33_09_53_Amd03.pdf

C-17 Type III Fuel System & Ramp Expansion FJRP159073 145th Airlift Wing, North Carolina Air National Guard

Section 33 09 53 Page 1

SECTION 33 09 53

AVIATION FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM

02/10

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 in the text by basic designation only.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

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

IEEE C62.41 (1991; R 1995) Recommended Practice on Surge Voltages in Low-Voltage AC Power Circuits

INTERNATIONAL SOCIETY OF AUTOMATION (ISA)

ISA 18.1 (1979; R2004) Annunciator Sequences and Specifications

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

NEMA IA 2 (2005) Programmable Controllers - Parts 1 thru 8

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 2011) Industrial Control and Systems: Enclosures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017) National Electrical Code

U.S. FEDERAL COMMUNICATIONS COMMISSION (FCC)

FCC Part 15 Radio Frequency Devices (47 CFR 15)

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UNDERWRITERS LABORATORIES (UL)

UL 1012 (2010; Reprint Apr 2016) UL Standard for Safety Power Units Other than Class 2

UL 1449 (2014; Reprint Mar 2016) UL Standard for Safety Surge Protective Devices

UL 508 (1999; Reprint Oct 2013) Industrial Control Equipment

1.2 ADMINISTRATIVE REQUIREMENTS

a. Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM applies to this Section, with the additions and modifications specified herein. The Hydrant Fueling System consists of fueling pumps that pump fuel to a Hydrant Hose Truck Check-out Pad, Truck Fill Stands, and fuel pits located on the airfield apron. Automatic pump starts and stops are based on system pressure and flow.

b. Programmable Logic Controllers (PLCs) receive information from pressure transmitters and other devices to control the pumps and control valves.

There are two PLCs that are connected in a redundant configuration, to assure continued operation of the Hydrant fueling System even if either PLC (but not both) fails. The Hydrant Fueling System also includes above ground fuel storage tanks and a product recovery tank.

c. The pump control panel, personal computer, graphic display panel, and annunciator are located in the Control Room of the Pumphouse. The control system shall be furnished by a single supplier. See Section 33 52 43.11 AVIATION FUEL MECHANICAL EQUIPMENT for other required components of the control system. The control system supplier shall be responsible for providing a fully functional control system, in accordance with the drawings and specifications, including the field devices. Installation shall be in accordance with NFPA 70.

d. Submit six copies of Operation and Maintenance Manuals, within 7 calendar days following the completion of factory tests. Installation, Operation, and Maintenance manuals for all equipment supplied shall be furnished following the completion of shop tests and shall include:

(1) Pump Control Panel including interior and exterior equipment layout. Complete guide outlining step-by-step procedures for system startup and operation.

(2) All documents previously submitted and approved with all comments and field changes annotated. Complete description of the sequence of operation including that described in PART 3 and any subsystems not controlled by the PLC (e.g., annunciator panel, EPDS, etc.).

(3) Complete listing of all programming of the PLCs, laptop computer, and Personal Computer.

(4) Complete relay ladder logic diagrams, PLC input/output diagrams, and control power distribution diagrams for the complete control system.

../Word/26 20 00.doc ../Word/33 52 43.11.doc

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(5) Complete troubleshooting guide, which lists possible operational problems and corrective action to be taken, including all as-built conditions.

e. Submit documents demonstrating the accuracy and completeness of the list of material and components, that items proposed comply fully with Contract Requirements, and are otherwise suitable for the application indicated. Documents shall consist of all data or drawings published by the manufacturer of individual items listed including manufacturer's descriptive and technical literature, performance data, catalog cuts, and installation instructions. Submit additional material if the listed items are not adequate to identify intent or conformance to technical requirements. Provide typed and electronic copies of these lists for approval. Any delays associated with resubmittals of incomplete or ambiguous initial submittals will be the Contractor's responsibility.

f. Documents shall be bound in a suitable binder adequately marked or identified on the spine and front cover. A table of contents page shall be included and marked with pertinent contract information and contents of the manual. Tabs shall be provided to separate different types of documents, such as catalog ordering information, drawings, instructions, and spare parts data. Index sheets shall be provided for each section of the manual when warranted by the quantity of documents included under separate tabs or dividers.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. Submittals with an "S" are for inclusion in the Sustainability Notebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Shop Drawing; G

SD-03 Product Data

Pump Control Panel (PCP) and Components; G

Programmable Logical Controller (PLC) Hardware and Software; G

Personal Computer (PC); G

Laptop Computer; G

FCC Computer; G

Laser Printer; G

Graphics Display Panel; G

Graphics Display Screen; G

../Word/01 33 29.doc ../Word/01 33 00.doc

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Control Wiring Data Lists; G

Tools and Spare Parts

SD-06 Test Reports

Certified Pump Control Panel (PCP) Shop Test Report

Record of Test

SD-07 Certificates

Experience and Qualifications; G

Training Plan for Instructing Personnel; G

Testing Plan; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G

1.4 TOOLS AND SPARE PARTS

Provide the following:

a. Any special tools necessary for operation and maintenance of the equipment providing supplier name, current cost, catalog order number, and a recommended list of spare parts to be stocked.

b. One spare set of fuses of each type and size.

c. Recommended manufacturer list of spare parts, including part number, current unit price, and source of supply.

d. One spare power supply module.

e. One spare I/O module for discrete devices and one for analog devices.

f. Two PLC RAM back-up batteries.

g. Two complete sets of ink cartridges for the laser printer.

h. Minimum of 10 spare lamps for the Alarm Annunciator.

i. Minimum of 10 spare lamps of each type of non-LED lamps used on the Pump Control Panel.

