QCS 2010

Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 1

4.

PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS ..................... 2

4.1

GENERAL ...................................................................................................... 2

4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6

Scope
Reference Standards
Submittals
Quality Standards
Manufacturers Test Certificates
Approved Manufacturers

4.2

PRODUCTS ................................................................................................... 3

4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8

Digital Indicators and Totalizers

Trip Amplifiers
Relays-Electromagnetic Type
Timers
Running Time Meters
Programmable Logic Controllers (PLCs)
Alarm Annunciators
Chart Recorders

4.3

INSTALLATION ............................................................................................. 7

4.3.1

General

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QCS 2010

Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 2

PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS

4.1

GENERAL

4.1.1

Scope

This Part specifies the panel mounted and miscellaneous instruments and equipment to
perform the required functions in conjunction with information and equipment specified in
other Parts of Section 10.

Unit Responsibility. It shall be the responsibility of the ICA Sub-Contractor as described in

Part 1 of this Section to ensure that the panel instruments and equipment supplied under this
Part are compatible with the primary elements and telemetry/SCADA equipment and
equipment specified under other Sections of these specifications, and that the signal
transmission methods are compatible.

Enclosures of front of panel mounted instruments shall be of uniform design and colour
scheme wherever possible. Front of enclosure colours shall be compatible with panel colours
and subject to final approval by the Employer. Normally, compatible standard colours of the
manufacturer shall be acceptable.

Related Sections and Parts

This Section
Part 1, General.

4.1.2

Reference Standards

The following standards are referred to in this Part:

BS 5515------------------ Documentation of computer based systems
BS 7165------------------ Recommendation for achievement of quality in software
BS EN 50081 ----------- Electromagnetic Compatibility
BS EN 61131-3P ------ Programming Languages for Programmable Controllers.
IEEE 472-1974 --------- Surge protection
ISO 3511 ---------------- Process measurement control functions - instrumentation symbolic
representation
ISO 9075 (BS 6964) -- Structured Query Language (SQL)

4.1.3

Submittals

Submittals shall be in accordance with Part 1 of this Section.

The following shall be included in the submittals:

(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)

shop drawings, product data, and samples

complete description, specifications, drawings, and descriptive literature on the
equipment.
make and model of each component
number of sizing electrical and control wires and power requirements
complete wiring and equipment instrumentation diagram
list of spare Parts to be provided
recommended procedure for protection of equipment against damage prior to
installation
complete system diagram showing required components, routing through in-plant
ductbank system.

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4.

QCS 2010

Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 3

The submittals shall be subject to approval by the Engineer. The Contractor shall submit the
final documentation based on the Engineers comments. The Engineers comments/approval
shall be issued to the Contractor within 21 calendar days of the submittal.

4.1.4

Quality Standards

Manufacturer: In addition to requirements of Part 1, instrumentation and control equipment

furnished shall be manufactured by a Company regularly and currently engaged in the design
and manufacture of similar equipment. All equipment furnished shall be new and of the most
recent design.

Maintainability: All equipment shall be designed for ease of maintenance and repair, and
access to critical Parts shall not require major dismantling. Internal field adjustments where
permitted or required herein shall be easily accessible upon removal of a panel or cover.

Materials and installation shall comply with the requirements of the current editions of
referenced electrical codes and standards, and the codes and standards referred to shall be
used for establishing the minimum quality of the materials and equipment supplied and
installed. All equipment of the same type shall be products of the same manufacturer.

4.1.5

Manufacturers Test Certificates

Manufacturers shall test and calibrate each input/output to operate within specified limits
Calibration and compliance certificates provided by the manufacturer, shall be authenticated
by the Contractor and submitted to the Employer.

4.1.6

Approved Manufacturers

All ICA equipment shall be provided by approved, prequalified manufacturers and suppliers
designated in the Project Specification.

4.2

PRODUCTS

4.2.1

Digital Indicators and Totalizers

Digital indicators shall be panel mounted type. 96 mm (w) by 48 mm (H) dimensions. 110 V
a.c. 50 Hz power supply. 4 1/2 digit LED or backlit LCD display for process variable. Range
shall be programmable in Engineering units. Input shall be 4-20 mA d.c. or volt free contact
as specified in the Project Specification. Loop power for 2-wire transmitter shall be provided
as required. At least two programmable alarm contacts for high or low alarms. Totalizers
shall have 8 digit display with manual reset facility.

