City of Portland

Bureau of Environmental Services

Wastewater Group
Control system philosophy, operation, design, and software standards

PREFACE

The purpose of this document is to provide information regarding control system design,
operation, and software standards developed for the Wastewater Group (WG).

Consultants, contractors, BES Engineering, maintenance and operations should

consult this document for any proposed control system changes.

· Benefits to the WG of a standard control system philosophy include:

v Uniform operator interfaces at wastewater facilities

v Standard control system software routines for software maintenance

v Standard control system hardware devices for operator interface,

troubleshooting, and maintenance

v Consistent design approaches on future WG projects

The standards in this document must be followed on any project for the WG. Any
deviation from these standards must be approved by the WG's Automation Planning
Team (APT) before being implemented in the design. In many instances typical details or
generalizations have been developed to illustrate a concept. The intent of these typical
details is to provide system definition while allowing flexibility for implementation of the
details. Each unit process, with its associated control strategies, may have unique
requirements that require deviation from the standards. However, the design should still
conform to the overall control system philosophy described in this document.

This document was developed following review meetings with the WG's staff:
Operations, Maintenance, Engineering, and Management. The workshops addressed the
following topics:

· Control philosophy
· Supervisory system (IFIX)1 requirements
· Hardware and wiring design standards
· PLC and IFIX application software standards

The discussions addressed past and present approaches used by the WG at their
facilities. Though some of these approaches differed significantly from one another,
consensus was reached with respect to future practices.

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Volume 1

Chapter 1 establishes the basic control system philosophy. The entire control system is
classified by five levels of control. These levels are defined according to the function
from an operations and maintenance standpoint of the different components of a control
loop and their configuration. Automatic control is normally accomplished using a PLC.
If control is accomplished using a single loop system or any means other than a PLC,
Automated Planning Team (APT) approval must be obtained prior to design.

Chapter 2 describes the design approaches that are to be used on WG projects. The
deliverables during and at the end of each design phase, preliminary design, and final
design are defined. Design criteria are specified for wiring design, interface with MCC’s
and package systems, control panel design, and so on.
Appendix A example of an Instrumentation & Control Process Narrative
Appendix B example of an Instrumentation Data Sheet
Appendix C Training Guidelines
Appendix D Deliverable Matrix
Appendix E Revision Proposal Submittal Form
Drawing Figures Drawings referenced throughout this Manual.

Volume 2

Section 16010 covers general electrical standards that are applicable for all
electrical and instrument design, construction and installation for the City of
Portland, Bureau of Environmental Services, Wastewater Group, including the
Columbia Blvd. Wastewater Treatment Plant, Tryon Creek Wastewater Treatment
Plant and the Wastewater Pump Stations maintained by the Group.
Section 16050 covers Basic Electrical Materials and Methods
Section 16150 refers to Motors
Section 16400 refers to Service and Distribution
Section 16480 refers to Motor Control
Section 16500 refers to Lighting
Section 16660 refers to Power Generation
Section 16700 refers to Communications
Section 16910 refers to Controls
Section 17100 refers to Instrumentation

Volume 3 contains the Scada (Supervisory Control and Data Acquisition) IFIX software
design standards.

Volume 4 contains Drawings and drawing numbering standards. (Future)

Volume 5 contains O&M Manual Development Guide. (Future)

Volume 6 contains PLC Programming Guide

Volume 7 contains the Facilities Guide (Future)

Volume 8 contains the Wastewater Pump Station Design Manual. (Future)

2003 Volume 1 Page ii of 14
Volume 9 contains the Maintenance standards (Future)

Several appendixes are included that contain example documents. They are referenced in
specific subsections.

This manual will be updated as the WG's practices evolve. Revisions to this document
must be submitted to and approved by WG's Automation Planning Team (APT). Minor
changes are accomplished by addendum rather than revisions. All revisions and minor
changes will be made to the Online Document, annually.
(APPENDIX E, Revision submittal form)

