26-41 Bay County Military Point Advance Wastewater Treatment Plant PLC Replacement

EXHIBIT 2
SCOPE OF WORK
Bay County Advanced Wastewater Treatment Facility (AWTF)
PLC Upgrades
Scope of Work and Technical Specifications
(Revised: 4/16/26)
PART 1 - GENERAL
1.01 PLC Components Replacement Scope
A. Work includes: Furnish and install new PLC and associated I/O modules and power supplies for
each location identified herein.
B. For each PLC replacement, Contractor shall:
a. Download and review existing program.
b. Provide all programming required to develop program for new PLC to completely match the
function of the existing PLC.
c. Perform all testing to verify complete functionality of new program prior to installation.
d. Duplicate or develop new tag numbers as required for complete compatibility with existing
systems that are not being replaced.
e. Perform "Factory Acceptance Test" as required to validate all programming. Owner shall
be notified of test a minimum of 7 days in advance and provide the opportunity to attend
in person or virtually.
f. Provide demonstration test on site prior to "cutover" from existing PLC to new PLC and
associated components.
g. Coordinate schedule for cutover with Owner. Maximum downtime on process shall be 12
hours.
h. Provide all updated documentation for new PLC and associated components. This
documentation shall include all drawings in CAD and PDF format, software program in
digital format acceptable to the Owner, O&M manuals for all components, model numbers
of all components for Owner's records.
i. New program shall be provided as version 36.
C. For each panel/location, Contractor shall furnish the replacement PLC (Allen-Bradley
CompactLogix 5380 series).
D. Contractor shall also furnish and install replacement power supply and I/O modules as identified
herein.
E. PLC Replacement panels/locations include:
a. BNR PLC
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1. Replace Allen-Bradley PLC-5/30A PLC with Allen-Bradley CompactLogix 5380 Series PLC.
2. Replace existing power supply with power supply compatible with new PLC.
3. Replace 3 Analog Input Modules with Discrete Input Modules compatible with new PLC.
4. Replace 2 Analog Output Modules with Discrete Output Modules compatible with new
PLC.
b. PLC 1
1. Replace Allen-Bradley PLC-5/30A PLC with Allen-Bradley CompactLogix 5380 Series PLC.
2. Replace existing power supply with power supply compatible with new PLC.
3. Replace 7 Discrete Input Modules with Discrete Input Modules compatible with new PLC.
4. Replace 1 Discrete Output Modules with Discrete Output Modules compatible with new
PLC.
5. Replace 2 Analog Input Modules with new Analog Input Modules compatible with new
PLC.
6. Replace 2 Analog Output Module with new Analog Output Module compatible with new
PLC.
Sub b. Replace associated remote I/O
1. Replace existing power supply compatible with new PLC.
2. Replace 2 Discrete Input Modules with Discrete Input Modules compatible with new
PLC.
3. Replace 1 Discrete Output Modules with Discrete Output Modules compatible with
new PLC.
4. Replace 1 Analog Input Modules with new Analog Input Modules compatible with
new PLC.
5. Replace 2 Analog Output Module with new Analog Output Module compatible with
new PLC.
c. Effluent PLC
1. Replace Allen-Bradley SLC 5/05 PLC with Allen-Bradley CompactLogix 5380 Series PLC.
2. Replace existing power supply with power supply compatible with new PLC.
3. Replace 4 Discrete Input Modules with Discrete Input Modules compatible with new PLC.
4. Replace 2 Discrete Output Modules with Discrete Output Modules compatible with new
PLC.
5. Replace 4 Analog Input Modules with new Analog Input Modules compatible with new
PLC.
6. Replace 2 Analog Output Module with new Analog Output Module compatible with new
PLC.
1.02 RELATED WORK
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A. The following listing of related sections may also apply and be required for proper performance
of this work.
a. Section 16010 - General Provisions, Electrical
b. Section 16075 - Electrical Identification
c. Section 16123 - Wire and Cable
d. Section 16131 - Conduit
e. Section 16138 - Boxes
f. Section 16139 - Cabinets and Enclosures
1.03 REFERENCE STANDARDS
A. NFPA 70 - National Electrical Code (NEC)
B. ISA-55.4 - Instrumentation Society of America (ISA)
C. UL-508A - Underwriters Laboratory Industrial Control Panel Certification
D. UL-698A - Underwriters Laboratory Industrial Control Panel Certification
1.04 QUALITY ASSURANCE
A. The modification to the existing PLC Control panels as specified in this section shall be
integrated systems and shall be provided by a single supplier that is responsible for the proper
operation of the entire system.