1.5 EXPERIENCE AND QUALIFICATIONS

Submit the following data for approval:

a. Certification stating that the manufacturer has manufactured, installed, and successfully completed at least five PLC-based systems for automatic cycling of pumps based upon varying dispensing demands ranging from 0 to 1,800 GPM utilizing multiple pumps. At least two of

Section 33 09 53 Page 5 the five PLC-based systems shall be for dispensing jet fuel into a pressurized, constant pressure, flow demand aircraft hydrant system.

b. Certification that the control systems have successfully operated over the last 2 years and are currently in service.

c. Project names, locations, and system description of these installations. Include user point-of-contact and current telephone numbers.

1.6 WARRANTY

The Pump Control and Annunciation System including devices, hardware and software shall be warranted for a period of one year from the date of acceptance of the system by the Government. This warranty service shall include parts and labor service for equipment supplied under this Specification. Upon notification by the Government of system or component failure, respond at the site with necessary parts within 48 hours of notification.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Pump Control Panel (PCP) and Components

NEMA ICS 1, NEMA ICS 6, NEMA 250, and UL 508. The PCP enclosure shall be a freestanding NEMA Type 12, smooth, gasketed enclosure constructed of 12-gauge steel. All seams shall be continuously welded and there shall be no drilled holes or knockout prior to delivery to the job site. The pump control panel dimensions shall be a maximum of 90 inches high, maximum 72 inches wide, and a maximum of 24 inches deep and shall have removable lifting eyes. The interior surfaces of the panel shall be properly cleaned, primed, and spray painted with white high-gloss enamel. Exterior surfaces shall have standard factory finish. Access for the PCP shall be front only and shall consist of hinged doors having 3-point latching mechanisms. The doors shall open approximately 120 degrees. Rack mounting angles, swing-out panels and other component mounting hardware shall be installed such that servicing of one component shall not require removal or disconnection of other components. No clearance shall be required between the back of the panel and the room walls. Terminal facilities shall be arranged for entrance of external conductors from the top or bottom of the enclosure.

2.1.2 Ventilation System

Provide two supply fans, single phase, 115 volt. Each fan must supply a minimum of 100 CFM. The supply and exhaust grill must contain a filter that is easily removed from the exterior of the enclosure. Also provide three thermostats with an adjustable set point range of 70 degrees F to 140 degrees F. Locate the thermostats near the top in the interior of the PCP.

2.1.3 Ground Bar

The control panel shall have a tin plated copper equipment ground bar. The bar shall have a minimum of twenty grounding screws.

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2.1.4 Standard Indicator Lights

NEMA ICS 1, NEMA ICS 2, and UL 508. Lights shall be heavy duty, NEMA 13, 1 inch mounting hole, round indicating lights operating at 120 volts ac/dc or 24 volts ac/dc. Long life bulbs shall be used. Indicator lights shall have a legend plate with words as shown on drawings. Lens color as indicated on the drawings. Lights shall be "push to test (lamp)" type. LED type lamps of comparable size and color may be substituted for standard indicator lights.

2.1.5 Selector Switches

NEMA ICS 1, NEMA ICS 2, and UL 508. Non-illuminated lever operated selector switches shall be heavy duty, NEMA 13, round, and utilize a 7/8 inches mounting hole. They shall have the number of positions as indicated on the drawings. Switches shall be rated 600 volt, 10 amperes continuous. Legend plates shall be provided with each switch with words as indicated on the Drawings.

2.1.6 Pushbuttons

NEMA ICS 1, NEMA ICS 2, and UL 508. Non-illuminated pushbuttons shall be heavy duty, NEMA 13, round, utilize a 7/8 inch mounting hole, and have the number and type of contacts as indicated on the Drawings or elsewhere in the Specifications. The emergency stop switch shall be a red mushroom head, 1.5 inch diameter, momentary contact type. Pushbuttons shall be rated 600 volt, 10 amperes continuous. Legend plates shall be provided with each switch with words as indicated on the Drawings.

2.1.7 Relays

IEEE C37.90, NEMA ICS 2, UL 508.

2.1.8 Nameplates

Nameplates shall be made of laminated plastic with black outer layers and a white core. Edges shall be chamfered. Nameplates shall be fastened with black-finished round-head drive screws or approved nonadhesive metal fasteners.

2.1.9 Transient Voltage Surge Suppression Devices

IEEE C62.41 for Category "B" transients, UL 1449.

2.1.10 Terminal Blocks

NEMA ICS 4. Terminal blocks for conductors exiting the PCP 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.

2.1.11 Circuit Breakers

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UL 508. Individual, appropriately sized, terminal block mounted, circuit breakers shall be provided for all 120 volt PCP mounted equipment and for the 120 volt terminal boards shown on the Drawings.

2.1.12 Uninterruptible Power Supplies

UL 1012. Input voltage shall be 120 volts (nominal), 1 phase, 60 Hertz.

Output voltage regulation shall be plus or minus 5.0 percent for the following conditions:

a. 20 to 100 percent load on output.

b. Input voltage variation of minus 15 to plus 10 percent.

c. Constant load power factor between 80 and 100 percent.

