AM1_Binder_McAAP_Diesel_Storage.pdf

i

AMENDMENT 0001

W912BV19R0040

REPLACE BULK DIESEL SYSTEM

MCALESTER AAP, OKLAHOMA

1. The revised/new sections/appendices/pages l isted below are hereby added to or revised and made a part of the solicitation. Revised or added/deleted information can be located in the specifications by searching for an asterisk and amendment number (i.e., *AM1).

REVISED/NEW SECTIONS/APPENDICES

33 09 52

2. Delete the following sections in their entirety:

DELETED SECTIONS

N/A

3. The revised drawings l isted below are hereby added to or revised and made a part of the solicitation.

REVISED DRAWINGS

-- END CONTINUATION SHEET --

FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM (NON-HYDRANT)

Replaced in it's entirety

M-505 MECHANICAL DETAILS SHEET 3 OF 3

Replace Bulk Diesel System, DESC18S2, McAlester AAP, Oklahoma OK21

SECTION TABLE OF CONTENTS

DIVISION 33 - UTILITIES

SECTION 33 09 52

FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM (NON-HYDRANT)

11/18

PART 1 GENERAL

1.1 REFERENCES

1.2 ADMINISTRATIVE REQUIREMENTS

1.3 SUBMITTALS

1.4 TOOLS AND SPARE PARTS

1.5 EXPERIENCE AND QUALIFICATIONS

1.6 WARRANTY

PART 2 PRODUCTS

2.1 MATERIALS AND SYSTEM COMPONENTS

2.1.1 Pump Control Panel (PCP) and Components

2.1.2 Ventilation System

2.1.3 Ground Bar

2.1.4 Standard Indicator Lights

2.1.5 Selector Switches

2.1.6 Pushbuttons

2.1.7 Relays

2.1.8 Nameplates

2.1.9 Transient Voltage Surge Suppression Devices

2.1.10 Terminal Blocks

2.1.11 Circuit Breakers

2.1.12 Uninterruptible Power Supplies

2.1.13 Miscellaneous Power Supplies

2.1.14 Alarm Annunciator

2.1.15 Alarm Horns

2.1.16 Laptop Computer

2.1.16.1 Hardware

2.1.16.2 Software

2.1.17 Personal Computer (PC)

2.1.17.1 Hardware

2.1.17.2 Software

2.1.18 Laser Printer

2.2 PROGRAMMABLE LOGICAL CONTROLLER (PLC) HARDWARE AND SOFTWARE

2.2.1 General

2.2.2 Central Processing Unit Module

2.2.3 Power Supply Module

2.2.4 Program Storage/Memory Requirements

2.2.5 Input/Output (I/O) Modules

2.2.6 Interfacing

2.2.7 Program Requirements

2.2.8 Diagnostics

PART 3 EXECUTION

SECTION 33 09 52 Page 1

Revised in Accordance with Am #0001

*AM1 Section 33 09 52 Replaced in it's entirety*

3.1 PUMP CONTROL PANEL (PCP) AND COMPONENTS

3.1.1 General

3.1.2 Wiring

3.1.3 Certified Pump Control Panel (PCP) Shop Test Report

3.1.4 Ventilation System

3.1.5 Grounding

3.1.6 Indicator Lights, Switches, and Pushbuttons

3.1.7 Surge Protective Devices

3.1.8 Terminal Blocks

3.1.9 Circuit Breakers

3.1.10 Uninterruptible Power supplies

3.1.11 Power Supplies

3.1.12 Alarm Annunciator and Horns

3.1.12.1 Non-critical Alarms

3.1.12.2 Critical Alarms

3.1.12.3 Alarm Sequence

3.1.13 Personal Computer

3.1.14 Laptop Computer

3.2 PROGRAMMABLE LOGICAL CONTROLLER (PLC) HARDWARE AND SOFTWARE

3.2.1 General

3.2.2 Programs

3.3 GRAPHICS DISPLAY SCREEN

3.3.1 General

3.3.2 Display Presentation

3.3.3 Process Schematic

3.3.4 Digital Flow and Pressure Indicators

3.4 INSTALLATION

3.4.1 Shop Drawing

3.4.2 System Start-Up and Testing

3.4.3 Training Plan for Instructing Personnel

3.5 PLC CONTROL SYSTEM SEQUENCE OF OPERATION

3.5.1 Abbreviations

3.5.2 Operating Tanks

3.5.2.1 Level Control

3.5.2.1.1 Low-Low Level

3.5.2.1.2 Low Level

3.5.2.1.3 High Level

3.5.2.1.4 High-High Level

3.5.2.2 Level Control

3.5.2.2.1 Low-Low Level

3.5.2.2.2 Low Level

3.5.2.2.3 High Level

3.5.2.2.4 High-High Level

3.5.2.3 Outlet Valve

3.5.3 Product Recovery Tank

3.5.3.1 Fuel Transfer Pump (FTP)

3.5.3.2 Overfill Valve (OV)

3.5.3.3 High Level Alarm

3.5.3.4 High-High Level Alarm

3.5.3.5 Leak Detection

3.5.4 Fueling Pumps (FP)

3.5.5 Flow Switch, Fueling Pump

3.5.6 Transmitters

3.5.6.1 Differential Pressure Transmitter (DPT)

3.5.7 Safety Circuit

3.5.7.1 Emergency Stop Status

3.5.7.2 Emergency Shutoff Valves (ESO) Status

