Appendix A: I&C Design Specifications And Examples

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Chapter 10 Instrumentation and Controls (SCADA)APPENDIX 10AI&C Design Specifications and ExamplesThe following specification are examples only. They are presented in Construction SpecificationsInstitute (CSI) MasterFormat (MF04). Revise, add, or delete these specifications based onproject-specific needs:These specifications have not been reviewed or approved for wide use. They are provided asinformational only. The design engineer may use this, but it should be thoroughly checked. 40 90 00 Instrumentation for Process Control 40 90 00A Loop Check-out Sheet 40 90 00B Instrument Certification Sheet 40 90 00C Final Control Element Certification Sheet 40 90 05 Control Loop Descriptions 40 91 10 Primary Elements and Transmitters 40 94 43 Programmable Automation Controller Control System 40 97 00 Control Auxiliaries 40 98 00 Control Panels and Enclosures 40 99 00 Surge Protection Devices for Instrumentation and Control EquipmentSPU Design Standards and GuidelinesDecember 2020i

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 2 of 121SPECIFICATION SECTION 40 90 00INSTRUMENTATION FOR PROCESS CONTROL: BASIC REQUIREMENTSPART 1 - GENERAL1.01SUMMARYA.Specification Section Includes:1.B.Basic requirements for complete instrumentation system for process control.Related Specification Sections include but are not necessarily limited to:1.CSC Parts 1, 2, 3, 4, and 6.2.Division 10 - Specialties.3.Division 26 - Electrical.4.Specification Section 26 05 00 - Electrical: Basic Requirements.5.Specification Section 26 05 16 - Wire and Cable: 600 Volt and Below.6.Specification Section 40 91 10 - Primary Elements and Transmitters.7.Specification Section 40 97 00 - Control Auxiliaries.8.Specification Section 40 98 00 - Control Panels and Enclosures.9.Specification Section 40 99 00 - Surge Protection Devices (SPD) for Instrumentationand Control Equipment.10.Specification Section 46 46 13 - Tipping Buckets.1.02QUALITY ASSURANCEA.Referenced Standards:1.Canadian Standards Association (CSA).2.FM Global (FM).3.The Instrumentation, Systems, and Automation Society (ISA):4.a.S5.1, Instrumentation Symbols and Identification.b.S5.3, Graphic Symbols for Distributed Control/Shared Display Instrumentation,Logic and Computer Systems.c.S5.4, Standard Instrument Loop Diagrams.d.S20, Standard Specification Forms for Process Measurement and ControlInstruments, Primary Elements and Control Valves.National Electrical Manufacturers Association (NEMA):a.250, Enclosures for Electrical Equipment (1000 Volts Maximum).

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.5.National Fire Protection Association (NFPA):a.National Institute of Standards and Technology (NIST).7.Underwriters Laboratories, Inc. (UL):a.913, Standard for Safety, Intrinsically Safe Apparatus and Associated Apparatusfor Use in Class I, II, and III, Division 1, Hazardous (Classified) Locations.b.508A, Industrial Control Panels.Seattle Public Utilities:a.B.70, National Electrical Code (NEC).6.8.SPU Design Guidelines & Standards, Section 10 – Instrumentation and Control,SCADA.Qualifications:1.Instrumentation subcontractor:a.Experience:1)C.Page 3 of 121Have satisfactorily provided and installed instrumentation for processcontrol systems for a minimum of five (5) projects of similar magnitudeand function.Miscellaneous:1.Comply with electrical classifications and NEMA enclosure types shown on Drawings anddefined in the Specification Sections.2.Equipment and installation in hazardous areas shall be suitable for installation and usein hazardous areas.1.03DEFINITIONSA.Hazardous Areas: Class I, II or III areas as defined in NFPA 70.B.Highly Corrosive and Corrosive Areas: Rooms or areas identified on the Drawings orSpecifications where there is a varying degree of spillage or splashing of corrosive materials suchas water, wastewater or chemical solutions; or chronic exposure to corrosive, caustic or acidicagents, chemicals, chemical fumes or chemical mixtures.C.Outdoor Area: Exterior locations where the equipment is normally exposed to the weather andincluding below grade structures, such as vaults, manholes, handholes and in-ground pumpstations.D.Intrinsically Safe Circuit: A circuit in which any spark or thermal effect is incapable of causingignition of a mixture of flammable or combustible material in air under test conditions asprescribed in UL 913.E.Calibrate: To standardize a device so that it provides a specified response to known inputs.

