40 67 33



***NOTE TO USER: DELETE THIS PAGE WHEN FINISHED***NOTES TO USERSThere are hidden Specifier Notes, shown as red, italicized text (i.e.: [NTS:], throughout this document. These specifier notes are meant to assist the user with tailoring the document to the specific information needed or required for the project. To view or hide these specifier notes, click the Paragraph symbol (?) representing the Show/Hide function in the Paragraph Group of the Home Tab. This text is formatted as hidden text; when the Show/Hide function is turned off, the hidden text will not show up when printed. Throughout this document users will also find braces surrounding text. These braces { } are representative of optional sections of text that may not be necessary to include in the section depending on the current project. Users may also find empty braces throughout the document. The specifier notes contained above the text will assist the user with what information is to be included in the empty braces, if necessary. THERE SHOULD BE NO REMAINING BRACES AFTER THE DOCUMENT HAS BEEN FULLY EDITED.Specifier notes are hidden text and therefore should not be modified in any way; they are simply an instructional tool to assist the user with modifying the hard text within the document. User must not delete or modify specifier notes in order to maintain integrity of the master template. An example [NTS] is located below to confirm the user’s MSWord settings are configured properly.[NTS: This note is visible to user when MSWord is configured as described above.]AGAIN, THESE NOTES WILL NOT PRINT WHEN THE SHOW/HIDE FUNCTION IS TURNED OFF.section 40 67 33Process control systempanel wiringGENERAL[NTS: Given the rapid rate of change in performance for many of the components included herein, check with vendors for the latest performance specifications.] [NTS: Keep this description brief. The SUMMARY Article is intended to only outline the contents of topics in this Specification Section. Do not stipulate specification requirements in this Article.]SUMMARYSection Includes:General: The SYSTEM INTEGRATOR shall provide all labor, material, equipment and incidentals, as specified herein and shown on the Contract Drawings, to furnish, install, calibrate, test, startup and place into satisfactory service complete control panels, junction boxes, alarm stations, control stations, and/or enclosures.Responsibility: It is the intent of these specifications that the SYSTEM INTEGRATOR be singularly responsible for providing labor and material for all panel and/or enclosure interior wiring and furnish, install and place into satisfactory operation completely assembled panels and/or enclosures. Applicable Specification Sections include, but are not necessarily limited to:Division 00 - Procurement and Contracting Requirements.Division 01 - General Requirements.Section 40 61 13 – Process Control System General ProvisionsSection 40 61 21 – Process Control System TestingSection 40 61 26 – Process Control System TrainingSection 40 61 93 – Process Control System Input/Output ListSection 40 61 99 - Process Control System Loop DiagramsSection 40 62 63 – Operator Interface Terminals (OIT)Section 40 63 43 – Programmable Logic Controllers (PLC) Section 40 66 00 – Network and Communication EquipmentSection 40 67 00 – Control System Equipment Panels and RacksSection 40 67 63 – Process Control System Uninterruptable Power Supply (UPS)Section 40 80 00 – Commissioning of Process Systemsquality assuranceReferenced Standards:American National Standards Institute (ANSI).ASTM International (ASTM):B75, Standard Specification for Seamless Copper Tube.National Electrical Manufacturers Association (NEMA):250, Enclosures for Electrical Equipment (1000 Volts Maximum).ICS 4, Industrial Control and Systems: Terminal Blocks.National Fire Protection Association (NFPA):70, National Electrical Code (NEC):Article 409, Industrial Control Panels.NEORSD Process Control System Standards and Conventions ManualNEORSD Electrical Standards and Conventions ManualNEORSD CAD StandardsUnderwriters Laboratories, Inc. (UL):508A, Standard for Safety Industrial Control Panels.698, Standard for Industrial Control Equipment for Use in Hazardous Locations698A, Standard for Industrial Control Panels Relating to Hazardous LocationsMiscellaneous:[NTS: Requiring certification is a means of obtaining services of quality panel builders. Although some individuals insist UL certification is optional, most states mandate panel certification. Do not waver on this requirement; mandate that all panels are UL certified.] All control panel assembly, fabrication