4-3.3 - Control Sys Specs

General Electricity & Water Corporation
TENDER NO. GTC 177/2007

Head works construction at Airport, Old Salwa, Doha SW & Messaieed town
SECTION 3.3
CONTROL AND INSTRUMENTATION
Appendix- A Section 3.3

Tender Documents GTC –177/2007 Page 1 of 50
Control & Instrumentation
SECTION 3.3 - CONTROL AND INSTRUMENTATION
3-3. 1 Control And Instrumentation, General 3/50
3-3. 2 Function Of Instrumentation And Control 10/50
3-3. 3 Control Signals 10/50
3-3. 4 Measurement Units 11/50
3-3. 5 System Instrumentation, General 11/50
3-3. 6 Man Machine Interface, General 18/50
3-3. 7 Programmable Logic Controllers 21/50
3-3. 8 Panel Design and Construction 26/50
3-3. 9 Equipment Testing 30/50
3-3.10 Required Technical Documentation 33/50
3-3.11 Spare Parts, Tools and Accessories 41/50
3-3.12 Training 42/50
3-3.13 Details/Schedule of the Minimum Instruments 43/50

3-3.1 CONTROL AND INSTRUMENTATION

GENERAL
Scope of Work
The scope of work in this specification shall include the design, construction, and
transportation of all material, installation, commissioning and testing of control desk, PLC
and marshalling cabinet, measuring instruments etc. as described in specification.
All required labour materials, machinery, tools and other appliances should be furnished by
the contractor. The work shall be carried out completely, properly satisfactory, continuously
and expeditiously in all aspects without effecting normal pumping operation.
The scope of work shall include the following but not limited to them:
1. Control desk shall include (one/two channel) chart reorder, for flow,
pressure, level, chlorine residual, indications for RPM and valve position
indicators, set points, auto/manual/SCADA/off, remote/local, selector
switches, main pumps start, stop, lower, raise push button, valves open
close push buttons etc.
2. Mimic and Annunciator panel shall be capable of accommodating

requirements for proposed and existing pumps and reservoirs etc.
3. (i) Complete PLC panel for proposed variable speed pumps
4. Marshalling cabinet shall include all analogue, status, alarm and command
signals, set points to and from NWCC including zoner barrier for analogue
I/O interposing relay, terminals and internal wiring.
5. Complete data logger panel
6. Providing of distribution board for mimic and control desk and connecting
to existing UPS.
7. Complete HMI system
8. 4-color DOT Matrix printer and laser printer
9. Emergency stop-push button including RPM meter.
10. Pump’s suction and delivery pressure gauge of burden tube type with
measuring range (0-1) and (0-15) bar respectively including isolating cock
and drain tape.
11. Pressure switch/transmitter complete with control contacts, working range

shall be 0-15 bar
12. 900 mm Electromagnetic flow meters and transmitters for new mains
13. Temperature monitoring and alarm panel, for pumps and motors bearing

and motor winding temperature.
14. Single wire armored multi pair; PVC sheathed cabling and installation
accessories and connection to all control and signalling equipment.
3-3-1.2 CONTROL FACILITIES
A. Local Panels
This level of control is the lowest level, each motorised valve and pump set shall have
an adjacent control panel, which provide localised facilities for maintenance or similar
purposes. Local control will generally be provided for the field application in case of
operation as backup to the automatic control system or those inherently local in design
philosophy; control transfer switches on these panels should be set to "REMOTE" to
permit centralised control from one of two control centres.
B. Control Centres
I- Local Control Room

The main control centre is located in the reservoir's site in a room next to pump house
and is called Local Control Room when the Local/Telemetry switches are set to "Local"
control from this centre is available.
II- National Water Control Centre (NWCC)

The NWCC building located at (location will be advised later) and Telemetry control of
facilities achieved when Local/Telemetry switches are set to Telemetry.
All analogue, status and alarm signals and command signals including set points to and
from NWCC, shall be brought and terminated with a proper Isolating link in a
marshalling cubicle for use by SCADA contractor, all the wiring and cubicle is part of
this scope of supply.
The signals that should be brought to the Marshalling panel for future use by other
contractors are as listed below as minimum, final list of signals shall be submitted for
KAHRAMAA's approval. The Marshalling panel shall be located in a room next to
control room
1) Transmission main
Measurements
- Distillate Water Flow Rate

- Chlorine Residual
- Inlet Valves Position
- Set Point Value
Set Points
- Distillate Flow Rate
- Valve Position

Digital Inputs - Statuses

- Valve Open
- Valve Closed
- Mode of Operation: Manual
- Mode of Operation: Auto
- Control Selection: Local
- Control Selection: Remote
- Control Available
Digital Inputs - Alarms

- Valve Failed
- Distillate Main, Low Flow
- Distillate Main, High Flow
- Chlorine Residual, Low
- Chlorine Residual, High.
Digital Outputs - Commands

- Valve, Open
- Valve, Close
- Valve, Stop
Total Values (Counters)
- Total Inlet Flow
2-Ground Reservoirs
Measurements
- Water Level Reservoir compartment - 1

- Water Level Reservoir compartment – 2
Set Points
- Inlet Flow Rate
Digital Inputs – Statuses (each reservoir valves)
- Reservoir inlet valve open

- Reservoir inlet valve closed
- Reservoir outlet valve compartment - 1 open
- Reservoir outlet valve compartment - 1 closed
- Reservoir outlet valve compartment - 2 open
- Reservoir outlet valve compartment - 2 closed

Reservoir over Ride Switch
- Reservoir compartment - 1 Low Level Override Switch, on

- Reservoir compartment - 1 Low Level Override Switch, off
- Reservoir compartment - 2 Low Level Override Switch, on
- Reservoir compartment - 2 Low Level Override Switch, off
- Reservoir Compartment -1 Low Level Override Switch, on
- Reservoir Compartment –2 Low Level Override Switch, off
- Water Level, low

- Water Level, high
- Water Level, low-low
- Sump Pump Failed
3-Pump (Individual)
Measurements
- Motor Current
- Motor Speed
- Motor Pressure
Digital Inputs-Statuses
- Suction Valve, Open

- Suction Valve, Closed
- Pump, Running
- Pump, Stopped
- Delivery Valve, Open
- Delivery Valve, Closed
- Pump, Duty
- Pump Set, Available
- Common Suction Valve, Open
- Common Suction Valve Closed
- Common Delivery Valve, Open
- Common Delivery Valve, Closed

- Mode of Operation: Manual
- Mode of Operation: Auto
- Control Selection: Local
- Control Selection: Remote
- Control Available
- Drive Control Available

Digital Inputs-Alarms
- Suction Valve Closed

- Delivery Valve, not fully open
- Delivery Valve, failed
- Motor Bearing Temperature, High
- Motor Stator Temperature, High
- Motor Current, High
- Common Suction Valve, Failed
- Common Delivery Valve, Failed
- Suction Pressure Low
- Drive Failed.
Digital Outputs on/off Commands
- Delivery Valve, Open

- Delivery Valve, Close
- Pump, Start
- Pump, Stop
- Raise speed
- Lower Speed.
- Pump set, Duty Selection
- Pump, Reset
- Common Suction Valve, Open
- Common Delivery Valve, Close
4-Rising Main
Measurements
- Pressure
- Chlorine Residual
- Valve, Position
-Flow (Instantaneous & Totalized)
- Re-Circulation Main Valve, Open

- Re-Circulation Main Valve, Close
- Control Selection, Local
- Control Selection, Remote
- Control Available

- Re-Circulation Main Valve, Failed
- Chlorination Residual, Low
- Chlorination Residual, High

Digital Outputs-Commands
- Re-Circulation Main Valve, Open

- Re-Circulation Main Valve, Close
5-Water Tower (N/A)
Measurements
- Water Level
- Inlet Valve Position
- Set Point Value of Flow Rate
Set Points
- Inlet Flow Rate Set Point
- Inlet Valve, Open

- Inlet Valve, Closed
- Outlet Valve, Open
- Outlet Valve, Closes
- Bypass Valve, Open
- Bypass Valve, Closed
- Inlet Valve Manual Mode
- Inlet Valve Auto Mode
- Control Selection - Local
- Control Selection - Remote.
Digital Inputs-Alarms
- Water Level, High
- Water Level, Low
- Water Level, High-High
- Inlet Valve, Failed
- Outlet Valve, Failed
- Bypass Valve, Failed
Digital Outputs- on/off Commands
- Inlet Valve Open
- Inlet Valve Close
- Inlet Valve Stop
- Outlet Valve, Open
- Outlet Valve, Close
- Bypass Valve, Open
- Bypass Valve, Close

6-Water Outlet
Measurements
- Water Flow to Site Consumption (each site)
- Water Flow to West Bay distribution main
- Water Flow to Gharrafa distribution main
- Valve No. Open

- Valve No. Close
- Valve No. Open
- Valve No Close
- Valve No. Open
- Valve No. Close
- Valve No. Open
- Valve No. Close
- Valve No. Open
- Valve No. Close
- Valve No. Open
- Valve No. Close
Totalized Values (Counters)
- Total Water Flow to Site Consumption

- Total Water Flow to Dukhan
7-Chlorination Equipment( not required)
Digital Inputs – Statuses (each pump)
- Dosing Pump No. 1 to Reservoir Inlet Running

- Dosing Pump No. 1 to Reservoir Inlet Stopped
- Dosing Pump No. 2 to Rising Main-1 Running
- Dosing Pump No. 2 to Rising Main-1 Stopped
- Dosing Pump No. 3 to Rising Main-2 Running
- Dosing Pump No. 3 to Rising Main-2 Stopped
- Dosing Pump No. 1 to Reservoir Inlet Failed

- Dosing Pump No. 2 to Rising Main-1 Failed
- Dosing Pump No. 3 to Rising Main-2 Failed

9-Common Equipment
Digital Inputs - Statuses
-Pump House De-Watering Pump, Running

-Pump House De-Watering Pump, Stopped
-Generator Running
-Generator Stopped

- Generator Failed
-Battery High
-Battery Low
-Charger Fail
-Output DC MCB Trip
-Fire Alarm System Operated
-Air-conditioning Fail
-UPS Failed
-Pump House De-watering pump failed
3-3-2 FUNCTION OF INSTRUMENTATION AND CONTROL SYSTEM
The following functions shall be carried out by the instruments and control system.
Measurement, transmission, indication, recording and logging of process variables
such as, pressure flow level residual. Further data processing such as advance
calculation, optimisation, etc.
* Control and regulation of process variables.

