technical specifications hh-935a division 16: electrical

TECHNICAL SPECIFICATIONS HH-935ADIVISION 16: ELECTRICAL. 16903: MONITORING AND CONTROL EQUIPMENT

PART 1- GENERAL

1.1 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required, and installcomplete, ready for operation, and test the monitoring and control equipment asspecified in this Section and shown on the Drawings.

B. The work includes but is not limited to the following:

1. Furnish and install Programmable Logic Controller (PLC), includingCentral Processing Unit (CPU), I/O modules, power supplies, localoperator interface(Thin client), circuit breakers and panel, electricaldistribution, inter-wiring, Ethernet network switch, communicationequipment and miscellaneous equipment as specified here in and as shownon the PLC Typical Wiring Schematics drawings. The PLC system shallbe installed inside the control building at Emery and Pelican Crossovers,and as specified in this Section 16903 and shown on the drawings.

2. Furnish all programming necessary for the new PLC's at Emery andPelican Crossovers.

3. Furnish all Ethernet radio programming necessary to ensure data security,IP address configuration, and radio configuration to ensure a reliable,secure Ethernet communication system exists between remote site andMoccasin Powerhouse.

4. All application programs for the PLCs shall be provided completelyfunctional and fully integrated into the system hardware and software. Itis the Contractors responsibility to use his or her appropriate developmentsoftware to ensure compatibility.

5. All WonderWare HMI screens will be developed by Hetch Hetchy Waterand Power, (HHWP), and will be completed for testing prior to systemstaPLCp and checkout.

6. Coordination between contractor and HHWP is essential for proper HMIscreen development and implementation, and is a requirement under thesespecifications.

7. Contractor/Programmer shall provide HHWP all necessary address/Opoint information, Alarm Descriptions, Set Points, and any additionalinformation necessary to make a complete and operational facility when

SFPUC Rev. 0 16903-1 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers

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TECHNICAL SPECIFICATIONS HH-935ADIVISION 16: ELECTRICAL16903: MONITORING AND CONTROL EQUIPMENT

complete.1.2 RELATED DOCUMENTS

A. Drawings and Specifications of Contract, including General and Supplementary

Conditions and Division I Specification Sections, apply to this Section.

1.3 QUALIFICATIONS

A. The System Integrator (SI) shall perform all work necessary to select, furnish,customize, supervise installation, connect, calibrate, coordinate with other Sectionsuppliers and City personnel of the Contract and place into operation all hardwareand software specified within this specified Section.

B. The SI shall be a company regularly engaged in the design, building, installation,and programming of programmable logic controllers and their associatedsubsystems, for process control as applied to the municipal water or wastewaterindustry. The company shall have been doing industrial process control andsystem integration for a minimum often (10) years.

C. The SI shall maintain a permanent, fully staffed manufacturer and equippedmaintenance service facility within 200 miles of the project site with personneland equipment required to build, maintain, and calibrate the systems specifiedherein.

D. Qualified System Integrators are:

1. Tesco Controls, Inc. (916) 395-88002. KBL Associates (510) 887-11173. Fluid IQ (707) 258-84004. Transdyn Control, Inc. (510) 225-16005. E&M (415) 315-3323

1.4 SUBMITTALS

A. Submit shop drawings and product data in accordance with the TechnicalSpecifications and General Requirements of Section 01300. The submittals listedin 1.04B below shall be submitted as required for each sites:

1. Emery Crossover2. Pelican Crossover

B. The submittals listed below are not in chronological order. Control strategy mustbe submitted first before any other documents. Submittals shall include as a




minimum, but not limited to the following:

1. Project Overview2. System Hardware3. Factory Test Procedure4. Installed Test Procedure5. Control Strategy6. Screens7. Panel Connection Diagram8. Data Logging List9. Cutover Plan

C. Project Overview

1. This submittal shall provide an overview of the proposed system includingsystem architecture (block) diagrams, the approach to work, the proposedwork schedule (including milestone dates for proposed meetings betweenthe Engineer and / or HHWP personnel, City Water Supply & Treatmentpersonnel and the SI project personnel), testing, and details of trainingprograms.

D. System Hardware

1. This submittal shall provide complete documentation of the proposedhardware including:

a. Data sheets for each equipment supplied with accessories.b. Descriptive literature for each equipment component which fully

describes the unit being provided.c. Complete block diagram showing the interconnections between

major hardware components and a complete input/output signallisting.

d. A complete conduit riser diagram and conduit schedule shall beprepared and submitted for the interconnection of all equipmentspecified in his Section. The riser diagram and conduit scheduleshall detail conduit identification number, size, wires and location.Where the riser diagram requires either more wires or largerconduits than detailed in the Contract Drawings, the SI shallcoordinate any required changes with the electrical contractorbefore installation begins.

e. Block diagrams for each equipment component showing theinterconnection of all modules and plug in circuit boards.

f. Complete to-scale drawings of all cabinets, panels and consolesSFPUC Rev. 0 16903-3 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



including internal and external layouts.g. A list of all hardware to be furnished and its electrical,

environmental, and performance characteristics.2. The System Hardware submittal shall also contain all planning

information, site preparation instructions, grounding and bondingprocedures, cabling diagrams, safety precautions or guards, and equipmentlayouts in order to enable the Contractor to proceed with the detailed sitepreparation for all equipment.

E. Factory Test Procedure

1. The factory test shall determine the fitness of the PLC Control Panel forshipment to the site.

2. The factory test procedure submittal shall include the step-by-stepprocedure to demonstrate to City witness that each control and monitoringpoint is wired correctly from i/O module to termination block inaccordance with Piping and Instrumentation Diagram (P&ID), controlloop diagrams, and connection diagrams.

3. The factory test procedure submittal shall include step-by-step procedureto demonstrate to City witness that each control and monitoring point isaddressed correctly within the program and functions per the submittedControl Strategy.

4. The format shall include check off and sign off blocks for City witness tocomplete.

F. Installed Test Procedure

1. The installed test shall determine the acceptance of the PLC ControlPanel, HMI local operator interface, remote control functionality, andcommunication system operability.

2. The installed test procedure shall demonstrate all control and monitoringfunctionality of the PLC program.

3. The installed test procedure shall be formatted to step through the controlstrategy, as submitted and accepted, such that each i/O point and functionis demonstrated to be operating correctly.

4. The format shall include check off and sign off blocks for City witness tocomplete.




5. An example of an accepted installed test procedure from a previous Cityproject is included in the appendix.

G. Control Strategy

1. The control strategy submittal shall determine the basis of theprogramming of the PLC functions. It shall be submitted and acceptedbefore any programming is done. It shall be submitted only after anycoordination meetings between HHWP and System Integrator required bythis specification.

2. The control strategy shall be written up in clear segments separating eachfunction. It shall include descriptions of set points, inputs, outputs andinterface with facility equipment within each operating segment.

3. The control strategy shall alert HHWP staff to implications of the differentprogramming methods that may affect function.

4. An example of an accepted control strategy submittal from a previous Cityproject is included in the appendix.

SH. Screens

1. HHWP will develop all screens for facilities included in thesespecifications.

1. Panel connection diagram

1. This submittal shall include detailed wiring diagrams of the PLC controlpanel, showing all interconnection for all components within the controlpanel and interconnection diagrams to all external components that arewired to 1/0 modules.

2. This submittal shall be submitted with all copies in 11" by 17" size sheets.

3. Final submittal is required after conclusion and acceptance of installed testthat includes updated hard copies in 11" by 17" size sheets and CD ofelectronic files. All electronic files shall be in AutoCAD 2004 or later.

J. Data Logging List shall be submitted directly following factory test and fourweeks before installed test is scheduled. The data-logging list is needed for Cityto prepare for installed test; therefore this submittal dictates the date of the


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TECHNICAL SPECIFICATIONS IIH-935ADIVISION 16: ELECTRICAL16903: MONITORING AND CONTROL EQUIPMENT

installed test.

1. Data logging list shall be made on Excel spread sheet.

2. The required columns are:a. Nameb. Descriptionc. Type - A1, AO, DI, DO, Floating Pointd. PLC Register Addresse. PLC Register Bitf. PLC Real World Register Address - PLC Address of the value of

the real world signalg. Engineering Scaleh. Usage or Special Note

ExamplesAnalog DisplaySet Point / ControlReal World I/ODiscrete DisplayAlarm BitsDiscrete Control

i. Units - Ft, PSI, GPM, etc.j. Numeric Rangek. Raw Count

1.5 FINAL DOCUMENTATION

A. The SI shall submit the following final documentation prior to final acceptance ofthe system:

1. As-built documentation of the system.2. Hardware maintenance documentation.3. Operator's manual.

B. The SI final documentation shall be new documentation written specifically forthis Contract, but may include standard and modified standard documentation.Modifications to existing hardware or software manuals shall be made on therespective pages or inserted adjacent to the modified pages. All standarddocumentation furnished shall have all portions that apply clearly indicated. Allportions that do not apply shall be lined out.




