IntraLink™ LC3000 PLC-Based SCADA Systems (Distribution/Collection Systems)
PART 1 GENERAL
1.1 WORK INCLUDED
A. This section covers work necessary for the design, documentation, assembly, test, installation, field testing, startup, training, and final documentation for a Supervisory Control and Data Acquisition (SCADA) system for the (description/location), as described herein.
B. The naming of a manufacturer in this specification is not intended to eliminate competition or prohibit qualified manufacturers from offering equipment. Rather, the intent is to establish a standard of excellence for the material used, and to indicate a principle of operation desired. The base bid shall be the specified USFILTER Control Systems system. Alternate equipment shall be submitted to the consulting engineer at least 14 days prior to bid (in accordance with the following prebid submittal requirements). The engineer will issue an addendum prior to bid listing approved alternate control systems.
1.2 GENERAL
A. Major components of this system shall include the specified software, materials, equipment, and installation required to implement a complete and operational SCADA system along with any associated panel or field mounted instrumentation.
B. In order to achieve standardization for appearance, operation, maintenance, spare parts and manufacturer's service, to the greatest extent possible, like items of equipment provided hereunder shall be the end products of one (1) manufacturer.
C. Requirements for the electrical work associated with the installation of the SCADA system and associated instrumentation equipment are as specified in Division 16000 ELECTRICAL.
1.3 RESPONSIBILITY FOR COMPLETE SYSTEM
A. The Contractor shall be responsible for and shall provide for the design, supply, delivery, installation, certification, calibration and adjustment, software configuration, testing and startup, owner training, warranty and routine future field services, of a complete coordinated system which shall perform the specified functions.
B. The Owner and the Engineer will review system technical information as submitted by the Contractor for software; operating system, database, control strategies and the graphical user interface, i.e. report and log formats, graphics, trends, alarming, etc. for complete compliance with these specifications.
C. The Contractor shall provide the Owner with all services and hardware to ensure that proper communications are established with off-site remote locations which are to be monitored and controlled. This work shall include, but not be limited to:
(Dedicated Telephone System Option)
1. Making arrangements with the local telephone facility for the installation of a type 3002 voice grade telephone line between remotely located sites and the Central location as shown on the plan drawings. A 3002 line is as defined by FCC Interstate Tariff No. 260 for point to point or multiple point communications.
2. Contractor shall bear all costs associated with the installation of this line. The Owner shall be responsible for all leasing costs charged by the telephone facility for the use of this line once installed.
(Radio System Option w/Licensed Frequencies)
1. System communications shall be based on the use of (Select One-VHF/UHF/926/952MHz/Trunking/SpreadSpectrum/Ethernet Wireless) radio transceivers. System supplier shall perform a radio propagation path analysis based on the use of this frequency to determine suitability for use, required antenna heights, and use and location of repeater units. The radio system shall be designed for 98% or better reliability for each station.
2. If FCC radio licensing is required by frequency selection, the system supplier shall be responsible to contact and coordinate with the appropriate FCC authorized Frequency Coordinator for radio communications in the project area. This includes but not limited to: Assist in the preparation and submittal of FCC main form 600 and necessary related schedules for application of licensing of assigned radio frequencies. If radio telemetry system design mandates, assist owner in preparation of any FAA forms or schedules required to gain FCC and FAA approvals.
3. All coordination and license application fees required for licensing shall be included in the bid price. The Owner will execute the necessary FCC documents at such times as needed during the licensing process.
4. Provide and install all radio, antenna, antenna supports, antenna grounding, antenna cable, surge arrestors and other hardware necessary for the radio system.
1.4 PREBID SUBMITTAL
A. General:
Any system supplier other than the named pre-approved system supplier must submit a pre-bid submittal document forteen (14) calendar days prior to project bid date. Provide two bound copies, with tabbed dividers and contents organized and presented as hereinafter specified.
1. Pre-Bid approval does not exempt the Contractor from meeting all the requirements of the Contract Documents nor does it give any prior acceptance of any equipment, software or services. The Contract Documents are the final authority for acceptance of the work provided. The Pre-Bid Submittal is not a part of the contract documents and as such does not exempt the Contractor from the requirements of contract submittals described hereinafter.
2. Information contained in the Pre-Bid Submittal shall be considered public information. All data submitted will become and remain the property of the Owner; none will be returned.
