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Section 11_____ Aeration System Controls Aeration DO and Variable Speed Positive Displacement Blower Control System w/ Flow

Control 1.0 General 1.1 Summary of Work A. This section provides the minimum requirements for integrated process monitoring and controls for the aeration system. The control system shall provide real time monitoring and control of dissolved oxygen (DO) and air flow for ______ (__) aeration basins and protection and control for ______ (__) variable speed multistage centrifugal blowers. All items identified as part of the scope of supply of this section, including items identified as supplied under this section but specified in other sections, shall be provided by a single manufacturer. The intent of this section is to have unit of responsibility for providing aeration controls, blower controls, field devices, and transmitters. B. Items to be included under this specification include all material and services identified or specified herein and as shown on the contract drawings, engineering, programming, commissioning services, and coordination with the requirements of other sections. The principal equipment to be provided includes: Aeration blower controls with sensors, transmitters, and protection devices Control panels with PLCs (Programmable Logic Controller) and HMI (Human Machine Interface) devices Variable Frequency Drives (VFDs) Automatic control valves Sensors and transmitters as identified here-in for aeration basins Spare parts and special tools

1.2 Quality Assurance A. The manufacturer(s) specified in this section have demonstrated experience and established a record of performance in the areas of responsibility specified herein. Alternate suppliers must provide the information identified herein to the engineer at least two weeks prior to bid date. Alternate suppliers will be accepted only if, in the sole judgement of the engineer, they can demonstrate that the alternate system will result in a total life cycle cost to the owner lower than the specified system(s). B. Pre-submittal information shall be provided by alternate suppliers not less than two weeks prior to bid date and shall include: An installation list of aeration control systems similar in scope and complexity to the specified system. A list of not less than five references for existing wastewater treatment facilities similar in scope and complexity to the specified system. The list shall include addresses, phone numbers, contact names, a description of the system design, process performance criteria, a description of major components, and date of commissioning. Field test data showing the actual long term process performance shall be provided for not less than two of the systems included in the reference list. A complete description of the proposed alternate, including control system architecture, manufacturers model information and performance data for the principal equipment identified above, an explanation of control logic and control algorithms proposed, and an itemized list of additions or deletions to the electrical wiring and mechanical installation shown in the contract documents for the specified system(s). A process performance guarantee according to the requirements of this section identifying the guaranteed nominal DO deviation from setpoint. Not less than one week but not more than eight weeks after bid closing the engineer shall identify the selected supplier based on the engineers evaluation of the performance and cost

C.

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effectiveness of the alternate system(s). The qualification of alternate supplier(s) shall be based solely on the engineers professional judgement as to the ability of the alternate supplier(s) to meet the specified performance requirements. Alternate suppliers not judged qualified will not be selected regardless of system cost. Suppliers judged qualified to meet the performance requirements will be evaluated based on a twenty year present worth analysis. The present worth analysis method shall be as demonstrated in the EPA Fine Pore Aeration Systems Design Manual, EPA/625/1-89/023, Chapter 7. The following criteria shall be used for calculating the present worth: Analysis period: 240 months Energy cost: $0.06/kWh Discount rate: 4.0% Initial Cost: contractor net installed price per bid form Process water DO concentration: 1.5 ppm plus the guaranteed nominal DO deviation BOD oxygen demand: _____ lbs/day at 1.1 lbO2/lbBOD Ammonia oxygen demand: _____ lbs/day at 4.6 lbO2/lbNH3 Blower discharge pressure: as required at nominal submergence and at average air flow conditions per manufacturers pre-submittal data Blower power requirements: kWh/SCFM as determined by the blower efficiency analysis specified in Section 11_______ Maintenance manpower costs: $25.00 per hour 1.3 Submittals A. The following shall be submitted in accordance with the requirements of Division 1: ______ copies of equipment drawings and catalog cuts. Drawings shall show panel layouts and electrical schematics, dimensions of all equipment, foundation and anchoring requirements, motor data, performance curves and performance data, materials of construction, field wiring requirements, included spare parts, and weights for all equipment heavier than 1,000 lbs. Any special installation procedures or tools must be identified in the submittals. Warranty information and performance guarantees as required in this section. Test procedures and copies of typical field and shop inspection reports for major equipment ______ copies of Installation, Operation, and Maintenance Manuals shall be provided after completion of commissioning. Manuals shall include as built drawings, periodic maintenance requirements, calibration procedures, troubleshooting procedures, and guidelines for adjusting and tuning the controls. 1.5 Equipment provided under this section but specified separately: Blower Variable Frequency Drives, Section 16____ 1.6 Additional sections applicable to equipment provided under this section: A. Field Instrumentation not specified in this section, Section 13______ PLCs and HMI Devices, Section 13______ Programmable Logic Controllers , Section 13______ Valves and Operators, Section 15______ B. In case of conflict between this section and the above referenced sections the provisions of this section shall take precedence.

