL 360

2.2.4 Fittings for Rigid Metal Conduit

Threaded type. Split couplings unacceptable.

2.2.5 Fittings for Rigid Nonmetallic Conduit

NEMA TC 3 for PVC, and UL 514B.

2.2.6 PVC Coated Rigid Metal Conduit

NEMA RN 1, Type 40, 40 mils thick.

2.3 OUTLET BOXES AND COVERS

UL 514C, surface mounted PVC, Type FS boxes with compatible weather tight device plates.

2.4 CABINETS, JUNCTION BOXES, AND PULL BOXES

Non-metallic PVC or fiberglass or Type 316 stainless steel, UL 508.

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2.5 WIRES AND CABLES

Wires and cables shall meet applicable requirements of NFPA 70 and UL for type of insulation, jacket, and conductor specified or indicated. Wires and cables manufactured more than 12 months prior to date of delivery to site shall not be used.

2.5.1 Conductors

Conductors No. 12 AWG and larger diameter shall be stranded. Conductors

No. 14 AWG and smaller diameter shall be solid, except that conductors for remote control, alarm, and signal circuits, classes 1, 2, and 3, shall be stranded unless specifically indicated otherwise. Conductor sizes and ampacities shown are based on copper, unless indicated otherwise. All conductors shall be copper.

2.5.1.1 Minimum Conductor Sizes

Minimum size for branch circuits shall be No. 12 AWG; for Class 1 remote-control and signal circuits, No. 14 AWG; for Class 2 low-energy, remote-control and signal circuits, No. 16 AWG; and for Class 3 low-energy, remote-control, alarm and signal circuits, No. 22 AWG.

2.5.2 Color Coding

Provide for service, feeder, branch, control, and signaling circuit conductors. Color shall be green for grounding conductors and white for neutrals; except where neutrals of more than one system are installed in same raceway or box, other neutrals shall be white with a different colored (not green) stripe for each. Color of ungrounded conductors in different voltage systems shall be as follows:

a. 208/120 volt, three-phase

(1) Phase A - black

(2) Phase B - red

(3) Phase C - blue

b. 480/277 volt, three-phase

(1) Phase A - brown

(2) Phase B - orange

(3) Phase C - yellow

c. 120/240-volt, single phase; black and red

2.5.3 Insulation

Unless specified or indicated otherwise or required by NFPA 70, power and lighting wires for use on the interior of the building shall be 600-volt, Type THWN/THHN conforming to UL 83 or Type XHHW or RHW conforming to UL 44, except that grounding wire may be type TW conforming to UL 83;

remote-control and signal circuits shall be Type THWN/THHN, conforming to

UL 83. Where lighting fixtures require 90-degree Centigrade (C) conductors, provide only conductors with 90-degree C insulation or better. All wires used underground shall be 600-volt, Type RHW-2 with

Hypalon or neoprene outer jacket conforming to UL 44.

2.5.4 Bonding Conductors

ASTM B1, solid bare copper wire for sizes No. 8 AWG and smaller diameter;

ASTM B8, Class B, stranded bare copper wire for sizes No. 6 AWG and larger diameter.

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2.6 INSTRUMENTATION CABLE

2/c #18 Copper, twisted, shielded pair, tray cable with 600-volt jacket.

2.7 SPLICES AND TERMINATION COMPONENTS

Low-voltage cable splices and terminations shall be rated at not less than

600 Volts. Splices in conductors No. 10 AWG and smaller shall be made with an insulated, solderless, pressure type connector, conforming to the applicable requirements of UL 486A-486B. Splices in conductors No. 8 AWG and larger shall be made with non-insulated, solderless, pressure type connector, conforming to the applicable requirements of UL 486A-486B.

Splices shall then be covered with an insulation and jacket material equivalent to the conductor insulation and jacket. Splices below grade or in wet locations shall be waterproofed by a sealant-filled, thick wall, heat shrinkable, thermosetting tubing.

2.8 SWITCHES

2.8.1 Disconnect Switches

NEMA KS 1. Provide heavy duty-type switches where indicated, where switches are rated higher than 240 volts, and for double-throw switches. Fused switches shall utilize Class R fuse holders and fuses, unless indicated otherwise. Switches serving as motor-disconnect means shall be horsepower rated. Provide switches in NEMA 4X, enclosure per NEMA ICS 6.

2.9 FUSES

NEMA FU 1. Provide complete set of fuses for each fusible switch.

Time-current characteristics curves of fuses serving motors or connected in series with circuit breakers shall be coordinated for proper operation. Submit coordination data for approval. Fuses shall have voltage rating not less than circuit voltage.