3. It is intended that the Owner shall receive the full benefit of any savings in cost involved in materials substitution as a result of a reduction of the contract price should they decide to accept an alternate.
4. The Engineer’s decision as to pre-bid approval shall be final. The Consulting Engineer shall be considered the sole judge of the merits of the alternate system and shall indicate pre-approval of the alternate system via a written addendum to the specifications prior to the actual bid date.
5. The right is reserved to reject any and all proposals, to waive any informality, irregularity, mistake, error or omission in any proposals received and to accept the proposal, as determined by the Engineer or Owner, deemed most favorable to the Owner's interests.
B. Contents:
1. Include a complete Table of Conformance to each and every paragraph or part of the specifications. Use a chart format with specification part identified, indicate whether each part is in compliance, a deviation or an exception to the specific part. If an exception or deviation, include a narrative description as to how the deviation or exception can benefit the end-user of the system over that item specified.
2. Provide a block diagram of the proposed system showing all major components and their interconnections and interrelationships. Label each diagram and indicate all external power and communications interfaces. All diagrams shall be in an 11 by 17 format.
3. Provide a written overview of the proposed SCADA system describing the principal functions and capabilities of the system’s PC, PLC’s, system communications and general system capabilities (maximum number of network nodes, PLC’s and I/O points, communication protocols available, etc.).
4. Provide an equipment list with descriptive literature and specifications for the proposed system. Included on the list shall be all major hardware items. List shall include as a minimum, the manufacturer, the quantity provided, and model numbers for each.
5. Provide an operating system and software applications list with descriptive literature for the proposed system. Include all major software items, supplier name, quantity, and model numbers. Indicate whether any proposed software is proprietary and would not be turned over to the owner.
6.
Information is required for:
a. Name and version of the proposed PC’s operating system.
b. Name and version of the proposed computer operator graphical user interface software package.
c. Name and version of the PLC on-line/off-line programming software for all controllers
d. Name and version of any required communications software, firmware, etc.
e. Name and version of the specified report application software
f. Name and version of the specified maintenance application software.
g. Describe how system data points are linked from the system database into various applications such as reporting or maintenance. If via DDE (Dynamic Data Exchange) describe specifically the steps required to import data automatically and on-line into the proposed software applications.
h. Briefly describe the required procedure for configuration and/or programming of the proposed system to add a simple remote PLC to the system in the future. Describe in detail, specifically how communications are programmed for the future remote PLC and the necessary changes required at the main controller.
i. Provide a description of any non-resident software required to program, troubleshoot or diagnose any devices in the system.
6. The system supplier must be an authorized System Integrator for the named PLC hardware/software supplier. Verification certificates shall be submitted directly from the manufacturer of the PLC hardware. In addition, submit references for minimum of (5) locations where the PLC equipment has been successfully installed, including name, address and telephone number for the appropriate utility person to contact.
7. The system supplier must submit evidence that they employ in excess of 25 personnel, including no less than 15 technical staff to include engineers, programmers, and field technicians. Submit the qualifications and license for a minimum of one professional engineer in the direct employ of the system supplier. Identify with resumes all personnel who may be assigned the specified project.
8. The system supplier must submit evidence from a qualified surety indicating they can provide performance/payment and maintenance bonds for SCADA and telemetry general contracts with a project value to $2,000,000. Additionally, the system supplier shall submit evidence that they carry a minimum of $10,000,000 of umbrella liability insurance. Liability insurance shall include $5,000,000 of “errors and omissions” insurance coverage. Bonding company must carry a rating of A or better. Insurance company must carry a rating of AAAA.
9. The system supplier must be an authorized facility for assembly of control panels in accordance with UL-508, 913, 698A standards as may be required by these specifications. Submit system supplier’s UL number which verifies their panel assembly shop is capable of providing UL labeled control panels.
10. Provide a tentative construction schedule for completion of the project within the specified Contract period. Indicate the following activities with milestones: Mobilization, radio communications licensing, submittal preparation, submittal review, equipment procurement, equipment assembly, system configuration and programming, factory testing, system delivery, system installation, startup, field testing and training, and post acceptance routine service intervals.
11. Describe the system supplier’s provisions for service, technical assistance and re-placement parts for the proposed system. Include the system supplier’s 1-800-toll free number. Identify with resumes, all personnel who will be providing technical support services for the project after it is accepted.
