SECTION 1.0
General Specification and Requirement for Control and
Instrumentation
SECTION 2.0
Instrument Panel and Local Control Panel
SECTION 3.0
Automation and Control
SECTION 4.0
Control and Signal Transmission Media
SECTION 5.0
Data Communication
SECTION 6.0
Instrument
SECTION 7.0
Final Control
i
Section 1 – General Specifications and Requirements for Control and Instrumentation
Section I
General Specifications and Requirements for
Control and Instrumentation
Section 1 – General Specifications and Requirements for Control and Instrumentation
Section 1 – General Specifications and Requirements for Control and Instrumentation
Page
1.0
GENERAL SPECIFICATIONS AND REQUIREMENTS
FOR CONTROL AND INSTRUMENTATION
1-1
1.1
Overview
1-1
1.2
Design Lifetime Requirements
1-1
1.3
Environmental Considerations
1-2
1.4
Construction of Circuitry
1-2
1.5
Solid-State Circuitry
1-2
1.6
Effect of Failures
1-2
1.7
Immunity to Interference
1-3
1.8
Proven Equipment
1-3
1.9
Tests before Delivery
1-3
1.10
Visibility and Readability of Displays
1-4
1.11
Certificates of Equipment
1-4
1.12
Responsibility for Testing and Acceptance of Works
Following Testing
1.13
1-4
Special Tests and Audit Testing by the Employer’s
Representative
1-4
1.14
Regulations
1-5
1.15
Materials of Malaysian Origin
1-5
1.16
Information from Manufacturer / Supplier
1-5
1.17
Standards
1-6
1.17.1 Reference Standards
1-6
1.17.2 Alternative Reference Standards
1-6
1.17.3 Applicable Issue
1-6
1.17.4 Abbreviations for Reference Standards
1-6
1-i
Section 1 – General Specification and Requirement for Control and Instrumentation
1.0
GENERAL SPECIFICATION AND REQUIREMENT FOR
CONTROL AND INSTRUMENTATION
1.1
OVERVIEW
This specification covers the technical requirements for control and instrumentation equipments. Control
and instrumentation equipments generally cover all station and field control equipments, instruments,
automation and telemetry equipments.
Any instrument or equipment, which is found to be sub-standard, faulty or not conforming to the
requirements of the Specification including any prior approval requirements, shall be rejected. Any
rejected instrument or equipment shall be rectified or replaced at the Manufacturer’s or Supplier’s
expense. The Manufacturer shall undertake Quality Assurance in accordance with this Specification to
ensure that the materials and workmanship of the supplied equipments meet the requirements.
The Manufacturer or Supplier shall provide the Employer’s Representative with access to the
Manufacturer’s quality systems to enable monitoring and quality auditing.
Quality systems proposed by the Manufacturer or Supplier shall be used as an aid to achieving
compliance with the Contract documents and to document such compliance. Such systems shall not
relieve the Manufacturer or Supplier of the responsibility to comply with the requirement of the
Specification.
All instruments and equipments and all of the corresponding components shall be offered by companies
who regularly manufacture and service their products.
The Manufacturer or Supplier shall supply all control, sensing, automation and telemetry equipments,
design and supply marshalling panel, instrument panels, etc. These systems and equipment shall be
collectively referred to as the control and instrumentation (C&I) system.
The Manufacturer or Supplier shall design, manufacture and supply the complete control and
instrumentation (C&I) works and equipment in accordance to the following:
a) Comply with the appropriate laws, regulations, standards, codes and to the satisfaction of the
Employer’s Representative;
b) Ensure the highest standards of operational reliability and maintainability.
Manufacturers who can provide adequate support services and spare parts within Malaysia are preferred.
1.2
Design Lifetime Requirements
Design lifetime shall refer to the period for which an item or system is designed to operate at or in
association with normal works at full design output without major overhaul. These involving
dismantling, anti-corrosion treatment, efficient reduction in excess of 5%, replacement of major
components, etc except for any limited-life components explicitly agreed during the time of Contract
award.
1-1
Section 1 – General Specification and Requirement for Control and Instrumentation
Minimum design lifetime shall be as follows:
a) Control, instrumentation, automation and telemetry equipments shall be in excess of 10 years;
b) Computer systems shall be in excess of 5 years.
1.3
Environmental Considerations
All control and instrumentation equipment shall be suitable for the environmental conditions. Equipment
mounted in enclosures shall be suitable for continuous operation at the maximum internal temperature
possible in service, due account being taken of internally generated heat and heat dissipated by other
equipment. All components shall be rated adequately and circuits shall be designed so that change of
component characteristics within the manufacturers’ tolerances shall not affect the performance of plant.
All equipment shall be designed to operate without artificial cooling.
The control and instrumentation equipment provided with anti-condensation heaters shall be capable of
operating without damage if the heaters are left on continuously.
1.4
Construction of Circuitry
All control and instrumentation equipment shall be designed for rapid fault-diagnosis and replacement of
sub-assemblies and components, which shall be mounted on printed-circuit boards or plug-in type bases
with high-grade, non-ageing plugs and sockets with gold-plated contacts. Components on printed circuit
boards shall be tropicalised and varnished. All transformers shall be double-wound with an earthed
screen between primary and secondary windings.
1.5
Solid-State Circuitry
Integrated circuits shall be used and except in critical protection and safety shutdown circuits, solid-state
devices shall be used in preference to moving-armature relays. Relays shall be of the plug-in type and
shall be hermetically sealed. The standard of reliability for moving armature relays shall not be less than
specified in BS-EN 60947-4-1:2001 or equivalent for medium voltage contactors of Class 3 mechanical
endurance. Operating coils shall be vacuum impregnated or epoxy-resin encapsulated.
Electronic units shall be fully transistorised and the selection and installation of transistors shall give the
maximum life possible. Wire-wound resistors shall be on ceramic formers and embedded in fireproof
and damp-proof material.
1.6
Effect of Failures
The control system shall be designed so that failures of components or power supplies initiate alarms or
protective actions and do not lead to any potentially hazardous condition or mask any actual alarm or
unhealthy state.
Plant protection and control systems shall be designed so that their outputs are de-energised or
neutralized whenever a failure occurs of any component or circuit or power supply associated with that
protection or control circuit.
1-2
Section 1 – General Specification and Requirement for Control and Instrumentation
No single equipment fault shall prevent the correct operation of any protection or shut-down circuit
whenever necessitated by a plant fault condition or control action. No statistically significant
combination of two faults in any protection or shut-down circuit shall prevent the safe operation of the
system whenever necessitated by a plant fault condition or control action
Under emergency, failure or shut-down circumstances each regulating device shall move to the
appropriate safe condition or stay as required.
1.7
Immunity to Interference
All devices shall be immune to normal industrial interference, mains borne interference and to radio
transmitting devices up to 2000 MHz. Transmitters of 5 watts RF power at up to 500 MHz and 1 watt at
up to 2000 MHz can be expected within 1 metre proximity. For radio frequency immunity, the test
standards shall conform to IEC 61000-4-3 : 2002.
1.8
Proven Equipment
All control and instrumentation equipment, including software, shall be proven, preferably in a sewage
treatment plant environment and shall be locally supported with fully capable local based engineering
and technical expertise. Local expertise shall be experienced in the detailed technical and engineering
aspects of the equipment and software.
In the case of programmable logic control (PLC) software, it shall be a requirement that there is at least
one fully operational installation in Malaysia of the software being proposed by the Manufacturer or
Supplier.
Backup central processing unit (CPU) for process automation controller, programmable logic controllers
or remote terminal units shall be supplied for every purchase of the controller or the remote terminal
units. The backup CPU shall be loaded up with all application software, programs and drivers that
similar to the unit installed for operation.
All application software, operating software, driver software, software authorization codes, hardware
dongles, software keys and any other associated written programs for all programmable controllers shall
be surrendered to Employer’s Representative upon delivery of the equipments.
1.9
Test before Delivery
All control and instrumentation equipment shall be subjected to inspection and testing before dispatch
unless officially waived in writing by the Employer’s Representative. All inspection, examination and
testing at the Manufacturer’s premises shall be carried out strictly in accordance with the appropriate
British or IEC Standards or such other standards as approved by the Employer’s Representative.
All costs to be incurred by the manufacturers in carrying out inspection and witness testing of
equipments shall be included in the Contract price or the prices of the equipments.
1-3
Section 1 – General Specification and Requirement for Control and Instrumentation
1.10
Visibility and Readability of Displays
All displays shall be clearly visible and readable in the lighting conditions that would normally be
expected in each location. In this context, “displays” shall include but not be limited to panel lamps,
LCD displays of any size and LED displays of any size.
All display equipments shall be selected, configured and installed such that they are clearly visible and
readable in all expected lighting conditions. It shall not be acceptable for the user to need to shade the
display with their body in order to use a display.
1.11
Certificates of Equipment
Once performance testing and testing at manufacturer’s premises of the control and instrumentation
equipments have been completed and approved by the Employer’s Representative, the manufacturer
shall prepare test certificate and test report in proper bound booklet format for hand over to Employer’s
Representative after approval was granted in writing by the Employer’s Representative.
All control and instrumentation equipments supplied shall be provided with certificates issued by the
manufacturers. Each certificate shall have manufacturer’s name, equipment model, serial number,
country of made, date of manufacture, etc. printed clearly on it. Unless officially waived in writing by
the Employer’s Representative, quality control and quality assurance certificates for all equipments shall
be handed over to Employer’s Representative up on delivery.
Warranty certificates shall be provided for all equipments and shall be handed over to Employer’s
Representative up on delivery.
1.12
Responsibility for Testing and Acceptance of Works
Following Testing
The Manufacturer or Supplier shall be solely responsible for carrying out and reporting to the
Employer’s Representative all testing necessary to ensure compliance with or required under the
Contract. The Employer’s Representative will advise the Manufacturer as to whether the tests indicate
that the work meets the requirements of the Specification. For instrument panels or marshalling panels,
unless otherwise directed, no work shall continue unless the Employer’s Representative has given his
approval of the work. The Employer’s Representative shall order special or further testing as required, at
manufacturers’ premises or some other laboratory. The cost of all testing shall be borne by the
Manufacturer or Supplier.
1.13
Special Tests and Audit Testing by the Employer’s
Representative
The Employer’s Representative shall have the right to enter for the purpose of inspection and testing at
any time during working hours any premises where articles for inclusion in the works are being
manufactured or stored. The Manufacturer or Supplier shall afford the Employer’s Representative every
opportunity to inspect any article, which is manufactured or stored off-site prior to delivery to the site for
inclusion in the works.
1-4
Section 1 – General Specification and Requirement for Control and Instrumentation
The Employer’s Representative reserves the right to order additional samples and testing to satisfy
himself that the requirements of the Contract are being adhered to. The Manufacturer or Supplier shall
arrange for carrying out of testing and/or the obtaining of samples by a testing Authority nominated by
the Employer’s Representative. The cost of audit testing will be reimbursed by the Employer’s
Representative for the costs of tests where the test results confirm that the Specification requirements
have been met. The Manufacturer or Supplier will, therefore, have to meet the costs of Audit tests which
fail.
The Manufacturer or Supplier shall supply all labour and equipment and render all assistance required to
enable carrying out of all tests and inspections which are necessary to ensure the products are in order.
The Manufacturer or Supplier shall perform all inspections and tests required by the Employer’s
Representative or requirement of the Specification and such other inspections and tests as are necessary
for proper compliance with the Project Quality Plan and good construction practice.
If the Manufacturer or Supplier fails to perform any of the foregoing obligations with regard to testing,
the Employer’s Representative shall be at liberty to perform or undertake any testing or inspection at the
Manufacturer’s or Supplier's works or elsewhere, and all costs and expenses incurred in the matter shall
be payable by the Manufacturer or Supplier to the Employer’s Representative on demand, or shall be
deducted and retained by the Employer’s Representative from monies due or that shall become due to the
Manufacturer or Supplier under the Contract.
1.14
Regulations
The Manufacturers or Suppliers shall have a fully operational quality assurance and quality control
program in place and shall comply with ISO 9001: 2000 standards for "Quality Systems- Model for
Quality Assurance in Design/Development, Production, Installation and Servicing.” Complete
documentation describing installation, operation, programming and simple field maintenance shall be
available in paper format and on CD-ROM.
All equipments or products shall have a warranty issued by the original manufacturer for a period of at
least 2 years from the date of delivery to the site and an optional extended warranty.
1.15
Materials of Malaysian Origin
Materials of Malaysian origin shall preferably be used by the Manufacturer or Supplier when the
materials are freely available and the price is competitive.
1.16
Information from Manufacturer / Supplier
The following information shall be made available to the Employer Representative upon delivery:
a)
b)
c)
d)
Storage requirements;
Installation requirement;
Operation and Maintenance manual; and
Drawings
All documents shall be properly compiled in well-labelled hard covered file.
1-5
Section 1 – General Specification and Requirement for Control and Instrumentation
1.17
Standards
1.17.1 Reference Standards
The works for electrical panels shall be carried out in accordance with the relevant quality standards. All
equipment supplied, inclusive of materials and workmanship of all equipments, shall meet or exceed the
relevant quality standards, test procedures or codes of practice, collectively referred to as Reference
Standards, listed in the relevant part of the Specification. The Manufacturers or Suppliers shall
familiarize fully with the requirements of such standards. If no Standard is indicated then the relevant
Malaysian Standard or, in the absence of such standards, internationally recognized Standards shall
apply.
1.17.2 Alternative Reference Standards
Other national Standards can be considered provided that they are, in the opinion of the Employer’s
Representative, not less exacting than the corresponding standard quoted in the Specification. The
Manufacturer or Supplier shall demonstrate to the Employer’s Representative that the alternative
Standard is suitable and equivalent to the specified standard. The Employers’ Representative will decide
whether or not the use of such alternative will be permitted as a Reference Standard. When an
alternative standard is proposed, the Manufacturer or Supplier shall supply the Employer’s
Representative with two copies of the relevant Standard as part of the submission of technical data for
the Employer’s Representative’s or Engineer’s approval.
1.17.3 Applicable Issue
The applicable issue of any Reference Standard shall, unless otherwise stated in the Specification, be the
issue current at the date three months preceding the date for submission of the tenders for the Contract.
1.17.4 Abbreviations for Reference Standards
The following abbreviations where used in the specification refer to Standards, Codes of Practice and
other publications published by the organizations listed.
MS
BS
EN
BS-EN
DIN
VDE
VDI
NEMA
IEEE
CE Marking
IEC
ISO
SI
ISA
ASTM
ANSI
Malaysian Standards
British Standards Institution
European Standards
British – European Standards
German Industrial Standards
Verband Deutscher Elektrotechniker
Verein Deutscher Ingenieure
National Environment Management Authority
Institute of Electrical and Electronics Engineers, Inc.
European Conformity to safety, public health and consumer protection
International Electrotechnical Commission
International Organisation for Standardisation
International System of Units
The Instrumentation, System and Automation Society
American Society for Testing and Materials
American National Standard Institute
1-6
Section 1 – General Specification and Requirement for Control and Instrumentation
ATEX
FM
CSA
UL
C-UL
FCC
ETL
ITU
TIA
EIA
ENV
Atmosphères Explosibles (Equipment intended for use in Potentially Explosive
Atmospheres)
Factory Mutual
Canadian Standards Association
Underwriters Laboratories Inc.
Underwriters Laboratories Inc. of Canada
Federal Communications Commission.
Intertek Testing Services
International Telecommunication Union
Telecommunications Industry Association
Electronic Industries Alliance
Environmental Standard
Reference Standards are referred to in the text of the Specification in abbreviated form (e.g. BS EN
60947-4-1 : 2001).
1-7
Section 2 – Instrument Panel and Local Control Panel
Section 2
Instrument Panel and Local Control Panel
Section 2 – Instrument Panel and Local Control Panel
Page
2.0
INSTRUMENT PANEL AND LOCAL CONTROL PANEL
2-1
2.1
General
2-1
2.2
Indoor Panel Requirements
2-1
2.3
Outdoor Panel Requirements
2-2
2.4
Panel Design and Construction
2-3
2.5
Component Arrangement
2-4
2.6
Indicating Lamp and Fitting
2-5
2.7
Push Buttons
2-6
2.8
Panel Lighting and Socket Outlets
2-7
2.9
Panel Heating
2-14
2.10
Panel Wiring
2-14
2.11
Terminal Block
2-16
2.12
Panel Earthing
2-16
2.13
Electrical Circuit Protection
2-16
2.14
Panel Piping and Tubing
2-17
2.15
Alarm Annunciating System
2-18
2.16
Interposing Relays
2-19
2.17
Trip Amplifiers
2-20
2.18
Signal Isolators
2-20
2.19
Lightning Protection Unit
2-21
2.19.1
Signal and Data Line Protection
2-22
2.19.2
Power Supply Line Protection
2-22
Product and Material Specification
Issue 01 / Rev 0
28th July 2008
2-i
Section 2 – Instrument Panel and Local Control Panel
LIST OF TABLES
Table 2.1
Colour-Coded for Panel Piping
LIST OF FIGURES
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
Typical Free-Standing Floor-Mounted Type Panel Front and Side View and Base Layout
Typical Free-Standing Floor-Mounted Type Panel Detail for Component Arrangement
Typical Desk-Pattern Type Panel Front, Rear, Side View and Base Layout
Typical Desk-Pattern Type Panel Detail for Component Arrangement
Typical Wall Mounted Type Panel Front, Section View and Base Layout
Typical Wall Mounted Type Panel Detail for Component Arrangement
Product and Material Specification
Issue 01 / Rev 0
28th July 2008
2-ii
Section 2 – Instrument Panel and Local Control Panel
2.0
INSTRUMENT PANEL AND LOCAL CONTROL PANEL
2.1
General
All panels in associate with instrument, local control, supervisory equipment, etc shall generally be freestanding floor-mounted cabinets of the cubicle or desk-pattern or wall mounted enclosures and will be
referred herein as panels. The panels shall generally conform to the requirements specified in the
Specification. The panels shall be of modular design and suitable for either indoor or outdoor locations
with metal clad enclosure requirement as set out in following clauses.
All supplied components and equipments shall be standardised as much as possible. Electrically identical
components shall be of one type and make. Components installed shall be tested in accordance with
recognized UL, C-UL, CSA, IEC and CE mark industrial standards.
2.2
Indoor Panel Requirements
Panels for indoor application shall be fabricated from prime quality, cold rolled and annealed mild steel
or zinc-coated mild steel sheet of adequate thickness and suitably braced to form a rigid structure without
welded cross-struts.
The entire panel enclosure shall provide a degree of protection not less than IP 42 in purpose designed
control rooms and IP 54 for other indoor locations. Locations, where there is a roof but no walls, shall be
considered as outdoors due to susceptibility of the panel to wind-blown rain.
All indoor panels installed with programmable controllers or others heat sensitive electronic equipments
shall be provided with forced ventilation. Panel manufacturers shall submit design calculations verifying
the fact. Fans shall be controlled automatically by mean of temperature sensing controllers with manual
by-pass switches. Fans shall be noise free. Fans shall be mounted with their axis horizontal and shall be
arranged to draw clean air into the panel. Air entries shall have filters, which can be renewed easily. The
design of the filtered air entries shall prevent entry spray, injurious fluids, sand or dust.
Non-deteriorable neoprene gaskets shall be fitted to the panel front doors and all cover plates to minimise
entry of dust. Gaskets shall be of minimum 6 mm in any direction. Gaskets shall be continuous without
joints around corners, and suitably arranged to minimise the transmission of vibration.
The panel sheet thickness shall be chosen with due regards to the panel size, number of cut-outs,
instruments weight, position of centre of gravity and method of fabrication, with the following minimum
thickness:-
Instrument bearing surfaces :
Gland plate
:
Pneumatic distribution plates :
Desktops
:
Internal mounting plate
:
Doors, covers, filler panels :
Hollow square sections
:
Main frame angle
:
2.3 mm
2.3 mm
2.3 mm
2.3 mm
2.3 mm
2.3 mm
40mm x 40mm x 2.3 mm
50mm x 50mm x 6 mm
2-1
Section 2 – Instrument Panel and Local Control Panel
The indoor service panel shall be made of electro galvanised sheet steel of rigid construction. Before
painting, the plates shall undergo the following pre-treatment process of cleaning with water and
chemical solutions as follows: a)
b)
c)
d)
e)
f)
Zinc-coating for chemical protection.
Phosphate treatment for enhancing paint-ability.
Chromate treatment to enhance corrosion resistance.
Degreasing process to remove greasy contaminants such as oils, fats and lubricants.
Rinsing with water at ambient temperature for 3-5 minutes.
Derusting / Descaling with acid pickling solution at 40-50 ºC for 12 minutes. Brushing method
shall be applied for removing of tough rust.
Rinsing with multi-purpose cleaner
Self dry in open air.
g)
h)
The preparation and painting shall be suitable for the environment in which the panels are to be
installed. Full details of preparation, treatment, final coat and painting system shall be submitted to
the Employer’s Representative for approval.
Painting shall be carried out with an electrostatic airless spray powder gun. Epoxy polyester paint
power shall be used. The paint thickness shall not less than 90 micro-metres and shall be made on dry
film using magnetic or eddy current properties. After the sheet steel painting is completed, it shall be
sent to an infra-red oven to be baked at 180ºC for a minimum 30 minutes.
Panel shall be mounted on reinforced concrete plinth having minimum 200 mm height from finished
floor level with provision for cable access. A reinforced concrete paved area for full length of the
panel and extending 1000 mm in front of the panel. Minimum clearance of 900 mm shall be made
available between an opened door and any fixed object, structure or facing panel.
2.3
Outdoor Panel Requirements
The panel construction for outdoor service panels shall use stainless steel sheet grade 316, marine grade
aluminium sheet or glass reinforced plastic. All outdoor panels shall be designed to provide a degree of
protection to IP 56. The panel sheet thickness shall be chosen with due regards to the panel size, number
of cut-outs, instruments weight, position of centre of gravity and method of fabrication, with the
following minimum thickness:-
Instrument bearing surfaces :
Gland plate
:
Pneumatic distribution plates :
Desktops
:
Internal mounting plate
:
Doors, covers, filler panels :
Hollow square sections
:
Main frame angle
:
2 mm
2 mm
2 mm
2 mm
2 mm
2 mm
40mm x 40mm x 2 mm
50mm x 50mm x 3 mm
The panels shall be fitted with lockable outside doors and a housing so designed that all controls,
instruments and such like are fully enclosed and the whole assembly is weatherproof and vandal proof.
The doors shall be fitted with stays to prevent overstraining of the hinge fixing, and allow fixing of the
doors in the open position. Inner cubicles shall also be weatherproof to allow operation of controls when
2-2
Section 2 – Instrument Panel and Local Control Panel
outside doors are open during inclement weather. The cubicles shall have a rear sloping outdoor roofing
projecting over the front by at least 75 mm. Slope of the roof shall be 1:20. Door mounted components
shall be protected by a vandal resistant secondary glazed door so that all controls and indicators are
clearly visible.
All outdoor panels installed with programmable controllers or others heat sensitive electronic
equipments shall be provided with forced ventilation. Panel manufacturers shall submit design
calculations verifying the fact. Fans shall be controlled automatically by mean of temperature sensing
controllers with manual by-pass switches. Fans shall be noise free. Fans shall be mounted with their axis
horizontal and shall be arranged to draw clean air into the panel. Air entries shall have filters, which can
be renewed easily. The design of the filtered air entries shall prevent entry of rain, spray, injurious fluids,
sand or dust.
A weather canopy constructed from hot dipped galvanized steel cladding shall be provided above the
free-standing floor mount panel to minimize direct sunshine to the panel. The canopy shall have an
extended roof at least 2000 mm from the panel. Gutter shall be provided accordingly.
Wall mounted type outdoor panels shall be provided with awning above the panels and extended at least
2000 mm from the wall. Gutter shall be provided accordingly.
Panel shall be mounted on reinforced concrete plinth having minimum 200 mm height from finished
floor or ground level with provision for cable access. A reinforced concrete slab hard-standing area
for the full length of the panel and extending 1000 mm in front of the panel. Minimum clearance of
900 mm shall be made available between an opened door and any fixed object, structure or facing
panel.
2.4
Panel Design and Construction
Panel fronts shall be flat and free from bow or ripple. Exterior corners and edges shall be rounded to
give a smooth overall appearance.
Stiffeners and supporting frameworks shall be provided where necessary and shall be welded to the
interior of the panels. The framework shall be suitable for installation of all cable trays, terminals, air
headers and pipe runs to individual instruments and for any item of equipment mounted within the panel.
The stiffeners and framework shall not interfere with connections to instruments or with access required
for adjustment, maintenance servicing or removal.
Unless otherwise approved, each panel shall be mounted on self-draining base frame fabricated from
50mm high, steel channel section and which shall be drilled or provided with clamps for bolting to the
concrete slab. The base frame shall be set back from the panel front face to give a toe space of not less
than 25mm. The outside of the base frame shall be covered with an approved kicking strip.
Ceiling and other fillers panels shall be fabricated from appropriate material as specified in former
sections and adequately stiffened. Each section shall have 50 mm returned edge along all the four sides
and shall be braced to the main frameworks of the panel.
Unless otherwise specified, all cable entry shall be from bottom. Gland plate shall be provided inside all
panels.
2-3
Section 2 – Instrument Panel and Local Control Panel
For free-standing floor mounted type and desk-pattern type panel, gland plates shall be provided at
300mm above the base frame level. Sufficient removable, undrilled gland plates shall be fitted close to
the appropriate terminal blocks not less than 300mm above the base frame level. Removable side covers
shall be incorporated, and give adequate access to the bottom side of the gland plates and at the same
time provide a vermin proof construction.
Panels containing pneumatic or other instruments using a fluid transmission medium shall have
distribution plates with bulkhead unions for the termination of internal and external pipe work.
Internal segregation shall be provided for installation of electrical and non-electrical instruments in the
same panel. All connections shall be arranged to ensure that no accidental damage to cabling or electrical
components can occur in the event of failure of any non-electrical components or connection.
Panel shall be supplied with hinged access doors fitted with chrome plated lockable car-type handle
operable from inside even when locked. All doors in one panel shall use the same lock and key
combination. Doors shall be rigid, of folded construction, open outwards and provided with close fitting
flexible seals to prevent ingress of dust and vermin. Hinges shall be of the lift-off pattern and one hinge
shall engage before the other for ease of fitting. Hinges shall not be spaced more than 1200mm apart.
No equipment other than front-of-panels items shall be mounted on internal panel surfaces.
Suitable lifting lugs together with blanking set screws shall be provided to facilitate unloading.
All panel constructional details and arrangements shall be approved before manufacture and will be
subject to inspection at agreed stages.
2.5
Component Arrangement
The following dimensions and component mounting positions are the guidelines for panel construction:
a)
Free-Standing Floor-Mounted Type Panels
i)
ii)
Height
:
Width of each tier :
not greater than 2100mm above finished floor level;
to suit design and installation requirement, and access doors shall
be double leaf type for panels width greater than 1000mm;
iii) Depth
: to suit design and installation requirement;
iv) Drawing pocket : minimum 250 mm x 250 mm x 20 mm on the inside of each panel;
v) Position of front-of-panel instruments and controls:
- Centre of instruments shall be between 1800mm and 750mm for indicators;
- Centre of instruments shall be between 1500mm and 750mm for recorders;
- Centre of instruments shall be between 1900mm and 1000mm for alarm fascias and
signal lamps;
- Centre of instruments shall be between 1600mm and 600mm for manual control
devices;
- Control switches and pushbuttons shall be positioned below or adjacent to the
associated reading instrument.
Figure 2.1 to Figure 2.2 show typical details for panel design and arrangement.
2-4
Section 2 – Instrument Panel and Local Control Panel
b)
Desk-Pattern Type Panels
i)
ii)
Height
:
Width of each tier :
not greater than 1450mm above finished floor level;
to suit design and installation requirement, and access doors shall
be double leaf type for panels width greater than 550mm;
iii) Depth
: to suit design and installation requirements;
iv) Drawing pocket : minimum 250 mm x 250 mm x 20 mm on the inside of each panel;
v) Position of instruments and controls at vertical front panel:
- Alarm annunciator, instrument read out indicator and counter, and temperature and
level indicator.
vi) Position of instruments and controls at desk-top front panel:
- Control mode selection, equipment control and common alarm control.
Figure 2.3 to Figure 2.4 show typical details for panel design and arrangement.
c)
Wall-Mounted Type Panels
i)
ii)
Height
:
Width of each tier :
not greater than 1600mm;
to suit design and installation requirement, and access doors shall
be double leaf type for panels width greater than 800mm;
iii) Depth
: to suit design and installation requirement;
iv) Drawing pocket : minimum 250 mm x 250 mm x 20 mm on the inside of each panel;
v) Position of front-of-panel instruments and controls :
- Centre of instruments shall be between 1150mm and 900mm for indicators;
- Centre of instruments shall be between 900mm and 300mm for recorders;
- Centre of instruments shall be between 1200mm and 600mm for alarm fascias and
signal lamps;
- Centre of instruments shall be between 990mm and 300mm for manual control devices;
- Control switches and pushbuttons shall be positioned below or adjacent to the
associated reading instrument.
Figure 2.5 to Figure 2.6 show typical details for panel design and arrangement.
Wall mounted type panel shall be located at least 600 mm from the floor. Wall mounted type panel
shall only be used at site that with space constraint and the use of floor standing type panel is not
practical. Unless otherwise specified, written approval shall be obtained from the Employer’s
Representative for using wall mounted type panels.
2.6
Indicating Lamp and Fitting
Status indication lamps on instrument panel, local control panel, etc shall be uniform type as far ad
possible, to minimize spares requirements. Lamps shall be easily removable and replaceable from the of
the panel by manual means not requiring the use of tools.
The bezel holding the lamp lens shall be of chromium plated and polished solid brass or die cast
aluminium. The bezel shall be easily removable from the body of the fitting so as to permit access to the
lamp and lamp lens.
Status indicating lamp circuits shall be separately fused.
2-5
Section 2 – Instrument Panel and Local Control Panel
Status indication lamps on instrument panel, local control panel, etc shall be of light emittting diode
(LED) type and lamp colours shall adhere to the following schedule unless revised by the Employer’s
Representative. :Red
Green
Amber
Yellow
White
Blue
-
Circuit-breaker opened
Motor stopped
Valve closed
Circuit-breaker closed
Motor running
Valve opened
Urgent alarm (plant tripped)
Non-urgent alarm
General, e.g. heater on
Duty
Each light shall have a descriptive label affixed beneath the light fitting or an engraving on the screen of
the fitting. All wording shall be approved by the Employer’s Representative before manufacture.
Indication lamps shall correspond in position above respective push buttons.
2.7
Push Buttons
All emergency stop push buttons shall be of the stay-put pattern arranged to permanently open a circuit
until deliberate reset action has been carried out.
All emergency stop push button shall have red mushroom headed pushes of the stay-put pattern, shall be
connected in control circuits such that they are effective under all conditions. They shall be capable of
being locked in the ‘depressed’ position by means of an external removable key. Resetting of the push
button shall not restart the device.
Emergency stop push button installed at a pole mounted enclosure shall be provided and positioned in
the immediate vicinity of the electrically driven equipment where there is no direct line of sight between
the equipment and the control centre or where the distance between the equipment and the control centre
exceeds 5 metres.
Push buttons shall comply with BS 9564. Push buttons shall be individual flush mounted units with
chromium plated and polished solid brass or die cast aluminium body and ring, circular in shape and 25
mm in diameter. The start and stop push buttons shall be effective in manual mode of operation only.
Push button colour shall adhere to the following schedule.
Green
Red
Yellow
Black
Blue
-
Motor start
Valve open
Motor stop
Valve close
Emergency stop
Alarm accept
Reset
Lamp test
2-6
Section 2 – Instrument Panel and Local Control Panel
Pole mounted push buttons shall be one (1) metre above floor level. Outdoor push button enclosure shall
be fibre glass reinforced polyester and weather proof to IP 56 with an internal mounting plate. The start,
stop and emergency stop push buttons shall also be weather proof to IP 56. Sunshades shall be provided
for outdoor push button stations. The stand assembly and sunshade shall be hot dipped galvanised.
Push button station for indoor application shall be the same as for outdoor application except degree of
protection is IP 54 for indoor application.
2.8
Panel Lighting and Socket Outlets
All panels shall be adequately and evenly illuminated internally and as free from dazzle as possible, by
fluorescent lighting. The lighting circuits shall be controlled from totally enclosed door operated
switches. The lighting circuit shall be independently fused and designed to allow lamps to be replaced
safely.
There shall also be one installed inspection lamp per three metres of panel length or part thereof with
adequate flexible cable to reach any point in the panel. The lamp shall come complete with control
switch.
Panels having 240 VAC supply shall be fitted with metal clad 13 A switched socket outlets at the rate of
one socket for each two metres of panel length with a minimum of two sockets. The sockets outlet shall
be fitted with Residual Current Circuit Breaker (RCCB) in accordance with Malaysian Electricity Supply
Act & Regulations and Rules, Electricity Regulations section, Part 36 for Protection Against Earth
Leakage Current.
Socket outlet circuit protective devices shall be independent of any instrumentation and control circuit.
Socket outlet circuit protective devices shall be sized taking into consideration the limited capacity of
any upstream UPS. It shall not be possible to trip the supply to the panel merely by connecting a heavy
load to an internal panel socket outlet.
2-7
Section 2 – Instrument Panel and Local Control Panel
Figure 2.1: Typical Free-Standing Floor-Mounted Type Panel Front and Side View and Base
Layout
2-8
Section 2 – Instrument Panel and Local Control Panel
Figure 2.2: Typical Free-Standing Floor-Mounted Type Panel Detail for Component Arrangement
Figure 2.3: Typical Desk-Pattern Type Panel Front, Rear, Side View and Base Layout
2-9
Section 2 – Instrument Panel and Local Control Panel
Figure 2.4: Typical Desk-Pattern Type Panel Detail for Component Arrangement
2-10
Section 2 – Instrument Panel and Local Control Panel
Figure 2.5: Typical Wall Mounted Type Panel Front, Section View and Base Layout
2-11
Section 2 – Instrument Panel and Local Control Panel
Figure 2.6: Typical Wall Mounted Type Panel Detail for Component Arrangement
2-12
Section 2 – Instrument Panel and Local Control Panel
2-13
Section 2 – Instrument Panel and Local Control Panel
2.9
Panel Heating
All cubicles shall be provided with one or more thermostatically controlled tubular heaters to prevent
condensation and assist ventilation. The rating shall not exceed 100 watts per metre, and the surface
temperature of any part that shall be contacted accidentally shall not exceed 60ºC.
The heaters shall be so situated that no detrimental effect on temperature sensitive apparatus or wiring in
the cubicle. The heating circuit shall be independently switched and fused complete with an RCCB of
30mA sensitivity, and controlled by a suitably labelled, rotary pattern, enclosed switch mounted in an
accessible position within the cubicle. Heat resistant cables shall be used for connection to the heaters.
Thermostats shall be mounted remote from the heaters and shall be fully adjustable over a range of not
less than 0 to 50ºC.
2.10
Panel Wiring
Panel circuits and wiring shall be segregated into the following categories:a)
Group 1 - Power, control and very high level signal wiring (above 50 V)
i)
ii)
iii)
iv)
b)
AC power supplies;
DC power supplies;
AC current signals above 50 mA (e.g. Current transformer circuits);
AC voltage and control signals above 50 volts (e.g. Voltage transformer circuits).
Group 2 - High level signal wiring (6 to 50 V DC)
i)
ii)
Signals from conventional electronic transmitters and controllers (eg 4-20 mA);
Circuits to alarm annunciators and other solid state devices (excluding those in categories
Group 2 Item i), Group 2 Item v) and Group 3);
iii) Digital signals;
iv) Emergency shut-down and tripping circuits;
v) On/off control circuits.
c)
Group 3 - Low level signal wiring (5 V DC and below)
i)
Signals from thermocouples;
ii) Signals from resistance thermometers and re-transmitting slide-wires;
iii) Signals from analytical equipment and strain gauges.
d)
Group 4 - Interconnecting wiring (between relays etc)
i) AC above 50 V;
ii) DC above 50 V;
iii) DC 50 V and below.
2-14
Section 2 – Instrument Panel and Local Control Panel
For Group 3 wiring, the external cable shall be gland to the panel gland plate. Internal connections to the
instruments shall be carried out by one of the following methods:a)
The twisted, screened conductors of the external cable shall be led direct to their appropriate
instruments via ducting systems installed for this purpose during construction of the panel.
b)
The conductors of the external cable shall be terminated on terminals segregated from each other
and from all other categories and the connections to the appropriate instruments shall be made using
twisted pairs with individual screening installed for this purpose during construction of the panel.
The maximum potential between any two points within the panel shall not exceed 250 volts.
Internal wiring for all circuits in Group 2 except those sharing a common connection shall be multistranded, twisted pair, 0.75 sq. mm minimum copper conductors with HDPE or PVC insulated cable of
adequate grade and rating in accordance with BS 6004:2000. Wiring for circuits in other Groups or
sharing a common connection shall be run in stranded, 1.5 sq. mm minimum copper conductor with
600 V grade, PVC insulated cable of adequate grade and rating.
Wiring sheath colours shall be red for phase and black for neutral for AC circuits, grey for DC circuits
(excluding thermocouple circuits), white for emergency shut-down and tripping circuits and light blue
for intrinsically safe circuit.
