QCS 2014 Section 10: Instrumentation Control Page 1

Part 01: General

1 GENERAL ...................................................................................................... 2

1.1 GENERAL REQUIREMENTS ........................................................................ 2

1.1.2 Scope 2
1.1.3 References Standards 2
1.1.4 System Responsibility 3
1.1.5 Presubmittal Meeting 3
1.1.6 Submittals 3
1.1.7 Quality Standards 6
1.1.8 Manufacturers Experience 6
1.1.9 Factory Inspection 7
1.1.10 Factory Tests and Test Certificates 7
1.1.11 Shipment, Storage, and Handling 7
1.1.12 Guarantee 7
1.1.13 Job Conditions 8
1.1.14 Approved Manufacturers 8
1.1.15 Approved Installation Subcontractors 8
1.1.16 Spare Parts and Tools 8
1.1.17 Software 8
1.2 PRODUCTS ................................................................................................... 9
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1.2.1 Materials 9
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1.2.2 Structural Steel Fabrications 9

1.2.3 Mountings 9
1.2.4 Instrument Identification 10
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1.2.5 Electronic Equipment 10

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1.2.6 Equipment Operating Conditions 10

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1.2.7 Power Supplies 10

1.2.8 Signal Isolators, Converters and Conditioners 11
1.2.9 Auxiliary Contacts by Others 11
1.2.10 Air Supply Valves 11
1.2.11 Instrument Piping 11
1.2.12 Filter Regulator 11
1.2.13 Manifolds 11
1.2.14 Painting and Protective Coatings 11
1.2.15 Electrical 11
1.2.16 Process Connections 12
1.3 INSTALLATION ........................................................................................... 12
1.3.1 Inspection 12
1.3.2 Preparation of Installation Areas 12
1.3.3 Installation and Supervision 12
1.3.4 Instrument Calibration 13
1.3.5 System Validation 13
1.3.6 Commissioning 14
1.3.7 Final Acceptance 14
1.3.8 Commissioning Assistance 14
1.3.9 Instruction and Training of The Owner's Personnel 14
1.3.10 Specialised Training Programme for Owner‟s Personnel 14
QCS 2014 Section 10: Instrumentation Control Page 2
Part 01: General

1 GENERAL
1.1 GENERAL REQUIREMENTS
1 This Part covers the general requirements for design, supply, installation and commissioning
of all instrumentation, control and automation (ICA) systems complete in every detail as
specified in the other Parts of Section 10.

2 The complete ICA system, shall be furnished by a single ICA Subcontractor to ensure system
uniformity, subsystem compatibility and co-ordination of all system interfaces. Deviations
shall be as specified in the Project Specification or approved by the Engineer.

1.1.2 Scope

1 Provide all tools, equipment, materials, and supplies and perform all labour required to
complete the supply and installation, including all instrumentation signal and power conduit
and wiring not specifically shown on the electrical drawings, validation, start-up and
commissioning of a complete and operable ICA system as indicated in the Project
Specification.

2 Provide all the necessary equipment components and interconnections and the services of
the manufacturers, engineering representatives for the engineering, implementation,
commissioning, operation, and instruction, to ensure that the Owner receives a completely
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integrated and operational ICA system as herein specified.
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3 Related Sections and Parts

This Section
Part 2, General Telemetry/SCADA
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Part 3, Primary Elements

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Part 4, Panel Mounted and Miscellaneous Field Instruments

Part 5, Panel and Control Room Hardware
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Section 8, Sewerage
Section 9, Mechanical and Electrical Equipment
Section 21, Electrical Works
1.1.3 References Standards

1 The standards referred to for Manufacturers quality procedures and documentation are:
ASTM A123, A386......Galvanizing
ASTM A36, A500, A501, A570, A618, Structural steel shapes

BS 970........................Wrought steel for mechanical and allied engineering purposes

BS 5308......................Instrumentation Cable

BS EN 10084..............Case hardening steels. Technical delivery conditions

BS EN 60654..............Operating conditions for industrial process measurement and control

BS ISO 5725 ..............Accuracy of measurement methods and results

BS ISO 9000-2 ...........Quality procedures
QCS 2014 Section 10: Instrumentation Control Page 3
Part 01: General

1.1.4 System Responsibility

1 Contractor's attention is directed to the fact that the ICA system as specified in these ICA
Parts of Section 10 is an integrated system, and therefore shall be provided by a single
competent, qualified instrumentation Subcontractor (hereinafter referred to in these ICA
Sections as the ICA subcontractor) who shall have total responsibility for the ICA work of this
Section. Entire system installation including calibration, validation, commissioning,
operational testing, and training shall be performed by qualified personnel, possessing all the
necessary equipment and who have had experience performing similar installations. The
system shall be integrated using the most modern and proven design and shall, as far as
practical, be of one manufacturer. Overall system performance shall be guaranteed by the
ICA Subcontractor.

2 The Contractor shall appoint a qualified ICA Subcontractor who shall perform the work under
this ICA Section, the Contractor shall be fully responsible at all times for the conduct and
performance of the appointed ICA Subcontractor. Although many references made herein
are to work requirements and responsibilities of the ICA Subcontractor such references shall
only mean that responsibility shall pass through the ICA Subcontractor but in the final
analysis shall rest with the Contractor.

3 The ICA Subcontractor shall be responsible for the correct installation of all hardware and
systems specified in this ICA Section. Certain primary elements, final control elements, etc.,
although provided as part of this Section, shall be installed in the process lines under other
Sections of these Specifications; however, this installation shall be under the direct
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supervision of the ICA Subcontractor.

4 The ICA Subcontractor shall be responsible to see that all components of the instrumentation
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system, including primary measuring, indicating, transmitting, receiving, recording, totalising,

controlling, and alarming devices and all appurtenances, are completely compatible and shall
function as outlined and he shall furnish and install such additional equipment, accessories,
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etc. as are necessary to meet

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1.1.5 Presubmittal Meeting

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1 The Contractor shall arrange a meeting between the ICA Subcontractor and the Engineer
within sixty (60) days after award of the Contract for a detailed discussion and verification of
the ICA Subcontractor's system engineering methods and equipment and to generally
provide a framework for communication and co-ordination. This meeting shall be attended
by ICA Subcontractor, Contractor and the Engineer.

1.1.6 Submittals

1 Submittals and approvals schedule shall generally be as specified under Section 9, Part 1,
Clause 1.1.4. All items proposed for this section shall be listed. Items shall be identified by
tag number, description, function, manufacturer, model number, descriptive literature and
statement as to whether items is “as specified or equivalent”. Logic diagrams and flow charts
illustrating the process control philosophy, shall be provided.

2 Shop Drawings. Before proceeding with any manufacturing, submit shop drawings for
approval in complete bound sets indexed by specification number. Describe the items being
submitted. Manufacturer's specification or data sheets shall be clearly marked to delineate
the options or styles to be furnished. Submit only complete systems, not pieces of equipment
from various systems.

(a) show dimensions, physical configurations, loop diagrams and cable termination
schedules
QCS 2014 Section 10: Instrumentation Control Page 4
Part 01: General

(b) submit fabrication drawings, nameplate legends, and control panel internal wiring and
piping schematic drawings clearly showing all equipment and tag numbers on all
panels
(c) submit panel graphic drawings where applicable. Include material specifications lists
where applicable. Include a draft of the theory of operation for all relay or PLC logic
circuits and analogue control loops
(d) Process and Instrumentation Diagrams. Prepare and submit instrumentation loop
diagrams for all work included in the ICA Sections in accordance with BS 1646.

3 Within 90 days from the start of the Contract, submit an "Equipment Specification Data" form
for each item of equipment which shall summarise the specification features as called for in
these Specifications and include such other necessary data as would provide a complete and
adequate specification for reordering an exact duplicate of the original item from the
manufacturer at some future date. The assigned tag numbers and manufacturer's part
numbers shall be included but will not be considered as a substitute for any of the required
statement of specifications. More than one tag numbered item may be included on a sheet.

4 Operation and Maintenance Manuals and Instructions. Furnish instruction manuals and part
lists for instrumentation equipment provided under the ICA sections. Obtain distribution
method instructions from the Engineer.

(a) schedule. Deliver two (2) copies of manuals 60 days before commencing the Site
Acceptance Tests. After installation is complete, update the manuals to reflect any
changes which occurred during installation and deliver the remaining three copies of
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manuals to the Engineer immediately after the Site Acceptance Test. The manuals
shall be in English.
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(b) manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment
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(c) where several sub-contractors and manufacturers have supplied equipment the
Contractor shall, if required by the Engineer provide a complete integrated manual
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which clearly demonstrates the inter-relation of the equipment

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(d) manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring
binders. Lever arch binders are not acceptable. The full project title shall appear on
the cover and spine
(e) the manuals shall enable the client to safely operate and maintain all parts of the works
(f) Original copies of leaflets and instructions provided by the specialist manufacturers
shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text
(g) all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and
in accordance with other recognised guidelines on technical manual writing.
(h) contents. include, in the manuals, not less than the following information, as
applicable, for each instrument, equipment, subsystem and/or control loop:
(i) general, introduction and overall description, purpose, functions, simplified
theory of operations, etc
(ii) specifications (including equipment specification data sheet as described above
under Shop Drawings)
(iii) installation procedures, commissioning and operational procedures and
precautions
(iv) shut-down procedures
(v) suitability based on HAZAN/HAZOP studies
(vi) maintenance, calibration, and trouble shooting instructions
QCS 2014 Section 10: Instrumentation Control Page 5
Part 01: General

(vii) schematics and wiring diagrams or flow charts

(viii) detailed circuit operational description including annotated programmable
controller ladder diagrams or flow charts
(ix) parts list and spare parts recommendations as specified in Section 9.
(x) material, test and calibration certificates
(xi) copies of final approved equipment specification data forms.
(i) format. Use drawings and pictorials to illustrate the text to the extent necessary to
ensure a clear, concise presentation. If manuals have been written to cover a family of
similar instruments or equipment, strike out inapplicable information in a neat fashion
or emphasise applicable portion by heavily weighted arrows, circles or boxes;
whichever provides the clearest and neatest presentation. Where identical
instruments are used in more than one control loop or subsystem, include only one
instruction manual, however, an index by tag number for all instruments shall identify
its location in that manual
(j) control loop and/or subsystem operational descriptions shall identify the function of
each instrument and its relation to the other instruments in the loop
(k) binding. Bind each manual in a cover which indicates the system name,
manufacturer's name, local address and telephone number, and year of purchase.
Punch and bind manuals in standard three ring binders and include system name and
ICA Subcontractor's name on binding.
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5 Further to the above Clause 1.1.5.4, the Contractor shall ensure that the structure of the
operation and maintenance manual meets the conditions specified in Section 1 Clause
7.12.2 or otherwise agreed with the Engineer.
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6 Record Drawings:
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(a) The Contractor shall submit complete schematics, wiring diagrams and installation
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drawings to include all installed field and panel conduit and piping/tubing runs and
routing, tray systems, supports, mounting details, point to point diagrams with a cable,
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wire, tube and termination numbers. One copy of applicable schematics and diagrams
shall be placed in each control panel in a protective envelope or binder
(b) the above are to be supplied to the satisfaction of the Engineer. The Contractor
shall provide the Owner prints of each on thick paper and one ISO size A1
negative of each. All drawings shall be prepared on a CAD system
and printed on ISO standard sized paper A3 unless specifically requested
otherwise. One set of drawings shall also be submitted in Windows based
AutoCAD System software version and storage media shall be as approved by the
Engineer. Each drawing shall be marked with the Owner‟s, Consultant‟s,
Contractor‟s and manufacturer‟s names and references, drawing number, title,
scales, date of completion and a full description and date of all amendments, and
shall be certified „as-built‟. The project title shall be included in a box at the bottom right
hand corner of each drawing.

7 ICA Subcontractor's System Validation Report. The ICA Subcontractor, shall submit a report
for each control system, panel and associated field instruments certifying that the equipment:

(a) had been properly installed under his supervision

(b) is in accurate calibration
(c) was placed in operation in his presence
(d) has been checked, inspected, calibrated and adjusted as necessary
(e) has been operated under maximum power variation conditions and operated
satisfactorily, and
QCS 2014 Section 10: Instrumentation Control Page 6
Part 01: General

(f) fully covered under the terms of the guarantee

This report shall indicate calculated system tolerances, data verifying that the system meets
these tolerances, and any provisional settings made to devices. Data sheets shall be similar
to those used for Calibration.
8 Factory Acceptance Test (FAT) and Site Acceptance Test (SAT). Submit for approval at
least 30 days prior to the test demonstration, a written plan for demonstrating that each
system of equipment provided under the ICA Sections meets the specified operational
requirements. The plan shall include procedures to be used in final operation testing of entire
systems including a description for each system of test methods and materials, testing
instruments and recorders, a list of the equipment involved with the functional parameters to
be recorded on each item, and shop drawings of required temporary by-passes and like
facilities.

9 Final Acceptance Report. Submit three copies of certified test results and records.

1.1.7 Quality Standards

1 Qualification and Manufacturers. The ICA Subcontractor shall be an approved systems

integrator, a panel fabricator, and installer of field instruments. The ICA Subcontractor shall
have a minimum of 5 years documented experience in providing ICA equipment on a single
system responsibility basis, of which at least 3 years shall be for municipal water and
wastewater pumping stations and sewage treatment works. The personnel employed for
system engineering, supervision, start-up, operational testing and training shall be regular
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employees of the ICA Subcontractor. The ICA Subcontractor shall be fully responsible for the
technical supervision of the installation to ensure that it is proper in all respects.
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2 Certification by Single ICA Subcontractor. At the time of quoting to prospective contractors

prior to tender opening, each prospective single ICA Subcontractor shall execute and submit
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a written certification of intent to assume full responsibility for the complete requirements of
the ICA Section including deputation of qualified personnel for instructing operating personnel
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and preparing technical documentation. A certificate of compliance with the ICA

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specifications shall also be provided.

3 Standard of Quality. Furnish equipment of the types and sizes specified which has been
demonstrated to operate successfully. Wherever, in the Project Specification and in these
specifications, materials or equipment have been specified by using the name of products or
manufacturers, the term "or equal and approved" is always understood to follow immediately.
Material and equipment, so specified, has been selected as being most suitable and is
regarded as a standard and is not intended to eliminate others of equal quality and
performance. Workmanship for the installation of instruments, wiring, piping, painting and
labelling shall be equal to the best industrial standards for instrumentation and control work.

4 All equipment shall be suitable for installation and continuous services in the climatic
conditions prevailing in Qatar.

5 All electrical equipment and materials, including their installation, shall conform to the
standards specified for each equipment, unless specified otherwise in this Section.

6 All equipment of a similar type shall be supplied from a single manufacturer to ensure
common spares, operation and maintenance procedures.

1.1.8 Manufacturers Experience

1 The ICA manufacturers shall demonstrate a successful track record of having complete
similar ICA installation works. The ICA Subcontractor shall provide a reference list from the
instrumentation manufacturers for having installed and commissioned instruments operating
under process and ambient conditions similar to the specified works.
QCS 2014 Section 10: Instrumentation Control Page 7
Part 01: General

1.1.9 Factory Inspection

1 Factory Inspection. The Engineer or his representative may inspect fabricated equipment at
the factory. Notify the Engineer at least 30 days prior to shipment, so that factory inspection
can be arranged. Factory inspection shall be made only after manufacturer has performed
satisfactory checks, adjustments, tests and operations. Tests shall be made using simulated
inputs and output loads. Approval of equipment at the factory only allows the manufacturer to
ship the equipment to the site, and does not constitute final acceptance by the Engineer.

2 The Engineer reserves the right to inspect the ICA equipment at the factory. The Engineer
will indicate on return of the approved submittal, each item requiring factory inspection.

1.1.10 Factory Tests and Test Certificates

1 Factory test carried out for primary elements shall include pressure and calibration tests.
Certificates shall be provided for pressure test, calibration test and conformity to
specifications. Material certificates shall be furnished if it is so specified.

2 Factory Acceptance Test (FAT) shall be carried out for the control and automation equipment
such as control panels. FAT procedure shall be submitted to the Engineer for approval. FAT
based on the approved test procedure shall be witnessed by the Engineer or his authorized
representative at expense of the Contractor.

3 If after examining or testing any equipment the Engineer, or his representative, shall decide
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that such equipment or any part thereof is defective or, not in accordance with the
specification, he may reject the said equipment or part thereof. He shall notify the Contractor
in writing within 7 calendar days of the rejection, stating the grounds on which the rejection is
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based.

1.1.11 Shipment, Storage, and Handling

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1 Box, crate, or otherwise enclose and protect instruments and equipment during shipment,
handling, and storage. Keep all equipment dry and covered from exposure to weather,
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moisture, corrosive liquids, and gases or any element which could degrade the equipment.
Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repair
any damage or replace defective equipment, as directed and approved by the Engineer.

1.1.12 Guarantee

1 The Contractor shall provide a guarantee during the maintenance period for all the equipment
in accordance with the General Conditions of the Contract.

2 Equipment warranty shall cover defects in materials or workmanship for 400 days from date
of satisfactory completion of Site performance test and issue of Practical Completion
Certificate.

3 Individual warranties by component manufacturer in lieu of single source responsibility shall

not be acceptable.

4 Items which fail during the warranty period, excluding expendable items, shall be replaced
without cost to the Owner.
QCS 2014 Section 10: Instrumentation Control Page 8
Part 01: General

1.1.13 Job Conditions

1 Drawings are diagrammatic and show the intended arrangement for system operation,
piping, and appurtenances. Conform to Drawings as closely as possible and exercise care to
secure neat arrangement of piping, valves, conduit, and like items, and to overcome
structural interferences. Verify dimensions and conditions at the place of work, and install
materials and equipment in the available spaces.

1.1.14 Approved Manufacturers

1 The ICA equipment shall be provided by approved, prequalified system manufacturers and
suppliers designated in the Project Specification.

1.1.15 Approved Installation Subcontractors

1 Installation Subcontractor shall be approved, prequalified and designated in the Project

Specification.

1.1.16 Spare Parts and Tools

1 Furnish the following items as specified herein. Provide the Engineer, with an itemised list in
a letter of transmittal accompanying each shipment.

2 Special Tools and Accessories. Furnish special tools, instruments, and accessories for
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maintaining instruments and equipment requiring periodic repair and adjustment as specified
elsewhere in this Section. Also, furnish special lifting and handling devices for equipment
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requiring such devices.

3 Maintenance Materials and Spare Parts. Deliver in manufacturer's original containers

labelled to completely describe contents and equipment for which it is furnished.
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4 Spare parts shall be sufficient for 2 years of normal service from completion of the
maintenance period, and shall include, as a minimum, the following basic items:
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(a) five (5) percent but not less than one (1) minimum of each type of plug-in unit, etched
or printed circuit board assembly
(b) ten (10) percent but not less than one (1) of each type relay and timer used
(c) ten (10) percent but not less than one (1) of each type switch used
(d) twenty (20) percent but not less than ten (10) of each type light bulb and fuse used
(e) 2 years supply of expendable items, diskettes, toner cartridges etc.

1.1.17 Software

1 The ICA Subcontractor shall be responsible for obtaining all software user licences for
development and runtime systems as necessary. Application software written specifically for
the Owner under this contract shall remain the property of the Owner and shall not be
disclosed, copied or distributed at any time to a third party without the Owners explicit written
consent.
QCS 2014 Section 10: Instrumentation Control Page 9
Part 01: General

1.2 PRODUCTS

1.2.1 Materials

1 The ICA Subcontractor shall provide instruments, equipment and materials suitable for
service conditions and meeting the appropriate British Standards. The intent of this
Specification is to secure instruments and equipment of a uniform quality and manufacture
throughout the plant; i.e., all instruments in the site, i.e., all instruments supplied by the ICA
Subcontractor, of the same type shall be by the same manufacturer. This allows the stocking
of the minimum number of spare parts.

1.2.2 Structural Steel Fabrications

1 The ICA Subcontractor shall design all fabrications for dynamic and vibratory loading. Use
structural steel shapes conforming to ASTM A36, A500, A501, A570, A618, or equal and
approved, as applicable. Conform welding to AWS D2.0 Code. Galvanize specific items in
accordance with ASTM A123 or A386 as applicable; use galvanized bolts and fasteners with
galvanized assemblies. Use minimum 6 mm thickness for steel entirely or partially
submerged during equipment operation. Submit design calculations showing adequate
structural integrity for the intended purpose.

