Tendernotice 2

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MAHARASHTRA JEEVAN PRADHIKARAN WM DIV. SATARA
e- TENDER NOTICE NO FOR 2017-2018
AUTOMATION WORKS
ATAL MISSION FOR REJUVENATION AND URBAN TRANSFORMATION (AMRUT)
Designing, providing, erecting, commissioning & giving satisfactory test & trial of
Automation work at raw & pure water pumping station WTP & ESR Management
for Satara Water Supply Scheme.
VOLUME-II
Office of the
THE EXECUTIVE ENGINEER
WATER MANAGEMENT DIVISION, SATARA
( SAVE WATER, EVERY DROP COUNTS )
Contractor No. of Corrections Executive Engineer

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NAME OF W ORK : ATAL MISSION FOR REJUVENATION AND URBAN TRANS-

FORMATION (AMRUT) IN SATARA WATER SUPPLY SCHEME
[ Automation Work]
Designing, providing, erecting, commissioning & giving
satisfactory test & trial of Raw and Pure Water pumping
machinery and Automation work at various pumping station
for Satara Water Supply Scheme.
e- TENDER NOTICE NO FOR 2016-2017
INDEX
Sr. No. Description From To
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

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GENERAL SPECIFICATION

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Name of work : ATAL MISSION FOR REJUVENATION AND URBAN

TRANSFORMATION (AMRUT) IN SATARA WATER SUPPLY SCHEME
Automation work at raw & pure water pumping station WTP &
ESR Management.
GENERAL SPECIFICATION
GS-1
1) All the materials used in the work shall be of best quality and the material rejected
shall be removed from the site by the contractor within 36 hours in the presence
of the Engineer in charge at his own cost.
2) All other rules regarding workmen compensations etc will be binding on the
contractor. Unwanted persons shall be dispensed with if called upon by the
Engineer in charge.
3) Other unforeseen items to be executed in course of work will have to be done by
the contractor as per specifications, in P.W.D. Hand book volume I and II (Latest
Edition) I.S. code of practice and as per standard specifications book of latest
edition.
4) The contractor shall be responsible and liable to pay for the damages caused by
him to public property etc.
5) All T and P machinery shall be provided by the contractor. Non availability of the
same shall not be an excuse for application for extension of time limit.
6) Water of good quality for labour, construction, washing and such other purposes
shall be provided by the contractor without any claim for extra cost.
7) Materials belonging to contractor if not removed from site of works after
completion of the work within a period of 15 days shall be taken over by
Maharashtra Jeevan Pradhikaran department at contractors risk and cost and
then shall be auctioned at the contractors risk and cost. The amount so recover
shall be credited to contractors account after recovery of any dues or over
payments etc.
8) The final bill and deposits will not be paid unless the site is cleared off all rubbish
materials and contractors stores etc from the site of the work.
9) The contractor will have to pay the royalties and municipal taxes, if charged by the
Maharashtra Jeevan Pradhikaran. The same will not be refunded.
10) Specifications given for relevant nature and type of work, for any particular item of
the tender shall also be applicable to the other item of work when similar work is
repeated or carried out in part or full although the item numbers may not have
been mentioned especially against the particular specifications.
11) The contractor shall be responsible for obtaining permission from Government
local bodies, private party for storing, stacking of materials required for execution
of work.
12) Necessary sign board, danger flags, red lamps shall be provided by the contractor
to avoid accidents. Necessary guarding will also have to be provided.
13) Before entering any land, the contractor shall make independent enquiry
regarding ownership of land. Any action regarding trespassing will be at the risk of
contractor.

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14) Materials remaining unsold or unserviceable as per discretion of the Executive

Engineer shall be confiscated destroyed or disposed off without any
compensation to the contractor, who will be responsible for all legal disputes at his
own cost and consequences without reference to the department.
15) In case of legal disputes for materials brought and stores at site without
permission of the Executive Engineer, the contractor will be responsible for all
legal disputes at his own cost and consequences without reference to the
department.
GS 2: SPECIFICATION OF WORK :
The work shall be carried out as per practices and procedures laid down in P.W.D.
Hand book Volume - I & II Latest Edition and Public Works Departments standard
specifications (Latest Publication of Government of Maharashtra) with
amendments from time to time and as per I. S. applicable for respective items of
works, as directed by the Engineer in charge.
GS 3: MOTIVE POWER :
No electric power supply shall be entered by the Maharashtra Jeevan
Pradhikaran during construction and testing of various structures under different
sub-works. The contractor shall have to make his own arrangement for the same
at is cost. During trial period of the plant, power supply shall be made available by
the department. The firm should inform within one month from the date of receipt
of work order, the total electrical load required for successful operation of the
treatment plant. This electrical load shall also include lighting load for inside and
outside light points etc. attached to the buildings in proper as well as premises of
the plant.
GS 4: FOUNDATION CONDITIONS AND PRESCRIBED BEARING CAPACITIES

The tenderer shall acquaint himself for results of S.B.C. by taking actual trial pits
on site and refilling them afterwards at his cost. The foundation depth shall be
considered as minimum 3.00 m below G.L. for the construction of BPT, MBR &
E.S.R.. The bearing capacities of the actual strata met with the foundation levels
shall wherever be required got tested from reputed institution, at contractors cost
and in the presence of Engineer-in-charge. Detailed design shall be prepared and
submitted by the contractor and got approved from the department after actual
confirmation of S.B.C.
GS 5: WATER TIGHTNESS TEST
All the water retaining and carrying structures will have to be tested for their water
tightness by filling them with water up to their designed F.S.L. Similarly the pipe
line will have to be tested hydraulically. Structures will be considered water tight
when the reductions in filled up level is not more than 6 mm in 48 hours with outer
surface dry. As regards pipe line, they should hold pressure as directed by
Engineer in charge without reduction for thirty minutes. The contractor will have to
give all such hydraulic tests by making his own arrangements for water supply,
filling and disposing off water after the test. He shall repeat this test if necessary
until the above results are achieved and certified by the Engineer-in-charge
without any claim for extra cost. The contractor shall carry out the rectification of
the structures or pipe lines to achieve the above tests at his own cost. The
structures and pipe lines shall be kept filled with water upto F.S.L. after the above
test are over at his own cost.

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GS 6: SATISFACTORY COMPLETION OF VARIOUS ITEMS :

The sub works included in the schedule of works for BPT MBR WTP & ESR on
Lump sum basis.The various items of the sub work are to fit in perfectly in the
whole system physically, hydraulically, architecturally and mechanically.
GS 7: DISPOSAL OF EXCAVATED STUFF :
All materials obtained from any excavation carried out under this contract will be
the property of Maharashtra Jeevan Pradhikaran and the contractor shall not have
any claim on it. It will not be used by the contractor for any other purpose than the
legitimate use on the work itself. Stuff still remaining surplus shall be spreaded
over the different site of work or disposed off as directed by the Engineer in
charge without extra cost.
GS 8: SUBMISSION OF DETAILED DESIGNS AND DRAWINGS AFTER

ACCEPTANCE OF TENDER :
For Lump sum job works the contractor shall submit complete detailed designs
and drawings within one month from the date of issue of work order for approval If
the department to the same. Piecemeal submission of designs and drawings shall
not be permitted to commence the actual work at site unless detailed structural
designs and working drawing are approved by the department. If called upon, the
contractor shall also submit within reasonable time relevant books and other
literature which have been referred to by him in working out the design for civil,
mechanical or electrical works involved in the construction. Such books and
literature will be returned to him. Reason of secrecy in regard to details of
designs, materials, equipments etc shall not be placed by the contractor in the
name of TRADE SECRET for not furnishing the requisite details called for the
Maharashtra Jeevan Pradhikaran. The design get approved from Govt.
Engineering College structurel consultants approved inlisted in MJP shall be
subjected to modifications if found necessary and such modification shall not
violet the contract. The contractor shall be responsible for the correctness and
soundness of the designs submitted by him. The structures shall be as per
recognized engineering practices and if any provisions, are found inadequate or
faulty, necessary modifications will have to be carried out by him at any stage up
to the expiry of guarantee period and no extra payment will be made on the
account.
Six copies of all the approved designs and drawings should be furnished by the
contractor to the department free of cost.
GS-9: REQUIREMENT OF STRENGTH OF CONCRETE
The contractor shall make field arrangements for testing of all materials for
cement concrete i.e. slumps test, compression test etc. The concrete cube
moulds 3 Nos. of 15 x 15 x 15 cm size shall be kept during concreting operation.
Three cubes shall be prepared from at site during concreting to be used in work
for compression test, for each concreting to be used in work for compression test,
for each concreting of the structures. One cube shall be tested for test at 7 days
age and two at 28 days in Regional Testing Laboratory at Govt.
Polytechnic/Engineering college or at any approved laboratory, by Engineer In-
Charge. ALL THE TESTING CHARGES SHALL BE PAID BY CONTRACTOR.
The entire responsibility of the testing of materials will be borne by the contractor.
Mixing of concrete shall be done with Concrete Mixers.
a) The contractor will make his own arrangement for receiving all materials,
tools, etc. required for the work.

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b) No extra charges for the carriages of water will be allowed.

c) The rates for all items are inclusive of all charges such as carting, lifting
etc. No extra payment for any lead and lifts will be paid for any item.
d) The contractor should not be subleted without written permission of the
Engineer-In-Charge.
e) The conditions in the tender notice will be binding on the contractor and the
Tender Notice will form a part of agreement.
f) The material required for carrying out the work for which the tender is
offered shall be brought by the tenderer.
GS-10 ORDINARY CONCRETE
Full payment shall be made when 75% of the result are equal and above the
specified strength and the remaining 25% of the result are above 75% of specified
strength. Cases failing outside the above limit shall be examined by the
Engineer-In-Change on merits in each case.
1) The charges for preliminary design of concrete mix shall be entirely borne by the
contractor .
2) For grades of concrete M-20 and above where cement is to be used by

weighment, the cost of extra cement required to make up under weight bags shall
be borne by the contractor.
3) For the item of concrete and other items in the agreement where cement is not to
be used by weighment the cement bags are received from the manufacturer shall
be assumed to contain cement of 50 kg. net weight. The work shall carried out as
per this method of reckoning.

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TECHNICAL SPECIFICATIONS

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NAME OF WORK : ATAL MISSION FOR REJUVENATION AND URBAN TRANS-
FORMATION (AMRUT) IN SATARA WATER SUPPLY SCHEME
[ Automation Work]
Automation work at Raw & Pure water pumping station WTP & ESR Management.
AUTOMATION & SCADA SYSTEM

DETAILED SPECIFICATIONS
Designing, Supplying, Installing, Testing & Commissioning of complete

Automation / SCADA system of water supply scheme including Raw Water
pumping, W.T.P., Pure Water Pumping Station, MBR/ESRs level monitoring system
with 5 years comprehensive annual maintenance contract.
The overall objective of the automation is to reduce human intervention, reduce

man power requirement, increase efficiency and increase managerial control with ease.
This work includes complete designing, supplying, installing, testing &

commissioning of SCADA, to monitor automatically the required flow from raw water at
intake up to outlet of every ESR. This includes flow monitoring of raw water at intake,
pure water of & WTP, including recirculation pumping machinery, pure water pumping
station at WTP and various ESRs (each inlet & outlet). It is responsibility of contractor to
design the SCADA for complete scheme from intake to outlet of each ESR considering
all items mentioned in schedule "B". It is binding on contractor, if any changes &
modification required as per site condition then same shall be carried out with no extra
cost. The entire SCADA/ Atomized operation system should be self sufficient to lift and
deliver required water in desired quantity and at equitable manner to all villages as per
demand, without manual operation. It should be able to maintain required pressure at
any point of transmission system. It should allow the air management, valve controls,
pump operations, backwash, treatment, chlorination etc. automatically. The system
should be robust and tamper proof and should maintain and build database of all inflows
and outflows at every lifting and delivery points. The details of item wise specifications
and requirements are as follows.
The overall objective of the automation is to reduce human intervention, reduce

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manpower requirement, increase efficiency and increase managerial control with ease.
This work includes complete designing, supplying, installing, testing & commissioning of
SCADA, to monitor automatically the required flow from raw water at intake up to outlet
of every ESR. This includes flow monitoring of raw water at intake, pure water& WTP
including re circulation pumping machinery, pure water pumping station at WTP and
various ESRs (each inlet & outlet). It is responsibility of contractor to design the SCADA
for complete scheme from intake to outlet of each ESR considering all items mentioned
in BOQ. It is binding on contractor, if any changes & modification required as per site
condition, then same shall be carried out with no extra cost. The entire SCADA/
Atomized operation system should be self sufficient to deliver required water in desired
quality and at equitable manner as per demand. It should allow the air management,
valve controls, pump operations, backwash, treatment, chlorination etc. automatically.
The system should be robust and tamper proof and should maintain and build database
of all inflows and outflows at every lifting and delivery points. The details of item wise
specifications and requirements are as follows.
The details of complete automation system / SCADA, make of equipments /
sensors / software etc. shall be submitted to the Superintending Engineer ( Mech
) & shall be got approved before actual execution of work.
SCOPE OF WORK :-
The scope of work includes Design, supply, installation, testing and commissioning of
Automation system for Raw water pumping machinery at Mahuli Headworks, & 27.5
MLD WTP at Viassava, Pure water pumping machinery at Visava MBRs/GSR/ESRs etc.
including instrumentation, control valve, PLC, SCADA, Electric-
al/Electronics/Mechanical/Civil Works with five years comprehensive operation & main-
tenance at following places as directed by Engineer-in-charge
Flow Meters - Ultrasonic / Electromagnetic/ AMR flow meter ( Not in the

scope of this tender)
Automatic Control Valves at inlet and Outlets of ESRs/ MBR/ GSR with
level sensor, pressure sensor, flow sensor for measurement of flow rate &
totalized flow

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Ultrasonic level sensors for filter beds of WTP, recirculation sump of

WTP, MBR & HLR of existing WTP, pure water sump , Pure water
sump
Smart Pressure Transmitters for Raw water pumps, Blowers of existing
Power Analysers for Raw water pumps, Blowers of WTP and Pure water
pumps at -Visava.
Energy Monitoring System interfacing to PLC Panel as per Schedule B for
Raw water pumping machinery, WTP, & pure water pumping machinery at -
--Visava--------------
PLC based control and communication software as per IEC 61131as per
Schedule B Raw water pumping machinery, WTP, & pure water pumping
machinery at Visava----------
PLC based Control PAC dosing / Clarifocculator system for WTP
Quality Monitoring Instruments for WTP
PLC Panel for collection and transmission of field data with solar panel with
Battery back up .
Power cables, Communication cables & Signal cables with Cable trays.
SCADA Software runtime and development version for perpectual licence
Developing/programming & installing SCADA software
Interfacing to Centralised Computer Station
46" LCD monitor at Conference Room for display of total water system
(Online)
Laptop with programming software run time version along with required
cables and communication devices for PLC and SCADA programming
Important
The contractor shall study the actual manual operation of the complete wa-
ter supply scheme. And following documents in standard format shall be
submitted for approval before starting execution.
Process and instrument Diagram. (P&I)
Process Description document (PDD)
Instrument Index sheet
Specification Sheet in ISA format.
Control strategy
Architecture

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The installation of following equipments shall be done under the guidance & supervision
of representative of Manufacturer.
1) Flow meters ( Not in the scope of this tender )
2) Field Data Transmitters (Programmable Microcontroller with Modem)
3) Ultrasonic level sensor
4) Pressure sensors
5) Automatic flow Control Valves
6) Computers/Servers
7) Solar Panel with Battery
The guarantee period starts from date of commissioning of the equipments. The defect
liability period for the Flow meters, Automatic flow Control Valves, Ultasonic Level
Transmitters/sensors, pressure sensors, multifunction meters, PLC, SCADA software,
pH/Turbidity/Chlorine Analyzers, Field data transmitters with Solar Panel with Battery &
Data Communication System, etc. will be counted from the date of Trial Run of entire
scheme. During this period all wear and tear to Flow meters, Automatic flow Control
Valves, Ultasonic Level sensors, pressure sensors, multifunction meters, PLC, SCADA
software, pH/Turbidity/Chlorine Analyzers, Field data transmitters with Solar Panel with
Battery & Data Communication System is to be borne by the Contractor, considering this
offer may be quoted.
1.0 GENERAL SPECIFICATIONS
1.1 Equivalency of Standards and Codes

Wherever reference is made in the contract to specific standards and codes
to be met by the goods and materials to be furnished, and work performed
or tested, the provisions of the latest current edition or revision of the rele-
vant standards and codes in effect shall apply, unless otherwise stated in
the contract. Where such standards and codes are national, or relate to a
particular country or region, other authoritative standards that ensure an
equal or higher quality than the standards and codes specified will be ac-
ceptable subject to the Engineer's prior review and written approval. Differ-
ences between the standards specified and the proposed alternative stan-
dards must be fully described in writing by the contractor and submitted to

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the Engineer at least 28 days prior to the date when the contractor desires
the Engineer's approval. In the event the Engineer determines that such
proposed deviations do not ensure equal or higher quality, the contractor
shall comply with the standards specified in the documents.
Standard and Codes
Generally the specifications for supply, implementation and support of the

product and services shall be governed by relevant Indian Standard (IS) is-
sued by the Bureau of Indian Standards (BIS) & CPHEEO manual on Water
Supply, IEC. In the absence of ISS the British Standards (BS) or American
Standards (AS) shall be followed. In all the cases the later issue/ version/
amendment shall apply. Where no ISS or alternatives are available, the spe-
cification suggested by the employer from other standard shall be adopted.
The relevant international standards for software development deployment
and maintenance shall be incorporated to the system and produced to the
engineer for reference. The employer shall clear the doubts and give final
decisions based on the request of the contractor. The decision intimated in
writing shall be binding on the contractor. Only SI system shall be followed.
A conversion utility as required by the engineer shall also be provided.
1.2 Sign Board

The Contractor shall provide a sign board at the site of the works of ap-
proved size and design which provides (i) the name of the project (ii) the
names and addresses of the Employer, the Contractor and the Consultant;
(iii) the name and short description of the project, (iv) the amount of the
Contract Price; and (v) the starting and completion dates.
1.3 Protection of Utilities
The Contractor is required to carefully examine the location of the Works and their
alignments and to make special enquiry's with all authorities concerning all utility
lines such as water, sewers, gas pipe, telephone (underground and/or overhead)
lines, electric cable (underground and/or overhead) lines, etc.; and to determine
and verify to his own satisfaction the character, sizes, position and lengths of such
utilities from authentic records. The Contractor shall be wholly responsible for the

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protection and/or facilitating relocation of such utilities as may be required, and

shall not make any claim for extra work or extra time that may be required to
protect or facilitate relocating such utilities. If any major shifting or realignment of
water, sewers, gas pipes, electric and telephone lines is necessary due to their
interference with the proposed Works, the same may be done by the Employer.
The cost of such relocation will be borne by the Employer.
In case the alignment of the pipeline crosses the high tension electrical
transmission lines belonging to the MSDCL or other authorities, the Contractor
shall take all precautions necessary to see that the work is carried out with care
and safety, without disturbing such transmission lines. The Contractor will be
responsible to carry out all construction activities in such reaches in consultation
with the owners of such facilities. However, satisfactory completion of the entire
work will be the responsibility of the Contractor.
Functions required at Pumping Station:
Pumps shall stop when the water level in the inlet sump/ reservoir is reached be-
low minimum set water level.
When the water level reaches to maximum, system shall give alarm.
The pump(s) shall stop when the water level in the destination sump/ reservoir
reaches to Maximum.
When the pressure level in delivery pipe near pump house reduces below set limit,
the pump shall stop and the delivery valve of the particular pump shall close.
When the power shuts down (Pump-off), the pump delivery valve has to be closed.
When the power is restored, application software and RTU shall start the pump on
the basis of duty pump selected and mode of operation viz. Auto/ Semi-Auto/ Ma-
nual and the signal shall be sent to the MCS.
If the power is restored within 30 minutes, the standby pump has to start and if the
power is stored after 30 minutes, the duty pump shall start duly opening the rela-
tive valves. When set duty hours of the pump running are over then during next

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power cut and restoration stand-by pump will become duty pump and that running
as stand-by.
Electrical parameters, like voltage, current, power factor, Frequency, Energy con-
sumption etc., for each pump shall be monitored using Load Manager (Electrical
Parameter Monitoring System) and if any of the parameter crosses set min or max
limits alarm shall be generated.
All other safety devices like level sensor, pressure sensor, installed in the pumping
station shall be interfaced with PLC/RTU and Min & Max limits for each parameter
shall be set. Any parameter crossing the set limits, there shall be an alarm.
Any other functions as desired by the Engineer in charge of the plant to make it
more easy for day-to-day operation and not involving any price implications shall
be included in the system.
Information / data for various parameters at pre-defined interval (say 15 minutes)

shall be recorded at each location along with trends and alarms data. Generation
of local Reports, Trends & Alarm shall be provided.
Functions required at WATER TREATMENT PLANT
Sludge out let valve shall open and the clarifier bridge shall start working as soon
as the sludge thickness in the sludge pit increases above desired level.
The flocculators shall work when there is flow and shall stop as soon as the flow in
the raw water channel stops.
The filter inlet valve and filtered water outset valve shall be open and back wash
inlet and outlet valve shall be closed. Backwash inlet and out let valves shall open
for 10 15 minutes. Before opening of backwash valves, filter inlet and outlet
valves shall close and vice-versa. The time between the opening of filter inlet and
outlet valve should be such that the level of water over the filter bed is to the de-
sired level.
Head loss due to clogging of the filter bed(s) shall be measured using ultrasonic
level sensor and automatic cleaning of such clogged filter bed shall be initiated by
PLC/ RTU and SCADA software. Only one filter bed shall be taken for backwash-
ing at a time.

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Monitoring of water quality parameters is one of the tasks at treatment plants.

Chemical dosing shall be controlled by the PLC /RTU on the basis of water quality
parameters monitored pre or post dosing.

shall be recorded at each location along with trends and alarms data. Generation
of local Reports, Trends & Alarm shall be provided.
Functions required at ESR locations:
Monitoring of water level in the reservoir (for each compartment in case of multi-
compartment GLSRS) using ultrasonic water level sensors;
Controlling inlet and outlet valve(s) locally as per pre-fed schedule and based on
the water level in the reservoir using solar operated DC actuators.

shall be recorded at each location along with trends and alarms data.
Data / information shall be transmitted to MCS periodically as defined in the sys-

tem over GSM/GPRS data communication network;
Receive the control commands received from MCS and accordingly perform the
valve operation.

Functions at Master Control Station (MCS):

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MCS is to be programmed and designed to receive all the data and information
from various stations specified. This has to be designed for expandable up to ad-
ditional 50 stations.
MCS shall receive the data from all Major Pumping Stations, treatment plants and
Master Balancing Reservoirs (MBR) directly over VHF wireless data communica-
tion network by adding additional radios in the communication network.
Data from ESRs, GLSRs and CMPTs shall be received over GSM/GPRS network
through MBR stations.
The MCS shall be able to view the data received on layer wise for any stations se-
lected to view the performance of each station and control.

4.0 General Technical specifications
4.1 Design Criteria
1. System shall be designed, manufactured, installed and tested to ensure the high
standards of operational reliability and suitable for continuous operation.
2. All electronic components shall be adequately rated and circuits shall be designed so
that change of component characteristics shall not affect plant/ pump operation.
3. All equipment shall be new, of proven design, reputed make and shall be suitable for
continuous operation.
4. Unless otherwise specified, all instruments shall be tropical zed. The outdoor equip-
ments shall be designed to withstand tropical rain. Wherever necessary space hea-
ters, dust and water proof cabinets shall be provided. Instruments offered shall be
complete with all the necessary mounting accessories.
5. Electronic instruments shall utilize solid-state electronic components, integrated cir-

cuits, micro controllers etc., and shall be of proven design.

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6. Unless otherwise specified, the normal working range of all indicating instruments
shall be between 30% and 80% of the full-scale range.
7. The instruments shall be designed to permit maximum interchange-ability of parts

and ease of access during inspection and maintenance.
8. The field instruments i.e. the instruments mounted outside the control panel shall be
mounted at a convenient height of approximately 1.2 m above grade platform.
9. The instruments shall be designed to work at the ambient conditions of temperature,

humidity and chlorine contamination that may prevail. The instruments shall be given
enough protection against corrosion.
10. All field instruments and cabinets/ panel mounted instruments shall have tag-plates/
name-plates permanently attached to them.
11. The performance of all instruments shall be unaffected for the 10% variation in
supply voltage and 5% variation in frequency simultaneously.
4.2 CONTROL, INSTRUMENTATION AND AUTOMATION

4.2.1 General
For uniformity of appearance all panels shall have a common appearance and
color. Adequate size shall be provided to accommodate all the necessary
equipment.
In order to reduce the holding of the spares to a minimum, the instruments and,
electrical, control and instrumentation equipment and components of similar type
and purpose, used throughout the works shall be of the same manufacturer and
type / series.
All ventilation grills provided to the control panel shall be provided with fly screens
to prevent the entry of insects.
4.2.2 Glossary
The following abbreviations have been used in this document:
(a) MBR - Master Balancing Reservoir
(b) AC - Alternating Current
(c) DC - Direct Current

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(d) I&C - Instrumentation and Control
(e) A - Ampere
(f) mA - Mille-ampere
(g) V - volt
(h) Hz - Hertz (cycles per second)
(i) MCB - Miniature Circuit Breaker
(j) CP - Control panel
(k) UPS - Uninterruptible Power Supply
(l) RTU - Remote Terminal Unit
(m) I/O - Input/ Output
(n) OIU - Operator Interface Unit
(o) LAN - Local Area Network
(p) PC - personal computer
(q) MCS - Master Control Station
(r) ppm - Parts Per Million
(s) HLR - High Level Reservoir
(t) CSR - Central Storage Reservoir
(u) VHF - Very High Frequency
(v) UHF - Ultra High Frequency
(w) RTU - Remote Terminal Unit
(x) PLC - Programmable Logic Controller
(y) IPS - Intermediate Pumping Station
(z) BPS - Booster Pumping Station
4.2.3 INSTRUMENTATION SYSTEM DESIGN CRITERIA
The design criteria to be applied to instrumentation systems shall be as follows:

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(a) All instruments shall be suitable for continuous operation
(b) All transmitting instruments shall have a 4-20 mA linear output
(c) All digital outputs shall be volt free
(d) All instruments shall be designed for the ambient conditions of temperature
(43oC) and humidity (Average level 800M MSL)
(e) All wetted parts of instruments sensors shall be non-corrosive and suitable
for use with potable water containing residual chlorine of maximum 5 ppm.
(f) All displays shall be of the digital type with no moving parts utilizing back-lit
liquid crystal diode technology
(g) Instrumentation shall utilize solid state electronic technology and avoid the
use of any moving parts wherever practicable
(h) Instruments shall resume operation automatically on application of power

following a power failure
1.2.4 INSTRUMENTATION & CONTROL SYSTEM POWER SUPPLY
230V/ 415V AC, 50 Hz feeders shall be made available for power supply to
instrumentation & control equipment. UPS shall be provided as a back-up power
supply for complete instrumentation & control, SCADA and VSAT AND
GSM/GPRS Data Communication System. The required DC voltages for these
systems shall be derived from the UPS supply by providing necessary converters.

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METHODOLOGY OF SCADA AND AUTOMATION SYSTEM

2. INTRODUCTION TO PROPOSED AUTOMATION SYSTEM:
The automation system proposed shall be with Integrated Water Distribution

Management system to monitor and operate supply of water from the source up
to the ESRs in ..Satara MJP............. Area.
The Integrated Water Distribution Management System (IWDMS) is aimed at

designing and implementing an engineering and management solution for
continuous Water Supply System based on the state of the art software and
hardware technologies.
An Operation Control System (OCS) consists of a set of equipment, activities and

processes allowing all the information on the operation of a water supply system
to be obtained and analyzed by transmission of the system data to an operational
centre. Based on these data, operational, routine or emergency decisions
regarding the different components of the system, from intake to distribution
network, are made and actions taken accordingly.
The OCS facilitates integrated operation of the scheme; The OCS includes a
SCADA (Supervisory Control and Data Acquisition) system, providing steady
receipt of information.
The functions of the OCS are to:

Coordinate routine and emergency operation of the integrated supply system.
Inform the water production centres of the flows required in each as well as
their respective schedules, taking into consideration and demand aspects.
Coordinate with the production centres the reduction of flows due to mainte-
nance or emergency measures, such that they do not affect the water supply.
Obtain all the pertinent data on the behaviour of the conveyance network and
storage reservoirs.
Allow fast operational decision-making in order to provide answers at any
given moment regarding system requirements.
Save power and water.
Maintain general data on system operation.
3. CONCEPTUAL ASPECTS:
Implementation of an OCS in a water supply system entails a division between
production, conveyance and supply through pressure zones. Thus, production
determines the conveyance system and/or main network, and the pressure zones,
as it done in present project. According to this scheme, the data inflows and
outflows are defined from and to Central Control Room (CCR).
It is very important to take in account the administrative and operation

organization of management of each one of the components of the water supply
system, because the main strategic concept proposed by TAHAL that based on
many years of experience to see SCADA system as instrument of management.
Central Control Room (CCR) or SCADA room is proposed to be located near

[22]
Water Treatment Plant (WTP).

Apart from central control room, Local control rooms with RTU containing PLC
and HMI are proposed at following locations to control the operations of that
particular station/plant.
Raw Water Pumping Station
....21 ( 21 + 7.50 )..... MLD WTP
MBR /ESR/ GSR
......... ESRs in ....SATARA MJP Area.
o ....0.. Nos. Proposed ESRs

o 13...... Nos. Existing ESR
Data from Raw Water Pump House (RWPH), WTP, Clear Water Pumping Stations
(CWPS), MBR, GSR and Elevated Service Reservoirs (ESRS) shall be
transmitted to Control room at Water Treatment Plant (WTP) via wireless GPRS
communication for monitoring. A GPRS gateway shall be provided at Central
Control Room to handle the signals from various locations (RWPH, MBRs, and
ESRs).
From WTP, entire data shall be transferred for monitoring to Remote stations
through GPRS communication.
The operation and control of Pumps at Raw water Pumping Station, Clear water
pumping station at WTP Sump, and entire Water treatment plant .The
backwashing of filters shall be controlled through a PLC / SCADA system. The
back washing of WTP shall be controlled through PLC/SCADA.
The RWPH, WTP, CWPH and ESRs are designed to operate in automatic mode
of operation at all given times. In the event of failure of the same, the facility is
provided to operate available reserve, if it was planned the availability to operate
each of systems or all plant in Manual mode available always. The hydraulic
protections such as level, flow and pressure are incorporated in the design to
ensure that the plant is operated in a safe condition at all times and to ensure
maximum uptime. The Local Manual Controls are provided adjacent to the units to
facilitate ease of day to day operation and maintenance
4. SYSTEM CONFIGURATION:
The SCADA System comprises five (5) zones, which are:

Raw Water Pumping Station (2 Working+1Standby pumps) 21.0 MLD
WTP.
Pure Water Pumping Station (1.... Working + ..1.... Standby pumps)
(150 HP (1+1)/270 HP (1+1) /135 HP (1+1) / 30 HP (1+1) /12.5 HP (1 + 1)
GSR - ......1 Nos, ( ..1..... Nos. Existing )
MBR/ ESR ..../...12.. Nos.(..12..... Nos. Existing )

[23]
All these zones are controlled from Central Control Room (CCR). The tables and
drawings showing the various zones and ESRs are attached herewith.
To cover all the project facilities with SCADA, the following types of PLC are
proposed:
Raw Water Pumping Station
Water Treatment Plant.
Pure Water Pumping Station
MBR
Elevated Service Reservoir (ESRs)

5. SCADA SYSTEM & DESCRIPTION:
The proposed SCADA system is hierarchical that can be best described by four
functional areas:
Operation Control Center (OCC) or Central Control Room (CCR)
Communications System
Local (Remote Stations) Control (PLC, GPRS)
Instrumentation and Process Automation
The above triangular structure is typical for many SCADA systems and has been
adopted for proposed project. To ease the reading the technical proposal is following this
division and order as much as possible.
The SCADA shall be of the distributed type, confirmed by the control levels. In the Scope
of Works associated with the SCADA, these generally do not include level 0 (this is part
of Control Circuits of MCC) of the equipment own, as for example: valves actuator).
Each levels function is described in general form as follows:

[24]
i. Level Zero: Direct operation and supervision in each particular equipment.
ii. Level One: Local operation and supervision of groups of equipment by means of
boards with instrumentation, controls, indication and other tools for safe process
operation. In this level two control modes are possible:
a. LOCAL MANUAL: The operator will have the handling of the equipment, and
the control from higher levels will be disabled.
b. LOCAL AUTOMATIC: If available, the control will be made by the control ele-
ments of the equipment. The control from higher levels is disabled.
The control from higher levels will be informed about this operation mode and
will not have.
iii. Level Two: This refers to the set of automation that controls all the operations of
a station. It monitors all the equipment, is capable of executing locally- or remote-
ly-requested general station operation orders, and can produce operation reports
as detailed as required.
Control level 2 will be the first level of basic control for the equipment, either of
each one in individual or of a limited set of equipment. Some level 2 equipment
will have their own microprocessor- based control and others will be integrated to
a PLC-based local control, therefore a commutation system shall be available for
selecting the desired control mode. the possibility of controlling it.
There shall be three control modes in level two:

Manual local
Automatic local
Remote: The control is made from higher levels, it is the normal operation
mode
In the "Local Manual" control mode the operator will have the handling of the
equipment and the control from higher levels is disabled.
In the "Local Automatic" control mode the equipment microprocessors and the
local control equipment will have the control, aided by the local programs that will
perform all the operation functions. In this mode the control from the higher levels
remains disabled.
In the "Remote" control mode, control is given to the higher levels. This mode will
be the normal control mode for the system operation, while the local control
remains disabled, except for the protections, which will have priority for stopping
the equipment or for holding them during the waiting or start up periods.
All level two equipment communicate with those of level three by means of the
communications network.

[25]
iv. Level Three: This corresponds to the SCADA where the operators will have
all the information from the system and will distribute operation commands to
the various sites. Monitoring and operation reports for each site will be available.
A database for system operation analysis shall be constructed. Practically this
refers to the Control Center.
This level will comprise the set of application programs that from the mentioned
operational control and information system, will automatically define operation
commands for each site that requires them based on the information collected in
the historical archives and based on the operation data pre-established by
statistical behavior patterns of the system
CONTROL OF DIFFERENT PUMPING UNITS:
The control of diverse elements of the system such as pumping will be made in
two ways : Local and Remote.
The LOCAL way of operation is detailed further ahead in the section referring to
PLC, where as the REMOTE way is handled from Control Centre Room. The
decision on which way will the equipment operate is based on a precedence order
and it will be taken in the site by means of a control switch (LOCAL/REMOTE).
The REMOTE operation to be executed by the Control Centre will be
REMOTE/AUTOMATIC or REMOTE/MANUAL. AUTOMATIC operation refers to
the way of operation pre-programmed according to the criteria established for
each site in individual, and the operation.
MANUAL will be performed under the command and supervision of the system
operator, according to the effective instructions for normal or emergency
operation, which is practically a forced way, executed directly by the operator.
Proposed system shall have 1No. work station at each location having latest PC
with at least21 LED Monitor. PCs shall be loaded with licensed software
Controller packages.
( To be provided for large Projects only)
6 LOCAL CONTROL PANEL FOR PUMPING STATIONS AND RESERVOIRS:
Each one of these installations shall have a local control panel or PLC Local
Control Panel shall be housed with a PLC Controller for Local Operations.
Local PLC Controller shall work in coordination with Main System in fully auto
mode. However, in event of requirement of Local Operation local PLC Controller
shall be fully capable of handling all local operations independently.
Manual or automatic control of different pumping or valve units; each RTU will be
equipped with a REMOTE/LOCAL control switch. The state of this switch will be
transmitted to the Control Center, and it will be presented in the corresponding
screens. In the REMOTE mode the handling of all the equipment will be executed

[26]
from the Control Center, according to previous details. In case of loss of

communication, the equipment will continue operating or maintaining the state
according to the last updated command.
In LOCAL mode the equipment will be operated by means of the PLC according
to the information available in the site, automatically. The Control Center will not
be able to send command to operate the equipment in this mode, while it shall
still be normally receiving the information. Also, the possibility exists of
programming a clock that allows the operation during 24 hours.
Additionally each PLC will be equipped with an amount of control switches equal
to the same number of devices (pumps, valves, etc.) to be controlled. This switch
will have three positions: AUTOMATIC/O/MANUAL. The state of this switch will be
transmitted to the Control Center and displayed in the corresponding screens.
The switch will allow choosing, for each pumping or valve unit, its operation
mode, according to the decision of the operation personnel in the PLC site. In the
AUTOMATIC mode the equipment will be controlled by means of the PLC
according to the state of the control switch REMOTE/LOCAL.
In the "O" mode the equipment will stop and it will not allow any operation.
The MANUAL mode will disconnect the PLC equipment and it will be handled in
conventional manual form. In this way the PLC will not have any possibility of
taking part in the operation of the equipment, not even in the activation of the
hydraulic protections, but if it will continue with the data collection and its
transmission to the Control Center for its processing and normal presentation.
Local control Panel (LCP) or PLC with following facilities:

Selector switch for Local/Off/Remote for LCP. to choose the mode of opera-
tion of PLC
Auto mode is selected all the pumps/valves/gates etc. can be operated from
the SCADA
START/STOP push buttons for corresponding Pump
SCADA receive the following feedback from the LCP:

RUN and combined TRIP feedback for corresponding Pump
Local/Off/Remote feedback for corresponding Pump
Emergency Stop feedback for corresponding Pump.
Auto/Off/Manual soft switch shall be provided at SCADA.
Start Permissive for different Modes;

In Remote Manual /Auto Modes the Logic shall execute only when the following
conditions are met:
The water level is not out of the operating range Duty Mode has to be se-
lected in SCADA.
Respective mode is available (Remote mode, Non Failure of mains power
supply) for operation.

[27]
Respective on off discharge valves (if any) are available (Remote mode &
Non Failure of mains power supply for operation.
No trips are generated by protection
Stop Permissive for different Modes;

The drives shall trip under the following abnormal conditions to ensure safe
operation and protection of Pumps:
Tank/Sump level out of range.
Respective drive is not available
Any trip alarm generated.
Pumps & Motorized valve/gate operation;
Local Mode:
When Local/Remote selector switch in pumps & valve/gate is in Local Mode,
each pumps & valve/gate can be operated through Push Button (PB) provided in
at LCP or PMCC/MCC valve/gate actuator panel.
Remote Mode:
When Local/Remote selector switch in pumps &valve/gate is in Remote Mode,
each pumps & valve/gate can be operated through RTU and /or SCADA in
Control room.
Auto Mode
When the selector switch is in Auto mode, each pumps & valve/gate shall operate
automatically based on the Control sequence logic built in the PLC or SCADA in
Control room
Manual Mode:
The operator in the Control Room can select Manual mode from SCADA for
enabling Manual operation from SCADA. In this mode all the pumps &
valves/gate can be operated individually.
Signal Interface to PLC Drives;

The following signals are hardwired between PLC and MCC/Soft Starter Panel
Drive Run feedback
Drive Trip feedback
Drive in Local/Off/ Remote Mode status
Drive Start/Stop Command
Drive Emergency Stop feedback
Motorized Valves/Gates;
The actuators for electrically operated Gates have their own inbuilt display board
and local control logic in built with the Actuators. The following controls are
provided:
Each actuator has the following facilities for local operation:
Lockable Selector switch for LOCAL / OFF / REMOTE.
OPEN / STOP / CLOSE push buttons
Lamp indication for Fully OPEN position / Fully CLOSED position

[28]
Lamps for Fault indication including HIGH Torque and other Fault indications
as per manufacturer requirement in the Display Board.
Lamps for status indication of Actuator towards Open Position, Actuator to-
wards Close position, Actuator in Local mode, Actuator in Remote mode and
other status as per manufacturer requirement in the Display Board.
PLC receives the following feedback from the actuators:

Collective fault indication for Actuator including the High Torque Fault
LOCAL / OFF / REMOTE position feedback
Valve/ Gate Fully open / fully closed position feedback.
Position indicating transmitter shall be available along with each control valve
actuator for position control based on desired set points.
OPERATION AND CONTROL PHILOSOPHY:

This section describes the general Operation and Control Philosophy of the
following:
Raw Water Pumping Station.
Water Treatment Plant.
Pure Water Pumping Station.
MBRs,ESR, GSR
OPERATION AND CONTROL PHILOSOPHY OF RAW WATER PUMPING

STATION:
RWPS and operation of Raw water Pumps to WTP should be controlled based on
the WTP Pure Water Tank water levels.
Details of Pumps to be installed on Jack well

Sr. Pumping to Type HP standby Discharge Head
No In LPS of In Mtr.
each
pump
1 As per BOQ & specs mentioned above
Raw water is pumped from Pumping Station at Mahuli ( Krishna River ) and
receives by 600.mm dia. pipeline by pumping to WTP aeration fountain . The
Raw water inlet will be monitored by insertion type flow meter provided before
Aeration fountain in the WTP premises. Web based arrangement shall have to be
provided on incoming 600 mm dia.. RWPS shall have a PLC, GPRS gateway,
Vsat and Field instruments etc. for facilitating transmitting the data of inflow of raw
water to the Central control centre.
If the WTP CWR water level reaches the pre-set high level, a soft alarm shall be
raised at the SCADA for alerting the operator. If the level continues to rise and
reaches the pre-set High High Level, again a soft alarm shall be raised at the
SCADA and also transmitted to the CCR.

[29]
In condition when the treatment process is interrupted (WTP is out of order), the
raw water inlet butterfly vale (in the premises of WTP) will be stopped through
SCADA.
When the water level in the Clear water reservoir of the WTP is above the pre-set
High High level and continue to rise and in case the water level in the tank will
reach overflow level, the raw water inlet butterfly valve ( in the premises of WTP)
will be closed. It will open automatically when the water level in the tank will drop
to the pre-set level. The local PLC will communicate with the overall system via
SCADA to control the raw water inlet butterfly valve.
PLC shall continuously register the opening status of Butterfly valve and display
the same in PLC Screen.
OPERATION AND CONTROL PHILOSOPHY OF WATER TREATMENT PLANT
AND CWPS:
The treatment plant consists of the following units:
Inlet chamber and Parshall Flume
Flash Mixing Section
Clariflocculation System
Filtration System
Wash water tank & Wash water pumps
Air wash arrangement & Blowers
Filter backwash water recovery tank- recirculation tanks & pumps (2W+2S)
Chemical Building (Coagulant & Polymer dosing system)
Chlorine Disinfection System
Clear Water Contact tank
Auxiliary/Drain System.
Control Process Assumptions

The control process philosophy will be based on the following assumptions:
The objective of the control system is to ensure proper operation of the water
treatment plant including its treatment components such as rapid mixing, coa-
gulation and flocculation, settling, filtration and water disinfection, with proper
control of chemical addition, e.g. chlorine gas, lime and Coagulant .
The central control system will be situated in the local electric room adjacent to
the filtration system and will gather all process information from the field in-
strumentation in order to control the process and to prepare reports.
Since the reports are an integral part of the control system all data acquisition
must identify and tackle problems of erroneous data.

[30]
Alarms and warning will be shown with blinking local light and sound. Alarms
will remain active as long as the site conditions prevail. When conditions revert
to normal operation, the alarm returns to its normal condition.
INLET CHAMBER AND PARSHALL FLUME:
The inlet chamber of the plant consists of electrically actuated gate valve to be
closed in case of emergency.
An online Turbidity and pH Analyzers shall be provided at the inlet to measure

the Turbidity and pH of the raw water coming from RWPS. The raw water
shall be delivered for sampling to the Plant laboratory by means of sampling
pumps.
Control system shall continuously monitor Inlet flow, turbidity, pH,
PARSHALL FLUME:
A Parshall flume arrangement is provided for flow measurement of aerated

&Coagulant dosed raw water. The Parshall flume acts as a velocity control device
so that the raw water passes through without turbulence. The ultrasonic insertion
type flow meter provided at inlet pipe to Aeration fountain shall measure the
average raw water flow. The raw water flows further by gravity to the Flash Mixing
System for further treatment.
FLASH MIXING SYSTEM:
The Flash Mixing System shall comprise a tank with flash mixer at the tank.
Coagulant dosed at the inlet of the treatment plant mixes with the raw water at the
flash mixing tank and passes to the Clarifies for further treatment.
Status (run/trip/local-off-remote) of the flash mixers shall be indicated at SCADA.

G Value of Flash Mixer shall be calculated and indicated at SCADA
In case the mixers is out of order SCADA will generate Alarm and send SMS.
CLARIFLOCCULATOR:
Clarifiers are designed for the removal of readily settle-able solids and suspended
particles and therefore, reduce the suspended particles content. The purpose of
the clarifiers is to remove a substantial portion of the organic solids from the raw
water, with a resulting decrease in the organic and suspended materials loadings
of the filter units. Clarifiers is constructed as circular concrete structures.
Clariflocculator is a combination of flocculator and clarifier fabricated to attain

economic and speedy construction. It shall have two concentric tanks where inner
tank serves as a flocculation basin and the outer tank serves as a clarifier.

[31]
Clariflocculators generally are used to perform the chemical primary treatment of

effluents.
The monitoring to be made in clariflocculator shall be for;

Turbidity at the common outlet channel of clarifiers
Instrumentation considered for clariflocculator shall be;

Turbidity Transmitter online at the common outlet channel of clarifiers Motor-
ised valve at sludge removal/drain
Loss of rotation switches for the scraper bridge.
Control system shall continuously monitor turbidity and based on turbidity or
time, motorized valve shall be operated for sludge removal process. Rotation
of the scraper bridge and the flocculation mixers should be controlled.
OPERATION IN AUTO MODE:
The operator has to put the selector switch in auto mode.
The opening and closing of drain valve shall depend on the turbidity fac-
tor/Time base as turbidity transmitter is provided at plant inlet, the time setting
can be adjusted from SCADA for opening and closing of valve during seasonal
changes.
OPERATION FROM SCADA:
Start Stop control shall be provided on SCADA in order to switch On or Off the
clarifier Bridge Motor and also Open/close feedbacks shall be shown on
SCADA.
Open/Close control shall be provided on SCADA in order to open and close

the sludge drain valves and also open close feedbacks shall be shown on
SCADA.
The sludge valves operation should be interlocked with the sludge level in the
Sludge balancing tank.
Status (run/trip/local-off-remote) of all motors shall be indicated at SCADA HMI. G

Value of Flocculators shall be calculated and indicated at SCADA
OPERATION FROM LOCAL CONTROL PANEL:
Auto/Manual selection will be provided on HMI screen in such way manual

mode is selected all the pumps/valves/gates etc. can be operated from the
HMI screen individual. Auto mode is selected all the pumps/valves/gates etc.
can be operated from the PLC/SCADA.