1.7 Additional sections to be coordinated with equipment provided under this section: A. SCADA System, Section 13______ Electric Motors, Section 16______ Aeration Blowers, Section 11____
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B.

In case of conflict between this section and the above referenced sections the provisions of this section shall take precedence.

1.8 Manufacturers Services A. Coordination of all performance and installation requirements for equipment provided under this section. Services shall include analysis of valve sizing, control and instrumentation wiring requirements. B. Coordination of the interface between equipment provided under this section but not included in the scope of supply of this section. Copies of the appropriate submittals shall be provided to the control system manufacturer for use in coordination with the control system requirements. Inspection of field installation and wiring of equipment. Field testing of all equipment provided under this section, verification of proper operation, confirmation of performance requirements, and initial system tuning. A CSV (Comma Separated Variable) file containing a list of all PLC registers and addresses required for the SCADA system to access process performance data, alarm and equipments status information, and critical control system setpoints shall be provided to the SCADA system supplier after submittal approval. An updated as built file shall be provided after completion of system field testing and system start-up. Training of operators personnel in system operating principles, tuning procedures, troubleshooting procedures, preventive maintenance, system calibration, and service procedures. The manufacturer may provide these services through qualified subcontractors or equipment manufacturers personnel but the manufacturer of the system specified shall maintain sole responsibility for coordination and proper performance of all services.

C. D. E.

F. G.

1.9 Spare Parts A. A one years supply of renewal components for instrumentation shall be provided. B. C. D. Spare fuses, lamps for pilot lights, and control relays shall be provided equal to 5% of the total quantity used in the system, but not less than six of each size and type used in the system. A full set of PLC program logic source code and HMI configuration data shall be provided to the owner on CD after execution by the owner of a single site license agreement. Any spare parts required under the individual specifications applicable to equipment provided under this section but not specified herein.

1.10 Delivery, Storage, and Handling A. The manufacturer shall be responsible for the cost of shipping and insuring during shipment all components to the jobsite and for properly packing and protecting all components prior to shipment. Any special handling and storage requirements shall be included in the shipping documents. B. The contractor shall be responsible for off loading all components, storage in a protected location, and protection of all equipment after installation and prior to acceptance by the owner.

1.11 Warranty A. The aeration control system includes a warranty on control panels and software . Materials are warranted free from defect in materials and workmanship for 12 months after acceptance or first beneficial use, or 18 months after delivery or offer to deliver, whichever occurs first.. The warranty
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shall include all PLC and operator interface parts, with removal and replacement labor provided by the owner. B. The manufacturer's standard warranty shall apply to VFDs, field sensors, control valves, wearable parts, and consumables, but shall not be less than 12 months after acceptance or first beneficial use, or 18 months after delivery or offer to deliver, whichever occurs first. The system supplier shall not be liable for consequential costs or liquidated damages. The aeration control system supplier shall warrant the process performance and control response of the system shall limit DO fluctuations under slug loading or diurnal loading conditions to a maximum excursion of 1.00 ppm for a maximum duration of one half hour and a maximum excursion of 0.50 ppm for a maximum duration of one hour, contingent on the limitations of blower capacity and oxygen transfer of the aeration system. The supplier shall be able to demonstrate oscillations, hunting, and system perturbations in response to a 2:1 change in system setpoint shall not exceed these limitations.

