Technical_Specifications_Section_40_95_00.pdf

Berlin Remote Control Upgrades

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 RELATED SPECIFICATIONS

1.4 SYSTEM DESCRIPTION

1.4.1 Sequence and Control - Programmable Logic Controller

1.4.1.1 General

1.4.1.2 PLC Architecture

1.4.1.3 Dam Control System

1.4.1.4 Software Development

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Detail Drawings

1.6.2 Manufacturer's Catalog

1.6.3 Material and Equipment Lists

1.6.4 Installation Procedures

1.7 DELIVERY, STORAGE, AND HANDLING

1.8 PROJECT/SITE CONDITIONS

1.8.1 Environmental Requirements

1.9 STANDARD PRODUCTS

1.10 GENERAL ARRANGEMENTS

1.11 QUALIFICATIONS

1.11.1 Panel Shop

1.11.2 System Integrator

1.12 WARRANTY

1.13 CODE COMPLIANCE

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 General Requirements

2.1.2 Operation

2.1.3 Points

2.1.4 Data Transmission Systems (DTS)

2.2 MATERIALS AND EQUIPMENT

2.2.1 Standard Products

2.2.2 Government Furnished Equipment

2.3 MONITORING AND CONTROL PARAMETERS

2.3.1 24 VDC Main Power Supply and Battery Backup System

2.3.1.1 Battery Backup Duration

2.3.1.2 Control Panel 24VDC Power and Battery Backup General

Features

2.4 CONTROL AND INSTRUMENTATION CABLE

2.4.1 General

2.4.2 PLC/PC Ethernet Communication Cable

2.4.3 Packaging

2.5 CONTROL CONSOLE CONSTRUCTION

SECTION 40 95 00 Page 1 Certified Final Documents - W911WN19B8004 - Amendment 2

2.5.1 General

2.5.2 Wiring

2.5.2.1 General

2.5.2.2 Installation

2.5.2.3 Clearance

2.5.3 Nameplates

2.5.4 Surge Suppression Receptacles

2.6 ENCLOSURES

2.6.1 General

2.6.2 Fabrication

2.6.3 Surfaces

2.6.4 Doors

2.6.5 Framing

2.6.6 Wall Mounting Reinforcements

2.6.7 Subpanels

2.6.8 Finish

2.6.8.1 General

2.6.8.2 Surface Preparation

2.6.8.3 Primer

2.6.8.4 Paint

2.6.8.5 Interior Surfaces

2.6.8.6 Exterior Surfaces

2.6.9 Wiring Entry

2.6.10 Enclosure Heater

2.6.11 Support Equipment

2.6.11.1 Line Conditioner

2.6.11.2 Power Supply

2.6.11.3 PLC I/O Racks

2.6.11.4 Exhaust Fan

2.6.12 Wiring

2.6.12.1 General

2.6.12.2 Installation

2.6.12.3 Terminal Blocks

2.6.12.4 Spare Wires

2.6.12.5 Clearance

2.6.12.6 Conductors

2.6.12.7 Inspection

2.7 DAM GATE CONTROLS

2.7.1 General

2.8 PANEL MOUNTED ALARM HORN

2.9 DAM WARNING HORN & BEACON

2.9.1 Dam Warning Siren

2.9.2 Warning Beacon

2.10 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.10.1 PLC General Requirements

