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City of PortlandBureau of Environmental Services

Wastewater GroupControl system philosophy, operation, design, and software standards

PREFACE

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

Consultants, contractors, BES Engineering, maintenance and operations shouldconsult this document for any proposed control system changes.

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

Uniform operator interfaces at wastewater facilities

Standard control system software routines for software maintenance

Standard control system hardware devices for operator interface,troubleshooting, and maintenance

Consistent design approaches on future WG projects

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

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

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

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

1 Revised 2003

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Volume 1

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

Chapter 2 describes the design approaches that are to be used on WG projects. Thedeliverables during and at the end of each design phase, preliminary design, and finaldesign are defined. Design criteria are specified for wiring design, interface with MCCsand package systems, control panel design, and so on.

Appendix A example of an Instrumentation & Control Process NarrativeAppendix B example of an Instrumentation Data SheetAppendix C Training GuidelinesAppendix D Deliverable MatrixAppendix E Revision Proposal Submittal FormDrawing Figures Drawings referenced throughout this Manual.

Volume 2

Section 16010 covers general electrical standards that are applicable for allelectrical and instrument design, construction and installation for the City ofPortland, Bureau of Environmental Services, Wastewater Group, including theColumbia Blvd. Wastewater Treatment Plant, Tryon Creek Wastewater TreatmentPlant and the Wastewater Pump Stations maintained by the Group.Section 16050 covers Basic Electrical Materials and MethodsSection 16150 refers to MotorsSection 16400 refers to Service and DistributionSection 16480 refers to Motor ControlSection 16500 refers to LightingSection 16660 refers to Power GenerationSection 16700 refers to CommunicationsSection 16910 refers to ControlsSection 17100 refers to Instrumentation

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

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

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

Volume 6 contains PLC Programming Guide

Volume 7 contains the Facilities Guide (Future)

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

2003 Volume 1 Page iii of 14

Volume 9 contains the Maintenance standards (Future)

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

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

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TABLE OF CONTENTS

Volume 1 Acronyms and Definitions .1 Chapter 1 CONTROL SYSTEM PHILOSOPHY...........2

1.1 Introduction..............................................................................................21.2 Levels of Control .............................................................................................2

Table 1-1 Levels of Control Primary Functions..31.2.1 Equipment Control Level...........................................................41.2.2 Local Control Level.. .....................................................................41.2.3 Programmable Logic Control (PLC)..................................41.2.4 System Process Control .........................................................41.2.5 Plant Control Level ....................................................................5

1.3 Operating Philosophy...................................................................................51.3.1 System Process Control Failure .............................................61.3.2 Programmable Logic Control (PLC) Failure .....................61.3.3 Local Control Panels..................................................6

1.3.3.1 Loop Control...................................................................61.3.3.2 Sequence Control........................................................7

Chapter 2 CONTROL SYSTEM DESIGN GUIDELINES ........82.1 Design Phase.........................................................8

2.1.1 Introduction....................................................................... ........82.1.2 Documentation................................................... ........... ........8

2.1.2.1 Process and Instrumentation Diagrams (P&IDs)..........92.1.2.2 Digital System Block Diagram.. ........... ........... ........92.1.2.3 Process Narratives..................................... ........... ........92.1.2.4 Electrical Drawings....................... ........... ......102.1.2.5 Control Panel Design ........................ ........... ......102.1.2.6 Installation Details ........................ ........... ......112.1.2.7 Interconnection Diagrams and Listings....122.1.2.8 Digital System Block Diagrams............ ........... ......122.1.2.9 Functional Descriptions.. ...................... ........... ......122.1.2.10 Instrument Data Sheets.... ..................... .122.1.2.11 I/O Data Base ................................................ ........... ......122.1.2.12 Instrument Lists..................................... ........... ......122.1.2.13 Conduit and Cable Schedules ........... ........... ......132.1.2.14 Equipment / Loop Numbers and MCC Space........... ......132.1.2.15 Elect. System Load Calc. & Coordination Study.132.1.2.16 Specifications................................................ ........... ......14

TABLES2-1 External Alarm Lighting Standards2-2 Acceptable Manufacturers2-3 ISA Identification Letters2-4 Typical Interconnection Listing2-5 Conduit and Cable Schedule

APPENDIX AInstrumentation & Control Process Narrative

APPENDIX BExample of Instrumentation Data Sheet

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APPENDIX CTraining Guidelines

APPENDIX DDeliverable Matrix

APPENDIX ERevision Proposal submittal form

AutoCAD Figures1-1 Schematic--Levels of Control1-2 Schematic--Levels of Control2-1 P&ID Legend2-2 P&ID Process Symbols2-3 P&ID example (Level Instrumentation & Pump Control)2-4 PLC System Block Diagram2-5 I/O Point List2-6 Wire Number & Device Number2-7 Typical Power Source

