SECTION 15952
SCADA SYSTEM
PART 1 - GENERAL
1.1 DESCRIPTION
A. Work included:
1. The Contractor shall furnish, install and place into satisfactory operation a wastewater plant supervisory data acquisition system (SCADA)consisting of a personal computer and two (2) in-plant telemetry interface panels at the wastewater treatment plant.
2. Installation shall be as shown on the drawings, in accordance with this specification and as recommended by the manufacturer.
3. The Contractor shall furnish and install all required equipment, including signal wiring, conduits and necessary mounting and accessory equipment to provide a complete operating system.
B. Related work described elsewhere:
1. Section 05500-Metal Fabrications
2. Section 16050-Basic Electrical Materials and Methods
1.2 QUALITY ASSURANCE
A. The equipment provided in this Section shall be the standard catalog products of a UL listed manufacturer of control and telemetry products. All level transducers, control, monitoring, telemetry equipment and software furnished shall be standard catalogued products of the system supplier to assure single source responsibility. Non-manufacturers or companies who integrate components manufactured by others are not acceptable. Not less than eighty percent by dollar volume of all equipment furnished shall be standard catalogued products of the system supplier. All equipment specified in this Section shall be provided by a single supplier who shall have responsibility for the coordination and operation of the system.
B. The equipment furnished in this Section shall communicate with existing equipment. The equipment shall be as manufactured by U.S. Filter/Control Systems in order to be compatible with the Owner's other existing equipment.
C. The equipment specified in this Section shall be constructed in a UL 508 and UL 913 listed controls manufacturing facility. The manufacturer shall provide certification of both ratings with submittals. The equipment shall bear the appropriate UL serialized label indicating the equipment supplied for this project shall be constructed in accordance with the practices and requirements of UL.
D. The proposed telemetry system shall utilize an industry standard communications protocol employing CRC16 or other high level error checking method to permit interface with future equipment. Protocols that are proprietary are not acceptable. The system must also be able to support communications protocols other than its own native protocols, including MODBUS, without any hardware changes.
1.3 STANDARDIZATION
A. For the purpose of standardization, all equipment provided in this section shall be the product of a single manufacturer and shall be of the latest and most modern design and shall have overall accuracy as guaranteed by the manufacturer. The manufacturer shall have system responsibility for the correct operation of the equipment after installation. Equipment which cannot be manufactured by the selected manufacturer must be either identified by name in these specifications or approved in writing by the Engineer prior to installation.
1.4 SUBMITTALS
A. General:
Comply with the provisions of Section 01330.
B. The supplier shall compile and submit no fewer than six (6) copies of:
1. Complete dimensional outline or general arrangement
2. Wiring diagrams (Field wiring revisions shall be documented)
3. Shop drawings
4. Hardware related shop drawings
5. Installation, operating and maintenance instructions
6. Complete parts lists and sectional drawings
7. Copies of field start-up reports
1.5 ADAPTATION OF EQUIPMENT
A. Furnish equipment readily available for installation and operation in the structure shown on the drawings.
B. Assume full responsibility for alteration of planned structure to accommodate other types of equipment.
C. Equipment which requires alteration of the structure of the planned equipment shall be considered only if the Contractor assumes all responsibility for making and coordinating all necessary alterations.
D. Provide all such alterations free of extra cost to the Owner.
PART 2- PRODUCTS
2.1 SCADA INTERFACE PANELS
Furnish, install and place into satisfactory operation two SCADA interface panels. SCADA panel #1 shall be mounted in the control building and shall be connected to the SCADA PC. SCADA panel #2 shall be mounted in the UV building. Communication between the 2 panels shall be via contractor provided shielded twisted pair. Inputs and outputs to each panel shall be as listed in the I/O schedule attached to this Section.
Each panel shall be furnished with all the following features:
A. Enclosure: All outdoor equipment shall be housed in NEMA 3R, minimum 14 gauge galvanized steel enclosures. Each enclosure shall be suitable for wall or pedestal mounting and shall have an exterior gray enamel finish. The outer door shall have a stainless steel hinge and pin and shall be padlockable.
B. Lightning Arrestor: A lightning arrestor shall be supplied in each panel and shall be connected to each line of the incoming side of the power terminals. The arrestor shall protect the control against damage as the result of transient voltage surges caused by lightning interference, switching loads and power line interferences.
C. Power Service: The incoming power service for each panel shall be 120 volts, single phase, two wire, 60 Hertz. All metering shall be done ahead of the main disconnect and control panel. The meter shall be installed by the Contractor in accordance with local power company requirements. Each panel shall be furnished with a properly sized circuit breaker. The breaker shall supply power to all control elements within the enclosure.
