DIVISION 17 INSTRUMENTATION - Prime Construction Group · 13. System training on new and existing Wonderware ArchestrA software application programming as specified herein. B. The

ORLANDO:45530-003 S017000 SEMINOLE COUNTYYANKEE LAKE WRF R&R

DIVISION 17

INSTRUMENTATION

ORLANDO:45530-003 S17000-1 final SEMINOLE COUNTYYANKEE LAKE WRF R&R

17000-1 INSTRUMENTATION AND CONTROLS

SECTION 17000 – INSTRUMENTATION AND CONTROLS

PART 1 -- GENERAL

1.01 SCOPE OF WORK

A. The instrumentation system integrator (INTEGRATOR) shall provide all hardware,software, and programming improvements as defined herein. The scope of the work tobe performed under this Section includes, as a minimum:

1. Upgrade of the existing programmable logic controllers (PLCs) for the Equalization(EQ) Building PLC 6011 and the Belt Filter Press (BFP) Building PLC 6012 fromMOSCAD PLCs to ACE3600 PLCs, including the migration and upgrade of theexisting PLC programming to meet current Seminole County (COUNTY)standards.

2. Remove programming in the upgraded BFP Building PLC 6012 for the existingRAS pumps and effluent transfer pumps (I/O moved to the MCC2 PLC 6019).

3. Update of the software programming on the existing ACE3600 PLC for the MCC2PLC 6019 to meet current Seminole County standards and to add input/output(I/O) for the new positive displacement (PD) blowers, the replacement returnactivated sludge (RAS) pumps, and the migrated effluent transfer pumps.

4. Modify the existing programming of the MCC2 PLC 6019 for the remaining twoexisting blowers (one being removed) and the two new positive displacementblowers and associated new variable frequency drives (VFDs) as specified herein.

5. Modify the existing programming of the Motor Control Center (MCC) 2 PLC 6019to include I/O and control of the smaller replacement RAS pumps and associatedreplacement variable frequency drives (VFDs) as specified herein. Migrate theexisting I/O and control of the effluent transfer pumps from the BFP Building PLC6012 to the MCC2 PLC 6019.

6. Installation of new hardware and associated programming to connect theupgraded PLCs to the existing plant local area network (LAN) using the lateststandard hardware products used by the COUNTY.

7. Furnish and place in service two wireless tablet computer (WTC) devices to allowfull access for monitoring and control of the Yankee Lake Water ReclamationFacility (YLWRF) process through the plant’s existing secure wireless network.

8. Furnish and place in service replacement uninterrupted power supplies (UPSs) forthe upgraded PLCs.

9. Furnish surge protection devices for new hardware as specified herein.

10. Furnish and install a new, rack-mounted PC work station in the existing electricalbuilding for full process interface.



11. Modifications to the existing ArchestrA System Platform Galaxy Repositorysoftware for operation of the new blower aeration supply system and thereplacement RAS pumps along with verification that full control interface andfunctions have been reinstated for the replacement filter backwash pumps andreplacement effluent transfer pumps (pumps replaced in kind under this project).

12. Development of reports as noted herein.

13. System training on new and existing Wonderware ArchestrA software applicationprogramming as specified herein.

B. The division of work for the CONTRACTOR, Electrical Subcontractor, and theINTEGRATOR with regards to the instrumentation system improvements is as follows:

1. The CONTRACTOR shall retain overall responsibility for the modifications to theYLWRF plant instrumentation and control system as specified herein.

2. The CONTRACTOR shall be responsible to install all new instruments as specifiedherein and as indicated on the Drawings.

3. The CONTRACTOR shall furnish and install new instrument supports, sunshield,and mounting hardware as shown on the Drawings.

4. The Electrical Subcontractor shall provide final termination and testing of allinstrumentation and control system signal wiring and power supply wiring at allequipment furnished under this Section.

5. The INTEGRATOR shall furnish transient voltage surge suppression systems forall new instruments which shall be installed by the Electrical Subcontractor.

6. The INTEGRATOR shall provide all remaining work efforts (hardware and softwaresupply and installation) necessary to complete the scope of work as outlined in theprevious paragraph along with all testing, calibration, training and startup servicesas specified herein.

1.02 INSTRUMENT AND HARDWARE SUBMITTALS

A. Submit information for all new hardware including, but not limited to, the following:

1. Product (item) name, description, and proposed tag name following COUNTYstandards for similar devices and equipment.

2. Catalog cuts with manufacturer's complete model number.

4. Location and mounting of the device.

5. Interface characteristics (power, signal, communications, grounds, etc.)

6. Range, size, ratings, capacities, etc.



7. Physical size with dimensional drawings, NEMA enclosure classification andmounting details.

8. Materials of construction of all enclosures, wetted parts and major components.

9. Instrument or control device sizing calculations where applicable.

10. Certified calibration data on all flow metering devices.

11. Environmental requirements during storage and operation.

12. Associated surge protection devices.

13. Mounting requirements, including replacement components for an existing PLC.

14. Environmental requirements during storage and operation.

15. Complete panel fabrication shop drawings including panel layouts and wiringdiagrams.

1.03 SOFTWARE AND OTHER SUBMITTALS

A. Software submittals shall include the following as a minimum:

1. PLC I/O schedules for interface with signals being sent to and received from theupgraded replacement PLCs or for existing ACE3600 PLCs where new I/O isrequired for new or modified control functions as specified herein. List completeaddresses and ArchestrA Objects for each new I/O following COUNTYstandards. List existing addresses and ArchestrA Objects for I/O that is reusedor retained.

2. Modifications to the existing ArchestrA System Platform Galaxy Repositoryexisting object templates, corresponding PLC register cross reference, scales,functions, etc.

