posted on website: 8 pages + 525 pages attachments + 15 ... · 229m-2016-11 – chamber no. 3 –...

Joanne Kehoe, Manager Construction Services

Purchasing and Materials Management Michael Pacholok, Director

City Hall 19th Floor, West Tower 100 Queen Street West Toronto, Ontario M5H 2N2

February 23, 2017 Posted on website: 8 pages + 525 pages attachments + 15 drawings

Addendum No. 6

Tender Call No. 341-2016

Contract No. 16ECS-LU-03TT

Re: Toronto Flow Meters Replacement and Upgrades

Closing Date: 12:00 NOON (LOCAL TIME), March 6, 2017 (Revised)

Re: Deadline for Questions – No further questions will be taken unless they are related to

Addendum No. 6 Please refer to the above Tender Call document in your possession and be advised of the

following:

I. EXTENSION TO CLOSING DATE

1. The Closing Date has been extended from February 28, 2017 to March 6, 2017 at

12:00pm.

II. SUMMARY OF ADDENDUM NO.6 CHANGES

The below Specifications, Section 4A - Division 13/16, were modified to include answers

to the questions raised during addendum period, reference the new PCS guidelines in the

documents, design changes (Milliken PS) requirements and update project and

instrumentation requirements.

T-13010 – Process Control General

T-13130 – Magnetic Flow Meter

T-13160 – Pressure Transmitter

T-13169 – Pressure Gauge

T-13305 – Filed Wiring

T-13510 – Local Area Network

T-16010 – Electrical General Requirements

The below Specifications contain the latest version of the City of Toronto’s Process

Control Systems (PCS) Implementation Guidelines. These existing PCS guidelines can

be found in the CD – Attachment No. 15. Replace original version with the updated

version issued in this addendum in its entirety.

T-13010A – PCS Guidelines

T-13010-01 to T-13010-13 – PCS Guidelines (Appendix C)

T-13105-02 to T-13105-04 – Instrumentation & Equipment testing sheets.

The below Process Narratives (PNs) were modified to include more detailed

programming and monitoring requirements of the SCADA system at each facility. The

1 of 183

existing Process Narratives can be found in the CD – Attachment No. 15. Replace

original version with the updated version issued in this addendum in its entirety.

T-13400-01 to T-13400-16 – Facilities Process Narrative

III. REVISIONS/ADDITIONS

a. Replace original Sections with the following Sections in its entirety:

Section T-13010 – Process Control General with Section T-13010 –

Process Control General in this addendum

Section T-13010-01 – Colour Convention with Section T-13010-01 –

Colour Convention-V2 in this addendum

Section T-13010-02 – RPU Software Programming with Section T-13010-

02 – RPU Software Programming-V2 in this addendum

Section T-13010-03 – RPU Standard Software Modules with Section T-

13010-03 – RPU Standard Software Modules-V2 in this addendum

Section T-13010-04 – Operator Interface Programming-V2 with Section

T-13010-04 – Operator Interface Programming-V2 in this addendum

Section T-13010-05 – Alarming with Section T-13010-05 – Alarming-V2

in this addendum

Section T-13010-06 – PCS Factory Acceptance Testing with Section T-

13010-06 – PCS Factory Acceptance Testing-V2 in this addendum

Section T-13010-07 – FAT and SAT Test-Check Sheet with Section T-

13010-07 – FAT and SAT Test-Check Sheet-V2 in this addendum

Section T-13010-08 – Process Logic Test Sheet with Section T-13010-08

– Process Logic Test Sheet-V2 in this addendum

Section T-13010-09 – PCS Site Acceptance Testing and Commissioning

with Section T-13010-09 – PCS Site Acceptance Testing and

Commissioning-V2 in this addendum

Section T-13010-10 – PCS Documentation with Section T-13010-10 –

PCS Documentation-V2 in this addendum

Section T-13010-11 – Training with Section T-13010-11 – Training-V2

in this addendum

Section T-13010-12 – Process Display Programming with Section T-

13010-12 – Process Display Programming-V2 in this addendum

Section T-13010-13 – Process Control Narratives with Section T-13010-

13 – Process Control Narratives-V2 in this addendum

Section T-13010A – PCS Guidelines with Section T-13010A – PCS

Implementation Guidelines-V3 in this addendum

Section T-13105-02 – Instrument and Equipment Testing with Section T-

13105-02 – Instrument and Equipment Testing-V2 in this addendum

Section T-13105-03 – Instrument Testing Log with Section T-13105-03 –

Instrument Testing Log-V2 in this addendum

Section T-13105-04 – Field Installation Testing Log with Section T-

13105-04 – Field Installation Testing Log-V2 in this addendum

Section T-13130 – Magnetic Flow Meter with Section T-13130 –

Magnetic Flow Meter in this addendum

Section T-13160 – Pressure Transmitter with Section T-13160 – Pressure

Transmitter in this addendum

Section T-13169 – Pressure Indicating Gauge with Section T-13169 –

Pressure Gauge in this addendum

2 of 183

Section T-13305 – Field Wiring with Section T-13305 – Field Wiring in

this addendum

Section T-13400-01 – Bayview Chamber – WTR-PBV-CH-0001 – PCN

with Section T-13400-01 – Bayview Chamber- Process Narrative in this

addendum

Section T-13400-02 – Woodbine & Steelcase – WRT-269-CH-0004 –PCN

with Section T-13400-02 – Woodbine & Steelcase – Process Narrative in

this addendum

Section T-13400-03 – Keele Reservoir – PCN with Section T-13400-03 –

Keele Reservoir Process Narrative in this addendum

Section T-13400-04 – Willowdale & Highland- WTR-359-CH-0004 –

PCN with Section T-13400-04 – Willowdale & Highland – Process

Narrative in this addendum

Section T-13400-05 – Yonge & Elgin- WTR-282-CH-0002 – PCN with

Section T-13400-05 – Yonge & Elgin – Process Narrative in this

addendum

Section T-13400-06 – Milliken PS PN with Section T-13400-06 –

Milliken PS Process Narrative in this addendum

Section T-13400-07 – Dufferin & Steeles – WTR-365-CH-0006 –PCN

with Section T-13400-07 – Dufferin & Steeles – Process Narrative in this

addendum

Section T-13400-08 – Bathurst & Steeles – WTR-250-CH-003B –PCN

with Section T-13400-08 – Bathurst & Steeles – Process Narrative in this

addendum

Section T-13400-10 – ThornhillPS PN with Section T-13400-10 –

ThornhillPS Process Narrative in this addendum

Section T-13400-11 – Keele & Steeles – WTR-194-CH-0007 –PCN with

Section T-13400-11 – Keele & Steeles – Process Narrative in this

addendum

Section T-13400-14 – McCowan & Steeles – WTR-316-CH-0006 –PCN

with Section T-13400-14 – McCowan & Steeles – Process Narrative in

this addendum

Section T-13400-15 – Islington & Steeles – WTR-300-CH-0011 –PCN

with Section T-13400-15 – Islington & Steeles – Process Narrative; in the

attachment

Section T-13400-16 – Adesso & Steeles – WTR-307-CH-0016 –PCN with

Section T-13400-16 – Adesso & Steeles – Process Narrative in this

addendum

Section T-13510 – Process Control System (PCS) Local Area Network

(LAN) with Section T-13510 – Process Control System (PCS) Local Area

Network (LAN) in this addendum

Section T-16010 – Electrical General Requirements with Section T-16010

– Electrical General Requirements in this addendum

3 of 183

b. Replace following Drawings in its entirety:

Drawing 308M-2016-18 Rev 3 with 308M-2016-18 Rev 4; in the

attachment


attachment


attachment


attachment

Drawing PBV-2016-7 Rev 6 with PBV-2016-7 Rev 7; in the

attachment

Drawing PBV-2016-10 Rev 6 with PBV-2016-10 Rev 7; in the

attachment

Drawing 229M-2016-4 Rev 6 with Drawing 229M-2016-4 Rev 7; in the

attachment

Drawing 229M-2016-11 Rev 3 with Drawing 229M-2016-11 Rev 4; in

the attachment

Drawing 30P-2016-7 Rev 6 with Drawing 30P-2016-7 Rev 7; in the

attachment


attachment


attachment


attachment


attachment


attachment


attachment

IV. QUESTIONS AND ANSWERS

Q1: The following information is required to complete the Victaulic ring check

sheet.

Line working pressure.

Line test pressure.

Type of ring required.

Is the existing piping lined or unlined?

What is the existing Pipe wall thickness?

A1. Line working pressure : Not available.

Line test pressure : 1200 kPa (174 psi)

4 of 183

Type of ring required : Type D for line sizes 750mm and greater. Type E for line

sizes less than 750mm.

Is the existing piping lined or unlined? Lined

What is the existing Pipe wall thickness? Contractor to confirm.

Q2: The following information is required for the Victaulic couplings.

Finish of coupling.

Gasket material.

Hardware material.

A2: Finish of coupling: Liquid Epoxy Coating compliant with AWWA C210

Gasket material: EPDM

Hardware material: Stainless Steel

Q3: Drawing 30P-2016-17 (I13) – Bill of materials for chambers 6&9 – York PAC

Panel, the 6 channel analog output card is obsolete (item 57). Please provide

a part number.

A3: Refer to attached drawing 30P-2016-17, Rev 7.

Q4: Drawings 28P-2016-11, 229M-2016-11 – Bill of materials item #17 is blank

and should be the outdoor enclosure. Can the item description and part

number be provided?

A4: Refer to attached drawing 28P-2016-11 Rev. 4 and 229M-2016-11, Rev. 4.

Q5: Drawings PBV-2016-9, PBV-2016-10, custom outdoor enclosure, Item 17 on

BOM. Drawing shows 36” wide enclosure, BOM has dimension of 72”.

Which is correct?

A5: Refer to attached drawing PBV-2016-9, Rev. 7.

Q6: Item #84 on all York chamber enclosure bill of materials is showing a ‘HF

SURGE SUPPRESSOR’. Can a part number and manufacture be provided?

A6: Refer to Drawings:

308M-2016-31 – Typical Drawing – Chamber 2,4,5,7,8,11,14,15&16 –

York PAC Panel Bill of Materials

229M-2016-11 – Chamber No. 3 – Keele St / Steeles Ave W– York PAC

Panel Bill of Materials

28P-2016-11 – Chamber No. 10 – Chamber No.10 -Thornhill Pumping

Station and Chamber - York PAC Panel Bill of Materials

Refer to item 84 in the Bill of materials.

Under the “Part Number” column:

Add: “DT-NFF”

5 of 183

Under the “Manufacturer” column:

Add: “POLYPHASER”

Q7: There are no drawings for chambers 12 & 13.

A7: There are no chamber 12 or chamber 13. The number 12 & 13 refer to

flowmeter 12 and 13 in a list of 16 flowmeters to be replaced. These two

flowmeters are located inside Milliken pumping station but they are not located

inside of any chamber.

Q8: Section 4 of the specifications describes items supplied by the City of

Toronto/York Region. COT is supplying flow meters for chambers 6, 9 & 10

and York Region is supplying a flow meter for chamber 1. Division 13

specifications are describing other items free issued as well. See below for

details and please provide an updated instrument list/free issued equipment

list.

Chamber 1 – flow tube and transmitter free issued.

Chamber 6 – only flow tube free issued, transmitter required.








A8: Refer to Civil drawings, P&IDs and Specifications for details on free issued,

existing and new instrumentation and required hardware. Information provided in

contract documents is accurate. Below is the summary of free-issued items:

Chamber No.

Flow Tube

(Free Issued)

Transmitter

(Free Issued)

1 Yes Yes

2 No

No

3 No

4 No

5 No

6 Yes

7 No

8 No

9 Yes

10 Yes

11 No

12 No

13 No

14 No

15 No

16 No

6 of 183

Note: Chambers No. 12 to 16 do not require flow tube upgrades. All Chambers

require transmitter upgrades.

Q9: Will there be separate Software and Panel FATs?

A9: Correct. Separate software and panel FATs shall be held.

Q10: Will documentation be duplicated for both Toronto and York Region?

A10: Provide two (2) complete sets of documentation for both City of Toronto and

York Region.

Q11: Will RFIs have to be answered by both Toronto and York Region?

A11: RFI will be coordinated and answered by contract administrator.

Q12: Will a single Consultant be chosen for Toronto and York Region?

A12: Yes

Q13: Will there be a single PM representative for Toronto and York Region?

A13: Yes

Q14: Will Toronto take the lead on this project?

A14: Yes

Q15: Given the simplicity and uniformity of these stations can the software and

panel FAT work be limited to 2 or 3 locations?

A15: Software and Panel FAT to be completed for each site.

Q16: Will the meetings be required after the first unique stations are completed?

A16: Meetings will be required as per Section 4A-11.

Q17: In regards to some of the analog I/O that was requested, the 1756 OF6CI (6-

channel isolated analog output module) is obsolete, and no longer being sold

by Rockwell. As a substitute, Rockwell recommends the 8 channel versions of

that card.

A17: Refer to Q3, A3 of this Addendum.

Q18: I have received several request from the supplier requesting the City of

Toronto list of approved manufactures for section 13158.1 Float Switch,

13160 Pressure Transmitter & Section 13169 Pressure Indicating Gauge.

7 of 183

A18: For section T-13158.1 - Float switch,

Refer to Section 2.4 “Approved Manufacturers”

Delete: “.1 Refer to list of approved manufactures by the city of Toronto”

Replace with:

.1 Xylem (Flygt)

.2 Magnetrol

.3 TM-Techmark Corporation

.4 Kobold

.5 Schneider Electric (Foxboro)

Refer to Section T-13160 - Pressure Transmitter attached in Addendum 6 for

Section T-13160 - Pressure Transmitter.

Refer to Section T-13169 - Pressure Gauge attached in Addendum 6 for Section

T-13169 - Pressure Indicating Gauge.

Q19: Addendum 5 – page 9-11 of 25 regarding item 28 Training. Please confirm

the training is per site

A19: Training is per site as indicated on Page 4A-52 (Addm-5) to 4A-54 (Addm-5)

Should you have any questions regarding this addendum contact Kristijan Milevski, Senior

Corporate Buyer by email at [email protected]

Please attach this addendum to your Request for Tender document and be governed accordingly.

Bidders must acknowledge receipt of all Addenda on the space provided on the Tender Call

Cover Page as per the Process Terms and Conditions, Section 1, Item 8 - Addenda, of the Tender

Call document. All other aspects of the Tender remain the same.

Yours truly,

Joanne Kehoe,

Manager, Construction Services

Purchasing and Materials Management

8 of 183

SECTION 4A – Additional Special Specifications

Tender Call No. 341-2016 Contract No. 16ECS-LU-03TT

Specification Division 13 Special Construction

Process Control - General

SECTION T-13010 – PAGE 1 OF 22 (Addm-6)

SECTION T-13010 – PROCESS CONTROL - GENERAL

PART 1 GENERAL

1.1 INTENT

.1 This Section contains General and Specific Requirements for process control and instrumentation for the Toronto Flow meter Replacement Project.

.2 Division 13 Section numbering nomenclature is as follows:

.1 All Division 13 Sections numbered with a “T-13XXX” shall refer to City of

Toronto Division 13 Sections.

.2 All Division 13 Sections numbered with a “Y-13XXX” shall refer to York

Region Division 13 Sections.

.3 City of Toronto Division 13 applies to the Toronto RPU panel and all Toronto SCADA programming.

.4 York Region Division 13 applies to the York Region PAC panel and all York PAC SCADA programming.

.5 These general requirements apply to all Toronto works to be performed at the facilities.

1.2 REFERENCES

.1 Comply with the requirements of Section 4A. Be responsible for all the requirements of this Section and of Section 4A. No additional cost will be considered for non-coordination between this Section and the other Sections in the Specification.

.2 Refer Division 16 for instructions that apply to the Work of Section T-13010.

.3 Refer to the Owner’s Process Control System (PCS) Implementation Guidelines (Version #3, December 30th, 2015).

.4 Refer to all sections in Division 13 specificatations for guidelines and instructions that aply to the work of section T-13010.

.5 Refer to the Owner’s Process Control Systems (PCS) Implementation Guidelines Version #3, December 30th, 2015) (Prior to commencing the development of the program, obtain the most up to date version from the Owner).

.6 Have the material, equipment, installation and workmanship also meet the latest edition and requirements of the following:

.1 Ontario Electrical Safety Code

.2 Canadian Standards Association (CSA)

.3 Canadian Electrical Manufacturers Association (CEMA)

9 of 183






.4 Institute of Electrical and Electronics Engineers (IEEE)

.5 National Electrical Manufacturers Association (NEMA)

.6 Electrical and Electronic Manufacturers Association of Canada (EEMAC)

.7 International Society for Measurement and Control (Formerly the Instrument Society of America, ISA)

.8 Electronic Industries Association / Telecommunications Industries Association (EIA/TIA 606)

.9 Underwriters Laboratory, (UL): 508, Standards for Safety, Industrial Control Equipment

1.3 SCOPE OF WORK

.1 The general requirements for the supply and installation of all process control equipment as specified herein and as shown in the drawings are covered in this section.

.2 Comply with the requirements of Section 4A

.3 Refer to Division 13, Section 4A and Division 16 Electrical for additional requirements.

.4 Refer to the Contract Drawings to ensure completeness of installation for all items and that these items are compatible with the control and operational intent of the design of this project.

.5 Without limitation to the following sections of this division, the equipment supplied shall be complete with all accessory items, whether specifically mentioned or not, so as to provide completeness of installation, controls and operation as intended. All equipment installation shall be as recommended by the equipment manufacturer or as described in the installation drawing. Contractor shall calibrate all instrumentation whether new or reused, by manufacturer certified technicians . Refer to Section T - 13105.

.6 Process control equipment and wiring as specified, or as shown on the drawings, are sized for the process, electrical and mechanical equipment as specified, or as may be necessary in the future. Any additional expense incurred because of approved substituted process control equipment from that specified shall be borne by the Contractor.

.7 Provide all necessary equipment, tools, labour, etc., for installing and testing all equipment supplied under this Division.

.8 Modify and/or remove existing equipment as shown on the Contract Drawings.

.9 Refer to T-13010A for Process Control System (PCS) Implementation Guidelines including programming and FAT and SAT requirements.

.10 Refer to Contract Documents for detailed design requirements and Bill of Materials.

10 of 183






.11 Locations of instrumentation provided in contract documents are approximate. Final instrument location and installation shall be coordinated with site inspector or engineer. Contractor shall install instrumentation to best fit the application.

.12 The successful system integrator shall possess software licences for all programming, testing, simulation (PICS Pro and SIM Magic) and commissioning purposes. All RPU/SCADA programming work to be by an approved “Project Instrumentation System

Integrator” as defined in the Section 1.8.

.13 Contractor and System Integrator shall coordinate with plant operation to develop and submit a Transition Plan or Work Plan for Plant Operation and PCS Staff to review and approve before starting the work of RPU/SCADA upgrades, in terms of shutdown items, dates, duration, temporary monitoring, and operation methods.

.14 For the SCADA System; develop new process graphics, sub-pictures, devices sub-pictures, setpoints, trends, alarm pages, run-hour graphics, HMI database and menus, as required by the scope of work. Comply with the Owner’s SCADA Standards for software development as specified in the Owner’s Process Control System (PCS) Guidelines using Owner’s standard modules.

.15 All Magnetic flowmeters (New and existing) shall undergo a verification test performed with the self-monitoring function to check the measuring device functionality. Test shall confirm original factory calibration is still valid and proper condition of the components.

.16 All Magnetic flowmeters (new, existing and issued by the City/York Region) shall be installed, and commissioned by the contractor.

.17 Provide additional Corrosion Protection coating (for additional touch ups) for every new magnetic flowmeter installed. Additional paint shall be provided by the flowmeter manufacturer, and shall be handed to the City.

.18 Systems Integrator Scope of Work

.1 Modify, update, test and commission the SCADA servers located at High Level Pumping Station and John st Pumping Station.

.2 Complete all PLC and SCADA programming as required in the Contract Documents.

.3 Programming shall comply with Toronto PCS standard programming templates. Systems Integrator with approval from the Engineer shall modify the standard PCS modules to suit and accommodate all tagging and functionality required by the Contract Documents.

.4 Existing GE iFix screens shall be modified to suit requirements shown on the Contract Documents.

.5 Re-configure the existing GE iFix tag database for the existing tags that are being modified. Configure existing tags to communicate with the new GE Rx3i RPU utilizing new I/O driver (IGS or GE9).

11 of 183






.6 Complete all PCS documentation to show all SCADA tags being added and removed, all SCADA tags being recorded by Historian.

.7 Host three separate alarm conditioning workshops with the City and Engineer to review alarm conditioning and prioritization. All alarm conditioning details shall be finalized and documented in the final PCN. Confiure and test PA system (WIN911) based on finalized alarm prioritarization results.

.8 The SCADA System Integrator is responsible for creating the final Process Control Narrative from the tender documents.

.9 The SCADA System Integrator shall maintain and keep updated Process Control Narratives during development and construction.

.10 Perform all Factory Acceptance Testing (FAT) in accordance with – T -13010.C – PCS Implementation Guidelines – PCS Factory Acceptance Testing.

.11 Perform all Site Acceptance Testing and commissioning in accordance with 13010.D -PCS Site Acceptance Testing and Commissioning.

1.4 GENERAL REQUIREMENTS

.1 Supply electricians to support all testing, commissioning and acceptance testing requirements for this Contract.

.2 Provide all supplies used during and prior to acceptance of equipment. In addition, provide an estimated one year’s supply of materials necessary for normal operation and

scheduled maintenance of all equipment.

.1 Supplies shall be furnished in the original sealed containers, correctly identified as to brand and grade, and with reference to the particular piece of equipment for which it is intended.

.2 Please see the individual equipment specifications for details on required supplies.

.3 The equipment specified shall generally be an "all electronic" control system, with 4-20mADC linear outputs from all instruments, unless otherwise noted. Equipment shall be suitable for 120 VAC, 60 Hz, single phase operation, or 24 VDC operation as shown on the drawings.

.4 Transmitting equipment shall generally be based on the force balance principle with minimum movement of any part and having receiving and control equipment compatible with the transmitting equipment. All equipment shall have a demonstratively good maintenance record.

.5 Supply and install all required current isolators, signal conditioners, etc., which may or may not be shown, but which are required for the entire control and instrumentation system to operate as intended.

12 of 183






.6 The entire system has been designed for operation on standby power. All instrument components shall have ample margin to withstand transient and other surge voltages which may occur, including transient periods under change over conditions.

.7 All equipment mounted outdoors shall be installed in NEMA 4X enclosures, with heaters, and be suitable for operating in temperatures from -30 to +50°C.

.8 All instrument local indicators shall be in metric engineering units unless specified otherwise.

.9 All instruments requiring wet taps shall be installed plumb such that all wetted parts are below the elevation of the lowest pipe wall tap. All process connections shall be 25 mm NPT - female, with pressure instruments to 25 mm, NPT male.

.10 All panels and instruments shall be complete with factory applied finishes. Repaint all damaged factory applied finishes.

.11 All panels installed outdoors and exposed to the public shall have the exposed surface coated with an anti-graffiti coating.

.12 Commissioning and Training

.1 Comply with the requirements set out in Section 4A.

.2 Demonstrate loop checks for the I/O identified by this scope of work. Before requesting witnessed loop checks, carry out Contractor’s own field and loop check tests to verify that the equipment operates as intended. Correct any problems or deficiencies prior to requesting witnessed checks.

.3 On site loop check must exercise the entire loop, including the field equipment and SCADA screens. Each loop check must be witnessed by, and successfully demonstrated to the Consultant for sign-off approval.

.4 Provide testing and commissioning services including those associated with installing and testing software prepared by System Integrator. Assign qualified staff when System Integrator requires it during RPU and SCADA software testing. Allow in the Contract Price, for any additional time deemed necessary to meet the testing and commission requirements.

.5 Provide Factory Acceptance Test (FAT) to demonstrate the operational functionality of PLCs, SCADA hardware, software and communications. Notify the Consultant ten (10) days in advance of FAT such that this test may be witnessed by the appropriate parties. Submit test report after the test duly signed by the Consultant and Contractor. Use only pre-approved test format. Comply with the Process Control System Implementation Manual for FAT requirements.

.6 Provide Site Acceptance Test (SAT) to demonstrate the correct operation of control system with both hardware and software in place. Provide site support services upon request by System Integrator during system SAT. Notify the Consultant ten (10) days in advance of SAT such that this test may be witnessed by the appropriate parties. Submit filled in test forms after commissioning.

13 of 183






Comply with the Process Control System (PCS) Implementation Guidelines for SAT requirements.

.7 Coordinate closely with the Consultant and System Integrator when carrying out all work to demonstrate overall system integrity, allowing sufficient time for the essential portions of SCADA and PLC software to be installed and tested.

.8 Maintain record drawings (As-Builts) for all drawings.

.9 Provide testing and verification services for all Network equipment as per the Owner’s ITM standards and requirements.

.10 General

a. Ensure the continuous operation of the existing systems and equipments.

b. At all times, ensure that work being carried out by the Consultant or the Owner’s operational staff is properly coordinated with all ongoing construction activities and are unhampered by unnecessary delays or obstructions.

c. Demonstrate operational systems and put all equipment into operational services to the satisfaction of the Consultant. Satisfactory performance of the system shall be assessed on the basis of the entire control system being fully operational conditions during the process run. Refer to Section 4A General Requirements for testing, start-up and commissioning requirements.

d. Provide documentation in timely manner and as specified.

e. Provide all the necessary power supplies, signal conditioners, terminal blocks, and all other accessories as required to make a complete working system for the various monitoring and control loops. Provide all the necessary relays, signal isolators, to realize the intent of the design.

1.5 RELATED WORK SPECIFIED IN OTHER SECTIONS

.1 Section 4A General Requirements

.2 Division 16 Electrical

1.6 SUBMITTALS

.1 Submittal to be in accordance with the Section 4A – Submittals and section T-13105.

.2 Shop drawings must be submitted and reviewed for all equipment in Division 13, before ordering or fabrication.

.3 Drawing Index: Prepare a clear, typed index listing the number and title of all proposed Purpose-made drawings and submit for review within fourteen (14) days after award of contract

14 of 183






.4 Milestone Schedule: Prepare and submit a proposed schedule of instrumentation and control work per General Conditions, indicating the following major milestones as a minimum.

.1 Hardware shop drawings submission – including initial issue of Product Data Sheets;

.2 Preliminary issue of operating and maintenance instruction manual;

.3 Panel inspection and factory acceptance testing (FAT);

.4 Signed calibration sheet or report on each field instrument;

.5 Report on proper site installation, inspection, and loop checks;

.6 Final submission and sign-off of Product Data Sheets;

.7 Site Acceptance Testing (SAT);

.8 Maintenance training sessions on field instruments.

.5 Unless otherwise specified or indicated, submit detail design drawings, shop drawings, specifications sheets or product data sheets for all instruments, devices, junction and terminal boxes. All dimensions, rating, curves, etc. to be in SI units.

.6 Product Data Sheets

.1 Product Data Sheets specifying instruments and equipment form part of this document. Complete the blank spaces on these sheets with the information noted below and any other data pertinent to the equipment and the application.

.2 Initial submission for review to accompany Shop Drawings:

a. The product manufacturer and the supplier or representative;

b. The complete model or catalogue number(s) including any special options;

c. The available adjustment range(s) and the project operating range(s).

.3 Second Submission during pre-commissioning, testing and calibration period:

a. Serial numbers, part numbers, dates of installation and calibration;

b. Any special procedures required to duplicate calibration;

c. This submission is for signature by the Contractor and the Consultant following acceptance of the operation of each instrument.

.4 Final Submission of signed-off Product Data Sheets included with Operating and Maintenance Instruction Manuals:

15 of 183






a. All of the above information; and;

b. Phone and fax numbers of contact person for product support/service.

.5 Where there is any discrepancy, the description provided on the Product Data Sheet takes precedence over the model number given in the data sheet.

.7 Purpose-made Drawings

.1 Prepare Purpose-made drawings neatly and accurately by means of Micro-Station V8 or as otherwise advised. Do not use external references or customized file extensions. Provide fully portable electronic AutoCAD file copies of all P&IDs, network architecture, RPU, and loop drawings.

.2 No typical drawings are acceptable for “As-Built” drawings.

.3 Make submissions on reproducible material such as Mylar, Vellum or legal-size paper, complete with a title block containing the Consultant’s E.O. number, your project number and company logo, a drawing and project title as stated in the Contract drawings, and a referenced drawing number (related to a file name if applicable). Provide tabular columns to record the original submission date, a revision number, date and reason for subsequent revisions, and signature of authorized issuing staff member.

.4 Submit, as a minimum, the following Purpose-made drawings:

a. Scaled, referenced, front of panel layouts, and general arrangement drawings;

b. Scaled, referenced, internal panel layouts (may be combined with the above);

c. Equipment and/or panel block wiring diagrams showing termination identification at each item of equipment, inter-wiring and cable numbering, all peripheral equipment, any RPU module DIP switch settings, pin assignments for D-shell connectors, plugs and jacks, and instrument/equipment tag numbers;

d. Submit, prior to the installation or fabrication of the instruments and panels, complete loop wiring diagrams showing all the wiring between instruments and devices;

e. Submit, prior to installation, layout drawings of each Control Panel showing construction details, materials and construction, bill of materials, location of instruments and devices, dimensions, etc.;

16 of 183






f. Where issued, loop drawings are typical for guidance only. Submit itemized instrument wiring arm drawings for all analog process loops and discrete connections, generally in accordance with ISA S5.4 format and as a minimum incorporating the following details: RTU terminal numbers, Control Cabinet terminal numbers, field terminal numbers, wire numbers, contact orientation, power source identifications and equipment numbers. The “Micro-Station” files for these drawings are to

be edited with “Record Drawing” detail and made accessible to the

Consultant during the Upgrades;

g. List of expendable materials and quantities;

h. List of Instrument, Equipment and Panel Identification Nameplates.

.8 For PLC and HMI programming, submit shop drawings as required by the Process

Control System (PCS) Implementation Guideline standards.

.9 Submission Format

.1 A complete set of Purpose-made Drawings, Shop Drawings, and the initial submission of the Product Data Sheets shall be bound into one volume and issued for approval before the commencement of work.

.10 Shop drawings shall include product datasheets of all the listed/selected materials or equipment.

1.7 OPERATING AND MAINTENANCE MANUALS

.1 In addition to requirements for operating and maintenance instruction manuals specified in earlier sections, include the following;

.1 Manufacturer’s hardware and distribution software manuals;

.2 Special instructions or procedures, including system, software and instrument trouble-shooting techniques;

.3 Systematic procedures for operations personnel to start up, shut-down, manually override and locally operate all related equipment in accordingly titled manual sections;

.4 Recommendations on equipment maintenance and suggested spare parts;

.5 Final Shop Drawings and signed-off Product Data Sheets as defined in this Specification;

.6 Copies of Record drawings of all Purpose-made Drawings;

.7 Name, address(s) and telephone number(s) for local qualified system and/or product service representatives; and,

17 of 183






.8 Calibration certificates from the manufacturers for each calibrated instrument.

.9 Updated SCADA manuals.

.2 Provide operating and maintenance instruction manual for Instrumentation & Controls in a separate indexed and tabbed manual, or separate indexed and tabbed section of the overall manual binder. Arrange sections in a logical, concise manner, and provide a cross- reference to enable all equipment/instruments to be located from its correct equipment tag.

.3 Prior to submission of final operating and maintenance instruction manuals, and at least thirty days prior to instrumentation and control system testing and commissioning commencing, submit to and review with the Consultant, two copies of the proposed data for the instrumentation and control work Section of the operating and maintenance instruction manuals.

.4 The delivery of manuals must be complete prior to application for a Certificate of Substantial Performance of the Work.

1.8 PROJECT SYSTEMS INTEGRATOR QUALIFICATIONS

.1 The work described in this section to be performed by one of the following system integrators:

.1 IBI Group

.2 Eramosa Engineering Inc.

.3 Hatch Mott MacDonald Ltd.

.4 CH2M Hill Canada Ltd.

.5 AECOM Canada

.6 Summa Engineering

.7 RTS

.2 Contractor shall Supervise and include the work of the following Sections with this Section and Guidelines:

.1 Section T-13400 – Remote Processing Units

.2 Section T-13510 – Process Control System (PCS) Local Area Network

.3 Section T-13520 – Wide Area Network (WAN)

.4 Section T-13600 – SCADA Computer System

.5 Section T-13010A – PCS Imlementation Guidelines – Integrated, Appendix C

18 of 183






PART 2 PRODUCTS

2.1 INSTRUMENT PANEL REQUIREMENTS

.1 In addition to specific panel requirements set out in the Sections T- 13310, 13320, 13325, 13330, and T-13340 for control panels and enclosures include:

.1 Supply power to field instruments from the RPU panel’s UPS backed power supply. Protect each instrument power circuit with a panel mounted terminal block type circuit breaker sized to suit. All communication devices to be powered by UPS power from the RPU panel.

.2 The UPS must provide filtered power to the instrumentation power supply and be able to be easily by-passed (using selector switch) to line power and disconnected by three prong plug (not hardwired) for easy of removal.

.3 Provide all EEMAC 4 (or NEMA 4) outdoor panels in 316 stainless steel. Field junction boxes are to be EEMAC 4X (or NEMA 4X). Indoor panels shall be EEMAC 12 (or NEMA 12) for dry and non-corrosive locations and EEMAC 4X (or NEMA 4X) for wet and corrosive locations.

.4 Provide lamicoid nameplates for all equipment, both door mounted and panel mounted.

.5 Provide all wall-mounted panels with 50 mm stainless steel spacers and incoming field cables.

.6 Do not allow panel floor mounted equipment (i.e. UPS) to block access to the panel back plane mounted equipment.

.7 Provide surge suppressers to protect process instrumentation against damage due to electrical transients induced in interconnecting lines by lightning and nearby electrical systems.

2.2 CONTROL PROCESSORS – RPU

.1 All control processors must comply with the Process Control System Implementation

Manual. Refer the following:

.1 T-13400 – Programmable Logic Controllers

.2 Provide all cables, line extenders and connection devices required for the connection of the system and for connection of any associated programming or operator interface devices. Provide double insulated cables unless otherwise specified. Select and provide connectors with electrical contact surfaces gold-plated, and D-shell connectors with metal or metalized plastic (shielded type) hoods.

