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Project Number: 228730

WWTE SCADA Upgrades

Issue Date: August 2017 Nashua, NH
Control Panel Manufacturer (or Comments
Components approved equivalent)
Pilot/Status Lights (Push |Allen Bradley Color code as follows: Red-Fault, Green-Run
to test) General Electric
Square D
HOR, On/Off, L/R Allen Bradley Refer to Section 26 27 26, Wiring Devices and
switches and push General Electric Miscellaneous Electrical Equipment. Furnish
buttons Square D switches and push buttons with matching nameplate

2.02 SPARE PARTS

A.

1.

2.

3.

4.

5.

Provide the following spare parts for the Project.

One of each type of surge arrestor

10 percent spare of each type of fuse used (minimum of 1 spare of each
type of fuse used)

One of each type of 24VDC communication power supply
One of each type of intrinsic safety barrier

One of each type of radio

2.03 SOURCE QUALITY CONTROL

A.

Provide in accordance with Division 01 General Requirements.

PART 3 — EXECUTION

3.01 CONTROL PANEL FABRICATION
A. General
1. The control panels shall include programmable logic controller, required

WOODARD & CURRAN

1/O modules with chassis (if applicable) and power supply, cables, and all
appurtenances as specified in this and all applicable sections. The
enclosures shall include switches, lights, annunciators and _ all
appurtenances as specified in this and all applicable sections. The panels
and miscellaneous materials shall be furnished by one Supplier.

All electronic equipment shall utilize printed circuitry and epoxy or equal
coating to prevent contamination by dust, moisture, and fungus. Solid-
state components shall be conservatively rated for their purpose, to
provide reliable performance over ambient atmosphere fluctuations
between 0 — 140 degrees F and 0 — 95 percent relative humidity, non-

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
40 67 00-7

Project Number: 228730 WWTE SCADA Upgrades
Issue Date: August 2017 Nashua, NH

condensing. The field mounted equipment and system components shall
be designed for installation in dusty, humid, and slightly corrosive service
conditions.

3. Equipment installed in a hazardous area shall meet Class, Group, and
Division to comply with the NFPA 70 and CCR, Title 8, Electrical and
General Safety Orders.

4. All equipment, cabinets, and devices furnished shall be heavy duty type,
designed for continuous industrial service. The PLC system shall contain
products of a single manufacturer, and shall consist of equipment models
which are currently in production.

5. The following paragraphs describe general fabrication requirements of
control panels, enclosures, consoles, and cabinets. All control panel
assemblies shall be UL listed, to comply with UL 508A standards.

6. Control panel enclosures shall be sized to provide at least 20 percent spare
space, for future expansion, addition of panel components, etc. This shall
minimize impact of the addition of unintended equipment during the
checkout and startup phases.

7. PLC hardware provided shall accommodate a minimum 20 percent spare
of each I/O type used in the panel, wired to terminals during the
fabrication process. This shall minimize impact of unintended I/O
requirements added during the checkout and startup phases of the Project.

B. Wiring

1. All interconnecting wiring shall be stranded and shall have 600 volt
insulation and be rated for not less than 90 degrees Celsius.

2. Power distribution wiring on the line side of fuses shall conform to
Division 26 requirements.

3. Power and low voltage DC wiring systems shall be routed in separate
wireways. Crossing of power distribution wiring and control wiring shall
be at right angles. Different system wires routed parallel to each other
shall be separated by at least 6 inches. Different wiring systems shall
terminate on separate terminal blocks. Wiring troughs shall not be filled to
more than 60 percent visible fill.

4. All wiring shall terminate onto single-or-double tier terminal blocks,
where each terminal is uniquely and sequentially numbered. Direct
interlock wiring between equipment is not allowed. The control panel
shall be fabricated with minimum 20 percent spare terminals. Terminal
blocks shall be arranged in vertical rows and separated into groups; power,

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
WOODARD & CURRAN 40 67 00-8

Project Number: 228730 WWTE SCADA Upgrades
Issue Date: August 2017 Nashua, NH

AC control, DC signal. Terminal blocks shall be the compression screw
type. Spring-clamp style terminals will not be accepted.

a. Discrete inputs and outputs (DI and DO) shall have 2 terminals per
point with adjacent terminal assignments. All active and spare
points shall be wired to terminal blocks.

b. Analog inputs/outputs (AI and AO) shall have a minimum of three
3 terminals per shielded pair. Three terminals shall be provided for
direct connection of powered, 4-wire loops. Four terminals shall be
provided for direct connection of loop powered, 2-wire loops. Five
terminals shall be provided for connection of analog loops
incorporating a local indicator or recorder. One terminal is for
shielded ground connections for cable pairs. Ground the shielded
signal cable at the PLC cabinet. All active and spare points shall be
wired to terminal blocks.