2003 Volume 1 Page iii of 14

 TABLE OF CONTENTS

Volume 1 Acronyms and Definitions ……………………………………………….1

Chapter 1 CONTROL SYSTEM PHILOSOPHY.……………………. .........2
1.1 Introduction……..............................................................................................2
1.2 Levels of Control .............................................................................................2
Table 1-1 Levels of Control Primary Functions…………………………..3
1.2.1 Equipment Control Level……...........................................................4
1.2.2 Local Control Level….. .....................................................................4
1.2.3 Programmable Logic Control (PLC)……….….................................4
1.2.4 System Process Control……… .........................................................4
1.2.5 Plant Control Level…… ....................................................................5
1.3 Operating Philosophy…...................................................................................5
1.3.1 System Process Control Failure……… .............................................6
1.3.2 Programmable Logic Control (PLC) Failure………… .....................6
1.3.3 Local Control Panels....………………..............................................6
1.3.3.1 Loop Control…...................................................................6
1.3.3.2 Sequence Control…… ........................................................7
Chapter 2 CONTROL SYSTEM DESIGN GUIDELINES…………… ........8
2.1 Design Phase…………………………….........................................................8
2.1.1 Introduction……....................................................................... ........8
2.1.2 Documentation………................................................... ........... ........8
2.1.2.1 Process and Instrumentation Diagrams (P&ID’s)…..........9
2.1.2.2 Digital System Block Diagram…….. ........... ........... ........9
2.1.2.3 Process Narratives…..................................... ........... ........9
2.1.2.4 Electrical Drawings…………....................... ........... ......10
2.1.2.5 Control Panel Design……… ........................ ........... ......10
2.1.2.6 Installation Details………… ........................ ........... ......11
2.1.2.7 Interconnection Diagrams and Listings………………....12
2.1.2.8 Digital System Block Diagrams……............ ........... ......12
2.1.2.9 Functional Descriptions…….. ...................... ........... ......12
2.1.2.10 Instrument Data Sheets…...…. ..................... ………….12
2.1.2.11 I/O Data Base ................................................ ........... ......12
2.1.2.12 Instrument Lists……..................................... ........... ......12
2.1.2.13 Conduit and Cable Schedules……… ........... ........... ......13
2.1.2.14 Equipment / Loop Numbers and MCC Space........... ......13
2.1.2.15 Elect. System Load Calc. & Coordination Study……….13
2.1.2.16 Specifications................................................ ........... ......14
TABLES
2-1 External Alarm Lighting Standards
2-2 Acceptable Manufacturers
2-3 ISA Identification Letters
2-4 Typical Interconnection Listing
2-5 Conduit and Cable Schedule

APPENDIX A
Instrumentation & Control Process Narrative
APPENDIX B
Example of Instrumentation Data Sheet

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APPENDIX C
Training Guidelines
APPENDIX D
Deliverable Matrix
APPENDIX E
Revision Proposal submittal form

AutoCAD Figures
1-1 Schematic--Levels of Control
1-2 Schematic--Levels of Control
2-1 P&ID Legend
2-2 P&ID Process Symbols
2-3 P&ID example (Level Instrumentation & Pump Control)
2-4 PLC System Block Diagram
2-5 I/O Point List
2-6 Wire Number & Device Number
2-7 Typical Power Source
2-7A Power Source
2-8 Typical Power Source Wiring Diagram
2-9 Cables, Instr.and Control (Typical Interconnecting Wiring Diagram)
2-10 Control Panel Enclosure Layout
2-11 Control Panel Power Distribution
2-12 Conduit Numbering System
2-13 See Table 2-4
2-14 Detailed Discrete Outputs Wiring Schematic
2-15 Detailed Discrete Inputs Wiring Schematic
2-16 See Table 2-5
2-17A Pump Station Motor Current Loop 9997
2-17B Removed
2-17C Pretend Dry Pit Exhaust Fan Flow Loop 9996
2-17D Pretend Level Loop 9999
2-17E Pretend Flow Loop 9998
2-18 Pressure Gauge Mounting Detail
2-19 Typical FVC & VFD Motor Control Electrical Schematic
2-20 24VDC Power Distribution Wiring Schematic
2-21 Instrument Field Device Installation

Volume 2

Section 16010 General Electrical Standards …………………...………….1 – 17

Example: Equipment Tag(s)......………………………………...….18 - 20

Section 16050 Basic Electrical Materials and Methods…………..………..1 – 23

Section 16150 Motors………………………………………………………1 – 6

Example: Motor Specification data sheet ……………………….………7

Section 16400 Service and Distribution ……………………….……….…..1 – 5

Section 16480 Motor Control ……………………………………….….….1 – 14

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 Section 16500 Lighting…………………………………………………..….1 – 5