3. Written control strategy documentation to describe the proposed added ormodified control logic in the PLCs, interface with the field signals, and description/ depiction of Wonderware ArchestrA operator interface features.

4. Upon approval of PLC I/O schedules, new Wonderware ArchestrA databasepoint list, and written control strategy documentation, submit a completeelectronic, searchable pdf file of fully commented modified or new PLC controllogic programming and a complete electronic, searchable, pdf file copy ofproposed Wonderware ArchestrA display screen modifications and constructedreports.

B. Submit a detailed resume and references of the INTEGRATOR’s project engineer thatwill be assigned for the duration of the project. The project engineer shall be anelectrical engineer specializing in the selection and implementation of instrumentation,control, and monitoring systems of the type specified herein for the past five (5)consecutive years.



C. Submit training outlines as specified hereinafter.

D. Submit testing forms for approval a minimum of three (3) weeks prior to the proposedtests.

E. Submit a 2-year warrantee from date of substantial completion. Warranty is to coverhardware and workmanship for the design, assembly, installation, and materialsprovided by the INTEGRATOR. Submit any standard manufacturer’s warranteesprovided with equipment supplied (PLC, UPS, etc.) with Seminole County Utilitiesnamed as the owner and beneficiary. Submit warranties for the fiber optic cable andnew PC as specified herein.

1.04 OPERATION AND MAINTENANCE MANUALS

A. Provide equipment operation and maintenance manuals for new instruments andhardware components supplied under this project. The manuals shall contain allillustrations, detailed drawings, wiring diagrams, and instructions necessary forinstalling, operating, and maintaining the equipment. The illustrated parts shall benumbered for identification. All modifications to manufacturer standard equipmentand/or components shall be clearly identified and shown on the drawings andschematics. All information contained therein shall apply specifically to the equipmentfurnished and shall only include instructions that are applicable. All such illustrationsshall be incorporated within the printing of the page to form a durable and permanentreference book.

B. The manuals shall be prepared specifically for this installation and shall include allrequired cuts, drawings, equipment lists, descriptions, etc. that are required to instructoperation and maintenance personnel unfamiliar with such equipment. The maintenanceinstructions shall include trouble shooting data and full preventive maintenanceschedules.

C. Provide the number and type of electronic and hard copies specified under the GeneralRequirements.

1.05 FINAL SYSTEM DOCUMENTATION

A. Provide two (2) copies on digital storage device for all software modifications for thePLC and Wonderware ArchestrA application, including report forms generated. PLCfiles shall include all comments.

B. Provide updated network diagrams and control panel wiring diagrams for allmodifications made under this project. Provide drawing files for diagrams in dwg andpdf format.

1.06 SHIPPING HANDLING AND STORAGE

A. In addition to shipping, handling and storage requirements specified elsewhere in theContract Documents, air conditioning/heating shall be provided for storage of all newinstruments, hardware, and ancillary devices to maintain temperatures between 20 and



25 degrees C and relative humidity 40 to 60 percent without condensation. The air shallbe filtered and free of corrosive contaminants and moisture.

1.07 INSTALLATION

A. All instrumentation and control system installation work shall conform to all applicablecodes and standards, including COUNTY standards for control systems, and be inaccordance with manufacturer’s recommendations.

B. All labor shall be performed by qualified craftsmen in accordance with the standards ofworkmanship in their profession and shall have had a minimum of five (5) years ofdocumented experience on similar projects.

D. All equipment and materials shall fit properly in their installations. Any required work tocorrect improperly fit installations shall be performed at no additional expense to theCounty.

E. The CONTRACTOR shall provide all required cutting, drilling, inserts, supports, bolts,and anchors, and shall securely attach all equipment and materials to their supports.

1.08 OWNER TRAINING

A. Provide a minimum of two (2) sessions, each approximately four (4) hours in duration, totrain operations staff on all new and modified control functions for the blowers and RASpumps.

B. Provide a minimum of two (2) sessions, each approximately four (4) hours in duration, totrain maintenance staff on all new instrument operation, calibration, and maintenance.

C. Provide a minimum of two sessions, a minimum of four (4) hours in duration, to trainoperations staff on the new report forms generated.

D. Provide a minimum of two (2) seats for factory Wonderware ArchestrA training, for twoseparate (4) sessions, each approximately eight (8) hours in duration, to train COUNTYsoftware maintenance staff on Wonderware ArchestrA software to increase their abilityto be self-sufficient in making upgrades and updates to the software used for plantcontrols. The area(s) of training shall be selectable by the COUNTY from a library ofstandard training events available

E. All the above training shall be professional digitally recorded to produce an audiblylegible, visual clear recording.

F. For each of the above training sessions, submit for approval a training plan to depict theproposed topics to be covered, time duration for each topic, instructor’s qualifications,and proposed training venue needed (class room, hands on at work stations, field, etc.).Submit training plans at least 30 calendar days prior to scheduled training event.



1.09 INTEGRATOR

A. The INTEGRATOR shall be a Motorola Inc. authorized Motorola Value Added Reseller,(VAR) of Fixed Data Products, registered as a Florida electrical contractor with a Floridalicensed electrical engineer on staff.

B. The INTEGRATOR shall have installed at least three (3) ACE3600 within the lasteighteen (18) months.

C. The INTEGRATOR shall be a Microsoft Solutions Provider and a WonderwareArchestrA Application Server Systems Integrator and have completed a minimum ofthree (3) Wonderware “ArchestrA” installations within the last eighteen (18) months.

D. The INTEGRATOR shall maintain an inventory of applicable spare Motorola ACE3600PLC parts and be able to provide delivery within four (4) hours for inoperable systemsand be able to provide a maximum on-site response time of four (4) hours for inoperablesystems and twenty-four (24) hours for trouble calls that do not cause system downtime

E. The INTEGRATOR shall be a UL certified panel manufacturer and all control panelssupplied shall have UL labels applied.