2.9.1 Fuse Holders

Provide in accordance with UL 512.

2.9.2 Cartridge Fuses, Current Limiting Type (Class R)

UL 198E, Class RK-1. Associated fuse holders shall be Class R only.

2.10 ENCLOSED CIRCUIT BREAKERS

UL 489. Individual molded case or insulate case circuit breakers with voltage and continuous current ratings, number of poles, overload trip setting, and short circuit current interrupting rating as indicated.

Enclosure shall be Type 316 stainless steel, NEMA 4X.

2.11 ASW CONTROL SYSTEM

2.11.1 Utility Enclosure Control Panels

The Utility Enclosure ASW Control System shall consist of multiple independent enclosures for the purpose of controlling, monitoring, and operating the utility enclosure ASW System. The major functions shall be multiple enclosures to house the ASW System controllers.

The Utility Enclosure ASW Control System integrates ASW pump control

SECTION 25 00 00.00 22 Page 8 and ASW Tower System Control.

The control system described above and HOA detailed below shall be housed within NEMA 4X stainless steel control enclosures as indicated. In addition, each panel shall be provided with a door-mounted (inside) data packet containing panel details, wiring diagrams, control strategies and schematics. Enclosures shall have hinged doors with mechanically latched doors. Provide interior component mounting panel in each enclosure.

2.11.2 Pump Station ASW Control System

The Pump Station ASW Control System shall consist of multiple independent enclosures for the purpose of controlling, monitoring, and operating the

Pump Station ASW System. The major functions shall be a single enclosure to house the ASW System Control Panel.

The control system described above and HOA detailed below shall be housed within NEMA 4X stainless steel control enclosures as indicated. In addition, each panel shall be provided with a door-mounted (inside) data packet containing panel details, wiring diagrams, control strategies and schematics. Enclosures shall have hinged doors with mechanically latched doors. Provide interior component mounting panel in each enclosure.

2.11.3 "ASW and Cooling Tower Pump" HOA

PUMP STATION

There shall be one (1) HOA panel for each pump. It shall include all necessary components to make a completely operable and independent system and shall include:

a. Circuit breaker/main disconnect with external operator, interlocked so that the door can be opened only when the circuit breaker is in the

"OFF" position.

b. Solid-state reduced voltage starter

c. Pump "RUN" pilot light (red)

d. Panel "POWER ON" pilot light (white)

e. Motor "Fault" alarm pilot light (red)

f. "Hand-Off-Auto" selector switch (three position rotary selector operator)

g. Pump "OFF" pilot light (green)

h. Control transformer (120-24 VAC)

i. Digital elapsed time meter (hours)

j. "Over Temperature" alarm light (red)

k. Isolated "Over Temperature" alarm dry contact, normally open

(Over-temperature alarm to dewatering pump control panel)

l. Isolated "Run" dry contact, normally open (pump status to dewatering pump control panel)

UTILITY ENCLOSURE

There shall be a master system control panel that includes:

a. Circuit breaker/main disconnect with external operator, interlocked so that the door can be opened only when the circuit breaker is in the

"OFF" position

b. Lead selector switch (2-position: "Pump1 Lead" and "Pump 2 Lead") for manual sequencing of pump operation (2 position rotary selector operator)

c. Interlocks between the Utility Enclosure cooling towers and ASW pumps for "Enable/Disable" of the cooling towers based on pump operation

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d. ASW Pump No. 1 "Run" pilot light (red)

e. ASW Pump No. 2 "Run" pilot light (red)

f. Pressure switch input (from N/O dry contacts) with on-off time delay relays to sequence/turn on the lag pump at 60 psi (adjustable from

0-150 psi) and send alarm to dewatering pump control panel.

g. Pressure switch input (from N/O dry contacts) with on-off time delay relays to alarm on "Low ASW pressure" below 50 psi (adjustable 0-150 psi) at dewatering pump control panel.

h. Digital "System Pressure-psi" display

i. "Lag Pump Required" pilot light (amber)

j. "Low System Pressure Acknowledge" switch (pushbutton operator)

k. "Low Pressure Alarm" pilot light (amber)

l. "Lag Pump Stop switch (pushbutton operator)

m. Digital "System Pressure" panel meter. (Based on Precision Digital

PD765 Series Process & Temperature panel meter, 1/8 DIN or Equal.)

n. "Power On" Indicator light (white)

2.11.3.1 Solid State Reduced Voltage Starter

The solid-state reduced voltage starter shall be integrated into the ASW

Pump Control Panel(s). The requirements for the solid-state reduced voltage starter are as follows:

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Each solid-state reduced voltage starter shall consist of two Silicon