1.2.3 Mountings

1 The ICA Subcontractor shall mount and install equipment as indicated in the Project
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Specification. Where not shown, mount site instruments according to best standard practice
on pipe mounts, pedestal mounts, or other similar means in accordance with suppliers
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recommendation. Where mounted in control panels, mount according to requirements of

Part 4 of this Section.
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2 Equipment specified for Site mounting shall be suitable for direct pipe mounting, pedestal
mounting, or surface mounting and non in-line indicators and equipment with calibration
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adjustments or requiring periodic inspection shall be mounted not lower than 900 mm nor
higher than 1500 mm above walkways, platforms, catwalks, etc. so as to provide easy
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access. All such equipment shall be weather and splash proof, and electrical equipment
shall be in IP 66 enclosures. External equipment shall be protected from direct sunlight by a
well ventilated cabinet, canopy or other type of sunshade. If mounted in a designated
hazardous area, the equipment shall be explosion proof or rated intrinsically safe, whether so
specified herein or not.

3 The equipment shall be guaranteed suitable for operation under the climatic conditions
specified in under Clause 1.2.6 of this Part and shall be designed:-

(a) such that routine and occasional maintenance throughout its life shall be a practical
minimum compatible with the preservation of maximum reliability
(b) to withstand the electrical, mechanical, thermal and atmospheric stresses to which it
may be subjected under operational conditions, without deterioration or failure
(c) constructed to the highest available standards of manufacture, reliability, accuracy and
repeatability
(d) the degree of protection for equipment enclosures shall be in accordance with
BS EN 60529

4 Provide protection from direct sun light for all ICA equipment installed outdoors.
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Part 01: General

1.2.4 Instrument Identification

1 All instrumentation and equipment items or systems specified in the Project Specification
shall be identified by system and tag numbers. This same number shall appear in the tag
number designations on the Drawings and on the schedules of the Project Specification.
Nameplates for panels and panel mounted equipment shall be as specified in the Project
Specification. Field equipment shall be tagged with assigned instrumentation tag number
and function. Tags shall be black lamacoid with engraved white characters of 5 mm
minimum height. Tags shall be attached to equipment with a commercial tag holder using a
stainless steel band with a worm screw clamping device or by a holder fabricated with
standard hose clamps and meeting the same description. In some cases where this would
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be impractical, use 0.5 mm stainless steel wires. For field panels or large equipment cases
use stainless steel screws, however, such permanent attachment shall not be on an
ordinarily replaceable part. In all cases the tag shall be plainly visible to a standing observer.
In addition to tags, field mounted control stations, recorders or indicators shall have a
nameplate indicating their function and the variable controlled or displayed. Nameplate shall
be attached by one of the above methods.

1.2.5 Electronic Equipment

1 If the equipment is electronic in nature, provide solid state equipment to the extent
practicable. Select components of construction for their suitability and reliability. Employ
adequate component derating to preclude failures because of transients and momentary
overloads reasonably expected in normal operation. Provide units for operation without
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forced cooling, unless such cooling is an integral part of the device. Provide protection on all
relevant circuits and equipment against the effects of lightning and other induced voltages.
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1.2.6 Equipment Operating Conditions

1 All equipment shall be rated for normal operating performance with varying operating
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conditions over the following minimum ranges.

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2 Power:
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(a) electrical. 240 V a.c. ± 5 %, 50 Hz ± 1 Hz except where specifically stated otherwise

on the drawings or in the specifications
(b) air. 1.4 bars.

3 Field Instruments:

(a) all the ICA equipment supplied shall be suitable for operation in the tropical climate
prevalent in Qatar. All ICA equipment shall be designed and constructed to operate
satisfactorily and without any deleterious effect for prolonged and continuous periods
at the following maximum ambient temperature conditions:
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(i) indoors in normally air-conditioned environment - 50 C
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(ii) indoors in a ventilated environment - 55 C
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(iii) outdoors under direct sunlight - 85 C

1.2.7 Power Supplies

1 The ICA Subcontractor shall provide electrical instruments, transmitter power supplies and
control devices for operation on 110 V a.c., 50 Hz. Transmitter power supplies shall be
provided for individual transmitters. Where designated in the Project Specification, process
critical instruments shall receive power from a UPS, as specified in Section 21.
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Part 01: General

1.2.8 Signal Isolators, Converters and Conditioners

1 The ICA Subcontractor shall ensure that input-output signals of all instruments and control
devices (whether supplied by the ICA Subcontractor or not) are compatible. Unless
otherwise specified in the Project Specification, signals between field and panels shall be volt
free contacts or 4 to 20 mAdc, unless specifically approved otherwise. Granting such
approval does not relieve the ICA Subcontractor from the compatibility requirement above.
Provide signal isolators and converters as necessary to obtain the required system
performance. Mount the devices behind control panels or in the Site at the point of
application.

1.2.9 Auxiliary Contacts by Others

1 The ICA Subcontractor shall provide instruments and equipment to interface with auxiliary
contacts provided under other Contracts, for alarms, status of equipment, interlocking, and
other functions as indicated and as specified in Project Specification.

1.2.10 Air Supply Valves

1 The ICA Subcontractor shall provide 316S12 valves for instrument air supply shutoff,
regulating, switching, metering, valve manifolds, etc. Provide a separate isolation valve for
each instrument or actuator feed line.

1.2.11 Instrument Piping

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1 The ICA Subcontractor shall provide instrument air header and instrument pneumatic piping,
as specified in the Project Specifications and as necessary and/or as specified herein.
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Connect to main instrument air header at a point not more than 3 m distant from air
consuming device(s). Use 10 mm minimum 316S12 tubing. All connections to equipment
shall be made with separable or union type fittings and shall include shut-off valves. All
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hydraulic and/or pneumatic piping shall be tested for leaks prior to placing the system in
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operation. All instrument pneumatic air fittings, shall be double compression type.
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1.2.12 Filter Regulator

1 The ICA Subcontractor shall provide a filter-regulator and discharge pressure gauge with a
dripwell assembly for each point of use where regulated instrument air is required. Separate
regulators shall be used for each control loop.

1.2.13 Manifolds

1 The ICA Subcontractor shall furnish an integral three-valve manifold for each differential
pressure transmitter on a flow application.

1.2.14 Painting and Protective Coatings

1 The ICA Subcontractor shall provide factory paint for all instruments and equipment except
where in pipelines. Provide paint as required for structural supports, brackets, etc. Painting
and protective coatings shall generally comply with the requirements specified in Part 8 of
Section 8.

1.2.15 Electrical

1 The ICA Subcontractor shall provide all the power supply wiring, instrumentation wiring,
interconnecting wiring and equipment grounding as indicated, specified and required.
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Part 01: General

2 Wiring installations shall include cables, conductors, terminals connectors, wire markers,
conduits, conduit fittings, supports, hardware and all other required materials not specifically
included in the work of other Sections.

3 Provide the materials and complete all the required installations for equipment grounding as
specified in Section 21 of these Specifications indicated on the Electrical Drawings or
necessary to complete the Work.

4 Incidental items, not specifically included in the Contract Documents, that can legitimately
and reasonably be inferred to belong to the instrumentation work shall be provided by the ICA
Subcontractor.

5 Field Wiring. Ring out signal wiring prior to termination. Provide wire number tags marked in
indelible waterproof form of slip-on type or equal for each termination. Provide preinsulated
crimp-on connectors for wire terminations and splices. Use ratchet type crimping tool which
does not release until proper crimp pressure has been applied.

1.2.16 Process Connections

1 Piping, tubing, and capillary tubing shall be of stainless steel. If this material is unsuitable for
ambient or process conditions, piping and tubing shall be of a material approved by the
Engineer. Slope lines according to service to promote self draining or venting back to the
process. Terminate connection to process lines or vessels in a service rated block valve,
that will permit closing off the sense line or removal of the element without requiring shut
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down of the process. Include drip legs and blow-down valves for terminations of sense lines
at the instruments when mounted such that condensation can accumulate. Process vessels,
line penetrations, connecting fittings, and block valves shall be furnished and installed under
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other Sections of these Specifications but coordinated by the ICA Parts. Instrument process
taps shall be a minimum 18 mm BSP except flowmeter taps which shall be 12 mm BSP.
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1.3 INSTALLATION
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1.3.1 Inspection
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1 Inspect each instrument and piece of equipment for damage, defects, completeness, and
correct operation before installing. Inspect previously installed related work and verify that it
is ready for installation of instruments and equipment.

1.3.2 Preparation of Installation Areas

1 Ensure that installation areas are clean and that concrete or masonry operations are
completed prior to installing instruments and equipment. Maintain the areas in a clean
condition during installation operations.

1.3.3 Installation and Supervision

1 Provide the services of suitably trained and experienced personnel in the installation of the
equipment to:

(a) complete the installation in accordance with the manufacturers instruction manual
(b) inspect, check, adjust as necessary, and prepare the equipment for system validation
(c) calibrate the instruments, in accordance with the specifications herein, until all trouble
or defects are corrected and the installation and operation are acceptable.
QCS 2014 Section 10: Instrumentation Control Page 13
Part 01: General

1.3.4 Instrument Calibration

1 The Contractor shall provide the services of trained and experienced instrumentation
technicians, tools and equipment to site calibrate each instrument to its specified accuracy in
accordance with the manufacturer's specifications and instructions for calibration.

2 Each instrument shall be calibrated at 10 percent, 50 percent and 90 percent of span using
test instruments to simulate inputs and read outputs that are rated to an accuracy of at least
5 times greater than the specified accuracy of the instrument being calibrated.

3 Test instruments shall hold a valid calibration certificate from a NAMAS accredited calibration
centre or alternative, subject to the approval of the Engineer

4 Provide a list and basic specifications for instruments used. Certify to the Engineer that each
instrument has been calibrated to its published specified accuracy. The calibration certificate
shall include all applicable data as listed below plus any defects noted, correction action
required, and correction made. Data shall be recorded on separate proformas attached to
the certificate and shall include not less than the following items:

(a) facility identification (name, location, etc.)

(b) loop identification (name or function)
(c) equipment tag and serial numbers
(d) scale ranges and units
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(e) test mode or type of test
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(f) input values or settings

(g) expected outputs and tolerances
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(h) actual readings

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(i) explanations or special notes as applicable

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(j) tester's certification with name and signature.

1.3.5 System Validation

1 Provide the services of trained and field experienced instrumentation engineer(s) to validate
each system to verify that each system is operational and performing its intended function
within system tolerance. System tolerance is defined as the root-mean-square sum of the
system component published specified accuracies from input to output.

2 Validate each system by simulating inputs at the first element in loop (i.e. sensor) of 10
percent, 50 percent and 90 percent of span, or on/off and verifying loop output devices (i.e.
recorder, indicator, alarm, etc. except controllers). During system validation, make
provisional settings on levels, alarms, etc. Verify controllers by observing that the final
control element moves in the proper direction to correct the process variable as compared to
the set point. Verify that all logic sequences operate in accordance with the specifications.

3 Cause malfunctions to sound alarms or switch to standby to check system operation. Check
all systems thoroughly for correct operation. Test equipment shall comply with Clause 1.3.4.

4 Immediately correct all defects and malfunctions‟ disclosed by tests. Use new parts and
materials as required and retest.

5 System validation report. Provide a report certifying completion of validation of each

instrument system.
QCS 2014 Section 10: Instrumentation Control Page 14
Part 01: General

1.3.6 Commissioning

1 Upon completion of instrument calibration and system validation, test all systems under
process conditions. The intent of this test is to demonstrate and verify the operational
interrelationship of the instrumentation systems. This testing shall include, but not be limited
to, all specified operational modes, taking process variables to their limits (simulated or
process) to verify all alarms, failure interlocks, and operational interlocks between systems
and/or mechanical equipment.

1.3.7 Final Acceptance

1 Final acceptance report. Immediately correct defects and malfunctions with approved
methods and materials in each case and repeat the testing. Upon completion of final
operational testing, submit certified report, with substantiating data sheets, indicating that
total ICA System meets all the functional requirements specified herein. The Engineer will
countersign this report and it shall constitute final acceptance of the ICA System.

2 Final Operational Testing shall be witnessed and approved by the Engineer. Notify the
Engineer in writing a minimum of 48 h prior to the proposed date for commencing the test.
Upon completion of this test the Contractor shall begin or have begun system start-up. The
Owner reserves the right to set the schedule.

1.3.8 Commissioning Assistance

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1 When specified elsewhere in this section or designed in the Project Specification, provide the
services of a factory trained and field experienced instrumentation engineer to assist the
Owner‟s personnel during commissioning of the system. Purpose of this assistance is to
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support in making final adjustments of settings on the instrument systems.

1.3.9 Instruction and Training of The Owner's Personnel

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1 After the ICA equipment has been calibrated, installed, tested and placed in satisfactory
operation the Contractor shall provide the services of qualified staff approved by the
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Engineer, or if specified in the Project Specification, of the manufacturer‟s representatives, to

instruct and train the Owner‟s personnel in the use and maintenance of the ICA equipment.
An instruction and training programme shall be conducted for up to six personnel designated
by the Owner. The Contractor shall give the Owner at least one month‟s written notice of the
proposed instruction and training programme. Instruction and training covering basic system
operation theory, routine maintenance and repair, and “hands on” operation of the ICA
equipment shall be included. Each trainee shall be provided with a training manual covering
operation and maintenance of the ICA equipment. The duration of the programme shall be
based on the complexity of equipment involved, and the Engineer‟s approval of instruction
adequacy obtained before terminating the programme. Instruction and training periods shall
be acceptable to the Engineer.

1.3.10 Specialised Training Programme for Owner’s Personnel

1 Where designated in the Project Specification the Contractor shall provide a specialised
training programme and manual for the Owner‟s key personnel in the equipment, electrical
systems and instrumentation systems, to be conducted by the supplier/manufacturer and
held at locations outside Qatar. The training programme and manual shall be submitted to
the Owner for approval and shall be designed to:

(a) provide in depth information and familiarisation of the equipment installed in the
Project
(b) receive specialised training in the design, proper operation, maintenance and
replacement of the equipment and components
QCS 2014 Section 10: Instrumentation Control Page 15
Part 01: General

2 The Contractor shall provide whatever assistance is requested by the Owner to develop
meaningful itineraries for the training programme. The Contractor shall provide hotel
accommodation, travelling expenses by air, land transport and per diem allowance as per the
Ministry of Education guidelines.

END OF PART

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QCS 2014 Section 10: Instrumentation Control and Automation Page 1
Part 02: Telemetry/SCADA

2 TELEMETRY/SCADA .................................................................................... 3

2.1 GENERAL ...................................................................................................... 3

2.1.1 Scope 3
2.1.2 References 3
2.1.3 Submittals 3
2.1.4 Quality Assurance 5
2.1.5 Delivery, Storage and Handling 5
2.1.6 Site Conditions 5
2.1.7 Commissioning 5
2.2 DESIGN ......................................................................................................... 6
2.2.1 Pre-Design Documentation 6
2.2.2 Hardware Design 6
2.2.3 Software Design 6
2.2.4 System Security 7
2.2.5 Operator Interface 7
2.3 MASTER STATION HARDWARE ................................................................. 8
2.3.1 Computer 8
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2.3.2 Redundancy 9
2.3.3 Visual Display Unit (VDU) 9
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2.3.4 Keyboard 9
2.3.5 Logging / Alarm / Report Printers - Continuous Feed 9
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2.3.6 Colour Printers 10

2.3.7 Monochrome Printers (Laser) 10
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2.3.8 Audible Alarm 10

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2.3.9 Data Storage 10

2.3.10 Uninterruptible Power Supply (UPS) System 11
2.4 MASTER STATION SOFTWARE FUNCTIONS .......................................... 11
2.4.1 General 11
2.4.2 Display Facilities 12
2.4.3 Monitoring and Alarms 13
2.4.4 Equipment Control 14
2.4.5 Data Archiving 14
2.4.6 VDU Mimic Displays 14
2.4.7 Tabular Representation of Data 15
2.4.8 Trend Displays 15
2.4.9 Manual Data Entry 15
2.4.10 Manually Corrected Data 15
2.4.11 Reports 15
2.4.12 Point Record 16
2.4.13 Profiling 16
2.4.14 Data Manipulation 16
2.4.15 Database Query Facilities 17
2.4.16 Downloading PLC Configuration 17
2.4.17 Diagnostics 17
2.4.18 Access Levels 17
QCS 2014 Section 10: Instrumentation Control and Automation Page 2
Part 02: Telemetry/SCADA

2.4.19 Control Loop and Sequence Programming 17

2.4.20 Program - Documentation 17
2.5 REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION .... 18
2.5.1 Future Expansion 18
2.5.2 RTU Hardware 18
2.5.3 RTU Software 19
2.6 PROGRAMMABLE LOGIC CONTROLLER (PLC) ...................................... 20
2.6.1 PLC Hardware 20
2.6.2 Input Modules 21
2.6.3 Output Modules 22
2.6.4 PLC Software 22
2.7 DATA COMMUNICATIONS LINKS ............................................................. 23
2.7.1 Communication Standards 23
2.7.2 Control Room Data Highway 23
2.7.3 Leased lines or PSTN 24
2.7.4 Radio 24
2.7.5 Radio Path Profiles 24
2.7.6 Radio Transmitters/Receivers 24
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2.7.7 Base Station Radio Transmitter/Receivers 24
2.7.8 Aerials and Aerial Structures 24
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2.7.9 Fibre Optic Network 25

2.8 INPUTS/OUTPUTS ..................................................................................... 26
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2.8.1 General 26
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2.8.2 Analogue Inputs 27

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2.8.3 Digital Outputs 27

2.8.4 Analogue Outputs 27
2.8.5 RTD Input 27
2.8.6 Thermocouple Input 27
2.8.7 Pulse Input 27
2.9 POWER SUPPLY REQUIREMENTS .......................................................... 27

2.10 MIMIC DIAGRAM......................................................................................... 28

2.10.1 General 28
2.10.2 Mosaic Tile 28
2.10.3 Projection 29
2.11 FACTORY INSPECTION AND TESTING .................................................... 29
2.11.1 General 29
2.11.2 Test Plan 30
2.12 INSTALLATION ........................................................................................... 31
2.12.1 Tools 31
2.12.2 Training for Owner‟s Personnel 31
2.12.3 Site Inspection and Testing 32
QCS 2014 Section 10: Instrumentation Control and Automation Page 3
Part 02: Telemetry/SCADA

2 TELEMETRY/SCADA
2.1 GENERAL

2.1.1 Scope

1 This Part includes the hardware manufacture, system software, factory testing, installation,
site testing and training of Owner‟s personnel in Telemetry/SCADA.

2 Related Sections and Parts

This Section
Part 1, General
Part 4, Panel Mounted and Miscellaneous Field Instruments
Part 5, Panels and Control Room Hardware
2.1.2 References

1 The following standards are referred to in this Part:

BS 1646......................Symbolic representation for process measurement control functions
and instrumentation.
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BS EN 60073..............Basic and safety principles for man-machine interface, marking and
identification. Coding principles for indicators and actuators
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BS EN 60255-22-5 .....Surge protection

BS EN 61000-6 ..........Electromagnetic Compatibility
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BS EN 61131-3 ..........Programming Languages for Programmable Controllers.

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BS EN ISO 9000-3 .....Recommendation for achievement of quality in software

BS ISO/IEC 6592 .......Documentation of computer based systems

BS ISO/IEC 9075 .......Structured Query Language (SQL)

ISO 3511 ....................Process measurement control functions - instrumentation symbolic

representation

2.1.3 Submittals

1 Submittals shall generally be in accordance with Part 1 of this Section.

2 Functional Design Specification (FDS). FDS shall be submitted to the Engineer and
approved before manufacture and purchasing commences. The ICA Subcontractor shall
include the following information as a minimum :
(a) design concept and criteria
(a) details of associated equipment
(b) functional design description including VDU mimics and report format.
(c) details of data archiving and trend configuration.
(d) quality plan
(e) outline of acceptance test procedures
QCS 2014 Section 10: Instrumentation Control and Automation Page 4
Part 02: Telemetry/SCADA

(f) implementation program for manufacture, installation and commissioning with

Particular reference to interface with existing equipment
(g) manufacturers literature for each item of equipment supplied
(h) name of the specialist Subcontractor

3 Drawings and Documentation. All drawings of telemetry and ICA equipment shall be on A3
or A4 size sheets with title blocks approved by the Engineer. The signature of the
Contractors authorised representative shall appear on each drawing to indicate the drawing
has been checked prior to submission.