* Control and sequencing of safety, shutdown and operational devices.
* Alarm annunciation
• Status indication of the final control elements.
3-3-3 CONTROL SIGNALS
The signals to be employed in this package shall be the Following:
i) 4 to 20 mA DC analogue signals for transmission from field to Control

Centre and vice versa. The signals shall operate over two wires and shall be
insulated from earth; the signals shall conform to B.S.3586. Analogue
signals shall be so connected that the failure
Of a remotely transmitted signals to another panel in no way affects other
readings on instruments operated by the same signals.
ii) Discrete signals (electrical) used for alarming, sequencing, interlocking,

shut-down purposes achieved through different switching mechanisms and
push buttons.

These signals are fed into the PLC system. Switching from automatic to
manual shall be bump less type.
3-3-4 MEASUREMENT UNITS
Indicating instruments shall be selected to operate using the following units:
i) Flow l/s Litres per Second

ii) Level m Metres
iii) Pressure m.hd Metres head of water
iv) Temperature 0 Degree Centigrade
v) Concentration ppm parts per million-mg/per litre
vi) Current A Amperes
vii) Voltage V Volts
ix) Electrical Energy kW Kilo-Watts
x) Frequency HZ Hertz
xi) Speed (rotational) rpm revolution per minute
3-3-5 SYSTEM INSTRUMENTATION

GENERAL
All instruments shall meet the requirements of this design criteria and this
Specification shall be used as a basis of design for the preparation of detailed

engineering, specification, supply of instruments included in this package.
Deviation from this design criteria will only be permitted by written
approval of Engineer.
However, supplier shall develop his own design, based on the requirements
stated in this specification and any other documents referred to and in complete
uniformity with the design of the plant, and shall be fully responsible for the
technical and economical aspects of his design and the materials and documents
to be provided.
All local control panels needed for operator local control shall be
included in the delivery as well as connection to the PLC system.
All instruments without exception shall be tropicalised and where ever installed
they shall be suitable for operation in the environmental conditions.
Panel mounted receiving instruments shall be of the electrically operated

miniature flush mounting type unless otherwise stated.
Where applicable each instrument chassis shall be easily withdrawable form its

housing for maintenance without interrupting its circuit.
All instrument bezels shall be finished to a British Standard colour to be

specified by the Engineer.
Scales shall be clearly marked with black numerals and graduations on a white
background. Instruments of the same type and range shall have identical scales.
All instrumentations installed outdoor in the site shall be equipped with suitable
sunshade.
The instrumentation shall include, but not necessarily be restricted to the

following:
3-3-5.1 RELIABILITY OF EQUIPMENT
A Instrumentation and control systems shall be so designed, manufactured and

installed as to ensure the highest standards of operational reliability.
B Apparatus mounted in panels shall be suitable for continuous operation at the

maximum internal panel temperature expected in service and due account shall
be taken of heat given off by other equipment. All electronic components shall
be adequately rated and circuits shall be designed so that change of component
characteristics shall not affect plant performance. In the selection of solid state
equipment special consideration shall be given to the effects of heat and
the need for artificial cooling. The air temperature range within which such
apparatus
Is designed to operate without affect on performance shall be stated.
C Where electronic units, such as amplifiers and oscillators are incorporated in an

instrument they shall be solid state and constructed on printed circuit boards
which can be replaced without soldering. Deviations from this requirement shall
be submitted to the Engineer for approval.
D The standards of reliability for moving armature relays and electromechanical

timers shall be not less than are specified in British Standard 775:part 1:1969 for
medium voltage contractors of Class III mechanical endurance, i.e. the number
of no-load operations which can be made before it becomes necessary to replace
mechanical parts shall be not less than 5 million and the number of no-load
operations shall be not less than 250000.All relays and timers, whether solid-
state or not, shall be mounted on a plug-in base to facilitate replacement.

3-3-5.2 PRESSURE INSTRUMENTS

PRESSURE TRANSMITTERS
- Reference accuracy shall not exceed (+,-) 0.25% of full scale

- Transmitters shall be 2 wires, 4-20 mA , 24VDC, complete with
integral indicator, preferably analogue-meter.
- Zero and span adjustments for each transmitter shall be non-interactive.
- Gaskets made of Teflon, Viton, or better.
- Bolting shall be carbon steel or better.
- Diaphragm material to be 316SS or Hastelloy.
- Flanged heads to be stainless steel or as specified.
- Each differential transmitter shall be equipped with a drain plug on both sides.
- Transmitter shall use silicones oil or CTFE as standard fill fluids.
In the case of offering smart transmitters, in addition to the above, followings

shall be provided.
- Total performance shall be improved through characterising the sensor against

the effects of static pressure and temperature. This characterisation shall be
permanently stored in the transmitter's memory.
- The transmitter shall be capable of communicating from a remote point, making

use of the output wiring (2 wires) and a hand-held terminal.
- It shall be possible to rearrange the transmitter from a remote point using hand-
held terminal.
- The transmitter shall continuously perform self diagnostics. The diagnostics

will detect electronic failures as well as meter body failures, such as sensor
failure (PV, Static p, T) and meter body overloads. Critical failures shall
cause the transmitter output to be selectably fail-safe high or low.
3-3-5.3 DIFFERENTIAL PRESSURE TRANSMITTERS
- Differential pressure transmitters shall be in accordance with clause

3-3-5.2 except that the transmitter shall be capable of withstanding over pressure
to the full rated static pressure on either side of the diaphragm without
calibration shift.

- The differential pressure transmitter sensor shall be capable of at least three

measurements. The sensor during operation shall measure differential pressure,
transmitter temperature. Static pressure and temperature measurements will be
stored in permanent memory and used to adjust the output signal for improved
accuracy and reliability under varying environmental conditions.
3-3-5.4 PRESSURE GAUGES
- Pressure gauges shall generally be selected so that normal operating pressure is

approximately in the middle third (%75 maximum range) of the scale. However,
the minimum range of the gauge shall be at least 1.2 times the maximum design
pressure of the process line or vessel.
- The dials for all gauges shall be 150mm nominal in diameter and shall have
micrometer adjustable pointers, white laminated plastic dials with black
numerals and marking and 270 degree rotation.
- The material of element shall be selected to suit the potable water and shall
generally be 316 stainless steel.
- Over pressure protection shall be 1.3 times the maximum tube rating to prevent
permanent set or loss of calibration from continuous over pressure.
3-3-5.5 PRESSURE SWITCHES AND DIFFERENTIAL PRESSURE

SWITCHES.
- Pressure switches shall have an internally adjustable set-point and a
reference or calibrated scale. The materials of construction in contact with
the process medium shall be chemically resistant to the potable water.
- The differential shall be adjustable and the switch shall have a repeatability
of (+,-) 0.5% of overall range.
- Switches shall have hermetically sealed contacts. Switch contacts must be

suitable for use with DC or AC control signals with minimum rating of 5A.
- The case shall be weatherproof with a durable, protective paint finish.
- Connection shall normally be 15mm NPT for 150mm gauges.
- Switches shall have hermetically sealed contacts. Switch contacts must be

suitable for use with DC or AC control signals with minimum rating of 5A.
- The case shall be weatherproof with a durable, protective paint finish.

3-3-5.6 ELECTROMAGNETIC FLOW METERS
Electromagnetic flow meters shall be of a robust construction; generally with the

requirements of BS 5792.Materials of construction shall have a high level of
corrosion resistance, be durable and where normally exposed, be resistant to
degradation by sunlight and high temperatures.
Construction shall comply with the following:
Sensor tube - stainless steel
Sensor tube lining - inert plastic material approved for use in contact with potable
water
Electrodes - stainless steel
Flanges - carbon steel drilled to BS 4504 PN 16
coated with an approved corrosion protection.
The meter installation shall include a microprocessor transmitter of a similar durable

construction to that of the meter. The transmitter shall incorporate a display indicating a
four digit flow rate.
All connections shall be watertight and be of a heavy duty design with high reliability.
The flow meters and transmitters shall be protected to the International Protection
Code IP68.
The installation shall be powered from a mains supply unless indicated otherwise.
3-3-5.7 LEVEL INSTRUMENTS
- DP- pressure transmitter shall be used in water tower & Reservoirs for the level
measurement and transmission. Reservoirs and water tower level transmitters
shall be installed in the drain/washout line.
- The requirement for differential pressure and pressure transmitters used for level
measurement is as stated in clauses 3-3-5.2 and 3-3-5.3 .
Level Switches
- Level switches shall be mainly float- operated type suitable for use in potable
water such as Mobrey level switch or equivalent.
3-3-5.8 VALVES ACTUATORS
Electrically operated actuators for valves shall be sized to guarantee valve

opening and closure at the maximum possible differential pressure across the
valve. The safety margin or major power available for unseating the valve shall
be at least 50% in excess of maximum closing torque at the nominal supply
voltage. The operating speed shall be such as to give valve closing and opening
at approximately 200-300mm per minute unless otherwise specified. The
actuator shall have an integral main isolator fitted.

