Updated_Specifications_40_95_00.pdf

Braddock L/D Dam Gate Control Upgrade

SECTION TABLE OF CONTENTS

DIVISION 40 - PROCESS INTERCONNECTIONS

SECTION 40 95 00

PROCESS CONTROL

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SYSTEM DESCRIPTION

1.3.1 General Requirements

1.3.2 Operation

1.3.3 Points

1.3.4 Data Transmission Systems (DTS)

1.4 SUBMITTALS

1.5 SEQUENCING

1.6 QUALIFICATIONS

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

2.1.2 Nameplates

2.2 GENERAL REQUIREMENTS

2.3 MONITORING AND CONTROL PARAMETERS

2.4 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.4.1 PLC General Requirements

2.4.2 Modular Chassis Based PLC

2.4.2.1 Central Processing Unit (CPU) Module

2.4.2.2 Communications Module

2.4.3 Program Storage/Memory Requirements

2.4.4 Diagnostics

2.5 PLC SOFTWARE

2.5.1 Operating System

2.5.1.1 Startup

2.5.1.2 Failure Mode

2.5.2 Functions

2.5.2.1 Analog Monitoring

2.5.2.2 Logic (Virtual)

2.5.2.3 State Variables

2.5.3 PLC Logic Documentation

2.5.3.1 Address and Rung Comments

2.5.3.2 Program Tags

2.6 CONTROL PANELS

2.6.1 Components

2.6.1.1 Enclosures

2.6.1.2 Terminal Blocks

2.6.1.3 Graphical User Interface

2.6.2 Panel Assembly

2.6.3 Electrical Requirements

2.6.4 Grounding

SECTION 40 95 00 Page 1 Certified Final RTA -W911WN-17-B-8002 Revised b y Amendment 0001

2.7 LAN ETHERNET SWITCHES

PART 3 EXECUTION

3.1 EQUIPMENT INSTALLATION REQUIREMENTS

3.1.1 Installation

3.1.1.1 Isolation, Penetrations and Clearance from Equipment

3.1.1.2 Device Mounting

3.2 INSTALLATION OF EQUIPMENT

3.2.1 Control Panels

3.2.2 Enclosures

3.3 WIRE, CABLE AND CONNECTING HARDWARE

3.3.1 LAN Cables and Connecting Hardware

3.3.2 Power Line Surge Protection

3.4 SOFTWARE INSTALLATION

3.5 CONTROL DRAWINGS

3.6 FIELD TESTING AND ADJUSTING EQUIPMENT

3.6.1 Performance Verification Test (PVT)

3.6.2 Exclusions

3.7 MANUFACTURERS' FIELD SERVICES

3.8 FIELD TRAINING

3.8.1 Preliminary Operator Training

3.8.2 Additional Operator Training

3.8.3 Maintenance Training

-- End of Section Table of Contents --

SECTION 40 95 00 Page 2

SECTION 40 95 00

PROCESS CONTROL

PART 1 GENERAL

1.1 REFERENCES

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

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C37.90.1 (2013) Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus

IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossary of Terms & Definitions

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 61131-2 (2007) Programmable Controllers - Part 2:

Equipment Requirements and Tests

IEC 61131-3 (2013) Programmable Controllers - Part 3:

Programming Languages

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

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

47 CFR 15 Radio Frequency Devices

1.2 DEFINITIONS

Definitions, Symbols, and engineering unit abbreviations shall conform to IEEE Stds Dictionary, as applicable.

1.3 SYSTEM DESCRIPTION

The process instrumentation and control system shall be used to monitor and control the operation of Braddock Dam. The new control system shall provide for operator interaction, overall control system supervision, and

SECTION 40 95 00 Page 3 process equipment control and monitoring. Provide hardware configured and sized to support expansion as specified and shown on the drawings.

1.3.1 General Requirements

The Braddock Dam Gate Control System Upgrade focuses on the migration from a Rockwell Automation (RA) SLC 500 based control system to an open architecture Rockwell Automation Logix based control system utilizing Ethernet communications. The existing dam gate control system consists of four Rockwell Automation SLC 5/04 processors, one per dam gate, communicating via Data Highway Plus (DH+) on fiber optic cable to one Human Machine Interface (HMI) personal computer (PC). Each individual dam gate SLC 5/04 processor communicates locally to two RA Remote I/O racks and a RA Dataliner display.