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.1.04SYSTEM DESCRIPTIONA.Control System Requirements:Page 4 of 1211.The instrumentation system consists of all primary elements, transmitters, switches,controllers, indicators, panels, signal converters, power supplies, special or shieldedcable, special grounding or isolation, auxiliaries, wiring, and other devices required toprovide complete control of the facility as specified in the Contract Documents.2.Application software for programmable automation controllers, Human MachineInterface, and Operator Interface Unit will be provided, configured, and programmed bythe Owner.B.All signals shall be directly linearly proportional to measured variable unless specifically notedotherwise.C.Single Instrumentation Subcontractor:1.Furnish and coordinate instrumentation system through a single instrumentationsubcontractor:a.The instrumentation subcontractor shall be responsible for functionaloperations of all field control systems, supervision of installation, finalconnections, calibrations, preparation of Drawings, testing procedures andOperation and Maintenance Manuals, training, demonstration of substantialcompletion and all other aspects of the instrumentation system, except forthose aspects specifically provided by others.2.Coordinate instrumentation with other work to ensure that necessary wiring, conduits,contacts, relays, converters, and incidentals are provided in order to transmit, receive,and control necessary signals to other control elements, and the Owner’s existingSCADA system.3.Provide testing, commissioning, and troubleshooting support for Owner’s programmerup to 24 hours. Additional hours may be requested by the Owner and will be funded ona time and materials basis.D.See Specification Section 46 46 13 - Tipping Buckets for the proximity switches and otherequipment associated with the tipping buckets that are being supplied by the tipping bucketsupplier. Coordination between the tipping bucket supplier and control system supplier isrequired; see Specification Section 46 46 13 - Tipping Buckets for requirements confirmingcoordination through co-signature. Receive intrinsic safety devices from tipping bucket supplierand install in Main Control Panel. Provide intrinsic safety ground. Install as required and persupplier recommendations for complete, fully-functional, code-compliant installation.E.See Specification Section 23 31 00 - HVAC: Ductwork for the sail-type flow switches associatedwith the HVAC supply and exhaust fans; coordinate provision and interface.

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.1.05SUBMITTALSA.Shop Drawings:Page 5 of 1211.See CSC Part 3.1 for requirements for the submittal process.2.Submittals shall be original printed material or clear unblemished photocopies oforiginal printed material:3.a.Facsimile information is not acceptable.b.In addition to printed copies, provide an electronic copy of submittals in PDFformat.Limit the scope of each submittal to one (1) Specification Section:a.Each submittal must be submitted under the Specification Section containingrequirements of submittal contents.b.Do not provide any submittals for Specification Section 40 90 00 Instrumentation for Process Control: Basic Requirements.4.Documentation of instrumentation subcontractor qualifications and experience asdefined above.5.Product technical data including:a.Equipment catalog cut sheets.b.Instrument data sheets:1)ISA S20 or approved equal.2)Separate data sheet for each instrument.c.Materials of construction.d.Minimum and maximum ranges, calibration information (in engineering units oras otherwise noted).e.Physical limits of components including temperature and pressure limits.f.Size and weight.g.Electrical power requirements and wiring diagrams.h.NEMA rating of housings.i.Submittals shall be marked with arrows to show exact features to be provided.Features and options not being provided shall be crossed out.6.Loop diagrams per ISA S5.4 as specified in Specification Section 40 98 00 - ControlPanels and Enclosures.7.Comprehensive set of wiring diagrams as specified in Specification Section40 98 00 - Control Panels and Enclosures.8.Panel fabrication drawings as specified in Specification Section 40 98 00 - ControlPanels and Enclosures.9.PAC equipment drawings.

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.10.Nameplate layout drawings.11.Engraving and escutcheon lettering legends.12.Drawings, systems, and other elements are represented schematically in accordancewith ISA S5.1 and ISA S5.3:a.The nomenclature, tag numbers, equipment numbers, panel numbers, andrelated series identification contained in the Contract Documents shall beemployed throughout submittals.13.All Shop Drawings shall be modified with as-built information/corrections.14.All panel and wiring drawings shall be provided in both hardcopy and softcopy:a.Furnish electronic files on CD-ROM or DVD-ROM media.b.Drawings in AUTO CAD and PDF format.15.Provide a parameter setting summary sheet for each field configurable device.16.Certifications:a.Documentation verifying that calibration equipment is certified with NISTtraceability.b.Approvals from independent testing laboratories or approval agencies, such asUL, FM or CSA:1)17.B.Page 6 of 121Certification documentation is required for all equipment for which thespecifications require independent agency approval.Testing reports: Source quality control reports.Operation and Maintenance Manuals:1.See CSC Part 3.1 for requirements for the submittal process:a.2.The mechanics and administration of the submittal process.See CSC Part 3.1 for the content of the Project Operation and Maintenance Manual.1.06SITE CONDITIONSA.See Material Application Schedule in Specification Section 26 05 00 - Electrical: BasicRequirements and Area Environmental Designation and Classification Schedule on DrawingSheet 156 for required types and materials.PART 2 - PRODUCTS2.01NEMA TYPE REQUIREMENTSA.See Material Application Schedule in Specification Section 26 05 00 - Electrical: BasicRequirements and Area Environmental Designation and Classification Schedule on DrawingSheet 156 for required types and materials.B.Provide enclosures/housing for control system components in accordance with MaterialApplication Schedule in Specification Section 26 05 00 - Electrical: Basic Requirements andArea Environmental Designation and Classification Schedule on Drawing Sheet 156.