B. For standardization and quality purposes the following System Suppliers are pre-approved for
the hardware integration portion: 1.) Vyper Automation; Greg Kumpula; (407) 335-0311.
C. The following criteria must be met by the System Integrator.
a. A minimum of Ten (10) years' experience performing similar work for municipalities. A list
of references shall be provided with submittal.
b. Shall have been in business a minimum of Ten (10) years operating under the same
company name.
c. Be advanced certified on VTScada.
D. Provide or supply all hardware and software specified herein. Provide all required and specified
collateral services in connection with the system such as testing, calibration, startup, operation
and maintenance manuals, and operator training without additional cost to the OWNER.
E. The System Supplier shall be responsible for coordinating with the CONTRACTOR to obtain all
necessary data from individual manufacturers to determine the necessary transition for
operation, control and/or monitoring from the manufacturer's equipment.
F. All materials, equipment sizes, and capacities shall conform to the requirements of the NEC, the
National Electric Manufacturer's Association, and to applicable regulations of the local electric
codes.
G. All materials and equipment must be UL listed and Control Panels must be UL-508A certified or
UL-698A certified for and all control panels with intrinsic safety barriers or hazardous locations.
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1.05 RESPONSIBILITY FOR COMPLETE SYSTEM
A. The System Supplier shall be responsible for and shall provide for the design, supply, delivery,
installation, certification, calibration and adjustment, software configuration, testing and start-
up, of a complete, coordinated system. A single supplier shall provide the PLC System upgrades
including software.
B. The System Supplier shall design and furnish a complete, integrated, and functionally
operational system, warranted to perform the intended functions as herein specified.
1.06 SUBMITTALS
A. Submit shop drawings and product data in accordance with Owner's requirements.
B. Submit full technical data complete with manufacturer's published data.
C. Submit manufacturer's descriptive literature, operating instructions, and maintenance and repair
data with an Equipment Data Sheet showing the exact part or model number with descriptive
break down of the model number. All pertinent information shall be included on the Equipment
Data Sheet.
D. Submit manufacturer's schematics and system layout drawings which shall include the following:
E. Hardware Submittals:
a. Provide a block diagram and description of the system configuration showing all
components and their interconnections etc. Label each diagram and specify all external
power and communications interfaces. All diagrams shall be 11x17 format and be
developed in latest version of AutoCAD in DWG file format.
b. Provide an equipment list with descriptive literature identifying component name,
manufacturer, model number, a description of the operation, quantity supplied and any
special characteristics.
c. Drawings of equipment to be supplied shall include, as a minimum, overall dimension
detail for each panel, console, etc., including internal and external arrangements and door
mounted operator devices with nameplate
d. designations. Elementary and wiring diagrams of equipment including field device
connections shall be included with specific installation/wiring requirements identified.
Provide detailed bills of materials with spare parts provided.
F. PLC Submittals:
a. PLC System Diagram: Provide a diagram showing all PLC and network components. Show
the exact PLC rack layout with details of the actual modules used and filler plates for
spare slots. Identify components by manufacturer and model number. Show
interconnecting cables with pin out details or model numbers of PLC manufacturers
cables.
b. Bill of Materials: A list of all components. Group components by type and include:
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1. Component manufacturer, model number and part number.
2. Component description.
3. Quantity supplied.
4. Reference to tag on drawings.
c. Descriptive Information: Provide catalog information, descriptive literature, performance
specifications, internal wiring diagrams, power and grounding requirements, power
consumption, and heat dissipation for all the equipment. Clearly mark all options and
features proposed for this project.
d. Interconnecting Wiring Diagrams: Provide diagrams that shall show all PLC and control
panel components, their interconnecting cables, wiring terminations, and terminations to
all interacting elements and subsystems. Terminations shall be numbered.
e. Outline Drawings: Provide equipment drawings showing external dimensions, enclosure
materials, conduit connections, and installation requirements.
f. Installation Details: Provide any modifications or further details as may be required to
supplement the Contract Documents and adequately define the installation of the PLC.
g. Input/output List: Provide for each I/O point list point type, tag number of the source or
final control element, equipment description, PLC number, terminal identification, and
address.