Upon completion of the upgrade, the new dam gate control system shall consist of four RA CompactLogix PLC processors, one for each dam gate, and three HMI PCs communicating via Ethernet. The existing SLC 5/04 processors and Remote I/O modules shall be replaced with RA 1747-AENTR modules. A new RA CompactLogix PLC processor and Stratix managed Ethernet switch shall be mounted in a new enclosure mounted next to each existing local dam gate control station. The existing Dataliner and gate position LCD displays shall be replaced with a RA PanelView Plus 6 (700 Model) graphic display touch screen terminal with Ethernet communications.

The existing Engineering laptop PC and dam gate control desktop PC shall be replaced with new government furnished PCs. All programming software, operator interface software, and communications shall be upgraded or provided as new to form a complete control system on a Windows 7 operating system installed by the Corps of Engineers on the Government furnished PCs. A total of three PCs shall be Government furnished equipment; one PC shall be connected to the Ethernet dam gate control network in the Middle Wall Operations Building, one PC shall be connected to the Ethernet dam gate control network via fiber optic cable in the Land Wall Administration Building, and one laptop PC shall be connected to the Ethernet dam control network in the Middle Wall Operations Building. Currently, only the Middle Wall PC is operating as a standalone RSView SE HMI operator interface terminal. The RSView SE software on the Middle Wall PC will have to be upgraded to the latest compatible version of FTView SE. The new PC on the Land Wall shall also be configured as a standalone HMI operator interface terminal and one new FTView SE license will be required. The laptop PC shall be configured as an Engineering work station and shall contain new RSLogix5000 and Studio 5000 fully licensed programming software.

The existing fiber optic cabling between the dam and the Middle Wall Operations Building shall be utilized for Ethernet communications. Two new 24-fiber fiber optic cables shall be installed, terminated, and tested between the Land Wall Administration Building and the second floor of the Middle Wall Operations Building. The new fiber optic cables shall be routed in existing raceways, cable trays, and conduits where available.

The lock chamber crossover is normally flooded and shall be pumped out by site personnel. All existing copper DH+ and Remote I/O cables shall be removed. All new Ethernet cables and copper to fiber media converters shall be provided as necessary for communications between devices.

1.3.2 Operation

The control system provided under this specification shall operate using programmable logic controllers (PLC) utilizing existing ladder logic type

SECTION 40 95 00 Page 4 programming software to provide the required sequences of operation. The number and location of control panels shown on drawings shall be provided as a minimum.

1.3.3 Points

Inputs to and outputs from the control system shall be as installed. Each connected analog output (AO), analog input (AI), digital output (DO), digital input (DI), pulse accumulator (PA), SSI-Synchronous Serial Interface input and other input or output device connected to the control system shall represent a "point" where referred to in this specification.

Soft points are points that are generated within a control system such as setpoints, alarm limits, and internal circuit system diagnostics and parameters that don't represent a physically connected Input/Output but are still utilized for control and (GUI)graphical user interface display. As shown in the (I/O) summary tables on the drawings many inputs and outputs are required to be safety rated I/O of a particular safety category level.

This is partially achieved through varying degrees of dual inputs, dual monitored inputs, and dual monitored inputs with discrepancy monitoring wired to safety I/O modules but only fully realized with configuration and logic within the PLC.

1.3.4 Data Transmission Systems (DTS)

Data transmission systems for communication between PLCs, and the HMI PCs shall be as shown on the drawings. The application of industrial protocols and industrial data transmission equipment will be contained in this specification and as shown on the drawings.

1.4 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-01 Preconstruction Submittals

Testing, Adjusting and Commissioning; G, DO Qualifications; G, DO

SD-02 Shop Drawings

Installation; G, DO Wiring; G, DO

Detail drawings containing complete piping, wiring, schematic, flow diagrams and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Piping and Instrumentation (P&ID) drawings (prepared using industry recognized device symbols, clearly defined and describing piping designations to define the service and materials of individual pipe segments and instrument tags employing Instrument Society of America suggested identifiers). Include in the Drawings, as appropriate: product specific catalog cuts; a drawing index; a list of symbols; a series of drawings for each control system using abbreviations, symbols, nomenclature and identifiers as shown; valve schedules; compressed instrument air station

SECTION 40 95 00 Page 5 schematics. In addition, drawing sheets shall contain field termination points. Generic, typical drawings shall not be accepted unless specifically noted in the required submittal drawing package requirements.

Control Panel Drawings; G, DO

Detailed control panel shop drawing packages will be provided for review. Each drawing package will include as a minimum the following sheets. The listed sheets are in the order of appearing in the drawing packages. Each drawing package shall include all the required information to build a complete assembly.

