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SCADA Master Plan Executive Summary ............................................................................... ES-1 Introduction........................................................................................................................ES-1 Recommendations .............................................................................................................ES-1 Existing Facility Control Systems....................................................................................ES-2 Network Architecture .......................................................................................................ES-2 Collection System Network ................................................................................ES-3 WWTP Networks .................................................................................................ES-3 Operations Data/Control Center and Operations Network..........................ES-3 Business Network.................................................................................................ES-4 Implementation..................................................................................................................ES-4 1 Alternatives Evaluation and Recommendations .......................................................... 1-1 1.1 Introduction............................................................................................................. 1-1 1.2 Recommendations .................................................................................................. 1-1 1.2.1 Controllers ................................................................................................. 1-1 1.2.2 Collection System Communications Recommendations .................... 1-2 1.2.3 WWTP Communications Recommendations ....................................... 1-2 1.2.4 Operations Data Collection Network Communications Recommendations .................................................................................... 1-2 1.2.5 Local Operator Interface .......................................................................... 1-2 1.2.6 Collection System Control Center Recommendation.......................... 1-3 1.2.7 WWTP Control Center Recommendation............................................. 1-3 1.2.8 Operations Data/Control Center Recommendation ........................... 1-4 1.3 Evaluation................................................................................................................ 1-5 1.3.1 Controllers ................................................................................................. 1-5 1.3.2 Collection System Communications Evaluation.................................. 1-9 1.3.3 WWTP Communication Evaluation .................................................... 1-12 1.3.4 Operations Data Network Communication Evaluation ................... 1-12 1.3.5 Local Operator Interface Evaluation.................................................... 1-12 1.3.6 Collection System Control Center Evaluation.................................... 1-13 1.3.7 WWTP Control Center Evaluation....................................................... 1-14 Implementation Plan ......................................................................................................... 2-1 2.1 Introduction............................................................................................................. 2-1 2.2 Recommendations .................................................................................................. 2-1 2.3 Design Criteria ........................................................................................................ 2-2 2.4 Standard Pump Station Design Documents ....................................................... 2-2 2.5 Procurement ............................................................................................................ 2-2 2.5.1 Collection System Request for Proposals Content............................... 2-2
..................................3 2............2-1 GNV310133631755(TOC).......4 Appendixes A B C D E F G Block Diagrams Design Criteria Pump Station Facility Design Criteria WWTP Facility Design Criteria Pump Station Design Spreadsheet WWTP Design Spreadsheet Standard Loop Specifications Page Collection System RFP Scope of Work .......................................................................................................................1-10 SCADA Life-Cycle Cost Considerations................................ 2-3 WWTP Request for Proposals Content.................................5........................................5................ 2-3 WWTP RFP Scope of Work ..DOC/081690001 IV ......2 2...... 2-3 Exhibit 1-1 1-2 2-1 Controller Comparison...........................CONTENTS.... CONTINUED Chapter 2.......1-5 Communication Alternatives Comparison .............................................................5................
DOC/081690001 V . Transform and Load Fixed-End Service Human Machine Interface input/output Internet Protocol Keyboard. Video Mouse liquid crystal display light emitting diode million bits per second Multi-Protocol Label Switching Microsoft ActiveX Directory Objects Network Address Translation Network Technology Group programmable logic controller request for proposal received signal strength Supervisory Control and Data Acquisition Virtual Private Network Wireless Mobile Access Wireless Local Area Network wastewater treatment plant GNV310133631755(TOC).Acronyms and Abbreviations API CDMA/FDD COTS C-P DCS DCS DPW ETL FES HMI I/O IP KVM LCD LED mpbs MPLS MS-ADO NAT NTG PLC RFP RSS SCADA VPN WiMAX WLAN WWTP Application Programming Interface Code Division Multiple Access with Frequency Division Duplex commercial off-the-shelf City of Baton Rouge/Parish of East Baton Rouge Distributed Control System distributed control system Department of Public Works Extract.
CH2M HILL recommends creating a SCADA system that utilizes programmable logic controllers (PLCs) at the pump stations for local and remote control and monitoring. managers. managers. and engineers. status information for use by operators. The number of collection system pump stations continues to grow each year. central Operations Data/Control Center that provides high-speed communications with plant and collection system control centers • The Operations Data/Control Center will collect. This recommendation would involve construction of a secure Collection System Control Center in a DPW facility supported by a secure wireless communications network. The data center will also include an information server that allows managers and engineers to view process graphics and to generate reports using the DCS manufacturer’s visualization application GNV310133631744(EXSUM). as well as three primary and five small WWTPs. and mobile laptop workstations used by operations and maintenance staff. . The wireless network is needed to support communications between the control center. pump stations. and archive measurements. The SCADA system is also needed for use in collecting operations and maintenance information and in responding to emergencies for all facilities. Recommendations For the collection system. The SCADA system will provide management and operational access to data for all facilities to meet the needs of facility operations and maintenance staff. CH2M HILL also recommends incorporating the five small WWTPs into the collection system SCADA system. and a connection to the DPW Operations Network. and engineers. which increases the need for a SCADA system that will improve operations and maintenance effectiveness and efficiency. DPW operates a network of more than 400 wastewater collection system pump stations.SCADA Master Plan Executive Summary Introduction The City of Baton Rouge/East Baton Rouge Parish (C-P) Department of Public Works (DPW) requires an integrated Supervisory Control and Data Acquisition (SCADA) system that provides for monitoring and control of each wastewater treatment plant (WWTP) as well as the collection system. As part of the SCADA Master Plan. reduce. alarms and.DOC/081640014 ES-1. CH2M HILL also recommends constructing: • • A new control systems at each of the three primary WWTPs to a common network topology and Distributed Control System (DCS) A secure control center at each plant supported by a secure communications network that both provides high-speed communications for both plant DCS and WWTP operation personnel anywhere on the DPW Operations Network A secure.
3. and Tesco Liquid 5 PLCs. critical alarms are forwarded from the HMI server to pump station supervisors’ cell phones. DPW.DOC/081640014 ES-2 . along with Pump Station No. WWTP Networks GNV310133631744(EXSUM). None of these existing systems are interconnected in any way. All of these systems are out-of-date and are not functioning at this time. Existing Facility Control Systems DPW has two existing collection system SCADA systems. Additionally. Originally. this older system provided monitoring and limited control of 51 pump stations. The older of the collection system SCADA systems shares a licensed radio system with public safety. Browser connections over the Internet to the HMI web server are used to support HMI workstations. The 14 pump stations incorporated into this system are the 13 booster pump stations that did not require replacement control panels. Appendix A includes a simplified block diagram for the three primary plants and the newer collection system SCADA systems. It is possible that the new radio system may be able to provide reliable timely communications to at least some pump stations. Collection System Network 2. Each of the three primary WWTPs has a standalone SCADA system composed of a pair of HMI workstations connected to a network of PLCs over a proprietary PLC copper wireline bus network. Communications in this system have been unreliable. Spare parts are also no longer available for the Aquatrol PLCs. once the collection system and individual WWTP control centers are in place. Network Architecture The proposed SCADA system is composed of the following five components including: 1. as well as a stand-alone SCADA system at each of the three primary WWTPs. The newer collection system SCADA system uses Verizon digital cellular links to the Internet for communications between the 14 pump stations and the Human Machine Interface (HMI) data and web server at the Network Technology Group’s (NTG’s) Baton Rouge data center. as discussed below. The newer collection system SCADA system provides monitoring and limited control of 14 pump stations. The Operations Data/Control Center can be utilized for centralized control of the system.SCADA MASTER PLAN EXECUTIVE SUMMARY software product installed on their business network workstations. if it is so desired. The system also has fallen into disrepair and is used occasionally for a few of the 51 pump stations originally served. The newer system was installed as part of a project to upgrade the existing older collection system SCADA system. The C-P is also in the process of upgrading the radio system to newer technology. Tesco Liquid 4. and has a mix of Aquatrol. This project has been suspended and is being revisited at this time. and other C-P mobile voice users. The two collection system SCADA systems combine to provide monitoring and limited control to 51 of the more than 400 pump stations in the collection system. which was added as an emergency repair to bring that station back online after a failure.
and a discussion of all components follows. WWTP networks include the following major components: • A WWTP Process Control Network housed in an air conditioned environment at each WWTP with security measures that limit access to network appliances. storage. • Operations Data/Control Center and Operations Network An Operations Data/Control Center is required to provide central collection. The monitoring and control system includes the following major components: • • PLCs at each pump station to provide autonomous local automatic control and to communicate with servers on the Collection System Process Control Network. Additionally. collects WWTP data and allows WWTP operators to monitor and control WWTP process equipment. Collection System Network The collection system SCADA system will be used by collection system operators to monitor and exercise control of collection pump stations in accordance with pump station design criteria. Existing Business Network Appendix A includes a simplified block diagram for the proposed network. diagnostic information presented to operators can be used to prioritize maintenance activities and to plan preventive maintenance. A wireless communications network to provide reliable communications between the pump stations and the process control network.SCADA MASTER PLAN EXECUTIVE SUMMARY 3. • WWTP Networks Each WWTP Process Control Network will be used by WWTP operators to monitor and control WWTP process equipment in accordance with operations procedures. Operations Data/Control Center 5. and processing of operations data from WWTPs and the collection system.DOC/081640014 ES-3 . The process control network collects collection system data and allows mobile collection system operators to monitor and exercise control of collection system pump stations without having to visit each pump station. An example of where control can be used is to pump down certain collection system pump stations in advance of a significant wet weather event to reduce the peak flows that will be experienced at the WWTPs during the wet weather event. DCS servers. Additionally. The process control network connects DCS system components. and workstation computers. It is recommended that wireless communications be accomplished by a digital cellular network at this time. The Operations GNV310133631744(EXSUM). diagnostic information presented to operators can be used to prioritize maintenance activities and to plan preventive maintenance. A fiber optic Fast Ethernet local area network (LAN) to provide reliable communications between DCS controllers and the process control network. A Collection System Process Control Network housed in an air conditioned environment with security measures that limit access to HMI servers and network appliances. Operations Network 4.
In the future. Credential limitations are used to manage access to prevent unauthorized persons from adjusting parameters. collection and treatment capacity and quality analysis. collection system and treatment capacity and quality analysis. Users connected to the Operations Network have credentials-limited remote monitoring and control access to any of the three WWTPs and the Collection System. However. Design GNV310133631744(EXSUM). The DCS manufacturer’s visualization application software product installed on existing Business Network user workstations will provide access to the operations information stored in the Operations Data Center and provide easy access to operations data for managers and engineers. installation. thereby completing the Collection System SCADA system and encompassing the design. The Operations Network provides reliable communications between each of the four Process Control Networks and the Operations Data Center. if desired in the future. This network will be implemented using leased lines and digital data services provided by the local telephone company. Users connected to the Business Network are subject to the same credential limitations and must also use a virtual private network (VPN) connection through the firewall for direct monitoring and control. Business Network The Business Network is an existing network that supports utility management and engineering activities. Centralized control of the entire system can be accomplished via the Operations Network. and improvements planning.DOC/081640014 ES-4 .SCADA MASTER PLAN EXECUTIVE SUMMARY Data/Control Center’s applications provide easy access to data for managers and engineers to support a number of activities. including regulatory reporting. A total of two RFPs are recommended: one for the collection system and one for all three major WWTPs. centralized control of the collection system and WWTPs can be accomplished at the Operations Data/Control Center. supporting a number of activities. The firewall in the Operations Data Center controls traffic between the three connected networks and serves to “protect” the Operations Network. a request for proposal (RFP) process is recommended. CH2M HILL recommends locating the Operations Data/Control Center on a separate network from both the Business Network and the Process Control Networks to provide isolation between the networks. such as chemical flows at a particular WWTP. while still allowing for future centralized control at the Operations Data/Control Center. the availability and integrity of both the Operations Data Center and the Process Control Networks are improved. management oversight. By isolating the networks. operations information is available to Business Network users directly from servers in the Operations Data Center. and improvements planning. The collection system RFP would be used to select a collection system provider that would build the Collection System Control Center and the communications network connections. and maintenance of the collection system SCADA system for 5-years. including regulatory reporting. Implementation In order to implement the recommendations. management oversight.
including costs. and. installation. and reliable SCADA system performance and to maintain a viable SCADA system as technology continues to rapidly evolve. and maintenance of the WWTP SCADA system for all three primary WWTPs. installation.DOC/081640014 ES-5 . will include all elements and allow the provider to be selected based on a combination of performance and cost information. Costs for purchasing. since these will be the only pump stations defined at the time that the RFP is written. will require that the communications network and control center delivered be capable of accepting controllers for the existing pump stations that are not to be replaced in the SSO program. responsive. The cost proposal portion of the RFP will only include pump station controllers for the pump stations that are being replaced as part of the SSO program. A separate WWTP RFP will be written based on a specific DCS that encompasses the design. and incorporation of future pump station controllers (including those at existing stations that are not included in the SSO program) can be added to the contract at the time they are needed. included in price proposals received. therefore. with the option for renewal. Proposals received in response to this RFP. Continuing and long-term support of the SCADA system is recommended to promote accurate. Including periodic major upgrades. with the option for renewal. The RFP will be written for a five year period. migration to newer hardware and software. as well as routine preventive maintenance and software update installation work in support contracts is recommended.SCADA MASTER PLAN EXECUTIVE SUMMARY criteria included with the RFP. GNV310133631744(EXSUM). The RFP will be written for a 5-year period.
and control centers for the collection system. advise mobile operations and maintenance staff of problems requiring attention.1 Introduction Several alternatives were evaluated for the entire Supervisory Control and Data Acquisition (SCADA) system.2. communications. and support graphical. The database servers should be housed in a separate room of the operations data/control center for security purposes.CHAPTER 1 Alternatives Evaluation and Recommendations 1. This operations data/control center can also be utilized in the future if centralized control of the collection system and WWTPs is desired. wastewater treatment plants (WWTPs). The WWTP control centers will house the DCS computer servers and workstation computers that collect information from DCS controllers. interactive HMI displays on mobile laptop workstations. and the DPW operations network. 1.2 1. as well as view and adjust setpoints and other adjustable parameters at either the pump station or at selected locations within the WWTP. and for the overall SCADA system as follows. • • The pump station control center will house the computer servers that collect information from pump station PLCs. transmit data to historian servers. transmit data to historian servers. The evaluation that follows focuses on differences between evaluated options with a discussion of common features. and support graphical. Local operator interfaces allow operations and maintenance staff to view process variables.DOC/081640015 1-1 . Evaluations included controllers. An Operations Data/Control Center will be utilized to house historical database servers that will collect operations data from treatment facilities and the collection system and place it in a database. interactive DCS workstation displays. Local operator interfaces were also evaluated. WWTPs. A total of nine different communication alternatives were considered for the collection system. The control centers will also advise mobile operations and maintenance staff of problems requiring attention. The evaluation discussed in the following sections outlines several options for communications that were considered for this SCADA Master Plan.1 Recommendations Controllers Controller recommendations include: GNV310133631745(CH1). • A total of eight programmable logic controllers (PLCs) from five manufacturers and one Distributed Control System (DCS) were evaluated for pump stations and WWTPs.
and life-cycle cost effectiveness. flexibility.2. Other advantages of the Ethernet interface include scalability. the LED type operator interface is recommended for the pump stations. ALTERNATIVES EVALUATION AND RECOMMENDATIONS 1. 1. and the LED type displays provide an adequate operator interface. Life-cycle cost effectiveness can be achieved by including life-cycle costs when selecting communications alternatives. Flexibility will reduce the risk of wholesale network replacement. the recommended network topology for each primary WWTP is a redundant fiber optic Ethernet star using Internet Protocol (IP) that provides continued operation after failure of a single link or switch. the recommended operations data collection network service is digital wireline supporting IP protocol.DOC/081640015 1-2 . and allow DPW to use several communication technologies in combination or to migrate the network from one communication technology to others. 1.4 Operations Data Collection Network Communications Recommendations As shown on the block diagram in Appendix A.2 Collection System Communications Recommendations Assuming the ownership and upgrading of the Verizon network service contract and conversion to Ethernet using Internet Protocol (IP) is recommended. The method for evaluating the controllers follows. two local operator interfaces were considered: liquid crystal display (LCD) and light emitting diode (LED). and life-cycle cost effectiveness. The planned initial data rate is 1.2. 2.3 WWTP Communications Recommendations As shown on the block diagram in Appendix A. if desired.5 million bits per second (Mbps) using a service such as Multi-Protocol Label Switching (MPLS). and can use combinations of a broad range of communications alternatives. 1.5 Local Operator Interface For pump stations. Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology. Continued use of the Tesco L2000 PLC that is currently in use at the pump stations. Recommended Verizon network improvements include conversion to a Fixed-End Service (FES). Assuming ownership and upgrading of the Verizon network service contract will ease obtaining the benefits of state government rates. The small Tesco LED operator interface requires no configuration and is well suited to use with the recommended Tesco L2000 pump station controller. and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. GNV310133631745(CH1). Scalability will allow the network to grow as required to incorporate future anticipated pump stations and. The Ethernet interface is ubiquitous. Installation of the Emerson Ovation DCS at each of the three primary WWTPs.CHAPTER 1. 1. Advantages of this interface include scalability. supports routing over networks.2. very flexible. integrate with the WWTP network.2. allow the communication network to adapt to technological improvements. Because DPW has experienced reliability problems with the LCD displays. This method of communication is the only method available at this time for the recommended Emerson Ovation DCS. flexibility.
Each operator interface will include a keyboard. which can run MS Windows.7 WWTP Control Center Recommendation As shown in the block diagram in Appendix A. These local operator interfaces would be located at each DCS controller. mouse and speakers connected to the workstation computer in the control center using a single Category 6 cable and a pair of Keyboard. The control center and control room for each of the three WWTP should be located in close proximity to each other on the WWTP site.DOC/081640015 1-3 . the laptops would use the Verizon private network and would not have Internet access. 1. As shown in the block diagram in Appendix A.2. Like the pump stations. and in a location with reliable power and access to reliable digital data wireline telephone service.CHAPTER 1. are recommended. video display. Multiple workstations and redundant servers are recommended at each WWTP control center to improve reliability and ease upgrades and patches. Separation of the operator interface from the workstation computer is recommended to limit access to computer media drives and communications ports. The upgrades will allow the data/ control center to support the mobile laptops and to ease business network access and use.2. 1. Expanding existing alarm messaging capabilities to provide voice notification to on-duty or on-call operators and maintenance staff members is recommended. Adding mobile laptop computer workstations to the Verizon digital wireless network is recommended to provide mobile operators with full human-machine interface (HMI) access to monitor collection system performance. providing separate control centers and control rooms at each of the primary WWTPs is recommended. corrosion-resistant. The same level of access would also be available any workstation on the operations data collection network where the HMI client is installed. and make trouble response decisions. Video Mouse (KVM) extenders. Providing alarm messaging GNV310133631745(CH1). industrially-hardened. redundant servers are recommended. ALTERNATIVES EVALUATION AND RECOMMENDATIONS For the WWTPs. investigate alarms. Control centers will house workstation and server computers. Continued use of Indusoft with upgrades to extend alarm messaging capabilities is recommended. A separate historical data collection server was included at the Network Technology Group (NTG) data center in existing pump station SCADA system. touch-screen LCD display terminals. Locating the control center in an environmentally-controlled space with physical access restricted and monitored is also recommended. A separate environmentally-controlled control room housing workstation operator interfaces is also recommended. DPW is currently using Indusoft HMI application for process monitoring and control. Upgrading the existing server and adding a DCS workstation to collect and transport collection system historical data to the operations data/control center is recommended. panel-mounted. The physical location is only limited by the requirement that the control center have reliable power and access to reliable digital data telephone service.6 Collection System Control Center Recommendation Housing the control center in an environmentally-controlled space with physical access restricted and monitored is recommended.
