Automation of Water Resource Recovery Facilities. Water Environment Federation

alt=""/> Panel and console drawings showing the layout of front-panel-mounted and internal-panel-mounted devices;

       Diagrams and lists of software programs developed for programmed devices (e.g., programmable logic controllers [PLCs] or computers);

       Software submittals documenting the implementation of control system narratives;

       Requirements for equipment samples and shop drawing submittals;

       Manufacturers’ calibration certifications or test reports; and

       As-built drawings and wiring tables;

      • Operations and maintenance (O&M) manuals furnished by the contractor, including

       Record drawings reflecting final as-built condition of the installed system;

       Copies of certifications and test reports, with shop and field tests;

       Copies of manufacturers’ instrumentation and technical bulletins, installation instructions, O&M instructions, troubleshooting instructions, repair instructions, spare parts lists, and device configuration;

       Instrument schedule, including device tag, type, service, location, calibrated range, and setpoints;

       Control narratives and logic descriptions; and

       Electrical interconnection diagrams;

      • Spare parts; and

      • Special tools.

      The “products” section (Part II) contains the following required data that must be edited to reflect materials, accuracy, performance, and other project-specific requirements for each specified control system device, network component, hardware, software, control system narrative, and instrument:

      • Control system hardware and software;

      • Control system narratives;

      • Communications equipment;

      • Networking components;

      • Database configuration requirements;

      • Process display requirements;

      • Report requirements;

      • Historical data collection requirements;

      • Instrument type;

      • Pipe size (for in-line instruments);

      • Minimum and maximum operating data (e.g., flow, pressure, temperature, and pH);

      • Environmental requirements (e.g., temperature, humidity, and corrosive or explosive atmosphere);

      • Method of connection to physical system (e.g., flange and fitting size);

      • Special installation hardware required;

      • Tagging requirements;

      • Range of measurement;

      • Accuracy;

      • Precision;

      • Enclosure;

      • Process or wetted part requirements;

      • Electrical voltage requirements;

      • Signal output;

      • Local or remote indication;

      • Diagnostics and testing;

      • Application vendor options;

      • Maintenance and calibration requirements;

      • Input signal required;

      • Type of setpoint adjustment (e.g., fixed or adjustable), if applicable;

      • Alarm switch with limit settings and the amount of deadband required when switches return to normal;

      • Construction materials;

      • References to standards (e.g., ISA, Underwriters’ Laboratory, and National Electrical Code); and

      • Appurtenances (e.g., mounting hardware, special tools, or calibration equipment).

      The “execution” section (Part III) of the specification details the requirement for implementation, including field testing, quality control, and others. Before the owner accepts a new or modified process control system, the system or modifications should pass the following three performance tests consistent with the size of the project:

      • Factory acceptance test (FAT),

      • System availability test (SAT), and

      • Site demonstration test.

      The FAT demonstrates that the control system is built to the project’s requirements (including specifications), that the system is in accordance with the manufacturer’s shop drawings, and that the system is properly configured and ready for shipment to the job site. After field installation, instrumentation testing should be integrated to SAT, which typically duplicates FAT testing at the job site using installed devices to completely test control system hardware, software, wiring, and communications media.

      Test criteria for these tests is developed by the design engineer, but the system integrator develops detailed test procedures for each control system because testing requirements may be unique based on the site and custom SCADA system. Testing is conducted by the system integrator and witnessed by the owner or design engineer. Instruments may be tested at the factory or in the field. Individual instruments (i.e., transmitters) and groups of devices (e.g., control panels) can be tested.

      During startup of the process control system, the contractor may have to tune control loops and demonstrate that the instrument works properly. For some devices (e.g., magnetic flow meters, mass meters, specialized analytical instruments, emission monitoring systems, etc.), a trained representative of the instrument manufacturer should commission the equipment for the contractor to properly demonstrate operation.

      Training specifications may require a minimum number of training hours and trainers’ resumés and require the contractor to submit a detailed outline for each course. These training courses should cover process control system hardware, software, and instrumentation.

      Specifications should also require the contractor(s) to provide the following control system documentation:

      • Corrected as-built drawings,

      • Shop drawings,

      • Panel drawings,

      • Fiber-optic patch panel drawings,

      • Loop drawings,

      • Application program documentation,

      • Hardware configuration documentation,

      • Control system hardware and software,

      • Control system interconnection drawings,

      • Communications equipment hardware