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.1.Areas designated as Class I hazardous, Groups A, B, C, or D as defined in NFPA 70:a.NEMA Type 7 unless all electrical components within enclosure or componentutilizes intrinsically safe circuitry:1)Utilize intrinsically safe circuits to the maximum extent practical and asdepicted in the Contract Documents.2.Inside control cabinet: NEMA Type 12.3.Areas designated to be subject to temporary submersion: NEMA 6P or 7.2.02PERFORMANCE AND DESIGN REQUIREMENTSA.Instrumentation Performance Criteria:1.Page 7 of 121Performance: All instruments and control devices shall perform in accordance withmanufacturer's specifications.2.03ACCESSORIESA.Provide identification devices for instrumentation system components in accordance withSpecification Section 10 14 00 - Identification Devices.B.Provide corrosion resistant spacers to maintain 1/4-IN separation between equipment andmounting surface in wet areas, on below grade walls and on walls of liquid containment.PART 3 - EXECUTION3.01DELIVERY, STORAGE, AND HANDLINGA.Do not remove shipping blocks, plugs, caps, and desiccant dryers installed to protect theinstrumentation during shipment until the instruments are installed and permanent connectionsare made.3.02INSTALLATIONA.Wherever feasible, use bottom entry for all conduit entry to instruments and junction boxes.Provide weep holes in conduits where necessary to prevent liquid buildup.B.Install electrical components per Division 26.C.Panel-Mounted Instruments:1.Mount and wire so removal or replacement may be accomplished without interruptionof service to adjacent devices.2.Locate all devices mounted inside enclosures so terminals and adjustment devices arereadily accessible without use of special tools and with terminal markings clearly visible.D.See Specification Section 26 05 16 - Wire and Cable: 600 Volt and Below.3.03FIELD QUALITY CONTROLA.Maintain accurate daily log of all startup activities, calibration functions, and final setpointadjustments:1.Documentation requirements include the utilization of the forms located immediatelyfollowing the end of this Specification Section:

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.B.a.Loop Check-out Sheet.b.Instrument Certification Sheet.c.Final Control Element Certification Sheet.Instrumentation Calibration:1.Verify that all instruments and control devices are calibrated to provide theperformance required by the Contract Documents.2.Calibrate all field-mounted instruments after the device is mounted in place to assureproper installed operation.3.Calibrate in accordance with the manufacturer's specifications.4.Check the calibration of each transmitter and gage across its specified range at 0, 25, 50,75, and 100 percent:a.Check for both increasing and decreasing input signals to detect and documentany hysteresis.5.Replace any instrument which cannot be properly adjusted or calibrated.6.Stroke control valves to verify control action, feedback, and positioner settings.7.Calibration equipment shall be certified by an independent agency with traceability toNIST:8.C.Page 8 of 121a.Certification shall be certified within one (1) year of the date of use.b.Use of equipment with expired certifications shall not be permitted.Calibration equipment shall be at least three (3) times more accurate as the devicebeing calibrated.Loop check-out requirements are as follows:1.Check control signal generation, transmission, reception and response for all controlloops under simulated operating conditions by imposing a signal on the loop at theinstrument connections:a.Use actual signals where available.b.Closely observe controllers, indicators, transmitters, displays, alarm and tripunits, and other control components:1)Verify that readings at all loop components are in agreement.2)Make corrections as required:a)Following any corrections, retest the loop as before.2.Stroke all control valves, from the local control station and from the local operatorinterface.3.Check all interlocks to the maximum extent possible.4.In addition to any other as-recorded documents, record all calibration changes on allaffected Contract Documents and turn over to the Owner.

