pimmmp control

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ParticularSpecification

Section 36 Part 1 RPSInstrumentation &Control Equipment

Appendix AScope of Work &Technical Information

Lusail DevelopmentConstruction Package No.6C

May 11Rev C

Page 1

CONTENTS

1.0 GENERAL 31.1. INTRODUCTION 31.2. SCOPE OF WORKS 31.3. DESIGN RESPONSIBILITY 31.4. STANDARDS 41.5. SUBMITTALS 42.0 INSTRUMENTATION AND CONTROL 52.1. ACCURACY 52.2. INSTRUMENTS 5

2.2.1 Level measuring/monitoring instruments 52.2.2 Flow measuring/monitoring instruments 52.2.3 Pressure measuring/monitoring instruments 5

2.3. MOTOR STARTERS & ELECTRONIC MOTOR PROTECTIONRELAYS 62.3.1 General 62.3.2 Motor Starters 62.3.3 Variable Speed Drives (VSD) 62.3.4 Electronic Motor Protection Relays 7

2.4. PROGRAMMABLE LOGIC CONTROLLERS (PLCs) 72.4.1 General 72.4.2 Human Machine Interfaces 8

2.5. PUMP STATION CONTROL PHILOSOPHY 92.5.1 Pump Modes of Operation 102.5.2 Pump Station General Control Philosophy 102.5.3 Control Philosophy for the Feed Pumps 122.5.4 Control Philosophy for Potable Water Pumps 132.5.5 Control Philosophy for the Jockey Pumps 132.5.6 Control Philosophy for the Fire Pumps 142.5.7 Standby Diesel Generator/Changeover Switch Control Philosophy 152.5.8 Ventilation system description & Control philosophy 152.5.9 Lighting and Fire Alarm for the Pump room 16

2.6. DOCUMENTS AND MANUALS 162.7. SPARES 172.8. TESTING AND COMMISSIONING 172.9. TRAINING 17APPENDIX A RPS2: 18Part 1.1 RPS2 INSTRUMENT SCHEDULE 18


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Part 1.2 RPS2 ICA DATA SHEETS 18Part 1.3 RPS2 I/O SCHEDULE 18APPENDIX B RPS3: 18Part 1.10 RPS3 INSTRUMENT SCHEDULE 18Part 1.11 RPS3 ICA DATA SHEETS 18Part 1.12 RPS3 - I/O SCHEDULE 18


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1.0 GENERAL

1.1. INTRODUCTION

1. This Specification covers the particular Instrumentation & Control requirementsfor the 4 no. Reservoir Pumping Stations (RPS 1 - 4) in addition to the Qatar

Construction Specifications (QCS) 2007. The requirements will apply to all 4 no.pumping stations, but only RPS2 and RPS3 are included in this ConstructionPackage.

1.2. SCOPE OF WORKS

1. The Contractor shall be responsible for the procurement, supply, delivery to site,installation, testing and commissioning of all equipment, fixtures and fittingsnecessary to complete the instrumentation & control installation whether detailedherein or not. The installation shall be in accordance with the relevant standardsand specifications, schedules, datasheets & drawings and shall include but notnecessarily be limited to the installation & control works associated with thefollowing:

(a) Supply and install all instrumentation as detailed in the Instrument

Schedule, including the power supply connection to the PLCs, etc.

(b) Supply and install all motor starters & Variable Speed Drives includingElectronic Motor Protection Controllers.

(c) Supply and install a comprehensive PLC system with all necessaryinput/output modules, power supply, and programming necessary foroperating the pumping station in automatic mode as described underSection 2.5 below.

(d) Supply and install power, control and instrumentation cables andassociated supports. The cabling installation shall include supply,install, gland, terminate, label, and test all power, control,instrumentation and telemetry/signal cabling associated with theequipment provided and installed under the Contract, including allconnection to the existing installation.

(e) Supply and install local control boxes, isolators and junction boxes.

2. Additional works to include:

(a) Construction and installation of all required cable draw-pits, ducts andtrenches as shown on the Site Layout and General Arrangement forthe new installation.

(b) Documentation, testing, commissioning and training.

(c) Liaise with local electricity supply authority (KAHRAMAA) forsubmissions and approvals.

1.3. DESIGN RESPONSIBILITY

1. All the equipment supplied and installed under this Contract shall comply in allrespects with QCS 2007, unless otherwise specified.