C. The manual shall contain all illustrations, detailed drawings, wiring diagrams, andinstructions necessary for installing, operating, and maintaining the equipment.The illustrated parts shall be numbered for identification. All informationcontained therein shall apply specifically to the equipment furnished and shallonly include instructions that are applicable. All such illustrations shall beincorporated within the printing of the page to form a durable and permanentreference book.

D. If the SI transmits any documentation or other technical information which heconsiders proprietary, such information shall be designated. Documentation ortechnical information which is designated as being proprietary will be used onlyfor the design, construction, operation, or maintenance of the system and, to theextent permitted by law, will not be published or otherwise disclosed.

E. The requirements for the Si's final documentation are as follows:

I. As-built documentation shall include all previous submittals, as describedin this Specification, updated to reflect the as-built system. Any errors inor modifications to the system resulting from the Factory and/or FieldAcceptance Tests shall be incorporated in this documentation.

2. The Hardware Maintenance Documentation shall describe the detailedpreventive and corrective procedures required to keep the system in goodoperating condition. Within the complete Hardware MaintenanceDocumentation, all hardware maintenance manuals shall make referenceto appropriate diagnostics, where applicable, and all necessary timingdiagrams shall be included. A maintenance manual or a set of manualsshall be furnished for all delivered hardware, including peripherals. TheHardware Maintenance Documentation shall include, as a minimum, thefollowing information:

a. Operation Information - This information shall include a detaileddescription of how the equipment operates and a block diagramillustrating each major assembly in the equipment.

b. Preventive-maintenance Instructions - These instructions shallinclude all applicable visual examinations, hardware testing anddiagnostic routines, and the adjustments necessary for periodicpreventive maintenance of the system.Special maintenance requirements particular to this system shall beclearly defined, along with special calibration and test procedures.

c. Corrective-maintenance Instructions - These instructions shallinclude guides for locating malfunctions down to the card-replacement level. These guides shall include adequate details for




quickly and efficiently locating the cause of an equipmentmalfunction and shall state the probable source(s) of trouble, thesymptoms, probable cause, and instructions for remedying themalfunction.

d. Parts Information - This information shall include theidentification of each replaceable or field-repairable module. Allparts shall be identified on a list in a drawing; the identificationshall be of a level of detail sufficient for procuring any repairableor replaceable part. Cross-references between System Supplier'spart number and manufacturer's part numbers shall be provided.

F. All documentation, O&M Manuals, PLC and HMI programming, Drawings, I/Olisting and control strategies shall be revised to reflect the installed system, andfurnished in both hard copy and CD ROM Disk Format. All drawings shall be inAutoCAD 2004 or later format.

1.6 SPARE PARTS

A. Spare parts shall be furnished to permit convenient and quick service restorationupon failure of a particular unit and shall include the following:

I PLC spares parts (the following list is considered a minimum and shall beaugmented by the number and type of spares as recommended by themanufacturer's O&M manual):

a. 20 percent (with a minimum of 5) spare of each fuse size utilized.b. 10 percent (with a minimum of 1) spare of each I/O moduleutilized.

2. One Modicon M340 BMX P34 2020 CPU's and two power suppliesmodel BMX CPS 3500.

B. All spare parts shall be packaged so as to prevent damage during long storage.All packages shall be legibly and properly identified with indelible markings onthe exterior as to contents.

C. Complete ordering information including manufacturer, part number, part name,and equipment for which the part is to be used shall be provided.

PART 2- PRODUCTS

2.1 PLC CONTROL PANELSFPUC Rev. 0 16903-8 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



A. General

1. The PLC's shall be Modicon M340 Series.

2. Control Panel shall be configured similar to PLC Typical WiringSchematics drawings included in Contract Drawings set.

B. Features

1. Central Processing Unit with 10 slot expandable base.

2. Non-volatile memory.

3. 12 -40 volt DC power supply.

4. Surge protection

5. Real time clock.

6. Input and output (I/O) modules (Quantity as required). All digital inputsand outputs shall have optical isolators, and analog inputs and outputsshall have overvoltage protection that meets IEEE surge withstandcapabilities. All 1/O points shall be wired to terminal blocks.

a. Digital Inputs: 40 min.b. Digital Outputs: 16 min.c. Analog Inputs: 16 min.d. Analog Outputs: 8 min.

7. Operating temperature range shall be -200C to + 600C.

8. The Local Operator Interface (LOI) shall be Hope Industrial SystemsHISML I 5STAF, 15" Touch Screen Panel.

9. The LOI shall be mounted on dead-front of the panel door inside panelbehind lockable outside door.

10. The WonderWare Thin Client node shall be Arista Microbox 6824-ACP.The Hope Industrial Systems Touch Screen Panel will connect to theMicrobox via an RS-232 serial interface, and the Microbox will connect tothe Cisco Ethernet switch via CAT 5 Ethernet.




11. Enclosure, 36"W x 48"H x 18"D minimum size NEMA 4.

12. Communication ports as indicated on drawings but one modbus port, oneUSB port, and one Ethernet port are a minimum requirement.

13. Ethernet switch shall be a Cisco Catalyst 2955S-12, and shall be mountedin the PLC cabinet. This switch will be used to connect all Ethernetenabled equipment at the facility, local VLAN. A CISCO 3960E-24TDwill be used to connect the VLAN to the Microwave uplink, that connectsthe site to the Control Network. This switch also has fiber optic uplinkports which are essential connections for future fiber optic cable back haulconnections.

C. Functional Requirements

1. Valves shall be operated (open or close) one or two at a time.2. Monitoring and control functions -The following is a list of 1/O points,

but not limited to:

DI DO Al AO

a. At Emery Crossover

Butterfly Valves (Typical of 10)(Typical for EC-D1 #1, EC-U1 #1,EC-DX 2/1, EC-UX 2/1, EC-DI #2,EC-Ul #2, EC-DX 3/2, EC-UX 3/2,EC-D1 #3 and EC-U1 #3)

aa. Valve open - control command xbb. Valve close - control command xcc. Valve stop - control command xdd. Valve position indication - open xee. Valve position indication - close xff. Selector switch remote operation xgg. Valve position status xhh. Phase fail motor fail to start x

ii. PLC/PLC

aa. AC power indication x

iii. UPS/Battery

aa. UPS fail xbb. Status on line x




cc_ Battery low voltage x

iv. Automatic Transfer Switch

aa. Normal power source xbb. Emergency power source x

V. Sump Pump (Typical for 2)

aa. Pump On xbb. Pump Off x

DI DO Al AO

cc. Sump water levelalarm high x

vi. Generator

aa. Start command xbb. Stop command xcc. Run status xdd. Failure alarm xee. Battery Low voltage alarm x

vii. Non-Automatic Transfer Switch

aa. Normal Power Source xbb. Emergency Power Source x

viii. Miscellaneous

aa. Roof hatches coversintrusion alarm x

bb. Propane tanklevel alarm low x

cC. Flow meters (Typical of 3)Readings x

dd. Pressure Transmitters (Typ. of 3)Readings x

b. At Pelican Crossover

i. Butterfly Valves (Typical of 12)(Typical for PC-DI #1, PC-Ul #1,PC-DX 2/1, PC-UX 2/1, PC-D1 #2,PC-U1 #2, PC-DX 3/2, PC-UX 3/2,PC-Di #3, PC-Ul #3, PC-DX 4/3




and PC-DI #4)

aa. Valve open control xbb. Valve close control xcc. Valve stop control command xdd. Valve position status-open xee. Valve position status-close xff. Selector switch remote operation xgg. Valve position indicator xhh. Phase fail motor fail to start x

ii. PLC/PLCDI DO Al AO

aa. AC power indication x

iii. UPS/Battery

aa. UPS fail xbb. Status on line xcc. Battery low voltage alarm x

iv. Automatic Transfer Switch

aa. Normal power source xbb. Emergency power source x

v. Sump Pump (Typical for 2)

aa. Pump On xbb. Pump Off xcc Sump water level

alarm high x

vi. Generator

aa. Start command xbb. Stop command xcc. Run status xdd. Failure alarm xec. Battery Low voltage alarm x

vii. Non-Automatic Transfer Switch

aa. Normal Power Source xbb. Emergency Power Source x

viii. MiscellaneousSFPUC Rev. 0 16903-12 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



aa. Roof hatches covers xintrusion alarm

bb. Propane tank xlevel alarm low

cc. Flow meters (Typical of 3)Readings x

dd. Pressure Transmitters (Typ. of 3)Readings x

C. PLC Programming Conventions and Configuration Standards

1. Configuration: The PLC shall be programmed in Unity Pro XL v4.1 orlater. PLC may be programmed in ladder logic or function blockprogramming. Either type of programming is acceptable but must stayconsistent within the program. All sites will be programmed in same typeof logic. No exceptions.

