General Construction Specifications
PART 1 - GENERAL
01 DESCRIPTION OF WORK
A. Under this item the Contractor shall furnish, test and place in operation a complete and operational instrumentation system as shown and as specified. The system shall include pump control systems, level sensing equipment, flow metering equipment, combustible gas analyzer, annunciators, telemetry system, interconnecting tubing and or wiring and such accessories as may be shown and or required to provide the functions indicated.
B. Submittals shall be made to the Owner or to his designated Representative in accordance with the General Conditions of the Contract. Submittals are often made under the general term of "Shop Drawings" but include all items listed in the General Conditions.
C. Some submittal requirements listed in the General Conditions or within the specifications are not ordinarily termed as Shop Drawings but still must be submitted as above.
D. The instrumentation section states a number of requirements which must be met. These include tests, certifications, calibrations, guarantees, etc. Such prepared data and reports shall be submitted in addition to:
1. Wiring diagrams
2. Instrument loop diagrams
3. Materials of construction
4. Panel layouts
5. Model numbers and catalog cuts
6. Outline dimensions
B. The instrumentation as specified in this section shall be supplied by the pump manufacturer. The pump manufacturer shall have total system responsibility.
1.02 REFERENCES
A. I.S.A. Instrument Society of America
B. Hydraulic Institute
C. ANSI - American National Standards Institute
D. NEMA - National Electrical Manufacturers Association
E. UL - Underwriters Laboratories
F. NEC - National Electric Code
1.03 PERFORMANCE - GENERAL REQUIREMENTS
A. The instrumentation shall be furnished by a manufacturer regularly engaged in the manufacture of process instrumentation and systems for water and wastewater treatment facilities. The instrument manufacturer shall produce detailed drawings for the complete coordination and installation of the various system components; shall provide the services of a qualified engineer to supervise the installation, and shall test and make any adjustments required, at no additional cost to the Owner, to the extent that the system initially functions as intended by this specification to the satisfaction of the Owner.
B. Owner's Representative will check after the Contractor certifies that all the instruments are installed and are operating as per intended specification. The Contractor shall be required to correct, at no extra cost to the Owner, all deviations and/or deficiency from the intended use of the instruments individually as well as the system in its entirety, which the Owner's Representative may find during the detail checkup of the system(s).
C. Each instrument shall be furnished in complete compliance with the specifications. The instrument supplier may propose substitutions and submit complete technical data on the same. If, in the opinion of the Owner the proposed substitute is indeed equal in the particular application proposed, he may approve the substitution. In evaluating a substitution, performance durability, availability of spare parts, inventory requirements, and ease of maintenance with existing personnel and plant will be considered.
D. Functional system data is shown diagrammatically on the Instrumentation Loop Schedules and details. All elements shall be provided as shown. Additional elements such as power supplies, pneumatic volume boosters, current repeaters, lighting/surge protection on all outdoor installed equipment, and other such elements as may be required to complete the system shall be provided even though not shown.
All digital and analog signals for the telemetry system required in Section 2.05, C., shall be supplied as isolated signals from any other control signals. The instrument manufacturers shall coordinate with the telemetry supplier.
E. Equipment shall be located and installed so that it will be readily accessible for operation and maintenance. The Contractor shall examine the architectural, structural, mechanical, electrical and shop drawings for the various pieces of in order to determine the exact routing and final terminations for conduits and signal lines. Instrumentation work shall be carefully coordinated between the various trades in order to secure the best arrangement of the work as a whole. No changes in the work shall be made without written acceptance of the Owner.
F. The Instrument Contractor shall submit evidences of his prior experience, technical skill, capacity to handle a project of the volume and reference of other clients for whom he has performed similar installations.
G. Services by Manufacturer and Guarantee
1. Certification sheets shall be prepared by the Instrumentation Manufacturer to guarantee that each component and loop has been calibrated and commissioned prior to start-up. Certification sheets shall be signed and dated by the Instrumentation Manufacturer and by the Owner or his Representative. All instruments shall be calibrated by an instrument traceable to a primary standard. All instruments shall be calibrated to within the accuracy stated by the manufacturer. Each instrument shall be checked for zero and full span and in addition, a check shall be made a minimum of 5 points between 10 and 90% of the actual span for each analog instrument. The certification sheets shall show "as found" and "as left" readings.
2. After all tests and adjustments have been made, the manufacturer shall fully instruct the Owner's Representative in all details of operation and maintenance of installed under his work.
3. The Contractor and his surety shall guarantee in writing for a period of one year from date of final acceptance that all materials, and labor furnished by him are free from defects. The
Contractor shall further guarantee that if any piece is found to be defective within the guarantee period because of faulty manufacturing, faulty installation or workmanship, in the opinion of the Owner's Representative, the Contractor will replace and install such material or without any additional expense to the Owner.
4. At least three copies of all manufacturer's guarantees and certificates which are obtained by the Contractor shall be furnished to the Owner.
5. The manufacturer shall have service and maintenance available at 24 hour notice.
H. Change of Scope Omissions
1. It shall become the responsibility of the Contractor working in conjunction with the Owner's Representative to perform any changes to the process system not covered by this or other Contracts, due to accidental omissions or change in work scope.
I. Installation, Calibration, Commissioning and Start-Up Assistance
1. Work Included
a) Install, calibrate, commission and assist in the start-up of instrumentation and controls including those furnished with purchased in accordance with this specification section, the applicable design drawings and other Contract Documents.
b) Furnish and install all necessary instrumentation materials and piping required to perform the work.
c) Furnish and install all one inch and small transmission control and process sensing piping with required valves, tubing, fittings, hangers and supports.
2. System Description
a) The required instrumentation and control system shall be defined on the following documents:
1) An Instrument List listing all instruments, controls and panels purchased for the project with cross reference to piping, electrical and instrument drawings.
2) Piping and instrument routing drawings showing location of instruments, controls and panels. Each item is identified by the tag number shown on the Instrument List.
3) Instrument installation details and electrical drawings showing the required method of installing and connecting the instruments.
4) Manufacturer's recommended installation instructions and drawings.
b) Locations shown on the drawings shall not be changed without the written approval of the Engineer.
J. Delivery, Storage and Handling
1. Receive, uncrate, inspect and store instruments, controls, control panels, tubing, piping and miscellaneous instrumentation materials.
