SECTION PROGRAMMABLE LOGIC CONTROLLER (PLC)

Transcription

1 SECTION PROGRAMMABLE LOGIC CONTROLLER (PLC) PART 1 GENERAL 1.01 DESCRIPTION A. This section covers the requirements for the Programmable Logic Controller (PLC) and PLC spare parts and tools. The Contractor shall be responsible for a system integration to perform work as shown on plans for control, communications and power systems to bring together a functioning system at Knights Landing Outfall Gates to operate the gates and all related apparatus. B. The contract item Programmable Logic Controller (PLC) includes the following: 1. PLC hardware and supporting equipment including programming software, cables, connectors, PLC/PC Ethernet network interface cards, serial communications cards, power supplies, laptop and any other hardware and/or development software necessary to ensure a complete and functional PLC system. C. The contract item Programmable Logic Controller (PLC) includes PLC spare parts and tools RELATED SECTIONS A. Supplementary General Conditions, General Conditions, Division 1 sections, and Drawings apply to this section. This section may require direct correlation with the following sections of the contract: 1. Section Panel Work. 2. Section Electrical Testing Requirements. 3. Section Basic Electrical Materials and Methods. 4. Section Grounding System. 5. Section Communication System. 6. Section Training Program N-10

2 1.03 REFERENCES A. The following publications form a part of this specification to the extent referenced. Application of these publications shall conform to Document Interpretation of the Contract: 1. American National Standards Institute (ANSI). 2. American Society for Testing and Materials (ASTM). 3. California Electric Code (CEC). 4. Institute of Electrical and Electronic Engineers (IEEE). 5. Instrument Society of America (ISA). 6. International Electrotechnical Commission (IEC). 7. National Electric Code (NEC). 8. National Electric Safety Code (NESC). 9. Underwriters Laboratories Inc. (UL) SUBMITTALS A. The Contractor shall submit the following drawings and data: 1. Provide physical planning and site preparation documents containing drawings of PLC equipment and related hardware, showing overall dimensions, part identifications, mounting details, clearance requirements, and environmental restrictions. 2. Power supply calculations showing electrical requirements of the hardware to be provided. 3. Equipment block diagrams. 4. Vendor specific catalog cuts, specifications, and manuals for all scheduled and unscheduled equipment called for in the Contractor s detailed design. 5. Standard operation and maintenance manuals which will enable the Department s personnel to maintain all new equipment. These manuals shall include but not be limited to: a. Installation Guides. b. Programming Guides N-10

3 c. User Guides. 6. Within the limits of this contract, descriptions of communications interfaces for the process network and serial communication links. This data shall include but not be limited to format, protocol, data exchange rates, and interface details both physical and electrical. 7. Statement from PLC manufacturer stating approved third party vendors for modules compatible with their platform, a product support statement stating expected product life, and a certification of spare parts availability for a minimum of 10 years. 8. Provide one copy of the fully-licensed version of the PLC s programming package. PART 2 PRODUCTS 2.01 GENERAL REQUIREMENTS A. PLC components shall be from one PLC manufacturer unless otherwise specified. PLC I/O modules shall be selected within one I/O product line. If approved by the Department, manufacturer approved third party vendors may provide modules that are certified compatible with their platforms. B. The Contractor shall provide detailed design documents for the following minimum list of PLC equipment: PLC power supply, CPU, I/O modules and termination blocks. The Contractor shall ensure that the entire PLC system will fit and operate properly in the space provided. C. At a minimum, the PLC shall be fully programmable in IEC compliant ladder logic, function block, sequential function chart, and structured text languages. D. The Contractor shall furnish the latest version of PLC, firmware, software, and equipment models available at the time the Contractor submits purchase orders for equipment. Firmware and software upgrades released during the execution of the contract shall be provided to the Department and implemented at the Department s discretion. E. The Contractor shall provide the operator interface as specified herein N-10

