25_14_01.pdf

Green Brook, Segment C-1

AMENDMENT # 4

SECTION 25 14 01

PUMP STATION INSTRUMENTATION AND CONTROL PANELS

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. The contractor is required to obtain and comply with the latest District's standards for communications, data processing, and electronics at time of execution.

ASTM INTERNATIONAL (ASTM)

ASTM A312/A312M (2017) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

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 C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms

IEEE 142 (2007; Errata 2014) Recommended Practice for Grounding of Industrial and Commercial Power Systems - IEEE Green Book

INTERNATIONAL SOCIETY OF AUTOMATION (ISA)

ISA MC96.1 (1982) Temperature Measurement Thermocouples

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

ANSI C12.1 (2008) Electric Meters Code for Electricity Metering

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

SECTION 25 14 01 Page 1

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

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) National Electrical Code

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST SP 250 (1991) Calibration Services Users Guide

UNDERWRITERS LABORATORIES (UL)

UL 1059 (2001; Reprint Oct 2011) Standard for Terminal Blocks

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

1.2 DEFINITIONS

Definitions, Symbols, and engineering unit abbreviations shall conform to IEEE 100, as applicable.

1.3 SYSTEM DESCRIPTION

The Pump Station instrumentation and control system shall be used to monitor and control the operation of equipment as specified and in accordance with the sequence of control and on the drawings. The control system shall provide for operator interaction, overall control system supervision, and equipment control and monitoring. Provide hardware configured and sized to support expansion as specified and shown on the drawings.

The intent of this specification is to specify the equipment associated with the pump station, sluice gate, and equipment installed inside the control and generator buildings, unless specifically stated otherwise.

The overall control and SCADA system includes, in general, installation of the equipment and software required to connect, monitor and control the pump station, sluice gates, and level sensors. The system shall also be remotely monitored via a separate internet connected PLC. This includes installation, testing, commissioning and providing the specified documentation.

1.3.1 General Requirements

Requirements specified in the Conditions of the Contract and Division 1 form a part of this Section. The Contractor shall furnish, install and place into service operating process instrumentation, control systems and

SECTION 25 14 01 Page 2 panels including accessories, related to this facility, all as shown on plans and specified herein. The Control System as specified in this section shall be provided, installed, configured, programmed, tested and commissioned by a Single I&C Sub-Contractor. The Single I&C Sub-Contractor shall build and install the Station Control Center.

Work Includes: Engineering, furnishing, installing, calibrating, adjusting, testing, documenting, starting up, and Government training for a complete Instrumentation and Control System.

Major parts are:

a. Instrumentation including primary elements, transmitters, and control devices.

b. Control Panels.

c. Programmable Logic Controllers.

d. Graphic Terminals and Human Machine Interface (HMI) software.

e. Programming and Testing.

f. Single I&C Sub-Contractor Work Scope

g. For I&C equipment and ancillaries provide the following:

1. Completing detail design.

2. Required Submittals.

3. Equipment and ancillaries.

4. Instructions, details, and recommendations to, and coordination with, Contractor for proper installation.

5. Verify readiness for operation.

6. Verify the correctness of final power and signal connections.

7. Adjusting and calibrating.

8. Starting up.

9. Testing and coordination of testing.

10. Training.

h. Verify following work not provided by the Single I&C Sub-Contractor is provided:

1. Correct type, size, and number of signal wires with their raceways.

2. Correct electrical power circuits and raceways.

3. Correct size, type, and number of I&C related pipes, valves, fittings, and tubes.

SECTION 25 14 01 Page 3

4. Correct size, type, materials, and connection of process mechanical piping for in line primary elements.

i. For equipment not provided by the Single I&C Sub-Contractor, but directly connected to equipment required by I&C Sub-Contractor:

1. Obtain from Contractor, manufacturer's information on installation, interface, function, and adjustment.

2. Coordinate with Contractor to allow required interface and operation with I&C System.

3. For operation and control, verify that installations, interfacing signal terminations, and adjustments have been completed with manufacturer's recommendations.

4. Test to demonstrate required interface and operation with I&C System.

5. Examples of items in this category include, but are not limited to the following: valve operators, position switches, and controls, chemical feed pump and feeder speed/stroke controls, motor control centers, adjustable speed drive systems, Examples of items not in this category, Internal portions of equipment provided under Division 26, Electrical, that are not directly connected to equipment under I&C System, internal portions of I&C Systems provided as part of package systems and that are not directly connected to equipment provided under I&C System, wiring external to equipment provided by Single I&C Sub-Contractor, Special control and communications cable: Provided by Single I&C Sub-Contractor.

1.3.1.1 Single I&C Subcontractor

The Contractor shall assign to the Single I&C Sub-Contractor full responsibility for the functional operation of all new instrumentation systems. The Contractor shall have said Sub-Contractor perform all engineering necessary in order to select, furnish, program, supervise installation, connect, calibrate, and place into operation all sensors, instruments, alarm equipment, control panels, accessories, and all other equipment as specified herein. The Single I&C Sub-Contractor shall have a maintenance office within a 200 mile radius of the project.

