Please refer to the above Request for Proposal (RFP) document in your possession and be advised of the following:

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1 Lou Pagano Director Purchasing and Materials Management Division City Hall, 18 th Floor, West Tower 100 Queen Street West Toronto, Ontario M5H 2N2 Victor Tryl, Manager Professional Services November 10, 2011 posted in pdf (189 pages) ADDENDUM NO. 1 Request for Proposal No FOR: Professional Engineering Services associated with the PLC Platform Migration & Upgrades in Water Treatment & Supply facilities. CLOSING: 12:00 NOON (LOCAL TIME), November 28, Please refer to the above Request for Proposal (RFP) document in your possession and be advised of the following: I. ADDED 1. The original Appendix E on the CD that was handed out at the prebid meeting or picked up at City Hall did not contain all the referenced appendices within the 'PCS Guidelines' document. The revised Appendix E document is attached, or you may also contact the buyer listed below to receive the pdf copy by The following is the list of firms who attended the mandatory prebid meeting held on November at Metro Hall. 1. Aecom 2. Associated Engineering 3. CH2M Hill 4. EMA 5. Eramosa Engineering Inc. 6. IBI Group 7. Insyght Systems Inc. 8. Hatch Mott MacDonald 9. Wardrop Engineering (Tetra Tech) 10. Westin 11. Scadex Technology 12. Summa Engineering Should you have any questions regarding this addendum contact Kay Humphrey at or by khumphre@toronto.ca. Please attach this addendum to your RFP document and be governed accordingly. Proponents must acknowledge receipt of all addenda in their Proposal in the space provided on the Proposal Submission Form as per Appendix B, Section 4 - Addenda of the RFP document. All other aspects of the RFP remain the same. Victor Tryl, P. Eng. Manager Professional Services 1 of 189

2 Implementation Guidelines Process Control System (PCS) Implementation Guidelines Version 1.0 July 30, of 189

3 Implementation Guidelines Process Contorl System (PCS) Implementation Guidelines Record of Revision Revision Date Of Revised Revised by Number Revision Pages 1.0 July 30, 2011 General 3 of 189

4 Implementation Guidelines Table of Contents 1. Introduction General Scope of Guideline Objectives Guideline Definitions and Roles RFP and Engineering Services Contract Award General Identify PCS Requirements Scope of Work RFP RFP Evaluation Engineering Services Contract Award Pre-Design General Project Commencement Field Verification Requirements Definition/50% Pre-Design % Pre-Design % Pre-Design Detailed Design General Tag List % Detailed Design % Detailed Design Detailed Technical Specifications Apply For Approval % Detailed Design % Detailed Design/Tender Document Construction - Equipment General Shop Drawings Equipment and Panel Procurement and Fabrication Test Sheets Equipment and Panel FATs Transition Plan Equipment Installation and Wiring Pre-Start Health and Safety EDOCSLIB-#9086-v of 189

5 Implementation Guidelines 5.9 Entity Information Lists Construction - Software General Flow Chart Development Software Modules Software Development FAT Plan Software FAT Construction Testing and Commissioning General Hardware SAT and Training Plan Hardware Training Hardware SAT Software SAT and Training Plan Software Training Software SAT Operational Test/System Performance Test As-Built Documentation Post Construction Warranty Period Appendix A - Project Tasks Flowcharts Appendix B - Project Tasks Implementation Checklists Associated Guidelines Field Verification Procedure Process Control Narrative P&ID Standard Symbols and Practices Colour Convention RPU Software Programming Standard Software Modules Operator Interface Programming Process Display Programming Alarming Instrument and Equipment Testing SCADA Factory Acceptance Testing SCADA Site Accecptance Testing and Commissioning PCS Documentation Training Appendix D Associated PCS Standards and Installation Drawings List EDOCSLIB-#9086-v of 189

6 Implementation Guidelines 1. Introduction 1.1 General Toronto Water has implemented a Process Control System (PCS) for control and monitoring of its facilities (Water treatment plants, Wastewater treatment plants, Water supply, and Sewage pumping stations). The PCS consists of instrumentation, control devices, wiring, networking, input/output devices, control panels, local and central Human Machine Interfaces (HMIs) and Remote Processing Units (RPUs) / Programmming Logic Controllers (PLCs). Any new project in Toronto Water that has a PCS component will require integration of the new project into the exisiting PCS of the facilitiy. The overall process for any project with a PCS component comprises six stages: 1. RFP development, issue, evaluation, and subsequent contract award for engineering services 2. Pre-design of the PCS component 3. Detailed design of the PCS component 4. Construction - Equipment 5. Construction Software 6. Construction Testing and Commissioning Please refer to Appendix A (Flowcharts) and Appendix B (Checklists) for tools to assist with the process of integrating any new project into the exisiting PCS of the facility. The relationship between deliverables and project stages is not always evident for projects where the PCS component is relatively small. Some of the stages/phases mentioned in the Flowcharts and Checklists may not apply for very small PCS projects. 1.2 Scope of Guideline This guideline provides high level information for consultants and project managers on project deliverables, phasing, and review requirements for Toronto Water projects that have a PCS component. 1.3 Objectives The guideline objective is to ensure that a clear understanding exists for City project managers and consultants as to the deliverable requirements for a PCS project or project with a PCS component, in terms of the phasing for those deliverables and services in step with various project phases from initial design stages to completion of the project, as well as defining the responsibilities for provision of information and deliverable review services. EDOCSLIB-#9086-v of 189

7 Implementation Guidelines 1.4 Guideline Guidance documentation for the PCS implementation comprises three separate and related documents: a series of project task flow charts illustrating the logical flow deemed necessary for successful implementation of the project (Appendix A); a checklist intended for project managers to ensure engineering services providers deliver the required services and documentation at the appropriate stage of the project (Appendix B); and the Process Control System Implementation Guideline (this document). Flowcharts for each stage are comprehensive and are designed to ensure the deliverables, their inter-relationships, and their delivery timing is appropriate for successful implementation of PCS projects. Depending upon the project size and scope, some of the steps in the various stages may not be required. Checklists for each stage provide a simplified review method for project managers to ensure consultant deliverables are provided at the right project stage, as well as indicate supply sources for information typically needed by the consultant and to indicate the in-house review group for all consultant technical deliverables. The checklists also indicate the flow of information and can be used as a tool by project managers to guide a PCS project. Depending upon the project size and scope, some of the steps in the various checklists may not be required. As part of the project scope development, the project manager with assistance from the PCS Unit will develop the project tasks checklists specific to the project. Once the scope of work for a RFP has been defined, then a project specific checklist shall be prepared, and provided in the RFP. The Process Control System Implementation Guideline is intended to address how engineering services are provided, and at what stage each service and its corresponding deliverable is provided, and provides more specific, and more detailed, assistance to the engineering services provider in how PCS projects should be conducted. External references to other, more specific, guideline documents are also provided throughout this document. 1.5 Definitions and Roles The groups typically involved in PCS projects and their respective roles are detailed below. 1. City The owner (City of Toronto) generally performs all tasks detailed below in Section 2 RFP and Engineering Services Contract Award as well as reviewing the work of the Consultant, Contractor, and Systems Integrator. The City may involve the following internal organizations, depending on the components and complexity of the project: City s Project Manager The project manager is the single point of contact for all communication between the City and the Consultant for the project, unless others are designated as contacts for specific purposes. Responsibilities of the project manager include: EDOCSLIB-#9086-v of 189

8 Implementation Guidelines i. Initial project planning and RFP preparation ii. Tendering and award for consulting services iii. Ensure timely submission of deliverables from Consultant and timely review by City staff For more detailed information on the responsibilities of the project manager, consult the Toronto Water Project Delivery System manual. Major Capital Projects (MCP) MCP is TW engineering group providing project management and advisory to the Operation Group for the various complex PCS and electrical systems projects.. PCS Unit (PCSU) PCSU (currently within MCP) maintains the standards and guidelines for PCS projects and technology. PCSU also maintains facilities PCS master documentation: Master P&ID, Master Process Control Narratives, SCADA Architecture Drawings, Hardware and Software Inventory Lists. As custodian of Electronic Tagging Management System (ETMS) PCSU manage tagging requests & approvals. They provide engineering support for review of design reports, engineering drawings, specifications and cost estimates. MCP also assists with coordinating the various internal City organizations for purposes of deliverable review and comment. Integrated Technology Management (ITM) The ITM group provides support for review of SCADA hardware and software deliverables such as servers, PLCs, networking, and all related customized programming. They are also active participants in Factory and Site Acceptance Tests. As custodian of PLC software modules ITM get involved in testing and approval of any new software module, if needed. Operation Group The Operation Group refers to the support staff at the facility at which the project is being undertaken. They will be the principal group driving the development of the Scope of Work, and will review deliverables for operatability and maintainability during the project, to ensure compatibility with existing equipment at the facility. They are also active participants in Factory and Site Acceptance Tests. Optimized Maintenance Unit (OMU) The OMU maintains the Work Management System (WMS) databases for TW assets including all PCS related equipment in Toronto Water Facilities. Their EDOCSLIB-#9086-v of 189

9 Implementation Guidelines involvement in PCS projects will typically be to review and approve WMS tagging assignments proposed by the Consultant. 2. Consultant The Consultant is contracted by the City to perform the Scope of Work as defined in the RFP. The Consultant generally performs all tasks detailed below in Section 3 Pre-Design and Section 4 Detailed Design as well as representing the City during the Construction phase. As the City s representative, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City. The Consultant also participates in FAT, SAT, Commissioning and Training activities, and updating of documentation of the project. A detailed list of the Consultant s responsibilities follows: Responsible for the engineering and design of the I&C and SCADA System, including integration with existing system control logic Preparation/Updating of Process Control Narratives and P&ID Preparation of Contract Specifications and Drawings of I&C and SCADA system Review of the RPU and HMI configuration, as prepared by the Contractor, and ensure compliance with City s standards Prepare requirements for factory acceptance test (FAT) plan Attend and witness FAT at the Contractor s facility to ensure compliance with City s requirements Attend and witness testing of all field instruments and control loops performed by the Contractor Prepare requirements for site acceptance test (SAT) plan Attend and witness SAT on site to ensure compliance with City s requirements Prepare requirements for operational test/system performance test Attend and witness operational test/system performance test Review Operation and Maintenance Manual prepared by the Contractor for compliance with the contract specifications Review Plant SCADA Operation Manual and submit at the specified milestones Prepare PCS training Testing and verification of the performance of the SCADA system EDOCSLIB-#9086-v of 189

10 Implementation Guidelines Prepare As-built PCS documentation 3. Contractor The Contractor is contracted by the City to perform the Scope of Work as defined in the tender package created by the Consultant during Detailed Design and generally performs all tasks detailed in Section 5 Construction - Equipment and Section 7 Construction Testing and Commissioning. A detailed list of the Contractor s responsibilities follows: Purchase and install all software, hardware, instrumentation and field wiring as specified Perform Hardware FAT at the Contractor s facility, (if possible) witnessed by the Consultants and the City s staff Perform field verification of all installed instruments, devices and control loops, witnessed by the Consultants and the City s staff Participate in Consultant s PCS training as applicable Perform Hardware SAT, witnessed by the Consultants and the City s staff Perform operational test/system performance test, witnessed by the Consultants and the City s staff. Hand over SCADA system to City s staff when accepted by the City. Provide required warranty (response within 24 hours) and guarantee of SCADA system Respond to City for all deficiencies Prepare I&C Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones 4. Systems Integrator The Systems Integrator is typically a subcontractor of the Consultant or Contractor and they generally perform all tasks detailed below in Section 6 Construction - Software and Section 7 Construction Testing and Commissioning. A detailed list of the System Integrator s responsibilities follows: Configure PLC program in accordance with specified process control narratives EDOCSLIB-#9086-v of 189

11 Implementation Guidelines Configure HMI program in accordance with specified process control narratives Submit PLC and HMI programs to Consultants for review to ensure compliance with Specifications Participate in Consultant s PCS training Perform Software FAT at the System Integrator s facility, (if possible) witnessed by the Consultants and the City s staff Perform Software SAT, witnessed by the Consultants and the City s staff Perform operational test/system performance test, witnessed by the Consultants and the City s staff. Hand over SCADA system to City s staff when accepted by the City. Provide required warranty (response within 24 hours) and guarantee of SCADA system Respond to City for all deficiencies Prepare SCADA Operation and Maintenance Manual and submit to the Consultants for review at the appropriate milestones EDOCSLIB-#9086-v of 189

12 Implementation Guidelines 2. RFP and Engineering Services Contract Award 2.1 General In general, RFP and Engineering Services Contract Award tasks are performed and/or coordinated by the City s Project Manager. See Appendix A Flowcharts for a concise depiction of tasks and deliverables required during this phase. 2.2 Identify PCS Requirements Conduct workshop(s) with PCSU, Operation Group, and ITM representitives to gather requirements of the new project including input on the following: Instrumentation Control System Hardware Software Networking Structured Cabling Electrical Gather input on how the proposed project will affect the current facility PCS, and what additions and changes may be required. 2.3 Scope of Work Draft a Scope of Work based on the information gathered at the workshop(s) and have it reviewed by the various groups to ensure that the PCS elements are consistent with City objectives and standards. Amend the Scope of Work as required. 2.4 RFP Draft the PCS elements of the RFP including project specific PCS checklist following City s PCS Guidelines, Standards, and the Project Delivery System (PDS). Drafted RFP shall be reviewed by PCSU, ITM and Operations group. Issue the RFP and involve PCSU, ITM, and the Operation Group as required during the RFP process. EDOCSLIB-#9086-v of 189

13 Implementation Guidelines 2.5 RFP Evaluation Evaluate RFP responses with input from PCSU, ITM, and the Operation Group as required 2.6 Engineering Services Contract Award Award the project to a Consultant with input from PCSU, ITM, and the Operation Group as required. EDOCSLIB-#9086-v of 189

14 Implementation Guidelines 3. Pre-Design 3.1 General In general, Pre-Design tasks are performed by the Consultant and supervised by the City. See Appendix A Flowcharts for a concise depiction of tasks and deliverables required during this phase. The Consultant shall follow Toronto Water s PCS Guidelines and Standards throughout all phases of the project. The purpose of the Pre-Design Report is to identify the key elements of the design to ensure that the final installation will meet the functional requirements and performance of Toronto Water. During the pre-design phase, the Consultant is expected to: 1. Visit the existing facility, or similar facility in Toronto Water, and familiarize themselves with the existing interfaces, PCS equipment including tagging, software, control strategies, and network architecture to be matched and/or upgraded. 2. Review all engineering reports and drawings for the PCS system related to the project. 3. Review previous pre-design report(s) and detailed designs prepared for the PCS system. In general, consultants will comply with Section A.4 PREDESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system. 3.2 Project Commencement Conduct a Project Commencement Meeting, and invite PCSU, ITM, and the Operation Group representatives. The purpose of the meeting is for the Consultant to introduce their project team and have a discussion of the general strategy and goals of the project. 3.3 Field Verification The Field Verification Procedure shall be completed on commencement of pre-design engineering to ensure that the design will meet the requirements of the facility. This will minimize potential future claims by Contractors during construction, resulting from inaccurate information portraying existing conditions. This activity will also accurately define the scope of work required for achieving the targeted level of automation. Refer to EDOCSLIB-#9091 Field Verification Procedure for more information. 3.4 Requirements Definition/50% Pre-Design The following elements should appear in the 50% submittal: EDOCSLIB-#9086-v of 189

15 Implementation Guidelines 1. Equipment and Instrumentation List - Design equipment and instrumentation to permit full monitoring and control capability under manual and/or automatic control. Prepare a table (example below) of all existing and proposed equipment and instrumentation to be installed for the project. The table should be filled in as much as possible during Pre-Design and then modification can continue through the Detailed Design and Construction phases. Refer to EDOCSLIB-#6449 General Instrumentation Standards for the list of approved instruments and manufacturers for the City s PCS projects. The list of approved manufacturers shall be reviewed in conjunction with the staff of the affected facility. This list is part of PCS Standards and Specifications that will be made available on request at this stage of the project as well as the other required Standards and Specifications referred to further in this document (see Appenix D for the full list of PCS Standards and Specifications). Notwithstanding the inclusion of equipment in the approved manufacturers list, the Consultant is responsible for engineering design and project performance. The Consultant shall review the existing equipment at the facility and the approved list, discuss with the City the current performance of the equipment, and in conjunction with the City provide recommendation for first named and alternate named equipment to be specified using the approved list as a base. Make recommendations to the City if additional manufacturers are requested to be added or removed as appropriate according to Consultant experience and the specific project requirements. This list will form the basis of named and alternate named manufacturers and suppliers in the Contract Specifications. Table 1: Equipment and Instrumentation List Headings of Table Development Stages Predesign Detailed Design As Constructed Process Required Required Required Location Required Required Required Area Required Required Required Unit Required Required Required Equipment Tag Required Required (WMS/PCS Tag Number) Comment Required Required Required Device Type Required Required Required Device Description Required Required Required P&ID Required Required Manufacturer Required Model Required Serial Number Required EDOCSLIB-#9086-v of 189

16 Implementation Guidelines Headings of Table Development Stages Predesign Detailed Design As Constructed Measured range Required Required Calibrated Range Required Required I/O Type Required Required Required 2. Servers/PLCs/Network - Review and document all existing hardware affected by the project, and determine system capacity. Discuss capability for expansion and identify all additional hardware required for modifications so as to fully integrate the new or expanded works into the existing system. Identify all obsolete hardware that must be replaced as part of the upgrading of the existing or expansion of the process control system. Refer to EDOCSLIB-#8243 SCADA Computer System and EDOCSLIB-#8239 PCS Local Area Network (Appendix D) for technical detail and requirements. 3. SCADA Software - Review and document all existing software affected by the project, and identify all additional software required for modifications to the HMI, PLC and networking devices so as to fully integrate the new or expanded works into the existing system. 4. Control Wiring and Structured Cabling Review and document all existing control wiring and network cabling, and identify all additional cabling that will be required so as to fully integrate the new or expanded works into the existing system. 5. Alarm Notification and Security Review the existing alarm notification and security system of the facility, and document the proposed modifications and additions to provide the required services for notification of the critical PCS alarms of the project. Refer to EDOCSLIB-#9100 Alarming () for technical details and requirements. 6. Electrical System and Emergency Power Review the existing power supplies to the relevant areas of the facility and document the proposed modifications and additions to provide the required electrical power for the proposed upgrades % Pre-Design In addition to updates to the elements of the 50% pre-design, the following should appear in the 75% submittal: 1. Process Narrative Provide a Process Narrative or update existing for each process, clearly describing how it is to be operated in all modes of process control. Process narratives shall be written in plain English to provide a clear understanding of the relationships between the equipments and the process variables to be monitored/controlled. Note that the Narrative will not apply solely to the new processes/equipment, but will detail all interaction with existing process/equipment control (i.e., alarm triggers, process variables shared by multiple processes, report EDOCSLIB-#9086-v of 189

17 Implementation Guidelines generation, etc.). Refer to EDOCSLIB-#9093 Process Control Narratives () Section for technical detail and requirements. 2. Process Flow Diagrams Provide a Process Flow Diagram or update existing to clearly illustrate the relationships between the various affected processes and associated instrumentation. 3. Design Alternatives The Consultant should include a section detailing any alternative designs that they feel might offer benefits to the City in terms of cost or functionality. 4. Cost Estimate Include a cost estimate to construct the project according to the guidelines provided in the RFP. 5. Electrical Area Classification Report If required, provide Electrical Area classifications report for the affected areas where electrical and instrumentation devices will be installed under the project % Pre-Design The 100% Pre-Design submittal should include updates to reflect the comments made during review of the 75% submittal. City staff will review the 100% submittal and again provide comments to allow the Consultant to finalize the Pre-Deisgn report. EDOCSLIB-#9086-v of 189

18 Implementation Guidelines 4. Detailed Design 4.1 General In general, Detailed Design tasks are performed by the Consultant and supervised by the City. See Appendix A Flowcharts for a concise depiction of tasks and deliverables required during this phase. Consultants will comply with Section A.5 DETAILED DESIGN ENGINEERING SERVICES of the RFP document, specifically with respect to the PCS system. 4.2 Tag List The City maintains a tag database known as the Enterprise Tagging Management System (ETMS). The Consultant shall have access to this database during design for the purpose of creating unique tagnames and producing a Tag List for review by the City. All equipment, equipment loop names, data and local area network cabling shall be tagged in accordance with EDOCSLIB-# 6454 Equipment and Data Names. These tag numbers shall be used in the P&ID drawing(s) and all related project documentations for the identification of all equipment and intruments % Detailed Design The following elements should appear in the 50% Detailed Design submittal: 1. Process Control Narrative (PCN) The Consultant will update the Master PCN provided by the City. Refer to EDOCSLIB-#9093 Process Control Narratives () for details of the requirements. 2. P&IDs - The Consultant will update the Master P&IDs provided by the City, or prepare new P&IDs (in case Master P&IDs do not exist). The City s instrumentation symbols and control and instrumentation loop diagrams, including process and instrumentation diagrams, are generally based on the Instrument Society of America Standards ANSI/ISA-S (R 1992) and ANSI/ISA-S , or latest revision. The ISA standards have been modified by the City to meet its own requirements. Consultants shall comply with EDOCSLIB-#9094 P&ID Standard Symbols and Practices (). 3. SCADA Architecture Drawings The Consultant shall update the SCADA Architecture drawing of the facility, to show modifications and additions of equipment. 4. Equipment Power Requirements The Consultant shall provide drawings and specifications for any power supply upgrades or additions required as a result of new or modified equipment. EDOCSLIB-#9086-v of 189