and wiring to be performed by a UL certified shop. Entire assembly shall be affixed with a UL 508A label "Listed Enclosed Industrial Control Panel" prior to shipment to the jobsite.Control panel(s) without an affixed UL 508A label shall be rejected and the CONTRACTOR shall return the rejected item to the factory.submittalsShop Drawings:See Specification Section 01 33 00 – Submittal Procedures for requirements for the mechanics and administration of the submittal process.See Specification Section 40 61 13 – Process Control System General Provisions.Product technical data including:Acknowledgement that products submitted meet requirements of standards referenced.Prepared with computer aided design (CAD) software. Acceptable software shall be:AutoCAD [NTS: Verify OWNER’S preferred AutoCAD version and specify here.]AutoCADAll drawings shall conform to the OWNER’S CAD Standards in format and content.Printed on 11 by 17 IN sheets.Drawings shall include a title block including, at minimum, the following information:Plant, Collection System site or facility name where panel(s) are to be installed.Drawing title.Drawing number.Revision list with revision number and dateDrawing date.Drawing scale.Manufacturer name, address, and telephone number.Cover sheet for each drawing set shall indicate the following:Plant, Collection System site or facility name.Project name.Submittal description.Revision number.Issue date.Table of contents sheet(s) shall indicate the following for each drawing in the set:Drawing number.Drawing title.Sheet number.Revision number.Submit detailed panel wiring diagrams consisting of the following:Panel power distribution diagrams.Control and instrumentation wiring diagrams.Clearly identified termination arrangements and terminal numbering.Clearly identified wire numbers.Identify wire colors and sizes.Wire and termination descriptions.{PLC}{RTU} I/O information:Model number of I/O module.Description of I/O module type and function.Rack and slot number.Terminal number on module.Point or channel number.Programmed point addresses.Signal function and type.Wiring diagrams shall identify each wire as it is to be labeled.Wiring diagrams shall clearly identify all field input devices and associated terminations.Wiring diagrams shall clearly identify all outputs and associated terminations to external panels and/or PCS.Wire-duct fill calculations depicting percent-fill for each duct with anticipated field wiring. Calculations should indicate current design separately from panel at full capacity. Full capacity is the now “future/spare space” populated with anticipated equipment. Design shall allow for 50% future capacity in each duct.{Shop Drawing electronic files:}{Electronic files for each Shop Drawing.}{Electronic files shall be in PDF format.}{Furnished on electronic or optical media.}{When panel color is selected, submit evidence of written statement advising electrical equipment manufacturers, subcontractors and other panel sources for the Project of the selected color specification, coating type, manufacturer.}[NTS: Include this in Contract Drawings if possible so spatial relationships are well understood prior to beginning fabrication of panels.]Scaled floor plan for the location of each panel and/or control station, showing relationship (scaled and dimensioned) between mechanical HVAC, electrical, plumbing, and structural items.Contract Closeout Information:Operation and Maintenance Data:See Specification Section 01 78 23 – Operation and Maintenance Data for requirements for the mechanics, administration, and the content of Operation and Maintenance Manual submittals.See Specification Section 40 61 13 – Process Control System General Provisions for PCS record documentation and other close-out requirements.[NTS: The Informational Submittals paragraph is used to list other submittals of information which are not subject to provisions of Specification Section 01 33 00 – Submittal Procedures review and approval.]Informational Submittals:As-delivered Panel Drawings:Updated panel drawings delivered with the panel(s) from the CONTRACTOR’s factory.Drawings shall be enclosed in transparent plastic and firmly secured within each panel.definitionsPanel: Control panels or enclosures listed in the schedule included in this Specification Section.Foreign Voltages: Voltages that may be present in circuits when the panel main power is disconnected.Intrinsically Safe:A device, instrument or component that will not produce sparks or thermal effects under normal or abnormal conditions that will ignite a specified gas mixture.Designed such that electrical and