3.5.7.3 Circuit Power Status

3.5.8 Pump Control Panel

SECTION 33 09 52 Page 2

3.5.8.1 CPU Faults

3.5.8.2 PCP Temperature Alarm

3.6 OPERATING PROGRAM REQUIREMENTS

3.7 AUTOMATIC MODE - ISSUE OR TRANSFER CONDITION

3.8 OFF MODE

3.9 MANUAL OPERATION OF FUELING PUMPS

-- End of Section Table of Contents --

SECTION 33 09 52 Page 3

SECTION 33 09 52

FUEL PUMP CONTROL AND ANNUNCIATION SYSTEM (NON-HYDRANT)

11/18

PART 1 GENERAL

1.1 REFERENCES

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

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C37.90 (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 2016) Industrial Control and Systems: Enclosures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

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

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

SECTION 33 09 52 Page 4

U.S. FEDERAL COMMUNICATIONS COMMISSION (FCC)

FCC Part 15 Radio Frequency Devices (47 CFR 15)

UNDERWRITERS LABORATORIES (UL)

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

UL 1449 (2014; Reprint Jul 2017) UL Standard for Safety Surge Protective Devices

UL 508 (2018) UL Standard for Safety 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.

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

c. The control system must be furnished by a single supplier. See Section 33 57 55 FUEL SYSTEM COMPONENTS (NON-HYDRANT) for other required components of the control system. The control system supplier must be responsible for providing a fully functional control system, in accordance with the drawings and specifications, including the field devices. Installation must 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 system components supplied must be furnished following the completion of shop tests and must include:

(1) Pump Control Panel including interior and exterior system components 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. alarm annunciator safety/circuit).

(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.

(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

SECTION 33 09 52 Page 5 contract requirements, and are otherwise suitable for the application indicated. Documents must 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 must be bound in a suitable binder adequately marked or identified on the spine and front cover. A table of contents page must be included and marked with pertinent contract information and contents of the manual. Tabs must be provided to separate different types of documents, such as catalog ordering information, drawings, instructions, and spare parts data. Index sheets must 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 information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance with 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, OMA

SD-03 Product Data

Tools and Spare Parts

Pump Control Panel (PCP) and Components; G, OMA

Laptop Computer; G, OMA

Personal Computer (PC); G, OMA

Laser Printer; G, OMA

Programmable Logical Controller (PLC) Hardware and Software; G, OMA

Control Wiring Data Lists; G, OMA

Graphics Display Screen; G, OMA

SD-06 Test Reports

Certified Pump Control Panel (PCP) Shop Test Report

Record of Test

SD-07 Certificates

SECTION 33 09 52 Page 6

Experience and Qualifications; G, OMA

Testing Plan; G, OMA

Training Plan for Instructing Personnel; G, OMA

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, OMA

1.4 TOOLS AND SPARE PARTS

Provide the following:

a. Any special tools necessary for operation and maintenance of the system components 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 spare 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 2400 GPM utilizing multiple pumps. At least two of the five PLC-based systems must 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 must be warranted for a period of one year from the date of

