Technical Specification For Instrumentation Controls and Electrical Requirements

TECHNICAL SPECIFICATION
FOR
INSTRUMENTATION, CONTROLS AND
ELECTRICAL REQUIREMENTS FOR PACKAGE SYSTEMS
FOR
PRAIRIE STATE ENERGY CAMPUS
BECHTEL CORPORATION
FREDERICK, MARYLAND
Bechtel Corporation 2007. Contains confidential and/or proprietary information to Bechtel
and its affiliated companies which shall not be used, disclosed, or reproduced in any format
by any non-Bechtel party without Bechtel's prior written permission. All rights reserved.
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25316-000-3PS-
JQ07-00001
SPECIFICATION
NO.
TECHNICAL SPECIFICATION FOR
INSTRUMENTATION, CONTROLS AND ELECTRICAL t - - - - - - - - - - - + - - - ~
REQUIREMENTS FOR PACKAGE SYSTEMS
FOR PRAIRIE STATE ENERGY CAMPUS
DATE REASON FOR REVISION
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Specification 25316-000-3PS-JQ07-00001, Revision 000
PART 1 - GENERAL 1
1.1 Applicability ~ 1
1.2 Services and Materials Included 1
1.3 Related Services and Materials Not Included 2
1.4 Codes and Standards 2
PART 2 - REQUIREMENTS 3
2.1 GE!rlE!rClI ~
2.1.1
2.1.2
System Requirements 3
Service Conditions 3
Power Cable 8
Conduit 9
Terminal Blocks and Fuses 9
Instrument and Control Wiring 7
Wiring, General 6
Control Components 10
Grounding 13
Detailed Requirements - Electrical 4
2.2.1 Cabinets, Panels, and Enclosures 4
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2
General 13
1/<:> .....24
Applicallilit)f 23
Design Requirements 23
Local Monitoring 17
Analyzers 18
Control Valves 18
Temperature 22
Vibration Monitoring 19
Local Annunciators 19
Process Connections 14
Processor and System 24
Miscellaneous Instrument Devices 20
Programming 26
PLC Local HMI 26
Instrument Locations and Mounting 16
Detailed Requirements - Instrumentation 13
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.3.11 Nameplates and Tagging 22
Detailed Requirements - Programmable Logic Controllers 22
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4
2.3
Bechtel Confidential Bechtel Power Corporation 2007. All rights reserved.
Pagei
PART 3 - DOCUMENTATION 29
PART 4 - INSPECTION AND TESTING 33
APPENDIXES
A APPROVED MANUFACTURERS LIST
B REQUIREMENTS FOR INSTRUMENT INDEX
C ORIENTATION OF INSTRUMENT CONNECTIONS
D PROGRAMMABLE LOGIC CONTROLLER (PLC) NETWORK REQUIREMENTS
E PLC SYSTEM NETWORK DIAGRAM
F INSTRUMENT TAG CONVENTIONS
G INSTRUMENT DATA SHEETS
Page ii
PART 1 GENERAL
1.1 Applicability
1.1.1 This specification is included as an attachment to the associated parent technical
equipment specification / material requisition. The parent technical specification /
material requisition governs the scope of supply, and may stipulate additional
requirements or supersede the requirements of this specification. In case of
conflict, the parent specification / material requisition has precedence.
1.1.2 This specification provides detailed requirements applicable to equipment
provided within Seller's scope of work. It defines the requirements for furnishing
the electrical, instrumentation, and control components and systems for the
equipment supplied by Seller. Requirements stated herein are applicable to the
extent the equipment is being furnished by Seller.
1.1.3 The General Project Requirements specification provides plant specific details
including voltage levels and ambient temperature range.
1.2 Services and Materials Included
1.2.1 Seller or Subcontractor shall design, fabricate, furnish, test, and deliver all
electrical, instrumentation, and control components (including, but not limited to,
associated motors, internal wiring, instrument valves, fittings, supports, piping,
and/or tubing) required for the proper operation and maintenance of the specified
system to the extent included in the parent technical specification/material
requisition and in accordance with this specification and appendices.
1.2.2 Seller shall provide complete documentation for all electrical, instrumentation,
and control devices supplied under the parent technical specification/material
requisition in accordance with the Document Submittal Requirement (DSR) in the
parent document.
1.2.3 Seller shall provide one set of special tools if other than standard tools are
required to repair, maintain, or adjust the equipment. Tools shall be new and
unused.
Page 1 of 34
1.2.4 Unless specifically excluded in the parent technical specification/material
requisition, Seller shall be responsible for providing heat tracing for equipment.
1.3 Related Services and Materials Not Included
1.3.1 Receiving, installation, external connections, acceptance testing, and training
unless included in the parent technical specification/material requisition.
1.3.2 Supply and installation of interconnecting wiring and raceway between Seller-
supplied skids or components, unless included in the parent technical
specification/material requisition.
1.3.3 Three phase motor starters, unless specifically required by the parent technical
specification/material requisition or specifically integral to a piece of equipment
furnished by Seller.
1.3.4 Foundations and anchor bolts.
1.4 Codes and Standards
Governing codes shall be those listed in the parent technical specification/material
requisition and the codes and standards section of the General Project Requirements
specification unless otherwise noted in this Section. Other codes and standards will
apply as referenced in the technical specifications.
Page 2 of 34
PART 2 - REQUIREMENTS
2.1 General
2.1.1 System Requirements
2.1.1.1 Seller's control package shall be a complete system, including controls,
instrumentation, control panels, etc., as required for proper operation of the
system.
2.1.1.2 Positive means of indicating equipment operating status (control valve with
fail safe direction, etc.) shall be provided, such as a limit switch on a valve,
auxiliary contacts from a motor starter, or an indicating system approved by
the Buyer.
o Hand switch contact closure (or PLC software equivalent)
commands are not acceptable.
o Alarm switch should be normally closed and will open when
alarmed or the position is changed.
o Position or status switches should be normally open and will close
to indicate the position or status. The switch will de-energize to trip.
o The equipment shall operate in a fail safe manner.
2.1.1.3 Appendix A (Approved Manufacturers List) lists the approved instrument
manufacturers for the type of instrument tabulated. Proposed manufacturers
of instruments, electrical or control devices not listed shall be approved by the
Buyer before they are incorporated into the system design.
2.1.2 Service Conditions
2.1.2.1 Refer to the Parent Technical Specification/Material Requisition and the
General Project Conditions for general project information and requirements.
2.1.2.2 Seller shall provide suitable enclosures for indoor and outdoor equipment for
operation under the environmental conditions specified in the General Project
Conditions specification.
Page 3 of 34
2.1.2.3 The facility may produce an atmosphere hostile to some electronic
components. High voltage equipment, large currents, and rotating machinery
will produce considerable potential for radio frequency and electromagnetic
interference. Seller's design shall incorporate provisions to avoid such
interference.
2.1.2.4 Seller shall consider the nature of the fuel used at this station and shall take
appropriate measures to avoid the ingress of dust or ash into control cabinets
or instrument enclosures. Seller shall comply with any requirements for
hazardous area classifications.
2.1.2.5 Interface points for services and utilities shall be in accordance with the
parent technical specification/material specification.
2.2 Detailed Requirements Electrical
2.2.1 Cabinets, Panels, and Enclosures
2.2.1.1 General requirements:
2.2.1.1.1 Seller shall provide enclosures that are suitable for the service conditions
where the cabinet/panel/enclosure will be installed.
National Electric Manufacturer Association (NEMA 12) enclosures for
indoor (non-hazardous) service.
NEMA 1 enclosures are acceptable for equipment located in rooms with
HVAC.
NEMA 3R for electrical equipment such as motors and starters
NEMA 4 for outdoor instrumentation.
NEMA 4X where equipment can get damaged by water or corrosion.
Equipment in hazardous locations shall have the proper classification for
the environment, in accordance with the National Electrical Code (NEC).
Equivalent International Electrotechnical Commission (IEC) enclosures are
acceptable provided the rating meets or exceeds the specified NEMA rating.
As a guide, the following equivalents may be assumed, NEMA 12 (IP55),
NEMA1 (IP20), NEMA 3R (IP22), NEMA 4 (IP66), and NEMA 4X (IP66 with
corrosion protection).
Enclosures in hazardous locations shall be fitted with an air-purge system
and pressure switch (e.g., Z-purge) and/or use intrinsically safe components.
Enclosures shall be located away from maintenance areas, excessive
vibration, and extreme temperature and provide adequate room for
operations and maintenance activities.
Bechtel ConfidentJal Bechtel Power Corporation 2007. All rights reserved.
Page 4 of 34
Specification 25316-000-3PS-JQ07-00001, .Revision 000
2.2.1.1.2 Provide enclosures with thermostatically controlled space heaters where
required to maintain internal temperature above dew point. If equipment is
located outdoors, space heaters must be provided unless otherwise approved
by Buyer.
2.2.1.1.3 Ensure that the enclosed equipment will be able to operate under the
ambient conditions specified in the parent technical specification/material
requisition. Provide heating and/or cooling as required. Note the ambient
condition considerations shall include solar gains, heat sink gains, wind chill,
etc.
2.2.1.1.4 Provide and permanently identify all electrical accessory devices, such as
fuse blocks, fuses, terminal blocks, wire markers, wireway, wiring, etc., as
necessary for a complete installation. Components shall be segregated by
voltage levels where practical.
2.2.1.1.5 Route circuits for lighting, convenience receptacles, cooling fan, and space
heater(s) inside the cabinet/panel/enclosure in metallic or PVC ducts/conduits
and wire to terminal points separated from control circuits. Provide terminal
blocks for separate power sources for these utility functions and the control
equipment within the cabinet.
2.2.1.1.6 Provide a clearly identified polarized AC plug-in strip for panel-mounted
devices supplied with cord sets.
2.2.1.1.7 Enclosures shall be completely assembled at the factory so that the entire
assembly is an operating unit, tested and ready for installation in the field. No
component shall be mounted less than 3 inches (75mm) from the floor or 1-
1/2 inches (40 mm) from the bottom of the panel, whichever is higher.
2.2.1.1.8 Panel design, materials, and workmanship shall result in a neat panel
appearance outside and inside, with no distortion, welds, holes, rivets, or bolt
heads apparent on exterior surfaces. All exterior surfaces shall be true and
smooth.
2.2.1.1.9 The exterior of all panels, other than main control room panels, shall be
manufacturers standard and panel interiors shall be manufacturers standard
painted white.