Drawing Sheets

1. Title Sheet and drawing legend

2. Symbol and abbreviation tables

3. Internal control panel power distribution

4. Panel hardwired logic and control circuits

5. PLC Chassis/Rack Layout

6. Panel door layout along with cut-out dimensions

7. Subplate layout and terminal block listings

8. Panel and Field device tagging

9. Bill of materials with full part numbers

Individual and common control panel shop drawing packages will be provided for review as listed below as a minimum. These same drawing packages will also be required for final review after completion of equipment installation and commissioning for "as installed" and "as-built" confirmation.

Control Panel Drawing Packages

New PLC Controller Enclosure, Gates 1 - 4; G, DO

SD-03 Product Data

Control Drawings; G, DO

Manufacturer's descriptive and technical literature, performance charts and installation instructions. Product specific catalog cuts shall be in booklet form, indexed to the unique identifiers, and shall consist of data sheets that document compliance with the specification. Where multiple components are shown on a catalog cut, the application specific component shall be marked.

The full part number shall be provided as an integral part of the cuts showing part number break down, and all options that are being specified as part of the assembly. This can be accomplished by circling appropriate items on a scanned cut sheet. Where cut sheets don't provide appropriate part number detail a separately generated sheet shall be submitted. All items shall be described with sufficient detail to provide the reviewing entity precise information as to the equipment without any need for interpretation. Control panel components considered commodity items such as panel wireway, terminals, terminal end barriers, terminal end anchors, din-rail, ground lug, and ground bar, don't require additional technical literature if described with sufficient detail in the control panel shop drawing set bill of

SECTION 40 95 00 Page 6 materials sheet.

Items shall identify and reference usage back to control panels and any other assemblies in which the equipment shall be used.

Items that will require technical literature will include but not be limited to:

Panel enclosures; G, DO Circuit protection as fuses, fuseblocks, circuit breakers; G, DO Power supplies; G, DO PLCs; G, DO PLC and Remote I/0 Communication modules; G, DO PLC I/O cards and expansion modules; G, DO Remote I/O Adapter modules; G, DO Instrumentation Wiring; G, DO Network Ethernet switches and connectors; G, DO PLCs and chassis; G, DO Graphical user interfaces; G, DO PLC I/O Terminal Block wiring systems; G, DO Preconfigured cabling systems; G, DO Sensors and Meters; G, DO

Training Manual; G, DO

Instruction manual within 200 days of Notice to Proceed.

Performance Verification Test (PVT); G, DO

The performance verification test procedure; it shall refer to the actions and expected results to demonstrate that the control system performs in accordance with the sequence of control.

Include a list of the equipment to be used during the testing plus manufacturer's name, model number.

Factory Test Procedure; G, DO

Documentation containing factory test methods and procedures.

SD-06 Test Reports

Performance Verification Test(PVT); G, DO

SD-10 Operation and Maintenance Data

Instrumentation and Control System; G, DO

Six (6) complete bound hardcopies of operating instructions outlining the step-by-step procedures required for system startup, operation and shutdown. Include in the instructions layout, wiring and control diagrams of the system as installed, the manufacturer's name, model number, service manual, parts list and a brief description of all equipment and their basic operating features. Manuals to include information relevant to reordering and field troubleshooting. Do not include hardcopies of programming manuals. Programming manuals shall be in electronic format.

One (1)electronic copy on CD of the above Operating and Maintenance Manuals.

SECTION 40 95 00 Page 7

One (1) fully documented electronic copy on CD of the PLC programmable logic controller developed software. Data tables, spreadsheets, and any supporting documentation used for developing the memory layout and program structure shall be included.

Programming manuals and instruction books shall be included with electronic copies.

One (1) electronic copy on CD for each graphical user interface system. Any supporting documentation used for screen and database development shall be included.

One (1) electronic copy on CD of each configurable industrial network file including EDS (Electronic Data Sheet) files. This includes any Ethernet switch configurations and files.

One (1) electronic copy on CD and six (6) hard copies of all installed "as-built" drawings this includes but is not limited to the drawings provided for submittals. ·

CD's shall be marked with version and date. O&M Manuals shall be of type where individual documents can be easily updated.

Preliminary 0 & M Manual shall be submitted electronically on CD only. If bound hardcopies 0 & M manual sets contains multiple binders, then one of binders shall contain the appropriate documents required for field trouble-shooting. All binders shall have spine labels indicating volume number in the set like 1 of 3, 2 of 3 so all manuals can be accounted for.

Manuals shall include a list of critical spares and separate list of maintenance spares. Critical spares are items causing extended downtime due to failure. Maintenance spares are all items required to recover from a typical fault or required for typical maintenance.

This final documentation will be in addition to any documentation and submittals that are required during the design phase.