2.10.2 Modular PLC

2.10.2.1 Central Processing Unit (CPU) Module

2.10.2.2 Communications Module

2.10.2.3 PLC Power Supply Module

2.10.2.4 Input/Output (I/O) Modules

2.10.3 Program Storage/Memory Requirements

2.10.4 Input/Output Characteristics

2.10.5 Wiring Connections

2.10.6 Diagnostics

2.11 PLC PROGRAMMING SOFTWARE

2.11.1 PLC Programming Language Printouts

2.11.2 Operating System

2.11.2.1 Startup

2.11.2.2 Failure Mode

SECTION 40 95 00 Page 2

2.11.3 Functions

2.11.3.1 Analog Monitoring

2.11.3.2 Logic (Virtual)

2.11.3.3 State Variables

2.11.3.4 Analog Totalization

2.11.3.5 Trending

2.11.4 Alarm Processing

2.11.4.1 Digital Alarms

2.11.4.2 Analog Alarms

2.11.5 Control Sequences and Control Loops

2.11.6 Command Priorities

2.11.7 Resident Application Software

2.11.7.1 Program Inputs and Outputs

2.11.7.2 Failure Mode

2.12 OPERATOR DISPLAY PANEL(OIT)

2.13 HMI SCADA SOFTWARE

2.14 LAP TOP COMPUTER FOR PLC SUPPORT

2.15 CONTROL PANELS

2.15.1 Control Panel Enclosures

2.15.2 Breather - Drain for Remote I/O Panels

2.15.3 Components and Pilot Devices

2.15.3.1 Standard Indicator Light

2.15.3.2 Selector Switches

2.15.3.3 Push Buttons

2.15.3.4 Relays

2.15.3.4.1 Discrete Input Interposing Relay Groups.

2.15.3.5 Din Rail Terminal Blocks And Labels

2.15.3.5.1 Din Rail Mounted Circuit Breakers

2.15.3.5.2 Din Rail Mounted Fuse Holders

2.15.4 Convenience Outlet

2.15.5 Panel Interior Light

2.15.6 Heating System

2.16 DAM CONTROL STATION AND REMOTE OPERATOR STATION EQUIPMENT

2.16.1 PLC Communication System

2.17 CENTRAL STATION SOFTWARE

2.17.1 PLC Programming Requirements

2.17.2 Graphical Operations

2.17.2.1 Display Information

2.17.2.2 System Graphics Implementation

2.17.2.3 Display Editor

2.17.2.4 Graphical Object Oriented Programming

2.17.2.5 Charting

2.17.2.6 System Menus and Displays

2.17.3 Command Software

2.17.3.1 Command Input

2.17.3.2 Command Input Errors

2.17.3.3 Special Functions

2.17.3.3.1 Help

2.17.3.3.2 Start/Enable

2.17.3.3.3 Stop/Disable

2.17.3.3.4 Display Diagram

2.17.3.3.5 Diagram Development

2.17.3.3.6 Auto/Override

2.17.3.3.7 Print Report

2.17.3.3.8 Confirm Action

2.17.3.3.9 Cancel Action

2.17.3.3.10 Memo Pad

2.17.3.4 Operator's Commands

2.17.3.5 Level of Addressing

SECTION 40 95 00 Page 3

2.17.3.5.1 Point

2.17.3.5.2 Unit

2.17.3.5.3 Sub-System

2.17.3.5.4 System

2.17.3.6 System Access Control

2.17.4 Alarms

2.17.4.1 Digital Alarms

2.17.4.2 Analog Alarms

2.17.4.3 Alarm Messages

2.17.4.4 Alarm Classes

2.17.5 Pop-up Note Function

2.17.6 Real Time Clock Synchronization

2.17.7 System Reaction

2.17.7.1 Occurrence

2.17.7.2 Location

2.17.8 Central Station Database

2.17.8.1 Database Definition Process

2.17.8.2 Dynamic Database

2.17.8.3 Dynamic Database Update

2.17.8.4 Static Database

2.17.8.5 Central Station Static Database Update

2.17.8.6 Workstation Access to Dynamic Data

2.17.9 Trending

2.17.10 Analog Totalization

2.18 DATA COMMUNICATION REQUIREMENTS

2.19 FACTORY WITNESS TEST

2.19.1 Factory Test Setup

2.19.2 Factory Test Procedure

2.19.3 Factory Test Report

2.20 MISCELLANEOUS CONTROL SYSTEMS

2.21 SPARE PARTS LIST

PART 3 EXECUTION

3.1 FUNCTION AND DESCRIPTION OF OPERATION

3.1.1 Specific Screens And Controls

3.2 EQUIPMENT INSTALLATION REQUIREMENTS

3.2.1 Installation

3.2.1.1 Device Mounting

3.2.2 Sequences of Operation

3.3 CONTROL CONSOLE INSTALLATION

3.4 OPERATION AND MAINTENANCE MANUALS

3.5 FIELD TESTING AND ADJUSTING EQUIPMENT

3.5.1 Dam Control Systems

3.5.2 Miscellaneous Control Systems

3.5.3 Testing, Adjusting and Commissioning

3.5.4 Performance Verification Test (PVT)

3.6 MANUFACTURERS' FIELD SERVICES

3.7 FIELD TRAINING

3.7.1 Additional Operator Training

3.7.2 Maintenance Training

3.8 OPERATION AND MAINTENANCE DATA REQUIREMENTS

-- End of Section Table of Contents --

SECTION 40 95 00 Page 4

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.

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ASHRAE FUN IP (2017) Fundamentals Handbook, I-P Edition

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2017; Errata 1-2 2017; INT 1 2017) National Electrical Safety Code

IEEE C37.90 (2005; R 2011) Standard for Relays and Relay Systems Associated With Electric Power Apparatus

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

Programming Languages

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 4 (2015) Application Guideline for Terminal Blocks

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

SECTION 40 95 00 Page 5

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14; TIA 17-15; TIA 17-16; TIA 17-17 )

National Electrical Code

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

47 CFR 15 Radio Frequency Devices

UNDERWRITERS LABORATORIES (UL)

UL 1059 (2001; Reprint Dec 2017) UL Standard for Safety Terminal Blocks

UL 489 (2016) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 508 (2018) UL Standard for Safety Industrial Control Equipment

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

1.2 DEFINITIONS

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

1.3 RELATED SPECIFICATIONS

SECTION 26 05 00.00 40 COMMON WORK RESULTS FOR ELECTRICAL, covers materials and methods to interconnect electrical panels and devices in this project.

And covers motor controls for the hydraulic system.

1.4 SYSTEM DESCRIPTION

The work provided for herein consists of furnishing all plant, labor, material, and equipment for the installation and testing of the control and instrumentation systems as specified herein and as shown on the drawings.

Unless specified otherwise all electrical material and equipment shall conform to the requirements of Sections 26 05 00.00 40 COMMON WORK RESULTS FOR ELECTRICAL, 26 05 19.10 10 INSULATED WIRE AND CABLE. The scope of this project includes networking different vendor's equipment to a common communication network and computerized control system. It shall be the responsibility of the Contractor to provide approved systems integration services and to furnish and install all materials, hardware, software, and testing, as required, to provide fully functional/communicating networks for instrumentation and control systems as follows:

1. Damcontrol system

2. Installation of control consoles

3. Installation of all control, instrumentation, and fiber-optic cables

4. Testing of all control systems

SECTION 40 95 00 Page 6

5. Training of Government operating personnel

1.4.1 Sequence and Control - Programmable Logic Controller

1.4.1.1 General

The PLC will monitor data from geographically diverse points and send it to the HMI's for display.

