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HomeMy WebLinkAboutPK Contractors Inc; 2002-07-22; 3675-2 Part 6 of 10The mixing efficiency shall be defined as the percentage of the highest chemical concentration anywhere in the pipe compared to the lowest chemical concentration anywhere in the pipe. 4. CONSTRUCTION. Mixers shall either be tabular mixing array type or a triple action labyrinth type. Tab type mixers shall incorporate a minimum of 12 tabs and labyrinth mixers shall consist of three full elements. Mixer manufacturers shall design a removable multiport injector (with a minimum of two openings) to distribute chemical across the flow stream and to enhance mixing efficiency. Injects shall be constructed of Schedule 80 PVC or Kynar. The injector openings shall have a minimum diameter of %inch. Mixers elements and spool pieces shall be designed to resist the maximum velocity and interior pressures with minimum factor of safety of two. A. GMF Feed PiDeline. The static mixer housing shall be Type 316 stainless steel containing a minimum of three mixing elements. The internal mixing elements shall be constructed of Type 316 stainless steel. The mixing element edges shall be smoothly contoured with large radius. The intersections of elements ends with the housing wall shall be at oblique angles, eliminating blind corners that can trap solids or fibrous materials. End connections shall be backer flanges constructed of either stainless steel or 150 Ib. carbon steel. Construction materials and dimensions shall be as follows: Stainless steel Pipe Flanges Plate & shapes Nuts, Bolts, Washers Steel Material and design Elements thickness Spool piece thickness Backer Flanges (Carlsbad Water) (Recycling Facility) ASTM 312, Grade B Type 316L Flat faced, AIS1 Type 316L ASTM A2401A226, Type 316 L Type 316L ANSIIAWWA C200 114" minimum 318" minimum ANSIIAWWA C207. Class E 11530 -3- B. MF Feed Pipeline. The static mixer housing shall be PVC containing a minimum of three mixing elements, The internal mixing elements shall be constructed of PVC. The mixing element edges shall be smoothly contoured with large radius. The intersections of element ends shall be at oblique angles, eliminating blind corners that can trap solids or fibrous materials. End connections shall be 150 Ib Van Stone flanges. 5. BASIS OF DESIGN. The basis of design shall be full scale shop and field tests from the manufacturers data for similar mixer configuration. Complete testing data shall be provided along with calculations which demonstrate the justification for the proportions of the proposed design. Full scale testing or field testing for this installation is not required. 6. GUARANTEE. The mixer manufacturer shall guarantee in writing that the mixer provided meets the specified mixing requirements at the maximum flow rate. Performance shall be demonstrated based on scaled design and performance data from similar projects, 7. DRAWINGS AND DATA. Complete drawings, details, specifications and certified test reports covering the static mixers shall be submitted in accordance with the submittals section. End of Section (Carlsbad Water) (Recycling Facility) 11530 -4- Section 11720 POLYMER FEED SYSTEMS Data Sheet /Para- [Description IData lunits I General P81D Drawing Reference. Coagulant Aid Polymer Feed System Service. PI41 and PI42 Filter Aid Polymer Feed System General Equipment Requirements required. G Yes. r NO. l9M [Dilution Water Flow. 1100 (PB-1195-1 & PB-1195-2) (Carlsbad Water) (Recycling Facility) (1-17-02) 11720 -1- Section 1 1720 POLYMER FEED SYSTEMS PART 1 - GENERAL 1-1. SCOPE. This section covers polymer feed equipment and accessories. 1-1.01. Terminology. When the phrase “as required” is stated in this section it shall mean “as required in the Data Sheet”. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Each item shall be furnished and installed complete with all mechanical and electrical equipment required for proper operation, all components indicated on the drawings or specified, and all additional materials or construction required by the design of the system. 1-2.01. General Equipment Requirements. When required, the General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.02. Governing Standards. All electrical equipment shall conform to applicable standards of the National Electrical Manufacturers Association and the National Electrical Code. 1-2.03. Power SUDD~Y. Unless otherwise specified, the power supply will be 120 volts, 60 Hz, single phase. Where control voltage lower than the power supply voltage is required, a suitable control power transformer shall be furnished. 1-2.04. Water Supply. Dilution water will be from the plant water supply. The water inlet pressure for the polymer preparation equipment shall not exceed 60 psig. 1-2.05. Electrical Equipment. All electrical equipment shall conform to applicable standards of the National Electrical Manufacturers Association and the National Electric Code. Both power and control equipment shall be insulated for not less than 600 volts even though operating voltages may be lower. Service voltage to the various items of equipment is indicated on the drawings. 1-2.06. Metal Thicknesses. Metal thicknesses and gages specified herein are the minimum required. Gages refer to US Standard gage. (Carlsbad Water) 11720 (Recycling Facility) -2- ( 1 -1 7-02) 1-2.07. Nameplates. A nameplate shall be provided and mounted on or adjacent to each chemical feeder to identify its function. Nameplates shall be approximately 1 by 3 inches, made from black on white phenolic material. Letters shall be engraved to the white interior and shall be at least 3/16 inch high. Feeder designations on the nameplates shall correspond to those indicated on the drawings. 1-3. SUBMITTALS 1-3.01. Drawinqs and Data. Complete fabrication, assembly, and installation drawings, process schematics, control description, and wiring diagrams, together with detailed specifications and data covering materials, parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. 1-3.02. Operation and Maintenance Data and Manuals. When required, operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals sections. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. PART 2 - PRODUCTS 2-1. SYSTEM SUPPLIER. The polymer feed systems shall be designed, coordinated, and supplied by a qualified System Supplier who is regularly engaged in the business of designing and assembling liquid emulsion polymer feed systems for wastewater treatment plant projects. The System Supplier shall assume full responsibility for providing a complete, operating system, designed for long life with a minimum of required maintenance, meeting the requirements specified herein and as shown on the drawings. 2-2. CONSTRUCTION. Polymer feed equipment shall be of substantial construction with all parts designed for long life under working conditions including corrosive atmospheres and intermittent or continuous operation. All wearing parts and items requiring adjustment shall be readily accessible. Each unit shall be completely enclosed and dust-tight when in operation. All parts which are exposed to corrosive conditions shall be made from corrosion-resistant materials or covered with suitable protective coatings. 2-3. POLYMER PREPARATION AND FEED SYSTEM. Polymer preparation and feed equipment shall be furnished as required, and installed to activate and dispense liquid emulsion polymer to the injection point. Each system shall automatically prepare a solution of polymer of a selected strength. Each unit (Carlsbad Water) (Recycling Facility) 11720 -3- (1-17-02) shall be completely prewired at the factory, and shall require only the connection of power and control wiring to and from remote equipment, as indicated on the Drawings. 2-3.01, Polymer FeededBlenders. Polymer feededblender units shall be furnished as required, and installed as indicated on the drawings. Each unit shall include a neat polymer pump, blender and controller, and shall be capable .of automatically metering, diluting, activating and transferring liquid solution polymer with water. The polymer feeder/blenders shall transfer the blended polymer solution to the point of application. Blender design shall be as required. All metal components in contact with the polymer or polymer solutions shall be Type 304 or 316 stainless steel. All piping material shall be Schedule 80 PVC. Valves shall be constructed of stainless steel or PVC and shall use chemically resistant seats and seals. All components that require periodic maintenance shall be readily accessible. The skid shall have forkliiing points for ease of transportation. The feededblenders shall have a power supply requirement of 120 volts ac, 60 Hz, single phase. FeederMender manufacturer shall be as required. Manufacturer’s standard equipment shall be modified as required to comply with the specification requirements. 2-3.01.01. Dilution Water Control. Primary dilution water shall be supplied to the mixing chamber of the polymer feededblender at a rate and pressure as required. The water supply shall have a manual rate set valve for throttling of water flow. Each unit shall have an electrically operated valve for onloff control of dilution water flow. A water flow switch shall be provided with each unit to shut down the unit if dilution water is not available. Each unit shall have a rotameter to measure primary dilution water flow into the feederlblender. The rotameter shall consist of a calibrated glass tube provided with a float constructed of material as recommended by the rotameter manufacturer. The rotameter shall be capable of indicating flow as required on a IO-inch scale with a nominal pressure drop of 50 inches of water. A dilution water temperature gauge and pressure gauge shall be provided integral to each feededblender, or provided loose and installed on the dilution water inlet line, as indicated on the Drawings. 2-3.01.02. Polymer Pump. Each blending unit shall have a neat polymer metering pump. Each pump shall be a positive displacement, solenoid driven diaphragm pump, having materials of construction selected for resistance to the pumped solution. Pump design shall be as required. (Carlsbad Water) (1-17-02) (Recycling Facility) 11720 -4- The pump shall be manually adjustable by two separate dial knobs, one for adjusting stroke length and the other for adjusting stroke frequency. Each pump shall have an automatichnanual switch which, when in automatic, will allow the pump to remotely adjust stroke frequency with a 4-20 mA DC signal. 2-3.01.03. Activation Chamber. Polymer activation shall be accomplished in a cylindrical, non-mechanical, hydrodynamic blending device specifically designed to dilute and activate emulsion polymers. The activation chamber's mixing energy shall be staged such that it provides for high, non-damaging mixing energy over the full operating range of the system. At no time shall polymer be exposed to excessive shear. As an alternative, each polymer activation chamber shall include a mixer to create high fluid sheer. The mixer impeller shall be driven by a 1M hp, 120 volts ac TENV or TEFC, washdown duty motor. Impeller speed shall be not exceed 1,725 rpm. The motor shall be direct-coupled to the impeller shaft. As an alternative, polymer activation shall be accomplished with a horizontally mounted activation chamber consisting of a rotor and stationary sleeve, each constructed of polymer-resistant synthetic materials. When rotating, the rotor shall generate a turbulent blending action within a number of horizontal cylindrical chambers internal to the rotor. Activated polymer solution shall exit from within these chambers through a series of radial openings, and pass through a controlled shear zone at the interface of the rotor into the stationary sleeve. Activated solution shall then flow through a series of slots in the sleeve and out of the activation chamber. 2-3.01.04. Control. Each unit shall have local manual and remote automatic startlstop control and polymer pump speed control. Remote start/stop shall be by use of a remote dry contact closure. Remote polymer pump speed control shall be via an external 4-20 rnA input signal. Controls shall be housed in a NEMA 4X enclosure and shall include a local run light and two sets of dry contacts. One contact shall close when the unit is on for a RUN indication, and the other contact shall close on loss of water flow for an ALARM indication. The unit shall clear itself and continue normal operation when flow resumes. The unit shall have a 4-20 mAdc output signal that represents polymer feed flow rate. 2-3.02. Polymer Solution Distribution Panel. One polymer solution distribution panel shall be provided with each polymer feed system in accordance with the piping schematics and as specified herein to distribute polymer solution flow to the points of application. The panel, nameplates, and all components shall be supplied loose for field installation. The carrier water panel shall come with a nameplate. (Carlsbad Water) (Recycling Facility) (1-17-02) 11720 -5- The panel shall be rigidly supported in the location indicated on the drawings. The panel shall be constructed of stainless steel or fiberglass reinforced plastic parts, suitably reinforced. The panel shall be a frame assembly that permits easy removal of components mounted on the panel. All facilities shall be rigidly mounted on the panel, including piping and valves necessary for control of polymer solution flow, rotameters, and other necessary appurtenances, all as indicated and required. Piping and valves shall conform to the specification sections therefor. The rotameter shall consist of a calibrated glass tube provided with float of materials as recommended by the manufacturer of the equipment. The rotameter shall be capable of indicating flow on a 10-inch scale with a nominal pressure drop of 50 inches of water. Rotameter flow capacity shall match that of the feederkdender rotameter. The metering accuracy shall be within plus or minus two percent of full scale over a 10 to 1 range. 2-4. ANCHOR BOLTS. Anchor bolts with associated nuts and washers shall be furnished as required for each item of equipment. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed. The bolts shall be at least 3/4 inch in diameter. Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-1/2 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 1/2 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. Anchor bolts shall be long enough to accommodate at least 1-112 inches of grout beneath the baseplate and to provide adequate anchorage into structural concrete. Anti-seize compound will be applied to the threads of all stainless steel bolts before assembly. End of Section (Carlsbad Water) (Recycling Facility) (1-17-02) 11720 6- Section 11727 LIQUID CHEMICAL FEED SYSTEMS Data Sheet Para- Description Data raDh C Solenoid-Operated Diaphragm Capacity Control Range. 0 to 100 Metering Range Discharge Pressure. 117 Maximum Stroke Rate 0.01 to 20.00 Accuracy, percent of scale over x Minimum Drive Motor. 60 metering range. Stroke Frequency Control. Automatic and Manual .- 0.5 r Manual r None Stroke Length Control. r Automatic and Manual (i Manual Units 'F (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -1- Jeach pump. IJ Pressure Relief Vale I7 Pulsation Dampener I7 Pressure Gauge & Switch r Four-Function Vak Diaphragm Leak Detection r SCR rive P Other additional accessories, When "Other" selected, indicate VFD Speed Controller Models. Acceptable Manufacturers and Milton Roy MROYA Model Number Backpressure Valve Valve Body Construction RA1 5-17 15 AI SESE M2 NN, or Equal r PVC F Alloy 20 body r 316 Stainless Steel r CPVC I I I Diaphragm Construction r Viton (i PTFE faced EPDM diaphragm Pressure Relief Valve Valve Body Construction r- PVC F Alloy 20 body C 316 Stainless Steel r CPVC Diaphragm Construction C Viton II IG PTFE faced EPDM diaphragm 1 btrainer lNot used. ]Pulsation Dampener Pulsation Dampener Body Alloy 20 body with Viton diaphragm onstruction Eductor Eductor required. r Yes No i Furbine Water Flowmeter (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -2- urbine water flowmeter required. r Yes ci No F Installing contractor. Anchor Bolts, Nuts and Washers. 1 ~ Galwnized steel, ASTM A153 and ' A385 r Ttanium. r Hastelloy C. F Group 1 or 2, ASTM F594, Alloy Stainless steel, ASTM F593. Alloy Group 1 or 2. Field Services llnstallation check required. IF Yes r- No When "Yes" is selected, indicate number of days. the0.5 When "Yes" is selected, indicate the1 number of round trips. C Yes Installation supervisor required. 6 No Nhen "Yes" is selected, indicate the number of days. When "Yes" is selected, indicate the number of round trips. (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -3- Section 1 1727 LIQUID CHEMICAL FEED SYSTEMS Data Sheet 'ara- Units Data Description raph General PglD Drawing Reference. Threshold Inhibitor Metering Pumps Service. PI-21 required. Seneral Equipment Requirements (i yes, Operation & Maintenance Manuals G Yes, required. r No. r No. I I IDesign Conditions and requirements Chemical. f7 Hydraulically Acutated Diaphragm Type of Pump. 2 Number of Pumps. MP-1178-1, 2 Pump Designation. Metering Pumps OF 70 Maximum Solution Temperature. 1.10 Maximum Specific Gravity. % 10 Concentration, percent by weight. Threshold Inhibitor I Solenoid-Owrated DiaDhraam I Capacity Control Range. x Minimum Drive Motor. psi 60 Discharge Pressure. spm 73 Maximum Stroke Rate gph 0.01 to 10.00 Metering Range 0 to 100 hP Accuracy, percent of scale over 0.5 metering range. % Stroke Frequency Control. f7 Automatic and Manual .- % r Manual r None Stroke Length Control. r Automatic and Manual (i Manual (Carlsbad Water) (Recycling Facility) (100% Submittal) 11 727 -1- accessories to be furnished with tk BackDressure Valve I !ach pump 113 Pressure Relief Valve p Pulsation Dampener p Pressure Gauge & Switch r Four-Function Valve r Diaphragm Leak Detection r SCR rive R Other Yhen "Other" selected, indicate ldditional accessories, VFD Speed Controller Milton Roy MROYA Model Number rcceptable Manufacturers and lalve Body Construction lackpressure Valve RA1 1-17 24 A1 SESE M2 NN, or Equi flodels. r PVC r Alloy 20 body G 316 Stainless Steel r CPVC )iaphragm Construction r Viton G PTFE faced EPDM diaphragm 'ressure Relief Valve lalve Body Construction r PVC r Alloy 20 body G 316 Stainless Steel r CPVC )iaphragm Construction r Viton G PTFE faced EPDM diaphragm itrainer 'ulsation Dampener Not used. 'ulsation Dampener Body :onstruction Type 316 stainless steel body with EPDM diaphragm iductor iductor required. 'urbine Water Flowmeter . " (Carlsbad Water) (Recycling Facility) (IOD% Submittal) 11 727 -2- hen "Yes" is selected, indicate the number of round trips. lches allons allons (Carlsbad Water) (Recycling Facility) (100% Submittal) 11727 -3- Section 1 1727 LIQUID CHEMICAL FEED SYSTEMS Data Sheet 'ara- PPh Data Description General G Yes, General Equipment Requirements Alum Metering Pumps Service. PI40 P&ID Drawing Reference. Alum Metering Pumps required. Operation 8 Maintenance Manuals G Yes, required. Design Conditions and r NO. r NO. requirements Chemical. MP-1182-1 and MP-1182-2 Pump Designation. Metering Pumps 100 Maximum Solution Temperature. 1.33 Maximum Specific Gravity. 48.5 Concentration, percent by weight. Alum @ Motor-Operated Diaphragm Type of Pump. 2 Number of Pumps. C Solenoid-Operated Diaphragm Capacity Control Range. 1 I4 Minimum Drive Motor. 100 Discharge Pressure. 100 Maximum Stroke Rate 0.05 to 4.00 Metering Range 0 to 100 2 metering range. Accuracy, percent of scale over Stroke Frequency Control. G Automatic and Manual r Manual r None Stroke Length Control. r Automatic and Manual (z Manual 6 F b ph pm si P b (Carlsbad Water) (Recycling Facility) (01-23-02) 11 727 -1- ach pump. P Pressure Relief Vale P Strainer I7 Pulsation Dampener P Pressure Gauge 8 Switch ,ccessories to be furnished with Backpressure Valve r Four-Function Valve r Diaphragm Leak Detection r SCR D"V~ F Other Vhen "Other" selected, indicate VFD Speed Controllers dditional accessories, ,cceDtable Manufacturers and IMilton ROY MROYA. or equal lodels. Lackpressure Valve 'alve Body Construction PVC r CPVC C 316 Stainless Steel r Carpenter 20Cb3 haphragm Construction C EPDM C Viton Iressure Relief Valve 'alve Body Construction e PVC r CPVC C 316 Stainless Steel r Carpenter 20Cb3 )iaphragrn Construction r EPDM Viton itrainer ;trainer Body Construction Transparent PVC r CPVC C 316 Stainless Steel C Carbon Steel 11727 -2- (Carlsbad Water) (Recycling Facility) (01-23-02) -Ring Construction f EPDM Pulsation Dampener Pulsation Dampener Body Construction C Carbon Steel II IT Teflon I r Installing contractor. r A385 r Tttanium. C Hastelloy C. Anchor Bolts, Nuts and Washers. Galmnized steel, ASTM A153 and f Group 1 or 2, ASTM F594, Alloy Stainless steel, ASTM F593. Alloy Group 1 or 2. Field Services Installation check required. Yes IC No hhen "Yes" is selected. indicate theb.5 I /number of days. hhen "Yes" is selected, indicate the11 I number of round trips. Installation supervisor required. r Yes C No (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -3- When "Yes" is selected, indicate the number of days. number of round trips. When "Yes" is selected, indicate the (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -4- Section 1 1727 LIQUID CHEMICAL FEED SYSTEMS Data Sheet Para- graph Description Data Units General P&ID Drawing Reference. Ferric Chloride Metering Pumps Service. PI-39 required. General Equipment Requirements (i Yes, Operation & Maintenance Manuals (i Yes, required. r No. r N~~ I IDesign Conditions and I ~ (Carlsbad Water) (Recycling Facility) (01 -1 7-02) 11727 -3- When “Other“ selected, indicate Milton Roy MROYA, or equal Acceptable Manufacturers and additional accessories, VFD Speed Controller Models. Backpressure Valve Valve Body Construction fi PVC r CPVC r 316 Stainless Steel r Carpenter 20Cb3 Diaphragm Construction r EPDM G Viton Pressure Relief Valve Valve Body Construction G PVC (r CPVC C 316 Stainless Steel C Carpenter 20-Cb3 Diaphragm Construction r EPDM G Viton Strainer Strainer Body Construction G Transparent PVC r CPVC I I IC 316 Stainless Steel ach pump p Pressure Relief Vale p Strainer p Pulsation Dampener j7 Pressure Gauge 8 Switch r Four-Function Vale r Diaphragm Leak Detection r SCR D~W Yj Other hccessories to be furnished with Ip Backpressure Vale ” ” ” ” ” ” ” ” ” ” (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -2- G Carbon Steel G Installing contractor. (Carlsbad Water) 11727 (Recycling Facility) -3- (01-17-02) mber of round trips. hen "Yes" is selected, indicate the (Carlsbad Water) (01-17-02) (Recycling Facility) 11727 -4- Section 11727 LIQUID CHEMICAL FEED SYSTEMS Data Sheet IPara- IDescription IData IP81D Drawing Reference. PI-36, 38 (Service. Sodium Hypochlorite Metering Pumps I beneral Equipment Requirements Ili yes . ". required. Operation & Maintenance Manuals Design Conditions and required. li yes. r No. r No. requirements Chemical. Concentration, percent by weight. Sodium Hypochlorite MP-1101-1, MP-1101-2, Pump Designation. Metering Pumps OF 100 Maximum Solution Temperature. 1.20 Maximum Specific Gravity. % 12.5 MP-1103-1, MP-1103-2 Number of Pumps. Motor-Operated Diaphragm Type of Pump. 4 r Solenoid-Operated Diaphragm (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -1 - T ccessories to be furnished with IF Backpressure Vale I ach pump r F Pressure Relief Vale p Strainer F Pulsation Dampener F Pressure Gauge 8 Switch r Four-Function Vale Diaphragm Leak Detection r SCR D~I\R t7 Other When "Other" selected, indicate additional accessories, VFD Speed Controller Milton Roy MROYA or MROYB, or equ; Acceptable Manufacturers and Models. Backpressure Valve Valve Body Construction r PVC I G CPVC c 316 Stainless Steel Carpenter 20-Cb3 Diaphragm Construction r EPDM G Viton Pressure Relief Valve Valve Body Construction r PVC G CPVC c 316 Stainless Steel C Carpenter 20-Cb3 Diaphragm Construction c EPDM G Viton Strainer Strainer Body Construction G Transparent PVC c CPVC C 316 Stainless Steel C Carbon Steel (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -2- I G Viton Pulsation Dampener Pulsation Dampener Body r Carbon Steel Construction I IG Teflon Eductor Eductor required. Yes No Turbine Water Flowmeter Turbine water flowmeter required. C Yes I No t" Flowmeter capacity Calibration Columns Number of Columns. 2 Diameter. 6 (MP-1101-1 BMP-1101-2) Capacity. 3(MP-I101-1 BMP-1101-2) 3 (MP-1103-1 B MP-1103-2) 0.4 (MP-1103-1 B MP-1103-2) Graduations. 0.2 (MP-1101-1 B MP-1101-2) Diffusers Number of Diffusers. 0 Diffuser Construction. Construction Furnisher of anchor bolts. r Pump manufacturer. 0.05 (MP-1103-1 & MP-1103-2) G Installing contractor. Anchor Bolts, Nuts and Washers. A305. Galvanized steel, ASTM A153 and r C Group 1 or 2, ASTM F594. Alloy Stainless steel, ASTM F593, Alloy Group 1 or 2. - Field Services Installation check required. G Yes r N~ When "Yes" is selected, indicate the0.5 number of days. When "Yes" is selected, indicate the1 number of round trips. $"- I inches t" gallons r" allons (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -3- Installation supervisor required. r Yes * No number of days. When "Yes" is selected, indicate the number of round trips. When "Yes" is selected, indicate the (Carlsbad Water) (Recycling Facility) (01-17-02) 11727 -4- Section 11727 LIQUID CHEMICAL FEED SYSTEMS PART 1 - GENERAL 1-1. SCOPE. This section covers liquid chemical feed systems. 1-1.01. Terminology. When the phrase “as required” is stated in this section it shall mean “as required in the Data Sheet”. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. Each item shall be furnished and installed complete with all mechanical and electrical equipment required for proper operation, all components indicated on the drawings or specified, and all additional materials or construction required by the design of the system. 1-2.01. Coordination. The System Supplier shall prepare system installation drawings, process schematics, interconnecting diagrams, panel layouts, and other data required for complete system description. The System Supplier shall verify that each system component is compatible with all other components of the system, that all pipe materials and sizes are appropriate, and that all devices necessary for a properly functioning system have been provided. Chemical feed systems were designed assuming metering pumps with a minimum suction lift of 10 feet of water. The System Supplier shall assume responsibility for ensuring that suction lift requirements do not exceeded pump capability, and that minimum suction head available (MSH,) is adequate for the pumps supplied. Pumps with lower suction lift capabilities will be considered; however, the System Suppler shall coordinate any changes with the Contractor (e.g. increasing pipe diameter of, or adding pulsation dampeners to, the metering pump suction piping), and assume any additional costs incurred as a result of these changes. The System Supplier shall submit suction lift or MSH, calculations for the pumps supplied in accordance with the submittals section. Review of drawings submitted prior to the final determination and coordination of related equipment to be provided will not relieve the Contractor from responsibility for supplying systems in full compliance with the specific requirements of the related equipment. (Carlsbad Water) (Recycling Facility) (01-23-02) 1 I727 -5- 1-2.02. Interchangeability. Similar components of different chemical feed systems shall be from the same manufacturer to facilitate maintenance and stocking of repair parts. Whenever possible, identical units shall be furnished. 1-2.03. General EQUipment Stipulations. When required, the General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.04. Governing Standards. All electrical equipment shall conform to applicable standards of the National Electrical Manufacturers Association and the National Electrical Code. 1-2.05. Power Supply. Unless otherwise specified, the power supply will be 480 volts, 60 Hz, three phase. Where control voltage lower than the power supply voltage is required, a suitable control power transformer shall be furnished. 1-2.06. Metal Thicknesses. Metal thicknesses and gages specified herein are the minimum required. Gages refer to US Standard gage. 1-2.07. Nameplates. A nameplate shall be provided and mounted on or adjacent to each chemical feeder to identify its function. Nameplates shall be approximately 1 by 3 inches, made from black on white phenolic material. Letters shall be engraved to the white interior and shall be at least 3/16 inch high. Feeder designations on the nameplates shall correspond to those indicated on the drawings. 1-3. SUBMITTALS. 1-3.01. Drawinas and Data. Complete fabrication, assembly, and installation drawings, process schematics, and wiring diagrams, together with detailed specifications and data covering materials, parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. 1-3.02. Operation and Maintenance Data and Manuals. When required, operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals sections. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 1-3.03. System Supplier's Qualifications. Within 30 days after the Notice of Award, the Contractor shall submit proof of the following qualifications for the intended System Supplier: (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -6- The System Supplier has the required financial capability The names of manufacturers whose products will be supplied The System Supplier maintains a qualified technical staff and design office. The System Supplier has the physical plant and fabricating personnel to complete the work specified. The System Supplier has and will maintain competent service personnel to service the equipment furnished. The System Supplier has successfully provided similar work for at least 5 years. The names of at least three references who are users of similar systems designed, assembled, and furnished by the System Supplier. 1-3.04. Calibration GraDhs. The Contractor shall prepare a calibration graph from field tests for each chemical feed unit which does not have a rate set device reading in gallons per hour. The graph shall show the rate setter graduation conversion to gallons per hour throughout the range of the feed unit. Each graph shall behrnished on hard paper and sealed in clear plastic. PART 2 - PRODUCTS 2-1. SYSTEM SUPPLIER. The chemical feed system shall be designed, coordinated, and supplied by a qualified System Supplier who is regularly engaged in the business of designing and assembling liquid chemical feed systems for water treatment plant projects. 2-2. CONSTRUCTION. Chemical feed equipment shall be of substantial construction with all parts designed for long life under working conditions including corrosive atmospheres and intermittent or continuous operation. All wearing parts and items requiring adjustment shall be readily accessible. Each unit shall be completely enclosed and dust-tight when in operation. All parts which are exposed to corrosive conditions shall be made from corrosion-resistant materials or covered with suitable protective coatings. 