.3 Provide a written confirmation from the manufacturer of each product stating that it is a current product and that it will be supported (spare parts, software drivers, service, etc.) for a period of not less than 5 years from the date of purchase. Submit confirmation with Shop Drawings.

19 of 183






.4 Provide FAT to demonstrate the operational functionality of PLC and SCADA hardware and communication by using simulation software, PICS Pro and SIM Magic. Notify the Consultant ten days in advance of FAT such that this test may be witnessed by the appropriate parties.

.5 Provide all software associated with the controllers licensed in Owner’s name, on original storage media in original storage packaging.

.6 Load and test the dummy program before delivery.

2.3 PROGRAMMING REQUIREMENTS

.1 The Project Instrumentation Systems Integrator shall use their own development software and license to produce the required control system programs. No development software is required to be provided by the Owner. The programming software shall match all times with the software required by the most recent Owner’s standard. Consult with the Owner for current programming version being used at the existing facility.

.2 All programming efforts to conform to the Process Control System Implementation Manual including Factory Acceptance Tests, Site Acceptance Tests, training and upgrading of operation and maintenance manuals. Refer and follow the Owner’s Process Control System (PCS) Implementation Guidelines and Appendices.

.3 The system integrator shall develop all required PLC logic to monitor the system at each facility and provide usefull information to operarations about the system and equipment. The System Intgrator shall use the base program with standard modules for the monitoring controlling, integration and communication of the system. Additional logic and calculations are required outside the modules in order to continuously monitor total flowrates at each facility.

.4 Develop new or modify existing iFIX SCADA Screens to monitor each facility. Update navigation screens, alarm and trend screens, pup up and setpoint screens. Develop the SCADA tag database, update existing OITs, configure OPC drivers, paging system (Win 911) and historian complying with the PCS implementation Guidelines.

.5 Program all hardwired signals shown in the contract drawings as well as all required soft signals generated in the PLC logic complying with city of Toronto tagging standards.

.6 Refer to Section 4A - Summary of Work for the details of specific requirements for the

programming under this Contract.

2.4 TERMINAL BLOCKS

.1 Refer Section T -13320 - Panel Wiring for terminal blocks specifications.

2.5 WIRE AND CABLE

.1 Refer Sections T- 13305 - Field Wiring for field and Section T-13320 - Panel Wiring for panel wiring.

20 of 183






.2 All wire and cable must be sized and installed in accordance with the H.E.P.C. Safety Code Requirements. No control wire smaller than # 14 gauge shall be used except where so indicated on the drawings or as specified in other Sections.

.3 Supply shielded cables in conduit as follows:

.1 Supply single pair shielded cables with 600 volt insulation; No. 16 AWG twisted stranded copper, equal to Belden 1118A.

.2 Supply multi-paired shielded cables individually shielded, complete with overall shield, No. 18 AWG, 600 volt insulation, equal to Belden 1051.

.3 Supply RS 485 two pair low capacitance shielded cables with 300 volt insulation; No. 22 AWG twisted stranded copper conductors, equal to Belden 3107A.

.4 Provide Teck armoured equivalents of the above cables for cable tray applications.

.4 Provide all concrete coring between floors as required.

.5 Provide adequate slack on cable harnesses to permit easy removal of I/O and other printed circuit cards and/or modules and instruments during service or repair.

.6 All feeders shall be run in continuous lengths between power supply point and the load with no splices.

.7 All wiring for signal system shall be identified as to circuit numbers with approved markers on the cables at all panels and terminal strips. Where hand written markers are necessary, use the manufacturer’s recommended indelible marker pen. Printing must be neat, capital alpha characters.

2.6 WIRING IDENTIFICATION

.1 Refer Sections T- 13305 - Field Wiring for field and T- 13320 - Panel Wiring for panel wiring.

.2 All instrumentation and control wiring is to be identified with markers as specified. The identification is to consist of the coding as detailed on the drawings and as specified herein.

.3 Tag field wires with the field device tag and terminal information:

.1 For devices connected to control panels or RPUs, show field source and destination information.

.2 For devices connected to other panels (e.g. switchgear) show field source information.

.3 Label wires at both ends with the same information.

21 of 183






.4 Wire number should not change unless there is a function change in the wire run i.e. a fuse, a relay, etc. Wires passing through a junction box without a change in function would retain the same wire number.

.5 Generally, keep the wire tag to 18 characters or less. For longer tags, use smaller font.

.4 Field source information consists of the following:

.1 In most cases, the device type (up to 4 characters) and loop number (up to five characters) make up the device tag information needed on the labels.

.5 The destination information consists of the following:

.1 Use the rack, slot and point information for RPUs and termination strip and terminal number for control panels.

.2 Inside an RPU panel, the wires and terminals are numbered by rack, slot and point/terminal.

.6 Termination Strip Numbering

.1 The RPU number (if more than one RPU in the panel), Rack and Slot information should be on a separate tag at the top of the respective terminal strip. The terminal strip would just need the terminal number.

.2 Terminal numbers may be sequential with interspersed shields.

.3 The module termination numbers need to be specific; for example GE analog input cards use Term-5 for Channel-3.

.7 Cable Numbers

.1 Field cables should be tagged with the field device tag information at both ends.

.2 Where cables carry wires from multiple field devices, the cable tag should use the device tag of the junction box.

.3 For cables tags, use P or C or I added to the device tag for Power, Control and Instrument respectively as some devices such as valves have all three cables.

.4 Cable numbering should show the Junction Box relevant numbers in that a cable runs to a JB, but the wiring itself would not have such designation.

.5 For example, in the case of a Cable from a Junction Box to an RPU, assign a unique "loop/device number" to the Junction Box and treat it as a Device.

.6 A Cable schedule will be provided showing Cable I.D., Cable Type, Origin, and Destination.

.8 Wire Markers

22 of 183






.1 Wire markers available from Brady amongst others allow more than one line of characters if required but one line should be used if possible.

.2 Wire markers should be kept to a minimum for ease of installation and readability. A single line of text should be used, minimizing the characters as much as possible.

.9 Use colour codes wires in communication cables, matched throughout system.

.10 Maintain phase sequence and colour coding throughout.

PART 3 EXECUTION

3.1 COORDINATION

.1 Carefully examine and monitor for compatibility, any instrumentation and control work provided as part of the Work of Sections of the Specification other than the Sections governed by this Section, or the Owner, and ensure that all trades involved are aware of any coordination problems or details.

.2 Incompatible work, such as instrument process connections, mounting of equipment, analog, discrete or communication wiring, voltages, or inconsistencies resulting from insufficient coordination of other related work, is to be satisfactorily resolved at no additional cost to the Contract.

.3 When scheduling site inspection, FAT, commissioning, or SAT with the Consultant, allow at least 10 working days advance notice.

.4 Coordinate with all programming and on-site actions with the instrument manufacturer, and panel shop technician. The system integrator shall attend facility I/O checks and pre-SAT sessions..

3.2 MANUFACTURER’S SERVICES AND INSTALLATION CERTIFICATION

.1 Comply with the requirements of the Section 4A - Commissioning.

.2 Allow in the tender for all the necessary services and expenses of a trained, qualified manufacturer’s representative for each device as specified in the specification, to ensure correctness of installation, testing, start-up, commissioning and training. The qualified representative is to:

.1 Provide onsite supervision of installation for the initial and critical stages of the work as agreed to with the manufacturer/supplier and as required by the Consultant.

.2 Supervise testing and calibration of equipment. Supervise retesting and recalibration of equipment at no additional cost to the Owner.

.3 Provide written certification stating that the work has been completed satisfactorily.

23 of 183






.4 Provide a complete Installation, Start-up Checklist and sign off on the start-up work completed.

.5 Provide operation and maintenance instruction to the Owner’s operating staff.

.3 Provide supervision of installation as required by the manufacturers for all equipment in this Division. The Owner/Consultant may order additional supervision at no cost to the Owner if, in their opinion, installation procedures are compromised.

.4 Provide all materials, labour and equipment to make any adjustments to the installation as required by the manufacturer or the Consultant to effect performance.

.5 On completion of installation and testing, obtain certification from the manufacturers that the equipment is installed correctly, is in full operating condition, and is operating in accordance with its design rating. Submit the original certificate to the Consultant.

.6 Include the service of the trained personnel to inspect and commission the equipment when ready for starting and to instruct the operating personnel in the operation and maintenance of the equipment. Time spent on site by the trained personnel must be witnessed by the Consultant.

.7 As a minimum requirement, allow for in the lump sum Tender Price, the following days for the service of a manufacturer’s representative. Not all days will necessarily be concurrent. If additional days are required to complete the work, include these additional days and trips in the Tender Price.

.1 RPU/PLC Panel 2 days

.2 Equipment not mentioned ½ day

3.3 PANEL INSPECTION AND FACTORY ACCEPTANCE TESTING (FAT)

.1 Panel inspection and FAT testing shall follow the Process Control System

(PCS)Implementation Guidelines. The System Integrator and Manufacturer shall use the Form “FAT and SAT Check Sheets” for the FAT, fill up the form with all the testing items and submit to Consultant and Owner for review prior the FAT. See Supplement documents.

.2 Make all necessary arrangements with equipment supplier(s) for panel inspection and FAT prior to delivery.

.3 Schedule the FAT session(s) with the Consultant a minimum of ten (10) working days in advance. Allot enough time for through testing and corrections to take place.

.4 Configure the RPU and workstation with a suitable “dummy” or shell program, establish

communication, temporarily wire digital inputs to test switches and digital outputs to indicating lights, analog inputs to 4-20mA generators and analog outputs to panel meters to demonstrate functionality of all hardware and software. Exercise the hardware (i.e. I/O, communications, panel mounted instruments, etc.) with appropriate software in place to demonstrate/monitor operation of all connected equipment and wiring.

24 of 183






.5 All basic functions shall be demonstrated, including I/O processing, communications, alarm handling, OIT display functions, alarm logging, as well as the specific functions listed herein. This operational test may run concurrently with the demonstration of hardware and software functions.

.6 Make the necessary corrections as indicated by the tests, or as directed by the Consultant. Shipment of equipment to site is contingent on the Consultant’s approval.

3.4 GENERAL INSTALLATION REQUIREMENTS

.1 Provide all necessary installation detail drawings and sufficient supervision to ensure that the installation of the instrument and the control system components is done to the satisfaction of the Consultant as work progresses.

.2 Provide all necessary adjusting, field calibration, testing and check-out of all equipment and control loops. After loop check-out, submit written test results to the Consultant. All instrument calibration procedures to be witnessed by the Consultant.

.3 Supply any materials and/or test facilities necessary for commissioning. The use of the Owner’s facilities, if suitable, may be considered upon written request.

.4 All tag labeling of the existing wiring to be maintained, and be consistent with the current Owner’s tagging standard. Refer T- 13040 Equipment Tag Standard Doc’s #72700.

.5 Field measure lengths for cables, and similar items prior to ordering. Mechanically protect cables and adequately secure in place without sagging.

.6 Install the instrumentation and auxiliary devices such that they are accessible for operation and maintenance.

.7 When installing conduit entry, protect internally mounted equipment from vibration, shock and metal filings. Conduit entries must maintain the equipment or panel EEMAC rating.

.8 Advise the Consultant in sufficient time to avoid delays to the Project of any perceived problems regarding implementation of installation details or standard practices for the particular application or if any requirements of this Specification, or a drawing detail, contradicts the equipment manufacturer’s instructions or recommendations in a manner, which could be detrimental to its operation, including the possibility of inducing adverse side effects elsewhere.

.9 Prior to the shutdown of any operating equipment, provide a written notice 48 hours in advance to the Owner/Consultant. Shut down of equipment is limited to a length of time determined by the Owner. Make all arrangements to minimize down time.

3.5 INSTALLING CONTROL EQUIPMENT

.1 Install, test, program, and commission controllers in accordance with the requirements of this specification, drawing for construction, and any special details as they apply. Where installation details are not indicated, conform to the manufacturer’s instructions and/or API RP550 recommendations.

25 of 183






.2 Provide individual breakers for power distribution to 120V AC instruments or power supplies.

.3 Install RPU and other related peripherals in EEMAC panels as indicated on the drawings. Mount floor-standing panels on a 150 mm (4”) concrete pad if stand-alone, at the same.

.4 Locate and install controller and panels to be easily accessible for maintenance and readability of displays.

.5 Displays and keyboards are to be protected during the construction and commissioning period, but remain readily accessible on the panel’s exterior.

.6 When drilling conduit entry points in panels, protect internally mounted equipment from vibration, shock or metal filings Angels and conduit installations made to them must maintain their appropriate EEMAC rating. Confirm panel location with the Consultant/Owner prior to fixing.

.7 Following Site Acceptance, provide to the Consultant a minimum of six (6) identified control panel keys for each panel.

.8 Follow the Manufacturer’s recommendations for loading resistors on digital outputs to limit the affect of leakage currents through triac and relay outputs.

.9 Follow the Manufacturer’s recommendations for surge suppression on inductive loads.

.10 Once RPU Panels are installed and sufficient field wiring is in place to power up the RTUs, immediately install keepers on any lighting panel or MCC circuit breaker feeding the RPU Panel. Unless otherwise authorized by the Consultant, the RPU Panel and PLC to remain powered up at all times.

.11 Once RTUs are installed at site and sufficient field wiring is in place to begin commissioning software, take the necessary steps to prevent hardware failure or unauthorized tampering with running control programs. Ensure RPU Panel and PLCs are not inadvertently switched off or crashed by unsanctioned activity.

.12 Take the necessary precautions to ensure computers installed at site are not inadvertently switched off, crashed by unsanctioned activity or tampered with in any way. Take every step necessary to minimize the risk and prevent disruption to plant operation.

3.6 SYSTEM WIRING REQUIREMENTS

.1 Provide all required system wiring in accordance with the Process Control System (PCS)

Implementation Guidelines. Refer Sections T- 13305 - Field Wiring and Section T-13320 - Panel Wiring.

.2 Provide all required system wiring. All wiring shall conform to the latest revision of the O.E.S.C. and to the Electrical Area Classification for Hazardous Locations where applicable.

.3 Where specific wiring types are not specified (except AC power wiring) provide types of wiring as recommended by the system component manufacturers.

26 of 183






.4 Provide conduit for all system wiring, except for power cords with integral plugs, and except where duct, tray or similar raceway are indicated, in accordance with Section 16051 - Installation of Cables in Trenches and Ducts. Unless otherwise specified, conduit and wiring requirements specified in Section 16051 apply to the work of this Section.

.5 Communication and analog signal conductor shields must be isolated and taped back at one end and terminated at a single ground point at the other as shown on the loop drawings. If the correct grounding information is unclear, confirm exact shield termination and isolation details with the equipment manufacturer and the Consultant.

.6 Seal all conduit terminations to prevent moisture penetration.

.7 Using suitable permanent wire markers and terminal block tags, number all control panel terminal blocks as indicated on the drawings.

.8 Install lightning and surge protection on all analog signal cabling entering or exiting buildings. Provide two spare units.

.9 Seal all conduit terminations to prevent moisture penetration.

.10 Install signal isolators (24 V DC externally powered if not loop-powered devices) on all analog loops with signal cabling running outside buildings, speed control signals into variable frequency drives, and any situation where potential EMF could damage electronic equipment. Provide two spare isolators.

3.7 IDENTIFICATION AND TAGGING

.1 All equipment and wiring identification and tagging shall comply with the Owner’s current tagging standard. Refer T- 13040 Equipment and Data Tagging.

.2 Submit with the Shop Drawings, a typed lists indicating all nameplate wording as well as proposed types, sizes and styles.

.3 Prior to installation of new items, apply identification nameplates to each instrument, panel, telemetry device and controller. Where existing instruments are re-used, or connected into the new system/control panel(s), provide identification nameplates for these instruments also.

.4 Wiring

.1 Identify all RPU I/O signals on field terminal rails with appropriate tag.

.2 Identify all wiring at both ends with appropriate, permanent wire markers.

3.8 MODIFICATIONS TO EXISTING EQUIPMENT

.1 Provide all hardware, wiring etc. to connect the instrumentation added, moved or modified under this and other Divisions for a complete, and operating system. Verify the actual site conditions and modify the proposals to effect the desired result without additional charge to the contract.

27 of 183






.2 During the tendering period, visit the site and ascertain the actual conditions and the extent of the work.

.3 Do not remove existing equipment from service without written approval.

.4 Prior to removing any control and monitoring equipment, ensure that all signals required for other devices are maintained.

.5 Removal of wiring means the disconnection and complete removal of related cables, conduit and wiring from the equipment involved.

.6 Remove and replace with new all conduit and cable between new/existing RPU and existing metering chamber.

.7 Terminate new wiring as shown on the drawings.

.8 Remove all existing Instrumentation equipment unless there is a definite safety hazard. Draw to the attention of the Consultant any such condition. If there is not a safety hazard, remove the equipment without any damage and return it to the city.

.9 Equipment taken out of service shall be removed and delivered to the Owner or left in place as directed by the Consultant.

3.9 RPU AND SCADA PROGRAMMING REQUIREMENTS

.1 All programming efforts to be consistent with the existing programming and to conform to the PCS Implementation Guidelines version 3 (dated December 30, 2015) including FAT and SAT tests, training and upgrading of operation and maintenance manuals. Refer the Process Control System Guidelines.

.2 Owner Standards and Baseline Programs

.1 Prior to the start of any programming, the Contractor shall contact the Consultant requesting the provision of any specific standards and/or baseline structure programs. The Contractor shall use the provided standards and programs, in addition to the standards defined here within, as a basis for developing the control software applications.

.3 Upon request, the Contractor is required to make minor software modifications at no extra cost. This also applies to logic modifications readily identifiable and implemented on-site by the mutual agreement between the Consultant and the Contractor.

.4 Major additions or changes in software following detailed definition and design only, shall be handled in accordance with the General Conditions requirements.

.5 With each software change released, all distributed documentation, program listings and file backups shall be amended accordingly. The Contractor shall retain at least one copy of the previous version.

28 of 183






3.10 SITE ACCEPTANCE TESTING (SAT)

.1 SAT Testing shall follow the Process Control System (PCS) Implementation Guidelines.

The System Integrator and Manufacturer shall use the “FAT and SAT Check Sheets” and “Process Logic Check Sheets” for the SAT, fill up the form with all the testing items and submit to Consultant and Owner for review prior the SAT.

3.11 TRAINING

.1 Comply with the requirements of the Owner’s Process Control System (PCS)

Implementation Guideline Training document. See Supplement documents.

.2 Submit a course outline to the Consultant for approval thirty (30) days prior to the start of the course. The Consultant reserve the right to modify the course content.

3.12 PROCESS PERFORMANCE OPERATION

.1 Provide all labor and materials necessary to support the process and the instrumentation and control system for the duration of the contract performance run. During this operation all equipment is expected to run in automatic mode.

3.13 WARRANTY AND GUARANTEE PERIOD ACTIVITIES

.1 During the warranty period, hardware service should be provided by a factory trained service representative who shall be on-site within 24 hours of a service request, 7 days/week, including weekends and holidays. The service representative shall be equipped with all necessary tools, testing equipment, spare parts, and expertise to perform the service in one visit.

.1 For each service call submit a report giving the following information:

a. Part numbers, description and prices for items replaced;

b. Revised hard copy/soft copy listings of program changes;

c. Hours worked by maintenance personnel;

d. Reason for the service call, and whether preventative, unscheduled or corrective maintenance was carried out;

e. Name of Owner’s technician present during repairs. Explain the problem and solutions to the owners’ technician;

f. Description of problem as discovered on arrival at site and itemized report of activities performed to isolate and correct problem;

g. Identification of any required actions to prevent similar future occurrence;

h. Name of attending operations representative, time of call and time of arrival on site.

29 of 183






.2 A single contact point shall be provided for all hardware such that the Owner’s representative need only call a single phone number irrespective of which piece of hardware has failed.

.3 Spare Components/Firmware & Software Upgrades:

a. The supplier should have access to a dedicated spare parts inventory for each component provided. Parts shall be available within 24 hours of a service parts request, 7 days/week.

b. Include key spare parts that are not normally available immediately from stock, in the Recommended Spare Parts List.

3.14 SUPPLEMENTS

.1 Supplements listed below, following “End of Section”, are part of this specification and are found in the attached CD. The following T-13010-xx documents are part of Appendix C in the Process Control System (PCS) Implementation Guidelines.

.1 T-13010-01 - Colour Convention-V2

.2 T-13010-02 - RPU Software Programming-V2

.3 T-13010-03 – RPU Standard Software Modules-V2

.4 T-13010-04 - Operator Interface Programming-V2

.5 T-13010-05 - Alarming-V2

.6 T-13010-06 - PCS Factory Acceptance Testing-V2, this includes panel and software tests

.7 T-13010-07 - FAT and SAT Test Check Sheets-V2

.8 T-13010-08 - Process Logic Test Sheet-V2

.9 T-13010-09 – PCS Site Acceptance Testing and Commissioning-V2

.10 T-13010-10 - PCS Documentation-V2

.11 T-13010-11 - Training-V2

.12 T-13010-12 - Process Display Programming-V2

.13 T-13010-13 – Process Control Narratives-V2

END OF SECTION

30 of 183

Process Control System (PCS) Guidelines

Appendix C

Colour Convention

T13010-01 - Colour Convention-V2

Page 1 of 5 (Addm-6) Mar 2016

1. Colour Convention

1.1 General

This design guideline sets out the use of colours to indicate information in a consistent manner. This guideline reserves some colours for the representation of alarms and status conditions and therefore may not be used for any other meanings or other uses.

Consultants shall comply with this design guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City.

In some instances, the use of colours is defined by codes governing fire protection, boilers, generators, engines, electrical distribution, personal health and safety and similar topics. In case of conflict between this guideline and codes, the code having jurisdiction will prevail.

1.2 Field Indicating Lights

Field status and alarm lights shall conform to the following colour convention: ITEM COLOUR Running, burner on, valve open, breaker closed Red Stopped, safe, burner off, valve closed, breaker open Green Overload, warning Amber Intermediate position (valve) White or Flashing White Alarm Flashing Red

Where field status and alarm lights are being added to an existing facility where such devices already exist, the Consultant shall consult with the City if the existing devices do not conform to the above convention.

1.3 Operator Display

Operator displays, at all levels, shall conform to the following colour convention: ITEM COLOUR NAME** HEX CODE** DECIMAL** Screen Background (except alarm

summaries) Cyan Color104 C0C000 12632064

Equipment/Device Status

Digital

On, OK Red Bright Red 0000FF 255 Open, OK (valves) Red Bright Red 0000FF 255

31 of 183


Appendix C

Colour Convention



ITEM COLOUR NAME** HEX CODE** DECIMAL** Active device Red Bright Red 0000FF 255 Off, OK Green Bright Green 00FF00 65280 Closed, OK (valves) Green Bright Green 00FF00 65280 Inactive devices (off scan) Grey Gray75 C0C0C0 12632256 Power off Grey Gray75 C0C0C0 12632256 Intermediate position (valves) Yellow Bright Yellow 00FFFF 65535 Priority 1 alarm (graphic symbol) Flashing* Priority 2 alarm (graphic symbol) Flashing* Priority 3 alarm (graphic symbol) Flashing* Priority 1 alarm page background Red Bright Red 0000FF 255 Priority 2 alarm page background Yellow Bright Yellow 00FFFF 65535 Priority 3 alarm page background Cyan Color136 888800 8947712 Analog

Normal range White White FFFFFF 16777215 Advisory range Yellow Bright Yellow 00FFFF 65535 Alarm range Red Bright Red 0000FF 255 Off scan (last value) Grey Gray75 C0C0C0 12632256

* Flashing is between current status colour and grey at normal flashing frequency (84 to

168 flashes per minute). ** CODE refers to the “Blue, Green, Red” colour intensities which are in the range of 00 to

FF in hexadecimal. E.g. White is made up of Blue at maximum intensity FF, Green at maximum intensity FF and Red at maximum intensity FF. The Hex code for white is therefore FFFFFF

** DECIMAL refers to the decimal conversion of the Hex Code. This is used in the iFIX “properties window” to specify colour properties for an object. (Most ‘colour picker’

software uses “Red, Green, Blue” to generate the hex code instead of “Blue, Green, Red”

which iFIX uses.)

1. Control Modes Local Status Colour Name Hex Code Decimal

Local Black Black 000000 0 Non-controllable from Computer (RPU) Grey Gray 75 C0C0C0 12632256

Computer Status

32 of 183


Appendix C

Colour Convention



Computer (RPU) auto Blue Bright Blue FF0000 16711680 Computer (RPU) manual White White FFFFFF 16777215

2. Miscellaneous Equipment Outlines (tank, etc.) White White FFFFFF 16777215 Building Outlines, etc. White White FFFFFF 16777215

3. Identification Labels

Dark Background

Colour Name Hex Code Decimal Screen Titles White White FFFFFF 16777215

Equipment White White FFFFFF 16777215 Other White White FFFFFF 16777215

Light Background

Colour Name Hex Code Decimal Screen Titles Dark Blue Blue 800000 8388608 Equipment Robin Blue Bright Cyan FFFF00 16776960 Other Black Black 000000 0 Where operator displays are being added to an existing system where operator displays already exist, the Consultant shall consult with the City if the existing displays do not conform to the above convention.

1.4 Process Piping

The colours shown on displays are modified from the MOEE (Ministry of Environment and Energy) guide for water pollution control plants, natural gas and propane installation codes. Banding is not used on displays for easier understanding of line continuity.

Material Handled

Pipe Colour from MOEE Guide

Pipe Colour for Displays Name Hex Code Decimal

Sewage Light Grey Light Grey Gray88 E1E1E1 14803425 Primary Tank Effluent Light Grey Light Grey Gray88 E1E1E1 14803425 Secondary Clarifier Effluent

Light Grey Gray88 E1E1E1 14803425

Chlorinated Effluent Medium Blue Color57 FF8C2C 16747564 Sludge and Scum Dark Brown Brown Color78 6A59A8 6969768 Grit and Screenings Brown Color78 6A59A8 6969768 Non-potable Water, Plant Water, Pre-Treated Water

Blush Yellow Medium Blue Color57 FF8C2C 16747564

Potable Water, City Water Light Blue Light Blue Bright Cyan FFFF00 16776960 Potable Hot Water Dark Blue Light Blue Bright Cyan FFFF00 16776960

33 of 183


Appendix C

Colour Convention



Material Handled

Pipe Colour from MOEE Guide

Pipe Colour for Displays Name Hex Code Decimal

Drainage Black Light Grey Gray88 E1E1E1 14803425 Raw Water Black Black 000000 0 Chlorine Gas Yellow Yellow Bright Yellow 00FFFF 65535 Chlorine Solution Yellow with Light

Blue Band Yellow Bright Yellow 00FFFF 65535

Digester Gas or Fuel Oil Orange Orange Orange 2C82FE 2917118 Natural Gas, Propane Yellow* Yellow* Bright Yellow 00FFFF 65535 Compressed Air Vine (Gloss) Light Green Bright Green 00FF00 65280 Circulating Air Vine (Flat) Light Green Bright Green 00FF00 65280 Alum Metallic Green Yellow-Green Color99 00D2A8 53928 Ferric Chloride, Ferrous Chloride

Metallic Green with Orange Band

Yellow-Green Color99 00D2A8 53928

Polyelectrolytes Metallic Green Yellow-Green Color99 00D2A8 53928 Sodium or Calcium Hypochlorite

Yellow with White Band

Yellow Bright Yellow 00FFFF 65535

Lime White with Orange Band

White White FFFFFF 16777215

Ozone Yellow Bright Yellow 00FFFF 65535 Fluoride Purple Color141 A000A0 10485920 Sulphur Dioxide Orange Orange 2C82FE 2917118 Aqua Ammonia Dark Blue Color120 A0A000 10526720 Sodium Hydroxide Lime Green Color85 00E000 57344 Potassium Hydroxide Lime Green Color85 00E000 57344 Polymer Grey Gray75 C0C0C0 12632064 Powder Activated Carbon (PAC)

Grey Gray75 C0C0C0 12632064

Phosphoric Acid Pink Custom F2B9B9 15907257 Foul Air Olive Yellow 808000 8421376 Other Chemicals Yellow Bright Yellow 00FFFF 65535

*Natural gas and propane piping colour identification are governed by separate codes.

Although the MOEE guideline for natural gas and propane does not conflict with the

codes per se, the use of yellow colour is recommended to avoid any confusion in piping

identification.

Note: sampling lines will retain their process stream colour.

Piping is to be identified to the requirements of GSB-24.3 Code for Piping Identification. The colour code for piping identification bands is:

34 of 183


Appendix C

Colour Convention



Classification Background Colour Legend Colour.

Hazardous Materials Yellow 505-102 Black 512-101 Inherently Low Hazard Materials Green 503-107 White 513-101 Fire Protection Red 509-102 White 513-101

35 of 183


Appendix C

RPU Software Programming

T-13010-02 - RPU Software Programming-V2


1. RPU Software Programming

1.1 General

This guideline is for the structure and documentation of Remote Processing Unit (RPU) programs. This document is to establish standards for a consistent approach to programming which will enable:

1. the maximum re-use of programs;

2. Reduced time to troubleshoot programs; and

3. Higher confidence and usability of RPU-based control systems.

Consultants shall comply with this design standard in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City

1.2 Standards

All programs shall conform to IEC 61131-3 Programmable controllers - Part 3: Programming

languages. In addition, the programs written for critical or hazardous applications shall conform to CAN/CSA-Q396 Quality Assurance Program for the Development of Software Used in

Critical Applications.

1.3 Documentation

1.3.1 Flow Charts

1. The method of documenting software logic design is the flow chart diagram, a type of sequential function chart. Document all applications programs in this manner.

2. Software for developing the flow charts is Visio only.

3. The flow chart is a design tool to get concurrence that functional requirements have been understood and incorporated into the design.

4. Show only automatic control mode.

5. The intent is to flow chart a process on one to two 11x17 sheets. The simple, high-level, ‘single sheet’ concept may actually need multiple sheets depending on the complexity of

the controls.

6. Show generic setpoints or test setpoints if pertinent to understanding the logic.

7. Show modules; represented by a box in the flow chart. The module type should be clearly indicated.

8. Show process interlocks.

9. Keep charts up to date to reflect the actual built state of the software.

36 of 183


Appendix C




Flow chart shapes should be used consistently as follows:

Function Shape

Logic Block Plain box Modules Box with end

bars. States Box with cross Decisions Diamond Operator Selections

Trapezoid

Message Parallelogram Start or Stop Oval Continuation Circle

An example of a flow chart is shown in Figure 1: Flow Chart Example.

37 of 183


Appendix C




Figure 1: Flow Chart Example

Grit Tank

Outlet Valve

Opened

Grit Tank

Level >1m

Grit Tank

Inlet Valve

Opened

Yes

Cleaning

Cycle Timer

Done

No

No

Grit Tank

Inlet Valve

Closed

Grit Tank

Outlet Valve

Closed

Yes

Yes

No

Total Flow

Reached

Target

Yes

Yes

Bar Screen Normal Operation

Operator selects

- Interval Max cycle time (xx minutes)

- Interval Min cycle time (xx minutes)

- Max totalized Flow rate (xxx m3/sec)

- Set Screen high level switch

- Duration cycle time for high level

operation (xxx minutes)

Totalized

Flow Rate

Target

reached

Yes

Yes

No

No

Grit Tank Normal Operation

Operator selects

- Cleaning Cycle timer (xxx Hours)

- Total flow Target (xxx m3)

- Tank in service

- Out of service

Grit Unwatering Pump System

Operator selects

- Duty and standby pump

- Unwatering pump cycle time

(xxx minutes)

- Min Tank Level (xx.x m)

- Low-Low Tank Level (xx.x m)

Grit Handling Watering System

Operator selects

- Duty and standby pump

- Unwatering pump cycle time

(xxx minutes)

- Min Tank Level (xx m)

- Low-Low Tank Level (xx m)

Call Module

to open

Grit Tank

Outlet valve

Call Module

to open

Grit Tank

Inlet valve

Air Process

Header

Opened

Call Module

to operate

Air Process

Header

No

Start Cleaning

Cycle Timer and

Accumulate

Flow

Start

Bar Screen

Process

Start

Maximum

Time Interval

Operation

High Level

Target

Reached

Start

Minimum

Time Interval

Operation

Start

High Level

Operation

Call Module

to close

Grit Tank

Inlet valve

Call Module

to close

Grit Tank

Outlet valve

Tank

In Service

Tank Out

of Service

Advisement

Send to

SCADA

Unwatering

Valve

Opened

No

Call Module

to open

Unwatering

Valve

Advisement

Send to

SCADA

Cycle time

Target

Reached

Yes

Start

Out of ServiceIn service

Operator

Start tank

cleaning

Tank

Cleaning

Process

Required

Air Header

Closed

No

No

Tank

Cleaning

Process

Required

Yes

Yes

Tank

Cleaning

Process

Started

Yes

No

No

38 of 183


Appendix C




1.3.2 Control Program Listings

1. All application programs shall be completed using ladder logic. 2. The entire program shall be annotated with comments. Explain what the program is

doing, and why. 3. Rung/IO comments shall be grammatically correct and in the English language. They

shall be sufficiently verbose to allow on-site troubleshooting. 4. Each I/O, derived value, register and coil, subroutine and object shall be identified by

descriptor.

1.4 Programming

The design logic shown in flow charts shall be structured to use standard software modules, where possible. Standard modules are described in "RPU Standard Software Modules"

Guidelines.

The standard modules are not to be altered without the permission of the Toronto Water. Any unusual or specific data manipulation is to be performed outside of the modules.

1.4.1 Update Procedure

The PCS component of any project will often involve updating an existing program rather than creating a new program. The following procedure should be considered when updating a program:

1. During pre-design, decide which existing RPUs will be involved in the project. The pre-design report should contain this list and determination made that capacity exists in those processors and I/O racks based on the estimated I/O or determine what upgrades are required to create the capacity

2. During detailed design, create drawings for any necessary hardware upgrades 3. During construction, the Systems Integrator will request the existing program(s) from

Toronto Water. Toronto Water will keep track of all requests in order to coordinate updates and version control.