1.4.1.2 PLC Architecture

1. The PLC will consist of one PLC control panel with a processor, input/output (I/O) modules, and an HMI. The PLC processors, I/O modules and communication modules will be located on level 3 of pier 8.

2. The Operator Station panel consisting of an HMI and manual pushbuttons will be located on level 4 of pier 8.

3. The PLC shall communicate the status of all monitored devices to the HMI's.

4. The PLC system reliability will be assured by using industry-tested PLC's in a simple configuration. Battery-powered memory modules in the processor and I/O racks shall protect PLC memory until power is restored.

1.4.1.3 Dam Control System

1. General. A network of distributed intelligence shall accomplish the monitoring of the dam valve actuators, sump pumps, and crest gates. The PLC shall gather and monitor data, perform logic and interlocking, and actuate equipment and devices.

2. Human Machine Interface (HMI). An HMI for monitoring will be located on the main PLC control panel and the Operator Station located in pier 8. The HMI shall serve several functions:

a. Operator Interface. The HMI shall present and accept data and commands in a format conducive to human comprehension.

b. Warning/Diagnostics. Abnormal conditions, on all equipment monitored, shall be annunciated to the operators, as well as diagnostic messages of explanation and logged within the alarm database. Operation and maintenance information on critical equipment such as system pressure, etc. shall be stored for quick retrieval.

c. Control Menus.

Software development shall include the following:

*Dam equipment Status *Alarms on all equipment controlled/monitored

The graphics display window selection menu shall control which display is called up to the graphics color monitor.

SECTION 40 95 00 Page 7

1.4.1.4 Software Development

The Contactor's PLC System supplier/integrator shall develop all programming required for the programmable controller system, for the auxiliary interfaces and equipment that allow the system(s) to intercommunicate. The contractor shall extract the program out of the existing PLC and convert it to CompactLogix. At a minimum, all logic and functions of the existing system shall be present in the new.

1. The HMI's shall be programmed for graphics displays and for data acquisition. HMI screens shall be of the same arrangement and function as the existing screens. Visual modifications may be made to fit new screen size and resolution.

1.5 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. Submit the following in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Factory Test Procedure; G, DO

Installation; G, DO

Testing, Adjusting And Commissioning; G, DO

Performance Verification Test (Pvt); G, DO

HMI Software; G, DO

Pre-fabrication Drawings and Mockup; G, DO

Breather - Drain for Remote I/O Panels; G, DO

UL 508A Certification; G, DO

System Integrator Certification; G, DO

SD-02 Shop Drawings

English Language Summary of PLC Program; G, DO

Spreadsheets of PLC and OIT variable Names and descriptions, addresses; G, DO

HMI Screens with annotations and descriptions; G, DO

Control Panels Dimensional Layouts; G, DO

Detail Drawings; G, DO

Installation Procedures; G, DO

a. Control and Instrumentation Systems Training.

b. Control and Instrumentation Systems Testing.

SECTION 40 95 00 Page 8

Pre-fabrication Drawings and Mockup; G, DO

See Drawings E-5110 Keynotes 8 and 9

SD-03 Product Data

HMIs; G, DO

HMI Software; G, DO

PLC Programming Software; G, DO

PLC and PLC IO Product Data; G, DO

Operator Display Panel (OIT); G, DO

24 VDC Main Power Supply and Battery Backup System ; G, DO

Components and Pilot Devices; G, DO

Din Rail Terminal Blocks And Labels; G,DO

Din Rail Mounted Circuit Breakers; G, DO

Din Rail Mounted Fuse Holders; G, DO

Spare Parts List; G, DO

Din Rail Mounted Fuse Holders

Manufacturer's Catalog; G, DO

Material and Equipment Lists; G, DO

Panel Mounted Alarm Horn; G, DO

Dam Warning Horn & Beacon; G, DO

SD-06 Test Reports

Factory Test Report

Performance Verification Test (PVT)Report

Dam Control Systems

Miscellaneous Control Systems

SD-07 Certificates

Materials and Equipment; G, DO

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, DO

PLC Programming Language Printouts; G, DO

SECTION 40 95 00 Page 9

SD-11 Closeout Submittals

As-built Drawings; G, DO

1.6 QUALITY ASSURANCE

1.6.1 Detail Drawings

Detail drawings consisting of equipment drawings, illustrations, schedules, instructions, diagrams, and other information necessary to define the installation. Detail drawings shall show the rating of items and systems and how the components of an item and system are assembled, function together, and how they will be installed on the project. Data and drawings for component parts of an item or system shall be coordinated and submitted as a unit. Data and drawings shall be coordinated and included in a single submission. Multiple submissions for the same equipment or system are not acceptable except where prior approval has been obtained from the Contracting Officer. In such cases, a list of data to be submitted later shall be included with the first submission. Detail drawings shall show physical arrangement, construction details, connections, finishes, materials used in fabrication, access requirements for installation and maintenance, physical size, electrical characteristics, foundation and support details, and equipment weight. Drawings shall be drawn to scale and/or dimensioned. Optional items shall be clearly identified as included or excluded. Detail drawings shall as a minimum include:

a. Control Stations.

b. I/O Rack Enclosures.

c. Control Cabinets, Construction, Painting, and Installation.

d. I/O Rack Wire and Wiring Diagrams.

e. Sensors and Switches, wiring.

If departures from the contract drawings are deemed necessary by the Contractor, complete details of such departures, including changes in related portions of the project and the reasons why, shall be submitted with the detail drawings. Approved departures shall be made at no additional cost to the Government.