Response time shall be 1.5 cycles or less. Battery capacity shall be such as to provide an orderly shut down of operating programs or as a minimum 10 minutes.

2.1.13 Miscellaneous Power Supplies

UL 1012. Certain field devices may require power other than 120 VAC (i.e., 24 VDC). The power supplies shall be convection cooled, have fully isolated independent outputs, have constant voltage, have short circuit and overvoltage protection, and have automatic current limiting.

2.1.14 Alarm Annunciator

UL 508 and ISA 18.1. The Alarm Annunciator shall provide visual annunciation, local and remote monitoring, constant or flashing visual and audible alarm as specified herein. The annunciator shall be completely solid state with no moving parts. The annunciator shall be furnished with cabinet and hardware appropriate for flush mounting on the control panel. A power supply either integral or separately mounted shall operate on 120 volts, 60 Hertz. The annunciator shall have windows arranged in a matrix configuration (rows and columns). Each window shall be at least 15/16 inch high by 1-5/8 inches wide and shall have rear illuminated translucent engraved nameplate. Lettering shall be at least 5/32 inches high. System lamp voltage shall be 24 to 28 volts dc. The cells shall be individually addressable and not hardwired.

2.1.15 Alarm Horns

UL 508. The alarm horns shall consist of 3-vibrating horns and 2-resonating horns. One vibrating horn is to be mounted in the PCP, and two vibrating and two resonating horns shall be mounted outside of the pumphouse as shown on the Drawings. The exterior horns shall each produce 100 db at 10 feet and shall be provided in a weather proof housing. The PCP horn shall produce 70 db at 10 feet.

2.1.16 Laptop Computer

2.1.16.1 Hardware

The following are the minimum hardware requirements for the laptop computer:

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a. Latest Pentium CPU operating at 2 GHz or faster.

b. 2 GB RAM.

c. 100 GB hard drive.

d. 16X Read Write DVD drive.

e. Color XGA LCD screen 14 inches.

f. Keyboard.

g. Pointing device (e.g., mouse, track ball).

h. Parallel communication port.

i. Serial communication port compatible with PLC (e.g., RS-232-C, RS-485).

j. 120VAC and Battery power supply.

k. All cables and connectors for interfacing with PLC and personal computer.

l. Modem compatible for remote troubleshooting of the system.

m. Two USB 2.0 communications ports.

n. Provide a carrying case for the Laptop Computer.

2.1.16.2 Software

The following is the minimum software to be loaded on the laptop. The software shall be the most current versions and compatible with each other to make a complete and usable system. All software needs to be fully site licensed and come with all disks to allow a full restore or reload of software in the event of a hard drive crash.

a. Operating system (e.g., the latest commercially available MS Operating system).

b. Software for programming the PLCs.

c. Software for programming the personal computer.

2.1.17 Personal Computer (PC)

2.1.17.1 Hardware

The following are the minimum hardware requirements for the personal computer:

a. Latest Pentium CPU operating at 2.4 GHZ or faster.

b. 2 GB RAM.

c. 250 GB hard drive.

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d. 16X Read Write DVD drive.

e. Color 17 inches flat screen monitor.

f. Keyboard.

g. Pointing device (e.g., mouse).

h. Parallel communication port.

i. Serial communication port compatible with PLC (e.g., RS-232-C, RS-485).

j. 120 VAC operating power.

k. All cables and connectors interfacing with PLC and Laser Printer.

l. Provide a modem capable of remote troubleshooting of the system. The modem will not be permanently connected to the System.

m. Two USB 2.0 communications ports.

2.1.17.2 Software

The following is the minimum software to be loaded on the personal computer.

The software shall be the most current versions and compatible with each other to make a complete and usable system. All software needs to be fully site licensed and come with all disks to allow a full restore or reload of software in the event of a hard drive crash.

a. Operating system (e.g., the latest commercially available MS Operating System).

b. Software for programming the PLCs.

c. The personal computer shall communicate with the PLCs to display system status and change system set points. The personal computer shall have run-time graphical software to display the graphical screens described later and to change set points.

d. Software for recording, tracking, trending, and printing out the pressures, flows, and operational status of all monitored components of the fueling system on a real time basis.

e. Provide MS Office Professional with Excel to allow the trending data described above to be imported to Excel where it can be studied, manipulated, graphed, and easily sent electronically.

2.1.18 Laser Printer

Provide color laser jet alarm/report printer. The unit must print in black at a minimum speed of twelve pages per minute. It must print in color at a minimum speed of ten pages per minute. As a minimum print color graphs of various system pressures, issue flow, and return flow vs. time in seven colors. Provide one set of spare replacement ink cartridges.

2.1.19 FCC Computer

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2.1.19.1 Hardware

The FCC computer must be a copy of the personal computer so that upon failure of the personal computer it could be relocated to the pumphouse to assume the personal computers duties. The normal duties of the FCC computer shall be to serve as a remote monitor only of the screens that are available on the personal computer. The following are the minimum hardware requirements for the FCC computer:

a. Latest Pentium CPU operating at 2.4 GHZ or faster;

b. 2 GB RAM;

c. 250 GB hard drive;

d. 16X Read Write DVD drive;

e. Color 17 inch flat screen monitor;

f. Keyboard;

g. Pointing device (e.g., mouse);

h. Parallel communication port;

i. Serial communication port compatible with PLC (e.g., RS-232-C, RS-485);

j. 120 VAC operating power;

k. All cables and connectors interfacing with PLC and Laser Printer;

l. Provide a modem capable of remote troubleshooting of the system. The modem will not be permanently connected to the System;

m. Two USB 2.0 communications ports.