2. The Contractor shall be responsible for the design of the installation & controlsystem to suit the rating and load duties of the equipment provided under thisContract.


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1.4. STANDARDS

1. In cases where there is a British Standard, International Standard or Code ofPractice which is appropriate to any item of equipment supplied, any componentincorporated in the Works, the testing of the Works or the installation of theequipment, then the British Standard or Code of Practice or International

Standard shall apply.

2. A (non exhaustive) list of applicable standards follows.

BS 1646 Symbolic representation for process measurementcontrol functions and instrumentation. Basicrequirements

BS 3680 Measurement of liquid flow in open channels. Weirsand flumes.

BS 5308 Instrumentation cables.

BS 5750-8 Quality systems. Guide to quality management andquality systems elements for services

BS 60529 Degrees of protection provided by enclosures (IP code)BS 7405 Guide to selection and application of flow meters for the

measurement of fluid flow in closed conduits

BS 7671 Requirements for electrical installations. IEE wiringregulations

BS EN ISO 5167 Measurement of fluid flow by means of pressuredifferential devices inserted in circular cross-sectionconduits running full. General principles andrequirements

IEC 61131 Programmable controllers

1.5. SUBMITTALS

1. All documentation submitted under this Contract shall be in accordance with theGeneral requirements Section 7 Submittals.

END OF PART


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2.0 INSTRUMENTATION AND CONTROL

2.1. ACCURACY

1. The intended use of a measured value will determine the accuracy requirement.Those instruments whose measured values are used directly by an automated

control system will demand high accuracy (0.5%). Instruments that measurevalues used by operators to monitor the process but do not directly control theprocess may be of lower accuracy (1.0%). Where instruments are providedpurely for display, these may be low accuracy (5.0%). Accuracy for particularinstrument types will be specified in the relevant sections below.

2. The method or location of installation can have a major affect on the accuracy ofthe measurement generated by any instrument. All instruments shall be installedin accordance with the instrument manufacturers installation requirements.

2.2. INSTRUMENTS

1. Instruments provided under this Contract shall be in accordance with QCS 2007and shall satisfy all requirements laid out therein. The Plant and Instrumentation

Diagrams indicate the requirements and locations of instrumentation necessaryto control and monitor the plant. The instrument requirements are summarised inthe instrument schedule.

2.2.1 Level measuring/monitoring instruments

1. The Contractor shall design, supply, install and commission the followinginstruments required for level measuring / monitoring for use in the scheme:

PumpStation

UltrasonicLevelDetectors

Electrodes(ConductivityProbes)

FloatSwitches

P&ID Dwg No.

RPS 2 2 3 6 GQ626/3301/2

RPS 3 2 3 6 GQ626/3301/3

2. In general all the a/m instruments shall be designed / supplied / installed /commissioned in accordance with QCS 2007, Section 10 Part 3.

2.2.2 Flow measuring/monitoring instruments

1. The Contractor shall design, supply, install and commission the followinginstruments required for flow measuring / monitoring for use in the scheme:

PumpStation

ElectromagneticFlowmeter

P&ID Dwg No.

RPS 2 4 GQ626/3301/2

RPS 3 3 GQ626/3301/3

2. In general all the a/m instruments shall be designed / supplied / installed/commissioned in accordance with QCS 2007, Section 10 Part 3.

2.2.3 Pressure measuring/monitoring instruments

1. The Contractor shall design, supply, install and commission the followinginstruments required for pressure measuring / monitoring for use in the scheme:


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PumpStation

PressureGauges

PressureTransducers P&ID Dwg No.

RPS 2 28 2 GQ626/3301/2

RPS 3 20 1 GQ626/3301/3

2. In general all the a/m instruments shall be designed / supplied / installed /commissioned in accordance with QCS 2007, Section 10 Part 3.

2.3. MOTOR STARTERS & ELECTRONIC MOTOR PROTECTIONRELAYS

2.3.1 General

1. In accordance with current KAHRAMAA regulations, motors up to and including11 kW shall be started direct on line. Motors above 11 kW shall incorporateassisted starting.

2. The electrical pumpsets labelled Feed Pumps and Potable Water Pumps, shall

be equipped with Variable Speed Drives (VSD), including Electronic MotorProtection Relays.