Submit Pre-fabrication Drawings and Mockup. A complete set of drawings shall be submitted before fabrication of panels. Drawings shall be coordinated and included in a single submission. Multiple submissions for the same equipment or system are not acceptable except where prior approval has been obtained from the Contracting Officer. Prefabrication drawings shall as a minimum include:

a. Control Stations.

b. I/O Rack Enclosures.

c. Control Cabinets, Construction, Painting, and Installation.

d. I/O Rack Wire and Wiring Diagrams.

e. Sensors and Switches, wiring.

SECTION 40 95 00 Page 10

1.6.2 Manufacturer's Catalog

Data composed of catalog cuts, brochures, circulars, specifications, product data, and printed information in sufficient detail and scope to verify compliance with the requirements of the contract documents.

a. Fiber-optic cable.

b. Network communication cable.

c. Twisted Pair Network Cable.

d. Twinaxial and triaxial signal cable.

e. I/O Rack Wire and Wiring Diagrams.

f. Power Supplies.

g. Line Conditioner.

h. Terminal Blocks.

i. Ventilation Fan.

j. Wire and Cable.

k. Pushbuttons and Switches.

l. Indicating Lights.

m. Displays.

1.6.3 Material and Equipment Lists

A complete itemized listing of equipment and materials proposed for incorporation into the work. Each entry shall include an item number, the quantity of items proposed, and the name of the manufacturer of each item.

a. Fiber-optic cable.

b. Network communication cable.

c. Twisted Pair Network Cable.

d. Twinaxial and triaxial signal cable.

e. I/O Rack Wire and Wiring Diagrams.

f. Power Supplies.

g. Line Conditioner.

h. Terminal Blocks.

i. Ventilation Fan.

j. Wire and Cable.

k. Pushbuttons and Switches.

l. Indicating Lights.

m. Displays.

1.6.4 Installation Procedures

Procedures shall include diagrams, instructions, and precautions required to install, adjust, calibrate, and test devices and equipment. The installation shall include all components within the systems, those listed above and:

a. Network Communications.

b. Installation and Wiring.

1.7 DELIVERY, STORAGE, AND HANDLING

Equipment specified in this section, comprised of electrical and electronic components, shall be scheduled for shipment to arrive on the job site no more than 30 days prior to its scheduled installation date. Upon delivery at the work site, the Contractor shall store all electrical and/or electronic equipment in his designated area. The conditions under which any equipment or materials are to be stored shall be in accordance with the

SECTION 40 95 00 Page 11 equipment manufacturer's recommendations and with the best standard practices to ensure that all equipment and materials will be in pristine condition at the time of installation. The Contractor shall familiarize itself with regard to the location of all other equipment, materials, and conditions that may affect the electrical work sequence so as to minimize any interference with other installations or to subject any items to detrimental conditions. The exact storage location of all electrical and electronic items shall be subject to the approval of the Contracting Officer.

1.8 PROJECT/SITE CONDITIONS

1.8.1 Environmental Requirements

The environment into which the electrical equipment will be installed is an outdoor facility subject to 100 percent humidity and temperature variations between 0 degrees F and 120 degrees F. The Contractor shall ensure that during installation all equipment is properly handled and stored so that it will not be adversely affected by the above conditions. The Contractor shall also ensure that the final installation of equipment meets the environmental requirements of the manufacturer.

1.9 STANDARD PRODUCTS

Unless otherwise approved by the Contracting Officer, the materials and equipment to be furnished under this specification shall be standard products of manufacturers regularly engaged in the production of such equipment and shall be the manufacturer's latest commercially available "off the shelf" design. Items of equipment proposed for use under these specifications shall essentially duplicate equipment that has been in satisfactory use at least two years prior to bid opening. Like equipment for similar service shall be of the same manufacturer, and when of the same size and rating, shall be interchangeable. Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

1.10 GENERAL ARRANGEMENTS

The general arrangements and approximate locations of the electrical equipment, conduit and wiring connections shall be as indicated on the drawings. The Contractor may, however, subject to the approval of the Contracting Officer, modify the layout indicated on the drawings or specified herein, to more readily conform to the space available and to the actual equipment proposed for use. Should the approved electrical equipment furnished be of a different size than indicated, the Contractor at his own expense shall make the necessary adjustments to the branch circuit wiring (8 AWG and smaller), disconnecting devices, branch-circuit protection, component wiring, component installation, I/O rack addressing, PLC programming, I/O rack fabrication and installation, and space requirements to accommodate the equipment actually installed.

1.11 QUALIFICATIONS

All work shall be performed in a skillful and workmanlike manner in accordance with the best modern shop practice for the manufacture of finished products of a nature similar to those covered by these specifications, and shall be performed by mechanics especially skilled for each kind of work and under competent supervision and direction. All materials and equipment shall be installed in accordance with

SECTION 40 95 00 Page 12 recommendations of the manufacturer as approved by the Contracting Officer.

Workmanship shall be of the highest grade and in accordance with modern practice.

1.11.1 Panel Shop

Control panels shall be manufactured by a UL508a certified panel shop.

Contractor shall submit UL 508A Certification for chosen panel shop.

1.11.2 System Integrator

The control system shall be designed and programmed by a Rockwell recognized system integrator. Submit System Integrator Certification.

1.12 WARRANTY

All equipment and material installed under this section shall be warranted to be free of defects in workmanship and material for a minimum of one year after acceptance by the Contracting Officer. The Contractor shall make written transfer of all manufacturers' warranties to the Government upon acceptance of the work by the Contracting Officer.