4. During programming, the Systems Integrator will use the memory map guidelines to determine areas of memory to use. This is critical to ensure consistency which will make future expansions and program maintenance easier.

5. New rungs should be commented to clearly show that they are part of the current project and help differentiate them from existing programming. New Auto logic should be contained within new routines rather than adding to existing routines to help differentiate new logic from existing logic. New I/O should be handled in existing routines and appropriately commented.

6. FAT/SAT documentation should indicate which routines were modified or added so Toronto Water staff has the opportunity to determine and test the effect on existing programming.

39 of 183


Appendix C




1.4.2 Analog Inputs

Scaling of analog values, shall be performed only in the Operator Workstation software in accordance with the following requirements:

1. All analog points shall be passed through the RPU as unscaled, primary data.

2. No scaling of inputs is permitted in analog input modules.

3. Where data is manipulated in the RPU for purposes of control, such manipulations shall not be interposed between the input from the instrument and the Operator Workstation software.

4. Data manipulations such as summation for displays or historical data shall be done in the Operator Workstation software. The method of scaling is shown in Figure 2 Analog Data

Flow

Process

Equipment

ANIN

Analog

Input

Module

Field sensors

Flow, level etc

Operator

Workstation

binary unscaled

Control program

Control

signal

Scaling

for control

purposes

PLC

Controller binary

unscaled

Database

Scaling

for control

purposes

Figure 2 Analog Data Flow

1.4.3 Memory Organization

1. The following paragraphs set out principles for memory allocation and program structure. Memory allocation for GE PLC's is presented in section 1.5.

2. RPU memory shall be organized into three major sections: I/O Registers; Control; and Communication (if needed).

3. Each section should contain memory for expansion up to the overall limit defined in the technical specifications for the RPU. Within each section, the memory should be further

40 of 183


Appendix C




organized into logical blocks, similar to the definition in the memory allocation in section 1.5.

1.4.3.1 I/O Registers

1. I/O should be organized in the same hierarchy as used for program structure. For RPUs in which I/O point numbering is not restricted to a pattern, the I/O should be assigned to addresses within the I/O register section. The I/O register should be split by type of I/O: analog inputs, analog outputs, digital inputs and digital outputs. I/O for similar devices should be put in the same order of address.

2. For RPUs in which I/O point numbering is restricted to a pattern, the assignment of addresses may be partially predetermined. As much as possible, follow the considerations for organization given in the preceding paragraph.

1.4.3.2 Control

1. The control logic should present all control actions directly and avoid using the same address or block of addresses for multiple uses. Logic for control should be organized into blocks by device and structured consistently following the guidelines herein.

2. Logic for the watchdog timer and system clock should be located first in this section if they are not part of system software or hardware.

3. General rule for Ladder Logic Rungs: Normally open input contacts will be used first. Normally close input contacts will be used next.

4. In normal situations, a rung can be separated into two sections: The first section is the Control logic. The second section is the Interlock logic.

5. The order for the control logic section is: Computer mode (If computer auto and computer manual modes are required in the

rung, then the parallel branch function will be used. Computer auto control logic is always on top of the branch).

Operation request (momentary contact). Operation Inhibit (if needed, can be more than one contact).

6. The order of the interlock logic section is: Operation permissive (can be more than one contact); Stop device request (can be more than one contact); then Device failure (can be more than one contact).

41 of 183


Appendix C




Control Logic Examples:

1. Rung layout with computer mode:

2. Rung layout with computer auto and manual modes:

Computer Operation Operation Stop Devicemode permissive permissive request failure Output

Interlock logic section

Control

logic section

Computer Operation Operation Operation Stop Device Rungauto mode Request inhibit permissive request failure Output

Computer Operation Operation

manual mode Request inhibit

RungOutput

Control logic section Interlock logic section

42 of 183


Appendix C




The following standard Bit Allocation shows a typical data map for pump and valve devices. This structure shall be followed as closely as possible. Any deviation will require the approval of Toronto Water.

Pump/Rotating Device Valve Bit 1 In computer mode In computer mode

Bit 2 Not available warning Not available warning

Bit 3 Running Status Open Status

Bit 4 Spare Close Status

Bit 5 Computer auto request Computer auto request

Bit 6 Computer manual request Computer manual request

Bit 7 Start request Open request

Bit 8 Stop request Close request

Bit 9 Spare Spare

Bit 10 Alarm reset request Alarm reset request

Bit 11 Auto start request by auto process

Auto Open request by auto process

Bit 12 Auto stop request by auto process

Auto Close request by auto process

Bit 13 Spare Spare

Bit 14 Spare Spare

Bit 15 Interlock alarm #1 Interlock alarm #1

Bit 16 Interlock alarm #2 Interlock alarm #2

Bit 17 Ready to operate Ready to operate

Bit 18 Computer auto mode Computer auto mode

Bit 19 Computer manual mode Computer manual mode

Bit 20 In running condition In open condition

Bit 21 In stopped condition In closed condition

Bit 22 Start permissive Open permissive

Bit 23 Alarm Stop request Close permissive

Bit 24 Start command Open command

Bit 25 Stop command Close command

Bit 26 Spare Spare

Bit 27 Reset start/stop command Spare

Bit 28 Restart inhibit Spare

Bit 29 Pump running latch Spare

Bit 30 General failure General failure

Bit 31 Uncommanded start alarm Uncommanded open alarm

Bit 32 Uncommanded stop alarm Uncommanded close alarm

Bit 33 Fail to start Fail to open

Bit 34 Fail to stop Fail to close

Bit 35 No request by RPU Unknown position

Bit 36 Spare Position lost track

Bit 37 Spare Spare

Bit 38 Run 1 hour Failure alarm start timing

Bit 39 Reset restart inhibit Spare

Bit 40 Spare Spare

43 of 183


Appendix C




Bit 41 Auto Start request by process Auto Open request by process

Bit 42 Auto Stop request by process Auto Close request by process

Bit 43 - 50 Spare Spare

The following standard Word allocation shows a typical data map for counters and timers. This structure shall be followed as closely as possible. Any deviation will require the approval of Toronto Water.

Internal Counter Internal Timer Word 1 Counter 1 (Current Value) Timer 1 (Current Value) Word 2 Counter 1 (Preset Value) Timer 1 (Preset Value) Word 3 Counter 1 (Control Word) Timer 1 (Control Word) Word 4 Counter 2 (Current Value) Timer 2 (Current Value) Word 5 Counter 2 (Preset Value) Timer 2 (Preset Value) Word 6 Counter 2 (Control Word) Timer 2 (Control Word) Word 7 Counter 3 (Current Value) Timer 3 (Current Value) Word 8 Counter 3 (Preset Value) Timer 3 (Preset Value) Word 9 Counter 3 (Control Word) Timer 3 (Control Word) Word 10 Spare Spare

1.4.3.3 Communications

1. Blocks of memory may need to be allocated for communication with other intelligent devices to manage communication speed. Communication blocks are not required for GE RPUs connected by Ethernet.

2. For example, communication with an operator station may require that a separate block or blocks be set up for an alarm and event array. The alarm and event array may be split into separate blocks, one for alarms and one for events. Even if alarms are also used for control, they should be copied to the alarm block. Separation of alarms is useful for testing alarm reporting separate from control logic.

3. Within the communication section, separate blocks should be set up for communication to minimize the number of messages needed to communicate data. Typically this means that a block for analog values, a block for receipt of operator commands and a block for setpoints and other parameters should be set up. A block for communication to and from other RPUs may need to be separate from the operator station interface blocks in order for fast communications.

44 of 183


Appendix C




1.5 Memory Allocation for GE 90-30 PLC

A. Analog Input and Analog Output 1. Analog Input: %AI00001 to %AI02048 2. Analog Output: %AQ00001 to %AQ00512

B. Analog Internal Default 1. Analog Internal: %R00001 to %R12032

a. SCADA to PLC: %R00001 to %R00500 b. PLC to SCADA: %R00501 to %R01000 c. Programming: %R01001 to %R08000 d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:

%R08001 to %R09000 e. Counter: %R09001 to %R10000 f. Timer: %R10001 to %R12032

B2. Analog Internal Hi Density 1. Analog Internal: %R00001 to %R24064

a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500 b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000 c. Programming: %R01001 to %R08000, %R14001 to %R20000 d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:

%R08001 to %R09000, %R20001 to %R21000 e. Counter: %R09001 to %R10000, %R21001 to %R22000 f. Timer: %R10001 to %R13000, %R22001 to %R23000 g. Modbus: %R23001 to %R24064

C. Discrete Input, Discrete Output & Hardware Configuration 1. Discrete Input: %I00001 to %I02048

a. Raw Discrete Input: %I00001 to %I01000 b. CPU Ethernet Status Address: %I01001 to %I01080 c. I/O Modules Status Address: %I01081 to %I02048

2. Discrete Output: %Q00001 to %Q02048 D. Discrete Internal

1. Discrete Internal: %M00001 to %M04096 a. SCADA to PLC: %M00001 to %M00500 b. PLC to SCADA: %M00501 to %M01500 c. Programming: %M01501 to %M04096

1.6 Transition Memory Allocation for GE RX3i PLC

A. Analog Input and Analog Output 1. Analog Input: %AI00001 to %AI02048 2. Analog Output: %AQ00001 to %AQ00512

B. Analog Internal Default 1. Analog Internal: %R00001 to %R12032

a. SCADA to PLC: %R00001 to %R00500

45 of 183


Appendix C




b. PLC to SCADA: %R00501 to %R01000 c. Programming: %R01001 to %R08000 d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:

%R08001 to %R09000 e. Counter: %R09001 to %R10000 f. Timer: %R10001 to %R12032

B2. Analog Internal Hi Density 1. Analog Internal: %R00001 to %R32640

a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500 b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000 c. Programming: %R01001 to %R08000, %R14001 to %R20000, %R24065

to %R32640 d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:

%R08001 to %R09000, %R20001 to %R21000 e. Counter: %R09001 to %R10000, %R21001 to %R22000 f. Timer: %R10001 to %R13000, %R22001 to %R23000 g. Modbus: %R23001 to %R24064

C. Discrete Input, Discrete Output & Hardware Configuration 1. Discrete Input: %I00001 to %I02048

a. Raw Discrete Input: %I00001 to %I01000 b. CPU Ethernet Status Address: %I01001 to %I01080 c. I/O Modules Status Address: %I01081 to %I02048

2. Discrete Output: %Q00001 to %Q02048 D. Discrete Internal

1. Discrete Internal: %M00001 to %M32640 a. SCADA to PLC: %M00001 to %M00500, %M05001 to %M07000 b. PLC to SCADA: %M00501 to %M01500, %M07001 to %M10000 c. Programming: %M01501 to %M05000, %M10001 to %M15000

1.7 Communications

Addresses

1. Each node on a RPU communications network must have a unique address on that network. Node addresses shall be chosen to integrate into existing networks. Nodes shall be assigned in consecutive node addresses. RPUs in hot standby shall have consecutive node addresses.

Control

1. Control and monitoring shall continue without disruption in the event of communication failures. Where control functions rely on information affected by communications failure, a safe mode of control shall be provided.

2. Design of software shall seek to reduce the amount of messages transferred between RPUs to the minimum.

46 of 183


Appendix C




Time Synchronization

All nodes on a RPU communications network shall have internal clocks synchronized periodically to a master clock. Synchronization shall provide time and date stamping accuracy to within one second of the master clock. Master clock and RPU clock shall be accessible from the Operator Workstation.

1.8 RPU Program Commissioning

RPU programs shall be tested and commissioned in accordance with CAN/CSA-Q396 Quality

Assurance Program for the Development of Software Used in Critical Applications. Each I/O shall be tested from source element to display screen. The source element shall be exercised wherever possible or else simulated. For example, a float switch should be tilted to verify the signal. After commissioning, if access to the float switch is not practical, then its action may be simulated by short circuiting the input loop.

47 of 183


Appendix C

RPU Standard Software Modules

T-13010-03 RPU Standard Software Modules-V2


1. RPU Standard Software Modules

1.1 General

This document describes Toronto Water’s standard software modules and establishes procedures

to guide the development, testing and deployment of new software modules. The Consultants shall ensure that the System Integrator complies with the programming and testing requirements with respect to software development.

1.2 Module Overview

A Module is defined as a stand-alone software component typically associated with a process device that has a number of inputs and outputs, and also has defined control functionality. In general, the City has already developed standard software modules for all existing in-plant process devices, which the Consultant shall ensure that the System Integrator use in the development of the RPU or HMI software. Where a module is unavailable to meet the software requirement of the project, the System Integrator shall develop an appropriate module as part of the contract.

The intent of module development is to develop standard components that can be easily incorporated in multiple instances into the development of process area applications where a large number of the process devices are used. A Module consists of sub units of HMI, RPU and Test Simulation software applications. In addition there will be some specialized modules that do not conform to this definition, but which will be used in the same way in multiple instances e.g. PID module, Analog Input Module, etc. As well as the software units, a module also includes associated documentation. The component parts of a module are as follows:

1. Functional description including module layout

2. RPU program design expressed in a flow chart

3. RPU program with embedded documentation

4. HMI program

5. Simulation program

6. Module Acceptance Report including test cases from Factory Acceptance Testing.

1.3 Available Modules

The device control modules are summarized in the following categories:

1. Conveyors and General Devices

2. Pumps

3. Valves

48 of 183


Appendix C




4. Other (Analog, PID, Duty, etc.)

Some general module descriptions are included below.

1.3.1 Device Control Modules – General

The Manual/Automatic Control Mode Selection modules allow the Operator to select an automatic or manual control mode. Most modules do not make any special provisions for the transfer from Local Control Mode to Computer Control Mode. For example, the module does not affect the motor run state upon transfer. However, if the motor is in automatic control mode, the automatic logic may change the state of the motor on the next execution of the logic.

Linking Automatic and Manual Control Logic to Output Values is achieved as follows. In automatic mode, the module enables control requests by the automatic control logic to start and stop devices. The modules typically use one momentary contact closure for start (or open) and another momentary contact closure for stop (or close). In manual mode, the module enables control requests by the Operator to start and stop (or open and close) devices. After a manual control request, the device feedback “zeroes” the action bit.

The modules shall generate alarms for discrepancies between requested and actual states. For example, an alarm is generated if within a set time period from a requested start or stop the motor feedback does not indicate motor run. The timer is adjustable by a System Technician.

If in computer control, upon indication of an alarm related to possible equipment damage, the module stops the motor and places it into computer manual. These types of lockout conditions are generally reset locally at the device. The Operator is responsible to reset the alarm from the HMI after checking field conditions before returned to Computer Auto Control. Equipment damage alarms if monitored include:

1. Motor overload

2. Motor start/stop fail timer and

3. Motor specific alarm such as low oil pressure

Upon indication of a process alarm, the module stops the motor. The process alarms shall be evaluated on a case-by-case basis for each motor. These types of alarms are generally reset automatically or from the operator interface. Process alarms, if monitored, include:

1. Low suction pressure

2. Low seal water pressure

3. Power failure and

4. Other process specific alarms such as high discharge pressure

49 of 183


Appendix C




The module shall not allow the motor to restart within a set restart inhibit time period after stopping. The timer is adjustable by a System Technician.

1.3.2 Analog Input Module

Scaling to Engineering Units is not performed by the module Analog data is passed to the HMI as unscaled values and the HMI is responsible for scaling.

Alarms for High-High, High, Low-Low, and Low alarms are generated by this module. The High-High, High, Low-Low, and Low alarm setpoints can be modified by the Operator. The analog input is compared to High-High, High, Low-Low, and Low alarm limits. If a limit is exceeded for more than three continuous seconds, an alarm bit is set. The alarm bit is reset when the analog value returns within a deadband from the limit. The deadband is adjustable.

An Out of Range Alarm contact is provided by this module when the analog input value reaches a value out of the 4-20 mA range for more than three continuous seconds.

1.3.3 Analog Filter Module

Provide Digital Filtering module on a case-by-case basis to filter noise from a measurement signal.

The filtering equation used is: Y = K(X - Y ) + Yn n n-1 n-1

Where: K = filter constant: 0 < K < 1 Xn = current input valve Yn = current filtered output value Yn-1 = previous filtered value

The value of K is set by the System Technician.

Note: with a K value near 1, the Analog Input Filter module has little effect at “smoothing” the

input signal. With a K value near 0, the output value of the Analog Input Filter module changes very slowly with a change in input value.

1.3.4 PID Loop Control Module

Automatic PID Loop Control shall be provided to send an analog output signal to a control device. The Operator may set the PID controller for automatic or manual control mode. In automatic mode, the Operator can select whether the module uses an Operator-entered setpoint or an automatically calculated setpoint. The module monitors its process variable (PV) and setpoint (SP) and changes its output based on the difference between the PV and SP. The action of the control module is based on the PID algorithm and the value of the tuning constants. The high and low output limits are set by the Operator. The Operator enters these limits as a 0-100% value and the Operator interface converts them appropriately for the PID controller.

In the manual control mode, the Operator can enter a control command value. The module

50 of 183


Appendix C




monitors its control variable (CV) and considering the user-defined parameters, will change the module output to match the command value.

In local control mode, the PID module is disabled and the setpoint is set equal to the process variable. The module also forces the PID module output equal to the control variable (CV). When the PID module is in AUTO or local control, the module forces the manual setpoint entry register to the value in the PID output register.

The module shall disable the PID calculation when the control device is unavailable, in local control or upon module failure and also if the process variable is out of range. An alarm contact is energized by the analog input module of the process variable

The tuning parameters KP, KI, and KD can be changed on-line while the program is running.

The PID module executes at a scan interval set by the System Technician.

The following guidelines are for setting the PID_ISA Control Function Block Initial configuration.

The setting of the initial parameter values prior to tuning and commissioning shall be as follows:

Parameter Configuration Guideline

Manual Command N/A Control This internal parameter is normally set to 0. Enable N/A Override Set to ON. Manual N/A Up N/A Down N/A Proportional (Proportional Gain)

1

Derivation (Derivation Gain)

0

Integral (Integral Rate) 0 SP, PV and CV Percentage Bar Graphs

N/A

SP/PV Range Optional integer values in PV Counts that define the highest and lowest display value for the SP and PV bar graphs.

SP Value N/A Sample Period 1.0 seconds for pressure control loops

2.0 seconds for flow control loops 2.0 seconds for level control loops 5.0 seconds for temperature control loops

Bias The usual setting for the Bias field is +16000 to let the function regulate error around the output midpoint.

51 of 183


Appendix C




Parameter Configuration Guideline

Dead Band Upper and Lower

Leave the dead band limits set to 0 until the PID loop gains are setup or tuned. It may then be desirable to add Dead Band to avoid small CV output changes due to small variations in error (i.e. to reduce mechanical wear).

Upper Clamp and Lower Clamp

Set the lower clamp to 0 and the upper clamp to +32,000.

Error Term Selects how the error will be calculated. Min Slew Time Set to the limit of the control device. Most control valves

have a minimum slew time of 60 seconds. Note: Set Minimum Slew Time to 0 (no CV rate limit) while tuning or adjusting PID loop gains.

Derivative Action No derivative action is required for most loops. Output Polarity Set according to type of loop.

1.4 Module Development

The module development process shall be as follows:

1. The Consultants shall prepare the module functional description and module flow chart, which is to be reviewed with the City.

2. Functional requirements are defined based on software related standards, process control narratives and experience. For example, the standard for alarm handling requires that if a point in the HMI has its alarm disabled, the control logic associated with the point value is also disabled. The modules should have this functionality.

3. The System Integrator shall develop the Module software for RPU, HMI and Simulation

4. The System Integrator shall develop test cases (see Module Testing Process).

5. Preliminary review is made by the Consultants and the City.

6. The System Integrator shall modify the documentation to incorporate changes.

7. The System Integrator shall modify the software code to incorporate full functionality and shall test the software to confirm that the desired results are achieved.

8. Full review is made by Consultants and the City.

9. Incorporate further required changes.

10. Test the module according to the Module Testing Process.

11. Submit module for acceptance.

52 of 183


Appendix C




1.4.1 Module Testing Process

The module testing process will follow general guidelines for component testing. The module testing process will have QA review, and feedback will be sought from the Consultants and the City throughout the development and testing process.

In the development of test cases, the System Integrator’s judgment and experience is used to

determine how thorough the test process needs to be. Different depths of detail are involved at the different stages of testing by the System Integrator, testing by the Consultants and testing by the City, if required. In addition, at each stage of testing, the Consultants or the System Integrator will be encouraged to look beyond the procedures as defined in the test cases to identify unforeseen problems. In some instances this will lead to the development of additional test cases.

The module testing process shall be performed in the following sequence:

1. The System Integrator shall develop a list of test cases using the following approach:

Use experience and judgment to develop the list of test cases.

Assume errors are distributed throughout the programs.

Prove functionality as defined in functional descriptions and flow chart.

2. The Consultants shall review the testing process

3. The System Integrator shall perform testing in a test environment that reflects the actual production environment

4. The System Integrator shall perform the Acceptance testing which the Consultants shall witness. Technical acceptance and sign-off shall be done by the Consultants for each module. Acceptance represents that:

The module meets the design as specified in the Module Functional Description as well as general PCS standards.

The methods for module development and testing were followed.

The representatives have confirmed that the module passed all tests outlined in the acceptance test documentation.

1.4.2 Module QC Process

The QC Process shall adhere to the requirements for QC/QA established for the project.

The Consultants may perform an independent test of each module according to the acceptance test procedure.

53 of 183


Appendix C




During the QC Process, the Consultants shall use a checklist for documenting issues and changes resulting from review. The QC checklist that follows is for each module. Each Software Module shall be assessed for conformity against the following list of items:

1. Meets Toronto Water PCS standards.

2. Meets functional requirements as described in the Module Functional Description.

3. Performs functions shown on flow charts and diagrams.

4. Developed and tested in a configuration that suitably represents the actual production environment.

5. Passes written internal testing procedures and signed by Consultants

54 of 183


Appendix C

Operator Interface Programming

T-13010-04 - Operator Interface Programming-V2


1. Operator Interface Programming

1.1 General

The Consultants shall comply with the following guidelines for the programming of Operator Interface Terminals (OIT) connected to Programmable Logic Controllers (PLCs).

Consultants shall comply with this guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City.

1.2 Programming – General

OITs are to be configured for monitoring and control functions of the local process ONLY. Unless otherwise noted, they are not intended to behave as a SCADA client.

The programming of the OIT shall conform to the following requirements:

1. All OIT points shall be programmed to display their full tag name and point information.

2. Analog points shall have values displayed in the same engineering units as at SCADA screens.

3. Digital points shall have value or state displayed logically, for example: Outputs as START/STOP, OPEN/CLOSE, etc.; and inputs as ON/OFF, NORMAL/ALARM, LOCAL/REMOTE, etc. as appropriate.

4. All displays shall have a consistent general layout in both form and function.

A hierarchical menu shall be constructed using the device keypad and programmable ‘soft’ keys

to provide a simple and intuitive method of accessing all of the screens provided. Where available, use an existing OIT program at the facility as a template for form and function.

Colours used for text and graphic elements shall use the same colours used on normal SCADA displays. Changes in colour that result from change of state shall also use the same colours as used at the SCADA displays. Refer to guideline "Colour Convention" for more information on colour standards.

1.3 Displays

Multiple displays shall be provided to show the state/status of every installed I/O point at the associated PLC, regardless of whether a field device is attached to the I/O point. One graphical schematic representation shall be provided for each process controlled and/or monitored by the associated PLC. Point states and values shall be refreshed dynamically as field conditions change.

All automatic control setpoint and related displays programmed on the central SCADA system shall also be available on the OIT.

55 of 183


Appendix C


T-13010-04 - Operator Interface Programming-V2


1.4 Trend Display

One or more graphical trend displays shall be provided to show the change in value, expressed in engineering units, for selected variables over the immediate past time period. Where possible, the same trend configurations used on the central SCADA system shall be available on the OIT. Trend data shall be stored locally on the OIT for a minimum 24 hour period.

1.5 Access Levels

Program the OIT so as to provide four separate access levels. Password levels required are:

1. LEVEL 0 (PUBLIC) – allows view only access to all operating screens

2. LEVEL 1 (OPERATOR) – allows access to lower levels, with ability to change state of any device, change analog setpoints, and acknowledge alarms

3. LEVEL 2 (SUPERVISOR) – allows access to lower levels, and can adjust program variables.

4. LEVEL 3 (ADMINISTRATOR) – allows access to lower levels, can adjust program logic, and can assign, re-assign password access to lower levels.

The default or power-on mode for the password shall be Level 0.

Any log-on or log-out attempt (successful or otherwise, and regardless of Level) shall be an event added to the alarm/event history at the device.

After fifteen minutes with no keypad activity the password level shall reset to Level 0.

1.6 Alarm and Event Log

Program the OIT so as to acquire (in real time) a log of alarm and event messages from the PLC to which the OIT is connected. Insert the date and time of occurrence at the beginning of each message describing the change of state. Maintain these logged messages in a first in/first out queue of a minimum 200 messages.

Note that the alarm/event log shall also capture for display the action and date and time of each attempted log-in, each successful log-in, and each log-out.

1.7 Alarm and Event Display

Program the OIT to allow recall of the alarm and event messages in order of most recent to least recent and display the messages in groups of 20 to a display.

56 of 183


Appendix C

Alarming

T-13010-05 -Alarming-V2


1. Alarming

1.1 General

This guideline shall be complied with in all control systems or equipment that generate alarms for process control applications. It shall also include details on the types of alarms that are required to be brought into the control system. Some examples have been provided herein, and the requirements of each specific facility will be determined at the detailed design stage.

Consultants shall comply with this design guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City

Uniformly applied principles of alarming will assist operators in responding appropriately to abnormal situations and this design guideline will:

1. determine information that needs to be alarmed 2. prioritize alarm information given to operators

1.2 Operating Conditions

Plant control rooms are not normally staffed. Operators (Plant Technicians) work in the process area and are trained and experienced on processes within the work area. Cross training on other areas is a goal, but not all operators will necessarily have the same level of skill and knowledge.

Work areas in the plant are staffed 24 hours a day.

1. In wastewater treatment plants, operators are assigned to one or more processes within a work area.

2. At water treatment plants, an operator may be assigned to the whole plant or a work area comprising part of the plant.

The process equipment is fully automated. Equipment automatically shuts down when operating beyond its safe limits. Auxiliary safety equipment starts automatically when needed; for example, ventilation fans during high toxic gas concentrations.

1.3 Operation Practices

Operators will periodically, typically every 45 to 60 minutes, review alarm summary displays for their process(es) or work areas on PCS workstations. After dealing with the alarms that have come up, operators will return to other duties.

Operators will be paged for immediate alarms. These alarms represent conditions that must be dealt with immediately and cannot wait for the periodic alarm summary display review.

57 of 183


Appendix C

Alarming



Important alarms that affect more than one operator are required to be paged to all operators involved. That is, a shut down of one process may affect another process or work area. In cases like this, the operator who is responsible for correcting the problem should be given an alarm message relating to the cause of the problem. Operators who are responsible for dealing with subsequent processes should be given alarm messages relating to the problem. For example, at Highland Creek, if sludge pumping from storage fails, the operator in that area should be paged with the pumping fail message. This operator deals with getting the sludge pumping back in operation. The operator in dewatering should be paged with a loss of sludge feed from storage alarm message. This operator deals with problems in dewatering caused by the loss of sludge feed.

1.4 Alarm Priority

There are 4 levels of alarm priority.

1. Pager (WIN911) Priority alarms require immediate operator attention.

2. High (H) Priority alarms require operator attention within the normal alarm review period (approximately an hour).

3. Medium (M) Priority alarms require operator attention within a shift.

4. Low (L) Priority alarms require operator attention within a shift.

Alarm priorities can be changed at the discretion of the facility manager.

58 of 183


Appendix C

Alarming



1.5 Alarm Creation and Priority Assignment Guidelines

While adding to or changing the alarm list in the Master PCN during the detailed design stage, the Consultant and City shall give careful consideration to how alarms are generated (referred to as “alarm conditioning”). Simply adding I/O points to the alarm list is not sufficient – Designers shall consider the conditions that can lead to an alarm condition and design the alarm logic and alarm descriptions accordingly.

For example, a low flow switch should not be alarmed if the switch was tripped due to the normal condition of a pump stopping. Another example is a high discharge pressure should not be alarmed if it is only momentary and the designers consider momentary high pressures to be normal conditions.

For new alarm points, the Consultant and the City will review and assign priority for each alarm during detailed design as part of the modifications to the Master Process Control Narrative. Examples presented in this section form a guideline and may not cover every situation. Priority assignment will be made on a case-by-case basis by the Consultant and approved by the City during review of the Master PCN.

Alarms need to be assigned priority consistently across the plant in order to more safely cross train operators on different processes and work areas. Alarms shall be assigned priority consistently across all plants in order to compare performance.

Examples of alarms at plants

Alarm Priority

1. Critical water quality conditions WIN911

2. Pump fail and its standby unit could not be started up. WIN911

3. Pump fail and its standby unit was started successfully. H

4. Safety alarms:

Chlorine leak WIN911

Chemical spill (ferric chloride, sodium hypochlorite) WIN911

Combustible gas (methane, natural gas) concentration high WIN911

Toxic gas (carbon dioxide, hydrogen sulfide) concentration high WIN911

Flood WIN911

Other safety alarms WIN911

5. High wet well level M

6. Impending high temperature condition of a pump motor H

7. Process controller failure. WIN911

59 of 183


Appendix C

Alarming



Alarm Priority

8. Historical logging computer failure WIN911

9. Failure of auxiliary systems (instrument air, lubrication system, heating, cooling, ventilation system, backup instrument power)

H

10. Instrument failure alarm H

11. Dissolved oxygen concentration low M

Example alarms at remote water supply sites

These alarms are needed at central pumping control for direct action to control the process and at the work area to be aware of problems.

Alarm Priority

1. High discharge pressure WIN911

2. Low discharge pressure WIN911

3. Power high WIN911

4. Power fail WIN911

5. Surge system fail WIN911

6. Pump fail (all pumps currently have manual remote start/stop) WIN911

7. Unauthorized access WIN911

8. Reservoir high WIN911

9. Reservoir low WIN911

10. Communications fail WIN911

11. No Flow (with pump running) WIN911

12. Flood Alarm WIN911

Alarms at remote sewage pumping stations

Alarm Priority

1. Pump failed and its standby unit could not be started up. WIN911

2. Unauthorized Access WIN911

3. Flood Alarm WIN911

4. Communications fail WIN911

60 of 183


Appendix C

Alarming



Chlorine leak alarms

1. Chlorine leak alarms are treated differently at the plants. This difference is acceptable as long as minimum safety requirements are met.

2. At the Ashbridges Bay Plant, chlorine leaks require immediate broadcast paging to all personnel because chlorine is stored in tank cars. At the Humber Plant, chlorine leaks require immediate broadcast paging to all personnel because residential areas are very close to the plant.

3. At water treatment plants, chlorine leaks should be paged to the designated operator, but not broadcast. The reported chlorine leak is investigated and if required, the plant’s

public address system is used to broadcast the alarm.

1.6 Alarm Configuration in Field

Safety alarms are defined as those involving personal safety of the operator, other staff and the public (fire, gas leak, chorine leak, flood, etc.).

1. All safety equipment such as chlorine gas detectors, fire detectors, etc. shall be specified to provide a separate set of contacts for alarm transmission to the control system.

2. All alarms and safety equipment contacts shall be double-pole double-throw, form C rated for 3 Amp AC or 5 Amp DC minimum.

3. Safety alarm loops shall be energized (supervised) in the normal state.

4. Safety alarm loops shall have an alarm circuit test switch which tests lights, horns and circuits for readiness to operate. This switch will be used periodically to test operability of the circuit. A full simulation of safety systems will also be performed periodically to test instruments, controls and controlled equipment with the test switch in normal position.

5. All safety alarms will be monitored by the control system.

The following table shows configuration by alarm type:

Alarm Type

Hardwire to Area Station

Hardwire to Local Horn

(130 db)

Hardwire to Local Beacon

Colour

(Note 1)

Where Silenced

Where Acknow-

ledged

Safety Alarm

Yes Yes

(note 2)

Yes

(note 3)

Red Local

(note 4)

Local

(note 4)

Other Alarm

No No No Yellow N/A Local

(note 4)

61 of 183


Appendix C

Alarming



Notes:

1. Alarm characters are black.

2. Chlorine leak alarm is also hardwired to plant siren at the Ashbridges Bay Plant.

3. Beacons are required at each entrance to the affected area in the case of chlorine leak alarms.

4. Local is the immediate area, panel or nearby designated safe location.

1.7 Alarm Activation

Alarms of any priority may require latching with manual reset at the local panel. Manual reset is required for all alarm conditions which affect personal safety.

Automatic reset of some alarms is acceptable for alarms caused by process changes such as undervoltage (power failure), seal water low pressure or low suction pressure

Alarm disable (suppression) during start-up or shut-down of a device or a process is acceptable. These alarms are determined during control strategy design on a case-by-case basis or are part of manufacturer designed controls for a particular piece of equipment.

All software functionality associated with a disabled alarm is also disabled.

The ability to manually disable alarms requires a high level of security login.

1.8 Alarm Monitoring

Alarms originating from field contacts or generated by software shall be displayed at area operator stations (if present) and central operator stations. While adding alarms to an existing SCADA system, the Systems Integrator shall follow the colour convention and styles/grouping that already exist so the alarm database remains consistent unless otherwise instructed by Toronto Water.

The preferred alarm monitoring practice is to bring into the SCADA system sufficient alarm details as needed for remote diagnosis of the problem. The alarm and related information should enable appropriate responses to be taken. The amount of alarms from a particular device or facility should be reviewed on a case by case basis for feasibility and economy.

1. In areas of the plant where there are a large number of closely related Medium priority alarms, it is sometimes desirable to annunciate the alarm conditions individually at the area station and retransmit a common alarm to the central operator station.

2. Alarm conditions from auxiliary systems that are essential to the functioning of the control system or process equipment (instrument air supply systems and equipment lubrication systems for example) should be monitored.

WIN911 Priority alarms need more information to be monitored than other types of alarms so that appropriate action may be taken quickly.