Section 16660 Standby Emergency Power Generation… ………………..….1 - 9

Section 16700 Communications **New 2003**………………………....1 – 15

Section 16910 Electrical Systems Control…………………………….…..1 – 12

Section 17100 Instrumentation……………………………………….……1 – 17

Volume 3 SCADA (iFIX) Software and Design Standards

1.0 Scope…………………………………………………………………………2
1.1 The Automation Planning Team……………………………………...2
1.2 iFIX Philosophy…………...…………………………………………2
2.0 General iFIX Information………….…………………………………………3
2.1 General Standards…………………………………………………….3
2.2 The Operational Area Designation…….……………………………..3
3.0 Database Builder………………………….…………………………………..3
3.10 Tag Names………..…………………………………………………3
3.11 Description………………………………………………………….4
3.12 Scan Time…………………………………………………………...4
3.13 Database Types Used………………………………………………..4
3.14 Alarming…………………………………………………………….4
3.15 Security Areas……………………………………………………….4
3.16 Labels………………………………………………………………..4
3.17 Invert Output………………………………………………………...5
4.0 Tag Group Editor……………………………………………………………..5
5.0 Picture Conventions…………………………………………………………..5
5.1 Resolution………….…………………………………………………5
5.2 Buttons………………………………………………………………..5
5.3 Color Usage…………………………………………………………..5
5.4 Required on Every Picture……………………………………………6
5.5 Text Fonts…………………………………………………………….6
5.6 Graphic Images In Pictures…………………………………………...6
5.7 Alarm Summaries…………………………………………………….6
5.8 Help Screens………………………………………………………….7

Volume 4 Drawings and drawing number standards (Future)

Volume 5 O&M Manual development guide (Future)

Volume 6 PLC Programming Guide

1.0 Scope……………………………………....………………………………….1
2.0 General Information…………………………………………………………..1
3.0 PLC Acceptance………………………………………………………………2

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 4.0 Program Changes……………………………………………………………..2
5.0 Security……………………………………………………………………….3
6.0 Programming Guidelines for Symate Plus……………………………………4
6.1 Subroutines…………………………………………………………...4
6.2 Labels…………………………………………………………………5
7.0 Programming Guidelines for Concept………………………………………..6
7.1 Introduction…………………………………………………....……...6
7.2 Details………………………………………………………………...6
7.3 Configuration…………………………………………………………7
7.4 Program and Sections……………………………………………….10
7.5 Systems Sections……………………………………………………12
7.6 Process Sections…………………………………………….…...….14
7.7 Miscellaneous……………………………………………………….16
7.8 Variable Naming Usage and Naming Convention………………….16
7.9 PLC Programming Considerations for Use with iFIX……………...17
7.9.1 Labels Used in PLC Programming……..…………....…..17
8.0 DFB Examples………………………………………………………...……19

Volume 7 Facilities guide (Future)

Volume 8 Wastewater pump station design manual (Future)

Volume 9 Mechanical Standards (Future)

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 ACRONYMS / DEFINITIONS

APT Automation Planning Team

COMA Computerized Maintenance System
CMU1 Concrete Masonary Unit
DRAWINGS AutoCad files and hard copy(s)
HOA Hand-off-auto
HOR Hand-off-remote
I/O Input / Output
IFIX2 Supervisory control system software
ISA Instrument Society of America
LCP Local control panel
MCC Motor control center
NEC National Electric Code
NEMA National Electrical Manufacturer’s Association
OCA Open-close-auto
P & ID Piping and instrumentation diagram
PC Personal computer
PID Proportional-integral-derivative
PLC Programmable Logic Controller
PMC Plant Monitoring and Control
RTU Remote terminal unit
SCADA3 Supervisory Control and Data Acquisition
SCADA NODE Operator interface that directly acquires field data
(PLC)
SPC System process control
SS Start- stop
TJB Terminal junction box
UL Underwriters Laboratory
UPS Un-interruptible power supply
VAC Volts AC
VDC Volts DC
VFD Variable frequency drive
VIEW NODE Operator interface that acquires field data through
SCADA nodes
WG Wastewater Group

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 CHAPTER 1

CONTROL SYSTEM PHILOSOPHY

1.1 INTRODUCTION

This chapter discusses the control system philosophy adopted by the WG for the operation of
its treatment plants and pump stations. Designers shall follow this document when designing
a control system.

A primary function of this chapter is to establish basic definitions of some of the terms. For
example: Section 1.2 of this chapter defines different levels of control and their
corresponding functions. A level refers to a function from an Operation and/or Maintenance
standpoint. Five levels of items are defined based on whether the function of the device is for
maintenance, manual, automatic, or supervisory control of several unit processes.

