SCADA_Master_Plan

Contents Chapter

Page

SCADA Master Plan Executive Summary ............................................................................... ES-1 Introduction........................................................................................................................ES-1 Recommendations .............................................................................................................ES-1 Existing Facility Control Systems....................................................................................ES-2 Network Architecture .......................................................................................................ES-2 Collection System Network ................................................................................ES-3 WWTP Networks .................................................................................................ES-3 Operations Data/Control Center and Operations Network..........................ES-3 Business Network.................................................................................................ES-4 Implementation..................................................................................................................ES-4 1

Alternatives Evaluation and Recommendations .......................................................... 1-1 1.1 Introduction............................................................................................................. 1-1 1.2 Recommendations .................................................................................................. 1-1 1.2.1 Controllers ................................................................................................. 1-1 1.2.2 Collection System Communications Recommendations .................... 1-2 1.2.3 WWTP Communications Recommendations ....................................... 1-2 1.2.4 Operations Data Collection Network Communications Recommendations .................................................................................... 1-2 1.2.5 Local Operator Interface .......................................................................... 1-2 1.2.6 Collection System Control Center Recommendation.......................... 1-3 1.2.7 WWTP Control Center Recommendation............................................. 1-3 1.2.8 Operations Data/Control Center Recommendation ........................... 1-4 1.3 Evaluation................................................................................................................ 1-5 1.3.1 Controllers ................................................................................................. 1-5 1.3.2 Collection System Communications Evaluation.................................. 1-9 1.3.3 WWTP Communication Evaluation .................................................... 1-12 1.3.4 Operations Data Network Communication Evaluation ................... 1-12 1.3.5 Local Operator Interface Evaluation.................................................... 1-12 1.3.6 Collection System Control Center Evaluation.................................... 1-13 1.3.7 WWTP Control Center Evaluation....................................................... 1-14

2

Implementation Plan ......................................................................................................... 2-1 2.1 Introduction............................................................................................................. 2-1 2.2 Recommendations .................................................................................................. 2-1 2.3 Design Criteria ........................................................................................................ 2-2 2.4 Standard Pump Station Design Documents ....................................................... 2-2 2.5 Procurement ............................................................................................................ 2-2 2.5.1 Collection System Request for Proposals Content............................... 2-2

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CONTENTS, CONTINUED

Chapter

Page 2.5.2 2.5.3 2.5.4

Collection System RFP Scope of Work .................................................. 2-3 WWTP Request for Proposals Content.................................................. 2-3 WWTP RFP Scope of Work ..................................................................... 2-3

Appendixes A B C D E F G

Block Diagrams Design Criteria Pump Station Facility Design Criteria WWTP Facility Design Criteria Pump Station Design Spreadsheet WWTP Design Spreadsheet Standard Loop Specifications

Exhibit 1-1 1-2

Controller Comparison.......................................................................................................1-5 Communication Alternatives Comparison ...................................................................1-10

2-1

SCADA Life-Cycle Cost Considerations..........................................................................2-1

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IV

Acronyms and Abbreviations API CDMA/FDD COTS C-P DCS DCS DPW ETL FES HMI I/O IP KVM LCD LED mpbs MPLS MS-ADO NAT NTG PLC RFP RSS SCADA VPN WiMAX WLAN WWTP

Application Programming Interface Code Division Multiple Access with Frequency Division Duplex commercial off-the-shelf City of Baton Rouge/Parish of East Baton Rouge Distributed Control System distributed control system Department of Public Works Extract, Transform and Load Fixed-End Service Human Machine Interface input/output Internet Protocol Keyboard, Video Mouse liquid crystal display light emitting diode million bits per second Multi-Protocol Label Switching Microsoft ActiveX Directory Objects Network Address Translation Network Technology Group programmable logic controller request for proposal received signal strength Supervisory Control and Data Acquisition Virtual Private Network Wireless Mobile Access Wireless Local Area Network wastewater treatment plant

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SCADA Master Plan Executive Summary Introduction The City of Baton Rouge/East Baton Rouge Parish (C-P) Department of Public Works (DPW) requires an integrated Supervisory Control and Data Acquisition (SCADA) system that provides for monitoring and control of each wastewater treatment plant (WWTP) as well as the collection system. The SCADA system will provide management and operational access to data for all facilities to meet the needs of facility operations and maintenance staff, managers, and engineers. DPW operates a network of more than 400 wastewater collection system pump stations, as well as three primary and five small WWTPs. The number of collection system pump stations continues to grow each year, which increases the need for a SCADA system that will improve operations and maintenance effectiveness and efficiency. The SCADA system is also needed for use in collecting operations and maintenance information and in responding to emergencies for all facilities.

Recommendations For the collection system, CH2M HILL recommends creating a SCADA system that utilizes programmable logic controllers (PLCs) at the pump stations for local and remote control and monitoring. CH2M HILL also recommends incorporating the five small WWTPs into the collection system SCADA system. This recommendation would involve construction of a secure Collection System Control Center in a DPW facility supported by a secure wireless communications network, and a connection to the DPW Operations Network. The wireless network is needed to support communications between the control center, pump stations, and mobile laptop workstations used by operations and maintenance staff. As part of the SCADA Master Plan, CH2M HILL also recommends constructing: •

A new control systems at each of the three primary WWTPs to a common network topology and Distributed Control System (DCS)

•

A secure control center at each plant supported by a secure communications network that both provides high-speed communications for both plant DCS and WWTP operation personnel anywhere on the DPW Operations Network

•

A secure, central Operations Data/Control Center that provides high-speed communications with plant and collection system control centers

The Operations Data/Control Center will collect, reduce, and archive measurements, alarms and, status information for use by operators, managers, and engineers. The data center will also include an information server that allows managers and engineers to view process graphics and to generate reports using the DCS manufacturer’s visualization application

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SCADA MASTER PLAN EXECUTIVE SUMMARY

software product installed on their business network workstations. The Operations Data/Control Center can be utilized for centralized control of the system, if it is so desired, once the collection system and individual WWTP control centers are in place.

Existing Facility Control Systems DPW has two existing collection system SCADA systems, as well as a stand-alone SCADA system at each of the three primary WWTPs. The two collection system SCADA systems combine to provide monitoring and limited control to 51 of the more than 400 pump stations in the collection system. None of these existing systems are interconnected in any way. Appendix A includes a simplified block diagram for the three primary plants and the newer collection system SCADA systems. The older of the collection system SCADA systems shares a licensed radio system with public safety, DPW, and other C-P mobile voice users. Originally, this older system provided monitoring and limited control of 51 pump stations, and has a mix of Aquatrol, Tesco Liquid 4, and Tesco Liquid 5 PLCs. Communications in this system have been unreliable. The system also has fallen into disrepair and is used occasionally for a few of the 51 pump stations originally served. Spare parts are also no longer available for the Aquatrol PLCs. The newer collection system SCADA system provides monitoring and limited control of 14 pump stations. The newer system was installed as part of a project to upgrade the existing older collection system SCADA system. The 14 pump stations incorporated into this system are the 13 booster pump stations that did not require replacement control panels, along with Pump Station No. 3, which was added as an emergency repair to bring that station back online after a failure. This project has been suspended and is being revisited at this time, as discussed below. The newer collection system SCADA system uses Verizon digital cellular links to the Internet for communications between the 14 pump stations and the Human Machine Interface (HMI) data and web server at the Network Technology Group’s (NTG’s) Baton Rouge data center. Browser connections over the Internet to the HMI web server are used to support HMI workstations. Additionally, critical alarms are forwarded from the HMI server to pump station supervisors’ cell phones. The C-P is also in the process of upgrading the radio system to newer technology. It is possible that the new radio system may be able to provide reliable timely communications to at least some pump stations. Each of the three primary WWTPs has a standalone SCADA system composed of a pair of HMI workstations connected to a network of PLCs over a proprietary PLC copper wireline bus network. All of these systems are out-of-date and are not functioning at this time.

Network Architecture The proposed SCADA system is composed of the following five components including: 1. Collection System Network 2. WWTP Networks

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3. Operations Network 4. Operations Data/Control Center 5. Existing Business Network Appendix A includes a simplified block diagram for the proposed network, and a discussion of all components follows.

Collection System Network The collection system SCADA system will be used by collection system operators to monitor and exercise control of collection pump stations in accordance with pump station design criteria. The monitoring and control system includes the following major components: •

PLCs at each pump station to provide autonomous local automatic control and to communicate with servers on the Collection System Process Control Network.

•

A Collection System Process Control Network housed in an air conditioned environment with security measures that limit access to HMI servers and network appliances. The process control network collects collection system data and allows mobile collection system operators to monitor and exercise control of collection system pump stations without having to visit each pump station. Additionally, diagnostic information presented to operators can be used to prioritize maintenance activities and to plan preventive maintenance. An example of where control can be used is to pump down certain collection system pump stations in advance of a significant wet weather event to reduce the peak flows that will be experienced at the WWTPs during the wet weather event.

•

A wireless communications network to provide reliable communications between the pump stations and the process control network. It is recommended that wireless communications be accomplished by a digital cellular network at this time.

WWTP Networks Each WWTP Process Control Network will be used by WWTP operators to monitor and control WWTP process equipment in accordance with operations procedures. WWTP networks include the following major components: •

A WWTP Process Control Network housed in an air conditioned environment at each WWTP with security measures that limit access to network appliances, DCS servers, and workstation computers. The process control network connects DCS system components, collects WWTP data and allows WWTP operators to monitor and control WWTP process equipment. Additionally, diagnostic information presented to operators can be used to prioritize maintenance activities and to plan preventive maintenance.

•

A fiber optic Fast Ethernet local area network (LAN) to provide reliable communications between DCS controllers and the process control network.

Operations Data/Control Center and Operations Network An Operations Data/Control Center is required to provide central collection, storage, and processing of operations data from WWTPs and the collection system. The Operations

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SCADA MASTER PLAN EXECUTIVE SUMMARY

Data/Control Center’s applications provide easy access to data for managers and engineers to support a number of activities, including regulatory reporting, management oversight, collection system and treatment capacity and quality analysis, and improvements planning. In the future, centralized control of the collection system and WWTPs can be accomplished at the Operations Data/Control Center. CH2M HILL recommends locating the Operations Data/Control Center on a separate network from both the Business Network and the Process Control Networks to provide isolation between the networks. By isolating the networks, the availability and integrity of both the Operations Data Center and the Process Control Networks are improved. The Operations Network provides reliable communications between each of the four Process Control Networks and the Operations Data Center. This network will be implemented using leased lines and digital data services provided by the local telephone company. The firewall in the Operations Data Center controls traffic between the three connected networks and serves to “protect” the Operations Network, while still allowing for future centralized control at the Operations Data/Control Center. Users connected to the Operations Network have credentials-limited remote monitoring and control access to any of the three WWTPs and the Collection System. Credential limitations are used to manage access to prevent unauthorized persons from adjusting parameters, such as chemical flows at a particular WWTP. Centralized control of the entire system can be accomplished via the Operations Network, if desired in the future. Users connected to the Business Network are subject to the same credential limitations and must also use a virtual private network (VPN) connection through the firewall for direct monitoring and control. However, operations information is available to Business Network users directly from servers in the Operations Data Center.

Business Network The Business Network is an existing network that supports utility management and engineering activities. The DCS manufacturer’s visualization application software product installed on existing Business Network user workstations will provide access to the operations information stored in the Operations Data Center and provide easy access to operations data for managers and engineers, supporting a number of activities, including regulatory reporting, management oversight, collection and treatment capacity and quality analysis, and improvements planning.

Implementation In order to implement the recommendations, a request for proposal (RFP) process is recommended. A total of two RFPs are recommended: one for the collection system and one for all three major WWTPs. The collection system RFP would be used to select a collection system provider that would build the Collection System Control Center and the communications network connections, thereby completing the Collection System SCADA system and encompassing the design, installation, and maintenance of the collection system SCADA system for 5-years. Design

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criteria included with the RFP, and, therefore, included in price proposals received, will require that the communications network and control center delivered be capable of accepting controllers for the existing pump stations that are not to be replaced in the SSO program. The cost proposal portion of the RFP will only include pump station controllers for the pump stations that are being replaced as part of the SSO program, since these will be the only pump stations defined at the time that the RFP is written. Costs for purchasing, installation, and incorporation of future pump station controllers (including those at existing stations that are not included in the SSO program) can be added to the contract at the time they are needed. The RFP will be written for a 5-year period, with the option for renewal. A separate WWTP RFP will be written based on a specific DCS that encompasses the design, installation, and maintenance of the WWTP SCADA system for all three primary WWTPs. Proposals received in response to this RFP, including costs, will include all elements and allow the provider to be selected based on a combination of performance and cost information. The RFP will be written for a five year period, with the option for renewal. Continuing and long-term support of the SCADA system is recommended to promote accurate, responsive, and reliable SCADA system performance and to maintain a viable SCADA system as technology continues to rapidly evolve. Including periodic major upgrades, migration to newer hardware and software, as well as routine preventive maintenance and software update installation work in support contracts is recommended.

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CHAPTER 1

Alternatives Evaluation and Recommendations 1.1

Introduction

Several alternatives were evaluated for the entire Supervisory Control and Data Acquisition (SCADA) system. Evaluations included controllers, communications, and control centers for the collection system, wastewater treatment plants (WWTPs), and for the overall SCADA system as follows. •

A total of eight programmable logic controllers (PLCs) from five manufacturers and one Distributed Control System (DCS) were evaluated for pump stations and WWTPs. The evaluation that follows focuses on differences between evaluated options with a discussion of common features.

•

A total of nine different communication alternatives were considered for the collection system, WWTPs, and the DPW operations network. The evaluation discussed in the following sections outlines several options for communications that were considered for this SCADA Master Plan.

•

Local operator interfaces were also evaluated. Local operator interfaces allow operations and maintenance staff to view process variables, as well as view and adjust setpoints and other adjustable parameters at either the pump station or at selected locations within the WWTP.

The pump station control center will house the computer servers that collect information from pump station PLCs, advise mobile operations and maintenance staff of problems requiring attention, transmit data to historian servers, and support graphical, interactive HMI displays on mobile laptop workstations. The WWTP control centers will house the DCS computer servers and workstation computers that collect information from DCS controllers. The control centers will also advise mobile operations and maintenance staff of problems requiring attention, transmit data to historian servers, and support graphical, interactive DCS workstation displays. An Operations Data/Control Center will be utilized to house historical database servers that will collect operations data from treatment facilities and the collection system and place it in a database. This operations data/control center can also be utilized in the future if centralized control of the collection system and WWTPs is desired. The database servers should be housed in a separate room of the operations data/control center for security purposes.

1.2

Recommendations

1.2.1

Controllers

Controller recommendations include:

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1. Continued use of the Tesco L2000 PLC that is currently in use at the pump stations. 2. Installation of the Emerson Ovation DCS at each of the three primary WWTPs. The method for evaluating the controllers follows.

1.2.2

Collection System Communications Recommendations

Assuming the ownership and upgrading of the Verizon network service contract and conversion to Ethernet using Internet Protocol (IP) is recommended. Recommended Verizon network improvements include conversion to a Fixed-End Service (FES), Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology, and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. The Ethernet interface is ubiquitous, very flexible, supports routing over networks, and can use combinations of a broad range of communications alternatives. Assuming ownership and upgrading of the Verizon network service contract will ease obtaining the benefits of state government rates. Other advantages of the Ethernet interface include scalability, flexibility, and life-cycle cost effectiveness. Scalability will allow the network to grow as required to incorporate future anticipated pump stations and, if desired, integrate with the WWTP network. Flexibility will reduce the risk of wholesale network replacement, allow the communication network to adapt to technological improvements, and allow DPW to use several communication technologies in combination or to migrate the network from one communication technology to others. Life-cycle cost effectiveness can be achieved by including life-cycle costs when selecting communications alternatives.

1.2.3

WWTP Communications Recommendations

As shown on the block diagram in Appendix A, the recommended network topology for each primary WWTP is a redundant fiber optic Ethernet star using Internet Protocol (IP) that provides continued operation after failure of a single link or switch. This method of communication is the only method available at this time for the recommended Emerson Ovation DCS.

1.2.4

Operations Data Collection Network Communications Recommendations

As shown on the block diagram in Appendix A, the recommended operations data collection network service is digital wireline supporting IP protocol. The planned initial data rate is 1.5 million bits per second (Mbps) using a service such as Multi-Protocol Label Switching (MPLS). Advantages of this interface include scalability, flexibility, and life-cycle cost effectiveness.

1.2.5

Local Operator Interface

For pump stations, two local operator interfaces were considered: liquid crystal display (LCD) and light emitting diode (LED). Because DPW has experienced reliability problems with the LCD displays, and the LED type displays provide an adequate operator interface, the LED type operator interface is recommended for the pump stations. The small Tesco LED operator interface requires no configuration and is well suited to use with the recommended Tesco L2000 pump station controller.

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For the WWTPs, panel-mounted, industrially-hardened, corrosion-resistant, touch-screen LCD display terminals, which can run MS Windows, are recommended. These local operator interfaces would be located at each DCS controller.

1.2.6

Collection System Control Center Recommendation

Housing the control center in an environmentally-controlled space with physical access restricted and monitored is recommended. The physical location is only limited by the requirement that the control center have reliable power and access to reliable digital data telephone service. Adding mobile laptop computer workstations to the Verizon digital wireless network is recommended to provide mobile operators with full human-machine interface (HMI) access to monitor collection system performance, investigate alarms, and make trouble response decisions. Like the pump stations, the laptops would use the Verizon private network and would not have Internet access. The same level of access would also be available any workstation on the operations data collection network where the HMI client is installed. DPW is currently using Indusoft HMI application for process monitoring and control. Continued use of Indusoft with upgrades to extend alarm messaging capabilities is recommended. As shown in the block diagram in Appendix A, redundant servers are recommended. Expanding existing alarm messaging capabilities to provide voice notification to on-duty or on-call operators and maintenance staff members is recommended. A separate historical data collection server was included at the Network Technology Group (NTG) data center in existing pump station SCADA system. Upgrading the existing server and adding a DCS workstation to collect and transport collection system historical data to the operations data/control center is recommended. The upgrades will allow the data/ control center to support the mobile laptops and to ease business network access and use.

1.2.7

WWTP Control Center Recommendation

As shown in the block diagram in Appendix A, providing separate control centers and control rooms at each of the primary WWTPs is recommended. Locating the control center in an environmentally-controlled space with physical access restricted and monitored is also recommended. Control centers will house workstation and server computers. A separate environmentally-controlled control room housing workstation operator interfaces is also recommended. Each operator interface will include a keyboard, video display, mouse and speakers connected to the workstation computer in the control center using a single Category 6 cable and a pair of Keyboard, Video Mouse (KVM) extenders. Separation of the operator interface from the workstation computer is recommended to limit access to computer media drives and communications ports. The control center and control room for each of the three WWTP should be located in close proximity to each other on the WWTP site, and in a location with reliable power and access to reliable digital data wireline telephone service. Multiple workstations and redundant servers are recommended at each WWTP control center to improve reliability and ease upgrades and patches. Providing alarm messaging

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capabilities to provide voice notification to roving operations and maintenance staff of alarms is also recommended to reduce the need for requiring personnel to be physically located in each WWTP control center. Combining treatment plant historical data collection with collection system historical data at a common Operations Data/Control Center is recommended to ease maintenance, access and use.