1.13 CODE COMPLIANCE

All work, specified herein or shown on the drawings shall conform to the applicable requirements of NFPA 70, IEEE C2, and Sections 26 05 19.10 10

INSULATED WIRE AND CABLE.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

The process instrumentation and control system will be used to monitor and control the operation of process equipment as specified and in accordance with the sequence of control and control schematics shown. The control system shall provide for operator interaction, overall control system supervision, process equipment control and monitoring, and configured and sized to support expansion as specified and shown.

2.1.1 General Requirements

The control system must consist of a complete programmable logic controller (PLC) based system and network.

2.1.2 Operation

The control system provided under this specification must operate using IEC 61131-3 ladder logic or other approved IEC 61131-3 programming languages as supervisory control to provide the required sequences of operation. Input data to the controller must be obtained by using instruments and controls interfaced to mechanical, electrical, utility systems and other systems as shown and specified. All required setpoints, settings, alarm limits, and sequences of operation must be as identified in the database/settings tables and or sequences of operation indicated. The number and location of control panels shown must be provided as a minimum.

2.1.3 Points

Provide inputs to and outputs from the control system as shown. Each

SECTION 40 95 00 Page 13 connected analog output (AO), analog input (AI), digital output (DO), digital input (DI), pulse accumulator (PA) input and other input or output device connected to the control system must represent a "point" where referred to in this specification.

2.1.4 Data Transmission Systems (DTS)

Provide data transmission systems for communication between PLCs as indicated.

2.2 MATERIALS AND EQUIPMENT

2.2.1 Standard Products

Materials and equipment must be standard unmodified products of a manufacturer regularly engaged in the manufacturing of such products for a minimum of ten years. Units of the same type of equipment must be products of a single manufacturer. Items of the same type and purpose must be identical and supplied by the same manufacturer, unless replaced by a new version approved by the Contracting Officer.

2.2.2 Government Furnished Equipment

The Government will furnish the following control equipment:

1769-L33ER Compact Logix Processor, Qty: 1 ILX69-PBM Profibus DPV1 Master Communications Card, Qty:3 Engineering Workstation Laptop, Qty: 1

Government furnished equipment will be held in the Resource Managers Office. The Contractor shall coordinate with the Contracting Officer to arrange for pickup. Written notification must be given to the Contracting Officer a minimum of 30 days prior to pickup.

2.3 MONITORING AND CONTROL PARAMETERS

The control system must 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 maintain the specified end-to-end process control loop accuracy from sensor to display and final control element. Control equipment must be powered by a 120 VAC, single phase, 60 Hz power source, with local transformers included as needed for signal transmission and subsystem operation. Connecting conductors must be suitable for installed service.

2.3.1 24 VDC Main Power Supply and Battery Backup System

The main control panel shall have a 24 VDC main power supply and battery backup system. Size the system to power all PLC equipment, network switches and camera systems with 20% spare DC Amps capacity. Submit design calculations showing the power supply system including battery backup meets the 20% margin.

The combined 24 VDC power supply with battery backup components must be a compatible set, and manufactured by a single manufacturer. The set of components must be regularly used by the integrator.

SECTION 40 95 00 Page 14

2.3.1.1 Battery Backup Duration

The 24 VDC battery back up system must power the respective panel for a period of 2 hours at full computed DC load at 60 deg F.

2.3.1.2 Control Panel 24VDC Power and Battery Backup General Features

The following general features are required. Submit on the details of each feature:

a. The system must operate in a temperature range of 32 deg F to 120 deg F.

b. Power input voltage range 85 V to 265 VAC.

c. Power supply dielectric strength 300 VAC.

d. Transient protection with varistor and gas filled surge arrestor.

e. The 24 VDC power supply output voltage must be adjustable from 22 VDC to 28 VDC.

f. Ability to connect DC Power supply in parallel.

g. Output ripple less than 50 MVpp.

h. Power supply efficiency 92% or better.

i. Power supply insulation input - output, 2 KV AC.

j. Power supply MTTF, greater than 50,000 hr at 120 Deg F.

k. Battery transfer/charger module compatible with lead acid gel type batteries.

l. Battery transfer/charger module must have boost and maintenance charging modes.

m. Battery transfer/charger module must transfer the load to the battery with a delay of less than 1 Millisecond.

n. Battery transfer charger module must have a dry contact to indicate that the system is on battery.

o. The system must utilize readily available lead acid gel cell batteries such as used in RV's, boats, and lawn equipment. Or the regularly manufactured battery packs integrated with the 24 VDC power supply system.

2.4 CONTROL AND INSTRUMENTATION CABLE

2.4.1 General

Unless specified otherwise, all cables shall comply with the applicable requirements for wire and cable as specified in Section 26 05 19.10 10 INSULATED WIRE AND CABLE. In all cases instrumentation cables shall be as recommended by the manufacturer of the applicable equipment provided it is approved by the Contracting Officer.

SECTION 40 95 00 Page 15

2.4.2 PLC/PC Ethernet Communication Cable

The cables used to provide communications between the PLC and the HMICs shall be Cat 6 twisted-pair Ethernet, and/or Fiber Optic, as recommended by the manufacturer of the PLC System, the Graphical User Interface software, or the PLC System Supplier (System Integrator), and approved by the Contracting Officer.

2.4.3 Packaging

All control, instrumentation, communication, and fiber-optic cables shall be shipped on industry standard non-returnable reels. The radius of each reel shall be at least two inches greater than the distance from the axis of the reel to the outside of the outermost layer of cable on the reel.

