ADDENDUM FIVE
SECTION 16418
LOW HARMONIC VARIABLE FREQUENCY DRIVES
PART 1 - GENERAL
1.1
Description
ADDENDUM FIVE
A.
This specification describes an AC variable speed/torque Direct Torque Control™ (DTC™)
Drive used to control the speed/torque of a NEMA design B induction motor. The drive
must also provide an optional operational mode for scalar or V/Hz operation.
B.
The Drive shall be manufactured by a firm with at least ten (10) years experience in the
production of this type of equipment.
C. Refer to Section 17300 for control scenarios.
1.2
Quality Assurance
A.
The Drive manufacturing facility shall be ISO 9001 and 14001 certified.
B.
The Drive shall be UL listed, or Canadian UL listed, or CSA listed and comply with EMC
Directive 89/336 EEC, Low Voltage Directive 73/23 EEC and Machinery Directive 98/37 EC
in accordance with the European Union’s CE directive.
C. All printed circuit boards shall be completely tested and burned-in before being assembled
into the completed Drive. The Drive shall then be subjected to a preliminary functional test,
minimum one (1) hour burn-in and computerized final test. The burn-in shall be at 104F
(40C), at full rated load, or cycled load. Drive input power shall be continuously cycled for
maximum stress and thermal variation.
D. The Drive shall utilize efficient IGBT technology throughout the entire Drive manufacturer’s
Power and Voltage range.
E.
The Drive shall utilize the same communications architecture, utilizing plug-in
communications cards, for high-speed noise immune connectivity throughout the entire
Drive manufacturer’s Power range.
F.
The Drive manufacturer shall have an analysis laboratory to evaluate the failure of any
component. The failure analysis lab shall allow the manufacturer to perform complete
electrical testing, x-ray components, and decap or delaminate components and analyze
failures within the component.
G. The Drive shall utilize surface mount technology in the manufacturing of internal printed
circuit boards and electronics, for maximum reliability.
1.3
Submittals
A.
The Submittals shall include the following information.
1. Outline Dimensions.
2. Weight.
3. Compliance to IEEE 519 - Harmonic analysis for particular jobsite including total
voltage harmonic distortion and total current distortion. The Drive manufacturer shall
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provide calculations, specific to this installation, showing total harmonic current
distortion (TDD), at the Point of Common Coupling (PCC), is less than required.
PART 2 - PRODUCTS
2.1
Manufacturer
A.
2.2
The Drive shall be manufactured by ABB, Model ACS-800-37-0210-5-C129-H350-H352K466; no equals allowed.
Adjustable Frequency Drives
A.
The Drive shall be solid state, with a Pulse Width Modulated (PWM) output. The drive shall
be a Direct Torque Control (DTC) AC to AC converter utilizing the latest isolated gate
bipolar transistor (IGBT) technology. The Drive shall employ Direct Torque Control (DTC)
inner loop torque control strategy that mathematically determines motor torque and flux
every 25 microseconds (s) (40,000 times per second). The drive must also provide an
optional operational mode for scalar or V/Hz operation. The drive shall eliminate low order
harmonics with an active converter controlled with DTC and high order harmonics with an
LCL line filter.
B.
Ratings
1. The Drive shall be rated to operate from 3-phase power at 230VAC to 500VAC +10/10%, 48Hz to 63Hz. The Drive shall employ a full wave rectifier to prevent input line
notching and operate at a fundamental (displacement) input power factor of 0.97 at
all speeds and loads. The Drive efficiency shall be 98% or better at full speed and
load. An internally mounted AC line reactor or DC choke shall be provided to reduce
input current harmonic content, provide protection from power line transients such as
utility power factor correction capacitor switching transients and reduce RFI
emissions.
2. The overvoltage trip level shall be a minimum of 30% over nominal, and the
undervoltage trip level shall be a minimum 35% under the nominal voltage.
3. Output voltage and current ratings shall match the adjustable frequency operating
requirements of standard 460VAC, 3ph, 60Hz, NEMA design A or NEMA design B
motors. The overload current capacity shall be 110% of rated current for one (1)
minute out of five (5). Output frequency shall be adjustable between 0Hz and
300Hz. Operation above motor nameplate shall require programming changes to
prevent inadvertent high-speed operation. The drive’s switching pattern shall be
continually adjusted to provide optimum motor flux and avoid the high-pitched
audible noise produced by motors energized by conventional PWM drives. The drive
shall be furnished in a UL Type 1 listed enclosure rated for operation at ambient
temperatures between 0 and 40C at an altitude not exceeding 3300 feet, with
relative humidity less than 95% and no condensation allowed. The drive shall be
protected from atmospheric contamination by chemical gasses and solid particles
pre IEC 721-3-3, classes 3C2 and 3S2. The drive shall be protected from vibration
per IEC 68-2-6 (max. sinusoidal displacement 1 mm, 5Hz to 13.2Hz and max.
acceleration 7m/s2, 13.2Hz to 100Hz).
C. Control Functions and Adjustments
1. An intelligent start-up assistant shall be provided as standard. The Start-up assistant
will guide the user through all necessary adjustments to optimize operation and will
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include “plug and produce” operation, which recognizes the addition
options/fieldbus adapters and provides the necessary adjustment assistance.
of
2. Start-up data entries shall include motor nameplate power, speed, voltage, frequency
and current.
3. A motor parameter ID function shall automatically define the motor equivalent circuit
used by the sensorless vector torque controller.
4. A PID speed/torque loop regulator shall be provided with an autotune function as
well as manual adjustments.
5. A selection of six (6) preprogrammed application macro parameter sets shall be
provided to minimize the number of different parameters to be set during start-up.
Macros included as standard are as follows: Factory Default, Hand/Auto, PID
Control, Sequential Control, and Torque Control. A selection of two (2) user defined
macros shall are also be available.
6. Start/Stop control functions shall include two (2) or three-(3) wire start/stop,
coast/ramp stop selections, optional dynamic braking and flux braking.
7. The drive shall be capable of starting into a rotating load (forward or reverse) and
accelerate or decelerate to reference without safety tripping or component damage
(flying start). The drive shall also be capable of flux braking at start to stop a
reverse spinning motor prior to ramp.
8. The drive shall have the ability to automatically restart after an overcurrent,
overvoltage, undervoltage, or loss of input signal protective trip. The number of
restart attempts, trial time, and time between reset attempts shall be programmable.
9. Accel/Decel control functions shall include two (2) sets of ramp time adjustments with
linear and three (3) s-curve ramp selections.
10. Speed/Torque control functions shall include:
a. Adjustable min./max. speed and/or torque limits.
b. Selection of up to 15 preset speed settings or external speed control.
c. Three (3) sets of critical speed lockout adjustments.
d. A built-in PID controller to control a process variable such as pressure, flow
or fluid level.
e. Reference signal processing shall include increase/decrease floating point
control and control of both speed/torque and direction using a “joystick”
reference signal. Two (2) analog inputs shall be programmable to form a
reference by addition, subtraction, multiplication, minimum selection or
maximum selection.
11. Output control functions shall include.
a. Flux optimization to limit the audible noise produced by the motor and to
maximize efficiency by providing the optimum magnetic flux for any given
speed/torque operating point.
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b. Current and torque limit adjustments to limit the maximum Drive output current
and the maximum torque produced by the motor. These limits shall govern the
inner loop torque regulator to provide tight conformance with the limits with
minimum overshoot.
c. A torque regulated operating mode with adjustable torque ramp up/down and
speed/torque limits.
12. The Drive shall be capable of sensing a loss of load (broken belt / broken coupling)
and signal the loss of load condition. The drive shall be programmable to signal this
condition via a keypad warning, relay output and/or over the serial communications
bus. Relay output shall include programmable time delays that will allow for drive
acceleration from zero speed without signaling a false underload condition.
13. The Drive shall have programmable “Sleep” and “Wake up” functions to allow the
drive to be started and stopped from the level of a process feedback signal.
14. Two (3) programmable critical frequency lockout ranges to prevent the AFD from
operating the load continuously at an unstable speed.
D. Static and Dynamic Performance
1. Open loop static speed regulation shall be 0.1% to 0.3% (10% of motor slip). When
motor speed feedback is provided from a suitable encoder, closed loop speed
regulation shall be 0.01% or better. Dynamic speed accuracy shall be 0.3-0.4 %-sec
or better open loop and 0.1-0.2 %-sec or better-closed loop.
E.
Operator Control Panel (Keypad)
1. Each Drive shall be equipped with a front mounted operator control panel (keypad)
consisting of a four- (4-) line by 20-character back-lit alphanumeric display and a
keypad with keys for Run/Stop, Local/Remote, Increase/Decrease, reset, menu
navigation and parameter select/save.
2. All parameter names, fault messages, warnings and other information shall be
displayed in complete English words or standard English abbreviations to allow the
user to understand what is being displayed without the use of a manual or crossreference table.
3. The Display shall have contrast adjustment provisions to optimize viewing at any
angle.
4. The control panel shall include a feature for uploading parameter settings to control
panel memory and downloading from the control panel to the same drive or to
another drive.
5. All Drives throughout the entire power range shall have the same customer interface,
including digital display, and keypad, regardless of horsepower rating.
6. The keypad is to be used for local control, for setting all parameters, and for stepping
through the displays and menus.
7. The keypad shall be removable and insertable under drive power, capable of remote
mounting, and shall have its own non-volatile memory.
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8. During normal operation, one (1) line of the control panel shall display the speed
reference, and run/stop forward/reverse and local/remote status. The remaining
three (3) lines of the display shall be programmable to display the values of any three
(3) operating parameters. At least 26 selections shall be available including the
following:
a. Speed/torque in percent (%), RPM or user-scaled units.
b. Output frequency, voltage, current and torque.
c. Input voltage, power and kilowatt hours.
d. Heatsink temperature and DC bus voltage
e. Status of discrete inputs and outputs
f.
Values of analog input and output signals
g. Values of PID controller reference, feedback and error signals
h. Control interface inputs and outputs shall include:
F.
I/O Capabilities
1. Six (6) discrete inputs, all independently programmable with at least 25 input function
selections. Inputs shall be designed for “dry contact” inputs used with either an
internal or external 24 VDC source.
2. Three (3) form C relay contact outputs, all independently programmable with at least
30 output function selections. Relay contacts shall be rated to switch 2 Amps at
24VDC or 115/230VAC. Function selections shall include indications that the drive is
ready, running, reversed and at set speed/torque. General and specific warning and
fault indications shall be available. Adjustable supervision limit indications shall be
available to indicate programmed values of operating speed, speed reference,
current, torque and PID feedback.
3. Three (3) analog inputs, one (1) +/- 0VAC - 10VAC and two (2) 4mA - 20mA, all
independently programmable with at least ten (10) input function selections. A
differential input isolation amplifier shall be provided for each input. Analog input
signal processing functions shall including scaling adjustments, adjustable filtering
and signal inversion. If the input reference (4-20mA or 2-10V) is lost, the AFD shall
give the user the option of the following: (1) stopping and displaying a fault, (2)
running at a programmable preset speed, (3) hold the AFD speed based on the last
good reference received, or (4) cause a warning to be issued, as selected by the
user. The drive shall be programmable to signal this condition via a keypad warning,
relay output and/or over the serial communications bus.
