Boiler Controls Controls... · Web viewGENERAL SCOPE OF WORK The control system provider shall design, supply, deliver, calibrate, checkout, startup, and place into operation an instrumentation

Boiler Control System Guide Specification

1. GENERAL

1.1. SCOPE OF WORK

1.1.1. The control system provider shall design, supply, deliver, calibrate, checkout, startup, and place into operation an instrumentation and control system including all materials and equipment in accordance with these specifications. The control system provider shall include operator training, operation & maintenance manuals (consisting of sequence of operation, factory acceptance test reports, field test reports, instrument configuration sheets, and load test reports), as-built drawings and other functions as necessary to make the package complete and ready to operate.

1.1.2. The work and material listed below is intended as a guide to assist the control system provider in developing and defining the total work and material requirements for a complete and functional system. The bid package submitted by the control system provider shall be based on a completely functional system, which shall include ALL elements of the specifications.

a) Boiler Control Panel with Operator Interface Station (OIS) and other devices as listed in the specifications per boiler

b) Plant Master Control Panel with Operator Interface Station (OIS) and devices as listed in the specifications

c) Plant Monitoring SCADA PC based system as listed in the specificationd) All field devices as specifiede) Field configure all new field instruments and final control elementsf) All Panels, OIS units, and PC hardware shall have and be connected with

Ethernet communicationsg) At the Owner’s option, a Factory Acceptance Test shall be conducted at the

control system provider’s shop to exhibit, display, review and discuss the testing, debugging and operational status of all panels. All panels shall be fully factory tested prior to shipment to site

h) All necessary hardware, software, and programming for control systems, OIS units and PC systems specified are to be included

1.2. STANDARDS

1.2.1. NFPA 85 for Boiler and Combustion Systems Hazards Codes.1.2.2. UL508A, Underwriters Laboratories, Inc.1.2.3. NEMA, National Electric Manufacturers Association.1.2.4. All materials and equipment installed as part of this trade section shall be listed by

Underwriters Laboratories, Inc. (UL) and shall bear the UL inspection label and shall also meet ISA, NEC, ANSI and EPA standards.

1.2.5. National Electrical Code (NEC).1.2.6. Factory Mutual (FM)1.2.7. The most rigid requirements will apply when there are differences between the

standards and codes.

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1.3. DRAWINGS AND SUBMITTALS

The control system provider shall submit as a minimum, the following drawings and reference data:

1.3.1. Drawing/Detail

a) Equipment lists and bills of materialb) Equipment Specifications, sizing criteria and dimensional data along with

installation detailsc) P&ID drawings with device tag namesd) Panel drawingse) Panel Internal wiring diagramsf) Panel external equipment wiring diagramsg) Local area Network layout diagram showing all communication paths.h) Written description of the sequence of operation.

1.3.2. The “Equipment and Installation Details” submitted shall include, as a minimum, all instrument specifications, data sheets, detailed dimension drawings, and mounting/installation details.

1.3.3. All “Panel and Wiring Drawings” shall be formatted and provided in AutoCAD 2014 or other pre-approved version number.

1.3.4. The “Equipment Lists and Bills of Material” shall be submitted for each panel, as well as for all field devices. Common lists are not acceptable.

1.3.5. Instruments and electrical plan drawings showing conduits size, plan layout, wire numbers, number of wires in each conduits, location of instruments and all wiring shall be provided for each panel and/or system.

1.3.6. Provide detail design and equipment configuration including but not limited to controller programming, OIS Programming and PC programming. Provide all documentation in electronic format CD ROM, for all programming and Logic files.

1.3.7. The control system provider shall provide onsite training for operating personnel.

The course shall include the classroom training, which covers overall configuration of system including location and interconnection of equipment and function of equipment. Courses shall include hands on training of boiler startup and shutdown procedures. OIS training shall be comprehensive and include review of all graphic representations for system, Controller Faceplate explanation, Setpoint and Mode changes, interaction between loops description, data trending, alarm management and overall system operation. A training syllabus shall be submitted for review and approval prior to training commencing.

1.3.8. At project closeout, the controls provider shall provide all “As-Built” documentation to include drawings, instrument configuration sheets, O&M manuals for all supplied equipment, Sequence of Operation for all supplied equipment and Warranty Statements. All information shall be bound within a set of three-ring



binders properly labeled with the project number, client’s name and address, plant location (if different) and supplier’s contact information.

