9117-11-7274 Addendum 1 - Toronto · Request for Proposal No. 9117-11-7274 ... 7.4 Hardware SAT ......

Lou Pagano Director

Purchasing and Materials Management Division City Hall, 18th Floor, West Tower 100 Queen Street West Toronto, Ontario M5H 2N2

Victor Tryl, Manager Professional Services

November 10, 2011 posted in pdf (189 pages)

ADDENDUM NO. 1

Request for Proposal No. 9117-11-7274 FOR: Professional Engineering Services associated with the

PLC Platform Migration & Upgrades in Water Treatment & Supply facilities. CLOSING: 12:00 NOON (LOCAL TIME), November 28, 2011.

Please refer to the above Request for Proposal (RFP) document in your possession and be advised of the following:

I. ADDED

1. The original Appendix E on the CD that was handed out at the prebid meeting or picked up at City Hall did not contain all the referenced appendices within the 'PCS Guidelines' document. The revised Appendix E document is attached, or you may also contact the buyer listed below to receive the pdf copy by email.

2. The following is the list of firms who attended the mandatory prebid meeting held on November 8. 2011 at Metro Hall.

1. Aecom 2. Associated Engineering 3. CH2M Hill 4. EMA 5. Eramosa Engineering Inc. 6. IBI Group 7. Insyght Systems Inc. 8. Hatch Mott MacDonald 9. Wardrop Engineering (Tetra Tech) 10. Westin 11. Scadex Technology 12. Summa Engineering

Should you have any questions regarding this addendum contact Kay Humphrey at 416-392-7326 or by email [email protected]. Please attach this addendum to your RFP document and be governed accordingly. Proponents must acknowledge receipt of all addenda in their Proposal in the space provided on the Proposal Submission Form as per Appendix B, Section 4 - Addenda of the RFP document. All other aspects of the RFP remain the same. Victor Tryl, P. Eng. Manager Professional Services

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Process Control System (PCS) Guidelines

Implementation Guidelines

Process Control System (PCS) Implementation Guidelines

Version 1.0

July 30, 2011

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Process Contorl System (PCS) Implementation Guidelines Record of Revision

Revision Number

Date Of Revision

Revised Pages Revised by

1.0 July 30, 2011 General

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Table of Contents

1. Introduction ..............................................................................................................................1-4 1.1 General ............................................................................................................................... 1-4 1.2 Scope of Guideline.............................................................................................................. 1-4 1.3 Objectives ........................................................................................................................... 1-4 1.4 Guideline ............................................................................................................................ 1-5 1.5 Definitions and Roles .......................................................................................................... 1-5

2. RFP and Engineering Services Contract Award ............................................................. 2-10 2.1 General ............................................................................................................................. 2-10 2.2 Identify PCS Requirements ............................................................................................... 2-10 2.3 Scope of Work .................................................................................................................. 2-10 2.4 RFP .................................................................................................................................. 2-10 2.5 RFP Evaluation ................................................................................................................. 2-11 2.6 Engineering Services Contract Award ............................................................................... 2-11

3. Pre-Design .............................................................................................................................. 3-12 3.1 General ............................................................................................................................. 3-12 3.2 Project Commencement .................................................................................................... 3-12 3.3 Field Verification .............................................................................................................. 3-12 3.4 Requirements Definition/50% Pre-Design ......................................................................... 3-12 3.5 75% Pre-Design ................................................................................................................ 3-14 3.6 100% Pre-Design .............................................................................................................. 3-15

4. Detailed Design ...................................................................................................................... 4-16 4.1 General ............................................................................................................................. 4-16 4.2 Tag List ............................................................................................................................ 4-16 4.3 50% Detailed Design ........................................................................................................ 4-16 4.4 70% Detailed Design ........................................................................................................ 4-17 4.5 Detailed Technical Specifications...................................................................................... 4-18 4.6 Apply For Approval .......................................................................................................... 4-18 4.7 95% Detailed Design ........................................................................................................ 4-18 4.8 100% Detailed Design/Tender Document .......................................................................... 4-18

5. Construction - Equipment ................................................................................................... 5-19 5.1 General ............................................................................................................................. 5-19 5.2 Shop Drawings ................................................................................................................. 5-19 5.3 Equipment and Panel Procurement and Fabrication ........................................................... 5-19 5.4 Test Sheets........................................................................................................................ 5-19 5.5 Equipment and Panel FATs ............................................................................................... 5-19 5.6 Transition Plan.................................................................................................................. 5-20 5.7 Equipment Installation and Wiring .................................................................................... 5-20 5.8 Pre-Start Health and Safety ............................................................................................... 5-20

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5.9 Entity Information Lists .................................................................................................... 5-21 6. Construction - Software ....................................................................................................... 6-22

6.1 General ............................................................................................................................. 6-22 6.2 Flow Chart Development .................................................................................................. 6-22 6.3 Software Modules ............................................................................................................. 6-22 6.4 Software Development ...................................................................................................... 6-22 6.5 FAT Plan .......................................................................................................................... 6-23 6.6 Software FAT ................................................................................................................... 6-23

7. Construction – Testing and Commissioning ..................................................................... 7-24 7.1 General ............................................................................................................................. 7-24 7.2 Hardware SAT and Training Plan...................................................................................... 7-24 7.3 Hardware Training ............................................................................................................ 7-24 7.4 Hardware SAT .................................................................................................................. 7-24 7.5 Software SAT and Training Plan ....................................................................................... 7-25 7.6 Software Training ............................................................................................................. 7-25 7.7 Software SAT ................................................................................................................... 7-25 7.8 Operational Test/System Performance Test ....................................................................... 7-25 7.9 As-Built Documentation ................................................................................................... 7-26 7.10 Post Construction Warranty Period ................................................................................... 7-26

Appendix A - Project Tasks Flowcharts

Appendix B - Project Tasks Implementation Checklists

Appendix C – Associated Guidelines

Field Verification Procedure Process Control Narrative P&ID Standard Symbols and Practices Colour Convention RPU Software Programming Standard Software Modules Operator Interface Programming Process Display Programming Alarming Instrument and Equipment Testing SCADA Factory Acceptance Testing SCADA Site Accecptance Testing and Commissioning PCS Documentation Training

Appendix D – Associated PCS Standards and Installation Drawings List

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1. Introduction 1.1 General Toronto Water has implemented a Process Control System (PCS) for control and monitoring of its facilities (Water treatment plants, Wastewater treatment plants, Water supply, and Sewage pumping stations). The PCS consists of instrumentation, control devices, wiring, networking, input/output devices, control panels, local and central Human Machine Interfaces (HMIs) and Remote Processing Units (RPUs) / Programmming Logic Controllers (PLCs). Any new project in Toronto Water that has a PCS component will require integration of the new project into the exisiting PCS of the facilitiy. The overall process for any project with a PCS component comprises six stages:

1. RFP development, issue, evaluation, and subsequent contract award for engineering services

2. Pre-design of the PCS component

3. Detailed design of the PCS component

4. Construction - Equipment

5. Construction – Software

6. Construction – Testing and Commissioning

Please refer to Appendix A (Flowcharts) and Appendix B (Checklists) for tools to assist with the process of integrating any new project into the exisiting PCS of the facility. The relationship between deliverables and project stages is not always evident for projects where the PCS component is relatively small. Some of the stages/phases mentioned in the Flowcharts and Checklists may not apply for very small PCS projects.

1.2 Scope of Guideline This guideline provides ‘high level’ information for consultants and project managers on project deliverables, phasing, and review requirements for Toronto Water projects that have a PCS component.

1.3 Objectives The guideline objective is to ensure that a clear understanding exists for City project managers and consultants as to the deliverable requirements for a PCS project or project with a PCS component, in terms of the phasing for those deliverables and services in step with various project phases from initial design stages to completion of the project, as well as defining the responsibilities for provision of information and deliverable review services.

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1.4 Guideline Guidance documentation for the PCS implementation comprises three separate and related documents: a series of project task flow charts illustrating the logical flow deemed necessary for successful implementation of the project (Appendix A); a checklist intended for project managers to ensure engineering services providers deliver the required services and documentation at the appropriate stage of the project (Appendix B); and the Process Control System Implementation Guideline (this document).

Flowcharts for each stage are comprehensive and are designed to ensure the deliverables, their inter-relationships, and their delivery timing is appropriate for successful implementation of PCS projects. Depending upon the project size and scope, some of the steps in the various stages may not be required.

Checklists for each stage provide a simplified review method for project managers to ensure consultant deliverables are provided at the right project stage, as well as indicate supply sources for information typically needed by the consultant and to indicate the in-house review group for all consultant technical deliverables. The checklists also indicate the flow of information and can be used as a tool by project managers to guide a PCS project. Depending upon the project size and scope, some of the steps in the various checklists may not be required. As part of the project scope development, the project manager – with assistance from the PCS Unit – will develop the project tasks checklists specific to the project. Once the “scope of work for a RFP” has been defined, then a “project specific checklist” shall be prepared, and provided in the RFP.

The Process Control System Implementation Guideline is intended to address how engineering services are provided, and at what stage each service and its corresponding deliverable is provided, and provides more specific, and more detailed, assistance to the engineering services provider in how PCS projects should be conducted. External references to other, more specific, guideline documents are also provided throughout this document.

1.5 Definitions and Roles The groups typically involved in PCS projects and their respective roles are detailed below.

1. City

The owner (City of Toronto) generally performs all tasks detailed below in Section 2 RFP and Engineering Services Contract Award as well as reviewing the work of the Consultant, Contractor, and Systems Integrator. The City may involve the following internal organizations, depending on the components and complexity of the project:

• City’s Project Manager

The project manager is the single point of contact for all communication between the City and the Consultant for the project, unless others are designated as contacts for specific purposes. Responsibilities of the project manager include:

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i. Initial project planning and RFP preparation

ii. Tendering and award for consulting services

iii. Ensure timely submission of deliverables from Consultant and timely review by City staff

For more detailed information on the responsibilities of the project manager, consult the Toronto Water Project Delivery System manual.

• Major Capital Projects (MCP)

MCP is TW engineering group providing project management and advisory to the Operation Group for the various complex PCS and electrical systems projects. .

• PCS Unit (PCSU)

PCSU (currently within MCP) maintains the standards and guidelines for PCS projects and technology. PCSU also maintains facilities PCS master documentation: Master P&ID, Master Process Control Narratives, SCADA Architecture Drawings, Hardware and Software Inventory Lists. As custodian of Electronic Tagging Management System (ETMS) PCSU manage tagging requests & approvals. They provide engineering support for review of design reports, engineering drawings, specifications and cost estimates. MCP also assists with coordinating the various internal City organizations for purposes of deliverable review and comment.

• Integrated Technology Management (ITM)

The ITM group provides support for review of SCADA hardware and software deliverables such as servers, PLCs, networking, and all related customized programming. They are also active participants in Factory and Site Acceptance Tests. As custodian of PLC software modules ITM get involved in testing and approval of any new software module, if needed.

• Operation Group

The Operation Group refers to the support staff at the facility at which the project is being undertaken. They will be the principal group driving the development of the Scope of Work, and will review deliverables for operatability and maintainability during the project, to ensure compatibility with existing equipment at the facility. They are also active participants in Factory and Site Acceptance Tests.

• Optimized Maintenance Unit (OMU)

The OMU maintains the Work Management System (WMS) databases for TW assets including all PCS related equipment in Toronto Water Facilities. Their

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involvement in PCS projects will typically be to review and approve WMS tagging assignments proposed by the Consultant.

2. Consultant

The Consultant is contracted by the City to perform the Scope of Work as defined in the RFP. The Consultant generally performs all tasks detailed below in Section 3 Pre-Design and Section 4 Detailed Design as well as representing the City during the Construction phase. As the City’s representative, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City. The Consultant also participates in FAT, SAT, Commissioning and Training activities, and updating of documentation of the project.

A detailed list of the Consultant’s responsibilities follows:

• Responsible for the engineering and design of the I&C and SCADA System, including integration with existing system control logic

• Preparation/Updating of Process Control Narratives and P&ID

• Preparation of Contract Specifications and Drawings of I&C and SCADA system

• Review of the RPU and HMI configuration, as prepared by the Contractor, and ensure compliance with City’s standards

• Prepare requirements for factory acceptance test (FAT) plan

• Attend and witness FAT at the Contractor’s facility to ensure compliance with City’s requirements

• Attend and witness testing of all field instruments and control loops performed by the Contractor

• Prepare requirements for site acceptance test (SAT) plan

• Attend and witness SAT on site to ensure compliance with City’s requirements

• Prepare requirements for operational test/system performance test

• Attend and witness operational test/system performance test

• Review Operation and Maintenance Manual prepared by the Contractor for compliance with the contract specifications

• Review Plant SCADA Operation Manual and submit at the specified milestones

• Prepare PCS training

• Testing and verification of the performance of the SCADA system

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• Prepare As-built PCS documentation

3. Contractor

The Contractor is contracted by the City to perform the Scope of Work as defined in the tender package created by the Consultant during Detailed Design and generally performs all tasks detailed in Section 5 Construction - Equipment and Section 7 Construction – Testing and Commissioning.

A detailed list of the Contractor’s responsibilities follows:

• Purchase and install all software, hardware, instrumentation and field wiring as specified

• Perform Hardware FAT at the Contractor’s facility, (if possible) witnessed by the Consultants and the City’s staff

• Perform field verification of all installed instruments, devices and control loops, witnessed by the Consultants and the City’s staff

• Participate in Consultant’s PCS training as applicable

• Perform Hardware SAT, witnessed by the Consultants and the City’s staff

• Perform operational test/system performance test, witnessed by the Consultants and the City’s staff.

• Hand over SCADA system to City’s staff when accepted by the City.

• Provide required warranty (response within 24 hours) and guarantee of SCADA system

• Respond to City for all deficiencies

• Prepare I&C Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones

4. Systems Integrator

The Systems Integrator is typically a subcontractor of the Consultant or Contractor and they generally perform all tasks detailed below in Section 6 Construction - Software and Section 7 Construction – Testing and Commissioning.

A detailed list of the System Integrator’s responsibilities follows:

• Configure PLC program in accordance with specified process control narratives

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• Configure HMI program in accordance with specified process control narratives

• Submit PLC and HMI programs to Consultants for review to ensure compliance with Specifications

• Participate in Consultant’s PCS training

• Perform Software FAT at the System Integrator’s facility, (if possible) witnessed by the Consultants and the City’s staff

• Perform Software SAT, witnessed by the Consultants and the City’s staff

• Perform operational test/system performance test, witnessed by the Consultants and the City’s staff.

• Hand over SCADA system to City’s staff when accepted by the City.

• Provide required warranty (response within 24 hours) and guarantee of SCADA system

• Respond to City for all deficiencies

• Prepare SCADA Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones

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2. RFP and Engineering Services Contract Award 2.1 General In general, RFP and Engineering Services Contract Award tasks are performed and/or coordinated by the City’s Project Manager. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

2.2 Identify PCS Requirements Conduct workshop(s) with PCSU, Operation Group, and ITM representitives to gather requirements of the new project including input on the following:

• Instrumentation

• Control System Hardware

• Software

• Networking

• Structured Cabling

• Electrical

Gather input on how the proposed project will affect the current facility PCS, and what additions and changes may be required.

2.3 Scope of Work Draft a Scope of Work based on the information gathered at the workshop(s) and have it reviewed by the various groups to ensure that the PCS elements are consistent with City objectives and standards. Amend the Scope of Work as required.

2.4 RFP Draft the PCS elements of the RFP including project specific “PCS checklist” following City’s PCS Guidelines, Standards, and the Project Delivery System (PDS). Drafted RFP shall be reviewed by PCSU, ITM and Operations group.

Issue the RFP and involve PCSU, ITM, and the Operation Group as required during the RFP process.

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2.5 RFP Evaluation Evaluate RFP responses with input from PCSU, ITM, and the Operation Group as required

2.6 Engineering Services Contract Award Award the project to a Consultant with input from PCSU, ITM, and the Operation Group as required.

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3. Pre-Design 3.1 General In general, Pre-Design tasks are performed by the Consultant and supervised by the City. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase. The Consultant shall follow Toronto Water’s PCS Guidelines and Standards throughout all phases of the project.

The purpose of the Pre-Design Report is to identify the key elements of the design to ensure that the final installation will meet the functional requirements and performance of Toronto Water. During the pre-design phase, the Consultant is expected to:

1. Visit the existing facility, or similar facility in Toronto Water, and familiarize themselves with the existing interfaces, PCS equipment including tagging, software, control strategies, and network architecture to be matched and/or upgraded.

2. Review all engineering reports and drawings for the PCS system related to the project.

3. Review previous pre-design report(s) and detailed designs prepared for the PCS system.

In general, consultants will comply with Section A.4 PREDESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system.

3.2 Project Commencement Conduct a Project Commencement Meeting, and invite PCSU, ITM, and the Operation Group representatives. The purpose of the meeting is for the Consultant to introduce their project team and have a discussion of the general strategy and goals of the project.

3.3 Field Verification The Field Verification Procedure shall be completed on commencement of pre-design engineering to ensure that the design will meet the requirements of the facility. This will minimize potential future claims by Contractors during construction, resulting from inaccurate information portraying existing conditions. This activity will also accurately define the scope of work required for achieving the targeted level of automation.

Refer to EDOCSLIB-#9091 Field Verification Procedure for more information.

3.4 Requirements Definition/50% Pre-Design The following elements should appear in the 50% submittal:

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1. Equipment and Instrumentation List - Design equipment and instrumentation to permit full monitoring and control capability under manual and/or automatic control. Prepare a table (example below) of all existing and proposed equipment and instrumentation to be installed for the project. The table should be filled in as much as possible during Pre-Design and then modification can continue through the Detailed Design and Construction phases.

Refer to EDOCSLIB-#6449 General Instrumentation Standards for the list of approved instruments and manufacturers for the City’s PCS projects. The list of approved manufacturers shall be reviewed in conjunction with the staff of the affected facility. This list is part of PCS Standards and Specifications that will be made available on request at this stage of the project as well as the other required Standards and Specifications referred to further in this document (see Appenix D for the full list of PCS Standards and Specifications).

Notwithstanding the inclusion of equipment in the approved manufacturers list, the Consultant is responsible for engineering design and project performance. The Consultant shall review the existing equipment at the facility and the approved list, discuss with the City the current performance of the equipment, and in conjunction with the City provide recommendation for first named and alternate named equipment to be specified using the approved list as a base.

Make recommendations to the City if additional manufacturers are requested to be added or removed as appropriate according to Consultant experience and the specific project requirements. This list will form the basis of named and alternate named manufacturers and suppliers in the Contract Specifications.

Table 1: Equipment and Instrumentation List

Headings of Table Development Stages Predesign Detailed Design As Constructed

Process Required Required Required Location Required Required Required Area Required Required Required Unit Required Required Required Equipment Tag (WMS/PCS Tag Number)

Required Required

Comment Required Required Required Device Type Required Required Required Device Description Required Required Required P&ID Required Required Manufacturer Required Model Required Serial Number Required

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Headings of Table Development Stages Predesign Detailed Design As Constructed

Measured range Required Required Calibrated Range Required Required I/O Type Required Required Required

2. Servers/PLCs/Network - Review and document all existing hardware affected by the project, and determine system capacity. Discuss capability for expansion and identify all additional hardware required for modifications so as to fully integrate the new or expanded works into the existing system. Identify all obsolete hardware that must be replaced as part of the upgrading of the existing or expansion of the process control system. Refer to EDOCSLIB-#8243 SCADA Computer System and EDOCSLIB-#8239 PCS Local Area Network (Appendix D) for technical detail and requirements.

3. SCADA Software - Review and document all existing software affected by the project, and identify all additional software required for modifications to the HMI, PLC and networking devices so as to fully integrate the new or expanded works into the existing system.

4. Control Wiring and Structured Cabling – Review and document all existing control wiring and network cabling, and identify all additional cabling that will be required so as to fully integrate the new or expanded works into the existing system.

5. Alarm Notification and Security – Review the existing alarm notification and security system of the facility, and document the proposed modifications and additions to provide the required services for notification of the critical PCS alarms of the project. Refer to EDOCSLIB-#9100 Alarming (Appendix C) for technical details and requirements.

6. Electrical System and Emergency Power – Review the existing power supplies to the relevant areas of the facility and document the proposed modifications and additions to provide the required electrical power for the proposed upgrades.

3.5 75% Pre-Design In addition to updates to the elements of the 50% pre-design, the following should appear in the 75% submittal:

1. Process Narrative – Provide a Process Narrative or update existing for each process, clearly describing how it is to be operated in all modes of process control. Process narratives shall be written in plain English to provide a clear understanding of the relationships between the equipments and the process variables to be monitored/controlled. Note that the Narrative will not apply solely to the new processes/equipment, but will detail all interaction with existing process/equipment control (i.e., alarm triggers, process variables shared by multiple processes, report

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generation, etc.). Refer to EDOCSLIB-#9093 Process Control Narratives (Appendix C) Section 1.3.1 for technical detail and requirements.

2. Process Flow Diagrams – Provide a Process Flow Diagram or update existing to clearly illustrate the relationships between the various affected processes and associated instrumentation.

3. Design Alternatives – The Consultant should include a section detailing any alternative designs that they feel might offer benefits to the City in terms of cost or functionality.

4. Cost Estimate – Include a cost estimate to construct the project according to the guidelines provided in the RFP.

5. Electrical Area Classification Report – If required, provide “Electrical Area classifications report” for the affected areas where electrical and instrumentation devices will be installed under the project.

3.6 100% Pre-Design The 100% Pre-Design submittal should include updates to reflect the comments made during review of the 75% submittal. City staff will review the 100% submittal and again provide comments to allow the Consultant to finalize the Pre-Deisgn report.

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4. Detailed Design 4.1 General In general, Detailed Design tasks are performed by the Consultant and supervised by the City. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Section A.5 DETAILED DESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system.

4.2 Tag List The City maintains a tag database known as the Enterprise Tagging Management System (ETMS). The Consultant shall have access to this database during design for the purpose of creating unique tagnames and producing a Tag List for review by the City. All equipment, equipment loop names, data and local area network cabling shall be tagged in accordance with EDOCSLIB-# 6454 Equipment and Data Names. These tag numbers shall be used in the P&ID drawing(s) and all related project documentations for the identification of all equipment and intruments.

4.3 50% Detailed Design The following elements should appear in the 50% Detailed Design submittal:

1. Process Control Narrative (PCN) – The Consultant will update the Master PCN provided by the City. Refer to EDOCSLIB-#9093 Process Control Narratives (Appendix C) for details of the requirements.

2. P&IDs - The Consultant will update the Master P&IDs provided by the City, or prepare new P&IDs (in case Master P&IDs do not exist). The City’s instrumentation symbols and control and instrumentation loop diagrams, including process and instrumentation diagrams, are generally based on the Instrument Society of America Standards ANSI/ISA-S5.1-1984 (R 1992) and ANSI/ISA-S5.4-1991, or latest revision. The ISA standards have been modified by the City to meet its own requirements. Consultants shall comply with EDOCSLIB-#9094 P&ID Standard Symbols and Practices (Appendix C).

3. SCADA Architecture Drawings – The Consultant shall update the SCADA Architecture drawing of the facility, to show modifications and additions of equipment.

4. Equipment Power Requirements – The Consultant shall provide drawings and specifications for any power supply upgrades or additions required as a result of new or modified equipment.

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5. Single-Line Drawings – If the new equipment requires changes to the facility’s single-line drawings, they shall be provided as part of this submission.

6. Electrical Area Classifications – These shall be updated from the classifications provided in the Pre-Design Report.

7. Cost Estimate – Provide an updated cost estimate.

4.4 70% Detailed Design In addition to updates to the elements of the 50% design, the following should appear in the 70% submittal:

1. Control Panel Drawings – The Consultant shall provide drawings for new panels or modifications to any existing control panels.

2. Loop Drawings – The Consultant shall produce loop drawings as required.

3. Equipment Layouts and Control Schematics – The Consultant shall produce equipment layout and control schematic drawings as required.

4. SCADA Hardware and Software Requirements – The Consultant shall create or update the Software Inventory List for the facility, indicating what new software or hardware is required for the SCADA system

5. Instrument Ranges and Setpoints – As part of the Process Control Narrative, this information shall be provided at this stage.

6. Alarm List - As part of the Process Control Narrative, this information shall be developed complete with “Alarm Conditioning” at this stage.

7. iHistorian, eOPS, POMS, LIMS Requirements - As part of the Process Control Narrative, this information shall be available at this stage.

8. Alarm Notification and Security – Detailed Design of the alarm notification requirements that were provided in the Pre-Design Report.

Coordinate with the City’s corporate security for security related issues.

9. Networking and Structured Cabling - Detailed Design of the networking and structured cabling requirements that were provided in the Pre-Design Report.

10. Equipment and Instrumentation Physical Tag List - Field equipment shall be tagged in accordance with EDOCSLIB-#6454 Equipment and Data Names. Provide completed Physical Tag List indicating details of the tag quantities and sizes.

11. Electrical Drawings and Requirements – Drawings showing electrical upgrades required for the project.

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12. Identify Hardware and Wiring Removal – Drawings to indicate obsolete hardware and wiring that is to be removed under the project.

13. Identify RPU/HMI Program/Code Removal – Produce a detailed list indicating which software tags/objects should be removed under the project.

4.5 Detailed Technical Specifications The Consultants shall refer to the PCS standards listed under PCS Standards and Specifications List (Appendix D) and shall use or adhere to those requirements. Consultants should obtain electronic versions of these standards related to the project from the City’s Project Manager.

The Consultants shall modify or edit the standards and create specifications to suit the project specific requirements of the contract, after getting consent from PCSU. However, where modifications are recommended, the Consultant is to highlight these proposed deviations to the City to ensure that the proposed changes do not compromise the City’s overall goal of standardizing PCS across Toronto Water facilities. The responsibility remains with the Consultant to ensure that contract specifications and drawings meet the requirements for proper project execution.

4.6 Apply For Approval Once the 70% Detailed Design package has been accepted by the City, it is expected that the Consultant will obtain approvals from agencies as required. Comments made by the approving agencies are to be incorporated into the documents for the 95% submittal to the City.


1. Pre-Start Health and Safety – The Consultant shall review and report as requried.

2. Electrical Area Classifications – The Consultant shall update electrical area classifications based on the detailed design

3. Updated Cost Estimate


1. Tender Document – The Consultant shall complete the preparation of the tender package.

2. Updated Cost Estimate

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5. Construction - Equipment 5.1 General In general, Construction – Equipment tasks are performed by the Contractor and supervised by the Consultant. See Appendix A – Project Tasks Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Section A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and solicit the City’s comments in addition to their own before returning reviewed deliverables to the Contractor.

5.2 Shop Drawings The Contractor is to submit shop drawings for all equipments and panels to be purchased for installation during the contract. The Consultant will review the shop drawings in accordance with EDOCSLIB-#9101 Instrument and Equipment Testing (Appendix C). The City has the option to review shop drawings as well though the responsibility for accuracy and correctness lies with the Consultant.

5.3 Equipment and Panel Procurement and Fabrication The Contractor will procure equipment and manufacture panels as required, after approval of the shop drawings. The Consultant will monitor the progress and ensure the project schedule is maintained.

5.4 Test Sheets Contractor is to provide Pre-FAT test documentation for major equipment such as MCCs, pumps, etc.

5.5 Equipment and Panel FATs The purpose of hardware FATs is to ensure the integrity of the equipment used to control and monitor the process at the City’s facilities. It is intended to demonstrate that the system configuration will function effectively once installed on site, and limits the need for on site modifications to hardware configurations.

The hardware FAT involves the following major components:

1. Control Panels & Local Operator Interfaces

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2. Networking Equipment

3. Workstations

4. PLCs.

The hardware FAT is performed at the Contractor's office. These tests must be completed by the contractor and approved by the Consultants prior to any equipment being delivered to the project site. The City has the option to witness the FATs as well, though the responsibility for approval lies with the Consultant.

5.6 Transition Plan A project will typically involve installing equipment into an existing, operating facility that has an operating PCS. The Contractor shall develop a transition plan that details the progression of installation tasks such that the impact on operations is minimized and the continued safe operation of the facility is assured. The plan should take the following considerations into account:

1. Features of the facility that may impose limitations during construction. For example, certain tasks might need to be performed during non-peak operating hours.

2. To maintain continuous operation and monitoring, provisions might need to be made for temporary parallel equipment. For example, if an older model PLC is being replaced, it might need to continue operating while the new PLC is installed and wired.

3. PCS upgrades typically require re-wiring of equipment that results in a temporary loss of use of the equipment. The transition plan needs to account for operational requirements while scheduling equipment down-time. The Operation Group will provide the Contractor with their operational constraints as required.

4. If PCS networking configuration changes are involved, the Contrator should consider the impact on the ability of the Operation Group to control and monitor related equipment.

Concsultant should review the transition plan prior submitting to City for approval.

5.7 Equipment Installation and Wiring Once equipment has been approved at the FAT and the Transition Plan has been accepted, the Contrator can deliver equipment to site and commence installation and wiring.

5.8 Pre-Start Health and Safety If a Pre-Start Health and Safety review and report are required (refer to the Toronto Water Prject Delivery System Manual for details), the Consultant shall produce the report and have it approved prior to the commencement of commissioning.

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5.9 Entity Information Lists The Contractor shall prepare the Entity Information Lists (WMS list) for all new and upgraded equipment in the project. See EDOCSLIB-#6454 Equipment and Data Names for the template.This information is used by the OMU for WMS purposes.