[32]
Individual Start/Stop push buttons shall be provided on local panel to operate

Sludge drain valves.
Indication lamps shall be provided on local panel which shall give Open,
Close, Trip indications for all motor actuated sludge drain valves.
Turbidity deviation or malfunction of any part of the unit should generate Alarm
FILTRATION SYSTEM:
The gravity filtration system comprises the following main

Inlet channel with weirs and inlet gates.
(4.) gravity sand filters BEDS ((EACH HAVING 2.) Sectons) WTP
Backwash water tank
Air scour system
Valves with actuators for inlet & outlet of filters, clf drain valve, back wash
pumps &
Blowers .
Instruments
Local filter control consoles (HMI)
SCADA connections
The filtration system containing eight rapid gravity sand filters contained in one
block.
A gravity filter consists essentially of an open-topped concrete tank. Tank is

designed to drain at the bottom, and partly filled with the filtering medium (clean
sand). Clarified water is admitted to the space above the filter media and flows
downward under the action of gravity. Purification takes place during this
downward passage, and treated water is discharged. Filter tank is provided with a
level Transmitter to control the water level.
Operation of the filter is provided by menace of the following Control valves:

Automatic Valves/ Gates:
Name Purpose
Filter Influent Allows incoming water into filter
Filter Effluent Allows treated water out of filter
Backwash Water in Allows clean backwash water into filter
Direct Filter to Drain Allows first filtered water out to drain
Backwash Air Allows backwash air into filter
FILTER CONTROL SYSTEM:
The filter operation is a complex phenomenon for making the system automated.
The filtration plant is going to work for the different flow conditions from 0 MLD to
(28.5.) MLD + 20% of WTP . The operation at the same time also envisages
constant rate filtration. The filters are also required to operate between the preset

[33]
high and low levels of water over the sand bed. All these conditions will have to be
suitably taken into considerations for automation of filter operation.
In case there is signal from partial flume measuring device that no raw water is
available to the plant or the water level in the filter box is at lower preset value,
then this shall trigger the close of filter outlet valve/valves. The sand filter gets
exhausted over a period of time while filtering the settled water. It then needs
back washing to remove the clogging and make it freshly available for the
process. The rate of exhaustion is measured in terms of pressure differential
across the filter. It is expected that the filter will work at the constant rate of
filtration and in turn develop the pressure differential. The owner desires to
automate the filter back washing operation. A back washing operation is carried
out as described below.
If the pressure differential across the filter reaches a preset value of say 1.8-m,
than the filter is taken out of filtration process for back washing. Prior to starting
the back washing, it has to be confirmed that power supply is healthy and the over
head wash water has sufficient water level. The inlet butterfly valve to the filter is
closed and the water over the filter is allowed to get through the filtration process.
Once the water recedes to preset level, the filter outlet valve is closed and the
drain valve is opened.
The blower is switched on and operated for preset time. The air supply valve is
opened no sooner than the blower is switched on. After air washing the filter sand
for preset time, the air inlet valve to the filter is closed and simultaneously the
blower is switched off. Consequently the wash water inlet valve to the filter is
opened and water wash is started. The water wash is provided after the preset
time is over, the wash waster inlet valve is closed. In order to ensure that the back
wash water gets drained fully a time lag based on the actual experience /
requirement needs to be incorporated for the drain valve to start getting closed,
the drain valve is closed. The inlet valve to the filter is opened and water is taken
for filtration. Simultaneously the filter outlet valve is gradually opened from its
closed position to a fully open position in a preset time. Simultaneously the
filtration rate-controlling valve has to operate itself in such a fashion, that the filter
out flow rate is reached to the designed value in preset time. With this filter back
wash operation is completed and the filter gets commissioned once again.
The pressure differential across the filter at this point of time has to be below a
preset value of say 0.25-m. In case it is more than this that a error needs to
flashed. Sooner the filter back wash is over the wash water pump shall be
switched on and the wash water tank shall be filled to the full supply level. In case
no water is available for filling the wash water tank at the source then this activity
is differed.
The filtered water passes over the rectangular notch meant for measuring output
flow of the filter. This measurement is calibrated based on the level of the water
over the notch. The level-measuring instrument along with the transfer of data in
real time to the computer is expected, to know the flow rate.
Turbidity and pH of the filtered water is also measured using an online turbidity

[34]
and pH analyzer provided at the inlet of clear water sump. Post chlorine shall also
be dosed at the inlet of the clear water sump. Each filter shall be operated in auto
mode from the SCADA HMI located at control room and Local control panel (HMI)
provided for each filter located at Filter House. In case of failure of auto mode, the
filter operation shall be done through Manual push button mode.
OVERALL OPERATION STRATEGY:
MODES OF OPERATION
The filtration system operating mode of each filter is determined by the filter
system mode selection located on the local filter system main control panel (HMI).
The system mode can be either AUTO, Out of Service or MANUAL, each filter
condition will be indicated on the HMI.
Manual Mode
If the filter is switched to MANUAL mode, automatic backwashing will not occur
and the operator must activate the local valves and pumps and blower switches
local to the equipment. Alarm indications are active while the system is in
MANUAL mode. As the interlocks and actions to alarms are not active, the
operator must be aware of potential problems that can occur during manual
backwash. If the system is conducting a backwash when in AUTO mode and the
operator switches to MANUAL mode, the backwash is abandoned immediately.
The backwashing and blower stop and the valves return to their filtration position.
All valves in Manual Mode to be actuated from the HMI at the upper filtering
gallery or locally near the valve location.
HMI should also contain buttons for Backwash valve actuation and Blower
operation so, that all backwash and valve operation in Manual Mode could be
done from local HMI of each filter.
Auto Mode
The Programmable Logic Controller (PLC) controls the backwash cycle. The
system performs backwash automatically based on the scheduling parameters set
up within the HMI mimic pages.
OFF or Out of Service

If a Filter is selected to Off or "out of service" via the selector switch on the Filter
Operation Box (HMI) a white light on the HMI will display that the filter is out of
service. "Out of service". When selected to Out of Service the PLC
automatically closes all filter valves, except the direct filter to drain valve), which
remains open to drain the filter troughs, until the water level is minimum + XX
minutes. To put a filter back into service the Auto/Off/manual selector switch must
be selected to Auto.
While in the "out of service" mode, the filter is bypassed by the PLC, when an
automatic backwash sequence is requested.
The "out of service" mode should not be relied upon during maintenance periods
(such as having to enter the filter) and manual isolation of the filter from the rest of
the system must also be done. This is required primarily in case the PLC fails.

[35]
The filter will default to filtration mode, opening the influent and effluent valves.
Sequencer
As mentioned previously, in AUTO mode the PLC controls the backwash

sequence cycles step by step.
Operator-Initiated Operation
Instead of utilizing the filter backwash schedule on the HMI, a backwash can be
manually initiated by pressing the "Start Backwash" button on the HMI. Once this
button is pressed, the chosen sequence begins as long as all per missives and
interlocks are met.
Individual Filter Manual and Automatic Mode
Each filter has a manual or automatic operation. There is a selector switch on the
HMI adjacent to each filter which allows the operator to select Auto operation or
Manual operation. The selected filter mode is indicated on the HMI. When the
mode is changed from automatic to manual, a red light is activated on the HMI to
notify plant personnel that these filters will no longer backwash automatically.
Automatic
The normal mode of operation is automatic, controlled by the PLC. A filter in
Automatic operates with no adjustments by the operator.
Manual
Individual filters in MANUAL mode will no longer backwash based on the inputted
schedules, but will continue to filter water. Once put into this operation, the
operator can open and close valves on that filter by selecting the valve selector
switch to local operation and using the open and close push buttons on the
valves. The operator must be aware that other filters in AUTO mode can still
backwash while the filter valves are being manipulated.
The push buttons for valve operation to be on the HMI.
Blower/backwash water valve Manual and Automatic Mode

Similar to the filters, each blower and backwash water valve have a
manual/off/automatic selector switch. When the switch is selected to Auto the
PLC program will control the equipment, if the selector switch is selected to
Manual the equipment will be started or stopped by the stop/start control station.
If the selected mode is Manual this is indicated on local stop/start control panel.
When the mode is changed from AUTO to MANUAL, the equipment item in
MANUAL mode will not be used in automatic backwashes. Plant personnel can
start and stop individual blower and the backwash valve in MANUAL mode while
leaving the rest of the system in full AUTO mode.

[36]
Automatic
The normal mode of operation is automatic, controlled by the PLC. A blower/pump

in AUTO mode operates automatically during backwashes in accordance to the
pre-set sequence.
Manual
In MANUAL mode a particular blower will not be used in automatic backwashes.

The PBs can be used to start/stop the equipment in MANUAL mode. When in
Manual automatic interlocks are not active, to start and stop these items of
equipment and prevent them from operating while the valves are in the incorrect
position, the operator should ensure that all the necessary valve are in the correct
position.
The overall operation strategy will adhere to the following sequence:
Operation start-up
The flow meter confirms that water is supplied to the works.
All actuated valves on the filters are put into AUTO mode.
The chlorine gas system is turned on and available.
The lime system is turned on and available.
The Coagulant system is turned on and available.

Operation shutdown
No Raw water flowing into the works.
The lime system is stopped.
The Coagulant system is stopped.
The chlorine gas system is stopped.
In case the Lime dosing system is stopped by the Operator, the Plant shut down
should be confirmed, otherwise the Plant will continue operation.
In case there is a failure in dosing operation the Plant should be stopped.
Filter Operation:
Normal Filtration Mode Valve Positions:
OPEN Influent and filtered water valves

CLOSED Backwash water direct filter to drain, and backwash air valves
(M1.x5).
Out of Service Mode Valve Positions:
OPEN direct filter to drain (by water level and time).

CLOSED Influent, effluent, backwash water and backwash air valves.
Under normal operation, the influent water passes through the media, gravel and

[37]
under drain, and enters the filter central drainage channel. The filtered water then
flows from the channel through the effluent valve (open during filtration mode) and
continues downstream to the clear water tank.
Filter Water Level Measurement

Each filter contains a continuous level sensor measuring the distance starting
from the media. During filtration mode, if the water level reaches an operator
adjustable level, set on the HMI, above the media elevation, a HIGH FILTER #
WATER LEVEL occurs.
Available is an enable/disable high level BW PB on the filter mimic screen on the

HMI. If enabled, a backwash will automatically occur on that filter after an inputted
delay time (60 to 1,800 seconds) or when the water level is raised to the pre-set
value. If disabled, the PLC will not initiate an automatic backwash. The operator
should review the situation to see what action, if any, is necessary.
The high level alarm is bypassed during a backwash event but is available while
an individual filter is in MANUAL mode. The alarm is inactive for an out-of-service
filter. Filter High Level will be displayed on the HMI mimic.
As filtration proceeds, the voids in the upper layers of the media are the first to
accumulate solids. Because the same volume of flow is being forced through a
smaller passageway, the water velocity increases. This increased velocity drives
the solids deeper into the media bed, allowing for depth-retention of solids and
longer filter runs between backwashes.
Normal backwash frequencies occur often enough to maintain a properly working

system.
The main indication that a filter backwash must be conducted is when the head
loss (corresponding to the liquid level in the filter) reaches the maximum
acceptable level (as determined by the high level alarm point).Before backwash to
start all interlocks and relevant units conditions to be met.
Pushbuttons and Indications Individual Filter

Each filter has a Filter Operation Box (HMI) which changesits operating, shown
below are the PBs and indications available on the individual filter:
Valve operation from the HMI to be resorted.
Selector
Description
Switch
i) When Auto is selected backwashing will operate auto-
matically provided all the valves, blowers and backwash
pumps are also selected to Auto.
Auto/Off/Manual
ii) When Off is selected the filter is Out of Service or off.
iii) When Manual is selected all automatic operations are
stopped.

[38]
Pushbuttons Description
Each time this PB is pressed and the filter is selected to
Auto, the individual filter will commence an automatic
backwash, provided none of the other filters are being
backwashed. If there is a backwash already happening
Start Backwash
within another filter then the PLC will put the filter which
has had the start backwash push button pressed into the
highest position in the queue and will be washed once the
other backwash has stopped.
Indications Description
Filtration in
Indicates that the filter is in automatic operation
Progress
Filter Washing Indicates the filter is being washed
Manual Indicates if the individual filter is in manual mode.
Backwash
Indicates that a backwash sequence has failed
Failed
Indicates that the filter has been switched to Off and is
Out of Service
out of service
General Backwashing Operation

Filter backwashing is performed by pumping air and water up through the filter
bottom. The backwash water and air rates used in the filters are 36 m/h water and
36 m/h air per square meter of filter surface area. This produces a vigorous
scrubbing action that removes captured material and flushes it upward from within
the filter bed into the backwash trough.
Backwashing of filters will be in three steps as follows:

First Step (air) Air scouring for approximately four minutes, adjustable at the
HMI by the operator between 0-10 minutes

Second Step - Surface wash Backwashing with linear velocity, for about 3 mi-
nutes maximum, again the time duration is adjustable by the operator between
0-10 minutes, 36 m/h.

Third Step direct filter to drain for a preset period of time set by the operator
at the HMI for the range of 0-15 minutes.

Valve Operation
When the individual filter is in AUTO mode, the PLC automatically controls the
valve positions, as shown in the table below.
If during a backwash any of the valves are signaled to open or close, and the
corresponding limit switch does not indicate that this has occurred, an alarm will
sound. The table below describes how a fault affects the backwash and the action

[39]
that occurs.
Note: Abandoning a backwash will return all filter valves to their filtration position
and an alarm will occur. After a pre-set period, adjustable at the HMI by the
operator between 0-60 minutes, the influent valve of the filter will open.
Step # Valve Fault Backwash Action

Abandon BW - If the BW were continued, influent would
1 Influent (close) flow together with the used backwash water. To minimize
this extra flow, the BW is abandoned
Abandon BW - If the valve fails to close at the start of
2 Effluent (close) BW, most of the backwash water, if not all, will not flow up
through the filter and backwash will be ineffective
Filter to drain Alarm If the valve fails to open. Use to drain the water
3
(open) before air scouring. Can continue BW
Abandon BW - If the valve fails to close, most of the
Filter to drain
4 backwash water, if not all, will not flow up through the fil-
(close)
ter and backwash will be ineffective
Abandon BW - If the valve fails to open at the start of
5 Air scour (open) BW, the backwash air blower will not start. Backwash is
not effective without the blower, so it is abandoned
Alarm - If the valve fails to close after air scouring, the
6 Air scour (close) backwash air blower will not start for the next backwash
filter
7 Backwash water
BW, the backwash will be abandoned
Air Blowers
Two (2) positive displacement backwash air blowers (1+1) are available for
operation.
Each blower is equipped with an inlet filter, inlet and discharge silencers, and
pressure indication. Ambient air is drawn through an inlet filter. Filtered air is
drawn through an inlet multi-chamber absorption silencer.
Blower Operation
A Hand-Off-Auto (HOA) switch will exist for each blower. When an individual filter
is in AUTO mode the backwash blowers are controlled by the PLC.
The blowers are interlocked so as not to allow both blowers to operate

simultaneously. A blower will not start unless at least one filter backwash air valve
is opened first. The PLC automatically alternates the blowers to run after each
successive start.
Manual/Auto
Each blower can be selected for manual or automatic operation. While an

[40]
individual filter system is in AUTO mode and the blower is in AUTO mode, the
PLC automatically starts and stops the blowers. While the blower is in MANUAL
mode, the blower can be started/ stopped using the associated PBs on the local
stop/start control station (backwash air valve interlocks are active during this
operation). Individual blowers in MANUAL mode are not selected for automatic
backwashes.
An alarm will sound when one blower is in MANUAL mode or out of operation.
If the blower is started and fault stops, a BACKWASH AIR BLOWER # FAULT
alarm will occur. This can occur due to an overload condition, a no-running signal,
or a low discharge pressure condition. The same backup procedure is followed as
when a low pressure condition occurs. If both blowers fault, the backwash is
abandoned and a BACKWASH ABANDONED alarm occurs.
Backwash Pump Station

Clear water from the clear water tank will be supplied to the Overhead wash water
tank by tapping on Pure Water Rising Main going to Khindwadi ESR. An
electromagnetic flow meter and pressure transmitter shall be provided at the
discharge header of100 MM Rising main. In case water in the overhead tank is
below max. Level, the backwash pump will start pumping.
In case of low level in the clear water tank the backwash pumps will not operate.
Overhead backwash water Tank
Water required for backwash of the filters will be stored in Overhead wash water
tank containing two compartments.
Both the compartments of the Backwash water tank, receiving water from the
clear water tank, shall be provided with an Ultrasonic Level transmitter for the
tanks water level indication and control. In case of backwash water overhead
tank high level, an alarm shall be generated at control room to alert the operator
and if the level of the backwash water tank still rises to high high level, back
wash water pump shall be tripped.
In case water level in both compartments of the tank is below the pre-set level,
backwash of the filters will be on hold in automatic mode and abandoned in
manual mode.
The discharge line to the filters will be equipped by flow transmitters.
The filter backwash could start in manual or auto mode in case all backwash
requirements specified are met and the relevant filter valve is open.
In case of low (high) pressure, low flow the Control system will generate Alarm.
DIRTY BACKWASH WATER TANK: - Recirculation Sump & Pump
Dirty back wash water tank shall be provided with 2 compartments and with a

[41]
level transmitter at each compartment. Drain water and dirty backwash water from
all the filter shall be transferred to this tank. Each compartment of dirty back wash
shall be connected with 1 pump & after the settlement of sludge at the dirty back
wash water tank with a bell mount arrangement the clear water shall be pumped
to inlet of the WTP in the rate less than 10% of the Plant inflow and the sludge
shall be transferred to Sludge Balancing tank by gravity.
Filling of the Dirty backwash water Tank should be related to the water level in the
tank. In case the level in both compartments is high, filter backwash should be
abandoned until the water level will drop to the pre-set level.
During cleared water discharge the pumps to be stopped in case the water
reaches the pre-set low level.
The effluent pumps will start automatically based in the level in the tank and on
the time passed after the last filling.
In case of low level, high level and overflow SCADA will generate Alarm.
The effluent pumps will operate in rotating manner and pump failure will generate
Alarm. In case the controlled discharge flow is less than the pre-set maximum
(minimum) value, the system will generate Alarm.
CHEMICAL BUILDING:
Chemical Building is provided to handle the following dosing systems of
chemicals:
Coagulant Dosing system and other associated equipment.
Polymer Dosing system and other associated equipment.
Lime dosing system
Coagulant preparation cum dosing system
Coagulant Dosing system and other associated equipment consists two numbers
of Coagulant solution and preparation cum dosing tanks. Each Coagulant solution
preparation tank shall be provided with an Agitator for proper mixing of Coagulant.
& level switch shall be provided at the Coagulant solution and preparation tank to
control the tank level and for the purpose of Coagulant solution dosing pump
operation. A Coagulant solution dosing Pumps shall pump to dosing point
Again a set of Coagulant dosing pumps pump Coagulant to single common
dosing point located at the inlet of the WTP near to Parshall flume channel. The
Coagulant dosing tank level and dosing pumps operation shall be controlled by
level switch provided at the dosing tank.
CoagulantPreparation
Activity Step Mechanical Action

Tank is not in function outlet is closed
Not in function
1 Minimum water level (L) in place and mixer in
(no solution )
function
Manually open "service water" valve at local
open/close push button station.
2
If the water level is not changing or low flow
Chemical
alarm
preparation
Manually stop "service water" valve (When wa-
3 ter reaches high level.
If water level reaches level HH, overflow

[42]
overflow alarm
Note: During the coagulant preparation phase

(when the mixer is functioning), a worker will add
powder to the tank
Chemical preparation and agitation phase (XXX
4 min) (initial value 10 min) the mixer is manually
started and stopped.
Manually open outlet valve at the local
Start Coagulant dosing pump according to PLC
operation
Ready to func- Water level reach min. level check availability
5
tion solution in the tank - if not (prepare Coagulant
alarm)
If water level reaches low level, inhibit pumps
from running and manually close outlet valve
associated with that tank.
Coagulant dosing tank is HH, the dosing pump
is stopped
Interlocks, permissive and Alarms.

Only one of the Coagulant dosing pumps could operate at the time.
- The pumps could not start until:
At least one preparation Tank is ready.
- At least one of the dosing tanks is ready with coagulant solution
Coagulant dosing
Coagulant addition from the Coagulant solution dosing tanks will commence
immediately after the raw water flow indication from the transmitter, and the water
level in the chemical tank is above minimum. The pump stroke will be adjusted
manually to give a uniform amount of coagulant solution as a function of the flow
measurement.
The pumps will stop and start according to the flow measurement, when restarted
the amount of dosing will have to be checked manually according to the raw water
flow entering the water treatment plant.
Not in
Tank is not in function
function
(no solu-
function
tion )
The coagulant level is above the minimum
Chemical
2 If water level reaches level HH, overflow over-
preparation
flow alarm

[43]
In case all interlocks and permissions met, dosing

3
is started by one pump
Manually open outlet valve at the local open/close
push button station.
Start coagulant dosing pump according to PLC
operation
Ready to Water level reach min. level check availability
4
function solution in the tank - if not (prepare coagulant
alarm)
If water level reaches low level, inhibit pumps from
running and manually close outlet valve associ-
ated with that tank.
coagulant dosing tank is HH, the transfer pump is
stopped
Coagulant PAC solution

Only one of the coagulant dosing pumps could operate at the time.
-The pumps could not start until:
- At least one preparation Tank is ready.
- WTP in flow is zero.
Lime preparation and dosing system
Lime Dosing system and other associated equipment consists two number of lime
solution and preparation tanks. Each lime solution preparation tank shall be
provided with an Agitator for proper mixing. level switch shall be provided at the
lime solution and preparation tank to control the tank level and for the purpose of
lime solution transfer pump operation. Lime solution transfer Pumps (1+1) shall
pump to lime solution/dosing tank.
Again lime dosing pumps pump lime to single common dosing point located at the
inlet of the WTP or to the inlet to the clear water tank. The lime dosing tank level
and dosing pumps operation shall be controlled by level switch provided at the
lime dosing tank.
Lime preparation
Not in func- 1 Tank is not in function outlet is closed
tion (no solu- Minimum water level (L) in place and mixer
tion ) in function
2 Manually open "service water" valve at local
Chemical alarm
preparation 3 Manually stop "service water" valve (When
water reaches high level.
overflow alarm

[44]
Note: During the lime preparation phase (when

the mixer is functioning), a worker will add
powder to the tank
4 Chemical preparation and agitation phase
(XXX min) (initial value 10 min) the mixer is
manually started and stopped.
5 Manually open outlet valve at the local
Start lime transfer pump according to PLC
operation
Ready to Water level reach min. level check avail-
function ability solution in the tank - if not (prepare
lime alarm)
Lime dosing tank is HH, the transfer pump is
stopped

Only one of the lime transfer pump could operate at the time.
- At least one of the dosing tanks is ready to receive lime solution
Lime dosing
Lime addition from the lime solution dosing tanks will commence immediately
after the raw water flow indication from the transmitter, when the water level in the
chemical tank is above minimum. The pump stroke will be adjusted manually to
give a uniform amount of lime solution as a function of the flow measurement.
the amount of dosing will have to be checked manually according to the flow
entering the water treatment plant.
Not in function
1 Minimum water level (L) in place and mixer
(no solution )
in function
The lime level is above the minimum
2 If water level reaches level HH, overflow
Chemical
overflow alarm
preparation
In case all interlocks and permissions met,
3
dosing is started by one pump
Ready to func- Manually open outlet valve at the local
4
tion open/close push button station.

[45]
Start transfer pump according to PLC opera-

tion
Water level reach min. level check availabil-
ity solution in the tank - if not (prepare lime
alarm)
stopped

Only one of the lime dosing pumps could operate at the time.
- WTP inflow is zero.
CHLORINE BUILDING / CHLORINE DISINFECTION SYSTEM:

A Chlorination Building shall be provided to house all chlorination equipment
including Chlorine Tonners, Chlorinators, Ejectors and all other associated
equipment.
Chlorine shall be used as disinfectant. Chlorine shall be drawn as a gas from

tonersand metered under vacuum, mixed with water in ejectors and transferred to
the points of application at the inlet to the clear water tank.
Liquid chlorine shall be drawn from tonner and the Chlorine gas shall be delivered
to the chlorinators through a gas grid. Liquid chlorine withdrawal system is
complete in all respect including connector valves, tubings and liquid chlorine
traps.
The tonner storage area shall also be provided adjacent to the chlorinator room in
the chlorination building. Chlorine leak detectors, one in the Chlorinator room and
two in the Chlorine Tonner area are provided to raise an alarm in case of Chlorine
gas leak.
Chlorine gas dosing will be set and adjusted manually in relation to the residual
WTP inflow Chlorine online measurement at the WTP outlet.
Motivation water for the chlorination system will be supplied by two pumps (1+1)
connected to the clear water reservoir. The discharge line will be equipped with
flow and pressure transmitters.
The motivation pumps operation will be interlocked with the inlet flow reading.
In case WTP has no inflow the motivation pumps will stop operation, but could be
brought into action manually.
In case the motivation water flow or pressure is out of the pre-set range SCADA

[46]
will generate Alarm.
AUTOMATION AND SCADA AT PURE WATER SUMP AND PUMPING

MACHINERY AT WTP
(.......) Capacity sump at WTP, will receive Purified water by gravity from existing
and WTP .
Details of Pumps to be installed on existing pure water sump
Sr. Pumping to Type HP standby Discharg Head
No e In Mtr.
In LPS
1 Camp V.T. 150 100 % 73 95
2 Camp V.T. 270 100 % 176.11 83
3 Khindwadi V.T. 135 100 % 72.77 91
4 Krishnanagar V.T. 30 100 % 67.22 65
5 Mhada Colony Subm 12.5 100 %
ersibl
e
The level in the pure water sump shall be continuously monitored by the level
sensors provided in the pure water sump. for operation of pure Water inlet, mm
dia. Butterfly valve with actuator shall be provided on the inlet pipeline. The
operator shall be able to adjust/open/close inlet Butterfly valve from pump house
and also from the SCADA Control Room.
Operation will also depend on residual chlorine concentration in the pure water
sump. In case the parameters will be out of the pre-set limits SCADA will generate
Alarm and the pumping will be interrupted. In case of pure water sump low level
an alarm shall be generated to alert operator at control room and when it reaches
to low level automatically all pure water pumps to MBR/ villages shall be tripped
automatically.
In case the water level of the clear water sump is above the High level SCADA will
generate Alarm and the pure water inlet will be stopped. Entire inlet valve shall be
operated in auto mode from the SCADA located at control room and Local control
panel located at sump. In case of failure of auto mode Inlet pure water Valve shall
be operated in Manual mode with all protections in place.

[47]
OPERATION AND CONTROL PHILOSOPHY OF PURE WATER

PUMPING STATION:
PWPS and operation of pure water pumps should be controlled based on the
WTP Clear Water Tank water levels. The pure water pumping station consists of a
sump well erected in the reservoir. Water level in the reservoir depends on
seasonal fluctuations. Water level in the sump well shall be continuously
monitored for pump protection purposes by the level sensors.
NORMAL PUMP STARTING / STOPPING SEQUENCE
a) Starting the Pump set
Switch ON START Push Button. Following sequence shall take place, with the
suitable delay timers for respective operations.
Confirm Sluice Valve on delivery side is fully closed, if confirmed go to b)

Other wise first give command to the actuator motor to close the sluice valve
completely.
Start actuator motor to open the sluice valve. Simultaneously give command
to the electrically operated solenoid valve at air vent connection of pump, to
open.
Give command to main motor starter to start the pumpset. Allow sufficient
time as required for opening the sluice valve completely.
Give command to Automatic Power Factor Controller Relay Panel to switch on

required bank of capacitors.
Monitor the delivery head pressure and display it on the screen continuously.
Close the air vent solenoid valve.
Monitor all the electrical parameters of the main motor like Average Voltage,
Average Current, Active Power KW, Reactive Power KVA, Intentions Power
Factor etc. by gathering respective information from the sensors like CTs, PTs
etc. directly or by computation and display all of them on a suitable LCD
window.
Monitor all mechanical parameters of the pumpset like pressure, discharge,

run time counter, total lifetime counter, bearing temperature and status display
etc. by gathering respective information from the respective sensors of
pressure gauge, flow meter, thermocouples/ RTDs etc. directly or by
computation and display all of them on a suitable LCD window. There shall be
sufficient battery backup for the timer counter so that even if the pumpset is
switched off, it shall take care of the lifetime counter and it shall read in
continuance when the pumpset is switched on next time.
b) Stopping the Pumpset

Switching OFF operation, Push down the OFF Push Button. Following
sequence shall take place.
Give command to actuator motor of sluice valve to close.

[48]
Confirm sluice valve is completely closed.
Give command to APFC Panel to switch of the banks of capacitors one by

one.
Give command to switch off the main motor.
If needed switch off the LCDs.
c) Emergency stopping of pumpset

Simply push down the Emergency Push Button.
In addition to above following monitoring of components on hourly basis is

required and to be logged and stored. Necessary reports shall be generated
and printed and filed on daily basis.
a. ON/OFF/Trip position
2. Pressure Sensor on Inlet Manifold to measure positive head on Pumps

3. Valve actuators
a. Valve open/close position
4. Manifold pressure sensor reading
5. Raw water flow meter reading
6. Efficiency of Pumps
Under routine working conditions one out of two pumps will be in operation. For
each pump rotation will be automatically initiated to insure equal working record.
The pumps shall normally run in Remote AUTO mode. In case the water level in
the wet well is below the pre-set minimum level the pumps could not be started.
In automatic mode pumps are starting and stopped after a pre-set delay. In
case,the water level in the wet well is below the pre-set level, the pumps will be
stopped. This could be a rare event in case the intake suction pipes are clogged.
If the pure water level reaches the pre-set high level, a soft alarm shall be raised
at the SCADA for alerting the operator. If the level continues to rise and reaches
the pre-set High High Level, again a soft alarm shall be raised at the SCADA and
also transmitted to the CCR.
If the pump continues to operate in MANUAL mode and the level in the reservoir
reaches pre-set low level, a soft alarm shall be raised at the HMI for alerting the
operator. If the level continues to drop further, a soft alarm shall be raised at pre-
set low low level and all the working pumps shall be tripped at this level. The
pumps shall also trip on Low Low or High High Pressure feedback from the
Pressure Transmitter in the pumping main to WTP.
Apart from the level and pressure protection, the Pumps shall also trip under the
following conditions to ensure safe operation and Protection of Pumps:
Discharge valve open feedback not available, within the specified time after
the start of the pumps.

[49]
The flow meter reading is out of pre-set range.

Low Low Level Switch Feedback (Hard wired control)
Pressure is out of pre- set range (Min, Max)
Reverse Rotation Protection (Hard Wired control)
Check valve remain closed (Pressure switch)
In case all local conditions are met, Control of the pure water Pumping station will
be related to the status of the Water treatment Plant and to the water level in the
Treated water Reservoir.
PLC shall continuously register the running time of each pump and display the
same reading in hours in PLC Screen. A pre-determined high limit of running
hours shall be attributed to each pump and when running-hour count crosses this
limit, an alarm shall be prompted at the PLC to alert the operator and the pump
sequence will be changed automatically. This sequence shall be continuously
rotated to achieve equal running time of all the pumps. In view of any running
pump getting tripped due to overload, the next pump shall automatically take over
in AUTO mode.
Control room proposed at pure water sump shall have a PLC, Operator work
Station, Ethernet switch, GPRS gateway, and Field instruments etc, for facilitating
automatic operation of the pumping station. However provision shall be made to
operate manually as and when required.
AUTOMATION AND SCADA FOR RESERVIOR MANAGEMENT SYSTEM
Water distribution lines in water supply scheme consists of number of ( Master

Balancing Reserior (MBR) and Elevated Service Reservoire (ESR). These
MBR/ESR may be located at different levels, some may be at higher levels and
some may be at lower level. Under such circumstances it is often seen that
distribution of pure water will be different in different zones. Lower zones will get
water with more pressure and flow, where as higher zones will face shortage of
water with low pressure.
Remote Controlled MBR/ESR management system is the only solution to avoid
above mentioned difficulties. This is a most modern and versatile concept of
automation in distribution system of water supply scheme. This unit works remotely
on timer or remote switch which will operate from central computer over GSM based
network. The unit requires very less amount of electrical power and can be easily
made available from Solar Power. Since opening and closing is entirely automatic,
timing of water supply to consumers never changes. Also this Remote Controlled
Water Delivery Unit has arrangement to control flow rate of water, hence it is
possible to have equal distribution of water through out water supply scheme.
Remote Controlled MBR/ESR management system has arrangement of measuring
volume of water flow (Cubic meter) and can be added .
Looking at these important features of Remote Controlled Water Delivery Unit, aim
of rendering maximum satisfaction to consumers is expected.
Features:
Equal distribution of water through out water supply scheme.
Automatic OPEN and CLOSURE of valve at desired set time through timer.

[50]
Remote and Automatic OPEN and CLOSURE of valve from central computer
with GSM network.
No need of man power.
Works on Solar power.
Provision of measuring water quantity being delivered.
Item No. ..Raw Water Pump house
1.1 Ultrasonic level transmitter- Radar Type
COMMON TECHNICAL SPECIFICATIONS

1.0 General Requirement
The scope of this work includes design, sizing, supply, erection and commissioning of
ultrasonic transmitters.
Transmitter design:-Transmitter design, Sizing & selection is based on process data,

process requirement, general requirement and specification as mentioned below.
Erection of transmitter: Erection includes mounting of process isolation valve, erection

of impulse piping, mounting of transmitter support and rack, laying of electrical cable
from PLC to transmitter, mounting of junction box, glanding, termination and interfacing
of transmitter with control system.
Commissioning: Commissioning of transmitter includes, calibration checking, loop
checking, testing of transmitter from PLC and open / closed loop checking from sub
control system & main control system.
Ultrasonic type level transmitters shall be provided with 4-20 mA DC output. All
necessary amplifiers, Zener isolations, signal distribution & associated electronics /
hardware / housing / mounting accessories shall have to be provided. The transmitters
shall be able to drive at least 600 ohms load. The power supply to the transmitters shall
be derived from the control system.
Accuracy of the transmitters shall be 0.2 % of calibrated span (minimum). Transmitter
housing shall be Weather proof as per IP-67 with durable corrosion resistant coating.
Ultrasonic level transmitters, consisting of a transducer, a display / transmitter unit, and

manufacturer's cable, shall be provided as specified below. Stainless steel tags for
ultrasonic level transmitters shall be provided as specified. The transmitter shall have
built in temperature compensation, digital level indicator and any other item required to
complete the level measuring system. The level measuring system shall be suitable for
mounting on the top of the Water trench, pump sump pit, water channel and Filter bed as
required
The level sensor material shall be non-corrosive. Contractor shall arrange for the
installation of the level transmitter on top location at suitable location. Accuracy of the
level transmitter shall not deteriorate even if suspended solids are present in the service
fluid.
Level transmitter shall be suitable for field mounting in safe area. Transmitter output shall
be isolated and shall be suitable for transmitting over long distance.
2.0 Transducer Required Features

Ultrasonic level transducers and manufacturer's cable assembly shall be provided with at

[51]
least the features specified below:
Measuring Principle Ultrasonic, time-to-flight / Pulse Time of flight

Range As indicated on the data sheet
Level Resolution Better than 1 mm
Beam angle 6 Degrees
Process connection Suitable for the Reservoir
Cable As indicated on the datasheet
Temperature compensation Full, automatic
Mounting As indicated on the datasheet
Manufacturers Standard suitable for the
Nominal frequency range
application
Operating conditions - 40 to + 950C or As indicated on the datasheet
Max Pressure 4 Kg / cm^2(g)
Range Liquids 0 to 25 m Refer process data
Sensor materials corrosion resistant PVDF wetted material
Principle Pulse Time of flight
Agency listings UL listed or FM approved
3.0 Display/Transmitter Unit Required Features

Display / transmitter units shall be furnished for use with the transducers specified above
and shall include at least the features specified below. At least two programming key
pads shall be included per project unless directed otherwise:
Yes-External Display Required, 4/5 line LCD display.

Display
Menu guided operation
Using Keypad on display OR suitable field
Configuration
configuration tool
Memory Parameters held in non volatile memory
Display Location Local / Sensor mounted
Temperature
Automatic , built in transmitter
compensation
4 to 20 mA analog, two wire, linear with process
Outputs engineering units. One Form C SPDT relay contacts,
5 amperes at 250 volts ac, non-inductive
Output Variables Level, Distance, Volume, Open Channel Flow
Supply voltage 24 VDC, loop powered
0.2% full scale measuring distance OR 4mm (+/- 2
Accuracy
mm) which-ever is better
Radio Frequency Less than 0.1 percent of span for frequencies 27 to
Interference (RFI)effect & 1,000 MHz and field intensity of 30 V/m Interference
Electromagnetic emission to EN 61326;Equipment class B, Interference
compatibility immunity to EN 61326;Appendix A (Industrial)
Voltage transient Up to 1000 volts common mode and 500 volts normal
immunity mode with output shift less than1.0 percent
On board transmitter compartment. Compatible with
HART or Foundation Field bus communications as
Surge suppression
applicable. Compliant with IEEE C62.41 Cat. B and
IEEE C37.90.1.

[52]
Housing & Ingress

Aluminium, rated NEMA 6P (IP68)
Protection
Operating conditions -20 to +500C
Agency listings UL listed and FM approved
Hazardous area
Safe Area
classification
4.0 Typical data sheet for transmitter

1 Tag Number During detail engineering
2 Service Raw / Dam water
At the Jack well pump floor above
3 Location
pump suction pit
4 Quantity As per BOM
A special arrangement of SS
structure to be fabricated &
mounted to install the
GENERAL 5 Mounting
USLT on River. Flange structure to
be fabricated to install the USLT on
pump pit
6 Area classification NA
7 Certification Required
8 Enclosure IP 65
Vendor to confirm during detail
9 Pipe Line number
Engineering
10 Fluid Raw / Dam water
11 Fluid State Liquid
12 Operating Pressure Atmospheric
Operating
13 50 Deg C
PROCESS Temperature
CONDITIONS Operating specific
14 Suitable for water
gravity
15 Operating Viscosity Suitable for water
16 Min./ Max Pressure Atmospheric
17 Design Pressure Vendor Standard
18 Design Temperature 75 Deg C
1) Dam water level measurement
before trash rack & after trash rack
19 Application
TRANSMITTER and 2) Raw water sump pit level
measurement
20 Type Ultrasonic
21 Principle time-to-flight / Pulse Time of flight
22 Housing Aluminium
23 Paint Epoxy or polyurethane- coated
24 Protection IP 68 NEMA 6P (IP68)
TRANSMITTER 25 Power Supply 24 V DC
Loop powered at 750 4-20 mA, 2
26 Output
wire linear with process (HART)
27 Level Resolution Better than 1 mm
28 Transmitter Location Local/Sensor mounted

[53]
Process Flanges and

29 Mtl Wet-side
Mounting arrangement
SS 316 Corrosion resistant PVDF
30 Material
wetted material
Body Material & Bolt & SS 316
31
accessories Material
32 Beam Angle 6 Degree
Vendor to size the transmitter
33 Instrument Span based on process data & submit
for Approval
34 Calibration Range Vendor to confirm
35 Alternate Range NA
36 Process connection Manufacturers standard
37 Electrical Connection Manufacturers standard
0.2% of span, 0.2% full scale
38 Accuracy measuring distance OR 4 mm (+/-
2 mm) which ever is better
39 Allowable Temp. Later* DISPLAY
4/5 line LCD
40 Display
display
Display Scale External Display ,Menu guided
41
Required, operation Match Calibration
42 Hydrostatic Certificate to be provided
Testing Memory Parameters held in non volatile
43
memory
44 Mounting Brackets 50 mm Pipe mounting
45 Lightning Protection YES Required
46 Communication Type HART
COMMUNICATION 47 Communication with: PLC -SCADA
AND SOFTWARE 48 Configuration from: Factory
49 Internal Diagnostics Required
Approved
50 Emerson/ABB/E&H/Siemens/Baner
Manufacturer
PURCHASE
51 Model Vendor to confirm
52 Purchase Spec Datasheet is a part of Specification
53 Serial Number During detail engineering
RADAR WATER LEVEL SENSOR

Display Type 4 LCD Display
Input Supply : 24 VDC
Out Put : 4-20 mA.
Range: : 0 to 30 m
Accuracy : < 0.03%
Power, Linearity, Repeatability : 0.01 ft (+ 3mm)
Resolution : 1 mm

[54]
Power : Sleep mode 7.6 mA typical

Active (measuring) 12 mA typical
Ambient Temperature : 45 Degree C
Relative Humidity : 0 to 100 % Non condensing
Pressure Transmitter
TECHNICAL SPECIFICATIONS
ultrasonic transmitters. The pressure transmitters are to be installed on the individual
delivery of Pumps one each & one transmitter on common manifold of pipe line
Transmitter design:- Transmitter design, Sizing & selection is based on process data,
Erection of transmitter: Erection includes mounting with mounting structure and

process isolation valve, erection of impulse piping, mounting of transmitter support and
rack, laying of electrical cable from PLC to transmitter, mounting of junction box,
glanding, termination and interfacing of transmitter with control system.
The pressure Transmitter shall be Micro-processor based 2 wire transmitters & shall
have an impressed output signal of 4 - 20 mA corresponding to zero to full range input. A
two-wire transmitter shall be used with accuracy of +/- 0.1 % or better of span.
Transmitter shall have external zero and span adjustment with self-diagnostics feature.
Transmitter shall have temperature sensor for process compensation. The transmitters
shall be of the SMART-type with HART protocol. The transmitter shall be indicating type
& shall have LCD display of Min 4 with engineering units.
Turn Turndown Ratio of all the transmitter shall be 100:1 for pressure transmitters and
50:1 for very low pressure applications. Load impedance shall be 600 ohm (min). The
repeatability shall be within a range of 0.1% of full span. Over Pressure of the transmitter
shall be 150% or more of the Maximum Range of the pressure transmitter or maximum
working pressure of equipment / pipe line.
The output signal of transmitter must be independent of the burden of the transmitter
output circuit including cable resistance over a wide range.
All transmitters shall be suitable for field installation and shall have strong, moisture and
dust proof cases of Aluminium housing with epoxy coating suitable for IP 67 or
equivalent degree of protection or better to be envisaged.
All wetted parts of the transmitters shall be SS316 or special material for corrosive
applications. Accessories like snubbers for pump discharge applications and chemical
diaphragm of 10 m PVC covered SS armoured capillary for remote services shall be
considered. Diaphragm seals shall be of the flanged type, suitable for the same
conditions as those for the transmitter. The material selection shall be according to the
requirements of the fluids to be measured. The seal shall be provided with a flushing

[55]
connection.
Transmitter shall be provided with Mounting bracket, mounting stand & nameplate.
Material of accessories shall be SS or better.
Process connection shall be -1/2NPT (F). 2 valve manifold to be considered for absolute
pressure, 3 valve manifold for gauge pressure and 5 valve manifold to be considered for
DP / level / flow measurements. Mounting bracket, mounting stand & name plate to be
envisaged. The material of accessories shall be SS or better.
Transmitter shall be capable of driving an output Impedance of 600 ohms at 24 VDC,

shall be generally powered from the control system I/O cards and provided with
integrated digital display in percentage and engineering units.
The removal of connected devices must not open the transmitter output circuit or cause
malfunction of this circuit. In the case of failure and return of the supply voltage within a
measuring circuit, no false signals endangering the system shall be issued. All
transmitters shall be individually fused.
2.0 Detailed Technical Specifications
Sr. No. Features Minimum requirement for electronic transmitter

Loop powered Microprocessor based 2 wire type,
1 Type of transmitter
SMART, HART protocol compatible.
2 Sensor type Capacitance
Measuring Capsule - AISI 316 SS or better;
3 Material Body CS / Stainless Steel as per fluid
application.
4 Ambient Temp. 0 - 50 Deg. C
5 Accuracy 0.1% of span
4-20 mA DC (Analog), Linear, along with
6 Output signal range superimposed digital signal (based on HART
protocol)
7 Range About 1.5 times normal value (min.)
8 Turn down ratio 100:1 for High pressure & 50:1 for Low pressure
9 Repeatability 0.05% of span or better
0.1% of calibrated span for 6 months up to 70
10 Stability Kg/cm and 0.25% for range more than 70
Kg/cm
11 Sensitivity 0.05% of span or better
0.015% per deg C at Max Span and 0.11% per
12 Zero and span drift
deg. C at min. span.
13 Load impedance 500 ohm (min.)
1.5 times the maximum span / Full static Pressure
14 Body / Element Rating
on one side with other side venting for DPT.
Housing & Enclosure Weather proof as per IP- 67 with durable
15
Class corrosion resistant coating. Die cast aluminium
16 Over pressure 150% of max. operating pressure
17 Connection (Electrical) Plug and socket type
18 Process connection 1/2 inch NPT/BSP will be accepted
19 Instrument Valve 2-Valve for PT / 5-Valve for DPT (Stainless Steel)

[56]
Manifold
20 Output Indicator LCD type.
Continuous, tamper proof, non-interacting remote
Span and Zero
21 as well as local manual from instrument with zero
adjustability
suppression and calibration facility.
a. Diaphragm seal, pulsation dampers,
siphon etc As required by service &
operating conditions
22 Accessories
b. Two valve manifold for absolute pressure
transmitters Three valve transmitters & Five
valve manifold for DP transmitters
23 Mounting Bracket Required
24 Diagnostic Self indicating feature
25 Power Supply 24V DC 10%
Adjustment/ Total five (5) no. of handheld calibrators shall be
26
calibration/maintenance provided.
Suitable to meet closed loop control reaction time
27 Response time
specified else where
Emerson / ABB / E&H /Siemens/Banner/
28 Make
Yokogawa
Power Analyzer
GeneralRequirement
The scope of this work includes sizing, designing, design, supply, erec-
tion and commissioning of Energy meters, communication cable and
software.
Power Analyser design: Design & selection of Power Analyser shall be
based on electrical consumption, mounting arrangement, interface re-
quirement with control system, general requirement and specifications be-
low.
Erection of Power Analyser : Erection includes mounting of energy meters
on existing switchgear panel, wiring from CT and PT to energy meter. Lay-
ing of communication cable from energy meter to communication switches-
mounted in PLC based control panel. Mounting of junction box, glanding,
termination and interfacing of energy meter with control system.
Commissioning: Commissioning of Power Analyser includes, calibration

checking, loop checking, testing of energy meter locally from switchgear
panel, remotely from PLC based SCADA system and from Historian station.
System description:
Energy Audit shall be part of automation of water treatment plant. To
accomplish this requirement Digital Power Analyser shall be mounted on
following switch gear panel, Incomer and outgoing breakers, PCC, MCC.
Raw water systemFor each pump feeder, Incomer feeder, transformer
feeder
Pure water systemFor each pump feeder, Incomer feeder, transformer
feeder

[57]
Filter systemIncomer feeder

Blower For each blower feeder
Backwash water systemFor each pump feeder
Recycle wate rsystem-For each pump feeder
Power Analyser falls under particular master PLC based control system sec-
tion shall be interfaced on Ring topology / Daisy chain network with each
other and this network finally shall be interfaced with that particular master
PLC. All the electrical parameters available in the Power Analyser shall be-
made available in the associated master PLC and SCADA.
These parameters shall be further made available in Historian server for database
management, Alarm management and Energy Audit. Contractor shall design,
supply, develop and program energy management software in the historian
server. Contractor shall develop the commercial analysis of energy audit and
represent it in the graphical, tabular and widget form for management reference.
Technical specifications:
Power Analyser shall have following minimum specifications but not limited to:
a. Selectable for system, 1Ph, 3Ph 3W and 3Ph 4W. (The Input CT and PT shall be
ratio programmable)
b. 21st Harmonics of voltages and currents (selectivity)
c. Import and Export Energy measurement
d. THD factors for currents and voltages
e. Measurement of power network parameters in balanced & unbalanced systems
f. Configured watt-hour meter for the selected harmonic
g. Backlit LCD4.5 screen, mono chromatic with backlight
h. In gress protection : IP65
i. Digital transmission to the master system through the RS-485 interface
(MODBUS)
j. Inbuilt Real Time Clock (RTC)
k. Configurable analog, alarm and pulse outputs (energy)
l. A programmable current output shall be 4 to20mA, programmable relay output,
potential free contacts, load capacity 250V/0.5
m. Output: 1Analog, 1Relays, 1OC, RS485 Modbus
n. Accuracy Class shall be: 0.2 for Voltage and current, 0.5 for power, energy &
Phase Angle
o. Universal Auxiliary Power supply, power consumption shall be not more than 7
Volt Ampere
p. Temperature with stand shall be 55Deg. C. and Relative Humidity with stand
capacity shall be 95%
q. The transmission bound rate shall be 38.4 K bits/second.

[58]
Data sheet of the Power Analyser :
List of parameters to be measured and their Ranges

Basic
Sr. Measured value Display range Measuring range error
No.
To be confirmed by
1 Current L1, L2 & L3 0 to 60 KA Contractor (+/-)0.2%
To be confirmed by
2 Voltage phase 0 to 1.1 MV Contractor (+/-)0.2%
To be confirmed by
3 Voltage line 1.0 to 1.9 MV Contractor (+/-)0.5%
To be confirmed by
4 Frequency 47 to 63 HZ Contractor (+/-)0.2%
To be confirmed by
5 Active power (-)9999 MW to 9999 Contractor (+/-)0.5%
MW
(-)9999 Mvar to To be confirmed by
6 Reactive power 9999 Contractor (+/-)0.5%
Mvar
To be confirmed by
7 Apparent power 0 VA to 9999 MVA Contractor (+/-)0.5%
To be confirmed by
8 Power factor (-)1.0 to 1.0 Contractor (+/-)1.0%
Tangent of phase To be confirmed by

9 angle (-)1.2 to 1.2 Contractor (+/-)1.0%
To be confirmed by
10 Cosine of phase an- (-)1.0 to 1.0 Contractor (+/-)1.0%
gle
To be confirmed by
11 Phase angle (-)180 to 180 Contractor (+/-)0.5%
To be confirmed by
12 Imported active 0 to 99999999.99 Contractor (+/-)0.5%
energy KWH
To be confirmed by
13 Exported active 0 to 99999999.99 Contractor (+/-)0.5%
energy KWH
Reactive inductive To be confirmed by
14 energy 0 to 99999999.99 Contractor (+/-)0.5%
Kvarh

[59]
Reactive capacitive To be confirmed by

15 energy 0 to 99999999.99 Contractor (+/-)0.5%
Kvarh
List of output parameters and their properties
1 Analog output Programmable current output in terms of 4-20 mA,

Programmablerelayout-
put,potentialfreecontacts,loadcapacity shall be 250
Pulse output for Ac- VAC/0.5 Amp
2 tive or Reactive ener- Required
gy
All the above listed parameters shall be made availa-

ble
3 Retransmitted output onRS-232/RS-485/modbus communication in vie of
interfacing the energy meters with PLC based SCA-
DA system
Note:Contractor shall provide memory mapping of all the electrical para
meters those are listed above in view of available these parametersin
PLC based SCADA and further to Historian for various analysis purpose.
Power Analysercommunicationcable:
Contractor shall design, size, supply,erect,and terminate the communica-
tion cable between energy meters to form thering/ daisy chain netwok
and from net work to PLC.
Cable specifications are as below:-

Sr. Description Particulars
No.
1 Characteristics Impedance(Ohm) 64.000 Nom.
2 Inductance (H/ft) 0.200 Nom.
3 Conductor to Conductor Capacitance 24.000 Nom.
ConductortoOtherConductor&Shield
4 Capacitance(pF/ft) 47
Nominal Conductor DC Re-
5 sistance DCR @ 20oC 16
(Ohm/1000 ft)
6 Max. Operating Voltage UL Voltage 300 V RMS (UL AWM Style 2092)
7 Max. Recommended Current 2.9 Amps per conductor @ 25 C

[60]
Softwarerequirement:-
Energy management software shall be provided which will be loaded in
the Historian server and further programmed to develop the energy audit-
for commercial analysis.The software shall be from reputed make. The
specification and make of the software shall be approved by consultant /
owner.
PLC Panel
1. It shall be a proven, intelligent PLC having local memory, processor, power supply
unit & communication cards. The main processor shall employ a minimum of 32
bit or higher word length for CPU processing. The PLC memory shall take care of
the I/O count requirement including serial points.
2. The supplied PLCs shall be microprocessor based, programmable and with eras-
able ROM / RAM Memory. Each of the PLCs shall have its own processor, memo-
ry, power supply unit & communication processor and I/O cards complete in all
respects. All PLCs shall be modular & from the same model product line with
identical capacities.
3. All field instrumentation signalling from Field Instruments shall be cabled up- to
the respective Hardware panels.
4. The PLC hardware shall have following basic features.
5. PLC shall be programmable in a structured programming language for ease of
programming and ease of de-bugging.
a. The I/O cards shall not be combined for the functionalities i.e. each card shall
be used to perform its own functionality with respect analog inputs, digital in-
puts, digital outputs.
b. The PLCs shall have a dual processor. The changeover in case of a dual pro-
cessor shall be bump less and should be fail-safe. Redundancy should be
provided for complete processor subsystem including CPU memory and power
supply
c. The PLC should be completely unaffected by a momentary loss of Power of
the order of 20 milliseconds.
d. The PLCs shall be configured such that failure of an individual module shall
not affect the integrity of the unit as a whole.
e. The high performance PLC must be designed to log the parameters with time
stamping.
f. The parameter logging interval can be set locally remotely from the central
control station. The logged data can then be downloaded to the central station
PC.
g. LED indication on the front panel shall be provided for the indication of the
present mode of operation and for alarm status along with its simultaneous
display on the MCS.

