PyNAWO Ssyvasas: wT SYARIKAT BEKALAN AIR SELANGOR SDN BHD 393257 TELEMETRY & INSTRUMENTATION SYSTEM SPECIFICATIONS Date: 4 January 2010Telemetry & Instrumentation System Specifications 10 20 30 40 50 TABLE OF CONTENTS INTRODUCTION 11 Type of Water Supply System 1.2. Requirement of Submission Process DESIGN REQUIREMENTS 21 Standard of Compliance 22 General Design 23 System Design 2.4 Software Requirement POWER SUPPLY SYSTEM 3.1 General 3.2 Battery Charger 3.3, Solar Power system 3.4 Sealed Lead Acid (SLA) Battery INSTRUMENTATION 4.1 Ultrasonic Level Sensor 42 Electrode Level Detector 43. Pressure Transmitter 44 Flowmeter. 45 Digital Indicators (Panel Meter) 46 — Trip Amplifier 47 Signal Isolator 48 Alarm Annunciator ‘TELEMETRY/SCADA SYSTEM 51 Remote Terminal Unit. “Page Dof ot W 20 n a 2D 23 24 24 26 a7 7 28 2960 7.0 80 90 52 DisTRI 61 62 63 64 65 66 Telemetry & Instrumentation System Specifications Communication System 5.2.1 GPRS & 3G Modem IBUTION SYSTEM General Type of Cable Installation Method Excavation and Backfilling of Trenches. Cable Protective Covers Record Drawings and Cable Schedules EARTHING SYSTEM... LIGHTNING PROTECTION SYSTEM 81 General 82. Power Lines Surge Protector for Main Incoming Supply. 83 Power Line Surge Filter for RTU and Instruments: 84 Single Lines Surge Protector for Data Transmission & Control System, 8.5. Earth Conductor for the Power & Signal Lines Surge... OTHERS 9.1 Control Relay. 92 Interposing Relay. 93 Circuit Breaker 93.1 General 932 Miniature Circuit Breakers (MCB) 9.33 Auto-Reclosure Earth Leakage Circuit Breakers (MCB) 31 32 34 36 41 44 a4 46 5 51 92 53 54 Page 3 of 67“Telemetry & Instrumentation System Specifications, Appendi Diagram Description ~ 4} TO | Block Diagram of A Typical "Telemetry & Instrumentation System | ~20 Typical Installation Diagram of Level Measurement 30 “Typical Installation Diagram of Pressure Measurement 2 40 | Typical Installation Diagram of Flow Measurement | Page 4 of 67‘Telemetry & Instrumentation System Specifications INTRODUCTION “This guideline serves to establish SYABAS minimum Telemetry & Instrumentation requirements for watet supply systems The extent of the system to be implemented will be dependent on the TYPE classification of the project as described below, 1.1 Types of Water Supply Systems Table 1.0 and 2.0 show the different types of water supply systems. The tables also show the primary instrumentation equipment requirements. TYPE code of Description of the Installation | installation _| }—— SERVICE RESERVOIR only ‘The following equipments are required: © Ultrasonic Level sensor at Reservoir (RESLn), © DC based electrode system to detect overflow level at the Reservoir, Flowmeter for each outlet of Reservoir (OUTEn) Instrument reading indicators | Additional parameters required connected to RTU; © Battery Charger Status (AC FAIL, BATTERY LOW & CHARGER FAIL) | = Panel Door Open Status © CATI & CAT2 surge arrestor health status A complete RTU system is required to monitor the Service Reservoir(s) parameters by sending all information back to master station at Command Centre Table 1.0 Page 5 of 61TYPE code of | installation _ TFolemetry & Instrumentation System Specifications, n of the Installation Descrip PUMPING INSTALLATION ‘The following equipments are required: @ Pressure at inlet pipe to Suction Tank (INPn), © Ultrasonic Level sensor at Suction Tank (SWLn), ® DC based electrode system to detect overflow level at the Suction Tank , ‘® Flowmeter for each pumping main to Reservoir (OUTFn) © Pressure at pumping main to reservoir (OUTPa) ‘Pump Status (ON,OFF,TRIP, LOCAYAUTO switch status) , Running Hour ‘2 Instrument Reading Indicators ‘Alarm Annunciation System via RTU ‘Additional parameters required connected to RTU: © Battery Charger Status (AC FAIL, BATTERY LOW & CHARGER FAIL) Panel Door Open Status CATI & CAT? surge arrestor health status ‘The instrumentation for associated Service Reservoir (8) will be as for a TYPE-1 installation. The instrumentation readings shall be displayed at the Pump House In the case where the distance between the Pump House and Reservoir is more than 500 meters, additional RTU shall be provided from the same Mmanufacturer to provide standardization and interchangeability of equipment but separately from pump control system. ‘A complete RTU system is required to monitor both the Service Reservoirls) and Pump House parameters by sending all information back to master station at ‘Command Centre: ~~ Table 2.0 Page 6 of 61Telemetry & Instrumentation System Specifications 1.2 Requirement of Submission Process 1.2.1 Application and Proposal The layout drawing must be done by an electrical consultant and centified by a professional clectrical/instrumentation engineer, and it MUST comprise the following: a. Site/Key Plan of the pump house /suction/service reservoir showing the respective locations of all the proposed instrumentations b Block diagram of the proposed instrumentation system Cubicle diagrams of the proposed Instrumentation” panels and cabinets. d._ Drawing showing the detailed installation diagram of RTU, level, pressure and flow measurement, ete ‘e. Instrumentation cabling showing details of cable marking (label), ‘cable schedule, the cable laying route, trenching as well as detailed dimensions and construction of cable joints {Lightning protection and instrument earthing system showing the layout and the connection of the earth continuity conductor to the main earth conductor. It shall also include the layout and ‘connection of the main earth conductor to the earth electrodes as wall as the dimensions and construction of the earthing chamber 1.2.2 Submission of Working Drawings Prior to Construction ‘The working drawings shall have the following items: a Full details of the equipment offered, copies of the manufacturer’s specification to enable the nature, quality and workmanship of the equipment offered to be assessed. b Fully dimensioned drawings showing the proposed installation of the equipment Page 7 of 61Telemetry & Instrumentation System Specifications 2.0 GENERAL REQUIREMENTS 24 22 Standard of Compliance All equipments/products must be registered and approved by Suruhanjaya Perkhidmatan Air Negara (SPAN) or other local related water authorities All equipment must comply with the British Standards or international regulatory bodies and local on products compliance and approval. All ‘equipments must pass all testing procedures and certified by local or international regulatory bodies such as CE, SIRIM, IEC, IEEE, CCITT and others. Evidence of certification must be provided whereas for surge protection devices (SPD), it evidence must be provided with certification and certification test report and proof of original copy if requested Where materials are not covered by British Standards or where the source of manufacture does not provide such compliance, approval to follow other Intemational Standards shall be sought from the Superintending Officer Products/equipments without any certification are not allowed to be used. Certificates of origin and standards compliance shall be made available on demand by the Superintending Officer General Design The system design shall be an independent and separated system so that a failure in any telemetry circuit shall have no effect on any other system component functions (i.e. pumping system} unless otherwise specified The whole telemetry and instrumentation system shall consist of, but not limited to the following sub-system: ‘* Power supply system © Transmitting Element (Tx) complete with measuring sensors, sensor cabling and transmitters 2 Receiving Element (Rx) complete with Indicators, Alarms and Remote Terminal Unit (RTU). © Instrumentation Cabling (DC) - Power, Digital and Analog Signal © Lightning Protection System Page 8 of 61221 220] 223 ‘Telemetry & Instrumentation System Specifications Interface to Pump Control System complete with separate panels, indicators, switches, ete System and Power Supply Unit All equipments/dlevices supplied must be operated using 24V DC power supply only and any equipment operated using AC power supply is not acceptable Transmitting Elements The transmitting element shall comprise of the transducer or sensor, sensor cabling, transmitter or converter and its cabinet or pedestal The different principle type to be employed for each category of measurement shall be as follows: 2 All level measurement : ULTRASONIC LEVEL SENSOR TYPE ¢ All pressure measurent: PIEZO-RESISTANCE PRESSURE TYPE ‘All flow measurement : ELECTROMAGNETIC TYPE Fach parameter of measurement (level, pressure ad flow) shall used standard unit as follows: ‘© All level measurement : in metres (m) © All pressure measurent : in metres (m) All flow measurement : in metre cube per hour (m3/h) Figure 2.0, 3.0 and 4.0 (Appendix) illustrate the typical installation diagrams of level, pressure and flow measurement systems Receiving Element Unless otherwise specified, receiving elements shall be provided in the form of: © Indicators © Remote Terminal Unit (RTU) The indicators mentioned above shall be a separate entity in that it shall not be the same display as that which is sometimes provided with a RTU. All receiving elements shall be neatly arranged and flush mounted onto an instrument panel, All indicators shall be properly labeled Page 9 of 61224 Telemetry & Instrumentation System Specifications ‘The instrument shall be high standard finished and it shall be positioned so as to provide easy means of display