SECTION PROCESS INSTRUMENTATION AND CONTROL SYSTEM PROGRAMMABLE LOGIC CONTROLLERS

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1 SECTION PROCESS INSTRUMENTATION AND CONTROL SYSTEM PROGRAMMABLE LOGIC CONTROLLERS PART 1 - GENERAL 1.01 WORK INCLUDED A. This Section covers work related to the Programmable Logic Controllers (PLC) of the PICS, and supplements the requirements of Section 11300, Process Instrumentation and Control System PLC NETWORK OVERVIEW A. The PLC network is based on the use of programmable logic controllers (PLC). An individual programmable logic controller is referred to as a PLC, followed by the PLCs identification number. B. Included in the PLC hardware are the PLC processors, I/O modules, network interface module and data hiway adapters, network data hiway lines, loader/monitors, remote I/O interface modules, monitor workstations, programming devices, and ancillary devices. Programmable logic controllers and their I/O are located in the process monitoring/control system panel (LCP). C. The PLCs shall be used for data acquisition and control and shall provide automatic sequencing and discrete control of selected process equipment as shown on the Drawings and shall function as the distributed I/O for the plant wide computer monitoring system DESIGN RELATED SUBMITTALS A. Hardware: Provide the following for all elements of the PLCs: 1. Block Diagram: A diagram showing all major PLC components. Identify components by manufacturer and model number. Show interconnecting cables diagrammatically (by type and size). 2. Bill of Materials: A list of all PLC components. Group components by type and include: a. Block Diagram: A diagram showing all major PLC components. Identify components by manufacturer and model number. Show interconnecting cables diagrammatically (by type and size). b. Bill of Materials: A list of all PLC components. Group components by type and include: a. Component manufacturer, model number, and part number. b. Component description

2 B. Software: c. Quantity supplied. d. Reference to component catalog information. c. Descriptive Information: Catalog information, descriptive literature, performance specifications, internal wiring diagrams, power and grounding requirements, power consumption, and heat dissipation of all elements of the PLCs. Clearly mark all options and features proposed for this project. d. Network Interface Wiring Diagrams: Show all PLC elements, their interconnecting cables and I/O wiring terminations, and all terminations to all interacting elements. Terminations shall be numbered. These Drawings shall supplement and be coordinated with the control panel wiring diagrams submitted under Section e. Shop Drawings: Equipment installation drawings showing external dimensions, enclosure material and spacing, mounting connections, and installation requirements. f. Installation Details: Any modifications or further details as may be required to supplement the Contract Documents and adequately define the installation of the PLC elements. g. Input/Output List: For each I/O point list type (input/output, discrete/analog), tag number or description of the source or final control element, equipment description, PLC number, PLC terminal identification, and PLC address. 1. Software Design Submittal: This submittal shall be a detailed description the PLC program. Submit this material during the program development stage. This submittal shall be reviewed for approval by the Engineer prior to the submittal of the Software Documentation. a. Program Description: A written overview description of each ladder or written logic program. These descriptions shall lead the user through the major subsections of the programs. They shall generally describe the programming methods and techniques that were used to implement the functional requirements of this Specification. b. Ladder Diagram Logic Listings: Each element (input, output, or special function block) shall have a 15 character minimum description. Ladder rungs shall have comments that describe the function of the rungs. Provide up to character comment lines per ladder rung. Provide complete ladder diagram logic listings. Provide the following additional information integral to the ladder listings to document the PLC programs: 1) I/O Point Cross Reference List: Each input and output shall be capable of being given up to a 27 character alphanumeric functional

3 identification that is printed above the respective input or output in the program listing. For each I/O point, the cross reference shall indicate each rung number where the point is used. 2) Internal Coil Cross Reference List: Each coil shall be capable of being given a 27 character alphanumeric function identification that is printed above the respective coil and all of its contacts in the program listing. For each coil, the cross reference shall indicate each rung number where the respective coil or contact is used. 3) Data Register Cross Reference List: For each register this list shall show the locations in the program where the register is used. 4) A listing of all programmed special functions, including memory locations used and location in the program where the special functions can be found. Function descriptions shall also be shown in the special function printout for all pertinent memory locations used in each special function. Programmed values of all memory locations used shall also be shown. 5) Timers, counters, integer add and subtract, move, PID function block, alternator counters, master control relay, and jump functions shall show all memory locations used and their programmed values. c. Variable data memory storage record, indicating the memory location and description of the variable data; i.e., tag number, timer number, counter number. C. Software Documentation: Provide this submittal at least 4 weeks prior to the witnessed Shop Tests. Provide a fully detailed version of all the software developed for the PLCs OPERATION AND MAINTENANCE MANUALS A. Hardware: Provide the following: 1. Updated versions of all material submitted previously with all corrections and revisions made. 2. Component Manufacturers' O&M Manuals: Include manuals to cover installation, operation, maintenance, troubleshooting, and calibration. 3. List of spare parts and expendables provided and list of spare parts recommended, with manufacturer's current price of each item. B. Software: Provide the following: 1. Programming Manuals: Component manufacturers' standard programming manuals, including communications software

