237 KB
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USACE / NAVFAC / AFCEC / NASA
UFGS-40 95 00 (October 2007)
---------------------------Preparing Activity: USACE
Superseding
UFGS-40 95 00 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2016
**************************************************************************
SECTION TABLE OF CONTENTS
DIVISION 40 - PROCESS INTERCONNECTIONS
SECTION 40 95 00
PROCESS CONTROL
10/07
PART 1
1.1
1.2
1.3
1.4
1.5
PART 2
GENERAL
REFERENCES
DEFINITIONS
SUBMITTALS
SITE ENVIRONMENTAL CONDITIONS
SEQUENCING
PRODUCTS
2.1
SYSTEM DESCRIPTION
2.1.1
General Requirements
2.1.2
Operation
2.1.3
Points
2.1.4
Data Transmission Systems (DTS)
2.2
MATERIALS AND EQUIPMENT
2.2.1
Standard Products
2.2.2
Nameplates
2.3
GENERAL REQUIREMENTS
2.4
MONITORING AND CONTROL PARAMETERS
2.4.1
Transmitter
2.4.2
Off-Gas or Vapor Service
2.4.3
Liquid Service
2.4.4
Flow Sensor
2.4.4.1
Flow Nozzle
2.4.4.2
Flow Switch
2.4.4.3
Magnetic Flowmeter
2.4.4.4
Natural Gas or Propane Flow Meter
2.4.4.5
Orifice Plate
2.4.4.6
Paddle Type Flowmeter
2.4.4.7
Pitot Tube
2.4.4.8
Annular Pitot Tube
2.4.4.9
Positive Displacement Flowmeter
2.4.4.10
Turbine Meters
2.4.4.11
Insertion Turbine Flowmeter
2.4.4.12
Ultrasonic Flowmeter
SECTION 40 95 00
Page 1
2.4.4.13
Variable Area Flowmeter
2.4.4.14
Venturi Tube
2.4.4.15
Vortex Shedding Flowmeter
2.4.5
Level Instrumentation
2.4.5.1
Bubble Type Level Sensor
2.4.5.2
Capacitance Type Level Sensor
2.4.5.3
Conductivity Switch
2.4.5.4
Displacement Type Level Switch
2.4.5.5
Mercury Float Switch
2.4.5.6
Reed Sensor
2.4.5.7
Ultrasonic Sensor
2.4.5.8
Leak Detection
2.4.6
Pressure Instrumentation
2.4.6.1
Pressure Sensor
2.4.6.2
Pressure Switch
2.4.6.3
Differential Pressure
2.4.6.4
Differential Pressure Switch
2.4.6.5
Pneumatic to Electric (PE) Switch
2.4.7
Temperature Instrumentation
2.4.7.1
Fluid Temperature Range
2.4.7.1.1
Type A Bimetal Thermometer
2.4.7.1.2
Type B Remote Reading Gas/Vapor Thermometer
2.4.7.1.3
Type C
2.4.7.2
Resistance Temperature Detector (RTD)
2.4.7.3
Continuous Averaging RTD
2.4.7.4
Infrared Temperature Sensor
2.4.7.5
Temperature Switch
2.4.7.6
Thermocouple
2.4.7.7
Thermowell
2.4.8
Process Analytical Instrumentation
2.4.8.1
Ammonia Gas
2.4.8.2
Calorimeter (Heat Capacity/Fuel Value)
2.4.8.3
Carbon Dioxide
2.4.8.4
Carbon Monoxide
2.4.8.5
Chlorine Gas
2.4.8.6
Chlorine in Liquid
2.4.8.7
Combustible Gas
2.4.8.8
Calorimetric Analyzer
2.4.8.9
Flame Ionization Detector (FID)
2.4.8.10
Hydrogen Sulfide Gas
2.4.8.11
Oxides of Nitrogen (NOx) Gas
2.4.8.12
Oxygen Gas
2.4.8.13
Oxygen Dissolved
2.4.8.14
Oxygen Reduction Potential (ORP)
2.4.8.15
Ozone (O3) Gas
2.4.8.16
Ozone (O3) in Water
2.4.8.17
pH Monitoring
2.4.8.18
Photoionization Detector
2.4.8.19
Total Dissolved Solids (TDS)
2.4.8.20
Water Turbidity
2.4.9
Electrical Instrumentation
2.4.9.1
Hour Meter
2.4.9.2
Watt-Hour Meter
2.4.10
Miscellaneous Measurements
2.5
COMPRESSED AIR STATIONS
2.5.1
Air Compressor Assembly
2.5.2
Compressed Air Station Specialties
2.5.2.1
Refrigerated Dryer, Filters and Pressure Regulator
2.5.2.2
Coalescing Filter
SECTION 40 95 00
Page 2
2.5.2.3
Flexible Pipe Connections
2.5.2.4
Vibration Isolation Units
2.5.2.5
Compressed Air Piping
2.5.3
Barrier Jacket
2.6
PROGRAMMABLE LOGIC CONTROLLER (PLC)
2.6.1
PLC General Requirements
2.6.2
Modular PLC
2.6.2.1
Central Processing Unit (CPU) Module
2.6.2.2
Communications Module
2.6.2.3
Power Supply Module
2.6.2.4
Input/Output (I/O) Modules
2.6.3
Loop PLC
2.6.3.1
Central Processing Unit (CPU)
2.6.3.2
Power Requirements
2.6.3.3
On-Off Switch
2.6.3.4
Parameter Input and Display
2.6.3.5
Self Tuning
2.6.3.6
Manual Tuning
2.6.4
Program Storage/Memory Requirements
2.6.5
Input/Output Characteristics
2.6.6
Wiring Connections
2.6.7
On-Off Switch
2.6.8
Diagnostics
2.6.9
Accuracy
2.7
PLC SOFTWARE
2.7.1
Operating System
2.7.1.1
Startup
2.7.1.2
Failure Mode
2.7.2
Functions
2.7.2.1
Analog Monitoring
2.7.2.2
Logic (Virtual)
2.7.2.3
State Variables
2.7.2.4
Analog Totalization
2.7.2.5
Trending
2.7.3
Alarm Processing
2.7.3.1
Digital Alarms
2.7.3.2
Analog Alarms
2.7.3.3
Pulse Accumulator (PA) Alarms
2.7.4
Constraints
2.7.4.1
Equipment Constraints Definitions
2.7.4.2
Constraints Checks
2.7.5
Control Sequences and Control Loops
2.7.6
Command Priorities
2.7.7
Resident Application Software
2.7.7.1
Program Inputs and Outputs
2.7.7.2
Failure Mode
2.8
CONTROL PANELS
2.8.1
Components
2.8.1.1
Enclosures
2.8.1.2
Controllers
2.8.1.3
Standard Indicator Light
2.8.1.4
Selector Switches
2.8.1.5
Push Buttons
2.8.1.6
Relays
2.8.1.7
Terminal Blocks
2.8.1.8
Chart Recorder
2.8.1.9
Event Recorders
2.8.1.10
Autodialer
2.8.1.11
Alarm Horns
SECTION 40 95 00
Page 3
2.8.2
Panel Assembly
2.8.3
Electrical Requirements
2.8.4
Power Line Conditioner
2.8.4.1
85 Percent Load
2.8.4.2
Load Changes
2.8.5
Grounding
2.8.6
Convenience Outlet
2.8.7
Panel Interior Light
2.8.8
Ventilation System
2.8.9
Heating System
2.8.10
Air Conditioning System
2.9
CENTRAL STATION AND OPERATORS WORKSTATION EQUIPMENT
2.9.1
Workstation Computer
2.9.1.1
Minimum Processor Operating Speed
2.9.1.2
RAM Memory
2.9.1.3
Power Supply
2.9.1.4
Real Time Clock (RTC)
2.9.1.5
Input/Output (I/O) Ports
2.9.1.6
SVGA Color Monitor
2.9.1.7
Hard Disk
2.9.1.8
Floppy Disk Drives
2.9.1.9
Zip Drive
2.9.1.10
Modem
2.9.1.11
CD Drive
2.9.1.12
Network Interface Card
2.9.2
Operator's Workstation Computer
2.9.3
Printer
2.9.4
LAN System
2.9.5
LAN Hubs
2.9.6
Uninterruptible Power Supply (UPS)
2.9.7
Portable Tester/Workstation
2.9.8
Communication and Programming Device
2.10
CENTRAL STATION SOFTWARE
2.10.1
Graphical Operations
2.10.1.1
Graphical User Interface
2.10.1.2
Display Information
2.10.1.3
System Graphics Implementation
2.10.1.4
Display Editor
2.10.1.5
Graphical Object Oriented Programming
2.10.1.6
Charting
2.10.1.7
System Menus and Displays
2.10.1.8
Hard-Copy Screen Request
2.10.2
Command Software
2.10.2.1
Command Input
2.10.2.2
Command Input Errors
2.10.2.3
Special Functions
2.10.2.3.1
Help
2.10.2.3.2
Start/Enable
2.10.2.3.3
Stop/Disable
2.10.2.3.4
Display Diagram
2.10.2.3.5
Diagram Development
2.10.2.3.6
Auto/Override
2.10.2.3.7
Print Report
2.10.2.3.8
Confirm Action
2.10.2.3.9
Cancel Action
2.10.2.3.10
Memo Pad
2.10.2.4
Operator's Commands
2.10.2.5
Level of Addressing
2.10.2.5.1
Point
SECTION 40 95 00
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2.10.2.5.2
Unit
2.10.2.5.3
Sub-System
2.10.2.5.4
System
2.10.2.6
System Access Control
2.10.3
Alarms
2.10.3.1
Digital Alarms
2.10.3.2
Analog Alarms
2.10.3.3
Alarm Messages
2.10.3.4
Alarm Classes
2.10.4
Pop-up Note Function
2.10.5
Real Time Clock Synchronization
2.10.6
System Reaction
2.10.6.1
Occurrence
2.10.6.2
Location
2.10.7
Report Generator
2.10.7.1
Periodic Automatic Report
2.10.7.2
Request Report Mode
2.10.8
Data Interchange
2.10.9
Control Panel and DTS Circuit Alarms
2.10.10
Central Station Database
2.10.10.1
Database Definition Process
2.10.10.2
Dynamic Database
2.10.10.3
Dynamic Database Update
2.10.10.4
Static Database
2.10.10.5
Central Station Static Database Update
2.10.10.6
Workstation Access to Dynamic Data
2.10.11
Historical Data Storage and Retrieval
2.10.12
Trending
2.10.13
Analog Monitoring
2.10.14
Analog Totalization
2.10.15
LAN Software
2.10.15.1
Access Control
2.10.15.2
Multiple Sessions
2.10.15.3
Other Functions and Configurations
2.11
DATA COMMUNICATION REQUIREMENTS
2.11.1
Central Station/Workstation
2.11.2
Central Station/PLC
2.11.3
Modem Communication
2.11.4
Error Detection and Retransmission
2.12
CONSUMABLE SUPPLIES
2.13
FACTORY TEST
2.13.1
Factory Test Setup
2.13.2
Factory Test Procedure
2.13.3
Factory Test Report
PART 3
EXECUTION
3.1
EQUIPMENT INSTALLATION REQUIREMENTS
3.1.1
Installation
3.1.1.1
Isolation, Penetrations and Clearance from Equipment
3.1.1.2
Device Mounting
3.1.1.3
Pneumatic Tubing
3.1.1.4
Grooved Mechanical Joints
3.1.2
Sequences of Operation
3.2
INSTALLATION OF EQUIPMENT
3.2.1
Control Panels
3.2.2
Flow Measuring Device
3.2.2.1
Flow Nozzle
3.2.2.2
Flow Switch
SECTION 40 95 00
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3.6.3.1
Phase I (Testing)
3.6.3.2
Phase II (Assessment)
3.6.3.3
Exclusions
3.7
MANUFACTURERS' FIELD SERVICES
3.8
FIELD TRAINING
3.8.1
Preliminary Operator Training
3.8.2
Additional Operator Training
3.8.3
Maintenance Training
3.8.4
Specialized Training
3.8.4.1
Flow Meter Training
3.8.4.2
Specialized Sensor Training
3.9
OPERATION AND MAINTENANCE DATA REQUIREMENTS
-- End of Section Table of Contents --
SECTION 40 95 00
Page 7
3.6.3.1
Phase I (Testing)
3.6.3.2
Phase II (Assessment)
3.6.3.3
Exclusions
3.7
MANUFACTURERS' FIELD SERVICES
3.8
FIELD TRAINING
3.8.1
Preliminary Operator Training
3.8.2
Additional Operator Training
3.8.3
Maintenance Training
3.8.4
Specialized Training
3.8.4.1
Flow Meter Training
3.8.4.2
Specialized Sensor Training
3.9
OPERATION AND MAINTENANCE DATA REQUIREMENTS
-- End of Section Table of Contents --
SECTION 40 95 00
Page 7
**************************************************************************
USACE / NAVFAC / AFCEC / NASA
UFGS-40 95 00 (October 2007)
---------------------------Preparing Activity: USACE
Superseding
UFGS-40 95 00 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2016
**************************************************************************
SECTION 40 95 00
PROCESS CONTROL
10/07
**************************************************************************
NOTE: This guide specification covers the
requirements for process instrumentation and control
systems.
Adhere to UFC 1-300-02 Unified Facilities Guide
Specifications (UFGS) Format Standard when editing
this guide specification or preparing new project
specification sections. Edit this guide
specification for project specific requirements by
adding, deleting, or revising text. For bracketed
items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in
respective project, whether or not brackets are
present.
Comments, suggestions and recommended changes for
this guide specification are welcome and should be
submitted as a Criteria Change Request (CCR).
**************************************************************************
PART 1
GENERAL
**************************************************************************
NOTE: Use Section 43 21 29 FLOW MEASURING EQUIPMENT
[POTABLE WATER] [SEWAGE TREATMENT PLANT] for simple
liquid flow applications.
**************************************************************************
1.1
REFERENCES
**************************************************************************
NOTE: This paragraph is used to list the
publications cited in the text of the guide
specification. The publications are referred to in
the text by basic designation only and listed in
this paragraph by organization, designation, date,
and title.
Use the Reference Wizard's Check Reference feature
SECTION 40 95 00
Page 8
when you add a RID outside of the Section's
Reference Article to automatically place the
reference in the Reference Article. Also use the
Reference Wizard's Check Reference feature to update
the issue dates.
References not used in the text will automatically
be deleted from this section of the project
specification when you choose to reconcile
references in the publish print process.
**************************************************************************
The publications listed below form a part of this specification to the
extent referenced. The publications are referred to within the text by the
basic designation only.
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
ANSI INCITS 154
(1988; R 2004) Office Machines and
Supplies - Alphanumeric Machines Keyboard Arrangement
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING
ENGINEERS (ASHRAE)
ASHRAE FUN IP
(2013; Addenda and Corrigendum 2013)
Fundamentals Handbook, I-P Edition
ASHRAE FUN SI
(2013; Addenda and Corrigendum 2013)
Fundamentals Handbook, SI Edition
AMERICAN WATER WORKS ASSOCIATION (AWWA)
AWWA C606
(2015) Grooved and Shouldered Joints
ASME INTERNATIONAL (ASME)
ASME B31.8
(2014; Supplement 2014) Gas Transmission
and Distribution Piping Systems
ASME BPVC SEC VIII D1
(2010) BPVC Section VIII-Rules for
Construction of Pressure Vessels Division 1
ASTM INTERNATIONAL (ASTM)
ASTM A536
(1984; R 2014) Standard Specification for
Ductile Iron Castings
ASTM B88
(2014) Standard Specification for Seamless
Copper Water Tube
ASTM B88M
(2013) Standard Specification for Seamless
Copper Water Tube (Metric)
ASTM D1238
(2013) Melt Flow Rates of Thermoplastics
by Extrusion Plastometer
ASTM D1693
(2015) Standard Test Method for
Environmental Stress-Cracking of Ethylene
SECTION 40 95 00
Page 9
Plastics
ASTM D2000
(2012) Standard Classification System for
Rubber Products in Automotive Applications
ASTM D635
(2014) Standard Test Method for Rate of
Burning and/or Extent and Time of Burning
of Self-Supporting Plastics in a
Horizontal Position
ASTM D638
(2014) Standard Test Method for Tensile
Properties of Plastics
ASTM D792
(2013) Density and Specific Gravity
(Relative Density) of Plastics by
Displacement
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 142
(2007; Errata 2014) Recommended Practice
for Grounding of Industrial and Commercial
Power Systems - IEEE Green Book
IEEE 802.3
(2012; ERTA 2013; BK 2013; BJ 2014; BM
2015) Standard Information
Technology--Telecommunications and
Information Exchange Between
Systems--Specific Requirements Part 3:
CSMA/CD Access Method and Physical Layer
Specifications
IEEE C37.90
(2005; R 2011) Standard for Relays and
Relay Systems Associated With Electric
Power Apparatus
IEEE C37.90.1
(2013) Standard for Surge Withstand
Capability (SWC) Tests for Relays and
Relay Systems Associated with Electric
Power Apparatus
IEEE 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 Stds Dictionary
(2009) IEEE Standards Dictionary: Glossary
of Terms & Definitions
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
IEC 61131-3
(2013) Programmable Controllers - Part 3:
Programming Languages
INTERNATIONAL SOCIETY OF AUTOMATION (ISA)
ISA 7.0.01
(1996) Quality Standard for Instrument Air
SECTION 40 95 00
Page 10
ISA MC96.1
(1982) Temperature Measurement
Thermocouples
INTERNATIONAL TELECOMMUNICATION UNION (ITU)
ITU V.34
(1998) Data Communication Over the
Telephone Network: A Modem Operating at
Data Signaling Rates of up to 33,600 Bit/S
for Use on the General Switched Telephone
Network and on Leased Point-To-Point
2-Wire Telephone-Type Circuits
ITU V.42 bis
(1990) Data Communication over the
Telephone Network: Data Compression
Procedures for Data Circuit Terminating
Equipment (DCE) Using Error Correction
Procedures
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
ANSI C12.1
(2008) Electric Meters Code for
Electricity Metering
NEMA 250
(2014) Enclosures for Electrical Equipment
(1000 Volts Maximum)
NEMA ICS 1
(2000; R 2015) Standard for Industrial
Control and Systems: General Requirements
NEMA ICS 2
(2000; R 2005; Errata 2008) Standard for
Controllers, Contactors, and Overload
Relays Rated 600 V
NEMA ICS 3
(2005; R 2010) Medium-Voltage Controllers
Rated 2001 to 7200 V AC
NEMA ICS 4
(2015) Terminal Blocks
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70
(2014; AMD 1 2013; Errata 1 2013; AMD 2
2013; Errata 2 2013; AMD 3 2014; Errata
3-4 2014; AMD 4-6 2014) National
Electrical Code
NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)
NIST SP 250
(1991) Calibration Services Users Guide
TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)
TIA-232
(1997f; R 2012) Interface Between Data
Terminal Equipment and Data
Circuit-Terminating Equipment Employing
Serial Binary Data Interchange
SECTION 40 95 00
Page 11
The control system must consist of [_____].
2.1.2
Operation
**************************************************************************
NOTE: Show the minimum number of control panels to
be provided on the drawings. Provide setpoint
ranges, alarm settings and other parameters not
addressed in the sequence of control in a data
base/setting table on the drawings.
**************************************************************************
The control system provided under this specification shall operate using
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 [in the database/ settings
tables] [and] [or] [sequences of operation indicated]. The number and
location of control panels shown on drawings shall be provided as a minimum.
2.1.3
Points
**************************************************************************
NOTE: Provide an input/output (I/O) summary table
on the drawings. List all inputs to and outputs
from the control system. Identify each point type,
analog, digital, pulse accumulator; input, output,
control, monitoring, etc. Identify alarms, software
and failure mode setting associated with each point
in the table. Label each point so that it can be
easily referenced to the control system schematic
drawings or process and instrumentation drawings.
**************************************************************************
Provide inputs to and outputs from the control system in accordance with
the Input/Output (I/O) Summary Table indicated. 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.
2.1.4
Data Transmission Systems (DTS)
**************************************************************************
NOTE: Include in the project specification any of
the following UFGS for the appropriate DTS: Section
27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM,
Section 33 82 00 TELECOMMUNICATIONS OUTSIDE PLANT
(OSP).
**************************************************************************
Provide data transmission systems for communication [between PLCs] [and]
[between PLCs and the central station] as specified in [Section 27 10 00
BUILDING TELECOMMUNICATIONS CABLING SYSTEM][Section 33 82 00
TELECOMMUNICATIONS OUTSIDE PLANT (OSP)] and as indicated.
SECTION 40 95 00
Page 16
2.2
2.2.1
MATERIALS AND EQUIPMENT
Standard Products
Materials and equipment must 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.
2.2.2
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 3 mm 1/8
inch thick, white with black center core. Nameplates shall be a minimum of
25 by 75 mm 1 by 3 inches with minimum 6 mm 1/4 inch high engraved block
lettering. Nameplates for devices smaller than 25 by 75 mm 1 by 3 inches
shall be attached by a nonferrous metal chain. All other nameplates shall
be attached to the device.