19 Implementation Guidelines 5. Single-Line Drawings If the new equipment requires changes to the facility s singleline drawings, they shall be provided as part of this submission. 6. Electrical Area Classifications These shall be updated from the classifications provided in the Pre-Design Report. 7. Cost Estimate Provide an updated cost estimate % Detailed Design In addition to updates to the elements of the 50% design, the following should appear in the 70% submittal: 1. Control Panel Drawings The Consultant shall provide drawings for new panels or modifications to any existing control panels. 2. Loop Drawings The Consultant shall produce loop drawings as required. 3. Equipment Layouts and Control Schematics The Consultant shall produce equipment layout and control schematic drawings as required. 4. SCADA Hardware and Software Requirements The Consultant shall create or update the Software Inventory List for the facility, indicating what new software or hardware is required for the SCADA system 5. Instrument Ranges and Setpoints As part of the Process Control Narrative, this information shall be provided at this stage. 6. Alarm List - As part of the Process Control Narrative, this information shall be developed complete with Alarm Conditioning at this stage. 7. ihistorian, eops, POMS, LIMS Requirements - As part of the Process Control Narrative, this information shall be available at this stage. 8. Alarm Notification and Security Detailed Design of the alarm notification requirements that were provided in the Pre-Design Report. Coordinate with the City s corporate security for security related issues. 9. Networking and Structured Cabling - Detailed Design of the networking and structured cabling requirements that were provided in the Pre-Design Report. 10. Equipment and Instrumentation Physical Tag List - Field equipment shall be tagged in accordance with EDOCSLIB-#6454 Equipment and Data Names. Provide completed Physical Tag List indicating details of the tag quantities and sizes. 11. Electrical Drawings and Requirements Drawings showing electrical upgrades required for the project. EDOCSLIB-#9086-v of 189

20 Implementation Guidelines 12. Identify Hardware and Wiring Removal Drawings to indicate obsolete hardware and wiring that is to be removed under the project. 13. Identify RPU/HMI Program/Code Removal Produce a detailed list indicating which software tags/objects should be removed under the project. 4.5 Detailed Technical Specifications The Consultants shall refer to the PCS standards listed under PCS Standards and Specifications List (Appendix D) and shall use or adhere to those requirements. Consultants should obtain electronic versions of these standards related to the project from the City s Project Manager. The Consultants shall modify or edit the standards and create specifications to suit the project specific requirements of the contract, after getting consent from PCSU. However, where modifications are recommended, the Consultant is to highlight these proposed deviations to the City to ensure that the proposed changes do not compromise the City s overall goal of standardizing PCS across Toronto Water facilities. The responsibility remains with the Consultant to ensure that contract specifications and drawings meet the requirements for proper project execution. 4.6 Apply For Approval Once the 70% Detailed Design package has been accepted by the City, it is expected that the Consultant will obtain approvals from agencies as required. Comments made by the approving agencies are to be incorporated into the documents for the 95% submittal to the City % Detailed Design In addition to updates to the elements of the 70% design, the following should appear in the 95% submittal: 1. Pre-Start Health and Safety The Consultant shall review and report as requried. 2. Electrical Area Classifications The Consultant shall update electrical area classifications based on the detailed design 3. Updated Cost Estimate % Detailed Design In addition to updates to the elements of the 95% design, the following should appear in the 100% submittal: 1. Tender Document The Consultant shall complete the preparation of the tender package. 2. Updated Cost Estimate EDOCSLIB-#9086-v of 189

21 Implementation Guidelines 5. Construction - Equipment 5.1 General In general, Construction Equipment tasks are performed by the Contractor and supervised by the Consultant. See Appendix A Project Tasks Flowcharts for a concise depiction of tasks and deliverables required during this phase. Consultants will comply with Section A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system. As the City s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and solicit the City s comments in addition to their own before returning reviewed deliverables to the Contractor. 5.2 Shop Drawings The Contractor is to submit shop drawings for all equipments and panels to be purchased for installation during the contract. The Consultant will review the shop drawings in accordance with EDOCSLIB-#9101 Instrument and Equipment Testing (). The City has the option to review shop drawings as well though the responsibility for accuracy and correctness lies with the Consultant. 5.3 Equipment and Panel Procurement and Fabrication The Contractor will procure equipment and manufacture panels as required, after approval of the shop drawings. The Consultant will monitor the progress and ensure the project schedule is maintained. 5.4 Test Sheets Contractor is to provide Pre-FAT test documentation for major equipment such as MCCs, pumps, etc. 5.5 Equipment and Panel FATs The purpose of hardware FATs is to ensure the integrity of the equipment used to control and monitor the process at the City s facilities. It is intended to demonstrate that the system configuration will function effectively once installed on site, and limits the need for on site modifications to hardware configurations. The hardware FAT involves the following major components: 1. Control Panels & Local Operator Interfaces EDOCSLIB-#9086-v of 189

22 Implementation Guidelines 2. Networking Equipment 3. Workstations 4. PLCs. The hardware FAT is performed at the Contractor's office. These tests must be completed by the contractor and approved by the Consultants prior to any equipment being delivered to the project site. The City has the option to witness the FATs as well, though the responsibility for approval lies with the Consultant. 5.6 Transition Plan A project will typically involve installing equipment into an existing, operating facility that has an operating PCS. The Contractor shall develop a transition plan that details the progression of installation tasks such that the impact on operations is minimized and the continued safe operation of the facility is assured. The plan should take the following considerations into account: 1. Features of the facility that may impose limitations during construction. For example, certain tasks might need to be performed during non-peak operating hours. 2. To maintain continuous operation and monitoring, provisions might need to be made for temporary parallel equipment. For example, if an older model PLC is being replaced, it might need to continue operating while the new PLC is installed and wired. 3. PCS upgrades typically require re-wiring of equipment that results in a temporary loss of use of the equipment. The transition plan needs to account for operational requirements while scheduling equipment down-time. The Operation Group will provide the Contractor with their operational constraints as required. 4. If PCS networking configuration changes are involved, the Contrator should consider the impact on the ability of the Operation Group to control and monitor related equipment. Concsultant should review the transition plan prior submitting to City for approval. 5.7 Equipment Installation and Wiring Once equipment has been approved at the FAT and the Transition Plan has been accepted, the Contrator can deliver equipment to site and commence installation and wiring. 5.8 Pre-Start Health and Safety If a Pre-Start Health and Safety review and report are required (refer to the Toronto Water Prject Delivery System Manual for details), the Consultant shall produce the report and have it approved prior to the commencement of commissioning. EDOCSLIB-#9086-v of 189

23 Implementation Guidelines 5.9 Entity Information Lists The Contractor shall prepare the Entity Information Lists (WMS list) for all new and upgraded equipment in the project. See EDOCSLIB-#6454 Equipment and Data Names for the template.this information is used by the OMU for WMS purposes. EDOCSLIB-#9086-v of 189

24 Implementation Guidelines 6. Construction - Software 6.1 General In general, Construction Software tasks are performed by the Systems Integrator and supervised by the Consultant. See Appendix A Flowcharts for a concise depiction of tasks and deliverables required during this phase. Consultants will comply with Section A.6 SERVICES DURING CONSTRUCTION of the RFP document, specifically with respect to the PCS system. As the City s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator and provide their comments to the City. 6.2 Flow Chart Development The Systems Integrator shall develop logic flow charts to demonstrate their interpretation of the design documents. Refer to EDOCSLIB-#9096 RPU Software Programming () for more detail on the development of flow charts. 6.3 Software Modules The City has developed a series of standard software modules that are to be used by programmers to implement the control functions required by the project. The goal of standard software modules is to reduce development and maintenance costs by ensuring that software deployed throughout Toronto Water facilities has a common look and logical base. Refer to EDOCSLIB-#9097 Standard Software Modules () for more detail on the use of software modules. In some cases, the Systems Integrator may find that a new or modified software module would be beneficial to the development of the software for the project. Modules can not be modified without the consent of PCSU/ITM. When the PCSU/ITM approves the development or modification of a software module, the Systems Integrator shall follow the procedure found in EDOCSLIB-#9097 Standard Software Modules (). 6.4 Software Development Once it has been determined that the software modules are sufficient for the project, the Systems Integrator can begin software development according to the following guidelines: 1. EDOCSLIB-#9099 Process Display Programming 2. EDOCSLIB-#9098 Operator Interface Programming 3. EDOCSLIB-#9100 Alarming EDOCSLIB-#9086-v of 189

25 Implementation Guidelines 4. EDOCSLIB-#9095 Colour Convention 5. EDOCSLIB-#9096 RPU Software Programming 6. EDOCSLIB-#9097 Standard Software Modules Software is to be submitted at the 70% stage at which time the Consultant and City representitives will review the components for accuracy, adherence to standards, and compatibility with the rest of the facility PCS. 6.5 FAT Plan Prior to carrying out a Factory Acceptance Test of the software, the Systems Integrator shall prepare a detailed test plan for review by the Consultant. The test plan will identify all field I/O to be tested such as equipment status, control modes, and hardwired alarms. Also virtual points such as alarms, setpoints, and operator entered parameters. The test plan will then identify automatic logic tests designed to prove that the program responds as detailed in the Process Control Narrative. The plan will also identify a graphics review as well as include the PCN and the contract drawings (control schematics, loop diagrams, and process and instrumentation drawings P&IDs) as part of the test plan. The Systems Integrator shall demonstrate that the test plan fulfils the intent and requirements of the PCN and will therefore result in the successful operation of the system when installed on site. The test plan should also include a proposed schedule and a description of the proposed testing environment (hardware setup, software utilized) for approval by the Consultant and the City. Refer to EDOCSLIB-#9104 Factory AcceptanceTesting () for details. Once the schedule and documentation have been accepted, the Systems Integrator shall submit a copy of all software components to the City (known as the Pre-FAT version of software). 6.6 Software FAT The Systems Integrator will host the Factory Acceptance Test according to the details presented in the schedule and FAT documentation. Refer to EDOCSLIB-#9104 Factory AcceptanceTesting () for details. Upon completion of the FAT and subsequent corrections and re-testing as required, the Systems Integrator shall submit a copy of all software componenets to the City (known as the Pre-SAT version of software). EDOCSLIB-#9086-v of 189

26 Implementation Guidelines 7. Construction Testing and Commissioning 7.1 General The Consultant shall comply with Appendix A7 SITE SERVICES DURING TESTING AND COMMISSIONING, of the RFP document for the engineering services required to be provided for the project. The Consultant shall specify in the contract document that the Contractor and Systems Integrator are required to comply with the City s standard procedure for the testing and commissioning of PCS. As the City s representative during construction, the Consultant will review all deliverables from the Contractor and System Integrator providing comments to the City. 7.2 Hardware SAT and Training Plan The Contractor is to submit a SAT Plan that includes the following: 1. Schedule 2. Testing procedure for each item 3. Sign-off documentation 4. Details of City involvement, including any operational requirements such as shutdowns, communication interruptions, etc. Refer to EDOCSLIB-#9101 Instrument and Equipment Testing and EDOCSLIB-#15167 Site Acceptance Testing () for more details. The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to EDOCSLIB-#9109 Training () for more details. 7.3 Hardware Training The Contractor shall perform training on the installed hardware prior to the SAT. Refer to EDOCSLIB-#9109 Training () for more details. 7.4 Hardware SAT A Hardware SAT is to ensure the integrity of the equipment used to control and monitor the process at the City s facilities once installed on site. Prior to the hardware SAT, the Consultant and Contractor must have jointly completed all I/O tests, loop tests, network tests, and instrumentation calibration verification sheets. EDOCSLIB-#9086-v of 189

27 Implementation Guidelines The hardware SAT involves the following major components: 1. Control Panels & Local Operator Interfaces 2. Networking Equipment (as available) 3. Workstations 4. PLCs 5. Instrumentation The hardware SAT is performed on site to ensure that the equipment has been installed, wired and configured correctly. The consultant shall compile all the SAT results and submit it to the City for their review. The testing of the networking equipment, workstations, and PLCs is intended to confirm that the network as designed, and the configuration of the hardware as specified functions as an integral network on site and in conjunction with the City s wide area network (WAN). 7.5 Software SAT and Training Plan The Systems Integrator s SAT Plan should include the same I/O and Logic check sheets that were used during the Software FAT. In addition to check sheets, there should also be sign-off documentation and a schedule of activities that details the City s involvement, including any operational requirements such as shutdowns, communication interruptions, etc. Refer to EDOCSLIB-#9107 Site Acceptance Testing and Commissioning () for more details. The Training Plan should contain a schedule and detailed outline of the material to be covered. Refer to EDOCSLIB-# 9109 Training () for more details. 7.6 Software Training The Systems Integrator shall perform training on the new software components prior to the SAT. Refer to EDOCSLIB-#9109 Training () for more details. 7.7 Software SAT After training has been completed, the Software SAT can be performed. It is intended to confirm that the software functions according to the Process Control Narrative and allow fine-tuning of control loops and other process variables. Refer to EDOCSLIB-#9107 Site Acceptance Testing and Commissioning () for more details. 7.8 Operational Test/System Performance Test The operational test/system performance is a 5-day test (unless otherwise defined in RFP) of the system to simulate the operation of the system under different loading conditions. The test shall EDOCSLIB-#9086-v of 189

28 Implementation Guidelines start on a Monday and will be restarted again on a Monday in the event of a failure of the system to operate as intended at any point in the 5-day period. During this period the software is to operate under Area Operator station and Central Operator station modes to simulate normal operation of the system. Where necessary, the Consultants will specify additional simulation logic to the RPU to allow the process area to be fully simulated for operational test/system performance. The provision of such simulation code is deemed to be within the scope of the Contractor services. Where necessary, the Consultant shall specify the provision of temporary piping and equipment in order to be able to carry out the simulation successfully. 7.9 As-Built Documentation The Contractor and Systems Integrator shall submit As-Built documentation during this phase. Refer the EDOCSLIB-#9108 PCS Documentation () for details Post Construction Warranty Period In general, the Systems Integrator shall provide all necessary services during the warranty period to update all software when deficiencies are found. Refer to the contract for specific warranty requirements. EDOCSLIB-#9086-v of 189

29 Implementation Guidelines Appendix A Project Tasks Flowcharts 29 of 189

30 PROJECT TASKS FLOW CHART RFP AND ENGINEERING SERVICES CONTRACT AWARD FOR PROJECTS WITH PCS COMPONENT INPUTS/REFERENCES TASKS DELIVERABLES Project Delivery System Manuals RFP Template Purchasing and Materials Management RFP and Policies RFP Initiation Initiate RFP process according to PDS Manuals Identify PCS Requirements Conduct workshop with Operation Group, PCSU, ITM to gather input on the following Instrumentation Control System Hardware Software Networking Structured Cabling Electrical No Scope of Work Prepare Scope of Work with input from Operation Group, PCSU, ITM Scope of Work Review by: PCSU, ITM, Operation Group Possible Documentation to be made available to authors/reviewers Scope of Work accepted? PCS Implementation Guidelines PCS Implementation Standards Facility Master Process Control Narratives Facility Process Flow Diagrams Facility Master P&IDs Facility SCADA Architecture Drawing Facility Structured Cabling Standards and Drawings Toronto Water Equipment Tag Standard Related Facility Drawings Operation Manuals City s Drawing Standards No Yes RFP Prepare PCS and Electrical elements for inclusion in the RFP RFP Review by: PCSU, ITM, Operation Group RFP accepted? Yes Finalize and Issue RFP Prepare Addenda as required. Involve PCSU, ITM, Operation Group as needed RFP Evaluation Involve PCSU, ITM in evaluation procedures as needed Award Contract Negotiation and Execution. Involve PCSU, ITM as needed 30 of 189 EDOCSLIB-#9087-V1 Page 1 of 11 Appendix A

31 PROJECT TASKS FLOW CHART Process Control System (PCS) Guidelines PRE-DESIGN (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Project Commencement Conduct Project Commencement meeting. Invite PCSU, ITM to attend. PCS Implementation Guidelines PCS Implementation Standards Existing Drawings (Electrical, Mechanical, I&C) Master P&IDs Master Process Control Narrative eops, WMS, POMS, LIMS requirements Field Verification Verify accuracy of existing documentation against the following field conditions Process and Equipment Control System Instrumentation Control Wiring and Structured Cabling Electrical Area Classification No Field Verification Report Prepare report including red-lined P&IDs, Condition Assessment and Design Alternatives Field Verification Report Review by: PCSU, ITM, Operation Group Field Verification Report accepted? Yes Existing SCADA Architecture Existing PLC/HMI Programs Related WMS Database Inventory Lists for Servers, PLCs, Network, Software Requirements Definition/ 50% Pre-Design Workshop(s) with PCSU, ITM, Operation Group and other Stakeholders as required. Identify the following requirements Instrumentation Servers, PLCs, Network SCADA Software Control Wiring and Structured Cabling Paging and Security Electrical System Emergency Power 50% Pre-Design Report No Review by: PCSU, ITM, Operation Group 50% Pre-Design Report accepted? Yes Consolidate review comments and prepare Outstanding Issues list No 75% Pre-Design Incorporate 50% Pre-Design comments Equipment and Instrumentation List Process Narrative (PN) Process Flow Diagrams (PFD) Design Alternatives Cost Estimate Electrical Area Classification Report 75% Pre-Design Report Review by: PCSU, ITM, Operation Group 75% Pre-Design Report accepted? Yes 31 of 189 EDOCSLIB-#9087-V1 Page 2 of 11 Appendix A Page-3

32 PROJECT TASKS FLOW CHART PRE-DESIGN (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Page-2 Consolidate review comments and prepare Outstanding Issues list 100% Pre-Design Incorporate 75% Pre-Design comments Updated Cost Estimate 100% Pre-Design Report No Review by: PCSU, ITM, Operation Group 100% Pre-Design Report accepted? Yes Pre-Design Complete Proceed to Detailed Design 32 of 189 EDOCSLIB-#9087-V1 Page 3 of 11 Appendix A

33 PROJECT TASKS FLOW CHART DETAILED DESIGN (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Tagging Database Enterprise Tagging Management System (ETMS) Toronto Water Tagging Standard Tag List Prepare tags for new Equipment and Instrumentation Tag List No Review by: OMU, PCSU, Operation Group Tag List accepted? Yes 50% Detailed Design Develop or update the following documents No Master Process Control Narratives Master P&IDs SCADA Architecture drawings Equipment Power Requirements Single-Line drawings Electrical Area Classification Cost Estimate 50% Detailed Design Documents Review by: PCSU, ITM, Operation Group 50% Detailed Design accepted? Yes Consolidate review comments and prepare Outstanding Issues list No Detailed Technical Specification Develop the following specifications (PCS related sections) Table of Contents Division 1 Division 11 Division 13 Division 15 Division 16 70% Detailed Design Develop or update the following documents Update 50% Detailed Design Documents Control Panel Drawings Loop Drawings Equipment Layouts and Control Schematics SCADA Hardware and Software Requirements Instrument Ranges and Setpoints Alarm List including Alarm Conditioning Identify ihistorian, eops, POMS, LIMS Requirements Paging and Security Networking and Structured Cabling Equipment and Instrumentation Physical Tag List Electrical Drawings and Requirements Identify Hardware and Wiring Removal Identify RPU/HMI Program/Code Removal 70% Detailed Design Documents 70% Detailed Design accepted? Review by: OMU, PCSU, ITM, Operation Group Yes Consolidate review comments and prepare Outstanding Issues list Page-5 33 of 189 EDOCSLIB-#9087-V1 Page 4 of 11 Appendix A

34 PROJECT TASKS FLOW CHART DETAILED DESIGN (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Page-4 Apply For Approval Send documents to Approval Agencies as required Submit Applications with associated documentation No Approvals received? Yes Incorporate Agency Comments into the Documents No 95% Detailed Design Develop or update the following Update 70% Detailed Design Documents Pre-Start Health and Safety Review and Report as required Electrical Area Classifications as required Cost Estimate 95% Detailed Design Documents 95% Detailed Design accepted? Review by: PCSU, ITM, Operation Group Yes Consolidate review comments and prepare Outstanding Issues list 100% Detailed Design Develop or update the following Update 95% Detailed Design Documents Tender Document Update Cost Estimate 100% Detailed Design/Tender Document No 100% Detailed Design/ Tender Document accepted? Review by: PCSU, ITM, Operation Group Yes Involve PCSU, ITM as required during Tendering Process 34 of 189 EDOCSLIB-#9087-V1 Page 5 of 11 Appendix A

35 PROJECT TASKS FLOW CHART CONSTRUCTION EQUIPMENT (PCS COMPONENT) Process Control System (PCS) Guidelines INPUTS/REFERENCES TASKS DELIVERABLES Contract PCS Start-up Involve Consultant s PCS staff, Systems Integrator, PCSU, ITM in kickoff meeting as required Bulk Construction (Conduits, Cable Trays, Duct Banks) Shop Drawings Prepare Applicable Shop Drawings Instrumentation Servers, PLCs, OITs Network Panels, Cabling MCCs, Switchgear Consultant s Review Shop Drawings No Review by: PCSU, ITM, Operation Group Shop Drawings accepted? Yes Equipment and Panel Procurement and Fabrication FAT/Whiteness Test Sheets Prepare Test Sheets for Equipment and Panels Consultant s Review Test Sheets No Review by: PCSU, Operation Group Test Sheets accepted? Yes Equipment and Panel Factory Acceptance Tests Where required, FAT(s) to be attended by General Contractor, Consultant, PCSU, ITM, Operation Group No Prepare FAT Reports Consultant s Review Factory Acceptance Test Reports Review by: PCSU, Operation Group Factory Acceptance Test Reports accepted? Yes Equipment received at site complete with O&M Manuals, Certificates, Reports, Drawings Page-7 35 of 189 EDOCSLIB-#9087-V1 Page 6 of 11 Appendix A