The electric motors shall have a time rating of 15 minutes, or twice the valve
stroking time, whichever is the longer.
Motor burn-out protection shall be provided by direct sensing of motor
temperature by a thermostat embedded in the motor winding. The trip shall not
be self resetting but shall include a changeover volt-free contact for remote
indication of motor tripped.
The actuator gear box shall be of the totally enclosed oil bath lubricated type,
and provided with the appropriate filling and drain plugs. The drive shall
incorporate a lost motion hammer blow feature. The output shaft shall be hollow
to accept a rising stem. Thrust bearing of the ball or roller type shall be provided
in such a way that the gear case can be opened for inspection or disassembled
without releasing the stem. Thrust bearing of the ball or roller type shall be
provided in such a way that the gear case can be opened for inspection or
disassembled without releasing the stem thrust or taking the valve out of service.
The hand wheel shall be provided for emergency operation engaged when the
motor is declutched by a lever or similar means, the drive being restored to
power automatically on starting the motor. The hand wheel drive shall be
mechanically independent of the motor drive, and any gearing shall be such as to
permit emergency manual operation in a reasonable time.
The valve actuator shall be furnished with a drive bushing easily detachable for
machining to suit the valve stem or gear box input shaft. The drive bushing shall
preferably be positioned to enable standard length valve stems to be used.
Electric actuators shall be provided with open and close torque and position
limit switches with changeover volt-free contacts at each end
Of travel for remote indication and interlocking. Means shall be provided to
prevent the open torque switch tripping while the initial unseating hammer-blow
effect is applied.
Mechanical dial indicator shall be provided to indicate whether the valve is fully
open, fully closed or in an intermediate position.
Provision shall be made in the design for the addition of a sealed potentiometer
of at least three watts rating,5k ohm resistance for continuous remote position
transmission where required by the specification. When so fitted, the mechanical
dial indicator shall also show continuous valve movement.
Unless otherwise specified, valve actuator shall be fitted with a three phase
mains isolator. The isolator shall be capable of interrupting the actuator motor
stalled current and shall have facilities for padlocking in the ON or OFF
positions.
The reversing contactor starter and local controls shall be integral with the valve
actuator. The starter shall comprise mechanically and electrically interlocked
reversing contactors of appropriate rating to the motor size, fed from a 240 volt
control transformer. The common connection of the contactor coils at the
transformer shall be earthed so that the contactors drop out in the event of
leakage to earth. The primary winding shall have taps for single and three phase
supplies and shall be separated from the secondary by an earthed screen. Two
primaries and one secondary fuse shall be provided of an easily replaceable

cartridge type.
Local controls shall comprise push button switches for OPEN, CLOSE and
STOP, and a LOCAL/REMOTE selector switch padlockable in any of the
following positions:
a) Local control
b) Remote control
c) Stop Locked off-no electrical operation.
Multi-turn actuators shall include integral control gear for the drive motor, local
and remote position indication and control facility, and motor protection by
torque limit switch and overhead detection.
Actuators whose position is under closed loop control shall be capable of
receiving a 4-20 mA position signal and driving automatically to the set point.
Actuators for control valves shall be equipped with built in current position
transmitter internally powered for transmitting of 4-20 mA signal for remote
valve position indication.
3-3-5.9 FIELD/INSTRUMENT PANEL INTERFACE
A All field signals shall be brought into the panel into grouped terminals. Initiating
contacts, which shall be voltage free changeover from field switches shall
operate directly into a multiple relay, the contacts of which shall then be wired
to the control logic, indications or alarm system as may be required.
B Analogue signals shall be routed directly to the primary loop within the interface
section of this panel.
C All analogue signals between chlorination building and pumping station room
(control room) should be through signal isolation cards.
3-3-5.10 INSTRUMENTATION CABLES
Instrumentation cables shall be multi-pair, screened, galvanised steel wire

armoured, PVC sheathed with a minimum conductor size of 1.5mm2 in
conformance with BS 6346, and shall be laid in ducts.
At least 20 percent spare terminal blocks and spare cores shall be provided over
and above those required for use.

3-3-6 MAN MACHINE INTERFACE
GENERAL
The man machine interface must be designed to allow optimum interaction

between the operator and the communications equipment. There must be
suitable devices placed in a clear, readily understood arrangement in the control
room in order to provide a rapid flow of information so that the operator can
take the necessary decisions quickly and, where necessary, intervene in the
process.
The interaction between the operator and system shall be accomplished via
mimic panel and the control desk. All the information showing the plant status
shall be shown as a mimic display of the whole system on the mimic panel. Push
buttons, selector switches. Set point adjusters and the announciator for alarms
shall be installed on the control desk.
3-3-6.1 PANEL EQUIPMENT
A Indicators
Panel mounted indicators shall be not less than 100mm diameter (or high/wide
for edgewise instruments), and shall have a 270 movement, conform to BS 89
and shall have an accuracy to BS 89 Class index 1.0 or better. DIN type format
shall be provided.
B Recorders
Panel mounted recorders shall have charts of not less than 100mm width, shall
be of the potentiometric type, shall conform to BS 90 and shall have an accuracy
of not less than +1%. Chart speed shall be programmable flow recorder shall
have flow recording by paper and digital storage. Chart paper shall have
recording range 0-100% and 24 hours time marks. DIN type format shall be
provided. Flow recorders shall have digital flow indication, recording,
totalization and transmission of total flow.
C Setting stations
Panel mounted setting stations shall be of a similar format to the indicators fitted
to the panel. Where appropriate, they shall be enclosed in the same housing as
the indicating instrument whose measured value they are controlling.
Signal isolation cards shall be used in an analogue loop where the signal is to be
fed to another equipment e.g. flow signal feeding to chlorination equipment.
D Signal modifying cards

Cards, which are required to modify the signal, e.g. square-root extractor,
scaling and bias, alarm set-point, analogue isolator etc. Shall be mounted within
a separate enclosure inside the instrumentation panel. The enclosure(s) shall
contain all necessary terminals and rack positions for an additional 20% signal
modifying cards.

Signal isolation cards shall be used in an analogue loop where the signal is to be
fed to equipment, e.g. Flow signal feeding to chlorination equipment
E Mimic display
The mimic diagram shall be based upon the mottled effect mosaic tile principle,
with all artwork, design etc., carried out by the Contractor. Colours, symbols
and layout shall be based on the relevant British Standards.
The surface of the diagram shall be flat with no projections, free of bow, glare
and scratch resistant. The colours used shall be change and fade resistant.
Adjacent
Mimics shall fit closely together with only a hairline crack exposed.
The size of the mimic schematic diagram and of lettering shall be such that it is
clearly visible/readable to the operator when seated at the control desk.
The mimic panel shall be capable of accommodating requirements for future
pumps, reservoirs, etc.
The mimic panel shall be recessed in the wall with rear opening having hinged
doors and with bottom cable entry. The existing mimic panel frame shall be
used and modified according to the requirements.
The whole diagram shall be surrounded with a bezel to ensure a neat overall
appearance. The layout of the diagram shall be approved by the Engineer before
manufacture.
F Indicating lamp test facility

Lamp test facility shall be provided on all instrument panels displaying more
than four indicating lamps. The lamps test shall be initiated by means of a
suitably located "LAMP TEST" push button, operating via auxiliary relays or
lamp test diodes as appropriate, the operation of the lamp test facility shall in no
way affect the monitoring or successful operation of the plant.
Each light shall be of the L.E.D type with either a descriptive label affixed
beneath the light fitting or an engraving on the screen of the fitting.
G Alarm Announciators
Each alarm condition shall be indicated on an alarm announciator having the
following basic features:
a) Audible alarm sounds upon the initiation of any alarm condition. The
audible signal shall be muted upon depression of the "ALARM ACCEPT"
push-button.
b) The appropriate announciator shall flash with an equal mark/space ratio at

approximately 180 flashes per minute upon the initiation of any alarm
condition.

c) Upon depression of the "ALARM ACCEPT" pushbutton the alarm

announciator shall change to steady indication.
d) Upon the clearing to the initiating alarm contact, the appropriate

announciator shall flash with an equal mark, space ratio at approximately
60 flashes per minute.
e) Upon the depression of the "ALARM RESET" push-button, any

announciator whose initiating contacts have cleared, the appropriate
announciator shall be reset and the lamp shall be extinguished.
f) Depression of the "ALARM RESET" push- button shall not reset any
alarms which have not been accepted and shall only reset alarms whose
initiating contacts have cleared.
g) Any subsequent alarm that occurs after the "ALARM ACCEPT" push-
button has been depressed shall be considered as a new alarm condition,
irrespective of the state of other alarm legends.
h) Depression of the "ALARM TEST" push-button shall

simulate the effect of an alarm and fast flash mode.
After a preset adjustable period of between 1-10
seconds, the test facility shall simulate the clearing of
the initiating condition to allow resetting of the
announciators.
i) All Annunciator shall be sized to permit an adequate unambiguous

description to be engraved in letters no smaller than 3.5 mm high. The
legends shall be black on an amber background and shall not be visible
unless illuminated.
j) The flashing of more than one announciator shall be synchronous to

minimise confusion between fast and slow flashing of multiple alarm.
H Clocks
A digital 24 hr. synchronous clock having numerals no less than 100mm high
shall be fitted at the top centre of the Main Instrument panel.
I Push-buttons and switches