SECTION 33 09 52 Page 7 acceptance of the system by the Government. This warranty service must include parts and labor service for system components 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 SYSTEM COMPONENTS

2.1.1 Pump Control Panel (PCP) and Components

NEMA ICS 1, NEMA ICS 6, NEMA 250, and UL 508. The PCP enclosure must be a freestanding NEMA Type 12, smooth, gasketed enclosure constructed of 12 gauge steel. All seams must be continuously welded and there must be no drilled holes or knockout prior to delivery to the job site. The interior surfaces of the panel must be properly cleaned, primed, and spray painted with white high-gloss enamel. Exterior surfaces must have standard factory finish. Access for the PCP must be front only and must consist of hinged doors having 3-point latching mechanisms. The doors must open approximately 120 degrees. Rack mounting angles, swing-out panels and other component mounting hardware must be installed such that servicing of one component must not require removal or disconnection of other components. No clearance will be required between the back of the panel and the room walls. Terminal facilities must 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 two 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 must have a tin-plated copper equipment ground bar. The bar must have a minimum of twenty grounding screws.

2.1.4 Standard Indicator Lights

NEMA ICS 1, NEMA ICS 2, and UL 508. Lights must 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 must be used. Indicator lights must have a legend plate with words as shown on drawings. Lens color as indicated on the drawings. Lights must 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 must be heavy duty, NEMA 13, round, and utilize a 7/8-inches mounting hole. They must have the number of positions as indicated on the drawings. Switches must be rated 600 volt, 10 amperes continuous. Legend plates must be provided with each switch with words as indicated on the drawings.

SECTION 33 09 52 Page 8

2.1.6 Pushbuttons

NEMA ICS 1, NEMA ICS 2, and UL 508. Non-illuminated pushbuttons must 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 must be a red mushroom head, 1.5inch diameter, momentary contact type. Pushbuttons must be rated 600 volt, 10 amperes continuous. Legend plates must 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 must be made of laminated plastic with black outer layers and a white core. Edges must be chamfered. Nameplates must 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 must be two-way type with double terminals, one for internal wiring connections and the other for external wiring connections. Terminal blocks must be made of bakelite or other suitable insulating material with full deep barriers between each pair of terminals. A terminal identification strip must form part of the terminal block and each terminal must be identified by a number in accordance with the numbering scheme on the approved wiring diagrams.

2.1.11 Circuit Breakers

UL 508. Individual, appropriately sized, terminal block mounted, circuit breakers must be provided for all 120 volt PCP mounted system components and for the 120 volt terminal boards shown on the drawings.

2.1.12 Uninterruptible Power Supplies

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

Output voltage regulation must be plus/minus 5.0 percent for the following conditions:

a. 20 to 100 percent load on output.

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

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

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

SECTION 33 09 52 Page 9

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 must 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 must provide visual annunciation, local and remote monitoring, constant or flashing visual and audible alarm as specified herein. The annunciator must be completely solid state with no moving parts. The annunciator must be furnished with cabinet and hardware appropriate for flush mounting on the control panel.

A power supply either integral or separately mounted must operate on 120 volts, 60 Hertz. The annunciator must have windows arranged in a matrix configuration (rows and columns). Each window must be at least 15/16-inch high by 1-5/8-inches wide and must have rear illuminated translucent engraved nameplate. Lettering must be at least 5/32-inches high. System lamp voltage must be 24 to 28 volts dc. The cells must be individually addressable and not hardwired.