1.2.8

Operations Data/Control Center Recommendation

As shown in the block diagram in Appendix A, providing separate central data center with provisions for a future central control center is recommended. Locating the data center in an environmentally-controlled space with physical access restricted and monitored is also recommended. The data center will house historical database and information servers, as well as future control center workstations. A separate future environmentally-controlled central control center housing workstation operator interfaces is also recommended. Each operator interface will include a keyboard, video display, mouse and speakers connected to the workstation computer in the data center using a single Category 6 cable and a pair of KVM extenders. Separation of the operator interface from the workstation computer is recommended to limit access to computer media drives and communications ports. The control center and control room should be located in close proximity to each other, and in a location with reliable power and access to reliable digital data wireline telephone service At WWTPs, historian redundant scanners running on two of the DCS workstations are recommended to collect historical data and transport it to the historian. Adding a single DCS workstation at the collection system control center is recommended to collect and transfer collection system historical data to the historian. Currently, the DCS applications cannot support the mobile laptops recommended for the pump station monitoring and control. In the future, it may be possible to phase out the Indusoft software and use DCS applications to support the mobile laptops. However, at this time, maintaining the Indusoft servers for support of the wireless laptop is recommended. Historical data can be transferred from the historical database to the existing DPW Oracle database. The method and complexity of data transfer between the historical database and the Oracle database depends on the volume of data being transferred. There are two possible methods of transferring data: Extract, Transform and Load (ETL) tools or custom programming. Custom programming would either use either the historian’s Application Programming Interface (API) and the Microsoft ActiveX Directory Objects (MS-ADO). ETL tools can be expensive, but should be evaluated further during implementation after a decision has been reached on the volume of data to be transferred. As shown in the block diagram in Appendix A, locating the operations data/control center on a separate network with controlled access from both the DPW Business Network and the collection system and WWTP process control networks is recommended to provide practical but effective isolation between the operations network and the business network, thereby improving the availability and integrity of both the Operations Data/Control Center and the process control networks.

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1.3

Evaluation

1.3.1

Controllers

Table 1-1 shows the comparison of the eight controllers that were evaluated as part of this SCADA Master Plan. As shown in Table 1-1, three of the PLC manufacturers (Allen-Bradley, Modicon and Siemens) share a large portion of the United States PLC market, while two other manufacturers (Tesco and Emerson) have a much smaller market share. The Tesco L2000 controller is included because it is well suited for pump station applications and because it is currently being used successfully by DPW. Two Emerson controllers, the Bristol Babcock ControlWave PLC and the Ovation DCS, are also included because ControlWave PLCs are well suited as pump station controllers, and the Ovation DCS is well suited to treatment plant control. All of the controller products evaluated except for the Tesco L2000, Emerson ControlWave PLC and Emerson Ovation DCS are commercial off-the-shelf (COTS) products. The Tesco and Emerson products are only available from the manufacturer and are more sensitive to manufacturer’s decisions on pricing increases and availability limitations than the other products, due to the dependence of the entire SCADA system on these products. However, Tesco and Emerson, as well as their products being evaluated here, have been available and supported for several decades, and they both have built up loyal customer bases. There is no reason to suspect that any of that will change, so the recommendation to continue using the Tesco L2000 for pump stations and to adopt the Emerson Ovation DCS for WWTPs was not affected by the possibility of limited availability or price increases. TABLE 1-1

Controller Comparison Controller Allen-Bradley CompactLogix with PanelViewPlus 400 Operator Interface

Environmental Suitable for industrial environment 140 degrees F

Monitoring & Control Full-featured Supports 4 of the IEC61131-3 languages Modular

Communications Ethernet & Async. Serial 3rd party MODBUS modules avail. Native CIP protocol

Operator Interface

+/-

Wide selection available

High cost (-)

Can significantly increase cost

Redundancy only with ControlLogix PAC CPUs (-)

Large Market Share (+)

Separate terminal blocks (+) Not hot swappable modules (-)

Allen-Bradley ControlLogix

Suitable for industrial environment 140 degrees F

Full-featured Supports 4 of the IEC61131-3 languages Modular

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Ethernet & Async. Serial

Graphical HMI RSView

3rd party MODBUS modules avail.

Can use 3rd party HMI’s

Native CIP protocol

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High Cost (-) Large Market Share (+) Redundancy (+) Hot swappable modules (+) Separate terminal blocks (+)

CHAPTER 1. ALTERNATIVES EVALUATION AND RECOMMENDATIONS

TABLE 1-1

Controller Comparison Controller Emerson Control Wave with Maple Systems, INC graphic operator interface

Environmental Suitable for industrial environment 158 degrees F

Monitoring & Control ControlWave Designer is fully IEC 61131-3 compliant

Communications Ethernet BSAP Protocol Modbus, DFI,

Operator Interface Maple Systems 6 options, nongraphical

Suitable for industrial environment

IEC 61131-3 Compliant

Ovation Network Ethernet Modbus

50 degrees C (112 F)

Medium cost (+/-) Small market share (-) Redudancy, but CPUs in the same rack (+/-) Hot swappable modules (+)

CIP DNP3

Emerson Ovation

+/-

Separate terminal blocks (+) Proprietary Plant wide graphical interface

High cost (-) Small market share (-) Redundancy (+) Hot swappable modules (+)

DNP3

Separate terminal blocks (+) Windows or Unix based system available (+) Modicon M340 with Magelis XBTGT11 Operator Interface

Suitable for industrial environment

Full-featured

140 degrees F

Full IEC 61131-3 capability

Modular

Ethernet & Async. Serial Native MODBUS & MODBUS TCP CIP module planned

Wide selection available

Medium cost (-)

Can significantly increase cost

Only with Quantum CPUs (-)

Large market share (-)

Not hot swappable modules (-) Separate terminal blocks (+)

Modicon Quantum

Suitable for industrial environment 140 degrees F

Conforms to IEC 61131-3

Ethernet & Async. Serial

Graphical HMI Citect

Full-featured

Native MODBUS & MODBUS TCP

Can use 3rd party HMI’s

Modular

High cost (-) Large market share (+) Redundancy (+) Hot swappable modules (+)

Modbus plus

Separate terminal blocks (+) Siemens S7300

Suitable for industrial environment

Full-featured

140 degrees F

Full IEC 61131-3 capability

Modular

Wide selection available

Medium cost (+/-)

PROFINET

Graphical HMI WinCC

Redundancy only with S7-400 Series (-)

Modbus RTU function block

Can use 3rd party HMI’s

Not hot swappable modules (-)

Ethernet & Async. Serial PROFIBUS

Large market share (+)

Separate terminal blocks (+)

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TABLE 1-1

Controller Comparison Controller Tesco L2000

Environmental Suitable for industrial environment 200 degrees F

Monitoring & Control Full-featured Using IEC 61131-3 reduces capability

Communications Dual Ethernet & Async Serial Native MODBUS RTU

Operator Interface Two sizes of Tesco Operator Interface Available Nongraphical

Tailored for application

May be more cryptic

Modular

+/Medium cost (+/-) Small market share (-) Not redundant (-) Hot swappable modules (+) Separate terminal blocks (+)

Wide selection of 3rd party also available

In the case that the Tesco L2000 were to be subject to pricing increases, lack of availability, or obsolescence, the C-P can simply choose another, similar product with an Ethernet interface and acceptable HMI interface software as a replacement for future and failed units. In the case of the Ovation DCS, which is a vertically-integrated solution that encompasses the controller, operator interface, and historian functions, replacement of the entire system would be required if pricing increases, lack of availability, or obsolescence forced the C-P to select another controller for the WWTPs.

1.3.1.1

Collection System Controllers

Seven of the eight controllers listed in Table 1-1 are suitable for use as controllers at collection system pump stations. A mix of all seven suitable controllers could be used. However, to ease support, reduce spare parts, and reduce HMI application complexity, standardizing on a single manufacturer and model PLC is recommended. The Allen Bradley ControlLogix and Modicon Quantum PLCs are larger and more expensive. The greater expense is unlikely to be justified for any but the largest pump station application. Eliminating these leaves the Allend Bradley CompactLogix, Bristol Babbcock ControlWave, Modicon M340, Siemens S7-300, and Tesco L2000. Of these, all but the CompactLogix and L2000 provide full IEC 61131-3 compliance with all five programming languages. IEC 61131-3 programming languages can produce more intuitive program documentation that is easier to understand and troubleshoot. Both the CompactLogix and L2000 provide some degree of limited IEC 61131-3 support. All five PLCs can use MODBUS RTU protocol. Maintaining MODBUS RTU capability may be useful if asynchronous serial communications are used in the future. Third party modules are required to use MODBUS with the CompactLogix. Using MODBUS protocol with the L2000 does eliminate some of the communication features, such as peer communications, available with Tesco’s Data Express protocol. However, none of the eliminated features are expected to be used.

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Of the controllers considered for pump stations, CompactLogix, ControlWave, M340, and L2000, only the ControlWave and L2000 have hot swappable input and output (I/O) modules. This feature is useful because it eases repair. However, care is still required because all outputs are frozen during module replacement and all I/O on the module with a failed point will be disconnected during replacement. As stated above, continued use of the Tesco L2000 controllers is recommended at the pump stations. The advantages of using the Tesco L2000 include: •

Tesco PLCs are specifically intended for use in remote water and wastewater pump stations and for communications over unreliable communications networks. Important features include built in lightning protection; unreliable media communications features; a maximum operating temperature of 200 degrees F; an adequate, easy-to-configure operator interface; and data recovery capability.

•

DPW has standardized on the modular Tesco L2000 series of controllers for collection system pump stations.

•

Tesco’s support services can and have been leveraged by DPW to supplement their own staff and available local support, reducing the need to attract and retain additional inhouse support staff. DPW is satisfied with Tesco support received to date.

•

Tesco offers two operator interfaces that are tailored to pump station operation and support both operations and tuning functions, eliminating the need for operations and maintenance staff to use programmers or learn the programming language.

•

The disadvantages of using the Tesco L2000 include:

•

Tesco is a relatively small manufacturer with a small share of a niche market. Reliance on small niche firms is generally considered to increase business risk.

•

Having a small user-base reduces the availability of technical support services available locally, which can reduce support reliability and increase support costs.

•

Having Tesco as a single-source-of-supply eliminates the ability to easily obtain competitive pricing for comparison. However, as long as common process and communications interfaces are used, DPW could migrate to another PLC manufacturer at some point in the future, if necessary.

•

Tesco’s implementation of IEC 61131-3 programming requires a third party application, has not been used by DPW and may be difficult to implement. Tesco’s default script or instruction list programming technique is currently used, but utilizing the lists increases the time required to program and troubleshoot programs.

1.3.1.2

WWTP Controllers

Four of the eight controllers listed in Table 1-1 are suitable for use as WWTP controllers. Of those four, all but the Ovation DCS are independent controllers, or PLCs, that are suitable for use with third party HMI applications. The Ovation DCS is a complete, verticallyintegrated, system that includes the controllers, communications network protocol, the HMI and the historian application. Ovation systems are able to interface to other systems and PLCs, but they are designed to work as a complete system.

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The other three controllers suitable for use in treatment plants are the Allen Bradley ControlLogix, Modicon Quantum, and Siemens S7-300 PLCs. Though not recommended, a mix of all three of these controllers could be used in a single plant supported by a single HMI application. However, to ease support, reduce spare parts, and reduce Human Machine Interface (HMI) application complexity, standardizing on a single manufacturer and model PLC is recommended. All but the ControlLogix provide full IEC 61131-3 compliance with all 5 programming languages. IEC 61131-3 programming languages can produce more intuitive program documentation that is easier to understand and troubleshoot. ControlLogix provides limited IEC 61131-3 support. As stated above, the Emerson Ovation DCS is recommended for use as the WWTP controller. Using the Emerson Ovation DCS has the following advantages: •

Having a system composed of products from a single manufacturer will simplify trouble shooting, modifications, and upgrades by eliminating the need to coordinate among a number of manufacturers.

•

DCSs provide a high level of redundancy that significantly improves reliability. This level of redundancy is not easily implemented with PLC based systems.

•

A common spare parts warehouse can be used for all three treatment plants and the number of spare parts required is reduced because all three plants use the same DCS.

•

LAN configurations are based on the DCS manufacturer standards reducing the need for local network configuration experts.

•

DCS controller configurations are generally more intuitive and straight forward than PLC configurations. Also, DCS configuration trouble shooting and modification by others than the original configuration author is usually easier than it is for PLC configurations.

The disadvantages of this approach include: •

The request for proposal (RFP) process required to select a DCS supplier complicates the Design-Bid-Construct delivery process that is normally utilized by the C-P.

•

DCSs are not as widely used in treatment plants as PLCs, which will limit the availability of local support alternatives.

•

DCSs and most DCS repair parts are only available from the DCS manufacturer and are subject to the manufacturer’s decisions on pricing and availability.

1.3.2

Collection System Communications Evaluation

All of the nine alternatives listed in Table 1-2 are capable of using the recommended collection system pump station interface and satisfying pump station requirements. However, the two fiber and the digital wireline alternatives are not considered further in this evaluation because they are not likely to be cost effective over the life cycle of the equipment, leaving the five wireless alternatives as well as analog wireline.

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One major consideration in selecting a communications alternative for distributed facilities is deciding who will own the communications infrastructure. C-P-owned (private) alternatives tend to berequire longer to deploy, have higher capital costs, and have lower recurring costs, though each alternative must be evaluated on its own merits. The opposite is true for provider-owned alternatives, which offer a pay-as-you-go model, allowing them to be quickly deployed or expanded for relatively low capital cost budgets. However, the monthly service fees (not normally required for private networks) are a recurring cost that must be paid monthly for as long as the service is used. If the C-P owns the network, it also has better control over all aspects of the communication network, which can improve service and reliability. However, being in control is a doubleedged sword because the owner is responsible for all support, maintenance, upgrade, repair, and disaster recovery. Permitting can also delay deployment and increase the costs for C-P-owned alternatives. Private point-to-multi-point radio, either licensed or unlicensed, may be life-cycle cost effective for some portion of the pump station network. However, private radio networks providing adequate performance and reliability are not expected to be life-cycle cost effective for large portions of the pump station network. Selection of a frequency, radio path measurements and analysis, as well as preparations of a cost estimate, would be required to better evaluate this alternative. The C-P public safety mobile radio network is being upgraded. The upgraded network may be able to provide life-cycle cost effective communications for some pump stations once it becomes available. However, historical issues with latency and availability during civil emergencies would need to be evaluated before widespread use could be recommended. TABLE 1-2

Communication Alternatives Comparison Alternative Private Point-toMulti-point Radio (Licensed or Unlicensed)

Owner City or DPW

Cost

Hurdles

+/-

Capital - High

Permitting

In control of own destiny (+)

Annual - Low

Licensing

Low to medium data rate (-)

Line-of-Site

Link reliability (-) Disaster recovery (-) Scalability issues (-)

City Radio Network

City

Digital Cellular

Provider

Information not available at this time.

Permitting

Capital - Low

Provider coordination

Good scalability (+)

Annual - Medium

Latency

Low to medium data rate (+)

Moving target

Disaster recovery probably better than private (+)

Line-of-Site

Evolving technology

Information not available at this time.

No SLA (-)

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TABLE 1-2

Communication Alternatives Comparison Alternative WLAN 802.11n/s

Owner City, DPW or Provider

Cost

Hurdles

City/DPW owns:

City/DPW owns:

Good scalability (+)

Capital – High

Permitting

Medium to high data rate (+)

Annual – Low

Network design

SLA if Provider owned (+)

Provider owns:

Provider owns:

Capital – Low

Same as for Digital Cellular

Disaster recovery depend on implementation (+/-)

Annual – High WiMAX 802.16e

Provider

Capital – Low Annual – High

Dark Fiber

City, DPW or Provider

+/-

City/DPW owns: Capital – V High

Same as for Digital Cellular

Probably Same as for Digital Cellular

City owns: Right-ofway

Good Scalability (+)

Provider owns: Coordination

Annual – Low

High data rate (+) Good reliability (+)

Provider owns: Capital – Low Annual – High Other Fiber

Shared with other public agencies or provider

Capital - Low Annual - Variable

Coordination with users or provider Throughput Privacy

Digital Wireline

Provider

High data rate (+) Good reliability (+) Depends on owner, SLA, maintenance level, and degree of over subscription (+/-)

Capital - Low

Provider coordination

Good scalability (+)

Annual - High

Moving target

Medium to high data rate (+)

Evolving technology

Disaster recovery (+) No SLA for DSL (-)

Analog Wireline

Provider

Capital - Low

May not be available

Low data rate (-)

Annual - Low

Dated technology

Reliability (-) Scalability (-)

The analog wireline alternative, though once common, is no longer considered viable because of reliability and support limitations. Neither Wireless Mobile Access (WiMAX) nor Wireless Local Area Network (WLAN) is yet available for pump stations. As either WiMAX or WLAN become available, they should be considered as expansion and migration alternatives. Therefore, improvement, expansion, and assuming ownership of the existing Verizon digital cellular communication network is recommended. Digital cellular is becoming more reliable, and technology improvements are improving telemetry performance. Also, digital cellular coverage is expected to be sufficient to provide coverage on most, if not all pump stations. Assuming ownership of the Verizon network service contract will ease obtaining the benefits of state government rates.

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As stated above, recommended improvements include conversion to a Fixed-End Service (FES), Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology, and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. Conversion to FES will move the pump station communications network off the Internet and maintain it on Verizon’s private network. This will drastically reduce the potential downside effects of the Internet thereby improving reliability and reducing malicious traffic. Additionally, replacing existing antennas with higher gain antennas and, when required, adding antenna amplifiers is recommended. Choosing replacement antennas inside the pump station that maximize the received signal strength (RSS) is also recommended. Conversion to CDMA/FDD should improve reliability, especially during conditions (such as storms) that might reduce signal levels. CDMA/FDD also offers drastically higher channel capacity when compared to the current CDMA technology that it replaces. The higher channel capacity is not expected to improve pump station communications performance. Antenna replacement and relocation should also improve signal levels.

1.3.3

WWTP Communication Evaluation

For the WWTPs, the redundant star topology is the only communications alternative supported by the selected DCS. Although it is somewhat dated, advantages of this interface include scalability and reliability. Scalability will allow the network to grow as required to accommodate plant expansions and upgrades. The redundant switches and media employed in this network will improve reliability by continuing to operate after failure of any single communications network component. The only other topology considered was a fiber optic Fast or Gigabit Ethernet loop at each plant. There may also be plant applications where a wireless LAN (WLAN) alternative is adequate and cost effective. However, reliability, capacity and security issues will need to be addressed on a case-by-case basis.

1.3.4

Operations Data Network Communication Evaluation

Five alternatives (WLAN, WiMAX, Dark Fiber, Other Fiber and Digital Wireline) compared in Table 1-2 are all capable satisfying data collection network requirements. Of these, only the digital wireline alternative is currently available. Evaluating other alternatives as they become available is recommended. When an available alternative is found to be superior to digital wireline, migration to that alternative can begin.

1.3.5

Local Operator Interface Evaluation

Available operator interfaces generally fall into two categories. The most basic operator interfaces provide one or more lines of LED display and a keyboard for selecting variables and keys for modifying adjustable parameters. The other type of operator interface has a graphic Liquid Crystal Display (LCD) and either a keyboard or a touch-screen interface. The LCD display types are more flexible, provide a more comprehensive interface and have more complex configurations. The LED types are less flexible, less comprehensive, and require less complex configurations.

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As stated above, the LED type of operator interface is recommended for the pump stations, while the LCD type (with a touch-screen display) is recommended for the WWTPs. For WWTPs, care must be taken to select a location and display terminal that will provide good display visibility when installed in areas with high ambient light levels, and acceptable service life. Locating the local operator interfaces in the doors of the DCS controller cabinets is expected to provide an acceptable environment and good visibility.

1.3.6

Collection System Control Center Evaluation

The control center commissioned in the existing pump station SCADA system is located at the NTG Tier IV data center in Baton Rouge. Tier IV data centers offer 99.995% reliability. The control center could be maintained at the NTG facility or relocated to a DPW facility. Relocation is likely to significantly reduce reliability; but is likely to ease access and eliminate recurring data center costs. As stated above, relocating the control center to a DPW facility is recommended. The InduSoft HMI application also added in the existing SCADA system has a very small market share when compared to major competitors, such as GE Intellution iFix, Invensys Wonderware Intouch, Citech and Rockwell RSViews. Also, CH2M HILL does not have any direct experience with InduSoft. However, InduSoft capabilities have been reviewed and water and wastewater users found have been interviewed. No significant technical shortcomings were found with InduSoft. Therefore, the continued use of InduSoft is recommended. •

Enhancing alarm messaging capabilities will reduce the time that operators must spend in front of a computer. Some alarm messaging is provided by the existing collection system HMI servers. However, third-party products are available that work with most major HMI applications that enhance alarm messaging as follows:

•

Alarm voice and text messaging for selected critical alarms to field staff.

•

A flexible central interface for assigning alarm groups to specific field staff personnel depending on staff’s current location and assignment.

•

A flexible communication interface that can be reconfigured to use the best available delivery alternative.

