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CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Technical Bulletin 6.02, Rev. 0 December 1998
Controls & Instrumentation
29 Royal Road, Guelph, Ontario, Canada N1H 1G2
Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com
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Table of Contents
Section 1.0 General
1.1 1.2 1.3 1.4 1.5 1.6 1.7 Scope Codes and Standards Inspections Shipment Drawings Utilities Interconnecting Installation
Page
2 2 2 2 3 3 4 4 5 5 5 6 7 22 22 22 24 25 29 30 30 30 30 34 35 36
2.0
Instrumentation
2.1 2.2 2.3 2.4 Scope Identification Instrumentation Design Requirements Field Mounted Instruments
3.0
Control Panels
3.1 3.2 3.3 3.4 3.5 Scope Enclosures Programmable Logic Controllers Control Panel Assembly Operator Interface Terminal (OIT)
4.0
Installation
4.1 4.2 4.3 4.4 4.5 4.6 Scope Enclosures Electrical Equipment Grounding Air Tubing Instrument Installation Guidelines
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Technical Bulletin 6.02, Rev. 0 December 1998 1.0 General
1.1 Scope The purpose of this specification is to establish the minimum requirements and standards for the design, materials, inspection and shipping of process instrumentation, control panels and equipment installations. 1.2 Codes and Standards References The latest edition or revision of the following references are part of this specification: U.S.A.: Occupational Safety and Health Administration (OSHA) National Electrical Code (NEC) Underwriters Laboratories, Inc. (UL) Institute of Electrical and Electronics Engineers (IEEE) American National Standards Institute (ANSI) Instrument Society of America (ISA) National Electrical Manufacturers Association (NEMA) Factory Mutual System (FM) Canada: Canadian Electrical Code (CEC) Canadian Standards Association, Inc. (CSA) Electrical and Electronics Manufacturers Association of Canada (EEMAC) Approvals The equipment shall be designed and manufactured in accordance with UL, or FM, or CSA, and EEMAC or NEMA standards where applicable. 1.3 Inspections The purchaser has the right to inspect all work in progress and witness all tests at his/her discretion.
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1.4 Shipment The equipment shall be released for shipment only after acceptance is received from the purchaser. Delicate instruments, computers, monitors etc., when necessary, shall be removed from the control panel and shipped in their original containers. The control panel shall be thoroughly cleaned in preparation for shipment. The entire panel shall be wrapped in plastic for protection against dirt and weather. The control panel shall be secured on a skid and crated in a wooden structure to prevent damage and contamination during shipment. The control panel shall be transported to the purchasers site on an air ride trailer or enclosed van. Electrical equipment and materials shall be handled with care to insure against mechanical and moisture damage. Equipment and materials for outdoor use which arrive at the construction site prior to the installation time shall be stored indoors or otherwise suitably protected. All equipment purchased with space heaters, such as large motors, switchgear, motor control centers, etc., shall have space heaters energized immediately after arrival on the site or any storage location and shall be kept energized until construction is completed. The PLC Processor shall also be energized during storage at site. 1.5 Drawings All drawings shall be prepared as per this specification. Drawing package shall consist of bills of material, layouts, cable schedules and schematic diagrams for the complete system. Electrical and Instrumentation system drawings shall be done in an 8 by 11 format and organized in a loose leaf binder. All drawings shall be prepared using AutoCAD drafting software. 3 diskettes containing all AutoCAD drawings shall be provided with the as built set of drawings. PLC Ladder Logic shall be provided after program testing.
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1.6 Utilities The following utilities shall be provided by the purchaser: 120 VAC, 60 HZ, single phase, preferably isolated and noise free power supply for all control and instrumentation circuits. 480 VAC or 575 VAC (as required), 60 HZ, three phase power supply for all motors, heaters etc. Dry, clean instrument air, with air pressure as required.
1.7
Interconnecting Installation Wiring from the Control Panel to each equipment skid and the Operators Console will be provided at the site by the purchaser following schematics supplied by the vendor. If required, a Motor Control Center (MCC) and local disconnect switches shall be provided by the purchaser. All wiring between vendor supplied motors or heaters and the MCC or disconnects is the responsibility of the purchaser. Where required, one instrument air connection point per equipment skid shall be provided for the purchaser to connect to the plant instrument air supply.