F. The INTEGRATOR shall be Revere Controls (Lakeland, Florida) or approved equal.

PART 2 -- PRODUCTS

2.01 PROGRAMMING STANDARDS AND LICENSING

A. Programming format: New and modified programming of software for any existing PLCsand the plant workstation Wonderware ArchestrA operator interface displays anddatabase shall be completed using the COUNTY’S latest standards using the existingprogramming software, current version. Programming of software for any new PLCsshall be completed using the latest Motorola ACE3600 software with a licensed copy ofsoftware provided to the County.

B. Licensing: All new software licenses shall be specified to be registered and licensed tothe Seminole County Board of County Commissioners, including equipment licenses forMotorola software (regardless of any existing agreements or licenses the COUNTYholds with Motorola).

C. Standards: All instrumentation and control work at the YLWRF shall meet or exceed thelatest version of Seminole County Environmental Services Department’s (SCESD’s)Instrumentation and Control Design Guidelines Document (I&C DGD) – current file is“Seminole County Design Guidelines Rev E 01252013.pdf”. This includes signal typeand voltages, equipment make and model numbers, surge protection, backup power,wiring practices, documentation, and all other aspects and features of the work providedfor this complete scope of services. The INTEGRATOR shall obtain a copy of the latestversion of the I&C DGD at time of bid and regularly maintain and update the document,meeting all latest standards, throughout the construction period.



2.02 PLC HARDWARE AND SOFTWARE

A. Replacement hardware components for upgrading and existing PLC to a Motorola ACEproduct shall be in accordance with SCESD’s SCADA Hardware Master Plan (SCADAHMP) recommended components as listed below. The intent of the list given below is tospecify model numbers offered by Motorola at the time of the latest update of theSCADA HMP. Motorola regularly updates model numbers. The latest equivalent versionof model number for the one listed below at the time of fabrication (even if a previousversion has already been approved in a submittal) shall be furnished.

Component Model Number

CPU Module: Motorola ACE FLN3524A

Expansion CPU Module Motorola ACE FLN4075A

Power Supply Modules:

W/ battery charger Motorola ACE FPN1903A

Expansion Module Motorola ACE FPN1654A

DI Module: 16pt, 24V, Motorola ACE 16DI FST

DO Module: 16pt, 2A, 24V, Motorola ACE 16DO ML RELAY

AI Module: 8pt, 4-20mA, Motorola ACE 8AI

AO Module: 4pt, 4‐20mA, Motorola ACE 4AO

Mixed IO Module: 16DI, 4EE AI+/‐20mA, Motorola ACE MIX IO

Ethernet Module Motorola ACE EXPANSION LAN

B. The number of I/O modules to be furnished for a replacement PLC shall be sufficient tohandle all the new and existing I/O to/from the PLC and shall also comply with the I&CDGD standards for spare I/O capacity, distribution of similar I/O points on a given PLC.

D. Replacement components shall be installed in available space within the existing PLCenclosure in place of the existing components. Submittal on the equipment shall depicthow the replacement equipment will be installed within the existing enclosure to verifyspace and mounting requirements.

2.03 UNINTERRUPTED POWER SUPPLY (UPS)

A. The new rack-mounted PC shall be powered through an uninterrupted power supply(UPS) furnished and installed under this section. The UPS shall be sized for at least150% of the connected loads, 30 minutes of backup power, and be installed with abypass switch. The UPS shall be mounted separately adjacent to the PC rack.

B. The UPS shall be of the on-line, double-conversion type with true sine wave output.UPS shall provide power conditioning to the load with UPS receptacles color-codedorange and identified as for UPS supplied equipment only.

C. The bypass switch shall be such that the UPS can be taken out for maintenance withoutdisturbing the devices the UPS protects. The design shall provide for power conditioningwhen the UPS is bypassed.



D. The UPS shall provide auxiliary contact outputs connected to the nearest PLC tomonitor UPS alarm, UPS Fail, low battery, main power fail, and UPS bypassed.Alternately, the UPS may be connected to the nearest PLC network over an Ethernetcable to obtain the above general UPS condition along with configuration information.

E. The UPS shall be either as manufactured by Powerware or APC and shall be incompliance with the I&C DGD requirements, including a surge protection device on the120V power source to the UPS.

F. Add all monitoring and alarm parameters for the new UPS to match existing UPSmonitoring displays (similar to “SER – UPS #1” display).

2.04 NETWORK HARDWARE AND SOFTWARE

A. The new rack-mounted PC shall be supplied with network communication hardware tomeet the minimum standards listed in the I&C DGD. The replacement PLC componentsshall include replacement of the PLC’s hardware to connect to the plant’s LAN to alsomeet the minimum standards listed in the I&C DGD. The intent of the list ofcomponents given below is to specify a specific brand listed in the latest update of theI&C DGD. However, the latest equivalent version of any model number given for the onelisted below at the time of fabrication (even if a previous version has already beenapproved in a submittal) shall be furnished.

Cisco Catalyst 3850 Series Poe48 Ethernet Network Switch

Cisco Ethernet Fiber-to-Copper Media Converter

CAT6 Ethernet Cable, plenum rated communication cables, within the PLC orbetween components located in the same building

Security, IP based network addressing

Fiber cable and patch panels as specified herein

Provide more than one network drop per location for backup

B. Provide single-mode fiber cable to connect the new PC to the existing server. Fiberoptic cable shall be installed with at least 50 percent spare conductors, minimum of two(2) spare conductors. All fiber optic cable, including spares, shall be tested anddemonstrate that 100% of the fibers in each cable meet the requirements of TIA/EIA568, Annex H. Provide a machine printout confirming cable testing results. Fiber Cableshall be as manufactured by Corning or approved equal and shall be provided with a 25-year warranty on the cable.