36 PROJECT TASKS FLOW CHART Process Control System (PCS) Guidelines CONSTRUCTION EQUIPMENT (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Page-6 Transition Plan Prepare a Transition Plan to address the following issues. Process Limitations Potential Parallel Equipement, Panels, HMIs Detailed Schedule of Terminations Network Configuration Hardware and Wiring Removal No Consultant s Review Transition Plan Transition Plan accepted? Review by: PCSU, ITM, Operation Group Yes Equipment Installation and Wiring Pre-Start Health and Safety Prepare Pre-Start Health and Safety Review and Report as Required (Consultant) Entity Information Lists Prepare Entity (Asset) Information Lists (WMS) Consultant s Review Entity (Asset) Information Lists (WMS) No Review by: PCSU, OMU WMS Lists accepted? Yes Proceed to Testing and Commissioning Page of 189 EDOCSLIB-#9087-V1 Page 7 of 11 Appendix A

37 PROJECT TASKS FLOW CHART CONSTRUCTION SOFTWARE (PCS COMPONENT) Process Control System (PCS) Guidelines INPUTS/REFERENCES TASKS DELIVERABLES Flow Chart Development PCS Implementation Guidelines PCS Standards Design Phase Drawings (Master P&IDs, Electrical, I&C) Master Process Control Narrative eops, WMS, POMS, LIMS requirements No Develop Logic Flow Charts Consultant s Review Review by: PCSU, ITM, Operation Group Logic Flow Charts Logic Flow Charts accepted? Yes Software Modules Library Software Modules Are existing software modules sufficient for the project? No Yes No New Software Modules Flow Chart Development Develop Logic Flow Charts Consultant s Review New Software Modules Logic Flow Charts New Software Modules Logic Flow Charts accepted? Review by: PCSU, ITM Yes Develop New Software Modules PLC, HMI, Simulation components as required New Software Modules FAT Attended by Consultant,PCSU, ITM, Operation Group as Required No FAT passed? Yes New Software Modules Documentation Consultant s Review Completed New Software Modules Documentation No New Software Modules Documentation accepted? Reviewed by: PCSU, ITM Yes Page-9 37 of 189 EDOCSLIB-#9087-V1 Page 8 of 11 Appendix A

38 PROJECT TASKS FLOW CHART CONSTRUCTION SOFTWARE (PCS COMPONENT) Process Control System (PCS) Guidelines INPUTS/REFERENCES TASKS DELIVERABLES Page-8 Existing Programs - PLC, HMI, Simulation Software Development PLC HMI Simulation Consultant s Review 70% Software Development (Screen Captures, PLC, HMI and Simulation Programs) No 70% Software Development accepted? Review by: PCSU, ITM (HMI, PLC), Operation Group (Screen Captures) Yes FAT Plan Develop FAT Documentation and Schedule Consultant s Review FAT Plan No Review by: PCSU, ITM Operation Group FAT Plan accepted? Yes Software Version: Pre-FAT FAT Factory Acceptance Testing Attended by Consultant, PCSU, ITM, Operation Group No FAT passed? Yes FAT Documentation and Sign-off Complete FAT Documentation and Sign-off Consultant s Review Completed FAT Documentation and Sign-Off Correct software deficiencies identified during FAT Software Version: Pre-SAT Page of 189 EDOCSLIB-#9087-V1 Page 9 of 11 Appendix A

39 PROJECT TASKS FLOW CHART CONSTRUCTION TESTING AND COMMISSIONING (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Page-7 Page-9 Hardware SAT and Training Plan Develop SAT Documentation, Schedule and Training Plan for: Equipment, Instrumentation, Network, Panels, Field Wiring Consultant s Review Hardware SAT and Training Plan No Review by: PCSU, Operation Group, ITM (Network), Hardware SAT and Training Plan accepted? Yes Hardware Training Provide Operation and Maintenance Training for: Equipment, Instrumentation, Network and Panels Hardware SAT Hardware Site Acceptance Testing Equipment Installation Test Instrumentation Calibration Panel Installation Test Network Testing Field Wiring Test Attended by Consultant, PCSU, Operation Group, ITM (Network) No Hardware SAT passed? Yes Hardware SAT Documentation and Sign-off Complete Hardware SAT Documentation and Sign-off Consultant s Review Completed Hardware SAT Documentation and Sign-Off Software SAT and Training Plan Develop SAT Documentation, Schedule and Training Plan Consultant s Review Software SAT and Training Plan No Review by: PCSU, ITM, Operation Group Software SAT and Training Plan accepted? Yes Software Training Provide Software Training by Consultant and Systems Integrator Page of 189 EDOCSLIB-#9087-V1 Page 10 of 11 Appendix A

40 PROJECT TASKS FLOW CHART CONSTRUCTION TESTING AND COMMISSIONING (PCS COMPONENT) INPUTS/REFERENCES TASKS DELIVERABLES Page-10 Software SAT Software Site Acceptance Testing Attended by Consultant, PCSU, ITM, Operation Group No Software SAT passed? Yes Software SAT Documentation and Sign-off Complete Software SAT Documentation and Sign-off Consultant s Review Completed Software SAT Documentation and Sign-Off Correct software deficiencies identified during SAT Operational Test/ System Performance Test No Operational Test passed? Yes Software Version: SAT As-Built Documentation Prepare Hardware and Software As- Built Documentation Consultant s Review As-Built Documentation No Review by: PCSU, ITM, Operation Group As-Built Documentation accepted? Yes Post Construction Warranty Period 40 of 189 EDOCSLIB-#9087-V1 Page 11 of 11 Appendix A

41 Implementation Guidelines Appendix B Project Tasks Implementation Checklists 41 of 189

42 Appendix B Project Tasks Implementation Checklist Project Phase: RFP and Engineering Services Contract Award for Projects with PCS Component ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 1.1 RFP Initiation Project Delivery System Manuals PCSU RFP Template Purchasing and Materials Management RFP and Policies PCSU PCSU 1.2 Identify PCS Requirements Conduct workshop to identify PCS Requirements PCSU, ITM, Operation Group 1.3 Scope of Work Definition Reviewed Scope of Work PCSU, ITM, Operation Group Prepare Scope of Work with input from PCSU, ITM, Operation Group Consolidate Scope of Work Review Comments PCSU, ITM, Operation Group Final Scope of Work PCSU, ITM, Operation Group 1.4 RFP PCS Implementation Guidelines PCSU PCS Implementation Standards Facility Master Process Control Narratives Facility Process Flow Diagrams Facility Master P&IDs Facility SCADA Architecture Drawing Facility Structured Cabling Drawings Tornto Water Equipment Tag Standard Related Facility Drawings Operation Manuals PCSU PCSU PCSU PCSU PCSU Operation Group PCSU Operation Group Operation Group City's Drawing Standards PCSU RFP RFP PCSU, ITM, OMU, Operation Group Reviewed RFP PCSU, ITM, OMU, Operation Group Consolidate RFP Review Comments PCSU Comnsolidated RFP Review Comments PCSU Final RFP PCSU, ITM, OMU, Operation Group 1.5 Finalize and Issue RFP Prepare Addenda as required. Involve PCSU, ITM, Operation Group as needed 1.6 RFP Evaluation Evaluate Proposals. Involve PCSU, ITM, Operation Group as needed 1.7 Award Contract Negotiation and Execution. Involve PCSU, ITM, Operation Group as needed 42 of 189 EDOCSLIB-#9088-v1 Page 1 of 7 9/26/2011

43 Implementation Checklists Project Tasks Implementation Checklist Project Phase: Pre-Design (PCS Component) ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 2.1 Project Commencement Conduct Project Commencement Meeting PCSU. ITM, OMU as required 2.2 Field Verification PCS Implementation Guidelines PCSU PCS Implementation Guidelines Consultant PCS Implementation Standards PCSU PCS Implementation Standards Consultant Existing Drawings Operation Group Existing Drawings Consultant Master P&IDs PCSU Master P&IDs Consultant Master Process Control Narrative PCSU Master Process Control Narrative Consultant eops, WMS, POMS, LIMS Requirements Operation Group eops, WMS, POMS, LIMS Requirements Consultant 2.3 Field Verification Report Red-lined P&IDs Consultant Red-lined P&IDs Condition Assessment Consultant Condition Assessment Design Alternatives Consultant Design Alternatives Reviewed Field Verification Report Consolidated Field Verification Report Review Comments PCSU, ITM, Operation Group PCSU Final Field Verification Report Consultant Final Field Verification Report PCSU, Operation Group PCSU, ITM, Operation Group PCSU, ITM, Operation Group Consolidate Field Verification Report Review Comments PCSU Consolidated Field Verification Report Review Comments Consultant PCSU, ITM, Operation Group 2.4 Requirements Definition/ 50% Pre-Design Existing SCADA Architecture PCSU Existing SCADA Architecture Consultant Existing PLC/HMI Programs ITM Existing PLC/HMI Programs Consultant Related WMS Database OMU Related WMS Database Consultant SCADA Hardware and software Inventory Lists PCSU Inventory Lists Consultant Instrumentation Consultant Instrumentation PCSU, Operation Group Servers. PLC, Network Consultant Servers. PLC, Network PCSU, ITM SCADA Software Consultant SCADA Software PCSU, ITM Control Wiring and Structured Cabling Consultant Control Wiring and Structured Cabling PCSU, Operation Group Paging and Security Consultant Paging and Security PCSU, Operation Group Electrical System Consultant Electrical System PCSU, Operation Group Emergency Power Consultant Emergency Power PCSU, Operation Group Reviewed 50% Pre-Design Consolidated 50% Pre-Design Review Comments PCSU, ITM, Operation Group PCSU Consolidate 50% Pre-Design Review Comments Consolidated 50% Pre-Design Review Comments PCSU Consultant % Pre-Design 50% Pre-Design Review Comments Incorporated Consultant 50% Pre-Design Review Comments Incorporated Equipment and Instrumentation List Consultant Equipment and Instrumentation List Process Narrative Consultant Process Narrative Process Flow Diagrams Consultant Process Flow Diagrams Design Alternatives Consultant Design Alternatives Cost Estimate Consultant Cost Estimate Electrical Area Classification Report Consultant Electrical Area Classification Report Reviewed 75% Pre-Design Consolidated 75% Pre-Design Review Comments PCSU, ITM, Operation Group PCSU Consolidate 75% Pre-Design Review Comments Consolidated 75% Pre-Design Review Comments PCSU, ITM, Operation Group PCSU, ITM, OMU,Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, ITM, Operation Group PCSU, Operation Group PCSU Consultant % Pre-Design 75% Pre-Design Review Comments Incorporated Consultant 75% Pre-Design Review Comments Incorporated Updated Cost Estimate Consultant Updated Cost Estimate Reviewed 100% Pre-Design Consolidated 100% Pre-Design Review Comments PCSU, ITM, Operation Group PCSU Consolidate 100% Pre-Design Review Comments Consolidated 100% Pre-Design Review Comments Final 100% Pre-Design Consultant Final 100% Pre-Design PCSU, ITM, Operation Group PCSU, Operation Group PCSU Consultant PCSU, ITM, Operation Group 43 of 189 EDOCSLIB-#9088-V1 Page 2 of 7 9/26/2011

44 Implementation Checklists Project Tasks Implementation Checklist Project Phase: Detailed Design (PCS Component) ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 3.1 Tag List Tagging Database - Enterprise Tagging Management System (ETMS) PCSU Tagging Database - Enterprise Tagging Management System (ETMS) Consultant Toronto Water Tagging Standard PCSU Toronto Water Tagging Standard Consultant Tag List Consultant Tag List OMU, PCSU, Operation Group Reviewed Tag List OMU, PCSU, Operation Group Consolidate Tag List Review Comments PCSU Consolidated Tag List Review Comments PCSU Consolidated Tag List Review Comments Consultant OMU, PCSU, Final Tag List Consultant Final Tag List Operation Group % Detailed Design Process Control Narratives Consultant Process Control Narratives P&IDs Consultant P&IDs SCADA Architecture Drawings Consultant SCADA Architecture Drawings Equipment Power Requirements Consultant Equipment Power Requirements Single-Line Drawings Consultant Single-Line Drawings Electrical Area Classification Consultant Electrical Area Classification Cost Estimate Consultant Cost Estimate Reviewed 50% Detailed Design Consolidated 50% Detailed Design Review Comments PCSU, ITM, Operation Group PCSU Consolidate 50% Detailed Design Review Comments Consolidated 50% Detailed Design Review Comments PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, ITM, Operation Group PCSU Consultant 3.3 Detailed Technical Specification Detailed Technical Specification (Divisions 1,11, 13, 15, 16) Consultant Detailed Technical Specification (Divisions 1,11, 13, 15, 16) PCSU, Operation Group % Detailed Design 50% Detailed Design Review Comments Incorporated Consultant 50% Detailed Design Review Comments Incorporated Control Panel Drawings Consultant Control Panel Drawings Loop Drawings Consultant Loop Drawings Equipment Layouts and Control Schematics Consultant Equipment Layouts and Control Schematics SCADA Hardware and Software Requirements Consultant SCADA Hardware and Software Requirements Instrument Ranges and Setpoints Consultant Instrument Ranges and Setpoints Alarm List including Alarm Conditioning Consultant Alarm List including Alarm Conditioning Identify ihistorian, eops, POMS, LIMS Requirements Consultant Identify ihistorian, eops, POMS, LIMS Requirements Paging and Security Consultant Paging and Security Networking and Structured Cabling Consultant Networking and Structured Cabling Equipment and Instrumentation Physical Tag List Consultant Equipment and Instrumentation Physical Tag List Electrical Drawings and Requirements Consultant Electrical Drawings and Requirements Reviewed 70% Detailed Design and Detailed PCSU, OMU, ITM, Consolidate 70% Detailed Design and Detailed Technical Specification g Operation Group Technical Specification Review Comments g PCSU Detailed Technical Specification Review Detailed Technical Specification Review Comments PCSU Comments PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, ITM, Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, ITM, Operation Group PCSU, OMU, Operation Group PCSU, Operation Group Consultant 3.5 Apply for Approval Agency Approvals Application Consultant Agency Approvals Received Consultant % Detailed Design 70% Detailed Design Review and Approval Agency Comments Incorporated Pre-Start Health and Safety Review and Report as required Consultant Consultant 70% Detailed Design Review and Approval Agency Comments Incorporated Pre-Start Health and Safety Review and Report as required Electrical Area Classification as required Consultant Electrical Area Classification as required Cost Estimate Consultant Cost Estimate Reviewed 95% Detailed Design Consolidated 95% Detailed Design Review Comments PCSU, Operation Group PCSU Consolidate 95% Detailed Design Review Comments Consolidated 95% Detailed Design Review Comments PCSU, OMU, ITM, Operation Group PCSU, Operation Group PCSU, Operation Group PCSU, ITM, Operation Group PCSU Consultant % Detailed Design/Tender 95% Detailed Design Review Comments Incorporated Consultant 95% Detailed Design Review Comments Incorporated PCSU, Operation Group 44 of 189 EDOCSLIB-#9088-v1 Page 3 of 7 9/26/2011

45 Implementation Checklists Project Tasks Implementation Checklist Project Phase: Detailed Design (PCS Component) ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 100% Detailed Design/Tender Consultant 100% Detailed Design/Tender Updated Cost Estimate Consultant Updated Cost Estimate Reviewed 100% Detailed Design/Tender Consolidated 100% Detailed Design/Tender Review Comments PCSU, Operation Group PCSU Consolidate 100% Detailed Design/Tender Review Comments Consolidated 100% Detailed Design/Tender Review Comments Final 100% Detailed Design/Tender Consultant Final 100% Detailed Design/Tender PCSU, Operation Group PCSU, Operation Group PCSU Consultant PCSU, Operation Group 45 of 189 EDOCSLIB-#9088-v1 Page 4 of 7 9/26/2011

46 Implementation Checklists Project Tasks Implementation Checklist Project Phase: Construction - Equipment (PCS Component) ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 4.1 Contract Start-up Conduct Kick-off Meeting Consultant's PCS Staff,PCSU, ITM, OMU as required 4.2 Shop Drawings Instrumentation (Reviwed by Consultant) Contractor/Consultant Instrumentation (Reviwed by Consultant) PCSU, Operation Group Servers, PLCs, OITs (Reviwed by Consultant) Contractor/Consultant Servers, PLCs, OITs (Reviwed by Consultant) PCSU, ITM, Operation Group Network (Reviwed by Consultant) Contractor/Consultant Network (Reviwed by Consultant) PCSU, ITM, Operation Group Panels, Cabling (Revied by Consultant) Contractor/Consultant Panels, Cabling (Revied by Consultant) PCSU, ITM, Operation Group MCCs, Switchgear (Reviwed by Consultant) Contractor/Consultant MCCs, Switchgear (Reviwed by Consultant) PCSU, Operation Group Reviewed Shop Drawings Consolidated Shop Drawings Review Comments Final Shop Drawings (Approved by Consultant) PCSU, ITM, Operation Group PCSU Contractor/Consultant Consolidate Shop Drawings Review Comments PCSU Consolidated Shop Drawings Review Comments Contractor, Consultant Final Shop Drawings (Approved by Consultant) PCSU, ITM, Operation Group 4.3 Equipment and Panel Procurement and Fabrication 4.4 FAT/Whiteness Test Sheets Test Sheets for Equipment and Panels (Reviewed by Consultant) Reviewed Test Sheets for Equipment and Panels Contractor/Consultant PCSU, Operation Group Test Sheets for Equipment and Panels (Reviewed by Consultant) Consolidate Test Sheets for Equipment and Panels Review Comments PCSU, Operation Group PCSU Consolidated Test Sheets for Equipment and Panels Review Comments PCSU Consolidated Test Sheets for Equipment and Panels Review Comments Contractor,/Consultant Final Test Sheets for Equipment and Panels (Approved by Consultant) Contractor/Consultant Final Test Sheets for Equipment and Panels (Approved by Consultant) Consultant, PCSU, Operation Group 4.5 Equipment and Panel Factory Acceptance Tests Perform Equipment and Panel FATs and Submit Reports (Reviewed by Consultant) Contractor/Consultant Equipment and Panel FATs Reports (Reviewed by Consultant) PCSU, Operation Group Reviewed Factory Acceptance Test Reports PCSU, Operation Group Consolidate Deficiency Lists PCSU Consolidated Deficiency Lists PCSU Consolidated Deficiency Lists Contractor, Consultant Final Factory Acceptance Test Report (Approved by Consultant) Contractor/Consultant Final Factory Acceptance Test Report (Approved by Consultant) PCSU, Operation Group 4.6 Transition Plan Identify Process Limitations (Reviewed by Consultant) Identify Potential Parallel Equipment, Panels, HMIs (Reviewed by Consultant) Prepare Detailed Schedule of Terminations (Reviewed by Consultant) Identify Network Configuration (Reviewed by Consultant) Reviewed Transition Plan Consolidated Transition Plan Review Comments Contractor/Consultant Contractor/Consultant Contractor/Consultant Contractor/Consultant PCSU, ITM, Operation Group PCSU Final Transition Plan (Approved by Consultant) Contractor/Consultant Process Limitations (Reviewed by Consultant) PCSU, ITM, Operation Group Potential Parallel Equipment, Panels, HMIs (Reviewed by Consultant) PCSU, ITM, Operation Group Detailed Schedule of Terminations (Reviewed by Consultant) PCSU, ITM, Operation Group Network Configuration (Reviewed by Consultant) PCSU, ITM, Operation Group Consolidate Transition Plan Review Comments PCSU Consolidated Transition Plan Review Comments Contractor,/Consultant Final Transition Plan (Approved by Consultant) Consultant, PCSU, ITM, Operation Group 4.7 Equipment Installation and Wiring Contractor 4.8 Pre-Start Health and Safety Pre-Start Health and Safety Review and Report as Required Consultant Pre-Start Health and Safety Review and Report as Required PCSU, Operation Group 4.9 Entity Information Lists Entity (Asset) Information Lists (WMS) (Reviewed by Consultant) Reviewed Entity (Asset) Information Lists (WMS). Consolidated Review Comments Contractor OMU Entity (Asset) Information Lists (WMS) (Reviewed by Consultant) Consolidate Entity (Asset) Information Lists (WMS) Review Comments OMU Contractor,Consultant Final Entity (Asset) Information Lists (WMS) Contractor/Consultant Final Entity (Asset) Information Lists (WMS) OMU EDOCSLIB-#9088-v1 Page 5 of 7 9/26/ of 189