2-3. MOTOR-OPERATED DIAPHRAGM METERING PUMPS. Motor-operated diaphragm metering pumps shall be furnished as required. Metering pump design shall be as required. (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -7- Each pump shall be of the positive displacement type, using a mechanical or hydraulic plunger actuated diaphragm. Diaphragms relying solely on friction and compression of the diaphragm material for installation and leak prevention will not be acceptable. Metering pumps shall have an internal drive shaft connected to a motor with support bearings on both ends within the gear case. Each pump shall have one adjustable head. Inlet and outlet check valves shall be of the single valve type, with valve housing which are removable without disassembly of the pipe fittings. Materials of construction shall be selected for resistance to the pumped solution, as acceptable to ENGINEER. The rate of metering shall be changed by varying the stroke length and the stroking speed as required. Minimum flow rate shall be achieved at a stroking length not less than 10 percent and a stroking speed not less than 20 spm. Each pump liquid end shall be equipped with a stroke length adjustment knob to provide capacity adjustment without the use of tools and while the pump is running. All moving parts shall be totally enclosed and self-lubricating. When automatic stroke length is required, the pump liquid end shall be equipped with automatic stroke length control set to operate from a remote signal. The input signal shall be 4-20 mA dc, and shall be ungrounded type with an input resistance of not more than 250 ohms. Motor horsepower for each pump shall be based on the above requirements and on the discharge back pressure required by the pump furnished. Motor shall not be less than the indicated horsepower. Power to the motor shall be provided by an adjustable frequency drive (AFD) speed controller as specified herein. Each pump shall be provided with an ac inverter-duty motor, rated 460 volts, 3- phase and suitable for variable speed operation with a AFD controller, PWM type. Input voltage to the AFD shall be 480 volts, 3-phase. Motors shall be designed to deliver full load torque from zero to full speed. Motors shall be totally enclosed type, chemical duty type, with class H insulation, as manufactured by Reliance Electric, or equal. The signal input to the AFD controller shall be 4-20 mA dc, and shall be ungrounded differential type with an input resistance of not more than 250 ohms. The controller shall accept either the remote signal or a manual rate control signal at the controller, and vary the motor speed as required to control the metering pump delivery rate. The variable frequency drive controller shall be Allen-Bradley Series "C" 160 smart speed controller, or equal. Each controller shall be rated 480 volts, 3-phase, and (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -8- mounted in a metering pump control panel as described in the Metering Pump Control Panel paragraph. Provide a diaphragm failure detection and alarm switch when required which shall promptly stop the pump drive motor and provide an alarm signal to the local control panel. Provide a normally-open, dry contact output from the local control panel which closes for remote alarming upon leakage of the pump diaphragm. Refer to schematic diagram. Each pump shall be mounted on a structural steel or cast iron base to be set on a concrete support as indicated on the drawings and shall include a self- lubricating speed reducer and liquid end splash guards. Each pump shall be furnished with the following accessories as required: One backpressure valve with socket ends. Valve body and diaphragm materials of construction shall be as required. Unless otherwise specified, the backpressure valve shall be field adjustable, and shall be factory set at a pressure of 25 psig. The valve shall be manufactured by Griffco, Hydroflo, or equal. Backpressure valves for metering pumps MP-1173-1, MP-1173-2, MP-1178-1, MP-I 178-2 shall be factory set at a pressure of 60 psi. One external pressure relief valve with socket ends, sized to pass the maximum displacement of the pump. Valve body and diaphragm materials of construction shall be as required. The valve shall have adjustable relief pressure setting, with initial relief pressure factory set at 50 psi. The valve shall be manufactured by Griffco, Hydroflo, or equal. One strainer installed in the inlet piping. The strainer shall be Y-pattern with 12-mesh screen and socket ends. Strainer body and O-ring seal materials of construction shall be as required. The strainer shall be manufactured by Ryan Herco, Hayward, or equal. One properly sized pulsation dampener installed in the discharge piping. The pulsation dampener shall be constructed as required, with Teflon diaphragm, air charging valve, air gauge, and flanged end. The chamber shall be sized to limit pressure surges to between 5 and 10 percent of mean pressure. The pulsation dampener shall be Blacoh Fluid Control “Sentry 11” or equal. One pressure gauge and pressure switch with isolating diaphragm installed in the discharge piping. The pressure gauge shall be indicating dial type with adjustable pointer and acrylic plastic or shatterproof glass window. The dial shall be 4-1/2 inches in diameter, with white background and black markings. Pointer travel shall be approximately 270 degrees. The unit of (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -9- measurement shall be pounds per square inch, and shall be indicated on the dial face. The gauge shall be selected SO that gauge readings will be mid-scale under normal operating conditions. The high pressure switch shall be adjustable and shall be set to alarm at the maximum expected normal discharge pressure of the pump. The pressure switch shall be Mercoid. Ashcroft, Barksdale, or equal. The isolating diaphragm shall protect the pressure guage and switch from the chemical solution and shall be factory assembled to the gauge and switch. Metering pump manufacturer and model shall be as required. 2-3.01. Meterinq Pump Control Panel. A local control panel shall be provided for each metering pump by the pump supplier. The control panel shall house all power and control components required for operation of the metering pump. The control panel shall be constructed from Type 316 stainless steel, NEMA Type 4X enclosure mounted as shown on the drawings. Power and control wiring from the panel to the metering pump and motor shall be verified by the Contractor from the shop drawings prior to installation and shall provide all required conduit and wiring. The one-line diagrams provide some indication of the conduit and wiring required but shall be verified by the Contractor. All wiring shall be furnished complete and ready for connection of an external power circuit. Each control panel shall be provided with an engraved nameplate indicating the controlled unit, and nameplates for all major components contained within the control panel. Each control panel shall contain, but not be limited to, a pump motor ”Local-Off- Remote” switch, pump “Run” and “Fail“ indication, a control power transformer with fusing, control relays, indicating lights, and a power disconnect switch. The power disconnect switch shall have an externally operable and lockable handle. Pump status and alarm signals shall be displayed on a ”Program Keypad Module” located on the door of the enclosure. In the “Remote” mode, the pump shall be started and stopped from a remote isolated contact input, which closes to start the pump and opens to stop the pump. In the “Remote” mode, pump motor speed shall be adjusted with remote 4-20 mA signal inputs. In the “Local” mode, pump motor speed shall be adjusted with a potentiometer or manual raisellower buttons located on the control panel or keypad module, while stroke length shall be adjusted with a manual dial on the metering pump. The controller shall be wired so that a “permissive” contact from the plant control system must be present in order for the pump to run in either the manual or remote mode. The “permissive” will be a normally open contact that closes when conditions are acceptable to operate the pump, The “permissive contact will open for conditions such as high pump discharge pressure or low suction level, as indicated on the P&ID drawings. (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -1 0- The controller shall provide isolated contact outputs rated a minimum of 5 amperes at 120 volts ac, which close to indicate pump running, and pump in "Remote" mode. 2-4. SOLENOID-OPERATED DIAPHRAGM METERING PUMPS. Solenoid- operated diaphragm metering pumps shall be provided as required. Metering pump design shall be as required. Solenoid-operated diaphragm metering pumps shall be of the electronic solenoid pulse type diaphragm construction, consisting of a simplex pump head and double ball check valves on both the inlet and outlet. The pump drive power supply shall be rated 11 5 volts, single phase, 60 Hz. The pump driver shall have only one moving part (the armature diaphragm assembly) and shall require no lubrication during service. The pump shall be furnished complete with grounding plug and cord. Each pump shall be manually adjustable by two separate dial knobs, one for adjusting stroke length and the other for adjusting stroke frequency. Each pump shall have an automatidmanual switch which, when in automatic, will allow the pump to remotely adjust stroke frequency with a 4-20 mA DC signal. Each pump shall be furnished with the following accessories as required: One four-function valve to provide anti-siphon protection, back pressure regulation, pressure relief and manual discharge pressure release for pump priming. One strainer installed in the inlet piping. The strainer shall be Y-pattern with 12-mesh screen and socket ends. Strainer body and O-ring seal materials of construction shall be as required. The strainer shall be manufactured by Ryan Herco, Hayward, or equal. One pressure gauge with isolating diaphragm installed in the discharge piping. The pressure gauge shall be indicating dial type with adjustable pointer and acrylic plastic or shatterproof glass window. The dial shall be 4-112 inches in diameter, with white background and black markings. Pointer travel shall be approximately 270 degrees. The unit of measurement shall be pounds per square inch, and shall be indicated on the dial face. The gauge shall be selected so that gauge readings will be mid-scale under normal operating conditions. The isolating diaphragm shall protect the pressure gauge from the chemical solution. All wiring shall be furnished complete and ready for connection of an external power circuit. Metering pump manufacturer and model shall be as required (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -1 1- 2-5. ACCESSORIES. Accessories shall be provided with each metering pump as required. 2-5.01. Chemical Induction Units. A chemical induction unit of standard and proven design shall be supplied for injection of sodium hypochlorite into the inlet of the chlorine contact basin. The unit shall have capacity as described herein. The chemical induction unit shall have the ability to create sufficient vacuum to operate satisfactorily with the selected gas feeder, and shall have the ability to fully mix the gaseous chlorine with the process water. All wetted parts of the chemical induction unit shall be suitable for contact with chlorine, chlorine solution, and process water. All parts and accessories which can come into contact with the process water shall be approved under NSF 61 for use in potable water treatment. The chemical induction unit shall be supplied with a 316 stainless steel rail system which will allow the unit to be installed from grade and lowered to the mounting elevation by the lifting device as shown on the drawings. The supplied lifting device shall be a hand operated winch with a manual stop device and a free fall brake. The lifting cable shall be constructed of 316 stainless steel. The winch and the lifting cable shall be rated for twice the weight of the chemical induction unit. A hose shall be supplied to conduct gaseous chlorine under a vacuum to the chemical induction unit. The supplied hose shall be of sufficient length to connect to the chemical induction unit from the aboveground chemical piping. The hose shall be constructed of materials resistant to gaseous chlorine and shall be rated for full vacuum. The hose shall be supplied with all the fittings necessary to connect to the supply piping and to the chemical induction unit. A control panel shall be supplied with the chemical induction unit. The control panel shall be of NEMA 4X construction and shall have a hand-off-auto control switch, status indicating pilot lights for run and stop, and a local lockable circuit breaker disconnect. The main circuit breaker shall be rated 600 volts, three phase, 60 Hz. The minimum short circuit rating of the main circuit breaker shall be 42,000 amperes rms symmetrical at 480 volts ac. The motor shall be 460 volt, 3 phase, 60 Hz and shall be of sufficient power rating to sufficiently and efficiently operate the chemical induction unit. The motor shall be suitable for continuous, submersible duty and shall be constructed of materials resistant to the surroundings. The motor windings shall be hermetically sealed and shall be moisture resistant. (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -12- The chemical induction unit shall be supplied with a power supply cable of sufficient length to attach to the chemical induction unit at its mounting location from the aboveground power source. The cable shall be suitable for submersible service, The cable shall have UL andlor CSA approved insulation and shall be non-wicking in the event of cable damage. Manufacturer shall submit results of factory test of equipment including motor amperage draw and maximum produce vacuum. Chemical induction units shall be Capital Controls “Chlor-a-vac” or US Filter/Stranco “Waterchamp”. Line Description Chemical Induction Units 1 .I 80 Designation M-1001-1 Quantity One (1) Chemical Induction Unit Capacity, ppd 1,000 Power Supply 460 V, 3 phase, 60 Hz Motor horsepower, hp At least 3 hp 2-5.02. Turbine Water Flowmeter. Turbine water flowmeters shall be furnished as required. The flowmeter shall have a capacity as required, and shall be Aailant turbine flowmeter “WPX Model 21 1”. The unit shall be furnished with a Aailant “Model 860” infrared pulser and a Aailant ”Model 1005” pulse to dc converter. A batch controller shall be provided with the flowmeter. The batch controller shall be a wall-mounted microprocessor-based unit capable of providing dual stage shutdown, display of rate of flow and batch count simultaneously, or total, rate of flow, or batch count individually. The controller shall have a 16 character vacuum fluorescent display, single key access to display values, flow input, control output, five programmable control inputs, menu type programming, ac-dc power, and a IO-year memory. The controller shall control a motor-operated globe valve downstream of the water flowmeter and shall output to a pulse to a dc converter. The globe valve shall be provided herein to ensure proper communication with the flowmeter controller. The controller shall ramp down water flow rate as the set point is approached to reduce water hammer. The controller shall be powered by 115 volts ac and capable of an output of 24 volts dc at 100 mA maximum. The wall-mounted panel, enclosure, from panel, and push buttons shall be rated NEMA Type 4X. The controller shall be an Aailant “Model 3030W/115”. 2-5.03. Calibration Column. Transparent plastic calibration columns shall be furnished as required, and installed on the metering pump suction piping as (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -1 3- indicated on the drawings. Columns shall be clear PVC or other resistant, rigid, transparent plastic tubing having a vented top cap and screwed flow fitting. Columns shall have size and capacity as required. Columns shall be graduated as required, with a numeral at each graduation. Columns shall be Valcom, Inc., "Model 8500", or equal, and shall be mounted in-line or on steel legs. The calibration column for sulfuric acid shall be made from Lucite with PVDF end- caps. The framing and supports for the sulfuric acid calibration column shall be made of non-metallic material. 2-5.04. Diffuser. Diffusers shall be provided as required, and shall be of the type indicated on the drawings. Diffuser tube material of construction shall be as required. 2-5.05. Injection Quills. Furnish metallic chemical injection quills with an integral spring loaded injection check valve to prevent backflow, as manufactured by Neptune or equal. Size shall be as recommended by the quill manufacturer, based on the maximum chemical pumping rate for the respective chemical. The injection line shall interface with the quill via an FNPT inlet, %inch minimum. A union fitting shall be incorporated at the interface to permit disassembly. The quill shall interface with the process line via a MNPT fitting, %-inch minimum. Quill materials shall be as follows: Sodium Hypochlorite service (microfilter feed): PVC Threshold Inhibitor: 316 Stainless Steel Sulfuric Acid: Alloy 20 2-6. SAFETY EQUIPMENT. Three chemical handling safety equipment kits shall be provided. Each kit shall include, but shall not be limited to, chemical splash goggles, dust and mist respirator, rubber gloves, and rubber apron, all packed in a suitable carrying case. 2-7. ANCHOR BOLTS. Anchor bolts with associated nuts and washers shall be furnished as required for each item of equipment. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed. Anchor bolt diameter shall be sufficient to provide adequate anchorage to the structural concrete. Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-1/2 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 112 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -14- Anchor bolts shall be long enough to accommodate at least 1-1/2 inches of grout beneath the baseplate and to provide adequate anchorage into structural concrete. Anti-seize compound will be applied to the threads of all stainless steel bolts before assembly. PART 3 - EXECUTION 3-1. INSTALLATION, Equipment and materials furnished under this section shall be installed in proper operating condition in full conformity with Drawings, specifications, and recommendations of the equipment manufacturer, unless exceptions are noted by the Engineer. All items necessary for a complete operating system shall be installed. 3-1.01. EquiDment Bases. Unless otherwise specified or indicated on the Drawings, each item of chemical feed equipment shall be mounted on a concrete base approximately six inches above the floor. If feeders or other components must be supported at higher elevations above the floor, suitable supplementary bases shall be provided. 3-2. FIELD QUALITY CONTROL, 3-2.01. Installation Check. An experienced, competent, and authorized representative of the manufacturer shall visit the site of the Work and inspect, check, adjust if necessary, and approve the equipment installation. The representative shall be present when equipment is placed in operation in accordance with Section 01650 and shall revisit the jobsite as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactoty in the opinion of ENGINEER. The manufacturer's representative shall furnish a written report certifying that the equipment has been properly installed; that gas piping has been properly cleaned; is in accurate alignment; is free from undue stress imposed by connecting piping or anchor bolts; and has been operated at full load conditions and that it operated satisfactorily. All costs for these services shall be included in the contract price for the number of days and round trips to the site as required. 3-2.02. Installation Supervision. The equipment manufacturer shall furnish a qualified field installation supervisor during the equipment installation. Such (Carlsbad Water) (Recycling Facility) (01-23-02) 11727 -1 5- services shall be included in the Contract Price for the number of days and round trips to the site, as required, Manufacturers' installation supervisor shall observe, instruct, guide, and direct the installing contractor's erection or installation procedures. The installing contractor will provide written notification 10 working days prior to the need for such services. End of Section (Carlsbad Water) (01-23-02) (Recycling Facility) 11 727 -1 6- Section 11 729A CHEMICAL TRANSFER PUMPS - SODIUM HYPOCHLORITE Data Sheet Para- graph Description Data Units General P&lD Drawing Reference. c yes. General Equipment Requirements Sodium Hypochlorite Transfer Pumps Service. PI-35 required. required. Operation & Maintenance Manuals c yes. r No. r No. I (Design Conditions and I I Furnlsher I r Installing contractor. Anchor Bolts, Nuts and Washers. Galmnized steel, ASTM A153 and A385. r Titanium. Hastelloy C. Stainless steel, ASTM F593, Alloy Group 1 or 2. r Group 1 or 2, ASTM F594. Alloy (Carlsbad Water) (Recycling Facility) (100%) 1 1729A -1 - Section 11729A CHEMICAL TRANSFER PUMPS - SODIUM HYPOCHLORITE PART 1 - GENERAL 1-1. SCOPE. This section covers liquid chemical transfer pumps 1-1.01. Terminology. When the phrase “as required” is stated in this section it shall mean “as required in the Data Sheet”. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with drawings, specifications, engineering data, instructions, and by ENGINEER. recommendations of the equipment manufacturer, unless exceptions are noted Each item shall be furnished and installed complete with all mechanical and electrical equipment required for proper operation, all components indicated on the drawings or specified, and all additional materials or construction required by the design of the system. 1-2.01. Coordination. The supplier shall prepare system installation drawings, process schematics, interconnecting diagrams, panel layouts, and other data required for complete system description. The supplier shall verify that each system component is compatible with all other components of the system, that all pipe materials and sizes are appropriate, and that all devices necessary for a properly functioning system have been provided. Review of drawings submitted prior to the final determination and coordination of related equipment to be provided will not relieve the supplier from responsibility for supplying systems in full compliance with the specific requirements of the related equipment. 1-2.02. Interchanqeability. Similar components of different chemical feed systems shall be from the same manufacturer to facilitate maintenance and stocking of repair parts. Whenever possible, identical units shall be furnished. 1-2.03. General Equipment Stipulations. When required, the General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.04. Governinq Standards. All electrical equipment shall conform to applicable standards of the National Electrical Manufacturers Association and the National Electrical Code. (Carlsbad Water) 11 729A (Recycling Facility) -2- (1 00%) 1-2.05. Power Supply. Unless otherwise specified, the power supply will be 480 volts, 60 Hz, 3 phase. Where control voltage lower than the power supply voltage is required, a suitable control power transformer shall be furnished. 1-2.06. Metal Thicknesses. Metal thicknesses and gages specified herein are the minimum required. Gages refer to US Standard gage. 1-2.07. Nameplates. A nameplate shall be provided and mounted on or adjacent to each chemical feeder to identify its function. Nameplates shall be approximately 1 by 3 inches, made from black on white phenolic material. Letters shall be engraved to the white interior and shall be at least 3/16 inch high. Feeder designations on the nameplates shall correspond to those indicated on the drawings. 1-3. SUBMITTALS. 1-3.01. Drawinqs and Data. Complete fabrication, assembly, and installation drawings, process schematics, and wiring diagrams, together with detailed specifications and data covering materials, parts, devices, and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. 1-3.02. Operation and Maintenance Data and Manuals. When required, operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals sections. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. PART 2 - PRODUCTS 2-1. CONSTRUCTION. Chemical transfer pumps shall be of substantial construction with all parts designed for long life under working conditions including corrosive atmospheres and intermittent or continuous operation. All wearing parts and items requiring adjustment shall be readily accessible. Each unit shall be completely enclosed and dust-tight when in operation. All parts which are exposed to corrosive conditions shall be made from corrosion-resistant materials or covered with suitable protective coatings. 2-2. TRANSFER PUMPS. Transfer pumps shall be furnished as required, and installed as indicated on the drawings. Pump design shall be as required. The pump motor shall be provided with 120 volt motor space heaters and shall be rated 480 volts, three phase, 60 Hz. (Carlsbad Water) (Recycling Facility) (1 00%) 11 729A -3- The pump shall be a seal-less magnetic drive centrifugal type pump. The pump shall have one piece solid ductile iron casing, The impeller shall be closed type, of one-piece construction. The shaft shall be of one-piece construction, replaceable, and non-rotating. The shaft shall be fully supported at both ends utilizing front shaft support and rear casing, with an axial groove for improved lubrication and particulate bypass. The magnetic coupling shall be designed for zero slippage and zero losses. All wetted parts shall be constructed of material resistant to the pumped solution, as acceptable to ENGINEER. The pump shall have provisions for remote run-stop control utilizing an isolated relay contact from the Plant Control System. Each pump shall be provided with a normally open relay contact that closes on pump fail for remote monitoring by the Plant Control System. Transfer pump manufacturer and model shall be as required. 2-3. ANCHOR BOLTS. Anchor bolts with associated nuts and washers shall be furnished as required for each item of equipment. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed. The bolts shall be at least 3/4 inch in diameter. Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-112 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 1/2 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. Anchor bolts shall be long enough to accommodate at least 1-112 inches of grout beneath the baseplate and to provide adequate anchorage into structural concrete. Anti-seize compound will be applied to the threads of all stainless steel bolts before assembly. 2-4 PRESSURE GAUGE. One pressure gauge and pressure switch with isolating diaphragm installed in the discharge piping. The pressure gauge shall be indicating dial type with adjustable pointer and acrylic plastic or shatterproof glass window. The dial shall be 4-112 inches in diameter, with white background and black markings. Pointer travel shall be approximately 270 degrees. The unit of measurement shall be pounds per square inch, and shall be indicated on the dial face. The gauge shall be selected so that gauge readings will be mid-scale (Carlsbad Water) (Recycling Facility) (1 00%) 1 1729A -4- under normal operating conditions. The high pressure switch shall be adjustable and shall be set to alarm at the maximum expected normal discharge pressure of the pump. The pressure switch shall be Mercoid, Ashcroft, Barksdale, or equal. The isolating diaphragm shall protect the pressure and switch from the chemical solution and shall be factory assembled to the gauge and switch. End of Section (Carlsbad Water) (Recycling Facility) (1 00%) 1 1729A -5- SECTION 11729B CHEMICAL TRANSFER PUMP -THRESHOLD INHIBITOR PART 1 -GENERAL 1-1. SCOPE. This section covers electric drum pump type liquid chemical transfer pumps for Threshold Inhibitor for the Reverse Osmosis System. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by the Engineer. Each item shall be furnished and installed complete with all mechanical and electrical equipment required for proper operation, all components indicated on the drawings or specified, and all additional materials or construction required by the design of the system. 1-2.01. Coordination. The supplier shall prepare installation drawings, process schematics, interconnecting diagrams, panel layouts, and other data required for complete system description. The supplier shall verify that each system component is compatible with all other components of the system, that all pipe materials and sizes are appropriate, and that all devices necessary for a properly functioning system have been provided. Review of drawings submitted prior to the final determination and coordination of related equipment to be provided will not relieve the supplier from responsibility for supplying systems in full compliance with the specific requirements of the related equipment. 1-2.02. Interchanqeability. Similar components of different chemical feed systems shall be from the same manufacturer to facilitate maintenance and stocking of repair parts. Whenever possible, identical units shall be furnished. 1-2.03. General Eouipment Stipulations. The General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.04. GoverninQ Standards. All electrical equipment shall conform to applicable standards of the National Electrical Manufacturer’s Association and the National Electrical Code. 1-2.05. Power SUPD~U. The power supply will be 120 volts, 60 Hz, single phase. Where control voltage lower than the power supply voltage is required, a suitable control power transformer shall be furnished. (Carlsbad Water) (Recycling Facility) (100% Submittal) 1 1729B -1- 1-2.06. Metal Thickness, Metal thicknesses and gages specified herein are the minimum required. Gages refer to US Standard gage. 1-2.07. Nameplates. A nameplate shall be provided and mounted on or adjacent to each chemical feeder to identify its function. Nameplates shall be approximately 1 by 3 inches, made from black on white phenolic material. Letters shall be engraved to the white interior and shall be at least 3/16 inch high. Feeder designations on the nameplates shall correspond to those indicated on the drawings. 1-3. SUBMITTALS. Refer to Section 01300. PART 2 - PRODUCTS 2-1. CONSTRUCTION. Chemical transfer pumps shall be of substantial construction with all parts designed for long life under working conditions including corrosive atmospheres and intermittent or continuous operation. All wearing parts and items requiring adjustment shall be readily accessible. Each unit shall be completely enclosed and dust-tight when in operation. All parts, which are exposed to corrosive conditions, shall be made from corrosion- resistant materials or covered with suitable protective coatings. 2-2. THRESHOLD INHIBITOR TRANSFER PUMP REQUIREMENTS: 2-2.01. General: Equipment Number: P-I 177 Specific Gravity: 1.05 - 1 .IO Temperature: 75 degrees F. 2-2.02. Pump Tube Reauirement: Type Mechanical Sealed polypropylene with Viton, PTFE. carbon, Tefzel, and Haselloy C wetted parts. Hose Connection %-inch Manufacturer: Flux, Part No. F430PP40/33; or equal. 2-2.03. Motor Requirements: Enclosure TEFC - Suitable for corrosive environments, corrosion resistant coating, splash-proof, built in overload protection (Carlsbad Water) (Recycling Facility) (100% Submittal) 1 17298 -2- switch. RPM 8,500 Weight 11 Ibs Power 120 VAC, 60 Hz, Single Phase Requirements Minimum Motor 114 hp Size Manufacturer: Flux, Model F458; or equal. 