Circuits supplied at 240 V AC or above, between 24 V and 110 V DC, shall also be segregated from
each other and from other circuits. Access to wiring and components of circuits having voltages
exceeding 240 V shall not be possible unless and until the circuit has been isolated.
Separate ducts, trunking, cable looms, tray work etc. shall be provided within the panel for each category
with at least 150 mm between parallel paths of Group 1 cables and those of any other Group. The field
side of intrinsically safe circuits and their terminals shall be segregated from all other circuits and
terminals, but shall be generally treated as for Group 2 circuits. Trunking for intrinsically safe wiring
shall be blue in colour.
All wiring shall be neatly and securely fixed by insulated cleats, bunched and secured by approved
plastic strapping or run in approved insulated wiring trunking or non-corrodible flexible tubing. Not
more than 75% of the capacity of trunking, ducts, or tubing shall be used. Insulated earth wiring shall be
so arranged that access to any equipment or connection point or the removal of any item of equipment is
unimpeded. Wiring for future equipment shall be secured and terminated on terminal blocks. Lacing for
wiring looms shall be of rot-proof cord or plastic strips. Inter-section wiring in multi-section cabinets
shall be via a terminal block in each section.
Any panel mounted device to which connections are made by means of a plug and socket instead of a
terminal block, shall be wired in a flexible cable of adequate rating between the 'free' plug and socket and
a fixed terminal block.
Identification ferrules shall be fitted at both ends of all wires. The ferrules shall be of insulating material
with permanent black characters on a glossy white or yellow background unaffected by oil or water.
They shall be arranged so that they can be read logically from left to right when viewed normally.
2-15
Section 2 – Instrument Panel and Local Control Panel
2.11
Terminal Block
A terminal block shall be provided as an interface between the corresponding conductors of each internal
and external connection. The terminal blocks shall be mounted vertically where possible and at least 230
mm from the gland plate. Each wire connected to a stud type or screw type terminal in panel mounted
equipment shall be terminated onto a crimped-on terminal. Not more than one core of any external cable
or internal wire shall be connected to any terminal.
The terminals of the terminal blocks shall clamp the wires securely without damage between two plates
by mean of captive screws or by mean of cage clamp. Terminal blocks shall permit the introduction of a
test milliammeter without disconnecting any wiring. Terminal blocks for circuits containing volt free
contacts internal or external to the cabinet shall be of the captive screws or Cage Clamp type or
equivalent. Terminal blocks shall permit the introduction of a test continuity meter without disconnecting
any wiring. Each row of terminal blocks provided shall contain at least 25% spare terminal over the
number required for terminating all cores of external cables in that row. All spare cores of external
cables shall be terminated in the terminal block and labelled accordingly.
Terminal for similar group of service shall be arranged and installed neatly in a group. Terminal blocks
input and output (I/O) points shall be arranged and installed in groups in accordance with type of
equipments. Terminal blocks use for application of similar equipment shall be grouped together and
arranged neatly.
2.12
Panel Earthing
All panels shall be provided with two earthing facilities.
The first earthing facility shall be a continuous tinned copper earth bar run the full length of each panel
and fixed and bonded electrically to the main frame. The earthing facilities shall be of minimum
25
mm x 6 mm cross section and shall be provided with suitable brass terminal of not less than 8 mm
International Standard screw thread for connection to the metal cladding. The cable gland shall be
provided with the similar brass terminal for connection to armouring of all incoming and outgoing cables
and to the station system.
The second earthing facility shall be tinned copper tape with cross section not less than 25 mm x 6 mm
and electrically isolated from the steelwork of the panel and metal cladding and armouring of cables.
This second earthing facility shall be used for signal earth connection of each instrumentation and
control device to the station instrumentation earthing system. The earthing facility shall have sufficient
brass terminals as specified above for each instrumentation and control device and the screen of every
shielded cable plus 25% spare terminals.
Each earthing facility shall be electrically bonded to the corresponding bars in the adjacent section(s).
2.13
Electrical Circuit Protection
Adequate facilities for isolation and protection by miniature circuit breaker or fuse for each control and
instrument circuit and sub-circuit shall be provided and shall be so arranged that any fuse failure causes
minimum disruption of plant, operates and appropriate alarm and cannot result in any unsafe operating
condition.
2-16
Section 2 – Instrument Panel and Local Control Panel
All Miniature Circuit Breakers (MCBs) shall comply with IEC 947-2 and shall be of DIN rail
mounted type. MCB shall not be used for controlling 3-phase equipment unless prior approval has
been obtained from the Employer’s Representative.
The breaking capacities of the MCBs shall be at least equal to the prospective fault level at the point
of the distribution system where they are installed and the ultimate service breaking capacity (ICS)
shall be minimum 10 KA. Each pole shall be provided with bimetallic thermal element for inverse
time delay protection and magnetic element for short circuit protection. Where switching of neutral is
required and for DC circuits, the MCB shall be of double-pole type. MCB shall be trip free type and
shall be capable of sustaining 20,000 switching operations.
The operating mechanism shall be quick make, quick break and mechanically trip free so as to prevent
the contacts from being held closed against short circuit and overload conditions. The operating
mechanism shall be so constructed to operate all poles in a multi-pole breaker simultaneously during
opening, closing and tripping conditions. The operating handle shall be of the toggle type
All fuses shall be of high rupturing capacity (HRC) cartridge type. Fuse and solid link carriers and
bases shall be made of plastic moulded insulating material of an approved make. The fuses shall be
rated to give maximum protection to the apparatus in circuit and the rating shall be inscribed on the
fuse label and on the fuse carrier. All live connections shall be effectively shrouded and it shall be
possible to change fuses with the circuit live without danger of contact with live metal. Shrouds shall
have a minimum degree of protection of IP 30.
Bolted covers on compartments incorporating live conductors shall be fitted with a warning label.
An adequate number of spare fuse cartridges for each rating shall be supplied and fitted in clips inside
the panel. Fuses and links in the same circuit shall be mounted opposite each other in separate rows and
shall not alternate in the same row. At least 20% unallocated fuses and links shall be provided.
Each instrument requiring a power supply shall be individually wired and protected. Power supply
circuits shall be of sufficient rating that any protective device shall operate without reducing the voltage
at the terminals of any other component to an unacceptable level. Remote alarms shall be operated on
failure of the electrical supply to a panel.
2.14
Panel Piping and Tubing
Panels containing equipment using a supply of compressed air shall have a common air pressurereducing station with duplicate pressure reducing valves and filters. The pressure reducing station shall
also include isolating valves upstream and downstream of each filter/reducing valve set, pressure relief
valve, pressure indicator and low pressure alarm unit for the low pressure header and a pressure indicator
for the high pressure pipe work. The pressure reducing station components shall be mounted in a clear
space inside the panel, supported on a suitable framework between the lower horizontal row of
instruments and the main low pressure header.
All piping, fittings and valves downstream of the pressure reducing station shall be of brass or copper.
Engineered plastic polytetrafluoroethylene (PTFE) tape shall not be used downstream of the main filters.
The low pressure header shall be brass and shall be near the panel floor with drain valves and tundishes
piped to a drain. Branch air headers shall be of brass (15 mm diameter minimum) and shall run
2-17
Section 2 – Instrument Panel and Local Control Panel
vertically from the header to the instrument. The low pressure header and each branch shall have a
6 mm minimum, non-ferrous shut-off valve for each instrument requiring an air supply and a
compression coupling for each air purge connection. At least 10% spare connections for possible future
instruments shall be provided in each panel section. Any header dismantled before shipment shall have
brass unions or flanges at each panel section junction.
Panel-mounted instruments shall be piped to bulkhead fittings on a gland plate during assembly at the
manufacturer's works. Piping shall be colour-coded as follows:
Table 2.1: Colour-Coded for Panel Piping
Service
Compressed Air
Air Release
Colour
Light Blue
White
BS 4800 Colour Code / Munsell Colour Ref. No.
20 E 51
00 E 55
The piping shall be segregated from wiring so that any leakage is harmless. Each panel-mounted
pressure gauge shall have a stainless steel flush-mounting shut-off and fine-regulating valve mounted
vertically below. A drip tray shall be provided below each row of gauges.
2.15
Alarm Annunciating System
Alarm functions shall be indicated on internally illuminated annunciator units bearing appropriate
legends and arranged on the panel in groups to be agreed with the Employer’s Representative.
Each annunciator shall have at least 20% spare ways for possible future alarms and shall be as compact
as possible without unnecessary decorative trim.
The alarm indications on each annunciator shall be logically arranged in a format to be agreed with the
Employer’s Representative. The alarm lights shall have secret legends which are invisible until
illuminated. The legends area of each indication shall not be more than 30 mm high and 60 mm wide.
The wording of all legends shall be approved by the Employer’s Representative before manufacture.
“Alarm accept", "Reset" and "Lamp test" pushbuttons shall be provided in the middle of the panel.
A buzzer and a siren of approved make approximately 80 decibels at 3 metres and of not less than 30
minute rating shall be mounted within the panel together with muting switches mounted inside for use
during commissioning and testing. Audible devices in the same room or area shall have distinguishable
sounds and adjustable sound levels.
Panel alarm annunciators and audible alarm shall operate as follows:
a)
When an alarm condition occurs, a light behind the appropriate legend shall flash on and off
intermittently and the audible alarm shall sound. The flashing rate shall not be less than 2 Hz and
shall not exceed 5 Hz;
b)
On pressing the "Alarm accept" push-button, the audible alarm shall be silenced and the flashing
light shall become steady;
2-18
Section 2 – Instrument Panel and Local Control Panel
c)
The alarm indication shall remain illuminated whether or not the alarm condition has returned to
normal until the 'alarm reset pushbutton has been operated whereupon the light shall be
extinguished if the fault condition no longer exists;
d)
Operation of the "lamp test" pushbutton shall cause all the alarm lamps to be illuminated
simultaneously and the audible alarm to be sounded;
e)
The alarm system shall respond to any new condition that might arise while an existing condition is
being indicated, whether accepted or not, and to any that might occur during a "lamp test"
operation.
The operation / acceptance of one alarm shall not inhibit the operation of the appropriate audible device
or the flashing of the appropriate alarm indicator if a further alarm condition occurs. Alarms operated on
two or more annunciators shall require acceptance at each annunciator. Alarms shall be accepted
automatically and the appropriate audible device silenced after an adjustable period of 1 to 5 minutes.
Alarms shall be initiated by opening or closing of volt-free contacts which shall remain unchanged
throughout the periods in which the alarm conditions exist.
Alarm circuitry, shall be arranged so that spurious or transient alarm states persisting for less than 0.5
seconds do not initiate any action. However, the suppression circuitry shall be such that repeated
spurious or transient status for the same alarm occurring in a five second period shall initiate the
appropriate action. The alarm system shall operate on a 24 V DC supply and be designed on the 'fail safe'
principle so that a fault in any circuit component causes an alarm to be given.
2.16
Interposing Relays
All interposing relays shall be extra low voltage and be of the plug-in type and fitted with plastic dust
proof covers, retaining clips, a base into which the relay plugs and external connections shall be made
using easily accessible screw clamp terminals. Bases and relays shall be keyed to prevent relays being
plugged into incorrect bases. If mounted on DIN rails, blocking pins shall be provided. Space and
drillings shall be provided for a minimum of 10% additional relays.
Relays shall be fitted with neon or LED indicator connected across the operating coil and easily visible
when the compartment door is open. Relays fitted with mechanical indicator shall not be accepted. D.C.
relays shall be ringed with a diode (1200 V, 1A).
The number of different contact configurations on relays shall be kept to a minimum even if some relays
have unused contacts, to assist in keeping spares stock to a minimum.
Multi-contact interposing relays shall be incorporated into panel circuitry where only one pair of
initiating contacts is provided on the plant being monitored, for the operation of different functions
simultaneously, e.g. a control initiation with alarm annunciation and data logging. The relay contacts
shall be so connected that a failure in any one circuit shall have no effect on any other.
The use of spare contacts on interface relays fitted within annunciator units or other secondary circuit
equipment, or any other form of cascade operation other than that controlled by the plant contacts, in
which the performance of one circuit is dependent on the correct operation of another, shall not be
accepted.
2-19
Section 2 – Instrument Panel and Local Control Panel
2.17
Trip Amplifiers
Trip amplifiers shall be suitable for back of panel or rack mounting and shall accept a 4-20 mA DC
linear signal as an input.
Single input single trip level or single input dual trip level models shall be provided according to the
requirements of the Specification.
The trip amplifier shall drive down scale on open circuit.
The trip adjustment shall be mounted on the instrument front and shall be infinitely variable by a
lockable single turn 260 degrees calibrated knob with 0 to 100% scale with calibration accuracy of + 1%;
repeatability shall be + 0.2% span.
The trip amplifier shall be suitable for operation on a nominal 240 volt 50 Hz power supply. The power
supply shall be fused and a spare fuse shall be included on the printed circuit board.
The output relay for each point shall be provided with switch contacts rated at 250 volt 5 amp 100VA
AC resistive load. The state of the relay shall be indicated by a red light emitting diode (LED) display for
each trip on the front of the trip amplifier. A 'power on’ indication shall also be provided.
Input and output and power supply isolation to 1500 volts root mean square (RMS) shall be provided.
The trip amplifiers shall be suitable for the following environmental conditions:a)
Ambient temperature
b)
c)
Humidity
Vibration
:
:
:
:
Working - 20 to + 60 degrees C;
Storage - 40 to + 70 degrees C;
5 to 98% relative humidity;
1 g at 15 Hz to 150 Hz no effect.
where 1 g = earth’s gravitational field or 9.8 ms-2
Input and output terminals shall be suitable for conductors up to 2.5 sq. mm.
The trip amplifier performance shall be equal to or better than the following:
a)
b)
c)
Series mode rejection
Common mode rejection
Temperature effect on trip point
d)
e)
Supply voltage on trip point
Radio frequency rejection
2.18
: Less than 0.1 % error for 50 Hz input at 50% span;
: Less than 0.1 % error for 250 volts RMS;
: Less than 0.01% per ºC or 7 micro volts per ºC,
whichever is the greater;
: Less than 0.01% per %;
: All normal industrial interference and radio frequency
up to 460 MHz shall have no effect on performance.
Signal Isolators
Signal or buffer isolators shall be suitable for back of panel or rack mounting and shall accept a linear 4
to 20 mA DC signal as an input. Signal isolators shall be provided in the respective supervisory panels
for all signals that are required for onward transmission to the SCADA system. In addition, each signal
that is to be duplicated shall be provided with a signal isolator.
2-20
Section 2 – Instrument Panel and Local Control Panel
The input impedance for each isolator shall be typically greater than one Mega-ohm for voltage.
The controls for zero and range adjustment shall be mounted on the instrument front and shall include a
"power on" indication.
The signal isolator shall be suitable for operation on a nominal 240 volts 50 Hz power supply. The
power supply shall be fused and a spare fuse shall be mounted on the printed circuit board.
The output signal shall be 4 to 20 mA DC directly proportional to the input signal.
Input to output mid power supply isolation to 2000 volts root mean square (RMS) by opto-electric
devices shall be incorporated.
The equipment shall be suitable for the following environmental conditions:
a)
Ambient temperature
b)
c)
Humidity
Vibration
:
:
:
:
Working 0 to +60ºC;
Storage -20 to +85 degrees C;
5 to 98% relative humidity;
1 g to 15 Hz to 150 Hz no effect;
where 1 g = earth’s gravitational field or 9.8 ms-2
Input and output terminals shall be suitable for conductors up to 2.5 sq. mm.
The instrument performance figures shall be equal to or better than the following:a)
b)
c)
Series mode rejection
Common mode rejection
Radio frequency rejection
2.19
:
:
:
Less than 0.29% error for 250 volt RMS;
Less than 0.29% error for 250 volt RMS;
All normal industrial interference and radio frequency up to
460 MHz shall have no effect on performance.
Lightning Protection Unit
In general, lightning surge and electrical surge protection units shall be provided for followings:
a)
b)
c)
d)
All outdoor equipment containing sensitive solid-state electronic components;
Control power cables which are installed outdoors (not inside any building), irrespective of any
protective housing or enclosures which have been provided for these cables;
Control panels located in an elevated, exposed location;
All analogue instrument cables.
The lightning protection units shall provide protection to the instrument circuits against surges and
transients induced in signal and power lines and antennas by lightning or electrical switching.
The manufacturer's instructions for earthing surge protection devices shall be rigidly adhered to.
Installation of earthing equipment required to be carried out strictly in accordance with manufacturer's
instructions. Circuit earth of protected equipment shall be connected to the earth terminals of the
respective lightning protection units except when such connections affect the normal operation of the
protected equipment. Earth resistance tests on each earth point utilised for surge protection devices and
report the results in writing to the Employer’s Representative.
2-21
Section 2 – Instrument Panel and Local Control Panel
Lightning protection units shall contain both gas and varistors elements so as to provide both high
clamping capacity and fast response. Transient rating shall be 10 kA (8/20 microsecond waveform) with
a response time of less than 10 ns.
The units shall not require manual resetting and shall self-reset when over voltage conditions have
ceased.
2.19.1 Signal and Data Line Protection
Lightning protection units for analogue signal wiring shall be suitable for use for 4-20 mA signals at the
loop power supply voltage. The units shall be rated to withstand a nominal discharge surge current of at
least 10 kA for a 8/20 microsecond pulse (8 microsecond rise time, 20 microsecond exponential decay
time) for line-to-line and line-to-earth transients and shall fail to the short circuit condition.
Lightning protection units for 240 V AC control cables shall have a continuous rating of at least 4 A at
240 V AC. The units shall be rated to withstand a nominal discharge surge current of at least 3 kA for
8/20 microsecond pulse.
The units shall provide both differential (active-neutral) and common (active- and neutral-earth) mode
protection and shall be capable of being used in conjunction with a 10 mA earth leakage circuit breaker.
Surge arrestors shall feature a means of visually identifying units that need replacing.
2.19.2 Power Supply Line Protection
The surge protection units shall provide full protection against all possible transient modes (phase to
neutral, phase to earth, neutral to earth). The transient let through voltage shall not exceed 720 V with
a surge current of 3 kA. The protection devices shall be rated for peak discharge current of 20 kA with
a phase to earth leakage current of less than 60 micro amps. The devices shall be provided with
facilities for continuous status indication for ‘full protection present’, ‘reduced level of protection’
and ‘protection failure’. Power supply line surge units shall be of the plug-in type with fixed base and
terminals with a plug-in suppression unit.
2-22
Section 3 – Automation and Control
Section 3
Automation and Control
Section 3 – Automation and Control
Page
3.0
AUTOMATION AND CONTROL
3-1
3.1
Programmable Controller
3-1
3.1.1
General
3-1
3.1.2
Process Automation Controller (PAC)
3-1
3.1.3
Programmable Logic Controller (PLC)
3-19
3.1.4
Remote Terminal Unit (RTU)
3-37
3.1.5
Peripheral Integrated Derivatives (PID) Controller
3-43
3.2
Graphic Terminal Touch Panel
3-46
3.2.1
General
3-46
3.2.2
Technical Requirements
3-46
3.2.3
Software Requirements
3-48
3.2.4
Hardware System
3-49
3.2.5
Service and Support
3-51
LIST OF TABLES
Table 3.1
Table 3.2
Table 3.3
Table 3.4
Table 3.5
Table 3.6
Table 3.7
Table 3.8
Table 3.9
Table 3.10
Table 3.11
Table 3.12
Table 3.13
Table 3.14
Table 3.15
Fault Report of Alarm Processor
Level of Security or Password Privilege Level
Availability of Discrete Input Points/Module
Availability of Discrete Output Points/Module
Availability of Mixed Input/Output Points/Module
Availability of Analogue Module
Fault Report of Alarm Processor
Level of Security or Password Privilege Level
User Selectable Program Documentation
Availability of Discrete Input Points/Module
Availability of Discrete Output Points/Module
Availability of Mixed Input/Output Points/Module
Availability of Analogue Module
Agency Approvals Overview
Standards Overview
LIST OF FIGURES
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Typical Architecture of Process Automation Controllers (PAC) in Wastewater Application
Block Diagram of Typical Programmable Logic Controller (PLC)
Typical Architecture of Remote Terminal Unit (RTU)
Block Diagram of Peripheral Integral Derivatives (PID) Controller
3-i
Section 3 – Automation and Control
3.0
AUTOMATION AND CONTROL
3.1
Programmable Controller
3.1.1
General
This Section covers the technical requirement for a programmable controller, which can receive
discrete and analog inputs. Through the use of relay ladder logic and other IEC languages, including
"C". The unit can control discrete and analog output functions, perform data handling operations and
communicate with external devices.
Backup central processing unit (CPU) for process automation controller, programmable logic
controllers, and remote terminal units shall be supplied for every purchase of the controller or the
remote terminal units. The backup CPU shall be loaded up with all application software, programs and
drivers that similar to the unit installed for operation.
All application software, operating software, driver software, software authorization codes, hardware
dongles, software keys and any other associated written programs for all programmable controllers shall
be surrendered to Employer’s Representative up on delivery of the equipments.
All installation for process automation controllers and programmable logic controllers shall be provided
with HMI (human-machine interface) of graphic terminal touch panels and support downloading data
and program instrument.
All products of programmable controllers shall be designed, manufactured, and tested in accordance
with recognized UL, C-UL, CSA, IEC and CE mark industrial standards. The system shall be
operational during and after testing.
3.1.2
Process Automation Controller (PAC)
3.1.2.1
General
The manufacturer shall have a fully operational quality assurance and quality control program in
place and shall comply with ISO 9001:2000 standards for "Quality Systems Model for Quality
Assurance in Design/ Development, Production, Installation, and Servicing."
This system shall comprise automatic functions implemented by a network of Process Automation
Controllers (PAC) and associated instrumentation. The technical specification in the next section
details the requirements of PAC system. A typical PAC architecture in wastewater application is
shown in Figure 3.1.
A complete PAC system shall consist of one or more racks containing a processor, inputs and outputs
modules, communication interface, watch dog timer, and real time clock, calendar and all other
necessary facilities necessary to ensure successful operation.
The system shall consist of rugged components designed specifically for industrial environments in
compliance with IEC 61000-4-3. The PAC and all associated equipment shall be designed to function
continuously in temperatures between 0 to 60ºC and humidity between 5 to 95% relative humidity
non-condensing. RFI (radio frequency interference) immunity, ground surge and electrostatic
discharge shall be compliant to IEC61000-4 series.
3-1
Section 3 – Automation and Control
The hardware of PAC shall be designed, manufactured, and tested in accordance with recognized UL,
C-UL, CSA, IEC and CE mark industrial standards.
The PAC system shall comply with the requirements of IEC 61131.
The system shall incorporate a modular design using plug-in assemblies with pin and socket
connectors. Wherever possible, all assemblies and sub-assemblies performing similar functions shall
be interchangeable. The system design shall accommodate the replacement of assemblies without
having to disconnect field wiring. Wherever possible, removable connectors shall be used to connect
field wiring to the individual circuit board assemblies.
All components within the controller family shall be manufactured with a high degree of durability
and shall be housed in structurally secure enclosures.
The power supply, battery, EEPROM Chips shall all operate equally well regardless of the CPU being
used.
The central processing unit (CPU) shall be modular and fully enclosed within a durable plastic
shroud. When mounted on the system base, the modular CPU shall not occupy more than two
available slots.
The I/O system shall be modular. Each module shall be fully enclosed within a durable plastic shroud
protecting the electronic circuitry from exposure. When mounted on the system base, each I/O
module shall not occupy more than one available slot. Loops shall be part of the module for securing
field wiring. There shall be at least two sizes of I/O bases available. The base shall support a high
speed serial bus and a high speed PCI bus. I/O modules shall be retained in their slot by a hinge on
the upper rear edge and snap on the lower rear edge of the baseplate. Removing the module shall
require no tools. I/O modules shall be installed in any available slot in the CPU or expansion base
plates, and shall require no tools for insertion and extraction and shall connect electrically to the base
plate via a pin and socket connector.
3.1.2.2
Power Supply Module
Power supply module shall be one of the following types:
a)
Type 1: Low Voltage, High Capacity AC/DC
A wide range supply operating from a voltage source in the range of 180 to 264 VAC and 90
to 125 VDC, providing 40 Watts of power. The power supply shall be no more than two
modules wide.
b)
Type 2: Extra Low Voltage, High Capacity DC
A DC power supply operating from a 12 VDC to 30 VDC voltage source provide 40 Watts of
power. Power supply shall be a single wide module.
The power supply shall contain internal diagnostics to detect over temperature and over load
conditions. LEDs on the power supply shall indicate over temperature and over load. This diagnostic
information will also be available to the CPU. The power supply shall support hot insertion. Multiple
power supplies shall be supported on the base to support redundant power supplies or for more
capacity. The power supply shall be modular in design, separate from the CPU and baseplate for easy
replacement in the unlikely event of failure. The power supply shall have an ON/OFF switch.
3-2
Section 3 – Automation and Control
3.1.2.3
Central Processing Unit (CPU)
The CPU shall be modular type and shall possess the capability to solve application logic, store the
application program, store numerical values related to the application processes and logic, and
interface to the I/O systems. The CPU shall need no additional modules to provide advanced
programming features such as floating point math, PID, modulo, math, double precision math, logical
functions, subroutines, data array move and indirect addressing.
The CPU shall contains a minimum Intel Pentium microprocessor operating at speeds no less than
300 MHz as the main processing element with memory mounted on the board. A minimum of
10Mbytes of memory shall be on board for user configurable application, data storage and
documentation storage.
The CPU shall contain a real-time calendar and clock that can be accessed by the user program. This
Time of Day clock and calendar shall be battery-backed and maintain seven time functions: Year (2
digits), Month, Day of Month, Hour, Minute, Second, and Day of week.
The CPU shall execute Boolean functions at a rate of 0.3 microseconds per instruction or lower.
The CPU shall be capable of controlling up to 79 I/O slots.
The CPU shall be able to provide special functions such as High Speed Counter function, Axis
Positioning function, and Local Area Networking function.
The CPU shall be able to provide two 9 pin RS232 serial ports and a 15 pin RS485 serial port for
communications.
The CPU shall contain a built-in Ethernet (IEEE802.4) port with either AAUI (Apple Attachment
Unit Interface) or 10BaseT connections. The port shall support simultaneous communications for
programming, PLC-to-PLC exchanges through programming, and Host/SCADA communications
from PCs or other networked devices equipped with the HCT Toolkit.
The CPU shall contain a built-in Ethernet (IEEE802.4) port built-in Ethernet switch with two
10/100Mbit ports (RJ-45). The Ethernet ports shall be auto-sensing for data rate, duplicity, and cable
crossover. The Ethernet port shall be 10/100 base-T/TX Ethernet Switch. The port shall support
simultaneous communications for programming, PAC-to-PAC exchanges through programming, and
Host/SCADA communications from PCs or other networked devices equipped with the Hardware
Compatibility Test (HCT) Toolkit.
The CPU shall contain a battery slot to support backup power for the SRAM. A RUN
ENABLED/RUN DISABLED/STOP switch shall be on the CPU behind a door for security.
LEDs on the CPU shall indicate the following:
a)
b)
c)
d)
e)
f)
g)
h)
CPU OK;
RUN mode;
Outputs Enabled;
I/O Force;
Battery condition;
System faults;
COMM 1 activity;
COMM 2 activity.
3-3
Section 3 – Automation and Control
3.1.2.4
System Diagnostics
3.1.2.4.1
Visual Diagnostics
Status of low or dead battery shall be indicated by a red Battery LED on the power supply module.
The diagnostic status of the fuses, for those discrete I/O modules containing fuses, shall be indicated
by a red LED mounted on the top of the module. The red LED shall illuminate when a blown fuse
condition is present.
3.1.2.4.2
Alarm Processor
The CPU shall contain an alarm processor that is special PAC feature designed to receive and process
faults. The diagnostics shall provide information on the configuration and CPU, memory,
communications and I/O status.
The alarm processor function shall log I/O and system faults in two fault tables that shall be
accessible for display on the PC compatible programming software screen or uploaded to a host
computer or other coprocessor.
The alarm processor shall maintain the states of up to 128 discrete system diagnostic bits to be read
by a host or incorporated as contacts into the ladder program for customized diagnostic routines.
Each fault table shall have a total capacity of 32 faults. The last 16 entries shall maintain the latest 16
faults. The first 16 shall be kept unchanged.
Faults shall be cleared by the user by way of a programmer. Provision shall be made by way of
passwords to protect these faults from unauthorized clearing.
3.1.2.4.3
Alarm Features
The alarm processor shall report three types of fault action; fatal, diagnostic, or informational, and the
CPU shall respond as follows:
Table 3.1: Fault Report of Alarm Processor
Fault Action
CPU Enters STOP Mode
Set Diagnostic Bit
Logged In Fault Table
Fatal
YES
YES
YES
Diagnostic
NO
YES
YES
Informative
NO
NO
YES
When an I/O fault occurs, the alarm processor shall report the rack and slot location of the fault, the
condition, the address and the circuit number if appropriate.
When CPU is used, this alarm processor function shall have the capability to time-stamp system
faults for future references.
3.1.2.4.4
System Security
The PAC shall have 4 levels of security or password privilege levels to prevent unauthorized changes
to the contents of the PAC. These built-in privilege levels shall be set in the programming software or
with the Hand-Held Programmer and shall impose the following constraints:
3-4
Section 3 – Automation and Control
Table 3.2: Level of Security or Password Privilege Level
Level
1
2
3
4
Constraint
Read PAC data only (except passwords)
Write to any data memory
#2 and write to all configuration or logic in STOP mode
#3 and write to logic in STOP or RUN mode (on-line change) and password level access
There shall be one password, one to four ASCII characters in length, for each privilege level in the
PAC, and the same password can be used for more than one level.
Any attempts to access or modify information in the PAC without the proper password privilege level
shall be denied.
The PAC shall have a software original equipment manufacturer (OEM) key that allows users to
control access to each subroutine in the relay ladder program.
The PAC shall have a software OEM key that allows users to protect the resident program from
unauthorized reads and writes.
3.1.2.4.5
CPU Memory
The PAC shall supply a modular design CPU that contains at least the following:
a)
b)
c)
d)
e)
f)
g)
10Mbytes for application programming;
Configurable up to 5Mbytes 16-bit registers for register and data usage;
Up to 32K control relays internal battery backed;
Up to 32K bits for discrete inputs;
Up to 32K bits for discrete outputs;
Configurable up to 32K 16-bit registers for analog inputs;
Configurable up to 32K 16-bit registers for analog outputs.
All application memory shall be available to the user program. Executive level operations performed
by the CPU shall not consume application memory.
The register values and the application program shall be stored in battery backed, SRAM. The
application program and system configuration shall also be stored in FLASH memory if so selected.
There shall be a long-life Lithium battery used to maintain the contents of the CMOS RAM memory
in the CPU.
There shall be an easily accessible battery compartment in the power supply with dual battery
connectors. The battery shall be replaceable with power applied to the PAC and without removing the
CPU.
An LED shall provide visual indication of the battery condition. Additionally, a low battery condition
shall be alarmed with a system diagnostic bit.
The CPU shall allow resident user program to be maintained in the CPU without power applied. Two
levels of maintainability shall be provided, short duration and long duration.
3-5
Section 3 – Automation and Control
For short duration, the program shall be maintained by a hi-capacity capacitor for a period of no less
than 1 hour. This allows adequate time for replacing the battery in the power supply module, should
the external supply to the CPU be interrupted.
For long duration, the CPU module shall maintain its contents by using the battery. This allows the
CPU module to be shipped via surface mail where power supply to the module is not available. This
method shall be achieved by providing internally mounted battery. If the CPU module does not have
an internal battery then an external battery board shall be used.
The CPU shall calculate the application program checksum at the end of every sweep. A complete
checksum calculation for a program shall take several sweeps. A fixed number of program memory
checksum shall be calculated each sweep. This number is configurable by the user. If the calculated
checksum does not equal the reference checksum, a fault shall be recorded, and the CPU mode will
change to STOP.
3.1.2.4.6
Programming Environment
At least two programming devices shall be available for development of application programs, a
small hand-held device with back-lit LCD readout and a Software programming package running on a
PC compatible laptop or desktop computer.
On-line and off-line, CPU and I/O configuration and application program development shall be
achieved with a PC compatible computer and programming and documentation software.
The PC compatible computer shall be connectable to the PAC via a built-in serial communication
port. In addition to the serial communications, the PC compatible computer shall be connectable to
the PAC via Ethernet TCP IP supporting the SRTP application protocol. A separate module of
Ethernet communications shall be provided through 10baseT connection.
The programming devices shall have access to the application program, the CPU and I/O system
configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O over-ride
capabilities.
The programming port and its protocol for operator interface shall be open in architecture. The
protocols of this communication port shall be published such that a user shall develop their own
operator interface device, software or hardware, to access Register, I/O status, I/O override and
system diagnostic memory data.
Through an open nature of this communications protocol, the PAC shall be able to be interfaced with
but shall not be limited to the following touch panel type operator interfaces:
a)
b)
c)
d)
e)
f)
g)
h)
i)
GE Fanuc SNP, SNP-X;
Allen-Bradley DFI & DH;
Allen-Bradley SLC500;
Siemens PPI;
Siemens MPI;
Siemens D SY/MAX;
CTC Cerial Driver;
Honeywell UMC Series;
Modbus RTU.
3-6
Section 3 – Automation and Control
3.1.2.4.7
Instruction Set
a. Programming Language
The CPU shall be capable of solving an application program whose source format shall be relay
ladder diagram. The language shall support relay, timers and counters, arithmetic, relational, bit
operation, data move, conversion, and control functions.
The CPU shall be capable of solving an application program whose main program format is in
Sequential Function Chart (SFC) with underlying code in relay ladder diagram.
b. Relay Functions
Relay ladder operations shall consist of the following contacts and coils:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Normally Open Contact;
Normally Closed Contact;
Coil;
Negated Coil;
Retentive Coil;
Negated Retentive Coil;
Positive Transition Coil;
Negative Transition Coil;
Set Coil (Latch);
Reset Coil (Unlatch);
Retentive Set Coil;
Retentive Reset Coil.
Positive transition coils and negative transition coils shall function as leading and trailing edge oneshot coils respectively.
Contacts shall be referenced any number of times within the application program.
A single rung shall contain more than one coil.
There shall be a service that allows user programs to be checked for multiple coil use. This flag shall
be set to:
1.
2.
3.
Disallow more than one coil in a single rung;
Allow multiple coil use but generate warning messages;
Allow multiple coil use without warnings.
c. Timers and Counters
Timer and counter operations and functions shall consist of the following types:
1.
2.
3.
4.
5.
Retentive On-Delay Timer (ONDTR);
Simple Off- Delay Timer (OFDT);
Simple On-Delay Timer (TMR);
Up Counter (UPCTR);
Down Counter (DNCTR).
3-7
Section 3 – Automation and Control
The retentive on-delay timer shall behave as a stop-watch that increments time when enabled and
holds the current timed value until receiving power flow to the reset input.
The simple on-delay timer shall increment while it receives power flow and reset to zero when power
flow stops.
The simple off-delay timer shall increment while it power flow stops and reset to zero when power
flow is present.
There shall be at least 10,666 programmed timers and/or counters available for use in application
programs.
Each timer or counter requires the use of three 16-bit registers within %R memory for storage of the
preset, the current value and a control word. These three registers shall be accessible to the user via a
register reference.
The timers and counters shall not require an output reference, the output of a timer or counter can be
used to energize a coil, or enable another function, such as a math function, or another timer or
counter.
The time/count limit shall be either a programmed constant or shall be programmable via a register
reference value.
The time shall be counted in tenths of seconds or hundredths of seconds, and the range for the timers
and counters is 0 to 32,767 time units.
d. Arithmetic
The arithmetic operations shall support two data types, Signed Integer (INT), and Double Precision
Integer (DINT). On the modular CPU, the Floating Point data type shall also be supported via floating
point emulation. Arithmetic functions shall consist of the following types:
1.
2.
3.
4.
5.
6.
Addition;
Subtraction;
Multiplication;
Division (quotient);
Modulo (remainder);
Square Root.
Signed Integers (INT) data shall be stored in 16 contiguous bits of memory, in 2’s complement
notation. The range for Signed Integer Data shall be -32,768 to +32,767.
Double Precision Integer (DINT) data shall be stored in 32 contiguous bits of memory, double
precision data is always signed. The range for Double Precision Integer Data shall be -2,147,483,648
to 2,147,483,647.
The arithmetic function blocks shall consist of 3 inputs and 2 outputs. The enable input shall begin
the execution. When the function is enabled, the two data inputs are operated upon and the result is
output. There shall also be an OK output that is always true when the function is enabled, unless an
overflow or other error exists.
All of the Arithmetic functions shall be such that they can be cascaded together in a single rung.
3-8
Section 3 – Automation and Control
e. Relational Functions
Relation Functions which are used to compare two numbers, shall operate on Signed Integer and
Double Precision Integer data types, and shall consist of the following types:
1. Equal To
2. Greater Than
3. Less Than
f.