4 Subcontractor‟s Drawings. The ICA Subcontractor shall submit four (4) reproducible copies
plus two photocopies of general and detailed dimensioned arrangement drawings,
schematics and wiring diagrams of all major items of equipment for the Engineer‟s approval.
Manufacture of an item of equipment shall not commence until the associated drawings have
been approved in writing by the Engineer. All modifications or revisions to drawings shall be
clearly indicated and the revision reference changed. Drawings affecting work by other
disciplines shall be provided to the Engineer within 6 weeks from the date of placing of the
order for the works. Drawings for electrical equipment shall include:

(a) Contractor‟s general arrangement drawings for all items showing clearly the position of
all cable glands and main components including, where appropriate, foundation plans
showing the position of all required holes and cutouts
(b) manufacturers‟ schematic diagrams and connection diagrams for all items showing
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all internal wiring and terminal connections suitably referenced. Connection diagrams
shall include existing and proposed outgoing cable connections
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(c) general layout of equipment showing cable routing

(d) block diagram showing all equipment, cable runs and cable reference numbers
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(e) cable schedules giving full details of use, destinations, size and number of conductors,
grade and class
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(f) layout of grounding facilities

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(g) proposed arrangements for cables laid below and above ground showing
identification references, voltage, depth of laying or cable rack size , route and length,
crossings with other services, location of any joints and position of ducts with cross
Sectional arrangements.

Where modifications to existing systems are involved, the Contractor shall modify existing
drawings to show the modifications. If suitable existing drawings are not available the
Contractor shall provide drawings showing the modifications.
5 As built Drawings. Comply with Part 1 of this Section.

6 Instruction Manuals. Comply with Part 1 of this Section and provide the following additional
information:
(a) configuration of data base, reports, logs and screen displays
(b) data communication interface standards and protocols.
7 The submittal shall be subject to approval by the Engineer. The Contractor shall submit the
final documentation based on the Engineer‟s comments. The Engineer‟s comments/approval
shall be issued to the Contractor within 21 calendar days of the submittal.
QCS 2014 Section 10: Instrumentation Control and Automation Page 5
Part 02: Telemetry/SCADA

2.1.4 Quality Assurance

1 All hardware and software proposed shall have been successfully proven in a similar
wastewater application for a period of at least three years, and be from established and
reputable suppliers. A single hardware vendor for each functional component of the system
shall be used exclusively on a given site. If this is not possible full compatibility shall be
demonstrated.

2 Upgrades and improvements to the manufacturers standard system that are released before
the expiration of the warranty period shall be supplied, installed and commissioned at no
additional cost. These shall include all hardware and software necessary to implement the
upgrade.

2.1.5 Delivery, Storage and Handling

1 The Contractor shall arrange for the delivery to Site, off loading, temporary storage in a
suitable environment.

2.1.6 Site Conditions

1 Temperature and Humidity Range. The equipment shall be installed in an environment

having a temperature range of 0 °C to 55 °C and a maximum relative humidity of 100 % (non
condensing). The Contractor shall use, where required, fans, heaters, and air conditioning
units to maintain a correct working temperature for his equipment. All Parts of the equipment
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shall be constructed of materials or treated to prevent the formation of mould, fungus or any
corrosion over the temperature and relative humidity ranges specified.
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2 EMI/RFI Noise Immunity. The equipment to be provided shall be adequately protected

against interference from the use of the radio transmitters, at any point external to the
equipment housings, and no malfunction of the equipment shall result from this cause.
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Responsibility for the correct and reliable operation of the equipment shall rest with the
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Contractor, who must ensure that the equipment is adequately protected against the ingress
of radiated, mains-borne signal-borne interference.
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3 Generated Interference. The Contractor shall ensure that the computer, instrumentation and
communications equipment conforms to BS EN 50081-1 for noise emissions.

4 Sequencing. The Contractor shall make applications to Qatar Telecom (Q-TEL) for provision
of communications and Qatar General Electricity & Water Corporation (QGEWC) for power
supply services. Applications shall be made in time`qw to ensure services are available for
installation and commissioning of the telemetry equipment.

5 Coordination. The Contractor shall check with other trades to ensure equipment and material
can be installed in space provided. Provide other trades with information necessary for them
to execute their work. Details on Drawings which are specific regarding dimensions and
locations, are for information purposes. Coordinate with other trades to ensure work can be
installed as indicated.

2.1.7 Commissioning

1 The Contractor, the Engineer and any appropriate personnel of the Owner shall be present
when the equipment or installation is commissioned.

2 Commissioning shall include operating the equipment in a variety of modes and sequences
to prove its satisfactory operation, prior to initialising the formal site inspection and testing.
QCS 2014 Section 10: Instrumentation Control and Automation Page 6
Part 02: Telemetry/SCADA

2.2 DESIGN

2.2.1 Pre-Design Documentation

1 Prior to design of the system the following documentation shall be submitted:

(a) operational functional requirements including MIS functional description;

(b) process description, including interlocks and alarms;
(c) process flow diagrams (PFDs)
(d) process and instrumentation diagrams (P&IDs)
(e) SCADA I/Os data base (Instrument data base)
(f) Programmable Logic Controller (PLC) listing
(g) process control strategies
(h) process monitoring requirements (manual & automatic)

2.2.2 Hardware Design

1 Programmable logic controllers shall be used as the basic SCADA hardware.

2 PLCs shall be installed at strategic locations throughout the plant areas to make optimal use
of the LAN and to minimize hardwiring of I/O‟s. Man machine interfaces (MMIs) shall be
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strategically located and installed within each nominated process area. These installations
shall form the nodes of a supervisory and distributed control and monitoring system.
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3 PLC nodes and MMI nodes shall be connected via the selected PLC/network communication
system to form a Local Area Network (LAN) for the site.
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4 Loss of the communication shall not impact on the internal control strategy.
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5 All system shall be capable of redundant communication. The failure of either of these links
shall not result in loss of system communication functionality and response. The failure shall
cause an alarm to the operator and to remote monitoring systems where required.

6 Plant areas and functional groups shall not be split across PLC‟s unless reliability benefits are
demonstrated. Any PLCs failure shall not interfere with more than a maximum of one plant
area.

7 Investigation of the surrounding environment (physical and other hardware components) shall
be conducted for all hardware components to optimize components‟ selection and location
for the site.

8 All PLCs shall be programmable via the SCADA network.

9 For retrofit installations, PLCs used to replace conventional hard-wired process system
control/starter controls shall be compatible to existing SCADA system and standards.

2.2.3 Software Design

1 PLCs software shall support higher-level languages such as ladder logic or any other
language (Function Block concept etc) and should comply with the intent of relevant British
Standard and International Standards.

2 Machine coded program segment shall not be offered nor accepted as solutions for control
implementation.
QCS 2014 Section 10: Instrumentation Control and Automation Page 7
Part 02: Telemetry/SCADA

3 Higher-level programming shall be in structured English statements.

4 Communication protocols shall be able to communication with PLC manufacturer‟s

equipment currently in use and any new PLCs.

5 Application software shall be selected from packages with ample support and market base,
proven in the industrial field to which it is applied. They shall have adequate local resources
for support and program development. Provision for automatic upgrade from the delivered
versions and future versions of software for a period of up to five years after delivery, shall be
included in the base contract.

6 Application software shall provide information in a clear and simple manner, at both summary
and details levels. This information shall include plant operational status, and the ability to
adjust and optimize readily start/stop or isolate the plant processes or individual items of
equipment. The specific control actions required shall be as described in the functional
requirements.

7 The system shall have provisions for an operator to intervene or select alternative predefined
control strategies.

8 The software shall allow data exchange and have software to allow external application
software developers to add-on to the functionality of the software.

9 The system shall be capable of providing additional parts for communication with the
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following:

(a) Existing SCADA systems

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(b) Radio modem where specified in the contract documents

(c) Existing RTUs
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(d) Future business management systems.

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10 No degradation of the plant SCADA system response times shall occur because of overhead
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imposed on the SCADA operating system as a result of these interfaces.

2.2.4 System Security

1 All access to the system shall be via password for operator access control functions and
system configuration. A minimum of two-step multi-level security shall be used. An
automatic timed log-out shall be provided.

2 Supplementary hardware-type security shall be provided where indicated in the contract

documents.

3 An automatic timed log-out shall be provided. Timing configuration for the log-out shall be
adjustable and determinable by the site‟s needs.

4 External access to the system shall be secured in such methods as dial-back and encryption.

5 All disk used in the system shall have scanned (including the data) labels and shall have
virus protection maintenance schedules.

6 The SCADA software shall provide for „Console Mode Assignment‟ features, giving the plant
operational team the ability to limit the use of the MMIs to specific levels of control and
monitoring as required.

7 Interfaces with external systems shall be on a read-only basis.

2.2.5 Operator Interface

QCS 2014 Section 10: Instrumentation Control and Automation Page 8
Part 02: Telemetry/SCADA

1 Number and location of MMIs and input devices such as touch screens or keyboards shall be
determined depending on plant production needs. Full control and monitoring capability shall
be available at each screen.

2 There shall be no single point of failure, i.e. the failure of one screen or its associated
hardware will not compromise the integrity of other MMIs.

3 The failure of any one screen or its associated hardware shall not compromise the integrity of
other MMIs.

4 For services plants a minimum one printer shall be provided for alarms/operator‟s actions.
The use of the printer shall be minimized and all alarms and operator records shall be
electronically stored and shall be periodically (and as required) printed in reporting format.
An additional printer shall be provided as required to satisfy report generation needs. At least
one colour printer shall be provided for serviced sites.

5 MMIs shall provide a focus for such activities as alarm reports generation, events logging and
the archiving of historical data. Where it can be justified operationally, remote MMI may also
be installed in area equipment rooms for the control of adjacent systems and plant items.

6 Where the MMI is used in an office environment, it shall be capable of generating business
reports using commonly used packages and shall have access to printer via LAN.

7 For plants with permanent staffing besides MMI, a programming console shall be provide for
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on-line system modifications and maintenance without disruptions to production activities.

8 For unattended (remote) plants provisions shall be made for the connection of a portable
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programming console and printing facility.

9 The system shall be designed so that data input shall be collected/entered only once and
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shall be accessible for various business reports. It shall also be capable of sharing this data
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with external computing systems as required, to provide the necessary plant information to
other applications in an accurate and timely manner.
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10 The Plant operator/Management shall be able to access the plant from remote sites through
dial-up or secured Internet laptop MMI. Critical alarms shall be reported to the central control
room as required for any emergency response during after hours.

11 A standard library of interface screens, graphics, symbols and colours shall be utilized to
create uniformity between systems. This shall be in accordance with BS 1646, BS EN 60073
unless otherwise stated in the contract documents.

2.3 MASTER STATION HARDWARE

2.3.1 Computer

1 The SCADA computer shall be an Industrial type PC (personal computer) of server /

workstation category running multitasking real time operating system suitable for process
control operations. These PCs shall have RAID1 implementation of mirroring and controller
duplexing. . The PC shall be latest one available in the market. Unless otherwise specified
in the project specification ,PC shall be minimum Intel core i7 processors with 6GB RAM ,1
Terabyte Hard disk, DVD R/W ,Sound cards and speakers ,2 numbers. Integrated 3 COM
10/100/1000 Ethernet Network Cards with other serial, USB, parallel ports, Keyboard and
mouse

2 The system shall support hardware and software interconnectivity to Programmable Logic
Controllers (PLCs) over RS 232/RS485 serial link or Ethernet over fibre/copper media using
appropriate protocols, or similar, subject to the approval of the Engineer.
QCS 2014 Section 10: Instrumentation Control and Automation Page 9
Part 02: Telemetry/SCADA

The memory capacity supplied shall be sized to accommodate an increase in inputs, outputs
or Programmable Logic Controller (PLC) of up to 50% of the original specified without
replacement of the memory unit. Further memory expansion shall be possible. The
Contractor shall state the maximum memory capacity that may be fitted.
3 Local HMI (Panel Mounted)
The local HMI (panel mounted) shall be an industrial type PC of server / workstation category
running multitasking real time operating system suitable for process control operations as
specified in clause -2.3.1 except RAID1 implementation, unless otherwise specified in the
project specification.
2.3.2 Redundancy

1 The master station shall be supplied with dual redundant computer equipment and suitable
software to ensure high system availability and to prevent loss of operational data.

2.3.3 Visual Display Unit (VDU)

1 Visual Display Units (VDU‟s) shall be 22 inch colour monitor screens unless otherwise stated,
capable of displaying information in alphanumeric, bar histogram, graphical.. The TFT shall
be color monitor with a 256-color palette as minimum and shall have the ability of displaying
mixed alphanumeric/semi graphical information. TFT shall be capable of high resolution
graphic displays non - interlaced, low radiation, flat screen with no discernible flicker. Display
of characters shall be legible and stable on a shadow mask tube, having a resolution of not
less than 1024 by 768 pixels and a refresh rate of not less than 70 Hz.The units shall include
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all the necessary picture controls to adjust the sharpness, contrast and position of the image.
The VDU shall have non-volatile memory of 2MB minimum. The VDU shall be industrial
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type.

2 Control room VDU‟s (Monitor) shall be 22inch and VDU‟s for local HMI at other locations
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(PLC panel), shall be 17 inch minimum size.

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3 VDU‟s shall be fitted with a power management system to reduce consumption upon
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detection of a stand-by signal from the PC.

2.3.4 Keyboard

1 The master station keyboards shall be of an enhanced pattern personal computer (PC)
keyboard, separate from the VDU, low profile and have non-reflecting surfaces and keys of
low intensity to minimise unwanted reflections.

2.3.5 Logging / Alarm / Report Printers - Continuous Feed

1 Printers used for logging of system wide events and alarms shall comply with the following:-

(a) print speed : 160 characters per second

(b) print quality : letter print with optional draft mode
(c) paper feed : adjustable width tractor feed mechanism
(d) paper width : 18 to 38 cm fan fold
(e) print pitch : 10 or 12 cpi
(f) print width : 132 characters at 10 cpi
(g) character set : Full ASCII
(h) noise level :  50 dBA.
QCS 2014 Section 10: Instrumentation Control and Automation Page 10
Part 02: Telemetry/SCADA

2.3.6 Colour Printers

1 Laser printers shall be used for the production of colour screen dumps and reports and shall
have a sufficiently sized buffer memory such that system performance will not be degraded
when the colour printer is operational and comply with the following:

(a) print speed : text, 80 characters per second

(b) print speed : colour graphics, 2 minutes per page full
(c) colours : compatible with VDU graphics
(d) paper feed : A3 and A4 with auto sheet feeder mechanism and minimum
50 sheets per tray
(e) paper width : A4/A3
(f) resolution : 600 DPI
(g) RAM : 8 MB

2.3.7 Monochrome Printers (Laser)

These printers shall comply with the following:
(a) print Speed : 8 pages per minute
(b) paper feed : A4 with auto sheet feeder mechanism and minimum
250 sheet paper tray.
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(c) resolution : 600 DPI
(d) character set : full ASCII
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(e) RAM : 4 MB

2.3.8 Audible Alarm

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1 An audible alarm located on the control desk, shall be provided which is initiated by any fault
condition arising and silenced on operator acceptance of all fault conditions. An alarm mute
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function shall be provided to silence the audible alarm without accepting any fault conditions.
It shall be possible to enable/disable this audible alarm only at the highest system access
level.

2 Use of the internal PC audible alarm will not be acceptable.

2.3.9 Data Storage

1 Provide a historical data storage system with removable media for archive and backup.

2 The data storage system shall store alarms and events, with the time of occurrence for one
month and selected analogue signals connected to the system. All alarms and events shall
be archived in a first in first out buffer, for a period of 40 days.

3 A high speed back up device with removable media, such as streaming tape cartridge or
optical disk, shall be provided for each server, suitable for backing up the whole system on a
weekly basis.

4 Data selected for archive shall be written to removable media which shall be sized to support
at least 180 days worth of archive data. The archive media also shall be sized to store
logged analogue data, at a maximum sample rate of 15 min for a period of 15 months.
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2.3.10 Uninterruptible Power Supply (UPS) System

1 The Contractor shall supply a UPS system with sufficient capacity to maintain power to the
computer equipment, its peripherals and process critical instrumentation during a mains
power failure for a minimum period of 8 hours. Refer to Section 21, Part 18 Uninterruptible
Power Supply Systems more detailed specification .

2 In the event of power failure, the master central system shall be supported by the UPS.

3 The central system equipment shall be programmed to degrade gracefully once UPS power
is exhausted or execute a shutdown routine after a preset time from the original mains
failure.

4 The UPS systems shall be monitored by the SCADA and a fault in the UPS system shall be
accorded the highest priority alarm status.

5 The FDS shall detail modes of failure and process shutdowns and itemise signals to be
supported by UPS.

6 Power distribution from the UPS in the control room area shall be via protected sockets, the
design of which will be such as to prevent inadvertent connections of non-system hardware.

2.4 MASTER STATION SOFTWARE FUNCTIONS

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2.4.1 General
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1 The Contractor shall be responsible for supplying complete software packages to enable the
equipment to operate as stated in this specification. Provision must be made for the adding of
further software tasks as and when required. All software functions shall be user friendly with
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instruction and messages to aid the operator. The Contractor shall make available all
standard software functions even if not specifically detailed in the specification. The sever /
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operator works stations shall be OPC compliant for communicating to other client works
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station

2 The computers shall utilise a real time multi-tasking and networked operating system with a
proven track record in real time control applications.

3 It is a requirement that the system be supported by on line configuration and editing of all
VDU mimic displays and database and to create new displays and additional database.

4 The system shall be capable of supporting the allocation of equipment groups into zones and
these zones may be allocated for the attention of Particular operator workstations (OWs).

5 Operational mimics and other graphics shall be presented in an industry standard graphical
user interface (GUI) format. A minimum of two active windows should be displayable
concurrently. Both text and graphics shall resize automatically to accommodate changes
made to the size of a window. The system shall be designed to minimise the operators use
of the keyboard. All major functions shall be accessible on-screen through use of the mouse
or track ball.

6 When designated in the Project Specification additional operator workstations shall be

provided for each process area. Functionality shall be identical to that of the master station
OW‟s allowing full access to all system functions at the authorised access level. Operator
system entry for each area will be password coded with different levels of entry depending on
the level of authority of the operator. Development and systems level entry passwords will be
provided for engineering workstations. Each action taken by any operator at any level of
entry, or, at any operator terminal shall be log file recorded, and time and date stamped. Log
in and out time and dates will be printed on the control room event logging printer.
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7 VDU mimics will display dynamic colour details of flow rates and pressures, pump status, well
levels, alarms, electrical power supplies and other general equipment status conditions. All
requests and commands shall be via icons, whether menu linked or linked to equipment
control actions. A permanent dynamic alarm banner shall be displayed at the bottom or top of
each operator screen. Each control action will be routed through a series of confirmation
routines.

8 The complete system database shall be available to each master-station OW offering

preconfigured reports per process area. These reports shall be available for printing in graph
or tabular format. Dynamic trend displays shall also be available for all analogue flow, level
and pressure values. Custom, as well as preconfigured reports and trends shall be available
to a higher level of entry. A colour A4 size screen dump printer shall be provided for graph
and trend prints.

9 An operator help utility shall be provided offering help linked to the particular action being
carried out by the operator at that time. At least one help screen per screen page shall be
available. This facility shall be preconfigured with an option for updating by operators via a
password entry. Typical information available shall consist of guides of actions to take under
Particular equipment conditions, general process information and help in operating the
telemetry system itself.

10 Provide a software watchdog timer function connected to one set of normally closed relay
contacts which are held open whilst the watchdog is healthy.
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2.4.2 Display Facilities

1 The displays shall be user configurable, with the user being able to construct any desired
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symbol for display. Any display shall appear (excluding historical recall) within 3 to 5 s of
selection and the displayed data shall be updated from the database as information is
recovered from the Programmable Logic Controllers (PLC‟s). Alarms shall typically appear
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within 3 to 5 s of occurrence and within 1 s of being received into the central system
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database.
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2 The Contractor shall configure all display pages as fully as possible. However, facility must
be incorporated to permit easy construction and modification of the display pages by using a
standard library of shapes and symbols. The library shall be added to and modified by the
user as required. The configuration shall be object orientated for ease of use. All layout
details and dimensions, including colours, symbols, line diagrams, legend text and
indications, shall be agreed with the Engineer.

3 The initial application software shall provide for the display pages listed below and any pages
necessary for the system to function as a complete entity.