2.2.1.2 Additional requirements for free-standing enclosures:
2.2.1.2.1 Free-standing enclosures shall have rigid bracing, removable lifting eyes, and
a three-point latching system with lockable door handles. Panels shall include
provisions for bolting or welding to floor and provisions to shim the panel to
level.
Page 5 of 34
2.2.1.2.2 Provide guard-protected interior lighting operated from a conveniently located
switch and at least one readily accessible AC receptacle in each free-
standing enclosure. Provide print pocket inside the enclosure.
2.2.1.2.3 Provide each free-standing enclosure with a copper ground bus extending the
full length of the enclosure, to effectively ground the entire structure. Free-
standing enclosures containing low level signal devices shall be provided with
a separate, isolated signal 'ground bus. All devices with self-contained power
supplies and metal housings shall be grounded to the power ground bus.
Ground bus shall be 1/4 in. x 1 in. (6 mm x 25 mm) minimum copper.
2.2.1.2.4 All free-standing panels and panel stiffening members shall be steel with a
corrosion resistant coating suitable for the environment. The external coating
shall also be photo-degradation resistant for outdoor panels. Depth and
height of individual panels shall be held to a tolerance of 1/2 in. (12 mm)
with the added restriction that the overall dimensions of a multi-section group
shall be +0/-1 in. (+0/- 25 mm) and height variations between adjacent panels
shall be no more than 1/2 in. (12 mm) Panel-mounted equipment shall be
located within a tolerance of +1/2 in. (12 mm).
2.2.1.2.5 Dimensions for free-standing enclosures shall be 72 to 90 inches (1830 to
2290 mm) high and a minimum depth of 18 inches (460 mm). Panel
mounted devices requiring operator activation or reading from a standing
position shall be located no lower than 30 inches (750 mm) and no higher
than 76 inches (1930 mm) above the floor.
2.2.2 Wiring, General
2.2.2.1 Route instrumentation, power and control wiring separately. Separation shall
be sufficient to prevent crosstalk and interference on the instrumentation and
control circuits.
2.2.2.2 Route wiring so that devices can be removed or serviced without disturbing
wIring.
2.2.2.3 Identify each internal wire at each end with Seller's wire number on a heat
shrink soft plastic sleeve, or self-laminating plastic label.
2.2.2.4 Provide extra flexible wiring (Class C minimum) over door hinges and other
locations where leads may be subject to flexing. All wiring between stationary
and movable subassemblies of a panel shall be firmly anchored on each
subassembly and shall be looped to cause the majority of the flexure to be by
torsion rather than bending.
2.2.2.5 Seller shall meet the requirements for flame retardant cables required by the
Industry Codes listed in the parent technical specification/material requisition.
Bechtel Confidentia/ Bechtel Power Corporation 2007. All rights reserved.
Page 6 of 34
2.2.2.6 Non-PVC wire ducts may be used provided they are made of flame retardant
material.
2.2.2.7 Provide terminal boxes with terminal blocks for devices mounted on skid-
mounted equipment. Run interconnecting wire in galvanized rigid steel
conduit (1/2-inch minimum) if not subjected to vibration, or flexible metallic
conduit if subjected to vibration. Use liquid-tight connections if outdoors or
subjected to water spray.
2.2.2.8 Wire all spare terminal points on panel-mounted devices to terminal blocks
for external connections. All wiring connecting devices within a single panel
(whether in the same shipping section or not) shall be routed inside the
enclosure. Provide wiring duct or conduit as required for cables and wiring.
2.2.2.9 Protect all wiring from metal corners and edges. Provide support for incoming
wiring at the point of entry to the panel.
2.2.2.10 Where American Wire Gauge (AWG) sizes are specified in this specification,
they may be substituted with the equivalent metric sizes provided they meet
all the requirements of the Codes and Standards listed in the parent technical
specificationlmateriaI requisition.
2.2.3 Instrument and Control Wiring
2.2.3.1 Wiring shall comply with the following:
2.2.3.1.1 Wiring that is contained completely (end-to-end) within the control panel or
local control boxes shall be No. 14 AWG (2.5 mm
2
) minimum, 600 volt flame
retardant XLPE (XHHW or SIS), 194F (90C), stranded copper cable, or
Buyer approved equal. When supplied, jacketing shall be Chlorinated
Polyethylene (CPE), Hypalon, PVC or Neoprene. Color code to follow ICEA
Method 1 Table E-2.
2.2.3.1.2 Control cables in raceway shall be No. 14 AWG (2.5 mm
2
) minimum, 600 volt
flame retardant, 194F (90C), stranded copper conductor with a highly flame
retardant insulation/jacketing system for control cables in raceway. Insulation
shall be cross linked polyethylene (XLPE), Ethylene Propylene Rubber (EPR)
or Buyer approved equal. When supplied, jacketing shall be CPE, Hypalon or
Neoprene. Color code to follow ICEA Method 1 Table E-2.
2.2.3.1.3 Analog instrumentation signal cables shall be 2/C, 3/C or 4/C shielded,
twisted cable, stranded copper No. 18 AWG (1.0 mm
2
), with XLPE or PVC
insulation and PVC jacket. Multi-pair/triad/quad cable is acceptable.
2.2.3.1.4 Provide thermocouple extension wiring where needed. Conductors shall be
no. 18 AWG (1.0 mm
2
). Insulation and jacketing shall utilize U.S. standard
colors, i.e., Type K, yellow and brown leads with yellow exterior jacket
Page 7 of 34
insulation; Type E, purple and red leads with purple exterior jacket insulation;
and Type J, red and white leads with black exterior jacket.
2.2.3.1.5 Smaller wire sizes may be used where such wires have suitable overcurrent
protection.
2.2.3.2 Ship any prefabricated cables intended for installation by Buyer with
connectors installed on one end only. The uninstalled connector shall be
provided and supplied with pin out drawing attached. Provide any special
tools required to make-up connectors in accordance with Paragraph 1.2.3
(e.g., crimp tool, etc.). Fiber optic cables for field installation in conduit or
raceway shall not have connectors attached; connectors shall be provided
separately.
2.2.3.3 Conductors for grounding instrument cable shield terminal points and signal
common conductors shall not be connected to the panel safety ground bus.
These conductors shall be terminated on the instrument ground bus.
2.2.3.4 Control and instrument wiring shall be listed or labeled by an independent
testing laboratory in accordance with the requirements of the NEC or IEC
codes as specified in the parent technical specification/material requisition.
2.2.3.5 Instrumentation, control, and power wiring shall be routed separately.
Separation shall be sufficient to prevent crosstalk and interference on the
instrumentation and control circuits. A minimum of 12 in. (300 mm) spacing
shall be applied; where this spacing cannot be maintained, low level wiring
shall be at right angles to control cables or installed in ferrous conduit.
2.2.4 Power Cable
2.2.4.1 Where the Seller is required to furnish power cable inside the control panel or
outside the panel in raceways, it shall be No. 12 AWG (4.0 mm
2
) minimum,
600 volt Class B Stranded copper conductors with a temperature rating of
194F (90C) for continuous operation, with a flame retardant
insulation/jacketing system for power cables. Insulation shall be cross-linked
polyethylene (XLPE) per Insulated Cable Engineers Association (ICEA) S-66-
524, Ethylene Propylene Rubber (EPR) per ICEA S-68-516, or Buyer
approved equal. Jacketing shall be CPE, Hypalon or Neoprene.
2.2.4.2 Size, protect, and install in accordance with the National Electric Code (NEC)
and ICEA, or IEC if specified in the parent technical specification/material
requisition.
2.2.4.3 Provide 12 AWG (4.0 mm
2
) minimum, copper stranded conductors, for
current transformer secondary leads and connect to short-circuiting type
Page 8 of 34
terminal blocks. Provide warning labels indicating lethal voltages may be
present if secondary left without a burden or load.
2.2.5 Terminal Blocks and Fuses
2.2.5.1 Terminal blocks shall allow convenient wiring and maintenance access.
2.2.5.2 Terminate field wiring conductors (other than factory soldered connections)
on terminal blocks with compression type terminations. Printed circuit card
termination of field wiring is not acceptable. Terminal blocks shall be rated
600V.
2.2.5.3 Terminate all circuits at terminal blocks. Provide 20 percent terminal spare
points uniformly distributed. Prepare, tape, tag, and tie back shields and
unused conductors. Shields will be landed (only if required) during
operational checkout.
2.2.5.4 Certain signal cables, such as analyzers, vibration monitors, and data
communication cables, shall be routed directly to the associated panel
mounted device.
2.2.5.5 Terminate all wiring on one side of terminal blocks, leaving other side entirely
free for Buyer's field cable connections. Leave adequate space for jacketed
field cables. Connect all conductors for each device, including shields, to
adjacent terminal points.
2.2.5.6 Do not connect more than two wires to one terminal point and jumper as
necessary to allow connection of only one wire per terminal point on the
outgoing side of terminal blocks. Do not splice, tape, or lace conductors.
2.2.5.7 Fuses and fuse holders shall be appropriately rated and shall be of the
indicating type.
2.2.5.8 Fuses shall be accessible for inspection, replacement or maintenance. All
fuse blocks shall be identified with their service and fuse ratings.
2.2.5.9 Buyer's side terminations shall accommodate No. 12 AWG (4.0 mm
2
)
minimum for control wiring, No. 16 AWG (1.5 mm
2
) minimum for
instrumentation wiring, and No. 12 AWG (4.0 mm
2
) through NO.2 AWG (35
mm
2
) for power supply cables.
2.2.6 Conduit
2.2.6.1 Conduit, if required, shall be rigid steel, intermediate metal, Electrical Metallic
Tubing (EMT), or rigid aluminum, consistent with the ambient environmental
conditions. In areas where conduit will be exposed to a chemically corrosive
environment, conduit shall be Polyvinyl Chloride (PVC) coated (0.040 inches
Page 9 of 34
or 1 mm minimum) rigid galvanized steel with urethane coated threads. If
PVC coating is not suitable for the service, Seller shall propose an alternative
coating for Buyer's approval.
2.2.6.2 Conduit shall be run at right angles to building lines indoors and shall not
interfere with passageways, equipment removal, or maintenance access.
2.2.6.3 Conduit terminating at vibrating equipment shall be connected with seal-tight
flexible metal conduit (FMC) for indoor installations, or liquid-tight FMC for
outdoor installations. The maximum unsupported length shall be in
accordance with NEC or IEC if specified in the parent technical
specification/material requisition but no longer than 3.3 ft (1.0 m).
2.2.6.4 Where required for hazardous areas, National Fire Protection Association
(NFPA) approved conduit seals shall be provided and installed.