Not Equal To;
Greater Than or Equal to;
Less Than or Equal to.
Bit Operation Functions
Bit Operation Functions shall perform comparison and movement operations on word data that is
specified as a continuous string of data in 16-bit increments, with the first bit of the first word being
the least significant bit, and the last bit of the last word being the most significant bit.
Bit Operation Functions that are used to perform Boolean operations on corresponding bits of two bit
strings of the same length shall consist of the following types:
1. Logical AND;
2. Logical OR;
3. Logical Exclusive OR.
Bit Operation Functions used to create an output string that is a copy of an input bit string, but with
its bits inverted, shifted, or rotated shall consist of the following types:
1.
2.
3.
4.
5.
Logical Invert (NOT);
Shift Left;
Shift Right;
Rotate Left;
Rotate Right.
The shift functions shall allow for the user to specify the number of places that the array is to be
shifted as an input, and provide the state of the last bit shifted out, and a copy of the shift register as
outputs.
g. Data Move Functions
Basic data movement capabilities shall be provided by the following list of functions:
1.
2.
3.
4.
5.
6.
7.
8.
Move;
Block Move;
Block Clear;
Shift Register;
Bit Sequencer;
Drum Sequencer;
Range;
Communications Request.
The movement of data (16 bit integer or word), as individual bits, from one location to another shall
be accomplished by the Move function. The user shall be able to specify the length of the move. The
Block Move function shall provide the functionality to move a block of 7 constants (integer or word)
to a specified location.
3-9
Section 3 – Automation and Control
The ability to fill a specified block of data (word) with zeros shall be accomplished by the Block
Clear function. The user shall be able to specify the length of the block.
The Shift Register function shall provide the functionality to shift one or more data words from a
reference location into a specified memory location. All of the data within the Shift Register shall be
accessible throughout the program from logic addressed memory.
A method of shifting a bit sequence through an array of bits shall be provided by a Bit Sequencer
function. The function shall provide the ability to reset the sequence, change the direction of the bit
pattern, or access the step location within the array.
A method of checking for a value to be contained within a group of values shall be provided in a
Range function.
Provisions to initiate communications with a specialized communication module shall be made
through the use of a Communication Request function. This function shall allow the PAC to behave
as a master on a serial communication link, thus providing the ability to communicate master/slave or
peer to peer with any controller or computer using the same serial communication protocol.
h. Table
Table operations shall consist of moving data into or out of tables and searching for data of values
equal to, not equal to, greater than, greater than or equal to, less than and less than or equal to a
specified value.
1.
2.
3.
4.
5.
6.
7.
Array moves;
Search Equal;
Search Not Equal;
Search Greater Than;
Search Greater Than or Equal to;
Search Less Than;
Search Less Than or Equal to.
The array move feature shall be capable of implementing indirect addressing applications.
i.
Conversion Functions
Two conversion functions shall be provided to convert a data item from a 4 digit Binary Coded
Decimal (BCD-4) data type to a 16 bit signed integer and vice versa.
j.
Control Functions
Control functions shall be provided to limit program execution, alter the way the CPU executes the
application program, or provide special PAC services. The following Control Functions shall be
provided:
1.
2.
3.
4.
5.
6.
CALL;
Immediate I/O updates (DO I/O);
Comment rung (COMMNT);
Master Control Relay (MCR, END MCR);
Jump to a label (JUMP, LABEL);
Special Service Requests (SVCREQ).
3-10
Section 3 – Automation and Control
An immediate I/O update function shall be provided for the update of all or a portion of the inputs or
outputs for one scan while the program is running, or to update I/O during the program in addition to
the normal I/O scan. Additionally, the function shall provide a mean to read inputs into memory
auxiliary to the true input table, and execute outputs from discrete memory alternate to the true output
table.
A comment rung function shall be provided to enter a rung explanation in the program. The rung
explanation shall have the capacity to hold 2048 characters of text. The memory required for the
comment shall be independent of the program storage memory. The comment shall have the ability to
be edited via the PC compatible programming software.
A master control relay function shall allow all rungs between the MCR and its subsequent END MCR
function to be executed without power flow.
A method for structuring the ladder program shall be provided with the use of a JUMP Function. This
will cause the program execution to jump to a specified location in the logic targeted by the location
of the LABEL function.
Seven different special PAC service requests shall be accessible by the programmer by utilizing one
of the Service Request Functions listed below:
1.
2.
3.
4.
5.
6.
7.
8.
Change/Read Checksum Task State and
Logical Number of Words to Checksum
Change/Read Time of Day Clock.
Shut Down the PAC.
Clear Fault Tables.
Read Last Fault Table Entry.
Read Elapsed time Clock.
Read I/O Override Status.
The Data written by these service request functions shall be in BCD or Packed ASCII format, and
written into user definable register locations.
k. PID Function
A single PID (Proportional-Integral-Derivative) function block instruction shall be provided by the
CPU without any additional module. Two versions of this closed loop control algorithm
(Proportional/Integral/Derivative) shall be available:
1. The standard ISA PID algorithm, which applies the proportional gain to each of the proportional,
derivative, and integral terms; and
2. The independent algorithm that applies the proportional gain only to the proportional gain term.
l.
Subroutine Function
A single function block shall be available to allow repetitive call of a function. A password to protect
the integrity of the subroutine shall also be available. A Subroutine shall be called from within
another subroutine. The nesting shall be at least 8 deep.
A Periodic Subroutine shall be available that is executed once a programmable interval. The interval
shall be between 1 and 10 milliseconds. The accuracy of the subroutine execution shall be 50
nanoseconds. Discrete I/O shall be available to update during the execution of the subroutine.
3-11
Section 3 – Automation and Control
3.1.2.4.8
Discrete I/O
a. Modularity
Interface between the PAC and user supplied input and output field devices shall be provided by rack
type I/O modules.
b. Configuration
There shall be an expandable system. An expandable I/O system shall be supported by a single slot
modular CPU, and shall accommodate up to 8 total racks or 79 I/O slots up to a total distance of 15
metres with the standard expansion racks and 200 metres with the remote expansion racks.
Serial expansion I/O racks shall be connected to the CPU rack via a high speed serial interface cable.
The receiver shall be contained within the expansion baseplates eliminating the requirement for
additional communication modules.
Ethernet expansion racks shall be connected via a 10/100Mbs Ethernet, RJ-45 connection. The
Ethernet network interface unit shall reside in the rack using the same I/O that is compatible with the
controller. The Ethernet network interface unit shall support the following:
1. Built-in switch to allow daisy chain connection to the next Ethernet network interface unit;
2. Support redundant controllers with automatic switch over;
3. Ethernet network interface unit shall support up to 79 I/O modules per drop with local expansion.
c. I/O Addressing
I/O reference addressing for each I/O module shall be assigned through the use of the PC compatible
configuration and programming software or the hand held programmer. There shall be no jumpers or
DIP switch settings required to address modules.
The circuit status of each I/O point on a module shall be indicated by a green LED mounted at the top
of the module. These LED’s shall be visible through a clear plastic lens. Each LED shall illuminate a
letter and number which corresponds to the energized I/O circuit.
Addressing of all references including I/O shall be represented as a Decimal Based number.
d. Construction
Terminal blocks shall be easily removable, and common to all discrete and analog I/O to allow for
convenient pre-wiring of field devices.
Each I/O module shall contain a hinged, clear plastic, terminal block cover (door) with a removable
label.
The inside of the label shall have the module description, catalog number, and circuit wiring diagram
for that module type, and the outside of the label shall have a user legend space to record circuit
identification information.
The label shall have color coding for quick identification of the module as high voltage (red), low
voltage (blue), or signal level (gray) type.
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Section 3 – Automation and Control
e. Electrical Specifications
I/O modules shall be designed for 1500 volt isolation between the field wiring and the system
backplane.
f.
Input Specifications
The 120 Volt AC input module shall accommodate an input voltage range from 0 to 132 volts.
The 240 Volt AC input module shall accommodate an input voltage range from 0 to 264 volts.
The 24 Volt DC positive and negative logic input modules shall accommodate an input voltage range
of 0 to +30 volts DC.
The 125 Volt DC input module shall accommodate an input voltage range from 0 to 150 volts.
g. Availability of Input Modules
As a minimum, the following discrete input modules shall be available:
Table 3.3: Availability of Discrete Input Points/Module
Description
Input Simulator
120 VAC Isolated Input
240 VAC Isolated Input
120 VAC Input
48 VDC Positive/Negative Logic Input
24 VAC / VDC Negative Logic Input
24 VDC Positive/Negative Logic Input
24 VDC Positive/Negative Logic Input, (1ms response)
125 VDC Positive/Negative Logic Input
5/12 VDC Positive/Negative Logic Input (TTL)
Points/Module
8, 16
8
8
16
16
16
8, 16, 32
16
8
32
h. Output Specifications
Discrete AC output modules shall have separate and independent commons allowing each group to be
used on different phases of AC supply. Each discrete AC output shall be provided with an RC
snubber to protect against transient electrical noise on the power line. Discrete AC outputs shall be
suitable for controlling a wide range of inductive and incandescent loads by providing a high degree
of inrush current (10x the rated current).
Discrete DC output modules shall be available with positive and negative logic characteristics in
compliance with the IEC industry standard. Discrete DC output modules shall be provided with at
least eight output points in a group with a common power input terminal per group. Discrete DC
output modules shall be compatible with a wide range of user-supplied load devices, such as: motor
starters, solenoids, and indicators.
A 2 Amp relay output module shall be capable of supplying 2 Amps resistive maximum load per
output and 4 amps resistive maximum load per group of 4 outputs.
3-13
Section 3 – Automation and Control
A 4 Amp relay output module shall have 8 isolated outputs per module and shall be capable of
supplying 4 amps resistive maximum load per output and 32 amps resistive maximum load per
module.
i.
Availability of Output Modules
As a minimum, the following discrete output modules shall be available:
Table 3.4: Availability of Discrete Output Points/Module
Description
120 VAC, 0.5A (2 groups)
120/240 VAC, 1A (2 groups)
20/240 VAC Isolated, 2A
48 VDC Positive Logic, 0.5A
12/24 VDC Positive Logic, 2A
12/24 VDC Positive Logic, 0.5A
12/24 VDC Negative Logic, 2A
12/24 VDC Negative Logic, 0.5A
125 VDC Positive/Negative Logic, 1A
5/12/24 VDC Negative Logic, 0.5A
Relay, Normally Open, 2A (4 groups)
Relay, Normally Open, 4A Isolated
Relay, Isolated, 4 Normally Closed,
Normally Open (Form B & C) 8A
Solenoid Valve Output (Pneumatic)
j.
Points/Module
12,16
8
5
8
8
8,16,32
8
8,16
6
32
16
8
Fuse Rating
3A
3A
3A
0.5A
5A
N/A
5A
N/A
N/A
N/A
N/A
N/A
# Fuses/ Module
2
2
5
2
2
0
2
0
0
0
0
0
8
N/A
0
11
100 psi
0
Availability of Mixed I/O Modules
As a minimum, the following discrete output modules shall be available:
Table 3.5: Availability of Mixed Input/Output Points/Module
Description
24 VDC Input, Relay Output
120 VAC Input, Relay Output
3.1.2.4.9
Points/Module
8 in, 8 out
8 in, 8 out
Analogue I/O
a. General Specifications
For the conversion of analogue to digital and digital to analogue conversion required by an
application, the following shall be available:
1. Analogue Voltage Input
The analogue voltage input module shall be capable of converting 4 or 16 channels of inputs in the
range of -10 to +10 volts.
Resolution of the converted analogue voltage input signal shall be 12 bits binary or 1 part in 4096.
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Section 3 – Automation and Control
All of the channels of converted analogue voltage input signals shall be updated each scan into a
dedicated area of data registers in a 16-bit 2’s complement format.
The conversion speed for all of the analogue voltage input channels shall be no less than 2
milliseconds and no greater than 13 milliseconds.
The analogue voltage input module shall be configurable to a 4 to 20 mA analogue current input via
an external resistor.
2. Analogue Current Input
The analogue current input module shall be capable of converting 4 or 16 channels of inputs in the
range of 4 to 20 mA or 0 to 20 mA.
Resolution of the converted analogue current input signal shall be 12 bits binary or 1 part in 4096.
All of the channels of converted analogue current put signals shall be updated each scan into a
dedicated area of data registers in a 16-bit 2’s complement format.
The conversion speed for all analog current input channels shall be a minimum of 2 milliseconds and
no greater the 13 milliseconds.
3. Analogue Voltage Output
The analogue voltage output module shall be capable of converting 2 or 8 channels of digital data to
analogue outputs in the range of -10 to +10 volts.
Resolution of the converted output signal shall be 13 bits or 16 bits.
All channels of analogue output data shall be updated each scan from a dedicated area of data
registers in a 16-bit 2’s complement format.
The analog voltage outputs shall be configurable to default to 0 mA, 4 mA or hold-last-state in the
event of a CPU failure.
4. Analogue Current Output
The analogue current output module shall be capable of converting 2 or 8 channels of digital data to
analogue outputs in the range of 0 to 20 mA. .
Resolution of the converted output signal shall be 12 bits or 16 bits.
All channels of analogue output data shall be updated each scan from a dedicated area of data
registers in a 16-bit 2’s complement format.
The analogue current outputs shall be configurable to default to 0 volts or hold-last-state in the event
of a CPU failure.
5. Analogue Combination
The analogue combo module shall be capable of converting 4 channels of analogue inputs to digital
data and 2 channels of digital data to analogue outputs.
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Section 3 – Automation and Control
All channels are configurable for 0-20mA, 4-20mA, 0-+10V, and -10-+10V. Resolution of the
converted input signals shall be 12 bits and output signals shall be 16 bits.
All channels of analogue data shall be updated each scan from a dedicated area of data registers in a
16-bit 2’s complement format.
The analogue outputs shall be configurable to default to 0 volts or hold-last-state in the event of a
CPU failure.
b. Module Availability
As a minimum, the following analogue modules shall be available:
Table 3.6: Availability of Analogue Module
Description
Input
Voltage Analogue Input
Current Analogue Output
Voltage Analogue Output
Universal V, C, RTD, TC, Strain
Combo Analogue Inputs/Outputs
Channels/Module
4, 16
4, 16
2, 8
2, 8
8
4/2
3.1.2.4.10 Specialty Module
a. Temperature Control Module
A specialised temperature control module shall be available to accommodate applications where
precise temperature control is needed. The temperature control module shall support auto-tuning,
closed looped PID control, and open looped manual control.
The temperature control module shall provide eight thermocouple inputs, 1 RTD input, and 8 PIDcontrolled output channels for controlling heaters.
The temperature control module shall provide alarms indications for each status zone, voltage failure,
open or reversed thermocouple, compensation temperature error, high or low temperature, high or
low temperature deviation, and open channel short circuit.
b. Motion Control
Specialised analogue and digital motion control modules shall be available to perform 4 axes of
closed or open loop servo control. These modules shall support encoder feedback with analogue (up
to 4 axis) or digital (up to 2 axis) output for velocity command.
The positioning mode shall support linear and S curve acceleration and deceleration.
The modules shall provide user-defined control inputs and outputs for application such as torque
follower and flying cut-off applications.
The modules shall have user defined inputs and outputs, an English-language programming software,
and automatic data transfer of data between PAC and axis positioning module with no user
programming.
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Section 3 – Automation and Control
The positioning mode shall have a powerful instruction set that includes absolute or incremental
move, wait to move, dwell, conditional jump and subroutine functions.
The modules shall provide non-volatile program storage without the use of battery or super capacitor.
The follower mode shall provide either parallel or cascade operation from a single master. The
follower mode shall provide a selectable master source of encoder, analogue, or internal time base.
The single axis module shall have a position loop update time of not more than 1 miliseconds. The
dual axis module shall have a position loop update time of not more than 2 miliseconds per axis.
c. High Speed Counter
A specialized high speed counter option module shall be available to accommodate applications
where pulse input rates exceed the input capability of the PAC.
The high speed counter module shall provide direct processing of rapid pulse signals up to 80 kHz in
frequency.
The high speed counter module shall be configurable as four independent counters counting either up
or down, two independent bi-directional counters, or one counter that can calculate the difference
between two changing count values.
3.2.2.4.11 Third Party Speciality I/O and Communication Modules
Based on open architecture specifications of the vendor and explicit permission of the vendor,
specialty module shall be available such as PID, Co-processor, stepper, etc.
Complete documentation, kits for building modules, and engineering resource shall be available for
the 3rd party based on the type of development.
3.1.2.4.12 Communication
a. Peer/Peer Communications
A specialized option module shall be available that will allow the PAC to communicate on a token
passing peer-to-peer, noise immune network providing high-speed transfer of control data.
The specialized communication module shall be configurable to broadcast data to and receive data
from up to 31 other devices on a network automatically and repeatedly from a shared and dedicated
database in RAM memory.
The communication medium for this specialized network shall be a high energy and noise immune
single shielded twisted pair cable transmitting data at an adjustable rate of up to 153.6 Kbaud. The
distance of the communication shall be up to 7500 ft at a lower baud rate.
b. Master/Slave Communications
The module shall provide 3 distinct communication protocols. There shall be a module that allows the
PAC to act as a master in a communication scheme that allows the PAC to interrogate other PACs for
data.
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Section 3 – Automation and Control
There shall be 2 ports provided on the module, thus allowing more than one task to run at the same
time. The two ports can be configured as communication ports in any combination.
c. Client/Server Interface
There shall be a module that provides CLIENT/SERVER with PEER to PEER communications over
Ethernet TCPIP.
Each CPU system and special module shall support up to 16 simultaneous connections.
d. Network Communications Interface Modules
Manufacture of PAC shall provide Ethernet, process field buses and DeviceNet master and slave
network modules. These modules shall be tightly coupled with the system including the integration
of the configuration in the control software and firmware.
The controller shall be able to support up to 3 network communications modules per system of
various types.
Figure 3.1: Typical Architecture of Process Automation Controllers (PAC) in Wastewater
Application
3-18
Section 3 – Automation and Control
3.1.3
3.1.3.1
Programmable Logic Controller (PLC)
General
The manufacturer shall have a fully operational quality assurance and quality control program in
place and shall comply with ISO 9001:2000 standards for "Quality Systems Model for Quality
Assurance in Design/ Development, Production, Installation, and Servicing."
Programmable logic controller (PLC) shall include one or more racks containing a processor, inputs
and outputs, communications interface, watch dog timer, and real time clock, calendar and all other
facilities necessary to ensure successful operation as shown in Figure 3.2.
The PLC shall consist of rugged components designed specifically for industrial environments in
compliance with IEC 61000-4-3. The PLC and all its associated equipment shall be designed to
function continuously in operating temperatures between 0 to 55oC and humidity between 0 to 95%
relative humidity non-condensing. Storage temperature for all PLC components shall be in the range
from -40ºC to 85ºC.
RFI immunity, ground surge and electrostatic discharge shall be compliant to IEC 61000-4. The PLC
hardware shall comply with UL, C-UL, CSA, IEC and CE mark industrial standards. The PLC system
shall comply with the requirements of IEC 61131.
The system shall incorporate a modular design using plug-in assemblies with pin and socket
connectors. Wherever possible, all assemblies and sub-assemblies performing similar functions shall
be interchangeable. The system design shall accommodate the replacement of assemblies without
having to disconnect field wiring. Wherever possible, removable connectors shall be used to connect
field wiring to the individual circuit board assemblies.
All components within the controller family shall be manufactured with a high degree of durability
and shall be housed in structurally secure enclosures.
The power supply, battery, EEPROM Chips should all operate equally well regardless of the CPU
being used.
The central processing unit (CPU) shall be modular type. The modular type CPU shall be fully
enclosed within a durable plastic shroud. When mounted on the system base, the modular CPU shall
not occupy more than one available slot.
The I/O system shall be modular. Each module shall be fully enclosed within a durable plastic shroud
protecting the electronic circuitry from exposure. When mounted on the system base, each I/O
module shall not occupy more than one available slot. There shall be at least two sizes of I/O bases
available.
I/O modules shall be retained in their slot by a hinge on the upper rear edge and snap on the lower
rear edge of the baseplate. Removing the module shall require no tools. I/O modules shall be installed
in any available slot in the CPU or expansion baseplates, and shall require no tools for insertion and
extraction. The I/O modules shall connect electrically to the baseplate via a pin and socket connector.
3-19
Section 3 – Automation and Control
3.1.3.2
Power Supply Module
Power supply module shall be one of the following types:
a)
Type 1: Low Voltage, High Capacity AC/DC
A wide range supply operating from a voltage source in the range of 180 to 264 VAC and 90 to
125 VDC, providing 30 Watts of power. Available power shall be 30 Watts at a +5VDC output,
15 Watts at a 24VDC relay power output, and 20 Watts at an isolated 24 VDC output.
b)
Type 2: Low Voltage, AC/DC
A wide range supply operating from a voltage source in the range of 180 to 264 VAC and 90 to
125 VDC, providing 30 Watts of power. Available power shall be 15 Watts at a +5VDC output,
15 Watts at a 24VDC relay power output, and 20 Watts at an isolated 24 VDC output.
c)
Type 3: Extra Low Voltage, High Capacity DC
A DC power supply operating from a 12 VDC to 30 VDC voltage source providing 30 Watts of
power, 30 Watts at a +5VDC output, 15 Watts at a 24VDC relay power output, and 20 Watts at
an isolated 24 VDC output.
d)
Type 4: Extra Low Voltage DC
A DC power supply operating from an 18 VDC to 56 VDC voltage source providing 30 Watts
of power, 15 Watts at a +5VDC output, 15 Watts at a 24VDC relay power output, and 20 Watts
at an isolated 24 VDC output.
The power supply shall contain an isolated, internal 24VDC power source for I/O modules requiring
24VDC power. A built-in serial communication port shall be available for the following usage:
a)
b)
Connect the programmer for PC compatible programming software;
Connect to one of the wide variety of third-party operator interfaces utilizing an open
architecture software protocol.
The serial port shall provide RS-422 signals with RS-485 compatibility. The characteristics of this
port shall be software configurable and shall be modem compatible.
The power supply shall contain dual battery connectors for supporting redundant power supplies to
protect programming CMOS RAM memory. Dual connectors are required to provide bumpless
battery power transfer.
The power supply shall be modular in design, separate from the CPU and base plate for easy
replacement in the unlikely event of failure.
The power supply shall be universal in design, compatible with main CPU racks, as well as with
expansion racks. There shall also be a super capacitor that provides a minimum of 1 hour batteryless
backup power for CPU RAM memory.
The backup battery for RAM memory shall be Lithium, long-life battery with a typical life of 6
months under load, and 8 to 10 years under no load. This battery shall be replaceable while power is
applied to the PLC. An optional external backup battery shall be available with a typical life of up to
75 months (shelf life of 10 years) of RAM memory backup with no power.
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Section 3 – Automation and Control
3.1.3.3
Central Processing Unit (CPU)
The CPU shall be modular type with up to six (6) different configurations. The CPU shall possess the
capability to solve application logic, store the application program, store numerical values related to
the application processes and logic, and interface to the I/O systems. The CPU shall need no
additional modules to provide at least the following advanced programming features such as Floating
Point Math, PID, Modulo, Math, Double Precision math, Logical functions, Subroutines, Data Array
Move and Indirect Addressing.
The CPU shall contain a minimum Intel 80186, Intel 80386EX microprocessor operating at speeds no
less than 10 MHz up to 25MHz as the main processing element, memory mounted on the board, and a
dedicated VLSI Instruction Sequencer Coprocessor (ISCP - Boolean Coprocessor) for performing
Boolean operations, and interfaces to a serial port and the system bus.
The CPU shall contain a real-time calendar and clock that can be accessed by the user program. This
Time of Day clock and calendar shall be battery-backed and maintain seven time functions: Year (2
digits), Month, Day of Month, Hour, Minute, Second, and Day of week.
The CPU shall execute Boolean functions at a rate of 0.3 microseconds per instruction or lower for
186 and 386 based microprocessor controllers. Boolean function at a rate of 0.15 microseconds per
instruction for 586 microprocessor based controllers.
The CPU shall be capable of controlling up to 49 I/O slots in the basic configuration and up to 79 I/O
slots in the advanced and shall be able to provide special functions such as High Speed Counter
function, Axis Positioning function, and Local Area Networking function.
Two additional serial ports, one phone jack RS232 and one 15-pin RS485 for communications shall
be available.
The CPU shall contain a built-in Ethernet (IEEE802.4) port with either AAUI (Apple Attachment
Unit Interface) or 10BaseT connections. The port shall support simultaneous communications for
programming, PLC-to-PLC exchanges through programming, and Host/SCADA communications
from PCs or other networked devices equipped with the HCT Toolkit.
The CPU shall contain a built-in Ethernet (IEEE802.4) port built-in Ethernet switch with two
10/100Mbit ports (RJ-45). The Ethernet ports shall be auto-sensing for data rate, duplicity, and cable
crossover. The Ethernet port shall be 10/100 base-T/TX Ethernet Switch. The port shall support
simultaneous communications for programming, PLC-to-PLC exchanges through programming, and
Host/SCADA communications from PCs or other networked devices equipped with the Hardware
Compatibility Test (HCT) Toolkit.
The PLC shall handle different fieldbus communication protocol for remote I/O operation. It shall be
able to handle but shall not be limited to the following type of fieldbus systems:
a)
b)
c)
d)
e)
Ethernet
Profibus DP
DeviceNet
CANopen
SERCOS interface
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Section 3 – Automation and Control
3.1.3.4
System Diagnostics
3.1.3.4.1
Visual Diagnostics
Status of low or dead battery shall be indicated by a red battery LED on the power supply module.
The diagnostic status of the fuses, for those discrete I/O modules containing fuses, shall be indicated
by a red LED mounted on the top of the module. The red LED shall illuminate when a blown fuse
condition is present.
3.1.3.4.2
Alarm Processor
The modular and embedded CPU’s shall contain an alarm processor that is special PLC feature
designed to receive and process faults. The diagnostics shall provide information on the configuration
and CPU, memory, communications and I/O status.
The alarm processor function shall log I/O and system faults in two fault tables that shall be accessible
for display on the PC compatible programming software screen or uploaded to a host computer or
other coprocessor.
The alarm processor shall maintain the states of up to 128 discrete system diagnostic bits to be read by
a host or incorporated as contacts into the ladder program for customized diagnostic routines.
Each fault table shall have a total capacity of 32 faults. The last 16 entries shall maintain the latest 16
faults. The first 16 shall be kept unchanged.
Faults shall be cleared by the user by way of a programmer. Provision shall be made by way of
passwords to protect these faults from unauthorized clearing.
3.1.3.4.3
Alarm Features
The alarm processor shall report three types of fault action; fatal, diagnostic, or informational, and the
CPU shall respond as follows:
Table 3.7: Fault Report of Alarm Processor
Fault Action
CPU Enters STOP Mode
Set Diagnostic Bit
Logged In Fault Table
Fatal
Yes
Yes
Yes
Diagnostic
No
Yes
Yes
Informative
No
No
Yes
When an I/O fault occurs, the alarm processor shall report the rack and slot location of the fault, the
condition, the address and the circuit number if appropriate. When modular CPU is used, this alarm
processor function shall have the capability to time-stamp system faults for future references.
3.1.3.5
System Security
3.1.3.5.1
PLC Memory Protection
The PLC shall have 4 levels of security or password privilege levels to prevent unauthorized changes
to the contents of the PLC. These built-in privilege levels shall be set in the programming software
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Section 3 – Automation and Control
and shall impose the following constraints:
Table 3.8: Level of Security or Password Privilege Level
Level
1
2
3
4
Constraint
Read PLC data only (except passwords)
Write to any data memory
#2 and write to all configuration or logic in STOP mode
#3 and write to logic in STOP or RUN mode (on-line change) and password level
access.
There shall be one password, one to four ASCII characters in length, for each privilege level in the
PLC, and the same password can be used for more than one level.
Any attempts to access or modify information in the PLC without the proper password privilege level
shall be denied.
3.1.3.5.2
Subroutine Password
The PLC shall have a software OEM key that allows users to control access to each subroutine in the
relay ladder program.
3.1.3.5.3
OEM Program Protection
The PLC shall have a software OEM key that allows users to protect the resident program from
unauthorized reads and writes.
3.1.3.6
CPU Memory
The CPU shall contain at least the following:
a)
b)
c)
d)
e)
f)
g)
h)
Either 32Kbytes or 240Kbytes for application programming;
Configurable up to 32K 16-bit registers for register and data usage;
1280 global references;
Up to 4,096 (4K) control relays internal battery backed;
Up to 2,048 (2K) bits for discrete inputs;
Up to 2,048 (2K) bits for discrete outputs;
Configurable up to 32K 16-bit registers for analogue inputs;
Configurable up to 32K 16-bit registers for analogue outputs.
All application memory shall be available to the user program. Executive level operations performed
by the CPU shall not consume application memory.
The register values and the application program shall be stored in battery backed, CMOS static RAM
memory. The application program and system configuration shall also be stored in FLASH,
EEPROM, EPROM memory if so selected. There shall be a long-life Lithium battery used to maintain
the contents of the CMOS RAM memory in the CPU.
The battery compartment in the power supply with dual battery connectors shall be accessible easily.
The battery shall be replaceable with power supply connected to the PLC and without removing it
from the CPU. An LED shall provide visual indication of the battery condition. Additionally, a low
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Section 3 – Automation and Control
battery condition shall be alarmed with a system diagnostic bit.
CPU shall allow resident user program to be maintained in the CPU without power supply connected
to it. Two levels of maintainability shall be provided, short duration and long duration.
a)
For short duration, the program shall be maintained by a hi-capacity capacitor for a period of no
less than 1 hour. This allows adequate time for replacing the battery in the power supply
module, should the external supply to the CPU be interrupted;
b)
For long duration, the CPU module shall maintain its contents by using the battery. This allows
the CPU module to be shipped via surface mail where power supply to the module is not
available. This method shall be achieved by providing internally mounted battery. If the CPU
module does not have an internal battery then an external battery board shall be used.
The CPU shall calculate the application program checksum at the end of every sweep. A complete
checksum calculation for a program shall take several sweeps. A fixed number of program memory
checksum shall be calculated each sweep. This number is configurable by the user. If the calculated
checksum does not equal the reference checksum, a fault shall be recorded, and the CPU mode will
change to STOP.
3.1.3.7
PLC Programming Environment
3.1.3.7.1
Programming Devices
On-line and off-line, CPU and I/O configuration and application program development shall be
achieved with a PC compatible computer and programming and documentation software. PC
compatible computer shall be connectable to the PLC via a built-in serial communication port on the
power supply or serial ports on the CPU.
The serial communication port shall provide RS-422 signals with RS-485 compatibility. In addition to
the serial communications, the PC compatible computer shall be connectable to the PLC via Ethernet
TCPIP supporting the SRTP application protocol. A separate module providing Ethernet
communications through 10baseT connection shall be available.
The programming devices shall have access to the application program, the CPU and I/O system
configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O over-ride
capabilities
3.1.3.7.2
Software
The software shall execute on a latest version, high-performance and crash-free Windows® platform.
The WINDOWS compatible software shall provide the capability of reading, writing, and verifying
the configuration and program with a compact disk backup. The software shall provide on-screen help
information throughout its execution paths.
It shall have the capability of programming the relay ladder program, store the program to the PLC,
monitor program and reference address status while the PLC is in Run or Stop mode.
The programming software shall support bumpless run mode storage of the program to the CPU. The
software shall be capable of generating a printout of the relay ladder program for documentation
purposes. The user shall be able to select any of the program documentation below:
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Section 3 – Automation and Control
Table 3.9: User Selectable Program Documentation
Types of Documentation
Print Program
Cross reference tables
Reference tables
Configuration Printout
Description
This printout shall print the program logic with or without the
equivalent Boolean instructions for each rung, the reference list,
reference descriptions and/or users rung comments.
This printout shall show the use of references in the program.
This printout shall show the values of each reference in each
selected table.
This printout shall allow the user to generate a rack hardware and
its assigned reference addresses listing, and the CPU configuration
listing.
The software shall be IEC 61131 compliant. The software shall provide the capability for
programming using user-defined variables (nicknames). The software shall have built-in modem
connection capabilities. The software shall have provisions for importing and exporting tag names,
comments and descriptions in a SQL format.
3.1.3.7.3
Operator Interface
The programming port and its protocol shall be open in architecture. The protocols of this
communication port shall be published such that a user shall develop their own operator interface
device, software or hardware, to access Register, I/O status, I/O override and system diagnostic
memory data. Through an open nature of this communications protocol, a wide variety of operator
interface shall be made available. These shall be manufacturer’s own brand or they shall be
manufactured by 3rd party vendors.
3.1.3.8
Instruction Set
3.1.3.8.1
Programming Language
The CPU shall be capable of solving an application program whose source format shall be relay
ladder diagram. The language shall support relay, timers and counters, arithmetic, relational, bit
operation, data move, conversion, and control functions.
The CPU shall also be capable of solving an application program whose main program format is in
Sequential Function Chart (SFC) with underlying code in relay ladder diagram.
3.1.3.8.2
Relay Functions
Relay ladder operations shall consist of the following contacts and coils:
a.
b.
c.
d.
e.
f.
g.
Normally Open Contact;
Normally Closed Contact;
Coil;
Negated Coil;
Retentive Coil;
Negated Retentive Coil;
Positive Transition Coil;
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Section 3 – Automation and Control
h.
i.
j.
k.
l.
Negative Transition Coil;
Set Coil (Latch);
Reset Coil (Unlatch);
Retentive Set Coil;
Retentive Reset Coil.
Positive transition coils and negative transition coils shall function as leading and trailing edge oneshot coils respectively. Contacts can be referenced any number of times within the application
program. A single rung can contain more than one coil.
There shall be a service that allows user programs to be checked for multiple coil use. This flag shall
be set to:
a. Disallow more than one coil in a single rung;
b. Allow multiple coil use but generate warning messages;
c. Allow multiple coil use without warnings.
3.1.3.8.3
Timers and Counters
Timer and counter operations and functions shall consist of the following types:
a.
b.
c.
d.
e.
Retentive On-Delay Timer (ONDTR);
Simple Off- Delay Timer (OFDT);
Simple On-Delay Timer (TMR);
Up Counter (UPCTR);
Down Counter (DNCTR).
The retentive on-delay timer shall behave as a stop-watch that increments time when enabled and
holds the current timed value until receiving power flow to the reset input. The simple on-delay timer
shall increment while it receives power flow and reset to zero when power flow stops.
The simple off-delay timer shall increment while it power flow stops and reset to zero when power
flow is present.
There shall be at least 10,666 programmed timers and/or counters available for use in application
programs. Each timer or counter requires the use of three 16-bit registers within %R memory for
storage of the preset, the current value and a control word. These three registers shall be accessible to
the user via a register reference. The timers and counters shall not require an output reference, the
output of a timer or counter can be used to energize a coil, or enable another function, such as a math
function, or another timer or counter.
The time/count limit shall be either a programmed constant or shall be programmable via a register
reference value. The time shall be counted in tenths of seconds or hundredths of seconds, and the
range for the timers and counters is 0 to 32,767 time units.
3.1.3.8.4
Arithmetic
The arithmetic operations shall support two data types, Signed Integer (INT), and Double Precision
Integer (DINT). On the modular CPU, the Floating Point data type shall also be supported via floating
point emulation. Arithmetic functions shall consist of the following types:
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Section 3 – Automation and Control
a.
b.
c.
d.
e.
f.
Addition;
Subtraction;
Multiplication;
Division (quotient);
Modulo (remainder);
Square Root.
Signed Integers (INT) data shall be stored in 16 contiguous bits of memory, in 2’s complement
notation. The range for Signed Integer Data shall be -32,768 to +32,767.
Double Precision Integer (DINT) data shall be stored in 32 contiguous bits of memory. The double
precision data shall always be signed. The range for Double Precision Integer Data shall be 2,147,483,648 to 2,147,483,647.
The arithmetic function blocks shall consist of 3 inputs and 2 outputs. The enable input shall begin the
execution. When the function is enabled, the two data inputs are operated upon and the result is
output. There shall also be an OK output that is always true when the function is enabled, unless an
overflow or other error exists. All of the Arithmetic functions shall be such that they can be cascaded
together in a single rung.
3.1.3.8.5
Relational Functions
Relation Functions, which are used to compare two numbers, shall operate on Signed Integer and
Double Precision Integer data types, and shall consist of the following types:
a. Equal To
b. Greater Than
c. Less Than
3.1.3.8.6
Not Equal To;
Greater Than or Equal to;
Less Than or Equal to.
Bit Operation Functions
Bit Operation Functions shall perform comparison and movement operations on word data that is
specified as a continuous string of data in 16-bit increments, with the first bit of the first word being
the least significant bit, and the last bit of the last word being the most significant bit. Bit Operation
Functions that are used to perform Boolean operations on corresponding bits of two bit strings of the
same length shall consist of the following types:
a. Logical AND;
b. Logical OR;
c. Logical Exclusive OR.
Bit Operation Functions used to create an output string that is a copy of an input bit string, but with its
bits inverted, shifted, or rotated shall consist of the following types:
a.
b.
c.
d.
e.
Logical Invert (NOT);
Shift Left;
Shift Right;
Rotate Left;
Rotate Right.