Transform and Load (ETL) tools or custom programming.CHAPTER 1. providing separate central data center with provisions for a future central control center is recommended. locating the operations data/control center on a separate network with controlled access from both the DPW Business Network and the collection system and WWTP process control networks is recommended to provide practical but effective isolation between the operations network and the business network. Custom programming would either use either the historian’s Application Programming Interface (API) and the Microsoft ActiveX Directory Objects (MS-ADO). However. The data center will house historical database and information servers. maintaining the Indusoft servers for support of the wireless laptop is recommended. Historical data can be transferred from the historical database to the existing DPW Oracle database. but should be evaluated further during implementation after a decision has been reached on the volume of data to be transferred. As shown in the block diagram in Appendix A. mouse and speakers connected to the workstation computer in the data center using a single Category 6 cable and a pair of KVM extenders. at this time. In the future. Adding a single DCS workstation at the collection system control center is recommended to collect and transfer collection system historical data to the historian. and in a location with reliable power and access to reliable digital data wireline telephone service At WWTPs. ETL tools can be expensive. thereby improving the availability and integrity of both the Operations Data/Control Center and the process control networks.8 Operations Data/Control Center Recommendation As shown in the block diagram in Appendix A.2. The control center and control room should be located in close proximity to each other. historian redundant scanners running on two of the DCS workstations are recommended to collect historical data and transport it to the historian. video display. There are two possible methods of transferring data: Extract. The method and complexity of data transfer between the historical database and the Oracle database depends on the volume of data being transferred. Combining treatment plant historical data collection with collection system historical data at a common Operations Data/Control Center is recommended to ease maintenance. Currently. access and use. ALTERNATIVES EVALUATION AND RECOMMENDATIONS capabilities to provide voice notification to roving operations and maintenance staff of alarms is also recommended to reduce the need for requiring personnel to be physically located in each WWTP control center. as well as future control center workstations.DOC/081640015 1-4 . 1. Locating the data center in an environmentally-controlled space with physical access restricted and monitored is also recommended. the DCS applications cannot support the mobile laptops recommended for the pump station monitoring and control. Separation of the operator interface from the workstation computer is recommended to limit access to computer media drives and communications ports. it may be possible to phase out the Indusoft software and use DCS applications to support the mobile laptops. A separate future environmentally-controlled central control center housing workstation operator interfaces is also recommended. GNV310133631745(CH1). Each operator interface will include a keyboard.
Tesco and Emerson. However. Native CIP protocol Operator Interface Wide selection available Can significantly increase cost +/High cost (-) Large Market Share (+) Redundancy only with ControlLogix PAC CPUs (-) Separate terminal blocks (+) Not hot swappable modules (-) Allen-Bradley ControlLogix Suitable for industrial environment 140 degrees F Full-featured Supports 4 of the IEC61131-3 languages Modular Ethernet & Async. ALTERNATIVES EVALUATION AND RECOMMENDATIONS 1. due to the dependence of the entire SCADA system on these products.3 1.3. Serial 3rd party MODBUS modules avail. Emerson ControlWave PLC and Emerson Ovation DCS are commercial off-the-shelf (COTS) products. There is no reason to suspect that any of that will change. and the Ovation DCS is well suited to treatment plant control.1 Evaluation Controllers Table 1-1 shows the comparison of the eight controllers that were evaluated as part of this SCADA Master Plan. TABLE 1-1 Controller Comparison Controller Allen-Bradley CompactLogix with PanelViewPlus 400 Operator Interface Environmental Suitable for industrial environment 140 degrees F Monitoring & Control Full-featured Supports 4 of the IEC61131-3 languages Modular Communications Ethernet & Async. are also included because ControlWave PLCs are well suited as pump station controllers. Native CIP protocol Graphical HMI RSView Can use 3rd party HMI’s High Cost (-) Large Market Share (+) Redundancy (+) Hot swappable modules (+) Separate terminal blocks (+) GNV310133631745(CH1). have been available and supported for several decades. Serial 3rd party MODBUS modules avail. three of the PLC manufacturers (Allen-Bradley. the Bristol Babcock ControlWave PLC and the Ovation DCS. as well as their products being evaluated here. so the recommendation to continue using the Tesco L2000 for pump stations and to adopt the Emerson Ovation DCS for WWTPs was not affected by the possibility of limited availability or price increases. The Tesco and Emerson products are only available from the manufacturer and are more sensitive to manufacturer’s decisions on pricing increases and availability limitations than the other products. As shown in Table 1-1. and they both have built up loyal customer bases. Two Emerson controllers.DOC/081640015 1-5 . while two other manufacturers (Tesco and Emerson) have a much smaller market share.CHAPTER 1. Modicon and Siemens) share a large portion of the United States PLC market. The Tesco L2000 controller is included because it is well suited for pump station applications and because it is currently being used successfully by DPW. All of the controller products evaluated except for the Tesco L2000.
Serial Native MODBUS & MODBUS TCP Modbus plus Graphical HMI Citect Can use 3rd party HMI’s High cost (-) Large market share (+) Redundancy (+) Hot swappable modules (+) Separate terminal blocks (+) Siemens S7300 Suitable for industrial environment 140 degrees F Full-featured Modular Full IEC 61131-3 capability Ethernet & Async. nongraphical +/Medium cost (+/-) Small market share (-) Redudancy. CIP DNP3 Operator Interface Maple Systems 6 options. Serial Native MODBUS & MODBUS TCP CIP module planned Wide selection available Can significantly increase cost Medium cost (-) Large market share (-) Only with Quantum CPUs (-) Not hot swappable modules (-) Separate terminal blocks (+) Modicon Quantum Suitable for industrial environment 140 degrees F Conforms to IEC 61131-3 Full-featured Modular Ethernet & Async. DFI. Serial PROFIBUS PROFINET Modbus RTU function block Wide selection available Graphical HMI WinCC Can use 3rd party HMI’s Medium cost (+/-) Large market share (+) Redundancy only with S7-400 Series (-) Not hot swappable modules (-) Separate terminal blocks (+) Emerson Ovation Suitable for industrial environment 50 degrees C (112 F) IEC 61131-3 Compliant Ovation Network Ethernet Modbus DNP3 GNV310133631745(CH1). ALTERNATIVES EVALUATION AND RECOMMENDATIONS TABLE 1-1 Controller Comparison Controller Emerson Control Wave with Maple Systems.DOC/081640015 1-6 . INC graphic operator interface Environmental Suitable for industrial environment 158 degrees F Monitoring & Control ControlWave Designer is fully IEC 61131-3 compliant Communications Ethernet BSAP Protocol Modbus.CHAPTER 1. but CPUs in the same rack (+/-) Hot swappable modules (+) Separate terminal blocks (+) Proprietary Plant wide graphical interface High cost (-) Small market share (-) Redundancy (+) Hot swappable modules (+) Separate terminal blocks (+) Windows or Unix based system available (+) Modicon M340 with Magelis XBTGT11 Operator Interface Suitable for industrial environment 140 degrees F Full-featured Modular Full IEC 61131-3 capability Ethernet & Async.
lack of availability. such as peer communications. and reduce HMI application complexity. and historian functions. In the case of the Ovation DCS. and Tesco L2000. Third party modules are required to use MODBUS with the CompactLogix. However. to ease support. Bristol Babbcock ControlWave. However.CHAPTER 1. IEC 61131-3 programming languages can produce more intuitive program documentation that is easier to understand and troubleshoot. Eliminating these leaves the Allend Bradley CompactLogix.1 Collection System Controllers Seven of the eight controllers listed in Table 1-1 are suitable for use as controllers at collection system pump stations.DOC/081640015 1-7 . GNV310133631745(CH1). The greater expense is unlikely to be justified for any but the largest pump station application. The Allen Bradley ControlLogix and Modicon Quantum PLCs are larger and more expensive. which is a vertically-integrated solution that encompasses the controller. Of these.3. standardizing on a single manufacturer and model PLC is recommended. 1. all but the CompactLogix and L2000 provide full IEC 61131-3 compliance with all five programming languages.1. similar product with an Ethernet interface and acceptable HMI interface software as a replacement for future and failed units. Maintaining MODBUS RTU capability may be useful if asynchronous serial communications are used in the future. operator interface. Using MODBUS protocol with the L2000 does eliminate some of the communication features. A mix of all seven suitable controllers could be used. none of the eliminated features are expected to be used. Modicon M340. or obsolescence. or obsolescence forced the C-P to select another controller for the WWTPs. ALTERNATIVES EVALUATION AND RECOMMENDATIONS TABLE 1-1 Controller Comparison Controller Tesco L2000 Environmental Suitable for industrial environment 200 degrees F Monitoring & Control Full-featured Using IEC 61131-3 reduces capability Tailored for application Modular Communications Dual Ethernet & Async Serial Native MODBUS RTU Operator Interface Two sizes of Tesco Operator Interface Available Nongraphical May be more cryptic Wide selection of 3rd party also available +/Medium cost (+/-) Small market share (-) Not redundant (-) Hot swappable modules (+) Separate terminal blocks (+) In the case that the Tesco L2000 were to be subject to pricing increases. All five PLCs can use MODBUS RTU protocol. lack of availability. reduce spare parts. available with Tesco’s Data Express protocol. Siemens S7-300. replacement of the entire system would be required if pricing increases. Both the CompactLogix and L2000 provide some degree of limited IEC 61131-3 support. the C-P can simply choose another.
DPW could migrate to another PLC manufacturer at some point in the future. GNV310133631745(CH1). Tesco’s default script or instruction list programming technique is currently used. verticallyintegrated. The advantages of using the Tesco L2000 include: • Tesco PLCs are specifically intended for use in remote water and wastewater pump stations and for communications over unreliable communications networks. reducing the need to attract and retain additional inhouse support staff.CHAPTER 1. continued use of the Tesco L2000 controllers is recommended at the pump stations.3. but utilizing the lists increases the time required to program and troubleshoot programs. or PLCs. However. However. a maximum operating temperature of 200 degrees F. Tesco offers two operator interfaces that are tailored to pump station operation and support both operations and tuning functions.1. Important features include built in lightning protection. ControlWave. DPW is satisfied with Tesco support received to date. CompactLogix. The disadvantages of using the Tesco L2000 include: Tesco is a relatively small manufacturer with a small share of a niche market. unreliable media communications features. care is still required because all outputs are frozen during module replacement and all I/O on the module with a failed point will be disconnected during replacement.2 WWTP Controllers Four of the eight controllers listed in Table 1-1 are suitable for use as WWTP controllers. DPW has standardized on the modular Tesco L2000 series of controllers for collection system pump stations. all but the Ovation DCS are independent controllers. Reliance on small niche firms is generally considered to increase business risk. and L2000. as long as common process and communications interfaces are used. which can reduce support reliability and increase support costs. system that includes the controllers. only the ControlWave and L2000 have hot swappable input and output (I/O) modules. easy-to-configure operator interface. has not been used by DPW and may be difficult to implement. ALTERNATIVES EVALUATION AND RECOMMENDATIONS Of the controllers considered for pump stations. Ovation systems are able to interface to other systems and PLCs. the HMI and the historian application. that are suitable for use with third party HMI applications. if necessary. communications network protocol. As stated above. M340.DOC/081640015 1-8 . Tesco’s support services can and have been leveraged by DPW to supplement their own staff and available local support. Of those four. This feature is useful because it eases repair. an adequate. and data recovery capability. but they are designed to work as a complete system. eliminating the need for operations and maintenance staff to use programmers or learn the programming language. Tesco’s implementation of IEC 61131-3 programming requires a third party application. The Ovation DCS is a complete. • • • • • • • • 1. Having a small user-base reduces the availability of technical support services available locally. Having Tesco as a single-source-of-supply eliminates the ability to easily obtain competitive pricing for comparison.
standardizing on a single manufacturer and model PLC is recommended. Though not recommended. modifications. DCS configuration trouble shooting and modification by others than the original configuration author is usually easier than it is for PLC configurations. to ease support. and upgrades by eliminating the need to coordinate among a number of manufacturers.2 Collection System Communications Evaluation All of the nine alternatives listed in Table 1-2 are capable of using the recommended collection system pump station interface and satisfying pump station requirements. Modicon Quantum. the Emerson Ovation DCS is recommended for use as the WWTP controller. GNV310133631745(CH1). ControlLogix provides limited IEC 61131-3 support. 1. As stated above.CHAPTER 1. • • • • The disadvantages of this approach include: • • • The request for proposal (RFP) process required to select a DCS supplier complicates the Design-Bid-Construct delivery process that is normally utilized by the C-P. and Siemens S7-300 PLCs.3. DCSs provide a high level of redundancy that significantly improves reliability.DOC/081640015 1-9 . leaving the five wireless alternatives as well as analog wireline. IEC 61131-3 programming languages can produce more intuitive program documentation that is easier to understand and troubleshoot. All but the ControlLogix provide full IEC 61131-3 compliance with all 5 programming languages. A common spare parts warehouse can be used for all three treatment plants and the number of spare parts required is reduced because all three plants use the same DCS. the two fiber and the digital wireline alternatives are not considered further in this evaluation because they are not likely to be cost effective over the life cycle of the equipment. However. a mix of all three of these controllers could be used in a single plant supported by a single HMI application. DCS controller configurations are generally more intuitive and straight forward than PLC configurations. This level of redundancy is not easily implemented with PLC based systems. reduce spare parts. DCSs and most DCS repair parts are only available from the DCS manufacturer and are subject to the manufacturer’s decisions on pricing and availability. which will limit the availability of local support alternatives. and reduce Human Machine Interface (HMI) application complexity. Also. LAN configurations are based on the DCS manufacturer standards reducing the need for local network configuration experts. DCSs are not as widely used in treatment plants as PLCs. ALTERNATIVES EVALUATION AND RECOMMENDATIONS The other three controllers suitable for use in treatment plants are the Allen Bradley ControlLogix. Using the Emerson Ovation DCS has the following advantages: • Having a system composed of products from a single manufacturer will simplify trouble shooting. However.
repair. If the C-P owns the network. Good scalability (+) Low to medium data rate (+) Disaster recovery probably better than private (+) No SLA (-) Provider GNV310133631745(CH1). upgrade. historical issues with latency and availability during civil emergencies would need to be evaluated before widespread use could be recommended. Permitting can also delay deployment and increase the costs for C-P-owned alternatives. The C-P public safety mobile radio network is being upgraded. maintenance. C-P-owned (private) alternatives tend to berequire longer to deploy. may be life-cycle cost effective for some portion of the pump station network. the monthly service fees (not normally required for private networks) are a recurring cost that must be paid monthly for as long as the service is used. either licensed or unlicensed. which can improve service and reliability. Selection of a frequency. though each alternative must be evaluated on its own merits. which offer a pay-as-you-go model. Private point-to-multi-point radio. private radio networks providing adequate performance and reliability are not expected to be life-cycle cost effective for large portions of the pump station network. and disaster recovery.Low Hurdles Permitting Licensing Line-of-Site +/In control of own destiny (+) Low to medium data rate (-) Link reliability (-) Disaster recovery (-) Scalability issues (-) City Radio Network Digital Cellular City Information not available at this time. ALTERNATIVES EVALUATION AND RECOMMENDATIONS One major consideration in selecting a communications alternative for distributed facilities is deciding who will own the communications infrastructure. TABLE 1-2 Communication Alternatives Comparison Alternative Private Point-toMulti-point Radio (Licensed or Unlicensed) Owner City or DPW Cost Capital . However.High Annual . allowing them to be quickly deployed or expanded for relatively low capital cost budgets. being in control is a doubleedged sword because the owner is responsible for all support. have higher capital costs. would be required to better evaluate this alternative. However. However. The opposite is true for provider-owned alternatives. it also has better control over all aspects of the communication network.Medium Permitting Line-of-Site Provider coordination Latency Moving target Evolving technology Information not available at this time.CHAPTER 1.DOC/081640015 1-10 . The upgraded network may be able to provide life-cycle cost effective communications for some pump stations once it becomes available. and have lower recurring costs. However. Capital . as well as preparations of a cost estimate. radio path measurements and analysis.Low Annual .
expansion. improvement. GNV310133631745(CH1). they should be considered as expansion and migration alternatives. if not all pump stations.Low Annual . Digital cellular is becoming more reliable.Low Annual . maintenance level. ALTERNATIVES EVALUATION AND RECOMMENDATIONS TABLE 1-2 Communication Alternatives Comparison Alternative WLAN 802. Therefore.16e Provider Capital – Low Annual – High Dark Fiber City. though once common.DOC/081640015 1-11 . and technology improvements are improving telemetry performance. digital cellular coverage is expected to be sufficient to provide coverage on most. Assuming ownership of the Verizon network service contract will ease obtaining the benefits of state government rates. Neither Wireless Mobile Access (WiMAX) nor Wireless Local Area Network (WLAN) is yet available for pump stations. SLA.CHAPTER 1.11n/s Owner City.High Provider coordination Moving target Evolving technology The analog wireline alternative. is no longer considered viable because of reliability and support limitations.Low May not be available Dated technology Low data rate (-) Reliability (-) Scalability (-) Hurdles City/DPW owns: Permitting Network design Provider owns: Same as for Digital Cellular Same as for Digital Cellular City owns: Right-ofway Provider owns: Coordination +/Good scalability (+) Medium to high data rate (+) SLA if Provider owned (+) Disaster recovery depend on implementation (+/-) Probably Same as for Digital Cellular Good Scalability (+) High data rate (+) Good reliability (+) Digital Wireline Provider Capital . As either WiMAX or WLAN become available. DPW or Provider Cost City/DPW owns: Capital – High Annual – Low Provider owns: Capital – Low Annual – High WiMAX 802.Variable Coordination with users or provider Throughput Privacy High data rate (+) Good reliability (+) Depends on owner. Also. DPW or Provider City/DPW owns: Capital – V High Annual – Low Provider owns: Capital – Low Annual – High Other Fiber Shared with other public agencies or provider Capital .Low Annual . and degree of over subscription (+/-) Good scalability (+) Medium to high data rate (+) Disaster recovery (+) No SLA for DSL (-) Analog Wireline Provider Capital . and assuming ownership of the existing Verizon digital cellular communication network is recommended.
There may also be plant applications where a wireless LAN (WLAN) alternative is adequate and cost effective. Conversion to CDMA/FDD should improve reliability. 1. Choosing replacement antennas inside the pump station that maximize the received signal strength (RSS) is also recommended. replacing existing antennas with higher gain antennas and.DOC/081640015 1-12 . when required. GNV310133631745(CH1). This will drastically reduce the potential downside effects of the Internet thereby improving reliability and reducing malicious traffic. adding antenna amplifiers is recommended.3. The LED types are less flexible. Dark Fiber. ALTERNATIVES EVALUATION AND RECOMMENDATIONS As stated above. less comprehensive. 1. especially during conditions (such as storms) that might reduce signal levels. The most basic operator interfaces provide one or more lines of LED display and a keyboard for selecting variables and keys for modifying adjustable parameters. 1. However. The other type of operator interface has a graphic Liquid Crystal Display (LCD) and either a keyboard or a touch-screen interface. Scalability will allow the network to grow as required to accommodate plant expansions and upgrades. and require less complex configurations. Conversion to FES will move the pump station communications network off the Internet and maintain it on Verizon’s private network. Evaluating other alternatives as they become available is recommended. Antenna replacement and relocation should also improve signal levels. Although it is somewhat dated. The only other topology considered was a fiber optic Fast or Gigabit Ethernet loop at each plant. and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. provide a more comprehensive interface and have more complex configurations. advantages of this interface include scalability and reliability.5 Local Operator Interface Evaluation Available operator interfaces generally fall into two categories.3. The higher channel capacity is not expected to improve pump station communications performance. The redundant switches and media employed in this network will improve reliability by continuing to operate after failure of any single communications network component. Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology. only the digital wireline alternative is currently available.4 Operations Data Network Communication Evaluation Five alternatives (WLAN. Of these. CDMA/FDD also offers drastically higher channel capacity when compared to the current CDMA technology that it replaces.3 WWTP Communication Evaluation For the WWTPs.3. WiMAX. The LCD display types are more flexible. capacity and security issues will need to be addressed on a case-by-case basis. the redundant star topology is the only communications alternative supported by the selected DCS. Other Fiber and Digital Wireline) compared in Table 1-2 are all capable satisfying data collection network requirements. When an available alternative is found to be superior to digital wireline.CHAPTER 1. Additionally. recommended improvements include conversion to a Fixed-End Service (FES). migration to that alternative can begin. reliability.