Instrument Cabling All cables shall be glanded to panels or to any plant mounted instrument. All cable glands shall be from non-plastic type. All gland for armoured cable shall be provided with easthing ring with cable connection tail type for earthing cable termination to earth bar All instrument cables shall be installed individually from instrumentation panel to the transmitting element and shall overall screen, single galvanized wire armour and overall PVC sheath: Conductors used for control and DC signal/power cable shall be segregated and shall not be mixed with the same multicore cable and panelicabinet. Each cable shall carry signals of only duty group and shall have separate panel or junction box. Instrument cables shall be considered in the following duty groups: a) High level analog signal (eg. 4-20mA) b) Plant state and repeat alarm signal of 24 volts DC ©) Emergency shut down and tripping circuits d) Control circuits e) Low level analog signals ‘The cables in group (a) , (b), (¢) and (d) shall be as recommended by the manufacturer of the equipment providing the signal, but shall not be fess than 7/0 5mm. The cores of cables in group (a) to (d) shall laid up in pairs with approximately one twist per 30 mm and shall include an overall scteen of copper braid or mylar backed aluminium foil giving a minimum coverage 85%. Individual and overall drain wires shall be provided The group (e) cables shall be as recommended by manufacture of the equipment providing the signal Instrument cables shall be segregated into duty groups; each group shall be separately fixed to trays, walls, etc. All instrument cables shall be separated by at least 600 mm from all other cables. Parallel runs of instrument cables and other types of cable shall be avoided Page 10 of 61Telemetry & Instrumentation System Specifications However, if parallel runs are unavoidable, a separation distance of not less than 1% of the length of any parallel run shall be provided with a minimum of 600 mm and a maximum of 4000 mm. Wirings, cables and accessories laid in outdoor ducts which may be submerged by groundwater shall waterproof, termite proof and shall be to the approval of the SO All cabling works shall be tested for continuity and insulation resistance between conductors and sheath by employing a 500 V insulation test. A copy of the (est results certified by competent personal shall be submitted to SYABAS. 23 System Design 234 232 Working Life The Equipment shall be designed and constructed to give a minimum operational life of 10 years continuous service when operated on a 24 hours, 365 days per year basis The Equipment handbooks shall state the maintenance procedures that are required to maintain such aservice Construction The Equipment shall be fully solid state and shall minimize use of discrete components The Equipment should preferably be of plug-in modular design. All necessary cables, connectors and materials for a complete installation shall be supplied together with the Equipment and their costs included therein The Equipment shall be fully tropicalized and suitable for working in an ambient temperature of 10 deg.°C to 70 deg °C with relative humidity of up to 95% without any degradation in performance and reliability, and shall be treated with fungicides The Equipment shall be dust and insect-proof All metal surfaces shall be treated against corrosion. Adequate means shall be provided for cooling the equipment to prevent overheating Materials used in the equipment should generally be incombustible Should the use of combustible materials be unavoidable, attention of Page 11 of 61Telemetry & Instrumentation System Specifications 233 the government must be drawn to these, and the location and layout, in particular wiring, shall be such as to minimize the risk of fire All components and printed circuit cards must be tested and rugged in construction. It shall be designed with adequate margins to withstand continuous services with a minimum of maintenance Any component or assembly shall be capable of replacement by one of an equivalent type, the characteristics of which fall within the limits of the manufacturer's tolerance, without affecting the performance, reliability or stability of the system Labeling All. components, units, boards and their mountings shall be submitted and sign written or marked to the satisfaction of the Superintending Officer (5 ©} to permit easy identification and cross reference to diagram, Components shall be individually identifiable from layout diagram relating to individual boards or units. All such markings shall be readily visible without displacing any component or wiring except that the marking of components of units or sub-units that are normally removed from the equipment for test or repair need only be visible when such units or sub-units are removed Form positions shall be marked to show the supply voltage and rating of the fuses fitted. All controls labels shall be clearly marked in English. Wiring and Cabling, All wiring and cabling within the equipment shall be of adequate size and rating, neatly arranged and adequately supported to minimize the tisk for mechanical damage during installation, operation or cartying out of normal maintenance operations All wiring and cabling orientation shall have adequate space to permit ease of maintenance and trouble shooting Where wiring of cable forms are adjacent, or attached to any part of the metal framework, the framework shall be covered with an approved insulating materials. Where a form passes to the back of a panel, suitable insulating bushing shall be provided to prevent cables from damage ~~ Page 12 of 61‘Telemetry & Instrumentation System Specifications 235 Wiring tags shall be so positioned that neither the tag, nor any possible wiring conductor there on may come into contact with any cover Sufficient slack shall be left at the end of all wires in forms, so as to permit replacement of components and sub-assemblies without difficulty ‘Tagging material shall be from cylindrical, hollow and white ferrule type only with printable text on it. During installation, it shall be secured by crimping together with cable lugs. Cable lugs shall only be from cylinder type and to be crimped using hexagonal crimping tool Wiring of cable forms, feeding hinged frameworks carrying apparatus shall be formed and run in such a manner as to prevent rubbing action and possibility of breakage of wires. The hinged mountings shall open and close without straining the wiring Equipment mounted on hinged panels or framework shall not depend on the hinges to provide electrical earth continually A flexible copper strap shall be provided, firmly bolted to the hinged panel or framework at one end, and to the main rack or cabinet at the other. All wires shall be neatly terminated on the apparatus to give a good mechanical and electrical connection Soldered termination shall be such that the wire may be unsoldered and removed from the tag without undue risk of breakage of the wire or tag, All cabling and wiring shall be such that inductive interferer is reduced to minimum. Precautions shall be taken within the ‘equipment to prevent danger to personnel from contact with parts of the equipment carrying main voltages. Panel Design and Construction The instrument, local control and supervisory panel complete with all associated equipment and terminal rack, etc shall generally be free = standing floor-mounted cabinets of the cubicle Material shall be from mild steel sheets with 2mm minimum thickness on walls and inside compartments. It shall be treated with phosphate, primed and finished with coats of beige color polyester powder paint to RAL7032. Page 13 of 6Telemetry & Instrumentation Systern Specifications All panels drawing shall be submitted by the contractor for approval before any fabrication works to be carryout. A drawing pocket of minimum size 250 mm x 250 mm x 20 mm shall be provided on the inside door of panel. Control switches and pushbuttons shall be positioned below ot adjacent to any associated reading instrument Panels for use in locations other than control rooms shall have _anti-vibration mountings. ‘The panel shall be designed to ensure adequate ventilation and ait Circulation without permitting the entry of vermin or the ingress of dust as far as practicable. Panels installed in a dusty environment shall be provided with non-combustible dust filters over the air circulation louvers Mf electrical and non-electrical instruments are mounted in the same panel, the panel shall be sub-divided internal to separate the electrical and non-electrical sections. All connections shall be arranged to ensure that no accidental damage to cabling ot electrical components can occur in the event of failure of any non-electrical components or connection. All panel construction details and arrangements shall be approved before manufacture and will be subject to inspection at agreed stages. Each panel shall be adequately illuminated internally, as even and as free from dazzle as possible, by fluorescent lighting controlled from totally enclosed door operated switches. The lighting circuit shall be independently fused and designed to allow lamps to be replaced safely Panel circuits shall be segregated into the following categories;- Goup 1 : Power, control and very high level signal wiring (above 50V) i. AC power supplies ii. DC power supplies iii. AC current signals above 5OmA iy. AC voltage and control signals above 50 volts Group 