4. Two (2) analog outputs providing 4mA to 20mA signals. Outputs shall be
independently programmable to provide signals proportional to at least 12 output
function selections including output speed, frequency, voltage, current and power.
G. Ethernet communications
1. Provide Ethernet communication capability for remote monitoring of the VFD.
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H. Microsoft Windows-based software shall be available for drive setup, diagnostic analysis,
monitoring and control. The software shall provide real time graphical displays of drive
performance.
I.
Protective Functions
1. For each programmed warning and fault protection function, the drive shall display a
message in complete English words or Standard English abbreviations. The five (5)
most recent fault messages and times shall be stored in the drive’s fault history.
2. The drive shall include internal MOV’s for phase to phase and phase to ground line
voltage transient protection.
3. Output short circuit and ground fault protection rated for 65,000 amps shall be
provided per UL508C without relying on line fuses. Motor phase loss protection shall
be provided.
4. The drive shall provide electronic motor overload protection qualified per UL508C.
5. Protection shall be provided for AC line or DC bus overvoltage at 130% of maximum
rated voltage or undervoltage at 65% of min. rated voltage and input phase loss.
6. A power loss ride through feature will allow the drive to remain fully operational after
losing power as long as kinetic energy can be recovered from the rotating mass of
the motor and load.
7. Stall protection shall be programmable to provide a warning or stop the drive after
the motor has operated above a programmed torque level for a programmed time
limit.
8. Underload protection shall be programmable to provide a warning or stop the drive
after the motor has operated below a selected underload curve for a programmed
time limit.
9. Over-temperature protection shall provide a warning if the power module
temperature is less than 5C below the over-temperature trip level.
10. Input terminals shall be provided for connecting a motor thermistor (PTC type) to the
drive’s protective monitoring circuitry. An input shall also be programmable to
monitor an external relay or switch contact (klixon).
J. Motor Protection Relay with Temperature Monitoring and Alarm System
1. The motor protection relay shall have 10 RTD inputs and Ethernet communications.
Provide SEL Part #071001B0X9X0X850200; no equals allowed.
K. Harmonics and EMC
1. The AFD shall have an active line supply unit which controls the low order harmonic
current drawn from the power line.
2. The AFD shall have an internal LCL line filter to eliminate high order harmonic
current, provide voltage boost when the line is low and provide Power Factor control.
3. The input current to the AFD shall have a total harmonic content less than 5% of the
AFD’s rated input on any power system and under all operating conditions. The input
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Power Factor shall be approximately unity under all conditions. AFD’s which use
filters or multi-pulse transformers external to the AFD shall not be allowed.
4. The AFD shall have an EMC filter which meets requirements for 2nd environment,
unrestricted distribution according to EN 61800-3.
L. Enclosure
1. Enclosure shall be UL Type 1 filtered.
2. Enclosure shall have bottom entry and exit of cables.
PART 3 - EXECUTION
3.1
Harmonic Distortion
A.
The variable frequency drive manufacturer shall perform a comprehensive pre-equipmentselection harmonic study to determine harmonic voltage and current distortion and the
ratings and characteristics of individual tuned filters or other attenuation equipment if these
are necessary to achieve the required distortion limits. In conducting the study, the
manufacturer shall calculate the total harmonic voltage distortion at the point of common
coupling which will be the 480 volt bus supplying the VFDs using an assumed source
impedance of 3.5 percent unless stated otherwise in the specifications or drawings.
B.
The harmonic distortion values contributed by operation of all variable frequency drive
motor-loads operating at full load shall be:
1. Maximum Allowable Total Harmonic Voltage Distortion (THVD) Contribution:
3 percent of the fundamental.
2. Maximum Allowable Total Harmonic Current Demand Distortion (THID) Contribution:
8 percent of the combined load current of the main feeder supplying all 480 volt
loads.
C. The Owner shall review and approve in writing, the harmonic study before equipment
manufacturing is begun.
3.2
Source Quality Control
A.
Testing and Test Reports:
1. Testing shall be per manufacturer’s standard.
2. A copy of the test reports shall be provided as part of the Closeout documentation.
B.
Verification of Performance:
1. A representative of the Owner may witness tests. Variable frequency drive
manufacturer shall notify the Owner 2 weeks in advance and shall provide testing
procedures to the Owner 4 weeks prior to actual testing. Failure of a test shall result
in rejection of the equipment until performance is in compliance with these
specifications.
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2. Certification on materials and records of shop tests necessary for the inspector to
verity that the requirements of these specifications are met shall be made available
to the inspector.
3. Submit signed and dated certification that all of the factory inspection and testing
procedures described herein have been successfully performed by the Contractor
prior to shipment.
3.3
Field Quality Control
A.
Provide the services on an experienced, factory trained technician or service engineer of
the variable frequency drive manufacturer at the jobsite for a minimum of 2 days for startup
of each VFD beginning at a date mutually agreeable to the Contractor and the Owner. One
additional day shall be provided for training. The technician shall be on duty at the site for
at least 8 hours per day and shall be available 24 hours per day when required to advise
concerning special problems with equipment and systems.
B.
Include in the bid an allowance for factory-trained service personnel to supervise field
installation, inspect, make final adjustments and operational checks, make functional
checks of spare parts, and prepare a final report for record purposes. Adjust control and
the Owner has accepted instrument equipment until this equipment has been field tested by
the Contractor and the results of these tests.
C. Include in the bid the training of personnel in the operation and maintenance of each
furnished variable frequency drive control system. For the purpose of this training section
of the Specifications, a system is by definition a group of driven equipment which all serve a
common function (e.g., filter influent pumps, chlorine mixers, flocculators).
3.4
Maintenance
A.
Spare Parts: As a minimum, furnish and list the following spare parts in the Bill of Material:
1. One set of all power and control fuses and indicating lamps for each variable
frequency drive.
2. One fully functional main control circuit board.
3. One of each inverter power semiconductor for each rating supplied for each variable
frequency drive.
B.
Tools and Equipment: Variable frequency drive manufacturer shall identify and supply
special tools or test equipment necessary to perform maintenance or repair tasks.
C. Field Services: Manufacturer shall describe the field service system available to support
the proposed variable frequency drive system. As a minimum describe:
1. Type of technical support available (e.g. system engineering and technician).
2. Location of field service personnel (maximum 100 miles).
3. Field service daily rates in dollars per hour and dollars per day.
4. Guaranteed response time to service requests.
3.5
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Acceptance Tests
16418 – Low Voltage VFD - 8 of 10
A.
Final Inspection: The Contractor to perform and submit the results of a final comprehensive
field performance survey after equipment installation.
B.
Performance Verification.
1. The Contractor shall field measure actual harmonic distortion and verify with tests
acceptable to the Owner after satisfactory full-load operation. Test methods shall be
acceptable to the Owner.
2. As part of the specified harmonic studies and measurement for this project, use
frequency scan analysis to identify and correct resonance conditions in the electrical
distribution system at no additional cost to the Owner.
3. Measurements shall include harmonic voltage and current spectra and individual and
total harmonic distortions.
C. System Performance:
1. During the three-week period between final inspection and delivery of the test and
as-built documentation, City of Santa Ana shall validate operation of the variable
frequency drive system by regular inspection during workdays.
2. Completion of the installation, final inspection, receipt of the test and as-built
documentation, and successful performance of the system for three-week period
shall constitute acceptance of the system.
3.6
Warranty
A.
With a certified start-up, warranty shall be 60 months from the date of start-up.
warranty shall include all parts, labor, travel time, and expenses.
The
END OF SECTION
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SECTION 16620
STANDBY GENERATOR
ADDENDUM FIVE
PART 1 - GENERAL
1.1
Work Included
A.
This specification outlines the requirements for installing and acceptance testing for a
complete and operable prototype tested standby diesel generator set as furnished by the
CITY. Generator shall be outdoors.
B.
The manufacturer will have available prototype test results for the assembled enginegenerator set. Individual component tests for the major components are not acceptable as
a substitute for prototype testing of the complete and assembled engine generator set. All
the equipment shall be new, and of current design and shall be constructed in accordance
with the applicable requirements of the IEEE, NEMA, NEC, UL, and ANSI standards.
C. Equipment and materials will be new and delivered to the job site factory tested and ready
for installation. The work includes the following:
1. Install City furnished engine-generator set with mounted and loose accessories as
described herein and shown on the drawings.
2. Furnish tests, documents and services as specified.
3. Furnish fuel, oil and antifreeze for testing and final fill.
D. The specifications and drawings describe the system, but do not purport to cover all
required details. Provide all appurtenances required, whether specifically noted herein or
not. It shall be the Contractor’s responsibility to coordinate with the generator supplier to
determine what field installation requirements will be necessary to make the equipment
complete and operable.
E.
The engine generator will be equipped with the necessary devices to meet current
SCAQMD regulations for the operation of the submitted diesel generator. Documentation
will list current Tier requirements and particulate filter. Contractor shall obtain a general
permit registration number to submit application, pay for, and obtain a South Coast Air
Quality Management District (SCAQMD) permit to construct and operate the standby
generator for the first year of operation. The generator fuel fill system shall meet the
requirements of the local fire department.
1. Air Emissions:
a. The CITY shall be solely responsible for providing a system that complies
with BACT standards at the time of equipment purchase. At a minimum, the
engines will be a minimum of Tier 3 Certified.
b. CITY will provide a particulate filter system as required by AQMD to maintain
pollutants below permitted value to allow operation in a “Sensitive Receptor’
location. Particulate filter shall be capable of reduction of pollutants level by
at least 70%.
c. CITY will submit certificate or “Source Test Report” for engine demonstrating
compliance with the BACT standards at the time of equipment purchase with
the draft permit applications.
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F.
1.2
Factory Engineer: CITY will coordinate services of factory-trained Service Engineer,
specifically trained on type of equipment specified. Contractor is responsible for the
installation, commissioning, startup, and acceptance testing for the diesel generator. The
Contractor is also responsible for providing generator fuel and coolant.
Submittal
A. The following submittal and shop drawing information will be provided for CONTRACTOR
reference.
1. Outline drawing for engine generator showing overall dimensions, power and control
wiring entrance locations, fuel connections, anchor points, weight, breaker location
and control panel.
2. Manufacturer data sheets for major components including engine, generator,
protective controls, voltage regulator, fuel tank, batteries, charger, exhaust
components, jacket water heater, load bank, and circuit breakers.
3. AC and DC wiring diagrams.
4. Vibration isolation certified calculations for Zone 4 installations.
5. Warranty and Prototype test documents.
6. Specification review noting compliance.
7. Computerized generator sizing report indicating steps.
B. The CITY will furnish, at time of startup, four (4) Operating and Maintenance Manuals in
three ring notebooks containing graphic diagrams, equipment data, spare parts lists,
maintenance instructions and operator and service instructions.