2.3
GENERAL REQUIREMENTS
**************************************************************************
Show hazardous area classification on the drawings.
**************************************************************************
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. Electrical
equipment will conform to Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
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.
2.4
MONITORING AND CONTROL PARAMETERS
**************************************************************************
NOTE: Provide a schedule on the drawings that
includes all required instrumentation. Provide
device information such as: Alpha-Numeric
designator, the operating range (pressure,
temperature, flow) of construction material, media
to be monitored or controlled, control signal, valve
type (2-way, 3-way, normally open, normally closed,
etc.). Include automatic control valves and
manually operated control valves.
It may be appropriate to defer the enclosure
requirements to the electrical section or to provide
different enclosures for different areas: indoor,
outdoor, areas with hazard classification indicated
on the drawings, etc. Within an area, the
requirements should be consistent.
**************************************************************************
SECTION 40 95 00
Page 17
ellipse. The thickness of the nozzle wall and flange shall be such that
the accuracy will not be degraded by distortion of the nozzle throat from
strains caused by the pipeline temperature and pressure, flange bolting, or
other methods of installing the nozzle in the pipeline. The outside
diameter of the nozzle flange or the design of the flange facing shall be
such that the nozzle throat shall be centered accurately in the pipe.
2.4.4.2
Flow Switch
Flow switch shall have a repetitive accuracy of plus or minus [10] [_____]
percent of actual flow setting. Switch actuation shall be adjustable over
the operating flow range. Flow switch for use in [water] [contaminated
groundwater] [sewage] [air] [vapor] [gas] [hot gas] [corrosive vapor]
[_____] system shall be rated for use and constructed of suitable materials
for installation in the environment encountered. The flow switch shall
have non flexible paddle with Form C snap action contacts, rated in
accordance with NEMA ICS 1.
2.4.4.3
Magnetic Flowmeter
Magnetic flowmeter shall be non-intrusive and shall measure fluid flow
through the use of a self generated magnetic field. The magnetic flow
element shall be encapsulated in [type 300 stainless steel] [or] [anodized
aluminum]. Flowmeter shall be capable of measuring clean or dirty flow up
to a maximum flow velocity of [3] [_____] m/s [10] [_____] fps. The
metering tube shall be constructed of [316 stainless steel] [anodized
aluminum] [material compatible with the fluid being measured]. The maximum
pressure drop across the meter and appurtenances shall be 34 kPa 5 psi at
the maximum flow rate.
2.4.4.4
Natural Gas or Propane Flow Meter
Flowmeter for natural gas or propane flows, corrected to standard
conditions, of up to 0.02 cu. m/sec 2500 cfh shall be of the positive
displacement diaphragm or bellows type and for flows above 0.02 cu. m/sec
2500 cfh, shall be of the axial flow turbine type. Meters shall be
designed specifically for natural gas or propane supply metering and rated
for the pressure, temperature and flow rates of the installation.
Permanent meters shall be suitable for operation in conjunction with an
energy monitoring and control system. Meter body shall be constructed of
[316 stainless steel] [_____]. Meter shall have a minimum turndown ratio
of [10] [_____] to [1] [_____] with an accuracy of plus or minus [1]
[_____] percent of actual flow rate. The meter index shall include a
direct reading mechanical totalizing register and electrical impulse dry
contact output for remote monitoring. The electrical impulse dry contact
output shall provide not less than 1 pulse per 2.8 cubic meters 100 cubic
feet of gas and shall require no field adjustment or calibration.
The
highest electrical impulse rate available from the manufacturer, not
exceeding 10 pulses per second, for the installed application shall be
provided.
2.4.4.5
Orifice Plate
**************************************************************************
NOTE: Show the operating ranges and ratings on the
drawings for operating pressures and flow.
Differential pressure output ranges for flow
conditions are to be coordinated. Accuracy of
computed flow will be improved with inclusion of
SECTION 40 95 00
Page 20
temperature and pressure of upstream conditions.
**************************************************************************
Orifice plate shall be made of [304] [316] series stainless steel sheet.
The outlet side of the bore shall be beveled at a 45 degree angle. The
thickness of the cylindrical face of the orifice shall [not exceed
one-fiftieth of the pipe inside diameter or one-eighth of the orifice bore,
whichever is smaller] [be 3.3 mm 0.125 inch nominal]. The orifice plate
shall be flat within 0.10 mm 20 mils. The orifice surface roughness shall
not exceed 0.5 micron 0.02 mils. Orifice plates shall be concentric plates
with a square and sharp upstream edge of the orifice. Orifice bore shall
be designed to match the operating parameters stated in the drawings.
Plate shall be permanently identified with line size, flange rating,
orifice bore diameter, plate thickness and material.
2.4.4.6
Paddle Type Flowmeter
Sensor accuracy shall be plus or minus [2] [_____] percent of rate of flow,
minimum operating flow velocity shall be [0.3] [_____] m/s [1.0] [_____] fps.
Sensor repeatability and linearity shall be plus or minus [1] [_____]
percent. Sensor shall be non-magnetic, with forward curved impeller blades
designed for water containing debris. Wetted materials shall be made from
non-corrosive materials and shall not contaminate water. The sensor shall
be provided with isolation valves.
2.4.4.7
Pitot Tube
The velocity sensing element shall be of the pitot tube type. Each
transmitter shall have a low range differential pressure sensing element
and a square root extractor. Sensing element accuracy shall be plus or
minus 1 percent of full scale. Transmitter accuracy shall be plus or minus
0.25 percent of the calibrated measurement. Overall accuracy shall be plus
or minus [3] [_____] percent over a range of 2.5 to 13 m/s 500 to 2500 fpm
scaled to air volume. The resistance to air flow shall not exceed 20 Pa
0.08 inch water at an air flow of 10 m/s 2000 fpm.
2.4.4.8
Annular Pitot Tube
**************************************************************************
NOTE: Annular pitot tubes should not be used where
the flow is pulsating or where pipe vibration is
allowed. Pulse flow is characteristic of positive
displacement pumps and blowers.
**************************************************************************
Sensor shall have an accuracy of plus or minus [2] [_____] percent of full
flow and a repeatability of plus or minus [0.5] [_____] percent of measured
value. Annular pitot tube shall be averaging type differential pressure
sensors with four total head pressure ports and one static port made of
austenitic stainless steel. The total head pressure ports shall extend
diametrically across the entire pipe.
2.4.4.9
Positive Displacement Flowmeter
Output accuracy shall be plus or minus 2 percent of the flow range. The
flow meter shall be a direct reading, gerotor, nutating disc or vane type
displacement device rated for liquid service. A counter shall be mounted
on top of the meter, and shall consist of a non-resettable mechanical
totalizer for local reading, and a pulse transmitter for remote reading.
SECTION 40 95 00
Page 21
The control system must consist of [_____].
2.1.2
Operation
**************************************************************************
NOTE: Show the minimum number of control panels to
be provided on the drawings. Provide setpoint
ranges, alarm settings and other parameters not
addressed in the sequence of control in a data
base/setting table on the drawings.
**************************************************************************
The control system provided under this specification shall operate using
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 [in the database/ settings
tables] [and] [or] [sequences of operation indicated]. The number and
location of control panels shown on drawings shall be provided as a minimum.
2.1.3
Points
**************************************************************************
NOTE: Provide an input/output (I/O) summary table
on the drawings. List all inputs to and outputs
from the control system. Identify each point type,
analog, digital, pulse accumulator; input, output,
control, monitoring, etc. Identify alarms, software
and failure mode setting associated with each point
in the table. Label each point so that it can be
easily referenced to the control system schematic
drawings or process and instrumentation drawings.
**************************************************************************
Provide inputs to and outputs from the control system in accordance with
the Input/Output (I/O) Summary Table indicated. 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.
2.1.4
Data Transmission Systems (DTS)
**************************************************************************
NOTE: Include in the project specification any of
the following UFGS for the appropriate DTS: Section
27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM,
Section 33 82 00 TELECOMMUNICATIONS OUTSIDE PLANT
(OSP).
**************************************************************************
Provide data transmission systems for communication [between PLCs] [and]
[between PLCs and the central station] as specified in [Section 27 10 00
BUILDING TELECOMMUNICATIONS CABLING SYSTEM][Section 33 82 00
TELECOMMUNICATIONS OUTSIDE PLANT (OSP)] and as indicated.
SECTION 40 95 00
Page 16
2.2
2.2.1
MATERIALS AND EQUIPMENT
Standard Products
Materials and equipment must 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.
2.2.2
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 3 mm 1/8
inch thick, white with black center core. Nameplates shall be a minimum of
25 by 75 mm 1 by 3 inches with minimum 6 mm 1/4 inch high engraved block
lettering. Nameplates for devices smaller than 25 by 75 mm 1 by 3 inches
shall be attached by a nonferrous metal chain. All other nameplates shall
be attached to the device.
2.3
GENERAL REQUIREMENTS
**************************************************************************
Show hazardous area classification on the drawings.
**************************************************************************
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. Electrical
equipment will conform to Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
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.
2.4
MONITORING AND CONTROL PARAMETERS
**************************************************************************
NOTE: Provide a schedule on the drawings that
includes all required instrumentation. Provide
device information such as: Alpha-Numeric
designator, the operating range (pressure,
temperature, flow) of construction material, media
to be monitored or controlled, control signal, valve
type (2-way, 3-way, normally open, normally closed,
etc.). Include automatic control valves and
manually operated control valves.
It may be appropriate to defer the enclosure
requirements to the electrical section or to provide
different enclosures for different areas: indoor,
outdoor, areas with hazard classification indicated
on the drawings, etc. Within an area, the
requirements should be consistent.
**************************************************************************
SECTION 40 95 00
Page 17
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 [1] [4] [4X] [7] [9] [12] [_____].
2.4.1
Transmitter
**************************************************************************
NOTE: Show all panels on the drawings. Distance
between transmitter and sensor is critical.
**************************************************************************
Unless indicated otherwise, each sensor shall be provided with a
transmitter, selected to match the sensor. Except where specifically
indicated otherwise on the drawings, the transmitter shall be provided with
a [four] [_____] digit or analog visual display of the measured parameter
and shall provide a [4 to 20 mAdc] [_____] output signal proportional to
the level of the measured parameter. Accuracy shall be plus or minus [0.5]
[1] [2] [5] [_____] percent of full scale reading with output error not
exceeding plus or minus [0.25] [0.5] [_____] percent of [the calibrated
measurement] [full scale]. Transmitter shall be located where indicated,
mounted integrally with the sensor, pipe mounted, wall mounted or installed
in the control panel. The distance between the sensor and transmitter
shall not exceed the manufacturer's recommendation. Field preamplifiers
and signal conditioners shall be included when necessary to maintain the
accuracy from sensor to the programmable logic controller or recorder.
2.4.2
Off-Gas or Vapor Service
**************************************************************************
NOTE: If there are substantial temperature or
pressure changes across a blower or unit process, it
may be cost effective to specify differing
requirements upstream and downstream of the process.
**************************************************************************
Sensors and meters in [off-gas] [or] [vapor] service shall be rated for
continuous duty service at fluid approach velocities from 2.5 to 25 m/s 500
to 5000 fpm with correspondingly higher constriction velocities over a
fluid temperature range from minus [18] [25] [_____] degrees C to [40] [50]
[66] [_____] degrees C minus [0] [15] [_____] degrees F to [105] [120]
[150] [_____] degrees F at pressures from minus [50] [_____] kPa gage up to
[100] [700] [_____] kPa gage minus [7.2] [_____] psi gage up to [15] [100]
[_____] psi gage.
2.4.3
Liquid Service
**************************************************************************
NOTE: If there are substantial temperature or
pressure changes across a pump or unit process, it
may be cost effective to specify differing
requirements upstream and downstream of the process.
SECTION 40 95 00
Page 18
**************************************************************************
Sensors and meters in liquid service shall be rated for continuous duty
service at fluid approach velocities from [0.1] [0.75] [_____] m/s to [2]
[3] [_____] m/s [0.327] [2.5] [_____] ft/s to [7] [10] [_____] ft/s with
correspondingly higher constriction velocities over a fluid temperature
range from [0] [_____] degrees C to [40] [50] [_____] degrees C [32]
[_____] degrees F to [105] [120] [_____] degrees F at pressures up to [70]
[350] [700] [1000] [_____] kPa [10] [50] [100] [150][_____] psi gage.
2.4.4
Flow Sensor
**************************************************************************
NOTE: Most flow meters need straight unobstructed
piping of 10 pipe diameters upstream and 5 pipe
diameters downstream. Verify that the location will
allow installation meeting the criteria or that the
accuracy of type of flow meter selected is not
affected by the location. Design includes attendant
elements such as mounting devices, differential
pressure transmitter and interpretive ancillary
components in this and other sections and on the
drawings to complete the system.
**************************************************************************
Liquid flow indication shall be provided in L/s gpm. [Off-gas] [or]
[Vapor] flow indication shall be provided in cubic m/second cubic feet per
minute. Pressure taps shall incorporate appropriate snubbers. Unless
indicated otherwise, the flow transmitter shall produce a signal that is
proportional to the volumetric flow rate, compensated for fluid
temperature, and shall have an accuracy of plus or minus [1] [3] [_____]
percent of [full flow] [the actual flow]. Flow transmitter shall be
located within 5 m 15 feet of the flow element. The flow transmitter shall
include a [digital] [_____] readout of the volumetric flow rate to [3]
[_____] significant figures. [The controller shall be provided with a
minimum of three alarm lights. The first alarm light shall indicate when
the lower (warning) detection level has been exceeded. The second alarm
light shall indicate when the upper (alarm) detection level has been
exceeded. The third alarm light shall indicate a controller malfunction,
including loss of power or loss of sensor input.] [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. Flow rate shall be controlled to within plus or
minus [5] [_____] percent of the design flow.
2.4.4.1
Flow Nozzle
Flow nozzle shall be made of austenitic stainless steel. The inlet nozzle
form shall be elliptical and the nozzle throat shall be the quadrant of an
SECTION 40 95 00
Page 19
end to a minimum of [0.087] [1.49] [_____] kPa [0.35] [6.0] [_____] inches
water at the high end. Two Form C contacts rated in accordance with
NEMA ICS 1 shall be provided.
2.4.6.5
Pneumatic to Electric (PE) Switch
Each switch shall have an adjustable set point range of [20] [_____] to
[137] [_____] kPa [3.0] [_____] to [20] [_____] psi gage and an adjustable
differential from [13] [_____] to [41] [_____] kPa [2.0] [_____] to [6.0]
[_____] psi. Contacts shall be Form C rated in accordance with NEMA ICS 1.
2.4.7
Temperature Instrumentation
**************************************************************************
NOTE: Component identifiers are to be coordinated
with the drawings using the Instrument Society of
America (ISA) suggested alphanumeric system for
development of discrete devise numbering.
**************************************************************************
The controller shall be provided with a minimum of three [alarm lights.
The first alarm light shall indicate when the lower (warning) detection
level has been exceeded. The second alarm light shall indicate when the
upper (alarm) detection level has been exceeded. The third alarm light
shall indicate a controller malfunction, including loss of power or loss of
sensor input] [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.
2.4.7.1
Fluid Temperature Range
**************************************************************************
NOTE: Include a schedule of temperature sensing
elements with operating range requirements. The
following includes sample tables to assist in
defining the exposure and service requirements.
Alternatively, tabulation of devices may be included
on the drawings. Include a table on the drawings
with the following headings:
ID No.
Description
Minimum, C
Maximum, C
Type
**************************************************************************
All devices must 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.
SECTION 40 95 00
Page 28
shall be adjustable over the operating temperature range. The switch shall
have Form C snap action contacts, rated in accordance with NEMA ICS 1.
2.4.7.6
Thermocouple
**************************************************************************
NOTE: Thermocouples should not be used for
measuring temperatures below 260 degrees C 500
degrees F.
**************************************************************************
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 E,] [Type K,] [Type J,] [or] [Type R].
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.
2.4.7.7
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, 50 mm 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 devise.
2.4.8
Process Analytical Instrumentation
**************************************************************************
NOTE: Add requirements for additional site specific
measurements, including span and accuracy for any
application not included in this specification.
**************************************************************************
Probes shall be easily removable without interrupting service. Sampling
pumps shall be included where necessary or applicable to the sensing
device. For sensors integral to the electronic controller the sample may
be drawn directly into the sensor or may be drawn through a sample tube.
For sensors remotely located the sample may be drawn through a sample
tube. Outdoor sample tubes shall be heat traced. Sensor and controller
construction shall be suitable for operation in the monitored medium.
Systems requiring automated zero and calibration gas or reagents shall be
provided with [_____] days supply of calibration gas or reagent. The
controller shall be provided with a minimum of three [alarm lights. The
first alarm light shall indicate when the lower (warning) detection level
has been exceeded. The second alarm light hall indicate when the upper
(alarm) detection level has been exceeded. The third alarm light shall
indicate a controller malfunction, including loss of power or loss of
sensor input] [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
SECTION 40 95 00
Page 30
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.
2.4.8.1
Ammonia Gas
The sensor shall be capable of monitoring ammonia in the range of [0]
[_____] to [10] [_____] mg/L with an accuracy of plus or minus [1] [_____]
percent of full scale reading. The sensor response time shall be [90]
[_____] percent in a maximum of [20] [_____] seconds.
2.4.8.2
Calorimeter (Heat Capacity/Fuel Value)
Calorimeter shall be a self-contained device capable of measuring the heat
capacity of a sample. The colorimeter shall measure the heat released from
the sample by igniting the sample reading use of multiple temperature
sensors. The sensor shall be capable of detecting methane in the range of
[0] [_____] to [100] [_____] ppmv with an accuracy of plus or minus [1]
[_____] percent of full scale reading.
2.4.8.3
Carbon Dioxide
Continuous emissions monitoring systems (CEMS) for measuring CO2 shall be
provided with installed back-up devices. The CEMS shall comply with
40 CFR 60, Appendix B, Performance Specification 2 and the QA/QC
requirements of 40 CFR 60, Appendix F. Calculation of emission rates shall
be in conformance with 40 CFR 60, Appendix A, Reference Method 19. The
sensor shall be capable of detecting carbon dioxide in the range of [0]
[_____] to [100] [_____] ppmv with an accuracy of plus or minus [1] [_____]
percent of full scale reading. The sensor response time shall be [90]
[_____] percent in a maximum of [60] [_____] seconds. The controller shall
monitor [a single point] [multiple points].
2.4.8.4
Carbon Monoxide
Continuous emissions monitoring systems (CEMS) for measuring CO shall be
provided with installed back-up devices. The CEMS shall comply with
40 CFR 60, Appendix B, Performance Specification 4 and the QA/QC
requirements of 40 CFR 60, Appendix F. Calculation of emission rates shall
be in conformance with 40 CFR 60, Appendix A, Reference Method 19. The
sensor shall be capable of detecting carbon monoxide in the range of [0]
[_____] to [50] [100] [500] mg/L with an accuracy of plus or minus [1]
[_____] percent of full scale reading. The sensor response time shall be
[90] [_____] percent in a maximum of [60] [_____] seconds.
2.4.8.5
Chlorine Gas
**************************************************************************
NOTE: Follow Chlorine Institute Recommendations.
**************************************************************************
All parts of the chlorine measurement system, including the sensors,
transmitters, controllers and peripheral devices, that may come in contact
with chlorine or a chlorine-filled environment shall be constructed of
materials suitable for this application. The chlorine sensor shall provide
continuous monitoring of the chlorine level in the range from [0] [_____]
SECTION 40 95 00
Page 31
test data, including all of the physical parameters under which the
calibration tests were performed, shall be submitted with each turbine
rotor. Calibration test data shall be analyzed to determine the rotor's
arithmetic average "K" factor, the best line fit and the plus or minus
deviation from these figures. Turbine flowmeter accuracy shall be plus or
minus 1 percent of reading for a minimum turndown ratio of 1:1 through a
maximum turndown ratio of 50:1. Repeatability shall be plus or minus 0.25
percent of reading. Accuracy of the transmitter shall be plus or minus
0.25 percent over the calibrated span. The turbine rotor response time
from minimum to maximum flow shall be less than 10 milliseconds.
2.4.4.12
Ultrasonic Flowmeter
**************************************************************************
NOTE: Doppler meters rely on reflectors in the
flowing liquid. To obtain reliable measurements
attention must be given to the lower limits for
concentrations and sizes of solids or bubbles. The
flow must also be rapid enough to keep these
materials in suspension. One manufacturer gives
values of 1.8 m/s 6 ft/s for solids and 0.75 m/s 2.5
ft/s for small bubbles. To perform within their
stated specifications, some Doppler meters require a
minimum Reynolds number of 4,000.
Transit-time meters rely on an ultrasonic signal's
completely traversing the pipe, so the path must be
relatively free of solids and air or gas bubbles.
To perform within stated specifications, one type of
transit-time meter requires a minimum Reynolds
number of 10,000.