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6. Construction - Software 6.1 General In general, Construction – Software tasks are performed by the Systems Integrator and supervised by the Consultant. See Appendix A – Flowcharts for a concise depiction of tasks and deliverables required during this phase.

Consultants will comply with Section A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and provide their comments to the City.

6.2 Flow Chart Development The Systems Integrator shall develop logic flow charts to demonstrate their interpretation of the design documents. Refer to EDOCSLIB-#9096 RPU Software Programming (Appendix C) for more detail on the development of flow charts.

6.3 Software Modules The City has developed a series of standard software modules that are to be used by programmers to implement the control functions required by the project. The goal of standard software modules is to reduce development and maintenance costs by ensuring that software deployed throughout Toronto Water facilities has a common look and logical base. Refer to EDOCSLIB-#9097 Standard Software Modules (Appendix C) for more detail on the use of software modules.

In some cases, the Systems Integrator may find that a new or modified software module would be beneficial to the development of the software for the project. Modules can not be modified without the consent of PCSU/ITM. When the PCSU/ITM approves the development or modification of a software module, the Systems Integrator shall follow the procedure found in EDOCSLIB-#9097 Standard Software Modules (Appendix C).

6.4 Software Development Once it has been determined that the software modules are sufficient for the project, the Systems Integrator can begin software development according to the following Appendix C guidelines:

1. EDOCSLIB-#9099 Process Display Programming

2. EDOCSLIB-#9098 Operator Interface Programming

3. EDOCSLIB-#9100 Alarming

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4. EDOCSLIB-#9095 Colour Convention

5. EDOCSLIB-#9096 RPU Software Programming

6. EDOCSLIB-#9097 Standard Software Modules

Software is to be submitted at the 70% stage at which time the Consultant and City representitives will review the components for accuracy, adherence to standards, and compatibility with the rest of the facility PCS.

6.5 FAT Plan Prior to carrying out a Factory Acceptance Test of the software, the Systems Integrator shall prepare a detailed test plan for review by the Consultant. The test plan will identify all field I/O to be tested such as equipment status, control modes, and hardwired alarms. Also virtual points such as alarms, setpoints, and operator entered parameters. The test plan will then identify automatic logic tests designed to prove that the program responds as detailed in the Process Control Narrative. The plan will also identify a “graphics review” as well as include the PCN and the contract drawings (control schematics, loop diagrams, and process and instrumentation drawings – P&IDs) as part of the test plan. The Systems Integrator shall demonstrate that the test plan fulfils the intent and requirements of the PCN and will therefore result in the successful operation of the system when installed on site.

The test plan should also include a proposed schedule and a description of the proposed testing environment (hardware setup, software utilized) for approval by the Consultant and the City. Refer to EDOCSLIB-#9104 Factory AcceptanceTesting (Appendix C) for details. Once the schedule and documentation have been accepted, the Systems Integrator shall submit a copy of all software components to the City (known as the “Pre-FAT” version of software).

6.6 Software FAT The Systems Integrator will host the Factory Acceptance Test according to the details presented in the schedule and FAT documentation. Refer to EDOCSLIB-#9104 Factory AcceptanceTesting (Appendix C) for details. Upon completion of the FAT and subsequent corrections and re-testing as required, the Systems Integrator shall submit a copy of all software componenets to the City (known as the “Pre-SAT” version of software).

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7. Construction – Testing and Commissioning 7.1 General The Consultant shall comply with Appendix A7 SITE SERVICES DURING TESTING AND COMMISSIONING, of the RFP document for the engineering services required to be provided for the project.

The Consultant shall specify in the contract document that the Contractor and Systems Integrator are required to comply with the City’s standard procedure for the testing and commissioning of PCS.

As the City’s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City.

7.2 Hardware SAT and Training Plan The Contractor is to submit a SAT Plan that includes the following:

1. Schedule

2. Testing procedure for each item

3. Sign-off documentation

4. Details of City involvement, including any operational requirements such as shutdowns, communication interruptions, etc.

Refer to EDOCSLIB-#9101 Instrument and Equipment Testing and EDOCSLIB-#15167 Site Acceptance Testing (Appendix C) for more details.

The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to EDOCSLIB-#9109 Training (Appendix C) for more details.

7.3 Hardware Training The Contractor shall perform training on the installed hardware prior to the SAT. Refer to EDOCSLIB-#9109 Training (Appendix C) for more details.

7.4 Hardware SAT A Hardware SAT is to ensure the integrity of the equipment used to control and monitor the process at the City’s facilities once installed on site. Prior to the hardware SAT, the Consultant and Contractor must have jointly completed all I/O tests, loop tests, network tests, and instrumentation calibration verification sheets.

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The hardware SAT involves the following major components:

1. Control Panels & Local Operator Interfaces

2. Networking Equipment (as available)

3. Workstations

4. PLCs

5. Instrumentation

The hardware SAT is performed on site to ensure that the equipment has been installed, wired and configured correctly. The consultant shall compile all the SAT results and submit it to the City for their review.

The testing of the networking equipment, workstations, and PLCs is intended to confirm that the network as designed, and the configuration of the hardware as specified functions as an integral network on site and in conjunction with the City’s wide area network (WAN).

7.5 Software SAT and Training Plan The Systems Integrator’s SAT Plan should include the same I/O and Logic check sheets that were used during the Software FAT. In addition to check sheets, there should also be sign-off documentation and a schedule of activities that details the City’s involvement, including any operational requirements such as shutdowns, communication interruptions, etc. Refer to EDOCSLIB-#9107 Site Acceptance Testing and Commissioning (Appendix C) for more details.

The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to EDOCSLIB-# 9109 Training (Appendix C) for more details.

7.6 Software Training The Systems Integrator shall perform training on the new software components prior to the SAT. Refer to EDOCSLIB-#9109 Training (Appendix C) for more details.

7.7 Software SAT After training has been completed, the Software SAT can be performed. It is intended to confirm that the software functions according to the Process Control Narrative and allow fine-tuning of control loops and other process variables. Refer to EDOCSLIB-#9107 Site Acceptance Testing and Commissioning (Appendix C) for more details.

7.8 Operational Test/System Performance Test The operational test/system performance is a 5-day test (unless otherwise defined in RFP) of the system to simulate the operation of the system under different loading conditions. The test shall

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start on a Monday and will be restarted again on a Monday in the event of a failure of the system to operate as intended at any point in the 5-day period. During this period the software is to operate under Area Operator station and Central Operator station modes to simulate normal operation of the system. Where necessary, the Consultants will specify additional simulation logic to the RPU to allow the process area to be fully simulated for operational test/system performance. The provision of such simulation code is deemed to be within the scope of the Contractor services. Where necessary, the Consultant shall specify the provision of temporary piping and equipment in order to be able to carry out the simulation successfully.

7.9 As-Built Documentation The Contractor and Systems Integrator shall submit As-Built documentation during this phase. Refer the EDOCSLIB-#9108 PCS Documentation (Appendix C) for details.

7.10 Post Construction Warranty Period In general, the Systems Integrator shall provide all necessary services during the warranty period to update all software when deficiencies are found. Refer to the contract for specific warranty requirements.

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Appendix A – Project Tasks Flowcharts

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Identify PCS RequirementsConduct workshop with Operation

Group, PCSU, ITM to gather input on the following

InstrumentationControl System HardwareSoftwareNetworkingStructured CablingElectrical

RFP InitiationInitiate RFP process

according to PDS Manuals

Project Delivery System ManualsRFP TemplatePurchasing and Materials Management RFP and Policies

Scope of WorkPrepare Scope of Work with input from

Operation Group, PCSU, ITM

Review by:PCSU, ITM, Operation Group

Scope of Work accepted?

Yes

No

RFP AND ENGINEERING SERVICES CONTRACT AWARDFOR PROJECTS WITH PCS COMPONENT

PROJECT TASKS FLOW CHART

Scope of Work

RFPPrepare PCS and Electrical elements

for inclusion in the RFP


RFP accepted?

No

RFP

Yes

Finalize and Issue RFPPrepare Addenda as required. Involve

PCSU, ITM, Operation Group as needed

RFP EvaluationInvolve PCSU, ITM in evaluation

procedures as needed

AwardContract Negotiation and Execution.

Involve PCSU, ITM as needed

Possible Documentation to be made available to authors/reviewers

PCS Implementation GuidelinesPCS Implementation StandardsFacility Master Process Control NarrativesFacility Process Flow DiagramsFacility Master P&IDsFacility SCADA Architecture DrawingFacility Structured Cabling Standards and DrawingsToronto Water Equipment Tag StandardRelated Facility DrawingsOperation ManualsCity’s Drawing Standards

TASKS DELIVERABLESINPUTS/REFERENCES


EDOCSLIB-#9087-V1 Page 1 of 11 Appendix A30 of 189

Field VerificationVerify accuracy of existing

documentation against the following field conditions

Process and EquipmentControl SystemInstrumentationControl Wiring and Structured CablingElectrical Area Classification

Project CommencementConduct Project Commencement

meeting. Invite PCSU, ITM to attend.

Field Verification ReportPrepare report including “red-lined” P&IDs, Condition Assessment and

Design Alternatives

Field Verification Report accepted?

No


Yes

Requirements Definition/50% Pre-Design

Workshop(s) with PCSU, ITM, Operation Group and other

Stakeholders as required. Identify the following requirements

InstrumentationServers, PLCs, NetworkSCADA SoftwareControl Wiring and Structured CablingPaging and SecurityElectrical SystemEmergency Power

PCS Implementation GuidelinesPCS Implementation StandardsExisting Drawings (Electrical, Mechanical, I&C)Master P&IDsMaster Process Control NarrativeeOPS, WMS, POMS, LIMS requirements

Existing SCADA ArchitectureExisting PLC/HMI ProgramsRelated WMS DatabaseInventory Lists for Servers, PLCs, Network, Software


50% Pre-Design Report accepted?

Consolidate review comments and prepare Outstanding Issues list

Yes

75% Pre-Design

Incorporate 50% Pre-Design commentsEquipment and Instrumentation ListProcess Narrative (PN)Process Flow Diagrams (PFD)Design AlternativesCost EstimateElectrical Area Classification Report

No



No

Yes

PRE-DESIGN (PCS COMPONENT)


Field Verification Report

50% Pre-Design Report


Page-3





100% Pre-Design

Incorporate 75% Pre-Design commentsUpdated Cost Estimate



No

Yes

Pre-Design CompleteProceed to Detailed Design


PRE-DESIGN (PCS COMPONENT)



Page-2



50% Detailed DesignDevelop or update the following

documents

Master Process Control NarrativesMaster P&IDsSCADA Architecture drawingsEquipment Power RequirementsSingle-Line drawingsElectrical Area ClassificationCost Estimate

Tag ListPrepare tags for new Equipment and

Instrumentation

50% Detailed Design accepted?

No


Yes

Tagging Database – Enterprise Tagging Management System (ETMS)Toronto Water Tagging Standard


DETAILED DESIGN (PCS COMPONENT)


50% Detailed Design Documents

Tag List

Tag List accepted?

No Review by:OMU, PCSU, Operation Group

Yes

70% Detailed DesignDevelop or update the following documents

Update 50% Detailed Design DocumentsControl Panel DrawingsLoop DrawingsEquipment Layouts and Control SchematicsSCADA Hardware and Software RequirementsInstrument Ranges and SetpointsAlarm List including Alarm ConditioningIdentify iHistorian, eOPS, POMS, LIMS RequirementsPaging and SecurityNetworking and Structured CablingEquipment and Instrumentation Physical Tag ListElectrical Drawings and RequirementsIdentify Hardware and Wiring RemovalIdentify RPU/HMI Program/Code Removal



Review by:OMU, PCSU, ITM, Operation

Group

Yes

Detailed Technical SpecificationDevelop the following specifications (PCS related

sections)

Table of ContentsDivision 1Division 11Division 13Division 15Division 16

No


Page-5




DETAILED DESIGN (PCS COMPONENT)


Apply For ApprovalSend documents to Approval Agencies

as required

Yes

Submit Applications with associated documentation

Approvals received?

No

Incorporate Agency Comments into the Documents


Update 70% Detailed Design DocumentsPre-Start Health and Safety Review and Report as requiredElectrical Area Classifications as requiredCost Estimate



Review by:PCSU, ITM, Operation

Group

No

Yes



Update 95% Detailed Design DocumentsTender DocumentUpdate Cost Estimate

Involve PCSU, ITM as required during Tendering Process


100% Detailed Design/Tender Document

accepted?

Yes

No

100% Detailed Design/Tender

Document

Review by:PCSU, ITM, Operation

Group

Page-4



Shop Drawings

Prepare Applicable Shop Drawings

InstrumentationServers, PLCs, OITsNetworkPanels, CablingMCCs, Switchgear

No

CONSTRUCTION – EQUIPMENT (PCS COMPONENT)


Shop Drawings

Review by:PCSU, ITM,

Operation Group

Bulk Construction (Conduits, Cable Trays, Duct Banks)


Contract PCS Start-up

Involve Consultant’s PCS staff, Systems Integrator, PCSU, ITM in kick-

off meeting as required

Shop Drawings accepted?

Yes

Equipment and Panel Factory Acceptance Tests

Where required, FAT(s) to be attended by General Contractor, Consultant,

PCSU, ITM, Operation Group

Equipment received at site complete with O&M Manuals, Certificates,

Reports, Drawings

Equipment and Panel Procurement and Fabrication

FAT/Whiteness Test Sheets

Prepare Test Sheets for Equipment and Panels

Test Sheets

Test Sheets accepted?

Review by:PCSU, Operation Group

Yes

No

Factory Acceptance Test

Reports

Factory Acceptance Test Reports accepted?

Yes

No

Page-7

Consultant’s Review


Prepare FAT Reports

Review by:PCSU, Operation Group




Transition Plan

Prepare a Transition Plan to address the following issues.

Process LimitationsPotential Parallel Equipement, Panels, HMIsDetailed Schedule of TerminationsNetwork ConfigurationHardware and Wiring Removal

Transition Plan


Operation Group

No

CONSTRUCTION – EQUIPMENT (PCS COMPONENT)



Page-6

Equipment Installation and Wiring

Entity (Asset) Information Lists

(WMS)

Review by:PCSU, OMU

Transition Plan accepted?

Pre-Start Health and Safety

Prepare Pre-Start Health and Safety Review and Report as Required

(Consultant)

Entity Information Lists

Prepare Entity (Asset) Information Lists (WMS)

WMS Lists accepted?

Yes

No

Page-10

Proceed to Testing and Commissioning



Yes



CONSTRUCTION – SOFTWARE (PCS COMPONENT)


Flow Chart Development

Develop Logic Flow Charts

Logic Flow Charts accepted?

No

Logic Flow Charts


Operation Group

Software Modules Library Software Modules

Are existing software modules sufficient for the project?

New Software Modules

Documentation accepted?

No

Yes

New Software Modules Flow Chart Development

Develop Logic Flow Charts

New Software Modules Logic Flow Charts

Review by:PCSU, ITM

New Software Modules Logic Flow Charts accepted?

No

Yes

Develop New Software Modules

PLC, HMI, Simulation components as required

New Software Modules FAT

Attended by Consultant,PCSU, ITM, Operation Group as Required

Completed New Software Modules

Documentation

FAT passed?

Reviewed by:PCSU, ITM

No

Yes

Yes


PCS Implementation Guidelines PCS Standards Design Phase Drawings (Master P&IDs, Electrical, I&C) Master Process Control Narrative eOPS, WMS, POMS, LIMS requirements

Page-9



New Software Modules Documentation


Yes

No




CONSTRUCTION – SOFTWARE (PCS COMPONENT)

Page-8


FAT Plan

Develop FAT Documentation and Schedule

FAT Plan

FAT Plan accepted?

Review by:PCSU, ITM

Operation Group

No

FAT

Factory Acceptance Testing

Attended by Consultant, PCSU, ITM, Operation Group

Completed FAT Documentation and Sign-Off

Yes

FAT passed?

No

SoftwareVersion: Pre-FAT

Yes

Correct software deficiencies identified during FAT

SoftwareVersion: Pre-SAT

Page-10

Software Development

PLCHMISimulation

70% Software Development

accepted?

70% Software Development

(Screen Captures, PLC, HMI and

Simulation Programs)

Review by:PCSU, ITM (HMI, PLC),

Operation Group (Screen Captures)

No

Existing Programs -PLC, HMI, Simulation


Yes


FAT Documentation and Sign-off

Complete FAT Documentation and Sign-off




CONSTRUCTION – TESTING AND COMMISSIONING (PCS COMPONENT)


Software SAT and Training Plan

Develop SAT Documentation, Schedule and Training Plan

Software SAT and Training Plan

Software SAT and Training Plan accepted?


Operation Group

No

Yes

Software Training

Provide Software Training by Consultant and Systems Integrator

Page-7 Page-9


Hardware SAT and Training Plan

Develop SAT Documentation, Schedule and Training Plan for:

Equipment, Instrumentation, Network, Panels, Field Wiring

Hardware SAT and Training Plan

Hardware SAT and Training Plan accepted?

Review by:PCSU, Operation Group, ITM (Network),

No

Hardware Training

Provide Operation and Maintenance Training for: Equipment,

Instrumentation, Network and Panels

Yes

Hardware SAT

Hardware Site Acceptance TestingEquipment Installation TestInstrumentation CalibrationPanel Installation TestNetwork Testing Field Wiring Test

Attended by Consultant, PCSU, Operation Group, ITM (Network)

Completed Hardware SAT Documentation and Sign-Off

Yes

Hardware SAT passed?

No

Page-11


Hardware SAT Documentation and Sign-off

Complete Hardware SAT Documentation and Sign-off





Software SAT

Software Site Acceptance Testing

Attended by Consultant, PCSU, ITM, Operation Group

Completed Software SAT

Documentation and Sign-Off

Yes

Software SAT passed?

No

Operational Test/ System Performance Test

Correct software deficiencies identified during SAT

SoftwareVersion: SAT

CONSTRUCTION – TESTING AND COMMISSIONING (PCS COMPONENT)



Page-10

Post Construction Warranty Period

Operational Test passed?

As-Built Documentation

Prepare Hardware and Software As-Built Documentation


accepted?



Operation GroupNo

Yes

Software SAT Documentation and Sign-off

Complete Software SAT Documentation and Sign-off


No

Yes






Appendix B – Project Tasks Implementation Checklists

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Process Control System (PCS) GuidelinesAppendix B

Project Phase: RFP and Engineering Services Contract Award for Projects with PCS Component

ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers

Received Delivered

1.1 RFP Initiation Project Delivery System Manuals PCSU

RFP Template PCSU

Purchasing and Materials Management RFP and Policies PCSU

1.2 Identify PCS RequirementsConduct workshop to identify PCS Requirements


1.3 Scope of Work DefinitionPrepare Scope of Work with input from PCSU, ITM, Operation Group


Reviewed Scope of WorkPCSU, ITM, Operation Group

Consolidate Scope of Work Review Comments

Final Scope of WorkPCSU, ITM, Operation Group

1.4 RFP PCS Implementation Guidelines PCSU

PCS Implementation Standards PCSU

Facility Master Process Control Narratives PCSU

Facility Process Flow Diagrams PCSU

Facility Master P&IDs PCSU

Facility SCADA Architecture Drawing PCSU

Facility Structured Cabling Drawings Operation Group

Tornto Water Equipment Tag Standard PCSU

Related Facility Drawings Operation Group

Operation Manuals Operation Group

City's Drawing Standards PCSU

RFP RFPPCSU, ITM, OMU, Operation Group

Reviewed RFPPCSU, ITM, OMU, Operation Group Consolidate RFP Review Comments PCSU

Comnsolidated RFP Review Comments PCSU Final RFPPCSU, ITM, OMU, Operation Group

1.5 Finalize and Issue RFPPrepare Addenda as required. Involve PCSU, ITM, Operation Group as needed

1.6 RFP EvaluationEvaluate Proposals. Involve PCSU, ITM, Operation Group as needed

1.7 AwardContract Negotiation and Execution. Involve PCSU, ITM, Operation Group as needed

MANAGER

Project Tasks Implementation Checklist

PROJECT

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Process Control System (PCS) GuidelinesImplementation Checklists

Project Phase: Pre-Design (PCS Component)


Received Delivered

2.1 Project Commencement Conduct Project Commencement MeetingPCSU. ITM, OMU as required

2.2 Field Verification PCS Implementation Guidelines PCSU PCS Implementation Guidelines Consultant

PCS Implementation Standards PCSU PCS Implementation Standards Consultant

Existing Drawings Operation Group Existing Drawings Consultant

Master P&IDs PCSU Master P&IDs Consultant

Master Process Control Narrative PCSU Master Process Control Narrative Consultant

eOPS, WMS, POMS, LIMS Requirements Operation Group eOPS, WMS, POMS, LIMS Requirements Consultant

2.3 Field Verification Report Red-lined P&IDs Consultant Red-lined P&IDsPCSU, Operation Group

Condition Assessment Consultant Condition AssessmentPCSU, ITM, Operation Group

Design Alternatives Consultant Design AlternativesPCSU, ITM, Operation Group

Reviewed Field Verification ReportPCSU, ITM, Operation Group

Consolidate Field Verification Report Review Comments PCSU

Consolidated Field Verification Report Review Comments PCSU

Consolidated Field Verification Report Review Comments Consultant

Final Field Verification Report Consultant Final Field Verification ReportPCSU, ITM, Operation Group

2.4Requirements Definition/ 50% Pre-Design Existing SCADA Architecture PCSU Existing SCADA Architecture Consultant

Existing PLC/HMI Programs ITM Existing PLC/HMI Programs Consultant

Related WMS Database OMU Related WMS Database Consultant

SCADA Hardware and software Inventory Lists PCSU Inventory Lists Consultant

Instrumentation Consultant InstrumentationPCSU, Operation Group

Servers. PLC, Network Consultant Servers. PLC, Network PCSU, ITM

SCADA Software Consultant SCADA Software PCSU, ITM

Control Wiring and Structured Cabling Consultant Control Wiring and Structured CablingPCSU, Operation Group

Paging and Security Consultant Paging and SecurityPCSU, Operation Group

Electrical System Consultant Electrical SystemPCSU, Operation Group

Emergency Power Consultant Emergency PowerPCSU, Operation Group

Reviewed 50% Pre-DesignPCSU, ITM, Operation Group

Consolidate 50% Pre-Design Review Comments PCSU

Consolidated 50% Pre-Design Review Comments PCSU

Consolidated 50% Pre-Design Review Comments Consultant

2.5 75% Pre-Design50% Pre-Design Review Comments Incorporated Consultant

50% Pre-Design Review Comments Incorporated


Equipment and Instrumentation List Consultant Equipment and Instrumentation List

PCSU, ITM, OMU,Operation Group

Process Narrative Consultant Process NarrativePCSU, Operation Group

Process Flow Diagrams Consultant Process Flow DiagramsPCSU, Operation Group

Design Alternatives Consultant Design AlternativesPCSU, Operation Group

Cost Estimate Consultant Cost EstimatePCSU, ITM, Operation Group

Electrical Area Classification Report Consultant Electrical Area Classification ReportPCSU, Operation Group





2.6 100% Pre-Design75% Pre-Design Review Comments Incorporated Consultant

75% Pre-Design Review Comments Incorporated


Updated Cost Estimate Consultant Updated Cost EstimatePCSU, Operation Group





Final 100% Pre-Design Consultant Final 100% Pre-DesignPCSU, ITM, Operation Group

MANAGER


PROJECT

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Project Phase: Detailed Design (PCS Component)


Received Delivered

3.1 Tag ListTagging Database - Enterprise Tagging Management System (ETMS) PCSU

Tagging Database - Enterprise Tagging Management System (ETMS) Consultant

Toronto Water Tagging Standard PCSU Toronto Water Tagging Standard Consultant

Tag List Consultant Tag ListOMU, PCSU, Operation Group

Reviewed Tag ListOMU, PCSU, Operation Group Consolidate Tag List Review Comments PCSU

Consolidated Tag List Review Comments PCSU Consolidated Tag List Review Comments Consultant

Final Tag List Consultant Final Tag ListOMU, PCSU, Operation Group

3.2 50% Detailed Design Process Control Narratives Consultant Process Control NarrativesPCSU, ITM, Operation Group

P&IDs Consultant P&IDsPCSU, ITM, Operation Group

SCADA Architecture Drawings Consultant SCADA Architecture DrawingsPCSU, ITM, Operation Group

Equipment Power Requirements Consultant Equipment Power RequirementsPCSU, ITM, Operation Group

Single-Line Drawings Consultant Single-Line DrawingsPCSU, Operation Group

Electrical Area Classification Consultant Electrical Area ClassificationPCSU, Operation Group


Reviewed 50% Detailed DesignPCSU, ITM, Operation Group

Consolidate 50% Detailed Design Review Comments PCSU

Consolidated 50% Detailed Design Review Comments PCSU

Consolidated 50% Detailed Design Review Comments Consultant

3.3Detailed Technical Specification

Detailed Technical Specification (Divisions 1,11, 13, 15, 16) Consultant

Detailed Technical Specification (Divisions 1,11, 13, 15, 16)

PCSU, Operation Group

3.4 70% Detailed Design50% Detailed Design Review Comments Incorporated Consultant

50% Detailed Design Review Comments Incorporated


Control Panel Drawings Consultant Control Panel DrawingsPCSU, ITM, Operation Group

Loop Drawings Consultant Loop DrawingsPCSU, Operation Group

Equipment Layouts and Control Schematics Consultant Equipment Layouts and Control SchematicsPCSU, Operation Group

SCADA Hardware and Software Requirements Consultant SCADA Hardware and Software RequirementsPCSU, ITM, Operation Group

Instrument Ranges and Setpoints Consultant Instrument Ranges and SetpointsPCSU, Operation Group

Alarm List including Alarm Conditioning Consultant Alarm List including Alarm ConditioningPCSU, Operation Group

Identify iHistorian, eOPS, POMS, LIMS Requirements Consultant

Identify iHistorian, eOPS, POMS, LIMS Requirements


Paging and Security Consultant Paging and SecurityPCSU, ITM, Operation Group

Networking and Structured Cabling Consultant Networking and Structured CablingPCSU, ITM, Operation Group

Equipment and Instrumentation Physical Tag List Consultant

Equipment and Instrumentation Physical Tag List

PCSU, OMU, Operation Group

Electrical Drawings and Requirements Consultant Electrical Drawings and RequirementsPCSU, Operation Group

Reviewed 70% Detailed Design and Detailed Technical Specification

PCSU, OMU, ITM, Operation Group

Consolidate 70% Detailed Design and Detailed Technical Specification Review Comments PCSUg

Detailed Technical Specification Review Comments PCSU

gDetailed Technical Specification Review Comments Consultant

3.5 Apply for Approval Agency Approvals Application Consultant

Agency Approvals Received Consultant

3.6 95% Detailed Design70% Detailed Design Review and Approval Agency Comments Incorporated Consultant

70% Detailed Design Review and Approval Agency Comments Incorporated

PCSU, OMU, ITM, Operation Group

Pre-Start Health and Safety Review and Report as required Consultant

Pre-Start Health and Safety Review and Report as required


Electrical Area Classification as required Consultant Electrical Area Classification as requiredPCSU, Operation Group


Reviewed 95% Detailed DesignPCSU, Operation Group

Consolidate 95% Detailed Design Review Comments PCSU

Consolidated 95% Detailed Design Review Comments PCSU

Consolidated 95% Detailed Design Review Comments Consultant

3.7100% Detailed Design/Tender

95% Detailed Design Review Comments Incorporated Consultant

95% Detailed Design Review Comments Incorporated


MANAGER


PROJECT

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Project Phase: Detailed Design (PCS Component)


Received Delivered

MANAGER


PROJECT

100% Detailed Design/Tender Consultant 100% Detailed Design/Tender PCSU, Operation Group

Updated Cost Estimate Consultant Updated Cost EstimatePCSU, Operation Group

Reviewed 100% Detailed Design/Tender PCSU, Operation Group

Consolidate 100% Detailed Design/Tender Review Comments PCSU

Consolidated 100% Detailed Design/Tender Review Comments PCSU

Consolidated 100% Detailed Design/Tender Review Comments Consultant

Final 100% Detailed Design/Tender Consultant Final 100% Detailed Design/TenderPCSU, Operation Group



Project Phase: Construction - Equipment (PCS Component)


Received Delivered

4.1 Contract Start-up Conduct Kick-off MeetingConsultant's PCS Staff,PCSU, ITM, OMU as required

4.2 Shop Drawings Instrumentation (Reviwed by Consultant) Contractor/Consultant Instrumentation (Reviwed by Consultant) PCSU, Operation Group

Servers, PLCs, OITs (Reviwed by Consultant) Contractor/Consultant Servers, PLCs, OITs (Reviwed by Consultant) PCSU, ITM, Operation Group

Network (Reviwed by Consultant) Contractor/Consultant Network (Reviwed by Consultant) PCSU, ITM, Operation Group

Panels, Cabling (Revied by Consultant) Contractor/Consultant Panels, Cabling (Revied by Consultant) PCSU, ITM, Operation Group

MCCs, Switchgear (Reviwed by Consultant) Contractor/Consultant MCCs, Switchgear (Reviwed by Consultant) PCSU, Operation Group