2.1.19.2 Software

The following is the minimum software to be loaded on the FCC computer. The FCC computer shall be capable of replacing the Personal computer in the pumphouse if the personal computer fails. It will be set up initially to serve only as a remote monitor of the system while located at the FCC.

Should the personal computer fail, the FCC computer will be relocated to the pumphouse and then assume the role of the personal computer. The computer software shall have a built in command to tell the computer whether it is serving as the personal computer or as the remote monitor only. The software shall be the most current versions and compatible with each other to make a complete and usable system. All software needs to be fully site licensed and come with all disks to allow a full restore or reload of software in the event of a hard drive crash.

a. Operating system (the latest commercially available MS Operating System).

b. Software to tell the computer which mode it is to operate in, i.e., (personal computer or remote monitor).

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c. Software to run as a remote monitor.

d. Software for programming the PLCs.

e. The personal computer shall communicate with the PLCs to display system status and change system set points. The personal computer shall have run-time graphical software to display the graphical screens described later and to change set points.

f. Software for recording, tracking, trending, and printing out the pressures, flows, and operational status of all monitored components of the fueling system, on a real time basis.

g. Provide MS Office Professional with Excel to allow the trending data described above to be imported to Excel where it can be studied, manipulated, graphed, and easily sent electronically.

2.2 PROGRAMMABLE LOGICAL CONTROLLER (PLC) HARDWARE AND SOFTWARE

2.2.1 General

a. NEMA IA 2. Each PLC must be able to receive discrete and analog inputs and through its programming it shall control discrete and analog output functions, perform data handling operations and communicate with external devices and remote I/O racks. The PLCs shall be a modular, field expandable design allowing the system to be tailored to the process control application. The capability shall exist to allow for expansion to the system by the addition of hardware and/or user software. At a minimum the PLCs shall include mounting backplanes, power supply modules, CPU module, communication modules, and I/O modules.

b. Design and test each PLC provided for use in the high electrical noise environment of an industrial plant. The PLC modules must comply with the FCC Part 15 Part A for radio noise emissions. The programmable controller processor must be able to withstand conducted susceptibility tests as outlined in NEMA ICS 2, IEEE C37.90.

c. The PLCs must function properly at temperatures between 32 and 122 degrees F, at 5 to 95 percent relative humidity non-condensing and have storage temperatures between minus 40 and plus 140 degrees F at 5 to 95 percent relative humidity non-condensing.

d. The PLCs must have manufacturer's standard system status indicators (e.g., power supply status, system fault, run mode status, back-up battery status).

2.2.2 Central Processing Unit Module

The CPU must be a modular self-contained unit that will provide time of day, scanning, application (ladder rung logic) program execution, storage of the application program, storage of numerical values related to the application process and logic, I/O bus traffic control, peripheral and external device communications and self-diagnostics.

2.2.3 Power Supply Module

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a. The power supply module shall be plugged into the backplane not separately mounted. The power supply shall be wired to utilize 120 VAC, 60 Hz power, the system shall function properly within the range of minus 10 to plus 15 percent of nominal voltage. The power supply shall provide an output to the backplane at a wattage and voltage necessary to support the attached modules. A single main power supply module shall have the capability of supplying power to the CPU module and local communication and I/O modules. Auxiliary power supplies shall provide power to remote racks.

b. Each power supply shall have an integral on/off disconnect switch to the module. If the manufacturers standard power supply does not have an on/off disconnect switch a miniature toggle type switch shall be installed near the PLC and clearly labeled as to its function.

c. The power supply shall monitor the incoming AC line voltage for proper levels and have provisions for both over current and over voltage protection. If the voltage level is detected as being out of range the system shall have adequate time to complete a safe and orderly shutdown.

2.2.4 Program Storage/Memory Requirements

a. The PLC shall have the manufacturers standard nonvolatile executive memory for the operating system. The PLC shall also have EEPROM (Electrically Erasable Programmable Read Only Memory) for storage of the user program and battery backup RAM for application memory. The EEPROM shall be loaded by use of the laptop computer or the personal computer.

b. Submit a calculation of the required amount of EEPROM and RAM (random access memory) needed for this application plus an extra 50 percent.

c. The number of times a normally open (N.O.) and/or normally closed (N.C.) contact of an internal output can be programmed shall be limited only by the memory capacity to store these instructions.

2.2.5 Input/Output (I/O) Modules

a. Provide all required I/O modules (analog input, analog output, discrete input, discrete output, and isolated discrete output) to manipulate the types of inputs and outputs as shown on the drawings and to comply with the sequence of operations. Also provide a minimum of 20 percent (round up for calculation) spare input and output points of each type provided, but not less than 2 of each type.

b. I/O modules shall be a self-contained unit housed within an enclosure to facilitate easy replacement. All user wiring to I/O modules shall be through a heavy-duty terminal strip. Pressure-type screw terminals shall be used to provide fast, secure wire connections. The terminal block shall be removable so it is possible to replace any input or output module without disturbing field wiring.

c. During normal operation, a malfunction in any remote input/output channel shall affect the operation of only that channel and not the operation of the CPU or any other channel.