For WWTPs. Upgrading the existing server to bring it up to current product versions will support mobile laptop graphic displays and historical data access. and acceptable service life. such as GE Intellution iFix. InduSoft capabilities have been reviewed and water and wastewater users found have been interviewed. As stated above.995% reliability. Also. The control center could be maintained at the NTG facility or relocated to a DPW facility. third-party products are available that work with most major HMI applications that enhance alarm messaging as follows: Alarm voice and text messaging for selected critical alarms to field staff. Citech and Rockwell RSViews.3. so it is recommended to continue to use the InduSoft HMI application at this time.CHAPTER 1. The InduSoft HMI application also added in the existing SCADA system has a very small market share when compared to major competitors. the LED type of operator interface is recommended for the pump stations. Adding a DCS workstation to collect and transport collection system historical data to a common data center will provide comprehensive historical data access for operations and maintenance staff as well as planning and engineering staff. However. • Enhancing alarm messaging capabilities will reduce the time that operators must spend in front of a computer. • • • Replacement of the InduSoft HMI application with a DCS workstation was also evaluated. but is likely to ease access and eliminate recurring data center costs.. A flexible central interface for assigning alarm groups to specific field staff personnel depending on staff’s current location and assignment. 1. ALTERNATIVES EVALUATION AND RECOMMENDATIONS As stated above. Locating the local operator interfaces in the doors of the DCS controller cabinets is expected to provide an acceptable environment and good visibility. A separate historical data collection server was included at the NTG data center in the existing SCADA system. No significant technical shortcomings were found with InduSoft. A flexible communication interface that can be reconfigured to use the best available delivery alternative. Invensys Wonderware Intouch. relocating the control center to a DPW facility is recommended. CH2M HILL does not have any direct experience with InduSoft. Therefore. Some alarm messaging is provided by the existing collection system HMI servers. care must be taken to select a location and display terminal that will provide good display visibility when installed in areas with high ambient light levels. the continued use of InduSoft is recommended. while the LCD type (with a touch-screen display) is recommended for the WWTPs.DOC/081640015 1-13 . current products available with the recommended DCS do not effectively support the mobile laptops needed by the collection system operations and maintenance staff. However.6 Collection System Control Center Evaluation The control center commissioned in the existing pump station SCADA system is located at the NTG Tier IV data center in Baton Rouge. However. Tier IV data centers offer 99. GNV310133631745(CH1). Relocation is likely to significantly reduce reliability.
3. However. in the future it may be possible to phase out the Indusoft servers and to support the mobile laptops on the Digital Cellular Network via the DCS servers. while also protecting the collection system and WWTP networks from possible mis-use via the Business Network. A historian scanner running on the workstation would collect historical data and transport it to the Ovation historian. As stated above. Also.1 Operations Data/Control Center Evaluation There are two options for collecting and transferring collection system data from the InduSoft servers (for the collection system SCADA) to the historical database.7. One option is to use the InduSoft server to provide an interface to the DCS client on the Engineering workstation at the Collection System Control Center.7 WWTP Control Center Evaluation Locating workstation computers in each WWTP control center along with the servers will limit access to media drives and communications ports. A disadvantage to the second option is the doubling of wireless network traffic. video displays. mice and speakers several hundred feet away by a single cable using KVM extenders. • • 1. The other option is to interface the Engineering workstation communications in parallel with Indusoft HMI and with the PLC using MODBUS protocol.DOC/081640015 1-14 . thereby reducing the opportunity to mis-use the DCS servers and workstations. A flexible central interface for assigning alarm groups to specific field staff personnel depending on staff’s current location and assignment. The workstations can be connected to keyboards. the recommendation should be reevaluated as technology advances and the cost of bandwidth becomes more cost effective.3. it is recommended that the operations data/control center be located on a separate network with controlled access from both the DPW Business Network and the collection system and WWTP process control networks to provide isolation between the networks This separation allows for future centralized control at the operations data/control center. Third-party products such as Win911 are supported by Ovation and provide for alarm messaging as follows: • Alarm text and voice messaging for selected critical alarms to roving or on-call operators. Alarm messaging capabilities reduce the need for an operator to be in front of a computer. While the current recommendation is for Indusoft to be maintained. ALTERNATIVES EVALUATION AND RECOMMENDATIONS 1. GNV310133631745(CH1). the recommended DCS doesn’t currently have a workstation application that is well suited for deployment on the digital cellular network since the currently available browser product doesn’t support alarm handling.CHAPTER 1. A flexible communication interface that can be reconfigured to use the best available delivery alternative.
2 Recommendations CH2M HILL recommends using an RFP process to provide selection of a single qualified collection system SCADA provider and a WWTP SCADA provider for 5 years. if not consistent from site-to-site and from project-to- GNV310133631746(CH2). the contract of the selected Contractor can be renewed for another 5 years. 2. After 5 years.1 Introduction The implementation plan describes how the SCADA system will be designed. Long-term SCADA support is critical to its success. The plan is broken down into two modules. Therefore. Table 2-1 shows some typical cost considerations for SCADA components. because the two are expected to be implemented separately. delivered. recommended design and delivery approaches are structured to facilitate long-term support. support is intended to include upgrade and migration to maintain a viable SCADA as technology continues to rapidly evolve. and for any additions to the SCADA system. and supported. Critical components are defined as those that. thereby assuring critical component and overall design consistency across all pump stations or WWTPs for 5 years.CHAPTER 2 Implementation Plan 2.DOC/081640016 2-1 . and providing routine preventive maintenance and software update installation. support and future collection system or WWTP work in a single contract. TABLE 2-1 SCADA Life-Cycle Cost Considerations Component Computers (Workstations and Servers) Network Appliances DCS Controllers. PLCs and RTUs Software Control System Support Telco Services Annual Costs Replacement Every 3 Years Replacement Every 5 Years Replacement Every 10 Years 15-20% Per Year + Periodic New Releases 5-15% Per Year 12 x Monthly Bill + Services Outside SLA Procurement of critical components is another important element of the plan. or another RFP can be used to select a provider for ongoing support and upgrade of the existing collection system or WWTP SCADA system. collection system and WWTPs. This will allow the C-P to select the most qualified provider and include needed maintenance. In addition to maintaining.
and maintenance) of the collection system SCADA and the WWTP SCADA components. For development projects likely to have pump stations not addressed by the standard pump station design documents. design instructions. Use references to included design criteria and standard design documents to clarify requirements and reduce duplication. installation.5 Procurement As stated above. Therefore. The existing standard pump station drawings should be updated to create standard control system drawings for each type of pump station likely to be included in developer projects.5. and make corrections. the existing standard pump station specifications should be updated to create standard control system specifications for each type of pump station included in developer projects. 2. 2. and/or documents.3 Design Criteria SCADA Design Criteria addressing pump stations and plants are included in Appendixes C through H for use in preparation and review of RFPs. Also. 2. Two separate RFPs will be written for each system.1 Collection System Request for Proposals Content Inclusion of the following design instructions in the collection system RFP is recommended: 1. Before each use. will significantly and negatively impact DPW’s ability to maintain the SCADA longterm. Pump Station Design Criteria GNV310133631746(CH2). include a SCADA overview including monitoring and control requirements. the standard pump station design documents should be updated to bring them into compliance with the Design Criteria in the appendices. In general.DOC/081640016 2-2 . network communications and communications interfaces. include a current version of the Design Criteria document and specific design instructions for the nonstandard pump stations. IMPLEMENTATION PLAN project. update Design Criteria as required to keep current.CHAPTER 2. an RFP process is recommended for procurement (including design. 3. Scope of Work. the delivery of critical components is separately addressed for each of the two major SCADA systems: collection system and WWTPs.4 Standard Pump Station Design Documents The purpose of the standard pump station design documents is to provide pump station design guidance for developers for a range of pump stations expected to be included in development projects. 2. since the systems can be implemented separately. Project schedule 4. 2. In the narrative. A narrative describing the work and expected delivery schedule. incorporate missing elements. SCADA Block Diagram 5.
SCADA Block Diagram 5.5.DOC/081640016 2-3 . 2. a list of communications service provider and utility contacts and ample references to the design criteria. Also. Scope of Work 3.2 Collection System RFP Scope of Work Provide a comprehensive summary of the scope of work including: 1. Standard Loop Specifications 8. A narrative describing the work and expected delivery schedule. Pump Station Standard input/output (I/O) list 7. WWTP Design Criteria 6. Define support requirements 2. IMPLEMENTATION PLAN 6. Use references to included design criteria and standard design documents to clarify requirements and reduce duplication. 3. include coordination requirements. WWTP Standard input/output (I/O) list 7. if any. List all tasks to be performed by the provider. Define coordination requirements for any other work expected to be in progress during construction 4. include a SCADA overview including monitoring and control requirements. Define programmable logic controller (PLC) and human machine interface application programming requirements.CHAPTER 2. Project schedule 4.3 WWTP Request for Proposals Content Inclusion of the following in design instructions in the WWTP RFP is recommended: 1. When applicable. including instructions on how to use the Standard Loop Specifications. Define pump station outage restrictions and coordination requirements 5. Clearly define important deliverables and sequencing requirements.5. 2.4 WWTP RFP Scope of Work Provide a comprehensive summary of the scope of work including: GNV310133631746(CH2). network communications and communications interfaces. Standard Loop Specifications 2. 2. In the narrative.5. standard pump station SCADA design documents for the standard pump station(s) with monitoring and control system(s) that most closely resembles the monitoring and control system(s) for the pump station(s) that will be designed along with narrative describing required deviations from the standard documents.
Define support requirements GNV310133631746(CH2).CHAPTER 2. including instructions on how to use the Standard Loop Specifications 3. a list of communications service provider and utility contacts and ample references to the design criteria. Also. include coordination requirements. workstation and server application programming requirements. 2. List all tasks to be performed by the provider. Define coordination requirements for any other work expected to be in progress during construction 4.DOC/081640016 2-4 . IMPLEMENTATION PLAN 1. Clearly define important deliverables and sequencing requirements. Define distributed control system (DCS) controller. Define equipment outage restrictions and coordination requirements 5.
Appendix A Block Diagrams .
GNV310133631747(APPA).DOC/081640017 A-1 .
DOC/081640017 A-2 .GNV310133631747(APPA).
Appendix B Design Criteria .
1. WWTP Control Centers. Major SCADA components covered by this document include: • • • • • • • Collection Pump Stations. Support requirements. The DPW Operations Data Center. Wastewater Treatment Plants (WWTPs).DOC/081640018 B-1 . Network and other communications requirements. Pump station specific criteria.1 Purpose The purpose of this technical memorandum is to define City of Baton Rouge-East Baton Rouge Parish (C-P) Department of Public Works (DPW) Supervisory Control and Data Acquisition System (SCADA). Physical design criteria. The Collection System wireless communications network. Testing requirements. GNV310133631748(APPB). Collection wireless network specific criteria.2 Background & Overview The SCADA system project for the C-P DPW will upgrade the existing wastewater collection pump station SCADA system and replace the SCADA systems at the three major WWTPs. Treatment plant SCADA improvements are expected to improve treatment performance and effluent quality. The following is a list of the major SCADA system goals and the basis for the design: • Increase Operational Reliability of Collection and Treatment: Collection system SCADA improvements are expected to reduce the chances of pump station spillage and overflow. Operations Network specific criteria. WWTP specific criteria. The DPW Operations Network. Standards and codes list. Applications programming requirements. Collection Control Center specific criteria. Functional requirements. Criteria provided include the following: • • • • • • • • • • • • • • • • • SCADA Background and Overview. WWTP Control Center specific criteria. Documentation requirements.1. The Collection System Control Center. Terminology and acronym definitions. Operations Data Center specific criteria.0 Introduction and Overview 1.
Ease of Access: Managers and engineers will have easy access to real-time and historical data including regulatory reporting, management oversight, collection system and treatment capacity and quality analysis and improvements planning. Improve Collection System and Treatment Facility Planning: Existing SCADA systems have limited data archiving ability. The upgraded SCADA systems will provide more, easily accessible and organized data to support planning efforts. The improved data archives can be used by DPW to improve collection and treatment systems understanding thereby allowing DPW to make better informed decisions regarding upgrading and expanding the water and wastewater systems. Reduce Operating Costs: Once Pump Station and WWTP staffs have gained confidence in the upgraded SCADA systems, labor savings will occur because of improved plant operations efficiencies and a reduction of the number of visits to each pump station. Support Facilities Information Management (FIM) Tasks: The upgraded SCADA systems will provide information in a format that is easily transferred to maintenance management or asset management software. As an example, the elapsed run time of process equipment can be downloaded from the SCADA system to a FIM system. These data can be used by the FIM system for scheduling maintenance activities. Network Isolation: Isolating the Operations Data Center on a separate network with controlled access from both the Business and Operations Networks provides isolation and protection of the Operations Network and the four control center networks thereby improving the availability and integrity of both the Operations Data Center and Process Control Networks.
The following additional general design criteria have been established for design and construction of the SCADA systems: • Routine Maintenance Requirements: The SCADA systems must be capable of being maintained on a day-to-day basis by DPW staff. Day-to-day activities are not expected to include any applications programming or system configuration work. Someone with a working knowledge of computer operating systems, computer networks and the applications being used will be required to periodically [probably monthly] review security, event and activity logs, and perform maintenance. Also, periodic [probably quarterly] maintenance by someone with detailed knowledge of SCADA applications and computer operating systems will be required to install software upgrades and patches, to review system logs, to groom files, and perform other system-level activities. Additional Staff Needs: Either training of existing staff members or adding staff will be required to perform the day-to-day duties listed above and other SCADA System O&M activities. SCADA system designers are expected to work with DPW to be identify specific skill requirements during design. The monthly and quarterly maintenance activities are expected to be provided as part of a renewable annual service agreement. Training Requirements: Training requirements, including course identification and training source, are expected to be identified during design. Application Programming Templates: SCADA system designs are expected to include templates to ease the amount of custom programming required to add pump stations or common plant equipment such as pump stations.
Environmental Design Provisions: Equipment, such as RTUs and panels, are expected to be located to reduce environmental impacts and hazards; and designed to withstand environmental conditions and mitigate hazards present. Communications Reliability: Reliable wireless and network communications, as well as ample, easy to access and use communications diagnostics including statistics are required, as is the ability to effectively continue operation during temporary communications failures. Design wireless communications links to work reliably during abnormal weather conditions such as heavy rain, high wind and temperature inversion. User Access Tailored to Job Responsibilities. Tailor each users access to job responsibilities. Work with DPW to determine user access requirements. Managers will generally have broad view only access. Supervisors are expected to have monitoring, control and preset parameter adjustment access for areas they are responsible for and view only access to associated areas. Operators will generally have monitoring and control Maintenance workers will have access tailored to their needs and responsibilities including the ability to modify configurations and applications programming. Network Security Provisions: Reasonable network and communications security controls in compliance with the current version of the National Institute of Standards and Technology (NIST) Special Publication (SP) 800-82 are required. Security controls include, but are not limited to, access control, intrusion detection and virus protection. Modular Design, Common Components for All Sites: Use the same manufacturer and model number components for all similar applications. Alarm Segregation, Categorization, Prioritization and Conditioning: Segregate [i.e. Collection/Treatment], categorize and prioritize alarms. Alarms will be conditioned to eliminate nuisance and all but critical unavoidable alarms. For example: Pump station alarms, except for LOW BATTERY, INTRUSION and HIGH HIGH LEVEL will be disabled during pump station power outages. Develop specific alarm conditioning rules during design and finalize them during construction. Route some alarms [i.e. pump station pump fail] directly to maintenance personnel with operations receiving a followup alarm if the original alarm is not acknowledged within a preset interval. Prevent communications failure alarms from being repeated each time the failed link is accessed. Physical Security: Work with DPW to establish physical security requirements for pump stations and plants. For control centers and data centers, locate all computers [servers and workstations] in locked adequately air conditioned rooms with reliable conditioned electric power. Limit access to those responsible for the maintenance of the control centers. Use Keyboard, Video Mouse (KVM) extenders to support a keyboard, dual monitors, a mouse, and dual speakers in the control room for each workstation.
SCADA System Overview
The simplified SCADA block diagram in Appendix A shows an overview of the complete SCADA system. Major elements include the following: • DPW Business Network: This is an existing network used by DPW for management, administration, and general purpose computing and is expected to include an existing interface through an Internet Service Provider (ISP) to the Internet. Users on this
network including managers, planners and engineers need access to SCADA data to fulfill their responsibilities. Interface the business network to the SCADA system as follows: 1. Connect the business network to the firewall in the DPW Operations Data Center. 2. Except for virtual private network (VPN) traffic, limit business network traffic to the DPW Operations Data Center located on demilitarized zone (DMZ) network established by the Firewall connecting the Business Network, the DPW Operations Data Center and the DPW Operations Network. 3. Other than VPN traffic block all traffic between the business network and the DPW Operations Network. Provide SCADA historian and information server clients on business network workstations requiring access to SCADA data. Provide VPN clients on business network workstations that will be used for direct connection to the SCADA system. Authenticate VPN users on the SCADA network. • Operations Data Center: On the DMZ network established by the firewall, provide an Operations Data Center for central collection, storage and processing of near real-time and historical operations data from wastewater treatment plants and pump station collection systems, and for presenting up-to-date process information to users on the business network. Locate the Operations Data Center in a physically secure location with access limited to those responsible for operation and maintenance of the data center. Provide both adequate, reliable temperature and humidity control and reliable, quality electric power. Also, provide uninterruptible power supply (UPS) capacity for maintaining control center operation for one hour. Locate the following SCADA system components in the Operations Data Center: 1. The historian servers which collect information from scanners installed on operator workstations in each of the three control centers, store the information, and retrieve and reduce information for presentation to operators at operator workstations and to business network users via historian clients installed on business network computers. On historian servers, also provide applications programming to reliably and efficiently extract selected historical information and load the historical information into C-P’s Oracle relational database. 2. Information servers which collect up-to-date process information from each of the four control centers for presentation to operators at operator workstations and to business network users via information server clients installed on business network computers. • The DPW Operations Network: Establish an Operations Network for interconnecting the four control centers and the Operation Data Center. Provide a network that allows adequately credentialed users connected to any of the four process control networks full monitoring and control access to all four control systems, and that supports VPN access to users connected to the business network.
2. provide UPS capacity for maintaining controller operation for one hour. Locate the keyboard. provide uninterruptible power supply (UPS) capacity for maintaining control room operation for one hour. provide UPS capacity for maintaining control center operation for one hour. programmable logic controller (PLC) monitoring and control of each pump station. as well as remote monitoring and limited remote control from mobile wireless laptop workstations connected to the central Collection System Control Center. Control Rooms. Use the Pump Station Design Criteria and I/O spreadsheet in appendices D and F in selecting signals for monitoring and control. 4. Local control panels housing a PLC and local human machine interface (HMI) with text and bar-graph displays and four-key menu-driven keypad data entry. monitor. Coordinate this work with the digital cellular network required for the collection system to both ease service management by C-P and take advantage of any available price reductions that might be available when both networks are provided by a single provider. The Collection Control System includes the following: 1. plants do not have standby electric generators. Where necessary to control installed costs.DOC/081640018 B-5 . Because. Provide both adequate. Distribute controllers throughout the plant in temperature and humidity controlled electrical rooms Because. quality electric power. Locate redundant primary fan-out switches as needed in data and control centers. Work with C-P in selecting the service and establishing a Service Level Agreement (SLA). GNV310133631748(APPB).5 million bits per second (Mbps) symmetric capacity for each connection. reliable temperature and humidity control and reliable. Provide both adequate. provided by telephone companies with a minimum of 1. • The Collection Control Systems: Provide a collection control system that provides local. Locate the control centers in a physically secure location with access limited to those responsible for operation and maintenance of the control center. Provide a redundant star network in accordance with DCS manufacturer standards. Use the WWTP Design Criteria and WWTP I/O spreadsheet in appendices E and G in selecting signals for monitoring and control. reliable temperature and humidity control and reliable. Local PLC Monitoring and Control.Use wireline services. quality electric power. and controller cabinets. 3. mouse and speakers for each workstation in a plant operations control room. Redundant. plants do not have standby electric generators. self-sufficient Distributed Control System (DCS) for each of the three major WWTPs. Control Center housing DCS servers and workstations. such as Multi-Protocol-Label-Switching (MPLS). Each DCS includes the following: 1. plants do not have standby electric generators. Use KVM extenders to support operator workstation interfaces in the control rooms. Locate redundant root switches in data and control centers. • The WWTP Distributed Control Systems: Provide an autonomous. autonomous. DCS Redundant Controllers. use remote input and output (I/O) for monitoring and control of systems with less critical monitoring and control requirements. Star Ethernet Network. Select controller locations to provide a balance between installed cost and signal wire length. Because.
