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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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.
4.7 95% Detailed Design In addition to updates to the elements of the 70% design, the following should appear in the 95% submittal:
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
4.8 100% Detailed Design In addition to updates to the elements of the 95% design, the following should appear in the 100% submittal:
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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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
Review by:PCSU, ITM, Operation Group
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
Process Control System (PCS) Guidelines
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
Review by:PCSU, ITM, Operation Group
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
Review by:PCSU, ITM, Operation Group
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
Review by:PCSU, ITM, Operation Group
75% Pre-Design Report accepted?
No
Yes
PRE-DESIGN (PCS COMPONENT)
PROJECT TASKS FLOW CHART
Field Verification Report
50% Pre-Design Report
75% Pre-Design Report
Page-3
TASKS DELIVERABLESINPUTS/REFERENCES
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 2 of 11 Appendix A31 of 189
Consolidate review comments and prepare Outstanding Issues list
100% Pre-Design
Incorporate 75% Pre-Design commentsUpdated Cost Estimate
Review by:PCSU, ITM, Operation Group
100% Pre-Design Report accepted?
No
Yes
Pre-Design CompleteProceed to Detailed Design
100% Pre-Design Report
PRE-DESIGN (PCS COMPONENT)
PROJECT TASKS FLOW CHART
TASKS DELIVERABLESINPUTS/REFERENCES
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Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 3 of 11 Appendix A32 of 189
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
Review by:PCSU, ITM, Operation Group
Yes
Tagging Database – Enterprise Tagging Management System (ETMS)Toronto Water Tagging Standard
Consolidate review comments and prepare Outstanding Issues list
DETAILED DESIGN (PCS COMPONENT)
PROJECT TASKS FLOW CHART
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
70% Detailed Design Documents
70% Detailed Design accepted?
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
Consolidate review comments and prepare Outstanding Issues list
Page-5
TASKS DELIVERABLESINPUTS/REFERENCES
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 4 of 11 Appendix A33 of 189
DETAILED DESIGN (PCS COMPONENT)
PROJECT TASKS FLOW CHART
Apply For ApprovalSend documents to Approval Agencies
as required
Yes
Submit Applications with associated documentation
Approvals received?
No
Incorporate Agency Comments into the Documents
95% Detailed DesignDevelop or update the following
Update 70% Detailed Design DocumentsPre-Start Health and Safety Review and Report as requiredElectrical Area Classifications as requiredCost Estimate
95% Detailed Design Documents
95% Detailed Design accepted?
Review by:PCSU, ITM, Operation
Group
No
Yes
Consolidate review comments and prepare Outstanding Issues list
100% Detailed DesignDevelop or update the following
Update 95% Detailed Design DocumentsTender DocumentUpdate Cost Estimate
Involve PCSU, ITM as required during Tendering Process
TASKS DELIVERABLESINPUTS/REFERENCES
100% Detailed Design/Tender Document
accepted?
Yes
No
100% Detailed Design/Tender
Document
Review by:PCSU, ITM, Operation
Group
Page-4
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 5 of 11 Appendix A34 of 189
Shop Drawings
Prepare Applicable Shop Drawings
InstrumentationServers, PLCs, OITsNetworkPanels, CablingMCCs, Switchgear
No
CONSTRUCTION – EQUIPMENT (PCS COMPONENT)
PROJECT TASKS FLOW CHART
Shop Drawings
Review by:PCSU, ITM,
Operation Group
Bulk Construction (Conduits, Cable Trays, Duct Banks)
TASKS DELIVERABLESINPUTS/REFERENCES
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
Consultant’s Review
Prepare FAT Reports
Review by:PCSU, Operation Group
Consultant’s Review
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 6 of 11 Appendix A35 of 189
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
Review by:PCSU, ITM,
Operation Group
No
CONSTRUCTION – EQUIPMENT (PCS COMPONENT)
PROJECT TASKS FLOW CHART
TASKS DELIVERABLESINPUTS/REFERENCES
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
Consultant’s Review
Consultant’s Review
Yes
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 7 of 11 Appendix A36 of 189
CONSTRUCTION – SOFTWARE (PCS COMPONENT)
PROJECT TASKS FLOW CHART
Flow Chart Development
Develop Logic Flow Charts
Logic Flow Charts accepted?