**************************************************************************
Ultrasonic flowmeter shall utilize high frequency [Doppler shift]
[transit-time] transducer. Flowmeter shall be capable of measuring flow up
to a maximum flow rate of [5] [_____] m/s [15] [_____] fps.
2.4.4.13
Variable Area Flowmeter
Meters shall have an accuracy of plus or minus [5] [_____] percent of full
scale. The flowmeter body shall be clear acrylic plastic with [brass]
[stainless steel] end fittings. The float shall be [glass] [or] [stainless
steel]. The metering tube shall be tapered and shall be provided with a
direct reading flow scale engraved on the meter body.
2.4.4.14
Venturi Tube
Venturi tube shall be made of cast iron or cast steel. The throat section
shall be lined with austenitic stainless steel. Thermal expansion
characteristics of the lining shall be the same as that of the throat
casting material. The surface of the throat lining shall be machined to a
plus or minus 1.2 micron 50 mils finish, including the short curvature
leading from the converging entrance section into the throat. The metering
tube shall be rated for continuous duty service at minimum pressure of
[700] [_____] kPa [100] [_____] psi gage.
2.4.4.15
Vortex Shedding Flowmeter
The accuracy shall be within plus or minus [0.8] [_____] percent of the
SECTION 40 95 00
Page 23
actual volumetric flow. The flow
stainless steel. Flowmeter shall
minimum pressure of [700] [_____]
shedding flowmeter body shall not
to replace the shedding sensor.
2.4.5
meter body shall be made of austenitic
be rated for continuous duty service at
kPa [100] [_____] psi gage. The vortex
require removal from the piping in order
Level Instrumentation
**************************************************************************
NOTE: Indicate the location and the NFPA hazard
classification on the drawings. Hazard
classification of sumps and tank interiors
frequently differ from the general area hazard
classification. Include a schedule of level sensing
elements with operating range requirements.
Tabulation of devices is to be included on the
drawings. Component identifiers are to be
coordinated with the drawings. Use the Instrument
Society of America (ISA) suggested alphanumeric
system for development of discrete device numbering.
**************************************************************************
Pressure taps shall incorporate appropriate snubbers. Relays and housing
shall be intrinsically safe or explosion proof as required by the NFPA
hazard rating for compatibility with the contents of the tank or sump.
[The controller shall be provided with a minimum of three alarm lights.
The first alarm light shall indicate when the lower (warning) detection
level has been exceeded. The second alarm light shall indicate when the
upper (alarm) detection level has been exceeded. The third alarm light
shall indicate a controller malfunction, including loss of power or loss of
sensor input.] [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.
2.4.5.1
Bubble Type Level Sensor
Bubbler type liquid level sensor shall be of the hydrostatic balance type,
operating from compressed air. Each gauging system shall contain the
following: an air set including [compressor] [or] [connection to plant
air], compressed air pressure regulating valve, air filter and moisture
trap; a sight feed bubbler with built-in adjusting needle valve; a tank
entry gland with air supply and equalized pilot signal connections; a 13 mm
1/2 inch [standard weight 316 stainless steel] [schedule 80 carbon steel]
dip tube; a direct reading circular gauge 300 mm 12 inch in diameter
calibrated for the connected tank and tank liquid; connections to the
circular gauge and to the pressure transducer for zero setting and
calibration check; a connecting bubbler supply and equalized pilot signal
[copper] [aluminum] [stainless] tubing with minimum field made joints; and
a pressure transmitter, selected to correspond to the range required to
SECTION 40 95 00
Page 24
gauge the connected tank.
2.4.5.2
Capacitance Type Level Sensor
Liquid level sensor shall produce a signal that is proportional to the
measured level. Sensor shall be capacitance type. The transmitter shall
have non-interacting zero and span adjustments, and shall have an accuracy
of plus or minus [0.1] [_____] percent of calibrated span. Assemblies
shall include wall bracket or mounting plate, austenitic stainless steel
rods, stainless steel bolts and corrosion resistant housing.
2.4.5.3
Conductivity Switch
The switch shall detect the presence of a fluid by measuring the electrical
resistance between a sensor and a ground electrode. Electrodes shall be
constructed of [316 stainless steel] [Hastelloy] [titanium]. Electrodes
shall be fully clad using [polyolefin] [polytetrafluoroethylene (PTFE)].
The conductivity switch shall be capable of [1] [2] [3] [4] separate level
set points. The switch shall [be provided with] [use the container as] a
ground electrode. Electrode lengths shall be as necessary, based on the
application and to meet the requirements of the control sequence. A relay
switching point shall be provided for each sensor. Contacts shall be rated
for a maximum of 240 vAc, 5 A. Switch shall have a maximum response time
of 2 seconds. Assembly shall be [flange mounted] [NPT thread (male)]
[including surface mounting bracket] and suitable for the indicated
environment.
2.4.5.4
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 austenitic 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 6 mm
1/4 inch of actual displacer setting.
2.4.5.5
Mercury Float Switch
Float switch assemblies for use in liquid systems shall consist of wall
bracket or mounting plate, galvanized steel rods, stainless steel bolts,
explosion proof and corrosion resistant housing, and intrinsically safe
relays. Each switch shall consist of two normally open mercury switches,
encapsulated in epoxy resin. The float casing shall be polypropylene. The
switch cable shall be oil resistant thermoplastic cable with 4 No. 18 gauge
stranded copper conductors, rated for 600 Volt application.
2.4.5.6
Reed Sensor
Sensor must consist of a transmitter tube with a reed strip located
inside. The tube length shall [be of sufficient length to permit
adjustment of switch actuation within process parameters] [extend the full
height of the tank]. A float containing a permanent magnet shall fit over
SECTION 40 95 00
Page 25
the transmitter tube and shall move up and down with the liquid level. The
transmitter tube and sliding float assembly shall be as required for the
application as shown on the drawings. Wetted parts shall be [_____], [316
stainless steel,] [PVC,] [polypropylene,] or [polytetrafluoroethylene
(PTFE)] suitable for the installed service indicated. Assembly shall be
[flange mounted] [NPT thread (male)] [include surface mounting bracket].
2.4.5.7
Ultrasonic Sensor
The sensor shall be microprocessor based and shall provide continuous,
non-contact level measurement of liquids and solids utilizing microwave
pulsed time of flight measurement method. The sensor shall operate in a
frequency band approved for industrial use. The sensor shall be capable of
measuring in a range of 0 to [7] [1] [_____] m 0 to [20] [3] [_____] feet
with an accuracy of plus or minus [1] [_____] percent of full scale.
The
sensor shall be capable of distinguishing between real echoes, reflections
and background noise. The sensor shall automatically compensate for
temperature changes. The sensor shall be capable of operating in a
temperature range from minus [25] [_____] degrees C to [40] [50] [_____]
degrees C minus [15] [_____] degrees F to [105] [120] [_____] degrees F.
Assembly shall be [flange mounted] [NPT thread (male)] [include surface
mounting bracket] of sufficient size to eliminate echoing and suitable for
the installed environment indicated. Mounting assembly shall be suitable
for service without requiring entry or drainage of the [vessel] [sump]
where level is being measured.
2.4.5.8
Leak Detection
Double walled containment system leak detectors shall use electrodes
mounted in the interstices of double walled containment systems with a
minimum time delay of [0.5] [_____] seconds. Leak detectors for open
systems shall be mounted at slab or floor level with either a minimum time
delay of [0.5] [_____] seconds or a minimum built-in-vertical adjustment of
[3] [_____] mm [1/8] [_____] inch to prevent activation due to high
humidity. Detector shall have a contact rating of 1.0 amps resistive or
200 mA inductive at 28 vDc. Leak detector panel shall indicate the
location and detector causing the alarmed state. The indicator shall be
manual reset type. A framed, non-fading half-size as-built location map in
laminated plastic shall be provided for the cable leak detection system in
double containment piping systems indicating the as installed system
configuration; sensing string layout shall be furnished. Marks in meters
feet along the length of pipeline interstitial cable shall be provided as
references to locate leaks.
2.4.6
Pressure Instrumentation
**************************************************************************
NOTE: Indicate on the drawings where visual
indication of the measured pressure is required.
Include a schedule of pressure sensing elements with
operating range requirements. Include a tabulation
of devices drawings. Component identifiers are to
be coordinated with the drawings using the
Instrument Society of America (ISA) suggested
alphanumeric system for development of discrete
device numbering.
**************************************************************************
Pressure taps shall incorporate appropriate snubbers.
SECTION 40 95 00
Page 26
The controller shall
2.5.1
Air Compressor Assembly
The air compressor shall be a high-pressure compressing unit with electric
motor. The compressor shall be equipped with a motor with totally enclosed
belt guard, an operating-pressure switch, safety relief valves, gauges,
intake filter and intake silencer and combination type magnetic starter
with under voltage protection and thermal overload protection for each
phase, and shall be supported by a steel base mounted on an air storage
tank. The air compressor shall provide the compressed air required for
control operation while operating not more than one-third of the time. The
tank shall be of sufficient volume so that no more than six compressor
starts per hour are required with the starting pressure switch differential
set at 140 kPa 20 psi gage. The air storage tank shall be fabricated for a
working pressure of not less than 1380 kPa 200 psi gage and constructed and
certified in accordance with ASME BPVC SEC VIII D1. The tank shall be
provided with an automatic condensate drain trap with manual override
feature. [A second (duplex arrangement) compressor of capacity equal to
the primary compressor shall be provided, with interlocked control to
provide automatic changeover upon malfunction or failure of either
compressor. A manual selector switch shall be provided to index the lead
compressor including the automatic changeover.]
2.5.2
2.5.2.1
Compressed Air Station Specialties
Refrigerated Dryer, Filters and Pressure Regulator
A refrigerated dryer shall be provided in the air outlet line of the air
storage tank. The dryer shall be of the size required for the full
[delivery capacity of the compressor] [air requirement of the control
system]. The air shall be dried at a pressure of not less than 483 kPa 70
psi gage to a temperature not greater than 2 degrees C 35 degrees F. The
dryer shall be provided with an automatic condensate drain trap with manual
override feature. The refrigerant used in the dryer shall be one of the
fluorocarbon gases and have an ozone depletion potential of not more than
0.05. A 5 micron prefilter and coalescing-type oil removal filter with
shut-off valves shall be provided in the dryer discharge. Each filter bowl
shall be rated for 1034 kPa 150 psi gage maximum working pressure. A
pressure regulator with high side and low side pressure gauges and a safety
valve shall be provided downstream of the filter. Pressure regulators of
the relieving type shall not be used.
2.5.2.2
Coalescing Filter
A coalescing prefilter, together with an automatic drain valve, shall be
provided for removal of liquids. The flow through the prefilter shall be
from inside to outside and reduce an entrained quantity of 50 ppmv oil to
0.0013 ppmv effluent liquid oil and water and remove all particulates
greater than 0.6 micron absolute. The prefilter housing (bowl) shall be
fitted with a drain port to eliminate collected liquids and provide
sufficient sump volume to prevent liquid re-entrainment, and an automatic
drain valve with adjustable cycle and drain times. Prefilter pressure drop
shall be less than 21 kPa 3 psi saturated. A particulate after filter,
outside to inside flow, designed to remove desiccant fines shall be
provided. The after filter cartridge shall have a particulate removal
rating of 0.5 micron absolute. Both prefilter and after filter housings
shall allow for service of elements without removing the entire assembly
from the system. Filter life shall be stated and guaranteed by the vendor.
SECTION 40 95 00
Page 37
end to a minimum of [0.087] [1.49] [_____] kPa [0.35] [6.0] [_____] inches
water at the high end. Two Form C contacts rated in accordance with
NEMA ICS 1 shall be provided.
2.4.6.5
Pneumatic to Electric (PE) Switch
Each switch shall have an adjustable set point range of [20] [_____] to
[137] [_____] kPa [3.0] [_____] to [20] [_____] psi gage and an adjustable
differential from [13] [_____] to [41] [_____] kPa [2.0] [_____] to [6.0]
[_____] psi. Contacts shall be Form C rated in accordance with NEMA ICS 1.
2.4.7
Temperature Instrumentation
**************************************************************************
NOTE: Component identifiers are to be coordinated
with the drawings using the Instrument Society of
America (ISA) suggested alphanumeric system for
development of discrete devise numbering.
**************************************************************************
The controller shall be provided with a minimum of three [alarm lights.
The first alarm light shall indicate when the lower (warning) detection
level has been exceeded. The second alarm light shall indicate when the
upper (alarm) detection level has been exceeded. The third alarm light
shall indicate a controller malfunction, including loss of power or loss of
sensor input] [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.
2.4.7.1
Fluid Temperature Range
**************************************************************************
NOTE: Include a schedule of temperature sensing
elements with operating range requirements. The
following includes sample tables to assist in
defining the exposure and service requirements.
Alternatively, tabulation of devices may be included
on the drawings. Include a table on the drawings
with the following headings:
ID No.
Description
Minimum, C
Maximum, C
Type
**************************************************************************
All devices must 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.
SECTION 40 95 00
Page 28
2.4.7.1.1
Type A Bimetal Thermometer
Direct reading, hermetically sealed, suitable for external adjustment.
Accurate within 1 percent of full range. Stainless steel construction.
Complete with thermowell.
2.4.7.1.2
Type B Remote Reading Gas/Vapor Thermometer
Direct reading, [stainless steel] [aluminum ] [phenolic] 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.
2.4.7.1.3
Type C
[_____]
2.4.7.2
Resistance Temperature Detector (RTD)
RTD shall be platinum, with an accuracy of plus or minus [0.1] [_____]
percent at 0 degrees C 32 degrees F. RTD shall be encapsulated in [epoxy,]
[stainless steel Series 300,] [anodized aluminum] [or copper].
2.4.7.3
Continuous Averaging RTD
**************************************************************************
NOTE: Indicate on the drawings where averaging
temperature probes are required.
**************************************************************************
Continuous averaging RTD shall have an accuracy of plus or minus [0.5] [2]
[_____] degrees C [0.9] [3.6] [_____] 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.
2.4.7.4
Infrared Temperature Sensor
Infrared temperature sensor shall be encapsulated in series 300 stainless
steel or anodized aluminum. Sensor shall have an accuracy of plus or minus
1 percent of temperature measured or 1.4 degrees C 2.5 degrees F, whichever
is less.
2.4.7.5
Temperature Switch
**************************************************************************
NOTE: Include a table on the drawings with the
following headings:
ID No.
Description
Minimum, C
Maximum, C
**************************************************************************
All devices shall be suitable for process temperatures, which define the
exposure of the element, and as described in the table shown on the
drawings. Temperature switch shall have a repetitive accuracy of plus or
minus [1] [_____] percent of the operating ranges shown. Switch actuation
SECTION 40 95 00
Page 29
shall be adjustable over the operating temperature range. The switch shall
have Form C snap action contacts, rated in accordance with NEMA ICS 1.
2.4.7.6
Thermocouple
**************************************************************************
NOTE: Thermocouples should not be used for
measuring temperatures below 260 degrees C 500
degrees F.
**************************************************************************
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 E,] [Type K,] [Type J,] [or] [Type R].
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.
2.4.7.7
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, 50 mm 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 devise.
2.4.8
Process Analytical Instrumentation
**************************************************************************
NOTE: Add requirements for additional site specific
measurements, including span and accuracy for any
application not included in this specification.
**************************************************************************
Probes shall be easily removable without interrupting service. Sampling
pumps shall be included where necessary or applicable to the sensing
device. For sensors integral to the electronic controller the sample may
be drawn directly into the sensor or may be drawn through a sample tube.
For sensors remotely located the sample may be drawn through a sample
tube. Outdoor sample tubes shall be heat traced. Sensor and controller
construction shall be suitable for operation in the monitored medium.
Systems requiring automated zero and calibration gas or reagents shall be
provided with [_____] days supply of calibration gas or reagent. The
controller shall be provided with a minimum of three [alarm lights. The
first alarm light shall indicate when the lower (warning) detection level
has been exceeded. The second alarm light hall indicate when the upper
(alarm) detection level has been exceeded. The third alarm light shall
indicate a controller malfunction, including loss of power or loss of
sensor input] [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
SECTION 40 95 00
Page 30
2.7.2.1
Analog Monitoring
The system shall measure and transmit all analog values including
calculated analog points.
2.7.2.2
Logic (Virtual)
Logic (virtual) points shall be software points entered in the point
database which are not directly associated with a physical I/O function.
Logic (virtual) points shall be analog or digital points created by
calculation from any combination of digital and analog points, or other
data having all the properties of real points, including alarms, without
the associated hardware. Logic (virtual) points shall be defined or
calculated and entered into the database. The calculated analog point
shall have point identification in the same format as any other analog
point.
2.7.2.3
State Variables
If an analog point represents more than two (up to 8) specific states, each
state shall be nameable. For example, a level sensor shall be displayed at
its measured engineering units plus a state variable with named states
usable in programs or for display such as low alarm/low/normal/high/high
alarm.
2.7.2.4
Analog Totalization
Any analog point shall be operator assignable to the totalization program.
Up to eight analog values shall be totalized within a selectable time
period.
2.7.2.5
Trending
**************************************************************************
NOTE: If the trending function is to be performed
at the central station and is not required to be
done at the PLC, this requirement will be deleted.
**************************************************************************
Any analog or calculated point shall be operator assignable to the trend
program. Up to eight points shall be sampled at individually assigned
intervals, selectable between 1 minute and 2 hours. A minimum of the most
recent 128 samples of each trended point shall be stored. The sample
intervals shall be able to be defined, modified, or deleted online.
2.7.3
Alarm Processing
**************************************************************************
NOTE: If the alarm processing function is to be
performed at the central station and is not to be
done at the PLC, this requirement will be deleted.
**************************************************************************
Each PLC shall have alarm processing software for AI, DI, and PA alarms for
all real and virtual points connected to that PLC.
2.7.3.1
Digital Alarms
Digital alarms are those abnormal conditions indicated by DIs as specified
SECTION 40 95 00
Page 44
and shown. The system shall automatically suppress analog alarm reporting
associated with a digital point when that point is turned off.
2.7.3.2
Analog Alarms
Analog alarms are those conditions higher or lower than a defined value, as
measured by an AI. Analog readings shall be compared to predefined high
and low limits, and alarmed each time a value enters or returns from a
limit condition. Unique high and low limits shall be assigned to each
analog point in the system. In control point adjustment (CPA)
applications, key the limit to a finite deviation traveling with the
setpoint. The system shall automatically suppress analog alarm reporting
associated with an analog point when that analog point is turned off.
2.7.3.3
Pulse Accumulator (PA) Alarms
Pulse accumulator alarms are those
values of accumulator inputs or PA
limits as specified and shown. PA
predefined limits and alarmed each
Unique limits shall be assigned to
2.7.4
2.7.4.1
conditions calculated from totalized
input rates that are outside defined
totalized values shall be compared to
time a value enters a limit condition.
each PA point in the system.
Constraints
Equipment Constraints Definitions
Each control point in the database shall have PLC resident constraints
defined and entered by the Contractor, including as applicable: maximum
starts (cycles) per hour; minimum off time; minimum on time; high limit
(value in engineering units); and low limit (value in engineering units).
2.7.4.2
Constraints Checks
All control devices connected to the system shall have the PLC constraints
checked and passed before each command is issued. Each command point shall
have unique constraints assigned. High and low "reasonableness" values or
one differential "rate-of-change" value shall be assigned to each AI. Each
individual point shall be capable of being selectively disabled by the
operator from the central station.
2.7.5
Control Sequences and Control Loops
**************************************************************************
NOTE: Sequences to be implemented will be developed
by the designer to meet site requirements. The
designer will define allowable process control loop
accuracies as a part of the sequences. Control
sequences and database tables will be shown on the
drawings.
**************************************************************************
Specific functions to be implemented are defined in individual system
control sequences and database tables shown on the drawings, and shall
include, as applicable, the following functions: PI control shall provide
proportional control and proportional plus integral control; two position
control shall provide control for a two state device by comparing a set
point against a process variable and an established dead band; floating
point control shall exercise control when an error signal exceeds a
selected dead band, and shall maintain control until the error is within
SECTION 40 95 00
Page 45
the dead band limits; signal selection shall allow the selection of the
highest or lowest analog value from a group of analog values as the basis
of control and shall include the ability to cascade analog values so that
large numbers of inputs can be reduced to one or two outputs; signal
averaging shall allow the mathematical calculation of the average analog
value from a group of analog values as the basis of control and shall
include the ability to "weight" the individual analog values so that the
function output can be biased as necessary to achieve proper control; reset
function shall develop an AO based on up to two AIs and one operator
specified reset schedule.
2.7.6
Command Priorities
A scheme of priority levels shall be provided to prevent interaction of a
command of low priority with a command of higher priority. Override
commands entered by the operator shall have higher priority than those
emanating from applications programs.
2.7.7
Resident Application Software
**************************************************************************
NOTE: The data base and settings tables will be
incorporated into the contract package. Specify
only those applications programs to be implemented
at time of acceptance. Do not specify a program
unless sensors and controls required to implement it
are included in the design package.