1.07 PLC OPERATION & MAINTENANCE MANUALS
A. Provide complete Operation and Maintenance Manuals for the PLC in an open software format.
At a minimum the O&M shall include:
B. Component Manufacturers' O & M Manuals: Include manuals to cover installation, operations,
maintenance, troubleshooting, and calibration.
C. Operating instructions shall incorporate a functional description of the entire system, including
the system schematics that reflect "as-built" drawings.
D. Provide system architecture diagram showing network communications including but not limited
to all PC's, PLC's, switches, cables, etc.
E. List of spare parts and expendables provided.
F. Panel equipment, field devices, and instruments data sheets, including complete "bill of
materials" of PLC's, control panel devices, computers, printers, software, field equipment, etc.
G. Communication Network Cable Testing documentation with the actual tests of each fiber after
terminations. All cable data shall be included on the form including but not limited to cable
manufacturer, part number, cable tag and location, fiber number and color, testing procedures,
test equipment utilized, actual readings and results, and personnel name with time and date the
testing was performed.
H. Digital copy of final configuration files, backups of system files and PLC programs.
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I. Complete operator instructions for all PLC components including download instructions with
details for functions and data entry.
J. Point lists for PLC inputs/outputs. Identify point number (tag), point description, point type,
range in engineering units (if analog point), PLC number, rack and slot number, and point
address.
K. The complete electronic O&M shall be provided with an easy-to-use index and bookmarks for
CAD drawings, Equipment Data Sheets, software or equipment manufacturers O&M literature,
etc. Clicking on an item on the index shall immediately display the Equipment Data Sheet and
software or equipment manufacturers O&M for the item. Likewise clicking on a drawing shown
on the index shall display the drawing. Other functions at a minimum shall include search, zoom
and print page or selection features. All contents of the O&M may also be displayed with
thumbnails. Clicking on the thumbnail shall immediately display the item, i.e. drawing,
Equipment Data Sheet, instruction literature, etc.
1.08 PLC PROGRAMS, AUTOCAD DRAWINGS AND DOCUMENTATION
A. All programs and configuration files developed and utilized for the project shall be owned by the
end user. All programs and configuration files shall be provided to the OWNER in their
documented form and in their native file format. This includes but is not limited to: PLC
components.
B. Provide all drawings in native (DWG) and PDF file formats.
C. Provide all PLC I/O lists in Excel file format.
1.09 SOFTWARE LICENSES
A. Purchase any required software packages (PLC Programming or other) required for the system
in the name of the authorized end user. All software shall be delivered to the OWNER with
original disks and in its original box.
1.10 FACTORY TESTING BY A QUALIFIED PROFESSIONAL
A. The factory testing will be observed and certified by a qualified professional that is a full-time
employee of the System Supplier.
B. Develop and submit a test plan, testing documentation and QA/QC check lists specific to the
project requirements and each control panel or PLC. Test all specific functions, I/O and control
loops, etc. Test all specific functions including, but not limited to, the following:
a. Failure mode and backup procedures: power failure, auto restart, disk backup and reload,
retentive outputs.
b. All network communications.
c. Operator Interface Terminal (OIT), all functions.
d. Completely simulate all possible field conditions and run in fully automatic and manual.
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e. Simulate all existing systems being interfaced to with new programs and configurations.
The System supplier must own or acquire all hardware required for the simulation.
f. Provide certified factory testing documents showing all tests performed and results
achieved.
C. Submit the completed certified factory testing documents showing all tests performed and
results achieved plus all QA/QC check lists prior to shipment of the system, control panels and or
PLC. The documents shall be signed by the qualified professional. The certified documents must
be approved prior to shipment.
D. Invite the CONTRACTOR and OWNER to observe the factory testing of the system. A two-week
notice of the testing date shall be provided.