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d. Isolation shall be used between all internal logic and external power circuits. This isolation shall meet the minimum specification of 1500 VRMS. Provide optically isolated I/O components which are compatible with field devices.

e. Each I/O module shall contain visual indicators to display ON/OFF status of individual input or output points.

f. Discrete output modules shall be provided with self-contained fuses for overload and short circuit protection of the module.

g. All input/output modules shall be color coded and titled with a distinctive label.

2.2.6 Interfacing

The PLC shall have communication ports and communication modules using the manufacturers standard communication architecture for connections of the Personal computer, Laptop Computer, remote I/O racks and interconnections between SYS 1 PLC and SYS 2 PLC for the redundant backup system of the PLCs.

2.2.7 Program Requirements

a. The programming format shall be ladder diagram type as defined by NEMA

IA 2.

b. There shall be a means to indicate contact or output status of the contact or output on the CRT (of the personal computer) or LCD screen (of the laptop computer). Each element's status shall be shown independently, regardless of circuit configuration.

c. The program shall be full featured in its editing capabilities (e.g., change a contact from normally open to normally closed, add instructions, change addresses, etc.).

2.2.8 Diagnostics

The CPU shall continuously perform self-diagnostic routines that will provide information on the configuration and status of the CPU, memory, communications and I/O. The diagnostic routines shall be regularly performed during normal system operation. A portion of the scan time of the controller should be dedicated to perform these housekeeping functions. In addition, a more extensive diagnostic routine should be performed at power up and during normal system shutdown. The CPU shall log I/O and system faults in fault tables, which shall be accessible for display. When a fault shuts down a CPU, a sequence shall be initiated that will automatically switch over to the other CPU. When a fault affects I/O or communication modules the CPU shall shut down only the hardware affected and continue operation by utilizing healthy system components. All faults shall be annunciated on the alarm annunciator.

2.3 GRAPHICS DISPLAY PANEL

2.3.1 Enclosure

The Graphics Display Panel (GDP) shall be a 42 inches LED Panel Display suitable for wall mounting and capable of accepting input from the Personal

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Computer. The Personal Computer shall be set up to normally display it's screen number four on the graphic Display Panel, but it shall be capable of sending any of its other screens to the display panel. Any combination of the screens shall be capable of being displayed on the Personal Computer Monitor and the Graphic Display Panel.

2.3.2 Display Presentation

The process schematic graphic representation shall be as shown on the drawings. Red, green, amber, etc., colors should display on the screen as indicated on the drawings. The indicated lights on the drawing shall display approximately 1/2 inch in diameter.

2.3.3 Digital Flow and Pressure Indicators

Digital indicators as shown on the drawings shall also be displayed on the Graphics Display Panel to provide flows in GPM and pressures in psig. The digital indicators shall display the indicated number of digits as shown on the drawings. Each digit shall be approximately 0.6 inches high.

PART 3 EXECUTION

3.1 PUMP CONTROL PANEL (PCP) AND COMPONENTS

3.1.1 General

a. Where two or more pieces of equipment performing the same function are required, they shall be exact duplicates produced by the same manufacturer. All display instruments of each type shall represent the same outward appearance, having the same physical size and shape, and the same size and style of numbers, characters, pointers, and lamp lenses.

b. The PCP shall include all required resident software programs and hardware to provide the specified sequence of operation. All software optical discs, including programming manuals, shall be turned over to the Government at the completion of start-up so modification can be done in the field with no outside assistance.

c. It is intended that process controlling devices except field devices, and motor controllers be attached to or mounted within the PCP enclosure and all interconnecting wiring installed prior to shipment to the job site. This is to allow shop testing of the system and to decrease field labor requirements.

d. The PCP shall be shipped fully assembled in one piece after the completion of the shop tests and all defects corrected.

3.1.2 Wiring

Wiring methods and practices shall be in conformance with NEMA ICS 1, NEMA ICS 2, NEMA ICS 4, and NEMA ICS 6 recommendations as applicable. All wiring to instruments and control devices shall be made with stranded wire, and wiring shall be permanently labeled with conductor/wire numbers within 1 inch of termination points. Labels shall be tubular heat-shrinkable wire markers that remain legible after exposure to industrial fluids and abrasion. Position markers so that wire numbers can be read without

Section 33 09 53 Page 15 disturbing or disconnecting wiring. Use of individual character-markers placed side-by-side is not acceptable. Numbers shall match approved shop drawings. All wiring shall be neatly laced from point of entry into enclosures to termination points with nylon lacing cord or plastic lacing ties. Lacing within wiring channels is not required. Provide typed Control Wiring Data Lists within each terminal cabinet and the PCP. The data lists shall include: Conductor identification number, wire gauge, wire insulation type, "FROM" terminal identification, "TO" terminal identification, and remarks. The preliminary lists generated by the Contractor will be submitted for approval to the Contracting Officer and will be updated to As- Built conditions by the Contractor. The As-Built data lists shall be placed in a document holder within each enclosure.

3.1.3 Certified Pump Control Panel (PCP) Shop Test Report

The manufacturer shall shop test the PCP, Personal computer, and lap top computer. The procedure shall include simulation of field components and shall provide for fully testing the pump control and annunciator system as a unit before delivery to the Project Site. The test shall, reveal system defects, including, but not limited to, functional deficiencies, operating program deficiencies, algorithm errors, timing problems, wiring errors, loose connections, short circuits, failed components and misapplication of components. The test shall be performed prior to shipment to the site and problems detected shall be corrected. The final testing and correction sequence shall be repeated until no problems are revealed and then two additional successful tests shall be performed. Submit certified test report within 15 days after completion of the test. The report shall include a statement that the Pump Control Panel performs as specified.