**************************************************************************
Provide resident applications programs developed in accordance with
paragraph Graphical Object Oriented Programming to achieve the sequences of
operation, parameters, constraints, and interlocks necessary to provide
control of the process systems connected to the control system. All
application programs shall be resident in the PLC and shall execute in the
PLC, and shall coordinate with each other, to insure that no conflicts or
contentions remain unresolved.
2.7.7.1
Program Inputs and Outputs
Use program inputs listed for each application program to calculate the
required program outputs. Where specific program inputs are not available,
a "default" value or virtual point appropriate for the equipment being
controlled and the proposed sequence of operation shall be provided to
replace the missing input, thus allowing the application program to operate.
2.7.7.2
Failure Mode
**************************************************************************
NOTE: Assure that the appropriate failure modes are
identified on the drawings.
**************************************************************************
In the event of a PLC failure, the controlled equipment shall continue to
function in the failure mode shown on the drawings.
2.8
CONTROL PANELS
**************************************************************************
NOTE: For locations or equipment that will be
SECTION 40 95 00
Page 46
2.4.8.12
Oxygen Gas
Continuous emissions monitoring systems (CEMS) for measuring O2 shall be
provided with installed back-up devices. The CEMS shall comply with
40 CFR 60, Appendix B, Performance Specification 2 and the QA/QC
requirements of 40 CFR 60, Appendix F. Calculation of emission rates shall
be in conformance with 40 CFR 60, Appendix A, Reference Method 19. Oxygen
in air shall be monitored by an oxygen sensor and electronic controller.
The oxygen sensor shall be rated for continuous monitoring of the oxygen
level in air in the range of [0] [_____] to [20] [25] [30] [_____] percent
with an accuracy of plus or minus [1] [_____] percent of full scale
reading. The sensor response time shall be [90] [_____] percent in a
maximum of [60] [_____] seconds. The controller shall have automatic
zeroing and shall require no normal maintenance or periodic recalibration.
2.4.8.13
Oxygen Dissolved
The dissolved oxygen sensor shall provide continuous measure of dissolved
oxygen. Wetted materials shall be [stainless steel,] [PVC] or glass.
Sensor shall be rated for continuous use to a depth of [15] [_____] m [50]
[_____] feet and shall be automatically temperature compensating over the
temperature range. Sensor shall be capable of measuring dissolved oxygen
level of from [0] [_____] to [15] [_____] ppmv. The sensor shall have an
accuracy of plus or minus [1] [_____] percent of full scale reading.
2.4.8.14
Oxygen Reduction Potential (ORP)
The sensor shall be [submersible] [flow-through] type. Sensor shall have a
range of plus or minus [500] [_____] mV and shall have an accuracy of plus
or minus [0.1] [_____] percent of sensor span. The sensor shall
automatically compensate for temperature over the temperature range. The
sensor body shall be PVC, CPVC or epoxy and suitable for installation in
the environment.
2.4.8.15
Ozone (O3) Gas
**************************************************************************
NOTE: The standard instrument provides the range
0-1,000 ppmv (parts per million by volume) an
alternate display of ozone concentration is in
millipascals.
**************************************************************************
Ozone in air shall be monitored by a ozone gas sensor and electronic
controller. The sensor shall be capable of detecting ozone in the range of
[0] [_____] to [1,000] [_____] ppmv with an accuracy of plus or minus [1]
[_____] percent of the full scale reading. The sensor response time shall
be [90] [_____] percent in a maximum of [60] [_____] seconds.
2.4.8.16
Ozone (O3) in Water
The dissolved ozone sensor shall provide continuous measurement of
dissolved ozone level from [0] [_____] to [20] [_____] mg/L. The sensor
shall automatically compensate for temperature over the temperature range.
The sensor shall have an accuracy of plus or minus [1] [_____] percent of
the full scale reading. [System shall include variable area flow meter and
needle valve to regulate rate of sample flow through sensor unit.] [Sensor
shall be suitable for direct submersion.]
SECTION 40 95 00
Page 34
2.4.8.17
pH Monitoring
**************************************************************************
NOTE: Limit the range to improve the sensitivity.
**************************************************************************
The sensor shall be [submersible] [or] [flow-through] type. Sensor shall
have a range of [1] [4] [5] [5.5] [_____] pH units to [8.5] [9] [11] [14]
[_____] pH units and shall have an accuracy of plus or minus [0.1] [0.01]
[_____] pH unit. The sensor shall automatically compensate for temperature
over the temperature range. The sensor body shall be PVC, CPVC or epoxy.
2.4.8.18
Photoionization Detector
**************************************************************************
NOTE: Refer to other Section where concentration
data is given. Show sampling points on the drawings.
**************************************************************************
Contaminant and background concentrations are [as follows:] [_____].
Photoionization detector shall be provided with a means to collect
representative continuous samples and measure for the presence of volatile
organic compounds (VOCs). Sampling points are as indicated on the
drawings. The system shall be provided with automated zero and calibration
gas system.
2.4.8.19
Total Dissolved Solids (TDS)
The TDS sensor shall measure the specific conductance using a conductivity
sensor, displaying the total dissolved solids value in [milligrams per
liter (mg/L) of dissolved NaCl equivalent] [microohms (microSiemens) per
centimeter (uS/cm)] and transmitting an analog signal for remote
processing. System shall be industrial grade and suitable for measurement
of conductivity in a solution [by insertion of the sensing element into the
pipeline, using a hot tap assembly] [including a variable area flow meter
and needle valve to regulate rate of sample flow through sensor unit].
Sensor assembly shall be suitable for periodic removal for adjustment and
cleaning without requiring shut down of the process. Sensor shall be
suitable for range of [0] [_____] to [10,000] [_____] [milligrams per liter
(mg/L) of dissolved NaCl equivalent] [microohms per centimeter (uS/cm)].
Range shall be field verified for the application and adjusted as
required. Sensing element shall be constructed of [316 stainless steel]
[_____] and glass, including temperature element, and be capable of
continuous operation. Sensing element shall be unaffected by color in the
fluid, pressure, and rate of flow. Sensor shall have automatic temperature
compensation and shall require no normal maintenance or periodic
recalibration.
2.4.8.20
Water Turbidity
System shall be complete and include indicating meter, sensing element and
a transmitter. System shall be industrial grade and suitable for
measurement of turbidity by [insertion of the sensing element into the
pipeline, using a hot tap assembly] [direct submersion of the sensing
element into the vessel or flow channel]. Sensor assembly shall be
suitable for periodic removal for adjustment and cleaning without requiring
shutdown of the process. Sensor shall be suitable for range from [0]
[_____] to [2] [20] [200] Nephelometric turbidity units (NTU). The
accuracy shall be plus or minus [2] [_____] percent of full scale reading.
SECTION 40 95 00
Page 35
Range shall be field verified for the application and adjusted as
required. Sensing element shall be constructed of [316 stainless steel]
[_____] and glass. Sensing element shall be unaffected by color in the
fluid, pressure, temperature and rate of flow. Sensor shall have automatic
zeroing and shall require no normal maintenance or periodic recalibration.
2.4.9
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).
2.4.9.1
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 [5] [6] [7] digits including [1] [_____] decimal places. The
display shall be non-resettable. The meter shall be driven by a [24] [120]
[240] vAc synchronous motor.
2.4.9.2
Watt-Hour Meter
Watt-hour meters shall be in accordance with ANSI C12.1 and shall have
pulse initiators for remote monitoring of watt-hour consumption. Meter
sockets shall be in accordance with ANSI C12.1. Pulse initiator shall
consist of Form C contacts with a current rating not to exceed 2 amperes
and voltage not to exceed 500 V, with combinations of VA not to exceed 10
VA, and a life rating of one billion operations.
2.4.10
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.
2.5
COMPRESSED AIR STATIONS
**************************************************************************
NOTE: If the control system does not utilize
pneumatic devices, the air compressor and
accessories should be deleted.
**************************************************************************
Submit instrumentation compressed-air station schematic diagram showing
equipment utilized, including compressor with motor output and voltage;
starter; isolators; manual bypasses; tubing sizes; drain piping and drain
traps; reducing valves; air-dryer; and data on manufacturer's names and
model numbers, mounting, access, and clearance requirements. Include in
the air-compressor and air-dryer data calculations of the air consumption
of current-to-pneumatic transducers (IPs), pneumatic control valves and of
other control system devices to be connected to the compressed-air station;
the number of starts per hour, the running time for the unit selected; and
the compressed air-supply dewpoint temperature at 552 kPa 80 psig.
SECTION 40 95 00
Page 36
2.5.1
Air Compressor Assembly
The air compressor shall be a high-pressure compressing unit with electric
motor. The compressor shall be equipped with a motor with totally enclosed
belt guard, an operating-pressure switch, safety relief valves, gauges,
intake filter and intake silencer and combination type magnetic starter
with under voltage protection and thermal overload protection for each
phase, and shall be supported by a steel base mounted on an air storage
tank. The air compressor shall provide the compressed air required for
control operation while operating not more than one-third of the time. The
tank shall be of sufficient volume so that no more than six compressor
starts per hour are required with the starting pressure switch differential
set at 140 kPa 20 psi gage. The air storage tank shall be fabricated for a
working pressure of not less than 1380 kPa 200 psi gage and constructed and
certified in accordance with ASME BPVC SEC VIII D1. The tank shall be
provided with an automatic condensate drain trap with manual override
feature. [A second (duplex arrangement) compressor of capacity equal to
the primary compressor shall be provided, with interlocked control to
provide automatic changeover upon malfunction or failure of either
compressor. A manual selector switch shall be provided to index the lead
compressor including the automatic changeover.]
2.5.2
2.5.2.1
Compressed Air Station Specialties
Refrigerated Dryer, Filters and Pressure Regulator
A refrigerated dryer shall be provided in the air outlet line of the air
storage tank. The dryer shall be of the size required for the full
[delivery capacity of the compressor] [air requirement of the control
system]. The air shall be dried at a pressure of not less than 483 kPa 70
psi gage to a temperature not greater than 2 degrees C 35 degrees F. The
dryer shall be provided with an automatic condensate drain trap with manual
override feature. The refrigerant used in the dryer shall be one of the
fluorocarbon gases and have an ozone depletion potential of not more than
0.05. A 5 micron prefilter and coalescing-type oil removal filter with
shut-off valves shall be provided in the dryer discharge. Each filter bowl
shall be rated for 1034 kPa 150 psi gage maximum working pressure. A
pressure regulator with high side and low side pressure gauges and a safety
valve shall be provided downstream of the filter. Pressure regulators of
the relieving type shall not be used.
2.5.2.2
Coalescing Filter
A coalescing prefilter, together with an automatic drain valve, shall be
provided for removal of liquids. The flow through the prefilter shall be
from inside to outside and reduce an entrained quantity of 50 ppmv oil to
0.0013 ppmv effluent liquid oil and water and remove all particulates
greater than 0.6 micron absolute. The prefilter housing (bowl) shall be
fitted with a drain port to eliminate collected liquids and provide
sufficient sump volume to prevent liquid re-entrainment, and an automatic
drain valve with adjustable cycle and drain times. Prefilter pressure drop
shall be less than 21 kPa 3 psi saturated. A particulate after filter,
outside to inside flow, designed to remove desiccant fines shall be
provided. The after filter cartridge shall have a particulate removal
rating of 0.5 micron absolute. Both prefilter and after filter housings
shall allow for service of elements without removing the entire assembly
from the system. Filter life shall be stated and guaranteed by the vendor.
SECTION 40 95 00
Page 37
prevent the loss of data packages.
2.9.2
Operator's Workstation Computer
**************************************************************************
NOTE: If an operator's workstation is required,
indicate its location on the drawings. Indicate the
operator's workstation and required DTS on the
control system block diagram. If an operator's
workstation is not required, reference to it will be
deleted. If the requirements for the operator's
workstation computer are different than those for
the central station computer, list those items that
are different.
**************************************************************************
The operator's workstation computer shall be the same as the central
station computer, except for the following items: [_____].
2.9.3
Printer
A laser printer shall installed at each of the following connections [the
central station computer] [and] [the operator workstation]. The printer
shall meet the following requirements: The input interface shall be a
parallel port connection. Resolution shall be a minimum of [23 by 23
dots/mm 600 by 600 dots/inch] [_____]. Printing speed shall be a minimum
of [4] [_____] pages per minute. The data buffer size shall be a minimum
of [10] [_____] megabytes. The size for paper and other media shall be [
216 by 28 mm 8.5 X 11 inches] [_____]. The paper cassette shall have a
[250] [_____] sheet minimum capacity.
2.9.4
LAN System
The local area network (LAN) shall be used to allow communication between
PLCs located in the control panel[s], the central station computer [and the
operator's workstation computer] [and the printer]. The LAN system
configuration and requirements shall comply with the control system
schematics and block diagram shown on the drawings and [Section 27 10 00
BUILDING TELECOMMUNICATIONS CABLING SYSTEM] [Section 33 82 00
TELECOMMUNICATIONS OUTSIDE PLANT (OSP)]. All LAN equipment shall fully
comply with IEEE 802.3 (10 BASE 2 or 10 BASE T) Ethernet networks. Cables
and connecting hardware shall conform to the requirements of [Section
27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM] [Section 33 82 00
TELECOMMUNICATIONS OUTSIDE PLANT (OSP)].
2.9.5
LAN Hubs
Network hubs shall provide communication between network devices using
network cables. Network hubs shall support protocol utilized in the LAN.
Network hubs shall be modular and expandable from a minimum of [_____] [16]
ports up to [_____] [48] ports. Each port shall have LED indicator for
network monitoring status. Network hubs shall permit online network
changes without disturbing network devices. Malfunctioning network devices
shall be automatically removed from service without shutting down the
network.
2.9.6
Uninterruptible Power Supply (UPS)
A self contained UPS suitable for installation and operation at the central
SECTION 40 95 00
Page 54
station [and operator's workstation] shall be provided. The unit[s] shall
be sized to provide a minimum of 10 minutes of operation of the central
station [and operator's workstation] computer. The UPS shall incorporate
surge suppression, noise filtering (normal and common mode) short circuit
protection and voltage regulation (brownout and overvoltage protection).
UPS shall be complete with all necessary power supplies, transformers,
batteries, and accessories and shall include visual indication of normal
power operation, UPS operation, abnormal operation and visual and audible
indication of low battery power. The UPS shall comply with the Federal
Communications Commission Standard 15J part A for radio noise emissions.
2.9.7
Portable Tester/Workstation
A portable tester/workstation shall be provided and shall be connectable to
any PLC. The portable tester/workstation shall consist of a portable
computer with a nominal 250 mm 10 inch active color matrix liquid crystal
display, capable of displaying up to 256 colors at a minimum resolution of
[640 x 480] [_____] pixels, 64 bit microprocessor operating at a minimum of
[133] [_____] MHz. The portable tester/workstation shall have, as a
minimum, [1.2] [_____] GB hard drive, [16] [_____] megabytes of memory,
integral pointing device, serial and parallel ports, color VGA video port
for an external color monitor, 88 mm 3.5 inch floppy disk drive, modem,
PCMCIA type 3 slot, rechargeable battery, battery charger and a compatible
network adapter. The portable tester/workstation shall be provided with
the proper cables, connectors, adapters and software required to connect to
and be compatible with the PLCs. Connection may be made directly to the
PLCs or to the communications network. The tester/work station shall be
capable of performing all workstation functions contingent on proper
password level.
2.9.8
Communication and Programming Device
A hand-held communication and programming device shall be provided. The
communication and programming device shall connect to the PLC directly for
readout of variables, override, control, servicing, troubleshooting and
adjustment of control parameters. The device shall be provided with all
necessary cables, connectors and adapters to allow connection to the PLC.
The device shall communicate in English language for inquiry, reporting and
programming purposes.
2.10
CENTRAL STATION SOFTWARE
**************************************************************************
NOTE: The designer should edit this paragraph, as
needed, to require only the central station software
that is necessary based on the requirements and
complexity of the control system. Where no
information is available on future expansion,
require a minimum expansion capability of 50
percent. Where specific expansion requirement
information is available, it shall be used to
determine the expansion capability requirements.
**************************************************************************
The central station software shall provide the communication, programming
and control capabilities necessary to support all specified points and
functions, plus a minimum expansion of [50] [_____] percent of the current
number of points, complete with their point database. The central station
shall be online at all times and shall perform all required functions as
SECTION 40 95 00
Page 55
specified. The central station software shall be one or more standard
software modules. Where multiple modules are used the modules shall be
capable of sharing data and operating together seamlessly. Software shall
be windowing type using icons and pull down menus. The system shall
support multiple user operation with multiple tasks for each user and shall
support operation and management of all peripheral devices.
2.10.1
2.10.1.1
Graphical Operations
Graphical User Interface
The central station shall be provided with an object-oriented, mouse
driven, graphical user interface. The graphical user interface shall
include a set of desktop utilities including the following: file
management; shell tool; calculator; text editor; and icon editor.
2.10.1.2
Display Information
The central station shall display information necessary to support all
requirements specified, including: operator commands; alarm notification;
reports; system graphics as specified and as shown, incorporating dynamic
data; and curve plotting.
2.10.1.3
System Graphics Implementation
System graphics displays shall be hierarchical displays which integrate
dynamic data into the display. System graphics shall reflect actual system
configuration. Each system schematic shall be included as a separate
display. Different colors, textures, and use of inverted video shall be
used for various components and dynamic data. The displays shall include
standard and/or custom symbols. A library of callable display symbols
containing symbols for all necessary equipment and control devices shall be
furnished. Symbols shall conform to ASHRAE FUN SI ASHRAE FUN IP where
applicable. Data associated with a display shall be updated within 5
seconds of the digital status change or the analog change in excess of the
analog change differential. Any dynamic data which is not current, due to
PLC communications failure, PLC failure, or point out of service, shall be
highlighted or flagged.
2.10.1.4
Display Editor
The display editor shall enable the user to create, modify, save and delete
displays and symbols. Within the display shall be dynamic fields. The
function of linking the dynamic fields with the database shall be handled
by a separate software module which shall be executed automatically as the
last step of the database generation and modification procedure.
2.10.1.5
Graphical Object Oriented Programming
The system shall include a graphical object oriented programming function
which shall be used to create all control sequences utilized in the control
panels. This function shall reside in the central station to create,
modify, and test software for control panel resident programs. The
graphical object oriented programming function shall provide programming
elements to be connected together to create a logic diagram. The diagram
shall be compilable to produce executable code for the control panel. The
graphical object oriented programming function shall include elements
necessary to create logic diagrams that represent sequences of operation.
Program elements shall be able to be combined into a custom template which
SECTION 40 95 00
Page 56
can then be used as a standard function. Program checkout and debug
facilities shall include display of dynamic and/or simulated system
variables and points on the programming screens. The user shall be able to
fix or force values of variables to enable program checkout during
debugging. The programming shall allow for the use of the portable tester
for loading files directly into the control panel, uploading of existing
control panel programming and database information and downloading of
control panel programming and database information.
2.10.1.6
Charting
The user shall be able to display data in chart formats, and the system
shall support the presentation of data: 1) with time on the X-axis
(horizontal) and amplitude on the Y-axis (vertical) for trend charts; and
2) in bar chart form with a minimum of 360 15-minute divisions and 31 1-day
divisions to be displayed on the X-axis.
2.10.1.7
System Menus and Displays
The user shall be able to call up the following displays by dedicated
function key, pull down menu or by icon and shall be able to page forward
and backward on linked multiple page displays. The system menu and index
displays shall also contain icons which can be used to call up subsequent
displays.
a.
System Menu (list of all graphics and menus).
b.
Index (list of all PLCs).
c.
Alarm Summary (list of all uncleared alarms).
d.
Abnormal Summary (list of all devices not in normal state; keeps track
of alarm conditions which have been cleared).
e.
Data Communications Summary (listing of availability for each
communication channel, by statistically processing the number of
transmission errors, outages, and other abnormal conditions for each
channel).
2.10.1.8
Hard-Copy Screen Request
The central station shall be able to obtain a hard copy of the monitor
display being viewed. This shall be an exact "snapshot" of the data and
device symbols shown on the selected monitor.
2.10.2
Command Software
The software shall provide for defining and selecting points, parameters,
graphics, report generation, and all other functions associated with
operation. The operator commands shall be usable from central station
computer and workstation keyboards with individual operator passwords as
specified.
2.10.2.1
Command Input
Command menus shall utilize full words and acronyms selected to allow
operators to use the system without extensive training or data processing
backgrounds. The system shall prompt the operator.
SECTION 40 95 00
Page 57
2.6.4
Program Storage/Memory Requirements
The CPU shall utilize the manufacturer's standard non-volatile memory for
the operating system. The controller shall have electronically erasable,
programmable, read only memory (EEPROM) for storage of user programs and
battery backed RAM for application memory. The EEPROM shall be loaded
through the controller keypad, central station or through the use of a
laptop computer. The CPU memory capacity shall be based on the system's
control requirements. The memory capacity shall be sized such that, when
the system is completely programmed and functional, no more than 50 percent
of the memory allocated for these purposes is used.