Controlled Rectifiers (SCRs) in a reverse parallel configuration per phase. The power section shall have three clamped semiconductor stacks, which are forced air cooled by integral fans, if necessary. The three power modules shall have individual heatsink assemblies. The controller mounting flange shall have grounding provisions. The power section shall operate at 480 volts, 3 phase, 60 hertz. Metal oxide varistors for transient protection shall be provided on the line terminals. A built-in circuit breaker and isolating contactor shall be included. The starter shall provide starting of a 75

HP, 460-volt, three phase induction motor as follows:

a. Soft start with selectable kick start

b. Current limit

c. Full voltage

The controller shall be designed to meet the applicable requirements of

UL, NEMA, IEC and IEEE. The power section shall consist of three clamped semiconductor stacks, which are forced air cooled by integral fans, if necessary. Each semiconductor stack shall have individual heatsink assemblies. The controller mounting flange shall have grounding provisions. Metal oxide varistors for transient protection shall be furnished and installed on the line terminals. The power section shall be capable of centrifugal pump duty of 300 percent for 30 seconds. The SCR's shall have a minimum repetitive inverse voltage rating of 1400 volts at

480 volts. The metal oxide varistors shall have a minimum rating of 80 joules. The controller shall be provided with an energy saving feature, which shall automatically cause the voltage of the power module to be reduced during times when the motor is unloaded or lightly loaded. The energy saver shall be defeatable. Line and load terminals shall be provided with a terminal cover.

The control module shall be designed for integral mounting on the power section. The control module shall incorporate a microcomputer and shall drive the power semiconductors located in the power section. The logic shall be designed to operate at 100-600 volts, 23-75 hertz. A control circuit transformer connected to the incoming line shall be provided.

Acceleration ramp time shall be adjustable from 20 to 120 seconds.

Deceleration ramp time shall be selectable from 0 to 60 seconds. This feature shall be field defeatable. Protection shall be provided during starting and running modes for start fault, line fault, temperature fault and stalled motor. Dual function LED indicators shall be provided for advisory status and fault annunciation. The controller shall have the following standard features:

a. Adjustable ramp time (0-120s)

b. Adjustable initial current (50-400%)

c. Adjustable maximum current (200-600%)

d. Adjustable full-voltage kick start (0.1 to 5 seconds or Off)

e. Selectable motor deceleration Control for Pumps (0-60s)

f. Phase loss and phase reversal protection

g. Adjustable motor full load amps (1-1200A)

h. Adjustable motor service factor (1.00-1.40)

i. Adjustable stalled motor detection (0-240s)

j. 800% FLA instantaneous overcurrent detection

k. Overcurrent (jam) protection (50-400%, 1 to 15 seconds or disabled)

l. Undercurrent protection (25-100%, 1 to 15 seconds or disabled)

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m. Automatic or manual overcurrent and undercurrent trip reset

n. Shorted SCR detection and SCR condition indication

o. Over temperature fault with indicator light

2.11.4 Control Wiring

All control wire shall be stranded tinned copper switchboard wire with

600-volt flame-retardant insulation Type SIS meeting UL 44, or Type MTW meeting UL 1063, and shall pass the VW-1 flame tests included in those standards. Hinge wire shall have Class K stranding. Current transformer secondary leads shall be not smaller than No. 10 AWG. The minimum size of control wire shall be No. 14 AWG. Power wiring for 480-volt circuits and below shall be of the same type as control wiring and the minimum size shall be No. 12 AWG. Special attention shall be given to wiring and terminal arrangement on the terminal blocks to permit the individual conductors of each external cable to be terminated on adjacent terminal points.

2.11.5 Control Circuit Terminal Blocks

NEMA ICS 4. Control circuit terminal blocks for control wiring shall be molded or fabricated type with barriers, rated not less than 600 volts.

The terminals shall be removable binding, fillister, or washer head screw type, or of the stud type with contact and locking nuts. The terminals shall be not less than No. 10 in size and shall have sufficient length and space for connecting at least two indented terminals for 10 AWG conductors to each terminal. The terminal arrangement shall be subject to the approval of the Contracting Officer and not less than four (4) spare terminals or 10 percent, whichever is greater, shall be provided on each block or group of blocks. Modular, pull apart, terminal blocks will be

SECTION 25 00 00.00 22 Page 12 acceptable provided they are of the channel or rail-mounted type. The

Contractor shall submit data showing that the proposed alternate will accommodate the specified number of wires, are of adequate current-carrying capacity, and are constructed to assure positive contact between current-carrying parts.