Notify the Contracting Officer and the Command Fuels Engineer 30 days prior to the final shop testing date. The Contracting Officer may require a Government witness at the final test before the PCP is shipped to the site.

3.1.4 Ventilation System

Thermostat T-1, shall control fan F-1 and thermostat T-2 shall control fan F-2. T-1 and T-2 shall be set at 80 degrees F to maintain interior air temperature to 20 degrees F above ambient. Thermostat T-3, set at 100 degrees F, shall provide a non-critical PCP HIGH TEMPERATURE alarm to the alarm annunciator.

3.1.5 Grounding

The PCP ground bar shall be connected to the building counterpoise via a #10 AWG conductor. Within the enclosure all I/O racks, processor racks, and power supplies, etc., shall be grounded to meet the manufacturer's specifications.

3.1.6 Indicator Lights, Switches, and Pushbuttons

Indicator lights, switches, and pushbuttons shall be mounted through the PCP enclosure and shall be arranged to allow easy vision and operation of each device. Each device shall have a nameplate and/or legend plate as indicated on the drawings. Nameplate wordings shall be as indicated on the Drawings.

3.1.7 Transient Voltage Surge Suppression Devices

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Transient voltage surge suppression (TVSS) devices shall be installed in the PCP to minimize effects of nearby lightning strikes, switching on and off of motors and other inductive loads. TVSS shall be provided for each control circuit ladder. Each ladder may contain any combination of the following devices: PLCs, power supplies (e.g., 24 volt), fans, relays, lights, switches etc. TVSS shall also be provided for PLC I/O originating outside of the building.

3.1.8 Terminal Blocks

As a minimum, any PCP device that connects to a field device (devices not located in the PCP) shall be connected to a terminal block. A connection diagram similar to the drawings shall be provided to the field Contractor for field connections to the PCP.

3.1.9 Circuit Breakers

As a minimum, any 120 volt PCP device i.e., (fans, lights, power receptacles, 24 VDC power supplies, PLC CPUs, PLC I/O racks) shall be provided with an individual circuit breaker. Additionally 120 volt terminal boards connecting to field devices (devices not located in the PCP) shall be protected by a 120 volt circuit breaker.

3.1.10 Uninterruptible Power supplies

The PCP shall contain three uninterruptible power supplies (UPS) each connected to a dedicated circuit. As shown on the drawings one UPS shall supply PLC System 1, one UPS shall supply PLC System 2, and the third UPS shall supply the miscellaneous device power. The UPSs output capacity shall be sufficient to drive all the equipment connected plus 25 percent. The UPSs shall be mounted on shelves near the bottom of the PCP but not rest on the floor of the PCP.

3.1.11 Power Supplies

Provide and install all 120 VAC and 24 VDC power supply. Interconnecting wiring between UPSs and PLC power supplies shall be completely installed prior to shipment to the job site.

3.1.12 Alarm Annunciator and Horns

Signals shall be initiated by hardwired field contacts or by PCP outputs as required. The annunciator shall energize alarm horns, both an integral panel mounted vibrating horn and remote horns, and flash the appropriate annunciator lamp. The minimum number of windows shall correspond to the number of alarm points, plus 15 percent spare. The Drawings indicate panel layout and the alarms to be annunciated.

3.1.12.1 Non-critical Alarms

Non-critical alarm windows shall be white with black lettering and shall sound the PCP mounted vibrating horn and the exterior mounted vibrating horns.

3.1.12.2 Critical Alarms

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Critical alarm windows shall be red with white lettering and shall sound the PCP mounted vibrating horn and the exterior mounted resonating horns.

Critical alarms shall also cancel all automatic pump starts in the PLC.

3.1.12.3 Alarm Sequence

Alarm sequence for each alarm shall be as follows (ISA 18.1 sequence 'A').

a. For a normal condition, visual indicator and horns will be off.

b. For an alarm condition, visual indicator will flash and horns will sound (this condition will be locked in).

c. Upon acknowledgment of the alarm condition, visual indicator will be steady on and the horns will be off.

d. If, after acknowledgment of an alarm condition, another alarm condition is established, the new alarm will cause the appropriate window to flash and the horn to sound.

e. When condition returns to normal after acknowledgment, the visual indicator and the horn will be off.

3.1.13 Personal Computer

The personal computer shall be a stand alone, desk top mounted unit. The personal computer shall download system parameters from the PLCs for display. The personal computer shall also upload new set point values that the operator has changed using the personal computer keyboard, after a password has been entered.

3.1.13.1 Screen Number 1

This shall be a general opening screen. As a minimum it shall display the name and location of the installation (e.g., Seymour Johnson Air Force Base, North Carolina), name of the project (e.g., Type III Hydrant Fueling System) and screen navigation information.

3.1.13.2 Screen Number 2

At a minimum the following items shall be displayed. The values shall be continuously updated, a 2 second delay maximum between updates will be acceptable.