D. Wiring: All wiring shall be minimum 600 volt UL type MTW or AWM and have a current carrying capacity of not less than 125% of the full load current. The conductors shall be in complete conformity with the National Electric Code, state, local and NEMA electrical standards. For ease of servicing and maintenance, all wiring shall be color coded. The wire color code shall be clearly indicated on all submittal and as-built drawings, with color indicated.
All control wiring shall be contained within wiring duct with covers as manufactured by Panduit or equal. Where dimensional constraints prevent the use of wiring duct, wires shall be trained to panel components in groupings. The wire groupings shall be bundled and tied not less than every three inches with nylon self locking cable ties as manufactured by Panduit or equal. Every other cable tie shall be fastened to the enclosure door or inner device panel with a cable tie mounting plate with pressure tape. Where wiring crosses hinged areas such as when trained from the inner device panel to the enclosure door, spiral wrap shall be used.
E. Signal Transient Protection: Transient protection or isolation shall be integrally provided with all equipment to protect all instrumentation and telemetry devices either receiving or sending signals. The transient protectors shall be the standard product of the telemetry manufacturer and shall be a three stage surge suppression device that shall effectively arrest most transients encountered in an instrumentation environment. Transient protectors utilizing single or dual stage suppression devices shall not be acceptable. The first stage of the transient protector shall consist of a gas tube arrestor connected across the signal wires to the ground. This stage shall be designed to suppress transients greater than 150 to 300 volts. The second stage of the transient protector shall consist of two varistors each connected between a signal line and ground. This stage shall suppress any transients less than 150 to 300 volts and clamps them to 56 volts. The third stage of the transient protector shall consist of two special purpose, high speed zener diodes which suppress any remaining transients to 51 volts. 50 ohm, 5 watt resistors shall be connected between the stages to dissipate the potential energy of the transients.
F. Condensation Heater: All enclosures mounted outdoors shall be furnished with a 120 volt AC condensation protective heater and high temperature cutout thermoswitch.
G. Analog Isolators: Every analog input shall be powered by an isolated power supply. The unit shall provide a minimum of 750 volts isolation between the voltage input of the panel and the instrument, and include three stage surge suppression for reliable operations during possible electrical transients.
H. Transceiver/Controllers: A Microprocessor-Based Controller/Telemetry Unit (MCT) shall be provided at the main WTP panel and at each remote tank and pump station sites for control and monitoring purposes. The controller shall consist of the following:
1) A Voltage regulation and battery charging circuitry shall be on-board. Battery backed operation shall be provided for this location to include the level transducer equipment.
2) The controller shall provide up to sixteen-user programmable control stages that shall control the various pumps. Pump and abnormal level alarm setpoint operation shall be determined by an integral user keypad.
3) The Microprocessor-based controller shall be a standard, catalogued product of a water and wastewater pumping automation equipment manufacturer regularly engaged in the design and manufacture of such equipment. The pump/alarm controller shall be specifically designed for water and wastewater pumping automation utilizing standard hardware and software. "One of a kind" systems using custom software with a generic programmable controller will not be acceptable.
4) The controller shall accept three (3) analog (1-5 VDC or 4-20 mADC) and twelve (12) digital inputs in its base form. The Controller/Telemetry Unit shall provide two (2) analog and ten (10) digital outputs in its base form. The unit shall incorporate 12-bit analog to digital and digital to analog conversion. Additional analog and digital signal monitoring capability shall be provided as necessary to via I/O expansion modules to accomplish the specified requirements. Additional local analog inputs shall be provided in increments of four (4). Additional local digital inputs or outputs shall be provided in increments of eight (8). Additional analog outputs shall be provided individually.
5) The controller shall have built in diagnostics allowing for in field troubleshooting of system I/O. The diagnostics shall allow the operator to view the current status of all discrete and analog I/O points in the system. The diagnostics shall be real time. Systems that require the use of Laptop computers, specialized equipment or software for troubleshooting or performing system diagnostics shall not be acceptable.
6) The controller operating program shall be resident in EEPROM and include full-scale ranging and pump-up/down determination. The controller shall have expansion capability to operate up to eight (8) pumps plus high and low alarms. The ON and OFF adjustments of each pump and alarm setpoint shall be full-range adjustable through use of an authorized operator access code and a keypad. The controller shall have 4 levels of operator access. The controller display shall show the operation of each control stage. Review of controller adjustments shall be possible by the operator without use of the access code.