1.4. CONTROL SYSTEM PROVIDER:

Boiler Control system provider shall be as listed below:

1.4.1. The firm selected for the Boiler Control system provider portion of the project must demonstrate that they have a minimum of twenty years of documented project experience in the Engineering, Procurement and Construction of Boiler Control Systems.

1.4.2. The firms’ business must specialize in Boiler Control Systems projects and satisfactorily demonstrate that they have completed a minimum of twenty of these projects.

1.4.3. The successful firm must have their own engineering staff consisting of controls, software, combustion, and electrical engineers.

1.4.4. The firm will have an in-house start up specialist for all systems, an electrical controls specialist and a training specialist on staff for post start up training of the facility employees.

1.4.5. The firm will be a Rockwell Recognized Systems Integrator

1.4.6. The firm will utilize Microsoft Project software for the project scheduling and AutoCAD 2014 or later for the drawings.

1.4.7. The firm must have a national presence and be capable of providing the facility with a service contract if requested.

1.4.8. The firm must be capable of providing a two year warranty on all systems if requested.

1.4.9. Minimum of 10 years experience in designing and manufacturing these control systems required. A minimum of 200 burner and combustion control units installed in the industry

1.4.10. The manufacturer of the control system must have system start-up technicians on staff and be able to provide the owners engineer with names and contact information prior to bidding the project

1.4.11. The system shall be completely configured from the factory.



2. PRODUCTS AND SYSTEMS

2.1. GENERAL

2.1.1. Design Criteria

a) Each boiler shall have an individual, locally mounted Boiler Control Panel.b) The Ancillary equipment (Balance of Plant) shall have a single Control Panel

(Plant Master Panel) to accommodate control requirements as described below.

c) An overall Energy Center Supervisory Control And Data Acquisition (SCADA) package shall be included to centralize all data and monitoring.

d) All devices and safety controls shall conform to all national, state or local code requirements in effect for fuel type(s) being fired.

e) The system shall be capable of bumpless, balanceless transfer between automatic and manual control and anti-reset windup.

2.2. DESIGN DETAILS

2.2.1. Design, material selection, and workmanship shall be such as to result in a neat appearance outside and inside, with no welds, rivets, or bolts apparent from the front faces of the panels and with all exterior surfaces true and smooth. No equipment shall be attached by rivets.

2.2.2. The control system provider shall be responsible for the proper physical and electrical clearances between components.

2.2.3. All fastening devices shall be corrosion resistant.

2.3. EQUIPMENT

2.3.1. All devices mounted on vertical surfaces shall be of a type suitable for such mounting and shall be calibrated for proper operation when so mounted.

2.3.2. Each device shall be so mounted and wired that removal and replacement may be accomplished without interruption of service to adjacent devices. All devices mounted inside the panel structure shall be so located that terminals and adjustment devices are readily accessible without use of special tools and with terminal markings clearly visible.

2.3.3. Wiring shall be so arranged that instruments or devices may be removed and serviced without unduly disturbing the wiring. No wire shall be routed across the face or rear of an instrument or other device, which will prevent the opening of a cover or obstruct access to leads, terminals, devices, or instruments.

2.4. BOILER CONTROL SYSTEMS

2.4.1. The Boiler Control System shall be designed as a fully metered, cross-limited system for a forced draft, dual fuel (natural gas and fuel oil) boiler. All necessary



controls shall be furnished to comply with NFPA 85 “Boiler and Combustion Systems Hazards Code”, and ASME CSD-1 “Controls and Safety Devices for Automatically Fired Boilers”. Flow measurements and individual actuators with position feedback as required shall be included. The Boiler Control System shall provide the following control functions:

a) Boiler Masterb) Air Flow Control c) Oxygen Trim Control (if required)d) Fuel Flow Control w/ dual fuel capabilitye) Water Level Controlf) Flue Gas Recirculation (FGR) (if required)g) Stack Draft control (if required)

The boiler master is a manual bias station, which provides the firing rate for the boiler based on the plant header pressure or temperature. The air and fuel will be independently controlled with individual actuators per element. Combustion air will be further adjusted by utilization of an Oxygen Trim Control. Drum or water level control shall be two (2) element.