2. All PLC programming shall be done in accordance with PLC softwaremanufacturers suggested program organization. Addresses used for HMI.internal logic usage, and engineering unit conversion shall be in a rangethat allows for future expansion of the logic and shall be used in such a

Sway as to alleviate the possibility of confusion for future programmodifications. These address ranges shall be submitted to HHWP prior toany program development. Program documentation, with routineexplanations will be provided as part of the program.

3. WonderWare HMI System / PLC Communications

a. All communications between the WonderWare HMI(this includesthe local thin client) and the Modicon PLC's is Modbus TCP/IPover Ethernet. The site communication system will consist of oneModicon M340 PLC with a CPU that has a native Ethemet port,one Cisco 2955 series 12 port Ethernet switch, CISCO 3560E-12Drouter and an Unlicensed or Licensed Microwave radio that isconnected via Microwave to HHWP's existing control network.All IP addresses for IP enabled devices connecting to the controlnetwork will be assigned by Hetch Hletchy Water and Power. Allfunction testing of the communications system will be done inconjunction with Hetch Hetchy water and power staff, andappropriate clearances will be issued prior to any connection ofnew devices to the control network.

4. Word Data or RegistersSFPUC Rev. 0 16903-13 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



a. Word data includes analog input data from monitored fieldinstruments, calculated or derived analog values, analog outputs,time-of-day values and set points.

5. Analog Input, Output and Calculated Values

a. Monitored or "real world" analog points are converted toEngineering units within the PLC and scaled values are placed in aregister that is directly accessed via the WonderWare HMI.Monitored (analog input) points should be grouped at the front of arange of registers, followed by an unused area to allow for futureadditions followed by the calculated or derived points and analogoutputs. PLC programmer shall submit address block definitionsand assignments for various housekeeping items within the PLCprogram prior to actually developing the program for the includedsites.

6. Set Points

a. Set points are set via Modicon PLC addresses.. The LOI and anyother WonderWare Node that has control functionality can set thevalue in the Modbus address in the local PLC. The set pointaddress shall be different than the control address in the internalPLC program. This is so verification that the PLC received the setpoint value can be made. WonderWare will write to one addressand read from another address.

7. Discrete Data

a. Discrete data includes discrete "real world" inputs, derived or"soft" points, and alarms. Each of these types of data should begrouped together with space reserved between them for futuregrowth.

8. Commands

a. Commands (discrete controls) that are initiated from WonderWarefor use by the PLC control strategy should be annotated asWWXXX in the PLC program so it is clear and easy tounderstand what addresses are being set or used by the HMI/DCS.A functional description of the PLC program is essential for HMI

programming to know what type of discrete control function shallSFPUC Rev. 0 16903-14 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers 0


TECHNICAL SPECIFICATIONS IIH-935ADIVISION 16: ELECTRICAL. 16903: MONITORING AND CONTROL EQUIPMENT

be used, i.e. Momentary, Maintained on, Normally Open,Normally closed, positive or negative transitional, etc.

PART 3 - EXECUTION

3.1 GENERAL

A. Install devices and equipment in accordance with manufacturer's instructions.

B. All input and output termination shall be made on screwed terminal strips with allconnection clearly labeled by machine.

C. Field test and verify that all hardware is installed and configured properly.

D. S.I. is required to attend software testing by City to coordinate hardwareinstallation with City supplied software. Five days of testing with City shall beincluded in addition to hardware testing and documentation as specified in thisSection.

E. Field test and verify that all system graphics and point linking operate properly.

. 3.2 TESTING REQUIREMENTS

A. Testing General

I. A factory test is required for one new PLC and Installed Tests are requiredfor new PLC and for modification work at two (E) PLC sites.

2. Testing, test plans, and test reports shall be provided by the Contractor asspecified in Section 01660 and in this and other sections of thesespecifications. The Contractor shall perform tests as required todemonstrate that the equipment and systems covered in this Sectionoperate safely and meet the requirements of these Specifications. TheContractor shall provide labor, instruments, and other material to completethe tests.

3. Test plans and test reports shall be submitted as formal submittals andshall meet all applicable requirements of Section 01345, of SectionSUBMITTALS of this Section.

4. Tests and test plans shall be in the cause and effect format. The personconducting the test shall initiate an action (cause) and, upon the system's


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or subsystem's producing the correct result (effect), the specific testrequirement will have been satisfied.

5. Tests and test plans shall be integrated across equipment and systems.The Contractor shall coordinate and integrate the documentation andefforts of suppliers and subcontractors to achieve unified tests and testplans.

B. Installed Tests

I. Prior to staPLCp, all equipment and systems specified under this Sectionshall be inspected and tested to show that they are ready for operation.Equipment will not be accepted by the City until all tests are successfullypassed.

2. The test shall be performed from a test plan prepared by the Contractor.

C. Each control loop shall be tested in the following sequence:

1. Testing Phases2. Wiring3. Individual components4. Individual loops5. Loop tuning

D. Testing Phases

1. Testing of wiring and individual components shall be successfully completedwith certified test reports submitted to the City prior to commencement ofindividual loop testing. Individual loop testing shall be successfullycompleted with certified test reports submitted to the City prior tocommencement loop tuning.

E. Wiring Testing

I. General: The following tests shall be performed on each instrumentation andcontrol system cable specified to be provided under Division 16, of thetechnical specifications. Tests shall be end-to-end test of installed cableswith the ends supported in free air, not adjacent to any grounded object. Testreports shall be made by the Contractor and submitted to the City. Cableswhich do not pass the following tests shall be replaced at no expense to theCity.



TECHNICAL SPECIFICATIONS HH-935ADIVISION 16: ELECTRICALO 16903: MONITORING AND CONTROL EQUIPMENT

2. Continuity Tests: Continuity tests shall be performed by measuringwire/wire and wire/shield loop resistances of each signal cable as the wires,taken one at a time, are shorted to the circuit shield and each other. No loopresistance measurement shall vary by more than +/- 2 ohms from thecalculated average loop resistance value.

3. Insulation Tests: Insulation resistance tests shall be performed by using a500 (250 Volt for 300 Volt cable) Volt megOhmmeter to measure theinsulation resistance between each circuit wire, between circuit wire and itsassociated circuit shield, between individual circuit shields in a multichannelcable. Between each individual circuit shield and the overall cable shield in amulticonductor cable, between the overall cable shield and the cables'metallic raceway (if provided) or local ground. Values of resistance less than10 megOhms will be unacceptable. Refer to testing procedure in thereference test form.

F. Individual Component Calibration and Test

I. General: Pressure transmitters and other instruments including existing,relocated instruments, shall be field calibrated in accordance with themanufacturer's recommended procedure. This work shall include all newinstruments provided by the City, and instruments supplied with mechanicalor electrical equipment. Instruments shall then be tested in compliance withISA S5 1.1 and this paragraph and the data entered on the applicable testform. Alarm trips, control trips, and switches listed in the instrumentschedule shall be set to initial values at this time. Final elements shall bechecked for range, deadband, and speed of response.

Any new component, including those supplied with mechanical or electricalequipment, which fails to meet the required tolerances shall be repaired bythe manufacturer or replaced, at no expense to the City, and the above testsrepeated until the component is within tolerance.

2. Technician Qualifications: Each instrument, except as noted below, shall becalibrated on site by an instrument technician who, by viPLCe of anacceptable training course or documentable experience, is qualified tocalibrate that instrument. Acceptable training shall include successfulcompletion of the manufacturer's training course or successful completion ofapplicable technical courses in a recognized trade school.

3. Certified Type Test Data: Where field calibration is not feasible (e.g.,vibration equipment, magnetic flow tubes, etc.), certified instrumentationcalibration reports may be substituted for field test data subject to prior




written approval of the City. A request to submit certified calibration data inlieu of field calibration data shall include the name and address of thelaboratory selected to provide off-site calibrations and a detailed descriptionof field test and inspection activities which will be performed to supplementoff-site calibration activities in order to ensure proper installation andfreedom from damage subsequent to the off-site test.

4. Calibration Procedure: Each analog instrument shall be calibrated at 10percent, 50 percent, and 90 percent of its specified full scale. Each signalsensing trip and process sensing switch shall be adjusted to the requiredsetting(s). All test data shall be entered on test forms in compliance with theprovisions of this Section. A report shall be delivered to HHWP containingall instruments, listed by instrument number, certifying that each instrumenthas been calibrated and meets contract requirements. For each instrument,the report shall include the test form, with test data entered, together with astatement of defects noted and corrective action taken. Any instrumentwhich fails to meet any Contract requirement or any published manufacturerperformance specifications for functional and operational parameters,whether or not specified in the Contract, shall be repaired or replaced, at thediscretion of the City, and at no cost to the City.