2-7A Power Source2-8 Typical Power Source Wiring Diagram2-9 Cables, Instr.and Control (Typical Interconnecting Wiring Diagram)2-10 Control Panel Enclosure Layout2-11 Control Panel Power Distribution2-12 Conduit Numbering System2-13 See Table 2-42-14 Detailed Discrete Outputs Wiring Schematic2-15 Detailed Discrete Inputs Wiring Schematic2-16 See Table 2-52-17A Pump Station Motor Current Loop 99972-17B Removed2-17C Pretend Dry Pit Exhaust Fan Flow Loop 99962-17D Pretend Level Loop 99992-17E Pretend Flow Loop 99982-18 Pressure Gauge Mounting Detail2-19 Typical FVC & VFD Motor Control Electrical Schematic2-20 24VDC Power Distribution Wiring Schematic2-21 Instrument Field Device Installation

Volume 2

Section 16010 General Electrical Standards ....1 17Example: Equipment Tag(s)..........18 - 20

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

Section 16150 Motors1 6Example: Motor Specification data sheet .7

Section 16400 Service and Distribution ....1 5

Section 16480 Motor Control ...1 14

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Section 16500 Lighting...1 5

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

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

Section 16910 Electrical Systems Control...1 12

Section 17100 Instrumentation.1 17

Volume 3 SCADA (iFIX) Software and Design Standards

1.0 Scope21.1 The Automation Planning Team...21.2 iFIX Philosophy...2

2.0 General iFIX Information.32.1 General Standards.32.2 The Operational Area Designation...3

3.0 Database Builder...33.10 Tag Names..33.11 Description.43.12 Scan Time...43.13 Database Types Used..43.14 Alarming.43.15 Security Areas.43.16 Labels..43.17 Invert Output...5

4.0 Tag Group Editor..55.0 Picture Conventions..5

5.1 Resolution.55.2 Buttons..55.3 Color Usage..55.4 Required on Every Picture65.5 Text Fonts.65.6 Graphic Images In Pictures...65.7 Alarm Summaries.65.8 Help Screens.7

Volume 4 Drawings and drawing number standards (Future)

Volume 5 O&M Manual development guide (Future)

Volume 6 PLC Programming Guide

1.0 Scope.....12.0 General Information..13.0 PLC Acceptance2

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4.0 Program Changes..25.0 Security.36.0 Programming Guidelines for Symate Plus4

6.1 Subroutines...46.2 Labels5

7.0 Programming Guidelines for Concept..67.1 Introduction.......67.2 Details...67.3 Configuration77.4 Program and Sections.107.5 Systems Sections127.6 Process Sections.....147.7 Miscellaneous.167.8 Variable Naming Usage and Naming Convention.167.9 PLC Programming Considerations for Use with iFIX...17

7.9.1 Labels Used in PLC Programming........178.0 DFB Examples...19

Volume 7 Facilities guide (Future)

Volume 8 Wastewater pump station design manual (Future)

Volume 9 Mechanical Standards (Future)

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ACRONYMS / DEFINITIONS

APT Automation Planning TeamCOMA Computerized Maintenance SystemCMU1 Concrete Masonary UnitDRAWINGS AutoCad files and hard copy(s)HOA Hand-off-autoHOR Hand-off-remoteI / O Input / OutputIFIX2 Supervisory control system softwareISA Instrument Society of AmericaLCP Local control panelMCC Motor control centerNEC National Electric CodeNEMA National Electrical Manufacturers AssociationOCA Open-close-autoP & ID Piping and instrumentation diagramPC Personal computerPID Proportional-integral-derivativePLC Programmable Logic ControllerPMC Plant Monitoring and ControlRTU Remote terminal unitSCADA3 Supervisory Control and Data AcquisitionSCADA NODE Operator interface that directly acquires field data

(PLC)SPC System process controlSS Start- stopTJB Terminal junction boxUL Underwriters LaboratoryUPS Un-interruptible power supplyVAC Volts ACVDC Volts DCVFD Variable frequency driveVIEW NODE Operator interface that acquires field data through

SCADA nodesWG Wastewater Group

1 Revised 20032 Revised 20033 Revised 2003

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CHAPTER 1

CONTROL SYSTEM PHILOSOPHY

1.1 INTRODUCTION

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

A primary function of this chapter is to establish basic definitions of some of the terms. Forexample: Section 1.2 of this chapter defines different levels of control and theircorresponding functions. A level refers to a function from an Operation and/or Maintenancestandpoint. Five levels of items are defined based on whether the function of the device is formaintenance, manual, automatic, or supervisory control of several unit processes.