C. Fiber Optic cable shall be installed by a certified installer and all fiber optic cable,including spares, shall be terminated or spliced in a fiber optic patch panel. Providepatch cables as required. The patch panels shall be provided as rack mountedinstallations in the new and existing racks.

2.05 WIRELESS TABLET COMPUTER (WTC)

A. Provide a minimum of two (2) WTC’s that are setup to utilize the secure wirelessnetwork at the YLWRF through demand credentials. WTC’s shall have the following:

Operating system: Windows 10 Pro 64



Processor family: Intel® Core™ i5 processor

Processor technology: Intel® Core™ i5 with vPro™ technology

Chipset: Chipset is integrated with processor

Memory: 4 GB DDR3L SDRAM (1 x 4 GB)

Internal drive: 128 GB M.2 SSD

Display: 12.5" diagonal FHD UWVA eDP 1.3 LED-backlit touch screen (1920 x

1080), multi-touch capacitive digitizer, auto rotate, Corning® Gorilla® Glass 3

Graphics: Intel® HD Graphics 4200

Ports: 1 DisplayPort 1.2; 1 USB 3.0; 1 USB 3.0 charging; 1 docking connector to

tablet for power keyboard; 1 side docking connector for power keyboard; 1

headphone/microphone combo; 1 4.5 mm multi-pin AC port; 1 RJ-45; 1 VGA

Expansion slots: 1 SD; 1 smart card reader

Audio: HD audio with DTS Sound+; Dual speakers (front facing); Dual microphone

array with echo cancellation, noise suppression; Headphone line-out and

microphone-in (combo)

Integrated camera: 2 MP 1080p FHD front-facing webcam; 5 MP FHD 1080p rear-

facing

Power keyboard: spill-resistant power keyboard with drain, HP Pro x2 612 Backlit

Pointing device: Touchpad with scroll zone, on/off button with LED indicator, two-

way scroll, two pick buttons for power keyboard

Wireless: Intel Dual Band Wireless-AC 7260 802.11a/b/g/n/ac (2x2) WiFi and

Bluetooth® 4.0 Combo

Power supply: HP 45 W Smart AC adapter

Battery: 4-cell, long life 29.3 WHr Li-ion polymer

Battery life: 4-cell, long life 29.3 WHr

Energy efficiency: ENERGY STAR® certified

Dimensions (W X D X H): 12.48 x 9.43 x 0.92 in (tablet with power keyboard)

Weight: 2.16 lb

Warranty: HP Elite Support with limited 1-year standard parts and labor (1/1/0)

warranty. Power Keyboard with one-year, worldwide parts-and-labor limited

warranty; 24x7 HP technical phone support during warranty.

Security management: TPM 1.2 (Infineon, soldered down); HP Fingerprint reader;

Integrated smart card reader (active); Preboot Authentication (password, Smart

Card); HP Client Security; HP File Sanitizer; Drive Encryption; Absolute

Persistence Module; HP Device Access Manager with Just in Time Authentication;

HP SpareKey

Application License: Wonderware ArchestrA “InTouch for System Platform for

Remote Desktop Services”.

2.06 WORKSTATION HARDWARE AND SOFTWARE

A. The new workstation computer shall meet the minimum requirements listed in the I&CDGD for operator workstations (OWS). The new workstation shall be a rack mountedsystem. The new work station PC shall have a full Wonderware ArchestrA “InTouch forSystem Platform for Remote Desktop Services” license (60,000 tags) with full I/O andtwo NIC cards along with development software to enable remote on-line programming



of the new Motorola PLC’s over the plant PLC network. Coordinate licenserequirements with County’s local InSource Representative, Rich Hinkle (804)419-9141.

B. Auxiliary and accessory devices necessary for system operation or performance, suchas network switches and media converters to interface with existing or new equipmentshall be included whether they are shown on the Drawings or not.

C. All equipment and installations shall satisfy applicable Federal, State and local codes.

D. Provide all programming, configuration, and related services required to achieve a fullyintegrated and operational workstation, including the following:

1. Provide configuration of the Wonderware ArchestrA application to mimic existingworkstations in full conformance with the County’s OWS graphical standards forthe County’s Invensys Archestra System Platform SCADA system

2. Provide configuration of the new workstation to fully support and allow operatoruse of the existing and any new report software and forms.

3. Provide for and test communications and functionality between all connecteddevices on the existing plant communication networks (PLCs and existing server).

4. All work shall be coordinated with plant operating personnel to minimize impactson daily operation. Delays caused for any reason shall be noted and formallysubmitted to the ENGINEER and the OWNER in the form of a letter.

5. Provide a backup Drive Image upon final software install and setup for the newPC. Provide a license and copy of the software used to create the backup driveimage.

E. Provide next day computer manufacturer on-site service for the PC hardware devicescovering parts and labor for five (5) years from date of purchase. The on-site service isto be performed by an authorized representative of the manufacture of the installedequipment.

F. Due to rapidly evolving technology of the equipment specified herein, the requirementsspecified are to establish a baseline for the type of equipment required. Providecomputer equipment of the current available technology of advertised retail price at thetime of shop drawing submittal equivalent in value to the advertised retail price at thetime of bid for the specified system in order to reflect technology advances during theelapsed construction period. The INTEGRATOR shall submit for approval the requireddata for the equipment as part of the hardware submittal. The equipment shall then beordered as late as possible dependent on the construction schedule to ensure the latestequipment available is provided. No equipment shall be ordered more than three (3)months prior to when it is needed to meet substantial completion.

G. Minimum requirements for the rack-mounted PC:

1. PC configured for installation in rack environment occupying 2U of rack space orless.



2. Dual Intel Quad Core Processors, 2.60 GHZ or greater, minimum of 20 MB cache,8 Core or greater.

3. 16 GB of RAM, at 1333 MHz speed minimum.