C.

2.0 Products 2.1 Master Control Panel (MCP) A. A NEMA 12 control panel shall be provided and located as shown on the drawings. The MCP panel shall provide PLC based control logic, Input/Output (I/O) devices, and data communications capability. The MCP shall provide data communications for the SCADA system. The MCP shall also provide local control and alarming for shared system parameters. Power for the panel shall be 120 VAC 1 Phase 60 Hz 25 Amp. B. The number of I/O signals and local control points for the MCP shall be as shown on the drawings. The I/O signals for each MCP shall include as a minimum: Mixed liquor DO concentration for each DO control zone Mixed liquor temperature for each DO control zone Air flow for each DO control zone Air flow control valve position control for each DO control zone Blower Start/Stop Run/Fail indication Blower inlet suction Blower discharge air temperature, motor speed, and motor amperage Main discharge header air pressure Control logic and data analysis included in the MCP shall include: 1. Calculation of individual control zone and total air flow required to meet system demand based on DO levels in the aeration control zone. If the DO level falls outside an operator adjustable range the aeration level for each basin will be adjusted by varying the air flow to the affected basin. The basin DO will be controlled by a floating control algorithm with a neutral range. The algorithm shall include compensation for OTE variations due to wastewater temperature, actual DO concentration, and DO saturation concentration. Systems employing Proportional-Integral-Derivative [PID] control are not acceptable. 2. Separate air flow meters and air flow control valves shall be provided for each control zone. The flow control loop shall minimize system pressure by maintaining one valve at maximum position at all times. The valve maintaining maximum position shall be determined by the flow control logic based on actual air demand. Flow control logic for all zones shall be integrated to maintain proportional air rates for each zone regardless of actual system air flow. Biased control shall be provided when decreasing flow to minimize instability. Systems employing independent air flow control logic for each zone are not acceptable. 3. Scheduled blower operation and air flow control zone flow proportioning shall be provided for use during system testing and maintenance. Up to four independent schedule periods
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C.

with separate starting times and air total system flows shall be provided. Blowers shall be stopped and started as required to maintain set air flows. Individual air flow control zones shall be adjusted to maintain air flow proportional to basin mixing requirements. 4. Selection of DO control or scheduled air blower operation 5. Determination of the total system air flow required and the number of blowers to operate and optimum blower configuration based on DO or schedule control calculations. Blower start/stop commands and air flow setpoints shall be communicated to the blower Local Control Panels (LCPs) for implementation. The MCP shall provide commands to the blower LCPs and the basin BCPs to prevent perturbation of control system operation during blower starting and stopping. After any blower failure the lag blower will be started. Blower protection shall be independent of the main controller operation. 6. Separate air flow control shall be provided for each zone as shown on the drawings. The flow control loop shall minimize system pressure using Most Open Valve (MOV) logic maintaining one valve at maximum position at all times. The valve maintaining maximum position shall be determined by the flow control logic based on actual air demand. Flow control logic for all zones shall be integrated to maintain proportional air rates for each zone regardless of actual system air flow. Biased control shall be provided when decreasing flow to minimize instability. Systems employing PID control algorithms or discharge pressure control are not acceptable. Operator adjustable mixing air flow and maximum air flow for each control zone shall override air flow targets calculated based on DO control. 7. Continuous monitoring of blower operation to prevent damage to the blowers from mechanical failure or improper operation. Monitored parameters include blower air flow as calculated from blower speed, slip, and displacement, motor overload, inlet suction (filter condition), discharge air temperature, and inlet suction. Blowers operating outside the safe operating range will be stopped and an alarm will be logged. Minimum and maximum operating speeds will override flow setpoints. Software time delays will be provided to prevent nuisance alarms while starting blowers. Blower protection shall be fully functional in Hand and Auto operation. A fail safe Run Permissive contact shall be provided to prevent blower starts if the safety shutdown system is not operating. 8. The control logic will adjust the blower speed to maintain constant air flow within the safe operating range. This loop will maintain the required air flow rate and start and stop blowers as required. Blower air flow will be modulated to meet system demand as calculated by the DO or schedule control logic. A local air flow setpoint shall override the calculated flow setpoint when the blower is operating in Hand. 9. Time delays shall be provided to prevent re-start of the blower before rotation has stopped and to prevent nuisance shutdown during blower starting. 10. Trending of critical process, blower, and diffuser performance parameters. As a minimum trends shall be provided for DO and air flow for each control zone, air flow for each blower, and discharge header pressure. 11. Alarming of critical process and blower performance parameters. Each alarm shall be logged with time and date stamps. As a minimum alarms shall be provided for DO and air flow for each control zone, air flow and failure status for each blower, and discharge header pressure and temperature. The control system shall provide real time data display and alarming. 12. Entry of setpoints, performance parameters, and tuning parameters.
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D.