3. The electrical pumpsets labelled Electric Motor Driven Fire Pumps and JockeyPumps shall be equipped with Motor starters, including Electronic MotorProtection Relays.

4. The Sump Pumps shall be equipped with Direct On Line contactors. DOL startershall consist of a TP contactor for switching direct on line in accordance withBS EN 60947-4-1 and fitted with auxiliary contacts.

2.3.2 Motor Starters

1. The following pumps shall be equipped with the soft starters: all Electric MotorDriven Fire Pumps and all Jockey Pumps.

2. Type of motor starters used for these pumps shall be soft starter type and shallbe rated to carry the full load current of its rated duty at its most severe loadconditions. All starters shall be capable of a minimum of 10 starts per hour at100% full load torque unless otherwise specified.

3. Soft Motor starters shall be provided in accordance with QCS 2007, Section 21Part 4.

2.3.3 Variable Speed Drives (VSD)

1. The following pumps shall be equipped with the Variable Speed Drives (VSD):all Feed Pumps and all Potable Water Pumps.

2. Variable Speed Drives (VSD) shall be of the solid state, static, voltage sourcetype, using minimum 32 bits microprocessor or the latest available, digital sinewave approximation Pulse Width Modulation (PWM) type. VSDs shall besuitable for the particular application, controlling pumps with variable torquecharacteristics.

3. The VSD shall be provided with communication interface and facility to integratethe operation of the system. The facility employing communication protocols,e.g. profibus, modbus, shall be compatible with other system equipments suchas the PLC.


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4. The VSD shall be of a proven design that provides high pump efficiency, highavailability, minimum maintenance, substantial energy reduction and longerbearing and seal life at reduced speeds and it should be in accordance withQCS 2007, Section 21 Part 5.

2.3.4 Electronic Motor Protection Relays

1. The Motor Protection shall be an intelligent electronic device that is user friendlyand user configurable, capable of controlling the motor manually or automatic.

2. Electronic Motor Protection Relay shall be provided in the MCC for each pumpmotor starter/VSD rated 11 kW and above.

3. The protection features shall include the following as minimum:-

(a) over load protection

(b) over current protection

(c) over voltage protection

(d) under voltage protection

(e) under current protection(f) phase sequence

(g) phase imbalance

(h) phase loss

(i) earth leakage

(j) earth fault

(k) thermistor broken

(l) open contactor

(m) locked rotor

4. Electronic Motor Protection Controllers should be in accordance with QCS 2007,Section 21, Part 3.

2.4. PROGRAMMABLE LOGIC CONTROLLERS (PLCS)

2.4.1 General

1. Where identified in the Particular ICA Specification, programmable logiccontrollers (PLCs) shall be used to control plant and process equipment.Operation of the plant and process equipment shall be governed by theprogramming of the controller, measured values and plant status inputs.

2. PLC programming shall follow industry best practice. Software developmentshall be carried out in accordance with the methodologies described in BS EN61508, BS EN 61511 and IEC 61131. Standard IEC libraries of Functions and

Function Blocks shall be used when writing application software.

3. The PLC shall be used to control the plant in automatic mode only. Manualcontrols shall be hardwired to allow plant operation in the event of a PLC failure.Emergency signals shall be hardwired any emergency signals wired to thePLC shall be duplicate repeated signals.

4. The programming of the PLC shall be held in non-volatile memory, such as anEPROM module, to enable normal operation to resume without operatorintervention on resumption of power supply following an outage.


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5. Where a PLC is supplied, the Contractor shall provide all assets associated withthe PLC. This shall include all hardware and software items, including (but notlimited to):

(a) All hardware including equipment racks, central processor units, I/Ocards, communications modules, programming cables, etc.

(b) All software including PC based configuration software (to include anydongle, licence or other such software protection device required toutilise the software), fully documented and commented source codefiles.

6. The PLC shall be provided with sufficient communication ports to enable thePLC programming device to be connected without a requirement to disconnectremote monitoring devices or any HMI/programmable operator terminal unitsinstalled. Where specified in the Specification a panel mounted VDU or a PCbased control station shall be provided for Man Machine Interface (MMI).

7. Indication of status of digital I/O shall be provided by LEDs on the face of the I/Omodule. A window shall be provided in the door of the Control andInstrumentation section or Local Area Control Panel door as appropriate to

enable I/O status to be viewed without gaining access to the Control andInstrumentation section or Local Area Control Panel.