4. Hot pluggable cooling fans with N+1 redundancy

5. Media Drives: Internal DVD ± Dual-layer Drive with both Read/Write Capability

6. Hard Drive: 1 TB of usable storage minimum

7. Video graphics capable of 1920 x 1200 pixels, 70 Hz refresh rate and 32 bit truecolor minimum. VGA, DVI, and HDMI or display port outputs. 512 MB of dedicatedvideo RAM minimum.

8. I/O Ports & devices: Minimum of four USB 2.0 ports

9. Interface devices: Sliding Rails with Cable Management for generic USB 104 keyWindows rack-mounted slide-out keyboard, no hot keys, two button USB opticalwireless mouse with scroll wheel on rack-mounted slide-out mouse pad, and arack-mounted LCD 24-inch wide screen touch pad display monitor compatible withgraphics card supplied, minimum resolution 1280 x 1024.

10. Networking: Two network cards in addition to any on-board network interfacehaving the following features:a. Support for latest Microsoft PC operating systemb. Gigabit Ethernet port, copper connection accepting standard CAT-6 cables for

Ethernet communicationsc. Support for PCI-X or PCI bus in the PCd. IEEE 802.3ab support for gigabit networking standarde. Support for Ethernet port teaming across network adapter cards for increased

bandwidth and fault tolerance of both adapter and attached Ethernet switchf. IEEE 802.3ad Link aggregation supportg. IEEE 802.1Q VLAN supporth. Auto sensing 10/100/1000 Mbpsi. SNMP manageablej. TCP/IP offload engine to minimize use of computer CPU for networking tasks

11. Redundant power supplies each with separate power cord. Power supplies mustoperate from the voltage specified, be able to support the specified equipment andbe auto switching.

12. Operating system: Latest release of Windows PC (2010) Standard Edition. Provideall DVD media required to reinstall operating system and system drivers from baremetal PC configuration. Furnished operating system must be compatible withWonderware ArchestrA application, PLC programming, I/O drivers, and any othersystem software furnished on the project. Provide a Client Access Licenses(CALs) for the PC.

13. Backup software: Backup software in addition to the default Microsoft WindowsBackup utility included with the operating system shall have the following features:



a. Support the Windows operating system installed on PC

b. Perform full system backups including all open files, system state and opendatabase files without the need to stop any services or applications runningon the PC.

c. Full restore of PC from bare metal state.

d. Restore individual files from tape to original locations or to alternativelocations on the PC.

e. Backup job scheduler capable of supporting multiple schedules for full,incremental and partial backup jobs

f. Backup software shall keep a log file of the status of all backup and restoreactivities. Log file shall easily export to a text file.

Provide Acronis or Symantec back-up software or equal. Provide a backup DriveImage upon final software install and setup.

14. Other Software:

a. Adobe Acrobat Reader (Latest Edition)

b. Virus scan and protection software either McAfee Virus Scan Enterprise orSymantec Norton AntiVirus Business Pack (Latest Edition)

c. Microsoft Internet Explorer (Latest Edition)

d. Microsoft Office Professional, latest version, with local versions of MicrosoftExcel, Word, Access, and PowerPoint programs, minimum.

15. Support Package: 3-Year Mission Critical Package including 4-Hour 7x24 On-SiteService with Emergency Dispatch and 3-Year 7x24 Hardware and SoftwareTechnical Support and Assistance.

16. PC Model: Rack-mounted PC equivalent to a Dell PowerEdge latest model orsimilar unit as supplied by Hewlett Packard.

2.07 FIELD INSTRUMENTS

A. Pressure Gauges:

1. All gauges shall be designed in accordance with the ASME B40.1 entitled,"Gauges, Pressure, Indicating Dial Type - Elastic Element".

2. All gauges shall be direct reading type. Snubbers shall be provided on all gauges.Gauge full-scale pressure range shall be selected such that the maximumoperating pressure shall not exceed the approximately 75% of the full-scale range.



3. Features:

a. Mounting: ½” NPT, lower stem mount type

b. Accuracy: 0.5% full scale

c. Case: Solid front, black phenolic material

d. Dial: White background and black letters

e. Glass: Shatterproof

f. Blow-out protection: Back

g. Pressure element: Stainless steel bourdon tube

h. Movement: Stainless steel, Teflon coated pinion gear and segment

i. Gaskets: Buna-N

4. Liquid-filled or equivalent mechanically-damped gauges shall be used if thegauges are installed with pumps, or where gauges are subjected to vibrations orpulsation. Filling fluid shall be silicone unless oxidizing agents such as sodiumhypochlorite are present, where halocarbon shall be used.

5. Gauge size shall be 2" for process line sizes up to 3" and 4½" for process linesizes of 4" or greater.

6. Provided with diaphragm seals, 316 stainless steel construction. However,diaphragm material shall be non-reactive with the process fluid. Seals shall have a3” process connection, 1/2-inch NPT valved flush port, 1/2-inch instrument tap,and capable of disassembly without loss of filler fluid.

7. The complete gauge assembly and appurtenances shall be fully assembled andtested prior to field mounting. A 3” isolation Type 316 stainless steel ball valveshall be provided for each gauge assembly.

8. Pressure gauges shall be Ashcroft Duragauge Model 1279, Ametek-U.S. GaugeDivision, H.O. Trerice Co., WIKA Instrument Corporation, or approved equal withHelicoid Type 100 HA, Mansfield & Green, Ashcroft, or approved equal diaphragmseals.