(a) mimic displays

(b) alphanumeric configuration pages for the complete I/O and PLC‟s
(c) graphic displays
(d) trend displays
(e) process alarms with tag, date time and cause
(f) event logs of past 72 h with date and time
(g) tabular display of data
(h) inset windows showing an analogue trends may be mixed with mimic displays. In such
a display the main mimic and inset trend shall all be live with automatic display
updates.
(i) network status and configuration.
(j) main power supplies status.
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Part 02: Telemetry/SCADA

(k) system alarms with equipment identity, date and time.

4 Indexing of information and menus shall be presented in the form of active windows on the
screen while the mimics etc. are still available for view.

5 No display or function shall effect the logging/monitoring of data. It shall be possible for the
master station terminal and auxiliary terminals to perform different tasks within the displays
simultaneously.

2.4.3 Monitoring and Alarms

1 The operator shall be able to monitor all of the information at all workstations. He shall be
able to view active equipment information on a series of VDU based graphical and tabular
displays.

2 In the event of an equipment alarm, the following shall occur at the master station:

(a) alarm message displayed in the alarm message area of the screen
(b) the audible alarm shall sound
(c) the appropriate Section of the display page shall change colour and flash
(d) a full message shall be written on the alarm page
(e) the full alarm message shall be printed on the alarm printer
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(f) the full alarm message shall be recorded, stored on disk and automatically
archived.
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3 The operator should be able to acknowledge the alarm by pressing an accept alarm key or
icon. This action shall stop all associated alarm messages and displays flashing, however
the display shall remain in the alarm state fixed colour to indicate an accepted alarm. When
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all outstanding alarms have been acknowledged the audible alarm shall be silenced.
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4 Once the alarm has cleared, the messages and displays shall return to normal. The alarm
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message shall stay recorded on the event/alarm log and an alarm cleared message shall
also be recorded.

5 If the alarm clears before being acknowledged the sequence of events shall continue as
above except the message shall change to indicate a cleared alarm.

6 An audible alarm silence function shall be provided to enable an operator to silence the
audible alarm without acknowledging all alarms. On occurrence of any subsequent alarm the
audible alarm shall sound.

7 For multiple bit points (where two or more inputs are combined to function as one point) the
assignment of status/alarm levels shall be on the combined signals.

8 Each signal within the configured system shall be capable of being assigned an alarm based
on the following:

(a) four levels per analogue (Lo Lo, Hi Hi, Lo and Hi)
(b) rate of change
(c) deviation from setpoint or other control parameter

9 Alarms shall be time tagged to 1 second resolution at PLC.

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10 A minimum of four alarm priorities shall be provided so that those requiring immediate
attention may be separated from alarms of lower priority. An audible alarm shall sound for
alarms requiring operator action. It shall be possible to acknowledge alarms from any
operator station provided the operator is logged on to an approved access level.

11 Typical alarm assignments are as follows:

(a) critical alarm - an alarm that requires immediate operator action

(b) non critical alarm - an alarm that requires operator action but not
necessarily immediate action
(c) operator guide alarm - an alarm that provides information to the operator
(d) event - a low priority condition which is recorded.

12 The alarm software shall produce an alarm summary which will show all currently active
alarms in priority and chronological order.

2.4.4 Equipment Control

1 The system shall support a high security equipment control facility and employ revertive
checking of control outputs based on a select, checkback and execute philosophy of
operation. Any command entered at any OW shall complete its action within 2 s.

2 Command execution performance time excludes the time for call set-up on PSTN and
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assumes no transmission errors or re-transmission of data occurs.

2.4.5 Data Archiving

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1 Continuous process (analogue) data, digital event states, alarms and operator actions shall
be archived to a removable media system. The archive media shall be sized to store logged
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analogue data, at a maximum sample rate of 15 min for a period of 15 months. Data
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recording shall be on dual media. The archive system shall generate an alarm when a file is
90 % full.
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2 Analogues will be stored at a rate selected by the operator in the range 1 second to 1 hour.
The operator shall have the facility to select the way in which an analogue is stored. The
system will provide any combination of the following:

(a) instantaneous value

(b) average value
(c) maximum value
(d) minimum value
(e) not stored.

3 Maximum, minimum and average values shall be calculated over a period set by the operator
in the range 15 min to 24 h, the default shall be 1 h.

4 The logging of new data and reception of alarms must be carried out at the same time as the
operator is viewing archived data. Any alarms received must be displayed as an overlay on
the visual display unit.

2.4.6 VDU Mimic Displays

1 The Contractor shall configure all the mimics to provide total detailed coverage of the
monitoring and control of equipment as detailed in this specification. It is expected that
display modifications will be required in the future and therefore the ability to change the
displays without programming skills is essential.
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2 Instrumentation shall be displayed using ISO standard symbols. For mimic configuration, it
shall be possible to call up a library of standard symbols representing items (e.g. pumps,
valves) and add new symbols to the library. Building mimics shall be simple and be achieved
by using a mouse or tracker ball pointing device. The mimic displays shall consist of the
following pages:

(a) a general diagram covering the whole of the system on a single screen with key data
(b) a general block diagram for each site or area of Site showing the equipment displayed
on a series of single screens with key data
(c) mimic of the equipment and instrumentation connected to each PLC displayed on as
many screens as necessary.

2.4.7 Tabular Representation of Data

1 It shall be possible to put any data into a tabular format, with the data entered in row or
columns. The user shall be able to add headings to any of the rows or columns and store the
table as a blank for later use.

2.4.8 Trend Displays

1 It shall be possible to plot dynamically updated real time data and archived data on a line
graph to represent analogue or digital information. Each graph shall be capable of displaying
8 plots overlaid on a graph of different colours and line texture. Next to the graph, there shall
be a key relating each colour to its function. The horizontal axis shall be time based and user
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selectable in minutes, hours, days, weeks, for example, together with a start time.
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2 The vertical axis shall be scaled as a percentage of range and be displayed in the colour of
the selected reading. To avoid cluttering, the vertical axis scale shall be changed by selecting
the individual display. The vertical axis shall be automatically scaled for each selected point
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between limits entered by the user. Actual values in engineering units shall be displayed by
positioning a cursor at the desired point of the trend graph.
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3 The display of the data shall also be available in tabular form.

2.4.9 Manual Data Entry

1 The system shall be provided with facility for entering data manually via the keyboard. This
data will fall into two types.

(a) constants which will be changed infrequently. This data may have time and date
associated with it
(b) maintenance related comments.

2.4.10 Manually Corrected Data

1 The system shall allow a person with authorised access to manually correct erroneous data
via the keyboard.

2.4.11 Reports

1 There shall be a real time spreadsheet facility supplied and installed by the Contractor in the
master station. The users shall be able to transfer data from either the archive system or live
data to the spreadsheet. The user shall be able to produce daily, weekly, monthly and annual
reports using any data and a mixture of formats (tables, graphs, summaries, spreadsheets).
Typical reports would be:

(a) power consumption

(b) total flows
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Part 02: Telemetry/SCADA

(c) failures of equipment

(d) maintenance schedules.

2 It shall be possible to configure and store blank templates for later use. Facilities for editing
stored templates shall also be provided.

2.4.12 Point Record

1 Each input shall have a record covering every characteristic of the input. This data shall be
automatically sent to the appropriate locations when the user has completed entering or
modifying data into the record. The Contractor shall compile all input records as indicated in
the input/output schedules, plus any other I/O to enable the complete and optimum
monitoring and control of the equipment. The user shall be able to modify, amend or create
new records. The Contractor shall ensure all possible characteristics are included in the
record including the following:

(a) point identity

(b) point description
(c) point type
(d) point state
(e) point range
(f) point units
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(g) status/alarm and priority levels
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(h) alarm set points - high, low, out of range high/low

(i) log interval - time between logs
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(j) log type - average, total, and others as required

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(k) log in PLC - for communications failures.

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2.4.13 Profiling

1 From an average, typical or manually entered plot, it shall be possible to set an exception
profile whereby readings within an upper and lower level are acceptable. Profiles shall be set
graphically via OW. The user may select for the system to alarm if the reading is outside the
profile and highlight such exceptions as Part of a report and so reduce the need to examine
all data to ensure acceptability. The number of exceptions shall be logged.

2.4.14 Data Manipulation

1 It shall be possible to perform simple mathematical functions on any data, including the
following functions:

(a) addition
(b) subtraction
(c) multiplication
(d) division
(e) square root

2 It shall be possible to log, display or use in a control loop the resultant data.
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2.4.15 Database Query Facilities

1 The system shall support the use of database relationships and wild card characters to
provide database query facilities. It shall be possible for applications integration to easily
configure queries and save them for future use. Support of Dynamic Data Exchange (DDE)
or Structured Query Language (SQL), to permit data exchange between the SCADA Master
Station and external applications, including spread sheets and databases.

2 Data shall be presented in tabular format and contain any combination of fields from the main
system database.

3 It shall be possible to manipulate the data by specifying search and sort criteria to define data
range limits.

4 Once a query table has been created it shall be possible to store the configuration and initiate
successive look ups using a point and shoot technique.

2.4.16 Downloading PLC Configuration

1 It shall be possible to download configuration to the PLC‟s from the engineer‟s terminal.

2.4.17 Diagnostics

1 The system shall have on-line diagnostic facilities to report system faults as they occur. A set
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of off-line diagnostic routines shall be supplied for more extensive fault diagnosis.
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2.4.18 Access Levels

1 The functions available on the system shall be fully flexible so as to allow users access levels
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to be customised by the system operator to suit individual user requirements.

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2 Access to management and engineering levels shall be restricted by user selectable

passwords or keyswitch. The security systems shall be based on a set of privileges which
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may be granted or denied to individual uses by the system operator.

2.4.19 Control Loop and Sequence Programming

1 The method of programming will depend upon the Manufacturers system requirements.
However, the following standards shall be followed:

(a) all programs shall be written such that they lend themselves easily to alterations
and additions
(b) good programming practice shall be followed using structured programming
techniques. All programs shall be tidy in format and logical to follow, and shall be
accompanied by flow diagrams. Programs should be extensively annotated with
comments and be self-documenting
(c) the system shall be supplied with programs that use a high level language for the OW.

2.4.20 Program - Documentation

1 As Part of the requirements of this specification full documentation is required as below :

(a) software user manuals

(b) database point allocation table
(c) complete program listing, flow charts for all sequences and control routines
(d) application software source code
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Part 02: Telemetry/SCADA

(e) end user license agreements for the programming software.

2.5 REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION

2.5.1 Future Expansion

1 The system hardware, application software and database shall be sized to accommodate a
total of 10 % increase in signal capacity overall and up to 25 % increase in an individual RTU.

2 Sufficient plug in modules shall be provided and wired to terminals ready to accept future
signals of up to 10 % or a minimum of one module, for each RTU.

2.5.2 RTU Hardware

1 Each microprocessor based RTU will be the main device used to control loops in each RTU
process area. Each RTU shall be able to receive analogue and digital inputs from the field,
perform input signal processing and alarm checking, perform algorithms control, and output
to valves and other actuators.

2 Each RTU controller shall be mounted in an IP65 enclosure and constructed to allow easy
replacement and maintenance of cards.

3 The RTU shall be suitably protected against exposure to the severe environmental conditions
prevalent in sewerage systems.
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4 The RTU shall be an intelligent device capable of handling data collection, logging, report by
exception, current data retrieval and pump sequence control programs.
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5 Each RTU shall be sized for controlling the specified input/outputs and future expansion.
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6 The RTU shall be of single board construction and as a minimum shall include input/output
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circuits:
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(a) 16 digital inputs

(b) 8 digital outputs
(c) 4 analogue inputs

It shall be possible to add one of the following input/output types on a single plug-in module.

(d) 16 digital inputs

(e) 8 digital outputs
(f) 4 analogue inputs
(g) 4 analogue outputs
(h) 4 pulse inputs

7 The program and data held within memory shall remain intact and error free if all external
power is removed from the RTU for a minimum period of two weeks.

8 The Contractor shall supply batteries for each RTU with sufficient capacity to maintain full
power to the RTU for 8 h, or as designated in the Project Specification, after a power failure.
The UPS system shall be integral to the RTU. The batteries shall be of a sealed maintenance
free type.

9 All field connections shall be made in terminal strips located for easy access. These
terminals shall be clearly marked and identified. Terminals carrying voltages in excess of
24 V shall be fully shrouded. All terminals shall be of the „flip up‟ isolator type with test points.
QCS 2014 Section 10: Instrumentation Control and Automation Page 19
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10 A hand held programmer, shall be provided for local display of signals, programming and
fault diagnosis.

11 RTU‟s shall be capable of being equipped with RS232/485 links for interconnection to
standalone control systems and standard equipment packages.
(a) connection to other devices will use Modbus ASCII or RTU protocol as standard
(b) details of other protocols available should be included within the tender
12 RTU‟s shall be configured such that a single RTU failure will not interrupt or degrade
equipment monitoring and control functions. RTU failure shall be alerted to the operator at
the highest alarm priority.

13 Surge protection shall meet the requirements of IEEE 472-1974

2.5.3 RTU Software

1 The RTU shall be capable of processing locally input equipment information before
transmitting it to the master station to reduce transmission overheads.

2 Total internal scan time interval for all inputs and outputs in an RTU shall not exceed 1 s.

3 There shall be two pairs of alarm settings for each analogue input, one an alarm warning of a
possible fault, the other warning that the input is outside a valid range of readings.
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4 The RTU shall operate on a report by exception basis.

5 The RTU‟s shall have sophisticated in built control facilities to permit control loop
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configuration using simple building blocks. These blocks shall sequence control, three term
control and other control routine components as required by the Specification. The RTU shall
be capable of routine signal processing including integration, summation, subtraction and
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totalisation of one or more inputs. Control loops shall incorporate deviation and rate of
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change alarms, bumpless transfer facility, set point and output high and low limits.
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6 The RTU shall be capable of executing sequential control logic. Programming of sequential
control shall be by means of vendor supplied high level function block language or ladder
diagram format as Part of an integrated package.

7 The RTU‟s shall have standalone capability, able to continue monitoring equipment and
executing control loops if the communication link to the master station fails. In the event of
such a failure the RTU shall log all alarms and required analogues until all the total memory
is filled. When the communication link is restored the RTU will automatically upload the
logged data to the data archiving system.

8 The RTU‟s shall have a watchdog function and full self-diagnostics capable of detecting and
reporting faults to the master station and displayed locally.

9 The Contractor shall program the RTU‟s fully under this Contract. It shall be possible to
modify the programs remotely by downloading from the engineers terminal.

10 It shall be possible to initiate a current data retrieval on demand, from the master station,
leaving the original RTU data contents intact for routine up-loading.
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2.6 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.6.1 PLC Hardware

1 The PLC system shall comprise of a central processing unit, input/output modules, serial
interface modules and programming units. The PLC shall be of modular construction with
plug in I/O cards and facility to install expansion racks/modules when necessary. The system
shall include 25% spare capacity in hardware and memory for future modifications.

2 PLC‟s shall be installed inside Local Control Panels or in separate cubicles, as specified in
the Project Specification. PLC shall be suitable for ambient temperature of up to 50ᴼ C and
95% relative humidity.

(a) PLC diagnostic indications shall include the following:

(i) Power ok
(ii) Low battery
(iii) Forced I/O
(iv) CPU fault
(v) I/O status indicators
(b) Central Processing Unit. The CPU shall perform the following function:
(i) Scan all inputs, execute relay ladder logic programs and generate outputs for
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the final control elements
(ii) Monitor status of system hardware and provide diagnostic information .
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(iii) Central Processing Unit ( CPU) shall 80 μs per 1 kb minimum process scan
time. Random Access Memory (RAM) for real time program execution with
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lithium battery backup for data retention and EEPROM flash backup for
permanent storage shall be provided. The PLC memory shall be as required for
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the programs and future requirements with a minimum of 1 MB flash / I MB

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SRAM, with a minimum of 204 K for IEC Logic or equivalent .

3 PLCs shall be supplied complete with a laptop programming and diagnostic device plus all
necessary leads and programming software & manuals. When a local SCADA computer is
installed and connected to the PLC locally, the PLC programming software is to be installed
in the same computer and the necessary cables/adaptors required for programming are to be
supplied.

4 PLCs shall have a minimum of 1 x RS 232 plus 1 x RS 232 /485 ports and 1 Ethernet port.

5 Compact Version and/or Fixed I/O type PLC shall be considered (physical I/O counts only) at
the discretion of the engineer depending upon the application requirements. The compact
version CPU‟s specification shall meet all other communication parameters.

6 PLC control equipment shall be housed in the common controls section of the MCC and shall
be fed by non door interlocked MCCB. A separate signal marshalling section shall be
provided to accommodate all input and output signals to the Control and Telemetry section.

7 The equipment shall accept status and analogue (4-20mA) signals from both field and panel
mounted instruments. Analogue inputs shall be scanned into a 12 bit binary (minimum)
analogue to digital converter with buffered inputs.

8 PLC power supply shall be 24Vdc, 240 V ac as specified. The equipment shall be maintained
in operation during a period of mains failure drawing power from the battery or UPS system
for a minimum back-up time of 8 hours. The battery/UPS system shall include diagnostic and
automatic self-test routines with volt-free contacts to initiate an alarm in the event of
malfunction.
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9 Panel mounted display (local HMI) units shall be provided for man machine interface, as a
permanently connected means of accessing set points, timer settings, control and monitoring
locally, unless otherwise specified in the project specification.

10 The HMI shall be pre-programmed to provide a basic graphical display of the process. Real-
time numeric display of process variables and alarm messages shall be available. All process
control functions shall be accessible for the operator from the HMI. The application program
shall be stored in "Non Volatile Memory". Local HMI size shall be as specified in the clause
2.3.3 Visual Display Unit (VDU)

11 A schematic block diagrams for an overview of the PLC system and general arrangement in
the MCC section indicating the location and proposed placement shall be submitted for
Engineer's review.

12 The Contractor shall ensure while submitting his proposal that the PLC systems selected
provides high availability and high level of integrity.

13 PLCs used for controller applications require a minimum built-in redundancy of Power supply
,CPU modules, Communication modules and communications with a hot-backup logic
configuration.

2.6.2 Input Modules

1 Digital input modules shall be 16-point (maximum per Card), 24 VDC, signal source type,
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with individual screw terminal connections. Where space restrictions or high-density signal
requirements are apparent 32-point 24VDC digital input modules may be permitted with the
approval of the engineer.
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2 All digital input units shall be capable of accepting, a volt-free contact signal, the source
voltage shall be regulated 24VDC and shall be derived from the PLC panel.
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3 Where the input from an external source is not volt-free then suitable isolation devices shall
be provided in order to prevent cross-connection of different supplies. This device may be
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e.g. interposing relay or optical-isolator. For frequencies of operation greater than 30

operations/hours, the use of electromechanical devices shall not be permitted. All
interface/isolation devices shall provide visual indication of Signal State.

4 All Input modules shall be segregated into groups, which relate to 24VDC supply commons.
Where different supplies are apparent in input connections, these shall be segregated in
accordance with supply common grouping.

5 Inputs signals from 'DUTY' equipment shall not be allocated to the same input module as
signals from 'STANDBY' equipment performing the same function.

6 The analogue current input module shall be capable of converting 4, 8 or 16 channels of

inputs in the range of 4 to 20 mA.

7 Resolution of the converted analogue current input signal shall be minimum 12 bits binary

8 All analogue signals shall be updated each scan into a dedicated area of data registers.

9 The conversion speed for all analogue current input channels shall be within 2 - 10
milliseconds

10 All digital input modules shall be provided with LED for each point (channel) for testing and
maintenance purposes.

11 All digital input modulus shall be provided with a dual independent power supply.
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Part 02: Telemetry/SCADA

2.6.3 Output Modules

1 Discrete AC output modules shall have separate and independent commons allowing each
group to be used on different voltages.

2 Discrete AC output where used shall be provided with an RC snubber circuit to protect
against transient electrical noise on the power line.

3 Discrete AC outputs shall be suitable for controlling a wide range of inductive and resistive
loads by providing a high degree of inrush current (10x the rated current).

4 Discrete DC output modules shall be available with positive and negative logic characteristics
in compliance with the IEC industry standard.

5 Discrete DC output modules shall be provided with a maximum of eight output points in two
groups with a common power input terminal per group.

6 Discrete DC output modules shall be compatible with a wide range of load devices, e.g.
motor starters, valves, and indicators etc.

7 The current rating of the relay output shall be capable of supplying the load according to the
applications.

8 The analogue voltage output module shall be capable of converting digital data to analogue
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outputs in the range of -10 to +10 volts.