4.2.2

Trip Amplifiers

Trip Amplifiers shall be surface or rack mounted with 110 V a.c. 50 Hz power supply. Input
shall be 4-20 mA d.c. 1 or 2 independent adjustable set points shall be provided as specified
in the Project Specification. Outputs shall be SPDT relay contacts rated 110 V a.c. 5A.

4.2.3

Relays-Electromagnetic Type

Relays shall be provided as necessary to perform switching functions required of control

panels and other control circuits.

Control Relays. Control relays shall be provided for the control and alarm circuits as indicated
in the Project Specifications. The relays shall be electrically held, 50 Hz, continuous duty,
multiple connected to 110 V a.c. control circuits and mounted inside control panels or
separate metal enclosures as indicated. Enclosures shall be IP66. The relay base assembly
shall accept from 1 through 8 convertible poles. Relays shall be attached to pre-shaped
mounting channels with captive screws.

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Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 4

Timers

Timers shall be provided as specified herein or indicated in the Project Specifications. Timers
shall have four types of operation: (1) On Delay (2) Off-Delay (3) Single Shot, and (4) Duty
Cycle timers. Time ranges shall be as shown in the Project Specification.

Panel mounted timers shall be of the motor driven adjustable type with dials and presentable
pointers. The timers shall operate from 110 V, single-phase, 50 Hz power and shall be of the
square bezel type for flush panel mounting. Output contacts shall be double throw and rated
for 10 A at 110 V a.c.. The number of contact sets shall be sufficient to perform the required
control functions. Where more contacts are required than supplied as commercial standards,
control relays of equal rating shall be used to supplement the timer contacts. When
specified, relay contacts shall be supplied as Part of the timer and shall be operated by the
timer control power independently of the timed contacts. Repeatability of the preset time
delays shall be within 2%. Timers shall be of the plug-in type and enclosed in dust-proof
cases. Connection shall be by numbered screw terminals in the rear of the timer connector.

On delay timers. When a start signal is applied, the timing cycle begins. Output contacts
change state after the time delay is completed. Contacts shall return to original state when a
reset signal is applied or power is removed.

Off delay timers. When a start signal is applied, the output contacts change state
immediately. When the start signal is removed, the timing cycle begins and the output
contacts return to the original state when the cycle is completed. Timer shall be reset by a
reset signal or by removal of power.

One shot timers. When a start signal is applied, the output contacts change state immediately
and the timing cycle begins. The output contacts return to the original state when the cycle is
completed. Timer shall be reset by a reset signal or by removal of power.

Duty Cycle timers. Two timer cycles shall be incorporated. When a start signal is applied,
the first timing cycle beings. The output Contacts change state at the end of the cycle and the
next timing cycle begins. When this delay is completed the output contacts return to the
original state. This sequence is repeated until a reset signal is applied or power is removed.

4.2.5

Running Time Meters

Running time meters shall be of the synchronous motor driven type having a minimum of six
(6) decimal digits where the least significant digit shall represent tenths (1/10's) of hours.
Unless specified otherwise in the Project Specification, they shall not be equipped with a
reset button. They shall be for panel mounting with a square bezel approximately 60 mm on a
side. Motor voltage shall be 110 V a.c.

4.2.6

Programmable Logic Controllers (PLCs)

General. Each PLC System shall comprise of a Central Processing Unit (CPU), Input/Output
modules, serial interface module and programming units. PLCs shall be installed inside
Local Control Panels or in separate cubicles, as specified in the Project Specification. PLC
shall be suitable for ambient temperature of up to 50C and 95% relative humidity. Power
supply shall be 110 V a.c. 50 Hz. The system shall include at least 25 % spare capacity for
future expansion. Panel mounted display units shall be provided for man machine interface
where specified in Project Specification. PLC shall be of modular construction with plug in
I/O cards and facility to install expansion modules when necessary. The PLC shall have a
real time clock with battery backup. PLCs used for controlling functions shall have a minimum
redundancy of Power Supply & CPU modules on a hot back-up type. PLCSs used for
controlling functions or RTU shall work on 24 volt DC input with a battery backup of 8 hours
minimum.