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Section 3 – Automation and Control
The shift functions shall allow for the user to specify the number of places that the array is to be
shifted as an input, and provide the state of the last bit shifted out, and a copy of the shift register as
outputs.
3.1.3.8.7
Data Move Functions
Basic data movement capabilities shall be provided by the following list of functions:
a.
b.
c.
d.
e.
f.
g.
h.
Move;
Block Move;
Block Clear;
Shift Register;
Bit Sequencer;
Drum Sequencer;
Range;
Communications Request.
The movement of data (16 bit integer or word), as individual bits, from one location to another shall
be accomplished by the Move function. The user shall be able to specify the length of the move. The
Block Move function shall provide the functionality to move a block of 7 constants (integer or word)
to a specified location.
The ability to fill a specified block of data (word) with zeros shall be accomplished by the Block
Clear function. The user shall be able to specify the length of the block.
The Shift Register function shall provide the functionality to shift one or more data words from a
reference location into a specified memory location. All of the data within the Shift Register shall be
accessible throughout the program from logic addressed memory.
Bit Sequencer function shall be used as the method for shifting a bit sequence through an array of bits.
The function shall provide the ability to reset the sequence, change the direction of the bit pattern, or
access the step location within the array.
Range function shall be used as the method for checking for a value to be contained within a group of
values.
Provisions to initiate communications with a specialized communication module shall be made
through the use of a Communication Request function. This function shall allow the PLC to behave as
a master on a serial communication link, thus providing the ability to communicate master/slave or
peer to peer with any controller or computer using the same serial communication protocol.
3.1.3.8.8
Table
Table operations shall consist of moving data into or out of tables and searching for data of values
equal to, not equal to, greater than, greater than or equal to, less than and less than or equal to a
specified value.
a. Array moves;
b. Search Equal;
c. Search Not Equal;
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Section 3 – Automation and Control
d.
e.
f.
g.
Search Greater Than;
Search Greater Than or Equal to;
Search Less Than;
Search Less Than or Equal to.
The array move feature shall be capable of implementing indirect addressing applications.
3.1.3.8.9
Conversion Functions
Two conversion functions shall be provided to convert a data item from a 4 digit Binary Coded
Decimal (BCD-4) data type to a 16 bit signed integer and vice versa.
3.1.3.8.10 Control Functions
Control functions shall be provided to limit program execution, alter the way the CPU executes the
application program, or provide special PLC services. The following Control Functions shall be
provided:
a.
b.
c.
d.
e.
f.
CALL;
Immediate I/O update (DO I/O);
Comment rung (COMMNT);
Master Control Relay (MCR, END MCR);
Jump to a label (JUMP, LABEL);
Special Service Requests (SVCREQ).
An immediate I/O update function shall be provided for the update of all or a portion of the inputs or
outputs for one scan while the program is running, or to update I/O during the program in addition to
the normal I/O scan. Additionally, the function shall provide a mean to read inputs into memory
auxiliary to the true input table, and execute outputs from discrete memory alternate to the true output
table.
A comment rung function shall be provided to enter a rung explanation in the program. The rung
explanation shall have the capacity to hold 2048 characters of text. The memory required for the
comment shall be independent of the program storage memory. The comment shall have the ability to
be edited via the PC compatible programming software.
A master control relay function shall allow all rungs between the MCR and its subsequent END MCR
function to be executed without power flow.
JUMP Function shall be used as the method for structuring the ladder program. This will cause the
program execution to jump to a specified location in the logic targeted by the location of the LABEL
function.
Seven different special PLC service requests shall be accessible by the programmer by utilizing one of
the Service Request Functions listed below:
a.
b.
c.
d.
e.
Change/Read Checksum Task State;
Logical Number of Words to Checksum;
Change/Read Time of Day Clock;
Shut Down the PLC;
Clear Fault Tables;
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Section 3 – Automation and Control
f. Read Last Fault Table Entry;
g. Read Elapsed time Clock;
h. Read I/O Override Status.
The Data written by these service request functions shall be in BCD or Packed ASCII format, and
written into user definable register locations.
3.1.3.8.11 PID Function
A single PID (Proportional-Integral-Derivative) function block instruction shall be provided by the
CPU without any additional module. Two versions of this closed loop control algorithm
(Proportional/Integral/Derivative) shall be available:
a) The standard ISA PID algorithm, which applies the proportional gain to each of the proportional,
derivative, and integral terms; and
b) The independent algorithm that applies the proportional gain only to the proportional gain term.
3.1.3.8.12 Subroutine Function
A single function block shall be available to allow repetitive call of a function. A password to protect
the integrity of the subroutine shall also be available. A Subroutine shall be called from within another
subroutine. The nesting shall be at least 8 deep.
A Periodic Subroutine shall be available that is executed once a programmable interval. The interval
shall be between 1 and 10 milliseconds. The accuracy of the subroutine execution shall be 50
nanoseconds. Discrete I/O shall be available to update during the execution of the subroutine.
3.1.3.9
Discrete I/O
3.1.3.9.1
General
Interface between the PLC and user supplied input and output field devices shall be provided by rack
type I/O modules. There shall be two varieties of I/O systems available, a fixed I/O system and an
expandable system.
Serial expansion I/O racks shall be connected to the CPU rack via a high-speed serial interface cable.
The receiver shall be contained within the expansion baseplates eliminating the requirement for
additional communication modules.
Ethernet expansion racks shall be connected via a 10/100Mbs Ethernet, RJ-45 connection. The
Ethernet network interface unit shall reside in the rack using the same I/O that is compatible with the
controller. The Ethernet network interface unit shall support the following:
a) Built-in switch to allow daisy chain connection to the next Ethernet network interface unit;
b) Support redundant controllers with automatic switch over;
c) Ethernet network interface unit shall support up to 79 I/O modules per drop with local expansion.
I/O reference addressing for each I/O module shall be assigned through the use of the PC compatible
configuration and programming software or the hand held programmer. There shall be no jumpers or
DIP switch settings required to address modules.
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Section 3 – Automation and Control
The circuit status of each I/O point on a module shall be indicated by a green LED mounted at the top
of the module. These LED’s shall be visible through a clear plastic lens. Each LED shall illuminate a
letter and number, which correspond to the energized I/O circuit.
Addressing of all references including I/O shall be represented as a Decimal Based number.
Each I/O module shall contain a hinged, clear plastic, terminal block cover (door) with a removable
label. The inside of the label shall have the module description, catalog number, and circuit wiring
diagram for that module type, and the outside of the label shall have a user legend space to record
circuit identification information. The label shall have color coding for quick identification of the
module as low voltage (red), extra-low voltage (blue), or signal level (gray) type.
I/O modules shall be designed for 1500 volt isolation between the field wiring and the system
backplane.
3.1.3.9.2
Input Specifications
The 120 Volt AC input module shall accommodate an input voltage range from 0 to 132 volts. The
240 Volt AC input module shall accommodate an input voltage range from 0 to 264 volts. The 24
Volt DC positive and negative logic input modules shall accommodate an input voltage range of 0 to
+30 volts DC. The 125 Volt DC input module shall accommodate an input voltage range from 0 to
150 volts.
As a minimum, the following discrete input modules shall be available:
Table 3.10: Availability of Discrete Input Points/Module
Description
Input Simulator
120 VAC Isolated Input
240 VAC Isolated Input
120 VAC Input
48 VDC Positive/Negative Logic Input
24 VAC/VDC Negative Logic Input
24 VDC, Positive/Negative Logic Input
24 VDC Positive/Negative Logic Input, (1ms response)
125 VDC Positive/Negative Logic Input
5/12 VDC Positive/Negative Logic Input (TTL)
3.1.3.9.3
Points/Module
8, 16
8
8
16
16
16
8, 16, 32
16
8
32
Output Specifications
Discrete AC output modules shall have separate and independent commons allowing each group to be
used on different phases of AC supply. Each discrete AC output shall be provided with an RC snubber
to protect against transient electrical noise on the power line. Discrete AC outputs shall be suitable for
controlling a wide range of inductive and incandescent loads by providing a high degree of inrush
current (10x the rated current).
Discrete DC output modules shall be available with positive and negative logic characteristics in
compliance with the IEC industry standard. Discrete DC output modules shall be compatible with a
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Section 3 – Automation and Control
wide range of user-supplied load devices, such as: motor starters, solenoids, and indicators.
3.1.3.9.4
Availability of Output Modules
As a minimum, the following discrete output modules shall be available:
Table 3.11: Availability of Discrete Output Points/Module
Description
120 VAC, 0.5A (2 groups)
120/240 VAC, 1A (2 groups)
120/240 VAC Isolated, 2A
48VDC Positive Logic, 0.5A
12/24 VDC Positive Logic, 2A
12/24 VDC Positive Logic, 0.5A
12/24 VDC Negative Logic, 2A
12/24 VDC Negative Logic, 0.5A
125 VDC Positive/Negative Logic, 1A
5/12/24 VDC Negative Logic, 0.5A
Relay, Normally Open, 2A (4 groups)
Relay, Normally Open, 4A Isolated
Relay, Isolated, 4 Normally Closed,
Normally Open (Form B & C) 8A
Solenoid Valve Output (Pneumatic)
3.1.3.9.5
Points/Module
12,16
8
5
8
8
8.16,32
8
8,16
6
32
16
8
Fuse Rating
3A
3A
3A
0.5A
5A
N/A
5A
N/A
N/A
N/A
N/A
N/A
# Fuses/Module
2
2
5
2
2
0
2
0
0
0
0
0
8
N/A
0
11
100 psi
0
Availability of Mixed I/O Modules
As a minimum, the following discrete output modules shall be available:
Table 3.12: Availability of Mixed Input/Output Points/Module
Description
24 VDC Input, Relay Output
120 VAC Input, Relay Output
3.1.3.10
Points/Module
8 in, 8 out
8 in, 8 out
Analogue I/O
3.1.3.10.1 General
For the conversion of analogue to digital and digital to analogue conversion required by an
application, the following shall be available:
a)
b)
c)
d)
e)
Analogue Voltage Input;
Analogue Current Input;
Analogue Voltage Output;
Analogue Current Output;
Analogue Combination.
The analogue voltage input module shall be capable of converting 4 or 16 channels of inputs in the
range of -10 to +10 volts. Resolution of the converted analogue voltage input signal shall be 12 bits
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Section 3 – Automation and Control
binary or 1 part in 4096. All of the channels of converted analogue voltage input signals shall be
updated each scan into a dedicated area of data registers in a 16-bit 2’s complement format. The
conversion speed for all of the analogue voltage input channels shall be no less than 2 milliseconds
and no greater than 13 milliseconds. The analogue voltage input module shall be configurable to a 4
to 20 mA analogue current input via an external resistor.
The analogue current input module shall be capable of converting 4 or 16 channels of inputs in the
range of 4 to 20 mA or 0 to 20 mA. Resolution of the converted analogue current input signal shall be
12 bits binary or 1 part in 4096. All of the channels of converted analogue current put signals shall be
updated each scan into a dedicated area of data registers in a 16-bit 2’s complement format. The
conversion speed for all analogue current input channels shall be a minimum of 2 milliseconds and no
greater the 13 milliseconds.
The analogue voltage output module shall be capable of converting 2 or 8 channels of digital data to
analogue outputs in the range of -10 to +10 volts. Resolution of the converted output signal shall be
13 bits or 16 bits. All channels of analogue output data shall be updated each scan from a dedicated
area of data registers in a 16-bit 2’s complement format. The analogue voltage outputs shall be
configurable to default to 0 mA, 4 mA or hold-last-state in the event of a CPU failure.
The analogue current output module shall be capable of converting 2 or 8 channels of digital data to
analogue outputs in the range of 0 to 20 mA. Resolution of the converted output signal shall be 12 bits
or 16 bits. All channels of analogue output data shall be updated each scan from a dedicated area of
data registers in a 16-bit 2’s complement format. The analogue current outputs shall be configurable
to default to 0 volts or hold-last-state in the event of a CPU failure.
The analogue combination module shall be capable of converting 4 channels of analogue inputs to
digital data and 2 channels of digital data to analogue outputs. All channels are configurable for 020mA, 4-20mA, 0-+10V, and -10-+10V. Resolution of the converted input signals shall be 12 bits
and output signals shall be 16 bits. All channels of analogue data shall be updated each scan from a
dedicated area of data registers in a 16-bit 2’s complement format. The analogue combination outputs
shall be configurable to default to 0 volts or hold-last-state in the event of a CPU failure.
3.1.3.10.2 Module Availability
As a minimum, the following analogue modules shall be available:
Table 3.13: Availability of Analogue Module
Description
Input
Voltage Analogue Input
Current Analogue Output
Voltage Analogue Output
Combo Analogue Inputs/Outputs
3.1.3.11
Channels/Module
4, 16
4, 16
2, 8
2, 8
4/2
Specialty Modules
3.1.3.11.1 Temperature Control Module
A temperature control module shall be available to accommodate applications where precise
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Section 3 – Automation and Control
temperature control is needed. The temperature control module shall support auto-tuning, closed
looped PID control, and open looped manual control. The temperature control module shall provide
eight thermocouple inputs, 1 RTD input, and 8 PID-controlled output channels for controlling heaters.
The temperature control module shall provide alarms indications for each status zone, voltage failure,
open or reversed thermocouple, compensation temperature error, high or low temperature, high or low
temperature deviation, and open channel short circuit.
3.1.3.11.2 Motion Control
Analogue and digital motion control modules shall be available to perform 4 axes of closed or open
loop servo control. These modules shall support encoder feedback with analogue (up to 4 axis) or
digital (up to 2 axis) output for velocity command. The positioning mode shall support linear and S
curve acceleration and deceleration.
The modules shall provide user-defined control inputs and outputs for application such as torque
follower and flying cut-off applications. The modules shall have user-defined inputs and outputs,
English-language programming software, and automatic data transfer of data between PLC and axis
positioning module with no user programming. The positioning mode shall have an instruction set,
which includes absolute or incremental move, wait to move, dwell, conditional jump and subroutine
functions.
The modules shall provide non-volatile program storage without the use of battery or super capacitor.
The follower mode shall provide either parallel or cascade operation from a single master. The
follower mode shall provide a selectable master source of encoder, analogue, or internal time base.
The single axis module shall have a position loop update time of not more than 1 msec. The dual axis
module shall have a position loop update time of not more than 2 msec. per axis.
3.1.3.11.3 High-Speed Counter
A high-speed counter option module shall be available to accommodate applications where pulse
input rates exceed the input capability of the PLC. The high-speed counter module shall provide direct
processing of rapid pulse signals up to 80 kHz in frequency. The high-speed counter module shall be
configurable as four independent counters counting either up or down, two independent bi-directional
counters, or one counter that can calculate the difference between two changing count values.
3.1.3.11.4 Programmable Co-Processor Module
A specialised high-performance programmable microcomputer module having up to 640 Kbytes of
on-board CMOS battery-backed user memory shall be available to perform co-processor functions.
The specialised co-processor module shall be programmable with BASIC language interpreter or ‘C’
Language to perform data acquisition, data storage and retrieval, real time computing, and operator
interface functions. The specialised co-processor module shall be capable of performing master/slave
or peer-to-peer serial communication tasks in point to point or multi-drop configurations utilizing a
serial communication protocol.
The configurable module shall have two serial communication ports, one RS-232 and the other a
selectable RS232 or RS-485. It shall have dual tasking capabilities, and shall be software configurable
to behave as:
a) One serial communication port;
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Section 3 – Automation and Control
b) Two independent serial communication ports;
c) One serial communication port and one ASCII/BASIC application using one port; or
d) One ASCII/BASIC application using one or both ports.
3.1.3.12
Third-Party I/O and Communications Modules
Based on open architecture specifications of the vendor and explicit permission of the vendor,
specialty module shall be available such as PID, Co-processor, stepper, etc.
Complete documentation, kits for building modules, and engineering resource shall be available for
the 3rd party based on the type of development.
3.1.3.13
Communications
3.1.3.13.1 Peer/Peer Communications
A specialised option module shall be available that will allow the PLC to communicate on a token
passing peer-to-peer, noise immune network providing high-speed transfer of control data.
The specialized communication module shall be configurable to broadcast data to and receive data
from up to 31 other devices on a network automatically and repeatedly from a shared and dedicated
database in RAM memory.
The communication medium for this specialized network shall be a high energy and noise immune
single shielded twisted pair cable transmitting data at an adjustable rate of up to 153.6 Kbaud. The
distance of the communication shall be up to 7500 ft at a lower baud rate.
3.1.3.13.2 Master/Slave Communications
The module shall provide 3 distinct communication protocols. There shall be a module that allows the
PLC to act as a master in a communication scheme that allows the PLC to interrogate other PLCs for
data. There shall be 2 ports provided on the module, thus allowing more than one task to run at the
same time. The two ports can be configured as communication ports in any combination.
3.1.3.13.3 Client/Server Interface
There shall be a module that provides CLIENT/SERVER with PEER to PEER communications over
Ethernet TCPIP. Each CPU system and special module shall support up to 16 simultaneous
connections.
3.1.3.13.4 Network Communications Interface Modules
Manufacture of PLC shall provide Ethernet, process field bus and DeviceNet master and slave
network modules. These modules shall be tightly coupled with the system including the integration of
the configuration in the control software and firmware. The controller shall be able to support up to 3
network communications modules per system of various types.
Figure 3.2: Block Diagram of Typical Programmable Logic Controller (PLC)
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Section 3 – Automation and Control
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Section 3 – Automation and Control
3.1.4
Remote Terminal Unit (RTU)
3.1.4.1
General
Remote terminal unit (RTU) shall be intelligent, modular unit, capable of both data acquisition and local
data processing. It shall monitor and control local equipment in a stand-alone mode as well as being an
intelligent node in a distributed system. It shall be based on multiprocessor architecture, in which a coprocessor is used for handling on-board input/output channels. To facilitate initial installation,
maintenance and future expansion, all external input/output modules shall connect to the basic controller
using a high-speed internal bus.
A complete RTU system shall consist of a power supply, a processor, inputs and outputs modules,
communication interface and real time clock, calendar and all other necessary facilities necessary to
ensure successful operation. A typical illustration of RTU architecture depicts in Figure 3.3.
The system shall consist of rugged components designed specifically for industrial environments in
compliance with IEC 61000-4-3. The RTU and all associated equipment shall be designed to function
continuously in temperatures between -40 to 70ºC and humidity between 5 to 95% relative humidity noncondensing. The RTU shall be suitable for operation on a single phase from 16 Vrms, 50/60Hz or 12/24
VDC power supply. 115/240 Vrms operating power supply shall be provided through the use of an
optional double winding isolating transformer. RFI immunity, ground surge and electrostatic discharge
shall be compliant to IEC 61000-4 series. The hardware of RTU shall be designed, manufactured, and
tested in accordance with recognized UL, C-UL, CSA, IEC and CE mark industrial standards.
The RTU system shall comply with the requirements of IEC 61131.
The RTU shall be configured and programmed with standard programming languages such as Relay
Ladder Logic (RLL), IEC 61131-3 programming standard and/or ANSI C. Programs shall be developed
and downloaded either directly to the controller using a standard RS-232 interface cable, or remotely
through the communication network media such as phone lines, dedicated lines, or wireless radios.
The RTU shall be supplied with the number and type of input/output modules and communication ports
as indicated elsewhere in the specifications. Future expansion can be made by simply plugging in
additional input/output modules to the I/O bus.
3.1.4.2
Central Processing Unit (CPU)
The central processing unit shall be high speed (minimum 14 MHz) or latest version, minimum 16 bit
CMOS microprocessor. The design should incorporate a separate co-processor for controlling
input/output channels.
The CPU shall be equipped with at least 128 Kbytes RAM for application programs, 128 Kbytes ROM
for firmware and application programs, and 0.5Kbytes EEPROM for storing system parameters and
configuration.
CPU RAM and Flash capacity shall be expandable to 1 MB RAM and 512 Kbytes Flash Memory
respectively.
The CPU shall include a real time clock/calendar, accurate to within one minute per month, with lithium
battery backup. The battery shall maintain the memory and clock/calendar for two years of power off
time.
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Section 3 – Automation and Control
All vital electronic components such as RAM, ROM, and communication port drivers shall be mounted
on sockets (not directly soldered on the board) to allow firmware upgrades and servicing of the unit in the
field.
Diagnostic LEDs shall be included for the following:
a)
b)
c)
d)
e)
Power supply;
Program Run/Stop;
Communication parameters (transmit, receive, clear to send, request to send, and carrier detect);
CPU status;
Forcing.
To minimize power consumption, the controller shall support the following:
a)
Sleep-Mode, which shall allow the CPU to turn off the power supply and reduces power
consumption to at least 120mW. The Sleep-Mode shall be controlled by the application program;
b)
All LEDs controlled by the CPU shall be disabled to reduce power consumption. A push button
switch on the CPU module shall allow the LEDs to turn on when field service is being performed.
The controller shall include a built-in power supply allowing AC and DC input. The power supply shall
be capable of providing 24 VDC output to power field transmitters.
3.1.4.3
Mixed Process Input/Output
The RTU shall include the following I/O:
a)
b)
c)
d)
16 digital inputs;
12 mechanical relays digital outputs;
8 isolated analog inputs;
2 analog outputs (where required).
Digital inputs shall be available for 12/24 VRMS/DC, 115 VRMS or 220 VRMS input ranges and shall
tolerate 150% over-voltage.
In addition to the above mentioned I/O, The controller shall include at least three high-speed counters (up
to 5 kHz) rated at 12/24 VRMS/DC. The counters shall also function as digital inputs.
Digital outputs shall be configured as follows:
a)
b)
c)
d)
e)
2 Form C individually isolated;
2 Form A individually isolated;
8 Form A with common ground for each group of four;
220 VRMS/240 VDC maximum operating voltage;
1000 VRMS contact isolation.
An isolated open-collector status output for fault annunciation shall be included in addition to the outputs
described above.
Analogue inputs shall be 0 - 5 V or 0 - 20mA, 12 bit resolution, ± 0.2% accuracy over the operating
temperature range, ± 0.1% accuracy at 25 °C (77 °F) with 1500W transient suppresser on each input.
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Section 3 – Automation and Control
Inputs shall be single ended and isolated from logic circuitry.
The RTU shall include one internal temperature measurement channel, readable in ºC or ºF to indicate the
operating temperature, for remote monitoring via the communication network, or use within the
application software. One RAM battery voltage measurement channel shall be provided, which can be
monitored remotely via the communication network.
Analogue outputs which can support 12 bit resolution, 0-20mA or 4-20mA software selectable, +/- 0.2%
accuracy over the operating temperature range, ± 0.05% accuracy at 25 °C (77° F) with 600W transient
suppresser on each output.
The RTU I/O shall be controlled by high performance co-processor. The state of digital and/or analog
output shall be configurable to hold last output value or go to off condition when the application program
is stopped.
Terminal blocks shall be removable and can accommodate solid or standard wires from 22 to 12 AWG.
This allows module replacement without disturbing the field wring.
The RTU shall be capable of supporting the following input/output points in total:
a)
b)
c)
d)
e)
276 digital inputs;
268 digital outputs;
136 analog inputs;
64 analog outputs;
32 pulse counters.
3.1.4.4 Communication
The RTU shall possess a minimum of three built-in communication ports with the following
characteristics:
a) Two RS-232, software controlled with full DCE/DTE operation to 38400 baud;
b) One RS-232, software controlled with full DCE/DTE operation to 115,200 baud.
The RTU shall support asynchronous operating mode, half and full duplex transmission.
3.1.4.5
Mechanical Design
The RTU shall be DIN rail mounted with screw clamp for vibration resistance. Front access to all
controls, indicators, lithium battery, communication ports and power supply shall be provided.
Communication ports shall be standard 9 pin RS-232 to allow easy access using standard cables. No
proprietary communication cables shall be allowed.
The complete RTU shall have a maximum footprint area of 33330 sq. mm (51.2 square inches).
3.1.4.6
Certifications and Standards
All inputs and outputs (except the serial communication ports) shall survive ANSI/IEEE C37.90 surge
withstand capability (SWC) tests without damage.
The controller shall be certified for electrical safety by UL as conforming to UL 508 or CSA as
conforming to CSA C22.2/142.
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Section 3 – Automation and Control
The controller shall meet or exceed the following standards:
a)
b)
c)
d)
Surge withstand capability: ANSI/IEEE C37.90;
RF emission compatibility: FCC part 15, Subpart J, Class A;
Electrical safety classification: UL 508/CSA C22.2/142;
Hazardous area classification: CSA Class 1, Division 2, Group A,B,C,D.
3.1.4.7
Communication Protocol
The RTU shall support an industry standard protocol, such as Modbus, with the following minimum
features:
a)
b)
c)
d)
Allows up to 65535 stations in one system;
Ability to transfer complete programs and data over the communication network;
Support high data security techniques such as Cyclic Redundancy Check CRC16;
Proprietary protocols shall not be allowed. RTU that need special gateway equipments for
interfacing between RTU to the existing or new systems, which are using open protocol, are not
acceptable.
The RTU shall have the following capabilities: a)
b)
c)
d)
e)
f)
Able to receive information from other sites and retransmit the message to another site, using the
same communication port;
Allow flexible communication algorithms on all communication ports. Any of the ports can act as
Master, Slave or Store and Forward at any time during the execution of the application program;
Able to function as an interconnection point between different communication systems such as
radio, leased lines, and radios with different frequencies;
Able to send broadcasting messages to a number of locations;
Able to perform report-by-exception (event driven communications) under the control of the
application program;
Support other protocols, such as Allen-Bradley DF1, DNP 3.0, Enron Modbus on any of the
communication ports.
3.1.4.8
Operating System
The software shall be based on a multi-tasking executive system optimized for real-time environment.
3.1.4.9
Programming Software
The programming software shall allow downloading of Relay Ladder Logic and/or standard ANSI C
programs from within one package. The software shall allow the user to develop and download the
application and system configuration over the communication network via radios, leased and dial-up
lines.
The RTU shall allow Ladder and C applications to run concurrently.
application shall not affect other applications running under C.
Any failure in the Ladder
The Relay Ladder Logic shall include the following functions:
a)
b)
c)
PID feedback control;
Modem dialling and control;
Timers, counters, mathematical functions, memory functions;
3-40
Section 3 – Automation and Control
d)
e)
f)
g)
Standard Ladder Logic functions such as coils and contacts;
Boolean logic functions;
Bit transfer functions;
Block transfer functions.
On-line monitoring of Relay Ladder Logic power flow shall be included to facilitate start-up and
debugging of programs. Relay Ladder Logic program shall be up to 12K words in size, with no fixed
limit on the number of networks.
The programming software shall support on-line monitoring and forcing of any register in the protocol
database when utilizing the built-in protocol. Forcing shall write a value to the register and prevent
modification of the register content by the communication protocol or the application software. A global
command to remove all forcing shall be included. In addition to forcing, the software shall be capable of
writing a value to any register in the protocol database but continue to allow the protocol or application
software to modify the contents of the register.
The RTU shall be capable of processing up to 32 PID loops with individual execution time bases from
0.1 to 25.5 seconds.
Standard ASNI C tools shall support the following functions:
a)
b)
c)
d)
e)
Database functions;
Modem dial-up functions;
PID functions;
System functions;
Protocol functions.
When downloading C programs, the communication message size shall be configurable to a minimum of
26 bytes and a maximum of 256 bytes. The software communication settings shall allow configurable
number of retries in addition to message time-out of up to 99 seconds.
The unit shall also support IEC 61131-3 programming using Sequential Function Chart (SFC), Functional
Block Diagram (FBD), Ladder Diagram (LD), Structured Text (ST), Instruction List (IL), Flow Chart
(FC) languages using a separate programming tools.
3.1.4.10
Data Logging Functionality
The software and hardware shall support time stamped data logging with up to 15 separate log functions
with 8 elements per log or 128 different variables. Data shall be selectable by opened serial
communication protocol registers in single bit, 16bit, 32bit and floating point registers.
Update frequency shall be selectable by the user and can very from 0.1 seconds to 999 months. The RTU
shall have a minimum of 384,000 words available for data logging. Configuration of the data log function
shall be made through the ladder logic programming software or IEC 61131-3 programming software.
Logs shall be triggered by timers or process events.
All data is retrievable as a .csv (comma separated value) file for customers use in Excel, Access, or
customers HMI software. Data could be uploaded to a PC using direct serial connection, radio or dial-up
modem.
3-41
Section 3 – Automation and Control
Figure 3.3: Typical Architecture of Remote Terminal Unit (RTU)
3-42
Section 3 – Automation and Control
3.1.5
Peripheral Integral Derivatives (PID) Controller
3.1.5.1
General
PID controllers shall conform to the CE conformity protection requirements of European Council
Directives such as 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive.
Conformity of the controllers with any other “CE Mark” Directive(s) shall not be assumed. The PID
controllers shall have high noise immunity that provides reliable and error-free performance in
industrial environments and shall conform to Group 1, Class A, ISA Equipment (EN 55011,
emissions), Industrial Equipment (EN61326, immunity).
PID controllers shall use solid-state components and shall have one or more independent loops of
control. A block diagram of PID controller is illustrated in Figure 3.4.
The controller shall include a real time clock with battery backed clock feature to allow operator to
start a setpoint program on a specific date and time.
The controller shall be suitable for panel-mounted installation and designed to UL and CSA approved
Type 4 moisture protections. The front bezel of the controller shall provide a degree of protection of
IP54 or IP66 with appropriate installation accessories.
The controller and all associated equipment shall be designed to function continuously in
temperatures between 0 to 55ºC and humidity between 5 to 90% relative humidity non-condensing.
The controller shall be suitable for operation on a single phase from 100V ± 10% to 240V ± 10%,
50Hz ± 4% or 24V DC ± 4V power supplies.
The controller design shall ensure bumpless transfer whenever the controller is switched from “auto”
to “manual” or vice versa. An auto-tune function shall be available.
The hardware of controller shall be designed, manufactured, and tested in accordance with recognized
UL, CSA and CE mark industrial standards.
The controller action shall be adjustable from direct to reverse and vice versa by the operation of a
control button. Analogue process controllers shall be capable of meeting the performance
requirements were being specified in the appropriate part of the EN60546-1:1993 or IEC605461:1987.
3.1.5.2
Operator Interface
The controller fascia shall have process variable value, and key-selected operating parameters such as
output, input, set value, active tuning parameter set, deviation, timer status, or minutes remaining in a
setpoint ramp. The controller shall have appropriate guidance displays, through language prompt, for
the operator during controller configuration.
The controller shall provide alarm, digital input annunciations, status of control relays, temperature
unit indication, auto/manual control mode, remote/local set points control status.
3.1.5.3
Analogue Input
The controller shall have analogue inputs with typical accuracy ± 0.10% of full scale input and a
typical resolution of 16 bits. The controller shall be configured to operate as universal and high level
inputs.
3-43
Section 3 – Automation and Control
Scanning rate of the analogue inputs shall not less than six times a second.
All actuations and characterizations are keyboard configurable. A separate cold junction compensator
is provided for each thermocouple type analogue input. Upscale, downscale or failsafe sensor break
protection shall be keyboard configurable. Square root extraction, ration/bias and a configurable
digital filter of 0 to 120 seconds for signal damping shall be provided for each input.
3.1.5.4
Outputs and Control
The controller shall have sufficient analogue outputs and digital outputs. These outputs shall be able
to be made up of two or more of the following types:
a)
b)
c)
d)
Current outputs (4-20mA or 0-20mA);
Electromechanical relays;
Dual electromechanical relays;
Open collector output.
The controller shall support one or more of the following output algorithms:
a) Time Proportional, which provides On-Off or Time Proportional (Relay) output;
b) Current Proportional, which supplies proportional direct current output for those final control
elements that require a 4-20mA signal. Output shall be configured via the keyboard for 0-20mA
operation without recalibration;
c) Position Proportional, which can be used to position a reversible motor with a feedback slidewire
in proportion to the output of the control algorithm. Requires the Dual Relay Output option and
the third analog input;
d) Current Proportional Duplex, which similar to current proportional but provides a second set of
tuning parameters and a split range current output or a second current output via one of the
optional current outputs, for the heat and cool zones;
e) Time Proportional Duplex, which is depending on control algorithm selection, duplex output
algorithm provides On-Off Duplex, Time Proportional Duplex, or Three Position Step Control
(TPSC). The Time Proportional Duplex output algorithm provides independent PID tuning sets
and time proportional outputs; these outputs are for heat zone above 50% output, and cool zone
below 50% output;
f) Current/Relay Duplex (Relay=Heat) is a variation of Duplex with Current active for 0 to 50%
output and Relay active 50 to 100% output;
g) Relay/Current Duplex (Relay=Cool) is a variation of Duplex with Current active for 50 to 100%
output and Relay active for 0 to 50% output.
The controller shall be able to be configured for the following control algorithms:
a)
b)
c)
d)
e)
On-Off;
PID-A;
PID-B;
PD with Manual Reset;
Three Position Step Control (TPSC).
3-44
Section 3 – Automation and Control
The TPSC algorithm is a form of motor control that does not require a feedback slidewire linked to
the motor shaft. Similar to Position Proportional control, TPSC uses relays to control an electric
motor; one to drive the motor upscale and the other to drive the motor downscale. TPSC is an
automatic back-up mode to Position Proportional Control if the feedback slidewire signal should fail.
3.1.5.5
Communication
Serial communications links with open protocol shall be made available. In addition an infrared
communication link that allows a non-intrusive configuration of the instrument. These communication
links allow communications between the controller and a host computer or PLC.
Figure 3.4: Block Diagram of Peripheral Integral Derivatives (PID) Controller
3-45
Section 4 – Control and Signal Transmission Media
Section 4
Control and Signal Transmission Media
Section 4 – Control and Signal Transmission Media
Page
4.0
CONTROL AND SIGNAL TRANSMISSION MEDIA
4-1
4.1
General
4-1
4.1.1
Delivery
4-1
4.1.2
Conductors
4-1
4.1.3
Insulant Colours
4-1
4.2
Control Cables
4-3
4.3
Screen Cables
4-3
4.4
Unshielded Twisted Pair (UTP Cable
4-4
4.4.2
Enhanced Category 5 (Cat 5E) UTP Cable
4-4
4.4.3
Enhanced Category 6 (Cat 6) UTP Cable
4-4
4.5
Fibre Optic Cable
4-5
4.5.1
General
4-5
4.5.2
Singlemode / Monomode Fibre Optic Cable
4-5
4.5.3
Multimode Fibre Optic Cable
4-6
4.5.4
Fibre Optic Connector
4-7
4.5.5
Fibre Optic Termination Panel
4-8
4.5.6
Fibre Optic Patch Cord
4-8
LIST OF TABLES
Table 4.1
Identification of Conductors
LIST OF FIGURES
Figure 4.1
Figure 4.2
Figure 4.3
Figure 4.4
Figure 4.5
Cross Section of Typical Three Cores Control Cable
Typical Shielded Twisted Pair Screen Cable
Illustration of Typical Unshielded Twisted Pair (UTP) Cable
Singlemode / Monomode Fibre Optic Cable
Multimode Fibre Optic Cable
4-i
Section 4 – Control and Signal Transmission Media
4.0
CONTROL AND SIGNAL TRANSMISSION MEDIA
4.1
General
The intent of this part of the document is to provide a standard specification that shall be used by all
Manufacturers and Suppliers for transmission media selection. This document provides the minimum
performance criteria for the media that the Manufacturer and Supplier shall meet to accommodate the
Contract requirements in excess of ten years.
The Supplier shall provide and use suitable control and signal transmission media. The type of
transmission media shall be suitable for the application and environment in which the transmission
media are to be installed. Full details of technical data and conformity standard for the transmission
media shall be submitted to the Employer’s Representative for approval.
After delivery, the Manufacturer and Supplier shall submit all documentation to support the warranty
in accordance with the manufacturer’s warranty requirements, and to apply for said warranty on
behalf of the Employer’s Representative. The warranty will cover the supplied components within the
warranty period that is a valid warranty claim.
Cables and wires shall be supplied by an approved manufacturer and as far as possible the same
manufacturer shall be used for all cables and wires. Each drum or coil shall be accompanied by a test
certificate stating the manufacturer’s name, rating of cable, results and date of tests. Cables
manufactured more than 12 months before delivery will not be accepted.
4.1.1
Delivery
All cables shall be delivered on robust cable drums with cable ends treated to form an effective seal.
When a cable is cut from a drum, the cable end and the end left on the drum shall be immediately
sealed in an approved manner to prevent the ingress of moisture.
4.1.2
Conductors
All cables shall comprise high conductivity stranded copper conductors of the sizes as shown in the
Drawings and to BS 6360. The conductors of single core cables shall be circular; those of multi-core
cables shall be generally shaped.
4.1.3
Insulant Colours
Insulant colours shall be in accordance with the recommendation of the IEE Regulations or BS 7671
Standard as shown in Table 4.1 below.