2: High level signal wiring (6 to 50 V de) Page 14 of 61‘Telemetry & Instrumentation System Specifications i Signal from conventional electronic transmitters and controllers (eg. 4-20mA) Circuit to other solid state devices Digital signals Emergency shut-down and tripping circuits v. On/off control circuits Group 3 : Interconnecting wiring (between relays etc) i AC above 50 V ii, DC above 50 V iii, DC 50 V and below Circuits supplied at 240V or above, between 240V and 110 VOC shall also be segregated from each other and from other circuits. Access to wiring and components of circuits having. voltages exceeding 240V shall not be possible unless and until the circuit has been isolated. All wiring shall neatly and securely fixed by insulated cleats, bunched and secured by approved plastic strapping, or run in approved insulated wiring trunking or non-corrodible flexible tubing. Wiring for future equipment shall be secured and terminated on the terminal blocks. Intersection wiring in multi- section cabinets shall be via a terminal block in each section. A terminal block shall_be provided as an interface between corresponding conductors of each intetnal and external connection Terminal blocks for analogue current signals shall permit the insertion multimeter test leads without disconnecting any wiring Terminal blocks for citcuits containing volt free contacts internal or extemal to the cabinet shall permits the introduction of a test continuity meter without disconnecting any wiring, Each row of terminal blocks provided shall contain at least 25% spare terminals over the number required for terminating all cores of external cables in that row. All spare cores of external cables shall be terminated in the terminal block and labeled accordingly. A continuous copper earth bar of not less than 25 mm x 3 mm cross section shall run the full length of each panel and be securely fixed and bonded electrically to the main frame. The cable gland plates and the earth bar shall be provided with suitable brass terminals of not less than 8 mm International Standard screw thread for Page 15 of 61Telemetry & Instrumentation System Specifications connection to metal cladding or armouring of all incoming and ‘outgoing cables and to the station earthing system. ‘A second continuous earth bar of not less than 25 mm x 3 mm cross section, electrically isolated from the steelwork of the panel and metal cladding and amouring of cables, shall be provided for earthing the signal earth connection of each instrumentation and control device to the station earth mat The earth bar shall have sufficient brass terminals as specified above for each instrumentation and control device and the screen of every shielded cable plus 25% spare terminals. Fach instrument requiring a power supply shall be individually wired and protected so that in the event of a failure of one circuit, the remainder is unaffected Power supply circuits shall be of sufficient tating that any protective device mat operates without reducing the voltage at the terminals of any other component to an unacceptable level Small Wiring and Auxiliary Control Supply Panel small witing, shall be carried out in copper multi ~ stranded PVC insulated cable to BS 6231 with 1000 volt grade and shall have ‘a minimum cross-section of 0.75 sq. mm for voltage circuits and 2.5 sq. mm for current circuits. Wiring shall be carried out in a neat and systematic manner and securely fixed by insulated cleats or approved method and arranged so that access to any apparatus or connection point is not impeded, Where inter-panel wiring passes through panel side sheets etc, the access hole shall be fitted with a suitable grommet The wiring colour code shall be as given below: Phases Red, Yellow, Blue Neutral Black DE Circuit Grey Earth Green Connections to volt free contacts intended for external connections shall be coloured white Page 16 of 61Telemetry & Instrumentation System Specifications Wiring shall not be mounted direct to panel steel plates. Panel wiring shall be run in neat looms and shall be installed vertically and horizontally and not diagonally across. Any framing cable looms shall be installed in PVC trunking Not more than 70% of the trunking shall be used Pre-insulated compression terminals or insulated sleeves shall be tight fitted at the end of wirings. Terminals shall be manufactured from high conductivity tin plated copper. Insulated sleeves shall be of nylon or PVC and the latter shall not be less than 0.8 mm thick Sleeves shall be colour coded for different ranges of conductors Sleeve type identification ferrules shall be fitted on all wites at both ends; the numbers and letters used shall correspond with the appropriate wiring diagram and shall read from terminal outwards Identification ferrules numbering shall not be repeated The wires shall not be jointed or broken between terminal points Where duplication of terminal blocks is necessary suitable solid bonding links shall be incorporated in the design of block selected jature circuit breakers of approved type shall be provided for all voltage transformer secondary circuits, auxiliary supply circuits {control and indication). The function and application of each MCB shall be clearly indicated MCBs shall be located at a convenient position for easy access and identification. For each switchboard, suitably rated MCBs and terminal to receive control supply from external source and outgoing bus wires to every panel shall be provided All outgoing circuits shall be protected by MCBs Each MCB shall be provided with voltfree spare auxiliary contact, wired to terminal for remote indication purpose where specified DC trip supply! closing supply/ AC supplies wiring to different protective systems shall be segregated from one another All wites associated with trip circuits shall have red ferrules marked "TRIP! Wiring between fixed and moving positions of the switch panel shall be run in flexible conduits Page 17 of 61237 Telemetry & Instrumentation System Specifications Small wiring used for extra low voltage and instrument signal which are likely to be affected by interference shall be screened and/or spaced from power cables to ensure no distortion or mal- operation Terminal Blocks “Terminal blocks for control wiring shall clamp the wire securely and without damage between two plates by means of a captive screw or by means of cage clamp. Terminals for incoming and outgoing power connection shail be of the bolted type with brass nuts and locknuts, cach core being fitted with a suitable lug Terminal blocks at different voltages shall be segregated into groups ind distinctively labelled, and the voltage grouping and terminal board layout shall correspond with the wiring diagram. Only one wire shall be terminated on each terminal block. Where duplication or terminals is necessary, purpose made solid links shall be provided Where approved barrier pattern crew or stucetype terminal blocks are tised covers of transparent insulating material which does not sustain combustion shall be provided Insulating barriers when provided between adjacent terminal blocks shall also allow easy access, in addition to adequate protection Terminals which may be alive when the main equipment is isolated from the mains supply shall be suitably labeled to reduce the risk of accidental contact. All terminals shall bear a permanent identification number or letter All the wires of a multi-core cable shall be connected to terminal blocks including the spare wires Adequate number of spare terminals (atleast 20%) shall be provided for each group of terminal blocks All spare core cables shall be terminated to spare terminal blacks. Removable DIN rail terminals shall be provided for all wiring, mounted at an angle to provide ease of access, with centre disconnecting link type terminals for analogue signal circuits, isolation or test purposes, sufficient, suitably sized earth terminals at the end Page 18 of 61Telemetry & Instrumentation System Specifications ‘Any exposed terminal of the terminal block shall have a clear plastic Clip-on cover covering the full length of the terminal to prevent accidental contact 2.48 Multi-Core Terminations On multi-panel switchboard, multi-core control circuit protection and indication cables shall be terminated directly at the panel concerned wherever specified. Terminal blocks shall be provided ‘adjacent to the cable gland at the point of entry but adequate space shall be left free for tails of cables to be installed on site Where terminations ate remote from the gland plate, easily accessible tunking or cable tray shall be provided within the tenclosue for securing the cores Where a terminal marshalling section is provided, e.g. on multi — tier panel switchboard each group of unit terminal blocks shall be clearly marked and, where appropriate, provided with an independent cover. A separate terminal shall be provided and identified in compliance with relevant clause for each core {inclucling spares) of all multicore cables. Boxes shall be of adequate dimensions to enable multicore tails to be separated. Boxes shall be provided with removable covers as appropriate to facilitate free access to connections and shall incorporate a removable undrilled gland plate. Interconnections shall be routed via trunking or similar arrangement forming part of the switchboard in a manner providing complete access to the wiring and connections for maintenance purpose without requiring access to any other panel 2.3.9 