2. Check all items for proper tagging, general physical condition and missing parts including all items previously received at the project site by others. Promptly report all incomplete shipments, missing parts and evidence of breakage or damage in transit, or in prior handling for corrective action.
3. Protect instruments, tubing, piping and miscellaneous instrument materials from water, foreign material and injury from time of receipt until final acceptance of the work. Be responsible for and repair or replace all items damaged from time of acceptance at the job site to item of completion of the work handled under this specification section.
K. Materials
1. Piping and Pipe Fittings
a) Materials shall conform to Section 15060, Piping and Fittings, and as shown on the drawings.
b) The minimum schedule thickness for pipe nipples 12 inch and shorter shall be as follows:
Size Schedule
Steel Pipe
1/4 inch thru 1 inch 40
A. Instrument Installation
1. Install in accordance with the installation details given on the drawings.
B. Tubing and Piping Installation
1. Protect capillary tubing for filled system temperature and pressure instruments by installing in channel supports, with capillary attached to channel with clips. Excess capillary shall be coiled and secured at the instrument.
1.02 GENERAL INSTRUMENT CONSTRUCTION
A. Transmission and Circuit Arrangement
1. Signal transmission between electronic instruments shall be 4-20 mA.
B. Attachments and Supports
1. All instrumentation and electrical shall be securely supported. It shall be the responsibility of the Contractor to provide adequate support for all he installs. Methods of support shall be subject to the approval of the Engineer.
2. All fastenings, supports, hangers, clamps, and anchors shall be of the type made for the specific purpose for which they are to be used. Toggle bolts or machine bolt fastenings shall be used for hollow tile, terra-cotta, or lath construction. Machine screws shall be used for structural steel fastening. Lead expansion shield and machine screws shall be used for solid masonry fastening. Lag screws or bolts shall be used for wood fastening. All conduit and tubing shall be rigidly and firmly installed to prevent swaying, vibration or sagging by malleable or wrought steel hangers of standard design, pipe clamps, or fabricated steel supports of approved design. Hangers for horizontal conduit runs shall be adjustable clevis type. Perforated strap iron hangers are not permitted.
3. All exterior fastening devices shall be Series 300 stainless steel.
4. Panels and other that is located on subgrade walls in unfinished areas or in damp locations, shall be mounted on square aluminum channel.
C. Special Tools
1. This Contractor shall furnish two sets of all special tools required for operation and maintenance of all furnished under his work. The tools shall be delivered to the Owner's Representative and receipt shall be obtained.
D. Identification Nameplates
1. All sensors, transmitters, terminal and junction boxes, and similar or related items shall be identified by name, function, and/or control. Nameplates shall be at least 1 inch by 3 inches with characters not less than 1/4 inch. They shall be made up of two laminated white plastic sheets bonded with a middle sheet of black plastic and characters engraved in one white sheet to the depth of the black plastic. Nameplates shall be attached with sheet metal screws or bolts and nuts.
2. A typewritten list of nameplates shall be submitted to the Engineer for approval before ordering.
3. Plastic tape embossed nameplates will not be acceptable.
E. Instructions
1. After all tests and adjustments have been made, this Contractor shall fully instruct the representatives of the Owner in all details of operation and maintenance of installed under his work.
F. Materials
1. All material shall be new, free from defects, and of the quality specified or shown. Each type of material shall be of the same manufacture throughout the work. All material shall be the product of established, reputable manufacturers normally engaged in the production of the particular item being furnished.
2. Care shall be exercised in the installation of all to avoid damage or disfiguration of any kind. All shall be protected from dust and moisture prior to and after installation. The panels and consoles shall be covered with a heavy polyethylene plastic sheet or laminated kraft paper having a moisture barrier during all stages of construction.
3. Equipment which is stored in unheated or open areas on the job shall be provided with thermostatically controlled heating units of sufficient size to keep the temperature of the above the dew point.
4. Failure of the Contractor to protect the as outlined herein shall be grounds for rejection of the equipment.
G. Indicating Scales
1. All instrument components furnished under this Contract requiring indicating scales or meters shall be furnished with the appropriate ranges and engineering units indicated on the loop diagrams. Indicating scale reading 0-100% in most cases will not be applicable unless so indicated on the loop diagrams.
H. Control Cabinets
1. The control cabinets shall be fully enclosed, with access to cabinets. The cabinets shall be completely wired at the factory and all wiring shall be in accordance with JIC standards. All wiring shall be brought out to terminal strips for field connection, except where direct connection is required for special reasons. All stranded conductors shall be lugged where connected to screw terminals. Each end of each wire shall be coded with coded marking ferrules in a uniform logical numbering system.
2. Cabinets shall include internal incandescent light, switch and duplex receptacle. A separate external circuit shall be provided for the illumination/receptacle power supply.
3. Cabinet control wiring shall be single conductor Type TW rated 90oC and shall be flame, moisture, and oil resistant polyvinyl chloride insulated No. 16 AWG minimum. Stationary conductors shall be Class B stranded. Cables crossing hinges shall be Class D stranded, and suitable means shall be provided to protect cables from chafing or undue stress when the hinged member is moved.
4. Wiring shall be tagged at all terminations with machine printed plastic sleeves. Wire shall be color coded as follows:
a) Hot: Black
b) Neutral: White
c) Ground: Green
d) Special: Blue
5. Covered channel for panel wiring made of perforated or slotted fiber or plastic shall be used to support the wiring. Wire shall be tied and laced where not supported in channel. Crimping type wire lug terminals with insulated sleeve as made by A.M.P., or equal, shall be used throughout the panel. All field connectors shall be wired to labeled terminal strips at the bottom of the panel.
6. Each termination of each wire in the panel shall be labeled with a plastic sleeve having a printed number. The wire numbers shall be assigned by the panel builder and shown on the schematic diagrams and the connection diagrams.
7. The cabinet builder shall provide complete and detailed connection diagrams for use by the electrician. These diagrams shall show all connections between the main control panel, the motor control center and to remote devices. The external connection diagrams shall be prepared and submitted for approval by the Engineers as part of the shop drawing submittal.
1.03 TESTING, CALIBRATION AND COMMISSIONING
A. As preparation for the calibration and commissioning of the instrumentation, the Contractor shall:
1. Inspect visually electrical devices and connections for compliance with specifications, drawings and manufacturer's recommended installation practice.