[61]
h. The PLC shall be battery backed-up so as to maintain time stamping during

power failure of the monitored Field Instruments parameters which can be
used in further analysis
i. The PLC shall be designed to have communication compatibility for wire/ wire-
less mode viz. for Radio, GSM / GPRS, VSAT or wired mode viz. OFC and
serial to transmit data and receive commands remotely. A total of 3 communi-
cation ports shall be required in the SURVELLIANCE Hardware considering:
Port 1: Host port for 3rd party communication
Port 2: Remote communication
Port 3: For acquisition of stored data through local hand held terminal
j. Above ports exclude the HMI panel to be provided on the PLC fascia.
PLC at each location shall be interfaced with communication equipment
through RS232 /RS 485 serial bus/ industrial Ethernet using standardized
communication protocol.
The complete PLCs shall be supplied with all its components including the
cabinets.
All the supplied PLCs shall be with same make & model no., differing only in
number of PLC I / O cards.
PLC Minimum Specifications:
The PLC shall comply with following in addition to the other requirements.
1 Power Supply Input 230V AC (170-270VAC), 50 Hz
Output As required by Processor & IO
modules
2 Central Processing Unit Type Microprocessor based
(CPU) Programmable Logic Controller
(PLC) 32 bit Ethernet or higher
Memory Minimum Program 512 Kb
(spare 50% after
commissioning)
Minimum Data 2 GB (capable
of holding 3 year station data)
Clock Battery backed RTC with max. 1
minute drip per year
Display Colour touch-screen HMI 10
minimum with Ethernet interface
mounted on front panel.
ADC 16 bit minimum

Watch-dog to reset CPU in any abnormal
function
Peripheral Using standard I/O Bus
Communication

[62]
Time Should accept external GPS

Synchronization Clock Pulse
Self Required
Diagnostics
3 I/O Modules Type Rack mount plug-in with base
I/O Count As per station requirement plus
25% spare to each type duly
wired up to terminal board.
Analog Module 8 CH (Max.) 16 bit, with LED
indicator, Max load 500 , cross
talk attenuation,
Digital Module 16 CH (Max), opto- isolated,
Communication ADN with Ethernet & Serial
Module connectivity using MODBUS or
any other standard
communication protocol
4 Relay Boards All Digital outputs in the PLC will
drive Relays 24V DC 2 C/O and
field signals routed through relay
contacts
PLC based control monitoring and communication software
PLC CONTROL SYSTEM

General
(a) Each pumping station control system shall be based on the use of program-
mable logic controllers (PLCs). Remote input / output modules (I/O modules
may also be used to link remote areas of a given process. Each PS control
panel (CP) shall be provided with its own local PC based Operator Interface
Unit (OIU).
(b) The control systems shall be designed for fully automatic operation of the
pumping systems. However, in the event of failure of the automatic controls
or by operator choice it shall be possible to revert to manual operation of
each item of Plant independently of the PLC function.
(c) The PS control systems shall be designed to recover fully to a normal opera-
tional state on restoration of power following a power failure without manual
intervention.
(d) The control system hardware at each PS shall comprise the following:
- PLC
- Control system power supplies;
- OIU ;
- Field cabling interfaces;

[63]
(e) The site instrumentation shall also form an integral part of the control sys-
tem.
(f) The equipment detailed in the aforementioned list and some components of
the instrumentation system shall be housed within the CP. The CP shall be
located in the control room.
PLC Control Panel

(a) Control panel shall be provided at each pumping station for automatic opera-
tion of pumping station.
(b) Each control panel (CP) shall provide control and human machine in-
terface facilities for the following:
Pumping station;
Clear water reservoirs;
Instrumentation systems;
Interface to the Water Management and Control Communications
System
(c) The surge suppression equipment shall be provided with its own self
contained motor control, control and instrumentation system. The
pumping stations control system shall monitor the operation of the
surge suppression system.
(d) Control panel shall be provided at each of the MBR, ESR & GLSR Loca-
tions for monitoring of the water levels and controlling motorized
valves.
(e) The control panel shall be pre-fabricated floor mounted and be envi-
ronmentally protected to IP 52. It shall present a vertical front face to
the operator on which shall be placed the MMI. The CP shall be de-
signed for bottom cable entry and rear access. The external colour of
panel shall be shade RAL 7032 and internal shade shall be glossy
white.
(f) The CP shall provide separate areas for the PLC, internal power distri-
bution, instrumentation, field cabling termination and for surge protec-
tion devices (SPDs). A separate instrumentation earth bar mounted on
insulating supports (a clean earth) shall be provided within the CP.
Instrumentation and control cable screens shall be connected to this
earth.
Construction
(a) Cubicles for PLC shall be prefabricated out of sheet steel. Adjacent frames,
dividers and covers shall be securely bolted to ensure earth continuity
throughout.
(b) The exterior corners and edges shall be rounded to give a smooth overall
appearance with projections kept to a minimum.

[64]
(c) Lifting lugs shall be provided for installation purposes and shall be replaced
with corrosion-resistant bolts after installation.
(d) Unless otherwise specified assemblies shall be prefabricated and floor
standing with lockable hinged front doors and bolted removable rear panels
where access to live equipment and terminals is possible.
(e) Instrumentation shall not be positioned above 2000 mm or below 500 mm
and devices for isolation and switching shall be accessible within the zone
500 mm to 1600 mm above floor level. Suitable warning labels and instruc-
tions for earthing and isolating shall be fitted where necessary.
(f) Unless otherwise specified cable entry shall be from the base and shall enter
an accessible cabling compartment via suitable cable glands and gland
plate. Access to cable terminations shall be via bolted panels either from the
rear or front as specified.
(g) Cubicles for outdoor locations shall be fitted with lockable outside doors and
housing so designed that all controls, instruments and such like are fully en-
closed with the whole assembly weatherproof and vandal proof. The doors
shall be fitted with stays arranged to prevent overstraining of the hinge fix-
ings and allow fixing of the doors in the open position.
(h) The internal cubicles shall also be weatherproof to allow operation of the
controls when the outside doors are open during inclement weather.
(i) Control panels and instrument enclosures, shall give a degree of protection
as follows:
(i) Indoor installations
Non air-conditioned areas : IP 52
Air-conditioned areas : IP 44
(iii) Outdoor installation : IP 65
PLC Control Panel Power Supply
The PLC control panel primary power supply shall be derived from the LV switch
board at 240 V AC. Power for the control system shall then be derived from this
source via an uninterruptible power supply (UPS).
The 24 V shall be derived from the UPS backed 240 V supply within the PLC
control panel by providing a regulated DC power supply unit in redundant
configuration and failure of each power supply unit shall be monitored and
alarmed.
PLC Control System Protection

(a) Short Circuit
All circuits shall be protected against short circuit by the provision of
adequate numbers of fuses or miniature circuit breakers.
For ease of maintenance and system security power supplies to each
instrument loop and each PLC output shall be protected with an individual
fuse (terminal type).

[65]
(a) Earthing
An instrumentation earth shall be provided in each control panel. This shall

comprise a copper bar of cross section not less than 25 x 6 mm and length
to suit the number of connections. It shall be mounted on at least two
insulated supports and be provided with a single earth connection to the
instrumentation earth. If due to the physical size of a control panel more
than one instrument earth bar is required the additional bar shall be
connected again with a single earth connection to the same point as before
on the control panel instrument earth bar. In this fashion all instrument
earths shall be connected radial from the same earth point.
Assemblies shall be provided with earthing facilities as follows:
For small single compartment assemblies an earth stud shall be provided. For
large single compartment or multi-compartment assemblies a clearly marked
continuous copper earth bar shall run the length of the assembly and shall be
provided with terminals for connections to the metal cladding or armouring of all
incoming and outgoing cables.
The short-term rating of the earth bus bar and connections shall be not less than
that of the associated equipment, or the maximum through-fault current of the
power source. The temperature rise of the bus bar and connections under fault
conditions shall not cause damage to the connections of any equipment to which
they may be connected.
No earth terminal bolts or studs shall be less than 8 mm diameter.
An earth bond of minimum size 6 mm2 shall be made to all enclosure doors.
Labels
The assembly as a whole and each compartment shall be clearly and unam-
biguously identified.
The labels shall be engraved letters and numbers filled black on a white
background.
Warning labels shall be engraved and filled black on a yellow background.
Labels shall be affixed with non-corrodible rivets or screws.
Internal labels shall be used to identify all components and terminal strips.
They shall be of plastic in construction and shall be affixed adjacent to the
component.
(b) Surge Protection
Surge protection devices (SPD s) shall be provided for analog signal and power
supply loop of all instruments located outside the control room. One SPD shall be
provided near the instrument at field end and the other SPD near the control panel
end. The SPDs shall be connected to earth and shall be suitable for arresting the
surge arising out of high energy static discharge / lightning strikes and protect the
equipment from damage. SPDs shall provide protection through quick acting

[66]
semiconductor like transorb, zener diodes, varistors and an automatic discharge and
reset circuit. SPDs shall be a passive unit and shall require no power for its
operation. During the lightning strike it shall clamp on the allowable voltage and pass
the resultant current to the ground. The SPD shall operate without in any way
affecting normal operation i.e., they should pass signal without attenuation while
diverting surge currents safely to earth and clamping output voltages to specific
levels. SPDs shall be of self resetting type to minimize the down time of the
measurement loop. SPDs shall be weather proof casing. There should be total
isolation between input, output and ground terminals. SPDs shall have a minimum
surge rating of 10 kA. The SPD s shall be grouped in a specific area within the CP to
ensure dirty signal cables do not come into direct contact with clean signal cables.
Input / Output Schedules (Sample)
Sr Instrument / Equipment PLC I/O

No
Ethernet RS SDI12 DI DO AI A
485 O
1 Pumping Station 1 1 1
Pump status Running, 16 8
Fault, Remote, Local
Maintenance, Duty,
Command Start, Stop
Control Valve status 24 8 1
Open, Close, Trip,
Overload, Remote,
Local, Maintenance
Valve position,
commands Open,
Close, Stop
Electrical Parameter 1
monitoring System
Temperature Scanner 1
Flow Meter 4
Pressure Transmitter 4
Ultrasonic Water Level 1
Transmitter.
Residual Chlorine 1
Measurement System
Turbidity Measurement 1
System
pH Measurement 1
System

[67]
Multi-function Controller 1
5 CH
Multi-function Controller 1
2 CH
Auto Manual switch 1
The I/O Schedule detailed is indicative only. The Contractor shall provide all I/O
necessary in order to achieve the control and monitoring requirements for
each site at various locations of the scheme.
Important: 25% extra for each type I/O cards duly wired up to terminal box shall
be considered while designing a system.
CONTROL PHILOSOPHY
General
(a) The fundamental control requirements of the pump control system is to:
(i) Match the average pumping rate under steady state conditions to
the steady state output from each pumping station;
(ii) Maintain the water level in the reservoirs within set limits;
(iii) Provide automatic system start-up and shutdown routines;
(iv) Provide alarms and fail-safe tripping circuits to protect plant and
equipment;
(v) Prevent an overflow at a downstream pumping station reservoir as
the result of a local power failure at that pumping station;
(vi) Provide information on the operation of the system to enable the
operator to be aware of conditions both locally and at up stream and
downstream sites;
(vii) Provide facilities to permit the manual control of the system in the
event of failure of the automatic controls;
(b) It is required that the transmission pumps be controlled using a start stop
method in order to effect the required flow balance whilst at all times
maintaining acceptable levels within the reservoirs. In addition the selec-
tion of suitable reservoir switching levels shall limit to an acceptable val-
ue the number of start / stop cycles each pump motor is subjected to.
(c) The control modes proposed for the system are as follows:
(i) Automatic mode;
(ii) Semi-automatic mode;
(iii) Local manual mode.
The control algorithms associated with each mode of control are as follows:
Automatic Control Mode

(a) General
(i) The automatic control mode is manually selected independently at
each pumping station by the positioning of a selector switch on the

[68]
control panel. This mode selection shall be accepted and retained by

the control system.
(ii) Pumps for operation as duty or standby shall be manually selected by
the operator from the OIU. Pumps shall accept duty or standby sta-
tus if they are available. i.e.
The pump motor starter manual-off-automatic selector switch is
set to automatic;
It has no faults;
Power is available at the starter;
The emergency stop device is not operated;
Any associated device such as the outlet valve is available.
(iii) There shall not be a limit on the number of pumps that may be se-
lected as duty or standby however the default status shall be all
pumps as duty.
(b) Pump Start Routine
(i) The pump automatic mode start routine shall be as follows:
Permissive conditions to start
- Suction valve is open
- Discharge isolation valve is open
- Discharge control valve is in throttled position
- Common discharge header valve is in open position
- Pump drive available
Start sequence
- Start pump drive and open discharge valve simultaneously
- Duty pump fails to start, standby pump shall be started
- Pump starts & discharge valve opens; start sequence is
completed
(ii) A software based pump start sequence failed to complete alarm shall
be provided. If a start sequence fails to complete within a set time
(not operator adjustable) an alarm shall be raised.
(c) Stop Sequence
(i) The pump automatic mode stop routine shall be as follows:
Close discharge valve command
Stop pump drive, when discharge valve is closed by 70% (70%
close signal shall be derived using timer)
when the pump stops, the stop sequence is complete

[69]
(ii) A software based pump stop sequence failed to complete alarm shall
be provided. If stop sequence fails to complete within a set time an
alarm shall be raised.
(iii) The pump shall stop immediately without going through the aforemen-
tioned sequence in case of power failure and hardwired trip condition.
(iv) The discharge valve shall close after the pump has stopped. In case
power supply is not available the valve shall close on resumption of
power.
(d) Duty Rotation
(i) The automatic system shall call on duty pumps to start or stop in ac-
cordance with the dictates of the reservoir level control algorithm.
The control system shall decide which pumps are to be start or stop
using the following procedure.
If the control system requires a duty pump to start it shall select

the duty pump which has been standing (not running) for the
longest time and start it.
If the control system requires a duty pump to stop it shall select
the duty pump which has been running for the longest time and
stop it.
(ii) If a duty pump should fail (either when running or not) then the lowest
numbered standby pump shall be selected and started if required to
run. The pump shall now run in all respects as a duty pump until re-
selected manually as a standby. If a duty pump is selected as stand-
by when it is running it shall stop.
(e) Catch Up Mode
(i) Catch up mode is a hybrid of the automatic mode and is typically used
following a prolonged power outage or some other severe disturbance
to the system in order to temporarily increase the throughput of water.
It can be manually selected at each of the pumping station using the
OIU and is then automatically applied to all the other pumping stations
(only if automatic mode is selected at that station).
(ii) It may be deselected at any of the pumping stations at any time
(f) Level Control Mode
(i) The duty pumps at a given pumping station shall be primarily controlled
by the level within the local source reservoir.
(ii) The level based controls use the signals from the local reservoir and
downstream reservoir(s).
(iii) Time gap between starts or stops of pump is 5 minutes
Auto-manual Control Mode
(i) In order to make the system responsive to changes within the system
an additional background level control algorithm is necessary. This
is identified as auto-manual control and is detailed as follows:

[70]
(ii) The purpose of this mode is to get the system up and running following a
disturbance. In this mode the operator (whilst the system is in automatic
mode) may prompt the starting of a duty pump by manual initiation. The op-
erator may start as many pumps as required up to the maximum permitted
by the algorithm.
(iii) Conversely the operator may also stop a duty pump at any time.
(iv) The above actions shall be carried out by the operator either by depressing
a duty pump start or duty pump stop push button once in order to start or
stop a duty pump. After a delay a further depression of either button shall
cause a further duty pump to start or stop as required and so on.
Semi-Automatic Control Mode
(a) The operator may select this mode of operation at the CP at any pumping sta-
tion. The control mode when selected shall only apply to that pumping sta-
tion.
(b) In this mode the operator may start and stop available pumps (i.e. pumps
available for automatic control) at will by using controls on the OIU. The con-
trol commands shall be routed through the PLC. The PLC shall prevent si-
multaneous starts or stops and shall carry out automatically any start up or
shut down routines necessary in order to start or stop a pump.
Local Manual Control Mode
(a) This mode of control will normally be used for maintenance purposes or in the
event of a PLC failure.
(b) In order to start a pump in this mode the operator must go to the drive starter
and set the automatic -off- manual selector switch to manual. The drive can
then be started or stopped using the local start and stop buttons or the start /
stop controls local to the drive if fitted. The operator will be required to carry
the operation of discharge valves etc. manually.
(c) In this mode only hardwired interlocks shall operate to stop the drives.
(d) Valve actuators shall be operated manually at the actuator by selecting the
local-off-remote selector switch to local and using the local controls at the
valve. Additionally open and close push buttons shall also be provided for the
pump discharge motorized valves on the starter panel of respective pump.
These push buttons shall be active only when the automatic / off / manual se-
lector switch is selected in manual mode.
(e) The valve closed contact shall be hard wired into the pump start circuit to pre-
vent starting of the pump when the discharge valve is not closed.
Control System Modeling
In order to ensure that commissioning takes place on site in the most efficient
manner the Contractor shall computer model the control algorithms and
demonstrate the stability of the system using theoretical flows from the treatment
works and from the pumping stations with different numbers of pumps running.
The model shall have a graphical interface and shall be free running (i.e. it shall
be possible to set the model running and be able to observe steady state and
transient operation). Facilities shall be provided to simulate pump failures, power

[71]
failures etc. in order to study their effects. The model shall be demonstrated to the
approval of the Engineer. All modifications and improvements to the control
algorithms identified during this stage of design shall be incorporated into the
Works.
Protection against Pipeline Burst
(a) A signal shall be derived in PLC from the pressure transmitter provided on
common discharge header of each pumping station. This shall operate if the
pressure in the line falls for a set time period below the static pressure ex-
pected at that point. This shall raise an alarm and prompt the operator to
switch off the pumps.
(b) An Stay put type push button shall be provided on the control panel to switch
off all pumps simultaneously in such an emergency. The device shall be cov-
ered or shrouded in some way to prevent accidental operation.
(c) Before operating the pipeline control valves the system will:
Compare the flow from the master balancing reservoir flow meter with the
flow in the pipeline at the control valve, if the difference is greater than
2000 l/s or a value to be decided during execution stage, a burst will be
assumed and the outlet valve at the MBR shall be closed and an alarm
shall be raised. It shall be possible for the operator to disable the closing
of the outlet valve in response to burst detection.
Level switching points shall be derived in the appropriate PLC from the
MBR level analogue signal. The analogue value used shall be the
controlling value as selected by the operator from the central SCADA.
(d) Interface to the Temperature scanners and Power Analysers
Temperature scanners for each pump shall be mounted on the front
face of control panel in the control room. These temperature scan-
ners shall be interfaced with the PLC system through suitable com-
munication link for monitoring the winding & bearing temperatures
and alarm and trip settings on the OIU.
Power Analyser shall be provided for the main incomer and individ-
ual pumps. These Power Analysers shall be interfaced with the PLC
system through suitable communication link for monitoring of all the
parameters of Power Analysers like three phase voltages, currents,
kW, kVA, kWh, kVAh, power factor etc., on the OIU.
Control Cable / Communication Cable /

Communication Cable / Cable Trays

[72]
CABLES AND ACCESSORIES
POWERANDCONTROLCABLES
Designcriteria
a. Powerandcontrolcableshallbesuitableforinstallationinatropical-
monsoonareahavingahot humid climate. The reference ambient tempera-
ture to be considered for the purpose of this specificationis50DegC.
b. The de-rating factor for various conditions of installation including the follow-
ing shall be considered while choosing the conductor size and calculations
shall be submitted for Owners approval:
i. Maximumambientairtemperature.
ii. Maximum groundtemperature
iii. Depthoflayingwhereverapplicable
iv. Groupingofcables
c. The maximum continuous conductor temperature and the maximum allowa-

ble conductor temperatureduringshortcircuitaretobetake-
nas70degCand160degCrespectivelyincase of PVC insulated cables and 90
deg C and 250 deg C respectively in case of XLPE insulated cables.
d. The cables shall be capable of continuous satisfactory operation under a

power supply system frequencyvariatio-
nof()5%,voltagevariationof()10%andcombinedfrequencyandvoltage varia-
tionof10%(absolutesum).
e. ThecablesshallingeneralcomplywiththerequirementsofthelatestrevisionofIS-
1554(Part I) for the LT PVC power and control cables or the relevant IEC
International Standard unless otherwise specified in this specification. The
design, manufacture, installation, testing and performance of the cables,
shall comply with the latest revisions of IS/ IEC/ NEMA/ ASTM Standard and
the most stringent conditions specified in these specification shall be appli-
cable.
General technicalrequirements
a. Type ofcable:-
Thecableshallbemulti-core/singlecore(XLPE),PVCandanypolymeric/ elasto-
mericinsulation typeasspecified.
b. Conductor:-
Thecableconductorshallbemadefromstandardcopper toformcompactconduc-
tor havingaresistancewithinthelimitsspecified.Allthecablesofsize()
sqmmandaboveshallhave sectorshapeconduc-
tors.Theminimumno.ofstrandsinconductorshallbe7(seven)exceptas otherwi-
sespecified.PowercablesshallbeofstrandedCopperconductorwithsize()

[73]
sqmmminimumand the control cables shall be stranded copper (electrolytic)

conductor with a minimum size of 1.5mm.
c. ConductorShield
Theconductorhavingasemi-
conductingscreenshallensureperfectlysmoothprofileandavoid stress concen-
tration. The conductor screen shall be extruded in the same operation as the
insulation,thesemi-conductingpolymershallbecrosslinkedforXLPEcables.
d. Insulation
The insulation of the cable shall be extruded type and shall be designed and
manufactured for the specified system voltage. The manufacturing process
shall ensure that insulation shall be free from voids. The insulation shall
withstand mechanical and thermal stresses under steady state and transient
operating conditions. The extrusion method should give a very smooth inter-
facebetweensemiconductingscreenandinsula-
tion.Theinsulationofthecablesshallbeof high standard quality. The minimum
volume resistivity of the PVC insulation of all the PVC insulatedcables-
shallbe1x1014ohm-cmat27degCand1x1011ohm-cmat70degC.
e. Insulationshield
In XLPE cables, to confine electrical field to the insulation, a non-magnetic
semi conducting shield shall be put over the insulation. The insulation shield
shall be extruded in the same operationastheconductorshieldandtheinsula-
tionbytripleextrusion/process.TheXLPEcable insulation shield shall be strip-
pable. Metallic screening for all type of power, control and special cables
shall be provided.
f. InnerSheath
Thesheathshallbesuitabletowithstandthesiteconditionsandthede-
siredtemperature.Itshall beofadequatethicknessandappliedbyaconti-
nuousprocesstoproduceasheathofconsistent qualityfreefromallde-
fects.PVCsheathshallbeextruded.
g. Armour
Hard drawn Aluminium wire armouring / galvanized steel tape/ wire ar-
mouring shall be used for singlecoreandmulti-
corecablerespectively.Theharddrawnaluminiumwireforarmourshallbe of
H4 grade, as per IS-8130 (having tensile strength above 150 N/mm) The
diameter of the aluminium wire shall be as per the table for the dimen-
sions of the galvanized steel wire armour givenintherelevantstandard.
h. Serving/outersheath

[74]
Extruded PVC serving as per IS: 5831 or as specified otherwise shall be

applied over the armouring with suitable additives to prevent attach by ro-
dent and termites. All serving must be given anti-termite treatment.
Codesandstandards
All cables to be supplied shall conform to the latest revisions of IS or any
other international standards acceptable to Owner. Some of the Indian
Standards/ IEC considered relevant to the cables are given below:
Sr. Standard Description

No.
PVCinsu-
IS:1554 (Part-I)
1 lated(heavyduty)electriccablesforworking vol-
tageuptoandincluding1100V.
PVCinsulated(heavyduty)electriccablesforworking vol-
IS:1554 (Part-II)
2 tagefrom3.3kVup toandincluding 11kV.
3 IS:3961 Recommended current ratings for cables.
4 IS:8130 Conductors for insulated electric cables and

flexible cords.
5 IS:5831 PVC insulation and sheath of electric cables.
6 IS:2982 Copper conductor in insulated cables and
cords.
7 IS:3975 Mild steel wires, strips and tapes for armouring
cables
Specificationforlowfrequencywirersandcables-
8 IS:5609 withPVC insulationandPVCSheath.
9 IS:6380 Spec. of elastomeric insulation of sheath of
electric cables.
10 IS:434(I and II) Specification for rubber insulation cables
Themethodsforinsulationsandsheathsofelectriccab-
11 IEC:540 lesand
cords(elastomericandthermoplasticcompounds).
12 IEC:230 Impulse tests on cables and their accessories.
13 IEC:60 High voltage test techniques.

[75]
Calculationsofthecontinuouscurren-
14 IEC:287 tratingof cables(100%loadfactor).
Nominalcross-
15 IEC:288 sectionalareaandcompositionofconductor ofin-
sulatedcables.
Extrudedsoliddielectricinsulatedpo-
16 IEC:502 wercables forratedvoltage-
sfrom1.00kVupto30kV.
Thermoplasticinsulatedwiresandcablesfortransmis-
17 NEMA-WC-5 sionand distributionofelectricalenergy.
19 IEC: 332-1 Test on electric cables under fire conditions.
Standardtestmethodfordensityofsmokefrom
20 ASTM-D-2843 burning/decomposition ofplastics.
21 ASTM-D-2863 Test for determination of Oxygen Index.
22 IEC-754-I Test method for acid gas generation.
23 IEC-331 Fire resisting characteristics of electric cables.
Constructionalrequirements
Cable shall have suitable filters laid up with the conductors to provide a
substantially circular crosssectionbeforethesheathisap-
plied.Fillersshallbesuitablefortheoperatingtemperature of the cable and
compatible with the insulating material. All materials shall be new, unused
and offinestquality.Workmanshipshallbeneat,cleanandofhighestgrade.
a. 415V system power cables - The cable shall be 1.1kV, grade, heavy duty,
stranded aluminium conductor, PVC Type-A Insulated galvanized steel
wire/strip armoured, flame retardant low
smoke(FRLS)extrudedPVCtypeST1outersheathed.
b. Control cables - The cable shall be 1.1kV grade, heavy duty, stranded
copper conductor, PVC Type-A insulated, galvanized steel wire / strip ar-
moured, flame retardant low smoke (FRLS) extrudedPVCofType-
ST1outersheathed.
Identificationofcores

[76]
TheinsulatedcoresofLTpowercablesshallbeidentifiedbycolor-
code.Thecontrolcables shall have identification by means of printing of
numbers of its cores at intervals not more than
75mm.Atleast20%coresshallbekeptassparesinthemulti-corecontrolcables.
Arrangementofcables
Asfarasfeasi-
ble,separatecablesshallbeprovidedforcircuitsofdifferentplantandauxiliaries,
for circuits of different voltages, and for circuit used separately. Power,
control and instrumentation circuit shall invariably be taken through differ-
ent routes, which shall not be laid togetheronthesamecabletrays.
Drumslengths
Drum lengths of the cables shall be so chosen that straight through joints
are eliminated. However, the drum lengths shall not be less than the fol-
lowing lengths:
i) 415Volt,1.1kVgradepowercables500M
ii) 1.1kVgradecontrolandinstrumentationcables1000M
Installationofcablesandearthingsystem
The GI/Al cable trays, and accessories, supports, conduits, cable glands,
lugs, ferrules, tags, clamps and other accessories for installation of cables
in cable trays, trenches etc. earthing system network/earth mat including
interconnections at necessary area of plant shall be provided.
DesignandConstructionalFeatures
a. InterPlantCabling:
Interplantcablingformainroutesshallbelaidalongoverheadtrestles
/ductbanks.However,from tap-offs, same can be through shallow
trenches. In case of Duct banks, pull-pits shall be filled withsandandprovi-
dedwithaRCCcovering.Directlyburiedcables,ifessential,shallnothave con-
centrationofmorethan4cablesinoneroute.
b. Cableentry:Shallbedecidedduringdetailengineering
c. Trenches:PCCflooringofbuiltuptrenchesshallbeslopedforeffectivedrainage
withsumppits andsumppumps.
Cabletrays,fittingsandaccessories
a. GI Cable trays shall be ladder/ perforated type as specified complete with
matching fittings (like brack-
ets,elbows,bends,reducers,tees,crosses,etc.)accessories(likesidecouplerpla
tes,etc. and hardware (like bolts, nuts, washers, GI strap, hook etc.) as re-
quired. Cable tray shall be laddertypeforpowerandcontrolcablesandperfora-

[77]
tedforinstrumentationcables.
b. Cable-
trays,fittingsandaccessoriesshallbefabricatedoutofrolledmildsteelsheetsfreefr
om flawssuchaslamina-
tions,rollingmarks,pittingetc.These(includinghardware)shallbehotdip galvani-
zedasperrelevantIS.
c. Cabletraysshallhavestandardwidthof 80mm,
200mm,300mmand600mmandstandardlengthsof 2.5 metre. Minimum thick-
ness of mild steel sheets used for fabrication of cable trays and fittings shall
be 2 mm. The thickness of side coupler plates shall be minimum 3 mm.
d. Cabletroughsshallberequiredforbranchingoutfewcablesfrommaincab-
leroute.Theseshall be U-shaped, fabricated of mild steel sheets of minimum
thickness 2 mm and shall be hot dip galvanizedasperrelevan-
tIS.Troughsshallbestandardwidthof50mmand75mmwithdepth of 25mm.
e. The size of the cable tray (80mm to 600mm width) depends on the size of
the cables and routingofthe-
trays.Bidderhastodecidebasedonsitevisit.Thetrayloadingshouldnotbemore
than70%oftraycapacity,noneofcablewillbelaidoverthecable.Thecablecostincl
udescost oftrayandnoseparatepaymentwillbemadeforcabletray.
Supportsystemforcabletrays
a. Cabletraysupportsystemshallbepre-fabricated.
b. Support system for cable trays shall essentially comprise of the two compo-
nents i.e. main supportchannelandcantileve-
rarms.Themainsupportchannelshallbeoftwotypes:
Havingprovisionofsupportingcabletraysononesideand
Havingprovisionofsupportingcabletraysonbothsides.
In general, the support system shall be as follows :

i. Cable supporting steel work for cable racks / cables shall comprise of var-
ious channel sections, cantilever arms, various brackets, clamps, floor
plates, all hard wares such as lock wash-
ers,hexagonnuts,hexagonheadbolt,supporthooks,studnuts,hexagonheads
crew, channelnut,channelnutwithsprings,fixingstuds,etc.
ii. The system shall be designed such that it allows easy assembly at site by
using bolting. All cablesupportingsteelwork,hard waresfittingsandaccesso-
riesshallbeprefabricatedfactory galvanized.
iii. Themainsupportandcantileverarmsshallbefixedatsiteusingnecessa-
rybrackets,clamps, fit-
tings,bolts,nutsandotherhardwareetc.toformvariousarrangementsrequiredt
osupport the cable trays. Welding of the components shall not be allowed.
However, welding of the brack-
et(towhichthemainsupportchannelisbolted)totheoverheadbeams,structural

[78]
steel, insertplatesorreinforcementbarswillbepermit-
ted.Anycuttingorweldingofthegalvanized surfaceshallbebrushedandred-
leadprimer,oilprimerandaluminiumpaintshallbeapplied.
iv. All steel components, accessories, fittings and hardware shall be hot dip
galvanized after completingweld-
ing,cutting,drillingandothermachiningoperation.
v. The main support channel and cantilever arms shall be fabricated out of
minimum 2.5 thick rolledsteelsheetconformingtoIS.
vi. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required.
The arm portion shallbesuitableforassemblingthecompletearmassem-
blyontocomponentconstructedof standard channel section. The back plate
shall allow sufficient clearance for fixing bolt to be tightenedwithtrayinposi-
tion.
Junctionboxes
c. Junction Boxes with IP:55 degree of protection, shall comprise of a case
with hinged door constructed from cold rolled sheet steel of minimum thick-
ness 2 mm. Top of the boxes shall be arranged to slope towards rear of the
box. Gland plate shall be 3 mm thick sheet steel with neo-
prene/syntheticrubbergaskets.Alljunctionboxesshallbeofadequatestrengthan
drigidity, hotdipgalvanizedasperrelevan-
tIS,andsuitableformountingonwall,columns,structuresetc. The boxes shall in-
clude brackets, bolts, nuts, screws M8 earthing stud etc. required for instal-
lation
d. Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one piece
moulding. It shall be complete with insulating barriers, Clip-on type terminals
and identification strips. Marking on terminal strip shall correspond to the
terminal numbering on wiring diagrams. It shall be Elmex typeCSLT-
1withinsulatingmaterialofMelamineconformingtoESIStandard12.1orequivalen
t. Terminal block shall be suitable for terminating 2 wires of 2.5mm on both
sides arranged to facilitateeasytermination
Terminations and straight through joints

1.1kVgradestraightthroughjointsshallbeofprovendesign.Asuitablecaretobetak
enduring jointandtermination.
Cable glands
Cable shall be terminated using double compression type cable glands. Ca-
ble glands shall conform to BS:6121 and be of robust construction capable
of clamping cable and cable armour (for armoured cables) firmly without in-
jury to insulation. Cable glands shall be made of heavy dutybrassmachinefi-
nishedandnickelchromeplated.Thicknessofplatingshallnotbelessthan 10 mi-
cron. All washers and hardware shall also be made of brass with nickel
chrome plating Rubber components shall be of neoprene and of tested qual-
ity. Necessary cable dimensions shallbefurnishedtothesuccessfulContractor.

[79]
Cablelugs/ferrules
CablelugsforpowercablesshallbeAluminiumsolderlesscrimpingtype-
conformingtoIS:8309 suitable for aluminium compacted conductor cables.
Cable lugs and ferrules for control cables shallbetinnedcopperconforming-
toIS:8309.Thecablelugsforcontrolcablesshallbeprovided withinsulatingslee-
veandshallsuitthetypeofterminalsprovidedontheequipments.
Cableclampsandstraps
The cable clamps required to clamp multi core cables on vertical run shall
be made up of Aluminiumstripof25x3mmsize.Forclampingthemulti core-
cables,self-locking,de-interlocking type nylon clamps/ straps shall be used.
The clamps/ straps shall have sufficient strength and shallnotgetaffectedby-
directexposuretosunraysandoutdoorenvironment
Installation
Cabletrayandsupportsysteminstallation
a. Cables shall run in cable trays mounted horizontally or vertically on cable

tray support system which in turn shall be supported from floor, ceiling,
overhead structures, trestles, pipe racks, trenchesorotherbuildingstruc-
tures.Allcabletraysshallbeinverticalconfigurationinboilerand ESPareas.
b. Horizontally running cable trays shall be clamped by bolting to cantilever

arms and vertically runningcabletraysshallbeboltedtomainsupportchannelby-
suitablebracket/clampsonboth top and bottom side rails at an interval of
2000 mm. For vertical cable risers/shafts cable trays shall be supported at
an interval of 1000mm. Fixing of cable trays to cantilever arms or main sup-
portchannelbyweldingshallnotbeaccepted.
c. The cantilever arms shall be positioned on the main support channel with a
minimum vertical spacin-
gof300mmunlessotherwiseindicatedintherelevanttraylayoutdrawings
d. All cable way sections shall have identification, designations as per cable
way layout drawings and painted/ stencilled at each end of cable way and
where there is a branch connection to another cable way. Minimum height of
letter shall be not less than 75 mm. For long lengths of trays, the identifica-
tion shall be painted at every 10 meter. Risers shall additionally be painted/
stencilledwithidentificationnumbersateveryfloor.
e. In certain cases it may be necessary to site fabricate portions of trays, sup-

ports and other non standard bends where the normal prefabricated trays,
supports and accessories may not be suitable. In such cases the Contractor

[80]
shall fabricate at site suitable sections of trays, supports andaccessoriesto-

maketheinstallationcompleteforthespecificpurposeafterobtainingProject
Manager's prior approval, which shall be neat in appearance and shall
match with the prefabricatedsectionsinthedimen-
sions.Theyshallbeappliedwithonecoatofredleadprimer, onecoatofoilprimerfol-
lowedbytwofinishingcoatsofaluminiumpaint.
Conduits/Pipes/Ductsinstallation
f. All openings in the floor/ roof/ wall/ cable tunnel/ cable trenches made for
conduit installation shall be sealed and made water proof. GI pull wire of
adequate size shall be laid in all conduits before installation. Metallic conduit
runs at termination shall have two lock nuts wherever requiredforjunction-
boxesetc.
g. Conduit runs/sleeves shall be provided with PVC bushings having round

edge at each end. All conduits/ pipes shall have their ends closed by caps
until cables are pulled. After cables are pulled, the ends of conduits/ pipes
shall be sealed with Glass-wool/ Cement Mortar/ Putty to prevententran-
ceofmoistureandforeignmaterial.
h. Exposed conduit/ pipe shall be adequately supported by racks, clamps,

straps or by other approved means. Conduits / pipe support shall be in-
stalled square and true to line and grade withanaveragespacingbetweenthe-
supportsasgivenbelow,unlessspecifiedotherwise.
The typical conduit sizes shall be per below table:
Sr. No. Particular Description
1 Conduit/ pipe size (dia) Spacing
2 Up to 40 mm 1.0 m
3 50 mm 2.0 m
4 65-85 mm 2.5 m
5 100 mm 3.0 m
Junction boxesinstallation
Junction boxes shall be mounted at a height of 1200mm above floor level
or as specified in the drawings or as decided by Project Manager and
shall be adequately supported/mounted on masonrywallbymeansofan-
chorfasteners/ expandableboltsorshallbemountedonanangle, plateoro-
therstructuralsupportsfixedtofloor,wall,ceilingorequipmentfoundations.

[81]
Cableinstallation
a. Cable installation shall be carried out as per IS:1255 and other applicable
standards. Cable drums shall be unloaded, handled and stored in an ap-
proved manner on hard and well drained surface so that they may not
sink. In no case shall be drum be stored flat i.e. with flange horizontal.
Rolling of drums shall be avoided as far as possible. For short distances,
the drums may be rolled provided they are rolled slowly and in proper di-
rection as marked on the drum. In absenceofanyindica-
tion,thedrumsmayberolledinthesamedirectionasitwasrolledduring takingup-
thecables.Forun-
reelingthecable,thedrumshallbemountedonsuitablejacksoron cable wheels
and shall be rolled slowly so that cable comes out over the drum and not
from be-
low.Allpossiblecareshallbetakenduringunreelingandlayingtoavoiddamaged
uetotwist, kink or sharp bends. Cable ends shall be provided with sealed
plastic caps to prevent damage andingressofmoisture.
b. Whilelayingca-
ble,groundrollersshallbeusedatevery2metreintervaltoavoidcabletouching
ground. The cables shall be pushed over the rollers by a gang of people
positioned in between the rollers. Cables shall not be pulled from the end
without having intermediate pushing arrange-
ments.Pullingtensionshallnotexceedthevaluesrecommendedbycablemanuf
acturer. Selection of cable drums for each run shall be so planned so as to
avoid using straight through
joints.Careshouldbetakenwhilelayingthecablessoastoavoiddamagetocable
s.
c. Cablesshallbelaidoncabletraysstrictlyinlinewithcableschedulefurnished.
d. Power and control cables shall be laid on separate tiers. The laying of
different voltage grade cables shall be on different tiers according to the
voltage grade of the cables. In horizontal tray
stacks,415Vpowercables(1.1kV)shallbelaidontop mosttierandcablesofsub-
sequentlower voltage-
grades/controlcablesonlowertiersoftrays.Singlecorecableintrefoilformations
hallbe laidwithadistanceoffourtimesthediameterofcablebetweentrefoil-
centerlinesandclamped at every two metre. All multi-core cables shall be
laid in touching formation. Power and control cables shall be secured fixed
to trays/ support with self locking type nylon cable straps with de-
interlocking facilities. For horizontal trays arrangements, multi-core power
cables and control cables shall be secured at every five meter interval. For
vertical tray arrangement, individual multi-core power cables and control
cables shall be secured at every one meter by nylon cable strap. After
completion of cable laying work in the particular vertical tray, all the control
cables shallbetiedto-
trays/supportsbyaluminiumstripsateveryfivemeterintervalandateverybend.
e. Bendingradiiforcablesshallbeaspermanufactur-

[82]
ersrecommendationsandIS:1255.
f. Wherecablescros-
sroads/railtracks,thecablesshallbelaidinhumepipe/PVCpipe.
g. Jointsforlessthan250Metersrunofcableshallnotbepermitted.
h. Controlcableterminationinsideequipmentenclosureshallhavesuffi-
cientlengthssothatshifting ofterminationinterminalblockscanbedonewithou-
trequiringanysplicing.
i. Theinstallationworkshallbecarriedoutinaneatworkmanlikemanneran-
dareasofworkshall be cleaned of all scraps, water, etc. after the comple-
tion of work in each area every day. RCC/ Steeltrenchcoversshallberepla-
cedaftertheinstallationworkinaparticularareaiscompleted orwhenfurther-
workisnotlikelytobetakenupforsometime.
j. Separation-Atleast300mmclearanceshallbeprovidedbetween:
- HTpowerandLTpowercables,
- LTpowerandLTcontrol/instrumentationcables,
k. Segregation
Segregation means physical isolation to prevent fire jumping.
All cables associated with the unit shall be segregated from cables of
other units.
Cable routes for one set of auxiliaries of same unit shall be segregated
from the other set.
m. Minimumnumberofsparecoresrequiredtobeleftforinterconnectionin-
controlcablesshall be as follows:
Sr. No. of cores in cable No. of spare cores

No.
1 2C, 3C NIL
2 5C 1
3 7C-10C 2
4 14C and above 3
n. Cablefiresealing
Wherever the cables pass through walls/ floors, fire proof cable penetra-
tion seals rated for two hours shall be provided. This shall be by suitable
block system using individual blocks with suitable framework or by silicon
RTV foaming system. In case foaming system is offered, damming-

[83]
board,ifused,shallnotbeconsideredforfireratingcriteria.Anyofthesystemoffer
ed shallbeofproventypeasperBS:476(Part-20)orequivalentstandard.
o. Directlyburiedcables
- Cabletrenchesshallbeconstructedfordirectlyburied-
cables.Constructionofcabletrenchfor cables shall include excavation,
preparation of sieved sand bedding, riddled soil cover, supply and installa-
tion of brick or concrete protective covers, back filling and compacting,
supply and installationofroutemarkersandjointmark-
ers.Layingofcablesandprovidingprotectivecovering shallbeasperIS:1255.
- RCC cable route and RCC joint markers shall be provided wherever re-
quired. The voltage grade of the higher voltage cables in route shall be
engraved on the marker. Location of underground cable joints shall be in-
dicated with cable marker with an additional inscription Cable-
Joint.Themarkershallproject150mmabovegroundandshallbespacedatanint
erval of 30 meters and at every change in direction. They shall be located
on both sides of road crossings and drain crossings. Top of cable mark-
er/joint marker shall be sloped to avoid accumulationofwa-
ter/dustonmarker.
p. Cabletagsshallbeprovidedonallcablesatea-
chend(justbeforeenteringtheequipment (enclo-
sure),onbothsidesofawallorfloorcrossing,oneachduct/ conduiten-
try,andatevery20 metersincable-
tray/trenchruns.Cabletagsshallalsobeprovidedinsidetheswitchgear,motor
controlcen-
tres,controlandrelaypanelsetc.whereanumberofcablesentertogetherthrougha
glandplate.Cabletagshallbeofrectangularshapeforpowercablesandcontrolcab
les.Cable tag shall be of 2 mm thick Aluminium with number punched on it
and securely attached to the cable by not less than two turns of 20 SWG GI
wire conforming to IS:280. Alternatively, cable tags made of nylon, cable
marking ties of TY-CAB or equivalent type with cable number heat stampe-
donthecabletagsmayalsobeprovided.
q. Whilecrossingthefloors,un-armouredcablesshallbeprotectedinconduitsup
toaheightof 500mmfromfloorlevelifnotlaidintray.
Cableterminationsandconnections
a. The termination and connection of cables shall be done strictly in accor-

dance with cable terminationkitmanufacturerinstruc-
tions,drawingsetc.Cablejointershallbequalifiedtocarryout satisfactorycable-
jointing/termination.
b. Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumb-

[84]
ing, soldering, drill-

ing,cutting,taping,preparationofcableend,crimpingoflug,insulatedsleevesover
control cable lugs, heat shrinking (where applicable), connecting to cable
terminal, shorting and groundingasrequiredtocompletethejob.
c. The equipment will be generally provided with undrilled gland plates for
cables/ conduit entry. TheContractorshallberesponsibleforpunchingof-
glandplates,paintingandtouchingup.Holes shallnotbemadebygascut-
ting.Theholesshallbetrueinshape.Allcableentrypointsshallbe sealed and
made vermin and dust proof. Unused openings shall be effectively sealed by
2mm thickaluminiumsheets.
d. Control cable cores entering control panel/ switchgear/ MCCs etc. Shall be
neatly bunched, clampedandtiedwithselflockingtypenyloncabletieswithdein-
terlockingfacilitytokeepthem inposition.
e. Thepanelswherealargernumberofcablesaretobeterminatedandcablei-
dentificationmaybe difficult, each core ferrule shall include the complete ca-
ble number as per the drawings. The ferrules shall be indelible interlocking
type and shall fit tightly on cores. Spare cores shall have similarlyferruleswi-
thasuffixletterSalongwithcablenumbersandcoiledupafterendsealing.
f. Allcableterminationsshallbeappropriatelytightenedtoensuresecu-
reandreliableconnections.
INSTRUMENTATIONCABLES
GeneralRequirements
a. The Contractor shall supply, erect, terminate and test all instrumentation
cables for control and instrumentation equipment/devices/systems included
under Contractor's scope.
b. Any other application where it is felt that instrumentation cables are required
due to sys-
tem/operatingconditionrequirements,arealsotobeprovidedbytheContractor.
c. Othertypeofcableslikeco-
axialcablesforsystembus,cablesforconnectionofperipheralsetc. (underCon-
tractor'sscope)alsoshallbefurnishedbytheContractor.
d. Contractorshallsupplyallcableerectionandlayinghardwarelikecab-
letrays,supports,flexible conduits, cable glands, lugs, pull boxes etc. on as
required basis for all the systems covered underthisspecification.
e. In addition to above, Contractor shall supply all the cables including co-axial
cables for station Wide LAN interconnecting entire control system in Con-
tractor's scope as well as the control systemswhicharealreadyinexistence.
Instrumentation Cable Specifications