47 Implementation Checklists Project Tasks Implementation Checklist Project Phase: Construction - Software (PCS Component) ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 5.1 Flow Chart Development PCS Implementation Guidelines(Related) PCSU PCS Implementation Guidelines(Related) Systems Integrator PCS Standards (Related) PCSU PCS Standards (Related) Systems Integrator Design Phase Drawings (P&IDs, Electrical, I+C) Consultant Design Phase Drawings (Master P&IDs, Electrical, I+C) Systems Integrator Process Control Narrative Consultant Master Process Control Narrative Systems Integrator eops, WMS, POMS, LIMS Requirements Consultant eops, WMS, POMS, LIMS Requirements Systems Integrator PCSU, ITM, Operation Logic Flow Charts (Reviewed by Consultant Systems Integrator Logic Flow Charts (Reviewed by Consultant Group PCSU, ITM, Operation Reviewed Flow Charts Group Consolidate Flow Charts Review Comments PCSU Consolidated Flow Charts Review Systems Integrator, Comments PCSU Consolidated Flow Charts Review Comments Consultant Final Flow Charts Systems Integrator/Consultant Final Flow Charts PCSU, ITM, Operation Group 5.2 Software Modules Software Modules Library ITM Software Modules Library Systems Integrator 5.3 New Software Modules Flow Chart Development Logic Flow Charts (Reviewed by Consultant) Reviewed Logic Flow Charts Consolidated Logic Flow Charts Review Comments Final Logic Flow Charts (Approved by Consultant) Systems Integrator/Consultant Logic Flow Charts ITM, PCSU Consolidate Logic Flow Charts Review ITM, PCSU Comments PCSU PCSU Systems Integrator/Consultant Consolidated Logic Flow Charts Review Comments Consultant/Systems Integrator Final Logic Flow Charts (Approved by Consultant) ITM, PCSU 5.4 Develop New Software Modules New Software Modules Systems Integrator New Software Modules Consultant, ITM, PCSU 5.5 New Software Modules FAT Perform Modules FAT and Submit Reports (Reviewed by Consultant) Reviewed New Software Modules FAT Reports and Documentation Consolidated Deficiency Lists and Documentation Review Comments Completed New Software Modules and Documentation (Reviewed by Consultant) Systems Integrator/Consultant New Software Modules FAT Reports ITM, PCSU Consolidate Deficiency Lists and ITM, PCSU Documentation Review Comments PCSU PCSU Systems Integrator/Consultant Consolidated Deficiency Lists and Documentation Review Comments Completed New Software Modules and Documentation (Reviewed by Consultant) ITM Systems Integrator,/Consultant 5.6 Software Development Existing Programs - PLC, HMI, Simulation ITM Existing Programs - PLC, HMI, Simulation Systems Integrator 70% Software Development (Reviewed by Consultant) Reviewed 70% Software Development Consolidated 70% Software Development Review Comments Systems Integrator/Consultant ITM, PCSU, Operation Group PCSU 70% Software Development (Reviewed by Consultant) Consolidate 70% Software Development Review Comments Consolidated 70% Software Development Review Comments ITM (HMI,PLC), Operation Group (Screens), PCSU (Coordination) PCSU Systems Integrator, Consultant 5.7 FAT Plan FAT Documentation and Schedule (Reviewed by Consultant) Reviewed FAT Documentation and Schedule Systems Integrator/Consultant PCSU,ITM, Operation Group FAT Documentation and Schedule (Reviewed PCSU, ITM, Operation by Consultant) Group Consolidate FAT Documentation and Schedule Review Comments PCSU Consolidated FAT Documentation and Schedule Review Comments PCSU Consolidated FAT Documentation and Schedule Review Comments Systems Integrator, Consultant Final FAT Documentation and Schedule (Approved by Consultant) Systems Integrator/Consultant Final FAT Documentation and Schedule (Approved by Consultant) PCSU,ITM, Operation Group 5.8 FAT Submit Pre-FAT Version of Software Systems Integrator Pre-FAT Version of Software ITM Perform FAT, Submit FAT Reports and FAT Reports and Documentation (Reviewed PCSU, ITM, Operation Documentation (Reviewed by Consultant) Systems Integrator by Consultant) Group Reviewed FAT Reports and Documentation PCSU, ITM, Operation Group Consolidate Deficiency Lists and Documentation Review Comments PCSU Consolidated Deficiency Lists and Documentation Review Comments Correct Software Deficiencies Identified During FAT (Verified by Consultant) Completed Documentation and Sign-off (Reviewed and Signed by Consultant) PCSU System Integrator/Consultant Systems Integrator/Consultant Consolidated Deficiency Lists and Documentation Review Comments Completed Documentation and Sign-off (Reviewed and Signed by Consultant) Systems Integrator, Consultant PSCU, ITM, Operation Group EDOCSLIB-#9088-v1 Page 6 of 7 9/26/ of 189

48 Implementation Checklists Project Phase: Construction - Testing and Commissioning (PCS Component) Project Tasks Implementation Checklist ID Task Deliverables/INPUT Provider/ PROJECT Deliverables/OUTPUT Recipients/ Custodian MANAGER Reviewers Received Delivered 6.1 Hardware SAT and Training Plan Develop SAT Documentation, Schedule and Training Plan (Reviewed by Consultant) Reviewed SAT Documentation, Schedule and Training Plan Contractor/Consultant PCSU, ITM, Operation Group Develop SAT Documentation, Schedule and Training Plan (Reviewed by Consultant) Consolidate SAT Documentation, Schedule and Training Plan Review Comments PCSU, Operation Group, ITM (Network) PCSU Consolidated SAT Documentation, Schedule and Training Plan Review Comments PCSU Consolidated SAT Documentation, Schedule and Training Plan Review Comments Contractor, Consultant Final SAT Documentation, Schedule and Training Plan (Approved by Consultant) Contractor/Consultant Final SAT Documentation, Schedule and Training Plan (Approved by Consultant) Consultant, Operation Group 6.2 Hardware Training Provide Operation and Maintenance Training Contractor Operation and Maintenance Training Operation Group, OMU (as required) 6.3 Hardware SAT Conduct Hardware Site Acceptance Testing, Submit SAT Reports and Documentation (Reviewed by Consultant) Reviewed Hardware SAT Reports and Documentation Consolidated Hardware SAT Deficiency Lists and Documentation Review Comments Correct Deficiencies Identified During SAT (Verified by Consultant) Completed Hardware Site Acceptance Testing Documention and Sign-off (Reviewed and Signed by Consultant) Contractor/Consultant PCSU, Operation Group, ITM (Network) PCSU Contractor/Consultant Contractor/Consultant Hardware Site Acceptance Testing, SAT Reports and Documentation (Reviewed by Consultant) Consolidat Hardware SAT Deficiency Lists and Documentation Review Comments Consolidated Hardware SAT Deficiency Lists and Documentation Review Comments PCSU, Operation Group, ITM (Network) PCSU Contractor, Consultant Completed Hardware Site Acceptance Testing Documention and Sign-off (Reviewed PCSU, Operation and Signed by Consultant) Group 6.4 Software SAT and Training Plan SAT Documentation, Schedule and Training Plan (Reviewed by Consultant) Reviewed SAT Documentation, Schedule and Training Plan Consolidated SAT Documentation, Schedule and Training Plan Review Comments Final SAT Documentation, Schedule and Training Plan (Approved by Consultant) System Integrator/Consultant PCSU, ITM, Operation Group PCSU System Integrator/Consultant SAT Documentation, Schedule and Training Plan Consolidate SAT Documentation, Schedule and Training Plan Review Comments Consolidated SAT Documentation, Schedule and Training Plan Review Comments Final SAT Documentation, Schedule and Training Plan (Approved by Consultant) PCSU, ITM, Operation Group PCSU System Integrator/Consultant PCSU, ITM, Operation Group 6.5 Software Training Software Training Consultant, System Integrator Software Training Operation Group 6.6 Software SAT Conduct Software SAT, Submit SAT Reports System and Documentation (Reviewed by Consultant) Integrator/Consultant PCSU, ITM, Operation Reviewed SAT Reports and Documentation Group Consolidated Software SAT Deficiency Lists and Documentation Review Comments PCSU Software SAT, SAT Reports and Documentation (Reviewed by Consultant) Consolidat Software SAT Deficiency Lists and Documentation Review Comments Consolidated Software SAT Deficiency Lists and Documentation Review Comments PCSU, ITM, Operation Group PCSU System Integrator, Consultant Correct Software Deficiencies Identified During SAT (Verified by Consultant) System Integrator/Consultant Completed Documentation and Sign-off (Reviewed and Signed by Consultant) Systems Integrator/Consultant Completed Documentation and Sign-off (Reviewed and Signed by Consultant) PCSU, ITM, Operation Group 6.7 Operational Test/System Performance Test Operational Test/Sytem Performance Test Operational Test/Sytem Performance Test Deficiancy Lists (if any) Consolidated Operational Test/Sytem Performance Test Deficiancy Lists (if any) PCSU Correct Deficiencies and Finalize Operational Test/Sytem Performance Test Submitt SAT Version of Software (Approved by Consultant) Consultant, System Integrator Operational Test/Sytem Performance Test PCSU, ITM, Operational Group Consultant, System Integrator System Integrator/Consultant Consolidate Operational Test/Sytem Performance Test Deficiency Lists (if any) Consolidated Operational Test/Sytem Performance Test Review Comments (if any) Final Operational Test/Sytem Performance Test SAT Version of Software (Approved by Consultant) PCSU, ITM, Operation Group PCSU Consultant, System Integrator PCSU, ITM, Operation Group ITM 6.8 As-Built Documentation Prepare Hardware and Software As-Built Documentation (Reviewed by Consultant) Reviewed Hardware and Software As-Built Documentation Consolidated Hardware and Software As-Built Documentation Review Comments Final Hardware and Software As-Built Documentation Consultant, Contractor, System Integrator PCSU, ITM, Operation Group PCSU Consultant, Contractor, System Integrator Hardware and Software As-Built Documentation Consolidate Hardware and Software As-Built Documentation Review Comments PCSU, ITM, Operation Group PCSU Consolidated Hardware and Software As-Built Consultant, Contractor, Documentation Review Comments System Integrator Final Hardware and Software As-Built Documentation PCSU, ITM, Operation Group 6.9 Post Construction Waranty Period Contractor/System Integrator EDOCSLIB-#9088-v1 Page 7 of 7 Appendix B 48 of 189

49 Implementation Guidelines Associated Guidelines 49 of 189

50 Implementation Guidelines Associated GuidelinesThe following list shows related Guideline documents for specific topics that are complementary to this document. Document Name Drawing # edocs # Field Verification Procedure 9091 Field Verification Log 9092 Process Control Narrative 9093 P&ID Standard Symbols and Practices 9094 P&ID Standard Symbols and Practices Attachments P&ID LEGEND XXXX-P&ID-I P&ID STANDARD SYMBOLS -1 XXXX-P&ID-I P&ID STANDARD SYMBOLS -2 XXXX-P&ID-I P&ID Blocks - Gates, Valves, Pumps P&ID Block P&ID Blocks - Blower, Fan, Damper P&ID Block P&ID Blocks - Vortex, Chamber P&ID Block P&ID Blocks - Bridge, Collector P&ID Block P&ID Blocks - Centrifuge P&ID Block P&ID Blocks - Generator, Communitor P&ID Block Colour Convention 9095 RPU Software Programming 9096 Standard Software Modules 9097 Operator Interface Programming 9098 Process Display Programming 9099 Alarming 9100 Instrument and Equipment Testing 9101 Instrument and Equipment Testing Attachments Instrument Testing Log 9102 Field Installation Testing Log 9103 SCADA Factory Acceptance Testing 9104 SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check Sheet 9105 Process Logic Test Sheet 9106 SCADA Site Accecptance Testing and Commissioning 9107 SCADA Factory Acceptance Testing Attachments Factory Acceptance Test and Site Acceptance Test Check Sheet 9105 Process Logic Test Sheet 9106 PCS Documentation 9108 Training 9109 EDOCSLIB-#9086-v of 189

51 1. Field Verification Procedure 1.1 Scope The Field Verification Procedure shall be completed on commencement of pre-design engineering to ensure that the design will meet the requirements of the facility. This will minimize potential future claims by Contractors during construction, resulting from inaccurate information portraying existing conditions. This activity will also accurately define the scope of work required for achieving the targeted level of automation. Important aspects of Field Verification include: 1. Verifying the accuracy of the existing site conditions and as-built documentation. 2. Verifying whether the existing process control system including instruments, electrical equipment, mechanical equipment, field wiring, control panels, and automation can be successfully integrated into the new operating strategies. The testing of instrument, field wiring and mechanical equipment is similar to the testing which is normally completed as part of the construction supervision and acceptance testing for new facilities. Refer to EDOCSLIB-#9101 Instrument and Equipment Testing. 1.2 Field Verification Procedure The following identifies the field verification procedure: 1. Verify the accuracy of all existing (and relevant) documentation and include all outstanding related details. 2. Confirm and document whether each existing instrument meets the design requirements, including range, accuracy, reliability, and installation details. Recommend the instrument upgrades required to achieve the proposed operational requirements, as compared with existing conditions. 3. Where concerns exist, test whether the existing control devices and process equipment can be operated as required under the new strategies. This includes control valves, motors, controls, wiring connections, and other control parameters. 4. Where concerns exist, verify the capacities/ratings of each piece of process equipment versus the new process requirements. 1.3 Completion Criteria Verification of existing instrumentation is deemed complete when all features, functions and information required in accordance with the Master Process Control Narratives and Master Process and Instrumentation Drawings have been documented as existing or not available, and instruments identified as suitably accurate within the anticipated operating EDOCSLIB-#9091-v1 Page 1 of 4 51 of 189

52 range for the process being monitored. This information is to also be recorded on the updated site condition drawings and details. Verification of control devices and mechanical equipment control circuits is deemed complete when the design requirements have been compared against the actual site conditions. Testing of wiring is deemed complete when all wiring related to a specific device or loop (Instrumentation, Control Circuits and Power) has been confirmed to have acceptable voltage and/or current draw, without losses, for all functions and information required in accordance with the Process Control Narratives and Process and Instrumentation Drawings. This information shall be included in the Pre-design Report complete with updated site drawings and details. 1.4 Participants and Responsibilities Consultants - Responsible for reviewing all record documentation and assessing existing conditions, scheduling verification procedures, requesting field assistance from plant personnel, reviewing schedule with plant staff, completing all field verification and tests with assigned plant staff, presenting findings and report to Toronto Water, all completed with the intent to proceed further with the preparation of Detailed Drawings and Specifications for the proposed upgrades. Toronto Water - Provide copies of all existing available site condition information and equipment reports or alternatively provide access to plant library, review Consultants work plan. In many cases, the available documentation is dated or does not exist. The Consultants shall review the field condition to satisfy themselves as to the as-built condition. 1.5 Documentation The requirements for the submission of all documentation to be used and/or produced by the Consultants during the Field Verification Procedure are detailed below Documents Provided By Toronto Water The following documents shall be assembled and reviewed by the Consultant prior to commencing any field investigation(s): 1. Any existing available engineering record drawings 2. Available copies of the Master Process Control Narratives and Master Process & Instrumentation (P&ID) Drawings 3. Any existing available equipment maintenance records, calibration reports, and shop drawings 4. Any available plans of other proposed construction works within area of project EDOCSLIB-#9091-v1 Page 2 of 4 52 of 189

53 5. Available verification sheets with all known information entered prior to site activities. 6. Requirements for eops, WMS, POMS, LIMS and any other information systems Verification Schedule Following the review of all available documentation, the Consultant shall provide a draft field verification schedule for review by Toronto Water. This will include dates for when the various test procedures are to be carried out, and the date and approximate time to when plant staff assistance is required to operate equipment or open panels. For all identified plant areas, and in particular the collection system facilities, detailed schedule coordination is required in order to organize traffic barriers, enter confined spaces, provide proper gas monitoring documentation, and other related tasks. This schedule must be approved in writing by Toronto Water, prior to the commencement of any field investigations. The verification program shall be performed in stages, one for each process area. A verification report shall be submitted to Toronto Water for each process area evaluated Documentation & Reporting The Consultant shall use and/or produce the following standard documentation as part of the Field Verification Report: 1. The Scope of the Specific Verification Procedure 2. Specific Objectives, beyond the General Objectives noted above 3. Field Visit and Inspection Records, including: Field Instrument Verification Logs Instrument Data Sheets Control Device Verification Logs Control Circuit Verification Logs Control Panel Inspection Logs 4. Updated Site Condition Drawings and Device Details, based on the findings of the investigation 5. Red-Lined Master Process & Instrumentation Drawings 6. Summary of Instrument, Device and Equipment Assessments, with the Instrument Verification Report and other test reports contained in an Appendix EDOCSLIB-#9091-v1 Page 3 of 4 53 of 189

54 7. Summary of the Condition of Existing Control, Instrumentation and selected Power Wiring, with the test reports contained in an Appendix EDOCSLIB-#9092-v1 - Field Instrument, Control Device, and Mechanical Equipment, Control Circuit Verification Log is attached to the end of this document as an example. Consultant could request document in its original format. EDOCSLIB-#9091-v1 Page 4 of 4 54 of 189

55 FIELD INSTRUMENT, CONTROL DEVICE, AND MECHANICAL EQUIPMENT, CONTROL CIRCUIT VERIFICATION Page of # EQUIPMENT TAG NUMBER EVALUATION, RECOMMENDATION & COST DOCUMENT VERIFICATION & INITIAL EVALUATION FIELD VERIFICATION PROCEDURE Recomm. Comments/ Reasons Records Available Initial Evaluation & Recommendation Results Reason & Proposed Modification Reuse Repair/ Modify Wiring Replace Other Partial Instrument/Control Device Repair Wiring Replacement Damaged/ Non Functional Out of Range Other (Please Specify) Cost Estimate Technical Manufacturer Data Sheet P&ID,Control Schematic, Electrical dwgs Contract Specifications Calibration Reports Maintenance Reports Product Meets Design Requirements Calibrated Range Meets Design Requirements Accuracy Meets Design Requirements Installation and Application Meets Design Requirements Wiring and I/O Meets Design Requirements Recommend Replacing in Entirety Recommend Replacing all associated wiring Proceed with Field Verification Other Recommendation (Please specify) Test Date Installation & Application Meets Design Loop Drawings and Control Schematics Verified Functions Properly Instrument/Device Output Measured at Controller (ma) Output in Engineering Unit Local Indication Maximum Calibrated Range (Engineering Units) Plant Reported Engineering Reading Error of Instrument Signal Error Accepted (A)/Rejected(R) Recommd Recalibration Recommend Replacing in Entirety Recommend Replacing all associated wiring Recommend Minor Modifications No Modifications Recommended Other (Please Specify) 1 Instrument 2 Control Device 3 Mechanical Equipmen na na na na na na na na na na na na na na na na TOTAL Page 1 $0.00 EDOCSLIB-#9092-v1 55 of 189

56 Process Control Narratives 1. Process Control Narratives 1.1 General The Process Control Narrative is a description of key control system elements and provides details on all manual and automatic modes of process control. It serves different purposes at different stages of the project design and construction phases and shall be used for one or more of the following purposes: 1. Background for planning and design of improvements 2. Process control software description 3. Operations manual 4. Operations practices review 5. Operations training Every existing facility under the management of Toronto Water has a comprehensive process control narrative (referred to as a Master Process Control Narrative or Master PCN. Ongoing expansion and rehabilitation projects with a PCS component will typically require that the Master PCN be modified. Preparation or modification of the Process Control Narratives shall commence during the Predesign phase and expand with more detail during the Detailed Design and Construction phases. Each PCN shall be identical in terms of format. The Pre-design portion of the PCN (also referred to as the Process Narrative) shall list, in generic terms, the equipment to be controlled and the proposed methods to be used. The final PCN shall be an expansion/enhancement of the Predesign portion and shall exactly define the equipment, points, tag names, equipment coding, methods of control and monitoring, etc. Consultants shall comply with this design standard and any proposed deviation must have the approval of the City. 1.2 Update Procedure The PCS component of any project will often involve updating an existing PCN rather than creating a new PCN. The following procedure should be considered when updating a PCN: 1. During pre-design, obtain the existing master PCN in Adobe format and decide which sections will need to be updated and submit request to Toronto Water for document release in native format. Toronto Water will track all requests in order to coordinate PCN updates where multiple projects may be involved. 2. Update the process descriptions of each affected section as needed including any additions to or deletions from the Process Equipment List. 3. During detailed design, update the control system description of each affected section as needed. Additions to the following information will need to be considered: o Control system configuration - if any panels, RPUs, workstations or other major components are being installed EDOCSLIB-#9093-v1 Page 1 of 6 56 of 189

57 Process Control Narratives o I/O List Add any additional I/O and remove any I/O being taken out o Control Logic Describe any new control logic o Interlocks add any new hardware or software interlocks o Alarms expand the alarm list as required o Trending expand the trending description as required o Business Systems expand the list of data for WMS, LIMS, eops, POMS as required 4. After the Construction phase is complete, update all sections with as-built information as required. 5. A new release request should be issued for every phase of the project unless Toronto Water notifies the Consultant otherwise. 1.3 Contents The Master PCN for a facility starts with a General introduction describing the facility in general terms including the overarching design philosophy and treatment goals. The PCN is then divided into process sections, with each section representing a distinct process within the facility. Each process section generally contains the following elements: Process description a general description of the process including physical layout, mechanical equipment, and treatment objectives. See section below for further details. This section should be developed during the Pre-design phase of a project and further refined during Detailed Design and Construction as required. Control system description details of the PCS aspects of the process including I/O lists, alarm details, historian requirements, business systems requirements. See section Process Description Process Definition The process shall be defined first. Definition shall include the process name, its relationship to other processes, its general components and the physical location boundaries as appropriate. Components may include the tanks, pumps and other devices of the main process, and the ancillary processes or systems. Provide a diagram to show the process components. The diagram shall show the process boundary and the inputs and outputs to the process components. Label each input to an output from the process with the name of the process stream and its destination or source. Show all lines as starting or ending from a process component. Do not directly connect lines because the control or lack of control over the junction or splitting of a process stream needs to be described and the process component is the place for this description. An example for the digestion process is shown in Figure 1: Example process diagram. Note that the combustible gas safety system shown in the figure is an ancillary process. EDOCSLIB-#9093-v1 Page 2 of 6 57 of 189

58 Process Control Narratives Digestion Sludge/Scum from Primary TWAS from Thickening Primary Digest Influent Distribution System Primary Digestion Digested Sludge Storage/Transfer System Combustible Gas Safety System Digestion Gas System Emergency Overflow to Primary Treatment Digester Gas to Plant Services Digested Sludge to Dewatering Figure 1: Example process diagram Objectives The objectives of the process and general goals shall be described in this section. These objectives are related to efficiency, effectiveness or quality. In some cases, the process will not have a specific pre-defined treatment objective. In such cases, identify a general objective Process Control Strategy The process control strategy shall describe the process decisions taken to achieve the treatment and transmission objectives. Indicate how often input variables are to be measured and the frequency or event which triggers a process adjustment. State the safe limits and operating targets for the process and operating equipment. Operating targets may be stated as a range if a specific target or set of targets is not required. List priority 1 alarms (alarms that need immediate attention from the operator) and alarms that affect more than one operator (noting the operators affected). Describe the alarms for each device and the process to bring into the SCADA system sufficient alarm details as needed for remote diagnosis or else state the use of a single, common alarm for multiple alarm conditions. For each alarm, state the requirements for activation and method of reset (manual or automatic). Describe automatic alarm reset logic Influent Sources Information on influent sources defines the source and nature of streams entering the specific process being described. The nature of these streams shall be defined in terms of flow variability EDOCSLIB-#9093-v1 Page 3 of 6 58 of 189