C. The following documents shall apply to the specified equipment.
1. IEEE 587
Surge Testing
2. NEMA MG1
Motors and Generators
3. NFPA 110
Emergency/Standby
4. NFPA 37
Installation and Use
5. UL 142
Fuel Tanks
6. UL 2200
Stationary Engine Generator Assemblies
D. CONTRACTOR shall prepare on behalf of the CITY permit applications for “Authority to
Construct” and “Permit to Operate” for the South Coast Air Quality Management District
(SCAQMD). The permit applications shall include all necessary documentation required by
SCAQMD including, but not limited to, shop drawings, source test requirements, etc. The
CONTRACTOR shall submit these applications to the CITY within 90 days from the date of
the Notice to Proceed. The CITY will then submit the permit applications to the SCAQMD
within 5 working days from when received from the CONTRACTOR. If the application is
deemed incomplete or not acceptable by the SCAQMD, the CONTRACTOR shall be
responsible for responding to any comments or requests for information from SCAQMD and
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for preparing any and all revised permit applications for resubmittal to SCAQMD. Obtaining
approved permits from SCAQMD shall be the sole responsibility of the CONTRACTOR. Any
changes to equipment and/or emission requirements that occur after the initial submittal to
SCAQMD shall be made at the CITY’s sole expense.
PART 2 - EQUIPMENT
2.1
Acceptable Manufacturers
A.
Subject to compliance with requirements, provide diesel generators, documents, tests, and
services by the supplier and the authorized distributor. Provide UL 2200 labeling.
B.
Authorized manufacturer's distributor shall be capable of providing equipment as specified,
maintaining parts inventory; performing initial start-up, warranty and 24 hour emergency
service.
C. Warranty for all products against defects in material and workmanship shall be provided by
the CITY for a period of 5 years from the date of Owner’s final acceptance. Warranty
coverage shall include parts, labor, travel expenses, and labor to remove/re-install
equipment. Engage supplier capable of administering the warranty service on all
components of the emergency system specified herein. Refer to Division 1 for Warranty
requirements.
D. Manufacturer shall be Caterpillar, Onan, Generac, or Kohler. No substitutions allowed.
2.2
Ratings
A.
The generator set shall be diesel powered, 1800 RPM, minimum rated for continuous
standby operation at ratings of 500 kw, 0.80 P.F., 277/480 volt, 3 phase 4 wire. Site
conditions: 110 degrees F, 1500 Ft. Generator shall be minimally sized as shown with a
maximum 20% voltage dip and 10% frequency dip. Provide generator sizing reports for
submitted generator.
1. Step 1: eleven 1 hp FVNR motor; one 13.4 kw single phase linear miscellaneous
load; two 3 hp FVNR motor; one 10 hp FVNR motor; one 3.3 kw single phase
miscellaneous linear load; one 7.5 ton air conditioner; one 1.5 hp FVNR motor.
2. Step 2: one 200 hp VFD (125%CL) non-loaded pump.
3. Step 3: one 200 hp SSRV (300%CL) non-loaded pump.
B.
2.3
The generator set shall be capable of picking up 100% load in one step in accordance with
NFPA Standard 110.
Engine and Equipment
A.
Engine shall be four cycle only,
turbocharged/aftercooled as required.
powered
by
#2
diesel,
water
cooled
and
B.
Positive displacement, full pressure, lubrication oil pump. Full flow lubrication oil filters with
replaceable spin-on canister elements and dipstick.
C. Engine Oil Drain Extension. Provide 2-inch stainless steel oil pan drain extension with a 2inch stainless steel ball valve. The valve shall extend to the side of the frame for ease of
maintenance during oil changes.
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D. Engine driven positive displacement fuel pump. Fuel filter with replaceable spin-on canister
element. Replaceable dry element air cleaner with restriction indicator.
E.
Provide a filter/water separator on the engine, Raycor filter, DAHL, or equivalent, just ahead
of the fuel filters to prevent condensation, or other water, present in the fuel from reaching
the engine filters, pumps, or injectors. Construct of heat-resistant glass, with an aluminumperforated baffle, for easy viewing of the amount of water contained.
F.
Engine mounted battery charging alternator, 45 ampere minimum, and solid-state voltage
regulator. Battery charger and fill control panel will be fed with a single 120 vac circuit.
G. Jacket water heater, UL Listed, 120 volt, single phase dedicated circuit.
H. Electronic governor with adjustable control. Frequency regulation shall be isochronous
under varying loads from no load to full load. Frequency variation shall be + 0.25 percent
of rated speed.
2.4
I.
Provide engine mounted radiator including belt-driven pusher fan, water pump and
thermostat. Cooling system shall be rated for full rated load operation in 122 degree F
ambient conditions. Include a duct adaptor flange for attachment of an air duct. Guard
rotating parts against accidental contact.
J.
The engine and generator shall be mounted on a heavy duty steel base with a battery tray
with battery holddown clamps within the base. Electrical and fuel stub up shall be within
the base rails.
K.
Provide a closed crankcase ventilation system by Racor CCV or equal.
Engine Starting
A.
Electric starter.
B.
Control cranking with three crank attempts with rest periods, 75 second minimum. Lock out
controls after third attempt.
C. Battery, 12 VDC, lead acid type. Battery shall provide sufficient capacity to provide 100
seconds cranking. Provide insulated stranded copper conductors to connect batteries to
generator starter. Mount batteries inside generator baserails. Provide battery tray and
seismic straps.
D. Battery charger, 120 VAC, 10 amp 12 VDC, voltage regulated on the skid. Equip with
adjustable float and manual equalize charge settings, and DC voltmeter and ammeter.
Provide contact and wiring for indication of low battery voltage on control panel. Charger
voltage regulator shall be temperature compensated to prevent thermal damage to
batteries. Provide Stored Energy Systems (SENS) NRG charger.
2.5
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Generator
A.
The generator shall be single bearing, four pole, two-thirds pitch, dripproof, and air cooled.
The rotor shall have amortisseur windings and be dynamically balanced.
B.
THD shall not exceed 5% of rated voltage at full load and no single harmonic shall exceed
3% of rated voltage at full load.
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C. The exciter shall be brushless, three phase, with full wave silicon diodes, surge suppressor
and exciter circuit breaker.
D. Provide permanent magnet generator (PMG) for isolation and sustained 300% short circuit
current for 10 seconds. Electronic current boost methods or CT boost methods are not
acceptable.
E.
The insulation system for rotor, stator, exciter and PMG shall be Class H. Temperature rise
shall not exceed 125 degrees C at full rating.
F.
The voltage regulator shall be 3 phase RMS sensing, temperature compensated, pulse
width modulated and + 0.5% regulation with overvoltage and overexcitation protection.
Overvoltage protection shall shut down regulator output on a sustained overvoltage of one
(1) second; overexcitation protection shall shutdown regulator output if overloads exceed
ten (10) seconds. The regulator shall allow frequency to decline to 58 Hz before correcting
the output voltage in a linear volts/hertz manner.
G. Shield generator, exciter and regulator to prevent radio frequency interference per
provisions of BS.800 and VDE Class G and N.
2.6
Generator Control
A.
The CITY will provide a NEMA 1 enclosed control panel mounted on the generator with
vibration isolators. Solid state components shall have surge suppression for protection.
Provide panel lighting with ON/OFF switch. Indicating meters (2%) and devices shall
include:
1. AC ammeter
2. AC voltmeter
3. Frequency meter
4. Phase selector switch with OFF position for meter display of current and voltage in
each generator phase.
5. Voltage adjustment 5%
6. Running time meter
7. Oil pressure gauge
8. Water temperature gauge
9. DC voltmeter
B.
Controls shall shut down and lock out the engine upon:
1. Overcrank
2. Overspeed
3. Low oil pressure
4. High engine temperature
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C. Provide DC powered engine monitor with the following lights on the control panel:
1. Run
green
2. Low oil pressure
(prealarm)
amber
3. High engine temp
(prealarm)
amber
4. Low engine temp
(prealarm)
amber
5. Low fuel
(prealarm)
amber
6. Fuel leak
(alarm)
red
7. Low oil pressure
(shutdown) red
8. High engine temp
(shutdown) red
9. Overcrank
(shutdown) red
10. Overspeed
(shutdown) red
11. Not in Automatic
(flashing)
red
12. Low coolant level
(alarm)
red
D. Provide the following SCADA dry contacts:
1. Run
2. Fail
3. Low fuel
4. Low battery
5. Breaker Open
E.
Operation of shut down circuits shall be independent of pre-alarm circuits. Panel mounted
switches shall reset the engine monitor and test all the lamps.
F.
Provide three position panel mounted switch (RUN-STOP-AUTO) to stop the engine in the
STOP position, start and run the engine in the RUN position, and allow the engine to start
and run by closing a remote contact, and stop by opening the remote contact when in the
AUTO position.
G. Provide two-position load bank control marked “on” and “off”.
H. Provide cranking cycle function, consisting of three crank attempts followed by rest periods.
Failure to start after three attempts (75 seconds) shall shut down and lockout engine. Two
means of cranking termination after engine start shall be provided, one as a backup to the
other.
I.
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Provide distribution circuit breaker as shown on drawings. Breaker shall U.L. listed molded
case, with overload and overcurrent trip. Breaker shall be rated for service entrance.
Provide auxiliary contact for breaker open position.
16620 – Standby Generator - 6 of 12
J.
2.7
The generator control panel shall have Ethernet communications.
Load Bank
A.
The generator unit set shall have a resistive load bank, which will operate only under
exercising function of the generator. The total rating of the load resistors shall be not less
than 50 percent of the full load kW rating of the generator to which it is connected, or larger,
as required by engine generator manufacturer to maintain by unit warranty. The load shall
be provided with a minimum of four load steps.
B.
The load bank shall be housed in a NEMA 1 enclosure, mounted integrally to the engine on
the front radiator. The load bank's load chamber shall have the physical dimensions
coordinated with the radiators duct flange. The radiator fans cooling capacity shall be
increased as necessary to prevent excessive static pressure build-up caused by the load
bank.
C. Resisters shall be constructed of high temperature alloy capable of continuous operation at
1920 deg., and designed to operate at an average of 750°F. The resisters shall be
assembled in a three-phase array with the phase-to-phase resister current balanced within
2%, and an overall kW tolerance within 5% of its normal rating.
D. A circuit breaker shall be provided in the engine generator supplying the load bank, sized at
125% of the full load bank. Provide fuse protection for the individual load bank section.
E.
Provide automatic electric contactors, as required, to activate load bank, in the exercising
mode. Provide all control interlocks with the automatic transfer switch for the unit, as
required, to provide the following functions:
1. Transfer switch exercising time lock starts generator and brings load bank on-line.
2. Exercising function operates for pre-selected period of time with the load bank
connected at 100% of load bank capacity.
3. At end of exercise period, load bank shall be automatically taken off line during
engine cool-down.
4. If utility power outage occurs during the exercise period, the load bank shall
immediately be de-energized before the emergency load automatic transfer switches
change position; generator shall continue to run during the disconnect of the load
bank.
F.