All setpoints, adjustments, and tuning shall be in engineering units. Operator accessible tuning and adjustments shall include: Target DO level for each control zone Response delays for all control algorithms Off-line status for tanks and blowers to allow for routine maintenance and service Flow control logic tolerances, bias, and valve adjustment parameters Off-line status for tanks to allow for routine maintenance and service Alarm levels and delays for critical process parameters Alarm acknowledgment and alarm log clearing Front panel devices for the MCP shall include: Color LCD touchscreen HMI, 15" diagonal nominal, with dynamic graphics capability, data display, real time clock, alarm logging functions, tuning and setpoint access, and process data trending. The operator interface shall be rated NEMA 4X. The operator interface shall be as manufactured by AVG or manufacturers standard. Manual override switches for each air flow control valve Emergency Stop pushbutton for each blower Hand-Off-Auto selector switch for each blower Alarm horn, alarm light, and alarm reset pushbutton Back panel devices for the MCP shall include: Pre-programmed PLC with CPU, I/O rack, battery back-up, real time clock, power supplies, all required I/O, all required communications ports, and local and remote I/O expansion capabilities. The actual program memory usage shall not exceed 75% of CPU capacity. All I/O shall have field removable terminal strips. The PLC shall be DirectLogic manufactured by Koyo or manufacturers standard. Transient voltage surge suppressors and filters for panel power Required DC power supplies Common alarm relay with SPDT dry contacts for customer use Relays and contactors for valve control Relays as required for VFD control Fuses and circuit breakers as required Field terminal strip with disconnect terminals for all analog and communications connections

E.

F.

2.2 Variable Frequency Drives A. The VFDs shall be as specified in the above referenced sections except as noted below. A total of ______ (__) shall be provided under this section. B. Drives shall be constant torque rated and suitable for operation with positive displacement blowers with 460 VAC 3 Phase motors. VFD rating shall be at least equal to motor nameplate horsepower, and VFDs shall be capable of providing the motor voltage, amperage, and frequency required for operation at the maximum motor speed needed to provide air flow and pressure specified for the blowers. The VFD enclosures shall be NEMA 1. Front panel devices shall include disconnect switch and membrane keypad display unit. The keypad shall be capable of manual operation of the VFD and shall provide access to all drive operating parameters and adjustments. The keypad shall display speed (%), output current (amps), output frequency (Hz), Manual or Automatic operating mode, and three phase power output (kW). The VFD shall provide discrete output contacts for indication of run and fault status, and shall provide discrete inputs for Run and Run Permissive contacts from the controls. The VFD shall provide 4-20 mA analog outputs for motor amperage and speed feedback and shall accept a 4-20 mA input for speed command. VFDs shall be Cutler Hammer SV-9000 engineer approved equal.