2.1.15 Alarm Horns

UL 508. The alarm horns must 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 must be mounted outside of the pumphouse as shown on the drawings. The exterior horns must each produce 100 db at 10 feet and must be provided in a weather proof housing. The PCP horn must 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:

a. Latest CPU operating at 3.9 GHz or faster

b. 8 GB RAM

c. 1 TB hard drive

d. 16X Read Write DVD drive

e. 15-inch 1080p LED - Backlit Display

f. Keyboard

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

h. 120VAC and Battery power supply i All cables and connectors for interfacing with PLC and personal computer

j. HDMI Port

k. Two USB 3.0 communications ports

SECTION 33 09 52 Page 10

l. 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 must 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 (provide with software key) 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 CPU operating at 2.4 GHZ or faster

b. 8 GB RAM

c. 1 TB hard drive

d. 16X Read Write DVD drive

e. Color 17-inches 1080p LED-Backlit 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 3.0 communications ports

n. Two HDMI ports

2.1.17.2 Software

The following is the minimum software to be loaded on the personal computer. The software must 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 (provide with software key) and come with all

SECTION 33 09 52 Page 11 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 must communicate with the PLCs to display system status and change system set points. The personal computer must 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. 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 two sets of spare replacement ink cartridges.

2.2 PROGRAMMABLE LOGICAL CONTROLLER (PLC) HARDWARE AND SOFTWARE

2.2.1 General

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

b. Design and test PLC provided for use in the high electrical noise environment of an industrial plant. PLC module 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. PLC 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 140 degrees F at 5 to 95 percent relative humidity non-condensing.

d. PLC must have manufacturer's standard system status indicators (e.g.

power supply status, system fault, run mode status, back-up battery status).

SECTION 33 09 52 Page 12

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

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

b. Each power supply must 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 must be installed near the PLC and clearly labeled as to its function.

c. The power supply must 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 must have adequate time to complete a safe and orderly shutdown.

2.2.4 Program Storage/Memory Requirements

a. The PLC must have the manufacturers standard nonvolatile executive memory for the operating system. The PLC must also have EEPROM (Electrically Erasable Programmable Read Only Memory) for storage of the user program and battery backup RAM for application memory. The EEPROM must 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.) or normally closed (N.C.)

contact of an internal output can be programmed must 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 must be a self-contained unit housed within an enclosure to facilitate easy replacement. All user wiring to I/O modules must be through a heavy-duty terminal strip. Pressure-type screw terminals must be used to provide fast, secure wire connections. The terminal

SECTION 33 09 52 Page 13 block must 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 must affect the operation of only that channel and not the operation of the CPU or any other channel.

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

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

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

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

2.2.6 Interfacing

The PLC must have communication ports and communication modules using the manufacturers standard communication architecture for connections of the Personal computer, and Laptop Computer.

2.2.7 Program Requirements

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

NEMA IA 2.

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

c. The program must be full featured in its editing capabilities (e.g.

change a contact from normally open to normally closed, add instructions, change addresses).

2.2.8 Diagnostics

The CPU must 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 must 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 must log I/O and system faults in fault tables, which must be accessible for display. When a fault affects I/O or communication modules the CPU must shut down only the hardware affected and continue operation by utilizing healthy system components. All faults must be annunciated on the alarm annunciator.

SECTION 33 09 52 Page 14

PART 3 EXECUTION

3.1 PUMP CONTROL PANEL (PCP) AND COMPONENTS

3.1.1 General

a. Where two or more system components performing the same function are required, they must be exact duplicates produced by the same manufacturer. All display instruments of each type must 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 must include all required resident software programs and hardware to provide the specified sequence of operation. All software optical discs, including programming manuals, must 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 must 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 must 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 must be made with stranded wire, and wiring must be permanently labeled with conductor/wire numbers within one-inch of termination points. Labels must 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 disturbing or disconnecting wiring. Use of individual character-markers placed side-by-side is not acceptable. Numbers must match approved shop drawings. All wiring must 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. Where the PCP contains intrinsically safe wiring, barriers or other devices, the panel must be arranged so that all intrinsically safe wiring is separated from non-intrinsically safe wiring by approved methods. Wiring channels containing intrinsically safe wiring must be blue and be labeled as "Intrinsically Safe Wiring Only" on the cover. All conduit penetrations into the PCP containing intrinsically safe wiring must be separated from non-intrinsically safe conduit penetrations by a minimum of 2-inches.