2.8
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Load bank systems shall be UL listed as manufactured by AVTRON, Simplex or equal.
Sound Attenuated Enclosure and Exhaust System
A.
The CITY will provide a weather-protective and sound attenuated enclosure with removable
or hinged doors to allow inspection and maintenance. Enclosure material shall be
aluminum alloy or steel with a minimum thickness of 14 gauge. Lockable latches shall be
of stainless steel. Doors shall have a common keyed latch. Provide two (2) sets of keys.
B.
Enclosure and engine exhaust system shall be sound attenuated to limit noise level when
operating at full rated load to a maximum of 75 dB(A) at 23 feet in any horizontal direction
from the center of the unit. Intake and discharge of cooling air shall be through top
mounted openings that are covered for weather protection. Provide acoustical material on
16620 – Standby Generator - 7 of 12
internal walls and surfaces of the enclosure. External holes and opening in the enclosure
shall be covered with galvanized or coated mesh to prevent entry of birds or rodents.
C. A super-critical degree silencer shall be provided as part of the diesel particulate filter.
Supplier shall furnish back pressure calculations for the installation, including the discharge
piping, verifying that engine limitation is not exceeded. Silencer shall be arranged for
horizontal mounting with bottom (side) inlet and end outlet. Provide a stainless steel
bellows type flexible exhaust connector at the engine exhaust outlet. Provide suitable
raincap or moisture drain. A "Critical Degree" silencer is considered to be one capable of
attenuating engine exhaust noise component to 85 dba at 10 feet in a free-field
environment.
2.9
Fuel Storage System
A.
The CITY will provide a sub-base mounted fuel storage tank capable of supporting the
generator set at rated load for 20 hours. The tank shall not extend beyond the generator
end of the base rails. Provide access for electrical conduit for the circuit breaker, battery
charger and jacket water heater power, and control wiring from below. Tank shall be built
and labeled in accordance with UL-142. Mounting feet shall provide clearance between
bottom of tank and foundation.
B.
Tank features shall include:
1. 2 inch filler neck and locking cap
2. Engine supply and return openings and draw tubes
3. Emergency vents per UL for both primary and secondary containment with approved
caps. Vents shall extend to outside of enclosure 12’ above generator pad.
4. Tank leak port
5. Fuel level indicator gauge, direct reading type
6. Low fuel level alarm switch, set at 4 remaining hour’s capacity
7. Secondary containment, totally closed design, by double wall construction. Provide
alarm contact for liquid in containment basin. Wire contact to alarm light in the
generator control panel.
8. 5 gallon Fill/Spill containment to contain fuel overfill spills that may occur during fillup.
2.10
Seismic Restraint
A.
2.11
Provide an IBC seismically approved generator with mounting details.
Spare Parts
A.
The CITY will provide spare parts as recommended by manufacturer for six months of
operation for engine-generator set plus the following:
1. Three filters of each type for all services.
2. Three fuses of each type and rating used.
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3. Three indicator light bulbs of each type and rating used.
B.
Pack spare parts in suitable containers or boxes bearing labels clearly designating contents
and piece of equipment for which they are intended.
C. The CITY will deliver spare parts at same time as equipment to which they pertain.
Properly store and safeguard spare parts until completion of the work at which time deliver
them where directed by the Engineer.
PART 3 - EXECUTION
3.1
Examination
A.
3.2
Examine areas and conditions under which diesel generators are to be installed and notify
of conditions detrimental to proper completion of the work. Do not proceed with the work
until unsatisfactory conditions have been corrected.
Delivery, Storage and Handling
A.
Deliver equipment properly packaged and mounted on skids to facilitate handling. Deliver
with recommended oil and coolant installed.
B.
Store equipment to protect from weather and construction traffic. Wherever possible, store
indoor; where necessary to store outdoors, store above grade with weather-protective
enclosure or plastic wrapping.
C. Handle equipment carefully to prevent physical damage. Do not install damaged
equipment; remove from site and replace damaged equipment with new.
3.3
Installation of Diesel Generator Set
A.
Install diesel generator as indicated, in accordance with the equipment manufacturer's
written instructions, and with recognized industry practices, to ensure that the unit fulfills
requirements. Comply with NFPA and NEMA standards pertaining to installation of engine
generator sets and accessories.
B.
Install generator suitable for Seismic Design Category’s D and F conditions. The CITY will
furnish certified anchor calculations.
C. Coordinate with other work, including raceways, electrical boxes and fittings, exhaust
piping, and accessories, as necessary to interface installation of engine generator
equipment work with other work.
3.4
Grounding
A.
3.5
Provide equipment grounding connections for diesel generator as indicated. Tighten
connections to comply with tightening torques specified in UL 486A to assure permanent
and effective grounding. Ground neutral at the generator (separately derived source).
Production Tests
A.
The CITY will provide certified factory production tests on the equipment performed at rated
load and 0.8 PF. Tests shall include:
1. Steady-state voltage and frequency analysis
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16620 – Standby Generator - 9 of 12
2. Rated load at rated PF
3. Maximum power analysis
3.6
Field Test
A.
Engage the services of the supplier's factory trained technicians to perform testing including
furnishing all test equipment.
B.
Submit notification of test schedule and procedure for approval by the Engineer not less
than two (2) weeks prior to the scheduled date. Notify all interested parties of the time and
date for the testing.
C. All tests shall be made with the door to the enclosure in which the generator is located
closed.
1. Verify all electrical, exhaust, fuel and water connections for proper size, continuity,
phase rotation, and tightness of fittings. Check all fluids for appropriate levels.
2. Verify operation of jacket water heater, battery charger, automatic transfer switch
and remote alarm connections.
3. Start up engine and make initial check of voltage, frequency, battery charging, oil
pressure, water temperature and safety shutdowns.
D. Connect a load bank at 100% of generator rating at unity power factor.
1. Generator set shall be run for 1 hour at 75% then 1 hour at 100%. Record every 15
minutes water temperature, oil pressure, ambient air temperature, voltage, current,
frequency, and kilowatts. Test all safety devices using methods recommended by
the manufacturer. At conclusion of test allow 10 minute unloaded cooldown before
shutdown.
E.
Test generator controls in Remote position using the building load. Simulate failure of the
normal power source by opening normal source breaker. Engine generator shall start and
assume load within 10 seconds.
1. Run the generator for 30 minutes on building load.
2. Record starting step voltage and frequency drops and provide report.
F.
Any failure or malfunction of equipment or controls during any time of test procedure shall
be corrected and retested at no additional cost to Owner.
G. Production and field test results shall be documented and forwarded to the Engineer.
Include test reports in O & M manuals.
H. Training by the CITY:
1. Training session: The CITY will provide one 4 hour classroom session for operations
and maintenance Provide one 4 hour field session for operations and maintenance.
2. Manufacturer shall submit a lesson plan to include operator training and
maintenance training at least two weeks prior to the training sessions.
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16620 – Standby Generator - 10 of 12
3. Training shall include both classroom and field "hands-on" training. Both types of
training shall provide full coverage of all techniques for the operators to fully
understand the generator operation, and for the maintenance personnel to fully
understand the requirements for preventive and corrective maintenance.
4. Acceptable operation and maintenance manuals must be onsite and available when
training sessions are implemented.
I.
At the conclusion of field testing, Contractor shall, at his expense, fill the fuel tank with
Diesel fuel.
END OF SECTION
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16620 – Standby Generator - 12 of 12
SECTION 17000
GENERAL INSTRUMENTATION AND CONTROL
PART 1 - GENERAL
1.1
ADDENDUM FIVE
Description
A.
This section of the specifications includes the requirements for the materials, testing,
installation, and configuration of the instrumentation and Process Control System (PCS),
including the programmable logic control system and local operator interface, as specified
herein and indicated on the drawings.
B.
Programming of the Central HMI system will be done by others under separate contract.
C. The Contractor shall provide, configure, calibrate, test, and commission all components of
the instrumentation, control, communications, and network systems supplied unless
specifically noted otherwise (UNO). The Contractor shall place the completed systems in
operation, including tuning loops and making final adjustments to instruments as required
during facility start-up. The Contractor shall provide the services of instrument technicians
for testing and adjustment activities.
D. Division 17 is an extension of, and includes all of the requirements of Division 16, Electrical.
All work performed under Division 17 shall also comply with the applicable sections of
Division 16 as well as the general provisions of Division 1.
E.
Division 17 Organization: The requirements for the PCS are described in this Section, the
drawings, and the following Division 17 Sections
1. Section 17100 - Instrumentation Cabinets and Enclosures
2. Section 17300 - Programmable Logic Controllers and Programmable Operator
Interfaces.
3. Section 17350 – Telemetry System Equipment
4. Section 17600 – Testing and Commissioning
5. Section 17700 – Programming
F.
These specifications shall not be interpreted as permission or direction to violate any
governing code or ordinance. Equipment, materials, and workmanship shall comply with
the latest revisions of the following codes and standards:
1. Instrumentation: International Society of Automation (ISA).
2. Wiring: National Electrical Code (NEC), ISA S5.3 and S5.4, 1976.
3. Control Panels and Equipment: NEMA, UL, and ANSI.
4. Piping: ANSI B31.3 (instrumentation piping).
1.2
Related Work Specified Elsewhere
A.
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One-year Guarantee: General Provisions.
17000 – General Instrumentation and Control - 1 of 24
B.
Permits and Licenses: General Provisions.
C. General Electrical Requirements: 16010
1.3
Abbreviations
A.
General
1. ANSI: American National Standards Institute
2. ATS: Automatic Transfer Switch (associated with backup generator)
3. FAT: Factory Acceptance Test
4. FM: Factory Mutual
5. HMI: Human-Machine-Interface. The software providing the graphical user interface
to the control system
6. GUI: Graphical User Interface.
7. IP: Internet Protocol
8. ISA: International Society of Automation
9. NEMA: National Electric Manufacturers Association
10. I/O : PLC Inputs and Outputs.
11. O&M: Operations and Maintenance.
12. P&ID: Piping and Instrumentation Diagram.
13. PCS: Process Control System
14. PLC: Programmable Logic Controller.
15. RAT: Reliability Acceptance Test
16. SAT: Site Acceptance Test
17. SCADA: Supervisory Control and Data Acquisition.
18. SHC: Sodium Hypochlorite
19. UPS: Uninterruptible Power Supply.
20. VAI, VAO: Virtual PLC analog input and analog output
21. VDI, VDO: Virtual PLC discrete input and discrete output
B.
Definitions
1. PCS Integrator: An Integrator meeting the experience qualifications detailed in 1.5 of
this Section and having, as a minimum, responsibility for integrating, configuring,
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17000 – General Instrumentation and Control - 2 of 24
testing and documenting, the PLC, Local HMI, networks, devices connected to the
network, and instruments.
2. Central: For this Contract whenever the term “Central” is used it means the City of
San Ana’s Water Utility Operations Center at 220 Daisy Street, Santa Ana,
California.
3. Virtual PLC I/O: PLC inputs and outputs that are read by the PLC or written by the
PLC over a network connection such as Modbus, or Ethernet, via a PLC
communications port.
