technical specification for instrumentation controls and electrical requirements

TECHNICAL SPECIFICATION

FOR

INSTRUMENTATION, CONTROLS AND

ELECTRICAL REQUIREMENTS FOR PACKAGE SYSTEMS

FOR

PRAIRIE STATE ENERGY CAMPUS

BECHTEL CORPORATIONFREDERICK, MARYLAND

©Bechtel Corporation 2007. Contains confidential and/or proprietary information to Bechteland its affiliated companies which shall not be used, disclosed, or reproduced in any formatby any non-Bechtel party without Bechtel's prior written permission. All rights reserved.

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25316-000-3PSJQ07-00001

SPECIFICATIONNO.TECHNICAL SPECIFICATION FOR

INSTRUMENTATION, CONTROLS AND ELECTRICAL t-----------+---~REQUIREMENTS FOR PACKAGE SYSTEMS

FOR PRAIRIE STATE ENERGY CAMPUS

DATE REASON FOR REVISION

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Specification 25316-000-3PS-JQ07-00001, Revision 000

PART 1 - GENERAL 1

1.1 Applicability ~ 1

1.2 Services and Materials Included 1

1.3 Related Services and Materials Not Included 2

1.4 Codes and Standards 2

PART 2 - REQUIREMENTS 3

2.1 GE!rlE!rClI ~

2.1.12.1.2

System Requirements 3Service Conditions 3

Power Cable 8

Conduit 9Terminal Blocks and Fuses 9

Instrument and Control Wiring 7Wiring, General 6

Control Components 10Grounding 13

Detailed Requirements - Electrical 42.2.1 Cabinets, Panels, and Enclosures 42.2.22.2.32.2.42.2.52.2.62.2.72.2.8

2.2

General 13

1/<:> ••••••••...••.•••••••••••••••••••••••.••••••••••••••••••••••••••••••••••••••••••24

Applicallilit)f 23Design Requirements 23

Local Monitoring 17Analyzers 18Control Valves 18

Temperature 22

Vibration Monitoring 19Local Annunciators 19

Process Connections 14

Processor and System 24

Miscellaneous Instrument Devices 20

Programming 26PLC Local HMI 26

Instrument Locations and Mounting 16

Detailed Requirements - Instrumentation 132.3.12.3.22.3.32.3.42.3.52.3.62.3.72.3.82.3.92.3.102.3.11 Nameplates and Tagging 22

Detailed Requirements - Programmable Logic Controllers 222.4.12.4.22.4.32.4.42.4.52.4.6

2.4

2.3

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Pagei


PART 3 - DOCUMENTATION 29

PART 4 - INSPECTION AND TESTING 33

APPENDIXES

A APPROVED MANUFACTURERS LISTB REQUIREMENTS FOR INSTRUMENT INDEXC ORIENTATION OF INSTRUMENT CONNECTIONSD PROGRAMMABLE LOGIC CONTROLLER (PLC) NETWORK REQUIREMENTSE PLC SYSTEM NETWORK DIAGRAMF INSTRUMENT TAG CONVENTIONSG INSTRUMENT DATA SHEETS


Page ii


PART 1 • GENERAL

1.1 Applicability

1.1.1 This specification is included as an attachment to the associated parent technicalequipment specification / material requisition. The parent technical specification /material requisition governs the scope of supply, and may stipulate additionalrequirements or supersede the requirements of this specification. In case ofconflict, the parent specification / material requisition has precedence.

1.1.2 This specification provides detailed requirements applicable to equipmentprovided within Seller's scope of work. It defines the requirements for furnishingthe electrical, instrumentation, and control components and systems for theequipment supplied by Seller. Requirements stated herein are applicable to theextent the equipment is being furnished by Seller.

1.1.3 The General Project Requirements specification provides plant specific detailsincluding voltage levels and ambient temperature range.

1.2 Services and Materials Included

1.2.1 Seller or Subcontractor shall design, fabricate, furnish, test, and deliver allelectrical, instrumentation, and control components (including, but not limited to,associated motors, internal wiring, instrument valves, fittings, supports, piping,and/or tubing) required for the proper operation and maintenance of the specifiedsystem to the extent included in the parent technical specification/materialrequisition and in accordance with this specification and appendices.

1.2.2 Seller shall provide complete documentation for all electrical, instrumentation,and control devices supplied under the parent technical specification/materialrequisition in accordance with the Document Submittal Requirement (DSR) in theparent document.

1.2.3 Seller shall provide one set of special tools if other than standard tools arerequired to repair, maintain, or adjust the equipment. Tools shall be new andunused.

Bechtel Confidential © Bechtel Power Corporation 2007. All rights reserved.Page 1 of 34


1.2.4 Unless specifically excluded in the parent technical specification/materialrequisition, Seller shall be responsible for providing heat tracing for equipment.

1.3 Related Services and Materials Not Included

1.3.1 Receiving, installation, external connections, acceptance testing, and trainingunless included in the parent technical specification/material requisition.

1.3.2 Supply and installation of interconnecting wiring and raceway between Sellersupplied skids or components, unless included in the parent technicalspecification/material requisition.

1.3.3 Three phase motor starters, unless specifically required by the parent technicalspecification/material requisition or specifically integral to a piece of equipmentfurnished by Seller.

1.3.4 Foundations and anchor bolts.

1.4 Codes and Standards

Governing codes shall be those listed in the parent technical specification/materialrequisition and the codes and standards section of the General Project Requirementsspecification unless otherwise noted in this Section. Other codes and standards willapply as referenced in the technical specifications.



PART 2 - REQUIREMENTS

2.1 General

2.1.1 System Requirements

2.1.1.1 Seller's control package shall be a complete system, including controls,instrumentation, control panels, etc., as required for proper operation of thesystem.

2.1.1.2 Positive means of indicating equipment operating status (control valve withfail safe direction, etc.) shall be provided, such as a limit switch on a valve,auxiliary contacts from a motor starter, or an indicating system approved bythe Buyer.

o Hand switch contact closure (or PLC software equivalent)commands are not acceptable.

o Alarm switch should be normally closed and will open whenalarmed or the position is changed.

o Position or status switches should be normally open and will closeto indicate the position or status. The switch will de-energize to trip.

o The equipment shall operate in a fail safe manner.

2.1.1.3 Appendix A (Approved Manufacturers List) lists the approved instrumentmanufacturers for the type of instrument tabulated. Proposed manufacturersof instruments, electrical or control devices not listed shall be approved by theBuyer before they are incorporated into the system design.

2.1.2 Service Conditions2.1.2.1 Refer to the Parent Technical Specification/Material Requisition and the

General Project Conditions for general project information and requirements.

2.1.2.2 Seller shall provide suitable enclosures for indoor and outdoor equipment foroperation under the environmental conditions specified in the General ProjectConditions specification.

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2.1.2.3 The facility may produce an atmosphere hostile to some electroniccomponents. High voltage equipment, large currents, and rotating machinerywill produce considerable potential for radio frequency and electromagneticinterference. Seller's design shall incorporate provisions to avoid suchinterference.

2.1.2.4 Seller shall consider the nature of the fuel used at this station and shall takeappropriate measures to avoid the ingress of dust or ash into control cabinetsor instrument enclosures. Seller shall comply with any requirements forhazardous area classifications.

2.1.2.5 Interface points for services and utilities shall be in accordance with theparent technical specification/material specification.

2.2 Detailed Requirements· Electrical

2.2.1 Cabinets, Panels, and Enclosures2.2.1.1 General requirements:

2.2.1.1.1 Seller shall provide enclosures that are suitable for the service conditionswhere the cabinet/panel/enclosure will be installed.

National Electric Manufacturer Association (NEMA 12) enclosures forindoor (non-hazardous) service.

NEMA 1 enclosures are acceptable for equipment located in rooms withHVAC.NEMA 3R for electrical equipment such as motors and startersNEMA 4 for outdoor instrumentation.NEMA 4X where equipment can get damaged by water or corrosion.Equipment in hazardous locations shall have the proper classification forthe environment, in accordance with the National Electrical Code (NEC).

Equivalent International Electrotechnical Commission (IEC) enclosures areacceptable provided the rating meets or exceeds the specified NEMA rating.As a guide, the following equivalents may be assumed, NEMA 12 (IP55),NEMA1 (IP20), NEMA 3R (IP22), NEMA 4 (IP66), and NEMA 4X (IP66 withcorrosion protection).

Enclosures in hazardous locations shall be fitted with an air-purge systemand pressure switch (e.g., Z-purge) and/or use intrinsically safe components.

Enclosures shall be located away from maintenance areas, excessivevibration, and extreme temperature and provide adequate room foroperations and maintenance activities.

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Specification 25316-000-3PS-JQ07-00001, .Revision 000

2.2.1.1.2 Provide enclosures with thermostatically controlled space heaters whererequired to maintain internal temperature above dew point. If equipment islocated outdoors, space heaters must be provided unless otherwise approvedby Buyer.

2.2.1.1.3 Ensure that the enclosed equipment will be able to operate under theambient conditions specified in the parent technical specification/materialrequisition. Provide heating and/or cooling as required. Note the ambientcondition considerations shall include solar gains, heat sink gains, wind chill,etc.

2.2.1.1.4 Provide and permanently identify all electrical accessory devices, such asfuse blocks, fuses, terminal blocks, wire markers, wireway, wiring, etc., asnecessary for a complete installation. Components shall be segregated byvoltage levels where practical.

2.2.1.1.5 Route circuits for lighting, convenience receptacles, cooling fan, and spaceheater(s) inside the cabinet/panel/enclosure in metallic or PVC ducts/conduitsand wire to terminal points separated from control circuits. Provide terminalblocks for separate power sources for these utility functions and the controlequipment within the cabinet.

2.2.1.1.6 Provide a clearly identified polarized AC plug-in strip for panel-mounteddevices supplied with cord sets.

2.2.1.1.7 Enclosures shall be completely assembled at the factory so that the entireassembly is an operating unit, tested and ready for installation in the field. Nocomponent shall be mounted less than 3 inches (75mm) from the floor or 11/2 inches (40 mm) from the bottom of the panel, whichever is higher.

2.2.1.1.8 Panel design, materials, and workmanship shall result in a neat panelappearance outside and inside, with no distortion, welds, holes, rivets, or boltheads apparent on exterior surfaces. All exterior surfaces shall be true andsmooth.

2.2.1.1.9 The exterior of all panels, other than main control room panels, shall bemanufacturers standard and panel interiors shall be manufacturers standardpainted white.