thermal energy limits inherently are at levels incapable of causing ignition.Cable: Multi-conductor, insulated, with outer sheath containing either building wire or instrumentation wire.Instrumentation Cable:Multiple conductors, insulated, twisted or untwisted, with outer sheath.Instrumentation cable is typically either TSP (twisted-shielded pair) or TST (twisted-shielded triad), and is used for the transmission of low current or low voltage signals.Ground Fault Circuit Interrupter (GFCI): A type of device (e.g., circuit breaker or receptacle) which detects an abnormal current flow to ground and opens the circuit preventing a hazardous situation.Programmable Logic Controller (PLC): A specialized industrial computer using programmed, custom instructions to provide automated monitoring and control functions by interfacing software control strategies to input/output devices.Remote Terminal Unit (RTU): An industrial data collection device designed for location at a remote site, that communicates data to a host system by using telemetry such as radio, cellular telephone, or leased telephone lines.Input/Output (I/O): Hardware for the moving of control signals into and/or out of a PLC or RTU.Process Control System (PCS): A system of electronic devices that executes process control and monitoring for a process facility. A PCS processes inputs from humans and process instruments, and provides control functions in accordance with approved design control strategy. A PCS is used to control the process within pre-set operating conditions, optimize operations, keep process variables within safety limits, provide operator interfaces for monitoring and control, and provide alarm/event logging, trending and reporting functions.Highway Addressable Remote Transducer (HART): An open, master-slave protocol for bus addressable field instruments.Digital Signal Cable: Used for the transmission of digital communication signals between computers, PLCs, RTUs, etc.Uninterruptible Power Supply (UPS): A backup power unit that provides continuous power when the normal power supply is interrupted.Loop Calibrator: Portable testing and measurement tool capable of accurately generating and measuring 4-20ma DC analog signals.productspanel wiring and termination[NTS: Comply with NEORSD Electrical Standards and Conventions Manual]All wiring to panel connections from field instruments, devices, and other panels shall be terminated at master- numbered terminal strips, unless otherwise specified.Splicing of conductors or cables is not permitted.Provide copper ground bar(s) for all panel equipment.Internal wiring shall be Type THHN/THWN dual rated, stranded copper wire with thermoplastic insulation rated for 600 V at 90 C for single conductors, color coded and labeled with wire identification.Panel wire duct shall be installed between each row of components, and adjacent to each terminal strip.Route wiring within the panel in wire-duct neatly tied and bundled with tie wraps.Follow wire-duct manufacturer's recommended fill limits. 50% spare capacity shall be allowed for in all ducts. Wire-duct shall have removable Snap-On covers and perforated walls for easy wire entrance.Wire-duct shall be constructed of nonmetallic materials with rating in excess of the maximum voltage carried therein.Wiring shall be installed such that if wires are removed from one (1) device, source of power will not be disrupted to other devices.Wire bunches to doors shall be “S” shaped with the vertical section by the door hinge and secured at the top curve and bottom curve so that when the door opens or closes, the bending or twisting will be around longitudinal axis of wire. Protect bend area with sleeve.Arrange wiring neatly, cut to proper length, with surplus wire removed. Arrange wiring with sufficient clearance.Provide abrasion protection for wire bundles that pass through openings or across edges of sheet metal.Wiring to pilot devices or rotary switches shall be individually bundled and installed with a "flexible loop" of sufficient length to permit the component to be removed from panel for maintenance without removing terminations.Internal panel wiring color code:AC circuits:Power wiring: BlackControl interconnections: RedNeutral: WhiteGround: GreenLow voltage DC circuits:Power wiring: (+): Red with White trace(-): Black with White traceControl interconnections:(+): Blue(-): White with Blue traceForeign voltage circuits: YellowAnnunciator circuits: RedIntrinsically safe circuits: Light Blue jacket(+): Light Blue (-): Light Blue with White traceFor internal panel DC signal wiring, use shielded, minimum No. 18 AWG. For