2-2.04. Pump Output Requirement. Flow (gpm) 33 Feet of Head 10 End of Section (Carlsbad Water) (Recycling Facility) (100% Submittal) 1 17298 -3- Division 13 Special Construction Section 131 90 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS Data Sheet (Carlsbad Water) (Recycling Facility) 13190 -1- ( 1-1 5-02) Std. Rev. 1.3, 11/16/2000 MFG Justin Tanks Erchigs Or Equal Tank heating required. Yes. r NO^ hcceDtable Manufacturers. IDEI Systems, Inc + - Minimum temperature to maintain. 100 Minimum outdoor ambient air 35 temperature. Tank insulation required. r Yes. . ”. No. Construction Exposed Metal. Gahenized steel, ASTM A153 and ‘ A385 r litanium. r HaStelloy c. Group 1 or 2. ASTM F594, Alloy Stainless steel. ASTM F593. Alloy Group lor 2. r Not acceptable. - Protected Metal. (i r Other. ASTM A36 Carbon Steel with fiberglass reinforced coating. When “Other“ is selected, alternate material. Furnisher of anchor bolts. (i Tank manufacturer. r litanium. r Hastelloy C. F Group 1 or 2, ASTM F594. Alloy Stainless steel. ASTM F593. Alloy Group 1 or 2. A385 Galranized steel, ASTM A153 and Stainless steel. ASTM ,393. Alloy G~UD 1 or 2. r (i. Group 1 or 2. ASTM F594. Alloy (Carlsbad Water) (Recycling Facility) (1 -1 5-02) 13190 -2- Std. Rev. 1.3, 11/16/2000 I Ir Buna-N. I r Other. when "Othef is selected, alternate I baterial. bccessones ank Vent. C Mushroom type None. I Ir Gooseneck type. I C Connect to vent piping system. Hinged covers required. Yes. Bag loader r No. required. Air Diffusers required. r Yes. No. Air Bubbler required. i- Yes. No. Borosilicate glass. Clear PFA Tellon. r Carbon steel. Type 316 stainless steel. r Carpenter 20-Cb3. (Carlsbad Water) (Recycling Facility) 13190 -3- (1-15-02)- .. Std. Rev. 1.3, 11/16/2000 bixer required. r Yes. c= No. When 'Yes" is selected, motor ?orrepower. When "Yes" is selected, type of nixer. Tank Node Schedule Schedule required. Schedule in specification. C No schedule (Carlsbad Water) (Recycling Facility) (1-15-02) 13190 -4- Std. Rev. 1.3. 11/16/2000 Section 131 90 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS Data Sheet (Carlsbad Water) (Recycling Facility) 13190 -1- (1 -1 562)- .. Std. Rev. 1.3, 11/16/2000 Acceptable Manufacturers. Tank heating required. r yes. (Minimum temperature to maintain. Minimum outdoor ambient air temperature. Tank insulation required. r yes. c No. c No. Construction Exposed Metal. r A385 Galwnized steel. ASTM A153 and Titanium. Hastelloy c. C Group 1 or 2, ASTM F594, Alloy Stainless steel. ASTM F593. Alloy Group lor 2. C Not acceptable. s Protected Metal. ASTM A36 Carbon Steel with fiberglass reinfomed coating. IC Other. hen 'Other" is selected. alternate I material. Furnisher of anchor bolts. Tank manufacturer. r Installing contractor. Anchor Bolts. Nuts and Washers. Galwnized steel. AS" A153 and A385. C Xtanium II lr Hastelloy C, k Group 1 or 2, ASTM F594. Alloy Stainless steel. ASTM F593, Alloy Group 1 or 2. Assembly bOlk nuts, and washers. Galwnized steel, ASTM ~153 and r A385 Stainless steel, ASTM F593, Alloy Group 1 or 2. I= Group 1 or 2. ASTM F594. Alloy Gasket material. c EPDM. r Viton. r BUM-N. 1 Other. (Carlsbad Water) (Recycling Facility) 13190 -2- (1-15-02)- .. ~ Std. Rev. 1.3, 11/16/2000 C Bomsilicate glass. r Clear PFA Teflon. material. 'when 'Other" is selected, alternate Baffles required. r Yes. No. Mixer required. r Yes. No. horsepower. Nhen "Yes" is selected. motor (Carlsbad Water) 13190 (Recycling Facility) (1 -1 5-02) -3- Std. Rev. 1.3, 11/16/2000 when "Yes" is selected, type of mixer. Tank Nonle Schedule Schedule required. @ Schedule in specification. r No schedule (Carlsbad Water) (Recycling Facility) (1 -1 5-02) 13190 -4- Std. Rev. 1.3, 11/16/2000 Section 131 90 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS Data Sheet (Carlsbad Water) (Recycling Facility) 13190 -1 - (1 -1 5-02) Std. Rev. 1.3. 11/16/2000 C No. Minimum temperature to maintain. Minimum outdoor ambient air 'temperature. Tank insulation required. r Yes. 6 No. Construction Exposed Metal. r C litanium. C Hastelloy C. A305. Galmnized steel, ASTM A153 and C Group 1 or 2, ASTM F594, Alloy Stainless steel, ASTM F593. Alloy Group lor 2. I I Ir ~ot acceptable. I Protected Metal. C ASTM A36 Carbon Steel with fiberglass reinforced coating. r Other. IFurnisher of anchor bolts. Tank manufacturer. C Installing contractor. Anchor Bolts, Nuts and Washers. Galuanized steel, ASTM A153 and A385. r Hastdloy C. 6 Group 1 or 2, ASTM F594. Alloy Stainless steel, ASTM F593, Alloy Group 1 or 2. Assembly bob nuts. and washers. ~ Galmnized steel, ASTM A153 and It 1' A385. II li Group 1 or 2, ASTM F594, Alloy Stainless steel, ASTM F593. Alloy Grow 1 or 2. Gasket material. EPDM. . r Viton. I I Buna-N. I (Carlsbad Water) (Recvclino Facilitv) 13190 -2- i1-15-02 j .I Std. Rev. 1.3, 11/16/2000 hen "Other" is selected, alternate Accessories Tank Vent. C Mushroom type. 6 Gooseneck type. r Connect to mt piping system. T I Hinged covers required. IC Yes G No. ir Diffusers required. Ir Yes. G No. Air Bubbler required. r Yes. E No. Ladder required. r yes. 6 No. Handrail required. r Yes. 6 No. Sight Level Gauge. 6 Flag type. r Clear type. r None. Material for clear type. r Clear PVC. r Borosilicate glass. r Clear PFA TeRon. r Other. hen "Other" is selected, alternate Material for magnetic flag type. c pvc. r CPVC. r Carbon steel. 6 Type 316 stainless steel C Carpenter 206b3. t " r Other. When "Other" is selected, alternate naterial. Baffles required. r Yes. 6 No. Mixer required. r Yes. 6 No. When "Yes" is selected, motor horsepower. (Carlsbad Water) (Recycling Facility) (1-15-02) 13190 -3- Std. Rev. 1.3, 11/16/2000 nixer. When "Yes" is selected, type of Tank Node Schedule Schedule required. Schedule in specification. r No schedule (Carlsbad Water) (Recycling Facility) (1 -1 5-02) 13190 -4- Std. Rev. 1.3, 11/16/2000 Useable Capacity. Tank Diameter. 515 ballons 5 beet Straight Shell LengthlHeight. 5 beet (Carlsbad Water) Recycling Faclity) (1 -1 6-02) 13190 -1- Std. Rev. 1.3, 11/16/2000 Acceptable Manufacturers. MFG Justin Tanks 3EI Systems, Inc Enhigs 3r Equal Tank heating required. r yes. No. Minimum temperature to maintain. Minimum outdoor ambient air temperature. Tank insulation required. r Yes. No. Construction IExposed Metal. ~ Galvanized steel, ASTM A153 and I rotected Metal. ' AS. r Titanium. C Hastelloy C. (i Group 1 or 2. ASTM F594, Alloy Stainless steel, ASTM F593. Alloy Group lor 2. C Not acceptable. ASTM A36 Carbn Steel with fiberglass reintorced coating. r Other material. When 'Other" is selected, alternate Furnisher of anchor bolts. Tank manufacturer. r Installing contractor. r A385. r litanium. C Hastelloy C. k Group 1 or 2. ASTM F594. Alloy Anchor Bolts, Nuts and Washen. Galvanized steel. ASTM A153 and Stainless steel. ASTM F593. Alloy Group 1 or 2. Assembly bd& nuts. and washers. Stainless steel, ASTM F593, Alloy Galwnized steel. ASTM ~153 and Group 1 or 2. r A305 (i Group 1 or 2. ASTM F594, Alloy (Carlsbad Water) Recycling Faclity) (1-16-02) 13190 -2- Std. Rev. 1.3, 11/16/2000 C Vitcn. r Buna-N r Other. (When 'Other" is selected, alternate I material. Accessories Tank Vent. r Mushroom type. I 1. Gooseneck type. I C Connect to wt piping system. inged coven required. r yes. I 1s No. I bir Diffusen required. (r yes. I 0 No. Air Bubbler required. r YS. No. Ladder required. c Yes. @ No. Handrail required. r yes. No. Sight Level Gauge. r Clear type. aterial for clear type. r Clear PVC. r Borosilicate glass. r Clear PFA Teflon. r Other. When 'Other" is selected, alternate material. Material for magnetic flag type. r pvc. r CPVC. r Carbon steel. I 1s Type 316 stainless steel. I I IC Carpenter 20Cb3. I (C Otter. hen "Other" is selected, alternate I baterial. pames required. lr Yes. I (Carlsbad Water) Recycling Faclitv) 13190 -3- (1-16-02) _. Std. Rev. 1.3. 11/16/2000 vixer required. c Yes. r No. When "Yes" is selected, motor When "Yes" is selected, type of 'lorrepower. 2 mixer. Direct drive type. Refer to Specification 11247 Tank Nozzle Schedule Schedule required. c Schedule in speckation. No schedule (Carlsbad Water) Recycling Faclity) (1 -1 6-02) 13190 4- Std. Rev. 1.3. 11/16/2000 Section 131 90 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS Data Sheet (Carisbad Water) Recycling Facility) 13190 -1- (1-14-02) Std. Rev. 1.3, 11/16/2000 I (MFG Justin Tanks, I brshings, or Equal pank heating required. Yes. (i No. Minimum temperature to maintain. temperature. Minimum outdoor ambient air Tank insulation required. c Yes. r= No. Construction Exposed Metal. c A385 Galwnized steel, ASTM A153 and Titanium. C Hastelloy C. * Group 1 or 2. ASTM F594. Alloy Stainless steel, ASTM F593. Alloy Group lor 2. c Not acceptable. Protected Metal. (i ASTM A36 Carbon Steel with fiberglass reinforced coating. Other. When 'Other" is selected, alternate baterial. I I urnisher of anchor bolts. 1s Tank manufacturer. C Installing contractor. Anchor Bolts, Nuts and Washers. A305 Galwnized steel, ASTM A153 and c Titanium. I IC Hastelloy C. I fi Grwp 1 or 2. ASTM F594. Alloy Stainless steel, ASTM F593. Alloy Group 1 or 2. sembly bolts, nuts, and washers. Galwnized steel. ASTM A153 and c A385 Stainless steel, ASTM F593, Alloy Group 1 or 2. G Group 1 or 2, ASTM F594. Alloy (Carlsbad Water) Recycling Facility) (1-14-02) 13190 -2- Std. Rev. 1.3, 11/16/2000 C Viton. C BUM-N. (Gasket material. EPDM. material. Baffles required. Yes. No. C Other. When 'Other" is selected, alternate material. Accessories Tank Vent. C Mushroom type. I IC Gooseneck type. 1 C Connect to ent piping system. Hinged covers required. r- Yes. No. Air Diffusers required. Yes. e No. Air Bubbler required. r yes. No. Ladder required. Yes. C No. Handrail required. Yes. r NO. Sight Level Gauge. C Clear type. I Flag type. I C None. (Material for clear type. IC Clear PVC. C Borosilicate glass. C Clear PFA Teflon. Other. When "Other" is selected, alternate material. Waterial for magnetic flag type. C pvc. C CPVC. C Carbon steel. I Type 316 stainless steel. I I (r Carpenter 20-Cb3. I Other. bhen "Other" is selected. alternate I (Carlsbad Water) Recycling Facility) (1-14-02) 13190 -3- Std. Rev. 1.3, 11/16/2000 Mixer required. r Yes. No. When "Yes" is selected, motor horsepower. When "Yes" is selected, type of mixer. Tank Nonle Schedule Schedule required. (i Schedule in specification. C No schedule (Carlsbad Water) Recycling Facility) (1-14-02) 13190 4- Std. Rev. 1.3. 11/16/2000 Section 131 90 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS Data Sheet I I Senenl %ID drawing 0 rank designatic :hemica1 service. bodium Hypochlorite ~~~~~ ~~~~~~ Iescription bat. nits I Senenl kodium Hypochlorite Storage Tank %ID drawing reference. T-1100-1 rank designation number. PI-35 Sodium Hypochlorite :hemica1 service. iurntm of tanks. 0 yes Senera1 Equipment Requirements 1 equired. )peration & Maintenance Manuals 0 Yes equired. kign Conditions and equirements :hemical(s) concentration, percent 12.5 % )y weight. Aaximum specific gravtty. 1.2 Aaximum temperature. 100 F nstalled location. r Inside r No CNO 0 Outside -ank configuration. r Horizontal cylindrical 0 Vertical cylindrical 'ank bottom/ends for horizontal anks. r Flat r cone r Dished r False Bottom 'ank top. r Remowble Useable capactty. feet 17 Straight shell lengthlheight. feet 12 Tank diameter. gallons 13,500 (Carlsbad Water) 13190 (Recycling Faciltty) -1- (1 -1 8-02) Std. Rev. 1.3. 11/16/2000 Minimum temperature to maintain. Bla temperature. Minimum outdoor ambient air Tank insulation required. c Yes No I Construction Exposed metal. 1- Gallanized steel. ASTM A153 and A385 C Ttanium r Hastelloy C Stainless steel, ASTM F593. Alloy I; Group 1 or 2, ASTM F594. Alloy Gmup lor 2 r Not acceDtable I Protected metal. I; ASTM A36 Carbon Steel with fiberglass reinforced coating r Other hen "Other" is selected, alternate 1 baterial. pmisher of anchor bolts. 1s Tank manufacturer I nchor Bolts, nuts and washers. A385 Gallanized steel, ASTM A153 and I. )r Hastelloy C 6 Gmup 1 or 2. ASTM F594. Alloy Stainless steel, ASTM F593. Alloy Group 1 or 2 Assembly bob nuts. and washen. Gallanized steel, ASTM A153 and A385 Stainless steel, ASN F593. Alloy Group 1 or 2 I; Group 1 or 2. ASW F594. Alloy Gasket material. 6 EPDM r Viton r BUW-N r Other (Carlsbad Water) (Recycling Facility) (1-18-02) 13190 -2- Std. Rev. 1.3, 11/16/2000 hhen "Other" is selected, alternate material. ACCeSOries Tank vent. r Mushroom type r Gooseneck type C Connect tom piping system Hinged covers required. r Yes GNo Air diffusers required. r Yes No Air bubbler required. r Yes c No Ladder required. r yes I p No Handrail required. r Yes GNo Sight level gauge. c Flag type r Clear type r None Material for clear type. C Clear PVC r Borosilicate glass r Clear PFA Teflon r Other hNhen "Other" is selected. alternate I I material. Material for magnetic flag type. r pvc ~ ~~ 0 CPVC r Catton steel r Type 316 stainless steel C Carpanter 2Wb3 r Other When "Other" is selected, alternate material. Baffles required. r Yes c No Mixer required. (Carisbad Water) (Recycling Facility) (1 -1 8-02) 13190 -3- Std. Rev. 1.3, 11/16/2000 en "Yes" is selected, motor hen "Yes" is selected, type of mixer. Tank Nozzle Schedule Schedule required. Schedule in specification I I No schedule I I (Carlsbad Water) (Recycling Facility) (1-18-02) 13190 -4- Std. Rev. 1.3, 11/16/2000 Section 13190 FIBERGLASS REINFORCED PLASTIC CHEMICAL STORAGE TANKS PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing of tanks fabricated of fiberglass reinforced plastic and intended for aboveground bulk storage of chemical solutions as required. Piping, pipe supports, valves, and accessories which are not an integral part of the equipment or are not specified herein are covered in other sections. 1-1.01. Terminology. When the phrase "as required" is stated in this section it shall mean "as required in the Data Sheet". 1-2. GENERAL. Equipment furnished under this section shall be fabricated and assembled in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer unless exceptions are noted by ENGINEER. 1-2.01. Coordination. CONTRACTOR shall coordinate the work between the suppliers of equipment to be used with or connected to the storage tanks to ensure that all required provisions for mounting the accessories are included. Where two or more units of the same class of equipment are required, they shall be the product of a single manufacturer; however, all the component parts of the system need not be the products of one manufacturer. 1-2.02. General EauiDment Reauirements. When required, the General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.03. Govemina Standards. Except as modfed or supplemented herein, materials and construction methods shall conform with the applicable provisions of the following standards: "Standard Specification for Contact-Molded Reinforced Thermosettina Plastic (RTP) Laminates for Corrosion Resistant Equipment", ASTM C582. - "Standard Specification for Filament-Wound Glass-Fiber Reinforced Thermoset Resin Chemical-Resistant Tanks", ASTM D3299. (Carlsbad Water) (Recycling Facility) (1-18-02) 13190 -5- Std. Rev. 1.3, 11/16/2000 "Standard Specification for Contact-Molded Glass-Fiber Reinforced Thermoset Resin Chemical-Resistant Tanks, ASTM D4097". 1-2.04. NameDlates. Each tank shall be provided with a nameplate to identify the chemical stored. The nameplates shall be of white phenolic material with black engraved lettering 1 inch [25 mm] high, shall be of adequate size to accommodate the legend, and shall be mounted on the tank straight shell. The chemical designation and the tank number to be engraved on the nameplate shall be as required. 1-2.05. Certification Plates. A stainless steel certification plate shall be mounted below each storage tank's nameplate. The following data shall be included on the certification plate: Name of tank fabricator. Date of manufacture. Manufacturer's serial number. Maximum allowable concentration and temperature of the specified chemical solution that can be stored safely. Resin designation. 1-3. SUBMITTALS, 1-3.01. Drawinas and Data. Complete drawings, details, and specifications covering the storage tanks and accessories shall be submitted in accordance with the submittals section. The data shall include full information on basic materials and test data confirming the chemical resistance of the proposed resins to the intended tank contents. The data shall also indicate the sizes of all major tank components; size, spacing, and design loading of supporting saddles; anchor bolt locations and details; and full information and details concerning field assembly and installation. 1-3.02. Operation and Maintenance Data and Manuals. When required, operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals sections. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. (Carlsbad Water) (Recycling Facility) ( 1-1 8-02) 13190 -6- Std. Rev. 1.3, 11/16/2000 14. DELIVERY, STORAGE. AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. PART 2 - PRODUCTS 2-1. DESIGN CONDITIONS AND REQUIREMENTS. Each tank shall be designed for storage of the chemical or chemicals specified at the design conditions as required. Useable capacdy shall be measured from the invert of the tank ovemow nozzle to the top of the pump suction nozzle. When vertical tanks are required, the tanks shall be vertical cylinders with a bottom and top constructed as required. When horizontal tanks are required, the tanks shall be a horizontal cylinder with flat or dished heads and supported on saddles. Tanks shall be provided with a suitable ovemow connection. Tanks shall be vented and will normally be used to store the specified chemical at atmospheric pressure, but shall be designed to withstand the hydrostatic head resulting from the tank being surcharged to 6 inches [I50 mm] above the top of the tank. 2-1.01. Equipment Bases. Unless otherwise indicated or specified, all tanks will be installed on concrete bases at least 6 inches [150 mm] high. The tanks will be anchored to the concrete base with suitable anchor bolts. 2-2. ACCEPTABLE MANUFACTURERS. Acceptable manufacturers shall be as required. 2-3. MATERIALS. Resin Bisphenol-A polyester or vinyl ester resins suitable for use with the specified chemical as recommended by the resin manufacturer. Reinforcement Glass fiber with a suitable coupling agent. Surfacing Mat Burlington Formed Fabrics "Nexus Veil" or Nicrofibers "Surmat 100. Plastic Laminate In conformity with the applicable governing standards. Exposed Metal As required. Protected Metal As required. (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13190 -7- Std. Rev. 1.3, 11/16/2000 Assembly and Anchor As required. Bolts, Nuts and Washers 24. CONSTRUCTION. The tanks shall be of hand lay-up, spray-up, or filament- wound construction in accordance with the applicable governing standard. The finished laminate shall be constructed of a single generic type of thermoset resin and shall not contain colorants, dyes, fillers, or pigments unless otherwise specified. Ultraviolet absorber shall be added to the resin used in the fabrication of tanks indicated on the drawings or specified for installation in exposed exterior locations. The inner surface layer of sodium hypochlorite and the hydrofluosilicic acid tanks shall consist of a resin rich corrosion barrier with a minimum thickness of 120 mils [3 mm]. The surface of the corrosion barrier exposed directly to the corrosive chemical shall consist of a two-ply surfacing veil with a minimum thickness of 20 mils [0.5 mm]. The remainder of the corrosion barrier shall consist of two layers or more of chopped strand mat or equivalent. The inner surface layer of all other tanks shall consist of a resin rich corrosion barrier with a minimum thickness of 11 0 mils [2.75 mm]. The surface of the corrosion barrier exposed directly to the corrosive chemical shall consist of a singly-ply surfacing veil with a minimum thickness of 10 mils [250 pm]. The remainder of the corrosion barrier shall consist of two layers or more of chopped strand mat or equivalent. Sodium hypochlorite tanks shall be catalyzed with a benzoic peroxideldimethyl aniline (BPOIDMA) catalyst system, and shall undergo a 180'F [82"C] four hour dry oven post-cure after fabrication per the resin manufacturer's recommendation. Use of thixotropic resin additives will not be allowed. Alternative catalyst systems will be considered if written confirmation from the resin manufacturer verifying the effectiveness of the proposed system is provided. When required, exposed metal parts will not be acceptable for the tank. All metal parts for these tanks shall be coated with a fiberglass reinforced plastic coating. When a vertical tank with removable top is required, the tank shall be provided with an outward projecting stiffening flange for connection of the removable top. A suitable elastomeric gasket and assembly bolts shall be furnished for attachment of the top. When a vertical tank with a flat or closed top is required, the top of the tank shall be reinforced as specified in the applicable governing standard. Additional reinforcement shall be provided as necessary to support the required (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13190 -a- Std. Rev. 1.3, 11/16/2000 accessories and personnel loads. Domed tops shall be provided with a nonslip finish. Bracketed flat surfaces shall be provided on the tank for installation of nameplate and certification plate. The tank shall be provided with lifting lugs for handling and installation and with hold-down lugs for anchoring the tank to the concrete base. 2-5. ACCESSORIES. 2-5.01. Special Tools and Accessories. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-5.02. Access Manwavs. Access manways shall have an inside diameter of at least 22 inches [550 mm]. The number and location of access manways on the tank shall be as indicated in the schedule. Each manway shall be flanged, fully gasketed, and furnished with a fabricated blind flange having the same properties as the tank wall laminate. Flange diameter and drilling shall conform to ANSI B16.5, Class 150. Side access manways shall be centered approximately 3 feet [900 rnm] above the bottom of the tank. 2-5.03. Hinqed Covers. When required, the tank shall be provided with half of the top hinged for access to the interior. The inactive half shall be bolted to the tank shell. The active half shall be hinged from the inactive half, shall be provided with a lifting handle, and shall be suitably supported on the tank shell when closed. The hinge shall be fabricated of AIS1 Type 316 stainless steel or chemically-resistant plastic. For Tank T-1625, dimensions of the hinged access shall be - inches x - inches. 2-5.04. Flanqed Nozzles. Nozzles for connecting piping and accessories shall be provided on each tank at the locations and of the sizes as indicated on the nozzle schedule. Each nozzle shall be flanged, with flange diameter and drilling conforming to ANSI B16.5, Class 150. Nozzles shall extend at least 4 inches [lo0 mm] from outside face of tank to face of flange. Nozzles for drain connections shall be installed so the invert is flush with the bottom of the tank to allow complete draining of the tank. Flanged nozzles shall be fabricated of the same material as the tank and shall be gusseted to the tank or otherwise reinforced in accordance with the governing standard. (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13190 -9- Std. Rev. 1.3. 11/16/2000 2-5.05. m. When required, the tank shall be provided with a vent of the Size recommended by the manufacturer to prevent pressurizing the tank during filling or drawing a vacuum inside the tank during pumping or draining. The vent shall be mushroom or gooseneck type, or shall be connected to a vent piping system, as required. 2-5.06. Air Diffusers. When required, the tank shall be equipped with an air diffuser fabricated from PVC pipe for mixing the contents of the tank. The air piping installed within each tank shall be supported along the interior wall and at the bottom of the tank with supports constructed as an integral part of the tank. 2-5.07. Air Bubblers. When required, the tank shall be equipped with an air bubbler pipe for a liquid level indicating system specified elsewhere. The air bubbler pipe shall be of In inch [12.7 mm] PVC piping, run vertically from a flanged nozzle at the top of the tank to a support at the bottom of the tank. The air bubbler piping shall be adequately supported throughout its length with supports constructed as an integral part of the tank. 2-5.08. Ladders and Handrail. When required, the tank shall be provided with an exterior ladder. Tanks with a total height greater than 16 feet [4.877 m] shall be provided with a safety cage. The ladder shall be supported on and anchored to the concrete base and bracketed to the tank shell as needed. When required, safety handrails and kickplates meeting current OSHA requirements shall be provided around the top of each tank. The handrail shall be attached to the ladder siderails, and anchored to the tank head as needed. The ladder shall be fabricated of fiberglass reinforced plastic shapes, stainless steel, or carbon steel completely coated with at least 118 inch [3 mm] of reinforced resin after fabrication. Uncoated or exposed carbon steel parts or fasteners will not be acceptable. The ladder shall have a clear width of at least 16 inches [400 mm], with rungs at least 3/4 inch [I9 mm] in diameter and spaced not more than 12 inches [300 mm] apart, and a clearance of at least 7 inches [I75 mm] between the back of the ladder and the tank wall. 2-5.09. Siaht Level Gauae. When required, each tank shall be provided with a sight level gauge. The gauges shall be clear type or magnetic flag type, as required. 2-5.09.01. Maanetic Flaa TvDe Gauaes. When required, magnetic flag type level indicators shall be externally mounted and consist of a chemical resistant magnetic float, externally mounted float housing, magnetic flag indicator assembly and scale. The indicator housing shall fasten to openings in the side of the tank, with the float assembly the full height of the tank. Each indictor shall have a 2 inch [50 mm] plastic pipe housing and shall be oriented so that the scale is visible from the normal personnel working area. The float housing material shall be as required. The float assembly shall be provided with isolation valves with integral ball checks. The level indicators shall have two-colored (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13190 -1 0- Std. Rev. 1.3, 11/16/2000 magnetic flags that flip colors to indicate liquid level. The level indicators shall include a metal scale to provide a numerical readout of the liquid level in gallons. The level indictors shall be as specified and provided under the Instrumentation Section 13560. 2-5.09.02. Clear Tvpe Level Gauqe. When required, a chemical-resistant Valve and gauge tube assembly shall be mounted on the tank. The gauge tube shall be fabricated of 1 inch [25 mm] diameter clear PVC, borosilcate glass, or clear PFA Teflon, as required. Steel protection rods shall be provided the full length of the gauge. Valve assemblies shall be of chemical resistant material with integral ball checks to prevent flow in the event of gauge tube failure. A graduation strip shall be mounted adjacent to the sight level gauge. The strip shall run the full length of the level gauge and shall be graduated in 1 inch [25 mm] high black lettering over a range from zero gallons [liters] to the rated capacity of the tank. The gauge tube assembly shall be manufactured by Emst Gage Company, Jogler Inc. or equal. 2-5.10. Baffles. When required, the tank shall include three baffles, equally spaced around the inside circumference of the tank. The baffles shall be constructed of FRP pieces, 12 inches (300 mm] wide, with 4 inch [lo0 mm] spacing off the tank wall. The baffles shall be supported with a minimum of four gussets, or by the manufacturer's standard baffle support method. The top of the baffles shall be 6 inches [150 mm] below the invert of the overflow connection. The baffles shall run the length of the straight shell for conical or dished-bottom tanks, and shall terminate 12 inches I300 mm] above the tank bottom for flat bottom tanks. 2-5.1 1. mr. When required, the tank shall be provided with a mixer suitable for continuous operation. The mixer shall be driven by a 480 volt, 60 Hz. 3 phase TEFC chemical duty electric motor. Minimum motor horsepower [kw shall be as required. The rotating speed of the mixer shall not exceed 1,750 rpm. The mixer shall be located to provide thorough mixing. Each mixer shall be mounted on a support beam running across the top of the tank. Clampmounted mixers will not be accepted. The mixer shaft and impeller shall be fabricated of AIS1 Type 316 stainless steel. The motor starter and miscellaneous contactors shall be as specified in other sections. A solid-state reset timer having a range of 1 minute to 100 hours shall be supplied with the mixer to stop the mixer at the end of the set time period. The enclosure shall be mounted in the MCC, shall be epoxy coated, and shall include a heavy-duty, oiltight, "ON-OFF (Reset)-AUTOMATIC" selector switch and wiring to a terminal strip. The timer shall be Eagle Signal "DG200 Mini-Flex", or equal. 2-5.12. Saddles. Saddle type supports at the spacing recommended by the fabricator shall be provided with each horizontal tank. Saddles shall be fabricated of fiberglass reinforced plastic or of carbon steel, factory coated after (Carlsbad Water) (Recycling Facility) (1 -1 6-02) 13190 -11- Std. Rev. 1.3, 11/16/2000 fabrication with at least 118 inch [3 mm] of reinforced plastic. Supports may be laminated to the tank or provided separately for field installation. Saddles shall be sized and designed to adequately support the tank and its contents, shall include provisions for anchoring to concrete bases. and shall be acceptable to ENGINEER. 2-5.13. Anchor Bolts. Anchor bolts with associated nuts and washers shall be furnished as required for each item of equipment. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed. The bolts shall be at least 3/4 inch 119 mm] in diameter. Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-1/2 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 112 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. Anchor bolts shall be long enough to accommodate at least 1-112 inches 138 mm] of grout beneath the baseplate and to provide adequate anchorage into structural concrete. Anti-seize compound will be applied to the threads of all stainless steel bolts before assembly. 2-5.14. Platform. CIP tank T-1625 shall be furnished with a separate platform attached to the side of the tank in the location shown in the Tank Nozzle Schedule. The platform shall incorporate a swing-out section on the perimeter railing to permit loading of dry bag pallets on the platform. Minimum dimensions of the platform shall be 4-feet by 6-feet. Walkways and platforms shall be designed for a live load of 250 pounds on a 4-inch by 4-inch area. The completed installation shall comply with the applicable OSHA standards. 2-5.15. Immersion Heater. CIP tank T-1625 shall be shall be furnished with an immersion heater (M-1625-1). It shall be a 120 kW, 480 volts, 3-phase, flanged immersion type. The heater shall have a type E-3 moisture tighffexplosion resistant terminal enclosure, 18 lncoloy sheathed elements and an 8-inch ANSI Class 150 Type 316 stainless steel mounting flange. Protective wells shall be included for temperature control and overtemperature protection. Heaters shall be Chromalox, Catalog No. TMIS-18120HE3; or equal. One control panel shall be provided for the heater. The enclosure shall be NEMA 4X Type 316 stainless steel with a stainless steel 12-inch leg set. A door (Carlsbad Water) (Recycling Faciltty) (1 -1 8-02) 13190 -12- Std. Rev. 1.3. 