Reviewed Shop DrawingsPCSU, ITM, Operation Group

Consolidate Shop Drawings Review Comments PCSU

Consolidated Shop Drawings Review Comments PCSU

Consolidated Shop Drawings Review Comments Contractor, Consultant

Final Shop Drawings (Approved by Consultant) Contractor/Consultant

Final Shop Drawings (Approved by Consultant) PCSU, ITM, Operation Group

4.3Equipment and Panel Procurement and Fabrication

4.4 FAT/Whiteness Test SheetsTest Sheets for Equipment and Panels (Reviewed by Consultant) Contractor/Consultant

Test Sheets for Equipment and Panels (Reviewed by Consultant) PCSU, Operation Group

Reviewed Test Sheets for Equipment and Panels


Consolidate Test Sheets for Equipment and Panels Review Comments PCSU

Consolidated Test Sheets for Equipment and Panels Review Comments PCSU

Consolidated Test Sheets for Equipment and Panels Review Comments Contractor,/Consultant

Final Test Sheets for Equipment and Panels (Approved by Consultant) Contractor/Consultant

Final Test Sheets for Equipment and Panels (Approved by Consultant)

Consultant, PCSU, Operation Group

4.5Equipment and Panel Factory Acceptance Tests

Perform Equipment and Panel FATs and Submit Reports (Reviewed by Consultant) Contractor/Consultant

Equipment and Panel FATs Reports (Reviewed by Consultant) PCSU, Operation Group

Reviewed Factory Acceptance Test Reports PCSU, Operation Group Consolidate Deficiency Lists PCSU

Consolidated Deficiency Lists PCSU Consolidated Deficiency Lists Contractor, Consultant

Final Factory Acceptance Test Report (Approved by Consultant) Contractor/Consultant

Final Factory Acceptance Test Report (Approved by Consultant) PCSU, Operation Group

4.6 Transition PlanIdentify Process Limitations (Reviewed by Consultant) Contractor/Consultant

Process Limitations (Reviewed by Consultant) PCSU, ITM, Operation Group

Identify Potential Parallel Equipment, Panels, HMIs (Reviewed by Consultant) Contractor/Consultant

Potential Parallel Equipment, Panels, HMIs (Reviewed by Consultant) PCSU, ITM, Operation Group

Prepare Detailed Schedule of Terminations (Reviewed by Consultant) Contractor/Consultant

Detailed Schedule of Terminations (Reviewed by Consultant) PCSU, ITM, Operation Group

Identify Network Configuration (Reviewed by Consultant) Contractor/Consultant

Network Configuration (Reviewed by Consultant) PCSU, ITM, Operation Group

Reviewed Transition PlanPCSU, ITM, Operation Group

Consolidate Transition Plan Review Comments PCSU

Consolidated Transition Plan Review Comments PCSU

Consolidated Transition Plan Review Comments Contractor,/Consultant

Final Transition Plan (Approved by Consultant) Contractor/ConsultantFinal Transition Plan (Approved by Consultant)

Consultant, PCSU, ITM, Operation Group

4.7Equipment Installation and Wiring Contractor

4.8 Pre-Start Health and SafetyPre-Start Health and Safety Review and Report as Required Consultant

Pre-Start Health and Safety Review and Report as Required PCSU, Operation Group

4.9 Entity Information ListsEntity (Asset) Information Lists (WMS) (Reviewed by Consultant) Contractor

Entity (Asset) Information Lists (WMS) (Reviewed by Consultant) OMU

Reviewed Entity (Asset) Information Lists (WMS). Consolidated Review Comments OMU

Consolidate Entity (Asset) Information Lists (WMS) Review Comments Contractor,Consultant

Final Entity (Asset) Information Lists (WMS) Contractor/Consultant Final Entity (Asset) Information Lists (WMS) OMU

MANAGER


PROJECT

EDOCSLIB-#9088-v1 Page 5 of 7 9/26/2011

46 of 189


Project Phase: Construction - Software (PCS Component)


Received Delivered

5.1 Flow Chart Development PCS Implementation Guidelines(Related) PCSU PCS Implementation Guidelines(Related) Systems Integrator

PCS Standards (Related) PCSU PCS Standards (Related) Systems Integrator

Design Phase Drawings (P&IDs, Electrical, I+C) Consultant

Design Phase Drawings (Master P&IDs, Electrical, I+C) Systems Integrator

Process Control Narrative Consultant Master Process Control Narrative Systems Integrator

eOPS, WMS, POMS, LIMS Requirements Consultant eOPS, WMS, POMS, LIMS Requirements Systems Integrator

Logic Flow Charts (Reviewed by Consultant Systems Integrator Logic Flow Charts (Reviewed by ConsultantPCSU, ITM, Operation Group

Reviewed Flow ChartsPCSU, ITM, Operation Group Consolidate Flow Charts Review Comments PCSU

Consolidated Flow Charts Review Comments PCSU Consolidated Flow Charts Review Comments

Systems Integrator, Consultant

Final Flow ChartsSystems Integrator/Consultant Final Flow Charts


5.2 Software Modules Software Modules Library ITM Software Modules Library Systems Integrator

5.3New Software Modules Flow Chart Development Logic Flow Charts (Reviewed by Consultant)

Systems Integrator/Consultant Logic Flow Charts ITM, PCSU

Reviewed Logic Flow Charts ITM, PCSUConsolidate Logic Flow Charts Review Comments PCSU

Consolidated Logic Flow Charts Review Comments PCSU

Consolidated Logic Flow Charts Review Comments

Consultant/Systems Integrator

Final Logic Flow Charts (Approved by Consultant)

Systems Integrator/Consultant

Final Logic Flow Charts (Approved by Consultant) ITM, PCSU

5.4 Develop New Software Modules New Software Modules Systems Integrator New Software Modules Consultant, ITM, PCSU

5.5 New Software Modules FATPerform Modules FAT and Submit Reports (Reviewed by Consultant)

Systems Integrator/Consultant New Software Modules FAT Reports ITM, PCSU

Reviewed New Software Modules FAT Reports and Documentation ITM, PCSU

Consolidate Deficiency Lists and Documentation Review Comments PCSU

Consolidated Deficiency Lists and Documentation Review Comments PCSU

Consolidated Deficiency Lists and Documentation Review Comments

Systems Integrator,/Consultant

Completed New Software Modules and Documentation (Reviewed by Consultant)


Completed New Software Modules and Documentation (Reviewed by Consultant) ITM

5.6 Software Development Existing Programs - PLC, HMI, Simulation ITM Existing Programs - PLC, HMI, Simulation Systems Integrator

70% Software Development (Reviewed by Consultant)


70% Software Development (Reviewed by Consultant)

ITM (HMI,PLC), Operation Group (Screens), PCSU (Coordination)

Reviewed 70% Software Development ITM, PCSU, Operation Group

Consolidate 70% Software Development Review Comments PCSU

Consolidated 70% Software Development Review Comments PCSU

Consolidated 70% Software Development Review Comments


5.7 FAT PlanFAT Documentation and Schedule (Reviewed by Consultant)


FAT Documentation and Schedule (Reviewed by Consultant)


Reviewed FAT Documentation and Schedule

PCSU,ITM, Operation Group

Consolidate FAT Documentation and Schedule Review Comments PCSU

Consolidated FAT Documentation and Schedule Review Comments PCSU

Consolidated FAT Documentation and Schedule Review Comments


Final FAT Documentation and Schedule (Approved by Consultant)


Final FAT Documentation and Schedule (Approved by Consultant)

PCSU,ITM, Operation Group

5.8 FAT Submit Pre-FAT Version of Software Systems Integrator Pre-FAT Version of Software ITM

Perform FAT , Submit FAT Reports and Documentation (Reviewed by Consultant) Systems Integrator

FAT Reports and Documentation (Reviewed by Consultant)


Reviewed FAT Reports and DocumentationPCSU, ITM, Operation Group

Consolidate Deficiency Lists and Documentation Review Comments PCSU

Consolidated Deficiency Lists and Documentation Review Comments PCSU

Consolidated Deficiency Lists and Documentation Review Comments


Correct Software Deficiencies Identified During FAT (Verified by Consultant)

System Integrator/Consultant

Completed Documentation and Sign-off (Reviewed and Signed by Consultant)



PSCU, ITM, Operation Group

MANAGER


PROJECT



Project Phase: Construction - Testing and Commissioning (PCS Component)


Received Delivered

6.1Hardware SAT and Training Plan

Develop SAT Documentation, Schedule and Training Plan (Reviewed by Consultant) Contractor/Consultant

Develop SAT Documentation, Schedule and Training Plan (Reviewed by Consultant)

PCSU, Operation Group, ITM (Network)

Reviewed SAT Documentation, Schedule and Training Plan


Consolidate SAT Documentation, Schedule and Training Plan Review Comments PCSU

Consolidated SAT Documentation, Schedule and Training Plan Review Comments PCSU

Consolidated SAT Documentation, Schedule and Training Plan Review Comments Contractor, Consultant

Final SAT Documentation, Schedule and Training Plan (Approved by Consultant) Contractor/Consultant

Final SAT Documentation, Schedule and Training Plan (Approved by Consultant)

Consultant, Operation Group

6.2 Hardware Training Provide Operation and Maintenance Training Contractor Operation and Maintenance TrainingOperation Group, OMU (as required)

6.3 Hardware SAT

Conduct Hardware Site Acceptance Testing, Submit SAT Reports and Documentation (Reviewed by Consultant) Contractor/Consultant

Hardware Site Acceptance Testing, SAT Reports and Documentation (Reviewed by Consultant)


Reviewed Hardware SAT Reports and Documentation


Consolidat Hardware SAT Deficiency Lists and Documentation Review Comments PCSU

Consolidated Hardware SAT Deficiency Lists and Documentation Review Comments PCSU

Consolidated Hardware SAT Deficiency Lists and Documentation Review Comments Contractor, Consultant

Correct Deficiencies Identified During SAT (Verified by Consultant) Contractor/Consultant

Completed Hardware Site Acceptance Testing Documention and Sign-off (Reviewed and Signed by Consultant) Contractor/Consultant

Completed Hardware Site Acceptance Testing Documention and Sign-off (Reviewed and Signed by Consultant)


6.4 Software SAT and Training PlanSAT Documentation, Schedule and Training Plan (Reviewed by Consultant)


SAT Documentation, Schedule and Training Plan


Reviewed SAT Documentation, Schedule and Training Plan


Consolidate SAT Documentation, Schedule and Training Plan Review Comments PCSU

Consolidated SAT Documentation, Schedule and Training Plan Review Comments PCSU

Consolidated SAT Documentation, Schedule and Training Plan Review Comments






6.5 Software Training Software TrainingConsultant, System Integrator Software Training Operation Group

6.6 Software SATConduct Software SAT, Submit SAT Reports and Documentation (Reviewed by Consultant)


Software SAT, SAT Reports and Documentation (Reviewed by Consultant)


Reviewed SAT Reports and DocumentationPCSU, ITM, Operation Group

Consolidat Software SAT Deficiency Lists and Documentation Review Comments PCSU

Consolidated Software SAT Deficiency Lists and Documentation Review Comments PCSU

Consolidated Software SAT Deficiency Lists and Documentation Review Comments

System Integrator, Consultant

Correct Software Deficiencies Identified During SAT (Verified by Consultant)






6.7Operational Test/System Performance Test Operational Test/Sytem Performance Test

Consultant, System Integrator Operational Test/Sytem Performance Test


Operational Test/Sytem Performance Test Deficiancy Lists (if any)

PCSU, ITM, Operational Group

Consolidate Operational Test/Sytem Performance Test Deficiency Lists (if any) PCSU

Consolidated Operational Test/Sytem Performance Test Deficiancy Lists (if any) PCSU

Consolidated Operational Test/Sytem Performance Test Review Comments (if any)

Consultant, System Integrator

Correct Deficiencies and Finalize Operational Test/Sytem Performance Test

Consultant, System Integrator

Final Operational Test/Sytem Performance Test


Submitt SAT Version of Software (Approved by Consultant)


SAT Version of Software (Approved by Consultant) ITM

6.8 As-Built DocumentationPrepare Hardware and Software As-Built Documentation (Reviewed by Consultant)

Consultant, Contractor, System Integrator

Hardware and Software As-Built Documentation


Reviewed Hardware and Software As-Built Documentation


Consolidate Hardware and Software As-Built Documentation Review Comments PCSU

Consolidated Hardware and Software As-Built Documentation Review Comments PCSU

Consolidated Hardware and Software As-Built Documentation Review Comments


Final Hardware and Software As-Built Documentation


Final Hardware and Software As-Built Documentation


6.9Post Construction Waranty Period

Contractor/System Integrator

MANAGER


PROJECT

EDOCSLIB-#9088-v1 Page 7 of 7 Appendix B

48 of 189



Appendix C – Associated Guidelines

49 of 189



EDOCSLIB-#9086-v1

Appendix C-1

Appendix C – Associated GuidelinesThe following list shows related Guideline documents for specific topics that are complementary to this document.

Document Name Drawing # eDOCS # Field Verification Procedure 9091 Field Verification Log 9092 Process Control Narrative 9093 P&ID Standard Symbols and Practices 9094 P&ID Standard Symbols and Practices Attachments P&ID LEGEND XXXX-P&ID-I-0101 9110 P&ID STANDARD SYMBOLS -1 XXXX-P&ID-I-0102 9111 P&ID STANDARD SYMBOLS -2 XXXX-P&ID-I-0103 9112 P&ID Blocks - Gates, Valves, Pumps P&ID Block 1 9113 P&ID Blocks - Blower, Fan, Damper P&ID Block 2 9114 P&ID Blocks - Vortex, Chamber P&ID Block 3 9115 P&ID Blocks - Bridge, Collector P&ID Block 4 9116 P&ID Blocks - Centrifuge P&ID Block 5 9117 P&ID Blocks - Generator, Communitor P&ID Block 6 9118 Colour Convention 9095 RPU Software Programming 9096 Standard Software Modules 9097 Operator Interface Programming 9098 Process Display Programming 9099 Alarming 9100 Instrument and Equipment Testing 9101 Instrument and Equipment Testing Attachments Instrument Testing Log 9102 Field Installation Testing Log 9103 SCADA Factory Acceptance Testing 9104 SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check

Sheet 9105 Process Logic Test Sheet 9106 SCADA Site Accecptance Testing and Commissioning 9107 SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check

Sheet 9105 Process Logic Test Sheet 9106 PCS Documentation 9108 Training 9109

50 of 189


Appendix C Field Verification Procedure

EDOCSLIB-#9091-v1

Page 1 of 4

1. Field Verification Procedure

1.1 Scope

The Field Verification Procedure shall be completed on commencement of pre-design

engineering to ensure that the design will meet the requirements of the facility. This will

minimize potential future claims by Contractors during construction, resulting from

inaccurate information portraying existing conditions. This activity will also accurately

define the scope of work required for achieving the targeted level of automation.

Important aspects of Field Verification include:

1. Verifying the accuracy of the existing site conditions and as-built documentation.

2. Verifying whether the existing process control system including instruments,

electrical equipment, mechanical equipment, field wiring, control panels, and

automation can be successfully integrated into the new operating strategies.

The testing of instrument, field wiring and mechanical equipment is similar to the testing

which is normally completed as part of the construction supervision and acceptance

testing for new facilities. Refer to EDOCSLIB-#9101 Instrument and Equipment

Testing.

1.2 Field Verification Procedure

The following identifies the field verification procedure:

1. Verify the accuracy of all existing (and relevant) documentation and include all outstanding related details.

2. Confirm and document whether each existing instrument meets the design

requirements, including range, accuracy, reliability, and installation details.

Recommend the instrument upgrades required to achieve the proposed operational requirements, as compared with existing conditions.

3. Where concerns exist, test whether the existing control devices and process

equipment can be operated as required under the new strategies. This includes control valves, motors, controls, wiring connections, and other control parameters.

4. Where concerns exist, verify the capacities/ratings of each piece of process equipment versus the new process requirements.

1.3 Completion Criteria

Verification of existing instrumentation is deemed complete when all features, functions

and information required in accordance with the Master Process Control Narratives and

Master Process and Instrumentation Drawings have been documented as existing or not

available, and instruments identified as suitably accurate within the anticipated operating

51 of 189



EDOCSLIB-#9091-v1

Page 2 of 4

range for the process being monitored. This information is to also be recorded on the updated site condition drawings and details.

Verification of control devices and mechanical equipment control circuits is deemed

complete when the design requirements have been compared against the actual site

conditions.

Testing of wiring is deemed complete when all wiring related to a specific device or loop

(Instrumentation, Control Circuits and Power) has been confirmed to have acceptable

voltage and/or current draw, without losses, for all functions and information required in

accordance with the Process Control Narratives and Process and Instrumentation Drawings.

This information shall be included in the Pre-design Report complete with updated site drawings and details.

1.4 Participants and Responsibilities

Consultants - Responsible for reviewing all record documentation and assessing existing

conditions, scheduling verification procedures, requesting field assistance from plant

personnel, reviewing schedule with plant staff, completing all field verification and tests

with assigned plant staff, presenting findings and report to Toronto Water, all completed

with the intent to proceed further with the preparation of Detailed Drawings and

Specifications for the proposed upgrades.

Toronto Water - Provide copies of all existing available site condition information and

equipment reports or alternatively provide access to plant library, review Consultants’

work plan. In many cases, the available documentation is dated or does not exist. The

Consultants shall review the field condition to satisfy themselves as to the as-built

condition.

1.5 Documentation

The requirements for the submission of all documentation to be used and/or produced by

the Consultants during the Field Verification Procedure are detailed below.

1.5.1 Documents Provided By Toronto Water

The following documents shall be assembled and reviewed by the Consultant prior to

commencing any field investigation(s):

1. Any existing available engineering record drawings

2. Available copies of the Master Process Control Narratives and Master Process & Instrumentation (P&ID) Drawings

3. Any existing available equipment maintenance records, calibration reports, and

shop drawings

4. Any available plans of other proposed construction works within area of project

52 of 189



EDOCSLIB-#9091-v1

Page 3 of 4

5. Available verification sheets with all known information entered prior to site activities.

6. Requirements for eOPS, WMS, POMS, LIMS and any other information systems

1.5.2 Verification Schedule

Following the review of all available documentation, the Consultant shall provide a draft

field verification schedule for review by Toronto Water. This will include dates for when

the various test procedures are to be carried out, and the date and approximate time to

when plant staff assistance is required to operate equipment or open panels.

For all identified plant areas, and in particular the collection system facilities, detailed

schedule coordination is required in order to organize traffic barriers, enter confined

spaces, provide proper gas monitoring documentation, and other related tasks.

This schedule must be approved in writing by Toronto Water, prior to the commencement

of any field investigations.

The verification program shall be performed in stages, one for each process area. A

verification report shall be submitted to Toronto Water for each process area evaluated.

1.5.3 Documentation & Reporting

The Consultant shall use and/or produce the following standard documentation as part of

the Field Verification Report:

1. The Scope of the Specific Verification Procedure

2. Specific Objectives, beyond the General Objectives noted above

3. Field Visit and Inspection Records, including:

Field Instrument Verification Logs

Instrument Data Sheets

Control Device Verification Logs

Control Circuit Verification Logs

Control Panel Inspection Logs

4. Updated Site Condition Drawings and Device Details, based on the findings of

the investigation

5. Red-Lined Master Process & Instrumentation Drawings

6. Summary of Instrument, Device and Equipment Assessments, with the Instrument

Verification Report and other test reports contained in an Appendix

53 of 189



EDOCSLIB-#9091-v1

Page 4 of 4

7. Summary of the Condition of Existing Control, Instrumentation and selected

Power Wiring, with the test reports contained in an Appendix

EDOCSLIB-#9092-v1 - Field Instrument, Control Device, and Mechanical Equipment,

Control Circuit Verification Log is attached to the end of this document as an example.

Consultant could request document in its original format.

54 of 189

FIELD INSTRUMENT, CONTROL DEVICE, AND MECHANICAL EQUIPMENT, CONTROL CIRCUIT VERIFICATION

Page ___ of ___

# EQUIPMENTTAG

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EVALUATION, RECOMMENDATION & COST DOCUMENT VERIFICATION & INITIAL EVALUATION FIELD VERIFICATION PROCEDURE

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EDOCSLIB-#9092-v1

55 of 189


Appendix C Process Control Narratives

EDOCSLIB-#9093-v1

Page 1 of 6

1. Process Control Narratives

1.1 General

The Process Control Narrative is a description of key control system elements and provides

details on all manual and automatic modes of process control. It serves different purposes at

different stages of the project design and construction phases and shall be used for one or more

of the following purposes:

1. Background for planning and design of improvements

2. Process control software description

3. Operations manual

4. Operations practices review

5. Operations training

Every existing facility under the management of Toronto Water has a comprehensive process

control narrative (referred to as a “Master Process Control Narrative” or “Master PCN”. Ongoing

expansion and rehabilitation projects with a PCS component will typically require that the

Master PCN be modified.

Preparation or modification of the Process Control Narratives shall commence during the Pre-

design phase and expand with more detail during the Detailed Design and Construction phases.

Each PCN shall be identical in terms of format. The Pre-design portion of the PCN (also referred

to as the Process Narrative) shall list, in generic terms, the equipment to be controlled and the

proposed methods to be used. The final PCN shall be an expansion/enhancement of the Pre-

design portion and shall exactly define the equipment, points, tag names, equipment coding,

methods of control and monitoring, etc.

Consultants shall comply with this design standard and any proposed deviation must have the

approval of the City.

1.2 Update Procedure

The PCS component of any project will often involve updating an existing PCN rather than

creating a new PCN. The following procedure should be considered when updating a PCN:

1. During pre-design, obtain the existing master PCN in Adobe format and decide which

sections will need to be updated and submit request to Toronto Water for document

release in native format. Toronto Water will track all requests in order to coordinate PCN

updates where multiple projects may be involved.

2. Update the process descriptions of each affected section as needed including any

additions to or deletions from the Process Equipment List.

3. During detailed design, update the control system description of each affected section as

needed. Additions to the following information will need to be considered:

o Control system configuration - if any panels, RPUs, workstations or other major

components are being installed

56 of 189



EDOCSLIB-#9093-v1

Page 2 of 6

o I/O List – Add any additional I/O and remove any I/O being taken out

o Control Logic – Describe any new control logic

o Interlocks – add any new hardware or software interlocks

o Alarms – expand the alarm list as required

o Trending – expand the trending description as required

o Business Systems – expand the list of data for WMS, LIMS, eOPS, POMS as

required

4. After the Construction phase is complete, update all sections with as-built information as

required.

5. A new release request should be issued for every phase of the project unless Toronto

Water notifies the Consultant otherwise.

1.3 Contents

The Master PCN for a facility starts with a General introduction describing the facility in general

terms including the overarching design philosophy and treatment goals. The PCN is then divided

into process sections, with each section representing a distinct process within the facility. Each

process section generally contains the following elements:

Process description – a general description of the process including physical layout,

mechanical equipment, and treatment objectives. See section 1.3.1 below for further

details. This section should be developed during the Pre-design phase of a project and

further refined during Detailed Design and Construction as required.

Control system description – details of the PCS aspects of the process including I/O lists,

alarm details, historian requirements, business systems requirements. See section 1.3.2.

1.3.1 Process Description

1.3.1.1 Process Definition

The process shall be defined first. Definition shall include the process name, its relationship to

other processes, its general components and the physical location boundaries as appropriate.

Components may include the tanks, pumps and other devices of the main process, and the

ancillary processes or systems.

Provide a diagram to show the process components. The diagram shall show the process

boundary and the inputs and outputs to the process components. Label each input to an output

from the process with the name of the process stream and its destination or source. Show all lines

as starting or ending from a process component. Do not directly connect lines because the control

or lack of control over the junction or splitting of a process stream needs to be described and the

process component is the place for this description. An example for the digestion process is

shown in Figure 1: Example process diagram. Note that the combustible gas safety system

shown in the figure is an ancillary process.

57 of 189



EDOCSLIB-#9093-v1

Page 3 of 6

Figure 1: Example process diagram

1.3.1.2 Objectives

The objectives of the process and general goals shall be described in this section. These

objectives are related to efficiency, effectiveness or quality. In some cases, the process will not

have a specific pre-defined treatment objective. In such cases, identify a general objective.

1.3.1.3 Process Control Strategy

The process control strategy shall describe the process decisions taken to achieve the treatment

and transmission objectives. Indicate how often input variables are to be measured and the

frequency or event which triggers a process adjustment.

State the safe limits and operating targets for the process and operating equipment. Operating

targets may be stated as a range if a specific target or set of targets is not required. List priority 1

alarms (alarms that need immediate attention from the operator) and alarms that affect more than

one operator (noting the operators affected). Describe the alarms for each device and the process

to bring into the SCADA system sufficient alarm details as needed for remote diagnosis or else

state the use of a single, common alarm for multiple alarm conditions. For each alarm, state the

requirements for activation and method of reset (manual or automatic). Describe automatic alarm

reset logic.

1.3.1.4 Influent Sources

Information on influent sources defines the source and nature of streams entering the specific

process being described. The nature of these streams shall be defined in terms of flow variability

Primary Digestion

Digestion Gas System

Digested SludgeStorage/Transfer

System

Primary DigestInfluent Distribution

System

Combustible GasSafety System

Digestion

Sludge/Scumfrom Primary

Digested Sludgeto Dewatering

Digester Gasto Plant Services

TWASfrom

Thickening

Emergency Overflowto Primary Treatment

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and the percentage of the total stream being treated in the specific process. Information about the

main process stream, as well as side streams shall be presented.

1.3.1.5 Effluent Destination

In this area of the template, information shall be presented on where effluent and waste from the

treatment process are normally directed. Estimate the percentage of the stream sent to each

destination where the stream is normally directed to more than one destination.

1.3.1.6 Process Control Equipment/Devices

In this section, describe each piece of equipment or device that can potentially control influents

and effluents or change the process as well as what equipment is available to control the process

when defining its operation, capabilities and limitations. Identification shall include its name and

when applicable, its equipment number, for example: raw sludge pump PRS07. Process

equipment includes pumps, valves, screens, chlorinators, mixers, etc.

Describe the use of each process control equipment/device. Information includes the device

operation, control objectives, performance measures and the control method (either automatic or

manual).

Describe the flexibility in using process equipment including provisions for future equipment

additions. For example, the chlorine processes for water treatment and supply can interchange

equipment (i.e. post chlorinators can be used for pre-chlorination if necessary). The chlorine

processes for wastewater treatment can interchange equipment (i.e. effluent disinfection

chlorinators can be used for plant water disinfection if necessary).

1.3.1.7 Ancillary Process Descriptions

Ancillary processes associated with each main process shall be listed. Ancillary processes are all

processes associated with the main process which are not specifically involved in transmitting

influent to the process or effluent from the process, or the actual treatment process. Ancillary

processes shall be described in the same way as the main process in separate process narratives.

1. Describe spill containment for both hazardous gas and liquid spills in a separate sub-

section of ancillary processes. If the containment provisions serve more than one process,

then put the description in a separate process narrative.

2. Describe sample stations/pumps in a separate sub-section of ancillary processes.

Description of sample stations and pumps belong with the narrative of the process that

uses the sample or sample tests.

3. Power distribution is an ancillary process to most processes. Describe power distribution

in a separate narrative with basic descriptions of automatic and manual switching.

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1.3.2 Control System Description

1.3.2.1 Description

This section shall describe the operation of the process in terms of the control system, including

panels and the control logic. Describe the control system configuration and components and

include:

1. Controllers, location of I/O and panels

2. Modes of control (Manual and Automatic modes at each control location; control

locations may include: equipment control panel, Motor Control Centre, area panel,

central panel, operator workstation)

3. Alarm horn operation, silencing and acknowledge or reset

1.3.2.2 Software Data Points

Provide a table showing all real I/O data points and program-generated data points associated

with the process. The table should show the following information:

1. Tag type

2. Tag name

3. Description

4. EGU range (in the case of analog points).

1.3.2.3 Control Logic

This section shall contain descriptions of:

1. Normal Operation (ie. Automatic logic) including start up and shutdown

2. A table of Control Setpoints associated with the Automatic logic. The table should

show tag name, data range, units, and default value.

3. Fault Response Operation. How should the equipment respond to abnormal

conditions? Common fault situations include power failure, instrumentation failure,

and loss of communication

1.3.2.4 Interlocks

1. Interlocks generated in software by the PLC

2. Interlocks hardwired into the control circuits

1.3.2.5 Alarms

Provide a table that shows every alarm condition that can be generated by the process. The table

should provide the following information:

1. Tag name

2. Alarm priority

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3. Alarm limit (in the case of alarms generated from analog points)

4. Details of how the alarm is generated ie. if a delay timer is required, if the alarm

depends on other conditions (eg. a pump running)

5. Details of how to reset the alarm as well as details of how to enable/disable the alarm

if applicable.

1.3.2.6 Trending

Provide a table detailing which data points should be trended by the system historian. The table

should provide the following information:

1. Tag name

2. Suggested trending deadband

3. Suggested grouping for displaying trended data for maximum effectiveness

1.3.2.7 Business Systems

Provide a table detailing which data points will need to be made available to Toronto Water

business systems. The table should provide the following information:

1. Tag name

2. Business system requiring the data (WMS, POMS, eOPS, LIMS)

1.3.2.8 Block diagram

A block diagram of the system shall be included for all systems. The diagram shall show logical

connection and interaction of the control system components.

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Appendix C P&ID Standard Symbols and Practices

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1. P&ID Standard Symbols and Practices

1.1 General

This standard clearly presents Toronto Water’ intent in developing P&IDs. This standard

is based on the Instrumentation Society of America (ISA) standard ISA-S5.1-1984,

“Instrumentation Symbols and Identification.” The material has been reformatted to be

directly applicable to the water and wastewater industry. Although this section is based

on ISA, it is not constrained by it.