PLC diagnostic indications shall include the following:

(a)

power OK

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4.2.4

QCS 2010
(b)
(c)
(d)
(e)
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Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 5

low battery
forced I/O
CPU fault
I/O status indicators

Central Processing Unit. The CPU shall perform the following function:
(a)
(b)
(c)

scan all inputs, execute relay ladder logic programs and generate outputs for the final
control elements
monitor status of in the system hardware and provide diagnostic information
the process scan time shall be 6ms/k minimum.

Random access memory (RAM) for real time progress execution with lithium battery backup
for data retention and EEPROM flash backup for permanent storage shall be provided. The
PLC memory shall be as required for the programs and future requirements with a minimum
of 1 MB flash / 512 K SRAM, with a minimum of 204 K for IEC Logic or equivalent.

Input/Output Module. Analogue input modules shall be for current, voltage, RTD Pt 100 or
thermocouple input type with a 16 bit resolution. Power supply for 2 wire transmitters shall be
provided where specified. Analogue outputs shall be isolated 4-20 mA d.c with 14 bit
resolution, unless otherwise specified. Digital I/Os shall be optically isolated. Contacts shall
be rated 1A at 24 Vd.c. The systems shall support on-line replacement of I/O modules, in
case of failure.

Programmer/Simulator.
Programming shall be through a lap-top programming unit.
Programming shall be user friendly, self documenting type with facility for identification and
comments. PLC programming shall be compliant with IEC 1131-3 standard on programming
languages for PLCs.

Serial Interface. PLC shall be provided with serial interface ports for peer to peer
communication, MMI for operator interface or Telemetry, as specified in the Project
Specification. Communication protocol shall conform with the seven layer ISO Open Systems
Interconnect (OSI) model, subject to approval by the Engineer.

Operator Interface. Where specified in the Project Specification, a panel mounted VDU or a
PC based control station shall be provided for Man-Machine Interface (MMI).

A panel mounted VDU shall be provided for the PLC when specified in the Project
Specification, as per the following specification.
(a)
(b)
(c)
(d)
(e)
(f)

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a panel mounted CRT or liquid crystal display unit for graphic, numeric and message
display
membrane keypad with one million cycles minimum operation
110 V a.c. 50Hz power supply
enclosure protected to IP65
EEPROM for application program storage
provide restricted access to the PLC database for simulating or forcing inputs/outputs.

A PC based control station for programming and real-time process control shall be
provided when specified in the Project Specification.
(a)

PC system hardware shall be subject to Engineers approval and as designated in the

Project Specification. It shall utilize current technology in terms of
architecture, system clock speed, processor bus, random access memory, disk drives
and input/output sub-systems. Programming and operations shall be accomplished
using an alphanumeric keyboard and mouse or trackball. As a minimum the PC shall
be provided with two 3 floppy disk drives, 21 colour monitor with 1600 x 1200
pixels resolution and tilt and swivel base. Communication ports shall be provided for
serial mouse, PLC interface including a port for a future PLC network, an additional
spare port and other requirements as specified in the Project Specification. The
monitor shall comply with EC60950 for product safety. The entire
system shall be ruggedised and suitable for a pumping station or a sewerage system
environment. A colour printer, with facility to print directly in black without combining
colours, shall be provided for alarms, reports and graphics printing. Print speed shall

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(b)

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 6

be minimum 4 ppm in monochrome and 2 minutes per full page in colour.

Uninteruptible Power Supply (UPS) with 15 minutes autonomy shall be provided to
facilitate orderly shut-down. Power supply 240 Va.c. 50 Hz.
software functions. The following software functions shall be provided for the
control stations:
(i)
windows/MS-DOS operating system.
(ii)
pixel based graphics.
(iii)
real-time and historical trends.
(iv) data logging functions
(v)
alarms reporting & handling.
(vi) floating point calculations and totalization functions.
(vii) generation of reports based on hourly, daily and monthly averages.
(viii) systems diagnostics.
Monitoring the status of the PLC and
(ix) communication link.
(x)
facility to download/upload data to the PLC.
(xi) password protection for programming functions.
(xii) a minimum of 50 pages of VDU mimic and report screens shall be
provided. Sufficient screen pages shall be configured to represent the process
the remainder shall be available for future use.
detailed display requirements shall be as specified in the Project Specification.