[85]
a. All the instrumentation cables i.e. twisted and shielded multi pair cables,
compensating cables, prefabricatedcable-
setc.shallbeflameretardantlowsmoke(FRLS)type.TheCablesshallbe supplied
in non returnable drums. The drum length shall be 1000m (+/-5%) up to &
including 8 pairsand500m(+/-5%)above8pairs.
b. Voltagegradeoftheinstrumentationcablesshallbe225V(peakvalue).
AllinstrumentationcablescoveredinthisspecificationshallcomplywithVDE0815,VD
E0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC
96.1, IS-8784, IS-10810
(latesteditions)anditsamendmentsreadalongwiththisspecification
COMMUNICATION CABLES
CAT6 CABLE (CATEGORY 6 PLUS)
1. SCOPE
This specification is based on the specifications of UL 444, ANSI/TIA/EIA-568-B,ISO/IEC
11801,
UL 1685(CM) and covers the requirements for Unshielded Twisted Pair (UTP) cables of
100 ,
Cat6 (U/UTP 6+) for Wideband Technology. Applicable cable size and type: 4 pairs,
PVC sheath, CM Grade.
2.1 CONDUCTORS
Each conductor shall be solid bare copper wire, circular in cross-section,
uniform in quality and free from defects. The diameter of each conductor shall be AWG
23 (Nom O.D.0.54 +/- 0.005).
2.2 INSULATION
Each conductor shall be insulated with solid high density Polyethylene (HDPE).
It shall be applied uniformly around the conductor with a minimum concentricity of 90%.
The nominal insulation diameter shall be 0.98mm0.03mm and the specific maximum
diameter shall be 1.22mm. If the concentricity of the conductor can be tested on the
manufacturing process before completing the product, it could be omitted in the test.
2.1.3 PAIRS
Two insulated conductors, designated "A" and "B" shall be uniformly twisted together to
form a pair. The insulation shall be coloured and striped longitudinally, as per Table 1.
The stripe colouring shall not be removable by normal stripping and wiring operations.
2.1.4 CABLE CORE ASSEMBLY

Two insulated conductors shall be twisted into a pair. Four twisted pairs shall be
assembled into a cable core. The cross-shaped filler shall be inserted between pairs for
sufficient isolations of pairs to improve crosstalk characteristics. Rip cord forms part of

[86]
the cable construction.
2.1.5 SHEATH
The material shall, as a minimum, meet the requirements of UL 444. The sheath shall be
applied over the cable assembly by an extrusion tubing technique, being close fitting, but
not adhering to the insulation, and readily removable for installation termination. The
sheath shall have a minimum wall thickness of 0.50mm and nominal 0.55mm. The
acceptable maximum cable diameter shall be 6.4mm. The sheath colours are given in
Table 2.
2.1.6 SHEATH MARKING

The cable shall be marked on the sheath to designate the transmission performance
and others. The marking shall be printed through the outer sheath clearly.
The specific legend requirements are given in Table 3.
2.2 PHYSICAL PERFORMANCE

2.2.1 SHEATH
The unaged tensile strength and elongation, measured in accordance with clause 7.8 of
UL 444 shall be minimum 13.5MPa and 150%, respectively. The heat-aged tensile
strength and elongation, measured in accordance with clause 7.8 of UL 444 shall be
minimum 12.5MP and 125%, respectively.
2.2.2 CABLE COLD BEND

All cables shall meet the requirements of clause 7.10 of UL 444. Cold bend (20deg +/-
2deg x 4h): 8 x Cable O.D. , no visible cracks. Page 4 of 5 Document ID:
130520_CAT6PLUS_UTP_Specification_Ver4_Z_Cust
2.2.3 FLAME REQUIREMENT

A cable marked CM shall comply with the vertical-tray flame test specified in
UL 1685 or IEC 60332-3.
2.2.4 CROSS-SHAPED FILLER

Cross-shaped filler (separator) complies with ROHS requirements. O.D. 4.5mm,
thickness 0.45mm
1.9.3 EARTHING
An instrumentation earth shall be provided in each control panel. This shall comprise a
copper bar of cross section not less than 25 x 6 mm and length to suit the number of
connections. It shall be mounted on at least two insulated supports and be provided with
a single earth connection to the instrumentation earth. If due to the physical size of a
control panel more than one instrument earth bar is required the additional bar shall be
connected again with a single earth connection to the same point as before on the
control panel instrument earth bar. In this fashion all instrument earths shall be
connected radial from the same earth point.
Assemblies shall be provided with earthing facilities as follows:
For small single compartment assemblies an earth stud shall be provided. For large
single compartment or multi-compartment assemblies a clearly marked continuous

[87]
copper earth bar shall run the length of the assembly and shall be provided with
terminals for connections to the metal cladding or armoring of all incoming and outgoing
cables.
The short-term rating of the earth bus bar and connections shall be not less than that of
the associated equipment, or the maximum through-fault current of the power source.
The temperature rise of the bus bar and connections under fault conditions shall not
cause damage to the connections of any equipment to which they may be connected.
No earth terminal bolts or studs shall be less than 8 mm diameter.
An earth bond of minimum size 6 mm2 shall be made to all enclosure doors.
Labels
The assembly as a whole and each compartment shall be clearly and
unambiguously identified.
The labels shall be engraved letters and numbers filled black on a white back-
ground.
Warning labels shall be engraved and filled black on a yellow background.
Labels shall be affixed with non-corrodible rivets or screws.
Internal labels shall be used to identify all components and terminal strips. They
shall be of plastic in construction and shall be affixed adjacent to the component.
1.10 Surveillance System

1. Introduction:
1.1. Surveillance CCTV system is required to ensure effective surveillance of an
area as well as create a tamperproof record for post event analysis. The System
shall provide an online display of video images on TFT monitors/Video Wall/Large
plasma monitors located in Central as well as Local control rooms.
1.2. System should facilitate viewing of live and recorded images and controlling of
all
cameras by the authorized users present in the LAN.
1.3. System should provide inter-operability of hardware, OS, software,
networking, printing, database connectivity, reporting, and communication
protocols. System expansion should be possible through off-the-shelf available
hardware.
1.4. Equipment with better specifications shall be accepted.
2. General Specifications:
2.1. Proposed CCTV system shall be an open standard based integrated system
with IP network centric functional and management architecture aimed at providing
high-speed manual /automatic operation for best performance.
2.2. System shall use video signals from various types of indoor/outdoor CCD
colour cameras installed at different locations, process them for viewing on
workstations / monitors at Central Control Room/local control rooms and
simultaneously record all the cameras after compression using MPEG 4 or better
standard. Joystick or Mouse-Keyboard controllers shall be used for Pan, Tilt,
Zoom, and other functions of desired cameras.
2.3. System shall have combination of Digital CCD Colour video Cameras with
individual IP address, analog CCD Colour Video Cameras with Fixed or P/T/Z
Lens, encoders / decoders, Network Video recorders (NVR/CAMERA SERVER),

[88]
Network attached storage (NAS) / Raid backup device for recording, Application
software, Colour Video Monitors, Keyboards with Joystick controllers / Mouse-
Keyboard, software based Video Matrix Switcher, workstation for System
Administration / Management / Maintenance etc.
2.5. Video Recorder shall offer both video stream management and video
stream storage management. Recording frame rate & resolution in respect of
individual
channel shall be programmable.
2.6. System should ensure that once recorded, the video can not be altered,
ensuring
the audit trail is intact for evidential purposes.
2.7. System shall provide sufficient storage of all the camera recordings for a
period of 30 days or more @ 25 FPS, at 4 CIF or better quality using necessary
compression
techniques for all cameras (extended capacity of cameras i.e. present capacity+25
%).
2.8. System shall use a combination of IP enabled cameras & analog CCD
cameras with external encoder. The video shall be compressed using MPEG-4 or
better standard and streamed over the IP network.
2.9. Encoders shall digitize analog video, compress the digital video using various
compression algorithms (MPEG - 4 or better standard), and transmit the
compressed
digital video over packet-based IP network. Encoders shall have less than 200 ms
of
latency and shall support dual stream MPEG 4.
2.10. The recording resolution and frame rate for each camera shall be user
programmable.
2.11. The Area under surveillance shall be monitored and controlled from
Central/Local
Control Room(s) through Joystick controllers.
2.12. Surveillance CCTV System shall operate on 230 V, 50 Hz single -phase
power supply. Power for all the equipment will be conditioned using on-line UPS
with minimum 30 minutes or more back up. If any equipment operates on any
voltage other than the supply voltage and supply frequency, necessary
conversion/correction device for supply shall be supplied along with the equipment.
2.14. All the indoor cameras & control equipment shall be suitable for operation at
ambient temp. 450 C.
3. System requirements:
3.1 Camera with external encoder or IP Camera shall be used for image cap-
ture.
3.2 Indoor cameras shall be either with fixed focal length lens or with Pan/Tilt &
Zoom lens as per site requirement. All outdoor Cameras shall be Day/Night
cameras.
3.2 Housing of cameras meant for indoor use shall be of IP 42 rating whereas
outdoor camera housing shall be of IP 66 or better rating. These must be in-
tegrated by the camera manufacturer.

[89]
3.4 System must provide built-in facility of watermarking or Digital certificate to en-
sure tamperproof recording so that these can be used as evidence at a later
date, if so desired. The recording shall support audit trail feature.
3.5 All camera recordings shall have Camera ID & location/area of recording as
well as date/time stamp. Camera ID, Location/Area of recording & date/time
shall be
programmable by the system administrator with User ID & Password.
3.6 Facility of camera recording in real-time mode (25 FPS)/15/12.5/10 or lower
FPS as well as in any desired combination must be available in the system.
3.7 Facility of Camera recording in CIF, 2CIF, 4 CIF as well as in any combination
i.e.
Any camera can be recorded in any quality Selective or Group of cameras
must
be available in the system.
3.8 System to have facility of additional camera installation beyond the originally
planned capacity.
3.9 In order to optimize the memory, while recording, video shall be compressed
using
MPEG-4 or better standard and streamed over the IP network. Once on the network,
video can be viewed on a Control room workstation or on analog monitor using a
hardware decoder (MPEG-4/compatible standard Receiver) and shall be recorded on
NVR
3.10 System shall be triplex i.e. it should provide facility of Viewing, Recording
&Replay
Simultaneously.
3.11 The offered system shall have facility to export the desired portion of clipping
(from a desired date/time to another desired date/time) on CD or DVD. View-
ing of this recording shall be possible on standard PC using standard software
like windows media player etc.
3.12 PTZ Cameras shall have 64 or more pre-defined positions, to be selected
through
suitable input alarm.
3.14 System shall have provision of WAN connectivity for remote monitoring.
4. System design:
4.1 Each camera should be connected to a Hardware Encoder, through cable,
which shall support minimum dual streams. Alternatively, the camera shall be
IP based, UTP ready. The encoders should be capable of producing streams
@ 25 fps for each camera for viewing on LAN and on monitors and also re-
cording into the NVR user selectable as per requirement, for each individual
camera.
4.2 Encoders shall be Power Over Ethernet (POE) compliant and connected to
Layer or Layer 3 switch as per system design using UTP CAT 6 Cable or fi-
ber optic cable and the required connectors as per standards.
4.3 Central/Local Control Room will have workstations along with controllers for
Camera operation. For monitoring purposes, Video monitors/Plasma moni-
tors/Video wall shall be setup with suitable mounting arrangements, as per
user requirements. Facility for viewing and controlling all the cameras at vari-
ous other locations, as required, shall be provided.

[90]
4.4 Monitoring at Local control rooms may be restricted to operation of certain

cameras only & system administrator should be able to configure the system,
accordingly. More then one Local Control rooms may be required in the pro-
posed system with individual configuration.
4.5 Each control room may have one or more Operators simultaneously using
the
installed Video monitors/Video wall. Operator control on cameras shall be on
a static basis or rotary basis depending on the policies to be decided at site.
4.6 There shall be a Control System with Video Control Software to manage all
the video surveillance devices.
4.7 Database Server shall keep track of all configurations & events. This will help
in proper System administration & management of redundancies etc.
4.8 Video stream from individual cameras shall be recorded on respective NVR
System shall have provision to automatically over-write the new information
after the period of 30/31 days & necessary script/algorithm must be available
in the Application.
6. DETAILED TECHNICAL SPECIFICATIONS

6.1 Colour video Dome Camera with PTZ
Image Device Interline transfer 1/4" or better format CCD

sensor
Focal length 4 mm to 72 mm or better (for Artificial
Intelligence Cameras with
better focal length i.e; 3.5 mm to 91 mm to be
used)
Optical zoom (For 18 X or better
Indoor Camera)
Optical zoom (For 26 X or better

Outdoor Camera)
Number of Pixels 720 X 576
Scanning System PAL

Resolution 480 TVL or better
Illumination (For 1.0 Lux (Color), 0.1 Lux (B/W) or better

Indoor camera)
Illumination (For 1.0 Lux (Color), 0.05 Lux (B/W) or better

Outdoor camera)
Pan Travel 360 Continuous
Tilt Travel 0 - 90
Manual Tilt Speed 0.5/SEC to 90/SEC
Manual pan speed 0.5/SEC to 90/SEC

[91]
Preset Tilt speed 0.5/SEC to 90/SEC
Preset Pan Speed 0.5/SEC to 300/SEC
Preset positions Min. 64

Iris Control Auto
Focus Auto
Back Light compensation Required with black masking or other suitable
technology
White balance Auto
Electronic shutter Auto
S/N ratio >= 48 dB
Power supply As per OEM's design, however generally AC
230 V @ 50Hz/12V or 24 V AC Rectifier and
SMPS if DC supply
6.2 Fixed Colour Dome Camera Varifocal:-
Image Device 1/3 or CCD Sensor

Number of Pixels 720 x 576
Minimum
Scanning System PAL Resolution 480 TV Lines or better
Min Illumination 1 Lux at F 1.2
S/N Ratio >=48 dB
Electronic Shutter AUTO
Lens Built- in Varifocal lens. Auto Iris, lens f = 4
9 mm.(approx.)
Backlight compensation Required
Power supply As per OEM's design
6.3. MPEG4 ENCODER (HARDWARE BASED):-
6.3.1 The encoder shall be built on embedded processor and real time operating
system. The Encoder should convert Analog Composite/S-Video input into
good quality digital stream on real time basis and shall be able to transmit as
Unicast /Multicast IP packet with low latency (less than 200 mSec.) for live
viewing as well as for recording.
6.3.2 The video resolution should be configurable at either of 4 CIF, 2 CIF, CIF @
25 fps or at lower frame rate per camera, user selectable.
6.3.3 The encoder should generate MPEG4 video stream Compliant with ISO/IEC
14496 standard. The encoder should be interchangeable with any standard encoder

[92]
of any other make, which generates MPEG4 video stream Compliant with ISO/IEC
14496
standard.
6.3.4 The Encoder should have the following specifications or should match with the
requirement.
Format PAL color, B/W, composite, 25 fps,

2:1 interlaced
Resolution (H x V pixels) 4 CIF 704 x 576, 2 CIF , CIF, QCIF
Frame Rate 25 fps (PAL) and lower
Encoding MPEG-4 Compliant with ISO/ IEC

14496 Standard
Video Parameters Brightness, contrast, hue,
sharpness, and sizing selectable
Video Latency Less than 200 mSec.
Connectors BNC for Composite Video for input,

suitable connectors for Power,
Alarm in, and Alarm out, RJ-45 for
Ethernet 10/100 Base-T output.
IP Address Static IP Address or as per System
requirement.
MPEG4 standard Compliant with ISO / IEC14496
IP Packets Unicast and Multicast
POE Compliant
Power supply As per OEM's design
6.4 Camera Housing & mount: The camera mount should be:
i. Of the same make as that of camera and suitable for the model number offered as
specified by the manufacturer and should be an integrated unit.
ii. Should be compact and indoor / outdoor type as required.
iii. Should support the weight of camera and accessories such as housing, pan & tilt
head in any vertical or horizontal position etc.
6.5 Speed dome controller/PTZ controller

Speed Dome Controller should have variable speed joystick, LCD display for
programming and it should be able to control the speed dome for PAN / TILT /
Zoom.
6.6 Cables:-
Sr. Connectivity Cable Type

[93]
No.
1 Camera to Video Encoder Coaxial RG 6/U / CAT 6 /
Fibre Optic
2 Video Encoder to Switch in control room UTP CAT 6 / Fibre Optic
3 Switch to Video Wall Switches UTP CAT 6 / Fibre Optic
4 From switches to NAS Box Fibre Optic
5 Hardware Decoder to monitor Composite signal cable

[94]
SA-2 Water Treatment Plant -Aeration Fountain
2.1 Open channel type ultrasonic flow Transmitter with FIT

Providing, erecting and commissioning and testing of open channel type ultrasonic
flow meter with FIT at aeration fountain at Visava..........Water treatment plant.
Ultrasonic level transmitter shall be CE marked with following technical parameters
for raw water and interface to PLC panel. Open channel flow meter include
monitoring type ( continuous or totalized ), viscosity and fluid purity An open
channel flow meter can display information at the meter, or transmit or transmit it
electronically to a remote location. Additional specification to consider are minimum
and maximum flow rate for open channel flow meter, the ability to measure flow of
Raw Water. Open channel flow meters must be able to handle variation in volumetric
flow data unless density (and sometimes also viscosity) is constant. When the
viscosity (volumetric flow) of incompressible liquid is measured, the presence of
suspended bubbles will cause error, therefore air and gas must be removed before
the fluid reaches the meter. Erection of water meters must be done in the presence &
guidance of manufacturers representative.
Medium Raw water.
Range 0- 5 meters.
Output 4 - 20 mA.
Power supply 24 V DC ext.
Display Backlit 4 LED
Accuracy - +/- 0.25% of full Scale or better.
Temp. With inbuilt temp compensation.
Encloser IP68,
2.2 PH Transmitter and analyser
pH measurement system shall include pH sensor with integral cable, pH transmitter with
Monochromatic liquid crystal display(LCD) & sensor mounting arrangement. The
measurement system shall have automatic buffer recognition feature. The analyzer shall
recognize the value of the buffer being measured and perform a self stabilization check.
Integral temperature sensor shall automatically compensate the change in pH due to
change in temperature.
Solid state/micro processor based system with system accuracy of 0.1% pH shall have
auto zero check, manual zero and span calibration facility. Range of measurement
should be for 0-14pH The measurement system shall have integral indicator, automatic
ultrasonic cleaner OR spray jet cleaner. Only auto cleaning is acceptable. Housing for

[95]
electrode and analyser shall be IP68. Output shall be HART signal of 4-20 mA DC
linear.
pH sensor shall be mounted on a sensor holder which shall be supported on

wall/pipe/column near process. The Transmitter/Analyzer shall be mounted near the
process on wall or pipe. Sensor shall be electrically interfaced with Transmitter/Analyzer.
Accessories shall include preamplifier, screened junction box for electrode. In high purity
water applications (specific conductivity below 50 micro-mhos/cm) the cell housings
specifically designed for high purity water shall be used. pH electrodes shall compliance
with IS-6804-1972.
DATASHEET FOR pH TRANSMITTERS

TECHNICAL SPECIFIFCATIONS
SR.NO. SPECIFIFCATIONS PARTICULARS
pH sensor
Helical path reference Glass Electrode with dirt
repellent PTFE diaphragm / Contacting
conductivity/Potentiometric without deviating other
1 Principle specifications
2 Applicable Standard pH electrodes shall conform to IS-6804-1972
Measuring and Reference Electrode combined
together in flow through type assembly for following
3 Application applications
1. Water channel from Raw water intake well to Flash
mixture
2. Clarifier to filter channel Pure water Sump
The flow through assembly shall be (Polypropylene
Material of
flow chambers,
4 Measuring &reference
Toughened sensitive pH glass, stainless steel,
electrode
Silicon
Mounting
5 arrangement 1 NPT M

[96]
6 Electrode housing Non destructible chemically resistant enclosure

Ingres Protection
7 class IP 68
8 Temperature comp. Required, integral with sensor, -10 to 100 Deg.C.
9 Temperature sensor NTC / Pt100
10 Integral Cable Required, upto transmitter location
11 Measured range 0-14 PH
12 Maximum Pressure 6 Kg/cm^2
13 Resolution 0.01pH, Temp 0.1C
14 Linearity Average 95 %
Additional
Certifications (if
applicable/not
15 mandatory) FM, ATEX, CSA
pH transmitter
Electronic(microprocessor Based indicating type with
16 Type adjustable range facility
Die-cast Aluminium /ABS PC
17 Material Fr
Electromagnetic Interference emission and immunity acc. to EN
18 compatibility 61326: 1997 / A1: 1998
19 Display LC display, two lines with status indicator
Protection class
20 of housing IP 67
21 Monitor output 4-20m Amp DC isolated output for PLC
22 Power supply 240V AC, 50Hz
23 Mounting Pipe Mounted Wall mounting/Flush mounting panel
24 Diagnostic feature Required
25 Accuracy/Repeatability 0.03 pH/0.02PH
26 Resolution 0.01pH or 1mV.1C
27 Stability 0.02 pH per week
5 seconds to reach 100
28 Reponse time %

[97]
Input 1 to 999
29 filter Seconds
Number : 2_SPDT Hi & Lo Hi and Lo Type : Snap
Annunciation Action Micro switch Rating :.,240 V AC, 0.5 Amp./24V
contacts for monitors: DC 5A
(Bidder has to select based on other components
ii) Co-axial cables as required
iii) Electrode holders & supports & mounting
arrangement in SS
iv) Alarm settings and indications on monitor
v) RFI/EMI shielded, weather and corrosion proof
casing
30 vi) Other accessories as per site requirement
2.3.1 Turbidity Analyser

The scope of this work includes sizing, design, supply, erection and
commissioning of Turbidity Transmitter/Analyzer.
Transmitter/Analyzer design: Sizing & selection of transmitter based on process

data, process requirement, general requirement and specification below.
Erection of Transmitter/Analyzer: Erection includes mounting of sensors,

erection of sensor support, mounting of Transmitter/Analyzer support and rack,
Laying of electrical cable from PLC to Transmitter/Analyzer, mounting of junction
box, glanding, termination and interfacing of Transmitter/Analyzer with control
system.
Commissioning: Commissioning of Transmitter/Analyzer includes, calibration

checking, loop checking, testing of Transmitter/Analyzer from PLC and open /
closed loop checking from sub control system & main control system.

[98]
1.0 Turbidity measurement
The turbidity Analyzer shall be a complete system consisting of sensor, analyzer,

flow chamber/ dabbler, and interconnecting cable. The analyzer shall accept input
from either one or two sensors.
The sensor shall be constructed of
a. Corrosion-resistant Delran with glass lamp and detector windows Glass OR
b. EPDM OR
c. Optical fibre OR
d. Stainless steel with chromium-dioxide coating and scratch resistant sapphire

lenses in a highly polished stainless steel sensor face.
The life of the Incandescent lamp and LED life (ISO-compliant sensor) shall be at
least five years. The sensor shall include advanced diagnostics, which can
continuously measure the lamp intensity and automatically adjust the lamp output
tin view of maintaining the correct lamp intensity. The sensor shall automatically
correct the lamp drifting and aging of the sensor and allow for longer sensor
operation with reduced calibration requirements.
Normally the sensors shall be mounted on open channel OR in the reservoir,
however in case necessary the measuring chamber constructed of ABS and
Delran along with bubble removing facility shall be provided. The sensor shall
accept a sample stream below 50 Deg.C temperature and upto 6 Kg/cm^2
pressure. The analyzer shall display fault and warning messages like lamp/LED
failure, weak strength of lamp and sensor failure. The Transmitter/Analyzers shall
have 4-20 mA outputs superimposed on HART protocol. Two number of relay
outputs to be provided. The alarms shall be fully programmable for high & low
outputs. Transmitter shall be capable to program to convert the measured turbidity
into a total suspended solids (TSS) reading.

[99]
DATASHEET FOR TURBIDITY TRANSMITTERS

TECHNICAL
SR.NO
. SPECIFIFCATIONS PARTICULARS
Turbidity Sensor
0 - 2000 NTU The measuring shall be confirmed
1 Measurement range during detail engineering
Glass, EPDM, Optical fibre/ Stainless
steel with chromium-dioxide coating and
scratch resistant sapphire lenses in a highly
polished stainless steel sensor face.
Nephelometric measuring principle 90 NIR
2 Material scattered light
according to EN 27027, Optical nephelometer (side
3 Principle scatter), Single beam scattered light
Max Process
4 temperature 50C
5 Max Process pressure 6 bar
6 Temperature sensor Integrated NTC temperature sensor
7 Connection Fixed cable connection
8 Ingress protection IP68
9 Additional Certifications Calibration certification
10 Resolution 0.01 NTU
11 Accuracy 0 - 2000 NTU: 2% of reading

12 Range: 0 to 2000 NTU (nominal)
13 Response time Less than1 second
14 Application 1. Raw water
2. Clarifier to bed filter channel
3. Pure water sump
The flow through assembly shall be (Polypropylene
flow chambers)
15 Approvals CSA Gen. Purpose

[100]
Turbidity Transmitter
Electronic(microprocessor based) indicating type
16 Type
with adjustable range facility.
17 Material Die-cast Aluminium /ABS PC Fr /Polycarbonate
Electromagnetic Interference emission and interference immunity as
18
compatibility per EN 61326: 1997 / A1: 1998
LC display, two lines, with status indicators user
19 Display
settable measuring menus ; red display for alarms
Protection class of field
20 IP 67/68, NEMA 4X
housing
21 Measuring Range To suit sensor range
Standard transmitter which shall be capable to
accept multi parameter input ( same unit should be
21 Measuring parameter
capable accepting input from any of the sensor for
of pH/Chlorine/Turbidity)
23 Monitor output 4-20mA DC output on HART to PLC
Current output
24 <5uA
resolution
25 Power supply 240V AC, +/- 15%, 50/60 Hz
26 Cable entry 1/2" NPT
No. of measuring
27 Maximum 2 channel
channels
Pipe Mounted / Wall mounting/Flush panel
28 Mounting
mounting
30 Accuracy/Repeatability Better than + 5 microgram /litre of full scale
31 Resolution Manufacturers Standard
32 Sensitivity 0.1 ppm.
33 Response time 6 seconds to reach 100 %
34 Input filter 1 to 999 Seconds
Annunciation contacts Number : 2 SPDT Hi and Lo

[101]
for monitors: Type : Snap action micro switch
Rating Rating : : 5 amp., 240V AC, 0.2 Amp. 220V DC
i) Automatic temperature compensation with

fast response integral temperature sensors
in the range -10 to100 Deg. C
ii) ii) Co-axial cables as required
iii) Electrode holders & supports & mounting ar-
Accessories
rangement in SS
iv) iv) Alarm settings and indications on monitor
v) RFI/EMI shielded, weather and corrosion
proof casing
v) vi) Other accessories as per site requirement
Endress +Hauser / Emerson / Hach / Yokowaga /
Approved Makes
ABB / Banner
2.3.2 Alum / PAC Dosing System
CHEMICAL BUILDING:
Chemical Building is provided to handle the following dosing systems of
chemicals:
Coagulant Dosing system and other associated equipment.
Polymer Dosing system and other associated equipment.
Lime dosing system
Coagulant preparation cum dosing system
Coagulant Dosing system and other associated equipment consists two numbers
of Coagulant solution and preparation cum dosing tanks. Each Coagulant solution
preparation tank shall be provided with an Agitator for proper mixing of Coagulant.
& level switch shall be provided at the Coagulant solution and preparation tank to
control the tank level and for the purpose of Coagulant solution dosing pump
operation. A Coagulant solution dosing Pumps shall pump to dosing point
Again a set of Coagulant dosing pumps pump Coagulant to single common
dosing point located at the inlet of the WTP near to Parshall flume channel. The
Coagulant dosing tank level and dosing pumps operation shall be controlled by
level switch provided at the dosing tank.
CoagulantPreparation

[102]
Tank is not in function outlet is closed

Not in function
(no solution )
function
Manually open "service water" valve at local
2
alarm
Manually stop "service water" valve (When wa-
ter reaches high level.
Chemical
overflow alarm
preparation 3
Note: During the coagulant preparation phase

(when the mixer is functioning), a worker will add
powder to the tank
Chemical preparation and agitation phase (XXX
4 min) (initial value 10 min) the mixer is manually
started and stopped.
Start Coagulant dosing pump according to PLC
operation
Ready to func- Water level reach min. level check availability
5
tion solution in the tank - if not (prepare Coagulant
alarm)
Coagulant dosing tank is HH, the dosing pump
is stopped

Only one of the Coagulant dosing pumps could operate at the time.
- The pumps could not start until:
- At least one of the dosing tanks is ready with coagulant solution
Coagulant dosing
Coagulant addition from the Coagulant solution dosing tanks will commence
immediately after the raw water flow indication from the transmitter, and the water
level in the chemical tank is above minimum. The pump stroke will be adjusted
manually to give a uniform amount of coagulant solution as a function of the flow
measurement.
the amount of dosing will have to be checked manually according to the raw water

[103]
flow entering the water treatment plant.

Not in
function
(no solu-
function
tion )
The coagulant level is above the minimum
2 If water level reaches level HH, overflow over-
Chemical
flow alarm
preparation
In case all interlocks and permissions met, dosing
3
is started by one pump
Manually open outlet valve at the local open/close
push button station.
Start coagulant dosing pump according to PLC
operation
Ready to Water level reach min. level check availability
4
function solution in the tank - if not (prepare coagulant
alarm)
If water level reaches low level, inhibit pumps from
running and manually close outlet valve associ-
ated with that tank.
coagulant dosing tank is HH, the transfer pump is
stopped
Coagulant PAC solution

Only one of the coagulant dosing pumps could operate at the time.
- At least one preparation Tank is ready.
- WTP in flow is zero.
Lime preparation and dosing system
Lime Dosing system and other associated equipment consists two number of lime
solution and preparation tanks. Each lime solution preparation tank shall be
provided with an Agitator for proper mixing. level switch shall be provided at the
lime solution and preparation tank to control the tank level and for the purpose of
lime solution transfer pump operation. Lime solution transfer Pumps (1+1) shall
pump to lime solution/dosing tank.
Again lime dosing pumps pump lime to single common dosing point located at the
inlet of the WTP or to the inlet to the clear water tank. The lime dosing tank level
and dosing pumps operation shall be controlled by level switch provided at the
lime dosing tank.
Lime preparation

[104]

Not in func- 1 Tank is not in function outlet is closed
tion (no solu- Minimum water level (L) in place and mixer
tion ) in function
2 Manually open "service water" valve at local
alarm
3 Manually stop "service water" valve (When
water reaches high level.
Chemical If water level reaches level HH, overflow
preparation overflow alarm
Note: During the lime preparation phase (when
the mixer is functioning), a worker will add
powder to the tank
4 Chemical preparation and agitation phase
(XXX min) (initial value 10 min) the mixer is
manually started and stopped.
5 Manually open outlet valve at the local
Start lime transfer pump according to PLC
operation
Ready to Water level reach min. level check avail-
function ability solution in the tank - if not (prepare
lime alarm)
stopped

Only one of the lime transfer pump could operate at the time.
- At least one of the dosing tanks is ready to receive lime solution
Lime dosing
Lime addition from the lime solution dosing tanks will commence immediately
after the raw water flow indication from the transmitter, when the water level in the
chemical tank is above minimum. The pump stroke will be adjusted manually to
give a uniform amount of lime solution as a function of the flow measurement.

[105]
the amount of dosing will have to be checked manually according to the flow
entering the water treatment plant.

Not in function
1 Minimum water level (L) in place and mixer
(no solution )
in function
The lime level is above the minimum
2 If water level reaches level HH, overflow
Chemical
overflow alarm
preparation
In case all interlocks and permissions met,
3
dosing is started by one pump
Start transfer pump according to PLC opera-
tion
Ready to func- Water level reach min. level check availabil-
4
tion ity solution in the tank - if not (prepare lime
alarm)
stopped

Only one of the lime dosing pumps could operate at the time.
- WTP inflow is zero.
2.4 Ultrasonic level transmitter
COMMON TECHNICAL SPECIFICATIONS

ultrasonic transmitters.
Transmitter design:-Transmitter design, Sizing & selection is based on process data,


[106]
Erection of transmitter: Erection includes mounting of process isolation valve, erection

of impulse piping, mounting of transmitter support and rack, laying of electrical cable
from PLC to transmitter, mounting of junction box, glanding, termination and interfacing
of transmitter with control system.
Ultrasonic type level transmitters shall be provided with 4-20 mA DC output. All
necessary amplifiers, Zener isolations, signal distribution & associated electronics /
hardware / housing / mounting accessories shall have to be provided. The transmitters
shall be able to drive at least 600 ohms load. The power supply to the transmitters shall
be derived from the control system.
Accuracy of the transmitters shall be 0.2 % of calibrated span (minimum). Transmitter
housing shall be Weather proof as per IP-67 with durable corrosion resistant coating.
Ultrasonic level transmitters, consisting of a transducer, a display / transmitter unit, and

manufacturer's cable, shall be provided as specified below. Stainless steel tags for
ultrasonic level transmitters shall be provided as specified. The transmitter shall have
built in temperature compensation, digital level indicator and any other item required to
complete the level measuring system. The level measuring system shall be suitable for
mounting on the top of the Water trench, pump sump pit, water channel and Filter bed as
required
The level sensor material shall be non-corrosive. Contractor shall arrange for the
installation of the level transmitter on top location at suitable location. Accuracy of the
level transmitter shall not deteriorate even if suspended solids are present in the service
fluid.
Level transmitter shall be suitable for field mounting in safe area. Transmitter output shall
be isolated and shall be suitable for transmitting over long distance.
2.0 Transducer Required Features

Ultrasonic level transducers and manufacturer's cable assembly shall be provided with at
least the features specified below:

[107]
Measuring Principle Ultrasonic, time-to-flight / Pulse Time of flight

Range 0 5 Mtr
Level Resolution Better than 1 mm
Beam angle 6 Degrees
Process connection Suitable for the Reservoir
Cable As indicated on the datasheet
Temperature compensation Full, automatic
Mounting As indicated on the datasheet
Manufacturers Standard suitable for the
Nominal frequency range
application
Operating conditions 45 50 Deg. C
Max Pressure 4 Kg / cm^2(g)
Range Liquids 0 to 5 m
Sensor materials Corrosion resistant PVDF wetted material
Principle Pulse Time of flight
Agency listings UL listed or FM approved
3.0 Display/Transmitter Unit Required Features
Display / transmitter units shall be furnished for use with the transducers specified above
and shall include at least the features specified below. At least two programming key
pads shall be included per project unless directed otherwise:
Display External Display 4 LCD.

Using Keypad on display OR suitable field
Configuration
configuration tool
Memory Parameters held in non volatile memory
Display Location Local / Sensor mounted
Temperature
Automatic , built in transmitter
compensation
4 to 20 mA analog, two wire, linear with process
Outputs engineering units. One Form C SPDT relay contacts,
5 amperes at 250 volts ac, non-inductive
Output Variables Level, Distance, Volume, Open Channel Flow
Supply voltage 24 VDC, loop powered

[108]
Accuracy +-0.25% full scale or better

Radio Frequency Less than 0.1 percent of span for frequencies 27 to
Interference (RFI)effect & 1,000 MHz and field intensity of 30 V/m Interference
Electromagnetic emission to EN 61326;Equipment class B, Interference
compatibility immunity to EN 61326;Appendix A (Industrial)
Voltage transient Up to 1000 volts common mode and 500 volts normal
immunity mode with output shift less than1.0 percent
On board transmitter compartment. Compatible with
HART or Foundation Field bus communications as
Surge suppression
applicable. Compliant with IEEE C62.41 Cat. B and
IEEE C37.90.1.
Housing & Ingress
Aluminium, rated NEMA 6P (IP68)
Protection
Operating conditions -20 to +500C
Agency listings UL listed and FM approved
Hazardous area
Safe Area
classification
4.0 Typical data sheet for transmitter

1 Tag Number During detail engineering
2 Service Raw / Dam water
At the Jack well pump floor above
3 Location
pump suction pit
4 Quantity As per BOM
A special arrangement of SS
GENERAL structure to be fabricated &
mounted to install the
5 Mounting
USLT on River. Flange structure to
be fabricated to install the USLT on
pump pit
6 Area classification NA
7 Certification Required

[109]
8 Enclosure IP 65
Vendor to confirm during detail
9 Pipe Line number
Engineering
10 Fluid Raw / Pure water
11 Fluid State Liquid
12 Operating Pressure Atmospheric
Operating
13 50 Deg C
PROCESS Temperature
CONDITIONS Operating specific
14 Suitable for water
gravity
15 Operating Viscosity Suitable for water
16 Min./ Max Pressure Atmospheric
17 Design Pressure Vendor Standard
18 Design Temperature 75 Deg C
Pure water sump pit level
19 Application
TRANSMITTER measurement / Filter Beds
20 Type Ultrasonic
21 Principle time-to-flight / Pulse Time of flight
22 Housing Aluminium
23 Paint Epoxy or polyurethane- coated
24 Protection IP 65
25 Power Supply 24 V DC
Loop powered at 750 4-20 mA, 2
26 Output
wire linear with process (HART)
27 Level Resolution Better than 1 mm
TRANSMITTER
28 Transmitter Location Local/Sensor mounted
Process Flanges and
29 Mtl Wet-side
Mounting arrangement
SS 316 Corrosion resistant PVDF
30 Material
wetted material
Body Material & Bolt & SS 316
31
accessories Material
32 Beam Angle 6 Degree

[110]
Vendor to size the transmitter

33 Instrument Span based on process data & submit
for Approval
34 Calibration Range Vendor to confirm
35 Alternate Range NA
36 Process connection Manufacturers standard
37 Electrical Connection Manufacturers standard
0.2% of span, 0.2% full scale
38 Accuracy measuring distance OR 4 mm (+/-
2 mm) which ever is better
39 Allowable Temp. Later* DISPLAY
4/5 line LCD
40 Display
display
Display Scale External Display ,Menu guided
41
Required, operation Match Calibration
42 Hydrostatic Certificate to be provided
Testing Memory Parameters held in non volatile
43
memory
44 Mounting Brackets 50 mm Pipe mounting
45 Lightning Protection YES Required
46 Communication Type HART
COMMUNICATION 47 Communication with: PLC -SCADA
AND SOFTWARE 48 Configuration from: Factory
49 Internal Diagnostics Required
Approved
50 Emerson/ABB/E&H/Siemens/Baner
Manufacturer
PURCHASE
51 Model Vendor to confirm
52 Purchase Spec Datasheet is a part of Specification
53 Serial Number During detail engineering
2.5 Power Analyzer

- Specifications as per Raw Water Item No SA-1 /1.3
2.6 PLC Panel with HMI for Filter Bed
2.7 Master PLC Panel

[111]
Note Pl refer SA1-1.4 for PLC Panel Specifications
FILTRATION SYSTEM AUTOMATION AND SCADA

The gravity filtration system comprises the following main
Inlet channel with weirs and inlet gates.
(4..) gravity sand filters with ((..) Sections) of existing (27.5..) MLD WTP
Backwash water tank
Air scour system
Valves with actuators for inlet & outlet of filters, clf drain valve, back wash
pumps & Blowers .
Instruments
Local filter control consoles - HMI with minimum 10 size for each Section/ Fil-
ter Bed
SCADA connections
The filtration system containing (4..) rapid gravity sand filters contained in one
block.
A gravity filter consists essentially of an open-topped concrete tank. Tank is
designed to drain at the bottom, and partly filled with the filtering medium (clean
sand). Clarified water is admitted to the space above the filter media and flows
downward under the action of gravity. Purification takes place during this
downward passage, and treated water is discharged. Filter tank is provided with a
level Transmitter to control the water level.
Operation of the filter is provided by menace of the following Control valves:
Automatic Valves/ Gates:
Name Purpose
Filter Influent Allows incoming water into filter
Filter Effluent Allows treated water out of filter
Backwash Water in Allows clean backwash water into filter
Direct Filter to Drain Allows first filtered water out to drain
Backwash Air Allows backwash air into filter
FILTER CONTROL SYSTEM:
The filter operation is a complex phenomenon for making the system automated.
The filtration plant is going to work for the different flow conditions from 0 MLD to
(27.5..) MLD + 20%. The operation at the same time also envisages constant
rate filtration. The filters are also required to operate between the preset high and
low levels of water over the sand bed. All these conditions will have to be suitably
taken into considerations for automation of filter operation.
In case there is signal from partial flume measuring device that no raw water is
available to the plant or the water level in the filter box is at lower preset value,
then this shall trigger the close of filter outlet valve/valves. The sand filter gets
exhausted over a period of time while filtering the settled water. It then needs
back washing to remove the clogging and make it freshly available for the
process. The rate of exhaustion is measured in terms of pressure differential
across the filter. It is expected that the filter will work at the constant rate of

[112]
filtration and in turn develop the pressure differential. The owner desires to
automate the filter back washing operation. A back washing operation is carried
out as described below.
If the pressure differential across the filter reaches a preset value of say 1.8 m,
than the filter is taken out of filtration process for back washing. Prior to starting
the back washing, it has to be confirmed that power supply is healthy and the over
head wash water has sufficient water level. The inlet butterfly valve to the filter is
closed and the water over the filter is allowed to get through the filtration process.
Once the water recedes to preset level, the filter outlet valve is closed and the
drain valve is opened.
The blower is switched on and operated for preset time. The air supply valve is
opened no sooner than the blower is switched on. After air washing the filter sand
for preset time, the air inlet valve to the filter is closed and simultaneously the
blower is switched off. Consequently the wash water inlet valve to the filter is
opened and water wash is started. The water wash is provided after the preset
time is over, the wash waster inlet valve is closed. In order to ensure that the back
wash water gets drained fully a time lag based on the actual experience /
requirement needs to be incorporated for the drain valve to start getting closed,
the drain valve is closed. The inlet valve to the filter is opened and water is taken
for filtration. Simultaneously the filter outlet valve is gradually opened from its
closed position to a fully open position in a preset time. Simultaneously the
filtration rate-controlling valve has to operate itself in such a fashion, that the filter
out flow rate is reached to the designed value in preset time. With this filter back
wash operation is completed and the filter gets commissioned once again.
The pressure differential across the filter at this point of time has to be below a
preset value of say 0.25-m. In case it is more than this that a error needs to
flashed. Sooner the filter back wash is over the wash water pump shall be
switched on and the wash water tank shall be filled to the full supply level. In case
no water is available for filling the wash water tank at the source then this activity
is differed.
The filtered water passes over the rectangular notch meant for measuring output
flow of the filter. This measurement is calibrated based on the level of the water
over the notch. The level-measuring instrument along with the transfer of data in
real time to the computer is expected, to know the flow rate.
Turbidity and pH of the filtered water is also measured using an online turbidity
and pH analyzer provided at the inlet of clear water sump. Post chlorine shall also
be dosed at the inlet of the clear water sump. Each filter shall be operated in auto
mode from the SCADA HMI located at control room and Local control panel (HMI)
provided for each filter located at Filter House. In case of failure of auto mode, the
filter operation shall be done through Manual push button mode.
OVERALL OPERATION STRATEGY:
MODES OF OPERATION
The filtration system operating mode of each filter is determined by the filter
system mode selection located on the local filter system main control panel (HMI).
The system mode can be either AUTO, Out of Service or MANUAL, each filter
condition will be indicated on the HMI.
Manual Mode
If the filter is switched to MANUAL mode, automatic backwashing will not occur

[113]
and the operator must activate the local valves and pumps and blower switches
local to the equipment. Alarm indications are active while the system is in
MANUAL mode. As the interlocks and actions to alarms are not active, the
operator must be aware of potential problems that can occur during manual
backwash. If the system is conducting a backwash when in AUTO mode and the
operator switches to MANUAL mode, the backwash is abandoned immediately.
The backwashing and blower stop and the valves return to their filtration position.
All valves in Manual Mode to be actuated from the HMI at the upper filtering
gallery or locally near the valve location.
HMI should also contain buttons for Backwash valve actuation and Blower
operation so, that all backwash and valve operation in Manual Mode could be
done from local HMI of each filter.
Auto Mode
The Programmable Logic Controller (PLC) controls the backwash cycle. The
system performs backwash automatically based on the scheduling parameters set
up within the HMI mimic pages.
OFF or Out of Service
If a Filter is selected to Off or "out of service" via the selector switch on the Filter
Operation Box (HMI) a white light on the HMI will display that the filter is out of
service. "Out of service". When selected to Out of Service the PLC
automatically closes all filter valves, except the direct filter to drain valve), which
remains open to drain the filter troughs, until the water level is minimum + XX
minutes. To put a filter back into service the Auto/Off/manual selector switch must
be selected to Auto.
While in the "out of service" mode, the filter is bypassed by the PLC, when an
automatic backwash sequence is requested.
The "out of service" mode should not be relied upon during maintenance periods
(such as having to enter the filter) and manual isolation of the filter from the rest of
the system must also be done. This is required primarily in case the PLC fails.
The filter will default to filtration mode, opening the influent and effluent valves.
Sequencer
As mentioned previously, in AUTO mode the PLC controls the backwash
sequence cycles step by step.
Operator-Initiated Operation
Instead of utilizing the filter backwash schedule on the HMI, a backwash can be
manually initiated by pressing the "Start Backwash" button on the HMI. Once this
button is pressed, the chosen sequence begins as long as all per missives and
interlocks are met.
Individual Filter Manual and Automatic Mode
Each filter has a manual or automatic operation. There is a selector switch on the
HMI adjacent to each filter which allows the operator to select Auto operation or
Manual operation. The selected filter mode is indicated on the HMI. When the
mode is changed from automatic to manual, a red light is activated on the HMI to
notify plant personnel that these filters will no longer backwash automatically.
Automatic
The normal mode of operation is automatic, controlled by the PLC. A filter in
Automatic operates with no adjustments by the operator.

[114]
Manual
Individual filters in MANUAL mode will no longer backwash based on the inputted
schedules, but will continue to filter water. Once put into this operation, the
operator can open and close valves on that filter by selecting the valve selector
switch to local operation and using the open and close push buttons on the
valves. The operator must be aware that other filters in AUTO mode can still
backwash while the filter valves are being manipulated.
The push buttons for valve operation to be on the HMI.
Blower/backwash water valve Manual and Automatic Mode
Similar to the filters, each blower and backwash water valve have a
manual/off/automatic selector switch. When the switch is selected to Auto the
PLC program will control the equipment, if the selector switch is selected to
Manual the equipment will be started or stopped by the stop/start control station.
If the selected mode is Manual this is indicated on local stop/start control panel.
When the mode is changed from AUTO to MANUAL, the equipment item in
MANUAL mode will not be used in automatic backwashes. Plant personnel can
start and stop individual blower and the backwash valve in MANUAL mode while
leaving the rest of the system in full AUTO mode.
Automatic
The normal mode of operation is automatic, controlled by the PLC. A blower/pump
in AUTO mode operates automatically during backwashes in accordance to the
pre-set sequence.
Manual
In MANUAL mode a particular blower will not be used in automatic backwashes.
The PBs can be used to start/stop the equipment in MANUAL mode. When in
Manual automatic interlocks are not active, to start and stop these items of
equipment and prevent them from operating while the valves are in the incorrect
position, the operator should ensure that all the necessary valve are in the correct
position.
The overall operation strategy will adhere to the following sequence:
Operation start-up
The flow meter confirms that water is supplied to the works.
All actuated valves on the filters are put into AUTO mode.
The chlorine gas system is turned on and available.
The lime system is turned on and available.
The Coagulant system is turned on and available.
Operation shutdown
No Raw water flowing into the works.
The lime system is stopped.
The Coagulant system is stopped.
The chlorine gas system is stopped.
In case the Lime dosing system is stopped by the Operator, the Plant shut down
should be confirmed, otherwise the Plant will continue operation.
In case there is a failure in dosing operation the Plant should be stopped.

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Filter Operation:
Normal Filtration Mode Valve Positions:
OPEN Influent and filtered water valves

CLOSED Backwash water direct filter to drain, and backwash air valves
(M1.x5).
Out of Service Mode Valve Positions:
OPEN direct filter to drain (by water level and time).