Replacement of the InduSoft HMI application with a DCS workstation was also evaluated. However, current products available with the recommended DCS do not effectively support the mobile laptops needed by the collection system operations and maintenance staff, so it is recommended to continue to use the InduSoft HMI application at this time. A separate historical data collection server was included at the NTG data center in the existing SCADA system. Upgrading the existing server to bring it up to current product versions will support mobile laptop graphic displays and historical data access. Adding a DCS workstation to collect and transport collection system historical data to a common data center will provide comprehensive historical data access for operations and maintenance staff as well as planning and engineering staff..

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1.3.7

WWTP Control Center Evaluation

Locating workstation computers in each WWTP control center along with the servers will limit access to media drives and communications ports, thereby reducing the opportunity to mis-use the DCS servers and workstations. The workstations can be connected to keyboards, video displays, mice and speakers several hundred feet away by a single cable using KVM extenders. Alarm messaging capabilities reduce the need for an operator to be in front of a computer. Third-party products such as Win911 are supported by Ovation and provide for alarm messaging as follows: •

Alarm text and voice messaging for selected critical alarms to roving or on-call operators.

•

A flexible central interface for assigning alarm groups to specific field staff personnel depending on staff’s current location and assignment.

•

A flexible communication interface that can be reconfigured to use the best available delivery alternative.

1.3.7.1

Operations Data/Control Center Evaluation

There are two options for collecting and transferring collection system data from the InduSoft servers (for the collection system SCADA) to the historical database. One option is to use the InduSoft server to provide an interface to the DCS client on the Engineering workstation at the Collection System Control Center. A historian scanner running on the workstation would collect historical data and transport it to the Ovation historian. The other option is to interface the Engineering workstation communications in parallel with Indusoft HMI and with the PLC using MODBUS protocol. A disadvantage to the second option is the doubling of wireless network traffic. Also, the recommended DCS doesn’t currently have a workstation application that is well suited for deployment on the digital cellular network since the currently available browser product doesn’t support alarm handling. However, in the future it may be possible to phase out the Indusoft servers and to support the mobile laptops on the Digital Cellular Network via the DCS servers. While the current recommendation is for Indusoft to be maintained, the recommendation should be reevaluated as technology advances and the cost of bandwidth becomes more cost effective. As stated above, it is recommended that the operations data/control center be located on a separate network with controlled access from both the DPW Business Network and the collection system and WWTP process control networks to provide isolation between the networks This separation allows for future centralized control at the operations data/control center, while also protecting the collection system and WWTP networks from possible mis-use via the Business Network.

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CHAPTER 2

Implementation Plan 2.1 Introduction The implementation plan describes how the SCADA system will be designed, delivered, and supported. The plan is broken down into two modules, collection system and WWTPs, because the two are expected to be implemented separately.

2.2 Recommendations CH2M HILL recommends using an RFP process to provide selection of a single qualified collection system SCADA provider and a WWTP SCADA provider for 5 years. This will allow the C-P to select the most qualified provider and include needed maintenance, support and future collection system or WWTP work in a single contract, thereby assuring critical component and overall design consistency across all pump stations or WWTPs for 5 years. After 5 years, the contract of the selected Contractor can be renewed for another 5 years, or another RFP can be used to select a provider for ongoing support and upgrade of the existing collection system or WWTP SCADA system, and for any additions to the SCADA system. Long-term SCADA support is critical to its success. Therefore, recommended design and delivery approaches are structured to facilitate long-term support. In addition to maintaining, and providing routine preventive maintenance and software update installation, support is intended to include upgrade and migration to maintain a viable SCADA as technology continues to rapidly evolve. Table 2-1 shows some typical cost considerations for SCADA components. TABLE 2-1

SCADA Life-Cycle Cost Considerations Component

Annual Costs

Computers (Workstations and Servers)

Replacement Every 3 Years

Network Appliances

Replacement Every 5 Years

DCS Controllers, PLCs and RTUs

Replacement Every 10 Years

Software

15-20% Per Year + Periodic New Releases

Control System Support

5-15% Per Year

Telco Services

12 x Monthly Bill + Services Outside SLA

Procurement of critical components is another important element of the plan. Critical components are defined as those that, if not consistent from site-to-site and from project-to-

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project, will significantly and negatively impact DPW’s ability to maintain the SCADA longterm. Therefore, the delivery of critical components is separately addressed for each of the two major SCADA systems: collection system and WWTPs.

2.3 Design Criteria SCADA Design Criteria addressing pump stations and plants are included in Appendixes C through H for use in preparation and review of RFPs, design instructions, and/or documents. Before each use, update Design Criteria as required to keep current, incorporate missing elements, and make corrections.

2.4 Standard Pump Station Design Documents The purpose of the standard pump station design documents is to provide pump station design guidance for developers for a range of pump stations expected to be included in development projects. For development projects likely to have pump stations not addressed by the standard pump station design documents, include a current version of the Design Criteria document and specific design instructions for the nonstandard pump stations. In general, the standard pump station design documents should be updated to bring them into compliance with the Design Criteria in the appendices. The existing standard pump station drawings should be updated to create standard control system drawings for each type of pump station likely to be included in developer projects. Also, the existing standard pump station specifications should be updated to create standard control system specifications for each type of pump station included in developer projects.

2.5 Procurement As stated above, an RFP process is recommended for procurement (including design, installation, and maintenance) of the collection system SCADA and the WWTP SCADA components. Two separate RFPs will be written for each system, since the systems can be implemented separately.

2.5.1 Collection System Request for Proposals Content Inclusion of the following design instructions in the collection system RFP is recommended: 1. A narrative describing the work and expected delivery schedule. In the narrative, include a SCADA overview including monitoring and control requirements, network communications and communications interfaces. Use references to included design criteria and standard design documents to clarify requirements and reduce duplication. 2. Scope of Work. 3. Project schedule 4. SCADA Block Diagram 5. Pump Station Design Criteria

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6. Pump Station Standard input/output (I/O) list 7. Standard Loop Specifications 8. When applicable, standard pump station SCADA design documents for the standard pump station(s) with monitoring and control system(s) that most closely resembles the monitoring and control system(s) for the pump station(s) that will be designed along with narrative describing required deviations from the standard documents, if any.

2.5.2 Collection System RFP Scope of Work Provide a comprehensive summary of the scope of work including: 1. List all tasks to be performed by the provider. Clearly define important deliverables and sequencing requirements. Also, include coordination requirements, a list of communications service provider and utility contacts and ample references to the design criteria. 2. Define programmable logic controller (PLC) and human machine interface application programming requirements, including instructions on how to use the Standard Loop Specifications. 3. Define coordination requirements for any other work expected to be in progress during construction 4. Define pump station outage restrictions and coordination requirements 5. Define support requirements

2.5.3 WWTP Request for Proposals Content Inclusion of the following in design instructions in the WWTP RFP is recommended: 1. A narrative describing the work and expected delivery schedule. In the narrative, include a SCADA overview including monitoring and control requirements, network communications and communications interfaces. Use references to included design criteria and standard design documents to clarify requirements and reduce duplication. 2. Scope of Work 3. Project schedule 4. SCADA Block Diagram 5. WWTP Design Criteria 6. WWTP Standard input/output (I/O) list 7. Standard Loop Specifications

2.5.4 WWTP RFP Scope of Work Provide a comprehensive summary of the scope of work including:

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1. List all tasks to be performed by the provider. Clearly define important deliverables and sequencing requirements. Also, include coordination requirements, a list of communications service provider and utility contacts and ample references to the design criteria. 2. Define distributed control system (DCS) controller, workstation and server application programming requirements, including instructions on how to use the Standard Loop Specifications 3. Define coordination requirements for any other work expected to be in progress during construction 4. Define equipment outage restrictions and coordination requirements 5. Define support requirements

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Appendix A Block Diagrams

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Appendix B Design Criteria

1.0 Introduction and Overview 1.1

Purpose

The purpose of this technical memorandum is to define City of Baton Rouge-East Baton Rouge Parish (C-P) Department of Public Works (DPW) Supervisory Control and Data Acquisition System (SCADA). Major SCADA components covered by this document include: • • • • • • •

Collection Pump Stations. Wastewater Treatment Plants (WWTPs). The Collection System Control Center. WWTP Control Centers. The DPW Operations Data Center. The DPW Operations Network. The Collection System wireless communications network.

Criteria provided include the following: • • • • • • • • • • • • • • • • •

1.2

SCADA Background and Overview. Terminology and acronym definitions. Standards and codes list. Physical design criteria. Network and other communications requirements. Functional requirements. Applications programming requirements. Documentation requirements. Testing requirements. Support requirements. Pump station specific criteria. WWTP specific criteria. Collection Control Center specific criteria. WWTP Control Center specific criteria. Operations Data Center specific criteria. Operations Network specific criteria. Collection wireless network specific criteria.

Background & Overview

The SCADA system project for the C-P DPW will upgrade the existing wastewater collection pump station SCADA system and replace the SCADA systems at the three major WWTPs. The following is a list of the major SCADA system goals and the basis for the design: •

Increase Operational Reliability of Collection and Treatment: Collection system SCADA improvements are expected to reduce the chances of pump station spillage and overflow. Treatment plant SCADA improvements are expected to improve treatment performance and effluent quality.

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•

Ease of Access: Managers and engineers will have easy access to real-time and historical data including regulatory reporting, management oversight, collection system and treatment capacity and quality analysis and improvements planning.

•

Improve Collection System and Treatment Facility Planning: Existing SCADA systems have limited data archiving ability. The upgraded SCADA systems will provide more, easily accessible and organized data to support planning efforts. The improved data archives can be used by DPW to improve collection and treatment systems understanding thereby allowing DPW to make better informed decisions regarding upgrading and expanding the water and wastewater systems.

•

Reduce Operating Costs: Once Pump Station and WWTP staffs have gained confidence in the upgraded SCADA systems, labor savings will occur because of improved plant operations efficiencies and a reduction of the number of visits to each pump station.

•

Support Facilities Information Management (FIM) Tasks: The upgraded SCADA systems will provide information in a format that is easily transferred to maintenance management or asset management software. As an example, the elapsed run time of process equipment can be downloaded from the SCADA system to a FIM system. These data can be used by the FIM system for scheduling maintenance activities.

•

Network Isolation: Isolating the Operations Data Center on a separate network with controlled access from both the Business and Operations Networks provides isolation and protection of the Operations Network and the four control center networks thereby improving the availability and integrity of both the Operations Data Center and Process Control Networks.

The following additional general design criteria have been established for design and construction of the SCADA systems: •

Routine Maintenance Requirements: The SCADA systems must be capable of being maintained on a day-to-day basis by DPW staff. Day-to-day activities are not expected to include any applications programming or system configuration work. Someone with a working knowledge of computer operating systems, computer networks and the applications being used will be required to periodically [probably monthly] review security, event and activity logs, and perform maintenance. Also, periodic [probably quarterly] maintenance by someone with detailed knowledge of SCADA applications and computer operating systems will be required to install software upgrades and patches, to review system logs, to groom files, and perform other system-level activities.

•

Additional Staff Needs: Either training of existing staff members or adding staff will be required to perform the day-to-day duties listed above and other SCADA System O&M activities. SCADA system designers are expected to work with DPW to be identify specific skill requirements during design. The monthly and quarterly maintenance activities are expected to be provided as part of a renewable annual service agreement.

•

Training Requirements: Training requirements, including course identification and training source, are expected to be identified during design.

•

Application Programming Templates: SCADA system designs are expected to include templates to ease the amount of custom programming required to add pump stations or common plant equipment such as pump stations.

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•

Environmental Design Provisions: Equipment, such as RTUs and panels, are expected to be located to reduce environmental impacts and hazards; and designed to withstand environmental conditions and mitigate hazards present.

•

Communications Reliability: Reliable wireless and network communications, as well as ample, easy to access and use communications diagnostics including statistics are required, as is the ability to effectively continue operation during temporary communications failures. Design wireless communications links to work reliably during abnormal weather conditions such as heavy rain, high wind and temperature inversion.

•

User Access Tailored to Job Responsibilities. Tailor each users access to job responsibilities. Work with DPW to determine user access requirements. Managers will generally have broad view only access. Supervisors are expected to have monitoring, control and preset parameter adjustment access for areas they are responsible for and view only access to associated areas. Operators will generally have monitoring and control Maintenance workers will have access tailored to their needs and responsibilities including the ability to modify configurations and applications programming.

•

Network Security Provisions: Reasonable network and communications security controls in compliance with the current version of the National Institute of Standards and Technology (NIST) Special Publication (SP) 800-82 are required. Security controls include, but are not limited to, access control, intrusion detection and virus protection.

•

Modular Design, Common Components for All Sites: Use the same manufacturer and model number components for all similar applications.

•

Alarm Segregation, Categorization, Prioritization and Conditioning: Segregate [i.e. Collection/Treatment], categorize and prioritize alarms. Alarms will be conditioned to eliminate nuisance and all but critical unavoidable alarms. For example: Pump station alarms, except for LOW BATTERY, INTRUSION and HIGH HIGH LEVEL will be disabled during pump station power outages. Develop specific alarm conditioning rules during design and finalize them during construction. Route some alarms [i.e. pump station pump fail] directly to maintenance personnel with operations receiving a followup alarm if the original alarm is not acknowledged within a preset interval. Prevent communications failure alarms from being repeated each time the failed link is accessed.

•

Physical Security: Work with DPW to establish physical security requirements for pump stations and plants. For control centers and data centers, locate all computers [servers and workstations] in locked adequately air conditioned rooms with reliable conditioned electric power. Limit access to those responsible for the maintenance of the control centers. Use Keyboard, Video Mouse (KVM) extenders to support a keyboard, dual monitors, a mouse, and dual speakers in the control room for each workstation.

1.3

SCADA System Overview

The simplified SCADA block diagram in Appendix A shows an overview of the complete SCADA system. Major elements include the following: •

DPW Business Network: This is an existing network used by DPW for management, administration, and general purpose computing and is expected to include an existing interface through an Internet Service Provider (ISP) to the Internet. Users on this

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network including managers, planners and engineers need access to SCADA data to fulfill their responsibilities. Interface the business network to the SCADA system as follows: 1. Connect the business network to the firewall in the DPW Operations Data Center. 2. Except for virtual private network (VPN) traffic, limit business network traffic to the DPW Operations Data Center located on demilitarized zone (DMZ) network established by the Firewall connecting the Business Network, the DPW Operations Data Center and the DPW Operations Network. 3. Other than VPN traffic block all traffic between the business network and the DPW Operations Network. Provide SCADA historian and information server clients on business network workstations requiring access to SCADA data. Provide VPN clients on business network workstations that will be used for direct connection to the SCADA system. Authenticate VPN users on the SCADA network. •

Operations Data Center: On the DMZ network established by the firewall, provide an Operations Data Center for central collection, storage and processing of near real-time and historical operations data from wastewater treatment plants and pump station collection systems, and for presenting up-to-date process information to users on the business network. Locate the Operations Data Center in a physically secure location with access limited to those responsible for operation and maintenance of the data center. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Also, provide uninterruptible power supply (UPS) capacity for maintaining control center operation for one hour. Locate the following SCADA system components in the Operations Data Center: 1. The historian servers which collect information from scanners installed on operator workstations in each of the three control centers, store the information, and retrieve and reduce information for presentation to operators at operator workstations and to business network users via historian clients installed on business network computers. On historian servers, also provide applications programming to reliably and efficiently extract selected historical information and load the historical information into C-P’s Oracle relational database. 2. Information servers which collect up-to-date process information from each of the four control centers for presentation to operators at operator workstations and to business network users via information server clients installed on business network computers.

•

The DPW Operations Network: Establish an Operations Network for interconnecting the four control centers and the Operation Data Center. Provide a network that allows adequately credentialed users connected to any of the four process control networks full monitoring and control access to all four control systems, and that supports VPN access to users connected to the business network.

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Use wireline services, such as Multi-Protocol-Label-Switching (MPLS), provided by telephone companies with a minimum of 1.5 million bits per second (Mbps) symmetric capacity for each connection. Work with C-P in selecting the service and establishing a Service Level Agreement (SLA). Coordinate this work with the digital cellular network required for the collection system to both ease service management by C-P and take advantage of any available price reductions that might be available when both networks are provided by a single provider. •

The WWTP Distributed Control Systems: Provide an autonomous, self-sufficient Distributed Control System (DCS) for each of the three major WWTPs. Each DCS includes the following: 1. Control Center housing DCS servers and workstations. Use KVM extenders to support operator workstation interfaces in the control rooms. Locate the control centers in a physically secure location with access limited to those responsible for operation and maintenance of the control center. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Because, plants do not have standby electric generators, provide UPS capacity for maintaining control center operation for one hour. 2. Control Rooms. Locate the keyboard, monitor, mouse and speakers for each workstation in a plant operations control room. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Because, plants do not have standby electric generators, provide uninterruptible power supply (UPS) capacity for maintaining control room operation for one hour. 3. DCS Redundant Controllers. Distribute controllers throughout the plant in temperature and humidity controlled electrical rooms Because, plants do not have standby electric generators, provide UPS capacity for maintaining controller operation for one hour. Select controller locations to provide a balance between installed cost and signal wire length. Where necessary to control installed costs, use remote input and output (I/O) for monitoring and control of systems with less critical monitoring and control requirements. Use the WWTP Design Criteria and WWTP I/O spreadsheet in appendices E and G in selecting signals for monitoring and control. 4. Redundant, Star Ethernet Network. Provide a redundant star network in accordance with DCS manufacturer standards. Locate redundant root switches in data and control centers. Locate redundant primary fan-out switches as needed in data and control centers, and controller cabinets.

•

The Collection Control Systems: Provide a collection control system that provides local, autonomous, programmable logic controller (PLC) monitoring and control of each pump station, as well as remote monitoring and limited remote control from mobile wireless laptop workstations connected to the central Collection System Control Center. The Collection Control System includes the following: 1. Local PLC Monitoring and Control. Local control panels housing a PLC and local human machine interface (HMI) with text and bar-graph displays and four-key menu-driven keypad data entry. Use the Pump Station Design Criteria and I/O spreadsheet in appendices D and F in selecting signals for monitoring and control.

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Also, comply with applicable portions of the DPW Pump Station Design Standards. Include battery backup power capable of maintaining the PLC and the communications interface in operation for 4-hours. 2. A Control Center housing HMI Servers and a DCS workstation. Relocate the existing control center from the Tier IV data center to a physically secure location with access limited to those responsible for operation and maintenance of the control center. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Configure the DCS workstation to use the existing HMI server’s object linking and embedding for process control (OPC) interface to connect to the active HMI server and provide Collection System monitoring and control from the distributed DCS system, as well as Collection System historical data collection. Also, provide UPS capacity for maintaining control center operation for one hour. 3. Mobile Wireless Laptop Workstations. Provide hardened mobile wireless workstations for use by mobile operators and maintenance staff. 4. Digital Cellular Network. Convert the existing 1xRTT (1 times Radio Transmission Technology) digital cellular network to CDMA-FDD (Code Division Multiple Access with Frequency Division Duplex). Also, add a fixed end service (FES) at the control center to moved the network off the Internet and onto the providers private network.

1.4

Terminology

Terminology and acronyms used in this Technical Memorandum are shown in Table 1-1. TABLE 1-1 Terminology And Acronyms Term Or Acronym

Meaning

ADO

ActiveX Data Objects

API

Applications Programming Interface

APPLICATION SOFTWARE

Software to provide functions unique to this project and that are not provided by standard software alone. Configuring data bases, tables, displays, reports, parameter lists, ladder logic, and control strategies required to implement functions unique to this project

City

City of Baton Rouge, Louisiana

CMMS

Computerized Maintenance Management System

C-P

City of Baton Rouge-East Baton Rouge Parish

DCS

Distributed Control System

DMARC

The point of demarcation for Verizon. It is the interface point where all facilities on one side are maintained by the Verizon and all facilities on the other are maintained by the City.