2.2.1.2 Additional requirements for free-standing enclosures:

2.2.1.2.1 Free-standing enclosures shall have rigid bracing, removable lifting eyes, anda three-point latching system with lockable door handles. Panels shall includeprovisions for bolting or welding to floor and provisions to shim the panel tolevel.



2.2.1.2.2 Provide guard-protected interior lighting operated from a conveniently locatedswitch and at least one readily accessible AC receptacle in each freestanding enclosure. Provide print pocket inside the enclosure.

2.2.1.2.3 Provide each free-standing enclosure with a copper ground bus extending thefull length of the enclosure, to effectively ground the entire structure. Freestanding enclosures containing low level signal devices shall be provided witha separate, isolated signal 'ground bus. All devices with self-contained powersupplies and metal housings shall be grounded to the power ground bus.Ground bus shall be 1/4 in. x 1 in. (6 mm x 25 mm) minimum copper.

2.2.1.2.4 All free-standing panels and panel stiffening members shall be steel with acorrosion resistant coating suitable for the environment. The external coatingshall also be photo-degradation resistant for outdoor panels. Depth andheight of individual panels shall be held to a tolerance of ±1/2 in. (±12 mm)with the added restriction that the overall dimensions of a multi-section groupshall be +0/-1 in. (+0/- 25 mm) and height variations between adjacent panelsshall be no more than 1/2 in. (12 mm) Panel-mounted equipment shall belocated within a tolerance of +1/2 in. (±12 mm).

2.2.1.2.5 Dimensions for free-standing enclosures shall be 72 to 90 inches (1830 to2290 mm) high and a minimum depth of 18 inches (460 mm). Panelmounted devices requiring operator activation or reading from a standingposition shall be located no lower than 30 inches (750 mm) and no higherthan 76 inches (1930 mm) above the floor.

2.2.2 Wiring, General2.2.2.1 Route instrumentation, power and control wiring separately. Separation shall

be sufficient to prevent crosstalk and interference on the instrumentation andcontrol circuits.

2.2.2.2 Route wiring so that devices can be removed or serviced without disturbingwIring.

2.2.2.3 Identify each internal wire at each end with Seller's wire number on a heatshrink soft plastic sleeve, or self-laminating plastic label.

2.2.2.4 Provide extra flexible wiring (Class C minimum) over door hinges and otherlocations where leads may be subject to flexing. All wiring between stationaryand movable subassemblies of a panel shall be firmly anchored on eachsubassembly and shall be looped to cause the majority of the flexure to be bytorsion rather than bending.

2.2.2.5 Seller shall meet the requirements for flame retardant cables required by theIndustry Codes listed in the parent technical specification/material requisition.

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2.2.2.6 Non-PVC wire ducts may be used provided they are made of flame retardantmaterial.

2.2.2.7 Provide terminal boxes with terminal blocks for devices mounted on skidmounted equipment. Run interconnecting wire in galvanized rigid steelconduit (1/2-inch minimum) if not subjected to vibration, or flexible metallicconduit if subjected to vibration. Use liquid-tight connections if outdoors orsubjected to water spray.

2.2.2.8 Wire all spare terminal points on panel-mounted devices to terminal blocksfor external connections. All wiring connecting devices within a single panel(whether in the same shipping section or not) shall be routed inside theenclosure. Provide wiring duct or conduit as required for cables and wiring.

2.2.2.9 Protect all wiring from metal corners and edges. Provide support for incomingwiring at the point of entry to the panel.

2.2.2.10 Where American Wire Gauge (AWG) sizes are specified in this specification,they may be substituted with the equivalent metric sizes provided they meetall the requirements of the Codes and Standards listed in the parent technicalspecificationlmateriaI requisition.

2.2.3 Instrument and Control Wiring2.2.3.1 Wiring shall comply with the following:

2.2.3.1.1 Wiring that is contained completely (end-to-end) within the control panel orlocal control boxes shall be No. 14 AWG (2.5 mm2

) minimum, 600 volt flameretardant XLPE (XHHW or SIS), 194°F (90°C), stranded copper cable, orBuyer approved equal. When supplied, jacketing shall be ChlorinatedPolyethylene (CPE), Hypalon, PVC or Neoprene. Color code to follow ICEAMethod 1 Table E-2.

2.2.3.1.2 Control cables in raceway shall be No. 14 AWG (2.5 mm2) minimum, 600 volt

flame retardant, 194°F (90°C), stranded copper conductor with a highly flameretardant insulation/jacketing system for control cables in raceway. Insulationshall be cross linked polyethylene (XLPE), Ethylene Propylene Rubber (EPR)or Buyer approved equal. When supplied, jacketing shall be CPE, Hypalon orNeoprene. Color code to follow ICEA Method 1 Table E-2.

2.2.3.1.3 Analog instrumentation signal cables shall be 2/C, 3/C or 4/C shielded,twisted cable, stranded copper No. 18 AWG (1.0 mm2

), with XLPE or PVCinsulation and PVC jacket. Multi-pair/triad/quad cable is acceptable.

2.2.3.1.4 Provide thermocouple extension wiring where needed. Conductors shall beno. 18 AWG (1.0 mm2

). Insulation and jacketing shall utilize U.S. standardcolors, i.e., Type K, yellow and brown leads with yellow exterior jacket


Page 7 of 34


insulation; Type E, purple and red leads with purple exterior jacket insulation;and Type J, red and white leads with black exterior jacket.

2.2.3.1.5 Smaller wire sizes may be used where such wires have suitable overcurrentprotection.

2.2.3.2 Ship any prefabricated cables intended for installation by Buyer withconnectors installed on one end only. The uninstalled connector shall beprovided and supplied with pin out drawing attached. Provide any specialtools required to make-up connectors in accordance with Paragraph 1.2.3(e.g., crimp tool, etc.). Fiber optic cables for field installation in conduit orraceway shall not have connectors attached; connectors shall be providedseparately.

2.2.3.3 Conductors for grounding instrument cable shield terminal points and signalcommon conductors shall not be connected to the panel safety ground bus.These conductors shall be terminated on the instrument ground bus.

2.2.3.4 Control and instrument wiring shall be listed or labeled by an independenttesting laboratory in accordance with the requirements of the NEC or IECcodes as specified in the parent technical specification/material requisition.

2.2.3.5 Instrumentation, control, and power wiring shall be routed separately.Separation shall be sufficient to prevent crosstalk and interference on theinstrumentation and control circuits. A minimum of 12 in. (300 mm) spacingshall be applied; where this spacing cannot be maintained, low level wiringshall be at right angles to control cables or installed in ferrous conduit.

2.2.4 Power Cable2.2.4.1 Where the Seller is required to furnish power cable inside the control panel or

outside the panel in raceways, it shall be No. 12 AWG (4.0 mm2) minimum,

600 volt Class B Stranded copper conductors with a temperature rating of194°F (90°C) for continuous operation, with a flame retardantinsulation/jacketing system for power cables. Insulation shall be cross-linkedpolyethylene (XLPE) per Insulated Cable Engineers Association (ICEA) S-66524, Ethylene Propylene Rubber (EPR) per ICEA S-68-516, or Buyerapproved equal. Jacketing shall be CPE, Hypalon or Neoprene.

2.2.4.2 Size, protect, and install in accordance with the National Electric Code (NEC)and ICEA, or IEC if specified in the parent technical specification/materialrequisition.

2.2.4.3 Provide 12 AWG (4.0 mm2) minimum, copper stranded conductors, for

current transformer secondary leads and connect to short-circuiting type



terminal blocks. Provide warning labels indicating lethal voltages may bepresent if secondary left without a burden or load.

2.2.5 Terminal Blocks and Fuses2.2.5.1 Terminal blocks shall allow convenient wiring and maintenance access.

2.2.5.2 Terminate field wiring conductors (other than factory soldered connections)on terminal blocks with compression type terminations. Printed circuit cardtermination of field wiring is not acceptable. Terminal blocks shall be rated600V.

2.2.5.3 Terminate all circuits at terminal blocks. Provide 20 percent terminal sparepoints uniformly distributed. Prepare, tape, tag, and tie back shields andunused conductors. Shields will be landed (only if required) duringoperational checkout.

2.2.5.4 Certain signal cables, such as analyzers, vibration monitors, and datacommunication cables, shall be routed directly to the associated panelmounted device.

2.2.5.5 Terminate all wiring on one side of terminal blocks, leaving other side entirelyfree for Buyer's field cable connections. Leave adequate space for jacketedfield cables. Connect all conductors for each device, including shields, toadjacent terminal points.

2.2.5.6 Do not connect more than two wires to one terminal point and jumper asnecessary to allow connection of only one wire per terminal point on theoutgoing side of terminal blocks. Do not splice, tape, or lace conductors.

2.2.5.7 Fuses and fuse holders shall be appropriately rated and shall be of theindicating type.

2.2.5.8 Fuses shall be accessible for inspection, replacement or maintenance. Allfuse blocks shall be identified with their service and fuse ratings.

2.2.5.9 Buyer's side terminations shall accommodate No. 12 AWG (4.0 mm2)

minimum for control wiring, No. 16 AWG (1.5 mm2) minimum for

instrumentation wiring, and No. 12 AWG (4.0 mm2) through NO.2 AWG (35

mm2) for power supply cables.

2.2.6 Conduit2.2.6.1 Conduit, if required, shall be rigid steel, intermediate metal, Electrical Metallic

Tubing (EMT), or rigid aluminum, consistent with the ambient environmentalconditions. In areas where conduit will be exposed to a chemically corrosiveenvironment, conduit shall be Polyvinyl Chloride (PVC) coated (0.040 inches



or 1 mm minimum) rigid galvanized steel with urethane coated threads. IfPVC coating is not suitable for the service, Seller shall propose an alternativecoating for Buyer's approval.

2.2.6.2 Conduit shall be run at right angles to building lines indoors and shall notinterfere with passageways, equipment removal, or maintenance access.

2.2.6.3 Conduit terminating at vibrating equipment shall be connected with seal-tightflexible metal conduit (FMC) for indoor installations, or liquid-tight FMC foroutdoor installations. The maximum unsupported length shall be inaccordance with NEC or IEC if specified in the parent technicalspecification/material requisition but no longer than 3.3 ft (1.0 m).

2.2.6.4 Where required for hazardous areas, National Fire Protection Association(NFPA) approved conduit seals shall be provided and installed.

2.2.6.5 Size and install in accordance with NEC and Institute of Electrical andElectronics Engineers (IEEE) 422, or IEC in accordance with the parenttechnical specification/material requisition. Minimum conduit size shall be 3/4inch (75 mm).