8. A printed schedule showing details of all connected I/O shall be provided. Theschedule shall be printed on non-combustible media or plastic encapsulatedsheet. The schedule may either be permanently fixed adjacent to the PLC orheld within a document holder mounted inside the panel.

9. DIN rail mounted disconnect terminals for all provided input and output signals(including unused spares) shall be provided below the PLC. Where outputterminals are required, these shall be incorporated with the terminals in a singleDIN rail mounted unit.

10. The PLC shall be powered by either a 110 V AC or 18-30 V DC supply.

11. The processor unit shall have a real time clock, which shall be battery backed. Abattery low indication lamp and telemetry alarm signal shall be provided tomonitor battery status.

12. PLC control equipment shall be housed in the common controls section of theMCC and shall be fed by non door interlocked MCCB.

2.4.2 Human Machine Interfaces

1. Where a limited number of variables are measured, a suitable number of panelmeter units shall be provided, located on the Control and Instrumentation sectionor Local Area Control Panel door. Where more variables are monitored, such anarrangement may become unwieldy and a more versatile programmableoperator terminal unit shall be provided, located on the Control and

Instrumentation section or Local Area Control Panel door.

2. Panel meters may be either numeric displays or a bar graph representation asappropriate. Input to panel meters shall be by 4-20 mA current loop. Where anumeric display is used, numerals shall be a minimum of 14 mm high. Thenumber of digits will be determined by the application. Where a bar graphrepresentation is used, the display shall be linear and proportional to themeasured value, and shall be scaled to enable display of a measurement of upto 120% of the normal full scale value. Bar graph displays shall be made up of aminimum of 30 segments with a minimum scale length of 100 mm.


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3. Programmable operator terminal units shall be configured to display data in alogically ordered format allowing quick and easy access to measured variables.Where displaying all data in one view would result in a cluttered or confusingdisplay, or where viewing and entry of control set points is possible from theprogrammable operator terminal, there will be a requirement for a number ofviews. Where data is split up across a number of views in this manner, data shall

be displayed and accessed in a clear and logical way. The method used toswitch between views shall be simple and intuitive. Periodic automatic scrollingof screens may be offered as an option but it shall be possible to disable thismode if desired.

4. Where the programmable operator terminal is used to view and enter control setpoints, it shall be necessary to enter a password via the numeric membranekeypad or via a touch screen representation of a numeric keypad (depending onhardware configuration). When the password is correctly entered, the new set-point value may be entered. The entered value will be error checked to ensurethat the entered value is within the acceptable range. If the value entered isacceptable, the operator shall be alerted that the set-point has been acceptedand the entered value shall be written to the relevant PLC register. If the value isoutside the acceptable limits, the operator shall be alerted that the entered value

is outside acceptable limits, the entered set-point shall not be written to the PLCand the existing set-point data shall be used.

5. Programmable operator terminal units shall have a backlit display with minimumdisplay area of 100 mm x 50 mm with a minimum resolution of 256 pixels x 128pixels and a wide viewing angle. Colour, greyscale or monochrome displaysshall be acceptable. The unit shall incorporate either an integral numericmembrane keypad or touch screen display. Membrane keypads shall be ratedfor a minimum of 2,000,000 key presses. Touch screens shall be divided intotouch cells, with each cell rated for a minimum of 1,000,000 presses.

6. The programmable operator terminal unit shall store its view configuration in nonvolatile memory to enable normal operation to resume without operatorintervention on resumption of power supply following an outage. A battery

backed real-time clock shall be provided.

7. Programmable operator terminals shall be provided with a communication portto enable connection to the PLC for operational use or a PC with suitableconfiguration software for programming purposes.

8. Where a programmable operator terminal is supplied, the Contractor shallprovide all assets associated with the device. This shall include all hardware andsoftware items, including (but not limited to):

(a) All hardware including communications modules, programming cables,etc.

(b) All software including PC based configuration software (to include anydongle, licence or other such software protection device required to

utilise the software), fully documented and commented source codefiles.

9. Programmable operator terminal units shall be powered by either a 110 V AC or18-30 V DC supply and shall have a power consumption of no greater than100 VA.