4-1
Section 4 – Control and Signal Transmission Media
Table 4.1: Identification of Conductors
Function
Protective conductors
Functional earthing conductor
Alphanumeric
Colour
Green-and-yellow
Cream
A.C Power Circuit(1)
Phase of single-phase circuit
Neutral of single- or three-phase circuit
Phase 1 of three-phase A.C. circuit
Phase 2 of three-phase A.C. circuit
Phase 3 of three-phase A.C. circuit
L
N
L1
L2
L3
Brown
Blue
Brown
Black
Grey
Two-wire Unearthed D.C Power Circuit
Positive of two-wire circuit
Negative of two-wire circuit
L+
L-
Brown
Grey
Two-wire Earthed D.C Power Circuit
Positive (of negative earthed) circuit
Negative (of negative earthed) circuit(2)
Positive (of positive earthed) circuit(2)
Negative (of positive earthed) circuit
L+
M
M
L-
Brown
Blue
Blue
Grey
Three-wire D.C Power Circuit
Outer positive of two-wire circuit derived from
three-wire system
L+
Brown
Outer negative of two-wire circuit derived from
three-wire system
L-
Grey
Positive of three-wire circuit
Mid-wire of three-wire circuit(2)(3)
Negative of three-wire circuit
L+
M
L-
Brown
Blue
Grey
Control Circuits, ELV and Other Applications
Phase conductor
L
Neutral or mid-wire(4)
N or M
Brown, Black, Red, Orange,
Yellow, Violet, Grey, White,
Pink or Turquoise
Blue
(Ref:BS 7671, Table 51)
NOTES:
(1) Power circuits include lighting circuits.
(2) M identifies either the mid-wire of a three-wire d.c. circuit, or the earthed conductor of a twowire earthed d.c. circuit.
(3) Only the middle wire of three-wire circuits may be earthed.
(4) An earthed PELV conductor is blue.
4-2
Section 4 – Control and Signal Transmission Media
4.2
Control Cables
Control cables for digital signals shall be minimum of 1.5mm2 conductor size and PVC/SWA/PVC
type. The insulation grade of the control cable shall have minimum 600/1000V with individually
numbered cores. Control cables shall be made up of 4, 7, 12, 19, 27 or 37 standard number of cores.
All cores shall be coloured white and shall be identified by black numbers arranged in sequence.
These numerals shall be lightly imprinted on the core insulation at intervals of not more than 75 mm
throughout the core length.
All control cables shall have 20% or two spare cores whichever is greater. In the case for final cables
to field devices having only one signal, one spare core shall be acceptable (total of three cores). The
cross section of typical three cores control cable is shown in Figure 4.1.
Any cable damaged and requiring repair of cable core or introduction of cable joint will result in the
cable being rejected.
Figure 4.1: Cross Section of Typical Three Cores Control Cable
4.3
Screen Cables
Unless other specified, screen cable shall be used for analogue signal transmission. Screen cable shall
be designed and manufactured to BS6500 and IEC227. Operating temperature for screen cables shall
be 0°C Minimum and 70°C maximum.
Cables for analogue signals shall be steel wire armoured, shielded twisted pair, multi-pair screen
cables with a minimum 1.5mm2 conductors as illustrated in Figure 4.2. The insulation capacity of the
multi-pair screen cable shall have minimum 500V. Conductors shall be multi-stranded 98% annealed
tinned copper and the coverage of the braided screen shall not less than 80%. All screen cables for
analogue signal transmission shall have 20% or one spare pair whichever is greater.
Figure 4.2: Typical Shielded Twisted Pair Screen Cable
4-3
Section 4 – Control and Signal Transmission Media
4.4
Unshielded Twisted Pair (UTP) Cable
4.4.1
Enhanced Category 5 (Cat 5E) UTP Cable
For applications that require to support data rate of 10BaseT (IEEE 802.3), 100BaseT (IEEE 802.3u),
1000BaseT (IEEE 802.3ab), 100 Vg-AnyLAN (IEEE 802.12), Token Ring (IEEE 805.5), TP-PMD
(ANSI X3T9.5), 100 Mbps Copper Distributed Data Interface (CDDI) and ATM 155, unshielded
twisted pair (UTP) Enhanced Category 5 (Cat 5E) type cable shall be used.
The Cat 5E UTP cable shall conform to UL, CSA, ETL and 3P Verified to ANSI/TIA/EIA568-B.2
Category 5 Enhanced, ISO/IEC 11801, NEMA WC 63.1 and prEN 50288-3-1. The Cat 5E UTP cable
shall meet the characteristic of following electrical and physical properties:
a)
b)
c)
d)
e)
f)
g)
h)
Impedance
Mutual Capacitance, max. nf/1000ft (305m)
DC Resistance, max. Ohms/1000ft (305m)
Propagation Delay Skew
Normal Velocity of Propagation
DC resistance Unbalance max. Ohms
Capacitance Unbalance (Pair to Ground)
Flame Retardant Test
: 100 ± 15 Ohms
: 17.1
: 28.6
: 45 nS/100M
: Non-Plenum insulation 65%
: 5% pf/100m max
: 330 pf/100m max
: CMR (Riser Flame Test)
There shall be two types of Cat 5E UTP cables. The solid conductor Cat 5E UTP cable is
recommended for all horizontal runs, between wiring closets, and for lengths over 25feet (7.6m).
Maximum recommended length is 100 meter. It shall not be flexed.
Cat 5E UTP stranded cable is built to withstand the repeated flexing, common in PC to wall plate
applications, without damage to inner conductors. Because of higher attenuation it is recommended
for short runs of 25 feet (7.6m) or less.
4.4.2
Enhanced Category 6 (Cat 6) UTP Cable
For applications that require to support data rate of 1000BaseT (IEEE 802.3ab), ATM 622 and
Broadband Video (77 Channels, 550 MHz), unshielded twisted pair (UTP) Category 6 (Cat 6) type
cable shall be used. The Cat 6 UTP cable shall conform to UL/CSA Listed, UL, ETL and 3P Verified
to ANSI/TIA/EIA568-B.2-1 Category 6, ISO/IEC 11801, NEMA WC 66 and UL444 prEN50288-6-1.
The Cat 6 UTP Cable shall consist of 23AWG solid bare copper conductor, Fire Retardant
Polyethylene (FRPE) Insulation, FRPE Isolator Separator and jacket Diameter of 6.90 ± 0.20mm. The
Cat 6 UTP Cable shall have and meet the characteristic of the following electrical and physical
properties:
a)
b)
c)
d)
e)
f)
g)
h)
i)
Impedance
Mutual Capacitance, max. nf/1000ft (305m)
DC Resistance, max. Ohms/1000ft (305m)
Propagation Delay Skew
Normal Velocity of Propagation
DC Resistance Unbalance of a pair
Capacitance Unbalance (Pair to Ground)
Dielectric Strength
Flame Retardant Test
: 100 ± 15 ohms
: 17.1
: 28.6
: 45 nS/100m
: 62% at 100Mhz
: 5% max
: 330 / nf/100m max
: AC 1.5 KV / MIN
: CMR (Riser Flame Test)
4-4
Section 4 – Control and Signal Transmission Media
There shall be two types of Cat 6 UTP cables. The solid conductor Cat 6 UTP cable is recommended
for all horizontal runs, between wiring closets, and for lengths over 7620mm (25 feet). Maximum
recommended length is 100 meters (328 feet). It should not be flexed.
Cat 6 UTP stranded cable is built to withstand the repeated flexing, common in PC to wall plate
applications, without damage to inner conductors. Because of higher attenuation it is recommended
for short runs of 7620mm (25 feet) or less.
Figure 4.3: Illustration of Typical Unshielded Twisted Pair (UTP) Cable
4.5
Fibre Optic Cable
4.5.1
General
The fibre optic backbone shall be able to carry voice, data and video signal in one single channel or
multiple channels. It must be sufficient to support and integrate Ethernet, fast Ethernet, ATM, Gigabit
Ethernet and other emerging technologies.
4.5.2
Singlemode / Monomode Fibre Optic Cable
Unless otherwise specified, singlemode fibre optic cable shall be 6-cores 9/125μm outdoor type fibre
optic cable. Fibre Termination Panel of 19” (0.5m) shall be utilized to serve as fibre backbone entry
point. The fibre cable shall have a length marking with hot foiled printed onto the cable jacket at an
interval of 1 meter. An illustration of typical singlemode fibre optic cable is shown in Figure 4.4.
Figure 4.4: Singlemode / Monomode Fibre Optic Cable
The fibre cables shall be colour coded for quick and easy identification for installation and shall meet
the following specifications of mechanical, physical and optical characteristics:
4-5
Section 4 – Control and Signal Transmission Media
a)
b)
c)
d)
e)
f)
g)
h)
i)
Cable minimum bending radius
Tensile strength
Storage, installation, operation’s temperature
Operating, Installation’s temperature
Refractive Index
Core Diameter
Cladding Diameter
Numerical Aperture
Average Attenuation
j)
Maximum Attenuation
4.5.3
: Min 10 times cable diameter
: Load 2500 – 3000 N
: -20 ~ +70ºC
: 0 – 100% non-condensing
: 9/125 μm
: 8 ± 1 μm
: 125 ± 1 μm
: 0.12 ± 0.01
: ≤0.35 dB/km @ 1310nm
: ≤ 0.25 dB/km @ 1550nm
: 0.40 dB/km @ 1310nm
: 0.30 dB/km @ 1550nm
Multimode Fibre Optic Cable
Unless otherwise specified, multimode fibre optic cable shall be 6-cores 50/125µm indoor type fibre
optic cable in multiple lengths to provide the vertical backbone connectivity. Fibre Termination Panel
of 19” (0.5m) shall be utilized to serve as fibre backbone entry point. An illustration of typical
multimode fibre optic cable is shown in Figure 4.5.
Figure 4.5: Multimode Fibre Optic Cable
The fibre cables shall be colour coded for quick and easy identification for installation and meet the
following specifications:
a)
Mechanical Performance
1.
2.
3.
4.
b)
Cable minimum bending radius
: Min 10 times cable diameter
Pulling force
: ≤ 1000N
Storage, installation, operation’s temperature : -40 ~ +75°C
Meet UL (OFNP and OFNR) flame-retardant testing
Physical Characteristics
1.
2.
3.
4.
5.
6.
7.
8.
Refractive Index
Core Diameter
Cladding Diameter
Coating Diameter
Coating Concentricity
Core non-circularity
Core Cladding off set
Standard proof test
: Graded-index (50/125)
: 50 ±3 μm
: 125 ±1 μm
: 245 ±10 μm
: ≥80%
: ≥2%
: ≤3 μm
: 100 Kps, 1%
4-6
Section 4 – Control and Signal Transmission Media
c)
Optical Characteristic
1. Attenuation range
2. Bandwidth range
3. Numerical Aperture
4. Zero Dispersion wavelength
5. Group Refractive Index
6. Temperature cycling
7. High Temperature exposure
8. Temperature & humidity cycling
4.5.4
: ≤3.5 dB/km @ 850nm
: ≤1.5 dB/km @ 1300nm
: 160 ~ 400 MHz-km @ 850nm
: 300 ~ 1200 MHz-km @ 1300nm
: 0.275 ± 0.015
: 1332 ~ 1354nm
: 1496 @ 850nm
: 1491 @ 1300nm
: -60° ~ +85°C, 5 cycles
: 85°C, 30 days
: -10°C ~ +85°C, 85%RH, 30 days cycle
Fibre Optic Connector
Fibre optical connector of the same family shall be used throughout the connectivity of fibre
installation. The connector shall be fully compliance with IEC 61754-6-1 or JIS C5973 F04 type
connector requirement. The connector must be field installable and capable of mounting on 0.9mm
tight buffered fibre.
The connector shall be epoxy type, with 2.5mm zirconia ferrule, pre-radiused ferrule, gives faster
physical contact PC polishing and provide push and pull mechanism. A PC polishing shall be utilized
on the tip to provide high yield during installation.
Terminate the connector with epoxy glue of quick cure type required no mixing or applicator.
The process of termination shall meet EIA and IEC standards for repeatability.
a)
Specification for 1300nm singlemode fiber optic cable shall be as follows:
1.
2.
3.
4.
5.
6.
b)
Insertion Loss
Return Loss
Durability (500 matings)
Operation Temperature
Storage Temperature
Humidity (non-condensing)
: 0.3db
: ≤ = -40 dB
: 0.2 dB Max Increase after 1000 notings
: -20°C ~ +70°C
: -40°C ~ +80°C
: 95% RH
Specification for 1300nm multimode fiber optic cable shall be as follows:
1.
2.
3.
4.
5.
6.
Insertion Loss
Durability (500 matings)
Cable Retention O.D. 3.0mm
Operation Temperature
Storage Temperature
Humidity (non-condensing)
: 0.5Db Max
: 0.3dB Max Increase
: 0.2dB Max Increase @ 10Kgs 1 minute
: -20°C ~ +70°C
: -40°C ~ +80°C
: 95% RH
Depend on the field requirement and the network design, the appropriate field installable fibre
connector shall be applied to terminate fibre optic cables from cable-to-cable, cable-to-equipment or
equipment-to-equipment, and to make jumpers.
4-7
Section 4 – Control and Signal Transmission Media
4.5.5
Fibre Optic Termination Panel
The fibre panel shall be in 1U (44.45 mm or 1.75 inches high) with capacity of 6 to 24 ports made in a
low profile, compact design and equip with splicing tray, cable router, splice protector sleeve, wiring
label and wire tie, shall capable of mounting on 19” (0.5m) equipment rack. The panel shall provide
protection from mechanical stress on the cable and fibres and from macro-bending losses. The
Routing Guides is mainly for storing excess length of cables. It shall make of aluminium alloy
housing, light-weighted, compact and rugged construction. The epoxy baked paint finish is corrosion
resistance to saline atmosphere.
Adapter module shall be removable and snap-out panel for easy installation, testing and replacement
for faulty adapters in case needed.
The fibre panel shall be equipped with thin membrane rubber grommets for cable entry and to keep
out insects and prevent dust settling inside the box.
The multimode fibre panel shall provide a centralized, rack mounted termination, identification and
service assignment point for optical fibre horizontal, backbone and equipment cabling at the
horizontal or main cross-connect, using optical fibre patch cords for connections. Each multimode
fibre panel shall contain of a front loaded flexible tray loaded with Standard Connector (SC)
multimode simplex couplers, accepting SC multimode simplex connector with front access.
The single mode fibre termination panel shall provide cross-connect, interconnect, splicing capability
and fibre identification within the premises. Each singlemode fibre panel shall consist of 6 ports
adapter module with SC ZrO2 singlemode simplex couplers, accepting SC singlemode simplex
connector with front access.
4.5.6
Fibre Optic Patch Cord
The fibre optic patch cords shall provide a cross-connection and interconnection of fibre optic
termination panel to network equipment. All cords shall available in length of 1m, 2m, 3m and 5m
include a quality control sticker to confirm insertion loss for each termination and label with a plastic
snap-on number on the patch cable for easy ports identification.
All fibre patch cords shall comply with EIA / TIA, IEC NTT and Bellcore GR-326-CORE.
The fibre patch cord for singlemode fibre optic cable shall consist of two single, buffered, gradedindex fiber with a 9/125μm cladding. Aramid yarn and a jacket of flame-retardant PVC shall cover the
fibre cladding. The patch cord shall be in duplex; terminated with SC Zr02 singlemode epoxy type
connector on each end, ultra low return loss, low insertion loss and the ferrule end face quality.
The fibre patch cord for multimode fibre optic shall consist of two single, buffered, graded-index
fibres with a 50/125μm cladding. Aramid yarn and a jacket of flame-retardant PVC shall cover the
fibre cladding. The patch cord shall have jacketed simplex, dual zipcord; terminated with SC
multimode epoxy type connector with identical or different connectors at each end.
The multimode optical fiber patch cable shall follow ITU specification and meet UL (OFNP and
OFNR) flame retardant rating with the following specifications:
a)
b)
Multimode Attenuation
: 3.5 dB/km @ 850nm; or
: 10.0 dB/km @ 1300nm.
Storage, installation and operation temperature : -40ºC ~ 75ºC.
4-8
Section 5 – Data Communications
Section 5
Data Communication
Section 5 – Data Communications
Page
5.0
DATA COMMUNICATIONS
5-1
5.1
General
5-1
5.2
Radio Link
5-2
5.2.1
General
5-2
5.2.2
Radio Equipment Parameters
5-2
5.2.3
Antennae
5-2
5.2.4
Towers and Masts
5-3
5.2.5
Communication Protocol
5-4
5.3
5.4
Global System for Mobile Communications (GSM)
5-6
5.3.1
General
5-6
5.3.2
Industrial Cellular Modem
5-6
Broadband Internet
5-8
5.4.1
General
5-8
5.4.2
Fixed Line
5-8
5.4.3
Wireless Connection
5-8
LIST OF FIGURES
Figure 5.1
Figure 5.2
Regeneration of a Signal with Radio Link
Illustration of Fixed Line Connection
5-i
Section 5 – Data Communications
5.0
DATA COMMUNICATIONS
5.1
General
This section of the documents covers the technical requirements for data communication devices. This
document provides the minimum performance criteria for the data communication devices that all
devices shall meet life span requirement in excess of ten years.
The distributed communication network, which is inclusive of data communication devices and the
appropriate communication media, shall provide a secured link for data exchange between the master
station and the various remote outstations. The communications system shall be based on one or more
of the following services as appropriate:
a)
b)
c)
d)
Radio communication;
Broadband internet;
Global system for mobile (GSM)/General packet radio service (GPRS);
Leased line.
The communication devices shall be able to be configured to handle routine data collection plus a
margin for unpredictable traffic (e.g. ad hoc interrogation of outstations, period of high activity
especially on power-up after a power failure, etc.) and extension of the total traffic load due to any
envisaged future extension and other unforeseen increase in the number of outstations, outstation data
loads and data collection frequency.
The communication devices shall support communication between master stations and outstations
which shall be carried out either as a set of inter-connected local area networks (LAN) or as a wide
area network (WAN). Both local and wide area networks shall support TCP/IP protocol suite together
with simple network management protocol (SNMP) on an IEEE 802.3 CSMA/CD media. In addition,
high-speed backbone linkages between LANs or with computers shall be via Fiber Distributed Data
Interface (FDDI). Wide area networks shall also support sending of IP packets over an International
Telecommunication Union – Telecommunication (ITU-T) Standardization Sector coordinates
standards protocol suite links.
The communication devices shall support the following alarms and shall be provided on the
communication panel:a)
b)
c)
Communication link failure;
Stalled or malfunctioning communication modules; and
Security disconnect of the malfunctioning remote outstation.
5-1
Section 5 – Data Communications
5.2
Radio Link
5.2.1
General
Directional antennae systems shall be provided at the points of communication. Any outstation, which
has data to be forwarded to the central processor, shall switch on the remote transmitter only for the
duration of the data burst.
Radio equipments shall be able to be configured to provide hot-standby configuration. An automatic
changeover to the back-up network shall be initiated in the event of errors reaching 25% of data on
one network. In the event both networks fail, switching shall occur between the networks every 15
minutes.
The radio receiver mode shall operate continuously whereas the transmitter shall be activated only
when data is to be sent through the transmitter. Only one outstation may send data at any one instant,
thus enabling the system to operate using only top radio frequencies. As a safety measure, an auto
cut-out shall be provided to prevent a faulty transmitter from locking up the channel. An illustration
of regeneration of a signal with radio link is shown in Figure 5.1.
5.2.2
Radio Equipment Parameters
The radio equipment shall have the following parameters:a)
b)
c)
d)
Frequency band
Audio bandwidth
Operating mode
Audio impedance
e)
f)
g)
h)
i)
j)
Transmit/receive spacing
Adjacent receiver channel spacing
Antenna characteristic impedance
Audio send and receive levels
Data rate
Modulation system
: VHF or UHF
: 300-3400 Hz
: Full duplex mode
: 4-wire VF termination with characteristic impedance
of 600 ohms
: 10 MHz
: 25 kHz
: 50 ohms
: Compatible with SCADA radio
: 4800 bit/s
: Frequency Modulation (FM); and
: Phase Modulation (PM)
The radio equipment shall suitable for rack mounted and shall support the following features:
a)
b)
c)
d)
5.2.3
Interface with a RTU, PLC or SCADA system;
Alarms output to give a visual indication to the radio equipment or local control panel and
SCADA system;
Status output to give a visual indication for transmitter and receiver;
Operate a set of relay contacts or logic outputs for extending `urgent’ and `non-urgent’ alarm to
the SCADA system.
Antennae
The antenna shall be a single directional stacked antenna array. Suitable directional antennae shall be
provided for all outstations radio. In any case, final design of the antennae shall be dependent on the
radio surveys carried out. Gain shall be 8 dB or better.
5-2
Section 5 – Data Communications
5.2.4
Towers and Masts
The telephone tower or mast specialist or manufacturer shall ensure the height of the towers or masts
is adequate, taking into account local obstructions, path lengths, number and size of antennae,
frequency, apparent earth curvature, mobile coverage area and any other factors that the Supplier,
Specialist or Manufacturer deems relevant. It shall be assumed initially that the top of the towers or
masts shall be at least 20 meters above ground level.
Towers shall be self-supporting, of lattice-type structure, manufactured from standard steel angle
sections to BS 4 Part 1 and BS 4848 or equivalent. The design and material lifetime of the towers
shall be in excess of 25 years.
Telescopic masts shall be manufactured from aluminum or equally strong and lightweight material,
and shall have a lifetime of at least 25 years.
5.2.4.1
Design Parameters
The design of the towers and masts shall meet the following design parameters:
(a)
Survival
Towers and masts shall survive without any subsequent degradation of performance in a wind gusting to
40 m/s from any direction. Wind speeds relate to 10m above ground level.
The tower or mast specialist shall provide calculation for wind pressures on the structural members of
a tower and antennas.
The maximum uplift and down-thrust load and horizontal shear forces for the tower base shall also be
provided in the technical proposal. The angle of worst wind attach for the tower shall also be stated.
The design shall take into account the topography of the site, particularly wind effects.
A similar criterion shall apply to telescopic masts fixed to buildings at the various outstations.
Full details of the method of securing telescopic masts to building shall be provided by the Supplier,
Specialist or Manufacturer before finalizing the radio system design.
(b)
Structural Members
The structural members of towers shall be designed to BS 449. Design calculations shall be stated in
the technical proposal giving wind loads, stress in members and tower deflections.
At survival, the factor of safety in any member of a tower shall be based on tabulated stresses given in
BS 449.
The structural members of the tower shall be constructed from steel to BS 4360.
All welding fabrication of the structural members of the tower shall comply with BS 5135. The
approval of welds shall comply with BS 4872 Part 1.
5-3
Section 5 – Data Communications
All steelwork for the towers shall be galvanized in accordance with BS 729 after all fabrication
operations have been completed.
(c) Tower Foundations
The telephone tower or mast specialist or manufacturer shall ensure the adequateness of all tower
foundations. The gravity block or raft foundations for a tower shall be designed in accordance with
the allowable bearing capacity of the soil at each site assuming ground water level at ground level in
each case. The factor of safety against uplift at survival shall be not less than 2.0.
Detailed design and detailed drawings of the foundation shall be provided for any tower to be erected
on the roof of a building. Estimated uplift, down thrust and shear forces acting upon the roof shall be
documented. In addition, detailed drawings of the method of fixing telescopic masts on the roof or
sides of buildings.
All hexagon bolts, screws and nuts shall comply with BS 4190 and shall be spun galvanized to BS
729. Feeder cable supports shall be supplied at intervals of 1 meter.
The specialist shall liaise with the appropriate authorities the need for painting towers or masts. If
required, the paint system shall be designed and applied in accordance with BS 5493. The paints
system shall have a minimum life to first maintenance of 10 years, without reliance on the galvanized
substrate. All painting shall conform to ICAO (International Civil Aviation Organization)
recommendation.
A lightning arrestor shall be provided on the top of the tower or mast and shall be connected to a
suitable earthing system.
Earthing facilities for all tower or masts shall be provided.
Aircraft warning light shall be supplied and fitted to the towers as and where required. Lighting shall
conform to ICAO recommendation.
5.2.5
Communication Protocol
Each outstation shall be linked to the master station via a duplicated communication system such that
failure in a single element e.g. communication cable, communication modules, modem, etc. would not
affect the normal working of the other elements. Automatic recovery techniques shall be applied, as
required.
The radio equipments shall support interrogate/reply sequent operation so that after sending a request
to an remote station radio, it shall not send a new request to the same remote radio station until a reply
to the previous request has been received and acted upon. However, automatic retry features shall be
incorporated.
The interrogation of the remote radio stations shall be based on ‘Any Change of Status’ and ‘Respond
All’ concepts. In response to ‘Any Change of Status’ interrogational, the remote radio station under
interrogation that has no change in data (within a predefined dead band) or status shall reply that all
equipment is healthy. In reply to a Respond All interrogation, the remote radio station shall respond
with all data whether or not any changes have taken place.
5-4
Section 5 – Data Communications
For both types of interrogation, it shall be possible to select a particular remote station and particular
type of interrogation form the desk keyboard.
If a remote radio station fails to respond to an interrogation after a pre-determined routine, an
audible/visual warning shall be displayed at the master station. The response time of the system shall
be within two seconds.
Tele-control shall be handled by transmitting the pre-selection code, returning the pre-selection code,
returning the check of pre-selection, followed immediately by automatically sending the execute code
and return the post-execution check. There shall be no interval between the successive steps in this
sequence. Each stage shall be checked internally by the tele-control system before proceeding to the
next step.
The radio equipments shall support communication for status check from the master station to all
linkup outstations. In case of master station send status check commands to each of the outstations,
the outstations shall return blocks of indications and alarms. On start-up and after a communication
line failure, the check request shall be sent automatically for all blocks of indications and alarms to be
returned from all outstations.
Communications security for data transmission, in both directions, between the master station and
outstations shall be provided by the CRC (Cyclic Redundancy Check) error technique or other equally
stringent methods which shall detect random bits and burst errors and reject all such data transmission
errors. All security checking at the master station shall be performed by hardware to facilitate
expansion and to avoid specialised software requirements.
Figure 5.1: Regeneration of a Signal with Radio Link
5-5
Section 5 – Data Communications
5.3
Global System for Mobile Communications (GSM)
5.3.1
General
In areas where other types of communication is not viable and would incur high cost, GSM system for
data communication shall be utilised. The GSM data communication shall be via Circuit Switched
Data (CSD) data collection or General Packet Radio Service (GPRS) IP connectivity. Data is
transmitted using Short Message System (SMS) through GSM with upgraded service possible through
GPRS and Enhanced Data for GSM Evolution (EDGE).
The latest available technology and error free proof GSM system from the service provider on the
market which is reliable and secure in data communications shall be utilised.
5.3.2
Industrial Cellular Modem
An industrial cellular modem shall be provided for the GSM data communications. The cellular
modem shall support RS-232/422 and 2/4-wire RS-485 serial interfaces. The two serial interfaces
shall be able to connect to all kind of devices, such as stand –alone controllers, PC COM ports, or
multi-dropped electric meters.
All serial signals are electronically isolated and can endure 2.5 kV RMS for 1 minute.
The modem shall be designed for DIN-rail or wall mounting without the need to add/assemble adaptor
or similar mounting plates. The power supply to the unit shall accommodate 12 to 48 V DC dual
redundant power input.
The serial ports are protected by 15 kV ESD (Electrostatic Discharge) line protection to ensure that
the system is safe from electrical discharge.
The modem shall be a Quad-band GSM/GPRS radio communication device. The communication
details shall be as follows:a)
b)
c)
d)
e)
f)
g)
h)
Band Selection: Quad-band 850/900 MHz, and 1800/1900 MHz;
Transmit Power: 1 watt GSM1800/1900, 2 watt Extended GSM 900/GSM 850;
GPRS Multi-slot class: Class 10, Coding Schemes: CS1 to CS4;
GPRS Terminal Device Class: Class B;
CSD (Circuit Switched Data) Data Transmission Rate: up to 14,400 bps;
SMS: Point-to-point Text/PDU (Packet Data Unit): Mobile Originated (MO) and Mobile
Terminated (MT Cell Broadcast: in accordance with GSM 07.05);
SIM Control: 3V/1.8V interface;
Antenna: Omni 0dBi/10cm, mini magnetic SMA (shape memory alloy), 3 meters.
The industrial modem’s operation status can be checked via LED indicators as follows:a)
b)
c)
d)
e)
POWER LED lights on: POWER-ON;
SIGNAL LED lights on: NETWORK REGISTERED;
PWR LED blinks/sec: RESET press & hold > 3sec;
ALL LED lights up except DATA: RESET press & hold > 10sec;
DATA LED lights up: Serial data exchange;
5-6
Section 5 – Data Communications
f)
g)
h)
GSM LED lights on: CSD call;
GSM LED blinks/sec: SMS tunnel mode;
GPRS LED lights on: GPRS.
The industrial modem is equipped with Windows Configurator, which allows users to configure
modem without using AT command. Configuration items are as follow:
a)
b)
c)
d)
e)
f)
g)
h)
Configure serial setting
Manage PIN code
Configure GSM call response
Configure GSM protocol
Configure GSM/GPRS radio band
Configure DTR (Data Terminal Ready) drop action
Configure SMS Tunnel mode
Set initial string
The industrial cellular modem operating temperature ranges from -20°C to 55°C.
The industrial cellular modem withstands a maximum continuous operating humidity of 95% without
condensation.
The media converter shall be certified for CE, FCC Class A.
5-7
Section 5 – Data Communications
5.4
Broadband Internet
5.4.1
General
Broadband internet services shall be used for data communication where such services are readily
available, the most cost effective, provide secure and high speed communication. The most suitable
package of broadband internet service provided by an Internet Service Provider (ISP) which suits the
Client’s requirement shall be utilised.
5.4.2
Fixed Line
For locations at where ISP is readily available, the technology which supports the broadband services
shall be based on Digital Subscriber Line (DSL). DSL is a direct connection to the Internet that is
always on. The type of DSL utilized shall be of the Asymmetrical Digital Subscriber Line (ADSL)
which allows simultaneous access to the net and usage of the telephone or fax line. The ADSL has the
ability to separate data traffic from voice communications via one pair of existing copper wire. The
voice communication is segregated from data traffic by Plain Old Telephone Service (POTS) splitter
and sent to the Public Switched Telephone Network (PSTN) hence allowing uninterrupted telephony
services even if the ADSL fails.
Certified ADSL modems shall be utilized. Splitter and micro filter shall be installed on the telephone
or fax line to avoid interference.
An illustration of fixed line connection is shown in Figure 5.2.
Figure 5.2: Illustration of Fixed Line Connection
5.4.3
Wireless Connection
For a wireless connection, a radio unit (customer provided equipment (CPE)) shall be connected to
the customer PC/Hub/Router as appropriate.
5-8
Section 6 – Instrument
Section 6
Instrument
Section 6 – Instrument
Page
6.0
INSTRUMENTS
6.1
General
6-1
6.1.1
Signal Transmission
6-1
6.1.2
Signal Transmitter
6-1
6.1.3
Signal Conditioning Device
6-1
6.2
Suspended Solids Analyser
6-2
6.3
Chlorine Analyser
6-4
6.3.1
Colorimetric Total Residual and Free Chlorine Analyser
6-4
6.3.2
Amperometric Free Chlorine Analyser
6-5
6.4
pH Analyser
6-7
6.5
Oxygen Reduction Potential (ORP) Analyser
6-8
6.6
Dissolved Oxygen (DO) Analyser
6-9
6.6.1
Luminescent Principle DO Analyser
6-9
6.6.2
Galvanic Technology Principle DO Analyser
6-10
6.7
Total Organic Carbon (TOC) Analyser
6-12
6.8
Density Meters
6-13
6.8.1
Open Channel Sludge Density Meter
6-13
6.8.2
Clamp-on Sludge Density Meter
6-14
6.9
Flowmeter
6-15
6.9.1
Electromagnetic Flowmeter
6-15
6.9.2
Intrinsically Safe Electromagnetic Flowmeter
6-17
6.9.3
Clamp-On Ultrasonic Flowmeter
6-19
6.9.4
Ultrasonic Open Channel Flowmeter
6-20
6.9.5
Differential Pressure Transmitter Used for Flow
6.9.6
6.10
Measurement
6-22
Rotameter or Variable Area Meter
6-23
Level Meter
6-24
6.10.1
Ultrasonic Level Meter
6-24
6.10.2
Intrinsically Safe Ultrasonic Level Meter
6-25
6.10.3
Level Electrode Controller
6-27
6.10.4
Capacitive Level Switch
6-28
6.10.5
Float Gauging Level Transmitter
6-29
6-i
Section 6 – Instrument
6.11
6.12
Pressure Meter and Switch
6-30
6.11.1
Pressure Gauge
6-30
6.11.2
Pressure Switch and Differential Pressure Switch
6-31
6.11.3
Pressure Transmitter
6-31
6.11.4
Differential Pressure Transmitter
6-33
Temperature Transmitter and Switch
6-34
6.12.1
Temperature Transmitter
6-34
6.12.2
Temperature Switch
6-34
6.12.3
Platinum Resistance Temperature Sensor (RTD’s)
6-34
6.12.4
Thermocouple
6-35
6.13
Paperless Recorder
6-36
6.14
Load Cell Weighing System
6-37
6-ii
Section 6 – Instrument
LIST OF FIGURES
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
Figure 6.7
Figure 6.8
Figure 6.9
Figure 6.10
Figure 6.11
Figure 6.12
Figure 6.13
Figure 6.14
Figure 6.15
Figure 6.16
Figure 6.17
Figure 6.18
Figure 6.19
Figure 6.20
Figure 6.21
Figure 6.22
Figure 6.23
Figure 6.24
Figure 6.25
Figure 6.26
Arrangement and Basic Components of Suspended Solids Analyser
Basic Components of Typical Chlorine Colorimetric Analyser
Basic Components of Typical Chlorine Amperometric Analyser
Differential Measuring Electrode in pH Sensor
Method of Detection for Luminescent DO Analyser
Handrail and Flotation Mounting Configuration for DO Analyser Hardware
Schematic of Typical TOC Analyser
Open Channel Sludge Density Meter
Concept of Operation for Clamp-on Sludge Density Meter
Construction of Electromagnetic Flowmeter
Components and Assembly of Clamp-on Transmissive Ultrasonic Flowmeter
Ultrasonic Open Channel Flowmeter used with Parshall Flume
Carrier-ring Type Orifice Assembly
Basic Components of Typical Rotameter
Components and Concepts of Ultrasonic Level Meter
Basic Sensing Electrodes for Level Electrode Controller
Principle of Measurement for Capacitive Level Switch
Float Gauging Level Transmitter
Pressure Gauge Mechanism
Pressure Switch Mechanism
Assembly of Pressure Transmitter and Sensor
Installation of Differential Pressure Transmitter for Flow Monitoring
Typical Installation of Temperature Transmitter for Surface Measurement
Illustration of Platinum Resistance Temperature Sensor (RTD)
Layout of Typical Thermocouple
Symbols for Various Application of Load Weighing System
6-iii
Section 6 – Instrument
6.0
INSTRUMENTS
6.1
General
All instruments, gauges and control equipment which perform similar duties shall be of uniform type
and manufacture throughout the scope in order to facilitate maintenance and stocking of spare parts.
Electromechanical and solid state relays and timing devices shall be of the plug-in type or be mounted
on plug-in circuit boards.
All equipment shall be fully tropicalised and suitable for the worst environmental operating
conditions. Panel mounted instruments shall have damp-protecting and dust-protecting cases.
Moving parts and contacts shall be adequately protected from the ingress of dust.
Equipment mounted in enclosures shall be suitable for continuous operation at the maximum internal
temperature possible in service, due account being taken of internally-generated and heat dissipated
by other equipment. All equipment shall be designed to operate without artificial cooling.
6.1.1
Signal Transmission
Analogue values shall be transmitted in accordance with BS 5863 Part 1 as electric signals in the
range of 4 to 20 mA DC, and shall be linearised where necessary.
Signal circuits operating more than one instrument or providing outputs of more than one instrument
or item of equipment shall be designed so that a fault in their interconnecting cables shall have no
effect on the operation of any other device in the same loop.
6.1.2
Signal Transmitter
Transmitting instruments shall be of the two wires, live zero type producing a 4 to 20 mA DC output
signal proportional to input range and having an accuracy of not less than +/-0.5% of span unless
otherwise specified. The output signal from each transmitter shall not be affected by the output circuit
load, including cable resistance, for its particular application. Each transmitter shall incorporate an
output signal indicator to monitor the output signal and also input and output test points for the
connection of portable instruments for testing and calibration. Transmitter shall be capable of meeting
the performance requirements laid down in BSEN 60770 Part 1.
6.1.3
Signal Conditioning Device
Signal conditioning devices shall include isolators, amplifiers, current-to-pulse and pulse-to current
converters, arithmetic modules, trip amplifiers and similar units. Each device shall be designed for
mounting within an enclosure using amounting plate rack or rail. An indication of ‘power supply on”
shall be provided at the front of each unit.
Input and output circuits shall have impedance’s to suit the signal sources and loads with which they
operate. Each analogue input and output circuit shall have independent zero and span adjustments.
Set-points on the instrument front shall be fully adjustable by means of a knob with an engraved lid.
The states of relays used in conjunction with digital inputs or out puts shall be indicated at the front of
the unit. Analogue inputs or outputs shall be indicated on the front.
6-1
Section 6 – Instrument
6.2
Suspended Solids Analyser
The suspended solids analyser shall consist of a digital sensor designed to connect to a separate unit
universal controller and with capabilities for the continuous measurement and monitoring.