G. Loop Test

1 . Each instrument loop and alarm circuit shall be tested as an integratedsystem. This test shall be designed to verify that indicators or recordersoperate correctly, function modules provide proper signal conditioning,alarms operate correctly, final elements move in the correct direction, andcontrol trips cause proper action in interlocking of control circuits. Signalsshall be injected at the signal connection to primary measuring elements.

2. The overall tolerance requirement for analog loops consisting of two or morecomponents shall be the root-sum-square (RSS) of the individual componentaccuracy requirements. Accuracy requirements of individual componentsshall be as specified in the contract documents or, where not specificallyspecified in the contract documents, shall be in accordance withmanufacturer's published performance specifications.

3. A component for the purpose of RSS testing, shall be any instrument,dropping resistor, or other device which converts a signal from one range toanother (such as from 4-20 mA to 1-5 volts) or from one media to another(such as analog to digital, current to voltage, voltage to pressure, pressure tometer readout, etc.). Loop tolerance for each required test point shall becalculated and entered on test forms prior to the commencement of the test.




4. Each analog loop shall be tested for RSS accuracy by injecting calibratedsignals at the primary sensing element's output signal connection andobserving or measuring the response at each receiver (PLC indicators,controllers, recorders, alarms, etc.). Where applicable, loops shall be testedfor RSS accuracy by manually setting the output of the loop (at the PLC orcontroller) and measuring the response of the final control element. Allanalog loops shall be tested at 10, 50, and 90 percent of span. Also, alarms.current signal trips, and other analog-to-discrete trip devices shall be tested attheir set point to verify the trip point is within RSS tolerances.

5. The difference between the signal injected at the primary sensing elementand each receiver shall not exceed the calculated acceptable RSS tolerance(stated in the appropriate units). Also, the difference between the outputsetting and the final control element response shall not exceed the calculatedtolerance. If the observed difference is greater than the allowable tolerance,corrections to the loop circuitry shall be made as necessary and the testrepeated until the difference is within the allowable tolerance.

6. If any final element moves in the wrong direction or fails to move over therequired range, corrections shall be made as necessary and the test repeateduntil final element action is correct.

7. In addition, measure and record the resistance of each loop.

8. This test shall also verify the proper operation of each discrete control loop toinsure the proper operation of hand switches, interlocks, solenoid valves,other auxiliary devices, status lights, and alarms.

H. Field Loop Ground Test

1. Each analog signal circuit entering the control panels from field transmittersand final control elements shall be tested to verify that the circuit is isolatedfrom electrical ground. This test shall be performed after the individualcomponent calibration and test, after all circuit components have beenconnected, and may be performed prior to, or as part of, the loop test. Thefield signal leads of the circuit under test shall be disconnected from the fieldinput terminals and connected together. Connect a 20 Volt (minimum)Ohmmeter between the (joined) signal leads and the panel ground bus andmeasure the resistance. Values of resistance less than 2 million Ohms shallnot be acceptable. If the loop fails the test, the Contractor shall troubleshootand modify the circuit to achieve isolation from ground greater than 2 millionOhms. Test shall be repeated until the circuit passes. Results shall berecorded on a appropriate test forms ands submitted.




I. End-To-End Test

1. After successful loop testing, every signal circuit connected to the PLCinput/output (I/O) terminals shall be tested to verify that it is properly wiredand functions as specified to send signals to or receive signals from the PLCand its 1/O equipment. Each circuit shall be tested. Signals shall be injectedat the signal connection to primary measuring elements. Where an existingcircuit is being intercepted but will remain in operation, the signal shall beinjected at the instrument or at the point of interconnection, at the discretionof the Engineer. The Contractor shall notify the City 30 days prior to eachend-to-end test that a test will occur, when it will occur, and which pointswill be tested. Verification of proper signal transmission shall be verified atthe PLC and determined by the Engineer.

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SFPUC Rev. 0 16903-20 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers 0

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APPENDIX

TO

SECTION 16903



TECHNICAL SPECIFICATIONS HH-935ADIVISION 16: ELECTRICAL16903: MONITORING AND CONTROL EQUIPMENT 0

INSTALLED TEST PROCEDURE

SAMPLE



San Francisco Water SCADA System

SAMPLE Installed Test Procedures Site 1234 - Pump Station & Reservoir

Site #1234- Pump Station & Reservoir

Test Procedure No.: TCI 7077B-I

Specification Reference:

Drawing Reference: 2015-2055-01 through -14, 2015-3055-01 through -04

Test Objective:

The purpose of this test is to verify proper installation and operation of the PLC VSAT and ADN communicationscables and equipment-

Test Case:

Communications

Expected Results:

The equivalent measured return loss of each antenna/cable system is 20dB or greater.

The measured attenuation is less than or equal to the length of the cable times 0.052 (attenuationcoefficient) plus 2.0 dB.

The results of a BER test is error free.

Test Procedure:

VSAT Testing

Reference: Specification Section 17340-3.0l.B

The communications cable between the PLC and the VSAT Indoor Unit has already been tested as it became anintegral part of the PLC.

1. Measure the return loss of each antenna cable.

Transmit Cable Receive Cable

-2. Verify that the return loss of each cable is equal to 20 dB or greater.

3. Measure the attenuation of each antenna cable.


-4. Note the length in feet of each cable.


-5. Verify that the attenuation of each cable is less than or equal to the length of the cabletimes 0.052 (attenuation coefficient) plus 2.0 dB.

ADN Testing

Reference: Specification Section 17350-3.0 .B

The communications cable between the PLC and the CSU/DSU has already been tested as it became an integral partof the PLC.

November 20, 2001 Installed Test Procedures Page 117000-3.01-E

Use or disclosure of the data contained within this submittalIs subject to the restrictions on the inside cover page of this submittal


-6. Verify that there is a CSU/DSU on both ends of the circuit.

-7. Place a data loopback connector on the RS232 port of the CSUJDSU at the appropriateOCC.

-8. Connect the DLM200 (protocol analyzer) to the RS232 port on the remote CSU/DSU.

9. Initiate a BERT/Perform via the DLM200.

I 0.Configure the DLM200 to use the 511 BERT Pattern and enter "0" in the passes field.

S11.Verify that after two hours of continuous testing the characters sent match the charactersreceived and the "Error Free See" field reads 100%.

SFPUC Rev. 0 16903-2 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers 0

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San Francisco Water SCADA SystemSAMPLE Installed Test Procedures Site 1234 - Pump Station & Reservoir

*Performance:

Passed: Passed as Noted: Failed:

Comments:

Acceptance:

Checked By: Date:

Witnessed By:




Site #7077B - 1234 Pump Station & XXX Reservoir

Test Procedure No.: TCI 7077B-2


Drawing Reference: 2015-2055-01 through -14, 2015-3055-01 through -04

Test Objective:

The purpose of this test is to verify proper installation and operation of the PLC and field instrumentation andequipment.

Test Case:

Wiring

Expected Results:

No loop resistance measurement shall vary by more than +/- 2 ohms from the calculated averageloop resistance value.

No insulation resistance measurement less than 10 megOhms.

Test Procedure:

Using the PLC/RJOU I/O Test Forms, perform continuity tests by measuring wire/wire andwire/shield loop resistances of each signal cable as the wires, taken one at a time, are shorted tothe circuit shield and each other.

- 1. Record wire/wire continuity resistance measurement on 1/O Test Form.

-2. Record wire/shield continuity resistance measurement on 1/O Test Form.

-3. Calculate average loop resistance once each signal cable has been continuity tested andrecord average on I/O Test Form.

-4. Verify continuity is within +/- 2 ohms of the calculated average loop resistance andrecord result on I/O Test Form.

Test Procedure:

Using the PLC/RIOU 1/O Test Forms, perform insulation tests by measuring the insulationresistance between each circuit wire and between each circuit wire and its associated circuitshield.

5. Record wire/wire insulation resistance measurement on 1/O Test Form.

6. Record wire/shield insulation resistance measurement on 1/O Test Form.

7. Verify insulation resistance is less than 10 megOhms and record result on I/O Test Form.

Test Case:SFPUC Rev. 0 16903-4 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



0 Individual Components

Expected Results:

All field instruments have been calibrated in accordance with the manufacturers recommendedprocedure and meets the contract requirements.

Test Procedure:

Using the Instrument Calibration Forms and simulating the process, set all listed alarm trips,control trips, and switches to initial values.

8. Record initial values on the Instrument Calibration Form.

Test Procedure:

Using the Instrument Calibration Forms and simulating the process calibrate each analoginstrument at 10 percent, 50 percent, and 90 percent of its specified full scale.

- 9. On the Instrument Calibration Form, record process measurements at 10, 50, and 90percent.