Cable Terminations All cable boxes, glands, gland plates and all other apparatus necessary to terminate all incoming and outgoing power and control cables shall be provided. Non- magnetic gland plates of not less than 6 mm thick shall be provided where single core cables are terminated. For cable sizes 400 sq. mm above, insulated cable ¢glands shall be fitted All cable boxes shall be suitable for air insulated termination of Vertically ascending power cables. Cable glands suitable for the Page 19 of 61Telemetry & Instrumentation System Specifications sizes of cable used any support shall be provided with each cable ox Suitable approved cable cleats shall be provided to ensure that weight of the cable will not be carried by cable gland Aluminium cable cores shall be terminated using approved bimetallic connectors The panel shall, unless otherwise specified, be provided with bottom cable entry Cable gland boxes, with removable side covers of at least 300 mm high above the base of the panel shall be provided, to enable easy termination of cables The gland plates shall be gasketed In view of the substantial cable derating that is normally applied, adequate terminals and cable termination space shall be provided in the switchboards Each panel shall include all necessary copper down droppers, terminal blocks and cable sockets. All terminals shall be numbered and the numbering shall conform to schematic and wiring diagram. Compression type cable lugs shall be provided. 2.4 Software Requirements The mimic display of each site shall consist of, but not limited to the following information: a. Site name complete with GPS coordinate in the format of WGS84 - Deg Min. Sec b. TWL, BWL and Capacity of each tank or reservoir Level information of Low-Low, Low, High, HighHigh and Overflow to be measured from the bottom d_ ID of site, pump house, pumps, suction/teservoir tanks, reservoir compartments, pressure, level and flowmeter. ©. Size of all incoming and outgoing pipes f Source (incoming) and destination (outgoing) of the water g. Other site's information (upon request) Page 20 of 61‘Telemetry & Instrumentation System Specifications 3.0 POWER SUPPLY SYSTEM 31 32 33 General Components shall be standardized as much as possible. Electrically identical components shall be of one type and make Components installed shall be type tested in accordance with relevant IEC specification and type test certificates shall be submitted Battery Charger Battery charger shall have function to provide power to loads while charging and to keep fully charged all backup batteries. ‘The charging system shall be 24VDC at 10A, continuous operating, type, combination of constant current & voltage and_voltage regulated switching system to be set (adjustable) at 2.25 to 23 volts/cell for float at 32°C or as per recommendation by battery manufacturer. It shall have adjustable settings for Low Voltage Disconnect, Battery Low, Float to Boost and Boost to Float level it shall have separate terminal connection for battery and load. ft shall automatically switches from charging mode to float mode and vice-versa depending on the battery voltage level/power capacity. When battery is in fully charged state, it shall provide tickle charge to maintain the backup battery power capacity It shall be provided with high temperature protection, resettable fuse for over-current low-voltage protection and _over-voltage/over- charging protection. The unit shall come with builtin voltmeter and TOA ammeter for load. It shall be equipped with individual dry contact alarms of Battery Low, Charge Failure and AC Failed for Solar Power Supply System Solar system shall consist of the solar PV module, intelligent charger/controller, trip/breaker, monitors/meters, SLA batteries, connection/wires, solar panel mounting rack and battery for 24 VOC operating voltage ‘The charger controller shall be from MPPT and PWM type to extract maximum power from PV. It shall come with LCD to display various Page 21 of 6FTelemetry & Instrumentation System Specifications 34, information ie. charging current, load current, nett current, PV voltage It shall able to select 12VDC or 24VDC system Jutomatically. It shall come with summary dry contact for charging failure, battery failure and PV fails The solar power system shall be sized based on a 4-hour daily availability of daylight the solar panel shall be high efficiency, high quality and weatherproof for outdoor installation. The solar panel shall be reliable, safe, effective and with warranty for 10 years minimum. It shall be moisture resistance, stable against UV and properly insulated. The contractor shall state the guarantee period and certification of warranty shall be issued on delivery. ‘The solar panels shall be water proofed and all the metallic part must be corrosion free. It shall not lose its transparency after prolonged exposure to high tadiation, high temperature, dust, oil and precipitation in the tropics The glass surface of the solar panels shall be tempered glass and able to provide ultra-clear performance for excellent light transmission and protects from wind anc impact. Terminal enclosure on the solar panel shall be designed for trouble-free field witing and environment protection The solar panel shall be installed at the top of the reservoir and shall be fixed to a roof top or mounted on top of a minimum 3m GI pole complete with am, bracket and fixing accessories to avoid from vandalism: Sealed Lead Battery For Charger and Solar The battery shall be from maintenance free Valve Regulated Lead ‘Acid (VRLA) or maintenance free Valve Regulated solar battery on {2V mono block It must be spilled-proof_ and in high impact container with low self-discharge current. The battery operating Voltage shall be up to 45°C and shall have expectancy of lifetime for minimum 10 years ‘The battery size for the charger system shall be able to provide backup for minimum 12V/60AH and for 5 days without charging for solar system. Page 22 of 61Telemetry & Instrumentation System Specifications 4. INSTRUMENTATIONS aq Ultrasonic Level Sensor Ultrasonic and level measuring instruments shall employ the principle of measuting distance in term of time by the propagation of sound waves in air from a transmitter and measuring the time interval between transmission and reception of the reflected sound wave “The transducer shall be sealed and coated with protective layer of PVDF EPDM and shail be an corrosive proof. The design of the enclosure shall suit the application and required characteristics of the transmitted and reflected sound beam The sensor, which shall be a two wire system with power and output analog, signal on the same pair of line, minimum of 12-meter range and positioned ft least 250 mm above the high water level it shall contain an electro dynamic transducer for the transmission and reception of sound waves. The overall accuracy of each installation shall be within + 0.25% over the complete working range including the linearity, repeatability and hysteresis A timing unit shall be included for determining the time for the overall travel and converting this time into distance. The reaction time shall not be more than 5s ‘Analogue to digital converters shall be incorporated for operating the remote integrators. The output from analogue instruments shall be 4-20 mA ‘The sensor shall be capable operating in temperatures from -20°C to + 60°C and shall be impervious to submersion and shall have a high resistance to corrosive atmosphere ‘The design and application of ultrasonic level meters shall take into account the tank type, the material, size, shape, environment, process fluid or material, the pressure of foam, granules, size etc. The installation shall be Chosen carefully in order to avoid any degradation of performance from Spurious reflections, absorption, sound velocity variations, sensors detection area, temperature fluctuations, shielding, stilling tube or other measures shall be provided to avoid effects on the measurement Page 23 of 61Telemetry & Instrumentation System Specifications 42 43 Electrode level detectors Level detectors of the electrode type shall operate by conductance, where possible, otherwise by capacitance Level electrodes shall be made of Grade 316 stainless steel rods encapsulated in heat shrinkable tubing down to 75 mm from end of the electrode Electrode heads shall be manufactured from reinforced glass fiber or similar corrosion proof insulated material and shall be protected to 1P65. Each head shall be permanently labeled on the outside with the function number and located above the highest possible flood level at each location. Electrode heads shall be designed to allow a minimum of 75mm adjustments of the electrode length. Electrode holder mounting brackets of Grade 316 stainless ste! shall be provided The associated DC 24VDC type amplifier {floatless relay) shall be of the transistorized plug-in type and easily replaceable. Unless it is integral with the head it shall be mounted in a 1P65 weatherproof housing. AC type amplifier (floatless relay) is not acceptable. Pressure Transmitter All pressure measurements shall provide by means of gauge pressure transmitters. The pressure measurement system shall consist of: © 1 inch diameter directs tapping complete with Gl. pipe or copper tubing and isolating corks. © Signal transmitter with LCD display ‘The system shall be of the gauge pressure type and the transmitter shall be a two wire system with power and output analog signal