2.11.6 Control Circuits

Control circuits shall have maximum voltage of 24 volts derived from control transformer in same enclosure. Transformers shall conform to UL 506, as applicable. Transformers, other than transformers in bridge circuits, shall have primaries wound for voltage available and secondary's wound for correct control circuit voltage. Size transformers such that 80 percent of rated capacity equals connected load. Provide disconnect switch on primary side. Provide fuses in each ungrounded primary feeder. One secondary lead shall be fused; other shall be grounded.

2.11.7 Enclosures for Motor Controllers

NEMA 4x stainless steel per NEMA

ICS 6.

2.11.8 Pilot and Indicating Lights

All pilot and indicating lights shall be panel mounted, LED, 30mm, modular, IP67 rated or better.

2.11.9 Pushbuttons

All pushbuttons shall be panel mounted, 30mm, modular, IP67 rated or better. Provide and arrange contact blocks as required.

2.11.10 Selector Switches

All rotary selector switches shall be panel mounted, 30mm, modular, IP67 rated or better. Provide 2 and 3 position operators as required. Provide and arrange contact blocks as required.

2.12 LOCKOUT REQUIREMENTS

Provide disconnecting means capable of being locked out for machines and other equipment to prevent unexpected startup or release of stored energy in accordance with 29 CFR 1910.147.

2.13 MANUFACTURER'S NAMEPLATE

Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable.

2.14 FIELD FABRICATED NAMEPLATES

ASTM D709. Provide laminated plastic nameplates for each equipment enclosure, relay, switch, and device as specified or as indicated on the drawings. Each nameplate inscription shall identify the function and, when applicable, the position. Nameplates shall be melamine plastic, 0.125-inch-thick, white with black center core. Surface shall be matte finish. Corners shall be square. Accurately align lettering and engrave into the core. Minimum size of nameplates shall be one by 2.5 inches.

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Lettering shall be a minimum of 0.25-inch-high normal block style.

2.15 WARNING SIGNS

Provide warning signs for flash protection in accordance with NFPA 70E and

NEMA Z535.4 for switchboards, panelboards, industrial control panels, and motor control centers that are in other than dwelling occupancies and are likely to require examination, adjustment, servicing, or maintenance while energized. Provide field installed signs to warn qualified persons of potential electric arc flash hazards when warning signs are not provided by the manufacturer. The marking shall be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment.

2.16 WIRING DIAGRAM ON ENGRAVED ALUMINUM SHEET

8 1/2" x 11" Aluminum photo engraved diagram as indicated on the Contract

Drawings. Provide wiring diagram on aluminum sheet with black text.

Submit drawings for review prior to printing.

2.17 WIREWAYS

UL 870. Material shall be stainless steel 16 gauge for heights and depths up to 6 by 6 inches, and 14 gauge for heights and depths up to 12 by 12 inches. Provide in length required for the application with screw cover

NEMA 4X enclosure per NEMA ICS 6.

2.18 FACTORY APPLIED FINISH

Electrical equipment shall have factory-applied painting systems which shall, as a minimum, meet the requirements of NEMA 250 corrosion-resistance test and the additional requirements as specified herein. Interior and exterior steel surfaces of equipment enclosures shall be thoroughly cleaned and then receive a rust-inhibitive phosphatizing or equivalent treatment prior to painting. Exterior surfaces shall be free from holes, seams, dents, weld marks, loose scale, or other imperfections.

Interior surfaces shall receive not less than one coat of corrosion-resisting paint in accordance with the manufacturer's standard practice. Exterior surfaces shall be primed, filled where necessary, and given not less than two coats baked enamel with semi-gloss finish. Equipment located indoors shall be

ANSI Light Gray, and equipment located outdoors shall be ANSI Light Gray.

Provide manufacturer's coatings for touch-up work and as specified in paragraph FIELD APPLIED PAINTING.

2.19 POINTS

Provide inputs to and outputs from the process control system in accordance with the Input/Output (I/O) Lists as outlined in the contract drawings (MS705, MS706, MS707, MS704, PM704). Each connected analog output (AO), analog input

(AI), Digital output (DO), Digital input (DI), Communication Network (COMMS) and other input or output device connected to the control system must represent a "point" where referred to in this specification.

2.20 BUILDING TELECOMMUNICATIONS CABLING (BTC)

Provide data transmission systems for communication between PLCs, network devices and the central station/ servers specified in Sections 27 10 00

BUILDING TELECOMMUNICATIONS CABLING SYSTEM and

33 82 00 TELECOMMUNICATIONS OUTSIDE PLANT (OSP) and as indicated.

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2.21 SYSTEM RELIABILITY

The system must be designed for maximum reliability, safety and integrity while maintaining an availability of 99.99% or better. Where indicated PLC's shall be arranged with a redundant controller and power supply; in addition, where indicated UPS systems shall be provided.

