ACUD Project

Cairo, Egypt

2.6 Plant Control System

2.6.1.1 Summary
This section provides the control system design, functional requirements, and integration requirements to
be employed for the operation of the DCP. This is intended to augment the tender standard
specifications.
The Contractor shall be responsible for selection and design of the DCP control system. The control
system design shall meet the following goals:

1. Minimize the number of operating personnel needed for operation of the system by providing
fully automated plant with provisional to integrate distribution network system to control the
supply pressure and plant loading based on current and forecasted weather conditions.
2. Standardized control system hardware, software, and field devices for the plant, to provide for
ease of maintenance.
3. A separate control system shall be provided for life safety and building services, including for
the plant HVAC temperature controls.
4. Online water measurements to optimize chemical dosing.
5. Level controls and alarms on all the tanks, including notification when new chemicals should
be ordered.
6. Control system shall be easily expandable to meet growth requirements of the DCP system.
7. Control system for the chiller plant shall be REDUNDANT in configuration and communicate
to all plant equipment (Chillers, Pumps, chemical treatment, Make up water systems,
Electrical system (S/S, TR, VFD etc) and all auxiliary equipment (Valves, Transmitters,
Switches etc) and for monitoring and controlling ETS.
8. The SCADA software shall be configured with dynamic graphics inline with the plant process
to communicate with existing plant PLC to incorporate controls and instrumentation as
mentioned in Section 16935 under Employer’s Technical Specifications (Part 2) is included in
contractor’s scope.
9. Supply, installation, testing and commissioning of any communication interfaces e.g. Modbus,
Profibus etc. to facilitate communication various plant areas like Chemical treatment, Make
up water systems, Electrical system (S/S, TR, VFD etc) and ETS control systems are
included in scope.
10. The control system shall be designed using commercially off the shelf products/software and
use open protocol communications/software; use of bespoke software shall only be on
agreement with the Employer
11. The Contractor shall consider spare requirement for the interfacing of ETS’s control and
monitoring as part of the overall DCP control system. The SCADA software and PLC shall have
enough space (tags, screens, memory etc.) and should not require any upgrade or licenses .
12. The DCP control system shall be powered from uninterruptible power supply (UPS) system.
PLC’s and SCADA shall include software and all necessary licenses provided by the
manufacturer that has been registered in the Owner’s name. The chillers and other

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equipment with integral controls shall be seamlessly integrated to the DCP control system so
that such equipment can be monitored and controlled by the system.

2.6.1.2 Codes and Standards

The control system design and components shall conform to the applicable provisions in the latest edition
of the following codes and standards.
In case of differing standards, materials and construction, the system shall be in accordance with those
standards requiring the highest grade.
1. International Electro Technical Commission (IEC) standards.
2. Instrument Society of America, recommendations, standards and monographs
3. BS 7671 (IEE wiring regulations for electrical installations in buildings)
4. ANSI - American National Standards Institute.
5. IEEE - Institute of Electrical and Electronic Engineers.
6. NEMA - National Electrical Manufacturers Association.

2.6.1.3 Control System Architecture

The DCP control system shall utilize industrial microprocessor based control system and field devices.
The control system shall be expandable, to incorporate programmable logic controllers (PLC’s), the
minimum being 30% in both I/O and program capacity. The field devices shall communicate with the
PLC’s using industry standard signals and/or open communication protocol). Controllers in the chiller
units and similar equipment shall communicate with the control system PLC’s using open communication
protocols. The control system shall include not less than two personal computer-type workstations with a
report printer and an alarm printer. The plant control system shall be capable of fully automatic operation,
with the workstations providing monitoring and plant adjustment control. The operational state of the
workstations shall not affect the operation of the plant. All fault conditions shall be resettable either at the
local PLC or from the workstations. The control system shall provide the ability to monitor and control
ETS’s from the DCP control room, as well as the number of ETS’s in operation. The system shall be
capable of trending and performing historical data storage in a retrievable format. The control system
hardware shall be selected with redundant controllers and UPS power systems in critical areas to
maximize control system availability as described in the following sections.