2.4.2. The Burner Management System (BMS) functions shall be provided via a Fireye BurnerLogix controller. The flame scanner shall be Infrared or Self-checking Ultraviolet as required by the burner manufacturer.

2.4.3. The Combustion Control System (CCS) functions shall be provided via a Programmable Logic Controller (PLC) as manufactured by Allen-Bradley; CompactLogix. The PLC shall have Ethernet Communications.

2.4.4. Controllers shall be panel mounted. Field I/O’s shall be accessed from the termination strips. The controllers shall have the ability to accept both analog and discrete inputs and provide both analog and isolated discrete outputs. No direct wiring to I/O modules from field or panel devices is acceptable; intermediate panel terminals are required.

2.4.5. Each controller microprocessor shall utilize a nonvolatile memory and provide the ability to implement the required functions of the control system.

2.4.6. This Boiler Control System will include fully adjustable pre-purge and post purge times.

2.4.7. The Operator Interface System (OIS) screen shall be a 10.4” color Allen Bradley PanelView Plus 1000 with touch screen and Factory Talk View software. The PanelView shall be mounted on the panel door. Ethernet communications to PLC is required.

2.4.8. Ethernet communications is required between all controllers, programming ports, OIS units and PC Systems or as approved by the Owner. A panel mount (DIN rail) Ethernet 5-port Switch (as a minimum) is required. All cabling between devices and the switch are to be provided and neatly routed within the panel.



2.4.9. If a controller or OIS is disconnected from the communications link, the rest of the communications shall continue uninterrupted. The disconnected controller shall still continue uninterrupted. The disconnected controller shall still continue control functions independently with the last input control adjustments and configuration accessible from the local data entry panel.

2.5. BOILER CONTROL PANELS / ENCLOSURES

2.5.1. All control enclosures shall carry a NEMA 12 rating as a minimum and comply with UL-508A requirements. All control wiring shall be grounded.

2.5.2. The panel shall be designed for 120VAC, 60 Hz supply.

2.5.3. Terminal strips shall be installed within the control panels to accommodate all field wiring, including shields, and internal panel wiring. All internal wiring shall be completed prior to shipment so that factory checkout can be completed.

2.5.4. Terminal strips shall be numbered to correspond with the numbers on the control diagrams and all wires within the panel shall be identified with one-piece markers.

2.5.5. All I/O boards shall be wired to field terminal. Fused terminals shall be provided for all outputs.

2.5.6. A panel mount (DIN rail) Ethernet 5-port Switch (as a minimum) is required.

2.5.7. Analog and 24DC wiring shall be run separately from AC wiring. Analog wiring shall be shielded twisted pairs with drain wire. Field terminals shall be provided for drain wire. Shield and drain wire shall be contiguous from analog board to field terminal.

2.5.8. Relays shall be Allen-Bradley, Potter Brumfield or equal. Relays shall be provided with indicator light and suppressor.

2.5.9. A hardwired Master Fuel Trip (MFT) circuit must be incorporated within the panel, containing all flame safety related control elements.

2.5.10. A single 24 VDC loop power supply shall be provided. The power supply shall be sized to handle total load for the system. Power supply shall be Allen-Bradley, SOLA or equal.

2.5.11. The following devices shall be mounted on the panel door:

a) Operator Interface System (OIS)b) Alarm Horn / Beaconc) Output Power On Pushbutton w/ indicating lightd) Output Power On LTe) Master On push button w/ indicating light. f) Master Off E-Stop style push-pull button

2.5.12. PLC I/O shall be provided for all analog and digital required for master control system. As minimum, I/O shall be provided for all devices shown on drawings.



Provide minimum 10% spare digital I/O and 10% spare analog. Spare I/O shall be wired to field terminals.

2.5.13. All equipment mounted on the outside of the control panel must have a NEMA 12 rating as a minimum.

2.6. BOILER CONTROL SYSTEM FIELD DEVICES

The following field devices are provided as a general outline and are listed on a per boiler basis.