System Issue Rate xxxx GPM

System Return Rate xxxx GPM

System Net Flow xxxx GPM

System Pressure xxxx PSI

System Operation Mode Auto/Off/Flush/Tightness test

Active System Sys-1/Sys-2

Lead Pump 1/2/3

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Fuel Pump #1 On/Off xxxxx.x HOURS

Fuel Pump #2 On/Off xxxxx.x HOURS

Fuel Pump #3 On/Off xxxxx.x HOURS

Backpressure Control Valve Closed/Enabled

Pressure Control Valve Closed/Enabled

Defuel/Flush Valve Closed/Enabled

Tank 1 Outlet Valve (I1) Open/Closed

Tank 2 Outlet Valve (I2) Open/Closed

Tank 3 Outlet Valve (I3) Open/Closed

Tank 1 Low Suction Outlet Valve Open/Closed

Tank 2 Low Suction Outlet Valve Open/Closed

Tank 3 Low Suction Outlet Valve Open/Closed

Tank 1 Inlet Valve (R11) Open/Closed

Tank 2 Inlet Valve (R13) Open/Closed

Tank 3 Inlet Valve (R12) Open/Closed

Manifold Setup Valve (I28) Open/Closed

Manifold Setup Valve (I29) Open/Closed

Manifold Setup Valve (I30) Open/Closed

Manifold Setup Valve (R8) Open/Closed

Manifold Setup Valve (R9) Open/Closed

Manifold Setup Valve (R10) Open/Closed

Only one of the words separated by a slash (/) shall be displayed. The xxxxx.x HOURS is the fuel pumps elapsed run time and the value shall not be lost when the lead PLC is switched. The pump and valve status words shall be color coded to match the colors used on the graphic display screen.

3.1.13.3 Screen Number 3

The following table shall be displayed. The table lists the set points that can be adjusted using the operator interface. A password shall be entered before the "current value" can be adjusted. The value entered can only be a number within the "set point range". The "default value" is the value held in the program that is loaded into EEPROM memory. (This screen may require more than one display screen.)

SET POINT DESCRIPTION SET POINT RANGE DEFAULT VALUE CURRENT VALUE

Lead pump starting pressure

30 to 150 psi 60 psi xxx psi

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SET POINT DESCRIPTION SET POINT RANGE DEFAULT VALUE CURRENT VALUE

Issue flow to start second pump in the sequence

750 to 950 gpm 840 gpm xxx gpm

Return flow to enable next pump in sequence to start

10 to 100 gpm 60 gpm xxx gpm

Return flow to stop second pump in the sequence (lag pump)

850 to 1100 gpm 1000 gpm xxx gpm

Return flow to initiate lead pump shutdown sequence

750 to 950 gpm 840 gpm xxx gpm

Timer to enable start-up of lead pump

0 to 120 seconds 0 seconds xx seconds

Timer to enable second pump to start

0 to 120 seconds 10 seconds xx seconds

Timer to stop second pump 0 to 120 seconds 15 seconds xx seconds

Timer to stop first pump 0 to 60 seconds 2 seconds xx seconds

Timer to disable Back Pressure Control Valve

0 to 360 seconds 60 seconds xx seconds

Timer to establish fueling pump failure

5 to 30 seconds 15 seconds xx seconds

System pressure to stop lead pump

130 to 200 psig 140 psig xxx psig

3.1.13.4 Screen Number 4

This screen shall be a duplicate of the Graphic Display Drawing showing a schematic of the process flow. This screen shall be referred to as the graphical display. Many operating parameters shall be displayed here as required in later paragraphs of this Specification.

3.1.13.5 Screen Number 5

This screen shall be a duplicate of the Alarm Annunciator and it shall be superimposed over the current active screen on the personal computer monitor when an alarm is activated.

3.1.13.6 Screen Number 6

This screen shall be a screen designed solely for assisting the testing team during initial start up to watch all of the significant parameters of the systems operation simultaneously on one screen. This screen shall include the system parameters i.e., (flows, pressures, and status) from screen 2, the set points from screen 3, and timers for all of the actions that will take place following a delay function.

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3.1.13.7 Screen Number 7

This screen shall be a screen designed solely for displaying the seven graphs as described in Section 33 08 53 AVIATION FUEL DISTRIBUTION SYSTEM START-UP. The following values shall be displayed concurrently against time: Issue flow, Issue pressure, Return flow, Pump #1 discharge pressure, Pressure upstream of BPCV, Pressure downstream of BPCV, and Hydrant Pit Pressure. The personal computer shall be capable of storing up to 1 week of data corresponding to the above values. The system will be able to produce graphs on the screen of this data and be able to print the data in seven colors on the laser printer.

3.1.13.8 Screen Number 8

This screen shall be an alarm history screen. This screen shall be referred to as the Alarm History Display. This screen shall be capable of storing and displaying all alarms that have occurred in the system for at least a period of 30 days.

3.1.13.9 Screen Number 9

This screen shall be a screen designed solely for displaying the parameters and process involved in the Tightness Test as described in this specification and on the drawings. The following values shall be displayed concurrently against time: Pressure (as sensed by PIT-153). The system will be able to produce graphs on the screen of this data and be able to print the data in color on the laser printer.

3.1.14 Laptop Computer

The Laptop computer shall be used to create, edit, and load the ladder logic program into the PLCs and the operator interface graphics control program into the personal computer. The Laptop shall also be used to monitor the PLCs memory and ladder logic program. The computer shall be stored in a lockable cabinet located within the Pump Control Panel.