11/16/2000 mounted disconnect shall be interlocked to prevent ingress while the disconnect is in the "ON" position. The control panel shall house the heating contactors, a single step temperature controller, an overtemperature controller and a 120-volt secondary control power transformer. A remote 120-volt, 5-amp dry contact will close for the heater to be "ON" and open to switch the heater "OFF." Panel mounted controls shall be rated NEMA 4 or better. This control panel shall be a Chromalox Model No. 4436-380-5-1-1 configured as above or equal. The heaters and panels shall meet the requirements for UL listing and shall have the UL stamp. 2-5.16. Bag Loading Hopper. CIP Tank T-1625 shall be furnished with a dry chemical bag loading hopper installed in the top (refer to the Tank Nozzle Schedule for location and dimensions of the opening). The bag loader shall be of all Type 316 stainless steel construction, Wallace and Tiernan Part No. U23751 or equal. PART 3 - EXECUTION 3-1. INSTALLATION. Equipment furnished under this section will be installed in accordance with Section 13199. End of Section (Carlsbad Water) (Recycling Facility) (1 -1 6-02) 13190 -13- Std. Rev. 1.3, 11/16/2000 PROJECT CARLSBAD WATER RECYCLING FACILITY EOUIPMENT NO. AND TITLE T-1625 RO CIP TANK CONTENTS: -. TANK DATA SHEET <,~ ~~ &&NG SOLUTION 1.986 GALLONS CAPACITY: DESIGN PRESSURE DESIGN TEMPERATURE ATMOSPHERIC MATERIAL 40 - llo'F FIBERGLASS PLATFORM BY MANUFACTURER 1. TANK SHALL BE SUPPLIED WITH AN INTERNAL SLOPED BOlTOM TO INSURE COMPLETE DRAINAGE. 1 2. INLET AND RETURN PIPES A. E, E. G. AN0 H SHALL BE PIPED 08" INTERNALLY TO RETURN SOLUTION TO AN ELEVATION OF 2"O" FROM THE TANK BOlTOM. DRILL A 1/2" DIA. HOLE AT THE PIPE HIGH POINT TO PREVENT SYPHONING. 3. DRAWING SHOWS NOZZLE HEIGHT ONLY. COORDINATE NOZZLE- LOCATION ARRANGEMENT. WITH MECHANICAL EOUIPMENT 4. PLATFORM AND LADDER NOT "I 1. SHOWN ON ELEVATION FOR CLARITY. - I w8" I I 1 r 8 MINIMIZE 8"O" ti 1 t TANK NOZZLE SCHEDULE EOUIPMENT NO. AND TITLE; FERRIC CHLORIDE BULK STORnGE (T-1190-1) CONTENTS: 40% FERRIC CHLORIOE CAPACITY: 4,000 GALLONS 8' OIAUETER (ll'-O* SHELL) DESIGN PRESSURE: ATMOSPHERIC DESIGN TEMPERATURE: 40"-100"F MATERIAL: FIEERGUISS REINFORCED PLASTIC NOZZLE SIZEITYPE DESCRIPTION 2' FLANGED OUTLET (SYPHON) 1' NPT VENT (NOTE 1) H I J ! ., c LADDER 0' 5 d PLAN ELEVATION NTS TANK NOZZLE SCHEDULE EWIPUENT NO. AND TITLE: UF BREAK TANK (T-0919) CONTENTS: MF EFFLUENT CAPACIN: 17,800 GALLONS 12' DIAMETER (15'-S' SHELL) DESIGN PRESSURE: ATUOSPHERIC DESIGN TEUPERATURE: 40" - 1OO'F MATERIAL: FIBERGLASS REINFORCED PLASTIC (W 43 ELEVATION NO SCALE I TANK DATA SHEET I I I TANK NOZZLE SCUEDUL E EOUIPNENT NO. AND TITLE: Ro FLUSH TANK (T- 1620) CONTENTS: RD PERNEATE CAPACITY: 4,515 GALLONS 8' DIAMETER (14'-0' SHELL) DESIGN PRESSURE: ATKSPHERIC DESIGN TEMPEMTURE: 40'-10O'F MATERIAL: FIBERGLASS REINFORCED PLASTIC NOZZLE OUTLET (SYPHW) 4' FLANGED A DESCRIPTION SIZEITYPE G I 2' FLANGED INLET 2" FLANGED J WAY 24" FLANGED I DRAIN 3' FLANGED H VENT ' PLAN .€LE VATION NTS TANK NOZZLE SCHEDULE EOUIPUENT NO. AND TITLE: SODIUM HYPOCHLORITE BULK STORAGE (T-1100-1) CWTENTS: 12.5% SODIUM HYPOCHLORITE ACITY: 13,500 G4LLONS 12' DIAUETER (17'-0' SHELL1 DESIGN PRESSURE: ATMOSPHERIC DESIGN TEMPERATURE: 40'-100'F MATERIAL: FIBERGLASS REINFORCED PLASTIC NOZZLE ~ SIZEI TYPE 2' FLANGED 1' NPT 2' FLANGED 2' FLANGED 2' FUWGED ~~_____ DESCRIPTION OUTLET (SYPHON) VENT (NOTE 1) OVERFLOW SIGHT GAUGE SIGHT WGE I I 12" FLANGED Wl BLIND FLANGE I J K 4' FLANGED INLET I I I I NOTES: 8 PLAN SECTION - NO SCALE TANK NOZZLE SCHEDULE EDUIFWENT No. AND TITLE: T- 1660.1 DECARBDNATDR CONTENTS: RD PERMEATE / TOWER PACKING AND ACCESSDRIES CAPACITY: 472 GPM DESIGN PRESSURE: ATUOSPnERIC DESIGN TEMPERATURE: 40'- 1DD'F MATERIAL: FIBERGLASS NOZZLE I SIZEITYPE I DESCRIPTION A I 6' FLANGED 1 INLET NOTE 1 BLOWER INLET F I 2" FLANGED lSiGHT GAUGE G 2' FLANGED SIGHT GAUGE H 24' FLANGED MAMYAY I I 24' FLANGED (WAY M 4" FLANGED DRAIN N 6' FLANGED OVERFLOW (NOTE 4) {DTES: 1. BLOWER INLET SIZE AND ELEVATION TO BE COORDINATED WITH THE BLOWER SUPPLIER. 2. ACCESS LADDER AND WALKWAY NOT SHOWN ON ELEVATION FOR CLARITY. 3. NOZZLE "E" IS INTERIOR TO THE VESSEL. 4. NOZZLE "N' SHALL BE PIPED INTERNALLY BOTTOM. DRILL A 11.2'0 HOLE AT THE TO AN ELEVATION OF 2'-0" FROM THE TANK PIPE HIGH POINT TO PREVENT SYPHDNING. PLAN ro EL EL VA TION Section 131 92 WELDED STEEL CHEMICAL STORAGE TANKS Data Sheet r Sodium Hydroxide (Carlsbad Water) (Recycling Facility) ( 1-1 8-02) 13192 -1- Std. Rev. 1.4, 11/17/2000 ((i No 'ank(s) heating required. r yes IG No I leater sue. kW linimum temperature to maintain. 'F ["CI linimum outdoor ambient 35 [1.7] 'F rc1 ?mperature. :onstruetion linimum wall thickness (not 3.25 16.351 'n. [mm] lcluding corrosion allowance). :orrosion allowance thickness. in. [mm] !tenor chemical resistant lining (i yes squired. iasket material. r EPDM No Vitm (FKP) Teflon C Other then "Other" is selected, alternate I I ,eceasories ank vent Mushroom type (i Connect to ent piping system adder@) required. r Yes :andrail required. Yes 15 No eve1 transmitter Ultrasonic Differential pressure transmitter Float c -0 ight level gauges. e Clear type (i Magnetic flag type (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13192 -2- Std. Rev. 1.4, 11/17/2000 haterial for clear type. C Clear PVC C Borosilicate glass c Clear PFA talon C Other material. When "Othel" is selected, alternate Material for magnetic flag type. C Pvc r CPVC C Carbon steel C Type 316 stainless steel r2 Carpenter 20Cb3 C MIA When "Other" is selected, alternate naterial. Furnisher of anchor bolts. 0 Tank manufacturer . ", . C Installing contractor Anchor bolts, nuts, and washers. Galwnized steel, ASTM A153 and r2 Type 316 stainless steel C Other When "Othet' is selected, indicate 'the alternative. lank Nozzle Schedule Schedule required. r2 Schedule in speciiication r NO schedule (Carlsbad Water) (Recycling Facility) ( 1-1 8-02) 13192 -3- Std. Rev. 1.4. 11/17/2000 Section 131 92 STEEL CHEMICAL STORAGE TANKS PART 1 - GENERAL 1-1. SCOPE. This section covers furnishing fabricated steel tanks for aboveground bulk storage of chemical solutions as required. Piping, pipe supports, valves, and accessories which are not an integral part of the equipment or are not specified herein are covered in other sections. 1-1.01. Terminoloqy. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-2. GENERAL. Equipment furnished under this section shall be fabricated and assembled in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer unless exceptions are noted by ENGINEER. 1-2.01. Coordination. CONTRACTOR shall coordinate the work between the suppliers of equipment to be used with 'or connected to the storage tanks to ensure that all necessary provisions for mounting the accessories are included. Where two or more units of the same class of equipment are required, they shall be the product of a single manufacturer; however, all the component parts of the system need not be the products of one manufacturer. 1-2.02. General EauiDment Reauirements. When required, the General Equipment Requirements shall apply to all equipment and materials provided under this section. 1-2.03. Nameplates. Each tank shall be provided with a nameplate to identd) the chemical stored and to identify the tank designation number. The nameplates shall be of white phenolic material with black engraved lettering 1 inch [25 mm] high, and shall be mounted on the tank straight shell. The chemical name and the tank designation number to be engraved on the nameplate shall be as required. 1-2.04. Certification Plate. A stainless steel certification plate shall be installed on the side of each storage tank. At least the following data shall be included on the certification plate. (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13192 4- Std. Rev. 1.4. 11/17/2000 Name of tank manufacturer. Date of manufacture. Manufacturer's serial number, Mechanical properties of the structure. Name of tank lining material, supplier, and applicator. Name of material stored 1-3. SUBMITTALS. 1-3.01. Drawinas and Data. Complete drawings and data covering the storage tanks and accessories shall be submitted in accordance with the submittals section. The data shall indicate the sizes of all major tank components, anchor bolt locations and details, and full information and details concsrning field assembly and installation. 1-3.02. OrJeration and Maintenance Data and Manuals. When required, operation and maintenance information shall be supplied. Operation and maintenance manuals shall be submitted in accordance with the submittals sections. The operation and maintenance manuals shall be in addition to any instructions or parts lists packed with or attached to the equipment when delivered. 14. QUALITY ASSURANCE, 1-4.01. Weldina Qualifications. All welding procedures and welding operators shall be qualified by an independent testing laboratory in accordance with the applicable provisions of AWS Standard Qualification Procedures. All procedure and operator qualifications shall be in written form and subject to ENGINEERS review. Accurate records of operator and procedure qualifications shall be maintained by CONTRACTOR and made available to ENGINEER upon request. 1-5. DELIVERY, STORAGE. AND HANDLING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. PART 2 - PRODUCTS (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13192 -5- Std. Rev. 1.4, 11/17/2000 2-1. DESIGN CONDITIONS AND REQUIREMENTS. 2-1.01. Tanks. Each tank shall be designed for storage of the chemical or chemicals specified at the design conditions as required. Useable capacity shall be measured from the invert of the tank Overflow nozzle to the top of the pump suction nozzle. When vertical tanks are required, the tanks shall be vertical cylinders with a bottom and top constructed as required. When horizontal tanks are required, the tanks shall be horizontal cylinders with flat or dished heads and supported on saddles. The wall thickness for each tank shall be determined by the tank manufacturer but shall not be less than the minimum wall thickness specified. Each tank not required to have a corrosion protection system shall include a corrosion allowance as required. Tank heads shall be seb-supporting, structurally reinforced to withstand a super-imposed load of 250 Ibs [1.1 kN] at any point and shall be additionally reinforced as necessary for the specified accessories. Any necessary supporting members shall be located on top of the head plate. Each tank shall be designed in accordance with the latest edition of Section VIII, Division 1, PART UW of the ASME Boiler and Pressure Vessel Code. Tanks will be supported on a concrete base. Tanks shall be provided with a suitable overflow connection. Each tank shall be vented and will normally be used to store the specified chemical at atmospheric pressure but shall be designed to withstand the hydrostatic head which would result with the tank and fill pipe surcharged with the stored chemical to 6 inches [150 mm] above the top of the tank. Tank nozzles and personnel manways shall be provided as indicated in the schedule. 2-1.02. EquiDment Bases. Unless otherwise indicated or specified, all equipment will be installed on concrete bases at least 6 inches [150 mm] high. The tanks will be anchored to the concrete base with suitable anchor bolts. 2-2. ACCEPTABLE MANUFACTURERS. Manufacturers shall be subject to acceptance by ENGINEER. 2-3. MATERIALS. Shell and plate ASTM A516, Grade 70, Nozzle and piping ASTM A53, Grade B, seamless. (Carlsbad Water) (Recycling Facility) (1-18-02) 13192 -6- Std. Rev. 1.4, 11/17/2000 Flanges Structural shapes Bolts and nuts Gaskets Electrodes Novolac Epoxy Lining Sulfuric acid Sodium hydroxide ASTM A516, Grade 70, flange quality. ASTM A36. Inside Tank -Alloy 20. Outside Tank - 316 Stainless Steel. 1/16 inch [1.5 mm] thick. ASME approved, of same composition as the base metal. KCC “EN 25.5” or PolySpec “NovoRez 353”. KCC “EN 25.5”. 24. CONSTRUCTION. 24.01. Welding. Each tank and appurtenances shall be fabricated from a minimum number of pieces, and vertical shell seams shall be staggered. Welding seams shall be located to clear all nozzle openings. All flange faces shall be true to the center line of the nozzles, and bolt holes shall straddle center lines unless noted elsewhere. All welding shall be done by the electric arc process. All welding shall be full and continuous, of uniform size and free from slag, porosity, undercuts, and other defects. All welds shall be fully penetrated. The manway flange shall be machined smooth for a gasket surface after welding. The entire interior of each tank shall present a smooth surface free of marked depressions, offsets, abrupt edges, or other protrusions. All welds shall be ground smooth. 24.02. Edae Grinding. Sharp comers of cut or sheared edges which will be submerged in operation shall be dulled by at least one pass of a power grinder to improve paint adherence. 24.03. Surface Preparation. When surfaces are specified to be lined, all steel surfaces shall be shop cleaned by sandblasting or equivalent, in strict conformance with the coating manufacturer’s recommendations. All mill scale, rust, and contaminants shall be removed before shop primer is applied. (Carlsbad Water) (Recycling Facility) (1-18-02) 13192 -7- Std. Rev. 1.4, 11/17/2000 When a lining is to be installed, the interior of the tank shall be cleaned to at least a SSPC SP-5 White Metal Clean. 24.04. ShoD Painting. When a lining is specified, all steel surfaces shall be protected by suitable coatings applied in the shop. Coatings shall be suitable for the environment where the equipment is installed. Exposed surfaces shall be finished, thoroughly cleaned, and filled as necessary to provide a smooth, uniform base for coating. 24.04.01. Exterior Surfaces. The exterior surfaces of each tank shall be shop painted with a suitable universal primer. The primer shall be not less than 4 mils [lo0 pm] dry film thickness (DFT). Field coating shall be as specified in the protective coatings section. 2-4.04.02. Interior Surfaces. When required, all interior surfaces of each tank shall be shop coated with a novolac epoxy corrosion resistant lining suitable for the chemical to be stored in the tank and the expected environmental conditions. The liner shall be a minimum of two coats at 15-20 mils [275-500 pm] DFT per coat for a total DFT of at least 35 mils [875 pm]. The liner material manufacturer shall approve the material used and the procedures to be used. Tank lining methodology shall be suitable to provide coating nozzle interior surfaces to the same lining thickness specified for the tank. The material manufacturer shall submit, in writing through CONTRACTOR, approval of the proposed material and the application procedures. The applicator shall be experienced in tank lining procedures. 2-5. ACCESSORIES. 2-5.01. SDecial Tools and Accessories. Equipment requiring special devices for lifting or handling shall be furnished complete with those devices. 2-5.02. Access Manway. Access manways shall have an inside diameter of at least 24 inches (600 mm]. The number and location of manways shall be as specified in the nozzle schedule. Manways shall be flanged, fully gasketed, and furnished with a 1 inch [25 mm] thick steel blind flange. Flange drilling and diameter shall conform to ANSI B16.5, Class 150. Side manways shall be centered approximately 3 feet 10.9 m] above the bottom of the tank. 2-5.03. Flanqed Nozzles. Nozzles for connecting piping and accessories shall be provided on each tank at the locations and of the sizes indicated on the nozzle schedule. Nozzles shall be flanged, with flange diameter and drilling conforming to ANSI B16.5, Class 150. Tank nozzles shall extend at least 4 inches [lo0 mm] from outside of face of tank to the face of the flange. Flanged nozzles shall be fabricated of the same material as the tank except for the pump suction connection on sulfuric acid tanks. Nozzles for the pump connection on (Carlsbad Water) (Recycling Facili) (1 -1 6-02) 13192 -0- Std. Rev. 1.4, 11/17/2000 sulfuric acid tanks shall be of Alloy 20 material and shall extend at least 3 inches [75 mm] inside the tank. Nozzles for drain connections shall be installed SO the invert is flush with the bottom of the tank to allow complete draining of the tank. The feed outlet line shall terminate 3-inches above the tank bottom inside of the tank. The filling line shall be flanged on the inside and outside of the tank. A flanged Alloy 20 pipe shall extend into the tank to a point 1 foot above the bottom. Four 3/8-inch diameter holes shall be drilled into the filling line just below the top of the tank flange to provide adequate venting for siphon prevention. 2-5.04. e. When required, the tank shall be provided with a vent of the size recommended by the manufacturer to prevent pressurizing the tank during filling or drawing a vacuum inside the tank during pumping or draining. The vent shall be a mushroom or gooseneck type, or shall be connected to a vent piping system, as required. 2-5.05. Tank Insulation. When required, the tank shall be provided with exterior insulation. The entire area of the sides and top of the tank shall be insulated with a minimum of 2 inches [50 mm] of insulation having a thermal resistivity of not less than R14. The tank shall have a reinforced fiberglass outer protective shell for protection of the insulation. The protective shell shall be constructed using a single generic type of thermoset resin throughout and shall not contain colorants, types, fillers, or pigments unless otherwise specified. Ultraviolet absorber shall be added to the resin used in the protective shell. 2-5.06 Tank Heater. The tank shall be electrically heated with an immersion type heater. The tank heater shall be supplied complete with heater, integral heater thermostats, and point level sensing device. The heater shall be sized and controlled to maintain the contents of the tank at the minimum tank temperature specified when the minimum outdoor ambient temperature is as indicated. The minimum heater size shall be as required and designed for 480 volt, three-phase power supply. Wetted parts shall be Type 304 stainless steel. Heater mounting connection shall be flanged. The heater shall be furnished with weather-tight electrical enclosure and integral 0 to 100°F [-I8 to 38"C] pilot duty thermostat. The tank heater shall also be provided complete with a level sensor for protection of the immersion heater. The level sensor shall be a capacitance-type point level sensor with integral electronics package. The point level sensor shall be powered by 120 volts ac and shall provide a contact output to shut off the tank heater when the level falls below the sensor elevation. The electronics package shall be weatherproof, suitable for mounting outdoors. The sensor shall be (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13192 -9- Std. Rev. 1.4, 11/17/2000 compatible with the sodium hydroxide and shall be of Sufficient length to accurately detect when the level falls below the sensor mounting elevation. 2-5.07. Ladders and Handrail. When required, the tank shall be provided with an exterior ladder. Tanks with a total height greater than 16 feet [4.9 m] shall be provided with a safety cage. The ladder shall be supported on and anchored to the concrete base and bracketed to the tank shell as needed. When required, safety handrails and kick plates meeting current OSHA requirements shall be provided around the top of each tank. The handrail shall be attached to the ladder side rails, and anchored to the tank head as indicated. The ladder shall have a clear width of at least 16 inches (400 mm], with rungs at least 3/4 inch [19 mm] in diameter and spaced not more than 12 inches (300 mm] apart, and a clearance of at least 7 inches (175 mm] between the back of the ladder and the tank wall. 2-5.08. Sight Level Gauges. When required, sight level gauges shall be provided. The gauges shall be clear type or magnetic flag type, as required. 2-5.08.01. Clear Type Level Gauge. When required, a chemical resistant valve and gauge tube assembly shall be mounted on the tank. The gauge tube shall be fabricated of 1 inch (25 mm] diameter clear Schedule 40 PVC, borosilicate glass, or clear PFA Teflon, as required. Steel protection rods shall be provided the full length of the gauge. Valve assemblies shall be of chemically resistant material with integral ball checks to prevent flow in the event of gauge tube failure. A graduation strip shall be mounted adjacent to the sight level gauge. The strip shall run the full length of the level gauge and shall be graduated in 1 inch (25 mm] high black lettering over a range from 0 gallons [liters] to the rated capacity of the tank. The gauge tube assembly shall be manufactured by Ernst Gage Company or Jogler Inc. 2-5.08.02. Magnetic Flag TvDe Level Gauae. When required, magnetic flag type level indicators shall be externally mounted and consist of a chemical resistant plastic coated magnetic float, externally mounted float housing, magnetic flag indicator assembly and scale. The indicator housing shall fasten to openings of the side of the tank, with the float assembly the full height of the tank. Each indicator shall have a 2 inch [50 mm] pipe housing and shall be oriented so that the scale is visible from the normal personnel working area. The float housing material shall be PVC, CPVC, carbon steel, AIS1 Type 316 stainless steel, or Carpenter 20-Cb3. as required. The float assembly shall be provided with isolation valves with integral ball checks. The level indicators shall have two- colored magnetic flags that flip colors to indicate liquid level. The level indicators shall include a plastic scale to provide a numerical readout of the liquid level in gallons [liters]. The level indicators shall be as specified and provided under the Instrumentation Section 13560. 2-5.09. Anchor Bolts and Expansion Anchors. Anchor bolts with nuts and washers shall be furnished for each item of equipment. The anchor bolts shall be (Carlsbad Water) (1 -1 8-02) (Recycling Facility) 13192 -1 0- Std. Rev. 1.4, 1 ll17/2000 at least 314 inch 119 mm] in diameter and shall be delivered together with templates or setting drawings. Anchor bolts shall be accurately located and centered in pipe sleeves having an inside diameter approximately 2-112 times the bolt diameter and a length approximately 8 times the bolt diameter. A square anchor plate with thickness of approximately 1/2 the bolt diameter and side dimensions 4 times the bolt diameter shall be welded to the bottom of each sleeve, with the anchor bolt extended through the plate and welded thereto. Two nuts and a washer shall be furnished with each anchor bolt. Anchor bolts shall be long enough to accommodate 1-1R inches [38 mm] of grout beneath the baseplate and to provide adequate anchorage into structural concrete. When expansion anchors are indicated on the drawings, only an acceptable expansion anchor shall be used. Alternative anchoring systems may be used only when acceptable to ENGINEER. Expansion anchors shall be installed in conformity with the manufacturer's recommendations for maximum holding power, but in no case shall the depth of the hole be less than six bolt diameters. The minimum distance between the center of any expansion anchor and an edge or exterior comer of concrete shall be at least six times the diameter of the bolt. Unless otherwise indicated on the drawings, the minimum distance between the centers of expansion anchors shall be at least 12 times the diameter of the bolt. Expansion anchors for concrete shall be Hilti "Kwik-Bolt II", ITW RamseURed Head "Thrubolt Wedge Anchor", or Rawlplug "Rawl-Stud Anchol". Nuts and washers for expansion anchors shall be as specified for anchor bolts. 2-5.10 Desiccant Drver. The sulfuric acid tank shall be furnished with a desiccant dryer ("1171) for installation on the tank vent line. The vent desiccant dryer shall have a maximum diameter of 16 inches and must be able to remove a minimum of 7.5 pounds of water before the desiccant resin is spent. The dryer shall be supported by a stainless steel framework mounted at grade or on the containment berm/wall to facilitate inspection and replacement of the desiccant. Vent piping to the dryer shall be Alloy 20 or PVDF pipe. The unit shall be provided with an observation port to permit visual determination of desiccant exhaustion. The vent dryer manufacturer shall supply 100 pounds of desiccant resin in an air-tight container suitable for long-term storage of the resin. The dryer shall be Model No. DB-12 as manufactured by Kemp Manufacturing Company or equal. 2-6. SHOP TESTING. When chemical resistant linings are required, the lining stiall be tested for holidays and pinholes using a low-voltage unit holiday detector approved by the lining manufacturer and acceptable to ENGINEER. Locations (Carlsbad Water) (Recycling Facility) (1 -1 8-02) 13192 -1 1- Std. Rev. 1.4, 11/17/2000 where holidays and pinholes are detected shall be marked for repair and retested after repair work has been completed. The manufacturer shall ceftii the lining is free of holidays and pinholes. PART 3 - EXECUTION 3-1. INSTALLATION. Equipment furnished under this section will be installed in accordance with Section 13199. End of Section (Carlsbad Water) (Recycling Facility) (1-18-02) 13192 -12- Std. Rev. 1.4. 11/17/2000 TANK NOZZLE SCHEDULE EOUIPMENT NO. AN0 TITLE: 1.1171 -1 SULFURIC ACID STORAGE TANK (TENTS: 93% SULFURIC ACIO (66' Be) CAPACITY: 3650 GALLONS DESIGN PRESSURE: ATLOSPHERIC DESIGN TEMPERATURE: 3S0-ll0'F MATERIAL: LINE0 STEEL I E I 2' FLANGEO ISIGHT GAUGE I 2' FLANGEO VENT 1 NOTES: ALL NOZZLES ON VERTIUL CENTER LINE. 1 ? -rF - i t Section 131 99 CHEMICAL STORAGE TANK INSTALLATION PART 1 - GENERAL 1-1. SCOPE. This section covers installation of tanks for aboveground bulk storage of chemical solutions. Tanks, piping, pipe supports, valves, and accessories which are not an integral part of the tanks are covered in other sections. 1-2. GENERAL. 1-2.01. Coordination. The tanks are to be installed in areas of limited access. The timing of installation for the tanks shall be coordinated with building construction and with construction under other contracts as needed. 1-3. DELIVERY, STORAGE, AND HANDLING. Handling and storage shall be in accordance with the handling and storage section. PART 2 - PRODUCTS Not applicable PART 3 - EXECUTION 3-1. INSPECTION. All equipment and accessories shall be inspected for damage and cleanliness before being installed. Any item damaged or contaminated in handling on the job shall not be used unless it has been repaired and re-cleaned to the original requirements by CONTRACTOR. Such items shall be segregated from clean or undamaged items and shall be inspected and approved by OWNER or his representative. before its use. 3-2. PREPARATION. The concrete base for each tank shall be constructed in accordance with the cast-in-place concrete section and shall be level and smooth to the tolerances recommended by the tank manufacturer. 3-3. INSTALLATION. When the tank containment area has a corrosion protection system specified, the protection system shall be applied and cured to the tank base before each tank is installed. Each tank shall be installed in accordance with the tank manufacturer’s recommendations, the applicable (Carlsbad Water) 13199 (1-11-02) (Recycling Facility) -1- Std. Rev. 1.0, 10/10/2000 governing standard, and to the satisfadion of ENGINEER. At any location where a containment corrosion protection system lining is penetrated including anchorage of a tank, a caulking material suitable for the specified service conditions and recommended by the protection system manufacturer shall used to seal around the penetration. Grouting under the tank, if recommended by the tank manufacturer, shall be accomplished with nonshrinking grout as specified in the equipment grout section. 34. FIELD QUALITY CONTROL. 34.01, Lininq Testing. When a corrosion resistant lining is specified, the liner shall be tested after installation for damage occurring during installation. The lining shall be tested for holidays and pinholes using a low-voltage unit holiday detector approved by the coating manufacturer and acceptable to ENGINEER. Locations where holidays and pinholes are detected shall be marked for repair and retested after repair work has been completed. CONTRACTOR shall certify the lining is free of holidays and pinholes. 34.02. Leakaae Testinq. Each tank, after installation of each tank and testing of any lining, shall be filled with water to the level required and allowed to stand for a period of not less than 48 hours. During testing, flanged connections may be plugged by installing temporary blind flanges on the outside of the tank, but shall not be blocked or plugged on the inside. All leaks or indication of leaks shall be repaired by the tank manufacturer and the tank re-tested to the satisfaction of ENGINEER. 3-5. CLEANING. When installation and testing have been completed and all connection have been made, all tank surfaces, both interior and exterior, shall be thoroughly cleaned as recommended by the tank manufacturer and to the satisfaction of ENGINEER. Abrasive cleaning agents shall not be used. End of Section (Carlsbad Water) (Recycling Facilik) (1-11-02) 13199 -2- Std. Rev. 1.0, 10/10/2000 Section 13500 PLANT CONTROL SYSTEM Data Sheet am- Data D&cription nPh General (PR 1-1 & 1-2) System designation r r Distributed control System (i Plant Control System r Other SupeMsoty Control and Data Acquisition (SCAM) System ~~~~ When "OM& is selected, indicate alternative. .1.02 F Computer system software (13520) F Computer system hardware (13510) System equipment r Distributed controi units (13532) r Remote terminal units (13531) Programmable logic controllers (13530) (13540) Multiple address radio equipment /p (13550) SoRware control block descriptions Requirements (13560) Instrumentation - General F Panel Mounted Instruments (13561) F Flow lnstments (13562) IF (13563) Pressure and Led Instruments F Analytical Instruments (13564) F Miscellaneous Instruments (13565) (13570) Panels, consoles. and appurtances IF (13580) Unintemptible power supply (Carlsbad Water) (Recycling Facility) 13500 -1- C Attached to this Data Sheet Furnished later r Three phase (TP) (Carlsbad Water) (Recycling Facility) 13500 -2- 2-5 e. When configuration by Owner, Engineer, or Configuration Contractor is selected: Number of hours for telephone assistance 2-5 f. When configuration by Owner. Engineer, or Configuration system at OWNERS or the Contractor is selected: Supply of ENGINEERS offices located at: Engineer, or Configuration Contractor is selected: Required delivery date 2-5 f. When configuration by Owner, Contractor is selected: Engineer, or Configuration Configuration peripherals to be supplied with the system CONTRACTOR selected, minimum number of custom graphic displays to be provided. 