on the same pair of line. The output of the system shall be linearly proportional to the pressure and shall have a live zero 4 to 20 mA DC against a load at least 600 ohms Zero and span calibration shall be non-interacting and shall be easily accessible to facilitate calibration works. The pressure transmitter shall utilize piezo-resistive method in the measurement of water pressure in the pipes. Pressure from the pipe shall be applied via a stainless steel 316 seal diaphragm and filing liquid to a silicon pressure sensor whose diaphragm is then flexed. The resistance change of the piezo-resistors in relation to the pressure acting on the diaphragm is then amplified and converted into an output current of 4 to 20 ma DC Page 24 of 6144 ‘Telemetry & Instrumentation System Specifications The pressure transmitter shall have an accuracy of +/-0 25%, including hysteresis and repeatability and have a long-term signal stability of at least +10 25% over a year with maximum span. The pressure transmitter shall be suitable for an operating temperature range of -30 to 85 deg Celsius. The pressure transmitter shall come with stainless steel housing and process connection. Ingress protection for the device shall be to IP65 AA local gauge shall be installed for indication. It shall be a 150 mm diameter with cast aluminum case, aluminum threaded ting, 05 inch bottom connection, blow-out back and shattered proof glass Flowmeter The flow measurement sensor shall be of low power consumption electromagnetic induction full bore type. It shall be able to operate fully on nominal 24V DC supply system. The sensor supplied shall conform to the following standard: 1. 1SO 4064:2005 - Pt 1, Pt 2 and Pt3 ~ Measurement of Water Flow in closed conduits ~ Meters for cold potable water 2. ISO 6817 ~ Measurement of conductive fluid flow in closed conduits ~ ‘Method of Using Electromagnetic Flow Meter 3. ISO 9104 - Test and Measurement of Fluid Flow in Closed Conduits For Electromagnetic Flow Meters For Liquids 4. EN 60529 - Degree Of Protection By Housing (IP Code) 5. EN 61010 ~ Protection Measures For Electrical For Measurement, Control,Regulation and Laboratory Procedures 6 EN 61326 (IEC 1326) ~ Electromagnetic Compatibility (EMC Requirements) ‘The sensor shall be from a remote type (detachable from converter) and can be connected to converter via IP68 cable and connectors with maximum length of 30m. It shall be rated to P68 (submersible up to 10m) for ingress protection and be constructed of materials suitable for outdoor/inside chamber installation, The sensor shall be free of any external influences that can affect the flow meter accuracy such as magnetic fields, electromagnetic fields interference etc. The sensor shall be of full or contoured bore design with ranges of diameters from 25mm to 1500mm. The flow meter sensor body shall be of flanged design and be rated to handle line pressures up to 16 bars Page 25 of 6145 Telemetry & Instrumentation System Specifications The sensor body shall be made of carbon steel and the electrodes shall be made from AISI 316 stainless steel. The lining shall be made from material suitable for potable water such as polypropylene or ebonite Grounding electrodes or earthing ring (upstream as well as downstream) must be provided with the sensor (detector head). The earthing rings shall be of stainless steel, Grounding termination for both side meter (sensor) to pipe shall used minimum of 4 mm? cable and shall be connected to earth The requirements of earthing ring system are to follow the recommendation as according to installation manual. The sensor shall have a combined accuracy with converter for 025% or better and repeatability of at least 0.5%. The sensor shall able to measure bi directional flow and come with empty pipe detection feature ‘The sensor shall operate satisfactorily in ambient temperatures up to 60°C Digital Indicators (Panel Meter) The digital indicator shall be of modular design incorporating signal input and conditioning, analogue to digital conversion power pack, analogue and/or BCD output modules and switch for decimal position. Indications shall be in engineering units to an accuracy of + 0.1% of reading + 1% count and better. Zero stability with temperature shall be equal to or better than Tuc All indicators shall operate from DC voltages of 24V DC nominal with + 20% variation and in temperature ranging from 0°C - 60°C. AC type indicators are not acceptable. The indicators shall be equipped with LCD displays with minimum of 14 mm height LED and can easily be seen from across a control room and at all viewing angles ‘The number of digits required for the difference type of measurements shall be as follows: 2 Level 99.99 m 2 Pressure 999.99 m ° Flow 9999.99 mi/hr © Totaliser —999,999,999m3 Page 26 of 6146 a7 Telemetry & Instrumentation System Specifications In case of flow measurement, the indicator shall provide both FLOWRATE and TOTALISER. It shall also incorporate RESET and security features. The flowrate shall have programmable scaling Trip Amplifiers Trip amplifier shall be suitable for back of panel or rack mounting and shall accept a 4-20mA DC linear signal as an input and provide dual trip level indication as output The trip amplifier shall drive down scale on open circuit The trip adjustment shall be mounted on the instrument front and shall be infinitely variable by a lockable single turn 260° degree calibrated knob with 0 to 100% scale with calibration accuracy of 1%; repeatability shall be + 0.2% span. The trip amplifier shall be suitable for operation on nominal 24 V DC supply The output relay for each point shall be provided with switch contacts rated 250V 5 Amp AC resistive loads. The state of the relay shall be indicated by a red light emitting diode (LED) display for each trip on the front of the trip amplifier A ‘power on’ indication shall also be provided Input and output terminals shall be suitable for conductors up to 2.5 sq mm. Signal Isolator Signal or buffer isolators shall be suitable for back of panel or rack mounting and shall accept a linear 4 to 20 mA DC signal as input. Signal isolators shall be provided in the respective supervisory panels for all signals that are required for onward transmission to the telemetry system. In addition, each signal that is to be duplicated shall be provided with a signal isolator The Signal isolator shall be standard equipment having the following features: Input 4-20mA, 0-5V or 0-10V Input impedance Current 100 ohm |_Voltage | > 100 k ohm az Output — 4-20mA, 0-5V or 0-10V Span Adjustment se Supply Range 9-60 Vde _Accuracy < 0.15% span_ Isolation ~__Min 2000 V RMS Page 27 of 61Telemetry & Instrumentation System Specifications 48 Alarm Annunciator System The purpose of using Alarm Annunciator System is to provide visible and audible alarm points. The following facilities shall be incorporated as minimum requirements: © Indicating lamps showing the low, high and overflow alarm status of suction and reservoir levels * Alarm siren indicating the operation of the sets point * Acknowledge buttons for test, accept and reset, Alarm functions shall be indicated on internally illuminated annunciator units bearing appropriate legends and arranged properly on the panel in groups The VO of the system shall be directly from the RTU. The alarm indications on each annunciator shall be logically arranged in a format to be agreed with the S.O. The alarm lights shall have secret legends which are invisible until illuminated. The legends area of each indication shall not more than 40mm high and 75mm wide. The wording of all legends shall be approved by the S.O before manufacture. ADC siren of approved make approximately 80 decibels at 3 meters and of not less than 5 minutes rating shall be mounted within the panel together with muting switches mounted inside for use during commissioning and testing The alarm system shall operate on a 24V DC supply and be designed on the ‘failsafe’ principle so that a fault in any circuit component causes an alarm to be given. “Alarm Accept”, *Reset” and ‘Lamp Test” pushbuttons shall be provided in the middle of the instrument panel Page 28 of 61Telemetry & Instrumentation System Specifications 5.0 TELEMETRY / SCADA SYSTEM 5a Remote Terminal Units (RTU) The Remote Terminal Unit (RTU) shall be of a modular design. It shall comprise a separate power supply unit, a separate CPU module and separate VO modules that can be added onto the backplane on an incremental basis. Failure to any module shall necessitate a change of the faulty module only The RTU shall utilize modular input/output modules and be expandable to support up to 1024 VO points. ‘Brick’ type RTUs where the CPU and some V/Os are built into integral units are not acceptable. The communication protocol provided between RTU ~ master station and RTU ~ RTU shall be DNP3.0 and the communication protocol between RTU and smart sensors shall be Modbus as minimum requirement. All communication protocols must ready for both serial and IP-based communication medium. DNP3 protocol must be configured in Unsolicited & Report By Exception mode in order to optimize data transmission. The analogue input modules shall accept 4-20 mA DC from field-mounted transmitters. The analogue inputs shall have minimum of a 12-bit resolution with signal input accuracy of at least 0.05% of full-scale span. Contact inputs shall be optically isolated and protect input circuits from transients and surges up to 3 kV input-to-logic, Analogue