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Technical Bulletin 6.02, Rev. 0 December 1998 2.0 Instrumentation
2.1 Scope The purpose of this specification is to establish the minimum requirements and standards for the design and materials for process instrumentation. 2.2 Identification All instrumentation shall be identified with instrument tag numbers shown on process and instrumentation diagrams and bills of material. All symbols and identification letters shall be in accordance with the ISA. Instrument Tagging Cross-Reference List The vendor shall supply a complete instrument tag list in a format that allows the purchaser to insert the plants specific tagging designations. This form can be used as a master cross-reference list between the vendors tag numbering system and the purchasers plant tagging system. Nameplates All instruments are to be identified with a nameplate permanently attached with stainless steel screws or stainless steel wire, and engraved with the Instrument Tag Number (i.e. FIT-1760). Instruments mounted on field located racks shall have nameplates mounted on the front of the rack. All nameplates shall be white lamacoid with black core letters, unless noted otherwise.
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2.3 Instrumentation Design Requirements 2.3.1 General Electronic analog transmitters (4-20 mA DC) shall have their output signals isolated from ground. Devices receiving electronic analog signals (4-20 mA DC) shall have their inputs isolated from ground. Devices requiring an external power source shall be rated for 120 VAC, 60 Hz operation. Field-mounted instrumentation shall be suitable for installation in areas with an ambient temperature between -20 and 120F and relative humidity of 10 to 95 percent. All field mounted instruments shall have housings rated NEMA/ EEMAC 4 as a minimum. When required, specialty analyzers that are not available with a NEMA/EEMAC 4 rating shall be protected by separate NEMA/EEMAC 12 enclosures. 2.3.2 Process Taps All instrument taps into process lines shall be as a minimum, 1/2" NPS Schedule 40 pipe, from tap point to the instrument isolator. 2.3.3 Isolating Diaphragms Isolating diaphragm seals shall be used where instrument wetted parts are not compatible with the process liquid. 2.3.4 Isolation Valves All isolation valves shall be a minimum of 1/2" NPS. All instruments requiring process taps shall be provided with isolation valves. Secondary isolating valves shall be provided for instruments mounted remote from process piping.
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2.4 Field Mounted Instruments 2.4.1 Differential Pressure Transmitters
Figure 2-1: Differential Pressure Transmitter Electronic differential pressure transmitters shall be diaphragm actuated, low hysteresis, two wire type. Maximum measurement error shall not exceed 0.25% of span, including combined effect of linearity, hysteresis and deadband. Zero shift shall not exceed 0.25% of upper range limit for 100F temperature shift. Output signal shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Transmitters shall be factory calibrated for the specific application. Zero and span shall be field-adjustable within selected transmitter range. Process connections shall be 1/2" NPT and shall be suitable for manifold mounting. Three-valve, 316SS manifolds directly mounted to the transmitters shall be provided. Universal mounting brackets shall be included. Wetted parts shall be 316SS unless application requires other material. LCD indicators shall be provided with scale in engineering units and accuracy 0.1% of span. Integral square root extraction shall be provided for flow measurement.
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2.4.2 Pressure-Type Level Transmitters
Figure 2-2: Pressure-Type Level Transmitter Pressure type liquid level transmitters shall be flange mounted, diaphragm actuated, low hysteresis, two-wire type. Maximum measurement error shall not exceed 0.25% of span, including combined effect of linearity, hysteresis and deadband. Zero shift shall not exceed 0.25% of upper range limit for 100F temperature shift. Output signal shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Transmitters shall be factory calibrated for the specific application. Zero and span shall be field-adjustable within selected transmitter range. Process connection shall be via a 3", 150 lb., 316SS flange, unless application requires other material or flange rating. All wetted parts shall be 316SS unless application requires other material. The transmitter fill material shall be silicone, unless otherwise noted. LCD indicators shall be provided with 0-100% scale and accuracy of 0.1% of span.