1.5 SEQUENCING

Project execution and construction for process controls shall be sequenced as follows: site conditions survey, control panel hardware design and approval process, field instrumentation and control equipment approval process, control panel fabrication and software (PLC, graphical user interface screen)development, field device and instrumentation procurement, software and graphical user interface screen approval process, pull ahead work, dam gate shutdown, new control system installation, pre start-up commissioning performed concurrently with installation, post installation start-up & commissioning, PVT, and final as-built documentation.

1.6 QUALIFICATIONS

Ther Contractor's qualified control system interator shall provide evidence thay have workee with and installed Rockwell Automation RSLogix5000 programming software for at least the past five years. The Contraactor performing the software and PLC upgrades shall submit evidence they are officially recognized by Rockwell Automation as a Rockwell Automation Recognized Systems Integrator.

SECTION 40 95 00 Page 8

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

Materials and equipment shall be standard unmodified products of a manufacturer regularly engaged in the manufacturing of such products.

Units of the same type of equipment shall be products of a single manufacturer. Items of the same type and purpose shall be identical and supplied by the same manufacturer, unless replaced by a new version approved by the Government.

All internal panel components will be labeled using laminated plastic, black text with white background. The tagging will be permanently mounted to the panel subplate or door through tag track, screws or rivets, adhesives will not be allowed. Tags will not be allowed to be mounted on field serviceable panel components.

2.1.2 Nameplates

Each major component of equipment shall have the manufacturer's name and address, and the model and serial number in a conspicuous place. Laminated plastic nameplates shall be provided for equipment devices and panels furnished. Each nameplate shall identify the device, such as pump "P-1" or valve "VLV-402". Labels shall be coordinate with the schedules and the process and instrumentation drawings. Laminated plastic shall be 1/8 inch thick, white with black center core. Nameplates shall be a minimum of 1 by 3 inches with minimum 1/4 inch high engraved block lettering. Nameplates for devices smaller than 1 by 3 inches shall be attached by a nonferrous metal chain. All other nameplates shall be permanently attached to the device through screws or rivets-adhesives will not be allowed.

2.2 GENERAL REQUIREMENTS

Equipment and wiring must be in accordance with NFPA 70, with proper consideration given to environmental conditions such as moisture, dirt, corrosive agents, and hazardous area classification. Field devices and instrumentation such as limit switch, valves, level sensors, and level switches but not limited to shall be provided as completely installed assemblies which include all mounting brackets, tripper plates, shims, coupling, and fittings. Equipment shall be NEMA rated. IEC rating may be approved.

2.3 MONITORING AND CONTROL PARAMETERS

The control system shall be complete including sensors, field preamplifiers, signal conditioners, offset and span adjustments, amplifiers, transducers, transmitters, control devices, engineering units conversions and algorithms for the applications; and shall maintain the specified end-to-end process control loop accuracy from sensor to display and final control element. Control equipment shall be powered by a 120 vAc, single phase, 60 Hz power supply mounted in a standalone enclosure near the control panel or within the motor control centers. Enclosures shall be rated for NEMA 12 unless noted otherwise on the drawings. Sensors and Meters shall provide signals compatible with the control system for seamless integration.

SECTION 40 95 00 Page 9

2.4 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.4.1 PLC General Requirements

PLCs shall be micro-processor based, capable of receiving discrete and analog inputs and, through programming, shall be able to control discrete and analog output functions, perform data handling operations and communicate with external devices. PLCs shall meet the requirements of Class A computing devices, and shall be labeled as set forth in 47 CFR 15 and shall be able to withstand conducted susceptibility test as outlined in IEC 61131-2 and IEEE C37.90.1. PLCs shall function properly at temperatures between 32 and 122 degrees F at 5 to 95 percent relative humidity non-condensing and shall tolerate storage temperatures between minus 40 and plus 140 degrees F at 5 to 95 percent relative humidity non-condensing.

2.4.2 Modular Chassis Based PLC

PLCs shall be based on a modular, field expandable design allowing the system to be tailored to the process control application. The system shall be expandable through the use of additional hardware and/or user software.

As a minimum, the PLC shall include a mounting backplane (chassis), power supply module, central processing unit (CPU) module, communications module, and input/output (I/O) module. The modules shall be grouped together in a mounting rack and installed in an industrial enclosure. The mounting rack backplane (chassis) shall provide the communications mechanism to fully integrate the individual modules located within the rack. The use of wire connectors between modules will not be allowed. The rack size shall be as needed to hold the equipment necessary while performing the required control functions. PLC I/O cards and expansion modules will provide system configurability to the required applications. The system configuration shall allow for the removal and/or installation of modules under power.