4 Terminology Terminology and acronyms used in this Technical Memorandum are shown in Table 1-1. provide UPS capacity for maintaining control center operation for one hour. Demilitarized Zone City of Baton Rouge Department of Public Works Fixed End Service Facilities Information Management Human Machine Interface Meaning City CMMS C-P DCS DMARC DMZ DPW FES FIM HMI GNV310133631748(APPB). Configuring data bases. add a fixed end service (FES) at the control center to moved the network off the Internet and onto the providers private network. displays. Provide both adequate. quality electric power. Also. It is the interface point where all facilities on one side are maintained by the Verizon and all facilities on the other are maintained by the City. 3. as well as Collection System historical data collection. reports. A Control Center housing HMI Servers and a DCS workstation. Mobile Wireless Laptop Workstations. tables. and control strategies required to implement functions unique to this project City of Baton Rouge. Louisiana Computerized Maintenance Management System City of Baton Rouge-East Baton Rouge Parish Distributed Control System The point of demarcation for Verizon. 4. parameter lists.DOC/081640018 B-6 . ladder logic. Configure the DCS workstation to use the existing HMI server’s object linking and embedding for process control (OPC) interface to connect to the active HMI server and provide Collection System monitoring and control from the distributed DCS system. Relocate the existing control center from the Tier IV data center to a physically secure location with access limited to those responsible for operation and maintenance of the control center. Digital Cellular Network. Convert the existing 1xRTT (1 times Radio Transmission Technology) digital cellular network to CDMA-FDD (Code Division Multiple Access with Frequency Division Duplex). Provide hardened mobile wireless workstations for use by mobile operators and maintenance staff. Also. TABLE 1-1 Terminology And Acronyms Term Or Acronym ADO API APPLICATION SOFTWARE ActiveX Data Objects Applications Programming Interface Software to provide functions unique to this project and that are not provided by standard software alone. 1.Also. Include battery backup power capable of maintaining the PLC and the communications interface in operation for 4-hours. comply with applicable portions of the DPW Pump Station Design Standards. reliable temperature and humidity control and reliable. 2.
includes such communication modes as frame relay. cellular. Remote Terminal Unit Supervisory Control and Data Acquisition System-generally used in reference to system wide control and data acquisition system Staging Site Demonstration Test Computer specifically designed for remote terminal operation and processing high volumes of I/O and simultaneous operations Service Level Agreement Commercial Software packages that are independent of the project on which they are used. UHF and spread spectrum radio.TABLE 1-1 Terminology And Acronyms Term Or Acronym I/O IP ISP KVM LAN Mbps MPLS OPC ORT OWS PAT PLC PICS PROCESS MONITORING AND CONTROL SOFTWARE RTU SCADA SDT SERVER SLA STANDARD SOFTWARE Input/Output Internet Protocol Internet Service Provider Keyboard. leased telephone line. Includes but is not limited to operating systems. Virtual Private Network High-end personal computer for use by an operator in monitoring and controlling remote facilities. control and data collection capability. Uninterruptible Power Supply Telephone company providing telephone services including plain old telephone. etc. Application independent software developed by digital equipment manufacturers and software companies. which provide process monitoring. Video. Communication between central servers and remote facilities. independent of the specific process control project on which they are used.DOC/081640018 B-7 . text editors. autodialers. Mouse Local Area Network Million bits per second Multi-Protocol Label Switching Object Linking and Embedding for Process Control Operational Readiness Test Operator Workstation Performance Acceptance Test Programmable Logic Controller Process Instrumentation and Control Systems Standard software packages. Standard software includes system software and process monitoring and control software. file management utilities. programming languages such as C++. frame relay. assemblers. dedicated fiber optic or copper cable. Cellular Digital Packet Data [CDPD] or other telephone services. Wastewater Treatment Plant Meaning SYSTEM SOFTWARE TELEMETRY UPS VERIZON VPN WORKSTATION WWTP GNV310133631748(APPB). debugging aides and diagnostics.
2 Introduction & Overview Control Strategy & Naming Conventions This section defines general SCADA system physical design criteria. define parameters of configuration and construction in addition to specific details outlined in this document. S Facility Code 10 Unit Process AFD ISA designation of process and function 05 Loop Number 01 Unit Number SF Clarifying Abbreviation Use the clarifying abbreviation to assure that all tags are unique.DOC/081640018 B-8 . National Electrical Manufactures Association OSHA.” GNV310133631748(APPB). TAGS A shorthand tag number notation is used in the Loop Specifications. National Fire Protection Association NIST. Systems and Automation Society UL. CONTROL STRATEGY Specific control strategies will be described in the Appendix H. Use only the underscore character (_) as a separator to improve “human readability. Underwriters Laboratories AWWA.1.1 2. Instrumentation. Standard Loop Specifications. American Water Works Association NEMA.0 Physical Design Criteria 2. govern nomenclature.5 Standards and Codes The following organizations have generated standards that are to be used as guides in assuring quality and reliability of components and systems. American National Standards Institute NFPA. Scientific Apparatus Manufacturers Association IEEE. • • • • • • • • • • • • ISA. American Petroleum Institute RP550 Manual on Installation of Refinery Instruments and Control Systems (API RP550) 2. National Electrical Code(ANSI/NFPA-70) API. Occupational Safety and Health Administration ANSI. Institute of Electrical and Electronic Engineers NEC. National Institute of Standards and Technology SAMA.
1 2. Redundancy is required for the following components: • • • • • • • • HMI I/O Servers.3 2.2 General System Requirements City Product Standards Single Point of Failure LATER. DCS controllers.3. use the following unit processes in the tagging convention: 10 20 30 40 50 60 70 80 90 Preliminary Treatment Primary Treatment Chlorination and Trickling Filter Final Settling Tanks and Secondary Sludge Pump Station Plant Water and Effluent Pumping Gravity Thickeners and Thickened Sludge Pump Stations Anaerobic Digesters and Control Building Energy Recovery and Sludge Dewatering Building and Support Systems Miscellaneous 2. DCS Historian Servers. DCS Operator Workstations.DOC/081640018 . but there are specific components for which redundancy is required for safety or continued operation.An example of an AFD tag would be: S_10_AFD_0501_SF FACILITY CODES N S C XXX North WWTP South WWTP Central WWTP Pump Station Facility Number UNIT PROCESSES For wastewater treatment plants.3. Components for which redundancy is not required include the following: • DCS data servers. This does not mean that all control and equipment has to be duplicated. In general. DCS authentication servers. DCS historical data scanners installed on operator workstations. Any City product standards will be adhered to. B-9 GNV310133631748(APPB). Switches at each tier in the WWTP star LANs. DCS LAN media and network connections. single points of failure are to be avoided.
Use single source manufacturer for each instrument type. Provide instrumentation of rugged construction designed for site conditions. instruments. 2.3 Color Coding of Pilot Devices Function On or Open Off or Closed Alarms Automatic or Remote Manual or Local Color Red Green Amber White Blue Unless noted otherwise. Individual control switches and pushbuttons shall have customized legend plates which indicate function.4 Nameplates All individual panels.1 Field Mounted Instrumentation General Provide instruments that return automatically and immediately to accurate measurement upon restoration of power after a power failure. All NEC clearance requirements shall be met for the appropriate voltage level. 2. Equipment or piping shall not have to be removed to access controls. together with manufacturer’s brand or trademark. All equipment and instrument tubing shall be rigidly installed. 2. Inc.4 2. All controls shall be mounted within five feet of finished floor. Use plastic laminate nameplates having black letters on a white background. except where specifically noted. and panel mounted devices shall be provided with nameplates. 2. and so marked or labeled. conforming to standards established by Underwriter’s Laboratories (UL).. GNV310133631748(APPB). use the following color code for lenses of indicating lights. Provide only new. Use the same manufacturer for different instrument types whenever possible.4. first-grade materials throughout.3. standard.3.5 Accessibility and Mounting All control equipment shall be mounted in an easily accessible location.• • • • PLCs and RTUs DCS I/O modules. Digital cellular communications links Instruments.3. It is intended that after installation a slight to moderate pressure on the installed device shall not move it and in no circumstance should it sway back and forth if pressure is suddenly removed.DOC/081640018 B-10 .
Mount equipment on instrument racks. 2.4.4.Instrument enclosures shall be NEMA rated for the environment. Rosemount “Smart” pressure transmitters will be used.4. For most pressure ranges. Dresser/Ashcroft and Ametek U. useful operation of a control system depends on effective maintenance and calibration.1. and Division as shown or specified. Use linear. Diaphragm or bellows type elements will be used for low pressure ranges.S. 2. GNV310133631748(APPB). Follow ISA-S50. Scale range shall be such that normal operating pressure lies between 50 and 80 percent of scale range.4 Pressure Measurement Pressure and Differential Pressure Transmitter Diaphragm type pressure transmitters will be used for gauge. glycerin-filled units will be used. Gauge are the preferred manufacturers. Pressure Diaphragm Seals Diaphragm seals will be sued to protect pressure instruments from corrosion and to keep solids out of instruments when they are connected to pipelines. stands or in enclosures near the sensor at a level that permits viewing from floor elevation. Isolation valves and calibration ports will be provided for pressure instruments. Provide space between instruments. differential pressure and absolute pressure measurement applications. solid-front. Dial size is to be 4 1/2 inches minimum. In general. meet the NEC Class.DOC/081640018 B-11 . install instrumentation to be accessible from floor level or grade. Include panel layouts to include ergonomic factors associated with maintaining the equipment. In hazardous areas. every effort must be made to make the system as easy to maintain and troubleshoot as possible. Submergence rated enclosures shall be provided in areas subject to flooding. Pressure Gauges For pressure gauges. do not install electrical transmitters process piping. Accuracy shall be two percent of span. 2. Typical manufacturers are Dresser/Ashcroft and Ametek. Install instrumentation and auxiliary devices to be accessible for maintenance.2 Installation Unless readily accessible for viewing and calibration from floor elevation. Provide instrument transmitters that produce isolated 4-20 mA dc analog signals.3 Maintenance and Troubleshooting The continued. Group. equipment. Bourdon-tube elements will be used. The availability of complete system documentation and the installation of proper test connections greatly assist in maintenance and calibration. and piping for ease of removal and servicing. direct reading indicators unless otherwise specified. During the design of the I&C system. Analyzers must be removable from the process lines without disrupting the process.
Transmitter enclosures shall be NEMA 4X rated.6 Level Measurement Ultrasonic type level sensors and transmitters will be used for level measurement. and a normally closed solenoid valve located just outside the hazardous area boundary. Float and displacer type level switches will be used in sump pump applications and for high level alarms. Endress and Hauser. The Bubbler system shall consist of the following equipment: differential pressure transmitter. The straight approach must be at least 10 diameters upstream and 10 diameters downstream from the flow element.The flow element must be installed through a hot tap assembly to facilitate cleaning flow elements without isolating the pipe line. Floats shall be watertight and shall have a diameter of at least 4 inches.DOC/081640018 B-12 . Typical manufacturers will be ABB/Fischer & Porter or Rosemount.4. and shall be NEMA 4X rated. Magnetic flow tubes require a minimum of five diameters of straight pipe upstream and two diameters of straight pipe downstream. Acceptable manufacturers are Ashcroft B Series. Floats shall be internally weighted and mechanically switched. Flow Element and Transmitter. A dirt/moisture separator should be installed upstream of the flow element. All ultrasonic level transmitters shall be microprocessorbased devices with external keypads. Collection system level measurements will be taken with a Bubbler system. Acceptable manufacturers are Fluid Components (FCI) or Kurz Instruments. Venturi tubes of orifice plates are not acceptable. air compressor. Units shall be temperature compensated.4. 2. and shall be programmable without the use of potentiometers. Thermal Mass Flow Airflow measurement for air applications will utilize thermal dispersion technology for flow measurement. Acceptable manufacturers are Contegra. air release valve. Transmitter shall include local LCD display of both the instantaneous flowrate and totalized flow. Chart recorders are not required. LCD display. 2.4. Floats containing mercury shall not be used. or STI. Transmitter will be remote (nonintegral) from the meter.5 Flow Measurement Electromagnetic Flow Element and Transmitter Magnetic flow meters will be used for sludge service. The ultrasonic units will be Siemens/Milltronics. 2. Siemens or Anchor Scientific.Pressure Switches Units shall be the diaphragm sealed piston actuator type with automatic reset and snap action switch. or United Electric. A minimum flow velocity of 5 fps through the flowmeter will be maintained for primary sludge and 3 fps for secondary sludge. except for Collection Systems Pump Stations.7 Analytical Measurement Dissolved Oxygen Analyzer and Transmitter GNV310133631748(APPB).
Indicator shall be LCD or LED.DOC/081640018 B-13 . Principle of operation shall be amperometric with pH buffering. Provide a complete unit consisting of the following: • • • • • Element Transmitter Cable Junction Box Expendables Units shall have integral temperature compensation. Unit shall measure either free or total chlorine residual. but is usually set for much lower ranges in clean water applications. Transmitter enclosure shall be NEMA 4X. Turbidity Analyzer and Transmitter. Accuracy shall be better than 0. The Luminescent DO sensors will be Hach sc100 LDO Analysis System.001 NTU. Acceptable manufacturers are Hach.05 pH units with 24 hour zero stability of 0. Principle of operation shall be light scatter detection measurement. Provide a complete unit consisting of the following: • • • • • • Analyzer/transmitter unit Mounting hardware Sample tubing connectors Reagent Expendables Sample Conditioning System GNV310133631748(APPB). Unit shall include a bubble trap and vent. field selectable. pH Analyzer and Transmitter Unit shall electromechanically measure pH without requiring electrolyte flow. Residual Chlorine Analyzer and Transmitter Unit shall measure continuously the chlorine residual of the sample process stream. Luminescent DO sensors with compatible transmitters will be used for dissolved oxygen measurement. Acceptable manufacturers are Hach. Low Range The unit shall measure turbidity of high quality filtered water. Range can be as high as 0-100 NTU.01 pH units. Provide a complete unit consisting of the following: • • • • • • • Element Analyzer/Transmitter Cable Mounting Hardware Lamp Units Calibration Kit Expendables Transmitter enclosure shall be NEMA 4X.Dissolved Oxygen measurement will utilize luminescent response to emitted light for DO measurement. The resolution shall be 0.
combustible-gas detectors should be installed along the ceiling and floor because both combustible-gas detectors should be installed along the ceiling and floor because both heavier-than-air combustible gases (such as gasoline vapors) and lighter-than-air combustible gases (such as methane) may be present. Combustible Gas Detection System Combustible-gas detectors must be provided in accordance with NFPA 820. Thermowells must be used for thermocouple liquid applications and must be made of 316 stainless steel. Ten ohm copper RTDs must be used in large motor windings and thermocouples must be considered for all ranges in vibration applications. Mercury thermometers are not acceptable.Sensitivity shall be better than 0. but bi-metal may be necessary in small vessels because of element size. Acceptable manufacturers are Ashcroft. Each area should be analyzed for the types of gases that may be present (heavier-than-air gases or lighter-than-air gases). in screen rooms. For example. Typical manufacturers are MSA and General Monitors. Ametek and U. Temperature Indicators and Gauges The preferred temperature gauge is pressure gauge with a vapor-pressure temperature element. The specific application must be the basis for choosing the T/C and extension wire used. Transmitter enclosure shall be NEMA 4X. Acceptable manufacturers are Hach. with detectors located appropriately. Unit shall have integral temperature compensation. Dial size shall be 4 1/2 inches minimum. Acceptable manufacturers are Foxboro or Rosemount.8 Temperature Measurement Temperature Transmitters Units shall be 3 or 4 wire RTDs with integral two wire transmitters. Gauge Division. Thermowells must not be used for gas applications unless the line cannot be depressurized easily for T/C maintenance.S. Combustible gas must be treated as a critical alarm. The long-term stability is better than bi-metal units. GNV310133631748(APPB). Thermocouples Thermocouples (T/C) must be used for applications in which the operation temperature is greater than 300 degrees Fahrenheit. vibrating can damage this unit. Hach SOLITAX sc sensors and sc100 controllers will be used for TSS analysis. 2. However. Combustible gas detectors with silicon/H2S poisoning-resistant cells should be specified. Total Suspended Solids (TSS) Analyzers TSS measurement will utilize a nephelometric method where light is passed through the sample and the amount of reflected light is measured. The alarm must be connected to a local annunciator and interfaced to the PLC.001 mg/l with a 4-second maximum response time.DOC/081640018 B-14 .4. Elements shall be 100ohm platinum conforming to SAMA Standard RC 21-4 accuracy specifications.
or air conditioners as required to prevent temperature build-up within the enclosure and maintain equipment within equipment temperature ratings as required.5.5 Termination of Wiring All PLC I/O wiring shall be terminated on removable terminal strips on the individual PLC modules that permit removing I/O modules without disconnecting the wiring. For example. the I/O modules should be in separate racks with separate power supplies.3 Distribute I/O Between Modules To comply with general philosophy of no single point of failure. 2. Control Panels Indoors in hose-down or corrosive areas should be NEMA 4X. Tag and mark all terminal blocks and individual wiring. Enclosures shall be provided with corrosion inhibitors. and painted white using electrostatically applied TGIC polyester urethane powder coating on the inside and outside. Provide outdoor enclosures with sunshields. terminate I/O for related equipment on different I/O modules. Provide individual fuses for each group of discrete inputs for a common piece of equipment. 2. 2. I/O. Provide louvers. and digital inputs for the other two pumps on a separate I/O module. provide 12VDC discrete inputs.1 Control Panels General Control Panels located indoors shall be painted steel or fiberglass. provide 24VDC discrete inputs. terminate digital inputs for two pumps onto one I/O module. Control Panels outdoors will be 316 stainless steel.5. NEMA 4X. thermostatically controlled space heaters. fiberglass or stainless steel. where practical.5. forced ventilation. Provide discrete output modules with dry contact relay outputs rated at 120 VAC. Separate groups of terminal blocks shall be provided for the following: GNV310133631748(APPB). Except for 4 wire transmitter loops. When multiple racks are provided. provide power supplies for all 4-20 mA signals from the control panel.5 2. For WWTP.2. All wiring from the field shall terminate on separate numbered terminal blocks. NEMA 12. Provide isolated 4-20 mA analog outputs. as manufactured by Hoffman or equal.DOC/081640018 B-15 . if there are 4 high service pumps.2 Signal Isolation and I/O Unless otherwise indicated or required for a specific application. and Loop Powering Practices Provide individual fuses for each 4-20 mA signal loop.5. Provide isolated 4-20 mA analog inputs.4 Panel Power Distribution. and corrosion inhibitors.5. 2. all PLC and DCS I/O shall meet the following: For pump stations.
provide contact material of gold or gold flashing over silver and rated 1 A at 28 Volts dc.9 4-20 mA Loop Indicators Indicators shall be of the digital panel mounted type. Neatly coil and securely fasten all cabling away from equipment and entrance doors rather than laying in the bottom of the enclosure. provide contact material of gold or gold flashing over silver and rated 1 A at 28 Volts dc.5. provide ground and neutral conductors that are no smaller than phase conductors. provide contacts rated 10 amps at 115 volts ac minimum. 2. Pilot lights shall allow for lens and bulb replacement through the front of the unit. to produce an impedance between the connected equipment and ground of 3 ohms.5. Where contacts switch 115 volt signals.• • • • • • • Discrete inputs Discrete outputs Analog inputs Analog outputs.6. Each different voltage level. Where contacts switch low voltage dc signals. rather than the analog gauge type. Where contacts switch low voltage dc signals.DOC/081640018 B-16 . Miniature type devices are not acceptable. 2. For alternating current loads. Each different voltage level shall also be on separate tracks at least 6 inches apart.7 Pilot Devices and Controls Provide oiltight/watertight.6 Conduit Entry Conduit entry into panels will generally be through the top or bottom. 2. All outside voltage sources of a like voltage level should be grouped together. and shall also be labeled and provided with individual disconnects. provide contacts rated 10 amps at 115 volts ac minimum. heavy duty pilot devices and controls. On the panel. 2. provide either push to test type or a common lamp test button pilot lights. including surge protectors. GNV310133631748(APPB). Provide transformer type pilot lights utilizing low voltage lamps.5.5.8 Relays and Timers Where contacts switch 115 volt signals. 2. Each different voltage source within the panel.6 2.1 Lightening Surge Protection and Backup Power Requirements Grounding Requirements Provide ground conductors and ground rods adequately sized and in close enough proximity to grounded equipment.
provide bypass switches and isolation breakers so that the UPS can be isolated and taken out of service for maintenance without disturbing the loads it powers. be connected to UPS power. UPS Fail. receptacles. Provide the on-line type UPS that and provides power conditioning to the load and shall automatically revert to line power after batteries are discharged without requiring manual reset. 4-20 mA signal circuits with any portion of the circuit traveling outside a building shall be provided with a surge protective device at each end of the circuit. and UPS bypassed. or individual instruments be required to be connected to the UPS system. fans. Consult with DPW to determine acceptable configuration of UPS power distribution. copiers. For the Collection Control System local PLC monitoring and control. Coordinate with provider to determine specific equipment being provided and power requirements. and communications equipment.3 2. For UPSs with distribution panels.6. Provide UPS power to communications equipment provided by Verizon and other communications service providers. UPSs shall provide auxiliary contact outputs connected to the PLCs and DCSs for UPS alarm. etc. GNV310133631748(APPB). PLCs. Where generators are provided. and Collection System Control Center will have the capacity for maintaining control center operation for one hour.6. the UPS shall be powered by the emergency generator bus such that in the event of a power failure the UPS is functional for the duration the emergency generator is operating.DOC/081640018 B-17 . WWTP Control Centers. 2. provide surge protection devices at the DMARC location between Verizon and DPW equipment.2 UPS Requirements In general provide either a UPS or battery power back up for all control panels. As a minimum UPSs provided for the Data Center. 2. It is not required that auxiliary control panel components such as space heaters. UPS receptacles to be color coded and identified as for UPS supplied equipment only. a single large facility UPS with power distribution to loads is preferred over individual UPS located in panels or equipment enclosures.6. DCS components. provide battery backup power capable of maintaining the PLC and communications interface in operator for four hours. Main Power Fail. It is not intended that printers. computers.4 Discrete Signal Line Protection Analog Signal Line Surge Protection Surge protection is not required.5 Telephone Circuit Surge Protection Unless DPW considers the protection provided by the Verizon to be adequate.6. For facilities with several loads requiring UPS power.2.