Qty Description Instrument/Valve type Approved Manufacturers(or equal)

1 Nat Gas Fuel Flow Measurement Thermal Mass Flow Fluid Components International,

Fox Thermal, Serra

1 Nat Gas Fuel Flow Control Valve

Globe or Eccentric Plug Flowserve, Fisher, Jamesbury

1 Fuel Oil Flow Measurement Inline Turbine Hoffer, Flo-Tech, Daniel1 Fuel Oil Flow Control Valve Globe, V-Ball Flowserve, Fisher, Jamesbury

1 Combustion Air Flow Measurement

Differential Pressure Transmitter

Yokogawa, Foxboro, Endress-Hauser

1 Combustion Air Flow Damper Actuator Pneumatic Or Electric Type-K, ABB, Remote Control

1 Steam Flow Measurement Vortex Yokogawa, Foxboro, Endress-Hauser

1 Steam Pressure Measurement

Gauge Pressure Transmitter


1 Feedwater Flow Measurement Vortex Yokogawa, Foxboro, Endress-

Hauser

1 Feedwater Flow Control Valve Globe Flowserve, Fisher, Jamesbury

1 Water Level Measurement Differential Pressure Transmitter


1 Oxygen Measurement In-Situ Zirconia Type Rosemount or Yokogawa

1 Minimum Combustion Air Flow Pressure Switch Ashcroft, Dwyer, Honeywell

1 Purge Air Flow Pressure Switch Ashcroft, Dwyer, Honeywell1 Gas Low Pressure Pressure Switch Ashcroft, Dwyer, Honeywell1 Gas High Pressure Pressure Switch Ashcroft, Dwyer, Honeywell

Oil Low Pressure Pressure Switch Ashcroft, Dwyer, Honeywell1 Flame Scanner Infrared Type Fireye, Honeywell

1 Low Water Alarm Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 Low Water Cutoff Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 High Water Alarm Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 Auxiliary Low Water Cutoff Float Switch Clark-Reliance, McDonnell & Miller

1 Hi Steam Pressure Pressure Switch Ashcroft, Dwyer, Honeywell



1 Hi-Hi Steam Pressure Pressure Switch Ashcroft, Dwyer, Honeywell

1 Blowdown Bypass Switch Pushbutton or foot switch Allen-Bradley, Square-D

1 Low Air Pressure Switch (if required) Pressure Switch Ashcroft, Dwyer, Honeywell

2 Gas Safety Shutoff Valves Rising Steam Guillotine Type Maxon

1 Fuel Vent Valve Rising Steam Guillotine Type Maxon

2 Oil Safety Shutoff Valves Rising Steam Guillotine Type Maxon

2 Pilot Safety Shutoff Valves Solenoid Asco, Magnatrol1 Pilot Vent Valve Solenoid Asco, Magnatrol

2.6.1. All measurement type instruments shall have an isolated 4-20mA output signal and a minimum turndown capability of 10:1 while maintaining the same accuracy and resolution.

2.6.2. All Differential Pressure and Pressure Transmitters shall be SMART allowing for configuration by a handheld configurator or Laptop computer. A stainless steel manifold is required with this type of instrument; 3-valve for differential pressure transmitters and a 2-valve for pressure transmitters.

2.6.3. All control valves and actuators shall accept a 4-20mA input along with an integral positioner or feedback signal for closed loop control, and contain the appropriate position switches for purge position and/or low fire position. Actuators shall be sized per the application and can be pneumatic or electric as required by the installation.

2.6.4. All Safety Shutoff Valves shall be electric actuated to open and spring closed with proof of position switch. Valves shall be rated and approved for the fuel utilized and application.

2.7. BOILER OPERATOR INTERFACE SYSTEM (OIS)

The OIS shall contain all screens required to properly operate, tune, analyze, trend and alarm all functions associated with the required boiler control. Utilization of a laptop or other means will not be acceptable to modify setpoints, variables or such. At least following screens shall be included.

2.7.1. An overview screen shall be provided to display all pertinent operating conditions

relating to the boiler. This will include all values being measured, signal for valve position, levels, flows etc within a graphical representation.

2.7.2. A screen shall be provided to display all BMS status messages and alarms.

2.7.3. Screens shall contain loop controller faceplates for the controlled items allowing for Auto/Manual control, biasing (where required), process variable, setpoint, controlled variable display, setpoint changes, and control variable changes.



2.7.4. A screen shall be provided to tune each control loop. The screen shall include trends, which contain pens for the loop’s set point, output, and process variable. All trends shall be in engineering units.

2.7.5. The alarm screen shall contain a list of active and not acknowledged alarms. The alarms shall include the time and date and descriptive text. The alarm screen shall have capability to silence the alarm horn and acknowledge the alarm.