Push-buttons for operational circuits shall be provided with a shroud, guard or
other suitable means to prevent inadvertent operation; they shall be in
accordance with the high standard generally required by the Specification as a
whole and by the equipment with which they are associated.
Illuminated push-buttons where used shall be of a design that allows easy

replacement of the lamps from the front of the panel.
If legends are engraved on the push-buttons they shall be clear and concise and
shall be approved by the Engineer before manufacture.
Control switches shall be in accordance with the high standard generally

required by the Specification as a whole and by the equipment with which they
are associated.
3-3-7 PROGRAMMABLE LOGIC CONTROLLERS (PLC)
The PLC-system for the complete plant (existing and new pumps) shall perform
the functions of control, and will provide the operator to allow a partial controls
and easy operation of the plant over any period of time. The PLC shall be
selected from approved Manufacturers' list
As this system is vital for the plant operation the architecture is to be designed in
order to eliminate bottlenecks, to guarantee availability and reliability to ease
and minimise maintenance intervention.
3-3-7.1 SYSTEM DESCRIPTION

The programmable Logic control system supplied under this specification shall,
as a minimum, is capable of performing the functions as specified. In addition,
Contractor my have other functions which are cost-effective and would be of
benefit to KAHRAMAA .These functions should be brought to the attention of
the Engineer for possible evaluation with the system .
The Contractor shall provide all configuration and software required to enable
the system to perform its specified functions. PLC programming shall be
carried out by the manufacturer licensed specialist.
The PLC memory shall have the capacity to accommodate program and PLC
chassis shall have the facility for digital and analogue input & output cards etc
for future pumps.
Contractor is responsible for giving all special tools which is necessary for
system.
System implementation shall be such that KAHRAMAA may revise the

configuration, grouping, limits, and other parameters as dictated by plant needs
without requiring the changes to be made in a programming language and
without requiring the system to be taken off-line to implement the changes.
Supplementary devices shall not be required, but will be optional at the
discretion of the Engineer
The functions of PLC system shall include but not necessarily be limited to the
following functions:

- Indication of analogue and digital signals
- Loop-control
- pump control and sequencing
- Motor-start/stop, raise/lower and control
- provide derive signals for mimic mosaic display
- System fault finding
- Self testing and diagnostic
- Sequence control and shut-down.
The PLC system shall be manufactured by an approved supplier. All plant

instruments and valve or motor drives shall provide status signals to the system.
The power supply to the controller shall incorporate over-voltage, surge and
spike protection.
Digital inputs and outputs shall operate at 24V dc via a power supply external to
the PLC.
The system shall be so designed that the Works can continue operating in
manual mode in the event of a major failure of the PLC.
Manual starting and stopping of every drive shall be possible without the PLC
operational. This shall apply also to the operation of all motorised valves,
solenoids and drives.
Power house load-shedding also has to be pre-planned in PLC-system basically
as follow:
In case of general-power failure, system must in form operator to switch on
category "A" in which, emergency loads can be switched on as per electrical
single line diagrams. There should be another category called "B" to permit
operator to run on another Electrical motor list and consumptions stand-by
during failure of each motor specified in category" A" PLC software shall
incorporate status feedback checks on plant controlled and raise an appropriate
alarm to signal "not running when required" where necessary. Similarly valve
actuator positions shall be checked for opened or closed status after the
appropriate drive commands.
The contractor shall design, supply, install and commission the PLC system
according to the drawings and to the satisfaction of the Engineer.
Regarding the process requirements and the related sequences for start/Stop of

the pumps and Open/Close of the valves the contractor shall design and carry
out the programming on the PLC system according to the details and
instructions introduced in the control and Instrumentation drawings.
Details and philosophy of pumps and valves operation are introduced as

following:
I) Pump Discharge Motorised Valve control Programme
1- Valve should be closed when the pump is not running.

2- When pump is started the valve should already been closed.
3- Valve shall be opened and closed in "Auto" or "Man" mode from "Control
room" or NWCC.
4- When stop signal for the pump is initiated the valve first closes and when
fully closed the pump shall be stopped.
5- Pump is started with the valve closed and stops with the valve again closed.
6- Valve shall be actuated only when "Valve Failed" alarm is not initiated.
II) Reservoir Distillate Inlet valves Control programme.

1- Flow through the valve shall be controlled according to the set point
determined by the control room (Or NWCC) and based on the loop control
which incorporates flow transmitter installed on the discharge line.
2- Valve shall be opened/closed/stopped in both "Auto" mode or "Man" mode.
3- Valve shall be opened/closed/stopped from both control room or NWCC.
4- Valve shall not be ready for operation in the event of "valve failed" alarm.
III) Water tower Inlet Valve Control Programme.

1- Valve shall be "Opened" or "Closed" whenever necessary.
2- Valve shall be closed by the signal generated from High High level switch
(as backup override switch) if the high level signal (from level switch) fails
to stop the pump in both Manual or Automatic mode.
IV) Water Tower Outlet Valve Control Programme

1- Valve shall be operated in "Manual" mode from control room and NWCC.
2- Valve shall be "opened" or "Closed" whenever necessary.
V) Pumps Control Programme for pumping water to water tower
1- Pump shall start when suction valve is open and the discharge valve is
closed.
2- Pump shall be started in "Auto" or "Man" from control room or NWCC.
3- Pump start shall be inhibited by reservoir "low low level switch" (if
initiated).

4- Reservoir's "override switch" shall provide ready to start for the pumps in
the event of maintenance work on the reservoir(s) when low water level (or
empty reservoir) happens.
5- First Duty pump shall start on one of the WT'S low level switching
6- Second duty pump shall start when two of low level switches of the water
tower are initiated and first duty pump has already started and is running.
7- Standby pump shall start if the duty pumps fail to start.
8- All pumps shall stop when high level switch is activated.
9- Pumps shall not be started in the event of "Valve Failed" alarm.
10- Pumps shall not be started if the Common reservoir outlet valves are closed
(Both valves should be open).
11- Pumps shall not be started if pressure in common suction line is low.
12- Pumps shall stop in the event of Rising Mains "Flow High".
13- Pumps shall stop when Reservoirs Low Low level switch is initiated.
V1) Variable Speed Pumps Control Programme for pumping water to Rising
Main. The Control philosophy shall be based on pressure control
The system shall be designed to function with both full or empty rising main.
There shall be three duties and three standby pumps to control and maintain a
suitable pressure in rising main as per recommendations of Pump Supplier and suit
conditions of flow, pressure etc.
Duty Speed
In automode, speed of motor shall be adjusted to the meet the required pre-set
pressure and pumps shall start and stop at pre-defined speeds. These speeds shall
be chosen to provide the most efficient operation for the system pumping at a
maximum head of 43 meter. Contractor shall liaise with pump manufacturer to
ascertain the recommended operating speeds & the PLC software programme
should be designed accordingly.
Control signals
Speed control signals shall be sent to each inverter. These signals shall vary
continuously and the pump speeds shall be continuously altered as required by the
control system with no delay or dead bands.
Variable speed pumps control programme
1- Pump shall start when suction valve is open and the discharge valve is
closed.
2– Pump shall be started in “Auto” or “Manual” from control room or
NWCC.
3– Pump start shall be inhibited by reservoir “ Low Low Level Switch” (if
initiated)

4– Reservoir’s “override switch” shall provide ready to start for the pumps in
the event for maintenance work on the reservoir(s) when low water level
(or empty reservoir) happens.
5– 1st.duty pump shall start by selecting Automode.
6– 2nd.duty pump shall start if the demand exceeds the capacity of 1st.duty
pump.
7– 3rd.duty pump shall start if the demand exceeds the capacity of 1st and 2nd
.duty pump.
8– Standby pump shall start if the duty pump fails to start.