Wherever combined control cables are split out of a common conduit. Provide power surge protection at the alternating current source power connection to each instrument and control panel and at each voltage level within a panel.2.6 Power Supply Surge Protection Provide power surge protection at each source power connection to each power distribution panel. Install fiber optic cable inside innerduct in conduit. 2.4 Shielded Twisted Cabling Provide shielded twisted pair or triad cabling for all analog signal circuits. Provide an appropriate level of spare pairs or triads. Separate copper and fiber optic cabling.7. Communications. Note that different control voltages shall not be combined. Individual conduit runs shall be kept to a minimum and control cabling may be combined in common conduits and routed to centralized terminal boxes to the greatest extent possible. Provide 50/125 micron. GNV310133631748(APPB). spares are not required. 2.2 Conductor Labeling Wire labels shall be provided for each individual conductor and multi-conductor cable at all termination points including termination/junction boxes. Evaluate cost effectiveness of installing a separate remote I/O cabinet near the monitored equipment. 2.7 2. Terminate all fiber optic cable(including spares) in fiber optic patch panels and satisfy test criteria.DOC/081640018 B-18 . multi-mode or 9/125 micron single mode fiber optic cable. 2. To minimize the effects of lightning and surges.1 Control. minimize the routing lengths. Labeling of “through” wiring [that is conductors not terminated or spliced] at pull boxes will not be required.7. provide a terminal box.7. underground control and communication cabling routed outside the building confines shall meet the following requirements: • • Use fiber optic cable where practical for underground or outdoor communication between PLC components. When any fibers in a cable are terminated in a patch panel. Provide power surge protection at the source power connection to each UPS.6. Where individual control or monitoring signals must be routed outside. and Power Cabling and Media Requirements General Except for designated direct-burial installations.3 Fiber Optic Cable Install all fiber optic cable with at least 50 percent spare fibers and a minimum of two spare fibers.7. Use patch cables installed in conduit for connection of transceivers to patch panels. Provide all patch panels indoors with NEMA 1 enclosures. install all cabling [copper and fiber optic] in conduit. For single circuits. Provide all panels outdoors in NEMA 4X enclosures. Selection between single mode and multi-mode fiber optic cable will be based on data rate and distance. terminate all fibers in that cable.
LAN cabling shall satisfy test criteria for operation at 100 Mbps.8. Provide vertical cable management along both sides of the rack. 2.2 Power Supply Provide one or more. GNV310133631748(APPB). For heavy equipment. install fans or cooling system at the top and bottom. 2. However. Each multi-conductor control cable should provide at least 25 percent spare conductors. Provide horizontal cable management above patch panels and switches with a minimum of 1 rack-mount unit of cable management for every 2 units of switches and patch panels. 2. Also. Use shelves that are deeper than the equipment it is supporting. 2. Provide both adequate. Provide racks with both front and back access for computer and network equipment. dedicated 120V power circuit for each rack. reliable temperature and humidity control and reliable.1 Layout In general. install heavy equipment near or at the bottom of the rack.8 Network and Server Rack Construction Requirements Locate network and computer racks in a physically secure location with access limited to those responsible for operation and maintenance of the components and applications housed in the racks. quality electric power..7. transformers and lighting ballast. as required. Provide a minimum 3 feet of clearance both directly in front and behind the rack. provide UPS capacity for maintaining operation for one hour.7.8.6 Local Area Network and Telephone Cable and Components All Local Area Network [LAN] and telephone cabling and components shall be listed and rated as “Category 6” and satisfy test criteria. For racks that require ventilation.DOC/081640018 B-19 . install UPSs near the top.5 Multi-conductor Control Cable Provide multi-conductor control cabling for all discrete signal wiring. Route LAN and telephone cabling to minimize proximity to alternating current wiring. Multi-conductor control cable shall be used over single conductor control cable due to ease of identifying individual conductors by color as well as individual conductor labeling. Locate the power distribution panel sourcing the power circuits inside the physically secure space housing the racks served. Add power strips as necessary to ease access and power cable management. Provide shelves for any equipment that is not rack-mountable.2. include drawer glides.
NEMA 4X areas. 2.2. is expected to be provided separately and not require control panel expansion.4 lux reflected light level and a 50 IRE sensitivity of 0. Suitable for installation in industrial.0 Network and Other Communication Requirements 3. Limit access to the control centers to the staff performing maintenance on the system.59 lux. For control centers and data centers. and dual speakers in the control room for each workstation. in a locked temperature controlled room with reliable conditioned power. Capable of storing 30 days of video for each camera at 4 frames per second (fps).1 Overview The following three types of networks are anticipated: GNV310133631748(APPB). design video intrusion systems to include local digital video recorders with the following capabilities: 1. including both servers and workstations. Necessity of video intrusion assessment or intrusion monitoring via discrete inputs will be determined during design and may significantly impact digital cellular network monthly costs. described herein and in compliance with the current version of NIST SP 800-82.9.DOC/081640018 B-20 . Control panels at collection system locations are to include a panel intrusion alarm. and AUTHORIZED INTRUDER discrete inputs. Door OPEN. Design lighting systems to provide adequate illumination for proper camera operation and to maintain a contrast ratio of better than 4:1. mouse. Certain collection system location panels may be required to be capable of accepting a Gate OPEN. 2. as well as appliance and operating system configuration to disable unnecessary or high risk services. virus protection. locate all computers. Design intrusion detection systems to eliminate false negative and minimize false negative events. 3.2 Physical Security Coordinate with DPW to establish physical security requirements for pump stations and plants. and intrusion detection and prevention. Network and computer security includes access control. INTRUSION (alarm from an intrusion detector). Access controls include controls provided by network appliances such as routers and firewalls. Capable of producing event clips which start a preset time before the event and end a preset time after the event.9. When necessary. All control panels are required to be pad-lockable and have door closed switches.1 Security Requirements Network and Computer Security Provide SCADA network and computer security as shown. Use KVM extenders to support a keyboard. limit access. and establish secure user names and passwords. when required. 3.9 2. Coordinate with DPW to establish secure networks and computer systems. dual monitors. user authentication and role-based access limitations. Video intrusion alarm assessment. For intrusion alarm assessment provide fixed cameras with manually adjustable lenses capable of full color operation at 2.
add antenna amplifiers to achieve at least -80 dB. and at the operations data center for interconnecting DCS components. 3. A digital cellular wireless network for connection of the pump stations and wireless mobile laptops to the collection system process control network.1. -80 dB is not achievable with a signal amplifier. Make site visits to pump stations to determine antenna locations verify received signal strengths greater than -80 dB. Work with DPW and Verizon to develop an acceptable SLA and service contract.2 Digital Cellular Network Work with DPW and Verizon to transfer ownership of the existing Verizon digital cellular communication network installed in Phase 4 of the on going pump Station SCADA project. For these applications address reliability.4 Digital Wireline Network Provide a digital wireline supporting IP protocol. integrate the FES and digital cellular network into a single contract and SLA with the digital wireline network. For pump stations provide a single industrially hardened switch supporting necessary protocols and suitable for installation in the pump station environment. select another communications method based on available alternatives and the relative importance of the pump station. GNV310133631748(APPB).3 Local Area Networks Provide LANs that provide both redundant switches and redundant media for each LAN connected computer or controller. 3. the Collection System Control Center for interconnecting DCS and HMI components. Advantages of this interface include scalability flexibility. The planned initial data rate is 1. Where signal strengths are lower than -80 dB. Also. can be configured and maintained by the DCS provider. the three WWTP Control Centers and the Collection System Control Center. and Ethernet digital cellular interfaces capable of providing Network Address Translation (NAT) and supporting Virtual Private Network (VPN) connections. verify that any appliance management ports required by Verizon provide adequate security. There may also be plant applications where a wireless LAN (WLAN) alternative is adequate and cost effective. 2. For LAN components installed outside the control centers and data center. 3. When. Code Division Multiple Access with Frequency Division Duplex (CDMA/FDD) radio technology. each pump station for interconnecting the PLC. and can be monitored by the DCS system. Include adequate support to assure reliable operation and timely notification and repair of outages. Local area networks (LANs) at each of the WWTP for interconnecting DCS components. and life-cycle cost effectiveness. digital cellular modem. use industrially hardened appliances.DOC/081640018 B-21 . Convert the Verizon service to a Fixed-End Service (FES). 3. Use the same network topology for all LANs except the pump station LANS. If practical. A digital wireline network for interconnecting the Operations Data Center. capacity and security issues on a case-by-case basis.5 million bits per second (Mbps) using a service such as Multi-Protocol Label Switching (MPLS). Work with the DCS provider to assure that the LAN design satisfies DCS requirements.
2. 4.DOC/081640018 B-22 . communications and network equipment.2 4. 4. Hardwired safety interlocks such as HIGH motor temperature will prevent manual equipment operation. pressure switches on the pump station bubbler systems provide hard-wired logic to maintain limited pump station operation in the event of a or PLC malfunction. 4.2. 4.2. It is intended that all equipment sequencing for motor restart after a power outage be programmed into the PLC or DCS. local autonomous equipment control such that the equipment is not dependent on communications links or operator intervention.2 Hard-Wired Backup Control Hard-wired backup controls are not required for most equipment. It is intended that all automatic control and equipment sequencing be accomplished through PLCs and DCS controllers. Since most equipment is controlled in a remote manual mode. reliability and redundancy apply equally to all computers. 4.1 General Requirements Requirements for environmental. Also.2.1 Monitoring and Control Local Autonomous Control At local equipment control panels or motor control centers. but need to be evaluated for each piece of equipment. and reasonable cost. Requirements for pump stations and DCS equipment located in electrical rooms and process areas differ and are addressed individually. Hardwired time delay relays in individual starters are not required. It is intended that local manual control will be used primarily for maintenance functions and not operation. provide stand-alone.Work with DPW and the data communications network provider to select a product that satisfies DPW needs including providing adequate capacity. ability to handle internet protocol (IP) traffic. acceptable reliability and SLA. GNV310133631748(APPB). automatic restart generally applies only to restoration of last state after a power failure.0 Functional Requirements 4.3 Local Manual Control The local control panel or motor control center operator interface will provide for local manual equipment control that will override PLC or DCS control.4 Equipment Protection and Safety In general hardwire protective devices which are required for electrical protection and personnel safety directly into individual equipment controllers or starters to eliminate reliance on PLCs or DCS controllers. verify that any appliance management ports required by the provider provide adequate security. physical security. Specifically.
9 Remote Operator Interface Remote operator interface requirements include provisions for HAND/OFF/AUTO (HOA) selectors for remote manual override control and duplication of the indicators and controls of the local operator interface.2. Motor Elapsed Runtime Meters. 4. 4. HIGH Temperature Indication. Also provide any additional monitoring and control displays and pop-ups required to support automated sequencing and analog control. for pump station applications.3 4. Pump ON.3. Categorization.2. some critical applications may require local manual start/stop or even speed control at the equipment. However. local operator interface requirements shall be evaluated for each piece of equipment.DOC/081640018 B-23 . status monitoring. In general. and Conditioning Alarm Conditioning Alarm conditioning in addition to that provided by each PLC will be required to account for conditions external to the plant and to further reduce nuisance alarms and improve alarm response. suppress FAIL alarms and performance alarms such as LOW FLOW GNV310133631748(APPB).6 PLC and DCS Monitoring of Equipment Status As a minimum.1 Alarm Segregation. provide local manual control at the drive.4. Equipment Fail. and drive control. as a minimum. Motor Current Indication with a Phase (A. as well as for monitoring other useful information such as motor current and drive diagnostics.7 Control of Variable Speed Drives Use Fieldbus interfaces to variable speed drives for speed monitoring and control.2.2. B. HIGH Moisture.5 Maintained Versus Momentary Controls It is intended that all discrete outputs from the PLCs or DCS controllers to individual equipment controllers be maintained contact outputs such that seal in contacts are not required in the control circuit. each equipment controller and control station shall provide isolated. Prioritization. provide local operator interfaces that. 4. 4. Wetwell HIGH HIGH and LOW level pressure switch alarm indication Pump Station Discharge Pressure Pump Station Discharge Flow for new or replacement pump stations. Wetwell Level Indication. However. include the following indicators and controls: a) b) c) d) e) f) g) h) Common FAIL Beacon. 4. C) selector. maintained contacts to the PLC to monitor each of the following: • • • Equipment Running/Stopped.2.8 Local Operator Interface In general. Equipment in Auto and ready to operate. For example.
should be for equipment for which the power has failed.3. 4.4 4. 4. Depending on the digital cellular contract and other issues use either parallel polling of the collection system PLCs or an the collection system HMI servers OPC servers to obtain the historical data.DOC/081640018 B-24 . Work with DPW in determining what data GNV310133631748(APPB). lower priority. alarms and place them in categories such as Plant Performance. Provide supervisor adjustable debounce delays to reduce nuisance alarms for analog variables.4. 4.1 Trending and Reporting Historical Trending Easy access and flexible graphical presentation of historical trend data over the last two years is required to support operational analysis and maintenance planning. Develop specific alarm conditioning rules during design and finalize them during construction. Log events or low priority alarms that aren’t annunciated for which a response can be scheduled. To prevent loss of data after two years.3. etc to ease performance analysis and maintenance scheduling. 4.4.2 Logical Alarm Summary Displays A logical alarm summary presentation on alarm summary displays is required to ease the decision process during emergencies.3 Collection System Historical Data Provide a DCS workstation and scanner in the Collection System Control Center to collect collection system historical data.3 Alarm Prioritization Alarms prioritization is required with only critical and important alarms presented on alarm summaries. redundant historical data scanners on two of the DCS operator workstations in each plant control center to collect plant historical data and transmit it to the historical data server. The goal is that any critical alarm requires immediate attention and that other alarms require timely action.4. Log other. Plant Capacity. 4.2 Plant Historical Data Provide dual. also provide an automated easy to use process for periodically archiving historical trend data to removable media.
4.8 Regulatory and Performance Reports Regulatory Reports Work with DPW to determine regulatory reporting needs and develop an automated system for producing reports using the DCS historian. significant events.5 188.8.131.52. Configure the historian to provide forms for manual data entry and for maintaining the manual entries in the historical data records.4.5 CMMS Interface It is possible that a computerized maintenance management system (CMMS) or other information management system interface will be required for the historical data servers to support preventative maintenance scheduling. Performance Reports Monthly performance reports are needed to track system performance. as well as operating and maintenance costs. 4. For the collection systems regulatory reports are generally not required. Either the API or ADO interface can be used by a custom applications program to move selected data from the DCS historical database to the C-P Oracle database. internal management reports are needed that summarize periodic collection system performance to track performance against the consent decree.4.2 Critical Alarm Delivery Method A flexible system that is capable of being reconfigured to use the best available delivery alternative is required for forwarding appropriate critical alarms to mobile staff. GNV310133631748(APPB).7 Operation Reports Work with DPW to determine operational reporting needs and develop an automated system for producing reports using the DCS historian. 4. 4.5. It may be necessary to locate an Oracle database server in the Operations Data Center to reduce firewall configuration complexity and reduce security risks.DOC/081640018 B-25 . 4. Determine which report variables are measurements and which must be manually entered.6 Reporting Application Provide a single reporting application for producing reports from both the DCS historical database and the C-P Oracle relational database. 4. However. for lab analysis for example.4. Work with C-P and the DCS manufacturer to develop requirements for and deliver the necessary application programming.1 Access for Mobile Operators and Maintenance Staff Notification of Critical Alarms Mobile operators and maintenance staff need to receive notification of appropriate critical alarms.5.4 Relational Database Interface The DCS historical database is expected to be proprietary with both an applications programming interface (API) and a Microsoft ActiveX Data Objects (ADO) interface. maintenance activity.
view process trends. Support. In contrast to the service item. and review alarm summaries. support.3 Support Support is needed for repair. Update the schedule routinely throughout design and construction of the SCADA system.Initially. as well as annual hardware and software service agreements.4 Mobile Laptop Workstations Provide Collection System operators and maintenance staff with hardened mobile laptop computers and digital cellular wireless cards linking the cards to the private digital cellular network for use in monitoring collection system performance and in resolving collection system problems. DCSs. Upgrade and Migration System. Support.5. 4. So. upgrade and migration to DPW for use in preparing annual budgets. 4.1 SCADA System Service. upgrade and routine maintenance of specialty SCADA hardware and software such as computers. Prepare a draft schedule early in design so that C-P can consider these costs when making technology and equipment selections. Some support services. response times and provider penalties for failure to comply with stipulated performance and response times. support is routinely delivered by technicians and engineers that actually visit the site to perform physical inspection. 4. as communications technologies continue to evolve. ISP. Service.5.6. repair and upgrade.2 Service Service fees include monthly fees for items such as out-sourced data centers. Provide a schedule that can be easily updated by DPW on a annual basis to make adjustments as necessary expenses and expense costs vary. Upgrade and Migration Schedule Provide a projected schedule of recurring expenses for system service. Include all of the items listed below. it’s possible that voice messaging will have to be used. The existing DPW cell phone contract does not support text messaging. maintenance. these services are generally delivered by remote service provider staff and using service provider facilities. performance parameters. outsourced communications links. However. such as software GNV310133631748(APPB). Except for out-sourced communication link technicians. leased SCADA components. as well as any others that are being considered for the SCADA system.6 4. These laptops will use browser access to the Collection System HMI servers to display graphics displays. the delivery system needs to be easily reconfigured to take advantage of current technologies. PLCs and HMI software installed at DPW facilities and out-sourced data centers. Work with providers and manufacturers to determine the appropriate service/support product suites for DPW and in developing SLA covering services provided. 4.6.3 Critical Alarm Assignment Method An easy to use configuration tool is needed for selecting critical alarms for mobile delivery and assigning those alarms to one or more mobile staff.6. 4. the most likely method of delivery will be text messaging to cell phones.DOC/081640018 B-26 .
4 Upgrade Periodic upgrades are needed to keep hardware and software current. topology or media to a replacement application. market conditions or evolving DPW needs. runtime. 5. Provide the following submittals: • • • • Design submittals including Schematic Design. Migration needs usually are driven by technological advancement. Provide and conduct routine coordination meetings with representatives of all parties during construction and starting with a pre-construction meeting. may be delivered by remote technicians under DPW supervision using secure communications links. Upgrades are less frequent. and Contract Document. OWS Workstations and HMI application programming plant including updates to OWS software screens including communications.0 Application Programming Requirements 5. Coordinate testing activities.6. 4. tuned and put back on line before others are upgraded. Provide for delivery of the following from the DCS manufacturer and/or the SCADA integrator: • • DCS and PLC application programming.1 General Requirements Develop detailed control descriptions in accordance with this design criteria and the Standard Loop Specification document in Appendix H. service. Design Development. Maintain and coordinate resolution of punch lists for all testing and inspection activities. Component submittals for all contractor furnished components Plans showing equipment layouts and locations Assembly submittals for all assemblies B-27 GNV310133631748(APPB). service. Upgrades usually require outages and configuration adjustments.6. 4. platform. totalizers. topology or media. To reduce disruption typically one of several workstations or redundant servers is upgraded. 6. more expensive and better scheduled than system support work.0 Coordination and Submittal Requirements Coordinate the work as follows: • • • • • • During design. submit and incorporate DPW comments at major design milestones. and historian.service patch installation.DOC/081640018 .5 Migration Migration is needed to allow moving from one application. Facilitate DPW participation and adjudicate DPW issues in all testing. platform. Facilitate DPW review and adjudicate DPW comments on all submittals.
Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Field or Factory Testing as applicable Included in Contract Documents Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Factory Testing Included in Contract Documents Included in Contract Documents Included in Contract Documents Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Included in Contract Documents. Provide design and construction documentation conforming to the following standards. Control Strategy Descriptions.1 Naming and Numbering Standards Drawings.• • • Cable plans showing cable routing Installation details showing equipment and assemble Electronic and hard copies of all O&M information and manuals 7.2 7.1 7.DOC/081640018 B-28 . Preliminary Construction Submittal Prior to Procurement Final Prior to Field or Factory Testing as applicable Prior to Procurement Prior to Installation Instrument Data Sheets Field Cable and Wire Schedule or Plans Programmable Controller I/O/DCS Controller List Data Cable Plans Typical Mounting and Installation Details Control Strategies/Loop Descriptions Control System Block Diagram Interconnection Wiring Diagrams Panel Layouts and Schedules Ladder Logic Diagrams Loop Diagrams Description GNV310133631748(APPB).2. Inclusion of detailed PLC and DCS panel drawings in the Contract Documents is intended to clarify requirements for bidders providing more competitive bids.2. When Required Included in Contract Documents Preliminary Construction Submittal Prior to Procurement Final Prior to Field Testing Included in Contract Documents. Data Sheets and Lists General Use the tag numbering and naming standards described in Section 2.0 Documentation Standards 7.
panel. Discrete Components: – – • • Tag number.2. terminal numbers and terminal strip numbers. Show each circuit individually and show names corresponding to other drawings or documentation for circuits entering and leaving an enclosure or panel. terminal numbers and location Switching Action. loop diagrams shall include content required by ANSI/ISA S5. In addition to the minimum standards set by ANSI/ISA-5. Relay Coils: GNV310133631748(APPB). and field. I/O tag number. • • • • Specific location of each device. Signal ranges and calibration information. and terminal block number.When Required Included in Contract Documents Preliminary Construction Submittal Prior to Procurement Final Prior to Field Testing Description Control Room Layout Floor Plans 7. and component descriptions. equipment. manufacturers. such as area. and process variable description I/O points: PLC/DCS cabinet unit number. the following information must also be included on the loop diagrams. At a minimum. Divide each loop diagram into areas for PLC/DCS. set point value and units. References to shop drawings or manufacturers' shop drawings for continuation of wiring will not be acceptable except where such reference is to contact inputs or relay outputs. terminal strip number. panel location. Instrumentation. I/O address. or motor control center number). Show unique rung numbers on the diagram and depict and identify all terminal connections. terminal junction box number. etc.4 Instrument Loop Diagrams. Typical diagrams may not be used. PLC/DCS slot number. The loop diagrams must depict the complete wiring of each control loop. including set point values for switches and alarm and shutdown devices PLC/DCS related items such as Input/Output (I/O) type and address.4. Ladder Logic Diagrams For discrete control and power circuits provide electrical ladder diagrams. rack number. Include devices related to discrete functions that require electrical connections. PLC/DCS rack number. PLC/DCS number. PLC/DCS point number.2 Drawings Loop Diagrams Detailed loop diagrams shall be provided for all control loops. Include the following as a minimum: • • Terminals: Location (enclosure number. and model numbers.DOC/081640018 B-29 . and PLC/DCS equipment manufacturer and part numbers.
and coil location (ladder rung and sheet number) Ground wires. show each circuit individually. Overall panel power wiring showing primary source of panel power. Energy sources of devices (field. surge protectors and connections Interconnection Wiring Diagrams Interconnection wiring diagrams for control panels and PLC/DCS enclosures shall be provided. PLC/DCS number. General location of devices such as field or panel. GNV310133631748(APPB). louvers. and subpanels. identify circuit or disconnect numbers. terminals. and calibration information (such as setpoints). For electrical sources. internal and external.– – • • Tag Number and its function Contact location by ladder number and sheet number Relay Contacts: Coil tag number. The interconnection wiring diagrams are to show the control or PLC/DCS panel internal wiring and the associated interconnections with field elements and equipment. terminals. MCC number). "FIELD". PLC/DCS rack number. • Scale Drawings: Show dimensions and location of panel mounted devices. "Typical" diagrams or "typical" wire lists may not be used. As a minimum. and signal range and calibration information (such as setpoints). References to shop drawings or manufacturers' shop drawings for continuation of wiring will not be acceptable except where such reference is to contact inputs or relay outputs. Circuit name or field wire numbers for wires entering or leaving a panel.DOC/081640018 B-30 . and PLC/DCS components part numbers. PLC/DCS slot number. PLC/DCS related items such as Input/Output (I/O) type and address. description. PLC/DCS point number. or otherwise) such as electrical power. Identify voltage and other applicable requirements. doors. voltages. Internal terminal strip number and terminal number assignments. panel. Field element tag number. Internal wire number assignments. and power connections to panel and field devices. enclosure. description. The diagrams must depict the complete interconnection wiring. All point-to-point interconnections with identifying numbers of electrical cable or wire. • • Panel Layout and Schedules Detailed drawings of the construction and layout of all control panels and PLC/DCS enclosures must be provided. branch circuits. The drawings should show the following. • • • • • • • • Panel instrumentation and control components’ tag number. scale range. function. location (e. the interconnection wiring diagrams will show the following.g.
In general the instrument installation should conform to standard industry practices as shown in American Petroleum Institute Recommended Practice 550 (API RP 550). PLC/DCS. interconnection and physical topology of PLCs/DCSs and computer workstations. nameplate inscriptions. Typical Mounting and Installation Details Typical mounting and installation details shall be developed for all instruments and control system components. model number. Control System Block Diagrams Provide block diagrams that are more detailed versions of those included in these design criteria and depict the following: • • Locations. type of mounting). panels. Instrumentation and control components schedule include item number. tag number. • • • If possible. panel material. wire and terminal block numbering and labeling scheme. “Manual on Installation of Refinery Instruments and Control Systems” and other standard references such as the “Instrument Engineers Handbook” (B. Location plans shall be sufficiently detailed so as to allow determination of usability. Data Cable Plans Provide sufficient documentation to illustrate data cable routing and installation conformance to cable. Location Plans Develop location plans which show locations of instruments. instrument scale. the components schedule and bill of materials should appear on the same drawing as the panel layout. and equipment.g. panel configuration (e. To maintain quality and consistency. Provide enough detailed information to avoid confusion and prevent field instruments and panels from being improperly mounted. and used. and other construction details. and quantity. Chilton Book Co) and “Instrumentation Handbook for Water and Wastewater Treatment Plants” (R. description.• Construction Details showing panel NEMA rating. Liptak. these details should be used whenever possible. Show type of cable (coaxial. tag designations. and any other special information and remarks required for clarity. Construction Notes: Panel wire color schemes. installed. communication hardware manufacturer installation specifications and requirements. Data communications cabling. Skretner.DOC/081640018 B-31 . enclosure dimensions. Bill of materials indicating item identifier. manufacturer. fiber optic) and connections. GNV310133631748(APPB). Lewis Publishers). Floor Plans of Control Room Layout Develop floor plans for all new and modified control rooms. and their in-plant communications networks. internal backplate dimensions.
2.• Individual PLC/DCS configuration including number of racks. The narrative shall be a concise. etc. the PLCADDR. POINTNO The point number in the slot that the I/O point is located. For discrete point: GNV310133631748(APPB). The PLC I/O list shall include as a minimum the following data fields. 7. This field will be left blank. This field will be left blank when IOADDR is PLC or DCS controller. This field will be left blank when IOADDR is PLC or DCS controller. This field will be left blank when IOADDR is PLC or DCS controller. Provide two sets of narratives for PLCs/DCSs. Field Name TAG DESCRIPT SGNLTYPE Field Description The ISA tag number for the data point (as described under "Instrumentation and Control Loop Tagging System" heading) A brief description of the function and location of the point Input or output signal type. Signal types include: AI AO DI DO IOADDR RACKNO = = = = Analog Input Analog Output Discrete Input Discrete Output The particular input or output address in the PLC/DCS controller. one set for use before the SCADA upgrade and modifications to support the SCADA upgrade. This typically corresponds to a 4 mADC signal. The rack number or address that the I/O point is located. Standard Loop Specifications as well as existing PLC/DCS programs and operator interface and data processing functions. and interfaces with other strategies and equipment.2. PLCNUM PLCADDR LORANGE The PLC or DCS controller number (or station number) that owns the I/O address. Internal PLC or DCS controller address for I/O mapping and communication between PLC and PMCS For analog point: The lowest value of the data point in engineering units. SLOTNO The slot number in the rack that the I/O point is located. easy-tofollow description of the control sequence. Narrative descriptions may be supplemented by logic diagrams.DOC/081640018 B-32 . I/O cards. power supplies. algorithm. which will be added during application software development. Include all PLC/DCS I/O list parameters with the exception of the I/O mapping address (PLCADDR).3 Control Strategies / Loop Descriptions Develop control narratives from Appendix H.4 DCS and PLC I/O List and Settings Develop DCS and PLC I/O list using the latest version of Microsoft Excel®. 7.
as applicable: GNV310133631748(APPB). this field will be left blank. Data sheets provided are to be similar to ISA data sheets. STATUS For discrete points: A word to describe what the status of the point is when the data point is set high (true).2. For discrete points. Data sheets for instrumentation and control components shall include the following information. Primary Elements and Control Valves. HIALARM The value in engineering units of the point at which a high value alarm is initiated. LOLOALARM The value in engineering units of the point at which a low low value alarm is initiated. STATUS words include: ON OFF STRT (Start) STOP OPND (Opened) CLSD (Closed) FWD (Forward) REV (Reverse) AUTO (Automatic) MAN (Manual) CASC (Cascade) REM (Remote) LOC (Local) HI (High) HIHI (High-High) LO (Low) LOLO (Low-Low) FAIL (Fail) TRBL (Trouble) ALM (Alarm) For analog points.5 Instrument Data Sheets Provide instrumentation data sheets for all instrumentation and panel components.Field Name HIRANGE For analog point: Field Description The highest value of the data point in engineering units. this field will be left blank. this field will be blank. For discrete points. ISA standard ISA-S20 Specification Forms for Process Measurement and Control Instruments. 7. This field will be left blank. For discrete points. This typically corresponds to a 20 mADC signal. For discrete point: LOALARM The value in engineering units of the point at which a low value alarm is initiated. EU The engineering units that the ranges and alarms are specified in. this field will be left blank. this field will be left blank. For discrete points.DOC/081640018 B-33 . For discrete points. this field will be left blank. HIHIALARM The value in engineering units of the point at which a high high value alarm is initiated.
• • • • • • • • • •
Instrument tag number Instrument type Instrument location or service Manufacturer and complete model number Size and scale range Setpoints Materials of construction Power requirements Mounting type Options included
Field Cable and Wire Schedule or Plans
All field wire, cables, and circuits shall be documented either on schedules or drawings. A field cable and wire schedule should include as a minimum the following information: • • • • Field cable and wire tag/number. Field cable and wire tagging scheme is outlined under "Field Cable and Wire Numbering System" heading. Indicate the quantity, type, and size of wire or cable (as applicable) Indicate origination of circuit Indicate destination of circuit
If drawings are used, include the above information, as a minimum, on the drawings.
8.0 Testing Procedures And Test Documentation
Factory Demonstration Tests, Operational Readiness Tests, and Performance Acceptance Tests are required for all work. All tests performed may be witnessed by a representative of the City’s staff or their designee. Coordinate schedules and activities associated with all tests with the City’s staff. Submittal requirements for each set of tests include draft test procedures, final procedures reflecting City review comments and completed test documentation including the initials of the person completing the tests and the signature of the witness.
Factory Demonstration Test (FDT)
Test fabricated panels, enclosures, or systems at their assembly location (referred to herein as "factory"). Test and verify panel power wiring, panel internal point-to-point wiring, and panel functions such as indicating lights, switch operation, and indicator operation. Simulate inputs and outputs for field primary elements, field final control elements, PLC/DCSs, and all other equipment excluded from the test to demonstrate that the panel or system is interconnected and operational. Include PLC/DCSs in the test. Correct any deficiencies found prior to shipment of equipment and panels to site. Failed Factory Demonstration Test shall be repeated and may be witnessed by the City.
Operational Readiness Test (ORT)
Conduct Operational Readiness Test (ORT) to inspect, test, and document that each system or subsystem being commissioned is ready for operation. For wellfield panels, test each panel separately just prior to startup. Test all loop, power, and interconnection wiring for proper termination and functionality. Complete loop status reports and component calibration sheets for each component. Use loop status reports to organize and track inspection, adjustment, and calibration of each loop and include the following. • • • • • • • • • Project name Loop number Loop description Tag number for each component. Checkoffs/Signoffs for each component: Tag/identification, installation, termination wiring, termination tubing, calibration/adjustment Checkoffs/Signoffs for the loop: Panel interface terminations, I/O interface terminations with PLC/DCSs I/O Signals for PLC/DCSs are operational: Received/sent, processed, adjusted Total loop operational Space for comments
Component calibration sheet for each active instrument and panel component (except simple hand switches, lights, gauges, and similar items) and each PLC/DCS I/O module shall include the following: • • • • • • Project name Loop number Component tag number or I/O module number Manufacturer Model number/serial number Summary of Operational Readiness requirements, for example: − Indicators and recorders, scale and chart ranges. − Transmitters/converters, input and output ranges. − Computing elements' function. − Controllers, action (direct/reverse) and control modes (PID). − Switching elements, unit range, differential (fixed/adjustable), reset (auto/manual). − I/O Modules: Input or output. Calibrations, for example, but not limited to: − Analog Devices: Actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling. − Discrete Devices: Actual trip points and reset points. − Controllers: Mode settings (PID). − I/O Modules: Actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling. Space for comments.
Correct any deficiencies encountered during the ORT prior to startup.
Performance Acceptance Tests (PAT):
Once ORT has been completed and facility has been started up, perform a witnessed Performance Acceptance Test (PAT) for each completed system or subsystem to demonstrate compliance with contract documents. Demonstrate each required function on a paragraph-by-paragraph, loop-by-loop, and site-by-site basis. For wellfield panels, the PAT will be conducted immediately following the deficiency correction for the ORT. Perform local and manual tests for each loop before proceeding to remote and automatic modes. Where possible, verify test results using visual confirmation of process equipment and actual process variables. Exercise and observe new and existing devices as needed to verify correct signals to and from such devices and to confirm overall system functionality. Test verification by means of disconnecting wires, measuring signal levels, or simulation is acceptable only where direct operation of equipment is not practical. PAT forms shall include: • • • • • • Project name Loop number Loop functional requirements Brief description of the demonstration test Cite required test results which will verify proper performance Space for signoff by witness
9.0 Operations and Maintenance Manuals
Provide Operations and Maintenance Manuals in electronic form for all work. Provide manuals with enough detail to allow operation, removal, installation, adjustment, calibration, maintenance and procurement of spare parts for each component. Develop manuals in a stepwise process including manual outline, preliminary manual and final manual submittals.
Provide the following training: • PLC/DCS maintenance and applications programming training for each type PLC/DCS provided. Provide standard manufacturer’s training classes for five of the City’s staff. Include all tuition, travel costs from the Baton Rouge area, and per diem costs for all staff for the duration of the training. Application programming training for each computer software application provided. Provide standard manufacturer’s training classes for five of the City’s staff. Include all tuition, travel costs from the Baton Rouge area, and per diem costs for all staff for the duration of the training.. Operations training of the HMI graphical user interface. Provide application-specific training in the use of the graphics provided, report production, trending, historical data collection and storage, and all other custom software and programming associated with this implementation. Include on-site training for up to 15 of the City’s staff.
GNV310133631748(APPB).11.DOC/081640018 B-37 .0 Spare Parts and Maintenance Service Agreements Spare parts and maintenance support requirements will be determined during design.
Appendix C Pump Station Facility Design Criteria .
Pump stations with more than three pumps will have divided wetwells including duplicate level instrumentation.DOC C-1 . • Programmable Logic Controller (PLC) monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria. appropriate odor control will be included in the initial pump station design. Pump runtime. Duplex and triplex pump stations will have two or three constant speed pumps. Pump stations will not have grinders. • Provisions for non-liquid-scrubber type odor control will be provided for all pump stations. Where. Pump stations with more than three pumps will have adjustable frequency drives for all pumps. All pumps will be submersible with moisture and temperature monitoring and protection. Phase Fault contact input. as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock. Lower explosive limit (LEL) measurements in wetwells. Incoming analog Hydrogen Sulfide measurement.Pump Station Facility Design Criteria The following is a list of general pump station process design criteria that will be used in establishing monitoring and control requirements for all future pump stations: Pump Station • • • • • • • All pump stations will be duplex. Odor control systems will include: − − − − Modulating flow control dampers. as well as a generator plug and manual transfer switch for connection of a portable generator. as well as permanent standby power generators with automatic transfer switches. GNV310133631749(APPC). 3-phase power monitors with analog Phase Voltage and Current. Analog Wetwell and Diversion Structure (if in design): Level measurement in each wetwell chamber. HIGH HIGH and LOW Level switches. Instrumentation. Constant speed blowers. or otherwise have an even number of pumps. triplex. Discrete HIGH. HIGH Differential Pressure switches. and Station Power measurements (for pump stations with more than two pumps only). monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: − − − − − − − Analog Discharge Flow and Pressure measurement.
secure. For pump stations without buildings. Instrumentation. Modulating plug type discharge valves to control return flow from storage to the pump station compartment for insertion back into the sanitary sewer system Tank Structure HIGH HIGH Level switches. For pump stations with buildings. outer control panel door CLOSED switches will be provided. Generator RUNNING and FAIL contacts. Where chainlink fencing is inappropriate. low-maintenance metal or masonry decorative fencing will be used. Communication links connecting pump stations to the central Pump Station Data Servers will not initially have capacity to support the video event assessment traffic and will require upgrade or replacement when video event assessment is added. setpoints and alarm conditions. Generators • • Transfer Switch position switches. Otherwise chainlink fencing will be used. building door CLOSED switches will be provided. Analog panel temperature measurement for facilities without buildings and analog building temperature measurement for facilities with buildings. Electrical Buildings will be air conditioned to reduce humidity and maintain the temperature below the high temperature limits of electrical and instrument/control equipment. Gate CLOSED switches will be provided. Storage Tanks • • Tank mixers. Tank analog Level measurement.DOC C-2 . All pump stations will be fenced to limit physical access to facilities. Facilities • • • Pump stations with more than three pumps will have an electrical building. Ethernet Local Area Network (LAN) pump stations communications which is suitable for future addition of digital video remote event assessment will be used at all pump stations. monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following − − − − − Analog Discharge Flow measurement. • • • • • • GNV310133631749(APPC).• Local operator interface including hard-wired manual override equipment control and touch-screen monitoring and control of automatic sequencing. Gate drives will not be provided. LEL measurement.
Appendix D WWTP Facility Design Criteria .
At the package system supplier’s discretion. GNV310133631750(APPD). Raw Sewage Pump Stations • • All pump stations will have an even number of pumps. HIGH Differential Level and JAM alarm contacts. Splitter Boxes • • Fixed or manual weirs.DOC/081640020 D-1 . the package control system can include a PLC and local weatherproof HMI. the package control system can include a programmable logic controller (PLC) and local weatherproof human machine interface (HMI). Instrumentation and controls will be provided in accordance with the Grit Removal Remote DCS Monitoring and Local Control Criteria including the following: − − General alarm contacts. At the package system supplier’s discretion. ON status contacts. Instrumentation and controls will be provided in accordance with the Bar Screen Remote DCS Monitoring and Local Control Criteria including the following: − − − Level and Differential Level analog signals. ON status contacts. HIGH level switch contacts when structure can overflow.Wastewater Treatment Plants Facility Design Criteria The following is a list of general wastewater treatment plant (WWTP) facility design criteria that will be used in establishing monitoring and control requirements for future modifications and upgrades at WWTPs: Mechanically Cleaned Bar Screens • • Self-contained package control system including differential level measurement and local control panel. All pumps will be submersible with moisture and temperature monitoring and protection. • Grit Removal • • • Self-contained package control system including a local classifier control panel.
On status contacts. including speed adjustment. as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock. and hard-wired indicators for important conditions such as ON. monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: − − − Analog Discharge Flow and Pressure measurement when required for process monitoring and control purposes. − − − • • Distributed Control System (DCS) monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria. These are expected to be networked onto a fieldbus network for communications to the DCS which will provide additional useful information. Pump runtime. Sludge pump In Remote. GNV310133631750(APPD). Larger or critical pump stations may have local HMI.• • • Pump stations will generally have adjustable frequency drives for all pumps. Sludge pump Fail alarm contacts. HIGH HIGH and LOW Level switches. ON status contacts. Primary Settling Basins: • • • Self-contained package control system including a local control panel. Analog Wetwell Level measurement in each wetwell chamber. 3-phase power monitors with analog Phase Voltage and Current. Lower explosive limit (LEL) measurements in wetwells when required to satisfy NFPA 820. Local operator interface including hard-wired manual override equipment control. Discrete HIGH. and Station Power measurements (for pump stations with more than two pumps only). Pump stations with more than two pumps may have divided wetwells including duplicate level instrumentation when needed to satisfy reliability requirements. Flow paced sludge pump control. At the package system supplier’s discretion. FAIL. Instrumentation and controls will be provided in accordance with the Basin Remote DCS Monitoring and Local Control Criteria including the following: − − − − − HIGH. Instrumentation. HIGH HIGH Torque and Fail alarm contacts. the package control system can include a PLC and local weatherproof HMI.DOC/081640020 D-2 .