62 of 183


Appendix C

Alarming



1. Example: Sewage pumping station high wetwell alarm needs to be augmented by remote monitoring of wetwell level and pump status. Note that sewage pumping station communications failure would also require immediate paging.

2. Example: Combustible gas alarm needs to differentiate between high combustible gas concentration, sensor fault and maintenance mode. The alarm needs to be augmented by the actual combustible gas concentration.

1.9 Pager Operation

The paging system is to communicate alarms from the process control system, security system and telephone system to personal pagers or phone/cellular phone. The alarm notification system is used to transmit critical alarms from the facility’s SCADA system and then transmit them

using the Win911 Server.

A pager may be assigned to a process or group of processes within the work area or the work area. An operator who has possession of the pager is responsible for responding to alarms. The same ‘beep’ tone shall be used for all pager alarms and shall display the alarm text description.

The paging system is configured to handle temporary staff shortages. For example, if a member of the team does not show up for work on time or calls in ill, people on-site need to reassign the paging areas. That is, the paging will roll over from one work area to another or from one process to another. If a page is not acknowledged within a set time, the paging will roll over to another designated person.

The Consultant is to be aware that any modifications or additions to the critical alarms that require notification must be integrated to the existing database that resides within the Win911 Server.

The Consultant is to ensure that the alarm notification complies with current facility standards. The alarm notification techniques vary between facilities and can be in the form of one of the following options;

1. An alphanumeric message that includes the tag name, time and description of the message that is transmitted to either an alphanumeric pager or via a SMS message to a cellular phone. This technique requires a standard dial modem to be installed within the Win911 server.

2. A voice message that includes the tag name, time and description of the message that is transmitted to a telephone or cellular phone. This technique requires a Dialogic card to be installed within the Win911 Server. Voice messages should be approved by the facility’s

staff for audibility and content.

63 of 183


Appendix C

PCS Factory Acceptance Testing

T-13010-06 -PCS Factory Acceptance Testing-V2


1. PCS Factory Acceptance Testing

1.1 General

The PCS Factory Acceptance Test (FAT) demonstrates that all SCADA and controller software are working properly and that all software configurations match the requirements identified in Detailed Software Design, including the detailed process narratives, and logic flow chart diagrams.

Test the software under all possible process conditions in order to ensure the software contains no defects. Include a wide range of operating scenarios, with all process setpoints, interlocks and alarm limits.

1.2 Objectives

The overall objectives of the PCS Factory Acceptance Test are to:

1. Confirm and document that the RPU I/O matches the type and quantity identified in the control schematics. Perform I/O checks to confirm the tag number;

2. Confirm and document that the individual device logic operates all field equipment correctly and safely, as described in the detailed process narrative, logic flow charts and HMI functionality;

3. Confirm and document that the software is fully integrated into the treatment process and plant/facility-wide control logic and operates correctly and safely, through the HMI and OIT (where applicable) as described in the detailed process narratives and logic flow charts

4. Confirm and document that the data to be integrated with eOPS, POMS, WMS, WIN 911 and LIMS are properly identified and operates correctly as described in the Process Control Narratives.

1.3 Submittals

The following submittals are made during the FAT procedure:

1. Submit the test plan: testing forms, procedures and schedules of work, not less than two (2) weeks prior to the scheduled test date.

2. Submit copies of the PLC program, HMI graphics, OIT graphics and simulation software on CD. This submittal should also include any Active X or other controls required allowing full simulation to be presented at the City site during the Pre FAT.

3. Submit copies of the current Control Flow Charts, Process Control Narratives, P&IDs and I/O Lists.

64 of 183


Appendix C




4. The test plan must be approved in writing by the City, prior to commencement and should show the schedule of work to include dates.

5. Submit the Factory Acceptance Test Report within one (1) week after completion of FAT.

6. On completion of the FAT, a locked down version of the HMI, OIT, simulation software and PLC software will be submitted to the ITM group for record. Once the FAT has been completed, it is assumed that there will be no modifications to any software to be integrated into the PCS.

1.4 Testing Process

The System Integrator shall conduct the tests. Consultant and the City’s representative will

actively participate in the tests. The City reserves the right to test any specified hardware/ software function whether or not explicitly stated in the test submittal.

The System Integrator is to invite the following representatives of the following groups to attend the FAT;

Facility Operations/Process End Users

ITM

PCSU

Consultant

The Consultant, PCSU (will coordinate with ITM as required) and the end user must attend the entire FAT and any possible subsequent FAT(s) as they sign off on all check lists.

The System Integrator should meet the following criteria prior to the start of the tests:

Complete submittals and resolve disputes.

Make hardware and software fully operational.

Have a Consultant and City's representatives reviewed and approved test procedure.

Set a test date, which is agreeable within the contract schedule, minimum of 2 weeks prior to testing.

Conduct factory acceptance tests at the System Integrator’s facility within the Greater Toronto Area or on-site if requested by the City. Limit testing, in general, to seven (7) hours per day.

65 of 183


Appendix C




Hold a meeting each morning to review the day’s test schedule and a meeting each evening to review the day’s test results and review or revise the next day’s test schedule. At the completion of the test, meet to review the list of deficiencies. The City will indicate those items which must be corrected prior to shipment.

At the discretion of the City, the FAT may be rejected. The FAT may be repeated as many times as required until the City has deemed the final software product to be satisfactory to progressing to field implementation and the Site Acceptance Testing. The City’s project manager will be

required to determine if the FAT is satisfactory.

Representatives of the System Integrator and the Consultant shall sign a FAT Sign-Off form to indicate completion of the tests. A deficiency list shall be submitted indicating required changes including a schedule for completion.

1.5 Testing Documentation

Prepare "Factory Acceptance Test-Check Sheet" (Attached for information only. Consultant should request document in its original format) showing the following information:

1. For all points list the device tag name, RPU tag name, Description of point, RPU I/O Address (if applicable), Date Verified, Comments and Issue Log Number.

2. For field inputs and outputs also list, HMI/RPU Address, I/O type, Rack, Slot, Remote I/O block (if applicable), Module Point or Channel, RPU Device Range (Minimum, Maximum and Units), RPU Range Raw Signal Test (Minimum, Mid range and Maximum), HMI Device Range (Minimum, Maximum and Units) and HMI Engineering Units Test (Minimum, Mid-range and Maximum

3. For analog input alarms also list the Trip point for the alarm in percent of span, Engineering units, Time Delay, Alarm NACK, Alarm ACK, Operator Control (Adjust Trip point and Disable), Alarm area, alarm priority, Paging Group and Data Transfer Frequency.

4. For discreet input alarms also list, time delay, Alarm NACK, Alarm ACK, Operator Control (Disable), Alarm area, alarm priority, Paging Group and Data Transfer Frequency.

5. For all alarms show and test alarm are conditioned as documented in Process Control Narratives.

6. For Virtual Points also list, read/write access, minimum value, maximum value, default value and units of measurement.

7. For trend points also list trending attributes (Frequency and Deviation) and Data Transfer Frequency.

66 of 183


Appendix C




Prepare "Process Logic Test Sheet" (Attached for information only. Consultant should request document in its original format) with information describing the normal and abnormal device operations. Provide a row for each transition to be tested and show the following information:

Current State Action/Transition Final State/Effect Comments List the tags and their current state relevant to testing the transition or action and observing the final state or effect List the HMI symbol colour and shape

Describe the action or transition that is being tested, e.g. Field Mounted Start P.B. is Depressed

List the tags and their expected final state List the HMI symbol expected colour and shape

During the test, note any deviation from the expected final state or effect

Normal Device Operations:

1. Local Mode Operations

2. Computer Manual Mode Operations

3. Transfer from Local to Computer

4. Transfer from Computer to Local

5. Computer Automatic Mode Operations

6. SCADA/Automation

Abnormal Device Operation

1. Uncommanded Operations

2. Unresponsive Commands

3. Device Operation Permissives

4. Device Alarms

5. Emergency Stop

67 of 183


Appendix C




1.6 Software Simulation

Prepare automated test programs using simulation software. Run test programs to demonstrate all functions in control logic and functions of operator interface screens.

68 of 183

Date:

Plant:

Process:

Location:

RPU:

PCS SITE ACCEPTANCE TEST

CHECK SHEET

Field Points Virtual Points Analogue Trends Alarms

Min Max Units Min Mid Max Min Max Units Min Mid Max Fre

q.

De

via

tio

n

Da

ta T

ran

sfe

r F

req

.

Ad

just

Trip

Pt

Dis

ab

le

CommentsTag Name Description RP

U I

/O A

dd

ress

HM

I/R

PU

Ad

dre

ss

RPU I/O

Typ

e

Ra

ck

Slo

t

De

fau

lt V

alu

e

Acce

ss R

or

R/W

Ma

x V

alu

e

HMI Engineering

Units TestHMI Device Range

Mo

du

le P

oin

t o

r C

ha

nn

el

RPU Range Raw

Signal Test

Da

te V

erifie

d

Min

Va

lue

RPU Device Range

Da

te V

erifie

d

Trip

Po

int

% o

f S

pa

n

Ala

rm A

rea

Ala

rm P

rio

rity

En

g.

Un

its

Trending

Attributes

Un

its

Da

te V

erifie

d

Da

te V

erifie

d

Issu

e L

og

No

.

Tim

e D

ela

y

Ala

rm N

AC

K

Ala

rm A

CK

Operator

Control

Pa

gin

g G

rou

p

Da

ta T

ran

sfe

r F

req

.

Ala

rm C

on

ditio

nin

g

Signatures: PCS Analyst/Developer ________________________

PCS Site Acceptance Test-Check Sheet-V2

PCS Coordinator ________________________

Page: 1 of 1 (Addm-6)

Consultant ________________________

Printed: 2/13/2017

69 of 183

Process Logic Test Sheet Date: __________

Test ID

Facility-

Process

Device

OperationMode Current State Action/ Transition Final State/Effect Con City Comments

Issue

Log

Normal Local

List the tags and their current state relevant to testing the

transition or action and observing the final state or effect.

List the HMI Symbol And Colour and shape.

Describe the action or transition that is being tested, e.g.

Field Mounted Start P.B. is Depressed

List the tags and their expected final state. List the

HMI symbol expected colour and shape.

During the test, note any deviation from the

expected final state or effect

Normal

Computer

Manual

Normal

Transfer from

Local to

Computer

Normal

Transfer from

Computer to

Local

Normal

Computer

Automatic

Local

Abnormal

Device

Operation

Permissives

Local

Abnormal

Emergency

Stop

Computer

Manual

Abnormal

Uncommanded

Operations

Computer

Manual

Abnormal

Unresponsive

Commands

Computer

Manual

Abnormal

Device

Operation

Permissives

Computer

Manual

Abnormal Device Alarms

Computer

Manual

Abnormal

Emergency

Stop

Computer

Auto

Abnormal

Uncommanded

Operations

Computer

Auto

Abnormal

Unresponsive

Commands

Computer

Auto

Abnormal

Device

Operation

Permissives

Computer

Auto

Abnormal Device Alarms

Computer

Auto

Abnormal

Emergency

Stop

1

Equipment Location, Identification and Process Condition

(Type description of the objective of the Test)

Process Logic Test Sheet-V2 Page 1 of 1 (Addm-6) Mar 201670 of 183


Appendix C

PCS Site Acceptance Testing and Commissioning

T-13010-09 -PCS Site Acceptance Testing and Commissioning-V2


1. PCS Site Acceptance Testing and Commissioning

1.1 General

The PCS Site Acceptance Test (SAT) demonstrates that all SCADA and controller software and hardware are working properly and that all software configurations match the requirements identified in Detailed Software Design, including the detailed process narratives, operating manuals and logic flow chart diagrams, both confirmed in the Factory Acceptance Test.

The software is the final versions that have been tested at the end of the FAT stage to ITM. This software has been locked down and cannot be modified by the Contractor/Consultant after the FAT or prior to the SAT.

Test the software under all possible process conditions in order to ensure the software contains no defects. Include a wide range of operating scenarios, with all process setpoints, interlocks and alarm limits. In phased installation, test each process separately after completing the installation in the process. In addition, test the complete system performance after each of the processes have successfully passed their SAT.

Also see "PCS Factory Acceptance Testing" for objectives and definitions.

1.2 Submittals

The following submittals are made during the SAT procedure:

1. Submit the test plan: testing forms, procedures and schedules of work not less than two (2) weeks prior to the scheduled test date. The test plan must be approved in writing by the City, prior to commencement.

2. Submit the Site Acceptance Test Report within one (1) week after completion of SAT.

3. On completion of the SAT, a locked down version of the HMI, OIT, simulation software and PLC software will be submitted to the ITM group for record. Once the SAT has been completed, it is assumed that there will be no modifications to any software to be integrated into the PCS.

1.3 Testing Process

The System Integrator shall conduct the tests. Consultant and the City’s representative will

actively participate in the tests. The City reserves the right to test any specified hardware/ software function whether or not explicitly stated in the test submittal.

The System Integrator is to invite the following representatives of the following groups to attend the SAT:

71 of 183


Appendix C




Facility Operations/Process End Users

ITM

PCSU

Consultant

The Consultant , PCSU (will coordinate ITM support as needed) and the end user must attend the entire SAT and any possible subsequent SAT(s) as they sign off on all check lists.

The System Integrator should meet the following criteria prior to the start of the tests:

Complete submittals and resolve disputes.

Make hardware and software fully operational.

Have a Consultant and the City's representatives reviewed and approved test procedure.

Set a test date, which is agreeable within the contract schedule, minimum of 2 weeks prior to testing.

HMI, OIT and PLC software will be loaded into the SAT testing equipment prior to deployment on the live system. The testing equipment will be provided under the contract or at each facility by the City if possible.

Limit testing, in general, to seven (7) hours per day. Hold a meeting each morning to review the day’s test schedule and a meeting each evening to review the day’s test results and review or

revise the next day’s test schedule. At the completion of the test, meet to review the list of

deficiencies. The City will indicate those items which must be corrected prior to Substantial Performance.

At the completion of the SAT it is the responsibility of the System Integrator, Consultant and City's representatives to sign-off all forms pertaining to the testing of the modified system. Following the sign-off of the SAT, the software can be moved into the post-SAT phase where the system can be integrated into the overall facility operations.

Upon completion of the SAT, the modified software will move into the Post-SAT phase. In this phase the System Integrator/Consultant will work with ITM to install the software into the production environment. Modifications will need to be made to the Main and Backup servers and new graphics will need to be distributed to the facility’s iClient computers, Win911 server, file server and iTerminal Server.

Below is an outline denoting the division between the SAT and Post-SAT environments:

72 of 183


Appendix C




1.4 Testing Documentation

Prepare "PCS Site Acceptance Test-Check Sheet" (Attached for information only. Consultant should request document in its original format) showing the following information:

1. For all points list the device tag name, RPU tag name, Description of point, RPU I/O Address (if applicable), Date Verified, Comments and Issue Log Number.

2. For field inputs and outputs also list, HMI/RPU Address, I/O type, Rack, Slot, Remote I/O block (if applicable), Module Point or Channel, RPU Device Range (Minimum, Maximum and Units), RPU Range Raw Signal Test (Minimum, Mid range and Maximum), HMI Device Range (Minimum, Maximum and Units) and HMI Engineering Units Test (Minimum, Mid-range and Maximum

3. For analog input alarms also list the Trip point for the alarm in percent of span, Engineering units, Time Delay, Alarm NACK, Alarm ACK, Operator Control (Adjust Trip point and Disable), Alarm area, alarm priority, Paging Group and Data Transfer Frequency.

73 of 183


Appendix C




4. For discreet input alarms also list, time delay, Alarm NACK, Alarm ACK, Operator Control (Disable), Alarm area, alarm priority, Paging Group and Data Transfer Frequency.

5. For all alarms show and test alarm are conditioned as documented in Process Control Narratives.

6. For Virtual Points also list, read/write access, minimum value, maximum value, default value and units of measurement.

7. For trend points also list trending attributes (Frequency and Deviation) and Data Transfer Frequency.

Prepare "Process Logic Test Sheet" (Attached for information only. Consultant should request document in its original format) with information describing the normal and abnormal device operations. Provide a row for each transition to be tested and show the following information:

Current State Action/Transition Final State/Effect Comments List the tags and their current state relevant to testing the transition or action and observing the final state or effect List the HMI symbol colour and shape

Describe the action or transition that is being tested, e.g. Field Mounted Start P.B. is Depressed

List the tags and their expected final state List the HMI symbol expected colour and shape

During the test, note any deviation from the expected final state or effect

Normal Device Operations:

1. Local Mode Operations

2. Computer Manual Mode Operations

3. Transfer from Local to Computer

4. Transfer from Computer to Local

5. Computer Automatic Mode Operations

6. SCADA/Automation

Abnormal Device Operation

1. Uncommanded Operations

74 of 183


Appendix C




2. Unresponsive Commands

3. Device Operation Permissives

4. Device Alarms

5. Emergency Stop

75 of 183


Appendix C

PCS Documentation

T-13010-10 -PCS Documentation-V2


1. PCS Documentation

1.1 General

This standard describes the requirements for Consultants and Contractor Manuals, which is to ensure that complete documentation is obtained and maintained.


Typically, Toronto Water facilities have existing SCADA Operations Manuals, Software Manuals, etc. The Consultant/Contractor/System Integrator will obtain a copy and update it as appropriate or create a new one as deemed necessary by Toronto Water.

1.2 Preparation

The Consultants shall include in the contract document that the contractor is responsible for preparation of the Equipment Operation and Maintenance Manuals for the entire process control system hardware and software. The Contractor shall obtain, prepare and assemble the operation and maintenance data/manual of the equipment and systems as well as installation documentation from the suppliers and manufacturers and the information shall be compiled into the Operating and Maintenance (O&M) Manuals. The Consultants shall ensure that the specified equipment and instrument manuals are provided by the contractor in compliance with the requirements of the I&C and SCADA specifications under the contract.

1.3 O&M Manual General Requirement

Submission requirements shall include the following information in the various submittal(s):

1. An outline of the O&M documentation including a complete list of the manuals. Indicate title, content, and Specification sections covered. Include formats and samples of representative pages of the manuals.

2. Draft copies in specified quantities of all documentation prior to shipping

3. Complete, ready-for-test copies in specified quantities prior to field testing or training.

4. Final documentation reflecting as-built status in specified quantities two months after commissioning.

Quantities of printed and software copies of the O&M are to be specified in the contracts based on a project’s needs. If this information is not included, Consultants and

76 of 183


Appendix C

PCS Documentation



Contractors are to provide the following quantities of their respective manuals as detailed below:

Document Draft

Manuals

Quantity

Final Version

Quantity

Source

SCADA Operation Manual 6 8 Consultants/Contractor

Contractor Equipment Operation and Maintenance Manual, including the following:

Control System Hardware Manuals

Software User’s Manual Configuration Manual Custom Software Manuals Source Materials Drawings – copies Drawings - reproducible

6 6

Contractor

In addition to the printed copies shown above, provide an electronic document version for each submission. (See notes below)

Printed Format: 1. Bind manuals in hard covered, loose-leaf, vinyl flat back binders for holding three-

hole, ANSI Standard size A (8.5x11) paper stock.

a. The manuals may be subdivided into as many volumes as required. b. Do not use binders more than 80mm thick.

c. Use binders that are the same in appearance except for contents labeling.

d. Lithographically print the Owner’s name, Contract description and number and

volume number on the front cover of each binder.

e. Identify the manual title, and volume number on the back edge (spine).

2. Print documents in accordance with the following requirements:

a. Use a clear 20mm margin on the top, bottom and right edge. Use a clear 30mm margin on the left (binding) edge.

b. Use either ANSI Size A (8.5 x 11) for text and drawings or Size B (11 x 17) for drawings.

c. Do not reduce originals to a degree which compromises legibility.

77 of 183


Appendix C

PCS Documentation



d. Have no lettering, symbols or characters less than font size 11in height.

e. Use plain font such as Times New Roman

f. Use offset, letterpress, diazo or xerographic print techniques. Do not use Xerography for pages which are available as offset or letterpress copies. Provide details which are crisp, black, dense and fully legible.

g. Punch materials for binding with holes to match the binders. Do not re-punch or inaccurately punch pages.

Electronic Format: 1. The Contractor shall structure the electronic documents in the format required by the

City and the Consultants shall ensure that these requirements are included in the contract document. The Contractor shall submit the electronic document to the Consultants and the City for inclusion in the Toronto Water Document Management System (Content Server & WMS) so they can be associated with data stored in the Works-wide Maintenance Management System.

2. Provide electronic documents on CD/DVD-ROM.

3. Provide electronic documents in its native format (i.e. Word, Excel, Access, AutoCAD etc) as appropriate. Use the software version cited in Toronto Water standards as the current authorized version.

Contents: 1. Organize operation and maintenance manuals to include the specified information.

The order of the material in the manuals may differ from the specifications.

a. Provide a table of contents in each binder for the contents of all volumes.

b. Provide a table of contents specific to the material in the binder or manual. Identify subject matter by title and page number.

c. Provide a list of illustrations with each manual and include the number, title, and page number of each illustration.

2. Identify products by their functional names in the table of contents and at least once in each chapter or section. Thereafter, abbreviations and acronyms may be used if their meaning is explained in a table in the back of each binder. Do not use model or catalog numbers or letters for identification exclusively.

3. Mark each product data sheet to identify the specific products and component parts used and applicable data. Delete inapplicable information.

4. Supplement product data sheets with drawings and text to fulfill specified requirements of the operation and maintenance manuals.

5. Provide licenses required for operation, indicating required renewal dates if necessary.

6. Include the following in the operation and maintenance manuals:

78 of 183


Appendix C

PCS Documentation



a. Description of equipment and software

b. Theory of operation

c. Applicable circuit diagrams and schematics

d. Calibration procedures

e. Preventive maintenance schedule

f. Corrective maintenance procedures

g. Parts lists applicable to equipment

h. Testing certifications, inspection reports, Contractor’s verification reports and

final performance acceptance test.

i. Guarantees/warranties and their terms and conditions, as well as their expiry dates.

1.4 SCADA Operations Manual

Provide draft manuals in accordance with the following requirements:

1. Bind these manuals separately from other information and provide information required to perform operating functions.

2. Make the manuals available for operator training.

3. Split material into separate binders according to work area.

Include the following information:

1. A simple pictorial presentation and description of the system, what it does and how this is accomplished.

2. A functional description of operation interfaces at each level of control.

3. Operations narratives describing functions of the control programs. Include process setpoints, control parameters and alarm limits. Explain how to set up the controls to run in local, remote-manual and remote-automatic control modes. Show how to operate from the graphic displays. Build upon the process narratives.

4. A description of each type of data format.

5. A description for each of the keyboard or other controls used in operation, its task and the response to the operator manipulation.

6. A description of each report.

7. A glossary of terms.

8. A separate step-by-step procedure for each action to be performed in operation including, but not be limited to, the following:

79 of 183


Appendix C

PCS Documentation



a. Start/stop operation.

b. Emergency procedures.

c. Control mode changes.

d. Alarm acknowledge and reset.

e. Printing screens and reports.

f. Retrieve archived historical data.

g. Software operations such as changing date and time, point calibration, point activation, point deactivation, tuning parameter and set-point changes.

h. Software procedures used to determine that the system is functioning properly.

i. Computer and peripheral equipment operating instructions.

j. Procedures for maintenance.

7. Screen prints in colour for all graphics, trends and alarm displays.

8. Control system plan drawings showing location of all devices

1.5 Contractor Equipment O&M Manual – Prepared by Contractor

Equipment and Instrument Descriptions: Provide the following information for each model piece of equipment and instrument:

1. Manufacturer’s design and performance specification data and descriptive literature.

2. Equipment dimensions, installation requirements, typical mounting details showing methods and materials required for installation and recommendations.

3. Required and optional accessories lists.

4. List of recommended spare parts and spare parts provided.

5. Electrical/pneumatic signal and power connection diagrams.

6. Operation and maintenance manuals.

Provide a written narrative describing the operating parameters, product maintenance requirements, performance limitations, warranty requirements, and recommended inspection requirements. Instrument Data Sheets:

1. Data sheets have been prepared during design and implementation to cover each instrument.

2. Each instrument will be listed and pertinent information recorded including: tag number and description, complete model number, ranges, setpoints, materials and special mounting details for non-typical applications.

80 of 183


Appendix C

PCS Documentation



3. The data sheets will be based on ISA Standard -S20: Specification Forms for Process

Measurement and Control Instruments, Primary Elements and Control Valves.

4. The data forms are available for the following instruments:

Annunciators Receiver Instruments Potentiometer Instruments Flowmeters - Magnetic Flowmeters - Orifice Plates and Flanges Flowmeters - Positive Displacement Meters Flowmeters - Rotameters (Variable Area Flowmeters) Flowmeters - Turbine Level Instruments - Capacitance Type Level Instruments - Displacer or Float Level Instruments - Gage Glasses and Cocks Pressure Instruments Pressure Gages Pressure Switches Temperature Instruments - Filled System Temperature Instruments - Industrial Bimetal and Glass Thermometers Temperature Instruments - Resistance Temperature Sensors Temperature Instruments - Thermocouples and Thermowells

5. Data forms are also available for the following control devices:

Valves - Control Valves Valves - Pressure Control Valves, Pilots and Regulators Valves - Pressure Relief Valves Valves - Self-Actuated Temperature Regulator Valves - Solenoid Valves Rupture Discs Traps and Drainers

Calibration Certificates and shop drawings for mounting fixtures from the manufacturer shall be submitted for each instrument calibrated prior to installation.

1.6 Control System Hardware Manuals – Prepared by Contractor

General: 1. Cover equipment comprising the system in the hardware instruction manuals. Provide

instructions for operation and maintenance of the installed system as well as operation and maintenance instructions for the individual equipment units comprising the system.

81 of 183


Appendix C

PCS Documentation



2. Provide a level of comprehension so that an experienced electronics or instrumentation and control technician can understand them. Convey an understanding of how the system operates and provide sufficient procedures for operation and maintenance. Use abbreviated tabular data such as charts, tables, checklists and diagrams, whenever practical, in lieu of written text. Make drawings, tables, etc. an integral part of the manuals.

3. Standard hardware manuals will be acceptable, provided that sheets are included to explain the specific models and options of the equipment provided.

Organization and Content:

1. Provide, in an introduction section, a brief explanation of the function of the equipment covered. Be concise and do not include detailed descriptions. Provide a quick orientation to the use and purpose of the manual and its relationship to the system and/or equipment.

2. Describe, in a safety precautions section, major hazards to personnel and equipment that are peculiar to the equipment or jobs covered. Intersperse specific hazard information, cautions or warning notes at appropriate points throughout other sections of the manual.

3. Limit a physical description section to physical description (size, dimension, weight, special attachments and physical orientation or clearances for installation and operation. Identify any special environmental (cooling, exhausting, or noise) constraints.

4. Explain, in a functional description section, how the various functions operate together to cause the desired results. Include block diagrams and flow diagrams for clarification and understanding. Provide text and diagrams which mutually support each other.

5. Include maintenance oriented operating procedures for the individual equipment in an operating procedures section so that maintenance personnel will be able to verify proper operation.

6. Describe each equipment, unit, and assembly in detail with regard to technical or theoretical operation. Include information to the component level. Describe each circuit and mechanical mechanism. Cross-reference descriptions so that the functions of each equipment are covered. Use schematic diagrams, sketches, equivalent diagrams, tables, and graphs to supplement the text.

7. Include the applicable checkout, troubleshooting, servicing, removal and replacement, and in-place repair procedures which are performed on the equipment, stand-alone and on a system basis. Provide written procedures for each and every adjustment point of the equipment.

8. Provide a tabular listing of special tools, equipment, and test equipment applicable to the test, adjustment and fault isolation procedures. Write maintenance instructions to enable correct use of test equipment.

82 of 183


Appendix C

PCS Documentation



9. Provide checkout procedures to verify the satisfactory operation of the system, subsystem, or unit as applicable. If the checkout requires detailed step-by-step procedure, include such procedures. Clearly indicate why the checkout is performed and what conditions are to be satisfied.

10. Provide troubleshooting procedures to isolate faulty components. Sequence the troubleshooting procedures in logical progression from malfunction indication to location of the faulty component(s). Indicate special connections or test equipment required for the troubleshooting.

11. Provide servicing requirements for cleaning, lubricating, replenishing, and other housekeeping and preventative maintenance procedures that apply to the particular equipment. Make reference to the applicable manuals which describe various servicing procedures.

12. Provide removal and replacement procedures which contain step-by-step instructions for removal and replacement of items which are subject to frequent replacement. If special tools are required, identify them by name and part number.

13. Provide schematic diagrams, logic diagrams, and associated data necessary for maintenance personnel to trace circuits, make continuity checks, and accomplish general and specific troubleshooting on inoperative or malfunctioning circuits. Provide pin wiring diagrams and cabling and plug tables showing to-and-from wiring information. Provide a symbol chart where necessary to explain graphic symbols that appear on diagrams.

14. Provide parts lists for equipment. Provide clear traceability from the equipment to the replaceable component. Identify each component part with original manufacturer’s

name and part number. Identify component parts, or assemblies modified for the project by a part number. The parts lists may be tabulated or may be supplied in the form of engineering or manufacturing drawings.

1.7 Software User’s Manual – Prepared by Contractor

Provide a development manual which defines how the various software components are used and how the basic system may be altered using this software.

Describe the following:

1. Operating system use.

2. System software including compilers, editors, system utilities and file handlers.

3. User packages including data base generator, graphics generator, report generator, historical data system, process control language and general operator workstation interface.

4. System operation including cold start, warm start, time/date initialization and backup procedures.

5. System reconfiguration and regeneration procedures.

83 of 183


Appendix C

PCS Documentation



1.8 Configuration Manual – Prepared by Contractor

Provide a configuration manual which describes how software in the final system is configured. Describe the unique data and parameters of the system.

Include the following: 1. Point database showing parameters of points, including process I/O, internal points

and calculations.

2. Controller configurations, including software, points, control modules, spare I/O and memory.

3. System memory allocation.

4. Historical data configuration.

5. Display organization and configuration.

1.9 Custom Software Manuals – Prepared by Contractor

Provide complete documentation for all software developed specifically to meet requirements of this Contract, i.e. modifications to standard software and nonstandard software.

1. Structure the documentation such that each level develops a different degree of detail.

2. Begin with a broad approach (Systems Manual), focus on smaller pieces of the overall system (Subsystem Documentation) and finally pinpoint the finest detail (Program Documentation).

Provide a system’s manual which describes the overall content of the systems software.

Describe what is included in the software and not how the components function. Provide a global view of the system and a complete description of the interaction of the various software subsystems. Include the following:

1. Table of contents.

2. Overall narrative of the system including special techniques and general philosophies.

3. A block diagram showing the interaction of all subsystems.

4. A list of subsystems including a brief discussion of the purpose of each.

5. A list of programs included, categorized by the subsystem to which each belongs.

6. A description of files or tables within the system which are not unique to any particular subsystem. Files or tables used uniquely within a subsystem may be defined therein.

84 of 183


Appendix C

PCS Documentation



Provide manuals for each subsystem. Define the components of the particular subsystem, the relationships between the components and, in general, what occurs within the subsystem. For each subsystem, include:


2. Overview which describes the purpose and scope of the subsystem.

3. Narrative which details the operation of the subsystem, completely describing how the subsystem works, what the specific components are (programs, files, process points, tables, etc.) and how they interact.

4. Flowchart which depicts the overall system, showing components and their interactions.

5. Report summary which includes a list of reports produced by the subsystem and a layout of each.

6. Display summary which includes a list of displays produced by the subsystem and a layout of each.

7. Input/output summary which includes a list of inputs and outputs (e.g., process points, tables, and files) pertinent to the subsystem.

Fully document every program. Define the details of the particular program and show how each function is performed. For each program, include:


2. Overview which describes the scope and purpose of the program.

3. Narrative which describes exactly how the program functions. Include any calculations and process points.

4. Data flow diagrams (DFD) which show the program and inputs, outputs, files, or process points used.

5. Program structure chart (PSC) which shows the hierarchy of the program logic.

6. List of variables which defines each variable name in the program, including specific characteristics (e.g., real, integer, and array).

Provide memory maps of main and mass memory storage. On memory maps, show the numbered locations of absolute storage areas and information stored in these locations.

85 of 183


Appendix C

Training

T-13010-11 -Training-V2


1. Training

1.1 General

Training of City’s Operation and Maintenance staff shall be provided by the Consultants and the

Contractor. The training provided by the Consultants is to emphasize the application of instrumentation, process devices and SCADA system technology for the control of the plant treatment and supply processes. The training provided by the Contractor is to explain, demonstrate and review both the instrumentation, process devices and SCADA hardware and software that have been installed under the contract for the control of the plant’s treatment and

supply process.

Training by the Consultants includes the newly constructed work and the application of SCADA technology to the new and existing Process Control System (PCS).

Training by the Contractor for Operations staff will include the review of the hardware and software installed and configuration of SCADA and RPU software supplied under the contract. In addition, it also includes training on how to monitor the process, adjust process setpoints and respond to process alarms. Training for maintenance staff will include troubleshooting of malfunctioning field devices, calibration and repairs of instruments and equipment.

1.2 Training by Consultants

1.2.1 General

The Consultants shall provide training to the City’s Operation and Maintenance staff on the operation of the plant treatment and supply process through the SCADA HMI system. The training shall include the following:

1. Operation and control of the plant treatment and supply process from the Control Room workstation or equivalent.

2. Operation and control of individual processes at the Area Operator Work Station. (This training is only required if there is a difference between the HMI in the Control Room and the HMI on the Area Operator Work Station.)

3. Operation and local control of individual equipment at the Local Control Panels.

4. Operation of the RPU and how devices and equipment are connected to it.

Training shall be provided at the plant in two stages; first stage will be in a “classroom” to be

followed by the second stage which is the practical demonstration (hands on training)on the operation of the plant or facility (or newly constructed work) through the SCADA system.

The Consultants shall provide all required pertinent training material to each Operation and Maintenance staff. Typically, the SCADA Operation Manual shall be used as a guide during training.

86 of 183


Appendix C

Training



1.2.2 Consultants’ Training Courses and Schedule

Training of the newly installed SCADA system shall commence one month prior to the newly constructed process treatment or supply work being completed for its intended use and placed into operation. Generally, this would also be about a month prior to substantial completion of the contract but where it is intended to place the work into operation prior to substantial completion because of mandatory connections to existing process or other processes constraints, then the training for the treatment or supply process and SCADA system must occur one month prior to the intention to place into operation the newly constructed work through the SCADA system.