59 Process Control Narratives and the percentage of the total stream being treated in the specific process. Information about the main process stream, as well as side streams shall be presented Effluent Destination In this area of the template, information shall be presented on where effluent and waste from the treatment process are normally directed. Estimate the percentage of the stream sent to each destination where the stream is normally directed to more than one destination Process Control Equipment/Devices In this section, describe each piece of equipment or device that can potentially control influents and effluents or change the process as well as what equipment is available to control the process when defining its operation, capabilities and limitations. Identification shall include its name and when applicable, its equipment number, for example: raw sludge pump PRS07. Process equipment includes pumps, valves, screens, chlorinators, mixers, etc. Describe the use of each process control equipment/device. Information includes the device operation, control objectives, performance measures and the control method (either automatic or manual). Describe the flexibility in using process equipment including provisions for future equipment additions. For example, the chlorine processes for water treatment and supply can interchange equipment (i.e. post chlorinators can be used for pre-chlorination if necessary). The chlorine processes for wastewater treatment can interchange equipment (i.e. effluent disinfection chlorinators can be used for plant water disinfection if necessary) Ancillary Process Descriptions Ancillary processes associated with each main process shall be listed. Ancillary processes are all processes associated with the main process which are not specifically involved in transmitting influent to the process or effluent from the process, or the actual treatment process. Ancillary processes shall be described in the same way as the main process in separate process narratives. 1. Describe spill containment for both hazardous gas and liquid spills in a separate subsection of ancillary processes. If the containment provisions serve more than one process, then put the description in a separate process narrative. 2. Describe sample stations/pumps in a separate sub-section of ancillary processes. Description of sample stations and pumps belong with the narrative of the process that uses the sample or sample tests. 3. Power distribution is an ancillary process to most processes. Describe power distribution in a separate narrative with basic descriptions of automatic and manual switching. EDOCSLIB-#9093-v1 Page 4 of 6 59 of 189

60 1.3.2 Control System Description Description Process Control System (PCS) Guidelines Process Control Narratives This section shall describe the operation of the process in terms of the control system, including panels and the control logic. Describe the control system configuration and components and include: 1. Controllers, location of I/O and panels 2. Modes of control (Manual and Automatic modes at each control location; control locations may include: equipment control panel, Motor Control Centre, area panel, central panel, operator workstation) 3. Alarm horn operation, silencing and acknowledge or reset Software Data Points Provide a table showing all real I/O data points and program-generated data points associated with the process. The table should show the following information: 1. Tag type 2. Tag name 3. Description 4. EGU range (in the case of analog points) Control Logic This section shall contain descriptions of: 1. Normal Operation (ie. Automatic logic) including start up and shutdown 2. A table of Control Setpoints associated with the Automatic logic. The table should show tag name, data range, units, and default value. 3. Fault Response Operation. How should the equipment respond to abnormal conditions? Common fault situations include power failure, instrumentation failure, and loss of communication Interlocks 1. Interlocks generated in software by the PLC 2. Interlocks hardwired into the control circuits Alarms Provide a table that shows every alarm condition that can be generated by the process. The table should provide the following information: 1. Tag name 2. Alarm priority EDOCSLIB-#9093-v1 Page 5 of 6 60 of 189

61 3. Alarm limit (in the case of alarms generated from analog points) Process Control System (PCS) Guidelines Process Control Narratives 4. Details of how the alarm is generated ie. if a delay timer is required, if the alarm depends on other conditions (eg. a pump running) 5. Details of how to reset the alarm as well as details of how to enable/disable the alarm if applicable Trending Provide a table detailing which data points should be trended by the system historian. The table should provide the following information: 1. Tag name 2. Suggested trending deadband 3. Suggested grouping for displaying trended data for maximum effectiveness Business Systems Provide a table detailing which data points will need to be made available to Toronto Water business systems. The table should provide the following information: 1. Tag name 2. Business system requiring the data (WMS, POMS, eops, LIMS) Block diagram A block diagram of the system shall be included for all systems. The diagram shall show logical connection and interaction of the control system components. EDOCSLIB-#9093-v1 Page 6 of 6 61 of 189

62 P&ID Standard Symbols and Practices 1. P&ID Standard Symbols and Practices 1.1 General This standard clearly presents Toronto Water intent in developing P&IDs. This standard is based on the Instrumentation Society of America (ISA) standard ISA-S , Instrumentation Symbols and Identification. The material has been reformatted to be directly applicable to the water and wastewater industry. Although this section is based on ISA, it is not constrained by it. 1.2 Purpose of Standard This standard is intended to provide a consistent way of showing information. Consistent presentation will speed reading and improve understanding of the diagrams. Consistent preparation of the diagrams will enable the use of data base access to and from information on the diagrams. This standard will be included by reference into each design project and design or construction contract that prepares or modifies P&IDs. Diagrams already prepared which are inconsistent with this standard will be converted to this standard whenever they are revised for other reasons. Existing diagrams which are not compliant with this standard may also be converted to this standard if people using the diagrams can show benefit for the cost. The P&ID legend sheet and P&ID symbol sheets should be included in each instrumentation and control (I&C) drawing set developed for Toronto Water. 1.3 ISA Reference Standard Duplication and conflict may exist between standards set by ISA and by other agencies or standards setting organizations such as Canadian Gas Association (CGA), National Fire Protection Association (NFPA), and International Standards Organization (ISO). Toronto Water has decided to produce P&IDs that are consistent with ISA in order to have documentation readily understood by as wide an audience as practicable. The use of specialist symbols on P&IDs would result in additional cost for training, documentation and workforce inflexibility. The use of symbols and nomenclature from standards other than ISA will be incorporated into this standard where no conflict exists. The CGA symbols were reviewed in detail as part of preparing this standard. The CGA does not require to prepare documentation using the symbols that the CGA itself uses in its standards and other publications. However, having documentation in a format familiar to boiler inspectors could expedite inspections and licensing of boilers. Therefore, the possibility of using CGA symbols instead of ISA symbols for boiler and digester gas applications was explored. A number of conflicts occurred, particularly where the CGA was showing instrumentation and control information. The major problems came from misunderstanding of CGA instrumentation symbols by people applying ISA meanings to them. An alternative of showing both symbols sets, ISA and CGA, on the same drawing was examined. It would greatly increase drawing complexity and could also be EDOCSLIB-#9094-v1 Page 1 of of 189

63 P&ID Standard Symbols and Practices misinterpreted as indicating two instruments when only one exists. Another alternative was explored of having two drawings, one where ISA symbols would be used if conflict occurs with CGA and another drawing showing only the CGA symbols. This method has several advantages. Two drawings are typically provided now. The ISA style drawing is part of the engineering design phase and the CGA drawing is part of the documentation provided by the boiler or compressor manufacturer. The result of this analysis is to prepare P&IDs consistent with ISA and incorporate symbols from other standards organizations as needed. The electrical symbol sheet (not ISA), likewise, should be included in each drawing set containing panel control diagrams. No duplication or conflict exists between the CGA and Toronto Water electrical symbols. Both Toronto Water and the CGA use ANSI/IEEE electrical symbols and nomenclature. 1.4 Purpose of P&ID P&IDs convey process, instrument and control equipment information. A P&ID should enable anyone reading it (and having a reasonable amount of plant knowledge) to understand the means of measurement and control of the process. A P&ID is a specific schematic representation of the mechanical, electrical, instrumentation and control aspects of a given process. The P&ID is developed from the process design engineer s drawings and is expanded by the control engineer to include other instrumentation as needed. The P&ID must be an accurate representation of the physical process or system and should show equipment in the proper functional relation. A P&ID should include the following: A. Process piping, tanks, structures, and equipment. B. Primary elements, transducers, and analyzers. C. Actuators and final control elements. D. Panels and controls. E. Input/output signals to digital controllers. F. Schematic representations of control signal interconnections. The P&ID is the only document which shows both process and control information. As such, it can be a valuable tool during design construction, and start-up. P&IDs are used during design as a basis for: A. Computer control strategy design. B. Computer input/output point list development. C. Field instrument schedule development. D. Control panel design. E. Electrical interface definition. EDOCSLIB-#9094-v1 Page 2 of of 189

64 F. Mechanical and electrical equipment tagging. G. Overall design coordination. During construction and start-up, P&IDs can be used for: EDOCSLIB-#9094-v1 Page 3 of 22 Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices A. Shop drawing review of computer controls, panel and loop submittals. B. Electrical interface coordination. C. Graphic display development/approval. D. Process control operational checkout. E. Developing as-built and operation and maintenance manuals. F. Training. In the next subsections, selected instrumentation terminology is defined and P&ID symbols are presented and discussed. Both the terminology and symbols were based on the Instrument Society of America (ISA) standards. The symbols were expanded while the terminology was abbreviated. 1.5 Drawing Phases The P&IDs are developed in stages in order to add information at the appropriate time. The usefulness of added details must be weighed against the expense of preparation and review effort. The P&ID development stages are shown in the following table. Major Item Preliminary Detailed Design Implementation Piping, tanks, equipment and valves for process and auxiliary processes Design Required Required Required Sensors, transmitters, switches Required Required Required Actuator type with pneumatic and Required Required Required hydraulic instrumentation Panel - Face mounted instrumentation new/modified custom panels existing custom panels equipment package panels specialty package panels Required Not required Not required Not required Required Required Not required Required Panel - Internal instrumentation new/modified custom panels existing custom panels equipment package panels specialty package panels Not required Not required Not required Not required Required Required Not required Required Required Required Required Required Required Required Required Required Representation Typical is okay No use of typicals No use of typicals Control loops - hardwired Required Required Required 64 of 189

65 EDOCSLIB-#9094-v1 Page 4 of 22 Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices Control loops - software Not required Required Required Setpoints, limits Not required Not required* Not required* * Required on instrument data sheets. 1.6 Scope of Drawings A set of P&IDs for a process or sub-process includes all aspects of the process or subprocess. That is, all of the piping, equipment, instrumentation and controls in the process or sub-process must be included on the drawing set. For example, the set of P&IDs for a pumping sub-process would include the main system, e.g. waste sludge or wash water pumping and all auxiliary systems such as sample system, drainage system, service water, city (potable) water, instrument air, power distribution, gas monitoring, hydraulic and pneumatic systems, security, fire alarm and suppression, safety systems and heating, ventilation and air conditioning. The information includes all components of the process or sub-process. That is, the drawing set must show: automated and non-automated systems, current project additions, deletions and modifications, existing conditions and future provisions if known. The information shown on the P&IDs includes major control logic of the process or subprocess control strategies. That is, the drawing set must show: all hardwired interlocks, totalizers and signal converters, all software controllers and software interlocks. The P&IDs must show all inputs and outputs of the Process Control System and the instruments and equipment which provide the inputs and receive the outputs. The P&IDs do not need to show virtual points except as needed to clarify control logic. 1.7 Update Procedure The PCS component of any project will often involve updating an existing Master P&ID rather than creating a new P&ID. The following procedure should be considered when updating a P&ID: 1. During pre-design, obtain the current set of Master P&IDs for the facility in Adobe format. 2. Identify where equipment and instrumentation pipe line etc upgrades or additions will be required and request specific drawings to be released by Toronto Water in their native CAD format. Toronto Water will keep track of all requests in order to coordinate drawings update in areas where request from more than one contract is issued. 3. During detailed design, update the drawing with the new equipment and instrumentation. Show the additions as future according to Toronto Water drawing standards. Also update the title block to indicate revision number and details. If a new P&ID is required, 65 of 189

66 P&ID Standard Symbols and Practices create a new drawing number consistent with the existing drawing set and submit to Toronto Water for approval. 4. Following successful Site Acceptance Testing of the new equipment, update the drawing so the new equipment and instrumentation is shown normally. Update the title block accordingly. 5. New release request should be issued for every phase of the Project unless Toronto Water notifies Consultant otherwise. 1.8 Terminology The following definitions are from ISA-S , Instrumentation Symbols and Identification. A. Instrument - A device used directly or indirectly to measure or control a variable or both. The term includes control valves, relief valves, and electrical devices such as annunciators and push-buttons. B. Instrumentation - A collection of instruments or their application for the purpose of observation, measurement, control, or any combination of these. C. Primary Element - That part of a loop or of an instrument that first senses the values of a process variable. The primary element is also known as a sensor. D. Final Control Element - The device that directly controls the value of the manipulated variable of a control loop. E. Switch - A device (instrument) that connects, disconnects, selects, or transfers one or more circuits and is not designated as a controller, a relay, or a control valve. F. Controller - A device having an output that varies in response to an input of a measured process variable to regulate a controlled variable in a specified manner. Typical instrument identifications are XC, XIC, and XFIC for controller, indicating controller and ration indicating controller respectively. X is the process or initiating variable. Controller types are auto/manual, computer/auto/manual or supervisory set point. G. Control Station - A manual loading station that also provides switching between manual and automatic control modes of a control loop. It may be called an automanual station or an auto-selector station. The word computer may be substituted for auto when the control station is used with a computer. Typical instrument identification is HK or HIK. In rare cases, XK or CIK may be used where X is the process variable. H. Manual Loading Station - A device having a manually adjustable output that is used to actuate one or more remote devices. It may be called a manual controller, manual station or remote manual loader. The station does not provide switching between manual and automatic control modes. Typical instrument identifications are HFK and EDOCSLIB-#9094-v1 Page 5 of of 189

67 P&ID Standard Symbols and Practices HIXK for hand ratio control station and hand indicating unclassified control station. Manual loading stations are rarely, if ever, used in computer control systems. I. Balloon - The circular symbol used to denote an instrument or instrument tagging. Synonym for bubble. J. P&ID - Process and Instrumentation Diagram. Do not substitute the words piping, instrument or drawing. EDOCSLIB-#9094-v1 Page 6 of of 189

68 P&ID Standard Symbols and Practices 2. Process Layout There are two general types of process layouts: those which show cast-in-place (concrete) or fabricated-in-place (steel) tanks and those which show mechanical equipment or prefabricated process systems. An example of the former is a wastewater secondary treatment process which includes aeration tanks, solid/liquid separators (clarifiers) return and waste sludge pumps, and the associated interconnecting piping and channels. Examples of the latter might include: centrifuges, incinerators, polymer batching system, instrument air supply systems, chlorinators and ejectors, and refining processes. Each layout has certain graphic presentation characteristics which are discussed below. 2.1 Tank System Layout Always use plan views on this type of layout. Although P&IDs aren t required to have a north-south orientation, in general, true north or plant north should be toward the top of the drawing. In some cases, you may wish to rotate the process 90 degrees on the drawing so that it fits better. Rotate the process counter clockwise so that north is to the left. Flow streams may enter and exit the drawing on all four sides. It is not necessary or desirable to maintain a left to right or top to bottom flow direction. Flow streams enter and exit in relation to the process orientation and actual layout of the process. Distinguish between channels and pipes and between prefabricated and cast-in-place tanks. Use double lines spaced about 1/8 to indicate channel or cast-in-place tank walls. Occasionally, you may have difficulty deciding whether to show a conduit as a pipe (single line) or a channel (two pairs of lines to represent walls). Use the following guidelines: Any conduit containing sluice gates, slide gates or flap gates either must be shown as a channel or must contain a gate structure to hold the gate. A conduit which is cast-in-place with a tank or set of tanks should normally be shown as a channel. Do not sacrifice clarity to show the process schematically. An elevation view of an aeration tank and pipe gallery is shown on the top part of Figure 1. The P&ID representation is shown on the bottom part. Notice that only the process tankage and piping are shown on the P&ID. The pipe gallery structure is not shown. Note how the piping layout has been shown on the P&ID. The top pipe has been shown farthest from and the bottom pipe shown closest to the aeration tank. Note how the tank effluent weir and channel were shown. The P&ID is a schematic representation and some liberties can be taken in the layout to provide sufficient space to show all instrumentation and balloons. EDOCSLIB-#9094-v1 Page 7 of of 189

69 P&ID Standard Symbols and Practices DO NOT typify process tanks or piping except through the use of process overview drawings. Some processes may require layering. For example, separate digester drawings might be required to show charging/withdrawal system; heating and mixing; and gas collection and supernatant draw-off. All drawings should use the same base which shows the digester tanks. 2.2 Mechanical Equipment Layout Plan or profile views may be used in this type of layout. In general, all piping to and from mechanical equipment or piping within a prefabricated process system should be shown in plan view. Exceptions might include an incinerator or a catalytic cracker where a profile view would better show the feed pipes at various levels. Flow direction should be from left to right and from top to bottom as much as possible. If a north-south orientation is desired or is shown on other drawings, use that orientation. EDOCSLIB-#9094-v1 Page 8 of of 189

70 P&ID Standard Symbols and Practices HANDRAIL BAFFLE PRIMARY EFFLUENT EFFLUENT WEIR AIR PIPE GALLERY RETURN SLUDGE DRAIN AERATION TANK 5 ELEVATION VIEW ~ ~ ~ ~ ~ ~ ~ AERATION TANK 4 PE ALP M RAS D BAFFLE AIR DIFFUSER ML RAS AERATION TANK 5 ~ ~ ~ ~ AERATION TANK 6 ~ ~ P&ID REPRESENTATION FIGURE 1 EDOCSLIB-#9094-v1 Page 9 of of 189

71 3. Controls Layout 3.1 Control Levels Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices Use a layered approach to distinguish the various levels of control. Place field instrument and equipment balloons above or next to the devices. Locate field controls, motor controls, and area control panels above the field devices at separate levels. Locate computer input/output symbols and tags at the highest level. If you know exactly what computer hardware is being provided, the upper level may be used to show programmable logic controller (PLC), remote terminal unit (RTU), distributed process controller (DPC) or remote station controller (RSC) identification. The normal approach should use the area or unit process identification as recommended by ISA. An I/O point sort by this identification can be used to establish the number of points in each area and the number of PLCs, RTU s, DPCs, or RSCs based on assumed or specified sizing constraints. 3.2 Package Panels Package panels are of two general types: equipment supplier furnished and specialty supplier furnished. Examples of equipment supplier furnished materials are: blower or centrifuge control panels, polymer or similar chemical mixing system control panels if furnished by the mixing system supplier and pneumatic transport system controls. Examples of specialty panels are: motor controllers, variable speed drives, sump pump control systems, and HVAC controls. For package panels, the supplier is responsible for the proper operation of the panel. The supplier must perform the detailed engineering design to meet the functional requirements specified. The functional requirements include the desired operation, face of panel mounted equipment, panel layout, and interfaces with other control panels or computers. In many cases, the panel specifications are included within the equipment specifications and are written by others. For example, a motor controller can be equipped with run lights, motor overload relays and lights, start/stop or on/off push-buttons and switches, local/remote switches and practically any other feature you desire including programmable controllers. Indicate these options on the P&IDs using a combination of balloons for face mounted equipment and signal line labels for signals which are derived interior to the package panel and used elsewhere in the control loop. Show the package panels as boxes with face of panel mounted instruments only. Do not show interconnections, interlocks, interior signal function balloons, or signal function codes within the box. All panels should be labeled in the upper left corner. If the package panel is shown on more than one drawing, the word PARTIAL shall be included with the label. EDOCSLIB-#9094-v1 Page 10 of of 189

72 3.3 Custom Panels EDOCSLIB-#9094-v1 Page 11 of 22 Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices Custom panels are those panels which are designed by the engineer for fabrication by a panel shop or the control system supplier. The supplier of the equipment controlled by these panels usually has no contractual responsibility for the proper operation of the equipment. Show these panels with both face and interior mounted instruments. Face mounted instruments have a single, solid line across the instrument balloon. Interior mounted instruments have a single, dashed line across the instrument balloon. Show balloon interconnections and electrical interlocks. Label panels in the same way as package panels. 3.4 Control Signals Run computer output signal lines to computer-manual selector switches to indicate that the switch selects between computer control and an alternate source of control. Show signals which are to be terminated within a panel by running the signal line up to the package panel border or through the custom panel. If the signal does not require termination in the panel, run the signal around the panel or use the break symbol. See Figure 2. Label signal lines any time you think the function of the signal may be unclear. The label should be enclosed in quotation marks. 3.5 Interlocks Process interlocks are control connections wired between two separate equipment items. For example, a hard-wired control connection that causes an electro-hydraulic check valve to operate whenever a pump starts and stops is a process interlock. Show all process interlocks. Process interlock details are shown on electrical drawings. Drawing notes should describe the function of all interlocks and should refer to the electrical drawings and/or specifications for additional details. Device protective interlock symbols should be shown if this is the policy started in the design guide for the particular project. Protective interlocks are usually provided with the control device. For example, a pump may have protective interlocks which cause shutdown if sensors detect conditions such as excess vibration or high bearing temperature. This type of interlock is generally specified as a part of the device specification. It may or may not be shown on the electrical drawings. Always show these interlocks if the condition is to be displayed, alarmed or monitored. 3.6 Typifying You can typify controls during preliminary design whenever you have typified equipment items. In addition, you can use typicals to reduce duplicated material. However, the typified controls must be functionally process related. Do not typify based on control interface only. For example, do not use one typical to show both return and waste sludge pump control. 72 of 189

73 P&ID Standard Symbols and Practices Do not sacrifice clarity when in doubt, do not typify even if additional drawings will be needed. When typifying controls, the following rules apply: 1. Show all signals to and from balloons, control devices or primary elements as shown for loop 101 in Figure Include equipment tags whenever there are no other balloons which indicate the loop number. See figure Typify panels as in Figure 3. CP 6 on the left side is typical of 2, CP 6 and CP 7. CP 6 on the right side is a single panel containing two sets of control switches. 4. Show the loop numbers, panel designations, and equipment tags of all devices represented by the typical box. As in Figure 3, list the loop number which is shown on the drawing first. Then list the loop number(s) which it typifies. Do the same for control panels and motor controls. 5. Signal line arrowheads should point to the typical. Figure 4 shows how signal lines had to be turned to facilitate typifying. Note: Panels in this example are shown in vertical arrangement one below the other. However due to limited space in the "Local/Field Control Panel" segment on the P&IDs panel could be shown in horizontal arrangement one beside the other or the combination of both. EDOCSLIB-#9094-v1 Page 12 of of 189