output modules shall convert data words into proportional, isolated 4-20 mA DC analogue output signal to adjust gate positions with minimum 8-bit resolution. The analogue power output shall be able to drive up to 500 ohm maximum resistance load The digital input module shall be capable of accepting switching of mechanical or solid state contacts. Protection rating of the input circuits from transients and surges up to 3 kV inputto-logic. All points must have configurable contact debounce features for noise filtering to filter high frequency noise from plant The RTU shall be equipped Pulse Counter function which can be assigned to any DI point. Its function is to accept any pulse connected to it and Page 29 of 6Telemetry & instrumentation System Specifications counts incrementally inside memory, even in sleep made. It must be able to count for a maximum caunt of 999,999,999 The pulse counter shall also be able to be set to any value and reset to zero ‘The digital output modules shail be capable of providing solid-state switches in either momentary (pulse], oF latched mode to control AC or OC powered loads. Isolation protection shall provide isolation up to 3 KV input-to-logic Digital output points switching current shall be 2A maximum RTU is recommended to have built-in surge suppressor of varistor type to clamp the DC surge level to 25% above the working voltage for all VO points The RTUs shall come with one TCP/IP Ethernet ports, one RS-232 and one S485 serial port as the port for RTU to RTU communication using Master/Slave configuration and communication to sensors, Data signal from the outstations shall be transmitted to the master station via the same single GPRS communication link using VPN connection RTU configuration software shall be provided to enable the RTUs to be configured at site. The RTU configuration software shall run on a notebook computer with Windows XP Pro minimum. It shall be possible to perform field upgrades by downloading a file through the RTU communication port locally or remotely via Operation Command Center, The RTU shall be suitable for operation a single phase 240 V + 10% 50Hz supply with auxiliary power supplies at 24 V DC supply or 24 VDC supply from a solar power system ‘The RTU shall be of a low-power design. This is to allow easy and cost effective installations using other power sources such as solar or battery power. A low power design will also enhance reliability of the CPU module ‘The RTU programming shall be compliant with IEC 1131-3 programming language standard and shall support as a miniraum ~ Ladder Diagram = Structured text ‘The RTU CPU shall have an integrated watchdog timer and a minimum of J6MB external RAM and shall use Flash/EEPROM/SD card memory to support the RTU non-volatile storage of data logging, parameter settings and “Page 30 of 61Telemetry & Instrumentation System Specifications 5.2 instruction sets. The RTU CPU shall come with a realtime clock The crystal oscillator of the real-time clock shall have a tolerance of no more than 10 parts per million to ensure accuracy of time tagging of data When there is a real-time communication link with the master station, the RTU shall be able to synchronize its reak-time clock with the master station clock via communication link and protocol The RTUs and all its associated equipment shall be designed to function continuously in temperatures between 0 - 70°C. and humidity between 0 to 95% relative humidity non-condensing, All RTUs shall be configured to perform local automation functions at the pumping stations independent of the master station and come with report. by-exception (RBE) and solicited reporting features to minimise the amount of unnecessary data transmitted to the master station, In the event of GPRS failure, RTU must use SMS as a backup in order to send important alarms/messages to Command Centre ie. Low, Low-Low, High, High-High, Overflow for analogs, all digital input events and control commands. RTU shall revert back to GPRS channel once available COMMUNICATION SYSTEM Cutstations RTU must be configured to use VPN over GPRS network. The data will be packeted and transmitted across the GSM network using GPRS to the nearby GSM Base Stations and will then be forwarded to the Internet Service Provider (ISP) and sent to SYABAS Head Office through IP based connection 5.2.1 GPRS & 3G Modem ‘The modems shall be versatile, sensitive, reliable and able to operate for 24-hours continuously over all the GSM bands available The modem shall come with 1 TCP/IP Ethernet ports and 1 nos. RS- 232/RS485 serial port (minimum) as the port for communication The modem shall have builtin firewall and supports SSH virtual private network (SSH-VPN) for secure communication to M2M Gateway located at Operation Command Center The modem shall be designed to function continuously in temperatures between -20 °C to 55°C with natural air circulation and Page 31 of 61‘Telemetry & Instrumentation System Specifications humidity between 5 to 85% relative humidity non-condensing The modem shall be suitable for power supply operation between 10 V DC to 30 V DC supply. It shall come with high-gain, omni-directional remote antenna with minimum 05 meter cable length and screw-type based for secured/permanent installation. The antenna shall be mounted permanently on top of RTU panel for maximum radio signal reach- ‘out to nearby based station. The installation shall not interfere with the original IP rating of RTU panel ‘The modem operation shall be transparent to RTUs and SCADA software at Operation Command Center where it shall not interfering, modifying, buffering, holding and removing the communication data encapsulated within the communication protecol “The modems shall support communication mode using SMS as a backup where data shall be generated and sent by SCADA system in this format in the event of failure on the IP-based communication channel 6.0 DISTRIBUTION SYSTEM - CABLING 64 General Requirements Cables and wires shall be supplied by an approved manufacturer and as far as possible the same manufacturer shall be used for all cables and wires Each drum or coil shall be accompanied by a test certificate stating the manufacturer's name, rating of cable, result and date of tests, Cables manufactured more than 12 months before delivery will not be accepted All armoured cables shall be terminated with mechanical glands which shall be of a type as to provide adequate mechanical support by positively Jocking on the armour and shall at the same time give a high level of earth continuity. The glands shall be provided with earth tails for connection to earth nearby earth bar at RTU panel side only. Cabling between the various items of Plant shall be of the types as shown in the Drawings a) Delivery Page 32 0f 61b) °) d) ‘Telemetry & Instrumentation System Specifications Al cables shall be delivered on robust cable drums with cable ends treated to form an effective seal. When a cable is cut from a drum the cable end and the end left on the drum shall be immediately sealed in an approved manner to prevent the ingress of moisture Conductors ‘All cables comprise high conductivity stranded copper conductors of the sizes and comply to BS 6360. The conductors of single core cables shall be circular; those of multicore cables shall be generally Shaped. Multicore control cables shall have a cross section not less than 2.5 sq. mm Insulant Colours: Insulant colours shall generally be in accordance with the recommendation of the LEE Regulations. Rating The Contractor shall ensure that each cable has sufficient rating for its duty under both normal and possible fault conditions, In assessing the rating and cross section required for each cable the following factors shall be taken into account:- () Fault level and durations as governed by circuit protection relays and MCCBs or MCBs. (iy Ambient air and soil temperature (ii) Allowable voltage drop under steady state (4% from source main 415 volt switchboard to sub-switchboard or MCC within a final sub-circuit) and transient (motor starting) conditions (iv) Loading under steady state and transient conditions (v)__ Disposition of cables, whether in air or laid in the ground (vi) Method of laying, (vii) Route length Page 33 of 67Telemetry & Instrumentation System Specifications 62 Types of Cable a b) a Instrumentation Cable pvcieve Instrumentation cables specified as PVC insulated, non-armoured ‘and PVC sheathed. The cable shall be 300/500V multi-tranded, ‘overall screened and tested to BS 5308. The cable shall be used for the exposed installation type and shall not less than 15mm dia PVC/PVCISWAIPVC Instrumentation cables specified as PVC insulated, armoured and PVC. sheathed. The cable shall be 300/500V multi-stranded, overall screened and tested to BS 5308, The cable shall be used for buried installation type and shall not {ess than 1.5mm dia Power Cable - Low Voltage DC power cables shall be from black and red color meanwhile 240VAC. power cable shall be brown, blue and green PVC/SWAIPVC ‘The underground distribution cables. shall have conductors of annealed copper PVC insulated, steel wire armoured and PVC sheathed adequately sized to carry the total power output and lighting circuit required for the works and taking into consideration voltage drop in accordance with LEE Regulations. PVC insulated armoured cables shall be manufactured in accordance with the current B'S. 6346. The voltage rating (EO/E) for the cable shall be 600V/1000V_ Power and