1.2 Purpose of Standard

This standard is intended to provide a consistent way of showing information. Consistent

presentation will speed reading and improve understanding of the diagrams. Consistent

preparation of the diagrams will enable the use of data base access to and from information on the

diagrams.

This standard will be included by reference into each design project and design or construction

contract that prepares or modifies P&IDs.

Diagrams already prepared which are inconsistent with this standard will be converted to this

standard whenever they are revised for other reasons. Existing diagrams which are not compliant

with this standard may also be converted to this standard if people using the diagrams can show

benefit for the cost.

The P&ID legend sheet and P&ID symbol sheets should be included in each instrumentation and

control (I&C) drawing set developed for Toronto Water.

1.3 ISA Reference Standard

Duplication and conflict may exist between standards set by ISA and by other agencies

or standards setting organizations such as Canadian Gas Association (CGA), National

Fire Protection Association (NFPA), and International Standards Organization (ISO).

Toronto Water has decided to produce P&IDs that are consistent with ISA in order to

have documentation readily understood by as wide an audience as practicable. The use

of specialist symbols on P&IDs would result in additional cost for training,

documentation and workforce inflexibility. The use of symbols and nomenclature from

standards other than ISA will be incorporated into this standard where no conflict exists.

The CGA symbols were reviewed in detail as part of preparing this standard. The CGA

does not require to prepare documentation using the symbols that the CGA itself uses in

its standards and other publications. However, having documentation in a format

familiar to boiler inspectors could expedite inspections and licensing of boilers.

Therefore, the possibility of using CGA symbols instead of ISA symbols for boiler and

digester gas applications was explored.

A number of conflicts occurred, particularly where the CGA was showing

instrumentation and control information. The major problems came from

misunderstanding of CGA instrumentation symbols by people applying ISA meanings to

them. An alternative of showing both symbols sets, ISA and CGA, on the same drawing

was examined. It would greatly increase drawing complexity and could also be

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misinterpreted as indicating two instruments when only one exists. Another alternative

was explored of having two drawings, one where ISA symbols would be used if conflict

occurs with CGA and another drawing showing only the CGA symbols. This method

has several advantages. Two drawings are typically provided now. The ISA style

drawing is part of the engineering design phase and the CGA drawing is part of the

documentation provided by the boiler or compressor manufacturer.

The result of this analysis is to prepare P&IDs consistent with ISA and incorporate

symbols from other standards organizations as needed.

The electrical symbol sheet (not ISA), likewise, should be included in each drawing set

containing panel control diagrams. No duplication or conflict exists between the CGA

and Toronto Water electrical symbols. Both Toronto Water and the CGA use

ANSI/IEEE electrical symbols and nomenclature.

1.4 Purpose of P&ID

P&IDs convey process, instrument and control equipment information. A P&ID should

enable anyone reading it (and having a reasonable amount of plant knowledge) to

understand the means of measurement and control of the process.

A P&ID is a specific schematic representation of the mechanical, electrical,

instrumentation and control aspects of a given process. The P&ID is developed from the

process design engineer’s drawings and is expanded by the control engineer to include

other instrumentation as needed.

The P&ID must be an accurate representation of the physical process or system and

should show equipment in the proper functional relation. A P&ID should include the

following:

A. Process piping, tanks, structures, and equipment.

B. Primary elements, transducers, and analyzers.

C. Actuators and final control elements.

D. Panels and controls.

E. Input/output signals to digital controllers.

F. Schematic representations of control signal interconnections.

The P&ID is the only document which shows both process and control information. As

such, it can be a valuable tool during design construction, and start-up. P&IDs are used

during design as a basis for:

A. Computer control strategy design.

B. Computer input/output point list development.

C. Field instrument schedule development.

D. Control panel design.

E. Electrical interface definition.

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F. Mechanical and electrical equipment tagging.

G. Overall design coordination.

During construction and start-up, P&IDs can be used for:

A. Shop drawing review of computer controls, panel and loop submittals.

B. Electrical interface coordination.

C. Graphic display development/approval.

D. Process control operational checkout.

E. Developing as-built and operation and maintenance manuals.

F. Training.

In the next subsections, selected instrumentation terminology is defined and P&ID

symbols are presented and discussed. Both the terminology and symbols were based

on the Instrument Society of America (ISA) standards. The symbols were expanded

while the terminology was abbreviated.

1.5 Drawing Phases

The P&IDs are developed in stages in order to add information at the appropriate time.

The usefulness of added details must be weighed against the expense of preparation and

review effort. The P&ID development stages are shown in the following table.

Major Item Preliminary

Design

Detailed Design Implementation

Piping, tanks, equipment and

valves for process and auxiliary

processes

Required Required Required

Sensors, transmitters, switches Required Required Required

Actuator type with pneumatic and

hydraulic instrumentation

Required Required Required

Panel - Face mounted

instrumentation

new/modified custom panels

existing custom panels

equipment package panels

specialty package panels

Required

Not required

Not required

Not required

Required

Required

Not required

Required

Required

Required

Required

Required

Panel - Internal instrumentation

new/modified custom panels

existing custom panels

equipment package panels

specialty package panels

Not required

Not required

Not required

Not required

Required

Required

Not required

Required

Required

Required

Required

Required

Representation Typical is okay No use of typicals No use of typicals

Control loops - hardwired Required Required Required

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Control loops - software Not required Required Required

Setpoints, limits Not required Not required* Not required*

* Required on instrument data sheets.

1.6 Scope of Drawings

A set of P&IDs for a process or sub-process includes all aspects of the process or sub-

process. That is, all of the piping, equipment, instrumentation and controls in the process

or sub-process must be included on the drawing set. For example, the set of P&IDs for a

pumping sub-process would include the main system, e.g. waste sludge or wash water

pumping and all auxiliary systems such as sample system, drainage system, service

water, city (potable) water, instrument air, power distribution, gas monitoring, hydraulic

and pneumatic systems, security, fire alarm and suppression, safety systems and heating,

ventilation and air conditioning.

The information includes all components of the process or sub-process. That is, the

drawing set must show:

automated and non-automated systems,

current project additions, deletions and modifications,

existing conditions and future provisions if known.

The information shown on the P&IDs includes major control logic of the process or sub-

process control strategies. That is, the drawing set must show:

all hardwired interlocks, totalizers and signal converters,

all software controllers and software interlocks.

The P&IDs must show all inputs and outputs of the Process Control System and the

instruments and equipment which provide the inputs and receive the outputs.

The P&IDs do not need to show virtual points except as needed to clarify control logic.

1.7 Update Procedure

The PCS component of any project will often involve updating an existing Master P&ID rather

than creating a new P&ID. The following procedure should be considered when updating a

P&ID:

1. During pre-design, obtain the current set of Master P&IDs for the facility in Adobe

format.

2. Identify where equipment and instrumentation pipe line etc upgrades or additions will be

required and request specific drawings to be released by Toronto Water in their native

CAD format. Toronto Water will keep track of all requests in order to coordinate

drawings update in areas where request from more than one contract is issued.

3. During detailed design, update the drawing with the new equipment and instrumentation.

Show the additions as “future” according to Toronto Water drawing standards. Also

update the title block to indicate revision number and details. If a new P&ID is required,

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create a new drawing number consistent with the existing drawing set and submit to

Toronto Water for approval.

4. Following successful Site Acceptance Testing of the new equipment, update the drawing

so the new equipment and instrumentation is shown normally. Update the title block

accordingly.

5. New release request should be issued for every phase of the Project unless Toronto Water

notifies Consultant otherwise.

1.8 Terminology

The following definitions are from ISA-S5.1-1984, “Instrumentation Symbols and

Identification.”

A. Instrument - A device used directly or indirectly to measure or control a variable or

both. The term includes control valves, relief valves, and electrical devices such as

annunciators and push-buttons.

B. Instrumentation - A collection of instruments or their application for the purpose of

observation, measurement, control, or any combination of these.

C. Primary Element - That part of a loop or of an instrument that first senses the values

of a process variable. The primary element is also known as a sensor.

D. Final Control Element - The device that directly controls the value of the manipulated

variable of a control loop.

E. Switch - A device (instrument) that connects, disconnects, selects, or transfers one or

more circuits and is not designated as a controller, a relay, or a control valve.

F. Controller - A device having an output that varies in response to an input of a

measured process variable to regulate a controlled variable in a specified manner.

Typical instrument identifications are XC, XIC, and XFIC for controller, indicating

controller and ration indicating controller respectively. X is the process or initiating

variable. Controller types are auto/manual, computer/auto/manual or supervisory set

point.

G. Control Station - A manual loading station that also provides switching between

manual and automatic control modes of a control loop. It may be called an auto-

manual station or an auto-selector station. The word computer may be substituted for

auto when the control station is used with a computer. Typical instrument

identification is HK or HIK. In rare cases, XK or CIK may be used where X is the

process variable.

H. Manual Loading Station - A device having a manually adjustable output that is used

to actuate one or more remote devices. It may be called a manual controller, manual

station or remote manual loader. The station does not provide switching between

manual and automatic control modes. Typical instrument identifications are HFK and

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HIXK for hand ratio control station and hand indicating unclassified control station.

Manual loading stations are rarely, if ever, used in computer control systems.

I. Balloon - The circular symbol used to denote an instrument or instrument tagging.

Synonym for bubble.

J. P&ID - Process and Instrumentation Diagram. Do not substitute the words “piping,”

“instrument” or “drawing”.

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2. Process Layout

There are two general types of process layouts: those which show cast-in-place

(concrete) or fabricated-in-place (steel) tanks and those which show mechanical

equipment or prefabricated process systems. An example of the former is a wastewater

secondary treatment process which includes aeration tanks, solid/liquid separators

(clarifiers) return and waste sludge pumps, and the associated interconnecting piping and

channels. Examples of the latter might include: centrifuges, incinerators, polymer

batching system, instrument air supply systems, chlorinators and ejectors, and refining

processes. Each layout has certain graphic presentation characteristics which are

discussed below.

2.1 Tank System Layout

Always use plan views on this type of layout.

Although P&IDs aren’t required to have a north-south orientation, in general, true north

or plant north should be toward the top of the drawing. In some cases, you may wish to

rotate the process 90 degrees on the drawing so that it fits better. Rotate the process

counter clockwise so that north is to the left.

Flow streams may enter and exit the drawing on all four sides. It is not necessary or

desirable to maintain a left to right or top to bottom flow direction. Flow streams enter

and exit in relation to the process orientation and actual layout of the process.

Distinguish between channels and pipes and between prefabricated and cast-in-place

tanks. Use double lines spaced about 1/8” to indicate channel or cast-in-place tank walls.

Occasionally, you may have difficulty deciding whether to show a conduit as a pipe

(single line) or a channel (two pairs of lines to represent walls). Use the following

guidelines:

Any conduit containing sluice gates, slide gates or flap gates either must be shown

as a channel or must contain a gate structure to hold the gate.

A conduit which is cast-in-place with a tank or set of tanks should normally be

shown as a channel. Do not sacrifice clarity to show the process schematically.

An elevation view of an aeration tank and pipe gallery is shown on the top part of

Figure 1. The P&ID representation is shown on the bottom part. Notice that only

the process tankage and piping are shown on the P&ID. The pipe gallery

structure is not shown. Note how the piping layout has been shown on the P&ID.

The top pipe has been shown farthest from and the bottom pipe shown closest to

the aeration tank. Note how the tank effluent weir and channel were shown. The

P&ID is a schematic representation and some liberties can be taken in the layout

to provide sufficient space to show all instrumentation and balloons.

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DO NOT typify process tanks or piping except through the use of process

overview drawings.

Some processes may require “layering”. For example, separate digester drawings might

be required to show charging/withdrawal system; heating and mixing; and gas collection

and supernatant draw-off. All drawings should use the same base which shows the

digester tanks.

2.2 Mechanical Equipment Layout

Plan or profile views may be used in this type of layout. In general, all piping to and

from mechanical equipment or piping within a prefabricated process system should be

shown in plan view. Exceptions might include an incinerator or a catalytic cracker where

a profile view would better show the feed pipes at various levels.

Flow direction should be from left to right and from top to bottom as much as possible.

If a north-south orientation is desired or is shown on other drawings, use that orientation.

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PRIMARY EFFLUENT

DRAIN

RETURN SLUDGE

AIR

EFFLUENT WEIR

AERATION TANK 5

PIPE GALLERY

ELEVATION VIEW

BAFFLE

HANDRAIL

D

~ ~

~

~

~ ~

RAS

M RAS

~ ~ ~ ~

~ ~ ~

ALP PE

BAFFLE

AERATION TANK 5

AERATION TANK 6

ML

AIR DIFFUSER

AERATION TANK 4

P&ID REPRESENTATION FIGURE 1

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3. Controls Layout

3.1 Control Levels

Use a layered approach to distinguish the various levels of control. Place field

instrument and equipment balloons above or next to the devices. Locate field controls,

motor controls, and area control panels above the field devices at separate levels. Locate

computer input/output symbols and tags at the highest level.

If you know exactly what computer hardware is being provided, the upper level may be

used to show programmable logic controller (PLC), remote terminal unit (RTU),

distributed process controller (DPC) or remote station controller (RSC) identification.

The normal approach should use the area or unit process identification as recommended

by ISA. An I/O point sort by this identification can be used to establish the number of

points in each area and the number of PLCs, RTU’s, DPCs, or RSCs based on assumed

or specified sizing constraints.

3.2 Package Panels

Package panels are of two general types: equipment supplier furnished and specialty

supplier furnished. Examples of equipment supplier furnished materials are: blower or

centrifuge control panels, polymer or similar chemical mixing system control panels if

furnished by the mixing system supplier and pneumatic transport system controls.

Examples of specialty panels are: motor controllers, variable speed drives, sump pump

control systems, and HVAC controls.

For package panels, the supplier is responsible for the proper operation of the panel. The

supplier must perform the detailed engineering design to meet the functional

requirements specified. The functional requirements include the desired operation, face

of panel mounted equipment, panel layout, and interfaces with other control panels or

computers. In many cases, the panel specifications are included within the equipment

specifications and are written by others.

For example, a motor controller can be equipped with run lights, motor overload relays

and lights, start/stop or on/off push-buttons and switches, local/remote switches and

practically any other feature you desire including programmable controllers. Indicate

these options on the P&IDs using a combination of balloons for face mounted equipment

and signal line labels for signals which are derived interior to the package panel and used

elsewhere in the control loop.

Show the package panels as boxes with face of panel mounted instruments only. Do not

show interconnections, interlocks, interior signal function balloons, or signal function

codes within the box.

All panels should be labeled in the upper left corner. If the package panel is shown on

more than one drawing, the word PARTIAL shall be included with the label.

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3.3 Custom Panels

Custom panels are those panels which are designed by the engineer for fabrication by a

panel shop or the control system supplier. The supplier of the equipment controlled by

these panels usually has no contractual responsibility for the proper operation of the

equipment.

Show these panels with both face and interior mounted instruments. Face mounted

instruments have a single, solid line across the instrument balloon. Interior mounted

instruments have a single, dashed line across the instrument balloon. Show balloon

interconnections and electrical interlocks.

Label panels in the same way as package panels.

3.4 Control Signals

Run computer output signal lines to computer-manual selector switches to indicate that

the switch selects between computer control and an alternate source of control. Show

signals which are to be terminated within a panel by running the signal line up to the

package panel border or through the custom panel. If the signal does not require

termination in the panel, run the signal around the panel or use the break symbol. See

Figure 2.

Label signal lines any time you think the function of the signal may be unclear. The label

should be enclosed in quotation marks.

3.5 Interlocks

Process interlocks are control connections wired between two separate equipment items.

For example, a hard-wired control connection that causes an electro-hydraulic check

valve to operate whenever a pump starts and stops is a process interlock. Show all

process interlocks. Process interlock details are shown on electrical drawings. Drawing

notes should describe the function of all interlocks and should refer to the electrical

drawings and/or specifications for additional details.

Device protective interlock symbols should be shown if this is the policy started in the

design guide for the particular project. Protective interlocks are usually provided with the

control device. For example, a pump may have protective interlocks which cause

shutdown if sensors detect conditions such as excess vibration or high bearing

temperature. This type of interlock is generally specified as a part of the device

specification. It may or may not be shown on the electrical drawings. Always show

these interlocks if the condition is to be displayed, alarmed or monitored.

3.6 Typifying

You can typify controls during preliminary design whenever you have typified equipment

items. In addition, you can use typicals to reduce duplicated material. However, the

typified controls must be functionally process related. Do not typify based on control

interface only. For example, do not use one typical to show both return and waste sludge

pump control.

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Do not sacrifice clarity — when in doubt, do not typify even if additional drawings will

be needed.

When typifying controls, the following rules apply:

1. Show all signals to and from balloons, control devices or primary elements as shown

for loop 101 in Figure 3.

2. Include equipment tags whenever there are no other balloons which indicate the loop

number. See figure 3.

3. Typify panels as in Figure 3. CP 6 on the left side is typical of 2, CP 6 and CP 7. CP

6 on the right side is a single panel containing two sets of control switches.

4. Show the loop numbers, panel designations, and equipment tags of all devices

represented by the typical box. As in Figure 3, list the loop number which is shown

on the drawing first. Then list the loop number(s) which it typifies. Do the same for

control panels and motor controls.

5. Signal line arrowheads should point to the typical. Figure 4 shows how signal lines

had to be turned to facilitate typifying.

Note: Panels in this example are shown in vertical arrangement one below the other.

However due to limited space in the "Local/Field Control Panel" segment on the P&IDs

panel could be shown in horizontal arrangement one beside the other or the combination

of both.

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Figure 2: Control Signals (Note that showing panels is dependent on the design stage).

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Figure 3: Typifying controls.

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Figure 4: Additional measures when typifying controls.

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4. Overviews and Detail Drawings

Set of facility’s Master P&ID will be available to consultant in Adobe format

4.1 Plant or System Overview Drawings

Prepare a plant or system overview drawing on all projects involving several unit

processes, plants, or process areas. It will serve as a road map for the P&IDs. The

overview should be prepared after the P&IDs are complete or near complete and should

precede the P&IDs in the drawing set.

The overview should show:

Each unit process, plant or process area by name and number.

Flow streams between processes.

P&ID or unit process overview drawing numbers.

4.2 Unit Process (Area) Overview Drawings

Large or complex processes may require a process overview drawing. The overview may

include a limited number of instruments and balloons. The overview should be oriented

with north toward the upper part of the drawing if at all possible. Show process stream

connections to other areas or unit processes. Subdivide the overview to correspond to the

detailed P&IDs. Process stream connections among P&IDs within the unit process need

not be shown.

4.3 Device Overview Drawings

Large or complex devices may be shown as an overview symbol on a P&ID and then

detailed on a separate drawing. The overview should identify the device, name the detail

reference and show which panels contain instrumentation presented on the detail. If a

panel is dedicated to the device it should only be shown on the device detail.

Some frequently occurring devices may also be shown as an overview symbol on a P&ID

and detailed on another drawing as standard devices. The number of overview and detail

layers should be minimized to reduce flipping between drawings. One drawing would be

more convenient in the field, because of less paper handling and less chance of not

bringing all the detail needed. Its usage should be restricted to where it is needed for

clarity and consistency.

The choice and number of standard device designations needs to be managed on each

project. .

4.4 Process Detail Drawings

This diagram shows full detail of the process and references P&ID layouts for standard

devices. Information shown on this drawing includes: flow meter size, tank size and

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capacity, trip points for level, pressure, temperature and similar switches which are set at

a fixed point in the field. Pipe sizes would be included on new construction. Process

parameters and set points would be shown on the actual control system display screens,

but would not be included on the P&ID.

4.5 Device Detail

The device detail shows full detail of instrumentation related to a device. It may be

shown on an overview or process detail or on a separate diagram.

4.6 Redundant Information

Information should only be shown once. Do not repeat symbols for the same I/O point,

instrument or piece of equipment.

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5. Symbol and Legend Sheets

Refer to Drawings XXXX-P&ID-I-0101, 0102, 0103 attached to this guideline. The

content of these sheets should be used for all Toronto Water Projects and could be

changed only with Toronto Water approval. Content of the drawing should be inserted

into the facility Master P&ID title block changing XXXX with appropriate facility code.

Further details are discussed below.

5.1 Primary Element Symbols

Identify the type of primary element early in the project. Mechanical layouts, instrument

takeoffs, instrument application engineering, and quality control require definition of the

type of primary element.

Minimize the use of unclassified primary element symbols. The most common use of the

unclassified flow symbol is for a flow switch. Use the unclassified level symbol when a

pressure sensing instrument is used to indicate level, or for vendor packaged level

instruments where the type is vendor dependent.

5.2 Miscellaneous Symbols

Any special, non-standard symbols can be added to this group with TW approval.

The sight glass must be used in the vertical position as shown.

5.3 Actuator Symbols

Always show the fail position designation at the lower right of the actuator symbol for

the fail-safe action in case of loss of air, hydraulic or electric power supply or control

signal. Use abbreviations: FO (fail open), FC (fail close) or FL (fail lock).

5.4 Valve and Gate Symbols

No specific guidelines.

5.5 Equipment Symbols

A wet pit pump does not have inlet piping. A screw pump does not have inlet or

discharge piping.

The turbine supply and return lines are shown as per ISA.

The process stream flows through the “coil” of the heat exchanger. Cooling or heating

liquid enters perpendicular to the process stream.

The ejector is sometimes called an eductor, jet or injector. The motive flow stream

always enters the rear of the symbol.

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5.6 Instrument and Function Symbols

Use separate, touching balloons for instruments that have more than one function such as

controllers, control stations, valve actuators, multiple electrode level switches, sludge

blanket detectors, and lighted switches.

Designate a panel mounted alarm light as:

LLL Level Light Low

For any light, the second letter must be an L. Placement of the L in the second position is

needed to distinguish between readouts and modifiers. For example:

1. L

A

L

L

A

L

level alarm low

2. L

L

= level low (level light makes no sense)

3. L

L

L

= level light low

4. = level light low low

Designate a panel mounted alarm annunciator point as:

LAL Level Alarm Low

Note that annunciators are distinct from alarm lights. An alarm light simply lights under

alarm conditions. An annunciator requires an acknowledgment to silence horns, stop the

light from flashing or other actions. An annunciator may be a single light or may be part

of an annunciator panel.

5.7 Input and Output Signals to Digital Controllers

See EDOCSLIB-#6454 Equipment and Data Tagging.

5.8 General Notes

Put general note (See P&ID Symbol and Legend Sheet) on all legend sheets. Add other

notes as may be required for the project.

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The instrument identification table is from Instrument Society of America (ISA) Standard

S5.1, 1984 Instrumentation Symbols and Identification. Do not change the table without

Toronto Water approval.

Attach the balloons for valve open and valve closed limit switches to the stem of the

valve operator.

5.9 Flow Stream Identification

Identify all flow streams. Use the flow stream identifications shown on the P&ID

Legend Sheet. If the project requires other flow stream identifications, you can alter the

table shown. However, try to minimize the number of changes.

Except for plant influent and primary influent, label all flow streams based on the

upstream process. For example, use primary effluent not secondary effluent.

If a line contains two flow streams, label both. For example, PS/SS is a flow stream

consisting of both primary sludge and secondary sludge.

The flow stream should be annotated to clarify the stream. If the flow stream must be

annotated, enclose the annotation in quotes. For example, a plant air system of a

particular pressure range could be designated:

“Plant Air – 5 Bar”

PA2

5.10 Equipment Tagging

Use the rectangular equipment tag box if no balloon is used. If you use equipment tags

which do not contain the loop number, you should use balloons to show the loop number.

Equipment tags are mandatory when typifying to show which device is associated with

which loop.

5.11 Flow Stream and Instrument Line Symbols

Use three different line weights to distinguish flow streams. The main flow stream is the

liquid train, the secondary flow streams include sludge and process air, and other flow

streams include chemicals, instrument air, drains, water, and steam.

Use dashed lines to indicate alternate flow streams. These streams included bypasses and

streams which are not used for normal operations or for automatic backup.

Show all cast-in-place open channels and tanks in plan view and use double lines to

indicate walls. Double lines help to distinguish between closed conduits (pipes) and

tanks and open channels. Line weights and dashed lines are used as in the two previous

items.

Use arrowheads to indicate direction of flow. Always use arrowheads where pipes

connect and where pipes enter tanks. Do not use arrowheads upstream of primary

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elements, gates, pumps, valves, and other equipment. Use enough for clarity and ease of

tracing the flow stream.

When annotating flow streams or signal lines, enclose the annotation in quotes.

Label process equipment with a functional name, e.g. “raw sludge pump” or “treated

water pump”. Underline the names of pumps, tanks and other process equipment.

All process flow streams and signal lines which are continued on another drawing shall

be linked using the labeled arrowheads. The arrowheads must be labeled with unique

labels. The label is composed of the drawing number where the line is continued and an

arrowhead number unique to that drawing. In complex cases, the arrowhead number

should be made unique to all drawings in a sub-process. It is not necessary to add any

other notes to indicate origin or destination.

Minimize the use of the continuation symbol, especially for flow streams.

Use the slashed arrowhead to indicate an origin or destination which is not a part of the

project and which is not continued on any other P&ID. Notes must be added to indicate

origin or destination. Non-process lines such as potable and non-potable water used for

flushing or pump seals, instrument-air lines and similar ancillary piping may be shown

without slashed arrowheads.

5.12 Explanatory Notations

Hand switch and instrument designations should be placed at about the 1 o’clock position

if at all possible. If confusion will result, place the designation at the 5 o’clock position.

HSC/L

C/L

• Prefered position for explanatory notations.• Alternate position

Use CL (computer/local) hand switches whenever possible. In situations where there are

two levels of panels, each with hand switches, use RL (remote/local) on the local level

and CM (computer/manual) on the higher level.

Use MFS (modulate faster/slower) and OSC (open/stop/close) momentary hand switches

for modulating control.

Spring return to center hand switches are similar to push-buttons. If a spring return

switch is used, place a note on the P&ID. If the project requires many spring return

switches, supplement the explanatory notations. Use HMS to designate momentary

switches.

Latching type push-buttons are not covered. If they are used, annotate them similar to

spring return switches. Use HS to designate maintained switches.

Hand switches and push-buttons may be equipped with lights. In most cases, the lights

are connected to field contacts such as valve position switches or motor running auxiliary

relays. In some cases, the light may be used to indicate the switch position.

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In some applications, you may wish to show both on and off status using two lights

driven from one auxiliary relay.

Show analysis instruments which are mounted in tees or which use pipe saddles or

corporation stops as tapped.

Show all signal converters including current loop isolators if used. Do not use current

isolators indiscriminately. They are expensive, become an additional component which

can fail, and require calibration.

Do not show interposing relays in panels. These are covered in the panel drawings and

specifications.

6. Attached Drawings

The following drawings are attached as part of this guideline.

Drawing Number Document

Number

Subject

XXXX-P&ID-I-0101 9110 P&ID LEGEND

XXXX-P&ID-I-0102 9111 P&ID STANDARD SYMBOLS -1

XXXX-P&ID-I-0103 9122 P&ID STANDARD SYMBOLS -2

P&ID Block 1 9113 GATES, VALVES, PUMPS

P&ID Block 2 9114 BLOWER, FAN, DAMPER

P&ID Block 3 9115 VORTEX, CHAMBER

P&ID Block 4 9116 BRIDGE, COLLECTOR

P&ID Block 5 9117 CENTRIFUGE

P&ID Block 6 9118 GENERATOR, COMMUNITOR

7. Glossary

CGA Canadian Gas Association

DPC distributed process controller

HVAC heating, ventilation and air conditioning

I&C instrumentation and control

I/O input/output

ISA Instrument Society of America

MC motor controller

MCC motor control centre

P&ID process and instrumentation diagram

PLC programmable logic controller

RSC remote station controller

NFPA National Fire Protection Association

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REVISIONS / CONTRACT NO.No. DATE INITIAL SIGNED

DRAFTING:

TORONTO WATEROPERATIONAL SUPPORT

DATE:

DESIGN:

SCALE: SHEET No.DRAWINGNUMBER:

CHECK: CONTRACT No.

DIRECTOR, DIRECTOR,ALEX MARICH

OPERATIONAL SUPPORT

P&ID LEGENDGENERAL

ENTER FACILITY NAME

1XXXX--P&ID-I-0101

INSTRUMENTATION-MASTER P&ID

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.

DIRECTOR,ALEX MARICH

OPERATIONAL SUPPORT

P&ID STANDARD SYMBOLS - 1GENERAL

ENTER FACILITY NAME

1XXXXX-P&ID-I-0102


N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID STANDARD SYMBOLS - 2GENERAL

ENTER FACILITY NAME

1XXXX-P&ID-I-0103


N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 1 - GATES, VALVES, PUMPSGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 2 - BLOWER, FAN, DAMPERGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 1 - GATES, VALVES, PUMPSGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 4 -BRIDGE, COLLECTORGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 5 - -CENTRIFUGEGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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DRAFTING:


DATE:

DESIGN:


CHECK: CONTRACT No.


OPERATIONAL SUPPORT

P&ID BLOCKS 6 - GENERATOR, COMMUNITORGENERAL

1

PCS STANDARDS

N.T.S

JULY, 2001

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Appendix C Colour Convention

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1. Colour Convention 1.1 General This design guideline sets out the use of colours to indicate information in a consistent manner. This guideline reserves some colours for the representation of alarms and status conditions and therefore may not be used for any other meanings or other uses.