2.2.7 Control Components2.2.7.1 Where Seller's controls shall interface to MCC's or switchgear provided by

others, the following component and circuit ratings shall apply:

a. 120 V AC, 1 phase, 2 wire, 60 Hz, solidly grounded for control circuits ofall AC motors powered from low voltage as specified in the GeneralProject Requirements Specification (200 hp and smaller).

b. 125 V DC for metal clad SWitchgear breakers.

c. 120 V AC for control circuits of medium voltage fused contacts feedingmotors (200 HP & larger) and load center/MCC transformers.

2.2.7.2 Provide insulation of Class H or better on control device coils whichcompletely seals the conductors to prevent penetration of moisture or othercontaminants and is rated for continuous operation at a temperature of 266°F(130°C).

2.2.7.3 Provide contacts rated for 120 V AC, 10 amp inductive loads, or 125 V DC, 0.5amp inductive loads, as required.

2.2.7.4 Provide surge protectors for solid-state equipment if not inherent in theequipment design, to prevent damage from the effect of lightning strikes orother electrical transients encountered in power plant operation.



2.2.7.5 Electric heat tracing shall be provided as needed for all process andinstrument piping, tubing, and devices that are temperature sensitive orsusceptible to freezing due to process conditions or material properties. Heattracing shall be self-regulating, consistent with the industry standard normallyused for these special applications. Monitoring and test panels shall beprovided for the heat tracing circuits. The heat tracing system shall includeappropriate controlling, monitoring, alarm, and power components.

2.2.7.6 Pushbuttons and Selector Switches

a. Furnish heavy-duty, oil-tight, pushbuttons, as listed in Appendix A or Buyerapproved equal, color coded as follows:

Function Color

Start Black

Stop Red

Jog Green

Reset Yellow

Auto White

Jog Open Black

Jog Closed Green

Furnish with manufacturer's standard sized permanent nameplates, firmlyattached using either bezel mount of component or device, or self-tappingsheet metal screws.

2.2.7.7 Indicating Lights

a. Provide indicating lights, as listed in Approved Manufacturers List (AppendixA) or Buyer approved equal. LED clusters are acceptable.

b. Furnish color caps or LED cluster colors in accordance with the following:

Red: liOn" to indicate motor running, device energized, or valve open orpartially open (not fully closed)

Green: liOn" to indicate motor not running, device not energized, or valveclosed or partially closed (not fully open)



Amber: "On" to indicate warning, abnormal equipment or system status, orsystem not in the steady-state mode

White: "On" to indicate power supply available in a supervisory manner orto indicate "Auto"

2.2.7.8 Local Motor Controllers and Contactors

a. Furnish combination type motor controllers consisting of a motor starterwith thermal or solid-state overload relays, molded case circuit breaker, andauxiliary control devices as required.

b. Motor controllers will be magnetic type, suitable for line voltage starting,per General Project Requirements Specification, of single speed inductionmotors. Overload protection shall consist of three manually reset,ambient compensated thermal overload relays of the bimetallic type orequivalent solid-state protection. Starters shall be minimum NEMA Size 1or IEC equivalent if specified in the parent technical specification/materialrequisition. The thermal units shall be sized in conjunction with the motorfull load current, per nameplate.

c. Provide a 120 volt control transformer for motor controllers, one sizelarger than standard (100 VA minimum), with a secondary fuse in theungrounded line. Provide an environmentally suitable enclosure for eachstarter and integral pre-wired start/stop controls, indicating lights, and anauxiliary relay for Buyer's use.

d. Molded case circuit breakers will be magnetic type only with adjustabletrip settings set in accordance with the NEC (or IEC if specified in theparent technical specification/material requisition) and with a faultinterrupting rating as specified in the General Project Requirements.Molded case breakers shall be provided with copper lugs.

e. Non-motor loads shall be provided with either thermal magneticcontactors or magnetic only breakers with fuses.

2.2.7.9 Relays and Meters

a. Install protective relays and meters on the front of the control cabinets,panels, and cubicles. The relays shall be of semi-flush drawout design withtesting devices. Meters shall be located such that they are visible to anoperator standing at the normal floor level. Types and details shall besubject to acceptance by Buyer.



b. Provide solid state type time delay relays with dial knob adjustable delay, aslisted in Appendix A or Buyer approved equal.

c. Provide semi-flush, panel mounted meters with expanded scales.

d. Provide meters with linear indicating scales which read directly inengineering units. Digital meters are acceptable with Buyer written approval.

2.2.8 Grounding2.2.8.1 Include provisions for connecting skids to Buyer's external ground grid.

Grounding pads suitable for standard NEMA two-hole lugs shall be providedat two points at opposite ends of the skid.

2.2.8.2 All skid-mounted equipment shall be electrically bonded together inaccordance with NEC or IEC. Instruments and control panels are consideredbonded when connected to grounded metallic conduit. Motors Y2 HP(0.375kW) and greater shall be grounded through the motor frame in additionto the ground connection provided through the power cable and raceway.

2.2.8.3 Where the power supply to equipment is included in Seller's scope of supply,such power supplies must include a ground fault return path in accordancewith the NEC or IEC as specified in the parent technical specification/materialrequisition.

2.2.8.4 All exposed conductive parts of systems and equipment shall be solidlygrounded.

2.2.8.5 Instrument cable shields shall be landed on terminal points for grounding orfor continuation of instrument cable shields for grounding at another location.

2.3 Detailed Requirements - Instrumentation

2.3.1 General

The following signal levels shall be used for transmitted indication and control signals:

a. Electronic: 4 to 20 mAde, 24V dc, 2-wire, accuracy +.25% of calibratedrange.

b. Pneumatic: 3 to 15 psig (200 mBar to 1 Bar).

c. Thermocouple: ANSI Type E, Chromel-Constantan, grounded junction,Type J and Type K for high temperature applications; thermocoupleconversions per 1PTS-68, accuracy + 1°C

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d. RTD: 100 Ohm Platinum, 3-wire (R100/Ro = 1.385), accuracy ± 1DC.

2.3.2 Process Connections

2.3.2.1 Orient instrument connections to process piping or vessels in accordancewith accepted industry practice. (See AppendiX C for instrumentconnections).

2.3.2.2 Seller shall provide a root valve of 1/2 in. (12 mm) minimum size suitable forapplication at each process connection, other than boiler combustion air anddraft connections.

Root valves shall normally be ball or full-ported gate style, of material whichmeets the temperature and pressure rating of the process piping. Double rootvalves shall be provided for applications with a pressure rating above ANSI900 or within the ASME Section I boundary (boiler code).

2.3.2.3 All steam flow element (nozzles, venturis and HHR flow tubes) root valvesmust be either high temperature ball or gate valves. The ID of the valve mustbe as close as possible to the 10 of the pipe. These valves must also beaccessible for emergency isolation of the condensate pot from the flowelement.

2.3.2.4 The following requirements are applicable to the main boiler and steamline drain pots.

All boiler drum level root valves upstream of the Condensate Pots must beeither high temperature ball or gate valves. The internal diameter (10) of thevalve must be as close as possible to the 10 of the pipe. These valves mustalso be accessible for emergency isolation of the condensate pot from thedrum.

All steam line drain pots using conductivity probe level switches must beeither high temperature ball or gate valves. The 10 of the valve must be asclose as possible to the 10 of the pipe. These valves must also be accessiblefor emergency isolation of the probe from the drain pot.

2.3.2.5 Process connections for differential pressure type flowmeters shall bearranged so that there is no offset due to elevation head at the primaryelement.

2.3.2.6 A thermowell shall be provided for each process temperature sensor. Thethermowell shall withstand two times the maximum system pressure. Thevelocity-induced frequency shall be less than 80 percent of the thermowellcritical (resonant) frequency during all modes of operation.



2.3.2.7 Seller shall provide root valves and thermowells with sufficient extension topreclude interference with piping, supports, and insulation.

2.3.2.8 Locate temperature connections downstream of pressure and flowconnections to avoid flow induced disturbances at the pressuremeasurement.

2.3.2.9 Instrument impulse lines between the root valve and the instrument shallgenerally be ASTM A-213 seamless 316 stainless steel, 3/8 in. 00 x0.065 in. wall (12 mm 00 x 2 mm wall) suitable for the application. Sellershall ensure suitability of the tubing material for the application, and ifrequired, the Seller shall propose an alternative tubing material for Buyer'sreview and approval prior to design finalization. Impulse lines for low-pressuregas or dust-laden service shall be 3/4 in. (75 mm) 00 minimum. Coppertubing ASTM 8-75, 3/8 in. 00 x 0.035 in. wall (12 mm 00 x 1 mm wall) may.be used for instrument air service. All installations shall be suitable for theconditions specified in the General Project Requirement specification.

2.3.2.10 Provide gate type root valve connections on tanks and vessels for externalcage level instruments in accordance with the following:

Type Size

Gauge Glass 1"

Displacer Type 2"

Multi-instrument stand pipes 2"

2.3.2.11 Provide 2 1/2 in. minimum connections, with provisions for rod-out, on dustladen ductwork. Blowback provisions shall be provided.

2.3.2.12 Provide test connections with root valves as required for troubleshooting orcalibration.

2.3.2.13 Locate flowmeters in straight runs of pipe in accordance with Table 2 ofASME Standard MFC-3M-2004. Provide two sets of pressure taps, with thesecond set plugged for future use. Use weld neck flanges where flanges arerequired.

2.3.2.14 For flowmeters or valve trim that could be damaged during flushing and/orsteam blow, furnish flowmeters or trim that can be easily removed. Providekits for such valves that include any parts required to seal the valve body withthe trim removed. Provide spool pieces, where required, to insert in place ofthe flowmeter. For each flowmeter requiring removal, attach a warning tagstating "Removal Required Prior to Flushing."


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2.3.2.15 Route tubing, properly supported and protected, to permit access toequipment for operation or maintenance.

2.3.2.16 Slope instrument impulse lines a minimum of 1/4 in. per foot (20 mm permeter) to prevent the accumulation of non-condensable in liquid lines orcondensate in gas lines. Provide drain and vent valves where required.

2.3.2.17 Provide isolation valves and calibration connections on impulse andpneumatic signal lines to permit in-place calibration.

2.3.2.18 Use air or liquid purges, chemical seals, or other suitable means to providelow maintenance, trouble-free operation for instruments in slurry, particulate,or chemical service.

2.3.3 Instrument Locations and Mounting2.3.3.1 Instruments shall be located where they are accessible for normal operations

and easily read from walkways. Instruments shall be oriented so that controls,dials, or displays are upright and facing in a direction for easy readability.