1.11 PROCESS CONTROL STRATEGY DESIGN MEETING AND SUBMITTALS
A. A video conference process control strategy design meeting shall be held with the OWNER's
personnel to discuss specific details of the control strategies, HMI graphics, trends, I/O and
SCADA System functions that are to be developed for the system.
B. Prior to the meeting the System Supplier shall submit a detailed narrative for each of the
proposed control strategies to the OWNER for review.
C. A follow up video conference process control strategy design meeting shall be held with the
OWNER's personnel within two weeks of the first one to review the final control strategy and
demonstration of the HMI graphics.
1.12 OPERATIONS, HARDWARE & SOFTWARE MAINTENANCE TRAINING
A. After the project substantial completion, provide two instructor days of onsite for the OWNER's
personnel in the operation of the System and software and hardware training for the OWNER's
maintenance technicians in the maintenance of the system hardware and software. Training
shall include:
a. Standard operational features of HMI, OIT and PLC equipment provided.
b. Operation of each function or mode: For example, AUTO/MANUAL control, control set
point settings, control mode selection, alarm acknowledgment and Constant Speed modes.
c. Interfaces with other controls and systems.
d. Standard hardware features of the HMI, PLC, OIT and field instrumentation, etc.
e. Specific training for the actual hardware configuration provided.
f. Test, adjustment, and calibration procedures.
g. Hardware troubleshooting, component removal and replacement, and periodic
h. maintenance.
i. Standard software features of all software provided, including but not limited to HMI, PLC
and OIT programming software.
j. Software troubleshooting, backups, restores, loading software and periodic maintenance.
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k. Software O&M functions and features.
B. Training sessions shall be video recorded and provided to the OWNER. Training sessions shall be
recorded in a digital media format and shall be capable of playing on any computer or tablet
environment.
C. Submit a training outline and agenda of specific topics and time to be used for each topic.
1.13 PRODUCT DELIVERY, HANDLING AND STORAGE
A. Comply with manufacturers' recommendations for delivery, handling, and storage.
B. Schedule the delivery of the equipment to coordinate with the project completion schedule.
C. Equipment shall be delivered by the System Supplier or a representative shall be onsite to
observe and inspect the unloading of all the equipment by the CONTRACTOR.
D. Each item of equipment shall be tagged with identifying number shown on the Shop Drawings
visible after packaging.
E. General CONTRACTOR's attention is directed to the fact that equipment has delicate
components and extreme care shall be taken in handling to avoid internal and/or external
damages.
F. Damaged equipment will not be accepted. Damaged equipment by the GC unloading or by
inadequate storage shall be replaced by the GC. Damaged equipment prior to delivery or in
transient shall be replaced by the System Supplier.
G. Equipment not for immediate use shall be stored inside an environmentally controlled building
with heat and air conditioning systems, with enclosures under protective coverings and shall be
fully protected from moisture, extreme heat and vibration.
1.14 FIELD TERMINATIONS AND COMMUNICATION NETWORK CABLE INSTALLATION AND
TESTING
A. All network wiring related conduit shall be provided and installed by the Electrical CONTRACTOR
(EC). All copper and fiber network cable (i.e. Fiber Optic; CAT 6 Ethernet; CAT 5E Ethernet) shall
be provided and terminated by the System Supplier.
B. The EC shall terminate all signal instrumentation cables for all field instrumentation.
C. The EC shall be responsible for properly and professionally labeling all cables and shall assist the
System Supplier as needed to locate and troubleshoot the field wiring during terminations and
testing.
D. All required fiber optic cable fibers shall be terminated and tested by the System Supplier. The
System Supplier must provide certified training documentation for the System Supplier personnel
performing the terminations and testing. Testing documentation shall be provided to prove the
actual tests of each fiber after terminations. All cable data shall be included on the form
including but not limited to cable manufacturer, part number, cable tag and location, fiber
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number and color, testing procedures, test equipment utilized, actual readings and results, and
personnel name with time and date the testing was performed.
E. The completed Record Documentation shall be included in all forms of the O&M Manuals.
1.15 SERVICE REPORTS
A. Service reports shall be provided for each day that a representative of the System Supplier is on
site. The service reports shall include all tasks performed, time on site, instrument tags,
instrument service and etc. Instrumentation Calibration Worksheets shall be provided and
attached to the associated service reports.