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2.4.3 Sonic Level Transmitters Sonic level transmitters shall be microprocessor-based, four-wire type, utilizing a remote transducer mounted on top of the tank. Transducer process connection shall be flange type. Transducer and mounting flange shall be made of material suitable for specific process application. Transducer shall be supplied with a cable for connection to the transmitter. Maximum measurement error shall not exceed 1% of the full range. Output signal shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Transmitters shall be supplied with an internal pre-wired test connector and precision resistor (or other hardware) allowing transmitter output test without interrupting the loop. LCD indicators shall be provided with 0-100% scale and accuracy of 0.1% of span. 2.4.4 Temperature Transmitters
Figure 2-3: Temperature Transmitter
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Temperature transmitters shall be electronic two-wire type compatible with 100W platinum RTD sensors conforming to International Temperature Standards. Maximum measurement error shall not exceed 0.5% of upper range limit for temperature shift of 100F. Grounding of the RTD sensor circuit shall not affect transmitter accuracy. Output signal shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. LCD indicators shall be provided with engineering units scale and an accuracy of 0.1% of span. Transmitters shall be factory calibrated for the specific application. RTD sensor assembly shall include the element, nipple, head, terminal blocks and thermowell. RTD sensor thermoelectric properties shall be = 0.00385W/W/C and R=100W at 0C. RTD sensor shall be a single sealed spring-loaded ungrounded element with 1/4" outside diameter and 316SS construction. RTD head shall be weatherproof with a screwed, gasketed cover fastened to the head with a chain or other retaining device. Terminals inside the head shall be clearly marked. Bar stock, 316SS, 0.26 bore and 1/3 to 1/2 pipe diameter insertion length thermowells shall be used. Thermowell process connections shall be 3/4" NPT.
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2.4.5 Conductivity Analyzers/Transmitters
Figure 2-4: Conductivity Analyzer/Transmitter
Conductivity analyzer/ transmitters shall be electronic two or four wire type, with temperature compensation, flow-through temperature compensated sensor, sample well and automatic isolation valve where required. Sensors for dilute acid and dilute caustic concentration measurements shall be inserted directly into the process lines for safety reasons. Maximum measurement error shall not exceed the following values: accuracy of 1% of full scale. repeatability of 0.5% of full scale.
Output signals shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Analyzers shall contain an integral indicator with engineering units scale. Regenerant analyzers shall indicate concentration percentages. Conductivity sensors shall be supplied with cable for connection to the analyzer.
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2.4.6 pH Analyzers/ Transmitters
Figure 2-5: pH Analyzer/Transmitter
pH analyzers shall be electronic two or four-wire type with temperature compensation, flow-through temperature compensated sensor, sample well and automatic sample valve where required. Maximum measurement error shall not exceed the following values: accuracy of 0.03 pH. repeatability of 0.01 pH.
Output signal shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Analyzers shall contain an integral indicator with engineering units scale. pH electrodes shall be supplied with a cable for connection to the analyzer.
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2.4.7 Silica Analyzers
Figure 2-6: Silica Analyzers Silica analyzers shall be rangable with output programmable over the range 0-5000 ppb of SiO2. Output signals shall be 4-20 mA DC. Analyzers shall be microprocessor based and shall incorporate the heteropoly blue method using ascorbic-acid reduction for analysis. Analyzers shall contain an integral indicator with engineering units scale. Maximum measurement error shall not exceed 1 ppb at a range of 0-100 ppb. Automatic reagent shut-off shall be provided.
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2.4.8 Sodium Analyzer
Figure 2-7: Sodium Monitor Sodium monitors shall be electronic four wire type, with temperature compensation, flow-through temperature compensated sensor, sample well and automatic isolation valve when required. Maximum measurement error shall not exceed the following values: accuracy of +/- 0.4% of span repeatability of +/- 0.5% of span
Output signals shall be 4-20 mA DC. 4 mA shall correspond to 0% span, 20 mA to 100% span. Monitors shall contain an integral indicator with engineering units scale. Sensors shall be supplied with cable for connection to the monitor.
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2.4.9 Hardness Analyzers Output signals shall be 4-20 mA DC. Local indicators shall be provided. Maximum measurement error shall not exceed 5% of range.
2.4.10 Turbidity Analyzers
Figure 2-8: Turbidity Analyzer
Output signals shall be 4-20 mA DC. Local indicators shall be provided. Maximum linearity measurement error shall not exceed 1% of full range.