9– Pump shall not be started in the event of “Valve Failed” alarm.
10– Pump shall not be started if the Common reservoir outlet valves are closed
(Both valves should be open).
11– Pump shall not be started if pressure in common suction line is low.
12– Pump shall trip in the event of Rising Mains “Flow High”.
13– Pumps shall trip when Reservoirs Low Low level switch is initiated.
VII) Rising Main Delivery Valve Control Programme

1- Valve shall be operated in "Manual mode" from control room or NWCC.
2- Valve shall close in the event of "High Flow" alarm is initiated for the
Rising Main line.
Interfaces between duty pumps (first, second and third duty pump), between
duty pump and standby pump, between valves and pumps, between valves and
interlocks such as water tower levels, between pumps and interlocks, etc. shall
be programmed by the contractor on the PLC system according to the drawings
and the section.
VIII- Recirculation main valve control program
1- Valve shall be opened in "man" mode from control room or NWCC
2- Valve shall be operated when water tower inlet valve closed and by pass
valve is open (pumping directly into network) or for testing pumps.
3- Valve shall be opened/closed/stopped in "man" mode
4- Valve shall not be ready for operation in the event of "valve failed" alarm

3-3.8 PANEL DESIGN & CONSTRUCTION
A General
Instrument and control panels shall be free-standing floor-mounting cabinets of
the cubicle, console or desk-pattern.
The height of cubicles shall not be greater than 2100 mm overall. The design
dimensions of console or control panels shall be determined according to their
intended function.
The panel design with equipment manufacturer's details shall be submitted to the
Engineer for approval prior to manufacture.
B Panel Construction
Panels shall be made of sheet steel of adequate thickness and suitable braced to
form a rigid structure. Panel fronts shall be flat and free from bow or ripple.
Exterior corners and edges shall be rounded to give a smooth overall
appearance.
A first class method of construction shall be employed and no design involving
the use of externally visible assemble bolts and screws nor any design resulting
in dust or water collecting crevices will be accepted.
Unless otherwise shown on the specification Drawings, each panel shall be
mounted on a self-draining steel plinth with a recessed kicking strip at the front.
A chequer plate floor shall be fitted not less than 230 mm above the floor level.
Removable side covers to the gland plates shall be incorporated, or any other
arrangement that shall give adequate access to the underside of the gland plates
and at the same time ensure a vermin proof construction.
Panels shall be supplied with hinged access doors fitted with lockable car-type
handles operable from inside even when locked. Doors shall be rigid and of
folded construction and provided with close fitting flexible seals to prevent
ingress of dust and vermin. Hinges shall be of the lift-off pattern and one hinge
shall engage before the other for ease of fitting. Where necessary removable
access covers secured by quick release fasteners shall be provided to ensure ease
of maintenance to all installed apparatus.
No equipment other than front-of -panel items shall be mounted on internal
panel surfaces and adequate provision shall be included for mounting-plates and
brackets which shall if necessary be hinged or otherwise arranged to give quick
and easy access when required to equipment securing screws terminals and
wiring.
The design of panels shall be such as to ensure adequate ventilation and air
circulation without permitting the entry of vermin and as far as possible, the
ingress of dust.
Temporary closures for panel openings shall be provided as necessary to prevent
ingress of dust and vermin during transit and installation. The panels shall be
further protected against damage prior to take-over.

C Panel Finish
The panel finish shall be hard, smooth, durable finish, free of blemishes and of
pleasing appearance. Before painting, all external welds and any rough areas
shall be smoothed, and all surfaces shall be free from rust, scale or grease. If
rust-proof steel work has not been used in the Construction, the panel shall be
treated with a passivating agent such as phosphoric acid. All internal surfaces
shall have a minimum of three coats of paint of which the first shall be an
approved anti-rusting priming coat and the final coat shall be an opaque gloss
white enamel.
All external surfaces shall have not less than five coats of paint of which the first
shall be an approved priming coat, and the second and
Third suitable undercoats, all of which shall be rubbed smooth when dry before
application of the next Coat. The two final coats shall be of stove enamel paint
gloss or semi-matt finish to a colour and finish to be advised by the Engineer.
Stoving shall be carried out in accordance with the recommendations of the
paint manufacturer.
D Panel Wiring
Panel wiring shall be carried out in PVC insulated multistrand cable to the
appropriate British Standard and of adequate grade and rating. Cable shall be
coloured black for a.c. supply circuits and grey for d.c. supply circuits. Circuits
in which the operating voltage exceeds 110 volts shall be neatly and securely
fixed by insulated cleats or bunched and securely fixed tubing Earth wiring for
instrument cases and to all apparatus shall be insulated. All wiring shall be
arranged so that access to any apparatus or connection point is not impeded.
Wiring for future
equipment shall be secured as far as possible and no wire left with bare ends.
Wiring caring low level d.c. signals shall be segregated from a.c. circuits and
screened if recommended by the manufacturer of the associated instrument. The
maximum potential between any two points within the panel shall not exceed
250 volts.
Any panel-mounted device to which connections are made by means of a plug
and socket instead of a terminal block shall be wired in flexible cable of
adequate rating between the free plug or socket and a fixed terminal block.
Identification ferrules shall be fitted at both ends of all wires not otherwise
permanently identified and the numbers or letters used shall correspond with the
appropriate wiring diagram. The ferrules shall be of insulating material with
permanent black characters on a glossy white or yellow background unaffected
by oil solvent or water. They shall be so arranged that they can read logically
form left to right when viewed normally.
For each wire connected to a stud-type or screw-type terminal panel-mounted

equipment shall be terminated in a Ross-Courtney or Crimped-on ring terminal.
E Panel Termination Blocks

Provision shall be made to terminate all incoming and outgoing wires at terminal
boards, which shall be mounted vertically where possible and not nearer than
230mm to the floor or less than 230mm from an incoming cable gland. They
shall be spaced not less than 100mm apart and set obliquely or otherwise
arranged to permit convenient access to wires and terminals and enable ferrule
numbers to be read without difficulty. Terminal boards for all incoming power
supplies shall be completely segregated from other cable terminations and shall
be distinctively labelled to show the appropriate A/C, or D.C. working voltage,
which shall be clearly marked along the corresponding section of each terminal
board, and groups of different voltage on the same board shall be separated by
insulated barriers.
All connections shall be made on the front of terminal boards and no live metal
shall be exposed at the back. Terminal blocks shall be of the klippon type or
equal which clamps the wire securely and without damage between two plates
by means of a captive screw. Pinch screw type terminal blocks will not be
accepted. The design shall be such that accidental contact between adjacent
terminal blocks cannot occur. Connectors on terminal blocks shall be with a
single cable only and connections between terminal blocks shall be with an
independent link. At least 20 per cent spare terminals shall be provided over and
above those required for use and spare cores of external multi-core cables.
Termination blocks shall be numbered consecutively in a logical manner which

facilitates identification and location of terminals. The terminal numbers,
voltage grouping and terminal board layout shall correspond precisely with
wiring diagrams so that quick and accurate identification of wiring can be made.
All terminal boards shall be sectionalised where possible to give access to
groups of terminals without uncovering all boards at the same time. Terminals
which may be live when the equipment is isolated from the mains supply shall
be suitably labelled to reduce the risk of accidental contact.
F Panel Earthing
A continuous copper earth bar of not less than 25mm x 3mm section shall run
the full length of each panel and be bonded electrically to the main frame. It
shall be provided with suitable brass terminals of not less than 7 mm for
connection to the metal cladding or armouring of all incoming and outgoing
cables and to the site earthing system. Suitable terminals shall also be provided
for connecting the earthing wiring of instrument cases and equipment.
G Panel Protection
Adequate protection of circuits and sub- circuits shall be provided by means of

MCB's and shall be so arranged that any circuit failure causes minimum

disruption of plant and cannot result in any unsafe operation condition.
All live connections shall be efficiently shrouded and it shall be possible to reset
MCB's with the circuit live without danger of contact with live metal. The
MCB's shall be rated to give maximum protection to the apparatus in circuit and
the rating shall be inscribed on the MCB.
MCB's and links in the same circuit shall be mounted opposite each other in
separate rows and shall not alternate in the same row. At least 10 percent spare
MCB's and links shall be provided Descriptive circuit labels shall be fitted
adjacent to all MCB's and links, the layout of which shall correspond with the
wiring diagram.
H Panel Isolation
Isolating switches, clearly labelled, shall be provided for all incoming power
supplies, they shall be of the quick make and break type with spring-loaded
contacts that close fully without requiring full operation of handle, which shall
be so interlocked with the cover that it cannot be operated when the cover is
open. The ON and OFF positions of each switch shall be unambiguously
indicated. Wiring from each isolator to its distribution board shall be capable of
carrying safely the isolator rated current unless a fused isolator is
employed. Plug-in isolating links or devices of an approved type shall also be
provided in any circuit that may still be live when the power supply isolators are
in the OFF position, as
For example in circuits controlling remotely -supplied equipment. Such links or

devices shall be properly screened and if not incorporated in or adjacent to their
associated outgoing terminals shall be labelled with suitable warning notices.
Every indicating or recording instrument requiring a power supply shall be

individually wired and protected so that in the event of a failure in one circuit
the remainder are unaffected. For this purpose socket outlets with fused plugs
may be used if considered more convenient or economical.
If the wiring of any instrument or panel subassembly terminates in soldered

connections, a 13 amp. 3-pin switched socket outlet, supplied at the panel mains
operating voltage, shall be fitted to provide a soldering iron supply.
3-3-9 EQUIPMENT TESTING

TESTING-GENERAL
Thorough testing of all Plant shall be undertaken to ensure compliance with

Standards, Specifications and Drawings. The testing shall be undertaken by the
Contractor who shall provide all assistance necessary, including accurate
test equipment and instruments required to undertake the tests. Signed test
certificates together with comprehensive test reports, shall be submitted in
triplicate to the engineer.