Wire and tube markers shall conform to Division 26 requirements.

d. Only one side of a terminal block row shall be used for internal
wiring. The field wiring side of the terminal shall not be within
6-inches of the side panel or adjacent terminal, or within 8-inches
of the bottom of the panel.

e. Whenever possible, the terminals for field wiring shall be located
to reduce the amount of routing through wireway necessary to
carry the field wiring to the termination point.

5. All wiring, internal to the panel and field wiring, shall be provided with a
service loop to allow for adjustment of the termination point in the future.
The service loop shall be no more than 4-5 inches, and shall be stored in
the associated wireway.

6. All wiring to hand switches, etc., which are live circuits independent of
the panel's normal circuit breaker protection, shall be clearly identified as
such.

7. All wiring shall be clearly tagged and color-coded in accordance with the

National Electric Code (NEC). All tag numbers and color-coding shall
correspond to the panel wiring diagrams prepared by the Engineer. All
power wiring, control wiring, grounding, and DC wiring shall utilize
different color insulation for each wiring system used. The color coding
scheme shall be:

a. Incoming 120 VAC Hot — Black
b. 120 VAC Hot Wiring (downstream of panel circuit breaker) — Red
120 VAC Neutral — White

a 0

Ground — Green

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
WOODARD & CURRAN 40 67 00-9

Project Number: 228730 WWTE SCADA Upgrades
Issue Date: August 2017 Nashua, NH

e. DC Wiring — Blue
f. Intrinsically Safe Wiring - Light Blue
g. Foreign Voltage — Yellow
C. Control Panel Loss of Power
1. Each control panel containing a PLC shall have an input configured to
alarm the operators upon loss of main control panel power. This alarm

shall be displayed on the SCADA nodes to alert the operators that
attention is required.

2. Each control panel containing a backup PLC shall have an input
configured in the main PLC to alarm the operators upon loss of backup
PLC power. This alarm shall be displayed on the SCADA nodes to alert
the operators that attention is required.

D. Control Panel Overcurrent Protection

1. All overcurrent protection devices shall be properly sized to protect the
devices and the loads to which they are associated.

2. Circuit Breakers
a. Circuit breakers in the panel shall be sized to protect the associated
equipment, and to provide the necessary power to operate.
3. Fuses
a. Glass fuses not associated with motor circuit protection shall be

specified as fast-acting style unless otherwise directed in the
manufacturer’s literature. Fuses associated with motor circuit
protection shall be specified as time delay style.

E. Lightning/Surge Suppression

1. Lightning/surge suppression shall be provided to protect the control panel
and associated equipment from surges on the incoming power circuits, or
those induced by lightning strikes and propagated along the signal or
power lines connected to the control panels. Surge protection shall be
provided by a qualified manufacturer complying with requirements in
Article 1.04. Surge protection shall be sized properly for its intended
purpose.

2. 120VAC surge suppression

a. The incoming 120VAC power source for the control panel shall be
provided with surge suppression in the control panel. Surge
suppressors shall be provided with an auxiliary contact, connected
to the PLC to indicate surge suppressor failure. Install surge

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
WOODARD & CURRAN 40 67 00-10

Project Number: 228730
Issue Date: August 2017

WWTE SCADA Upgrades
Nashua, NH

suppression in strict accordance with manufacturer’s
recommendations.

3. Analog signal surge suppression

a.

Analog signals connected to equipment or instrumentation that is
located outside the building where the control panel is installed
shall be supplied with German Institute for Standardization
(DIN) rail mounted surge suppression in the control panel. Provide
surge protection at both ends of the signal cable and mount surge
protection as close to the equipment, instrument, or termination
point as possible. Provide with a minimum of 10kA surge current
suppression.

4. Telephone Line and Ethernet surge suppression

a.

Copper-based telephone lines and Ethernet cabling connected to
the control panel that leaves the building where the control panel is
installed shall be provided with surge suppression in the control
panel. Provide surge protection at both ends of the telephone or
Ethernet cabling and mount surge protection as close to the
termination point as possible.

F. Selector Switches, Pushbuttons and Pilot Lights

1. All selector switches, pushbuttons, and pilot lights required for the
enclosures shall be provided in accordance with Section 26 27 26, Wiring
Devices and Miscellaneous Electrical Equipment.

G. Uninterruptible Power Supplies

1. Each control panel containing a PLC shall be provided with an
uninterruptible power supply (UPS) sized to provide a minimum of
10 minutes of power in the event of main control power loss. The UPS
shall be provided with relay contact outputs, connected to the PLC, to
indicate UPS fault and UPS low battery conditions.