The Single I&C Sub-Contractor shall demonstrate his ability to successfully complete projects of similar sizes and nature. Provide references (including phone number and contact name) for at least three projects successfully completed in which the following tasks were performed: system engineering, documentation including panel assembly, schematics and wiring diagram, programming, field testing, calibration and start up, operator instruction and maintenance training. The foregoing shall enable the Contractor and USACE to be assured that the full responsibility for the requirements of this Section shall reside in an organization which is qualified and experienced in the water management field and its process technology on a functional systems basis. The Single I&C Sub-Contractor shall have a U.L. approved shop and shall build all panels according to

UL 508.

1.3.2 Operation

The control system provided under this specification shall operate using

SECTION 25 14 01 Page 4 direct digital control (DDC) algorithms or ladder logic type and supervisory control to provide the required sequences of operation. Input data to the controller shall be obtained by using instruments and controls interfaced to mechanical, electrical, utility systems and other systems as shown and specified. All required setpoints, settings, alarm limits, and sequences of operation shall be as identified sequences of operation shown on the drawings. The number and location of control panels shown on drawings shall be provided as a minimum.

1.3.3 Points

Inputs to and outputs from the control system shall be in accordance with the P&ID drawings and manufacturer's requirements and recommendations.

Each connected analog output (AO), analog input (AI), digital output (DO), digital input (DI), pulse accumulator (PA) input and other input or output device connected to the control system shall represent a "point" where referred to in this specification.

1.4 SUBMITTALS

The Contractor shall submit detailed Shop Drawings and data prepared and organized by the Single I&C Sub-Contractor designated at the time of bidding. These Drawings and data shall be submitted as a complete bound package at one time.

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

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

SD-02 Shop Drawings

Installation; G, DO Wiring Schematics; G, DO

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

valve schedules; compressed instrument air station schematics and ASME air storage tank certificates for each type and make of compressed instrument air station.

Wiring Schematics and Installation Drawings showing definite diagrams for every instrumentation loop system. These diagrams shall show and identify each component of each loop or system using legend and symbols from ISA Standard S5.4, each having the format of ISA Standard S5.1 as used on the Project Drawing. (Each system or loop diagram shall be drawn on a separate Drawing sheet). All abreviations shall be indicated and spelt out on an

SECTION 25 14 01 Page 5

Abreviations sheet.

Drawings showing both schematic and wiring diagrams for control circuits. Complete details on the circuit interrelationship of all devices within and outside each control panel shall be submitted using schematic control diagrams. Piping and wiring diagrams shall consist of component Layout Drawings to scale, showing numbered terminals on components together with the unique number of the wire to be connected to each terminal. Piping and wiring diagrams shall show terminal assignments from ail primary measurement devices, such as flow meters, and to all final control devices, such as pumps, valves, and chemical feeders. The Contractor shall furnish all necessary equipment supplier's Shop Drawings to facilitate inclusion of this information by the Single I&C Sub-Contractor. Schematic and wiring diagram criteria shall be followed as established in NEMA Standards Publication ANSI/NEMA 1CS 1 1978, "Industrial Control and Systems."

Assembly and Construction Drawings for each control panel and for other special enclosed assemblies for field installation.

These Drawings shall include dimensions, identification of all components, surface preparation and finish data, nameplates, and the like. These Drawings also shall include enough other details, including prototype photographs, to define exactly the style and overall appearance of the assembly; a finish treatment sample shall be included.

Installation, mounting and anchoring details for all components and assemblies to be field mounted, including conduit connection or entry details.

Complete and detailed bills of materials. A master Bill of Materials listing all field mounted devices, control panels and other equipment that shall be shipped to the job site. A Bill of Materials for each control panel listing all devices within the panel.

Provide control and instrumentation Conduit Schedule with labeling and description of end points.

SD-03 Product Data

Cut Sheets; G, DO

Catalog cuts, illustrations, schedules, diagrams, performance charts, instructions and brochures illustrating size, physical appearance and other characteristics of materials or equipment required for the work.

Catalog Cut Sheets of all of the components required to complete the system. Must identify the complete ordering part number and demonstrate the component meets the specification. Must include warranty language when the contract requires extended product warranties.

a. The Cut Sheets shall show:

1. Component function description used herein and on the Drawings;

SECTION 25 14 01 Page 6

2. Manufacturer's model number or other product designation;

3. Project tag number used herein and on the Drawings;

4. Project system loop of which the component is a part;

5. Project location or assembly at which the component is to be installed;

6. Input and output characteristics;

7. Scale range and units (if any) and multiplier;

8. Requirements for electric supply;

9. Materials of component parts to be in contact with, or otherwise exposed to, process media;

10. Special requirements or features

A complete index shall appear in the front of each bound submittal volume. A separate technical brochure or bulletin shall be included with each instrument data sheet. The data sheets shall be indexed in the submittal by systems or loops, as a separate group for each system or loop. Each brochure or bulletin shall include a list of tag numbers for which it applies. System groups shall be separated by labeled tags.