74 P&ID Standard Symbols and Practices Figure 2: Control Signals (Note that showing panels is dependent on the design stage). EDOCSLIB-#9094-v1 Page 13 of of 189

75 P&ID Standard Symbols and Practices Figure 3: Typifying controls. EDOCSLIB-#9094-v1 Page 14 of of 189

76 P&ID Standard Symbols and Practices Figure 4: Additional measures when typifying controls. EDOCSLIB-#9094-v1 Page 15 of of 189

77 P&ID Standard Symbols and Practices 4. Overviews and Detail Drawings Set of facility s Master P&ID will be available to consultant in Adobe format 4.1 Plant or System Overview Drawings Prepare a plant or system overview drawing on all projects involving several unit processes, plants, or process areas. It will serve as a road map for the P&IDs. The overview should be prepared after the P&IDs are complete or near complete and should precede the P&IDs in the drawing set. The overview should show: Each unit process, plant or process area by name and number. Flow streams between processes. P&ID or unit process overview drawing numbers. 4.2 Unit Process (Area) Overview Drawings Large or complex processes may require a process overview drawing. The overview may include a limited number of instruments and balloons. The overview should be oriented with north toward the upper part of the drawing if at all possible. Show process stream connections to other areas or unit processes. Subdivide the overview to correspond to the detailed P&IDs. Process stream connections among P&IDs within the unit process need not be shown. 4.3 Device Overview Drawings Large or complex devices may be shown as an overview symbol on a P&ID and then detailed on a separate drawing. The overview should identify the device, name the detail reference and show which panels contain instrumentation presented on the detail. If a panel is dedicated to the device it should only be shown on the device detail. Some frequently occurring devices may also be shown as an overview symbol on a P&ID and detailed on another drawing as standard devices. The number of overview and detail layers should be minimized to reduce flipping between drawings. One drawing would be more convenient in the field, because of less paper handling and less chance of not bringing all the detail needed. Its usage should be restricted to where it is needed for clarity and consistency. The choice and number of standard device designations needs to be managed on each project Process Detail Drawings This diagram shows full detail of the process and references P&ID layouts for standard devices. Information shown on this drawing includes: flow meter size, tank size and EDOCSLIB-#9094-v1 Page 16 of of 189

78 P&ID Standard Symbols and Practices capacity, trip points for level, pressure, temperature and similar switches which are set at a fixed point in the field. Pipe sizes would be included on new construction. Process parameters and set points would be shown on the actual control system display screens, but would not be included on the P&ID. 4.5 Device Detail The device detail shows full detail of instrumentation related to a device. It may be shown on an overview or process detail or on a separate diagram. 4.6 Redundant Information Information should only be shown once. Do not repeat symbols for the same I/O point, instrument or piece of equipment. EDOCSLIB-#9094-v1 Page 17 of of 189

79 5. Symbol and Legend Sheets Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices Refer to Drawings XXXX-P&ID-I-0101, 0102, 0103 attached to this guideline. The content of these sheets should be used for all Toronto Water Projects and could be changed only with Toronto Water approval. Content of the drawing should be inserted into the facility Master P&ID title block changing XXXX with appropriate facility code. Further details are discussed below. 5.1 Primary Element Symbols Identify the type of primary element early in the project. Mechanical layouts, instrument takeoffs, instrument application engineering, and quality control require definition of the type of primary element. Minimize the use of unclassified primary element symbols. The most common use of the unclassified flow symbol is for a flow switch. Use the unclassified level symbol when a pressure sensing instrument is used to indicate level, or for vendor packaged level instruments where the type is vendor dependent. 5.2 Miscellaneous Symbols Any special, non-standard symbols can be added to this group with TW approval. The sight glass must be used in the vertical position as shown. 5.3 Actuator Symbols Always show the fail position designation at the lower right of the actuator symbol for the fail-safe action in case of loss of air, hydraulic or electric power supply or control signal. Use abbreviations: FO (fail open), FC (fail close) or FL (fail lock). 5.4 Valve and Gate Symbols No specific guidelines. 5.5 Equipment Symbols A wet pit pump does not have inlet piping. A screw pump does not have inlet or discharge piping. The turbine supply and return lines are shown as per ISA. The process stream flows through the coil of the heat exchanger. Cooling or heating liquid enters perpendicular to the process stream. The ejector is sometimes called an eductor, jet or injector. The motive flow stream always enters the rear of the symbol. EDOCSLIB-#9094-v1 Page 18 of of 189

80 5.6 Instrument and Function Symbols Process Control System (PCS) Guidelines P&ID Standard Symbols and Practices Use separate, touching balloons for instruments that have more than one function such as controllers, control stations, valve actuators, multiple electrode level switches, sludge blanket detectors, and lighted switches. Designate a panel mounted alarm light as: LLL Level Light Low For any light, the second letter must be an L. Placement of the L in the second position is needed to distinguish between readouts and modifiers. For example: 1. L A L 2. L L 3. L L L L level alarm low = level low (level light makes no sense) = level light low 4. = level light low low Designate a panel mounted alarm annunciator point as: LAL Level Alarm Low Note that annunciators are distinct from alarm lights. An alarm light simply lights under alarm conditions. An annunciator requires an acknowledgment to silence horns, stop the light from flashing or other actions. An annunciator may be a single light or may be part of an annunciator panel. 5.7 Input and Output Signals to Digital Controllers See EDOCSLIB-#6454 Equipment and Data Tagging. 5.8 General Notes Put general note (See P&ID Symbol and Legend Sheet) on all legend sheets. Add other notes as may be required for the project. EDOCSLIB-#9094-v1 Page 19 of of 189

81 P&ID Standard Symbols and Practices The instrument identification table is from Instrument Society of America (ISA) Standard S5.1, 1984 Instrumentation Symbols and Identification. Do not change the table without Toronto Water approval. Attach the balloons for valve open and valve closed limit switches to the stem of the valve operator. 5.9 Flow Stream Identification Identify all flow streams. Use the flow stream identifications shown on the P&ID Legend Sheet. If the project requires other flow stream identifications, you can alter the table shown. However, try to minimize the number of changes. Except for plant influent and primary influent, label all flow streams based on the upstream process. For example, use primary effluent not secondary effluent. If a line contains two flow streams, label both. For example, PS/SS is a flow stream consisting of both primary sludge and secondary sludge. The flow stream should be annotated to clarify the stream. If the flow stream must be annotated, enclose the annotation in quotes. For example, a plant air system of a particular pressure range could be designated: 5.10 Equipment Tagging PA2 Plant Air 5 Bar Use the rectangular equipment tag box if no balloon is used. If you use equipment tags which do not contain the loop number, you should use balloons to show the loop number. Equipment tags are mandatory when typifying to show which device is associated with which loop Flow Stream and Instrument Line Symbols Use three different line weights to distinguish flow streams. The main flow stream is the liquid train, the secondary flow streams include sludge and process air, and other flow streams include chemicals, instrument air, drains, water, and steam. Use dashed lines to indicate alternate flow streams. These streams included bypasses and streams which are not used for normal operations or for automatic backup. Show all cast-in-place open channels and tanks in plan view and use double lines to indicate walls. Double lines help to distinguish between closed conduits (pipes) and tanks and open channels. Line weights and dashed lines are used as in the two previous items. Use arrowheads to indicate direction of flow. Always use arrowheads where pipes connect and where pipes enter tanks. Do not use arrowheads upstream of primary EDOCSLIB-#9094-v1 Page 20 of of 189

82 P&ID Standard Symbols and Practices elements, gates, pumps, valves, and other equipment. Use enough for clarity and ease of tracing the flow stream. When annotating flow streams or signal lines, enclose the annotation in quotes. Label process equipment with a functional name, e.g. raw sludge pump or treated water pump. Underline the names of pumps, tanks and other process equipment. All process flow streams and signal lines which are continued on another drawing shall be linked using the labeled arrowheads. The arrowheads must be labeled with unique labels. The label is composed of the drawing number where the line is continued and an arrowhead number unique to that drawing. In complex cases, the arrowhead number should be made unique to all drawings in a sub-process. It is not necessary to add any other notes to indicate origin or destination. Minimize the use of the continuation symbol, especially for flow streams. Use the slashed arrowhead to indicate an origin or destination which is not a part of the project and which is not continued on any other P&ID. Notes must be added to indicate origin or destination. Non-process lines such as potable and non-potable water used for flushing or pump seals, instrument-air lines and similar ancillary piping may be shown without slashed arrowheads Explanatory Notations Hand switch and instrument designations should be placed at about the 1 o clock position if at all possible. If confusion will result, place the designation at the 5 o clock position. HS C/L C/L Prefered position for explanatory notations. Alternate position Use CL (computer/local) hand switches whenever possible. In situations where there are two levels of panels, each with hand switches, use RL (remote/local) on the local level and CM (computer/manual) on the higher level. Use MFS (modulate faster/slower) and OSC (open/stop/close) momentary hand switches for modulating control. Spring return to center hand switches are similar to push-buttons. If a spring return switch is used, place a note on the P&ID. If the project requires many spring return switches, supplement the explanatory notations. Use HMS to designate momentary switches. Latching type push-buttons are not covered. If they are used, annotate them similar to spring return switches. Use HS to designate maintained switches. Hand switches and push-buttons may be equipped with lights. In most cases, the lights are connected to field contacts such as valve position switches or motor running auxiliary relays. In some cases, the light may be used to indicate the switch position. EDOCSLIB-#9094-v1 Page 21 of of 189

83 P&ID Standard Symbols and Practices In some applications, you may wish to show both on and off status using two lights driven from one auxiliary relay. Show analysis instruments which are mounted in tees or which use pipe saddles or corporation stops as tapped. Show all signal converters including current loop isolators if used. Do not use current isolators indiscriminately. They are expensive, become an additional component which can fail, and require calibration. Do not show interposing relays in panels. These are covered in the panel drawings and specifications. 6. Attached Drawings The following drawings are attached as part of this guideline. Drawing Number Document Subject Number XXXX-P&ID-I P&ID LEGEND XXXX-P&ID-I P&ID STANDARD SYMBOLS -1 XXXX-P&ID-I P&ID STANDARD SYMBOLS -2 P&ID Block GATES, VALVES, PUMPS P&ID Block BLOWER, FAN, DAMPER P&ID Block VORTEX, CHAMBER P&ID Block BRIDGE, COLLECTOR P&ID Block CENTRIFUGE P&ID Block GENERATOR, COMMUNITOR 7. Glossary CGA DPC HVAC I&C I/O ISA MC MCC P&ID PLC RSC NFPA Canadian Gas Association distributed process controller heating, ventilation and air conditioning instrumentation and control input/output Instrument Society of America motor controller motor control centre process and instrumentation diagram programmable logic controller remote station controller National Fire Protection Association EDOCSLIB-#9094-v1 Page 22 of of 189

84 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT ENTER FACILITY NAME GENERAL P&ID LEGEND INSTRUMENTATION-MASTER P&ID No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED DESIGN: SCALE: DATE: DRAFTING: N.T.S JULY, 2001 CHECK: CONTRACT No. DRAWING NUMBER: XXXX--P&ID-I-0101 SHEET No of 189

85 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH OPERATIONAL SUPPORT ENTER FACILITY NAME GENERAL P&ID STANDARD SYMBOLS - 1 INSTRUMENTATION-MASTER P&ID No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED DESIGN: SCALE: DATE: DRAFTING: N.T.S JULY, 2001 CHECK: CONTRACT No. DRAWING NUMBER: XXXXX-P&ID-I-0102 SHEET No of 189

86 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT ENTER FACILITY NAME GENERAL P&ID STANDARD SYMBOLS - 2 INSTRUMENTATION-MASTER P&ID No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED DESIGN: SCALE: DATE: DRAFTING: N.T.S JULY, 2001 CHECK: CONTRACT No. DRAWING NUMBER: XXXX-P&ID-I-0103 SHEET No of 189

87 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 1 - GATES, VALVES, PUMPS PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

88 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 2 - BLOWER, FAN, DAMPER PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

89 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 1 - GATES, VALVES, PUMPS PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

90 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 4 -BRIDGE, COLLECTOR PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

91 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 5 - -CENTRIFUGE PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

92 DIRECTOR, TORONTO WATER OPERATIONAL SUPPORT ALEX MARICH DIRECTOR, OPERATIONAL SUPPORT GENERAL P&ID BLOCKS 6 - GENERATOR, COMMUNITOR PCS STANDARDS DESIGN: DRAFTING: CHECK: CONTRACT No. No. DATE REVISIONS / CONTRACT NO. INITIAL SIGNED SCALE: DATE: N.T.S JULY, 2001 DRAWING NUMBER: SHEET No of 189

93 Colour Convention 1. Colour Convention 1.1 General This design guideline sets out the use of colours to indicate information in a consistent manner. This guideline reserves some colours for the representation of alarms and status conditions and therefore may not be used for any other meanings or other uses. Consultants shall comply with this design guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City. In some instances, the use of colours is defined by codes governing fire protection, boilers, generators, engines, electrical distribution, personal health and safety and similar topics. In case of conflict between this guideline and codes, the code having jurisdiction will prevail. 1.2 Field Indicating Lights Field status and alarm lights shall conform to the following colour convention: ITEM Running, burner on, valve open, breaker closed Stopped, safe, burner off, valve closed, breaker open Overload, warning Intermediate position (valve) Alarm COLOUR Red Green Amber (should it be yellow?) White or Flashing White Flashing Red Where field status and alarm lights are being added to an existing facility where such devices already exist, the Consultant shall consult with the City if the existing devices do not conform to the above convention. 1.3 Operator Display Operator displays, at all levels, shall conform to the following colour convention: ITEM COLOUR NAME** HEX CODE** DECIMAL** Screen Background (except alarm summaries) Cyan Color104 C0C Equipment/Device Status Digital On, OK Red Bright Red 0000FF 255 Open, OK (valves) Red Bright Red 0000FF 255 EDOCSLIB-#9095-v1 Page 1 of 4 93 of 189

94 Colour Convention ITEM COLOUR NAME** HEX CODE** DECIMAL** Active device Red Bright Red 0000FF 255 Off, OK Green Bright Green 00FF Closed, OK (valves) Green Bright Green 00FF Inactive devices (off scan) Grey Gray75 C0C0C Power off Grey Gray75 C0C0C Intermediate position (valves) Yellow Bright Yellow 00FFFF Priority 1 alarm (graphic symbol) Priority 2 alarm (graphic symbol) Priority 3 alarm (graphic symbol) Flashing* Flashing* Flashing* Priority 1 alarm page background Red Bright Red 0000FF 255 Priority 2 alarm page background Yellow Bright Yellow 00FFFF Priority 3 alarm page background Cyan Color Analog Normal range White White FFFFFF Advisory range Yellow Bright Yellow 00FFFF Alarm range Red Bright Red 0000FF 255 Off scan (last value) Grey Gray75 C0C0C * Flashing is between current status colour and grey at normal flashing frequency (84 to 168 flashes per minute). ** CODE refers to the Blue, Green, Red colour intensities which are in the range of 00 to FF in hexadecimal. E.g. White is made up of Blue at maximum intensity FF, Green at maximum intensity FF and Red at maximum intensity FF. The Hex code for white is therefore FFFFFF ** DECIMAL refers to the decimal conversion of the Hex Code. This is used in the ifix properties window to specify colour properties for an object. (Most colour picker software uses Red, Green, Blue to generate the hex code instead of Blue, Green, Red which ifix uses.) 1. Control Modes Local Status Colour Name Hex Code Decimal 1. Local Black Black Non-controllable from Computer (RPU) Grey Gray 75 C0C0C Computer Status EDOCSLIB-#9095-v1 Page 2 of 4 94 of 189

95 Colour Convention Computer (RPU) auto Blue Bright Blue FF Computer (RPU) manual White White FFFFFF Miscellaneous Equipment Outlines (tank, etc.) White White FFFFFF Building Outlines, etc. White White FFFFFF Identification Labels Dark Background Colour Name Hex Code Decimal Screen Titles White White FFFFFF Equipment White White FFFFFF Other White White FFFFFF Light Background Colour Name Hex Code Decimal Screen Titles Dark Blue Blue Equipment Robin Blue Bright Cyan FFFF Other Black Black Where operator displays are being added to an existing system where operator displays already exist, the Consultant shall consult with the City if the existing displays do not conform to the above convention. 1.4 Process Piping The colours shown on displays are modified from the MOEE guide for water pollution control plants, natural gas and propane installation codes. Banding is not used on displays for easier understanding of line continuity. Material Handled Pipe Colour from MOEE Guide Pipe Colour for Displays Name Hex Code Decimal Sewage Light Grey Light Grey Gray88 E1E1E Primary Tank Effluent Light Grey Light Grey Gray88 E1E1E Secondary Clarifier Light Grey Gray88 E1E1E Effluent Chlorinated Effluent Medium Blue Color57 FF8C2C Sludge and Scum Dark Brown Brown Color78 6A59A Grit and Screenings Brown Color78 6A59A Non-potable Water, Plant Water, Pre-Treated Water Blush Yellow Medium Blue Color57 FF8C2C Potable Water, City Water Light Blue Light Blue Bright Cyan FFFF Potable Hot Water Dark Blue Light Blue Bright Cyan FFFF EDOCSLIB-#9095-v1 Page 3 of 4 95 of 189

96 Colour Convention Material Handled Pipe Colour from MOEE Guide Pipe Colour for Displays Name Hex Code Decimal Drainage Black Light Grey Gray88 E1E1E Raw Water Black Black Chlorine Gas Yellow Yellow Bright Yellow 00FFFF Chlorine Solution Yellow with Light Blue Band Yellow Bright Yellow 00FFFF Digester Gas or Fuel Oil Orange Orange Orange 2C82FE Natural Gas, Propane Yellow* Yellow* Bright Yellow 00FFFF Compressed Air Vine (Gloss) Light Green Bright Green 00FF Circulating Air Vine (Flat) Light Green Bright Green 00FF Alum Metallic Green Yellow-Green Color99 00D2A Ferric Chloride, Ferrous Metallic Green Yellow-Green Color99 00D2A Chloride with Orange Band Polyelectrolytes Metallic Green Yellow-Green Color99 00D2A Sodium or Calcium Yellow with White Yellow Bright Yellow 00FFFF Hypochlorite Band Lime White with Orange White White FFFFFF Band Ozone Yellow Bright Yellow 00FFFF Fluoride Purple Color141 A000A Sulphur Dioxide Orange Orange 2C82FE Aqua Ammonia Dark Blue Color120 A0A Sodium Hydroxide Lime Green Color85 00E Potassium Hydroxide Lime Green Color85 00E Polymer Grey Gray75 C0C0C Powder Activated Carbon (PAC) Grey Gray75 C0C0C Other Chemicals Yellow Bright Yellow 00FFFF *Natural gas and propane piping colour identification are governed by separate codes. Although the MOEE guideline for natural gas and propane does not conflict with the codes per se, the use of yellow colour is recommended to avoid any confusion in piping identification. Note: sampling lines will retain their process stream colour. Piping is to be identified to the requirements of GSB-24.3 Code for Piping Identification. The colour code for piping identification bands is: Classification Background Colour Legend Colour. Hazardous Materials Yellow Black Inherently Low Hazard Materials Green White Fire Protection Red White EDOCSLIB-#9095-v1 Page 4 of 4 96 of 189

97 RPU Software Programming 1. RPU Software Programming 1.1 General This guideline is for the structure and documentation of Remote Processing Unit (RPU) programs. This document is to establish standards for a consistent approach to programming which will enable: 1. the maximum re-use of programs; 2. Reduced time to troubleshoot programs; and 3. Higher confidence and usability of RPU-based control systems. Consultants shall comply with this design standard in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City 1.2 Standards All programs shall conform to IEC Programmable controllers - Part 3: Programming languages. In addition, the programs written for critical or hazardous applications shall conform to CAN/CSA-Q396 Quality Assurance Program for the Development of Software Used in Critical Applications. 1.3 Documentation Flow Charts 1. The method of documenting software logic design is the flow chart diagram, a type of sequential function chart. Document all applications programs in this manner. 2. Software for developing the flow charts is Visio only. 3. The flow chart is a design tool to get concurrence that functional requirements have been understood and incorporated into the design. 4. Show only automatic control mode. 5. The intent is to flow chart a process on one to two 11x17 sheets. The simple, high-level, single sheet concept may actually need multiple sheets depending on the complexity of the controls. 6. Show generic setpoints or test setpoints if pertinent to understanding the logic. 7. Show modules; represented by a box in the flow chart. The module type should be clearly indicated. 8. Show process interlocks. 9. Keep charts up to date to reflect the actual built state of the software. EDOCSLIB-#9096-v1 Page 1 of of 189

98 RPU Software Programming Flow chart shapes should be used consistently as follows: Function Logic Block Modules States Decisions Operator Selections Message Start or Stop Continuation Shape Plain box Box with end bars. Box with cross Diamond Trapezoid Parallelogram Oval Circle An example of a flow chart is shown in Figure 1: Flow Chart Example. EDOCSLIB-#9096-v1 Page 2 of of 189