The suspended solids sensor shall use dual infrared light beam technique design utilizing an LED light
source in the sensor to transmit an infrared/scattered dual beam into the sample stream at an angle to
the sensor face.
A backscatter photoreceptor positioned at an angle to the transmitted beam, shall detect light scattered
for suspended solids readings. The sensor shall analyze the dual-beam data and provides a colour
independent measurement. The sensor shall have a self-cleaning device to prevent erroneous values
and maintenance problems caused by biological activity, scum build-up and gas bubbles. Optical
surfaces that are exposed to the process shall be scratch resistant. The self-cleaning device shall
ensure that measurements are accurate, continuous and completely colour independent.
The sensor shall have an operating range of 0.001 to 50 g/L suspended solids. The analyser shall be
supplied with insertion mounting kit and the sensor shall be capable of insertion into a pipe. The
materials of construction shall be stainless steel.
The sensor shall have an operating temperature of 0 to 40ºC. The initial response time shall be 1
second and user-adjustable from 1 second up to 300 seconds.
The controller shall be “Plug and Play” microprocessor-based instrument with the option for
RS232/MODBUS or RS485/MODBUS serial input/ output capability for two-way communication to
a computer and have wireless downloading capability through an infrared (IR) Port located on the
interface unit to download and print real time data, calibration history and current set points in a
comma-separated values (CSV) format. It shall have a built-in data logger with the capacity to store
data on 15-minute intervals for up to 6 months with two sensors per controller.
Operators shall be able to control the sensor and interface function with menu-driven software 4 to
20mA outputs signal programmed to cover any part of the instrument range shall be provided. At least
two volt-free form ‘C’ user-configurable contacts and at least one instrument alarm contacts shall be
provided. The enclosure for the controller unit shall be metal type with corrosion-resistant and provide
a degree protection of IP66.
The overall accuracy shall be less than 5% of reading as defined according to ISO/WD 13530. The
repeatability shall be less than 3% of reading as defined according to ISO/WD 13530. The resolution
shall be 1 mg/L or better.
The sensor shall tested in accordance with recognized CE mark industrial standard to EN 61326-1,
EN61326/A1, EN 61326/A2 and EN 61010-1. The controller unit shall be certified for electrical
safety by UL as conforming to UL 61010A-1.
A typical arrangement and basic components of suspended solids analyser is illustrated in Figure 6.1.
6-2
Section 6 – Instrument
Figure 6.1: Arrangement and Basic Components of Suspended Solids Analyser
6-3
Section 6 – Instrument
6.3
Chlorine Analyser
6.3.1
Colorimetric Total Residual and Free Chlorine Analyser
The total residual chlorine analyser shall be a complete monitoring system for the automatic,
continuous measurement and dosing control of total residual chlorine in sample delivered to
measuring cells from selected locations. The analyser is using colorimetric measuement principle to
detemine the total residual chlorine level in the sample. Total residual chlorine shall be determined
using the N,n-Diethyl-P-Phenylene-Diamine (DPD) method in accordance to EN ISO 7393-2; ASTM
(American Society for Testing and Materials).
The analyser shall include measurement and control electronics, photometer, flow indicator, reaction
chamber, reagent dosing system and reagent containers. The analyser shall have optional feature for
integrated pH measurement with temperature compensation. The analyser shall be able integrated to
all usual devices for disinfectants and pH control either through relays or analog output signals. Two
independent controllers shall be able to operate simultaneously. The analyser shall have a function to
interrupt dosing of disinfection automatically with an external signal e.g. during sample flow
interruption.
If the analyser is required to have optional features for pH measurement with temperature
compensation:
a. The analyser shall have at least two selectable measurement values as analog output signals for
total residual chlorine and pH measurement with temperature compensation;
b. Automatic temperature compensation shall be provided for sample and ambient temperature
ranging between 0 to 50ºC.
The analyser shall have alarm display and activation of alarm relay shall be energized when user
defined or critical limits for total residual chlorine, pH or temperature are reached. It shall have
continuous, automatic monitoring of sample flow and reagent supply. Unless otherwise specified, a
means shall be provided of detecting that sample flow is healthy and where applicable, that a reagent
supply is available. Volt free contacts shall be provided for remote signalling of these conditions and
any other instrument fault condition. The analyser shall have option to add the chemical cleaning
module. The analyser shall be factory tested, ready for installation and operation.
The transmitter shall incorporate an integral indicator and produce a 0-20mA or 4-20 mA signal
proportional to residual chlorine. The unit shall be housed in a surface mounting enclosure protected
to IP 66. The transmitter shall have control function of programmable relay or current outputs for 1 or
2 pulse dosing pumps, solenoid valves or for one motor valve. Programmable P, PI, PID or PD control
function parameters shall be provided.
The transmitter shall have a minimum of the following communication interface:
a. RS485 with fieldbus protocol Modbus or Profibus DP;
b. WebServer connection via Modbus.
The analyser shall have the following accuracy for the given measurement ranges:
a. Accuracy shall be ±0.01 ppm for measurement range of 0.00-1.00 ppm;
b. Accuracy shall be ±0.06 ppm for measurement range of 1.00-3.00 ppm;
c. Accuracy shall be ±0.2 ppm for measurement range of 3.00-5.00 ppm.
A basic components of typical chlorine colorimetric analyser is illustrated in Figure 6.2.
6-4
Section 6 – Instrument
6.3.2
Amperometric Free Chlorine Analyser
The measuring technology shall be amperometric or membrane, which shall comprise measuring
cells, transmitters, indicator units, electrode, membrane and electrolyte. These shall be arranged for
continuous monitoring of the free chlorine in samples delivered to measuring cells from selected
locations. Figure 6.3 shows the basic components of typical chlorine amperometric analyser.
Each measuring unit shall include a bi-metallic cell generating a micro-ampere signal proportional to
the free chlorine in the sample passed through the cell. Where necessary, each unit shall incorporate
the facility for addition of a buffer solution to minimize the effect of pH variations on cell output or to
increase cell output at high pH. The sample flow-rate through the cell shall be adjustable by means of
a spring and diaphragm regulator or similar device. Construction material of the probe body shall be
PVC. The materials of construction of the cathode electrode and the anode electrode shall be gold and
silver respectively. Measuring cell enclosures manufactured from acrylic shall incorporate means of
maintaining the electrodes free from fouling.
Unless otherwise specified, a means shall be provided of detecting that sample flow is healthy. Volt
free contacts shall be provided for remote signalling of these conditions and any other instrument fault
condition.
The analyser shall automatically compensate for sample temperature that shall be between 2 – 45°C.
The measuring range shall be from 0 to 20.0 mg/L HOCl with minimum detection limit of 5ppb or
0.005 mg/L HOCl.
The transmitter shall be microprocessor type and connection between transmitter and sensor shall be
plug-and-play. The transmitter shall incorporate an integral indicator and produce a 4-20 mA signal
proportional to free chlorine. The unit shall be housed in a surface mounting enclosure protected to IP
66. The fascia shall have graphic dot matrix LCD, 128 x 65 pixels with LED backlighting.
The transmitter shall have option for serial input / output capability for two-way communication to a
computer and have wireless downloading capability through an infrared (IR) port located on the
interface unit to download and print real time data, calibration history and current set points in a
comma-separated values (CSV) format. It shall have a built-in data logger with the capacity to store
data on 15-minute intervals for up to 6 months with two sensors per controller.
The transmitter shall be incorporated alarm features for low alarm conditions, low alarm point
deadband, high alarm point, and high alarm point deadband, OFF delay and ON delay.
The overall accuracy of the amperometric free chlorine analyser shall be 2% or ± 10ppb HOCl,
whichever is greater and suitable for operation in tropical ambient condition and 0 to 95% relative
humidity non-condensing.
The controller unit and sensor unit shall be certified for electrical safety by UL as conforming to UL
61010A-1.
6-5
Section 6 – Instrument
Figure 6.2: Basic Components of Typical Chlorine Colorimetric Analyser
Figure 6.3: Basic Components of Typical Chlorine Amperometric Analyser
6-6
Section 6 – Instrument
6.4
pH Analyser
The pH analyser shall consist of differential electrode sensors, a built-in preamplifier reference cell
chamber, resistance thermometer for temperature compensation, and analyser transmitter with
capabilities for the continuous measurement and monitoring of pH.
The pH electrode assembly shall be of the same manufacturer as the associated analyser. Unless
otherwise specified the pH electrode assembly shall be of the flow-through type.
Threads shall be provided on both ends of the sensor for convertible mounting style either mounting
into a tee-pipe for flow-through mounting or attaching to the end of a pipe for immersion mounting.
The pH analyser shall have pH measurement capability of measuring range from 0 to 14 pH with
performance accuracy 0.1% of span. The repeatability shall be 0.1% of span. The analyser shall have
two electromechanical SPDT relays as a standard option and have an option to expand to an
additional of two more electromechanical SPDT relays, if required.
Two isolated 0-20mA or 4-20mA shall be provided in the pH analyser. RS-232 communication shall
be a standard feature for the pH analyser. The pH analyser shall be housed in a ¼ DIN, IP65 enclosure
with hardware for surface and panel or pipe mounting.
The analyser shall be provided for with automatic and manual temperature compensated by an integral
temperature sensor.
The pH sensor shall utilize accurate differential measurement technique. It shall use three measuring
electrodes to perform the measurement as illustrated in Figure 6.4. It shall also be able to withstand a
working temperature of -5 to 95ºC and has a maximum allowable pressure of 100 psig. The pH sensor
should have a sensitivity of not more than 0.005pH.
The electronics components of the pH sensor shall be encapsulated within a chemical resistant liquid
crystal polymer (LCP) body. The sensor shall have a built-in preamplifier to boosts the high
impedance analogue signals of the electrodes and enables it to generate a strong signal for
transmission of up to 3000 feet.
The analyser shall have air/water blast cleaning washer head for the immersion mounting style
applications with user-supplied air/water system. The washer head shall be provided with 6.35mm
(0.25 inches) spray nozzle and barded fitting. The spray nozzle shall be manufactured from PVDF
(Polyvinylidene Difluoride).
Figure 6.4: Differential Measuring Electrode in pH Sensor
6-7
Section 6 – Instrument
6.5
Oxygen Reduction Potential (ORP) Analyser
The Oxygen Reduction Potential (ORP) analyser shall consist of differential electrode sensors, a builtin preamplifier reference cell chamber, resistance thermometer for temperature compensation, and
analyser transmitter with capabilities for the continuous measurement and monitoring of ORP.
The ORP electrode assembly shall be of the same manufacturer as the associated analyser. Unless
otherwise specified the ORP electrode assembly shall be of the flow-through type.
Threads shall be provided on both ends of the sensor for convertible mounting style either mounting
into a tee-pipe for flow-through mounting or attaching to the end of a pipe for immersion mounting.
The ORP analyser shall have ORP measurement capability of measuring range from -2000 to 2000
mV with performance accuracy 0.1% of span. The repeatability shall be 0.1% of span. The analyser
shall have two electromechanical SPDT relays as a standard option and have an option to expand to
an additional of two more electromechanical SPDT relays, if required.
Two isolated 0-20mA or 4-20mA shall be provided in the ORP analyser. RS-232 communication shall
be a standard feature for the ORP analyser. The ORP analyser shall be housed in a ¼ DIN, IP65
enclosure with hardware for surface and panel or pipe mounting.
The analyser shall be provided for with automatic and manual temperature compensated by an integral
temperature sensor.
The ORP sensor shall utilize accurate differential measurement technique. It shall use three measuring
electrodes to perform the measurement. It shall also be able to withstand a working temperature of -5
to 95ºC and has a maximum allowable pressure of 100 psig. The ORP sensor should have a sensitivity
of not more than 0.5 mV.
The electronics components of the ORP sensor shall be encapsulated within a chemical resistant
liquid crystal polymer (LCP) body. The sensor shall have a built-in preamplifier to boosts the high
impedance analog signals of the electrodes and enables it to generate a strong signal for transmission
of up to 3000 feet.
The analyser shall have air/water blast cleaning washer head for the immersion mounting style
applications with user-supplied air/water system. The washer head shall be provided with spray
nozzle and barded fitting. The spray nozzle shall be manufactured from PVDF (Polyvinylidene
Difluoride).
6-8
Section 6 – Instrument
6.6
Dissolved Oxygen (DO) Analyser
6.6.1
Luminescent Principle Dissolved Oxygen Analyser
The DO analyser shall consist of a probe with luminescent material coated sensor, designed to
connect to a separate unit digital controller by an integral sensor cable and with capabilities for the
continuous measurement and monitoring.
The DO sensor shall utilize luminescent sensor technology for DO detection in the sample as
illustrated in Figure 6.5. The probe material shall be foamed Noryl (modified polyphenylene Oxide
(PPO)) and 316 stainless steel. The probe shall be fully corrosion resistant and fully immersible.
Measuring range of the probe shall be 0-20 mg/L dissolved oxygen with accuracy ±0.2% of span
regardless to flow rate. The sensitivity and repeatability of the probe shall be ±0.5% of span.
The material of the sensor shall be polybutyl methoacrolate, which is a luminescent material that
emits red light when excited with blue light depending on the dissolved oxygen concentration.
The sensor shall be not be affected by pH swings, hydrogen sulfide, wastewater chemical or organic
build-up on the sensor. Warm-up time shall not be required and analyser shall be able to start
measuring within 30 seconds from energization of the analyser.
The probe shall provide electrolyte-free operation without the requirement of sample conditioning.
The probe shall support pole mounting or ball-float mounting style.
The controller shall be “Plug and Play” microprocessor-based instrument with the option for
RS232/MODBUS or RS485/MODBUS serial input/output capability for two-way communication to a
computer and have wireless downloading capability through an infrared (IR) port located on the
interface unit to download and print real time data, calibration history and current set points in a
comma-separated values (CSV) format. It shall have a built-in data logger with the capacity to store
data on 15-minute intervals for up to 6 months with two sensors per controller.
Operators shall be able to control the sensor and interface function with menu-driven software. 4 to
20mA outputs signal programmed to cover any part of the instrument range shall be provided. At least
two volt-free form ‘C’ user-configurable contacts and at least one instrument alarm contacts shall be
provided. The enclosure for the controller unit shall be cast aluminium coated with polymer powder
coating for corrosion resistance and provide a degree protection of IP66.
The controller unit shall be certified for electrical safety by UL as conforming to UL 61010A-1.
Figure 6.5: Method of Detection for Luminescent DO Analyser
6-9
Section 6 – Instrument
6.6.2
Galvanic Technology Principle Dissolved Oxygen Analyser
The galvanic principle DO analyser shall consist of a probe uses galvanic technology principle sensor,
designed to connect to a separate unit digital controller by an integral sensor cable and with
capabilities for the continuous measurement and monitoring.
The DO sensor shall utilize galvanic technology sensor technology for dissolved oxygen detection in
the sample. The sensor shall automatically compensate for changes in process temperature. The sensor
shall be provided with a dozen disposable calibration bags to perform “Saturation Method” air
calibrations. The disposable calibration bags shall provide a stable atmosphere around the sensor
membrane for highly accurate calibration.
Material of construction for wetted materials of the probe shall be as follows:Probe Part
Probe body
Probe mounting adapter
O-ring
Membrane
Cartridge assembly
Cable grip/strain relief
Material
Foamed Noryl® (modified polyphenylene Oxide (PPO))
PVC (Polyvinyl chloride)
Viton Compound (Fluoroelastomer)
Polypropylene
Noryl® and Ryton® (polyphenylene sulfide (PPS))
Nylon
Each cartridge assembly shall include a pre-installed, semi-permeable membrane, electrolyte and
electrodes.
The electrodes shall be in a replaceable cartridge filled with electrolyte and covered by a pre-installed,
40 μm thick gas permeable membrane. The hydrophobic membrane shall be constructed of
Polypropylene. Material of construction for cathode electrode shall be Nickel-chrome and anode
electrode shall be constructed from lead.
The probe shall be fully corrosion resistant and fully immersible to a depth of 107 m. The probe shall
have maximum pressure limit up to 1050 kPa. Measuring range of the probe shall be 0-40 mg/L
dissolved oxygen with measurement accuracy ±2% of span to minimum flow rate of 5 mm/s. The
sensitivity and repeatability of the probe shall be ±0.5% of span.
Self-contained air blasts cleaning systems, complete with air compressor shall be provided for
automatic sensor cleaning. A separate washer head air blast assembly shall be installed.
The controller shall be “Plug and Play” microprocessor-based instrument with the option for
RS232/MODBUS or RS485/MODBUS serial input/output capability for two-way communication to a
computer and have wireless downloading capability through an infrared (IR) Port located on the
interface unit to download and print real time data, calibration history and current set points in a
comma-separated values (CSV) format. It shall have a built-in data logger with the capacity to store
data on 15-minute intervals for up to 6 months with two sensors per controller. The controller unit
shall be certified for electrical safety by UL as conforming to UL 61010A-1.
Operators shall be able to control the sensor and interface function with menu-driven software. 4 to
20mA outputs signal programmed to cover any part of the instrument range shall be provided. At least
two volt-free form ‘C’ user-configurable contacts and at least one instrument alarm contacts shall be
provided. The enclosure for the controller unit shall be cast aluminium coated with polymer powder
coating for corrosion resistance and provide a degree protection of IP66.
6-10
Section 6 – Instrument
The DO analyser hardware shall support the following mounting options of configurations:a)
Economy Pole Mounting Kit (without swivel) consisting of a 38mm (1-1/2 inch) diameter by
2.3 m (7.5 ft) long straight pipe and straight handrail mount. Pivot shall be provided for the
sensor assembly;
b)
Handrail Mounting Hardware consisting of a 38mm (1-1/2 inch) diameter by 2.3 m (7.5 ft) long
pipe, straight coupling for sensor, swivel/pivot/pipe clamp assembly, and surface-mount IP66
junction box with quick disconnect receptacle for sensor with metal plug on its cable;
c)
Flotation Mounting Hardware consisting of a 38mm (1-1/2 inch) diameter by 2.3 m (7.5 ft) long
pipe, angle coupling for sensor, ball float, swivel/pivot/pipe clamp assembly, and surface-mount
IP66 junction box with quick-disconnect receptacle for sensor with metal plug on its cable;
d)
Submersion Mounting Hardware consisting of a 38mm (1-1/2 inch) diameter by 1.5 m (5 ft)
long pipe, and surface-mount IP66 junction box with quick-disconnect receptacle for sensor
with metal plug on its cable;
e)
Flow-through Union Hardware consisting of a 50.8mm (2-inch) “T” tee with socket-weld
connections, and a 50.8mm (2-inch) union.
A typical handrail and floatation mounting configuration for the DO analyser is shown in Figure 6.6.
Figure 6.6: Handrail and Flotation Mounting Configuration for DO Analyser Hardware
6-11
Section 6 – Instrument
6.7
Total Organic Carbon (TOC) Analyser
The total organic carbon (TOC) analyser shall employ a high temperature, large volume furnace
reactor coupled with a peristaltic pump based sample injection method to measure TOC with acid
sparging for TOC removal. The analyser shall employ a Non-dispersive Infrared (NDIR) carbon
dioxide (CO2) detection system to measure TOC. The analyser shall operate by continuous sample
injection method. Figure 6.7 depicts a standard addition system of typical TOC analyser.
The measurement range shall be 0 to 20,000 mg/L TOC with accuracy and repeatability ± 5% of
reading at ranges less than 1000 mg/L with and without dilution at 25ºC and ± 2% of reading in the
range of 2000 to 20,000 mg/L with dilution at 25ºC. The minimum detection limit shall be less than
0.1 mg/L at range 0-25 mg/L at 25ºC. The inlet pressure shall be 0.15-6 bar (2-87 psig) and flow rate
of 20-200 mL/min.
The analyser shall consist of dual enclosures with analytical/ electrical separation. The enclosure shall
have ingress protection of at least IP 54 rated and made of epoxy powder-coated cold rolled steel. The
analyser shall be equipped with grab sample and validation utilities for unknown sample or reference
standard measurement. The analyser shall complete with user programmable auto calibration, auto
validation and auto cleaning routines. The analyser shall be equipped with loss of sample flow and
reactor feed detection and hinged pump assembly module.
The analyser shall consist of two 4-20mA parameter mapped analog outputs, 5 volt free function
mapped relay outputs and one optional RS232 or RS485 serial communication output (MODBUS,
comma-separated values (CSV)).
Figure 6.7: Schematic of Typical TOC Analyser
6-12
Section 6 – Instrument
6.8
Density Meter
6.8.1
Open Channel Sludge Density Meter
The open channel sludge density meter shall consist of a process and immersion sensor designed to
connect to a separate unit universal controller and a transmitter suitable for wastewater application
and with capabilities for the continuous measurement and monitoring, and facilities for installation
and cable connection accessories. Figure 6.8 illustrates the installation arrangement of typical open
channel sludge density meter.
The sensor of open channel sludge density meter shall utilise nephelometric 90º scattered light method
with a measuring frequency in the near infrared range of light (880 nm) according to ISO7027/EN
27027 guarantees a measurement of the density value under standardised and comparable condition.
In the concept of the nephelometric 90º scattered light method, the excitation radiation of an infrared
transmitter strikes the medium at a defined angle of beam. The different refractive indices of the
entrance window and the measuring medium are taken into account. Particles in the medium generate
a scattered radiation, which strikes the scattered light receiver at a defined angle. The measurement in
the medium is constantly adjusted with the values of a reference receiver.
The sensor shall have a self-cleaning device to prevent erroneous values and maintenance problems
caused by biological activity, scum build-up and gas bubbles. Optical surfaces that are exposed to the
process shall be scratch resistant. The self-cleaning device shall ensure that measurements are
accurate, continuous and completely colour independent with adjustable timing.
The sensor shall have an operating range of 0 to 300 g/l suspended solids and an operating
temperature of -5ºC to 50ºC. The sensor shall be supplied with insertion mounting kit and the sensor
shall be capable of insertion into a pipe. The materials of construction for the sensor shall be stainless
steel. The storage temperature of the sensor shall be in the range of -20ºC to 60ºC.
The controller shall be “Plug and Play” microprocessor-based instrument with the transparent
communication connecting automation systems and decentralised field devices and for two-way
communication to a computer. The controller shall be provided with built-in data logger saving
10,000-point real time measurement data annually.
Operators shall be able to control the sensor and interface function with menu-driven software. 4 to
20mA outputs signal programmed to cover any part of the instrument range shall be provided. At least
two volt-free form ‘C’ user-configurable contacts and at least one instrument alarm contacts shall be
provided. The enclosure for the controller unit shall be polycarbonate and provide ingress protection
of IP65 for field installation or IP54 for panel mounting installation.
The overall accuracy of the open channel sludge density meter shall be ±2% of reading with
repeatability ±1% of reading. The resolution shall be 0.1 g/l or better. The sludge density meter shall
comply with interference emission and interference immunity in accordance with EN61326-1:1998.
6-13
Section 6 – Instrument
6.8.2
Clamp-On Sludge Density Meter
Clamp-on sludge density meter shall be a non-contacting ultrasonic measurement instrument suitable
for wastewater application. The clamp-on sludge density meter shall utilize envelope energy average
method principle that saves signal envelop and then calculates its energy as depicts in Figure 6.9. It
shall measure density of suspended solid in liquid that flow through a pipe and with capabilities for
the continuous measurement and monitoring.
The sludge density meter shall consist of a probe, a controller, a Class A PVC flanged pipe section
and facilities for installation and cable connection. The controller, which runs a firmware, controls the
ultrasonic probe and analyses signals from the probe.
The material of construction for the probe shall be stainless steel grade 316 with ingress protecting
rating of IP68. The probe shall utilise single transmission multi reception technology to maximise
measurement stability. The probe shall have measuring ranges of 2 to 200 g/l suspended solids. The
probe shall be supplied with a Class A PVC flanged pipe section and probe clamp-on mounting kits.
The operating temperature range for the probe shall be -50ºC to 100ºC.
The controller shall control attenuated signals received from the transmission sensor and then convert
the signals into density values in real time. The controller shall be provided with built-in data logger
saving 10,000-point real time measurement data annually.
The controller shall incorporate integral indicator and produce a 4-20mA current output, three SPDT
(single pole double throw) relay outputs and a RS232C digital communication as the standard feature.
Digital communication of RS485 or Profibus-DP shall be available as optional communication. The
operating temperature range for the controller shall be -20ºC to 60ºC.
The material of construction of the body and cover of the controller shall be FRP (Fiberglass
reinforced plastic). The display unit window of the controller shall be made from polycarbonate. The
controller shall be constructed to meet ingress protection of IP67.
The clamp-on sludge density meter shall be suitable for application in 100 VAC to 240 VAC, 50 Hz
to 60 Hz power supply system.
The overall accuracy of each installation shall be within ±5% of reading or ±5g/l. The receptivity shall
be ±1% of reading.
Figure 6.8: Open Channel Sludge Density Meter
Figure 6.9: Concept of Operation for Clamp-on
Sludge Density Meter
6-14
Section 6 – Instrument
6.9
Flowmeter
6.9.1
Electromagnetic Flowmeter
The flowmeter shall be of electromagnetic type with no moving parts. It shall be suitable for fluids
with minimum conductivity of 50 micro S/cm. It shall consist of a flow sensor, which forms a section
of the pipe and an electronic signal converter as illustrated in Figure 6.10.
The electromagnetic flowmeter shall use DC excitation on the sensor’s field coils. The DC magnetic
field is generated by a switched direct current of alternating polarity. The measurement circuit shall
include an “Autozero” circuit which ensure a stable zero point. The electromagnetic flowmeter shall
have an accuracy of ± 0.5% of reading down to 0.5 m/s and repeatability of 0.2% of reading.
The flow sensor shall consist of stainless steel metering tube lined with Hard Rubber lining and
stainless steel 316 electrodes. The end connections of the flow sensor shall be flanged. Flanges
provided must comply with DIN2501, PN16. Flanges material shall be of carbon steel St37-2, DIN
17100. The flow sensor must be able to withstand a nominal pressure of 16 bar.
The fitting lengths of the sensors must be designed according to ISO 13359 standard. This will ensure
that it can be replaced easily, without cutting or welding of pipe, with any flow meter designed to the
same standard. The wetted parts liner shall be made of NSF (a not-for-profit safety and public health
organization), KTW (German Institute for Consumer Health Protection recommendation on plastics in
contact with drinking water), WIRAS Test (UK approval body) or equivalent compliant material.
For compact flow meter, it shall have an enclosure with protection grade of at least IP67 and shall
withstand medium temperature of 80ºC maximum and 0ºC minimum. It shall be suitable for
continuous outdoor application.
For remote type, the flow sensor shall have an enclosure with protection grade of at least IP68 and
shall withstand medium temperature of 80ºC maximum and 0ºC minimum. It shall be suitable for
continuous submission to a minimum depth of 6 meters and constructed to IEC144 Standard IP68.
IP68 sensor head shall from manufacturer factory.
Signal cables between the flow sensor and the converter must be screen to suppress interference and
the entry at the flow sensor shall maintain watertight to IP68, to protect the coil enclosure. The
interconnecting cable shall be terminated and sealed on the flow sensor by the manufacturer before
shipment from the factory. Empty pipe detection (EPD) and reference electrodes shall be included as
standard.
The flow converter/transmitter shall be completely microprocessor controlled and can be mounted
remotely up to 200m from sensor. The converter housing shall be at least IP67 protected and coated
with at least 2-component epoxy resin. Cable connection should be easily done by opening the cover
to the wiring compartment. Local display shall be 2-lines illuminated LCD. Programming can be done
through three push buttons or laptop.
The LCD shall display at least:
a)
b)
c)
d)
e)
Flow rate as % or unit (SI or Imperial Unit);
Total flow value (unit independent of flow rate unit setting);
Other programming parameters like creep suppression time constant, etc;
Access code for security;
Error messages.
6-15
Section 6 – Instrument
Power supply voltage shall be 24V DC. The power consumption of the system shall not exceed 6 VA.
All electronic boards in the converter shall be modular in design and freely interchangeable for
different sizes of the measuring sensor heads thereby minimising the need for stocking of spares.
The converter shall include the following features: a) All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated from
each other;
b) 0-20mA or 4 - 20mA active current output, with maximum load resistance of 700 Ohm;
c) selectable time contact (0.5 to 99.99 sec);
d) Passive pulse output:1. Passive
: Open Collector, 30V DC, 250mA;
2. Pulse width
: 50ms to 2s, selectable pulse polarity (+ve or -ve).
e) Frequency output up to 100Hz, pulse width max. 2s;
f) Frequency output scaling to be independently set regardless of scaling for current output;
g) Data storage on power failure for all system data, calibration data, totaliser value and without
needing any batteries;
h) Conform to electromagnetic interference requirement in accordance to IEC 801/VDE 0843 and
NAMUR recommendation.
The converter shall be able to provide internal simulation output of current and frequency, without the
need of any actual liquid flow or external simulator sources.
The flowmeter shall be provided with flange adapter for easy and rigid installation. The flowmeter
shall meet installation requirement of minimum of five pipe diameters of straight pipe from the last
valves, washout, or pipe bend, etc., at the upstream of the flow sensor.
All flowmeters shall be able to be wet-calibrated on precision calibrating rigs at the Works and
adjustment thereafter shall not be required.
Validation of flow meter shall be able to be performed without removal of electronic from the
transmitter. All validation data shall be able to be downloaded to a personal computer.
The electromagnetic flowmeter shall be provided with data logger for saving real time measurement
data. Users shall be able to configure data logging interval set up. The data logger shall deliver
graphical data and comma-separated values (CSV) data file up to 20,000 data point that can be open
with standard PC program.
Figure 6.10: Construction of Electromagnetic Flowmeter
6-16
Section 6 – Instrument
6.9.2
Intrisically Safe Electromagnetic Flowmeter
Intrinsically safe electromagnetic flowmeter shall meet or exceed ATEX, FM or CSA intrinsically
safe standard for use in Class I, Division 1, Group A, B, C and D; Class II, Division 1, Groups E, F
and G. and Class III, Division 1, indoor and outdoor hazardous locations. The assemblies of this
instrument for application in hazardous location shall exceed intrinsically safe requirements in
accordance to international standard, such as ATEX, FM or CSA.
The flowmeter shall be of electromagnetic type with no moving parts. It shall be suitable for fluids
with minimum conductivity of ≥5 micro-S/cm. It shall consist of a flow sensor, which forms a section
of the pipe and an electronic signal converter. The electromagnetic flowmeter shall use DC excitation
on the sensor’s field coils. The DC magnetic field is generated by a switched direct current of
alternating polarity. The measurement circuit shall include an “Autozero” circuit which ensure a
stable zero point.
The electromagnetic flowmeter shall have an accuracy of ± 0.5% of volume flowrate or ±1 mm/s of
the average velocity of flow and repeatability of ± 0.1% of volume flowrate ±0.5 mm/s of the average
velocity of flow.
The flow sensor shall consist of stainless steel metering tube lined with polyurethane and hard rubber
lining and stainless steel 316 electrodes. Alloy-C22 or tantalum made electrodes shall be available as
option for various applications. The end connections of the flow sensor shall be flanged. Flanges
provided shall comply with DIN2501, PN16. Flanges material shall be of carbon steel RSt37-2, DIN
17100. The flow sensor must be able to withstand a nominal pressure of 16 bar.
The fitting lengths of the sensors must be designed according to ISO 13359 standard. This will ensure
that it can be replaced easily, without cutting or welding of pipe, with any flow meter designed to the
same standard. The wetted parts liner shall be made of NSF (a not-for-profit safety and public health
organization), KTW (German Institute for Consumer Health Protection recommendation on plastics in
contact with drinking water), WIRAS Test (UK approval body) or equivalent compliant material.
For compact flow meter, it shall have an enclosure with protection grade of at least IP67 and shall
withstand medium temperature of 80ºC maximum and 0ºC minimum. It shall be suitable for
continuous outdoor application.
For remote type, the flow sensor shall have an enclosure with protection grade of at least IP68 and
shall withstand medium temperature of 80ºC maximum and 0ºC minimum. It shall be suitable for
continuous submersion to a minimum depth of 6 meters and constructed to IEC144 Standard IP68.
IP68 sensor head shall from manufacturer factory.
Signal cables between the flow sensor and the converter must be screen to suppress interference and
the entry at the flow sensor shall maintain watertight to IP68, to protect the coil enclosure.
The interconnecting cable shall be terminated and sealed on the flow sensor by the manufacturer
before shipment from the factory. Empty pipe detection (EPD) and reference electrodes shall be
included as standard.
The flow converter/transmitter shall be completely microprocessor controlled and can be mounted
remotely up to 200m from sensor. The converter housing shall be at least IP67 protected and coated
with at least 2-component epoxy resin. Cable connection shall be easily done by opening the cover to
the wiring compartment. Local display shall be 2-lines illuminated LCD. Programming can be done
through three push buttons or laptop.
6-17
Section 6 – Instrument
The converter shall include the following features: a) All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated from
each other;
b) 0-20mA or 4 - 20mA active current output, with maximum load resistance of 700 Ohm;
c) selectable time contact (0.5 = 99.99 sec);
d) Passive pulse output:1. Passive
: Open Collector, 30V DC, 250mA, galvanically isolated;
2. Pulse width
: 0.5ms to 2s, selectable pulse polarity (+ve or -ve) and pulse value.
e) Frequency output of full scale range from 2 to 1000 Hz (Maximum frequency = 1250 Hz), pulse
width max. 10s;
f) Frequency output scaling to be independently set regardless of scaling for current output;
g) Data storage on power failure for all system data, calibration data, totaliser value and without
needing any batteries;
h) Conform to electromagnetic interference requirement in accordance to IEC 61326/EN61326 and
NAMUR recommendation.
The converter shall be able to provide internal simulation output of current and frequency, without the
need of any actual liquid flow or external simulator sources.
LCD to display at least:
a)
b)
c)
d)
e)
Flow rate as % or unit (SI or Imperial Unit);
Total flow value (unit independent of flow rate unit setting);
Other programming parameters like creep suppression time constant, etc.;
Access code for security;
Error messages.
Power Supply voltage shall be 24V DC. The power consumption of the system shall not exceed 6 VA.
All electronic boards in the converter shall be modular in design and freely interchangeable for
different sizes of the measuring sensor heads thereby minimising the need for stocking of spares.
The flowmeter shall be provided with flange adapter for easy and rigid installation. The flowmeter
shall meet installation requirement of minimum of five pipe diameters of straight pipe from the last
valves, washout, or pipe bend, etc., at the upstream of the flow sensor.
All flowmeters shall be able to be wet-calibrated on precision calibrating rigs at the Works and
adjustment thereafter shall not be required.
Validation of flow meter shall be able to be performed without removal of electronic from the
transmitter. All validation data shall be able to be downloaded to a personal computer.
The intrinsically safe electromagnetic flowmeter shall be provided with data logger for saving real
time measurement data. Users shall be able to configure data logging interval set up. The data logger
shall deliver graphical data and comma-separated values (CSV) data file up to 20,000 data point that
can be open with standard PC program.
Intrinsically safe electromagnetic flowmeters shall be used for sludge digester tank and associated
equipment. Their assemblies for application in hazardous location shall exceed intrinsically safe
requirements.
6-18
Section 6 – Instrument
6.9.3
Clamp-On Ultrasonic Flowmeter
The flowmeter shall be of clamp-on ultrasonic type with no moving parts. It shall be suitable for bidirectional flow measurement for liquids with a gas content of less than 1% or a solids content of less
than 5% regardless of the pressure, temperature, conductivity and viscosity. It shall consist of a pair of
flow sensor, which clamped on a section of acoustically transmissive pipe and an electronic signal
converter connected by a pair of coaxial cable as shown in Figure 6.11.
The clamp-on ultrasonic flowmeter shall operate on the principle of transit time difference. An
acoustic or ultrasonic signal is transmitted in both directions from one measuring sensor to the other.
As the signal propagation velocity of the ultrasonic wave is less when the waves travel against the
direction of flow then along the direction of flow, a transit time difference occurs. This difference is
directly proportional to the flow of the fluid. The signal converter calculates the flow from the pipe
cross sectional area and the measured transit time difference.
The Clamp-On Ultrasonic flowmeter shall have an accuracy of ± 2% of reading down to 0.3 m/s and
repeatability of 0.3% of reading.
The flow sensor shall be suitable for pipe diameter from 100mm to 4000mm. It should be suitable for
various sonically conductive homogeneous type pipe materials with or without liner.
The flow sensor shall have an enclosure with protection grade of at least IP68 and shall withstand
medium temperature of 80°C maximum and 0°C minimum. It shall be suitable for continuous
submersion to a minimum depth of 10 meters and constructed to IEC 144 Standard IP68.
Signal cables between the flow sensor and the converter shall be screen to suppress interference and
the entry at the flow sensor shall maintain watertight to IP68, to protect the coil enclosure. The
interconnecting cable shall be supplied by the manufacturer of the converter.
The clamp-on ultrasonic flowmeter shall be provided with data logger for saving real time
measurement data. Users shall be able to configure data logging interval set up. The data logger shall
deliver graphical data and tabulated data point that can be exported to a personal computer (PC) based
program spreadsheet.