2.2.6.5 Size and install in accordance with NEC and Institute of Electrical and
Electronics Engineers (IEEE) 422, or IEC in accordance with the parent
technical specification/material requisition. Minimum conduit size shall be 3/4
inch (75 mm).
2.2.7 Control Components
2.2.7.1 Where Seller's controls shall interface to MCC's or switchgear provided by
others, the following component and circuit ratings shall apply:
a. 120 V AC, 1 phase, 2 wire, 60 Hz, solidly grounded for control circuits of
all AC motors powered from low voltage as specified in the General
Project Requirements Specification (200 hp and smaller).
b. 125 V DC for metal clad SWitchgear breakers.
c. 120 V AC for control circuits of medium voltage fused contacts feeding
motors (200 HP &larger) and load center/MCC transformers.
2.2.7.2 Provide insulation of Class H or better on control device coils which
completely seals the conductors to prevent penetration of moisture or other
contaminants and is rated for continuous operation at a temperature of 266F
(130C).
2.2.7.3 Provide contacts rated for 120 V AC, 10 amp inductive loads, or 125 V DC, 0.5
amp inductive loads, as required.
2.2.7.4 Provide surge protectors for solid-state equipment if not inherent in the
equipment design, to prevent damage from the effect of lightning strikes or
other electrical transients encountered in power plant operation.
Page 10 of 34
2.2.7.5 Electric heat tracing shall be provided as needed for all process and
instrument piping, tubing, and devices that are temperature sensitive or
susceptible to freezing due to process conditions or material properties. Heat
tracing shall be self-regulating, consistent with the industry standard normally
used for these special applications. Monitoring and test panels shall be
provided for the heat tracing circuits. The heat tracing system shall include
appropriate controlling, monitoring, alarm, and power components.
2.2.7.6 Pushbuttons and Selector Switches
a. Furnish heavy-duty, oil-tight, pushbuttons, as listed in Appendix A or Buyer
approved equal, color coded as follows:
Function Color
Start Black
Stop Red
Jog Green
Reset Yellow
Auto White
Jog Open Black
Jog Closed Green
Furnish with manufacturer's standard sized permanent nameplates, firmly
attached using either bezel mount of component or device, or self-tapping
sheet metal screws.
2.2.7.7 Indicating Lights
a. Provide indicating lights, as listed in Approved Manufacturers List (Appendix
A) or Buyer approved equal. LED clusters are acceptable.
b. Furnish color caps or LED cluster colors in accordance with the following:
Red: liOn" to indicate motor running, device energized, or valve open or
partially open (not fully closed)
Green: liOn" to indicate motor not running, device not energized, or valve
closed or partially closed (not fully open)
Page 11 of 34
Amber: "On" to indicate warning, abnormal equipment or system status, or
system not in the steady-state mode
White: "On" to indicate power supply available in a supervisory manner or
to indicate "Auto"
2.2.7.8 Local Motor Controllers and Contactors
a. Furnish combination type motor controllers consisting of a motor starter
with thermal or solid-state overload relays, molded case circuit breaker, and
auxiliary control devices as required.
b. Motor controllers will be magnetic type, suitable for line voltage starting,
per General Project Requirements Specification, of single speed induction
motors. Overload protection shall consist of three manually reset,
ambient compensated thermal overload relays of the bimetallic type or
equivalent solid-state protection. Starters shall be minimum NEMA Size 1
or IEC equivalent if specified in the parent technical specification/material
requisition. The thermal units shall be sized in conjunction with the motor
full load current, per nameplate.
c. Provide a 120 volt control transformer for motor controllers, one size
larger than standard (100 VA minimum), with a secondary fuse in the
ungrounded line. Provide an environmentally suitable enclosure for each
starter and integral pre-wired start/stop controls, indicating lights, and an
auxiliary relay for Buyer's use.
d. Molded case circuit breakers will be magnetic type only with adjustable
trip settings set in accordance with the NEC (or IEC if specified in the
parent technical specification/material requisition) and with a fault
interrupting rating as specified in the General Project Requirements.
Molded case breakers shall be provided with copper lugs.
e. Non-motor loads shall be provided with either thermal magnetic
contactors or magnetic only breakers with fuses.
2.2.7.9 Relays and Meters
a. Install protective relays and meters on the front of the control cabinets,
panels, and cubicles. The relays shall be of semi-flush drawout design with
testing devices. Meters shall be located such that they are visible to an
operator standing at the normal floor level. Types and details shall be
subject to acceptance by Buyer.
Page 12 of 34
b. Provide solid state type time delay relays with dial knob adjustable delay, as
listed in Appendix A or Buyer approved equal.
c. Provide semi-flush, panel mounted meters with expanded scales.
d. Provide meters with linear indicating scales which read directly in
engineering units. Digital meters are acceptable with Buyer written approval.
2.2.8 Grounding
2.2.8.1 Include provisions for connecting skids to Buyer's external ground grid.
Grounding pads suitable for standard NEMA two-hole lugs shall be provided
at two points at opposite ends of the skid.
2.2.8.2 All skid-mounted equipment shall be electrically bonded together in
accordance with NEC or IEC. Instruments and control panels are considered
bonded when connected to grounded metallic conduit. Motors Y2 HP
(0.375kW) and greater shall be grounded through the motor frame in addition
to the ground connection provided through the power cable and raceway.
2.2.8.3 Where the power supply to equipment is included in Seller's scope of supply,
such power supplies must include a ground fault return path in accordance
with the NEC or IEC as specified in the parent technical specification/material
requisition.
2.2.8.4 All exposed conductive parts of systems and equipment shall be solidly
grounded.
2.2.8.5 Instrument cable shields shall be landed on terminal points for grounding or
for continuation of instrument cable shields for grounding at another location.
2.3 Detailed Requirements - Instrumentation
2.3.1 General
The following signal levels shall be used for transmitted indication and control signals:
a. Electronic: 4 to 20 mAde, 24V dc, 2-wire, accuracy +.25% of calibrated
range.
b. Pneumatic: 3 to 15 psig (200 mBar to 1 Bar).
c. Thermocouple: ANSI Type E, Chromel-Constantan, grounded junction,
Type J and Type K for high temperature applications; thermocouple
conversions per 1PTS-68, accuracy + 1C
Page 13 of 34
d. RTD: 100 Ohm Platinum, 3-wire (R
100
/R
o
= 1.385), accuracy 1DC.
2.3.2 Process Connections
2.3.2.1 Orient instrument connections to process piping or vessels in accordance
with accepted industry practice. (See AppendiX C for instrument
connections).
2.3.2.2 Seller shall provide a root valve of 1/2 in. (12 mm) minimum size suitable for
application at each process connection, other than boiler combustion air and
draft connections.
Root valves shall normally be ball or full-ported gate style, of material which
meets the temperature and pressure rating of the process piping. Double root
valves shall be provided for applications with a pressure rating above ANSI
900 or within the ASME Section I boundary (boiler code).
2.3.2.3 All steam flow element (nozzles, venturis and HHR flow tubes) root valves
must be either high temperature ball or gate valves. The ID of the valve must
be as close as possible to the 10 of the pipe. These valves must also be
accessible for emergency isolation of the condensate pot from the flow
element.
2.3.2.4 The following requirements are applicable to the main boiler and steam
line drain pots.
All boiler drum level root valves upstream of the Condensate Pots must be
either high temperature ball or gate valves. The internal diameter (10) of the
valve must be as close as possible to the 10 of the pipe. These valves must
also be accessible for emergency isolation of the condensate pot from the
drum.
All steam line drain pots using conductivity probe level switches must be
either high temperature ball or gate valves. The 10 of the valve must be as
close as possible to the 10 of the pipe. These valves must also be accessible
for emergency isolation of the probe from the drain pot.
2.3.2.5 Process connections for differential pressure type flowmeters shall be
arranged so that there is no offset due to elevation head at the primary
element.
2.3.2.6 A thermowell shall be provided for each process temperature sensor. The
thermowell shall withstand two times the maximum system pressure. The
velocity-induced frequency shall be less than 80 percent of the thermowell
critical (resonant) frequency during all modes of operation.
Page 14 of 34
2.3.2.7 Seller shall provide root valves and thermowells with sufficient extension to
preclude interference with piping, supports, and insulation.
2.3.2.8 Locate temperature connections downstream of pressure and flow
connections to avoid flow induced disturbances at the pressure
measurement.
2.3.2.9 Instrument impulse lines between the root valve and the instrument shall
generally be ASTM A-213 seamless 316 stainless steel, 3/8 in. 00 x
0.065 in. wall (12 mm 00 x 2 mm wall) suitable for the application. Seller
shall ensure suitability of the tubing material for the application, and if
required, the Seller shall propose an alternative tubing material for Buyer's
review and approval prior to design finalization. Impulse lines for low-pressure
gas or dust-laden service shall be 3/4 in. (75 mm) 00 minimum. Copper
tubing ASTM 8-75, 3/8 in. 00 x 0.035 in. wall (12 mm 00 x 1 mm wall) may.
be used for instrument air service. All installations shall be suitable for the
conditions specified in the General Project Requirement specification.
2.3.2.10 Provide gate type root valve connections on tanks and vessels for external
cage level instruments in accordance with the following:
Type Size
Gauge Glass 1"
Displacer Type 2"
Multi-instrument stand pipes 2"
2.3.2.11 Provide 2 1/2 in. minimum connections, with provisions for rod-out, on dust-
laden ductwork. Blowback provisions shall be provided.
2.3.2.12 Provide test connections with root valves as required for troubleshooting or
calibration.
2.3.2.13 Locate flowmeters in straight runs of pipe in accordance with Table 2 of
ASME Standard MFC-3M-2004. Provide two sets of pressure taps, with the
second set plugged for future use. Use weld neck flanges where flanges are
required.
2.3.2.14 For flowmeters or valve trim that could be damaged during flushing and/or
steam blow, furnish flowmeters or trim that can be easily removed. Provide
kits for such valves that include any parts required to seal the valve body with
the trim removed. Provide spool pieces, where required, to insert in place of
the flowmeter. For each flowmeter requiring removal, attach a warning tag
stating "Removal Required Prior to Flushing."
Page 15 of 34
2.3.2.15 Route tubing, properly supported and protected, to permit access to
equipment for operation or maintenance.
2.3.2.16 Slope instrument impulse lines a minimum of 1/4 in. per foot (20 mm per
meter) to prevent the accumulation of non-condensable in liquid lines or
condensate in gas lines. Provide drain and vent valves where required.
2.3.2.17 Provide isolation valves and calibration connections on impulse and
pneumatic signal lines to permit in-place calibration.
