City of San Mateo Clean Water Program Programmable Logic Controller (PLC) and Human Machine Interface (HMI) Programming Services

Transcription

1 ATTACHMENT A SAMPLE SCOPE OF SERVICES PLC & HMI PROGRAMMING City of San Mateo Clean Water Program Programmable Logic Controller (PLC) and Human Machine Interface (HMI) Programming Services December, 2017

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3 ATTACHMENT A Scope of Services The Subcontractor will provide programming services for the project elements listed in this Scope of Services. The project and fee negotiations will be executed with the General Contractor for each project for the services defined in this Scope of Services: Task 1 Task Management Services Task 2 Submittal Phase Services Task 3 Programming Services Task 4 Testing, Installation, Commissioning and Warranty Services Typical tasks that are required of the Subcontractor under these categories are detailed in the following sections. Throughout the construction of this project, the Subcontractor will submit deliverables for review and approval by the City and other governing agencies as required. The deliverables required by the Subcontractor will vary depending on the programming services defined in the Contract Documents for each project. All drawings and maps shall be developed using AutoCAD, ArcGIS, and PDFs capable of plotting at a legible scale on both 11x17 and 22x34 sheets shall be provided. Additional deliverable information is provided in the various task descriptions below. The City reserves the right to discontinue, alter, or postpone services at any time. Task 1 General Services Project management and coordination include tasks that will be performed by the Subcontractor throughout the project. Task 1 will cover all task management services required for the Clean Water Program projects. These services include: General Project Management and Coordination Workshops and Meetings Management of Sub Subcontractors (if any) Equipment procurement and install of Process Control System (PCS) Hardware, Software, and Subnet (if required) Task 1.1 Project Management Task General Management The Subcontractor will be responsible for detailed management of the project, including Sub Subcontractors, and will keep the General Contractor appraised of the status of the project. The Subcontractor will provide the key management personnel as described in their proposal on this project. The Subcontractor will not reassign the key project personnel without prior approval of the City per the Standard Agreement for Professional Subcontractor Services. Task Progress Report and Invoices The Subcontractor will prepare and submit monthly progress reports and invoices that include a narrative of the work completed by task, project action item log, upcoming work, project issues, budget and schedule status, percent complete, cost to complete, earned value versus actual spent analysis, potential scope or budget changes, and other important project information. The current and previous billing period invoicing, as well as a summary of the budget spent, budget remaining, cost to complete, and all backup documentation for expenses will be included. The PAGE 1 OF 9

4 monthly progress report and project schedule will be submitted with the project invoice as part of the monthly request for payment. Task 1.2 Workshops and Meetings The Subcontractor will prepare and submit to the General Contractor an agenda and meeting minutes for each formal meeting or workshop, and hold progress meetings as necessary. Task 1.3 Management of Sub Subcontractors If the Subcontractor requires the services of any Sub Subcontractors, then the Subcontractor will include a list of Sub Subcontractors in the proposal, explain why they are needed, and provide a general description of their effort. The Subcontractor will manage the activities of Sub Subcontractors during performance of the project. All requirements of the contract shall also apply to Sub Subcontractors. Task 1.4 Programming Management Plan Subcontractor shall work with the General Contractor to prepare an overall Process Control System (PCS) programming project plan that includes the PCS programming tasks. At a minimum, the Programming Management Plan shall include the following: 1. Programming Schedule: a) Programming schedule by phase. b) PLC and HMI programming standards review meeting c) All client programming workshops 2) Programming Team: Develop a programming team organizational chart defining the names and contact information of individuals who will be acting in the roles of Project Manager, lead PLC programmer, lead HMI programmer, and lead network analyst (if needed). Task 2 Submittal Phase Services Subcontractor shall submit a proposed submittal breakdown consisting of sequencing and packing of information in accordance with the General Contractor s Project Schedule. Partial submittals not in accordance with the Project Schedule will not be accepted. Subcontractor shall adhere to the following requirements for the submittal format: 1. Hard copy: required for all submittals. 2. Electronic copies: required, unless otherwise noted for specific items. 1) Manufacturers standard documents: Adobe Acrobat PDF. 2) Documents created specifically for the project: a) Text and graphics: Microsoft Word. b) Lists: Microsoft Excel, unless otherwise noted for specific items. c) Drawings: AutoCAD With each submittal the Subcontractor shall include the letterhead and / or title block of the firm responsible for the preparation of the submittals. The following shall be included in the title block as a minimum: 1. Registered business name of firm. PAGE 2 OF 9