9 Resolution of the converted output signal shall be minimum 12 bits.

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10 All analogue signals shall be updated each scan into a dedicated area of data registers.
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11 The analogue voltage outputs shall be configurable to default to 0 mA, 4 mA or hold-last-

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state in the event of a CPU failure.

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12 Output signals to 'DUTY' equipment shall not be derived from the same output module as
'STANDBY' equipment performing the same function.

13 Digital outputs used for AC inductive loads shall be fitted with arc suppression devices as
close to the load as is practicable.

14 Means shall be provided to allow the disconnection of outputs causing unsafe movements or
actions without removing power from the PLC Processor or inhibiting program execution.

15 All digital input modules shall be provided with LED for each point (channel) for testing and
maintenance purposes.

16 All digital input modulus shall be provided with a dual independent power supply.

2.6.4 PLC Software

1 PLC Software shall be developed within the BS EN 61131-3 environment. Application

program shall be developed by using software package that only conform to BS EN 61131-3
requirements.

2 Standard IEC libraries of Functions and Function Blocks shall be used when writing
application software.

3 All software shall be suitably documented to include the following as a minimum:

(a) suitable comments;

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Part 02: Telemetry/SCADA

(b) function description;

(c) symbolic addressing local data areas;
(d) symbolic addressing global data areas;
(e) descriptions of all constants;
(f) list of cross-references.

4 The PLC shall be suitable to employ minimum two programming devices for development of
application programs, a small hand-held device with back-lit LCD readout and a Software
programming package running on a PLC compatible laptop or desktop computer.

5 On-line and off-line, CPU and I/O configuration and application program development shall
be achieved with a PLC compatible computer and programming and documentation
software.

6 Both the PC compatible computer and the hand-held programmer shall be connectable to the
PLC via built-in serial communication port. The PLC shall connect to the computer over the
computer's RS 232C serial port for programming.

7 In addition to the serial communications, the PLC compatible computer shall be connectable
to the PLC via Ethernet TCPIP supporting the SRTP application protocol.

8 The programming devices shall have access to the application program, the CPU and I/O
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system configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O
over-ride capabilities
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2.7 DATA COMMUNICATIONS LINKS

2.7.1 Communication Standards

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1 Transmission of data shall conform to a recognised Consultative Committee for International

Telephone and Telegraphy (CCITT) standard. The data transfer system shall be self
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monitoring such that any equipment or line failure shall be displayed at both ends.

2 The protocol used shall safeguard against false data transmission, allow for error detection,
recovery, failure detection and initiate switchover the redundant data highway. A diagnostic
routine shall be included to monitor the highway performance. Data protocols and
diagnostics shall be fully documented.

2.7.2 Control Room Data Highway

1 All master station operator workstations and control room hardware shall be linked by a
totally redundant local area network to transfer data between the servers, work stations and
serial line multiplexers. The system shall continuously monitor the performance of both links
and output an alarm on detection of an abnormal condition. Fibre Optic cables shall be
provided for control room Data Highway, unless otherwise specified in the project
specification

2 The following features shall be provided as a minimum:

(a) all data highway networks are to monitored at all times

(b) communications diagnostics are to be continuous such that a failure is alarmed in the
minimum time
(c) each network node shall have message checking capability
(d) there shall be no single point of failure
QCS 2014 Section 10: Instrumentation Control and Automation Page 24
Part 02: Telemetry/SCADA

(e) the maximum distance between nodes shall be up to 600 meters, with a maximum
highway distance of 3500 meters
(f) communication rates shall be at least 10 M baud.

2.7.3 Leased lines or PSTN

1 The system shall use the public switched telephone network (PSTN) or leased data circuits to
transfer data between the master station and the RTU‟s located at remote sites. The
modems used by the master station and the RTU‟s shall have auto dial, auto answer
capability and be PTT approved.

2 All radio equipment shall comply with the appropriate local recommendations and shall have
been approved for licensing by the radio frequency allocation authority. Additionally the
equipment shall comply with the most recent edition of the appropriate national and
international standards specifications.

2.7.4 Radio

1 Type approval numbers issued by the national frequency allocation committee in the country
of manufacture shall be supplied, together with CCIR recommendations, national and
international standards, specification and recommendations met by the equipment at this
time of tender.
The radio system shall be of the following type :
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frequency : UHF/VHF as allocated by Frequency Allocation Authority
modulation : FM
base mode : full duplex
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outstation mode : two frequency simplex

channel spacing : 12.5 kHz
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2.7.5 Radio Path Profiles

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1 The Owner shall provide path profiles and subsequent technical examinations prior to
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detailed design of the radio system.

2.7.6 Radio Transmitters/Receivers

1 Transmitter/receiver radio units shall be single units without standby facilities. These units
shall have sufficient battery back up for the system to function for 8 h in the event of mains
failure. Provision for this may be from the main RTU battery back up supply. The units may
be either wall mounted or incorporated within the RTU enclosure.

2.7.7 Base Station Radio Transmitter/Receivers

1 Base station transmitter/receiver radio units shall be of a dual main/standby type with auto
changeover of the duty units. The Contractor shall supply within the tender document and
explanation of how this changeover shall be accomplished. An alarm signal shall be
transmitted to the Master Station when a changeover occurs. The base station shall be
provided with power supply equipment, including nickel cadmium battery and 240 V 50 Hz
a.c. mains fed battery charger and have sufficient battery back up to allow for the system to
operate for 4 h in the event of mains failure and capable of automatically recharging the
battery to full capacity within 24 h while the radio equipment continues to operate at full duty.

2.7.8 Aerials and Aerial Structures

1 The Contractor shall supply and install all aerials and aerial support structures and shall
provide drawings to show how each type of aerial is to be mounted.

2 The base stations shall have omnidirectional aerials plus any associated duplexers.
QCS 2014 Section 10: Instrumentation Control and Automation Page 25
Part 02: Telemetry/SCADA

3 UHF outstations shall have a single 12 element, yagi aerial with a gain of 12 dB with respect
to a half wave dipole on the corresponding base station. Any VHF outstations shall have
3 element yagi VHF aerials planned on the corresponding base station.

4 The Contractor shall supply and install all necessary low loss coaxial down leads for
connection for the radio unit and lightning protection for the aerial system.

2.7.9 Fibre Optic Network

1 The Contractor shall carry out a study whether it is necessary to lay a fibre optic
communication media for use as main data highway link. The study shall include the security
level required in the designed site communication where fibre optic cable considered being
highly secured and highly accurate communication medium.

2 This particular specification is to be read in conjunction with QCS 2010 Section 21 Part 14
Structured Cabling Systems

3 Qualifications and Responsibility of Contractor

4 The Contractor shall furnish and install all fibre optic equipment and materials specified in
this section and shown on the tender drawings. The fibre optic system shall be the unit
responsibility of one system supplier. The supplier shall use qualified personnel, possessing
the necessary equipment and having experience in similar installations
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(a) Submittals:
Submit the following information:
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(i) Catalog data and installation instructions on the splice method, hardware, and
splicing
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(ii) equipment (if any).

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(iii) Catalog data on the fiber optic cable, pull boxes, connectors, cable lubricant,
duct
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(iv) sealant, closures, pull rope, enclosures, identification tape, and mounting
hardware.
(v) Catalog data on the testing equipment including a written test procedure
outlining the
(vi) steps and methods that will be used to test the cable during and after
installation.
(vii) Include a sample copy of the test form that will be used in the test procedure.
(viii) Cable installation procedures for the applicable method of installation, outlining
the
(ix) construction methods that will be used. Identify steps that will be taken to ensure
(x) that the cable is not damaged during the installation.
(xi) Complete factory test results for cable reel stating the signal loss for fiber in the
cable
(xii) prior to and after extrusion of duct around cable if applicable.
(xiii) Record drawings indicating the locations of all splices (if any) and manholes .
(xiv) Certified test results for each cable after installation stating the signal loss of
each fiber in the cable between splices, across all splices, and from end to end
after splicing is complete.
(b) Qualifications and Responsibility of Contractor
(i) The Contractor shall furnish and install all fibre optic equipment and materials
QCS 2014 Section 10: Instrumentation Control and Automation Page 26
Part 02: Telemetry/SCADA

specified in this section and shown on the tender drawings. The fibre optic
system shall be the unit responsibility of one system supplier. The supplier shall
use qualified personnel, possessing the necessary equipment and having
experience in similar installations.
(c) Material
(i) The Single mode optical fiber cables which are optimized for use in both wave
lengths 1310 nm and 1550 nm.
(ii) The multimode optical fibre cables which are optimized for use in both wave
lengths 850 nm and 1310 nm.
(iii) The optical fibre cables shall meet the requirements stated in ITU-T Rec. by
international telecommunication Union, BS EN 50173-3 standard.
(iv) The cable shall be new, unused and of current design and manufacture.
Suitable optical fibre cables shall be selected based on the distance travel,
bandwidth, indoor and outdoor application and shall be approved by the
Engineer.
(v) The single mode fiber shall be used for fibre optic network more than 300 m
distance data transmission, unless otherwise justified by the manufacturer.
(vi) The material of the fibre shall be silica glass fibre.
(d) Fibre characteristics
(i) The fibre utilized in the cable must meet ITU-T: G651.1, G652 and have
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maximum attenuation at 850 nm of 3.75 dB/km at 1310 nm of 0.4 dB/km, at
1550 nm of 0.3 dB/km or less. If used for outdoor, then the fibre cable must be
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loose-tube non-dielectric type.

(e) Installation
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(i) Refer to the QCS Section 21 Part 14, clause 14.2.3

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2.8 INPUTS/OUTPUTS
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2.8.1 General

1 All process I/O and equipment interface boards shall comply with the following:

(a) Equipment wiring termination‟s shall accommodate up to 0.9 mm diameter

conductors. Terminals shall be of the test disconnect type to permit ease of signal
isolation and loop monitoring for commissioning and maintenance purposes.

2 Hot (powered) removal of I/O boards shall be possible without special tools.

3 Provision to power two wire loop powered transmitters, where required.

4 Digital inputs shall meet the following requirements:

(a) all digital inputs shall be optically isolated.

(b) all alarm and state indications shall be from dry contacts or 24 V d.c. wet contacts.
An isolated +24 V d.c. supply shall be provided to source the opto-isolated inputs
when connected to dry contacts, adequate filter circuits and software debounce
techniques will be necessary.
(c) Contact operation shall be as follows :
(i) Alarms: in the healthy condition the contacts shall be closed with the relay
coil energised: in the alarm condition the contacts shall be opened with the
relay de-energised.
QCS 2014 Section 10: Instrumentation Control and Automation Page 27
Part 02: Telemetry/SCADA

(ii) States: contacts shall be open with relay coil de-energised in the off (logic
„0‟) condition, and closed in the on (logic „1‟) condition.
(iii) Two bit Digital: One contact shall close when the equipment is in one state
and a second contact shall close when the equipment is in the opposite state.

2.8.2 Analogue Inputs

1 Independently configured channels in the range 4 - 20 mA, 1-5 V d.c., 0-1 V d.c., 0-5 V d.c.,
0-10 V d.c. or +/-10 V d.c. All analogues shall be screened and segregated from other
cables. The signal ground shall be separate from the system ground. Input impedance shall
be greater than 1 M  for voltage inputs. ADC conversion at ten times per second shall be
16 bit, system accuracy ± 0.2% of span.

2.8.3 Digital Outputs

1 All digital outputs shall be optically isolated.

2 All control circuits shall operate from a 24 V d.c. supply. The contact will be normally open
and energised to close when an action is initiated. Outputs shall be either open-collector or
volt-free contacts as follows:

(a) Open collector : 100 mA at 35 V d.c.

(b) Contact : 1 A at 24 V d.c. or 120 VA (resistive) 0.5 A at 24 V d.c. or
120 VA (inductive).
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2.8.4 Analogue Outputs
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1 In general all analogue outputs shall be 4-20 mA or 1-5 V d.c., selectable, and drive a
maximum loop impedance of 1000  for current outputs and 2000  for voltage outputs. The
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signal ground shall be separate from the system ground. DAC conversion shall be 14 bit,
system accuracy ± 0.2% of span.
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2.8.5 RTD Input

1 Capable of receiving 10  copper or 100  platinum resistance temperature devices directly

without external transmitter. Conditioned signal must be capable of being directly accessed
by the on board RTU controller without external intervention.

2.8.6 Thermocouple Input

1 Capable of receiving type E, J, K, input directly without an external transmitter. Linearisation

shall be performed at the PLC without external intervention.

2.8.7 Pulse Input

1 Capable of receiving a zero based pulse or rectangular wave or sinusoidal wave form with
amplitude of 4-6 or 21.6-27 V and rate of 0 to 5000 pulses per second for totalizing. Where
frequency counting is required a rate of 0 to 1000 pulses per second should be provided

2.9 POWER SUPPLY REQUIREMENTS

1 All power supplies provided by the Contractor shall conform to the following:

(a) be comprised of standard available units

(b) be fitted with adequate input/output fuse protection
(c) power supplies to be fitted, if applicable, with short circuit protection and current
limiting facilities
QCS 2014 Section 10: Instrumentation Control and Automation Page 28
Part 02: Telemetry/SCADA

(d) all power supplies to be selected such that they are derated to allow for future
expansion to improve the reliability, and help increase the MTBF of the units. With all
the expansion described in this specification, the loading on the power supplies shall
not exceed 75 % of their total capacity
(e) modular with one for N redundancy
(f) modular failure indicated at the PLC and Master Station
(g) failed module shall be removed without disconnecting system power or affecting
control.

2.10 MIMIC DIAGRAM

2.10.1 General

1 Where required in the Project Specification a modular mimic diagram shall be provided. The
Mimic will be configured to display the status of all principal items of equipment in the area
covered.

2 No Part of the mimic panel display area shall be below 760 mm or above 2100 mm from the
floor.

3 All layout details and dimensions, including main construction, colours, symbols, line
diagrams, legend text and indications, shall be agreed with the Engineer.
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4 The mimic diagram driver shall be housed in either the mimic diagram enclosure or a
separate enclosure. In either case the driver shall consist of modules mounted in standard 19
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inch card frames. The mimic driver shall consist of a client device directly connected to the
data centre LAN.
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5 Colour coding shall be in as provided below and where not stipulated in accordance with BS
EN 60073:2000:
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Satus of Operation Colour Code

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Equipment running and normal Green

Equipment stopped and normal White/Grey
Equipment tripped Yellow
Equipment selected “on Auto” Blue
Equipment or process unsafe / danger in operation Red
Panel Energised /isolator or ACB ON White
Process Flow ON (e.g. Valves open) Green
Process flow Stopped OFF (e.g. Valves closed) White
2.10.2 Mosaic Tile

1 The face of the mimic diagram shall comprise a mosaic of precision formed tiles, which shall
clip into a supporting grid to form a robust construction of flush and neat appearance. The tile
faces shall have a durable, scratch-resistant non-reflective finish. The background colour of
the mimic diagram tiles shall be to the approval of the Engineer. The face dimensions of tiles
shall be subject to approval by the Engineer.

2 The face of the tile mosaic shall be engraved and/or printed or painted to provide a diagram.
The printing or painting shall be durable throughout the lifetime of the equipment.

3 The mimic diagram face and supports shall be rigidly held in a robust floor mounting frame.
The surround to the mosaic tile area and the ends of the frame shall be enclosed in
decorative panelling to provide a high quality aesthetic finish. The complete construction shall
be formed into an enclosed panel, with a access to enable the ready replacement of
defective components and the rearrangement of tiles. Tiles and components shall be
replaceable without disturbance to the surrounding areas of the mimic face.
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Part 02: Telemetry/SCADA

4 Wiring troughs or clips shall be provided at the rear of the mimic diagram to enable wiring to
electrically driven components to be neatly dressed and supported. Flexible wiring of
adequate length shall be used to enable electrically driven components to be relocated on the
mimic diagram without the necessity for rewiring.

5 All illuminated indications shall use high radiance, light emitting diodes (LED‟s). Either single
peep-through or multiple-element/planar types shall be used, as appropriate. The illuminated
area shall have even intensity across the whole face. All LED‟s shall have a wide viewing
angle in excess of 60  without significant change in perceived luminosity.

6 A 20 % spare capacity shall be provided (equipped) within the mimic driver and the wiring to
the mimic board to allow for future modifications. The spare capacity shall be evenly
distributed.

7 All driver outputs shall be protected against overload and short-circuit.

8 Lamp test facilities shall be provided such that operators can initiate the test from their
workstation positions. This facility shall ensure that both the mimic LED‟s and the driver
circuitry are exercised.

2.10.3 Projection

1 The mimic diagram shall be displayed using high resolution 1280 by 1024 panel rear
projection technology onto multiple projectors and screens arranged in a matrix to produce
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an integrated display, or an equivalent quality as specified in the particular Specifications.

2 The screens shall offer a wide viewing angle, + 40  horizontal and + 12  vertical, and good
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contrast in full ambient light conditions. The projector and screen assembly shall occupy a
floor space of less than 1.5 m, deep by the length of the mimic.
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3 Dynamic configuration of the display shall be from X-windows style environment and provide
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intuitive on screen menu drive display. The ability to interface multiple sources, up to a
maximum of 10 using an RS232/422 serial interface shall be provided.
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4 A software package shall be provided to adjust brightness, contrast, time, colour, sharpness
and geometry and convergence settings from one computer. Image adjustments shall be
stored for each source such that the projector will automatically select the correct settings for
the Particular source.

5 An auto convergence system shall be provided to automatically align the projected image on
the screen, manual convergence shall also be possible.

6 A live video window facility shall be provided to display real time video images anywhere on
the screen matrix. The video signal may originate directly from a site security video camera
or via a live antenna signal.

7 A remote pointer facility shall be provided to allow the operator to use the local keyboard and
mouse to move the cursor on the mimic display and interact with the applications. The
system shall support upto three operators simultaneously with a security interlock system to
avoid conflicts between users.

2.11 FACTORY INSPECTION AND TESTING

2.11.1 General

1 The Contractor shall advise the Engineer the date on which the equipment is available for
factory inspection and tests 30 days in advance. No equipment shall be shipped to Site
without written permission of the Engineer.
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Part 02: Telemetry/SCADA

2 Before dispatch from a manufacturer‟s works each item of equipment, software and its
components shall be tested in accordance with the relevant specification or code issued by
the British Standards Institution or similar internationally recognised standards authority. In
the absence of such a specification or code, these tests shall be performed in a manner
subject to the approval of the Engineer, and may be witnessed and approved by the Engineer
or his representative.The equipment will be inspected by the Engineer and his representative,
to ascertain compliance with the functional design specification, satisfactory finish and
workmanship, and relevant functional tests shall be carried out with simulated inputs/outputs
as necessary.

3 If simulated inputs/outputs are necessary then the simulation equipment shall be provided by
the Contractor as Part of the Works unless otherwise agreed.

4 Subject to the Engineer agreement, the works system tests shall take place according to the
program detailed by the Contractor.

5 Any surface coating applied prior to the initial inspection of equipment shall be considered
sufficient reason for its rejection. Where any attempt to conceal defects is discovered the
works may be rejected.

2.11.2 Test Plan

1 A test plan shall be produced for the Engineer‟s approval, by the Contractor, for the factory
and site acceptance tests. The plan shall indicate a logical step by step schedule comprising
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step, action and reaction, e.g.:
Step 1 Action : Simulate high level
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Reaction : Tank Symbol Change Colour

(a) Hardware Tests
(i) All hardware including spares shall be required to pass an agreed preliminary
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hardware performance test to ensure known hardware operability before

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software testing begins.

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(b) Functional Testing

(i) Functional testing using the system software shall be comprehensive.
Simulation of the inputs and responses from equipment operation shall be as
realistic a reproduction as possible of Site conditions. Systems to which the
PLC/SCADA is required to interface with but are outside the scope of this
contract shall be emulated to demonstrate correct operation of the hardware and
software.
(c) System Diagnostics
(i) The means of fault detection and diagnostics provided by the system
software shall be validated. This will involve making provision for including a
sufficient variety of faults and out-of-range conditions in the system to ensure
the detection processes are adequately tested.
(d) The Engineer shall have the option not to attend these tests and to instruct the
Contractor to carry them out on a Self Certification basis.
(e) Three copies of all manufacturers tests certificates, log sheets, performance curves,
etc. relating to the tests at manufacturer‟s works shall be dispatched to Site for
the Engineer‟s approval prior to system installation and commissioning.
QCS 2014 Section 10: Instrumentation Control and Automation Page 31
Part 02: Telemetry/SCADA

2.12 INSTALLATION

2.12.1 Tools

1 The Contractor shall include for the supply of all spanners, key, special tools, gauges and all
other electronic and calibration tools required for the efficient installation, commissioning and
operation of the equipment.