2.5. PUMP STATION CONTROL PHILOSOPHY

1. The following describe the operation of the Pumping Station water pumps,generator auto changeover and HVAC units. The focus is on describing


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automatic and manual (local) modes of operation as these are the normalmodes of operation.

2.5.1 Pump Modes of Operation

1. For each pump, at each pumping station, a mode switch shall be providedallowing the following operational modes to be selected:

2. Auto The pump station PLC shall be used to control the pumps in automaticmode only. Manual controls shall be hardwired to allow plant operation in theevent of a PLC failure.

3. Local Manual Control is required for all pumps. In local control, pumps will bestarted and stopped using pushbuttons located on the associated MCC panel. Arotary control will be provided on the MCC panel door to allow adjustment ofpump speed.

4. Off Pumps will be unavailable for any mode of control.

2.5.2 Pump Station General Control Philosophy

1. Each pump station control system shall provide controls/monitoring for itsassociated pumps, these comprising:

(a) RPS 2:

(i) 3 feed pumps, 4 potable water pumps, 2 jockey pumps and 2electric motor driven fire pumps and 2 diesel engine drivenfire pumps.

(b) RPS 3:

(i) 4 potable water pumps, 2 jockey pumps and 2 electric motordriven fire pumps and 2 diesel engine driven fire pumps.

2. For each system:

(a) Operational control of the pumps shall be provided by a programmablelogic controller (PLC) responding to a flow variation on the dischargemanifolds and levels in the storage tanks. Operation of the pumps andassociated equipments shall be governed by the programming of thecontroller, measured values and plant status inputs.

3. Pump sequencing will depend on the demand requirements. The PLCprogramming should be such as to be able to react to different scenarios.

4. The starting and stopping of the pumps and the number of pumps operating willbe controlled by the maximum and minimum flow set points. The maximum andminimum flow set points will be a function of the pump speed and number ofpumps in operation. The pump manufacturer shall provide the minimum andmaximum pump flow curves for all pumps operating scenarios.

5. The speed of the pumps will be modulated, according to flow variation on thedischarge manifolds to maintain an active set-point pressure.

6. The pressure set point shall have two modes of operation. For each pumpingstation. A mode switch shall be provided allowing the following pressure modesto be selected:

(a) Manual Pressure Mode: the pressure set point shall a fix value andadjustable from the PLC.


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(b) Auto Pressure Mode: the pressure set point shall be calculated every 60seconds from the rising main flow reading based on the following formula:

Active Press SP = C1+C2*Flow2

C1 & C2 will be adjustable and to be set during commissioning based on

network conditions.

7. Level sensors shall be incorporated in the reservoirs giving high and low levelalarms. All pumps except the diesel engine driven fire pumps shall be inhibitedto start in Auto and Manual modes to protect against dry running. Pumps shallbe inhibited when:

(a) a low level condition is detected in both the storage reservoirs; or

(b) a low level condition is detected in one storage reservoir whilst theisolation valve on the corresponding suction pipe remains open; or

(c) A flood level condition is detected in pump room.

8. On receipt of a flood level sensed inside the pump room all pumps (including fire

pumps and excluding sump pump) will be inhibited to start and all valves willclose. Flood protection sensor shall be automatically disconnected when firepump(s) are in operation.

9. On receipt of high level alarm in either of the reservoirs (tanks 1 & 2), the inletflow control valve will throttle closed.

10. The following Table gives level and pressure set-points for alarms, floodprotection and pump inhibits. All levels in the Table are in metres and relative toQatar National Datum. All pressure set-points in the Table are in metres ofgauge pressure:

Instrument Signal RPS 2 RPS 3

Feed pump stop and

inhibit level / Potable waterpump stop level / Low levelalarm

(storage tank 1 and 2)

+1.40 m

(*)

n/a

Potable water and electricfire pump inhibit / Low Lowlevel alarm


+0.58 m +0.18 m

Feed pump minimum startlevel

+0.73 m n/a

Potable pump minimumstart level

+0.78 m +0.50 m

High level alarm


+5.45 m +4.35 m

High High level alarm


+5.55 m +4.45 m

High level alarm (pumproom sump)

-1.45 m -1.19 m

Flood level Protection -0.95 m -0.69 m


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valve closure & pumpinhibit (pump room sump)

High pressure alarm ( feedpump discharge manifold)

40.0 m n/a

High pressure alarm

(potable water pumpsdischarge manifold)

60.0 m 65.0 m

(*) Storage of 5,500 m reserved for fire pumps.