2. Remove all shipping stops and install components such as charts, mercury, etc., which have been supplied separately but are integral parts of the instruments.
3. Operationally check all instruments, including those provided with and marked on the "piping and Instrument Diagrams". After, or during checking, each instrument shall be calibrated and commissioned.
4. Furnish and report forms recording the calibration of all devices and settings of all final adjustments.
5. Check calibration of all instruments with respect to zero, span and linearity. Calibrate instruments individually. Attach a calibration sticker to each item after calibration. Furnish a signed calibration report each instrument.
a) If, during calibration procedures, any reason is discovered to question the conformance of any device or installation with applicable codes and regulations, the Engineer shall be notified so that corrective measures may be taken.
b) When doubt exists as to the correct method of calibrating an instrument, the manufacturer's printed recommendations shall be used.
1.04 START-UP ASSISTANCE
A. After completion of calibration and commissioning operations, the Contractor will provide start-up assistance. It shall include but not be limited to the following:
1. Adjust controls for stability.
2. Reset limit switches as required, but only after approval has been obtained.
3. Clean out blocked or restricted impulse lines.
1.05 SUBMITTALS
A. The instrumentation section states a number of requirements which must be met. These include tests, certifications, calibrations, guarantees, etc. Such prepared data and reports shall be submitted in addition to:
1. Materials of construction
2. Model numbers and catalog cuts
3. Outline dimensions
1.06 SHOP DRAWING
A. Shop drawings submission procedures shall be in accordance with Section 01340. Specific requirements for instrumentation are as follows:
B. Complete shop drawings shall be submitted for acceptance prior to manufacture of any instrument equipment. Drawings shall be submitted on 8-1/2 by 11 inch, 11 by 17 inch or 24 by 36 inch paper and shall show dimensions, materials of construction, schematic electrical and pneumatic connections, calibrations, ranges, scales, and specification data. Manufacturer shall furnish loop diagrams of professional quality with each loop shown completely on a single point-to-point wiring and/or piping drawing. Typical wiring or piping diagrams of individual components shall not be acceptable in lieu of the specified loop diagrams. All components, component terminals and/or ports shall be accurately and clearly identified on the loop diagrams. The Contractor shall verify all existing wiring and show all existing on the loop diagrams as required for system operation.
C. Individual control diagrams shall be made for each separate annunciator point and status light. Control diagrams shall detail the logic relationship between the field device and microprocessor.
1.07 RECORD DRAWINGS AND INSTRUCTION MANUALS
A. Record drawing preparation and instruction manual submissions shall be in accordance with the General Requirements. Specific requirements for instrumentation are as follows:
1. The Contractor shall maintain a neatly marked set of record drawings showing installed location and/or routing of interconnecting conduits, cables and tubing. Drawings shall be kept current with the work and shall be subject to inspection by the Owner at any time.
2. Prior to acceptance of the work, the Contractor shall deliver to the Owner two sets of neatly marked record drawings showing the information required in the foregoing paragraph, and record reproducible prints of all instrumentation wiring and tubing diagrams required under "Shop Drawings".
3. The Contractor shall provide the Owner with three complete sets of manufacturer's operating and maintenance instructions and recommended spare parts lists for all instrumentation furnished.
PART 2 - PRODUCTS
02 LEVEL SENSING EQUIPMENT
A. Submersible Level Sensor:
1. The transducer shall be of the solid-state head-pressure sensing type, suitable for continuous submergence and operation and shall be installed in accordance with manufacturer's instructions. The bottom diaphragm face of the sensor shall be installed at elevation recommended by the manufacturer. The sensor shall be mounted using a stainless steel cable system in a location and as shown on the Contract Documents. The transducer shall be installed in a pipe for easy removal.
2. The transducer housing shall be fabricated of Type 316 stainless steel with a bottom diaphragm 2-5/8" diameter of heavy-duty, limp, foul-free, molded Teflon bonded to a synthetic rubber back/seal.
3. A hydraulic fill liquid behind the diaphragm shall transmit the sensed pressure to a solid-state variable-capacitance transducer element to convert the sensed pressure to a corresponding electrical value. The sensed media shall exert its pressure against the diaphragm which flexes minutely so as to vary the proximity between an internal ceramic diaphragm and a ceramic substrate to vary the capacitance of an electrical field created between the two surfaces. A stable, hybrid, operational amplifier assembly shall be incorporated in the transducer to excite and demodulate the sensing mechanism. The transducer shall incorporate laser-trimmed, temperature compensation and high quality components and construction to provide a precise, reliable, stable output signal directly proportional to the sensed pressure over a factory-calibrated range.
4. The transducer element shall incorporate high over-pressure protection and be designed to withstand intermittent over-pressures five times the full scale range being sensed. Metallic diaphragms shall not be acceptable in that they are subject to damage or distortion. Sensing principles employing LVDTs, resistive or pneumatic elements shall not be acceptable.
5. The transducer/transmitter shall include easily accessible offset and span adjustments in the upper assembly. Span shall be adjustable from 100% down to 15% of the sensor range. Fine and coarse adjustments for both span and offset shall be provided, using 25-turn potentiometers. Offset and span adjustments shall be non-interactive, for ease of calibration.
6. The internal pressure of the lower transducer assembly shall be relieved to atmospheric pressure through a heavy-duty urethane jacketed hose/cable assembly and a slack PVC bellows mounted in the Nema 3X fiberglass upper assembly. The sealed breather system shall compensate for variations in barometric pressure and expansion and contraction of air due to temperature changes and altitude as well as prevent fouling from moisture and other corrosive elements.
7. The transducer assembly shall be installed where directed by the Engineer and connected with other system elements and placed in successful operation. It shall be provided with input power and output signal transient protection, associated control elements as specified herein and in accordance with manufacturer's instructions.
8. The liquid level of the wet well shall be sensed by a Consolidated Electric Company Bulletin A1000, Model 157GSCI Submersible Level Transducer or approved equal. The transducer shall be a 4-wire type to operate on 120 VAC incoming power and produce a 4-20 mADC instrumentation signal into a 0-1,000 ohm load in direct proportion to the measured level excursion over a factory-calibrated range of zero to 40 feet of water.