2.22 SENSORS

2.22.1 Transmitter

Unless indicated otherwise, each sensor must be provided with a transmitter, selected to match the sensor. Except where specifically indicated otherwise on the drawings, the transmitter must be provided with a digit visual display of the measured parameter and must output a 4 to 20 mAdc signal linearly proportional to the measured parameter.

Accuracy must be plus or minus 1 percent of full-scale reading with output error not exceeding +/- 0.5 percent of full scale.

Transmitter must be located where indicated, mounted integrally with the sensor, pipe mounted, wall mounted or installed in the control panel.

The distance between the sensor and transmitter must not exceed the manufacturer's recommendation. Field preamplifiers and signal conditioners must be included when necessary to maintain the accuracy from sensor to the programmable logic controller or recorder.

2.22.2 Level Instrumentation

Pressure taps must incorporate appropriate snubbers. Relays and housing must be intrinsically safe or explosion proof as required by the NFPA hazard rating for compatibility with the contents of the tank or sump. The controller must be provided with a minimum of three sets of dry contacts rated in accordance with NEMA ICS 1. The first set of contacts must close when the lower (warning) detection level has been exceeded. The second set of contacts must close when the upper (alarm) detection level has been exceeded. The third set of contacts must close when a controller malfunction has occurred, including loss of power or loss of sensor input. The alarm levels must be individually adjustable. The controller must provide a 4-20 mAdc output signal to the programmable logic controller, linearly proportional to the measured parameter.

2.22.2.1 Microswitch Float Switch

Float switch assemblies for use in liquid systems must consist of wall bracket or mounting plate, galvanized steel rods, stainless steel bolts, corrosion resistant housing, and microswitch. Each switch must consist of one normally open microswitch, encapsulated in epoxy resin. The float casing must be polypropylene. The switch cable must be oil resistant neoprene or PVC cable with 3 No. 18 gauge stranded copper conductors, rated for 600 Volt application.

2.22.3 Pressure Instrumentation

Pressure taps shall incorporate appropriate snubbers.

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2.22.3.1 Pressure Sensor and Transducer

The sensing element must be diaphragm type. The pressure transducer must withstand up to 150 percent of rated pressure, with an accuracy of plus or minus 0.14 percent of span. Pressure must be measured in psi gage.

Continuously (external) adjustable span, zero and dampening (internal) adjustment.

Requirements:

1. Ambient operating temperature range of minus 40-degrees F to plus 250 degrees F.

2. Provide with 2, 3 or 5 valve manifolds, as required by the Contract

Drawings, with vent, drain, block, equalize, valves and bleed valve plugs.

3. Sensor or transmitter failure alarm - High or low failure mode - shall be provided and shall be user selectable.

4. Sensor fill fluid shall be vegetable oil NSF41 approved.

5. Process wetted parts and diaphragm shall be as recommended by the manufacturer for the intended service and installation application.

6. Housing material shall be 316 stainless steel or as recommended by the manufacturer for the intended service and installation application. At a minimum, housing shall be rated NEMA 4X.

7. Non-wetted parts shall be as recommended by the manufacturer for the intended service and installation application.

8. Transmitter shall have an integral digital LCD indicator scaled linearly in engineering units.

9. Process connection style shall be -inch NPT or flange, the Contractor shall provide fittings as needed to adapt instrument process connections to available pressure ports on process equipment. Connection style and flange size rating and material shall be as recommended by the manufacturer and as indicated in the data sheet for the intended service and installation application.

10. Provide mounting hardware suitable for the intended service and installation application (e.g. surface mounting, 2-inch pipe, etc

Where indicated, diaphragm seals shall be provided. The diaphragm seal shall attach to the inlet connection of a pressure instrument in order to isolate its measuring element from the process fluid due to incompatibility and/or high process fluid temperature. Displacement of the liquid fill in the pressure element through the movement of the diaphragm shall transmit process pressure changes directly to a gauge, transmitter, switch, or other pressure instrument.

Diaphragm seals shall consist of bottom housing, lower ring, diaphragm capsule, fill screw, flushing connection, and a top housing. The bottom housing shall be removable in order to permit servicing. Bottom housing material shall be compatible with the process liquid as recommended by the manufacturer. As a minimum, top housing and bolts shall be 316 stainless steel, or as recommended by the manufacturer for the intended service and installation application. Diaphragm capsule material shall be compatible with the process liquid as recommended by the manufacturer. The diaphragm seal shall be factory-assembled to the corresponding pressure instrument and factory-filled. The space between the diaphragm and the pressure element shall be completely filled with a suitable liquid as recommended by the manufacturer for the intended service and installation application. Material of exposed surfaces, housings, and diaphragm shall be as recommended by the manufacturer for the intended service and installation application. The seal shall be provided with a ring, flushing port connection, and fill/bleed connection. The

SECTION 25 00 00.00 22 Page 16 diaphragm seal shall be shipped a tag reading "Do not disassemble for installation.