7) Input signal conditioning shall provide keypad-selectable averaging of the input signals with one reading taken every second and from one to ninety-nine readings being selectable with the controller displaying and providing control based on a moving average of the selected number of samples.
8) The controller shall monitor analog and digital information. Analog variable setpoints shall be provided for the analogs. Each analog shall be presented in engineering units.
9) The digital controller shall include keypad adjustable on-delay timing logic to provide staggered pump starting following a power failure condition. The controller shall also provide keypad adjustable off delay timing for each pump control stage to provide smooth transition between control stages.
10) In addition to the pump control and abnormal level alarm setpoint capability, the controller shall provide alarm annunciation. The controller display shall show abnormal alarms, signal failure and system monitor/alarm outputs of a watchdog timer. Upon the occurrence of an alarm, an audible device shall operate and the controller display will flash with the alarm description, complete with the time and date of the alarm occurrence. An acknowledge push-button shall be provided to allow silencing of the audible device while the digital display will continue to show the alarm function, complete with time and date information, until the condition has cleared. The controller shall be able to historically store system events with a time and date stamp system. The historical log shall store and make available for operator review events including failures, acknowledgments, return to normal, pump starts and stops, etc.... The historical alarm log shall allow a minimum of 1000 historical events to be stored and displayed. The following alarms shall be provided for:
11) The following additional capabilities shall be available:
a) Multiple analog inputs with alarm and control setpoint capability for each
b) Multiple pump alternators (for varying sized pumps)
c) Varying alternation and sequencing schemes (rotary, first-on, first-off, manual, fixed)
d) Load cycling/shedding with automatic or manual activation
e) Automatic pump replacement upon a pump failure input (pump failed/replaced)
f) Analog input adder-subtractor-multiply-divide
g) Automatic highest/lowest analog signal selector (for basis of control)
h) Pump run time/time of day/day of week/external digital input alternator advancement
12) The display shall operate in a manual scrolling menu mode with the various displays shown in sequence as selected by the keypad's up/down arrow keys. The display shall indicate the specific function entered on the keypad to confirm that selection of a particular output or other function from the keypad during adjustment or review routines. When operating a key of the controller the audible alarm shall chirp briefly to confirm that the selected key has operated.
13) The controller digital display/keypad shall be housed in a flush-mounted, environmentally-protected assembly and mounted on the door of the control system.
14) The unit shall employ an operator interface having a 32-character alphanumeric backlit LCD display with character height not less than .3" and with a 16 position keypad operating in menu mode.
15) A watchdog function shall be provided in the controller which observes meaningful microprocessor activity. In the unlikely event of
microprocessor stoppage the watchdog shall reset the processor. In addition, it shall transfer Form C contacts provided to job connection terminals.
16) The Controller shall have two (2) RS-232C serial communications ports. One serial port shall be used with a modem interface for communications. The other serial port shall be available as an interface for a microcomputer or a serial alarm and event logging printer.
17) It is the specific intention of this specification that a standard Microprocessor-based pump controller be provided, with all of the control features described as a fully-integrated assembly. The Controller shall be a US Filter Control Systems Consolidated Electric Bulletin D620i -JMC.
I. Communications Modem: A modem shall be provided with each of the previously specified MCTs with telemetry for communications. The modem shall be at least 1200 baud. All data and control signals between the modem and MCT shall be pin compatible at RS-232 levels.
The modem shall have on-board LEDs for indication of transmit data, receive data, transmit enable (radio key) and carrier detect. A Transient Level potentiometer shall provide adjustment of the signal from -9 to 0dBm into 600 ohms.
K. Control Power Circuit Breaker: A 1 pole 15 Amp trip thermal magnetic molded case industrial type circuit breaker shall be supplied on the inner door for control power interrupt.
L. 12 VDC Power Supply: A regulated 12 VDC power supply for the microprocessor based digital controller, radios and other control system components shall be provided as required. The power supply shall include a terminal block for the incoming AC, output DC and ground connections. The power supply AC input circuitry shall include integral fusing. The power supply shall be rated with 40% spare capacity for future equipment. The unit shall include 12 volt battery sized to provide 4 hours minimum of operation during incoming service power failure. The unit shall include necessary battery charging circuitry to maintain battery at full charge during normal service operation.
2.2 SCADA COMPUTER AND SOFTWARE
A. SCADA Computer: The PC shall be the central point of process control and monitoring. The Operator shall have access, through the PC, to all operating and historical process data available. The PC shall be capable of directing process control, telemetry and SCADA operations without the need for a local operator. PC shall be Dell Dimension, or approved equal.