99 RPU Software Programming Start Grit Tank Normal Operation Operator selects - Cleaning Cycle timer (xxx Hours) - Total flow Target (xxx m3) - Tank in service - Out of service Bar Screen Normal Operation Operator selects - Interval Max cycle time (xx minutes) - Interval Min cycle time (xx minutes) - Max totalized Flow rate (xxx m3/sec) - Set Screen high level switch - Duration cycle time for high level operation (xxx minutes) Grit Unwatering Pump System Operator selects - Duty and standby pump - Unwatering pump cycle time (xxx minutes) - Min Tank Level (xx.x m) - Low-Low Tank Level (xx.x m) Grit Handling Watering System Operator selects - Duty and standby pump - Unwatering pump cycle time (xxx minutes) - Min Tank Level (xx m) - Low-Low Tank Level (xx m) In service Out of Service Grit Tank Outlet Valve Opened No Call Module to open Grit Tank Outlet valve Grit Tank Inlet Valve Closed No Call Module to close Grit Tank Inlet valve Yes Grit Tank Inlet Valve Opened No Call Module to open Grit Tank Inlet valve Yes Grit Tank Outlet Valve Closed No Call Module to close Grit Tank Outlet valve Yes Yes Tank In Service Grit Tank Level >1m No Air Header Closed Tank Out of Service Yes No Start Cleaning Cycle Timer and Accumulate Flow Air Process Header Opened No Call Module to operate Air Process Header Operator Start tank cleaning Start Bar Screen Process Cleaning Cycle Timer Done No Total Flow Reached Target Tank Cleaning Process Required Yes Yes Totalized Flow Rate Target reached No Start Maximum Time Interval Operation Tank Cleaning Process Required Unwatering Valve Opened No Call Module to open Unwatering Valve Yes Yes High Level Target Reached No Start Minimum Time Interval Operation Advisement Send to SCADA Tank Cleaning Process Started Yes Start High Level Operation Cycle time Target Reached Yes Advisement Send to SCADA Figure 1: Flow Chart Example EDOCSLIB-#9096-v1 Page 3 of of 189

100 RPU Software Programming Control Program Listings 1. All application programs shall be completed using ladder logic. 2. The entire program shall be annotated with comments. Explain what the program is doing, and why. 3. Rung/IO comments shall be grammatically correct and in the English language. They shall be sufficiently verbose to allow on-site troubleshooting. 4. Each I/O, derived value, register and coil, subroutine and object shall be identified by descriptor. 1.4 Programming The design logic shown in flow charts shall be structured to use standard software modules. Where possible, the program shall make use of standard modules. Standard modules are described in EDOCSLIB-#9097 RPU Standard Software Modules. The standard modules are not to be altered without the permission of the Toronto Water. Any unusual or specific data manipulation is to be performed outside of the modules Update Procedure The PCS component of any project will often involve updating an existing program rather than creating a new program. The following procedure should be considered when updating a program: 1. During pre-design, decide which existing RPUs will be involved in the project. The predesign report should contain this list and determination made that capacity exists in those processors and I/O racks based on the estimated I/O or determine what upgrades are required to create the capacity 2. During detailed design, create drawings for any necessary hardware upgrades 3. During construction, the Systems Integrator will request the existing program(s) from Toronto Water. Toronto Water will keep track of all requests in order to coordinate updates and version control. 4. During programming, the Systems Integrator will use the memory map guidelines to determine areas of memory to use. This is critical to ensure consistency which will make future expansions and program maintenance easier. 5. New rungs should be commented to clearly show that they are part of the current project and help differentiate them from existing programming. New Auto logic should be contained within new routines rather than adding to existing routines to help differentiate new logic from existing logic. New I/O should be handled in existing routines and appropriately commented. 6. FAT/SAT documentation should indicate which routines were modified or added so Toronto Water staff has the opportunity to determine and test the effect on existing programming. EDOCSLIB-#9096-v1 Page 4 of of 189

101 RPU Software Programming Analog Inputs Scaling of analog values, shall be performed only in the Operator Workstation software in accordance with the following requirements: 1. All analog points shall be passed through the RPU as unscaled, primary data. 2. No scaling of inputs is permitted in analog input modules. 3. Where data is manipulated in the RPU for purposes of control, such manipulations shall not be interposed between the input from the instrument and the Operator Workstation software. 4. Data manipulations such as summation for displays or historical data shall be done in the Operator Workstation software. The method of scaling is shown in Figure 2 Analog Data Flow Process Equipment PLC Control program Operator Workstation Control signal Controller Scaling for control purposes binary unscaled Scaling for control purposes Database Field sensors Flow, level etc ANIN Analog Input Module binary unscaled Figure 2 Analog Data Flow Memory Organization 1. The following paragraphs set out principles for memory allocation and program structure. Memory allocation for GE RPUs is presented in section RPU memory shall be organized into three major sections: I/O Registers; Control; and Communication (if needed). 3. Each section should contain memory for expansion up to the overall limit defined in the technical specifications for the RPU. Within each section, the memory should be further EDOCSLIB-#9096-v1 Page 5 of of 189

102 RPU Software Programming organized into logical blocks, similar to the definition in the memory allocation in section I/O Registers 1. I/O should be organized in the same hierarchy as used for program structure. For RPUs in which I/O point numbering is not restricted to a pattern, the I/O should be assigned to addresses within the I/O register section. The I/O register should be split by type of I/O: analog inputs, analog outputs, digital inputs and digital outputs. I/O for similar devices should be put in the same order of address. 2. For RPUs in which I/O point numbering is restricted to a pattern, the assignment of addresses may be partially predetermined. As much as possible, follow the considerations for organization given in the preceding paragraph Control 1. The control logic should present all control actions directly and avoid using the same address or block of addresses for multiple uses. Logic for control should be organized into blocks by device and structured consistently following the guidelines herein. 2. Logic for the watchdog timer and system clock should be located first in this section if they are not part of system software or hardware. 3. General rule for Ladder Logic Rungs: Normally open input contacts will be used first. Normally close input contacts will be used next. 4. In normal situations, a rung can be separated into two sections: The first section is the Control logic. The second section is the Interlock logic. 5. The order for the control logic section is: Computer mode (If computer auto and computer manual modes are required in the rung, then the parallel branch function will be used. Computer auto control logic is always on top of the branch). Operation request (momentary contact). Operation Inhibit (if needed, can be more than one contact). 6. The order of the interlock logic section is: Operation permissive (can be more than one contact); Stop device request (can be more than one contact); then Device failure (can be more than one contact). EDOCSLIB-#9096-v1 Page 6 of of 189

103 RPU Software Programming Control Logic Examples: 1. Rung layout with computer mode: Computer Operation Operation Stop Device mode permissive permissive request failure Output Control logic section Interlock logic section 2. Rung layout with computer auto and manual modes: Computer Operation Operation Operation Stop Device Rung auto mode Request inhibit permissive request failure Output Computer Operation Operation manual mode Request inhibit Rung Output Control logic section Interlock logic section EDOCSLIB-#9096-v1 Page 7 of of 189

104 RPU Software Programming The following standard Bit Allocation shows a typical data map for pump and valve devices. This structure shall be followed as closely as possible. Any deviation will require the approval of Toronto Water. Pump/Rotating Device Valve Bit 1 In computer mode In computer mode Bit 2 Not available warning Not available warning Bit 3 Running Status Open Status Bit 4 Spare Close Status Bit 5 Computer auto request Computer auto request Bit 6 Computer manual request Computer manual request Bit 7 Start request Open request Bit 8 Stop request Close request Bit 9 Spare Spare Bit 10 Alarm reset request Alarm reset request Bit 11 Auto start request by auto process Auto Open request by auto process Bit 12 Auto stop request by auto process Auto Close request by auto process Bit 13 Spare Spare Bit 14 Spare Spare Bit 15 Interlock alarm #1 Interlock alarm #1 Bit 16 Interlock alarm #2 Interlock alarm #2 Bit 17 Ready to operate Ready to operate Bit 18 Computer auto mode Computer auto mode Bit 19 Computer manual mode Computer manual mode Bit 20 In running condition In open condition Bit 21 In stopped condition In closed condition Bit 22 Start permissive Open permissive Bit 23 Alarm Stop request Close permissive Bit 24 Start command Open command Bit 25 Stop command Close command Bit 26 Spare Spare Bit 27 Reset start/stop command Spare Bit 28 Restart inhibit Spare Bit 29 Pump running latch Spare Bit 30 General failure General failure Bit 31 Uncommanded start alarm Uncommanded open alarm Bit 32 Uncommanded stop alarm Uncommanded close alarm Bit 33 Fail to start Fail to open Bit 34 Fail to stop Fail to close Bit 35 No request by RPU Unknown position Bit 36 Spare Position lost track Bit 37 Spare Spare Bit 38 Run 1 hour Failure alarm start timing Bit 39 Reset restart inhibit Spare Bit 40 Spare Spare EDOCSLIB-#9096-v1 Page 8 of of 189

105 RPU Software Programming Bit 41 Auto Start request by process Auto Open request by process Bit 42 Auto Stop request by process Auto Close request by process Bit Spare Spare The following standard Word allocation shows a typical data map for counters and timers. This structure shall be followed as closely as possible. Any deviation will require the approval of Toronto Water. Internal Counter Internal Timer Word 1 Counter 1 (Current Value) Timer 1 (Current Value) Word 2 Counter 1 (Preset Value) Timer 1 (Preset Value) Word 3 Counter 1 (Control Word) Timer 1 (Control Word) Word 4 Counter 2 (Current Value) Timer 2 (Current Value) Word 5 Counter 2 (Preset Value) Timer 2 (Preset Value) Word 6 Counter 2 (Control Word) Timer 2 (Control Word) Word 7 Counter 3 (Current Value) Timer 3 (Current Value) Word 8 Counter 3 (Preset Value) Timer 3 (Preset Value) Word 9 Counter 3 (Control Word) Timer 3 (Control Word) Word 10 Spare Spare Communications 1. Blocks of memory may need to be allocated for communication with other intelligent devices to manage communication speed. Communication blocks are not required for GE RPUs connected by Ethernet. 2. For example, communication with an operator station may require that a separate block or blocks be set up for an alarm and event array. The alarm and event array may be split into separate blocks, one for alarms and one for events. Even if alarms are also used for control, they should be copied to the alarm block. Separation of alarms is useful for testing alarm reporting separate from control logic. 3. Within the communication section, separate blocks should be set up for communication to minimize the number of messages needed to communicate data. Typically this means that a block for analog values, a block for receipt of operator commands and a block for setpoints and other parameters should be set up. A block for communication to and from other RPUs may need to be separate from the operator station interface blocks in order for fast communications. EDOCSLIB-#9096-v1 Page 9 of of 189

106 RPU Software Programming 1.5 Memory Allocation for GE RPU A. Analog Input and Analog Output 1. Analog Input: %AI00001 to %AI Analog Output: %AQ00001 to %AQ00512 B. Analog Internal Default 1. Analog Internal: %R00001 to %R12032 a. SCADA to PLC: %R00001 to %R00500 b. PLC to SCADA: %R00501 to %R01000 c. Programming: %R01001 to %R08000 d. Clock/Peer to Peer/Modules configuration/diagnostic and PLC system: %R08001 to %R09000 e. Counter: %R09001 to %R10000 f. Timer: %R10001 to %R12032 B2. Analog Internal Hi Density 1. Analog Internal: %R00001 to %R24064 a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500 b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000 c. Programming: %R01001 to %R08000, %R14001 to %R20000 d. Clock/Peer to Peer/Modules configuration/diagnostic and PLC system: %R08001 to %R09000, %R20001 to %R21000 e. Counter: %R09001 to %R10000, %R21001 to %R22000 f. Timer: %R10001 to %R13000, %R22001 to %R23000 g. Modbus: %R23001 to %R24064 C. Discrete Input, Discrete Output & Hardware Configuration 1. Discrete Input: %I00001 to %I02048 a. Raw Discrete Input: %I00001 to %I01000 b. CPU Ethernet Status Address: %I01001 to %I01080 c. I/O Modules Status Address: %I01081 to %I Discrete Output: %Q00001 to %Q02048 D. Discrete Internal 1. Discrete Internal: %M00001 to %M04096 a. SCADA to PLC: %M00001 to %M00500 b. PLC to SCADA: %M00501 to %M01500 c. Programming: %M01501 to %M Transition Memory Allocation for RX3i PLC A. Analog Input and Analog Output 1. Analog Input: %AI00001 to %AI Analog Output: %AQ00001 to %AQ00512 B. Analog Internal Default 1. Analog Internal: %R00001 to %R12032 a. SCADA to PLC: %R00001 to %R00500 EDOCSLIB-#9096-v1 Page 10 of of 189

107 RPU Software Programming b. PLC to SCADA: %R00501 to %R01000 c. Programming: %R01001 to %R08000 d. Clock/Peer to Peer/Modules configuration/diagnostic and PLC system: %R08001 to %R09000 e. Counter: %R09001 to %R10000 f. Timer: %R10001 to %R12032 B2. Analog Internal Hi Density 1. Analog Internal: %R00001 to %R32640 a. SCADA to PLC: %R00001 to %R00500, %R13001 to %R13500 b. PLC to SCADA: %R00501 to %R01000, %R13501 to %R14000 c. Programming: %R01001 to %R08000, %R14001 to %R20000, %R24065 to %R32640 d. Clock/Peer to Peer/Modules configuration/diagnostic and PLC system: %R08001 to %R09000, %R20001 to %R21000 e. Counter: %R09001 to %R10000, %R21001 to %R22000 f. Timer: %R10001 to %R13000, %R22001 to %R23000 g. Modbus: %R23001 to %R24064 C. Discrete Input, Discrete Output & Hardware Configuration 1. Discrete Input: %I00001 to %I02048 a. Raw Discrete Input: %I00001 to %I01000 b. CPU Ethernet Status Address: %I01001 to %I01080 c. I/O Modules Status Address: %I01081 to %I Discrete Output: %Q00001 to %Q02048 D. Discrete Internal 1. Discrete Internal: %M00001 to %M32640 a. SCADA to PLC: %M00001 to %M00500, %M05001 to %M05500 b. PLC to SCADA: %M00501 to %M01500, %M05501 to %M06000 c. Programming: %M01501 to %M05000, %M06001 to %M Communications Addresses 1. Each node on a RPU communications network must have a unique address on that network. Node addresses shall be chosen to integrate into existing networks. Nodes shall be assigned in consecutive node addresses. RPUs in hot standby shall have consecutive node addresses. Control 1. Control and monitoring shall continue without disruption in the event of communication failures. Where control functions rely on information affected by communications failure, a safe mode of control shall be provided. 2. Design of software shall seek to reduce the amount of messages transferred between RPUs to the minimum. EDOCSLIB-#9096-v1 Page 11 of of 189

108 RPU Software Programming Time Synchronization All nodes on a RPU communications network shall have internal clocks synchronized periodically to a master clock. Synchronization shall provide time and date stamping accuracy to within one second of the master clock. Master clock and RPU clock shall be accessible from the Operator Workstation. 1.8 RPU Program Commissioning RPU programs shall be tested and commissioned in accordance with CAN/CSA-Q396 Quality Assurance Program for the Development of Software Used in Critical Applications. Each I/O shall be tested from source element to display screen. The source element shall be exercised wherever possible or else simulated. For example, a float switch should be tilted to verify the signal. After commissioning, if access to the float switch is not practical, then its action may be simulated by short circuiting the input loop. EDOCSLIB-#9096-v1 Page 12 of of 189

109 Standard Software Modules 1. Standard Software Modules 1.1 General This document describes Toronto Water s standard software modules and establishes procedures to guide the development, testing and deployment of new software modules. The Consultants shall ensure that the System Integrator complies with the programming and testing requirements with respect to software development. 1.2 Module Overview A Module is defined as a stand-alone software component typically associated with a process device that has a number of inputs and outputs, and also has defined control functionality. In general, the City has already developed standard software modules for all existing in-plant process devices, which the Consultant shall ensure that the System Integrator use in the development of the RPU or HMI software. Where a module is unavailable to meet the software requirement of the project, the System Integrator shall develop an appropriate module as part of the contract. The intent of module development is to develop standard components that can be easily incorporated in multiple instances into the development of process area applications where a large number of the process devices are used. A Module consists of sub units of HMI, RPU and Test Simulation software applications. In addition there will be some specialized modules that do not conform to this definition, but which will be used in the same way in multiple instances e.g. PID module, Analog Input Module, etc. As well as the software units, a module also includes associated documentation. The component parts of a module are as follows: 1. Functional description including module layout 2. RPU program design expressed in a flow chart 3. RPU program with embedded documentation 4. HMI program 5. Simulation program 6. Module Acceptance Report including test cases from Factory Acceptance Testing. 1.3 Available Modules The device control modules are summarized in the following categories: 1. Conveyors and General Devices 2. Pumps 3. Valves EDOCSLIB-#9097-v1 Page 1 of of 189

110 Standard Software Modules 4. Other (Analog, PID, Duty, etc.) Some general module descriptions are included below Device Control Modules General The Manual/Automatic Control Mode Selection modules allow the Operator to select an automatic or manual control mode. Most modules do not make any special provisions for the transfer from Local Control Mode to Computer Control Mode. For example, the module does not affect the motor run state upon transfer. However, if the motor is in automatic control mode, the automatic logic may change the state of the motor on the next execution of the logic. Linking Automatic and Manual Control Logic to Output Values is achieved as follows. In automatic mode, the module enables control requests by the automatic control logic to start and stop devices. The modules typically use one momentary contact closure for start (or open) and another momentary contact closure for stop (or close). In manual mode, the module enables control requests by the Operator to start and stop (or open and close) devices. After a manual control request, the device feedback zeroes the action bit. The modules shall generate alarms for discrepancies between requested and actual states. For example, an alarm is generated if within a set time period from a requested start or stop the motor feedback does not indicate motor run. The timer is adjustable by a System Technician. If in computer control, upon indication of an alarm related to possible equipment damage, the module stops the motor and places it into computer manual. These types of lockout conditions are generally reset locally at the device. The Operator is responsible to reset the alarm from the HMI after checking field conditions before returned to Computer Auto Control. Equipment damage alarms if monitored include: 1. Motor overload; 2. Motor start/stop fail timer; and 3. Motor specific alarm such as low oil pressure. Upon indication of a process alarm, the module stops the motor. The process alarms shall be evaluated on a case-by-case basis for each motor. These types of alarms are generally reset automatically or from the operator interface. Process alarms, if monitored, include: 1. Low suction pressure; 2. Low seal water pressure; 3. Power failure; and 4. Other process specific alarms such as high discharge pressure. EDOCSLIB-#9097-v1 Page 2 of of 189

111 Standard Software Modules The module shall not allow the motor to restart within a set restart inhibit time period after stopping. The timer is adjustable by a System Technician Analog Input Module Scaling to Engineering Units is not performed by the module Analog data is passed to the HMI as unscaled values and the HMI is responsible for scaling. Alarms for High-High, High, Low-Low, and Low alarms are generated by this module. The High-High, High, Low-Low, and Low alarm setpoints can be modified by the Operator. The analog input is compared to High-High, High, Low-Low, and Low alarm limits. If a limit is exceeded for more than three continuous seconds, an alarm bit is set. The alarm bit is reset when the analog value returns within a deadband from the limit. The deadband is adjustable. An Out of Range Alarm contact is provided by this module when the analog input value reaches a value out of the 4-20 ma range for more than three continuous seconds Analog Filter Module Provide Digital Filtering module on a case-by-case basis to filter noise from a measurement signal. The filtering equation used is: Y = K(X - Y ) + Y n n n-1 n-1 Where: K = filter constant: 0 < K < 1 Xn = current input valve Yn = current filtered output value Yn- 1 = previous filtered value The value of K is set by the System Technician. Note: with a K value near 1, the Analog Input Filter module has little effect at smoothing the input signal. With a K value near 0, the output value of the Analog Input Filter module changes very slowly with a change in input value PID Loop Control Module Automatic PID Loop Control shall be provided to send an analog output signal to a control device. The Operator may set the PID controller for automatic or manual control mode. In automatic mode, the Operator can select whether the module uses an Operator-entered setpoint or an automatically calculated setpoint. The module monitors its process variable (PV) and setpoint (SP) and changes its output based on the difference between the PV and SP. The action of the control module is based on the PID algorithm and the value of the tuning constants. The high and low output limits are set by the Operator. The Operator enters these limits as a 0-100% value and the Operator interface converts them appropriately for the PID controller. EDOCSLIB-#9097-v1 Page 3 of of 189

112 Standard Software Modules In the manual control mode, the Operator can enter a control command value. The module monitors its control variable (CV) and considering the user-defined parameters, will change the module output to match the command value. In local control mode, the PID module is disabled and the setpoint is set equal to the process variable. The module also forces the PID module output equal to the control variable (CV). When the PID module is in AUTO or local control, the module forces the manual setpoint entry register to the value in the PID output register. The module shall disable the PID calculation when the control device is unavailable, in local control or upon module failure and also if the process variable is out of range. An alarm contact is energized by the analog input module of the process variable The tuning parameters KP, KI, and KD can be changed on-line while the program is running. The PID module executes at a scan interval set by the System Technician. The following guidelines are for setting the PID_ISA Control Function Block Initial configuration. The setting of the initial parameter values prior to tuning and commissioning shall be as follows: Parameter Configuration Guideline Manual Command N/A Control This internal parameter is normally set to 0. Enable N/A Override Set to ON. Manual N/A Up N/A Down N/A Proportional (Proportional 1 Gain) Derivation (Derivation 0 Gain) Integral (Integral Rate) 0 SP, PV and CV Percentage N/A Bar Graphs SP/PV Range Optional integer values in PV Counts that define the highest and lowest display value for the SP and PV bar graphs. SP Value N/A Sample Period 1.0 seconds for pressure control loops 2.0 seconds for flow control loops 2.0 seconds for level control loops 5.0 seconds for temperature control loops Bias The usual setting for the Bias field is to let the EDOCSLIB-#9097-v1 Page 4 of of 189