2.12.2 Training for Owner’s Personnel

1 Training shall be conducted by personnel employed by the ICA Subcontractor, familiar with
the system supplied, experienced and trained in developing and implementing instructional
courses.

2 The Contractor shall submit information on the training program for approval prior to
shipment of the equipment. This submittal shall include a course outline, time required,
course schedule, sample workbook and instructor qualification information for each level.

3 The Contractor make a workbook on each course available to every person taking the
courses listed herein. The workbook shall be of sufficient detail so at a later date a trainee
could review in detail the major topics of the course.

4 The training times shall be scheduled by Owner in advance so as not to disrupt Owner‟s
ability to operate the equipment.
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5 Specialised training shall be provided for a minimum of three of the Owner‟s personnel in the
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operation and maintenance of the system at the manufacturers facility or in Qatar, as

specified in the Project Specification. The training programme shall be divided into two
segments and each shall consist of at least five, eight hour working days.
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6 The maintenance training programme shall be developed for personnel that have electronics
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maintenance and repair experience and a general knowledge of computer systems, but shall
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not assume any familiarity with the specific hardware furnished. As a minimum, the following
subjects shall be covered:

(a) system architecture and layout

(b) hardware components
(c) module switch settings (configuration switches)
(d) I/O modules
(e) power supplies
(f) data highway
(g) programmer connection
(h) PLC programming and diagnostic techniques
(i) battery replacement and recording
(j) PC and workstation familiarization and maintenance
(k) troubleshooting
(l) disassembly
(m) cleaning
(n) component replacement
(o) reassembling.
QCS 2014 Section 10: Instrumentation Control and Automation Page 32
Part 02: Telemetry/SCADA

7 The operation training program shall include the following topics:

(a) power-up, bootstrapping and shutdown of all hardware devices

(b) interpretation of all standard displays
(c) appropriate actions for software and hardware error occurrences
(d) use of operator interface displays and keyboards
(e) use of printer including replenishment of supplies
(f) manual data entries
(g) creation and editing of graphic operator display screens
(h) loading of any required software into the system
(i) data base creation and editing.

8 System Management:
The training in this area shall cover the following:
(a) the daily supervision of the System: e.g., archiving data, system housekeeping, fault
reporting, preventing repetitive alarms
(b) system administration e.g., planning and providing system expansion and
reconfiguration of hardware, control of users and privileges, software and hardware
fault analysis
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(c) Engineering functions, configuration and application programming e.g., additions and
changes to the system, points, displays, reports and logs, preparation and
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downloading of sequence control programs and schedules and software development.

2.12.3 Site Inspection and Testing

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1 The Engineer shall have the option to attend the inspection and tests before setting the
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equipment to work. The Contractor shall notify the Engineer, in writing, 48 hours before
commencing tests.
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2 A Site Acceptance Test (SAT) shall be conducted as part of the ICA system validation and
shall include all equipment and software within the Contractor‟s scope of supply. This test
shall be conducted after the above equipment has been installed at the Site and the
Contractor is satisfied of the correctness of the installation and of the operation of the
equipment.

3 Particular Test Requirements

(a) communication test

(i) the Contractor shall firstly conduct a test to establish the correct functioning and
ability to correctly transmit data to and from each port on the system
communications network. In the event of any problem or deficiency being
identified in any equipment supplied by others, this shall be reported fully in
writing by the Contractor to the Engineer
(b) hardware test
(i) demonstrate correct operation of hardware using off-line diagnostics
(c) functionality test
(i) demonstrate the system performance and functionality meets the specification
(d) test details
(i) the SAT shall be carried out in accordance with a test specification produced by
the Contractor, and approved by the Engineer
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Part 02: Telemetry/SCADA

(ii) test equipment and test software shall be provided by the Contractor to load the
system to the worst case scenario defined in the test specification
(iii) the Contractor shall prepare a test report following the SAT.

4 System Commissioning

(a) where required in the Project Specification the Contractor shall provide staff to
work in conjunction with the Owner to ensure the satisfactory operation in service
of all equipment in the system, and to assist the Owner to adjust configuration data
and to develop/modify application programs e.g., sequence controls.

5 System Takeover

(a) The criteria for takeover of the system shall be:

(i) submission by the Contractor and approval of as-built drawings
(ii) submission by the Contractor of all documentation
(iii) submission of all software design and support documentation and the lodging
of source codes in a place of secure safe-keeping and storage with a third Party
(iv) provision of information and examples of each type of report and each item of
user-configurable functionality
(v) issue of all relevant test certificates
(vi) successful completion of the SAT
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(vii) system commissioning and issue of Final System Test Certificate by the
Contractor.
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Following satisfactory completion of the above, the „Engineer‟ will issue the necessary
system takeover certificate.
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END OF PART
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QCS 2014 Section 10: Instrumentation Control and Automation Page 1
Part 03: Primary Elements

3 PRIMARY ELEMENTS .................................................................................. 2

3.1 GENERAL ...................................................................................................... 2

3.1.1 Scope 2
3.1.2 References Standards 2
3.1.3 Submittals 2
3.1.4 Quality Standards 2
3.1.5 Warranty 3
3.2 PRODUCTS ................................................................................................... 3
3.2.1 Electromagnetic Flow Meters 3
3.2.2 In - Line Ultrasonic Flow Meters 3
3.2.3 Rotameters 4
3.2.4 Venturi Flumes 4
3.2.5 Flow Switches 4
3.2.6 Ultrasonic Level Measurement 5
3.2.7 Hydrostatic Level Transmitter 5
3.2.8 Level Sensing System - Air Reaction Type 5
3.2.9 Capacitance Level Transmitter 6
3.2.10 Multiple Level Measurement Systems 6
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3.2.11 Tilting Float Level Switches 7
3.2.12 Level Switches - Conductivity Probe 7
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3.2.13 Electronic Pressure Transmitters 8

3.2.14 Electronic Differential Pressure Transmitters 8
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3.2.15 Pressure Gauges 8

3.2.16 Vacuum Gauges 8
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3.2.17 Pressure Switches 9

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3.2.18 Limit Switches 9

3.2.19 Temperature Sensors 9
3.2.20 Gas Detection System 9
3.2.21 Guided Wave Radar Level Transmitter 10
3.3 INSTALLATION ........................................................................................... 10
3.3.1 General 10
3.3.2 Testing and Final Acceptance 10
3.3.3 Spare Parts and Tools 10
QCS 2014 Section 10: Instrumentation Control and Automation Page 2
Part 03: Primary Elements

3 PRIMARY ELEMENTS
3.1 GENERAL

3.1.1 Scope

1 This Part includes specifications for Primary Elements, their design, manufacture, installation
and commissioning.

2 Related Sections and Parts

This Section
Part 1, General
Part 2, General Telemetry/SCADA
3.1.2 References Standards

1 The following standards are referred to in this Part:

BS 907........................Dial gauges for linear measurement
BS 1042......................Flow Measurement
BS 1780......................Bourdon tube pressure and vacuum gauges
BS 1904......................Industrial platinum resistance thermometer sensors
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BS 2765......................Dimensions for temperature detecting equipment and their pockets
BS 3680......................Open channel Flow and Level Measurement
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BS EN 50014 to BS EN 50020 Protection

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BS EN 60529..............Ingress Protection
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BS EN ISO 6817 ........Flow measurement for conductive liquids

3.1.3 Submittals

1 Submittals shall be in accordance with Part 1 of this Section.

2 Manufacturer’s literature, illustrations, specifications and engineering data including

dimensions, weight, instrument set point and range, ambient temperature and humidity
rating, process pressure rating, enclosure specifications, installation and wiring diagrams
shall be included.

3 The submittal shall be subject to approval by the Engineer. The ICA Subcontractor shall
submit the final documentation based on the Engineer’s comments. The Engineer’s
comments/approval shall be issued to the Contractor within 21 calendar days of the
submittal.

3.1.4 Quality Standards

1 Manufacturer. In addition to requirements of Part 1 of this Section, instrumentation and

controls equipment furnished shall be manufactured by a Company regularly and currently
engaged in the design and manufacture of similar equipment. All equipment furnished shall
be new and of current design. The manufacturer shall be approved and designated in the
Project Specification.
QCS 2014 Section 10: Instrumentation Control and Automation Page 3
Part 03: Primary Elements

2 Maintainability. All equipment shall be designed for ease of maintenance and repair, and
access to critical parts shall not require a major dismantling. Internal field adjustments, where
permitted or required herein, shall be easily accessible upon removal of a panel or cover.

3 Materials and installation shall comply with the requirements of the current editions of
referenced electrical codes and standards, and the codes and standards referred to shall be
used for establishing the minimum quality of the materials and equipment supplied and
installed. All equipment of the same type shall be products of the same manufacturer.
Capacities of all equipment shall not be less than that indicated on the Drawings or specified
in the Project Specification.

3.1.5 Warranty

1 The equipment manufacturer shall warrant his product to be free from defects in
workmanship for a period of 400 days from the date of satisfactory completion of
performance test.

2 Warranties and guarantees by the suppliers of various components in lieu of single-source

responsibility by the equipment manufacturer will not be accepted. The Contractor shall be
solely responsible for the warranty. In the event a component fails to perform as specified or
is proven defective in service during the warranty period, excluding items normally expended
during operation, the equipment manufacturer shall provide the replacement Part without
cost to Employer. The Contractor shall be responsible for the supply for all such spares under
warranty.
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3 The Contractor shall furnish the Employer with manufacturer’s guarantee and warranty
certificates for all equipment, duly registered with the manufacturer.
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3.2 PRODUCTS
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3.2.1 Electromagnetic Flow Meters

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1 General. Electromagnetic flow meters shall use electromagnetic induction to produce a dc

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voltage proportional to the liquid flow velocity. The flow meter shall be certified intrinsically
safe and suitable for hazardous area Zone 1, gas group IIA to EN 50014, where specified in
the Project Specification. Flowmeter shall be pressure tested and calibrated by the
manufacturer and certified. Overall accuracy shall be better than ±0.5 % of the range
throughout the operating range. Repeatability shall be within ±0.2 %.

2 Sensor. Sensor shall have NP16 flanged process connections. Metering tube, flanges and
earthing rings shall be of stainless steel 304 to BS 970. Electrodes shall be of stainless steel
316 to BS 970. The sensor lining shall be of Teflon or equivalent material suitable for the
application, unless otherwise specified in the Project Specification. The sensor enclosure
shall be protected to IP68. Screened and armoured cable between the sensor and the
transmitter shall be fitted and potted by the manufacturer. The preamplifier input impedance
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of the sensor shall be a minimum of 10 megaohms to minimise errors due to sensor coating.
Ultrasonic electrode cleaning equipment with all accessories for automatic or manual
operations, shall be provided when specified in the Project Specification.

3 Transmitter. Transmitter shall be remotely installed from the sensor. Transmitter power
supply shall be 240 V a.c , 50Hz, unless otherwise specified in the Project Specification.
Transmitter shall be microprocessor based with programmable range and engineering units.
Outputs shall be isolated 4-20 mA d.c. and pulse with adjustable span. Programmable in-built
alarm relays shall be provided for empty pipe, low and reverse flows. Transmitter shall have
an inbuilt digital display for flow rate, total and alarms. Transmitter enclosure shall be
protected to IP65. Calibration and programming kit shall be provided

3.2.2 In - Line Ultrasonic Flow Meters

QCS 2014 Section 10: Instrumentation Control and Automation Page 4
Part 03: Primary Elements

1 General. Ultrasonic Doppler type flow meter with nonintrusive sensor permanently bonded to
the pipeline. Overall accuracy shall be within ±2 % of the range with a repeatability of ±0.2 %

2 Transducer. Dual transducers shall be permanently bonded or clamped on to the pipe line to
ensure that locked air pockets are eliminated.

3 Transmitter. Transmitter shall be remotely installed from sensor. 240 V a.c. 50 Hz power
supply, unless otherwise specified in the Project Specification. Wall mounted with in-built
flow rate and total display. Enclosure protected to IP65. Automatic gain adjustments to suit
pipe line material shall be available. Alarm contacts configurable for diagnostic or low flow
alarm shall be provided. Operating velocity range shall be user selectable. Output shall be
isolated 4-20 mA d. and facility for connecting industrial standard fieldbus

3.2.3 Rotameters

1 Rotameters shall have borosilicate glass metering tube, stainless steel 316 float and wetted
Parts to BS 970, scale shall have black markings on white background with a nominal length
of 250 mm. Graduation units shall be as specified in the Project Specification. Flanged
process connection. 2 % accuracy and 10:1 rangeability. Glass tube shall be easily
removable for cleaning.

3.2.4 Venturi Flumes

1 Rectangular flumes used for open channel flow measurement to BS 3680 Part 4c, shall be
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moulded in a single GRP piece with 5 mm thick walls, reinforcing ribs and internal removable
blocking to prevent distortion during shipment. Provide staff gauge, 50 mm width by full depth
with 1 mm increments recessed into flume. The flume shall be self supporting and be
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provided with an adequate number of lugs integral to the structure to enable the flume to be
cast into a reinforced concrete channel without additional internal or external supports.
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2 U-throated flumes to BS 3680 Part 4C, shall be used for measurement of flows in sewers
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and other conduits running partly full.

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3.2.5 Flow Switches

1 General. Flow switches shall sense an adjustable preset flow rate of fluid in a pipe and
operate a SPDT switch to actuate alarms or control circuits. The switch shall be rated for 1
ampere load at 110 V a.c., 50 Hz or 1 Ampere at 30 V d.c.

2 Vane type flow switches shall be housed in a watertight case, unless explosion proof is
specified in the Project Specification, with electrical conduit connection. Switches for
mounting in 40 mm pipe or larger shall be fitted for BSP thread mounting directly in the pipe.
Smaller sizes shall be supplied mounted on a pipe fitting with female BSP threads. The
switch assembly shall be isolated form the flow by a diaphragm or suitable seal. The
actuator vane and other wetted parts shall be stainless steel, monel, brass or other corrosion
resistant material suitable for the fluid in the pipe. These flow switches are suitable for gases
or clear liquid applications only and shall not be used for raw sewage applications.

3 Thermal type flow switches shall be housed in an explosion proof or watertight case as
specified in the schedule with NPT electrical conduit connection and shall be either of the
probe type of insertion in the pipe or shall incorporate a pipe spool for installation in the line,
end fittings as shown on the Drawings. They shall operate by means of sensing the
differential cooling of heated sensor elements caused by flow and no flow condition, and shall
be all solid state. The switches shall be available for pressure up to 14 MPa and shall be
capable of sensing velocities as low as 3 cm/s. Wetted parts shall be stainless steel to
BS 970 or other materials suitable for the application.
QCS 2014 Section 10: Instrumentation Control and Automation Page 5
Part 03: Primary Elements

4 Operating Conditions. The flow switch shall be sized and adjusted for the pipe, fluid and flow
rate or velocity shown in the Flow Switch Schedule. Repeatability of sensing shall be within
10 percent for any setting, and differential shall be less than 4.0 percent within the flow range
specified. Set point shall be within 10 percent of flow rate of velocity specified. Care should
be taken while installing, to avoid locations with turbulent flow conditions.

3.2.6 Ultrasonic Level Measurement

1 General. Unless otherwise specified in the Project Specification, the system shall comprise of
a separate transducer and a transmitter. Overall accuracy shall be better than ±1% of the
span with a repeatability of ±0.5%. Ultra-sonic level measurement is to be accomplished by
the use of non-contact, echo-time measuring equipment operating at ultra-sonic frequency.
The equipment is to transmit pulses, which are reflected back to the sensor from the surface
of the liquid whose level is being measured. Provide equipment with automatic temperature
compensation and suitable for operation in the designated application under the specified
climatic conditions.

2 Transducer. The enclosure shall be protected to IP68. Automatic compensation for changes
in ambient temperature shall be in-built. The transducer shall be certified for hazardous area
use if necessitated by the installed conditions, unless otherwise specified in the Project
Specification. The transducer shall be supplied complete with all required mounting
accessories.

3 Transmitter. Surface or panel mounted transmitter with 240 V a.c. 50 Hz power supply.
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Microprocessor based transmitter with programmable range and alarms. Transmitter shall
be complete with in-built indication for level or for flow, if used for open channel flow
measurement. 4 Nos. in-built relay contacts, shall be provided for process and diagnostic
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alarms. Transmitter shall be provided with an in-built keypad or a hand held programming
unit of programming the instrument. Output shall be isolated 4-20 mA d.c and facility for
connecting industrial standard fieldbus.
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3.2.7 Hydrostatic Level Transmitter

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1 Hydrostatic head type level transmitters shall be used for tank level measurement at
atmospheric pressure. Flush diaphragm type capacitance sensor suspended inside the tank.
Sensor shall be certified intrinsically safe and protected to IP68. Sensor material shall be
stainless steel 316 to BS 970. Two wire transmitter with 4-20 mA d.c. output ±0.5 %
accuracy. Flanged process connection on top of the tank.

3.2.8 Level Sensing System - Air Reaction Type

1 General. The level sensing system shall be designed to operate on the back pressure
caused by the level of the liquid above the open end of a pipe through which air is being
discharged. The device shall be capable of sensing a rising or a falling liquid level and shall
translate this rise or fall into a proportional analogue signal. Device shall be two-wire loop
powered 4-20 mA dc output and facility for connecting industrial standard fieldbus with an
accuracy of +/- 0.5% of span. All equipment such as required to meet the operational
requirements set forth herein shall be included and connected to obtain a complete functional
system as specified herein.

2 Air Supply. The system shall operate from the auxiliary air sources specified below. To
facilitate control, the system shall include a strainer, shutoff valve, pressure regulator with
gage, flow control valve and flow metering rotameter with differential pressure regulator. A 4-
way purging valve or equivalent shall permit purging of the bubbler tube while isolating the
pressure sensing line.
QCS 2014 Section 10: Instrumentation Control and Automation Page 6
Part 03: Primary Elements

3 Piping Connections. A "tee" with a removable plug for cleaning purposes shall be provided to
connect the air tubing to the bubbler tubing in the wet well. The plug shall be readily
accessible for cleaning.. The wet well sensing tube shall be 12 mm diameter stainless steel
to BS 970 grade 316 S12 and extend to 150 mm below the low alarm level or as otherwise
shown on the Drawings and be supported on not more than 1200 mm centres using stainless
steel clamps on the wet well wall to avoid movement due to turbulence. Static pressure
connection to the 4-way purging valve shall be 8 mm polyethylene tubing, enclosed in steel
conduit or equivalent protection. The pressure output signal shall be sensed by indicator
dials, pressure switches, electronic or pneumatic transmitters as specified in the Project
Specification.

4 Auxiliary Air Supply. The system shall incorporate and operate from internally mounted dual
oil-less heavy duty air compressors, each capable of providing the required air flow. The
compressors shall operate in a duty-standby mode. Failure of the duty compressor shall
generate an alarm and start the standby compressor. Facility shall be provided to drain out
condensate from the system.

3.2.9 Capacitance Level Transmitter

1 General. Radio frequency type level sensors shall sense the varying capacitance admittance
of a sensing probe as function of the level of submersion. Varying capacitance is converted
to a 4-20 mA d.c current signal or volt free contact output as indicated in the Project
Specification.
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2 Specific Requirements. The type of process medium, temperature range, pressure other than
atmospheric, measurement range, indicators, switches, etc. shall be as specified in the
Project Specification. Unless otherwise specified the accuracy shall be ±1 % of full scale.
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The electronics for the sensor shall incorporate circuitry which shall act to cancel error
caused by coating build-up on the probe.
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3 Construction. The radio frequency level sensor shall consist of a probe and a solid state
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electronic unit housed in an IP66 case for surface or panel mounting. Probes shall be
designated for mounting through a threaded flange adapter unless otherwise shown on the
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Drawings. The probe mounting parts shall be stainless steel 316 to BS 970 and the probe
shall be in accordance with the manufacturer's recommendation for the application specified.
Rigid probes shall be Teflon coated. Local indicators shall be mounted on the electronics
housing and shall indicate in the engineering units specified in the Project Specification. The
output shall be isolated 4-20 mA d.c. unless otherwise required by the Project Specification.

4 Power. The level sensing system shall either be a two wire transmitter loop powered by the
receiver or operate from 110 V a.c., 50 Hz power supply.