4 1.05 RECORD DRAWINGS 2. Software Documentation: Provide a final version of all the software development of the PLCs. Provide both a hard copy of the documentation plus two backup sets of 3 memory stick file copies. A. Provide record drawings of the PLC software ladder logic and the hardware configuration layout as specified in Section RESPONSIBILITIES A. MANUFACTURER 1. The manufacturer shall provide the computer system, programmable logic controller(s), power supply, I/O modules, chassis, operator interface, communication wiring, uninterruptible power supplies, warranty programming guides, and system support. 2. The manufacturer must be approved by the Engineer of Record. B. SYSTEMS INTEGRATOR 1. The systems integrator shall obtain the necessary equipment containing microprocessors from an approved manufacturer and shall assemble the control system. 2. The systems integrator shall provide the control, monitoring, and reporting programs to operate the facilities as indicated. 3. The systems integrator shall direct the contractor as to the support needs; i.e. power requirements, control wiring, panel installation, and specials. C. STARTUP AND FIELD SERVICE 1. The systems integrator shall be responsible for verifying all control connections and the system is de-bugged prior to placing the system into service. Startup shall include operator interface, reports, O & M manuals, and Management Program. 2. The systems integrator shall include in his price the services of a competent field technician for a period of not less than 4 trips and 10 days. This service shall be for the purpose of commissioning the system, initial startup, certification, and instruction of treatment plant personnel. 3. A follow up trip and two days training shall be completed at three months. 4. A follow up trip and two days training shall be completed at six months. 5. A follow up trip and two days training shall be completed at one year

5 6. Start Up Report D. WARRANTY PART 2 - PRODUCTS 2.01 GENERAL a. A written report covering the systems integrator s field service technician s findings and installation approval shall be submitted to the engineer covering all inspections, and outlining in detail all deficiencies that were noted. b. The deficiencies noted in the report shall be corrected by the systems integrator or to the system integrator s satisfaction and so noted. 1. The warranty shall cover all parts, materials, labor, programming, O&M manual documentation revisions, and site visits for the duration of the warranty. 2. Lightning damage shall be included as part of the warranty. 3. The systems integrator shall provide start up services plus a minimum of six days and four trips support service. 4. The warranty period for the SCADA system shall be for 2 years from the date of acceptance. The warranty shall ensure that the system works as specified. A. The PLCs shall be used for data acquisition and control as indicated on the Drawings. The operations described hereinafter are intended to identify minimum acceptable performance. The Contractor shall provide all hardware and software features required to make the PLCs totally operational. B. All final versions of the designer program for each controller shall be turned over to the owner. This is required to reside on the SCADA server for proper integration into the OE system PROCESS INPUTS/OUTPUTS (I/O): A. The PICS supplier shall provide sufficient I/O capacity to create a complete and operable system. The block diagrams on the drawings shall not be considered as representative of the final I/O requirements for the system. B. Spare I/O: 1. Each I/O base shall have installed spare I/O points. For each type of I/O points used on a given base, the number of spare points of that type shall be at least one, but not less than 10 percent of the total points of that type that are used on the base. 2. Each I/O base shall also have space for at least one future I/O module, unless the Engineer determines that a full base is adequate in certain cases

6 2.03 DATA ACQUISITION AND CONTROL REQUIREMENTS A. Each device shall operate in one of two control modes: LOCAL, or REMOTE. The mode shall be operator defined at each control panel or through the plant wide computer monitoring/control station. If conflicting control modes are initiated the following order of precedence indicates the active control point: 1. VFD or Motor Control Center 2. Local Control Panel (LCP) 3. Central Processing Unit (CPU) B. Critical Interlocks: All critical interlocks shall be done external to the PLC system. Critical interlocks shall be defined as interlocks where either personnel safety is at risk, major equipment damage is possible, or a function is otherwise defined as critical. C. Power Failure and System Restart: Each PLC shall be connected to on-line UPS. In case of PLC require automatically reinitialize itself. This shall include restarting the processor, performing startup diagnostics, I/O scans, and memory scans. The PLC shall resume control as it was before an event. When incoming power drops below acceptable level, the PLC shall begin an orderly shutdown. The auto restart functions shall be logically staggered so as to minimize instantaneous peak power demand. D. Adjustable Timers: The preset values for PLC program timers shall be able to be adjusted through the PLC loader/monitor PROCESSOR A. Processor RAM memory shall be a minimum industry standard for program storage. B. Processor Scan Time shall not exceed industry standard. C. Basic Processor Functions 1. Real-time control of output points for turning on and off digital devices such as motor starters and solenoids. 2. Read the status of real world digital inputs from limit switches, float switches, and other field devices. 3. Real-time control of analog process control variables. 4. Read the status of real world analog set points and feedback values. 5. Perform timing, counting, sequencing, and interlocking functions for pump control. 6. Process local alarm handling functions