2-5.03 When configuration by CONTRACTOR is selected, reports to be provided. minimum number of separate daily Systems Check (PR 3-2) 2-5 f. When configuration by Owner, 2-5.02 When configuration by 3-2.01 Field manager required 3-2.02 Field inspection at delivery required Number of working days for field inspection at delivery installation and wiring procedures required Number of working days for Installation Contractor training 3-2.03 Training of Installation personnel in 3-2.04 Field inspection prior to start up Number of working days for field Number of working days for stari uy assistance . Printer ' Color wdeo copier . Field control deice No. Yes . No No. Yes 'No No. : CONTRACTORS Engineer Programmer 0 INo. (Carlsbad Water) (Recycling Facility) 13500 -3- CNO Required hours at Contractor facility No. Number of students at Contractor No. (Carlsbad Water) (Recycling Facility) 13500 4 (Carlsbad Water) (Recycling Facility) 13500 -5- Section 13500 PLANT CONTROL SYSTEM PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installation of a plant control system as designated and as required. The system shall be furnished as specified, complete with all software, human machine interface (HMI) hardware, input/output hardware, instrumentation, and all devices, accessories, appurtenances, testing, and training necessary for proper operation. 1-1.01. Terminoloqy. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-1.02. Associated Sections. This section also includes the equipment and services specified in the following sections and Data Sheets as required. Section 13510 Section 13520 Section 13530 Section 13550 Section 13560 Section 13561 Section 13562 Section 13563 Section 13564 Section 13565 Section 13570 Section 13580 (Carlsbad Water) (Recycling Facility) COMPUTER SYSTEM HARDWARE COMPUTER SYSTEM SOFTWARE PROGRAMMABLE LOGIC CONTROLLERS SOFTWARE CONTROL BLOCK DESCRIPTIONS INSTRUMENTATION -GENERAL REQUIREMENTS PANEL MOUNTED INSTRUMENTS FLOW INSTRUMENTS PRESSURE AND LEVEL INSTRUMENTS ANALYTICAL INSTRUMENTS MISCELLANEOUS INSTRUMENTS PANELS, CONSOLES, AND APPURTENANCES UNINTERRUPTIBLE POWER SUPPLY 13500 -6- 1-1.03. Coordination with Microfiltration Control System. The microfibation control system, consisting of Allen-Bradley programmable controllers and a PC workstation with RS-View32 software, will be provided and programmed by others. The control system furnished under this section of the specifications shall be interfaced with the microfiltration control system. Further details are described in Section 13550. The supplier of this section shall meet with the supplier of the microfiltration control system, at the Owner's facility or other mutually acceptable location, to coordinate the control system interface requirements. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, speciftcations, engineering data, instructions, and recommendations of the equipment manufacturer. unless exceptions are noted by ENGINEER. 1-2.02. General EauiDment Reauirements. As required, the General Equipment Requirements shall apply to all equipment provided under this section. The supplier shall have as a minimum 5 years in the design, coordination and supply of computer-based monitoring, control, and data acquisition systems. 1-2.03. Drawinas. The drawings indicate locations and arrangements of equipment and may include inpuffoutput lists and block and one-line diagrams showing connections and interfaces with other equipment. The inpuffoutput (I/O) lists are included as required. 1-2.04. Codes, Permits and Aaencv ADprovals. All work performed and all materials used shall be in accordance with the National Electrical Code, and with applicable local regulations and ordinances. Where mandated by codes, panels, assemblies, materials, and equipment shall be listed by Underwriters' Laboratories or other testing organizations acceptable to the governing authority. CONTRACTOR shall, as part of their work, arrange for and obtain all necessary permits, inspections, and approvals by the authorities having local jurisdiction of such work. This shall include any third-party inspections and testing of panels and equipment. 1-2.05. Coordination. Systems supplied under this section shall be designed and coordinated for proper operation with related equipment and materials furnished by other suppliers under other sections of these specifications, under other contracts, and, where applicable, with related existing equipment. All equipment shall be designed and installed in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the manufacturer, and the manufacturer of the related equipment. (Carlsbad Water) (Recycling Facility) 13500 -7- 1-2.06. Related Equipment and Materials. Related equipment and materials may include, but will not be limited to, instrumentation, motor controllers, valve actuators, chemical feeders, analytcal measuring devices, conduit, cable, and piping as described in other sections or furnished under other contracts. 1-2.07. Interface to the Future City of Carlsbad Water Operations Control Center. The plant control system shall be capable of being interfaced to a future Carlsbad Water Operations Control Center located a few miles from the treatment plant. The future communications link to the Control Center is planned to be a digital data grade leased telephone circuit, with a router to be located at the WRF plant to allow remote access to the file server computer. 1-2.08. Future Reclaimed Water Pumpina Station Control Interface. A reclaimed water pumping station will be provided by others. It is planned for this pumping station to have a PLC-based control system with a communication link to the City of Carlsbad Operations Control Center, for remote control. Under this contract, a fiber optic Ethernet circuit from the WRF plant control system shall be provided and reserved for possible future connection to the pumping station PLC. The WRF plant control system shall monitor the pump running status and water storage level from the pumping station PLC. 1-3. GENERAL REQUIREMENTS. The drawings and specifications indicate the extent and general arrangement of the systems. If any departures from the drawings or specifications are deemed necessary by CONTRACTOR, details of such departures and the reasons shall be submitted to ENGINEER for review with or before the first stage submittal. No departures shall be made without prior written acceptance. The specifications describe the minimum requirements for hardware and software. Where CONTRACTORS standard configuration includes additional items of equipment or software features not specifically described herein, such equipment or features shall be furnished as a part of the system and shall be warranted as specified herein. 1-3.01. Govemina Standards. Equipment furnished under this section shall be designed, constructed, and tested in accordance with IEEE 519. ANSI C37.90, FCC Part 15 - Class A, and NEMA ICs-1-109.60. 1-3.02. Dimensional Restrictions. Layout dimensions will vary between manufacturers and the layout area indicated on the drawings is based on typical values. The CONTRACTOR shall review the contract drawings, the manufacturer's layout drawings and installation requirements, and make any modifications requisite for proper installation subject to acceptance by (Carlsbad Water) (Recycling Facility) 13500 -8- ENGINEER. At least three feet of clear access space shall be provided in front of all components of the computer control system components. 1-3.03. WorkmanshiD and Materials. CONTRACTOR shall guarantee all equip- ment against faulty or inadequate design, improper assembly or erection, defective workmanship or materials, and leakage, breakage, or other failure. Materials shall be suitable for service conditions. All equipment shall be designed, fabricated, and assembled in accordance with recognized and acceptable engineering and shop practice. Individual parts shall be manufactured to standard sizes and thicknesses so that repair parts, furnished at any time, can be installed in the field. Like parts of duplicate units shall be interchangeable. Equipment shall not have been in service at any time prior to delivery, except for testing. 1-3.04. Abbreviations. Reference to standards and organizations in the Specifications shall be by the following abbreviated letter designations: ANSI American National Standards Institute ASTM American Society for Testing and Materials AWG American Wire Gage FCC Federal Communications Commission IEEE Institute of Electrical and Electronics Engineers ISA Instrument Society of America NEC National Electrical Code NEMA National Electrical Manufacturers Association UL Underwriters' Laboratories 14. SUBMITTALS. Complete dimensional, assembly, and installation drawings, wiring and schematic diagrams: and details, specifications, and data covering the materials used and the parts, devices and accessories forming a part of the system furnished, shall be submitted in accordance with the submittals section. Submittal data shall be grouped and submitted in three separate stages. The submittal for each stage shall be substantially complete. Individual drawings and data sheets submitted at random intervals will not be accepted for review. Equipment tag numbers or identifications used on the drawings shall be referenced where applicable. (Carlsbad Water) (Recycling Facility) 13500 -9- 14.01. First Staae Submittal. The first stage submittal shall include the following items. a. b. C. d. e. f. 9. h. I. A detailed list of any exceptions, functional differences, Or discrepancies between the system proposed by CONTRACTOR and this specification. Product catalog cut sheets on all hardware items, clearly marked to show the model number, optional features, and intended service of each device. A brief, concise description of the proposed system, including major hardware and software components, field services, and personnel training. A block diagram or schematic drawing showing the principal items of equipment furnished, including model numbers, and their interrelationships. Drawings showing floor space or desktop area requirements for all equipment items, including allowances for door swings and maintenance access. Environmental and power requirements, including heat release information for each equipment item. Standard system engineering and user manuals describing the use of the system and application programming techniques for creating reports, graphics, database, historical records, and adding new process 110 nodes to the system. Standard field termination drawings for all process inputloutput equipment, showing typical terminations for each type of point available in the system. A copy of the proposed software licenses for all software associated with the system. 14.02. Second Stase Submittal. Before any equipment is released for shipment to the jobsite and before factory testing is scheduled, the following data shall be submitted. At CONTRACTORS option, the first and second stage submittals may be combined. a. Detailed functional descriptions of all software modules specified and furnished as part of CONTRACTORS standard system. The descriptions shall be identified with the applicable specification (Carlsbad Water) (Recycling Facility) 13500 -1 0- paragraph. Complete panel fabrication drawings and details of panel wiring, piping, and painting. Panel and subpanel drawings shall include overall dimensions, metal thickness, door swing, mounting details. weight, and front of panel arrangement to show general appearance, with spacing and mounting height of instruments and control devices. Wiring and installation drawings for all interconnecting wiring between components of the system and between related equipment and the equipment furnished under this section. Wiring diagrams shall show complete circuits and indicate all connections. If panel terminal designations, interdevice connections, device features and options, or other features are modified during the fabrication or factory testing, revised drawings shall be submitted before shipment of the equipment to the jobsite. Review of drawings submitted prior to the final determination of related equipment shall not relieve CONTRACTOR from supplying systems in full compliance with the specific requirements of the related equipment. lnputloutput listings showing point names, numbers, and addresses. lnputloutput identification numbers from the contract documents shall be cross-referenced in this submittal. Proposed lesson plans or outlines for all training courses specified herein, including schedule, instructors' qualifications and experience, and recommended prerequisites. b. C. d. e. f. 14.03. Third Staae submittal. Complete system documentation, in the form of Operation and Maintenance Manuals, shall be submitted before the commence- ment of field acceptance testing. Operation and Maintenance Manuals shall include complete instruction books for each item of equipment furnished. Where instruction booklets cover more than one specific model or range of device, product data sheets shall be included which indicate the device model number and other special features. A complete set of "as-buitt" wiring, fabrication, and interconnection drawings shall be included with the manuals. If field-wiring modifications are made after these drawings are submitted. the affected drawings shall be revised and resubmitted. 1-5. PREPARATION FOR SHIPMENT. All electronic equipment and instruments shall be suitably packaged to facilitate handling and to protect against damage during transit and storage. All equipment shall be boxed, crated, or otherwise completely enclosed and protected during shipment, handling, and storage. All equipment shall be protected from exposure to the (Carlsbad Water) (Recycling Facility) 13500 -1 1- elements, shall be kept dry at all times, and shall not be exposed to adverse ambient conditions. Painted surfaces shall be protected against impact, abrasion, discoloration, and other damage. Painted surfaces that are damaged prior to acceptance of equipment shall be repainted to the satisfaction of ENGINEER. Each shipment shall include an appropriate shipping list that indicates the contents of the package, including the specific instrument tags. The shipping list shall be accessible without exposing the instruments to the atmosphere. The shipping list shall also contain any cautionary notes regarding storage of the instruments, including requirements to protect the instrument from static discharge, desensitizing chemicals (solvents, paints, etc.), or ambient atmospheric conditions. Individual instruments shall be appropriately tagged or labeled to positively identify the device. All identiftcation shall be visible without the need to unpack the instrument from its protective packaging. Instrument shipment and storage requirements shall be coordinated with ENGINEER or OWNER prior to shipment. CONTRACTOR shall provide adequate storage and be ready to accept the shipment before shipping any equipment to the Work Site. Additional shipping and storage requirements shall be as detailed in the individual instrument specifications. Components which are shipped loose due to transportation limitations shall be assembled and disassembled by the manufacturer prior to shipment to assure that all components ffi together and are adequately supported. 1-6. DELIVERY, STORAGE, AND SHIPPING. Shipping shall be in accordance with the shipping section. Handling and storage shall be in accordance with the handling and storage section. 1-7. SPARE PARTS. Spare parts and consumable items shall be provided as required. 1-7.01. Packaging. All spare parts shall be delivered to OWNER before final acceptance of the system. Packaging of spare parts shall provide protection against dust and moisture and shall be suitable for storage. Circuit boards and other electronic parts shall be enclosed in anti-static material. All packages shall be clearly marked with the manufacturer's name, part number or other identifi- cation, date of manufacture, and approximate shelf life. 1-7.02. Replacement. CONTRACTOR may utilize spare parts and supplies during system installation, de-bugging, startup, or training, but shall restore all (Carlsbad Water) (Recycling Facility) 13500 -12- PART 2 - PRODUCTS 2-1. GENERAL REQUIREMENTS. All equipment furnished under each attached section referenced in SCOPE is a part of this section and shall be selected by CONTRACTOR for its superior quality and intended performance. Equipment and materials used shall be subject to review. 2-1.01, Standard Products. The systems furnished shall be standard products. Where two or more units of the same type of equipment are supplied, they shall be the products of the same manufacturer; however, all components of the systems furnished hereunder need not be the products of one manufacturer unless specified herein. 2-2. PERFORMANCE AND DESIGN REQUIREMENTS. The design of the systems furnished hereunder shall utilize concepts, techniques and features that provide maximum reliability and ease of maintenance and repair. The systems shall include board-level devices such as light emitting diodes or other indicators to facilitate quick diagnosis and repair. Diagnostic software shall be furnished to facilitate system-level troubleshooting. Where redundant hardware is provided, the system shall be capable of performing all specified functions, without reconfiguring hardware or software, with only one device of each category in service. 2-2.01. Y2K Compliance. All hardware, software, and firmware, furnished as stand alone components, or as embedded portions of other systems, shall process information related to dates in a manner so that information for dates beyond December 31, 1999 does not cause false operation, require operator intervention, or otherwise impact the function of the device. 2-2.02. Factow Assembly. Equipment shall be shipped completely factory assembled, except where its physical size, arrangement, configuration, or shipping and handling limitations make the shipment of completely assembled units impracticable. 2-2.03. Expandability. The system shall be capable of expansion as required. 2-3. POWER SUPPLY. Unless othewise specified, power supply to all equipment will be 120 volts, 60 Hz, single phase, CONTRACTOR shall be responsible for distribution of power among enclosures, consoles, peripherals, and other components of the system from the power supply receptacles and (Carlsbad Water) (Recycling Facility) 13500 -1 3- junction boxes indicated on the drawings. Power distribution hardware shall include cables and branch circuit overcurrent protection installed in accordance with the electrical section. 2-3.01, Facilitv Distribution Svstem. Equipment not indicated to be powered from an uninterruptible power source shall be suitable for being supplied from the facility distribution system and shall be capable of withstanding voltage variations of +lo percent and harmonics up to the limits of IEEE 519 without affecting operation. CONTRACTOR shall provide voltage conditioning or filtering equipment if necessary to meet the requirements specified. 2-3.02. Power Supplies. Power supplies for voltages other than those listed above shall be an integral part of the equipment furnished. Internal power supplies shall be regulated, current limiting, and self-protected. 2-3.03. Surae Withstand. All equipment shall meet all surge withstand capability tests as defined in ANSI C37.90 without damage to the equipment. 2-3.04. Uninterruptible Power SUDDIY. As required, an uninterruptible power supply (UPS) shall be furnished hereunder to power the equipment indicated on the drawings or will be furnished under another section. CONTRACTOR shall be responsible for coordinating the size of the UPS unit with the equipment furnished hereunder, and shall advise ENGINEER if a unit of higher capacity is necessary. 2-4. SERVICE CONDITIONS AND ENVIRONMENTAL REQUIREMENTS. The equipment provided for the computer control system shall be suitable for the service conditions specified in the attached equipment sections. All equipment shall be designed and selected to operate without degradation in performance throughout the environmental extremes specified. Equipment shall be designed to prevent the generation of electromagnetic and radio frequency interference and shall be in compliance with FCC Rules and Regulations, Part 15, for Class A computing devices. 2-4.01. Ambient Temmrature. All system equipment located in air conditioned rooms shall be suitable for operation in ambient temperatures from 10°C to 35°C and a relative humidity of 10 to 80 percent, noncondensing. All equipment located in non air conditioned indoor areas shall be suitable for an ambient temperature range of 0°C to 50°C and a relative humidity of 10 to 95 percent, noncondensing. All equipment located outdoors shall be suitable for operation in an ambient temperature range of -15°C to 55°C and a relative humidity of 5 to 100 percent. Heaters and air conditioningkooling equipment shall be provided where essential to maintain equipment within its manufacturer-recommended operating ranges. (Carlsbad Water) (Recycling Facility) 13500 -14- 2-4.02. Deleterious Effects. All system equipment will be installed in areas without anti-static floor construction and without any provisions for control of particulates or corrosive gases other than ordinary office-type HVAC filtering. CONTRACTOR shall furnish any additional air cleaning equipment, anti-static chair pads, or other protective measures necessary for proper operation of the system. All input/output hardware shall meet or exceed, without false operation, all requirements of NEMA ICs-1-109.60, Electrical Noise Tests. 2-4.03. Noise Level. The equivalent "A" weighted sound level for any system equipment located in the control room, except printers, shall not exceed 35 dBA. The sound level for printers shall not exceed 65 dBA. Sound reduction enclosures shall be provided where necessary to comply with these limits. 2404. Liahtnina Protection. In addition to other environmental protection specified herein, the entire system shall be provided with lightning protection. Lightning protection measures shall include the following. 2404.01, Grounding. All major components of the system shall have a low resistance ground connection. Grounding system provisions indicated on the drawings shall be modified as recommended by CONTRACTOR. 2404.02. Surae Arresters. Surge and lightning arresters shall be non-fautting. non-interrupting. and shall protect against line-to-line and line-to-ground surges. Devices shall be solid-state metal oxide varistor (MOV) or silicon junction type, with a response time of less than 50 nanoseconds. Surge protective devices shall be applied for the following: a. All power connections to PLCs, instruments and control room equipment. Surge arresters shall be similar to Transtector "ACP-100 Series", Power Integrity Corporation "ZTA Series", or MCG Surge Protection "400 Series". b. All connections to coaxial-based networked equipment (including CCTV, CATV, ethernet, Arcnet, and satellite) where any part of the circuit is outside of the building envelope. Surge arresters shall be Telematic "VPOV, Transtector "TCP Series", Northern Technologies "TCS-CP3 Series", or their functional equivalent. c. All analog signal circuits where any part of the circuit is outside of the building envelope. Circuits shall be protected at both the transmitter and the control system end of the circuit. Surge protection devices shall not impede or interfere with the use of smart transmitter calibration/communication. Protection devices located near the (Carlsbad Water) (Recycling Facility) 13500 -1 5- transmitter shall be Telematic TP48." Protection devices in control panels shall be Transtector 'TSP Series", Telematic "Model 378", or Citel "BP1-24." d. All metallic pair (twisted and untwisted) conductor local area network and data highway termination points, where any part of the data highway cable is routed outside of the building envelope. Single-port protective devices shall be Phoenix Contact "TRABTECH C-UFBICN- UFB Series" or Telematic "NP Series." e. All serial, PLC data highway. and remote 110 network termination points where any part of the circuit is routed outside of the building envelope. Surge protection devices shall be Transtector "DLP Series" (EIA-232); Transtector 'FSP4000MC Series" (EIA-422); Phoenix Contact "TRABTECH D-UFB" (in-line) or "MT Series" (panel-mount); Citel "E280 Series"; or their functional equivalent. f. All radio antenna leads, if required. g. All telephone lines at points of connection to the system. Protection devices for dial-up circuits shall be Transtector "TSJ Series", Telebyte "Model 22PX", Citel "BP1-T", or equal. Protection devices for full period circuits shall be Transtector "LMP Series", Northern Technologies "DLP-S Series", or Circuit Components, Inc. "SPR-TM Series." 2-5. SYSTEM SOmARE CONFIGURATION. System software shall be configured by the CONTRACTOR. Configuration services shall consist of the creation of the system database, report formats, operator interface graphic and tabular display screen formats, password and secunty implementation, and programming of control units to provide a fully functioning system. The CONTRACTOR shall fully configure the system using data provided herein or supplied by the ENGINEER and/or the OWNER after award of the contract. The system that is delivered to the field for installation, checkout, and startup shall have all files, or databases, that are configurable in size, be sized in a manner in which there will be a 50% available space available for future work after the completion of this project. This sizing should include the addition of memory modules, disk drives, or any other device to insure the 50% spare space availability. All "tuning" of software that is dependant on space requirements shall be done prior to the completion of this project. Tuning of software programs shall be accomplished is such a manner that the program operates at its highest performance level. These programs include, but (Carlsbad Water) (Recycling Facility) 13500 -16- . are not limited to Microsoft SQL Server, all PLC ladder logic, and others 2-5.01. Control Svstem Database. The control system database shall be developed and configured by the CONTRACTOR. The CONTRACTOR shall enter information obtainable from the Contract Documents into the database prior to soliciting input from the ENGINEER and the OWNER. The CONTRACTOR shall determine the need for any "pseudo" database points and shall ascertain and enter all information needed to define these points. The CONTRACTOR is responsible for entering all information associated with each point. This includes but is not limited to, descriptions, engineering units, associated displays, areas, security, etc. All fields associated with each database point must be completely filled out accurately. 2-5.02 GraDhic Screen DisDlavs. The CONTRACTOR shall be responsible for developing and configuring the custom graphic displays. Each piece of major process equipment that is monitored by the control system shall be displayed on one or more graphic screen. Graphic screens shall be representations of the equipment and piping. The screens must accurately show all devices and equipment that is part of the control loops. These items must be done in accordance to the Configuration Standards and Conventions as described later in this section. The requirement for alarm and/or event displays shall also be provided and proven functional prior to acceptance of the system. A means of capturing and printing of all graphic screens shall also be included. The software program provided must be capable of printing the screen in a black and white (using gray scale) or color format. This program must be accessible from all terminals provided under this contract. The black and white printing shall be done in a manner in which the use of the black background is not represented in the printout. This is done to keep the. utilization of ink cartridge and toner cartridge to a minimum. The use of pictures taken by digital cameras will be considered as an alternative to custom developed equipment symbols when appropriate. All equipment pictures shall be animated to indicate the current state of the piece of equipment. The following screens shall minimally be provided. Main Overview of Plant Alarm Summary Event Summary Overview of each major process area (with vectoring to sub-areas) 0 Summary screen to vector to all video trends 2-5.03. Report Formats. Report formats shall be developed and programmed by the CONTRACTOR using tag names defined in the database creation. Reports shall be provided as summarized below and as listed on the data sheet. All reports will be provided with a header on each page to indicate the contents (Carlsbad Water) (Recycling Facility) 13500 -17- of each column of information. Each page shall be numbered and indicate the name of the report, the date the report was printed, and the time of the printout. The printout shall also include the time span of the information shown on the report. . . Daily Operating Report. A daily report, listing the major plant variables shall be provided. The report shall include hourly values and minimum/maximum/average values where appropriate. . Monthly Operating Report. A monthly operating report, which averages the values from the above daily reports, shall be provided. The report shall include monthly minimum/maximum/average values where appropriate. 2-5.04. Confiauration Standards and Conventions. A 'Software Configuration Standards and Conventions" document shall be prepared and submitted by the CONTRACTOR. The document shall be submitted for review and approval before software configuration commences. The document shall describe and define such items as proposed graphic display process line colorslrepresentations; color standards for *on", "off, "opened", "closed", and "alarm" conditions; alarm handling conventions; how items will be selected for control; methods for navigation between displays; address usagehaming conventions; and security setup. Before submitting the initial draft document, the CONTRACTOR shall meet with the ENGINEER andlor OWNER to review any of the Owner's existing standards and conventions. All copies of this submittal shall be provided in color to insure the accuracy of each item. No black and white copies will be accepted. The colors used in the printed submittal shall accurately depict the colors and shapes proposed for use on the final system. In addition to submitting the document for review, an updated version of the document shall be submitted as part of the O&M Manuals. The document shall be revised to document any additional standards that are established throughout the configuration process. 2-5.05. Confiauration Review Meetinas. Proposed graphic screens and report formats shall be reviewed with the OWNER and ENGINEER throughout the configuration process. The CONTRACTOR'S programming personnel shall attend the initial review meeting. A second review meeting, held at approximately 50 percent completion, but prior to the factory acceptance test, shall also be held. Both meetings shall be held at the OWNERS facilities. The CONTRACTORS programming personnel shall also meet with the supplier of the microfiltration control system as described under the scope paragraphs in this section. 2-506. Software Functional Reauirements. General functional requirements for system configuration are indicated on the drawings and described in the (Carlsbad Water) (Recycling Facility) 13500 -1 8- specifications. The information presented herein and indicated on the drawings illustrates the general functional intent of the system, and may not be sufficient to fully configure the system. The CONTRACTOR shall be responsible for determining what additional information may be required to complete the configuration tasks, and for obtaining this information from the ENGINEER or the OWNER. 