DC field signal wiring, terminal strips shall be capable of handling minimum No. 12 AWG wiring. All DC signal wiring must use black and clear conductor colors, where black is used for (+) terminals and clear is used for (-) or common terminals.For internal panel AC power wiring, use minimum No. 12 AWG. For AC signal and control wiring, use minimum No. 16 AWG. For wiring carrying more than 15 amps, use sizes required by the NEC.Separate and shield DC signal wiring from power and control wiring by a minimum of 12 inches. Design to avoid DC and power/control wiring from crossing each other. If a crossing cannot be avoided, then the crossing shall be at right angles. See Table 2.5 – Separation Distances provided under Specification Section 40 67 00 – Equipment Panels and Racks.Provide at least 6 IN of separation between intrinsically safe devices and circuits and non-intrinsically safe devices and circuits.Group or bundle parallel runs of wire using covered wire-way. Maximum bundle size to be 1 inch. Install wire wire-way along horizontal or vertical routes to present a neat appearance. Angled runs are not acceptable.Mount wire-way parallel to terminal strips. Provide adequate spacing, with a 2" minimum, in order to read wire identification tag without opening wire-duct or moving any wires or panel components.Rear panel-mounted (sub-plate) equipment such as loop power supplies, receptacles, surge protection devices, media converters, etc. shall be mounted on Allen-Bradley 1492-DR5 standard DIN rail. Terminal blocks and other small, lightweight components such as circuit breakers, relays, etc. shall be mounted on Allen-Bradley 1492-DR6 high rise DIN rail.Adequately support and restrain all wiring runs to prevent sagging or other movement.All wiring shall be installed such that if wires are removed from any one device, power will not be disrupted to any other device.Provide and install spare terminal blocks in accordance with Section 40 63 43 – Programmable Logic Controllers. Provide a separate terminal for grounding each shielded cable.Where wires pass through panel walls, provide suitable bushings to prevent cutting or abrading of insulation. Penetrations to be sealed according to panel NEMA rating and environmental requirements.Conduit entry shall be made in bottom of control panels for panels furnished under Division 40. Conduit entries in the top of control panels is not acceptable. {Panel fabricator to coordinate with CONTRACTOR} {CONTRACTOR to site verify} that bottom entry conduit is viable before control panel design is complete. If bottom entry conduit is not viable, the explanation must be clearly stated in the submittal. See NEORSD Electrical Standards and Conventions Manual for conduit and conduit fitting requirements.Provide complete wiring diagram showing "as built" circuitry. All revisions must be done in CAD, no hand-written revisions allowed. Diagram shall be enclosed in transparent plastic and placed in easily accessible pocket built into panel door.Control panels shall comply with applicable requirements of NEORSD PCS Standards and Conventions Manual, Volume 5.grounding requirementsEquipment grounding conductors shall be separated from incoming power conductors at the point of entry.Minimize grounding conductor length within the enclosure by locating the ground reference point as close as practical to the incoming power point of entry.Bond electrical racks, chassis and machine elements to a central ground bus.Nonconductive materials, such as paint, shall be removed from the area where the equipment contacts the enclosure.Bond the enclosure to the ground bus.It is imperative that good electrical connections are made at the point of contact between the ground bus and enclosure.Panel-mounted devices shall be bonded to the panel enclosure or the panel grounding system by means of locknuts or pressure mounting methods.Sub-panels and doors shall be bonded to ground.Use separate 5/16 inch diameter copper grounding studs for instrument signal cable shields and AC power. Instrument signal shield ground bus (ground lug and associated ground bar(s)) shall be isolated from the AC power bus.Shop drawings shall require a connection between the AC ground bar and instrument signal shield ground bar(s). The drawings shall also require that the connections between the AC and signal shield ground bars shall be removed upon field installation if an isolated signal shield ground cable is run to the panel.Minimize instrument cable leads outside of shields (1?" max). Instrument signal cable shields are not to be terminated at the instrument or PLC, but