H. Ethernet Switches

1. Ethernet switches shall be configured to accept the number of connections
shown on the Drawings.

2. Ethernet switches shall be provided with a minimum of 20 percent spare
RJ-45 ports available for future expansion.

WOODARD & CURRAN

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
40 67 00-11

Project Number: 228730 WWTE SCADA Upgrades

Issue Date: August 2017 Nashua, NH
I. Seal Fail and Motor Temperature Relays
1. Pumps, or mixers, equipped with proprietary seal fail and motor

temperature relays, shall require these relays to be mounted in the SCADA
control panel unless otherwise noted in the Drawings. The seal fail and
motor over temperature alarm contacts shall be connected to the PLC as
discrete inputs.

J. Intrinsic Safety Barrier Panels

1. Intrinsic safety barriers required for interfacing with equipment and
instruments located in a classified area shall be mounted in a panel
separate from the control panels.

2. Panels housing intrinsic safety barriers shall be laid out to facilitate
separation of hazardous and non-hazardous wiring. Wireway containing
hazardous area wiring shall be clearly indicated as such.

K. Equipment Mounting/Arrangement

1. All components shall be mounted in a manner that permits servicing,
adjustment, testing and removal without disconnecting, moving or
removing any other component. Components mounted on the inside of
panels shall be mounted on removable plates and not directly to the
enclosure. Mounting shall be rigid and stable unless shock mounting 1s
required by the manufacturer to protect equipment from vibration.
Components shall be identified with suitable plastic or metal engraved
tags attached with drive pins adjacent to each component, identifying the
component in accordance with the Drawings and Specifications.

2. All exterior panel mounted equipment shall be installed with suitable
gaskets, faceplates, or covers required to maintain the NEMA rating of the
panel.

3. A minimum of 1-1/2 inches shall be provided between panel wireway and

terminal blocks, to insure that wiring can be accessed easily.

4. Maintain manufacturer recommended spacing around panel-mounted
equipment, for heating and ventilation concerns.

5. ISA Recommended Practice RP60.3 shall be used as a guide in layout and
arrangement of panels and panel mounted components.

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
WOODARD & CURRAN 40 67 00-12

Project Number: 228730 WWTE SCADA Upgrades

Issue Date: August 2017 Nashua, NH
L. Nameplates
1. All panels and panel devices shall be supplied with suitable nameplates

that identify the panel and individual devices as required. Each device
nameplate shall include up to 3 lines, with the first line containing the
device tag number as shown on the Drawings, the second line containing a
functional description, and the third line containing a functional control
description.

2. Unless escutcheon plates are specified or unless otherwise noted on the
Drawings, nameplates shall be 3/32-inch thick, black and white, Lamacoid
with engraved inscriptions. The letters shall be black against a white
background. Edges of the nameplates shall be beveled and smooth.
Nameplates with chipped or rough edges will not be acceptable.
Nameplates shall be affixed to the panels using #4-40 threaded stainless
steel button head hex screws.

3.02 CONTROL PANEL QUALITY ASSURANCE

A.

Panel Shop shall, upon fabrication of the control panels, apply power to each
panel to ensure that panels are wired correctly, and all devices contained within
the panels power up properly. Panel Shop shall provide written confirmation to
the Engineer that a power up test was completed.

Panel Shop shall complete a point-to-point wiring checkout for all wiring
contained in the control panels, and correct any errors or omissions found during
that process. Panel Shop shall provide written confirmation to the Engineer that
checkout was completed.

Panel Shop shall provide advance notice to the Engineer that control panel
fabrication is complete, and shall make the control panels available in their
facility for completion of the Factory Acceptance Test by the Engineer or System
Integrator. Panel Shop shall not ship control panels prior to execution of the
Factory Acceptance Test, unless indicated in writing by the Engineer.

3.03 INSTALLATION AND MOUNTING

A.

Provide all labor, tools, material, and equipment required to mount the SCADA
Panel, Intrinsic Barrier Panel, and/or other panel(s) in the locations shown on the
Drawings, in accordance to manufacturer-recommended mounting practices. The
location of panels shown on the Drawings is approximate only. Exact location
shall be as approved by the Owner or Engineer during construction. Obtain in the
field all information relevant to the placing of process control Work and in case of
any interference with other Work, proceed as requested by the Engineer.

All control panels shall be powered up upon installation, and all field wiring shall
be tested for proper termination. All analog signals shall be simulated for a
full-scale 4-20ma test.

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS

WOODARD & CURRAN 40 67 00-13

Project Number: 228730 WWTE SCADA Upgrades
Issue Date: August 2017 Nashua, NH

3.04 FIELD QUALITY CONTROL
A. Provide in accordance with Division 01 General Requirements.

3.05 STARTUP & COMMISSIONING

A. Provide all labor, tools, materials, personnel, and equipment necessary to assist in
the startup and testing of the SCADA system with the Integrator after installation
of control panels and instruments, and termination of field wiring to panels is
complete. Start up and testing shall be witnessed by the Owner and/or Engineer.

3.06 CLOSEOUT ACTIVITIES

A. Provide in accordance with Division 01 General Requirements.

END OF SECTION

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
WOODARD & CURRAN 40 67 00-14

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