Pump stations will generally have adjustable frequency drives for all pumps. − Flow paced disinfectant flow control. Flow paced sludge pump control. − Residual Chlorine. Analog Wetwell Level measurement in each wetwell chamber. the package control system can include a PLC and local weatherproof HMI. Pump stations with more than two pumps may have divided wetwells including duplicate level instrumentation when needed to satisfy reliability requirements. At the package system supplier’s discretion. HIGH HIGH Torque and Fail alarm contacts. On status contacts. monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria including the following: − − Analog Discharge Flow and Pressure measurement when required for process monitoring and control purposes. All pumps will be vertical turbine.DOC/081640020 D-3 . ON status contacts. Possible integration of the Final Effluent and Yard Water Pump Stations • Treated Effluent Pump Stations • • • • • All pump stations will have an even number of pumps. Turbidity and Flow Measurement.Trickling Filters Final Settling Basins: • • • Self-contained package control system including a local control panel. pH. Sludge pump In Remote. Instrumentation. Instrumentation and controls will be provided in accordance with the Basin Remote DCS Monitoring and Local Control Criteria including the following: − − − − − HIGH. Sludge pump Fail alarm contacts. GNV310133631750(APPD). Snail Shell Screens Chlorine Contact Basin • Instrumentation and controls will be provided in accordance with the Chlorine Contact Basin Remote DCS Monitoring and Local Control Criteria including the following: − HIGH Level alarm contacts.
Instrumentation and controls will be provided in accordance with the Gravity Thickener Remote DCS Monitoring and Local Control Criteria including the following: − − − − − HIGH. and Station Power measurements (for pump stations with more than two pumps only). HIGH HIGH and LOW Level switches. GNV310133631750(APPD). Gravity Belt Thickeners • • PLC based package control system and local control panel including a weatherproof HMI. Flow paced sludge pump control. Belt Alignment and Fail alarm contacts. HIGH HIGH Torque. and wash water booster pumps. as well as the actual time-of-day when pumps are running will be derived from the pump ON status input and the programmable logic controller’s real-time clock. ON status contacts.− 3-phase power monitors with analog Phase Voltage and Current. Larger or critical pump stations may have local HMI. Pump runtime. and hard-wired indicators for important conditions such as ON. Local operator interface including hard-wired manual override equipment control. Connection of the PLC to the WWTP DCS to provide integration with supporting equipment such as sludge and polymer feed pumps. Discrete HIGH. Gravity Thickeners • • Self-contained package control system including a local control panel.DOC/081640020 D-4 . − − • • DCS monitoring and control will be provided in accordance with the Pump Station Monitoring and Control Criteria. Sludge pump In Remote. • Anerobic Digesters • DCS based control with local equipment control panels as needed. Sludge pump Fail alarm contacts. sludge storage levels. and wash water booster pumps. Instrumentation and controls will be provided in accordance with the Local Monitoring and Control Criteria including the following: − − − HIGH. FAIL. including speed adjustment. ON status contacts. Control of remote ancillary equipment including sludge and polymer feed pumps. On status contacts. HIGH HIGH Torque and Fail alarm contacts. These are expected to be networked onto a fieldbus network for communications to the DCS which will provide additional useful information.
sludge storage levels. Facilities • • Analog panel temperature measurement for all control panels containing DCS components and analog temperature measurement for all electrical rooms. Otherwise chainlink fencing will be used. low-maintenance metal or masonry decorative fencing will be used. and wash water booster pumps.DOC/081640020 D-5 . Belt Filter Press • • PLC based package control system and local control panel including a weatherproof HMI. Connection of the PLC to the WWTP DCS to provide integration with supporting equipment such as sludge and polymer feed pumps. Sludge heater monitoring and control Sludge circulation pump On/Fail status monitoring and Run control. ON status contacts. secure. Instrumentation and controls will be provided in accordance with the Burner Remote DCS Monitoring and Local Control Criteria including the following: − − − − On status and Fail alarm contacts. GNV310133631750(APPD). Discharge Gas Pressure control valve modulation to maintain Digester Gas Pressure. • Generators • • Transfer Switch position switches. Sludge Temperature and Digester Gas Pressure analog measurements. Digester Gas Burner • • Self-contained package control system including a local control panel. Instrumentation and controls will be provided in accordance with the Local Monitoring and Control Criteria including the following: − − − Belt Alignment and Fail alarm contacts. Digester gas valve train monitoring and control Burner flame monitoring and control. Perimeter fencing to limit physical access to facilities. Control of remote ancillary equipment including sludge and polymer feed pumps. Where chainlink fencing is inappropriate. and wash water booster pumps.• Instrumentation and controls will be provided in accordance with the Monitoring and Control Criteria including the following: − − − − − Level. Sludge valve OPEN/CLOSE monitoring and control. Natural gas valve train monitoring and control. Generator RUNNING and FAIL contacts.
Communication links connecting WWTPs to the central Historical Data Servers will initially have capacity to support very limited video event assessment traffic and may require upgrade or replacement if significant video event assessment traffic is expected.DOC/081640020 D-6 . Building exterior door access control including proximity card readers. • • • • GNV310133631750(APPD). Fiber Optic Gigabit Ethernet Local Area Network (LAN) WWTP communications which is suitable for future addition of digital video remote event assessment will be used. Gate OPEN and CLOSED switches will be provided.. door monitoring and electric door locks will be considered for each WWTP. visitor and delivery gates. Electrical rooms will be air conditioned to reduce humidity and maintain the temperature below the high temperature limits of electrical and instrument/control equipment. cameras for remote driver classification and remote gate control will be provided for employee.• Automated gate drives with proximity card readers.
Appendix E Pump Station Design Spreadsheet .
DOC/081640025 E-1 Remote Alarm* X X X X X Local Alarm* .Remote HMI Indication PLC Discrete Output Local HMI Indication Remote HMI Control PLC Analog Output PLC Discrete Input Local HMI Control PLC Analog Input INSTRUMENTS: Wetwell Level Measurement 1 LSL1 LSH1 LSHH1 Measurement Measurement PUMPS: On Status Fail Status In Remote Status High Moisture High Temperature Run Command Speed Adjust 1 Speed Feedback 1 ODOR CONTROL: Hydrogen Sulfide High Differential Pressure Flow Control Damper X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Discharge Flow Discharge Pressure Measurement Measurement Open Command Close Command In Remote Status Opened Status Closed Status X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Blower On Status In Remote Status Run Command STORAGE TANK: Lower Explosive Limit Discharge Flow Level Measurement Measurement Measurement LSL4 LSHH Mixer On Status In Remote Status High Temperature Run Command X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X GNV310133631751(APPE).
level. 3 Pump stations with electrical buildings will have electrical building temperature monitoring. 2 Pump stations with electrical buildings will have building door switches. and are divided into 2 wetwells with duplicate level instruments. Audible alarm not required for SCADA. Remote Alarm*: Visual alarm capability remote from the pump station via operator interface screens. Those without electrical buildings will have door switches on the control panel outside doors. X X X X X X X X X X X X X 3 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X GNV310133631751(APPE). 4 LSL is for monitoring of transfer pump station wetwell. Represents status or alarm condition PLC Discrete Output: Two state (ON/OFF) output.Remote HMI Indication PLC Discrete Output Local HMI Indication Remote HMI Control PLC Analog Output PLC Discrete Input Local HMI Control PLC Analog Input Storage Outlet Valve In Remote Position GENERATOR5: Transfer Switch Utility Position Generator Position Generator: On Status Fail Status PUMP STATION POWER: Phase Voltage Phase Current Phase Fault FACILITIES: Gate Closed Status Building Door/Control Panel Door2 Building/Control Panel Temperature3 Video Intrusion Alarm Assessment6 COLUMN DESCRIPTIONS: PLC Discrete Input: Two state (ON/OFF) input. Local Alarm*: Visual and/or audible alarm capability at the pump station via local operator interface. Those without electrical buildings will have control panel interior temperature monitoring. a 10 state standard was enacted requiring both audible and visible alarms. NOTES: 1 Pump stations with 4 or more pumps have an electrical building housing adjustable speed drives. * In 1990. 5 Pump stations with 2 pumps will have generator plugs and transfer switches for connection of a portable standby generator. 6 Addition of future intrusion detection and remote video intrusion alarm assessment may require increases in communication link capacity. pressure PLC Analog Output: 4-20 mA continuous output.DOC/081640025 E-2 Remote Alarm* X Local Alarm* . Remote HMI Control: Control capability at the centralized operator station remote from pump station. For equipment control such as pump speed Local HMI Indication: Operator monitoring of pump station at pump station via operator interface. Local HMI Control: Control capability at the pump station via operator interface. Represents process variable such as flow. Pump station with 4 or more pumps will have permanent standby generators. For equipment control or status/alarm condition PLC Analog Input: 4-20 mA continuous input. Remote HMI Indication: Operator monitoring of pump station remote from pump station via operator interface.
Appendix F WWTP Design Spreadsheet .
Indication S .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication BAR SCREENS: Level Bar Screens High Differential Level Alarms Jam Alarms Overload Alarm 1 OVerload Alarm 2 On Status 1 On Status 2 Motor Drive Reset INFLUENT PUMP STATION (GRAVITY TRAIN ONLY): Pump On Status Fail Status In Remote status High Moisture High Moisture Run Command Speed Adjust Speed Feedback Level Measurement LSL LSHH Flow Measurement WET WEATHER PUMP STATION (GRAVITY TRAIN ONLY): Pump On Status In Remote Status Fail Status High Moisture High Temperature Run Command Speed Adjust Speed Feedback Level Measurement LSL LSHH X X X X X X I I I I I I X X X X X X S I I I I I I X X X X X X Measurement 1 Measurement 2 X X I I X X X X X X X X X X X X X X I I I I I X X X X X S A X X I I I I I I I I X X X X X I I X X X X X X X X X X X I I I I I X X X X X S A X X I I I I X X X X I I I I GNV310133631752(APPF).DOC/081640026 F-1 Remote Alarm* Local Control Local Alarm* Nomenclature: A .Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X X X X X X X .Local Hand Switch X .Adjustment C .HMI I .Parameter Present # .
PRIMARY SETTLING BASIN: Level Measurement W3 Control Valve Open Command Clarifier Mechanism Fail Alarm High Torque High High Torque Alarm On Status Discharge Pressure PSH PSL Primary Sludge Pump Flow Present In Remote Status On Status Fail Alarm Primary Effluent Pump In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Primary Effluent Level Measurement LSL LSHH It is assumed that there are no pumps for scum removal. A level switch would eliminate the possibility of an overflow.Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X X X X X . X X X X X X X X X X X X X X X X X X X X X I X S X I I I I I X X X X X I I I I I I I I I I I I I I X X X X X X X X X X X X X S X A X X I I I I I X X X I I GNV310133631752(APPF).PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication GRIT BASIN (FORCE MAIN)/GRIT CHAMBER (GRAVITY TRAIN): On Status X I Fail Alarm X I Grit Classifier On Status X I Fail Alarm X I LSH X Aerated Grit Removal (Tank/Blowers)** ** .DOC/081640026 F-2 Remote Alarm* Local Control Local Alarm* Nomenclature: A .HMI I .Adjustment C .Local Hand Switch X .Indicates equipment present in the Gravity Train Main Only Grit Pump SPLITTER BOX: LSH X X X X X X I I I X I (1) It is assumed that the hydraulic profile of the top of the source structure wall is higher than that of the splitter box.Parameter Present # .Indication S .
Adjustment C .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication TRICKLING FILTERS: Distributors Blowers TRICKLING FILTER RECIRCULATION PUMP STATION: Level LSH LSL Pump In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Flow Measurement FINAL SETTLING BASIN: Level W3 Control Valve Clarifier Mechanism Measurement Open Command Fail Alarm High Torque Alarm High High Torque Alarm On Status Clarifier Scum Pump Fail Alarm On Status Cycle Start Status In Remote Status Run Command PSH PSL In Remote Status On Status Fail Run Command Speed Feedback Speed Adjust X X X X X X X X X X X X X I X A X I I I X X X X X S X I I I I X X X X S X I I X X I X X X X X X X I I I I X X X X X S X I I I X X X X X X X X X X X X I I I I I I I X X X X X S X A X X X I I I Discharge Pressure Secondary Sludge Pump I GNV310133631752(APPF).Indication S .DOC/081640026 F-3 Remote Alarm* Local Control Local Alarm* Nomenclature: A .Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X .Local Hand Switch X .HMI I .Parameter Present # .
Local Hand Switch X .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication SNAIL SHELL SCREENS: Snail Screen Snail Screen Pump CHLORINE CONTACT BASIN: LSH Total Chlorine Flow Plant Effluent Valve X Measurement Measurement Open Command Close Command Opened Status Closed Status On Status Yard Water Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust Suction Level PRV Enable FINAL EFFLUENT PUMP STATION: Final Effluent Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust COMPOSITE SAMPLERS: Composite Sampler (Bar Screens and Chlorine Contact Basin) Flow Rate System Alarm ANALYSIS INSTRUMENTATION: pH Turbidity Chlorine Lower Explosive Limit (LEL) Measurement Measurement Measurement Measurement X X X X I I I I X X X X X X X X X X X X I X S X I X A X I X I I I X X X S X X X X X X I I I X X X X X I I X X X S S X X I X I X X X X X X I I I I X X X S X A X X I I I X X X S X I X GNV310133631752(APPF).Adjustment C .Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X .Indication S .HMI I .DOC/081640026 F-4 Remote Alarm* Local Control Local Alarm* Nomenclature: A .Parameter Present # .
PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication GRAVITY THICKENER: Gravity Thickener Enable Status (Local Handswitch) In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust High Torque Alarm Gravity Thickener Pump In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust GRAVITY BELT THICKENER: Intake Flow Intake Valve Measurement In Remote Status Position Adjust Position Feedback Polymer Mixer Differential Pressure GBT Intake Control Valve Opened Status Closed Status In Remote Status Open Command Close Command Measurement Opened Status Closed Status In Remote Status Open Command Close Command GBT On Status Fail Alarm Sludge Flow GNV310133631752(APPF).Parameter Present # .HMI I .DOC/081640026 F-5 X X X X X X X X X X X X X X I I I I I I I I I I X X X X S X S X X X X S X A X X X X I I I X X X X X X X X X X X X X X X X X X X C C C I C C C X X X X X X X X C C X X X Plant Water Flow Process Gravity Drain C C C C X X X X C C X X C C C X X X I Remote Alarm* Local Control Local Alarm* Nomenclature: A .Local Hand Switch X .Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X .Indication S .Adjustment C .
Local Hand Switch X .DOC/081640026 F-6 X X X X X X X X X X X X X X X X X X X X X X X X X C C C C C C C C C C I I I I I I X X X X X X X X X X X X S X X X X S S X X X I C C C C X X X C X C X X I 2 X X X X X X X X X X I I I I I I Pressure Mixing Pump X X X S X X S S X X X X X X I Remote Alarm* Local Control Local Alarm* Nomenclature: A .HMI I .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication Polymer Flow Plant Water Flow Polymer Pump Speed Sludge Pump Speed Sludge Pump Call Polymer Pump Call Plant Water Pump Call High High Alarm Plant Water Pump Status Sludge Pump Status GBT Polymer Aging Tank Mixer On Status In Remote Status Mixer Run Command Tank Level Measurement Discharge Valve Opened Status Discharge Valve Closed Status In Remote Status Discharge Valve Open/Close Command Close Command Feed Pumps In Remote Status On Status Fail Alarm Run Command Speed Feedback Speed Adjust ANEROBIC DIGESTERS: Level Measurement LSH Measurement Run Command On Status In Remote Status Sludge Transfer Valve Open Command Close Command Opened/Closed/In Remote Status Closed Status In Remote Status GNV310133631752(APPF).Indication S .Adjustment C .Quantity of Signals per Piece of Equipment Remote HMI Indication X X X .Parameter Present # .
DOC/081640026 Remote Alarm* Local Control Local Alarm* Nomenclature: A .Indication S .Local Hand Switch X .Adjustment C .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication Heater Temperature Measurement 1 Temperature Measurement 2 Temperature Measurement 3 Digester Gas Discharge Valves (Assume 3 valves.Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X X .HMI I .Parameter Present # . one signal per valve) Opened Status X Closed Status X In Remote Status X Open Command X Close Command X Digester Gas Foam Separator Intake Pressure Foam Separator/Digester Discharge Pressure Foam Separator/Digester Discharge Flow Gas Burner On Status X Fail Alarm X Burner Intake Flow Burner Intake Pressure Gas Burner Intake Control Valve In Remote Status X Position Adjust Position Feedback Digester Building Alarm Panel Trouble Alarm X Warn Alarm X High LEL Alarm X Recirculation Pumps Run Command X On Status X Fail Alarm X Assumes no gas digester storage SLUDGE DEWATERING: BFP Feed Pump In Remote Status On Status Fail Alarm Enabled Status Run Command Speed Feedback Speed Adjust Measurement F-7 X X X I I I I I I X X X X X X S S X X X X X I I I I I I I I X X X X X X X X X S X X X X X S X I X I I I X X X I X X X I I I I I I X X X X X X X X X X C C C C C C X X X X C X C X X X I I I I Flow GNV310133631752(APPF).
Quantity of Signals per Piece of Equipment Remote HMI Indication X X .Indication S .PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication Polymer Mixer In Remote Status On Status Fail Alarm Speed Adjust Speed Feedback Water Booster Pump On Status In Remote Status Run Command Water Supply Valve Open Command Close Command In Remote Status Opened Status Closed Status Belt Filter Press Intake Flow Intake Valve Measurement In Remote Status Position Adjust Position Feedback Polymer Mixer Differential Pressure BFP Intake Control Valve Opened Status Closed Status In Remote Status Open Command Close Command Measurement Opened Status Closed Status In Remote Status Open Command Close Command BFP On Status Fail Alarm Polymer Flow Plant Water Flow Sludge Pump Speed GNV310133631752(APPF).Local Hand Switch X .HMI I .Parameter Present # .Adjustment C .DOC/081640026 F-8 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X C C C C C C X X X C X X X C C C X X X X I C C C C C C C C C C X X X X X C X X X X X C C X X X Plant Water Flow Process Gravity Drain Valve C C C C X X X X C C X X C C C C C X X X X X I Remote Alarm* Local Control Local Alarm* Nomenclature: A .
Local HMI Control: Control capability at the pump station via operator interface. Remote HMI Control: Control capability at the centralized operator station remote from pump station. Remote Alarm*: Visual alarm capability remote from the pump station via operator interface screens.DOC/081640026 F-9 Remote Alarm* Local Control Local Alarm* Nomenclature: A . GNV310133631752(APPF).Local Hand Switch X . * In 1990. pressure PLC Analog Output: 4-20 mA continuous output. Remote HMI Indication: Operator monitoring of pump station remote from pump station via operator interface.Parameter Present # . For equipment control or status/alarm condition PLC Analog Input: 4-20 mA continuous input.Quantity of Signals per Piece of Equipment Remote HMI Indication X X X X X . Audible alarm not required for SCADA.PLC Discrete Output Remote HMI Control PLC Analog Output PLC Discrete Input PLC Analog Input Local Indication Sludge Pump Call Polymer Pump Call Plant Water Pump Call Cake Plant Water Status Sludge Pump Status GENERATOR: Transfer Switch Generator Position Utility Position Generator: On and Fail Status FACILITIES: Gate Open Status Gate Closed Status Building Door/Control Panel Door Building/Control Panel Temperature Video Instrusion Alarm Assessment COLUMN DESCRIPTIONS: X X X X X X C C C C C X X X C X X X X X X X X X X X X X X X X X X X X X X X X X X X X X PLC Discrete Input: Two state (ON/OFF) input. For equipment control such as pump speed Local HMI Indication: Operator monitoring of pump station at pump station via operator interface. a 10 state standard was enacted requiring both audible and visible alarms. level.HMI I . Represents process variable such as flow. Local Alarm*: Visual and/or audible alarm capabilty at the pump station via local operator interface.Adjustment C .Indication S . Represents status or alarm condition PLC Discrete Output: Two state (ON/OFF) output.