Provide TVSS schedule for all transient voltage surge suppression components.

Provide IP and data addressing numbering plans for the communications systems. Include the configurations parameters schedules/templates for the SCADA and communications equipment.

Provide battery ventilation system detail drawings.

Training Manual; G, DO

Instruction manual, and video DVDs of all training sessions.

Performance Verification Test (PVT); G, DO

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

Include a list of the equipment to be used during the testing plus manufacturer's name, model number, equipment function, the date of the latest calibration and the results of the latest calibration.

Factory Test Procedure; G, DO

Documentation containing factory test methods and procedures.

SD-05 Design Data

PLC Control Ladder Logic; G, DO HMI Graphics and database;G, DO

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SD-06 Test Reports

Factory Test Report; G, DO Testing, Adjusting and Commissioning; G, DO Performance Verification Test(PVT); G, DO Endurance Test; G, DO Ground Rods Test

Calibration test data.

SD-07 Certificates

Control and Sensor Wiring; G, DO

Certified test results for surge protection.

SD-10 Operation and Maintenance Data

Instrumentation and Control System; G, DO

Ten complete copies of operating instructions outlining the step-by-step procedures required for system startup, operation and shutdown. Include in the instructions layout, wiring and control diagrams of the system as installed, the manufacturer's name, model number, service manual, parts list and a brief description of all equipment and their basic operating features.

Ten complete copies of maintenance instructions listing routine maintenance procedures, possible breakdowns and repairs and troubleshooting guides.

Submit operation and maintenance data in accordance with Section

01 78 23 OPERATION AND MAINTENANCE DATA.

1.5 SITE ENVIRONMENTAL CONDITIONS

a. Instrumentation equipment and enclosures shall be suitable for ambient conditions specified. All system elements shall operate properly in the presence of telephone lines, power lines, and electrical equipment.

b. Inside control rooms and climate-controlled electrical rooms, the temperature will normally be 20 to 25 degrees Celsius; relative humidity 40 to 80 percent without condensation and the air will be essentially free of corrosive contaminants and moisture. Appropriate air filtering shall be provided to meet environmental conditions (i.e., for dust).

c. Other indoor areas may not be air conditioned/heated; temperatures may range between 0 and 40 degrees Celsius with relative humidity between 40 and 95 percent.

d. Field equipment including instrumentation and panels may be subjected to wind, rain, lightning, and corrosives in the environment, with ambient temperatures from -20 to 40 degrees Celsius and relative humidity from 10 to 100 percent. All supports, brackets and interconnecting hardware shall be 316 stainless steel as shown on the installation detail drawings.

SECTION 25 14 01 Page 8

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

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

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

2.1.2 Nameplates

Each major component of equipment shall have the manufacturer's name and address, and the model and serial number in a conspicuous place. Laminated plastic nameplates shall be provided for equipment devices and panels furnished. Each nameplate shall identify the device, such as pump "P-1" or valve "VLV-402". Labels shall be coordinate with the schedules and the process and instrumentation drawings. Laminated plastic shall be 1/8 inch thick, white with black center core. Nameplates shall be a minimum of 1 by 3 inches with minimum 1/4 inch high engraved block lettering. Nameplates for devices smaller than 1 by 3 inches shall be attached by a nonferrous metal chain. All other nameplates shall be attached to the device.

2.2 GENERAL REQUIREMENTS

Equipment located outdoors, not provided with climate controlled enclosure, shall be capable of operating in the ambient temperature range indicated in paragraph ENVIRONMENTAL CONDITIONS, unless otherwise specified. Equipment and wiring must be in accordance with NFPA 70, with proper consideration given to environmental conditions such as moisture, dirt, corrosive agents, and hazardous area classification.

2.3 MONITORING AND CONTROL PARAMETERS

The control system shall be complete including sensors, field preamplifiers, signal conditioners, offset and span adjustments, amplifiers, transducers, transmitters, control devices, engineering units conversions and algorithms for the applications; and shall maintain the specified end-to-end process control loop accuracy from sensor to display and final control element. Control equipment shall be powered by a 120 VAC, single phase, 60 Hz power source, with local transformers included as needed for signal transmission and subsystem operation. Connecting conductors shall be suitable for installed service. Enclosures shall be rated for NEMA 4X outside and NEMA 12 indoors.

2.3.1 Liquid Service

Sensors and meters in liquid service shall be rated for continuous duty service at fluid approach velocities from 0.327 ft/s to 10 ft/s with correspondingly higher constriction velocities over a fluid temperature range from 32 degrees F to 300 degrees F at pressures up to 150 psi gage.

2.3.2 Level Instrumentation

Pressure taps shall incorporate appropriate snubbers. Relays and housing shall be intrinsically safe or explosion proof as required by the NFPA

SECTION 25 14 01 Page 9 hazard rating for compatibility with the contents of the tank or sump. The controller shall be provided with a minimum of three sets of dry contacts rated in accordance with NEMA ICS 1. The first set of contacts shall close when the lower (warning) detection level has been exceeded. The second set of contacts shall close when the upper (alarm) detection level has been exceeded. The third set of contacts shall close when a controller malfunction has occurred, including loss of power or loss of sensor input.