1.5 SUBMITTALS
A. Hardware Submittals:
Before any components are fabricated, and/or integrated into assemblies or shipped to the job site, furnish to the Engineer for their review six (6) copies of submittal documents. Submittals shall include full details, shop drawings, catalog cuts and such other descriptive matter and documentation as may be required to fully describe the equipment and to demonstrate its conformity to these specifications. Specifically, the Contractor shall submit the following materials:
1. Block diagram and operational description of the system showing all major components and their interconnections and interrelationships. Label each diagram and specify all external power and communications interfaces. All diagrams shall be in an 11 by 17 format. Required documentation sets shall be furnished in bound hardcopy and final documentation shall also be provided in electronic format on CD.
2. Drawings of equipment to be supplied shall include, as a minimum: overall dimension details for each panel, console, etc., including internal and external arrangements and door mounted operator devices with nameplate designations. Wiring diagrams of equipment including field device connections shall be included and specific installation/wiring requirements identified.
3. Operational Description shall include the principal functions/capabilities of the personal computer (PC) and PLC’s as provided and configured /programmed. Included shall be a description of system communications.
4. Provide a detailed Bill of Materials along with descriptive literature identifying component name, manufacturer, model number, and quantity supplied.
B. Software Submittals:
1. Provide complete user manuals for all supplier configured software and firmware. For ancillary software such as operating systems, spreadsheets, etc. being supplied under this contract, only a listing of the manuals which will be included with the Operations and Maintenance documentation is required.
2. Sample communication and control database programs for project in hardcopy form. As a minimum, hardcopy form shall be fully documented, including code, comments, addressing data and cross-references, etc. Every line or section of code shall be accompanied by a comment describing its function.
3. Provide initial graphic display and report format layouts as described later in this specification. List and briefly describe all operator interface functions provided at the PC, including: alarm annunciation and acknowledgment, status displays, control capabilities, report generation, event logging, charting and trending, etc.
C. Test Outlines and Procedures Submittals
Test descriptions shall be in sufficient detail to fully describe the specific tests to be conducted to demonstrate conformance with this specification.
D. Spares and Expendable Recommendations
The Contractor shall provide a list of recommended spares and expendable items. The list shall be exclusive of any spares furnished under this Contract. A total purchase cost for the recommended list shall be provided in addition to the unit cost for each item.
1.6 ON SITE SUPERVISION
A. The Contractor shall provide experienced personnel to supervise, perform, and coordinate the installation, adjustment, testing, and startup of the SCADA system. The personnel shall be present on-site as required to effect a complete and operating system.
1.7 TESTING AND STARTUP
A. All elements of the SCADA system shall be tested to demonstrate that the total system satisfies all of the requirements of this Specification. The Contractor shall provide all special testing materials and equipment. The Contractor shall coordinate and schedule all of his testing and startup work with the Owner. As a minimum, the testing shall include both a factory test and a field test. Testing requirements are as follows:
1. Factory Tests
The PC with peripherals, PLC’s and all other associated hardware shall be tested at the factory, prior to shipment, so as to demonstrate that each component is operational and meets the requirements of these specifications. Test results shall be certified, with written documentation provided to the Owner upon test completion. The Owner or Engineer will not witness factory testing.
2. Field Tests
All system components shall be checked to verify that they have been installed properly and that all terminations have been made correctly. Witnessed field tests shall be performed on the complete system. Each function shall be demonstrated to the satisfaction of the Owner and Engineer on a paragraph-by-paragraph basis.
Each test shall be witnessed and signed off by the Contractor and the Engineer upon satisfactory completion. The Contractor shall notify the Owner at least one (1) week prior to the commencement date of the field tests.
1.8 TRAINING
A. The training program shall educate operators, maintenance, engineering, and management personnel with the required levels of system familiarity to provide a common working knowledge concerning all significant aspects of the system being supplied. The training program shall consist of two 8-hour days. Both classroom-type and field site sessions shall be provided. At least two weeks prior to the requested start of the program, the proposed dates of training shall be submitted to the Owner and the Engineer for approval.
B. The supplier shall provide all instructional course material, equipment and manuals to conduct the training program. Owner shall provide facilities for the training.
1.9 OPERATION AND MAINTENANCE MANUALS
A. The Contractor shall provide (6) complete sets of hard-covered ring bound loose-leaf O&M manuals. In addition to “as-built” system drawings, the manuals shall include internal wiring diagrams and operating and maintenance literature for all components provided under this section.