2.22.3.2 Pressure Gauge

Pressure gauges shall be 4-1/2 inches, with white laminated dials and black graduations, and have either a shatterproof glass or acrylic window. The gauges' bottom connection size shall be ¼ inch. Sensing element shall be bourdon tube with welded, stress-relieved joints. Sensing element material shall be as recommended by the manufacturer and as indicated in the data sheet. Gauges shall have an accuracy of plus and minus

1/2-percent of full scale. Body material shall be as recommended by the manufacturer Gauge shall be liquid-filled. Gauges shall be provided with a

316 stainless steel pulsation dampener (snubber) and diaphragm a seal. The pulsating dampener shall absorb system pressure pulses.

2.22.3.3 Pressure Switch

Sensors must be diaphragm-actuated and must be constructed of 316 stainless steel. Pressure switch must have a repetitive accuracy of plus or minus 0.2 percent of the operating range and must withstand up to 150 percent of rated pressure. Each switch must be installed with a diaphragm seal.

Switch actuation set point must be adjustable over the operating pressure range with a differential adjustment span of 20 to 80 percent of the range of the switch. The switch must have Form C snap-action contacts rated in accordance with NEMA ICS 1.

2.22.4 Limit Switch

Limit switch must be induction/proximity type, contacts must be heavy duty and rated A600 or N600. Enclosure must be metal. The actuating head must vary based upon the application.

2.23 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.23.1 PLC General Requirements

PLCs must be micro-processor based, capable of receiving binary and analog inputs and, through programming, must be able to control binary and analog output functions, perform data handling operations and communicate with external devices.

PLCs must meet the requirements of Class A computing devices, and must be labeled as set forth in 47 CFR 15 and must be able to withstand conducted susceptibility test as outlined in NEMA ICS 1, NEMA ICS 2, NEMA ICS 3, and IEEE C37.90.1. PLCs must function properly at temperatures between 32 and 122 degrees F at 5 to 95 percent relative humidity non-condensing and must tolerate storage temperatures between minus 40 and plus 140 degrees F at 5 to 95 percent relative humidity non-condensing.

2.23.2 Modular PLC

PLCs must be based on a modular, field expandable design allowing the system to be tailored to the process control application. The system must be expandable through the use of additional hardware and/or user software. As a minimum, the PLC must include a mounting backplane, power supply module, central processing unit (CPU) module, communications module, and input/output (I/O) module. The modules must be grouped together in a mounting rack or cabinet. The mounting rack backplane must provide the communications mechanism to fully integrate the individual modules located within the rack. Modules other than I/O modules must also plug directly

SECTION 25 00 00.00 22 Page 17 into the backplane. The use of wire connectors between modules will not be allowed except for expansion of the system to include multiple backplanes. The rack size must be as needed to hold the equipment necessary while performing the required control functions.

2.23.2.1 Central Processing Unit (CPU) Module

The CPU module must be a self-contained, microprocessor based unit that provides time of day, scanning, application program execution, storage of application programs, storage of numerical values related to the application process and logic, I/O bus traffic control, peripheral and external device communications and self diagnostics. The scan time must be 25 milliseconds or less including spare I/O channels.

2.23.2.2 Communications Module

The communications module must allow peer-to-peer communication with other PLCs and must allow the PLC to communicate with the central station, or workstation.

The communication module must utilize the manufacturer's standard communication architecture and protocol, ethernet architecture and protocol or a combination of these. The communication module must allow programming of the PLC to be done locally through the use of a laptop computer.

2.23.2.3 Power Supply Module

One or more power supply modules must be provided as necessary to power other modules installed in the same cabinet. Auxiliary power supplies may be used to supply power to remote cabinets or modules.

a. Power supply modules must use AC power with a nominal voltage of

120 vAc plus or minus 5 percent. The power supply module must monitor the incoming line voltage level and must provide over current and over voltage protection. If the voltage level is detected as being out of range the power supply module must continue to provide power for an adequate amount of time to allow for a safe and orderly shutdown. Power supply modules must be capable of withstanding a power loss for a minimum of 20 milliseconds while remaining in operation and providing adequate power to all connected modules.

b. Each power supply module must be provided with an on-off switch integral to the module. If the manufacturer's standard power supply module is not provided with an on-off switch, a miniature toggle type switch must be installed near the PLC and must be clearly labeled as to its function.

c. Provide power supply modules with an indicating light which must be lit when the module is operating properly.