3-3.9.1 FACTORY INSPECTION AND TESTING
A All items of Plant shall be subject to inspection and testing before despatch.
Unless otherwise authorised by the Engineer the Contractor shall arrange routine
and functional tests to demonstrate to the Engineer conformity with the
Specification.
The cost of all visits for the purpose of witnessing tests on major items of plant
shall be borne by the Contractor. The cost shall include airfares,
accommodations and subsistence allowance for two persons representing
KAHRAMAA.
B No materials shall be delivered to the Site without inspection having been

carried out or waived in writing by the Engineer.
C Where witness tests are not required, the test certificates and performance curves
shall be forwarded to the Engineer within two weeks after instructions to waive
witness tests have been received. On each test certificate, sufficient information
to enable the Engineer to issue a release certificate including the Specification
Contract number and details, shall be given for ready identification of the
material or equipment to which the certificate refers.
No inspection or passing by the Engineer or the Engineer's Representative of the
work, Plant or materials covered by this Contract, whether carried out or
supplied by the Contractor, shall not release him from any of his obligations
under the Contract.
D Any equipment used in the testing of the Plant shall in all respects comply with
the appropriate safety regulations and /or requirements regarding electrical
apparatus for the safety of the Plant and the men working thereon.
E As and when the Engineer is satisfied that any plant is in accordance with the
specification and has passed the pre-set workshop tests, he will notify the
Contractor in writing to that effect.
F The net cost of abortive visits for the purpose of witnessing tests, or of further
visits to inspect plant previously found to be defective, or otherwise unable to
meet the specified requirements or of any other expenses incurred for the same
reason by the Engineer will be charged to the Contractor unless it can be shown
that he look all reasonable steps to avoid such occurrences.
G Calibration certificates for instruments used for such tests shall be produced for
the Engineer's approval and, if necessary, instruments shall be recalibrated
before the commencement of the tests.

3-3.9.2 INSTALLATION INSPECTION
During erection of the Plant, the Engineer will inspect the installation from time
to time in the presence of the Contractor's Supervisor to establish conformity
with the requirements of the Specification.
3-3-9.3 CONTRACTOR'S COMMISSIONING, TESTING AND SETTING TO

WORK OF THE PLANT
A The Contractor shall undertake all necessary commissioning and testing to set the
Plant to work. When the Contractor is satisfied that the Plant is operating
correctly, he shall inform the Engineer, that he is ready for the Test on
completion.
B All labour, materials, power apparatus and equipment of every kind as may be
required for the tests shall be provided by the Contractor. Unless specific
approval has been obtained from the Engineer, special tools and test equipment
supplied under the Contract shall not be used for these tests.
3-3-9.4 TESTS ON COMPLETION

After the Plant has been set to work and the Contractor has ascertained that the
Plant is working correctly the Tests on Completion shall be carried out. On
satisfactory completion of these tests a Certificate of Completion will be issued
with respect to the Plant.
The Contractor shall demonstrate the correct operation and accuracy of all the
equipment supplied under the Contract in the manner indicated below or as
otherwise directed by or agreed with the Engineer:
i) Pressure instruments
A dead weight tester shall be applied to each pressure transmitter at point's

equivalent to 0% 25%, 50%, 75% and 100% full scale for rising
and falling pressure to prove that a correct output signal is produced at these
values.
ii) Pressure switches
A dead weight tester shall be applied to each pressure switch at points

equivalent to 0%,25%, 50%AND 75% and 100% full scale to prove correct
operation when preset to switch at these values.

iii) Level instruments
The correct operation of level transmitters shall be proved at 0%, 25% 50%,75%
and 100% full scale for rising and falling level to prove that a correct output
signal is produced at these values.
iv) Level electrodes
Level electrodes shall be shown to be installed at the correct levels by reference

to the top and bottom water level.
Correct operation of the level electrodes system shall be demonstrated by a
method to be agreed with the Engineer.
v) Flow instruments
Magnetic flow meters shall be proved by applying a flow simulator to the flow
converter or amplifier at values corresponding to 0%, 25%, 50%, 75% and
100% full scale for increasing and decreasing flows. Any indicator fitted on the
flow converter or amplifier shall be correctly calibrated and receiving
instruments shall be proved to respond correctly.
Flow tests covering the whole installed flow measuring system. e.g.
displacement tests, shall be carried out, when required in accordance
with the Particular Specification by the Contractor in conjunction with the
Engineer, who will arrange the availability of associated Plant. The tests shall be
carried out at various flow rates and of sufficient duration to establish the system
accuracy to the satisfaction of the Engineer. During the course of these tests,
accuracy’s of all instruments associated with each measurement shall be proved
to conform with the Specification.
vi) All push buttons, control switches and equipment state indicating lamps shall be
shown to function correctly utilising the actual plant concerned wherever
possible.
vii) All alarm and trips shall be tested by operation of the primary initiating device.
viii) All receiving instruments, analogue and digital displays, recorders, lamp and
alarm indications, control functions, etc. and transmission systems shall be
shown to operate correctly utilising the plant or equipment concerned. If line
monitoring equipment is not included in telemetry equipment, the Contractor
shall provide such equipment and connect so that the performance of the
communication link may be observed during the tests. Any equipment supplied
under the Contract that requires readjustment during the above tests shall, after
read- adjustment, again be demonstrated by the Contractor to the satisfaction of
the Engineer.

After the Engineer has signified his approval of the complete control and
instrumentation installation, the Contractor shall demonstrate that the equipment
operates continuously in a satisfactory manner for a period of seven consecutive
days or for any other such period as may be previously agreed with the
Engineer. During the whole of this period the Contractor shall operate and adjust
the Plant supplied under the Contract as instructed by the Engineer.
The seven day period of operation shall complete the Tests on Completion for
those sections of the Plant involved.
3-3-10 REQUIRED TECHNICAL DOCUMENTATION
GENERAL
The Contractor shall provide Technical Documentation including Drawings,

Documents, Manuals and Technical Information as set out in this Annex to
permit:
a) KAHRAMAA to examine and comment on all principal features of design,

materials and layout.
b) The design of the associated civil works, structures, equipment and services
to proceed.
c) The erection of the Plant and installation of pipe work and cabling
according to the agreed work programme.
Contractor shall prepare a document routing and distribution procedure such that
KAHRAMAA will automatically receive the Technical Documentation as they
are developed by supplier.
Contractor shall schedule the delivery of Technical Documentation to
KAHRAMAA in a manner congruent with the detailed schedule of performing
the works such that the documentation requiring other documentation as pre-
requisite will be preceded by such pre-requisites.
KAHRAMAA will not be responsible for delays arising out of withholding his
Approvals due to unavailability of pre-requisite Documents.
All weights and measures shall be given in SI system of measurement. All
written materials shall be in English.
Contractor shall produce all original Technical Documentation in the name of

KAHRAMAA. The original of all such Documents provided by supplier shall
be the property of KAHRAMAA and shall be handed over to KAHRAMAA.
Contractor shall provide required number of reproducible and copies of all

Technical Documentation of the works and submit them during the period of
engineering works of plant.

The Technical Documentation listed herein is not to be construed as limiting in

any way or manner contractor liability and obligation to provide all other
documents as may be called for by KAHRAMAA and as relevant to the works.
All drawings of reduced size regardless of what purpose they are provided for
shall be submitted to KAHRAMAA in one additional reproducible each.
Contractor shall in addition to the above provide KAHRAMAA with the
necessary number of copies and transparencies of the interim Technical
Documentation for Approval and/or review together with revisions there to.
All drawings to be submitted by the Contractor shall be of one of the following
sizes: A0, A1, A2, or A4.
Contractor shall additionally submit to KAHRAMAA, at no additional cost, the

following Technical Documentation and devices:
a) Five sets of prints of all final drawings as per Time Schedule.
b) One set of reproducible transparent copies of all final drawings, as per time
Schedule.
c) One set of PC secondary storage’s, as per Time Schedule,
The said storage’s shall be compatible with the hardware
and software being used by KAHRAMAA.
3-3-10.1 LIST OF TECHNICAL DOCUMENTATION TO BE SUBMITTED FOR

CONTROL & INSTRUMENTATION
Contractor's services shall comprise the delivery of technical documentation for

process instrumentation and control system necessary for engineering,
installation, pre-commissioning, commissioning, operation and maintenance as
specified hereinafter but not limited thereto.
- Instrumentation design criteria
- Control and operational requirements
- Instrument list
- Instrumentation P&I diagrams
- Composite instrument manuals (description of control systems and

instrumentations, interlocking systems and control rooms)
- System control diagrams complete with all instrumentation hardware,

ranges, controller setting and etc.

- Alarm list and trip settings with instrument ranges.
- Technical specifications for all instruments and valves.
- Complete technical data sheets for all instruments, valves & equipment.
- Flow elements, control valves and safety relief valves calculation sheets.
- Loop diagrams for analogue and logic functions.
- Layouts for control room and any other auxiliary rooms
- Equipment layouts and components lists
- Control room, local panel's layout, equipment cut-out & construction

drawings.
- Instrument location layouts for all field instruments and junction boxes with
exact location and elevation for tapping points, instrument locations, cable
routes and termination points
- Outline drawings, wiring and tubing information for junction boxes.
- Cable tray and cable trunking requirements
- Arrangement of electric signal lines.
- Trenches and trunking for instrument cables
- Layout for electrical supply cables.
- Instrument hook-up drawings containing bulk materials.
- Cable schedule
- Single line diagrams for instrument electricity supply.
- Instruments grounding diagrams
- Instrument cable lists.
- Typical installation drawings
- Specifications for instrumentation installation

- Shutdown and sequence logic circuits diagrams & system description
- Co-ordination of manufacturer's drawings, diagrams and data with project

drawings
- Project bill of material and material take off sheets
- Concept of:
Digital (on-of) control systems (PLC's interlocks)
- Plant safety systems (alarms, emergency shut-down systems)
- Requirements for auxiliary energy such as electrical power, and other

peripheral systems.
- All interface works in connection with packaged units.
- Detailed information required specifically for PLC system including

software and hardware.
= Software:
. Software management and operating system description and capabilities
. Block diagram for design structure
. System database management
. System memory organisation
. Communication system including detail description of all

communication levels such as data highway, interface to PC, PLC,
external computer and relevant protocols.
. High level and assembly languages.
. Test and trouble shooting procedure
. I/O organisation list and detail description of I/O addressing scheme.
. Detail design description of project specified functions.
. System software manuals.
. Description of documentation plant
. Hardware:

. System hardware configuration and organisation.
. Block diagram of system hardware.
. System hardware and peripheral devices description.
. Physical arrangement of modules in racks, terminal and cable

connection arrangement of modules and restrictions in I/O configuration,
if any
. I/O connection diagrams and system wiring diagram.
. Cable types and installation requirement for I/O bus
. All levels of system communication structure diagram including

communication bus, interface modules to external computer.
. Terminal block diagram
. Circuit diagram for each module
. Hardware trouble shooting and test procedure
. System hardware manuals
. List of manufacturer of each part
. Spare part list for commissioning and 2 years operation
- Test procedures and requirement for unit plant and equipment.