The alarm levels shall be individually adjustable. The controller shall be provided with an audible warning horn that sounds when the upper detection level has been exceeded, and a warning horn silence button. The controller shall provide a 4-20 mA DC output signal to the programmable logic controller, proportional to the measured parameter. The controller shall be provided with an internal battery to maintain operation for a minimum of 12 hours if power is lost.

2.3.2.1 Shaft Encoder Type Level Transmitter

Provide a shaft encoder type level transmitter for the stilling wells in the pump bay and station intake and discharge canal as follows:

a. Measure water level by monitoring the position of a float and pulley.

b. Input: Shaft angle + Turn count

c. Encoder: Absolute, non-contact (optical & magnetic)

d. Outputs: 4-20mA optically isolated

e. Display: 4-1/2 Digits x .4 in characters (±199.99 or ±19999.)

f. Resolution: 65,536 (16-bit) counts/revolution.

g. Accuracy: 1/4096 (.00024 rev)

h. Max Turns: ±32,768 rev

i. Max Rotation Speed: 20 rev/sec

j. Offset Adjust: SDI-12 or front panel adjust

k. Loop Voltage: 8.0V min, 35V max

l. Resolution: 4FA (12-bit DAC)

m. Voltage Input: 9.6 to 16.0 Volts DC

n. Current: 150FA typical (sleep mode)

o. 40mA typical (making measurement)

p. Turn Count Battery (internal):

q. Battery Type: CR-1/3N (3.3V, 160mAh, lithium). Lifetime: 10 years.

r. Operating Temperature: -40º to 60Eº C

s. Storage Temperature: -40º to 70º C

SECTION 25 14 01 Page 10

t. Humidity: 0 to 100%

u. Bearing: Double ball bearing with external seal.

v. Starting Torque: 0.15 oz·in typical, 0.50 oz·in max over temperature.

w. Standard Shaft: 5/16 in. diameter x 1.25 in. long, with setscrew flat.

x. Optional Threaded Shaft: 5/16 in. diameter x 1.75 in. long, 24-threads per in. x 0.75 in.

y. Material: Anodized Aluminum

z. Size: 5.25 in. wide (housing), 7.0 in. wide (mount flange), 4.0 in.

deep (not including shaft or connectors), 4.25 in. high (not including adjust knob).

aa. Digital shaft encoder shall be a Model H-3341 Water Log Series by Design Analysis Associates (or approved equal).

The encoder shall be battery powered and magnetic sensing with a built-in LCD display.

2.3.2.2 Displacement Type Level Switch

Liquid level switch shall be displacement type, having a minimum of two tandem floats with each float independently activating a set of Form C contacts at two different level settings. Each switch shall have a narrow differential band. The mounting connections shall be threaded, flanged or surface mounted to suit the application. All surfaces in contact with the tank contents shall be 316 stainless steel. The switch enclosure shall be explosion proof for use in a hazardous environment, complete with a sealed water tight junction box, terminal block, and mounting plate. Each set of contacts shall be snap action, dry contact type with one normally open and one normally closed, contact rated in accordance with NEMA ICS 1. The switch shall be actuated by a magnetically equipped stainless steel displacer. Repetitive accuracy shall be plus or minus 1/4 inch of actual displacer setting. Pump bay mounted pump cutoff switches shall be Jerguson Model JDC2D (or approved equal). The switch shall have a carbon steel chamber and a pressure tube that meets ASTM A312/A312M T 316.

2.3.2.3 Submersible Pressure Transducer

The sensor shall be 316 L stainless steel with a 4 to 20mA output.

Accuracy shall be 0.1 percent FS or less and total error band shall be 0.25 percent FS or less. Operating temperature shall be -10 to 60 degrees C.

The sensors shall be Campbell Scientific Model CS460-L (Keller America Acculevel) or approved equal.

2.3.2.4 Magnetostrictive Level Transmitter

The pump bay shall have a 4 to 20 mA magnetostrictive water level sensor.

The rod and float shall be constructed of 316 stainless steel. Operating temperature range shall be -10 to 85 degrees C. The maximum linear deviation shall be 0.02 percent of 500 to max nominal stroke. The sensors shall be Balluff Model BTL-5-E-17-M3048W-SU-034-K05 or approved equal.

SECTION 25 14 01 Page 11

2.3.3 Temperature Instrumentation

The controller shall be provided with a minimum of three sets of dry contacts rated in accordance with NEMA ICS 1. The first set of contacts shall close when the lower (warning) detection level has been exceeded.

The second set of contacts shall close when the upper (alarm) detection level has been exceeded. The third set of contacts shall close when a controller malfunction has occurred, including loss of power or loss of sensor input. The alarm levels shall be individually adjustable. The controller shall be provided with an audible warning horn that sounds when the upper detection level has been exceeded, and a warning horn silence button. The controller shall provide a 4-20 mAdc output signal to the programmable logic controller, proportional to the measured parameter. The controller shall be provided with an internal battery to maintain operation for a minimum of 12 hours if power is lost.