2.23.2.4 Input/Output (I/O) Modules

Modules must be self-contained, microprocessor-based units that provide an interface to field devices. The modules must be located in the same cabinet as the other PLC components. Each module must contain visual indication to display the on-off status of individual inputs or outputs.

Each I/O must be protected against reversal of polarity of the signal. Analog inputs and analog outputs must have 'open, short and out of range circuit' detection. Configuration to detect these faults must be configurable per channel.

2.23.3 Program Storage/Memory Requirements

The CPU must utilize the manufacturer's standard non-volatile memory for the operating system. The controller must have electronically readable and writeable

SECTION 25 00 00.00 22 Page 18 non-volatile memory (EPROM, EEPROM, or Flash PROM) and battery backup volatile memory. Must be possible to change battery with power on for storage of user programs. The user programs must be loaded through the through the use of a laptop computer. The CPU memory capacity must be based on the system's control requirements. The memory capacity must be sized such that, when the system is completely programmed and functional, no more than 50 percent of the memory allocated for these purposes is used. A minimum of 16GB shall be provided.

2.23.4 Input/Output Characteristics

Each controller must allow for analog input, analog output, binary input and binary output. The number and type of inputs and outputs for the system must be as shown on the drawings and must comply with the sequence of control. The system capacity must include a minimum of 20 percent spare input and output points (no less than four points) for each point type provided. During normal operation, a malfunction in any input/output channel must affect the operation of that channel only and must not affect the operation of the CPU or any other channel. All input circuits must have a minimum optical isolation of 1500

VRMS and must be filtered to guard against high voltage transients from the externally connected devices. All output circuits must have a minimum optical isolation of 1500 VRMS and must be filtered to guard against high voltage transients from the externally connected devices.

2.23.4.1 Analog Inputs

Analog input circuits must be available in 4-20 mA.

2.23.4.2 Digital Inputs

Binary input circuits must be available in 10-30 vDc.

2.23.4.3 Analog Outputs

Analog output circuits must be available in 4-20 mA.

2.23.4.4 Digital Outputs

Binary output circuits must be available in 10-30 vDc.

2.23.4.5 Pulse Inputs

Pulse inputs must be able to detect a pulse of 1 milliseconds or less.

2.23.5 Wiring Connections

Wiring connections must be heavy duty, self-lifting, pressure type screw terminals to provide easy wire insertion and secure connections. The terminals must accept two #14 AWG wires. A hinged protective cover must be provided over the wiring connections. The cover must have write-on areas for identification of the external circuits.

2.23.6 On-Off Switch

Each controller must be provided with an integral on-off power switch. If the controller is not provided with a manufacturer's standard on-off switch, a miniature toggle type switch must be installed in the control panel near the controller and must be clearly labeled as to its function.

2.23.7 Diagnostics

Each PLC must have diagnostic routines implemented in firmware. The CPU must

SECTION 25 00 00.00 22 Page 19 continuously perform self-diagnostic routines that will provide information on the configuration and status of the CPU, memory, communications and input/output. The diagnostic routines must be regularly performed during normal system operation. A portion of the scan time of the controller must be dedicated to performing these housekeeping functions. In addition, a more extensive diagnostic routine must be performed at power up and during normal system shutdown. The CPU must log input/output and system faults in fault tables which must be accessible for display. When a fault affects input/output or communications modules the CPU must shut down only the hardware affected and continue operation by utilizing the healthy system components. All faults must be annunciated at the PLC and the HMI. Diagnostic software must be useable in conjunction with the portable tester. The following diagnostics must be performed:

d. Analog Inputs: Sensor out of range, open or shorted loop, analog-to-digital converter check

e. Analog Outputs: Open or shorted loop

f. Configuration: Check compatibility and availability of selected I/O hardware and software

g. Memory: Checksum, parity check End-to End CPU memory

2.23.8 Accuracy

Controllers shall have an accuracy of plus or minus 0.25 percent of input span.

2.24 PLC SOFTWARE

2.24.1 Operating System

Each PLC must be provided with the manufacturer's standard operating system software package. The PLC must maintain a point database in its memory that includes all parameters, constraints and the latest value or status of all points connected to the PLC. Execution of the PLC application programs must use the data in memory resident files. The operating system must support a full complement of process control functions. It must be possible to define these functions using a mix of ladder logic diagrams, function blocks, sequential function charts and text programming. Programming methods and interactions must be based on IEC 61131-3. A combination of the programming methods must be possible within a single controller. The operating system must allow loading of control logic locally. It must also support data entry and diagnostics using an operator interface panel attached directly to the PLC. Each PLC must be capable of operating in standalone mode.