2.3.3.2 Instrument installations shall consider maintenance access. Sufficientflexibility shall be left in impulse lines to permit instrument removal withoutdamaging the tubing installation or the instrument. Flexibility shall be providedby tubing offsets maintaining the required slope, not by loops in the impulseline. Two-valve manifolds for pressure and three- or five-valve manifolds fordifferential pressure applications shall be provided at the instrument

2.3.3.3 Required instrument accessibility will be in accordance with the followingtable:

Type of Instrument I II IIIControl valves, Process pressure Xregulators, and MOVsTransmitters XLocal indicators XPressure gauges (not line mounted) XPressure gauges (line mounted) XSelf-contained air regulators XLocal controllers XProcess actuated switches XLocally adjustable instruments XEmergency instruments XAnalytical Instruments XThermocouples XRoot Valves X


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Type of Instrument I II IIIInstrument Manifolds XValve Position Switches XLegend:I = Grade, platform, stairway, or permanent or portable ladder less

than 15 feet (4,570 mm). Access from permanent or portableladder will be limited to those cases where the area or pipingarrangement precludes locating the instrument so as to beaccessible from grade or platform.

II = Grade, platform, stairway, or permanent inclined ladderIII = Grade or fixed platformThe above accessibility table is applicable for all instruments. Theseaccessibility requirements; however, are not applicable to vendorpackaged, skid-mounted instruments, which are based onmanufacturer's standard offering.

Where instrument manifolds are not provided, the above-stated criteria will beapplied to the instrument block valves.

Instruments shall be located so that required clearances are maintained forwalkways, access ways, and operation and maintenance of valves andequipment.

2.3.4 Local Monitoring2.3.4.1 Provide each pump with a discharge pressure gauge. For small chemical

metering pump installations that have installed spares, one pressure gauge inthe common discharge header shall be provided.

2.3.4.2 Provide each process strainer and filter with a differential pressure indicatorand switch, except small instrument filters and V-strainers on the suction ofsmall chemical metering pumps which do not require this indication.

2.3.4.3 Provide cooling water flow sight glasses in addition to flow switches for allequipment requiring cooling or seal water.

2.3.4.4 Provide local level indication on all closed tanks or vessels.

2.3.4.5 Provide sight glasses on all pump bearing oil sumps.

Bechtel Confidentia/© Bechtel Power Corporation 2007. All rights reserved.

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2.3.5 Analyzers2.3.5.1 Where continuous process analysis equipment is to be provided, Seller shall

ensure that the sampling point is truly representative of the process.

2.3.5.2 Specific Buyer approval of each type of analysis equipment, either throughlisting in Appendix A or through a specific request by Seller, shall be obtainedbefore the equipment is used in the design.

2.3.5.3 The Seller shall ensure that all materials of construction are compatible withthe intended service.

2.3.5.4 Provisions shall be made in the installation of analyzers subject to desiccationto ensure that the analyzer sample chambers are continuously immersed influid whether in operation or idle during plant shutdown periods.

2.3.5.5 Where in-line pH, conductivity, or similar probes are to be used, they shall beinstalled so as to be easily removed for maintenance.

2.3.5.6 Each analyzer that uses a consumable reagent shall be provided withsufficient reagent for 1 year of operation after acceptance of the system byBuyer. Delayed shipments of reagent may be required due to short shelf livesof some chemicals.

2.3.5.7 Analyzers dependent upon continuous flow of sample or dilution water shallbe equipped with a head tank and automatic provisions to shut off reagentflow on loss of dilution water flow.

2.3.5.8 Seller shall identify the quantity of sample that must either be taken to drainor returned to the process in order to provide a valid sample at the analyzerfor measurement. Seller shall locate liquid service analyzers so that theamount of fluid that requires draining to waste is minimized and the majorityof the flow is returned to the process.

2.3.5.9 Any analyzer probes or components which could be damaged by shipment,shall not be shipped installed, but SUitably packed and shipped loose for latermounting. Components which could be damaged by storage exceeding onemonth shall be shipped later when requested by Buyer.

2.3.6 Control Valves2.3.6.1 Size valves to pass 110 percent of the maximum operating flow. Control valve

body size shall not be smaller than two sizes under the inlet pipe size.

2.3.6.2 All modulating control valves shall be pneumatically operated.



2.3.6.3 Size actuators to shut off against at least 125 percent of the maximum shutoffpressure differential. Size actuators to operate with a minimum air pressure of80 psig (550 kPa).

2.3.6.4 Limit maximum sound level to 85 d8A when measured 1 meter from thevalve.

2.3.6.5 Furnish a handwheel on each control valve where necessary for manualcontrol. Handwheels shall not be provided where they can prevent automaticprotective actions required of the valve.

2.3.6.6 Furnish positioners with input, output(s), and supply gauges.

2.3.6.7 Control valves shall conform to the applicable portions of the following codesand standards:

ANSI 816.5 Pipe Flanges and Flanged Fittings

ANSI 816.34 Valves - Flanged, Threaded, and Welding End

FC170.2 Control Valve Seat Leakage

MSS SP 61 Pressure Testing

MSS SP 85 Valves Socket Welding and Threaded Ends

2.3.7 Vibration Monitoring2.3.7.1 Vibration monitoring shall be provided for horizontal shaft driven equipment

rated 2000kW (2500 hp) and above and where specified in the parenttechnical specification/material requisition.

2.3.7.2 All vibration monitoring shall be as specified in Appendix A. Proximitor typeprobes will be used for split bearing, oil film type bearings andvelocity/seismic probes will be used for roller element type bearings.

2.3.7.3 Provide two probes per bearing oriented at 90 degrees from one another. Akeyphasor shall also be provided.

2.3.7.4 A 4 to 20 mA dc signal shall be provided for the Buyer's DCS from eachvibration measurement unless specified otherwise in the parent technicalspecification/material requisition.

2.3.8 Local Annunciators2.3.8.1 Where local annunciators are provided, they shall be of solid-state design

with integral logic and backlighted nameplate displays having at least two



lamps per display window. Local annunciators shall have minimum 1 in. by 3in. backlighted nameplate displays. Window engraving character height shallbe % inch (6 mm) minimum. Provide 20 percent spare windows, distributedamong the layout.

2.3.8.2 Provide first-out sequence of operation in accordance with TheInstrumentation, Systems, and Automation Society (ISA) S18.1 (SequenceF3A). Provide a local audible alarm with each panel that contains anannunciator.

2.3.8.3 Annunciators shall operate from 120 V ac.

2.3.8.4 Provide two SPDT (form c) master alarm contacts for each annunciator wiredto terminals for Buyer's use. Activate when any channel alarms or on loss ofAC power and maintain in that state until all channels return to normal.Provide a reflash feature that momentarily interrupts the master alarm outputwhenever a subsequent channel alarms.

2.3.8.5 Arrangement and engraving of annunciator windows shall be logicallyarranged and shall provide a clean and unambiguous indication of theprocess condition.

2.3.8.6 Status (non-alarm) windows, such as completion of demineralizerregeneration, shall be grouped separately from alarm windows and shall notbe wired to the master relay.

2.3.9 Miscellaneous Instrument Devices2.3.9.1 In general, instrument accuracies shall be 0.5 percent or better. Pressure

gauges and other local instruments shall be 1 percent or better andtransmitters shall be 0.1 percent or better.

2.3.9.2 Provide linear indicating scales or digital readouts reading directly inengineering units.

2.3.9.3 Provide condensate chambers in steam service to maintain a constantelevation head. Provide siphons or pigtails where required to isolate aninstrument sensing element from vapor temperatures high enough to affect ordamage the instrument.

2.3.9.4 Provide snubbers or other suitable damping device for pulsating service.

2.3.9.5 Pneumatically operated final control devices shall be provided with liPconverters and, where functionally necessary, for modulating final controldevices provide positioners and position transmitters.

2.3.9.6 Provide pneumatic controllers with input and output signal pressure gauges.



2.3.9.7 Seller shall provide individual filter regulators for each pneumatic device orstack of manifolds. Filter regulators shall generally be located on the device.Unless associated with a positioner having a supply pressure gauge, all filterregulators shall be provided with an output gauge.

2.3.9.8 Panel-mounted pneumatic equipment may be served by a commoninstrument air header in the panel, served by a pressure reducing stationsized for the entire panel load, a common air filter and mounted in the panel.In such installations, each stack of manifolds or individual device shall havean isolation valve.

2.3.9.9 Provide power supplies for all electronic instrumentation unless statedotherwise in the parent technical specification/material requisition.

2.3.9.10 Provide solenoid valves with Class H coils, NEMA 4 (IP66) enclosures.Where external field wiring is by Buyer, the solenoid and the valve limitswitches shall be wired to a junction box located on the actuator. In watertreatment applications only, the use of banked solenoids with Class F coilswith connectors/terminals are acceptable.

2.3.9.11 All controllers shall be provided with anti-reset windup.

2.3.9.12 All differential pressure transmitters including those used for flowmeasurement shall be provided with three or five valve instrument manifolds.Pressure transmitters and gauges shall be provided with two valve

instrument manifolds (block and bleed valve). Calibration tees shall beprovided for all other instruments.

2.3.9.13 Provide nominal 4-1/2" (115 mm) diameter pressure gauges with white faceand black markings. On small bore non-metallic pipe (less than 2 inches or50 mm) only, pressure gauges shall be 2 ~ inch (65 mm) diameter becauseof weight considerations. Pressure indicators provided as part of controlvalves, pressure regulators or pneumatic controllers shall be manufacturer'sstandard.

2.3.9.14 Pressure gauges will be supplied with either a blow-out disk or a blow-outback and have either a shatter-proof or acrylic front face.

2.3.9.15 Pressure and temperature indicator scales shall be such that the normalreadout of the indicator shall be between 1/3 and 3/4 of the scale.

2.3.9.16 In-line paddle flow switches are not acceptable.

2.3.9.17 All pressure and temperature switches shall be provided with DPDT (two formc) contacts except where the high deadband of DPDT switches isunacceptable for the application. Switch actuation point shall be in the centerone-third of the instrument range.



2.3.9.18 Pressure and level transmitters shall be provided as indicating type.

2.3.102.3.10.1

TemperatureProvide dual element thermocouples, spring loaded, grounded junction, withweatherproof (aluminum or iron) head, internal grounding screw, and externalground terminal. Provide test thermowells with a brass or bronze plug or cappermanently attached with a chain or wire and with lagging extensions whererequired.