2.3 Dissolved Oxygen Transmitters A. Basin DO shall be monitored by sensors as shown on the drawings. A total of _____ ( ) DO sensors shall be provided. Each sensor shall include analyzer, digital display, air calibration
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circuitry and separate 4-20 ma DC analog outputs for DO and mixed liquor temperature. Membrane, electrodes, and electrolyte shall be in a single removable cartridge for service. Unit enclosure shall be fiberglass and rated NEMA 4X. Mounting brackets shall be provided for probe and transmitter. DO output range shall be adjustable from 0-5 mg/l through 0-20 mg/l. A sensor self cleaning system employing a periodic blast of high pressure air across the sensor face shall be provided. An air compressor, storage reservoir, solenoid valves, and timing circuitry shall be included in the transmitter enclosure. DO transmitters shall be ATI or manufacturers standard. 2.4 Thermal Mass Air Flow Transmitters A. Air flow transmitters for the aeration basin flow controls shall be provided for each flow control zone. A total of _____( ) shall be provided and located as shown on the drawings. Air flow transmitters shall be of the fast response thermal mass type. The system shall include stainless steel insertion type probes with stainless steel compression fittings and Teflon ferrules for insertion in " NPT female pipe taps in the piping. A separate NEMA 4X electronics enclosure for the air flow transmitter shall be provided. Transmitter shall be 24 VDC powered and output shall be 4-20 mA. A local LCD display of air flow in SCFM shall be provided. A local keypad and an RS232 serial port and cable for re-scaling of the transmitter shall be provided. Flow transmitters shall be provided for pipe sizes as shown on the drawings. A factory supplied cable twenty-five feet long shall be provided to connect the probe to the electronics enclosure. Mass air flow transmitters shall be Sage Metering or manufacturers standard. 2.5 Aeration Basin Flow Control Valves A. Basin balancing valves will be motor operated butterfly valves. A total of _____ ( ) shall be provided, sized as shown on the drawings. Valves will be of the resilient seated type with bubble tight seal. Butterfly Valves shall be generally sized as shown on the drawings, but the aeration control system manufacturer is responsible for confirmation of valve sizing. Valve bodies shall be cast iron wafer style. Disks shall be cast iron undercut to minimize dry breakaway torque. Shaft shall be stainless steel. Seats and seals shall be EPDM for 225/F service. Valves shall be DeZurik, Milwaukee Valve Co. or manufacturers standard. B. Motor operators will accept 110 VAC, 1 Phase, 60 Hz control signals. Each operator will one set of Max/Min travel limit switches and a second set of include SPDT dry contact limit switches for external status indication. A spring applied electrically released motor brake shall be provided to eliminate over-travel. Intermediate valve position feedback shall not be required and 4-20 mA or pneumatic positioners are not acceptable. Valve actuation time shall be 60 seconds for 90 degrees travel. An internal anti-condensation heater and thermostat shall be provided for all outdoor mounted actuators. Motor operators shall have NEMA 4 enclosure. Motor operators shall be Texsteam/RCS, Auma, or manufacturers standard.

2.6 Blower Discharge Air Temperature Transmitters A. Blower bearing temperature shall be monitored by means of Resistance Temperature Detectors (RTDs). Transmitters shall include integral loop powered 4-20 mA transmitter with 0 to 300 /F range, compression fitting with Teflon ferrule and " NPT connector for tapped holes in the air piping, and 12 feet of integral PVC sheathed leads. A total of ___ (_) shall be provided. Transmitters shall be manufacturers standard. 2.7 Blower Inlet Suction Transmitters A. Blower inlet filter condition shall be monitored by means of inlet suction transmitters. The transmitter shall be heavy duty suction transducer, 0-25 inches water column range, with stainless steel wetted parts, NEMA 4 electrical enclosure, LCD display, and loop powered 4-20 mA output. A total of ___ (_) shall be provided. Transmitters shall be Ashcroft, Foxboro, or manufacturers standard. 2.8 Blower Discharge Pressure Transmitters A. Blower discharge pressure shall be monitored. The transmitter shall be heavy duty pressure transducer, 0-15 psig range, with stainless steel wetted parts, NEMA 4 electrical enclosure, LCD
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display, and loop powered 4-20 mA output. A total of ___ (_) shall be provided. Transmitters shall be Ashcroft, Foxboro, or manufacturers standard. 2.9 Communications System A. Communications between the MCP, and SCADA shall be by means of an RS-485 serial link. B. The RS-485 serial link shall utilize the PLC manufacturers standard protocol. Communications shall be 9600 bps minimum.