2-6. SOFTWARE DOCUMENTATION. CONTRACTOR shall furnish complete documentation on all software supplied with the systems specified herein. Operating systems, compilers, assemblers, and utility and diagnostic programs that are standard commercial products of third parties need not be included in the magnetic media backup. Software documentation shall consist of the following principal items. a, b. C. d. e. f. One backup set of any integrated circuit or solid-state memory-based plug-in firmware used. Two complete back up copies of system and application software in executable format on magnetic media compatible with the system furnished. Three sets of user reference manuals for all standard system and application software. One set of user reference manuals for all operating system software. Three sets of printed as-buitt reference documentation for any special software provided specifically for this contract. For each licensed software product, all documentation provided by the product manufacturer shall be provided. This includes all reference manuals and any other documents that were provided by the manufacturer. There should be one set of this documentation for each and every piece of equipment provided. Multiple pieces of similar equipment or software require multiple copies of this documentation. 2-7. SOFTWARE LICENSE. All software programs supplied as a standard part of CONTRACTORS products for this project shall be licensed to OWNER for use on the system specified herein. Such license shall not restrict OWNER from using the software on the system provided hereunder or its replacement. OWNER shall have the right to make copies of the software for use on the system provided. Specific requirements of CONTRACTORS software license are subject to review and approval by OWNER and ENGINEER. 2-8. INSTALLATION TEST EQUIPMENT. All necessary testing equipment for calibration and checking of system components shall be provided by (Carlsbad Water) (Recycling Facility) 13500 -1 9- CONTRACTOR. CONTRACTOR shall also furnish calibration and maintenance records for all testing and calibration equipment used on the site if requested by ENGINEER. PART 3 - EXECUTION 3-1. INSTALLATION REQUIREMENTS. The installation of equipment furnished hereunder shall be the responsibility of CONTRACTOR or his subcontractors. 3-1.01. Field Wiring. Field wiring materials and installation shall be in accordance with the electrical section. 3-1.02. Instrument Installation. Additional requirements for mounting, piping, and calibration of field instruments are described in the instrumentation section. 3-2. SYSTEMS CHECK. As required, CONTRACTOR shall provide the services of a field manager and a trained and experienced field supervisor to assist the installation contractor during installation, and to calibrate, test, and advise others of the procedures for installation, adjustment, and operation. 3-2.01. Field Manager. As required, CONTRACTOR shall appoint a field services manager who shall be responsible for the coordination of all system check-out and startup activities, and who shall be immediately available to ENGINEER and OWNER by phone or on site for the duration of this project. 3-2.02. Field Inspection at Delivery. As required, the field supervisor shall inspect major equipment items within five working days of delivery, to assure that the equipment was not damaged during shipment and shall supervise or assist with unpacking, initial placement, and initial wiring of the system. 3-2.03. Trainina for Installation Personnel. As required, the field supervisor shall train the installation personnel in reading and understanding submittal drawings, and in the correct installation and wiring procedures for the equipment. 3-2.04. Field lnswxtion Prior to Start UD. After installation and wiring connections are complete, the field supervisor, with additional CONTRACTOR’S personnel for the number of days as required, shall venfy that each external connection to the system is correctly wired and field process components and devices are functioning as intended. 3-2.04.01. Analoq Sianals. Analog input signals shall be simulated at the transmitting source, and verified to be received at the proper register address in the control system. Analog outputs shall be generated at the control system, and (Carlsbad Water) (Recycling Facility) 13500 -20- verified to be received with the Correct polarity, at the respective receiving device. 3-2.04.02, Discrete Sisnals. Discrete input and output signals shall be simulated and verified that they are received at the respective receiving device, and at the proper voltage. 3-2.04.03. Devices by Other SuDpliers. If interrelated devices furnished by other suppliers or under other contracts, such as valve actuators, motor controls, chemical feeders, and instruments, do not perform properly at the time of system checkout, the field supervisor shall use suitable test equipment to introduce simulated signals to and/or measure signals from these devices to locate the sources of trouble or malfunction. 3-2.04.04. System Check Out ReDort. A written report on the results of such tests shall be submitted to ENGINEER. Additional documentation shall be furnished as requested by ENGINEER to establish responsibility for corrective measures. CONTRACTOR shall veq, in writing, to ENGINEER or OWNER that CONTRACTOR has successfully completed the external connection check before beginning system startup or field acceptance testing. 3-2.05. Start UD Assistance. After the field supervisor has completed the system check and submitted his report, CONTRACTOR shall supply a factory- trained engineer and a programmer to provide on site start up assistance for the number of days as required. During the startup period, these personnel shall thoroughly check all equipment, correct any deficiencies, and verify the proper operation of all components. 3-3. TESTING. The system shall be acceptance tested at the factory and on site. CONTRACTOR shall prepare a testing procedure to be approved by OWNER and ENGINEER that shall demonstrate that the system conforms to the specifications. The testing procedure shall be submitted at least 30 days in advance of testing. The testing shall be conducted by CONTRACTOR and witnessed by OWNER andlor ENGINEER. CONTRACTOR shall notify ENGINEER and OWNER in writing at least 14 days before the proposed testing date. If the factory acceptance test is concluded unsuccessfully, the test shall be repeated. CONTRACTOR shall reimburse OWNER and ENGINEER for all expenses incurred in connection with attending repeated factory or on-site testing necessitated by system failure or inadequate preparation. (Carlsbad Water) (Recycling Facility) 13500 -21- 3-3.01, Factory Acceptance Testing. After system assembly and debugging at CONTRACTORS facility, the system shall be tested before the System is shipped to the project site. As required, the factory test shall be conducted On the complete system, including all field 110 devices, communications equipment, and peripherals; or as required, using at least the minimum system consisting of computer hardware, software, printer, and one field 110 device. The entire system, including all peripherals and associated software, shall be factory tested under simulated operating conditions. Both normal operating sequences and fault conditions shall be simulated. The results shall be noted on the CRT displays and the logging printer for hard copy. The testing procedures for hardware and software are described below. All basic functions shall be demonstrated, including 110 processing, communications, alarm handling, HMI display functions, alarm logging, report generation, and historical data storage, as well as the specific functions listed herein. The system shall operate continuously for at least a 72 hours without faults. This operational test may run concurrently with the demonstration of hardware and software functions. The test procedure shall also include at a OWNER. least four-hour period for discretionary tests to be conducted by ENGINEER or 3-3.01.01. Hardware Test. Processors, processor modules, and peripheral devices associated with the system shall be assembled together as they will be installed in the field and shall be tested. The test shall demonstrate proper operation of each hardware device and communications among devices, and shall include verification of selected analog and discrete inputs and outputs. 3-3.01.02. Software Test. All system software modules specified herein shall be demonstrated. Software tests shall include running all diagnostics, debugging routines, and system test routines. The operating system, advanced process control language compiler, and all associated drivers shall be fully tested and operable for the system test. Software "patches" or changes to bypass failed or flawed modules during the test will not be acceptable. 3-3.02. Site Acceptance Testing. After installation and checkout by CONTRACTORS personnel, the system shall be subjected to an acceptance test. Site acceptance testing shall be scheduled after receipt of the System Check Out Report and CONTRACTOR shall verify that all field signal changes are reflected in the proper address locations in the system database. The site acceptance testing shall follow the same procedure as the factory testing and shall operate without loss of basic functions. The number of days of (Carlsbad Water) (Recycling Facility) 13500 -22- continuous operation for the test shall be as required. The operational demonstration shall confirm that the status, alarm, and process variable signals are valid and are being updated appropriately, and that the discrete and analog output signals from the control system are being correctly transmitted and implemented. Any errors or abnormal occurrences shall be recorded by CONTRACTORS field representative. CONTRACTORS field representative need not be continuously present during the site acceptance testing, but shall be available to respond to the site within one hour of notification. The representative shall inspect the system for faults at least once every 24 hours and shall log or record any noted problems. The log shall include a description of the problem, its apparent cause, and any corrective action taken. 3-3.02.01. Failure of Redundant EQuiDrnent. Failure of redundant equipment shall not be considered downtime provided that automatic failover occurs as specified and, in the opinion of ENGINEER, the failure was not caused by deficiency in design or installation. In the event of repeated failure of any hardware component or software module, the acceptance test shall be terminated and re-started. 3-3.02.02. ComDletion of Test. Successful completion of the site acceptance test, including the operational demonstration, is prerequisite to Substantial Completion as specified in the Supplementary Conditions. 34. TRAINING. CONTRACTOR shall conduct training courses for personnel selected by OWNER. Seven categories of training, instrument, control system maintenance, operator (pre-installation), operator (post-installation), programmer (HMI software), programmer (PLC software), and supplemental shall be provided as required. Training shall be conducted by experienced instructors who are familiar with the specific system supplied. 34.01. General Trainina Reauirements. In general, CONTRACTORS standard training courses may be used to meet the training objectives specified. Where standard courses do not meet these objectives, additional coursework shall be developed. Clock hour requirements for each level of training are listed below. A "clock hour" is defined as one hour of instruction or supervised training exercise. Minimum requirements listed for each training category shall be as required. Training hour requirements noted in the data sheet are the number of hours of training to be provided for each student. Additional training time shall be provided if considered necessary to meet the training objectives. 34.01.01. TraininQ Costs. All costs associated with the training program; excluding travel, lodging, and per diem expenses for OWNERS and ENGINEERS personnel to attend off-site training programs; shall be the responsibility of CONTRACTOR and shall be included in the contract price. (Carlsbad Water) (Recycling Facility) 13500 -23- 34.01.02. Lessons. Training lesson plans and other information for the second stage submittal as defined herein shall be submitted at least 30 days prior to the start of training. 34.01.03. Video Taping. Not used. 34.02. Instrument Training. Training on the calibration, maintenance, troubleshooting, and repair for the instrument devices provided under this project shall be provided. Training shall be conducted at the CONTRACTOR'S or OWNER'S facilities as required, Training shall also be provided for any hand- held or computer-based calibration devices and their associated software. 34.03. Control Svstem Maintenance Training. System maintenance training shall be provided to enable OWNERS personnel to perform routine and preventive maintenance, troubleshoot, and repair all hardware furnished with the system, except equipment provided by the HMI computer manufacturer. Maintenance and repair instruction shall assume that OWNERS personnel will repair equipment by replacing circuit boards and modules, and shall not include instruction on circuit board level repair. 34.03.01. Classes. All maintenance training shall be conducted at OWNERS facilities. Each training session shall consist of the number of hours and for the number of OWNERS personnel as required. 34.03.02. Content of Classes. The training shall cover at least the following topics: a. Preventive, scheduled maintenance for all equipment. b. Function and normal operation of circuit boards and modules. c. Diagnosis of hardware failures to the faulted board or module. d. Removal and replacement of removable circuit boards and modules. e. Emergency maintenance and restoration procedures. The maintenance-training program shall be developed for personnel who have experience in electronics maintenance and repair and a general knowledge of computer systems, but not necessarily any familiarity with the specific hardware furnished. 34.04. Operator Training. OWNER'S operators will utilize the system for day- to-day monitoring andlor control of the facilities. The training program shall provide operators with sufficient knowledge to move from screen to screen within the system, understand the contents of group and detailed point displays, react to and acknowledge alarms, adjust control setpoints and alarm limits, configure (Carlsbad Water) (Recycling Facility) 13500 -24- and print shift reports, print preconfigured reports on demand, control equipment connected to the system, and react to and resolve minor system errors. 34.04.01. Classes. Operator training may include both pre-installation and post-installation sessions as required. 34.04.01.01. Pre-installation Session. Not used. . 34.04.01.02. Post-installation Session. The post-installation training shall include two separate, but identical, sessions for two shifts of personnel and shall be conducted at OWNERS facilities. Each class shall consist of the number of hours as required of instruction using the same lesson plan as the pre- installation training. The post-installation sessions may have to be conducted outside normal working hours to accommodate the working schedule of OWNERS personnel. The post-installation training sessions shall be conducted for the number of OWNERS operating personnel as required. 34.04.02. Content of Classes. Each session shall cover at least the following topics. a. b. C. d. e. f. 9. h. 1. j. k. 1. Power-up, "bootstrapping", and shutdown of all hardware devices. Logging on and off the system and the use of passwords. Access and interpretation of standard displays and diagnostics. Use and care of operator workstations, servers, video displays, printers, and other control room hardware, including replenishment of supplies and replacement of ribbons and ink cartridges. Moving from screen to screen within the graphic display environment. Interpretation of preconfigured group and detailed point or database displays. Response to and acknowledgment of alarms. Adjustment of control set points and alarm limits. Configuration and printing of shift and other reports by schedule or on demand. Control of field equipment and devices connected to the system. Manual entries to database points. Generation of current (real-time) and historical custom and predefined (Carlsbad Water) (Recycling Facility) 13500 -25- reports and trend displays. m. Appropriate responses to software and hardware errors. n. Enabling and disabling individual inputs and outputs. The operator-training program shall be developed for personnel with no prior computer experience. 3-4.05. Proarammer Traininq (HMI Software). The programmer training shall be furnished as described in this section. System programming training shall be provided to enable OWNERS and ENGINEERS personnel to maintain and reconfigure the system. Programming tasks shall include addition or modification to the system database; modification or creation of graphic and tabular display and report formats; and creation and modification of historical archiving groups and data reduction algorithms. 3405.01. Classes. Programmer training shall be conducted in two sessions. The first session shall consist of the number of hours as required of instruction for the number of programmers as required and shall be conducted at OWNERS facilities. The second session shall consist of the number of hours as required of instruction for the number of programmers as required and shall be conducted at OWNER'S facillty. 3405.02. Content of Classes. Programmer training shall include, but shall not be limited to the following topics: a. Loading of any supplied software into the system. b. Use of basic operating system commands for file management, system startup, and creation and editing of batch files. c. Creation and editing of database. d. Configuration of printed report formats. e. Creation and editing of tabular and graphic HMI interface display screens. f. Diagnostic routines. g. Creation and modification of control algorithms. h. Addition of new 110 points and new RTUs, PLCs or DCUs to the system. I (Carlsbad Water) (Recycling Facility) 13500 -26- i. Historical record retrieval, data reduction, archiving, and disk housekeeping. j. System backup procedures and reloading from backup. Programmer training shall be designed for personnel who have a general familiarity with computer control system operation and high-level application programs, but not necessarily with the specific hardware or software furnished for this project. 34.05.03. Hardware and Software. Programmer training shall be conducted using equipment and software installed at the site. 34.06. Proqrammer Traininq (PLC Software). Programmer training shall be provided for the PLC software furnished. Programmer training shall minimally be provided on the following topics. a. File management and backup procedures. b. Documentation printing options. c. Entering I10 and database points d. Logic function programming. e. PID loop programming and tuning. f. Error recovery and interpretation of errors. g. Communication protocol set-up and diagnostics PLC software programmer training shall be conducted at OWNERS facility. The number of hours as required of instruction for the number of programmers as required shall be provided. 34.07. SuDdemental Training. Not used. End of Section (Carlsbad Water) (Recycling Facility) 13500 -27- Section 1351 0 COMPUTER SYSTEM HARDWARE Data Sheet - 0ra- raph - .2.01 lescription ieneral (PR 1-1 through 1-2) Data (i. yes. ieneral Equipment Requirements. r NO. ;@re parts. r 5,000 sheets of paper for alarms and 12 extra ribbons. one print head, and events printer. 3 toner kits and 3.000 sheets of paper for report printer. 25 floppy drie disks. r 1.000 sheets of paper for graphics 3 ink caltridges of each color and printer. lr Other. When "Othef' is selected indicate alternative. Number of spare CD-RW disks. Computer (PR 2-1 through PR 2- 30 1.03) Required. -1.01 C yes. Server and Historian Computer(s) r NO. Type of processor. (i. Pentium 111. r Pentium 111 )(eon. t Other. When "Othet" is selected indicate alternative, Units (Carlsbad Water) (Recycling Facility) 13510 -1- Processor speed. c 866 Mhz. 800 Mhz. 933 Mhz. k I Ghz. Other. When "Other is selected indicate alternative. Monitor type. C CRT. Flat Panel. Monitor size. c 15'. r lr. k 1Y. e 21". Memory size (RAM). c 512 MS. (i. 1 GB. Number of ethernet cards. k 2. r I. Enclosure style. 19 Rackmwnt. 0 Tower style. Manufacturer. F Dell. F Cornpaq. F Hewlett Packard. r Other. When "Other is selected indicate alternative. I- .01.01 k yes. Magnetic storage device required. c NO. .01.02 - .01.03 DLT tape required. .01.04 CD-RW drive required. - Removable hard drive required. c yes. (5 No. Cz Yes. r NO. Yes. r NO. (Carlsbad Water) (Recycling Facility) 13510 -2- communications port Ic yes. I 11.01.05(expander required. Ili. No. I 1 I !2- IModem required. I Ili. Yes. 11.01.061 2-1.02 Local Operator Interface li. Yes. Workstation Computer@) Required. Type of processor li. Pentium 111. r NO. r Pentiurn N. C Other. When "Othef is selected indicate alternative. Processor speed. 800 Mhz. t- 866 Mhz. r 933 Mhz. r 1 Ghz. r Other. alternative. When "Othef is selected indicate Monitor type. r CRT. li. Flat Panel. Monitor size. r lr. li. 15. r- 19. r 21". Memory size (RAM). li. 512 MB. C 1 GB. Manufacturer. F Dell. F -wq. F Hewlett Packard. F Other. When "Othef is selected indicate alternative Nernatron. Advantech, or equal 2- 1.02.01 rz yes. Magnetic storage device required. r NO. (Carlsbad Water) (Recycling Facility) 13510 -3- E02 Network routers required. I: :: ~ Field Services. Refer to specification section See Section 13500. indicated. (Carisbad Water) (Recycling Facility) 13510 -4- Section 13510 COMPUTER SYSTEM HARDWARE PART 1 - GENERAL 1-1. SCOPE. This section covers the furnishing and installation of standard computer hardware fully configured to work with the software specified in another section. Principal items of the computer and peripheral hardware to be furnished as specified or are indicated on the control system block diagram on the drawings. CONTRACTOR shall furnish all necessary interconnecting cables, accessories, and appurtenances as well as additional computer or peripheral hardware required for proper operation and to meet the functional requirements indicated on the drawings and specified herein. All equipment shall be capable of tolerating and "riding through" a power interruption of 8 milliseconds or less without interruption of normal operation. 1-1.01. Terminology. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-1.02. Control System. Section 13500 shall apply to all computer hardware furnished under this section. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by ENGINEER. 1-2.01. General Equiment Reauirements. When required, the General Equipment Requirements shall apply to all equipment provided under this section. 1-3. SUBMITTALS. Submittals shall be as required in Section 13500. 1-4. DELIVERY, STORAGE, AND SHIPPING. Delivery, storage and shipping shall be as required in Section 13500. (Carlsbad Water) (Recycling Facility) 13510 -5- 1-5. SPARE PARTS. Spare parts and consumable items shall be provided as required. All consumables and spares shall be supplied by the computer or printer manufacturer or by a vendor expressly recommended by the manufacturer. CONTRACTOR shall replace any consumables or spares that are spent during setup, testing, and commissioning of the system. PART 2 - PRODUCTS 2-1. SYSTEM COMPUTERS. CONTRACTOR shall ensure that all computers are configured to operate properly with all software, inpuffoutput devices, and peripherals supplied. 2-1.01. Server Comwters. When required each Server Computer and File Server/Historian Computer shall be comprised of the following configuration. This configuration is to be provided as a minimum: Two (2) 8 GB SCSl Wide Ultra 2/3 hard drives with integrated RAID controller Single CPU (with dual CPU capabilities) 32X CD-ROM Integrated VGA compatible video controller 256 kB Cache Six hot-pluggable hard drive bays Standard 3.5” 1.44 MB diskette drive Redundant power supplies One or two 10/100 Mbps RJ-45 connectivtty ethernet cards as required 19” rack mount or tower enclosure as required Mouse Standard Windows keyboard 2 Serial Ports standard (Carlsbad Water) (Recycling Facility) 13510 -6- 1 Parallel Ports standard Monitor as required 2-1.01.01. Maanetic Storaae Device. One 120 MB, 3.5 inch, or one 250 MB, lomega Zip fixed-mounted floppy drive shall be supplied and mounted in the computer enclosure as required. The floppy drives shall be manufactured by Imation, Panasonic, or equal. An internal IDE floppy drive controller shall be supplied to control the drive. 2-1.01.02. Removable Hard Drive. Not Used. 2-1.01.03. DLT TaDe. When required a DLT tape drive shall provide at least 20 GB of uncompressed data storage per single cartridge. The tape drive shall be supplied with spare tapes as required. The drive shall be HP Surestore, Quantum, Compaq or equal, 2-1.01.04. CD-RW Drive. When required a CD-RW (readhnrrite) drives shall be capable of Orange Book standard with a minimum of 8x read and 4x record. CD drive shall be manufactured by HP, Sony, Panasonic or equal. CD drives shall be supplied with spare disks as required. 2-1.01.05. Serial Communications Port ExDander. Not Used, 2-1.01.06. Modem. When required, an internal fax-modem, rated 33.6kBPS or 56kBPS, shall be supplied with the computer. The fax-modem shall support ITU- T V.17, V.29, V.27, ITU Group 111 standards for fax transmissions and ITU-T V.34, V.32bis, Bell 212 and 103 standards for data transmissions. A 56kBPS modem shall also support V.90 standards. The fax-modem shall be US Robotics or equal. 2-1.02. Local ODerator Interface Workstation ComDuters. When required each local Workstation Computer shall be comprised of the following configuration. The workstation computer for the EWPCF control room location shall be a desktop unit suitable for locating on an existing control room desk or console. The workstation computer for the Plant Supervisory PLC Panel location shall be an industrially hardened panel-mount style with all components rated at least NEMA 12. The following configuration is to be provided as a minimum: 6 GB hard drive Single CPU (Carlsbad Water) (Recycling Facility) 13510 -7- 512 MB RAM 256 kB Cache Standard 3.5" 1.44 MB diskette drive One 10/100 Mbps RJ-45 connectivtty ethernet cards as required Mouse, trackball, or touchscreen Standard Windows or equivalent keyboard 2 Serial Ports standard 1 Parallel Ports standard Monitor: 15 inch minimum, color TFVLCD XGA, 1024 X 768 resolution. 2-1.02.01. Maqnetic Storaae Device. One 120 MB, 3.5 inch, or one 250 MB, lomega Zip fixed-mounted floppy drive shall be supplied and mounted in the computer enclosure as required. The floppy drives shall be manufactured by Imation, Panasonic, or equal. An internal IDE floppy drive controller shall be supplied to control the drive. 2-1.02.02. CD-RW Drive. When required a CD-RW (readhnrrite) drives shall be capable of Orange Book standard with a minimum of 8x read and 4x record. CD drive shall be manufactured by HP, Sony, Panasonic or equal. CD drives shall be supplied with spare disks as required. 2-1.03. Notebook Computer. When required a notebook computer shall be provided. The notebook computer shall be configured as a minimum of a Pentium 111 processor with a 14.1" TFT display, 256Mb of RAM, one 10GB ElDE hard drive, 24X CD-ROM, video controller with 8 MB of memory, standard 3.5" 1.44 MB diskette drive, and ethernet card that supports 10/100 Mbps RJ-45 connectivity, integrated sound, and V.90/K56 modem. The notebook computer shall be provided with a lithium/metal-halide battery to provide a minimum of three hours of use. The notebook computer shall be a Dell Latitude, Hewlett Packard Omnibook, Toshiba Tecra, Compaq Armanda, or equal. 2-2. SYSTEM PRINTERS. When required, a dot matrix printer shall be supplied for logging system alarms and events, a laser printer shall be supplied for generating system reports, and a color graphics printer shall be supplied for producing color plots of process graphic screens, trends, and charts. (Carlsbad Water) (Recycling Facility) 13510 -0- 2-2.01. Alarms and Events Printers. Not 2-2.02. Report Printer. The report printer shall be laser type, capable of printing on letter or legal sized sheets of standard paper. The printer shall accept paper fed manually or from one of two paper trays, each with a minimum capacity of 200 sheets. The report printer shall print at least 10 pages of text per minute at a resolution of 1200 dpi or greater. The printer shall contain a minimum of 8 MB of on-board RAM, expandable to 40 MB. The report printer shall be a Hewlett Packard LaserJet 2100 series or equal. When required the color graphics printer must be provided with a lO/lOOBase-TX interface to provide connectivity to the computers over the ethernet network. The reports printer shall be supplied with at least three spare toner kits and 3,000 sheets of paper. 2-2.03. Color GraDhics Printer. Not 2-3. NETWORK HARDWARE. Network hardware shall be furnished when required. 2-3.01. Ethernet Switches. When required the ethernet switch shall provide isolation between the various segments of the network to minimize traffic and to prevent failure of one segment from disrupting the entire network. Each switch shall have UTP (Ethernet) ports with RJ45 connectors. Each switch connection shall automatically sense the network speed of the devices to which it is connected. Switches shall be Cisco "Catalyst Series", Hewlett Packard 'Procurve Switch" series, 3Com "Superstack 11" series, or equal. All necessary memory upgrades, software feature sets, and cables needed for proper operation of these switches shall be furnished with each switch. The switch shall have at least two spare (unused) ports available after all indicated network connections are made. 2-3.02. Network Routers. Not Used. 2-3.03. Hubs. Ethernet hubs shall be provided at PLC connection points to allow for local access to the network via a laptop programming terminal. At least one spare port shall be available in addition to the network programming port. PART 3 - EXECUTION (Carlsbad Water) (Recycling Facility) 13510 -9- 3-1. INSTALMTION REQUIREMENTS. Installation, fBld check, testing and training shall be as described in Section 13500. End of Section (Carlsbad Water) (Recycling Faciltty) 13510 -1 0- Section 13520 COMPUTER SYSTEM SOFTWARE Data Sheet MS Windows ME198. MS Windows 2000 Radio diagnostics. r Other. When "Other" is selected, indicate alternative Software 2-2.01 Process Control Application r Wonderware FactorySuite. r lntellution iFlX r USDATA Factory Link r lntec Paragon. RS View. r Or equal. R Without exception. r Other. When '"Other" is selected, indicate alternative. Dual networks for full LAN redundancy C Yes. G No. 2-2.02 Number of security levels required G T~~. r Other. nits (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -1 - 2- 2.10.07 Alarm Processing Software. C= Yes. r No. 2-2.12 Storage of user displays c 100 ll 200 300 r Other hhen "Other is selected. indicate I 1 alternative 2- Report formats in On-line report G Yes, 2.15.02 editor 2-2.16 Historical Data Storage. G Yes. r No. r No. package shall be Report Format spreadsheet r Lotus 1-24 r Excel. G Other. bhen "Other is selected, indicate brystal Reports alternative 2-2.17 Off-line storage software rz Required. C Not required. f Pdsions for adding in the Mure. 2- lnternetllntranet Connectivity (i- Yes. r No. 2.17.03 (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -2- F Mouse. r Trackball. r Touch Screen r Voice. F Other. computer alternative When "Other" is selected, indicate As required for local operator interface 2-3 Software documentation media F Electronic F Written networks Supports all NetBlOS compatible r Yes. Software Installation Full development software package C One. version. on server(s). 