2.6.5
Input/Output Characteristics
Each controller shall allow for analog input, analog output, discrete input
and discrete output. The number and type of inputs and outputs for the
system shall be as shown on the drawings and shall comply with the sequence
of control. The system capacity shall include a minimum of 20 percent
spare input and output points (no less than two points) for each point type
provided. During normal operation, a malfunction in any input/output
channel shall affect the operation of that channel only and shall not
affect the operation of the CPU or any other channel. Analog input
circuits shall be available in [+/-10V] [+/-5V] [0-10V] [0-5V] [4-20 mA].
Discrete input circuits shall be available in [5 volt TTL] [10-30 vDc]
[18-26 vDc] [79-132 vAc]. All input circuits shall have a minimum optical
isolation of 1500 VRMS and shall be filtered to guard against high voltage
transients from the externally connected devices. Analog output circuits
shall be available in [+/-10V] [4-20 mA]. Discrete output circuits shall
be available in [5 volt TTL] [10-30 vDc] [18-26 vDc] [79-132 vAc]. All
output circuits shall have a minimum optical isolation of 1500 VRMS and
shall be filtered to guard against high voltage transients from the
externally connected devices.
2.6.6
Wiring Connections
Wiring connections shall be heavy duty, self lifting, pressure type screw
terminals to provide easy wire insertion and secure connections. The
terminals shall accept two #14 AWG wires. A hinged protective cover shall
be provided over the wiring connections. The cover shall have write-on
areas for identification of the external circuits.
2.6.7
On-Off Switch
Each controller shall be provided with an integral on-off power switch. If
the controller is not provided with a manufacturer's standard on-off
switch, a miniature toggle type switch shall be installed in the control
panel near the controller and shall be clearly labeled as to its function.
2.6.8
Diagnostics
Each PLC shall have diagnostic routines implemented in firmware. The CPU
shall continuously perform self-diagnostic routines that will provide
information on the configuration and status of the CPU, memory,
communications and input/output. The diagnostic routines shall be
regularly performed during normal system operation. A portion of the scan
time of the controller shall be dedicated to performing these housekeeping
functions. In addition, a more extensive diagnostic routine shall be
performed at power up and during normal system shutdown. The CPU shall log
input/output and system faults in fault tables which shall be accessible
SECTION 40 95 00
Page 42
for display. When a fault affects input/output or communications modules
the CPU shall shut down only the hardware affected and continue operation
by utilizing the healthy system components. All faults shall be
annunciated at [the PLC] [and] [the central station]. Diagnostic software
shall be useable in conjunction with the portable tester.
2.6.9
Accuracy
Controllers shall have an accuracy of plus or minus 0.25 percent of input
span.
2.7
PLC SOFTWARE
All PLC software described in this specification shall be furnished as part
of the complete control system.
2.7.1
Operating System
Each PLC shall be provided with the manufacturer's standard operating
system software package. The PLC shall maintain a point database in its
memory that includes all parameters, constraints and the latest value or
status of all points connected to the PLC. Execution of the PLC
application programs shall use the data in memory resident files. The
operating system shall support a full compliment of process control
functions. It shall be possible to define these functions using a mix of
function blocks, ladder logic diagrams, sequential function charts and text
programming. Programming methods and interactions shall be based on
IEC 61131-3. A combination of the programming methods shall be possible
within a single controller. The operating system shall allow loading of
software locally or from the central station and data files from the
portable tester. It shall also support data entry and diagnostics using an
operator interface panel attached directly to the PLC. Each PLC shall be
capable of operating in stand alone mode.
2.7.1.1
Startup
The PLC shall have startup software that causes automatic commencement of
operation without human intervention, including startup of all connected
I/O functions. A PLC restart program based on detection of power failure
at the PLC shall be included in the PLC software. The restart program
shall include start time delays between successive commands to prevent
demand surges or overload trips.
2.7.1.2
Failure Mode
Upon failure for any reason, each PLC shall perform an orderly shutdown and
force all PLC outputs to a predetermined (failure mode) state, consistent
with the failure modes shown and the associated control device.
2.7.2
Functions
The controller operating system shall be able to scan inputs, control
outputs, and read and write to its internal memory in order to perform the
required control as indicated in the sequence of control on the drawings.
The controller shall periodically perform self diagnostics to verify that
it is functioning properly.
SECTION 40 95 00
Page 43
2.7.2.1
Analog Monitoring
The system shall measure and transmit all analog values including
calculated analog points.
2.7.2.2
Logic (Virtual)
Logic (virtual) points shall be software points entered in the point
database which are not directly associated with a physical I/O function.
Logic (virtual) points shall be analog or digital points created by
calculation from any combination of digital and analog points, or other
data having all the properties of real points, including alarms, without
the associated hardware. Logic (virtual) points shall be defined or
calculated and entered into the database. The calculated analog point
shall have point identification in the same format as any other analog
point.
2.7.2.3
State Variables
If an analog point represents more than two (up to 8) specific states, each
state shall be nameable. For example, a level sensor shall be displayed at
its measured engineering units plus a state variable with named states
usable in programs or for display such as low alarm/low/normal/high/high
alarm.
2.7.2.4
Analog Totalization
Any analog point shall be operator assignable to the totalization program.
Up to eight analog values shall be totalized within a selectable time
period.
2.7.2.5
Trending
**************************************************************************
NOTE: If the trending function is to be performed
at the central station and is not required to be
done at the PLC, this requirement will be deleted.
**************************************************************************
Any analog or calculated point shall be operator assignable to the trend
program. Up to eight points shall be sampled at individually assigned
intervals, selectable between 1 minute and 2 hours. A minimum of the most
recent 128 samples of each trended point shall be stored. The sample
intervals shall be able to be defined, modified, or deleted online.
2.7.3
Alarm Processing
**************************************************************************
NOTE: If the alarm processing function is to be
performed at the central station and is not to be
done at the PLC, this requirement will be deleted.
**************************************************************************
Each PLC shall have alarm processing software for AI, DI, and PA alarms for
all real and virtual points connected to that PLC.
2.7.3.1
Digital Alarms
Digital alarms are those abnormal conditions indicated by DIs as specified
SECTION 40 95 00
Page 44
and shown. The system shall automatically suppress analog alarm reporting
associated with a digital point when that point is turned off.
2.7.3.2
Analog Alarms
Analog alarms are those conditions higher or lower than a defined value, as
measured by an AI. Analog readings shall be compared to predefined high
and low limits, and alarmed each time a value enters or returns from a
limit condition. Unique high and low limits shall be assigned to each
analog point in the system. In control point adjustment (CPA)
applications, key the limit to a finite deviation traveling with the
setpoint. The system shall automatically suppress analog alarm reporting
associated with an analog point when that analog point is turned off.
2.7.3.3
Pulse Accumulator (PA) Alarms
Pulse accumulator alarms are those
values of accumulator inputs or PA
limits as specified and shown. PA
predefined limits and alarmed each
Unique limits shall be assigned to
2.7.4
2.7.4.1
conditions calculated from totalized
input rates that are outside defined
totalized values shall be compared to
time a value enters a limit condition.
each PA point in the system.
Constraints
Equipment Constraints Definitions
Each control point in the database shall have PLC resident constraints
defined and entered by the Contractor, including as applicable: maximum
starts (cycles) per hour; minimum off time; minimum on time; high limit
(value in engineering units); and low limit (value in engineering units).
2.7.4.2
Constraints Checks
All control devices connected to the system shall have the PLC constraints
checked and passed before each command is issued. Each command point shall
have unique constraints assigned. High and low "reasonableness" values or
one differential "rate-of-change" value shall be assigned to each AI. Each
individual point shall be capable of being selectively disabled by the
operator from the central station.
2.7.5
Control Sequences and Control Loops
**************************************************************************
NOTE: Sequences to be implemented will be developed
by the designer to meet site requirements. The
designer will define allowable process control loop
accuracies as a part of the sequences. Control
sequences and database tables will be shown on the
drawings.
**************************************************************************
Specific functions to be implemented are defined in individual system
control sequences and database tables shown on the drawings, and shall
include, as applicable, the following functions: PI control shall provide
proportional control and proportional plus integral control; two position
control shall provide control for a two state device by comparing a set
point against a process variable and an established dead band; floating
point control shall exercise control when an error signal exceeds a
selected dead band, and shall maintain control until the error is within
SECTION 40 95 00
Page 45
the dead band limits; signal selection shall allow the selection of the
highest or lowest analog value from a group of analog values as the basis
of control and shall include the ability to cascade analog values so that
large numbers of inputs can be reduced to one or two outputs; signal
averaging shall allow the mathematical calculation of the average analog
value from a group of analog values as the basis of control and shall
include the ability to "weight" the individual analog values so that the
function output can be biased as necessary to achieve proper control; reset
function shall develop an AO based on up to two AIs and one operator
specified reset schedule.
2.7.6
Command Priorities
A scheme of priority levels shall be provided to prevent interaction of a
command of low priority with a command of higher priority. Override
commands entered by the operator shall have higher priority than those
emanating from applications programs.
2.7.7
Resident Application Software
**************************************************************************
NOTE: The data base and settings tables will be
incorporated into the contract package. Specify
only those applications programs to be implemented
at time of acceptance. Do not specify a program
unless sensors and controls required to implement it
are included in the design package.
**************************************************************************
Provide resident applications programs developed in accordance with
paragraph Graphical Object Oriented Programming to achieve the sequences of
operation, parameters, constraints, and interlocks necessary to provide
control of the process systems connected to the control system. All
application programs shall be resident in the PLC and shall execute in the
PLC, and shall coordinate with each other, to insure that no conflicts or
contentions remain unresolved.
2.7.7.1
Program Inputs and Outputs
Use program inputs listed for each application program to calculate the
required program outputs. Where specific program inputs are not available,
a "default" value or virtual point appropriate for the equipment being
controlled and the proposed sequence of operation shall be provided to
replace the missing input, thus allowing the application program to operate.
2.7.7.2
Failure Mode
**************************************************************************
NOTE: Assure that the appropriate failure modes are
identified on the drawings.
**************************************************************************
In the event of a PLC failure, the controlled equipment shall continue to
function in the failure mode shown on the drawings.
2.8
CONTROL PANELS
**************************************************************************
NOTE: For locations or equipment that will be
SECTION 40 95 00
Page 46
powered by an uninterruptible power supply (UPS)
during a commercial power outage, the control panel
shall be included on the UPS.
Include in the design package requirements for
sufficient ventilation, heating or air conditioning
to ensure that the control panel internal
temperature and humidity will be maintained within
the PLCs operational parameters when exposed to the
temperature and humidity indicated in paragraph SITE
ENVIRONMENTAL CONDITIONS. Include allowance for any
solar gain. If the requirements for ventilation,
heating and air conditioning are not necessary, they
will be deleted.
**************************************************************************
2.8.1
2.8.1.1
Components
Enclosures
The enclosure for each control panel shall conform to the requirements of
NEMA 250 for the types specified. 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 [1] [4] [12]; those for
installation in clean, dry indoor occupied space may be Type 1; other
locations shall be as otherwise specified or shown. Enclosures for
equipment installed outdoors shall be Type 4 or as shown. Enclosures for
installation in a corrosive environment shall be Type 4X and shall be
constructed of [stainless steel] [fiberglass] [polymer plastic]. 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.
2.8.1.2
Controllers
Controllers shall be in accordance with paragraph Programmable Logic
Controller (PLC).
2.8.1.3
Standard Indicator Light
Indicator lights shall comply with NEMA ICS 1, NEMA ICS 2 and UL 508.
Lights shall be heavy duty, round and shall mount in a 22.5 mm 0.875 inch
mounting hole. Indicator lights shall be LED type and shall operate at 120
vAc or 24 vDc. Long life bulbs shall be used. 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.
2.8.1.4
Selector Switches
**************************************************************************
NOTE: Indicate on the drawings where key operated
switches are required.
**************************************************************************
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 22.5 mm
SECTION 40 95 00
Page 47
0.875 inch mounting hole. The number of positions shall be as indicated on
the drawings. Switches shall be [illuminated] [non-illuminated] [as
indicted of the drawings]. 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.
2.8.1.5
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 22.5 mm 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.
2.8.1.6
Relays
Relays shall comply with IEEE C37.90 and derated for altitude above 1,500
m. Relays shall be [single-pole, single-throw (SPST)] [single-pole,
double-throw (SPDT)] [double-pole, single throw (DPST)] [double-pole,
double-throw (DPDT)] [as required by the Sequence of Control]. Relay coil
shall be [120 vAc] [24 vDc] and shall be provided with matching mounting
socket. Power consumption shall not be greater than 3 watts.
2.8.1.7
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.
2.8.1.8
Chart Recorder
**************************************************************************
NOTE: Delete this paragraph if no chart recorders
are required as part of control panels. If multiple
control panels are provided, indicate on the
drawings which are to be provided with chart
recorders.
**************************************************************************
Chart recorders shall be microprocessor based circular recorder capable of
recording up to [1] [2] [4] [_____] inputs simultaneously. Input
applications shall include temperature, pressure, flow and level. The
recorder shall receive inputs in the form of [4-20 mA] [or] [0-5 vDc]
signals and shall record the data in the proper engineering units. Each
chart shall record [24 hours] [7 days] [the time frame indicated on the
drawings]. Pens shall be replaceable, felt tip type. Recorder shall have
an accuracy of plus or minus [1] [_____] percent of full scale. Charts
shall be paper, 250 mm 10 inches in diameter. Recorder shall operate
using [120] [240] vAc electrical power and shall operate in a temperature
SECTION 40 95 00
Page 48
purging, and calibration. Any deviations shall be documented and submitted
to the Government for approval prior to mounting.
Damaged insulation
shall be replaced or repaired after devices are installed to match existing
work. Damaged galvanized surfaces shall be repaired by touching up with
zinc paint.
3.1.1.3
Pneumatic Tubing
Tubing shall be concealed in finished areas. Tubing may be run exposed in
unfinished areas, such as mechanical equipment rooms. For tubing to be
enclosed in concrete, rigid metal or intermediate metal conduit shall be
provided. Tubing shall be installed parallel or perpendicular to building
walls throughout. Maximum spacing between tubing supports shall be 1.5 m 5
feet. Each tubing system shall be tested pneumatically at 1.5 times the
working pressure for 24 hours, with a maximum pressure drop of [0.15]
[_____] kPa [1.0] [_____] psig with compressed air supply turned off.
Joint leaks shall be corrected by remaking the joint. Caulking of joints
will not be permitted. Tubing and two insulated copper phone wires for
installation checkout may be run in the same conduit.
Tubing and
electrical power conductors shall not be run in the same conduit; however,
control circuit conductors may be run in the same conduit as polyethylene
tubing.
3.1.1.4
Grooved Mechanical Joints
Grooves shall be prepared according to the coupling manufacturer's
instructions. Grooved fittings, couplings, and grooving tools shall be the
products of the same manufacturer. Pipe and groove dimensions shall comply
with the tolerances specified by the coupling manufacturer. The diameter
of grooves made in the field shall be measured using a "go/no-go" gauge,
vernier or dial caliper, narrow-land micrometer, or other method
specifically approved by the coupling manufacturer for the intended
application. Groove width and dimension of groove from end of pipe shall
be measured and recorded.
3.1.2
Sequences of Operation
Study the operation and sequence of local equipment controls, as a part of
the conditions report, and note any deviations from the described sequences
of operation on the contract drawings. Perform necessary adjustments to
make the equipment operate in an optimum manner and shall fully document
changes made.
3.2
INSTALLATION OF EQUIPMENT
Install equipment as specified, as shown and as required in the
manufacturer's instructions for a complete and fully operational control
system.
3.2.1
Control Panels
Control panels shall be located as indicated on the drawings. Devices
located in the control panels shall be as shown on the drawings or as
needed to provide the indicated control sequences.
3.2.2
Flow Measuring Device
Fluid flow instruments shall be installed in accordance with manufacturer's
recommendations, unless otherwise indicated in the specification. The
SECTION 40 95 00
Page 69
minimum straight unobstructed piping for the flowmeter installation shall
be 10.0 pipe diameters upstream and 5.0 pipe diameters downstream. Meters
for gases and vapors shall be installed in vertical piping, and meters for
liquids shall be installed in horizontal piping, unless otherwise
recommended by the manufacturer or indicated in the specifications.
3.2.2.1
Flow Nozzle
Flow nozzles flanges shall be installed so that the pressure taps are in a
horizontal plane with the centerline of the pipe. Flow nozzles shall be
installed for ease of accessibility for periodic maintenance. Differential
pressure sensors shall be installed as close to the flow nozzle as possible.
3.2.2.2
Flow Switch
Flow switches shall be installed in such a manner as to minimize
disturbance of the flow of fluid while maintaining reliable operation of
the switch.
3.2.2.3
Magnetic Flowmeter
**************************************************************************
NOTE: Locating magnetic flowmeters near large
electric motors or transformers should be avoided.
**************************************************************************
Meter shall be installed in vertical piping so that the flow tube remains
full of the process fluid under all operating conditions. A minimum of
five pipe diameters straight run upstream of the flowmeter and two pipe
diameters straight run downstream of the flowmeter shall be provided.
3.2.2.4
Natural Gas or Propane Flowmeter
Meters shall be installed in accordance with ASME B31.8. Permanent gas
meters shall be installed with provisions for isolation and removal for
calibration and maintenance, and shall be suitable for operation in
conjunction with an energy monitoring and control system.
3.2.2.5
Orifice Plates
Orifice plates shall be installed for ease of accessibility for periodic
maintenance. Differential pressure sensors shall be as close to the
orifice plates as possible. Orifice plates for liquid measurement shall be
located in horizontal pipe runs with the orifice plate flanges installed so
that the pressure taps are in the horizontal plane with the centerline of
the pipe. For liquid, the differential pressure transmitter shall be
installed below the orifice taps. For gas measurement, the orifice plate
flanges shall be installed so that the pressure taps are 45 degrees or more
above the horizontal plane with the centerline of the pipe. For gas
measurement the required differential pressure transmitter shall be
physically installed above the orifice taps.
3.2.2.6
Paddle Flowmeter
Meter shall be installed using manufacturer's published procedures.
Installers shall be trained for such installations in the pipes
encountered. Provide certificates demonstrating installer's qualifications.
SECTION 40 95 00
Page 70
2.8.7
Panel Interior Light
[Where indicated,] [Each] control panel[s] shall be provided with a [60
watt incandescent] [40 watt fluorescent] 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.
2.8.8
Ventilation System
[Where indicated,] [Each] control panel[s] shall be provided with two
single phase, 120 volt ac ventilation fans. Each fan shall supply a
minimum of 50 L/s 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 21 to 60 degrees C 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.
2.8.9
Heating System
[Where indicated,] [Each] control panel(s) shall be provided with a
thermostatically controlled electric heater capable of maintaining an
enclosure temperature of [2] [_____] degrees C [35] [_____] degrees F when
continuously exposed to an ambient temperature of [_____] degrees C degrees
F.
2.8.10
Air Conditioning System
[Where indicated,] [Each] control panel[s] shall be provided with a
mechanical refrigeration air conditioning system. The system shall be
capable of maintaining a temperature of [38] [_____] degrees C [100]
[_____] degrees F inside the enclosure with all equipment in the panel
operating and while continuously exposed to [full sunlight and] an ambient
air temperature of [_____] degrees C degrees F. The compressor and
condenser shall be located outside the control panel enclosure. Provisions
shall be made to remove condensate from the control panel and to protect
all devices within the enclosure from condensate.
2.9
2.9.1
CENTRAL STATION AND OPERATORS WORKSTATION EQUIPMENT
Workstation Computer
**************************************************************************
NOTE: The designer must edit the following
paragraph to require only the computer equipment
that is necessary based on the requirements and
complexity of the control system. If an operator's
workstation is not required or if its requirements
differ from those for the central station computer,
reference to it shall be deleted from this section.
If the requirements for the operator's workstation
computer are the same as those for the central
station computer, this section will be used for
both. Indicate on the drawings where the central
station is to be located. Verify that the location
for the equipment will be provided with climate
controls to provide a suitable environment for the
equipment. Indicate the central station and the
required DTS on the control system block diagram.
SECTION 40 95 00
Page 51
**************************************************************************
Computer shall be a standard [desk top] [tower] configuration, unmodified
digital computer of modular design. Computing devices, as defined in
47 CFR 15, supplied as part of the control system shall be certified to
comply with the requirements of Class B computing devices and shall be
labeled as set forth in 47 CFR 15.
2.9.1.1
Minimum Processor Operating Speed
[Dual micro processors] [A single microprocessor] with Processors with
minimum processor operating speed of [3.06GHz] [2.80GHz] [2.66GHz]
[2.53GHz] [2.40GHz] [2.20GHz] [2.0GHz] [1.8GHz] [1.7GHz] [233MHz] [166MHz]
[_____].