A personal computer (PC) shall be provided for monitoring the in-plant filtration and treatment process and the remote distribution system RTUs. The most current Microsoft Windows operating system software shall be provided. This shall permit "Off the shelf" software applications to run concurrently with the provided SCADA system software/Human-Machine Interface (HMI). The HMI shall support Microsoft Windows Dynamic Data Exchange (DDE) and Net DDE. DDE shall provide the sharing of data between applications.
The PC shall meet the following specifications as a minimum:
1) Pentium 4 microprocessor, at least 1000 MHz, with 32 KB L1 cache, and 512 KB internal L2 cache.
2) User Memory (RAM) 256 MB, expandable to 768 MB on system board.
3) Integrated 64-bit XGA adapter with 8 MB video memory, VGA resolution with 32,768 colors, 75 Hertz refresh at 1600 x 1200.
4) Integrated EIDE hard disk and floppy diskette drive controller.
5) 40x speed CD ROM drive.
6) 3.5 inch, 1.4 MB diskette drive
7) 9.1 GB, 10 ms EIDE hard disk drive.
8) 100 MB internal ZIP Drive
9) 10/20 GB EIDE TR5 Tape Backup
10) Four PCI and One PCI/ISA slots.
11) PS/2 Keyboard.
12) Ports: Two USB, Two parallel, one serial and two PS/2 compatible ports.
13) PS/2 mouse.
14) Internal 56.6 kbaud fax/data modem.
B. CRT Monitor: A 19 inch SVGA color monitor shall be provided. The monitor shall be capable of displaying 1280 by 1024 (SVGA) at 85 Hertz refresh non-interlaced. The basic functions of this unit shall be to act as an input device to the computer with information or commands entered at the keyboard and as an output device with data from the computer displayed on the video screen.
C. System Printers: Two printers shall be furnished. A dot matrix printer shall be furnished, dedicated for printing of alarm and status inputs. An ink jet color printer shall be furnished for periodic reports, trend printouts, screen printouts and system processes.
The dot matrix printer shall be Okidata wide-carriage MicroLine 391 Turbo. Printer shall have 200 million character printhead life, 104 cps letter quality, 10,000 hours MTBF. Printer shall be furnished with paper tray or printer stand as required with office furniture.
The inkjet printer shall be HP DeskJet 895 CSE. Printer shall have 2 MB built in RAM, 48 KB receiver buffer, 600 dpi black resolution, 2 ink cartridges (1 black and 1 color), 3000 pages per month volume, and shall print up to 10 ppm black and 8 ppm color.
D. Uninterruptable Power Supply: An uninterruptable power supply (UPS) shall be provided for continued system operation of the PLC, MCT and computer in the event of a power failure. The unit shall be capable of providing one-half hour of battery backed operation for all Master Station equipment. The UPS shall be capable of providing full on-line protection and standby battery operation suitable for computer type loads.
E. Software Requirements:
1) General Description: The software shall consist of a field proven, human-machine interface (HMI) designed for use on the latest Pentium based Personal Computer systems. The software shall run in the Microsoft Windows XP/Windows NT multi-tasking environment using the standard Windows graphical user interface. The HMI operating license shall be furnished to the Owner.
2) The HMI shall support mouse, touchscreen, trackball, light pen, keyboard and any other pointing device supported by Microsoft Windows. The HMI shall provide graphic animation of incoming data to facilitate quick identification of process values and alarm status. This animation should include dynamic changes to graphic colors, sizes, vertical/horizontal percent fill, vertical/horizontal sliders, rotation and visibility.
3) The HMI shall provide real time and historical trend charts of both analog and digital signals. Up to four pens shall be plotted on each chart. Multiple charts can be displayed on the screen at one time. Historical charts shall be capable of forward/backward zooming, scrolling and centering charts. All trend displays shall be capable of being printed out.
4) Alarm handling shall be provided as part of the HMI. Digital inputs shall be definable as alarm conditions. In addition, analog alarms shall be generated when the parameter is outside a user specified range. All alarms shall be capable of being displayed, logged to disk or printed.
5) In order to facilitate report generation the HMI must be capable of using Window's Dynamic Data Exchange (DDE). DDE shall be used to link third party spreadsheet, database and word processor programs for data manipulation, display and printing of graphs, charts and reports. This capability shall include sending keystrokes to other applications.
6) The HMI package shall be purchased on behalf of the Owner. The software shall be provided to the City completely configured and ready to run. The HMI operating license, hardware keylock and documentation shall be turned over to the City at time of system acceptance.