3.2.10 Multiple Level Measurement Systems

1 General. Multiple level detection systems shall be used for pump control or multiple level
alarm applications. Each system shall comprise of one or more electrode assemblies and a
controller.

2 Electrodes. Conductivity type electrode assemblies shall have a weatherproof enclosure to

IP56. Electrodes shall be of 316S12 material to BS 970 Part 1. Process connection shall be
BSP threaded or flanged to BS 4504. The electrode assembly shall have a glazed ceramic
insulator cemented to the metal housing. The measuring electrodes shall be Teflon insulated
except at the tip.
QCS 2014 Section 10: Instrumentation Control and Automation Page 7
Part 03: Primary Elements

3 Controller: Controller power supply shall be 110 V a.c. 50 Hz. Provide double pole
changeover contact for the output relays. Controller shall have LED indication for relay
status. Zener barriers shall be provided for intrinsically safe installations when the electrode
assembly is located in hazardous areas. Multiple level detection signals shall be used by the
Controller for control of up to 4 pumps or level alarm. The number of control modules in
each controller shall depend on the number of level signals and control contacts required.

3.2.11 Tilting Float Level Switches

1 General. Tilting float level switches shall use the tilting movement of a float, whose specific
weight is less than that of the process liquid, to actuate switches as the level changes. The
switch(es) shall be integrally mounted in the float and connected to a control box by an
appropriate, waterproof electric cable. A movable weight shall be mounted on the cable to
allow adjustment of the setpoint(s). Sufficient cable length shall be provided to facilitate
termination in a control or electrical room unless otherwise stated in the Project Specification.
The float shall be polyethylene, stainless steel or other approved material.

2 Specific Requirements. The desired switching action Pump-up ("pump-down”, or alarm), level
set-points, cable length and optional features shall be as specified in the schedule.
Contractor may utilise either a series of floats or a single float to provide the specified
switching action. The "pump-up" type shall close a contact at a low level and open it at a high
level. The "pump-down" type shall provide the opposite action.

3 The switch shall be rated for 1 A, 110 V 50 Hz or 1 A, 24 V d.c. inductive load.

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3.2.12 Level Switches - Conductivity Probe
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1 General. Level sensing switches of the conductivity probe type shall use the electric
conductivity property of the sensed fluid to close an electric circuit between two or more
sensing probes or between probe and an electrically conductive tank shell. The level
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switches shall consist of a probe assembly and an electronic sensing unit.

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2 Sensing Unit. The solid state sensing unit shall operate from a power source of 110 V a.c.,
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50 Hz, but shall not apply more than 10 V to probes and the current shall be limited to one
milliampere maximum. The unit shall be housed in an IP66 enclosure, unless explosion proof
is specified in the Schedule, and shall be for pipe stand or surface mounting. The unit shall
be suitable for direct or inverse operation (i.e. output contacts) operate on liquid contact or
non-contact. The output shall have two SPDT switches, rated at 5 A resistive load at 110 V
a.c., with provision for latching or non-latching operation, by appropriate connection of the
output contacts, to provide for "pump-up", "pump down" or alarm type operation.

3 Probes. The probes shall be either of the rod or flexible wire type when not specified the
Contractor shall select the type most suitable for the application and submit the choice for
approval. Solid rods shall generally be used only where the installation requires less than 2 m
in length. Both rod and flexible wire types shall be insulated except at the sensing end. Either
type shall be suspended from a holder which provides liquid tight connections, and when
installed in a pressure vessel they shall be pressure tight to at least twice the system
operating pressure. Exposed probe ends shall be type 316 stainless steel to BS 970 and
holder shall be cadmium plated cast iron, unless otherwise stated in the Project Specification.
The number of probes per holder shall be as specified in the Project Specification. The
holder mount type (i.e. pipe threaded, flanged or conduit style) shall be selected to suit the
installation unless otherwise specified in the Project Specification.
QCS 2014 Section 10: Instrumentation Control and Automation Page 8
Part 03: Primary Elements

3.2.13 Electronic Pressure Transmitters

1 General. Unless otherwise specified in the Project Specification, the instrument shall be a
two-wire loop powered transmitter with a 4-20 mA dc output, with an accuracy of 0.25% of
span. The wetted parts shall be stainless steel Grade316S31 to BS 970 and the enclosure
protected to IP67. Complete with flush diaphragm or remote seal sensing system. To achieve
optimum accuracy, transducers shall be selected to have a range as close as possible to the
anticipated operating range. A datum point shall be provided adjacent to the transducer
installation. An engraved plate shall define any offsets resulting from its elevation relative to the
tapping point (zero level) and also define the range of the transducer. All elevation
measurement shall be in metres, with the equivalent bar offset shown. Sensors shall be
positioned in a location accessible for safe maintenance. Where separate transducers and
transmitters are used, the transmitter where possible, shall be positioned locally to the
transducer to facilitate calibration. Site operatives shall be provided with a remote readout at a
convenient point.

2 Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified in
Project Specification. Enclosure and wetted surface material shall be stainless steel to
BS 970 or as indicated in the Project Specification.

3.2.14 Electronic Differential Pressure Transmitters

1 General. Electronic differential transmitters shall convert a differential pressure

measurement to a loop powered 4 to 20 mA d.c. output signal. Range shall be as indicated
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in the Project Specifications and span shall be field adjustable over at least a 10 to 1 range.
Elevation or suppression facility shall be provided. Overload protection shall be at least +3.5
MPa. Accuracy shall be +0.5 percent of full scale span or better. Integral adjustable damping
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shall be provided. An indicating meter shall be provided. Zero and span adjustments shall be
provided.
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2 Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified is
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schedule. The process connection shall be 12 mm NPT. Enclosure and wetted surface
material shall be stainless steel to BS 970. Vent drain plug shall be provided on meter body.
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A 3-valve manifold shall be provided such that the transmitter can be removed without
disturbing piping connections.

3.2.15 Pressure Gauges

1 Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have
black markings on white background. Dial size shall be 100 mm unless otherwise specified.
Wetted Parts and case shall be 316 stainless steel to BS 970. Accuracy shall be ±1 %.
1/2 inch NPT process connection unless otherwise specified. Pressure range and units shall
be as specified in the Project Specification.

2 Isolation diaphragm shall be stainless steel 316 to BS 970 with silicone fill, pulsation
dampeners or vibration snubbers shall be provided where specified in the Project
Specification.

3.2.16 Vacuum Gauges

1 Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have
black marking son white background. Dial size shall be 100 mm unless otherwise specified.
Wetted Parts and case shall be stainless steel 316 to BS 970. Accuracy shall be ±1 %. 1/2
inch NPT process connection unless otherwise specified. 0-760 mm HgA range unless
otherwise specified in the Project Specification. Cases shall be black phenolic.
QCS 2014 Section 10: Instrumentation Control and Automation Page 9
Part 03: Primary Elements

3.2.17 Pressure Switches

1 Pressure switches shall have a diaphragm type sensor with a switching differential adjustable
within 25 % of the range. Contact shall be micro switch SPDT rated 110 V a.c. 5A, 30 V d.c.
2A. Accuracy shall be ±1 % of span. Stainless steel enclosure certified explosion proof
where specified in the Project Specification.

3.2.18 Limit Switches

1 Limit switches shall be provided to sense the limiting positions of equipment, such as valves.
The switches shall be non-contact reed type, magnetically coupled to the actuating device.
SPST contacts shall be rated 110 V a.c. 3A. Reed switch shall have a life expectancy of one
million operations.

3.2.19 Temperature Sensors

1 General. Temperature sensors shall be (RTD) platinum resistance element. RTD sensors
shall have a temperature resistance relationship and tolerances for 100 ohm platinum
resistance element to BS 1904.

2 Construction. Temperature sensors shall be equipped with accessory equipment as

specified in the Schedule. In general, accessory equipment shall consist of general purpose,
or explosion proof connection heads; pipe extension with union connectors or bushings; wells
or protecting tubes and spring-loading assemblies. Well or protecting tube material shall be
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to BS 2765. Sensors shall be integrally mounted with transmitters to provide a 4-20 mA,
loop powered signal, where specified in the Project Specification.
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3.2.20 Gas Detection System

1 General. Gas detection system shall be rack-mounted. The system shall measure and
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display gas concentration and shall provide audio and visual alarms when preset limits are
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exceeded. Relay output for alarms and malfunction indications and analogue signal
representing gas concentrations shall be provided. The system shall be configured for fail
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safe operation. Failure of a sensor shall generate an alarm. The system shall consist of a
sensor, control module, and calibration check kit including sensor separation accessories
and calibration gas tanks. Sensor and transmitter location shall be as shown on the drawings
and schedule. The gas detection system shall operate from 110 V a.c., 50 Hz power.

2 Control Module. The control module shall amplify the sensor current signal through a solid-
state amplifier for display and alarm functions. The control module shall include a two or
three-digit LED display and three discrete alarm levels: Low, high, and malfunction. Output
relay contact shall be rated at 2 amp, 110 V a.c. and single pole, double throw. Analogue
output signal representing the gas concentration shall be 4-20 mA.

3 Oxygen Gas Detector. The oxygen gas detector shall have a 0-25 percent range, full scale.
The oxygen sensor shall be housed in an explosion proof enclosure. The sensor shall be the
electrochemical fuel cell type and not require the periodic addition of reagents.

4 Combustible Gas Detector. The combustible gas detector shall have a 0-100 LEL range, full
scale calibrated on methane gas. The combustible gas sensor shall be the catalytic bead
type. The sensor must have a demonstrated resistance to degradation by silicones and
reduced sulphur gases.

5 Hydrogen Sulphide Gas Detector. The hydrogen sulphide gas detector shall have a 1-100
ppm range; full scale. The hydrogen sulphide sensor shall be of the electrochemical type
which shall not require periodic addition of reagents.
QCS 2014 Section 10: Instrumentation Control and Automation Page 10
Part 03: Primary Elements

6 Chlorine Gas Detector. The chlorine gas detector shall have a 0-10 ppm range, full scale.
The chlorine gas sensor shall detect a minimum concentration of 0.5 ppm by volume and a
maximum response time of 30 s for 80 % of range to 10 ppm gas at 20 C. Sensor
recovering time shall be 3 minutes for 90 % of range at 10 ppm chlorine.

3.2.21 Guided Wave Radar Level Transmitter

1 The probe shall:

(a) have single rod with extended flexible wire, minimum probe diameter 6mm and
constructed of stainless steel to BS970-1 Grade316S31 (partially replaced by BS EN
10084);
(b) have flange mounted and threaded process connections;
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(c) be able to work with ambient rating of 150 C at 20 bar, for a dieletric range of 10-100;
(d) have ingress protection and hazardous area protection and shall meet the CE
requirements on Electromagenetic compatibility
(e) be energised in an intrinsically safe way.

2 The transmitter shall:

(a) (a) have locally remote wall/post mounting with a flexible connection to the probe head;
(b) (b) give a 4-20mA output with a resolution of 0.01mA;
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(c) (c) have a push button keypad and a HART communicator, with menu language
English;
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(d) (d) have ingress protection and hazardous area protection and shall meet the CE
requirements on Electromagenetic compatibility.
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3.3 INSTALLATION
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3.3.1 General
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1 Installation, testing and commissioning shall be in accordance with Part 1 of this Section.

3.3.2 Testing and Final Acceptance

1 All the primary elements shall be calibrated and tested prior to final acceptance, in
accordance with Part 1 of this Section.

3.3.3 Spare Parts and Tools

1 Spare Parts for all instruments listed in the schedules shall be provided for two (2) years of
normal service. Refer to Part 1 of this Section for additional spare parts requirements.

END OF PART
QCS 2014 Section 10: Instrumentation Control and Automation Page 1
Part 04: Panel Mounted and Miscellaneous Instruments

4 PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS ..................... 2

4.1 GENERAL ...................................................................................................... 2

4.1.1 Scope 2
4.1.2 Reference Standards 2
4.1.3 Submittals 2
4.1.4 Quality Standards 3
4.1.5 Manufacturers Test Certificates 3
4.1.6 Approved Manufacturers 3
4.2 PRODUCTS ................................................................................................... 3
4.2.1 Digital Indicators and Totalizers 3
4.2.2 Trip Amplifiers 3
4.2.3 Relays-Electromagnetic Type 4
4.2.4 Timers 4
4.2.5 Running Time Meters 4
4.2.6 Programmable Logic Controllers (PLC’s) 4
4.2.7 Alarm Annunciators 5
4.2.8 Chart Recorders 6
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4.3 INSTALLATION ............................................................................................. 6
4.3.1 General 6
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QCS 2014 Section 10: Instrumentation Control and Automation Page 2
Part 04: Panel Mounted and Miscellaneous Instruments

4 PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS

4.1 GENERAL

4.1.1 Scope

1 This Part specifies the panel mounted and miscellaneous instruments and equipment to
perform the required functions in conjunction with information and equipment specified in
other Parts of Section 10.

2 Unit Responsibility. It shall be the responsibility of the ICA Sub-Contractor as described in

Part 1 of this Section to ensure that the panel instruments and equipment supplied under this
Part are compatible with the primary elements and telemetry/SCADA equipment and
equipment specified under other Sections of these specifications, and that the signal
transmission methods are compatible.

3 Enclosures of front of panel mounted instruments shall be of uniform design and colour
scheme wherever possible. Front of enclosure colours shall be compatible with panel colours
and subject to final approval by the Employer. Normally, compatible standard colours of the
manufacturer shall be acceptable.

4 Related Sections and Parts

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This Section
Part 1, General.
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4.1.2 Reference Standards

1 The following standards are referred to in this Part:

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BS 5515......................Documentation of computer based systems

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BS 7165......................Recommendation for achievement of quality in software

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BS EN 50081..............Electromagnetic Compatibility
BS EN 61131-3P ........Programming Languages for Programmable Controllers.

IEEE 472-1974 ...........Surge protection

ISO 3511 ....................Process measurement control functions - instrumentation symbolic

representation
ISO 9075 (BS 6964) ...Structured Query Language (SQL)

4.1.3 Submittals

1 Submittals shall be in accordance with Part 1 of this Section.

2 The following shall be included in the submittals:

(a) shop drawings, product data, and samples

(b) complete description, specifications, drawings, and descriptive literature on the
equipment.
(c) make and model of each component
(d) number of sizing electrical and control wires and power requirements
QCS 2014 Section 10: Instrumentation Control and Automation Page 3
Part 04: Panel Mounted and Miscellaneous Instruments

(e) complete wiring and equipment instrumentation diagram

(f) list of spare Parts to be provided
(g) recommended procedure for protection of equipment against damage prior to
installation
(h) complete system diagram showing required components, routing through in-plant
ductbank system.

3 The submittals shall be subject to approval by the Engineer. The Contractor shall submit the
final documentation based on the Engineer’s comments. The Engineer’s comments/approval
shall be issued to the Contractor within 21 calendar days of the submittal.

4.1.4 Quality Standards

1 Manufacturer: In addition to requirements of Part 1, instrumentation and control equipment

furnished shall be manufactured by a Company regularly and currently engaged in the design
and manufacture of similar equipment. All equipment furnished shall be new and of the most
recent design.

2 Maintainability: All equipment shall be designed for ease of maintenance and repair, and
access to critical Parts shall not require major dismantling. Internal field adjustments where
permitted or required herein shall be easily accessible upon removal of a panel or cover.

3 Materials and installation shall comply with the requirements of the current editions of
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referenced electrical codes and standards, and the codes and standards referred to shall be
used for establishing the minimum quality of the materials and equipment supplied and
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installed. All equipment of the same type shall be products of the same manufacturer.

4.1.5 Manufacturers Test Certificates

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1 Manufacturers shall test and calibrate each input/output to operate within specified limits
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Calibration and compliance certificates provided by the manufacturer, shall be authenticated

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by the Contractor and submitted to the Employer.

4.1.6 Approved Manufacturers

1 All ICA equipment shall be provided by approved, prequalified manufacturers and suppliers
designated in the Project Specification.

4.2 PRODUCTS

4.2.1 Digital Indicators and Totalizers

1 Digital indicators shall be panel mounted type. 96 mm (w) by 48 mm (H) dimensions. 110 V
a.c. 50 Hz power supply. 4 1/2 digit LED or backlit LCD display for process variable. Range
shall be programmable in Engineering units. Input shall be 4-20 mA d.c. or volt free contact
as specified in the Project Specification. Loop power for 2-wire transmitter shall be provided
as required. At least two programmable alarm contacts for high or low alarms. Totalizers
shall have 8 digit display with manual reset facility.

4.2.2 Trip Amplifiers

1 Trip Amplifiers shall be surface or rack mounted with 110 V a.c. 50 Hz power supply. Input
shall be 4-20 mA d.c. 1 or 2 independent adjustable set points shall be provided as specified
in the Project Specification. Outputs shall be SPDT relay contacts rated 110 V a.c. 5A.
QCS 2014 Section 10: Instrumentation Control and Automation Page 4
Part 04: Panel Mounted and Miscellaneous Instruments

4.2.3 Relays-Electromagnetic Type

1 Relays shall be provided as necessary to perform switching functions required of control

panels and other control circuits.

2 Control Relays. Control relays shall be provided for the control and alarm circuits as indicated
in the Project Specifications. The relays shall be electrically held, 50 Hz, continuous duty,
multiple connected to 110 V a.c. control circuits and mounted inside control panels or
separate metal enclosures as indicated. Enclosures shall be IP66. The relay base assembly
shall accept from 1 through 8 convertible poles. Relays shall be attached to pre-shaped
mounting channels with captive screws.

4.2.4 Timers

1 Timers shall be provided as specified herein or indicated in the Project Specifications. Timers
shall have four types of operation: (1) On Delay (2) Off-Delay (3) Single Shot, and (4) Duty
Cycle timers. Time ranges shall be as shown in the Project Specification.

2 Panel mounted timers shall be of the motor driven adjustable type with dials and presentable
pointers. The timers shall operate from 110 V, single-phase, 50 Hz power and shall be of the
square bezel type for flush panel mounting. Output contacts shall be double throw and rated
for 10 A at 110 V a.c.. The number of contact sets shall be sufficient to perform the required
control functions. Where more contacts are required than supplied as commercial
standards, control relays of equal rating shall be used to supplement the timer contacts.
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When specified, relay contacts shall be supplied as Part of the timer and shall be operated by
the timer control power independently of the timed contacts. Repeatability of the preset time
delays shall be within ± 2%. Timers shall be of the plug-in type and enclosed in dust-proof
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cases. Connection shall be by numbered screw terminals in the rear of the timer connector.

3 On delay timers. When a start signal is applied, the timing cycle begins. Output contacts
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change state after the time delay is completed. Contacts shall return to original state when a
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reset signal is applied or power is removed.

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4 Off delay timers. When a start signal is applied, the output contacts change state
immediately. When the start signal is removed, the timing cycle begins and the output
contacts return to the original state when the cycle is completed. Timer shall be reset by a
reset signal or by removal of power.

5 One shot timers. When a start signal is applied, the output contacts change state
immediately and the timing cycle begins. The output contacts return to the original state
when the cycle is completed. Timer shall be reset by a reset signal or by removal of power.

6 Duty Cycle timers. Two timer cycles shall be incorporated. When a start signal is applied,
the first timing cycle beings. The output Contacts change state at the end of the cycle and the
next timing cycle begins. When this delay is completed the output contacts return to the
original state. This sequence is repeated until a reset signal is applied or power is removed.

4.2.5 Running Time Meters

1 Running time meters shall be of the synchronous motor driven type having a minimum of six
(6) decimal digits where the least significant digit shall represent tenths (1/10's) of hours.
Unless specified otherwise in the Project Specification, they shall not be equipped with a
reset button. They shall be for panel mounting with a square bezel approximately 60 mm on a
side. Motor voltage shall be 110 V a.c.

4.2.6 Programmable Logic Controllers (PLC’s)

1 See Section 10, Part 2, Telemetry/SCADA for PLC specifications.

QCS 2014 Section 10: Instrumentation Control and Automation Page 5
Part 04: Panel Mounted and Miscellaneous Instruments

2 PLC’s shall be installed inside Local Control Panels or in separate cubicles, as specified in
the Project Specification.