Cable ends, whether exposed or concealed, shall be sealed with heat shrinkable caps. Cap sizes shall be as recommended by the manufacturer for the cable OD and materials. Caps shall contain sufficient adhesive so that shrinkage of the cap during application results in formation of a positive watertight seal capable of withstanding complete immersion or totally exposed storage over a period of several months without permitting the entrance of moisture.

2.5 CONTROL CONSOLE CONSTRUCTION

2.5.1 General

Wire and cable shall comply with the requirements of Section 26 05 19.10 10

INSULATED WIRE AND CABLE.

2.5.2 Wiring

2.5.2.1 General

All insulated wires and cables used within the control consoles shall conform to the requirements of Section 26 05 19.10 10 INSULATED WIRE AND

CABLE.

2.5.2.2 Installation

All wiring shall be neatly and carefully installed in wiring ducts, raceways, or bundled and secured with wire wraps or lacing. Wiring shall be terminated at terminal blocks plainly lettered or marked.

2.5.2.3 Clearance

Sufficient clearance shall be provided for all leads and lead identification. All leads for external circuit wiring shall be connected to grouped terminal blocks located for convenient connection of external circuits. Splices shall not be permitted in any console wiring.

2.5.3 Nameplates

Each major component of equipment shall have the manufacturer's name, address, and catalog number on a nameplate securely attached to the equipment in a conspicuous location. In addition, specific nameplates shall be provided as delineated on the drawings. Nameplates shall be fabricated of laminated plastic of sufficient size to accommodate minimum size lettering of 1/4". Engraving shall be white letters on black background.

SECTION 40 95 00 Page 16

2.5.4 Surge Suppression Receptacles

The control consoles shall be provided with surge suppression receptacles.

The surge suppression receptacles shall be UL Listed, 20 amp, 115 VAC duplex type.

2.6 ENCLOSURES

2.6.1 General

All PLC and control console enclosures shall be NEMA 4X stainless steel (shelter installation) and NEMA 12 steel (interior). Sizes of enclosures shall be determined by the Contractor to accommodate the equipment as specified herein. Dimensions on the drawings are for general guidance only;

the contractor shall be responsible for final determination of all dimensions subject to the approval of the Contracting Officer. All enclosures shall comply with NEMA ICS 6. The enclosures shall be constructed in accordance with the manufacturer's standards, subject to approval by the Contracting Officer. All enclosures shall be self-supporting with subframe or plate framework as necessary to obtain proper stiffness and support. The body of the enclosures shall be a minimum of leveled USS 12 gauge stainless steel sheets and formed stainless steel members rigidly welded together to form a self supporting structure. Welds on exposed surfaces of the structure shall be ground smooth. Finished surfaces shall be free of waves, bellies and other imperfections.

2.6.2 Fabrication

All fabrication shall be of stainless steel or steel plate with welded construction throughout. Welds shall be ground smooth, all corners shall be rounded, and all weld spatters cleaned. Corner construction shall be minimum of 1/8-inch inside radius. The enclosures shall have completely sealed bottoms.

2.6.3 Surfaces

The surface of the enclosures shall be free from defects and marred areas.

Finished surfaces shall be flat within 1/16-inch in 6 feet and shall be smooth with rounded edges. Finished surfaces shall be 3/16-inch thick. Any necessary cutouts and drillings shall be straight, accurate, and free of rough edges.

2.6.4 Doors

Doors shall be provided for each enclosure. Doors shall have triple point latch, stainless steel handle and lock, full length 'piano' type hinges, and sponge rubber gaskets. Doors shall be arranged to swing out through 180 degrees from the closed position. Stops shall be provided as required to limit door swing and prevent damage to hinges or adjacent equipment. The clearance between any edge of a hinged door, when closed and any adjacent panel shall be uniform and shall not exceed 1/8-inch.

2.6.5 Framing

Each enclosure shall be provided with necessary framing, cross bracing, and stiffness to form a rigid, self-supporting type of structure. Vertical edges of sections shall be formed and bolted together so that no part of edges exposed to view will pass a 1/32-inch gauge. To prevent warping, SECTION 40 95 00 Page 17 stiffeners shall be provided to adequately support all heavy equipment.

The panels, trim, door, and frames shall match and present a neat appearance when assembled as an enclosure.

2.6.6 Wall Mounting Reinforcements

2.6.7 Subpanels

Each enclosure shall be provided with inner back and side subpanels, as required, for mounting all internal components. Subpanels shall be constructed of leveled USS 10-gauge carbon steel.

2.6.8 Finish

2.6.8.1 General

Stainless steel surfaces shall not be painted. All interior carbon steel subpanel surfaces shall be finished with a weather-resistant, rust inhibiting paint.

2.6.8.2 Surface Preparation

All steel surfaces shall be chemically cleaned to provide a bond between paint and metal surfaces to help prevent the entrance of moisture and formation of rust under the paint film. After preparation of surfaces, all pits or indentations shall be filled with a 100 percent solid catalyzed epoxy putty compound. After hardening of the putty filler, the filled areas shall be sanded smooth. Surface shall be smooth and uniform to receive the paint.

2.6.8.3 Primer

After cleaning and filling, one coat of ferrous metal primer shall be applied to all ferrous surfaces to receive paint and shall have a minimum of 1 to 2 mils dry film thickness.

2.6.8.4 Paint

All paints shall be spray applied to produce a smooth, uniform coat, free of defects. Each coat shall be properly cured according to the manufacturer's instructions before application of succeeding coats.