B. The submitted literature shall be in sufficient detail to facilitate the operation, removal, installation, programming and configuration, adjustment, calibration, testing and maintenance of each component and/or instrument.
C. Operation and Maintenance manuals shall include copies of all PLC programs written to accomplish the monitoring and control functions specified. Programs shall be updated after startup is complete, with the program(s) provided to the Owner on compact disk (CD). Two (2) copies to be provided.
D. The contents of the O&M manuals shall be generally organized as follows:
1. System Hardware/Installation
2. System Software
3. Operation
4. Maintenance and Troubleshooting
(Radio Systems)
E. A separate section containing all data pertinent to the radio system shall be provided. This section shall include:
1. Radio system block diagram.
2. Computer generated radio path signal strength calculations and their associated support materials.
3. Licensing information where applicable. Owner shall provide a photocopy of the FCC license for incorporation into the manuals.
1.10 DEFINITION OF ACCEPTANCE
A. System acceptance shall be defined as that point in time when the following requirements have been fulfilled:
1. All O&M documentation has been submitted, reviewed and approved.
2. The complete SCADA system and instrumentation have successfully completed all testing requirements specified herein and have successfully been started up.
3. All Owner's staff personnel training programs have been completed.
4. Owner/Engineer sign a document indicating SCADA system has formally been accepted.
PART 2 PRODUCTS
2.1 GENERAL
A. The functions and features specified herewith are the minimum acceptable requirements for the SCADA system. The provided system shall equal or exceed each requirement.
B. In some cases, the specifications may allow the accomplishing of certain functions by means of more than one hardware/firmware/software approach. Any approach that is proposed shall equal or exceed all functional, operational, convenience and maintenance aspects of the one described.
C. Major equipment, component and software items are specified; however the Contractor shall, provide all appurtenant items necessary to achieve the required operation as hereinafter specified.
2.2 FUNCTIONAL REQUIREMENTS
INSERT OPERATIONAL DESCRIPTION HERE. DESCRIPTION SHOULD INCLUDE THE FOLLOWING AS A MINIMUM:
· Basic system overview description
· Descriptive control strategies required
· Input/Output listings for all locations
· Mandatory system functions to be performed
· Mandatory software functions to be performed.
2.3 COMPONENT SPECIFICATIONS
A. General
1. Remote and Master PLC enclosures shall be corrosion resistant welded NEMA Type 4 for outdoor locations, NEMA Type 12 for indoor locations. Enclosures shall be fabricated from a minimum of 14 gauge cold rolled steel with a baked enamel finish in the manufacturer’s standard color. Units shall include a single gasketed front door. Full height hinges, locking hasp and door clamping hardware shall be included. All enclosures shall be UL listed.
2. Controls shall operate from a source of 120 volts, 1 phase, 60 Hz. All controls shall be protected from lightning or other transient voltages by a power arrestor.
3. Condensation protection shall be provided. Enclosure shall have a heater which operates continuously to prevent condensation build-up. A freeze protective heater and thermostat shall also be provided at those outdoor locations containing hydraulics or sensitive electronic equipment subject to freezing conditions.
5. All power supplies required for operation shall be provided. Power supplies shall be sized to have a minimum of 40% spare capacity providing increased reliability and allowing for the addition of future equipment.
6. All wiring shall be in complete conformance with the National Electric Code, state, local and NEMA electrical standards. All incoming and outgoing wires shall be connected to numbered terminal blocks and all wiring neatly tied and fastened to chassis as required. For ease of servicing and maintenance, all wiring shall be color coded and uniquely numbered. The wire color code and number shall be clearly shown on the drawings, with each wire's color and number indicated.
B. Battery Back Up System
1. Included with each remote and master PLC, and working in conjunction with the unit’s DC power supply, shall be an intelligent battery back up system including voltage converter, battery health logic module, charger and sufficiently sized battery. Battery system shall provide a seamless switchover to battery upon detection of main DC power supply failure. Once main DC power is restored, the unit shall provide seamless switchback to normal DC power source and recharge the battery. Battery health logic module shall individually monitor main DC power supply, battery and converter voltages for low voltage conditions, and provide low voltage cutoff to protect battery from an unrecoverable depletion. An on board LED, or local Operator Interface (OI) if provided shall locally indicate detection of an alarm condition. In addition to local indication, all battery health and voltage information shall be transmitted to the Master PLC for centralized monitoring and alarm detection.