1.4
Software Configuration
A. The PCS subcontractor shall be responsible for software configuration, programming, and
integration of the following as a minimum, to meet the requirements of these specifications:
1. The Modicon M580 series programmable logic controller (PLC).
2. The Magelis iPC series local HMI on the Main Control Panel.
3. The Ethernet and Modbus communications networks and network devices.
4. The variable frequency drives (VFDs) and solid state starters.
5. The single loop pressure controller and PID controllers configured within the PLC.
6. The Eaton Power meter
7. Other microprocessor based devices provided as part of this project.
B. The PCS subcontractor shall be responsible for software configuration, programming and/or
integration of Owner supplied systems including:
1. Control Panel for SA-2
2. Control Panel for City Well 29
3. Backup generator/ATS
4. SHC System
C. The Integrator is to configure the PCS system to meet the following requirements.
1. Operator setpoints and pump duties can be set and changed by an Operator at the
the Local Station HMI. The local HMI shall be configured for both monitoring and
control. The PLC is to accept the most recent Operator set value/ instructions
entered from the local HMI. The PLC is to update the HMI such that it always
displays the current operational values and setpoints.
2. Access to the local HMI for all functions except viewing, to be protected by a
password.
3. If communications with Central is lost, the station is to maintain automatic operation,
using the last entered operator setpoints. The functionality of the Local HMI is to be
unaffected by this loss of communications.
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17000 – General Instrumentation and Control - 3 of 24
1.5
Responsibility of Contractor and PCS Integrator
A. PCS Integrator
1. The Contractor shall employ an experienced and well qualified PCS Integrator for the
design and software configuration of the PLC, local Operator Interface, and
communication networks. All systems shall be the responsibility of the one system
supplier for all PCS hardware. The programmable logic control system installation
and wiring connections to peripheral equipment and instruments shall be the
responsibility of the PCS Integrator using qualified personnel possessing the
necessary equipment and having experience with similar installations.
2. All instrumentation and industrial electronic systems and functions shall be provided
under the supervision of a single PCS Integrator, chosen by the Contractor, who is
regularly engaged in the design, configuration, and installation of similar systems of
equal or greater scope and complexity. The PCS Integrator shall be enjoined by the
Contractor as a Subcontractor. The assignment of specific responsibilities herein to
the PCS Integrator shall not, in any way or under any conditions, diminish the
Contractor's full and complete responsibility for all work performed and all materials
installed under the contract. The contract between the Contractor and the PCS
Integrator shall specifically require that the PCS Integrator conform to and meet all
requirements specified in the contract documents. The assignment of the PCS
Integrator as an equipment supplier shall not be acceptable. Programming of the
PLC and the SCADA system may be performed by others, but the associated
hardware will be supplied by the PCS Integrator. All equipment in the instrument and
control system including network systems, field equipment, panels, work stations,
server racks, control panels, and instruments will be the responsibility of the PCS
integrator. The PCS Integrator will work with PLC/SCADA programmers to test,
commission and start up the plant.
B. Acceptable PCS Integrators:
1. The Control System shall be designed, constructed, and commissioned by full time
or contract employees with a minimum of 5 years of experience and a minimum of
one year with Integrator. The PCS Integrator shall configure and program all devices
and equipment supplied to perform the functions indicated in the contract documents
unless specifically noted otherwise. Engineering and site integration services shall
only be provided by staff members directly employed by the PCS Integrator. Contract
labor is not acceptable for engineering and programming services.
2. Evidence of such qualification, as well as notification of the assuming unit
responsibility, shall be furnished to the City in writing prior to commencement of the
work. The qualification evidence shall include the following:
i. The Contractor shall have had a minimum of five years experience with the
installation of industrial control systems similar in type to those to be installed in
this project.
ii. A complete list of similar installations including names and address of
Department, name of project, and date of completion.
iii. The name and qualifications of supervisory personnel to be directly responsible
for the installation of the control system.
10-15-dp
17000 – General Instrumentation and Control - 4 of 24
iv. WITHHOLDING OF APPROVAL: The Contractor and the proposed PCS
Integrator shall anticipate that the Project Representative may withhold approval
of a proposed PCS Integrator or employee if, in the opinion of the Project
Representative, the PCS Integrator or employee does not have the experience,
capability, or an acceptable performance and execution record of similar projects
in the past. No Contractor, PCS Integrator, or employee denied approval by the
Project Representative shall be entitled to any extension of time or to any claim
for damages related to any consequences resulting from the withholding of
approval for any reason whatsoever. Applicable consequences may include but
are not limited to associated extra or unanticipated costs, hindrances, delays, or
complications of any kind.
v. Instrumentation systems and control panels, with the exception of Pressure
Reducing Valve Vault Instrumentation Systems and control panels, shall be
supplied, installed, calibrated, and tested by the following pre-qualified suppliers:
10-15-dp
Mr. Greg Beebe
Brithinee Electric
620 South Rancho
Avenue Colton, CA 92324
Phone- 909-825-7971
FAX- 909-825-2044
greg_beebe@mail.brithinee.com
Russ Cotton
CC-Powertec
31441 Santa Margarita Pwky., A390
Rancho Santa Margarita, CA 92688
Phone- 949-702-2434
FAX- 949-858-8587
russcotton@cox.net
Dave Stone
Control Technologies
6780 Katella Ave.
Cyprus, CA 90630
Phone- 714-901-3500
FAX- 714-527-3335
davids@control- technologies.com
Mr. Brian Downing
Delta System Eng., Inc.
3550 North Central Avenue, Suite 1900
Phoenix, AZ 85012
Phone 602-266-4658
FAX 602-266-4953
bdowning@deltaseinc.com
Mr. Peter Matthews
Morrow-Meadows Corp.
665 Brea Canyon
Walnut, CA 91789
Phone- 909-772-5428
FAX- 909-468-0593
pmatthews@morrow-meadows.com
Mr. Joe Engle
Neal Electric
13250 Kirkham Way
Poway, CA 92604
Phone- 858-513-2525
FAX- 858-513-9499
jengle@nealelectric.com
Mr. Salib Mansour
Soffa Electric
5901 Corvette Street
Commerce, CA 90040
Phone- 323-728-0230
FAX- 323-887-8076
salib.mansour@soffaelectric.com
Mr. Jerry Horst
TESCO Controls, Inc.
3434 52nd Avenue
Sacramento, CA 95823
Phone- 916-395-8800
FAX- 916-429-2817
rmartinez@tescocontrols.com
17000 – General Instrumentation and Control - 5 of 24
Mr. Dean McLaughlin
Trimax Systems
565 Explorer
Brea, CA 92821
Phone- 714-255-8590
FAX- 714-255-1922
deanm@trimaxsystems.com
C. Under this section, the PCS Integrator shall furnish and be responsible for the following:
1. Detailed Design of Control Panels: The drawings shall depict the functional and
operational requirements of the control system and are at times diagrammatic. The
PCS Integrator shall provide detailed, scaled design of all components on and in
control panels and determine specific physical, thermal, and electrical requirements.
2. Detailed Design of Control Circuitry: The drawings shall depict the functional and
operational requirements of the control system and are at times diagrammatic. The
PCS Integrator shall be responsible for the final selection of all control system
components, except for components specified as “no equal”, and all detailed circuit
design and component interconnection required to meet the general and functional
requirements indicated in or implied by the Drawings and Specifications. Where
components are specified as “no equal”, the PCS Integrator shall provide all detailed
design, including specification of miscellaneous or interfacing components required
to integrate the specified component into the PCS Integrator’s control system design.
It is the responsibility of the PCS Integrator to ensure that all devices selected, and
the proposed interconnection of those devices, perform as intended to provide a
complete and operable system meeting the requirements of the anticipated
environment and area classifications. The PCS Integrator shall define all
requirements for all interfacing components and shall supply all appurtenances,
accessories, and all such devices which may be required for proper functioning and
interfacing of components as part of the control system. An example of such
appurtenances would be interposing relays or analog isolators.
All such
aforementioned necessary ancillary components not specifically indicated in the
Contract Documents shall be considered incidental to the contract and shall be
required just as if they had been specifically indicated.
3. INTERCONNECTING WIRING: The design of all interconnecting wiring of control
equipment, including remote control panels, packaged equipment panels,
mechanical equipment with control components, etc. Provide PLC I/O schematics for
each PLC slot and Motor Starter schematics for each starter unit in the MCCs
showing all the external and internal wiring.
4. INTEGRATION TESTING: Integration testing of all system and related components
simultaneously in the PCS Integrator’s facility. This testing shall include all panels,
instruments, process switches, test fixtures, MCCs, motor controllers, available
equipment packages, communications and networking equipment, SCADA system
hardware and software (UNO), PLC system hardware and software (UNO), etc. Per
Section 17600.
5. COORDINATION WITH GC: Coordinate with the Contractor for specific
requirements and locations of raceway penetrations and field wiring in control
panels. The PCS Integrator shall supply the Contractor with all necessary detailed
installation drawings and/or written instruction for installation of all control
components and sensing devices as required for proper system operation.
6. CALIBRATION: Calibration of all field instruments UNO. Per Section 17600.
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17000 – General Instrumentation and Control - 6 of 24
7. COMMUNICATIONS AND NETWORKS: Set up, configuration, test, and verification
of all communications equipment, channels, and networks including new and reused
communication circuits. Integration with the City’s existing Dynac SCADA system
shall be coordinated with the City’s SCADA system service provider, Kapsch.
Contractor shall solicit the services of Kapsch during control system development,
configuration, testing, and validation tasks associated with integration with the City’s
Dynac SCADA system.
8. STARTUP AND TESTING: System start up, commissioning, functional testing
following installation. Per Section 17600.
9. INSTRUMENTS: Provide all instruments specified unless specifically noted
otherwise. Some instruments shall be provided by packaged equipment vendors.
The PCS Integrator shall integrate vendor provided instruments and equipment.
10. CONFIGURATION Configure all supplied devices, equipment, and software unless
specifically noted otherwise. All computers are to be configured for application
programming by others. Configuration and programming of devices and equipment
supplied as a part of packaged systems shall be provided by the vendor of each
packaged system.
11. EQUIPMENT SUBMITTAL REVIEW: Review all equipment and packaged system
submittals which include Division 17 items. Notify the Contractor of any and all
needed modifications to submitted equipment, package system scope of services or
supply, or PCS Integrator supplied equipment required to accommodate and
integrate submitted equipment into the PCS Integrator’s work. Specifically note how
submittals which include variances from the contract documents will impact PCS
Integrator provided control panels and MCC's if accepted by the contractor.
12. Spare parts.
13. Special tools and test equipment required by the supplier.
14. Operator training.
15. Warranty (one year from City issuance of Notice of Completion)
i. The PCS Integrator shall be solely and completely responsible for all maintenance
of control systems they supply from time of installation to the date of substantial
completion of all work under the contract. The PCS Integrator shall correct all
deficiencies and defects and make any and all repairs, replacements,
modifications, and adjustments as malfunctions or failures occur. The PCS shall
perform all such work required or considered to be required by the owner to
properly maintain the system.
ii. The PCS Integrator shall make any and all repairs, replacements, modifications,
and adjustments required to eliminate any and all defects in design, materials,
and workmanship which are discovered within the one year guarantee period.