The Consultants shall use the following table as a guideline when designing a training schedule. The actual amount/duration of training will depend on the specific project complexity.

Course Duration Class Size Number of Classes

1. Operation and control of the plant treatment or supply process from the Control Room work station or equivalent, including the use of the SCADA Operation Manual prepared by the Consultants.

8 hours 10 3

2. Operation and control of individual processes at the Area Operator Work Station. (This training will only be required if the HMI is different than the Control Room Work station)

4 hours 10 3

3. Operation and local control of individual equipment at the Local Control Panels and RPUs.

4 hours 10 3

1.2.3 Operation and Control from the Control Room Work Station

Training on the operation and control of the SCADA system from the Control Room workstation shall be carried out in a “classroom” on the theoretical and practical aspects of the SCADA

system as it relates to both the new treatment or supply process and current installed (or expanded) SCADA system and its integration to the existing treatment or supply process to be followed by the hands-on demonstration from the Control Room workstation.

Consultants shall review, train and demonstrate (hands on training) to staff the following:

1. Overview and features of the newly installed SCADA system, including design of system, configuration and system architecture. Include the identification (tagging) of installed hardware, network routing, operator work stations and servers. The training will cover everything from how the signal is generated to how the signal gets to the HMI.

87 of 183


Appendix C

Training



2. The user interface functions such as log-on, log-off, password protection, etc.

3. The screen displays of newly installed SCADA system. (This may not be necessary if the expansion is relatively small. In this case, proceed to the next item below.)

4. Screen display of integrated SCADA system for data, trending and plant and process control system schematics.

5. Procedure for the control of treatment process through the SCADA system using the integrated HMI screens and overview of the process which can be controlled from each location.

6. Procedure for navigation of available screen display of daily operating data, trending and plant/process schematics as well as changes or modifications technique for these displays.

7. Emergency response of critical treatment process under SCADA failure mode of operation.

8. The availability and control of backup equipment under failure mode for both automatic and manual switchover.

1.2.4 Control of Equipment at the Area Operator Station

(This section will only be required if the Area Operating Station HMI is different than the Control Room Work Station HMI) Control of treatment or supply process equipment may be necessary at the Area Operator Station because of the failure of the SCADA system or that maintenance work has to be performed at the Central Operator Station. The Consultants shall review, demonstrate and train Operation and Maintenance staff on the availability or capability of control at the Area Operator Station of the following:

1. All equipment monitored and controlled at the Operator Station.

2. Manual adjustments of equipment controller’s set-points.

3. Control of backup equipment under failure mode, both automatic and manual switchover.

4. Where redundant area processors are provided, demonstrate the switch-over procedure.

1.2.5 Control of Equipment at the Local Area Control Panels and RPU

Control of plant treatment process equipment at the Local or Area Controller Panels is at the lowest control hierarchy (besides the Local Hand Stations which is common for all equipment) of the SCADA system. At the panel, each individual piece of equipment can be turned on or off and process equipment controllers’ set-points manually adjusted.

Consultants shall review, demonstrate and train staff (hands on training) on the following:

1. Procedure for manual switch-over of backup equipment.

2. Key critical process procedure prior to manually switching over of backup equipment.

88 of 183


Appendix C

Training



3. Review alarm and statues of the equipment that has failed prior to manually switching over of backup equipment.

4. Lockout equipment that must not be restarted from the Area Operator Station or at the Central Operator Station when it is under the control of Local or Area Controller Panels.

1.3 Training by Contractor

1.3.1 General

The Contractor shall provide training of the City’s personnel in the proper operation and

maintenance of the equipment and systems installed under this project.

The Contractor shall provide on-the-job training of the City’s personnel for equipment as

specified. Training shall include instruction of operation personnel in equipment operation and preventative maintenance and instruct plant mechanics, electricians and electronics technicians in normal maintenance or repair.

1.3.2 Submission of Training Material

The Contractor shall supply the following information to the City. Due to phased testing and start-up activities, separate submittals may be prepared for equipment items or systems. The material shall be reviewed and accepted by the Consultants and the City no later than one month prior to delivery of the training.

1. Detailed lesson plans for each training session are to be supplied to the City one month prior to the session taking place. In addition, training manuals, handouts, visual aids and other reference materials shall be included. The City reserves the right to approve and request modifications to the plan and/or materials.

2. Date, time, and subject of each training session and identity and qualifications of individuals to be conducting the training. The City has the right to request a change of inspector if necessary.

3. Concurrent classes will not be allowed in training schedule.

1.3.3 Training Requirements

The training to be provided by the Contractor shall be as follows:

1. The Contractor shall conduct training sessions for the City’s operation and maintenance

personnel to instruct the staff on the proper operation, care and maintenance of the equipment and systems installed under the contract. Training shall take place at the site of the work and under the conditions as specified. Vendor operation and maintenance manuals shall be available to City’s personnel at least 5 working days prior to the date

scheduled for the individual training session.

2. Field training session shall take place at the site of the equipment. The Contractor shall provide a training facility with a capacity for at least 10 persons for classroom training.

89 of 183


Appendix C

Training



3. Formal detailed written lesson plans shall be prepared for each training session. Lesson plans shall include an outline of the material to be presented together with description of visual aids to be utilized during the session. Each plan shall contain a time allocation for each subject. One complete set of originals of the lesson plans, training manuals, handouts, visual aids and reference material shall be the property of the City and shall be properly bound for proper organization and easy reproduction in an identical manner into the equipment Operation and Maintenance Manual. The Contractor shall furnish enough copies of the required training manuals to meet the needs of the training session at least 5 working days prior to each training session.

4. Each training session shall be comprised of time spent both in the classroom and at the location of the equipment. The training session shall cover the following topics for each equipment or system:

(i) Familiarization

(ii) Safety

(iii) Operation

(iv) Calibration

(v) Troubleshooting

(vi) Preventive maintenance

(vii) Corrective maintenance

(viii) Parts

(ix) Local representatives

(x) Equipment Operation and Maintenance Manuals

5. The City may perform video recording of the training session(s) or retain the services of a commercial video taping service to perform the video recording. After the recording session, the material may be edited and supplemented with professionally produced graphics to provide a permanent record. The Contractor shall advise all manufacturers providing training sessions that the training session(s) may be videotaped.

90 of 183


Appendix C

Training



1.3.4 Contractor Training Courses and Schedule

The Contractor shall use the following table as a guideline when designing a training schedule. The actual amount/duration of training will depend on the specific project complexity.

Course Duration Class Size Number of Classes

1. Operation and control of the plant treatment process at the Central Operator’s Station. Review of SCADA

and RPU software configuration and programming carried out by the Contractor and its integration to the existing SCADA system. Use the SCADA and RPU software manual and Equipment Maintenance Manual prepared by the Contractor. Explain and demonstrate all safety interlocks. Both classroom and training at the Central Operator’s Station required.

8 hours 10 3

2. Operation and control of individual processes at the Area Operator Station. Demonstrate RPU process control and explanation of the RPU software programming and its linkage to the Area Operator Station.

4 hours 10 3

3. Operation and local control of individual equipment at the Local or Area Controller Panels. Demonstrate safety interlocks and manual setting of local controllers and by-passing under emergency condition.

4 hours 10 3

All training shall be conducted and completed by the Contractor prior to operational testing and commissioning periods. Classes shall be scheduled such that classroom sessions are interspersed with field instruction in logical sequence. The Contractor shall arrange to have the training conducted on consecutive days, with no more than 4 hours of classes scheduled for any one day. The Contractor will not be permitted to perform the operational testing and commissioning until the training has been completed to the satisfaction of the City.

1.3.5 Contractor’s Classroom Training for Operation Staff

Classroom training of equipment for Operation staff will include:

1. Using slides, PowerPoint and drawings, discuss the equipment specific location in the plant and an operational overview.

91 of 183


Appendix C

Training



2. Purpose and function of the equipment.

3. A working knowledge of the operating theory of the equipment.

4. Start-up, shutdown, normal operation, and emergency operation procedures, including a discussion on system integration and electrical interlocks, if any.

5. Review, demonstrate and train Operation staff on the RPU and OIT program logic and stepping through the program from beginning to the end to show and explain how the control of the equipment is carried out and how to resolve programming / control problem(s).

6. Identify and discuss safety items and procedures.

7. Routine preventative maintenance, including specific details on lubrications and maintenance of corrosive protection of the equipment and ancillary components.

8. Operator detection, without test instruments, of specific equipment trouble symptoms.

9. Required equipment exercise procedures and intervals.

10. Routine disassembly and assembly of equipment if applicable (as judged by the City on a case-by-case basis) for purposes such as operator inspection of equipment.

11. Calibration of the unit, showing staff how to make set point adjustments.

1.3.6 Contractor’s Hands-on Training for Operation Staff

Hands-on equipment training for Operations staff will include:

1. Identify location of equipment and review the purpose

2. Identifying instrumentation:

(i) Location of primary element.

(ii) Location of instrument readout.

3. Discuss purpose, basic operation and information interpretation.

4. Discuss, demonstrate, and perform standard operating procedures and checks.

5. Discuss and perform start-up and shutdown procedure.

6. Perform the required equipment exercise procedure.

7. Perform routine disassembly and assembly of equipment if applicable.

8. Identify and review safety items and perform safety procedures, if feasible.

9. Calibration of the unit, showing staff how to make set point adjustments.

1.3.7 Contractor’s Classroom Training for Maintenance Staff

Classroom equipment training for the maintenance and repair personnel will include:

92 of 183


Appendix C

Training



1. Theory of operation.

2. Description and function of equipment.

3. Start-up and shutdown procedures.

4. Normal and major repair procedures.

5. Equipment inspection and trouble shooting procedure including the use of applicable test instruments and the “pass” and “no pass” test instrument readings.

6. Review, demonstrate and train Maintenance staff on trouble shooting of the RPU and OIT when the system crash. Explain and train staff on the RPU and OIT program logic and stepping through the program from beginning to the end to show and explain how the control of the equipment is carried out and how to resolve programming / control problem(s). Demonstrate and train Maintenance staff on trouble shooting and replacement of the CPU, network interface units, network communication modules, power supply, controllers, I/O cards etc.

7. Routine and long-term calibration procedures.

8. Safety procedures.

9. Preventative maintenance such as lubrication; normal maintenance such as belt, seal, and bearing replacement; and up to major repairs such as replacement of major equipment part(s) with the use of special tools, welding jigs, etc.

1.3.8 Contractor’s Hands-on Training for Maintenance Staff

Hands-on equipment training for Maintenance staff shall include:

1. Locate and identify equipment components

2. Review the equipment function and theory of operation.

3. Review normal repair procedures.

4. Perform start-up and shutdown procedures.

5. Review and perform the safety procedures.

6. Perform City’s-approved practice maintenance and repair job(s), including mechanical and electrical adjustments and calibration and trouble shooting of equipment problems.

7. Demonstrate and train Maintenance staff on replacement of the CPU, network interface units, network communication modules, power supply, controllers, I/O cards, etc.

8. Review and use equipment manufacturer’s manual.

93 of 183


Appendix C

Process Display Programming

T-13010-12 -Process Display Programming-V2


1. Process Display Programming

1.1 General

This guideline applies to all operator workstations.

This guideline is for the structure and documentation of process displays and establishes standards for a consistent approach to programming which will enable:

1. maximum re-use of programs

2. reduced time to troubleshoot programs and

3. higher confidence and usability of operator workstations

This guideline will be reviewed whenever a new workstation software package is selected or when the software version is changed.


1.2 Display Names

Each graphic display shall be identified by its version number (Vx.x) and its name. Record the location of the primary copy of the display. Use the naming convention in the following table for all graphics:

File Types File Naming Convention (Notes 1,2 and 3)

Process Graphics PLT_AREA_XXXXX Trend Charts PLT_AREA_trend_XXXXX Setpoint Graphics PLT_AREA_setpt_XXXXX Run-Hour Graphics PLT_AREA_runhour_XXXXX Legend & Info Graphics PLT_AREA_legend_XXXXX RPU Status Graphics PLT_plc_XXXXX Plant-Wide Trend Menus PLT_chartmenu Alarm Summary PLT_alarmsummary Mainmenu PLT_mainmenu Alarm Page PLT_AREA_sub_alarm Process Sub-Picture PLT_AREA_sub_XXXXX

Drop Down Menu PLT_AREA_sub_menu_XXXXX Process Area Trend Menus PLT_AREA_trendmenu

Notes:

94 of 183


Appendix C




1. PLT: 3-character Plant Code to be defined in 13040-Equipment and Data Tagging standard document (e.g. FHA for Harris Filtration Plant).

2. AREA: Process Area codes to be defined in 13040-Equipment and Data Tagging

standard document (e.g. FLT for filtering process). 3. XXXXX: specific graphic name left to the discretion of the developer. Use a similar

naming method to those graphics that already exist.

1.3 Display Guidelines

1.3.1 Update Procedure for HMI displays

The PCS component of any project will often involve updating an existing display rather than creating a new display. The following procedure should be considered when updating an HMI display:

1. During pre-design, determine which HMI hardware components will be affected by the project. This may include SCADA servers, Operator workstations, or local OITs. If possible, determine specifically which process graphics will be affected.

2. During detailed design, create or further refine the list of affected process graphics. Consider if any changes will be required to the menu bar (and User.FXG file)

3. During Construction, the System Integrator will request the existing HMI application from Toronto Water. ITM can determine, at their discretion, if the facility’s entire HMI

application is to be locked down during construction or just the specific affected graphics. The software should be considered signed-out and locked down while in the System Integrator’s possession to facilitate version control.

4. The System Integrator will FAT the software modifications according to normal Toronto Water procedures.

5. When the project is ready for the SAT, the System Integrator will obtain ITM’s approval

for integrating their software modifications with the system in operation at the facility. The process graphics and new/modified database tags should be uploaded and then the SAT performed according to normal TW procedures.

1.3.2 Update Procedure for iHistorian, eOPS

1. As part of the Process Control Narrative update, determine which iHistorian and eOPS tags need to be changed, added, or deleted and determine the associated parameters (update deadband, etc.)

2. The Systems Integrator will program the changes to the iHistorian as part of their software development

3. The FAT for any eOPS database and reports changes will be performed on the ITM eOPS test system at the Tiffield Road facility. This may be a separate FAT from the standard software FAT typically performed at the Systems Integrator’s office.

4. After a successful FAT, the Systems Integrator will forward the iHistorian changes to ITM. ITM will install the changes on the production system at the facility.

5. The Systems Integrator will SAT the iHistorian changes.

95 of 183


Appendix C




6. The next working day following a successful SAT of the iHistorian changes, the eOPS changes will be implemented by ITM at the Tiffield Road facility. The Systems Integrator will then SAT the updated database and reports.

1.3.3 Layout

1. Graphic displays should have minimal information on the left side where pop-up windows initially appear.

2. The amount of information on a graphic display should be in the range of 30 to 60 information points. An information point is an analog value, an alarm or event message, a monitored or controlled device symbol, a bar graph symbol or display call button. Exceptions to this guideline will likely occur for summary displays or some complex processes.

3. Layout the graphic either according to plant floor location or the P&ID drawings as appropriate for the information being presented.

4. Generally process inputs come from left side of the screen and outputs go to right side of the screen.

5. All process graphics must contain a title bar across the top.

6. The title bar must display:

name of the graphic display using the format “PLT – Description”

date;

time; and

icons accessing: plant overview

alarm summary

operator log-in

process miscellaneous menu

Print Screen function and

trend menu

1.3.4 Text

Font style and size should be suited to the graphic display. Preferred font styles are plain such as Simplex or Arial. Standard fonts are shown in the following table:

Item Font Font Size

Title of graphic Arial, italic, bold 17

96 of 183


Appendix C




Item Font Font Size

Date Arial, regular, bold 12 Time Arial, regular, bold 12 Device tag name Arial, regular, bold 9 Device status Arial, regular, bold 9

Abbreviations should use codes in 13040-Equipment and Data Tagging, flow stream identifiers contained in 03 P&ID Symbols and Practices or other Toronto Water standards.

1.3.5 Colour

The use of colours shall conform to "Colour Convention" guideline. Other colours may be used where the use of colours is not defined in that standard.

1.3.6 Shape

1. Shape will be used to make key information more evident and to reduce errors due to colour-blindness.

2. Shape will be used to show tank levels where the tank is shown in profile, i.e. elevation view.

3. Change of the shape or icons to indicate status will be selectable by the operator. When selected, the usage of shape change will be as follows:

a) Mode Identification

A Automatic

L Local

M Manual

N Not Available b) Status Identification

O Open

C Closed

T Transition

R Run

S Stop

I Inhibit

L Run Low Speed

H Run High Speed

Forward

97 of 183


Appendix C




Reverse

1.3.7 Icons

1. Toronto Water maintains a software library of icons developed for use in displays. Use icons in the library for representing individual devices rather than creating alternative shapes.

2. Icons should resemble field equipment to make recognition easier. Label each icon with the equipment number. On any individual display, use icons of a similar type (i.e. all 2-D or all 3-D), similar orientation (i.e. all profile or all plan view) and similar relative size to give consistent presentation.

3. Icons incorporate the colour and alarm conventions. The colour convention including rules for using flashing to indicate unacknowledged alarms is given in "Colour

Convention" guideline. The alarm convention is explained in "Alarming" guideline.

4. Icons should be consistent in size across all displays; however, some process displays may require reduced icon sizes in order to accommodate all of the devices.

5. As 3-D icons have different sizes, shapes and complexities, it is difficult to use colour fill on the symbol to display status and mode; therefore, the following method is used to indicate status and mode. The 'Status' colour is displayed in a small square while the 'Mode' colour is displayed in a small triangle. Both the square & triangle are layered on top of the 3D symbol or close to the symbol. Since the 'Status' & 'Mode' colour fill is separate from the original symbol, this way of displaying 'Status' & 'Mode' colour can be used in every symbols independent of the symbol shapes and complexities and eliminate the effort of re-developing the colour fill linking to every symbol.

6. Provide each icon with access to its corresponding pop-up window.

7. A bitmap photo of the real device can be used in some cases as the icon. Submit suggested photos to the City for review and approval.

8. Where new symbols are required, the Consultants may request the City to consider the addition of new symbols. If the City approves the addition of such symbols, the development and testing will be performed by the Contractor as detailed in "RPU Standard Software Modules" guideline. On completion of the development of the symbols, the Contractor shall submit the information in the format that will permit the City to add the data or information to the City’s library.

1.3.8 Pop-up Windows

Pop-up windows should initially appear on the left side of the screen, ensuring minimal coverage of the screen. Pop-up windows may be moved and sized by the operator. Pop-up windows will contain:

1. the name and description of the equipment or item on the top

98 of 183


Appendix C




2. current status e.g.:

a. running/off,

b. opened/closed,

c. enabled/disabled,

d. manual/automatic/cascade,

e. alarm/normal

3. current conditions e.g.:

a. speed,

b. position,

c. electrical current

4. current alarms and acknowledge function

5. controls e.g.:

a. start/stop,

b. open/close,

c. setpoint entries

6. mode selection:

a. manual/automatic/cascade,

b. enable/disable

1.4 Graphic Display Structure

The displays are interconnected in a hierarchy structure. In addition, interconnection is provided for process streams continued on other process graphics. The structure and access to other displays is shown in Figure 1 - Graphic Display Structure. Multiple displays may be needed to show all of the information and control icons required for operation. Where multiple displays are required, a process overview should be created along with equipment overviews and details.

1. The main menu is a picture of the facility or map of the area with links to the process overviews.

2. Process overviews show process flow, summary information and major components or groups of components. The displays are usually in plan view (building level); the top of the screen is North. (Status only). Objects may be represented by simple symbols (circles squares etc) in grey. Links to equipment overviews or equipment detail screens

3. Equipment overview graphics may be needed to show sub-processes or groups of components. Equipment layout (status and control) can use simple or complex icons depending on number of components on the screen.

99 of 183


Appendix C




4. Equipment detail graphics may be needed for devices with monitored or controlled sub-components or other complex display requirements.

5. For situations where a number of components or component groups are the same, e.g. aeration tanks or filters, either make one detail screen with tag groups or separate screens for each tank or filter, whichever is more appropriate for the situation. One screen with tag groups is more appropriate for simple situations.

6. The RPU Status Graphics have the same look and feel as standard process graphics. Each page of the RPU Status Graphic is allocated to the display of the RPU status for one or more process areas in the plant.

The displays for every process area consist of a set of graphics as follows:

1. Process Graphics of the process area (one of which is an Overview);

2. Trend Menus;

3. Trend Graphics;

4. Setpoint Graphics (viewing and modifying setpoints for the process area);

5. Run-Hour Graphics (viewing and modifying device run-hours for the process area);

6. Legend and Info Graphics;

7. Process Sub-Pictures

In addition to the graphics for the process areas, there are other graphics for plant-wide use, e.g. Alarm Summary or RPU Status Graphics.

The first screen is the Mainmenu. It is displayed on system start up. From the Mainmenu, there are selections for the various process areas. When one process area is selected, a process graphic for the process area (normally the overview graphic) is displayed. From the Mainmenu, there are also selections for other plant wide graphics, e.g. Alarm Summary or RPU Status Graphics.

Every graphic in the system shares a similar look and feel. There are several Buttons in the Title bar to access some common use functions. Each graphic also contains a Back & Forward button for navigational purposes and Menu Buttons for accessing other graphics in the process area.

The displays are shown in following sections.

100 of 183


Appendix C




Figure 1 - Graphic Display Structure

System Login

Process Sub-Pictures

Devices Sub- -Pic

Alarm

Alarm Page

Legend & Info Graphic

Mainmenu

Process Graphics

Trend Charts

Plant-wide Tend Menu

Alarm Summary

Setpoint Graphics

Run-Hour Graphics

Process Area 1

Area 2 Area 3

Process Area Trend Menu

Note: Every graphic can access the Mainmenu via the Home Button & other graphics through the drop down menu.

RPU Status Graphics

Part of software modules.

101 of 183


Appendix C




1.5 Graphics Examples

MainMenu

Link to the first page of the Process Graphics (i.e. Overview) in one process area. When there are unacknowledged alarms in the process area, the text will flash in a red colour.

System Login

Button to access Plant-Wide Trend Menu

Button to access Alarm Summary

Button to access RPU Status Graphics

102 of 183


Appendix C




Process Graphics

Back and Forward Buttons – to go back and forward through previous displays (up to the last 7 displays).

Menu Buttons – the 11 Menu Buttons to display various process graphics in the process area.

Login Button – for system login

Print Button – print screen to the default printer.

Trends Button – display Trends menu for this process printer.

103 of 183


Appendix C




Alarm Summary

An Alarm page is a full screen display of filtered alarms for a process area. When a graphic is opened, the alarm page is not displayed. By selecting the Alarm Page Button (clicking with the left mouse button), the Alarm page will appear in place of the process graphic screen. By selecting the Alarm Page button again, the Alarm page will disappear. The alarm area used for filtering is indicated in the Alarm Page status line.

Alarm Page Button

Alarm Page status line – will display “Sort Order”, “Total Alarms”, and “Filtered Alarm Area.”

104 of 183


Appendix C




Process Miscellaneous Button

In all process graphics, the user can display the Misc menu by clicking the Process Misc Button. Selection available on the Process Misc menu include:

Alarm Setpoints - Set alarm limits for various instruments Process Setpoints - Set process automation setpoints such as pump start/stop levels Run Time/Counts - Display pump and valve runtime data Legend & Info - Access Legend graphics & other symbol information Pipe Colour - Display colour standards Close Sub-Pics - Close all open sub pictures View Tags - Display device tag names on the current graphic View Status - Display device status (i.e. Local (L), Running (R) etc.) on the current

graphic. When device status is displayed, device tag name will be turned off and vice versa.

Hide Tag/Status - Turn off display of device status and tag names.

105 of 183


Appendix C




System Miscellaneous Button

The Misc button in the menu button bar displays a drop down menu of various miscellaneous pop-up displays of general plant information such as flow summaries, power usage, etc.

106 of 183


Appendix C




Process Sub-Pictures

Process sub-pictures are normally accessible by clicking on a device such as a pump or chlorinator. Other sub-pictures may be available through the pull-down menu for the process such as setpoints or power consumption information. The process sub-pictures normally contain summary information or relevant information for the same process areas or other process areas which are useful for the operators.

Button to access drop down menu for process

Device control pop-up

Setpoints pop-up

107 of 183


Appendix C




Trend Graphics

The Trend Charts are accessed from the Process Area Trend Menus. When Trend Charts are opened, the Trends will display historical data for the past 24 hours. There are four (4) Duration buttons for selecting different display durations (4, 8, 12, 24 hour-periods). Using the Calendar button, a calendar is displayed and the date of trending display can be selected. Multiple Trend Charts can be displayed on the screen.

Menu Buttons – The 11 menu buttons to select various Process Area Trend Menus in the plant

Fast Backward Scroll Show/Hide Calendar (go back ½ period) (Show or hide the Calendar to select date of display) Slow Backward Scroll Buttons to Add/Delete Pens Slow Forward Scroll (go back 1/8 period) (go forward 1/8 period)

Fast Forward Scroll 4 Duration buttons (go forward ½ period)

108 of 183


Appendix C




1.6 Plant Alarm Areas

Plant Alarm Areas should be configured and names assigned to the alarm areas should be prefixed with the facility abbreviation.

1.6.1 Access

The log-in function will restrict access to process control and system features. Access will be restricted according to access group. The groups are:

1. Guest Access to log-in window. Access to view displays including alarm page and pre-configured reports. No access to process control functions.

2. Operator

Access to view displays including alarm page and pre-configured reports. Access to configuring trend and group displays. Access to all process control functions and alarm acknowledgement (potentially not

access to disabling alarms and changing alarm priorities).

3. Supervisor/System Technician Access to view displays including alarm page and pre-configured reports. Access to configuring trend and group displays. Access to all process control functions and alarm acknowledgement including

disabling alarms, changing alarm priorities and tuning parameters. 4. System Administrator

Access to all aspects of workstation software management including process control functions, display viewing, display creation, report printing, report creation, workstation set-up, network management, passwords and data base editing.

Password access is not required for Guest. Users in all other groups require individual passwords.

After successful log-in, access is available for a limited time. The access time is adjustable for each user group by the system administrator.

109 of 183


Appendix C




1.7 Time Synchronization

Time synchronization shall be done at two levels: Operator Interface and RPU (controller). One of the Operator Interface servers shall be designated as having the master clock. All other Operator Interface servers and workstations shall be synchronized to this GPS master clock.

All RPUs (control nodes) on a communications network then in turn, shall have internal clocks synchronized periodically to the master clock. Synchronization shall provide time and date stamping accuracy to within one second of the master clock.

Master clock shall be accessible by the operator from the Operator Workstation.

110 of 183


Appendix C

Process Control Narratives

T-13010-13 -Process Control Narratives-V2


1. Process Control Narratives

1.1 General

The Process Control Narrative is a description of key control system elements and provides details on all manual and automatic modes of process control. It serves different purposes at different stages of the project design and construction phases and shall be used for one or more of the following purposes:

1. Background for planning and design of improvements

2. Process control software description

3. Operations manual

4. Operations practices review

5. Operations training

Every existing facility under the management of Toronto Water has a comprehensive process control narrative (referred to as a “Master Process Control Narrative” or “Master PCN”. Ongoing

expansion and rehabilitation projects with a PCS component will typically require that the Master PCN be modified.

Preparation or modification of the Process Control Narratives shall commence during the Pre-design phase and expand with more detail during the Detailed Design and Construction phases.

Each PCN shall be identical in terms of format. The Pre-design portion of the PCN (also referred to as the Process Narrative) shall list, in generic terms, the equipment to be controlled and the proposed methods to be used. The final PCN shall be an expansion/enhancement of the Pre-design portion and shall exactly define the equipment, points, tag names, equipment coding, methods of control and monitoring, etc.

Consultants shall comply with this design standard and any proposed deviation must have the approval of the City.

1.2 Update Procedure

The PCS component of any project will often involve updating an existing PCN rather than creating a new PCN. The following procedure should be considered when updating a PCN:

1. During pre-design, obtain the existing master PCN in Adobe format and decide which sections will need to be updated and submit request to Toronto Water for document release in native format. Toronto Water will track all requests in order to coordinate PCN updates where multiple projects may be involved.

2. Update the process descriptions of each affected section as needed including any additions to or deletions from the Process Equipment List.

3. During detailed design, update the control system description of each affected section as needed. Additions to the following information will need to be considered:

o Control system configuration - if any panels, RPUs, workstations or other major components are being installed

111 of 183


Appendix C




o I/O List – Add any additional I/O and remove any I/O being taken out o Control Logic – Describe any new control logic o Interlocks – add any new hardware or software interlocks o Alarms – expand the alarm list as required o Trending – expand the trending description as required o Business Systems – expand the list of data for WMS, LIMS, eOPS, POMS as

required

4. After the Construction phase is complete, update all sections with as-built information as required.

5. A new release request should be issued for every phase of the project unless Toronto Water notifies the Consultant otherwise.

1.3 Contents

The Master PCN for a facility starts with a General introduction describing the facility in general terms including the overarching design philosophy and treatment goals. The PCN is then divided into process sections, with each section representing a distinct process within the facility. Each process section generally contains the following elements:

Process description – a general description of the process including physical layout, mechanical equipment, and treatment objectives. See section 1.3.1 below for further details. This section should be developed during the Pre-design phase of a project and further refined during Detailed Design and Construction as required.

Control system description – details of the PCS aspects of the process including I/O lists, alarm details, historian requirements, and business systems requirements. See section 1.3.2.

1.3.1 Process Description

1.3.1.1 Process Definition

The process shall be defined first. Definition shall include the process name, its relationship to other processes, its general components and the physical location boundaries as appropriate. Components may include the tanks, pumps and other devices of the main process, and the ancillary processes or systems.

Provide a diagram to show the process components. The diagram shall show the process boundary and the inputs and outputs to the process components. Label each input to an output from the process with the name of the process stream and its destination or source. Show all lines as starting or ending from a process component. Do not directly connect lines because the control or lack of control over the junction or splitting of a process stream needs to be described and the process component is the place for this description. An example for the digestion process is shown in Figure 1: Example process diagram. Note that the combustible gas safety system shown in the figure is an ancillary process.

112 of 183


Appendix C




Figure 1: Example process diagram

1.3.1.2 Objectives

The objectives of the process and general goals shall be described in this section. These objectives are related to efficiency, effectiveness or quality. In some cases, the process will not have a specific pre-defined treatment objective. In such cases, identify a general objective.

1.3.1.3 Process Control Strategy

The process control strategy shall describe the process decisions taken to achieve the treatment and transmission objectives. Indicate how often input variables are to be measured and the frequency or event which triggers a process adjustment.

State the safe limits and operating targets for the process and operating equipment. Operating targets may be stated as a range if a specific target or set of targets is not required. List priority 1 alarms (alarms that need immediate attention from the operator) and alarms that affect more than one operator (noting the operators affected). Describe the alarms for each device and the process to bring into the SCADA system sufficient alarm details as needed for remote diagnosis or else state the use of a single, common alarm for multiple alarm conditions. For each alarm, state the requirements for activation and method of reset (manual or automatic). Describe automatic alarm reset logic.

1.3.1.4 Influent Sources

Information on influent sources defines the source and nature of streams entering the specific process being described. The nature of these streams shall be defined in terms of flow variability

Primary Digestion

Digestion Gas System

Digested Sludge

Storage/Transfer

System

Primary Digest

Influent Distribution

System

Combustible Gas

Safety System

Digestion

Sludge/Scum

from Primary

Digested Sludge

to Dewatering

Digester Gas

to Plant Services

TWAS

from

Thickening

Emergency Overflow

to Primary Treatment

113 of 183


Appendix C




and the percentage of the total stream being treated in the specific process. Information about the main process stream, as well as side streams shall be presented.

1.3.1.5 Effluent Destination

In this area of the template, information shall be presented on where effluent and waste from the treatment process are normally directed. Estimate the percentage of the stream sent to each destination where the stream is normally directed to more than one destination.

1.3.1.6 Process Control Equipment/Devices

In this section, describe each piece of equipment or device that can potentially control influents and effluents or change the process as well as what equipment is available to control the process when defining its operation, capabilities and limitations. Identification shall include its name and when applicable, its equipment number (tag number), for example: raw water pump FHA-RW-P-0801. Process equipment includes pumps, valves, screens, chlorinators, mixers, etc.

Describe the use of each process control equipment/device. Information includes the device operation, control objectives, performance measures and the control method (either automatic or manual).

Describe the flexibility in using process equipment including provisions for future equipment additions. For example, the chlorine processes for water treatment and supply can interchange equipment (i.e. post chlorinators can be used for pre-chlorination if necessary). The chlorine processes for wastewater treatment can interchange equipment (i.e. effluent disinfection chlorinators can be used for plant water disinfection if necessary).

1.3.1.7 Ancillary Process Descriptions

Ancillary processes associated with each main process shall be listed. Ancillary processes are all processes associated with the main process which are not specifically involved in transmitting influent to the process or effluent from the process, or the actual treatment process. Ancillary processes shall be described in the same way as the main process in separate process narratives.

1. Describe spill containment for both hazardous gas and liquid spills in a separate sub-section of ancillary processes. If the containment provisions serve more than one process, then put the description in a separate process narrative.

2. Describe sample stations/pumps in a separate sub-section of ancillary processes. Description of sample stations and pumps belong with the narrative of the process that uses the sample or sample tests.

3. Power distribution is an ancillary process to most processes. Describe power distribution in a separate narrative with basic descriptions of automatic and manual switching.

114 of 183


Appendix C




1.3.2 Control System Description

1.3.2.1 Description

This section shall describe the operation of the process in terms of the control system, including panels and the control logic. Describe the control system configuration and components and include:

1. Controllers, location of I/O and panels

2. Modes of control (Manual and Automatic modes at each control location; control locations may include: equipment control panel, Motor Control Centre, area panel, central panel, operator workstation)

3. Alarm horn operation, silencing and acknowledge or reset

1.3.2.2 Software Data Points

Provide a table showing all real I/O data points and program-generated data points associated with the process. The table should show the following information:

1. Tag type 2. Tag name 3. Description 4. EGU range (in the case of analog points).

1.3.2.3 Control Logic

This section shall contain descriptions of:

1. Normal Operation (ie. Automatic logic) including start up and shutdown

2. A table of Control Setpoints associated with the Automatic logic. The table should show tag name, data range, units, and default value.