5 2. Physical address, address, and phone number of firm. 3. Owner s name. 4. Project name and location. 5. Drawing name. 6. Revision level 7. Personnel responsible for the content of the drawing. 8. Date. Task 2.1 Process Control System Software Submittals The Subcontractor will submit the following for the PCS software. ATTACHMENT A: SAMPLE SCOPE OF SERVICES 1. Submit a complete description of the standard application software (PLC and HMI) programs, operating system and utility programs, and include modifications and an explanation of how specific functional requirements are met: 1) Provide a cross-reference between the Specification requirements and the software submittal in order to provide the City the ability to identify how each specified requirement or function is met. 2. A complete listing of the PCS system point I/O database: 1) Include for each data point, relevant parameters such as range, contact orientation, limits, incremental limits, I/O card, I/O hardware address, and PLC assignment. 2) Organize on a PLC panel by panel basis, separate by point type. 3) In addition to the active I/O points, list the implemented spare I/O points and the available I/O points remaining on each card, as well as other defined future points specified or shown. 4) The documentation associated with the PLC programs as described in the City s Programming Standards. 3. Detailed descriptions of procedures used to implement and modify control strategies and database construction. 4. PLC Programs: The Subcontractor shall provide a soft copy (Adobe PDF format) and a hard copy print out of the PLC program logic. The submittal shall follow the standards described in the City s PLC Programming standards and shall include the following at a minimum: 1) Proposed code organization 2) Code format (ladder logic, function blocks), and tag organization 3) Each routine, subroutine, and add-on instruction shall be named and described in the outline 5. HMI Displays: All HMI display submittals shall be in full color as they will appear on the display screen: 1) This submittal shall be prepared after the requisite HMI graphic display meetings 2) The submittal shall include: a) Graphic displays b) Trend displays 3) Each display shall be uniquely titled: a) Locations for process data shall be clearly identified either through the use of simulated data or by showing variables on the displays and providing a reference list describing those variables b) All dynamic points shall be identified by tag number as a minimum and their operation shall be described on separate sheets PAGE 3 OF 9

6 4) Three sets of submittals, with screen prints in color on a white background, are required for review by the Owner and Engineer 5) One set will be returned with comments Task 2.2 Testing, Start-up, and Commissioning Submittals The Subcontractor shall develop and submit detailed test procedures to show that the integrated PCS system software is fully operational and in compliance with the requirements specified in the Contract Documents. Each submittal shall provide a statement of test objectives for each test. Each submittal shall include specific procedures for each process system and shall describe sequentially the steps to be followed in verifying the correct operation of each process system, including all features described in the loop descriptions, control strategies, and shown in the P&IDs. Implied or generic test procedures are not acceptable. The Subcontractor shall prepare forms and checklists for the following: 1. Factory Acceptance Tests (FAT) 2. Loop Validation Tests 3. Functional Tests 4. Commissioning The FAT procedure shall be submitted four weeks prior to the scheduled date for the FAT. The FAT procedure shall include the additional minimal requirements: 1. Control system testing block diagram 2. Estimated test duration 3. Details on the simulator construction, components, and operation The Subcontractor will submit the proposed procedures to be followed during tests for the PCS software in two components: 1. Preliminary submittal: outline of the specific proposed tests and examples of proposed forms and checklists. 2. Detailed submittal: after successful review of the preliminary submittal, submit the proposed detailed test procedures, forms, and checklists, and include a statement of test objectives with the test procedures Task 3 Programming Services Task 3.1 PLC Programming Subcontractor will use the City s supplied Programming Standards and Rockwell PLC blocks for all PLC programming. Any missing code blocks shall be developed by the Subcontractor and fully documented and included in the set to be used throughout the project. One instance of each standard code block shall reside in each PLC and shall be referenced in main routines and subroutines. New code blocks or modifications to existing code blocks that the Subcontractor would like to use as a standard shall be submitted to the City for review and approval. The Subcontractor shall arrange, organize, and conduct at least one two-hour workshop to coordinate all equipment and instrument tags for each PLC included in the design. The Subcontractor shall arrange, organize, and conduct a series of no less than two half-day PLC programming workshops with City. The workshops will be for demonstrating programming PAGE 4 OF 9