3.2 PROGRAMMABLE LOGICAL CONTROLLER (PLC) HARDWARE AND SOFTWARE

3.2.1 General

The basic operation of the redundant PLC system is (Reference "Control System Block Diagram" on the Drawings):

a. CPU-1 and it's associated I/O rack (I/O-1) sends system outputs to appropriate devices and receive input signals from System-1 redundant field devices (PIT-151, DPT-151, DPT-153, flow switches, valve limit switches), System-2 redundant field devices (PIT-152, DPT-152, DPT-154, flow switches, valve limit switches), and all nonredundant field devices as listed on the Drawings.

b. CPU-2 and it's associated I/O rack (I/O-2) sends system outputs to appropriate devices and receive input signals from System-1 redundant field devices (PIT-151, DPT-151, DPT-153, flow switches, valve limit switches), System-2 redundant field devices (PIT-152, DPT-152, DPT-154, flow switches, valve limit switches), and all nonredundant field devices as listed on the Drawings.

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Section 33 09 53 Page 21

c. Within each rack (I/O-1 and I/O-2) System-1, System-2, and nonredundant inputs and outputs shall not be mixed on the same input/output module.

d. Under normal operation: The system input select switch is in the "SYS- 1" position. CPU-1 is controlling the system using System-1 and nonredundant inputs from I/O-1 and any set point changes from the personal computer. CPU-2 is being updated by CPU-1 or concurrently monitoring System-1 inputs from I/O-2.

e. If under normal operation CPU-1 recognizes that a System-1 input has failed (see note below) it shall change over to the System-2 redundant input on I/O-1 and report the failure to the personal computer alarm screen.

Note: The pressure indicating transmitters and the differential pressure transmitters are the only devices that the PLC can monitor for a possible failure. Failures shall be defined in the following manners: When the pressure indicating transmitters differ from each other by more than 10 psig after a ten second delay, assume the lower reading transmitter has failed.

When the issue differential pressure transmitters differ from each other by more than 30 gpm after a ten second delay, assume the lower reading transmitter has failed. When the return differential pressure transmitters differ from each other by more than 20 gpm after a ten second delay, assume the lower reading transmitter has failed.

f. During normal operation there are two ways for CPU-2 to take control of the system: 1) CPU-1 identifies its own internal fault and hands over control to CPU-2. 2) CPU-2 identifies a fault in CPU-1 and takes control from CPU-1. When CPU-2 is in control of the system it shall annunciate the fault condition and shall be using any updated inputs from the personal computer and shall use System-1 inputs. If CPU-2 senses a fault on a System-1 input it shall then switch over to the appropriate System-2 input. If power is lost to System-1 inputs then CPU-2 shall use all of the System-2 inputs.

g. CPU-2 shall also report any of its internal faults to CPU-1 and CPU-1 shall report any faults it detects in CPU-2.

h. When the operators think the system is not working and the PLCs do not detect any faults the operator can move the system input select switch from the "SYS-1" position to the "SYS-2" position. With the switch in the "SYS-2" position the PLCs are using System-2 inputs.

3.2.2 Programs

a. Provide two copies of all working programs (i.e., PLC logic, personal computer) on read only optical discs as well as a printed program listing.

b. Provide rung comments (documentation) in the ladder logic program.

Each device, on the ladder, shall be identified as to the type of device, i.e., limit switch XX, flow indicator XX, motor starter XX, etc. Rung comments shall be provided for input and output rungs. The programmer shall also provide a comment describing the function of each rung or group of rungs that accomplish a specific function.

Section 33 09 53 Page 22

3.3 GRAPHICS DISPLAY PANEL

The graphic display panel shall be shipped fully assembled in one piece after it has been shop tested as an integral part of the pump control panel and all defects corrected. The graphic display panel shall be able to depict the same screens as the personal computer displays. The default screen on the GDP shall be the graphic display screen. The other screens that the personal computer can display will also be able to be chosen from the personal computer to be displayed here.

3.4 GRAPHICS DISPLAY SCREEN

3.4.1 General

The graphic display screen shall be capable of being displayed on the personal computer monitor and the GRAPHICS DISPLAY PANEL.

3.4.2 Display Presentation

The Graphic Display shall depict the process fuel flow schematically as indicated on the drawings. Red, green, and amber symbols shall be integrated with the process schematic to provide current equipment status graphically. The symbols shall be located immediately adjacent to related equipment symbol.

3.4.3 Process Schematic

The process schematic graphic representation shall utilize conventional symbols when possible. Symbols and flow lines shall be sized and spaced so as to provide a clear representation of the system process. The Graphic Display shall be suitable for supervised field modification when future items are added. Minor changes may be incorporated to allow proper line width and spacing. Component arrangement, piping routing, and location of valves shall match the flow diagram. The Graphic Display layout shall be approved by the Government.

3.4.4 Digital Flow and Pressure Indicators

The graphics display screen shall have digital displays for the flows and pressures as indicated on the Drawings.

3.5 INSTALLATION

Installation shall conform to the manufacturer's drawings, written recommendations, and directions.

3.5.1 Shop Drawing

The shop drawing shall be clear and readable and preferably drawn using a computer aided drafting package. At the conclusion of the Project the diagram drawings shall be redrafted to include all as-built conditions.

These updated drawings shall be included in the O&M Manuals and appropriate section of the drawings placed in a data pocket located in each of the enclosures. The shop drawing at a minimum shall show:

a. Overall dimensions, front, side and interior elevation views of the PCP showing size, location, and…