3. Fault Response Operation. How should the equipment respond to abnormal conditions? Common fault situations include power failure, instrumentation failure, and loss of communication

1.3.2.4 Interlocks

1. Interlocks generated in software by the PLC

2. Interlocks hardwired into the control circuits

1.3.2.5 Alarms

Provide a table that shows every alarm condition that can be generated by the process. The table should provide the following information:

1. Tag name

2. Alarm priority

115 of 183


Appendix C




3. Alarm limit (in the case of alarms generated from analog points)

4. Details of how the alarm is generated ie. if a delay timer is required, if the alarm depends on other conditions (e.g. a pump running)

5. Details of how to reset the alarm as well as details of how to enable/disable the alarm if applicable.

1.3.2.6 Trending

Provide a table detailing which data points should be trended by the system historian. The table should provide the following information:

1. Tag name

2. Suggested trending deadband

3. Suggested grouping for displaying trended data for maximum effectiveness

1.3.2.7 Business Systems

Provide a table detailing which data points will need to be made available to Toronto Water business systems. The table should provide the following information:

1. Tag name

2. Business system requiring the data (WMS, POMS, eOPS, LIMS)

1.3.2.8 Block diagram

A block diagram of the system shall be included for all systems. The diagram shall show logical connection and interaction of the control system components.

116 of 183


Implementation Guidelines

Process Control System (PCS) Implementation Guidelines

Version 3

December 30, 2015

117 of 183



Process Control System (PCS) Implementation Guidelines Record of Revision

Revision Number

Date Of Revision

Revised Pages

Revised by

1 July 30, 2011 General 2 October 30, 2012 Various Boro Djunisijevic 3 December 30, 2015 Various Boro Djunisijevic

118 of 183



PCS Implementation Guidelines-V3

1-2 Dec 2015

Table of Contents

1. Introduction ......................................................................................................................... 1-4

1.1 General ..................................................................................................................................... 1-4 1.2 Scope of Guideline .................................................................................................................. 1-4 1.3 Objectives ................................................................................................................................ 1-4 1.4 Guideline ................................................................................................................................. 1-5 1.5 Definitions and Roles .............................................................................................................. 1-5

2. RFP and Engineering Services Contract Award ........................................................... 2-10

2.1 General ................................................................................................................................... 2-10 2.2 Identify PCS Requirements ................................................................................................... 2-10 2.3 Scope of Work ....................................................................................................................... 2-10 2.4 RFP ........................................................................................................................................ 2-10 2.5 RFP Evaluation ...................................................................................................................... 2-10 2.6 Engineering Services Contract Award ................................................................................... 2-11

3. Pre-Design ......................................................................................................................... 3-12

3.1 General ................................................................................................................................... 3-12 3.2 Project Commencement ......................................................................................................... 3-12 3.3 Field Verification ................................................................................................................... 3-12 3.4 Requirements Definition/50% Pre-Design ............................................................................ 3-12 3.5 75% Pre-Design ..................................................................................................................... 3-14 3.6 100% Pre-Design ................................................................................................................... 3-15

4. Detailed Design .................................................................................................................. 4-16

4.1 General ................................................................................................................................... 4-16 4.2 Tag Lists ................................................................................................................................ 4-16 4.3 50% Detailed Design ............................................................................................................. 4-17 4.4 70% Detailed Design ............................................................................................................. 4-18 4.5 Detailed Technical Specifications ......................................................................................... 4-20 4.6 Apply For Approval ............................................................................................................... 4-20 4.7 95% Detailed Design ............................................................................................................. 4-20 4.8 100% Detailed Design ........................................................................................................... 4-21

5. Construction - Equipment ............................................................................................... 5-22

5.1 General ................................................................................................................................... 5-22 5.2 Shop Drawings ...................................................................................................................... 5-22 5.3 Equipment and Panel Procurement and Fabrication .............................................................. 5-22 5.4 Test Sheets ............................................................................................................................. 5-22 5.5 Equipment and Panel FATs ................................................................................................... 5-22 5.6 Transition Plan ....................................................................................................................... 5-23 5.7 Equipment Installation and Wiring ........................................................................................ 5-23 5.8 Pre-Start Health and Safety ................................................................................................... 5-23 5.9 Entity Information Lists ......................................................................................................... 5-24

119 of 183




1-3 Dec 2015

6. Construction - Software ................................................................................................... 6-25

6.1 General ................................................................................................................................... 6-25 6.2 Flow Chart Development ....................................................................................................... 6-25 6.3 Software Modules .................................................................................................................. 6-25 6.4 Software Development .......................................................................................................... 6-25 6.5 FAT Plan ................................................................................................................................ 6-26 6.6 Software FAT ........................................................................................................................ 6-26

7. Construction – Testing and Commissioning .................................................................. 7-27

7.1 General ................................................................................................................................... 7-27 7.2 Hardware SAT and Training Plan ......................................................................................... 7-27 7.3 Hardware Training ................................................................................................................. 7-27 7.4 Hardware SAT ....................................................................................................................... 7-27 7.5 Software SAT and Training Plan ........................................................................................... 7-28 7.6 Software Training .................................................................................................................. 7-28 7.7 Software SAT ........................................................................................................................ 7-28 7.8 Operational Test/System Performance Test .......................................................................... 7-28 7.9 Tag Lists and PCS I/O List .................................................................................................... 7-29 7.10 As-Built Documentation ........................................................................................................ 7-29 7.11 Post Construction Warranty Period ....................................................................................... 7-29

Appendix A – Project Tasks Flowcharts

Appendix B – Project Tasks Implementation Checklists

Appendix C – Associated Guidelines

Appendix D – Associated Standards and Installation Drawings List

Field Verification Procedure Process Control Narrative P&ID Standard Symbols and Practices Colour Convention RPU Software Programming Standard Software Modules Operator Interface Programming Process Display Programming Alarming Instrument and Equipment Testing SCADA Factory Acceptance Testing SCADA Site Accecptance Testing and Commissioning PCS Documentation Training

120 of 183




1-4 Dec 2015

1. Introduction

1.1 General Toronto Water has implemented a Process Control System (PCS) for control and monitoring of its facilities (Water treatment plants, Wastewater treatment plants, Water supply, and Sewage pumping stations). The PCS consists of instrumentation, control devices, wiring, networking, input/output devices, control panels, local and central Human Machine Interfaces (HMIs) and Remote Processing Units (RPUs) / Programmable Logic Controllers (PLCs). Any new project in Toronto Water that has a PCS component will require integration of the new project into the existing PCS of the facility. The overall process for any project with a PCS component comprises six stages:

1. RFP development, issue, evaluation, and subsequent contract award for engineering services

2. Pre-design of the PCS component

3. Detailed design of the PCS component

4. Construction - Equipment

5. Construction – Software

6. Construction – Testing and Commissioning

Please refer to Appendix A (Flowcharts) and Appendix B (Checklists) for tools to assist with the process of integrating any new project into the existing PCS of the facility. The relationship between deliverables and project stages is not always evident for projects where the PCS component is relatively small. Some of the stages/phases mentioned in the Flowcharts and Checklists may not apply for very small PCS projects.

1.2 Scope of Guideline This guideline provides ‘high level’ information for consultants and project managers on project deliverables, phasing, and review requirements for Toronto Water projects that have a PCS component.

1.3 Objectives The guideline objective is to ensure that a clear understanding exists for City project managers and consultants as to the deliverable requirements for a PCS project or project with a PCS component, in terms of the phasing for those deliverables and services in step with various project phases from initial design stages to completion of the project, as well as defining the responsibilities for provision of information and deliverable review services.

121 of 183




1-5 Dec 2015

1.4 Guideline Guidance documentation for the PCS implementation comprises three separate and related documents: a series of project task flow charts illustrating the logical flow deemed necessary for successful implementation of the project (Appendix A); a checklist intended for project managers to ensure engineering services providers deliver the required services and documentation at the appropriate stage of the project (Appendix B); and the Process Control System Implementation Guideline (this document).

Flowcharts for each stage are comprehensive and are designed to ensure the deliverables, their inter-relationships, and their delivery timing is appropriate for successful implementation of PCS projects. Depending upon the project size and scope, some of the steps in the various stages may not be required.

Checklists for each stage provide a simplified review method for project managers to ensure consultant deliverables are provided at the right project stage, as well as indicate supply sources for information typically needed by the consultant and to indicate the in-house review group for all consultant technical deliverables. The checklists also indicate the flow of information and can be used as a tool by project managers to guide a PCS project. Depending upon the project size and scope, some of the steps in the various checklists may not be required. As part of the project scope development, the project manager – with assistance from the Toronto Water PCS Unit – will develop the project tasks checklists specific to the project. Once the “scope of work for a RFP” has been defined, then a “project specific checklist” shall be prepared, and provided in the RFP.

The Process Control System Implementation Guideline is intended to address how engineering services are provided, and at what stage each service and its corresponding deliverable is provided, and provides more specific, and more detailed, assistance to the engineering services provider in how PCS projects should be conducted. External references to other, more specific, guideline documents are also provided throughout this document.

1.5 Definitions and Roles The groups typically involved in PCS projects and their respective roles are detailed below.

1. City

The owner (City of Toronto) generally performs all tasks detailed below in Section 2 RFP and Engineering Services Contract Award as well as reviewing the work of the Consultant, Contractor, and Systems Integrator. The City may involve the following internal organizations, depending on the components and complexity of the project:

City’s Project Manager

The project manager is the single point of contact for all communication between the City and the Consultant for the project, unless others are designated as contacts for specific purposes. Responsibilities of the project manager include:

122 of 183




1-6 Dec 2015

i. Initial project planning and RFP preparation

ii. Tendering and award for consulting services

iii. Ensure timely submission of deliverables from Consultant and timely review by City staff

For more detailed information on the responsibilities of the project manager, consult the Toronto Water Project Delivery System manual.

Capital Works Delivery (CWD)

CWD is TW engineering group providing project management and advisory to the Operation Group for the various complex electrical systems projects. The CWD is custodian of TW facilities Master Single Line Diagrams (SLD)

PCS Unit (PCSU)

PCSU reffers to PCS unit within Toronto Water, Operational Support providing:

Capital Project Support Services

Toronto Water Network Services

SCADA Maintenance & Integration Services

PCSU maintains the standards and guidelines for PCS projects and technology. PCSU also maintains facilities PCS master documentation: Master P&ID, Master Process Control Narratives, SCADA Architecture Drawings, Hardware and Software Inventory Lists. As custodian of Electronic Tagging Management System (ETMS) PCSU manage tagging requests & approvals. The unit provides engineering support for review of design reports, engineering drawings, specifications and cost estimates. PCSU also assists with coordinating the various internal City organizations for purposes of deliverable review and comment.

The PCSU provides support for review of SCADA hardware and software deliverables such as servers, PLCs, networking, and all related customized programming. As custodian of PLC software modules PCSU get involved in testing and approval of any new software module, if needed.

Operation Group

The Operation Group refers to the support staff at the facility at which the project is being undertaken. They will be the principal group driving the development of the Scope of Work, and will review deliverables for operability and maintainability during the project, to ensure compatibility with existing equipment at the facility. They are also active participants in Factory and Site Acceptance Tests.

Optimized Maintenance Unit (OMU)

123 of 183




1-7 Dec 2015

The OMU maintains the Work Management System (WMS) databases for TW assets including all PCS related equipment in Toronto Water Facilities. Their involvement in PCS projects will typically be to review and approve WMS tagging assignments proposed by the Consultant.

2. Consultant

The Consultant is contracted by the City to perform the Scope of Work as defined in the RFP. The Consultant generally performs all tasks detailed below in Section 3 Pre-Design and Section 4 Detailed Design as well as representing the City during the Construction phase. As the City’s representative, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City. The Consultant also participates in FAT, SAT, Commissioning and Training activities, and updating of documentation of the project.

A detailed list of the Consultant’s responsibilities follows:

Responsible for the engineering and design of the I&C and SCADA System, including integration with existing system control logic

Preparation/Updating of Process Control Narratives and P&ID

Preparation of Contract Specifications and Drawings of I&C and SCADA system

Review of the RPU and HMI configuration, as prepared by the Contractor, and ensure compliance with City’s standards

Prepare requirements for factory acceptance test (FAT) plan

Attend and witness FAT at the Contractor’s facility to ensure compliance with City’s requirements

Attend and witness testing of all field instruments and control loops performed by the Contractor

Prepare requirements for site acceptance test (SAT) plan

Attend and witness SAT on site to ensure compliance with City’s requirements

Prepare requirements for operational test/system performance test

Attend and witness operational test/system performance test

Review Operation and Maintenance Manual prepared by the Contractor for compliance with the contract specifications

Review Plant SCADA Operation Manual and submit at the specified milestones

Prepare PCS training

124 of 183




1-8 Dec 2015

Testing and verification of the performance of the SCADA system

Prepare As-built PCS documentation

3. Contractor

The Contractor is contracted by the City to perform the Scope of Work as defined in the tender package created by the Consultant during Detailed Design and generally performs all tasks detailed in Section 5 Construction - Equipment and Section 7 Construction – Testing and Commissioning.

A detailed list of the Contractor’s responsibilities follows:

Purchase and install all software, hardware, instrumentation and field wiring as specified

Perform Hardware FAT at the Contractor’s facility, (if possible) witnessed by the Consultants and the City’s staff

Perform field verification of all installed instruments, devices and control loops, witnessed by the Consultants and the City’s staff

Participate in Consultant’s PCS training as applicable

Perform Hardware SAT, witnessed by the Consultants and the City’s staff

Perform operational test/system performance test, witnessed by the Consultants and the City’s staff.

Hand over SCADA system to City’s staff when accepted by the City.

Provide required warranty (response within 24 hours) and guarantee of SCADA system

Respond to City for all deficiencies

Prepare I&C Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones

4. Systems Integrator

The Systems Integrator is typically a subcontractor of the Consultant or Contractor but also could be integral part of the Consultant's/Contractor's team. In any case System Integrator generally perform all tasks detailed below in Section 6 Construction - Software and Section 7 Construction – Testing and Commissioning.

A detailed list of the System Integrator’s responsibilities follows:

125 of 183




1-9 Dec 2015

Configure PLC program in accordance with specified process control narratives

Configure HMI program in accordance with specified process control narratives

Submit PLC and HMI programs to Consultants for review to ensure compliance with Specifications

Participate in Consultant’s PCS training

Perform Software FAT at the System Integrator’s facility, (if possible) witnessed by the Consultants and the City’s staff

Perform Software SAT, witnessed by the Consultants and the City’s staff

Perform operational test/system performance test, witnessed by the Consultants and the City’s staff.

Hand over SCADA system to City’s staff when accepted by the City.

Provide required warranty (response within 24 hours) and guarantee of SCADA system

Respond to City for all deficiencies

Prepare SCADA Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones

126 of 183




2-10 Dec 2015

2. RFP and Engineering Services Contract Award

2.1 General In general, RFP and Engineering Services Contract Award tasks are performed and/or coordinated by the City’s Project Manager. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

2.2 Identify PCS Requirements Conduct workshop(s) with PCSU and Operation Groupto gather requirements of the new project including input on the following:

Instrumentation

Control System Hardware

Software

Networking

Structured Cabling

Electrical

Gather input on how the proposed project will affect the current facility PCS, and what additions and changes may be required.

2.3 Scope of Work Draft a Scope of Work based on the information gathered at the workshop(s) and has it reviewed by the various groups to ensure that the PCS elements are consistent with City objectives and standards. Amend the Scope of Work as required.

2.4 RFP Draft the PCS elements of the RFP including project specific “PCS checklist” following City’s PCS Guidelines, Standards, and the Project Delivery System (PDS). Drafted RFP shall be reviewed by PCSUand Operations group.

Issue the RFP and involve PCSUand the Operation Group as required during the RFP process.

2.5 RFP Evaluation Evaluate RFP responses with input from PCSUand the Operation Group as required

127 of 183




2-11 Dec 2015

2.6 Engineering Services Contract Award Award the project to a Consultant with input from PCSUand the Operation Group as required.

128 of 183




3-12 Dec 2015

3. Pre-Design

3.1 General In general, Pre-Design tasks are performed by the Consultant and supervised by the City. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase. The Consultant shall follow Toronto Water’s PCS Guidelines and Standards throughout all phases of the project.

The purpose of the Pre-Design Report is to identify the key elements of the design to ensure that the final installation will meet the functional requirements and performance of Toronto Water. During the pre-design phase, the Consultant is expected to:

1. Visit the existing facility, or similar facility in Toronto Water, and familiarize themselves with the existing interfaces, PCS equipment including tagging, software, control strategies, and network architecture to be matched and/or upgraded.

2. Review all engineering reports and drawings for the PCS system related to the project.

3. Review previous pre-design report(s) and detailed designs prepared for the PCS system.

In general, consultants will comply with Appendix A.4 PREDESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system.

3.2 Project Commencement Conduct a Project Commencement Meeting, and invite PCSUand the Operation Group representatives. The purpose of the meeting is for the Consultant to introduce their project team and have a discussion of the general strategy and goals of the project.

3.3 Field Verification The Field Verification Procedure shall be completed on commencement of pre-design engineering to ensure that the design will meet the requirements of the facility. This will minimize potential future claims by Contractors during construction, resulting from inaccurate information portraying existing conditions. This activity will also accurately define the scope of work required for achieving the targeted level of automation.

Refer to Field Verification Procedure for more information.

3.4 Requirements Definition/50% Pre-Design The following elements should appear in the 50% submittal:

129 of 183




3-13 Dec 2015

1. Equipment and Instrumentation List - Design equipment and instrumentation to permit full monitoring and control capability under manual and/or automatic control. Refer to Instrumentation Design Standard. Prepare a table (example below) of all existing (reused) and proposed equipment and instrumentation (also refers as equipment, device or asset) to be installed for the project. The table should be filled in as much as possible during Pre-Design and then modification can continue through the Detailed Design and Construction phases. The table would be the source document for preparation of Tag List(s) to be created at the beginning of Detailed Design. It will also be used for Entity Information List (WMS list) initially populated by Consultant and completed by Contractor after the installation and commissioning.

Refer to General Instrumentation Requirements Standard for the list of approved instruments and manufacturers for the City’s PCS projects. The list of approved manufacturers shall be reviewed in conjunction with the staff of the affected facility. This list is part of PCS Standards and Specifications that will be made available on request at this stage of the project as well as the other required Standards and Specifications referred to further in this document (see Appendix D for the full list of PCS Standards and Specifications).

Notwithstanding the inclusion of equipment in the approved manufacturers list, the Consultant is responsible for engineering design and project performance. The Consultant shall review the existing equipment at the facility and the approved list, discuss with the City the current performance of the equipment, and in conjunction with the City provide recommendation for first named and alternate named equipment to be specified using the approved list as a base.

Make recommendations to the City if additional manufacturers are requested to be added or removed as appropriate according to Consultant experience and the specific project requirements. This list will form the basis of named and alternate named manufacturers and suppliers in the Contract Specifications.

Table 1: Equipment and Instrumentation List

Headings of Table Development Stages Predesign Detailed Design As Constructed

Equipment (Device)Tag (WMS/PCS Tag Number)

Required Required

Device (Tag) Description (WMS Asset Entity Name)

Required Required Required

P&ID Required Required Process Required Required Required Area Required Required Required Unit Required Required Required Device Type Required Required Required Status Required Required Required

130 of 183




3-14 Dec 2015

Headings of Table Development Stages Predesign Detailed Design As Constructed

Comment Required Required Required

Note: Naming convention for the Equipment (Device) Tag Name (in WMS referred as Entity Name) is described in Tagging Standard: Equipment and Data Tagging.

2. Servers/PLCs/Network - Review and document all existing hardware affected by the project, and determine system capacity. Discuss capability for expansion and identify all additional hardware required for modifications so as to fully integrate the new or expanded works into the existing system. Identify all obsolete hardware that must be replaced as part of the upgrading of the existing or expansion of the process control system. Refer to SCADA Computer System and PCS Local Area Network (Appendix D) for technical detail and requirements.

3. SCADA Software - Review and document all existing software affected by the project, and identify all additional software required for modifications to the HMI, PLC and networking devices so as to fully integrate the new or expanded works into the existing system.

4. Control Wiring and Structured Cabling – Review and document all existing control wiring and network cabling, and identify all additional cabling that will be required so as to fully integrate the new or expanded works into the existing system.

5. Alarm Notification and Security – Review the existing alarm notification and security system of the facility, and document the proposed modifications and additions to provide the required services for notification of the critical PCS alarms of the project. Refer to Alarming (Appendix C) for technical details and requirements.

6. Electrical System and Emergency Power – Review the existing power supplies to the relevant areas of the facility and document the proposed modifications and additions to provide the required electrical power for the proposed upgrades.

3.5 75% Pre-Design In addition to updates to the elements of the 50% pre-design, the following should appear in the 75% submittal:

1. Process Narrative – Provide a Process Narrative or update existing for each process, clearly describing how it is to be operated in all modes of process control. Process narratives shall be written in plain English to provide a clear understanding of the relationships between the equipments and the process variables to be monitored/controlled. Note that the Narrative will not apply solely to the new processes/equipment, but will detail all interaction with existing process/equipment control (i.e., alarm triggers, process variables shared by multiple processes, report

131 of 183




3-15 Dec 2015

generation, etc.). Refer to Process Control Narratives (Appendix C) Section 1.3.1 for technical detail and requirements.

2. Process Flow Diagrams – Provide a Process Flow Diagram or update existing to clearly illustrate the relationships between the various affected processes and associated instrumentation.

3. Design Alternatives – The Consultant should include a section detailing any alternative designs that they feel might offer benefits to the City in terms of cost or functionality.

4. Cost Estimate – Include a cost estimate to construct the project according to the guidelines provided in the RFP.

5. Electrical Area Classification Report – If required, provide “Electrical Area classifications report” for the affected areas where electrical and instrumentation devices will be installed under the project.

3.6 100% Pre-Design The 100% Pre-Design submittal should include updates to reflect the comments made during review of the 75% submittal. City staff will review the 100% submittal and again provide comments to allow the Consultant to finalize the Pre-Design report.

132 of 183




4-16 Dec 2015

4. Detailed Design

4.1 General In general, Detailed Design tasks are performed by the Consultant and supervised by the City. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Appendix A.5 DETAILED DESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system.

4.2 Tag Lists The City maintains a tag database known as the Enterprise Tagging Management System (ETMS). The Consultant shall have access to this database during design for the purpose of creating unique tag names and producing a Tag Lists for review by the City. If access to ETMS is not provided Consultant shall request ETMS tag report for the related facility and process(es). All equipment, equipment loops, data and local area network cabling shall be tagged in accordance with Equipment and Data Tagging Standard (Appendix D). Use of ETMS shall secure uniqueness and proper tag structure in accordance with Standards. However Consultant shall use related Master P&IDs in conjunction with ETMS/ETMS tag report in order to assure tag loop numbers follow the existing tagging logic. These tag numbers shall be used in the P&ID drawing(s) and all related project documentation for the identification of all equipment. Tags will be reserved in ETMS and could be modified during the life of Project. Any modification to the tagging should be identified by Consultant followed by request to City for approval.

Consultant shall prepare:

1. New equipment tag list. Consultant shall prepare and submit for approval new equipment tag list in particular format. "TagImportTemplate.xsl" spread sheet will be issued on requested.

2. Replace equipment tag list. This list refers to the equipment that is going to be replaced or upgraded. Equipment tag will not be changed but equipment description might (i.e. gate valve replaced with butterfly valve, valve actuator added or variable speed drive added to the pump). These types of changes are to be identified in separate "New description" column. Changes to the ETMS will be done by City once construction is completed. At that time also Entity Information List (WMS list) shall be completed in accordance with Equipment and Data Tagging (Section 3.12) for all replaced and upgraded equipment.

3. Reuse equipment tag list. This list refers to the equipment that is going to be reused in same or different capacity (function). Any changes are to be identified and to be dealt with the same way as for the "Replace equipment tag list" above.

133 of 183




4-17 Dec 2015

4. Reused tag list. This list refers to tags of the removed or "to be removed" equipment but there is intention to reuse (recycle) tags. Consultant should identified measures during transition if there is period where two identical tags in the field and SCADA would exist (old equipment to be removed after new equipment is commissioned). After construction is completed ETMS database should be updated. WMS data for the old equipment are to be retired. WMS data for the new equipment shall be completed in accordance with Equipment and Data Tagging Standard (Section 3.12) for all replaced and upgraded equipment.

5. Remove/Delete equipment tag list. Consultant is to identify and submit list of the equipment that will be removed. After construction is completed tags in ETMS and WMS databases will retire.

4.3 50% Detailed Design The following elements should appear in the 50% Detailed Design submittal:

1. Process Control Narrative (PCN) – The Consultant shall update the Master PCN provided by the City. Refer to Process Control Narratives (Appendix C) for details of the requirements.

2. P&IDs - The Consultant shall update the Master P&IDs provided by the City, or prepare new P&IDs (in case Master P&IDs do not exist). The City’s instrumentation symbols and control and instrumentation loop diagrams, including process and instrumentation diagrams, are generally based on the Instrument Society of America Standards ANSI/ISA-S5.1-1984 (R 1992) and ANSI/ISA-S5.4-1991, or latest revision. The ISA standards have been modified by the City to meet its own requirements. Consultants shall comply with P&ID Standard Symbols and Practices (Appendix C).

3. SCADA Architecture Drawings – The Consultant shall update the Master SCADA Architecture drawing of the facility, to show modifications and additions of equipment.

4. Typical I&C Drawings – The Consultant shall develop typical device Control Schematics and typical Instrument Wiring Diagram/Loop Drawings. Refer to Electrical Control Schematic Diagrams Standard (Appendix C) for drawings development.

5. Equipment Power Requirements – The Consultant shall provide drawings and specifications for any power supply upgrades or additions required as a result of new or modified equipment.

6. SingleLine Drawings – If the new equipment requires changes to the facility’s Master SLD, they shall be provided as part of this submission.

7. Electrical Area Classifications – These shall be updated from the classifications provided in the Pre-Design Report.

8. Cost Estimate – Provide an updated cost estimate.

134 of 183




4-18 Dec 2015

4.4 70% Detailed Design In addition to updates to the elements of the 50% design, the following should appear in the 70% submittal:

Equipment Layouts – The Consultant shall produce equipment and instrumentation layout drawings as required. The layouts are 'not to scale' drawings that shall show approximately position of the devices within the facility/area.

I & C Schematics – The Consultant shall produce for each device/instrument Device Control Schematics and Instrument Wiring Diagram/Loop Drawings based on the approved typical I&C drawings developed in 50% detailed design phase. Refer to Electrical Control Schematic Diagrams Standard (Appendix C) for Control Schematic development.

Control Panel Drawings – The Consultant shall provide drawings for new panels or modifications to any existing control panels. Refer to Control Panel Design (Appendix C).Control Panel Drawings should include:

1. Control Panel Layouts

2. RPU (PLC) Layout

3. Panel Power Distribution

4. I/O Modules Wiring Diagram

Refer to Electrical Control Schematic Diagrams Standard (Appendix C) for typical I/O module wiring diagrams development.

Cable Block Diagram Requirements – The Consultant shall identify requirements for development of cable block diagrams by Contractor during the construction phase. These diagrams should show all cables, as a minimum identifying: source and destination location (from-to), type, number of wires, wire size and all junction boxes between source and destination where applicable. Cable block diagrams should be included in Consultant's as built PCS drawings.

SCADA Hardware and Software Requirements – The Consultant shall create or update the Hardware and Software Inventory Lists (Server, Client, RPU and Access Closet hardware and software inventory and available capacity) for the facility, indicating what new software or hardware is required for the SCADA system

Instrument Ranges and Setpoints – As part of the Process Control Narrative, this information shall be provided at this stage.

PCS I/O tag list - Consultant shall provide PCS I/O tag list (example below), also referred as signal/data or PCS I/O point tag name, for inclusion in ETMS database upon approval from City. The list shall identify related device status: new, reuse, replace, and

135 of 183




4-19 Dec 2015

delete as well as intention to reuse (recycle) device tag. ETMS database will be populated in stages as described earlier (see 4.2 Tag Lists).

Alarm List - As part of the Process Control Narrative, this information shall be developed complete with Alarm Priority (High, Medium, Low, WIN911) and “Alarm Conditioning” at this stage.

iHistorian, eOPS, POMS, LIMS Requirements - As part of the Process Control Narrative, this information shall be available at this stage.

Alarm Notification and Security – Detailed Design of the alarm notification requirements that were provided in the Pre-Design Report.

Coordinate with the City’s corporate security for security related issues.

Networking and Structured Cabling - Detailed Design of the networking and structured cabling requirements that were provided in the Pre-Design Report.

Entity Information List (WMS list) – Consultant shall initially populate Entity Information List (WMS list) with design data (Tag name, description, type, location, size, range, etc.). See Equipment and Data Tagging Standard (Appendix D) for the template. The list will be further developed in Construction phase.

Equipment Physical Tag Lists - Field equipment shall be tagged in accordance with Equipment and Data Tagging. Templates are included in the Document. Provide completed Physical Tag Lists indicating details of the tag quantities and sizes.

Electrical Drawings and Requirements – Drawings showing electrical upgrades required for the project.

Identify FAT and SAT Requirements – Provide Initial FAT/SAT Check Sheet and Process Logic Test Sheet in accordance with PCS Factory Acceptance Testing and PCS Site Acceptance Testing and Commissioning (Appendix C). FAT/SAT Check and Process Logic Test Sheets are to be further developed in Construction phase.

Identify Hardware and Wiring Removal – Drawings to indicate obsolete hardware and wiring that is to be removed under the project.

Identify RPU/HMI Program/Code Removal – Produce a detailed list indicating which software tags/objects should be removed under the project.

Table 2: PCS I/O tag list

Headings of Table Development Stages Detailed Design As Constructed

PCS I/O Tag Required Required PCS I/O Tag Description Required Required

Signal/Data Type

Physical Required Required Virtual Required Required

136 of 183




4-20 Dec 2015

Headings of Table Development Stages Detailed Design As Constructed

Analog Required Required Digital Required Required

Engineering Units Required Required

Signal Used

PCS Required Required iHistorian Required Required eOPS Required Required POMS Required Required LIMS Required Required WMS Required Required

Comment Required Required

Note: PCS I/O Tag Description shall be description of the associated signal easily understandable to the Operator and shall be limited to 40 characters.

4.5 Detailed Technical Specifications The Consultants shall refer to the PCS standards listed under PCS Standards and Specifications List (Appendix D) and related Guidelines Appendices and shall use or adhere to those requirements. Consultants should obtain electronic versions of these standards and appendices related to the project from the City’s Project Manager.

The Consultants shall modify or edit the standards and appendices and create specifications to suit the project specific requirements of the contract, after getting consent from PCSU. However, where modifications are recommended, the Consultant is to highlight these proposed deviations to the City to ensure that the proposed changes do not compromise the City’s overall goal of standardizing PCS across Toronto Water facilities. The responsibility remains with the Consultant to ensure that contract specifications and drawings meet the requirements for proper project execution.

4.6 Apply For Approval Once the 70% Detailed Design package has been accepted by the City, it is expected that the Consultant will obtain approvals from agencies as required. Comments made by the approving agencies are to be incorporated into the documents for the 95% submittal to the City.


137 of 183




4-21 Dec 2015

1. Pre-Start Health and Safety – The Consultant shall review and report as required.

2. Electrical Area Classifications – The Consultant shall update electrical area classifications based on the detailed design

3. Updated Cost Estimate


1. Tender Document – The Consultant shall complete the preparation of the tender package.

2. Updated Cost Estimate

138 of 183




5-22 Dec 2015

5. Construction - Equipment

5.1 General In general, Construction – Equipment tasks are performed by the Contractor and supervised by the Consultant. See Appendix A – Project Tasks Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Appendix A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and solicit the City’s comments in addition to their own before returning reviewed deliverables to the Contractor.

5.2 Shop Drawings The Contractor is to submit shop drawings for all equipments and panels to be purchased for installation during the contract. The Consultant will review the shop drawings in accordance with Instrument and Equipment Testing (Appendix C). The City has the option to review shop drawings as well though the responsibility for accuracy and correctness lies with the Consultant.

5.3 Equipment and Panel Procurement and Fabrication The Contractor will procure equipment and manufacture panels as required, after approval of the shop drawings. The Consultant will monitor the progress and ensure the project schedule is maintained.

5.4 Test Sheets Contractor is to provide Pre-FAT test documentation for major equipment such as MCCs, pumps, etc.

5.5 Equipment and Panel FATs The purpose of hardware FATs is to ensure the integrity of the equipment used to control and monitor the process at the City’s facilities. It is intended to demonstrate that the system configuration will function effectively once installed on site, and limits the need for on site modifications to hardware configurations.

The hardware FAT involves the following major components:

1. Control Panels & Local Operator Interfaces

2. Networking Equipment

139 of 183




5-23 Dec 2015

3. Workstations

4. PLCs.

The hardware FAT is performed at the Contractor's office. These tests must be completed by the contractor and approved by the Consultants prior to any equipment being delivered to the project site. The City has the option to witness the FATs as well, though the responsibility for approval lies with the Consultant.

5.6 Transition Plan A project will typically involve installing equipment into an existing, operating facility that has an operating PCS. The Contractor shall develop a transition plan that details the progression of installation tasks such that the impact on operations is minimized and the continued safe operation of the facility is assured. The plan should take the following considerations into account:

1. Features of the facility that may impose limitations during construction. For example, certain tasks might need to be performed during non-peak operating hours.

2. To maintain continuous operation and monitoring, provisions might need to be made for temporary parallel equipment. For example, if an older model PLC is being replaced, it might need to continue operating while the new PLC is installed and wired.

3. PCS upgrades typically require re-wiring of equipment that results in a temporary loss of use of the equipment. The transition plan needs to account for operational requirements while scheduling equipment down-time. The Operation Group will provide the Contractor with their operational constraints as required.