No
Logic Flow Charts
Review by:PCSU, ITM,
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
TASKS DELIVERABLESINPUTS/REFERENCES
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
Consultant’s Review
Consultant’s Review
New Software Modules Documentation
Consultant’s Review
Yes
No
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 8 of 11 Appendix A37 of 189
PROJECT TASKS FLOW CHART
CONSTRUCTION – SOFTWARE (PCS COMPONENT)
Page-8
TASKS DELIVERABLESINPUTS/REFERENCES
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
Consultant’s Review
Yes
Consultant’s Review
FAT Documentation and Sign-off
Complete FAT Documentation and Sign-off
Consultant’s Review
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 9 of 11 Appendix A38 of 189
CONSTRUCTION – TESTING AND COMMISSIONING (PCS COMPONENT)
PROJECT TASKS FLOW CHART
Software SAT and Training Plan
Develop SAT Documentation, Schedule and Training Plan
Software SAT and Training Plan
Software SAT and Training Plan accepted?
Review by:PCSU, ITM,
Operation Group
No
Yes
Software Training
Provide Software Training by Consultant and Systems Integrator
Page-7 Page-9
TASKS DELIVERABLESINPUTS/REFERENCES
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
Consultant’s Review
Hardware SAT Documentation and Sign-off
Complete Hardware SAT Documentation and Sign-off
Consultant’s Review
Consultant’s Review
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 10 of 11 Appendix A39 of 189
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)
PROJECT TASKS FLOW CHART
TASKS DELIVERABLESINPUTS/REFERENCES
Page-10
Post Construction Warranty Period
Operational Test passed?
As-Built Documentation
Prepare Hardware and Software As-Built Documentation
As-Built Documentation
accepted?
As-Built Documentation
Review by:PCSU, ITM,
Operation GroupNo
Yes
Software SAT Documentation and Sign-off
Complete Software SAT Documentation and Sign-off
Consultant’s Review
No
Yes
Consultant’s Review
Process Control System (PCS) Guidelines
EDOCSLIB-#9087-V1 Page 11 of 11 Appendix A40 of 189
Process Control System (PCS) Guidelines
Implementation Guidelines
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
PCSU, ITM, Operation Group
1.3 Scope of Work DefinitionPrepare Scope of Work with input from PCSU, ITM, Operation Group
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)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
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
PCSU, ITM, Operation Group
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
Reviewed 75% Pre-DesignPCSU, ITM, Operation Group
Consolidate 75% Pre-Design Review Comments PCSU
Consolidated 75% Pre-Design Review Comments PCSU
Consolidated 75% Pre-Design Review Comments Consultant
2.6 100% Pre-Design75% Pre-Design Review Comments Incorporated Consultant
75% Pre-Design Review Comments Incorporated
PCSU, ITM, Operation Group
Updated Cost Estimate Consultant Updated Cost EstimatePCSU, Operation Group
Reviewed 100% Pre-DesignPCSU, ITM, Operation Group
Consolidate 100% Pre-Design Review Comments PCSU
Consolidated 100% Pre-Design Review Comments PCSU
Consolidated 100% Pre-Design Review Comments Consultant
Final 100% Pre-Design Consultant Final 100% Pre-DesignPCSU, ITM, Operation Group
MANAGER
Project Tasks Implementation Checklist
PROJECT
EDOCSLIB-#9088-V1 Page 2 of 7 9/26/201143 of 189
Process Control System (PCS) GuidelinesImplementation Checklists
Project Phase: Detailed Design (PCS Component)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
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
Cost Estimate Consultant Cost EstimatePCSU, ITM, 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
PCSU, ITM, Operation Group
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
PCSU, ITM, Operation Group
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
PCSU, Operation Group
Electrical Area Classification as required Consultant Electrical Area Classification as requiredPCSU, Operation Group
Cost Estimate Consultant Cost EstimatePCSU, ITM, 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
PCSU, Operation Group
MANAGER
Project Tasks Implementation Checklist
PROJECT
EDOCSLIB-#9088-v1 Page 3 of 7 9/26/201144 of 189
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Project Phase: Detailed Design (PCS Component)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
Received Delivered
MANAGER
Project Tasks Implementation Checklist
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
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Process Control System (PCS) GuidelinesImplementation Checklists
Project Phase: Construction - Equipment (PCS Component)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
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
PCSU, Operation Group
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 Tasks Implementation Checklist
PROJECT
EDOCSLIB-#9088-v1 Page 5 of 7 9/26/2011
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Process Control System (PCS) GuidelinesImplementation Checklists
Project Phase: Construction - Software (PCS Component)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