2.4.2.1 Central Processing Unit (CPU) Module

The CPU module shall be a self contained, microprocessor based unit that provides time of day, scanning, application (ladder rung logic) 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.

Development of standard control shall be through a single project using common development software.

Provide Rockwell Automation Compact Logix Process Module #1769-L30ER.

2.4.2.2 Communications Module

Remote I/O Adapter modules shall allow peer-to-peer communication with other PLCs, Remote I/O modules and shall allow the PLC to communicate with existing dam gate control I/O modules and PC HMI Control Stations. The communication module shall utilize the manufacturer's standard (native) communication architecture and protocol, Ethernet/IP (Industrial Protocol). The communication module shall allow programming of the PLC to be done locally through the use of a laptop computer or from the engineering workstation. These shall be provided per the drawings and shall be the latest revisions providing the maximum connectivity.

Devices that bridge different communication protocols via a memory map or thru polling devices are prohibited. Bridge devices shall directly

SECTION 40 95 00 Page 10 repackage the packet and transmit the embedded command to the target device.

Provide Rockwell Ethernet/Adapter #1747-AENTR #1756-EN2T.

2.4.3 Program Storage/Memory Requirements

The CPU shall utilize the manufacturer's standard non-volatile memory for the operating system. The controller shall have electronically erasable, programmable, read only memory (EEPROM) for storage of user programs and battery backed RAM for application memory. The CPU memory capacity shall be based on the system's control requirements. The memory capacity shall 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.

2.4.4 Diagnostics

Each PLC shall have diagnostic routines implemented in firmware. The CPU shall 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 shall be regularly performed during normal system operation. A portion of the scan time of the controller shall be dedicated to performing these housekeeping functions. In addition, a more extensive diagnostic routine shall be performed at power up and during normal system shutdown. The CPU shall log input/output and system faults in fault tables which shall be accessible for display. When a fault affects input/output or communications modules the CPU shall shut down only the hardware affected and continue operation by utilizing the healthy system components. All faults shall be annunciated at control consoles. Safety I/O in addition to performing internal circuit diagnostics also performs external safety diagnostics of safety circuits. This is accomplished through the use of pulse outputs, dual channel monitoring, dual channel monitoring with discrepancy, in which faulted devices can be detected in the form of shorts, faults, and welded contacts. Safety I/O shall be wired and programmed as per the drawings to comply with the expected safety categories as listed in the tables.

2.5 PLC SOFTWARE

All PLC software described in this specification shall be furnished as part of the complete control system.

2.5.1 Operating System

Each PLC shall be provided with the manufacturer's latest firmware and development system software package. At the beginning of the software development phase, the latest firmware and development software shall be baselined for the project. Version updates during the software development/test phases shall only be done if necessary. The PLC shall 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 shall use the data in memory resident files. The operating system shall support a full compliment of process control functions. It shall be possible to define these functions using a mix of function blocks, ladder logic diagrams, sequential function charts and text programming. Programming methods and interactions shall be based on IEC 61131-3. A combination of the programming methods shall be possible within a single controller. The operating system shall allow loading of software locally or from the engineering work station and data files from the portable tester. It shall

SECTION 40 95 00 Page 11 also support data entry and diagnostics graphical user interfaces at control consoles and lockmaster HMI (GUI) communicating on Ethernet/IP utilizing CIP protocols to the PLC. Each PLC shall be capable of operating in stand alone mode. The Contractor will be responsible to provide the latest revisions of firmware, software, service packs, patches.

The number of software packages/protocols shall be limited. Custom drivers/software shall not be used. Software shall be typical off the shelf and seamlessly integrated.

Provide Rockwell #RSLogix5000, RSNetworx, RSLinx, FactoryTalk

2.5.1.1 Startup

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

2.5.1.2 Failure Mode

Upon failure for any reason, each PLC shall perform an orderly shutdown and force all PLC outputs to a predetermined (failure mode) state, consistent with the failure modes shown and the associated control device.

2.5.2 Functions

The controller operating system shall be able to scan inputs, control outputs, and read and write to its internal memory in order to perform the required control.

2.5.2.1 Analog Monitoring

The system shall measure and transmit all analog values including calculated analog points. All analog signal scaling, calculations, and totals shall be done at the PLC level so the same data value can be used by the processors and displayed on multiple interfaces. Parallel data streams for unscaled data are prohibited. Scaling within the developed graphical user interface screens will not be allowed. Analog values shall be averaged at the PLC Level. Use of instantaneous analog values will require government approval.