2.7.6. Screens shall be provided to enter values in the look up tables required by the system for demand based firing rates; and for instrument ranging of values for variables.

2.7.7. Controls available through the HMI have four levels of access. All but the operator level require a user name and password to access. All other screens used for tuning of control loops and configuring lookup tables shall be password protected. Logins shall be recorded and time stamped. The available levels are:

OperatorOperator may view boiler status and alarm screens, start and stop the boiler, acknowledge alarms, view trend screens, view I/O status screens and operate the boiler master control.

MaintenanceMaintenance mode allows all Operator level functions plus access to P&ID faceplates and adjustment to basic operational parameters.

EngineerEngineer mode allows all Maintenance level functions plus access to the lookup tables for air and fuel and other boiler tuning functions.

Manufacturer Manufacturer mode is reserved to the manufacturer’s engineers only, allowing all above functions plus access to purge timers and other critical parameters not normally adjusted after system design.



3. PLANT MASTER CONTROL SYSTEM

3.1.1. The Plant Master Controller’s primary function shall provide the Header Pressure or Temperature Demand Signal to the Boiler Control Panels.

3.1.2. Further the Plant Master Control System shall provide a central point of control for all auxiliary systems (balance of plant) such as Condensate system, Deaerator, and Feedwater Systems.

3.1.3. The Plant Master Control System shall provide the following control functions:

a) Plant Header Pressure or Temperature Control (Boiler demand-lead/lag)b) Deaerator Pressure and Level Controlc) Surge Tank Level Control

3.1.4. All control units shall be Programmable Logic Controllers (PLC’s) as manufactured by Allen-Bradley; CompactLogix series.

3.1.5. Controllers shall be panel mounted. Field I/O’s shall be accessed from the termination strips. The controllers shall have the ability to accept both analog and discrete inputs and provide both analog and isolated discrete outputs. No direct wiring to I/O modules from field or panel devices is acceptable; intermediate panel terminals are required.

3.1.6. Each controller microprocessor shall utilize a nonvolatile memory and provide the ability to implement the required functions of the control system.

3.1.7. The Operator Interface System (OIS) screen shall be a 10.4” color Allen Bradley PanelView Plus 1000 with touch screen and RS Factory Talk View software. The PanelView shall be mounted on the panel door. Ethernet communications to the PLC is required.

3.1.8. Ethernet communications are required between all controllers, Programming ports, OIS units and PC Systems. A panel mount (DIN rail) Ethernet 8-port Switch (as a minimum) is required. All Ethernet cabling between devices and the switch are to be provided and neatly routed within the panel.

3.1.9. If a controller or OIS is disconnected from the communications link, the rest of the communications shall continue uninterrupted. The disconnected controller shall still continue uninterrupted. The disconnected controller shall still continue control functions independently with the last input control adjustments and configuration accessible from the local data entry panel.



3.2. PLANT MASTER CONTROL PANELS / ENCLOSURES



3.2.3. Terminal strips shall be installed within the control panels to accommodate all field wiring, including shields, and internal panel wiring. All internal wiring shall be completed prior to shipment so that factory checkout can be completed.

3.2.4. Terminal strips shall be numbered to correspond with the numbers on the control diagrams and all wires within the panel shall be identified with one-piece markers.

3.2.5. All I/O boards shall be wired to field terminal. Fused terminals shall be provided for all outputs.

3.2.6. A panel mount (DIN rail) Ethernet 8-port Switch (as a minimum) is required.

3.2.7. Analog and 24DC wiring shall be run separately from AC wiring. Analog wiring shall be shielded twisted pairs with drain wire. Field terminals shall be provided for drain wire. Shield and drain wire shall be contiguous from analog board to field terminal.

3.2.8. Relays shall be Allen-Bradley, Potter Brumfield, Magnecraft or similar. Relays shall be provided with retaining clips and pilot light.

3.2.9. A single 24 VDC loop power supply shall be provided. The power supply shall be sized to handle total load for the system. The power supply shall be Phoenix, SOLA or as Owner approved. Power supply failure alarm shall be provided.

3.2.10. The following devices shall be mounted on the panel door:a) Operator Interface System (OIS)b) Alarm Horn / Beaconc) Master On push button with indicating lightd) Master Off E-Stop style push-pull button

3.2.11. PLC I/O shall be provided for all analog and digital required for master control system. As minimum, I/O shall be provided for all devices shown on drawings.