(30) Days after receipt.
Supplier is responsible to rectify and correct all shortcomings noticed by

Company or state his reasons therefore. In any case Supplier's liabilities
shall remain as stated in this Contract.

MANUALS
3-3-10.2 GENERAL
The following final engineering packages shall be prepared in accordance with

instructions given here below and shall be submitted to KAHRAMAA for
Approval.
All manuals shall include reduced scale arrangement drawings and diagrams and
a detailed index.
Provisions shall be made for additions and deletions which may be indicated by
operational experience. Where these amendments are indicated to be necessary
during Initial operation before Final Acceptance, Supplier shall supply the
amended sections.
Supplier shall submit to KAHRAMAA, at no additional cost, seven (7) sets of

the Approved manuals and Engineering Dossiers, as specified here below, 3
months before the commissioning.
3-3.10.3 OPERATING MANUALS
Complete operating instructions, or documents provided as a guide to system

use. These include the instructions which permit remote station operators to use
the facilities provided for them, without necessarily explaining how the
Equipment works.
The operating manuals shall be comprehensive, but shall also include the basic
and most common instructions in brief summary form.
The use of all controls provided shall be explained and the sequence of
operation shall be stated for all the tasks which plant operating staff must
normally perform.
All instruction manuals as a minimum shall contain reduced size prints of all
major drawings including process flow diagrams and piping and instrument
diagrams.
The format of operating manuals should

Generally cover the following aspects but not be limited to:
- Describing briefly different Sections and plant.
- A full description of operation of each Section together with a general

arrangement drawing.

- Preparation for start-up, describing:
. Safety procedures, possibility

. Hydrostatic testing
. Flushing
- Plant operation describing the following for each Section:
. Start up
. Normal operation
. Normal shut down
. Emergency shut down
. Loss of feed
. Loss of critical Equipment
. Loss of A.C. power
. Loss of D.C. power
- A full description of operation of control circuitry of each Section.
- Safety guide in the form of a general warning of hazard to be encountered in

operating the
Equipment. A warning with respect to potential causes of damage to Equipment
should also be included
. Detail regarding supporting facilities such as batteries and chargers shall be

provided
- Drawings
All major drawings including process and flow diagrams, piping and instrument
diagrams, electrical single line diagrams as well as the necessary Vendors,
drawings shall be included.
3-3.10.4 MAINTENANCE MANUALS
- Complete maintenance instructions or documents provided as a guide to system

maintenance. The instructions shall be comprehensive covering all adjustment
and maintenance procedures required by the system.
- Maintenance instructions need not necessarily describe the principles of system

operation.
- The procedures for routing checks, adjustments and calibrations shall be listed
and a format shall be recommended for the regular recording of this data.

The frequency of the various procedures for preventive maintenance shall be

specified. The logical sequence to be followed in fault finding.
- The use of computer diagnostic and trace routines shall be explained from the
user's point of view and examples shall be given.
- The procedures to be followed in the case of a major equipment failure within

the system shall be described and necessary co-operation
Between operator and maintenance staff at such time shall be defined.
- User’s manual for all instruments and control equipment and all software
packages shall be given.
- Maintenance manuals shall be comprehensive it shall included reduced scale
exploded view drawings. Detailed part list, recommended spare parts and a
detailed index.
The format of the Maintenance manuals should generally cover the following
aspects but not be limited to:
- Equipment list, identifying each Equipment with description, designer tag

number, Vendor reference number and Equipment rating and data.
- Wiring and dimensional outline drawings and foundation plans, specially giving
size, location and rates of various Equipment.
- Assembly drawings and relevant details of machinery, instrument, electrical and

special Equipment.
- Exploded view drawings showing working parts and internals with parts list
covering all the individual components of instrument, electrical and special
Equipment.
- Drawings for all Equipment and accessories, showing sufficient details for
disassembly and assembly during maintenance.
- A section should be included in the manual to outline maintenance procedures

for all equipment supplied.
- Schedules for maintenance to be affected on a daily, weekly, monthly, overhaul

or on an hours run basic should be included.
- Guidance with respect to selection of lubricating oil, use of additions, etc.
- Repair and adjustment instructions.
- A fault finding procedure to enable diagnosing of any malfunction/maloperation

considered likely to occur in service.

- Listing the reference outputs and conditions, where possible, to facilitate

diagnosis.
3-3.11 SPARE PARTS, TOOLS AND ACCESSORIES
A The contractor shall prepare, for approval by the Engineer a comprehensive list
of spare parts together with Spare Part Inter chaingable requirements (S P I R )
and special tools which are required for two years maintenance (after expiry of
contract maintenance period) and servicing of all items of plant and equipment.
All Spares and tools shall be of high quality and to be supplied in accordance
with the list. Details of the manufacturer(s) shall be submitted to the Engineer
for his approval.
B Notwithstanding the recommendation of the manufacturers, the list shall include

the following items as a minimum requirement
1 No. of each type of the following:
Flow recorder
Flow converter
Level controller
1 No. Lap-top portable programming terminal with printer compatible with the
P.L.C. (including software and hard ware) with separate terminal and printer
adjustable stands and chairs.
Other items shall include the following:
200 Nos. charts for recorders 6 Nos. boxes of programme listing forms (plain)
for printer.
1 No. processor for PLC and 1No.of power supply, 2 No. each input and output
cards for the PLC.
1 No. adaptor module.

1 No. outstation service terminal
All spare parts shall be suitably treated and packed by the manufacturers for
long storage under the climate conditions prevailing in Qatar. Every part or
assembly subject to deterioration through exposure to moisture, damp or dust be
individually protected by a sealed enclosure, each single part of assembly shall
be individually labelled with information in English identifying:
a. The machine or piece of equipment for which the part is intended.
b. The description and functions of the part.
c. The part reference number.
The labelling shall remain legible after long periods of storage and shall be
visible
from the outside of protectively sealed enclosures. Each single part of assembly
shall be individually labelled with information in English:

3-3.12 TRAINING
The contractor shall prepare, for approval by the Engineer, a training plan for the
operating, maintaining and trouble shooting control system, instruments and
PLC equipment. The plan shall include as a minimum period of 3 weeks
training, location, and number of personnel to be trained.
The contractor shall provide training for 10 people by PLC/Instrument specialist

based on approved training plan.

3-3-13 Details/Schedule of the Minimum Instruments and signal in Field/Local, MCC Panel, Control
Desk, Work Station, Mimic Panel, Annuanciator, NWCC Marshalling Box
S.No Item Field/Local MCC Panel Control Work Station Mimic Panel Annuanciator NWCC Marshalling
. Description Desk Box
a Rising main Local pressure Not Display of • Display of Display of • High alarm • Display
Pressure display & applicable instantaneou instantaneous instantaneous • Low Alarm • Set value
pressure switch s pressure pressure pressure on • High alarm
on recorder • Set value indicator • Low Alarm
b Distillate inlet Local flow Not Display of • Display of Display of • No • Display of
Flows Display ,pressure applicable instantaneou instantaneous instantaneous flow instantaneous flow with
indication s flow on flow with flow and • High alarm totalizing
recorder totalizing pressure on Low Alarm • No flow alarm
with • set point to indicator • set point to
totalizing & control incoming control incoming flow
pressure flow • High alarm
indication • pressure • Low Alarm
indication • Pressure indication
c Rising main Local Display Not Display of • Display of Display of • No • Display of