2.5.2.2 Logic (Virtual)

Logic (virtual) points shall be software points entered in the point database which are not directly associated with a physical I/O function.

Logic (virtual) points shall be analog or digital points created by calculation from any combination of digital and analog points, or other data having all the properties of real points, including alarms, without the associated hardware. Logic (virtual) points shall be defined or calculated and entered into the database. The calculated analog point shall have point identification in the same format as any other analog point.

2.5.2.3 State Variables

If an analog point represents more than two (up to 8) specific states, each state shall be nameable. For example, a level sensor shall 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

SECTION 40 95 00 Page 12 alarm.

2.5.3 PLC Logic Documentation

The PLC program shall be fully documented to aid in understanding program operation.

2.5.3.1 Address and Rung Comments

Address and Rung comments shall be utilized to describe operation of algorithms, subroutines, blocks of logic, to aid in understanding the operation of the program and troubleshooting.

2.5.3.2 Program Tags

The specified Rockwell PLC allows for the creation of program tags as part of its data base and programming. These will be of a particular data type like integer, Boolean, real, float as an example. The tag naming convention shall utilize a mix of names and acronyms to describe usage in the program.

For example, "Gate G2S_Position" of Data Type Real could be the tag name for the actual position of Gate G-2S from 0 to 100% open. This is in contrast to traditionally PLCs of the past that utilized address based programming.

2.6 CONTROL PANELS

2.6.1 Components

Instrumentation Wiring

2.6.1.1 Enclosures

Panel enclosures for each PLC control panel shall conform to the requirements of NEMA 250 for the types specified. Enclosures shall be as shown on the drawings. Finish color shall be the manufacturer's standard ANSI 49 or 61 gray, unless otherwise indicated. Damaged surfaces shall be repaired and refinished using original type finish.

Provide Enclosures and quantities per the drawings

2.6.1.2 Terminal Blocks

Terminal blocks for conductors exiting control panels shall be two-way type with double terminals, one for internal wiring connections and the other for external wiring connections. Terminal blocks shall be made of bakelite or other suitable insulating material with full deep barriers between each pair of terminals. A terminal identification strip shall form part of the terminal block and each terminal shall be identified by a number in accordance with the numbering scheme on the approved wiring diagrams.

Provide Rockwell #1492-W4 and accessories approved equal

2.6.1.3 Graphical User Interface

Graphical user interfaces shall be the Panelview Plus 6 terminal 700 Model with touch-screen, antiglare overlay. Backlights and bezels shall be field replaceable with an expected life expectancy of 50,000 hours. They shall be provided with Ethernet/IP communication protocols. One graphic user interface will be mounted in each PLC control enclosure per the drawings.

SECTION 40 95 00 Page 13

They shall be programmed using FactoryTalk View Studio Machine Edition development software.

Provide Rockwell #2711P series Provide Rockwell FactoryTalk View Studio Machine Edition Software

2.6.2 Panel Assembly

Control panels shall be factory assembled and shipped to the jobsite as a single unit. Panels shall be fabricated as indicated and devices shall be mounted as shown or required. PLC module I/O shall be wired to labeled terminals to provide ease of field wire installation. Use of wireways and tie wraps shall provide for neat orderly routing of all wire throughout the panel. All terminations and mounting will be torqued to the manufacturers specifications. All equipment shall be mounted per manufacturers specifications for clearances and orientation. If device mounting allows for both din-rail or screw mounting din-rail will be utilized.

2.6.3 Electrical Requirements

Each control panel shall be powered by 120 volts ac from the existing PLC panel. Wiring shall terminate inside the panel on terminal blocks.

Electrical work shall be as shown on the drawings. Panels shall have based on the drawings Circuit protection as fuses, fuseblocks, circuit breakers.

2.6.4 Grounding

Control panel enclosures shall be equipped with a solid copper ground bus or equivalent. The ground bus shall be securely anchored to the enclosure so as to effectively ground the entire structure. Terminals sized large enough to carry the maximum expected current shall be provided on the ground bus for grounding cables. Where a definite circuit ground is required, a single wire not less than #10 AWG shall run independently to the panel ground bus and shall be fastened to the ground bus with a bolted terminal lug. Cases of instruments, relays and other devices shall be effectively grounded through the enclosures steel structure unless otherwise indicated as having device specific grounding terminals.

Insulated wiring having a continuous rated current of not less than the circuit fuse rating shall be used for grounding. Grounding terminals of power receptacles shall be solidly grounded to the panel enclosure. Enough paint shall be removed from panel subplates to indicate and provide proper grounding of ground bus and ground lug. Panel doors shall be provided with bonding provisions to ground panel doors to enclosure grounding bus.