The PCS Integrator shall begin all repairs, replacements, modifications and
adjustments within twenty-four (24) hours of notification by telephone by the
owner and shall complete such repairs, replacements, modifications and
adjustments within forty-eight (48) hours of notification.
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17000 – General Instrumentation and Control - 7 of 24
iii. The PCS Integrator shall anticipate that the Owner may delay acceptance of all
work under the contract if, in the judgment of the Owner, malfunctions or failures
in operation of the supplied control system repeatedly occur after start-up to an
unacceptable extent. The PCS Integrator shall not be entitled to an extension of
time or to any claim for damages because of hindrances, delays, or
complications caused by or resulting from delay by the owner in accepting the
work because of malfunctions or failures in operation of the supplied control
system.
16. Shipping and receiving.
D. All calibration and final checkout of the instrumentation and programmable logic control
system shall be witnessed by the City's Representative to determine if the system complies
with the contract documents. Instrumentation calibration by the Contractor shall include both
new and existing instruments, PCS equipment, and devices that are part of the system.
E. The PCS Integrator shall be directly responsible for the coordination and integration of the
control system with motor controls, packaged equipment controls, and other related
equipment. The PCS Integrator shall be responsible to obtain submittal information on
equipment specified or provided by other suppliers or disciplines and to integrate all the
equipment into the control system to form a complete working system as outlined by the
Contract Documents.
F. The PCS Integrator shall communicate directly with the manufacturer(s) and supplier(s) of
all related equipment to determine all details of the equipment that may influence or affect
the control system. The PCS Integrator shall determine all requirements for and shall
cause integration of the control system into a unified operating system. All correspondence
shall include Carbon Copying (cc:) the General Contractor and City Project Manager.
G. The system supplier will provide PLC programs as required by the contract documents.
Descriptions of the system operation and PLC functions are provided in Sections 17300,
17700, and the Contract drawings, to help the Contractor understand the complete system
and its operation.
H. The PCS Integrator shall:
1. Provide a PLC and HMI system whose input and output configuration complies with
the requirements of the contract documents, including specific I/O register
assignments when applicable.
2. Notify the Owner of any changes to the input/output configurations described by the
contract documents at the time of submittal of shop drawings.
3. Continue to notify the Owner after submittal review immediately of any PLC
input/output changes which impact the configuration as defined in the contract
documents.
4. Allow forty (40) hours every three (3 months) of on-site programming changes per
the direction of the City of Santa Ana. These changes will reflect system control
adjustments as necessary to fine tune the overall control strategy. This effort is to be
responsive within three (3) days notice and includes changes desired by the City of
Santa Ana at Walnut Pump Station. This requirement will be in effect for a period of
one (1) year from the date of final acceptance at no additional cost to the City of
Santa Ana.
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17000 – General Instrumentation and Control - 8 of 24
I.
1.6
The PCS has been designed to include operator interfaces for all system functions. All
systems have been designed to be manually operable via discrete devices and via
programmed Human Machine Interface devices. Systems have been designed to be
monitored and controlled in a hierarchical manner. Basic functions have been designed to
be provided at field stations, local panels, and MCC’s by discrete panel switches, indicator
lights, and displays. The overall department wide SCADA system has been designed to
provide monitoring and control of all systems and equipment at the facility. All programmable
devices and systems have been designed to, and shall communicate over a TCP/IP plant
Ethernet network. The PCS Integrator, the Contractor, and packaged equipment suppliers
shall ensure that all components of supplied plant systems fully and seamlessly integrate
into this system architecture.
Submittals
A.
General
1. Submittals shall be in three-ring hardcover binders and arranged for convenient use
including tab sheets, all indexed, and cross-referenced. Bill of materials, cut sheets,
shop drawings, schematics, panel layouts, schedules, etc., shall be crossreferenced, indexed, or otherwise related by unique identifier for each item. The
Engineer may reject improperly organized or notated submittals.
2. Provide pdf file with page numbers in table of contents as well as bookmark links to
section coversheets in pdf file.
3. Suppliers shall provide re-submittals which include responses to all submittal review
comments separately and at a level of detail commensurate with each comment.
Supplier responses shall indicate how the supplier resolved the issue pertaining to
each review comment. Responses that only indicate that the review comment was
noted, will be looked into, etc., are not satisfactory. Re-submittals which do not
comply with this requirement may be rejected and returned without review.
Contractor shall be allowed no extensions of any kind to any part of their contract
due to the rejection of non-compliant submittals. Submittal review comments not
addressed by the contractor in re submittals shall continue to apply whether restated
or not in subsequent reviews until adequately addressed by the contractor to the
satisfaction of the reviewing and approving authority.
4. Labeling:
Label submittal title sheet with Project title, submittal title, date,
Specification Section number, submittal number, and version (re-submittal).
5. Submit catalog cut sheets for all products. Identify all cut sheets by unique bill of
material item number, index, or key. Notate catalog cuts to indicate only those items,
models, options, or series of equipment to be furnished. Cross out or otherwise
obliterate all extraneous materials and information. Clearly identify all configuration
options for the equipment to be furnished.
6. Submit copies of all Division 17 specification sections with each paragraph notated to
indicate compliance. A check mark shall indicate complete compliance. Explanations
shall be provided for all non-compliant items.
7. In the case of deviations from the contract documents, particularly related to the
impact of the configuration of submitted packaged equipment supplied to the project,
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17000 – General Instrumentation and Control - 9 of 24
submit marked up copies of applicable Electrical and Instrumentation contract
drawings notated to identify and explain all proposed deviations from the contract
documents. Items not notated on the submitted marked up copies shall be assumed
to be 100% compliant with the bid documents. This requirement applies to electrical
one lines, MCCs, MCC control schematics, panel schedules, and control schematics.
This requirement does not apply to plan drawings and conduit schedule which shall
be marked up to reflect the as constructed project configuration and submitted as
record drawings.
8. Submit operation and maintenance information as specified in any Division 17
specification section. O&M manuals shall include product data for all materials and
items supplied in compliance with the submittal requirements of this section.
9. Submit all drawings described in this and other Division 17 sections including
elementary, loop, single-line, schematic, fabrication, installation, field wiring, panel
layout and assembly, etc., drawings. Drawings shall be updated following submittal
review, factory test, and commissioning. Updates shall be provided to the Project
Representative in a timely manner. Cross reference drawing elements with BOM and
catalog cut sheet unique references. Drawings shall use project tag formats and
numbers. Unique and separate drawings shall be provided for each item supplied
including but not limited to all panels and all MCC units. Typical drawings that apply
to multiple panels or multiple MCC motor control units are not acceptable. Individual
I/O schematics diagrams are to be provided for each I/O slot based on the typicals in
the design and the PLC I/O List. Individual motor starter schematics are to be
provided for each starter unit including VFD and breaker units as well as spare or
space units.
10. Submit dimensional, installation, and wiring diagrams and drawings for all supplied
components.
11. Submit test plans, calibration forms, test forms, test results, and test reports required
by any Division 17 specification section.
12. Provide to the Owner in a timely fashion. Contractor to plan and make submittals to
avoid project delays or conflicts. Include sufficient time for the City to check and
approve the document.
13. Variations from Contract Documents. Clearly list separately all proposed variations
from the Contract Documents. Provide information which explains the advantages of
the proposed alternative approach or alternative equipment.
B.
Design Submittals
1. Product Information
a. Catalog product sheets shall include, but not be limited to:
1. Catalog cuts, data sheets, performance surveys, test reports, equipment
lists, material list, diagrams, pictures, and descriptive material.
2. All items including PLCs, instruments, cabinets, mechanical devices,
mounting components, wiring, terminal strips, connectors, accessories,
and spare parts.
b. Clearly identify proposed items and selected options, sizes and speeds, by
highlighting or encircling.
10-15-dp
17000 – General Instrumentation and Control - 10 of 24
c. Cross out all extraneous catalog cut material.
d. Include performance data and specifications for each item.
e. List all proposed modifications or changes to standard items.
f.
Submit, for review prior to commencement of manufacture (or shipment for
stock items).
2. Shop Drawings
a. General
1. Include, block diagrams, panel schematics, scaled panel general
arrangement drawings, loop diagrams and installation details.
2. For all drawings provide borders, title block, revision date, Contractor’s
name, Owner’s names, and cross references to related drawings.
3. In the drawing revision block identify the changes made since the last
revision.
4. Drawings shall be prepared utilizing a computer aided drafting program.
CAD shop drawings shall be updated and provided to the Project
Representative prior to factory testing, prior to system installation, and
with the O&M manuals in hardcopy and electronic file formats.
5. Size drawings 22 inch by 34 inch, except loop drawings. Size loop
drawings 11 inch by 17 inch.
6. Provide both hard and electronic copies (CAD and PDF) on a labeled
CD/DVD/solid state drive.
b. Block Diagram
1. Show major subsystems and interrelationships between them to provide
an overview of the complete facility PCS system.
2. Provide a separate block diagram for each facility.
c. Panel Fabrication and Layout Drawings: Show the placement, labeling and
wiring of components within panels, cabinets and consoles. Include:
1. Front, back, and side panel elevations with dimensions.
2. A bill of materials with device tag, English narrative description,
manufacturer, model, and quantities.
3. Sufficient detail to demonstrate material choices, outward appearance,
construction methods, and seismic force resistance.
4. Neutral and earth bars where applicable.
5. Panel ventilation, heating and cooling systems.
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17000 – General Instrumentation and Control - 11 of 24
6. Paint color and dry film thickness.
7. Paint color and dry film thickness.
8. Conduit entry points.
9. Draw panel to a scale appropriate (architectural units)
10. Show all additions and deletions of devices and wires in existing
enclosures.
11. Provide panduits within the panel for organizing wire bundles, with a
minimum of 20 percent spare wire capacity.
12. Provide separate panduits for low voltage DC signal wires.
13. Arrange panel to provide the maximum spare panel space to
accommodate mounting future equipment. Provide a minimum of 20
percent spare panel mounting area.
14. The City has the right to make modifications to the interior and exterior
layouts of panels as part of the shop drawing review. Provide in the bid
price at least one panel redesign for incorporating the requested City
modifications.
d. Panel Schematics: Provide schematic drawings showing all control panel
components, the interconnection of all control panel components, all field
devices, and the connection of all field devices to control panels. Schematic
diagrams shall also show all communications components, their
interconnection, and their interface with other control panel components.
Provide wire and terminal block numbers.
e. Interconnection Diagrams: Prepare and submit panel interconnection
diagrams. Loop diagrams are not acceptable as a substitute for connection
diagrams.
1. Show the external wiring between terminals of associated equipment,
control panels, motor control centers, terminal boxes, field instruments,
and any other device, panel, or enclosure.
2. Show wiring and cable numbers and device tags. Number wiring and
cables in conformance with the City’s standards.