- 10.On the Instrument Calibration Form, record output measurements at 10, 50, and 90percent.

Test Case:

Loop Test. Expected Results:

All indicators or recorders operate correctly, function modules provide proper signalconditioning, alarms operate correctly, final elements move in the correct direction, and controltrips cause proper acting in interlocking of control circuits. The difference between the signalinjected at the primary sensing element and each receiver is within the calculated acceptabletolerance. The difference between the output setting and the final control element be within thecalculated acceptable tolerance. Resistance of loop ground testing be more than 2 million Ohmsfor each analog loop.

Test Procedure:

Using the PLC/RIOU 1/O Test Forms, simulate each analog input loop by injecting calibrated10 percent, 50 percent, and 90 percent signals at the primary sensing element's output signalconnection and observing/measuring the response at each receiver.

11 .For each receiver, record the manufacturer's published loop tolerance for each test pointon the I/O Test Form.

12.For each receiver, record the values observed for 10, 50, and 90 percent signal on the I/OTest Form.

13.Measure and record the resistance of the loop on the I/O Test Form.

Test Procedure:




Using the PLC/RIOU I/O Test Forms, simulate each analog output loop by manually setting theoutput of the loop at the PLC controller and measuring the response at the final control element.

1 I4.Record the manufacturer's published loop tolerance for each test point on the I/O TestForm.

- 15.Record the response measured at the final control element on the I/O Test Form.

- 16.Measure and record the resistance of the loop on the 1/0 Test Form.

Test Procedure:

Using the PLC/RIOU I/O Test Forms, verify the proper operation of each discrete input controlloop to insure the proper operation of hand switches, interlocks, alarms, etc. Alarms will beverified locally at the PLC (Common Alarm, LOI, etc.).

17.Generate each discrete input from the source input device and record the results on theI/O Test Form.

Test Procedure:

Using the PLC/RIOU 1/O Test Forms, verify the proper operation of each discrete outputcontrol loop to insure proper operation of status lights, valve operation, etc. Outputs will beforced within the PLC controller and the result observed at the final control device.

S18.Force each discrete output at the PLC controller and record the observed result on the 1/OTest Forms.

Test Procedure:

Using the PLC/RIOU I/O Test Forms, test each analog signal circuit entering the control panelsfrom field transmitters and final control elements to verify the circuit is isolated from electricalground. The field signal leads of the circuit under test shall be disconnected from the fieldterminals and connected together. Resistance will be measured between the signal leads and thepanel ground bus.

19.Measure and record the loop ground resistance on the I/O Test Form.

- 20.Record the result of the loop ground test as compared to 2 million Ohms.

Test Case:

End-To-End Test

Expected Results:

Every signal circuit connected to the PLC input/output terminals is properly wired and functionsas specified to send signals to or receive signals from the PLC and its I/O equipment. Values andstatus is correctly received at the LOI and appropriate MCS SCADA workstation.

Test Procedure:

Using the PLCJRIOU I/O Test Forms, verify each discrete input from the source device. Status




* and alarms will be verified both at the LOT and the appropriate MCS SCADA workstation.

21 .Generate each discrete input from the source device. Verify the input is received at boththe LOI and MCS SCADA workstation, and record the results on the I/O Test Form.

Test Procedure:

Using the PLC/RIOU I/O Test Forms, verify each discrete output to the final control clement.

Outputs will be verified both from the LOT and the appropriate MCS SCADA workstation.

22.Exercise each discrete output from both the LOI and MCS SCADA workstation. Verifyeach output generated is received at the final control element, and record the results onthe I/O Test Form.

Test Procedure:

Using the PLC/RIOU 1/O Test Forms, verify each analog input from the source device. Signalswill be injected at the signal connection to primary measuring elements. Values will be verified

both at the LOT and the appropriate MCS SCADA workstation.

23.Simulate each analog input from the primary measuring element. Record the 10, 50, and90 percent values received both at the LOI and MCS SCADA workstation.

Test Procedure:

Using the PLC/RIOU I/O Test Forms, verify each analog output to the final control device.Outputs will be verified both from the LOT and the appropriate MCS SCADA workstation.Signals will be measured where the connection is made at the final control device.

__ 24.At increments of 10, 50, and 90 percent, exercise each analog output from both the LOIand MCS SCADA workstation. Measure the output values at the final control device andrecord the results on the 1/O Test Form.

Test Case:

PLC Field Test

Expected Results:

There is no visual or suspected damage to the PLC, including the enclosure. The PLC processorand I/O properly form a completed unpowered state (including loss of backup power). The PLCenclosure powers up and appears ready for operation. The battery backup system operatesproperly.

Test Procedure:

Visual inspection of the PLC enclosure and components.

__ 25.Verify the PLC enclosure has no visual damage.

__ 26.Verify the PLC components are securely mounted and bear no visual signs of damage.

Test Procedure:

Verify the PLC processor and 1/O properly form a completed unpowered state (including loss of

November 20, 2001 Installed Test Procedures Page 7

17000-3 01-EUse or disclosure of the data contained within this submittal

Is subject to the restrictions on the inside cover page of this submittal


backup power).__ 27.Remove both commercial and battery backup power from the PLC.__ 28.Verify the PLC processor and 1/0 properly form a completed unpowered state.

Test Procedure:

Veri y proper power up of the PLC.

__ 29.Replace commercial power to the PLC.

- 30.Replace battery backup power to the PLC.S31 .Verify all equipment in the PLC enclosure powers up and appears ready for operation.

Test Procedure:

Verify PLC battery backup system operates properly.

- 32.Remove commercial power from the PLC.__ 33.Verify all 24VDC equipment remains powered up.

34.Verify PLC remained in the RUN state and no re-booting occurred.


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* Performance:


Comments:

Acceptance:

Checked By: Date:

Witnessed By:





Test Case: Control Logic Test

Test Procedure No.: TCI-7077B-3


System Reference: Site Monitoring and Control Description Submittal

Test Objective:Verify proper operation of the configured control strategies per the Site Monitoring and Control DescriptionSubmittal as well as Specification Section 17425.

Expected Results:

All configured control strategies listed below function as defined in the Site Monitoring andControl Description Submittal and Specification Section 17425.

Test Procedure:

CS 2 - Pump Station ControlReference: Specification Section 17425-2.03.B

Pump Controls - Peer-To-Peer:

. Adjust the "Peer Comm Restoration" period setpoint to 120 seconds via the LOI and/or the SCADAworkstation.

-2. Adjust the "Level" setpoint via the LOI and/or the SCADA workstation so that it is -5.5 ft.

-3. Adjust the "Level" deadband to 1 ft via the LOI and/or the SCADA workstation.

-4. Adjust the "Pump Start" delay setpoint to 20 seconds via the LOI and/or the SCADA workstation.

-5. Adjust the "Pump Stop" delay setpoint to 20 seconds via the LOI and/or the SCADA workstation.

6. Adjust the "Pump Failed to Start" and the "Pump Failed to Stop" setpoints to 15 seconds via the LOI and/orthe SCADA workstation.

-7. Adjust the "First Pump Required" delay setpoint to 60 seconds via the LOI and/or the SCADA workstation.

-8. Adjust the "Surge Valve Close" delay to 20 seconds via the LOI and/or the SCADA workstation.-9. Verify communications between the PLC and its Peer SCADA station are valid.

-10. Generate a Remote input from the "Local-Remote" switch for each pump.

- 11. Generate an Auto input from the "Hand-Off-Auto" switch for each pump.


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- 12. Enter a valid lead/laglilag2/standby assignment and note pump designations below.

Pump1__ Pump2 Pump3 __ Pump4__

_ 13. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

_14. Verify that the lead pump is called to run after the "First Pump Required" delay has expired.

__ 15. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadband) and verify that no other pumps have beencalled to run.

16. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

17. Simulate a pump fail-to-run condition for the lead pump.

18. Verify that the surge valve is called to open.

19. Verify that the standby pump is called to run after the "First Pump Required" and the "Pump Start" delayhave expired.


-21. Clear the pump fail-to-run alarm for the lead pump and verify the standby pump is called to stop.

-22. Verify that the surge valve is called to open.

23. Verify that the lead pump is called to run after the "First Pump Required" delay has expired.

-24. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

-25. Adjust the Reservoir Level input to -7 ft (i.e. below deadband) and verify that the lagl pump is called to runafter the "Pump Start" delay has expired.

26. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadband) and verify that no other pumps have beencalled to run.

-27. Adjust the Reservoir Level input to -7 ft (i.e. below deadband) and verify that the lag2 pump is called to runafter the "Pump Start" delay has expired.

_28. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadband) and verify that no other pumps have beencalled to run.

_29. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the lag2 pump is called to stopafter the "Pump Stop" delay has expired.