2. Battery system shall be of sufficient capacity to provide a minimum of four (4) hours of backup in the event of a failure of the main power source. To avoid battery damage and erroneous data transmissions when operating on battery, should the battery voltage drop below 10.8 V, the PLC shall be inhibited from operation. Recovery shall be automatic upon restoration of normal power. The intelligent battery back up system shall be able to source 5 Amps allowing operation of mission critical components including; sensors, local alarm and communication equipment during a power failure condition.
C. UL Labeling (Select 508A or 968A/913)
SERIALIZED UL LABEL REQUIREMENT (508A)
1. Panels provided under this section shall be constructed in compliance with Underwriter's Laboratories Inc. category 508A standards - Enclosed Industrial Control Panels listing and following-up. The control panel(s) shall bear the Underwriter's Laboratories serialized label for “Enclosed Industrial Control Panel”.
2. While the use of U.L. listed components is encouraged, their use alone will not be considered an acceptable or satisfactory alternate to the “Enclosed Industrial Control Panel” serialized label specified above. Upon request from the Engineer, the panel manufacturer shall supply documentation to the owner proving they are a U.L. recognized manufacturing facility for the type of equipment required. Only the labeled products of U.L.508A/“Enclosed Industrial Control Panel” recognized panel manufacturer shall be considered acceptable for use on this project.
SERIALIZED UL LABEL REQUIREMENT (698A/913) -
NOTE: Use the following spec for applications requiring intrinsic safety barriers to render sensors located in hazardous sewage wetwell environments (N.E.C. Class I, Groups C & D) “explosion proof”.
1. Panels provided under this section shall be constructed in compliance with Underwriter's Laboratories Categories 698A and 913 standards – “Enclosed Industrial Control Panel Relating to Hazardous Locations with Intrinsically Safe Circuit Extensions” listing and following-up service. The control panel(s) shall bear the Underwriter's Laboratories serialized label for “Enclosed Industrial Control Panel Relating to Hazardous Locations with Intrinsically Safe Circuit Extensions”.
2. While the use of U.L. listed components is encouraged, their use alone and/or the alternate use of a U.L. 508A – “Enclosed Industrial Control Panel” serialized label will not be considered an acceptable or satisfactory alternate to the “Enclosed Industrial Control Panel Relating to Hazardous Locations with Intrinsically Safe Circuit Extensions” serialized label specified above. Upon request from the Engineer, the panel manufacturer shall supply documentation to the owner proving they are a U.L. recognized manufacturing facility for the type of equipment required. Only the labeled products of U.L.698A and 913 “Enclosed Industrial Control Panel Relating to Hazardous Locations with Intrinsically Safe Circuit Extensions” recognized panel manufacturer shall be considered acceptable for use on this project.
D. PLC Control/Telemetry System
1. General:
a. The main site and each remote location shown on the plan drawings and as described herein shall be of the PLC type with adequate memory and instruction sets required to make the unit perform all of the functions required by this specification. Units shall communicate with the Master PLC over the previously specified telemetry medium. Systems using a PC for master communications shall not be acceptable.
b. All control signals, status signals, alarm and process variable data shall be transmitted and received between the central location and the remote sites via the SCADA system. The system shall convert commands, alarms and variable analog data to digital blocks and transmit this information between the Central and the multiple remote locations. The master and remote PLCs shall be capable of stand-alone control to maintain programmed logic.
c. Units shall be furnished completely configured and tested providing the specified communication, monitoring, display, input/output, annunciation, computational and other requirements for operation of the SCADA system. Any additional components required for operation, whether specifically referenced herein or not, shall be provided.
d. The PLC system shall be based on a scalable modular multi-use open architecture platform that can be efficiently applied to perform the necessary functions at each location. Each controller/telemetry unit shall be a modular hardware style PLC consisting of a CPU with adequate memory and instructions, power supply, local and remote input/output modules, communications ports, and all other components required to make the unit perform all of the functions required in this specification.
e. It is required that the same model PLC device be used throughout the SCADA system including; RTU, MTU and IRTU (repeaters) sites providing a complete solution with one common technology. This is to insure complete system continuity, compatibility between like devices, enhancing overall system efficency by the reduced need to learn, maintain, support and carry spare parts for multiple technologies.
f. The PLC system shall support true system open architecture allowing use of specialized for water and wastewater hardware and software and full integration of other third party generic hardware/software devices. The architecture shall meet the requirements as herein defined and allow economical expansion of function and features based on new and evolving technologies. Systems using non-scalable and/or closed proprietary architectures shall not be acceptable.