2.3.2.18 Use air or liquid purges, chemical seals, or other suitable means to provide
low maintenance, trouble-free operation for instruments in slurry, particulate,
or chemical service.
2.3.3 Instrument Locations and Mounting
2.3.3.1 Instruments shall be located where they are accessible for normal operations
and easily read from walkways. Instruments shall be oriented so that controls,
dials, or displays are upright and facing in a direction for easy readability.
2.3.3.2 Instrument installations shall consider maintenance access. Sufficient
flexibility shall be left in impulse lines to permit instrument removal without
damaging the tubing installation or the instrument. Flexibility shall be provided
by tubing offsets maintaining the required slope, not by loops in the impulse
line. Two-valve manifolds for pressure and three- or five-valve manifolds for
differential pressure applications shall be provided at the instrument
2.3.3.3 Required instrument accessibility will be in accordance with the following
table:
Type of Instrument I II III
Control valves, Process pressure X
regulators, and MOVs
Transmitters X
Local indicators X
Pressure gauges (not line mounted) X
Pressure gauges (line mounted) X
Self-contained air regulators X
Local controllers X
Process actuated switches X
Locally adjustable instruments X
Emergency instruments X
Analytical Instruments X
Thermocouples X
Root Valves X
Page 16 of 34
Type of Instrument I II III
Instrument Manifolds X
Valve Position Switches X
Legend:
I = Grade, platform, stairway, or permanent or portable ladder less
than 15 feet (4,570 mm). Access from permanent or portable
ladder will be limited to those cases where the area or piping
arrangement precludes locating the instrument so as to be
accessible from grade or platform.
II = Grade, platform, stairway, or permanent inclined ladder
III = Grade or fixed platform
The above accessibility table is applicable for all instruments. These
accessibility requirements; however, are not applicable to vendor-
packaged, skid-mounted instruments, which are based on
manufacturer's standard offering.
Where instrument manifolds are not provided, the above-stated criteria will be
applied to the instrument block valves.
Instruments shall be located so that required clearances are maintained for
walkways, access ways, and operation and maintenance of valves and
equipment.
2.3.4 Local Monitoring
2.3.4.1 Provide each pump with a discharge pressure gauge. For small chemical
metering pump installations that have installed spares, one pressure gauge in
the common discharge header shall be provided.
2.3.4.2 Provide each process strainer and filter with a differential pressure indicator
and switch, except small instrument filters and V-strainers on the suction of
small chemical metering pumps which do not require this indication.
2.3.4.3 Provide cooling water flow sight glasses in addition to flow switches for all
equipment requiring cooling or seal water.
2.3.4.4 Provide local level indication on all closed tanks or vessels.
2.3.4.5 Provide sight glasses on all pump bearing oil sumps.
Bechtel Confidentia/ Bechtel Power Corporation 2007. All rights reserved.
Page 17 of 34
2.3.5 Analyzers
2.3.5.1 Where continuous process analysis equipment is to be provided, Seller shall
ensure that the sampling point is truly representative of the process.
2.3.5.2 Specific Buyer approval of each type of analysis equipment, either through
listing in Appendix A or through a specific request by Seller, shall be obtained
before the equipment is used in the design.
2.3.5.3 The Seller shall ensure that all materials of construction are compatible with
the intended service.
2.3.5.4 Provisions shall be made in the installation of analyzers subject to desiccation
to ensure that the analyzer sample chambers are continuously immersed in
fluid whether in operation or idle during plant shutdown periods.
2.3.5.5 Where in-line pH, conductivity, or similar probes are to be used, they shall be
installed so as to be easily removed for maintenance.
2.3.5.6 Each analyzer that uses a consumable reagent shall be provided with
sufficient reagent for 1 year of operation after acceptance of the system by
Buyer. Delayed shipments of reagent may be required due to short shelf lives
of some chemicals.
2.3.5.7 Analyzers dependent upon continuous flow of sample or dilution water shall
be equipped with a head tank and automatic provisions to shut off reagent
flow on loss of dilution water flow.
2.3.5.8 Seller shall identify the quantity of sample that must either be taken to drain
or returned to the process in order to provide a valid sample at the analyzer
for measurement. Seller shall locate liquid service analyzers so that the
amount of fluid that requires draining to waste is minimized and the majority
of the flow is returned to the process.
2.3.5.9 Any analyzer probes or components which could be damaged by shipment,
shall not be shipped installed, but SUitably packed and shipped loose for later
mounting. Components which could be damaged by storage exceeding one
month shall be shipped later when requested by Buyer.
2.3.6 Control Valves
2.3.6.1 Size valves to pass 110 percent of the maximum operating flow. Control valve
body size shall not be smaller than two sizes under the inlet pipe size.
2.3.6.2 All modulating control valves shall be pneumatically operated.
Page 18 of 34
2.3.6.3 Size actuators to shut off against at least 125 percent of the maximum shutoff
pressure differential. Size actuators to operate with a minimum air pressure of
80 psig (550 kPa).
2.3.6.4 Limit maximum sound level to 85 d8A when measured 1 meter from the
valve.
2.3.6.5 Furnish a handwheel on each control valve where necessary for manual
control. Handwheels shall not be provided where they can prevent automatic
protective actions required of the valve.
2.3.6.6 Furnish positioners with input, output(s), and supply gauges.
2.3.6.7 Control valves shall conform to the applicable portions of the following codes
and standards:
ANSI 816.5 Pipe Flanges and Flanged Fittings
ANSI 816.34 Valves - Flanged, Threaded, and Welding End
FC170.2 Control Valve Seat Leakage
MSS SP 61 Pressure Testing
MSS SP 85 Valves Socket Welding and Threaded Ends
2.3.7 Vibration Monitoring
2.3.7.1 Vibration monitoring shall be provided for horizontal shaft driven equipment
rated 2000kW (2500 hp) and above and where specified in the parent
technical specification/material requisition.
2.3.7.2 All vibration monitoring shall be as specified in Appendix A. Proximitor type
probes will be used for split bearing, oil film type bearings and
velocity/seismic probes will be used for roller element type bearings.
2.3.7.3 Provide two probes per bearing oriented at 90 degrees from one another. A
keyphasor shall also be provided.
2.3.7.4 A 4 to 20 mA dc signal shall be provided for the Buyer's DCS from each
vibration measurement unless specified otherwise in the parent technical
2.3.8 Local Annunciators
2.3.8.1 Where local annunciators are provided, they shall be of solid-state design
with integral logic and backlighted nameplate displays having at least two
Page 19 of 34
lamps per display window. Local annunciators shall have minimum 1 in. by 3
in. backlighted nameplate displays. Window engraving character height shall
be % inch (6 mm) minimum. Provide 20 percent spare windows, distributed
among the layout.
2.3.8.2 Provide first-out sequence of operation in accordance with The
Instrumentation, Systems, and Automation Society (ISA) S18.1 (Sequence
F3A). Provide a local audible alarm with each panel that contains an
annunciator.
2.3.8.3 Annunciators shall operate from 120 V ac.
2.3.8.4 Provide two SPDT (form c) master alarm contacts for each annunciator wired
to terminals for Buyer's use. Activate when any channel alarms or on loss of
AC power and maintain in that state until all channels return to normal.
Provide a reflash feature that momentarily interrupts the master alarm output
whenever a subsequent channel alarms.
2.3.8.5 Arrangement and engraving of annunciator windows shall be logically
arranged and shall provide a clean and unambiguous indication of the
process condition.
2.3.8.6 Status (non-alarm) windows, such as completion of demineralizer
regeneration, shall be grouped separately from alarm windows and shall not
be wired to the master relay.
2.3.9 Miscellaneous Instrument Devices
2.3.9.1 In general, instrument accuracies shall be 0.5 percent or better. Pressure
gauges and other local instruments shall be 1 percent or better and
transmitters shall be 0.1 percent or better.
2.3.9.2 Provide linear indicating scales or digital readouts reading directly in
engineering units.
2.3.9.3 Provide condensate chambers in steam service to maintain a constant
elevation head. Provide siphons or pigtails where required to isolate an
instrument sensing element from vapor temperatures high enough to affect or
damage the instrument.
2.3.9.4 Provide snubbers or other suitable damping device for pulsating service.
2.3.9.5 Pneumatically operated final control devices shall be provided with liP
converters and, where functionally necessary, for modulating final control
devices provide positioners and position transmitters.
2.3.9.6 Provide pneumatic controllers with input and output signal pressure gauges.
Page 20 of 34
2.3.9.7 Seller shall provide individual filter regulators for each pneumatic device or
stack of manifolds. Filter regulators shall generally be located on the device.
Unless associated with a positioner having a supply pressure gauge, all filter
regulators shall be provided with an output gauge.
2.3.9.8 Panel-mounted pneumatic equipment may be served by a common
instrument air header in the panel, served by a pressure reducing station
sized for the entire panel load, a common air filter and mounted in the panel.
In such installations, each stack of manifolds or individual device shall have
an isolation valve.
2.3.9.9 Provide power supplies for all electronic instrumentation unless stated
otherwise in the parent technical specification/material requisition.
2.3.9.10 Provide solenoid valves with Class H coils, NEMA 4 (IP66) enclosures.
Where external field wiring is by Buyer, the solenoid and the valve limit
switches shall be wired to a junction box located on the actuator. In water
treatment applications only, the use of banked solenoids with Class F coils
with connectors/terminals are acceptable.
2.3.9.11 All controllers shall be provided with anti-reset windup.
2.3.9.12 All differential pressure transmitters including those used for flow
measurement shall be provided with three or five valve instrument manifolds.
Pressure transmitters and gauges shall be provided with two valve
instrument manifolds (block and bleed valve). Calibration tees shall be
provided for all other instruments.
2.3.9.13 Provide nominal 4-1/2" (115 mm) diameter pressure gauges with white face
and black markings. On small bore non-metallic pipe (less than 2 inches or
50 mm) only, pressure gauges shall be 2 ~ inch (65 mm) diameter because
of weight considerations. Pressure indicators provided as part of control
valves, pressure regulators or pneumatic controllers shall be manufacturer's
standard.
2.3.9.14 Pressure gauges will be supplied with either a blow-out disk or a blow-out
back and have either a shatter-proof or acrylic front face.
2.3.9.15 Pressure and temperature indicator scales shall be such that the normal
readout of the indicator shall be between 1/3 and 3/4 of the scale.
2.3.9.16 In-line paddle flow switches are not acceptable.
2.3.9.17 All pressure and temperature switches shall be provided with DPDT (two form
c) contacts except where the high deadband of DPDT switches is
unacceptable for the application. Switch actuation point shall be in the center
one-third of the instrument range.