7 organization and tagging use. Also, the Subcontractor shall use the workshops to present new and modified code blocks for potential inclusion in City s standards. The exact number of PLC programming and tagging workshops will be determined by the scope of work during the negotiations with the General Contractor. The Subcontractor shall provide an updated copy of all of the PLC programs and the programming documentation to the City after substantial completion of the Project. Task 3.2 HMI Programming Subcontractor will use the City s HMI Standards for all HMI programming. The Subcontractor shall re-use any applicable HMI graphics where possible. The Subcontractor shall arrange, organize, and conduct a series of no less than two four hour workshops with City. The workshops will be for demonstrating graphics organization, navigation, animation, and control functions. The Subcontractor shall use the workshops to present new and modified OIT/HMI graphics for potential inclusion in City s standards. The Subcontractor shall will implement the tagging information into the Wonderware Historian. Tags will be derived from the tagging coordination meetings noted above. The Subcontractor will coordinate and perform a tagging verification for each project phase to the City s satisfaction. Tagging coordination must be completed prior to acceptance of any project phase. The Subcontractor shall provide transfer of tags from the PLC system to the Wonderware Historian The City will implement tags into the HachWIMS Historian. The Subcontractor shall coordinate with the City on the transfer of tags and data points from the Wonderware Historian/NAS Historian to the HachWIMS Historian. The City will provide and license the HachWIMS Historian. The Subcontractor will configure the Wonderware Historian to setup, test, and transfer data to the HachWIMS Enterprise Historian. The Subcontractor shall provide an updated copy of all of the HMI programs and the programming documentation to the City after substantial completion of the Project. Task 3.3 Packaged and External System Coordination The Subcontractor will work with the General Contractor to coordinate with the Packaged System Vendors for each project. The Subcontractor will work with the General Contractor to coordinate the protocols and IO points to be transferred between Packaged System PLCs and other external controllers (e.g. Power Monitors). The Subcontractor shall review the control narratives and IO lists for the packaged systems to ensure that the PCS is programmed with the correct IO points and control logic to ensure that the packaged systems operate with the PCS as described in the Contract Documents. The Subcontractor shall establish the exact number of packaged systems during the negotiation phase. The Subcontractor shall establish the number of packaged system factory demonstration tests to be witnessed during the negotiation phase. PAGE 5 OF 9

8 Task 4 Testing, Installation, Commissioning, and Warranty Services Task 4.1 Factory Acceptance Test (FAT) The Subcontractor shall submit the FAT plan two months prior to the scheduled date of the FAT. The Subcontractor shall coordinate with the General Contractor regarding the location of the FAT. The FAT shall be conducted on the PCS hardware to be installed with the project as much as it is feasible. Representatives from the City, the Engineer, and the General Contractor can chose to attend the FAT. The City retains the right to observe all factory test activities including any and all subsystem preparation, pretests, troubleshooting, retests, warm-up, and software modification and/or updates. The Owner reserves the right to test any specified function whether or not explicitly stated in the test submittal. Any deficiencies observed during the test shall be corrected and retested before completion of the test. Any changes and/or corrections shall be noted on the test forms. The FAT shall make use of hardware simulators that contain switches, pilot lights, variable analog signal generators, and analog signal level displays, which shall be connected to the I/O points within the PCS. All inputs and outputs shall be simulated and proper control and system operation shall be validated. The use of jumper wires, terminal block mounted pilot lights, and loose meters to act as or supply the functionality of a simulator shall not be allowed. The hardware simulator may consist of a PLC, operating under a PCS software package, or other approved software that has its I/O points wired to PLC s I/O points. Software operating on a PC may then act as the switches, pilot lights, variable analog signal generators, and analog signal level displays. The Subcontractor shall be responsible for leading the FAT based on the submitted and approved FAT test procedures. The City shall witness the revisions and/or corrections prior to leaving the test site. If the corrections and/or revisions are too extensive to be made while the City is scheduled to be at the FAT test site, the FAT shall be, at the City s sole discretion, considered failed, and the test shall be restarted at a later date. All costs for the re-test shall be borne by the Subcontractor. Test methodology: 1) Discrete inputs: Apply appropriate input at a panel terminal, observe input card indicator, observe data value at each indicated data address, and observe data received on all operator interface displays (HMI displays) 2) Discrete outputs: Issue commands from operator interface screen, verify output card indicator light, and measure response at field wiring terminals 3) Analog inputs: Apply appropriate analog input signal at panel terminals, observe data value at each indicated data address, and observe data properly received at each operator screen; check each point at 0 percent, 50 percent, and 100 percent of scale 4) Analog outputs: Enter scaled values in the output buffer file, observe the output data file value, and measure appropriate response at panel wiring terminals System configuration test: 1) Demonstrate and test the setup and configuration of all operator stations, servers, development stations, and peripherals. 2) Demonstrate all utility software and functions, such as virus protection, backup, optical drive burning, network monitoring, etc. PAGE 6 OF 9