11. Detailed pump monitoring, such as temperature and vibration, overload,overtorque, speed difference, shall be interlocked with pump control bydedicated integrated electronic motor protection relay controllers. In the event ofthe detection of any a/m condition the pumps will be tripped at the starter and analarm generated. The pumps will not operate in automatic or manual control untilthe fault has been cleared.

12. Pressure relief valve on discharge manifold at each of the four reservoirpumping stations shall be set to avoid pumps running at shut off head (no flow)

condition.

13. All setpoints shall be confirmed on pump commissioning.

2.5.3 Control Philosophy for the Feed Pumps

1. At RPS 1 & 2 there will be 3 feed pumps on a duty/assist/standby basis. Pumpswill be equipped with the variable speed drives (VSD). The speeds will bemodulated together to ensure that the two running pumps are operating at thesame speed. The pump speed shall modulate to maintain an active pressure setpoint on the discharge manifold. When the running pump has reached themaximum flow set point, and after a time delay, the running pump will drop tolow speed and the assist pump will be started at the low speed. When the pumpspeeds have equalised, both pumps will modulate at the same speed to sustainthe active pressure set point. When the pumps are running and the flow drops

below the minimum flow set point for 2 pumps the assist pump will be stoppedand the duty pump will speed up to maintain the active pressure setpoint.

2. During one pump operation, if the flow goes below the minimum flow set pointfor one pump, then after a time delay, the pump shall stop and an alarm shall betriggered (Q1MINalarm).

3. In normal operation it is expected that the feed pumps will be operating all thetime. The pump duty shall rotate automatically on duty pump stop, or every 12hours, whichever is sooner.

4. The feed pumps shall stop and be inhibited to operate in auto or manual modeat low level as indicated on Table in section 2.5.2.10.

5. The feed pumps shall stop and be inhibited to operate in auto or manual modewhen any fire pump is called to start or in operation.

6. The following Table gives pressure set-point for all feed pumps when operatingin Manual Pressure Mode. All set-points in the Table are in metres of gaugepressure:

Pumps in Operation RPS 2


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Duty Feed Pump (solo) 21 m

Duty / assist Feed Pumps (two pumps) 30 m

Note: Set-points will need to be adjusted during commissioning.

2.5.4 Control Philosophy for Potable Water Pumps

1. At each RPS there will be 4 potable water pumps on a duty/assist/assist/standbybasis. Pumps will be equipped with the variable speed drives (VSD). Thespeeds will be modulated together to ensure that all running pumps areoperating at the same speed. When the running pumps have reached themaximum flow set point for that number of running pumps, then after a timedelay , the running pumps will drop to low speed and an additional assist pumpwill be started at the low speed. When the pump speeds have equalised, thepump speeds will modulate to maintain the active pressure setpoint on thedischarge. When the pumps are running and the flow drops below the minimumflow set point for that number of running pumps, then after a time delay, onepump will be stopped and the remaining pumps will speed up to maintain theactive pressure setpoint.

2. During one pump operation, if the flow goes below the minimum flow set pointfor one pump then after a time delay, the pump shall stop.

3. The potable water pumps shall stop at low level in auto mode and be inhibited tooperate in auto or manual mode at low low level as indicated on Table in section2.5.2.10

4. Potable water pumps will be running all the time with the exception of lowdemand periods, when the jockey pumps will run. Number of pumps running, willdepend on the actual demand.

5. Pump duty shall rotate automatically on duty pump stop, or every 12 hours,whichever is sooner.

6. The following Table gives pressure set-point for all potable water pumps whenoperating in Manual Pressure Mode. All set-points in the Table are in metres ofgauge pressure:

Pumps in Operation RPS 2 RPS 3

Duty Pump (solo) 35 m 41 m

Duty / Assist Pumps (two pumps) 40 m 46 m

Duty / Assist / Assist Pumps (threepumps)

44 m 49 m


2.5.5 Control Philosophy for the Jockey Pumps

1. At each RPS there will be 2 fixed speed Jockey pumps running on aduty/standby basis. In a normal mode of operation the Jockey pumps will not berunning except during the off peak hours, i.e. low flow conditions, when thepotable water pumps will be stopped.