Section 1.3 provides more detail about Operation philosophy under different failure modes, as
well as discussion of Backup Operator Interface devices.

The control system at Wastewater Group (WG) facilities is distributed. Modicon2

programmable logic controllers (PLC’s) serve as the distributed processors and an IFIX
supervisory system serves as the Operator Interface. Control panels are provided for manual
backup purposes. At Columbia Boulevard and Tryon treatment plants, Modicon PLC's shall
be used to allow networking with their Ethernet ports. Stand-alone PLC's may be Modicon,
PLC's without Ethernet ports.

The Wastewater Group Process Control Software Standards are as follows (2003)3:

Ø Intellution IFIX is used for process control

Ø SQD’s Powermonitor SMS 3000 software
Ø Milltronics DolphinPlus, Rev. 1.33 or higher
Ø Vibration Monitoring - Vibrameter (SKF) software
Ø HVAC – Security, LifeSafety – Lonworks software or compatible

Due to the cost of software upkeep and training costs, all proposed equipment must be
compatible with the above mentioned software or it is not approved for installation.

1.2 LEVELS OF CONTROL

As a general operations philosophy, all plants will have five different functional levels of
control (shown schematically in Figures 1-1 and 1-2):
· Equipment control
· Local control
· Programmable Logic Controller (PLC) control
· System Process control
· Plant Monitoring/Control

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 Defining these levels of control helps communicate WG's operation philosophy, which is
broken down into five subtopics. Each of these subtopics is discussed separately with a
statement of its purpose, WG's needs and requirements, as well as some guidelines to meet
these requirements. This classification tries to group the components of a Loop by their
function. This should help designers in deciding whether a component is necessary, and, if so,
how the Loop shall be configured. Table 1-1 provides a summary of these classifications.

Table 1-1

Levels of Control Primary Functions

Level of Primary Function Remarks
Control
Plant The Plant supervisory system will normally IFIX is the standard. System Process
Monitoring/ serve as the supervisory Operator Interface Control is used to initiate and
Control for the entire plant. However, it may monitor control actions. Control
perform System Process Control (SPC). logic is executed in the PLC with
interface to/from IFIX.
System Primary Operator Interface provides a IFIX IFIX is the standard. System Process
Process window into the process for monitoring Controls are used to initiate and
Control and control monitor control actions. Control
logic is executed in PLC with
interface to/from IFIX.
PLC Automatic Control Provides normal automatic system
control
Local Manual or automatic centralized control of Provides backup in case of
equipment. supervisory system failure and/or
PLC failure. Local control panels
contain backup Operator Interface
devices like hand switches, lights,
level control, PID's. etc.
Equipment Maintenance and troubleshooting Not intended for normal operation of
equipment.
VFD’s, speed pots4 etc.

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1.2.1 EQUIPMENT CONTROL LEVEL

Equipment controls located at the equipment are meant for maintenance and troubleshooting
only. This level is not meant for normal day-to-day operation of the equipment. Control at
this level shall bypass all interlocks except those required for equipment or personnel safety.

Examples of equipment control include: local disconnects, jog switches, start/stop switches
and speed adjustment on variable frequency drives (VFD’s). These devices are located near
the equipment being controlled.

1.2.2 LOCAL CONTROL LEVEL

This level of control provides automatic and manual control of processes. It also provides
manual control under different failure modes, such as System Process Control (SPC) failure or
programmable logic controller (PLC) failure. It is important to note that the word ‘local’
refers to function, not physical location. Thus, when several different pieces of equipment are
controlled so that together they achieve an overall control strategy for one or more unit
processes, they are said to be local - even if equipment is located relatively far apart. Local
Control may be accomplished from one panel or adjacent panels as long as manual operation
is carried out from one location.

This level of control usually includes local control panels (LCP’s). These panels provide
Operator Interface devices that allow manual control of a unit process, or automatic control
through the PLC. LCP’S generally have auto/manual hand switches and/or Local/Remote
switches. In Remote/Automatic position, control of the process or equipment is transferred to
the supervisory system.

1.2.3 PLC SYSTEM CONTROL

PLC’s normally control the system automatic process.

1.2.4 SYSTEM PROCESS CONTROL

Several System Process Controls (SPC's) are located throughout the plant. A single SPC may
monitor and control several unit processes. These unit processes usually have related
functions. For example, one SPC may monitor and control the Headworks and primary
treatment. Another SPC may control secondary treatment, and yet another, solids handling.