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

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

1.2 Field Indicating Lights Field status and alarm lights shall conform to the following colour convention: ITEM COLOUR Running, burner on, valve open, breaker closed Red Stopped, safe, burner off, valve closed, breaker open Green Overload, warning Amber (should it be

yellow?) Intermediate position (valve) White or Flashing White Alarm Flashing Red

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

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

summaries) Cyan Color104 C0C000 12632064

Equipment/Device Status

Digital

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

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

Analog

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

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

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

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

** DECIMAL refers to the decimal conversion of the Hex Code. This is used in the iFIX “properties window” to specify colour properties for an object. (Most ‘colour picker’ software uses “Red, Green, Blue” to generate the hex code instead of “Blue, Green, Red” which iFIX uses.)

1. Control Modes

• Local Status Colour Name Hex Code 1. Local Black Black 000000 0

Decimal

Non-controllable from Computer (RPU) Grey Gray 75 C0C0C0 12632256

• Computer Status

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

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

3. Identification Labels

Dark Background

Colour Name Hex Code Decimal Screen Titles White White FFFFFF 16777215

Equipment White White FFFFFF 16777215 Other White White FFFFFF 16777215

Light Background

Colour Name Hex Code Screen Titles Dark Blue Blue 800000 8388608

Decimal

Equipment Robin Blue Bright Cyan FFFF00 16776960 Other Black Black 000000 0 Where operator displays are being added to an existing system where operator displays already exist, the Consultant shall consult with the City if the existing displays do not conform to the above convention.

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

Material Handled

Pipe Colour from MOEE Guide

Pipe Colour for Displays Name Hex Code Decimal

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

Light Grey Gray88 E1E1E1 14803425

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

Blush Yellow Medium Blue Color57 FF8C2C 16747564

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

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Material Handled

Pipe Colour from MOEE Guide

Pipe Colour for Displays Name Hex Code Decimal

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

Blue Band Yellow Bright Yellow 00FFFF 65535

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

Metallic Green with Orange Band

Yellow-Green Color99 00D2A8 53928

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

Yellow with White Band

Yellow Bright Yellow 00FFFF 65535

Lime White with Orange Band

White White FFFFFF 16777215

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

Grey Gray75 C0C0C0 12632064

Other Chemicals Yellow Bright Yellow 00FFFF 65535 *Natural gas and propane piping colour identification are governed by separate codes. Although the MOEE guideline for natural gas and propane does not conflict with the codes per se, the use of yellow colour is recommended to avoid any confusion in piping identification.

Note

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

: sampling lines will retain their process stream colour.

Classification Background Colour Legend Colour.

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

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Appendix C RPU Software Programming

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1. RPU Software Programming

1.1 General

This guideline is for the structure and documentation of Remote Processing Unit (RPU)

programs. This document is to establish standards for a consistent approach to programming

which will enable:

1. the maximum re-use of programs;

2. Reduced time to troubleshoot programs; and

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

Consultants shall comply with this design standard in the design of the works and ensure that the

contract documentation for construction conform to this requirement. Any proposed deviation

must have the prior approval of the City

1.2 Standards

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

languages. In addition, the programs written for critical or hazardous applications shall conform

to CAN/CSA-Q396 Quality Assurance Program for the Development of Software Used in

Critical Applications.

1.3 Documentation

1.3.1 Flow Charts

1. The method of documenting software logic design is the flow chart diagram, a type of

sequential function chart. Document all applications programs in this manner.

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

3. The flow chart is a design tool to get concurrence that functional requirements have been

understood and incorporated into the design.

4. Show only automatic control mode.

5. The intent is to flow chart a process on one to two 11x17 sheets. The simple, high-level,

‘single sheet’ concept may actually need multiple sheets depending on the complexity of

the controls.

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

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

indicated.

8. Show process interlocks.

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

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Flow chart shapes should be used consistently as follows:

Function Shape

Logic Block Plain box

Modules Box with end

bars.

States Box with cross

Decisions Diamond

Operator

Selections

Trapezoid

Message Parallelogram

Start or Stop Oval

Continuation Circle

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

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Figure 1: Flow Chart Example

Grit TankOutlet Valve

Opened

Grit TankLevel >1m

Grit TankInlet Valve

Opened

Yes

CleaningCycle Timer

Done

No

No

Grit TankInlet Valve

Closed

Grit TankOutlet Valve

Closed

Yes

Yes

No

Total FlowReached

Target

Yes

Yes

Bar Screen Normal Operation

Operator selects

- Interval Max cycle time (xx minutes) - Interval Min cycle time (xx minutes) - Max totalized Flow rate (xxx m3/sec) - Set Screen high level switch - Duration cycle time for high level operation (xxx minutes)

TotalizedFlow Rate

Target reached

Yes

Yes

No

No

Grit Tank Normal Operation

Operator selects

- Cleaning Cycle timer (xxx Hours) - Total flow Target (xxx m3) - Tank in service - Out of service

Grit Unwatering Pump System

Operator selects

- Duty and standby pump - Unwatering pump cycle time(xxx minutes) - Min Tank Level (xx.x m) - Low-Low Tank Level (xx.x m)

Grit Handling Watering System

Operator selects

- Duty and standby pump - Unwatering pump cycle time(xxx minutes) - Min Tank Level (xx m) - Low-Low Tank Level (xx m)

Call Moduleto open

Grit TankOutlet valve

Call Moduleto open

Grit TankInlet valve

Air ProcessHeaderOpened

Call Moduleto operate

Air ProcessHeader

No

Start CleaningCycle Timer and

AccumulateFlow

StartBar Screen

Process

StartMaximum

Time IntervalOperation

High LevelTarget

Reached

StartMinimum

Time IntervalOperation

StartHigh LevelOperation

Call Moduleto close

Grit TankInlet valve

Call Moduleto close

Grit TankOutlet valve

TankIn Service

Tank Outof Service

AdvisementSend toSCADA

UnwateringValve

Opened

No

Call Moduleto open

UnwateringValve

AdvisementSend toSCADA

Cycle timeTarget

Reached

Yes

Start

Out of ServiceIn service

OperatorStart tankcleaning

Tank CleaningProcessRequired

Air HeaderClosed

No

No

TankCleaningProcessRequired

Yes

Yes

Tank CleaningProcessStarted

Yes

No

No

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1.3.2 Control Program Listings

1. All application programs shall be completed using ladder logic.

2. The entire program shall be annotated with comments. Explain what the program is

doing, and why.

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

shall be sufficiently verbose to allow on-site troubleshooting.

4. Each I/O, derived value, register and coil, subroutine and object shall be identified by

descriptor.

1.4 Programming

The design logic shown in flow charts shall be structured to use standard software modules.

Where possible, the program shall make use of standard modules. Standard modules are

described in EDOCSLIB-#9097 RPU Standard Software Modules.

The standard modules are not to be altered without the permission of the Toronto Water. Any

unusual or specific data manipulation is to be performed outside of the modules.

1.4.1 Update Procedure

The PCS component of any project will often involve updating an existing program rather than

creating a new program. The following procedure should be considered when updating a

program:

1. During pre-design, decide which existing RPUs will be involved in the project. The pre-

design report should contain this list and determination made that capacity exists in those

processors and I/O racks based on the estimated I/O or determine what upgrades are

required to create the capacity

2. During detailed design, create drawings for any necessary hardware upgrades

3. During construction, the Systems Integrator will request the existing program(s) from

Toronto Water. Toronto Water will keep track of all requests in order to coordinate

updates and version control.

4. During programming, the Systems Integrator will use the memory map guidelines to

determine areas of memory to use. This is critical to ensure consistency which will make

future expansions and program maintenance easier.

5. New rungs should be commented to clearly show that they are part of the current project

and help differentiate them from existing programming. New Auto logic should be

contained within new routines rather than adding to existing routines to help differentiate

new logic from existing logic. New I/O should be handled in existing routines and

appropriately commented.

6. FAT/SAT documentation should indicate which routines were modified or added so

Toronto Water staff has the opportunity to determine and test the effect on existing

programming.

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1.4.2 Analog Inputs

Scaling of analog values, shall be performed only in the Operator Workstation software in

accordance with the following requirements:

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

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

3. Where data is manipulated in the RPU for purposes of control, such manipulations shall

not be interposed between the input from the instrument and the Operator Workstation

software.

4. Data manipulations such as summation for displays or historical data shall be done in the

Operator Workstation software. The method of scaling is shown in Figure 2 Analog Data

Flow

ProcessEquipment

ANINAnalogInput

Module

Field sensorsFlow, level etc

OperatorWorkstation

binary unscaled

Control program

Controlsignal

Scalingfor controlpurposes

PLC

Controller binaryunscaled

Database

Scalingfor controlpurposes

Figure 2 Analog Data Flow

1.4.3 Memory Organization

1. The following paragraphs set out principles for memory allocation and program structure.

Memory allocation for GE 90-30 RPUs is presented in section 1.5.

2. RPU memory shall be organized into three major sections:

I/O Registers;

Control; and

Communication (if needed).

3. Each section should contain memory for expansion up to the overall limit defined in the

technical specifications for the RPU. Within each section, the memory should be further

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

1.5.

1.4.3.1 I/O Registers

1. I/O should be organized in the same hierarchy as used for program structure. For RPUs in

which I/O point numbering is not restricted to a pattern, the I/O should be assigned to

addresses within the I/O register section. The I/O register should be split by type of I/O:

analog inputs, analog outputs, digital inputs and digital outputs. I/O for similar devices

should be put in the same order of address.

2. For RPUs in which I/O point numbering is restricted to a pattern, the assignment of

addresses may be partially predetermined. As much as possible, follow the considerations

for organization given in the preceding paragraph.

1.4.3.2 Control

1. The control logic should present all control actions directly and avoid using the same

address or block of addresses for multiple uses. Logic for control should be organized

into blocks by device and structured consistently following the guidelines herein.

2. Logic for the watchdog timer and system clock should be located first in this section if

they are not part of system software or hardware.

3. General rule for Ladder Logic Rungs:

Normally open input contacts will be used first.

Normally close input contacts will be used next.

4. In normal situations, a rung can be separated into two sections:

The first section is the Control logic.

The second section is the Interlock logic.

5. The order for the control logic section is:

Computer mode (If computer auto and computer manual modes are required in the

rung, then the parallel branch function will be used. Computer auto control logic is

always on top of the branch).

Operation request (momentary contact).

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

6. The order of the interlock logic section is:

Operation permissive (can be more than one contact);

Stop device request (can be more than one contact); then

Device failure (can be more than one contact).

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Control Logic Examples:

1. Rung layout with computer mode:

2. Rung layout with computer auto and manual modes:

Computer Operation Operation Stop Devicemode permissive permissive request failure Output

Interlock logic section

Control

logic section

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

Computer Operation Operation

manual mode Request inhibit

RungOutput

Control logic section Interlock logic section

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The following standard Bit Allocation shows a typical data map for pump and valve devices.

This structure shall be followed as closely as possible. Any deviation will require the approval of

Toronto Water.

Pump/Rotating Device Valve Bit 1 In computer mode In computer mode Bit 2 Not available warning Not available warning Bit 3 Running Status Open Status Bit 4 Spare Close Status Bit 5 Computer auto request Computer auto request Bit 6 Computer manual request Computer manual request Bit 7 Start request Open request Bit 8 Stop request Close request Bit 9 Spare Spare Bit 10 Alarm reset request Alarm reset request Bit 11 Auto start request by auto

process Auto Open request by auto process

Bit 12 Auto stop request by auto process

Auto Close request by auto process

Bit 13 Spare Spare Bit 14 Spare Spare Bit 15 Interlock alarm #1 Interlock alarm #1 Bit 16 Interlock alarm #2 Interlock alarm #2 Bit 17 Ready to operate Ready to operate Bit 18 Computer auto mode Computer auto mode Bit 19 Computer manual mode Computer manual mode Bit 20 In running condition In open condition Bit 21 In stopped condition In closed condition Bit 22 Start permissive Open permissive Bit 23 Alarm Stop request Close permissive Bit 24 Start command Open command Bit 25 Stop command Close command Bit 26 Spare Spare Bit 27 Reset start/stop command Spare Bit 28 Restart inhibit Spare Bit 29 Pump running latch Spare Bit 30 General failure General failure Bit 31 Uncommanded start alarm Uncommanded open alarm Bit 32 Uncommanded stop alarm Uncommanded close alarm Bit 33 Fail to start Fail to open Bit 34 Fail to stop Fail to close Bit 35 No request by RPU Unknown position Bit 36 Spare Position lost track Bit 37 Spare Spare Bit 38 Run 1 hour Failure alarm start timing Bit 39 Reset restart inhibit Spare Bit 40 Spare Spare

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Bit 41 Auto Start request by process Auto Open request by process Bit 42 Auto Stop request by process Auto Close request by process Bit 43 - 50 Spare Spare

The following standard Word allocation shows a typical data map for counters and timers. This

structure shall be followed as closely as possible. Any deviation will require the approval of

Toronto Water.

Internal Counter Internal Timer

Word 1 Counter 1 (Current

Value)

Timer 1 (Current

Value)

Word 2 Counter 1 (Preset Value) Timer 1 (Preset Value)

Word 3 Counter 1 (Control

Word)

Timer 1 (Control

Word)


Value)

Timer 2 (Current

Value)



Word)

Timer 2 (Control

Word)


Value)

Timer 3 (Current

Value)



Word)

Timer 3 (Control

Word)

Word 10 Spare Spare

1.4.3.3 Communications

1. Blocks of memory may need to be allocated for communication with other intelligent

devices to manage communication speed. Communication blocks are not required for GE

RPUs connected by Ethernet.

2. For example, communication with an operator station may require that a separate block

or blocks be set up for an alarm and event array. The alarm and event array may be split

into separate blocks, one for alarms and one for events. Even if alarms are also used for

control, they should be copied to the alarm block. Separation of alarms is useful for

testing alarm reporting separate from control logic.

3. Within the communication section, separate blocks should be set up for communication

to minimize the number of messages needed to communicate data. Typically this means

that a block for analog values, a block for receipt of operator commands and a block for

setpoints and other parameters should be set up. A block for communication to and from

other RPUs may need to be separate from the operator station interface blocks in order

for fast communications.

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1.5 Memory Allocation for GE 90-30 RPU

A. Analog Input and Analog Output

1. Analog Input: %AI00001 to %AI02048

2. Analog Output: %AQ00001 to %AQ00512

B. Analog Internal Default

1. Analog Internal: %R00001 to %R12032

a. SCADA to PLC: %R00001 to %R00500

b. PLC to SCADA: %R00501 to %R01000

c. Programming: %R01001 to %R08000

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

%R08001 to %R09000

e. Counter: %R09001 to %R10000

f. Timer: %R10001 to %R12032

B2. Analog Internal Hi Density


a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500

b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000

c. Programming: %R01001 to %R08000, %R14001 to %R20000


%R08001 to %R09000, %R20001 to %R21000

e. Counter: %R09001 to %R10000, %R21001 to %R22000

f. Timer: %R10001 to %R13000, %R22001 to %R23000

g. Modbus: %R23001 to %R24064

C. Discrete Input, Discrete Output & Hardware Configuration

1. Discrete Input: %I00001 to %I02048

a. Raw Discrete Input: %I00001 to %I01000

b. CPU Ethernet Status Address: %I01001 to %I01080

c. I/O Modules Status Address: %I01081 to %I02048

2. Discrete Output: %Q00001 to %Q02048

D. Discrete Internal

1. Discrete Internal: %M00001 to %M04096

a. SCADA to PLC: %M00001 to %M00500

b. PLC to SCADA: %M00501 to %M01500

c. Programming: %M01501 to %M04096

1.6 Transition Memory Allocation for RX3i PLC

A. Analog Input and Analog Output

1. Analog Input: %AI00001 to %AI02048

2. Analog Output: %AQ00001 to %AQ00512

B. Analog Internal Default


a. SCADA to PLC: %R00001 to %R00500

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b. PLC to SCADA: %R00501 to %R01000

c. Programming: %R01001 to %R08000


%R08001 to %R09000

e. Counter: %R09001 to %R10000

f. Timer: %R10001 to %R12032

B2. Analog Internal Hi Density


a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500

b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000

c. Programming: %R01001 to %R08000, %R14001 to %R20000, %R24065

to %R32640


%R08001 to %R09000, %R20001 to %R21000

e. Counter: %R09001 to %R10000, %R21001 to %R22000

f. Timer: %R10001 to %R13000, %R22001 to %R23000

g. Modbus: %R23001 to %R24064

C. Discrete Input, Discrete Output & Hardware Configuration

1. Discrete Input: %I00001 to %I02048

a. Raw Discrete Input: %I00001 to %I01000

b. CPU Ethernet Status Address: %I01001 to %I01080

c. I/O Modules Status Address: %I01081 to %I02048

2. Discrete Output: %Q00001 to %Q02048

D. Discrete Internal

1. Discrete Internal: %M00001 to %M32640

a. SCADA to PLC: %M00001 to %M00500, %M05001 to %M05500

b. PLC to SCADA: %M00501 to %M01500, %M05501 to %M06000

c. Programming: %M01501 to %M05000, %M06001 to %M10000

1.7 Communications

Addresses

1. Each node on a RPU communications network must have a unique address on that

network. Node addresses shall be chosen to integrate into existing networks. Nodes shall

be assigned in consecutive node addresses. RPUs in hot standby shall have consecutive

node addresses.

Control

1. Control and monitoring shall continue without disruption in the event of communication

failures. Where control functions rely on information affected by communications failure,

a safe mode of control shall be provided.

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

RPUs to the minimum.

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Time Synchronization

All nodes on a RPU communications network shall have internal clocks synchronized

periodically to a master clock. Synchronization shall provide time and date stamping

accuracy to within one second of the master clock. Master clock and RPU clock shall be

accessible from the Operator Workstation.

1.8 RPU Program Commissioning

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

Assurance Program for the Development of Software Used in Critical Applications. Each I/O

shall be tested from source element to display screen. The source element shall be exercised

wherever possible or else simulated. For example, a float switch should be tilted to verify the

signal. After commissioning, if access to the float switch is not practical, then its action may be

simulated by short circuiting the input loop.

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Appendix C Standard Software Modules

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1. Standard Software Modules 1.1 General This document describes Toronto Water’s standard software modules and establishes procedures to guide the development, testing and deployment of new software modules. The Consultants shall ensure that the System Integrator complies with the programming and testing requirements with respect to software development.

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

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

1. Functional description including module layout

2. RPU program design expressed in a flow chart

3. RPU program with embedded documentation

4. HMI program

5. Simulation program

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

1.3 Available Modules The device control modules are summarized in the following categories:

1. Conveyors and General Devices

2. Pumps

3. Valves

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

Some general module descriptions are included below.

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

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

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

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

1. Motor overload;

2. Motor start/stop fail timer; and

3. Motor specific alarm such as low oil pressure.

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

1. Low suction pressure;

2. Low seal water pressure;

3. Power failure; and

4. Other process specific alarms such as high discharge pressure.

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

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

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

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

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

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

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

1 = previous filtered value

The value of K is set by the System Technician.

Note: with a K value near 1, the Analog Input Filter module has little effect at “smoothing” the input signal. With a K value near 0, the output value of the Analog Input Filter module changes very slowly with a change in input value.

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

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In the manual control mode, the Operator can enter a control command value. The module monitors its control variable (CV) and considering the user-defined parameters, will change the module output to match the command value.

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

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

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

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

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

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

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

1

Derivation (Derivation Gain)

0

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

N/A

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

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

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

Bias The usual setting for the Bias field is +16000 to let the

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Parameter Configuration Guideline function regulate error around the output midpoint.

Dead Band Upper and Lower

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

Upper Clamp and Lower Clamp

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

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

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

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

1.4 Module Development The module development process shall be as follows:

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

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

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

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

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

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

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

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

9. Incorporate further required changes.

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

11. Submit module for acceptance.

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

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

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

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

• Assume errors are distributed throughout the programs.

• Prove functionality as defined in functional descriptions and flow chart.

2. The Consultants shall review the testing process

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

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

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

• The methods for module development and testing were followed.

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

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

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

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

1. Meets Toronto Water PCS standards.

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

3. Performs functions shown on flow charts and diagrams.

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

5. Passes written internal testing procedures and signed by Consultants

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Appendix C Operator Interface Programming

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1. Operator Interface Programming 1.1 General The Consultants shall comply with the following guidelines for the programming of Operator Interface Terminals (OIT) connected to Programmable Logic Controllers (PLCs).

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

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

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

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

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

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

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

A hierarchical menu shall be constructed using the device keypad and programmable ‘soft’ keys to provide a simple and intuitive method of accessing all of the screens provided. Where available, use an existing OIT program at the facility as a template for form and function.

Colours used for text and graphic elements shall use the same colours used on normal SCADA displays. Changes in colour that result from change of state shall also use the same colours as used at the SCADA displays. Refer to guideline EDOCSLIB-#9095 Colour Convention for more information on colour standards.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Appendix C Process Display Programming

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1. Process Display Programming

1.1 General

This guideline applies to all operator workstations.

This guideline is for the structure and documentation of process displays and establishes standards for a consistent approach to programming which will enable:

1. maximum re-use of programs;

2. reduced time to troubleshoot programs; and

3. higher confidence and usability of operator workstations.

This guideline will be reviewed whenever a new workstation software package is selected or

when the software version is changed.

Consultants shall comply with this design guideline in the design of the works and ensure that

the contract documentation for construction conform to this requirement. Any proposed

deviation must have the prior approval of the City

1.2 Display Names

Each graphic display shall be identified by its version number (Vx.x) and its name. Record the

location of the primary copy of the display. Use the naming convention in the following table for

all graphics:

File Types File Naming Convention (Notes 1,2 and 3)

Process Graphics PLT_AREA_XXXXX

Trend Charts PLT_AREA_trend_XXXXX

Setpoint Graphics PLT_AREA_setpt_XXXXX

Run-Hour Graphics PLT_AREA_runhour_XXXXX

Legend & Info Graphics PLT_AREA_legend_XXXXX

RPU Status Graphics PLT_plc_XXXXX

Plant-Wide Trend Menus PLT_chartmenu

Alarm Summary PLT_alarmsummary

Mainmenu PLT_mainmenu

Alarm Page PLT_AREA_sub_alarm

Process Sub-Picture PLT_AREA_sub_XXXXX

Drop Down Menu PLT_AREA_sub_menu_XXXXX

Process Area Trend

Menus

PLT_AREA_trendmenu

Notes:

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1. PLT: 3-character Plant Code to be defined in EDOCSLIB-#6454 Equipment and

Data Names (eg. FHA for Harris Filtration Plant).

2. AREA: Process Area codes to be defined in EDOCSLIB-#6454 Equipment and Data

Names (eg. FLT for filtering process).

3. XXXXX: specific graphic name left to the discretion of the developer. Use a similar

naming method to those graphics that already exist.

1.3 Display Guidelines

1.3.1 Update Procedure for HMI displays

The PCS component of any project will often involve updating an existing display rather than

creating a new display. The following procedure should be considered when updating an HMI

display:

1. During pre-design, determine which HMI hardware components will be affected by the

project. This may include SCADA servers, Operator workstations, or local OITs. If

possible, determine specifically which process graphics will be affected.

2. During detailed design, create or further refine the list of affected process graphics.

Consider if any changes will be required to the menu bar (and User.FXG file)

3. During Construction, the System Integrator will request the existing HMI application

from Toronto Water. ITM can determine, at their discretion, if the facility’s entire HMI

application is to be locked down during construction or just the specific affected graphics.

The software should be considered signed-out and locked down while in the System

Integrator’s possession to facilitate version control.

4. The System Integrator will FAT the software modifications according to normal Toronto

Water procedures.

5. When the project is ready for the SAT, the System Integrator will obtain ITM’s approval

for integrating their software modifications with the system in operation at the facility.

The process graphics and new/modified database tags should be uploaded and then the

SAT performed according to normal TW procedures.

1.3.2 Update Procedure for iHistorian, eOPS

1. As part of the Process Control Narrative update, determine which iHistorian and eOPS

tags need to be changed, added, or deleted and determine the associated parameters

(update deadband, etc.)

2. The Systems Integrator will program the changes to the iHistorian as part of their

software development

3. The FAT for any eOPS database and reports changes will be performed on the ITM eOPS

test system at the Tiffield Road facility. This may be a separate FAT from the standard

software FAT typically performed at the Systems Integrator’s office.

4. After a successful FAT, the Systems Integrator will forward the iHistorian changes to

ITM. ITM will install the changes on the production system at the facility.

5. The Systems Integrator will SAT the iHistorian changes.

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6. The next working day following a successful SAT of the iHistorian changes, the eOPS

changes will be implemented by ITM at the Tiffield Road facility. The Systems

Integrator will then SAT the updated database and reports.

1.3.3 Layout

1. Graphic displays should have minimal information on the left side where pop-up windows initially appear.

2. The amount of information on a graphic display should be in the range of 30 to 60

information points. An information point is an analog value, an alarm or event message, a

monitored or controlled device symbol, a bar graph symbol or display call button.

Exceptions to this guideline will likely occur for summary displays or some complex

processes.

3. Layout the graphic either according to plant floor location or the P&ID drawings as appropriate for the information being presented.

4. Generally process inputs come from left side of the screen and outputs go to right side of the screen.

5. All process graphics must contain a title bar across the top.

6. The title bar must display:

name of the graphic display using the format “PLT – Description”

date;

time; and

icons accessing:

plant overview;

alarm summary;

operator log-in;

process miscellaneous menu;

Print Screen function; and

trend menu.

1.3.4 Text

Font style and size should be suited to the graphic display. Preferred font styles are plain such as Simplex or Arial. Standard fonts are shown in the following table:

Item Font Font Size

Title of graphic Arial, italic, bold 17

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Item Font Font Size

Date Arial, regular, bold 12

Time Arial, regular, bold 12

Device tag name Arial, regular, bold 9

Device status Arial, regular, bold 9

Abbreviations should use codes in EDOCSLIB-#6454 Equipment and Data Names, flow stream

identifiers contained in EDOCSLIB-#9094 P&ID Symbols and Practices or other Toronto

Water standards.

1.3.5 Colour

The use of colours shall conform to DOCS1#9095 Colour Convention. Other colours may be used

where the use of colours is not defined in that standard.

1.3.6 Shape

1. Shape will be used to make key information more evident and to reduce errors due to

colour-blindness.

2. Shape will be used to show tank levels where the tank is shown in profile, i.e. elevation view.

3. Change of the shape or icons to indicate status will be selectable by the operator. When selected, the usage of shape change will be as follows:

a) Mode Identification

A Automatic

L Local

M Manual

N Not Available

b) Status Identification

O Open

C Closed

T Transition

R Run

S Stop

I Inhibit

L Run Low Speed

H Run High Speed

Forward

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Reverse

1.3.7 Icons

1. Toronto Water maintains a software library of icons developed for use in displays. Use

icons in the library for representing individual devices rather than creating alternative shapes.

2. Icons should resemble field equipment to make recognition easier. Label each icon with

the equipment number. On any individual display, use icons of a similar type (i.e. all 2-D

or all 3-D), similar orientation (i.e. all profile or all plan view) and similar relative size to give consistent presentation.

3. Icons incorporate the colour and alarm conventions. The colour convention including

rules for using flashing to indicate unacknowledged alarms is given in EDOCSLIB-

#9095 Colour Convention. The alarm convention is explained in EDOCSLIB-#9099

Alarming.

4. Icons should be consistent in size across all displays; however, some process displays

may require reduced icon sizes in order to accommodate all of the devices.

5. As 3-D icons have different sizes, shapes and complexities, it is difficult to use colour fill

on the symbol to display status and mode; therefore, the following method is used to

indicate status and mode. The 'Status' colour is displayed in a small square while the

'Mode' colour is displayed in a small triangle. Both the square & triangle are layered on

top of the 3D symbol or close to the symbol. Since the 'Status' & 'Mode' colour fill is

separate from the original symbol, this way of displaying 'Status' & 'Mode' colour can be

used in every symbols independent of the symbol shapes and complexities and eliminate the effort of re-developing the colour fill linking to every symbol.

6. Provide each icon with access to its corresponding pop-up window.

7. A bitmap photo of the real device can be used in some cases as the icon. Submit suggested photos to the City for review and approval.

8. Where new symbols are required, the Consultants may request the City to consider the

addition of new symbols. If the City approves the addition of such symbols, the

development and testing will be performed by the Contractor as detailed in EDOCSLIB-

#9097 Standard Software Modules. On completion of the development of the symbols,

the Contractor shall submit the information in the format that will permit the City to add the data or information to the City’s library.

1.3.8 Pop-up Windows

Pop-up windows should initially appear on the left side of the screen, ensuring minimal coverage

of the screen. Pop-up windows may be moved and sized by the operator. Pop-up windows will contain:

1. the name and description of the equipment or item on the top.

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2. current status: e.g. running/off, opened/closed, enabled/disabled, manual/automatic/cascade, alarm/normal

3. current conditions: e.g. speed, position, electrical current

4. current alarms and acknowledge function

5. controls: e.g. start/stop, open/close, setpoint entries

6. mode selection: manual/automatic/cascade, enable/disable

1.4 Graphic Display Structure

The displays are interconnected in a hierarchy structure. In addition, interconnection is provided

for process streams continued on other process graphics. The structure and access to other

displays is shown in Figure 1 - Graphic Display Structure. Multiple displays may be needed to

show all of the information and control icons required for operation. Where multiple displays are required, a process overview should be created along with equipment overviews and details.