Page 21 of 34
2.3.9.18 Pressure and level transmitters shall be provided as indicating type.
2.3.10
2.3.10.1
Temperature
Provide dual element thermocouples, spring loaded, grounded junction, with
weatherproof (aluminum or iron) head, internal grounding screw, and external
ground terminal. Provide test thermowells with a brass or bronze plug or cap
permanently attached with a chain or wire and with lagging extensions where
required.
Type E and Type K thermocouples are preferred. The thermocouples shall be
manufactured per ISA MC96.1.
2.3.10.2 All thermocouple instruments shall be provided with upscale burnout
protection.
2.3.10.3 Provide bimetallic, any-angle dial thermometers with white face and black
scale markings. The dial size shall be 4.5 or 5-inch diameter (minimum).
2.3.10.4
2.3.11
2.3.11.1
RTDs shall be 100 ohm, platinum type, three-wire circuits (Temperature
Coefficient = 0.00385), and ungrounded. The element shall be spring
loaded, mounted in a thermowell, and connected to a cast iron or an
aluminum head assembly.
Nameplates and Tagging
Provide nameplates with black 3/16 inch (5 mm) minimum letters on white
background for all panel designations and panel mounted devices. Provide
an additional nameplate showing the device number inside the panel for each
device.
2.3.11.2 Secure nameplates to panel with stainless steel self-tapping screws.
Adhesive may be used inside the panel where screws cannot be used.
2.3.11.3 Each instrument, control valve, electrical device and loose accessory shall be
tagged with a 3 inch by 1 Y.4 inch (75 mm by 30 mm) minimum, 16 gauge
minimum, non-corroding metal tag which is securely affixed to the instrument
by pins, metal screws, or stainless steel wire. Tagging information shall
include Buyer's purchase order number, P.O. item number, and Buyer's
identification tag number, stamped on the tag in 3/16-inch (5 mm) minimum
size letters.
2.4 Detailed Requirements - Programmable Logic Controllers (PLC)
Page 22 of 34
2.4.1
2.4.1.1
2.4.1.2
2.4.1.3
2.4.2
2.4.2.1
Applicability
Section 2.4 is applicable only if the system provided includes PLC based
control.
If required by the parent technical specification/material requisition, the system
shall be supplied with redundancy to include as a minimum processors,
memories, power supplies, power feeds, and data communication channels.
Provide automatic fail-over in the event of any redundant component failure.
As a minimum, redundancy of mechanical equipment shall not be
compromised by the control system.
For the PLC based system required by the parent technical
specification/material requisition to integrate with the DCS and/or other PLC
vendors, the PLC system must comply with the networking and integration
standards stated in Appendices 0 and E. Specific permission MUST be
obtained to deviate from the specified PLC and HMI platforms, and the
specified software versions must be used.
Design Requirements
Each PLC system shall accommodate two power supply feeds by the Buyer.
The primary feed will be from Buyer's UPS (or other source) and the secondary
feed will be from unregulated AC. Seller shall distribute the selected source of
power and provide protective fuses and/or breakers within the PLC for power
distribution, thermal protection of wiring and overcurrent protection. In addition,
fuses, breakers and or current limiting I/O shall be provided so that an
accidental grounding of a field conductor will not disable more than the one I/O
point to which the conductor is connected.
PLC HMls shall be supplied by UPS power unless the manufacturer's standard
HMI comes equipped with dual power source capability. The Processor and
I/O rack power supplies shall be fed from the primary source, with the
secondary source as backup. A 'Diode OR' of the two power supply outputs is
acceptable for DC voltages. Input modules shall utilize the same selected
(primary or secondary) source for interrogating field input devices.
Field power for digital output modules shall be fed from the unregulated power
source, to avoid undue loading of the UPS. An exception to this will be the
motor control centers (whether Seller supplied or not) where input and output
modules source of power will be the individual motor starter control power
transformer.
2.4.2.2 Power supplies shall include thermal overload, short circuit, and surge
protection.
Page 23 of 34
(MR1 & MR2) Each PLC system shall
accommodate two power supply feeds. The
primary feed will be from Seller's UPS and the
secondary feed will be from Buyer's unregulated
AC.
2.4.2.3 The PLC processor and its auxiliary devices (power supplies, I/O racks, etc.)
shall be mounted in a cabinet compatible with its environment. The enclosure
rating shall be per Section 2.2.1.
2.4.2.4 PLC's required to be networked by the parent technical specification/ material
requisition shall be equipped with necessary modules to connect to the PLC
Network per Appendices D and E.
2.4.2.5 Ethernet connectivity from the PLC Operator interface shall be provided to a
common Buyer supplied Ethernet LAN. The PLC shall be capable of being
networked according to the requirements of the parent technical
2.4.2.6 Seller shall utilize Buyer assigned addressing for any PLC and any remote I/O
or other device connected to PLC bus.
2.4.2.7 Buyer will establish protocol and tag numbering upon contract award.
Instrument and DCS tag numbers shall be shown on all applicable documents
and drawings (Le., ladder logic, logic diagrams, schematics, etc.).
2.4.2.8 The system shall provide on-line system diagnostics to detect, identify, and
alarm any malfunctioning module or malfunction within the system.
2.4.2.9 All components shall be shielded against electrical noise, Radio Frequency
(RF) interference, and heat. Any limitations shall be clearly indicated on the
affected equipment and in the engineering documentation.
2.4.2.10 Provide for equipment heat dissipation without forced ventilation.
2.4.3
2.4.3.1
2.4.3.2
2.4.3.3
Processor and System
The processor(s) shall be in accordance with Appendices A and D. The
software for PLC shall be from the PLC manufacturer.
Communication links with the plant DCS system and/or the main control room
PLC-HMI shall be provided via Ethernet interface as shown on Appendices D
and E.
A minimum of 20 percent spare user memory shall be provided.
2.4.4 I/O
2.4.4.1 All I/O points shall be pre-wired to interposing terminal blocks. Where I/O
chassis are located in motor control centers, the terminals in the starter
compartments shall be defined as interposing terminal blocks.
Page 24 of 34
(MR1 & MR2)
The silo, chemical feed and dewatering equipment shall have local I/O racks to
communicate into the main HMI in the water treatment control room. The dewatering
equipment will be provided with a local HMI (10 inch monitor panel) communicating
into the main HMI. The local dewatering HMI Panel shall have the same graphics
and screens as the main HMI. The remote I/O and PLC processes/HMI shall be in
accordance with the requirements of this specification.
Local I/O rack shall be provided by area. Local I/O rack shall be provide for the
following areas at a minimum: Sludge Dewatering Area, Chemical Feed Area, Lime
Silo, Soda Ash Silo, Raw Water PreTreatment Equipment Area (MR1 only), Fluoride
Removal Equipment Area (MR2 only)
2.4.4.2 Digital input modules will be rated for up to 120V AC isolated or non-isolated.
Minimum isolation between input and logic voltage shall be 1500 V rms. Each
input shall have an LED to indicate on/off status. Digital inputs to the PLC shall
be individually fused. Digital inputs shall not exceed 16 per card, except where
agreed to by Buyer.
2.4.4.3 Digital output modules will be rated up to 120V AC isolated or non-isolated
solid state with sufficient ampacity to handle normal inductive loads found in
the facility, such as motor starter coils and solenoid valve coils. Advise and so
state if the inductive devices require arc suppression. Outputs shall have an
LED to indicate on/off status and blown fuse condition.
2.4.4.4 Digital output signals from the PLC shall be individually fused in the control
system. Digital outputs shall not exceed 16 per card, except where agreed to
by Buyer. The system shall be capable of providing normally open and
normally closed contact outputs.
2.4.4.5 Analog input signals to the PLC shall be isolated, and individual channels shall
be either current limited or fused. Analog inputs shall not exceed 16 per card.
The system shall provide quality checks for all analog inputs. Data shall be
automatically tagged as bad on all displays or logs if the input value is out of
range. System accuracy shall not exceed 1% of calibrated range (excluding
transmitter).
2.4.4.6 Analog output signals from the PLC shall be isolated, and individual channels
shall be either current limited or fused. System accuracy shall not exceed 0.50/0
of output signal range (excluding final element). A maximum of 16 points per
card is permitted.
2.4.4.7 If the I/O modules individual internal fuses are not readily accessible, or cannot
be replaced without taking the entire module out of service, then external fuses
shall be provided. These fuses shall be coordinated with the internal module
fuse and sized to blow before the internal fuse. Fuses shall be equipped with a
blown fuse indicator.
2.4.4.8 Provide at least 15 percent installed spare I/O points of each type used and 15
percent installed spare intermediate terminal blocks. In addition, cabinets shall
be furnished with at least 100/0 spare card slots in every card cage and 200/0 in
each cabinet for future use.
2.4.4.9 Any redundancy provided in mechanical equipment shall be maintained by the
I/O assignment of the PLC system. Redundant equipment (i.e. pumps, valves,
etc.) I/O shall be spatially separated on different I/O cards and preferably on
different I/O racks/channels.
Page 25 of 34
2.4.4.10 The PLC shall be assigned such that each controller will not be more than 70
0
/0
loaded for the processing of all its I/O, control and monitoring functions.
Control loop processing time shall not exceed 250 msec.
2.4.5
2.4.5.1
2.4.5.2
2.4.5.3
2.4.5.4
2.4.5.5
2.4.5.6
Programming
All initial programming and programming changes in the controller system shall
be by Seller.
All necessary tools (computer hardware, including computer(s) and
communications adapters) and one copy of all licensed software necessary for
all programming and configuration tasks shall be provided with Buyer's
approval. These shall be equal to or better than the tools used by Seller to
accomplish the initial configuration and programming of the system. The
programming software shall be suitable for on-line, remote (via Ethernet) or off-
line configuration. If used by Seller prior to shipment, all software licenses shall
be transferred to Owner at or before the time of shipment of the processor to
the jobsite.
The control system will have the capability of recording from memory to hard
drive, to load memory from hard drive or CD as required, and to verify memory
against the data in the hard drive. The hard drive and CD drive shall be
provided as an integral part of the PLC programming computer.
Outputs shall fail off, and the system operation will fail safe (to a zero state)
upon loss of I/O rack power, loss of communication with their processor, or any
other fault detection that could inhibit proper output reaction to process
requirements. Diagnostic alarms shall be configured for each condition.
All programming and monitoring equipment shall be able to be connected or
disconnected with the controller in operation. The controller, including output
devices, shall shut down in an orderly manner and alarm in the event of a
disruption of program execution or scan, a loss of logic power, loss of
communication between controller essential devices, or a memory error.