2.6.8.5 Interior Surfaces

Interior subpanel surfaces shall be painted with no less than two coats of synthetic semi-gloss white enamel. Finish shall have a minimum of 4 to 5 mils dry film thickness. The Contractor shall restore any damaged places in the paint after the installation of equipment.

2.6.8.6 Exterior Surfaces

Exterior stainless steel surfaces shall not be painted.

2.6.9 Wiring Entry

Wiring into the enclosure shall enter through the bottom or top of the enclosure by way of conduits using watertight conduit hubs complying to

UL 514B.

SECTION 40 95 00 Page 18

2.6.10 Enclosure Heater

Enclosures shall be provided with an electrical heater, as indicated.

Heaters shall be 120V, and sized to prevent condensation within the console. The heaters shall work in conjunction with a thermostat to provide operation below an adjustable set temperature.

2.6.11 Support Equipment

2.6.11.1 Line Conditioner

Each PLC I/O rack enclosure shall have a line conditioner to be used exclusively for filtering power to the PLC I/O rack power supply. The line conditioner shall be terminal style, single phase, with a power rating of 150 percent of the calculated I/O rack load at each enclosure, 120 VAC input and output voltage, 60Hz, minimum 60dB Normal Mode Noise Attenuation at 100kHz, minimum 146 dB Common Mode Noise Attenuation at 100kHz, and shall be UL listed. The line conditioner shall be as recommended by the PLC manufacturer for the I/O racks and power supplies furnished under this contract.

2.6.11.2 Power Supply

Each PLC I/O rack enclosure shall have separate power supplies, as required, to power the pushbuttons, limit switches, pilot power for the PLC remote I/O cards, fiber-optic converters, and position transmitters. These power supplies shall not be used to power the water level sensing system transmitters. The water level sensing system power supplies shall be as specified in Paragraph Water Level Sensing Systems, subparagraph Power Supplies. Power supplies shall operate on 120 VAC, 60 Hz and shall be of the enclosed type and UL listed. Power supplies shall be sized at 150% of the anticipated load.

2.6.11.3 PLC I/O Racks

The I/O racks as provided by the PLC System Supplier shall be installed in the I/O rack enclosures on the metal sub panels. The manufacturer of the PLC system shall make written approval of the installation.

2.6.11.4 Exhaust Fan

I/O Rack enclosures shall be provided with an exhaust fan, as indicated on the drawings. The fan shall operate on 120 VAC, 60 Hz, single-phase power and deliver 20 cubic feet per minute (CFM) of air at zero static pressure.

The exhaust fan shall have an air outlet exhaust grille and filter at the air intake side of the fan. The fan shall work in conjunction with an adjustable thermostat to provide operation above a set temperature.

2.6.12 Wiring

2.6.12.1 General

All wiring used within the I/O rack enclosures shall conform to the requirements of Section 26 05 19.10 10 INSULATED WIRE AND CABLE. The PLC equipment enclosures shall be completely wired at the factory, with the exception of field wiring and wiring between enclosures. Splices shall not be accepted in internal enclosure wiring.

SECTION 40 95 00 Page 19

2.6.12.2 Installation

All internal wiring shall be neatly and carefully installed in bundles.

Wiring of different signal levels shall be separated by use of separate wire ducts, where practicable. Each wire shall be plainly marked to facilitate future maintenance. Wire marking methods shall be as specified in Section 26 05 19.10 10 INSULATED WIRE AND CABLE.

2.6.12.3 Terminal Blocks

All internal wiring shall be terminated at terminal blocks plainly lettered or marked in accordance with the drawings. Terminal blocks that are attached to are provided with approved PLC modules shall be considered in compliance with this specification. Terminal blocks shall be molded or fabricated type with barriers rated not less than 300 volts. Terminal blocks shall be knife-switch type with appropriate end sections, partitions, mounting rails, identifying label holder, and end brackets.

2.6.12.4 Spare Wires

All spare wires which are not terminated shall be neatly coiled and strapped to the bundle of used wire from which it originates. Spare wires shall be left as long as possible and shall have no insulation removed.

2.6.12.5 Clearance

Sufficient clearance shall be provided for all leads and lead identification. All leads for external circuit wiring shall be connected to grouped terminal blocks located for convenient connection of external circuits.

2.6.12.6 Conductors

Unless specified otherwise in these specifications or on the drawings, all wiring in the PLC remote I/O rack enclosures shall be factory installed using SIS No. 16 wire as specified in Paragraph Input/Output Rack Wiring, subparagraph General. All wiring between PLC components shall be as recommended by the manufacturer of the PLC equipment.Conductor colors shall be as follows:

- AC Power: Black

- 120V AC Control: Red

- DC Control: Blue

- 24V DC +: Blue

- DC COM: White w/ Blue stripe

2.6.12.7 Inspection

The Contractor shall notify the Contracting Officer 10 days prior to completion of the PLC remote I/O rack enclosures. At his option, the Contracting Officer may inspect the enclosures. If an enclosure fails any inspection, the Contractor shall make the necessary changes and adjustments at no additional cost to the Government, and notify the Contracting Officer when ready for re-inspection. Shipment of the enclosures shall not be made until the completion of these inspections.

SECTION 40 95 00 Page 20

2.7 DAM GATE CONTROLS

2.7.1 General

The Contractor shall furnish and install all necessary connectors, cables, electronic equipment, electrical devices, and miscellaneous hardware to fulfill the control function specified herein and as shown on the drawings for the dam. The Contractor shall adjust the length of any manufacturer-supplied cable so that connection points are accessible without splices. Unless specified otherwise, all equipment and installation shall conform to Sections 26 05 19.10 10 INSULATED WIRE AND CABLE. The dam shall normally be controlled by manual control from the HMI stations on level 3 and level 4. The Contractor shall furnish and install all enclosures, control relays, pushbuttons and other hardware to construct the dam control system.