113 Standard Software Modules Parameter Dead Band Upper and Lower Upper Clamp and Lower Clamp Error Term Min Slew Time Derivative Action Output Polarity Configuration Guideline function regulate error around the output midpoint. Leave the dead band limits set to 0 until the PID loop gains are setup or tuned. It may then be desirable to add Dead Band to avoid small CV output changes due to small variations in error (i.e. to reduce mechanical wear). Set the lower clamp to 0 and the upper clamp to +32,000. Selects how the error will be calculated. Set to the limit of the control device. Most control valves have a minimum slew time of 60 seconds. Note: Set Minimum Slew Time to 0 (no CV rate limit) while tuning or adjusting PID loop gains. No derivative action is required for most loops. Set according to type of loop. 1.4 Module Development The module development process shall be as follows: 1. The Consultants shall prepare the module functional description and module flow chart, which is to be reviewed with the City. 2. Functional requirements are defined based on software related standards, process control narratives and experience. For example, the standard for alarm handling requires that if a point in the HMI has its alarm disabled, the control logic associated with the point value is also disabled. The modules should have this functionality. 3. The System Integrator shall develop the Module software for RPU, HMI and Simulation 4. The System Integrator shall develop test cases (see Module Testing Process). 5. Preliminary review is made by the Consultants and the City. 6. The System Integrator shall modify the documentation to incorporate changes. 7. The System Integrator shall modify the software code to incorporate full functionality and shall test the software to confirm that the desired results are achieved. 8. Full review is made by Consultants and the City. 9. Incorporate further required changes. 10. Test the module according to the Module Testing Process. 11. Submit module for acceptance. EDOCSLIB-#9097-v1 Page 5 of of 189

114 1.4.1 Module Testing Process Process Control System (PCS) Guidelines Standard Software Modules The module testing process will follow general guidelines for component testing. The module testing process will have QA review, and feedback will be sought from the Consultants and the City throughout the development and testing process. In the development of test cases, the System Integrator s judgment and experience is used to determine how thorough the test process needs to be. Different depths of detail are involved at the different stages of testing by the System Integrator, testing by the Consultants and testing by the City, if required. In addition, at each stage of testing, the Consultants or the System Integrator will be encouraged to look beyond the procedures as defined in the test cases to identify unforeseen problems. In some instances this will lead to the development of additional test cases. The module testing process shall be performed in the following sequence: 1. The System Integrator shall develop a list of test cases using the following approach: Use experience and judgment to develop the list of test cases. Assume errors are distributed throughout the programs. Prove functionality as defined in functional descriptions and flow chart. 2. The Consultants shall review the testing process 3. The System Integrator shall perform testing in a test environment that reflects the actual production environment 4. The System Integrator shall perform the Acceptance testing which the Consultants shall witness. Technical acceptance and sign-off shall be done by the Consultants for each module. Acceptance represents that: The module meets the design as specified in the Module Functional Description as well as general PCS standards. The methods for module development and testing were followed. The representatives have confirmed that the module passed all tests outlined in the acceptance test documentation Module QC Process The QC Process shall adhere to the requirements for QC/QA established for the project. The Consultants may perform an independent test of each module according to the acceptance test procedure. EDOCSLIB-#9097-v1 Page 6 of of 189

115 Standard Software Modules During the QC Process, the Consultants shall use a checklist for documenting issues and changes resulting from review. The QC checklist that follows is for each module. Each Software Module shall be assessed for conformity against the following list of items: 1. Meets Toronto Water PCS standards. 2. Meets functional requirements as described in the Module Functional Description. 3. Performs functions shown on flow charts and diagrams. 4. Developed and tested in a configuration that suitably represents the actual production environment. 5. Passes written internal testing procedures and signed by Consultants EDOCSLIB-#9097-v1 Page 7 of of 189

116 Operator Interface Programming 1. Operator Interface Programming 1.1 General The Consultants shall comply with the following guidelines for the programming of Operator Interface Terminals (OIT) connected to Programmable Logic Controllers (PLCs). Consultants shall comply with this guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City. 1.2 Programming General OITs are to be configured for monitoring and control functions of the local process ONLY. Unless otherwise noted, they are not intended to behave as a SCADA client. The programming of the OIT shall conform to the following requirements: 1. All OIT points shall be programmed to display their full tag name and point information. 2. Analog points shall have values displayed in the same engineering units as at SCADA screens. 3. Digital points shall have value or state displayed logically, for example: Outputs as START/STOP, OPEN/CLOSE, etc.; and inputs as ON/OFF, NORMAL/ALARM, LOCAL/REMOTE, etc. as appropriate. 4. All displays shall have a consistent general layout in both form and function. A hierarchical menu shall be constructed using the device keypad and programmable soft keys to provide a simple and intuitive method of accessing all of the screens provided. Where available, use an existing OIT program at the facility as a template for form and function. Colours used for text and graphic elements shall use the same colours used on normal SCADA displays. Changes in colour that result from change of state shall also use the same colours as used at the SCADA displays. Refer to guideline EDOCSLIB-#9095 Colour Convention for more information on colour standards. 1.3 Displays Multiple displays shall be provided to show the state/status of every installed I/O point at the associated PLC, regardless of whether a field device is attached to the I/O point. One graphical schematic representation shall be provided for each process controlled and/or monitored by the associated PLC. Point states and values shall be refreshed dynamically as field conditions change. All automatic control setpoints and related displays programmed on the central SCADA system shall also be available on the OIT. EDOCSLIB-#9098-v1 Page 1 of of 189

117 1.4 Trend Display Process Control System (PCS) Guidelines Operator Interface Programming One or more graphical trend displays shall be provided to show the change in value, expressed in engineering units, for selected variables over the immediate past time period. Where possible, the same trend configurations used on the central SCADA system shall be available on the OIT. Trend data shall be stored locally on the OIT for a minimum 24 hour period. 1.5 Access Levels Program the OIT so as to provide four separate access levels. Password levels required are: 1. LEVEL 0 (PUBLIC) allows view only access to all operating screens 2. LEVEL 1 (OPERATOR) allows access to lower levels, with ability to change state of any device, change analog setpoints, and acknowledge alarms 3. LEVEL 2 (SUPERVISOR) allows access to lower levels, and can adjust program variables. 4. LEVEL 3 (ADMINISTRATOR) allows access to lower levels, can adjust program logic, and can assign, re-assign password access to lower levels. The default or power-on mode for the password shall be Level 0. Any log-on or log-out attempt (successful or otherwise, and regardless of Level) shall be an event added to the alarm/event history at the device. After fifteen minutes with no keypad activity the password level shall reset to Level Alarm and Event Log Program the OIT so as to acquire (in real time) a log of alarm and event messages from the PLC to which the OIT is connected. Insert the date and time of occurrence at the beginning of each message describing the change of state. Maintain these logged messages in a first in/first out queue of a minimum 200 messages. Note that the alarm/event log shall also capture for display the action and date and time of each attempted log-in, each successful log-in, and each log-out. 1.7 Alarm and Event Display Program the OIT to allow recall of the alarm and event messages in order of most recent to least recent and display the messages in groups of 20 to a display. EDOCSLIB-#9098-v1 Page 2 of of 189

118 Process Display Programming 1. Process Display Programming 1.1 General This guideline applies to all operator workstations. This guideline is for the structure and documentation of process displays and establishes standards for a consistent approach to programming which will enable: 1. maximum re-use of programs; 2. reduced time to troubleshoot programs; and 3. higher confidence and usability of operator workstations. This guideline will be reviewed whenever a new workstation software package is selected or when the software version is changed. Consultants shall comply with this design guideline in the design of the works and ensure that the contract documentation for construction conform to this requirement. Any proposed deviation must have the prior approval of the City 1.2 Display Names Each graphic display shall be identified by its version number (Vx.x) and its name. Record the location of the primary copy of the display. Use the naming convention in the following table for all graphics: File Types File Naming Convention (Notes 1,2 and 3) Process Graphics PLT_AREA_XXXXX Trend Charts PLT_AREA_trend_XXXXX Setpoint Graphics PLT_AREA_setpt_XXXXX Run-Hour Graphics PLT_AREA_runhour_XXXXX Legend & Info Graphics PLT_AREA_legend_XXXXX RPU Status Graphics PLT_plc_XXXXX Plant-Wide Trend Menus PLT_chartmenu Alarm Summary PLT_alarmsummary Mainmenu PLT_mainmenu Alarm Page PLT_AREA_sub_alarm Process Sub-Picture PLT_AREA_sub_XXXXX Drop Down Menu PLT_AREA_sub_menu_XXXXX Process Area Trend PLT_AREA_trendmenu Menus Notes: EDOCSLIB-#9099-v1 Page 1 of of 189

119 Process Display Programming 1. PLT: 3-character Plant Code to be defined in EDOCSLIB-#6454 Equipment and Data Names (eg. FHA for Harris Filtration Plant). 2. AREA: Process Area codes to be defined in EDOCSLIB-#6454 Equipment and Data Names (eg. FLT for filtering process). 3. XXXXX: specific graphic name left to the discretion of the developer. Use a similar naming method to those graphics that already exist. 1.3 Display Guidelines Update Procedure for HMI displays The PCS component of any project will often involve updating an existing display rather than creating a new display. The following procedure should be considered when updating an HMI display: 1. During pre-design, determine which HMI hardware components will be affected by the project. This may include SCADA servers, Operator workstations, or local OITs. If possible, determine specifically which process graphics will be affected. 2. During detailed design, create or further refine the list of affected process graphics. Consider if any changes will be required to the menu bar (and User.FXG file) 3. During Construction, the System Integrator will request the existing HMI application from Toronto Water. ITM can determine, at their discretion, if the facility s entire HMI application is to be locked down during construction or just the specific affected graphics. The software should be considered signed-out and locked down while in the System Integrator s possession to facilitate version control. 4. The System Integrator will FAT the software modifications according to normal Toronto Water procedures. 5. When the project is ready for the SAT, the System Integrator will obtain ITM s approval for integrating their software modifications with the system in operation at the facility. The process graphics and new/modified database tags should be uploaded and then the SAT performed according to normal TW procedures Update Procedure for ihistorian, eops 1. As part of the Process Control Narrative update, determine which ihistorian and eops tags need to be changed, added, or deleted and determine the associated parameters (update deadband, etc.) 2. The Systems Integrator will program the changes to the ihistorian as part of their software development 3. The FAT for any eops database and reports changes will be performed on the ITM eops test system at the Tiffield Road facility. This may be a separate FAT from the standard software FAT typically performed at the Systems Integrator s office. 4. After a successful FAT, the Systems Integrator will forward the ihistorian changes to ITM. ITM will install the changes on the production system at the facility. 5. The Systems Integrator will SAT the ihistorian changes. EDOCSLIB-#9099-v1 Page 2 of of 189

120 Process Display Programming 6. The next working day following a successful SAT of the ihistorian changes, the eops changes will be implemented by ITM at the Tiffield Road facility. The Systems Integrator will then SAT the updated database and reports Layout 1. Graphic displays should have minimal information on the left side where pop-up windows initially appear. 2. The amount of information on a graphic display should be in the range of 30 to 60 information points. An information point is an analog value, an alarm or event message, a monitored or controlled device symbol, a bar graph symbol or display call button. Exceptions to this guideline will likely occur for summary displays or some complex processes. 3. Layout the graphic either according to plant floor location or the P&ID drawings as appropriate for the information being presented. 4. Generally process inputs come from left side of the screen and outputs go to right side of the screen. 5. All process graphics must contain a title bar across the top. 6. The title bar must display: name of the graphic display using the format PLT Description date; Text time; and icons accessing: plant overview; alarm summary; operator log-in; process miscellaneous menu; Print Screen function; and trend menu. Font style and size should be suited to the graphic display. Preferred font styles are plain such as Simplex or Arial. Standard fonts are shown in the following table: Item Font Font Size Title of graphic Arial, italic, bold 17 EDOCSLIB-#9099-v1 Page 3 of of 189

121 Item Font Font Size Date Arial, regular, bold 12 Time Arial, regular, bold 12 Device tag name Arial, regular, bold 9 Device status Arial, regular, bold 9 EDOCSLIB-#9099-v1 Page 4 of 17 Process Control System (PCS) Guidelines Process Display Programming Abbreviations should use codes in EDOCSLIB-#6454 Equipment and Data Names, flow stream identifiers contained in EDOCSLIB-#9094 P&ID Symbols and Practices or other Toronto Water standards Colour The use of colours shall conform to DOCS1#9095 Colour Convention. Other colours may be used where the use of colours is not defined in that standard Shape 1. Shape will be used to make key information more evident and to reduce errors due to colour-blindness. 2. Shape will be used to show tank levels where the tank is shown in profile, i.e. elevation view. 3. Change of the shape or icons to indicate status will be selectable by the operator. When selected, the usage of shape change will be as follows: a) Mode Identification A L Automatic Local M Manual N Not Available b) Status Identification O C T R S I L H Open Closed Transition Run Stop Inhibit Run Low Speed Run High Speed Forward 121 of 189

122 1.3.7 Icons Reverse Process Control System (PCS) Guidelines Process Display Programming 1. Toronto Water maintains a software library of icons developed for use in displays. Use icons in the library for representing individual devices rather than creating alternative shapes. 2. Icons should resemble field equipment to make recognition easier. Label each icon with the equipment number. On any individual display, use icons of a similar type (i.e. all 2-D or all 3-D), similar orientation (i.e. all profile or all plan view) and similar relative size to give consistent presentation. 3. Icons incorporate the colour and alarm conventions. The colour convention including rules for using flashing to indicate unacknowledged alarms is given in EDOCSLIB- #9095 Colour Convention. The alarm convention is explained in EDOCSLIB-#9099 Alarming. 4. Icons should be consistent in size across all displays; however, some process displays may require reduced icon sizes in order to accommodate all of the devices. 5. As 3-D icons have different sizes, shapes and complexities, it is difficult to use colour fill on the symbol to display status and mode; therefore, the following method is used to indicate status and mode. The 'Status' colour is displayed in a small square while the 'Mode' colour is displayed in a small triangle. Both the square & triangle are layered on top of the 3D symbol or close to the symbol. Since the 'Status' & 'Mode' colour fill is separate from the original symbol, this way of displaying 'Status' & 'Mode' colour can be used in every symbols independent of the symbol shapes and complexities and eliminate the effort of re-developing the colour fill linking to every symbol. 6. Provide each icon with access to its corresponding pop-up window. 7. A bitmap photo of the real device can be used in some cases as the icon. Submit suggested photos to the City for review and approval. 8. Where new symbols are required, the Consultants may request the City to consider the addition of new symbols. If the City approves the addition of such symbols, the development and testing will be performed by the Contractor as detailed in EDOCSLIB- #9097 Standard Software Modules. On completion of the development of the symbols, the Contractor shall submit the information in the format that will permit the City to add the data or information to the City s library Pop-up Windows Pop-up windows should initially appear on the left side of the screen, ensuring minimal coverage of the screen. Pop-up windows may be moved and sized by the operator. Pop-up windows will contain: 1. the name and description of the equipment or item on the top. EDOCSLIB-#9099-v1 Page 5 of of 189

123 2. current status: e.g. running/off, opened/closed, enabled/disabled, manual/automatic/cascade, alarm/normal 3. current conditions: e.g. speed, position, electrical current 4. current alarms and acknowledge function 5. controls: e.g. start/stop, open/close, setpoint entries 6. mode selection: manual/automatic/cascade, enable/disable 1.4 Graphic Display Structure Process Control System (PCS) Guidelines Process Display Programming The displays are interconnected in a hierarchy structure. In addition, interconnection is provided for process streams continued on other process graphics. The structure and access to other displays is shown in Figure 1 - Graphic Display Structure. Multiple displays may be needed to show all of the information and control icons required for operation. Where multiple displays are required, a process overview should be created along with equipment overviews and details. 1. The main menu is a picture of the facility or map of the area with links to the process overviews. 2. Process overviews show process flow, summary information and major components or groups of components. The displays are usually in plan view (building level); the top of the screen is North. (Status only). Objects may be represented by simple symbols (circles squares etc) in grey. Links to equipment overviews or equipment detail screens 3. Equipment overview graphics may be needed to show sub-processes or groups of components. Equipment layout (status and control) can use simple or complex icons depending on number of components on the screen. 4. Equipment detail graphics may be needed for devices with monitored or controlled subcomponents or other complex display requirements. 5. For situations where a number of components or component groups are the same, e.g. aeration tanks or filters, either make one detail screen with tag groups or separate screens for each tank or filter, whichever is more appropriate for the situation. One screen with tag groups is more appropriate for simple situations. 6. The RPU Status Graphics have the same look and feel as standard process graphics. Each page of the RPU Status Graphic is allocated to the display of the RPU status for one or more process areas in the plant. The displays for every process area consist of a set of graphics as follows: 1. Process Graphics of the process area (one of which is an Overview); 2. Trend Menus; 3. Trend Graphics; 4. Setpoint Graphics (viewing and modifying setpoints for the process area); EDOCSLIB-#9099-v1 Page 6 of of 189

124 Process Display Programming 5. Run-Hour Graphics (viewing and modifying device run-hours for the process area); 6. Legend and Info Graphics; 7. Process Sub-Pictures In addition to the graphics for the process areas, there are other graphics for plant-wide use, e.g. Alarm Summary or RPU Status Graphics. The first screen is the Mainmenu. It is displayed on system start up. From the Mainmenu, there are selections for the various process areas. When one process area is selected, a process graphic for the process area (normally the overview graphic) is displayed. From the Mainmenu, there are also selections for other plant wide graphics, e.g. Alarm Summary or RPU Status Graphics. Every graphic in the system shares a similar look and feel. There are several Buttons in the Title bar to access some common use functions. Each graphic also contains a Back & Forward button for navigational purposes and Menu Buttons for accessing other graphics in the process area. The displays are shown in following sections. EDOCSLIB-#9099-v1 Page 7 of of 189

125 Process Display Programming System Login Alarm Summary Plant-wide Tend Menu Mainmenu Process Area Trend Menu Trend Charts RPU Status Graphics Setpoint Graphics Process Graphics Run-Hour Graphics Device s Sub-Pic Part of software modules. Alarm Alarm Page Legend & Info Graphic Process Sub-Pictures Note: Every graphic can access the Mainmenu via the Home Button & other graphics through the drop down menu. Process Area 1 Area 2 Area 3 Figure 1 - Graphic Display Structure EDOCSLIB-#9099-v1 Page 8 of of 189

126 Process Display Programming 1.5 Graphics Examples MainMenu Link to the first page of the Process Graphics (i.e. Overview) in one process area. When there are unacknowledged alarms in the process area, the text will flash in a red colour. System Login Button to access Plant-Wide Trend Menu Button to access Alarm Summary Button to access RPU Status Graphics EDOCSLIB-#9099-v1 Page 9 of of 189

127 Process Display Programming Process Graphics Back and Forward Buttons to go back and forward through previous displays (up to the last 7 displays). Login Button for system login Menu Buttons the 11 Menu Buttons to display various process graphics in the process area. Print Button print screen to the default printer. Trends Button display Trends menu for this process EDOCSLIB-#9099-v1 Page 10 of of 189

128 Alarm Summary Process Control System (PCS) Guidelines Process Display Programming An Alarm page is a full screen display of filtered alarms for a process area. When a graphic is opened, the alarm page is not displayed. By selecting the Alarm Page Button (clicking with the left mouse button), the Alarm page will appear in place of the process graphic screen. By selecting the Alarm Page button again, the Alarm page will disappear. The alarm area used for filtering is indicated in the Alarm Page status line. Alarm Page Button Alarm Page status line will display Sort Order, Total Alarms, and Filtered Alarm Area. EDOCSLIB-#9099-v1 Page 11 of of 189

129 Process Miscellaneous Button Process Control System (PCS) Guidelines Process Display Programming In all process graphics, the user can display the Misc menu by clicking the Process Misc Button. Selection available on the Process Misc menu include: Alarm Setpoints - Set alarm limits for various instruments Process Setpoints - Set process automation setpoints such as pump start/stop levels Run Time/Counts - Display pump and valve runtime data Legend & Info - Access Legend graphics & other symbol information Pipe Colour - Display colour standards Close Sub-Pics - Close all open sub pictures View Tags View Status Hide Tag/Status - Display device tag names on the current graphic. - Display device status (i.e. Local (L), Running (R) etc.) on the current graphic. When device status is displayed, tag name display will be turned off and vice versa. - Turn off display of device status and tag names. EDOCSLIB-#9099-v1 Page 12 of of 189

130 System Miscellaneous Button Process Control System (PCS) Guidelines Process Display Programming The Misc button in the menu button bar displays a drop down menu of various miscellaneous pop-up displays of general plant information such as flow summaries, power usage, etc. EDOCSLIB-#9099-v1 Page 13 of of 189

131 Process Sub-Pictures Process Control System (PCS) Guidelines Process Display Programming Process sub-pictures are normally accessible by clicking on an device such as a pump or chlorinator. Other sub-pictures may be available through the pull-down menu for the process such as setpoints or power consumption information. The process sub-pictures normally contain summary information or relevant information for the same process areas or other process areas which are useful for the operators. Device control pop-up Button to access drop down menu for process Setpoints pop-up EDOCSLIB-#9099-v1 Page 14 of of 189

132 Trend Graphics Process Control System (PCS) Guidelines Process Display Programming The Trend Charts are accessed from the Process Area Trend Menus. When Trend Charts are opened, the Trends will display historical data for the past 24 hours. There are four (4) Duration buttons for selecting different display durations (4, 8, 12, 24 hour-periods). Using the Calendar button, a calendar is displayed and the date of trending display can be selected. Multiple Trend Charts can be displayed on the screen. Menu Buttons The 11 menu buttons to select various Process Area Trend Menus in the plant Fast Backward Scroll (go back ½ period) Show/Hide Calendar (Show or hide the Calendar to select date of display) Slow Backward Scroll Buttons to Add/Delete Pens Slow Forward Scroll (go back 1/8 period) (go forward 1/8 period) Fast Forward Scroll 4 Duration buttons (go forward ½ period) EDOCSLIB-#9099-v1 Page 15 of of 189

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