A password shall be required for modification to each program. This password
shall be user defined and user changeable. The password(s) in use by Seller
shall be given to Buyer upon delivery of the system.
2.4.6 PLC Local HMI
2.4.6.1 The seller shall provide at least one HMI (operator interface) to be located in
the field, unless specified otherwise in the parent technical
specification/material requisition, to facilitate local operation and maintenance.
2.4.6.2 The Local HMI shall consist of a 21 inch (525 mm) monitor with keyboard,
trackball or mouse and CPU, or equivalent membrane panel display. Displays
Page 26 of 34
shall be capable of being read in all lighting conditions, and provision shall be
made for screens exposed to direct sunlight, either by tilting of the screen or
appropriate sunshade or other method.
2.4.6.3 The local HMI shall be capable of functioning as an engineering workstation
and as an operator station
2.4.6.4 All controls shall be controlled by video-based HMI(s) that interface with the
PLC. Seller shall provide a complete package of instrumentation and controls
to:
Include automatic control with interlock functions to minimize operator
actions,
Semiautomatic operations for the plant with control interlocks, and
Manual operation for performing startup, operation and shutdown
functions, with sufficient interlocks to prevent unsafe operation.
2.4.6.5 The graphic displays shall include the flow diagram for the entire system.
Graphics shall be built using guidelines provided by Buyer. These guidelines
specify the different colors used to identify different functions. All equipment
and instruments with status indication and analog values shall be represented
on the graphic display flow diagrams at the appropriate points. The graphics
shall be sufficient for complete system startup, control, monitoring, trending,
and alarm summary and shall clearly identify the following as a minimum:
Valve status (open, close, % open for control valves, or in travel for open
closed valves). Fail to open or close shall be indicated by change in
color.
Pump status (on/off/trip)
Fan or Blower status (on/off/trip)
Analog values (Le., temperatures, pressures, flows, tank levels, analyzer
values, etc.) Analog signals shall display bad quality for signals which
are out of range.
Indication of permissives and trips
2.4.6.6 In addition to the graphic displays, provide trend displays for all of the analog
values (e.g., pressure, conductivity, pH, temperature, flow, etc.) required by the
parent technical specification/material requisition. The system shall permit the
operator to view trends in time frames from 1 minute to 30 days. HMI graphic
Page 27 of 34
displays shall be sufficient for complete system start-up, control, monitoring,
trending, and alarm summary.
2.4.6.7 Failure of the PLC or HMI shall transmit a "PLC System Trouble" alarm to
Buyer's control system through an isolated dry contact. Seller shall add alarms
as deemed necessary, but shall suppress alarms on idle equipment to
eliminate nuisance alarms that may misguide either the local or control room
operator.
Page 28 of 34
PART 3 - DOCUMENTATION
3.1 To maintain compatibility with Buyer's numbering system, Buyer will assign
one or more system designators and a block of instrument loop numbers for
Seller's use. Identification of instruments shall be per Appendix F.
3.2 Seller's drawings shall be appropriately cross referenced to facilitate location
of components on multiple drawings.
3.3 The parent technical specification/material requisition specifies the
documents to be provided in the Document Submittal Requirements (DSR)
section. This section details the requirements applicable to documents listed
in the DSR. Note that not all documents listed below will necessarily be
required by the DSR; such documents are not considered in Seller's scope of
supply.
3.3.1 Electronic copy (CD ROM, DVD, or HDDVD) of instrument index identifying
all instrumentation provided by Seller. (Refer to Appendix B for requirements
for the Instrument Index.)
3.3.2 Completed instrument data sheets per ISA-20 or equivalent (Appendix G).
3.3.3 Control panel/cabinet general arrangement drawings, including overall
dimensions, instrument layout, terminal block identification, mounting details,
cable entry points, assembly weight, environmental restrictions, and panel bill
of materials.
3.3.4 Complete back-of-board point-to-point wiring diagrams showing all wiring,
instruments, and devices in their relative physical relationship, including the
interconnecting wire numbers on the terminal blocks.
3.3.5 Schematic diagrams, including the location of all devices when mounted in
separate locations, and contact development for all control switches.
3.3.6 Connection diagrams showing interconnecting wiring among all Seller
supplied equipment. Seller shall identify terminals that interface with other
equipment.
3.3.7 External wiring, tubing, and piping diagrams showing terminal block details,
layout for termination of field wiring, and location of process connection for all
instruments (hook-up drawings).
Page 29 of 34
Specification 25316-000-3PS-JQ07-00001 J Revision 000
3.3.8 Details of prefabricated cables, including minimum bending radius, maximum
pulling tension, maximum permissible sidewall pressure, overall connector
size, and connector details.
3.3.9 Installation requirements for loose-shipped instrumentation.
3.3.10 Piping and instrument diagrams (P&IDs) showing the complete system,
including mechanical equipment, piping, valves, ductwork, instrumentation,
and controls. Also include instrument and equipment tag numbers, equipment
names, direction of flow, identification of Buyer/Seller interface of
components furnished by others. Pipe and duct sizes shall appear on P&IDs
unless shown on other drawings. Use drawing standard ISA-5.1-1984
(R1992) - Instrument Symbols and Identification, for instrument symbols on
P&IDs.
3.3.11 A detailed technical description of theory of operation and all sequential
operations must be provided for all systems.
3.3.12 Listing of all input and output signals associated with the control package with
information on tag name, service description, process range, process units,
voltage level, and signal range, as a minimum.
3.3.13 Listing of all input and output signals available through the DCS interface with
tag name, service description, information on rung or register location, signal
ranges, state descriptors, process range and process units, as a minimum.
DCS interface address list shall be in consecutive order.
3.3.14 Electrical power distribution, single line and three line diagrams of Seller's
supplied equipment.
3.3.15 Block diagrams or functional control diagrams showing the function of
equipment supplied and its component parts of Seller's supplied equipment
3.3.16 Detailed Bill of Material including name of manufacturer and model number of
all components of Seller's supplied equipment
3.3.17 Time-current curves (original and full size copy) for protective relays, auxiliary
relays, and circuit breakers of Seller's supplied equipment
3.3.18 Nameplate schedule for transformer- rectifiers, etc.
3.3.19 Circuit and raceway schedule of Seller's supplied equipment including
interconnecting wiring between Seller supplied skids or components.
3.3.20 Instruction manuals covering basic design principles, theory of operation,
operational adjustment, maintenance, troubleshooting, repair, site storage,
installation, and start-up. Manuals shall include reduced copies of final
Page 30 of 34
drawings for all appropriate system documentation, such as P&IDs, electrical
schematics, logics, and functional drawings, etc.
3.3.21 Catalog data on all components furnished. Use symbols and method of
drawing presentation in accordance with NEMA ICS 1, Industrial Control and
Systems General Requirements.
3.3.22 Recommended start-up spare parts list detailing items that should be available
during commissioning and a recommended one year spare parts list detailing
items that should be available for one year of operation.
3.3.23 PLC specific documentation (application only if PLC provided):
3.3.23.1 Network Diagram - This diagram shall be the basis from which the rest of the
system is developed. It shall show all of the system cabinets (including
processor, liD racks, modules, power supplies, spare liD, etc.) communication
cable connections, connector termination details, power requirements, and
power distribution. Any DIP switches that require settings shall be indicated on
this drawing. The manufacturer and catalog numbers shall be shown for each
component.
3.3.23.2 liD Wiring and Connection Diagram - These drawings shall show all internal
cabinet wiring and connections. I/O cards shall be shown with the
manufacturers' part number, the liD rack and slot number in which the module
is located, the devices connected to each terminal of the module, and point to
point wiring of each termination.
3.3.23.3 Cabinet Wiring Drawing - These drawings shall show outline dimensions of all
equipment, equipment mounting details, required clearances, weights, cable
entry areas, terminal block arrangements and rack locations.
3.3.23.4 Program documentation - Documentation in any of the IEC 61131-4
programming languages is acceptable (viz. instruction list, structured text,
ladder diagram, function block diagram or sequential function charts). This
document provides system programming in completely annotated form. The
printout shall contain program title block, address labels and descriptions, and
line comments describing each line or loop function. An address cross-
reference report shall also be included. Printed hard copy and electronic files
on a CD ROM, DVD, or HDDVD media are to be provided.
3.3.23.5 Listing for data interface to DCS. Seller shall provide cross-referenced block
transfer lists with addresses or other suitable format for documenting the data
interface to the DeS.
3.3.23.6 System logic and functional control diagrams showing functional operation of
the system.
Page 31 of 34
3.3.23.7 Graphic display diagrams, including definitions of colors used, changeable
fields, poke fields, point identification, etc. For systems that do not have
graphic display, diagrams need to be provided that pictorially depict the
equipment and identify the associated data available through the DeS
interface.
3.3.23.8 Graphic display hierarchy including relationships between diagrams for
paging, etc.
3.3.23.9 Seller shall identify all alarms available to the operator on applicable
documentation.
3.4 Seller shall include Buyer's instrument and equipment tag numbers on all
documents as applicable.
3.5 Seller shall identify the electrical load requirements (peak and continuous) for
each power source.
3.6 Seller shall identify the air consumption (peak and continuous) for each
interface point.
3.7 Seller shall identify the heat loads produced by equipment to be installed
indoors.
3.8 Seller shall submit a factory test plan and test reports for review.
Page 32 of 34
PART 4 - INSPECTION AND TESTING
4.1 Seller shall pressure test in his shop all pressure-containing components
except pneumatic devices for 5 minutes at 1.5 times design pressure with no
detectable leakage. Use dry, oil-free air or nitrogen if working fluid is a gas.
4.2 Seller shall verify the calibration and operability of each device in
measurement and control systems involving electronic or pneumatic
transmission by applying a simulated input signal over the full range. All
instrumentation shall be supplied with factory calibration certificates. Seller
shall provide separate calibration certificates and data for all instruments
required for the performance testing specified in the parent technical
specification/ material requisition.
4.3 Seller shall test relays, switches, and lamps in accordance with
manufacturer's standard test procedure.
4.4 Seller shall perform a functional test of each circuit by actuating associated
controls, disconnects, and breakers.
4.5 Seller shall perform a 1DO-percent point-to-point continuity test for Seller-
installed wiring.
4.6 Insulation and clearance to ground shall be such that the live parts, except
solid state and microprocessor devices, will withstand a high potential test of
not less than 2200 volts, 60 hertz for 1 minute.
4.7 Software logic for programmable devices shall be factory tested prior to
shipment to verify proper functionality, to verify proper field contact sense and
signal levels, and to verify preset trip points and timer settings. Any and all
temporary logic or modifications made for testing shall be documented and
removed from the system prior to shipment.