4 2.02 PLC HARDWARE REQUIREMENTS A. General: 1. PLC manufacturer and product line shall be Modicon, Quantum (Unity Pro XL); Allen-Bradley, ControlLogics (RSLogics 5000 Enterprise); or equal. 2. The PLCs shall be from one family of the manufacturer s product line. The product line used shall have an expected product life of over ten (10) years. Products nearing the end of their life cycle are not acceptable. 3. Electronic components shall be mounted on plug-in printed circuit cards or modular subassemblies. Each printed circuit card and subassembly shall be model and serial numbered to uniquely identify it. Printed circuit cards shall plug into a panel-mounted backplane and contain modular, quick disconnect, card edge connectors. 4. PLC hardware shall be UL recognized. 5. Empty I/O module slots in the backplane shall be filled with a door cover or filler module. 6. I/O modules shall have a power present indication. 7. The PLC hardware shall operate within an ambient temperature range of 0 to 60 degrees C, with an ambient temperature rating for storage of -20 to 85 degrees C. 8. The PLC hardware shall function continuously in the relative humidity range of 5 percent to 95 percent with no condensation. 9. Equipment shall be sufficiently sturdy to withstand handling during shipment, placement, and start-up without damage or distortion. B. PLC Processor and Memory: 1. The PLC processor (CPU) shall be a Modicon, Quantum Unity Processor; an Allen Bradley, ControlLogix 1756-L6x; or equal. The CPU shall also supply I/O scanning and inter-processor and peripheral communications functions. 2. At the time of power up, the PLC shall inhibit operation of the processor and I/O modules until the dc voltages of the backplane are within manufacturer s specifications N-10

5 3. The PLC shall have a stand-alone restarting capability, i.e., no reloading of software programs for common logic, communications, and I/O processing at the PLC shall be required to resume operation following a loss of power. 4. The operating system firmware shall be contained in nonvolatile memory. 5. The PLC programs shall be resident in battery backed memory with at least a 3 year battery life. Battery shall be capable of being changed without loss of program. Alternate means of program storage such as writing contents of RAM to internal Flash during power down are acceptable. 6. The PLC processor shall contain a minimum of 750 Kbytes of IEC program memory with field expandability, in various increments, up to approximately 8 Mbytes. 7. As a minimum the PLC CPU board shall have LED or LCD indications for run, CPU fail, and low battery. 8. As a minimum the CPU module shall have integrated RS-232 ports and one integrated, or external, 10/100 BASE T, IEEE 802.3, Ethernet port. An integrated USB/serial programming interface is required. 9. The PLC shall continually monitor its operation and shall enter a fail-safe mode in case of a failure that would cause a faulty solution of logic. A running PLC shall identify communication failures, I/O assembly errors, I/O module errors, and CPU battery failure and shall be capable of reporting such faults to a supervisory control system. 10. The PLC shall be capable of maintaining a real-time clock function and accept a clock synchronization signal from an NTP time server. C. PLC Power Supply: 1. The PLC shall operate in compliance with an electrical service of 93 to 132 V ac, single phase, in the frequency range from 57 to 63 Hz. 2. A single main power supply shall have the capability of supplying power to the CPU and all local input/output modules and communications modules with a spare capacity of at least 33 percent N-10

6 3. The power supply shall monitor the incoming ac line voltage for proper levels and provide an alarm indication and safe PLC shutdown functionality when levels are outside allowable limits. 4. The power supply shall provide surge protection, isolation, and outage carry-over of up to one-halfcycles of the ac line. 5. The power supply shall include a diagnostic indicator mounted in a position to be easily viewed by the user. This indicator shall provide the user with the status of the dc power applied to the backplane of the PLC. D. PLC IEEE Ethernet TCP/IP Communications Requirements: 1. The Ethernet TCP/IP interface shall support the following: a. MODBUS TCP/IP communications. b. Standard Ethernet media (10/100 baset). c. Subnet masking. d. Communications through standard repeaters, bridges, routers, host computers and peer PLCs. e. An RJ-45 port. 2. Network addressing shall be done in software and all module configuration details shall be configured in the PLC controller. E. PLC Serial Communications Requirements: 1. The PLC serial interface module shall support at least two RS-232 and RS-485 connections with 9600 baud rate. 2. Baud rate shall be user configurable. 3. The PLC serial interface module shall support Modbus serial protocol (configurable as master or slave). F. PLC Remote I/O Communications Requirements: 1. The remote I/O interface shall support the following: a. Message error checking. b. Retries of unacknowledged messages. c. Diagnostic checks of remote I/O modules N-10