2. Hardware:
a. The PLC system shall be based on a robust, field proven, current technology hardware platform allowing utilization of the latest advances in technology and permitting the most open programming and communication architectures. The PLC system shall be modular and scalable to be efficiently applied at each of the specified sites within the system.
b. The PLC system shall include a real time of day time clock w/battery back up for time stamping of data log records and scheduling of periodic time of day based events. Clock shall not require reset after a site power failure has occurred.
c. The PLC shall store system parameters including, logic configuration, setpoints, time delays, alarm and event data, counters and totalizers, etc.. in field programmable (FLASH) non-volatile memory. Sufficient non-volatile memory must be provided to protect at least 8,000 variables. The PLC shall also provide enough protected memory for time stamped data logging of up to 200,000 process values. This data shall be unaffected by power interruptions.
d. The PLC shall have enough processing power and working (DRAM) memory to enable high level programs such as Internet Web Servers to operate efficiently without affecting other simultaneous multitasking operations.
e. The PLC shall be furnished with a minimum of 6 communication ports with true multitasking and allow simultaneous support of all ports. Ports can be configured for local I/O, Operator Interface/display support, LAN/WAN, etc..
f. The PLC processor shall meet the following as a minimum:
1. CPU - True 32 Bit running at 50 MHz.
2. 16 MB – 32 bit Dynamic RAM
3. 8 MB FLASH
4. 512 KB Static RAM
5. 1 (One) Ethernet 10/100 BaseT port (RJ45)
6. 2 (Two) RS-232 Serial Communications (115 KB PS) (RJ45)
7. 1 (One) RS485 Serial Multi-Drop Communications
8. 1 (One) Local I/O port
9. 1 (One) Display Serial Communications Port
g. The PLC shall not require any specialized tools for removal of the unit. System components including PLC, power supplies, etc. shall be DIN rail mounted. Terminations shall be via plug in connectors facilitating quick field replacement.
h. PLC’s and associated I/O modules shall meet national and international safety standards including UL, CSA, CE, DNV and Zone 2 Rated. In addition to the safety standards PLC system components shall also meet IEEE-472 (ANSI C37.90) surge withstand and IEC68-2-6 Vibration standards.
i. The PLC shall operate from a 10-30 VDC power source. A battery and charger as previously specified shall be supplied to power the master & remote unit during 120 Volt service power outage conditions.
j. The PLC’s shall have an operational temperature range of -40OC to 70OC (-40OF to 158OF) under relative humidity conditions of 5 to 95% non-condensing. Storage temperature range up to 85OC (185OF)
3. Software:
a. The PLC shall have a high performance open source software architecture that utilizes a true multitasking operating system running a combination of standard and specially designed for water and wastewater application software modules. The system provided shall utilize an integrated system approach providing a comprehensive common configuration tool for all components within the system including I/O, Processor, Communications, and Operator Interface Display. The architecture shall permit all system components to be configured, simulated, tested and downloaded from one terminal to all system components.
b. The operating system shall be multitasking and allow a minimum of two separate programs to run simultaneously without affecting each other.
c. To provide for and insure multiple source support, the PLC system shall utilize industry standard programming language certified by the PLC open committee for all five languages supported by the IEC 61131-3 standard including; Sequential Function Chart, Ladder Diagram, Structured Text, Instruction List and Function Block Diagram. All five languages must be included. Any one or a combination of the aforementioned programming languages can be used to implement the system strategy. The programming software must be WindowsÔ based and be able to operate on WindowsÔ 95, 98, NT, 2000, Millennium and XP operating systems.
d. PLC’s provided under this specification shall be capable of performing the necessary logic to control the system as previously defined. These capabilities shall include, but not be limited to the following:
1. Discrete input/output 10. Latch/unlatch relays
2. Analog input 11. Counters
3. Analog output 12. Comparators
4. Timers 13. Ladder logic
5. Pump Controller 14. Flow Totalization/Integration
6. Pump Alternation 15. Intrusion Detection
7. Mathematical Function Blocks 16. Time of Day Control w/Lockout
8. Stage Blocks 17. Ramp Blocks
9. Trending 18. Data Logging
e. PLC’s shall be capable of performing diagnostic functions. CPUs shall continuously
monitor the functionality of the system and record errors and specific system events. A
diagnostic buffer shall retain fault and interrupt events.