4.8 PLC Inspection and Testing (if PLC provided)
4.8.1 Perform a complete shop test, witnessed by Buyer's engineer, of the entire
PLC system prior to shipment. Tests shall include, but are not limited to,
complete testing of I/O, graphics/HMI functionality, logic and modulating
control. All tests shall be performed with the data highway fully connected as
per application distance. Advise Buyer at least two weeks in advance that
the system is ready for witnessed tests.
Page 33 of 34
4.8.2
Provide full simulation of system diagnostics, redundancy, security, and I/O
modules.
Page 34 of 34
Specification 25316-000-3PS-JQ07-00001, Rev. 000
Appendix A
APPENDIX A - APPROVED MANUFACTURERS LIST
CONTROL SYSTEMS
Pneumatic Analog
DCS
Programmable Controllers
FIELD INSTRUMENTS
Electronic Transmitters (Pressure
and Differential Pressure)
Flow Meters (magnetic, vortex)
Flow Meters (variable area)
Flow Meters (Ultrasonic)
Flow Meters (Turbine)
Flow Meters (Mass)
Flow Glass
Pneumatic Controllers (Local)
liP Converters
Conductivity Instruments
pH Instruments
Dissolved O
2
MANUFACTURER
Emerson (Fisher), Foxboro, Siemens, Moore
ABB (Bailey), Emerson (Ovation), Invensys
(Foxboro)
Rockwell (Allen-Bradley ControlLogix)
Emerson (Rosemount 3051 series smart
transmitters with ASME B31.1 Coplanar
style integral manifolds)
Foxboro, Emerson (Rosemount), Endress &
Hauser, Krohne
Krohne, S&K Automation, Emerson
(Brooks), ASS (Fischer & Porter), US Filter
(Wallace & Tiernan), Schutte-Koerting
Magnetrol, Krohne, Siemens (Controlotron)
Emerson (Daniel), Badger, Flo-Tech
FCI, Sierra, Emerson (Rosemount)
Universal Flow, Penberthy
Emerson (Fisher), Foxboro
Emerson (Fisher 546), Moore Industries,
Masoneilan I/PEX 9000
Honeywell, Thornton-Mettler, Emerson
(Rosemount Analytical), Hach (GLI)
Honeywell, Thornton-Mettler, Emerson
(Rosemount Analytical), Hach (GLI)
Emerson (Rosemount Analytical)
Page 1 of 4
Sodium Instruments
Silica Instruments
Level Controllers or
Transmitters (Displacer Type)
Level Instruments (Ultrasonic)
Level Probes, Capacitance
Level Switches (Conductivity)
Level Switches (Displacer/ Float Type)
Level Gauges
Level Gauges, Magnetic
Moisture Analyzer
Flow Nozzles
Orifice Plates
Pitot Tubes
Pressure Switches
Pressure Gauges
DP Switches
DP Switches (Low Pressure)
DP Indicators
RTDs, Thermocouples, Thermowells
Temperature Switches
Temperature Transmitters
Thermometers (Dial Type)
Appendix A
Thermo Scientific (Orion)
ASS, Hach, Waltron
Emerson (Fisher), Magnetrol
Magnetrol, Siemens Sitrans L, Endress &
Hauser
Emerson (Rosemount), Magnetrol, Endress-
Hauser
Solartron-Mobrey
Magnetrol, Emerson (Fisher), Static-O-Ring
Penberthy, Jerguson
Magnetrol, K-Tek, Orion
Emerson (Fisher Rosemount), Panametric
Fluidic Techniques, Emerson (Daniel)
Fluidic Techniques, Emerson (Daniel)
Emerson (Rosemount), Veris
Static-a-Ring, Dwyer (Mercoid), United
Electric, Ashcroft
Ashcroft, Ametek (US Gauge), WIKA
Dwyer (Mercoid), Ashcroft, Nuflotech
(Barton)
Dwyer
Ashcroft, WIKA
STI, Pyco, Daily Thermetrics, Ashcroft
Static-a-Ring, United Electric, Ashcroft ,
Watlow
Emerson (Rosemount)
Ashcroft, Palmer Wahl, Ametek (Rochester)
Page 2 of 4
Solenoid Valves
Limit Switches
CONTROL VALVES
General Service
Severe Service
Desuperheaters
Turbine Bypass/ Steam Conditioning
Valves
Metal Seated Ball Valves
Butterfly
Diaphragm
Regulators (Self-Contained)
Positioners
CONTROL PANEL DEVICES
Indicating Lights
Vertical Indicators
Annunciators
Strip Chart Recorders
Multipoint Recorders
Control Switches
Appendix A
Emerson (ASCo), Leslie (Laurence)
NAMCO, Honeywell (Microswitch), GO
Switch
Emerson (Fisher), Flowserve (Valtek),
Samson (W&T), Masoneilan, Leslie
Emerson (Fisher), CCI, Tyco (Sempell),
Masoneilan, Copes-Vulcan SPX, Leslie
Emerson (Fisher), CCI, Tyco (Sempell,
Narvik, Yarway), WEIR (Blakeborough), SPX
(Copes-Vulcan), Samson (W&T)
CCI, Samson (W&T), Emerson (Fisher),
Tyco (Sempel), Masoneilan (AuXiliary Steam
service only), SPX (Copes-Vulcan steam
atomizing designs only)
Valve Technologies, Mogas, Metso, Velan
Fisher, Metso, Masoneilan, Tyeo
ITT (Grinnell-Saunders), Crane, Flowserve
Emerson (Fisher), Masoneilan, Cashco
Emerson (Fisher DVC), Masoneilan (Smart)
GE, Eaton (Cutler Hammer), Rockwell
(Allen-Bradley)
Hach (Sigma), Ametek (Dixson), Yokagawa
Ametek (Panalarm Series 90)
Honeywell, Yokagawa, Chessell
Honeywell, Yokagawa, Chessell
Eaton (Cutler Hammer), Eleetroswitch,
Rockwell (Allen-Bradley), GE
Page 30f4
Transducers, Electrical
MISCELLANEOUS DEVICES
Vibration Monitors
Tube Fittings
Instrument Valves
Time Delay Relays
Opacity Monitors
In Situ Oxygen Monitors
S02, NOx, CO, C02 Monitors
Signal Conditioners
Terminal Blocks
Instrument Filter-Regulators
Instrument Manifold Valves
Starters
Auxiliary Relays
Circuit Breakers
Pushbuttons
Indicating Lamps
Appendix A
Ametek (Rochester)
Bentley Nevada
Parker-Hannifin A-10k, Swagelok
Swagelok (Whitey, Nupro), PGI, Parker-
Hannifin, Anderson-Greenwood
Tyco (Agastat SSA)
Teledyne (Monitor Labs), Durag, Ametek
Land Inc.
Teledyne (Monitor Labs), Emerson
(Rosemount), Yokagawa COSA
Teledyne (Monitor Labs), TECO, API,
Emerson (Rosemount)
Moore, Ametek (Rochester)
Marathon, Weidmuller, GE, Phoenix, State
Emerson (Fisher 67FRA), Norgren
Anderson Greenwood & Co
Rockwell (Allen-Bradley), GE, Schneider
(Square D), Eaton (Cutler-Hammer)
Tyco (Potter Brumfield), Rockwell (Allen-
Bradley)
Eaton (Cutler Hammer), Schneider (Square
D), GE
GE, Rockwell (Allen-Bradley)
GE, Rockwell (Allen-Bradley)
Page 4 of 4
Appendix B
APPENDIX B REQUIREMENTS FOR INSTRUMENT INDEX
1.0 INSTRUMENT INDEX
Seller will be furnished with a CD ROM or DVD of the Buyer's Instrument Index
database. This database shall be used to develop an Instrument List to describe
the instruments furnished by Seller.
2.0 COMPUTER SYSTEM REQUIREMENTS
The Instrument Index database files are designed for use on a personal computer
with Windows 98 or higher operating system and application software. The
database is compatible for use with Microsoft's Access version 7.0 or may be
converted for use with other widely used spreadsheet or database programs. It is
preferable that the completed database file is returned in the Access format.
3.0 DATA FIELDS
The minimum required Instrument Index data fields are as described below. Seller
should complete all applicable fields. When information is not available, the field
should be left blank. Non-applicable fields should be completed by entering "N/A
ll
"',
SE'OUENCENUMs'ER
Field Name
REV
UNIT
FUNCTION CODE
SLJFFIX
"
Max. Definitions & Explanation of Content Instru- Control
Length ment Valves
3 . This is ..' .. : .. \:k'i.: '<':';','.":. :'.
'> " x:
instrument list is' ,,/;';:. ".::'
entered as .. ", ""';';' ".' .... ,>/: ,: ::T'}':
..,. ......,';".,,>,' i; J;:,:":;}<i"/.;, ..;,;',; "",. ;;:::;'
2' Suffix
Page 1 of 4
Appendix B
TAG 24 Tag number (Bechtel Assigned)
This information is generally provided as a
Buyer comment on the Preliminary submittal
of the Seller's drawings/documentation.
Contains a 2-letter system designation,
followed by a 2 or 3-letter ISA function X X
description, and a sequential loop number.
Digital points are tagged in a similar
convention. This number is formed from the
catenation of the following fields.
VENDOR 8 Seller Name or Initials.
X X
VEND TAG 20 Vendor Tag
-
Where vendors have there own specific tags
already allocated and cross-referenced in
X X
other documentation, they may be entered
here.
PID 24 The piping and instrument diagram/drawing
on which the instrument appears. Use the
Buyer assigned vendor drawing number
after the first P&ID submittal (e.g., 22803-
o15-M6-XXXX, where "XXXX" is the drawing
number.
This shall reference either the P&ID or
X X
process flow diagram on which the
instrument is shown. If shown on more than
one type of document the P&ID shall take
preference and reference to other drawings
shall be indicated in the "NOTE" field.)
PIO REV 4 Current P&ID revision
X X
-
DESCR 1 16 Description specifying primary
-
service/function of the item.
This is a short, unique-to-the-device
identification, which describes the device or X X
instrument purpose (e.g., Main Feedwater
Flow, Main Steam Temperature, etc.)
DESCR 2 16 For process and alarm switches, the
-
description shall indicate the process
condition when contact is closed. For
example, a low-level alarm switch (open to X X
alarm) should read "XXXX Tank Level Not
Low".
Page 2 of 4
Appendix B
MANUFACTURER 25 Inst/Valve Manufacturer
Manufacturer of component or instrument,
X X
and not necessarily the Seller of the system.