Provide typed Control Wiring Data Lists within each terminal cabinet and the PCP. The data lists must 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 must be placed in a document holder within each enclosure.

SECTION 33 09 52 Page 15

3.1.3 Certified Pump Control Panel (PCP) Shop Test Report

The manufacturer must shop test the PCP, Personal computer, and laptop computer. The procedure must include simulation of field components and must provide for fully testing the pump control and annunciator system as a unit before delivery to the project site. The test must, 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 must be performed prior to shipment to the site and problems detected must be corrected. The final testing and correction sequence must be repeated until no problems are revealed and then two additional successful tests must be performed. Submit certified test report within 15-days after completion of the test. The report must include a statement that the Pump Control Panel performs as specified.

Notify the Contracting Officer and the Service Headquarters 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, must control fan F-1 and thermostat T-2 must control fan F-2.

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

3.1.5 Grounding

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

3.1.6 Indicator Lights, Switches, and Pushbuttons

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

3.1.7 Surge Protective Devices

Surge protective devices (SPD) must be installed in the PCP to minimize effects of nearby lightning strikes, switching on and off of motors and other inductive loads. SPD must 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. SPD must 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) must be connected to a terminal block. A connection diagram similar to the drawings must 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

SECTION 33 09 52 Page 16 receptacles, 24 VDC power supplies, PLC CPUs, PLC I/O racks) must be provided with an individual circuit breaker. Additionally 120 volt terminal boards connecting to field devices (devices not located in the PCP) must be protected by a 120 volt circuit breaker.

3.1.10 Uninterruptible Power supplies

The PCP must contain two uninterruptible power supplies (UPS) (each connected to a dedicated circuit). As shown on the drawings one UPS must supply the PLC System , and the second UPS must supply the miscellaneous device power. The UPSs output capacity must be sufficient to drive all the system components connected plus 25 percent. The UPSs must 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 must be completely installed prior to shipment to the job site.

3.1.12 Alarm Annunciator and Horns

Signals must be initiated by hardwired field contacts or by PCP outputs as required. The annunciator must energize alarm horns, both an integral panel mounted vibrating horn and remote horns, and flash the appropriate annunciator lamp. The minimum number of windows must 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 must be white with black lettering and must sound the PCP mounted vibrating horn and the exterior mounted vibrating horns.

3.1.12.2 Critical Alarms

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

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

3.1.12.3 Alarm Sequence

Alarm sequence for each alarm must 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.

SECTION 33 09 52 Page 17

3.1.13 Personal Computer

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

3.1.14 Laptop Computer

The Laptop computer must 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 must also be used to monitor the PLCs memory and ladder logic program. The computer must 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 PLC system is (Reference "Control System Block Diagram" on the drawings):

a. The CPU and its associated I/O rack (I/O-1) sends system outputs to appropriate devices and receive input signals from field devices (PITs-1, DPTs-1, DPTs-3, flow switches, valve limit switches).

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, must be identified as to the type of device, i.e. limit switch XX, flow indicator XX, motor starter XX.

Rung comments must be provided for input and output rungs. The programmer must also provide a comment describing the function of each rung or group of rungs that accomplish a specific function.

3.3 GRAPHICS DISPLAY SCREEN

3.3.1 General

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

3.3.2 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.

3.3.3 Process Schematic

The process schematic graphic representation shall utilize conventional

SECTION 33 09 52 Page 18 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.

3.3.4 Digital Flow and Pressure Indicators

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

3.4 INSTALLATION

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

3.4.1 Shop Drawing

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

These updated drawings must 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 must show:

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

b. Overall dimensions, front elevation of the GDP showing graphical layout and size, location and labeling of each device.

c. Power ladder diagram indicating power connections between SDP, power conditioners, PLCs, power supplies and field and panel devices. Any terminal block connection numbers used must be indicated.

d. Control ladder diagram indicating control connections between field and devices and PLC I/O modules. Terminal block connection numbers and PLC terminal numbers must be indicated.

e. Communication connections between PLCs and I/O racks. Communication channel numbers must be indicated.

f. Bill of materials.

g. Written control sequence covering all inputs, outputs, and control scheme.