9. Acceptable Equal Manufacturers:
a) EG Pump Controls
b) Healy-Ruff
2.02 PUMP CONTROL SYSTEMS
A. Scope:
1. The manufacturer of the system shall take responsibility for the proper operation/sequencing of the complete pump control system. The control system shall operate the four (4) new pumps in an integrated manner as described by the Engineer.
2. The pump control system manufacturer shall be responsible for all programming of the system, and any interface required to provide a complete operational system.
3. The pump control system shall be as manufactured by:
a) EG Pump Controls
b) Systecon, Inc.
c) Allen-Bradley
B. Design Data:
1. The pump control system shall be capable of operating (4) four new (exact pump HP to be determined by pump manufacturer) pumps in the wet-well in a variable speed mode in order to convey sewage to the central wastewater treatment plant without causing a sewage over-flow wherever possible irregardless of system demands.
2. New VFD's, solid state starters, and transformers shall be supplied for the new pumps.
3. The number of operational pumps must be able to be programmed into the system, through an English message display system, and the system must then operate accordingly to how many pumps are available.
4. The new pump control system shall receive signals from the level sensing as specified for maintaining the liquid level in the wet well. The level sensing to be utilized for control signals shall be operator selectable at the MCP. The pump control system shall use the second set of level controls in the wetwell for the back up system.
C. Manufacturer's Experience:
1. The manufacturer of the control system shall be certified by Underwriters Laboratories (UL) as being a UL 508 listed systems panel shop certified to install a serialized label for quality control and insurance liability considerations.
2. The manufacturer of the control system must submit documentation verifying at least 5 years of experience in manufacturing and integrating AC VFD systems of a similar size and scope.
3. The manufacturer of the control system must submit to the Consulting Engineer documentation proving experience in successfully designing and manufacturing at least 5 similar systems of a similar scope.
4. Manufacturer's Quality Control: The control system shall be functionally tested at the manufacturers facility and certified as a complete system to assure proper operation per specification in order to minimize costly field changes. The Engineer and the individuals designated by the Engineer reserve the right to witness this final system functional test.
D. Shop Drawings:
1. The Engineer reserves the right to approve or disapprove any and all based upon evaluation. Approval for fabrication and installation will be made only after submittal and review of all shop drawings. The information required for approval shall include the following sets as a minimum:
a) Electrical diagram of the control system.
b) Complete electrical schematics detailing every wire and connection within the system as well as all field connections.
c) Detailed drawings of the enclosure (size, construction, entry/exit, mounting).
d) Bill of Materials and Product Data Sheets.
E. Hydraulic System Analysis:
1. The supplier of the variable speed control system shall supply a complete hydraulic analysis of the system in order to verify that the system should operate without damage due to pump operation too far to the left of the curve during low speed operation, too far right of the curve during high speed operation, hydraulic overload, or inefficient / heat generation / cost prohibitive operation at various critical speeds / frequencies. The control system manufacturer shall coordinate with the pump and VFD manufacturer to obtain all necessary information.
a) Graph which shows the system input horsepower, taking into account the efficiencies of the pump, VFD, and the motor, plotted against all flows on a continuous basis from project minimum to maximum flows.
b) Graphs which plot the system curve against the pump curves at 100% speed, 90%, 80%, etc., in 10% increments, until the pump speed does not generate enough head to overcome the system static head. These curves must also show curves of constant hydraulic horsepower to verify non-overloading.
c) Tabulated data shall be provided showing the following information, starting at the pump(s) speed required to overcome the system static, in 2% speed increments:
1) % speed
2) Flow (GPM)
3) T.D.H.
4) Line H.P.
5) Cost/million gallons
6) Wire to water efficiency
d) Wet-well model detailing the following:
1) Level excursions plotted against the diurnal inflow profile on a 24 hour basis.
2) Summary of the projected run-time for the pumps.
3) Projected yearly energy consumption.
e) The current drawn by the motor and by the VFD, at all operating speeds, in order to verify that neither the VFD nor the motor will be overloaded at any point in the operating range.
f) This hydraulic analysis shall be provided to the Engineer along with the initial submittal drawings. This analysis shall again be done once the final pumps, motors, variable speed controls, piping, etc. has been approved by the Engineer to verify proper system hydraulic performance under "As-built" conditions.
F. Programmable Controller/System Controller:
1. Acceptable Manufacturers
a) Systecon Inc., Cincinnati, Ohio
b) Allen-Bradley
c) E.G. Pump Controls
2. The wetwell level control system shall utilize two (2) Systecon Model S9511 Universal Controllers for redundant control. The two universal controllers shall be designed to transfer automatically from one to the other in the event of failure of the operating controller. The control system shall maintain a constant wetwell level utilizing the wire-to-water efficiency calculations and shall add and subtract pumps based on wire-water efficiency control.
3. The Receiver/Controllers shall be flush mounted in the door of the control system enclosure and shall be microcomputer based. On-line programmable data entries, such as setpoints, calculated results, and totalization shall be stored in non-volatile memory. All data entry shall be keypad in engineering units.
4. 25% spare input and output points on the system controller shall be provided for usage directed by the Engineer if required during start-up. these points are to be prewired to a plug-in terminal strip. A minimum of 3 interposing relays and 2 time delay relays, are to be prewired and mounted for interfacing purposes. A real time clock function shall be provided.
5. The programmable controller shall meet or exceed the following specifications.
a) U.L., E.T.L. or CSA approved
b) Supply Voltage: 120 VAc, 50/60 Hz
c) Operating Voltage: 85% to 110% of rated voltage
d) Operating Temperature: 0-500C
e) Built-in PLC fault contacts
f) Diagnostic functions both in the "Run" and "Program" mode.
g) Capable of processing analog signals and performing mathematical calculations, i.e., addition, subtraction, comparison, multiplication, division, and square foot.
h) PLC memory shall be of the non-volatile type: battery backed RAM or EEPROM so field modifications to the program can be easily made and a loss of system power will not affect the memory of the PLC.
I) All terminal strips on the PLC must be plug-in type for quick removal/insertion due to component failure.
6. Each Receiver/Controller shall have as an integral part of its hardware design a watch-dog timer reset function and shall be powered by 115 VAC to 60 HZ. The incoming power and input/output circuitry design shall facilitate rejection of EMI, electromagnetic interferences, and RFI, radio-frequency interferences.