DMZ

Demilitarized Zone

DPW

City of Baton Rouge Department of Public Works

FES

Fixed End Service

FIM

Facilities Information Management

HMI

Human Machine Interface

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TABLE 1-1 Terminology And Acronyms Term Or Acronym

Meaning

I/O

Input/Output

IP

Internet Protocol

ISP

Internet Service Provider

KVM

Keyboard, Video, Mouse

LAN

Local Area Network

Mbps

Million bits per second

MPLS

Multi-Protocol Label Switching

OPC

Object Linking and Embedding for Process Control

ORT

Operational Readiness Test

OWS

Operator Workstation

PAT

Performance Acceptance Test

PLC

Programmable Logic Controller

PICS

Process Instrumentation and Control Systems

PROCESS MONITORING AND CONTROL SOFTWARE

Standard software packages, independent of the specific process control project on which they are used, which provide process monitoring, control and data collection capability.

RTU

Remote Terminal Unit

SCADA

Supervisory Control and Data Acquisition System-generally used in reference to system wide control and data acquisition system

SDT

Staging Site Demonstration Test

SERVER

Computer specifically designed for remote terminal operation and processing high volumes of I/O and simultaneous operations

SLA

Service Level Agreement

STANDARD SOFTWARE

Commercial Software packages that are independent of the project on which they are used. Standard software includes system software and process monitoring and control software.

SYSTEM SOFTWARE

Application independent software developed by digital equipment manufacturers and software companies. Includes but is not limited to operating systems, programming languages such as C++, assemblers, file management utilities, text editors, debugging aides and diagnostics.

TELEMETRY

Communication between central servers and remote facilities; includes such communication modes as frame relay, dedicated fiber optic or copper cable, UHF and spread spectrum radio, leased telephone line, autodialers, etc.

UPS

Uninterruptible Power Supply

VERIZON

Telephone company providing telephone services including plain old telephone, cellular, frame relay, Cellular Digital Packet Data [CDPD] or other telephone services.

VPN

Virtual Private Network

WORKSTATION

High-end personal computer for use by an operator in monitoring and controlling remote facilities.

WWTP

Wastewater Treatment Plant

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1.5

Standards and Codes

The following organizations have generated standards that are to be used as guides in assuring quality and reliability of components and systems; govern nomenclature; define parameters of configuration and construction in addition to specific details outlined in this document. •

ISA, Instrumentation, Systems and Automation Society

•

UL, Underwriters Laboratories

•

AWWA, American Water Works Association

•

NEMA, National Electrical Manufactures Association

•

OSHA, Occupational Safety and Health Administration

•

ANSI, American National Standards Institute

•

NFPA, National Fire Protection Association

•

NIST, National Institute of Standards and Technology

•

SAMA, Scientific Apparatus Manufacturers Association

•

IEEE, Institute of Electrical and Electronic Engineers

•

NEC, National Electrical Code(ANSI/NFPA-70)

•

API, American Petroleum Institute RP550 Manual on Installation of Refinery Instruments and Control Systems (API RP550)

2.0 Physical Design Criteria 2.1

Introduction & Overview

This section defines general SCADA system physical design criteria.

2.2

Control Strategy & Naming Conventions

CONTROL STRATEGY Specific control strategies will be described in the Appendix H, Standard Loop Specifications. TAGS A shorthand tag number notation is used in the Loop Specifications. S

10

AFD

05

01

SF

Facility Code

Unit Process

ISA designation of process and function

Loop Number

Unit Number

Clarifying Abbreviation

Use the clarifying abbreviation to assure that all tags are unique. Use only the underscore character (_) as a separator to improve “human readability.”

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An example of an AFD tag would be: S_10_AFD_0501_SF FACILITY CODES N

North WWTP

S

South WWTP

C

Central WWTP

XXX

Pump Station Facility Number

UNIT PROCESSES For wastewater treatment plants, use the following unit processes in the tagging convention: 10

Preliminary Treatment

20

Primary Treatment

30

Chlorination and Trickling Filter

40

Final Settling Tanks and Secondary Sludge Pump Station

50

Plant Water and Effluent Pumping

60

Gravity Thickeners and Thickened Sludge Pump Stations

70

Anaerobic Digesters and Control Building

80

Energy Recovery and Sludge Dewatering Building and Support Systems

90

Miscellaneous

2.3

General System Requirements

2.3.1

City Product Standards

LATER. Any City product standards will be adhered to.

2.3.2

Single Point of Failure

In general, single points of failure are to be avoided. This does not mean that all control and equipment has to be duplicated, but there are specific components for which redundancy is required for safety or continued operation. Redundancy is required for the following components: • • • • • • • •

HMI I/O Servers. DCS Operator Workstations. DCS controllers. DCS historical data scanners installed on operator workstations. DCS authentication servers. DCS Historian Servers. Switches at each tier in the WWTP star LANs. DCS LAN media and network connections.

Components for which redundancy is not required include the following: •

DCS data servers.

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• • • •

PLCs and RTUs DCS I/O modules. Digital cellular communications links Instruments.

2.3.3

Color Coding of Pilot Devices

Unless noted otherwise, use the following color code for lenses of indicating lights.

2.3.4

Function

Color

On or Open

Red

Off or Closed

Green

Alarms

Amber

Automatic or Remote

White

Manual or Local

Blue

Nameplates

All individual panels, instruments, and panel mounted devices shall be provided with nameplates. Use plastic laminate nameplates having black letters on a white background. Individual control switches and pushbuttons shall have customized legend plates which indicate function.

2.3.5

Accessibility and Mounting

All control equipment shall be mounted in an easily accessible location. Equipment or piping shall not have to be removed to access controls. All controls shall be mounted within five feet of finished floor. All NEC clearance requirements shall be met for the appropriate voltage level. All equipment and instrument tubing shall be rigidly installed. It is intended that after installation a slight to moderate pressure on the installed device shall not move it and in no circumstance should it sway back and forth if pressure is suddenly removed.

2.4

Field Mounted Instrumentation

2.4.1

General

Provide instruments that return automatically and immediately to accurate measurement upon restoration of power after a power failure, except where specifically noted. Use single source manufacturer for each instrument type. Use the same manufacturer for different instrument types whenever possible. Provide instrumentation of rugged construction designed for site conditions. Provide only new, standard, first-grade materials throughout, conforming to standards established by Underwriter’s Laboratories (UL), Inc., and so marked or labeled, together with manufacturer’s brand or trademark.

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Instrument enclosures shall be NEMA rated for the environment. In hazardous areas, meet the NEC Class, Group, and Division as shown or specified. Submergence rated enclosures shall be provided in areas subject to flooding. Provide instrument transmitters that produce isolated 4-20 mA dc analog signals. Follow ISA-S50.1. Use linear, direct reading indicators unless otherwise specified. Analyzers must be removable from the process lines without disrupting the process.

2.4.2

Installation

Unless readily accessible for viewing and calibration from floor elevation, do not install electrical transmitters process piping. Mount equipment on instrument racks, stands or in enclosures near the sensor at a level that permits viewing from floor elevation. Install instrumentation and auxiliary devices to be accessible for maintenance. Provide space between instruments, equipment, and piping for ease of removal and servicing. Include panel layouts to include ergonomic factors associated with maintaining the equipment. In general, install instrumentation to be accessible from floor level or grade.

2.4.3

Maintenance and Troubleshooting

The continued, useful operation of a control system depends on effective maintenance and calibration. The availability of complete system documentation and the installation of proper test connections greatly assist in maintenance and calibration. During the design of the I&C system, every effort must be made to make the system as easy to maintain and troubleshoot as possible.

2.4.4 Pressure Measurement Pressure and Differential Pressure Transmitter Diaphragm type pressure transmitters will be used for gauge, differential pressure and absolute pressure measurement applications. Rosemount “Smart” pressure transmitters will be used.

Pressure Gauges For pressure gauges, solid-front, glycerin-filled units will be used. For most pressure ranges, Bourdon-tube elements will be used. Diaphragm or bellows type elements will be used for low pressure ranges. Dial size is to be 4 1/2 inches minimum. Accuracy shall be two percent of span. Scale range shall be such that normal operating pressure lies between 50 and 80 percent of scale range. Dresser/Ashcroft and Ametek U.S. Gauge are the preferred manufacturers.

Pressure Diaphragm Seals Diaphragm seals will be sued to protect pressure instruments from corrosion and to keep solids out of instruments when they are connected to pipelines. Typical manufacturers are Dresser/Ashcroft and Ametek. Isolation valves and calibration ports will be provided for pressure instruments.

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Pressure Switches Units shall be the diaphragm sealed piston actuator type with automatic reset and snap action switch. Acceptable manufacturers are Ashcroft B Series, or United Electric.

2.4.5 Flow Measurement Electromagnetic Flow Element and Transmitter Magnetic flow meters will be used for sludge service. A minimum flow velocity of 5 fps through the flowmeter will be maintained for primary sludge and 3 fps for secondary sludge. Magnetic flow tubes require a minimum of five diameters of straight pipe upstream and two diameters of straight pipe downstream. Typical manufacturers will be ABB/Fischer & Porter or Rosemount.

Flow Element and Transmitter, Thermal Mass Flow Airflow measurement for air applications will utilize thermal dispersion technology for flow measurement. Venturi tubes of orifice plates are not acceptable.The flow element must be installed through a hot tap assembly to facilitate cleaning flow elements without isolating the pipe line. A dirt/moisture separator should be installed upstream of the flow element. The straight approach must be at least 10 diameters upstream and 10 diameters downstream from the flow element. Transmitter will be remote (nonintegral) from the meter, and shall be NEMA 4X rated. Transmitter shall include local LCD display of both the instantaneous flowrate and totalized flow. Acceptable manufacturers are Fluid Components (FCI) or Kurz Instruments.

2.4.6

Level Measurement

Ultrasonic type level sensors and transmitters will be used for level measurement, except for Collection Systems Pump Stations. All ultrasonic level transmitters shall be microprocessorbased devices with external keypads, LCD display, and shall be programmable without the use of potentiometers. Transmitter enclosures shall be NEMA 4X rated. Units shall be temperature compensated. The ultrasonic units will be Siemens/Milltronics, Endress and Hauser, or STI. Collection system level measurements will be taken with a Bubbler system. The Bubbler system shall consist of the following equipment: differential pressure transmitter, air compressor, air release valve, and a normally closed solenoid valve located just outside the hazardous area boundary. Chart recorders are not required. Float and displacer type level switches will be used in sump pump applications and for high level alarms. Floats shall be watertight and shall have a diameter of at least 4 inches. Floats shall be internally weighted and mechanically switched. Floats containing mercury shall not be used. Acceptable manufacturers are Contegra, Siemens or Anchor Scientific.

2.4.7 Analytical Measurement Dissolved Oxygen Analyzer and Transmitter

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Dissolved Oxygen measurement will utilize luminescent response to emitted light for DO measurement. Luminescent DO sensors with compatible transmitters will be used for dissolved oxygen measurement. The Luminescent DO sensors will be Hach sc100 LDO Analysis System.

pH Analyzer and Transmitter Unit shall electromechanically measure pH without requiring electrolyte flow. Provide a complete unit consisting of the following: • • • • •

Element Transmitter Cable Junction Box Expendables

Units shall have integral temperature compensation. Accuracy shall be better than 0.05 pH units with 24 hour zero stability of 0.01 pH units. Indicator shall be LCD or LED. Transmitter enclosure shall be NEMA 4X. Acceptable manufacturers are Hach.

Turbidity Analyzer and Transmitter, Low Range The unit shall measure turbidity of high quality filtered water. Principle of operation shall be light scatter detection measurement. Range can be as high as 0-100 NTU, but is usually set for much lower ranges in clean water applications. The resolution shall be 0.001 NTU. Unit shall include a bubble trap and vent. Provide a complete unit consisting of the following: • • • • • • •

Element Analyzer/Transmitter Cable Mounting Hardware Lamp Units Calibration Kit Expendables

Transmitter enclosure shall be NEMA 4X. Acceptable manufacturers are Hach.

Residual Chlorine Analyzer and Transmitter Unit shall measure continuously the chlorine residual of the sample process stream. Unit shall measure either free or total chlorine residual, field selectable. Principle of operation shall be amperometric with pH buffering. Provide a complete unit consisting of the following:

• • • • • •

Analyzer/transmitter unit Mounting hardware Sample tubing connectors Reagent Expendables Sample Conditioning System

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Sensitivity shall be better than 0.001 mg/l with a 4-second maximum response time. Unit shall have integral temperature compensation. Transmitter enclosure shall be NEMA 4X. Acceptable manufacturers are Hach.

Combustible Gas Detection System Combustible-gas detectors must be provided in accordance with NFPA 820. Each area should be analyzed for the types of gases that may be present (heavier-than-air gases or lighter-than-air gases), with detectors located appropriately. For example, in screen rooms, combustible-gas detectors should be installed along the ceiling and floor because both combustible-gas detectors should be installed along the ceiling and floor because both heavier-than-air combustible gases (such as gasoline vapors) and lighter-than-air combustible gases (such as methane) may be present. Combustible gas detectors with silicon/H2S poisoning-resistant cells should be specified. Combustible gas must be treated as a critical alarm. The alarm must be connected to a local annunciator and interfaced to the PLC. Typical manufacturers are MSA and General Monitors.

Total Suspended Solids (TSS) Analyzers TSS measurement will utilize a nephelometric method where light is passed through the sample and the amount of reflected light is measured. Hach SOLITAX sc sensors and sc100 controllers will be used for TSS analysis.

2.4.8 Temperature Measurement Temperature Transmitters Units shall be 3 or 4 wire RTDs with integral two wire transmitters. Elements shall be 100ohm platinum conforming to SAMA Standard RC 21-4 accuracy specifications. However, vibrating can damage this unit. Ten ohm copper RTDs must be used in large motor windings and thermocouples must be considered for all ranges in vibration applications. Acceptable manufacturers are Foxboro or Rosemount.

Temperature Indicators and Gauges The preferred temperature gauge is pressure gauge with a vapor-pressure temperature element. The long-term stability is better than bi-metal units, but bi-metal may be necessary in small vessels because of element size. Mercury thermometers are not acceptable. Dial size shall be 4 1/2 inches minimum. Acceptable manufacturers are Ashcroft, Ametek and U.S. Gauge Division.

Thermocouples Thermocouples (T/C) must be used for applications in which the operation temperature is greater than 300 degrees Fahrenheit. The specific application must be the basis for choosing the T/C and extension wire used. Thermowells must be used for thermocouple liquid applications and must be made of 316 stainless steel. Thermowells must not be used for gas applications unless the line cannot be depressurized easily for T/C maintenance.

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2.5

Control Panels

2.5.1

General

Control Panels located indoors shall be painted steel or fiberglass, NEMA 12, as manufactured by Hoffman or equal. Enclosures shall be provided with corrosion inhibitors. Control Panels outdoors will be 316 stainless steel, NEMA 4X, and painted white using electrostatically applied TGIC polyester urethane powder coating on the inside and outside. Provide outdoor enclosures with sunshields, thermostatically controlled space heaters, and corrosion inhibitors. Control Panels Indoors in hose-down or corrosive areas should be NEMA 4X, fiberglass or stainless steel. Provide louvers, forced ventilation, or air conditioners as required to prevent temperature build-up within the enclosure and maintain equipment within equipment temperature ratings as required.

2.5.2

Signal Isolation and I/O

Unless otherwise indicated or required for a specific application, all PLC and DCS I/O shall meet the following: For pump stations, provide 12VDC discrete inputs. For WWTP, provide 24VDC discrete inputs. Provide discrete output modules with dry contact relay outputs rated at 120 VAC. Provide isolated 4-20 mA analog inputs. Except for 4 wire transmitter loops, provide power supplies for all 4-20 mA signals from the control panel. Provide isolated 4-20 mA analog outputs.

2.5.3

Distribute I/O Between Modules

To comply with general philosophy of no single point of failure, terminate I/O for related equipment on different I/O modules, where practical. For example, if there are 4 high service pumps, terminate digital inputs for two pumps onto one I/O module, and digital inputs for the other two pumps on a separate I/O module. When multiple racks are provided, the I/O modules should be in separate racks with separate power supplies.

2.5.4

Panel Power Distribution, I/O, and Loop Powering Practices

Provide individual fuses for each 4-20 mA signal loop. Provide individual fuses for each group of discrete inputs for a common piece of equipment.

2.5.5

Termination of Wiring

All PLC I/O wiring shall be terminated on removable terminal strips on the individual PLC modules that permit removing I/O modules without disconnecting the wiring. Tag and mark all terminal blocks and individual wiring. All wiring from the field shall terminate on separate numbered terminal blocks. Separate groups of terminal blocks shall be provided for the following: GNV310133631748(APPB).DOC/081640018

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•

Discrete inputs

•

Discrete outputs

•

Analog inputs

•

Analog outputs.

•

Each different voltage level. Each different voltage level shall also be on separate tracks at least 6 inches apart.

•

Each different voltage source within the panel.

•

All outside voltage sources of a like voltage level should be grouped together, and shall also be labeled and provided with individual disconnects.

2.5.6

Conduit Entry

Conduit entry into panels will generally be through the top or bottom. Neatly coil and securely fasten all cabling away from equipment and entrance doors rather than laying in the bottom of the enclosure.

2.5.7

Pilot Devices and Controls

Provide oiltight/watertight, heavy duty pilot devices and controls. Miniature type devices are not acceptable. Where contacts switch 115 volt signals, provide contacts rated 10 amps at 115 volts ac minimum. Where contacts switch low voltage dc signals, provide contact material of gold or gold flashing over silver and rated 1 A at 28 Volts dc. Provide transformer type pilot lights utilizing low voltage lamps. On the panel, provide either push to test type or a common lamp test button pilot lights. Pilot lights shall allow for lens and bulb replacement through the front of the unit.

2.5.8

Relays and Timers

Where contacts switch 115 volt signals, provide contacts rated 10 amps at 115 volts ac minimum. Where contacts switch low voltage dc signals, provide contact material of gold or gold flashing over silver and rated 1 A at 28 Volts dc.

2.5.9

4-20 mA Loop Indicators

Indicators shall be of the digital panel mounted type, rather than the analog gauge type.

2.6

Lightening Surge Protection and Backup Power Requirements

2.6.1

Grounding Requirements

Provide ground conductors and ground rods adequately sized and in close enough proximity to grounded equipment, including surge protectors, to produce an impedance between the connected equipment and ground of 3 ohms. For alternating current loads, provide ground and neutral conductors that are no smaller than phase conductors.

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2.6.2

UPS Requirements

In general provide either a UPS or battery power back up for all control panels, PLCs, DCS components, computers, and communications equipment. Provide the on-line type UPS that and provides power conditioning to the load and shall automatically revert to line power after batteries are discharged without requiring manual reset. As a minimum UPSs provided for the Data Center, WWTP Control Centers, and Collection System Control Center will have the capacity for maintaining control center operation for one hour. For the Collection Control System local PLC monitoring and control, provide battery backup power capable of maintaining the PLC and communications interface in operator for four hours. UPS receptacles to be color coded and identified as for UPS supplied equipment only. Where generators are provided, the UPS shall be powered by the emergency generator bus such that in the event of a power failure the UPS is functional for the duration the emergency generator is operating. Provide UPS power to communications equipment provided by Verizon and other communications service providers. Coordinate with provider to determine specific equipment being provided and power requirements. It is not intended that printers, copiers, or individual instruments be required to be connected to the UPS system. It is not required that auxiliary control panel components such as space heaters, receptacles, fans, etc. be connected to UPS power. For facilities with several loads requiring UPS power, a single large facility UPS with power distribution to loads is preferred over individual UPS located in panels or equipment enclosures. Consult with DPW to determine acceptable configuration of UPS power distribution. For UPSs with distribution panels, provide bypass switches and isolation breakers so that the UPS can be isolated and taken out of service for maintenance without disturbing the loads it powers. UPSs shall provide auxiliary contact outputs connected to the PLCs and DCSs for UPS alarm, UPS Fail, Main Power Fail, and UPS bypassed.

2.6.3

Discrete Signal Line Protection

Surge protection is not required.

2.6.4

Analog Signal Line Surge Protection

4-20 mA signal circuits with any portion of the circuit traveling outside a building shall be provided with a surge protective device at each end of the circuit.

2.6.5

Telephone Circuit Surge Protection

Unless DPW considers the protection provided by the Verizon to be adequate, provide surge protection devices at the DMARC location between Verizon and DPW equipment.

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2.6.6

Power Supply Surge Protection

Provide power surge protection at each source power connection to each power distribution panel. Provide power surge protection at the alternating current source power connection to each instrument and control panel and at each voltage level within a panel. Provide power surge protection at the source power connection to each UPS.