f. Communications between the Master PLC and the computer shall be accomplished using standard off-the-shelf drivers allowing use of standard Windows DDE and or OPC software drivers. The PLC system configuration software shall allow the MTU tagname data base to be exported to the computer HMI software providing continuity between PLC and HMI tagnames and making future changes/upgrades more efficient and less prone to database tagname error. Communications between the Computer and Master unit and the Master unit and the remote (off-site) units shall be via high speed communications port (RS-232 (up to 115 Kbps) or Ethernet 10/100 BaseT (10/100 Mbps) in conjunction with a modem over the previously specified telemetry medium.
g. Each PLC shall have memory protected built in historical archiving/data logging of system alarms & events and process variables. Data logger shall be able to log data based on time or an event. PLC shall have enough memory allocated to allow 200,000 time and date stamped discrete and/or analog values to be archived. The historical archive shall allow the oldest data to roll off the system as memory is used keeping the 200,000 most current data points available. Process point time stamping frequency shall be selectable within the configuration software. It shall be possible for the archived data to be exported in CSV format allowing use with standard spreadsheet and data base software applications.
h. Each PLC shall have built in web server capability allowing system information to be stored in a format that allows for easy access and viewing with standard WindowsÔ based browser. Each unit shall be furnished with built in O & M data associated with its specific site including; as a minimum, basic system information, panel layouts, wiring diagrams, material lists w/part numbers, and operational summary. This information shall be accessible locally or remotely.
4. Communications:
a. The PLC telemetry system shall utilize USFilter “open” industry non licensed standard communications protocol that will permit interface with other equipment that may not be supplied by the same manufacture. Protocols that are proprietary and closed ended will not be acceptable. Upon request by the end user, the system supplier shall provide, to the owner, documentation describing the supplied communications protocol so that it may be used in future telemetry additions to insure interface-ability of other third party RTUs and or PLCs.
b. The telemetry system must be able to simultaneously support multiple communications protocols. The system supplied, as a minimum shall be able to supply USFilter “open” and Modbus RTU/ASCII (Remote/Slave) output data via RS-232, 485 & Ethernet format thus insuring a primary means of interfacing with non-related equipment.
c. The PLC system shall allow telemetry operations over multiple (LAN/WAN) communication media affording the most efficient and reliable solution including; DC metallic wire pair, dedicated leased voice grade phone line, standard dial up phone line, wireless cellular dial up system, cable TV, Fiber optics, Ethernet 10/100 BaseT, VHF Radio, UHF Radio, Dedicated Microwave Radio, and Ethernet Wireless. System communication architecture can be based on any one or a combination of these media. The communications speed shall be set to the highest speed allowed by the selected media. This system shall be based on the use of _______ as the primary communication media(s).
d. The system shall support multiple modes of telemetry operation allowing highest possible system reliability and real-time response including; standard polling cycles, peer-to-peer, quiescent (Report on exception), store and forward (Repeater). System communication architecture can be based on any one or a combination of these modes of operation. This system shall utilize ________ mode(s) of operation.
e. The PLC telemetry system shall employ a high level, efficient, secure communications protocol for communications between Master Telemetry Unit (MTU) and Remote Telemetry Unit(s) (RTU). As a minimum the telemetry system shall utilize BCH, CRC16 or other high level error detection/rejection protocol to ensure true transmission/reception of data. Systems utilizing communications protocols with less capable error detection/rejection capabilities shall not be suitable for this application and will be summarily rejected.
f. The PLC system shall allow local or remote configuration or RTU troubleshooting without the need to be onsite. The system protocol shall support remote upload and down load file transfers between the master unit and associated RTUs. File transfer function shall provide reliable means of remotely transferring RTU configuration files so that any RTU configuration can be uploaded through the selected telemetry communications media to the online PC via the MTU, modified and then downloaded to the RTU. The system shall support transfer of RTU historical files for recovery of historical data stored at each RTU in the event of communication or MTU failure. Historical files can be reassembled at the MTU/PC so that no loss of data occurs due to temporary communications interruptions. The Main PLC shall be supplied with a standard dial up modem allowing remote system access for factory service and technical support.