3.2.12. Provided minimum 10% spare digital I/O and 10% spare analog. Spare I/O shall be wired to field terminals.

3.2.13. All equipment mounted on the outside of the control panel must have a NEMA 12 rating as a minimum.



3.3. PLANT MASTER FIELD DEVICES

The following field devices are provided as a general outline. The listing is typical and not all inclusive as items will be equipment and application specific.

Qty Description Instrument / ValveType

Approved Manufacturers (or equal)

1 Steam Header Pressure Transmitter



1 DA Tank Level Transmitter Differential Pressure Transmitter


1 DA Tank Pressure Transmitter



1 Surge Tank Level Transmitter

Differential Pressure Transmitter


1 DA Tank Low Water Alarm Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 DA Tank Low Water Cutoff Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 DA Tank High Water Alarm Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 Surge Tank Low Water Alarm

Water Column Probe Clarke-Reliance, McDonnell & Miller, Warrick

1 Surge Tank Low Water Cutoff


1 Surge Tank High Water Alarm


1 Low Air Pressure Switch Pressure Switch Ashcroft, Dwyer, Honeywell

3.3.1. All measurement type instruments shall have an isolated 4-20mA output signal and a minimum turndown capability of 10:1 while maintaining the same accuracy and resolution.

3.3.2. All Differential Pressure and Pressure Transmitters shall allow for configuration by a handheld configurator or Laptop computer. A stainless steel manifold is required with this type of instrument; 3-valve for differential pressure transmitters and a 2-valve for pressure transmitters.

3.3.3. All control valves and actuators shall accept a 4-20mA input signal. Actuators are to be sized per the application and can be pneumatic or electric as required by the installation.

3.3.4. All switches will be 120VAC SPDT type.



3.4. PLANT MASTER OPERATOR INTERFACE SYSTEM (OIS)

The OIS shall contain all screens required to properly operate, tune, analyze, trend and alarm all functions associated with the required boiler control. Utilization of a laptop or other means will not be acceptable to modify set points or variables. At least following screens shall be included.

3.4.1. An overview screen shall be provided to display all pertinent operating conditions

relating to the balance of plant. This will include all values being measured, signal for valve position, levels, flows and such within a graphical representation. To include the Deaerator, Surge Tank and Feedwater Systems.

3.4.2. Screens shall contain loop controller faceplates for the controlled items allowing for Auto/Manual control, biasing (where required), process variable, setpoint, controlled variable display, setpoint changes, and control variable changes.

3.4.3. A screen shall be provided to tune each control loop. The screen shall include trends, which contain pens for the loop’s set point, output, and process variable. All trends shall be in engineering units.

3.4.4. The alarm screen shall contain a list of active and not acknowledged alarms. The alarms shall include the time and date and descriptive text. The alarm screen shall have capability to silence the alarm horn and acknowledge the alarm.

3.4.5. Screens shall be provided to enter values in the look up tables required by the system for demand based firing rates; and for instrument ranging of values for variables.

3.4.6. Controls available through the HMI have four levels of access. All but the operator level require a user name and password to access. All other screens used for tuning of control loops and configuring lookup tables shall be password protected. Logins shall be recorded and time stamped. The available levels are:

OperatorOperator may view boiler status and alarm screens, start and stop the boiler, acknowledge alarms, view trend screens, view I/O status screens and operate the boiler master control.

MaintenanceMaintenance mode allows all Operator level functions plus access to P&ID faceplates and adjustment to basic operational parameters.

EngineerEngineer mode allows all Maintenance level functions plus access to the lookup tables for air and fuel and other boiler tuning functions.

Manufacturer Manufacturer mode is reserved to the manufacturer’s engineers only, allowing all above functions plus access to purge timers and other critical parameters not normally adjusted after system design.



3.4.7. A Control Screen shall contain loop controller faceplates for the Deaerator tank level and pressure; and pump control with shutdown.

3.4.8. A Control Screen shall contain loop controller faceplate for Surge tank level control and pump control with shutdown.

3.4.9. A Control Screen shall contain a controller faceplate for the plant master Steam Header Pressure or Temperature Controller with output to each Boiler Panel.