5000 point count Two, 6 No. r Other. alternative When "Other is selected, indicate Runtime software package on workstation(s) r TWO. r me. r Four. IC Other. bhen "Othef is selected, indicate hs specified herein I Jalternative (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -3- Section 13520 COMPUTER SYSTEM SOFTWARE PART 1 - GENERAL 1-1, SCOPE. This section covers computer software to be furnished and installed by CONTRACTOR on computer hardware specified in another section. CONTRACTOR shall furnish standard, field proven, fully debugged and supported software packages for this application with a minimum of additions or changes. Customized or specially written software shall be furnished only if required to meet all functional requirements specified herein. Software is described in functional categories. CONTRACTOR shall furnish a complete software package including the functional requirements specified, along with any additional software required for proper and efficient operation of the system. No attempt has been made to list all software or all characteristics of software required by CONTRACTOR to meet the functional requirements specified, nor to determine the location of the software modules within the system. The computer control software shall meet the design conditions and performance as required. 1-1.01. Control System. Section 13500 shall apply to all software furnished under this section. Additional software requirements are indicated in Section 13550. 1-2. GENERAL. Software packages shall control computer system level activities as well as higher level process control activities, allowing the process to be monitored and controlled through an interactive operator interface. 1-2.01. Interface. Users shall be able to interface to all process control activities through fully interactive software modules initiated and operated using easily recognized icons or custom symbols or driven by full-screen and pull-down menus. Selection of icons or menus shall be through pointing devices and shall not normally require the use of an alphanumeric keyboard. Systems that require the use of typed commands to move from module to module or from display to display are not acceptable. (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -4 - 1-2.02. Execution. Throughout the execution of all software modules, the operator shall be presented with all command or operation choices available at that point in the program to make the choices self-explanatory and unambiguous Question-and-answer or fill-in-the-blank requests are acceptable only where file names, tag names, or other unique text or numerical information is required. 1-2.03. Configuration. All programs shall be self-configuring to obtain the size and configuration of the system from parameters contained in the various files created during system generation. No parameters related to the hardware configuration shall be hard coded into any of the software. 1-2.04. Version. All programs shall be the latest version commercially available at the time the system is delivered to OWNER. Superseded versions, revisions, or releases are not be acceptable. 1-2.05. Y2K Compliance. All software shall be year 2000 compliant. 1-2.06. Terminolocly. When the phrase "as required is stated in this section it shall mean "as required in the attached Data Sheet". 1-2.07. General Eauipment Reauirements. Not Used. 1-2.08. Drawings. Supplementing this section, the drawings indicate locations and arrangement of computer enclosures and provide one-line and block diagrams regarding the connection and interaction with other equipment. 1-3. SUBMITTALS. In addition to the requirements of Section 13500, a complete description of the software packages and modules shall be submitted to verify compliance with this section. 1-4. DELlVERY AND SHIPPING. Delivery and shipping shall be as required in Section 13500. PART 2 - PRODUCTS 2-1, OPERATING SYSTEM SOFTWARE. Operating system software shall be as required and shall include a complete and unmodified operating system that provides system level functions. A Graphical User Interface (GUI) shall also be provided to enhance the usability of the operating system. 2-2. PROCESS CONTROL SYSTEM APPLICATION SOFTWARE. Process control software shall be as required and shall enable the operator to monitor and contrpl field devices connected to PLCs, RTUs, or other input/output hardware. The process control system application software shall meet the following (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -5- minimum requirements and shall exceed these requirements where necessary to comply with the functional requirements of the project. 2-2.01. Approved Software. The software shall be RS-View32, without exception, and shall include any drivers necessary to communicate with the PLCs and other system hardware as indicated on the drawings. Two SCADA server packages shall be provided and these shall operate as fully redundant automatic failover systems. At least one of the server packages shall have full software development and configuration capabilities. A runtime or view client version of the software shall be provided on the local operator interface computer and on the EWPCF operator workstation. These runtime or view-client stations may use the RSView 32 Active Display System to provide the workstation functions A license shall be issued for each machine loaded with process control software. 2-2.02. Password Protection. Operator access within the control system software shall be controllable through a password-based security scheme. Operators shall be assigned their own user account and password. A number of levels of security protection shall be provided as required. Each system display, database block, control action, and software module shall be assigned its own security levels and shall be inaccessible to users without proper security clearance. After initial creation, passwords shall be field alterable, but only by the assigned user or a system administrator. 2-2.03. Svstem Response. All responses to the operator shall be clear, unambiguous, and complete. Every operator menu, target selection, or request shall generate a response providing the range of choices for the next step in the process, or indicating that the request or chosen operation has been completed, is being processed, or cannot be performed. Every operator menu or target pick shall generate a graphic or text message response, even if it is a negative one. 2-2.04. Interactive Software Commands. The software's interactive command structures, user interface, menu organization, and procedures shall be consistent and predictable for all software modules throughout the system. Similar operations shall be performed in a similar manner, so that an operator will not need to learn different techniques for initiating the same operation in different software modules. 2-2.05. Operator Commands. The software shall accept each operator command or selection, decode it, and check its validity and correctness in the sequence of data and operations previously presented. Invalid or incorrect commands or menu selections shall not be processed; instead, a message shall be generated which explains why the command or menu selection is invalid. When a command or selection is canceled prior to being fully processed, the (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -6 - software shall clear all pending sequences and shall not initiate any system control commands. 2-2.06. Database. The software shall include a comprehensive interactive database system for creating, sorting, editing, and monitoring all process inputs and outputs and internally used variables and control blocks. The system shall request, receive, process, and store all real-time data according to the information contained in the database. Database points shall be enabled or disabled individually at any time by an operator working at the proper security level. When required, all internal database point information shall be accessible to other external database software applications through an SQL-compliant interface. 2-2.07. Interactive Database Editor. An interactive database editor software module shall be provided for creation, inspection, and modification of database entries. Modification, addition, or deletion of database information shall not require direct changes to the program source code. Changes made in the database contents or formatting shall automatically update all locations at which the information is stored or used. 2-2.08. Custom Alqorithms. The software shall enable the users to create their own custom algorithms or command sequences through accessing database points, internal pseudo-point variables, math and logic comparisons, and standard system functions. Each algorithm and command sequence shall run independently and shall be configurable to be executed on demand, based upon an event or condition, on a timed-interval, or at a set time of day. 2-2.09. Proqrammins Lanquase. A programming-type language or environment shall be considered acceptable f it is integrated into the base control system software product; if any compilers, linkers, and other necessary software modules are either included with the base software or supplied and configured by CONTRACTOR; if technical support is provided directly by the control software vendor: and if all control system database points and variables are accessible to the programmer. 2-2.10. Alarm Processing. Alarm processing software shall be provided to recognize and report alarms to the operator in an organized, unambiguous, clear, and convenient manner. Alarms shall be classified into at least five priority levels and at least two independent classes. System events shall be considered alarms classified by their own specific priority or class. 2-2.10.01. Alarms. Alarm processing software shall generate alarms for at least the following conditions. (Carlsbad Water) (Recycling Facility) (1 -16-02) 13520 -7- Discrete input or output change of state if defined as an alarm in the database. Analog value exceeding the alarm limits defined in the database Analog rate of change exceeding the limits defined in the database Failure of any process inputloutput hardware, communications link, or other major hardware component. 2-2.10.02. Acknowledament. Alarms shall be generated as they occur and shall not be cleared until they have been acknowledged and conditions have returned to normal. 2-2.10.03. Alarm Summarv Display. An alarm summary display shall be provided which lists at least 100 of the most recent alarms in all classes, with the most recent alarm listed first. Alarms shall appear flashing or in a unique color until they are acknowledged by the operator. Alarms of different priorities shall be easily distinguished on all alarm displays through the use of unique colors or similar methods. 2-2.10.04. Alarm Loqqinq. Alarm logs shall constitute a hard-copy record of all alarms, events, and significant operator actions. Alarm displays and alarm log entries shall include the date and time that the alarm was detected, the tag name and description of the alarmed point, and an entry describing the nature of the alarm. Alarms shall be logged on an alarm and event printer as they occur. 2-2.10.05. Responses to Alarms. An audible alarm shall sound at the operator's console at each occurrence of a new alarm event. The audible alarm shall be silenced when it is acknowledged by the operator. The audible alarm shall use an external sound system, such as a sound card and external speakers. 2-2.10.06. Alarm Enabling. Alarms originating from database entries such as discrete change of state or analog limit violations shall be enabled or disabled on a point-by-point basis. 2-2.10.07. Alarm Processing Software. An external alarm processing software package shall be provided to generate alarms for a paging system. Two licensed copies of the software shall be provided. The software shall be Win91 1 or SCADAlarm, or equal, 2-2.11. Operator Interface. System software shall be suitable for creation and modification of alphanumeric and graphic displays and linking of dynamic fields to database variables. (Carlsbad Water) (Recycling Facility) ( 1-1 6-02) 13520 -a- 2-2.12. System Storaqe. The system shall be capable of storing and utilizing full-screen user displays and pop-up windows. as required, each containing any number of the following components. Static and dynamic alphanumeric information. Static and dynamic or object-based graphics. Dynamic bar graph displays. Dynamic analog real-time and historical trends displays. Static and dynamic bitmap (Windows .BMP compatible) graphics. 2-2.13. Component and Confitauration Information. The software shall enable the user to reuse components and configuration information from any screen or pop-up window with or without modification. All configuration information shall be displayed in any of 256 colors, flashing or non-flashing. Dynamic fields shall change color or from flashing to non-flashing and back in response to a change in value, state, or alarm condition of the linked variable. Dynamic objects linked to process inputs and outputs shall be capable of displaying at least three equipment states, such as on/off/alarm for pumps, or openlcloselinterrnediate for valves. 2-2.14. Communications. System software shall support communications among computers and PLCs as indicated on the drawings and as specified herein. CONTRACTOR shall be responsible for any device driver development required to support the communications indicated. 2-2.14.01. Data Retrieval and Transmission. The software shall retrieve and send data from and to all remote field devices indicated on the drawings. The software shall perform all required error checking to ensure the validity of all data transactions and proper completion of the scan sequence. All communication system malfunctions, including "no response", shall be reported to the system as alarms. Re-transmission shall be utilized to correct or overcome communication errors. 2-2.14.02. Communications Driver. The software shall be supplied with communications drivers capable of communicating with any existing remote field devices indicated on the drawings as well as all software input/output drivers required to communicate with all field devices and system hardware that are furnished as part of the control system. 2-2.15. ReDorts. Report logs shall constitute a hard-copy summary of user- selected process data. At least 30 report formats shall be available in the (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -9- system. Reporting software shall be Crystal Reports. Report printing Software shall include a user-interactive, on-ltne report editor to allow the operator to select the following parameters for each report. Data consisting of measured variables, calculated variables, and manually entered data. Starting and ending time of data to be included in the report Print format for each variable Titles and subtitles to appear on each page of the report, including report name, current time, and date. Print pitch (from 5 to 16.5 characters per inch), Number of columns on each page Number of lines per page and number of pages per report. 2-2.15.01. Database Points. All database points in the system, including all inputloutput points, manually entered points, and calculated points, shall be available for use in reports. Reports shall include sample, average, minimum, and maximum values for analog variables and the time of occurrence for minimum and maximum values. Information printable for discrete variables shall include running time, state, and transition count. 2-2.15.02. Report Formats. Report logs shall constitute a file or a hard-copy summary of user-selected process data. All historical data for points in the history database shall be available for reporting from an SQL and ODBC compliant database. Reporting software shall have the following features. Creation and modification of report formats or content shall not require direct modification of system source code. Reports shall have the ability to be created in third party software packages. All database points in the system, including all inputloutput points, manually entered points, and calculated points, shall be available for use in reports. Reports shall have the ability to include actual value, average, minimum, and maximum values for analog variables and the time of occurrence for minimum and maximum values. Information printable for discrete variables shall include running time, state, and transition count. 2-2.16. Historical Data Storaqe. The software shall include modulesfor historical data gathering, data reduction, and reporting. Real-time analog signal values shall be collected and stored in the historical database based on a user (Carlsbad Water) (Recycling Facility) ( 1-1 6-02) 13520 - 10 - defined time interval of 1 second to 1 day, or on a change of state deadband configured for each database point. The historian shall support the following features. The historical database shall be a real-time relational database. The database shall be an extension of Microsoft SQL Server. The historical database shall acquire point information from the graphical user database Access to data shall be by any SQL or ODBC compliant software package, such as Crystal Reports, Oracle database applications, Microsoft Excel, or Microsoft Access. Database shall allow the use of a separate I10 server for data from the programmable logic controller system. 2-2.16.01. Data Reduction Capabilities. Data reduction capabilities shall be provided to average and reduce data to hourly records, and the hourly records to daily records. Entries for all hourly and daily averaged records shall include sample, average, minimum and maximum values as defined by OWNER. Both hourly and daily averages for each day shall be stored in the historical database. 2-2.16.02. Retrieval Software. Data retrieval software shall be provided to allow access to historical data files for the following uses: Tools shall be provided for remote trending and display of the data on all user workstations. Trend displays shall allow up to eight tags to be graphed in the window. Graphs shall allow stacking or separate display of each tag. Displays shall allow save functions for retrieval from the computer hard drive. Trends shall display real-time data, or display data from the history files. The trend display shall show the time frame of stored data. Import/export of data fromfio ASCII files. Inclusion in user-generated reports. Tools for Microsoft Excel display of data shall be included, Tools shall allow the retrieval and display of real-time data, or historical data. 2-2.17. Off-line Storaqe. The software shall include provisions for copying to backup media any or all of the historical data currently stored on the hard drive. The software shall support archival of data to tape and to any other backup devices specified in the system hardware section. Archival of data shall be intuitive and the archival software shall guide an operator through the backup process. (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 - 11 - 2-2.17.01. BackuP Data. Once historical data is copied to back-up media, the software shall allow the operator to delete it without negative consequences to free space on the hard drive. Archived historical data shall be re-loadable and usable in all the same ways as historical data that has not been removed from the local hard drive. 2-2.17.02. Loaical Disk Drive. If the backup device is on-line and addressable by a logical disk drive letter (e.g., an optical disk drive defined as ”D:”), historical data archived to that device shall be accessible directly without restoration to a local hard drive. 2-2.17.03. Internevlntranet ConnectiviW. When required, the software shall include provisions for making connections to the process data through the existing corporate lntranet or through a connection made on the Internet. This ”thin client” solution shall provide authorized users access to all displays and process information by utilizing any standard Internet browser. The application software shall include software for development for web browser based interface. Features shall include the following: The software shall allow access to the real-time process operations through any web browser without special software on the computer. The software shall provide security to prevent unauthorized use. The software shall allow the user to view alarms through the browser. The software shall allow the user to view historical data through the browser. 2-3. SOFTWARE DOCUMENTATION. CONTRACTOR shall relinquish all documentation supplied with the software furnished, such as user manuals. programmer guides, reference cards or keyboard templates, and related materials. In addition, CONTRACTOR shall generate and submit to OWNER and ENGINEER written documentation of any configuration work, modifications of the system, or setup of software done before or after installation of equipment on the site. Documentation shall be electronic or written as required. This includes any and all information on the development of any “wizards” or “scripts” created for the use in this project. 2-4. PLC SOFTWARE. The requirements for PLC software are specified in Section 13530. 2-5. EXTENDED SUPPORT OR WARRANTY. The process control system software shall include the extended or comprehensive support service of the manufacturer. The service shall include all software updates and phone and (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 -12- personal support when needed. The service shall be for a period Of one year after final acceptance and shall cover all software packages supplied under this contract. 2-6. TRAINING SERVICES. Training requirements are specified in Section 13500. PART 3 - EXECUTION 3-1. INSTALLATION REQUIREMENTS. The CONTRACTOR shall install the process control software on the control system hardware specified in another section. 3-1.01, Conflauration. CONTRACTOR shall install and properly configure any supplemental programs, modules, and software packages necessaty to meet the functional requirements of the project as described in Section 13500 and 13550. 3-1.02. Quantity. The CONTRACTOR shall install a full development software package on each control system server and runtime software packages, one on each of the operator workstations as required. End of Section (Carlsbad Water) (Recycling Facility) (1-16-02) 13520 - 13 - Section 13530 PROGRAMMABLE LOGIC CONTROLLERS Data Sheet 'ara- IDescription IData /Units 1 lmph General (PR 1-1 thru 1-5) Tag Numbers Drawing Numbers Plant Supervisory PLC PLC designations No. 1 Quantity of PLCs required PLC-2; -2.01 G Yes General Equipment Requirements lrequired IC No -5 used in the PLCs processor modules of each type 1 Spare parts. Number of spare -5 Number of spare power supply 1 modules of each tvpe used in the No. No. _. IPLCS -5 INumber of spare 110 cards of each h /No. type used in'the PLCs -5 Number of spare communications modules used in the PLCs Service Conditions Location r Air conditioned TOM No. IR Non air conditioned room I r outdoors Outdoor location ambient temperature range -15to55C r Sun shades Required environmental controls "F ['C] Ir Air conditioned enclosures I I /R Heated enclosure I (Carlsbad Water) (Recycling Facility) 13530 -1- -1.05 Manufacturer JR Allen-Bradley )r GE-Fanuc IT Modicon r Siemens r Or equal 6 Without Exception ~ -1.04 r Digital output Signal Power supplies required for -1.06 % 125 Expandibility Digital input R Analog input R Analog output r Other When "Other" is selected, indicate alternative Separate fused power supply required for digital inputs 6 Yes r NO r 24 Vdc R 120 Vac -1.08 (i' As indicated on block diagram PLC Arrangement C As summarized Large PLC Processor (PR 2-2) with rack mounted I/O EPROM Memory requred c Yes -2 c Yes Large industrial rack mounted type 6 No r NO Inpuffoutput Hardware input. High speed pulse accumulator r Yes Platinum RTD analog Input c Yes r NO c NO Binary-Coded-Declmal (BCD) thumbwheel input C Yes c NO (Carlsbad Water) (Recycling Facility) 13530 -2- Discrete Input (Dl) Modules r 1 Amp at 100 - 130 dts ac r 1 Amp at 20 - 28 wlts dc r With isolation - 100-130 wlts ac r With isolation - 20-28 mlts ac Discrete Output (DO) Modules r loo - 130 wits ac 20 - 28 mlts dc r Isolated modules - 100-130 wlts ac r lsolated modules - 20-28 wlts dc r Relay modules Interposing relays r yes r NO r On all UO circuits r AS shown vo lists r Discrete Outputs only Analog Inputs (AI) Modules r 4-20mA r With isolation r With (VI) signal isolators r Other When "Other is selected, indicate alternative required. Analog Output (AO) modules r Yes r No .3 Mini PLC Processor Mini PLC type with rack mounted @ Yes 11/0 InpuUOutput Hardware standard modules on card c 4 r8 c 16 r 32 I/O Hardware contained entirely in Remowble Type of 110 hardware PLC enclosure c Yes @ No I 1 C Non-remowble (Carlsbad Water) (Recycling Facility) 13530 -3- IDiscrete Input (Dl) Modules IR 1 Amp at 100-130 mlts ac r 1 Amp at 20-28 mlts dc r With isolation Discrete Output (DO) Modules r 100-130 Wits r 20-28 mlts dc r Isolated modules P Relay modules Analog Inputs (AI) Modules P 4-20mA R With (Ul) signal isolators r Other When 'Other" is selected, indicate alternative Analog Output (AO) Modules R 4-2omA r Other When "Other" is selected, indicate alternative Communications (PR 2-5) Communications modules required for p Local input/output hahare P Remote inputloutput hardware P Other PLCs P Host computers Communications media R Cable I7 Data highway IF Fiber optics I Ir Radio I required for network Number of addressable nodes 30 minimum r Other I I I bhen "Other is selected, indicate I alternative PLC to PLC Communication hardware e Yes r NO I PLC to Remote 110 Communication hardware c yes r NO hardware PLC to Host Communications Yes r NO (Carlsbad Water) (Recycling Facility) 13530 4- Fiber Optic Communlcations hardware c Yes e Yes Radio Communications hardware r NO (i- No Communication media Remote WO network PLC cmrn. network C Both Data Highway Plus cabling r Yes 6 No Modbus Plus cabling f- Yes (i- No Metallic LAN cabling (i- Yes r NO Type of metallic LAN cabling. Coaxial (i SF Fiber Optic cable (i- Yes r NO Fiber Optic Comrn hardware (i- Yes r NO Radio Comm hardware c Yes (i- No Programming Hardware and Software (PR 2-6 h 2-7) Notebook computer required (i- Yes r NO Copies of PLC programming licenses required including R OWNER copy documentation and manuals r ENGINEER COPY r Other When "Other is selected, indicate alternative Software standard Manufacturers standard Third party r Concept r Other (Carlsbad Water) (Recycling Facility) 13530 -5- Vhen "Other" is selected, indicate lternative anguages I7 Relay ladder logic r Function block r Sequential function chart r structured text r State logic r 1~c-1131 I PLC emulation testing required c Yes No Enclosures (PR 2-8) PLC housed in I7 Shopassembled r Existing Field Services (PR 3-1) Refer to specification section indicated Section 13500 Fiber Optic Cable testing required G Yes r NO r- (Carlsbad Water) (Recycling Facility) 13530 -6- Section 13530 PROGRAMMABLE LOGIC CONTROLLERS PART 1 - GENERAL 1-1. SCOPE. This section covers programmable logic controllers (PLCs) as designated and as required, including associated input/output hardware to control process equipment and serve as the interface to field devices. 1-1.01, Terminoloqy. When the phrase "as required" is stated in this section it shall mean "as required in the attached Data Sheet". 1-1.02. Control Svstem. Section 13500 shall apply to all equipment furnished under this section. Additional PLC software requirements are indicated in Section 13550. 1-2. GENERAL. Equipment furnished and installed under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions, and by ENGINEER. recommendations of the equipment manufacturer, unless exceptions are noted 1-2.01. General EauiDment Reauirements. The General Equipment Requirements shall apply to all equipment provided under this section. 1-2.02. Drawinas. Supplementing this section, the drawings indicate the number and sizes of PLCs, locations of PLCs, and provide diagrams and schematics regarding connection and interaction with other equipment. All hardware, including power supplies, special cables, and other appurtenant equipment, shall be provided to meet the functional requirements described herein and indicated on the drawings. 1-2.03. 110 List. An input/output (I/O) field device signal listing is included as an appendix attached to this section. 1-3. SUBMITTALS. Submittals shall be as required in Section 13500 14. DELIVERY, STORAGE, AND SHIPPING. Delivery, storage and shipping shall be as required in Section 13500. 1-5. SPARE PARTS. Spare processor modules, spare power supply modules, spare I/O cards, and spare communications modules shall be supplied in the (Carlsbad Water) (Recycling Facility) 13530 -7- numbers as required. Additional spare parts shall be provided as required PART 2 - PRODUCTS 2-1, GENERAL. All equipment furnished under this section shall be expressly selected by CONTRACTOR for its superior quality for the intended purpose and shall comply with the following requirements. 2-1.01. Interchanqeability. All programmable logic controller systems shall be products of the same manufacturer and of the same series or product line. Processors, local and remote inpuffoutput hardware, communications modules, and specialty modules such as coprocessors and ASCII modules shall be interchangeable among all 110 panels and systems. PLC modules and hardware by other manufacturers will be acceptable only if the PLC manufacturer does not offer suitable modules and hardware for the same functions. 2-1.02. Initial. Soare. and Future Memorv (RAM). CONTRACTOR shall provide adequate memory for the amount of 110, control algorithms, and communications in the initial system. Each programmable logic controller shall include provisions for future expansion and shall have 100 percent spare memory capacity and 100 percent spare data capacity installed. The spare memory capacity shall be documented by submitting to ENGINEER, during factory testing, a statement indicating the amounts of memory of all types being utilized and the total amount available in each system. The statement shall include an estimate of the total program and data memory necessary. including spare memory, based on the I/O hardware for the system, and previous programming experience. 2-1.03. Spare 110. Each PLC inputloutput enclosure shall be provided with at least 20 percent spare inputs and outputs of each type. Spare 110 shall be installed, wired, and interfaced properly to the terminal strip. The spare 110 shall be in addition to any 110 installed and reserved for future process signals as may be indicated on the 110 list. In addition, each PLC inpuffoutput enclosure shall be capable of accommodating 25 percent of additional inpuffoutput capacity of each type as originally assembled, without the need for additional expansion racks or PLC power supplies. 