Type E and Type K thermocouples are preferred. The thermocouples shall bemanufactured per ISA MC96.1.

2.3.10.2 All thermocouple instruments shall be provided with upscale burnoutprotection.

2.3.10.3 Provide bimetallic, any-angle dial thermometers with white face and blackscale markings. The dial size shall be 4.5 or 5-inch diameter (minimum).

2.3.10.4

2.3.11

2.3.11.1

RTDs shall be 100 ohm, platinum type, three-wire circuits (TemperatureCoefficient = 0.00385), and ungrounded. The element shall be springloaded, mounted in a thermowell, and connected to a cast iron or analuminum head assembly.

Nameplates and TaggingProvide nameplates with black 3/16 inch (5 mm) minimum letters on whitebackground for all panel designations and panel mounted devices. Providean additional nameplate showing the device number inside the panel for eachdevice.

2.3.11.2 Secure nameplates to panel with stainless steel self-tapping screws.Adhesive may be used inside the panel where screws cannot be used.

2.3.11.3 Each instrument, control valve, electrical device and loose accessory shall betagged with a 3 inch by 1 Y.4 inch (75 mm by 30 mm) minimum, 16 gaugeminimum, non-corroding metal tag which is securely affixed to the instrumentby pins, metal screws, or stainless steel wire. Tagging information shallinclude Buyer's purchase order number, P.O. item number, and Buyer'sidentification tag number, stamped on the tag in 3/16-inch (5 mm) minimumsize letters.

2.4 Detailed Requirements - Programmable Logic Controllers (PLC)


2.4.12.4.1.1

2.4.1.2

2.4.1.3

2.4.22.4.2.1


ApplicabilitySection 2.4 is applicable only if the system provided includes PLC basedcontrol.

If required by the parent technical specification/material requisition, the systemshall be supplied with redundancy to include as a minimum processors,memories, power supplies, power feeds, and data communication channels.Provide automatic fail-over in the event of any redundant component failure.As a minimum, redundancy of mechanical equipment shall not becompromised by the control system.

For the PLC based system required by the parent technicalspecification/material requisition to integrate with the DCS and/or other PLCvendors, the PLC system must comply with the networking and integrationstandards stated in Appendices 0 and E. Specific permission MUST beobtained to deviate from the specified PLC and HMI platforms, and thespecified software versions must be used.

Design RequirementsEach PLC system shall accommodate two power supply feeds by the Buyer.The primary feed will be from Buyer's UPS (or other source) and the secondaryfeed will be from unregulated AC. Seller shall distribute the selected source ofpower and provide protective fuses and/or breakers within the PLC for powerdistribution, thermal protection of wiring and overcurrent protection. In addition,fuses, breakers and or current limiting I/O shall be provided so that anaccidental grounding of a field conductor will not disable more than the one I/Opoint to which the conductor is connected.

PLC HMls shall be supplied by UPS power unless the manufacturer's standardHMI comes equipped with dual power source capability. The Processor andI/O rack power supplies shall be fed from the primary source, with thesecondary source as backup. A 'Diode OR' of the two power supply outputs isacceptable for DC voltages. Input modules shall utilize the same selected(primary or secondary) source for interrogating field input devices.

Field power for digital output modules shall be fed from the unregulated powersource, to avoid undue loading of the UPS. An exception to this will be themotor control centers (whether Seller supplied or not) where input and outputmodules source of power will be the individual motor starter control powertransformer.

2.4.2.2 Power supplies shall include thermal overload, short circuit, and surgeprotection.


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(MR1 & MR2) Each PLC system shall accommodate two power supply feeds. The primary feed will be from Seller's UPS and the secondary feed will be from Buyer's unregulated AC.

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2.4.2.3 The PLC processor and its auxiliary devices (power supplies, I/O racks, etc.)shall be mounted in a cabinet compatible with its environment. The enclosurerating shall be per Section 2.2.1.

2.4.2.4 PLC's required to be networked by the parent technical specification/ materialrequisition shall be equipped with necessary modules to connect to the PLCNetwork per Appendices D and E.

2.4.2.5 Ethernet connectivity from the PLC Operator interface shall be provided to acommon Buyer supplied Ethernet LAN. The PLC shall be capable of beingnetworked according to the requirements of the parent technicalspecification/material requisition.

2.4.2.6 Seller shall utilize Buyer assigned addressing for any PLC and any remote I/Oor other device connected to PLC bus.

2.4.2.7 Buyer will establish protocol and tag numbering upon contract award.Instrument and DCS tag numbers shall be shown on all applicable documentsand drawings (Le., ladder logic, logic diagrams, schematics, etc.).

2.4.2.8 The system shall provide on-line system diagnostics to detect, identify, andalarm any malfunctioning module or malfunction within the system.

2.4.2.9 All components shall be shielded against electrical noise, Radio Frequency(RF) interference, and heat. Any limitations shall be clearly indicated on theaffected equipment and in the engineering documentation.

2.4.2.10 Provide for equipment heat dissipation without forced ventilation.

2.4.32.4.3.1

2.4.3.2

2.4.3.3

Processor and System

The processor(s) shall be in accordance with Appendices A and D. Thesoftware for PLC shall be from the PLC manufacturer.

Communication links with the plant DCS system and/or the main control roomPLC-HMI shall be provided via Ethernet interface as shown on Appendices Dand E.

A minimum of 20 percent spare user memory shall be provided.

2.4.4 I/O2.4.4.1 All I/O points shall be pre-wired to interposing terminal blocks. Where I/O

chassis are located in motor control centers, the terminals in the startercompartments shall be defined as interposing terminal blocks.


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(MR1 & MR2) The silo, chemical feed and dewatering equipment shall have local I/O racks to communicate into the main HMI in the water treatment control room. The dewatering equipment will be provided with a local HMI (10 inch monitor panel) communicating into the main HMI. The local dewatering HMI Panel shall have the same graphics and screens as the main HMI. The remote I/O and PLC processes/HMI shall be in accordance with the requirements of this specification. Local I/O rack shall be provided by area. Local I/O rack shall be provide for the following areas at a minimum: Sludge Dewatering Area, Chemical Feed Area, Lime Silo, Soda Ash Silo, Raw Water PreTreatment Equipment Area (MR1 only), Fluoride Removal Equipment Area (MR2 only)

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2.4.4.2 Digital input modules will be rated for up to 120V AC isolated or non-isolated.Minimum isolation between input and logic voltage shall be 1500 V rms. Eachinput shall have an LED to indicate on/off status. Digital inputs to the PLC shallbe individually fused. Digital inputs shall not exceed 16 per card, except whereagreed to by Buyer.

2.4.4.3 Digital output modules will be rated up to 120V AC isolated or non-isolatedsolid state with sufficient ampacity to handle normal inductive loads found inthe facility, such as motor starter coils and solenoid valve coils. Advise and sostate if the inductive devices require arc suppression. Outputs shall have anLED to indicate on/off status and blown fuse condition.

2.4.4.4 Digital output signals from the PLC shall be individually fused in the controlsystem. Digital outputs shall not exceed 16 per card, except where agreed toby Buyer. The system shall be capable of providing normally open andnormally closed contact outputs.

2.4.4.5 Analog input signals to the PLC shall be isolated, and individual channels shallbe either current limited or fused. Analog inputs shall not exceed 16 per card.The system shall provide quality checks for all analog inputs. Data shall beautomatically tagged as bad on all displays or logs if the input value is out ofrange. System accuracy shall not exceed 1% of calibrated range (excludingtransmitter).

2.4.4.6 Analog output signals from the PLC shall be isolated, and individual channelsshall be either current limited or fused. System accuracy shall not exceed 0.50/0of output signal range (excluding final element). A maximum of 16 points percard is permitted.

2.4.4.7 If the I/O modules individual internal fuses are not readily accessible, or cannotbe replaced without taking the entire module out of service, then external fusesshall be provided. These fuses shall be coordinated with the internal modulefuse and sized to blow before the internal fuse. Fuses shall be equipped with ablown fuse indicator.

2.4.4.8 Provide at least 15 percent installed spare I/O points of each type used and 15percent installed spare intermediate terminal blocks. In addition, cabinets shallbe furnished with at least 100/0 spare card slots in every card cage and 200/0 ineach cabinet for future use.

2.4.4.9 Any redundancy provided in mechanical equipment shall be maintained by theI/O assignment of the PLC system. Redundant equipment (i.e. pumps, valves,etc.) I/O shall be spatially separated on different I/O cards and preferably ondifferent I/O racks/channels.



2.4.4.10 The PLC shall be assigned such that each controller will not be more than 700/0loaded for the processing of all its I/O, control and monitoring functions.Control loop processing time shall not exceed 250 msec.

2.4.52.4.5.1

2.4.5.2

2.4.5.3

2.4.5.4

2.4.5.5

2.4.5.6

ProgrammingAll initial programming and programming changes in the controller system shallbe by Seller.

All necessary tools (computer hardware, including computer(s) andcommunications adapters) and one copy of all licensed software necessary forall programming and configuration tasks shall be provided with Buyer'sapproval. These shall be equal to or better than the tools used by Seller toaccomplish the initial configuration and programming of the system. Theprogramming software shall be suitable for on-line, remote (via Ethernet) or offline configuration. If used by Seller prior to shipment, all software licenses shallbe transferred to Owner at or before the time of shipment of the processor tothe jobsite.

The control system will have the capability of recording from memory to harddrive, to load memory from hard drive or CD as required, and to verify memoryagainst the data in the hard drive. The hard drive and CD drive shall beprovided as an integral part of the PLC programming computer.

Outputs shall fail off, and the system operation will fail safe (to a zero state)upon loss of I/O rack power, loss of communication with their processor, or anyother fault detection that could inhibit proper output reaction to processrequirements. Diagnostic alarms shall be configured for each condition.

All programming and monitoring equipment shall be able to be connected ordisconnected with the controller in operation. The controller, including outputdevices, shall shut down in an orderly manner and alarm in the event of adisruption of program execution or scan, a loss of logic power, loss ofcommunication between controller essential devices, or a memory error.

A password shall be required for modification to each program. This passwordshall be user defined and user changeable. The password(s) in use by Sellershall be given to Buyer upon delivery of the system.

2.4.6 PLC Local HMI2.4.6.1 The seller shall provide at least one HMI (operator interface) to be located in

the field, unless specified otherwise in the parent technicalspecification/material requisition, to facilitate local operation and maintenance.