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2. The duty Jockey pump will start when the pressure drops below the lowpressure set-point. The Jockey pump will stop when pressure rises to the highpressure set-point.

3. Once the demand/flow increases and the Jockey pump is not able to sustain thelow pressure set-point, the first potable water pump will start at low speed and

ramp up slowly, while Jockey pumps will be switched off.

4. Interlock should be provided to prevent starting of the potable water pumps whilejockey pumps are in operation. Or from starting jockey pumps while potablewater pumps are in operation.

5. Pump duty shall rotate automatically on duty pump stop, or every 6 hours,whichever is sooner.

6. The following Table gives pressure set-point for all jockey pumps. All set-pointsin the Table are in metres of gauge pressure:

Pump Operating Range RPS 2 RPS 3

Low Pressure (pump start) 28 m 31 m

High Pressure (pump stop) 31 m 34 m


2.5.6 Control Philosophy for the Fire Pumps

1. At RPS 2 & 3 there will be 2 fixed speed electric motor driven fire pumps with 2backup diesel engine driven fire pumps.

2. In normal operation electrical and diesel fire pumps will be off. In the event offire, i.e. when all 3 duty potable water pumps are running and the maximum flowsetpoint for the potable water pumps is exceeded after time delay, the firstelectric motor driven fire pump shall start, and the 3 potable water pumps shallmodulate to maintain the active pressure on the discharge. When the first firepump is operating and the running potable water pumps maximum flow set pointis exceeded after a time delay, the second electric motor driven fire pump shalloperate. The potable water pump speeds will then modulate to maintain theactive pressure set point on the discharge.

3. When one or two electric motor driven fire pumps are in operation, the potablepumps are running and the flow is 50% lower than the maximum flow setpointfor the potable water pumps after a time delay, one electric motor driven firepump will be stopped and the potable pumps will speed up to maintain the activeset-point pressure. The 50% flow setpoint for for stopping fire pumps will need toconfirmed on commissioning. After all electric motor driven fire pumps arestopped, the potable pumps shall continue to operate as detailed in part 2.5.4above.

4. If all potable water pumps and electric fire pumps are in operation and themaximum flow setpoint for the potable water pumps is exceeded after timedelay, the pumping station shall completely shut down and an alarm shall beraised. The shutdown sequence shall be the following. The fire pumps shallstop in sequence, the potable water pumps shall reduce to minimum speed andstop in sequence. This event should only occur due to a considerable loss inpressure of the potable water network due to catastrophic pipeline failure.


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5. When a low level of water is sensed in the reservoir and the electric fire pump(s)are running an alarm shall be raised and all pumps shall continue to operate andshall stop at low low / inhibit level as indicated on Table in section 2.5.2.10,except the diesel engine fire pumps. .

6. If there is a power failure while the fire pumps are running or for any reason the

electric motor driven fire pumps fail to operate when called, the backup dieselengine driven fire pumps will automatically start. Once the diesel pumps arerunning they can only be manually switched off.

7. Interlock should be provided to prevent starting of the electrical fire pumps whilediesel fire pumps are in operation, even after the restoration of the power.

8. Interlock shall be provided to inhibit operation of feed pumps while any fire pumpis in operation.

2.5.7 Standby Diesel Generator/Changeover Switch Control Philosophy

1. The control system for standby generation and transfer switch shall be providedas a complete package. The following general strategy shall apply for all pumpstations:

(a) Generator to start on loss of grid (network) supply. Once the generatoris operating in a steady state, the load shall be transferred to thegenerator.

(b) After transferring to the Generator, the load shall not be transferredback to the Grid until grid power has remained on for a period of 5minutes.

(c) The Generator shall not stop until the load has been successfullytransferred back to the grid.

(d) Changeover-switch control shall be integrated with control circuit forstandby power generator.

2. After restoration of the power/transfer to the generator all the pumps that were in

auto mode should start automatically. The order of pumps starting will dependon which was running before power failure.

3. For instance, should the power failure occur during low flow conditions (i.e. onlythe Jockey Pumps are running) the system does not need to start any otherhigher priority pumps other than the Jockey Pumps.

4. However in the event of power failure situation when there is maximum waterdemand during peak hours, when it is required to achieve maximum flow asquickly as possible, the Potable Water Pumps will sequence in first. The lowestpriority pumps to start shall be the Feed Pumps.