2.3.3.1 Fluid Temperature Range

All devices shall be suitable for process temperatures, which define the exposure of the element, and are described in the table on the drawings.

Mercury shall not be used in thermometers.

a. Type A shall be bimetal thermometer: Direct reading, hermetically sealed, suitable for external adjustment. Accurate within 1 percent of full range. Stainless steel construction. Complete with thermowell.

b. Type B shall be remote reading gas/vapor thermometer: Direct reading, stainless steel case designed for panel mounting, complete with armor cable, bulb and ancillary components for complete system.

Movementless design, resistant to shock and vibration and free from error created by elevation. Provided with gas operated molecular sieve. Accurate within 1 percent over full range.

2.3.3.2 Resistance Temperature Detector (RTD)

RTD shall be platinum, with an accuracy of plus or minus 0.1 percent at 32 degrees F. RTD shall be encapsulated in stainless steel Series 316.

2.3.3.3 Continuous Averaging RTD

Continuous averaging RTD shall have an accuracy of plus or minus 0.9 degrees F at the reference temperature, and shall be of sufficient length to ensure that the resistance represents an average over the cross-section in which it is installed. The sensor shall have a bendable copper sheath.

2.3.3.4 Thermocouple

Thermocouple shall be factory assembled with Series 300 stainless steel sheathing. Wiring insulation shall be magnesium oxide. Minimum insulation resistance wire to wire or wire to sheath shall be 1.5 megohm at 500 V dc.

Thermocouple shall be Type K. Thermocouple error shall not exceed that specified in ISA MC96.1. All wire/cable from thermocouple to transmitter shall be of the type necessary to match the thermocouple used. Transmitter selected shall match the type of thermocouple provided. The transmitter shall include automatic cold junction reference compensation with span and offset adjustments, and upscale open thermocouple detection.

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2.3.3.5 Thermowell

Thermowell shall be monel, brass, or copper for use in water lines; wrought iron for measuring flue gases; and austenitic stainless steel for other applications. Calibrated thermowells shall be provided with threaded plug and chain, 2 inch lagging neck and inside diameter insertion neck as required for the application. The thermowell shall include a connection box, sized to accommodate the temperature sensing device.

2.3.4 Electrical Instrumentation

Electrical power measurements with a range for the specific application, plus or minus 1.0 percent of range (display and print to nearest kWh and kW). Electrical measurements with a range for the specific application plus or minus 1.0 percent of range (display and print to nearest 0.1 for volts and amperes, and to the nearest 0.01 for VAR and PF).

2.3.4.1 Hour Meter

Hour meter shall provide a totalized readout of the number of hours of operation for the equipment monitored. Meter shall provide readout with a minimum of 7 digits including 1 decimal place. The display shall be non-resettable. The meter shall be driven by a 120 VAC synchronous motor.

2.3.5 Miscellaneous Measurements

Miscellaneous measurements with a range for the specific application plus or minus 1.0 percent of range (display and print to nearest 0.1 of the specified units.

2.4 PANELS

2.4.1 Components

2.4.1.1 Enclosures

The enclosure for each control panel shall conform to the requirements of NEMA 250 unless otherwise specified for the types defined in the standard.

Finish color shall be the manufacturer's standard, unless otherwise indicated. Damaged surfaces shall be repaired and refinished using original type finish. Enclosures for installation in mechanical equipment rooms shall be Type 12; those for installation in clean, dry indoor occupied space may be Type 1; Control panels containing any type of electronic equipment including but not limited to PLCs, etc. shall be NEMA 4X 316L stainless steel. Enclosures for installation outdoors shall be Type 4X and shall be constructed of stainless steel. Painted steel shall not be allowed for use in a corrosive environment. Enclosure shall be provided with a single, continuously hinged exterior door with print pocket, 3-point latching mechanism and key lock and a single, continuously hinged interior door.

2.4.1.2 Controllers

Controllers shall be in accordance with paragraph Programmable Logic Controller (PLC).

2.4.1.3 Standard Indicator Light

Indicator lights shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508.

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Lights shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. Indicator lights shall be LED type and shall operate at 120 VAC or 24 VDC. Indicator light shall be provided with a legend plate labeled as shown on the drawings. Lens color shall be as indicated on the drawings.

Lights shall be push to test (lamp) type.

2.4.1.4 Selector Switches

Selector switches shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508.

Selector switches shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. The number of positions shall be as indicated on the drawings. Switches shall be non-illuminated. Switches shall be rated for 600 volts, 10 amperes continuous. Selector switches shall be provided with a legend plate labeled as shown on the drawings. Where indicated or required, dual auxiliary contacts shall be provided for the automatic position to provide position sensing at the central station or workstation. Auxiliary contacts shall be rated for 120 VAC, 1A as a minimum. Where indicated on the drawings, switches shall be key operated.

All keys shall be identical.