2.08 SPARE PARTS

A. The following spare parts shall be provided:

1. One PLC processor, pre-configured

2. One of each type PLC I/O module

3. One PLC Power Supply



4. One of each type of PLC communication module

5. Two of each type of surge suppressor.

6. Minimum of five of each type of fuse.

7. Samsung - T1 500GB External USB 3.0 Portable Solid State Drive

PART 3 -- EXECUTION

3.01 BLOWER PROCESS FUNCTIONAL DESCRIPTION

A. Control Description

1. BLOWER CONTROL – The new and existing blowers shall operate as followsbased on an existing ORP analyzer signal across the PLC network:

a. The LEAD positive displacement (PD) blower VFD speed shall modulate in

response to the error signal between the actual measured ORP and an

adjustable ORP setpoint. Typically, only one of the new PD blowers will be

needed for this process function. There are three existing ORP probes. The

ORP signal used to control the new blowers shall be the ORP probe located in

the control variable process train zone as determined by the operators.

Provide a software selection switch to enable operators to select the desired

signal to control the blowers.

b. When the actual measured ORP is not able to be maintained by the LEAD PD

blower, the LAG PD blower shall be started and the speed output shall ramp

the LAG PD blower VFD to match the speed of the LEAD PD blower VFD and

then modulate both PD blower VFDs in response to the error signal between

the actual measured ORP and the ORP setpoint.

c. If both PD blowers are running at minimum speed for an adjustable time

period, the LEAD PD blower shall turn off and the LAG PD blower shall

become the new LEAD PD blower.

d. Lead/Lag selection shall be through a software LEAD 1 / ALT / LEAD 2

selector switch where LEAD/LAG PD blowers shall rotate each duty cycle when

in ALT, PD Blower 1 is always lead when in LEAD 1, and PD Blower 2 is

always lead when in LEAD 2.

e. If one of the two PD blowers is out of service or has failed and a second blower

is required to maintain the ORP setpoint, the LEAD PD blower shall be turned

off and the LEAD existing centrifugal blower shall be turned on in its place. An

alarm of this condition shall alert operators to this change in control mode. The

existing PLC control logic and OWS interface for two of the three existing

centrifugal blowers and the associated bleed valve shall be maintained and

shall be utilized to run a LEAD centrifugal blower when it is called to run

(controls the blower, associated inlet valve, and the air header bleed off valve).



The existing programming shall be modifed to remove all I/O and display

features for blower 2 (being removed under this project). The existing

programming shall be modified to add a software LEAD 1 / LEAD 2 selector

switch for the two remaining existing centrifugal blowers to allow operators to

select which of the blowers is LEAD.

2. MOTOR TEMPERATURE PROTECTION CIRCUIT – Each PD blower motor hasmotor high temperature switches. At the VFD, a hard-wired circuit shall stop theblower in the event that a motor high temperature condition occurs (see Section16370, Variable Frequency Drives). Alarm from the VFD shall be indicated on theOWS and that blower shall be taken out of service and replaced with the otherblower as the LEAD. Blower shall require manual reset to restart either at the VFDor by remote reset command from the OWS.

3. DISCHARGE HEADER HIGH TEMPERATURE PROTECTION CIRCUIT – EachPD blower discharge pipe has a high temperature switch. At the VFD, a hard-wired circuit shall stop the blower in the event that a discharge high temperaturecondition occurs (see Section 16370, Variable Frequency Drives). Alarm from theVFD shall be indicated on the OWS and that blower shall be taken out of serviceand replaced with the other blower as the LEAD. Blower shall require manualreset to restart either at the VFD or by remote reset command from the OWS.

4. DISCHARGE HEADER HIGH PRESSURE PROTECTION CIRCUIT – Each PDblower discharge pipe has a high pressure switch. At the VFD, a hard-wired circuitshall stop the blower in the event that a discharge high pressure condition occurs(see Section 16370, Variable Frequency Drives). Alarm from the VFD shall beindicated on the OWS and that blower shall be taken out of service and replacedwith the other blower as the LEAD. Blower shall require manual reset to restarteither at the VFD or by remote reset command from the OWS.

5. LOCK-OUT STOP – Each PD blower has a local control station with a lock-outstop (LOS) pushbutton. The signal from this pushbutton shall be hard-wired to theVFD to stop the blower (see Section 16370, Variable Frequency Drives) and anauxiliary second set of contacts on the pushbutton shall send a signal to the PLCto indicate the blower has been stopped for this reason. The blower shall be takenout of service and replaced with the other blower as LEAD.

6. VFD FAULT – Each PD blower VFD fault circuit shall stop the blower in the eventthat a VFD fault occurs (overcurrent, undercurrent, overvoltage, etc., see Section16370, Variable Frequency Drives). Alarm from the VFD shall be indicated on theOWS and that blower shall be taken out of service and replaced with the otherblower as the LEAD. Blower shall require manual reset to restart either at the VFDor by remote reset command from the OWS.

B. Equipment Local Control:

LOS pushbutton for each blower Hand-Off-Remote Selector Switch on each VFD RESET pushbutton on each VFD Manual Speed Adjustment on each VFD



C. OWS Display Interface Hand/Off/Auto Control Selection for each blower Manual Speed adjustment for each blower when in Hand Run Status for each blower Runtime Indication (in hours and tenths of hours) for each blower Remote Status for each blower VFD Fault Alarm for each blower High Motor Temp Indication for each blower High Discharge Header Temp Indication for each blower High Discharge Header Pressure Indication for each blower Blower LOCKED-OUT event Speed Indication for each blower Current (amps) indication for each blower Ready Indication for each blower (in remote, in auto, no alarms) Blower Remote Reset command (common reset) Blower start command for each blower ORP setpoint ORP probe 1/2/3 control signal selection ORP indication (existing display for each of the three probes) START LAG blower time delay setpoint MIN blower speed setpoint LEAD 1 / ALT / LEAD 2 PD blower rotation selection ORP sensor signal lost Alarm LEAD 1 / LEAD 2 centrifugal blower selection Backup Blower Control running (2 PD blowers not available)