4. If PCS networking configuration changes are involved, the Contractor should consider the impact on the ability of the Operation Group to control and monitor related equipment.

Consultant should review the transition plan prior submitting to City for approval.

5.7 Equipment Installation and Wiring

Once equipment has been approved at the FAT and the Transition Plan has been accepted, the Contractor can deliver equipment to site and commence installation. Prior starting field wiring of the equipment, instrumenatation and control pannels contractor shall prepare Cable Block Diagrams as outlined in 4.4 Detaild Design.

5.8 Pre-Start Health and Safety If a Pre-Start Health and Safety review and report are required (refer to the Toronto Water Project Delivery System Manual for details), the Consultant shall produce the report and have it approved prior to the commencement of commissioning.

140 of 183




5-24 Dec 2015

5.9 Entity Information Lists The Contractor shall populate with manufacturer's data and maintenance recommendations the Entity Information Lists (WMS list) initially developed by Consultant for all new and upgraded equipment in the project. See Equipment and Data Tagging Standard (Appendix D) for the template. This information is used by the OMU for WMS purposes.

141 of 183




6-25 Dec 2015

6. Construction - Software

6.1 General In general, Construction – Software tasks are performed by the Systems Integrator and supervised by the Consultant. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Appendix A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and provide their comments to the City.

6.2 Flow Chart Development The Systems Integrator shall develop logic flow charts to demonstrate their interpretation of the design documents. Refer to RPU Software Programming (Appendix C) for more detail on the development of flow charts.

6.3 Software Modules The City has developed a series of standard software modules that are to be used by programmers to implement the control functions required by the project. The goal of standard software modules is to reduce development and maintenance costs by ensuring that software deployed throughout Toronto Water facilities has a common look and logical base. Refer to Standard Software Modules (Appendix C) for more detail on the use of software modules.

In some cases, the Systems Integrator may find that a new or modified software module would be beneficial to the development of the software for the project. Modules cannot be modified without the consent of PCSU. When the PCSU approves the development or modification of a software module, the Systems Integrator shall follow the procedure found in Standard Software Modules (Appendix C).

6.4 Software Development Once it has been determined that the software modules are sufficient for the project, the Systems Integrator can begin software development according to the following Appendix C guidelines:

1. Process Display Programming

2. Operator Interface Programming

3. Alarming

4. Colour Convention

142 of 183




6-26 Dec 2015

5. RPU Software Programming

6. Standard Software Modules

Software is to be submitted at the 70% stage at which time the Consultant and City representatives will review the components for accuracy, adherence to standards, and compatibility with the rest of the facility PCS.

6.5 FAT Plan Prior to carrying out a Factory Acceptance Test of the software, the Systems Integrator shall prepare a detailed test plan for review by the Consultant. The test plan is to broaden the FAT Check Sheet and Process Logic Test Sheet developed by Consultant in the Design Stage. The test plan will identify all field I/O to be tested such as equipment status, control modes, and hardwired alarms. Also virtual points such as alarms (including priority and conditioning), setpoints, and operator entered parameters. The test plan will then identify automatic logic tests designed to prove that the program responds as detailed in the Process Control Narrative. The plan will also identify a “graphics review” as well as include the PCN and the contract drawings (control schematics, loop diagrams, and process and instrumentation drawings – P&IDs) as part of the test plan. The Systems Integrator shall demonstrate that the test plan fulfils the intent and requirements of the PCN and will therefore result in the successful operation of the system when installed on site.

The test plan should also include a proposed schedule and a description of the proposed testing environment (hardware setup, software utilized) for approval by the Consultant and the City. Refer to Factory Acceptance Testing (Appendix C) for details. Once the schedule and documentation have been accepted, the Systems Integrator shall submit a copy of all software components to the City (known as the “Pre-FAT” version of software).

6.6 Software FAT The Systems Integrator will host the Factory Acceptance Test according to the details presented in the schedule and FAT documentation. Refer to Factory Acceptance Testing (Appendix C) for details. Upon completion of the FAT and subsequent corrections and re-testing as required, the Systems Integrator shall submit a copy of all software components to the City (known as the “Pre-SAT” version of software).

143 of 183




7-27 Dec 2015

7. Construction – Testing and Commissioning

7.1 General The Consultant shall comply with Appendix A7 SITE SERVICES DURING TESTING AND COMMISSIONING, of the RFP document for the engineering services required to be provided for the project.

The Consultant shall specify in the contract document that the Contractor and Systems Integrator are required to comply with the City’s standard procedure for the testing and commissioning of PCS.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City.

7.2 Hardware SAT and Training Plan The Contractor is to submit a SAT Plan that includes the following:

1. Schedule

2. Testing procedure for each item

3. Sign-off documentation

4. Details of City involvement, including any operational requirements such as shutdowns, communication interruptions, etc.

Refer to Instrument and Equipment Testing and Site Acceptance Testing (Appendix C) for more details.

The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to Training (Appendix C) for more details.

7.3 Hardware Training The Contractor shall perform training on the installed hardware prior to the SAT. Refer to Training (Appendix C) for more details.

7.4 Hardware SAT A Hardware SAT is to ensure the integrity of the equipment used to control and monitor the process at the City’s facilities once installed on site. Prior to the hardware SAT, the Consultant and Contractor must have jointly completed all I/O tests, loop tests, network tests, and instrumentation calibration verification sheets.

144 of 183




7-28 Dec 2015

The hardware SAT involves the following major components:

1. Control Panels & Local Operator Interfaces

2. Networking Equipment (as available)

3. Workstations

4. PLCs

5. Instrumentation

The hardware SAT is performed on site to ensure that the equipment has been installed wired and configured correctly. The consultant shall compile all the SAT results and submit it to the City for their review.

The testing of the networking equipment, workstations, and PLCs is intended to confirm that the network as designed, and the configuration of the hardware as specified functions as an integral network on site and in conjunction with the City’s wide area network (WAN).

7.5 Software SAT and Training Plan The Systems Integrator’s SAT Plan should include the same I/O and Logic check sheets that were used during the Software FAT. In addition to check sheets, there should also be sign-off documentation and a schedule of activities that details the City’s involvement, including any operational requirements such as shutdowns, communication interruptions, etc. Refer to Site Acceptance Testing and Commissioning (Appendix C) for more details.

The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to Training (Appendix C) for more details.

7.6 Software Training The Systems Integrator shall perform training on the new software components prior to the SAT. Refer to Training (Appendix C) for more details.

7.7 Software SAT After training has been completed, the Software SAT can be performed. It is intended to confirm that the software functions according to the Process Control Narrative and allow fine-tuning of control loops and other process variables. Refer to Site Acceptance Testing and Commissioning (Appendix C) for more details.

7.8 Operational Test/System Performance Test The operational test/system performance is a 5-day test (unless otherwise defined in RFP) of the system to simulate the operation of the system under different loading conditions. The test shall start on a Monday and will be restarted again on a Monday in the event of a failure of the system to operate as intended at any point in the 5-day period. During this period the software is to

145 of 183




7-29 Dec 2015

operate under Area Operator station and Central Operator station modes to simulate normal operation of the system. Where necessary, the Consultants will specify additional simulation logic to the RPU to allow the process area to be fully simulated for operational test/system performance. The provision of such simulation code is deemed to be within the scope of the Contractor services. Where necessary, the Consultant shall specify the provision of temporary piping and equipment in order to be able to carry out the simulation successfully.

7.9 Tag Lists and PCS I/O List Consultant is to finalize Tag Lists and PCS I/O list identifying all changes made throughout construction and commissioning for inclusion into the ETMS and WMS.

7.10 As-Built Documentation The Contractor and Systems Integrator shall submit As-Built documentation during this phase. Refer the PCS Documentation (Appendix C) for details. Consultant is also to submit As-Built documentation integrating all changes into documentation prepared in the Design phase of the Project.

7.11 Post Construction Warranty Period In general, the Systems Integrator shall provide all necessary services during the warranty period to update all software when deficiencies are found. Refer to the contract for specific warranty requirements.

146 of 183




Appendix A-1

Dec, 2015

Appendix A – Project Tasks Flowcharts

147 of 183




Appendix B-1

Dec, 2015

Appendix B – Project Tasks Implementation Checklists

148 of 183




Appendix C-1 Dec, 2015

Appendix C – Associated Guidelines The following list shows related Guideline documents for specific topics that are complementary to this document.

Document Name Drawing # Field Verification Procedure

Field Verification Log

Process Control Narrative

P&ID Standard Symbols and Practices

P&ID Standard Symbols and Practices Attachments P&ID LEGEND XXXX-P&ID-I-0101 P&ID STANDARD SYMBOLS -1 XXXX-P&ID-I-0102 P&ID STANDARD SYMBOLS -2 XXXX-P&ID-I-0103 P&ID Blocks - Gates, Valves, Pumps P&ID Block 1 P&ID Blocks - Blower, Fan, Damper P&ID Block 2 P&ID Blocks - Vortex, Chamber P&ID Block 3 P&ID Blocks - Bridge, Collector P&ID Block 4 P&ID Blocks - Centrifuge P&ID Block 5 P&ID Blocks - Generator, Communitor P&ID Block 6 P&ID Blocks - Instrumentation P&ID Block 7 Colour Convention


Standard Software Modules



Alarming

Instrument and Equipment Testing

Instrument and Equipment Testing Attachments Instrument Testing Log

Field Installation Testing Log

SCADA Factory Acceptance Testing

SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check Sheet

Process Logic Test Sheet

SCADA Site Acceptance Testing and Commissioning

SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check Sheet

Process Logic Test Sheet

PCS Documentation Training

149 of 183




Appendix D-1

Dec, 2015

Appendix D – Associated Standards and Installation Drawings List The following list shows PCS Standards and Installation Drawings that will be made available to Consultant on the request.

SPECIFICATION # DWG. # DESCRIPTION

DIVISION 13 - PROCESS CONTROL

13000 PROCESS CONTROL

13010 Process Control - General

13040 SPECIALITIES

13040 Equipment and Data Tagging

WMS Entity Information Spread Sheet

Equipment (Asset) Tag List – Aluminum (Example)

Equipment (Asset) Tag List – Lamacoid (Example)

Lamacoid Supplemental Tag List – MCC Starter Disconnect (Example)

Lamacoid Supplemental Tag List – Source of Power (Example)

Lamacoid Supplemental Tag List – Control Station (Example)

13100 INSTRUMENTATION STANDARDS

13100 Instrumentation Design

13105 General Instrumentation Requirements

13110 ANALYSIS INSTRUMENTS

13110.1 Particle Analyzer

13110.2 Turbidity Analyzer - Low Range

13110.3 Turbidity Analyzer - High Range

13110.4 Suspended Solids Meter - Insertion Type

13110.5 Suspended Solids Meter

13110.6 Sludge Density Meter, In-Line

13110.7 Sludge Density Meter, Ultrasonic

13111 Chlorine Residual Analyzer

13113 pH Analyzer

13115 Conductivity Analyzer

13116 Dissolved Oxygen Analyzer

13118 Fluoride Analyzer

13120 Streaming Current Analyzer

150 of 183




Appendix D-2

Dec, 2015


13121 Phosphate Analyzer

13122 Ammonia Analyzer

13125.1 Chlorine Leak and Sulphur Dioxide Monitor

13125.2 Ozone Gas Leak Detector

13125.3 Combustible Gas Detector

13125.5 Hydrogen Sulphide Monitor

13125.6 Oxygen Monitor

13125.7 Stack Gas Monitor

13125.8 Gas Detector

13125.9 Ozone Concentration Transmitter, Wet Gas

13126.1 Ozone-In-Oxygen Monitor - Low Range

13126.2 Ozone-In-Oxygen Monitor - Medium Range

13126.3 Ozone-In-Oxygen Monitor - High Range

13130 FLOW INSTRUMENTS

13130 Magnetic Flow Meter

13131 Vortex Shedding Flow Meter

13132.1 Clamp-on Ultrasonic (Doppler) Flow Meter

13132.2 Clamp-on Ultrasonic (Transit Time) Flow Meter

13133 Insertion Ultrasonic (Transit Time) Flow Meter

13134 Thermal Mass Flow Meter

13136 Coriolis Mass Flow and Density Meter

13137.1 Orifice Plate

13137.2 Pitot Tube

13137.3 Venturi

13137.4 Parshall Flume

13137.5 Flow Broad Crested Weir

13138.1 Paddle Wheel Flow Switch

13138.2 Thermal Flow Switch

13142 Open Channel Flow Meter - Submersible

13143 Open Channel Flow Meter - Radar

13150 LEVEL INSTRUMENTS

13150.1 Ultrasonic Level Transmitter

13150.3 Radar Level Transmitter - Horn Antenna

13150.4 Radar Level Transmitter- Rod Antenna

13152 Capacitance Level Transmitter

13153.1 Level-Direct Sensing DPT (Level), Flange Mounted

13153.2 Level-Submersible DPT

13157.1 Sludge Blanket Detector, Fixed

151 of 183




Appendix D-3

Dec, 2015


13158.1 Float Switch (Tilt)

13158.2 Ultrasonic Level Switch

13158.3 Capacitance Level Switch

13158.4 Vibration Level Switch

13158.5 Conductivity Level Switch

13160 PRESSURE INSTRUMENTS

13160 Pressure Transmitter

13161 Pressure Differential Transmitter

13166 Pressure Seal

13167 Annular Pressure Seal

13168 Pressure Switches

13169 Pressure Indicating Gauge

13170 TEMPERATURE INSTRUMENTS

13170.1 Temperature Element and Transmitter, RTD

13170.2 Temperature Element and Transmitter, Thermocouple

13171.1 Ambient Air Temperature and Humidity Transmitter

13171.2 Duct Air Temperature and Humidity Transmitter

13171.3 Ambient Air Humidity Transmitter

13171.4 Duct Air Humidity Transmitter

13176 Thermowell

13177 Temperature Switches

13178 Temperature Indicators

13180 MISCELLANEOUS INSTRUMENTS

13180 Sampler

13183 Limit Switch

13184 Motion Detector

13187 Weight Scale Hydraulic Weight Cell

13188 Weigh Scale Load Cell

13190 Smoke Detector

13191 Heat Detector

13199 Instrument Listing / Instrument Data Sheets

13300 CONTROL PANEL STANDARDS

13300 Control Panel Design

13305 Field Wiring

13310 Panel Construction

13311 Enclosures

152 of 183




Appendix D-4

Dec, 2015


13312 Enclosure Accessories

13320 Panel Wiring

13325 DC Power Supply

13340 Panel Services

13350 Selector Switches, Push-Buttons, and Status Lights

13351 Annunciator

13352 Single Loop Controller

13353 Dual Loop Controller

13354 LCD Digital Panel Indicator

13354.1 LED Digital Panel Indicator

13355 Paperless Chart Recorder

13360 ELECTRICAL MONITORING AND PROTECTION

13361 Power Monitor Unit

13366.1 Motor Protection Unit (469)

13367 Generator Management Relay (489)

13368 Feeder Protection Unit (750)

13369 Transformer Protection Unit (735)

13369.1 Transformer Differential Protection Unit (745)

13370 SIGNAL CONDITIONING EQUIPMENT

13370 Signal Conditioning Equipment

13371 Power Monitoring Serial to Ethernet Conversion Unit

13372 Power Monitoring Information and Relay Configuration Tool

13400 PROGRAMABLE LOGIC CONTROLLERS

13400 Programmable Logic Controllers

13500 NETWORKING

13510 Local Area Network

13520 Wide Area Network

13600 COMPUTER HARDWARE

13600 SCADA Computer System

Appendix D1: Installation Drawings

General for Instruments and Panels

G01 Instrument Stand, floor mount

G02 Instrument Wall Mounting, Pipe

G05 Instrument Sun Shield Installation Detail

153 of 183




Appendix D-5

Dec, 2015


G06 Instrument Purge Air

Analysis Instruments

A02 pH Sensor - In-Line Mount

A03 pH Sensor - Y Mount

A06.2 DO Probe, Hand-Rail Mount

A14.1 Suspended Solids Meter (Low Range)

A14.2 Suspended Solids Meter (Higher Concentration of Solids)

A15.1 Suspended Solids Meter - In-line

A15.2 Suspended Solids Meter – Pipe Tee Insertion

A32 Gas Detection - Conduit Mounted Sensor

A35 Chlorine Leak Sensor

Flow Instruments

F01.2 Flow - Magnetic Flow Meter (With Ultrasonic Cleaning Electrodes)

F01.3 Flow - Magnetic Flow Meter (Remote Mounted Signal Converter)

F04.1 Flow Switch (Paddle Wheel) Pipe Mounting

F05.1 Flow Switch (Thermal) Duct Mounting. Air

F07 Self Averaging Pitot, Standard

F08 Self Averaging Pitot, Hot Tap

F09 Self Averaging Pitot, Flanged

F10 Ventury Tube

F35 Parshall Flume Ultrasonic Sensor Mounting Detail

Level Instruments

L02 Ultrasonic Level, Through Concrete

L11 Ultrasonic Level, Enclosed Tank

L12.1 Radar Level, Horn Antenna, Enclosed Tank

L12.2 Radar Level, Horn Antenna, Grit Hopper/Tank

L12.3 Radar Level, Horn Antenna, Enclosed Tank Flange Mounted

L12.4 Radar Level, Horn Antenna, Open Tank, Side Mounted

L12.5 Radar Level, Horn Antenna, Scum Hopper/Tank

L12.6 Radar Level, Horn Antenna, Enclosed Tank, Floor Mounted

L13 Radar Level Transmitter - Rod

L20 Level Probe In Side Of Tank

L25 Float Switch for Sumps

L25.1 Float Switch for Sumps, Multi Level Regulator Hanger

L37 Weir –Ultrasonic Level Sensor Mounting Detail

Pressure Instruments

P01 Pressure Tap - Pipe Tee and Threadolet

P02 Pressure Tap - Tank (FRP and Steel)

P03 Pressure Tap - Pipe Saddle

154 of 183




Appendix D-6

Dec, 2015


P12 DPT For Flow In Overhead Process Line

P14 DPT For Flow In Lower Process Line

P15 DPT For Steam Flow

P16 DPT For Level Of Vented Tank

P18 Pressure - DPT For Filter Head Loss

P18.1 Differential Pressure Transmitter

P22 PS and PI, normal

P23 PS and PI, with diaphragm seal

P24 PS and PI, with annular diaphragm seal

Temperature Instruments

T01 Thermowells Installation

T02 Thermowells Installation

DIVISION 15 MECHANICAL

15000 MECHANICAL DESIGN STANDARDS

15110 Valves and Operators

DIVISION 16 ELECTRICAL

16000 ELECTRICAL DESIGN STANDARDS

16020 Electrical Control Schematic Diagrams

1.01 Electrical Symbols

2.01A Constant Speed Computer - Maintained, Local -Pushbuttons

2.01B Constant Speed Computer - Momentary, Local -Pushbuttons

2.01C Reversing: Computer - Maintained, Local - Pushbuttons

2.01D Reversing: Computer - Momentary, Local - Pushbuttons

2.02A Two Speed: Computer-Maintained, Local - Push-buttons

2.02B Two Speed: Computer - Momentary, Local - Push-buttons

2.03A Variable Speed Magnetic Drive: Speed - 4-20 mA

2.04A Full Open/Close Valve or Gate: Computer - Momentary, Local - Pushbuttons

2.05A Slow Moving Valve or Gate: Computer - Maintained, Local - Selector Switch

2.05B Slow Moving Valve or Gate: Computer - Momentary, Local - Pushbuttons

2.06A Modulating Valve or Gate: Computer - 4-20 mA, Local - Setpoint

2.06B Modulating Valve or Gate: Computer - Maintained, Local - Pushbuttons

16280 Uninterruptible Power Supplies and Power Conditioners

155 of 183




Appendix D-7

Dec, 2015


16281 Computer Room, Uninterruptible Power Supply

156 of 183


Appendix C


T-13105-02 -Instrument and Equipment Testing-V2

Page 1 of 8 (Addm-6)

Mar 2016

1. Instrument and Equipment Testing

1.1 General

Consultants shall comply with this design standard in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the PCSU.

The testing of instrument and equipment are performed at two separate stages during

the construction works and these are:

1. Field instrument acceptance test to confirm that the field instruments are installed in accordance with the terms and conditions of the contract (Installation point of view)

2. Field instruments and equipment are installed and perform in accordance with the terms and conditions of the contract (Performance point of view)

The difference between the two is highlighted above in italics to emphasize the difference. The following sections provide detail on the procedure for each of the above test procedure.

Comply with the following when performing instrument and equipment testing:

1.2 Field Instrument Testing

1.2.1 General

The field instrument acceptance test shall be performed by the Contractor and witness by the Consultants to confirm that the field instruments are installed in accordance with the contract documents and meet operation requirements. This includes confirmation that the units have been correctly calibrated (by qualified personnel), and verification that the equipment is available to properly receive and/or transmit information to/from all devices in the loop.

Where it is identified that the requirements of the Contract have not been met, the Consultants shall ensure that the Contractor rectify all deficiencies immediately, if possible, to allow re-testing during the same test phase.

1.2.2 Acceptance Tests Objectives

The objectives of the field instrument acceptance test are:

1. Acceptance of instruments as installed by the Contractor.

2. Confirmation of the performance in accordance with the Consultant’s Design.

3. Confirm and document that all new instruments meet the contract specification and drawing requirements, including range, accuracy, repeatability, reliability, calibration, and installation details.

4. Confirm that all discrete and analog signals (both new and existing) to be transmitted to and from the instrument are available and functioning correctly.

157 of 183


Appendix C




Mar 2016

1.2.3 Completion Criteria

The Field Instrument Acceptance Test shall be deemed to be complete when all features, functions and information required in accordance with the Process Narratives and Process and Instrumentation Drawings have been verified as present and functioning, and documented as accurate within the anticipated operating range for the process being monitored.

The Instrument Acceptance Report is to be used to identify and manage all outstanding issues, until they are resolved.

1.2.4 Participants and Responsibilities

The Consultant shall schedule the required tests in consultation with plant staff and ensure that all the required documentation has been submitted by the Contractor as specified. The Consultants shall review all documents and ensure it meets the contract requirements. In addition, the Consultants shall also witness all tests performed by the Contractor and sign-off forms as required to indicate that they have witnessed the tests and on completion of tests, ensure that the Contractor submits all required documents. All testing procedures and tools to be used shall be specified by the Consultant. The Consultant will also supervise and approve all procedures and tools used.

Plant Liaison and Process Control System Unit (PCSU) representative shall review Consultant’s

work plan, assign plant staff to assist with field testing, coordinate with plant operating, maintenance, and other construction activities and to provide plant staff to participate and assist in the instrument acceptance testing in order to both provide site knowledge, local coordination when necessary, and adopt the new test procedures.

The Contractor shall be responsible for planning tests, gathering information, preparing instrument test reports prior to commencing, scheduling testing, requesting field assistance from plant personnel, reviewing schedule with plant supervisors, completing testing which is to be witnessed by the Consultants, then presenting findings and reporting to the Consultants.

1.2.5 Documents Required Prior to Field Work

The Consultants shall ensure that the following documents are assembled and submitted by the Contractor to the Consultants for review prior to conducting the Instrument Acceptance Testing:

1. Reviewed shop drawings, including ISA data sheets, for each instrument installed (multiple copies for multiple installations);

2. “For Construction” P&IDs, process narratives, control schematics, and electrical drawings;

3. Configuration and calibration certificates from the manufacturer(s) for each calibrated instrument, where specified by the Consultant in the Contract Documents;

4. Results of factory performance tests, where specified by the Consultant in the Contract Documents;

5. Instrument field calibration reports, where specified by the Consultant;

158 of 183


Appendix C




Mar 2016

6. Prepared instrument acceptance reports with all equipment numbers and relevant details entered;

Prior to commencement of testing, the Consultants shall define the following for each piece of field equipment:

1. Calibration Procedure(s) to be followed by the Contractor;

2. Any special Procedure(s) to be followed by the Contractor;

3. Site verification, set-up, and calibration required by the equipment manufacturers.

1.2.6 Testing Schedule

The Consultants shall ensure that the testing procedures and schedules of work are submitted by the Contractor not less than ten (10) working days prior to the projected test date for the individual component. This will include specific dates for when the various test procedures are to be carried out, and the plant staff assistance required to complete the field portion of the investigation. The Consultants shall ensure that the Contractor have allowed flexibility in his schedule to permit emergency requests by plant staff, plus unexpected field and operation findings.

The schedule must be approved in writing by the Consultants, the Plant Engineer, and the Electrical and Instrumentation Supervisors, prior to the commencement of any field testing.

The field equipment acceptance report must be presented 1 week after completion by the Contractor in order to identify and resolve all critical issues which affect scope, cost or schedule in a timely manner.

In certain cases, testing will be required to be scheduled outside normal business hours to accommodate operating issues and/or low flow conditions. This should be discussed and resolved with plant management when planning the test schedule.

1.2.7 Documentation and Reporting

The Contractor shall use the following standard documentation for instrument acceptance tests:

1. Field Instrument Acceptance Report ("Instrument Testing Log" and "Field Installation

Testing Log" are attached to the end of this document as an example. Consultant should request documents in its original format)

2. Field Calibration Report, in electronic documentation, transferable in standard spreadsheet format

3. Shop drawings, Instrument Data Sheets and calibration reports (update as required) 4. “As Built” P&ID, control schematics, and electrical drawings (update as required)

The Contractor shall present the Instrument Acceptance Test Reports findings in electronic and printed reports which shall contain the following, as a minimum:

1. The scope of the specific Instrument Acceptance Test

159 of 183


Appendix C




Mar 2016

2. Specific Objectives beyond the General Objectives noted above

3. Summary of Outstanding Issues, with the detailed test reports contained in an Appendix

4. Recommendations on improvements/upgrades to contract scope in order to achieve operational requirements if applicable. For upgrades with a capital cost greater than $15,000, a simple cost/benefit analysis must be provided

5. Cost estimates for all recommended improvements

1.2.8 Instrument Acceptance - General

The Contractor shall inspect and document that each instrument matches the reviewed shop drawing. The inspection shall be witnessed by the Consultants. The inspection shall include, but not be limited to the following (as applicable):

1. Verify that instrument product details match shop drawings and Contract Documents, (including Instrument Data Sheets)

2. Confirm soundness of instrument, i.e. without damaged parts

3. Confirm completeness in all respects as specified for instrumentation

4. Confirm correctness of setting, alignment, and relative arrangement

5. Inspect power, signal, and grounding wiring identified on the control schematics and documenting the results. All wiring to be verified for continuity

1.2.9 Instrument Acceptance – Specific to Devices

The Contractor shall perform test on all devices for their repeatability, accuracy and operation by varying the process and simultaneously measuring and recording the information displayed by:

1. An independent measuring instrument;

2. The local transmitter indicator;

3. All remote digital/mechanical indicators;

4. The 4-20mA (or digital value) measured at both RPU panels’ and operator panels’ terminal

blocks and converted into engineering units.

Performance of all tests will be witnessed by the Consultants.

Test results shall be compared against the instrument calibration reports and planned RPU analog input range. As an example, flow sensors will require testing using a “draw and fill” test of a local

container.

1.2.10 Instrument Acceptance – Specific to Switches

The Contractor shall perform test on all instrument switches, such as pressure switches or building flood alarms, for their accuracy and operation by varying the process conditions (for example: high then low pressure) and simultaneously measuring and recording the information displayed by:

160 of 183


Appendix C




Mar 2016

1. An independent measuring instrument

2. The instrument switch

3. All remote lights and indicators

4. The digital input status measured at both the RPU and operator panels’ terminal blocks

Performance of all tests shall be witnessed by the Consultants.

Test results are to be compared against the instrument calibration/setting reports and planned RPU discrete input setting.

1.2.11 Testing Tools and Equipment

The Consultants shall ensure that the Contractor and/or respective Calibration Contractors or Equipment Manufacturers provides proper protection for all instruments and devices that may be damaged by high voltage tests. If damages occur, the respective parties shall be held fully responsible for the replacement of damaged parts and/or components.

Calibration method and tools shall not cause any error greater than +/- 0.5% in any test. The accuracy of the calibration tools must be traceable to National Standards. The Consultants shall review all testing procedures, and tools to be used. The Contractor shall use only electronic calibration equipment unless it can be demonstrated that such electronic calibration equipment is not available for the required specific test. Provide a form for electronic documentation, transferable to a standard spreadsheet format.

The Consultants or the Contractor shall follow the applicable City’s safety requirements. For all

identified plant areas, and in particular the collection system facilities, provide proper safety equipment for personnel entering (manholes and other) confined spaces, plus hazardous gas locations.

1.3 Instrument and Equipment Testing

1.3.1 General

The instrument and equipment shall be tested to confirm that the field instruments and equipment installed perform in accordance with the Contract Documents. Testing shall be performed by the Contractor and witnessed by the Consultants.

The testing shall confirm that:

1. The units have been correctly installed.

2. The units have been correctly calibrated.

3. All discrete and analog signals (both new and existing) to be transmitted to and from the units are available and functioning correctly.

4. The units are capable of working as specified.

161 of 183


Appendix C




Mar 2016

The work will be accepted if all the above criteria have been met and where it is identified that the requirements of the Contract have not been met, the Contractor shall rectify all deficiencies immediately to allow re-testing during the same test phase.

Testing will be deemed complete when all features, functions and information required in the Contract Documents have been verified as present and functioning, and documented as accurate within the anticipated operating range for the process being monitored.

1.3.2 Submission of Documents

The Contractor shall submit the following documents prior to conducting the Instrument and Equipment Acceptance Testing:

1. Calibration Procedure(s) to be followed in the test. The calibration method and tools will not cause greater than +/- 0.5% error in any test;

2. Any special Procedure(s) to be followed in the test;

3. Identify site verification, set-up and calibration to be performed by the equipment manufacturers.

Update shop drawings, Instrument Data Sheets, calibration reports and “As Built” drawings

including: P&ID, control schematics and electrical drawings as required to match field conditions.

1.3.3 Testing Schedule

The Contractor shall submit testing procedures and schedules of work no less than one (1) month prior to the projected test date for the individual component. This will include specific dates for when the various test procedures are to be carried out and identified assistance from City’s staff.

In some cases, testing may be scheduled outside normal business hours to accommodate operating issues and/or low flow conditions. Testing may be interrupted by the City’s staff for

emergency process operation.

Submit test results to the Consultants at the end of each day of testing.

1.3.4 Testing Procedure

The Consultants shall ensure that the following documents have been prepared and assembled by the Contractor and available on site prior to conducting Instrument and Equipment Acceptance Testing:

1. Reviewed shop drawings, including ISA data sheets, for each instrument installed and for each piece of the equipment (multiple copies for multiple installations);

2. “For Construction” P&IDs, process control narratives, control schematics and electrical drawings;

3. Configuration and calibration certificates from the manufacturer(s) for each calibrated instrument, where specified in the Contract Documents;

162 of 183


Appendix C




Mar 2016

4. Results of factory performance tests, as specified in the Contract Documents;

5. Instrument and equipment field calibration reports, as specified Contract Documents;

6. Prepared instrument and equipment acceptance reports with all equipment numbers and relevant details entered.

The Contractor, witnessed by the Consultant, shall inspect and document that each instrument and equipment matches the reviewed shop drawing. The inspection shall include, but not be limited to the following (as applicable):

1. Verifying that instrument and equipment product details match shop drawings and Contract Documents, (including Instrument Data Sheets);

2. Confirming soundness of instrument and equipment, i.e. without damaged parts;

3. Confirming completeness in all respects as specified for instrumentation and equipment;

4. Confirming correctness of setting, alignment, and relative arrangement

5. Inspecting power, signal, and grounding wiring identified on the control schematics and documenting the results. All wiring to be verified for continuity.

1.3.5 Instrument Acceptance – Specific to Devices

Devices are also to be tested by the Contractor for their repeatability, accuracy and operation by varying the process and simultaneously measuring and recording the information displayed by:


2. The local transmitter indicator;

3. All remote digital/mechanical indicators;

4. The 4-20mA (or digital value) measured at terminal blocks in RPU panels and operator panels.

The Contractor shall compare test results against the instrument calibration reports and planned RPU analog input range. As an example, flow sensors will require testing using a “draw and fill”

test of a local container.

Where no field calibration has been done, perform a calibration test. Go up, down, then back up the instrument range, testing at five (5) points each time: 0%, 25%, 50%, 75% and 100%.

1.3.6 Instrument Acceptance – Specific to Switches

The instrument switches, such as pressure switches or building flood alarms, shall be tested by the Contractor for their accuracy and operation by varying the process conditions (for example: high then low pressure) and simultaneously measuring and recording the information displayed by:


2. The instrument switch;

163 of 183


Appendix C




Mar 2016

3. All remote lights and indicators;

4. The digital input status measured at both the RPU and operator panels’ terminal blocks.

Test results are to be compared against the instrument calibration/setting reports and planned RPU discrete input setting.

1.3.7 Testing Tools and Equipment

Protect instruments and equipment that may be damaged by testing. If damages occur, the Contractor shall be fully responsible for replacement of damaged parts and/or components.

Use calibration tools that will not cause greater than +/- 0.5% error in any test. The accuracy of the calibration tools must be traceable to National Standards. The City’s preference is the use of

electronic calibration equipment that will provide a form of electronic documentation, transferable in a standard spreadsheet format.

Comply with the applicable City’s safety requirements. Provide the proper safety equipment for entering (manholes and other) confined spaces, and hazardous gas locations.