CLOSED Influent, effluent, backwash water and backwash air valves.
Under normal operation, the influent water passes through the media, gravel and
under drain, and enters the filter central drainage channel. The filtered water then
flows from the channel through the effluent valve (open during filtration mode) and
continues downstream to the clear water tank.
Filter Water Level Measurement
Each filter contains a continuous level sensor measuring the distance starting
from the media. During filtration mode, if the water level reaches an operator
adjustable level, set on the HMI, above the media elevation, a HIGH FILTER
WATER LEVEL occurs.
Available is an enable/disable high level BW PB on the filter mimic screen on the
HMI. If enabled, a backwash will automatically occur on that filter after an inputted
delay time (60 to 1,800 seconds) or when the water level is raised to the pre-set
value. If disabled, the PLC will not initiate an automatic backwash. The operator
should review the situation to see what action, if any, is necessary.
The high level alarm is bypassed during a backwash event but is available while
an individual filter is in MANUAL mode. The alarm is inactive for an out-of-service
filter. Filter High Level will be displayed on the HMI mimic.
As filtration proceeds, the voids in the upper layers of the media are the first to
accumulate solids. Because the same volume of flow is being forced through a
smaller passageway, the water velocity increases. This increased velocity drives
the solids deeper into the media bed, allowing for depth-retention of solids and
longer filter runs between backwashes.
Normal backwash frequencies occur often enough to maintain a properly working
system.
The main indication that a filter backwash must be conducted is when the head
loss (corresponding to the liquid level in the filter) reaches the maximum
acceptable level (as determined by the high level alarm point).Before backwash to
start all interlocks and relevant units conditions to be met. Pushbuttons and
Indications Individual Filter
Each filter has a Filter Operation Box (HMI) which changesits operating, shown
below are the PBs and indications available on the individual filter:
Valve operation from the HMI to be resorted.
Selector
Description
Switch
i) When Auto is selected backwashing will operate auto-
matically provided all the valves, blowers and backwash
Auto/Off/Manual pumps are also selected to Auto.
ii) When Off is selected the filter is Out of Service or off.
iii) When Manual is selected all automatic operations are

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stopped.
Pushbuttons Description
Each time this PB is pressed and the filter is selected to
Auto, the individual filter will commence an automatic
backwash, provided none of the other filters are being
backwashed. If there is a backwash already happening
Start Backwash
within another filter then the PLC will put the filter which
has had the start backwash push button pressed into the
highest position in the queue and will be washed once the
other backwash has stopped.
Indications Description
Filtration in
Indicates that the filter is in automatic operation
Progress
Filter Washing Indicates the filter is being washed
Manual Indicates if the individual filter is in manual mode.
Backwash
Indicates that a backwash sequence has failed
Failed
Indicates that the filter has been switched to Off and is
Out of Service
out of service
General Backwashing Operation

Filter backwashing is performed by pumping air and water up through the filter
bottom. The backwash water and air rates used in the filters are 36 m/h water and
36 m/h air per square meter of filter surface area. This produces a vigorous
scrubbing action that removes captured material and flushes it upward from within
the filter bed into the backwash trough.
Backwashing of filters will be in three steps as follows:
First Step (air) Air scouring for approximately four minutes, adjustable at the
HMI by the operator between 0-10 minutes
Second Step - Surface wash Backwashing with linear velocity, for about 3 mi-
nutes maximum, again the time duration is adjustable by the operator between
0-10 minutes, 36 m/h.
Third Step direct filter to drain for a preset period of time set by the operator
at the HMI for the range of 0-15 minutes.
Valve Operation
When the individual filter is in AUTO mode, the PLC automatically controls the
valve positions, as shown in the table below.
If during a backwash any of the valves are signalled to open or close, and the
corresponding limit switch does not indicate that this has occurred, an alarm will
sound. The table below describes how a fault affects the backwash and the action

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that occurs.
Note: Abandoning a backwash will return all filter valves to their filtration position
and an alarm will occur. After a pre-set period, adjustable at the HMI by the
operator between 0-60 minutes, the influent valve of the filter will open.
Valve
Step Backwash Action
Fault
Abandon BW - If the BW were continued, influent would
Influent
1 flow together with the used backwash water. To minimize
(close)
this extra flow, the BW is abandoned
Abandon BW - If the valve fails to close at the start of
Effluent
2 BW, most of the backwash water, if not all, will not flow up
(close)
through the filter and backwash will be ineffective
Filter to
Alarm If the valve fails to open. Use to drain the water
3 drain
before air scouring. Can continue BW
(open)
Filter to Abandon BW - If the valve fails to close, most of the
4 drain backwash water, if not all, will not flow up through the fil-
(close) ter and backwash will be ineffective
Air scour
5 BW, the backwash air blower will not start. Backwash is
(open)
not effective without the blower, so it is abandoned
Alarm - If the valve fails to close after air scouring, the
Air scour
6 backwash air blower will not start for the next backwash
(close)
filter
Backwash Abandon BW - If the valve fails to open at the start of
7
water BW, the backwash will be abandoned
Air Blowers
Two (2) positive displacement backwash air blowers (1+1) are available for
operation.
Each blower is equipped with an inlet filter, inlet and discharge silencers, and
pressure indication. Ambient air is drawn through an inlet filter. Filtered air is
drawn through an inlet multi-chamber absorption silencer.
Blower Operation
A Hand-Off-Auto (HOA) switch will exist for each blower. When an individual filter
is in AUTO mode the backwash blowers are controlled by the PLC.
The blowers are interlocked so as not to allow both blowers to operate
simultaneously. A blower will not start unless at least one filter backwash air valve
is opened first. The PLC automatically alternates the blowers to run after each
successive start.
Manual/Auto
Each blower can be selected for manual or automatic operation. While an
individual filter system is in AUTO mode and the blower is in AUTO mode, the
PLC automatically starts and stops the blowers. While the blower is in MANUAL
mode, the blower can be started/ stopped using the associated PBs on the local
stop/start control station (backwash air valve interlocks are active during this

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operation). Individual blowers in MANUAL mode are not selected for automatic
backwashes.
An alarm will sound when one blower is in MANUAL mode or out of operation.
If the blower is started and fault stops, a BACKWASH AIR BLOWER # FAULT
alarm will occur. This can occur due to an overload condition, a no-running signal,
or a low discharge pressure condition. The same backup procedure is followed as
when a low pressure condition occurs. If both blowers fault, the backwash is
abandoned and a BACKWASH ABANDONED alarm occurs.
Backwash Pump Station
Clear water from the clear water tank will be supplied to the Overhead wash water
tank (with two compartments) by back wash water pumps (1+1). An
electromagnetic flow meter and pressure transmitter shall be provided at the
discharge header of back wash water pumps. In case water in the overhead tank
is below max. Level, the backwash pump will start pumping.
In case of low level in the clear water tank the backwash pumps will not operate.
Overhead backwash water Tank
Water required for backwash of the filters will be stored in Overhead wash water
tank containing two compartments.
Both the compartments of the Backwash water tank, receiving water from the
clear water tank, shall be provided with an Ultrasonic Level transmitter for the
tanks water level indication and control. In case of backwash water overhead
tank high level, an alarm shall be generated at control room to alert the operator
and if the level of the backwash water tank still rises to high high level, back
wash water pump shall be tripped.
In case water level in both compartments of the tank is below the pre-set level,
backwash of the filters will be on hold in automatic mode and abandoned in
manual mode.
The discharge line to the filters will be equipped by flow transmitters.
The filter backwash could start in manual or auto mode in case all backwash
requirements specified are met and the relevant filter valve is open.
In case of low (high) pressure, low flow the Control system will generate Alarm.
DIRTY BACKWASH WATER TANK: - Recirculation Sump & Pump
Dirty back wash water tank shall be provided with 2 compartments and with a
level transmitter at each compartment. Drain water and dirty backwash water from
all the filter shall be transferred to this tank. Each compartment of dirty back wash
shall be connected with 1 pump & after the settlement of sludge at the dirty back
wash water tank with a bell mount arrangement the clear water shall be pumped
to inlet of the WTP in the rate less than 10% of the Plant inflow and the sludge
shall be transferred to Sludge Balancing tank by gravity.
Filling of the Dirty backwash water Tank should be related to the water level in the
tank. In case the level in both compartments is high, filter backwash should be
abandoned until the water level will drop to the pre-set level.
During cleared water discharge the pumps to be stopped in case the water
reaches the pre-set low level.
The effluent pumps will start automatically based in the level in the tank and on
the time passed after the last filling.
In case of low level, high level and overflow SCADA will generate Alarm.
The effluent pumps will operate in rotating manner and pump failure will generate
Alarm. In case the controlled discharge flow is less than the pre-set maximum
(minimum) value, the system will generate Alarm.

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2.8 Control Cable /2.8.2 Communication Cable / 2.9 Signal Cable / 3.0 Cable
Trays
- Specifications as per Raw Water Item No SA-1/ 1.6/ 1.7/1.8 1.9
4.0 Blower -4.1 Pressure Transmitter for Blower
4.2 Ultrasonic Level Transmitter for Wash Water Tank
4.3 Priming arrangement
PLC based priming arrangement for priming of Centrifugal Monoblock/ Coupled
Pumps with Vacuum Pumps shall be designed and operated by the contractor in
such a manner that it shall synchronize with the operation of Main Centrifugal
Monoblock/ Coupled Pumps as enlisted in Item No SA1.4/1.5 and as per site
situation and instructions of Engineer-In charge
4.4 Surveillance system
SA 3 Flash Mixer & Clariflocculator PLC Panels

FLASH MIXING SYSTEM:
The Flash Mixing System shall comprise a tank with flash mixer at the tank.
Coagulant dosed at the inlet of the treatment plant mixes with the raw water at the
flash mixing tank and passes to the Clarifies for further treatment.
Status (run/trip/local-off-remote) of the flash mixers shall be indicated at SCADA.
G Value of Flash Mixer shall be calculated and indicated at SCADA
In case the mixers is out of order SCADA will generate Alarm and send SMS.
CLARIFLOCCULATOR:
Clarifiers are designed for the removal of readily settle-able solids and suspended
particles and therefore, reduce the suspended particles content. The purpose of
the clarifiers is to remove a substantial portion of the organic solids from the raw
water, with a resulting decrease in the organic and suspended materials loadings
of the filter units. Clarifiers is constructed as circular concrete structures.
Clariflocculator is a combination of flocculator and clarifier fabricated to attain
economic and speedy construction. It shall have two concentric tanks where inner
tank serves as a flocculation basin and the outer tank serves as a clarifier.
Clariflocculators generally are used to perform the chemical primary treatment of
effluents.
The monitoring to be made in clariflocculator shall be for;
Turbidity at the common outlet channel of clarifiers
Instrumentation considered for clariflocculator shall be;
Turbidity Transmitter online at the common outlet channel of clarifiers

Motorised valve at sludge removal/drain
Loss of rotation switches for the scraper bridge.
Control system shall continuously monitor turbidity and based on turbidity or
time, motorized valve shall be operated for sludge removal process. Rotation
of the scraper bridge and the flocculation mixers should be controlled.

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OPERATION IN AUTO MODE:

The operator has to put the selector switch in auto mode
The opening and closing of drain valve shall depend on the turbidity fac-
tor/Time base as turbidity transmitter is provided at plant inlet, the time setting
can be adjusted from SCADA for opening and closing of valve during seasonal
changes.
OPERATION FROM SCADA:

Start Stop control shall be provided on SCADA in order to switch On or Off the
clarifier Bridge Motor and also Open/close feedbacks shall be shown on
SCADA.
Open/Close control shall be provided on SCADA in order to open and close
the sludge drain valves and also open close feedbacks shall be shown on
SCADA.
The sludge valves operation should be interlocked with the sludge level in the
Sludge balancing tank.
Status (run/trip/local-off-remote) of all motors shall be indicated at SCADA
HMI. G Value of Flocculators shall be calculated and indicated at SCADA
OPERATION FROM LOCAL CONTROL PANEL:

Auto/Manual selection will be provided on HMI screen in such way manual
mode is selected all the pumps/valves/gates etc. can be operated from the
HMI screen individual. Auto mode is selected all the pumps/valves/gates etc.
can be operated from the PLC/SCADA.
Individual Start/Stop push buttons shall be provided on local panel to operate
Sludge drain valves.
Indication lamps shall be provided on local panel which shall give Open,
Close, Trip indications for all motor actuated sludge drain valves.
Turbidity deviation or malfunction of any part of the unit should generate Alarm
SA 4 Valves with actuator
- Specifications as per MJP CSR
SA 5 Pure Water Pump house
5.2 Pressure Transmitter
5.3 pH analyser
5.4 Turbidity analyser
5.5 Residual chlorine analyser
Residual chlorine measuring system shall consist of Chlorine sensor, sensor cable
Transmitter/Analyzer, sensor holding arrangement. The sensor shall be rugged in
construction and shall be suitable for continuous operation. Residual chlorine shall work
on Amperometric Or Chlorometric principle, Bidder has to select best suited for

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application without compromising specifications listed. The measurement shall have an

integral temperature and pH compensator.
The Residual chlorine sensor shall be submerged in the reservoir from the top by making
an opening/by providing nozzle in the slab. The Transmitter/Analyzer shall be mounted
near the mounting nozzle.
Transmitter/Analyzer shall be suitable for field mounting and shall accept the input from
Residual chlorine sensor. The Transmitter/Analyzer shall provide 4-20 mA output
proportional to chlorine available in the process. Transmitter output shall be suitable for
transmitting over long distance. Transmitter/ Analyzer shall have LCD display to indicate
instantaneous residual chlorine in water.
The sensor shall be suitable for the determination of free chlorine in water without the
use of sample conditioning reagents without sample pre treatment . The sensor shall be
suitable to use in the samples having pH as high as 9.5. The sensor shall be a two-
electrode membrane-covered sensor. pH sensor shall be an integral part of the Chlorine
sensor which shall be used to compensate the effect of pH on the chlorine
measurement. Sensor maintenance shall require no special tools or fixtures. The sensor
shall be provided with integral cable.
DATASHEET FOR CHLORINE TRANSMITTERS / ANALYSER
TECHNICAL
SR.NO
. SPECIFIFCATIONS PARTICULARS
Chlorine sensor
1 Measuring principle Amperometeric OR Chlorometric
2 Process temperature 0 to 45C, non-freezing
3 Process pressure 0 to 1 Kg/sq.cm
4 Ingress Protection IP67
0 - 8 (ppm) mg/l of Cl2 , (pH between 6
5 Measurement range to 9.2)
6 pH range 4 to 9 pH
7 Measured value resolution approx. 15 g/l Cl2
8 Maximum measured error 2 % of measured value

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9 Repeatability 1%
25 sec to 100% of final reading at
10 Response time Ambient temp.
11 Sensor wetted parts Silicone, platinum, and polyethersulfone

Sensor shall have integral cable to be
12 Sensor signal output wired to transmitter
Required to store - calibration data,
13 Sensor memory sensor model, serial number etc
Chlorine transmitter
Electronic (microprocessor based)
indicating type with adjustable range
14 Type facility.
Die-cast Aluminium /ABS PC Fr
/Polycarbonate Interference emission and
15 Material interference
Electromagnetic immunity as per EN 61326: 1997 / A1:
16 compatibility 1998
LC display, two lines, with status
indicators user settable measuring
17 Display menus ; red display for alarms
Protection class of field IP 65 Nema 4 housing protection class
18 housing required.
19 Measuring Range To suit sensor range
Standard transmitter which shall be
capable to accept multi parameter input (
same unit should be capable of accepting
input from any of the sensor for
20 Measuring parameter pH/Chlorine/Turbidity)
21 Monitor output 4-20mA DC output on HART to PLC
22 Current output resolution <5uA
23 Power supply 240V AC, +/- 15%, 50/60 Hz
24 Cable entry 1/2" NPT
25 No. of measuring Maximum 2 channel

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channels
Pipe Mounted / Wall mounting/Flush
26 Mounting panel mounting
28 Accuracy/Repeatability Better than 2 microgram/litre of full scale
29 Resolution Manufacturers Standard
30 Sensitivity 0.1 ppm.
31 Response time 6 seconds to reach 100 %
32 Input filter 1 to 999 Seconds
Number : 2 SPDT Hi and Lo

Type: Snap action micro switch
Rating: 5 amp., 240V AC, 0.2 Amp. 220V
Annunciation contacts for DC
33 monitors:
i) Automatic temperature compensation
with fast response integral temperature
34 Accessories sensors in the range -10 to100 Deg. C
ii) Co-axial cables as required
iii) Electrode holders & supports &
mounting arrangement in SS
iv) Alarm settings and indications on
monitor
v) RFI/EMI shielded, weather and
corrosion proof casing
vi) Other accessories as per site
requirement
5.6 Power Analyzer

5.7 PLC Panel at Pure Water Pump House
5.8 PLC based control monitoring and communication for Pure Water Pump House
5.9 Surveillance system
- Specifications as per Raw Water Item No SA-1 .10

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SA 6: SCADA SOFTWARE :
6.1 TECHNICAL SPECIFICATION FOR SCADA MANAGEMENT SOFTWARE

1. Architecture
The SCADA architecture shall provide the following:
Client / Server architecture based on TCP/IP networking and report-by-exception
(RBE) technology
Standalone single server operation.
Symmetric main-standby & capacity for triple standby server functionality.
Additional servers for client load sharing and remote locations.
Permanent Standby Server designed to be placed outside corporate firewalls pro-
viding a read-only access to the server while ensuring corporate security.
Fully automated data transfer between servers to provide complete server redun-
dancy. This transfer shall include configuration, real-time data, historic data and
event lists. Database updates shall be on an incremental basis with tuneable pa-
rameters
A scalable fully distributable architecture providing:
Unlimited number of server systems.
Unlimited number of display clients.
Where multiple servers are deployed, the system shall be capable of being con-
figurable from a single client.
All redundancy shall be handled by the database, with the operational state of
systems preserved through a server changeover. The system shall not rely on
driver redundancy for data transfer when providing redundant server. The system
shall present a uniform view of data including communication status after a fail
over.
Forced changeover between main and standby allowing seamless changeover
between main and standby servers without shutting down either server.
Clients to connect to a synchronizing server as soon as the configuration and cur-
rent data in the database has synchronized. Incomplete data sets as per clients
request on event or trend provide indications that the synchronization is still in
progress to ensure that conclusions are not drawn from incomplete data sets.
Configurable compression of data communications between client/server and
server/server to allow optimisation of communications performance over WAN
networks.
Change reporting on Client/Server and Server/Server links rather than polled
communication to permit operation on WAN networks.
Capable of operating Client/Server and Server/Server links over low to medium
speed channels depending upon database size (e.g. 128K)
Application shall be native 32-bit and 64-bit versions and supported on Windows
Server and Workstation operating systems including Windows 2000, Windows XP,
Windows 2000 Server, Windows 2003 Server, Windows 7 (32 and 64 bit) and
Windows Server 2008 R2 and later.
2. Database
The SCADA database shall be of true relational database design and optimized for real-
time SCADA operation. The database shall be object oriented and organized in a
hierarchical structure. It shall support user-created Templates that allows management

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of common configuration from a single point in the database. Instances of templates

shall be used for repetitive, standard configuration.
Templates of standard configuration shall support multiple object types including, but not
limited to:
Point / Tag objects
PLC objects
Mimics or Graphic display objects
Trend objects
Logic programs
Schedules
Link objects
The SCADA database shall allow users to extend the database schema to store custom
data, in either the configuration or data stream. These changes can be performed online
without need for server restart.
3. Operator Interfaces
SCADA software shall provide the ability to support multiple local and remote dis-
play clients.
Display facilities shall be available via LAN, WAN and dial-up connection.
Display clients shall be supported as Rich Clients without the requirement of a da-
tabase resident at the display node.
Rich Clients shall support database management and configuration changes.
Rich Clients shall support multiple monitors (multi-head display), allow logon for
all heads from a single location. The system should also provide navigation facili-
ties such that displays on each head can be controlled from any head. (yoking)
Integrated Web Sever capability shall be available, providing all display and oper-
ational facilities of the Rich Client without the need for additional software to be
installed.
Web Clients shall allow users to view Mimics, Trends, Database Objects, Reports
as well as perform control functions using a standard web browser.
Changes made to the SCADA server shall require no additional steps to be per-
formed in order for those changes to be available to Rich Clients and Web
Clients.
Each full function Rich Client shall be configurable to connect to one, or multiple
server systems
Full function display clients shall automatically fail-over & reconnect to a redun-
dant server node when server change-over occurs.
Current generation Windows look and feel shall be provided by the SCADA sys-
tem operator interfaces, including provision for favourites lists comprising links to
any server object. This includes, but is not limited to: Mimics, Graphs, List Queries
SCADA software shall provide the ability to support for Citrix XenApp and Win-
dows Terminal Services.
4. Mimics / Graphics
SCADA system Mimics shall support a wide range of graphical facilities. Scalable Vector
Graphics are required in order to permit operation of the SCADA system with different

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resolution clients operating simultaneously. Fixed resolution bitmap graphics are not
acceptable.
Mimics shall be multi-layered, object oriented and permit mimics to be embedded in
other mimics. Other objects that must be available for embedding in a mimic include:
Button objects
Hyperlinks
Disk images (e.g. JPG, motion JPEG)
Remotely updated images
Hyperlinks with embedded queries (for generating filtered lists directly from a
mimic)
Object menus
Graphical facilities within a mimic must also be object oriented including the ability to
manipulate attributes of embedded objects in real time, supporting animation including
but not limited to:
Fill factors
Fill colour
Rotation
Position
Line thickness
Text attributes
Transparency
Alpha blending
Multi-rate Flashing
*Text entry boxes shall support on screen keyboard

24-bit Colour shall be supported on mimics as standard.
A suite of Graphical Symbols shall be provided for integration with configuration
templates and embedding within other mimics.
Import of mimics shall be supported from DXF format, including integration of multi-
layered DXF drawings in to native SCADA mimics.
Adding Custom database fields dynamically to Metadata where the server does not have
to be restarted after adding or modifying.
Mimics shall support the ability to specify OPC data source information to display directly
on the mimic. This permits data from other systems to be seamlessly integrated in to the
SCADA display.
Other facilities required to be supported by mimics includes:
Context sensitive object menus available from mimic
Accept an alarm from a mimic
Issue a control from a mimic
Operator Notes (as a native feature)
ToolTips
Hyperlinks to external documents (e.g. HTML, PDF, MS Office suite documents)
Objects embedded and displayed on any mimic shall be viewable through both the full
function client and web client displays.
5. Start-up
The SCADA system shall start-up unattended, and without compromising system
security. The SCADA server process shall operate as a Windows Service. The

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SCADA server shall start without the requirement for an HMI client to start.
Windows logon shall be available prior to display client start-up which must provide
additional security.
Shutting down a display client (including on the server node) shall not affect other
users or the server. Administrative privilege shall be required to shutdown a SCADA
server.
6. Configuration
The SCADA software shall provide full seamless On-line configuration of all database
parameters including but not limited to:
Communication Channel
PLCs
Points / Tags
Squences
Schedules
Alarm redirection
Mimics / Graphics
Trends/graphs
Reports
Configuration changes shall be capable of being made from local and remote
workstations using Rich Clients, with appropriate privilege. Configuration changes are
to be applied to the Main SCADA server and seamlessly applied to Standby server
and other SCADA server nodes such as user performance sharing SCADA nodes.
Further, configuration changes made to mimics and other display objects shall be
immediately available to local and remote Rich and Web display Clients without any
manual intervention. Changes should be updated automatically in local caches where
appropriate. This facility shall be a native feature of the product and not require
external scripts or customisation.
All aspects of the look and feel of the SCADA system, including default field values,
shall be configurable. It is not acceptable for colour regimes, communication
parameters and other aspects of the system to be hard-coded.
It shall be possible to add user defined fields to the SCADA database. These fields
should be accessible both internally and externally to the SCADA system; being
exposed via OPC, ODBC, OLE Automation, XML/SOAP, etc.
The SCADA server shall provide detailed diagnostics concerning its internal
operation. The diagnostics shall be available through capture to a log file as well as
online locally on a server and remotely via Telnet and Web interface.
The SCADA software shall provide the ability to perform a complete audit trail of all
database changes down to the individual property level of objects to ensure complete
system integrity and safe system operation. These details shall be provided as a
built-in integrated part of the system and shall include, but not be limited to the
following:
Time of change
Object on which change was performed
Property of the object that was modified
Property value before and after the change
User that made the change
Reason for the change

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Stored configuration records should be maintained in the historic database for a

configurable time period, support redundant SCADA server configurations and allow
access from standard database interfaces such as queries and simple mechanisms
for displaying and filtering the configuration records.
7. Alarm Management
The alarm system shall provide facilities where actions can be triggered by alarms.
These facilities shall be provided as a built-in integrated part of the system and shall
include, but not be limited to the following:
Configuration criteria for alarm actions
Escalate Alarm priority
Delivery of alarm to users via SMS
Delivery of alarm to users via E-mail
Trigger other actions including sequences
Integrated paging facilities shall be provided without the need for additional software.
The paging facilities shall include calendar operation for roster based user lists with
flexible interface for reconfiguration of alarm management.
Tracking of alarms shall provide as a minimum:
Alarm activation including point name, state, timestamp, priority
Alarm de-activation
Alarm acceptance including time, user responsible, optional comment
Custom alarm fields for display of additional or operations specific informa-
tion
Where a full function Rich Client is connected to multiple SCADA systems, alarms
from all systems shall be combined and filtered, based on user privilege and areas of
responsibility.
System administrators shall be able to configure user accounts with default filters so
that operator alarm lists can be confined for users to those areas where they assume
responsibility.
Full function Windows & Web clients shall provide indication of alarm condition, with
the ability to change alarm tone, colour, and other attributes based on alarm priority.
Full page and window display of the current alarm list to be shown. It shall also be
possible to modify the background colour of alarm lists.
Alarm display, acceptance, query and comment entry shall be available via an
integrated product Web interface.
Alarm limit time profiles allowing analogue set point levels to vary over the course of
a day to account for conditions at the site.
Consequential alarms to allow one (or more) alarms to be suppressed as the result of
another alarm occurring. Suppressed alarms will be received and processed by the
SCADA Server and recorded in the event journal for future auditing, however the
operator shall not be forced to take an action on an alarm where the cause is known.
8. Event Journal
The system shall provide, as a built in feature and without the requirement for custom
or external software, facilities for event logging. These facilities shall be separate
from the alarm list and include the capability to insert user comments at any place in

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the event list.

Event lists shall be obtainable through an SQL-like query or filtered through user
entry on a forms-based display.
Event data is to be stored in a time-series relational database. Each event record
shall comprise a timestamp, responsible user, point name, message, and reason for
event log.
The event journal shall support the following:
ODBC / SQL interface to event data
Filter and browse via full function display client
Filter and browse from Web client interface
9. Historical Data
The SCADA system shall provide a built in data historian with the following facilities as
standard features.
Time-series relational database
ODBC / SQL interface to historical (trend) data
Historical data to be stored with time-stamp, point quality, alarm status
Historic storage is to be based on configurable criteria including time be-
tween samples, alarm state change
Compression capability
Historical files supporting fixed interval sampling only will not be accepted.
Where historic data can be retrieved through communication devices such as PLC/,
the historic data sub-system shall natively provide the capability to backfill this data in
to the historian.
No loss of data or gaps in data as a result of communication or server failure shall be
accepted. The vendor must demonstrate its ability to ensure data integrity and
history data recovery.
An API shall be included to provide interface capability with the SCADA database.
This shall be based on OLE Automation and/or .NET
The historic data subsystem shall provide fixed and user configurable views of the
historic data tables. These views are required to provide SQL pre-processing and
present historic data in aggregate format.
The SCADA server shall provide Historian functions including the capability to
validate historic data prior to exposing it externally to the SCADA system, selectable
archiving rates, point-by-point storage compression regimes, annotation on history
samples for tracking comments on operational conditions, modification of historic
data for normalization and correction (tracks previous value and modifying user and
is subject to user privilege), auditing of modified or annotated history.
10. System Security & Access
The SCADA system shall provide a high level of inherent security. To this end the
SCADA software shall provide security access down to data point level, and support
individual Users, User Groups and a matrix of system capability and access to any
level of the SCADA database.
Full function Rich & Web client interfaces shall require explicit administrative
configuration to valid connection to the SCADA server.
Web interface facilities shall provide the capability to operate the Web interface using
SSL and encrypted data. The Web functionality shall be provided in an integrated

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way with the web server facility tightly coupled with the SCADA database. It is not
acceptable for the system to utilize IIS or similar external web interfaces, or require
web pages to be published from the SCADA system. Changes in configuration to
the SCADA system shall not require additional steps in order to provide modified
information to the SCADA Web interface.
The SCADA system security shall provide the ability to be integrated with Windows
domains to authenticate logon attempts against a trusted domain. Validation should
occur across all client interfaces, ensuring that users utilizing all types of clients are
subject to the built in system security policies.
11. Open Connectivity
To provide easy access for customized reports and external data manipulation the
SCADA software shall provide inherent OPC and ODBC database connectivity
without the need for additional software options or modules. Integration with desktop
Microsoft products is essential.
The following Open interfaces shall be provided as integrated components of the
SCADA system are required:
OPC Data Access (OPC-DA) to the SCADA server real-time and configuration
database
ODBC and OLE-DB to the SCADA server real-time database, historian, event /
parameter journal and configuration database
OPC Historic Data Access (OPC-HDA) to historian
OPC Alarm & Event (OPC-AE) to event sub-system
OLE Automation interface to the SCADA server database
12. Reports
An integrated reporting package shall be able to generate, print and export

reports:
Triggered by SCADA events
On user demand
On timed schedules
Report generation shall use latest technology in database access and be capable
of combining data from multiple databases via ODBC/SQL. This shall include
SCADA and non-SCADA databases.
Reports shall be able to be generated in a number of formats including:

HTML for viewing via Web interface
PDF format
CSV format
MS Office suite format
Generated reports shall be able to be:

viewed in Rich Clients and Web Clients
printed on a local or network printer
stored on disk file, locally or remotely
e-mailed to assigned users

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13. Standard Drivers

The SCADA system shall provide native support for fully integrated Wide Area
SCADA PLC protocols. This shall include the capability for supporting all protocols
in redundant SCADA server configurations and support redundant communication
paths.
All drivers shall provide the ability to monitor communication statistics, log driver
diagnostics, and provide online access to driver and channel diagnostics remotely
via Telnet or similar mechanism. Captured diagnostics shall be able to be
translated to HTML for analysis in clear human-readable format.
Apart from PLC communication drivers, the system shall also support as standard
the following drivers:
SMS (with TAP and UCP service) to mobile phones and pagers with a GSM or
CDMA modem connected directly to the SCADA server.
A full function system is required including calendar based rosters
SNMP monitoring of network devices such as routers, computers, UPS, etc.
NTP time server monitoring and alarming
ODBC query data from other databases
Windows Performance Monitoring
OPC-DA driver
14. PLC Protocol Support
Wide area PLC protocols shall support:

Local serial port communication
terminal server serial port communication
Ethernet LAN communication via TCP and UDP ports
Time synchronisation
Presetting output configuration points where configured
Fully integrated incorporation of events from a PLC
Unsolicited exception reporting
Where PLCs utilise the DNP3 communications protocol, those devices must sup-
port the DNP3 Secure Authentication standard.
All drivers shall support capability to update SCADA database point value / alarm
state / point quality / timestamp. PLC protocol drivers shall support the ability the
backfill time-stamped data into Event Logs, Historic Data to maintain data integrity
in the event of communication failure.
The driver architecture shall support user accessible interfaces to access major
driver functions. This shall include, but not be limited to:
Enable / disable PLC communications
Trigger an integrity poll
Alter communication parameters
Drivers shall maintain current state of target device information, and when used in
redundant server architecture shall retain state information and be able to receive
solicited and unsolicited information from the PLC immediately following a server
transition. It is not acceptable for the system to indicate communication failure or
not be able to receive communication from a remote device during the period of
transition from one server to another.

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DNP3 protocol shall be fully supported natively, including operation as a DNP3

Master and DNP3 Slave. DNP3 driver shall operate with fully redundant SCADA
server architectures and natively support a variety of communication methods:
Direct serial communications
Flow control serial devices (including data radios)
PSTN dial-up systems
Ethernet DNP3 communications supporting both UDP and TCP communi-
cations as per the DNP User Group requirements
Dual Networking configuration with built-in channel switching
DNP3 direct communications with PSTN backup
DNP3 driver should support operation as Level 1, Level 2 and Level 3 Master, and
additionally support:
DNP3 file transfer
DNP3 floating point analogue static and event objects
Virtual Terminal encapsulation of other protocols
DNP3 string points
A Device Profile shall be provided for the driver as per the requirements of the
DNP User Group.
Furthermore, the following protocols shall be supported as a minimum and
integrated with the product:
Modbus Master serial protocol
Modbus Slave serial protocol
Open Modbus /TCP Master protocol
Open Modbus /TCP Slave protocol
Allen-Bradley DF1
OPC-DA client driver (for connection to OPC Server driver)
The OPC-DA interface shall include as a minimum, integration with SCADA

database value / state / quality / timestamp data, support OPC-DA 1.0 and 2.0
specification interfaces, polled and exception modes, tag browsing.
14 CLOCK SYNCHRONIZATION SYSTEM

General Requirement and specifications of the Time Synchronization Equipment:
Automation of the water treatment plant includes................. ( ) master PLCs with
their SCADA, ..................( ) micro PLCs, web server of historian station, firewall
gateway, Enterprise data network communication system.
The different PLCs are distributed in different sections of the water treatment plant
for monitoring and control of that plant section. The distributed PLC network
needs to bring in a same time zone in view of reading the real
time data from the distributed PLC network at real time
stamping.
The intent of this specification is to design, supply erect, configure, communicate
and commissioning of the GPS synchronized timing system.
A GPS synchronized timing system receiver and its required accessories shall be
designed supplied & commissioned by the contractor. All PLC based SCADA
systems shall synchronize with the system clock to within 0.001 second of a time
signal received from a GPS synchronized timing receiver. The system may also
use Network Time Protocol (NTP), Simple Network Management Protocol

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(SNMP), or TCP/IP. All, software, and cables shall be provided to support a fully
functional time synchronization system. The system shall be fully configured at
the site by the Contractor.
15. Compliance Tables
The bidder shall fill in the following compliance tables fully detailing the level of
compliance and how the level of compliance is achieved.
Description Compliance
1. SCADA Architecture
Client / Server architecture
Standalone single server operation
Symmetric main-standby & capacity for
triple standby server functionality
Additional servers for user load sharing
Fully automated data transfer between
servers
A scalable fully distributable architecture
Configurable from a single client
Redundancy shall be handled by the
database
Configurable compression of data
communications
Change reporting on Client/Server and
Server/Server
Capable of operating Client/Server and
Server/Server links over low to medium
speed channels
Latest Windows Operating System
2. SCADA Database
True relational database design
Optimisation for real time operation
Object oriented
Hierarchical structure
User-created Template
3. Operator Interfaces
Multiple local and remote clients
Display facilities shall be available via
LAN, WAN and dial-up connection.
Display clients shall be supported as Thin
Clients
Integrated desktop Web capability
Changes made to the SCADA server shall
require no additional steps
Each full function display client shall be
configurable to connect to one, or multiple
server systems
Full function display clients shall
automatically fail-over & reconnect to a
redundant server node

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Current generation Windows look and

feel
4. Mimics
Scalable Vector Graphics
different resolution clients operating
simultaneously
Fixed resolution bitmap graphics are not
acceptable
multi-layered, object oriented
mimics to be embedded in other mimics
manipulate attributes of embedded objects
in real time
24-bit Colour
A suite of Graphical Symbols shall be
provided
Import of mimics shall be supported from
DXF format
Ability to specify OPC data source
information
Context sensitive object menus available
from mimic
Accept an alarm from a mimic
Operator Notes (as a native feature)
ToolTips
Hyperlinks to external documents
5. Start-up
Unattended start-up
Operate as a Windows Service
Start without the requirement for an HMI
client to start
Windows logon shall be available prior to
display client start-up
Shutting down a display client (including
on the server node) shall not affect other
users or the server
Administrative privilege shall be required
to shutdown a SCADA server
6. Configuration
Seamless On-line configuration of all
database parameters including but not
limited to:
Communication channels
PLCs
Points
Sequences
Schedules
Alarm redirection
Mimics
Trends/graphs

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Reports
Configuration changes shall be capable of
being made from local and remote
workstations
Configuration changes are to be applied to
the Main SCADA server and seamlessly
applied to Standby server and other
SCADA server nodes such as user
performance sharing SCADA nodes.
Configuration changes made to mimics
and other display objects shall be
immediately available to local and remote
full function and web display clients
without any manual intervention
Changes should be updated automatically
in local caches where appropriate
Look and feel of the SCADA system,
including default field values, shall be
configurable
Add user defined fields to the SCADA
database
The SCADA server shall provide detailed
diagnostics
7. Alarm Management
Facilities where actions can be triggered
by alarms. These facilities shall be
provided as a built-in integrated part of the
system
Configuration criteria for alarm actions
Escalate Alarm priority
Delivery of alarm to users via SMS
Delivery of alarm to users via E-mail
Trigger other actions including sequences
Integrated paging facilities
Tracking of alarms
alarms from all systems shall be combined
and filtered, based on user privilege and
areas of responsibility
Full function display clients shall provide
audible indication of alarm condition
ability to change alarm tone, colour, and
other attributes based on alarm priority
Full page and window display of the
current alarm list to be shown
modify the background colour of alarm lists
Alarm display, acceptance, query and
comment entry shall be available via an
integrated product Web interface
8. Event Journal

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In Built feature
Separate form Alarm List
Ability to insert user comments
Event lists shall be obtainable through an
SQL-like query
Event data is to be stored in a time-series
relational database
The event journal shall support the
following:
-ODBC / SQL interface to event data
-Filter and browse via full function display
client and Web Client
9. Historical Data
In built historian
Time-series relational database
ODBC / SQL interface to historical (trend)
data
Historical data to be stored with time-
stamp, point quality, alarm status
Historic storage is to be based on
configurable criteria
Compression capability
Capability to backfill this data in to the
historian
A programmable API
Fixed and user configurable views of the
historic data tables
Validate historic data prior to exposing it
externally to the SCADA system
Selectable archiving rates
Point-by-point storage compression
regimes
Annotation on history samples
Modification of historic data for
normalization and correction
Auditing of modified or annotated history
10. System Security
High level of inherent security
Security access down to data point level,
support individual Users, User Groups
Full function client interfaces shall require
explicit administrative configuration to valid
connection to the SCADA server
Web interface facilities shall provide the
capability to operate the Web interface
using SSL and encrypted data
Web functionality shall be provided in an
integrated way with the web server facility
tightly coupled with the SCADA database

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11. Open Connectivity

Inherent OPC and ODBC database
connectivity
Integration with desktop Microsoft products
OPC Data Access
ODBC
OPC Historic Data Access
OPC Alarm & Event
OLE Automation interface
ODBC / SQL to the SCADA historical
database
ODBC / SQL to the SCADA event
database
12. Reporting
integrated reporting package
Report generation shall use latest
technology in database access
Reports shall be able to be generated in a
number of formats including:
- HTML for viewing via Web
- PDF format
- CSV format
- MS Office suite format
Generated reports shall be able to be:
- printed on a local or network printer
- stored on disk file, locally or remotely
- e-mailed to nominated users
13. Drivers
Native support for fully integrated Wide
Area SCADA PLC protocols
Redundant SCADA server configurations
and support redundant communication
paths
Monitor communication statistics, log
driver diagnostics, and provide online
access to driver and channel diagnostics
remotely
Captured diagnostics shall be able to be
translated to HTML for analysis in clear
human-readable format
14. Standard Drivers
SMS / Paging
SNMP
NTP
ODBC
Windows Performance Monitoring
OPC-DA driver
15. PLC Protocol Support
Local serial port communication

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Terminal server serial port communication

Ethernet LAN communication via TCP and
UDP ports
Time synchronization
Presetting output configuration points
Fully integrated incorporation of events
from a PLC
Unsolicited exception reporting
update SCADA database point value /
alarm state / point quality / timestamp
support the ability the backfill time-
stamped data in to Event Logs, Historic
Data
Driver architecture shall support user
accessible interfaces to access major
driver functions.
- enable / disable outstation
communications
- trigger an integrity poll
- alter communication parameters
maintain current state of target device
information
redundant server architecture shall retain
state information and be able to receive
solicited and unsolicited information from
the outstation immediately following a
server transition
DNP3 protocol shall be fully supported
natively
DNP3 Master and DNP3 Slave
DNP3 driver shall operate with fully
redundant SCADA server architectures
DNP Driver shall natively support a variety
of communication methods:
- direct serial communications
- flow control serial devices (including data
radios)
- PSTN dial-up systems
- Ethernet DNP3 communications
supporting both UDP and TCP
communications as per the DNP User
Group requirements
- Dual Networking configuration with built-
in channel switching
- DNP3 direct communications with PSTN
backup
DNP3 driver should support operation as
Level 1, Level 2 and Level 3
DNP3 file transfer

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DNP3 floating point analog static and

event objects
Virtual Terminal encapsulation of other
protocols
DNP3 string points
DNP Device Profile shall be provided for
the driver as per the requirements of the
DNP User Group
16. Other PLC/RRU Protocol Support
Modbus Master serial
Modbus Slave serial
Open Modbus/TCP Master
Open Modbus/TCP Slave
Allen Bradley DF/1
RS/link
OPC-DA client driver
17. Logic
support logic sequences with full access to
all SCADA system services at run time
Programming of sequences shall be to the
IEC61131-3 international standard
functional block librarian
Sequences shall be able to me modified
and started and stopped online
Sequence changes shall be a native part
of the database and replicated to
redundant SCADA servers
6.2 LOGIC DEVELOPMENT
The SCADA system shall support logic sequences with full access to all SCADA system
services at run time. Programming of sequences shall be to the IEC61131-3 international
standard and support as a minimum the following languages:
Ladder Diagrams
Function Blocks
Structured Text
Sequential Function Charts
A functional block librarian is also required.

Sequences shall be able to me modified and started and stopped online. Sequence
changes shall be a native part of the database and replicated to redundant SCADA
servers.
Special scripting languages to perform the control strategy will not be accepted.
6.3 HISTORIAN SERVER
Data Acquisition and management system, Historian server, alarm

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management and Equipment performance system

GeneralRequirements
a. Itisnotintenttocoveralldetailengineeringforequipmentde-
sign,manufacture,installation,testsand commissioninginthisspecifica-
tion,buttocoverthegeneralandoverallrequirementstobeappliedto thePlantHis-
torian,Datamanagement,andAlarmmanagementsystem.
Any omissions in the specification shall not relieve the contractor from his
obligation to provide a system compatible with the intent of the specification.
All components shall be of a proven and reliable design and the highest
possible uniformity and inter changeability of all parts shall be
reached.Contractorshallacceptfullsystemresponsibilityforallsuppliedhardwar
eandsoftwareand providenecessarytrain-
ing,supervision,andspares.TheyarefullyresponsibleforInstallation,startup
andcommissioningassistanceuntilsuccessfulhandovertoowner.
Each device/unit supplied in the system shall work independently to guaran-
tee the reliability of Plant Historian, Data management, and Alarm manage-
ment system.
All technical services necessary to satisfy the various documentation and
drawing requirements identified in this specification is included in a master
drawing list.
The equipment, materials, and services to be furnished shall include, but not
necessarily be limited to, the following major items
b. RedundantEthernetswitcheswithbuiltinfibreopticports
c. NetworkCabinetformountingEthernetswitchesinElectronicEquipmentroom
d. Fibreopticpatchpanelasrequired
e. Allcable(communicationcable,prefabricatedcableetc)
f. OperatorcumEngineeringworkstation
g. WebbasedVirtualserv-
er,suitabletointerfaceonenterprisedatacommunicationnetworkon4G
h. Backupserver(Firewall,DMZ),webbased
i. OPCServer
j. Interfacenodeforbuffering(DedicatedServer)
k. NetworkcolourlaserprinterforAlarm
l. NetworkcolourlaserprinterforDatabase&graphs
m. Operatorcontrolcon-
sole(Desk),40LEDmonitor&workstationasspecifiedinPLCspecifications
n. CableTerminationMaterialsandaccesso-
ries(Lugs,Glands,ferrules,Fittings,connectors(Ethernet, fibre optic)etc.
o. Required software for database management, Alarm management, Histo-
rian, Enterprise data communicationnet-
work,clocksynchronization,firewallandGateway,internalLAN,OS
p. Otheraccessoriesasrequiredbythesystem
Designcriteria:

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AsexplainedinthespecificationsofPLCandSCADAbasedcontrolsystem Thedefi-
nitionsofthevariousterminologiesinthisspecificationareasbelow:
Sr No. Terminology Description

De militarized zone, The zone in the firewall gateway
1 DMZ from where all the request and data transfer is veri-
fied to avoid unauthorized access.
2 Resiliency time The time required for ring topology network to recov-
er
3 VPN Virtual plant network

4 Enterprise data An integral group of components developed to re-
communication network ceive and transmit the plant data from plant server
via. Firewall & transmit in Air by medium of Antenna.
The network operates on predefined bandwidth li-
censed by internationally recognized operators on
minimum 3G network
The information from Seven master PLCs integrated

5 OPC Server at one place and buffered to the interface node
6 Interface node Interface between OPC server and web based histo-
rian server. Data base buffering takes place
The tag based information collected in the OPC

server integrated at one place to further analyzer
and optimize in different form. Based on it, a different
7 Plant Server , web based type of graphs in the form of trends, x-y plots, bar
charts, text displays, group displays, alarm display,
system display and summery graphs can be devel-
oped as a dash board and different schedules of
Alarms can be managed
A processor in which data from the historian is made

available and updated periodically. The server has
different virtual compartments like server with DMZ
and firewall, virtualized SAN and fiber network, addi-
8 Virtual Server, web based tional networks to manage and isolate information
traffic. Virtual server produces a full redundancy dur-
ing maintenance period. Two virtual servers are
needed on separate hardware boxes.
Historian server redundancy is expected.

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9 Engineer/Operator Work A processor has perform configuration console. Fea-

Station ture functions for apart the from Engineer to the op-
erator
2.0 SystemDescription
The data highway integrates the total system and shall be configured with
Redundant Architecture for high reliability. The system shall be fully oper-
ational with one data highway out of service and with no degradation in
performance for components. Only the listed manufacturers are recog-
nized to maintaining the level of quality of workmanship required by the
specification. All the micro-
PLCs&MasterPLCsshallbeprovidedwithwirelessmodem if re-
quired.Asetof1,3,4&13microPLCs, shallbeinterfacedwitheachotheron-
pointtopointandRingtopologynetworkcommunication&this setisfurtherinter-
facedwiththerespectiveMasterPLConwirelesscommunication.
.
AlocalcontrolCabinshallbeconstructedineachsectiontoinstallthe-
MasterPLCsforPurewater, Raw water and systems. The Filter house
master PLCs shall be located in the centralized maincontro-
lroom.AllthemasterPLCsshallbeinterfacedwitheachother.
AnOPC(ObjectLinkingandEmbeddingforProcessControl)serverisenvisag
edtocollectthedata from various PLCs in the plant and further pass it to
interfacenode.
AninterfacenodeisamachinewhichinterfacebetweenOPCserverandweb-
basedplantHistorian server. Data buffering shall take place in the inter-
face node. In case the communication between interface node and histo-
rian is disabled the data shall remain in the buffer so that it can be used
forreportingoncethecommunicationisresumed.
Twowebbasedserversareenvisagedwheredatafromplantiscollectedan-
dupdatedperiodically through OPC and buffer node. The data storage,
data analysis and optimization shall be done in the historian server.
Based on the analyzed data various alarms can be developed managed
in scheduled manner. Mutually discussed and accepted method will be
used during commissioning andfurtherrunningoftheplant.
Both the servers shall be virtualized and have different virtual compart-
ments like server with DMZ and firewall, virtualized SAN and fiber net-
work, additional networks to manage and isolate information traffic. Vir-
tual server shall produce a full redundancy during maintenance period.

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Servershallbeabletointerfacethenet-
workswitches,fiberopticalnetwork,workstationsdedicated on master
PLCs, printers, Enterprise data connectivity network (MJP/ MUNICIPAL
COUNCIL server and tablet phones), LED, capital equipment, analytical
instruments, smart devices and many more.
Server shall Poll real time data continuously or on-demand, measure critical
parameters from theseas-
sets,establishconnectionusingvariousprotocolslikeOPC,Modbusetc.
Historian and Data Acquisitionsystems
DataAcquisitionSys-
tem(DAS)softwareshallbeloadedintheeachEngineeringcumoperatorwork
stationassociatedwithMas-
terPLCs.ThereareSevenMasterPLCsthereforeminimumsevenDAS shall be
associated with the historian. Historian license shall be suitable to operate
minimum Nine devices. The total minimum number of tags shall be but not
limited to 16000 + 970 (for energy me-
ters).Softwaretagsareunlimitedasperlicenseagreementandhardwarepoints
arerestrictedto the number specified. The detailed quantity of tag numbers
shall be discussed during detailed engineer-
ing.Contractorshalldefineanddeclaretheamountofmemoryspacetobeacquir
edbythe DASindestination
DAS shall continuously process all relative important process point signals
and status signals of equipmentoftheunittoprovideplantpersonnelwithinfor-
mationtoimplementthesafeandeffective operation of the unit. Alarm whenev-
er any abnormal condition of unit exists, so to increase the availabilityof-
theunit.
DAS shall poll data from its connected PLC at defined frequency. The mini-
mum frequency shall be
2000Tags/Sec.DASshallbemasterandPLCshallbeslave.DASshallbeabletous
eallstandard communicationproto-
cols(e.g.Modbus,OPCetc.)andstandardcommunicationchannel(e.g.serial,
Etherne-
tetc.)thosecanbesupportedbyallPLCsfromstandardmakenamelyRockwell,Mit
subishi, Siemens,GE,Emerson.DASshallalsobesuitabletointerfacewithOPC.