1. The main menu is a picture of the facility or map of the area with links to the process overviews.

2. Process overviews show process flow, summary information and major components or

groups of components. The displays are usually in plan view (building level); the top of

the screen is North. (Status only). Objects may be represented by simple symbols (circles squares etc) in grey. Links to equipment overviews or equipment detail screens

3. Equipment overview graphics may be needed to show sub-processes or groups of

components. Equipment layout (status and control) can use simple or complex icons

depending on number of components on the screen.

4. Equipment detail graphics may be needed for devices with monitored or controlled sub-components or other complex display requirements.

5. For situations where a number of components or component groups are the same, e.g.

aeration tanks or filters, either make one detail screen with tag groups or separate screens

for each tank or filter, whichever is more appropriate for the situation. One screen with tag groups is more appropriate for simple situations.

6. The RPU Status Graphics have the same look and feel as standard process graphics. Each

page of the RPU Status Graphic is allocated to the display of the RPU status for one or

more process areas in the plant.

The displays for every process area consist of a set of graphics as follows:

1. Process Graphics of the process area (one of which is an Overview);

2. Trend Menus;

3. Trend Graphics;

4. Setpoint Graphics (viewing and modifying setpoints for the process area);

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5. Run-Hour Graphics (viewing and modifying device run-hours for the process area);

6. Legend and Info Graphics;

7. Process Sub-Pictures

In addition to the graphics for the process areas, there are other graphics for plant-wide use, e.g.

Alarm Summary or RPU Status Graphics.

The first screen is the Mainmenu. It is displayed on system start up. From the Mainmenu, there

are selections for the various process areas. When one process area is selected, a process graphic

for the process area (normally the overview graphic) is displayed. From the Mainmenu, there are

also selections for other plant wide graphics, e.g. Alarm Summary or RPU Status Graphics.

Every graphic in the system shares a similar look and feel. There are several Buttons in the Title

bar to access some common use functions. Each graphic also contains a Back & Forward button

for navigational purposes and Menu Buttons for accessing other graphics in the process area.

The displays are shown in following sections.

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Figure 1 - Graphic Display Structure

System Login

Process

Sub-Pictures

Device

s Sub- -Pic

Alarm

Alarm Page

Legend & Info Graphic

Mainmenu

Process

Graphics

Trend

Charts

Plant-wide Tend Menu

Alarm Summary

Setpoint

Graphics

Run-Hour Graphics

Process Area 1

Area 2

Area 3

Process Area Trend Menu

Note: Every graphic can access the Mainmenu via the Home Button & other graphics through the drop down menu.

RPU Status

Graphics

Part of software

modules.

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1.5 Graphics Examples

MainMenu

Link to the first page of the Process Graphics (i.e. Overview) in one process

area. When there are unacknowledged alarms in the process area, the text will flash in

a red colour.

System Login

Button to access Plant-Wide Trend Menu

Button to access Alarm Summary

Button to access RPU Status Graphics

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Process Graphics

Back and Forward Buttons – to go back and forward through previous displays (up to the last 7 displays).

Menu Buttons – the 11 Menu Buttons to display various process graphics in the process area.

Login Button – for system login

Print Button – print screen to the default printer.

Trends Button – display Trends menu for this process printer.

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Alarm Summary

An Alarm page is a full screen display of filtered alarms for a process area. When a graphic is

opened, the alarm page is not displayed. By selecting the Alarm Page Button (clicking with the

left mouse button), the Alarm page will appear in place of the process graphic screen. By

selecting the Alarm Page button again, the Alarm page will disappear. The alarm area used for

filtering is indicated in the Alarm Page status line.

Alarm Page Button

Alarm Page status line – will display “Sort Order”, “Total Alarms”, and “Filtered Alarm Area.”

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Process Miscellaneous Button

In all process graphics, the user can display the Misc menu by clicking the Process Misc Button.

Selection available on the Process Misc menu include:

Alarm Setpoints - Set alarm limits for various instruments

Process Setpoints - Set process automation setpoints such as pump start/stop levels

Run Time/Counts - Display pump and valve runtime data

Legend & Info - Access Legend graphics & other symbol information

Pipe Colour - Display colour standards

Close Sub-Pics - Close all open sub pictures

View Tags - Display device tag names on the current graphic.

View Status - Display device status (i.e. Local (L), Running (R) etc.) on the

current graphic. When device status is displayed, tag name

display will be turned off and vice versa.

Hide Tag/Status - Turn off display of device status and tag names.

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System Miscellaneous Button

The Misc button in the menu button bar displays a drop down menu of various miscellaneous

pop-up displays of general plant information such as flow summaries, power usage, etc.

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Process Sub-Pictures

Process sub-pictures are normally accessible by clicking on an device such as a pump or chlorinator.

Other sub-pictures may be available through the pull-down menu for the process such as setpoints or

power consumption information. The process sub-pictures normally contain summary information

or relevant information for the same process areas or other process areas which are useful for the

operators.

Button to access drop down menu for process

Device control pop-up

Setpoints pop-up

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Trend Graphics

The Trend Charts are accessed from the Process Area Trend Menus. When Trend Charts are

opened, the Trends will display historical data for the past 24 hours. There are four (4) Duration

buttons for selecting different display durations (4, 8, 12, 24 hour-periods). Using the Calendar

button, a calendar is displayed and the date of trending display can be selected. Multiple Trend

Charts can be displayed on the screen. Menu Buttons – The 11 menu buttons to select various Process Area Trend Menus in the plant

Fast Backward Scroll Show/Hide Calendar (go back ½ period) (Show or hide the Calendar to select date of display) Slow Backward Scroll Buttons to Add/Delete Pens Slow Forward Scroll (go back 1/8 period) (go forward 1/8 period)

Fast Forward Scroll 4 Duration buttons (go forward ½ period)

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1.6 Plant Alarm Areas

Plant Alarm Areas should be configured and names assigned to the alarm areas should be

prefixed with the facility abbreviation.

1.6.1 Access

The log-in function will restrict access to process control and system features. Access will be

restricted according to access group. The groups are:

1. Guest

Access to log-in window.

Access to view displays including alarm page and pre-configured reports.

No access to process control functions.

2. Operator


Access to configuring trend and group displays.

Access to all process control functions and alarm acknowledgement (potentially not

access to disabling alarms and changing alarm priorities).

3. Supervisor/System Technician


Acc ess to configuring trend and group displays.

Access to all process control functions and alarm acknowledgement including

disabling alarms, changing alarm priorities and tuning parameters.

4. System Administrator

Access to all aspects of workstation software management including process control

functions, display viewing, display creation, report printing, report creation,

workstation set-up, network management, passwords and data base editing.

Password access is not required for Guest. Users in all other groups require individual

passwords.

After successful log-in, access is available for a limited time. The access time is adjustable for

each user group by the system administrator.

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1.7 Time Synchronization

Time synchronization shall be done at two levels: Operator Interface and RPU (controller). One

of the Operator Interface servers shall be designated as having the master clock. All other

Operator Interface servers and workstations shall be synchronized to this GPS master clock.

All RPUs (control nodes) on a communications network then in turn, shall have internal clocks

synchronized periodically to the master clock. Synchronization shall provide time and date

stamping accuracy to within one second of the master clock.

Master clock shall be accessible by the operator from the Operator Workstation.

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1. Alarming

1.1 General

This guideline shall be complied with in all control systems or equipment that generate alarms

for process control applications. It shall also include details on the types of alarms that are

required to be brought into the control system. Some examples have been provided herein, and

the requirements of each specific facility will be determined at the detailed design stage.

Consultants shall comply with this design guideline in the design of the works and ensure that

the contract documentation for construction conform to this requirement. Any proposed

deviation must have the prior approval of the City

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

1. determine information that needs to be alarmed,

2. prioritize alarm information given to operators.

1.2 Operating Conditions

Plant control rooms are not normally staffed. Operators (Plant Technicians) work in the process

area and are trained and experienced on processes within the work area. Cross training on other

areas is a goal, but not all operators will necessarily have the same level of skill and knowledge.

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

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

work area.

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

comprising part of the plant.

The process equipment is fully automated. Equipment automatically shuts down when operating

beyond its safe limits. Auxiliary safety equipment starts automatically when needed; for

example, ventilation fans during high toxic gas concentrations.

1.3 Operation Practices

Operators will periodically, typically every 45 to 60 minutes, review alarm summary displays for

their process(es) or work areas on PCS workstations. After dealing with the alarms that have

come up, operators will return to other duties.

Operators will be paged for immediate alarms. These alarms represent conditions that must be

dealt with immediately and cannot wait for the periodic alarm summary display review.

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Important alarms that affect more than one operator are required to be paged to all operators

involved. That is, a shut down of one process may affect another process or work area. In cases

like this, the operator who is responsible for correcting the problem should be given an alarm

message relating to the cause of the problem. Operators who are responsible for dealing with

subsequent processes should be given alarm messages relating to the problem. For example, at

Highland Creek, if sludge pumping from storage fails, the operator in that area should be paged

with the pumping fail message. This operator deals with getting the sludge pumping back in

operation. The operator in dewatering should be paged with a loss of sludge feed from storage

alarm message. This operator deals with problems in dewatering caused by the loss of sludge

feed.

1.4 Alarm Priority

There are 4 levels of alarm priority.

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

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

(approximately an hour).

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

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

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

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1.5 Alarm Creation and Priority Assignment Guidelines

While adding to or changing the alarm list in the Master PCN during the detailed design stage,

the Consultant and City shall give careful consideration to how alarms are generated (referred to

as “alarm conditioning”). Simply adding I/O points to the alarm list is not sufficient – Designers

shall consider the conditions that can lead to an alarm condition and design the alarm logic and

alarm descriptions accordingly.

For example, a low flow switch should not be alarmed if the switch was tripped due to the

normal condition of a pump stopping. Another example is a high discharge pressure should not

be alarmed if it is only momentary and the designers consider momentary high pressures to be

normal conditions.

For new alarm points, the Consultant and the City will review and assign priority for each alarm

during detailed design as part of the modifications to the Master Process Control Narrative.

Examples presented in this section form a guideline and may not cover every situation. Priority

assignment will be made on a case-by-case basis by the Consultant and approved by the City

during review of the Master PCN.

Alarms need to be assigned priority consistently across the plant in order to more safely cross

train operators on different processes and work areas. Alarms shall be assigned priority

consistently across all plants in order to compare performance.

Examples of alarms at plants

Alarm Priority

1. Critical water quality conditions WIN911

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

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

4. Safety alarms:

Chlorine leak WIN911

Chemical spill (ferric chloride, sodium hypochlorite) WIN911

Combustible gas (methane, natural gas) concentration high WIN911

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

Flood WIN911

Other safety alarms WIN911

5. High wet well level M

6. Impending high temperature condition of a pump motor H

7. Process controller failure. WIN911

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Alarm Priority

8. Historical logging computer failure WIN911

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

H

10. Instrument failure alarm H

11. Dissolved oxygen concentration low M

Example alarms at remote water supply sites

These alarms are needed at central pumping control for direct action to control the process and at

the work area to be aware of problems.

Alarm Priority

1. High discharge pressure WIN911

2. Low discharge pressure WIN911

3. Power high WIN911

4. Power fail WIN911

5. Surge system fail WIN911

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

7. Unauthorized access WIN911

8. Reservoir high WIN911

9. Reservoir low WIN911

10. Communications fail WIN911

11. No Flow (with pump running) WIN911

12. Flood Alarm WIN911

Alarms at remote sewage pumping stations

Alarm Priority

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

2. Unauthorized Access WIN911

3. Flood Alarm WIN911

4. Communications fail WIN911

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Chlorine leak alarms

1. Chlorine leak alarms are treated differently at the plants. This difference is acceptable as

long as minimum safety requirements are met.

2. At the Ashbridges Bay Plant, chlorine leaks require immediate broadcast paging to all

personnel because chlorine is stored in tank cars. At the Humber Plant, chlorine leaks

require immediate broadcast paging to all personnel because residential areas are very

close to the plant.

3. At water treatment plants, chlorine leaks should be paged to the designated operator, but

not broadcast. The reported chlorine leak is investigated and if required, the plant‟s

public address system is used to broadcast the alarm.

1.6 Alarm Configuration in Field

Safety alarms are defined as those involving personal safety of the operator, other staff and the

public (fire, gas leak, chorine leak, flood, etc.).

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

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

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

4. Safety alarm loops shall have an alarm circuit test switch which tests lights, horns and

circuits for readiness to operate. This switch will be used periodically to test operability

of the circuit. A full simulation of safety systems will also be performed periodically to

test instruments, controls and controlled equipment with the test switch in normal

position.

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

The following table shows configuration by alarm type:

Alarm Type

Hardwire

to Area Station

Hardwire to

Local Horn (130 db)

Hardwire

to Local Beacon

Colour

(Note 1)

Where

Silenced

Where

Acknow-ledged

Safety Alarm

Yes Yes

(note 2)

Yes

(note 3)

Red Local

(note 4)

Local

(note 4)

Other

Alarm

No No No Yellow N/A Local

(note 4)

Notes:

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1. Alarm characters are black.

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

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

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

1.7 Alarm Activation

Alarms of any priority may require latching with manual reset at the local panel. Manual reset is

required for all alarm conditions which affect personal safety.

Automatic reset of some alarms is acceptable for alarms caused by process changes such as

undervoltage (power failure), seal water low pressure or low suction pressure

Alarm disable (suppression) during start-up or shut-down of a device or a process is acceptable.

These alarms are determined during control strategy design on a case-by-case basis or are part of

manufacturer designed controls for a particular piece of equipment.

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

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

1.8 Alarm Monitoring

Alarms originating from field contacts or generated by software shall be displayed at area

operator stations (if present) and central operator stations. While adding alarms to an existing

SCADA system, the Systems Integrator shall follow the colour convention and styles/grouping

that already exist so the alarm database remains consistent unless otherwise instructed by

Toronto Water.

The preferred alarm monitoring practice is to bring into the SCADA system sufficient alarm

details as needed for remote diagnosis of the problem. The alarm and related information should

enable appropriate responses to be taken. The amount of alarms from a particular device or

facility should be reviewed on a case by case basis for feasibility and economy.

1. In areas of the plant where there are a large number of closely related Medium priority

alarms, it is sometimes desirable to annunciate the alarm conditions individually at the area station and retransmit a common alarm to the central operator station.

2. Alarm conditions from auxiliary systems that are essential to the functioning of the

control system or process equipment (instrument air supply systems and equipment

lubrication systems for example) should be monitored.

WIN911 Priority alarms need more information to be monitored than other types of alarms so

that appropriate action may be taken quickly.

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1. Example: Sewage pumping station high wetwell alarm needs to be augmented by remote

monitoring of wetwell level and pump status. Note that sewage pumping station

communications failure would also require immediate paging.

2. Example: Combustible gas alarm needs to differentiate between high combustible gas

concentration, sensor fault and maintenance mode. The alarm needs to be augmented by

the actual combustible gas concentration.

1.9 Pager Operation

The paging system is to communicate alarms from the process control system, security system

and telephone system to personal pagers or phone/cellular phone. The alarm notification system

is used to transmit critical alarms from the facility‟s SCADA system and then transmit them

using the Win911 Server.

A pager may be assigned to a process or group of processes within the work area or the work

area. An operator who has possession of the pager is responsible for responding to alarms. The

same „beep‟ tone shall be used for all pager alarms and shall display the alarm text description.

The paging system is configured to handle temporary staff shortages. For example, if a member

of the team does not show up for work on time or calls in ill, people on-site need to reassign the

paging areas. That is, the paging will roll over from one work area to another or from one

process to another. If a page is not acknowledged within a set time, the paging will roll over to

another designated person.

The Consultant is to be aware that any modifications or additions to the critical alarms that

require notification must be integrated to the existing database that resides within the Win911

Server.

The Consultant is to ensure that the alarm notification complies with current facility standards.

The alarm notification techniques vary between facilities and can be in the form of one of the

following options;

1. An alphanumeric message that includes the tag name, time and description of the

message that is transmitted to either an alphanumeric pager or via a SMS message to a

cellular phone. This technique requires a standard dial modem to be installed within the

Win911 server.

2. A voice message that includes the tag name, time and description of the message that is

transmitted to a telephone or cellular phone. This technique requires a Dialogic card to be

installed within the Win911 Server. Voice messages should be approved by the facility‟s

staff for audibility and content.

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Appendix C

Instrument and Equipment Testing

EDOCSLIB-# 9101-v1

Page 1 of 8

1. Instrument and Equipment Testing

1.1 General

Consultants shall comply with this design standard in the design of the works and ensure

that the contract documentation for construction conform to this requirement. Any

proposed deviation must have the prior approval of the PCSU.

The testing of instrument and equipment are performed at two separate stages during

the construction works and these are:

1. Field instrument acceptance test to confirm that the field instruments are installed in accordance with the terms and conditions of the contract and

2. Field instruments and equipment are installed and performs in accordance with the terms and conditions of the contract.

The difference between the two is high lighted above in italics to emphasize the difference. The following sections provide detail on the procedure for each of the above test procedure.

Comply with the following when performing instrument and equipment testing:

1.2 Field Instrument Testing

1.2.1 General

The field instrument acceptance test shall be performed by the Contractor and witness by the

Consultants to confirm that the field instruments are installed in accordance with the contract documents and meet operation requirements. This includes confirmation that the units have been correctly calibrated (by qualified personnel), and verification that the equipment is available to properly receive and/or transmit information to/from all devices in the loop.

Where it is identified that the requirements of the Contract have not been met, the Consultants shall ensure that the Contractor rectify all deficiencies immediately, if possible, to allow re-testing during the same test phase.

1.2.2 Acceptance Tests Objectives

The objectives of the field instrument acceptance test are:

1. Acceptance of instruments as installed by the Contractor.

2. Confirmation of the performance in accordance with the Consultant’s Design.

3. Confirm and document that all new instruments meet the contract specification and drawing requirements, including range, accuracy, repeatability, reliability, calibration, and installation details.

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4. Confirm that all discrete and analog signals (both new and existing) to be transmitted to and from the instrument are available and functioning correctly.

1.2.3 Completion Criteria

The Field Instrument Acceptance Test shall be deemed to be complete when all features,

functions and information required in accordance with the Process Narratives and Process and Instrumentation Drawings have been verified as present and functioning, and documented as accurate within the anticipated operating range for the process being monitored.

The Instrument Acceptance Report is to be used to identify and manage all outstanding issues, until they are resolved.

1.2.4 Participants and Responsibilities

The Consultant shall schedule the required tests in consultation with plant staff and ensure that all

the required documentation has been submitted by the Contractor as specified. The Consultants shall review all documents and ensure it meets the contract requirements. In addition, the Consultants shall also witness all tests performed by the Contractor and sign-off forms as required

to indicate that they have witnessed the tests and on completion of tests, ensure that the Contractor submits all required documents. All testing procedures and tools to be used shall be specified by the Consultant. The Consultant will also supervise and approve all procedures and tools used.

Plant Liaison and Process Control System Unit (PCSU) representative shall review Consultant’s work plan, assign plant staff to assist with field testing, coordinate with plant operating,

maintenance, and other construction activities and to provide plant staff to participate and assist in the instrument acceptance testing in order to both provide site knowledge, local coordination when necessary, and adopt the new test procedures.

The Contractor shall be responsible for planning tests, gathering information, preparing instrument test reports prior to commencing, scheduling testing, requesting field assistance from plant personnel, reviewing schedule with plant supervisors, completing testing which is to be witnessed by the Consultants, then presenting findings and reporting to the Consultants.

1.2.5 Documents Required Prior to Field Work

The Consultants shall ensure that the following documents are assembled and submitted by the

Contractor to the Consultants for review prior to conducting the Instrument Acceptance Testing:

1. Reviewed shop drawings, including ISA data sheets, for each instrument installed (multiple copies for multiple installations);

2. “For Construction” P&IDs, process narratives, control schematics, and electrical drawings;

3. Configuration and calibration certificates from the manufacturer(s) for each calibrated instrument, where specified by the Consultant in the Contract Documents;

4. Results of factory performance tests, where specified by the Consultant in the Contract Documents;

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5. Instrument field calibration reports, where specified by the Consultant;

6. Prepared instrument acceptance reports with all equipment numbers and relevant details entered;

Prior to commencement of testing, the Consultants shall define the following for each piece

of field equipment:

1. Calibration Procedure(s) to be followed by the Contractor;

2. Any special Procedure(s) to be followed by the Contractor;

3. Site verification, set-up, and calibration required by the equipment manufacturers.

1.2.6 Testing Schedule

The Consultants shall ensure that the testing procedures and schedules of work are submitted by

the Contractor not less than ten (10) working days prior to the projected test date for the individual component. This will include specific dates for when the various test procedures are to be carried out, and the plant staff assistance required to complete the field portion of the investigation. The Consultants shall ensure that the Contractor have allowed flexibility in his schedule to permit emergency requests by plant staff, plus unexpected field and operation findings.

The schedule must be approved in writing by the Consultants, the Plant Engineer, and the Electrical and Instrumentation Supervisors, prior to the commencement of any field testing.

The field equipment acceptance report must be presented 1 week after completion by the

Contractor in order to identify and resolve all critical issues which affect scope, cost or schedule in a timely manner.

In certain cases, testing will be required to be scheduled outside normal business hours to accommodate operating issues and/or low flow conditions. This should be discussed and resolved with plant management when planning the test schedule.

1.2.7 Documentation and Reporting

The Contractor shall use the following standard documentation for instrument acceptance tests:

1. Field Instrument Acceptance Report (EDOCSLIB-#9102 Instrument Testing Log and EDOCSLIB-#9103 Field Installation Testing Log are attached to the end of this document

as an example. Consultant should request document in its original format)

2. Field Calibration Report, in electronic documentation, transferable in standard spreadsheet format

3. Shop drawings, Instrument Data Sheets and calibration reports (update as required)

4. “As Built” P&ID, control schematics, and electrical drawings (update as required)

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Appendix C


EDOCSLIB-# 9101-v1

Page 4 of 8

The Contractor shall present the Instrument Acceptance Test Reports findings in electronic and printed reports which shall contain the following, as a minimum:

1. The scope of the specific Instrument Acceptance Test;

2. Specific Objectives beyond the General Objectives noted above;

3. Summary of Outstanding Issues, with the detailed test reports contained in an Appendix;

4. Recommendations on improvements/upgrades to contract scope in order to achieve operational requirements if applicable. For upgrades with a capital cost greater than $15,000, a simple cost/benefit analysis must be provided.

5. Cost estimates for all recommended improvements.

1.2.8 Instrument Acceptance - General

The Contractor shall inspect and document that each instrument matches the reviewed shop

drawing. The inspection shall be witnessed by the Consultants. The inspection shall include, but not be limited to the following (as applicable):

1. Verify that instrument product details match shop drawings and Contract Documents, (including Instrument Data Sheets);

2. Confirm soundness of instrument, i.e. without damaged parts;

3. Confirm completeness in all respects as specified for instrumentation;

4. Confirm correctness of setting, alignment, and relative arrangement

5. Inspect power, signal, and grounding wiring identified on the control schematics and documenting the results. All wiring to be verified for continuity.

1.2.9 Instrument Acceptance – Specific to Devices

The Contractor shall perform test on all devices for their repeatability, accuracy and operation by varying the process and simultaneously measuring and recording the information displayed by:

1. An independent measuring instrument;

2. The local transmitter indicator;

3. All remote digital/mechanical indicators;

4. The 4-20mA (or digital value) measured at both RPU panels’ and operator panels’ terminal blocks and converted into engineering units.

Performance of all tests will be witnessed by the Consultants.

Test results shall be compared against the instrument calibration reports and planned RPU analog

input range. As an example, flow sensors will require testing using a “draw and fill” test of a local container.

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Appendix C


EDOCSLIB-# 9101-v1

Page 5 of 8

1.2.10 Instrument Acceptance – Specific to Switches

The Contractor shall perform test on all instrument switches, such as pressure switches or

building flood alarms, for their accuracy and operation by varying the process conditions (for example: high then low pressure) and simultaneously measuring and recording the information displayed by:


2. The instrument switch;

3. All remote lights and indicators;

4. The digital input status measured at both the RPU and operator panels’ terminal blocks.

Performance of all tests shall be witnessed by the Consultants.

Test results are to be compared against the instrument calibration/setting reports and planned

RPU discrete input setting.

1.2.11 Testing Tools and Equipment

The Consultants shall ensure that the Contractor and/or respective Calibration Contractors or

Equipment Manufacturers provides proper protection for all instruments and devices that may be damaged by high voltage tests. If damages occur, the respective parties shall be held fully responsible for the replacement of damaged parts and/or components.

Calibration method and tools shall not cause any error greater than +/- 0.5% in any test. The

accuracy of the calibration tools must be traceable to National Standards. The Consultants shall review all testing procedures, and tools to be used. The Contractor shall use only electronic calibration equipment unless it can be demonstrated that such electronic calibration equipment is not available for the required specific test. Provide a form for electronic documentation, transferable to a standard spreadsheet format.

The Consultants or the Contractor shall follow the applicable City’s safety requirements. For all identified plant areas, and in particular the collection system facilities, provide proper safety equipment for personnel entering (manholes and other) confined spaces, plus hazardous gas locations.

1.3 Instrument and Equipment Testing

1.3.1 General

The instrument and equipment shall be tested to confirm that the field instruments and equipment

installed performs in accordance with the Contract Documents. Testing shall be performed by the Contractor and witnessed by the Consultants.

The testing shall confirm that:

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Appendix C


EDOCSLIB-# 9101-v1

Page 6 of 8

1. The units have been correctly installed.

2. The units have been correctly calibrated.

3. All discrete and analog signals (both new and existing) to be transmitted to and from the units are available and functioning correctly.

4. The units are capable of working as specified.

The work will be accepted if all the above criteria have been met and where it is identified that the requirements of the Contract have not been met, the Contractor shall rectify all deficiencies immediately to allow re-testing during the same test phase.

Testing will be deemed complete when all features, functions and information required in the Contract Documents have been verified as present and functioning, and documented as accurate within the anticipated operating range for the process being monitored.

1.3.2 Submission of Documents

The Contractor shall submit the following documents prior to conducting the Instrument and

Equipment Acceptance Testing:

1. Calibration Procedure(s) to be followed in the test. The calibration method and tools will not cause greater than +/- 0.5% error in any test;

2. Any special Procedure(s) to be followed in the test;

3. Identify site verification, set-up and calibration to be performed by the equipment manufacturers.

Update shop drawings, Instrument Data Sheets, calibration reports and “As Built” drawings

including: P&ID, control schematics and electrical drawings as required to match field conditions.

1.3.3 Testing Schedule

The Contractor shall submit testing procedures and schedules of work no less than one (1) month prior to the projected test date for the individual component. This will include specific dates for when the various test procedures are to be carried out and identified assistance from City’s staff. In some cases, testing may be scheduled outside normal business hours to accommodate

operating issues and/or low flow conditions. Testing may be interrupted by the City’s staff for emergency process operation.

Submit test results to the Consultants at the end of each day of testing.

1.3.4 Testing Procedure

The Consultants shall ensure that the following documents have been prepared and assembled by the Contractor and available on site prior to conducting Instrument and Equipment Acceptance Testing:

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Appendix C


EDOCSLIB-# 9101-v1

Page 7 of 8

1. Reviewed shop drawings, including ISA data sheets, for each instrument installed and for each piece of the equipment (multiple copies for multiple installations);

2. “For Construction” P&IDs, process control narratives, control schematics and electrical drawings;

3. Configuration and calibration certificates from the manufacturer(s) for each calibrated instrument, where specified in the Contract Documents;

4. Results of factory performance tests, as specified in the Contract Documents;

5. Instrument and equipment field calibration reports, as specified Contract Documents;

6. Prepared instrument and equipment acceptance reports with all equipment numbers and relevant details entered.

The Contractor, witnessed by the Consultant, shall inspect and document that each instrument and equipment matches the reviewed shop drawing. The inspection shall include, but not be limited to the following (as applicable):

1. Verifying that instrument and equipment product details match shop drawings and Contract Documents, (including Instrument Data Sheets);

2. Confirming soundness of instrument and equipment, i.e. without damaged parts;

3. Confirming completeness in all respects as specified for instrumentation and equipment;

4. Confirming correctness of setting, alignment, and relative arrangement

5. Inspecting power, signal, and grounding wiring identified on the control schematics and documenting the results. All wiring to be verified for continuity.

1.3.5 Instrument Acceptance – Specific to Devices

Devices are also to be tested by the Contractor for their repeatability, accuracy and operation by varying the process and simultaneously measuring and recording the information displayed by:


2. The local transmitter indicator;

3. All remote digital/mechanical indicators;

4. The 4-20mA (or digital value) measured at terminal blocks in RPU panels and operator panels.

The Contractor shall compare test results against the instrument calibration reports and planned

RPU analog input range. As an example, flow sensors will require testing using a “draw and fill” test of a local container.

Where no field calibration has been done, perform a calibration test. Go up, down, then back up the instrument range, testing at five (5) points each time: 0%, 25%, 50%, 75% and 100%.

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Appendix C


EDOCSLIB-# 9101-v1

Page 8 of 8

1.3.6 Instrument Acceptance – Specific to Switches

The instrument switches, such as pressure switches or building flood alarms, shall be tested by

the Contractor for their accuracy and operation by varying the process conditions (for example: high then low pressure) and simultaneously measuring and recording the information displayed by:


2. The instrument switch;

3. All remote lights and indicators;

4. The digital input status measured at both the RPU and operator panels’ terminal blocks.

Test results are to be compared against the instrument calibration/setting reports and planned RPU discrete input setting.