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
PCSU, ITM, Operation Group
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)
Systems Integrator/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)
Systems Integrator/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
Systems Integrator, Consultant
5.7 FAT PlanFAT Documentation and Schedule (Reviewed by Consultant)
Systems Integrator/Consultant
FAT Documentation and Schedule (Reviewed by Consultant)
PCSU, ITM, Operation Group
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
Systems Integrator, Consultant
Final FAT Documentation and Schedule (Approved by Consultant)
Systems Integrator/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)
PCSU, ITM, Operation Group
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
Systems Integrator, Consultant
Correct Software Deficiencies Identified During FAT (Verified by Consultant)
System Integrator/Consultant
Completed Documentation and Sign-off (Reviewed and Signed by Consultant)
Systems Integrator/Consultant
Completed Documentation and Sign-off (Reviewed and Signed by Consultant)
PSCU, ITM, Operation Group
MANAGER
Project Tasks Implementation Checklist
PROJECT
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Process Control System (PCS) GuidelinesImplementation Checklists
Project Phase: Construction - Testing and Commissioning (PCS Component)
ID Task Deliverables/INPUT Provider/ Deliverables/OUTPUT Recipients/Custodian Reviewers
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
PCSU, ITM, Operation Group
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)
PCSU, Operation Group, ITM (Network)
Reviewed Hardware SAT Reports and Documentation
PCSU, Operation Group, ITM (Network)
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)
PCSU, Operation Group
6.4 Software SAT and Training PlanSAT Documentation, Schedule and Training Plan (Reviewed by Consultant)
System Integrator/Consultant
SAT Documentation, Schedule and Training Plan
PCSU, ITM, Operation Group
Reviewed SAT Documentation, Schedule and Training Plan
PCSU, ITM, Operation Group
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
System Integrator/Consultant
Final SAT Documentation, Schedule and Training Plan (Approved by Consultant)
System Integrator/Consultant
Final SAT Documentation, Schedule and Training Plan (Approved by Consultant)
PCSU, ITM, Operation Group
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)
System Integrator/Consultant
Software SAT, SAT Reports and Documentation (Reviewed by Consultant)
PCSU, ITM, Operation Group
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)
System Integrator/Consultant
Completed Documentation and Sign-off (Reviewed and Signed by Consultant)
Systems Integrator/Consultant
Completed Documentation and Sign-off (Reviewed and Signed by Consultant)
PCSU, ITM, Operation Group
6.7Operational Test/System Performance Test Operational Test/Sytem Performance Test
Consultant, System Integrator Operational Test/Sytem Performance Test
PCSU, ITM, Operation Group
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
PCSU, ITM, Operation Group
Submitt SAT Version of Software (Approved by Consultant)
System Integrator/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
PCSU, ITM, Operation Group
Reviewed Hardware and Software As-Built Documentation
PCSU, ITM, Operation Group
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
Consultant, Contractor, System Integrator
Final Hardware and Software As-Built Documentation
Consultant, Contractor, System Integrator
Final Hardware and Software As-Built Documentation
PCSU, ITM, Operation Group
6.9Post Construction Waranty Period
Contractor/System Integrator
MANAGER
Project Tasks Implementation Checklist
PROJECT
EDOCSLIB-#9088-v1 Page 7 of 7 Appendix B
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Process Control System (PCS) Guidelines
Implementation Guidelines
Appendix C – Associated Guidelines
49 of 189
Process Control System (PCS) Guidelines
Implementation Guidelines
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
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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
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Appendix C Field Verification Procedure
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
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Appendix C Field Verification Procedure
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
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Appendix C Field Verification Procedure
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
NUMBER
EVALUATION, RECOMMENDATION & COST DOCUMENT VERIFICATION & INITIAL EVALUATION FIELD VERIFICATION PROCEDURE
Recomm.Comments/
ReasonsRecords Available Initial Evaluation & Recommendation Results Reason & Proposed Modification
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Appendix C Process Control Narratives
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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
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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.