9 3) Demonstrate the proper operation of all peripheral hardware. 4) Demonstrate all general PCS functions. 5) Demonstrate proper operation of log-on and other access security functions. 6) Demonstrate the proper operation of all historical data storage, trend, display, backup, and report functions. 7) Test automatic fail over of redundant equipment. 8) Demonstrate proper operation of the alarm display and acknowledgement functions. Control logic testing requirements: 1) Demonstrate each function described in Contract Documents. Demonstrate in detail how each function operates under a variety of operating scenarios. Test to verify the application of each general control strategy function to each specific control strategy or loop description. 2) Demonstrate the proper operation of the programming and configuration for each control strategy or loop description. Test each strategy or loop description on a sentence by sentence and function by function basis. Loops with similar or identical logic must each be tested individually. 3) Demonstrate the proper operation of all digital communication links and networks. Verify each digital communication I/O point. 4) Failure testing: In addition to demonstrating correct operation of all specified features, special effort shall be made to demonstrate how the system responds to and recovers from abnormal conditions including, but not limited to: equipment failure, operator error, communications subsystem error, communications failures, simulated/forced software lockups, power failure (both utility power and power to PCS hardware), process equipment failure, and high system loading conditions. Task 4.2 Installation Testing The Subcontractor shall work with the General Contractor during the installation testing period to ensure that the PCS software functions as specified and that all of the tests are successfully conducted. The Subcontractor shall participate in the loop testing activities. The loop tests shall include, but not be limited to: 1) Test PCS system inputs from field device to PCS system operator workstations. 2) Test PCS system outputs from PCS operator interfaces to the field devices and equipment. The Subcontractor shall provide the I/O list to the General Contractor and shall provide assistance to the General Contractor in the preparation of the installation testing forms and reports. The Subcontractor shall remedy any software deficiencies discovered during the loop testing. Once the loop tests have been completed, the Subcontractor shall conduct the functional tests with the General Contractor. Control logic operational validation during the functional tests: The purpose of control logic validation is to field test the operation of the complete control system, including all parts of the PCS system, all control panels (including vendor control panels), all control circuits, all control stations, all monitored/controlled equipment, and final control elements. All control functionality shown on the P&IDs, control schematics, and other drawings, and specified in the loop descriptions, control strategies, electrical specifications, and mechanical equipment specifications shall be demonstrated during these tests. Each step of the control logic shall be PAGE 7 OF 9

10 tested in detail on a function-by-function and sentence-by-sentence basis. All final control elements, controlled equipment, control panels, and ancillary equipment under startup, shut down, and steady-state operating conditions shall be verified such that all logic and control is achieved. The field control logic validation tests to include, but not limited to: a repeat of all control logic tests from the FAT, modified and expanded to include all field instruments, control panels, circuits, and equipment. Task 4.3 Commissioning and Performance Test During the commissioning period, the Subcontractor shall tune all of the control loops with the actual process conditions to meet the City s requirements. The Subcontractor shall exercise each system function, e.g., status report, alarms, logs, and displays, several times at a minimum, and in a manner that approximates "normal" system operation. The Subcontractor shall provide a competently trained technician or programmer on the project site during all normal working days and hours from the start of the performance test until final acceptance of the system. The Subcontractor shall provide a programmer to be at the plant site within twenty-four hours for any major failure. Each time a technician is required to respond to a system malfunction, they must complete a report which includes details concerning the nature of the complaint or malfunction and the resulting repair action required and taken. If a malfunction occurs which clears itself or that the operator on duty is able to correct, no report is required or logged as specified above. If a technician has performed work but no report is written, then a major failure is considered to have occurred. Each report shall be submitted within twenty-four hours to the City or its representative. Task 4.4 Training and Warranty Services The Subcontractor shall provide project-specific PLC software training that covers the programming conventions, new standardized software modules, specific control strategy programs, and documentation created for the work performed under the corresponding project. This training will include the specific knowledge needed to modify, expand, duplicate, troubleshoot, and repair the PLC programs provided under this project, and be provided by a qualified member of the Subcontractor team who is thoroughly familiar with the delivered system, and is one of the senior programmers who programmed the PLCs for this project. The Subcontractor shall provide a HMI training course that will enable City staff to develop and maintain all aspects of the operator interface system applications. Topics to be included: 1) Operating systems and utilities such as virus protection software. 2) Point (tag) database development and modification 3) Graphic screen creation and editing 4) Scripting 5) Trending 6) Alarms and events 7) System security, access levels, and areas of responsibility 8) General system maintenance, including backups, history data archive, version control, file naming and cataloging conventions, and system file housekeeping The Subcontractor shall provide warranty services for all of the PLC and HMI programming work provided under this project for one calendar year after the final project completion. The PAGE 8 OF 9

11 scope and fee for the Programming Warranty services will be negotiated with the General Contractor during the initial negotiation phase. PAGE 9 OF 9