2.24.1.1 Startup

The PLC must have startup software that causes automatic commencement of operation without human intervention, including startup of all connected I/O functions. A

PLC restart program based on detection of power failure at the PLC must be included in the PLC software. The restart program must include start time delays between successive commands to prevent demand surges or overload trips.

2.24.1.2 Failure Mode

Upon failure for any reason, each PLC must perform an orderly shutdown. Systems which are not Primary/Secondary must force all PLC outputs to a predetermined

(failure mode) state, consistent with the failure modes shown and the associated control device. Primary/Secondary systems must transfer I/O scan and control to the PLC not currently failed.

SECTION 25 00 00.00 22 Page 20

2.24.2 Functions

The controller operating system must be able to scan inputs, control outputs, and read and write to its internal memory in order to perform the required control as indicated in the sequence of control on the drawings and as noted here in the

Contract Documents. The controller must periodically perform self-diagnostics to verify that it is functioning properly.

2.24.2.1 Analog Monitoring

The system shall measure and transmit all analog values including calculated analog points.

2.24.2.2 Logic (Virtual)

Logic (virtual) points must be software points entered in the point database which are not directly associated with a physical I/O function. Logic (virtual) points must be analog or binary points created by calculation from any combination of binary and analog points, or other data having all the properties of real points, including alarms, without the associated hardware. Logic (virtual) points must be defined or calculated and entered into the database. The calculated analog point must have point identification in the same format as any other analog point.

2.24.2.3 State Variables

If an analog point represents more than two (up to 8) specific states, each state must be nameable. For example, a level sensor must be displayed at its measured engineering units plus a state variable with named states usable in programs or for display such as low alarm/low/normal/high/high alarm.

2.24.2.4 Binary Alarms

Binary alarms are those abnormal conditions indicated by BIs as specified and shown. The system must automatically suppress analog alarm reporting associated with a binary point when that point is turned off.

2.24.2.5 Analog Alarms

Analog alarms are those conditions higher or lower than a defined value, as measured by an AI. Analog readings must be compared to predefined high and low limits, and alarmed each time a value enters or returns from a limit condition.

Unique high and low limits must be assigned to each analog point in the system. In control point adjustment (CPA) applications, key the limit to a finite deviation traveling with the setpoint. The system must automatically suppress analog alarm reporting associated with an analog point when that analog point is turned off.

2.24.2.6 Pulse Accumulator (PA) Alarms

Pulse accumulator alarms are those conditions calculated from totalized values of accumulator inputs or PA input rates that are outside defined limits as specified and shown. PA totalized values must be compared to predefined limits and alarmed each time a value enters a limit condition. Unique limits must be assigned to each

PA point in the system.

2.24.3 Constraints

2.24.3.1 Equipment Constraints Definitions

Each control point in the database must have PLC resident constraints defined and entered by the Contractor, including as applicable: maximum starts (cycles) per hour; minimum off time; minimum on time; high limit (value in engineering units);

SECTION 25 00 00.00 22 Page 21 and low limit (value in engineering units).

2.24.3.2 Constraint Checks

All control devices connected to the system must have the PLC constraints checked and passed before each command is issued. Each command point must have unique constraints assigned. High and low "reasonableness" values or one differential

"rate-of-change" value must be assigned to each AI. Constraint checks shall also include checking if an analog signal is less than 4 mA or greater than 20 mA <and other criteria, as appropriate>. Each individual point must be capable of being selectively disabled by the operator from the central station. Signals that fail constraint checks shall be designated as Failed by the system.

2.24.4 Control Sequences and Control Loops

Specific functions to be implemented are defined in individual system control sequences and database tables shown on the drawings, and must include, as applicable, the following functions: PI control must provide proportional control and proportional plus integral control; two position control must provide control for a two state device by comparing a set point against a process variable and an established dead band; floating point control must exercise control when an error signal exceeds a selected dead band, and must maintain control until the error is within the dead band limits; signal selection must allow the selection of the highest or lowest analog value from a group of analog values as the basis of control and must include the ability to cascade analog values so that large numbers of inputs can be reduced to one or two outputs; signal averaging must allow the mathematical calculation of the average analog value from a group of analog values as the basis of control and must include the ability to "weight" the individual analog values so that the function output can be biased as necessary to achieve proper control; reset function must develop an AO based on up to two AIs and one operator specified reset schedule.

2.24.5 Command Priorities

A scheme of priority levels must be…