2.4.6.2 The Local HMI shall consist of a 21 inch (525 mm) monitor with keyboard,trackball or mouse and CPU, or equivalent membrane panel display. Displays


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shall be capable of being read in all lighting conditions, and provision shall bemade for screens exposed to direct sunlight, either by tilting of the screen orappropriate sunshade or other method.

2.4.6.3 The local HMI shall be capable of functioning as an engineering workstationand as an operator station

2.4.6.4 All controls shall be controlled by video-based HMI(s) that interface with thePLC. Seller shall provide a complete package of instrumentation and controlsto:

• Include automatic control with interlock functions to minimize operatoractions,

• Semiautomatic operations for the plant with control interlocks, and

• Manual operation for performing startup, operation and shutdownfunctions, with sufficient interlocks to prevent unsafe operation.

2.4.6.5 The graphic displays shall include the flow diagram for the entire system.Graphics shall be built using guidelines provided by Buyer. These guidelinesspecify the different colors used to identify different functions. All equipmentand instruments with status indication and analog values shall be representedon the graphic display flow diagrams at the appropriate points. The graphicsshall be sufficient for complete system startup, control, monitoring, trending,and alarm summary and shall clearly identify the following as a minimum:

• Valve status (open, close, % open for control valves, or in travel for openclosed valves). Fail to open or close shall be indicated by change incolor.

• Pump status (on/off/trip)

• Fan or Blower status (on/off/trip)

• Analog values (Le., temperatures, pressures, flows, tank levels, analyzervalues, etc.) Analog signals shall display bad quality for signals whichare out of range.

• Indication of permissives and trips

2.4.6.6 In addition to the graphic displays, provide trend displays for all of the analogvalues (e.g., pressure, conductivity, pH, temperature, flow, etc.) required by theparent technical specification/material requisition. The system shall permit theoperator to view trends in time frames from 1 minute to 30 days. HMI graphic



displays shall be sufficient for complete system start-up, control, monitoring,trending, and alarm summary.

2.4.6.7 Failure of the PLC or HMI shall transmit a "PLC System Trouble" alarm toBuyer's control system through an isolated dry contact. Seller shall add alarmsas deemed necessary, but shall suppress alarms on idle equipment toeliminate nuisance alarms that may misguide either the local or control roomoperator.


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PART 3 - DOCUMENTATION

3.1 To maintain compatibility with Buyer's numbering system, Buyer will assignone or more system designators and a block of instrument loop numbers forSeller's use. Identification of instruments shall be per Appendix F.

3.2 Seller's drawings shall be appropriately cross referenced to facilitate locationof components on multiple drawings.

3.3 The parent technical specification/material requisition specifies thedocuments to be provided in the Document Submittal Requirements (DSR)section. This section details the requirements applicable to documents listedin the DSR. Note that not all documents listed below will necessarily berequired by the DSR; such documents are not considered in Seller's scope ofsupply.

3.3.1 Electronic copy (CD ROM, DVD, or HDDVD) of instrument index identifyingall instrumentation provided by Seller. (Refer to Appendix B for requirementsfor the Instrument Index.)

3.3.2 Completed instrument data sheets per ISA-20 or equivalent (Appendix G).

3.3.3 Control panel/cabinet general arrangement drawings, including overalldimensions, instrument layout, terminal block identification, mounting details,cable entry points, assembly weight, environmental restrictions, and panel billof materials.

3.3.4 Complete back-of-board point-to-point wiring diagrams showing all wiring,instruments, and devices in their relative physical relationship, including theinterconnecting wire numbers on the terminal blocks.

3.3.5 Schematic diagrams, including the location of all devices when mounted inseparate locations, and contact development for all control switches.

3.3.6 Connection diagrams showing interconnecting wiring among all Sellersupplied equipment. Seller shall identify terminals that interface with otherequipment.

3.3.7 External wiring, tubing, and piping diagrams showing terminal block details,layout for termination of field wiring, and location of process connection for allinstruments (hook-up drawings).


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Specification 25316-000-3PS-JQ07-00001 J Revision 000

3.3.8 Details of prefabricated cables, including minimum bending radius, maximumpulling tension, maximum permissible sidewall pressure, overall connectorsize, and connector details.

3.3.9 Installation requirements for loose-shipped instrumentation.

3.3.10 Piping and instrument diagrams (P&IDs) showing the complete system,including mechanical equipment, piping, valves, ductwork, instrumentation,and controls. Also include instrument and equipment tag numbers, equipmentnames, direction of flow, identification of Buyer/Seller interface ofcomponents furnished by others. Pipe and duct sizes shall appear on P&IDsunless shown on other drawings. Use drawing standard ISA-5.1-1984(R1992) - Instrument Symbols and Identification, for instrument symbols onP&IDs.

3.3.11 A detailed technical description of theory of operation and all sequentialoperations must be provided for all systems.

3.3.12 Listing of all input and output signals associated with the control package withinformation on tag name, service description, process range, process units,voltage level, and signal range, as a minimum.

3.3.13 Listing of all input and output signals available through the DCS interface withtag name, service description, information on rung or register location, signalranges, state descriptors, process range and process units, as a minimum.DCS interface address list shall be in consecutive order.

3.3.14 Electrical power distribution, single line and three line diagrams of Seller'ssupplied equipment.

3.3.15 Block diagrams or functional control diagrams showing the function ofequipment supplied and its component parts of Seller's supplied equipment

3.3.16 Detailed Bill of Material including name of manufacturer and model number ofall components of Seller's supplied equipment

3.3.17 Time-current curves (original and full size copy) for protective relays, auxiliaryrelays, and circuit breakers of Seller's supplied equipment

3.3.18 Nameplate schedule for transformer- rectifiers, etc.

3.3.19 Circuit and raceway schedule of Seller's supplied equipment includinginterconnecting wiring between Seller supplied skids or components.

3.3.20 Instruction manuals covering basic design principles, theory of operation,operational adjustment, maintenance, troubleshooting, repair, site storage,installation, and start-up. Manuals shall include reduced copies of final



drawings for all appropriate system documentation, such as P&IDs, electricalschematics, logics, and functional drawings, etc.

3.3.21 Catalog data on all components furnished. Use symbols and method ofdrawing presentation in accordance with NEMA ICS 1, Industrial Control andSystems General Requirements.

3.3.22 Recommended start-up spare parts list detailing items that should be availableduring commissioning and a recommended one year spare parts list detailingitems that should be available for one year of operation.

3.3.23 PLC specific documentation (application only if PLC provided):

3.3.23.1 Network Diagram - This diagram shall be the basis from which the rest of thesystem is developed. It shall show all of the system cabinets (includingprocessor, liD racks, modules, power supplies, spare liD, etc.) communicationcable connections, connector termination details, power requirements, andpower distribution. Any DIP switches that require settings shall be indicated onthis drawing. The manufacturer and catalog numbers shall be shown for eachcomponent.

3.3.23.2 liD Wiring and Connection Diagram - These drawings shall show all internalcabinet wiring and connections. I/O cards shall be shown with themanufacturers' part number, the liD rack and slot number in which the moduleis located, the devices connected to each terminal of the module, and point topoint wiring of each termination.

3.3.23.3 Cabinet Wiring Drawing - These drawings shall show outline dimensions of allequipment, equipment mounting details, required clearances, weights, cableentry areas, terminal block arrangements and rack locations.

3.3.23.4 Program documentation - Documentation in any of the IEC 61131-4programming languages is acceptable (viz. instruction list, structured text,ladder diagram, function block diagram or sequential function charts). Thisdocument provides system programming in completely annotated form. Theprintout shall contain program title block, address labels and descriptions, andline comments describing each line or loop function. An address crossreference report shall also be included. Printed hard copy and electronic fileson a CD ROM, DVD, or HDDVD media are to be provided.

3.3.23.5 Listing for data interface to DCS. Seller shall provide cross-referenced blocktransfer lists with addresses or other suitable format for documenting the datainterface to the DeS.

3.3.23.6 System logic and functional control diagrams showing functional operation ofthe system.



3.3.23.7 Graphic display diagrams, including definitions of colors used, changeablefields, poke fields, point identification, etc. For systems that do not havegraphic display, diagrams need to be provided that pictorially depict theequipment and identify the associated data available through the DeSinterface.

3.3.23.8 Graphic display hierarchy including relationships between diagrams forpaging, etc.

3.3.23.9 Seller shall identify all alarms available to the operator on applicabledocumentation.

3.4 Seller shall include Buyer's instrument and equipment tag numbers on alldocuments as applicable.

3.5 Seller shall identify the electrical load requirements (peak and continuous) foreach power source.

3.6 Seller shall identify the air consumption (peak and continuous) for eachinterface point.

3.7 Seller shall identify the heat loads produced by equipment to be installedindoors.

3.8 Seller shall submit a factory test plan and test reports for review.



PART 4 - INSPECTION AND TESTING

4.1 Seller shall pressure test in his shop all pressure-containing componentsexcept pneumatic devices for 5 minutes at 1.5 times design pressure with nodetectable leakage. Use dry, oil-free air or nitrogen if working fluid is a gas.

4.2 Seller shall verify the calibration and operability of each device inmeasurement and control systems involving electronic or pneumatictransmission by applying a simulated input signal over the full range. Allinstrumentation shall be supplied with factory calibration certificates. Sellershall provide separate calibration certificates and data for all instrumentsrequired for the performance testing specified in the parent technicalspecification/ material requisition.

4.3 Seller shall test relays, switches, and lamps in accordance withmanufacturer's standard test procedure.

4.4 Seller shall perform a functional test of each circuit by actuating associatedcontrols, disconnects, and breakers.

4.5 Seller shall perform a 1DO-percent point-to-point continuity test for Sellerinstalled wiring.

4.6 Insulation and clearance to ground shall be such that the live parts, exceptsolid state and microprocessor devices, will withstand a high potential test ofnot less than 2200 volts, 60 hertz for 1 minute.

4.7 Software logic for programmable devices shall be factory tested prior toshipment to verify proper functionality, to verify proper field contact sense andsignal levels, and to verify preset trip points and timer settings. Any and alltemporary logic or modifications made for testing shall be documented andremoved from the system prior to shipment.

4.8 PLC Inspection and Testing (if PLC provided)

4.8.1 Perform a complete shop test, witnessed by Buyer's engineer, of the entirePLC system prior to shipment. Tests shall include, but are not limited to,complete testing of I/O, graphics/HMI functionality, logic and modulatingcontrol. All tests shall be performed with the data highway fully connected asper application distance. Advise Buyer at least two weeks in advance thatthe system is ready for witnessed tests.