1.3.7 Testing Tools and Equipment

Protect instruments and equipment that may be damaged by testing. If damages occur, the

Contractor shall be fully responsible for replacement of damaged parts and/or components.

Use calibration tools that will not cause greater than +/- 0.5% error in any test. The accuracy of the calibration tools must be traceable to National Standards. The City’s preference is the use of

electronic calibration equipment that will provide a form of electronic documentation, transferable in a standard spreadsheet format.

Comply with the applicable City’s safety requirements. Provide the proper safety equipment for entering (manholes and other) confined spaces, and hazardous gas locations.

149 of 189

EDOCSLIB-#9102-v1

INSTRUMENT TESTING LOGPage ___ of ___

# INSTRUMENT TAG NUMBERSTATUS DOCUMENTS TEST AND CALIBRATION

Existing Records Available Results

New

Re-

Use

d

Re-

Cal

ibra

ted

Rep

aire

d

Tec

hnic

al M

anuf

actu

rer D

ata

Shee

t

P&ID

,Con

trol S

chem

atic

, Ele

ctric

al d

wgs

Con

tract

Spe

cific

atio

ns

Orig

iona

l C

alib

ratio

n R

epor

ts

Mai

nten

ance

Rep

orts

Test

Dat

e

Inst

alla

tion

& Ap

plic

catio

n M

eets

Des

ign

& M

anuf

actu

rers

Rec

omm

enda

tion

Span

in E

ngin

eerin

g U

nits

Cal

ibra

ted

Ran

ge In

Eng

inee

ring

Uni

ts

Min

i. C

alib

. Ran

ge In

Eng

inee

ring

Uni

ts

Min

i. C

alib

. Ran

ge In

(m/A

)

Max

. Cal

ib. R

ange

In E

ngin

eerin

g U

nits

Max

. C

alib

.Ran

ge In

(m/A

)

Inst

rum

ent R

eadi

ng A

t 25%

(m/A

)

Inst

rum

ent R

eadi

ng A

t 50%

(m/A

)

Inst

rimen

t REa

ding

At 7

5% (m

/A)

Inst

rum

ent R

eadi

ng A

t 100

% (m

/A)

Inst

rum

ent R

eadi

ng A

t 75%

(m/A

)

Inst

rum

ent R

eadi

ng A

t 50%

(m/A

)

Inst

rum

ent R

eadi

ng A

t 25%

(m/A

)

Erro

r ( D

iff. I

n En

gine

erin

g U

nits

)

Erro

r %

Acce

pted

(A) /

Rej

ecte

d (R

)

Reasons Of Non-Acceptance

1 Instrument

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

150 of 189

EDOCSLIB-#9103-v1

FIELD INSTALLATION TESTING LOG

Page ___ of ___ DEVICE INSPECTION STATUS CONTROL

CONTROLLER (RPU) INPUTS FIELD CONTROLLER (RPU ) OUTPUTS FIELD

# DEVICE OR EQUIPMENT

IDEN

TIFI

CA

TIO

N

PRO

DU

CT A

CCEP

TAN

CE

INST

ALLA

TIO

N A

CCEP

TAN

CE

CALI

BRAT

ION

ACC

EPTA

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LOCA

L PA

NEL

SW

ITCH

ES

LOCA

L/R

EMO

TE C

ON

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L

RU

NN

ING

/ O

PEN

CLO

SED

ANAL

OG

IN

PUT

1

ANAL

OG

RAN

GE

OK

ANAL

OG

IN

PUT

2

ANAL

OG

RAN

GE

OK

FIEL

D A

LAR

MS

OTH

ER

OTH

ER

LOCA

L IN

DIC

ATO

RS

REM

OTE

IN

DIC

ATO

RS

OTH

ER

STAR

T /

OPE

N

STO

P

CLO

SE

SETP

OIN

T 1

SETP

OIN

T 2

OTH

ER

LOCA

L H

AND

SWIT

CHES

REM

OTE

HAN

DSW

ITCH

ES

OTH

ER

AUTO

LO

GIC

TES

TED

AC

CEP

TED REASON (S) FOR NON - ACCEPTANCE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

151 of 189


Appendix C PCS Factory Acceptance Testing

EDOCSLIB-#9104-v1

Page 1 of 5

1. PCS Factory Acceptance Testing

1.1 General

The PCS Factory Acceptance Test (FAT) demonstrates that all SCADA and controller software

are working properly and that all software configurations match the requirements identified in

Detailed Software Design, including the detailed process narratives, and logic flow chart

diagrams.

Test the software under all possible process conditions in order to ensure the software contains

no defects. Include a wide range of operating scenarios, with all process setpoints, interlocks and

alarm limits.

1.2 Objectives

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

1. Confirm and document that the RPU I/O matches the type and quantity identified in the

control schematics. Perform I/O checks to confirm the tag number;

2. Confirm and document that the individual device logic operates all field equipment

correctly and safely, as described in the detailed process narrative, logic flow charts and HMI functionality;

3. Confirm and document that the software is fully integrated into the treatment process and

plant/facility-wide control logic and operates correctly and safely, through the HMI and

OIT (where applicable) as described in the detailed process narratives and logic flow charts

4. Confirm and document that the data to be integrated with eOPS, POMS, WMS, WIN 911

and LIMS are properly identified and operates correctly as described in the Process

Control Narratives.

1.3 Submittals

The following submittals are made during the FAT procedure:

1. Submit the test plan: testing forms, procedures and schedules of work, not less than two

(2) weeks prior to the scheduled test date.

2. Submit copies of the PLC program, HMI graphics, OIT graphics and simulation software

on CD. This submittal should also include any Active X or other controls required

allowing full simulation to be presented at the City site during the Pre FAT.

3. Submit copies of the current Control Flow Charts, Process Control Narratives, P&IDs

and I/O Lists.

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EDOCSLIB-#9104-v1

Page 2 of 5

4. The test plan must be approved in writing by the City, prior to commencement and

should show the schedule of work to include dates.

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

FAT.

6. On completion of the FAT, a locked down version of the HMI, OIT, simulation software

and PLC software will be submitted to the ITM group for record. Once the FAT has been

completed, it is assumed that there will be no modifications to any software to be

integrated into the PCS.

1.4 Testing Process

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

actively participate in the tests. The City reserves the right to test any specified hardware/

software function whether or not explicitly stated in the test submittal.

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

the FAT;

Facility Operations/Process End Users

ITM

PCSU

Consultant

The Consultant, PCSU (will coordinate with ITM as required) and the end user must attend the

entire FAT and any possible subsequent FAT(s) as they sign off on all check lists.

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

Complete submittals and resolve disputes.

Make hardware and software fully operational.

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

procedure.

Set a test date, which is agreeable within the contract schedule, minimum of 2

weeks prior to testing.

Conduct factory acceptance tests at the System Integrator’s facility within the Greater Toronto

Area or on-site if requested by the City. Limit testing, in general, to seven (7) hours per day.

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EDOCSLIB-#9104-v1

Page 3 of 5

Hold a meeting each morning to review the day’s test schedule and a meeting each evening to

review the day’s test results and review or revise the next day’s test schedule. At the completion

of the test, meet to review the list of deficiencies. The City will indicate those items which must

be corrected prior to shipment.

At the discretion of the City, the FAT may be rejected. The FAT may be repeated as many times

as required until the City has deemed the final software product to be satisfactory to progressing

to field implementation and the Site Acceptance Testing. The City’s project manager will be

required to determine if the FAT is satisfactory.

Representatives of the System Integrator and the Consultant shall sign a FAT Sign-Off form to

indicate completion of the tests. A deficiency list shall be submitted indicating required changes

including a schedule for completion.

1.5 Testing Documentation

Prepare EDOCSLIB-#9105 Factory Acceptance Test and Site Acceptance Test Check Sheet

(Attached for information only. Consultant should request document in its original format)

showing the following information:

1. For all points list the device tag name, RPU tag name, Description of point, RPU I/O

Address (if applicable), Date Verified, Comments and Issue Log Number.

2. For field inputs and outputs also list, HMI/RPU Address, I/O type, Rack, Slot, Remote

I/O block (if applicable), Module Point or Channel, RPU Device Range (Minimum,

Maximum and Units), RPU Range Raw Signal Test (Minimum, Mid range and

Maximum), HMI Device Range (Minimum, Maximum and Units) and HMI Engineering

Units Test (Minimum, Mid-range and Maximum

3. For analog input alarms also list the Trip point for the alarm in percent of span,

Engineering units, Time Delay, Alarm NACK, Alarm ACK, Operator Control (Adjust

Trip point and Disable), Alarm area, alarm priority, Paging Group and Data Transfer

Frequency.

4. For discreet input alarms also list, time delay, Alarm NACK, Alarm ACK, Operator

Control (Disable), Alarm area, alarm priority, Paging Group and Data Transfer

Frequency.

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

Narratives.

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

value and units of measurement.

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

Frequency.

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EDOCSLIB-#9104-v1

Page 4 of 5

Prepare EDOCSLIB-#9106 Process Logic Test Sheet (Attached for information only.

Consultant should request document in its original format) with information describing the

normal and abnormal device operations. Provide a row for each transition to be tested and show

the following information:

Current State Action/Transition Final State/Effect Comments

List the tags and their current

state relevant to testing the

transition or action and

observing the final state or effect

List the HMI symbol colour

and shape

Describe the action or

transition that is being

tested, e.g. Field

Mounted Start P.B. is Depressed

List the tags and their expected

final state

List the HMI symbol expected colour and shape

During the test, note any

deviation from the

expected final state or

effect

Normal Device Operations:

1. Local Mode Operations

2. Computer Manual Mode Operations

3. Transfer from Local to Computer

4. Transfer from Computer to Local

5. Computer Automatic Mode Operations

6. SCADA/Automation

Abnormal Device Operation

1. Uncommanded Operations

2. Unresponsive Commands

3. Device Operation Permissives

4. Device Alarms

5. Emergency Stop

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EDOCSLIB-#9104-v1

Page 5 of 5

1.6 Software Simulation

Prepare automated test programs using simulation software. Run test programs to demonstrate all

functions in control logic and functions of operator interface screens.

156 of 189

Date: Plant: Process: Location: RPU:

FACTORY ACCEPTANCE TEST

CHECK SHEET

Signatures: PCS Analyst/Developer ________________________

EDOCSLIB-#9105-v1

PCS Coordinator ________________________

Printed: 9/27/2011

Consultant ________________________

Page: 1

Field Points Virtual Points Analogue Trends Alarms

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

q.

De

via

tion

Da

ta T

ran

sfe

r F

r

Ad

just

Trip

Pt

Dis

ab

le

CommentsDa

te V

erif

ied

Issu

e L

og

No

.

Tim

e D

ela

y

Ala

rm N

AC

K

Ala

rm A

CK

Operator Control

Pa

gin

g G

rou

p

Da

ta T

ran

sfe

r F

req

.

Ala

rm C

on

diti

on

ing

Da

te V

erif

ied

Trip

Po

int

% o

f S

pa

n

Ala

rm A

rea

Ala

rm P

riorit

y

En

g.

Un

its

I/O

Typ

e

Ra

ck

Slo

t

De

fau

lt V

alu

e

Acc

ess

R o

r R

/W

Ma

x V

alu

e

HMI Engineering Units TestHMI Device Range

Mo

du

le P

oin

t o

r C

ha

nn

el

RPU Range Raw Signal TestRPU Device Range

Trending Attributes

Un

its

Da

te V

erif

ied

Tag Name Description RP

U I

/O A

dd

ress

HM

I/R

PU

Ad

dre

ss

RPU Da

te V

erif

ied

Min

Va

lue

157 of 189

EDOCSLIB-#9106-v1 Page 1 of 1

Test ID

Facility-Process

Device Operation Mode Current State Action/ Transition Final State/Effect Con City Comments

Issue Log

Normal Local

List the tags and their current state relevant to testing the transition or action and observing the final state or effect. List the HMI Symbol And Colour and shape.

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

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

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

NormalComputer Manual

Normal

Transfer from Local to Computer

Normal

Transfer from Computer to Local

NormalComputer Automatic

Local Abnormal

Operation Permissives

Local Abnormal

Emergency Stop

Computer Manual Abnormal

Uncommanded Operations


Unresponsive Commands


Device Operation Permissives

Computer Manual Abnormal Device AlarmsComputer Manual Abnormal

Emergency Stop

Computer Auto Abnormal






Computer Auto Abnormal Device AlarmsComputer Auto Abnormal

Emergency Stop

Process Logic Test Sheet

1

Equipment Location, Identification and Process Condition(Type description of the objective of the Test)

158 of 189


Appendix C PCS Site Acceptance Testing and Commissioning

EDOCSLIB-#9107-v1

Page 1 of 5

1. PCS Site Acceptance Testing and Commissioning

1.1 General

The PCS Site Acceptance Test (SAT) demonstrates that all SCADA and controller software and

hardware are working properly and that all software configurations match the requirements

identified in Detailed Software Design, including the detailed process narratives, operating

manuals and logic flow chart diagrams, both confirmed in the Factory Acceptance Test.

The software is the final versions that have been tested at the end of the FAT stage to ITM. This

software has been locked down and cannot be modified by the Contractor/Consultant after the

FAT or prior to the SAT.

Test the software under all possible process conditions in order to ensure the software contains

no defects. Include a wide range of operating scenarios, with all process setpoints, interlocks and

alarm limits. In phased installation, test each process separately after completing the installation

in the process. In addition, test the complete system performance after each of the processes

have successfully passed their SAT.

Also see EDOCSLIB-#9105 PCS Factory Acceptance Testing for objectives and definitions.

1.2 Submittals

The following submittals are made during the SAT procedure:

1. Submit the test plan: testing forms, procedures and schedules of work not less than two

(2) weeks prior to the scheduled test date. The test plan must be approved in writing by

the City, prior to commencement.

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

3. On completion of the SAT, a locked down version of the HMI, OIT, simulation software

and PLC software will be submitted to the ITM group for record. Once the SAT has been

completed, it is assumed that there will be no modifications to any software to be

integrated into the PCS.

1.3 Testing Process

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

actively participate in the tests. The City reserves the right to test any specified hardware/

software function whether or not explicitly stated in the test submittal.

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

the SAT;

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EDOCSLIB-#9107-v1

Page 2 of 5

Facility Operations/Process End Users

ITM

PCSU

Consultant

The Consultant , PCSU (will coordinate ITM support as needed) and the end user must attend the

entire SAT and any possible subsequent SAT(s) as they sign off on all check lists.

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

Complete submittals and resolve disputes.

Make hardware and software fully operational.

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

procedure.

Set a test date, which is agreeable within the contract schedule, minimum of 2

weeks prior to testing.

HMI, OIT and PLC software will be loaded into the SAT testing equipment prior to deployment

on the live system. The testing equipment will be provided under the contract or at each facility

by the City if possible.

Limit testing, in general, to seven (7) hours per day. Hold a meeting each morning to review the

day’s test schedule and a meeting each evening to review the day’s test results and review or

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

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

Performance.

At the completion of the SAT it is the responsibility of the System Integrator, Consultant and

City's representatives to sign-off all forms pertaining to the testing of the modified system.

Following the sign-off of the SAT, the software can be moved into the post-SAT phase where

the system can be integrated into the overall facility operations.

Upon completion of the SAT, the modified software will move into the Post-SAT phase. In this

phase the System Integrator/Consultant will work with ITM to install the software into the

production environment. Modifications will need to be made to the Main and Backup servers

and new graphics will need to be distributed to the facility’s iClient computers, Win911 server,

file server and iTerminal Server.

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

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EDOCSLIB-#9107-v1

Page 3 of 5

1.4 Testing Documentation

Prepare EDOCSLIB-#9105 Factory Acceptance Test and Site Acceptance Test Check Sheet

(Attached for information only. Consultant should request document in its original format)

showing the following information:

1. For all points list the device tag name, RPU tag name, Description of point, RPU I/O

Address (if applicable), Date Verified, Comments and Issue Log Number.

2. For field inputs and outputs also list, HMI/RPU Address, I/O type, Rack, Slot, Remote

I/O block (if applicable), Module Point or Channel, RPU Device Range (Minimum,

Maximum and Units), RPU Range Raw Signal Test (Minimum, Mid range and

Maximum), HMI Device Range (Minimum, Maximum and Units) and HMI Engineering

Units Test (Minimum, Mid-range and Maximum

3. For analog input alarms also list the Trip point for the alarm in percent of span,

Engineering units, Time Delay, Alarm NACK, Alarm ACK, Operator Control (Adjust

Trip point and Disable), Alarm area, alarm priority, Paging Group and Data Transfer

Frequency.

161 of 189



EDOCSLIB-#9107-v1

Page 4 of 5

4. For discreet input alarms also list, time delay, Alarm NACK, Alarm ACK, Operator

Control (Disable), Alarm area, alarm priority, Paging Group and Data Transfer

Frequency.

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

Narratives.

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

value and units of measurement.

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

Frequency.

Prepare EDOCSLIB-#9106 Process Logic Test Sheet (Attached for information only.

Consultant should request document in its original format) with information describing the

normal and abnormal device operations. Provide a row for each transition to be tested and show

the following information:

Current State Action/Transition Final State/Effect Comments

List the tags and their current state relevant to testing the

transition or action and

observing the final state or

effect

List the HMI symbol colour

and shape

Describe the action or transition that is being

tested, e.g. Field

Mounted Start P.B. is

Depressed

List the tags and their expected final state

List the HMI symbol expected

colour and shape

During the test, note any deviation from the

expected final state or

effect

Normal Device Operations:

1. Local Mode Operations

2. Computer Manual Mode Operations

3. Transfer from Local to Computer

4. Transfer from Computer to Local

5. Computer Automatic Mode Operations

6. SCADA/Automation

Abnormal Device Operation

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1. Uncommanded Operations

2. Unresponsive Commands

3. Device Operation Permissives

4. Device Alarms

5. Emergency Stop

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Date: Plant: Process: Location: RPU:

SITE ACCEPTANCE TEST

CHECK SHEET

Signatures: PCS Analyst/Developer ________________________

EDOCSLIB-#9105-v1

PCS Coordinator ________________________

Printed: 9/27/2011

Consultant ________________________

Page: 1

Field Points Virtual Points Analogue Trends Alarms

Min Max Units Min Mid Max Min Max Units Min Mid Max Freq

.

Dev

iatio

n

Dat

a Tr

ansf

er F

req.

Adj

ust T

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CommentsRac

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Tag Name Description RP

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ss

HM

I/RP

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ss

RPU I/O T

ype

Uni

ts

Dat

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erifi

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Dat

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erifi

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Def

ault

Val

ue

Acc

ess

R o

r R/W

Min

Val

ue

Max

Val

ue

Dat

a Tr

ansf

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req.

HMI Engineering Units TestHMI Device Range

Mod

ule

Poi

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nnel

Dat

e V

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of S

pan

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RPU Range Raw Signal TestRPU Device Range Trending Attributes

Ala

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EDOCSLIB-#9106-v1 Page 1 of 1

Test ID

Facility-Process

Device Operation Mode Current State Action/ Transition Final State/Effect Con City Comments

Issue Log

Normal Local

List the tags and their current state relevant to testing the transition or action and observing the final state or effect. List the HMI Symbol And Colour and shape.

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

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

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

NormalComputer Manual

Normal

Transfer from Local to Computer

Normal

Transfer from Computer to Local

NormalComputer Automatic

Local Abnormal

Operation Permissives

Local Abnormal

Emergency Stop







Computer Manual Abnormal Device AlarmsComputer Manual Abnormal

Emergency Stop







Computer Auto Abnormal Device AlarmsComputer Auto Abnormal

Emergency Stop

Process Logic Test Sheet

1

Equipment Location, Identification and Process Condition(Type description of the objective of the Test)

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Appendix C PCS Documentation

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1. PCS Documentation

1.1 General

This standard describes the requirements for Consultants and Contractor Manuals, which

is to ensure that complete documentation is obtained and maintained.

Consultants shall comply with this design guideline in the design of the works and ensure

that the contract documentation for construction conform to this requirement. Any

proposed deviation must have the prior approval of the City.

Typically, Toronto Water facilities have existing SCADA Operations Manuals, Software

Manuals, etc. The Consultant/Contractor/System Integrator will obtain a copy and update

it as appropriate or create a new one as deemed necessary by Toronto Water.

1.2 Preparation

The Consultants shall include in the contract document that the contractor is responsible

for preparation of the Equipment Operation and Maintenance Manuals for the entire

process control system hardware and software. The Contractor shall obtain, prepare and

assemble the operation and maintenance data/manual of the equipment and systems as

well as installation documentation from the suppliers and manufacturers and the

information shall be compiled into the Operating and Maintenance (O&M) Manuals. The

Consultants shall ensure that the specified equipment and instrument manuals are

provided by the contractor in compliance with the requirements of the I&C and SCADA

specifications under the contract.

1.3 O&M Manual General Requirement

Submission requirements shall include the following information in the various

submittal(s):

1. An outline of the O&M documentation including a complete list of the

manuals. Indicate title, content, and Specification sections covered. Include

formats and samples of representative pages of the manuals.

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

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

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

months after commissioning.

Quantities of printed and software copies of the O&M are to be specified in the contracts

based on a project’s needs. If this information is not included, Consultants and

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

below:

Document Draft

Manuals

Quantity

Final Version

Quantity

Source

SCADA Operation Manual 6 8 Consultants

/Contractor

Contractor Equipment Operation and

Maintenance Manual, including the

following:

Control System Hardware

Manuals

Software User’s Manual

Configuration Manual

Custom Software Manuals

Source Materials

Drawings – copies

Drawings - reproducible

6 6

Contractor

In addition to the printed copies shown above, provide an electronic document version for

each submission. (see notes below)

Printed Format:

1. Bind manuals in hard covered, loose-leaf, vinyl flat back binders for holding three-hole, ANSI Standard size A (8.5x11) paper stock.

a. The manuals may be subdivided into as many volumes as required.

b. Do not use binders more than 80mm thick.

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

d. Lithographically print the Owner’s name, Contract description and number and volume number on the front cover of each binder.

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

2. Print documents in accordance with the following requirements:

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

margin on the left (binding) edge.

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

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

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

e. Use plain font such as Times New Roman

f. Use offset, letterpress, diazo or xerographic print techniques. Do not use

Xerograpy for pages which are available as offset or letterpress copies. Provide details which are crisp, black, dense and fully legible.

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

inaccurately punch pages.

Electronic Format:

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

City and the Consultants shall ensure that these requirements are included in the

contract document. The Contractor shall submit the electronic document to the

Consultants and the City for inclusion in the Toronto Water Document Management

System (eDOCS) so they can be associated with data stored in the Works-wide

Maintenance Management System.

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

3. Provide electronic documents in its native format (i.e. Word, Excel, Access,

AutoCAD etc) as appropriate. Use the software version cited in Toronto Water

standards as the current authorized version.

Contents:

1. Organize operation and maintenance manuals to include the specified information. The order of the material in the manuals may differ from the specifications.

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

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

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

page number of each illustration.

2. Identify products by their functional names in the table of contents and at least once

in each chapter or section. Thereafter, abbreviations and acronyms may be used if

their meaning is explained in a table in the back of each binder. Do not use model or

catalog numbers or letters for identification exclusively.

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

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

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

necessary.

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

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a. Description of equipment and software

b. Theory of operation

c. Applicable circuit diagrams and schematics

d. Calibration procedures

e. Preventive maintenance schedule

f. Corrective maintenance procedures

g. Parts lists applicable to equipment

h. Testing certifications, inspection reports, Contractor’s verification reports and final performance acceptance test.

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

1.4 SCADA Operations Manual

Provide draft manuals in accordance with the following requirements:

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

2. Make the manuals available for operator training.

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

Include the following information:

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

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

3. Operations narratives describing functions of the control programs. Include process

setpoints, control parameters and alarm limits. Explain how to set up the controls to

run in local, remote-manual and remote-automatic control modes. Show how to operate from the graphic displays. Build upon the process narratives.

4. A description of each type of data format.

5. A description for each of the keyboard or other controls used in operation, its task and the response to the operator manipulation.

6. A description of each report.

7. A glossary of terms.

8. A separate step-by-step procedure for each action to be performed in operation

including, but not be limited to, the following:

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a. Start/stop operation.

b. Emergency procedures.

c. Control mode changes.

d. Alarm acknowledge and reset.

e. Printing screens and reports.

f. Retrieve archived historical data.

g. Software operations such as changing date and time, point calibration, point activation, point deactivation, tuning parameter and set-point changes.

h. Software procedures used to determine that the system is functioning properly.

i. Computer and peripheral equipment operating instructions.

j. Procedures for maintenance.

7. Screen prints in colour for all graphics, trends and alarm displays.

8. Control system plan drawings showing location of all devices

1.5 Contractor Equipment O&M Manual – Prepared by Contractor

Equipment and Instrument Descriptions: Provide the following information for each

model piece of equipment and instrument:

1. Manufacturer’s design and performance specification data and descriptive literature.

2. Equipment dimensions, installation requirements, typical mounting details showing methods and materials required for installation and recommendations.

3. Required and optional accessories lists.

4. List of recommended spare parts and spare parts provided.

5. Electrical/pneumatic signal and power connection diagrams.

6. Operation and maintenance manuals.

Provide a written narrative describing the operating parameters, product maintenance

requirements, performance limitations, warranty requirements, and recommended

inspection requirements.

Instrument Data Sheets:

1. Data sheets have been prepared during design and implementation to cover each

instrument.

2. Each instrument will be listed and pertinent information recorded including: tag

number and description, complete model number, ranges, setpoints, materials and special mounting details for non-typical applications.

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3. The data sheets will be based on ISA Standard -S20: Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves.

4. The data forms are available for the following instruments:

Annunciators

Receiver Instruments

Potentiometer Instruments

Flowmeters - Magnetic

Flowmeters - Orifice Plates and Flanges

Flowmeters - Positive Displacement Meters

Flowmeters - Rotameters (Variable Area Flowmeters)

Flowmeters - Turbine

Level Instruments - Capacitance Type

Level Instruments - Displacer or Float

Level Instruments - Gage Glasses and Cocks

Pressure Instruments

Pressure Gages

Pressure Switches

Temperature Instruments - Filled System

Temperature Instruments - Industrial Bimetal and Glass Thermometers

Temperature Instruments - Resistance Temperature Sensors

Temperature Instruments - Thermocouples and Thermowells

5. Data forms are also available for the following control devices:

Valves - Control Valves

Valves - Pressure Control Valves, Pilots and Regulators

Valves - Pressure Relief Valves

Valves - Self-Actuated Temperature Regulator

Valves - Solenoid Valves

Rupture Discs

Traps and Drainers

Calibration Certificates and shop drawings for mounting fixtures from the manufacturer

shall be submitted for each instrument calibrated prior to installation.

1.6 Control System Hardware Manuals – Prepared by Contractor

General:

1. Cover equipment comprising the system in the hardware instruction manuals. Provide

instructions for operation and maintenance of the installed system as well as operation

and maintenance instructions for the individual equipment units comprising the system.

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2. Provide a level of comprehension so that an experienced electronics or

instrumentation and control technician can understand them. Convey an

understanding of how the system operates and provide sufficient procedures for

operation and maintenance. Use abbreviated tabular data such as charts, tables,

checklists and diagrams, whenever practical, in lieu of written text. Make drawings, tables, etc. an integral part of the manuals.

3. Standard hardware manuals will be acceptable, provided that sheets are included to

explain the specific models and options of the equipment provided.

Organization and Content:

1. Provide, in an introduction section, a brief explanation of the function of the

equipment covered. Be concise and do not include detailed descriptions. Provide a

quick orientation to the use and purpose of the manual and its relationship to the

system and/or equipment.

2. Describe, in a safety precautions section, major hazards to personnel and equipment

that are peculiar to the equipment or jobs covered. Intersperse specific hazard

information, cautions or warning notes at appropriate points throughout other sections

of the manual.

3. Limit a physical description section to physical description (size, dimension, weight,

special attachments and physical orientation or clearances for installation and

operation. Identify any special environmental (cooling, exhausting, or noise)

constraints.

4. Explain, in a functional description section, how the various functions operate

together to cause the desired results. Include block diagrams and flow diagrams for

clarification and understanding. Provide text and diagrams which mutually support

each other.

5. Include maintenance oriented operating procedures for the individual equipment in an

operating procedures section so that maintenance personnel will be able to verify proper operation.

6. Describe each equipment, unit, and assembly in detail with regard to technical or

theoretical operation. Include information to the component level. Describe each

circuit and mechanical mechanism. Cross-reference descriptions so that the functions

of each equipment are covered. Use schematic diagrams, sketches, equivalent

diagrams, tables, and graphs to supplement the text.

7. Include the applicable checkout, troubleshooting, servicing, removal and

replacement, and in-place repair procedures which are performed on the equipment,

stand-alone and on a system basis. Provide written procedures for each and every

adjustment point of the equipment.

8. Provide a tabular listing of special tools, equipment, and test equipment applicable to

the test, adjustment and fault isolation procedures. Write maintenance instructions to enable correct use of test equipment.

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9. Provide checkout procedures to verify the satisfactory operation of the system,

subsystem, or unit as applicable. If the checkout requires detailed step-by-step

procedure, include such procedures. Clearly indicate why the checkout is performed

and what conditions are to be satisfied.

10. Provide troubleshooting procedures to isolate faulty components. Sequence the

troubleshooting procedures in logical progression from malfunction indication to

location of the faulty component(s). Indicate special connections or test equipment

required for the troubleshooting.