4. PLANT SCADA PC SYSTEM

4.1. The control system provider shall supply a computer based system that will communicate with all boiler control panels and the plant master control panel, and shall be used as both an additional operating system and a system data logger.

4.2. Computers shall be generally a recognized name brand system with the following minimum requirements. Control system provider shall make an allowance for the following computer but shall buy the latest model computer and hardware at the time of configuration:

o Intel Core i5 or AMD Phenom II Processoro Windows 7 Professional operating systemo 4-GB RAM, 500-GB hard drive, 48x CD-RW/DVDo Keyboard and mouseo Ethernet 10/100 base T NICo Speakerso 23” flat panel LCD color monitor and 1024 x 768 minimum resolutiono Surge protecting type power strip for power and Etherneto One Hewlett-Packard Color Inkjet printer or later model and cableo A desk type Ethernet 5-port Switch (as a minimum) is required

4.3. Software

a) The process control software shall consist of an operator interface software (OIS) system utilizing Allen-Bradley RS FactoryTalk View which includes support for process supervisory control, data acquisition, alarming, trending, and management report generation. The system shall have the built-in flexibility of permitting easy configuration of the system in accordance with the specific objectives of the end user, as well as quick and easy modification of the end application by the user in the field.

b) OIS User Interface

o The operator shall be able to access displays using soft key menus with a choice of function keys, cursor control keys, or any key on the keyboard. In addition, the system shall support the use of a mouse.

o The system shall support operator access to multiple displays at one time, including split screens where the operator may view more than one process area at a time. In addition, the system shall support unlimited use of pop-up displays for additional diagnostic information.

o Access to all displays and all command functions shall be password protected against unauthorized use.

o Visibility of command buttons, symbols, etc. shall be controlled based on operator security level.



o The operator shall be prompted by pop-up displays to acknowledge an alarm, and then be given the opportunity to go to an alarm summary display or return to the current display.

c) Command/Control Function

o The operator shall be able to control a discrete point using an action command button. This control includes non-momentary on, momentary off, toggle on off, set and reset.

o The operator shall be able to use the command button to adjust set points up and down on a percentage or absolute basis. Each request for increase or decrease shall be evaluated against valid operating limits before allowing adjustment.

o Control of individual set points shall be based on an individual or group basis, with support for groups and subgroups.

d) OIS Graphic Displays Capability

o The system shall allow the user to view animated graphics for process templates, including tanks, pumps, valves, etc. This includes:

i. Percent fill of the object, including irregular shapes such as polygons, ellipse, etc.

ii. Color change of object

iii. Blinking of objects based on any alarm in the system of upon a designated group of alarms.

iv. Each object shall have a visibility attributes option allowing for visibility of an object based on a condition in the system.

v. The system shall support animation of objects, allowing for resizing based on a change in a process variable.

vi. Objects shall be made to change color based on any user-defined criteria made up of other tag names in the system. This includes the use of AND, OR, and NOT, using expressions of the same status of analog and discrete values in the system.

o Objects shall be able to blink or change color

e) OIS Graphic Description

o The system shall support the use of true-type scaleable fonts that may be scaled according to the desired size of the text. The fonts shall be loaded by the operating system. The user may choose from up to 32 different text colors.



o The system shall support change of text color based on the process value going into eight different alarm states.

o The text shall be able to blink based on any user definable condition occurring in the system, such as alarm or a particular set point, alarm on any value in a group, or based on the actual value of a process variable.

o The system shall display process values based on the security level of the operator.

o The text shall be able to be made visible or invisible based on an alarm condition in the process or any other state change in the system.

f) The system shall be able to read the data tables of the PLC’s and dynamically display the status of the actual process as it occurs on the monitor.

g) Retrieve historical events based on time and date on a screen.

h) Software will let historical files be exported to the other program for further detailed analysis and reporting.

i) Software shall be suitable to operate in Microsoft Windows XP Professional environment. Software shall be Allen-Bradley RS Factory Talk View, or owner approved. Propriety custom software shall not be accepted.