control cables specified as PVC insulated, galvanized steel wire amoured cable with an overall PVC sheath are hereinafter Page 34 of 61‘Telemetry & Instrumentation System Specifications referred to as PVC/SWAJ/PVC and shall be manufactured and tested to BS 6346, ‘The cores of PVC/SWA/PVC cables shall be laid up to form a circular cable and, where fillers are necessary for this purpose, they shall be of PVC. Textile or other hygroscopic fillers are prohibited There shall be no adhesion between bedding or sheath and insulation. A polyethylene terephthalate (PTP) binder tape over the laid iup cores shall be included by manufacturer The amour bedding shall consist of an extruded layer of Type 6 or Type PVC compound complying with BS 6746, The radial thickness shall be in accordance with BS 6346 ‘Amour shall consist of galvanized steel wires applied generally in accordance with the requirements of BS 6346. Galvanizing shall meet the requirements of BS 1442 The outer covering the amour wires for all multicore control cable shall consist of a black extruded PVC sheath which shall comply with the requirements of BS 6746 for Type 1 compound. The thickness shall be in accordance with BS 6346 Conductors used for AC and DC systems shall not be mixed in the same multicore cable, Control cables shall be made up of the following standard numbers of cores : 4, 7, 12, 19, 27 and 37. All cores shall be coloured white and shall be identified by black numbers arranged in sequence, eg. 1,2,3,4,5,6, etc ‘These numerals shall be lightly imprinted on the core insulation at intervals of not more than 75 mi throughout the core length. The Shall be permanent in nature and not easily removed without severe mechanical scraping, The figure ‘9" shall be distinguished from the figure ‘6’, thus ‘9’ Cables laid direct in the ground shall be laid in prepared trenches rot less than 600mm deep for LT. cables and of sufficient width to ‘accommodate the number and size of cables required. There shall be 2 layer of compacted sand not less than 25mm thick as bedding, ‘After the cables have been laid, sand shall be spread over the cables covering the entire length and width of the trench to a minimum thickness of 25mm above the largest cable and leveled. The sand Page 35 of 6(iii Telemetry & Instrumentation System Specifications used shall be fine river sand with no stones included. A layer of bricks shall be placed over the cables. Backfilling shall be made with first quality material and well compacted where cable trenches run across turfed area and roadways ‘The turfing and reinstatement of the road shall be properly carried out to the C&S Specification requirement. Wherever possible cables shall be laid in continuous unjointed lengths for the entire length of the cable route Where joining of cable is unavoidable, cables shall be properly jointed using approved cable-joint box to ensure full conductivity at rated current. The SO. reserves the right to reject cables in short lengths below 27.5 metres pvc Power cables specified as single core PVC insulated are hereinafter referred to as PVC cable and shall be manufactured and tested to BS 6004. Such cables shall be terminated as specified elsewhere PVC/PVC Power cables specified as single core PVC insulated and sheathed are hereinafter refered to as PVCPVC cable and shall be manufactured and tested to BS Code 6004 or BS 6746 as appropriate. Such cables shall be terminated by mechanical glands similar to that specified for PVC/SWA/PVC cables 63. Installation Methods a) General Cables which are to be run on walls, ceiling or other building structures shall, unless otherwise agreed by the S.O., be secured on cable trays or enclosed in GI conduit as appropriate. Every cable shall be neatly run vertically or parallel to adjacent walls, beams or other structural members Where the building structure incorporates purpose-built covered duct or trench systems for cables, power cables and control cables shall be segregated and installed on separate trays, secured to the walls and/or floor of the trenches. However, over short distances, control Page 36 of 61‘Telemetry & Instrumentation System Specifications cables may be run with the power cables, rated not more than 600 volt with some spacing between the control and power cables. Where the structure incorporates general service ducts or trenches containing pipework, chemical lines and other services, all cabling shall be segregated from the other services and shall be run on the trench walls, secured to cable trays. Crossover shall be kept to a minimum and cabling shall be taken above wet service pipework Throughout the installation, due regard shall be paid to the spacing of cables to maintain current rating, to prevent interference between power and signal cables, and to avoid unnecessary crossovers and deration Cable hangers, cleats, saddles, brackets and similar supporting devices shall be of an approved type and of adequate strength for the cables they are supporting. They shall be treated to withstand site conditions without cooding. Self locking plastic buckle clips and strapping shall not be used. Re-usable cable ties may however be used. Cable ties shall be of nylon for indoor installations and stainless steel straps covered with PVC/nylon for outdoor installations Nylon straps shall be of ultraviolet stabilized type Cables installed outside trenches, on the floor and walls shall be provided with trunking covers to protect the cables against mechanical damage. Cables installed in areas of direct sunfight shall be covered with cable tray trunking covers or GI conduits entirely up to instruments cable entry holes, All power cables shall be laid in a single layer and no bunching is allowed. A minimum spacing of one time the cable diameter shall be maintained for the power cables Control/signal cables may be bunched to a maximum or two layers. Wherever it is necessary to remove the PVC sheath of a cable, eg. at a joint, only the minimum length necessary shall be removed and the exposed armour or copper sheath shall be neatly protected by PC tape or sleeves or other suitable means. Where cables pass through walls below ground level, the Contractor shall ensure that the point of entry is scaled against the ingress of moisture. Cables shall be wrapped with “Denso-tape” or approved equal and any remaining Page 37 of 61by Telemetry & Instrumentation System Specifications spaces around the cable filled with “Denso-mastic’ or similar approved materials Cables for high level signals, low level signals, resistance thermometers and thermocouples, shall be segregated from each other and each shall be separated from cables for power, communications and other electrical services. Other cables run in the vicinity of instrumentation cables shall be separated from instrumentation cables by a distance of not less than 1% of the length of any parallel run, with a minimum of 600 mm and a maximum of 4000 mm. Initiating devices for plant protection and personnel safety shall be connected by individual cables direct to the tripping or safety device and shall not be routed via any intermediate junction, marshalling box, cabinet, relay, etc. The other sheaths of such cables shall be coloured orange. Other circuits may, subject to the provisions of the above paragraph, be grouped in multipair cables. Terminals and glanding facilities shall be provided in junction boxes, marshalling boxes, switchgear, etc. as appropriate, Cable Tray Cable tray shall be of the heavy duty, return flange perforated type, fabricated out of electrogalvanised steel sheet and polyester power coated The galvanised steel sheet shall be penetrated to remove oil, grease, dirt, rust, millscale and the metal surface passivated before polyester powder coating is applied and cured at 200° C. The polyester powder coat shall not be less than 80 micron thick The thickness and suppott spacing of cable trays shall be as follows: Sheet Steel Support Width Thickness Spacing (Max) Up to 300 mm, 15mm 750 mm above 300 mm to 600 mm 20mm 800 mm above 600 mm to. 25mm 800 mm 900 mm Page 38 of 61Telemetry & Instrumentation System Specifications ° ‘The height of the return flange shall not be less than 50 mm. Loading on cable trays shall not cause at mid span a deflection greater than 4 mm. All supports and tray work shall be a suitable for withstanding a temporary weight of 125 kg. The cable trays and accessories shall be sized to provide 25% additional free space available after installation of the cables. The minimum clearance behind the tray shall be sufficient to allow for fixing of cables, which will relate to tray width, but shall not be less than 25 mm. Where trays are tiered, clear access shall be available to all trays, with minimum 300 mm separation between trays ‘Arms and supporting channels for cable trays shall be hot dipped galvanized and shall be mill strut or approved equal Fixings for cable trays shall be disposed at regular intervals specified and not more than 200 mm from bends to fix together adjacent sections of cable trays and/or accessories Conduit All conduits shall be of Class B hot dipped galvanized and screwed steel type. Stove enameled conduit shall not be used without the written permission of the SO. Conduit fittings shall be of malleable cast iron and be hot dipped galvanized. Fitting with covers shall have a machined surface around the perimeter, mating with a similar machined surface on the cover The cover fixing screws shall be of brass. Conduit