2.7

Control, Communications, and Power Cabling and Media Requirements

2.7.1

General

Except for designated direct-burial installations, install all cabling [copper and fiber optic] in conduit. Separate copper and fiber optic cabling. Install fiber optic cable inside innerduct in conduit. Individual conduit runs shall be kept to a minimum and control cabling may be combined in common conduits and routed to centralized terminal boxes to the greatest extent possible. Wherever combined control cables are split out of a common conduit, provide a terminal box. Note that different control voltages shall not be combined. To minimize the effects of lightning and surges, underground control and communication cabling routed outside the building confines shall meet the following requirements: •

Use fiber optic cable where practical for underground or outdoor communication between PLC components.

•

Where individual control or monitoring signals must be routed outside, minimize the routing lengths. Evaluate cost effectiveness of installing a separate remote I/O cabinet near the monitored equipment.

2.7.2

Conductor Labeling

Wire labels shall be provided for each individual conductor and multi-conductor cable at all termination points including termination/junction boxes. Labeling of “through” wiring [that is conductors not terminated or spliced] at pull boxes will not be required.

2.7.3

Fiber Optic Cable

Install all fiber optic cable with at least 50 percent spare fibers and a minimum of two spare fibers. Provide 50/125 micron, multi-mode or 9/125 micron single mode fiber optic cable. Selection between single mode and multi-mode fiber optic cable will be based on data rate and distance. Terminate all fiber optic cable(including spares) in fiber optic patch panels and satisfy test criteria. When any fibers in a cable are terminated in a patch panel, terminate all fibers in that cable. Use patch cables installed in conduit for connection of transceivers to patch panels. Provide all patch panels indoors with NEMA 1 enclosures. Provide all panels outdoors in NEMA 4X enclosures.

2.7.4

Shielded Twisted Cabling

Provide shielded twisted pair or triad cabling for all analog signal circuits. Provide an appropriate level of spare pairs or triads. For single circuits, spares are not required.

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2.7.5

Multi-conductor Control Cable

Provide multi-conductor control cabling for all discrete signal wiring. Multi-conductor control cable shall be used over single conductor control cable due to ease of identifying individual conductors by color as well as individual conductor labeling. Each multi-conductor control cable should provide at least 25 percent spare conductors.

2.7.6

Local Area Network and Telephone Cable and Components

All Local Area Network [LAN] and telephone cabling and components shall be listed and rated as “Category 6” and satisfy test criteria. Route LAN and telephone cabling to minimize proximity to alternating current wiring, transformers and lighting ballast. LAN cabling shall satisfy test criteria for operation at 100 Mbps.

2.8

Network and Server Rack Construction Requirements

Locate network and computer racks in a physically secure location with access limited to those responsible for operation and maintenance of the components and applications housed in the racks. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Also, provide UPS capacity for maintaining operation for one hour. Provide a minimum 3 feet of clearance both directly in front and behind the rack. Provide racks with both front and back access for computer and network equipment.

2.8.1

Layout

In general, install heavy equipment near or at the bottom of the rack. However, install UPSs near the top. For racks that require ventilation, install fans or cooling system at the top and bottom. Provide horizontal cable management above patch panels and switches with a minimum of 1 rack-mount unit of cable management for every 2 units of switches and patch panels. Provide vertical cable management along both sides of the rack. Add power strips as necessary to ease access and power cable management. Provide shelves for any equipment that is not rack-mountable. Use shelves that are deeper than the equipment it is supporting. For heavy equipment, include drawer glides.

2.8.2

Power Supply

Provide one or more, as required, dedicated 120V power circuit for each rack. Locate the power distribution panel sourcing the power circuits inside the physically secure space housing the racks served..

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2.9

Security Requirements

2.9.1

Network and Computer Security

Provide SCADA network and computer security as shown, described herein and in compliance with the current version of NIST SP 800-82. Network and computer security includes access control, virus protection, and intrusion detection and prevention. Access controls include controls provided by network appliances such as routers and firewalls, user authentication and role-based access limitations, as well as appliance and operating system configuration to disable unnecessary or high risk services, limit access, and establish secure user names and passwords. Coordinate with DPW to establish secure networks and computer systems.

2.9.2

Physical Security

Coordinate with DPW to establish physical security requirements for pump stations and plants. For control centers and data centers, locate all computers, including both servers and workstations, in a locked temperature controlled room with reliable conditioned power. Limit access to the control centers to the staff performing maintenance on the system. Use KVM extenders to support a keyboard, dual monitors, mouse, and dual speakers in the control room for each workstation. All control panels are required to be pad-lockable and have door closed switches. Control panels at collection system locations are to include a panel intrusion alarm. Certain collection system location panels may be required to be capable of accepting a Gate OPEN, Door OPEN, INTRUSION (alarm from an intrusion detector), and AUTHORIZED INTRUDER discrete inputs. Video intrusion alarm assessment, when required, is expected to be provided separately and not require control panel expansion. Necessity of video intrusion assessment or intrusion monitoring via discrete inputs will be determined during design and may significantly impact digital cellular network monthly costs. When necessary, design video intrusion systems to include local digital video recorders with the following capabilities: 1. Suitable for installation in industrial, NEMA 4X areas. 2. Capable of storing 30 days of video for each camera at 4 frames per second (fps). 3. Capable of producing event clips which start a preset time before the event and end a preset time after the event. Design intrusion detection systems to eliminate false negative and minimize false negative events. For intrusion alarm assessment provide fixed cameras with manually adjustable lenses capable of full color operation at 2.4 lux reflected light level and a 50 IRE sensitivity of 0.59 lux. Design lighting systems to provide adequate illumination for proper camera operation and to maintain a contrast ratio of better than 4:1.

3.0 Network and Other Communication Requirements 3.1

Overview

The following three types of networks are anticipated:

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1. A digital cellular wireless network for connection of the pump stations and wireless mobile laptops to the collection system process control network. 2. Local area networks (LANs) at each of the WWTP for interconnecting DCS components, the Collection System Control Center for interconnecting DCS and HMI components, each pump station for interconnecting the PLC, digital cellular modem, and at the operations data center for interconnecting DCS components. 3. A digital wireline network for interconnecting the Operations Data Center, the three WWTP Control Centers and the Collection System Control Center.

3.2

Digital Cellular Network

Work with DPW and Verizon to transfer ownership of the existing Verizon digital cellular communication network installed in Phase 4 of the on going pump Station SCADA project. Make site visits to pump stations to determine antenna locations verify received signal strengths greater than -80 dB. Where signal strengths are lower than -80 dB, add antenna amplifiers to achieve at least -80 dB. When, -80 dB is not achievable with a signal amplifier, select another communications method based on available alternatives and the relative importance of the pump station. Convert the Verizon service to a Fixed-End Service (FES), Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology, and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. Work with DPW and Verizon to develop an acceptable SLA and service contract. Include adequate support to assure reliable operation and timely notification and repair of outages. Also, verify that any appliance management ports required by Verizon provide adequate security. If practical, integrate the FES and digital cellular network into a single contract and SLA with the digital wireline network.

3.3

Local Area Networks

Provide LANs that provide both redundant switches and redundant media for each LAN connected computer or controller. Use the same network topology for all LANs except the pump station LANS. Work with the DCS provider to assure that the LAN design satisfies DCS requirements, can be configured and maintained by the DCS provider, and can be monitored by the DCS system. For LAN components installed outside the control centers and data center, use industrially hardened appliances. For pump stations provide a single industrially hardened switch supporting necessary protocols and suitable for installation in the pump station environment. There may also be plant applications where a wireless LAN (WLAN) alternative is adequate and cost effective. For these applications address reliability, capacity and security issues on a case-by-case basis.

3.4

Digital Wireline Network

Provide a digital wireline supporting IP protocol. The planned initial data rate is 1.5 million bits per second (Mbps) using a service such as Multi-Protocol Label Switching (MPLS). Advantages of this interface include scalability flexibility, and life-cycle cost effectiveness. GNV310133631748(APPB).DOC/081640018

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Work with DPW and the data communications network provider to select a product that satisfies DPW needs including providing adequate capacity, ability to handle internet protocol (IP) traffic, acceptable reliability and SLA, and reasonable cost. Also, verify that any appliance management ports required by the provider provide adequate security.

4.0 Functional Requirements 4.1

General Requirements

Requirements for environmental, physical security, reliability and redundancy apply equally to all computers, communications and network equipment. Requirements for pump stations and DCS equipment located in electrical rooms and process areas differ and are addressed individually.

4.2

Monitoring and Control

4.2.1

Local Autonomous Control

At local equipment control panels or motor control centers, provide stand-alone, local autonomous equipment control such that the equipment is not dependent on communications links or operator intervention. It is intended that all automatic control and equipment sequencing be accomplished through PLCs and DCS controllers. It is intended that all equipment sequencing for motor restart after a power outage be programmed into the PLC or DCS. Hardwired time delay relays in individual starters are not required. Since most equipment is controlled in a remote manual mode, automatic restart generally applies only to restoration of last state after a power failure.

4.2.2

Hard-Wired Backup Control

Hard-wired backup controls are not required for most equipment, but need to be evaluated for each piece of equipment. Specifically, pressure switches on the pump station bubbler systems provide hard-wired logic to maintain limited pump station operation in the event of a or PLC malfunction.

4.2.3

Local Manual Control

The local control panel or motor control center operator interface will provide for local manual equipment control that will override PLC or DCS control. It is intended that local manual control will be used primarily for maintenance functions and not operation. Hardwired safety interlocks such as HIGH motor temperature will prevent manual equipment operation.

4.2.4

Equipment Protection and Safety

In general hardwire protective devices which are required for electrical protection and personnel safety directly into individual equipment controllers or starters to eliminate reliance on PLCs or DCS controllers.

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4.2.5

Maintained Versus Momentary Controls

It is intended that all discrete outputs from the PLCs or DCS controllers to individual equipment controllers be maintained contact outputs such that seal in contacts are not required in the control circuit.

4.2.6

PLC and DCS Monitoring of Equipment Status

As a minimum, each equipment controller and control station shall provide isolated, maintained contacts to the PLC to monitor each of the following: • • •

Equipment Running/Stopped. Equipment in Auto and ready to operate. Equipment Fail.

4.2.7

Control of Variable Speed Drives

Use Fieldbus interfaces to variable speed drives for speed monitoring and control, status monitoring, and drive control, as well as for monitoring other useful information such as motor current and drive diagnostics. In general, provide local manual control at the drive. However, some critical applications may require local manual start/stop or even speed control at the equipment.

4.2.8

Local Operator Interface

In general, local operator interface requirements shall be evaluated for each piece of equipment. However, for pump station applications, provide local operator interfaces that, as a minimum, include the following indicators and controls: a) b) c) d) e) f) g) h)

4.2.9

Common FAIL Beacon. Motor Elapsed Runtime Meters. Pump ON, HIGH Moisture, HIGH Temperature Indication. Motor Current Indication with a Phase (A, B, C) selector. Wetwell Level Indication. Wetwell HIGH HIGH and LOW level pressure switch alarm indication Pump Station Discharge Pressure Pump Station Discharge Flow for new or replacement pump stations.

Remote Operator Interface

Remote operator interface requirements include provisions for HAND/OFF/AUTO (HOA) selectors for remote manual override control and duplication of the indicators and controls of the local operator interface. Also provide any additional monitoring and control displays and pop-ups required to support automated sequencing and analog control.

4.3

Alarm Segregation, Categorization, Prioritization, and Conditioning

4.3.1

Alarm Conditioning

Alarm conditioning in addition to that provided by each PLC will be required to account for conditions external to the plant and to further reduce nuisance alarms and improve alarm response. For example, suppress FAIL alarms and performance alarms such as LOW FLOW

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should be for equipment for which the power has failed. Provide supervisor adjustable debounce delays to reduce nuisance alarms for analog variables. Develop specific alarm conditioning rules during design and finalize them during construction. The goal is that any critical alarm requires immediate attention and that other alarms require timely action. Log events or low priority alarms that aren’t annunciated for which a response can be scheduled.

4.3.2

Logical Alarm Summary Displays

A logical alarm summary presentation on alarm summary displays is required to ease the decision process during emergencies.

4.3.3

Alarm Prioritization

Alarms prioritization is required with only critical and important alarms presented on alarm summaries. Log other, lower priority, alarms and place them in categories such as Plant Performance, Plant Capacity, etc to ease performance analysis and maintenance scheduling.

4.4

Trending and Reporting

4.4.1

Historical Trending

Easy access and flexible graphical presentation of historical trend data over the last two years is required to support operational analysis and maintenance planning. To prevent loss of data after two years, also provide an automated easy to use process for periodically archiving historical trend data to removable media.

4.4.2

Plant Historical Data

Provide dual, redundant historical data scanners on two of the DCS operator workstations in each plant control center to collect plant historical data and transmit it to the historical data server.

4.4.3

Collection System Historical Data

Provide a DCS workstation and scanner in the Collection System Control Center to collect collection system historical data. Depending on the digital cellular contract and other issues use either parallel polling of the collection system PLCs or an the collection system HMI servers OPC servers to obtain the historical data. Work with DPW in determining what data

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4.4.4

Relational Database Interface

The DCS historical database is expected to be proprietary with both an applications programming interface (API) and a Microsoft ActiveX Data Objects (ADO) interface. Either the API or ADO interface can be used by a custom applications program to move selected data from the DCS historical database to the C-P Oracle database. Work with C-P and the DCS manufacturer to develop requirements for and deliver the necessary application programming. It may be necessary to locate an Oracle database server in the Operations Data Center to reduce firewall configuration complexity and reduce security risks.

4.4.5

CMMS Interface

It is possible that a computerized maintenance management system (CMMS) or other information management system interface will be required for the historical data servers to support preventative maintenance scheduling.

4.4.6

Reporting Application

Provide a single reporting application for producing reports from both the DCS historical database and the C-P Oracle relational database.

4.4.7

Operation Reports

Work with DPW to determine operational reporting needs and develop an automated system for producing reports using the DCS historian. Determine which report variables are measurements and which must be manually entered, for lab analysis for example. Configure the historian to provide forms for manual data entry and for maintaining the manual entries in the historical data records.

4.4.8

Regulatory and Performance Reports

Regulatory Reports Work with DPW to determine regulatory reporting needs and develop an automated system for producing reports using the DCS historian. For the collection systems regulatory reports are generally not required. However, internal management reports are needed that summarize periodic collection system performance to track performance against the consent decree.

Performance Reports Monthly performance reports are needed to track system performance, maintenance activity, significant events, as well as operating and maintenance costs.

4.5

Access for Mobile Operators and Maintenance Staff

4.5.1

Notification of Critical Alarms

Mobile operators and maintenance staff need to receive notification of appropriate critical alarms.

4.5.2

Critical Alarm Delivery Method

A flexible system that is capable of being reconfigured to use the best available delivery alternative is required for forwarding appropriate critical alarms to mobile staff.

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Initially, the most likely method of delivery will be text messaging to cell phones. However, as communications technologies continue to evolve, the delivery system needs to be easily reconfigured to take advantage of current technologies. The existing DPW cell phone contract does not support text messaging. So, it’s possible that voice messaging will have to be used.

4.5.3

Critical Alarm Assignment Method

An easy to use configuration tool is needed for selecting critical alarms for mobile delivery and assigning those alarms to one or more mobile staff.

4.5.4

Mobile Laptop Workstations

Provide Collection System operators and maintenance staff with hardened mobile laptop computers and digital cellular wireless cards linking the cards to the private digital cellular network for use in monitoring collection system performance and in resolving collection system problems. These laptops will use browser access to the Collection System HMI servers to display graphics displays, view process trends, and review alarm summaries.

4.6

SCADA System Service, Support, Upgrade and Migration

4.6.1

System, Service, Support, Upgrade and Migration Schedule

Provide a projected schedule of recurring expenses for system service, support, upgrade and migration to DPW for use in preparing annual budgets. Provide a schedule that can be easily updated by DPW on a annual basis to make adjustments as necessary expenses and expense costs vary. Prepare a draft schedule early in design so that C-P can consider these costs when making technology and equipment selections. Update the schedule routinely throughout design and construction of the SCADA system. Include all of the items listed below, as well as any others that are being considered for the SCADA system. Work with providers and manufacturers to determine the appropriate service/support product suites for DPW and in developing SLA covering services provided, performance parameters, response times and provider penalties for failure to comply with stipulated performance and response times.

4.6.2

Service

Service fees include monthly fees for items such as out-sourced data centers, ISP, outsourced communications links, leased SCADA components, as well as annual hardware and software service agreements. Except for out-sourced communication link technicians, these services are generally delivered by remote service provider staff and using service provider facilities.

4.6.3

Support

Support is needed for repair, upgrade and routine maintenance of specialty SCADA hardware and software such as computers, DCSs, PLCs and HMI software installed at DPW facilities and out-sourced data centers. In contrast to the service item, support is routinely delivered by technicians and engineers that actually visit the site to perform physical inspection, maintenance, repair and upgrade. Some support services, such as software

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service patch installation, may be delivered by remote technicians under DPW supervision using secure communications links.

4.6.4

Upgrade

Periodic upgrades are needed to keep hardware and software current. Upgrades are less frequent, more expensive and better scheduled than system support work. Upgrades usually require outages and configuration adjustments. To reduce disruption typically one of several workstations or redundant servers is upgraded, tuned and put back on line before others are upgraded.

4.6.5

Migration

Migration is needed to allow moving from one application, platform, service, topology or media to a replacement application, platform, service, topology or media. Migration needs usually are driven by technological advancement, market conditions or evolving DPW needs.

5.0 Application Programming Requirements 5.1

General Requirements

Develop detailed control descriptions in accordance with this design criteria and the Standard Loop Specification document in Appendix H. Provide for delivery of the following from the DCS manufacturer and/or the SCADA integrator: •

DCS and PLC application programming.

•

OWS Workstations and HMI application programming plant including updates to OWS software screens including communications, runtime, totalizers, and historian.

6.0 Coordination and Submittal Requirements Coordinate the work as follows: • • • • • •

During design, submit and incorporate DPW comments at major design milestones. Provide and conduct routine coordination meetings with representatives of all parties during construction and starting with a pre-construction meeting. Facilitate DPW review and adjudicate DPW comments on all submittals. Coordinate testing activities. Facilitate DPW participation and adjudicate DPW issues in all testing. Maintain and coordinate resolution of punch lists for all testing and inspection activities.

Provide the following submittals: • • • •

Design submittals including Schematic Design, Design Development, and Contract Document. Component submittals for all contractor furnished components Plans showing equipment layouts and locations Assembly submittals for all assemblies

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• • •

Cable plans showing cable routing Installation details showing equipment and assemble Electronic and hard copies of all O&M information and manuals

7.0 Documentation Standards 7.1

Naming and Numbering Standards

Use the tag numbering and naming standards described in Section 2.2.

7.2

Drawings, Control Strategy Descriptions, Data Sheets and Lists

7.2.1

General

Provide design and construction documentation conforming to the following standards. Inclusion of detailed PLC and DCS panel drawings in the Contract Documents is intended to clarify requirements for bidders providing more competitive bids. When Required

Description

Included in Contract Documents

Loop Diagrams

Preliminary Construction Submittal Prior to Procurement Final Prior to Field Testing Included in Contract Documents.

Ladder Logic Diagrams

Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Field or Factory Testing as applicable

Interconnection Wiring Diagrams

Included in Contract Documents

Panel Layouts and Schedules

Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Factory Testing

Data Cable Plans

Included in Contract Documents

Typical Mounting and Installation Details

Included in Contract Documents

Control Strategies/Loop Descriptions

Included in Contract Documents

Control System Block Diagram

Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Included in Contract Documents.

Programmable Controller I/O/DCS Controller List

Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Procurement

Instrument Data Sheets

Prior to Installation

Field Cable and Wire Schedule or Plans

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When Required

Description

Included in Contract Documents

Control Room Layout Floor Plans

Preliminary Construction Submittal Prior to Procurement Final Prior to Field Testing

7.2.2

Drawings

Loop Diagrams Detailed loop diagrams shall be provided for all control loops. Typical diagrams may not be used. At a minimum, loop diagrams shall include content required by ANSI/ISA S5.4 Instrument Loop Diagrams. In addition to the minimum standards set by ANSI/ISA-5.4, the following information must also be included on the loop diagrams. •

Specific location of each device, such as area, panel location, rack number, etc.