3. Reference related drawings by drawing number.
f.
Loop Diagrams: Provide elementary loop diagrams for all discrete loops in
compliance with ISA S5.4. Elementary diagrams and loop diagrams shall
show circuits and devices of a system and include identification of power
source. These diagrams shall be arranged to emphasize device elements
and their functions as an aid to understanding the operation of a system and
maintaining or troubleshooting that system.
1. Show both discrete and analog devices and signals.
2. Do not combine multiple loops on a single drawing.
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17000 – General Instrumentation and Control - 12 of 24
3. Show wire numbers, color codes, signal polarities, and terminal block
numbers. Tables for wire numbers, signal polarity, and terminal block
numbers are not acceptable.
4. Show all field wiring, field junction boxes, instruments, cabinet terminals
and associated PLC inputs/outputs.
5. Reference related drawings by drawing number.
g. Cabinet Cooling Calculations
1. Provide cooling calculations for all cabinets and panels containing
electronic equipment.
2. Provide cabinet fans or alternative cooling to maintain equipment within
the manufacturer’s recommended operating range.
h. Record Drawings:
1. Also referred to as as-built drawings.
2. SHOP DRAWINGS: All submitted drawings shall be updated over the
course of the construction project to reflect the installations and
equipment as-built. A full set of record drawings shall be provided to the
Project Representative upon completion of the project and shall be
included in the O&M manuals. Record drawing requirements shall be the
same as submittal drawing requirements.
3. CONTRACT DRAWINGS: The contractor shall maintain a set of record
plan markup drawings on site during construction. The contractor shall
mark up the record drawing set to indicate any and all deviations of the
installed systems from the contract documents. The marked-up drawings
shall be provided to the project representative at project close out.
C. Testing Submittals
1. Test Plans: Also see requirements in Section 17300 and 17600. Provide:
a. Submit test plans for the following tests:
b. HMI Communications Test
c. Factory Demonstration Test
d. HMI Demonstration Test
e. Functional Acceptance Test
f.
Radio Communications Test
D. Training submittals: As specified in Section 1.10.
E.
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Preliminary O&M Submittal: A preliminary copy of the Final O&M, delivered prior to the Site
Acceptance Test.
17000 – General Instrumentation and Control - 13 of 24
F.
Final O&M Submittal: Detailed Systems Drawings and Data: The submittal shall consist of
six sets of detailed drawings and data prepared and organized by the Contractor who was
designated at the time of bidding. These drawings and data shall be submitted as a
complete package at one time.
1. Detailed JIC-style schematic diagrams of each discrete I/O point.
2. Detailed instrumentation diagrams of each analog I/O instrumentation and control
loop, per ISA S5.3 and S5.4 standards.
3. Detailed programmable logic controller (PLC) connection loop diagrams.
4. Data sheets for each component, together with a technical product brochure or
bulletin. The data sheets shall show:
a. Component name.
b. Manufacturer’s model number.
c. Project tag number.
d. Project location.
e. Input and output characteristics.
5. The data sheets shall be grouped together in the submittal by systems or loops as a
separate group for each system or loop. If within a single system or loop, a single
component is employed more than once, one data sheet with one brochure or
bulletin may cover all identical uses of that component in that system.
6. Component interconnect drawings showing the interconnecting wiring between each
component including equipment supplied under other sections requiring interfacing
with the control system.
7. Arrangement and construction drawings for consoles, control panels, and for other
special enclosed assemblies for field installation. These drawings shall include
dimensions, identification of all components, preparation and finish data,
nameplates, and the like. These drawings also include enough other details to
define the style and overall appearance of the assembly; a finish color sample shall
be included. Drawings shall include:
a. Electrical drawings as required by Section 16010, General Electrical Diagrams.
b. Loop diagrams to ISA 5.4 standards. One loop per sheet, in a 11” x 17” format.
8. Installation, mounting, and anchoring detail for all components or entry details.
9. Electronic Files of Shop Drawings: Submit electronic files of all shop drawings in
CAD and PDF format.
10. Complete detailed bills of material.
11. Fully annotated PLC logic diagrams as described in Section 17300.
12. Record “as built” drawings and corresponding CAD files.
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17000 – General Instrumentation and Control - 14 of 24
13. Calibration sheets for instruments and other devices requiring field adjustment.
Includes as a minimum:
a. All field instruments including analog instruments (4 -20mA), pressure, flow,
level, and analytical instrument switches.
b. PLC analog inputs and outputs.
c. Valve end-of-travel switches.
14. Proposed acceptance test methodology and record sheets submitted for approval by
the Owner, prior to acceptance testing beginning.
15. Final Site Acceptance Test record sheets, signed by the Owner.
16. “As built” equipment configuration sheets for all equipment with user configurable
parameters including PID configuration/set points. This includes VFDs, SSTs,
controllers, and network devices.
17. Updated English control strategy narratives.
1.7
Instruments
A.
The Contractor shall:
1. Remove any existing instruments mounted on process equipment or pipes that are
being removed.
2. Remount the instruments on the new equipment or pipe.
3. Recalibrate all instruments, and automatic valves, and check they are in good order.
4. Provide and install new instruments where shown on the contract documents.
5. Submit all calibration sheets to the Owner for approval as required under paragraph
“Submittals”
B.
1.8
In cases where an instrument not supplied by the Contractor, cannot be properly calibrated
because of its condition or is judged by the PCS Integrator to be unreliable, the Contractor
shall inform the Owner in writing within 24 hours of the failed calibration attempt or negative
evaluation. The Owner will direct the Contractor on the action to be taken.
Workshop
A.
The PCS Integrator shall attend a 3 hour workshop no later than 3 weeks after the Notice to
Proceed, to review the PCS specifications requirements, and discuss the PCS integrators
proposed architecture. The PCS Integrator shall present a draft systems architecture at the
workshop.
B.
Workshop purpose: To clarify the requirements for the PCS and discuss the initial
approach proposed by the PCS integrator. The following topics will be covered.
1. Review of the PCS requirements and goals. Led by the City.
2. Presentation of PCS Integrator’s approach. Led by PCS Integrator.
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17000 – General Instrumentation and Control - 15 of 24
3. Review and discussion of submittal and testing requirements. Led by City.
4. Other topics.
C. The City will prepare the workshop minutes.
1.9
Testing
A.
1.10
As specified in section 17600
Training
A.
General
1. The PCS Integrator shall conduct specifically organized training sessions to educate
and train the owner's personnel in the maintenance and operation of all aspects and
components of the control system they supply. Training on all system components
shall include, but not be limited to, the following subjects:
a. All O&M manual items
b. All system users’ manual items
c. Local HMI programming training: For City maintenance staff.
d. Pump Station controls training: For Operator and maintenance staff.
2. Schedule all training courses Tuesday through Thursday between 8:00am and 3:30
PM.
3. Obtain approval from the Owner for the proposed training schedule.
4. Pump station controls training:
The PCS Integrator shall provide a minimum of 16 hours of on-site instruction to the
owner's employees after start-up and commissioning of the system. The owner shall
be allowed to video tape all or any part of the training sessions. The PCS Integrator
shall prepare and assemble specific instruction materials for each training session
and shall supply such materials to the Project Representative at least two (2) weeks
prior to the time of the training. The O&M manuals and the system users’ manual
shall be complete and shall be used in the training sessions.
a. Provider: PCS Integrator.
b. Class length: 4 hour sessions.
c. Audience: City operations and maintenance staff (up to 10 attendees).
d. Location: Part classroom (Utility Administration Building), part at Walnut Pump
Station site.
e. Content:
1. Overview of new controls.
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17000 – General Instrumentation and Control - 16 of 24
2. Control strategies
3. Communications
4. Local HMI screens
5. Control modes, control options and operation.
6. Power failure and recovery
f.
1.11
Handouts:
Provide attendee’s
understanding of the system.
with
handout
material
which
assist
Guarantee
A.
The Contractor shall repair or replace defective components, rectify malfunctions, correct
software problems (for any software supplied by the Contractor), and correct faulty
workmanship, all at no additional cost to the Owner during the guarantee period. To fulfill
this obligation, he shall utilize technical service personnel designated by the Contractor who
was originally assigned project responsibility. Services shall be performed within five
calendar days after notification by the Owner's Representative.
PART 2 - MATERIALS
2.1
Designation of Components
A.
Component and Equipment naming
1. In these specifications and on the plans, all systems, and other elements are
represented schematically and are designated by numbers, as derived from criteria
in International Society of Automation (ISA) Standards.
2. The nomenclature and numbers designated on the Contact Documents shall be
employed exclusively throughout shop drawings, data sheets, and the like. Any
other symbols, designations, and nomenclature unique to a manufacturer' standard
methods shall not replace those prescribed above without prior Owner authorization.
2.2
2.3
Instrument Tagging
A.
Attach a stainless-steel tag to the instrument at the factory.
stainless-steel tag with the instrument tag number.
B.
The manufacturer’s standard metal nameplate as a minimum shall denote model number,
serial number, operating electrical voltage and amperage (when applicable), date of
manufacturer, and where applicable, operational range and output signal range.
Matching Style, Appearance, and Type
A.
10-15-dp
Permanently mark the
Power provided for the instrument system shall be 24Vdc, from a single source. This
system will supply 100% of the control power for the PLC and instruments. Provide battery
backup system for all components in the Main Control Panel, and for instruments and
network devices on the project.
17000 – General Instrumentation and Control - 17 of 24
B.
Where d-c power supplies are not furnished integral with any one instrument system loop,
provide separate solid-state power supplies.
C. All display instruments of each type shall represent the same outward appearance, having
the same physical size and shape and the same size and style of numbers and pointers.
2.4
Analog Signal Isolator/Repeater – Dual Output
A.
2.5
Manufacturer: WAGO JumpFlex 857-423, no equal
Level Indicating Transmitter
A.
The level transmitter shall use hydrostatic pressure to measure level. It shall include a
sensor/cable assembly 35 feet long and a NEMA 4X housing to mount at the well head or
tank. The housing shall contain an electronics module with zero and span adjustments. It
shall include a 3 1/2 digit LCD, and the output shall be 4-20 mA isolated. Supply power
shall be 24 VDC loop powered. The sensor housing shall be 316 SS.
B.
Manufacturer: Level indicating transmitter shall be manufactured by Delta Controls, Model
592Y-CN-G4Y-4X-35V-328; no-equals allowed.
Tag No.
LIT-201
2.6
Service
Reservoir Level
Probe Length
35 feet
Dwg.
E-2
Level Switches – Conductance Probe Sensor
A.
General: Units shall activate isolated contacts when a conductive liquid completes a circuit
between electrodes. Units shall consist of electrode holder, electrode(s), and control
relays.
1. Electrode holders shall be cast iron pressure-tight assemblies and shall mount with 2
1/2-inch NPT. Unit shall include the number and length of electrodes as required to
accommodate the noted set points. Electrode material shall be Type 316 stainless
steel. Electrodes shall be manufactured by Charles F. Warrick Company, Type
3RXC4 (with PVC sheathing) or 3RXC0 (without PVC sheathing for common probe
only); no-equals. Electrode holder shall be manufactured by Charles F. Warrick
Company, Type 3E2A; no-equals.