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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
84 of 189
REVISIONS / CONTRACT NO.No. DATE INITIAL SIGNED
DRAFTING:
TORONTO WATEROPERATIONAL SUPPORT
DATE:
DESIGN:
SCALE: SHEET No.DRAWINGNUMBER:
CHECK: CONTRACT No.
DIRECTOR,ALEX MARICH
OPERATIONAL SUPPORT
P&ID STANDARD SYMBOLS - 1GENERAL
ENTER FACILITY NAME
1XXXXX-P&ID-I-0102
INSTRUMENTATION-MASTER P&ID
N.T.S
JULY, 2001
85 of 189
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 STANDARD SYMBOLS - 2GENERAL
ENTER FACILITY NAME
1XXXX-P&ID-I-0103
INSTRUMENTATION-MASTER P&ID
N.T.S
JULY, 2001
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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 BLOCKS 1 - GATES, VALVES, PUMPSGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
87 of 189
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 BLOCKS 2 - BLOWER, FAN, DAMPERGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
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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 BLOCKS 1 - GATES, VALVES, PUMPSGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
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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 BLOCKS 4 -BRIDGE, COLLECTORGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
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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 BLOCKS 5 - -CENTRIFUGEGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
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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 BLOCKS 6 - GENERATOR, COMMUNITORGENERAL
1
PCS STANDARDS
N.T.S
JULY, 2001
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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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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)
Word 4 Counter 2 (Current
Value)
Timer 2 (Current
Value)
Word 5 Counter 2 (Preset Value) Timer 2 (Preset Value)
Word 6 Counter 2 (Control
Word)
Timer 2 (Control
Word)
Word 7 Counter 3 (Current
Value)
Timer 3 (Current
Value)
Word 8 Counter 3 (Preset Value) Timer 3 (Preset Value)
Word 9 Counter 3 (Control
Word)
Timer 3 (Control
Word)
Word 10 Spare Spare
1.4.3.3 Communications
1. Blocks of memory may need to be allocated for communication with other intelligent
devices to manage communication speed. Communication blocks are not required for GE
RPUs connected by Ethernet.
2. For example, communication with an operator station may require that a separate block
or blocks be set up for an alarm and event array. The alarm and event array may be split
into separate blocks, one for alarms and one for events. Even if alarms are also used for
control, they should be copied to the alarm block. Separation of alarms is useful for
testing alarm reporting separate from control logic.
3. Within the communication section, separate blocks should be set up for communication
to minimize the number of messages needed to communicate data. Typically this means
that a block for analog values, a block for receipt of operator commands and a block for
setpoints and other parameters should be set up. A block for communication to and from
other RPUs may need to be separate from the operator station interface blocks in order
for fast communications.