•

Instrumentation, equipment, and component descriptions, manufacturers, and model numbers.

•

Signal ranges and calibration information, including set point values for switches and alarm and shutdown devices

•

PLC/DCS related items such as Input/Output (I/O) type and address, PLC/DCS rack number, PLC/DCS slot number, PLC/DCS point number, PLC/DCS number, and PLC/DCS equipment manufacturer and part numbers.

The loop diagrams must depict the complete wiring of each control loop. References to shop drawings or manufacturers' shop drawings for continuation of wiring will not be acceptable except where such reference is to contact inputs or relay outputs. Divide each loop diagram into areas for PLC/DCS, panel, and field.

Ladder Logic Diagrams For discrete control and power circuits provide electrical ladder diagrams. Include devices related to discrete functions that require electrical connections. Show unique rung numbers on the diagram and depict and identify all terminal connections. Show each circuit individually and show names corresponding to other drawings or documentation for circuits entering and leaving an enclosure or panel. Include the following as a minimum: •

Terminals: Location (enclosure number, terminal junction box number, or motor control center number), terminal strip number, and terminal block number.

•

Discrete Components: – –

Tag number, terminal numbers and location Switching Action, set point value and units, and process variable description

•

I/O points: PLC/DCS cabinet unit number, I/O tag number, I/O address, terminal numbers and terminal strip numbers.

•

Relay Coils:

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– –

Tag Number and its function Contact location by ladder number and sheet number

•

Relay Contacts: Coil tag number, function, and coil location (ladder rung and sheet number)

•

Ground wires, surge protectors and connections

Interconnection Wiring Diagrams Interconnection wiring diagrams for control panels and PLC/DCS enclosures shall be provided. The interconnection wiring diagrams are to show the control or PLC/DCS panel internal wiring and the associated interconnections with field elements and equipment. "Typical" diagrams or "typical" wire lists may not be used; show each circuit individually. The diagrams must depict the complete interconnection wiring. References to shop drawings or manufacturers' shop drawings for continuation of wiring will not be acceptable except where such reference is to contact inputs or relay outputs. As a minimum, the interconnection wiring diagrams will show the following. •

Panel instrumentation and control components’ tag number, description, terminals, scale range, and calibration information (such as setpoints).

•

Internal terminal strip number and terminal number assignments.

•

Internal wire number assignments.

•

General location of devices such as field or panel.

•

All point-to-point interconnections with identifying numbers of electrical cable or wire.

•

Field element tag number, description, terminals, location (e.g. "FIELD", enclosure, MCC number), and signal range and calibration information (such as setpoints).

•

Circuit name or field wire numbers for wires entering or leaving a panel.

•

PLC/DCS related items such as Input/Output (I/O) type and address, PLC/DCS rack number, PLC/DCS slot number, PLC/DCS point number, PLC/DCS number, and PLC/DCS components part numbers.

•

Overall panel power wiring showing primary source of panel power, voltages, branch circuits, and power connections to panel and field devices.

•

Energy sources of devices (field, panel, or otherwise) such as electrical power. Identify voltage and other applicable requirements. For electrical sources, identify circuit or disconnect numbers.

Panel Layout and Schedules Detailed drawings of the construction and layout of all control panels and PLC/DCS enclosures must be provided. The drawings should show the following. •

Scale Drawings: Show dimensions and location of panel mounted devices, doors, louvers, and subpanels, internal and external.

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•

Construction Details showing panel NEMA rating, enclosure dimensions, panel configuration (e.g. type of mounting), panel material, internal backplate dimensions, and other construction details.

•

Instrumentation and control components schedule include item number, tag designations, nameplate inscriptions, instrument scale, and any other special information and remarks required for clarity.

•

Bill of materials indicating item identifier, tag number, description, manufacturer, model number, and quantity.

•

Construction Notes: Panel wire color schemes, wire and terminal block numbering and labeling scheme.

If possible, the components schedule and bill of materials should appear on the same drawing as the panel layout.

Data Cable Plans Provide sufficient documentation to illustrate data cable routing and installation conformance to cable, PLC/DCS, communication hardware manufacturer installation specifications and requirements.

Typical Mounting and Installation Details Typical mounting and installation details shall be developed for all instruments and control system components. To maintain quality and consistency, these details should be used whenever possible. Provide enough detailed information to avoid confusion and prevent field instruments and panels from being improperly mounted, installed, and used. In general the instrument installation should conform to standard industry practices as shown in American Petroleum Institute Recommended Practice 550 (API RP 550), “Manual on Installation of Refinery Instruments and Control Systems” and other standard references such as the “Instrument Engineers Handbook” (B. Liptak, Chilton Book Co) and “Instrumentation Handbook for Water and Wastewater Treatment Plants” (R. Skretner, Lewis Publishers).

Floor Plans of Control Room Layout Develop floor plans for all new and modified control rooms. Location plans shall be sufficiently detailed so as to allow determination of usability.

Location Plans Develop location plans which show locations of instruments, panels, and equipment.

Control System Block Diagrams Provide block diagrams that are more detailed versions of those included in these design criteria and depict the following: •

Locations, interconnection and physical topology of PLCs/DCSs and computer workstations. and their in-plant communications networks.

•

Data communications cabling. Show type of cable (coaxial, fiber optic) and connections.

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•

Individual PLC/DCS configuration including number of racks, power supplies, I/O cards, etc.

7.2.3

Control Strategies / Loop Descriptions

Develop control narratives from Appendix H, Standard Loop Specifications as well as existing PLC/DCS programs and operator interface and data processing functions. Provide two sets of narratives for PLCs/DCSs; one set for use before the SCADA upgrade and modifications to support the SCADA upgrade. The narrative shall be a concise, easy-tofollow description of the control sequence, algorithm, and interfaces with other strategies and equipment. Narrative descriptions may be supplemented by logic diagrams.

7.2.4

DCS and PLC I/O List and Settings

Develop DCS and PLC I/O list using the latest version of Microsoft Excel®. Include all PLC/DCS I/O list parameters with the exception of the I/O mapping address (PLCADDR); the PLCADDR, which will be added during application software development. The PLC I/O list shall include as a minimum the following data fields. Field Name

Field Description

TAG

The ISA tag number for the data point (as described under "Instrumentation and Control Loop Tagging System" heading)

DESCRIPT

A brief description of the function and location of the point

SGNLTYPE

Input or output signal type. Signal types include: AI

=

Analog Input

AO

=

Analog Output

DI

=

Discrete Input

DO

=

Discrete Output

IOADDR

The particular input or output address in the PLC/DCS controller.

RACKNO

The rack number or address that the I/O point is located. This field will be left blank when IOADDR is PLC or DCS controller.

SLOTNO

The slot number in the rack that the I/O point is located. This field will be left blank when IOADDR is PLC or DCS controller.

POINTNO

The point number in the slot that the I/O point is located. This field will be left blank when IOADDR is PLC or DCS controller.

PLCNUM

The PLC or DCS controller number (or station number) that owns the I/O address.

PLCADDR

Internal PLC or DCS controller address for I/O mapping and communication between PLC and PMCS

LORANGE

For analog point:

The lowest value of the data point in engineering units. This typically corresponds to a 4 mADC signal.

For discrete point:

This field will be left blank.

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Field Name HIRANGE

LOALARM

Field Description For analog point:

The highest value of the data point in engineering units. This typically corresponds to a 20 mADC signal.

For discrete point:

This field will be left blank.

The value in engineering units of the point at which a low value alarm is initiated. For discrete points, this field will be left blank.

LOLOALARM

The value in engineering units of the point at which a low low value alarm is initiated. For discrete points, this field will be left blank.

HIALARM

The value in engineering units of the point at which a high value alarm is initiated. For discrete points, this field will be left blank.

HIHIALARM

The value in engineering units of the point at which a high high value alarm is initiated. For discrete points, this field will be left blank.

EU

The engineering units that the ranges and alarms are specified in. For discrete points, this field will be blank.

STATUS

For discrete points: A word to describe what the status of the point is when the data point is set high (true). STATUS words include: ON OFF STRT (Start) STOP OPND (Opened) CLSD (Closed) FWD (Forward) REV (Reverse) AUTO (Automatic) MAN (Manual) CASC (Cascade) REM (Remote) LOC (Local) HI (High) HIHI (High-High) LO (Low) LOLO (Low-Low) FAIL (Fail) TRBL (Trouble) ALM (Alarm) For analog points, this field will be left blank.

7.2.5

Instrument Data Sheets

Provide instrumentation data sheets for all instrumentation and panel components. Data sheets provided are to be similar to ISA data sheets, ISA standard ISA-S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves. Data sheets for instrumentation and control components shall include the following information, as applicable:

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• • • • • • • • • •

Instrument tag number Instrument type Instrument location or service Manufacturer and complete model number Size and scale range Setpoints Materials of construction Power requirements Mounting type Options included

7.2.6

Field Cable and Wire Schedule or Plans

All field wire, cables, and circuits shall be documented either on schedules or drawings. A field cable and wire schedule should include as a minimum the following information: •

Field cable and wire tag/number. Field cable and wire tagging scheme is outlined under "Field Cable and Wire Numbering System" heading.

•

Indicate the quantity, type, and size of wire or cable (as applicable)

•

Indicate origination of circuit

•

Indicate destination of circuit

If drawings are used, include the above information, as a minimum, on the drawings.

8.0 Testing Procedures And Test Documentation 8.1

General

Factory Demonstration Tests, Operational Readiness Tests, and Performance Acceptance Tests are required for all work. All tests performed may be witnessed by a representative of the City’s staff or their designee. Coordinate schedules and activities associated with all tests with the City’s staff. Submittal requirements for each set of tests include draft test procedures, final procedures reflecting City review comments and completed test documentation including the initials of the person completing the tests and the signature of the witness.

8.2

Factory Demonstration Test (FDT)

Test fabricated panels, enclosures, or systems at their assembly location (referred to herein as "factory"). Test and verify panel power wiring, panel internal point-to-point wiring, and panel functions such as indicating lights, switch operation, and indicator operation. Simulate inputs and outputs for field primary elements, field final control elements, PLC/DCSs, and all other equipment excluded from the test to demonstrate that the panel or system is interconnected and operational. Include PLC/DCSs in the test. Correct any deficiencies found prior to shipment of equipment and panels to site. Failed Factory Demonstration Test shall be repeated and may be witnessed by the City.

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8.3

Operational Readiness Test (ORT)

Conduct Operational Readiness Test (ORT) to inspect, test, and document that each system or subsystem being commissioned is ready for operation. For wellfield panels, test each panel separately just prior to startup. Test all loop, power, and interconnection wiring for proper termination and functionality. Complete loop status reports and component calibration sheets for each component. Use loop status reports to organize and track inspection, adjustment, and calibration of each loop and include the following. • • • • • • • • •

Project name Loop number Loop description Tag number for each component. Checkoffs/Signoffs for each component: Tag/identification, installation, termination wiring, termination tubing, calibration/adjustment Checkoffs/Signoffs for the loop: Panel interface terminations, I/O interface terminations with PLC/DCSs I/O Signals for PLC/DCSs are operational: Received/sent, processed, adjusted Total loop operational Space for comments

Component calibration sheet for each active instrument and panel component (except simple hand switches, lights, gauges, and similar items) and each PLC/DCS I/O module shall include the following: • • • • • •

•

•

Project name Loop number Component tag number or I/O module number Manufacturer Model number/serial number Summary of Operational Readiness requirements, for example: − Indicators and recorders, scale and chart ranges. − Transmitters/converters, input and output ranges. − Computing elements' function. − Controllers, action (direct/reverse) and control modes (PID). − Switching elements, unit range, differential (fixed/adjustable), reset (auto/manual). − I/O Modules: Input or output. Calibrations, for example, but not limited to: − Analog Devices: Actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling. − Discrete Devices: Actual trip points and reset points. − Controllers: Mode settings (PID). − I/O Modules: Actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling. Space for comments.

Correct any deficiencies encountered during the ORT prior to startup.

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B-35

8.4

Performance Acceptance Tests (PAT):

Once ORT has been completed and facility has been started up, perform a witnessed Performance Acceptance Test (PAT) for each completed system or subsystem to demonstrate compliance with contract documents. Demonstrate each required function on a paragraph-by-paragraph, loop-by-loop, and site-by-site basis. For wellfield panels, the PAT will be conducted immediately following the deficiency correction for the ORT. Perform local and manual tests for each loop before proceeding to remote and automatic modes. Where possible, verify test results using visual confirmation of process equipment and actual process variables. Exercise and observe new and existing devices as needed to verify correct signals to and from such devices and to confirm overall system functionality. Test verification by means of disconnecting wires, measuring signal levels, or simulation is acceptable only where direct operation of equipment is not practical. PAT forms shall include: • • • • • •

Project name Loop number Loop functional requirements Brief description of the demonstration test Cite required test results which will verify proper performance Space for signoff by witness

9.0 Operations and Maintenance Manuals Provide Operations and Maintenance Manuals in electronic form for all work. Provide manuals with enough detail to allow operation, removal, installation, adjustment, calibration, maintenance and procurement of spare parts for each component. Develop manuals in a stepwise process including manual outline, preliminary manual and final manual submittals.

10.0 Training Provide the following training: •

PLC/DCS maintenance and applications programming training for each type PLC/DCS provided. Provide standard manufacturer’s training classes for five of the City’s staff. Include all tuition, travel costs from the Baton Rouge area, and per diem costs for all staff for the duration of the training.

•

Application programming training for each computer software application provided. Provide standard manufacturer’s training classes for five of the City’s staff. Include all tuition, travel costs from the Baton Rouge area, and per diem costs for all staff for the duration of the training..

•

Operations training of the HMI graphical user interface. Provide application-specific training in the use of the graphics provided, report production, trending, historical data collection and storage, and all other custom software and programming associated with this implementation. Include on-site training for up to 15 of the City’s staff.

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11.0 Spare Parts and Maintenance Service Agreements Spare parts and maintenance support requirements will be determined during design.

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Appendix C Pump Station Facility Design Criteria

Pump Station Facility Design Criteria The following is a list of general pump station process design criteria that will be used in establishing monitoring and control requirements for all future pump stations:

Pump Station •

All pump stations will be duplex, triplex, or otherwise have an even number of pumps.

•

All pumps will be submersible with moisture and temperature monitoring and protection.

•

Duplex and triplex pump stations will have two or three constant speed pumps, as well as a generator plug and manual transfer switch for connection of a portable generator.

•

Pump stations with more than three pumps will have adjustable frequency drives for all pumps, as well as permanent standby power generators with automatic transfer switches.

•

Pump stations with more than three pumps will have divided wetwells including duplicate level instrumentation.

•

Pump stations will not have grinders.

•

Instrumentation, monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: − − − − − − −

•

Provisions for non-liquid-scrubber type odor control will be provided for all pump stations. Where, appropriate odor control will be included in the initial pump station design. Odor control systems will include: − − − −

•

Analog Discharge Flow and Pressure measurement. Analog Wetwell and Diversion Structure (if in design): Level measurement in each wetwell chamber. 3-phase power monitors with analog Phase Voltage and Current, and Station Power measurements (for pump stations with more than two pumps only). Discrete HIGH, HIGH HIGH and LOW Level switches. Phase Fault contact input. Lower explosive limit (LEL) measurements in wetwells. Pump runtime, as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock.

Modulating flow control dampers. Constant speed blowers. HIGH Differential Pressure switches. Incoming analog Hydrogen Sulfide measurement.

Programmable Logic Controller (PLC) monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria.

GNV310133631749(APPC).DOC

C-1

•

Local operator interface including hard-wired manual override equipment control and touch-screen monitoring and control of automatic sequencing, setpoints and alarm conditions.

Generators •

Transfer Switch position switches.

•

Generator RUNNING and FAIL contacts.

Storage Tanks •

Tank mixers.

•

Instrumentation, monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following − − − − −

Analog Discharge Flow measurement. Modulating plug type discharge valves to control return flow from storage to the pump station compartment for insertion back into the sanitary sewer system Tank Structure HIGH HIGH Level switches. Tank analog Level measurement. LEL measurement.

Facilities •

Pump stations with more than three pumps will have an electrical building.

•

Analog panel temperature measurement for facilities without buildings and analog building temperature measurement for facilities with buildings.

•

All pump stations will be fenced to limit physical access to facilities. Where chainlink fencing is inappropriate, secure, low-maintenance metal or masonry decorative fencing will be used. Otherwise chainlink fencing will be used.

•

Gate drives will not be provided.

•

Gate CLOSED switches will be provided.

•

For pump stations without buildings, outer control panel door CLOSED switches will be provided.

•

For pump stations with buildings, building door CLOSED switches will be provided.

•

Electrical Buildings will be air conditioned to reduce humidity and maintain the temperature below the high temperature limits of electrical and instrument/control equipment.

•

Ethernet Local Area Network (LAN) pump stations communications which is suitable for future addition of digital video remote event assessment will be used at all pump stations. Communication links connecting pump stations to the central Pump Station Data Servers will not initially have capacity to support the video event assessment traffic and will require upgrade or replacement when video event assessment is added.

GNV310133631749(APPC).DOC

C-2

Appendix D WWTP Facility Design Criteria

Wastewater Treatment Plants Facility Design Criteria The following is a list of general wastewater treatment plant (WWTP) facility design criteria that will be used in establishing monitoring and control requirements for future modifications and upgrades at WWTPs:

Mechanically Cleaned Bar Screens •

Self-contained package control system including differential level measurement and local control panel.

•

At the package system supplier’s discretion, the package control system can include a programmable logic controller (PLC) and local weatherproof human machine interface (HMI).

•

Instrumentation and controls will be provided in accordance with the Bar Screen Remote DCS Monitoring and Local Control Criteria including the following: − − −

Level and Differential Level analog signals. HIGH Differential Level and JAM alarm contacts. ON status contacts.

Grit Removal •

Self-contained package control system including a local classifier control panel.

•

At the package system supplier’s discretion, the package control system can include a PLC and local weatherproof HMI.

•

Instrumentation and controls will be provided in accordance with the Grit Removal Remote DCS Monitoring and Local Control Criteria including the following: − −

General alarm contacts. ON status contacts.

Splitter Boxes •

Fixed or manual weirs.

•

HIGH level switch contacts when structure can overflow.

Raw Sewage Pump Stations •

All pump stations will have an even number of pumps.

•

All pumps will be submersible with moisture and temperature monitoring and protection.

GNV310133631750(APPD).DOC/081640020

D-1

•

Pump stations will generally have adjustable frequency drives for all pumps.

•

Pump stations with more than two pumps may have divided wetwells including duplicate level instrumentation when needed to satisfy reliability requirements.

•

Instrumentation, monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: −

Analog Discharge Flow and Pressure measurement when required for process monitoring and control purposes.

−

Analog Wetwell Level measurement in each wetwell chamber.

−

3-phase power monitors with analog Phase Voltage and Current, and Station Power measurements (for pump stations with more than two pumps only). These are expected to be networked onto a fieldbus network for communications to the DCS which will provide additional useful information.

−

Discrete HIGH, HIGH HIGH and LOW Level switches.

−

Lower explosive limit (LEL) measurements in wetwells when required to satisfy NFPA 820.

−

Pump runtime, as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock.

•

Distributed Control System (DCS) monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria.

•

Local operator interface including hard-wired manual override equipment control, including speed adjustment, and hard-wired indicators for important conditions such as ON, FAIL. Larger or critical pump stations may have local HMI.

Primary Settling Basins: •

Self-contained package control system including a local control panel.

•

At the package system supplier’s discretion, the package control system can include a PLC and local weatherproof HMI.

•

Instrumentation and controls will be provided in accordance with the Basin Remote DCS Monitoring and Local Control Criteria including the following: − − − − −

HIGH, HIGH HIGH Torque and Fail alarm contacts. ON status contacts. Sludge pump In Remote, On status contacts. Sludge pump Fail alarm contacts. Flow paced sludge pump control.

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D-2

Trickling Filters Final Settling Basins: •

Self-contained package control system including a local control panel.

•

At the package system supplier’s discretion, the package control system can include a PLC and local weatherproof HMI.