3.02 RAS PUMP PROCESS FUNCTIONAL DESCRIPTION

A. Control Description

1. PUMP CONTROL – The RAS pumps shall operate as follows based on an existingflow meter signal:

a. The LEAD RAS pump shall run continuously to modulate in response to the

error signal between the actual flow and an adjustable flow setpoint.

b. When the actual measured flow is not able to be maintained by the LEAD

pump, the LAG pump shall be started and the speed output shall ramp the

LAG pump VFD to match the speed of the LEAD pump VFD and then

modulate both pump VFDs in response to the error signal between the actual

measured flow and the flow setpoint.

c. If two RAS pumps are running at minimum speed for an adjustable time period,

the LEAD pump shall turn off and the LAG pump shall become the new LEAD

pump. No more than two RAS pumps should ever be needed to maintain the

flow setpoint.

d. Lead/Lag selection shall be through an OWS lead/lag matrix selection as

shown below where LEAD/LAG pumps rotate each duty cycle or after an time

rotation setpoint is reached. Lead/Lag pump operation shall be selected by the

operator to control the sequencing of the pumps as follows:



1. Manual Mode: The Lead/Lag pump selection shall maintain the operatingpump’s assignment without rotating the sequence entered by theoperator (per matrix shown below). Lead/Lag pump selection shall notallow a pump to be assigned more than one role and the PLC shall alertthe operator if such selection is made.

2. Automatic Mode: The Lead/Lag pump selection sequence shall alternateeach pump process pump stop condition (first on, first off). If the processhas not allowed the Lead pump to stop, the rotation time shall force arotation. The rotation time shall be operator adjustable from the OWS.

3. Control: Provide lead/lag assignment control as follows:

Lead/Lag Pump Selection

Auto/Manual Selection Auto Manual

Auto Time Rotation 24.0 Hours

Pump No. 1 Lead Lag1 Lag2



e. There are three existing destinations to which RAS can be sent. Each

destination (Anoxic zone, EQ Tank, and Pretreatment) has a separate flow

meter and modulating valve. The flow signal used to control the RAS pumps

shall be selected by the operators. Provide a software selection switch to

enable operators to select the desired flow signal to control the RAS pumps

with an adjustable response time delay to allow program time to react to

selected flow meter setpoint. If the selected flow signal reads zero, operate the

pump(s) at a preset adjustable speed and provide an alarm to alert operators

that the destination switch may not be set correctly.

f. Each of the existing RAS destination points includes a modulating valve that in

the previous program was used to throttle the existing pumps (pumps were too

high a capacity). The replacement RAS pumps are of a lower capacity and

normally no throttling will be required as the running pumps can vary in speed

to meet the flow setpoint. Normally, the three existing throttling valves shall be

set at 100% open when any RAS pump is called to run to that selected

destination. If only one RAS pump is running as LEAD and the pump is

running at minimum speed for an adjustable time period (actual flow is higher

than setpoint), utilize the existing PLC program output to the selected

destination throttling valve to modulate the valve position to allow the pump

speed to operate at 5% over the minimum speed setting. As the pump output

rises above this point to maintain the flow setpoint, open the valve until it

returns to 100% open.

g. The existing PLC controls include a RAS ratio control and a flow mode of

operation. Utilize both these control modes to set the value of the RAS pump

flow setpoint (either calculated based on a RAS flow ratio to influent flow under



RATIO control or as a setpoint manually entered by operators under FLOW

mode).

2. MOTOR TEMPERATURE PROTECTION CIRCUIT – Each pump motor has motorhigh temperature switches. At the VFD, a hard-wired circuit shall stop the pump inthe event that a motor high temperature condition occurs (see Section 16370,Variable Frequency Drives). Alarm from the VFD shall be indicated on the OWSand that pump shall be taken out of service and replaced with the next pump in thematrix. Pump shall require manual reset to restart either at the VFD or by remotereset command from the OWS.

3. MOISTURE SEAL PROTECTION CIRCUIT – Each pump has a moisture seal failswitch. At the VFD, a hard-wired circuit shall alarm the condition but will not stopthe pump in the event of a moisture seal failure (see Section 16370, VariableFrequency Drives). Alarm from the VFD shall be indicated on the WOS and thatpump shall continue to run. Alarm shall require manual reset either at the VFD orby remote reset command from the OWS.

4. PUMP DISCHARGE LOW FLOW MONITORING – If the RAS flow is zero, thealarm for this condition is sent to operators as noted above and the pump(s) shallrun at minimum speed while the flow remains zero. If the no flow alarm isacknowledged (assumes the correct RAS destination has been selected), only oneRAS pump is running (at the preset speed for no flow), and the RAS flowcontinues to read zero after an adjustable time delay, that pump shall be stopped,taken out of service, and replaced with the next available RAS pump. If flowreturns, the stopped pump shall be placed in an alarm condition and alerted to theoperators. Alarm shall require manual reset from the OWS but can still be runmanually at the VFD. If two pumps are running with no flow reading feedback,continue to operate the pumps at the preset speed even after the time delay,continue to energize the no flow alarm.

5. LOCK-OUT STOP – Each RAS pump has a local control station with a lock-outstop (LOS) pushbutton. The signal from this pushbutton shall be hard-wired to theVFD to stop the pump (see Section 16370, Variable Frequency Drives) and anauxiliary second set of contacts on the pushbutton shall send a signal to the PLCto indicate the pump has been stopped for this reason. The pump shall be takenout of service and replaced with the next pump in sequence.