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Data base development and system configuration shall be the Contractors and the ICA
Subcontractors responsibility. The data base developed by using the P&IDs and I/O point list
shall be submitted to the Engineer for approval prior to installation in the operating system

4.2.7

Alarm Annunciators

All windows in the alarm and status annunciator shall be nominally 36 mm by 76 mm, of white
plastic, and rear lighted with two low voltage, heavy filament lamps. The plastic windows
shall be engraved with black letters in accordance with the Drawings. The windows shall be
removable from the front for lamp replacement. The lamp units and electronic drivers shall
be in one case, unless otherwise approved in writing, with a removable cover and designed
for panel mounting. The lamps shall be mounted such that replacement is possible from the
front of the annunciator panel without tools. Lamp sockets and mountings shall be robustly
constructed, so as not to be loosened or misaligned when lamps are replaced. The windows
shall be in rows of six, unless otherwise shown. The monitoring modules shall be of all solid
state plug-in design. There shall be sufficient electronic modules to drive all required
annunciator windows, including spares.
When specified, provide repeater contacts
terminated on a terminal strip for externally monitoring each alarm status. The annunciator
power supply shall be sufficient to drive all required loads. Alarm points shall be driven by
modules with the operating sequence shown below. The windows for status indication, when
specified shall be off and steady on only, colour shall be white or as shown in Table 4.1:

QCS 2010

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Section 10

QCS 2010

Section 10

Part 4

Panel Mounted and Miscellaneous

Instruments

Page 7

Table 4.1
Alarm Module Operational Sequence

Condition

Audible

Off
Flash
Steady On

Off
On
Off

Off

Off

Flash

On

The alarm and status actuators shall be contacts or as shown on the Drawings. The
annunciator shall accept either Normally Open (N.O.) or Normally closed (N.C) contacts. The
sensing voltage shall not exceed 24 V d.c. The units shall be supplied with audible-flasher
cards as required that shall operate on receipt of alarms from any of the alarm points to the
panel. A buzzer shall be provided and mounted in the control panel. A horn in a weather
proof housing shall be provided for external mounting when specified. On receipt of any
alarm the monitor card shall cause the flasher to flash the appropriate indicating window and
sound the alarm.

There shall be a test button and an acknowledge button. The test button shall actuate all
alarm and status points and sound the audible alarm. The acknowledge button shall perform
the functions as outlined in the operational sequence, but shall not prevent any future alarm
points from being annunciated visually and audibly. The unit shall operate from 110 V a.c.,
50 Hz commercial power.

When specified, a "first out" sequence shall be provided in which the first alarm in a related
group, as designated, shall flash red while subsequent alarms in the group shall be nonflashing white. A first out reset button shall be provided for each designated group.

4.2.8

Chart Recorders

Paperless video graphic recorders with colour LCD display and internal and external storage,
networking capability shall be provided having the following specification:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)

screen size 127mm (minimum) front panel to IEC 529 IP65 standard and cut out size
138mm x 138mm
required number of input channels but never less than two and capable of 4020mA,
mV, V, RTD, thermocouple inputs
minimum scan rate of 125ms and chart speed of 1mm/hour to 1200mm/hour
totaliser with mathematical functions
RS232 serial Ethernet 10 Base T interfaces
data storage facilities with a minimum of 1MB internal flash
integral smart media with 128MB smart card and media door lock
capability of being configured by both PC keyboard and via tactile membrane front door
key.

4.3

INSTALLATION

4.3.1

General

Installation, testing, calibration, validation, start-up, and instructions shall be in accordance

with Part 1 of this Section.
END OF PART

QCS 2010

BURHAN INTERNATIONAL

Normal
Alert
Acknowledge
Return to Normal after
Acknowledge
Return to Normal before
Acknowledge

Display