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2.4.11 Magnetic Flowmeters
Figure 2-9: Magnetic Flowmeter
Magnetic flowmeters shall include a flow tube and remote flow indicator. Maximum measurement error shall not exceed 1% of range. Output signals shall be 4-20 mA DC. Flow tubes installed in lined or other non-conductive pipe shall have grounding rings.
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2.4.12 Differential Pressure Switches
Figure 2-10: Differential Pressure Switch All wetted parts shall be 316SS, or as application requires. Maximum error shall not exceed the following values: 5% of full scale. 1% of full scale - repeatability of set point.
One single-pole double-throw contact shall be provided. Rating shall be 5 A at 120 VAC minimum. Where indication is required, scales shall be direct-reading type.
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2.4.13 Pressure Indicators
Figure 2-11: Pressure Indicator Pressure indicators shall be bourdon tube or bellows, back blow-out type. Materials of construction shall be suitable for the application. All wetted parts shall be 316SS. Maximum indication error shall not exceed 1% of span. Indicator dials shall be minimum 2-1/2" in diameter. Normal operating range shall be between 33 and 67% of span. Pigtail syphons for direct-mounting shall be provided for steam service. Isolating diaphragms with silicone fill, unless otherwise noted, shall be provided where required by process, complete with 1/2" NPT inlet and outlet connections.
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2.4.14 Differential Pressure Flow Indicators
Figure 2-12: Differential Pressure Flow Indicator Differential pressure flow indicators shall be bellows, diaphragm or piston type. Materials of construction shall be suitable for the application. Maximum indication error shall not exceed 5% of span. Indicator dials shall be minimum 4-1/2" In diameter. Normal operating range shall be between 33 and 67% of span. Process connections shall be 1/4" NPT. 2.4.15 Current-to-PneumatIc Transducers I/P Transducers shall accept 4-20 mA DC input signal. The output signal shall be 3-15 PSI. 4 mA inputs shall correspond to 3 PSI output (0% span); 20mA inputs shall correspond to 15 PSI output (100% span). Zero and span shall be field-adjustable. The instrument air inlet to the transducer shall be through a filter regulator provided by the vendor.
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2.4.16 Filter/Regulators
Figure 2-13: Filter/Regulator Filter/regulators shall be suitable for reducing pressure from 80-100 psig to 20-50 psig, as required. Filter/regulators shall have a 1.5" dial pressure gauge for outlet pressure measurement. Range shall be as noted on the drawings. Filters shall be a 5-micron grade or better. 2.4.17 Automatic Isolation Valves Automatic isolation solenoid valves shall be 2-way, 316SS body, 1/4" NPT connection, complete with screw type terminals and junction box. The valve housing including junction box shall be rated NEMA 4 as a minimum.
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2.4.18 Orifice Plates Orifice plates shall be paddle-type, concentric bore, 316 stainless steel. Plates for lines sized 1-1/2 through 10 shall be nominal 1/8 thickness. Plates for 12 and larger line sizes shall be 1/4 thickness. All outside diameters shall be machined. Stamping or burning will not be accepted. Orifice plates shall be fabricated from stretcher-leveled stainless steel sheet. Finish shall be 15 to 30 microinch roughness. Bore tolerance shall be 0.005. Bore concentricity shall be at least 0.002. Manufacturer shall perform orifice edge sharpness test. Plates shall be in accordance with ASME flow meter standards. Preferred differential pressure range is 100" WC. Beta Ratio shall be between 0.2 and 0.75. 2.4.19 Valves For automatic valves see Technical Bulletin 6.16. Air solenoid valves shall be either: Four-way, manifold-mounted, aluminum alloy body, with 1/8" NPT connections, and locking manual overrides. Three- or four-way, forged brass body with 1/4" NPT connections, common air header, and with locking manual overrides.
Figure 2-14: Solenoid Valves
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Technical Bulletin 6.02, Rev. 0 December 1998 3.0 Control Panels
3.1 Scope The purpose of this specification is to establish the minimum requirements and standards for the fabrication, electrical design, materials, testing, inspection and shipping of control panels, operator consoles and control stations. 3.2 Enclosures The enclosures shall conform to the relevant requirements of EEMAC or NEMA standards, for the specified rating. The control panel shall be a totally enclosed, free-standing structure. The enclosure shall be rigid, stiffened and reinforced to withstand all stresses incidental to shipping, installation, and operation, without distortion. Enclosure design shall be such that adequate clearance is available for servicing or removing all panel-mounted devices without interruption of service to adjacent devices. The enclosure shall be complete with hinged doors. The doors shall be fully gasketed. Enclosures shall be equipped with three-point latches and lockable handles. Enclosures shall be mounted on a removable base. Adequate lifting lugs shall be furnished with each enclosure. Enclosure shall be fabricated using the following sheet steel (minimum): doors - 11 GA. rear wall-16 GA. mounting panel - 11 GA NEMA 4X rated enclosures shall be 316SS.