2.9.1.2
RAM Memory
Ram memory shall be [2GB] [128MB] [32MB] [_____], expandable to a minimum
of [_____] GB.
2.9.1.3
Power Supply
Minimum power supply shall have a capacity of [250] [180] [160][_____]
watts. Suspend to RAM (S3) sleep support with wakeup capabilities.
2.9.1.4
Real Time Clock (RTC)
Real time clock accurate to within plus or minus [one] [_____] minute per
month. Battery backed for a minimum of 3 months.
2.9.1.5
Input/Output (I/O) Ports
1 PS/2 keyboard 101 key, 64 character standard ASCII character set
based on ANSI INCITS 154 with 8 programmable hotkeys.
1 PS/2 [2 button] [touch pad] mouse: minimum resolution of 16 dots per
mm 400 dots per inch.
1 NIC
2 serial [_____] TIA-232 ports. Data transmission rate shall be
software adjustable between 9600 and 57,600 bps.
1 enhanced parallel port.
1 Ethernet
1 [1000 G network connection] [1180 wireless network adapter] [RJ-45
network port]
[8] [_____] USB [2] [_____] in front and [6] [_____] in rear
1 graphic
1 microphone
1 audio in
SECTION 40 95 00
Page 52
with the manufacturer's recommendation.
leakage of flue gases at the sensor.
3.2.6.9
Installation shall prevent all
Oxygen and Ozone in Air Monitor
The controller shall be mounted in the control panel or as otherwise shown
on the drawings. The oxygen sensor shall be located in accordance with the
manufacturer's recommendations and as shown on the drawings. High and low
alarm settings shall be set as required by the sequence of control.
Settings shall be verified through the use of a manufacturer's standard
calibration kit.
3.2.6.10
Dissolved Oxygen
The dissolved oxygen sensor shall be immersed in the fluid to be monitored
using manufacturer's mounting assembly. The sensor shall be located in an
area of continuous fluid flow. The transmitter shall be located remote
from the sensor. The transmitter and wiring connections shall be in a
weathertight enclosure. [The transmitter shall be mounted to allow the
digital readout to be easily viewed.]
3.2.6.11
PH and ORP Sensor
Pipe mounted flow sensor shall be located in a threaded tee or fitting to
allow removal from the pipe. Submersible sensor shall be completely
immersed in the fluid being monitored using an ensemble that will allow for
removal of the sensor from the fluid for replacement. The sensor shall be
located in an area of continuous flow. The transmitter shall be located
[at the sensor] [remote from the sensor]. [The transmitter shall be
mounted to allow the digital readout to be easily viewed].
3.2.6.12
Total Dissolved Solids
The sensor shall be [pipe] [tank] [submersible] type as indicated on the
drawings. [Pipe mounted sensor shall be mounted in a threaded tee or
fitting to allow removal of the sensor.] [Tank mounted sensor shall be
mounted in a threaded fitting to allow removal of the sensor.] [Submersible
sensor shall be mounted in an assembly that will allow removal of the
sensor from the fluid for replacement.] The transmitter shall be located
[at the sensor] [remote from the sensor]. The transmitter and wiring
connections shall be located in a weathertight enclosure.
3.2.7
Instrument Shelters
Instrument shelters shall be installed in the location shown with the bottom
1.2 meter 4.0 feet above the supporting surface using legs and secured
rigidly to minimize vibrations from winds. Instrument shelters shall be
oriented with door facing North. Instruments located in shelters shall be
mounted in the 3-dimensional center of the open space of the shelter.
3.2.8
3.2.8.1
Electric Power Devices
Potential and Current Transformers
Install potential and current transformers in enclosures unless otherwise
shown. Current transformer leads shall be shorted when they are not
connected to the measurement circuits.
SECTION 40 95 00
Page 75
3.2.8.2
Hour Meters
Meters shall be located in the control panel or as otherwise shown. Power
to the meter shall be connected to the motor starter auxiliary contacts for
pumps, blowers and other motor driven devices. For devices without motor
starters, the meter shall be connected in parallel with the load. Where
the meter voltage differs from the metered devices voltage, transformer
shall be provided as necessary.
3.2.8.3
Watt-hour Meters
Install watt-hour meters and transducers in enclosures unless otherwise
shown.
3.2.8.4
Transducers
Transducers shall be wired in accordance with the manufacturer's
instructions, and installed in enclosures.
3.2.8.5
Current Sensing Relays and Current Transducers for Motors
When used to sense meter/fan/pump status, current sensing relays shall be
used for applications under 4 kW 5 hp. Applications over 4 kW 5 hp shall
use a current transducer.
3.2.9
Output Devices
Output devices (transducers, relays, contactors, or other devices) which
are not an integral part of the control panel, shall be mounted in an
enclosure mounted adjacent to the control panel, unless otherwise shown.
Where H-O-A and/or override switches on the drawings or required by the
control sequence, the switches shall be installed so that the control
system controls the function through the automatic position and other
controls work through the hand position.
3.2.10
Enclosures
All enclosure penetrations shall be from the bottom of the enclosure, and
shall be sealed to preclude entry of water using a silicone rubber sealant.
3.2.11
Transformers
Transformers for control voltages below 120 vAc shall be fed from the
nearest power panel or motor control center, using circuits provided for
the purpose. Provide a disconnect switch on the primary side and a fuse on
the secondary side. Transformers shall be enclosed in a steel cabinet with
conduit connections.
3.3
3.3.1
WIRE, CABLE AND CONNECTING HARDWARE
LAN Cables and Connecting Hardware
LAN cables and connecting hardware shall be installed in accordance with
Section 27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM and Section
33 82 00 TELECOMMUNICATIONS OUTSIDE PLANT (OSP).
3.3.2
Metering and Sensor Wiring
Metering and sensor wiring shall be installed in accordance with the
SECTION 40 95 00
Page 76
requirements of ANSI C12.1, NFPA 70, Section 33 71 02 UNDERGROUND
ELECTRICAL DISTRIBUTION and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
3.3.2.1
Power Line Surge Protection
Control panels shall be protected from power line surges.
meet the requirements of IEEE C62.41.1 and IEEE C62.41.2.
be used for surge protection.
3.3.2.2
Protection shall
Fuses shall not
Sensor and Control Wiring Surge Protection
Digital and analog inputs shall be protected against surges induced on
control and sensor wiring. Protect digital and analog outputs against
surges induced on control and sensor wiring installed outdoors and as
shown. Fuses shall not be used for surge protection. Test the inputs and
outputs in both the normal and common mode using the following two
waveforms: The first waveform shall be 10 microseconds by 1000
microseconds with a peak voltage of 1500 volts and a peak current of 60
amperes. The second waveform shall be 8 microseconds by 20 microseconds
with a peak voltage of 1000 volts and a peak current of 500 amperes.
Submit certified test results for surge protection.
3.4
SOFTWARE INSTALLATION
Load software required for an operational control system, including
databases (for points specified and shown), operational parameters, and
system, command, and application programs. Adjust, tune, debug, and
commission all software and parameters for controlled systems to assure
proper operation in accordance with the sequences of operation and database
tables.
3.5
CONTROL DRAWINGS
Control drawings, [framed, non-fading half-size in laminated plastic]
[reproducible, with corresponding CADD files] [_____], shall be provided
for equipment furnished and for interfaces to equipment at each respective
equipment location. Condensed operating instructions explaining preventive
maintenance procedures, methods of checking the system for normal safe
operation and procedures for safely starting and stopping the system
manually shall be prepared in typed form, [framed as specified for the
instrumentation and control diagrams] [reproducible, with corresponding
word processor files] [_____] and posted beside the diagrams. Diagrams and
instructions shall be submitted prior to posting. The framed instructions
shall be posted before acceptance testing of the system.
3.6
FIELD TESTING AND ADJUSTING EQUIPMENT
Provide personnel, equipment, instrumentation, and supplies necessary to
perform site testing. The Government will witness the PVT, and written
permission shall be obtained from the Government before proceeding with the
testing. Original copies of data produced, including results of each test
procedure, during PVT shall be turned over to the Government at the
conclusion of each phase of testing prior to Government approval of the
test. The test procedures shall cover actual equipment and functions
specified for the project.
3.6.1
Testing, Adjusting and Commissioning
**************************************************************************
SECTION 40 95 00
Page 77
3.6.3.3
Exclusions
The Contractor will not be held responsible for failures resulting from the
following: Outage of the main power supply in excess of the capability of
any backup power source, provided that the automatic initiation of all
backup sources was accomplished and that automatic shutdown and restart of
the control system performed as specified. Failure of a Government
furnished communications link, provided that the PLC automatically and
correctly operates in the stand-alone mode as specified, and that the
failure was not due to Contractor furnished equipment, installation, or
software. Failure of existing Government owned equipment, provided that
the failure was not due to Contractor furnished equipment, installation, or
software.
3.7
MANUFACTURERS' FIELD SERVICES
Obtain the services of a manufacturer's representative experienced in the
installation, adjustment, and operation of the equipment specified. The
representative shall supervise the installing, adjusting, and testing of
the equipment.
3.8
FIELD TRAINING
**************************************************************************
NOTE: The number of hours required to instruct a
Government representative in operation and
maintenance of the system will depend on the
complexity of the system specified. Designer is to
establish the number of hours of training based on
equipment manufacturer recommendations, system
complexity and consultation with the installation.
**************************************************************************
Field training oriented to the specific system shall be provided for
designated personnel. Furnish a copy of the training manual for each
trainee plus [two] [_____] additional copies. Manuals shall include an
agenda, the defined objectives for each lesson, and a detailed description
of the subject matter for each lesson. Furnish audiovisual equipment and
other training supplies and materials. Copies of the audiovisuals shall be
delivered with the printed training manuals. The Government reserves the
right to videotape training sessions for later use. A training day is
defined as 8 hours of classroom instruction, excluding lunchtime, Monday
through Friday, during the daytime shift in effect at the training
facility. Submit the training manual and schedule to receive approval from
the Government at least 30 days before the training.
3.8.1
Preliminary Operator Training
Prior to the start of field testing, preliminary operator training shall be
taught at the project site for [_____] consecutive training days. Upon
completion of this course, each student, using appropriate documentation,
should be able to perform elementary operations with guidance and describe
the general hardware architecture and functionality of the system. This
course shall include: general system architecture; functional operation of
the system, including workstations; operator commands; application
programs, control sequences, and control loops; database entry and
modification; reports generation; alarm reporting; diagnostics; and
historical files.
SECTION 40 95 00
Page 80
3.8.2
Additional Operator Training
Following the field testing, additional classroom training for operators
shall be taught for [_____] consecutive training days; individual
instruction sessions of [4] [_____] -hour periods in the morning (or
afternoon) of the same weekday for [_____] consecutive weeks and an
additional [_____] day classroom session for answering operator questions.
Individual instruction shall consist of "hands-on" training under the
constant monitoring of the instructor. Classroom training shall include
instruction on the specific hardware configuration of the installed control
system and specific instructions for operating the installed system.
Schedule activities during this period so that the specified amount of time
on the equipment will be available for each student. The final session
will address specific topics that the students need to discuss and to
answer questions concerning the operation of the system. Upon completion
of the course, the students should be fully proficient in system operation
and have no unanswered questions regarding operation of the installed
control system. Each student should be able to start the system, operate
the system, recover the system after a failure and describe the specific
hardware architecture and operation of the system and be fully proficient
in all system operations. Report the skill level of each student at the
end of this course.
3.8.3
Maintenance Training
**************************************************************************
NOTE: Fit training requirements to the systems.
**************************************************************************
Following the [endurance test] [_____], a minimum period of [five] [_____]
training days shall be provided by a factory representative or a qualified
Contractor trainer for [ten] [_____] designated personnel on maintenance of
the equipment. The training shall include: physical layout of each piece
of hardware, calibration procedures, preventive maintenance procedures,
schedules, troubleshooting, diagnostic procedures and repair instructions.
3.8.4
Specialized Training
**************************************************************************
NOTE: Coordinate with specifications for the unit
processes, adding or deleting parts.
**************************************************************************
Following the maintenance training, a minimum period of [five] [_____],
total training day(s) shall be provided by a factory representative or a
qualified Contractor trainer for [ten] [_____] people on the input devices.
3.8.4.1
Flow Meter Training
Each type of flow meter, to include calibration, maintenance and testing of
flow elements and transducers.
3.8.4.2
Specialized Sensor Training
Each type of specialized sensor such as [chlorine,] [turbidity,] [pH,]
[NOx,] [_____] to include calibration, maintenance and testing of sensing
elements and transducers.
SECTION 40 95 00
Page 81
2.10.2.2
Command Input Errors
The system shall supervise operator inputs to ensure they are correct for
proper execution. Operator input assistance shall be provided whenever a
command cannot be executed because of operator input errors.
2.10.2.3
Special Functions
The system shall support the following special functions by using a mouse,
in addition to all other commands specified:
2.10.2.3.1
Help
produce a display of all commands available to the operator. The help
command, followed by a specific command, shall produce context sensitive
listing with a short explanation of the purpose, use, and system reaction
to that command.
2.10.2.3.2
Start/Enable
Manually start equipment and enable monitoring and control of points.
2.10.2.3.3
Stop/Disable
Manually stop equipment and disable monitoring and control components.
2.10.2.3.4
Display Diagram
Display diagrams of specific utility systems or other systems.
2.10.2.3.5
Diagram Development
Facilitate development of diagrams of specific utility systems or other
systems.
2.10.2.3.6
Auto/Override
Override automatic operation of a point or return a point to automatic
operation.
2.10.2.3.7
Print Report
Allow the operator to print reports.
2.10.2.3.8
Confirm Action
Allow the operator to confirm that the desired command sequence has been
correctly entered and is to be executed.
2.10.2.3.9
Cancel Action
Perform the opposite function of the confirm action, at any time prior to
executing confirm action.
2.10.2.3.10
Memo Pad
Allow the operator to create, store and retrieve pop-up notes.
SECTION 40 95 00
Page 58
2.10.2.4
Operator's Commands
The operator's commands shall provide the means for entry of control and
monitoring commands, and for retrieval of information. The operator's
commands shall perform such tasks as requesting a display of any digital,
analog, or accumulator point, or any group of related points, startup and
shutdown selected systems or devices, modifying, adjusting, enabling or
defining a point or point parameters.
2.10.2.5
Level of Addressing
**************************************************************************
NOTE: When specifying level of addressing for
identification, delete Area or Facility where not
required.
**************************************************************************
Provide four levels of addressing for identification as follows:
2.10.2.5.1
Point
The individual sensor or control device within a unit.
2.10.2.5.2
Unit
The unit that a point is associated with, such as a blower.
2.10.2.5.3
Sub-System
The sub-system that a point is located in or near.
2.10.2.5.4
System
The system that a sub-system is located in or near.
2.10.2.6
System Access Control
A minimum of [_____] passwords shall be usable with the control system
software. The system shall maintain an ASCII disk file logging all
operators logged onto the system, alarm acknowledgments, commands issued
and all database modifications for each password. Each password shall be
definable as to the functions that the operator can perform.
2.10.3
Alarms
The software shall notify an operator of the occurrence of an alarm
condition. The control system alarm history shall be stored in an ASCII
file and shall be recallable by the operator using the report generator.
Alarm messages shall take precedence over other functions. A minimum of
the most recent [25] [_____] system alarms shall be directly available at
the central station computer. Operator acknowledgment of one alarm shall
not be considered as acknowledgment of any other alarm nor shall it inhibit
reporting of subsequent alarms. Alarm data to be displayed and stored
shall include: identification of the alarm; date and time to the nearest
second of occurrence; device or sensor type; limit exceeded (if analog);
engineering units; current value or status; alarm class; and alarm messages.
SECTION 40 95 00
Page 59
2.10.3.1
Digital Alarms
Digital alarms shall be subject to immediate reporting, within the alarm
response time, at the central station.
2.10.3.2
Analog Alarms
These alarms shall be subject to immediate reporting, within the alarm
response time, at the central station. The control panel analog readings
shall be compared to predefined high and low limits, and alarmed to the
central station each time a value enters or returns from a limit
condition. The program shall automatically change the high or low limits,
or both, of any analog point, based on time scheduled operations as
specified, allowing for a time interval before the new alarm limit becomes
effective. For those applications where setpoint adjustments are made, the
alarm limit shall be keyed to a finite deviation traveling with the
setpoint.
2.10.3.3
Alarm Messages
A unique message with a field of 60 characters shall be provided for each
alarm. Assignment of messages to a point shall be an operator editable
function. Secondary messages shall be assignable by the operator for
printing to provide further information, such as telephone lists or
maintenance functions, and shall be editable by the operator.
2.10.3.4
Alarm Classes
Classes of alarms, which will be identified for each item, include class 1
and class 2 alarm conditions. Class 1 (Critical) shall include display,
print, and audible alarm at occurrence and at return-to-normal.
Acknowledgment of class 1 alarms by the operator shall be required at
occurrence and at return-to-normal. Class 2 (Informational) shall include
display, print, and audible alarm at occurrence and at return-to-normal.
No acknowledgment of class 2 alarms is required unless otherwise shown.
2.10.4
Pop-up Note Function
A pop-up note function shall be included with the central station,
providing the operator a capability of noting any data which may be
associated with alarms or with any other event. A note created by an
operator shall be automatically called up when any other workstation calls
up the associated point, alarm, or alarm summary. The pop-up note function
shall also support free form entry of data which can be used by any
workstation operators as general reminders or instructions.
2.10.5
Real Time Clock Synchronization
**************************************************************************
NOTE: If real time clock synchronization is not
required, this paragraph will be deleted.
**************************************************************************
The system shall synchronize each central station computer, real time
clock, within one second and at least once per day automatically, without
operator intervention and without requiring system shutdown. The central
station computer shall automatically initiate a call once per day to the
NIST clock to obtain the correct time and date and update the real time
clock. The central station computer shall generate a report showing the
SECTION 40 95 00
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time difference.
2.10.6
System Reaction
Under system normal heavy load, no more than [10] [_____] seconds shall
lapse from the time a digital status alarm or analog alarm occurs at a PLC
until the change is displayed at the central station [and operator's
workstation]. The total system response time from initiation of a control
action command to display of the resulting status change shall not exceed
[20] [_____] seconds under system normal heavy load conditions, assuming a
zero response time for operation of the PLC's control device. The alarm
printer shall continue to print out all occurrences, including time of
occurrence, to the nearest second. All system normal heavy load conditions
shall be introduced to the system via AIs and DIs.
2.10.6.1
Occurrence
System normal heavy load conditions are defined as the occurrence
throughout the system of a total of three status changes, three digital
alarms, three analog high or low limit alarms, and three analog quantity
changes within the high and low limits during a single 1-second interval.
This number of similar occurrences shall repeat on a continuous basis
during successive 1-second intervals for a period of 2 minutes.
2.10.6.2
Location
System normal heavy load conditions, as specified, shall have 50 percent of
the changes and alarms, including no less than one of each type, occurring
at a single PLC with the remaining changes and alarms distributed among the
remaining PLCs.
2.10.7
Report Generator
Software shall be provided to generate and format standard and custom
reports for displaying, printing, and storing on disk. Reports shall use
database values and parameters, values calculated using the real time
static database or historical data base; with the reports subsequently
stored on hard disk or zip drive. Dynamic operation of the system shall
not be interrupted to generate a report. The report shall contain the time
and date when the sample was taken, and the time and date when the report
was printed.
2.10.7.1
Periodic Automatic Report
The system shall allow for specifying, modifying, or inhibiting the report
to be generated, the time the initial report is to be generated, the time
interval between reports, end of period, and the output peripheral.
2.10.7.2
Request Report Mode
The system shall allow for the operator to request, at any time, an
immediate printout of any report.
2.10.8
Data Interchange
Software shall be provided to format and store on a removable diskette the
data, trends, profiles, reports and logs as specified in a defined,
standard format such as ASCII text or DIF for export and further processing
by other software and/or computer systems.
SECTION 40 95 00
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2.10.9
Control Panel and DTS Circuit Alarms
The system shall supervise each control panel, I/O function and DTS circuit
for alarm reporting, including: control panel not responding; control panel
responding (return to normal); control panel to central station DTS circuit
high error rate; control panel to control panel DTS circuit high error
rate; control panel/central station real time clock error more than 15
seconds (adjustable); control panel intrusion alarm; control panel offline;
control panel online (return to normal); control panel failure
(self-diagnostics); point not responding to command; and point change of
state without command.
2.10.10
Central Station Database
The central station database shall be stored on disk and in memory. The
static database shall be downloadable as required to control panels in the
system.
2.10.10.1
Database Definition Process
Software shall be provided to define and modify each point in the database
using operator commands. The definition shall include all physical
parameters and constraints associated with each point. Each database item
shall be callable for display or printing, including EEPROM, ROM and RAM
resident data. Each point shall be defined and entered into central
station database.
2.10.10.2
Dynamic Database
The dynamic database includes those variables which change with time or
conditions including all DIs, AIs, PAs, and virtual (logic) points.