7 D. Math and Advanced Functions 1. Four function math in floating point or signed integer format 2. Convert to/from BCD 3. Data comparison and manipulation 4. Scaling from integer data into engineering units such as flow and pressure 5. Full PID Instructions for control of process control variables such as flow and pressure. 6. ASCII instruction set for interfacing to ASCII devices 7. Built-in processor interrupt functionality to report recoverable processor faults back to the polling master 8. Compute Instruction which executes a mathematical expression and can be used for totalizing functions 9. Trigonometric and Exponential math functions E. Real-Time Calendar Clock for time stamping alarms and events. Clock must be accurate to within plus or minus 60 seconds per month while operating at 25 deg. C. F. Built-in RS-485 port for SCADA serial communications G. Removable processor key switch to guard against program tampering by unauthorized personnel I/O CARDS A. Discrete Input Cards: Solid-state input circuits rated for 10-30VDC operation. Cards must be available in 8 and 16 point configurations and shall source current to the field device. Each input point shall have a status LED which indicates the ON or CLOSED condition for that field sensor or switch. Cards with 16 points must have removable terminal strips so that module can be easily replaced without disturbing the field wiring. B. Analog Input Cards: Analog inputs shall capable of reading in 4 to 20mA. The A/D converter shall provide a minimum 4095:1 resolution (12 bits) over the full range from module minimum to module maximum. C. Analog Output Cards: Analog Outputs shall be capable of outputting 4 to 20mA signals. The A/D converter shall provide a minimum 4095:1 resolution (12 bits) over the full range from module minimum to module maximum COMMUNICATIONS

8 A. Processor shall have a built-in communications port that allows it to communicate on a multipoint, peer-to-peer, data communications network with the following performance: 2.09 DIAGNOSTICS 1. Refer to specification Appendix A at the end of this section. A. The processor shall have built-in diagnostics and self-test, such that each time power is cycled, the processor does a complete CPU and RAM memory test. Additionally the power-up test will momentarily light up all diagnostic LED s to be sure they are working. The processor shall be capable of reporting major and minor fault codes and processor status information back to the polling master, provided the fault is not a catastrophic hardware failure where the processor is unable to power up. B. The processor shall have a built-in watchdog timer to ensure that all processor program scans occur within the time limit set by the watchdog timer. The watchdog timer cycle shall be adjustable from 20 msec to 2.5 seconds in 10 msec increments. C. The processor shall have individual LED indicators that are clearly visible and labeled for easy identification. At a minimum the following indicators must be provided: 1. CPU is in RUN mode 2. CPU is FAULTED 3. CPU battery is LOW 4. I/O points are FORCED and are not under program control 5. COMMUNICATION channels are active 2.10 FIBER OPTIC MODULE A. The 62.5 MM fiber optic Ethernet TCP/IP communication modules shall be fully compatible with the PLC system provided. The modules shall be rack mounted and serve to convert network communications into an optical medium. PART 3 - EXECUTION 3.01 TESTING A. Witnessed Shop Tests: Test all non-loop-specific functions including, but not limited to, the following: 1. Failure Mode and Backup Procedures: Power failure, auto restart, disk backup and reload, diagnostic functions. 2. Communication with the computer network system. 3. Man-Machine Interface: Operation of monitor/loader stations and operator workstations. 4. Programming and documentation methods and features

9 3.02 OWNER TRAINING A. Operations: Provide a minimum of (5) five days of training at the jobsite for the Owner's personnel in the operation of the PLCs. Training shall include: 1. Standard operational features of PLC equipment provided. 2. Specific features provided for this project including loop functions, operation of each loop, and interfaces with other loops and subsystems. 4. Training shall focus on software programming of PLC, hardware knowledge of existing personnel is at a higher level currently than a software knowledge. 5. Training shall focus on the overall system improvements. B. Maintenance: Provide a minimum of (3) days of on-site training for the Owner's personnel in the maintenance of the PLC system. Training shall include: 1. Standard hardware features of the PLCs. 2. Specific training for the actual hardware configuration provided. 3. Test, adjustment, and calibration procedures. 4. Troubleshooting, component removal and replacement, and periodic maintenance. END OF SECTION

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