The SPC’s are personal computer (PC) - based workstations loaded with IFIX software. All
of the SPC’s will be tied to a single, plant wide Ethernet (see Figure 1-1 & 1-2). All the
displays, the necessary logic for communication and other supervisory system functions, are
stored on PC, SCADA nodes. The SPC'S will be used to initiate and monitor control actions,
but all process control logic will be implemented through the PLC. NO continuous, real time
control will be done from IFIX.
Current system process control areas are:

Preliminary Treatment--pumping, screening, grit removal

Primary Treatment--settling, skimming, sludge pumping

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 Activated Sludge--pumping, aeration, clarifiers, split flow

Digestion--heating, mixing, feed thickening, flow pacing, gas storage, gas

transmission

Sludge Processing--thickening, de-watering, sludge hoppers

Composter--sludge stabilization, carbon storage and recycle

Disinfection--storage, dosage control

Effluent pumping--effluent pumps, outfall control

Water Reuse--pumping screening, disinfection

Maintenance--Electric power distribution, instrument air

Wet Weather Treatment--pumping, screening, grit removal settling, effluent

pumping, disinfection

Pump Stations—Wastewater Group (WG) has 100 + pump stations throughout the
metropolitan area.

1.2.5 PLANT CONTROL LEVEL

The Plant supervisory system will normally serve as the Supervisory Operator Interface for the
entire plant. However, it may perform System Process Control (SPC). WG has selected IFIX
as the standard for the supervisory system at the Plant Control Level and System Process
Control Level.
The IFIX system shall have color displays that provide process and equipment status
information, facility-wide control, alarm annunciation, historical trending, and access security.
Requirements of the IFIX software are discussed in greater detail in Volume 3.

1.3 OPERATING PHILOSOPHY

Local control is activated when SPC and PMC (Plant Monitoring and Control) are not
available. All control logic will be implemented at the local control level. Under normal
operation, the PLC will be used to implement all control actions. Exceptions to this rule
include equipment that requires local manual start/stop and situations that warrant the use of
single loop controllers.

When in local control, PLC and PID loop controllers will only make changes to the process
from data derived from their own inputs. Meaning that, data retrieved from any
communications port is not used in a control program. In cases where this is not practical,
Automation Planning Team (APT) approval is required.

In addition to automatic control, this level of control provides backup operator interface
devices that allow the operator to "see" the process, should an SPC system fail.
Panel-mounted switches, lights, and indicators allow the plant to be run manually in the event
of a PLC failure. Any failure, SPC or PLC, is assumed to be temporary.

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The Local Control Panel (LCP) will have annunciators and status lights mounted on it.
Critical alarms shall be hardwired, with other alarms PLC-driven or hardwired, as necessary.
Examples of critical alarms are: high digester gas pressure, lower explosion limit detection,
and chlorine leak(s).

1.3.1 SYSTEM PROCESS CONTROL FAILURE

In the event of an operator interface failure at the SPC level, control will be possible at the
plant control level operator interface or the LCP.

1.3.2 PROGRAMMABLE LOGIC CONTROLLER FAILURE

As a backup against PLC failure, LCP’S will be provided. These LCP’S will have
open-close-auto (OCA), hand-off-auto (HOA) switches, status lights, and possible PID
controllers as needed to allow manual operation of the plant or pump station in the event of a
PLC failure.

All switches, lights, and other devices required for manual operation of a process will be
located on one panel, or adjacent panels, so that manual operation can be carried out from one
location. For example, all the valve controls, status lights, sequence indicators, and other
devices required for manually operating the Effluent Pumps will be located on the same panel.

1.3.3 LOCAL CONTROL PANELS

The LCP’S shall have devices mounted on them that allow operation of the Process if the
supervisory system or PLC fails. The LCP’S shall have devices that, under normal operation,
facilitate loop control, sequence control, or any other control necessary to operate one or more
unit processes. Shown below are examples of two different types of loop and sequence
control with associated panel mounted devices.

1.3.3.1 Loop Control

Loop control refers to a case where an analog variable needs to be maintained at a given set
point. This is achieved by using a (PID) control algorithm. A PID controller will have an
analog input (the process variable), an analog output (the manipulated variable), and a set
point. The set point may be either operator entered, or the output of another PID loop
(Cascade Control).