- 30. Adjust the Reservoir Level input to -6 ft (i.e. inside lower deadband) and verify that no other pumps havebeen called to stop.

-31. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the lag] pump is called to stopafter the "Pump Stop" delay has expired.

_32. Adjust the Reservoir Level input to -6 ft (i.e. inside lower deadband) and verify that no other pumps havebeen called to stop.

-33. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the surge valve is called toopen.

_ 34. Verify that the lead pump is called to stop after the "First Pump Required" delay has expired.


Pump Control - Stagger Start:

November 20, 2001 Installed Test Procedures Page I I17000-3.01-E

Use or disclosure of the data contained within this submittal



36. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

37. Verify that the lead pump is called to run after the "First Pump Required" delay has expired.


39. Leave the Reservoir Level input at -7 ft (i.e. below deadband) and verify that the lagi pump staggers onafter the "Pump Start" delay has expired.

40. With the Reservoir Level input still at -7 ft (i.e. below deadband), verify that the lag2 pump staggers onafter the "Pump Start" delay has expired.

-41. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the pumps stagger off with thelag2 pump called to stop first.

42. Verify that before the lead pump staggers off, the surge valve is called to open and then the lead pump iscalled to stop.


Pumn Control - Loss of Signal:

-44. Disconnect the Reservoir Level input while all three pumps are running and verify that the pumps continueto run and a "Reservoir Level Out Of Range" alarm is generated.

45. Reconnect the Reservoir Level input and verify that the "Reservoir Level Out Of Range" alarm clears.

-46. Generate a pump fail-to-run condition for the lag2 pump and verify after the "Pump Start" delay expires thestandby pump is called to run.

47. Disconnect the Reservoir Level input once again and verify that the pumps continue to run and a "ReservoirLevel Out Of Range" alarm is generated.

-48. Reconnect the Reservoir Level input and verify that the "Reservoir Level Out Of Range" alarm clears.


-50. Verify that before the lead pump staggers off, the surge valve is called to open and then the lead pump iscalled to stop.

- 51. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

-52. Clear the pump fail-to-run alarm for the lag2 pump.

Bumpless Transfer

-53. Enable the duration setting for "Manual Pump Run Control" mode at the LOI and/or the SCADAworkstation.

-54. Adjust the "SCADA Manual Pump Run" period to 30 seconds via the LOI and/or the SCADA workstation.

-55. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

-56. Verify that the lead pump is called to run after the "First Pump Required" delay has expired.


SFPUC Rev. 0 16903-12 San Joaquin Pipeline SystemSeptember 28,2009 Crossovers



58. Leave the Reservoir Level input at -7 ft (i.e. below deadband) and verify that the lagi pump staggers onafter the "Pump Start" delay has expired.

59. With the Reservoir Level input still at -7 ft (i.e. below deadband), verify that the lag2 pump staggers onafter the "Pump Start" delay has expired.

60. With all three pumps running in L/R switch position "Remote" and pump control mode "Auto", change the

pump control mode to "Manual" via the LOT and/or the SCADA workstation.

61. Verify that the pumps remain running without interruption.

62. Verify that after the "SCADA Manual Pump Run Period" expires, the pumps stagger off.

63. Verify that before the last pump staggers off, the surge valve is called to open and then the lead pump iscalled to stop.


65. Place the L/R switch in the "Local" position for all three pumps.

66. Place the HOA switch in the "Hand" position for all three pumps and verify all three pumps are called tostart.

67. Change the pump control mode to "Auto" via the LOI and/or the SCADA workstation.

-68. With all three pumps running in L/R switch position "Local" and HOA switch position "Hand", place the

L/R switch in the "Remote" position for all three pumps.

69. Verify that all three pumps are called to stop and proceed to start if required, in L/R switch position"Remote" and HOA switch position "Hand", given the normal start delays. Note: "Remote-Hand" and

"Remote-Auto" are switch selections, not software selections (i.e. the software selections are "Auto" and"Manual" via the LOI and/or SCADA workstation). "Hand" and "Auto" contacts are physically tiedtogether at each switch per the contract drawings.


71. Verify that before the lead pump staggers off, the surge valve is called to open and then the lead pump is

called to stop.


73. With all three pumps NOT running in L/R switch position "Remote" and pump control mode "Auto",change the pump control mode to "Manual" via the LOT and/or the SCADA workstation.

74. Verify that the pumps are NOT called to run.

75. Change the pump control mode to "Auto" via the LOt and/or the SCADA workstation.

Pump Controls - SCADA:

_ 76. Adjust the "SCADA Comm Restoration" period setpoint to 120 seconds via the LOT and/or the SCADA

workstation.

77. Disconnect the communications link between the PLC and its Peer SCADA station.

78. Verify that the communications between the PLC and SCADA are valid.

79. Verify that after the "Peer Comm Restoration" period has expired and found to be in fault, the PLC is nowusing the remote reservoir level from SCADA and a "Peer SCADA Communication Failure" alarm is

received at the SCADA workstation.


17000-3.01-EUse or disclosure of the data contained within this submittal



-80. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

81. Verify that the lead pump is called to run after the 'First Pump Required" delay has expired.

82. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.83. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadhand) and verify that no other pumps have been

called to run.

84. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ). and verify that the lagI and lag2 pumpsstagger on.

-85. Disconnect the communications link between the Pump Station PLC and SCADA.

86. Verify that after the "SCADA Comm Restoration" period has expired and found to be in fault, the pumpsstagger off.

-87. Verify that before the lead pump staggers off, the surge valve is called to open and then the lead pump iscalled to stop,


Surge Tank Air Compressor - PLC Controls:

-89. Adjust the "Compressor Start Level" setpoint to 24 inches via the LOI and/or the SCADA workstation.

-90, Adjust the "Compressor Stop Level" setpoint to 12 inches via the LOI and/or the SCADA workstation,91. Adjust the "Compressor Start" delay setpoint to 30 seconds via the LOI and/or the SCADA workstation.

-_ 92. Adjust the Surge Tank Level input to 25 inches.

-- _93. Verify that the compressor is called to run after the "Compressor Start" delay has expired.

-94. Adjust the Surge Tank Level input to I I inches.

-95. Verify that the compressor is called to stop.

96. Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

-97. Verify that Pump I (lead) is called to run after the "First Pump Required" delay has expired.-98. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

-99. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadband) and verify that no other pumps have beencalled to run.

100.Adjust the Surge Tank Level input to 25 inches.

- 101. Verify that the compressor is not called to run while Pump I is running.

- 102. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the surge valve is called toopen.

- 103.Verifv that the lead pump is called to stop after the "First Pump Required" delay has expired.

- 104.Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

- 105. Verify that the compressor is now called to run.

SEPUC Rev. 0 16903-14 San Joaquin Pipeline SystemSeptember 28, 2009 Crossovers



106.Adjust the Reservoir Level input to -7 ft (i.e. below deadband ) and verify that the surge valve is called toopen.

107. Verify that the compressor is called to stop.

108. Verify that Pump I (lead) is called to run after the "First Pump Required" delay has expired.


S110. Adjust the Reservoir Level to -6 ft (i.e. inside lower deadband) and verify that no other pumps have beencalled to run.

111. Adjust the Surge Tank Level input to 20 inches.

- 112. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the surge valve is called toopen.

1 13.Verify that the lead pump is called to stop after the "First Pump Required" delay has expired.


It 15.Verify that the compressor in not called to run.

PLC Control on Loss of Commercial Power:

Note: Pump control is in "Remote/Auto". Level setpoint is -5.5 ft and level deadband is 1 ft.

- 116. Adjust the "Standby Mode Start Level" setpoint to -10 ft via the LOI and/or the SCADA workstation.

- 117. Adjust the "Standby Mode Start Delay" setpoint to 15 seconds via the LOI and/or the SCADA workstation.

- 118. Adjust the "Standby Mode Stop Level" setpoint to -6 ft via the LOI and/or the SCADA workstation.

O 119. Adjust the "Standby Mode Stop Delay" setpoint to 15 seconds via the LOI and/or the SCADA workstation.

120. Adjust the "Generator Cool Down Period Delay" setpoint to 3 minutes via the LOI and/or the SCADAworkstation.

121. Adjust the "Commercial Power Available Delay" setpoint to 15 seconds via the LOI and/or the SCADAworkstation.

122. Adjust the "ATS Commercial Power Available Delay" setpoint to 2 minutes via the LO1 and/or the SCADAworkstation.

123.Disconnect the ATS commercial power available status input.

124. Open circuit breaker #1 within the PLC in order to receive a commercial power failure alarm.

125. Adjust the Reservoir Level input to 9 ft.

126. Verify that the generator is NOT called to run as the level is above the "Standby Mode Start Level".

127. Adjust the Reservoir Level input to Il ft.

128. Verify that the generator is called to run after the "Standby Mode Start Delay" has expired.

129.Close circuit breaker #1 within the PLC in order to clear the commercial power failure alarm.