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 9 of 121D.Provide verification of system assembly, power, ground, and I/O tests.E.Verify existence and measure adequacy of all grounds required for instrumentation andcontrols.F.Perform Start-up and Training as defined in this Section and other Sections:1.See Specification Section - 40 98 00 - Control Panels and Enclosures for description ofcontrol cabinet testing requirements, which includes many tests for the completesystem.END OF SPECIFICATION SECTION 40 90 00

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 10 of 121Loop Check-out SheetCity of SeattleSeattle Public UtilitiesProject Name:Project Location:PageProject Owner:Regulatory Agency Project No. (if applicable):Project No.:Date:ofLEAK AND TERMINATION/CONTINUITY CHECKSFIELDDESCRIPTIONCONTROL CABLEAK CHECK(1)Device TagNo.ProcessConn.TERM/CONT CHECK(2)Signal TubeDevice TagNo.TerminationIdent.TERM/CONT CHECK(2)Device Tag No.TerminationIdent.1. Leak check for pneumatic signal tubing to be per ISA-PR7.1.2. Termination/continuity check includes check at terminated equipment for: (a) correct polarity, (b) appropriate signal generation, transmission and reception, and (c)correct shield & ground terminations.OPERATOR INTERFACE CHECK-OUTMONITORING POINTS OBSERVEDPARAMETER TYPETAG NO.TAG NO.TAG NO.TAG NO.TAG NO.TAG NO.TAG NO.LOCATIONPROCESS VAREQUIP STATUSALARM POINTOPERATOR CONTROL FUNCTIONS CHECKEDFUNCTION TYPETAG NO.LOCATIONTAG NO.LOCATIONAS LEFT SETTINGSTAG NO.SWITCH & ALARM SPCONTROLLERSGainReset, rpmDeriv. (rate), minPV Set PointDescribe all interlocks checked, equipment started/stopped, valves/operators stroked. Describe modes of operation checked, and location of operator interface(local/remote).

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 11 of 121I certify that the control loop referenced on this page has been completely checked and functions in accordance with applicabledrawings and specifications.Certified by:(Work Performed By)Witnessed by:Date:Date:

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 12 of 121Instrument Certification SheetCity of SeattleSeattle Public UtilitiesProject Name:Project No::Project Owner:Regulatory Agency Project No. (if applicable):Project No:Date:Control Loop No.:Instrument Tag No.Transmitter/gauge span:Manufacturer:Switch set-point:Model No.Switch dead band:Serial No.Switch range:TRANSMITTERS AND INDICATORSINCREASING INPUT% OF SPANINPUTOUTPUTDECREASING INPUTERROR(% of span)INPUTOUTPUTERROR(% of span)0%25%50%75%100%Other (if applicable)Other (if applicable)SWITCHESINCREASING INPUTACTUATION POINTINPUTOUTPUTHigh (Increasing input)Low (Decreasing input)Maximum allowable error (per Contract Documents):Remarks:ERROR(% of range)DECREASING INPUTINPUTOUTPUTERROR(% of range)

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 13 of 121CALIBRATION EQUIPMENT UTILIZEDDEVICE TYPEMFR/MODEL NO.ACCURACYNIST TRACEABILITY?Certified by:Date Certified:Witnessed by:Date:

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 14 of 121Final Control ElementCertification SheetCity of SeattleSeattle Public UtilitiesProject Name:Project:Project Owner:Regulatory Agency Project No. (if applicable):Project No.Date:Control LoopNo :Actuator:Pneumatic: Electric:Tag Manufacturer:I/P Converter:Input:Model No.Valve toon air failureSerial No.Valve toon power failureReverse:Output:Output:I/P CONVERTERINCREASING INPUT% OF SPANINPUTDECREASING INPUTERROR(% of span)OUTPUTINPUTOUTPUTERROR(% of span)0%25%50%75%100%Specified I/P converter accuracy:% of span.FINAL CONTROL ELEMENTINCREASING INPUT% OF SPAN0%25%50%75%100%Remarks:INPUTTRAVELDECREASING INPUTERROR(% of full travel)INPUTTRAVELERROR(% of full travel)

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 15 of 121CALIBRATION EQUIPMENT UTILIZEDDEVICE TYPEMFR/MODEL NO.ACCURACYNIST TRACEABILITY?Certified by:Date Certified:Witnessed by:Date:

INSTRUMENTATION FOR PROCESS CONTROL:BASIC REQUIREMENTSError! Unknown document property name.Page 16 of 121SPECIFICATION SECTION 40 90 05CONTROL LOOP DESCRIPTIONSPART 1 - GENERAL1.01SUMMARYA.Specification Section Includes:B.1.Instrumentation control loops.2.The intent of including this specification section is to describe how the site willoper

Specification Section 26 05 16 - Wire and Cable: 600 Volt and Below. 6. Specification Section 40 91 10 - Primary Elements and Transmitters. 7. Specification Section 40 97 00 - Control Auxiliaries. 8. Specification Section 40 98 00 - Control Panels and Enclosures. 9. Specification Section 40 99 00 - Surge Protection Devices (SPD) for Instrumentation

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