164 of 183

INSTRUMENT TESTING LOGDate: ________________

Page ____ of ____

# INSTRUMENT TAG NUMBERSTATUS DOCUMENTS TEST AND CALIBRATION

Existing Records Available Results

New

Re-U

sed

Re-C

alib

rate

d

Repaired

Technic

al M

anu

factu

rer

Data

Shee

t

P&

ID,C

ontr

ol S

chem

atic, E

lectr

ical dw

gs

Contr

act S

pecific

ations

Ori

gio

na

l C

alib

ration R

epo

rts

Main

tenan

ce R

ep

ort

s

Test D

ate

Insta

llation &

Applic

cation M

eets

Desig

n

& M

anu

factu

rers

Recom

mend

ation

Span

in E

ngin

ee

ring U

nits

Calib

rate

d R

an

ge I

n E

ngin

ee

ring U

nits

Min

i. C

alib

. R

ange

In E

ngin

ee

ring U

nits

Min

i. C

alib

. R

ange

In (

m/A

)

Max. C

alib

. R

ange

In E

ngin

ee

ring U

nits

Max . C

alib

.Ran

ge I

n (

m/A

)

Instr

um

ent

Read

ing A

t 25

% (

m/A

)

Instr

um

ent

Read

ing A

t 50

% (

m/A

)

Instr

iment

RE

adin

g A

t 75

% (

m/A

)

Instr

um

ent

Read

ing A

t 10

0%

(m

/A)

Instr

um

ent

Read

ing A

t 75

% (

m/A

)

Instr

um

ent

Read

ing A

t 50

% (

m/A

)

Instr

um

ent

Read

ing A

t 25

% (

m/A

)

Err

or

( D

iff. I

n E

ngin

ee

ring U

nits)

Err

or

%

Accepte

d (

A)

/ R

eje

cte

d (

R)

Reasons Of Non-Acceptance

1 Instrument

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

Instrument Testing Log-V2 (Addm-6) Mar 2016165 of 183

FIELD INSTALLATION TESTING LOG Date: _____________

Page ____ of ____

DEVICE INSPECTION STATUS CONTROL

CONTROLLER (RPU) INPUTS FIELD CONTROLLER (RPU ) OUTPUTS FIELD

# DEVICE OR EQUIPMENT

IDE

NT

IF

ICA

TIO

N

PR

OD

UCT A

CCEPTAN

CE

INSTALLATIO

N A

CCEPTAN

CE

CALIB

RATIO

N A

CCEPTAN

CE

LO

CAL P

AN

EL S

WIT

CH

ES

LO

CAL/R

EM

OTE C

ON

TRO

L

RU

NN

ING

/ O

PEN

CLO

SED

AN

ALO

G I

NPU

T 1

AN

ALO

G R

AN

GE O

K

AN

ALO

G I

NPU

T 2

AN

ALO

G R

AN

GE O

K

FIE

LD

ALARM

S

OTH

ER

OTH

ER

LO

CAL I

ND

ICATO

RS

REM

OTE I

ND

ICATO

RS

OTH

ER

STAR

T /

OPEN

STO

P

CLO

SE

SETPO

INT 1

SETPO

INT 2

OTH

ER

LO

CAL H

AN

DSW

ITCH

ES

REM

OTE H

AN

DSW

ITCH

ES

OTH

ER

AU

TO

LO

GIC

TE

ST

ED

AC

CE

PT

ED

REASON (S) FOR NON - ACCEPTANCE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Field Installation Testing Log-V2 (Addm-6) Mar 2016166 of 183




Magnetic Flow Meter


SECTION T-13130 MAGNETIC FLOW METER

PART 1 GENERAL

1.1 GENERAL

.1 The design guidelines expressed in this document define minimum requirements for transmitters. Supplementary requirements may be required by specific applications.

.2 Refer to Section T-13105 – General Instrumentation Standard for additional general requirements.

PART 2 PRODUCT SPECIFICATION

2.1 GENERAL

.1 Signal and excitation cables : For all remote mounted sensor transmitter pairs, provide manufacturer’s signal and excitation cables direct from sensor to transmitter without joints, splices or junction boxes via flexible weatherproof conduit.

.2 Grounding Rings: Supply one set of grounding rings when the flow meter is installed in line with non-conductive or lined pipes up or downstream of the flow meter as indicated in 2.3 - Datasheet.

.3 Magnetic Flowmeters shall be manufactured with a certified corrosion protection coating that complies with ISO 12944 - Corrosion Protection Classification Guidelines. The selected paint system coating shall be suitable for the type of environment in which the flowmeter is being installed.

.4 Magnetic flowmeter shall have a self-monitoring function to check the measuring device functionality. The verification shall check whether the measuring device components comply with the factory specifications. Both, sensor and electronic modules must be included in the test. Verification shall be performed on demand and shall comply with ISO 9001 (measuring points relevant to quality).

.5 All Magnetic flowmeters (New and existing) shall undergo a verification test performed with the self-monitoring function to check the measuring device functionality. Test shall confirm original factory calibration is still valid and proper condition of the components.

2.2 MAGNETIC FLOW METER

B. Performance

1. Flow Range: As per 2.3 Data Sheet

2. Accuracy: ± 0.2% of the range.

167 of 183




Magnetic Flow Meter


4. Response Time <1 second for 2 meter/second step change to stated accuracy

5. Measure Repeatability 0.2% of range

C. Flow Sensor:

1. Type: Electromagnetic.

2. Process Line Size: As noted in contract documents, See 2.3 Data Sheet Process Line flanges class to fit with flowmeter body flanges class.

3. Body Material: Carbon Steel flow tube with Corrosion protection coating.

4. Grounding: Yes, External via a ground ring/connection. Follow the manufacturer instruction.

5. Electrode. Cleaning: No

6. Empty Pipe Detection: Yes

7. Additional Features: 1. Continuous on-line Self-diagnostics

2. Built in web-browser for easy configuration

3. Integrated data logger for the measured value monitoring.

D. Transmitter

1. Enclosure: Remote Mounted.

2. Power Supply: 120VAC, 60Hz

3. Sensor Cable: see Data Sheet 2.03 , Contractor to check on site

4. Analog Output: 4-20mA (with HART) DC isolated into 600 ohms

5. Relay Output One SPDT , 5A rated at 120VAC (instrument fault)

6. Indication: Local LCD, Eng units, 3-1/2 digits, (½” minimum height)

7. Display: LCD indication of both current flow & totalized flow

E. Electrical

1. Approval: CSA

F. Acceptable Manufacturers

1. Endress & Hauser

2. Krohne

3. ABB

4. Rosemount

5. Siemens

168 of 183




Magnetic Flow Meter


2.3 DATASHEET

Metering Chamber

CHAMBER# 1

BAYVIEW PS

CHAMBER# 2

WOODBINE / STEELES

CHAMBER# 3

KEELE / STEELES

Tag name:

WTR-BVP-FIT-0101 WTR-269-FIT-0401 WTR-317-FIT-0401

P&ID Dwg: PBV-2016-3 140M-2016-4 229M-2016-3 Installation Detail DWG: 308M-2016-45 308M-2016-45 308M-2016-45 Service: N/A Water Distribution Water Distribution Fluid: N/A Water Water Process Temp min/max: N/A 5C to 40C 5C to 40C Ambient Temp min/max: N/A Minus 40C to 60C Minus 40C to 60C (Forward) Calibration Range: To be provided to successful

proponent To be provided to successful proponent

To be provided to successful proponent

(Reverse) Calibration Range: To be provided to successful proponent



Low Flow Cuttoff: N/A 0.04 m/s 0.04 m/s Bi-directional: N/A YES YES Sensor Head N/A Direct Buried IP68, Type 6P,

Fully potted: Corrosion Protection EN ISO 12944 Im2/Im3

Direct Buried IP68, Type 6P, Fully potted: Corrosion Protection EN ISO 12944 Im2/Im3

Sensor-Transmitter Cables: N/A 40 m (to fit the application) 45 m (to fit the application) Process Pipe: 1050 mm 450 mm 600 mm End Connections: N/A ANSI/ASME Class 150 -

Carbon Steel Flange with corrosion protection

ANSI/ASME Class 150 - Carbon Steel Flange with corrosion protection

Spool Piece Required: N/A NO NO Liner Material: N/A hard rubber hard rubber Electrode Material: N/A Alloy C22 or Hastalloy C-276,

Bullet Nose Alloy C22 or Hastalloy C-276, Bullet Nose

Approval: N/A CSA , NSF61, OIML R49 class 2

CSA , NSF61, OIML R49 class 2

Class/Div/Group: Unclassified Unclassified Flow Tube Required: NO YES YES Transmitter Required: NO YES YES

Metering Chamber

CHAMBER# 4

WILLOWDALE/HIGHLAND

CHAMBER# 5

YONGE / ELGIN

CHAMBER# 6

(MILLIKEN PS)

Tag name: WTR-359-FIT-0401 WTR-282-FIT-0201 WTR-PMI-FIT-0001

P&ID Dwg: 264M-2016-4 173M-2016-4 30P-2016-5 Installation Detail DWG: 308M-2016-45 308M-2016-45 308M-2016-45 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C (Forward) Calibration Range: To be provided to successful






Low Flow Cuttoff: 0.04 m/s 0.04 m/s 0.04 m/s Bi-directional: YES YES NO Sensor Head Direct Buried IP68, Type 6P,



N/A

169 of 183




Magnetic Flow Meter


Sensor-Transmitter Cable 20 m (to fit the application) 20 m (to fit the application) 45 m (to fit the application) Process Pipe: 450 mm 600 mm 600 mm End Connections: ANSI/ASME Class 150 -

Carbon Steel Flange with corrosion protection


ANSI/ASME Class 150 - Stainless Steel Flange.

Spool Piece Required: NO NO N/A Liner Material: hard rubber hard rubber N/A Electrode Material: Alloy C22 or Hastalloy C-276,

Bullet Nose Alloy C22 or Hastalloy C-276, Bullet Nose

N/A

Approval: CSA , NSF61, OIML R49 class 2



Class/Div/Group: Unclassified Unclassified Unclassified Flow Tube Required: YES YES NO Transmitter Required: YES YES YES Metering Chamber

CHAMBER# 7

DUFFERIN / STEELES

CHAMBER# 8

BATHURST / STEELES

CHAMBER# 9

(MILLIKEN PS)

Tag name: WTR-365-FIT-0601 WTR-250-FIT-3B01 WTR-PMI-FIT-0002

P&ID Dwg: 271M-2016-4 143M-2016-5 30P-2016-5 Installation Detail DWG: 308M-2016-45 308M-2016-45 308M-2016-45 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C (Forward) Calibration Range: To be provided to successful






Low Flow Cuttoff: 0.04 m/s 0.04 m/s 0.04 m/s Bi-directional: YES YES NO Sensor Head Direct Buried IP68, Type 6P,



N/A

Sensor-Transmitter Cable 30 m (to fit the application) 30 m (to fit the application) 45 m (to fit application) Process Pipe: 900 mm 600 mm 900 mm End Connections: AWWA C207 Class E - Carbon

Steel Flange with corrosion protection.


ANSI/ASME Class 150 - Stainless Steel Flange.

Spool Piece Required: NO NO N/A Liner Material: hard rubber hard rubber N/A Electrode Material: Alloy C22 or Hastelloy C-276,

Bullet Nose Alloy C22 or Hastelloy C-276, Bullet Nose

N/A




Class/Div/Group: Unclassified Unclassified Unclassified Flow Tube Required: YES YES NO Transmitter Required: YES YES YES Metering Chamber

CHAMBER# 10

THORNHILL PS

CHAMBER# 11

KEELE / STEELS

CHAMBER# 12

(MILLIKEN PS)

Tag name:

WTR-PTH-FIT-0101 WTR-194-FIT-0701 WTR-PMI-FIT-0004

P&ID Dwg: 28P-2016-3 84M-2016-3 30P-2016-5 Installation Detail DWG: 308M-2016-45 308M-2016-45 308M-2016-45 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C

170 of 183




Magnetic Flow Meter


Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C (Forward) Calibration Range: To be provided to successful






Low Flow Cuttoff: 0.04 m/s 0.04 m/s 0.04 m/s Bi-directional: YES YES YES Sensor Head N/A Direct Buried IP68, Type 6P,


N/A

Sensor-Transmitter Signal Cable

30 m (to fit the application) 35 m (to fit the application) 15 m (to fit application)

Process Pipe: 900mm 400 mm 900 mm End Connections: ANSI/ASME Class 150 -

Stainless Steel Flange. ANSI/ASME Class 150 - Carbon Steel Flange with corrosion protection

N/A

Spool Piece Required: N/A NO N/A Liner Material: N/A hard rubber N/A Electrode Material: N/A Alloy C22 or Hastelloy C-276,

Bullet Nose N/A




Class/Div/Group: Unclassified Unclassified Unclassified Flow Tube Required: NO YES NO Transmitter Required: YES YES YES Metering Chamber

Chamber #13

MILLIKEN PS

CHAMBER# 14

McCOWAN / STEELES

CHAMBER# 15

ISLINGTON / STEELES

Tag name:

WTR-PMI-FIT-0005 WTR-316-FIT-0601 WTR-300-FIT-1101

P&ID Dwg: 30P-2016-5 224M-2016-4 210M-2016-4 Installation Detail DWG: 308M-2016-45 308M-2016-45 308M-2016-45 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C (Forward) Calibration Range: To be provided to successful






Low Flow Cuttoff: 0.04 m/s 0.04 m/s 0.04 m/s Bi-directional: YES YES YES Sensor Head N/A N/A N/A Sensor-Transmitter Cable 15 m (to fit application) 35 m (to fit the application) 20 m (to fit the application) Process Pipe: 1200 mm 600 mm 400 mm End Connections: N/A N/A N/A Spool Piece Required: N/A N/A N/A Liner Material: N/A N/A N/A Electrode Material: N/A N/A N/A Approval: CSA , NSF61, OIML R49 class

2 CSA , NSF61, OIML R49 class 2


Class/Div/Group: Unclassified Unclassified Unclassified Flow Tube Required: NO NO NO Transmitter Required: YES YES YES

171 of 183




Magnetic Flow Meter


Metering Chamber

CHAMBER# 16

ADESSO DR. / STEELES

Tag name:

WTR-307-FIT-1601

P&ID Dwg: 200M-2016-4 Installation Detail DWG: 308M-2016-45 Service: Water Distribution Fluid: Water Process Temp min/max: 5C to 40C Ambient Temp min/max: Minus 40C to 60C (Forward) Calibration Range: To be provided to successful

proponent (Reverse) Calibration Range: To be provided to successful

proponent Low Flow Cuttoff: 0.04 m/s Bi-directional: YES Sensor Head N/A Sensor-Transmitter Signal Cable

40 m (to fit application)

Process Pipe: 600 mm End Connections: N/A Spool Piece Required: N/A Liner Material: N/A Electrode Material: N/A Approval: CSA , NSF61, OIML R49 class

2 Class/Div/Group: Unclassified Flow Tube Required: NO Transmitter Required: YES

PART 3 EXECUTION

3.1 GENERAL

.1 See Section 13105 General Instrumentation Standard for general execution requirements.

3.2 INSTALLATION

.1 All metering chamber installations shall be potted with dielectric gel to plug of conduit port openings and appropriately rated conduit and conduit glands.

.2 The instrument shall be installed in accordance with the manufacturer’s drawings and instructions.

.3 The instrument shall be located approximate locations shown on the contract drawings.

.4 Install a by-pass line and three shutoff valves for critical process units so the meter can be removed without process line shutdown. Provide flushing and draining connections.

172 of 183




Magnetic Flow Meter


.5 The scope of contract work is to replace the existing flowmeters with new electromagnetic flowmeters. Provide spool pieces, where required, as per contract drawings and Data Sheet 2.3

.6 The instrument shall be grounded by using the grounding conductor when powered from the electrical service and by the surge suppression device when loop powered. The casing of the instrument shall be grounded/bonded as per Code and the requirements of the manufacturer.

.7 All electrical connections shall be by way of liquid tight outdoor flexible conduits. All entry terminations shall be sealed with non- perishing washers.

.8 Install the transmitter remotely from the primary element where the primary element is in a location where a submergence hazard exists, or on a vertical pipe, or on a pipe with high vibration or where the pipe is150mm (6 inches) or more in diameter.

.9 Ground the meter in accordance with manufacturer’s instructions.

.10 Install meters with at least five pipe diameter straight line upstream and two pipe diameter straight line downstream.

.11 Install separate conduits for signal and power wiring to the meter and between the transmitter and control panel.

.12 The local display shall be easily viewable.

.13 For application where only the flow transmitter is required (to replace the existing transmitter, keeping the flow sensor), contractor to check the compatibility of the existing flow sensor with the new transmitter being to be ordered. Consult the manufacturer before ordering.

END OF SECTION

173 of 183




Pressure Transmitter

SECTION 13160 – PAGE 1 OF 4 (Addm-6)

SECTION T-13160 - PRESSURE TRANSMITTER

PART 1 GENERAL

1.1 GENERAL

.1 See Section T-13105 General Instrumentation Standard for general requirements.


2.1 PRESSURE TRANSMITTER, ELECTRONIC

A. Performance 1. Pressure Range: Noted range shall be between 40% and 80% of the

maximum adjustable range. 2. Accuracy: ±0.1% of span

B. Sensor 1. Type: Variable capacitance or strain gauge diaphragm 2. Wetted parts including

process flanges and drain/vent valves:

316 stainless steel, unless otherwise noted

3. Wetted O-Rings: Glass Filled TFE, Graphite Filled PTFE or Viton, unless otherwise noted

4. Fill Fluid: Silicone, unless otherwise noted 5. Manifold: 316 SS, 2 Valve Block and Bleed

C. Transmitter

1. Output: 4-20mA DC isolated into 600 ohms 2. Power Supply 24VDC loop powered 3. Indicator: Four-digit LCD indicating the noted range in engineering

units (1/2” minimum height) 4. Enclosure: NEMA 4X, unless otherwise noted. 5. Mounting: 50mm (2”) Pipestand 6. Fittings: SS brackets with SS bolts 7. Housing: Modular with separate compartments for electronics and

field connections 8. Housing material: Epoxy coated aluminum, unless otherwise noted 9. Communication

Protocol HART

D. Accepted Manufacturers Endress & Hauser ABB Emerson (Rosemount) Reotemp Instrument Siemens (Moore) Yokogawa Kobold Schneider Electric (Foxboro)

174 of 183






2.2 REMOTE DISPLAY

.1 For all instruments supply in this section provide a separate LCD display that shows the current value in engineering unit and diagnostics for the instrument.

Acceptable Manufacturer:

1. Precision Digital or approved equal

2.3 DATASHEET

Metering Chamber CHAMBER# 2

WOODBINE / STEELCASE

CHAMBER# 3

KEELE / STEELES

CHAMBER# 4

WILLOWDALE/HIGHLAND

Tag name: WTR-269-PIT-0401 WTR-317-PIT-0401 WTR-359-PIT-0401

P&ID dwg: 140M-2016-4 229M-2016-3 264M-2016-4 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 30C to 85C Minus 30C to 85C Minus 30C to 60C Process Press min/max: 0 – 1000 kPa 0 – 1000 kPa 0 – 1000 kPa Calibration Range: To be provided to Successful

proponent To be provided to Successful proponent

To be provided to Successful proponent

Sensor material: Stainless Steel Stainless Steel Stainless Steel Transmitter version: Compact NEMA 4X Compact NEMA 4X Compact NEMA 4X Process Connections: ½” NTP Stainless Steel ½” NTP Stainless Steel ½” NTP Stainless Steel Installation detail dwg: 308M-2016-46 308M-2016-46 308M-2016-46 Approval: CSA , NSF61 CSA, NSF61 CSA , NSF61 Class/Div/Group: Unclassified Unclassified Unclassified Remote Display Required:

YES YES YES


YONGE / ELGIN

CHAMBER# 6 /

(MILLIKEN PS)

CHAMBER# 7

DUFFERIN / STEELES

Tag name: WTR-282-PIT-0201 WTR-PMI-PIT-0002 WTR-365-PIT-0601

P&ID Dwg: 173M-2016-4 30P-2016-5 271M-2016-4 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max:

Minus 30C to 60C Minus 30C to 60C Minus 30C to 60C

Process Press min/max: 0 – 1000 kPa 0 - 1000 kPa 0 – 1000 kPa Calibration Range: To be provided to Successful



Sensor material: Stainless Steel Stainless Steel Stainless Steel Transmitter version: Compact NEMA 4X Compact NEMA 4X Compact NEMA 4X Process Connections: ½” NTP Stainless Steel See Note 1. ½” NTP Stainless Steel Installation detail: 308M-2016-46 308M-2016-46 308M-2016-46 Approval: CSA , NSF61 CSA, NSF61 CSA , NSF61 Class/Div/Group: Unclassified Unclassified Unclassified Remote Display Required:

YES NO YES

175 of 183






Metering Chamber

CHAMBER# 8

BATHURST / STEELES

CHAMBER# 9 /

(MILLIKEN PS)

CHAMBER# 10 and

THORNHILL PS

Tag name: WTR-250-PIT-3B01 WTR-PMI-PIT-0003 WTR-PTH-PIT-0101

P&ID Dwg: 143M-2016-5 30P-2016-5 28P-2016-3 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 30C to 60C Minus 30C to 60C Minus 30C to 60C Process Press min/max: 0 - 1000 kPa 0 - 1000 kPa 0 - 1000 kPa Calibration Range: To be provided to Successful



Sensor material: Stainless Steel Stainless Steel Stainless Steel Transmitter version: Compact NEMA 4X Compact NEMA 4X Compact NEMA 4X Process Connections: ½” NTP Stainless Steel See Note 1 See Note 1 Installation detail: 308M-2016-46 308M-2016-46 308M-2016-46 Approval: CSA , NSF61 CSA, NSF61 CSA, NSF61 Class/Div/Group: Unclassified Unclassified Unclassified Remote Display Required:

YES NO NO

Metering Chamber

CHAMBER# 11

KEELE / STEELES

CHAMBER# 14

McCOWAN / STEELES

CHAMBER# 15

ISLINGTON / STEELES

Tag name: WTR-194-PIT-0401 WTR-316-PIT-0601 WTR-300-PIT-1101

P&ID: 84M-2016-3 224M-2016-4 210M-2016-4 Service: Water Distribution Water Distribution Water Distribution Fluid Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 30C to 60C Minus 30C to 60C Minus 30C to 60C Process Press min/max: 0 – 1000 kPa 0 – 1000 kPa 0 – 1000 kPa Calibration Range: To be provided to Successful



Sensor material: Stainless Steel Stainless Steel Stainless Steel Transmitter version: Compact NEMA 4X Compact NEMA 4X Compact NEMA 4X Process Connections: ½” NTP Stainless Steel ½” NTP Stainless Steel ½” NTP Stainless Steel Installation detail: 308M-2016-46 308M-2016-46 308M-2016-46 Approval: CSA , NSF61 CSA, NSF61 CSA, NSF61 Class/Div/Group: Unclassified Unclassified Unclassified Remote Display Required:

YES YES YES

Metering Chamber

CHAMBER# 16

ADESSO DR. / STEELES

Tag name: WTR-307-PIT-1601

P&ID Dwg: 200M-2016-4 Service: Water Distribution Fluid: Water Process Temp min/max: 5C to 40C Ambient Temp min/max: Minus 30C to 60C Process Press min/max: 0 – 1000 kPa Calibration Range: To be provided to Successful

proponent Sensor material: Stainless Steel Transmitter version: Compact NEMA 4X Process Connections: ½” NTP Stainless Steel Installation detail: 308M-2016-46 Approval: CSA , NSF61 Class/Div/Group: Unclassified

176 of 183






Remote Display Required:

YES

Note 1.- Contractor shall price for ¾”. Exact process connection to be confirmed by contractor onsite.

PART 3 EXECUTION

3.1 GENERAL

.1 See Section T-13105 General Instrumentation Standard for general execution requirements.

3.2 INSTALLATION

.1 The instrument shall be installed in accordance with the manufacturer’s drawings and

instructions.

.2 The instrument shall be located in the locations shown on the contract drawings.

.3 Install separate conduits for signal and power wiring

.4 The instrument shall be grounded by using the grounding conductor when powered from the electrical service and by the surge suppression device when loop powered. The casing of the instrument shall be grounded/bonded to Code and the requirements of the manufacturer.

.5 All electrical connections shall be by way of liquid tight outdoor flexible conduits. All entry terminations shall be sealed with non- perishing washers.


3.3 COMMISSIONING

.1 Tag the instrument using stainless steel stamped labels and wire in accordance with the drawings or the requirements of the owner.

.2 Span and zero instruments to the requirements of the specifications.

END OF SECTION

177 of 183




Pressure Gauge


SECTION T-13169 – PRESSURE GAUGE

PART 1 GENERAL

1.1 GENERAL

.1 See Section T-13105 General Instrumentation Standard for general requirements.


2.1 PRESSURE INDICATOR

A. Performance 1. Accuracy: ±0.5%of span

B. Gauge 1. Type: Bourdon tube, ANSI Grade 2A 2. Wetted parts including 316 Stainless Steel (316 SS) 3. Gear Mechanism: 316 Stainless Steel (316 SS) 4. Fill Fluid: Silicone, unless otherwise noted 5. Manifold: 316 SS, 3 Valve Block and Bleed 6. Indicator (Dial): 115mm white plastic laminated metal dial with black marking.

Indicator rests approximately in the 50% range, under normal operating condition.

7. Enclosure: NEMA 4X, unless otherwise noted. 8. Case material: Black polypropylene 9. Window: Shatter-proof 10. Housing: Modular with separate compartments for electronics and field

connections 11. Housing material: 12. Calibration: 13. Process connection: 14. 3-Valve Manifold:

Epoxy coated aluminum, unless otherwise noted Slotted calibration screw 13mm (1/2”) Threaded –female NPT, bottom connection 316 SS Block and Bleed

D. Accepted Manufacturers Ashcroft Winters Instruments Kobold Trerice Co. WIKA Instruments Ltd. Reotemp Instrument

E. Approval: CSA, NSF 61

2.2 DIAPHRAM SEAL

1. Material: SS, Teflon coated 2. Fill Fluid: DC 200 3. Additional: Provide flushing connection in bottom housing

178 of 183




Pressure Gauge


2.3 DATASHEET


WOODBINE / STEELCASE

CHAMBER# 3

KEELE / STEELES

CHAMBER# 4

WILLOWDALE/HIGHLAND

Tag name: WTR-269-PI-0401 WTR-317-PI-0401 WTR-359-PI-0401

P&ID dwg: 140M-2016-4 229M-2016-3 264M-2016-4 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 85C Minus 40C to 85C Minus 40C to 60C Process Press min/max: 0 – 1000 kPa 0 – 1000 kPa 0 – 1000 kPa Diaphragm Seal NO NO NO Installation detail Dwg: 308M-2016-46 308M-2016-46 308M-2016-46 Class/Div/Group: Unclassified Unclassified Unclassified


YONGE / ELGIN

CHAMBER# 7

DUFFERIN / STEELES

CHAMBER# 8

BATHURST / STEELES

Tag name: WTR-282-PI-0201 WTR-365-PI-0601 WTR-250-PI-3B01

P&ID Dwg: 173M-2016-4 271M-2016-4 143M-2016-5 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C Process Press min/max: 0 – 1000 kPa 0 – 1000 kPa 0 – 1000 kPa Diaphragm Seal NO NO NO Installation detail Dwg: 308M-2016-46 308M-2016-46 308M-2016-46 Class/Div/Group: Unclassified Unclassified Unclassified

Metering Chamber

CHAMBER# 11

KEELE / STEELES

CHAMBER# 14

McCOWAN / STEELES

CHAMBER# 15

ISLINGTON / STEELES

Tag name: WTR-194-PI-0401 WTR-316-PI-0601 WTR-300-PI-1101

P&ID Dwg: 84M-2016-3 224M-2016-4 210M-2016-4 Service: Water Distribution Water Distribution Water Distribution Fluid: Water Water Water Process Temp min/max: 5C to 40C 5C to 40C 5C to 40C Ambient Temp min/max: Minus 40C to 60C Minus 40C to 60C Minus 40C to 60C Process Press min/max: 0 – 1000 kPa 0 – 1000 kPa 0 – 1000 kPa Diaphragm Seal YES YES YES Installation detail Dwg: 308M-2016-46 308M-2016-46 308M-2016-46 Class/Div/Group: Unclassified Unclassified Unclassified

Metering Chamber

CHAMBER# 16

ADESSO / STEELES

Tag name: WTR-307-PI-1601

P&ID: 200M-2016-4 Service: Water Distribution Fluid Water Process Temp min/max: 5C to 40C Ambient Temp min/max: Minus 40C to 60C Process Press min/max: 0 – 1000 kPa Diaphragm Seal NO Installation detail Dwg: 308M-2016-46 Class/Div/Group: Unclassified

179 of 183




Pressure Gauge


PART 3 EXECUTION

3.1 GENERAL

.1 See Section T-13105 General Instrumentation Standard for general execution requirements.

3.2 INSTALLATION

.1 The instrument shall be installed in accordance with the manufacturer’s

drawings and instructions.

.2 The instrument shall be located in the locations shown on the contract drawings.


3.3 COMMISSIONING

.1 Tag the instrument using stainless steel stamped labels and wire in accordance with the drawings or the requirements of the owner.

.2 Span and zero instruments to the requirements of the specifications.

END OF SECTION

180 of 183




Field Wiring


SECTION T-13305 – FIELD WIRING

PART 1 GENERAL

1.1 FIELD WIRING

.1 Field Wiring is the wiring that connects the field equipment (instruments, control stations, control panels, MCC) to the Main Process Control Unit. Use only CSA approved and labelled cables and conductors.

.2 Provide field cables as per Division 16 - Electrical.

.3 All network wiring needs to follow T-13510 specifications

.4 All field wiring entering the Toronto section of the Electrical enclosure shall follow T-13305 – Field Wiring Specifications unless noted otherwise.

PART 2 PRODUCTS

2.1 ANALOG SIGNALS

.1 Definition: Analog signals are 4-20 mA inputs received from field instruments.

.2 Single Pair Cable: For individual instrument circuits use single-pair, two inch lay, twisted, foil 100% shielded with drain wire, #16 AWG, 19 strand copper conductors CSA labelled tray cable at 600 volts.

.3 Multi-Pair Cables: For multiple instrument circuits, use multi-pair cables made up of individual single pair, two inch lay, twisted, foil 100% shielded with suitable drain wire, #16 AWG, 19 strand copper conductors CSA labelled tray cable at 600 volts.

.4 Shields: Signal shields should have one ground point located at the power source unless otherwise recommended by the instrument/equipment manufacturer. Shields should be continuous through cabinets, panels and junction boxes.

2.2 DC DIGITAL SIGNALS

.1 DC digital signals are at 24VDC originating from contact inputs.

.2 Single Pair Cable: For individual contact closure circuits use single pair, two inch lay, twisted #16 AWG, 19 strand copper conductors CSA labelled tray cable at 600V with RW90 insulation with PVC jacket.

.3 Multi-pair Cable: For multiple contact closure circuits use multi-pair cables made up of individual single pair two inch lay, twisted, #16 AWG, 19 strand copper conductors CSA labelled tray cable at 600V with RW90 insulation with PVC jacket.

181 of 183




Field Wiring


2.3 AC DIGITAL SIGNALS

.1 AC digital signals are 120VAC and less than 15 amperes, and received from contact outputs used for controlling 120V devices such as motor starters, push-buttons, pilot lights, and the like.

.2 Single Conductor: For single circuit use single conductor #14 AWG, 19 strand copper conductor at 600V with RW90 insulation with PVC jacket.

.3 Multi-Conductor: For multiple circuits use multiple conductor #14 AWG, 19 strand copper conductor at 600V with RW90 insulation with PVC jacket.

2.4 FIBER OPTIC CABLE

.1 Refer to Drawing 30P-2016-17 for fibre optic cable details.

PART 3 INSTALLATION

3.1 GENERAL

.1 Avoid running cables inside or under power cable trays. Where field wiring is in power cable trays, insulation must be equal to or greater than the highest voltage in the cable tray.

.2 Where power or signal cables must cross, make them cross at an angle of 90 degrees.

.3 Communication cables will not be mixed with power or signal cables.

.4 All fibre optic cables shall be installed by an installer certified with Corning Fiber Installation (CFI) and Corning Fibre Testing & troubleshooting (CFTT).

.5 All fibre optic components shall be installed as per Corning’s instructions sheets, TIA standards and the BICSI Installation Methods Manual.

.6 All testing of the fiber optic installation shall be performed with test equipment from JDSU NGC-4500 or Fluke DTX-1800 Cable Analyser.

.7 Optical Loss Test Sets (OLTS) test shall be performed to all installed fibre optic cables. Test results reports shall be submitted to the engineer and the city for review. The report shall include the flowing information for each fibre optic cabling element tested:

.1 Actual measured attenuation, max allowable attenuation and the attenuation margin at the specified wavelengths. Individual test that fails the link criteria shall be marked as fail.

.2 Reference method.

.3 Number of Mated connectors

182 of 183




Field Wiring


.4 Actual length and max allowable length. Individual test that fails the link criteria shall be marked as fail.

.5 Group refracting index (GRI) for the type of fibre tested, if length was typically measured.

.6 Tester manufacturer, model, serial number and software version.

.7 Circuit ID number (cable Tag ID) and facility name

.8 Link criteria used

.9 Overall pass/fail indication

.10 Date and time of test.

3.2 SIGNAL SEPARATION

.1 Analog and 24VDC Discrete Signals: Analog 4-20mA signals and 24VDC discrete signals should normally be in separate conduits. An exception to this standard may be made in cases where it would cause parallel conduit runs to the same device and combining signals would eliminate one conduit. In cases where the exception is used, both the analog and discrete signals should be twisted shielded pairs as described for analog signals previously. This exception will be limited to 3 meters only.

.2 AC Digital and Control: AC digital signals and AC control wiring may occupy the same conduit but all instrument power circuits should be isolated by a separate conduit from all AC digital and control circuits.

.3 All conduits for signal cables shall be rigid metallic conduit unless indicated otherwise with the last meter flexible connecting to the field instrument with condensation loop.

3.3 MISCELLANEOUS

.1 Thermocouple Extension Wire: Thermocouple extension circuits should be solid conductors and same gauge as the T/C of the same material as the associated thermocouple. Thermocouple signal lines should be continuous from the thermocouple connection head to the final termination point.

.2 Spare Conductors: Spare conductors in each conduit should be equal to 15% of the number required for both present and (defined) future conditions, but in no case less than two spare wires or one pair, should be installed. Each cable should have 10% spare conductors but not less than two conductors. Spare conductors should be terminated on a marked terminal strip or connector pin at each end.

.3 Termination: Wire at both ends of the cable should be terminated with pre-insulated solderless spade or ring lugs for maximum physical strength and electrical conduction. Wires should not be terminated on adjacent terminal points if accidental short-circuiting could cause tripping or closing of a breaker.

183 of 183