7) Communications Efficiency Summary: The system software configuration shall include a graphic display that shall provide a list showing each remote location with communications information to aid in troubleshooting the system. The communications efficiency summary shall list each remote location and it's communications efficiency as a percentage. The communications efficiency information shall be presented as a trend graphic display and in tabular format.
8) Analog Display and Alarm and Control: Setpoints Each analog signal shall be shown digitally in engineering units (level in feet, flow in GPM or MGD, etc.) and as a dynamic graphic vertical bargraph proportionate to the actual signals. Adjacent to the bargraph shall be configurable numeric fields for high and low alarm setpoints and pump and valve control stages. Note that the flow signals do not require alarm or control setpoints.
9) Alarm Handling: An alarm screen shall be provided to indicate alarms. The screen shall include two alarm windows; one for current alarms/events and another for alarm/event history. It shall be possible to scroll through the historical alarm/event listing by clicking on previous/next push-buttons. Each alarm and event in the log shall be tagged with the data and time of its occurrence, it's name and a value (state or condition). It shall be possible to acknowledge alarms by predefined groups (location) or globally (all). It shall be possible to access the alarm screen and acknowledge alarms from any system screen. Site specific alarms shall be depicted on each site graphic display. Alarms shall be grouped by site. Each alarm grouping shall be viewable on the alarm screen. In addition, all alarm groups can be selected for viewing.
10) Trending: An eight pen trending recorder shall be provided. It shall be possible to configure the trend inputs to accept any monitored analog signal. The trend chart length and pen color shall be configurable. It shall be possible to scroll through the displayed trend data, going forward and backward in time.
11) System Graphic Displays: Dynamic system graphic displays shall be provided and displayed on the system CRT. Actual graphic displays shall be
submitted for Engineer's approval. As a minimum, graphic displays shall be provided for the following:
Home Screen: System Overview
Headworks Screen: Bar Screen, Grit Removal, Influent Flowmeter
Treatment Screen: Anoxic and Aeration Tanks, Clarifiers, RAS pump station
Sludge Screen: Digesters and Sludge Lagoons
Effluent Screen: Filters, UV Disinfection, Post Aeration, Effluent Flowmeter
12) A "map"-type system overview display, showing all locations monitored by the SCADA system. Each remote location shall be depicted and have common alarm indication. In addition, the tank levels shall be indicated. By selecting a particular location with the mouse the operator shall be able to zoom in to view more detailed information specific to that site.
13) A site-specific display, showing information transmitted from each remote station. Each of these displays shall include a dynamic graphic depiction of the on-site equipment. A dynamic level display shall be provided for the tanks. All site-specific alarms shall be provided. A miniature trend snapshot shall be provided to indicate the levels.
14) A separate, third-party remote control/access and communications package shall be provided for interfacing to the hereinafter specified notebook computer.
15) An alarm monitoring system shall be installed to detect alarm conditions for discrete and analog variables. An Alarm Dialer Interface screen shall be provided to interface with the Owner's existing telephone dialer which will be moved from an existing telemetry site. It shall be possible to configure all system alarms to input any of the available alarm dialer channels from the PC's keyboard via simple point and click operations.
16) Control: A Hand-Off-Auto or Open-Close-Auto selection capability shall be provided for each pump and valve in the system. The selection shall be included on the respective site-specific graphic display. User-configurable setpoints shall be provided for level and other process variable signals that are to be used as a basis of control. User adjustment of the setpoints shall be via simple point-and-click or fill-in-the-blank approach.
PART 3 - EXECUTION
3.1 SURFACE CONDITIONS
Examine the areas and conditions under which work of this Section will be performed. Correct conditions detrimental to timely and proper completion of the Work. Do not proceed until unsatisfactory conditions are corrected.
3.2 INSTALLATION
A. Install the work of this Section in strict accordance with the approved design and manufacturer’s recommendations.
B. The manufacturer shall provide the services of a factory trained service technician to inspect the installed equipment, supervise start-up and train the Owner's personnel in the proper operation and maintenance of the equipment. This allowance shall be for a minimum of three(3) eight hour days.
C. The supplier shall provide systems training for operations staff totaling no less than four(4) hours. Maintenance and troubleshooting training shall be included in the specified time.
D. All training shall be at the job site. All travel and per diem expenses for training shall be the responsibility of the manufacturer.
3.3 GUARANTEE
All equipment shall against defects in materials and workmanship for a period of one year from the date of Owner's final inspection and acceptance to the effect that any equipment shall be repaired or replaced without cost or obligation to the Owner.
END OF SECTION