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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
1. Analog Internal: %R00001 to %R24064
a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500
b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000
c. Programming: %R01001 to %R08000, %R14001 to %R20000
d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:
%R08001 to %R09000, %R20001 to %R21000
e. Counter: %R09001 to %R10000, %R21001 to %R22000
f. Timer: %R10001 to %R13000, %R22001 to %R23000
g. Modbus: %R23001 to %R24064
C. Discrete Input, Discrete Output & Hardware Configuration
1. Discrete Input: %I00001 to %I02048
a. Raw Discrete Input: %I00001 to %I01000
b. CPU Ethernet Status Address: %I01001 to %I01080
c. I/O Modules Status Address: %I01081 to %I02048
2. Discrete Output: %Q00001 to %Q02048
D. Discrete Internal
1. Discrete Internal: %M00001 to %M04096
a. SCADA to PLC: %M00001 to %M00500
b. PLC to SCADA: %M00501 to %M01500
c. Programming: %M01501 to %M04096
1.6 Transition Memory Allocation for RX3i PLC
A. Analog Input and Analog Output
1. Analog Input: %AI00001 to %AI02048
2. Analog Output: %AQ00001 to %AQ00512
B. Analog Internal Default
1. Analog Internal: %R00001 to %R12032
a. SCADA to PLC: %R00001 to %R00500
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b. PLC to SCADA: %R00501 to %R01000
c. Programming: %R01001 to %R08000
d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:
%R08001 to %R09000
e. Counter: %R09001 to %R10000
f. Timer: %R10001 to %R12032
B2. Analog Internal Hi Density
1. Analog Internal: %R00001 to %R32640
a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500
b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000
c. Programming: %R01001 to %R08000, %R14001 to %R20000, %R24065
to %R32640
d. Clock/Peer to Peer/Modules configuration/Diagnostic and PLC system:
%R08001 to %R09000, %R20001 to %R21000
e. Counter: %R09001 to %R10000, %R21001 to %R22000
f. Timer: %R10001 to %R13000, %R22001 to %R23000
g. Modbus: %R23001 to %R24064
C. Discrete Input, Discrete Output & Hardware Configuration
1. Discrete Input: %I00001 to %I02048
a. Raw Discrete Input: %I00001 to %I01000
b. CPU Ethernet Status Address: %I01001 to %I01080
c. I/O Modules Status Address: %I01081 to %I02048
2. Discrete Output: %Q00001 to %Q02048
D. Discrete Internal
1. Discrete Internal: %M00001 to %M32640
a. SCADA to PLC: %M00001 to %M00500, %M05001 to %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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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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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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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 view displays including alarm page and pre-configured reports.
Access to configuring trend and group displays.
Access to all process control functions and alarm acknowledgement (potentially not
access to disabling alarms and changing alarm priorities).
3. Supervisor/System Technician
Access to view displays including alarm page and pre-configured reports.
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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Instrument and Equipment Testing
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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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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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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:
1. An independent measuring instrument;
2. The instrument switch;
3. All remote lights and indicators;
4. The digital input status measured at both the RPU and operator panels’ terminal blocks.
Performance of all tests shall be witnessed by the Consultants.
Test results are to be compared against the instrument calibration/setting reports and planned
RPU discrete input setting.
1.2.11 Testing Tools and Equipment
The Consultants shall ensure that the Contractor and/or respective Calibration Contractors or
Equipment Manufacturers provides proper protection for all instruments and devices that may be damaged by high voltage tests. If damages occur, the respective parties shall be held fully responsible for the replacement of damaged parts and/or components.
Calibration method and tools shall not cause any error greater than +/- 0.5% in any test. The
accuracy of the calibration tools must be traceable to National Standards. The Consultants shall review all testing procedures, and tools to be used. The Contractor shall use only electronic calibration equipment unless it can be demonstrated that such electronic calibration equipment is not available for the required specific test. Provide a form for electronic documentation, transferable to a standard spreadsheet format.
The Consultants or the Contractor shall follow the applicable City’s safety requirements. For all identified plant areas, and in particular the collection system facilities, provide proper safety equipment for personnel entering (manholes and other) confined spaces, plus hazardous gas locations.