- 130. Verify that the surge valve is called to open after the "Commercial Power Available Time Delay" hasexpired.

131. Verify that Pump I is called to run after the "First Pump Required" delay has expired.






--- 133.Adjust the Reservoir Level to -9 ft and verify that no other pumps have been called to run.134.Adjust the Reservoir Level to - I ft and verify that the Lag I and Lag2 pumps stagger on.

-. 135. Adjust the Reservoir Level input to -5 ft (i.e. above setpoint) and verify that the pumps stagger off with thelag2 pump called to stop first.

136. Verify that before the lead pump staggers off, the surge valve is called to open and then the lead pump iscalled to stop.


138. Adjust the Reservoir Level input to -11 ft.

139. Verify that the surge valve is called to open after the "Commercial Power Available Time Delay" hasexpired.

140. Verify that Pump I is called to run after the "First Pump Required" delay has expired.__ 141.Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

142. Adjust the Reservoir Level to -9 ft and verify that no other pumps have been called to run.

- 143. Adjust the "Standby Mode Stop Level" setpoint to -8 ft (below regular level setpoint) via the LOI and/orthe SCADA workstation.

- 144. Adjust the Reservoir Level input to -7.8 ft.

145. Verify that the surge valve is called to open after the "Commercial Power Available Time Delay" hasexpired.

- 146. Verify that Pump I is called to stop after the "First Pump Required" delay has expired.

147. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.148. Verify that after the "Generator Cool Down Period Delay" has expired, due to pumps not being required to

run, the generator is called to stop.149. Place the pump control strategy into "manual over-ride" mode from the LOI and/or the SCADA

workstation.

150. Adjust the Reservoir Level input to -9 ft.

151. Open circuit breaker #1 within the PLC in order to receive a commercial power failure alarm.

152. Issue a Pump I start command via the LOI and/or the SCADA workstation.

153, Verify that the generator is called to run.154. Close circuit breaker # I within the PLC in order to clear the commercial power failure alarm.

-- 155. Verify that the surge valve is called to open after the "Commercial Power Available Time Delay" hasexpired.

156. Verify that Pump I is called to start after the "First Pump Required" delay has expired.


158.Issue a Pump I stop command via the LOI and/or the SCADA workstation.


160. Verify that Pump I is called to stop after the "First Pump Required" delay has expired.161. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.




162. Verify that after the "Generator Cool Down Period Delay" has expired, due to pumps not being required torun, the generator is called to stop.

163.Place the pump control strategy into "auto" mode from the LOI and/or the SCADA workstation.

- 164. Open circuit breaker #1 within the PLC in order to receive a commercial power failure alarm.

165- Adjust the Reservoir Level input to -11 ft.

166. Verify that the generator is called to run after the "Standby Mode Start Delay" has expired.

167. Close circuit breaker # 1 within the PLC in order to clear the commercial power failure alarm.

168. Venify that the surge valve is called to open after the "Commercial Power Available Time Delay" hasexpired.

169. Verify that Pump 1 is called to run after the "First Pump Required" delay has expired.


-- 171.Adjust the Reservoir Level to -9 ft and verify that no other pumps have been called to run.

172. Reconnect the ATS commercial power available status input.

173. Verify that the "ATS Commercial Power Available Delay Timer" starts to timeout (this can be viewedwithin the reference data editor - word 400511).

__ 174.Disconnect the ATS commercial power available status input.

175. Verify that the "ATS Commercial Power Available Delay Timer" stops timing out and returns to zero.

176. Reconnect the ATS commercial power available status input.

177. Verify that the surge valve is called to open after the "ATS Commercial Power Available" and the* _ "Commercial Power Available Time" delays have expired.

178. Verify that Pump I is called to stop after the "First Pump Required" delay has expired.


180. Verify the transfer switch output is enabled for 3 seconds.

181. Verify that the surge valve is called to open after the "Commercial Power Available Time Delay" has

expired as the reservoir level is below the lower deadband.



184. Adjust the Reservoir Level to -6 ft and verify that no other pumps have been called to run.

185. Verify that after the "Generator Cool Down Period Delay" has expired due to ATS commercial poweravailable, the generator is called to stop.

- 186.Adjust the Reservoir Level input to -5 ft (i.e- above setpoint) and verify that the surge valve is called toopen.



Pump Alarms:

Verify the following alarms can be generated and are displayed at the LOT and the SCADA

workstation as applicable.

November 20, 2001 Installed lest Procedures Page 17


s subject to the restrictions on the inside cover page of this submittal


189.Pump I Fail-to-Run (remove pump on input while pump is running and wait for the alarm delay to expire)

- 190.Pump 2 Fail-to-Run (remove pump on input while pump is running and wait for the alarm delay to expire)

1 191.Pump 3 Fail-to-Run (remove pump on input while pump is running and wait for the alarm delay to expire)- 192. Pump 4 Fail-to-Run (remove pump on input while pump is running and wait for the alarm delay to expire)

- 193.Pump I Fail-to-Stop (simulate a pump on input while pump is not being called to run and wait for the alarmdelay to expire)

194.Pump 2 Fail-to-Stop (simulate a pump on input while pump is not being called to run and wait for the alarmdelay to expire)

195. Pump 3 Fail-to-Stop (simulate a pump on input while pump is not being called to run and wait for the alarmdelay to expire)

196.Pump 4 Fail-to-Stop (simulate a pump on input while pump is not being called to run and wait for the alarmdelay to expire)

- 197. Low Priority (switch from remote to local)




Performance:


Comments:

Acceptance:

Checked By: Date:

Witnessed By:


17000-3. 01-ELse or disclosure of the data contained within this submittal






Specification Reference: Clarification #82


Test Objective:Verify proper operation of the configured control strategies per the Site Monitoring and Control DescriptionSubmittal as well as Clarification #82.

Expected Results:

All configured control strategies listed below function as defined in the Site Monitoring andControl Description Submittal and Clarification #82.

Test Procedure:

CS 3 -Sodium Hypochlorite Pump ControlReference: Clarification #82

Manual Mode:

Note: Prior to testing the following control strategies, some assumptions have been made.

* SFWD has installed the "Remote-Local Flow Control" switch. This includes wiring the mainlineflow signal and analog output point from the PLC to the switch.

* SFWD has personnel available to manipulate the DART controller." SFWD has terminated the "Pump Speed" feedback signal within the PLC or at least brought the

wires to the PLC for Transdyn/Cresci JV to terminate. The "Pump Speed" feedback signal mustbe a 4-20 mA signal.

- 1. Have SFWD personnel place the DART controller in "Manual".- 2. Have SFWD personnel adjust the pump speed output via the DART controller and verify that the speed

feedback coincides with the requested speed output.-3. Have SFWD personnel place the DART controller in the "Off' position and verify the pump is stopped.

Local Flow Control:

- 4. Have SFWD personnel place the DART controller in "Auto".

- 5. Place the "Remote-Local Flow Control" switch in the "Local" position.




-6. Verify that the pump speed output is directly proportional to the mainline flow signal.

Supervisory Remote Manual Control:

7. Place the Pump control mode in "Supervisory Manual Pump Speed control" from the LOI and/or theSCADA workstation.

8. Place the "Remote-Local Flow Control" switch in the "Remote" position.

9. Verify that the Pump Speed can be adjusted manually for each pump from the LOI and/or the SCADAworkstation.

10. Place the "Remote-Local Flow Control" switch in the "Local" position.

1 1. Place the Pump Speed control back into "PLC" from the LOI andor the SCADA workstation.

12. Place the Pump control mode in "Supervisory Manual Pump Stroke control" from the LOI and/or theSCADA workstation.

13. Verify that the Pump Stroke can be adjusted manually for each pump from the LOI and/or the SCADAworkstation.

Automatic Speed Control:

14. Adjust the stroke output to 45% (11.2 mA).

15. Connect a signal generator to the XXX Reservoir Flowrate Out input terminal points.

16. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out equals 24000 GPM.

17. Verify that the Metering Pump Speed Ratio setpoint can only be adjusted from 0.2 to 3.0 via the LOI andthe SCADA workstation.

18. Adjust the Metering Pump Speed Ratio setpoint via the LOI and/or the SCADA workstation to 1.0.

19. Place the "Remote-Local Flow Control" switch in the "Remote" position.

20. Verify that the pump speed output is 50% (12 mA).

-21. Adjust the Metering Pump Speed Ratio setpoint via the LOI and/or the SCADA workstation to 2.0.

22. Verify that the pump speed output is now 100% (20 mA).

-23. Adjust the Metering Pump Speed Ratio setpoint via the LOt and/or the SCADA workstation to 1.0.

24. Verify that the pump speed output is once again 50% (12 mA).

-25. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out equals 48000 GPM.