3 Data base development and system configuration shall be the Contractor’s and the ICA
Subcontractor’s responsibility. The data base developed by using the P&IDs and I/O point
list shall be submitted to the Engineer for approval prior to installation in the operating system

4.2.7 Alarm Annunciators

1 All windows in the alarm and status annunciator shall be nominally 36 mm by 76 mm, of
white plastic, and rear lighted with two low voltage, heavy filament lamps. The plastic
windows shall be engraved with black letters in accordance with the Drawings. The windows
shall be removable from the front for lamp replacement. The lamp units and electronic
drivers shall be in one case, unless otherwise approved in writing, with a removable cover
and designed for panel mounting. The lamps shall be mounted such that replacement is
possible from the front of the annunciator panel without tools. Lamp sockets and mountings
shall be robustly constructed, so as not to be loosened or misaligned when lamps are
replaced. The windows shall be in rows of six, unless otherwise shown. The monitoring
modules shall be of all solid state plug-in design. There shall be sufficient electronic modules
to drive all required annunciator windows, including spares. When specified, provide
repeater contacts terminated on a terminal strip for externally monitoring each alarm status.
The annunciator power supply shall be sufficient to drive all required loads. Alarm points
shall be driven by modules with the operating sequence shown below. The windows for
status indication, when specified shall be off and steady on only, colour shall be white or as
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shown in Table 4.1:
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Table 4.1
Alarm Module Operational Sequence
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Condition Display Audible

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Normal Off Off

Alert Flash On
Acknowledge Steady On Off
Return to Normal after Acknowledge Off Off
Return to Normal before Acknowledge Flash On

2 The alarm and status actuators shall be contacts or as shown on the Drawings. The
annunciator shall accept either Normally Open (N.O.) or Normally closed (N.C) contacts.
The sensing voltage shall not exceed 24 V d.c. The units shall be supplied with audible-
flasher cards as required that shall operate on receipt of alarms from any of the alarm points
to the panel. A buzzer shall be provided and mounted in the control panel. A horn in a
weather proof housing shall be provided for external mounting when specified. On receipt of
any alarm the monitor card shall cause the flasher to flash the appropriate indicating window
and sound the alarm.

3 There shall be a test button and an acknowledge button. The test button shall actuate all
alarm and status points and sound the audible alarm. The acknowledge button shall perform
the functions as outlined in the operational sequence, but shall not prevent any future alarm
points from being annunciated visually and audibly. The unit shall operate from 110 V a.c.,
50 Hz commercial power.

4 When specified, a "first out" sequence shall be provided in which the first alarm in a related
group, as designated, shall flash red while subsequent alarms in the group shall be non-
flashing white. A first out reset button shall be provided for each designated group.
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Part 04: Panel Mounted and Miscellaneous Instruments

4.2.8 Chart Recorders

1 Paperless video graphic recorders with colour LCD display and internal and external storage,
networking capability shall be provided having the following specification:

(a) screen size 127mm (minimum) front panel to IEC 529 – IP65 standard and cut out size
138mm x 138mm
(b) required number of input channels but never less than two and capable of 4020mA,
mV, V, RTD, thermocouple inputs
(c) minimum scan rate of 125ms and chart speed of 1mm/hour to 1200mm/hour
(d) totaliser with mathematical functions
(e) RS232 serial Ethernet 10 Base T interfaces
(f) data storage facilities with a minimum of 1MB internal flash
(g) integral smart media with 128MB smart card and media door lock
(h) capability of being configured by both PC keyboard and via tactile membrane front
door key.

4.3 INSTALLATION

4.3.1 General
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1 Installation, testing, calibration, validation, start-up, and instructions shall be in accordance
with Part 1 of this Section.
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END OF PART
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QCS 2014 Section 10: Instrumentation Control and Automation Page 1
Part 05: Control Panels and Control Room Hardware

5 CONTROL PANELS AND CONTROL ROOM HARDWARE ......................... 2

5.1 GENERAL ...................................................................................................... 2

5.1.1 Scope 2
5.1.2 Reference Standards 2
5.1.3 Submittals 2
5.1.4 Quality Standards 3
5.1.5 Approved Manufacturers 3
5.1.6 Delivery, Storage and Handling 3
5.2 PRODUCTS ................................................................................................... 3
5.2.1 Panels General 3
5.2.2 Panel Construction 4
5.2.3 Panel Wiring and Termination 5
5.2.4 Instrument Labelling 5
5.2.5 Control Desk 5
5.3 INSTALLATION ............................................................................................. 7
5.3.1 General 7
5.3.2 Site Inspection 7
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5.3.3 Testing and Commissioning 7
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QCS 2014 Section 10: Instrumentation Control and Automation Page 2
Part 05: Control Panels and Control Room Hardware

5 CONTROL PANELS AND CONTROL ROOM HARDWARE

5.1 GENERAL

5.1.1 Scope

1 This Section covers control panels for work of the ICA Sections, and all unit panels unless
modified under other Sections.

2 Related Sections and Parts

This Section
Part 1, General
5.1.2 Reference Standards

1 The following standards are referred to in this Part:

BS 88..........................Fuses
BS 546........................Electrical outlets
BS EN 60898..............Design of MCBs
BS 7430......................Code of practice for earthing
BS EN 60529,.............Ingress protection
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BS EN 60439..............Low voltage switchgear and controlgear assemblies
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5.1.3 Submittals

1 Submittals shall be in accordance with Part 1 of this Section.

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2 Shop Drawings. The ICA Subcontractor shall submit shop drawings for all control panels,
including details for the following items, as applicable:
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(a) electric power wiring circuits and schematics

(b) air supply piping schematics
(c) electric signal wiring circuits and schematics
(d) pneumatic signal tubing schematics
(e) fabrication drawings
(f) details of all panels accessories
(g) listing of all panel mounted (both front and rear) instruments
(h) control panel layouts and nameplate inscriptions

3 The submittal shall be subject to approval by the Engineer. The Contractor shall submit the
final documentation based on the Engineer’s comments. The Engineer’s comments/approval
shall be issued to the Contractor within 21 calendar days of the submittal.

4 Factory Test Reports. The Contractor shall submit from the equipment manufacturer, or his
authorised representative, a certified test report in accordance with the requirements of the
relevant test procedure.
QCS 2014 Section 10: Instrumentation Control and Automation Page 3
Part 05: Control Panels and Control Room Hardware

5.1.4 Quality Standards

1 All equipment furnished shall be of a design that has been used in similar applications and
shall be demonstrated to the satisfaction of the Engineer that the quality is equal to the
specified equipment. The manufacturer shall have successfully designed and furnished
similar sized or larger panels for a similar application.

2 The Engineer or his representative may inspect the panel at the factory. The Contractor shall
notify the Engineer at least three weeks prior to shipment so that the factory inspection may
be arranged. Factory inspection will be made after the manufacturer has performed
satisfactory checks, adjustments and tests. Approval of equipment at the factory only allows
the manufacturer to ship the equipment to the site and does not constitute final acceptance.

5.1.5 Approved Manufacturers

1 Control panels and all the associated hardware shall be provided by approved, prequalified
manufacturers and suppliers designated in the Project Specification.

5.1.6 Delivery, Storage and Handling

1 Control panels shall be assembled and shipped in sections, properly packed to prevent
damage during shipment. Panel sections shall facilitate easy handling and Site installation.
Panels and associated instrumentation shall be handled carefully to avoid damage. Proper
lifting and handling equipment and accessories such as grounding straps for handling
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electronic cards, shall be used.

2 ICA equipment shall only be delivered to Site just prior to their installation to minimise the
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possibility of damage. Delivered instrumentation shall be protected and not scattered or left
unprotected on the Site.
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3 Materials and equipment not required for immediate installation shall be stored in a separate
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store protecting them from shock, weather, dust and damage from chemical and construction
material
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4 ICA equipment shall not be stacked unless crated.

5.2 PRODUCTS

5.2.1 Panels General

1 Control panels shall be free standing and floor mounted cabinets of console or desk pattern.
Console layouts shall permit the operator to readily observe all instruments.

2 The panels shall be manufactured to a high standard of quality in terms of visual appearance,
colour and finish. The panels located in the main control room shall have an appearance and
quality suitable for a pumping installation environment.

3 The panel design including colour, style and appearance and detailed specifications of panel
instruments shall be submitted to the Engineer for approval prior to manufacture.

4 Control voltage. Panel instruments and controls shall operate from 110 V a.c. power supply,
unless otherwise specified in Project Specification. A separate 24 V d.c. circuit shall be
provided for the indicating lamps and panel instruments, as necessary.

5 Where specified in the Project Specification, panel space shall be provided for instruments
supplied by others. Installation and wiring of such instruments shall be carried out by the
panel manufacturer. Coordination of instrument delivery shall be the Contractor’s
responsibility.
QCS 2014 Section 10: Instrumentation Control and Automation Page 4
Part 05: Control Panels and Control Room Hardware

6 Unit Control Panels for mechanical and electrical equipment can be the manufacturers
standard panels. Details of such panels shall be submitted to the Engineer for approval, prior
to manufacture. The Contractor shall be responsible for interfacing the unit control panels
with the main control panel or central control system, as necessary.

5.2.2 Panel Construction

1 All consoles and auxiliary cabinets shall be fabricated of cold rolled sheet-steel and be of rigid
and stable construction without bows and ripples. The front surface shall be flat and the
corners and edges shall be rounded to give a smooth appearance.

2 Panels shall be of sufficient size to enclose all the panel instruments with ample interior
clearance to allow for installation and maintenance of instruments. Annunciator displays shall
be located in the top portion of the console assembly. Control panels shall be of sectional
design with provision for easy extension. Pushbuttons shall be provided to enable
acknowledgement and resetting of alarm annuciators and lamps on the console.

3 Panels shall be formed of IP55 panel sections and each enclosure shall be a maximum of
2100 mm high, 800 mm wide and 600 mm deep unless otherwise specified in the Project
Specification. Each section shall be fully enclosed including the top and bottom with no
visible seams on the front. Externally visible screws and bolts shall not be acceptable.

4 Each panel section shall be provided with two door rear access. Door hinges shall be knuckle
type. Handles and other hardware shall be chromium plated. Where necessary, removable
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access covers secured by quick release fasteners shall be provided to facilitate easy
maintenance.
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5 Undrilled gland plates shall be fitted at a sufficient height above the floor level to provide easy
access under the gland plate. Suitable side covers shall provide access to the gland plates
and also provide the specified ingress protection.
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6 Electrical general purpose outlets for test and repair purpose shall be provided in all consoles
and cabinets. The outlets shall be in accordance with BS 546.
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7 All consoles and auxiliary cabinets shall be ventilated mechanically or by natural circulation to
maintain the internal equipment working temperature to below 10°C above ambient.

8 Panel lighting shall be provided to ensure adequate illumination for carrying out delicate
adjustments or repairs on small items of equipment.

9 Finish. After fabrication, all external welds must be ground smooth. The entire unit shall be
thoroughly degreased, then filled and sanded. At least one coat of synthetic primer shall be
applied, baked on, and sanded. This first coat shall be followed by two coats of baked-on
synthetic enamel. The first coat shall be sanded after baking. The final two coats shall
provide a glossy or semi-matt finish to a colour and finish approved by the Engineer. The
average overall finish shall be at least 1.25 micrometres in thickness. Any minor damage to
the finish during installation shall be touched up at Site, provided such remedial works are to
the approval of the Engineer.

10 Panel Earthing. A copper earth bar shall be provided within the panel for earthing of the
panel, all the panel instruments and the cables to BS 7430, code of practice for earthing.

11 Panel Isolation. Isolating switches shall be provided for all incoming power supplies. These
switches shall be clearly identified, labelled and suitably protected from inadvertent operation.

12 Panel Protection. MCBs to BS 3871, shall be provided for the distribution of electrical power
within the panel. The MCBs shall be arranged to minimise disruption to the equipment
operation and also to prevent unsafe operating conditions. Power supplies from control
panels shall conform to BS 5486.
QCS 2014 Section 10: Instrumentation Control and Automation Page 5
Part 05: Control Panels and Control Room Hardware

5.2.3 Panel Wiring and Termination

1 Panel wiring shall be carried out in PVC insulated multi-strand cable of adequate grade and
rating. Wiring within each panel shall be done in a structured manner, grouped and
supported to give a neat appearance.

2 110 V a.c. wiring shall be colour coded with black-unswitched live phase, red-switched live
phase, white-neutral and green-ground. Signal and d.c. wiring shall also be neatly segregated
under an approved colour coding scheme. Wiring shall be bundled and laced or tied with
plastic ties and supported to prevent ragging or damage.

3 All control and auxiliary cabinets shall be manufactured and assembled with all internal wiring
connected to terminals blocks, requiring only connection to external wiring at Site.

4 Separate terminal blocks shall be provided for incoming and outgoing analogue and digital
signals and power supply connections. Each terminal block shall be clearly identified and
labelled. Layout shall permit convenient access to terminals and wires and enable ferrule
numbers to be easily read. Terminals shall be at sufficient height from the cable gland to
facilitate easy routing of wires. Terminals shall clamp the wire between two plates using a
captive screw. Where wires are terminated on screw terminals, insulated crimp spade lugs
shall be used.

5.2.4 Instrument Labelling

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1 All panel instruments shall have engraved nameplates showing their tag number and service
in the English language.
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2 Materials for nameplates shall be selected in accordance with the relevant environmental
conditions and shall be of non-metallic material, with black inscription on a white background.
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3 Name plates on control panels shall be mounted on or near the relevant instruments to
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ensure clear identification

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4 An additional nameplate engraved with the instrument tag number only, mounted at the rear
of the panel, shall be provided for each panel mounted instrument. These plate shall be
attached to the instrument, the panel or instrument support near the instrument.

5 For panels where opening the circuit breaker does not shut off all of the power, the following
sign shall be provided:
"THIS CABINET CONTAINS CIRCUITS SUPPLIES FROM EXTERNAL SOURCES."
"OPENING THE CIRCUIT BREAKER DOES NOT TURN OFF ALL POWER".
Letters shall be 6 mm high, red colour on a white background.
5.2.5 Control Desk

1 SCOPE

(a) This section defines the minimum requirements for the manufacture, supply,
inspection, installation, testing of control desks or consoles required to be used on this
Contract. Control desks or consoles shall be of the custom made industrial type and
material for construction shall comply with MCC’s panel construction as specified in
QCS Section 21 Part 2. The requirements for lockable doors, ventilation fans, anti-
condensation heaters etc. shall complied with as specified in this section.

2 CODES AND STANDARDS

(a) The following list of standards indicates the minimum requirements. Any other
standards not listed below or elsewhere in these documents shall be subject to
review and approval by the Engineer.
QCS 2014 Section 10: Instrumentation Control and Automation Page 6
Part 05: Control Panels and Control Room Hardware

BS EN 527-1 Office furniture, Work tables and desks

BS EN 1335-1 Office furniture, Office work chair
BS EN ISO 26800 Ergonomics, General approach, principles and concepts

3 SITE CONDITIONS

(a) It is the Contractor’s responsibility to furnish and install the control desks or consoles to
withstand and operate properly under the prevailing ambient conditions as described in
the General Technical Requirements. This Specification serves as a guideline to the
Contractor. The Contractor shall include all the necessary equipment based on his
previous experience on similar installations. Control desks or consoles shall be able to
operate continuously without their normal physical and functional reliability being
affected by the tropical environment.

4 DESIGN CONSIDERATIONS AND FABRICATION REQUIREMENTS

(a) The control desks and consoles shall be designed so that it is comfortable to use, thus
enabling operators to maximize their efforts, incorporating the latest principles of
ergonomic design, as described in BS EN ISO 26800.Monitors (and instruments if
applicable) shall ideally be arranged so that they are all are equidistant from the
operator’s eyes. Similarly, all the associated controls should be equidistant from the
operator's shoulder pivot points. This arrangement avoids any body movement, but
demands a convex panel in both planes. If this is not a practical proposition then flat
panels shall be provided which are angled to each other and which require only some
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limited body movements, such as bending the trunk or pivoting a chair, to operate the
keyboards or view the VDUs (monitors) .The display area shall be divided either
vertically or horizontally. Vertical division shall be utilized for mounting VDUs. If small
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instruments are fitted then parallax errors may be introduced are mounted above or
below eye level, although this danger can be avoided by using those with digital
displays. In most cases horizontal division is the simplest and gives the greatest area
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of panel space free from parallax errors within the operator's control. When a large
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number of instruments or controls are involved, horizontal and vertical division shall be
combined. The desk shall then become a winged console.
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(b) Sufficient rack space shall be provided in the base to enclose all control desk
equipment and permit access for installation and maintenance purposes. Cable entry
shall be via floor mounted cable gland plates with facility to route cables through desk
sections as required. All servers/works stations shall be placed inside the control desk
with lockable doors. Ventilation louvers and fans are to be fitted in the desk for
sufficient air circulation.

5 PANEL LAYOUTS

(a) Where indicators ,Monitors and controls are to be fitted on panels then the actual
arrangement must receive careful consideration. When designing the layout, the
center of the various instruments should be arranged so as to be opposite the
operator's eye position. Controls should be mounted below shoulder level. Space
above this level shall preferably be utilized to house indicators, or infrequently used
controls.

6 DESK SIZING

(a) The design shall such that when the operator is sitting correctly (trunk erect, but
shoulders relaxed) elbows shall be about level with the working surface. Desks used
for keyboards shall be slightly lower than one used for general duties, so as to bring
the actual working surface to the correct level. Draw out type tray arrangement shall
be provided for keyboard and mouse. Care shall be taken that the underside of the
desk will allow the thighs of an operator to fit comfortably between it and the top of the
seat; a minimum of 200 mm clearance shall be allowed. The front surface shall be flat
and the corners and edges shall be rounded to give a smooth appearance
QCS 2014 Section 10: Instrumentation Control and Automation Page 7
Part 05: Control Panels and Control Room Hardware

(b) Desk thickness shall be as specified in Section 21 Part 2 MV Factory Built Assemblies
(FBA’s).
(c) Generous leg space shall be provided to ensure operator comfort. It shall be possible
for the operator(s) to move easily to and from the desk to this end a minimum a
minimum of 400 mm clearance is to be provided.

7 SEATING

(a) The seat height shall be no higher than the length of the lower leg when it forms a right
angle with the upper leg and the foot is resting flat, to ensure operator comfort,. An
adjustable seat shall be provided to achieve this. If this leads to a large difference
between the eye positions of short and tall operators then as an alternative a fixed
height seat shall be provided which will suit the tall operator together with an adjustable
foot rest for the use of others.

8 CONSTRUCTION

(a) Materials of construction shall generally comply with the MCC’s panel construction
requirements specified in the Section 21 Part 2 MV Factory Built Assemblies (FBA’s).
Consoles shall be built on a plinth fabricated from rolled steel. They shall consist of a
closed skeletal steel or forged aluminum framework with rigid panels screwed or
bonded in place or alternatively hinged or fixed with quick release fasteners . Consoles
shall be prefabricated in the factory. Assembly on site is acceptable but on site
fabrication is not acceptable.
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(b) Console sizes shall be determined by equipment sizes, number of operators. Where
practicable, the unit shall be designed in individual modules, which are then bolted
together. Apertures shall be sized and finished to accept specific equipment and/or
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fitted with standard rack mount fixings. All components shall be protected against
corrosion by means of passivation, fusion bonded epoxy coating or high grade epoxy
factory applied spray baked finish. Brush painting is not acceptable. Color shall be a
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RAL shade as directed by the Engineer. Areas subject to abrasion or wear shall be
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suitably protected with replaceable rubber mats, stainless steel finishes, or similar.
(c) The desk or console IP rating shall be IP 54 as a minimum or higher to match the
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grade of any installed equipment.

5.3 INSTALLATION

5.3.1 General

1 Installation, testing, calibration, validation, commissioning, and instructions shall be in

accordance with Part 1 of this section.

5.3.2 Site Inspection

1 Each instrumentation item shall be checked by the Contractor upon receipt for compliance
with purchase specifications, damage, shortage and shortage of components. Items shall be
repaired, replaced or the vendor notified of non-conformance as instructed by the Engineer.

5.3.3 Testing and Commissioning

1 All control panels and instruments shall be tested and commissioned by the Contractor
according to procedures outlined in Part 1 of this Section, prior to final inspection and
acceptance by the Engineer.

2 Calibration of all panel instruments shall be tested and corrected as necessary.

3 Panel wiring shall be tested to ensure that wiring is done as per the submitted wiring
schedules. Correct identification on ferrules and tag plates shall also be verified.
QCS 2014 Section 10: Instrumentation Control and Automation Page 8
Part 05: Control Panels and Control Room Hardware

4 Panel power supply voltages shall be checked to ensure that they are within the operational
limits of each instrument.

5 Damaged or defective instruments and equipment shall be identified and replaced.

END OF PART

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