Appendix G Standard Loop Specifications .
Display status for discrete variables such as ON/OFF/FAIL status for motors and OPEN/CLOSE/FAIL status for valves. (input. or pulse frequency). PRESENT A discrete signal is present when the contact producing the input is closed or the signal exceeds its true state value. output. some displayed variables will not normally appear on displays but will be accessible through easily identifiable point-and-click targets. Display value.DOC/081640027 G-1 .LOOP SPECIFICATIONS The Loop Specifications are divided into the following Sections: • Definitions This Section defines basic functions and other terms used in subsequent sections (Global Functions Modular Functions and Unit Processes). and valve positions. Runtime and totalizer counters are an example of variables that might not normally appear. DISPLAY (Tag) • Display variables on appropriate Human Machine Interface (HMI) displays. and totalizer value when appropriate. • Global Functions Global functions are required for all applicable variables and are not listed in the Unit Process Loop Specifications. for analog variables such as process variables. To prevent clutter and to ease operation. • Unit Process Loop Specification Unit Process Loop Specifications are included for each Unit Process and include extensive references to Definitions and Modular Functions. GNV310133631753(APPG). Provide the same processing and functions for pulse frequency signals as are provided for analog signals. drive speeds. Set points. DEFINITIONS VARIABLE Any signal (discrete. analog. • Modular Functions Modular functions include extensive references to the definitions and are included by reference in the subsequent Unit Process Loop Specifications. or calculated). Pulse frequency signals are a type of analog signal.
Upon acknowledgement. silence the alarm tone and indicate the alarm condition on appropriate HMI displays and the alarm summary display. ON (RUNNING) The equipment or adjustable speed motor is ON when the equipment or motor drive ON status contact is closed. Unless otherwise noted or shown. a valve is confirmed closed by receiving Close limit switch contact from the valve. acknowledgement. Display steady yellow when Alarm is present and is Acknowledged. Remove acknowledged alarms from the alarm summary once they are cleared. along with a time and date stamp. and add to the HMI alarm summary display. Display alarms as follows: • • • Display flashing yellow when Alarm is present and is Unacknowledged. ALARM Sound the alarm tone. A constant speed motor is ON when a motor normally open auxiliary motor contact (M-Contact) from the motor is closed. For adjustable speed motors.DOC/081640027 G-2 . Display the trend on selectable HMI screens with appropriate scaling and units. but the valve is not confirmed to be within a preset percentage of Set Point within a preset time. but is not confirmed closed within a preset time. provide alarm logic that resets automatically when the acknowledged alarm condition clears. The open/closed (or high/low) state of a discrete signal representing that condition will depend on the configuration of the device producing the discrete signal. Unless otherwise noted. indicate the alarm condition on appropriate HMI displays. POSITION FAIL A modulating valve is commanded to a Set Point position. and clearance in the alarm log file. Log alarm occurrence. TREND At intervals appropriate for the variable being trended. GNV310133631753(APPG). CLOSE FAIL A valve is commanded-to-close. Display ceases when Alarm clears and is or has been Acknowledged. use the ON status variable or contact from the drive that is TRUE when the drive is in operation. into a historical trend file for that variable.TRUE A condition is true when it exists. place the current value of analog variable.
ELAPSED RUN TIME Calculate the total time (in tenths of an hour) that a motor or piece of equipment has been in operation. use the ON status variable or contact from the drive that is TRUE when the drive is in operation. RUN FAIL A motor is commanded-to-run. or motor undergoes. but is not confirmed running within a preset time. a valve is confirmed open by receiving OPEN limit switch contact from the valve. calculate the time that the valve is open. For valves. For adjustable speed motors. SINGLE-ACTION INITIATION Provide logic to perform a sequence of events after receiving a single initiation command. include password protected operator reset that sets elapsed run time to zero.DOC/081640027 G-3 . Unless otherwise noted. valve. For example: Provide logic to complete a backwash sequence upon receiving a backwash initiation command. but is not confirmed open within a preset time. one cycle is defined as the transition from OFF to ON. STOP Cease the maintained Run command. GNV310133631753(APPG). START Issue a maintained Run command. TOTALIZE Integrate flow type variable with respect to time. For valves.OPEN FAIL A valve is commanded-to-open. CYCLE COUNT Count the number of cycles a piece of equipment. running is confirmed by receiving an ON status M-contact from the motor’s starter. one cycle is defined as the transition from CLOSED to OPEN. use starter M-contacts to detect when the equipment or motor is running. Unless otherwise noted. For equipment and constant speed motors. For equipment and motors. Unless otherwise noted includes password protected operator reset that sets the totalized value to zero. Unless otherwise noted.
Process Variable Set Point. During startup tune the loop by adjusting proportional band and integral time settings.TWO-MODE FEEDBACK CONTROL Maintain a process variable at a Set Point value by means of feedback control of a control variable such as pump speed or valve position using both proportional and integral action. GLOBAL FUNCTIONS TAGS Provide unique tags for each variable based on the following specification Format: 10 Unit Process 5 Loop Number AFD ISA designation of process and function 1 Unit Number SF Clarifying Abbreviation Refer to Design Criteria for Unit Process number assignments and conventions.DOC/081640027 G-4 . Use the clarifying abbreviation to assure that all tags are unique. generate an AVAILABLE for automatic control status variable when all of the equipment’s HAND/OFF/AUTO. or OPEN/CLOSE/AUTO selectors are in the AUTO position (IN PLC signal present) and no active alarms GNV310133631753(APPG). Use only the underscore character (_) as a separator to improve “human readability. Provide password protected access to tuning parameters such as proportional band and reset rate. Provide a Set Point Deviation Alarm that is activated when the process variable deviates by more than x percent from Set Point for a sustained time. ON/OFF/AUTO. Set Point Deviation Alarm Set Point. NETWORK CONNECTED PACKAGE SYSTEMS Network connect package systems are defined as those package control systems that are connected to the Ethernet network.” An example of an AFD Speed Feedback tag would be: 10_AFD_0501_SF AVAILABLE (for AUTOMATIC/PLC control) In the PLC. Controlled Device. Parameters Defined in the Specific Unit Process Loop Description: Process Variable.
AUTOMATIC (PLC) CONTROL Automatically sequence AVAILABLE equipment in accordance with these loop specifications. For equipment not sequenced by a PLC. MANUAL (PLC) CONTROL For equipment automatically sequenced by a PLC. provide AUTO/MANUAL selection and remote manual control of AVAILABLE equipment from HMI workstations. For all modulating devices. immediately start the device if the Auto Mode so commands. If a device has been running in Auto. Once the transition occurs. b. BUMPLESS TRANSFER Configure all “software” Manual/Auto switches to provide “bumpless transfer. maintain the last analog control variable output value on transition to Manual. configure so it runs at the same speed once placed in Manual. configure so it does not run once placed in Manual.” 1.DOC/081640027 G-5 . For modulating devices. Use manual control pop-up displays to reduce clutter. Auto to Manual Transition: a. If a device has not been running in Auto. enable the automatic control algorithm to commence incrementally from the final manual value. After the transition.affecting the equipment are present. provide a Generator Load Display to be used by operators to manage generator load as follows: GNV310133631753(APPG). If an adjustable speed device has been running at a certain speed in Auto. RECOVERY AFTER A POWER OUTAGE For facilities with generators. c. initially maintain the last manual control variable output value on transition to Auto. Manual to Auto Transition: a. 3. d. configure so it continues to run once placed in Manual. provide remote manual control of AVAILABLE equipment from HMI workstations. Disable and reset FAIL TO START/OPEN/CLOSE alarms when the selector is not in the AUTO position. Use manual control pop-up displays to reduce clutter. b.
4.13. Generator ON. 3. Diesel Engine Generator Set. Both Utility Sources 1 and 2 (Bus A and B) fail. Generator powers loads using future load enabling table. disable all loads except for the “Base Load. Diesel Engine Generator Set. Generator powers both loads using future load enabling table. Supplement Table 1 for load enabling priority. TIE and Generator breakers from the Generator PLC to manage generator load as follows: 1. wait for an adjustable delay set between 15 and 60 seconds. Lump remaining loads into a single “Base Load” line at the bottom of the table. Once the generator power is available.DOC/081640027 G-6 . Use the Generator Status for each load and power source information such as Normal Power Available. Table 1 for load enabling priority. 3. 6. OPEN/CLOSE positions of MAIN. Work with the Owner to establish which loads “Generator Status” will initially be “Enabled” and which will be “Disabled. Table 1 for load enabling priority. wait for an adjustable delay set between 15 and 60 seconds. Sequentially Enable loads whose Generator Status is “Enabled.” 2.13.” Refer to Section 26 32 13. Disallow toggling and permanently Enable the Status of the “Base Load” line. Refer to Section 26 32 13.” Once the Tiebreaker OPEN and Main Breaker CLOSED status is confirmed. Sequentially Enable ALL loads waiting for an adjustable delay set between 15 and 60 seconds between enabling loads. Diesel Engine Generator Set.) equal to or greater than 75 kW in load on a separate line with columns for “Load” in kW and “Generator Status. Place each individual load (Pump. Power Failed. Supplement . Except for the “Base Load. Generator power loads using future load enabling table. 2. 2. Provide password protected HMI editing of Load Entries and Toggling of the Enabled/Disabled Generator Status for each load. Future Utility Source 2 (Bus B) fails. Utility Source 1 (Bus A) fails.13. 3. 5. Use submittal information to determine actual load values. etc.” waiting for an adjustable delay set between 15 and 60 seconds between enabling loads. Once utility power is restored. Refer to Section 26 32 13.1. Calculated and prominently display on each page of the Generator Load Display the “Total Generator Load” value which is the sum of all currently Enabled Loads. GNV310133631753(APPG).” disable all loads included on the Generator Load Display on power failure. Make provisions for easy modification of the power recovery sequence for the addition of a second utility feed to recover from a power outage for the following scenarios: 1.
Requirements for facilities without generators: [LATER] DISPLAY (TAG) Display all discrete and all analog variables. and contact bounce delays. ALARM PRIORITIZATION Prioritize alarms into two levels: critical and noncritical. Provide separate colors and audible tones for critical and noncritical alarms. and include startup delays. Maintain summary of disabled alarms GNV310133631753(APPG). Set Points. Make all generator system displays and data available on the plant process control SCADA network. Coordinate with the generator supplier in developing generator displays and historical data processing. tuning coefficients (for example proportional and integral). control sequence presets.13. Diesel Engine Generator Set for generator monitoring. and alarm trip points. For example disable all but selected alarms when power is off.” NUISANCE ALARM SUPPRESSION Provide nuisance alarm suppression by conditioning alarm signals. Provide for PLC programmer entry and adjustment of parameters designated as “preset” or “preset but adjustable. Use red for critical alarms and yellow for noncritical alarms. Does not prevent point status from being shown on graphic process displays. The intent is to allow the maintenance staff to tune facility performance and operation without having to alter the PLC program. Log but don’t alarm events that do not require an immediate action. 2. Categorize alarms into unit process categories. Suppress dysfunctional alarms during and immediately following power outages.Refer to Section 26 32 13. Present these parameters in an efficient easily navigated format. timer presets. DISABLE ALARM PROCESSING: 1. momentary excursion delays. control and historical data handling requirements.DOC/081640027 G-7 . Selectable by the supervisor on a point-by-point basis. but not limited to. 3.” Provide password protected HMI display of and entry/modification of all other adjustable parameters including. ADJUSTABLE PARAMETER ACCESS Provide for HMI operator entry and adjustment of parameters designated as “operator adjustable” or “operator entry. Provide adequate information to allow the facility maintenance staff to easily identify each variable.
etc. remove the run command. EQUIPMENT OR MOTOR FAIL ALARM Provide fail alarms for each fail condition. Indicate runtime counters on appropriate HMI displays. Include open position for valves with either electric or pneumatic operators. Upon fail. ELAPSED RUN TIME INDICATORS Provide elapsed run time counters for each motor and electrical equipment item.999.].9 hours. Perform all logic in the PLC. Maintain a nonresetable 99.0 counts per minute at full-scale flow. TOTALIZERS Provide 6-digit totalizers for all flow type variables [flow. OPEN FAIL ALARM Provide open fail alarms for each nonmodulating valve with OPEN position feedback.999. remove the run command. Include OPEN/CLOSE (non-modulating) valves with either electric or pneumatic operators. CYCLE COUNTERS Provide cycle counters for each motor and electrical equipment.9 hour cumulative counter that rolls over to zero after 99. Upon open fail. ALARM CONTACT INPUTS Alarm: Discrete contact inputs representing abnormal conditions or identified as alarms on the P&IDs. Maintain a nonresetable 99. Start counter logic will be performed in the PLC/RTU.DOC/081640027 G-8 .999 counts. Upon motor run fail.RUN FAIL ALARM Provide run fail alarms for each motor. GNV310133631753(APPG). CLOSE FAIL ALARM Provide close fail alarms for each nonmodulating valve with CLOSED position feedback. remove the close command. Increment counters after each tenth of an hour of operation. chemical feed rate. Select least significant digit values that result in 0. POSITION FAIL ALARM Provide position fail alarms for each modulating valve with position feedback. Indicate counters on appropriate HMI displays.5-2.999 start cumulative counter that rolls over to zero after 99. Upon close fail. remove the open command.
Provide a procedure for archiving to CD or DVD trend. Reports: As a minimum. and alarm summary files for two years. 2.DOC/081640027 G-9 . maintain equipment in the last state following a loss of communications. Log each discrete and output change of state. To avoid nuisance alarming. overwrite the tape each day and eject after the incremental backup is complete on the day before the weekly backup is scheduled. when communications watchdog alarms is disabled. Reports Content: 1. maximum. display a message at the HMI indicating this condition. For the weekly backup. Maintain storage of trend. maintain automatic equipment control and sequencing during a loss of communications. Report up to thirty process variables per report. Monthly Equipment Runtime Report. 2. For incremental backups. TAPE BACKUP SYSTEM Configure the tape backup systems to make complete weekly backups on a separate tape and incremental daily backups for each server. 3. Create a watchdog function to alarm at the HMI if any of the PLCs do not communicate within a preset time or when any PLC is unable to communicate with any I/O base. log. one each of the following reports shall be provided: 1. Monthly Chemical Use Report. This nominal update period will be noted during startup. Additionally. For PLC controlled equipment under automatic PLC control. log. eject the tape when the backup is complete. and alarm summary files on a monthly basis. For PLC controlled equipment operating under HMI Manual control.HISTORICAL DATA COLLECTION Trend all analog variables storing an instantaneous value every 10 seconds. make the preset at least three times the nominal update period for the specific device. Monthly totals in the case of flows or runtimes. as identified by the Owner. Provide at the HMI a means of disabling communications alarming for use by the operator during extreme conditions such as storms or network outages. COMMUNICATIONS WATCHDOG (applies to any PLC or SCADA link). and average for each process variable over the time period identified by the report. GNV310133631753(APPG). 3. Monthly Operations Report. Minimum.
Provide the following Security Levels: 1. 4. Flow Control: Enable IGMP snooping.DOC/081640027 G-10 . control commands and all operator adjustable parameters. error rates. HMI Password/Security: Provide password protected HMI access to prevent unauthorized users from making changes from operator workstation(s). the operator interface including pop up screens. tag numbers. PACKAGE SYSTEMS HMI AND PLC SOFTWARE INTEGRATION AND DEVELOPMENT Fully integrate the monitoring and control of network connected package systems into the HMI so that I/O.ETHERNET NETWORK MANAGEMENT Provide a network display for the network showing traffic volumes. Engineer Level: Access to all data parameters. 2. Segmentation: a) If necessary to maintain I/O and HMI update frequencies. ETHERNET NETWORK CONFIGURATION 1. as well as all adjustable parameters. Display Level: No changes allowed. For unmanaged devices. use separate EBNT modules on separate VLANs for I/O and HMI functions. Topology: HIPER-Ring. unused capacity. including HMI messaging. and all operator level functions. 2. 3. 4. within the package GNV310133631753(APPG). Operator Level: Set Points. and the status (using red/ yellow/green stoplight metaphor) of every SNMP managed device including PLC and I/O Ethernet interfaces. on a single VLAN. alarm inhibit status. scan inhibit status. provide OSI layer 1 heartbeat response and reply status indication. graphic colors. monitoring and control functions and global functions are. Disable Rapid Spanning Tree protocol. 3. c) Limit access to Remote I/O bases to that required for supporting I/O functions. b) Keep all messaging. Supervisor Level: Access to alarm limits. Access Control: a) Limit SNMP access to that required for network management displays. b) Limit HMI server access to that required for supporting HMI functional requirements.
> Alternation Trigger: <List alternation triggers for each group. provide all PLC/HMI code and PLC/HMI tags and graphics for the future equipment. noted and specified.> Group Selection Criteria: <List selection criteria for each group.> GNV310133631753(APPG). Set the HMI tags off scan and disable alarming for all future equipment.system’s process monitoring and control capabilities. Provide a LEAD selector for each controlled equipment group. global functions. See Specific Unit Process Requirements for: Controlled Equipment Group: <List of equipment groups. Indicate the unavailable status of all future equipment on HMI screens by means of distinctive color and text. to the degree possible. AFD MONITORIG AND CONTROL INTEGRATION Fully integrate the monitoring and control of Fieldbus connected AFDs into the HMI so that I/O. as shown. tag numbers. MODULAR FUNCTIONS ALTERNATION Change assignments (alternate) a group of controlled equipment in a predetermined automatic sequence. monitoring and control functions and global functions are as shown. Disable PLC logic for future equipment. and consistent with those provided for the rest of the plant. ESS FUNCTIONS As shown and noted. Fully implement relevant global functions. provide alternation that is triggered automatically. Fully implement. FUTURE EQUPMENT Where future equipment is shown or noted in contract documents.DOC/081640027 G-11 . noted and specified. and in accordance with Electronic Security Systems (ESS) specifications. When the LEAD selector is in the AUTO position.
PRESSURE ALARM ALARM: High and Low Pressure. FLOW ALARM ALARM: High and Low Flow. CHEMICAL SOLUTION MASS FLOW Use Solution Demand for Chemical Solution Mass Flow. DOSE CONTROL Accept operator entry of Dose. LEVEL ALARM ALARM: High and Low Level. TEMPERATURE ALARM ALARM: High and Low Temperature. WEIGHT ALARM ALARM: High and Low Weight.DOC/081640027 G-12 . CHEMICAL LEAK ALARM ALARM: [Change-in-Level]/[Elapsed Time While All Pumps Off] > Preset. CURRENT ALARM ALARM: High Current.775 x [Dose] x [Treated Stream Flow]/[Solution Strength] Solution Demand = [lbs/hr] of solution GNV310133631753(APPG). Change in Level = [Level] – [Level at Time the Last Chemical Feed Pump Stopped] Elapsed Time While All Pumps Off = [Time since Last Chemical Feed Pump Stopped] Disable and Rest the Alarm while any chemical feed pump on. SPEED ALARM ALARM: Low Speed. High and Low. Disable inappropriate alarms such as low turbidity. Calculate Demand using: [Solution Demand] = 34.ANALYSIS ALARM ALARM: Concentration.
For chemical addition of the finished water (FW) line into the Clearwell.DOC/081640027 G-13 . INSERT INDIVIDUAL UNIT PROCESS LOOP DESCRIPTIONS FOR EACH UNIT PROCESS. Calculate Chemical Feed Pump Speed Adjust Output as follows: [Pump Capacity] = 500.7 x [Density]/[Calibration Factor] [Chemical Feed Pump Speed Adjust Output] = 100 x [Solution Demand]/[Pump Capacity] Density = [g/cm3] Calibration Factor = [Minutes/Gallon] of Solution Chemical Feed Pump Speed Adjust Output = [%] Solution Demand = [lbs/hr] of solution Pump Capacity = [lbs/hr] of solution Provide for operator entry of Calibration Factor for each chemical feed pump. Initially set Recovery Factor at 95% UNIT PROCESS LOOP DESCRIPTIONS [USING THE EXAMPLE UNIT PROCESS LOOP DESCRIPTIONS PROVIDED AND DEFINITIONS IN THE INTRODUCTION TO THE LOOP SPECIFICATIONS.] END OF LOOP SPECIFICATIONS GNV310133631753(APPG). calculate Treated Stream Flow as follows: Treated Stream Flow = [Raw Water Flow] x [Recovery Factor]/100 Recovery Factor = [Membrane Filtration System Discharge Flow]/[Raw Water Flow] Provide for operator adjustment on Recovery Factor.Dose = [mg/l] of chemical Treated Stream Flow = [mgd] Solution Strength = [%] by weight of chemical in the chemical solution Provide for operator entry of Dose and Solution Strength for each chemical.
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