2.10.10.3
Dynamic Database Update
The dynamic database shall be updated from the field, allowing the operator
to select update times from 0.1 seconds to 2.0 seconds.
2.10.10.4
Static Database
The static database includes those fixed parameters and constraints from
all PLCs which define the characteristics of the system and I/O functions
such as alarm limits, start/stop times, point names, PLC channel addresses,
and sensor spans.
2.10.10.5
Central Station Static Database Update
A copy of each control panels static database shall be updated
automatically once per day, each time an authorized change is submitted or
upon demand from the central station database.
2.10.10.6
Workstation Access to Dynamic Data
Any workstation with proper access password and connected to the central
station via the DTS, or via a dial-up telephone circuit, shall have access
to the central station's dynamic data. Display of data shall commence
within 5 seconds.
SECTION 40 95 00
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2.10.11
Historical Data Storage and Retrieval
A historical data storage and retrieval function shall be provided at the
central station to collect and store dynamic data. This function shall be
in addition to other data storage requirements. The function shall have
the capability to collect and store alarm status changes, point values,
events and operator commands, and system responses. The storage function
shall also have the capability to collect and store multiple sets of analog
data at pre-specified sampling rates. This function shall have the
capability to retain historical data on hard disk for pre-specified time
periods, up to forty five days using last day roll over, for short-term
analysis, and then output the data to the zip drive for long-term
retention. The operator shall also be able to selectively recall
short-term data stored on hard disk. Retrieval and printing of the
contents of any selected historical data file shall be available using the
data retrieval and report generation program. The output of the report
generation program shall be capable of being viewed on the screen, printed
in a report, or stored.
2.10.12
Trending
Any analog or calculated point shall be operator assignable to the trend
program. Points shall be sampled at individually assigned intervals,
selectable between one minute and 24 hours. The system shall automatically
store the accumulated trend data to an ASCII disk file. The size of the
trend data file shall be limited only by available disk space. The program
shall print portions of the file as selected by the operator.
2.10.13
Analog Monitoring
The system shall measure, transmit, and display analog values, including
calculated analog points. Differential measurements shall be displayed as
positive or negative values with respect to their reference points shown.
An analog change in value is defined as a change exceeding a preset
differential value as specified. Each analog change in value shall be
operator selectable and settable to provide for a minimum reporting change
in value of one-half the specified end-to-end accuracy of the measured
variable. Displays and reports shall express analog values in proper
engineering units with sign. Provide 128 different sets of engineering
unit conversions. Each engineering conversion unit shall include range,
span, and conversion equation.
2.10.14
Analog Totalization
Any analog or calculated point shall be operator assignable to the
totalization program. The analog totalization time period shall be defined
uniquely for each point. At the end of the period, totals shall be stored
on disk for future reference. Totalization shall then restart from zero
for the next time period. The program shall keep track of the peak and
total value measured during the current period and for the previous
period.
The operator shall be able to initiate a summary of totalization
information on a point, unit, sub-system or system. The operator shall be
able to set or reset each totalized value individually. The operator shall
be able to define, modify, or delete the time period online.
2.10.15
LAN Software
A network operating system shall be supplied as part of the LAN software.
The network operating system shall support network device access to the
SECTION 40 95 00
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central station. The system shall provide workstation access to the
central station as a virtual terminal. The network shall provide network
access to shared peripherals. The LAN software shall provide for
transparent communication with any node on the system. The LAN software
shall support the following:
2.10.15.1
Access Control
Access control to the central station computer and workstations. Operators
shall be able to perform all specified functions, given the proper
passwords, including database definition/modification, graphic
creation/modification, and trending.
2.10.15.2
Multiple Sessions
Support operation in multiple sessions.
2.10.15.3
Other Functions and Configurations
Other functions and configurations shown.
2.11
DATA COMMUNICATION REQUIREMENTS
**************************************************************************
NOTE: The designer will edit the following
paragraph as needed to require only the data
communications requirements that are necessary based
on the requirements and complexity of the control
system. A communications system layout or block
diagram must be provided on the drawings to clearly
show the communications system configuration
requirements.
**************************************************************************
Control system data communications shall support the specified functions
and control system configuration shown on the drawings.
2.11.1
Central Station/Workstation
Each workstation shall be able to communicate with the central station as a
virtual terminal. The workstation shall be able to initiate uploads or
downloads of programs and resident data, including parameters of connected
systems PLCs and devices, constraints and programs in the central station.
2.11.2
Central Station/PLC
The central station shall be able to initiate an upload or download of PLC
data programs.
2.11.3
Modem Communication
**************************************************************************
NOTE: Indicate on the communications system layout
diagram, on the drawings, where modem communication
is required. Coordinate this with the central
station/workstation computer requirements.
**************************************************************************
Communication with other computer systems shall be accomplished using a
SECTION 40 95 00
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modem and dialup circuit. The central station or workstation shall be able
to initiate upload or download of data files, however, answering incoming
calls shall not be possible (for system security reasons).
2.11.4
Error Detection and Retransmission
Asynchronous transmission system shall use cyclic code error detection
methods. The predicted undetected error rate shall not exceed 1 bit in 1
billion. A message shall be in error if one bit is received incorrectly.
The system shall retransmit messages with detected errors. Where a LAN is
not utilized for data transmission, a 2-digit decimal number shall be
operator assignable to each communication link representing the number of
retransmission attempts. When the number of consecutive retransmission
attempts equals the assigned quantity, the central station shall close down
transmission to that particular device, and print an alarm message. The
operator shall manually reopen any communications line after automatic
closedown, subject to the same error checking and automatic closedown
procedures in effect before the first automatic closedown. The system
shall monitor the frequency of data transmission errors for display and
logging.
2.12
CONSUMABLE SUPPLIES
**************************************************************************
NOTE: The designer will edit the following
paragraph as needed to require only the supplies
that are necessary based on the type and quantity of
computer equipment required.
**************************************************************************
Provide the following consumable supplies, after the endurance test, to the
Government. These extraordinary supplies shall not be used during system
installation or testing.
CONSUMABLE SUPPLIES
blank zip cartridges
[10] [_____] each
diskettes 89 mm 3-1/2 inch
[2] [_____] boxes of 10 each
laser printer toner cartridges
[2] [_____] each
color printer ink cartridges
[2] [_____] per color
dot matrix printer ribbons
[2] [_____] each
color printer paper
[2] [_____] boxes
alarm printer fanfold paper
[1] [_____] box
2.13
FACTORY TEST
**************************************************************************
NOTE: Evaluate the need for factory tests. Take
into account the size of the system, the complexity
of the system, the devices that comprise the system
SECTION 40 95 00
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as well as other pertinent information. If a
factory test is deemed necessary, the factory test
requirements below shall be tailored to the control
system to be tested. If any factory test is deemed
unnecessary, delete it from the following paragraphs.
**************************************************************************
The control system shall be tested at the factory prior to shipment.
Written notification of planned testing shall be given to the Government at
least 21 days prior to testing, and in no case shall notice be given until
after the Contractor has received written Government approval of the test
procedures.
2.13.1
Factory Test Setup
**************************************************************************
NOTE: Items not applicable to the factory test
should be deleted.
**************************************************************************
Assemble and integrate the factory test setup as specified to prove that
performance of the system satisfies all requirements of this project,
including system communications requirements in accordance with the
approved test procedures. The factory test shall take place during regular
daytime working hours on weekdays. Equipment used shall be the same
equipment that is to be delivered to the site. The factory test setup
shall include the following:
Factory Test
central station equipment
one each of the components
workstation
one of each type
control panel
not less than two control panels: at least
one of each type used in the system plus
at least one per DTS type
test set
one of each type
portable tester
one of each type
communications circuits
one of each type and speed to be utilized
in the proposed system including bridges,
modems, encoder/decoders, transceivers and
repeaters
surge protection equipment
for power, communications, I/O functions
and networks
I/O functions
sufficient to demonstrate the I/O
capability and system normal operation
SECTION 40 95 00
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Factory Test
software
2.13.2
software required for proper operation of
the proposed system including application
programs and sequences of operation
Factory Test Procedure
Test procedures shall define the tests required to ensure that the system
meets technical, operational, and performance requirements. The test
procedures shall define location of tests, milestones for the tests, and
identify simulation programs, equipment, personnel, facilities, and
supplies required. Provide for testing all control system capabilities and
functions specified and shown. Ccover actual equipment and sequences to be
used for the specified project and include detailed instructions for test
setup, execution, and evaluation of test results.
The test reports shall
document results of the tests. Surge testing need not be conducted
acceptable documented proof can be provided that such testing has been
satisfactorily demonstrated to the Government with identical surge
protection applied.
The procedures shall include the following:
Test Procedure
equipment
block diagram
hardware and software
descriptions
commands
operator commands
I/O functions
test database points with failure modes
passwords
required for each operator access level
each type of digital and analog
point in the test database
description
test equipment
list
surge protection
circuit diagrams
inputs required (I/O point values
and status) and corresponding
expected results of each set of
input values
for each application program
default values
for the application program inputs not
implemented or provided for in the contract
documents for the application programs to be
tested
2.13.3
Factory Test Report
Submit original copies of data produced during the factory test, including
results of each demonstration procedure within 7 days after completion of
SECTION 40 95 00
Page 67
each test. Arrange the report so that commands, responses, and data
acquired are correlated to allow logical interpretation of the data.
PART 3
3.1
EXECUTION
EQUIPMENT INSTALLATION REQUIREMENTS
3.1.1
Installation
Install system components and appurtenances in accordance with the
manufacturer's instructions and provide necessary interconnections,
services, and adjustments required for a complete and operable system.
Adjust or replace devices not conforming to the required accuracies.
Replace factory sealed devices, rather than adjusting.
a.
Install instrumentation and communication equipment and cable grounding
as necessary to preclude ground loops, noise, and surges from adversely
affecting system operation.
b.
Install wiring in exposed areas, including low voltage wiring, in
metallic raceways or EMT conduit as specified in Section 26 20 00
INTERIOR DISTRIBUTION SYSTEM. Wiring in air plenum areas installed
without conduit shall be plenum-rated in accordance with NFPA 70.
c.
Submit detail drawings containing complete piping, wiring, schematic,
flow diagrams and any other details required to demonstrate that the
system has been coordinated and will properly function as a unit.
Piping and Instrumentation (P&ID) drawings (prepared using industry
recognized device symbols, clearly defined and describing piping
designations to define the service and materials of individual pipe
segments and instrument tags employing Instrument Society of America
suggested identifiers). Include in the Drawings, as appropriate:
product specific catalog cuts; a drawing index; a list of symbols; a
series of drawings for each control system using abbreviations,
symbols, nomenclature and identifiers as shown; valve schedules;
compressed instrument air station schematics and ASME air storage tank
certificates for each type and make of compressed instrument air
station.
3.1.1.1
Isolation, Penetrations and Clearance from Equipment
Dielectric isolation shall be provided where dissimilar metals are used for
connection and support. Penetrations through and mounting holes in the
building exteriors shall be made watertight. Holes in concrete, brick,
steel and wood walls shall be drilled or core drilled with proper
equipment; conduits installed through openings shall be sealed with
materials which are compatible with existing materials. Openings shall be
sealed with materials which meet the requirements of NFPA 70 and Section
07 84 00 FIRESTOPPING. Installation shall provide clearance for
control-system maintenance. Control system installation shall not
interfere with the clearance requirements for mechanical and electrical
system maintenance.
3.1.1.2
Device Mounting
Devices shall be installed in accordance with manufacturers'
recommendations and as shown. Control devices to be installed in piping
shall be provided with required gaskets, flanges, thermal compounds,
insulation, piping, fittings, and manual valves for shutoff, equalization,
SECTION 40 95 00
Page 68
purging, and calibration. Any deviations shall be documented and submitted
to the Government for approval prior to mounting.
Damaged insulation
shall be replaced or repaired after devices are installed to match existing
work. Damaged galvanized surfaces shall be repaired by touching up with
zinc paint.
3.1.1.3
Pneumatic Tubing
Tubing shall be concealed in finished areas. Tubing may be run exposed in
unfinished areas, such as mechanical equipment rooms. For tubing to be
enclosed in concrete, rigid metal or intermediate metal conduit shall be
provided. Tubing shall be installed parallel or perpendicular to building
walls throughout. Maximum spacing between tubing supports shall be 1.5 m 5
feet. Each tubing system shall be tested pneumatically at 1.5 times the
working pressure for 24 hours, with a maximum pressure drop of [0.15]
[_____] kPa [1.0] [_____] psig with compressed air supply turned off.
Joint leaks shall be corrected by remaking the joint. Caulking of joints
will not be permitted. Tubing and two insulated copper phone wires for
installation checkout may be run in the same conduit.
Tubing and
electrical power conductors shall not be run in the same conduit; however,
control circuit conductors may be run in the same conduit as polyethylene
tubing.
3.1.1.4
Grooved Mechanical Joints
Grooves shall be prepared according to the coupling manufacturer's
instructions. Grooved fittings, couplings, and grooving tools shall be the
products of the same manufacturer. Pipe and groove dimensions shall comply
with the tolerances specified by the coupling manufacturer. The diameter
of grooves made in the field shall be measured using a "go/no-go" gauge,
vernier or dial caliper, narrow-land micrometer, or other method
specifically approved by the coupling manufacturer for the intended
application. Groove width and dimension of groove from end of pipe shall
be measured and recorded.
3.1.2
Sequences of Operation
Study the operation and sequence of local equipment controls, as a part of
the conditions report, and note any deviations from the described sequences
of operation on the contract drawings. Perform necessary adjustments to
make the equipment operate in an optimum manner and shall fully document
changes made.
3.2
INSTALLATION OF EQUIPMENT
Install equipment as specified, as shown and as required in the
manufacturer's instructions for a complete and fully operational control
system.
3.2.1
Control Panels
Control panels shall be located as indicated on the drawings. Devices
located in the control panels shall be as shown on the drawings or as
needed to provide the indicated control sequences.
3.2.2
Flow Measuring Device
Fluid flow instruments shall be installed in accordance with manufacturer's
recommendations, unless otherwise indicated in the specification. The
SECTION 40 95 00
Page 69
minimum straight unobstructed piping for the flowmeter installation shall
be 10.0 pipe diameters upstream and 5.0 pipe diameters downstream. Meters
for gases and vapors shall be installed in vertical piping, and meters for
liquids shall be installed in horizontal piping, unless otherwise
recommended by the manufacturer or indicated in the specifications.
3.2.2.1
Flow Nozzle
Flow nozzles flanges shall be installed so that the pressure taps are in a
horizontal plane with the centerline of the pipe. Flow nozzles shall be
installed for ease of accessibility for periodic maintenance. Differential
pressure sensors shall be installed as close to the flow nozzle as possible.
3.2.2.2
Flow Switch
Flow switches shall be installed in such a manner as to minimize
disturbance of the flow of fluid while maintaining reliable operation of
the switch.
3.2.2.3
Magnetic Flowmeter
**************************************************************************
NOTE: Locating magnetic flowmeters near large
electric motors or transformers should be avoided.
**************************************************************************
Meter shall be installed in vertical piping so that the flow tube remains
full of the process fluid under all operating conditions. A minimum of
five pipe diameters straight run upstream of the flowmeter and two pipe
diameters straight run downstream of the flowmeter shall be provided.
3.2.2.4
Natural Gas or Propane Flowmeter
Meters shall be installed in accordance with ASME B31.8. Permanent gas
meters shall be installed with provisions for isolation and removal for
calibration and maintenance, and shall be suitable for operation in
conjunction with an energy monitoring and control system.
3.2.2.5
Orifice Plates
Orifice plates shall be installed for ease of accessibility for periodic
maintenance. Differential pressure sensors shall be as close to the
orifice plates as possible. Orifice plates for liquid measurement shall be
located in horizontal pipe runs with the orifice plate flanges installed so
that the pressure taps are in the horizontal plane with the centerline of
the pipe. For liquid, the differential pressure transmitter shall be
installed below the orifice taps. For gas measurement, the orifice plate
flanges shall be installed so that the pressure taps are 45 degrees or more
above the horizontal plane with the centerline of the pipe. For gas
measurement the required differential pressure transmitter shall be
physically installed above the orifice taps.
3.2.2.6
Paddle Flowmeter
Meter shall be installed using manufacturer's published procedures.
Installers shall be trained for such installations in the pipes
encountered. Provide certificates demonstrating installer's qualifications.
SECTION 40 95 00
Page 70
3.2.2.7
Annular Pitot Tubes
Annular pitot tubes shall be installed so that the total head pressure
ports are set-in-line with the pipe axis upstream and the static port
facing downstream. The total head pressure ports shall extend
diametrically across the entire pipe. Annular pitot tubes shall not be
used where the flow is pulsating or where pipe vibration is allowed.
3.2.2.8
Positive Displacement Flow Meters
Flow meters shall be installed horizontally, and aligned correctly in the
direction of flow.
3.2.2.9
Turbine Meters
Turbine meters shall be installed so that the sensor is located in the
center of the fluid flow pipe on the main axis. The minimum straight
unobstructed piping for the flow meter installation shall be 10 pipe
diameters upstream and 5 pipe diameters downstream.
3.2.2.10
Insertion Turbine Flowmeters
Turbine meters shall be installed without interruption to service. Install
a welded flanged riser of appropriate pipe line rating, with a full opening
valve bolted to it. Sensor shall be located in accordance with the
manufacturer's instructions for the specified flow rates and installation
conditions. Reduced diameter pipe sections shall be provided as necessary
to achieve required flow velocities. Meters shall be installed using the
hot-tap method with tools recommended by the manufacturer. The minimum
straight unobstructed piping for the flow meter installation shall be 10
pipe diameters upstream and 5 pipe diameters downstream.
3.2.2.11
Ultrasonic Flowmeter
Meter shall be installed using manufacturer's published procedures for
installation. Installers shall be trained for such installations in the
pipes encountered. Provide certificates demonstrating installer's
qualifications.
3.2.2.12
Variable Area Flowmeter
Meters shall be installed in a vertical piping section with full flow
through the meter.
3.2.2.13
Venturi Flowmeter
The flowmeter shall be installed with its top above the pipeline in
horizontal pipe run installations. The direction of flow shall be upward
in vertical pipe run installations. The flowmeter shall be aligned to the
direction of the flow and shall be rigidly mounted and vibration free. The
minimum straight unobstructed piping for the flow meter installation shall
be 10 pipe diameters upstream and 5 pipe diameters downstream.
3.2.2.14
Vortex Shedding Flowmeters
The flowmeter shall be installed with its top above the pipeline in
horizontal pipe run installations. The direction of flow shall be upward
in vertical pipe run installations. The flowmeter shall be aligned to the
direction of the flow and shall be rigidly mounted and vibration free. The
SECTION 40 95 00
Page 71
minimum straight unobstructed piping for the flow meter installation shall
be 10 pipe diameters upstream and 5 pipe diameters downstream.
3.2.3
3.2.3.1
Level Instruments
Liquid Level Sensor (Bubble Type)
The air pressure regulating valve, air filter, moisture trap, air flow
adjustment valve, level gauge, air isolation valve and pressure transducer
shall be mounted on a panel where indicated on the drawings. The level
gauge shall be labeled to identify the tank being measured. The isolation
valve shall be located in the air supply line upstream of the moisture
trap, air filter and pressure regulator. The air inlet line to the dip
tube and the dip tube shall be mounted to a flange at the top of the
tank.
The dip tube shall extend to the bottom of the tank, leaving the
manufacturer's recommended clearance between the dip tube and tank
bottom.
The dip tube material shall be compatible with the tank
contents. The pressure regulating valve shall be adjusted to the outlet
pressure recommended by the manufacturer. Where exposed, the air supply
line to the tank and from the tank to the level gauge and pressure
transducer shall be protected from damage.
3.2.3.2
Capacitance Liquid Level Sensors
The sensing probes shall be located close to, and parallel with, the tank
or sump wall.
3.2.3.3
Conductivity Switch
Level switches shall be installed vertically and in accordance with the
manufacturer's instructions. Switches shall be accessible for maintenance
and calibration. In applications where switches cannot be directly mounted
to a tank by the threaded or flanged connection, a mounting bracket shall
be provided for connection to the inside tank wall, maintaining the minimum
recommended distance from the tank fill opening.
3.2.3.4
Displacement Type Liquid Level Switch
Level switches shall be installed in accordance with the manufacturer's
instructions. Switches shall be accessible for maintenance and
calibration. In applications where switches cannot be directly mounted to
a tank by the threaded or flanged connection, a mounting bracket shall be
provided for connection to the inside tank wall.
3.2.3.5
Mercury Float Switches
Switches shall be mounted in accordance with manufacturer's published
instructions. Procedures shall be those used for equipment in hazardous
locations.
3.2.3.6
Ultrasonic Sensor
Sensor shall be installed vertically in the top of the tank and in
accordance with the manufacturer's instructions. Switches shall be
accessible for maintenance and calibration. In applications where switches
cannot be directly mounted to a tank by the threaded or flanged connection,
a mounting bracket shall be provided for connection to the inside tank
wall. Sensor shall be positioned to maximize the return echo signal and
minimize vessel obstructions in the sensors line of sight. The minimum
SECTION 40 95 00
Page 72
recommended distance from the tank fill opening and from the side of the
tank shall be maintained .