3.4.2 System Start-Up and Testing

a. At PCP start-up and testing provide personnel, onsite, to provide technical assistance, program fine tuning, and to start-up and test the system. Start-up and testing must be coordinated with the overall fueling system start-up test specified in Section 33 08 55 COMMISSIONING OF FUEL FACILITY SYSTEMS. Prior to this test, all connections must have been made between the PCP, the personal computer, the motor control center, and all field devices. In addition, wiring must have been checked for continuity and short circuits. Adjust set

SECTION 33 09 52 Page 19 point values, timing values, and program logic as required to provide a functional hydrant fuel control system. Once the system has been fine tuned and passed the system test, the new system default values, must be loaded into the PLC EEPROM and the personal computer screens adjusted to indicate the new values.

b. A step-by-step Testing Plan of the PCP must be submitted. The test must be designed to show that every device (lights, switches, personal computer display screens, alarms) on the PCP and personal computer is in working order and that the PLC program controls the system per specifications. The test must be performed in conjunction with Section 33 08 55 COMMISSIONING OF FUEL FACILITY SYSTEMS. The plan must include a place for the Contractor and government representative to initial each step of the plan after satisfactory completion and acceptance of each step. The complete initialed Record of Test must be certified by the Contractor and then submitted.

3.4.3 Training Plan for Instructing Personnel

a. Upon completion of the system start-up a competent technician regularly employed by the PCP manufacturer must hold a training class for the instruction of Government personnel in the operation and maintenance of the system. Provide both classroom type theory instruction and hands-on instruction using operating system components provided. The period of instruction must be a minimum of three 8-hour working days.

The training must be designed to accommodate 8 operators, 4 maintenance personnel, and 2 programmers. The Contracting Officer must receive written notice a minimum of 14-days prior to the date of the scheduled classes.

b. Furnish a written lesson plan and training schedule for Government approval at least 60-days prior to instructing operating, maintenance and programming personnel. Concurrently submit above to the Service Headquarters or officially designated alternate for their input into the review process. Approval of lesson plan will be based on both Government and Service Headquarters' concurrence. This plan must be tailored to suit the requirements of the Government. The training must be divided into three separate classes. Each class must be tailored to a specific group of personnel. The groups are: 1) Operators, those that will use the control system on a day-to-day basis; 2) Maintenance personnel, those that will perform routine and non-routine maintenance and trouble shooting of the control system; 3) Programmers, those that will make changes to and trouble shoot the PLC and personal computer programs. The training program must provide:

(1) a detailed overview of the control system including the complete step-by-step procedures for start-up, operation and shut-down of the control system.

(2) a general overview of programmable logic controllers.

(3) the maintenance of system components installed.

(4) the programming of the PLC and Personal Computer.

(5) troubleshooting of the system.

c. Complete approved Operation and Maintenance manuals for this specification and 26 20 00 INTERIOR DISTRIBUTION SYSTEM (specifically

SECTION 33 09 52 Page 20 pertaining to the motor control center and its relay ladder diagrams) must be used for instructing operating personnel. Training must include both classroom and hands-on field instruction. The class must be recorded in DVD format.

d. Provide training courses in DVD format covering system overview, operation, maintenance, trouble shooting, and programming. These DVDs must be produced onsite by the Contractor using the supplied Pump Control Panel as the teaching aid, or commercially produced DVDs by the PLC manufacturer or third party who specializes in training on PLC systems. Along with the DVDs, provide workbooks, which follow along with the DVDs.

3.5 PLC CONTROL SYSTEM SEQUENCE OF OPERATION

The following describes general functions of the fueling system components.