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All cutouts shall be punched or hand-cut. Cutout dimensions shall be verified. Any dimensional variations resulting in changes in panel layout shall be reported for resolution before proceeding with fabrication. The front of the panel shall be stiffened, if necessary, and supports shall be provided for heavy components, to insure that no warping or distortion results from the cutting operation or from the load imposed by the instruments. Any stiffeners, supports, etc., must not interfere with access to instruments. All enclosure surfaces shall be clean and free from scratches, dents, excess of welding material and other defects. Interior and exterior of the enclosure shall be painted beige. All enclosure surfaces shall be prepared for painting by cleaning and phosphating, rinsing and re-rinsing with desalinated water. Manufacturers recommended primer shall be applied to all surfaces. Final coat of paint shall be an acrylic-urethane enamel. Enclosures shall be checked for correct overall dimensions, cutout dimensions and location.
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3.3 Programmable Logic Controllers The programmable logic controller (PLC) shall be located in the system control panel enclosure. The PLC shall be configured in the single slot addressing mode. All PLC inputs including spares shall be wired to terminal blocks. All programmable controller outputs including spares shall be wired to fused terminal blocks. The processor and rack power supplies, input modules and output modules shall be supplied with 120 VAC through separate fuses.
Figure 2-15: PLC Rack The PLC shall be selected from the Allen-Bradley PLC 5 Series of logic controllers, unless otherwise noted. Discrete I/O modules shall be 16 point - 1771-IAD and 1771-OAD (120 VAC) or 1771-IBD and 1771-OBD (24 VDC), or equal. Power supplies shall be - 1771 -P7 or 1771 -PS4, or equal.
29 Royal Road, Guelph, Ontario, Canada N1H 1G2 Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com
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If communication to an Operator Interface Terminal or the purchasers DCS is required, a 1770-KF2, or equal, Communications interface module shall be used. Analog I/O modules shall be-1771-IFE (4-20 mA DC) and 1771 - OFE2 (4-20 mA DC), or equal, configured for single-ended mode. Isolated discrete output modules shall be 1771-OD, (120 VAC, triac), or equal. Isolated discrete input modules shall be 1771-1D16 (120 VAC), or equal. 3.4 Control Panel Assembly 3.4.1 General All equipment shall be installed in accordance with the control panel and schematic drawings. All wiring shall be run in plastic wiring ducts. Wiring ducts and wiring shall be run in horizontal or vertical planes only. AC signals shall be routed separately from DC and analog signals. Wiring duct must not interfere with access for calibration, maintenance or removal of any device. All wires for each device shall be bundled together. The bundle shall be long enough to allow for removing of the device without cutting wires to adjacent instruments. Wires from wiring ducts, terminal blocks or bundles to devices shall be neatly formed and secured to the panel. Bends shall be carefully made to avoid insulation damage. Each enclosure section shall contain an internal fluorescent light. A light switch and 120 VAC convenience outlet shall be provided in the panel. If required, a fan complete with screen and filter or louvres, or an air conditioner, shall be provided to maintain the required environmental conditions inside the control panel. All instruments that require 120 VAC power shall be individually fused to allow for instrument Isolation. Instrument cable shields and DC signal common conductors shall be connected to a separate copper ground bus, electrically isolated from the control panel structure (DC GROUND BUS). All analog shields shall be connected to ground at one point only. A copper ground bus to effectively ground the entire structure shall be provided. (AC GROUND BUS)
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3.4.2 Wiring 120 VAC and 24 VDC control wire shall be moisture and heat resistant PVC or XLPE insulated, multi-strand copper conductors, 90C minimum, 600 V, 16 AWG minimum. Low-level DC analog signal cables shall be PVC or Hypalon-insulated shielded pair, 18 AWG minimum. The following wire sizes for low voltage wiring shall be used: 120 VAC control signals - 16 AWG minimum. 120 VAC power - 16 AWG minimum. neutral - 16 AWG minimum. AC ground - 16 AWG minimum. foreign voltage - 16 AWG minimum. 24 VDC-16 AWG minimum. 0 VDC - 16 AWG minimum. DC ground-16 AWG minimum. analog signals - 18 AWG minimum, shielded pair.