Page 33 of 34

4.8.2


Provide full simulation of system diagnostics, redundancy, security, and I/Omodules.


Page 34 of 34

Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix A

APPENDIX A - APPROVED MANUFACTURERS LIST

CONTROL SYSTEMS

Pneumatic Analog

DCS

Programmable Controllers

FIELD INSTRUMENTS

Electronic Transmitters (Pressure

and Differential Pressure)

Flow Meters (magnetic, vortex)

Flow Meters (variable area)

Flow Meters (Ultrasonic)

Flow Meters (Turbine)

Flow Meters (Mass)

Flow Glass

Pneumatic Controllers (Local)

liP Converters

Conductivity Instruments

pH Instruments

Dissolved O2

MANUFACTURER

Emerson (Fisher), Foxboro, Siemens, Moore

ABB (Bailey), Emerson (Ovation), Invensys(Foxboro)

Rockwell (Allen-Bradley ControlLogix)

Emerson (Rosemount 3051 series smarttransmitters with ASME B31.1 Coplanar

style integral manifolds)

Foxboro, Emerson (Rosemount), Endress &Hauser, Krohne

Krohne, S&K Automation, Emerson(Brooks), ASS (Fischer & Porter), US Filter(Wallace & Tiernan), Schutte-Koerting

Magnetrol, Krohne, Siemens (Controlotron)

Emerson (Daniel), Badger, Flo-Tech

FCI, Sierra, Emerson (Rosemount)

Universal Flow, Penberthy

Emerson (Fisher), Foxboro

Emerson (Fisher 546), Moore Industries,Masoneilan I/PEX 9000

Honeywell, Thornton-Mettler, Emerson(Rosemount Analytical), Hach (GLI)

Honeywell, Thornton-Mettler, Emerson(Rosemount Analytical), Hach (GLI)

Emerson (Rosemount Analytical)


Page 1 of 4

Sodium Instruments

Silica Instruments

Level Controllers or

Transmitters (Displacer Type)

Level Instruments (Ultrasonic)

Level Probes, Capacitance

Level Switches (Conductivity)

Level Switches (Displacer/ Float Type)

Level Gauges

Level Gauges, Magnetic

Moisture Analyzer

Flow Nozzles

Orifice Plates

Pitot Tubes

Pressure Switches

Pressure Gauges

DP Switches

DP Switches (Low Pressure)

DP Indicators

RTDs, Thermocouples, Thermowells

Temperature Switches

Temperature Transmitters

Thermometers (Dial Type)


Thermo Scientific (Orion)

ASS, Hach, Waltron

Emerson (Fisher), Magnetrol

Magnetrol, Siemens Sitrans L, Endress &Hauser

Emerson (Rosemount), Magnetrol, EndressHauser

Solartron-Mobrey

Magnetrol, Emerson (Fisher), Static-O-Ring

Penberthy, Jerguson

Magnetrol, K-Tek, Orion

Emerson (Fisher Rosemount), Panametric

Fluidic Techniques, Emerson (Daniel)

Fluidic Techniques, Emerson (Daniel)

Emerson (Rosemount), Veris

Static-a-Ring, Dwyer (Mercoid), UnitedElectric, Ashcroft

Ashcroft, Ametek (US Gauge), WIKA

Dwyer (Mercoid), Ashcroft, Nuflotech(Barton)

Dwyer

Ashcroft, WIKA

STI, Pyco, Daily Thermetrics, Ashcroft

Static-a-Ring, United Electric, Ashcroft ,Watlow

Emerson (Rosemount)

Ashcroft, Palmer Wahl, Ametek (Rochester)


Solenoid Valves

Limit Switches

CONTROL VALVES

General Service

Severe Service

Desuperheaters

Turbine Bypass/ Steam ConditioningValves

Metal Seated Ball Valves

Butterfly

Diaphragm

Regulators (Self-Contained)

Positioners

CONTROL PANEL DEVICES

Indicating Lights

Vertical Indicators

Annunciators

Strip Chart Recorders

Multipoint Recorders

Control Switches


Emerson (ASCo), Leslie (Laurence)

NAMCO, Honeywell (Microswitch), GOSwitch

Emerson (Fisher), Flowserve (Valtek),Samson (W&T), Masoneilan, Leslie

Emerson (Fisher), CCI, Tyco (Sempell),Masoneilan, Copes-Vulcan SPX, Leslie

Emerson (Fisher), CCI, Tyco (Sempell,Narvik, Yarway), WEIR (Blakeborough), SPX(Copes-Vulcan), Samson (W&T)

CCI, Samson (W&T), Emerson (Fisher),Tyco (Sempel), Masoneilan (AuXiliary Steamservice only), SPX (Copes-Vulcan steamatomizing designs only)

Valve Technologies, Mogas, Metso, Velan

Fisher, Metso, Masoneilan, Tyeo

ITT (Grinnell-Saunders), Crane, Flowserve

Emerson (Fisher), Masoneilan, Cashco

Emerson (Fisher DVC), Masoneilan (Smart)

GE, Eaton (Cutler Hammer), Rockwell(Allen-Bradley)

Hach (Sigma), Ametek (Dixson), Yokagawa

Ametek (Panalarm Series 90)

Honeywell, Yokagawa, Chessell

Honeywell, Yokagawa, Chessell

Eaton (Cutler Hammer), Eleetroswitch,Rockwell (Allen-Bradley), GE


Page 30f4

Transducers, Electrical

MISCELLANEOUS DEVICES

Vibration Monitors

Tube Fittings

Instrument Valves

Time Delay Relays

Opacity Monitors

In Situ Oxygen Monitors

S02, NOx, CO, C02 Monitors

Signal Conditioners

Terminal Blocks

Instrument Filter-Regulators

Instrument Manifold Valves

Starters

Auxiliary Relays

Circuit Breakers

Pushbuttons

Indicating Lamps


Ametek (Rochester)

Bentley Nevada

Parker-Hannifin A-10k, Swagelok

Swagelok (Whitey, Nupro), PGI, ParkerHannifin, Anderson-Greenwood

Tyco (Agastat SSA)

Teledyne (Monitor Labs), Durag, AmetekLand Inc.

Teledyne (Monitor Labs), Emerson(Rosemount), Yokagawa COSA

Teledyne (Monitor Labs), TECO, API,

Emerson (Rosemount)

Moore, Ametek (Rochester)

Marathon, Weidmuller, GE, Phoenix, State

Emerson (Fisher 67FRA), Norgren

Anderson Greenwood & Co

Rockwell (Allen-Bradley), GE, Schneider(Square D), Eaton (Cutler-Hammer)

Tyco (Potter Brumfield), Rockwell (AllenBradley)

Eaton (Cutler Hammer), Schneider (SquareD), GE

GE, Rockwell (Allen-Bradley)

GE, Rockwell (Allen-Bradley)


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix B

APPENDIX B • REQUIREMENTS FOR INSTRUMENT INDEX

1.0 INSTRUMENT INDEX

Seller will be furnished with a CD ROM or DVD of the Buyer's Instrument Indexdatabase. This database shall be used to develop an Instrument List to describethe instruments furnished by Seller.

2.0 COMPUTER SYSTEM REQUIREMENTS

The Instrument Index database files are designed for use on a personal computerwith Windows 98 or higher operating system and application software. Thedatabase is compatible for use with Microsoft's Access version 7.0 or may beconverted for use with other widely used spreadsheet or database programs. It ispreferable that the completed database file is returned in the Access format.

3.0 DATA FIELDS

The minimum required Instrument Index data fields are as described below. Sellershould complete all applicable fields. When information is not available, the fieldshould be left blank. Non-applicable fields should be completed by entering "N/All

"',

SE'OUENCENUMs'ER

Field Name

REV

UNIT

FUNCTION CODE

SLJFFIX"

Max. Definitions & Explanation of Content Instru- ControlLength ment Valves

3 .This is theJevisiqhdf?Y~hgf~P&>lml:~Qtry~.~rl,~<:' ..' .. : .~ .. \:k'i.: '<':';','.":. :'.

,'~~a~~; '~e~~lb~t~9m~;la"i~~II'~ii¥:,;{@; '> ~., " x:instrument list is' b~ingsu~rnltf~\d:,lr.sH~U'be;'.(;/',. ,,/;';:. ".::'entered as nUnieric;O~9;' .. ", ""';';' :"::.:!~ ".' .... ,>/: ,: ::T'}':

..,. ......,';".,,>,' •• i; J;:,:":;}<i"/.;, ..;,;',; "",. ;;:::;'

2' Suffix



TAG 24 Tag number (Bechtel Assigned)This information is generally provided as aBuyer comment on the Preliminary submittalof the Seller's drawings/documentation.Contains a 2-letter system designation,followed by a 2 or 3-letter ISA function X Xdescription, and a sequential loop number.Digital points are tagged in a similarconvention. This number is formed from thecatenation of the following fields.

VENDOR 8 Seller Name or Initials.X X

VEND TAG 20 Vendor Tag-Where vendors have there own specific tagsalready allocated and cross-referenced in

X Xother documentation, they may be enteredhere.

PID 24 The piping and instrument diagram/drawingon which the instrument appears. Use theBuyer assigned vendor drawing numberafter the first P&ID submittal (e.g., 22803-o15-M6-XXXX, where "XXXX" is the drawingnumber.

This shall reference either the P&ID or X X

process flow diagram on which theinstrument is shown. If shown on more thanone type of document the P&ID shall takepreference and reference to other drawingsshall be indicated in the "NOTE" field.)

PIO REV 4 Current P&ID revisionX X-

DESCR 1 16 Description specifying primary-service/function of the item.This is a short, unique-to-the-deviceidentification, which describes the device or X Xinstrument purpose (e.g., Main FeedwaterFlow, Main Steam Temperature, etc.)

DESCR 2 16 For process and alarm switches, the-description shall indicate the processcondition when contact is closed. Forexample, a low-level alarm switch (open to X Xalarm) should read "XXXX Tank Level NotLow".



MANUFACTURER 25 Inst/Valve ManufacturerManufacturer of component or instrument,

X Xand not necessarily the Seller of the system.

MODEL NO 50 Manufacturer's model numberX X

DATA SHEET 24 Vendor's data sheet numberRefers to ISA data sheet or specificationshowing calibration, range, material, etc.Use the commodity code group and Buyer'ssequence number assigned to the Seller'sdocument after the first submittal (e.g.,

X X22803-015-JXX-XXX, where "JXX" is thecommodity code group and "XXX" is thesequence number). This number shall beprefixed by a "V" when entered in theappropriate data field (e.g., "VXXX").