Figure 6.11: Components and Assembly of Clamp-on Transmissive Ultrasonic Flowmeter
6-19
Section 6 – Instrument
6.9.4
Ultrasonic Open Channel Flowmeter
The flowmeter shall be non-contact, automatic, continuous measurement and monitoring flow of
fluids in open channels. It shall consist of an ultrasonic technology level sensor and a flow transmitter
as illustrated in Figure 6.12.
The ultrasonic flow meter system shall have an accuracy of 0.1% of set measuring range. It shall have
a measured value resolution of better then 1mm. The overall flow measurement accuracy shall be
better then 2%.
The ultrasonic sensor shall be operated based on time-of-flight method. The sensor transmits
ultrasonic pulses in the direction of the product surface. There, they are reflected back and received by
the same sensor. The transmitter measures the time between pulse transmission and reception. The
instrument uses the time of flight divide by two, then multiply by the velocity of sound to calculate
the distance between the sensor membrane and the product surface.
Since the distance between the sensor’s membrane surface and the empty level is fixed and entered
into the device, the actual level can be calculated by minus the distance from the empty distance. An
integrated temperature sensor shall compensate for changes in the velocity of sound caused by
temperature changes. The ultrasonic sensor shall be of the same manufacturer of flow transmitter. It
shall be at least IP68 protected with 5m minimum length of sensor cable.
The transmitter shall include an interference echo suppression feature in the transmitter to ensure that
interference echo (e.g. from edges, welded joints and installations) are not interpreted as level echo.
The flow transmitter and the ultrasonic sensor shall be of the same manufacturer and shall have
standard calibration curve build in for Parshall Flumes of 76mm (3 inches) till 2438mm (8 feet). An
additional 32 points user linearisation function shall be available for customised level to flow
conversion.
The ultrasonic flow transmitter shall be completely microprocessor controlled. The whole system
shall be at least IP65 protected. Cable connection should be easily done by opening the cover to the
wiring compartment. Local display shall be 2-lines illuminated liquid crystal display (LCD).
LCD to display at least:
a)
b)
c)
d)
Level or flow rate as % or unit (SI or Imperial Unit);
Other programming parameters like creep suppression time constant, etc;
Access code for security;
Error messages.
The programming shall be able to be done through membrane keypad or Laptop. The transmitter shall
be able to provide internal simulation output of 4-20mA current signal, without the need of any actual
level or external simulator sources.
The transmitter housing shall be aluminium c/w seawater resistance, chromed and powder coated. The
material of the sensor shall be made of Polyvinylidene fluoride (PVDF) and ethylene propylene diene
monomer (EPDM) shall be used as the sealant.
The transmitter shall include the following features: a)
b)
All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated
from each other;
4 - 20mA active current output, with maximum load of 700 Ohm;
6-20
Section 6 – Instrument
c)
d)
e)
f)
g)
h)
i)
Freely selectable output damping of 0 to 255 seconds;
Data storage on power failure for all system data, calibration data without needing any batteries;
Resistance to alternating temperature cycles according to DIN EN 60068-2-14; Nb test: +80ºC/
-40ºC, 1K/min, 100 cycles;
Climate class according to DIN EN 60068-2-38 (Test Z/AD) DIN/IEC 68 T2-30Db;
Ingress protection to IP66;
EMC interference immunity according to EN61326, appendix A(Industrial) and NAMUR
recommendation NE 21 (EMC);
Vibration resistance according to DIN EN 60068-2-64/IEC68-2-64: 20 to 2000 Hz; 3 x 100
min.
Power supply shall be 230V AC 50Hz. The power consumption of the system shall not exceed 15W.
All electronic boards in the transmitter shall be modular in design and freely interchangeable for
different model transmitter within the same product family, thereby minimising the need for stocking
of spares. It shall also be designed to be upgradeable with additional features and interfaces like
Profibus-PA, etc.
Calibration shall be easily done by entering the empty distance and the span to calibrate the flow
meter.
The ultrasonic open channel flowmeter shall be provided with data logger for saving real time
measurement data. Users shall be able to configure data logging interval set up. The data logger shall
deliver graphical data and tabulated data point that can be exported to a personal computer (PC) based
program spreadsheet.
Figure 6.12: Ultrasonic Open Channel Flowmeter used with Parshall Flume
6-21
Section 6 – Instrument
6.9.5
Differential Pressure Transmitter Used for Flow Measurement
Flow transducers of the differential pressure type shall be designed and installed in compliance with
BS 1042. Primary devices shall be either carrier-ring type orifice assemblies with a stainless steel
orifice plate or venturi tubes. The orifice plate or venturi tubes shall be suitable for the measurement
of full pipe flow of sewerage, sludge, chemical gases, etc. A typical carrier-ring type orifice assembly
is shown in Figure 6.13.
All materials shall be appropriate to the metered fluid and service conditions. The locations of
primary elements in pipe work shall be agreed with the Employer’s Representative.
Where necessary, a special diaphragm shall be used to segregate the sensor from corrosive fluid
media. In ammonia applications, the diaphragm shall be in stainless steel. In chlorine application, the
diaphragm shall be in silver or tantalum. In sulphur dioxide applications, the diaphragm shall be in
tantalum.
Orifice assemblies shall have identification tags showing the direction of flow, orifice diameter and
position of drain hole. Each orifice plate shall be furnished with calibrated name plate, which detailing
its internal diameter, throat bore and flow rate, etc.
Differential pressure transmitters shall have over-range protection up to 1.5 times the maximum line
pressure. They shall convert the differential pressure into an analogue electrical signal. They shall be
adjacent to the primary element and shall be connected to the tapings via a five valve manifold with
provision for connection of a portable instrument for calibration purposes.
Where applicable, an integral square root extraction device shall provide a 4-20 mA output signal
linearly proportional to flow. Different pressure transmitters shall have an accuracy of +/-0.15% of
span or better.
The flowmeter shall be provided with data logger for saving real time measurement data. Users shall
be able to configure data logging interval set up. The data logger shall deliver graphical data and
tabulated data point that can be exported to a personal computer (PC) based program spreadsheet.
The differential pressure transmitters shall meet or exceed ATEX, FM or CSA intrinsically safe
standard for use in Class I, Division 1, Group A, B, C and D; Class II, Division 1, Groups E, F and G.
and Class III, Division 1, indoor and outdoor hazardous locations. The assemblies for application in
hazardous location or in the digester tank and associated equipment shall be intrinsically safe.
Figure 6.13: Carrier-ring Type Orifice Assembly
6-22
Section 6 – Instrument
6.9.6
Rotameter or Variable Area Meter
The rotameter is variable area measuring instrument for measurement of flow rates for liquids and
gases. Rotameter shall have a float moving vertically in a tapered tube, in which the position of the
float being proportional to the flow. A basic component of typical rotameter is shown in Figure 6.14.
The tube of the rotameter shall be calibrated for the specific fluid in mass or flow units. The
calibration conditions shall be engraved on the tube. Linearity shall be +/- 3% of full scale or better
and repeatability shall be +/- 1% of full scale or better across a 10:1 flow range.
Rotameter shall have a glass or stainless steel tube according to the particular application.
Metering tube shall be removable for range change or cleaning without dismantling the meter or
removing it from the line. Metering tubes shall have ends of equal cross-sectional area and if O ring
seals are used, tube retainer springs shall be outside the fluid stream. End fittings shall be rotatable to
any angle.
Glass metering tubes shall be of borosilicate glass and shall be adequately shielded with safety glass
on the reading side and amply vented on sides, back and bottom.
Rotameters shall be installed in locations free from vibration and with sufficient clearance for the
removal of the float. If used in conjunction with a flow regulating valve, the valve and meter shall be
close together, with the valve downstream of the meter. Pipe work shall be supported, having regard
to the weight of the meter.
If fitted with switches, the terminal enclosures shall have a degree of protection of IP65 except for
locations prone to flooding the enclosure shall be protected to IP68 with a minimum submergence of
10 metres for 8 hours.
Figure 6.14: Basic Components of Typical Rotameter
6-23
Section 6 – Instrument
6.10
Level Meter
6.10.1
Ultrasonic Level Meter
The level measurement system shall be of ultrasonic type with no moving parts. It shall be a compact
transmitter suitable for continuous, non-contact level measurement in fluids and coarse bulk materials.
Additionally, the device can be used for flow measurement in open channels and measuring weirs. A
typical components and concepts of ultrasonic level meter is illustrated in Figure 6.15 below.
Ultrasonic level meter with measuring range more than 8m up to 15m, the accuracy of the meter shall
be of ±4mm or 0.2% of set measuring range and the measured value resolution of better then 2mm.
Ultrasonic level meter with measuring range up to 8m, the accuracy of the meter shall be of ±2mm or
0.2% of set measuring range and the measured value resolution of better then 1mm.
The ultrasonic level sensor shall be operated based on time-of-flight method. The sensor transmits
ultrasonic pulses in the direction of the product surface. There, they are reflected back and received by
the same sensor. The transmitter measures the time between pulse transmission and reception. The
instrument uses the time of flight divide by two, then multiply by the velocity of sound to calculate
the distance between the sensor membrane and the product surface.
Since the distance between the sensor’s membrane surface and the empty level is fixed and entered
into the device, the actual level can be calculated by minus the distance from the empty distance. An
integrated temperature sensor shall compensate for changes in the velocity of sound caused by
temperature changes. The ultrasonic sensor shall be of the same manufacturer of flow transmitter. It
shall be at least IP68 protected with 5m length of sensor cable.
The transmitter shall include an interference echo suppression feature in the transmitter to ensure that
interference echo (e.g. from edges, welded joints and installations) are not interpreted as level echo.
The ultrasonic level transmitter shall be completely microprocessor controlled. The whole device shall
be at least IP68 protected. Cable connection should be easily done by opening the cover to the wiring
compartment. Local display shall be 4-lines illuminated liquid crystal display (LCD).
LCD to display at least:
a)
b)
c)
d)
Level as % or unit (SI or Imperial Unit);
Other programming parameters like creep suppression time constant, etc;
Access code for security;
Error messages.
The transmitter shall be able to provide internal simulation output of 4-20mA current signal, without
the need of any actual level or external simulator sources. Programming shall be allowed to be done
through three push buttons or laptop.
The transmitter shall include the following features: a)
b)
c)
d)
e)
f)
All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated
from each other;
4 - 20mA active/passive current output, with maximum load of 700 Ohm;
Freely selectable output damping of 0 to 255 seconds;
Data storage on power failure for all system data, calibration data without needing any batteries;
Resistance to alternating temperature cycles according to DIN EN 60068-2-14; Nb test: +80ºC/ 40ºC, 1K/min, 100 cycles;
Climate class according to DIN EN 60068-2-38 (Test Z/AD) DIN/IEC 68 T2-30Db;
6-24
Section 6 – Instrument
g)
h)
i)
Ingress protection to IP68, with test according to NEMA 6P (24 hours at 1.83m under water);
EMC interference immunity according to EN61326, appendix A(Industrial) and NAMUR
recommendation NE 21 (EMC);
Vibration resistance according to DIN EN 60068-2-64/IEC68-2-64: 20 to 2000 Hz; 3x100
minutes.
The transmitter housing shall be aluminium c/w seawater resistance, chromed and powder coated. The
material of the sensor shall be made of Polyvinylidene fluoride (PVDF) and ethylene propylene diene
monomer (EPDM) shall be used as the sealant. In case of the sensor required to have flange type
process connection, the flange shall be made of stainless steel grade 316.
Power supply voltage shall be 10.5 – 32V DC. The power consumption of the system shall not exceed
1W. All electronic boards in the transmitter shall be modular in design and freely interchangeable for
different model transmitter within the same product family, thereby minimising the need for stocking
of spares. It should also be designed to be upgradeable with additional features and interfaces like
Profibus-PA, etc.
Calibration shall be easily done by entering the empty distance and the span to calibrate the level
meter. No special tools are necessary for calibration.
Figure 6.15: Components and Concepts of Ultrasonic Level Meter
6.10.2
Intrinsically Safe Ultrasonic Level Meter
The intrinsically safe ultrasonic level meter shall be used for sludge digester tank and its associated
equipment. The intrinsically safe ultrasonic level measurement system shall be non-contact,
automatic, continuous measurement and monitoring flow of fluids in open channels. It shall consist of
an ultrasonic technology level sensor and a flow transmitter.
The ultrasonic level meter system shall have an accuracy of 0.1% of set measuring range. It shall have
a measured value resolution of better then 1mm. The overall level measurement accuracy shall be
better then 2%. Calibration shall be easily done by entering the empty distance and the span to
calibrate the level meter.
The ultrasonic level sensor shall be operated based on time-of-flight method. The sensor transmits
ultrasonic pulses in the direction of the product surface. There, they are reflected back and received by
the same sensor. The transmitter measures the time between pulse transmission and reception. The
instrument uses the time of flight divide by two, then multiply by the velocity of sound to calculate
the distance between the sensor membrane and the product surface.
6-25
Section 6 – Instrument
Since the distance between the sensor’s membrane surface and the empty level is fixed and entered
into the device, the actual level can be calculated by minus the distance from the empty distance. An
integrated temperature sensor shall compensate for changes in the velocity of sound caused by
temperature changes. The ultrasonic sensor shall be of the same manufacturer of flow transmitter. It
shall be at least IP68 protected with 5m length of sensor cable.
The transmitter shall include an interference echo suppression feature in the transmitter to ensure that
interference echo (e.g. from edges, welded joints and installations) are not interpreted as level echo.
The transmitter shall be completely microprocessor controlled. The whole system shall be at least
IP65 protected or IP66 according to area of application. Cable connection should be easily done by
opening the cover to the wiring compartment. Local display shall be 2-lines illuminated liquid crystal
display (LCD). Programming can be done through membrane keypad or laptop.
LCD shall display at least:
a)
b)
c)
d)
Level rate as % or unit (SI or Imperial Unit);
Other programming parameters like creep suppression time constant, etc;
Access code for security;
Error messages.
The transmitter shall be able to provide internal simulation output of 4-20mA current signal, without
the need of any actual level or external simulator sources.
The transmitter shall include the following features: a)
b)
c)
d)
e)
f)
g)
h)
i)
All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated
from each other;
4 - 20mA active current output, with maximum load of 700 Ohm;
Freely selectable output damping of 0 to 255 seconds;
Data storage on power failure for all system data, calibration data without needing any batteries;
Resistance to alternating temperature cycles according to DIN EN 60068-2-14; Nb test: +80ºC/
-40ºC, 1K/min, 100 cycles;
Climate class according to DIN EN 60068-2-38 (Test Z/AD) DIN/IEC 68 T2-30Db;
Ingress protection to IP66 for outdoor application. For installation in cabinet door, the ingress
protection shall be IP65;
EMC (electromagnetic compatibility) interference immunity according to EN61326, appendix
A(Industrial) and NAMUR recommendation NE 21 (EMC);
Vibration resistance according to DIN EN 60068-2-64/IEC68-2-64: 20 to 2000 Hz; 3x100 min.
The transmitter housing shall be aluminium c/w seawater resistance, chromed and powder coated. The
material of the sensor shall be made of Polyvinylidene fluoride (PVDF) and ethylene propylene diene
monomer (EPDM) shall be used as the sealant.
Power supply shall be 230V AC 50Hz. The power consumption of the system shall not exceed 15W.
All electronic boards in the transmitter shall be modular in design and freely interchangeable for
different model transmitter within the same product family, to minimise the need for stocking of
spares. It shall be designed to be upgradeable with additional features and interfaces like Profibus-PA.
The sensor for intrinsically safe ultrasonic level meter shall meet or exceed ATEX, FM or CSA
intrinsically safe standard for use in Class I, Division 1, Group A, B, C and D; Class II, Division 1,
Groups E, F and G. and Class III, Division 1, indoor and outdoor hazardous locations. The assemblies
of this instrument for application in hazardous location shall exceed intrinsically safe requirements in
accordance to international standard, such as ATEX, FM or CSA.
6-26
Section 6 – Instrument
6.10.3
Level Electrode Controller
Level electrode controller system shall consist of a solid state type controller, electrode cable and
three or more sensing electrodes. The system shall be suitable for operation on 240 volts AC and shall
have suitably rated volt free contacts.
Each electrode assembly shall be provided with a minimum 25mm outside diameter grade 316
stainless steel electrode to suite the lengths as required. The electrodes shall be encapsulated in heat
shrinkable tubing up to 75 mm from the end of the electrodes. The ends of the electrodes shall be
sealed. The insulating tubing shall be heat shrinkable wall polyolefin or equivalent. Intermediate insulated support brackets shall be installed to prevent the electrodes from swaying and to prevent contact
among the electrodes. Each electrode assembly shall permit an adjustment in operating levels at least
150 mm without the necessity to cut or extend the electrodes.
Each electrode holder shall consist of two parts, a base support for electrodes and a bolted access
cover. Electrode holders shall be manufactured from reinforced glass fibre or similar corrosion proof
insulated material and shall have ingress protection of IP55. Grade 316 stainless steel mounting
brackets shall be provided for mounting of the electrode holders. All electrode holders shall be
suitable for working pressure of at least 200psi.
Level control system shall comprise at least three electrodes as shown in Figure 6.16. The first shall
be used as common for earth return, the second shall trip the respective equipment at pre-determined
water level, and the remaining one to ensure that the equipment cannot be manually reenergized until
the water level has reached another pre-determined level. A separate electrode shall be provided for
earth connection as a standard.
The open circuit voltage between any electrode and earth shall not exceed 25 volts AC. Sensitivity of
the detection units shall be adjustable using a lockable sensitivity control potentiometer over a range
of 100 to 2000 ohms with a switching differential not greater than 5% of the set point.
Figure 6.16: Basic Sensing Electrodes for Level Electrode Controller
6-27
Section 6 – Instrument
6.10.4
Capacitive Level Switch
The capacitive level measuring principle shall base on the changes in capacitance of the capacitor due
to the probe being covered by liquid as illustrated in Figure 6.17.
The capacitive level switch active sensing probe shall either partial insulated or fully insulated. When
immersed by the rising process fluid, the capacitance will be altered enabling the instrument to detect
the presence of the fluid.
The probe shall be capable of measuring interface detection of different liquids, e.g. water or oil, and
capable of detecting foam of conducting liquids. The wetted materials shall be PFA (Perfluoroalkoxy
Plastic) or PTFE (Polytetrafluoroethylene Plastic) in conformity with FDA. The level switch shall be
one piece unit having an enclosure to IP 66 or better.
The probe shall be suitable for application in both vacuum and overpressure up to 100 bars. The
sealing of the probe shall be capable of withstanding continuous operating of -80ºC to +200ºC in the
medium container.
The housing and cover material shall be either cast aluminium with plastic coating or corrosive
resistance 316L uninsulated stainless steel. Sealant for aluminium cover and 316L stainless steel
cover shall be EPDM (ethylene propylene diene monomer rubber) and silicon respectively.
The correct operation of the level switch shall be resistant to build-up on the probe. The measuring
frequency is at 500 kHz with measuring span from 0 to 1600pF.
The level switch shall have a relay output rated at 240V AC 2A.
Figure 6.17: Principle of Measurement for Capacitive Level Switch
6-28
Section 6 – Instrument
6.10.5
Float Gauging Level Transmitter
Float operated level transmitters shall comprise a float and tension device. Floats shall be of stainless
steel. An illustration of typical float gauging level transmitter is shown in Figure 6.18.
The float shall be suspended by a stainless steel wire or perforated tape which shall operate the
transmitter installed above the float stilling well or measuring chamber.
The transmitter shall provide a 4 to 20mA DC output signal proportional to the level measurement
range and shall be housed in an enclosure protected to IP65. For locations prone to flooding the
enclosure shall be protected to IP 68 with a minimum submergence of 10 metres for 8 hours.
The accuracy shall be +/- 0.35% or better.
Figure 6.18: Float Gauging Level Transmitter
6-29
Section 6 – Instrument
6.11
Pressure Meter and Switch
6.11.1
Pressure Gauge
Pressure gauges shall be available to read both differential and single-ended pressure. By far the most
common measurements are single-ended, although differential gauges are used to read head loss on
water and air filters. The gauge shall be installed where the lens will not get damaged and where it can
be read easily. Choose a gauge with a top-mounted stem where it will be installed near the ceiling so
that the dial will read right-side up. A block and bleed valve shall be installed between the process and
the gauge for service and maintenance.
Where a pressure gauge is reading a pressure produced by a pump (normally required) the gauge shall
be protected from vibration by filling it with either silicone liquid or glycerine. Silicone shall be used
if the ambient temperature will fall below -30°C.
Construction material for socket, welding, casing and ring of the pressure gauge shall be 316 stainless
steel. Window gasket, blow out vent and filling plug shall be made of ethylene propylene diene
monomer (EPDM). A bronze or 316 stainless steel bourdon tube mechanism shall be used. Where
necessary, a special bourdon tube mechanism shall be used for gauge application for corrosive fluid
media. In ammonia applications, the tube shall be in stainless steel. In chlorine applications, the tube
shall be in silver or tantalum. In sulphur dioxide applications, the tube shall be in tantalum. For
applications on other chemical lines, the manufacturer shall consult the Employer’s Representative
about the compatibility between the process and the gauge material.
The accuracy class of the pressure gauge shall be 1 as per BS EN 837.1. Operating ambient
temperature range shall be within -25 to 65ºC. The pressure gauge shall be suitable for continuous
application for process temperature range from -40ºC to 150ºC. The pressure gauge shall be able to
withstand continuous pulsation working pressure up to 90% of the full scale value and withstand
continuous static working pressure up to 100% of the full scale value. The pressure gauge shall be
protected to IP65 as per IEC529.
The pressure gauges shall meet or exceed ATEX, FM or CSA intrinsically safe standard for use in
Class I, Division 1, Group A, B, C and D; Class II, Division 1, Groups E, F and G. and Class III,
Division 1, indoor and outdoor hazardous locations. The assemblies for application in hazardous
location or in the digester tank and associated equipment shall be intrinsically safe.
A typical mechanism of pressure gauge is shown in Figure 6.19 below.
Figure 6.19: Pressure Gauge Mechanism
6-30
Section 6 – Instrument
6.11.2
Pressure Switch and Differential Pressure Switch
Pressure switch and differential pressure switch shall have contacts with differing cut-in and cut-out
pressure values. The nominal pressure values at which pressure and differential pressure switch shall
be fully adjustable over the whole range of the range of the instrument and the set value shall be
clearly indicated by means of a scale and point. Pressure switch shall have over range protection. Set
point repeatability shall be ±1% of adjustable range of better.
Corrosive resistant diaphragm shall be used to segregate the instruments from the corrosive measured
media. In ammonia application, the diaphragm shall be in stainless steel. In chlorine application, the
diaphragm shall be in tantalum or silver.
Pressure switches shall be housed in cast aluminium alloy enclosures. The degree of protection shall
be IP65. For application in locations where subject to flooding, the instrument shall be rated IP68 with
maximum submergence of 10 metres for 8 hours.
The pressure switches shall meet or exceed ATEX, FM or CSA intrinsically safe standard for use in
Class I, Division 1, Group A, B, C and D; Class II, Division 1, Groups E, F and G. and Class III,
Division 1, indoor and outdoor hazardous locations. The assemblies for application in hazardous
location or in the digester tank and associated equipment shall be intrinsically safe.
A typical mechanism of pressure switch is shown in Figure 6.20.
Figure 6.20: Pressure Switch Mechanism
6.11.3
Pressure Transmitter
The pressure transmitter shall be of dry capacitive sensor type. The sensor shall provide continuous
measurement of absolute and gauge pressure in gases, vapours and liquids. The pressure to be
measured causes a small deflection of the ceramic diaphragm of the sensor. A change in capacitance
proportional to the pressure is measured by electrodes on the ceramic sensor directly.
Measuring ranges of the pressure transmitter and sensor system shall be up to 40 bars with over
pressure limit of maximum 60 bars. The system shall be suitable for operation in the process
temperature range from -40ºC to +100ºC. Maximum measured error shall be ±0.2% of set span. It
shall have a response time of less than 50 ms. The long-term stability shall be 0.1% of URL per year
or better. The pressure transmitter and sensor system shall be at least IP66 with 5 meters minimum
cable attached. A typical assembly of pressure transmitter is shown in Figure 6.21.
6-31
Section 6 – Instrument
Power supply voltage shall be 11.5 – 45V DC. The current consumption of the system shall not
exceed 11mA ±1mA.
The transmitter shall provide terminals for 4 to 20mA without communication protocol and port for
process automation interface communication protocol. The transmitter shall be possible to be
calibrated ±5% zero adjustment. Special tools shall not be required for operating, commissioning and
calibration the pressure transmitter and the sensor.
The enclosure of the transmitter shall be manufactured from aluminium. A local pluggable liquid
crystal display (LCD) with bar graph indication. The display shall be able to be rotated in 90° stages.
The LCD to display shall at least:
a)
b)
c)
d)
Process Value as % or unit (SI or Imperial Unit);
Other programming parameters like creep suppression time constant, etc;
Access code for security;
Error messages
The transmitter shall include the following features: a) All inputs and outputs galvanically isolated form power supply up to 500V, and also isolated from
each other;
b) 4 - 20mA active/passive current output, with maximum load of 700 Ohm;
c) Resistance to alternating temperature cycles according to DIN EN 60068-2-14; Nb test: +80 deg.
C/ -40 deg. C, 1K/min, 100 cycles;
d) Climate class according to DIN EN 60068-2-38 (Test Z/AD) DIN/IEC 68 T2-30Db;
e) Ingress protection to IP68, with test according to NEMA 6P (24 hours at 1.83m under water);
f) EMC interference immunity according to EN61326, appendix A(Industrial) and NAMUR
recommendation NE 21 (EMC);
g) Vibration resistance according to DIN EN 60068-2-64/IEC68-2-64: 20 of 2000 Hz; 3x100
minutes.
The transmitters shall meet or exceed ATEX, FM or CSA intrinsically safe standard for use in Class I,
Division 1, Group A, B, C and D; Class II, Division 1, Groups E, F and G. and Class III, Division 1,
indoor and outdoor hazardous locations. The assemblies for application in hazardous location or in the
digester tank and associated equipment shall be intrinsically safe.
Figure 6.21: Assembly of Pressure Transmitter and Sensor
6-32
Section 6 – Instrument
6.11.4
Differential Pressure Transmitter
The differential pressure measurement device shall be of capacitive sensor with electrodes in a
ceramic measuring cell. Measuring cell shall be filled with silicone oil or mineral oil. A differential
pressure causes a corresponding deflection of both diaphragms that change the respective capacitances
of both diaphragms. The capacitance are converted to digital signal and fed to the transmitter.
The pressure transmitter and measuring sensor shall have over range protection up to 1.5 times the
maximum line pressure. The instrument shall capable of withstanding full line pressure on any side
with the other side vented to atmosphere without damage of effect on the calibration. No plastic
material shall be used in the instrument construction.
Corrosive resistant diaphragm shall be used to segregate the instruments from the corrosive measured
media. In ammonia application, the diaphragm shall be in stainless steel. In chlorine application, the
diaphragm shall be in tantalum or silver.
The zero and span of a pressure transmitter shall not change by more than ±0.05% of the span per ºC
change in ambient temperature. After application for 10 minutes of pressure at 130% of maximum
pressure, the change in zero shall not exceed ±0.1% of the span.
The transmitter shall provide terminals for 4 to 20mA without communication protocol and port for
process automation interface communication protocol.
The system shall have an accuracy of ±0.15% of span or better.
Figure 6.22 shows a typical installation of differential pressure transmitter for flow monitoring using
orifice plate.
Figure 6.22: Installation of Differential Pressure Transmitter for Flow Monitoring
6-33
Section 6 – Instrument
6.12
Temperature Transmitter and Switch
6.12.1
Temperature Transmitter
Temperature transmitter shall provide a 4 to 20mA DC output proportional to the temperature.
Temperature transmitter, unless otherwise specified, shall use platinum resistance elements for
measuring spans of up to 200ºC and chromel-alumel thermocouples for spans exceeding 200ºC.
Temperature transmitters shall have an accuracy of +/-0.15% of span, or better and shall be protected
to IP 65 or higher. For transmitters installed in locations prone to flooding they shall be to IP 68 for a
maximum submergence of 10 metres for 8 hours.
Each temperature sensor, unless otherwise specified, shall have a stainless steel pocket and extension
assembly, corrosion proof metal sheath and waterproof terminal head. Pockets for steam, oil and
pressurized water lines shall be welded and pockets for other duties shall be screwed. The sensor
assembly shall be designed to permit removal of the temperature element without twisting the leads.
Terminal switch & amplifier enclosures shall have a degree of protection of IP 65 or better.
Figure 6.23: Typical Installation of Temperature Transmitter for Surface Measurement
6.12.2
Temperature Switch
Temperature switch shall have contacts with differing “cut-in” and “cut-out” values. Their nominal
operating points shall be fully adjustable over the whole range of the instrument and the set-value
shall be clearly indicated by a dial and pointer. Set point repeatability shall be +/- 1% adjustable
range or better.
6.12.3
Platinum Resistance Temperature Sensor (RTD)
RTD’s shall comply with BS 1041 and BS EN 60751 and shall have fundamental intervals of not less
than 38.5 Ohms. Each element shall be artificially aged during manufacture. Terminal heads and
amplifiers shall be designed for four-wire connections between head and amplifier.
RTD elements shall be spring-loaded and fully encapsulated in ceramic material and the elements and
high temperature resistant lead wires shall be hermetically sealed as illustrated in Figure 6.24. The
associated resistance-to-current converters shall have zero and span adjustments and input-output
circuit isolation.
6-34
Section 6 – Instrument
Figure 6.24: Illustration of Platinum Resistance Temperature Sensor (RTD)
6.12.4
Thermocouple
Thermocouple shall be of the mineral insulated type and unless otherwise specified shall be of the
chromel-alumel (nickel-chromium vs. nickel-aluminum) type and shall comply with BS 1041 and BS
4937. Wires shall not be smaller than 16 SWG. Thermocouple junctions shall be welded. Ceramicinsulation material may be used for base metal thermocouples but low-silicon insulation material shall
be used for noble metal thermocouples. Thermocouple systems shall have thermoelectric ice point
reference chambers or receivers or amplifiers with automatic cold junction compensation.
Thermocouple receivers and amplifiers shall also have zero and span adjustment, common and series
mode interference rejection circuits, radio-frequency filters, input-output circuit isolation and
thermocouple break feature whereby the output is driven to zero or full scale as specified when the
receiver or amplifier input circuit is broken.
Thermocouple elements shall be electrically isolated from their sheaths but each terminal head shall
have facilities for earthing the thermocouple and for terminating the shield of the extension or
compensation cables. Amplifier chassis shall have facilities both for being earthed to the instrument
case via a capacitor and for being electrically isolated from the instrument case.
The layout of typical thermocouple is shown in Figure 6.25.
Figure 6.25: Layout of Typical Thermocouple
6-35
Section 6 – Instrument
6.13
Paperless Recorder
The recorder shall be paperless type with colour graphic. Housing of the recorder shall be 144m x
144mm, constructed to meet IP54 or NEMA 2X with installation depth of 170mm. The recorder can
be connected up to 6 analogue signals and 1 digital input. Up to 14 set points can be freely
programmable as minimum or maximum alarms and assignable to any of the channels. The set point
over-/undershoots are discretely displayed and can trigger 4 on-board relays for external alarm
annunciation elements such as sirens or lamps. Alternatively valves or pumps can be switched.
The power supply shall be 120/240 VAC 50/60 Hz or 24 VAC/DC.
The data can be stored in the internal memory or extended memory (Compact Flash). The data can
then be access using the communication ports available i.e. USB port for one to one communication
& RS485 for simple serial networks.
Optionally, the recorder can be remote monitored via the use of a modem (connected to RS232),
where it can be connected to a telephone line and remotely accessed from anywhere in the world. It
can also comes with the Ethernet communications as an option.
The recorder shall be able to perform integration and analysis.
6-36
Section 6 – Instrument
6.14
Load Cell Weighing System
Load cell systems shall comprise a load indicator transmitter unit and load cells that operate on the
strain gauge application. Load cell types (e.g. compression, tension, load beam) shall be selected to
suit the application. Multiple strain gauges shall be used within each load cell to provide offsetting
positive and negative strain readings. The load cell weighing system shall provide a 4-20 mA DC
output signal proportional to the force applied by the load. It shall be possible to utilize multiple load
cells at strategically placed supporting points with a single indicator transmitter to provide weight
readings for loads such as platforms, silos and tanks.
Load cell shall be constructed of high quality materials, such as stainless steel, suitable for the
application and environment. Load cells shall be hermetically sealed to prevent the ingress of liquids
and gases. Load cells shall be constructed to IP68 capable of submergence in water to a depth of a
minimum of 4 days without affecting instrument stability or measuring performance.
Load cell shall be protected against mechanical overloads up to 250% of their rating. Electrical
overloads to 150% of the load cell rating shall not cause damage or malfunction. The load cell
measuring system shall have an overall accuracy equal to or better than +/-0.075% of full scale.
Load cells shall be suitable for intrinsically safe installation where specified.
Indicator transmitters shall be protected to IP65 and shall provide local indication and remote retransmission of the following signals as described:
a)
b)
c)
d)
e)
f)
Gross weight (local only);
Net weight (local and remote);
Tare weight (local only);
Adjustable high weight alarm (local and remote);
Adjustable low weight alarm (local and remote);
System failure (local and remote).
If being used in a belt weighing application the system shall also provide a totalizing pulse output and
display with an accuracy of +/-0.5% totalized weight or better.
Symbol of load weighing system in various applications for the purpose of process control
documentation is shown in Figure 6.26.
Figure 6.26: Symbols for Various Application of Load Weighing System
6-37
Section 7 – Final Control
Section 7
Final Control
Section 7 – Final Control
Page
7.0
FINAL CONTROL
7-1
7.1
Actuator
7-1
7.2
7.1.1
Electric Actuator
7-1
7.1.2
Pneumatic Actuator
7-6
Switch
7-16
7.2.1
Time Switch
7-16
7.2.2
Control and Selector Switch
7-16
7.2.3
Limit Switch
7-16
7.2.4
Proximity Switch
7-16
7.2.5
Speed Switch
7-16
7.3
Control Relay
7-17
7.4
Timer
7-18
7.5
Indicator
7-19
7.6
Integrator
7-20
LIST OF TABLES
Table 7.1
Table 7.2
Definition of Corrosion Resistance Classes
Calibration / Tolerance Table for Tubes
LIST OF FIGURES
Figure 7.1
Figure 7.2
Illustration of Typical Electric Actuator
Direct Acting Diaphragm Pneumatic Actuator
7-i
Section 7 – Final Control
7.0
FINAL CONTROL
7.1
Actuator
7.1.1
Electric Actuator
7.1.1.1
General
The electric actuator shall be suitable for use on nominal voltage of 415 volts 3-phase 50 Hz power
supply and incorporated with motor drive, integral reversing starter, local control and indication
facilities, terminal remote control and indication and cable terminals suitably housed in separate
designated compartment within self contained and sealed enclosure. The actuator shall include a
device to ensure that the motor runs with the correct rotation for the required direction of valve travel
irrespective of the connection sequence of the power supply. A typical illustration of electric actuator
is shown in Figure 7.1.
In order to maintain the integrity of the enclosure, setting of the torque levels, position limits and
configuration of the indication contacts etc shall be carried out without the removal of any actuator
covers. Commissioning tools shall be provided with the actuators and must meet the enclosure
protection and certification levels of the actuators.
Commissioning tools shall not form an integral part of the actuator and must be removable for secure
storage/authorised release. In addition, provision shall be made for the protection of configured
actuator settings by a means independent of access to the commissioning tool.
7.1.1.2
Actuator Sizing
The actuator shall be sized to guarantee valve closure at the specified differential pressure. The safety
margin of motor power available for seating and unseating the valve shall be sufficient to ensure
torque switch trip at maximum valve torque with the supply voltage 10% below nominal. The
operating speed shall be such as to give valve closing and opening at approximately 10 – 12 inches
(255 to 305 mm) per minute unless otherwise specified.
7.1.1.3
Environmental
Actuator shall be suitable for indoor and outdoor application. The actuator shall be capable of
functioning in an ambient temperature ranging from 22°F (-30°C) to 158°F (70°C). Actuators for
explosion-hazardous applications shall in addition be certified Flameproof for Zones 1 and 2
(Divisions 1 and 2 Group gases).
7.1.1.4
Enclosure
Actuator shall be O-ring sealed, watertight protection conforming to IP68 and shall at the same time
have an inner watertight protection and dustproof O-ring seal between the terminal compartment and
the internal electrical elements of the actuator. The motor and all other internal electrical elements of
the actuator shall be protected from ingress of moisture and dust when the terminal cover is removed
for site for cabling.
Enclosure shall allow for temporary site storage without the need for electrical supply connection. All
external fasteners shall be of stainless steel, however, the use of unprotected stainless steel fasteners
(including grease lubricated) in aluminium alloy casings is not permitted.
7-1
Section 7 – Final Control
7.1.1.5
Motor
The electric motor shall be Class F insulated, with a time rating of at least 15 minutes at 40°C (104°F)
or twice the valve stroking time, whichever is longer, at an average load of at least 33% of maximum
valve torque. Electrical and mechanical disconnection of the motor should be possible without
draining the lubricant from the actuator gearcase.