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

The control system at Wastewater Group (WG) facilities is distributed. Modicon2programmable logic controllers (PLCs) serve as the distributed processors and an IFIXsupervisory system serves as the Operator Interface. Control panels are provided for manualbackup purposes. At Columbia Boulevard and Tryon treatment plants, Modicon PLC's shallbe used to allow networking with their Ethernet ports. Stand-alone PLC's may be Modicon, PLC's without Ethernet ports.

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

Intellution IFIX is used for process control SQDs Powermonitor SMS 3000 software Milltronics DolphinPlus, Rev. 1.33 or higher Vibration Monitoring - Vibrameter (SKF) software HVAC Security, LifeSafety Lonworks software or compatible

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

1.2 LEVELS OF CONTROLAs a general operations philosophy, all plants will have five different functional levels ofcontrol (shown schematically in Figures 1-1 and 1-2): Equipment control Local control Programmable Logic Controller (PLC) control System Process control Plant Monitoring/Control 2 Revised 20033 Added 2003 (Also in section 16480, 2.7.6)

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

Table 1-1

Levels of Control Primary Functions

Level ofControl

Primary Function Remarks

PlantMonitoring/Control

The Plant supervisory system will normallyserve as the supervisory Operator Interfacefor the entire plant. However, it mayperform System Process Control (SPC).

IFIX is the standard. System ProcessControl is used to initiate andmonitor control actions. Controllogic is executed in the PLC withinterface to/from IFIX.

SystemProcessControl

Primary Operator Interface provides a IFIXwindow into the process for monitoringand control

IFIX is the standard. System ProcessControls are used to initiate andmonitor control actions. Controllogic is executed in PLC withinterface to/from IFIX.

PLC Automatic Control Provides normal automatic systemcontrol

Local Manual or automatic centralized control ofequipment.

Provides backup in case ofsupervisory system failure and/orPLC failure. Local control panelscontain backup Operator Interfacedevices like hand switches, lights,level control, PID's. etc.

Equipment Maintenance and troubleshooting Not intended for normal operation ofequipment.VFDs, speed pots4 etc.

4 Revised 2003

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1.2.1 EQUIPMENT CONTROL LEVEL

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

Examples of equipment control include: local disconnects, jog switches, start/stop switchesand speed adjustment on variable frequency drives (VFDs). These devices are located nearthe equipment being controlled.

1.2.2 LOCAL CONTROL LEVEL

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

This level of control usually includes local control panels (LCPs). These panels provideOperator Interface devices that allow manual control of a unit process, or automatic controlthrough the PLC. LCPS generally have auto/manual hand switches and/or Local/Remoteswitches. In Remote/Automatic position, control of the process or equipment is transferred tothe supervisory system.

1.2.3 PLC SYSTEM CONTROL

PLCs normally control the system automatic process.

1.2.4 SYSTEM PROCESS CONTROL

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

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

Preliminary Treatment--pumping, screening, grit removal

Primary Treatment--settling, skimming, sludge pumping

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

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

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

Composter--sludge stabilization, carbon storage and recycle

Disinfection--storage, dosage control

Effluent pumping--effluent pumps, outfall control

Water Reuse--pumping screening, disinfection

Maintenance--Electric power distribution, instrument air

Wet Weather Treatment--pumping, screening, grit removal settling, effluentpumping, disinfection

Pump StationsWastewater Group (WG) has 100 + pump stations throughout themetropolitan area.

1.2.5 PLANT CONTROL LEVEL

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

1.3 OPERATING PHILOSOPHY

Local control is activated when SPC and PMC (Plant Monitoring and Control) are notavailable. All control logic will be implemented at the local control level. Under normaloperation, the PLC will be used to implement all control actions. Exceptions to this ruleinclude equipment that requires local manual start/stop and situations that warrant the use ofsingle loop controllers.

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

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

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

1.3.1 SYSTEM PROCESS CONTROL FAILURE

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

1.3.2 PROGRAMMABLE LOGIC CONTROLLER FAILURE

As a backup against PLC failure, LCPS will be provided. These LCPS will haveopen-close-auto (OCA), hand-off-auto (HOA) switches, status lights, and possible PIDcontrollers as needed to allow manual operation of the plant or pump station in the event of aPLC failure.

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

1.3.3 LOCAL CONTROL PANELS

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

1.3.3.1 Loop Control

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

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

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1.3.3.2 Sequence Control

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

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Chapter 2

CONTROL SYSTEM DESIGN GUIDELINES

This chapter provides guidelines for design phases and the deliverables that the WGexpects at the end of each phase. Outline all5 deviations from these standards for approval bythe APT.

2.1 DESIGN PHASE

2.1.1 INTRODUCTION

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

The BES CONTROL SYSTEMS STANDARDS DELIVERABLES MATRIX outlinesthe what and when of deliverables. (Appendix D)

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

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

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

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

2.1.2 DOCUMENTATION

The following narratives are provided to describe document requirements.