LOWER RANGE VALUE 12 Lower range value of the calibrated range of- -the instrument. X

UPPER RANGE VALUE 12 Upper range value of the calibrated range of- -the instrument. X

SCALE UNITS 10 Engineering units for applicable device (e.g.,of, psig, etc.) X

SIGNALLEVEL 15 Signal level (e.g., 4 to 20 mA, etc.)X

SIGNALTYPE 25 Signal type description (i.e. electric,pneumatic) X

ALARM LOW 12 Alarm low level setpointX

ALARM LOW LOW 12 Alarm low-low level setpointX- -

ALARM HIGH 12 Alarm high level setpointX

ALARM HIGH HIGH 12 Alarm high-high level setpointX- -

CONTROL SETPOINT 12 Control setpointX

DPRESS 12 Design PressureX X

DTEMP 12 Design TemperatureX X

NPRESS 12 Normal PressureX X



NTEMP 12 Normal TemperatureX X

INST LOC 25 Location of InstrumentVendor drawing showing plan and elevationof the instrument physical process taplocation. This number shall be prefixed by a"V" when entered in the appropriate data X Xfield (e.g., "VXXX").Indicate drawing number showing instrumentlocation

INSTALL DTL 24 Installation Details-Vendor drawing number showing installationdetails of how to install, mount, support,tube, and wire the instrument. This numbershall be prefixed by a "V" when entered in

X Xthe appropriate data field (e.g., "VXXX").

For valves reference to installation guidesand documentation must be indicated.

NOTES 90 Additional reference drawings etc.

REMARKS 100 Remarks or comments. This field is to beused to provide amplifying information onthe equipment under the Seller's scope ofsupply. Typical information would includespecific installation information or storageand calibration information.

POWERYN 1 Is external power required (default N).X X

PURCHASE ORDER 25 Purchase Order number:The purchase order under which Bechtel

X Xpurchased this equipment.

L1NECTN 24 Line Number.X X


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix C

ORIENTATION OF INSTRUMENT CONNECTIONS FOR HORIZONTAL LINES

ALTERNATIVE

PREFERRED

PREFERRED

ALTERNATIVE

AIR OR GAS

PREFERRED

ALTERNATIVE

PREFERRED

PREFERRED

ALTERNATIVE

STEAM,VAPOR,AIR, OR GAS

PREFERRED

HIGH TEMP. FLUIDS OR GAS ABOVE 750°F

JOB NO. 25316

ALTERNATIVE

LINE FLUID

STEAM OR VAPOR

ALTERNATIVE

ENERGY

PREFERRED

PREFERRED

PREFERRED

SLURRYONLY

STATE

ALTERNATIVE *

I

LIQUID OR SLURRY

ALTERNATIVE* - ORIENTATION FOR CLOSE COUPLEDPRESSURE GAUGES IN HORIZONTAL PIPEONLY.

PRAIRIECAMPUS

PROJECT

W0:::::>I-

~W0....~ NOTE*~ THIS ORIENTATION FOR TEMPERATURE

INSTRUMENTS WILL NOT APPLY IF THEPIPE DIAMETER IS SMALL AND REQUIRESA TEE OR ELBOW TO BE USED.

PREFERRED

BELOW 750°F ALL FLUIDS

~ LIQUID OR SLURRYCO«0::: ALTERNATIVE~ 00 (PREFERRED FORo ~ SLURRY ONLY)

W --J0::: «~ ~ PREFERRED«W~ NOTE*

FOR pH AND CONDUCTIVITY PROBES REFER TOMANUFACTURER GUIDELINES FOR ORIENTATION

ORIENTATION OF INSTRUMENT CONNECTIONS FOR HORIZONTAL MAIN-LINES

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~OJc..+-'XCw(1)CI)Cl)C-"- a(1)0:3:coc])t:~O'C.n~

w>..cc+-'roc>.0.n

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£~w c..c.. c])00"-Xc..c])w"'O.ec])+-'CI)(1)::J"ro"-aCI) •"-"'0C])C])>0'-0~

+-' .e.- xcwOJ _.- "'CCl)c])w c"'Oroc])o.c-+-' -"'0"'0c.~roc..+-'0C0Q) E"C::JQ)000::J

"'C"CaCI)".- c...eQ)1-"-


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix D

APPENDIX D - PLANT PROGRAMMABLE LOGIC CONTROLLER (PLC) NETWORKREQUIREMENTS

a. Seller shall provide PLC interfaces as described in this section to interface with the plantEthernet network. A Buyer supplied link between the plant PLC Ethernet network and the Buyer'sDCS will permit the transmission of data from the PLC to the DCS for supervisory control, trending,and historical archiving.

b. Design, configure, and provide controls to permit supervisory control via the interface to theDCS such as, but not limited to, initiating automatic operation, alarm monitoring, processindication, and process data trending as described in the following paragraphs. In addition,configure the interface and logic so that, at a future date, component level control from the DCS ofthe packaged equipment can be implemented.

c. The Buyer's distributed control system (DCS) will provide commands to initiate automaticsequential programs by interfacing with the Seller-supplied programmable logic controller basedcontrol system, which is responsible for all direct control of the packaged equipment. The DCS willnot contain process logic for the packaged equipment. Individual selection of each component willbe initiated from the PLC human-machine interface (HMI). In the future, the DCS may beconfigured to prOVide the commands to initiate functions such as start/stop, open/close at theindividual component level.

d. The Seller provided PLC shall be the Allen-Bradley ControlLogix system programmed basedon the RS Logix 5000 full edition package (version of software shall be approved by the Buyerduring detail design) and the HMI graphics shall use Allen-Bradley RSView Supervisory Family ofsoftware (SE Server RSLINX Bundle and SE Client with Buyer approved version).

e. Where redundant PLC control processors are specified in the parent technicalspecification/material requisition each shall interface to the redundant plant PLC Ethernet network.

f. Provide HIRSCHMANN Managed Ethernet switches for interface between single or redundantControlLogix PLC and the HMI. The switch shall include Fiber Optic Single mode SC connectionfor the Buyer's remote access. Self-diagnostic Ethernet alarm message generated by the switchshall be configured to automatically show up in the alarm summary display of the HMI. Fiber opticcable will be by Buyer. Detailed addressing etc. will be provided during detailed design.

g. The control logic configuration in the Allen-Bradley ControlLogix PLC shall use ISA type ofpoint name instead of address only.

h. The Seller shall interface the PLC systems to an HMI in the main control room (supplied andinstalled by the Buyer) which is shared between plant PLCs via the plant PLC Ethernet which willprovide the control room operator with operating and engineering functions normally available atthe local HMI. This will include accommodating network addressing and providing a version of theoperating graphics in a form that will run on the control room HMI.

i. Equip the PLC with local HMI(s) to support commissioning and local operation andmaintenance. If operator intervention is required, either the PLC HMI in the main control room or 'the local HMI will be used.


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix E

APPENDIX E

[PROJECT PLC SYSTEM NETWORK DIAGRAM WILL BE PROVIDED DURING DETAILDESIGN PHASE]


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix F

APPENDIX F - INSTRUMENT TAG CONVENTIONS

1.0 Each instrument is to have a unique instrument tag number.

2.0 The Buyer's instrument tag number consists of several elements, as thefollowing example illustrates:

AB-PT-011-A

Where:

AB = System identifier

PT = Instrument functional identifier

011 = Instrument loop number, common to related instruments in asingle 'loop

A = Alpha suffix: parallel, redundant or multiple device identifier

3.0 Instrument tagging conventions are in general conformance with ISA StandardS5.1, with specific modifications as shown on drawing 25316-000-M6J-YA-00005and -M6J-YA-00006, Symbols and Legends for Piping and InstrumentationDiagrams.

4.0 Instrument tags for packaged mechanical systems are to be assigned by theBuyer and incorporated by the Seller.

5.0 Bechtel standard system identification codes shall be used.

6.0 All instruments in a single loop should share a common loop number.

7.0 Loop numbers should start with 001 in each system. Therefore, the systemdesignation, instrument type (functional identifier), and loop number are allnecessary to uniquely define a device.

8.0 Loop numbers should be assigned in a logical manner to assist in determiningthe portion of the system served by the instrument.

9.0 For systems where various Sellers will supply instruments, the Buyer will allocatea block of loop numbers for the use of each individual Seller. This allocation ofloop numbers will be tabulated by system in the instrument index.

10.0 The instrument functional code shall generally follow the function of theinstrument, not its construction. That is, a pressure transmitter monitoring level


Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix F

in an atmospheric tank shall be tagged LT, and differential pressure transmitterssensing flowmeter differentials shall be tagged FT.

11.0 The use of a suffix after the loop number applies as follows:

• Redundant measurements: Differ only in suffix, e.g., three furnacepressure transmitters, BA-PT-001A, -0018, -001 C.

• Parallel equipment: Follow the mechanical equipment suffix designation,e.g., discharge pressure for two de-mineralizer feed pumps, AN-P-01 Aand B; tags may be AN-PI-003A and -0038; for pumps -P04 and -P05,use separate loop numbers without a suffix.

• Multiple measurements for a single component: DO NOT use a commonloop number with a suffix to differentiate between different measurementson the same component, e.g., instruments sensing suction and dischargepressure on a pump should have different loop numbers.

12.0 Each instrument shall be tagged with a non-corroding metal tag as shown inAppendix D. Panel-mounted equipment is an exception to this requirement.Panel-mounted devices shall be identified with nameplates in accordance withAppendix E.


Page 2 of 2

Specification 25316-000-3PS-JQ07-00001, Rev. 000Appendix G

APPENDIX G - INSTRUMENT DATA SHEETS

1.0 The Seller shall complete instrument data sheets for all instruments and controldevices, including control valves, supplied within the Seller's scope.

2.0 Appropriate blank data sheet electronic files (typically in MS Excel format) will beprovided to the Seller by Bechtel after the required data sheets are determinedand requested by the Seller. The Seller may submit data using this format oranother, equivalent, format such as ISA or vendor standard data sheets,provided an acceptable level of detail is provided.

3.0 Should the Seller choose to use Bechtel data sheets, and should the formatsprovided not apply to any instruments in the Seller's scope, Bechtel will provideappropriate blank data sheets, or, should the required data sheet not exist inBechtel's library, instruct the Seller to prepare a data sheet using the Bechtelformat.


technical specification for instrumentation controls and electrical requirements

Documents

system requirements

design requirements

parent specification

instrument valves

instrument locations

control wiring

control valves

seller shallbe responsible