7 G. Discrete Input Modules: 1. The discrete input interface modules shall be capable of accepting isolated wet or dry contact status inputs. Wet and dry contacts shall be separated onto different I/O cards. 2. Wet contact inputs shall be 125 V dc sink inputs from existing field devices, with the wetting voltage provided by the Department. Input isolation, group to group, shall be a minimum of 1,500 V rms for 1 minute and isolation, group to bus, shall be a minimum of 2,500 V for 1 minute. 3. Dry contact inputs shall be 24 V dc sink and the Contractor shall supply the wetting voltage from a source separate from that of the PLC s logic power supply. Input isolation, group to group, shall be a minimum of 500 V rms for 1 minute and isolation, group to bus, shall be a minimum of 1,500 V rms for 1 minute. 4. The PLC shall be sized with a minimum of 10 percent spare capacity wired and tested. 5. I/O modules shall be software configurable. 6. I/O modules shall have the ability to define a failure mode, i.e. upon a failure indication the module shall be configured to either zero inputs/outputs, go to a predefined safe state, or hold the last value that the module received prior to failure. H. Discrete Output Modules: 1. Discrete output drive circuitry shall be designed such that any single logic component failure in the PLC does not energize a discrete output. 2. Each individual discrete output shall be capable of actuating a 24 V dc interposing relay with a coil current requirement of at least 400 ma. 3. Every output on a card shall be capable of being energized simultaneously without exceeding the maximum current capability of the individual card as specified by the manufacturer. 4. The PLC shall be sized to meet a minimum of 10 percent spare capacity wired and tested. 5. I/O modules shall have the ability to define a failure mode, i.e. upon a failure indication, the module shall be configured to either zero N-10

8 inputs/outputs, go to a predefined safe state, or hold the last value that the module receives prior to failure. I. Analog Input Modules: 1. Analog input cards shall include 4-20mA input signals. 2. The PLC shall be sized with a minimum of 10 percent spare capacity wired and tested. 3. Transducer power shall be provided by a dedicated 24 V dc power supply to be provided by the Contractor and installed in the controller assembly cabinet as shown. 4. Current input modules shall have broken wire and out-of-range fault indication. Input isolation, channel to channel, shall be a minimum of 30 V dc and channel to bus isolation shall be a minimum of 1,000 V for 1 minute. 5. Voltage input modules shall be bi-polar and multi-range. Input isolation, channel to channel, shall be a minimum of 200 V dc for 1 minute and channel to bus isolation shall be a minimum of 750 V dc for 1 minute. 6. Input/Output modules shall have the ability to define a failure mode, i.e. upon a failure indication the module shall be capable of being configured to either zero-inputs/outputs, go to a predefined safe state, or hold the last value that the module received prior to failure. 7. Minimum resolution allowable for analog to digital conversion is 16 bits. Analog input cards with 12 bit analog to digital conversion shall be approved on a case by case basis before being allowed. 8. The analog input accuracy shall be 99.9 percent or better at 25 degrees C. Mean accuracy shall drift no more than.002 percent per degree C within the specified operating temperature range of the PLC. J. Analog Output Modules: 1. Analog outputs requiring power shall be driven from the 24 V dc power supply provided by the Contractor and installed in the MCC Electronic Enclosure. 2. The current output module shall have broken wire fault detection. 3. The PLC shall be sized with a minimum of 10 percent spare capacity wired and tested N-10

9 K. PLC Termination Adapter Plates and I/O Terminations: 1. The existing field I/O wire shall be maintained. The Contractor shall be responsible for verifying space requirements and wiring restrictions prior to detailed design approval. 2. Termination adapter plates shall be provided and shall be directly pluggable to the input and output modules in the PLC chassis. 3. Termination adapter plates shall support direct power connections to PLC I/O cards when required. 4. Termination adapter plates shall supply high-density cable connection headers for pre-made cable connections to field wiring interface modules. L. Other Power Supplies: 1. Power supplies external to the PLC chassis shall be as specified in Section Panel Work. 2. Power supply status shall be monitored by the PLC via hard-wired dry-contact digital inputs PLC SOFTWARE AND DEVELOPMENT SYSTEM REQUIREMENTS A. The PLC shall be capable of being programmed to provide the overall system functions as described herein. Specific PLC development functions which shall be performed via PLC-level software include, but are not limited to, the following functions as specified below. B. Development software shall be the latest version of PLC manufacturer s programming package and shall be Unity, Pro XL; RSLogiX, 5000 Enterprise; or equal. 1. General Requirements: The following are the requirements for the PLC programming software package. a. Shall be Windows Based. b. Shall be able to run in a fully functional simulation mode. c. Shall contain an equation editor for complex algorithms. d. Shall have quick key support. e. Shall be in compliance with IEC programming languages N-10