1.16 WARRANTY
A. Systems supplier shall furnish a one-year onsite warranty for the system, providing for a 24-hour
response time in normal working hours, five days per week for the length of a one-year
warranty period.
B. For any service visit during this period, provide the OWNER with a written report stating the
reason for equipment failure and recommendations to prevent recurrence.
PART 2 - PRODUCTS
2.01 GENERAL
A. All equipment and materials shall be new, unused and proven by previous use of similar
products to be completely suitable for the service intended.
B. All of the equipment shall be the manufacturer's latest and proven design. Specifications and
drawings call attention to certain features but do not necessarily cover all details for the design
of the System.
C. Mount process indicators and Operator Interface Terminals (OIT) at eye level, 60" from floor to
centerline of instrument.
D. Panel wiring for all 4-20mA analog input signals shall be two-conductor, shielded cable with
drain. Cable and connectors shall be Belden No. 8760, UL Style 2092, 20 AWG minimum, or
equal. Single conductors shall be tinned copper with 600V insulation, gauge as required.
E. PVC wiring duct shall be provided as required and shall have removable non-slip covers. Wiring
duct shall contain 50% spare space. Wiring duct must be mounted with machine grade screws.
Plastic and/or aluminum rivets are not acceptable. For consistency and standardization, wiring
duct shall be by Panduit Corporation, no exceptions, color gray. All wiring in control enclosures
not in wiring duct shall be bound with continuous type spiral windings or neatly bound with tie
wraps not less than two inches apart consistently and shall not allow the shown wires to cross
each other within the bundle.
F. All equipment mounted within the PLC enclosure shall be mounted on the enclosure back panel,
neatly organized, labeled with a tag as shown on OWNER-approved control panel drawings and
shall be in accordance with the manufacturer's recommendations.
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G. All field wiring shall be mounted either at the bottom or side of the enclosure back panel,
depending on where the I/O conduits penetrate the enclosure.
H. The field wiring terminals and panel wires shall be clearly labeled and identified and shown on
the panel drawings.
I. Jumpers between adjacent terminal blocks shall be tinned copper jumper bars supplied by the
terminal block manufacturer.
J. Interconnection drawings shall be provided along with wire numbers, terminal numbers,
equipment tag numbers and panel physical layout drawings.
K. All systems and individual components, whether panel or field mounted units, that are located in
different areas of the plant, one inside building to device outside of building, shall be protected
from voltage and/or current surges.
L. Provide a surge protection device "SPD" for 12OVAC power entering all PLC cabinets. The SPD
shall be SSI model USPT1P1DIN-21. Units shall be DIN rail mounted. Units shall be listed to
UL1449 current addition.
M. Provide a surge protection device "SPD" for all analog 4-20mA signal circuits entering PLC or
control cabinets. The SPD shall be SSI model CLP###AxDIN-B-21 (### equals voltage, x
equals number of wires i.e. 2, 4, or 6). Units shall be listed to UL497B and shall be DIN rail
mounted.
N. Control and instrumentation power supplies shall be adequately sized to provide 150% of that as
required by the equipment served.
O. The input and output of each separate DC power supply shall be individually fused with easily
accessible DIN-rail mounted fused switch. Provide separate fused disconnects for each PLC, OIT,
each DC power supply, etc.
P. All power supplies shall be DIN Rail mounted and shall have screw terminals for all connections.
Solder type connections will not be allowed. All screw terminal connections shall be finger safe.
Q. All pushbuttons, selector switches, and pilot light units shall be heavy duty, 30.5mm, NEMA type
4/4X, corrosion resistant, bulletin 800H by Allen-Bradley.
R. Terminal strips shall be mounted using DIN rails. Terminal strips shall be as manufactured by
Wiedmueller, Phoenix, Entrelec, or approved equal.
S. All digital inputs shall be isolated from field wiring through terminal strips and 24 VDC,
interposing mechanical relays, no exceptions.
T. All digital outputs, including spares, shall be isolated from field wiring through terminal strips
and 24 VDC, interposing mechanical relays.
U. All mechanical control relays shall be DIN rail mounted. Minimum contact rating for mechanical
control relays shall be 10 Amps at 250 VAC. All control and auxiliary relays shall have LED
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