shall be run on the surface or sunk as specified and be neatly arranged, and ways shall be provided for additional conduits at all distribution boards. The sizes of conduit used shall be determined by the number of cables to be drawn in as scheduled in the LEE. Regulations or as specified for a particular position but in no case shall conduit smaller than 20 mm diameter be used. Sunk and concealed conduit systems shall support fittings independently or any false ceiling Conduit shall be supported by hot dipped galvanized mild steel hangers fixed to walls/floors ‘The conduits shall be screwed into spout outlets of conduit boxes or where fixed to boxes drilled with properly sized clearance holes they shall be secured by means of sockets and hexagon bushes. Alt threads shall be cut clean and all burrs shall be removed with a Page 39 of 61Telemetry & Instrumentation System Specitications reamer. Exposed threads and plates where galvanizing has been damaged, shall be cleaned and painted with two coats of an approved metallic zinc based paint. The teatment applied as the work proceeds Standard rectangular junction or adaptor boxes shall be provided at all junctions and at sharp changes of direction in addition to any other special positions where they are called for by the SO. on Site Inspection couplers may be used in long runs to facilitate drawing in cables, subject to the approval of the S.O Particular care must be taken to ensure that no water is allowed to enter the conduit at any time and all conduits shall be arranged with adequate ventilation and drainage where necessary as directed by the $.0. Inaccessible junction boxes will not be allowed. Only continuous lengths of buried conduit shall be installed between boxes, no joint boxes being allowed in the floor screeds. Conduits crossing expansion joints shall be fitted with couplings of approved manufacture with an earthing clip at each side of the coupling connected by the correct size of tinned copper stranded wire The ends of conduits laid or set in formwork prior to concreting shall be temporarily sealed off with a coupler and a solid brass plug. Fixing to surfaces of walls shall be by means of galvanized steel stand-off saddles or 25 mm aluminum strip saddles where more than one conduit is run in parallel, securely fixed by brass screws and nylon plugs. Conduits shall be supported at regular intervals not exceeding 75 mm on horizontal runs and 900 mm on vertical runs Where conduits are concealed ot laid in constructional floors, they shall be held in position with substantial fixings of a make and pattein the approval of SO, A junction or adaptor box shall be provided in all conduit runs exceeding 10 metre in length or containing more than two tight angle bends or the equipment, to facilitate the draw-in of wires. Junction and adaptor boxes shall be made from galvanized steel and be provided with gasketed flat covers secured with brass screws Weatherproof boxes and accessories shall be used outdoors, where agreed on Site by the $ O. Conduit shall be installed such as to permit complete rewiring without the need to remove false ceilings or carry out builders work. Page 40 of 61ad Telemetry & Instrumentation System Specifications Cables for drawing into conduit shall be single core PVC insulated, non-sheathed, 1000 V grade and shall be supplied by an approved manufacturer. Insulation shall be coloured to indicate phase and neutral in accordance with the 1£.£ Regulations Care is to be taken in the number of cables in conduit and in no case shall conduits enclose more cables than that set out in the I.E, Regulations. No single conduit serving a single phase socket outlet, lighting point or switch shall contain more than one phase. Switch wires shall be white in colour Wiring shall be carried out on the looping-in systems and no joints other than at looping-in points will be allowed. Cables shall be only drawn into the conduit after the conduit installation has been completed All conduits before painting shall be washed with C1 Litho form or approved material and shall then be primed with an approved chromate primer followed by one undercoat and two coats of approved gloss finish for general areas. In chemical building and other corrosive areas such as chlorine building, the undercoat and top coats shall be resistant to corrosion Flexible conduits shall be of steel with PVC over-sheath and a separate earth wire shall be provided for earth continuity ‘Trunking ‘Trunking shall only be used with the written consent of the $.O , where large multiple parallel conduit runs occur The trunking shall be manufactured from electro-galvanized steel of minimum thickness 1.5 mm, and shall be polyester coated. The trunking shall have two retum flanges for rigidity and removable cover. The covers shall overlap the trunking and be made of the same gauge. Each length shall be supplied with necessary connection sleeves and joggled sides to allow flush fitting The number of cables installed in each trunking shall be such that space factor of 45% is not exceeded. Separate compartments shall be allocated using sheet stee! barriers welded to trunking for circuits requiring segregation Page a1 oF 6164 Telemety & Instrumentation System Specifications ‘The Contractor shall ensure that the size of the trunking is adequate for the number of cables passing through it, but as a minimum the size should be 50 mm x 50 mm. All bends, tees and intersections shall be of the gusset type and manufactured by the maker of the trunking and to a similar standard. The trunking shall be fixed to the ceilings by means of a secure and permanent fastening to be approved by the § 0 Trunking shall be supported at intervals not exceeding 2 metre horizontally of 2.5 metre vertically Where the trunking is installed in a vertical position insulated cable supports shall be provided and packing shall be used at positions where trunking goes through floor. Cables shall be retained in the trunking when the cover is removed, by means of saps. Trunking covers shall be fixed with centre and sideways captive screws or spring-on type and no selftapping screws will be accepted When trunking passes through a fire wall, a floor slab, a barrier of adequate fire rating shall be installed to prevent the possible spread of fire Cover plates shall be supplied in short lengths for easy removal Every entry to finished trunking shall be so placed as to prevent the ingress of water Cover plates shall be securely fixed after wiring is completed For cables containing termite repellents, the drums shall bear a label ‘on the outside, warning that gloves shall be worn when handling the cable Cable drums are to be non-returnable and are to be thoroughly tweated with cuprinol or equal insecticide and wood preservative Excavation and Backlilling of Trenches The exact location of each cable trench will be settled on the Site by the SO. when the Contractor is ready to commence work. Trenches shall be kept as straight as possible and shall be excavated to approved formation and dimensions, and shall generally be 800 mm deep for cables of rated voltage up to 1000 V and 1000 mm deep for cables of voltage grade above 1 kV up to and including 33 kV. Trenches shall have Page 42 of 61Telemetry & Instrumentation System Specifications vertical sides and are to be timbered and sheeted where necessary to prevent subsidence. The bottom of excavated trenches shall be free of sharp stones and other obstacles Where cables of different voltages are laid together, at the same depth, vertical cable tiles shall be used to segregate the cables, Before the cables are laid, the bottom of the trench shall be lined with sand which is to be punned down to a thickness of 150 mm to form a bed. After the cables are laid, the first 150 mm depth of cover backfill shall consist of sand, aver which shall be placed protective covers After all cables and protective covers have been laid, the trenches shall be refilled in 150 mm layers, each layer being well rammed and consolidated. The surfaces of refilled trenches shall be temporatily reinstated and maintained in a thoroughly safe condition until complete consolidation of the soil is achieved ‘The Contractor shall include for all materials and labour to reinstate the ground to the same condition prior to excavation i.e turfing, drains and roads, ete. The excavation of trenches shall include, by way of amplification but not of limitation, all timbering, pumping and bailing required and the provision of all necessary labour, plant, tools, additional soil, fuel and motive power for such purposes and the cost of the expendable materials shall be included UPVC cable ducts shall be provided and installed at road crossings. Only one cable shall be permitted in each cable duct. The external diameter of cable duct shall be 150 mm for cables of overall diameter 65 mm or more 100 mm diameter ducts may be considered for smaller cables. These ducts shail be encased in a concrete jacket of 150 mm thick. The ducts shall be laid at a minimum depth of 1000 mm Cables shall normally go under all obstruction such as mains, sewers, drains, conduits and the like which cross the trench The trench bottom shall be ramped firm. Where it is not practical to go undemeath culverts and drains, cables shall at discretion of $ O. go over them The cables shall be adequately supported and protected at the crossing. The type of support and protection proposed shall be subject to the approval of SO Page 43 of 61