•

Instrumentation and controls will be provided in accordance with the Basin Remote DCS Monitoring and Local Control Criteria including the following: − − − − −

HIGH, HIGH HIGH Torque and Fail alarm contacts. ON status contacts. Sludge pump In Remote, On status contacts. Sludge pump Fail alarm contacts. Flow paced sludge pump control.

Snail Shell Screens Chlorine Contact Basin •

•

Instrumentation and controls will be provided in accordance with the Chlorine Contact Basin Remote DCS Monitoring and Local Control Criteria including the following: − HIGH Level alarm contacts. − Residual Chlorine, pH, Turbidity and Flow Measurement. − Flow paced disinfectant flow control. Possible integration of the Final Effluent and Yard Water Pump Stations

Treated Effluent Pump Stations •

All pump stations will have an even number of pumps.

•

All pumps will be vertical turbine.

•

Pump stations will generally have adjustable frequency drives for all pumps.

•

Pump stations with more than two pumps may have divided wetwells including duplicate level instrumentation when needed to satisfy reliability requirements.

•

Instrumentation, monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: −

Analog Discharge Flow and Pressure measurement when required for process monitoring and control purposes.

−

Analog Wetwell Level measurement in each wetwell chamber.

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D-3

−

3-phase power monitors with analog Phase Voltage and Current, and Station Power measurements (for pump stations with more than two pumps only). These are expected to be networked onto a fieldbus network for communications to the DCS which will provide additional useful information.

−

Discrete HIGH, HIGH HIGH and LOW Level switches.

−

Pump runtime, as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock.

•

DCS monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria.

•

Local operator interface including hard-wired manual override equipment control, including speed adjustment, and hard-wired indicators for important conditions such as ON, FAIL. Larger or critical pump stations may have local HMI.

Gravity Thickeners •

Self-contained package control system including a local control panel.

•

Instrumentation and controls will be provided in accordance with the Gravity Thickener Remote DCS Monitoring and Local Control Criteria including the following: − − − − −

HIGH, HIGH HIGH Torque and Fail alarm contacts. ON status contacts. Sludge pump In Remote, On status contacts. Sludge pump Fail alarm contacts. Flow paced sludge pump control.

Gravity Belt Thickeners •

PLC based package control system and local control panel including a weatherproof HMI.

•

Connection of the PLC to the WWTP DCS to provide integration with supporting equipment such as sludge and polymer feed pumps, sludge storage levels, and wash water booster pumps.

•

Instrumentation and controls will be provided in accordance with the Local Monitoring and Control Criteria including the following: − − −

HIGH, HIGH HIGH Torque, Belt Alignment and Fail alarm contacts. ON status contacts. Control of remote ancillary equipment including sludge and polymer feed pumps, and wash water booster pumps.

Anerobic Digesters •

DCS based control with local equipment control panels as needed.

GNV310133631750(APPD).DOC/081640020

D-4

•

Instrumentation and controls will be provided in accordance with the Monitoring and Control Criteria including the following: − − − − −

Level, Sludge Temperature and Digester Gas Pressure analog measurements. Sludge valve OPEN/CLOSE monitoring and control. Sludge heater monitoring and control Sludge circulation pump On/Fail status monitoring and Run control. Discharge Gas Pressure control valve modulation to maintain Digester Gas Pressure.

Digester Gas Burner •

Self-contained package control system including a local control panel.

•

Instrumentation and controls will be provided in accordance with the Burner Remote DCS Monitoring and Local Control Criteria including the following: − − − −

On status and Fail alarm contacts. Natural gas valve train monitoring and control. Digester gas valve train monitoring and control Burner flame monitoring and control.

Belt Filter Press •

PLC based package control system and local control panel including a weatherproof HMI.

•

Connection of the PLC to the WWTP DCS to provide integration with supporting equipment such as sludge and polymer feed pumps, sludge storage levels, and wash water booster pumps.

•

Instrumentation and controls will be provided in accordance with the Local Monitoring and Control Criteria including the following: − − −

Belt Alignment and Fail alarm contacts. ON status contacts. Control of remote ancillary equipment including sludge and polymer feed pumps, and wash water booster pumps.

Generators •

Transfer Switch position switches.

•

Generator RUNNING and FAIL contacts.

Facilities •

Analog panel temperature measurement for all control panels containing DCS components and analog temperature measurement for all electrical rooms.

•

Perimeter fencing to limit physical access to facilities. Where chainlink fencing is inappropriate, secure, low-maintenance metal or masonry decorative fencing will be used. Otherwise chainlink fencing will be used.

GNV310133631750(APPD).DOC/081640020

D-5

•

Automated gate drives with proximity card readers, cameras for remote driver classification and remote gate control will be provided for employee, visitor and delivery gates.

•

Gate OPEN and CLOSED switches will be provided.

•

Building exterior door access control including proximity card readers, door monitoring and electric door locks will be considered for each WWTP.

•

Electrical rooms will be air conditioned to reduce humidity and maintain the temperature below the high temperature limits of electrical and instrument/control equipment.

•

Fiber Optic Gigabit Ethernet Local Area Network (LAN) WWTP communications which is suitable for future addition of digital video remote event assessment will be used. Communication links connecting WWTPs to the central Historical Data Servers will initially have capacity to support very limited video event assessment traffic and may require upgrade or replacement if significant video event assessment traffic is expected..

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D-6

Appendix E Pump Station Design Spreadsheet

Remote Alarm*

X X X X X

Local Alarm*

X X X X X

Remote HMI Control

Remote HMI Indication X X X X X X

Local HMI Control

Local HMI Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

X X X X X X

X X X X

X X X X

X

X

X X

X X

X X

X X

X

X

X X

X X

X

X

INSTRUMENTS: Wetwell Level Measurement 1 LSL1 LSH1 LSHH1 Measurement Measurement

Discharge Flow Discharge Pressure

X X X X X X

PUMPS: On Status Fail Status In Remote Status High Moisture High Temperature Run Command Speed Adjust 1 Speed Feedback 1 ODOR CONTROL: Hydrogen Sulfide High Differential Pressure Flow Control Damper

Measurement Measurement Open Command Close Command In Remote Status Opened Status Closed Status

X X X X X X

X X

X X

X

X

X

X X

X X

X X X X X X

X X X

X X X

X X

X X

X X

X X

X X

X X

X

X

Blower On Status In Remote Status Run Command

X

STORAGE TANK: Lower Explosive Limit Discharge Flow Level

Measurement Measurement Measurement LSL4 LSHH

X X

X X

X X

X X X

X X X

X X X

X X X

X X X

X X X

Mixer On Status In Remote Status High Temperature Run Command

GNV310133631751(APPE).DOC/081640025

E-1

X

X

X

Local Alarm*

Remote Alarm* X X

X X

X X

X X

X

X

X X X

X X X

X

X

X X X

X X X X

X

X X

Remote HMI Control

Remote HMI Indication

X X

Local HMI Control

Local HMI Indication

X X

PLC Analog Output

X X

PLC Analog Input

X X

PLC Discrete Output

X X

PLC Discrete Input

X X

Storage Outlet Valve In Remote Position

X

Utility Position Generator Position On Status Fail Status

X

GENERATOR5: Transfer Switch

Generator:

PUMP STATION POWER: Phase Voltage Phase Current Phase Fault

3 3 X

FACILITIES: Gate Closed Status Building Door/Control Panel Door2 Building/Control Panel Temperature3 Video Intrusion Alarm Assessment6

X X X

COLUMN DESCRIPTIONS: PLC Discrete Input: Two state (ON/OFF) input; Represents status or alarm condition PLC Discrete Output: Two state (ON/OFF) output; For equipment control or status/alarm condition PLC Analog Input: 4-20 mA continuous input; Represents process variable such as flow, level, pressure PLC Analog Output: 4-20 mA continuous output; For equipment control such as pump speed Local HMI Indication: Operator monitoring of pump station at pump station via operator interface. Remote HMI Indication: Operator monitoring of pump station remote from pump station via operator interface. Local HMI Control: Control capability at the pump station via operator interface. Remote HMI Control: Control capability at the centralized operator station remote from pump station. Local Alarm*: Visual and/or audible alarm capability at the pump station via local operator interface. Remote Alarm*: Visual alarm capability remote from the pump station via operator interface screens. * In 1990, a 10 state standard was enacted requiring both audible and visible alarms. Audible alarm not required for SCADA. NOTES: 1 Pump stations with 4 or more pumps have an electrical building housing adjustable speed drives; and are divided into 2 wetwells with duplicate level instruments. 2 Pump stations with electrical buildings will have building door switches. Those without electrical buildings will have door switches on the control panel outside doors. 3 Pump stations with electrical buildings will have electrical building temperature monitoring. Those without electrical buildings will have control panel interior temperature monitoring. 4 LSL is for monitoring of transfer pump station wetwell. 5 Pump stations with 2 pumps will have generator plugs and transfer switches for connection of a portable standby generator. Pump station with 4 or more pumps will have permanent standby generators. 6 Addition of future intrusion detection and remote video intrusion alarm assessment may require increases in communication link capacity.

GNV310133631751(APPE).DOC/081640025

E-2

Appendix F WWTP Design Spreadsheet

X X X X X X

Remote Alarm*

I I I I I I

Local Alarm*

X X

Remote HMI Control

Remote HMI Indication

I I

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I I I I I I

X X X X X X

I

X

I I

X X

I I

X X

I I I

X X X

I I

X X

BAR SCREENS: Level

Measurement 1 Measurement 2

X X

Bar Screens High Differential Level Alarms Jam Alarms Overload Alarm 1 OVerload Alarm 2 On Status 1 On Status 2 Motor Drive Reset INFLUENT PUMP STATION (GRAVITY TRAIN ONLY): Pump On Status Fail Status In Remote status High Moisture High Moisture Run Command Speed Adjust Speed Feedback Level Measurement LSL LSHH Flow Measurement WET WEATHER PUMP STATION (GRAVITY TRAIN ONLY): Pump On Status In Remote Status Fail Status High Moisture High Temperature Run Command Speed Adjust Speed Feedback Level Measurement LSL LSHH

GNV310133631752(APPF).DOC/081640026

F-1

X X X X X X

S

X X X X X

I I I I I

X X X X X

X

S A

X X

I

X

X

I I I I

X X X X

I I I I I

X X X X X

X X X

X X X X X X

S A

X X

I

X

I I

X X X

X X X

X X

X X

Remote Alarm*

Remote HMI Control

X X X X X

I

X

I I

X X

X

I

X

Local Control

Local Alarm*

GRIT BASIN (FORCE MAIN)/GRIT CHAMBER (GRAVITY TRAIN): On Status X I Fail Alarm X I Grit Classifier On Status X I Fail Alarm X I LSH X Aerated Grit Removal (Tank/Blowers)** ** - Indicates equipment present in the Gravity Train Main Only Grit Pump

Remote HMI Indication

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

SPLITTER BOX: LSH

X

(1) It is assumed that the hydraulic profile of the top of the source structure wall is higher than that of the splitter box. A level switch would eliminate the possibility of an overflow.

PRIMARY SETTLING BASIN: Level Measurement W3 Control Valve Open Command Clarifier Mechanism Fail Alarm High Torque High High Torque Alarm On Status Discharge Pressure PSH PSL Primary Sludge Pump Flow Present In Remote Status On Status Fail Alarm Primary Effluent Pump In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Primary Effluent Level Measurement LSL LSHH It is assumed that there are no pumps for scum removal.

GNV310133631752(APPF).DOC/081640026

F-2

X

I

X

X

S

X X X X X X

I I I I I I

X X X X X X

X X X X

I I I I

X X X X

X X X

I I I

X X X

X X

I

X

I I I

S

X

A

X

I I I

X X X

I I

X X

I

X

I

X

I I

X X

X

X

X X

X

X X X

Local Alarm*

Remote Alarm*

X X X

I I I

X X X

I

X

I

X

I

X

Remote HMI Control

Remote HMI Indication

X X

Local Control

Local Indication

I I

PLC Analog Output

X X

PLC Analog Input

I I

PLC Discrete Output

X X

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment TRICKLING FILTERS: Distributors Blowers TRICKLING FILTER RECIRCULATION PUMP STATION: Level LSH LSL Pump In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Flow Measurement

X X X X

S

X

A

X

S

X

FINAL SETTLING BASIN: Level W3 Control Valve Clarifier Mechanism

Measurement Open Command

X

X

X

Fail Alarm High Torque Alarm High High Torque Alarm On Status

X X X X

I I I I

X X X X

I I I

X X X

Fail Alarm On Status Cycle Start Status In Remote Status Run Command PSH PSL

X X X X

I I I I

X X X X

I

X

I I

X X

In Remote Status On Status Fail Run Command Speed Feedback Speed Adjust

X X X

I

X

Clarifier Scum Pump

Discharge Pressure

X

S

X X

X

X X

Secondary Sludge Pump

GNV310133631752(APPF).DOC/081640026

F-3

I I I

X X X

X X

I X

S

X

A

X

X

Local Alarm*

Remote Alarm*

X X X

Remote HMI Control

Remote HMI Indication

I I

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I

X

I

X

I

X

I I I

X X X

I

X

SNAIL SHELL SCREENS: Snail Screen Snail Screen Pump CHLORINE CONTACT BASIN: LSH Total Chlorine Flow Plant Effluent Valve

X Measurement Measurement Open Command Close Command Opened Status Closed Status On Status

X X X X X X X

I I I

X X X

X X X

I I I

X X X

S S

X X

S

X

A

X

S

X

Yard Water Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Suction Level PRV Enable FINAL EFFLUENT PUMP STATION: Final Effluent Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust COMPOSITE SAMPLERS: Composite Sampler (Bar Screens and Chlorine Contact Basin) Flow Rate System Alarm

X X

I

X

X X

I

X

X

X X X

I I I

X X X

X X

I

X X

ANALYSIS INSTRUMENTATION: pH Turbidity Chlorine Lower Explosive Limit (LEL)

GNV310133631752(APPF).DOC/081640026

Measurement Measurement Measurement Measurement

F-4

X X X X

I I I I

X

A

X

S

X

X

X

X

S

X X X X

X

S

X

Remote Alarm*

S

Local Alarm*

X X X X

Remote HMI Control

Remote HMI Indication

I I I I

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I

X

I

X

I

X

I

X

GRAVITY THICKENER: Gravity Thickener Enable Status (Local Handswitch) In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust High Torque Alarm

X X X X

In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust

X X

I

X

X

I

X

X X X

I I I

X X X

X

Gravity Thickener Pump

X X

I

S

X

A

X

X

X

C C

X X

C C

X X

X

X

GRAVITY BELT THICKENER: Intake Flow Intake Valve

Measurement In Remote Status Position Adjust Position Feedback

X

C

X

C

X

X

C

X

X

I

X

C C C

X X X

X X

Polymer Mixer Differential Pressure GBT Intake Control Valve

Plant Water Flow Process Gravity Drain

Opened Status Closed Status In Remote Status Open Command Close Command Measurement

X X X X X X

C

X

Opened Status Closed Status In Remote Status Open Command Close Command

X X X

C C C

X X X

On Status Fail Alarm Sludge Flow

X X

X X

GBT

GNV310133631752(APPF).DOC/081640026

F-5

X

C C C

X X X

X X

X X

I I I I

X X X X

Remote HMI Control

I I

Local Control

X X X X X X X X X X

Remote Alarm*

X X X X

C C C C C C C C C C

Local Alarm*

X X

Remote HMI Indication

PLC Analog Output

PLC Analog Input

X X

Local Indication

Polymer Flow Plant Water Flow Polymer Pump Speed Sludge Pump Speed Sludge Pump Call Polymer Pump Call Plant Water Pump Call High High Alarm Plant Water Pump Status Sludge Pump Status

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I

X

I

X

I

X

GBT Polymer Aging Tank Mixer On Status In Remote Status Mixer Run Command Tank Level Measurement Discharge Valve Opened Status Discharge Valve Closed Status In Remote Status Discharge Valve Open/Close Command Close Command

X X X X X X X X X

S

X

S S

X X

Feed Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust

X X X

C C C

X X X

C

X

X X X

C

X

C

X

ANEROBIC DIGESTERS: Level Measurement LSH Measurement

Pressure Mixing Pump

Run Command On Status In Remote Status

2 I

X X X

I I

X X

X X X X X

S

X

S S

X X

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X X X X X

I I I

X X X

X X X S S

X X

Remote Alarm*

I I I

Local Alarm*

X X X

Remote HMI Control

Remote HMI Indication

I I I

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I

X

I I I

X X X

X X

I

X

C C C C

X X X X

I I I I

X X X X

C

X

C

X

Heater Temperature Measurement 1 Temperature Measurement 2 Temperature Measurement 3 Digester Gas Discharge Valves (Assume 3 valves, one signal per valve) Opened Status X Closed Status X In Remote Status X Open Command X Close Command X Digester Gas Foam Separator Intake Pressure Foam Separator/Digester Discharge Pressure Foam Separator/Digester Discharge Flow Gas Burner On Status X Fail Alarm X Burner Intake Flow Burner Intake Pressure Gas Burner Intake Control Valve In Remote Status X Position Adjust Position Feedback Digester Building Alarm Panel Trouble Alarm X Warn Alarm X High LEL Alarm X Recirculation Pumps Run Command X On Status X Fail Alarm X Assumes no gas digester storage

X X X

X X X

I I I

X X X

X X

I I I I

X X X X

I

X

I

X

I I I

X X X

I I

X X

S

S

X

X

SLUDGE DEWATERING: BFP Feed Pump

Flow GNV310133631752(APPF).DOC/081640026

In Remote Status On Status Fail Alarm Enabled Status Run Command Speed Feedback Speed Adjust Measurement F-7

X X X X X X X X

C

X

C

X

X

C C

X X

Remote Alarm*

C

Local Alarm*

X X X

Remote HMI Control

Remote HMI Indication

C C C

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

I

X

I

X

Polymer Mixer In Remote Status On Status Fail Alarm Speed Adjust Speed Feedback

X X X

On Status In Remote Status Run Command

X X

X

C

X

X

C

X

X X

C C

X X

C

X

C C

X X

C C

X X

X

Water Booster Pump

Water Supply Valve Open Command Close Command In Remote Status Opened Status Closed Status Belt Filter Press Intake Flow Intake Valve

X X X

Measurement In Remote Status Position Adjust Position Feedback

X X

C C C

X X X

C

X

C

X

X X

C

X

X

C

X

C C C

X X X

Polymer Mixer Differential Pressure BFP Intake Control Valve

Plant Water Flow Process Gravity Drain Valve

Opened Status Closed Status In Remote Status Open Command Close Command Measurement

X X X

X

C

X

Opened Status Closed Status In Remote Status Open Command Close Command

X X X

C C C

X X X

On Status Fail Alarm Polymer Flow Plant Water Flow Sludge Pump Speed

X X

X X

X X

BFP

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X X X

C C C C C

X X X X X

X

Remote Alarm*

C

Local Alarm*

X X X

Remote HMI Control

Remote HMI Indication

C C C

Local Control

Local Indication

PLC Analog Output

PLC Analog Input

PLC Discrete Output

PLC Discrete Input

Nomenclature: A - Adjustment C - HMI I - Indication S - Local Hand Switch X - Parameter Present # - Quantity of Signals per Piece of Equipment

C C

X X

X X

X X

X X

X X

X X

On and Fail Status

X

X

X

X

X

Gate Open Status Gate Closed Status Building Door/Control Panel Door Building/Control Panel Temperature Video Instrusion Alarm Assessment

X X X

X X X

X X X

X

X

X

X

Sludge Pump Call Polymer Pump Call Plant Water Pump Call Cake Plant Water Status Sludge Pump Status

X X X

Generator Position Utility Position

X X X

GENERATOR: Transfer Switch

Generator:

FACILITIES:

X

X

COLUMN DESCRIPTIONS: PLC Discrete Input: Two state (ON/OFF) input; Represents status or alarm condition PLC Discrete Output: Two state (ON/OFF) output; For equipment control or status/alarm condition PLC Analog Input: 4-20 mA continuous input; Represents process variable such as flow, level, pressure PLC Analog Output: 4-20 mA continuous output; For equipment control such as pump speed Local HMI Indication: Operator monitoring of pump station at pump station via operator interface. Remote HMI Indication: Operator monitoring of pump station remote from pump station via operator interface. Local HMI Control: Control capability at the pump station via operator interface. Remote HMI Control: Control capability at the centralized operator station remote from pump station. Local Alarm*: Visual and/or audible alarm capabilty at the pump station via local operator interface. Remote Alarm*: Visual alarm capability remote from the pump station via operator interface screens. * In 1990, a 10 state standard was enacted requiring both audible and visible alarms. Audible alarm not required for SCADA.