7. VFD FAULT – Each RAS pump VFD fault circuit shall stop the pump in the eventthat a VFD fault occurs (overcurrent, undercurrent, overvoltage, etc., see Section16370, Variable Frequency Drives). Alarm from the VFD shall be indicated on theOWS and that pump shall be taken out of service and replaced with the nextavailable pump. Pump shall require manual reset to restart either at the VFD or byremote reset command from the OWS.

B. Equipment Local Control:

LOS pushbutton for each pump Hand-Off-Remote Selector Switch on each VFD RESET pushbutton on each VFD Manual Speed Adjustment on each VFD



C. HMI and OIU Interface Hand/Off/Auto Control Selection for each pump Manual Speed adjustment for each pump when in Hand Run Status for each pump Runtime Indication (in hours and tenths of hours) for each pump Remote Status for each pump VFD Fault Alarm for each blower High Motor Temp Indication for each pump Moisture Seal Fail Indication for each pump No Flow warning alarm (alert to check destination setting) No Flow Indication for each pump (if verified after time delay) No Flow time delay setpoint Pump LOCKED-OUT alarm Speed Indication for each pump Current (amps) indication for each blower Ready Indication for each pump (in remote, in auto, no alarms) Pump Remote Reset command (common reset) Pump start command for each pump Flow Control selector (Ratio/Flow) Flow setpoint (flow mode) Ratio flow setpoint (ratio mode) Calculated flow setpoint (ratio mode) Flow indication MIN pump speed setpoint LEAD / LAG pump rotation selection matrix as indicated above Flow signal lost Alarm Flow signal Anoxic / EQ / Pretreatment destination selection Flow signal switching time delay setpoint Throttling valve position output Throttling valve position indication

3.03 EFFLUENT TRANSFER PUMPS

A. Copy and place in operation the existing effluent transfer pump control logic and I/Ointerface from the BFP Building PLC to the MCC2 PLC to accommodate the location ofthe relocated drives for the pumps.

3.04 REPORTS AND SYSTEM COORDINATION

A. Provide up to four custom report forms and functions as developed during acoordination meeting with COUNTY staff. Custom report forms shall utilize SCADAdatabase real time data as directed by the County and the report forms shall generallybe expected to meet the County’s monthly regulatory reporting (FDEP MOR’s) andadministrative (resource use) needs. This coordination meeting shall be held withinthirty (30) days after notice to proceed and prior to any submittals under this Section.Other topics to discuss at this meeting include scheduling, procedures for developingand implementing program changes, INTEGRATOR staffing qualifications, andproposed hardware and software to be used. The INTEGRATOR shall generate thereport forms and functions as directed in the meeting and submit the report forms forreview prior to startup.



3.05 SCHEDULE OF PAYMENT

A. Progress payments shall be in accordance with the approved Payment Schedule. Theinstrumentation programmer will be allowed to request partial payments for submittals,initial download of programming, and final completion.

B. The payment schedule and project milestones shall be defined in Division 1.

3.06 TESTING REQUIREMENTS

A. The INTEGRATOR shall provide the services of experienced factory trained technicians,tools and equipment to field calibrate, test, inspect, and adjust all equipment inaccordance with manufacturer's specifications and instructions.

B. The proper control of all final control elements shall be verified by tests conducted inaccordance with the requirements specified herein.

C. All modulating final control elements shall be tested for appropriate speed or positionresponse by applying power and input demand signals, and observing the equipment forproper direction and level of reaction. Each final control element shall be tested at 0,25, 50, 75, and 100 percent of signal input level and the results checked againstspecified accuracy tolerances. Final control elements which require turndown limitssuch as VFD's shall be initially set during this test.

D. Prior to control system startup and testing, each monitoring and control loop shall betested on an individual basis from the primary element to the final element, including theoperator work station or loop controller level, for continuity and for proper operation andcalibration.

E. Signals from transducers, sensors, and transmitters shall be utilized to verify controlresponses. Simulated input data signals may be used subject to prior written approvalby the ENGINEER. All modes of control shall be exercised and checked for properoperation.

F. Control system startup and testing shall be performed to demonstrate completecompliance with all specified functional and operational requirements. Testing activitiesshall include the simulation of both normal and abnormal operating conditions.

G. Each loop and control strategy test shall be witnessed and signed off by theINTEGRATOR, the CONTRACTOR, the OWNER, and the ENGINEER uponsatisfactory completion.

H. Specific testing of the control system modifications and added features shall be inaccordance with SCESD’s I&C DGD. These tests shall include:

1. Factory Demonstration Test (FDT) for the new PC and PDA’s with simulation ofthe new PLC and OWS programming for the blowers and RAS pumps.

2. Staging Site Demonstration Test (SSDT) for the PLC and OWS programming forthe blowers and RAS pumps (run with the FDT).



3. Operational Readiness Test (ORT) for all installed new equipment and modifiedprogramming to test all control loops individually for satisfactory control of theprocess elements.

4. Performance Acceptance Test (PAT) for starting up and placing all new equipmentand controls in satisfactory operation.

H. Upon completion of the PAT and prior to final system acceptance, the new controls shallbe tested under normal operating conditions, initiated either automatically or manually,over a fourteen (14) continuous day startup period to demonstrate continuous reliableoperation as intended. Substantial completion shall be at the successful conclusion ofthis startup test period.

I. If the system fails (defined as inability of the system to remain in continuous satisfactoryautomatic mode to maintain the YLWRF permit conditions) the fourteen (14) day startuptest period, the fourteen (14) day test period shall be restarted after the failedcomponents or software is repaired / replaced and full operation is restored.

3.07 FINAL ACCEPTANCE

A. Final acceptance of the instrumentation programming will be determined complete bythe ENGINEER and OWNER, and shall be based on successful completion of startuptesting period, training of the operations staff to the OWNER’s satisfaction, and turnoverof spare parts and as-built documents.

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