27. Adjust the Metering Pump Speed Ratio setpoint via the LOI and/or the SCADA workstation to 2.0.

28. Verify that the pump speed output does not exceed 100% (20 mA).

29. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out input equals 20.5 mA.

30. Verify that the pump speed output goes to 0% (4 rmA),

31. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out equals 48000 GPM.


33. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out input equals 2.5 mA.

34. Verify that the pump speed output gocs to 0% (4 mA).


17000-3 01 -EUse or disclosure of the data contained within this submittal



- 35. Adjust the output of the signal generator so that the XXX Reservoir Flowrate Out equals 48000 GPM.

36. Verify that the pump speed output is now 100% (20 mA).37. Remove the signal generator from the XXX Reservoir F[owrate Out input terminal points.

38. Verify that the pump speed output goes to 0% (4 mA).

Automatic Stroke Control:

-39. Connect a signal generator to the Chlorine Residual input terminal points.

-40. Adjust the output of the signal generator so that the Chlorine Residual equals 1.00 mg/L.-41. Place the Pump control mode in "PLC Pump Stroke control" from the LOI and/or the SCADA workstation.

-42. Adjust the Chlorine Residual setpoint to 2.5 mg/L.

43. Enter tuning parameter values for PID loop operation (gain, reset, rate).

44. Adjust Station Flowrate via the signal generator and verify that the Pump Stroke control output changes inrelation to the variable flow signal.

-45. As Pump Stroke control output changes, verify that the control output does not reach a value below 20%.

DYNAC Alarms

46. Adjust the "High Residual" alarm setpoint at SCADA to 2.00 mg/L.

-47. Adjust the "Low Residual" alarm setpoint at SCADA to 0.25 mg/L.

-48. Adjust the "Low-Low Residual" alarm setpoint at SCADA to 0.15 mg/L.

49. Adjust the output of the signal generator so that the Chlorine Residual equals 2.00 mg/L.

-50. Verify that a "High Residual" alarm is generated at SCADA.


-52. Verify that a "Low Residual" alarm is generated at SCADA.


-54. Verify that a "Low-Low Residual" alarm is generated at SCADA.

-55. Adjust the "High Speed" alarm setpoint at SCADA to 55.0%.

56. Adjust the "Low Speed" alarm setpoint at SCADA to 3.0%.

- 57. Adjust the "Low-Low Speed" alarm setpoint at SCADA to 2.5%.-58. Place the Pump control mode in "Supervisory Manual Pump Speed control" from the LOI and/or the

SCADA workstation.

-59. Adjust the manual metering pump speed to 55.0%.

-60. Verify that a "High Speed" alarm is generated at SCADA.

-61. Adjust the manual metering pump speed to 3,0%.

-62. Verify that a "Low Speed" alarm is generated at SCADA.

-63. Adjust the manual metering pump speed to 2.5%.

-64. Verify that a "Low-Low Speed" alarm is generated at SCADA.




*Performance:


Comments:

Acceptance:

Checked By: Date:

Witnessed By:

November 20, 2001 Installed Test Procedures Page 2317000-3.0J-E

Use or disclosure of the data contained within this submittal








Test Objective:

Verify proper operation of the configured control strategies per the Site Monitoring and Control DescriptionSubmittal as well as Specification Section 17425.

Expected Results:


Test Procedure:

CS 4 - Station Monitoring and Alarming

Reference: Specification Section 17425-2.03,D

Station Intrusion Monitoring and Alarming:

- 1. Simulate an energized station entry input and verify that the station intrusion alarm is normal.2. Take the station entry input away and verify that a station intrusion alarm is generated after 10 seconds.

3. Verify that the common alarm indicator on the PLC is activated.-4. Simulate an energized station entry input and verify that after an LOI/SCADA-adjustable reset interval

(initially set at 30 seconds), the station intrusion alarm returns to normal.-5. Verify that the common alarm indicator on the PLC is deactivated.

PLC Intrusion Monitoring and Alarming:

-6. Hold the plunger in for the PLC entry switch and verify that the PLC intrusion alarm is normal.-7. Release the plunger and verify that a PLC intrusion alarm is generated after 5 seconds.

- 8. Verify that the common alarm indicator on the PLC is activated.

-9. Hold the plunger in for the PLC entry switch and verify that after an LOIISCADA-adjustable reset interval(initially set at 30 seconds), the PLC intrusion alarm returns to normal.

-10. Verify that the common alarm indicator on the PLC is deactivated.

Fire Monitoring and Alarming:

- 11. Simulate an energized fire alarm input and verify that the fire alarm is normal.- 12. Take the fire alarm input away and verify that a fire alarm is generated after 5 seconds.




- 13. Verify that the common alarm indicator on the PLC is activated.

-14. Simulate an energized fire alarm input and verity that after an LOl/SCADA-adjustable reset interval(initially set at 30 seconds), the fire alarm returns to normal.

15. Verify that the common alarm indicator on the PLC is deactivated.

Commercial Power Failure Monitoring and Alarming:

16. Verify that there is commercial power available within the PLC and that the commercial power failurealarm is normal.

17. Turn off the 20A breaker within the PLC and verify that a commercial power failure alarm is generatedafter 5 seconds.

18. Verify that the common alarm indicator on the PLC is activated.

19. Turn the 20A breaker within the PLC back on and verify that after an LOI/SCADA-adjustable reset interval(initially set at 30 seconds), the commercial power failure alarm returns to normal.

20. Verify that the common alarm indicator on the PLC is deactivated.

Common Alarming:

21. Verify that each alarm generated activates the common alarm indicator on the PLC.

November 20, 2001 Installed Test Procedures Page 2517000-3 01-E


TECHNICAL SPECIFICATIONS H-935ADIVISION 16: ELECTRICAL16903: MONITORING AND CONTROL EQUIPMENT

Performance:


Comments:

0

Acceptance:

Checked By: Date:

Witnessed By:









Test Objective:

Verify proper operation of the configured control strategies per the Site Monitoring and Control DescriptionSubmittal as well as Specification Section 17425.

Expected Results:


Test Procedure:

CS 8 - Supervisory Manual Pump and Valve Control

Reference: Specification Section 17425-2.03.H

Supervisory Manual Pump Control (This includes manual control described in CS2):

- 1. Adjust the "Level" setpoint so that it is at -7.5 ft via the LOT and/or the SCADA workstation.

-2. Adjust the "Level" deadband to 4 ft via the LOT and/or the SCADA workstation.

-3. Enable the duration setting for "Manual Pump Run Control" mode at the LOI and/or the SCADAworkstation.

- 4. Adjust the "SCADA Manual Pump Run" period to 30 seconds via the LOI and/or the SCADA workstation.

5. Adjust the Reservoir Level input to -8 ft (i.e. below level setpoint).

6. Place the pump control strategy into "manual over-ride" mode from the LOI and/or the SCADAworkstation.

-7. Enter a Pump 1 start command from the LOI and/or the SCADA workstation.




11. Verify that after the "SCADA Manual Pump Run Period" has expired, the surge valve is called to open.



14. Enter a Pump I start command from the LOI and/or the SCADA workstation.







17. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.18. Raise the Reservoir Level input to -7 ft (i.e. above level setpoint) prior to the "SCADA Manual Pump Run

Period" expiring.

19, Verify that Pump I is NOT called to stop.

-20. Verify that after the "SCADA Manual Pump Run Period" has expired, the surge valve is called to open.



23. Enter a Pump I start command from the LOI and/or the SCADA workstation.




-27. Enter a Pump 1 stop command prior to the expiration of the "SCADA Manual Pump Run" period.


-29. Verify that Pump I is called to stop after the "First Pump Required" delay has expired.


-31. Enable the continuous setting for "Manual Pump Run Control" mode at the LOI and/or the SCADAworkstation.

32. Adjust the Reservoir Level input to -8 fit (i.e. below level setpoint).

133, Enter a Pump I start command from the LOI and/or the SCADA workstation.


-35. Verify that Pump 1 is called to run after the "First Pump Required" delay has expired.


- 37. Adjust the Reservoir Level input to -7 ft (i.e. above the level setpoint).

-38. Verify that Pump 1 is NOT called to stop.

_ 39. Enter a pump stop command.


-41. Verify that Pump I is called to stop after the "First Pump Required" delay has expired.-42. Verify that the surge valve is called to close after the "Surge Valve Close" delay has expired.

43. Repeat the above steps for all pumps.

Pump Lockout

-- 44. Enable the pump lockout command for Pump I and verify that the LOI and SCADA read "Enabled".

45. Enter a Pump I start command from the LOI and/or the SCADA workstation and verify that Pump 1 isNOT called to run.

46. Disable the pump lockout command for Pump I and verify that the LOI and SCADA read "Disabled".


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technical specifications hh-935a division 16: electrical

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