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The DAS shall send the real-time data to OPC server. The DAS can be a
part of the individual SCADA or a separate device which can interface PLC
& OPC server.
MainServershallaggregatethedatafromallDASthroughOPCandprovidea-
comprehensivedata management system and historian. Custom dashboard,
widgets and reports shall be developed based on the database. A dedicated
License for OPC, DAS, interface node plant optimization system, energy
management system, Alarm management and report management tool shall
be provided.
Short-Term(Trend)DataStorage.
The historian shall have short-term data storage to allow data retrieval for
recent and active trend displays. The system shall be able to store and dis-
play the variables like I/O point and calculated variables in the form of trend
display, process control display, or report.
Long-Term(Historian)DataStorage.
Thesystemshallbecompletewithhardwareandsoftwareandabletostorethelong-
termdatainthe form of plant data and information on permanent storage me-
dia for later retrieval and use. The historianshallutilizerelationaldatabase-
technologytoprovidestorageofplantinformationinaformat that is accessible to
all SCADA applications as well as external databases and third-party appli-
cations. A relational database management system (RDBMS) shall be in-
cluded to allow data access through standard Open Database Connectivity
(ODBC) and Structured Query Language
(SQL).Theretrieveddatashallbeaccessiblefromallthenormalsystemperipheral
devicessuchas operator work station monitors, LED and printers. The long-
term data shall be available for use in trenddis-
plays,processcontroldisplays,reports,andcalculations.Thedataretrievalcapabi
lityshall beminimumofFiveyears.
Features:Thehistoricaldatacollection,datafunctionsshallhavedatacollectionand
storagesystemwithfollowingfeatures:
Abletostoreallsystemvariablesli-
keI/Opoint,calculatedvariable,systemmessages,datainthe formoffilesli-
kealarmlist,periodicreport,etc.
Abilitytoexecuteperiodicsummarycalcula-

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tions,suchasaveragevalue,minimumvalue,maximum val-
ue,summation,orruntime.Thesefunctionsshallbeuserselectableonaperpoint
basis.
Storageofadditionalparameterssuchaspointdescrip-
tion,engineeringunits,scalinginformation, andalarmlimitsshallbeuserselec-
tableonaperpointbasis.
Storageofcontrolfunctionblockparame-
ters(setpoint,deviation,blockoutput)shallbeuser selectableonaperblockbasis.
Thedatacollectionfrequen-
cy,pointcollectiondeltavalue,orcollectionchangeofstateshallbeper point ba-
sis and user selectable. Minimum collection frequency shall be at a mini-
mum, collection frequencie-
sof0.5second,1second,10seconds,1minute,10minutes,and1hour.
Thepointdatatobestoredshallhavemini-
mum,tagname,valueorstatus,andtimetag.
The system hardware and software shall be sized to allow collection and
permanent storage, the permanent storage medium shall be rewritable on
CD, DVD, pen drive, hard disk and their jukebox. All operator interfaces to
the disk subsystem shall be menu driven and all the special command struc-
tures shall be transparent to the operator. Data shall be automatically written
to disk provided the storage medium is in a condition to receive data; other-
wise, an alarm message shall be generated and the data shall be buffered
on the historian hard disk drives.
The Contractor shall furnish all consumables (rewritable CDs, rewritable

DVDs, etc.) required for long-term data storage for the duration until last day
of annual maintenance contract.
DisplayFunctions:Thesystemshallinclude,operatingdisplay,groupdisplay,bar-
chart and Alarm screen. The logging shall include periodic logging, post trip
review log, trip
dataLog,historicaldatastorageandretrievalandPlantperformancecalculations
GenerationrequirementofDisplay:
a. ThelatestWindowdisplaytechnologyshallbeappliedwithsuchasmulti-
windowdisplay,scrollthe screendisplay,zoomimagesdisplaymenu-
drivendisplay.
b. Ahierarchicaldisplaystructureshallbea-
dopted.Thenumberoflevelsdisplayedshallbedetermined inaccordancewith-
theprocesssystemandtherequirementofoperationandhistorianforthisproject.

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Itshallbecompletelycustomizedtopermittheoperationtoconvenien-
tlyalarmthroughthehierarchy toobtainthenecessarydetailsasrequiredandana-
lysisofthespecificsituation.
c. ThefastswitchdisplaytoolNavigation-
keys(suchasthenavigationwindow,thedrop-downmenu) shallbeprovidedso-
thattheofficersshallachieveinformationinminimumsteps.Atthesametime
thehotnavigationkeysshallalsobeprovidedtoallowstaffachieveneces-
sarymonitororcontrol screeninonlyonetimekeystrokes.
d. EachLEDdisplayshallbecapableofdisplayingcombinedalphanumeri-
candgraphicinformation, through which the plant operator may be able to ma-
nipulate the process and monitor the plant operation.
e. It is possible to display all process points (including analog inputs, analog

outputs, digital inputs, digitalout-
puts,intermediatevariableandcalculatedvalue)inthesystem.Thepointidentifica
tiontag, descrip-
tion,value,quality,engineeringunit,highandlowlimits,etc.,shallbedisplayedfore
achpoint to bedisplayed.
Plantsimulateddiagramdisplay
Thebiddershallprovideat-
least100customersimulatedgraphics.Thenumberofgraphicdisplay can-
beincreasedduringengineerdesignstageoftheprojectwithoutextraex-
penses.
Although the simulated images shall be designed as per user-supplied P &

ID, but it also shall combinewiththecontrac-
torsrichexperience,notonlysubjecttotheseP&ID,forexample,enough profile-
display,three-dimensionalimageetc.
Each graphic shall be capable of displaying real-time value of process pa-

rameter and status of operatingequip-
ment.Allthedatashallberefreshedin5sec.Displaycolourandfigureshallvarywith
process.Bar-
chartsandtrendinggraphicsshallbeabletobedisplayedinanylocationi-
nanygraphic.
Bymeansofkey-
board,anycontrolleddevicesingraphicshallbecontrolledmanuallybyoperator
s. Last status of operating equipment and step of automatic programs
shall be displayed in the simulated graphics when the equipment dis-
played in the graphic is in automatic mode. Failure of automaticprogram-
shallbealarmedandindicatedatwhichstepthefailureoccurred.
InHistorianstationownershallbecapableofeditingandmodifyinggraph-

[147]
icbyuseofeditingprogram stored in station. The Contractor shall provide

standard symbols library of process device and instrumentconsistedwithI-
SA.WhencustomerusedsymbolsdonotbelongtoISA,newself-defined symbols
shall be generated by customers using symbol generator provided by the
Contractor. Customerself-definednewonecanbestoredandeasilyrecallable.
TheContractorshallstategraphicdisplaycapabili-
ty;eachgraphiccancontainhowmanysymbols andhowmanyprocess-
pointswhicharereal-timetype(includinganaloganddigital)duringdetailed en-
gineering.
OperatingDisplay
Ahierarchicaldisplaystructureshallbeadoptedasperdifferenttype-
suchasmodulatingcontrol, sequence controlmonitoring.
Operatingguidanceshallbedesignedforplantandequip-
ment,andshallbedisplayedingraphicor wordondis-
play.Operatingguidanceconsistsofthreepartse.g.start-
upmode,normalworkingmode and tripmode.
Standard operation display panel shall be able to show at least eight control
loop, with the current process parameters, including process variables (PV),
set value (SV), output value, control mode,
alarm,looplabel,biasandsoon.PV,SVandoutputshalladoptdynamiccolourbargr
aphanddigital format. The standard panel display screen shall include all the
modulating control loop and on-off controlloop.
StandardGraphicDisplay
Contractorshallpreparewellstandardgraphicinhissys-
tem,suchasalarmdisplay,trenddisplay, groupdisplay,bar-
chartdisplayetc,orslightlymodifiedonactualrequirementofthisproject.
GroupDisplay
Analoganddigitalsig-
nal,whicharerelatedintechnique,shallbegroupedingroupdisplay,andshall be
stored in memory for operator to recall it easily. Group display shall be com-
bined as request of operator, and be stored in memory or deleted as re-
quired. Colour intensified display and bar-chart displayshallbeincludedin-
groupdisplay.Morethan20pointsshallbecontainedinagroupdisplay, and sys-

[148]
tem shall provide 40 group displays at least. Any point exceeding its alarm
limit shall be showninredandflash.
BarChartDisplay
Itshalldisplay,onoperatorsrequest,dynamicbar-
charttodisplayprofilesofvariousplantvariables. Bar-chart shall be configured
and displayed in any graphic, each bar-chart can be set in any proportion.
At least 16 bar-charts shall be arranged in one screen, and system shall
provide 20 display screens at least which only have bar-charts to be dis-
played. Any analog input in control system shall be available as bar-charts
to be displayed. Any bar which exceeds the alarm set-point shallhavethat-
portionofitsbardisplayedinred.
TrendDisplay
Systemshallbeabletoprovide400historicaldatatrendand400real-
timedatatrenddisplay.Trend shall be displayed either in whole screen or in
other display in any scale. All analog signal and calculatedvalueshallbeavai-
lableastrenddisplay.
OneLEDScreenshallbeabletodisplayaminimumo-
feight(8)analogtrendvaluessimultaneously in same time at the time axis and
adopt different colours. Each real-time data trend curve shall consist of 600
real-time trend values, time division shall be one, ten, thirty seconds which
can be selectedbytheoperator.
Each historical data trend curve shall consist of 600 historical trend values,
time division may be selectable from 0.5 minutes, 1 minute, 2 minutes, 5
minutes , 10 minutes, 15 minutes, 30 minutes and 60 minutes. Trend curve
shall display the variable value numerically simultaneously. Trend display
shall be stored in internal memory and shall be easily recalled by operator.
By request, operatormayconfiguretrendandkeeptheminexternalmemoryforfu-
tureuse.Thevalueofanytime pointcanbeobservedonthetrendcurve.
Equipmentrun-time

[149]
AlarmDisplay
System shall be able to distinguish from normal, abnormal or change of
state, by means of contact change or by compare scanning signals with pre-
stored reference values. These signals include analogin-
put,calculatedpoint,averagevalue,varyingrateandothertransfervalue.Whenon
esignal overthereferenceli-
mits,alarmwillbedisplayedonLED,meanwhileaudiosignalshallbegivenout.
Alarm display shall be listed in chronological order with last alarm appearing
at the top of the list. Eachalarmmayhave-
six(6)prioritiesandshallbedistinguishedintagusingsix(6)variantcolours.
Alarmshallbeacknowledgedbyasinglekeys-
troke.Afteracknowledgeonealarminonestation,itis effectiveforallotherstatio-
natthesametime.Onceacknowledgeaalarm,backgroundcolourofthe alarmon-
LEDshallbechanged,andaudioalarmshalldisappear.
Means of flash and changing colour shall be used to distinguish acknowl-
edged alarm from unacknowledged alarm. When an unacknowledged
alarmed variable returns to normal, It shall be removed from the alarm list
and the remaining points shall restock to eliminate gaps in the alarm display.
Anyalarmoccurrenceandreturntonormalshallbeprintedoutonalarmprin-
ter.Ifanacknowledged alarmreappearsa-
gain,Itshallbeputonthetopofalarmdisplayasalastalarm.Thecolourchange will
indicate the number of alarm change the point of labelling to indicate the co-
lour of the re- occurrenceofthenumberofalarm
All analog and calculated variables with alarm limit shall be set dead band,
so as to decrease frequentnuisancealarmwhenparameterapproachtheli-
mit.Incaseofequipmentstart-upandshut- down, alarm block function shall be
provided to prevent analog and digital signal from nuisance alarming. This
function shall be implemented in Operator Station. On completion of start-
up,alarm blockfunctionshallberemovedautomatical-
ly.Thisfunctionshallnotinfluencevariablescanningand collecting.
Adjustable alarm set-point shall be considered for all input signal and calcu-
lated variable. These alarmset-

[150]
pointsmaybethefunctionofprocessparameter(suchasload,flow,temperature).
Alarm message shall indicate the corresponding search label of the graphic
display that deals with the alarm. It shall be able to call more than one alarm
summary in operator station by a single keystroke. The alarm summary shall
be format of table, and including the following information: tag name of the
point, point identification, present value in engineering unit, alarm set-point
in engineering unit, present alarm state (high or low) and occurrence time.
Each page of alarm summary shall have 20 alarm points, alarm summaries
shall have 3000 alarm points at least (includingsystemdiagnosealarmpoint).
Allalarmpointsshallbestored,andmaybechosebytheoperatortoprintout.
OtherDisplay
a. HelpDisplay
Inordertoassisttheoperatorinsuccessfulmanipulationofplantpro-
cessduringstart-up,shut-down andevenemergencycondi-
tions,thesystemshallbeprovidedwithanon-linehelpdisplaypackage. Means
shall be provided for the operator to call up the help display by pressing the
corresponding Helpkey.
Inadditiontothestandardhelpdis-
play,thispackageshallallowtheOwnertoincorporatecustomers helpprocedu-
resintoanyhelpdisplaytosuitspecificoperatingconditions.
b. SystemStatusDisplay
System status display shall present the status of each controller connected
to the data communication highway. The operating status of all I/O modules
residing in each drop shall be included in the system status display. Failure
of any drop or module shall be highlighted with changing colour in the cor-
responding status display to call operators prompt attention.
c. Apartfromthedisplayfunctionsexplaineda-
bove,Historianshallcompliancewithallthefeatures ofdisplayfunctionexplai-
nedinsection6.0ControlandInformationDisplayFunctionsasa super-
visoryfunctioninPLCsection.

[151]
3.04.6 Information System

Information shall be provided to the operator in several formats as follows
and the contractor shall include them in his scope of work:-
X(t) plots, Bar charts, All graphic formats and dynamic information to be
prepared from the flow diagrams, All log formats and report formats, All
start-up guidance formats, System Summaries, Single Point Trend, Group
Trend, Sequential Points Print Out, Alarm Summary, Review of Alarm Lim-
its,DeadbendsScan/CalculationRates,OffScanSummary,ConstantsSummary
,ScanPeriod Summary, Point Quality Summary, Trend Log Summary, Trend
Recording Assignment, Bar Graph Assignment Summary, Group Review
Summary, Reports & Logs, Shift, Daily, Other Reports, Raw water perfor-
mance Report, Pure water performance Report, River water level record,
Dosing chemicalconsump-
tion,PumpStatus/Repairrecord,Filterefficiency,Filterbackwashrecord,Pump
Diagnostic Log, Pure water quality Record, Hill reservoir water quality
Record, Maintenance Data Log, Special Logs, Overall Performance Log,
Operator Command Summary Log, Long Term Historical storage and Re-
trieval, Process Graphic Displays Faceplate Displays, Bar Chart Displays,
Trend Displays, Permissive Displays & Step Indicator, Operator Guidance
Messages, Printed Reports and Logs.
LoggingFunction
Programmable headings shall be used for all logs, pre-printed forms shall
not be used. The Contractor shall format all headings for logs in accordance
with Owners definition.
Loggingfunctionsshallbeinitiatedbyprogramcontrol-
and/oroperatordemand.Anyprocesspointin thedata-
baseshallbeavailableforthelogs.
Periodiclogging
Periodic logging includes shift log, daily log and monthly log. Shift log and
daily log shall report 500 predeterminedvariablesforeachhourdivi-
sion.Monthlylogshallreport500predeterminedvariables for each day division.

[152]
Periodic log shall print entire contents at the end of shift or day or month au-
tomaticallyorcalledupbyoperatordemand.
OperatorActionLog
The system shall record all the actions performed by the unit control room
operator with accurate timeofoccurrenceforanalyzingtheoperationalpurpo-
seofoperatorandtheoriginoffaultconditions. Thesystemshallatleastpro-
vide5000unable-deletedlog.
PostTripReviewLog
Post Trip Review Log shall be provided for analyzing. Integrated log of 128
variables describing majorequipmentofunitshallbeprintedoutimmediatelyon-
cedetectedanymajorequipmentofunit trip. Other variables there into shall be
printed rapidly every ten seconds before the trip ten minutes and every one
second after the trip five minutes. Post trip review log message shall be
printed out automaticallyorbytheoperatordemand.
Operatorlog
Operator log may be implemented as required to print out immediately or in
the time interval predeter-
mined.Operatorlogmayconsistof20groups,16parametersforeachgroup.Allthe
points withaddresscanbeconfiguredtooperatorlog.
Equipment operationrecord
Attheendofthe-
day,thecumulativerunninghoursandthenumberofstart/stopofpumps,fansand
othermajorauxiliaryequipmentsshallbeprintout.
HistoricalDataStorageandRetrieval(HSR)
The purpose of HSR is to keep detail operation information for a long term.
HSR
stations should be providedwithsystemsandnetworkmanagement,database
management,datastorageandretrieval functions. Operator shall be able to
retrieve historical data from any of the work station from the plant.
HSR station shall be able to handle at least 20,000 process point, the im-
portant analog control and monitoringpointsrelatedtoequipmentandperso-

[153]
nalsafetyshouldbesampledatleast1persecond othernon-
importantprocesssamplingpointsmaybeappropriatetoincreasethesam-
plecycle.Allthe process data of HSR station can be stored for 90 days, the
system design shall adopt advance technologytoreducedatastorages-
pace.Thebiddershallsubmitdetaildescriptionaboutscanning cycles of dif-
ferent important level process I / O points, and provide the calculation me-
thod about varioustypeso-
fI/OpointsoccupystoragespaceandHSRstationharddisktotalcapacity(atleast
80GB (1 TB) hard disk)inthebiddingdocument.
The bidder shall provide readable and writeable CD-ROM drive (DVD) or
tape drive to store long- termhistoricalda-
ta,whenthedatastoragespaceoftheHSRstationupto60%oftotalcapacity,the
systemshallautomaticallytransferdatatoreadableandwriteableCD-
ROMortapedrive,andalarm on LED to inform operator. All document re-
trieval of HSR Station can be printed or displayed in the LED asdemand.
DataManagementSystemandHistorianSpecifications
Following are the minimum feature of the Historian but not limited to:
Sr. Particulars D
Web based software hosted on a server or cloud plat-
form
1 General Re-
Should run on Windows Server OS or Linux OS
quirements
Shouldbecapableofinterfacingwithother EnterpriseSys-
tems,e.g.SAP Long term data storage capability for 10
years
Server Envi- OS - Windows 2012 Server / Red Hat Linux latest ver-
ronment Re- sionDatabase (latest version) Oracle / SQL Server /
2 MySQLEnterprise Virus Protection Software Firewall
quirements
RAID5 for data redundancy

[154]
Functional Should be capable of acquiring real time data from de-

3 requirements vices
(PLC / SCADA / Energy Meters/flow meters etc.) of
various manufacturers. Connection using various pro-
tocols like OPC, Modbus etc. Two-way communication
capability Role based dashboards System level and
Device level
Visualization Custom widgets for each dashboard to be developed

4
as per MJP/MUNICIPAL COUNCIL requirements Drill
down to individual devices from the dashboard Real
time data values / trends
Mobile and tablet interface for online data and status
Define alarms based on parameter value limits low
5 Alarm Man- low / low / high / high high fine condition based alarms
agement based on values of multiple parameters Audio-visual
display on browser Alerts by SMS / email . A dedicated
Licence for Alarm management
6 Historian Data and alarms historian Long term secure data sto-
rage Data export to .csv (Excel) / SQL / custom format
Custom reports and charts to be developed as per
MJP/MUNICIPAL COUNCIL requirements
7 Reporting A Report Creation Tool such that users can define,
save and generate simple reports and charts at runtime
Reports display and printing in HTML, Excel, PDF for-
mats, comprehensive reporting and charting module.
Standard and customized reports Downtime Report,
Asset utilization Report, Maintenance due & mainten-
ance log Report,
Automatic report scheduling and delivery thru email,
printer etc.
Mini-
mum25standardreportsshallbedevelopedpersystem,th
ereportingsystem shall be able to develop user de-
fined reports also. A dedicated License forAlarm man-
agement
8 Manual data entry forms(Manual data entry engine)
Manual Data Mapping of manual data with PLC data
Upward integration with Enterprise Applications like
ERP, Plant Optimization System etc. Downward inte-
9 Data Integra- gration with different data sources like from devices,
tion SQL data source and other sources.
Sending data to MJP/MUNICIPAL COUNCIL Server

[155]
Fully configurable system User friendly interface to add

/ change devices, parameters, alarms, users as well as
10 Configuration other entities as and when needed User authentication.
Extensive administration tool to configure device, sites,
parameters and users Rolebasedauthorizationandac-
cessrightsforreports,dashboardandotherparts ofsystem
Automatic backup facility Quick data recovery in case
11 Housekeep- of server crash / data corruption Data redundancy
ing
MinimumnumberofReportsandwidgetstobeproducedbycontractor-
shallbeas
below but not limited to : The total no of reports are mentioned be-
low, which may exceed during detail engineering, bidder need to es-
timate accordingly & Bid the tender.
Quantity of Reports
Name of the system /Widgets to be prepared Remark
Raw water system ..
Intake well ..
Chemical dosing system ..
Clarifier ..
Water filter ..
Back wash water system ..
Blower system ..
Chlorine dosing system ..
Recycle water system ..
Pure water system ..
Energy metering system ..
Reservoir ..
Other ..
(Figures should be as per our system requirement)
5.0 EquipmentperformancecalculationandmonitoringSystem
Equipment performance and monitoring System shall be provided with all
necessary features considering that its primary function shall be to inform
operator about the performance status and health of the mechanical and
electrical equipments based on the preprogrammed equipment performance
calculations and available process data. Based on the performance status
operator shall be able to initiate the corrective actions to prevent damage.
The system shall be capable to recordthehistoryofthedatasothatoperator-
shallbeabletomakethemaintenancescheduleofthe equipments. The operator
advisory should include the fault, severity of problem and corrective actions

[156]
to be taken. Further system shall allow the user to optimize corrective action
as per experiencegainedfromoperationoftheplant.
A suitable equipment performance software shall have features of pump

efficiency calculation, energy management and energy auditing, filter effi-
ciency calculations
Equipment performance calculation and monitoring package shall include

but not be limited to following:
a. EquipmentperformancesoftwareforOn-
linedataanddatagatheredbyofflineinstruments.
b. Pump/Blower efficiencycalculation
c. Energymanagementandenergyauditing
d. Filterefficiencycalculationsandoptimizationofbackwashcycles
e. Graphicalmanmachineinterfaceforrealtimedisplayofdata.
f. Databaseandplottingpackageforstorageandtrendingofbothconditio-
nandprocess da-
ta.
g. Package to allow implanting/merging of plant and equipment maintenance
history like balancing records,analysisreports,alignmentrecords.
h. Contractorshallfurnishthecompletewrite-
upanddetailsofHistorian,databasemanagement,Alarm managementand-
PerformancemonitoringandAnalysissystemin his offer.
Following minimum equipments shall be covered under equipment per-

formance calculation and monitoring however, the exact quantity shall be
finalized during detail engineering.
a. Rawwaterpumpandaccessories
b. Purewaterpumpandaccessories
c. Optimizationofchemicaldosing
d. Clarifiers
e. Filterandaccessories
f. BlowerandBackwashwatersystem
g. Chlorinesystem
h. Recyclewatersystem
6.0 SpecificationsofDatarepresentationinTabular/Graphical/Widgetsform:
The decision support model allows users to perform below main
tasks
a. To analyse historic and current data such as bed states, bed flow & head
loss and tocompare works outputs.
b. To schedule filter bed skims for the next month and to forecast works out-
put under the resulting schedules,and

[157]
c. Toschedulefilterbedreactivations,resandandtop-
upsforthenexttwoyears,sothatbestuseismade ofthesandbaysandknock-
oneffectscanbeplannedfor.
i. Dailyflowsummaries
ii. Daily pressuresummaries,
iii. Daily summary statistics for special periods (including nightline, morn-
ing and evening calculations)
iv. Maximumdeliveryvalueobservedintheday
v. Minimumdeliveryvalueobservedintheday
vi. Averageofvaluesobservedintheday
vii. ZonalDemands(Predicted),Actualdelivery
viii. Calculatedperformance
ix. Reservoircalcula-
tions(includingwaterageinthereservoir,inflowsandoutflows)
d. Thewidgetscanbemadepersonalizedorcanbemadeprivatetotheirloginor-
publictoalltheusers.
e. Usersshouldbeabletoperformthefollowingoperationsongraphs:
i. Comparethedatafromtwoormoresignalsinthesamewidget.
ii. Draganddropsignalsontothefaceplateforviewingthesignaldatainthat-
widget.
iii. Easilynavigatethedatawithinthewidget
iv. Zoomin/out
v. Exportthedataasexcelsheets/CSV/flatfiles.
vi. Printthedata/graphs.
vii. Playbackthedatabetweentimeintervalsselected.
f. TheseGraphsshallallowtheusertoviewthehistoricstatesofoneorall-
bedsinthecurrentworks. Thegraphshoulddisplayofanhistoricplanning-
boarddisplayillustratingthestatesofthebedsover theselecte-
dyears.Itshouldalsodisplaythedatesandsandlevelsforallactivitiesforthisbe
d.
g. Followingarethelistof-
Graphs,TablesandWidgetspereachsystem.Contractortoprepareminimum
numberofbutnotlimitedtothebelowlisted-
Graphs,TablesandWidgetspereachsystemandsubmit forconsul-
tant/ownersApproval.Contractorshallhavesufficientdomainknowledgewhich
isessential fordevelopmentofbelowlistedManagementinformationsystem.
Raw water pump Clarifier

[158]
Graphical Report ,Table Graphical Report ,Table forms

forms and Widgets : and Widgets :
Sr. Description Sr. Description
1 River water level details 1 pH details before & after Clarifier
2 Pump Sump pit level details 2 Turbidity details before & after
Dam level details Clarifier
PowerconsumptionVsClarifiero-
3 3 peration time
4 Thrash Rack cleaning de- 4 Clarifier performance calculation
tails
Predicted Vs Actual water Predicted Vs Actual perfor-
5 level 5 mance of clarifier
6 Water level history Details Clarifiermaintenancefore-
6 cast&history Details
7 Pump pressure details 7 Effect of Clarifier mainten-
ance Vs Performance
Pump Flow details EffectofRiverwaterchannelclea-
8 8 ningVs ClarifierPerformance
Pump head Vs flow curve, Clarifiermax-
9 standard 9 imum&minimumoperation time
Pump head Vs flow curve, permonth
Effect of season change Vs
10 actual 10 Clarifier Performance
Preparation of Clarifier mainten-
ance schedulebasedonRawwa-
11 Pumping rate calculation 11 terquality, Changeinsea-
son,totaloperationtime
12 Pump efficiency calculation 12 View productivity in Tabular Re-
Pump maintenance status ports
Clarifier Running time Vs
13 13 Clarifier sequencing sche-
Compare Pump Efficiency ForecastingofInventoryrequire-
14 Vs Pump maintenance 14 mentfor next twoyears
Compare Pump Efficiency Effect of natural calamity on
15 Vs. River water level 15 Clarifier operation & through-
Compare Pump Efficiency Identificationoftheclarifierthathave-
16 Vs. Water channel cleaning 16 been outofserviceduringlastOne-
Pump Maximum & Minimum Identify the clarifier which appear to
17 vibration readings be working but output is below thre-
17 shold values & need frequent main-
Pump Maximum & Minimum tenance
MTBF of each clarifier
18 bearing temperature readings 18
Pump Maximum & Minimum
19 winding temperature readings Chemical dosing System
Pump flow rate Vs Pump Graphical Report ,Table
20 power consumption forms and Widgets :
Pump maximum & mini-
21 mum power consumption Sr. Description
Pump power consumption Vs No. Chemical level measurement &
22 Maintenance Schedule forecast of chemicalrefillinthe-
1 chemicaltankbasedon theRaw-
watersupply&changeinseason

[159]
Pump power consumption

23 Vs River channel cleaning 2 Instantaneous chemical dos-
schedule ing rate
Effect of River channel clean-
ing Vs. Pumppowerconsump- PH&TurbidityVschemicaldosi
24 tionatmaximum constantflow 3 ngrate curve
EffectofPumpmaintenan- Maxi-
25 ceVs.Pump powerconsump- 4 mum&Minimumchemicaldosing
tionatmaximumflow rate in aday
River channel cleaning
26 schedule Vs Season 5 Chemical dosing rate Vs sea-
Preparation of Pump main-
tenance schedulebasedon-
pumpperformance, vibra- Chemicalinventorycalcula-
27 tion,windingtemp&bearingtem 6 tionsfornext Threecalculation
28 Effect of Pump mainten- 7 ChemicaldosingrateVsseaso-
ance Vs. Bearing vibra- nalchange Vsmeasured PH &
tions & temperature Turbidity
Preparation of water channel
29 cleaning schedule based on
pump performance
View productivity in Tabular Back Wash water System :
30 Reports Graphical Report ,Table forms
31 Minimum flow rate by pump Sr. Description
32 Maximum flow rate by pump 1 Back wash water level details
Total flow rate by Raw wa- BackwashwaterPumpdischar-
ter pump house per day gepressure details
33 per no. of pump in opera- 2
tion
TotalwaterutilityVsTotalflo- Back wash water Pump Flow
34 wrateby Rawwaterpumphou- 3 details
seperday
Pump Running time Vs BW water Pump head Vs
35 Pump sequencing 4 flow curve, standard
Pump sequencing schedule BW water Pump head Vs flow
36 Vs Pump Maintenance Sche- 5 curve, actual
dule BWwaterPumpin-
37 Pump maintenance Vs sea- 6 grate&performance calcula-
son tion
38 Cooling water avail- 7 BW water Pump maintenance
ability & Consump- status
Cooling water consumption ForecastofBackwashwatercon-
Vs Raw water flow sumption basedon-
39 8 no.offilteravailabilityforecast&
Pure waterAudit
Audit of cooling water Predicted Vs Actual BW water con-
40 9 sumption
Forecasting of Inventory re- BW water consumption Vs Fil-
41 quirement for next two years 10 ter maintenance(Sand charg-
ing) schedule

[160]
Effectofnaturalcalamityo- Maximum & Minimum

42 nRawwater supply 11 BW water consumption
Identificationthepumpsthatha- BWwaterpumpRunningti-
vebeen out of service for days meVsPump sequencingsche-
43 during the last tendays. 12 dule
44 Identify the pumps which ap- 13 BWwaterpumpsequencing-
pear to be pumping but head scheduleVs Pump Maintenan-
and/or flow values are below ceSchedule
threshold values & need fre-
quent maintenance
Raw water pump house IdentificationtheBWpumpsthatha-
45 predicted performance Vs 14 vebeen outofserviceduringlast-
Actual performance tendays.
ForecastingoftheRawwater- IdentifytheBWpumpswhichap-
supplyby eachpumpfornextO- peartobe pumping but head
46 15 and/or flow values are below
neMonth
threshold values & need frequent
47 Forecasting of the total Raw ForecastingoftheBWpump-
water supplyfromtheRawwa- downtime based on the
tersystemfor next OneMonth 16 pump Run time & pump se-
Forecasting of the pump
down time based on the 17 MTBF of each BW water pump
48 pump Run time & pump se-
quencing
Forecastingofthewaterdelive-
rylimitto each consumer based
49 on the seasonal wateravailabili-
50 ty
MTBF of each Raw water
pump
Pure water pump
Graphical Report ,Table
forms and Widgets :
Pure water sump level de- Forecastingofthepumpdown-
1 tails 45 timebased onthepumpRun-
2 Pure water pump Sump pit 46 MTBF of each Raw water
level details
Dam water availability Vs pump
PH,Chlorine&Turbiditydetails
3 Pure Water sump level 47 atPure wa-
No. of filter bed availability PH,Chlorine&Turbiditymeas
4 Vs Pure Water sump level 48 urement trendsVsseasonal-
Pure water flow Vs Pure water AnalysisofWateratvariousloca-
sump le- tions,time based
5 velVsno.filterbedavailableVsDa 49
m wateravailability
Predicted Vs Actual water Leakage Audit by comparing To-
6 level of pure water sump 50 tal Pure waterVstotalRawwate-
rintakeintheplant

[161]
No. offilterbedtobeopera- LeakageAuditbycomparing-

tedVsPure Water consumption TotalPure waterutilityfromHil-
for next two days(Days can be 51 lReservoirVsPure water
7 changed based on thedatare-
quirement) Total Electrical power received
8 Water level history Details 52 from SubstationVsPowercon-
sumptionatRaw waterSystem
9 Pump discharge pressure
detailsFlow details
10 Pump Blower Sys-
11 Pump head Vs flow curve, Graphical Report ,Table forms
standard and Widgets :
12 Pump head Vs flow curve, Sr. Description
actual
13 Pumping rate calculation 1 Blower discharge pressure
14 Pump efficiency calculation 2 details
Blower maintenance status
Pump maintenance status ForecastofBlowerconsumption-
15 3 basedon
no.offilteravailabilityforecast
Compare Pump Efficiency Predicted Vs Actual Blower
16 Vs Pump maintenance 4 utilization
Compare Pump Efficiency Blower utilization Vs Filter
17 Vs. Pump sump water level 5 maintenance(Sand charging)
Compare Pump Efficiency Maximum & Minimum Blower
18 Vs. Filter Backwash & Sand 6 utilization
Pump Maximum & Minimum BlowerRunningtimeVsBlowerse-
19 vibration readings 7 quencing schedule
Pump Maximum & Minimum Blowersequencingschedu-
20 bearing temperature readings 8 leVsBlower Maintenance-
Pump Maximum & Minimum Schedule
Identification of the Blower that
21 bearing temperature readings 9 have been out of service during
last ten days.
Pump flow rate Vs Pump IdentifytheBlowerwhichap-
power consumption peartobe blowing but head
values are below threshold
22 10 values & need frequent
Pump maximum & mini- ForecastingoftheBlowerdown-
23 mum power consumption 11 timebased ontheBlowerRun-
Pump power consumption MTBF of each Blower
24 Vs Pump Maintenance 12
Pump power consumption Vs
25 Filter maintenance(Sand charg-
Effect of Pump maintenance
Vs. Pump powerconsumptio-
26 natmaximumpointof operation Chlorine System
Pump maintenance Vs Graphical Report ,Table forms
27 change in season and Widgets :
28 Preparation of Pump main-
tenance schedulebasedon-
pumpperformance, vibra-
tion,windingtemp&bearingtem
p status,power

[162]
EffectofPumpmaintenan- Chlorine Pressure details

29 ceVs.Bearing vibra- 1
30 View productivity in Tabular 2 Chlorine weight details
Reports
Minimum flow rate by pump Chlorine consumption Vs Water
31 3 Quality Vs VolumeofRawwa-
terVsSeasonalchanges
Maximum flow rate by pump ForecastofChlorineconsump-
32 4 tionfornext onemonth
Total flow rate by Pure wa- Actual chlorine consumption Vs
ter pump house per day 5 Predicted
33 per no. of pump in opera-
TotalwaterutilityVsTotalflo-
34 wrateby Purewaterpumph-
ouseperday
Pump Running time Vs Pump
35 sequencing schedule Recycle Water System
Pumpsequencingschedu- Graphical Report ,Table forms

36 leVsPump Maintenance- and Widgets :
Schedule
Pump maintenance Vs
37 change in Season
ForecastingofInventoryrequi- Recycle water Pump Pressure
38 rementfor next twoyears 1 details
Effectofnaturalcalamityon- Recycle water Sump Turbidity

39 Purewater supply 2 details
Identificationthepumpsthatha- Recycle water Sump Level de-
40 vebeen outofservicedurin- 3 tails
glasttendays.
Identify the pumps which ap-
pear to be pumping but head
and/or flow values are below 4 Recycle water pump flow details
41 threshold values & need fre-
Pure water pump house Recycle Water Sump level Vs
predicted performance Vs Filter maintenanceSta-
42 Actual performance 5 tusVsRawwaterTurbidity VsSea-
ForecastingofthePurewater- ForecastofRecyclewatercollec-
43 supplyby eachpumpfornextO- 6 tionfornext Tendays
Forecasting of the total Pure "Actual Vs Predicted" Recycle
water supplyfromthePurewa- water
44 tersystemfor next OneMonth 7
Filter-
Graphical Report ,Table forms and Widgets

[163]
Bed Flow Details, Sand ,Bed Analyses recent trends in the NHL
Installation, Bed States Histo- 34 value of the bed.
1 ry, Head Graphs of Bed de-
tails
PredictedVsAc- Assumption can be made that,
tualoutput,FlowValues & val- 35 NHL will grow at the same rate
2 ue Position of Beds, NHL over the next four weeks as it was
Values of during the last ten days.
Beds,FiltrationRateofBeds
VariousActivityDetailsof- The Forecasting are assumed to be-
Beds,Compare Water out- gin in either of the following two sce-
3
puts of Beds, Compare Per- narios The NHL of the filter bed ex-
36
formanceofBeds ceeds a triggervalue; The length of
the filter run exceeds a maximumva-
lue.
View productivity in Tabular The NHL value to forecast and the
Reports, MaximumFiltratio- maximum allowable filter run
4 nRateofBed,Minimum Filtra- 37 length are set for each Bed Para-
Similarly the schedule durations,
Maximum Run Length of which determine how long the
Bed, Default Starting NHL for forecast schedule will last are also
5 Bed runs, Default NHL 38 set during bed Parameters.
Using these trends and trigger val-
Maximum Run Length of ues, an initial estimate of which
Bed, Default Starting NHL for 39 beds need Scanning within the
6 Bed runs, Default NHL next four weeks and when is de-
An assumption shall be made that,
Various other parameters to a bed which is currently being
7 be configured for a work are 40 reactivated, re sanded or topped
up will not return to service during
Totalsandonthe- Such beds are excluded from the
works,TopWaterlevels in- hydraulic calculation and cannot
8 DAM,Minimumsumplevel,Def 41 appear in the Skim Schedule.
aultBed startingvalue
Pumps maximum head Thesystemshallforecastoutpu-
starting value, Hydraulicsal- tofthe waterthat
gorithm,Sandbaycapacity, willbefilteredbyeachworkfor-
9 42
DurationofResands thenext oneyearforeachworki-
noperation.
Thesystemshallcapturedata- Systemshallforecastthefollowing-
relatedto quantity of water forthe next fewyears.
flow through the beds & other a. Bedstates
parameter- 43 b. Sand inStorage
setc.Thiswillhelpinarrivingat c. Beds inservice
10 thevolumeflownthroughva- d. Waterfiltered/cleaned
riousbedsand helpsinmana-
gingthebedmaintenance.
Various other parameters to Bed Flow Details in graphi-
11 be configured for a work are 44 cal form (Eachbedstatetobe-
representedusinga different-
colourcode)

[164]
Totalsandonthe-
works,TopWaterlevels in- 45 Bed Number
12 DAM,Minimumsumplevel,Def
aultBed startingvalue
Pumps maximum head starting
value, Hydraulicsalgo- 46 Current Bed state
13 rithm,Sandbaycapacity, Dura-
tionofResands
Thesystemshallcapturedatare-
latedto quantity of water flow
through the beds & other para-
14 47 Flow Since Last reactivation
meter-
setc.Thiswillhelpinarrivingat
Operational data about the
beds such as meterinformatio-
15 nofquantityofwaterflow through 48 Average flow through bed in a
each bed, Head losses, Valve day
positionetcaretobecollectedfo-
reachbed onadaytodaybasis.
System shall collect daily aver-
ages for head loss and valve Bed Volumes.
position and daily total for flow
16 49
values.
Ifaveragesarenotavaila- Eachbedstatetoberepresentedu-
17 ble,spotreadings maybeuse- 50 singa differentcolourcode.
dinstead.
18 Manual data entry 51 Top Sand Level
The system shall allow the da-
ta to edit the live data values
Minimum Sand Level
for flow, head & valve position
19 52
which are captured from OMS
systems for any dates for vari-
ous beds.
Thesystemshallfacilitatema-
nualfeedfor livedataforrecent- 53 No of days in Current Activity
20 daysforwhichnodata currentlyex-
ist.
Thefollowingbusines- The graph shall allow the user to
srules/logicshouldbe used ar- compare the forecastedwork-
21 rive at the NHL Growth para- soutputwiththeactual filter out-
meters 54
put for the corresponding pe-
riod.Thefollowingaretheoutputs:
Collecttheh- Graphs of predicted and actual
22 55
ead,flowandvalveposition da- outputs in current works
taforthelasttendays.
Predicted and actual values shall be
Identify the beds that have indicated by different coloured lines
23 been out of servicefordays- 56 on the graphs.

[165]
Identifythebedswhichappear- Values shall show aggregated at

tobefiltering but head and/or work for a given day.
24 flow values are below thre- 57
sholdvalues.
Identifythebedswhichappear- The shall be able to predict outputs
tobefiltering but the head 58 for the next 4 years.
25 and/or flow values are above
thresholdvalues.
Markdatapointsforwhich- Predicted Vs Actual output
26 theNHLvalueis obviouslytoo- 59
highandexcludethem.
Adjust NHL values to al- Graphs of predicted and actual
27 low for valve position. 60 outputs in current works
Predicted and actual values shall be
Uselinearregressiontocalcu- 61 indicated by different coloured lines
28 latestarting NHLandgrowth- on the graphs.
The system shall calculate de- Values shall indicate aggregated at
rived values of Filtration Rate 62
work for a given day.
29 (The values can be calculated
using the Flow and Bed Area
values)
The system shall calculate de-
rived values of Productivity val- Shallbeabletopredicttheoutputs-
30 ues ( Productivity is a measure 63
forthe next oneyear.
of how hard each bed has
worked during its last completed
31 Thefollowingvaluesshouldbe-
computedas partofproductivity.
a. Productivityvalue
b. Lengthofthe-
run(Forwhichproductivity is-
calculated)(days)
d. Length of the current filter
32 Bed Scheduler Forecasting:
Following pointstobeconside-
redforForecastingthe bed-
Calculate how long each filter-
33 ing bed has been in service
Firewall & Gate
General requirement and system description:

a. ThecompletePLCnetwork&HistorianservershallbeinterfacedwithMJP/ MU-
NICIPAL COUNCILinternetnetwork.
Anenterprisenetworkconnectivitymo-
dule(ENCM)onvirtualprivatenetwork(VPN)tobeestablished atplantsideafter-

[166]
firewallon4Gnetwork.TheinterfaceofMJP/MUNICIPAL COUNCILHisto-
rianwithMJP/MUNICIPAL COUNCILservershallbe developedonVPNnet-
work.Thenetworksystemsecurityshalllimittheaccesstocriticalinformation
toauthorizedpersonalon-
ly.ThisnetworkshallbeprovidedwithproperfirewallorGatewaytoavoid theu-
nauthorizedac-
cess.ThisnetworkshallbealsointerfacedwithTabletdevicesprovidedtoMJP/M
UNICIPAL COUNCIL officers.
b. The fire wall provided shall have proper De militarized zone (DMZ). The
enterprise network connectivitymo-
dule(ENCM)shallcommunicatewiththeplantsidedataserverthroughDemilitar
ized zone (DMZ) for both way communication. Contractor shall develop
the same arrangementat MJP server end so as to establish the safe en-
terprise data communication network between plant and officeend.
UPS & Battery Charger
1.0 GeneralRequirement
Thescopeofthisworkincludessiz-
ing,design,supply,erection,cablingandcommissioningof Uninterruptable
power supply (UPS).
UPS design: Design of UPS shall be based on electrical consumption,

mounting arrangement, interface requirement with control system, general
requirement and specifications below.
Erectiono-
fUPS:ErectionincludesmountingofUPSatdesignatedcontrolroom,layingofca
blefrom UPStocontrolsys-
tem.UPSandbatterychargercanbeprovidedasasingledevice.
Commissioning: Commissioning of UPS includes initial charging of batte-

ries, starting of the UPS panel and conducting the performance trials.
Systemdescription:
Automation of water treatment plant is distributed in five major areas from

control point of view. These areas are provided with Master control system,
micro control system and centralized control system. Uninterruptible Power
Supply (UPS) System of 5 KVA each shall be provided for each controlsys-
temalongwithnecessarycabi-
net&batterystand.ThenumberofUPStobeprovidedper controlsystemshall-
beasbelow.

[167]
Historianatmaincontrolroom at WTP5KVA,1Nos.
SpecificationsofUninterruptiblePowerSupply(UPS)System
The UPS system shall have following accessories:

2x100%parallelredundantchargersandinverters,
1x100%batterybank,
Bypasslinetransformersandvoltagestabiliser,
othernecessaryprotectivedevicesandaccessories
a. The kVA rating of UPS shall be minimum 5 KVA and include 10% spare ca-
pacity guaranteed at 50 deg. C ambient. The UPS shall have an over load
capacity of 125 % rated capacity for 10 minutes
and150%ratedcapacityfor10seconds.TheinvertershallhavesufficientI2tcapabi
litytoclearfault in the maximum rated branch circuit. The sizing of UPS shall
be based on the power factor of the loadsbeingfedsubjecttoamaximumof0.8.
b. Eachofthetwoset-
sof2x100%redundantchargersshallbesizedtomeetthe100%UPSloadplus re-
chargethefullydischargedbatterywithin8hours.
c. TheUPSbatteryshallhavesufficientamp-
hourcapacitytosupply100%fullloadcurrentofUPSfor 480 minutes. ( 8 Hours)
For this, the UPS capacity to be considered as the finally selected UPS rat-
ing, irrespectiveoftheactualloado-
nUPS.Adropof4Vfrombatterystationtotheinverterinputshallbe consideredfor-
design.
d. TheUPSsystemdesignshallensurethatincaseoffailureofmainsinputpow-
ersupplytooneofthe charg-
ers,theotherchargerwhosemainsinputpowersupplyishealthy,shallfeedtooneo
rboththe inverters.
StaticInverters
a. Thestaticinvertershallbesolidstatetypeusingprovenpulsewidthmodu-
lation(PWM)/quasisquare
wave/stepwavetechnique.Theinverterequipmentshallincludeallnecessarycirc
uitryanddevices toconformtorequirementslikevoltageregula-
tion,currentlimiting,waveshaping,transientrecovery, automatic synchronizatio-
netc.
b. The steady state voltage regulation shall be +2% and transient voltage regu-
lation (on application/removal of 100% load) shall be +20%. Time to recover
from transient to normal voltage shallnotbemorethan50msec.

[168]
c. Frequency regulation for all conditions of input supplies, loads and tempera-
ture occurring simultaneouslyorinanycombinationshallbebetter-
than0.5%(automaticallycontrolled).Thetotal harmoniccontent-
shallbe5%maximumandcontentofanysingleharmonicshallbe3%maximum.
Theinverterefficiencyshallbeatleast85%onfullloadand80%on50%load.
d. The inverter shall be provided with suitable HRC fuses at the input and out-
put which will permit proper coordination with other protective devices and at
the same time protect the inverter against damageduetointernal-
faults.Allnecessaryequipmentshallbeprovidedtoprotecttheinverter against
overload, short circuit and 100% loss of load. The inverter shall be self pro-
tecting against damage if energized with full load connected.
e. Inverterequipmentshallincludeallsolidstatecircuitryanddevice-
sincludingstableoscillatoretc.to enable inverters to operate satisfactorily in
parallel sharing mode each inverter taking 50% load during normal opera-
tion. In case of failure of either inverter, 100% load shall automatically be
transferred to healthy inverter without any break and degradation in the
quality of UPS output and disconnectingthefaultyinverterautomatically.
f. Theinverterfailureshallbealarmedandthehealthyinvertershallget-
synchronizingsignalfromthe standby AC source and remain synchronized
within the set limits. The limits for the synchronisation betweenhealthyinver-
terandstandbyACsourceshallbefieldadjustable.
StepDownTransformerandVoltageStabilizer
Thetransformershallbeoflowimpedancetypeandtheratingshallbesuch-
thatextremelyfastfault clearance is achieved even in the largest rated branch
circuit. The overload capacity of the transfor-
mer/stabilizershallnotbelessthan300%for200ms.Thestabilizershallemploysilic
onsolid statecircuitryandtheoutputvoltageregulation-
shallbe2%.Theefficiencyofthestabilisershallbe 95% orbetter.
Batteries
The batteries shall be heavy duty Nickel-cadmium (Ni-cd) type only and
shall be sized for 8 hour of full load operation during non-availability of AC
supply. The Ni-Cd batteries shall conform to IS:10918. For sizing calcula-
tion, an aging factor of 0.8 and a temperature correction factor of 0.935 (ba-
sedontemperaturecharacteristicscurvetobesubmittedbythecontracto-
randatatemperature
of4deg.C).Capacityfactorshallbetakenintoconsideration,ifapplicableandambi
enttemperature shallbeconsideredastheelectrolytictempera-
ture.Thesizingofthebatteryshallbeasapprovedby consultant/owner during de-
tailed engineering. However, contractor shall consider a voltage drop of
4VfrombatterystationtoUPS,whilesizingthebattery.

[169]
Codes and Standards

All Nickel-Cadmium batteries shall be as per the following standards and
codes:
IS:10918SpecificationforventedtypeNickelCadmiu
mBatteries.
IS:1069Qualitytolerancesforwaterforstoragebatteri
es.
6.4 WORKSTATION
a. A PC based Server cum Operator work station(OWS) cum engineering work
Stations (OWS) shall have 32 inch (minimum) flat panel LED displays (dual
monitor) with TFT active matrix, a minimum resolution of 1200 by 1600 pix-
els, minimum 400:1 contrast ratio, minimum dot/pixel pitch of 0.255 mm, and
a minimum brightness of 250 cd/m2. Controls shall be provided on the front
of each monitorforcon-
trast,brightness,horizontal/verticalposition,andhorizontalsize.
b. Each work station shall include, at a minimum, CD quality audio capabilities.