10 C. Diagnostics and System Programming: Specific functions, which shall be performed via PLC-level software, shall include, but are not limited to, the following functions: 1. PLC network configuration, including IP addressing. 2. CPU module configuration. 3. I/O module configuration. 4. I/O database configuration. 5. Water level measurement system readings shall be recorded, used in control logic and communicated to the California Data Exchange Center every hour on the hour in 15 minute intervals by the PLC through Department furnished cellular modem. 6. The PLC shall provide two modes of operation, manual and automated. In manual mode each gate s position shall be controlled by the MCC MCP Panel or the PLC via the HMI operator interface. In automated mode the control logic provided by Department shall be used to operate the gates. 7. The PLC shall compare the water level system s readings to the water level desired in the control logic provided by the Department. The default water level desired shall be 25.3 feet and adjustable in the PLC via the HMI operator s interface. 8. Each gate s position measured in tenths of a percent and a normal / alarm status for each gate shall be recorded and communicated to the California Data Exchange Center every hour on the hour in 15 minute intervals from the PLC through Department furnished cellular modem. 9. All electrical actuators functionally shall be controlled from the PLC via the HMI operator s interface. All actuator status and alarm diagnostic messages shall be available to the PLC and operator interface. Settings and programming shall be as specified and approved by the Department Engineer on the project. The Contractor shall be responsible for installation settings and programming for the devices. 10. The PLC shall store three phone numbers that can be changed via the HMI panel. The phone numbers shall be used for phone notification when there is an alarm status from the gates. 11. The PLC shall store gate positions, gate alarm statuses and water level system readings in 15 minute intervals for a minimum of N-10

11 72 hours. The backup of information shall be easily retrievable and sent to CDEC in the event the CDEC interface goes down. D. The PLC programming software shall be the full version of the package provided by the manufacturer. It shall include all the latest service packs provided for the programming package by the manufacturer with discs, manuals, and certificates in their original packaging. The software shall be licensed in the name of the California Department of Water Resources. E. The Contractor shall make available to the Department any update provided by the manufacturer for any provided software during the guarantee period. F. The Contractor shall furnish a minimum of two PLC programming cables OPERATOR INTERFACE/LOCAL DISPLAY DEVICE A. An industrial-grade operator interface shall be provided within the controller cabinet. The interface panel outside dimension shall fit in the MCC bucket no larger than 24 inches by 24 inches by 24 inches. B. The HMI display shall be minimum of 7 inches and shall fit inside the dimensions of the MCC bucket shown on plans. C. The HMI display shall be mounted in the front door of the controller cabinet or be easily viewed through a clear panel mounted in the door of the controller cabinet unless otherwise approved. D. The operator interface shall be capable of providing real-time PLC data points to operations and field maintenance personnel. E. The operator interface shall be touch screen or membrane keypad equipped. F. The operator interface shall be capable of operation in the following environmental conditions: 1. Temperatures of -10 to 50 degrees Celsius. 2. Relative humidity of 10 percent to 90 percent noncondensing. 3. When panel mounted, maintain the cabinet s NEMA rating. G. The operator interface shall support Modbus TCP/IP protocol through a 10/100 Base T interface N-10