In the case of critical loops, which need to remain operational even if the PLC fails,
stand-alone loop controllers shall be used. These loop controllers may also be used for non-
critical loops. These loop controllers shall be mounted on the LCP and shall have a digital link
to the PLC so that set points and tuning parameters can be communicated to and from the
PLC. Process variable and loop output information will be communicated to the PLC. The
PLC will also be able to monitor and change the mode of operation (e.g., manual or
automatic) of the loop controllers. The loop controllers will be programmable so that default
settings can be chosen in the event of a PLC failure. Chlorination is an example of critical
loops.

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1.3.3.2 Sequence Control

Sequence control involves a number of consecutive steps that must be followed to perform a
given operation. Examples include the belt sequences. All logic sequencing functions will be
programmed in the PLC. All devices necessary to manually operate the sequences will be
mounted on the LCP in a logical sequencing order.

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 Chapter 2

CONTROL SYSTEM DESIGN GUIDELINES

This chapter provides guidelines for design phases and the deliverable’s that the WG
expects at the end of each phase. Outline all5 deviations from these standards for approval by
the APT.

2.1 DESIGN PHASE

2.1.1 INTRODUCTION

The design phase involves a conceptual design of the control system. This phase considers
technical process requirements, as well as operations and maintenance issues. All design
effort will employ Volume 2, Electrical and Instrumentation Construction Standards. The
design referred to in this section is distinct from similar phases of the "IFIX and PLC
programming" effort. "PLC Program Design" commences at, or near, the completion of the
process and hardware design. Refer to Volumes 3 and 6 for IFIX and PLC programming
design guidelines.

The BES CONTROL SYSTEMS STANDARDS DELIVERABLES MATRIX outlines

the “what and when” of deliverables. (Appendix D)

The WG prefers to have the designer do most, if not all, of the detailed engineering.

In a control system detailed design, the designer is responsible for providing most of the
design specifications and drawings required to construct the project.

NOTE: The Wastewater Group (WG) Engineering Department will supply the Maintenance
Planners with existing drawings of facilities to be re-modeled. This will allow the Planners to
update the equipment numbers to the current standards. After the equipment numbers have
been updated, the Planners will return the drawings to Engineering for distribution.

Drawings not provided by the designer include control panel structural details, and detailed
loop wiring diagrams, which are typically provided by a contractor. Note: Loop wiring
diagrams are organized according to loop numbers and show detailed point-to-point
connections per ISA Standards.

2.1.2 DOCUMENTATION

The following narratives are provided to describe document requirements.

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2.1.2.1 PROCESS AND INSTRUMENTATION DIAGRAMS (P&ID’S)

The main functions of P&ID's are to coordinate the different design disciplines--process,
mechanical, electrical, and control systems--and serve as an interface with WG. The P&IDs,
along with the process narratives, are also used during development of the IFIX and PLC
programs.

The P&IDs should clearly represent the entire process with proper cross-referencing between
them to indicate continuation of piping and control signals. All piping connections, block
valves, and control valves are shown, including optional sizes, and all equipment is uniquely
identified. Instruments, control valves, and other final control elements are assigned loop
numbers and tagged according to Instrument Society of America (ISA) convention. Each
monitored and controlled variable has a unique loop number. Where continuous loop control
is involved, the sensing element and final controller are given the same loop number.

The P&IDs show all input/output (I/O) points, both discrete and analog. All continuous
control loops are identified with the I/O (analog) pair for each loop. All elements of a control
loop have the same loop number. A complete legend of all drawing symbols and
abbreviations used shall be placed at the beginning of said drawings.

Figures 2-1, 2-2 and 2-3 are examples of typical legend sheets and a P&ID.

2.1.2.2 DIGITAL SYSTEM BLOCK DIAGRAM

A preliminary diagram shall be provided that identifies the different PLC’S, Land’s, Video’s,
and Audio with their areas of control. This diagram shall also show interconnections between
the PLC’S and the supervisory system, and shall identify where the SPC workstations are
located. Figure 2-4 is an example of a digital system block diagram and Figure 2-5 and I/O
listing.

2.1.2.3 PROCESS NARRATIVES

Narratives developed by the process designers are used to describe the operation of the
portions of the plant which are affected by the project. They shall be used in conjunction with
P&IDs and shall reference the appropriate equipment on the P&IDs. The narratives will
describe the design criteria and specify the control parameters used. An example process
narrative is shown in Appendix A.
Typical Process Narratives will include:

· General requirements for typical control schemes, alarm annunciator sequence, loop
interface requirements, analog alarms, and filtering and scaling.