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Low voltage wiring shall be color coded as follows: 3.4.3 120 VAC control signals 120 VAC power neutral AC ground foreign voltage 24 VDC 0 VDC DC ground 4 to 20 mA (+) 4 to 20 mA (-) drain red. black. white. green. yellow. blue. blue with white stripe. green with white stripe. black. white. bare.
Terminal Blocks Terminal blocks shall be compression type, capable of accepting a minimum of two 12 AWG wires and rated no less than 20 A. Terminal blocks shall be grouped according to function and voltage level. As a minimum, twenty percent spare terminals shall be provided. Terminal blocks shall be grouped as shown on the drawings. Jumpering of live voltages using non-insulated comb type jumpers will not be accepted isolated comb jumpers, wire jumpers or jumper bars shall be used. Terminal blocks shall be installed flush with the wiring duct. Terminal blocks shall be installed a minimum of six inches above the panel floor, and flush with the wiring duct front face. Not less than two inches shall be provided between terminal blocks and wiring duct or equipment for ease in wiring and wire number legibility. Terminal block groups shall be permanently identified with an engraved lamacoid nameplate as specified on the Control Panel drawings. Field side of terminal block shall be free of wiring. An empty run of wiring duct shall be provided for field wiring.
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All wires going to external devices shall be terminated at terminal blocks. No more than two wires shall be connected to one terminal. Each wire shall be a continuous run; splices will not be permitted. 3.4.4 Identification Each wire shall be identified at both ends with a wire number as indicated on the drawings. Each DC shielded cable shall be identified at both ends with a cable number. Individual wires need not be tagged but proper color coding shall be observed. All tags shall be as indicated on the drawings. Wire markers shall be fire-retardant, heat shrink type. Each component of the control panel shall be permanently identified with an engraved lamacoid nameplate. Nameplates shall be white with black lettering, engraved as per the drawings. Terminal blocks shall be marked with consecutive numbers as shown in the control panel drawings. Wire numbers will not be used for identifying terminal blocks. Each group of terminal blocks shall be clearly identified with a nameplate as identified on the drawings. 3.4.5 Testing All tags and nameplates shall be checked for correct color, size, letter size, spelling and location. Continuity and point-to-point tests of all wiring shall be performed. High voltage test shall be performed according to the requirements of NEC or CEC standards. Prior to applying high voltage all delicate electronic instruments shall be disconnected.
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3.5 Operator Interface Terminal (OIT)
Figure 2-16: OIT Enclosure With PC
The OIT shall be a PC compatible workstation running Windows NT as a minimum. The PC shall meet or exceed the following requirements: 166 MHz processor, 512 Kilobyte Cache memory, 500 Megabyte hard drive, 32 Megabyte RAM memory, 16X CD-ROM, 104 key keyboard and 3 button mouse. The color monitor shall be 15-inch diagonal, SVGA capable with 0.28-mm dot pitch maximum. The OIT shall be located in a freestanding, NEMA 4 enclosure, separate from the control panel.
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Technical Bulletin 6.02, Rev. 0 December 1998 4.0 Installation
4.1 Scope The purpose of this specification is to establish the minimum requirements and standards for installation methods, materials, wire, related hardware, and solenoid and junction boxes. 4.2 Enclosures All enclosures shall conform to the relevant requirements of EEMAC or NEMA standards, for the specified rating. Solenoid boxes and junction boxes shall be rated NEMA 4 and constructed of either painted carbon steel, fiberglass-reinforced plastic or stainless steel. In all cases hinges shall be either 316SS or non-metallic. Conduit entrances into the solenoid boxes and junction boxes shall be from the side or bottom only. Junction boxes for field wiring terminations shall be installed not higher than four feet above the equipment level. 4.3 Electrical Equipment 4.3.1 General All equipment shall be installed in accordance with the certified drawings. Any changes or conflicts shall be submitted for resolution and approval. A single source of instrument air shall be provided for each solenoid box, complete with filter/regulator, pressure gauge, drain and plug. 4.3.2 Wiring Wire for 120 VAC and 24 VDC signals shall be moisture and heat resistant PVC or XLPE insulated, multi-strand copper conductors, 90C minimum, 600 V, 16 AWG minimum. Low-level DC analog signal cables shall be PVC or Hypalon insulatedshielded pair, 18 AWG minimum.