12 H. Display shall be at a minimum 320 x 240 pixels, lighted, color graphic LCD or TFT with the ability of providing a power saving sleep mode when not in use for long periods. I. The power requirements of the operator interface shall support an input voltage of 24 V dc. The Contractor shall make available the 24 V dc required for these equipment. J. The operator interface shall be UL listed and CE certified. K. The operator interface shall be a QSI Corporation, QTERM G-55; Schneider Electric, Magelis XBT; Allen Bradley, PanelView Plus; or equal MATERIALS A. Terminal Blocks: 1. Terminal blocks shall be as specified in Section Panel Work SHOP TESTS A. Shop/factory calibration and testing shall be performed in accordance with PLC manufacturer s standard manufacturing and quality control testing procedures. B. The PLCs shall be integrated with the other components of the PLC system and tested as part of the system demonstration test as specified in Section Electrical Testing Requirements. In addition to the general system test requirements, the PLC shall be subjected to the tests described in this section with a written confirmation of the test results SPARE PARTS AND TOOLS A. The Contractor shall furnish spare parts for the PLC. Material shall be packaged for long-term storage and identified with labels describing contents. The minimum spare parts shall be provided as follows: 1. I/O Cards: Provide as a minimum one spare of each type of card identified. 2. Processors: Provide as a minimum one spare of each type of CPU identified. 3. Power Supplies: Provide as a minimum one spare of each type of power supply identified N-10

13 4. Memory Cards: Provide as a minimum one spare of each type of card identified. 5. Specialty Modules: Provide as a minimum one spare of each type of module identified. 6. Interposing Relays: If used in the installation, provide one complete compliment of eight interposing relays complete with cards, mounting brackets, and specialty cable assemblies. B. The spare parts shall be interchangeable and of the same material and workmanship as the original parts provided. The spare parts shall be complete with electrical connections, screws and/or other fasteners as required to replace the corresponding parts, and shall include the materials required for assembly and installation. C. One set of any specialty tools required for assembly, installation, and maintenance shall be provided. D. Laptop Requirements: 1. Hardware: The laptop computer shall have the following minimum requirements: a. A2 GHz processor or greater. b. 4G RAM. c. 100 GB hard drive. d. 40X/32X/24X CD-RW drive. e. 4G DVD. f. 2G video card. g. 16 bit sound card. h. DB-9 serial port. i. 10/100 integrated NIC. j. 56 K integrated modem. k. NTSC VGA out. l. Four USB ports. m WiFi capability N-10

14 n. Wireless Bluetooth capability. o. PCMCIA Type I/II slot. p. 14 inch LCD display. q. Three hour lithium ion battery. r. Spare three hour lithium ion battery. s. AC adapter w/charger. t. Leather carrying case with handle and shoulder belt with at least three compartments. 2. The Contractor shall install the following manufacturer s software: PART 3 EXECUTION a. PLC development software. b. The most recent PLC operational program DELIVERY OF SPARE PARTS AND TOOLS A. Spare parts shall be delivered at the time equipment to be installed is shipped and no sooner. Spare parts shall be delivered to Department s Sacramento Maintenance Yard PLC FIELD WIRING A. General: 1. The PLC and appurtenances furnished under this contract shall be furnished, installed, wired, and tested as shown and specified herein. 2. The Contractor s representative shall be at the work site to assist the installation troubleshooting, calibration and testing of the PLC. The Contractor s representative shall provide certification that the PLC has been installed correctly and is operating correctly. B. Field Device Wiring: 1. The Contractor shall perform the connections of the PLC s I/O modules to the existing field device wiring. The existing field wiring shall be re-terminated and labeled as specified herein. The site interface for these connections shall be at the controller cabinet as shown N-10

15 C. Miscellaneous Wiring: 1. Final power and grounding connections within the controller cabinet shall be performed by the Contractor as required to provide a complete and operable PLC system. Grounding of the PLC, wiring shields, and associated components shall be in strict accordance with the PLC manufacturer s recommendations. 2. Installation and wiring for installing the data transmission interface devices and other Department furnished equipment shall be as approved FIELD TEST REQUIREMENTS A. The Contractor shall notify the Engineer in writing a minimum of 14 days prior to the field tests. B. The Contractor shall perform tests as specified in Section Electrical Testing Requirements. PART 4 PAYMENT 4.01 PAYMENT A. The contract price will be paid for PROGRAMMABLE LOGIC CONTROLLER (PLC); which price shall include full compensation for all costs incurred under this section. END OF SECTION N-10