7. Each Receiver/Controller shall add standby pumps on excessive deviation from setpoint. It shall also have loop alarms for all analog inputs. Failure of any remote transmitter shall remove that transmitter signal from the remaining control functions. The readout shall be multi-line plasma type capable of displaying any setpoint value, input or output signals, process value, and alarm functions in engineering units such as GPM, PSI, feet of head, or wire-to-water efficiency. The Receiver/Controller shall be capable of operating in automatic or manual modes. Time of day or digital input overrides shall be provided over all analog inputs. Two levels of security in the form of operator passwords shall be provided for protection of field programs and setpoints. Pumps shall be programmed for Wire-to-Water Efficiency Control using system flow in GPM, system head and system KW to achieve optimum wire-to-water efficiency.
G. Control System Operation:
1. The wet-well levels shall be monitored and maintained by the level sensing system as specified.
2. System Controller:
a) The system controller shall supervise all sequencing, pump combinations, pump speeds, non critical annunciation, system testing, system monitoring and back-up systems, and overall system status and control.
b) The pumping system shall have the capability of being operated in simplex, duplex, triplex, quadruplex mode.
3. Sequence of Operation:
a) Functional Description:
1. The system shall be designed to produce an outflow from the wet well, in an energy efficient manner, such that the wet well does not overflow.
2. The control system shall be of the Proportional and Integral (P1) type.
3. All variable speed driven, equal HP pumps will operate at the same speed for equal loadsharting, minimized energy consumption during parallel operation.
(a) The pump control system shall respond to a change in wet well level as follows:
(b) High level alarm
(c) Maintain level with 4 pumps running
(d) Start lag, lag, lag pump
(e) Stop lag, lag, lag pump
(f) Maintain level with 3 pumps running
(g) Start lag, lag pump
(h) Open 54" isolation valve
(i) Stop lag, lag pump
(j) Close 54" isolation valve
(k) Maintain level with 2 pumps running
(l) Start lag pump running
(m) Stop lag pump
(n) Maintain level with 1 pump running
(o) Start lead pump running
(p) Stop lead pump
b) Energy Efficient Optimized Pumping:
1) The system controller shall be programmed with the pertinent information from the hydraulic analysis in order to maximize the system energy savings and reduce the possibility of operating the pumps in a damaging mode.
c) Data Entry/System Programming: The data entry system shall consist of an English message display and a control plate with 13 buttons and lights. All operator adjustments shall be prompted with the appropriate English phrases: Systems which require data entry in any form other than by the response to English prompts, such as in programmable controller ladder logic, data register entry, etc., shall not be acceptable.
1) The message display shall provide access to all important operating parameter setpoints such as individual pump minimum and maximum speed setting, pump turn on levels, # of pumps and associated speeds at each wet-well level, differential, alternation choice, and speed ramp adjustments.
2) Default values/error checking will be programmed into the system, based upon input from the Engineer, such that improper data cannot be entered into the system which would cause improper system operation.
3) The message display shall display all critical alarms, along with the annunciator panel, for ease of trouble shooting of problems.
4) When an alarm has occurred, the "Fault Log" illuminated pushbutton shall light up indicating such. Upon depressing the "Fault Log" button, the last 5 faults shall be sequentially displayed in the message display.
5) The English message display shall be controlled by appropriate switches. Switch/capability substitution is not allowed.
6) Test capabilities shall be built into the system to simulate a rising or falling wet-well in order for the operator to perform a complete system test when desired.
7) The message display and operating pushbuttons shall be mounted on the aluminum deadfront. Systems that require the operator to open the control cabinet and thus expose himself to dangerous voltages (> = 120V) will not be acceptable.
d) VFD Alternation:
1) Automatic alternation shall be time based.
2) Alternation time shall be adjustable by the user and should be factory set to alternate once every 7 hours such that two VFD's are checked within one 8-hour shift.
3) Manual alternation and sequence adjustment shall be available such that the Operator may choose the VFD alternation sequence which he deems appropriate. The Operator must be allowed to choose any alternation sequence which he chooses by designating any pump to be in any of the possible 4 sequencing positions.
e) Pump Alternation:
1) Automatic alternation shall occur on a First On, Last Off basis in order to best equalize pump run time for all pumps.
2) Automatic Pump alternation shall be time based and shall be coordinated with the alternation of the variable frequency drives.
3) Manual selection of pump sequencing shall be available through appropriate switches.
f) Automatic Flush Down Sequence:
1) This sequence will allow the wet-well to rise to the maximum allowable height at which time a predesignated number of pumps, sequencing on on a time delayed basis, are run at full speed in order to flush the discharge piping of any material/debris which may have settled due to low speed/low flow operation.
2) This sequence will be time based and shall be user adjustable.
g) Back-Up Systems and Redundancy:
1) Stand-By Level System: Any and all system or component failures which can cause the wet-well to rise to an undesirable height shall activate this system when the wet-well thus rises to the "Stand-By Level System On" level.
(a) Predesignated pumps shall sequence on, with use of adjustable hard wired time delays, in order to keep the wet-well under control.
(b) All time delays and other components inherent in this system shall be "hardwired" and independent of the primary transducer and the PLC/Controller operation.
(c) All pump protective relays and sensors shall be "hardwired" into the level sensor back-up system and shall be independent of the PLC/Controller operation.
(d) The pumps will sequence off only when the wet-well level reaches the "stop" level.
2. Controller Back-Up: Failure of the system controller shall cause the passive stand-by level system to be activated in order to keep the wet-well from overflowing. The control system shall be supplied with a completely redundant system controller. Both system controller's shall be functional at all times to provide 100% back-up.
3. Control Power Transformer (CPT) Back-Up: Automatic transfer to a stand-by CPT must occur in less than 1 second if the primary CPT fails.
h) Alarm Annunciation: All faults shall energize the main alarm light and horn, in a flashing mode, on the enclosure. The alarms shall be displayed in "English" on the message display. Every alarm must be "acknowledged" and "reset" in the following manner:
-Acknowledge: Depressing the "acknowledge" button shall turn off the main alarm(s) and change the light(s) on the panel door from flashing to steady on. A steady-on light thus indicates that a fault has occurred and has been acknowledged by the Operator, thus assuming that action is being taken to correct the fault.