11. Provide servicing requirements for cleaning, lubricating, replenishing, and other

housekeeping and preventative maintenance procedures that apply to the particular

equipment. Make reference to the applicable manuals which describe various

servicing procedures.

12. Provide removal and replacement procedures which contain step-by-step instructions

for removal and replacement of items which are subject to frequent replacement. If special tools are required, identify them by name and part number.

13. Provide schematic diagrams, logic diagrams, and associated data necessary for

maintenance personnel to trace circuits, make continuity checks, and accomplish

general and specific troubleshooting on inoperative or malfunctioning circuits.

Provide pin wiring diagrams and cabling and plug tables showing to-and-from wiring

information. Provide a symbol chart where necessary to explain graphic symbols that appear on diagrams.

14. Provide parts lists for equipment. Provide clear traceability from the equipment to the

replaceable component. Identify each component part with original manufacturer’s

name and part number. Identify component parts, or assemblies modified for the

project by a part number. The parts lists may be tabulated or may be supplied in the form of engineering or manufacturing drawings.

1.7 Software User’s Manual – Prepared by Contractor

Provide a development manual which defines how the various software components are

used and how the basic system may be altered using this software.

Describe the following:

1. Operating system use.

2. System software including compilers, editors, system utilities and file handlers.

3. User packages including data base generator, graphics generator, report generator,

historical data system, process control language and general operator workstation interface.

4. System operation including cold start, warm start, time/date initialization and backup

procedures.

5. System reconfiguration and regeneration procedures.

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1.8 Configuration Manual – Prepared by Contractor

Provide a configuration manual which describes how software in the final system is

configured. Describe the unique data and parameters of the system.

Include the following:

1. Point database showing parameters of points, including process I/O, internal points and calculations.

2. Controller configurations, including software, points, control modules, spare I/O and

memory.

3. System memory allocation.

4. Historical data configuration.

5. Display organization and configuration.

1.9 Custom Software Manuals – Prepared by Contractor

Provide complete documentation for all software developed specifically to meet

requirements of this Contract, i.e. modifications to standard software and nonstandard software.

1. Structure the documentation such that each level develops a different degree of detail.

2. Begin with a broad approach (Systems Manual), focus on smaller pieces of the

overall system (Subsystem Documentation) and finally pinpoint the finest detail (Program Documentation).

Provide a system’s manual which describes the overall content of the systems software.

Describe what is included in the software and not how the components function. Provide

a global view of the system and a complete description of the interaction of the various software subsystems. Include the following:

1. Table of contents.

2. Overall narrative of the system including special techniques and general philosophies.

3. A block diagram showing the interaction of all subsystems.

4. A list of subsystems including a brief discussion of the purpose of each.

5. A list of programs included, categorized by the subsystem to which each belongs.

6. A description of files or tables within the system which are not unique to any

particular subsystem. Files or tables used uniquely within a subsystem may be

defined therein.

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Provide manuals for each subsystem. Define the components of the particular subsystem,

the relationships between the components and, in general, what occurs within the subsystem. For each subsystem, include:


2. Overview which describes the purpose and scope of the subsystem.

3. Narrative which details the operation of the subsystem, completely describing how

the subsystem works, what are the specific components (programs, files, process points, tables, etc.) and how they interact.

4. Flowchart which depicts the overall system, showing components and their interactions.

5. Report summary which includes a list of reports produced by the subsystem and a

layout of each.

6. Display summary which includes a list of displays produced by the subsystem and a layout of each.

7. Input/output summary which includes a list of inputs and outputs (e.g., process points, tables, and files) pertinent to the subsystem.

Fully document every program. Define the details of the particular program and show

how each function is performed. For each program, include:


2. Overview which describes the scope and purpose of the program.

3. Narrative which describes exactly how the program functions. Include any calculations and process points.

4. Data flow diagrams (DFD) which show the program and inputs, outputs, files, or process points used.

5. Program structure chart (PSC) which shows the hierarchy of the program logic.

6. List of variables which defines each variable name in the program, including specific

characteristics (e.g., real, integer, and array).

Provide memory maps of main and mass memory storage. On memory maps, show the numbered locations of absolute storage areas and information stored in these locations.

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Appendix C Training

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1. Training

1.1 General

Training of City’s Operation and Maintenance staff shall be provided by the Consultants and the

Contractor. The training provided by the Consultants is to emphasize the application of

instrumentation, process devices and SCADA system technology for the control of the plant

treatment and supply processes. The training provided by the Contractor is to explain,

demonstrate and review both the instrumentation, process devices and SCADA hardware and

software that have been installed under the contract for the control of the plant’s treatment and

supply process.

Training by the Consultants includes the newly constructed work and the application of SCADA

technology to the new and existing Process Control System (PCS).

Training by the Contractor for Operations staff will include the review of the hardware and

software installed and configuration of SCADA and RPU software supplied under the contract.

In addition, it also includes training on how to monitor the process, adjust process setpoints and

respond to process alarms. Training for maintenance staff will include troubleshooting of

malfunctioning field devices, calibration and repairs of instruments and equipment.

1.2 Training by Consultants

1.2.1 General

The Consultants shall provide training to the City’s Operation and Maintenance staff on the

operation of the plant treatment and supply process through the SCADA HMI system. The

training shall include the following:

1. Operation and control of the plant treatment and supply process from the Control Room

workstation or equivalent.

2. Operation and control of individual processes at the Area Operator Work Station. (This

training is only required if there is a difference between the HMI in the Control Room

and the HMI on the Area Operator Work Station.)

3. Operation and local control of individual equipment at the Local Control Panels.

4. Operation of the RPU and how devices and equipment are connected to it.

Training shall be provided at the plant in two stages; first stage will be in a “classroom” to be

followed by the second stage which is the practical demonstration (hands on training)on the

operation of the plant or facility (or newly constructed work) through the SCADA system.

The Consultants shall provide all required pertinent training material to each Operation and

Maintenance staff. Typically, the SCADA Operation Manual shall be used as a guide during

training.

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1.2.2 Consultants’ Training Courses and Schedule

Training of the newly installed SCADA system shall commence one month prior to the newly

constructed process treatment or supply work being completed for its intended use and placed

into operation. Generally, this would also be about a month prior to substantial completion of the

contract but where it is intended to place the work into operation prior to substantial completion

because of mandatory connections to existing process or other processes constraints, then the

training for the treatment or supply process and SCADA system must occur one month prior to

the intention to place into operation the newly constructed work through the SCADA system.

The Consultants shall use the following table as a guideline when designing a training schedule.

The actual amount/duration of training will depend on the specific project complexity.

Course Duration Class Size Number of

Classes

1. Operation and control of the plant

treatment or supply process from the

Control Room work station or

equivalent, including the use of the

SCADA Operation Manual prepared by

the Consultants.

8 hours 10 3

2. Operation and control of individual

processes at the Area Operator Work

Station. (This training will only be

required if the HMI is different than the

Control Room Work station)

4 hours 10 3

3. Operation and local control of

individual equipment at the Local

Control Panels and RPUs.

4 hours 10 3

1.2.3 Operation and Control from the Control Room Work Station

Training on the operation and control of the SCADA system from the Control Room workstation

shall be carried out in a “classroom” on the theoretical and practical aspects of the SCADA

system as it relates to both the new treatment or supply process and current installed (or

expanded) SCADA system and its integration to the existing treatment or supply process to be

followed by the hands-on demonstration from the Control Room workstation.

Consultants shall review, train and demonstrate (hands on training) to staff the following:

1. Overview and features of the newly installed SCADA system, including design of

system, configuration and system architecture. Include the identification (tagging) of

installed hardware, network routing, operator work stations and servers. The training will

cover everything from how the signal is generated to how the signal gets to the HMI.

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2. The user interface functions such as log-on, log-off, password protection, etc.

3. The screen displays of newly installed SCADA system. (This may not be necessary if the

expansion is relatively small. In this case, proceed to the next item below.)

4. Screen display of integrated SCADA system for data, trending and plant and process

control system schematics.

5. Procedure for the control of treatment process through the SCADA system using the

integrated HMI screens and overview of the process which can be controlled from each

location.

6. Procedure for navigation of available screen display of daily operating data, trending and

plant/process schematics as well as changes or modifications technique for these displays.

7. Emergency response of critical treatment process under SCADA failure mode of

operation.

8. The availability and control of backup equipment under failure mode for both automatic

and manual switchover.

1.2.4 Control of Equipment at the Area Operator Station

(This section will only be required if the Area Operating Station HMI is different than the

Control Room Work Station HMI) Control of treatment or supply process equipment may be

necessary at the Area Operator Station because of the failure of the SCADA system or that

maintenance work has to be performed at the Central Operator Station. The Consultants shall

review, demonstrate and train Operation and Maintenance staff on the availability or capability

of control at the Area Operator Station of the following:

1. All equipment monitored and controlled at the Operator Station.

2. Manual adjustments of equipment controller’s set-points.

3. Control of backup equipment under failure mode, both automatic and manual switchover.

4. Where redundant area processors are provided, demonstrate the switch-over procedure.

1.2.5 Control of Equipment at the Local Area Control Panels and RPU

Control of plant treatment process equipment at the Local or Area Controller Panels is at the

lowest control hierarchy (besides the Local Hand Stations which is common for all equipment)

of the SCADA system. At the panel, each individual piece of equipment can be turned on or off

and process equipment controllers’ set-points manually adjusted.

Consultants shall review, demonstrate and train staff (hands on training) on the following:

1. Procedure for manual switch-over of backup equipment.

2. Key critical process procedure prior to manually switching over of backup equipment.

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3. Review alarm and statues of the equipment that has failed prior to manually switching

over of backup equipment.

4. Lockout equipment that must not be restarted from the Area Operator Station or at the

Central Operator Station when it is under the control of Local or Area Controller Panels.

1.3 Training by Contractor

1.3.1 General

The Contractor shall provide training of the City’s personnel in the proper operation and

maintenance of the equipment and systems installed under this project.

The Contractor shall provide on-the-job training of the City’s personnel for equipment as

specified. Training shall include instruction of operation personnel in equipment operation and

preventative maintenance and instruct plant mechanics, electricians and electronics technicians

in normal maintenance or repair.

1.3.2 Submission of Training Material

The Contractor shall supply the following information to the City. Due to phased testing and

start-up activities, separate submittals may be prepared for equipment items or systems. The

material shall be reviewed and accepted by the Consultants and the City no later than one month

prior to delivery of the training.

1. Detailed lesson plans for each training session are to be supplied to the City one month

prior to the session taking place. In addition, training manuals, handouts, visual aids and

other reference materials shall be included. The City reserves the right to approve and

request modifications to the plan and/or materials.

2. Date, time, and subject of each training session and identity and qualifications of

individuals to be conducting the training. The City has the right to request a change of

inspector if necessary.

3. Concurrent classes will not be allowed in training schedule.

1.3.3 Training Requirements

The training to be provided by the Contractor shall be as follows:

1. The Contractor shall conduct training sessions for the City’s operation and maintenance

personnel to instruct the staff on the proper operation, care and maintenance of the

equipment and systems installed under the contract. Training shall take place at the site of

the work and under the conditions as specified. Vendor operation and maintenance

manuals shall be available to City’s personnel at least 5 working days prior to the date

scheduled for the individual training session.

2. Field training session shall take place at the site of the equipment. The Contractor shall

provide a training facility with a capacity for at least 10 persons for classroom training.

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3. Formal detailed written lesson plans shall be prepared for each training session. Lesson

plans shall include an outline of the material to be presented together with description of

visual aids to be utilized during the session. Each plan shall contain a time allocation for

each subject. One complete set of originals of the lesson plans, training manuals,

handouts, visual aids and reference material shall be the property of the City and shall be

properly bound for proper organization and easy reproduction in an identical manner into

the equipment Operation and Maintenance Manual. The Contractor shall furnish enough

copies of the required training manuals to meet the needs of the training session at least 5

working days prior to each training session.

4. Each training session shall be comprised of time spent both in the classroom and at the

location of the equipment. The training session shall cover the following topics for each

equipment or system:

(i) Familiarization

(ii) Safety

(iii) Operation

(iv) Calibration

(v) Troubleshooting

(vi) Preventive maintenance

(vii) Corrective maintenance

(viii) Parts

(ix) Local representatives

(x) Equipment Operation and Maintenance Manuals

5. The City may perform video recording of the training session(s) or retain the services of a

commercial video taping service to perform the video recording. After the recording

session, the material may be edited and supplemented with professionally produced

graphics to provide a permanent record. The Contractor shall advise all manufacturers

providing training sessions that the training session(s) may be videotaped.

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1.3.4 Contractor Training Courses and Schedule

The Contractor shall use the following table as a guideline when designing a training schedule.

The actual amount/duration of training will depend on the specific project complexity.

Course Duration Class Size Number of

Classes

1. Operation and control of the plant

treatment process at the Central

Operator’s Station. Review of SCADA

and RPU software configuration and

programming carried out by the

Contractor and its integration to the

existing SCADA system. Use the

SCADA and RPU software manual and

Equipment Maintenance Manual

prepared by the Contractor. Explain

and demonstrate all safety interlocks.

Both classroom and training at the

Central Operator’s Station required.

8 hours 10 3

2. Operation and control of individual

processes at the Area Operator Station.

Demonstrate RPU process control and

explanation of the RPU software

programming and its linkage to the

Area Operator Station.

4 hours 10 3

3. Operation and local control of

individual equipment at the Local or

Area Controller Panels. Demonstrate

safety interlocks and manual setting of

local controllers and by-passing under

emergency condition.

4 hours 10 3

All training shall be conducted and completed by the Contractor prior to operational testing and

commissioning periods. Classes shall be scheduled such that classroom sessions are interspersed

with field instruction in logical sequence. The Contractor shall arrange to have the training

conducted on consecutive days, with no more than 4 hours of classes scheduled for any one day.

The Contractor will not be permitted to perform the operational testing and commissioning until

the training has been completed to the satisfaction of the City.

1.3.5 Contractor’s Classroom Training for Operation Staff

Classroom training of equipment for Operation staff will include:

1. Using slides, PowerPoint and drawings, discuss the equipment specific location in the

plant and an operational overview.

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2. Purpose and function of the equipment.

3. A working knowledge of the operating theory of the equipment.

4. Start-up, shutdown, normal operation, and emergency operation procedures, including a

discussion on system integration and electrical interlocks, if any.

5. Review, demonstrate and train Operation staff on the RPU and OIT program logic and

stepping through the program from beginning to the end to show and explain how the

control of the equipment is carried out and how to resolve programming / control

problem(s).

6. Identify and discuss safety items and procedures.

7. Routine preventative maintenance, including specific details on lubrications and

maintenance of corrosive protection of the equipment and ancillary components.

8. Operator detection, without test instruments, of specific equipment trouble symptoms.

9. Required equipment exercise procedures and intervals.

10. Routine disassembly and assembly of equipment if applicable (as judged by the City on a

case-by-case basis) for purposes such as operator inspection of equipment.

11. Calibration of the unit, showing staff how to make set point adjustments.

1.3.6 Contractor’s Hands-on Training for Operation Staff

Hands-on equipment training for Operations staff will include:

1. Identify location of equipment and review the purpose

2. Identifying instrumentation:

(i) Location of primary element.

(ii) Location of instrument readout.

3. Discuss purpose, basic operation and information interpretation.

4. Discuss, demonstrate, and perform standard operating procedures and checks.

5. Discuss and perform start-up and shutdown procedure.

6. Perform the required equipment exercise procedure.

7. Perform routine disassembly and assembly of equipment if applicable.

8. Identify and review safety items and perform safety procedures, if feasible.

9. Calibration of the unit, showing staff how to make set point adjustments.

1.3.7 Contractor’s Classroom Training for Maintenance Staff

Classroom equipment training for the maintenance and repair personnel will include:

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1. Theory of operation.

2. Description and function of equipment.

3. Start-up and shutdown procedures.

4. Normal and major repair procedures.

5. Equipment inspection and trouble shooting procedure including the use of applicable test

instruments and the “pass” and “no pass” test instrument readings.

6. Review, demonstrate and train Maintenance staff on trouble shooting of the RPU and

OIT when the system crash. Explain and train staff on the RPU and OIT program logic

and stepping through the program from beginning to the end to show and explain how the

control of the equipment is carried out and how to resolve programming / control

problem(s). Demonstrate and train Maintenance staff on trouble shooting and

replacement of the CPU, network interface units, network communication modules,

power supply, controllers, I/O cards etc.

7. Routine and long-term calibration procedures.

8. Safety procedures.

9. Preventative maintenance such as lubrication; normal maintenance such as belt, seal, and

bearing replacement; and up to major repairs such as replacement of major equipment

part(s) with the use of special tools, welding jigs, etc.

1.3.8 Contractor’s Hands-on Training for Maintenance Staff

Hands-on equipment training for Maintenance staff shall include:

1. Locate and identify equipment components

2. Review the equipment function and theory of operation.

3. Review normal repair procedures.

4. Perform start-up and shutdown procedures.

5. Review and perform the safety procedures.

6. Perform City’s-approved practice maintenance and repair job(s), including mechanical

and electrical adjustments and calibration and trouble shooting of equipment problems.

7. Demonstrate and train Maintenance staff on replacement of the CPU, network interface

units, network communication modules, power supply, controllers, I/O cards, etc.

8. Review and use equipment manufacturer’s manual.

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Appendix D-2

Appendix D – Associated Standards and Installation Drawings List The following list shows PCS Standards and Installation Drawinings that will be made available to Consultant on the request.

SPECIFICATION # eDOCS.# DWG. # DESCRIPTION

DIVISION 13 - PROCESS CONTROL

13000 PROCESS CONTROL

13010 6450 v1 Process Control - General 13040 SPECIALITIES

13040 6454 v1 Equipment and Data Tagging 13100 INSTRUMENTATION STANDARDS

13100 6448 v1 Instrumentation Design 13105 6449 v1 General Instrumentation Requirements

13110 ANALYSIS INSTRUMENTS

13110.1 6456 v1 Particle Analyzer 13110.2 6457 v1 Turbidity Analyzer - Low Range 13110.3 6458 v1 Turbidity Analyzer - High Range 13110.4 6459 v1 Suspended Solids Meter - Insertion Type 13110.5 6460 v1 Suspended Solids Meter 13110.6 6461 v1 Sludge Density Meter, In-Line 13110.7 6462 v1 Sludge Density Meter, Ultrasonic

13111 6463 v1 Chlorine Residual Analyzer 13113 6464 v1 pH Analyzer 13115 6465 v1 Conductivity Analyzer 13116 6466 v1 Dissolved Oxygen Analyzer 13118 6467 v1 Fluoride Analyzer 13120 6468 v1 Streaming Current Analyzer 13121 6469 v1 Phosphate Analyzer 13122 6470 v1 Ammonia Analyzer

13125.1 6471 v1 Chlorine Leak and Sulphur Dioxide Monitor 13125.2 6472 v1 Ozone Gas Leak Detector 13125.3 6473 v1 Combustible Gas Detector

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Appendix D-3


13125.5 6474 v1 Hydrogen Sulphide Monitor 13125.6 6475 v1 Oxygen Monitor 13125.7 6476 v1 Stack Gas Monitor 13125.8 6477 v1 Gas Detector 13125.9 6478 v1 Ozone Concentration Transmitter, Wet Gas 13126.1 6479 v1 Ozone-In-Oxygen Monitor - Low Range 13126.2 6481 v1 Ozone-In-Oxygen Monitor - Medium Range 13126.3 6480 v1 Ozone-In-Oxygen Monitor - HighRange

13130 FLOW INSTRUMENTS

13130 6512 v1 Magnetic Flow Meter 13131 6513 v1 Vortex Shedding Flow Meter

13132.1 6514 v1 Clamp-on Ultrasonic (Doppler) Flow Meter 13132.2 6515 v1 Clamp-on Ultrasonic (Transit Time) Flow Meter

13133 6516 v1 Insertion Ultrasonic (Transit Time) Flow Meter 13134 6517 v1 Thermal Mass Flow Meter 13136 6518 v1 Coriolis Mass Flow and Density Meter

13137.1 6519 v1 Orifice Plate 13137.2 6520 v1 Pitot Tube 13137.3 6521 v1 Venturi 13137.4 6522 v1 Parshall Flume 13137.5 6523 v1 Flow Broad Crested Weir 13138.1 6524 v1 Paddle Wheel Flow Switch 13138.2 6525 v1 Thermal Flow Switch

13142 6526 v1 Open Channel Flow Meter - Submersible 13143 6527 v1 Open Channel Flow Meter - Radar

13150 LEVEL INSTRUMENTS

13150.1 6544 v1 Ultrasonic Level Transmitter 13150.3 6545 v1 Radar Level Transmitter - Horn Antenna 13150.4 6546 v1 Radar Level Transmitter- Rod Antenna

13152 6547 v1 Capacitance Level Transmitter 13153.1 6548 v1 Level-Direct Sensing DPT (Level), Flange Mounted 13153.2 6549 v1 Level-Submersible DPT 13157.1 6550 v1 Sludge Blanket Detector, Fixed 13158.1 6551 v1 Float Switch (Tilt) 13158.2 6552 v1

Ultrasonic Level Switch

13158.3 6553 v1 Capacitance Level Switch 13158.4 6554 v1 Vibration Level Switch 13158.5 6555 v1 Conductivity Level Switch

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Appendix D-4


13160 PRESSURE INSTRUMENTS

13160 6568 v1 Pressure Transmitter 13161 6569 v1 Pressure Differential Transmitter 13166 6570 v1 Pressure Seal 13167 6571 v1 Annular Pressure Seal 13168 6572 v1 Pressure Switches 13169 6573 v1 Pressure Indicating Gauge

13170 TEMPERATURE INSTRUMENTS

13170.1 6580 v1 Temperature Element and Transmitter, RTD 13170.2 6581 v1 Temperature Element and Transmitter, Thermocouple 13171.1 6582 v1 Ambient Air Temperature and Humidity Transmitter 13171.2 6583 v1 Duct Air Temperature and Humidity Transmitter 13171.3 6584 v1 Ambient Air Humidity Transmitter 13171.4 6585 v1 Duct Air Humidity Transmitter

13176 6586 v1 Thermowell 13177 6587 v1 Temperature Switches 13178 6588 v1 Temperature Indicators

13180 MISCELLANEOUS INSTRUMENTS

13180 6602 v1 Sampler 13183 6603 v1 Limit Switch 13184 6604 v1 Motion Detector 13187 6605 v1 Weight Scale Hydraulic Weight Cell 13188 6606 v1 Weigh Scale Load Cell 13190 6607 v1 Smoke Detector 13191 6608 v1 Heat Detector 13199 6609 v1 Instrument Listing / Instrument Data Sheets

13300 CONTROL PANEL STANDARDS

13300 6618 v1

Control Panel Design 13305 6619 v1 Field Wiring 13310 6620 v1 Panel Construction 13311 6621 v1 Enclosures 13312 6622 v1 Enclosure Accessories 13320 6623 v1 Panel Wiring 13325 6624 v1 DC Power Supply 13350 6625 v1 Selector Switches, Push-Buttons, and Status Lights 13351 6626 v1 Annunciator

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13352 6627 v1 Single Loop Controller 13353 6628 v1 Dual Loop Controller 13354 6629 v1 LCD Digital Panel Indicator

13354.1 6630 v1 LED Digital Panel Indicator 13355 6631 v1 Paperless Chart Recorder

13360 ELECTRICAL MONITORING AND PROTECTION

13366 8219 v1 Motor Protection Unit (269) 13366.1 8220 v1 Motor Protection Unit (469)

13367 8221 v1 Generator Management Relay (489) 13368 8222 v1 Feeder Protection Unit (750) 13369 8223 v1 Transformer Protection Unit (735)

13369.1 8224 v1 Transformer Differential Protection Unit (745) 13370 SIGNAL CONDITIONING EQUIPMENT

13370 8231 v1 Signal Conditioning Equipment 13371 8232 v1 Power Monitoring Serial to Ethernet Conversion Unit 13372 8233 v1 Power Monitoring Information and Relay Configuration Tool

13400 PROGRAMABLE LOGIC CONTROLLERS

13400 8237 v1 Programmable Logic Controllers 13500 NETWORKING

13510 8239 v1 Local Area Network 13520 8240 v1 Wide Area Network

13600 COMPUTER HARDWARE

13600 8243 v1 SCADA Computer System Appendix D1: Installation Drawings

General for Instruments and Panels

8916 v1 G01 Instrument Stand, floor mount 8917 v1 G02 Instrument Wall Mounting, Pipe 8918 v1 G05 Instrument Sun Shield Installation Detail 8919 v1 G06 Instrument Purge Air Analisys Instruments

8924 v1 A02 pH Sensor - In-Line Mount 8925 v1 A03 pH Sensor - Y Mount 8926 v1 A06.2 DO Probe, Hand-Rail Mount

8927 v1 A14.1 Suspended Solids Meter (Low Range)

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8928 v1 A14.2 Suspended Solids Meter (Higher Concentration of Solids) 8929 v1 A15.1 Suspended Solids Meter - In-line

8930 v1 A15.2 Suspended Solids Meter – Pipe Tee Insertion

8931 v1 A32 Gas Detection - Conduit Mounted Sensor 8932 v1 A35 Chlorine Leak Sensor Flow Instruments

8966 v1 F01.2 Flow - Magnetic Flow Meter (With Ultrasonic Cleaning Electrodes)

8967 v1 F01.3 Flow - Magnetic Flow Meter (Remote Mounted Signal Converter)

8968 v1 F04.1 Flow Switch (Paddle Wheel) Pipe Mounting 8969 v1 F05.1 Flow Switch (Thermal) Duct Mounting. Air 8970 v1 F07 Self Averaging Pitot, Standard 8971 v1 F08 Self Averaging Pitot, Hot Tap 8972 v1 F09 Self Averaging Pitot, Flanged 8973 v1 F10 Ventury Tube

8974 v1 F35 Parshall Flume Ultrasonic Sensor Mounting Detail

Level Instruments

8985 v1 L02 Ultrasonic Level, Through Concrete 8986 v1 L11 Ultrasonic Level, Enclosed Tank

8987 v1 L12.1 Radar Level, Horn Antenna, Enclossed Tank 8988 v1 L12.2 Radar Level, Horn Antenna, Grit Hopper/Tank 8989 v1 L12.3 Radar Level, Horn Antenna, Enclossed Tank Flange Mounted 8990 v1 L12.4 Radar Level, Horn Antenna, Open Tank, Side Mounted 8991 v1 L12.5 Radar Level, Horn Antenna, Scum Hopper/Tank 8992 v1 L12.6 Radar Level, Horn Antenna, Enclossed Tank, Floor Mounted

8993 v1 L13 Radar Level Transmitter - Rod 8994 v1 L20 Level Probe In Side Of Tank 8995 v1 L25 Float Switch for Sumps

8996 v1 L25.1 Float Switch for Sumps, Multi Level Regulator Hanger

8997 v1 L37 Weir –Ultrasonic Level Sensor Mounting Detail

Pressure Instruments

9012 v1 P01 Pressure Tap - Pipe Tee and Threadolet 9013 v1 P02 Pressure Tap - Tank (FRP and Steel) 9014 v1 P03 Pressure Tap - Pipe Saddle 9015 v1 P12 DPT For Flow In Overhead Process Line 9016 v1 P14 DPT For Flow In Lower Process Line 9017 v1 P15 DPT For Steam Flow 9018 v1 P16 DPT For Level Of Vented Tank 9019 v1 P18 Pressure - DPT For Filter Head Loss

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Appendix D-7


9020 v1 P18.1 Diferrential Pressure Transmitter 9021 v1 P22 PS and PI, normal 9022 v1 P23 PS and PI, with diaphragm seal 9023 v1 P24 PS and PI, with annular diaphragm seal

Temperature Instruments

9036 v1 T01 Thermowells Installation 9037 v1 T02 Thermowells Installation

DIVISION 15 MECHANICAL

15000 MECHANICAL DESIGN STANDARDS

15110 8245 v1 Valves and Operators DIVISION 16 ELECTRICAL

16000 ELECTRICAL DESIGN STANDARDS

16020 8250 v1 Ladder Diagram 8770 v1 1.01 Electrical Symbols 8771 v1 2.01A Constant Speed Computer - Maintained, Local -Pushbuttons 8772 v1 2.01B Constant Speed Computer - Momentary, Local -Pushbuttons 8773 v1 2.01C Reversing: Computer - Maintained, Local - Pushbuttons

8774 v1 2.01D Reversing: Computer - Momentary, Local - Pushbuttons

8775 v1 2.02A Two Speed: Computer-Maintained, Local - Push-buttons 8776 v1 2.02B Two Speed: Computer - Momentary, Local - Push-buttons 8777 v1 2.03A Variable Speed Magnetic Drive: Speed - 4-20 mA

8778 v1 2.04A Full Open/Close Valve or Gate: Computer - Momentary, Local - Pushbuttons

8779 v1 2.05A Slow Moving Valve or Gate: Computer - Maintained, Local - Selector Switch

8780 v1 2.05B Slow Moving Valve or Gate: Computer - Momentary, Local - Pushbuttons

8781 v1 2.06A Modulating Valve or Gate: Computer - 4-20 mA, Local - Setpoint

8782 v1 2.06B Modulating Valve or Gate: Computer - Maintained, Local - Pushbuttons

16280 8247 v1 Uninterruptible Power Supplies and Power Conditioners 16281 8248 v1 Computer Room, Uninterruptible Power Supply

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9117-11-7274 Addendum 1 - Toronto · Request for Proposal No. 9117-11-7274 ... 7.4 Hardware SAT ......

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