2.10 Acceptable Manufacturers A. The complete Aeration Control System shall be manufactured by ESCOR - Energy Strategies Corporation, Milwaukee, Wisconsin, or engineer approved equal. B. The contract documents have been prepared based on the above referenced supplier. The contractor is responsible for providing all changes in equipment, engineering, and installation labor required to accommodate alternate suppliers at no cost to the owner. Acceptance of alternate suppliers is contingent on the engineers evaluation of pre-submittal data, performance data, and life cycle costs as identified herein.

3.0 Execution 3.1. General Instructions A. Installation, wiring, and wire termination shall be performed by the contractor in accordance with the manufacturers written procedures and instructions. B. Removal of existing equipment, installation of new equipment, testing, and start-up shall be coordinated with the owners personnel to minimize the impact on the operation and performance of existing treatment systems. Proper notice shall be given to the owner prior to performing work that may affect the operation of existing treatment systems.

3.2 Mounting and Anchoring A. The contractor shall be responsible for foundations, slabs, equipment supports, and miscellaneous hardware not indicated in the manufacturers submittal documents as being supplied by the manufacturer. B. The contractor shall coordinate all mounting and anchoring hardware with the manufacturer as needed for conformance with the manufacturers requirements for form, fit, and function.

3.3 Wiring and Wire Terminations A. The contractor shall be responsible for field wiring, conduit, wire duct, miscellaneous hardware and wiring devices, and wire terminations per the manufacturers submittals and instructions. B. The contractor shall coordinate all wiring and conduit runs with the manufacturer as needed for conformance with the manufacturers requirements.

3.4 Inspection, Testing and Tuning A. The manufacturer shall provide on site service to inspect installation and wiring for equipment provided under this section, in addition to inspection services required under the individual specifications applicable to equipment provided under this section but not specified herein. Written confirmation of satisfactory installation and termination shall be provided by the manufacturer to the owner. B. The manufacturer shall field test all control panels, sensors, transmitters, and field devices provided with the system for proper function and verify that all PLC I/O identified herein are fully functional. Each operator interface screen shall be tested to verify that process performance and

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tuning data is accurately displayed and scaled. All communications links to the SCADA system shall be tested and verified, subject to the availability of SCADA software. C. Each control loop, alarm function, and data reporting function identified herein shall be tested and verified by the manufacturer. Control loops shall be tested for stability, response, and accuracy and performance data during the testing shall be recorded. Tuning shall be adjusted as required to meet the performance parameters defined. A written report showing the process performance data shall be provided. The manufacturer shall demonstrate system performance per the requirements identified herein to the owner or engineer as a condition of acceptance. Written confirmation of acceptance of the system performance by the owner shall be provided by the manufacturer to the contractor. A minimum of four days on site service shall be provided by the manufacturer for inspection, testing, and tuning.

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E.

3.5 Operator Training A. Training shall be provided on site to all appropriate personnel designated by the owner. Training shall include instruction in the theory of system operation and hands-on demonstration of equipment functions and adjustment. Tuning, testing, and service procedures shall be included. All safety requirements and safety procedures shall be identified. The owner shall be given proper notice prior to training sessions and the manufacturer shall verify acceptance of the training schedule by the owner. The owner may videotape all training for future use. B. C. A nominal session of four hours shall provided by the manufacturer for training, subject to owners approval. Written confirmation of acceptance of the training by the owner shall be provided by the manufacturer to the contractor.

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