All work stations shall include the current state-of-the-art hardware platform
(CD/DVD rewriteable drives, ports, processor/bus, RAM, etc.) All monitors
shall be designed to minimize reflection and glare from external light
sources. The key boards shall be provided for control, monitoring and pro-
gramming func-
tion.OnenumberA3sizecolourinkjetprintershallbeprovidedalongwithoperatorw
orkstation at each control station. The work station shall be server class ma-
chine. Contractor shall provide all thenecessarycertifi-
cates/documentsissuedbyservermanufacturer.
c. The work station shall perform the functions of Server, Engineer work sta-
tions & operator work station. The term Server/engineer work station refers
to the work stations that have typically been calledEngineeringWorkSta-
tions(EWS),buthavethedualfunctionalityofanEWSandServer.
d. Theworkstationshallbeabletomoni-
tor,view,create,modify,debug,anddocumentanycontrolor informationdis-
play,program,database,orotherfunction.Servershallbeabletostore&operateon
therequiredsoft-
waresfordevelopmentandmodificationofcontrolanddataacquisitionprograms.
e. The work station hardware shall meet system software requirements. Server
shall be supplied with minimum RAID 5 configuration (Redundant Array of In-
dependent Disks) and redundant power supply configuration. System hard-
ware and softwareshallbelatest.Server/ Engineeringstationshallbeabletocal-
luprelateddatastoredintheir associatedPLC.

[170]
f. Theworkstationshallbeusedforhistoricaldatastorageandretriev-
al.Eachworkstationshallconsist ofmoni-
tor(s)asspecifiedabove,operatorkeyboard(s),pointingdevice(s),andsupporting
electronics (operator interface processors, display generators, data highway
communications network equipment,networkaccessoriesetc.).
g. Work station shall have provision for event recording, trending and report
generation. The work stationshallhaveoptiontoreusepreviousengineering-
worklikeoptionstoimporttagsfromPLCand screens with tag from Local HMI
stations dedicated for each PLC. Shall have read/write options to PLC as
well as to Local HMI workstation. Engineering work station shall include the
capability to providebothon-lineandoff-
linedevelopmentofdataacquisitionprogramsandinformationdisplay.
h. The workstation shall perform control, monitoring and operation of all in-
struments/ drivesinteractingwithPLCbasedcontrolsys-
tem.Theworkstationshallbepossibletouseasprogramming stationofthePLCal-
so.
3.04.1 The work station shall basically perform the minimum following func-
tions:
Providepointandclickactionsrequiredfortheoperatortointeract-
withthesystem,suchascursor positioning, display selection, menu selection,
menu item selection, Operator functions shall include local/ remote selec-
tion, A/M selection, open/ close operation, sequence auto, start/ stop se-
lection, ON/OFF, raise, lower, bypassing system, Select and execute
process and equipment controlfunctions.
Followingarethemajorfunctionstobeperformed:
a. Supervisory functions like Select any display to any monitor, and select
display combinations of processControldis-
plays,trenddisplays,alarmdisplays,alarmsummary,groupdisplays,reportsand
barchartdisplaysonanymoni-
tor.Selectpointsandassignparametersfortrenddisplays,group dis-
plays,andbarChartdisplays.Assignpoints,collectionperiods,andprintperiodsf
orreports.The system shall be designed to display and print the following
minimum logs such as general log, shift log, daily log, alarm log ,reports
etc on a scheduled basis, or on operator demand. User configurablea-
larmmessagesthatcanbedisplayedonanygraphicscreen.
b. RuntimeHMIsoftwarerequiredtoconsolidateandpresentallrelevantin-
formationinstandard&user configurable format, through which the plant op-
erator shall be able to monitor and control the plant operation.
c. Each work station shall include key lock and/or password protection to re-

[171]
strict access to critical functionstobeperformedbyauthorizedpersonnelon-

ly.Thesefunctionswillbedefinedbytheowner duringthedesignphaseofthepro-
ject.
d. Programming station shall have access to the processor of the control

system for programming. Programming shall be user friendly &shall not
require special computer skills. Programming, self- diagnostics, testing of
sequence, simulation and sequence modification shall be possible on the
programmingconsole.
e. Programmingshallbepossibleinanyofthefollowingformats:
Blocklogicrepresentingtheinstructionsgraphically.
Ladderdiagrams.
Universally accepted latest technique
f. Aforcingfacilityshallbeprovidedforchangingthestatesofinputsan-
doutputs,timersandflags to facilitate fault finding and other testing re-
quirements. It shall be possible to display the signal flowduringoperatio-
noftheprogram.ProgrammingshallbepossibleOFFline.
g. ANOR-
MAL/TEST/PROGRAM/OFFlockableselectorswitchshallbeprogrammed.
Incaseof testmodeofoperation,alloutputsshallbeblocked.
h. Provision shall be made for erasing and duplicating the user program
and long term storage facilitiesshallbeprovidedwiththehelpofEPROM-
fromworkstation.
i. Manual intervention shall be possible at any stage of operation. Protec-

tion commands shall havepriorityovermanualcommandsandmanual-
commandsshallprevailoverautocommands.
Specifications of engineering/operating work station

Sr. Description Particulars
Latest with adequate no. of Ethernet/ LAN connectivi-
1 CPU ty port
2 Main memory Min 10 GB or higher

[172]
3 Drives Drives DVD R/W
4 Hard disk Min. 3 TB
5 Monitor 32" TFT Graphic LED
6 Accelerator 8 MB or better
7 Communication 2 serial plus one parallel, min 6 USB port

port
8 Expansion slots 5
9 Other Features 101 Keys Key board OR latest and wireless Mouse
Industrial grade furniture (Two computer tables & Four

10 Accessories chairs) for work station, accessories & its prin-
ter,asapprovedduringdetailedengineering
a. General MS Windows 8 and all other software
requiredforsystem functionality, antivirus, etc. The
11 Software operating software shall be latest & shall capable to
operate PLC, SCADA, Historian & Energy manage-
ment software of all standard & reputed contractors
b. Application specific to suit specific requirement
3.05 Printer
One number A3 size colour laser inkjet duplex printer with networking
capability per main PLC at each control room shall be provided. It shall
print out all alarm/ trip conditions and event changes in plant status
along with date and time of occurrence. The least count of time for event
recording shall not be more than 100 milliseconds. The printer shall be
able to print the trends, displays and graphs also.
Software
a. Thebiddershallprovideentiresetofsoftwarerequiredbythesystemfor-
meetingthefunctionaland parametric requirements of the specification like
implementation of control logic, operator station dis-
plays/logs,storage&retrievalofprogram.
b. The software and programs shall include high level languages as far as
possible. The bidder shall providesufficientdocumentationandprogramlis-
tinginviewofmakingmodificationsinprogramata laterdate.

[173]
c. Industry standard Latest operating systems like WINDOWS8/10 etc. to

ensure openness and connectivity with other system in industry standard
protocols (TCP-IP/ OPC etc.) shall be provided. The system shallhaveuse-
rorientedprogramminglanguage&graphicuserinterface.
d. All system related software including Real Time Operating System, File
management software, screen editor, database management software.
On line diagnostics/debug software, peripheral drivers software and latest
versions of standard PC-based software and latest WINDOWS based
package-
setc.andanyotherstandardlanguageofferedshallbefurnishedasaminimum.
e. All application software for PLC system functioning like input scanning,
data acquisition, conditioning processing, control and communication and
software for operator interface of monitors, displays, trends, curves, bar
charts etc. Historical storage and retrieval utility, and alarm functionsand-
wirelessinterfacedriversetc.shallbeprovided.
f. The software shall be password protected. The Bidder shall provide soft-
ware locks and passwords to buyers engineers nominated by the manage-
ment authority at site for all operating & application software so that buyers
engineers can take backup of these software and shall be able to perform
modificationsatsite.
Software Documentation and SoftwareListings
a. All technical manuals, reference manuals, users guide etc., written in Eng-
lish those are required for modification/editing/addition/deletion of fea-
tures in the software of the PLC System shallbefur-
nished.TheBiddershallfurnishacomprehensivelistofallsystem/applicationsoft
ware documentationaftersystemfinalisationforownersreviewandapproval.
b. All the software listings including Source code for application software, all
special-to-project data filesetc.shallbesubmittedbytheBidder.
c. Software Licences : The Bidder shall provide software license for all soft-
ware being used in PLC- SCADA. The software licenses shall be provided
for the MJP/Municipal Council site and shall not be hardware/machine-
specific. That is, if any hardware/machine is upgraded or changed, the
same licenseshallholdgoodanditshallnotbenecessaryforownertoseekanew-
license/renewlicense duetoupgradation/changeofhardware/machineinPLC-
SCADAatsite.Alllicensesshallbevalid forthecontinuousservicelifeoftheplant.

[174]
d. Each master PLC shall be provided with one Runtime & One development
version software for PLC & SCADA with all license capability. (..) License
for Master PLCs (Including Runtime & One development version) & ()
License for SCADA (Including Runtime & One development version)
e. Each master PLC for filter section shall be provided with dedicated License for
the associated Micro PLCs & HMI programming with all license capability.
f. (.........) License for micro PLCs (Including Runtime & One development version)
& (.........) License for HMI (Including Runtime & One development version)
g. Historian shall be provided with dedicated Runtime & development version of Li-
cense with all licensecapability.
h. Energy management, Vibration monitoring & Alarm management software
shall be provided with dedicated Runtime & development version of License
with all license capability.
i. Bidder to provide suitable OS for server class workstation which must be suit-
able to operate the requested Licenses. All the License Required to run this
project on the server is a responsibility of thebidder.
j. Software Upgrades: As a customer support, theBiddershallperiodicallyin-

formthedesignatedengineeringofficeroftheowneraboutthesoftwa-
reupgrades/newreleasesthatwould be taking place after the system is
commissioned so that if required, same can be procured & implemented at
site. The up gradation software until the completion of last year of Annual
MaintenanceContract(AMC)shallbeunderscopeoffcontractor.
Databases
AnI/Olistdatabasewillbedevelopedtoallowdesigninformationtransmittalbetwe
entheownerand theContrac-
tor.AsystemdatabaseshallbedevelopedthatwillallowaccessoftheI/Osbythecon
trol system.
In the databases, a unique identifying code (tag name) shall be assigned to
each analog, digital, calcu-
lated,datalinked,ormanuallyinsertedpoint,bywhichthepointmaybereferencedb
yboththe operator and the system. The code shall consist of at least 14 al-
phanumeric characters. The code format shall be as determined by the Pur-
chaser and shall not be subject to any Contractor requirements.
A historian database shall be developed as a data acquisition system
I/O listdatabase
The owner shall provide initial information, including the tag name, function-
al point description, and electricalcharacteristicsfortheproces-

[175]
sI/O,usingacommerciallyavailabledatabaseprograminan agreeduponfor-
mat.AftertheinitialI/Olistdatabasesubmittalbytheowner,thecontractorshallbe
responsibleformaintenanceofthedatabaseuntilthesystemisshipped-
totheprojectsite.
Alarm priorities, data storage requirements, and similar information will be
submitted by the owner duringdetailedde-
sign.Theownermay,fromtimetotime,provideotheradditionsorrevisionstothe
database that the Contractor shall incorporate into the master database.
The additions or revisions maybeinhardcopyorelectronicfor-
mat.Atthetimeofshipment,theContractorshallfurnishanas- shippe-
dI/Olistdatabasetotheowner.Theas-
shippeddatabaseshallbeinthesameformatasthe initial I/O list database pro-
vided by the owner. The Contractor shall use the I/O list database to gene-
ratethesystemdatabase.
Systemdatabase
The Contractor shall provide a system database covering all system points
and their attributes. The database organization shall be a standard database
format, so that a point shall be stored as a file record and the attributes of
that point shall be stored in the file as fields. Each point shall be supported
by a set of parameters that represent the point properties. Typical point pa-
rameters shall include, but shall not be limited to, tag name functional point
description, engineering units (analog points), state descriptions (digital
points), scan rate, alarm limits, and value.
DiagnosticPrograms
Diagnostic programs shall be provided for the following diagnostic tests:
a. Initiationchecks.
The initiation checks shall be initiated each time power is applied to a con-
trol or operator interface processor. These checks shall monitor the start up
sequences of the processor to ensure that the processor has been success-
fully powered up and in the proper working condition.
b. On-linediagnostics.
Theon-linediagnosticsshallbeexecutedautomaticallyduringnormalon-
lineoperationofthecontrol and operator interface processor, providing conti-
nuous monitoring of the processor functions, includ-
ing,butnotlimitedto,memoryfunctions,andcommunicationsfunctions.
Data highway communications network, I/O bus communication network,
RS-485 bus network, wirelesscommunicationnet-
work,controller,card,anderrorstatusinformationshallbeavailable.The system
shall present this information in English terms. Cross-referencing of numeric
values to a diagnosticmanualforinitialproblemdeterminationisnotacceptable.

[176]
Hardware diagnostic test software shall be provided for the following com-
puter equipment. These diagnostics shall include fault analysis to the circuit
board level:
i. Memories.
ii. Peripheralanddisplaydevices.
iii. Allcommunicationsnetworks,etc
iv. PeripheraldeviceslikeMassmemo-
ries(disks,etc.),Multiplexingsystem,Printers
"Watchdog" diagnostics shall be provided which can periodically check the

operation of all communications network nodes and alarm detected prob-
lems. Time synchronization between all nodes shall be periodically checked
and set by the control system network to prevent inaccurate timing of alarms
ProgrammingTechniques
The programming format shall be IEC 61131-3 compliant ladder diagram
(LD), function block diagram (FBD), sequential function chart (SFC), and
structured text (ST) languages. The Programmable Automation Controller
shall organize user applications as Tasks, which can be specified as conti-
nuous, periodic, or event based.
The programming techniques shall compliance with following features:

a. Periodictasksshallrunviaaninterruptatauser-
definedintervalinminimumincrementsfrom1mS to 2000 S. The increment pe-
riod will be decided and approved by consultant/owner during detail engi-
neering. The interrupt mechanism of periodic and event tasks shall adhere
to the IEC 61131-3 definitionofpre-emptivemultitasking.
b. The PLC shall be able to accommodate a maximum of 32 individual tasks, of

which one can be continuous. The periodic and event tasks shall have an
associated, user-assignable priority from 115 (1 being the highest priori-
ty), which specifies that tasks relative execution priority in the multitasking-
hierarchy.
c. Each task shall have a user-settable watchdog timeout, which is unique to

that task. Each task can include a maximum of 100 programs, which can be
prioritized for execution within the task. Each program shall be able to in-
clude routines that could be programmed in LD ( Ladder Diagramme ), FBD
( Functional Block Programme), SFC (sequential function charts ) , or
ST(structured text) languag-
es.Oneoftheroutinescanbespecifiedasthemainroutineandonecanbespecified
asan optional fault routine. All routines shall be capable of being edited
when online. The number of routinesthatcanbecontainedinaprogramislimite-

[177]
donlybymemory.
d. Tag naming convention shall adhere to specifications in IEC 61131-3. Tags

may be created offline, on-
line,andatthesametimetheroutinelogicisentered.Thesystemshallhavethecapa
bilitytostore user tag names in the PLC. Tags shall be available to all tasks
in the PLC or limited in scope to the routineswithinasingleprogramasdefi-
nedbytheuser.
e. Itshallbepossibletoprogramladderdia-
gram(LD)rungswiththefollowingrestrictions:
i. Seriesinstructioncountlimitedonlybyusermemory
ii. Branchextensionslimitedonlybyusermemory
iii. Branchnestingtosixlevels
It shall be possible to insert ladder diagram (LD) rungs anywhere in the pro-
gram, even between existing rungs, so far as there is sufficient memory to
accommodate these additions. A single program command or instruction
shall suffice to delete an individual ladder diagram (LD) rung from memo-
ry.Aclock/calendarfeatureshallbeincludedwithintheCPU.Accesstothetimeand
dateshall befromtheprogrammingterminaloruserprogram.
f. Latchfunctionsshallbeinternalandprogramma-
ble.Thesystemshallhavethecapabilitytoaddress software timers and software
counters in any combination and quantity up to the limit of available memory.
All the operations of these instructions into memory shall be handled by the
CPU. Instructions shall permit programming timers in the ON or OFF Delay
modes. Timer programming shallalsoincludethecapabilitytointerrupttimingwi-
thoutresettingthetimers.Countersshallbe
Programmablebyusingup-incrementanddown-
increment.Timerinstructionsshallhaveatimebase of 1.0 ms. The timing range
of each timer shall be from 0 2,147,483,648 increments. It shall
be possibletoprogramanddisplayseparatelythetimer'spresetandaccumu-
latedvalues.
g. TheProgrammableAutomationControllershallstoredatainthefollowingformats:
i. Booleanvalues(0or1).
ii. Shortintegernumbersrangingfrom-128127.
iii. Integernumbersrangingfrom-32,76832,767.
iv. Double integer numbers ranging from -2,147,483,6482,147,483,647.
v. Floatingpointnumbersconsistingofeightsignificantdi-
gits.Fornumberslarger thaneightdi-
gits,theCPUshallconvertthenumberintoexponentialformwitha
rangeof1.1754944E-38to3.402823E+38.
vi. Longintegernumbersrangingfrom-

[178]
9,223,372,036,854,775,808
9,223,372,036,854,775,807.
h. The Programmable Automation Controller shall support for integer and

floating point signed math functionsconsistingofaddi-
tion,subtraction,multiplication,division,squareroot,negation,modulus and
absolute value. Trigonometric instructions supported must include Sine,
Cosine, Tangent, Inverse-
Sine,InverseCosine,andInverseTangent.Theseinstructionsmustfullysupportf
loating- point-
math.AdditionalfloatingpointinstructionssupportedmustincludeLog10,Natura
lLog,and Exponential.
i. It shall be possible to complete complex, combined calculations in a single

instruction, such as flow totalizing or equations of the format ((A+((B-
C)*D))|E).File function instructions supported shall also include-
Sort,Average,andStandardDeviation.
j. TheCPUshallsupportindexedaddressingofarrayele-
ments.Arrayelementmanipulation instruc-
tions,suchasarraycopy(COP),arraycopywithdataintegrity(CSP),andarrayfill
(FLL),arraytoarray(MOV),elementtoarray(FAL),arraytoelement(FAL),andfirstin
- firs-
tout(FIFO)shallbesupportedbythesystem.Thefourfunctionandmathinstructions
and instructions for performing logical OR, logical AND, exclusive OR, and
comparison instructions, such as less than, greater than, and equal to shall
be included within the sys-
tem.Allinstructionsshallexecuteoneithersinglewordsorarrayelements.
k. PLCshallhaveajumpinstructionthatwillallowtheprogrammertojumpoverportions
oftheuserprogramtoaportionmarkedbyamatchinglabelinstruction.
l. PLC shall have an ability to provide a master system clock and the IEEE
1588 PTP ver-
sion2CIPSyncobjecttoallowtimesynchronizationandtransportandroutingofa
systemclocktothecontrolsystemandcommunicationsystem.
m. Theprogramformatshalldisplayallinstructionsonaprogrammingpanel-
withappropriate mnemonicstodefinealldataenteredbytheprogram-
mer.Thesystemshallbecapableof providing a HELP utility, which, when in-
voked by the programmer, will display a list of instructions and all data and
keystrokes required to enter an instruction into the system memoryonthepro-
grammingpanel.
n. Thesystemshallhavethecapabilitytoenterrungcommentsaboveladder-
diagram(LD) rungs. These comments may be entered at the same time the

[179]
ladder logic is entered. The capability shall exist for adding, removing, or mod-
ifying logic during program executioninroutinesofladderdia-
gram(LD),functionblockdiagram(FBD),sequential function chart (SFC), and
structured text (ST) languages. When changes to logic are made or new logic
is added, it shall be possible to test the edits of such logic before removalof-
thepriorlogicoccurs.
o. Itshallbepossibletomanuallyset(force)allhardwireddiscreteinputoroutput
pointstoeitherONorOFFfromtheprogrammingpanel.Itshallalsobepossible to-
manuallyset(force)ananaloginputoroutputtoauser-specifiedvalue.Removalof
theseforce-
dI/Opointsshallbeachievedeitherindividuallyortotallythroughselected keys-
trokes.TheprogrammingterminalshallbeabletodisplayforcedI/Opoints.
p. PLCshallhavetheabilitytocreateAdd-
onProfiles,includinggenericprofilestoprovide openintegrationonthird-
partymodulesusedintheProgrammableAutomationController sys-
tem.PLCfilesshallhavetheabilitytobeexportedandeditedintextorXMLformat.
Standards andCertificates
a. TheProgrammableAutomationControllerprocessorshallbeableto-
withstandconducted testsasoutlinedinthefollowing:
Sr. Environmental Test Industrial Standard

No. IEC
1 Temperature 600682
1 IEC
2 Humidity IEC 60068230

3 Vibration IEC 6006826
4 Shock IEC
60068227
5 Radiated Emissions CISPR 11: Group 1, Class A
6 Conducted Emissions CISPR 11/22:
Group 1, Class A
7 Conducted Emissions Telecomm EN6100064
8 ESD Immunity IEC 6100042
9 Radiated RF Immunity IEC 6100043
10 EFT/B Immunity IEC 6100044
11 Surge Immunity IEC 6100045
12 Conducted RF Immunity IEC 6100046
13 Magnetic field Immunity IEC 6100048
14 AC Voltage Variation IEC 61000411
15 DC Voltage Variation IEC 61000429
16 Oscillatory Waves IEC 61000418
b. PLCcontrollershallbecertifiedby:

[180]
Sr. Certification De-

a c-UL-us (certified for US and Canada)
b UL Listed for Class I, Division 2 Group A,B,C,D Hazardous Locations
CE (European Union 2004/108/EC EMC Directive), compliant with:

EN 61326-1; Meas./Control/Lab., Industrial Requirements
c EN61000-6-2;IndustrialImmunity
EN61000-6-4;IndustrialEmissions
EN61131-2;ProgrammableControllers(Clause8,ZoneA&B)
Ex European Union 94/9/EC ATEX Directive, compliant with:
EN60079-15;PotentiallyExplosiveAtmospheres,Protectionn
EN60079-0;GeneralRequirements
II3GExnAIICT5X
5.0 CommunicationSystem
a. The PLC system shall be provided with necessary interface hardware, and
software for dual Fibre optic connectivity with other stations and Historian
server. PLCs shall be provided with necessary interface hardware, wire-
less modem, and software for wireless connectivity of micro PLCs with
mas-
terPLCs.ThePLCsystemshallbeprovidedwithnecessaryinterfacehardwarea
ndsoftwarefor communication with programming devices, energy meters,
printers on Ethernet/mod bus/RS 485 communicationfortwo-
waytransferofsignalsforthepurposeofinformationsharing.
b. ThecompletePLCnetwork&HistorianservershallbeinterfacedwithMJP/ MU-
NICIPAL COUNCILinternetnetwork.
Anenterprisenetworkconnectivitymo-
dule(ENCM)onvirtualprivatenetwork(VPN)tobeestablished atplantsideafter-
firewallon4Gnetwork.The same network shall be establishe data MJPser-
verend. Theinterfaceof MJPHistorianwithMJPservershallbedevelope-
donVPNnetwork.Thenetwork system security shall limit the access to criti-
cal information to authorize personal only. This network shallbeprovided-
withproperfirewallorGatewaytoavoidtheunauthorizedac-
cess.Thisnetworkshall bealsointerfacedwithTabletdevicesprovidedtoMJP
officers.
c. HistorianservershallbeprovidedwithbackupservernamedDataserve-
ratplantend.Thedataserver shallbeupdatedperiodicallyinlinewithmainhisto-
rianserver.Thefirewallprovidedshallhaveproper Demilitarized-
zone(DMZ).Theenterprisenetworkconnectivitymodule(ENCM)shallcommu
nicate with the plant side data server through De militarized zone (DMZ)
for both way communications. Contractorshalldevelopthesamearrange-
mentatMJPserverendsoastoestablishtheenterprise datacommunication-
networkbetweenplantandofficeend.

[181]
d. Thenecessarysoft-
ware,hardware,antenna,towershallbeprovidedbycontractor.Thestandardan
d reputedprivateoperatorslikeI-
dea,BSNL,Airtel,Vodaphoneshallbeemployedforestablishingthe private-
networkintermsofenterprisenetworkconnectivi-
ty.Thepermonthrentandotherexpenses required for running this network
until last day of Annual Maintenance Contract (AMC) shall be beared by
the contractor. Contractor shall also mention about the penalty condition
clause, for the penalty to be charged to the communication service provid-
er for their network down time period, in thecontractwiththem.
e. The exact data structure shall be as decided during detailed engineering.

All required plant data shall be transferred to/from through this ensuring
completesecurity.
f. The exact number of points to be transferred through the above communi-

cation link and the format ofthedatashallbefinalisedduringdetailedengi-
neering.Thecontrolsystemshallhaveopensystem architecture so that ex-
pansion of the system shall be possible by adding extra stations on the
data highwaymodularlywithoutdisturbingoperationofrestofthesystem.
g. The communication system shall include a redundant System Bus with hot
back-up and other applicablebussystemslikecubicle-
bus,localbus,I/Obusetc.
TheCommunicationSysteminsidetheplantshallhavefollowingminimum-
features:
a. Redundantcommunicationcontrollersshallbeprovidedtohandlethecom-
municationbetweenI/O Modules and PLCs and between PLCs and op-
erator work station. During normal operation 50% loading and during
worst case only 70% loading of the communication throughput shall be
utilized.

182
b. The design shall be such as to minimise interruption of signals. It shall

ensure that a single failure anywhere in the media shall cause not more
than a single message to be disrupted and that message shall automati-
cally be retransmitted. Any failure or physical removal of any sta-
tion/module connected to the system bus shall not result in loss of any
communication functiontoandfromanyotherstation/module.
c. If the system bus requires a master bus controller philosophy, it shall

employ redundant master buscontrollerwithautomaticswitchoverfacility.
d. Built-in diagnostics features shall be provided for easy fault detection.

Communication error detection and correction facility shall be provided
at all levels of communication. Failure of one busandchangeovertothes-
tandbysystembusshallbeautomaticandcompletelybumplessand thesa-
meshallbesuitablyalarmed/logged.
e. The design and installation of the system bus shall take care of the envi-
ronmental conditions asapplicable.
f. Data transmitting speed shall be sufficient to meet the responses of the

system in terms of dis-
plays,controletc.plus25%sparecapacityshallbeavailableforfutureexpansio
n.
g. Single-
mode8coreFibreopticcablesshallbeemployednecessaryapplications.Theb
iddershall furnish details regarding the communication system like com-
munication protocol, bus utilisation calculation-
setc.forownersreviewandapproval.
h. TheContractorshallfurnishallnecessarydevicesforestablishingdata-
communicationssystem. These devices(rack mounted) shall be installed
in system cabinets/Network cabinet in power block building , and may
include, but not be limited to, Ethernet switches with built in fibre optic
ports, fibre-optic patch panels signal conditioners, and prefabricated
cables ,with all necessary powerdistribution-
strips,powerreceptacles/boxes,andothersupportingelectricalinfrastructure
i. The Contractor shall furnish line drivers or short-haul modems for both
ends of all interfaces for cable lengths of longer than 50 feet (15 meters)
for all RS-232 interfaces, or longer than 3,900
feet(1,200meters)forallRS-422andRS-485interfaces.
Contractor No. of correction Executive Engineer

183
j. AllEthernetbasedcommunicationnetworksshalluseCate-
gory5e(orbetter)unshieldedtwisted pair UTP for cables run inside the
control room and single-mode, 8 core fibre optic cable for cables run
outside the control room or between buildings. Twisted pair cable net-
works shall conform to ISO 8802.3 100BASE-TX or 1000BASE-T or
newer requirements. Fibre-optic cable networks shall conform to ISO
8802.3 100BASE- FX or 1000BASE-SX or newer requirements. The
network shall be designed for maximum speed through the use of Giga-
bit (or faster) componentswherepossi-
ble.Ethernetcommunicationsnetworksshallincludeallnecessaryhubs,
switches, connectors, patch panels, fan out kits, taps, repeaters, cables,
terminators and any other components required for a complete commu-
nications system. The entire communication networkshallberedundant.
Thecommunicationsystemhardwareshallmeetthefollowingrequirements:
a. Industrialswitchershallbewithmodularde-
sign,flexibleconfigurationandshallsupportoperating tempera-
ture0to55C,forfanlessdesign
b. Anti-
electromagneticinterferenceperformanceismorethanfourle-
vel;supporttrouble-free communica-
tion,withzeropacketlosstechnology
c. SupportVLAN(VirtualLAN)sub-
network,supportportsecurity(portMACaddressbinding,port accesscon-
trol),safeisolatedindustrialcontroldata
d. Ringnetworkself-
healingrecoverytime<5ms/switchestoensurenetworksecurity
e. Toensuretheequipmentworkingstabilityinharshoperatingenviron-
menttheProtectiongradeshall beIP40
f. Switchshallhaveafive-yearswarranty
g. Failureofanysystemorcomponentconnectedwiththecommunication-
systemshallnotfailthe communicationsystemoranyothersystemor-
component.
h. Thecommunicationnetworkshallberedun-
dant,includingredundanthighwayinterfacemodules&all relatedaccesso-
ries.Boththeredundantdatahighwaysshallbeactivesimultaneouslyatalltimes
.
i. Allstationsinterfacedonthehighwaysshallhaveaccesstodataonthe-
highwayandmaysenddata to thehighway.
j. The data communication system shall be designed to be loaded not more
than 40 percent for Ethernetand60percentforToken-

184
netunderworstcaseconditionstoallowforfutureexpansion.The methodofex-
aminationandcalculationshouldbesubmittedbythecontractor.
k. ThedataHighwayspeedandaccesstimeshallbesuchthatanyoperatorac-
tionmustbeexecutedin 1 second or less under upset as well as steady
state conditions. The Contractor shall confirm his guaranteedresponseti-
meunderalloperatingconditions.
l. Thedatacommunicationsys-
temsprotocolshallincludesuchacodesasCRC(CycleRedundant Check) ,
parity error, etc, to detect errors and take protective action to assure a
high degree of transmissionreliability.
m. Information about communication protocol (e.g. massage structure, ad-
dressing and direction of transmis-
sion,formatofdatablocklength,modulationandtransmissionmedium),diagno
sisfunctions and equipment, automatic recovery for failed stations and
access time per station, etc., shall be describedandsubmittedindetailby-
thecontractorinhisproposal.
n. Incaseanyerrorisoccurredthedatacommunicationsystemshallbesmarte-
noughtoautomatically request the data to be retransmitted or the hard-
ware must simply notify the software and the latter mustdecidewhatac-
tiontobetaken.Iftherearestillerrorsinthedatatransferafterseveralattempts,
anautomaticmeaningfulsafereactionshallbeper-
formed.(e.g.switchingoffdefectivecomponents orswitchingtoredundan-
cy,etc).
o. Allthecommunicationhighwaysshallbeprotectedfromanykindofabra-
sion,mechanicalvibration, mois-
ture,corrosioncauseofcommunicationfailure.
p. Datacommunicationssystemshallbeinaccordancewithinternationals-
tandardsandrecommended require-
ments,suchasIEC,IEEEandsoon.Themostimportantisthattheanti-
noiseinterferenceof allsystemsshouldmeetIEC60255-
4specification,orIEEErecommendedrequirements.
q. Theplantcontrolsystemcommunicationinterfaceshallmonitorandre-
portwhethertheequipmentis innormalworkingconditionor-
not.Inadditiontoprocessinformation,thecontrolsystemshallalso access-
thecontrolsystemfaultdiagnosisinformationthroughthecommunicatio-
ninterface.
r. Whenfailureoccursinthecontrolsys-
tem,operatorcangetinformationatoperationstationLED.

185
s. Allnecessarycommunicationinterfaceequipmentincludesnetworkinter-
facecards,drivers,network communicationcablesandcompleteinterface-
software.
5.02 ThirdpartyInterfaces(TPI)
a. The Contractor shall provide all hardware and drivers to communicate
with owner-furnished foreign devices, such as personal computers and
programmable logic controllers (PLC) as defined. The communications-
mediumshallbetwistedshieldedcopperconductorsforindoorlocation-
sandthose areas not subjected to induced signal noise. For communica-
tions networks routed outdoors or in areaswhereinducedsignalnoiseis-
probable,fibre-opticcableshallbeprovided.
b. TheContractorshallfurnishlinedriversorshort-
haulmodemsforbothendsofallinterfaces. The Contractor shall also furnish
line drivers or short-haul modems for both ends where the Contractor's
equipment design recommends their use for isolation or other require-
ments.
c. The interfaces shall permit the data generated in the foreign devices to be
used in any process controller, displayed on any operator work station, or
used in any report. The interface shall also allow the configuration of push
buttons and control stations on the control station operator work station,
which can be further used to start and stop motors, open or close valves,
etc., that are controlledbythePLCsasforeigndevice.
ControlandInformationDisplayFunctionsasasupervisoryfunction
The display functions shall be assignable by the operator to work station
within the system. All systempointsincludingana-
log,digital,andcalculatedvariablesshallbecapableofbeingdisplayed on the
operator work station monitors. The use of colour on the displays shall
serve to rapidly draw operator attention to important data. The colour of
each item shall be as determined by the owner duringthedesignphaseof-
thesystem.
TrendDisplays.
Trend displays shall consist of a time plot of a minimum of five points con-
currently. Each trace shall be in a unique colour. Alphanumeric informa-
tion shall be overlaid on the same screen to identify
points,scales,currentvalue,andrelatedinformation.Thelatestvalueshallbeap
pearingattheright- handsideofthe-
screen.Timeshallbeplottedonthehorizontalaxis.Theoperatorshallbeabletos
et the zero and full-scale values for each trended variable in any screen
location. The system shall permit the operator to set the grid roll speed
and the interval between time lines. The system shall provide standard

186
trend displays with variable full-scale time ordinates. All trends shall be
backward and forward scrollable from the trend start time. Selection of
points to be trended shall be menu driven. The system shall allow any
system variable to be trended, and shall allow points from short- term and
long-term storage to be trended. The trend display period between points
on trends using datafromshort-termandlong-
termdatastorageshallbethesameasthestoragefrequencyselected forthose-
points.Trendingresolutionshallnotbecoarserthan1/2percentfullscale.
The system shall also provide the capability to incorporate trend displays
into any user created controlorinformationdis-
play.Trenddisplayswillbedefinedbytheownerandshallbeconfiguredat the-
factorybythebidder.
BarChartDisplays.
The system shall display dynamic bar charts. The bar chart format shall
consist of a series of separate display pages, each with a minimum of 20
vertical or horizontal bars. Each bar shall represent the value of a mea-
surement. Alphanumeric information shall be overlaid on the same screen
to identify points, scales, current value, and related information. Each
point shall have high andlowalarmlimitsvaluesthatshallbe-
shown.Anybarinthegroupthattraversesbeyonditslimits shallbeidentified-
byachangeincolour.Barchartdisplayswillbedefinedbytheownerandshallbe
configuredatthefactorybythecontractor.
X-YPlotDisplays.
Upon operator request, the system shall graphically display the relation-
ship between two analog points on X-Y plots. This display shall permit up
to four points on the Y axis to be plotted against a singlepointontheX-
axis.Thesystemshallhavethecapabilitytostorecurves(valueofYexpressed
asafunctionofXsuchasapumpcurve)andimposethecurvesontheX-Yplots.
Alphanumeric information shall be overlaid on the same screen to identify
points, scales, current values,andrelatedinformation.X-
Yplotdisplayswithstaticcurveswillbedefinedbytheownerand shallbefactory-
configuredbythe.
ProcessControlDisplays.
The CONTROL SYSTEM shall include process control displays designed
to provide the means for the operator to monitor and control the plant
equipment. Each process control display shall contain textual, geometric
graphic, dynamic analog trending, dynamic bar chart, and alarm informa-
tion representing plant systems, equipment, and other process informa-
tion.
The process control displays shall be implemented on a high-resolution
display system that, at a minimum, includes the following capabilities:

187
Each display shall allow selection of at least 256 colours from a colour pa-
lette of at least 65,536 colours. Alphanumeric characters shall be display-
able in different sizes.
Dynamic numeric data linked to analog variables shall display the current
numeric value of the variable, scaled as specified in the database, with
engineering units.
The latest in pictorial abilities such as automation of symbols with three-

dimensional effects applied to lines and symbols shall be available. Stan-
dard geometric shapes shall include, as a minimum, lines, polygons, rec-
tangles, arcs, ellipses.
Standardgeometricsym-
bols(tanks,vessels,pipe,valves,etc.)andtheabilitytocreatenewsymbols
usingstandardsymbolsandstandardgeometricshapesshallbeincluded.
The capability to fill any closed geometric shape with any available colour
shall be included. This capabilityshallallowfillinproportiontothevalueofana-
nalogvariable,andtoselectthefillcolourin responsetotheanalogvariableorac-
cordingtothestatusofadiscretevariable.
Thedisplaysystemshallalsoincludethefollowinguserselec-
tablecapabilities: Crea-
tion,modification,andselectionofcoloursinthecolourlibrary.
Definitionofattributesofalltextualandgeometricgraphicele-
ments,suchascolour,lineweight,line
type,blinking,anddynamicconditionallinkagetosystemvariablesandattribute
s.
The system shall provide, at a minimum, the capability for any process
control display to show 200 dynamic variables per screen (analog and
digital) and/or geometric symbols, control 10 data entry points, and control
100 target points. Based on an operator clicking on or selecting a dynamic
varia-
ble,thesystemshallprovidethefunctionalitytojumpdirectlytoitspointdetaildispl
ay.Through operatorentryofavalueintoadataentry-
point,thesystemshallprovidethefunctionalitytostoreand usethatvalueforpro-
cessandequipmentcontrol,forexample,sendingoperationlimitsoftheplantor

188
othermanuallyentereddatatothedispatchsystemviadatabase-
points.Byanoperatorclickingonor selectingatarget-
point,thesystemshall,ataminimum,providethefollowingfunctionality:
Activation of a "pop-up" control station as defined below, to allow process

and equipment control.
Activationofadisplayand/ortrend
The system shall be sized to store and display the quantity of process
control displays to be specified. Process control displays shall be defined
by the owner and shall be factory configured by the bidder.
Pop-upcontrolstations
The system shall include pop-up control stations that the operator can call
up to operate the plant equip-
ment.Eachcontrolstationshall"popup"onthecurrentprocesscontroldisplaywh
enselected bytheopera-
tor.ThesystemshallnotallowsimultaneousdisplayOperatorInterfaceDisplays
/Logsof morethanonepop-upcontrolstationonanyprocesscontroldisplay.
Thesystemshallincludealibraryofpredefinedpop-
upcontrolstationtemplatesthatshallbeusedto create control stations for op-
erator control of plant equipment. Templates provided shall include au-
to/manual analog control stations, bias stations, hand stations, ratio sta-
tions, motor control stations, valve/damper control stations, equipment
tag-out stations, pulse accumulator control stations, and multiple mea-
surement control stations. The system shall allow the user to add to or
modifytemplatesinthelibraryaswellastocreateauniqueuserlibrary.
Each control station template shall be available as many times as needed
by defining the text and databasepointinformationspecifictoaparticularpie-
ceofplantequipment.Thesystemshallallowa controlstationforanyplantdevice-
tobeselectedfromasmanyprocesscontroldisplaysasrequired forproperplan-
toperation.
TextDisplays
The control system shall include text displays to provide information to aid
in the operation of the plant and its equipment. Text displays shall include
equipment permissive displays, help displays, equipment run time dis-
plays, and sequence displays.
Equipmentpermissivedisplaysshallbeprovidedtodynamicallyindica-
tetheconditionsthatmustbe met for a designated piece of equipment to
start or operate. Colour differentiation shall be used to informtheoperato-
rofthecurrentstatus(allowordisallowoperation)ofeachcondition.Accesstoan

189
equipmentpermissivedisplayshallbebyasingleoperatorcommandonce-
theequipmenthasbeen selected.
Help displays shall be static text displays that provide guidance messages
on the operation of the control system or plant equipment. Access to a
help display shall be by a single operator request once the operation or
equipment has been selected.
Equipmentruntimedisplaysshallbeprovidedtodynamicallyindicate-
theaccumulatedrunningtime in hours for selected plant equipment. The
displays shall include the ability for the operator to individuallyresetthe-
counterforeachdevice.
Sequencedisplaysshallprovidedynamicindicationofthestatusandpro-
gressofequipment,group, andunitlevelstartupandshutdownse-
quences.Thedisplaysshallincludestatictextforeachstepof the start up, dy-
namic text to indicate process values or statuses, and links to other dis-
plays for individual equipment start up. The sequence displays shall in-
clude, for each step, an individual indication that confirms that each step
has been completed. Sequence displays shall provide the operatorwith-
theabilitytostart,stop,step,hold,andsetthemodeofeachsequence.
Thesystemshallbesizedtostoreanddisplaythetextdis-
plays.Textdisplaysshallbedefinedbythe Purchaser and shall be configured
at the factory by the Contractor in the quantity approved during detail en-
gineering by consultant/owner. The quantity of each type of text display
will be selected by thePurchaser.
GroupDisplays
The system shall allow the user to create and store text type displays that
show the tag name and point description adjacent to the current value or
status of selected groups of points. The user shall beabletocreateeach-
displayfromaContractorprogrammedtemplatethatallowstheusertoenter the
point tag name for at least 50 points in a columnar format. The system
shall provide storage for 50suchgroupsfordisplaybytheoperator.
AlarmDisplays
Thetexttypealarmdisplaysshalldisplayall-
points(analogordigital)inthealarmstateintheformof writtenmessageswi-
theachmessagecontainingtagname,pointdescription(refertothedigitalpoint
descriptionrequirementsinAr-
ticle17101.2.5.2),timetag,pointvalueorstatus,andalarmlimit.
Thealarmsshallbedisplayedonthemonitorintheorderofoccur-
rence.Analarm,whenfirstoutput to the screen, shall be displayed on the top

190
line of the screen. A newer alarm shall push all older alarmmessageson-
thescreendownbyoneline.Allalarmmessagespushedoutofthescreenshall
bebackloggedandorganizedinpages.
Thesystemshallbecapableofdisplayingthebackloggedalarmpagesonde-
mandbytheoperator. When an alarm point has been returned to normal,
the message shall disappear from the display afteritisacknow-
ledged.Thesystemshallcategorizeallpointsinalarmintoprioritylevels,and dis-
tinctionsshallbemadebetweenhighprioritylevelandlowprioritylevel-
alarmswhendisplayedon themonitorsandprinters.
Thesystemshallallowtheoperatortofilterthealarmdisplayonanyopera-
torworkstationbypriority or specific plant area (if the user has assigned
plant areas). The filter shall be applied to the alarm displayonthatparticula-
roperatorworkstationonly.
A separate alarm history display shall be provided that displays the most
recent 5,000 alarm occurrencesinchronologicalord-
er.Thealarmhistoryshalldisplayalarmsofallpriorities,incremental
alarms,andreturntonormalmessages.
SystemDisplays
The Contractor shall provide a hierarchy of system displays that provides
status and health information for the system and for all individual compo-
nents (Switches, server) within the system. Thesesystemstatusdisplays-
shallprovidetheuserwithadetailedviewofthesystemasdesignedto indicate
the status of each component along with an associated diagnostic sum-
mary for each component. Equipment status indication shall be distinctive
so as to allow determination of health, trouble, or fault for each operator
interface processor, control server, power supply, switch and associated-
memoryusedinthesys-
tem.Thesesystemdisplaysshallbeinadditiontothequantities ofdisplaysdefi-
nedinControlandInformationDisplayFunction-
sonthe17101SpecificationSheets.
Summaries
The system shall be configured to allow the operator to display on any op-
erator work station monitor and print the following summaries:
Summary of all points in alarm.
Summary of all existing "bad" quality points.

191
Summary of all existing points with substituted (forced) values.
Summary of all existing points not being scanned or alarm limit checked.
Summary of all existing analog and digital inputs and outputs with point
specifications such as ranges, limits, etc.
Summary of all points in tag-out.
SCADAshallhavefollowingminimumfeatures:
a. Share data and integrate seamlessly with other software and control de-
vices. It shall have a common services such as security, alarming and di-
agnostics. SCADA shall have capability of accessing tag information in
the controller, eliminating the need to create HMI tags. A defining feature
of View shall have an ability to directly reference live information from
any vendors controllers
b. SCADAshallhaveacommonaddressbookoffactoryresourcessothatchange-
satoneplaceofthe automationsystemshallupdatedautomaticallyacross-
theentirecontrolsystem.
c. SCADA shall have an ability to provide a centralized security authority for

all components in the sys-
tem.TheDiagnosticsshallmakeiteasytorecordinformation,warningsanderro
rsgeneratedby thesystemanduserstoacentrallocation.
d. SCADA shall be able to configure the application from anywhere on the

network and easily make changestoarunningsys-
tem,withnoneedtocopygraphicsfromaServertoClients.Itshallhavea Multi-
userconfigurationcapabili-
ty.Itshallprovideanaudittrailofoperatorandalarminformationina centralized
log database and shall have an ability of validating the user access with
private and Windows security options.
e. Providestheoptionofspecifyingasecon-
dary,orredundant,servertotakeoverincasetheprimary server fails (native
redundancy). Software shall have Decreases development time and in-
creases codeconsistency,andincreasesdisplayconsistency.

192
SystemDataReportingFunctions
Thecontrolsystemshallprovidedatareportingfunc-
tions,allreportsshallbemadefromstoreddata so that once a report is in-
itiated, it can be completed without interruption. The system shall include
majortypesofreportsdescribedbelow.
ThesystemshallincludealibraryofContractor-
configuredreportformatsasspecifiedinthefollowing articles. Contractor-
configured reports shall include all required headers, footers, subhead-
ings, columnheadings,anddescriptivetext.
The quantity of Contractor-configured reports shall be as specified on the

17101 Specification Sheets. All reports and summaries shall be confi-
gured and tested by the Contractor prior to the factory acceptance test.
The system tools shall allow the user to assign run time properties to any
reportfor-
mat,suchasspecificpointtagnames,title,filename,executiontimeoreventinfor
mation, and destination. For each report, the user shall be able to define
whether that report is sent to a printer, viewed on screen, or saved as a
file with complete formatting information. Supported file typesshallin-
clude,asaminimum,comma-delimitedASCII,comma-
separatedvariable(CSV),XML, MicrosoftExcelspreadsheet,andHTMLfile.
PeriodicReports.
Periodic reports shall contain the current and averaged values of system
variables collected during thepe-
riod.Thereportsshallbeprintedoutautomaticallyatdesignatedtimesandonde
mandbythe operator. Each report shall be designed to collect data for a
minimum of 100 points. The actual numberofpointscontainedineachre-
port,thepointstobecollected,andtheprinttimesshallbeuser selectable.
TrendReports.
Trend reports shall contain current and averaged values of system va-
riables at predetermined intervals. The reports shall be printed out auto-
matically at designated times, on demand by the opera-
tor,andautomaticallyontheoccurrenceofadesignatedevent.Eachreportshall
bedesigned tocollectdataforaminimu-
mof100points.Theactualnumberofpointscontainedineachreport,the
pointstobecol-

193
lected,theprinttimes,thelengthofthecollectionintervals,andthedesignatedev
ent shallbeuserselectable.
Post-TripReviewReport.
Thepost-
tripreviewreportshallcontaincurrentvaluesofsystemvariablesat-
predeterminedintervals before and after a plant or major equipment trip.
The report shall be printed out on demand by the operator. The report
shall be designed to collect data for a minimum of 100 points. The actual
number of points contained in the report, the points to be collected, the
length of the collection inter-
vals,andthenumberofcollectionsbeforeandafterthetripshallbeuserselectabl
e.
MaintenanceDataReport
The maintenance data report shall calculate and display the number of
starts and stops and the accumulated running time of all rotating equip-
ment monitored by the system. The report shall be printed out automati-
cally at designated times and on demand by the operator. The report shall
be designedtocollectdataforaminimu-
mof100piecesofequipment.Theactualquantityofequipment containedinthe-
reportandtheprinttimesshallbeuserselectable.
HousekeepingReport
The housekeeping report shall contain a listing of all changes made to the
system by operating and engineering personnel. The reports shall be
printed out automatically at designated times and on demand by the oper-
ator. The print times shall be user selectable.
UserReports.
The system shall also include a report writer package that allows the user
to create, edit, and store new reports and new report formats in addition to
the Contractor-configured reports defined above. The reporting package
shall allow reports to be built in a flexible free-format environment similar
to commercial spreadsheet software and shall provide the following fea-
tures:
Real-time data and messages combined in flexible layouts to produce

meaningful reports.
Information such as headers, footers, number of columns, column format,
column headings, calculation equations, and descriptive text defined and
entered by user for each report.