2.7 LAN ETHERNET SWITCHES

Panel mounted network Ethernet switches shall provide communication between network devices using network cables. Network Ethernet switches shall support protocol utilized in the LAN. Control panel Ethernet switches shall be industrial-rated managed switches, modular, din rail mountable, 24vDc powered capable of accepting two power supply connections and expandable from a minimum of 8 10/100 copper ports and 2 SFP slots for fiber transceivers. Each port shall have LED indicator for network monitoring status. Network Ethernet switches shall permit online network changes without disturbing network devices. Other features shall include: Layer 2 capabilities, VLAN, full duplex capabilities on all ports, autonegotiation & manual configurable speed/duplex, IGMP snooping, port mirroring, STP, QoS, SNMP, REP (resilient Ethernet protocol), MAC ID Port Security, bandwidth threshold alarming, DHCP per port, CIP SYNC (IEEE 1588), and

SECTION 40 95 00 Page 14

IEEE802.1x Security. Malfunctioning network devices shall be automatically removed from service without shutting down the network. They shall have removable Compact flash cards for configuration storage and ease of replacement. It shall have the capability of utilizing both resilient ring topologies and star.

Provide Network Ethernet switches and connectors of the type of switch as specified in the drawings along with expansion modules to meet the application, Stratix 8000 series, or approved equal for in panel mounting.

2.10.4 PART 3 EXECUTION

3.1 EQUIPMENT INSTALLATION REQUIREMENTS

3.1.1 Installation

Install system components and appurtenances in accordance with the manufacturer's instructions and shall provide necessary interconnections, services, and adjustments required for a complete and operable system.

Instrumentation and communication equipment and cable grounding shall be installed as necessary to preclude ground loops, noise, and surges from adversely affecting system operation. Adjust or replace devices not conforming to the required accuracies. Factory sealed devices shall be replaced (rather than adjusted). Wiring in exposed areas, including low voltage wiring, shall be installed in metallic raceways or EMT conduit as specified. Wiring in air plenum areas installed without conduit shall be plenum-rated in accordance with NFPA 70.

3.1.1.1 Isolation, Penetrations and Clearance from Equipment

Dielectric isolation shall be provided where dissimilar metals are used for connection and support. Penetrations through and mounting holes in the building exteriors shall be made watertight. Holes in concrete, brick, steel and wood walls shall be drilled or core drilled with proper equipment; conduits installed through openings shall be sealed with materials which are compatible with existing materials. Openings shall be sealed with materials which meet the requirements of NFPA 70. Installation shall provide clearance for control-system maintenance. Control system installation shall not interfere with the clearance requirements for mechanical and electrical system maintenance.

3.1.1.2 Device Mounting

Devices shall be installed in accordance with manufacturers' recommendations and as shown. Control devices to be installed in piping shall be provided with required gaskets, flanges, thermal compounds, insulation, piping, fittings, and manual valves for shutoff, equalization, purging, and calibration. Any deviations shall be documented and submitted to the Government for approval prior to mounting. Damaged insulation shall be replaced or repaired after devices are installed to match existing work. Damaged galvanized surfaces shall be repaired by touching up with zinc paint.

3.2 INSTALLATION OF EQUIPMENT

Install equipment as specified, as shown and as required in the manufacturer's instructions for a complete and fully operational control system.

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3.2.1 Control Panels

Control panels shall be located as indicated on the drawings. Devices located in the control panels shall be as shown on the drawings or as needed to provide the indicated control sequences.

3.2.2 Enclosures

All enclosure penetrations shall be sealed to preclude entry of water using a silicone rubber sealant.

3.3 WIRE, CABLE AND CONNECTING HARDWARE

3.3.1 LAN Cables and Connecting Hardware

LAN cables and connecting hardware shall be installed in as shown on the contract drawings.

3.3.2 Power Line Surge Protection

Control panels shall be protected from power line surges. Surge suppressors shall be MTL Instruments MA15 Series or MA30 Series or approved equal. Fuses shall not be used for surge protection.

3.4 SOFTWARE INSTALLATION

Load software required for an operational control system, including databases (for points specified and shown), operational parameters, and system, command, and application programs. Adjust, tune, debug, and commission all software and parameters for controlled systems to assure proper operation in accordance with the sequences of operation and database tables.

3.5 CONTROL DRAWINGS

"As Built", "As Installed" control drawings and O&M manuals shall be provide as per the submittal process.