5. EXECUTION

5.1. STARTUP ASSISTANCE AND PERFORMANCE TESTING

5.1.1. Calibration

a) All field devices and controls shall be calibrated / configured and checked out. The control system provider shall include all calibration / configuration and test equipment.

b) Each field or panel device calibrated will be tagged by the control system provider and verified by the Owner.

c) The purpose of commissioning instruments prior to startup of a plant shall assure their performance in accordance with the specifications under simulated operating conditions.

d) If any doubt exists as to the correct method for calibrating or checking the calibration of an instrument, the manufacturer’s printed recommendations shall be used as an acceptance standard.

e) The control system provider shall test the calibrations of all instruments and make all necessary adjustments to assure correct indication of recording. If any instrument cannot be properly adjusted, it shall be immediately called to the attention of the Owner and a report of its condition confirmed in writing.

5.1.2. Loop Checks

a) The control system provider shall functionally check each indication and control loops to verify correct and accurate performance. The functional test will include all loop elements (signal conditioners, etc.) with the exception of the computer interface electronic units.

b) Each transmitter and signal transducer will be excited and the resultant reading verified for accuracy on its respective receiver instrument(s). Acceptable loop accuracy shall be + or –2 percent. Signal simulation will be an acceptable substitute for primary element excitations. Thermocouples, read only by a computer, do not have to be functionally checked; only their wiring verified.

c) Its respective controller in the manual mode will exercise each final control element. Proper stroke response in magnitude (+ or –5 percent controller input versus pneumatic signal on diaphragm) and direction will constitute correct operation.

d) The operation of a control valve should be verified within the limits of practicality. Particular attention must be given to the manufacturer’s instructions and the applicable nameplate data in reference to valve spring



scale and actuation conditions. Note that some valves cannot be fully stroked without nominal line operating pressure. Do not adjust spring rate unless a complete simulation of valve operating conditions is possible. If valve disassembly is required for any reason, the stem length and the compression nut must be indexed to assure correct reassembly. Check valve action for conformance to specifications (open or closed on air failure). Check for conformance to specifications relative to spring action and input range (particularly for split range applications), valve action, and length of stroke. If the valve Positioner is fitted with a standard characterize cam, check to see if the proper cam is mounted. If the specifications call for a specially cut cam, check to see if the cam is properly cut for the specification.

5.1.3. Startup

a) Following the completion of system installation, the control system provider shall provide an experienced staff engineer to be responsible for the following on-site field services:

o Conduct a system inspection of the boilers, the piping, the primary control elements, the valves, and the instrumentation. The control elements will be calibrated; checked for accuracy, repeatability and speed of response. Transmitters and transducers will be calibrated.

o Conduct an inspection of the control system to check the wiring of the controller and the inter-controller wiring including power, ground, shields, isolation, etc. The control panels shall be powered up and their proper installation shall be evaluated. Calibration shall be checked along with verification of Control Integrator determined parameters and a test of the required algorithms’ operation.

o The control system provider will be responsible for the full functionality of all the boiler controls including, but not limited to, the Burner Management System, the Combustion Control System, and all field devices. The Balance of Plant systems (Plant Master and SCADA) systems are to be commissioned with the same sequence and thoroughness.

o The control system provider shall observe the operation of each boiler for possible problems.

o The control system provider shall observe the Balance of Plant equipment for possible problems.

5.1.4. Reports and Certification

a) At the completion of the work, the control system provider shall submit to the Owner a certification that all instruments and control systems have been commissioned and are in operating condition in accordance with the contract drawings and specifications. A Letter of Acceptance will be submitted for approval; upon signature, the system(s) will be turned over for the benefit of use by the Owner; and the warranty period will begin.



b) All reports, As-Built drawings and manuals are to be turned over prior to Acceptance of the System being accomplished.

6. Acceptable Manufacturers:

6.1. This control specification is based on systems as manufactured by Lipten Company:o CombustionPac™ series Boiler Control Systemo MasterPac™. Series Plant Master Control Systemo SCADAPac™ Monitoring and Control System

Owner approved equal systems may be furnished that provide technology and functions equal to these systems. The systems shall be pre-configured, PLC based with components as manufactured by Allen Bradley or equal as approved by the owner. Only locally available, off the shelf control components will be acceptable. Only non-proprietary control software and hardware will be acceptable.

6.2. Control Systems other than the system specified in Article 6.1 must be submitted to the Owner’s engineer and approved in writing a minimum of 15 working days prior to the bid date. No exceptions will be allowed.

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Boiler Controls Controls... · Web viewGENERAL SCOPE OF WORK The control system provider shall design, supply, deliver, calibrate, checkout, startup, and place into operation an instrumentation