2-1.04. Expandability. Each PLC processor and associated 110 shall have a future expandability of at least 25% of the provided system or as required, whichever is greater. 2-1.05. Acceptable Manufacturers. The PLCs shall be Allen-Bradley; SLC-5/05, without exception. (Carlsbad Water) (Recycling Facility) 13530 -0- 2-1.06. Signal Power Supplies. A regulated dc power supply for analog output and for analog input loops shall be provided for each 110 rack when required. Power supplies shall be suitable for an input voltage variation of k10 percent, and the supply output shall be fused or protected against short-circuiting. Output voltage regulation shall be as required by the instrumentation equipment supplied under another section. The loop power supply shall be separate from the power supply circuit for the processor and racks. A separately fused 120 Vac power source shall be provided for all digital inputs from field devices as required. Unless otherwise noted, all field devices will be provided with dry contacts that close to provide an input to the PLC. 2-1.07. Appurtenances. The PLC processor and 110 hardware shall be provided as complete systems, as shown on the block diagram drawings. The PLCs shall include all necessary hardware and software for a complete working system. All special rack or panel mounted power supplies, special interconnecting and programming cables, special grounding hardware, or isolation devices shall be furnished as required for proper operation of the equipment. Signal converters, signal boosters, amplifiers, special power supplies, special cable, special grounding, intrinsically safe relays and current repeaters, surge suppression devices, and isolation devices shall be furnished and installed as required for proper operation of the equipment. 2-1.08. PLC Arrangement. The PLCs shall be distributed and arranged as indicated on the block diagram. 2-2. LARGE PLC PROCESSOR Not used 2-3. MINI PLC PROCESSOR. The programmable logic controller processor shall be an industrial type that utilizes battery-backed CMOS type memory with EEPROM backup. Battery-backed memory shall include integral batteries with sufficient capacity for at least 6 months' memory retention without power to the processing unit. Standby and shelf life of the batteries shall be at least 5 years 2-3.01. Diaanostics. The processor shall utilize self-monitoring diagnostic techniques. Easily visible LEDs shall indicate "run" and "halt" status as well as memory and inputloutput error conditions. Diagnostic codes shall also be available through the programming device to facilitate troubleshooting. 2-3.02. Proarammina Port. The processor shall be able to be programming through a spare Ethernet port on the hub located within the PLC enclosure. 2-3.03. Communications. The processor shall be programmed to operate autonomously, regardless of communications status with other units. (Carlsbad Water) (Recycling Facility) 13530 -9- 2-3.04. Environment, The processor shall be suitable for operation in the environments specified in another section. A key switch shall be provided on the processor to select the operating mode and as a security measure. 2-3.05. Proqramminq. The processor shall be programmable using conventional relay ladder logic, or as required, and shall include the following functions and features. Contacts, coils, branching. Data comparisons. On-delay and offdelay timers. Counters with comparators. Floating Point Math and Logical instructions. Master control relay Transitional or one-shot outputs Standard and userdefined data tables for discrete and analog value storage. 2-3.06. CaDabilities. The processor shall include the following capabilities for programming, debug of programs, and troubleshooting. Off-line programming. On-line status of coils and registers. Inpuffoutput forcing. 2-3.07. Confiquration. Processors shall be configured for standard rack mounting and shall be of plug-in printed circuit board construction. Each programmable logic controller shall include integral communications ports for the programming device, remote inputloutput, HMI device, or remote communications interfaces as required. Programmable logic controller systems shall support the following types of input/output. (Carlsbad Water) (Recycling Facility) 13530 -10- 120 volt ac discrete input and output 24 volt dc discrete input and output. 4-20 mA dc analog input and output. 2-4. InpuVOutput Hardware. For rack mounted PLCs, inpuffoutput hardware shall be supplied in standard modules of 4, 8, 16, or 32 points each for assembly in local and remote inputloutput enclosures. . All digital inputloutput hardware shall include isolation against surges of at least 1500 volts, All output hardware connected to inductive loads shall be supplied with surge suppression devices as required and recommended by the PLC manufacturer to prevent damage to output hardware. 2-4.01. Wirins Terminals. All inputloutput modules shall utilize easily removable plug-in or hinged field wiring terminals to allow removal of modules without disconnecting individual wires. 2-4.02. I/O Circuit Power SUDDI~. Outputs for motor driven equipment will typically be powered from the driven equipment. Discrete outputs for miscellaneous equipment shall be powered either from the controlled equipment or the PLC enclosure as indicated on the drawings or as coordinated with the controlled equipment supplier. Outputs that control process equipment specified under other sections or provided under other contracts shall be fully isolated or shall operate relay-type discrete output modules or interposing relays in the PLC cabinet. 2-4.03. Discrete Input Modules. Discrete input modules shall sense voltages between 100 and 130 volts ac as required and shall have LED indicators for each point to display the status of the field contact. Each input module shall be suitable for being connected to a separate voltage source and return. Return voltage may be common to the entire input module. 2-4.04. Isolated Discrete Input Modules. Not used. 2-4.05. Discrete Output Modules. Not used. 2-4.06. Isolated Discrete Output Modules. Not used. 2-4.07. Relav Discrete Output Modules. Discrete output modules shall control voltages from 24 to 110 volts dc and 24 to 230 volts ac and shall be rated at least 2 amperes. Outputs shall be individually fused and shall have LED indicators to display output status. Digital outputs for motor driven equipment shall be powered by the driven equipment. Outputs shall withstand a surge of at least 80 amperes for 15 milliseconds. (Carlsbad Water) (Recycling Facility) 13530 -1 1- 2-4.08. Analoq Input Modules. Analog input modules shall accept linear 4-20 mA dc signals from field transmitters. Input circuitry shall be floating differential type designed to prevent loop grounding. Analog to digital conversion accuracy shall be at least 12 bit (0-4095 count) resolution. 2-4.09. Analoa Output Modules. Analog output modules shall transmit linear 4-20 mA dc signals to field devices. Loop power for all analog outputs shall be provided by regulated power supplies in each inputloutput enclosure and shall be capable of driving a 0 to 600 ohm load. Digital to analog conversion accuracy shall be at least 12 bit (0-4095 count) resolution. 2-4.10. Panel Terminations. All PLC inpuvoutput signals for field connections shall be terminated through panel enclosure terminal strips. Direct connection of field wiring to the I/O module terminals is not acceptable. 2-5. COMMUNICATIONS. Each programmable controller system shall be furnished complete with communication hardware modules for local inputloutput hardware, remote inputloutput hardware, other programmable controllers, or for host computers as required. Communication hardware shall be compatible with the cable, data highway, fiber optic, or radio communication media as required. 2-5.01. Addressabiliw. Each programmable logic controller shall be individually addressable so that only the selected controller responds when queried. At least 30, or a larger number as required, distinct network addresses shall be available. Designation of a controller's network address may be either a software or hardware function. 2-5.02. Communications Hardware. CONTRACTOR shall provide all necessary communications hardware. Hardware shall be included for, but not be limited to, remote 110, data highway, host computer, fiber optics, Ethernet and radio. 2-5.02.01 PLC to PLC Communications Hardware. Each PLC shall communicate to other PLCs over an Ethernet data highway communications network. CONTRACTOR shall include all rack mounted, enclosure mounted, or desktop mounted communications modules required for a complete working system. 2-5.02.02 PLC to Remote Communications Hardware. The master PLC shall communicate with the remote PLC or I/O rack over a remote 110 communications network. CONTRACTOR shall include all rack mounted, enclosure mounted, or desktop mounted communications modules required for a complete working system. (Carlsbad Water) (Recycling Facility) 13530 -12- 2-5.02.03 PLC to Host Communications Hardware. Each PLC shall communicate to the host computer over an Ethernet data highway communications network. CONTRACTOR shall include all rack mounted, enclosure mounted, or desktop mounted communications modules required for a complete working system. The computer system hardware is covered in another section.. 2-5.02.04 Fiber Optic Communications Hardware. CONTRACTOR shall provide all necessary fiber optics transceivers and modems for the PLC system. Communications hardware shall meet the requirements of the manufacturer of the PLCs. 2-5.02.05 Radio Communications Hardware. Not used. Not used 2-5.03. Communications Media. CONTRACTOR shall provide all necessary cabling for the PLC communications network and PLC remote 110 communications network. Communications cables shall meet the requirements of the manufacturers of the PLCs and communications modules. 2-5.03.01. Cable. CONTRACTOR shall provide all necessary cabling for the PLC system. Communications cables shall meet the requirements of the manufacturers of the PLCs and communications modules. 2-5.03.01.01. Data Hiqhwav Plus Cabling. Not used, 2-5.03.01.03. Metallic IAN Cable. Cable shall be coaxial or shielded pair suitable for installation in conduit. Cable furnished shall meet the following minimum requirements. Twisted, Shielded pair (STP) Category 5 Copper conductors #24 AWG Aluminumlpolyester shield with drain 300 volt rated Minimum 0.037 inch PVC jacket (Carlsbad Water) (Recycling Facility) 13530 -1 3- Plenum rated 2-5.03.01.04. Fiber Optic Cable. Fiber optic cable shall have a loose tube construction with silicon gel filling. The cable shall have at least three Pair of 62.5/125 micron multimode fibers. Spare fibers shall be fitted with connectors. Where patch panels or fiber distribution panels are used, all fibers, including spares, shall be properly terminated in the panel. Fiber diameter shall be coordinated with the transceivers or modems supplied. Cable shall be suitable for outdoor or raceway installation. Cable shall have a heavy duty MDPE outer jacket and a fiberglass or Aramid inner strength member. Cables shall be Corning Cable Systems/Siecor, Belden MLD6006, or equal. Cable connectors shall be ST type. Exposed fiber optic cable within PLC enclosures shall be a jacketed "zip-cord'' with industry standard connectors. Single, unjacketed fibers shall not be used for terminations on PLC equipment. Bulk fibers entering a PLC enclosure shall be terminated in a patch panel. Zip-cords shall be run from the patch panel to the PLC components. Fiber optic terminations shall be performed by CONTRACTOR in accordance with the manufacturer's recommendations. 2-5.03.02. Fiber ODtic Communications Hardware. CONTRACTOR shall provide all necessary fiber optics transceivers and modems for the PLC system. Communications hardware shall meet the requirements of the manufacturer of the PLCs. 2-5.03.03. Radio Communications Hardware. Not used. 2-6. PROGRAMMING DEVICE HARDWARE. The programming device shall be a portable notebook computer as specified in another section. CONTRACTOR shall provide two interconnecting cables. each 5 meters long, to connect the computer to the programmable logic controller. The cables shall be shielded data cable and shall be terminated on both ends with the appropriate connectors. Connectors shall be labeled to identify the connected equipment. 2-6.01. SDecial Devices. CONTRACTOR shall provide two sets of any special devices (such as null modems, adapter cards, interface converters, etc.) required to establish an operational programming line between the programmable logic controllers and programming device. 2-7. PROGRAMMING SOFTWARE. CONTRACTOR shall furnish one licensed copy of PLC programming software for the OWNERS use. The software shall be functionally identical and shall be suitable for running on the programming device specified elsewhere. A full legal set of programming software documentation (Carlsbad Water) (Recycling Facility) 13530 -14- shall accompany each copy of the software. Each copy of the programming software shall include all necessary device drivers and add-on software packages. 2-7.01. Standard Product. The programming software shall be personal computer based and a standard product of the PLC manufacturer. The software shall be RS Logix for A-B. 2-7.02. PLC Emulation. Not used 2-7.03. Proqrammina Software Features. The programming software shall allow off-line development of all PLC-related programming, including user annotation of the program, and creation and printing of application programs and I10 cross- reference lists. Special programming tasks originally provided by CONTRACTOR shall also be included. PLC and 110 hardware diagnostic and status information shall be accessible using the software in on-line mode. 2-8. SYSTEM ENCLOSURES. Programmable logic controllers and inputloutput hardware shall be housed in shop-assembled panels as indicated on the drawings and as described in another section. PART 3 - EXECUTION 3-1. INSTALLATION REQUIREMENTS. PLCs installation requirements are specified in Section 13500 except as described herein. Field check, testing, and training shall be as described in Section 13500. 3-2. CONFIGURATION, 3-2.01. PLC Proqrammina and Confiauration. Configuration services are specified in Section 13500. 3-2.02. Communications Confiauration. The communications shall be fully configured and installed by CONTRACTOR. 3-3. FIBER OPTIC CABLE INSTALLATION AND TESTING. The fiber optic cable shall be installed, terminated, and tested by an experienced fiber optic network installer. Each fiber of each fiber optic cable shall be tested after installation. For each fiber with a length of more than 100 ft. an end-to-end power attenuation (insertion loss) test shall be performed. The attenuation test shall utilize a stabilized optical source and an optical power meter calibrated to the appropriate wavelength (850 or 1300 nm). (Carlsbad Water) (Recycling Facility) 13530 -1 5- For each installed fiber the power attenuation shall not exceed the values recommended by the fiber optic transceiver manufacturer. Any fiber optic cables containing one or more fibers not meeting this performance will not be accepted by the Owner. Cable shall be repaired or replaced. All necessary hardware, test equipment, cables and test meters, required for the testing shall be provided. The results of the fiber optic cable testing shall be documented and submitted to the Owner. End of Section (Carlsbad Water) (Recycling Facility) 13530 -16- ". IIIIIIIIIIIIIIIII I 1 Section 13550 SOFTWARE CONTROL BLOCK DESCRIPTIONS Data Sheet ara- IDescription IData JUnits raph PLC Programming Functional Requirements These descriptions are applicable to I7 Section 13520 he software specified in these Section 13530 r Other When "Other is selected, indicate other Sections. Flow Value Totalization in PLCs (i yes Ir No Database provided by Owner 1: ;: -1.03. r NO Yes Interface with Microfiltration Control System Required. Number of real time trend displays Minimum 20 required Number of historical trend displays required Minimum 20 required 3 Number of historical facility reports (Carlsbad Water) (Recycling Facility) 13550 -1- Section 13550 SOFTWARE CONTROL BLOCK DESCRIPTIONS PART 1 - GENERAL 1-1. SCOPE. This section provides functional descriptions of the PLC and computer software requirements for the Computer Control System as indicated on the drawings and as required. These descriptions are intended to provide an overview of the operating concept of the plant process equipment rather than describing in detail every operating feature or interlock. 1-1.01. Control Svstem. Section 13500 shall apply to all systems described in this section. 1-1.02. Terrninoloqy. When the phrase “as required” is stated in this section it shall mean “as required in the attached Data Sheet“. 1-1.03. Interface with Owner-furnished Microfiltration Control Svstem. The Owner-furnished microfiltration control system shall be interfaced with the plant control system as summarized in Section 13500. The microfiltration control system will consist of a PC workstation running Allen-Bradley RS-View32 HMI software. Graphic displays, database information and alarms from the microfiltration control system shall be incorporated into the plant control system server computers. Information from the plant control system (RO and filter controls) will not need to be displayed at the microfiltration workstation. PART 2 - PRODUCTS 2-1. SOFTWARE. Software products are described in other sections of these specifications. PART 3 - EXECUTION 3-1. PLC PROGRAMMING FUNCTIONAL REQUIREMENTS. The following paragraphs describe general configuration tasks that are required for the plant control system PLC(s). These tasks shall be programmed in any applicable PLC. Each PLC may have multiple instances of each of these tasks, or may have no instances of some or all of these tasks. The input/output lists (located in these documents as required in Section 13500) and detailed equipment control descriptions (attached to this Section) should be referenced to determine the requirements for each PLC. (Carlsbad Water) (Recycling Facility) 13550 -2- The following paragraphs cover functional requirements of the Software, which are generic and may or may be not related to any specific control loop. 3-1.01. Available Process Values. All process alarm, equipment Status, and process variable values shall be available at any operator workstation. 3-1.02. Manual Entry of Data. The human machine interface (HMI) computers shall allow manual entry of laboratory data and other variables, which shall then be available for display and use in reports. Operator entered commands from any of the HMI computers shall be logged at all HMI computers. 3-1.03. Flow Values. Flow values shall be integrated, totalized, and stored in the PLC registers so the values displayed on the HMI Computers and on the field processor will be identical. 3-1.04. System Failure. Failure of a PLC shall result in safe shutdown of associated process equipment. Interposing relays shall be provided where required to assure that equipment will revert to its fail-safe condition. Failure of any PLC or its communication shall be alarmed on the HMI computer. 3-1.05. HMI Computers. The SCADA server computers and the local operator station computers shall all function as HMI workstation computers. The HMI workstation computers shall function as a monitoring system, not as a controller, for the process equipment. The computer shall download set points and other information to the PLCs. and the PLCs shall perform all control algorithms, so a temporary failure of the any HMI computer will not disrupt plant control. 3-1.06. RacklModule Confiauration. The rack and module definitions for each PLC, as well as the PLC communications configuration shall be completely configured to allow proper addressing of all field connected 110 points. This shall include configuration of any remote inpuffoutput (RIO) racks. 3-1.07. PLC Database Definition. The PLC database will include both field 110 points and internally generated points required for programming. All field I/O points and internal programming points shall be fully defined according to database naming conventions approved by OWNER. As a minimum, each database point shall be provided with a tag name, engineering unit, alarm parameters, and description. 3-1.08. Analoq Scalinq. Each analog input and output will be appropriately scaled for use in internal PLC programming, monitoring by the HMI computers, or transmission to other PLCs. Requirements for raw count values shall be coordinated with the operator interface software to ensure compatibility. 3-1.09. Equiment Runtimes. For each equipment item whose "run" status is (Carlsbad Water) (Recycling Facility) 13550 -3- monitored by a PLC, an internal equipment runtime shall be accumulated by the respective PLC. The runtime procedure will monitor the status of the equipment "run" contact and, when the equipment is running, increment a software timer that maintains equipment runtime to within a one-minute resolution. The timer shall stop incrementing, but not reset, when the "run" contact indicates that the equipment is not running. The timer value shall increment an hour counter that maintains an integer value representing the equipment run time in hours. The counter value shall be available for display on the HMI computer workstations. A manual reset of the runtime value shall be available at the HMI computer workstations for personnel at the supervisor level and above. 3-1.10. Chanqe-of-State Alarms. While equipment is controllable from the PLC ("in remote"), discrete output commands shall be compared to their respective process feedback status signal (where available) to verify proper execution. If the feedback status does not match the most recent output command (after an adjustable 2 to 300 second time delay), an alarm message shall be displayed on the HMI computer and the condition shall be logged as an alarm, requiring operator acknowledgment. The alarm shall remain energized until the proper discrete condition is sensed or until the operator resets the alarm through the HMI computer. 3-1 .I 1. Eauipment Availability. In general, equipment with PLC control has been provided with a local selector switch that transfers control to the PLC. The PLC shall monitor the position of this switch to determine if the equipment is available for PLC control. If the equipment is not available, the PLC program shall not attempt to implement remote manual or automatic status changes for the equipment. The PLC program may, however, need to implement special routines if equipment unavailability affects a sequence (as described in the detailed equipment descriptions). 3-1.12. MaintainedlMomentaw Outputs. The need for maintained or momentary control outputs shall be determined from the inputloutput listing and the electrical schematics. In general, equipment with only one control output indicated in the I10 list shall be programmed for a maintained control output. Equipment with two (or more) control outputs shall be programmed for momentary outputs. Provisions shall be made, in either case, to remove the active state (start, open, forward, initiate, etc.) control output when an equipment failure is sensed or when the equipment transitions from available to unavailable (local switch change). 3-1.13. EquiDment Mode Changes. Unless otherwise indicated in the equipment control descriptions, equipment in automatic mode shall be transitioned to manual mode (and stopped) if the equipment fails or becomes unavailable or if the PLC processor resets. 3-1.14. ManuaVAuto 6UmDleSS Transfer. Unless otherwise indicated in the (Carlsbad Water) (Recycling Facility) 13550 4- equipment control descriptions, equipment changes from automatic to manual control shall be bumpless. Equipment running or stopped in automatic mode shall remain running or stopped when manual mode is selected. 3-2. HMI FUNCTIONAL REQUIREMENTS. The following paragraphs describe general configuration tasks that are required for the HMI computers and related software. 3-2.01. Database. The system database, including field 110 and internal points shall be established according to the database point naming conventions approved by OWNER. Database generation for field I/O shall include all required coordination with PLC level addresses. If no OWNER database point naming conventions are available, the database names shall utilize an ISA or ISA-like tag name. In the default scheme, the format of the tag name is XXX-YYY-ZA XXX is the ISA function designation. YYY-ZA is the unique loop designation defined by the P&IDs. Where possible YYY-ZA will correspond to the loop numbers on the P&IDs. Otherwise, a unique number should be assigned. Z is a number (1, 2, 3) to designate similar loops associated with trains of equipment. A is a letter (A, 6, C) to designate identical functions within the same loop. For instance, if there are two ferric sulfate metering pumps and the loop number chosen is 222, the remote status input for pump number one might be HS-222-1 and the remote status input for pump number two might be HS-222-2. If there is more than one switch input for either pump the tag name would be HS-222-1A and the second switch would be HS-222-1B. Function designations currently defined are listed below: AI'S (Analog Inputs) AIT - Analytical Input PDlT - Differential Pressure Input (Headloss) EIT - Voltage Input PIT - Pressure Input EllT - VAR Input ST - Speed or Rate Input FIT - Flow Input TIT- Temperature Input IIT - Current Input WIT -Weight Input JIT - Power Input ZT - Position Input (Carlsbad Water) (Recycling Facility) 13550 -5- LIT - Level Input AOs AC - Residual Proportioning Control FC - Flow Proportioning Control Dl's AAH -Analytical Alarm High AAL - Analytical Alarm Low FSH - High Flow Status FSL - Low Flow Status HS - Hand Switch Status JA - Electrical Alarm LSH - High Level Status LSHH - High Water Cutoff Alarm LSL - Low Level Status LSLL - Low Water Cutoff Alarm DO'S LC - PLC Generated LWCO Output XC - General Control Output YC - Equipment Start/Stop Command SC - Speed or Rate Control ZC - Position Control PDSH - High Differential Status PS - Pressure Alarm HilLo or Unspecified PSL - Low Pressure Status PSLL - Low Pressure Cutoff Alarm WAL - Low Weight Alarm XA - General or Unspecified Alarm YA - Equipment Overload Alarm (Failure) YS - Equipment Run Status ZSC - Position Closed Status ZSO - Position Open Status ZCC - Equipment Close Command ZCO - Equipment Open Command Initially, the facility database shall be configured so all database points are defined as belonging to a specific area (as allowed by the graphical interface software). The areas designated for the facility shall be coordinated with OWNER. If OWNER has no existing standards for area designations, all points can be placed in appropriate areas selected by SYSTEM SUPPLIER. (Carlsbad Water) (Recycling Facility) 13550 -6- 3-2.02. Trend Displavs. Trend displays shall be developed to present real-time and historical process data in an X-Y graph format. Real-time trends shall utilize current process values to generate temporaly graphs that do not retain data values. Historical trends shall utilize historically collected data and shall access the data files directly for use in the trend display. Historical trends shall allow paging forward and back to the limits of the collected data. The trending package shall be configured to automatically retrieve historical data from the proper data file to accommodate the paging functions. Content of the trends will be determined after meeting with OWNER. The quantity of real-time trend displays and historical trend displays shall be as required. 3-2.03. Alarms. Complete system alarming shall be configured. This shall include configuration of graphical alarm displays, and configuration of audible alarms through the HMI computer speakers. All process or system alarms shall appear on an alarm summary screen and the alarm banner of each process graphic. Alarms and events shall be color coded on the alarm summary screen, with initial colors based on OWNER conventions or the default colors associated with the graphics package. The colors may be adjusted after meeting with OWNER. Alarm prioritizing and area assignments (if any) shall be coordinated with OWNER at the first configuration meeting. For LOW or LOW-LOW analog or discrete alarms which do not apply if associated equipment is not operating, provisions shall be made to prevent generation of the alarm unless the associated equipment is operating. This shall include alarms such as low amperage alarms for pumps that are not running. This may also include low flows or pressures when associated pumps are not operating (this will only apply if periodic operation of the equipment is considered normal). All alarms/events shall be time stamped when displayed or printed. Unacknowledged alarms shall not automatically clear from the alarm summary if they return to normal before being acknowledged. 3-2.04. Reporting. System reporting shall be accomplished using the standard operator interface software-reporting package. All necessary report development, including macro development in spreadsheets, shall be supplied to access real-time and historical data for reporting. The quantity of historical, monthly facility reports shall be as required. 3-2.05. Historical Data Collection. System data shall be collected for historical archiving and for use in trending and reporting functions. Requirements for data collection shall be as needed to support the trends and reports developed. (Carlsbad Water) (Recycling Facility) 13550 -7- 3-3. EQUIPMENT CONTROL AND CONTROL MODE OVERVIEW. The following paragraphs explain the general format and control modes that are used in the detailed equipment descriptions. These paragraphs apply to the attached, project specific, equipment control descriptions included herein. 3-3.01, General. Appended to this section are the equipment control programming requirements, with requirements for both PLC programming and the minimum operator interface functions. The HMI requirements represent the anticipated display generation requirements and shall be adjusted if the PLC programming warrants adjustment. 3-3.02. Control Modes. There are two general control modes available for the process equipment: 1) remote manual, and 2) remote auto. Remote manual control provides a means for operators to adjust equipment status or setpoint, through the HMI computers, using manually initiated commands. Remote automatic control provides a means for automatically changing equipment status or setpoint based on measured process parameters, calculated values, or operator setpoints. Some equipment may have more than one remote auto mode. Descriptions for local control are included in the detailed equipment control descriptions. They are provided primarily for documentation purposes and for information. These controls are hardwired and require no programming effort. 34. DETAILED EQUIPMENT CONTROL DESCRIPTIONS. The specific functional requirements for various software control blocks in the control system are described on the attached Loop Function Data Sheets. These descriptions are intended to provide an overview of the operational concept for the facilities, rather than describing in detail every operating feature or interlock. 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