2.8 PANEL MOUNTED ALARM HORN

The panel mounted alarm horn must use a 30 mm hole, sound with an input voltage from 6-28VDC, audio output of 80-91db at 2900Hz, screw terminals, continuous operation, and CUL/UL listed.

2.9 DAM WARNING HORN & BEACON

The Contractor shall furnish and install all necessary connectors, cables, electronic equipment, electrical devices, and miscellaneous hardware for a complete dam warning system. The system shall consist of a beacon and warning siren.

2.9.1 Dam Warning Siren

1. Suitable for outdoor applications

2. Operating Voltage: 120V, 60Hz

3. Audible Output: 110 dB at 10 feet

2.9.2 Warning Beacon

1. Operating Voltage: 24 VDC or 120 VAC

2. Output: 80,000 candela (min)

3. Beacon: Rotating 95 - 135 FPM

4. Lamp: 55 Watt Halogen

5. Dome: Red

2.10 PROGRAMMABLE LOGIC CONTROLLER (PLC)

Submit PLC and PLC IO product data.

2.10.1 PLC General Requirements

PLCs must be micro-processor based, capable of receiving discrete and analog inputs through programming, control discrete and analog output functions, perform data handling operations, and communicate with external devices. PLCs must meet the requirements of Class A computing devices, labeled in accordance with 47 CFR 15, able to withstand conducted susceptibility test in accordance with NEMA ICS 1, NEMA ICS 2, and IEEE C37.90.1. PLCs must function properly at temperatures between 0 and 122 degrees F at 5 to 95 percent relative humidity non-condensing and tolerate storage temperatures between minus 40 and plus 140 degrees F at 5

SECTION 40 95 00 Page 21 to 95 percent relative humidity non-condensing.

2.10.2 Modular PLC

PLCs must be based on a modular, field expandable design allowing the system to be tailored to the process control application through the use of additional hardware and/or user software. As a minimum, the PLC must include a power supply module, central processing unit (CPU) module, communications module, and input/output (I/O) module. The modules must be grouped together on a standard Din Rail line up. The PLC manufacturer is required to have produced PLC products and systems for at least 10 years and has allowed seamless integration of new products with legacy products.

The control logics type PLC systems must be a current product manufactured by a company in the USA.

2.10.2.1 Central Processing Unit (CPU) Module

The CPU module must be a self contained, microprocessor based unit that provides time of day, scanning, application (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. The central processing unit must store all of the PLC source code including tag names and labels for quick recovery and diagnostics, able to use both single and double precision ISA real numbers in the programming and program execution, and have memory capacity at least 30% spare after all programming, startup, editing is done at the end of the project.

2.10.2.2 Communications Module

The communications module must allow peer-to-peer communication with other PLCs and allow the PLC to communicate with the central station, or workstation, utilize the manufacturer's standard communication architecture and protocol, Ethernet architecture, and allow programming of the PLC to be done locally through the use of a laptop computer or from the central station or remote workstation.

2.10.2.3 PLC Power Supply Module

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

a. Power supply modules must use DC power with a nominal input voltage of 24 VDC plus or minus 10 percent. The power supply module monitors the incoming line voltage level and provides 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. Provide power supply modules capable of withstanding a power loss for a minimum of 20 milliseconds while still 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 clearly labeled as to its function.

SECTION 40 95 00 Page 22

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

2.10.2.4 Input/Output (I/O) Modules

Modules must be self contained, microprocessor based units that provide an interface to field devices, located in the same mounting lineup as the other PLC components, and plug directly onto the Din Rail Lineup or I/O rack system of the manufacturer. Each module must contain visual indication to display the on-off status of individual inputs or outputs.

2.10.3 Program Storage/Memory Requirements

The CPU must utilize the manufacturer's standard non-volatile memory for the operating system and have electronically erasable, programmable, read only Flash memory for storage of user programs and battery backed RAM for application memory. Flash memory must be loaded through the controller keypad, central station or through the use of a laptop computer. The CPU memory capacity must be based on the system's control requirements, sized such that, when the system is completely programmed and functional, no more than 60 percent of the memory allocated for these purposes is used. In addition the PLC CPU must store the source code of the program and the tags, labels for debugging and editing of the program.

2.10.4 Input/Output Characteristics

Each controller must allow for analog input, analog output, discrete input and discrete output. The number and type of inputs and outputs for the system as shown 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 two 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. Analog input circuits must be available in 0-10V, 0-5V and 4-20 mA. Discrete input circuits must be available in 10-30 VDC and 79-132 VAC. The analog inputs must provide a 16 bit conversion.

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.

Analog output circuits must be available in 4-20 mA. Discrete output circuits must be available in 10-30VDC and 79-132 VAC. 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.

2.10.5 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 one #14 AWG wire. Finger proof terminals must be provided over the wiring connections.

2.10.6 Diagnostics

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

SECTION 40 95 00 Page 23 must 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. Diagnostic software must be useable in conjunction with the portable tester.

2.11 PLC PROGRAMMING SOFTWARE

All PLC software described in this specification must be furnished as part of the complete control system. This includes the source code for the PLC application, and all HMI related configuration and software.

2.11.1 PLC Programming Language Printouts

The PLC Programming Software must support the…