5 Revised 2003

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2.1.2.1 PROCESS AND INSTRUMENTATION DIAGRAMS (P&IDS)

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

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

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

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

2.1.2.2 DIGITAL SYSTEM BLOCK DIAGRAM

A preliminary diagram shall be provided that identifies the different PLCS, Lands, Videos,and Audio with their areas of control. This diagram shall also show interconnections betweenthe PLCS and the supervisory system, and shall identify where the SPC workstations arelocated. Figure 2-4 is an example of a digital system block diagram and Figure 2-5 and I/Olisting.

2.1.2.3 PROCESS NARRATIVES

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

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

Set points

Descriptions of individual control schemes, interlocks, and interactions betweendifferent control loops.

Failure response for each control scheme. Failure response at the unit process level or system level.

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Interface with panel-mounted devices

Interface with IFIX

Loops descriptions at 90% design will provide enough detail so that programmers cansuccessfully program the computer system and the IFIX system to meet the plant design andoperations intent.

2.1.2.4 ELECTRICAL DRAWINGS

All drawings, including manufactures equipment drawings, must be provided in electronicform (AutoCAD) in addition to hard copies. All pre-existing drawings affected by the projectmust be revised to reflect changes. (also see volume 4 Drawing Numbering Standards)

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

Wiring diagrams shall include all electrical analog and digital signals.

At a minimum wiring diagrams should have the following features:

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

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

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

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

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

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

2.1.2.5 CONTROL PANEL DESIGNThe control panel design consists of drawings that show power distribution, elevationsincluding exterior, interior and door layouts, shop drawings and schedules, and the internalconfiguration. Each of these is discussed below. Structural design of the panel is generallyleft to the contractor. However all proposed panel dimensions must be verified as standardmanufactured products (dimensions must be realistic, obtainable and provide 15 %for futureexpansion). The contractor is required to provide equipment that fits within the specified

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

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

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

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

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

Manufacturer Drawings. Manufacturer Drawing(s) shall be provided in electronic form(AutoCAD) and their standardized drawings, when printed, shall have non-applicable portionsdeleted or crossed out.

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

2.1.2.6 INSTALLATION DETAILS

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

Flow meter placement in process piping:1. Flow meter elevation.2. Number of diameters upstream and downstream and distance to

next bend or restriction. Installation details that are hidden from view when the process is operating

e.g.: captive air bells. Tank elevations for level measurement including information on the

elevation of bypass levels, bubblers, captive air devices (bells) and levelswitches.

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2.1.2.7 INTERCONNECTION DIAGRAMS AND LISTINGS

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

Figure 2-13 shows a typical interconnection diagram listing.

2.1.2.8 DIGITAL SYSTEM BLOCK DIAGRAMS

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

2.1.2.9 FUNCTIONAL DESCRIPTIONS

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

2.1.2.10 INSTRUMENTATION DATA SHEETS

The final specifications shall instruct the contractor to provide:

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

2.1.2.11 I/O DATA BASE

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

2.1.2.12 INSTRUMENT LISTS

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

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2.1.2.13 CONDUIT AND CABLE SCHEDULES

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

Figure 2-16 shows conduit and cable schedule format.

2.1.2.14 EQUIPMENT NUMBERS, LOOP NUMBERS AND MCC SPACE

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

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

The designer shall:

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

And/Or

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

The Planner(s) shall:a. Review each submittalb. Allocate equipment COMA number(s), assign loop number(s), allocate MCC

space and appropriate information.c. Complete the review process and return the submittal to the designer with

appropriate information.

2.1.2.15 ELECTRICAL SYSTEM LOAD CALCULATIONS AND COORDINATIONSTUDY

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

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2.1.2.16 SPECIFICATIONS

Final specifications shall include the following as a minimum:

Coordination / load calculations Summary of work, work sequence, and identification of any critical / special work

items. Special submittal requirements General testing plan requirements (see Volume 2, Electrical and Instrument design

standards for Circuit Level Testing Requirements) Detailed equipment training-plan proposed by the consultant. Must be based on

consulting with WG personnel and using appendix C The Process portion of the Operation & Maintenance6 (O&M) manual requirements in

electronic form. (The contractor is to provide equipment portion of the O&Minformation. The design consultant to provide the final O&M manual).

Onsite startup services requirements Technical requirements (Contractor qualifications / applicable certifications) Requirement of a list of recommended spare parts and expendables, especially those

not stocked locally. WG maintenance will review the list for appropriate stockingitems.

Requirement that the contractor shall provide Instrument Data Sheets for eachinstrument, control valve, and electrical adjustable speed devices.

6 Revised 2003