-Fault Reset: Depressing the "fault reset" button will turn off the fault light(s) on the panel door after the fault has been corrected. If the fault has not been corrected, the light will not turn off. If a fault clears itself, the light(s) will turn off.
1) Alarm and informational indicator lights and functions shall be as shown on the drawings:
2) Alarm, Informational, and Test Features:
(a) LAMP TEST: Depressing the "Lamp Test" button shall energize all alarm and informational lights. Control functions associated with the lights shall not be affected.
(b) VFD FAILED: The "VFD Failed" message alarm will come on flashing if the VFD has failed. To reset the "VFD Failed" light(s), push the "Fault Reset" pushbutton. Pressing the "Acknowledge" pushbutton will cancel the main audible and visual alarms and change the flashing "VFD Failed" light(s) to steady on.
(c) VFD FAILED AND RESET: The "VFD Failed and Reset" message alarm comes on flashing if the VFD has failed and then automatically reset successfully. Pressing the "Acknowledge" pushbutton will change the light from flashing to steady on. Pressing the "Fault Reset" pushbutton will turn the light off.
(d) POWER MONITOR: The "Power Monitor" message alarm comes on flashing in the event of loss of phase, phase reversal, overvoltage, or undervoltage. The pumps will be stopped in the event of any of these faults if running in "Auto" mode. The alarm will not come on if the phase or phases that were lost are the "control power" phase(s).
(e) PLC FAILED: The "PLC Failed" message alarm will come on steady if the PLC fails.
(f) STAND-BY LEVEL SYSTEM: The "Stand-By Level System" light will come on if the PLC fails and/or the wet well level rises all the way to the "Stand-By Level System On" level. The "Stand-By Level System" light and the main alarms will remain on steady until manually reset with the "Fault Reset" button.
(g) HIGH LEVEL (same concept for low level): The "High Level" message alarm and the main alarm will come on flashing if the wet well reaches high level. The "High Level" light will remain on until acknowledged and reset. The main alarm will go off when the wet well level drops below the high level point.
(h) AUTO PUMP DOWN: The "Auto Pump Down" message will come on when the Auto Pump Down cycle is in progress.
H. Positive Run Verification System: This will allow the system to isolate failures to the specific piece of failed to assist with troubleshooting, and reduce system downtime. In order to verify pump run, the control manufacturer shall supply limit switches on the check valves in each pump discharge pipe. If the selected to run pump does not open the check valve after a preset adjustable time the system shall signal a pump failure and start another pump.
I. Equipment Identification:
1. Identify all electrical in accordance with these specifications.
2. All identification labels, both within the enclosure and external, shall be engraved phenolic nameplates. All nameplates on the deadfront of the controller shall be permanently attached with either stainless steel screws or with a gasketed assembly.
3. Provide engraved nameplates to identify all individually mounted pushbuttons, rocker switches, lights, meters, disconnect switches, circuit breakers, motor starters, transformers, relays, fuses, phase monitors, surge arrestors, and any other for which identification is required for eventual service or replacement.
J. Spare Parts:
1. 2 spares of every type and color of light and illuminated pushbutton.
2. 2 spares of each type of fuse used in the system.
3. 2 spares of each type of relay used in the controller.
K. Installation/Start-Up:
1. The Contractor shall include in his bid the services of a factory trained representative for whatever period of time, assuming 1 trip, is required to inspect, start-up, test the control system an instruct plant personnel in the proper maintenance and operation of such (5 days minimum).
2. The Owner of this shall supply any personnel to assist the factory start-up crew which are required to oversee or perform actual work if so required by labor/credit contracts. This cost shall be born by the Contractor.
3. Prior to final approval, the manufacturer shall submit a letter certifying that the installation has been tested and functions as per the plans and specifications.
2.03 COMBUSTIBLE GAS ANALYZERS
A. Furnish and install a combustible gas analyzer system for the pump station as shown on the Contract Drawings.
B. The indicating unit shall provide two isolated contact outputs when the level reaches a preset adjustable limit. One output shall be transmitted to the building alarm panel and the other to the telemetry system for transmission to the central WWTP.
C. Combustible gas analyzer systems shall consist of remote diffusion heads, transformer unit, control units, housing and connecting cables.
D. Diffusion heads shall consist of a conduit containing a four element bridge. The head shall have a special protection cap with provision for compressed air connection for purging and calibration check. Heads shall be Class I, Division 1, explosion proof, stainless steel.
E. Indicator range shall be 0-100 percent lower explosive limits. Indicators shall include contact closure output when the lower explosive limit reaches a preset adjustment limits. Trouble, warnings, and alarm relays shall be spdt, 5-a contacts.
F. A diffusion head calibration check kit shall be included with each analyzer.
G. The combustible gas analyzer shall be a continuous monitoring system as manufactured by Interscam Corporation, or an approved equal.
2.04 ANNUNCIATORS
A. Annunciators shall be complete with annunciator cabinets containing the number of rows and columns as required, translucent white windows, flasher and audible modules, plug-in modules, sequence AF, audible alarms, power packs, silence and test pushbuttons, 120-V, 60-Hz supply, and nameplates with engraved legends as approved by the Engineer.
2.05 TELEMETRY SYSTEM
A. The Contractor shall provide and install a complete telemetry system for operation and control of the pump station from a remote location. The telemetry system shall be compatible with the existing Metro Water Services Equipment. The telemetry system shall be completely functional and supplied with all required accessories. The Contractor shall include this cost in his Lump Sum Bid.
B. The Contractor shall furnish and install all telemetry related conduit and cables. Conduits shall run underground or concealed in concrete from the control room to the telemetry pole. Conduits shall terminate 5 ft. above finished grade. The telemetry relay cabinet shall be supplied and installed by the Owner. The Contractor shall provide excess cable for termination at relay cabinet.
C. The telemetry system shall be as follows:
1. The remote terminal unit shall be a completely self-contained, state-of-the-art, microprocessor/EEPROM based unit designed specifically for the monitor and control, via a UHF, two-way radio communication system, of various functions at unattended remote locations.
2. The basic remote terminal unit shall be of modular construction and shall be able to support multiple digital and analog inputs and multiple digital and analog control outputs. Optional expansion modules shall allow the remote terminal unit to be expanded either from the factory or in the field using available digital or analog input and output modules.