7.1.1.6
Motor Protection
Protection shall be provided for the motor as follows:a) The motor shall be de-energized in the event of a stall when attempting to unseat a jammed valve;
b) Motor temperature shall be sensed by a thermostat de energising the motor in case of overheating;
c) Lost phase protection.
7.1.1.7
Gearing
The actuator gearing shall be totally enclosed in an oil-filled gearcase suitable for operation at any
angle. All drive gearing and components must be of metal construction and incorporate a lost-motion
hammerblow feature. For rising spindle valves the output shaft shall be hollow to accept a rising stem,
and incorporate thrust bearings of the ball or roller type at the base of the actuator. The design should
be such as to permit the opening of the gearcase for inspection or disassembled without releasing the
stem thrust or taking the valve out of service.
7.1.1.8
Hand Operation
A handwheel shall be provided for emergency operation, engaged when the motor is declutched by a
lever or similar means, the drive being restored to power automatically by starting the motor. The
handwheel or selection lever shall not move on restoration of motor drive.
Provision shall be made for the hand/auto selection lever to be locked in both hand and auto positions.
It should be possible to select hand operation while the actuator is running or start the actuator motor
while the hand/auto selection lever is locked in hand without damage to the drive train.
The handwheel drive must be mechanically independent of the motor drive and any handwheel
gearing should be such as to permit emergency manual operation in a reasonable time. Clockwise
operation of the handwheel shall give closing movement of the valve unless otherwise stated in the
job specification. The material for handwheel shall be from marine alloy (BS 1490, LM5M).
7.1.1.9
Emergency Power Supply
All actuators, which have permanent power supply facilities and are required to comply to fail safe
operation requirements, shall be provided with uninterruptible power supply (UPS) for emergency
shut down when permanent power supply failed.
7.1.1.10
Electrical Socket for Portable Power Supply Connection
All remote actuators, which permanent power supply is not available, electrical socket point shall be
provided for each of the actuators. The electrical socket point shall be used for connection with
portable generator or specifically designed battery power pack for operating the actuator.
7-2
Section 7 – Final Control
7.1.1.11
Drive Bushing
The actuator shall be furnished with a drive bushing easily detachable for machining to suit the valve
stem or gearbox input shaft. Normally the drive bush shall be positioned in a detachable base of the
actuator. Thrust bearings, when housed in a separate thrust base should be of the sealed for life type.
7.1.1.12
Torque and Turns Limitation
Torque and turns limitation shall be adjusted as follows:
a) Position setting range
b) Torque setting
: 2.5 to 100,000 turns, with resolution to 15º of actuator output;
: 40% to 100% rated torque.
"Latching" shall be provided for the torque sensing system to inhibit torque off during unseating or
during starting in mid travel against high inertia loads.
The electrical circuit diagram of the actuator should not vary with valve type remaining identical
regardless of whether the valve is to open or close on torque or position limit.
7.1.1.13
Remote Valve Position / Actuator Status Indication
Four contacts shall be provided which can be selected to indicate any position of the valve. Provision
shall be made for the selection of a normally closed or open contact form. Contacts shall maintain and
update position indication during handwheel operation when all external power to the actuator is
isolated.
The contacts shall be rated at 5A, 250V AC, 30V DC.
As an alternative to providing valve position any of the four above contacts shall be selectable to
signal one of the following:a)
b)
c)
d)
e)
Valve opening, closing or moving;
Thermostat tripped, lost phase;
Motor tripped on torque in mid travel, motor stalled;
Remote selected;
Actuator being operated by handwheel.
7.1.1.14
Local Position Indication
The actuator shall include a digital position indicator with a display from fully open to fully close in
1% increments. Red, green and yellow lights corresponding to Open, Closed and Intermediate
position shall be included on the indicator. End of travel indication colours shall be reversible.
The digital display shall be maintained and updated during handwheel operation when all external
power to the actuator is isolated. The display shall incorporate valve, actuator and control status
indication. Provision shall be made to orientate the display through increments of 90°. Provision shall
be made in the design for the addition of a contactless transmitter to give a 4-20mA analogue signal
corresponding to valve travel for remote indication when required.
Provision shall be made in the design for the addition of a contactless transmitter to give a 4-20mA
analogue signal corresponding to actuator output torque for remote indication when required.
7-3
Section 7 – Final Control
7.1.1.15
Actuator Display
The actuator shall incorporate a unique liquid crystal display developed specifically for actuator
indication application for various installation applications. The display shall allow easy, distance
viewing of valve position, torque and diagnostic screens. A diffused LED backlighting system
provides high visibility in all light conditions. The LCD display shall supplement with position
indication lights, green, yellow and red.
The display unit and the viewing panel shall be robust and modular in construction and replaceable.
The replacement of the viewing glass panel shall be easy and ingress protection shall be maintained as
original namely IP68.
7.1.1.16
Integral Starter and Transformer
The reversing starter, control transformer and local controls shall be integral with the valve actuator
suitably housed to prevent breathing and condensation. The starter shall be suitable for 60 starts per
hour and of rating appropriate to motor size. The controls supply transformer shall be fed from two of
the incoming three phases and incorporate overload protection. It shall have the necessary tappings
and be adequately rated to provide power for the following functions:a)
b)
c)
d)
Energisation of the contactor coils;
24V DC output where required for remote controls;
Supply for all the internal electrical circuits;
Integral local control and control mode selector.
The actuator shall incorporate local controls for Open, Close and Stop and a Local/Stop/Remote mode
selector switch lockable in any one of the following three positions: local control only, stop (no
electrical operation), remote control plus local stop only. It shall be possible to select maintained or
non-maintained local control.
The local controls shall be arranged so that the direction of valve travel can be reversed without the
necessity of stopping the actuator.
Provision shall be made to orientate the local controls through increments of 90°.
7.1.1.17
Control Facilities
The necessary wiring and terminals shall be provided in the actuator for the following control
functions:a) Open and close external interlocks to inhibit local and remote valve opening and/or closing
control;
b) Provision shall be made to configure the interlocks to be active in remote control only;
c) Remote controls fed from an internal 24V DC supply and/or from an external supply between
20V and 120V AC or 20V and 60 V DC, to be suitable for any one or more of the following
methods of control:1. Open, Close and Stop control;
2. Open and Close maintained or “push to run” (inching) control;
3. Overriding Emergency Shut-down to Close (or Open) valve from a normally closed or open
contact;
4. Two-wire control, energise to close (or open), de-energise to open (or close).
7-4
Section 7 – Final Control
It shall be possible to reverse valve travel without the necessity of stopping the actuator. The starter
contactors shall be protected from excessive current surges during travel reversal by an automatic time
delay on energisation of the contactor coils.
The internal circuits associated with the remote control and monitoring functions are to be designed to
withstand simulated lighting impulses of up to 1.1kV.
7.1.1.18
Monitoring Facilities
Facilities shall be provided for monitoring actuator operation and availability. Monitor relay having
one changeover contact shall be provided for monitoring control mode availability. The relay can be
energised from the control transformer only when the Local/Off/Remote selector is in the Remote
position to indicate that the actuator is available for remote (control room) operation.
Where required, it shall be possible to provide indication of Thermostat trip and Remote selected as
discreet signals.
The actuator shall include a diagnostic module, which will store and enable download of historical
actuator operation and torque data to permit analysis of actuator and valve in-service performance.
Data download shall be carried out without removing any covers and all shall be available locally to
the actuator or remotely via telecom data transfer.
Diagnostic and configuration software shall be made for user PC systems.
7.1.1.19
Wiring and Terminals
Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate size for the control
and 3-phase power. Each wire shall be clearly identified at each end. The terminals shall be embedded
in a terminal block of high tracking resistance compound. The terminal compartment shall be
separated from the inner electrical components of the actuator by means of a watertight sea and shall
be provided with a minimum of 3 threaded cable entries with provision for a minimum of 4.
All wiring supplied as part of the actuator to be contained within the main enclosure for physical and
environmental protection. External conduit connections between components are not acceptable. A
durable terminal identification card showing plan of terminals shall be provided attached to the inside
of the terminal box cover indicating:a)
b)
c)
d)
Serial number;
External voltage values;
Wiring diagram number;
Terminal layout.
This must be suitable for the Manufacturer or Supplier to inscribe cable core identification alongside
terminal numbers.
7.1.1.20
Start-up Kit
Each actuator shall be supplied with a start-up kit comprising installation instruction manual,
electrical wiring diagram and cover seals to make good any site losses during the commissioning
period. In addition, sufficient actuator commissioning tools shall be supplied to enable actuator set up
and adjustment during valve/actuator testing and site installation commissioning.
7-5
Section 7 – Final Control
7.1.1.21
Performance Test Certificate
Each actuator must be performance tested. Individual test certificates shall be supplied free of charge.
The test equipment shall simulate a typical valve load, and the following parameters shall be recorded.
a)
b)
c)
d)
Current at maximum torque setting;
Torque at max. torque setting;
Flash test voltage;
Actuator output speed or operating time.
In addition, the test certificate shall record details of specification such as gear ratios for both manual
and automatic and second stage gearing if provided, drive closing direction, wiring diagram number.
Figure 7.1: Illustration of Typical Electric Actuator
7.1.2
Pneumatic Actuator
7.1.2.1
Air Compressor
Piston or screw type compressor shall be used for compressed air generation. The compressor shall be
of an oil free type, which employs piston or screw operation principle. Each compressor shall be
completed with the followings:a)
b)
c)
d)
e)
f)
Non-Return-Valve in the air-circuit;
Pressure gauge;
Pressure switch ON and OFF – adjustable up to max. 10 bar;
Switch and starting load rejection;
Electrical driven auto condensing water drainage;
Pressure regulating and filtration service unit.
The maximum output pressure of the compressor shall not exceed 10 bar, but with a minimum output
pressure of 8 bar.
Each pneumatic network shall consist of at least 2 compressors, 1 unit duty and the other unit as
standby (each of them shall be able to run the whole network independently). Both compressors shall
work under alternating conditions. The sizing of the compressors shall be based on maximum runtime of not exceeding 10 minutes/hour and shall be not lower than 1 cycle/hour.
7-6
Section 7 – Final Control
The compressors shall be equipped with a simple control where it is able to auto start while pressure
is lower then the preset value and auto cut off when the desired maximum pressure is archived. The
compressors shall be arranged for automatic changeover on failure of the duty unit. Failure of the duty
unit shall initiate an alarm. Control equipments shall include automatic unloading valves, pressure
switches for duty and standby.
The design shall ensure the air discharged is oil free. The air quality shall be DIN ISO 8573-1
7.1.2.2
Compressed Air Outlet
Compressed air outlets shall consist of air filter, pressure regulator c/w pressure gauge, on/off valve
and self-closing coupling manufactured from high grade material shall be used.
7.1.2.3
Air Pressure Regulator, Filtration and Electrical Driven Auto Drain Service Unit
Filters, regulators or combination units, when specified, shall be of the modular type designed for
easy servicing, replacement and expansion without disturbing pipe-work. They shall be suitable for
industrial use, up to the maximum pressure and temperature encountered under tropical climate. Air
passage capacity and unit port sizes shall suit the type and flow requirements at the outlets.
Filters shall generally be provided with a safety-clear transparent bowl together with an automatic or
manual drain assembly as specified. The filter element shall be of 40 micron mesh, except where
indicated otherwise. Where the use of electro-pneumatic positional is required in the systems,
additional micro filter of 0.01 micron shall be used.
Regulator shall be of relieving type with balance valve for quick response. The pressure adjusting
knob shall be non-rising design with a suitable locking device. The regulating spring pressure range
shall, unless otherwise specified, be suitable from 0.15 Bar to 7 Bar. Regulators shall be provided
complete with pressure gauge graduated up to at least 10 Bar.
The electrical driven auto drain unit shall be able to detect condensate level even with high oil contain
and provide immediate discharge by itself. The auto drain unit shall be able to operate in both
automatic drain as well as manual drain. Beside that, it should allow either end of line installation or
combine installation with filter regulator unit.
Lubricator is not allowed in the pneumatic system to prevent lubrication oil leak and contaminate the
water. The pneumatic system shall run under oil free condition.
7.1.2.4
Compressed Air Storage Vessel
Standby compressed air stored in vessels/tanks is required as a buffer between compressor and airsupply-network. Additionally it works as a pre-separator for the accumulating condensate. The
average stand-by capacity of the storage vessel shall be having a minimum of 2 hours supply to the
pneumatic network. The air pressure vessel shall be of all welded steel construction to BS5169 Class
III, Grade C or ASMEI Boiler and Pressure Vessel code, Section VIII.
The pressure vessel shall have flanged inlet, outlet and drain down ports. In additional, pressure
gauge/switch, relief valve and level switch tapping shall be provided. The vessel shall be fitted with a
manhole. Large vessel with manhole exceeding 2.0m from floor level shall be supplied with a
galvanised mild steel ladder to the access manhole.
The vessel shall be fitted with a pressure gauge of at least 150mm diameter gauge, connected such
that it read the air pressure in the vessel and thereby indicating the pressure in the system.
7-7
Section 7 – Final Control
The upper dome of the vessel shall be fitted with a suitable spring loaded pressure relief valve, which
shall be arranged to commence to open at 110% of the maximum system working pressure and be
fully open at the 120% of this pressure.
A manually operated air release valve shall be provided, to enable the system to be de-pressurised to
atmospheric before the vessel is drained.
Pressure switches shall be robustly constructed and suitable for the arduous duties involved and shall
be fully adjustable over their working range, together with adjustable differentials.
Testing of the vessel shall be carried out at the manufacturer’s works. And a test certificate duly
endorsed by the Factory and Machinery Department shall be issued. The working and test pressures
shall be both stamped and stencilled onto the outside of the vessel such that they are clearly visible.
7.1.2.5
High Performance Air – Dryer System
Compressed air to be stored and acting the pneumatic network shall conform to DIN ISO 8573-1. The
air shall be dried to avoid malfunction in the equipment of the air-circuit and to reduce the
maintenance as well as the running costs of the whole air-network.
Preferably a cooling-dryer respectively absorption dryer shall be used, the dryer shall be able to run
under intermittent duty. The flow capacity of the dryer is related to the lay-out of the compressor and
shall be subject to the same flow capacity.
7.1.2.6
Design Requirements for Pneumatic Process Actuator
7.1.2.6.1
Corrosion Test Cycle
All the pneumatic process actuators have to pass all the corrosion tests as stated below:
a.
b.
c.
d.
e.
Hot-Cold aging (-20ºC to 120ºC);
Alternating condensing water climate as per DIN 50017 KFW;
Alternating condensing SO2 climate as per DIN EN ISO 6988 KFW 0.2 S (Kesternich test);
Salt spray mist test with sodium chloride solution as per DIN 50021 SS;
All weather out door test.
7.1.2.6.2
Endurance Test for Pneumatic Actuator
All pneumatic actuator shall have minimum 1,000,000 cycles.
7.1.2.6.3
Leakage Test under Pressure for Pneumatic Actuator
The allowance for leakage rate of pneumatic actuator shall be 1 bubble of 6mm diameter each 3
seconds.
7.1.2.6.4
Temperature Test for Pneumatic Actuator
All pneumatic actuator shall allow to work under temperature between -20ºC to 80ºC
7.1.2.6.5
Crack Test with Oil and/or Air for Pneumatic Actuator
The breaking or oil leakage pressure for all pneumatic actuator shall be 2.5 time the actuator
maximum supply pressure allowed, (MSA 10 bar x 2.5 = 25 bar)
7-8
Section 7 – Final Control
7.1.2.6.6
Corrosion Protection of Pneumatic Actuator
All actuators shall conform to a minimum corrosion-resistance- class-3 (CRC-3) within the following
test cycle requirements:
Table 7.1: Definition of Corrosion Resistance Classes
Class
Corrosion exposure
Requirements for test as per
Part 2 (in cycles 1)
KFW3
SO24
≥10
≥5
≥1
≥1
≥10
≥8
≥3
≥3
≥10
≥10
≥5
≥5
≥10
≥10
≥10
≥10
W/K2
CRC1
Light
protection
CRC2
(Standard)
Medium
protection
CRC3
Heavy
protection
CRC4
Extraheavy
protection
Components with light corrosion exposure. Protection
for transport and storage. Components without
significant decorative function of surface, e.g. installed
out of sight internally or behind covers.
Components with medium corrosion exposure.
Externally visible components with significant
decorative function in direct contact with normal
industrial atmosphere or media such as coolants and
lubricants.
Components with heavy corrosion exposure. Externally
visible components with significant decorative function
in direct contact with normal industrial atmosphere or
media such as solvents and cleaning agents, where the
surface requirement is predominantly functional.
Components with very heavy corrosion exposure.
Components in contact with aggressive media, e.g. in
food or chemical industries. These applications must, if
necessary, be verified by special tests with the media
concerned.
SS5
(Ref : Festo)
Note:
1) A cycle is a complete 24-hour test cycle of the relevant tests.
2) W/K = Hot / Cold aging +120ºC / -20ºC.
3) KFW = Alternating condensation climate DIN 50 017-KFW.
4) SO2 = Kesternich test (SO2) DIN EN ISO 6988 KFW 0.2 S (former DIN 50018)
5) SS = Spray-mist test sodium chloride solution DIN 50 021-SS.
7.1.2.7
Pneumatic Part Turn Actuator
Part-turn-actuator shall be designed and calculated for an effective output torque at the drive shaft,
rated at 5.6 bar air-supply pressure and subject to a minimum safety margin of at least 30% on the
required torque of any specific process valve. All part turn actuators shall be designed to be
maintenance free and for use with oil-free compressed air.
All part turn actuators shall be designed, certified and tested as follows:
a) CE marked;
b) PED certified;
c) Interface:
i. Actuator – Solenoid Valve shall be standardised as per VDI / VDE 3845 NAMUR and shall
be aligned to allow horizontal assembly of the solenoid valve
7-9
Section 7 – Final Control
ii. Actuator – Process Valve shall be standardised as per ISO 5211 preferably with doublesquare shaft connection as per following:
Ø d (mm)
36
42
50
70
102
125
140
165
254
298
Flange
F03
F04
F05
F07
F10
F12
F14
F16
F25
F30
Square V (mm)
9,10
11,12
14,16
17,19
22,24,27
27,32
36
46
55,60
75
Holes
4xM5
4xM6
4xM6
4xM8
4xM10
4xM12
4xM16
4xM20
8xM16
8xM20
iii. Actuator – Switchgear / Positional shall be standardised as per VDI / VDE 3845 NAMUR to
allow direct assembly of any standard switchbox / Process controller as follows:
A (mm)
50
50
80
80
130
130
150
B (mm)
25
25
30
30
30
30
30
C (mm)
20
30
20
30
30
50
30
d) Every specific actuator shall come with an end-position-adjustment for at least 1 direction:
i. Butterfly valves to be adjusted in closed position, to guarantee maximum lifetime of the
sealing systems of the process valves as well as preventing from cavitational/erosional effects;
ii. Ball valves to be adjusted in open position, to guarantee maximum lifetime of the materials
on preventing from cavitational / erosional effects.
e) Operating media: Dry, non-lubricated air;
f) The maximum particle size shall not exceed 40microns;
g) Air supply Pressure max. 10.0 bar (The pressure shall generally be adjusted between 2.5 up to 8.4
bar);
h) Operating temperature range from -20°C up to +80°C;
i) Standard turning angle 90° (adjustable within 85°– 95°);
j) The actuator shall come with end position adjustment;
k) The actuator shall be suitable for both indoor and outdoor installation with minimum corrosion
resistant class : CRC 3;
l) The actuator shall have minimum ATEX approved with ATEX code: II 2 GD c X;
m) Material of construction:
i. Body shall be aluminium alloy with AlMgSi compound;
ii. End cap cover shall be aluminium alloy with AlMgSi compound;
iii. Piston shall be minimum SS304.
n) Dynamic sealing design shall come with protective slide ring. Only O-ring sealing is not
acceptable.
7-10
Section 7 – Final Control
7.1.2.8
Pneumatic Linear Actuator
All linear pneumatic actuators shall be designed and calculated for an effective output force at the
piston-rod, rated at 5.6 bar air-supply pressure and subject to a minimum safety margin of at least
30% on the required force of any specific process valve.
All linear actuators shall be designed to be maintenance free and for use with oil-free compressed air.
All linear actuators shall be designed, certified and tested as follows:
a. Actuators of diameter <=160 mm shall designed as extruded profile without anchor bolts;
b. Actuators of diameter >=200 mm shall designed as anchor bolt type with a tube and anchor bolts
of stainless steel of minimum quality AISI 304;
c. Interface:
i. Actuator – Process Valve interface shall be standardised as per ISO 5210 preferably with
double-square shaft connection;
ii. Actuator – Solenoid Valve interface shall be standardised as per VDI / VDE 3845 NAMUR
and shall be aligned to allow horizontal assembly of the solenoid valve;
iii. Actuator – Switchgear / Positional interface shall be standardised as per VDI / VDE 3845
NAMUR to allow direct assembly of any standard switchbox / process controller.
d. Sealing design shall be of self-sharpening lip sealing system. O-ring sealing as dynamic sealing is
not acceptable;
e. The actuator shall come with internal air channelling system to avoid fittings/tubing whilst fitted
with NAMUR solenoid valves;
f. Direct mounting slots integrated in the profile for mounting limit switches without additional
brackets of slot-size 8mm;
g. Dove tail slots integrated in the profile for fixing e.g. devices like local control units;
h. All linear actuators shall have in standard, pistons with magnetic strap giving the possibility for
electrical position indication;
i. Operating media: Dry, non lubricated air;
j. The maximum particle size shall not exceed 40 microns;
k. Air supply pressure max. 10.0 bar (The pressure shall generally be adjusted between 2.5 up to
8.4 bar);
l. The actuator shall be suitable for both indoor and outdoor installation with minimum corrosion
resistant class : CRC 3;
m. The actuator shall have minimum ATEX approved with ATEX code: II 2 GD c T4 T120C;
n. Material of constructions;
i. Extruded profile shall be AlMgSi alloy with anodised surface;
ii. Non extruded profile shall be minimum SS304;
iii. Cover and flanges shall be AlMgSi alloy with anodised surface;
iv. Piston shall be AlMgSi alloy;
v. Piston rod shall be minimum SS304.
7.1.2.9
Solenoid Valves (Stand Alone Unit)
All solenoid valves shall have a connection interface to the actuator according to VDI / VDE 3845
NAMUR or shall come with a conversion plate to the appropriate interface.
Materials used for the solenoid valves and the surface protection shall in any case prepare for a
minimum corrosion protection CRC3 and a minimum enclosure of IP65 to allow outdoor and indoor
installation without restriction under the weather conditions of Malaysia with high temperatures and
high humidity along with condensing water.
7-11
Section 7 – Final Control
All solenoid valves shall be designed to be maintenance free and for use with oil-free compressed air.
All solenoid valves shall be designed, certified and tested as follows:
a.
b.
c.
d.
Working temperature range
:
Working pressure
:
Air flow capacity
:
Coil connecting system shall be either :i) F-coil;
ii) Cnomo.
–10 °C up to + 60 °C
2 to 10 bar
min. 900 l / min
e. Voltage & tolérances : i) 12, 24, 42, 48 V/DC ±10%;
ii) 24, 42, 48, 110, 230 240 V AC ±10% at 50 - 60 Hz ±5%
f. Coil shall be exchangeable;
g. Connection with:i) 3-wire cable terminal blocks;
ii) 3-pin type socket.
h. Cycle time “ON” time not more then 50ms;
i. Cycle time “OFF” time not more then 100 ms .
7.1.2.10
Valve Terminals (Integrated with/without Bus Interface)
The valve terminals shall be modular design with capability of supporting up to minimum 25 units of
solenoid valve. The design shall base on the following:
a. The configuration of the valve terminal shall be flexible and allow assembly with mixture of flow
pattern, port size, etc such as:
i) 5/3 way, 3/2 way, 3/3 way;
ii) 3.175mm (1/8”) port size, 6.35mm (¼”) port size, 12.7mm (½”) port size .
b. Double coil actuation and Single coil actuation;
c. Valve terminal shall have basically a multi-pin connector;
d. Valve terminal with bus interface shall be able to integrate with digital / analogue Input and
Outputs module;
e. Valve terminal with multi pin connection shall be extendable for Bus-Interfaces without
exchanging the coils and terminals;
f. The valve terminal shall be flexible on selection of bus interface, it shall accept either one of the
following:
i) Profibus PA & DP;
ii) Device Net;
iii) Modbus TCP;
iv) AS-Interface
g. The material used for the valve terminal shall be able to use for outdoor and indoor installation
and with a minimum corrosion protection up to CRC3 and minimum IP protection of grade 65;
h. Working temperature range : –10ºC up to + 60ºC;
i. Working pressure
: 2 - 10 bar
j. Air flow capacity
: min. 900 l/min;
k. Coil connecting system:
i) F-coil;
ii) CNOMO.
7-12
Section 7 – Final Control
l.
Voltage & tolerances:
i) 12, 24, 42 or 48 VDC ±10%;
ii) 24, 42, 48, 110, 230 or 240 VAC ±10% at 50 to 60 Hz ±5%.
m. Cycle time “ON”
n. Cycle time “OFF”
: 50ms
: 100 ms
A small, handy handheld terminal shall be provided, which provides data pooling, configuration and
diagnosis function for the valve terminal. Data shall able to be read in or out at any location with onehand operation. PC or laptop shall not be needed to do the diagnosis function.
This handheld shall function as below:
a.
b.
c.
d.
e.
Plug and work
User Friendly
Diagnostics function
IP protection
Password
7.1.2.11
: No programming or additional software required
: Easy understanding text display
: Identifies fault and store last 40 fault even with time stamp
: Minimum IP65
: Access shall be protected with password
Position Sensor for Rotary Actuator
All sensors for rotary actuator shall have a size to fit to the NAMUR interface according VDI / VDE
3845. Materials used for the limit switches / housing and the surface protection shall in any case
prepare for a minimum corrosion protection of CRC3 and a minimum enclosure of IP65 to allow
outdoor and indoor installation without restriction under the weather conditions of Malaysia with high
temperatures and high humidity along with condensing water.
The sensor shall be proximity type with operating voltage of 24VDC. The housing shall be able to
provide visibility on valve position by changing of colour.
All position sensors for rotary actuator shall be assembled in housing with minimum:
a.
b.
c.
d.
e.
IP 65 enclosure;
Properly sealed with O-ring;
Cable entry of PG connection subject to sealing according to IP 65;
Working temperature range from -10ºC to +60ºC;
Voltage tolerance:
i) 12,24,42 or 48VDC ± 10%
ii) 24,42,48,110,230 or 240VAC ± 10% at 50/60Hz ± 5%
f.
Connection
i) 2 or 3 wire;
ii) 2 or 3 pin socket
7.1.2.12
Position Sensor for Linear Actuator
All sensors shall have a size to fit to linear pneumatic actuator slots with 8mm size.
Materials used for the limit switches and the surface protection shall in any case prepare for a
minimum corrosion protection of CRC3 and a minimum enclosure of IP65 to allow outdoor and
indoor installation without restriction under the weather conditions of Malaysia with high
temperatures and high humidity along with condensing water.
7-13
Section 7 – Final Control
The sensor shall be either proximity or reed type with an operating voltage of 24V DC. The sensor
shall come with LED indication for visibility convenient.
All position sensors shall minimum comply with the following specification:
a.
b.
c.
d.
e.
IP 67 enclosure;
Proximity or reed type;
LED indication of switching;
Temperature range from -10ºC to +60ºC;
Voltage tolerance
iii) 12, 24, 42 or 48VDC ± 10%;
iv) 24, 42, 48, 110, 230 or 240VAC ± 10% at 50/60Hz ± 5%
f.
Connection
i) 2 or 3 wire;
ii) 2 or 3 pin socket.
7.1.2.13
Pneumatic Flexible Air Tubing
Tubing shall be outer diameter calibrated type to ensure a proper and absolutely tight connection as
well as a multiple releasing and clamping. All tubes are subject to a special defined thickness, shorehardness, surface and ovality. The fittings to be used shall not have any reduction of the nominal size
of the piping system. The surface of the tubes shall not have any manufacturing dependant defects as
scoring. The Shore hardness shall be 90 Shore A to 70 Shore D.
The tubing to be used shall base on the following design:
a.
b.
c.
d.
e.
f.
g.
Material
: Polyethylene
Colour
: Black
Resistant
:UV, Hydrolysis, Chemical and Microbes resistant
Bending radius min.
: 62 mm
Type
: Inner / outer diameter calibrated
Maximum working pressure : 10 bar
Temperature range
: - 30ºC up to + 80ºC
Table 7.2: Calibration / Tolerance Table for Tubes
Tube Outside Diameter
Ovality d1 / d2
7.1.2.14
4 ± 0.1
6 ± 0.1
8 ± 0.1
10 ± 0.15
12 ± 0.15
1.05
1.03
1.03
1.03
1.03
Pneumatic Fitting and Connection
All fittings for connection of elastic tubing shall be of quick-connecting type to allow a multiple
releasing and clamping. Securing by means of interlock / threaded clamping ring is not acceptable.
The locking of the elastic tubing shall only be done by pushing the tube into the fitting, which is a
self locking mechanism, consisting of push / pull –ring. A stainless steel claw, which shall secure the
tube without damage, is to assure a proper and leakage-free holding of the tube without damage the
tubing. The mechanism shall allow removal of the elastic tube from the fitting by just pushing the
push/pull -ring without damage of any part of the tubing connection.
7-14
Section 7 – Final Control
Connection of elastic tubing shall be outside calibrated to ensure a proper and absolutely tight
connection
Additionally the tubes are subject to a special defined thickness, shore-hardness, surface and ovality.
Fitting to be used shall design base on the following:
a)
b)
c)
d)
e)
Push / pull- ring
Elastomer
Body
Clamping segment
Threaded piece
: Polycarbonate
: Nitrile
: Nickel plated brass / SS 304
: Nickel plated brass / SS 304
: Nickel plated brass / SS 304
Figure 7.2: Direct Acting Diaphragm Pneumatic Actuator
7-15
Section 7 – Final Control
7.2
Switch
7.2.1
Time Switch
Time switch shall be of the circular dial capable of one `ON' and one `OFF' operation per day, and
with a 24 hour spring reserve. Time switch shall operate load contactors of adequate continuous
rating to cater for the loads. A three (3) position selector switch providing the following operation of
Automatic, Manual `On' and Manual `Off' shall be provided.
7.2.2
Control and Selector Switch
Control and selector switch shall conform to BS EN 60947 or IEC 947.
Control switch shall be of the three position type with spring return action to a central neutral position
and shall complete with proper label. The switch shall be lockable in the neutral position. Control
switch shall have different shape of handles like spade, tee or other approved shape handles for each
type of control function namely, Open/N/Close, Lower/N/Raise, etc.
Selector switch shall make before break and shall remain in the position selected and be key lockable
in that position. They shall be rotary spring loaded type with spade shaped handles and each position
shall be labelled.
Contacts and terminals of all switches shall be shrouded with clear perspex cover to permit inspection
without dismantling. A bezel shall be provided for each switch, at least 50 mm square. Where key
operated switches are provided it shall not be possible to operate them without the key, but also be
possible to lock them in any position and withdraw the key.
7.2.3
Limit Switch
Limit switch shall be heavy duty industrial units with single pole double throw (SPDT) contacts rated
for 230 VAC 2A. Where hard wired protection circuits are required in addition to SCADA system
connection, limit switch shall be DPDT with dual cable entry glands. Cams, rocker arms, or
“whiskers” type switch shall be used as appropriate for the application. Limit switch shall be rated to
IP 65 or better.
7.2.4
Proximity Switch
Proximity switch shall be of the inductive sensing type with a 3 wire 24 VDC interface. Suitable
sensing targets shall be provided and rigidly attached in cases where the surface to be detected is nonferrous. Proximity switch shall have hermetically sealed cables or IP68 rated plug connectors.
Sensing distance shall normally be a minimum of 12 mm but in any event shall be commensurate with
the mechanical tolerances involved.
7.2.5
Speed Switch
Speed switch shall be used to verify correct operation of rotation plant such as conveyors. Speed
switch shall consist of a proximity switch to detect the passing of a rotary or reciprocating part and a
switching unit. The switching unit shall monitor the frequency of pulses from the proximity switch
and hence determine if the speed has exceeded or fallen below preset levels. The switching unit shall
provide a SPDT volt free contact output corresponding to each preset switch point. Speed switch
points shall be adjustable. The switching unit shall have indicators for power and output relay status
visible with all covers closed and shall have an enclosure rated to IP65 or better.
7-16
Section 7 – Final Control
7.3
Control Relay
Relays shall be either plug-in or block type. Relays shall be housed in dust-proof and totally enclosed
cases to BS 5490, IP 64 enclosure. The cases shall be of transparent plastic capable of being replaced.
Plug-in relays shall be fitted with transparent plastic dust-proof covers, retaining clips, a base into
which the relay plugs and external connections shall be made using easily accessible screw clamp
terminals. Bases and relays shall be keyed to prevent relay being plugged into incorrect bases. If
mounted on DIN rails, blocking pins shall be provided. Space and drillings shall be provided for a
minimum of 10% additional relays. Block type relays shall be totally encapsulated.
Relays shall be fitted with neon or LED indicator connected across the operating coil and easily
visible when the compartment door is open. Relays fitted with mechanical indicators will not be
acceptable.
DC relays shall be ringed with a diode (1200V, 1A).
Relays with different voltage coils or different configuration of contact shall not be interchangeable.
Mixed voltages shall not be connected to different contacts of a particular relay. If necessary,
additional relays shall be used.
When voltages exceeding 55 volts to earth are employed in relay compartments or non-door
interlocked sections then such terminals shall be shrouded, segregated and fitted with warning labels.
Where supply voltages from remote are used, then care shall be taken to ensure relays associated
equipment, terminal fuses etc. shall be shrouded and segregated where possible.
7-17
Section 7 – Final Control
7.4
Timer
Timers shall be solid state, plug-in type, provided with cable connection sockets with ‘energised’ and
‘timed-out’ indications. They shall have linearly calibrated scales, in units of time, each scale division
being maximum of 5% of full scale. Repeat accuracy shall be within 0.5% of full scale. Timers shall
be anchored by quick fastening vibration proof devices. Pneumatic timers shall not be acceptable.
Timers and bases shall be keyed to prevent mismatching. The pin configuration of each timer shall be
printed on the casing.
7-18
Section 7 – Final Control
7.5
Indicator
Analogue indicators shall have critically damped movements and shall be manufactured to a standard
equal to or better than BS 89:1997 (IEC 51:1973). An accuracy ±0.5% of full scale span or better
shall be provided unless otherwise specified.
Panel mounted analogue indicators shall be of the same style. Vertical edgewise (upright or
horizontal format) type shall have a linear scale length of not less than 100 mm with digital indicator
unless otherwise specified. Circular analogue indicators shall have 240º deflection scale and not less
than 70 mm in diameter. Each indicator shall be provided with near Zero adjustment, anti-parallax
platform scales enclosed in damp and dustproof cases and suitable for the site environment.
Scale ranges and calibrations shall be clearly marked in SI units with black lettering and graduations
on a white background, and shall be approved by the Engineer before manufacture. Instruments of
the same type and range shall have identical scales. Scale markings shall be in accordance with BS
3693 Part I, and shall not discolour or peel with age.
Digital indicators shall be of a modular design incorporating signal input and conditioning, analogue
to digital conversation power pack, analogue and/or binary-coded decimal (BCD) output modules and
switch for decimal position. Indications shall be in engineering units to an accuracy of ±0.05% of
reading ±2 count or better. Zero stability with temperature shall be equal to or better than ±1 μV/ºC.
Digital indicators shall incorporate bright 14mm red LED uniplanar numerals which can easily be
seen from across a control room and at all viewing angles. Instrument cases shall be die-cast
aluminium.
7-19
Section 7 – Final Control
7.6
Integrator
Unless otherwise specified, integrators or totalizing impulse counters shall have cyclometer type
counters with a minimum of eight digits. The height of each digit shall not be less than 4mm and
width not less than 2mm. Each integrator shall have sufficient adjustment of the pulse rate to avoid
the use of any multiplying factor except in integer power of 10. An adjustable limiter shall be
incorporated whereby any input below a preset value is inoperative.
Integrators shall be electromechanical or electronic as specified. Electronic integrators shall retain
their reading indefinitely in the absence of external power. Integrators operating in conjunction with
an electromagnetic or ultrasonic flowmeter shall use the pulse output from the flow transmitter. Any
integrator operating from a device without a pulse output shall have an integral or separate current-to
pulse converter with sufficient adjustment of the pulse rate to avoid the use of any multiplying factor
except in integer power of 10. Each integrator shall incorporate an adjustable limiter whereby any
input below a preset value is inoperative. Unless otherwise specified, integrators shall have a
minimum of eight digits with a decimal point where applicable.
7-20
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Bela Liptak, Third Edition, CRC Press, 1995
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PID controller
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Why Do We Use RTD’s to Monitor the Freeze Drying Process?
Thomas A. Jennings, Interpharm Press, Buffalo Grove, IL, 2003
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i