2.4.1.5 Push Buttons

Push buttons shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508. Push buttons shall be heavy duty, round and shall mount in a 0.875 inch mounting hole. The number and type of contacts shall be as indicated on the drawings or required by the Sequence of Control. Push buttons shall be rated for 600 volts, 10 amperes continuous. Push buttons shall be provided with a legend plate labeled as shown on the drawings.

2.4.1.6 Relays

Relays shall comply with IEEE C37.90 and derated for altitude above 1,500

m. Relays shall be double-pole, double-throw (DPDT). Relay coil shall be 120 VAC and shall be provided with matching mounting socket. Power consumption shall not be greater than 3 watts.

2.4.1.7 Terminal Blocks

Terminal blocks shall comply with NEMA ICS 4 and UL 1059. Terminal blocks for conductors exiting control panels shall be two-way type with double terminals, one for internal wiring connections and the other for external wiring connections. Terminal blocks shall be made of bakelite or other suitable insulating material with full deep barriers between each pair of terminals. A terminal identification strip shall form part of the terminal block and each terminal shall be identified by a number in accordance with the numbering scheme on the approved wiring diagrams.

2.4.1.8 Alarm Horns

Alarm horns shall be provided where indicated on the drawings. Horns shall be vibrating type and shall comply with UL 508. Horns shall provide 100 dB at 10 feet. Exterior mounted horns shall be weather proof by design or shall be mounted in a weather proof enclosure that does not reduce the effectiveness of the horn.

2.4.2 Panel Assembly

Control panels shall be factory assembled and shipped to the jobsite as a single unit. Panels shall be fabricated as indicated and devices shall be

SECTION 25 14 01 Page 14 mounted as shown or required. Each panel shall be fabricated as a bottom-entry connection point for control system electrical power, control system main air source, control system wiring, and communications system wiring to other control panels.

a. Control panels shall be furnished and installed under this Contract. They shall house the instrumentation, control devices, indicating lights, PLC, RTU, alarm chassis, displays, all necessary accessories, wiring and terminal blocks as necessary and as shown on the Drawings and as described herein.

b. Control panel doors shall be equipped with a door latch kit or a fast operating clamp assembly as applicable. Control Panels shall have a door mount NEMA style control power disconnect switch.

c. 120 volt AC control voltage in a control panel shall be supplied with a line noise suppressing transformer. Each control panel shall be properly grounded and as such be provided with a ground terminal block.

Control panels shall be properly sized for installation through new and existing entry ways and custom, fit for locations as shown on the drawings.

d. All panels listed shall be provided by the systems integrator. The generator control panel shall be provided by the respective manufacturer. Refer to the P&IDs for I/O requirements. Design and size each panel accordingly and provide submittals as specified herein.

Station Control Center (SCC) shall house the main PLC, the hot standby processor, the industrial ethernet switch, the UPS, and the HMI. The PLCs shall be Allen Bradley Control Logix.

1. Gate Control Panel: This panel will be a termination point for the controls associated with the gates. The panel will include the HOA switch, indicator lights, and gate controls.

2. Station Control Center (SCC): The panel shall include the PLC, I/O rack, HMI panel, UPS and Ethernet switch for communication with the PLC panels in the pump station.

3. Web PLC Enclosure: This panel shall include the internet (web) connected T-Box or approved equal PLC, industrial Ethernet switch, DVR, wireless modem, fiber optic converters, and UPS. The web PLC shall receive analog and digital inputs from the SCC enclosure (duplicated from the inputs to the SCC PLC). The internet connected Ethernet network shall be used for remote monitoring of the pump station status from the web PLC. No network connection shall be made to the SCC PLC as that would constitute a cyber security risk.

e. Panel used in doors shall be NEMA-1 14 guage steel.

f. Outdoor: All outdoor control panels shall be NEMA 4X with drip and sun shield kit, 3 point latch mechanism and 316 stainless steel 14 gauge construction.

g. Cooling: Panels shall have sufficient cooling and/or ventilation not to exceed the maximum operating temperature of any of the internal components. Ambient temperature limits shall be 90 degrees F for indoor and 100 degrees F for outdoor control panels. Outdoor control panels with electronic equipment shall be furnished with sun shields around

SECTION 25 14 01 Page 15 and on top of the control panels. Panels equipped with PLCs shall have 2 louvers on bottom and a thermostat controlled exhaust fan on top.

Outdoor panels shall be equipped with insect screen.

h. Signal and Control Circuit Wiring

1. Wire Type and Sizes: Conductors shall be flexible stranded copper wire; these shall be U.L. listed Type THWN and shall be rated 600 volts. Wire for control signal circuits and alarm input circuits shall be 14 AWG. All instrumentation cables shall be shielded No. 16 AWG with a copper drain wire unless specified otherwise.

All special instrumentation cable such as between sensor and transmitter shall be supplied by the Single I&C Sub-Contractor.

2. Wire Insulation Colors: Conductors supplying 120 volt AC power on the line side of a disconnecting switch shall have a black insulation for the ungrounded conductor. Grounded circuit conductors shall have white insulation. Insulation for ungrounded 120 volt AC control circuit conductors shall be red. All wires energized by a voltage source external to the control board(s) shall have yellow insulation. Insulation for all DC conductors shall be blue.