3. For ease of expansion or repair, remote terminal unit expansion modules shall be added or removed via two screws and two quick-disconnect terminal connectors. All input and output wiring connections to the modules shall be made via 14 pin quick-disconnect connectors.
4. Remote Terminal Unit hardware shall minimally consist of:
a) A single, compact RTU module supplying the following features and capabilities:
1) FSK encode/decode, code security, channel monitor, unit self-test and LED status display circuitry.
2) An "on-board", field re-programmable, EEPROM resident, RTU parameters data base that supports up to 4 RTU addresses and one of four basic configurations:
(a) Eight digital status inputs (dry contacts, <3Kohms=closed, >40Kohms=open) and one digitally controlled, momentary "FORM A" relay contact (120 Vac, 6A rated).
(b) Six digital status inputs (dry contacts, <3Kohms=closed, >40Kohms=open) and two digitally controlled, momentary "FORM A" relay contacts (120 Vac, 6A rated).
(c) Six digital status inputs (dry contacts, <3Kohms=closed, >40Kohms=open), one digitally controlled, momentary "FORM A" relay contact (120 Vac, 6A rated) and one analog input (4-20 mA only).
(d) Eight digital counter inputs that provide the capability to report on counts of 4 types: totalizer, pulse duration, pulse rate or run time. There shall be a maximum of 8 counter inputs per RTU.
(e) The system shall be configured by the manufacturer for the following:
(1) (4) Pump Start/Stop - digital signal (output)
(2) (4) Pump Running - digital signal (input)
(3) Wet Well Level - analog signal (input)
(4) (1) Dry Well High Level Alarm - digital signal (input)
(5) (1) Chemical Storage Tank Low Level - digital signal (input)
(6) Pump Station Entry Alarm - digital signal (input)
(7) (4) Chemical Feed Pumps Running - digital signal (input)
(8) Rate of Overflow - analog signal (input)
(9) (4) Pump Run Meters Total Hours - (input)
(10) Overflow Totalized - (input)
(11) (1) Chemical Storage Tanks High Level - digital signal (input)
(12) Rate of Flow Force Main No. 1 - analog signal (input)
(13) Rate of Flow Force Main No. 2 - analog signal (input)
(14) (2) Pump Controller Failure - digital signal (input)
(15) (4) VFD Failure - digital signal (input)
(16) Explosive Gas System - Alarm Level - digital signal (input)
(17) Explosive Gas System - Warning Level - digital signal (input)
(18) Protected Water System - Pump Failure - digital signal (input)
(19) Protected Water system - Low Tank Level - digital signal (input)
(20) Protected Water System - High Tank Level - digital signal (input)
b) A system communications module consisting of:
1) A 20 watt UHF transceiver with an operational range of 440-470 Mhz.
c) A 115 Vac 50/60 Hz power supply, float charger and a 12Vdc, sealed, lead-acid backup battery for up to 30 hours emergency power backup with one, 2-second transmission per hour. A power fail alarm shall be reported if AC power is not restored within 1 minute. The charger shall recharge a fully discharged battery in not more than 24 hours while the unit operates directly from 115 Vac.
d) A NEMA-4 rated, metal expansion housing shall be supplied as described:
1) A housing with a maximum size of 23.5" H (596mm) x 15.0" W (381mm) x 8.25" D (209mm), that includes a locking device and, on radio units, an N-type female antenna connector. The housing shall hold up to the required modules (the basic RTU modules and 7 expansion modules).
e) A unit operating temperature range of -300 to +600 C with up to 90% relative humidity, non-condensing.
5. Remote Terminal Unit expansion hardware shall include:
a) Status expansion modules (one supplied) that provide the capability to report on the condition of up to 8 additional digital alarm or change-of-state inputs. There shall be a maximum of 128 digital inputs per RTU.
b) An analog input module (one supplied) that provides the capability to report up to 6 analog inputs of 2 types: + 1v or 4-20mA. There shall be a maximum of 13 analog inputs per RTU.
c) Control expansion module (one supplied) shall provide the capability to digitally control an additional 4, "FORM C", 120 Vac, 0.6A rated, relay contacts. There shall be a maximum of 34 digital control outputs per RTU.
6. Remote Terminal Unit functions and operations shall include:
a) Report on the condition of digital alarm, change-of-state, counter or analog inputs in response to an interrogation (poll) from the system central station.
b) Report on the condition of digital alarm, change-of-state, counter or analog inputs in response to an internally timed and generated transmit command. The timer shall be programmable from 5 minute to 48 hours.
c) Report on the condition of digital alarm, change-of-state, counter or analog inputs as soon as remote site conditions change (contention).
d) Report the new measured value of counter and analog inputs whenever they vary by a preset value or percentage from the last reported value.
e) Generate digitally controlled relay contact or current or voltage outputs to control remote site functions.
f) Alarm memory in case of a radio system fade or lengthy system busy.
g) System intercommunications via UHF, two-way radio at a data rate of at least 600 bps. The signalling format used shall be two-position, non-return-to-zero (NRZ), pulse duration FSK. Raw signalling Bit Error Rate (BER) shall be a minimum 1 in 10-6 at 20db s/n ratio or better. Uncorrected bit errors shall be zero. Each remote terminal unit encode or decode message shall include, at a minimum: remote terminal unit address, input or output information, frame synchronization, bit count, Bose-Chaudhuri Cyclic coding and an overall parity check to ensure message validity.
h) Unit operational self-test on unit power-up or after depression of the test switch. The self-diagnostics routine shall check the entire remote terminal unit for proper operation and the outcome shall be displayed via the unit's built-in LED display.
7. Basic Conventional Radio System Operation:
a) In quiescent operation, the remote terminal unit's FSK decoder shall be monitoring the associated UHF radio communication channel and its FSK encoder shall be monitoring associated digital and analog inputs.
b) Upon receipt of an interrogation request (poll) from the system central station, the remote terminal unit shall scan all of its inputs and, after monitoring the communication channel and finding it clear, shall transmit a message to the system central station reporting the results of the scan.
c) Upon receipt of the input status message from the remote terminal unit, the system central station shall monitor the channel and on finding it clear, transmit back an acknowledgement of the receipt of the message.
d) The remote terminal unit shall also independently report any new digital alarm, change-of-state, counter or analog input changes as soon as it detects them and is able to get a clear communication channel (contention reporting). The remote terminal unit shall periodically repeat these self-initiated status messages until it receives an acknowledgement message from the system central station or its report cycle times out.