· Set points

· Descriptions of individual control schemes, interlocks, and interactions between

different control loops.

· Failure response for each control scheme.

· Failure response at the unit process level or system level.

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 · Interface with panel-mounted devices

· Interface with IFIX

Loop’s descriptions at 90% design will provide enough detail so that programmers can
successfully program the computer system and the IFIX system to meet the plant design and
operations intent.

2.1.2.4 ELECTRICAL DRAWINGS

All drawings, including manufactures’ equipment drawings, must be provided in electronic

form (AutoCAD) in addition to hard copies. All pre-existing drawings affected by the project
must be revised to reflect changes. (also see volume 4 Drawing Numbering Standards)

Wiring diagrams aid in initial construction and subsequent maintenance of the system. Since
the drawings are used only once for construction and many times for maintenance, the
configuration of the wiring diagrams should be oriented towards the maintenance
functions.

Wiring diagrams shall include all electrical analog and digital signals.

At a minimum wiring diagrams should have the following features:

· Clear identification of all components by name and label. These components include;
field devices, I/O cards, and operator interface devices, plus other devices such as
relays, timers, and isolators.

· Identification of all termination devices (e.g., TJB's, MCC's, and I/O devices) and
termination points (e.g., terminal strips, terminal points, and I/O points).

· Wiring details and cable numbers, wire (conductor) numbers, etc.

Figures 2-6, 2-7, 2-8 and 2-9 show different wiring diagrams formats, any proposed deviation
must receive APT approval.

Electrical control ladder schematics show the electrical circuit in a logical flow of operation
with component referencing to all affected sheets. It does not show all connection details or
equipment location. They are used for circuit trouble shooting.

The final electrical ladder schematics shall be completed at 50% project completion.

2.1.2.5 CONTROL PANEL DESIGN

The control panel design consists of drawings that show power distribution, elevations
including exterior, interior and door layouts, shop drawings and schedules, and the internal
configuration. Each of these is discussed below. Structural design of the panel is generally
left to the contractor. However all proposed panel dimensions must be verified as standard
manufactured products (dimensions must be realistic, obtainable and provide 15 %for future
expansion). The contractor is required to provide equipment that fits within the specified

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dimensions or provide the necessary modifications at no cost to the owner. The contractor
typically provides control panel structural details.

Control Panel Power Distribution and Wiring. Control panel power distribution design
drawings show how wiring is distributed to the various control circuits and other devices
requiring power, including fans, outlets, lights, power conditioners and analog circuits. These
designs must meet all local codes and requirements, including UL listing.

Examples of power distribution wiring diagrams are shown in figure 2-8.

Panel Elevations and Schedules. A control panel elevation gives a panel's dimensions and
shows in detail, the layout of devices on the face of the panel. A schedule identifies each
device by its component label, component specification number, nameplate inscription and
part number.

Internal Configuration. The detailed configuration of the panel interior, showing wireways,
terminal strips, and so on, may be left to the contractor. However, the design engineer shall
lay out the panel interior in sufficient detail (showing major devices such as PLC's, I/O bases,
and power supplies) to ensure that the control panel is sized correctly. The contractor must
provide detailed layouts for approval prior to construction.

Manufacturer Drawings. Manufacturer Drawing(s) shall be provided in electronic form

(AutoCAD) and their standardized drawings, when printed, shall have non-applicable portions
deleted or crossed out.

Examples of typical panel elevations, schedules, and internal configurations are shown on
Figure 2-10.

2.1.2.6 INSTALLATION DETAILS

Show details schematically. Show general installation details for instruments and their
supports as well as any special requirements, including earthquake consideration.
Installation details for all instruments primary elements shall include, where applicable:

· Flow meter placement in process piping:

1. Flow meter elevation.
2. Number of diameters upstream and downstream and distance to
next bend or restriction.
· Installation details that are hidden from view when the process is operating
e.g.: captive air bells.
· Tank elevations for level measurement including information on the
elevation of bypass levels, bubblers, captive air devices (bells) and level
switches.