Any TSE polishing plant (RO/UF) or internal water treatment included with this project shall be integrated
into the control system.
The intent of this section is to present the concept of the overall plant control. This will be used as guide
for the final equipment selection, coordination with vendors, and preparation of the technical proposal for
approval.

2.6.1.4 Levels of Control

Tabreed is adopting a control system uniformity strategy that all plants in the same geographical area
shall be procured, designed and operated in an identical fashion, therefore, the description of levels of
control and philosophy of control apply to all plants in the same area.

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The control system shall have the following levels of control:

A. Plant’s control room (PCR)
B. Local from Panel Views, near each group of equipment at different floors (LPV)
C. Electrical room (ER)
D. Local Control (LC)
Operators shall monitor and control the chilled water plant and distribution system from Plant’s Control
Room.

The control system shall be configured to maximize the ability of the superintendent to remotely manage
and control the plant and distribution systems, thus minimizing the need for personnel at the plant or
customer locations. The Contractor shall consider the implications of safe plant operation from a remote
location within his deign and provide safety interlocks as required.

2.6.1.5 SCADA and Workstations

The following is a recommendation of what type of hardware and software would be appropriate for its
intended use.
The true multi-client/server architecture and fault tolerant configuration shall be used to increase the
system resilience. This is to carry out its assigned function even in the presence of one or more faults in
the hardware or software without loss of a system function.
Two-operator work stations at (PCR) shall be provided primarily one to monitor the operation of the plant
and one engineering workstation with which the qualified personal at this plant will be able to modify the
operating sequences or parameters of any equipment

2.6.1.6 Database and Data logging

Database with open system design shall be implemented to comply to the standard ODBC interface such
as Microsoft SQL server database to log data such as alarms, events and point values so that it is
possible to later retrieve this stored information for reports and different ODBC-compliant application

Database logging occurs on both systems. So, if one system fails, the other system continues to log data.

Both computers shall have the storage and archiving functionality of historical values (long- time history
and trending), the generation of the user defined reports by reports manager, historical data analyzing,
recipes, and calculation functions. The archiving of the process data will be to a DVD as a backup-
storage system installed in both the systems.

Database management software shall be the most recent field proven revision to manage the history,
data archiving, trending, and reporting.

DVD media shall be implemented for data archiving and backup.

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2.6.1.7 System sentry

System sentry software shall be implemented to keep providing system real-time information and the
health of the computers and applications. It will provide alert and remedial action and tools so that the
cause of the fault could be cleared immediately

2.6.1.8 System Immunity

The control system design and components shall be designed to take into account the electromagnetic
environment associated with high voltage plant and variable frequency equipment. The design of the
plant in general is to conform to international standards for EMC emissions and the control system shall
be designed to conform to international standards for EMC emissions and include consideration for
altitude, ambient temperature, humidity, possibility of condensation, ventilation, vibration, airborne
contamination, noise and electrical power quality.

2.6.1.9 Safety Integrity Level

The control system and components shall be designed to take into account, the nature of hazards,
consequence and risk reduction, the intended safety integrity level and the type of technology
implemented in the system. The Contractor shall provide documentation as part of his design
submissions to illustrate compliance with the IEC 61508, to the intended safety integrity level.

2.6.1.10 Integrator
A control system integrator (Integrator) shall be engaged and shall be responsible for interfacing the plant
controls and ETS controls into the cooling control system. The Integrator shall have appropriate
experience in successful implementation of control systems in electric power generation facilities, heating
plants, cooling plants or industrial refrigeration plants. The Integrator shall be capable of supplying the
Contractor services, functional requirements preparation, functional description preparation, control
system engineering, instrumentation engineering and installation engineering for all components of the
cooling control system. The Integrator shall also provide on-site services during construction check out
and start-up of the district cooling system

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