2.5.8 Ventilation system description & Control philosophy

1. The Main Pump room has been ventilated with 10 air changes using roofmounted units with two speed motor complete with low profile weatherproofaerodynamically efficient GRP cowl and galvanised base with deep spunventure and incorporating an axial impeller and electronic speed controller.Fresh air intake complete with sand trap louvers with filters are provided on theother side as detailed in the Drawings.

2. The fan shall be of the Terminator type and shall be supplied complete withbackdraught shutters, bird guard, purlin box curb, hand guard and soaker sheet,specific details of the curb and soaker sheet to be confirmed by the Contractor.


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3. The Contractor shall make due allowance for supporting the fan via the provisionof purpose made trimmers between purlins. The trimmers shall be sized toadequately support the weight of the fans.

4. The compact control system shall be complete with all necessary controls tofacilitate the operation of the ventilation system. It shall come complete with an

integral PCB which will control the fan unit within the desired design parametersand provide the interface between all external control devices and the unit itself.The fan unit shall have the following components integrally mounted, pre-wiredto interface with the purpose made PCB, all components pre-wired, configuredand factory fitted by the manufacturer: -

(a) Integral two speed controller.

(b) Integral maximum and minimum speed adjustment.

(c) Integral adjustable run on timer.

(d) Integral BMS interfaces (if BMS is provided) 0-10v speed adjustment.

(e) Integral BMS interfaces (if BMS is provided) Volt free failure andstatus indication.

(f) Multiple IDC sockets for interconnection of sensors or fans using pre-plugged 4-core low voltage cable.

5. The controls will enable the unit to automatically vary its 2 speed motor as itreceives signals from the temperature sensors. When the signal is received thefan shall either increase or decrease speed to achieve the required designatedtemperature set point.

6. The large pumps in the plant room will make the temperature higher than 24degrees Celsius in the pump room, however all variable speed drives andcontrol panels are located in the MCC room.

2.5.9 Lighting and Fire Alarm for the Pump room

1. There will be an automatic analogue addressable fire alarm system comprising

of smoke and heat detectors. The fire alarm will have a 2nd Stage alarm. If onedevice is operated then the system goes into alert mode, and when a seconddevice is operated during the alert mode the system then goes into fire alarmmode and evacuation. An inert gas fire suppression system as per FM200argonoite, inergen or equivalent on double knock detectors shall be provided.

2. In case of fire mode, the fans will automatically be switched off upon receivingthe signal (2nd Stage Alarm) from the fire alarm panel via the fire alarm interfaceunit to each of the individual fan control panels. The fire alarm system shall betested and commissioned to make sure that all the interfaces operate and thecorrect alarm stages are obtained.

3. Lights have been provided to meet the lux requirements; in the pump roomaccess to strip lighting would be inadequate and spot lights along the wall for

ease of maintenance have been provided.

2.6. DOCUMENTS AND MANUALS

1. On completion of the Contract or contract stage and before handing over, theContractor shall submit comprehensive documentation detailed in QCS 2007and the General Requirements, including but not limited to:

(a) Design information and calculations

(b) As-built schedules, drawings and diagrams


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(c) Manufacturer equipment Maintenance and Operation Manuals

(d) Factory test certificates and reports

(e) Test and commissioning results, certificates and reports

2.7. SPARES

1. Spares shall be provided as recommended by equipment manufacturers

2.8. TESTING AND COMMISSIONING

1. The Contractor shall test and commission the installation in accordance with therequirements of QCS 2007. The Contractor shall provide the following:

(a) Commissioning Plan

(b) Commissioning Manual

(c) Commissioning Log

(d) Test Documentation, schedules, logs and final status report

2.9. TRAINING

1. Training shall be provided for the Employer's Personnel, either directly bymanufacturers of the different equipment or through their suppliers.


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APPENDIX A RPS2:

Refer to the following parts for:

PART 1.1 RPS2 INSTRUMENT SCHEDULE

PART 1.2 RPS2 ICA DATA SHEETSPART 1.3 RPS2 I/O SCHEDULE

APPENDIX B RPS3:

Refer to the following parts for:

PART 1.10 RPS3 INSTRUMENT SCHEDULE

PART 1.11 RPS3 ICA DATA SHEETS

PART 1.12 RPS3 - I/O SCHEDULE

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