3. Wiring Installation: All wires shall be run in plastic wireways except (1) field wiring, (2) wiring run between mating blocks in adjacent sections, (3) wiring run from components on a swing out panel to components on a part of the fixed structure, and (4) wiring run to panel mounted components. Wiring run from components on a swing out panels to other components on a fixed panel shall be made up in tied bundles. These shall be tied with nylon wire ties, and shall be secured to panels at both sides of the "hinge loop" so that conductors are not strained at terminals.

Wiring run to control devices on the front panels shall be tied together at short intervals with nylon wire ties and secured to the inside face of the panel using adhesive mounts. Wiring to rear terminals on panel mount instruments shall be run in plastic wireways secured to horizontal brackets run above or below the instruments in about the same plane as the rear of the instruments.

Shields of shielded instrument cable shall only be grounded on one side of each cable run. The side to be grounded shall be at the panel.

Care shall be exercised to properly insulate the ungrounded side, to prevent ground loops from occurring.

Conformance to the above wiring installation requirements shall be reflected by details shown on the Shop Drawings for the Government's review.

4. Wire Marking: Each signal, control, alarm, and indicating circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on all Shop Drawings. These numbers shall be marked on all conductors at every terminal using permanently marked heat shrink plastic.

Instrument signal circuit conductors shall be tagged with unique

SECTION 25 14 01 Page 16 multiple digit numbers. Black and white wires from the circuit breaker panelboard shall be tagged including the one (1) or two

(2) digit number of the branch circuit breaker.

5. Terminal Blocks: Terminal blocks shall be molded plastic with barriers and box lug terminals, and shall be rated 15 amperes at 600 volts. White marking strips, fastened securely to the molded sections, shall be provided and wire numbers or circuit identifications shall be marked thereon with permanent marking fluid.

6. Control panels shall be thoroughly cleaned and sandblasted immediately after, the surfaces shall be primed with a primer of 3 mils dry thickness, followed by two (2) or more coats of white finish with a thickness of 3 mils dry. Total thickness of the complete system shall be 6 mils dry.

2.4.2.1 LIGHTNING/SURGE PROTECTION:

a. General

Lightning/surge protection shall be provided to protect the electronic instrumentation system from induced surges propagating along the signal and power supply lines. The protection systems shall be such that the protective level shall not interfere with normal operation, but shall be lower than the instrument surge withstand level, and be maintenance free and self restoring. All signal lines including power cables, antenna cables etc. entering or leaving the control room or IT room must be equipped with surge protection. Where Antenna cables are concerned provide an 8 port polyphase bulkhead and provide surge protectors for these cables to be mounted on the entrance bulkhead.

Instruments shall be housed in a suitable metallic case and solidly grounded. Ground wires for all surge protectors shall be connected to a solid earth ground and where practical, each ground wire run individually and insulated from each other. These protectors shall be mounted within the instrument enclosure or a separate NEMA 4X junction box coupled to the enclosure.

b. Power Supply

Protection of all 120 VAC instrument power supply lines shall be provided. Control panels and groups of field instruments, as approved by the Government, shall be protected by line noise suppressing isolation transformers and surge suppressors. The line noise suppressing isolation transformer shall be Topaz Series 30 Ultra isolators or approved equal. The suppressor shall be Edco HSP-121 or equal.

c. Analog Signals

Protection of analog signal lines be provided by Lightning Surge Arresters, (LSA)s at the For analog signal lines the LSA shall be Edco PC 642 or SRA 64 series. For field mounted two wire instruments the LSAs shall be encapsulated in stainless steel pipe nipples, Edco SS64 series or equal. For field mounted four wire instruments the LSAs shall be provided in a NEMA 4X enclosure, Edco SLAC series or equal.

SECTION 25 14 01 Page 17

2.4.3 Signal Isolators

Signal Isolators shall provide complete isolation of 1500 Vrms between input, output and power. Models shall have optional inputs of 4 20mA into 25 ohms, 1 5V or 0 10V. Output shall be 4 20mA into 0 1200 ohms with output current limiting. Power input shall be 117VAC 50/60 Hz. Unit shall have non interacting span and zero adjustments and have an accuracy of + .1%.

RFI/EMI immunity up to 10V/m at 20 500 MHZ shall be standard.

Isolator shall offer optional loop power excitation. Mounting is to be DIN rail for economical high density installation.

2.4.4 Working Voltages

The motor starter control circuits shall be 120VAC and shall use a buffer relay rated 10A/120VAC between the starter circuit and the PLC control circuits. All Wetting voltages shall be 24vdc. All analog loops shall be 24vdc. Provide a fuse for each PLC I/O card control circuits.

2.4.5 Horn

Horn shall produce one of three different high decibel tone outputs from same unit. The tone choice shall be "wail", "yelp" or horn and it shall be user selectable by reconfiguring internal jumpers.

Horn shall be capable of producing up to 111 dB at 10 feet, made of rugged high impact plastic construction, resistant to ultraviolet light, and rated

NEMA 3R.