MODEL NO 50 Manufacturer's model number
X X
DATA SHEET 24 Vendor's data sheet number
Refers to ISA data sheet or specification
showing calibration, range, material, etc.
Use the commodity code group and Buyer's
sequence number assigned to the Seller's
document after the first submittal (e.g.,
X X
22803-015-JXX-XXX, where "JXX" is the
commodity code group and "XXX" is the
sequence number). This number shall be
prefixed by a "V" when entered in the
appropriate data field (e.g., "VXXX").
LOWER RANGE VALUE 12 Lower range value of the calibrated range of
- -
the instrument. X
UPPER RANGE VALUE 12 Upper range value of the calibrated range of
- -
the instrument. X
SCALE UNITS 10 Engineering units for applicable device (e.g.,
of, psig, etc.) X
SIGNALLEVEL 15 Signal level (e.g., 4 to 20 mA, etc.)
X
SIGNALTYPE 25 Signal type description (i.e. electric,
pneumatic) X
ALARM LOW 12 Alarm low level setpoint
X
ALARM LOW LOW 12 Alarm low-low level setpoint
X
- -
ALARM HIGH 12 Alarm high level setpoint
X
ALARM HIGH HIGH 12 Alarm high-high level setpoint
X
- -
CONTROL SETPOINT 12 Control setpoint
X
DPRESS 12 Design Pressure
X X
DTEMP 12 Design Temperature
X X
NPRESS 12 Normal Pressure
X X
Page 3 of 4
Appendix B
NTEMP 12 Normal Temperature
X X
INST LOC 25 Location of Instrument
Vendor drawing showing plan and elevation
of the instrument physical process tap
location. This number shall be prefixed by a
"V" when entered in the appropriate data X X
field (e.g., "VXXX").
Indicate drawing number showing instrument
location
INSTALL DTL 24 Installation Details
-
Vendor drawing number showing installation
details of how to install, mount, support,
tube, and wire the instrument. This number
shall be prefixed by a "V" when entered in
X X
the appropriate data field (e.g., "VXXX").
For valves reference to installation guides
and documentation must be indicated.
NOTES 90 Additional reference drawings etc.
REMARKS 100 Remarks or comments. This field is to be
used to provide amplifying information on
the equipment under the Seller's scope of
supply. Typical information would include
specific installation information or storage
and calibration information.
POWERYN 1 Is external power required (default N).
X X
PURCHASE ORDER 25 Purchase Order number:
The purchase order under which Bechtel
X X
purchased this equipment.
L1NECTN 24 Line Number.
X X
Page 4 of 4
Appendix C
ORIENTATION OF INSTRUMENT CONNECTIONS FOR HORIZONTAL LINES
ALTERNATIVE
PREFERRED
PREFERRED
ALTERNATIVE
AIR OR GAS
PREFERRED
ALTERNATIVE
PREFERRED
PREFERRED
ALTERNATIVE
STEAM,VAPOR,AIR, OR GAS
PREFERRED
HIGH TEMP. FLUIDS OR GAS ABOVE 750F
JOB NO. 25316
ALTERNATIVE
LINE FLUID
STEAM OR VAPOR
ALTERNATIVE
ENERGY
PREFERRED
PREFERRED
PREFERRED
SLURRY
ONLY
STATE
ALTERNATIVE *
I
LIQUID OR SLURRY
ALTERNATIVE
* - ORIENTATION FOR CLOSE COUPLED
PRESSURE GAUGES IN HORIZONTAL PIPE
ONLY.
PRAIRIE
CAMPUS
PROJECT
W
0:::
::>
I-
W
0....
NOTE*
THIS ORIENTATION FOR TEMPERATURE
INSTRUMENTS WILL NOT APPLY IF THE
PIPE DIAMETER IS SMALL AND REQUIRES
A TEE OR ELBOW TO BE USED.
PREFERRED
BELOW 750F ALL FLUIDS
LIQUID OR SLURRY
CO
0::: ALTERNATIVE
00 (PREFERRED FOR
o SLURRY ONLY)
W --J
0:::
PREFERRED
W
NOTE*
FOR pH AND CONDUCTIVITY PROBES REFER TO
MANUFACTURER GUIDELINES FOR ORIENTATION
ORIENTATION OF INSTRUMENT CONNECTIONS FOR HORIZONTAL MAIN-LINES
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Appendix D
APPENDIX D - PLANT PROGRAMMABLE LOGIC CONTROLLER (PLC) NETWORK
REQUIREMENTS
a. Seller shall provide PLC interfaces as described in this section to interface with the plant
Ethernet network. A Buyer supplied link between the plant PLC Ethernet network and the Buyer's
DCS will permit the transmission of data from the PLC to the DCS for supervisory control, trending,
and historical archiving.
b. Design, configure, and provide controls to permit supervisory control via the interface to the
DCS such as, but not limited to, initiating automatic operation, alarm monitoring, process
indication, and process data trending as described in the following paragraphs. In addition,
configure the interface and logic so that, at a future date, component level control from the DCS of
the packaged equipment can be implemented.
c. The Buyer's distributed control system (DCS) will provide commands to initiate automatic
sequential programs by interfacing with the Seller-supplied programmable logic controller based
control system, which is responsible for all direct control of the packaged equipment. The DCS will
not contain process logic for the packaged equipment. Individual selection of each component will
be initiated from the PLC human-machine interface (HMI). In the future, the DCS may be
configured to prOVide the commands to initiate functions such as start/stop, open/close at the
individual component level.
d. The Seller provided PLC shall be the Allen-Bradley ControlLogix system programmed based
on the RS Logix 5000 full edition package (version of software shall be approved by the Buyer
during detail design) and the HMI graphics shall use Allen-Bradley RSView Supervisory Family of
software (SE Server RSLINX Bundle and SE Client with Buyer approved version).
e. Where redundant PLC control processors are specified in the parent technical
specification/material requisition each shall interface to the redundant plant PLC Ethernet network.
f. Provide HIRSCHMANN Managed Ethernet switches for interface between single or redundant
ControlLogix PLC and the HMI. The switch shall include Fiber Optic Single mode SC connection
for the Buyer's remote access. Self-diagnostic Ethernet alarm message generated by the switch
shall be configured to automatically show up in the alarm summary display of the HMI. Fiber optic
cable will be by Buyer. Detailed addressing etc. will be provided during detailed design.
g. The control logic configuration in the Allen-Bradley ControlLogix PLC shall use ISA type of
point name instead of address only.
h. The Seller shall interface the PLC systems to an HMI in the main control room (supplied and
installed by the Buyer) which is shared between plant PLCs via the plant PLC Ethernet which will
provide the control room operator with operating and engineering functions normally available at
the local HMI. This will include accommodating network addressing and providing a version of the
operating graphics in a form that will run on the control room HMI.
i. Equip the PLC with local HMI(s) to support commissioning and local operation and
maintenance. If operator intervention is required, either the PLC HMI in the main control room or '
the local HMI will be used.
Appendix E
APPENDIX E
[PROJECT PLC SYSTEM NETWORK DIAGRAM WILL BE PROVIDED DURING DETAIL
DESIGN PHASE]
Appendix F
APPENDIX F - INSTRUMENT TAG CONVENTIONS
1.0 Each instrument is to have a unique instrument tag number.
2.0 The Buyer's instrument tag number consists of several elements, as the
following example illustrates:
AB-PT-011-A
Where:
AB = System identifier
PT = Instrument functional identifier
011 = Instrument loop number, common to related instruments in a
single 'loop
A = Alpha suffix: parallel, redundant or multiple device identifier
3.0 Instrument tagging conventions are in general conformance with ISA Standard
S5.1, with specific modifications as shown on drawing 25316-000-M6J-YA-00005
and -M6J-YA-00006, Symbols and Legends for Piping and Instrumentation
Diagrams.
4.0 Instrument tags for packaged mechanical systems are to be assigned by the
Buyer and incorporated by the Seller.
5.0 Bechtel standard system identification codes shall be used.
6.0 All instruments in a single loop should share a common loop number.
7.0 Loop numbers should start with 001 in each system. Therefore, the system
designation, instrument type (functional identifier), and loop number are all
necessary to uniquely define a device.
8.0 Loop numbers should be assigned in a logical manner to assist in determining
the portion of the system served by the instrument.
9.0 For systems where various Sellers will supply instruments, the Buyer will allocate
a block of loop numbers for the use of each individual Seller. This allocation of
loop numbers will be tabulated by system in the instrument index.
10.0 The instrument functional code shall generally follow the function of the
instrument, not its construction. That is, a pressure transmitter monitoring level
Page 1 of 2
Appendix F
in an atmospheric tank shall be tagged LT, and differential pressure transmitters
sensing flowmeter differentials shall be tagged FT.
11.0 The use of a suffix after the loop number applies as follows:
Redundant measurements: Differ only in suffix, e.g., three furnace
pressure transmitters, BA-PT-001A, -0018, -001 C.
Parallel equipment: Follow the mechanical equipment suffix designation,
e.g., discharge pressure for two de-mineralizer feed pumps, AN-P-01 A
and B; tags may be AN-PI-003A and -0038; for pumps -P04 and -P05,
use separate loop numbers without a suffix.
Multiple measurements for a single component: DO NOT use a common
loop number with a suffix to differentiate between different measurements
on the same component, e.g., instruments sensing suction and discharge
pressure on a pump should have different loop numbers.
12.0 Each instrument shall be tagged with a non-corroding metal tag as shown in
Appendix D. Panel-mounted equipment is an exception to this requirement.
Panel-mounted devices shall be identified with nameplates in accordance with
Appendix E.
Page 2 of 2
Appendix G
APPENDIX G - INSTRUMENT DATA SHEETS
1.0 The Seller shall complete instrument data sheets for all instruments and control
devices, including control valves, supplied within the Seller's scope.
2.0 Appropriate blank data sheet electronic files (typically in MS Excel format) will be
provided to the Seller by Bechtel after the required data sheets are determined
and requested by the Seller. The Seller may submit data using this format or
another, equivalent, format such as ISA or vendor standard data sheets,
provided an acceptable level of detail is provided.
3.0 Should the Seller choose to use Bechtel data sheets, and should the formats
provided not apply to any instruments in the Seller's scope, Bechtel will provide
appropriate blank data sheets, or, should the required data sheet not exist in
Bechtel's library, instruct the Seller to prepare a data sheet using the Bechtel
format.

Technical Specification For Instrumentation Controls and Electrical Requirements

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Technical Specification For Instrumentation Controls and Electrical Requirements

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TECHNICAL SPECIFICATION

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