3.2.4
Pressure Instruments
**************************************************************************
NOTE: Do not use differential pressure switches on
liquid pumps. Gage pressure switches are better
suited for liquid application. Indicate by
appropriate icon on the drawings where the switches
are to be located and which type is to be used.
**************************************************************************
Pressure sensors and pressure transducers shall be verified by
calibration. All pressure taps shall incorporate appropriate snubbers.
Pressure sensors and pressure switches shall have valves for isolation,
venting, and taps for calibration. Pressure switches and pressure
transducers installed on liquid or steam lines shall have drains. Pressure
transducers, differential pressure sensors and differential pressure
switches shall have nulling valves. Pressure switches shall be adjusted to
the proper setpoint and shall be verified by calibration. Switch contact
ratings and duty shall be selected for the application.
3.2.5
3.2.5.1
Temperature Instrument Installation
RTD
[When the RTD is installed in pipe or is susceptible to corrosion or
vibration, the] [Each] RTD shall be installed in a thermowell. Thermowells
shall be filled with conductive heat transfer fluid prior to installation
of the RTD in the thermowell. RTDs used for space temperature sensing
shall include a housing suitable for wall mounting. RTDs used for outside
air sensing shall have an instrument shelter or sun shield as shown to
minimize solar effects, and shall be mounted to minimize building
effects.
RTD assemblies shall be readily accessible and installed to
allow easy replacement.
3.2.5.2
Temperature Switches
Temperature switches shall be installed as specified for RTDs. Temperature
switches shall be adjusted to the proper setpoint and shall be verified by
calibration. Switch contact ratings and duty shall be selected for the
application.
3.2.5.3
Thermometers and Temperature Sensing Elements
Thermometers and temperature sensing elements installed in liquid systems
shall be installed in thermowells.
3.2.5.4
Thermocouples
Each thermocouple shall be installed in a protective tube or in a
thermowell. Thermocouples shall be insulated from ambient temperature
effects. Thermocouple wires shall not be installed in the same conduits as
power wiring. Thermocouples shall not be used for measuring temperatures
below 260 degrees C 500 degrees F. Type E thermocouples may be used when
the atmosphere is chemically reducing environment. Type K thermocouples
may be used when the atmosphere is a chemically oxidizing environment.
SECTION 40 95 00
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3.2.6
3.2.6.1
Process Analytical Instrumentation
Ammonia Monitor
The controller shall be located as shown on the drawings. The ammonia
sensor shall be mounted as recommended by the manufacturer. The location
of the sensor shall be representative of the area to be monitored and shall
allow access to the sensor for periodic calibration. The sensor shall be
located in a dry area or shall be protected from moisture without
restricting the flow of ammonia gas to the sensor.
3.2.6.2
Carbon Dioxide Measurement
The controller shall be located in the control panel or other location as
shown on the drawings. Where a sample tube is used, the size and maximum
length of sample tubing shall be as recommended by the manufacturer.
Sample tubing shall be not crimped or kinked.
3.2.6.3
Carbon Monoxide Measurement
Carbon monoxide controller and sensor shall be located as shown on the
drawings or as recommended by the manufacturer. The location shall be
representative of the area to be monitored. Installation shall be in
accordance with the manufacturer's instructions.
3.2.6.4
Chlorine in Air
The controller shall be located in the control panel or other location as
shown on the drawings. Where a sample tube is used, the size and maximum
length shall be a recommended by the manufacturer. The sample tube shall
not be crimped or kinked. The location of the [controller] [sample tube
inlet] shall be near the bottom of the area to be monitored.
3.2.6.5
Chlorine in Water
The controller shall be located in the control panel or other location as
shown on the drawings. The chlorine sensor shall be immersed in the fluid
being monitored using an assembly that will allow removal of the sensor
from the water. The sensors hall be located in an area of continuous flow.
3.2.6.6
Combustible Gas Sensor
The sensor and transmitter shall be located as shown or the drawings or as
recommended by the manufacturer. The location of the sensor shall be
representative of the area to be monitored and shall allow access to the
sensor for periodic replacement.
3.2.6.7
Hydrogen Sulfide
The controller shall
by the manufacturer.
maximum length shall
shall not be crimped
tube inlet] shall be
3.2.6.8
be located as shown on the drawings or as recommended
Where a sample tube is used, the tube size and
be a recommended by the manufacturer. The sample tube
or kinked. The location of the [controller] [sample
representative of the area to be monitored.
NOx Monitor
The controller shall be mounted in the control panel or as otherwise
shown.
Sensor shall be located in the flue as shown and in accordance
SECTION 40 95 00
Page 74
with the manufacturer's recommendation.
leakage of flue gases at the sensor.
3.2.6.9
Installation shall prevent all
Oxygen and Ozone in Air Monitor
The controller shall be mounted in the control panel or as otherwise shown
on the drawings. The oxygen sensor shall be located in accordance with the
manufacturer's recommendations and as shown on the drawings. High and low
alarm settings shall be set as required by the sequence of control.
Settings shall be verified through the use of a manufacturer's standard
calibration kit.
3.2.6.10
Dissolved Oxygen
The dissolved oxygen sensor shall be immersed in the fluid to be monitored
using manufacturer's mounting assembly. The sensor shall be located in an
area of continuous fluid flow. The transmitter shall be located remote
from the sensor. The transmitter and wiring connections shall be in a
weathertight enclosure. [The transmitter shall be mounted to allow the
digital readout to be easily viewed.]
3.2.6.11
PH and ORP Sensor
Pipe mounted flow sensor shall be located in a threaded tee or fitting to
allow removal from the pipe. Submersible sensor shall be completely
immersed in the fluid being monitored using an ensemble that will allow for
removal of the sensor from the fluid for replacement. The sensor shall be
located in an area of continuous flow. The transmitter shall be located
[at the sensor] [remote from the sensor]. [The transmitter shall be
mounted to allow the digital readout to be easily viewed].
3.2.6.12
Total Dissolved Solids
The sensor shall be [pipe] [tank] [submersible] type as indicated on the
drawings. [Pipe mounted sensor shall be mounted in a threaded tee or
fitting to allow removal of the sensor.] [Tank mounted sensor shall be
mounted in a threaded fitting to allow removal of the sensor.] [Submersible
sensor shall be mounted in an assembly that will allow removal of the
sensor from the fluid for replacement.] The transmitter shall be located
[at the sensor] [remote from the sensor]. The transmitter and wiring
connections shall be located in a weathertight enclosure.
3.2.7
Instrument Shelters
Instrument shelters shall be installed in the location shown with the bottom
1.2 meter 4.0 feet above the supporting surface using legs and secured
rigidly to minimize vibrations from winds. Instrument shelters shall be
oriented with door facing North. Instruments located in shelters shall be
mounted in the 3-dimensional center of the open space of the shelter.
3.2.8
3.2.8.1
Electric Power Devices
Potential and Current Transformers
Install potential and current transformers in enclosures unless otherwise
shown. Current transformer leads shall be shorted when they are not
connected to the measurement circuits.
SECTION 40 95 00
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3.2.8.2
Hour Meters
Meters shall be located in the control panel or as otherwise shown. Power
to the meter shall be connected to the motor starter auxiliary contacts for
pumps, blowers and other motor driven devices. For devices without motor
starters, the meter shall be connected in parallel with the load. Where
the meter voltage differs from the metered devices voltage, transformer
shall be provided as necessary.
3.2.8.3
Watt-hour Meters
Install watt-hour meters and transducers in enclosures unless otherwise
shown.
3.2.8.4
Transducers
Transducers shall be wired in accordance with the manufacturer's
instructions, and installed in enclosures.
3.2.8.5
Current Sensing Relays and Current Transducers for Motors
When used to sense meter/fan/pump status, current sensing relays shall be
used for applications under 4 kW 5 hp. Applications over 4 kW 5 hp shall
use a current transducer.
3.2.9
Output Devices
Output devices (transducers, relays, contactors, or other devices) which
are not an integral part of the control panel, shall be mounted in an
enclosure mounted adjacent to the control panel, unless otherwise shown.
Where H-O-A and/or override switches on the drawings or required by the
control sequence, the switches shall be installed so that the control
system controls the function through the automatic position and other
controls work through the hand position.
3.2.10
Enclosures
All enclosure penetrations shall be from the bottom of the enclosure, and
shall be sealed to preclude entry of water using a silicone rubber sealant.
3.2.11
Transformers
Transformers for control voltages below 120 vAc shall be fed from the
nearest power panel or motor control center, using circuits provided for
the purpose. Provide a disconnect switch on the primary side and a fuse on
the secondary side. Transformers shall be enclosed in a steel cabinet with
conduit connections.
3.3
3.3.1
WIRE, CABLE AND CONNECTING HARDWARE
LAN Cables and Connecting Hardware
LAN cables and connecting hardware shall be installed in accordance with
Section 27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM and Section
33 82 00 TELECOMMUNICATIONS OUTSIDE PLANT (OSP).
3.3.2
Metering and Sensor Wiring
Metering and sensor wiring shall be installed in accordance with the
SECTION 40 95 00
Page 76
requirements of ANSI C12.1, NFPA 70, Section 33 71 02 UNDERGROUND
ELECTRICAL DISTRIBUTION and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
3.3.2.1
Power Line Surge Protection
Control panels shall be protected from power line surges.
meet the requirements of IEEE C62.41.1 and IEEE C62.41.2.
be used for surge protection.
3.3.2.2
Protection shall
Fuses shall not
Sensor and Control Wiring Surge Protection
Digital and analog inputs shall be protected against surges induced on
control and sensor wiring. Protect digital and analog outputs against
surges induced on control and sensor wiring installed outdoors and as
shown. Fuses shall not be used for surge protection. Test the inputs and
outputs in both the normal and common mode using the following two
waveforms: The first waveform shall be 10 microseconds by 1000
microseconds with a peak voltage of 1500 volts and a peak current of 60
amperes. The second waveform shall be 8 microseconds by 20 microseconds
with a peak voltage of 1000 volts and a peak current of 500 amperes.
Submit certified test results for surge protection.
3.4
SOFTWARE INSTALLATION
Load software required for an operational control system, including
databases (for points specified and shown), operational parameters, and
system, command, and application programs. Adjust, tune, debug, and
commission all software and parameters for controlled systems to assure
proper operation in accordance with the sequences of operation and database
tables.
3.5
CONTROL DRAWINGS
Control drawings, [framed, non-fading half-size in laminated plastic]
[reproducible, with corresponding CADD files] [_____], shall be provided
for equipment furnished and for interfaces to equipment at each respective
equipment location. Condensed operating instructions explaining preventive
maintenance procedures, methods of checking the system for normal safe
operation and procedures for safely starting and stopping the system
manually shall be prepared in typed form, [framed as specified for the
instrumentation and control diagrams] [reproducible, with corresponding
word processor files] [_____] and posted beside the diagrams. Diagrams and
instructions shall be submitted prior to posting. The framed instructions
shall be posted before acceptance testing of the system.
3.6
FIELD TESTING AND ADJUSTING EQUIPMENT
Provide personnel, equipment, instrumentation, and supplies necessary to
perform site testing. The Government will witness the PVT, and written
permission shall be obtained from the Government before proceeding with the
testing. Original copies of data produced, including results of each test
procedure, during PVT shall be turned over to the Government at the
conclusion of each phase of testing prior to Government approval of the
test. The test procedures shall cover actual equipment and functions
specified for the project.
3.6.1
Testing, Adjusting and Commissioning
**************************************************************************
SECTION 40 95 00
Page 77
NOTE: Delete reference to a factory test if no
factory test is to be required.
**************************************************************************
After successful completion of the factory test as specified, the
Contractor will be authorized to proceed with the installation of the
system equipment, hardware, and software. Once the installation has been
completed, test, adjust, and commission each control loop and system in
accordance with NIST SP 250 and shall verify proper operation of each item
in the sequences of operation, including hardware and software. Calibrate
field equipment, including control devices, adjust control parameters and
logic (virtual) points including control loop setpoints, gain constants,
constraints, and verify data communications before the system is placed
online. Test installed ground rods as specified in IEEE 142 and submit
certification stating that the test was performed in accordance with
IEEE 142. Calibrate each instrumentation device connected to the control
system control network by making a comparison between the reading at the
device and the display at the workstation, using a standard at least twice
as accurate as the device to be calibrated. Check each control point
within the control system control network by making a comparison between
the control command at the central station and field-controlled device.
Deliver trend logs/graphs of all points showing to the Government that
stable control has been achieved. Points on common systems shall be
trended simultaneously. One log shall be provided showing concurrent
samples taken once a minute for a total of [4] [_____] hours. One log
shall be provided showing concurrent samples taken once every 30 minutes,
for a total of [24] [_____] hours. Verify operation of systems in the
specified failure modes upon Control system network failure or loss of
power, and verify that systems return to control system control
automatically upon a resumption of control system network operation or
return of power. Deliver a report describing results of functional tests,
diagnostics, calibrations and commissioning procedures including written
certification to the Government that the installed complete system has been
calibrated, tested, adjusted and commissioned and is ready to begin the
PVT. The report shall also include a copy of the approved PVT procedure.
3.6.2
Performance Verification Test (PVT)
Submit test procedures for the PVT. The test procedure shall describe all
tests to be performed and other pertinent information such as specialized
test equipment required and the length of the PVT. The test procedures
shall explain, in detail, step-by-step actions and the expected results, to
demonstrate compliance with all the requirements of the drawings and this
specification. The test procedure shall be site specific and based on the
inputs and outputs, required calculated points and the sequence of
control. 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.
Demonstrate that the completed Control system complies with the contract
requirements. All physical and functional requirements of the project
including communication requirements shall be demonstrated and shown.
Demonstrate that each system operates as required in the sequence of
operation. The PVT as specified shall not be started until after receipt
of written permission by the Government, based on the written report
including certification of successful completion of testing, adjusting and
commissioning as specified, and upon successful completion of training as
SECTION 40 95 00
Page 78
specified. Upon successful completion of the PVT, furnish test reports and
other documentation.
3.6.3
Endurance Test
Use the endurance test to demonstrate the overall system reliability of the
completed system. The endurance test shall be conducted in phases. The
endurance test shall not be started until the Government notifies the
Contractor in writing that the PVT is satisfactorily completed, training as
specified has been completed, outstanding deficiencies have been
satisfactorily corrected, and that the Contractor has permission to start
the endurance test. Provide an operator to man the system 8 hours per day
during daytime operations, including weekends and holidays, during Phase I
endurance testing, in addition to any Government personnel that may be made
available. The Government may terminate testing at any time when the
system fails to perform as specified. Upon termination of testing by the
Government or by the Contractor, commence an assessment period as described
for Phase II. Upon successful completion of the endurance test, deliver
test reports and other documentation, as specified, to the Government prior
to acceptance of the system.
3.6.3.1
Phase I (Testing)
**************************************************************************
NOTE: The designer will determine the required
Phase I testing period. The testing period should
be based on the system size and complexity.
**************************************************************************
The test shall be conducted 24 hours per day, 7 days per week, for [_____]
consecutive calendar days, including holidays, and the system shall operate
as specified. Make no repairs during this phase of testing unless
authorized by the Government in writing.
3.6.3.2
Phase II (Assessment)
After the conclusion of Phase I, identify failures, determine causes of
failures, repair failures, and deliver a written report to the Government.
The report shall explain in detail the nature of each failure, corrective
action taken, results of tests performed, and shall recommend the point at
which testing should be resumed. After delivering the written report,
convene a test review meeting at the job site to present the results and
recommendations to the Government. The meeting shall not be scheduled
earlier than 5 business days after receipt of the report by the
Government. As a part of this test review meeting, demonstrate that
failures have been corrected by performing appropriate portions of the
performance verification test. [The Government reserves the right to
cancel the test review meeting if no failures or deficiencies occur during
the Phase I testing. If the Government chooses to do so, the Contractor
will be notified in writing.] Based on the Contractor's report and the test
review meeting, the Government will determine if retesting is necessary and
the restart point. The Government reserves the right to require that the
Phase I test be totally or partially rerun. Do not commence any required
retesting until after receipt of written notification by the Government.
After the conclusion of any retesting which the Government may require, the
Phase II assessment shall be repeated as if Phase I had just been completed.
SECTION 40 95 00
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3.6.3.3
Exclusions
The Contractor will not be held responsible for failures resulting from the
following: Outage of the main power supply in excess of the capability of
any backup power source, provided that the automatic initiation of all
backup sources was accomplished and that automatic shutdown and restart of
the control system performed as specified. Failure of a Government
furnished communications link, provided that the PLC automatically and
correctly operates in the stand-alone mode as specified, and that the
failure was not due to Contractor furnished equipment, installation, or
software. Failure of existing Government owned equipment, provided that
the failure was not due to Contractor furnished equipment, installation, or
software.
3.7
MANUFACTURERS' FIELD SERVICES
Obtain the services of a manufacturer's representative experienced in the
installation, adjustment, and operation of the equipment specified. The
representative shall supervise the installing, adjusting, and testing of
the equipment.
3.8
FIELD TRAINING
**************************************************************************
NOTE: The number of hours required to instruct a
Government representative in operation and
maintenance of the system will depend on the
complexity of the system specified. Designer is to
establish the number of hours of training based on
equipment manufacturer recommendations, system
complexity and consultation with the installation.
**************************************************************************
Field training oriented to the specific system shall be provided for
designated personnel. Furnish a copy of the training manual for each
trainee plus [two] [_____] additional copies. Manuals shall include an
agenda, the defined objectives for each lesson, and a detailed description
of the subject matter for each lesson. Furnish audiovisual equipment and
other training supplies and materials. Copies of the audiovisuals shall be
delivered with the printed training manuals. The Government reserves the
right to videotape training sessions for later use. A training day is
defined as 8 hours of classroom instruction, excluding lunchtime, Monday
through Friday, during the daytime shift in effect at the training
facility. Submit the training manual and schedule to receive approval from
the Government at least 30 days before the training.
3.8.1
Preliminary Operator Training
Prior to the start of field testing, preliminary operator training shall be
taught at the project site for [_____] consecutive training days. Upon
completion of this course, each student, using appropriate documentation,
should be able to perform elementary operations with guidance and describe
the general hardware architecture and functionality of the system. This
course shall include: general system architecture; functional operation of
the system, including workstations; operator commands; application
programs, control sequences, and control loops; database entry and
modification; reports generation; alarm reporting; diagnostics; and
historical files.
SECTION 40 95 00
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3.8.2
Additional Operator Training
Following the field testing, additional classroom training for operators
shall be taught for [_____] consecutive training days; individual
instruction sessions of [4] [_____] -hour periods in the morning (or
afternoon) of the same weekday for [_____] consecutive weeks and an
additional [_____] day classroom session for answering operator questions.
Individual instruction shall consist of "hands-on" training under the
constant monitoring of the instructor. Classroom training shall include
instruction on the specific hardware configuration of the installed control
system and specific instructions for operating the installed system.
Schedule activities during this period so that the specified amount of time
on the equipment will be available for each student. The final session
will address specific topics that the students need to discuss and to
answer questions concerning the operation of the system. Upon completion
of the course, the students should be fully proficient in system operation
and have no unanswered questions regarding operation of the installed
control system. Each student should be able to start the system, operate
the system, recover the system after a failure and describe the specific
hardware architecture and operation of the system and be fully proficient
in all system operations. Report the skill level of each student at the
end of this course.
3.8.3
Maintenance Training
**************************************************************************
NOTE: Fit training requirements to the systems.
**************************************************************************
Following the [endurance test] [_____], a minimum period of [five] [_____]
training days shall be provided by a factory representative or a qualified
Contractor trainer for [ten] [_____] designated personnel on maintenance of
the equipment. The training shall include: physical layout of each piece
of hardware, calibration procedures, preventive maintenance procedures,
schedules, troubleshooting, diagnostic procedures and repair instructions.
3.8.4
Specialized Training
**************************************************************************
NOTE: Coordinate with specifications for the unit
processes, adding or deleting parts.
**************************************************************************
Following the maintenance training, a minimum period of [five] [_____],
total training day(s) shall be provided by a factory representative or a
qualified Contractor trainer for [ten] [_____] people on the input devices.
3.8.4.1
Flow Meter Training
Each type of flow meter, to include calibration, maintenance and testing of
flow elements and transducers.
3.8.4.2
Specialized Sensor Training
Each type of specialized sensor such as [chlorine,] [turbidity,] [pH,]
[NOx,] [_____] to include calibration, maintenance and testing of sensing
elements and transducers.
SECTION 40 95 00
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3.9
OPERATION AND MAINTENANCE DATA REQUIREMENTS
Outline 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.
List routine maintenance procedures, possible breakdowns and repairs and
trouble shooting guides.
-- End of Section --
SECTION 40 95 00
Page 82
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