194
Reports enhanced through the use of various formatting styles, colour to

highlight information, and insertion of charts such as bar charts and pie
charts.
Usercreatedtemplatesandmacrosforfrequen-
tlyusedformats. Thesystemshallprovidestorage-
forthequantityofuserreports
Suitabledisplaysandreportsforcontrolopera-
tion&monitoringshallbeprovided.Thedetailsshall befinalisedduringdetaile-
dengineeringstage.
Functions:
Modulating (Continuous) ControlFunctions
Theanalogcontrolloopcontrolstationsshallsimulateconventional-
hand/autostations,allowingthe operatortoselectamodeandtoprovidemanua-
linterfacecommands,andshallprovideadisplayof all relevant variables as-
sociated with the control loops including the set point, the feedback signal,
thecontrolsignals,andthestatusoftheloop.
The required modes of operation and operator controllable parame-

ters shall be as follows:
Automatic Mode: This mode shall permit full automatic operation of the
system with no intervention on the part of the operator except for the func-
tions designated as operator adjustable, such as set point adjustment and
biasing of control signals.
Manual Mode: This mode shall permit manual "Raise" and "Lower" of sys-
tem demand signals. Operator interface for analog control loops shall also
include one, two, three, and four vertical bar indicatingstationsforindicatio-
nofanalogvalues.Eachverticalbaronthestationshallalsodisplay a short de-
scription of that point, and the point's process value and engineering units.
The multiple measurement loop control stations shall allow the operator to
select the multiple measurement mode, and shall provide a vertical bar
and analog value display for each of the analog inputs and forthemultiple-
measurementloopout-
put.Thestationshallalsodisplaythemultiplemeasurement modeandqualityo-
feachanalogvalue.

195
The pulse accumulator loop control stations shall allow the operator to re-
set and hold pulse accumulation, and shall provide an analog value dis-
play of the accumulated total.
All operator interface command functions, except screen paging, shall be

designed for two-step opera-
tion.Theoperatorshallberequiredtomakeonekeyboardortouchscreenactiont
oselectthe functiontobeperformedandasecondkeyboardortouchscreenac-
tiontoexecutethefunction.For exam-
ple,theoperatormustselectthe"Auto"buttonforadeviceandthenexecutetheau
tofunction topreventaccidentaltouchscreenorkeyboardactivationofcontrol-
commands.
Operatorinterfacefunctionsshallincludeinterfacetotheanalogcon-
trolloops,multiplemeasurement loops, and pulse accumulator loops, by the
operator, from faceplates on the operator work station monitors.
Discrete (Sequential) Control Functions

Discrete Control Functions:
ThesequentialORdiscretecontrolfunctionsshallbeconfiguredforthe-
followingapplications,which shallin-
clude,butnotnecessarilybelimitedto,thefollowing:
a. Start/StopofRawwater&Purewaterpumpmotorsinsequentialform
b. Open/Close/Stop of motor-operated valves
c. Filterbedsequentialoperationinmanual/automode
OperatorInterfaceFunctions.
Operatorinterfacefunctionsshallincludemodeselection
andinitiationofmanualcom-
mands,madebytheoperatorfromcontrolstationsontheoperatorwork station
monitors. The control stations shall provide control functions, including,
but not necessarily limitedto,thefollowing:
Start,stop,open,close,auto,manual,reset,andtrip
commands. Maintainedpushbuttons.

196
Momentary push buttons (with adjustable pulse duration).

Status indication for motor running/stopped/tripped and valve open/closed.
Indication for equipment mode, permissive condition, failure condition,
first-out indication, and operational sequence status.
All operator interface functions, except screen paging functions, shall be

designed for two-step opera-
tion.Theoperatorshallberequiredtomakeonekeyboardortouchscreenactiont
oselectthe functiontobeperformedandasecondkeyboardortouchscreenac-
tiontoexecutethefunction.The systemshallprovidesystemdisplaysfortheon-
linemonitoringofcontrollogicsignalflowonoperator worksta-
tion.Thesedisplaysshallusecolourandotheruniquesymbolsornomenclaturet
oindicate on-state, off-state, and signal flow path for all logic blocks, con-
tacts, coils, and associated connections.
AlarmFunctions
AnalogAlarmFunctions
The system shall perform comparison of limit functions on any or all ana-
log points, as determined during detailed design. The system shall allow
the user to selectively activate or deactivate these alarms. Each analog
input variable, or calculation result, shall have an individual set of alarm
limits. These limits shall be either manually set, calculated as functions of
other variables, or rates of change with time. Violations of these limits
shall initiate alarms and/or initiate execution of special software programs.
Theanalogalarmfunctionsshallbeonaperanalogpointba-
sis,andshallinclude,butnotbelimited to, thefollowing:
Provision to assign high and low transducer range limits for quality deter-
mination.
Provisionforanalogpointstobedeletedfromandrestoredtoalarmsta-
tusbytheuseror automaticallyfrominternallygeneratedvariables.
Provisiontoassignhighandlowalarmli-
mits,andatleastonelevelofincrementalalarm lim-
its,eitherfixedorasafunctionofanothersystempoint.
Provision to assign an alarm dead band.
Provision to assign rate of change alarm limits and dead band.

197
Provision to impose alarm cut out (masking) conditions as a function of

another system point.
A copy of the comprehensive alarm list which includes all I/O generated
and internally calculated alarms shall be submitted to the Purchaser for
review.
DigitalAlarmFunctions.
The system shall compare the status of any or all digital points against the
user selectable alarm state of these points, as determined during detailed
design. The system shall allow the user to selectively activate or deacti-
vate these alarms. Digital points entering the alarm state shall initiate
alarm-
sand/orinitiateexecutionofspecialsoftwareprograms.Thedigitalalarmfunctio
nsshallbeon aperdigitalpointba-
sis,andshallinclude,butnotbelimitedto,thefollowing:
Provision for digital points to be deleted from and restored to alarm status
by the user or automatically from internally generated variables.
Provisiontoalarmonadigitalpointstatusof"1"(on)or"0"(off). Provisiontoalarm-
digitalpointsonanychangeofstate.
Provision to impose alarm cutout (masking) conditions as a function of

another system point.
Description for a point that is to be alarmed, the alarm message text dis-
played to the operator shall be similar to the input point description, with
the words "NOT", NO or other negative text omitted. Thebiddershallbe-
responsibleforprogrammingthealarmmessagetextinamannerthatdoesnot
usethewordsNot,Noorothernegativetextinthealarmmessagetext.
SystemAlarms
The system shall provide alarms for system failure conditions including,
but not limited to, the following:
Loss of any server power supply.

198
Battery-
low(manyhoursbeforedeteriorationtotheextentthatitcannotmaintainthefun
ctionsof theequipmentitsupplies).
6.3 Failure of any Server.
6.4 Server history function failure. Server synchronization failure.
6.5 Failure of Data historian data retrieval. Failure of any operator interface
processor. FailureofanyForeignDeviceInterface(FDI) Failureofanycommu-
nicationsnetwork. Diagnostic programs shall have routines to generate
component status alarms. These alarms shall include, but not be limited
to, the following:
6.5.1 Operator interface processor failure. Server Hard disk failure.
6.5.2 Communications failure. Disk read/write error.
6.5.3 Printer failure.
Allfailuresandmalfunc-
tions,whendetected,shallimmediatelybealarmedthroughtheoperatorwork
stationsandrecordedonthealarmprin-
ter(s).Acopyofthecomprehensivesystemalarmlistshallbe submittedto-
theownerforreview.
Datasheet of Supervisory Control And Data Acquisition System

Sr. (SCADA)
Particulars Description Status
No.
2 SCADAs (Master
1 Reliability Redundancy and Slave) and Required
Server redundancy
Alarm/Event history Required
2 Maintenance Maintenance online screen change Required

199
3 System Scale number of operator sta- Limited, to be de-

tions cided during detail
engineering
Communication protocol
suitable for all ap-
proved manufacturers Support the OPC
of PLC & SCADA will Server and client
be acceptable.
configuration
Support to DDE Required

connection, (Serv-
er/Client)
Monitoring Number of available 1,00,000 points
Screen tags Minimum
Number of pens per

trend window 256 pens, Mini-
mum
Number of historical
trend data to be col- Unlimited
lected concurrently
Number of screens to
Unlimited
be displayed concur-
rently
Minimum sampling pe- 1 Second.
riod
Communication
Communication per- Sampling period
formance (number of shall be minimum
4 Performance
tags and sampling 20,000
period) points/S to
50,000 points/S
Alarm detection pe-
riod (Detect an
alarm at a specified Required
period)
Sampling period of From 10 millise-
Monitoring trend data conds
to 24 hours

200
Storage period for Minimum 12

historical trend Months
Storage period for 999 hours at the

real- time trend collection cycle of
200 ms
5 Basic function Real time da-
ta historical
Trend trend 3D
graph and the
charts
Alarm (sum- Required
mary/history)
Event (Operation Required
Basic func-
tion log
Security Required
Recipe Required
Scheduling Required
Demand monitoring Required
High perfor-
Animation mance animation
including 3D op-
symbol must be
Easy to create a
part of software
Drawing user- defined tem-
for copy & paste.
plate
Readymade
Template Template for
parts(types) general purpose
industry
Data manage- Backup of a project Required
ment file
storage of historical
trend data( connec- Required, preferred
tion to database, CSV SQL Server.
file, etc)
Operation Trend graph opera- Expansion and re-
Automatic window Required
size adjustment
Enlarge/Reduce win- Required
dow size

201
Window search Required
E-mail Required
User-defined tem- Symbol Factory
plate Required
Multi-languages Required
.net support Required
Simultaneous appli-
Required
Extended cation (windows-
function based) The screen can
Web function
be displayed by
(Remote monitoring) Web a browser.
6
The setting is al-
Extended function
Historical data acqui-
sition package (ex. Required
Historian
package for col- Required
Connectivity lected data analy-
to other soft- connectivity Connectivity to
ware pack- to MIS/ERP/POS
ages MIS/ERP/PO shall possible
7 Others Supported Win-
OS
dows OS
English, German,
French, Italian,
Supported language Russian, Czech
Language OS Republic word,
Menu, fixed display and Chinese
English
character
Alarm AnnunciationSystem
a. Thesystemshallallowtheopera-
tor/engineeringworkstationtodisplaythealarmsofthatparticular control
system. All alarms shall be displayed on the work station monitor in a
dedicated alarm management window and/or distributed eight line
alarm strips (as specified by the owner). The system shall also include

202
an audible alarm that shall have adjustable volume control. The audible
alarmshallbeuserconfigurablefordifferenttonesorpatternstodistin-
guishbetweenaminimumof four alarm priority levels. The system shall
use global alarm acknowledgment, allowing a single acknowledg-
mentfromthededicatedworkstation.
b. The system shall record all alarm events to a storage file in chronologi-
cal order The printer designatedtothecontrolsystemshallautomatically-
printouteachalarmeventandalarmresetasit occursorshallprintalarmeven-
tandalarmresetreportsondemand.
c. Bidder shall provide annunciation system as integral part of PLC sys-

tem. Field contacts shall be acquired through PLC only. The annuncia-
tion sequence logics shall be implemented as a part of PLC controllers.
OWS based alarm system shall be provided with audio alarm facility (
beep/tone generator).Hootersarealsotobeprovided.
d. Window based annunciation shall be provided wherever required which

can be discussed during detail engineering. The annunciation window
lamps mounted on control panel shall be driven through contact output
modules of PLC. It shall be preferable to have each window as mosaic
compatible. The lamp box shall have removable impact polystyrene
window shall be 50 mm x 50
mmor48mmx48mmwith5mmsizeinscriptioninblackletteringonwhitebackg
round.
e. Each annunciation window shall be back lighted with two long life LED
lamps The changing of lamps shall be conveniently done from the front
by single removal of window. Redundantaudibledevicesfora-
larmsshallbeconetypeormetallichorntypeandshallbedrivenbyelectronic
tone generator of adjustable width and sound level. The trip alarm audi-
ble & ring back audible shall bedifferentiatedfromotheralarms.
f. The annunciator sequence shall conform to ISA sequence ISA-2A. The

number of annunciation facia windows and the provision for original in-
put will be on as required basis. However, the minimumnumberoffacia-
windows,signalinputtotheannunciationsystemshallbe25nos.
6.5 LED Monitor 46 -

46" High-Performance LED Edge-lit Commercial-Grade Display w/
Integrated Speakers
46"sizecommercial-gradelarge-
screenLEDdisplaywithconsiderablescreensizetobeprovided. Thedisplay-
shallutilizesLED-
backlightingtodeliveraslimdepthandlowpowerconsumption.The display
shall have full high-definition panel which can delivers brilliant imagery.

203
Contractor shall indicateintheirofferabouttheamountofpowerreductiondu-

etoLEDbacklightingtechnology.
The Built-in expansion slot shall support the Open Pluggable Specification
(OPS).
Thedisplayshallhavefull1080phigh-
definitionresolutionwhichshallcompilestunningcommercial- gradeLEDpa-
nelandcomponents.
a. Followingaretheminimumoperatingrequirementsofdisplay
LED display shall be interfaced with historian server and work as one of
the work stations. LED shall be capable to access all the work stations in
the plant for monitoring and control functionasotheroperatorsta-
tions.TheLEDdisplayshallbedividedintosixwindows toshowtheplantpro-
cessparameters,plantcontrolsysteminformation,closecircuitTVinformation
etc. Minimum six images shall have picture-in-picture feature, the projec-
tor screen and LED screen shall display exactly the same format, includ-
ing real-time parameters such as refresh and mouse- clickoperation.
b. LEDdisplaydrivermanagementprogramshallbeinstalledintheLEDopera-
torstation, whereallnecessaryset-
tings,configurationandcontrolfunctionstobeprovidedthrough LED station
operators.
c. ThecontractorshallsupplyacompletesetofLEDincludinghard-
ware,software,power supplyu-
nit,necessaryservices,technicalsupportandsubmitthedetailedLEDsetting
solutionandfunctionalconfigurationinthepropos-
al.ContractorshallalsoprovideLED displaysdetailedtechnicalperformance-
parameters.
d. LED display and operator station design shall in accordance with ergo-
nomics, personnel easily to surveillance and reduce fatigue. The LED
shall not produce glare andhavesufficientbrightnesstoenablestafftoclear-
lywatchcontent.Thecontractorshallsubmitthe detailedsuggestionofcontro-
lroomlightandcontrolpanellayouttosuittheLED.
e. TheLEDshallbeplacedatdisplaywallincontrolroom.
Specifications of LED
Sr.N Particu- Descrip-

204
1 Display
Panel Technology UVA
Viewable Image Size 46"
Native Resolution, mini- 1920 x 1080
mum Pitch, minimum
Pixel 0.92mm
Backlight Type LED Edge-lit
Brightness (typical) 320cd/m2
Brightness (maximum) 460cd/m2
Contrast Ratio (typical) 5000:01:00
Viewing Angle 178 Vert., 178 Hor. (89U/89D/89L/89R) @
Refresh Rate, minimum CR>10
60Hz
Aspect Ratio 16:09
Active Screen Area 69.7 x 39.2 in. / 1771.2 x 996.3mm
Orientation Landscape/Portrait
Displayable Colours More than 1 billion
2 Synchronization Range
Horizontal (Analog 31.5-91.1 kHz
/Digital)
Vertical 50-85 Hz
3 Input Signal
Video Analog RGB 0.7 Vp-p/75 Ohms
Sepa-
Sync rate&Compositesync:TTLLeve
4 Connectivity
PC Signal Compatibility Required
Macintosh Compatibility Required
5 Input Terminals
Digital Display Port, HDMI, DVI-D
Analog VGA 15-pin D-sub, 5 BNC
(RGBHV, DVD/HD or Video), BNC Compo-
Audio Audio Mini-Jack, Display Port Audio, HDMI
External Control Audio
RS-232C,LAN,DDC/CI RS-
6 Output Terminals 232C,LAN,DDC/CI
Audio Audio Mini-Jack, External Speaker Jack (2)
Digital DVI-D
External Control RS-232C
7 Power Consumption
On 230W, maximum
ECO Mode Standby <2W, maximum
8 Physical Specifications
Bezel Width 1.2 in./1.2 in., 1.2in./1.2in. ;
(Left/Right, 29.7mm/29.7mm, 29.7mm
9 Environmental Condi-
Operating Temperature 41-104F / 5-40C
Operating Humidity 20-80%
Operating Altitude 9843 ft. / 3000m
Storage Temperature -4-140F / -20-60C

205
Storage Humidity 10-90%

Storage Altitude 40,000 ft. / 12,192m
Warranty (parts &
10 labor, including back- 3 years
11 Additional Features Advanced thermal capabilities
Tile Matrix (10x10)
Tile Comp
Separate group/Monitor ID function
Ethernet Control and Communication
RS-232 Control and Communication
Landscape/portrait capable
Carbon footprint meter
Plug and Play (DDC/CI, DDC2B)
Scheduler (w/ real-time clock)
Sharpness/softness adjustment
Screen saver function
Ambient light sensor (AmbiBright)
10-bit colour
Metal rear cabinet
POP
Side-by-Side
Handles
Variable picture modes
Advancedvideoset-
tings(NoiseReduction,Adaptive Contrast)
Input labeling
Backlight adjust
Aspect ratio control
Built-
inspeak-
LED edge-lit backlighting
OPS/Expansion slot
12 Accessories Stand (ST-801)
Wall Mount Kit (WMK-3257)
OPSwithInte-
li5,250GBHardDrive,W7e (OPS-
Internal HD-SDI Card (SB-01HC)
Internal 3G-SDI Card (SB-04HC)
Digital IP Tuner (SB-03TM)
Wall Mount Kit (WMK-3257)
Display Wall Calibrator Kit (KT-LFD-CC)
Slim Wall Mount Kit (WMK-4655S-
6.6 Laptop for Programming:

Screen Size 15.6 inches
Screen Resolution 1920x1080

206
Max Screen Resolution 1920x1080 pixels

Processor 2.3 GHz Core i5 6300HQ
RAM 8 GB DDR3L SDRAM
Memory Speed 1600 MHz
Hard Drive 1 TB SSD
Graphics Coprocessor NVIDIA GeForce GTX 960M 4GB GDDR5
Chipset Brand Intel
Card Description dedicated
Graphics Card Ram Size 4000 MB
Wireless Type 802.11 A/C
Number of USB 3.0 Ports 3
Average Battery Life (in hours) 4.5 hours
Other Technical Details
Hardware Platform PC
Operating System Windows 10
Item Weight 6 pounds
Product Dimensions 15.1 x 15.1 x 10.4 inches
Item Dimensions L x W x H 15.08 x 15.08 x 10.43 inches
Color Black
Processor Brand Intel
Processor Count 4
Computer Memory Type DDR3 SDRAM
Flash Memory Size 256
Hard Drive Interface Solid State
Optical Drive Type Not included
Power Source AC
Batteries 1 Lithium ion batteries required. (included)
SA 7 MBR / GSR / ESR

7.2 PLC Panel suitable for Wireless communication
Monitoring & control of MBR/ ESR in distribution network:
GPRS / GSM based PLC controller Panel:
This panel will control Automatic flow control valve depending upon water level
of MBR / ESR. This system will work on backup power charged and generated
from solar energy of suitable strength. This panel will have indications for
OPEN/CLOSE status of valve and level indications for EMPTY and FULL levels.
This panel will work in both AUTO/MANUAL modes. In AUTO mode the opening
and closing of valve will be done depending on water level automatically.
In MANUAL mode operator should press pushbuttons of OPEN/CLOSE
provided on front door of panel.
Programmable Logic Controller :
Sr.No. Description of Specifications

207
Parameters
1 Operating Voltage 12/24 VDC
2 Related Power Frequency 50 Hz
3 Digital Inputs Depending on requirement.
4 Digital Outputs Depending on requirement.
5 Communication Port RS 232/Industrial Ethernet
Programming port
6 Maximum Baud rate 19200 bps
7 Enclosure Engineering Plastic
GPRS / GSM Controller:

GPRS / GSM controller will monitor MBR / GSR water levels and accordingly
EMPTY OR FULL levels will be transmitted to central SCADA station, which is
located at water treatment plant.
The GPRS / GSM controller is a small rugged computer, which provides
intelligence in the field and allows SCDM master unit to communicate with the
field instrument. Its function is to control process equipment at the remote site,
acquire data from the equipment and transfer the data from the equipment back
to SCDM master unit. GPRS / GSM controller consists of following hardware
features.
I/O interfaces to DI/DO
CPU
Serial communication port.
Secure power supply with back up battery.
Solar Photovoltaic panel with battery charger.
Watchdog timer.
Electrical protection against spikes.
Bank of Contact Free Sensors to measure water level.
Suitable gain antenna.
GPRS/GSM controller has always been used in a situation where

communication is very difficult and the GPRS/GSM controller strength was its
ability to handle difficult communication. RTU will operate scanning its inputs,
normally fairly at a fast rate. It may do some processing such as change of
state and to report to the master unit. RTU is used for remote control and
monitoring in the various applications.
Features of GPRS / GSM controller:

Wireless Communication.
Event notification.
Remote Control.
Remote cell phone support for data messaging
Simple installation
Specification of GPRS / GSM controller:

208
S. N. Parameters Range
1 Operating Voltage. 12/24 VDC.
2 Mode of Transmission. Supporting to GSM dual band
3 Inputs. 4 Digital inputs as EMPTY
HALF FULL etc.
4 Data transmitting format. Through RS 232 with
GSM/GPRS network /
Programmable Logical
Controller (PLC) with RF radio
network.
5 Attachment of field instruments. Sensors and logic controllers.
6 Solar panel Suitable solar photovoltaic
panel to charge battery through
microcontroller based intelligent
charger.
7 Extra reporting facility to Available to maximum two
registered Mobile. different Cell numbers for any
change in water level.
8 Status reports facility through Available with a password.
mobile.
9 Water level sensing Water level sensing is done
through Contact Free Sensors
type M 301
10 Interfacing cable Suitable core, shielded cable.
11 Enclosure of PLC Suitable for outdoor installation
and has protection against
electrical spikes.
Contact free sensor: This sensor is specially developed to sense liquid level.
The sensor is made of engineering plastic material and can be used for water,
acids, viscous oils, solvents, petrochemicals etc. The switching contact is her-
metically sealed in glass, totally protecting from surroundings. The switch is
isolated from external media by magnetic coupling giving long life of operation.
This sensor has wide applications in process control systems.
Specifications:
1. Sensor type : Contact free potential free
2. Number of operation : More than 10 x 6
3. Accuracy or level sensing: +/- 5 mm.
3. DATA LOGGER
Power Requirements
Voltage : 12/24V DC
Inputs-Outputs
Digital Inputs : 8 Nos.
Digital Outputs : 8 Nos.
Analog Inputs and Analog output : 4 Nos. (Expandable up to 8)

209
Ports RS-232/ RS -485/Industrial

Ethernet/USB
Memory
Program Memory : 256 KB
Storage Memory : 4 MB FLASH, expandable to 16GB
Display : 256K Coloured Graphics display
Keyboard/Touch Interface : Yes, membrane keys will be provided
for local programming.
ADC Resolution : 24 Bit
u-Processor : 32 Bit
Mounting Enclosure IP-65
Data Transmission Interval : Programmable from 15 minute to 24
hours
Recording interval : Programmable
Configuration and programming : Windows Based
software
Environmental
Operating Temperature : -40 to 60 degree Centigrade
Relative Humidity : 0-100 % non-condensing
Housing for equipment : For housing equipment IP-65
enclosure will be provided.
MAINS POWER SUPPY
Battery Charger : Microprocessor based
Indications
: Mains ON
: Battery Charging
: Battery Low
: Battery Reverse
: Battery Full
Protection
: Short-Circuit
: Overload
: Under-Voltage
Battery : Sealed Maintenance Free (SMF)
Make : Exide/Amron/Amco
Capacity : 12 V / 200 AH ( May change as per
power calculations)
Enclosure : MS fabricated wall-mount panel

210
enclosure for housing DCP.
4. GSM/GPRS MODEM
Type : GSM/GPRS Modem
Input Supply : 12/24 V DC
Input signal : RS-232 output from DASTU / PC
Transmit power : 1 Watt
Operating frequency : 900/1800/1900 MHz Tri band
Receive sensitivity of modem : -102 dBm
Dynamic range : 62 dB
Frequency Tolerance : <+ 0.1 ppm
SIM card holder : Internal
Antenna Interface : Yes
Operating Temperature : -25 to 60oC
Humidity 0-95 % Non condense
5. VSAT TERMINAL
Type : VSAT Terminal
Out Band Carrier :
Standard : DVB-S
Carrier Bit Rate : 340 Kbps 66 Mbps
Modulation : QPSK
Coding : Viterbi & Reed somolon or Turbo
FEC rate : , 2/3, , 5/6, 7/8
Inbound Carrier
Access Scheme : Combined TDMA, FDMA
Bit Rate : 60 Kbps 2 Mbps ( as per requirement)
Modulation : GMSK
Coating : Turbo coding FEC 3/4, 7/8
Out Door Unit :
Antenna Size : Ku Band 0.55 m to 1.2 m, C band 1.8 m
Operating Temp : -40 to + 60 C
Humidity : Up to 100 %
Transmitter ODU : 1W, 2W Ku Band
LNB : Standard TVRO type
Indoor Unit :

211
Operating Voltage : 100-240 VAC

RF Input / Output : Two F Connectors, 75 Ohm Female
Data Interface : 100 Base T / RS-232 ( Optional)
Size : 300 X 233 X 50 mm
Environment Conditions :
Operating Temperature : - 5 to + 50 oC
Storage Temperature : - 40 to + 70 oC
Relative Humidity : Up to 90 %
7.3 Solar Panel with Battery
Solar technology that directly converts sunlight into electricity is called solar
photovoltaic (PV) technology. PV produces direct current electricity, which
can be used on-site, stored or converted to alternating current for long-
distance transmission.
Solar modules are the key element of every solar power system as they
convert sunlight into electricity. Their quality and the optimum use of the
respective technology are therefore decisive for the yield and profit of the
system.
Solar panel should be capable of charging 12 VDC Required capacity
batteries through charge controller. Solar modules are the key element of
every solar power system as they convert sunlight into electricity. Their
quality and the optimum use of the respective technology are therefore
decisive for the yield and profit of automatic ESR / MBR / GSR filling
system.
Open Circuit Voltage (Voc) in Volts - 21
Short Circuit Current (Isc) in Amps - 1.15
Maximum power during full exposure Suitable to automatic ESR filling system.
Maximum System Voltage - 600 V
Back Up Minimum Three (3) Days
Physical Parameters
Solar Cells Per Module (Units) - 36
Junction Box (Terminals) - 2
Diode in Junction Box - 1
Measurement Tolerance on Power +/- 5%.
All electrical parameters Specified at STC 25 cell temperature, 1000W/M
irradiance,
Type of cell Multi-Crystalline Si Certifications: IEC 61215 / IEC 61730-1 / IEC
61730-2
Front Face Tempered Glass & Low Iron All modules are supplied with screw less
Hollow section frames
Encapsulate Ethylene Vinyl Acetate Warranty: Limited Extended warranty up to
10 years
Frame Anodized Aluminum
Junction Box Weather Proof Nylon 6
SA 8 ESR Management Systems (RMS)
Automatic flow control valve ( ACV)

Requirement of instruments:

212
Ultrasonic Level Sensor/Transmitter for level measurement in MBR/ESR

Automatic Flow control Valve on Inlet & Outlet of ESR for controlling of flow
as per levels in ESR
Field Data Transmitter/PLC to transmit data i.e. Level, Flow, On/Off of Auto
control Valve to Central Processing Unit at WTP through GPRS
Solar Panel with Battery for supplying power to the instruments
Signal Cables for connecting various instruments.
Automatic Control Valve is a Solenoid Control unit to be installed over pipeline

which either opens or closes upon receiving an electrical signal to the solenoid
pilot control.
Operation of Automatic Control Valve shall be very similar to that of valve
actuator system, in case of valve actuator opening and closing of valve is done
by circular rotation of electrically driven actuator either in a clock wise or
anticlockwise direction, whereas in case of Automatic control valve, water flow
through pipeline is controlled by moving flexible membrane in a linear axis.
Sr. Parameter details Units

1 Suitability for pipelines. 80/100/150/200/250 mm diame-
2 Designed for media. Potable water.
3 On line mounting arrangement. Designed to ANSI Class 150
4 Material of body and cover Body and Cover in CS ASTM
5 Flexible membrane arrangement Mounted on AISI 304 (S.S. 304)
6 Material of flexible membrane Neoprene with nylon reinforce-
7 Pressure rating. PN1.0, PN1.6 up to 20 Kg/cm2
8 Operational control. Through solenoid valves.
9 Operating voltage of solenoid vale 12/24 VDC.
10 Status of solenoid valve OPEN or CLOSE as per applica-
11 Power supply From Electricity board or Solar
12 Suitability Gravity line or rising main of wa-
ter supply scheme.
Valve Components and Material of Construction

Valve Body, Cover CS ASTM A216 GrWCB
Seat Ring AISI 304 (S.S.304)
Disc Retainer AISI 304 (S.S.304)
Stem AISI 304 (S.S.304)
Stem Nut AISI 304 (S.S.304)
Guide Bushings AISI 304 (S.S.304)

213
Diaphragm Neoprene with nylonreinforcement

Fasteners High tensilesteel
Pilot Tubing : Stainlesssteel
Needle Valve : Stainlesssteel
Pipe connectors: Brass / SS / Zinc platedMS
Testing
The Automatic Control Valvess shall be tested at manufacturers work in
presence of the third party agency approved by MJP and Engineer-in-charge or
his representative.
The scope of inspection shall be : -
Review of raw material test certificate and quality control Procedures.
Hydrostatic test.
Calibration test.
Field data transmitters (PLC with Modem)
The Field Data Transmitter has got a highly-sensitive circuitry of measur-
ing parameters like Flow/level/Pressure which will be sensor output and in
the form of analog output like current (here typically it will be 4 to 20 mA)
or pulse particularly with bulk flow sensors, that can be periodically de-
tected corresponding to a particular water fixture. It is also possible to
monitor and control automatic control valve from remote location or from
web site. The system can also included with a GSM/GPRS circuit which
will create a set of text instructions for relaying water data as and when
required by user in the form of SMS or data packets and will communi-
cate water data after preset period to the central computer that can col-
lect, store, and further analyze data or to web server. It is also possible to
log water data over to website for set scan time. Field Data Transmitters
will have setting of scanning time in min or hours from 1 min. to 24 Hrs.
and shall be user friendly. Field Data Transmitter will have back up supply
in the form of rechargeable battery to provide water data readings over to
central computer even in case of power failure. FDT works over GSM /
GPRS network of suitable serviceprovider.
Specifications:
1. Monitors 8 digitalinputs.
2. 4 relay controlled digitaloutputs.
3. 6 analogue input to measure 4 to 20 mA fromsensors.
4. Monitors two pulse inputs from flowmeter.
5. Able to operate on GSM/GPRSnetwork.
6. Reports on set point alarms and sends SMS as desired
7. Working voltage is 12/24VDC.
Features

214
3 days Battery backup through rechargeable battery of 12/24VDC.

Analogue input: 4-20 mA or pulse from bulk flowmeter.
Scan time is settable and in steps of 1 hour with maximum 24hours.
Parameters are set through software provided withdevice.
WEB based Data Acquisition software should be suitable for data col-
lection from differentFDT.
Mode of transmission: GSM/GPRSnetwork.
Transmission antenna: High gain whip antenna suitable to requirement.
Data transmitting format: Through RS 232/485/ethernetcompatible.
Backup supply in case of power failure:Available.
Enclosure: Antistatic and antimagnetic PVCenclosure
Mounting: Wall mountingenclosure.
Internet connectivity should be secured/connectivity should be dedicated
IPs.
SA 11 Comprehensive O & M
Operation and Maintenance Charges of the whole water supply scheme on SCADA
and generation of daily report of water quality parameters and electrical parameters
with specific consumption in kWh/ml . The report shall be mailed daily to the head
quarters for monitoring purpose. All the cost of operation of GPRS/GSM/VSAT
modems/Broadband internet modems, data transmission charges payable to service
providers are included in this item.
Comprehensive operation & maintenance of the SCADA & AUTOMATION

system
The entire SCADA & AUTOMATION system to be installed under this work is to
be compulsory operated & maintained by the contractor for the period of 5
years after one year initial guarantee period.
Since this work is intended for human drinking water supply project for about
souls, the efficient & qualitative operation is of utmost importance.
In order to meet the day to day operation & maintenance of the entire project
following persons are to be deployed on full time basis as under
1) At Head works :- Raw water pump Raw water pumping station 1
skilled and qualified SCADA technician shall have to be employed for three
shifts day. i.e. 3 persons need to be deployed. They should have in depth know-
ledge of the basic operation and maintenance of the SCADA & AUTOMATION
system with basic knowledge of 11/33 kV switch yard transformer substation &
operation of LT/HT motor pumps. He shall be responsible for the day to day op-
eration and maintenance of the entire plant with the SCADA & AUTOMATION

215
system. He is also responsible for reporting & attending any fault / abnormal
eventualities to his team leader.
2) Water treatment plant :- This is the most important component of the

entire project which is directly related to the quality of drinking water supplied to
the villages / Town.
Skilled SCADA Technician with thorough knowledge of the entire water
treatment process and thorough knowledge of basic SCADA & AUTOMATION
system shall have to be employed. One Technician shall work in each shift. So
that total 3 Technicians shall be working in the day.
The Chlorination operation is to be monitored manually as it is a very
hazardous gas & harmful. It is kept out of AUTOMATION. However, the alarm
generation in the event of lowering in acceptable doses, & SMS generation
shall be done automatically. So also, in case of leakages in the chlorination
system, the presence of chorine in the air at chlorine room premises beyond
safety limits shall have to be detected and alarm signals and SMS shall be
generated and issued. Also, beyond the acceptable limits, the system shall
have auto shut off feature. The operator shall be responsible for operation of
entire plant.
3) ESR and MBR Management system : All ESR and MBRs covered un-
der this project are to be operated, monitored and maintained through a team of
2 skilled technicians having in depth knowledge of Vsat / GSM based modems,
level transmitters, pilot operated Automatic flow control valves, solar panel and
inverter battery system etc. Two teams each comprising of 1 persons shall be
formed & each team shall visit to 2 MBR & 27 ESRs per week. Each team shall
be provided with a motor cycle. The team shall be responsible for the day to
day operation of the ESR Inlet/Outlet Automatic Control valves with solar panel
system, level sensor, Pressure Transmitter,Field Data Transmitter etc. Also, this
solar panel system installed over the ESR for Power supply requirements, shall
be thoroughly cleaned with water every week. The electrolyte in the battery

216
shall have to be checked and replenished every 2 months.

4) To control, monitor and maintain the above entire system a team
leader having required qualification and in depth knowledge of the entire
water supply system with SCADA and AUTOMATION system is required :
This team leader shall be stationed at central station situated at WTP. He shall
be responsible for day to day report generation and maintaining the system in
the most efficient manner.
He shall be provided with 4 wheeler utility vehicle with all necessary tools,
instruments and gauges etc. required for attending any breakdown / preventive
maintainance of the system. He shall normally work during office hours and
shall be responsible for the entire job.
The Abstract of personnel required for attending the day to day O & M of the
entire SCADA & AUTOMATION system shall be as tabulated below :
Sr. Name of Post Qualification Experien No. of No. Remark

No. Designation ce perso of
ns per shift
shift /
day
1 Team leader B.E. instru. / Elect. & 8 years 1 (.3..) General
Tel. duty with
utility
vehicle with
driver
2 SCADA DEE / ITI / Electrical / 5 Years 1 (3..)
Technician Electronics
R/W P/M
3 SCADA DEE / ITI Electrial / 5 Years 1 (.3..)
Technician Electronics
WTP/PWPM
4 ESR / MBR DEE / ITI Electric / 5 Years (....) (....) (....)
management Electronic persons
technician with (....)
nos. of

217
motor
Cycle
needed
Abstract
Team leader :- (....) No.
SCADA :- (....) Nos.
Technician/Operator
ESR / MBR / GSR :- (....) Nos.
Technicians
Total :- (....)
persons
Operation & Maintenance

Operation and maintenance of the system broadly can be divided in into following
parts-
1. To facilitate remote maintenance of the Automation system components the
contractor shall provide a TEAM VIEWER facility for this project. Necessary li-
cense software shall be provided and installed.
2. Spares, components for the system
3. Consumables during operation of the system
4. Assistance Services for operation of the system
5. Maintenance Services for the System
6. Special purpose tools and calibration equipments.
Operation and maintenance of the system generally involves following activities

1. Operational Assistance:
This includes routine day to day operation of the system like operation of the control
instruments and pumps from the system, generating the reports based on the real-
time archived data, monitoring & acknowledging alarms and taking necessary action
to deactivate critical alarms.
2. Preventive Maintenance:
This includes preventive maintenance of the measurement equipments, calibration of
the instruments and replenishing the regents and other consumables, to ensure the
smooth working of the system components.
3. Corrective Maintenance:
As and when required it is necessary to carry out the corrective maintenance of the
faulty instruments, equipments. This includes the removing the faulty instrument from
the system, replace with the spare instrument and repair the same at site or in the

218
manufacturers workshop depending upon the severity of the fault.

Specifications for O&M
This section applies to the specifications for operation and maintenance of
Instrumentation and controls used in the System. The Contractor shall maintain the
complete system including instrumentation & control system for WTP and pure
pumping stations with monitoring of all existing for Water Supply Scheme.
Specifications
The specification of materials used for repairs shall be the same as have been used in
the original work. Specifications for any materials which were not used during
construction shall be approved by engineer prior to commencement of the operation
and maintenance period. Without being limited by this clause, during O&M period the
Contractor shall use appropriate material for repairs even if material required for such
repairs has not been approved earlier, and no delay in making such repairs shall be
subjected to such limitation. However, subsequent to use of such material, the
Contractor shall submit proposals for the approval of specifications of such material.
Activities during O & M Period
General
Within the framework of the Contractors responsibilities, the Contractor shall
carry out the following activities. However, these shall not limit the requirement
for other activities which otherwise are required as per terms and conditions of
Contract or to fulfill the Contractors responsibilities or are essential as per good
industrial practices. The Contractor shall be responsible for, but not limited to, the
following:
a) Providing the maintenance services for the system as directed by the
engineer-
in-charge.
b) Providing the required staff during operation and maintenance period.
c) Providing all required consumables required for functioning of plant and
equipment.
d) Maintenance of instrumentation (all field instruments) & control system,
software, PCs, control room, radio telemetry system UPS, A.C. etc. and all other
works constructed in this Contract.
e) Entering into AMC (Annual Maintenance Contract) contracts with
system/equipment suppliers, as necessary.
f) Periodic calibration check of all supplied instrumentation and controls
during the period of operation and maintenance.
g) Reporting;
Repair history of all mechanical, electrical and instrumentation control
equipment in raw water and pure water pumping stations, WTP & water
transmission mains;
Every day input voltage and current, frequency, power factor, kWh meter
readings and kW reading for Substations at pure water Pumping Station,
WTP.
Daily log of operations of all the important instrumentation & equipment
Daily startstop operation of pumps with every hour readings for operating
voltage, amperage and power factor;
Hourly readings of pressure, flow rate and integrated quantity of water;

219
Hourly levels of sumps;

Daily list of alarms with time tag;
Logbook format and the data to be included in the logbook shall be decided
in consultation with department;
Last periodic maintenance done for all equipment/buildings of the system;
h) Providing required spares and maintaining adequate inventory of required
accessories or equipment itself for repair of system so that all instrumentation
and control equipments, software and communication system can work
efficiently for the proper functioning of System. Prior approval to the changes
required to be carried out during O&M shall be obtained by the contractor from
the engineer. The required changes shall be reported well in time. Necessary
drawing and literature for any changes shall be submitted to the employers
representative. The Contractor shall be solely responsible for the safety and
security of the goods in the store and will be responsible for any loss or
damages in stores for any reason. He may opt for insurance cover against the
value of the goods to be stored without any additional costs on the Department.
i) Periodic routine maintenance of structures/control room / chambers of each
location of WTPs, pumping station, ESRs etc and others built in the Contract.
Such maintenance must ensure adequate cleanliness, ventilation, illumination
and structural safety. In addition to this, the general hygienic standards must be
maintained.
j) Providing transportation facilities between various locations for the maintenance
staff.
k) Submission of Daily report (Water audit / energy Audit / Water balance).
l) Co-ordination with other contractors and/ or agencies responsible for the
execution, operation and maintenance of other works of the system.
m) Insurance: The Contractor shall, without limiting his or the Employers
obligations and responsibilities, insure;
I. The work together with material and plant for incorporation therein, to the
full replacement cost (term cost in this context shall include profit).
II. The Contractors equipment and other things brought onto site by the
Contractor, for a sum sufficient to provide for their replacement at the site.
III. The insurance shall be in the joint names of the Contractor and the
Employer at the Contractors cost and shall cover the Employer and the
Contractor against all losses or damages from whatsoever cause arising
from the start of the O&M until the date of completion of O&M in respect of
the facility or any section or part thereof as the case may be.
IV. Any amount not insured or not recovered from the insurer shall be borne by
the Contractor
WTPs, Pumping Stations Reservoirs

(i) Operation of System as required, including provision of required manpower and
services for proper operation and monitoring of remote locations of WTPs, Water
pumping stations and Reservoirs.

220
(ii) Periodic site calibration of all measuring/metering equipment and

instrumentation at every 6 months minimum or as recommended by the
manufacturer.
(iii) Repair or replacement, as required, of damaged instrumentation and controls for
proper functioning of system.
(iv) Maintenance of the System including central server, softwares, PCs, UPS, A.Cs,
telemetry system etc.
(v) Routine maintenance of the field instruments as per recommendation of the
manufacturer.
(vi) Routine monitoring of each remote location for damage / repair of any equipment
/ parts and taking preventive measures as required
(vii) Keeping the hourly records of:
Status of pumps of each pumping location
Status of all water quality parameters of WTP
Current
Voltage
Frequency
Water level at suction reservoir/Sump
Rate of flow
pressure
Keeping hourly / daily records of:
Total number of hours of operation
Total quantity pumped
Total energy(kWh) consumption
(x) Providing safety accessories such as gloves, shoes, first aid box etc.
(xi) Ensuring safety of plant and equipment.
(xii) Furnishing required information to Employer as and when required.
Spare parts & stores

All spare parts used for the equipment in the maintenance of the system must be from
the manufacturer of the equipment or, if the equipment itself has been made with parts
from other manufacturers, the parts must be of the same make as used in the
equipment supplied and installed.
All spare parts shall be packed for long storage under the climatic conditions
prevailing at the Site. Each spare part shall be labelled on the outside of its packing
with its description, number and purpose and, if more than one spare is packed in a
single case, a general description of the case contents shall be shown on the outside
and a packing list enclosed. The cost of O & M shall inclusive of spare parts during O
& M contract period. The store inventory, the issuing and recording of spare parts will
be the responsibility of the Contractor.
The Contractor is also be responsible for providing spare parts and instrumentation
required for the Operation and Maintenance during the operation period, and shall

221
bear the cost of the same, including the cost of storing and safeguarding.
The Contractor will make all necessary arrangements to ensure the continuous supply
of spare parts and instrumentation for the works, and the rate of supply of these
materials shall be in such quantities and amount as would ensure uninterrupted
operations.
COMPLETION OF O&M CONTRACT

On the date of Contract Completion or if the Contract is terminated, all the
installations, works and equipment's placed under the Contractor's responsibility shall
be handed over to the Employer, at no cost, in good working order, barring normal
wear and tear. The Employer may perform any inspections, tests from expert
appraisals he shall find necessary with a view to checking that this property is in good
working order.
At the end of O&M period, the Contractor shall be entitled to receive an Operation &
Maintenance Completion Certificate within One Month of the Completion of the
Contract.
The delivery of such Completion Certificate will relieve the Contractor from his
responsibility as regard to the Operation and Maintenance and confirm that the
Contractor has fulfilled all of his obligations under the Contract.
Documents to be provided by the Contractor (Operation Log book)
The Contractor shall keep a permanent record of plant in Operation (logbook).
This logbook shall be kept at the site and shall be presented on request to the
Employer.
On a daily basis the following information shall be recorded in the logbook
Result of analysis and tests conducted on site to determine the quality of raw and
treated water and treatment parameters,
Machinery Operation data, its operating parameters
Maintenance records, shut down record of each machinery & equipment
Readings from the different meters, indicators and recorders (Including but not limited
to consumption of energy and chemicals, volume of water treated, operating times of
the different equipments).
Computer documents and tapes produced by monitoring and surveillance equipment,
shall be attached to the logbook.
Financial Provisions
No Advance shall be paid by the Employer.

222
The contractor shall arrange third party inspection as per MJP approved norm
and approved by MJP agencies in presence of MJP Superintending Engineer
(MECH) and his representative and bear all expense including testing fee etc.
complete. As under
SCHEDULE OF THIRD PARTY INSPECTION.
NO/ MJP/MS/TS - 1/350/ 4161 Dated/- 10.12.1998
CIRCULAR
THIRID PARTY INSPECTION OF ELECTRICAL /MECHANICAL EQUIPMENT
In order to improve the quality of Electrical and Mechanical equipments, the scope of
THIRD PARTY INSPECTION is revised as under, superceeding the circular issued
under this office letter No. MWSSB / AB / B / STORES / 613 Dated 19 Sept 1989
Sr.
Equipment Limits Scope of Inspection
No.
All Will be finalised at the

1 AUTOMATION & SCADA equipment time of submission of
s QAP by the Contractor
It must be carefully noted by the contractor that it is the responsibility of the
contractor to organise the third party inspection ( by approved agency of MJP)
and the contractor has to bear all expenses including inspection charges. The
contractor should furnish the details of specifications / test etc. to the inspection
agency and the inspection agency shall furnish the copy of inspection report to
the Department and copy to the contractor.
Signature Not Verified

Digitally signed by RAJENDRA
BASAVANAPPA ANTAD
Date: 2017.06.02 06:21:53 PDT
Location: Maharashtra

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[1]

MAHARASHTRA JEEVAN PRADHIKARAN WM DIV. SATARA

e- TENDER NOTICE NO FOR 2017-2018

ATAL MISSION FOR REJUVENATION AND URBAN TRANSFORMATION (AMRUT)

( SAVE WATER, EVERY DROP COUNTS )

Contractor No. of Corrections Executive Engineer

MAHARASHTRA JEEVAN PRADHIKARAN WM DIV. SATARA

NAME OF W ORK : ATAL MISSION FOR REJUVENATION AND URBAN TRANS-

e- TENDER NOTICE NO FOR 2016-2017

Contractor No. of Corrections Executive Engineer

Contractor No. of Corrections Executive Engineer

MAHARASHTRA JEEVAN PRADHIKARAN WM DIV. SATARA

Name of work : ATAL MISSION FOR REJUVENATION AND URBAN

Contractor No. of Corrections Executive Engineer

14) Materials remaining unsold or unserviceable as per discretion of the Executive

GS 4: FOUNDATION CONDITIONS AND PRESCRIBED BEARING CAPACITIES

Contractor No. of Corrections Executive Engineer

GS 6: SATISFACTORY COMPLETION OF VARIOUS ITEMS :

GS 8: SUBMISSION OF DETAILED DESIGNS AND DRAWINGS AFTER

Contractor No. of Corrections Executive Engineer

b) No extra charges for the carriages of water will be allowed.

2) For grades of concrete M-20 and above where cement is to be used by

Contractor No. of Corrections Executive Engineer

Contractor No. of Corrections Executive Engineer

MAHARASHTRA JEEVAN PRADHIKARAN WM DIV. SATARA

AUTOMATION & SCADA SYSTEM

Designing, Supplying, Installing, Testing & Commissioning of complete

The overall objective of the automation is to reduce human intervention, reduce

This work includes complete designing, supplying, installing, testing &

The overall objective of the automation is to reduce human intervention, reduce

Contractor No. of Corrections Executive Engineer

Flow Meters - Ultrasonic / Electromagnetic/ AMR flow meter ( Not in the

Contractor No. of Corrections Executive Engineer

Ultrasonic level sensors for filter beds of WTP, recirculation sump of

Contractor No. of Corrections Executive Engineer

1.0 GENERAL SPECIFICATIONS

1.1 Equivalency of Standards and Codes

Contractor No. of Corrections Executive Engineer

Standard and Codes

Generally the specifications for supply, implementation and support of the

1.2 Sign Board

Contractor No. of Corrections Executive Engineer

protection and/or facilitating relocation of such utilities as may be required, and

Functions required at Pumping Station:

Contractor No. of Corrections Executive Engineer

Information / data for various parameters at pre-defined interval (say 15 minutes)

Functions required at WATER TREATMENT PLANT

Contractor No. of Corrections Executive Engineer

Monitoring of water quality parameters is one of the tasks at treatment plants.

Information / data for various parameters at pre-defined interval (say 15 minutes)

Functions required at ESR locations:

Information / data for various parameters at pre-defined interval (say 15 minutes)

Data / information shall be transmitted to MCS periodically as defined in the sys-

Information / data for various parameters at pre-defined interval (say 15 minutes)

Functions at Master Control Station (MCS):

Contractor No. of Corrections Executive Engineer

Information / data for various parameters at pre-defined interval (say 15 minutes)

4.0 General Technical specifications

4.1 Design Criteria

5. Electronic instruments shall utilize solid-state electronic components, integrated cir-

Contractor No. of Corrections Executive Engineer

7. The instruments shall be designed to permit maximum interchange-ability of parts

9. The instruments shall be designed to work at the ambient conditions of temperature,