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The following wire sizes for low voltage wiring shall be used: 120 VAC control signals - 16 AWG minimum. 120 VAC power - 16 AWG minimum. neutral - 16 AWG minimum. AC ground-16 AWG minimum. foreign voltage - 16 AWG minimum. 24 VDC - 16 AWG minimum. 0 VDC - 16 AWG minimum. DC ground-16 AWG minimum. analog signals - 18 AWG minimum, shielded pair.
Low voltage wiring shall be color coded as follows: 120 VAC control signals red. 120 VAC power neutral AC ground foreign voltage 24 VDC 0 VDC DC ground 4 to 20mA (+) 4 to 20 mA (-) drain black. white. green. yellow. blue. blue with white stripe. green with white stripe. black. white. bare.
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4.3.3 Terminal Blocks Terminal blocks shall be compression type, capable of accepting a minimum of two 12 AWG wires and rated no less than 20 A. Terminal blocks shall be grouped as shown on the drawings. Jumpering of live voltages using non-insulated comb type jumpers will not be accepted. Isolated comb jumpers, wire jumpers or jumper bars shall be used. Terminal blocks shall be installed flush with the wiring duct. Not less than two inches shall be provided between terminal blocks and wiring duct or equipment for ease in wiring and wire number legibility. Terminal block groups shall be permanently identified with a nameplate as specified on the electrical drawings. Terminal blocks for solenoids and other 120 VAC field devices such as limit switches, temperature switches etc., shall be provided in the solenoid box. Terminal blocks for terminating analog cable shields shall be provided in DC junction boxes. Each shield shall be connected to ground at one point only. One side of terminal blocks and an empty run of wiring duct shall be provided for field wiring. All wires going to external devices shall be terminated at terminal blocks. No more than two wires shall be connected to one terminal. Each wire shall be a continuous run; splices will not be permitted. 4.3.4 Identification Each wire shall be identified at both ends with wire numbers as indicated on the drawings. Each DC shielded cable shall be identified at both ends with cable numbers; individual wires need not to be tagged but proper color coding shall be observed. All tags shall be as indicated on the drawings. Wire markers shall be fire-retardant heat shrink type. Each component of the control system shall be permanently identified with a nameplate. Terminal blocks shall be marked with consecutive numbers as shown on the drawings. Wire numbers shall not be used for identifying terminal blocks. Each group of terminal blocks shall be clearly identified with a nameplate as identified on the drawing.
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4.3.5 Rigid Conduit It is recommended that all conduit be schedule 40 PVC. However, rigid hotdipped galvanized steel conduit may be selected as an option. The galvanized conduit shall have heavy walls and uniform wall thickness to permit the cutting of clean true threads. The option for galvanized conduit may be used except for chemical skids where rigid PVC conduit shall be used. Galvanized conduit exterior surfaces shall be thoroughly and evenly coated with metallic zinc applied directly to the surface of the metal. Interior surfaces of the steel conduit shall be protected by zinc or other corrosion resistant coating. Minimum conduit size shall be 3/4" trade size. Each length shall be threaded at each end and a coupling shall be supplied for one end. All clamps, channel supports, nuts, bolts and miscellaneous hardware shall be corrosion resistant electroplated galvanized steel or malleable iron. Cut ends or mounting channel shall have a field-applied galvanized coating. Conduit runs shall present a neat mechanical appearance and shall be run along the bottom and inside perimeter of skids, parallel or perpendicular to equipment structural members. Supports shall not interfere with installation or maintenance of other equipment. Allow minimum of 12" clearance at heat sources. Conduit ends shall be cut square, reamed smooth and free of spurs that may damage cables when pulled. Conduit shall be supported every 29 inches for PVC or five feet for galvanized as a minimum. Supports shall be spaced adequately to support loads imposed on the conduit. Junction boxes shall be supported independently of the conduit and easily accessible. When rigid conduit is specified, liquid-tight flexible conduit shall be used for final connections to equipment that requires periodic removal. The maximum length shall be approximately 30".