Flow applicable instantaneou instantaneous instantaneous flow instantaneous flow with
s flow on flow with flow on • High flow totalizing
recorder totalizing indicator alarm • No flow alarm
with • set point to • Low Alarm • set point to
totalizing control outgoing control outgoing flow
flow • High alarm
• Low Alarm

d Ground Not applicable Low-low Display & Display & log of Display of • High -High Display of continuous
Reservoirs indication log of continuous level instantaneous alarm level
Level (all continuous • High -High level on • High- level • High -High
compartment level on alarm indicator Alarm alarm
) recorder • High- level • Low – • High- level Alarm
Alarm level alarm • Low –level
• Low – • Low- alarm
level alarm low level • Low-low level
Low-low level alarm alarm
alarm
e Residual local display of Not Display & Display of pH, Display Residual pH, Residual Chlorine,
Chlorine pH, Residual applicable log of pH, Residual Residual Chlorine Low Temperature value,
monitor Chlorine, Residual Chlorine, Chlorine on & High alarm Conductivity, Residual
Temperature, Chlorine, Temperature, indicator Chlorine Low & High
Conductivity, Temperatur Conductivity, alarm
Residual Chlorine e, Residual
Low & High Conductivit Chlorine Low &
alarm y, Residual High alarm &
Chlorine instantaneous
Low , High value graph
alarm &
instantaneou
s value of
residual
chlorine on
recorder


f Distillate inlet •Open, close & Not • Ope • Open, • Open, close Failed alarm •Open, close & stop
valve stop function applicable n, close & close & stop & Failed function
•Indication of stop push function indication •Open & close
percentage of button • Open, indication
opening • Ope close •Available indication
•Remote & local n & close indication •Indication of
selector switch indication • Indicatio percentage of opening
• Avai n of percentage •Failed signal
lable of opening
indication • Available
• Indica indication
tion of
percentage
of opening
g Pump & •Emergency stop •Run & stop •Run & stop •Run & stop •Run ,stop • Failed •Run & stop function
Motor push button push button push button function &Tripped alarm •Run ,stop &Tripped
•Run ,stop •Run ,stop •Run ,stop indication •High winding indication
&Tripped &Tripped &Tripped/failed & bearing •Speed lower & higher
indication indication indications temperature function
•Remote & •Speed & •Speed lower & high alarm •Speed & current
local selector current higher function • Emerg indications
switch indicators •Speed & current ency stop •High winding &
•Emergency •Speed lower indications push button bearing temperature
stop push & higher •High winding & pressed high indications
button push button bearing alarm •Emergency stop push
•Speed lower •Pump Duty temperature button pressed alarm
& higher push selector indications •Main Breaker on & off
button switch •Main Breaker on indication
•Speed & •Emergency & off indication Failed indication

current stop push •Emergency stop

indications button push button
•High winding activated
& bearing indication
temperature
indications
h Common •Pressure switch •Signal to trip • Low •Low indication •Not applicable • Low •Low alarm
Pump Suction pump indication alarm
Individual •Pressure switch •Signal to trip • Low •Low indication •Not applicable • Low •Low alarm
Pump Suction pump indication alarm
i Pump •Open, close & Not •Open, close •Open, close & • Open, close Failed alarm •Open, close & stop
Delivery stop function applicable & stop stop function & Failed function
Valve •Indication of push button •Open & close indication •Open & close
percentage of •Open & indication indication
opening close •Indication of •Available indication
•Remote & local indication percentage of •Indication of
selector switch •Available opening percentage of opening
indication •Available
•Indication of indication
percentage
of opening
j Pump suction •Open & close Signal to trip •Open & •Open, close • Open, close Failed alarm •Open & close function
valves function pump if valve close push function & Failed •Open, trip & close
•Remote & local is closed button •Open, close indication indication
selector switch •Open & indication •Available indication
close •Available
indication indication
•Available
indication

k Rising Main •Open, close & Signal to trip •Open, close •Open, close & • Open, close Failed alarm •Open, close & stop
outlet Valve stop function pump if valve & stop stop function & Failed function
•Indication of is closed push button •Open, close indication •Open ,trip & close
percentage of •Open & indication indication
opening close •Indication of •Available indication
•Remote & local indication percentage of •Indication of
selector switch •Available opening percentage of opening
indication •Available
•Indication of indication
percentage
of opening
l Recirculation •Open, close & Not •Open, close •Open, close & • Open, close Failed alarm •Open, close & stop
valves stop function applicable & stop stop function & Failed function
•Indication of push button •Open, close indication •Open, trip & close
percentage of •Open & close indication indication
opening indication •Indication of •Available indication
•Remote & local •Available percentage of •Indication of
selector switch indication opening percentage of opening
•Indication of •Available
percentage indication
of opening
m Ground •Manual hand Not •Open & •Open, close • Open, close none •Open & close
Reservoirs operating valve applicable close push indication indication indication
inlet, outlet but remotely button •% of opening •% of opening
valves viewing % of •% of

opening opening
n Reservoir •Manual hand Not Open & Open, close • Open, close none Open & close indication
Equalizing operating valve applicable close indication & Failed
valve indication indication
o Chlorination • Run & Not • Set point • Set point • Run & • Failed • Set point
Equipment stop push applicable potentiomet • High & low stop alarm • High & low indication
button er indication indications • High • Residual chlorine
• Dosing pump • Residual • Residual fume alarm value
running stopped chlorine chlorine value • High & low • High fume indication
& failed monitor and High fume alarm
indication recorder indication
• Duty selector
switch
• Set point
• Recorders with
high & low alarm
Fume detector
p Dewatering • Run & Not Not • Run, Stop & • Run, Stop & • Failed • Run, Stop & failed
pump/ Sump stop push applicable applicable failed indication failed alarm indication
level button • High level indication • High level • High level indication
• Auto & manual indication indication •
selector switch, •
• Duty selector
Switch
• Run, Stop &
failed indication
• High level
indication

• Volt & Current

indications
• Supply available
indication
• Reset button
q MCC main ACB All required Not On, off & Not applicable Tripped alarm • On, off & tripped
incomer standard applicable tripped indication
indications indication • Voltage indication
r Generator ACB All required Not On, off & Not applicable Tripped alarm On, off & tripped
incomer standard applicable tripped indication
indications indication
s Fire alarm • Operated Not Not • Operated Not applicable • Operat • Operated
• Power supply applicable applicable • Power supply ed • Power supply failed
failed failed • Power • Battery low
• Fire Zone • Battery low supply failed
indication
• Battery low
t UPS On & failed Not Not On & failed Not applicable Failed alarm On & failed indication
indication applicable applicable indication
u PLC • Battery low Not Not • Battery low Not applicable • Battery low • Battery low
• Power supply applicable applicable Power supply • Power supply • Power supply failed
failed failed failed
v Field manual •Open & close Not Open & •Open, close • Open, close Not applicable •Open & close
valves(inside hand wheel applicable close indication indication indication
the reservoir indication
and pump
station
premises )

w Field •Open & close Not •Open & •Open, close • Open, close Failed alarm •Open & close function
motorized function applicable close push function & Failed •Open & close
valves •Remote & local button •Open, close indication indication
selector switch •Open & indication •Available indications
close •Available
indication indication
Available
indication
x VFD Supply on ,off & •Speed •Speed •Speed Lower & Not applicable Failed alarm •Speed Lower & Rise
Available indication Lower & Rise function function
indication •Available Rise push •Speed indication •Speed indication
indication button •Available •Available indication
•Available indication
indication
•Speed
indication
y Station . Not applicable Remote & • Auto, • Manual Control Not applicable Master • Manual Control (
control ( Local selector control desk ( where operator Emergency where operator can set
selector & switch , telemetry can set any activated any pressure /flow
emergency & off pressure /flow value while station on
switch) selector value while run
switch station on run • Auto Control ( only run
• Master • Auto Control on predetermined
Emergency ( only run on pressure /flow value
Switch predetermined • Master emergency stop
pressure /flow button
value


4-3.3 - Control Sys Specs

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4-3.3 - Control Sys Specs

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General Electricity & Water Corporation

TENDER NO. GTC 177/2007

CONTROL AND INSTRUMENTATION

Appendix- A Section 3.3

SECTION 3.3 - CONTROL AND INSTRUMENTATION

3-3. 1 Control And Instrumentation, General 3/50

3-3. 2 Function Of Instrumentation And Control 10/50

3-3. 3 Control Signals 10/50

3-3. 4 Measurement Units 11/50

3-3. 5 System Instrumentation, General 11/50

3-3. 6 Man Machine Interface, General 18/50

3-3. 7 Programmable Logic Controllers 21/50

3-3. 8 Panel Design and Construction 26/50

3-3. 9 Equipment Testing 30/50

3-3.10 Required Technical Documentation 33/50

3-3.11 Spare Parts, Tools and Accessories 41/50

3-3.12 Training 42/50

3-3.13 Details/Schedule of the Minimum Instruments 43/50

Appendix- A Section 3.3

3-3.1 CONTROL AND INSTRUMENTATION

2. Mimic and Annunciator panel shall be capable of accommodating

3. (i) Complete PLC panel for proposed variable speed pumps

5. Complete data logger panel

7. Complete HMI system

8. 4-color DOT Matrix printer and laser printer

9. Emergency stop-push button including RPM meter.

11. Pressure switch/transmitter complete with control contacts, working range

Appendix- A Section 3.3

and motor winding temperature.

3-3-1.2 CONTROL FACILITIES

I- Local Control Room

II- National Water Control Centre (NWCC)

- Distillate Water Flow Rate

Appendix- A Section 3.3

Digital Inputs - Statuses

Digital Inputs - Alarms

Digital Outputs - Commands

Total Values (Counters)

- Total Inlet Flow

- Water Level Reservoir compartment - 1

- Inlet Flow Rate

Digital Inputs – Statuses (each reservoir valves)

- Reservoir inlet valve open

Appendix- A Section 3.3

Reservoir over Ride Switch

- Reservoir compartment - 1 Low Level Override Switch, on

Digital Inputs - Alarms

- Water Level, low

- Suction Valve, Open

- Common Delivery Valve, Closed

Appendix- A Section 3.3

- Suction Valve Closed

Digital Outputs on/off Commands

- Delivery Valve, Open

- Re-Circulation Main Valve, Open

Digital Inputs - Alarms

Appendix- A Section 3.3

- Re-Circulation Main Valve, Open

5-Water Tower (N/A)

- Inlet Flow Rate Set Point

- Inlet Valve, Open

Appendix- A Section 3.3

- Valve No. Open