8. The remote terminal unit shall also be equipped with a time-out-timer, tone coded squelch on the transmitter, a yagi directional antenna with associated transmission line, and A.C. surge protection.
9. Complete installation of the remote terminal unit with antenna and transmission line shall be included as well as the first year's maintenance (parts and labor).
10. The remote terminal unit shall be Motorola Model F6774 or approved equal in accordance with standard used by the Metropolitan Water and Sewer Division.
2.06 MAGNETIC FLOW METER
A. The Contractor shall furnish and install the following magnetic flowmeter for the measurement of the flow of domestic wastewater. The magnetic flowmeter shall be for installation in 54 inch diameter lines. The maximum operating pressure is 150 psi, and the maximum temperature of the process fluid is 1800F.
B. The magnetic flowmeter shall operate on the principle of a power generator, a voltage being induced when a conductive flue cuts across lines of force in a magnetic field. The in-line flow element shall consist of a section of 54 inch steel pipe surrounded by the necessary core and coils which provide a magnetic field. The steel tube shall be lined with Teflon. The fluid passing through the magnetic field shall generate a voltage directly proportional to the average velocity across the section. The flow element shall operate from a 120 volt, 60 Hz, single-phase power source.
C. The flow element shall be furnished with fabricated steel housing, fully gasketed to provide the environmental protection of NEMA 6. End connections for the flow element shall be AWWA Class 125 flat-face. The electrodes shall be 316L stainless steel, conical shape.
D. The flow signal generated by the magnetic flow element shall go directly to a magnetic flow transmitter for subsequent retransmission of a 4 to 20 mA dc current. The transmitter shall be of all solid-state construction employing electromagnetic and electrostatic shielding techniques. The transmitter shall be contained in a housing suitable for surface mounting. The housing shall provide environmental protection of NEMA Type 6.
E. The transmitter shall provide in addition to the dc signal, a pulse rate output to drive an electromechanical counter for purposes of flow integration. The necessary 24-volt section power supply to drive the electromechanical counter shall be furnished.
F. The pulse rate shall be adjustable from 1.0 to 10 pps at maximum flow rate. A decade counter with an electrical link to place it in the circuit and to enable reducing the output pulse rate by a factor of 10 shall be provided.
G. The necessary special shielded cable to connect the magnetic flow element to the magnetic flow transmitter shall be furnished complete, as required for installation.
H. The magnetic flow element and transmitter shall have a system accuracy of + 1.0% of span.
I. The output of the effluent magnetic flow transmitter shall be a 4 to 20 mA dc signal to transmit to a receiver-recorder-totalizer. The electronic receiver shall be contained in a case designed for panel mounting and provided with a electric chart drive. The receiver element shall be complete with case-mounted power supply. The electronic receiver shall have an accuracy of +0.5% of span.
J. There shall be a 6-digit electromechanical counter driven from the pulse rate output of the effluent magnetic flow transmitter.
K. The magnetic flow meter shall be Model Mag-X as manufactured by Fisher and Porter, Danfoss, or approved equal.
L. The existing 54" magmeter shall be relocated as shown on the Drawings. The Contractor shall provide all accessories required to relocate and provide a complete operating system. The Contractor shall provide new indicator, totalizer and recorder for the existing magmeter to be installed in the new M.C.P.
2.07 MAIN CONTROL PANEL (MCP)
A. The Contractor shall furnish and install the main control panel as described in this section for the space as shown on the Contract Documents.
B. The MCP shall contain the following items and any other items required for pump station operation:
1. Level sensing indicators, controls, and recorders.
2. Pump control system.
3. Combustible gas monitor.
4. Annunciators.
5. Telemetry system.
6. New flow meter totalizers, indicators and recorders for existing and new flow meter.
7. Pump station totalizer.
PART 3 - EXECUTION
03 MANUFACTURER'S SERVICES
A. All manufacturer's visits to construction site prior to final performance test shall be the responsibility of the Contractor. At any time within a six-month period, subsequent to completion of hereinbefore specified Final Performance Tests, the Contractor, at the request of the Owner, shall furnish the Owner with services of manufacturer's representatives for a period of 10 man-days, divisible into a maximum of 3 separate times.
B. Applicable contract lump sum prices shall include the furnishing of all said services. Furthermore, said services shall be additional to those furnished in connection with erection, installation, testing and the correction of deficiencies. Services provided shall consist of furnishing detailed instructions to personnel of the Owner regarding operation and maintenance after personnel of the Owner have had an opportunity to become familiar with pump station equipment.
04 INSTRUCTION MANUALS
A. Contractor shall furnish, prior to initial testing, twelve copies of an indexed maintenance manual composed of suppliers' maintenance manuals on all and suppliers' brochures on all specialty equipment, including performance curves with size, model, figure number, etc., indicated to identify unit furnished. Maintenance manuals are to be of a hardback, loose-leaf type and of a durable quality. Manuals are to be for the specific provided. Manuals describing general lines will not be accepted.
B. Each set is to include the following:
1. Manufacturer's parts list identified with the make, model and serial number of the furnished.
2. Control and wiring diagrams.
3. Installation, operation, lubrication and maintenance instructions.
4. Manufacturer's recommended spare parts lists.
B. If an Owner's Representative is assigned to the project either through the Owner or the Engineer, the Contractor(s) shall make a copy of all instruction manuals available to the Representative. Manuals on specific items shall be available prior to installation of the item. This requirement in no way relieves the Contractor of his other responsibilities.
3.02 OPERATOR TRAINING
A. Contractor shall provide five (5) days of operator training at pump station site. This training shall include operation of the system and basic troubleshooting. Operators shall be made familiar with each item. Operations shall be made familiar with downloading functions such control setpoint, alarm setpoint, start/stop and valve open/close functions. Operators shall be made familiar with manual override procedures for interrupting automatic control. Operators shall be trained in interpreting system diagnosis.
B. Manufacturer shall quote price for providing detailed programming and maintenance training.
3.03 FACTORY ACCEPTANCE TEST
A. Contractor shall assembly main control panel at one location after all processor programming and system configurations have been approved by Engineer and downloaded into equipment. A complete system simulation shall be demonstrated to the satisfaction of Owner and Engineer before is shipped.
END OF SECTION