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4.3.6 Flexible Conduit Flexible PMA conduit shall be used when flexible conduit is specified. The conduit and fittings shall be capable of withstanding temperatures from -40F to 180F. Note that this conduit is not suitable for use on equipment handling strong acids or alkalies. 4.3.7 Fittings Fittings for PVC and rigid galvanized steel conduit shall be of the same grade of material, technology and manufacturer as the straight conduit. Connectors for liquid-tight flexible conduit shall insure a liquid-tight seal. Pull boxes and junction boxes shall be NEMA 4 or NEMA 4X rated, PVC or galvanized pressed steel. Conduit bodies shall be PVC or cast malleable iron or Ferraloy with cadmium-coated steel covers complete with corrosion resistant screws and waterproof gaskets. 4.3.8 Immersion Heaters Immersion heaters shall be totally insulated, flange-mount style. The heater shall be moisture and corrosion resistant. The heater shall operate using 120 VAC, 60 Hz, 1 phase or 480 VAC, 60 Hz, 3 phase or 575 VAC, 60Hz, 3 phase power. High limit cut-off thermostat, integral to the heater shall be provided. 4.4 Grounding Grounding shall be installed as per the drawings and in accordance with National Electrical Code and any other applicable codes and ordinances. Grounding conductors shall be continuous lengths between ground points. Splices or joints will not be permitted.
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4.5 Air Tubing
Figure 2-17: Air Tubing
Air tubing shall be minimum diameter of 1/4". Air tubing shall be installed parallel to piping and close to support structures where practical. Each run of tube shall be continuously supported and held in place with the appropriate tubing clips and fasteners. Tubing supports shall be installed in a manner to preclude failure due to vibration. Each solenoid box shall be completely tubed and wired to all skid devices that are connected through the box. Solenoid cabinet shall be mounted on a rack at the equipment where the solenoids are tubed. Branch air supply piping from the air header shall be 1/2" schedule 40, carbon steel pipe conforming to class C, or 1/4" OD tubing. All branch takeoffs shall be from the top of the air header. Line size blowdown valves shall be provided for each air header run of different elevation.
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TM

4.6 Instrument Installation Guidelines 4.6.1 Impulse Piping Instrument impulse piping shall be installed parallel to process piping, except for slope where required. Instrumentation manufacturer instructions shall be followed. All horizontal runs have a slope of 1 per ft and shall be towards an instrument for liquid and steam service, and from an instrument for gas service. Continuous supports, tubing clips and fasteners shall be used. 4.6.2 Instrument Installation Silica and sodium analyzers shall be located by the customer in a laboratory room. All instruments shall be rigidly supported, leveled, protected from damage, excessive heat, vibration and shock. If a vibration-free location is not available, appropriate rubber grommets or other vibration dampers designed for vibration absorption shall be provided. Instruments shall not interfere with other equipment, piping and electrical installations. Pipe mounting studs or instrument manufacturer supplied brackets shall be used wherever possible. Brackets shall be welded to the racks. Instruments shall not be mounted to removable panels. All instruments shall be accessible from grade, operator aisles or platforms. Differential pressure flow transmitters, flow switches and flow indicators for liquid and steam service shall be located below appropriate taps. Differential pressure transmitters shall be connected to process through three-valve manifolds. All manifolds shall be adequately supported.
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CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Controls & Instrumentation

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Figure 2-3: Temperature Transmitter

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Figure 2-4: Conductivity Analyzer/Transmitter

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Figure 2-5: pH Analyzer/Transmitter

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

2.4.10 Turbidity Analyzers

Figure 2-8: Turbidity Analyzer

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

Figure 2-9: Magnetic Flowmeter

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS

29 Royal Road, Guelph, Ontario, Canada N1H 1G2

Telephone:(519) 836-0500, Fax:(519) 837-3067, Website www.glegg.com

CONTROLS & INSTRUMENTATION Water Conditioning GRD2000 TECHNICAL SPECIFICATIONS