5. I/O Systems:
a. The PLC system shall have I/O resources to support a wide variety of applications without needing to depend upon alternate technologies to meet various system data requirements. Each PLC shall be supplied with the required I/O to meet the specified requirements and allow for a minimum of 100% spare capacity for future expansion. The PLC system shall be easily scaled from a stand alone unit capable of supporting up to 1,024 local, 1,024 remote I/O, and 10,000 Ethernet networked I/O points or one of 254 RTUs with a total system data handling capability of 50,000 points.
b. The PLC system shall support a wide variety of modular I/O with various configurations to permit the most efficient use of I/O hardware and panel space. I/O modules shall be available for local I/O (within control panel), remote I/O (RS-485 based distributed outside of the control panel) and Ethernet based I/O (Distributed I/O on high speed in plant network or wireless Ethernet). Each I/O module shall be DIN rail mounted, have compression wire type terminals capable of accepting 14 AWG wire, have wire identification markers and I/O wiring diagram. Each module shall include diagnostic LEDS indicating module operational and I/O status. Each I/O module shall be electrically isolated, meet IEEE-472 (ANSI C37.90) surge withstand certification, shall be removable under power and easily field replaced with a spare module requiring no software/hardware reconfiguration adjustments. Each module shall be safety keyed to insure proper installation. I/O modules shall permit installation and operation in hazardous locations as classified under UL, CSA Class 1, Div. 2, Groups A, B, C & D.
c. Local I/O modules shall be connected to the PLC by a dedicated high speed serial communications port and shall allow local networking of 128 I/O modules for a total of 1024 I/O points via 2 twisted shielded wire pairs separated by up to 50 Ft. Local I/O to PLC update time shall not exceed 150 mS.
d. Remote I/O modules shall be connected to the PLC by a dedicated high speed isolated serial communications port and shall allow networking of 32 I/O modules directly or with up to 4 gateway I/O expansion modules allow 128 I/O modules for a total of 1,024 I/O points via RS-485 multidrop communications network separated by up to 10,000 ft. Remote I/O modules shall support multiple communications protocols including Modbus ASCII and RTU allowing connection to any device supporting these protocols
e. Ethernet I/O modules shall be connected to the PLC by on board Ethernet 10/100 BaseT connection port. Ethernet I/O modules shall support multiple communications including TCP/IP and Modbus ASCII and RTU allowing connection to any device supporting these protocols over standard Ethernet backplane.
f. Master & Remote PLCs shall be IntraLink LC3000 as manufactured by US Filter Control Systems or pre-approved equal.
6. Operator Interface Panel (Optional)
a. An Operator Interface/Keyboard Display shall be supplied for the Master PLC and (Remote PLCs) and is to be mounted on the door of the enclosure. Keypad/Display shall allow the Operator to view and modify system variables within the PLC. Keypad/Display shall be NEMA 4 rated, have 20 system/function keys with tactile feedback, and have a minimum of 64 x 128 pixels capable of displaying graphics and a minimum of 8 lines with 20 characters per line. The display shall be a high contrast backlit LCD display so that it is unaffected by a wide range of ambient light conditions.
b. Operator interface shall have sufficient performance to permit real time updates of system data and shall be capable of display update at least 3 times per second. Operator initiated screen change shall occur within 50 mSec. The display shall incorporate a power save feature that shuts down the display after 5 minutes of keyboard inactivity.
c. The system display shall be preconfigured to reflect system parameters. The display shall support a minimum of 50 customizable main level process system displays. These displays shall be configured with graphical and text based data for the specific application to meet system monitoring and process control needs. The display shall be easily navigated by using a simple menu type format branching down to sub menus/levels. The display shall allow an operator to return to the main level with a one step push button entry. All system data and parameters shall be security protected. The system shall employ a hierarchal security password system affording a minimum of three (3) levels of password protected access to the system.
d. The display system shall incorporate a basic trending package that shall allow sixty samples of time based data for a single discrete or analog based data point to be displayed. The system shall allow trend display of any data point in the system.
e. The display system shall be able to display current and historical alarms and events. Upon the occurrence of a new unacknowledged alarm, the display shall show the date and time and sound an audible tone indicating the presence of an unacknowledged alarm. Acknowledging the alarm via the display keyboard shall silence the audible tone. Subsequent alarms shall reactivate the alarm audible tone. Historical alarm and event information shall be viewable from the display with the last 1,000 alarms or events including date and time of alarm being available.
f. The Operator Interface shall provide locally viewable system diagnostics for the PLC system to permit an on site method of troubleshooting the system without the need for specialized tools or knowledge. Diagnostics indicating system processor and communication errors and CPU