Horn shall be mounted on No. 4A969 weatherproof box. It shall be pointed within 360 half sphere of area.

The horn shall have standard voltages of 24VDC and shall be UL listed (464) indoor, outdoor; Canadian Underwriters Laboratories approved (464).

Horn shall be manufactured by Federal Signal Corporation model 1N742 or approved equal. Additional horns shall be installed at the Trash Rake local control panel, Operations floor level main control panel and at the Fuel farm to alert a phone call.

2.4.6 Electrical Requirements

Each panel shall be powered by a dedicated 120 volts ac circuit, with a fuse, 10 amp , and a disconnect switch located inside the panel. Wiring shall terminate inside the panel on terminal blocks. Electrical work shall be as shown on the drawings.

2.4.7 Power Line Conditioner

Each control panel shall be provided with a power line conditioner to provide both voltage regulation and noise rejection. The power line conditioner shall be of the ferro-resonant design, with no moving parts and no tap switching, while electrically isolating the secondary from the power line side. The power line conditioner shall be sized for 125 percent of the actual connected kva load. Characteristics of the power line conditioner shall be as follows:

2.4.7.1 85 Percent Load

At 85 percent load, the output voltage shall not deviate by more than plus or minus 1 percent of nominal voltage when the input voltage fluctuates

SECTION 25 14 01 Page 18 between minus 20 percent to plus 10 percent of nominal voltage.

2.4.7.2 Load Changes

During load changes of zero to full load, the output voltage shall not deviate by more than plus or minus 3 percent of nominal voltage. Full correction of load switching disturbances shall be accomplished within 5 cycles, and 95 percent correction shall be accomplished within 2 cycles of the onset of the disturbance.

2.4.8 Grounding

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

Grounding terminals of power receptacles shall be solidly grounded to the panel enclosure.

2.4.9 Convenience Outlet

A 120 volt ac, 20 amp, ground fault interruption (GFI) type duplex convenience outlet shall be provided inside the panel. The outlet circuit shall be separate from the panel power circuit.

2.4.10 Panel Interior Light

Each control panel shall be provided with a 40 watt LED light. The light shall be operated by a manual on-off switch mounted on the interior door of the enclosure. The light shall be powered by the same circuit as the convenience outlet.

2.4.11 Ventilation System

Each control panel shall be provided with two single phase, 120 volt ac ventilation fans. Each fan shall supply a minimum of 100 cfm of ventilation air through the enclosure. Each fan shall be provided with a line voltage thermostat. Thermostat setpoints shall be adjustable in a range of 70 to 140 degrees F as a minimum. Each supply and exhaust grille shall contain a filter that is easily removed for cleaning or replacement.

2.4.12 Heating System

Each control panel(s) shall be provided with a thermostatically controlled electric heater capable of maintaining an enclosure temperature of 35 degrees F when continuously exposed to an ambient temperature of 32 degrees F.

SECTION 25 14 01 Page 19

2.5 SCADA SYSTEM EQUIPMENT

2.5.1 Programmable Logic Controller

a. Control and data acquisition associated with the pump station equipment shall be performed by a Programmable Logic Controller (PLC)in a hot standby configuration. Each PLC shall consist of a primary central processing unit (CPU), power supply, an Input/Output (I/O) chassis controlnet communication module and a human-machine interface.

PLC hot standby redundancy modules shall be used in the Station Control Center (SCC) to ensure a PLC failure will not disturb pump station operations. Furnish the SCC with an Allen-Bradley Controllogix PLC or apprvoed equal including all necessary modules cards, wiring, and interfaces to provide fully functional hot backup configuration.

Program both PLC'S to provide redundant online switchover capabilities.

Contractor shall size the PLC CPU according to the number of I/O modules and memory storage required plus an additional 50% memory for a fully functional redundant system. Provide 128MB compact flash memory cards, Model no. 1748-CF128 or approved equal to each PLC to allow instant start up after power down. PLCs shall be configured to write the PLC program to the compact flash cards and to download the program in the event the PLC loses power and power is restored. PLC'S shall comply with NEMA IA 2.1 and shall be designed specifically for industrial control. PLC'S shall not require cooling fans for operation in the specified ambient temperatures. Personal computers and other microcomputer-based equipment designed primarily for commercial applications are not acceptable under this specification. All components of the PLC system, except for the programming unit, shall be standard products of a single manufacturer. Third-party components shall not be permitted.

b. PLC Main Chassis: each AB 1756 or approved equal series PLC system shall include processor, power supplies, Ethernet and EN BT card, hot standby modules, and battery-backed timing and memory modules.

2.5.1.1 Pump Station PLC I/O Equipment

a. The control system shall be capable of handling the required number of process inputs and outputs as tabulated in the I/O list and as indicated on the P&ID drawings, including an additional 25 percent active spares, plus capacity to accommodate 25 percent future inputs and outputs by the addition of I/O cards. Process interface units shall be provided with screw-type terminal blocks with barriers between adjacent terminals for connection of field inputs. Terminals shall be suitable for accepting up to and including No. 14 AWG wire.