3.5.1 Abbreviations

a. SYS: components of System including UPS, power supply, CPU, I/O, and system input and outputs.

b. CPU: SYS PLC CPU.

c. I/O: SYS PLC input/output modules.

d. PCP: Pump Control Panel.

e. PC: Personal Computer.

f. UPS: Uninterruptible Power Supply.

3.5.2 Operating Tanks

3.5.2.1 Level Control

Each operating tank has four level float switches to measure low-low, low, high and high-high levels.

3.5.2.1.1 Low-Low Level

When the low-low level float is activated the associated tank's graphic display low-low level light must light up. If the selected tank's level drops below the low-low sensor the alarm annunciator's low-low level alarm sequence activates, issue pumps running in automatic mode must be disabled. If all tanks are at low-low level, no issue pumps in automatic mode must be enabled.

3.5.2.1.2 Low Level

When the low level float is activated the associated tank's graphic display low level light must light up and the alarm annunciator's non-critical low level alarm sequence activates.

3.5.2.1.3 High Level

When the high level float is activated the associated tank's graphic display high level light must light up and the alarm annunciator's non-critical high level alarm sequence activates.

SECTION 33 09 52 Page 21

3.5.2.1.4 High-High Level

When the high-high level float is activated the associated tank's graphic display high-high level light must light up, the alarm annunciator's critical high-high level alarm sequence activates, the pump control panel must de-energize the solenoid on the tank's high level shutoff valve to force it closed.

3.5.2.2 Level Control

Each operating tank has level switches to monitor low-low, low, high, and high-high fuel levels.

3.5.2.2.1 Low-Low Level

When the low-low level elevation is attained the associated tank's GDP low-low level light must light up. If the selected tank's level drops below the low-low sensor the alarm annunciator's low-low level alarm sequence activates, issue pumps running in automatic mode must be disabled. If all tanks are at low-low level, no issue pumps in automatic mode must be enabled.

3.5.2.2.2 Low Level

When the low level elevation is attained the associated tank's GDP low level light must light up and the alarm annunciator's non-critical low level alarm sequence activates.

3.5.2.2.3 High Level

When the high level elevation is attained the associated tank's GDP high level light must light up and the alarm annunciator's non-critical high level alarm sequence activates.

3.5.2.2.4 High-High Level

When the high-high level elevation is attained, the associated tank's GDP high-high level light must light up and the alarm annunciator's critical high-high level alarm sequence activates. The pump control panel must de-energize the solenoid on the tank's high level shutoff valve to force it closed.

3.5.2.3 Outlet Valve

Each operating tank's outlet valve has two limit switches to indicate valve position. The closed limit switch is DPDT. The closed limit switch must close when the valve is fully closed. When the closed limit switch is closed the associated tank's valve graphic display closed light must activate. When the valve is fully open, the open limit switch is closed.

At this time the associated tank's valve graphic display open light must activate.

3.5.3 Product Recovery Tank

3.5.3.1 Fuel Transfer Pump (FTP)

The pump's motor controller has a status relay to indicate the on/off status of the pump. When status relay is open the pump's graphic display

SECTION 33 09 52 Page 22 off light must activate. When the status relay is closed the pump's graphic display on light must light up. The status relay state must also be used to start and stop the pumps elapsed run time timer.

3.5.3.2 Overfill Valve (OV)

The tank's overfill valve has a limit switch to indicate valve position.

The switch is SPST. The switch must close when the valve is fully closed.

When the limit switch is closed, the tank's graphic display valve closed light must light up and the alarm annunciator's non-critical alarm sequence activates. When the limit switch is open the tank's graphic display valve open light must light up.

3.5.3.3 High Level Alarm

The tank has a high level alarm float switch. The switch is SPST. When the high level alarm float is activated the tank's graphic display high level light must light up and the alarm annunciator's critical alarm sequence activates.

3.5.3.4 High-High Level Alarm

The tank has a high-high level alarm float switch. When the high-high level alarm float is activated the tank's graphic display high-high level light must light up and the alarm annunciator's critical alarm sequence activates.

3.5.3.5 Leak Detection

The tank has a leak detection…