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2.1.2.7 INTERCONNECTION DIAGRAMS AND LISTINGS

Show interconnection diagrams, and listings, detailing all instrumentation and control
connections in the facility, including TJB's (Terminal Junction Boxes), MCC's, and Control
Panels. These diagrams differ from wiring diagrams in the way the information is organized--
according to multi-conductor cables or TJB's and terminal strips. For example, in an
interconnection diagram, all connections on either side of a multi conductor cable are shown
together. Alternately, all connections to terminal strips in a TJB are shown together.
Interconnection cable drawings and reports that are organized according to cable types (i.e.,
each cable is shown with all connections at either end). These drawings or reports will be
used by the contractor to terminate the wires.

Figure 2-13 shows a typical interconnection diagram listing.

2.1.2.8 DIGITAL SYSTEM BLOCK DIAGRAMS

Final diagrams shall show the layout of the digital system in detail, including details of
individual I/O points. Examples of such drawings are shown in Figures 2-14, and 2-15.

2.1.2.9 FUNCTIONAL DESCRIPTIONS

These are similar to process narratives, but are revised to include more detail regarding the
application software. The functional descriptions are part of the Software Preliminary task.
BES will designate who will accomplish the work and when.

2.1.2.10 INSTRUMENTATION DATA SHEETS

The final specifications shall instruct the contractor to provide:

A data sheet that follows ISA guidelines for each instrument and final control element. These
data sheets should contain specific information regarding manufacturer, model number, serial
number, range, special materials of construction, power requirement, output signal, etc. The
data sheets should also reference plan drawings and installation details.
Examples of data sheets are provided in Appendix B.

2.1.2.11 I/O DATA BASE

An I/O database shall be developed using Access software. This database shall include all
analog and digital points. At a minimum, the database shall contain the information shown in
the PLC Programming Guide.

2.1.2.12 INSTRUMENT LISTS

Instruments are listed in order of Loop number for all instruments and final control elements.
This list will also provide a short description of the instrument’s application with regard to the
project, the suggested manufacturer, including the model number and range. The list shall be
provided on a drawing as part of the construction plans.
Figure 2-17 shows an instrument list format.

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2.1.2.13 CONDUIT AND CABLE SCHEDULES

Conduit and cable schedules uniquely identify each conduit and cable, along with its source
and destination. Conduit drawings include conductor tables showing all conductors within the
individual conduit runs by their tag numbers.

Figure 2-16 shows conduit and cable schedule format.

2.1.2.14 EQUIPMENT NUMBERS, LOOP NUMBERS AND MCC SPACE

All equipment numbers, instrument loop numbers and MCC space allocations are controlled
and supplied by the Electrical, Instrument and Mechanical Planner(s) after the designer has
identified the new and existing equipment.

All requests for information will be processed through the Project Manager.

The designer shall:

(a) Initiate the review process by contacting the Mechanical Planner for a complete list
of existing equipment in the facility affected by the project

And/Or

(b) After initial design, and/or each upgrade, submit to the Mechanical planner a list of
additional, revised or reused equipment with the following: (1) Equipment
description. Example: Sewage Pump #1 (2) Equipment location. Example: Main
building, east wall (3) The drawing reference number. Example: C-3 for review.

The Planner(s) shall:

a. Review each submittal
b. Allocate equipment COMA number(s), assign loop number(s), allocate MCC
space and appropriate information.
c. Complete the review process and return the submittal to the designer with
appropriate information.

2.1.2.15 ELECTRICAL SYSTEM LOAD CALCULATIONS AND COORDINATION

STUDY

Load calculations are made to insure that the existing system (MCC, Transformer etc.), can
support the load changes. Review fuse, breaker and other protective devices to insure that the
changes do not require modification to the existing protective device coordination.

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2.1.2.16 SPECIFICATIONS

Final specifications shall include the following as a minimum:

· Coordination / load calculations

· Summary of work, work sequence, and identification of any critical / special work
items.
· Special submittal requirements
· General testing plan requirements (see Volume 2, Electrical and Instrument design
standards for Circuit Level Testing Requirements)
· Detailed equipment training-plan proposed by the consultant. Must be based on
consulting with WG personnel and using appendix C
· The Process portion of the Operation & Maintenance6 (O&M) manual requirements in
electronic form. (The contractor is to provide equipment portion of the O&M
information. The design consultant to provide the final O&M manual).
· Onsite startup services requirements
· Technical requirements (Contractor qualifications / applicable certifications)
· Requirement of a list of recommended spare parts and expendables, especially those
not stocked locally. WG maintenance will review the list for appropriate stocking
items.
· Requirement that the contractor shall provide Instrument Data Sheets for each
instrument, control valve, and electrical adjustable speed devices.

6
Revised 2003
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