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X

Appendix G Standard Loop Specifications

LOOP SPECIFICATIONS The Loop Specifications are divided into the following Sections: •

Definitions This Section defines basic functions and other terms used in subsequent sections (Global Functions Modular Functions and Unit Processes).

•

Global Functions Global functions are required for all applicable variables and are not listed in the Unit Process Loop Specifications.

•

Modular Functions Modular functions include extensive references to the definitions and are included by reference in the subsequent Unit Process Loop Specifications.

•

Unit Process Loop Specification Unit Process Loop Specifications are included for each Unit Process and include extensive references to Definitions and Modular Functions.

DEFINITIONS VARIABLE Any signal (discrete, analog, or pulse frequency), (input, output, or calculated). Pulse frequency signals are a type of analog signal. Provide the same processing and functions for pulse frequency signals as are provided for analog signals. DISPLAY (Tag) •

Display variables on appropriate Human Machine Interface (HMI) displays. Display status for discrete variables such as ON/OFF/FAIL status for motors and OPEN/CLOSE/FAIL status for valves. Display value, and totalizer value when appropriate, for analog variables such as process variables, Set points, drive speeds, and valve positions. To prevent clutter and to ease operation, some displayed variables will not normally appear on displays but will be accessible through easily identifiable point-and-click targets. Runtime and totalizer counters are an example of variables that might not normally appear.

PRESENT A discrete signal is present when the contact producing the input is closed or the signal exceeds its true state value.

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TRUE A condition is true when it exists. The open/closed (or high/low) state of a discrete signal representing that condition will depend on the configuration of the device producing the discrete signal. ALARM Sound the alarm tone, indicate the alarm condition on appropriate HMI displays, and add to the HMI alarm summary display. Upon acknowledgement, silence the alarm tone and indicate the alarm condition on appropriate HMI displays and the alarm summary display. Remove acknowledged alarms from the alarm summary once they are cleared. Log alarm occurrence, acknowledgement, and clearance in the alarm log file. Unless otherwise noted or shown, provide alarm logic that resets automatically when the acknowledged alarm condition clears. Display alarms as follows: •

Display flashing yellow when Alarm is present and is Unacknowledged.

•

Display steady yellow when Alarm is present and is Acknowledged.

•

Display ceases when Alarm clears and is or has been Acknowledged.

ON (RUNNING) The equipment or adjustable speed motor is ON when the equipment or motor drive ON status contact is closed. A constant speed motor is ON when a motor normally open auxiliary motor contact (M-Contact) from the motor is closed. For adjustable speed motors, use the ON status variable or contact from the drive that is TRUE when the drive is in operation. TREND At intervals appropriate for the variable being trended, place the current value of analog variable, along with a time and date stamp, into a historical trend file for that variable. Display the trend on selectable HMI screens with appropriate scaling and units. CLOSE FAIL A valve is commanded-to-close, but is not confirmed closed within a preset time. Unless otherwise noted, a valve is confirmed closed by receiving Close limit switch contact from the valve. POSITION FAIL A modulating valve is commanded to a Set Point position, but the valve is not confirmed to be within a preset percentage of Set Point within a preset time.

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OPEN FAIL A valve is commanded-to-open, but is not confirmed open within a preset time. Unless otherwise noted, a valve is confirmed open by receiving OPEN limit switch contact from the valve. RUN FAIL A motor is commanded-to-run, but is not confirmed running within a preset time. Unless otherwise noted, running is confirmed by receiving an ON status M-contact from the motor’s starter. START Issue a maintained Run command. STOP Cease the maintained Run command. TOTALIZE Integrate flow type variable with respect to time. Unless otherwise noted includes password protected operator reset that sets the totalized value to zero. ELAPSED RUN TIME Calculate the total time (in tenths of an hour) that a motor or piece of equipment has been in operation. For equipment and constant speed motors, use starter M-contacts to detect when the equipment or motor is running. For adjustable speed motors, use the ON status variable or contact from the drive that is TRUE when the drive is in operation. For valves, calculate the time that the valve is open. Unless otherwise noted, include password protected operator reset that sets elapsed run time to zero. CYCLE COUNT Count the number of cycles a piece of equipment, valve, or motor undergoes. For equipment and motors, one cycle is defined as the transition from OFF to ON. For valves, one cycle is defined as the transition from CLOSED to OPEN. SINGLE-ACTION INITIATION Provide logic to perform a sequence of events after receiving a single initiation command. For example: Provide logic to complete a backwash sequence upon receiving a backwash initiation command.

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TWO-MODE FEEDBACK CONTROL Maintain a process variable at a Set Point value by means of feedback control of a control variable such as pump speed or valve position using both proportional and integral action. During startup tune the loop by adjusting proportional band and integral time settings. Provide a Set Point Deviation Alarm that is activated when the process variable deviates by more than x percent from Set Point for a sustained time. Provide password protected access to tuning parameters such as proportional band and reset rate. Parameters Defined in the Specific Unit Process Loop Description: Process Variable. Process Variable Set Point. Controlled Device. Set Point Deviation Alarm Set Point. NETWORK CONNECTED PACKAGE SYSTEMS Network connect package systems are defined as those package control systems that are connected to the Ethernet network.

GLOBAL FUNCTIONS TAGS Provide unique tags for each variable based on the following specification Format: 10

5

AFD

1

SF

Unit Process

Loop Number

ISA designation of process and function

Unit Number

Clarifying Abbreviation

Refer to Design Criteria for Unit Process number assignments and conventions. Use the clarifying abbreviation to assure that all tags are unique. Use only the underscore character (_) as a separator to improve “human readability.” An example of an AFD Speed Feedback tag would be: 10_AFD_0501_SF AVAILABLE (for AUTOMATIC/PLC control) In the PLC, generate an AVAILABLE for automatic control status variable when all of the equipment’s HAND/OFF/AUTO, ON/OFF/AUTO, or OPEN/CLOSE/AUTO selectors are in the AUTO position (IN PLC signal present) and no active alarms

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affecting the equipment are present. Disable and reset FAIL TO START/OPEN/CLOSE alarms when the selector is not in the AUTO position. AUTOMATIC (PLC) CONTROL Automatically sequence AVAILABLE equipment in accordance with these loop specifications. MANUAL (PLC) CONTROL For equipment automatically sequenced by a PLC, provide AUTO/MANUAL selection and remote manual control of AVAILABLE equipment from HMI workstations. Use manual control pop-up displays to reduce clutter. For equipment not sequenced by a PLC, provide remote manual control of AVAILABLE equipment from HMI workstations. Use manual control pop-up displays to reduce clutter. BUMPLESS TRANSFER Configure all “software” Manual/Auto switches to provide “bumpless transfer.” 1.

3.

Manual to Auto Transition: a.

Once the transition occurs, immediately start the device if the Auto Mode so commands.

b.

For modulating devices, initially maintain the last manual control variable output value on transition to Auto. After the transition, enable the automatic control algorithm to commence incrementally from the final manual value.

Auto to Manual Transition: a.

If a device has been running in Auto, configure so it continues to run once placed in Manual.

b.

If a device has not been running in Auto, configure so it does not run once placed in Manual.

c.

If an adjustable speed device has been running at a certain speed in Auto, configure so it runs at the same speed once placed in Manual.

d.

For all modulating devices, maintain the last analog control variable output value on transition to Manual.

RECOVERY AFTER A POWER OUTAGE For facilities with generators, provide a Generator Load Display to be used by operators to manage generator load as follows:

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1. Place each individual load (Pump, etc.) equal to or greater than 75 kW in load on a separate line with columns for “Load” in kW and “Generator Status.” 2. Lump remaining loads into a single “Base Load” line at the bottom of the table. 3. Use submittal information to determine actual load values. 4. Work with the Owner to establish which loads “Generator Status” will initially be “Enabled” and which will be “Disabled.” Refer to Section 26 32 13.13, Diesel Engine Generator Set, Supplement , Table 1 for load enabling priority. 5. Provide password protected HMI editing of Load Entries and Toggling of the Enabled/Disabled Generator Status for each load. Disallow toggling and permanently Enable the Status of the “Base Load” line. 6. Calculated and prominently display on each page of the Generator Load Display the “Total Generator Load” value which is the sum of all currently Enabled Loads. Use the Generator Status for each load and power source information such as Normal Power Available, Power Failed, Generator ON, OPEN/CLOSE positions of MAIN, TIE and Generator breakers from the Generator PLC to manage generator load as follows: 1. Except for the “Base Load,” disable all loads included on the Generator Load Display on power failure. 2.

Once the generator power is available, wait for an adjustable delay set between 15 and 60 seconds. Sequentially Enable loads whose Generator Status is “Enabled,” waiting for an adjustable delay set between 15 and 60 seconds between enabling loads. Refer to Section 26 32 13.13, Diesel Engine Generator Set, Supplement Table 1 for load enabling priority.

3. Once utility power is restored, disable all loads except for the “Base Load.” Once the Tiebreaker OPEN and Main Breaker CLOSED status is confirmed, wait for an adjustable delay set between 15 and 60 seconds. Sequentially Enable ALL loads waiting for an adjustable delay set between 15 and 60 seconds between enabling loads. Refer to Section 26 32 13.13, Diesel Engine Generator Set, Table 1 for load enabling priority. Make provisions for easy modification of the power recovery sequence for the addition of a second utility feed to recover from a power outage for the following scenarios: 1. Utility Source 1 (Bus A) fails. Generator powers loads using future load enabling table. 2. Future Utility Source 2 (Bus B) fails. Generator power loads using future load enabling table. 3. Both Utility Sources 1 and 2 (Bus A and B) fail. Generator powers both loads using future load enabling table.

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Refer to Section 26 32 13.13, Diesel Engine Generator Set for generator monitoring, control and historical data handling requirements. Coordinate with the generator supplier in developing generator displays and historical data processing. Make all generator system displays and data available on the plant process control SCADA network. Requirements for facilities without generators: [LATER] DISPLAY (TAG) Display all discrete and all analog variables. ADJUSTABLE PARAMETER ACCESS Provide for HMI operator entry and adjustment of parameters designated as “operator adjustable” or “operator entry.” Provide password protected HMI display of and entry/modification of all other adjustable parameters including, but not limited to, Set Points, tuning coefficients (for example proportional and integral), timer presets, control sequence presets, and alarm trip points. Present these parameters in an efficient easily navigated format. Provide adequate information to allow the facility maintenance staff to easily identify each variable. The intent is to allow the maintenance staff to tune facility performance and operation without having to alter the PLC program. Provide for PLC programmer entry and adjustment of parameters designated as “preset” or “preset but adjustable.” NUISANCE ALARM SUPPRESSION Provide nuisance alarm suppression by conditioning alarm signals. For example disable all but selected alarms when power is off, and include startup delays, momentary excursion delays, and contact bounce delays. Suppress dysfunctional alarms during and immediately following power outages. ALARM PRIORITIZATION Prioritize alarms into two levels: critical and noncritical. Provide separate colors and audible tones for critical and noncritical alarms. Use red for critical alarms and yellow for noncritical alarms. Log but don’t alarm events that do not require an immediate action. Categorize alarms into unit process categories. DISABLE ALARM PROCESSING: 1. Selectable by the supervisor on a point-by-point basis. 2. Does not prevent point status from being shown on graphic process displays. 3. Maintain summary of disabled alarms

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RUN FAIL ALARM Provide run fail alarms for each motor. Upon motor run fail, remove the run command. EQUIPMENT OR MOTOR FAIL ALARM Provide fail alarms for each fail condition. Upon fail, remove the run command. OPEN FAIL ALARM Provide open fail alarms for each nonmodulating valve with OPEN position feedback. Upon open fail, remove the open command. CLOSE FAIL ALARM Provide close fail alarms for each nonmodulating valve with CLOSED position feedback. Upon close fail, remove the close command. POSITION FAIL ALARM Provide position fail alarms for each modulating valve with position feedback. TOTALIZERS Provide 6-digit totalizers for all flow type variables [flow, chemical feed rate, etc.]. Select least significant digit values that result in 0.5-2.0 counts per minute at full-scale flow. ELAPSED RUN TIME INDICATORS Provide elapsed run time counters for each motor and electrical equipment item. Include open position for valves with either electric or pneumatic operators. Increment counters after each tenth of an hour of operation. Maintain a nonresetable 99,999.9 hour cumulative counter that rolls over to zero after 99,999.9 hours. Indicate runtime counters on appropriate HMI displays. Perform all logic in the PLC. CYCLE COUNTERS Provide cycle counters for each motor and electrical equipment. Include OPEN/CLOSE (non-modulating) valves with either electric or pneumatic operators. Maintain a nonresetable 99,999 start cumulative counter that rolls over to zero after 99,999 counts. Indicate counters on appropriate HMI displays. Start counter logic will be performed in the PLC/RTU. ALARM CONTACT INPUTS Alarm: Discrete contact inputs representing abnormal conditions or identified as alarms on the P&IDs.

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HISTORICAL DATA COLLECTION Trend all analog variables storing an instantaneous value every 10 seconds. Log each discrete and output change of state. Maintain storage of trend, log, and alarm summary files for two years. Provide a procedure for archiving to CD or DVD trend, log, and alarm summary files on a monthly basis. Reports: As a minimum, one each of the following reports shall be provided: 1. Monthly Operations Report. 2. Monthly Equipment Runtime Report. 3. Monthly Chemical Use Report. Reports Content: 1. Report up to thirty process variables per report, as identified by the Owner. 2. Minimum, maximum, and average for each process variable over the time period identified by the report. 3. Monthly totals in the case of flows or runtimes. TAPE BACKUP SYSTEM Configure the tape backup systems to make complete weekly backups on a separate tape and incremental daily backups for each server. For incremental backups, overwrite the tape each day and eject after the incremental backup is complete on the day before the weekly backup is scheduled. For the weekly backup, eject the tape when the backup is complete. COMMUNICATIONS WATCHDOG (applies to any PLC or SCADA link). Create a watchdog function to alarm at the HMI if any of the PLCs do not communicate within a preset time or when any PLC is unable to communicate with any I/O base. To avoid nuisance alarming, make the preset at least three times the nominal update period for the specific device. This nominal update period will be noted during startup. Provide at the HMI a means of disabling communications alarming for use by the operator during extreme conditions such as storms or network outages. Additionally, when communications watchdog alarms is disabled, display a message at the HMI indicating this condition. For PLC controlled equipment operating under HMI Manual control, maintain equipment in the last state following a loss of communications. For PLC controlled equipment under automatic PLC control, maintain automatic equipment control and sequencing during a loss of communications.

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ETHERNET NETWORK MANAGEMENT Provide a network display for the network showing traffic volumes, unused capacity, error rates, and the status (using red/ yellow/green stoplight metaphor) of every SNMP managed device including PLC and I/O Ethernet interfaces. For unmanaged devices, provide OSI layer 1 heartbeat response and reply status indication. ETHERNET NETWORK CONFIGURATION 1. Topology: HIPER-Ring. Disable Rapid Spanning Tree protocol. 2. Flow Control: Enable IGMP snooping. 3. Segmentation: a) If necessary to maintain I/O and HMI update frequencies, use separate EBNT modules on separate VLANs for I/O and HMI functions. b) Keep all messaging, including HMI messaging, on a single VLAN. 4. Access Control: a) Limit SNMP access to that required for network management displays. b) Limit HMI server access to that required for supporting HMI functional requirements. c) Limit access to Remote I/O bases to that required for supporting I/O functions. HMI Password/Security: Provide password protected HMI access to prevent unauthorized users from making changes from operator workstation(s). Provide the following Security Levels: 1. Engineer Level: Access to all data parameters. 2. Supervisor Level: Access to alarm limits, alarm inhibit status, scan inhibit status, and all operator level functions, as well as all adjustable parameters. 3. Operator Level: Set Points, control commands and all operator adjustable parameters. 4. Display Level: No changes allowed. PACKAGE SYSTEMS HMI AND PLC SOFTWARE INTEGRATION AND DEVELOPMENT Fully integrate the monitoring and control of network connected package systems into the HMI so that I/O, tag numbers, graphic colors, the operator interface including pop up screens, monitoring and control functions and global functions are, within the package

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system’s process monitoring and control capabilities, as shown, noted and specified, and consistent with those provided for the rest of the plant. Fully implement, to the degree possible, global functions. AFD MONITORIG AND CONTROL INTEGRATION Fully integrate the monitoring and control of Fieldbus connected AFDs into the HMI so that I/O, tag numbers, monitoring and control functions and global functions are as shown, noted and specified. Fully implement relevant global functions. FUTURE EQUPMENT Where future equipment is shown or noted in contract documents, provide all PLC/HMI code and PLC/HMI tags and graphics for the future equipment. Indicate the unavailable status of all future equipment on HMI screens by means of distinctive color and text. Set the HMI tags off scan and disable alarming for all future equipment. Disable PLC logic for future equipment. ESS FUNCTIONS As shown and noted, and in accordance with Electronic Security Systems (ESS) specifications.

MODULAR FUNCTIONS ALTERNATION Change assignments (alternate) a group of controlled equipment in a predetermined automatic sequence. Provide a LEAD selector for each controlled equipment group. When the LEAD selector is in the AUTO position, provide alternation that is triggered automatically. See Specific Unit Process Requirements for: Controlled Equipment Group: Group Selection Criteria: Alternation Trigger:

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ANALYSIS ALARM ALARM: Concentration, High and Low. Disable inappropriate alarms such as low turbidity. FLOW ALARM ALARM: High and Low Flow. LEVEL ALARM ALARM: High and Low Level. CHEMICAL LEAK ALARM ALARM: [Change-in-Level]/[Elapsed Time While All Pumps Off] > Preset. Change in Level = [Level] – [Level at Time the Last Chemical Feed Pump Stopped] Elapsed Time While All Pumps Off = [Time since Last Chemical Feed Pump Stopped] Disable and Rest the Alarm while any chemical feed pump on. PRESSURE ALARM ALARM: High and Low Pressure. CURRENT ALARM ALARM: High Current. SPEED ALARM ALARM: Low Speed. TEMPERATURE ALARM ALARM: High and Low Temperature. WEIGHT ALARM ALARM: High and Low Weight. CHEMICAL SOLUTION MASS FLOW Use Solution Demand for Chemical Solution Mass Flow. DOSE CONTROL Accept operator entry of Dose. Calculate Demand using: [Solution Demand] = 34.775 x [Dose] x [Treated Stream Flow]/[Solution Strength] Solution Demand = [lbs/hr] of solution

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Dose = [mg/l] of chemical Treated Stream Flow = [mgd] Solution Strength = [%] by weight of chemical in the chemical solution Provide for operator entry of Dose and Solution Strength for each chemical. Calculate Chemical Feed Pump Speed Adjust Output as follows: [Pump Capacity] = 500.7 x [Density]/[Calibration Factor] [Chemical Feed Pump Speed Adjust Output] = 100 x [Solution Demand]/[Pump Capacity] Density = [g/cm3] Calibration Factor = [Minutes/Gallon] of Solution Chemical Feed Pump Speed Adjust Output = [%] Solution Demand = [lbs/hr] of solution Pump Capacity = [lbs/hr] of solution Provide for operator entry of Calibration Factor for each chemical feed pump. For chemical addition of the finished water (FW) line into the Clearwell, calculate Treated Stream Flow as follows: Treated Stream Flow = [Raw Water Flow] x [Recovery Factor]/100 Recovery Factor = [Membrane Filtration System Discharge Flow]/[Raw Water Flow] Provide for operator adjustment on Recovery Factor. Initially set Recovery Factor at 95%

UNIT PROCESS LOOP DESCRIPTIONS [USING THE EXAMPLE UNIT PROCESS LOOP DESCRIPTIONS PROVIDED AND DEFINITIONS IN THE INTRODUCTION TO THE LOOP SPECIFICATIONS, INSERT INDIVIDUAL UNIT PROCESS LOOP DESCRIPTIONS FOR EACH UNIT PROCESS.]

END OF LOOP SPECIFICATIONS

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