grounded at their associated terminal strip within the panel.termination requirementsWiring to circuits external to the panel shall be connected to interposing terminal blocks.Terminal blocks rigidly shall be mounted on DIN rail mounting channels.Terminal strips shall be located to provide adequate space for entrance and termination of the field conductors.One (1) side of each strip of terminal blocks reserved exclusively for the termination of field conductors.Terminal block markings:Marking shall be the same as associated wire marking.Legible, machine-printed markings.Markings as identified in the shop drawings.Terminal block mechanical characteristics, and electrical characteristics shall be in accordance with NEMA ICS 4.Terminal blocks with continuous marking strips.Each terminal block shall be identified with machine printed labels.Terminals shall facilitate wire sizes as follows:120 Vac applications: Conductor size 12 AWG minimum.Other: Conductor size 14 AWG minimum.Analog signal cable shield drain conductors shall be individually terminated.Install minimum of 20 percent spare terminals.Bladed, knife switch, isolating type terminal blocks where control voltages enter or leave the panel.Fused terminal blocks shall be used in the following circuits:Control voltage is used to energize a solenoid valve.DC power is connected to 2-wire, loop-powered instruments.Fused terminal blocks shall be provided with blown fuse indicators.When control circuits require more than one (1) field conductor connected to a single wiring point, a sufficient number of terminal points shall be connected internally to allow termination of only one (1) field conductor per terminal block.DIN rail mounting channels shall be installed along full length of the terminal strip areas to facilitate future expansion.Connections to devices with screw type terminals shall be made using spade-tongue, insulated, compression terminators.power distributionMain incoming power circuits shall be protected with a thermal magnetic circuit breaker {and surge suppressor} {and surge suppressor unless the control panel is protected by a dedicated UPS}.Limit load to maximum of 80 percent of circuit breaker rating.Surge suppressor shall be type UL 1449.Phoenix Contact SFP 1-20/120AC (2856702) or ponent types listed below shall be individually fused so that they may be individually de-energized for maintenance:PLC/RTU power supply modules.Single-loop controllers.Recorders.Alarm annunciators.Each control panel with PLC/RTU components shall be furnished with power protection in the form of an on-line, double conversion UPS. See Specification Section 40 67 63 – Uninterruptable Power Supply.Equip each panel with necessary power supplies with ratings required for installed equipment and with minimum 25 percent spare capacity.Constant voltage transformers, balancing potentiometers, and rectifiers as necessary for specific instrument requirements.executioncontrol panel signal and control circuit wiringWiring Installation: Wires shall be run in plastic/nylon wire-duct except (1) when terminal blocks are on the edge of the control panel and do not permit space for wire duct, or (2) wiring from components on a swing out panel to components on a part of the fixed structure Wiring run from components on a swing out panel shall be bundled and affixed to the panel.. These bundles shall be tied with nylon wire ties and shall be secured to panels at both sides of the hinge loop so that conductors are not strained at the terminals.Wiring run to control devices on the front panels shall be tied together at short intervals with nylon wire ties and be secured to the inside face of the panel using adhesive mounts.There shall be a vertical run of the door wiring cable run parallel to the hinge to provide smooth door opening, but prevent the cable from bowing or looping out into the cabinet space when the door is closed.Wiring to rear terminals on panel-mount instruments shall be in plastic wire ways secured to horizontal brackets above or below the instruments in about the same plane as the rear of the instruments.Shop Drawings shall show conformance to the above wiring installation requirements.Wire Marking: Each signal, control, alarm, and indicating circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on Shop Drawings. These numbers shall be marked on conductors at every terminal. Pre-printed self-sticking labels for coding all wiring shall be as manufactured by W.H. Brady, 3M, or approved equal. No hand-written labels are permitted.END OF SECTION ................
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