1.3 Instrument and Equipment Testing
1.3.1 General
The instrument and equipment shall be tested to confirm that the field instruments and equipment
installed 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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Instrument and Equipment Testing
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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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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:
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 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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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:
1. An independent measuring instrument;
2. The instrument switch;
3. All remote lights and indicators;
4. The digital input status measured at both the RPU and operator panels’ terminal blocks.
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.
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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
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Ran
ge In
Eng
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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
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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
NCE
LOCA
L PA
NEL
SW
ITCH
ES
LOCA
L/R
EMO
TE C
ON
TRO
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
Process Control System (PCS) Guidelines
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.
152 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Factory Acceptance Testing
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.
153 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Factory Acceptance Testing
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.
154 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Factory Acceptance Testing
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
155 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Factory Acceptance Testing
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
Computer Manual Abnormal
Unresponsive Commands
Computer Manual Abnormal
Device Operation Permissives
Computer Manual Abnormal Device AlarmsComputer Manual Abnormal
Emergency Stop
Computer Auto Abnormal
Uncommanded Operations
Computer Auto Abnormal
Unresponsive Commands
Computer Auto Abnormal
Device Operation Permissives
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
Process Control System (PCS) Guidelines
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;
159 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Site Acceptance Testing and Commissioning
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:
160 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Site Acceptance Testing and Commissioning
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
Process Control System (PCS) Guidelines
Appendix C PCS Site Acceptance Testing and Commissioning
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
162 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Site Acceptance Testing and Commissioning
EDOCSLIB-#9107-v1
Page 5 of 5
1. Uncommanded Operations
2. Unresponsive Commands
3. Device Operation Permissives
4. Device Alarms
5. Emergency Stop
163 of 189
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
rip P
t
Dis
able
CommentsRac
k
Slo
t
Tag Name Description RP
U I/
O A
ddre
ss
HM
I/RP
U A
ddre
ss
RPU I/O T
ype
Uni
ts
Dat
e V
erifi
ed
Dat
e V
erifi
ed
Def
ault
Val
ue
Acc
ess
R o
r R/W
Min
Val
ue
Max
Val
ue
Dat
a Tr
ansf
er F
req.
HMI Engineering Units TestHMI Device Range
Mod
ule
Poi
nt o
r Cha
nnel
Dat
e V
erifi
ed
Trip
Poi
nt %
of S
pan
Ala
rm A
rea
RPU Range Raw Signal TestRPU Device Range Trending Attributes
Ala
rm C
ondi
tioni
ng
Ala
rm P
riorit
y
Eng
. Uni
ts
Dat
e V
erifi
ed
Issu
e Lo
g N
o.
Tim
e D
elay
Ala
rm N
AC
K
Ala
rm A
CK
Operator Control
Pag
ing
Gro
up
164 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
Computer Manual Abnormal
Unresponsive Commands
Computer Manual Abnormal
Device Operation Permissives
Computer Manual Abnormal Device AlarmsComputer Manual Abnormal
Emergency Stop
Computer Auto Abnormal
Uncommanded Operations
Computer Auto Abnormal
Unresponsive Commands
Computer Auto Abnormal
Device Operation Permissives
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)
165 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Documentation
EDOCSLIB-#9108-v1
Page 1 of 10
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
166 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Documentation
EDOCSLIB-#9108-v1
Page 2 of 10
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.
167 of 189
Process Control System (PCS) Guidelines
Appendix C PCS Documentation
EDOCSLIB-#9108-v1
Page 3 of 10
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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Process Control System (PCS) Guidelines
Appendix C PCS Documentation
EDOCSLIB-#9108-v1
Page 4 of 10
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:
1. Table of contents.
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:
1. Table of contents.
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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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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SPECIFICATION # eDOCS.# DWG. # DESCRIPTION
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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SPECIFICATION # eDOCS.# DWG. # DESCRIPTION
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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SPECIFICATION # eDOCS.# DWG. # DESCRIPTION
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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SPECIFICATION # eDOCS.# DWG. # DESCRIPTION
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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SPECIFICATION # eDOCS.# DWG. # DESCRIPTION
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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