3.6 FIELD TESTING AND ADJUSTING EQUIPMENT

Provide personnel, equipment, instrumentation, and supplies necessary to perform site testing. The Government will witness the PVT, and written permission shall be obtained from the Government before proceeding with the testing. Original copies of data produced, including results of each test procedure, during PVT shall be turned over to the Government at the conclusion of each phase of testing prior to Government approval of the test. The test procedures shall cover actual equipment and functions specified for the project.

3.6.1 Performance Verification Test (PVT)

Prepare test procedures for the PVT. The test procedure shall describe all tests to be performed and other pertinent information such as specialized test equipment required and the length of the PVT. The test procedures shall explain, in detail, step-by-step actions and the expected results, to demonstrate compliance with all the requirements of the drawings and this specification. The test procedure shall be site specific and based on the inputs and outputs, required calculated points and the sequence of control.

Demonstrate that the completed Control system complies with the contract

SECTION 40 95 00 Page 16 requirements. All physical and functional requirements of the project including communication requirements shall be demonstrated and shown.

Demonstrate that each system operates as required in the sequence of operation. The PVT as specified shall not be started until after receipt by the Contractor of written permission by the Government, based on the Contractor's written report including certification of successful completion of testing, adjusting and commissioning as specified, and upon successful completion of training as specified. Upon successful completion of the PVT, deliver test reports and other documentation as specified to the Government.

3.6.2 Exclusions

The Contractor will not be held responsible for failures resulting from the following: Outage of the main power supply in excess of the capability of any backup power source, provided that the automatic initiation of all backup sources was accomplished and that automatic shutdown and restart of the control system performed as specified. Failure of a Government furnished communications link, provided that the PLC automatically and correctly operates in the stand-alone mode as specified, and that the failure was not due to Contractor furnished equipment, installation, or software. Failure of existing Government owned equipment, provided that the failure was not due to Contractor furnished equipment, installation, or software.

3.7 MANUFACTURERS' FIELD SERVICES

Obtain the services of a manufacturer's representative experienced in the installation, adjustment, and operation of the equipment specified. The representative shall supervise the installing, adjusting, and testing of the equipment.

3.8 FIELD TRAINING

Field training oriented to the specific system shall be provided for designated personnel. Furnish a copy of the training manual for each trainee plus two additional copies. Manuals shall include an agenda, the defined objectives for each lesson, and a detailed description of the subject matter for each lesson. Furnish audiovisual equipment and other training supplies and materials. Copies of the audiovisuals shall be delivered with the printed training manuals. The Government reserves the right to videotape training sessions for later use. A training day is defined as 8 hours of classroom instruction, excluding lunchtime, Monday through Friday, during the daytime shift in effect at the training facility. Submit the training manual and schedule to receive approval from the Government at least 30 days before the training.

3.8.1 Preliminary Operator Training

Prior to the start of field testing, preliminary operator training shall be taught at the project site for 2 consecutive training days. Upon completion of this course, each student, using appropriate documentation, should be able to perform elementary operations with guidance and describe the general hardware architecture and functionality of the system. This course shall include: general system architecture; functional operation of the system, including control consoles; operator commands; application programs, control sequences, and control loops.

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3.8.2 Additional Operator Training

Following the field testing, additional classroom training for operators shall be taught for 2 consecutive training days; individual instruction sessions of 4-hour periods in the morning (or afternoon) of the same weekday for 1 weeks and an additional 1 day classroom session for answering operator questions. Individual instruction shall consist of "hands-on" training under the constant monitoring of the instructor. Classroom training shall include instruction on the specific hardware configuration of the installed control system and specific instructions for operating the installed system. Schedule activities during this period so that the specified amount of time on the equipment will be available for each student. The final session will address specific topics that the students need to discuss and to answer questions concerning the operation of the system. Upon completion of the course, the students should be fully proficient in system operation and have no unanswered questions regarding operation of the installed control system. Each student should be able to start the system, operate the system, recover the system after a failure and describe the specific hardware architecture and operation of the system and be fully proficient in all system operations. Report the skill level of each student at the end of this course.

3.8.3 Maintenance Training

Following the endurance test, aA minimum period of five training days shall be provided by a factory representative or a qualified Contractor trainer for ten designated personnel on maintenance of the equipment. The training shall include: physical layout of each piece of hardware, calibration procedures, preventive maintenance procedures, schedules, troubleshooting, diagnostic procedures and repair instructions.

3.8.4 Specialized Training

Following the maintenance training, a minimum period of five, total training day(s) shall be provided by a factory representative or a qualified Contractor trainer for ten people on the input devices.

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SECTION 40 95 00 Page 18

2.7 LAN ETHERNET SWITCHES