2. Induction relay contacts shall be rated for 8 amperes at 120 Vac. Units shall be
powered by 120 volt, 50/60 Hertz. The sensitivity shall be field adjustable by use of
external resistors. Manufacturer shall be Gems, Series 26; no-equals.
B.
Manufacturer:
Units shall be conductance-activated liquid level control systems
manufactured by Charles F. Warrick Company; no-equals allowed.
Tag No.
Common
LSL-110
2.7
Probe Length
TBD
TBD
Dwg.
E-4
E-4
Electronic Pressure Indicating Switch/Transmitter
A.
10-15-dp
Service
Low Water Cutoff
Low Water Cutoff
The electronic pressure indicating switch/transmitter shall provide continuous pressure
monitoring. Pressure switch shall include an 8-digit 14-segment LED display with bargraph
and trend indication.
17000 – General Instrumentation and Control - 18 of 24
B.
All parameters shall be configured by keypad. Display units shall be selectable from: Bar,
psi, psi x 10, hPa, and mbar. The options for pressure measuring ranges are (PSIG): 0150, 0-1500, 0-3000, 0-6000, and 0-9000.
C. Unit shall provide 4 relay outputs and 1 analog output. The analog output shall have an
accuracy of 0.5% full scale. The SPDT relay output contacts shall be rated for 5 amps at
250 VAC. Unit shall be Barksdale Model UDS3-05-N-5; no equals allowed.
D. The following units shall be provided:
Tag No.
PSH/PSL-120
PSH/PSL-130
PSH/PSL-140
PSH/PSL-150
PSH/PSL-160
2.8
10-15-dp
Dwg.
E-4
E-4
E-4
E-4
E-4
A.
Intrusion switches shall be mounted and wired in series such that upon opening any
exterior door shall provide an alarm to the PLC. Intrusion switch shall be NEMA 4X.
Provide Allen Bradley 802MC-AY5; or equal.
B.
The following intrusion switches shall be provided:
Service
Workshop
Electrical Room
Pump Station
Pump Station
Pump Station
Utility Closet Hatch
Sodium Hypochlorite Storage Room
POL Storage Room
Valve Vault 1 Intrusion
Valve Vault 2 Intrusion
Meter Vault Intrusion
Reservoir Access Hatch Intrusion
Butterfly Valve Vault Hatch Intrusion
Dwg.
E-4
E-4
E-4
E-4
E-4
E-4
E-4
E-4
E-7
E-4
E-4
E-8
E-8
Flood Switch
A.
Switch shall be a stem mounted float device with 304 stainless steel stem, Buna N Float
Material, Lucite Slosh Shield, IMO/GEMS Model LS-270 or approved equal.
B.
The following flood switches shall be provided:
Tag No.
LS-107
LS-117
LS-197
LS-200
2.10
High/Low Setpoints
TBD
TBD
TBD
TBD
TBD
Lever Arm Intrusion Switch
Tag No.
ZS-168A
ZS-168B
ZS-168C
ZS-168D
ZS-168E
ZS-168F
ZS-171A
ZS-171B
ZS-108
ZS-118
ZS-198
ZS-199
ZS-200
2.9
Service
Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Service
Valve Vault 1 Flood
Valve Vault 2 Flood
Meter Vault Flood
Butterfly Valve Vault Flood
Dwg.
E-7
E-4
E-4
E-8
Chlorine Analyzer
17000 – General Instrumentation and Control - 19 of 24
A.
General: Unit shall monitor water continuously for total residual chlorine.
B.
Manufacturer: ProMinent Total Chlorine Analyzer; no-equals allowed.
Tag No.
AIT-170
Service
CL2 Residual
Range
TBD
Dwg.
E-4
PART 3 - EXECUTION
3.1
Installation
A.
The drawings indicate connections for typical equipment only. If the equipment furnished is
different from what is shown, provide the modifications necessary for a safe and properly
operating installation in accordance with the equipment manufacturer's recommendations.
B.
The drawings indicate diagrammatically the desired location and arrangement of
equipment. Field determine exact location based on physical size and arrangement of
equipment, finished elevations, and obstructions.
C. Work or equipment not indicated or specified which is necessary for the complete and
proper operation of the instrumentation and control systems shall be accomplished without
additional cost to the Owner.
D. The PCS Integrator shall determine all requirements for and shall cause integration of the
supplied control systems, MCCs, and any supplied packaged equipment control systems
into a complete and unified system. The PCS Integrator shall be responsible for the
coordination and integration of the supplied control system with motor controls and other
related equipment such as VFDs, powermeter, SHC, and back-up generator/ATS.
E. INSTALLATION BY CONTRACTOR: The control system and associated instruments and
connections shall be installed by the contractor.
F. INSTALLATION INSTRUCTIONS: The control system shall be installed in accordance with
the installation drawings and instructions provided by the PCS Integrator, packaged system
suppliers, and other equipment suppliers.
G. SUPERVISION: The PCS Integrator's instrumentation and controls project engineer shall
supervise and coordinate all activities related to the installation of Division 17 requirements.
H. EXPERTISE OF INSTALLER: Installation shall be performed by the workers who are
skilled and experienced in the installation of electrical instrumentation and control systems.
Installation shall include all elements and components of the control systems and all
conduit and interconnecting wiring between all elements, components, sensors, valve
operators, etc.
10-15-dp
I.
LOCATION: Equipment shall be located so that it is readily accessible for operation and
maintenance.
J.
INSTRUMENT TECHNICIAN: The PCS Integrator shall provide the services of skilled
instrument technicians for testing, calibration, and adjustment activities.
17000 – General Instrumentation and Control - 20 of 24
3.2
Mounting of Equipment and Accessories
A.
Mount equipment in accordance with the installation detail drawings as prepared by the
Contractor and reviewed by the Owner. Mount equipment so that they are rigidly
supported, level and plumb, and in such a manner as to provide accessibility; protection
from damage; isolation from heat, shock, and vibration; and freedom from interference with
other equipment, piping, and electrical work. Do not install consoles, cabinets, and panels
until heavy construction work adjacent to computer and telemetry equipment has been
completed to the extent that there shall be no damage to the equipment.
B.
Locate devices, including accessories, where they shall be accessible from grade, except
as shown otherwise.
C. Mount local equipment in cabinets or existing panels as specified. Mount associated I/O
terminals on a common panel or rack; mounting panels and rack shall be baked enamel.
D. Provide cooling for all cabinets containing electronic equipment. Maintain temperatures
inside the cabinet to within the recommended manufacturer’s limits for the equipment
mounted in the cabinet, and not greater than 8 degrees C above ambient. Submit
calculations to Owner for approval prior to manufacturing.
3.3
E.
Coordinate the installation of the electrical service to components related to the system to
assure a compatible and functionally correct system. All accessories shall be coordinated
and installation supervised by the Contractor.
F.
Test the complete system after installation to assure that all components are operating with
the specified range and all interlocks are functioning properly.
Testing
A.
The Contractor shall perform testing and start-up of the instrumentation and control
equipment following the PCS written test procedures, submitted and pre-approved by the
Owner, per Section 17600.
B.
Testing results shall be fully documented by the PCS Integrator. Each step of the test shall
be witnessed and signed off by the Owner or his representative per section 17600.
C. The PCS Integrator shall pre-test the system following the pre-approved test procedures,
prior to the start of witnessed test by the Owner. All problems discovered during the pretest
shall be resolved prior to the witnessed test, per section 17600.
3.4
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Maintenance and Repair Manuals
A.
Maintenance manuals shall be prepared and submitted to the City's Representative for
preliminary review in six copies. When the City's Representative is satisfied that these are
complete and properly prepared, six final sets shall be delivered to the City's
Representative. These manuals shall be submitted two weeks prior to City staff training.
B.
The complete Maintenance manual shall contain all the information included in the
preliminary equipment submittal, the detailed installation submittal, programming
instructions, and the additional information required herein, all bound in hard-cover binders
and arranged for convenient use including tab sheets, all indexed and cross referenced,
and all final As-Built drawings.
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C. The maintenance manuals shall contain:
1. Calibration and maintenance instructions.
2. Trouble-shooting instructions
3. Component replacement procedures.
4. Preventative maintenance procedures.
5. Listing of recommended spare parts.
6. Instructions for ordering replacement parts.
7. Listing of recommended maintenance tools and equipment.
8. Catalog data for all equipment and devices supplied, organized per submittal
requirements.
9. Complete set of “as built” drawings.
10. PLC logic diagrams, comprehensively annotated.
11. “As-built” configuration sheets for all devices with user set parameters, including
VFDs, SSTs, controllers, network devices, and PID tuning parameters.
D. At the time of submittal of the Operations and Maintenance Manuals, the Contractor shall
provide “as-built” versions of submittal drawings, and equipment manufacturers shop
drawings. All contract drawings and control strategy specification sections and all submittal
drawings shall be revised to reflect as-built conditions at the end of the project. Record
drawings and documents shall be submitted with the O&M manuals.
E.
Electronic Files Of Shop Drawings and O&M manuals: In addition to hard copies of
manuals, provide two sets of electronic files on labeled CDs/DVD/solid state drives
containing all:
1. “As-built” shop drawings (CAD files).
2. O&M manuals. Include electronic (pdf) files of all.
a. Manufacturer’s manuals (user and installation)
b. Manufacturer’s data sheets
c. Manufacturer’s drawings
d. Maintenance procedures
e. Equipment List
f.
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Instrument List
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F. SYSTEM USERS MANUAL
1. The PCS Integrator shall develop and submit a detailed user manual covering all
aspects of the operation and use of the components and systems they supply. The
manual shall cover the following:
a. OVERVIEW: An overview of the architecture of the control system including
control panels, MCC's, field devices, PLC, HMI, SCADA, remote alarm
notification, communications, networks, remote access, etc.
b. FUNCTIONS: All hardware/hardwired, programmed, manual, automatic,
display, control, alarming, timer, communications, networking, etc. features and
functions of the systems and components they supply.
c. HARDWIRED ELEMENTS: Descriptions of the meaning and function of all
hardwired panel, MCC, and field mounted discrete operator interface
monitoring and control devices. Correlate functions to the control strategies.
d. TAG LISTS: PLC, HMI, SCADA, remote alarm notification system, tag data
base lists, and register listings.
e. CONFIGURATION SETUP: Configuration screens for all PLC, HMI, SCADA,
PIDs, timers, remote alarm notification, communications, and network system
components.
f. Network schema: Provide IP address listing
g. SECURITY: System, application, data base, remote access, etc., security.
Provide all configured user and administrator user names and passwords.
h. START UP: System start up procedures for SCADA systems supplied and
configured by the contractor for the project.
2. USED IN TRAINING: The system users manual shall be completed prior to and shall
be used for required training. The manual shall be updated to incorporate comments
received during training and re submitted for inclusion in the Final O&M manual.
Submit 2 weeks prior to training.
END OF SECTION
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