Ultrasonic level measuring system

Ultrasonic level measuring systems applied to open channel flow measurement

or liquid level measurement shall comprise a sensor and control unit.

The sensor shall be suitable for flange or bracket mounting as required and have
a minimum protection to BS EN 60529:1992, IP 66.

The accuracy of the sensor shall be ｱ 1% or better.

The associated control unit shall be mounted in an enclosure with

protection to BS EN 60529:1992, IP 65. It shall be programmable with an
integral programming keyboard and include a digital display, 5 No adjustable
relays for alarm, control and system fault and shall provide an isolated 4 to 20mA dc
output signal.

For flow applications a totaliser pulse output shall be provided.

The design and application of ultrasonic level meters shall take into
account the vessel or channel construction, the material, size, shape,
environment, process fluid or material, the presence of foam, granules, size etc.

The installation shall avoid any degradation of performance from spurious

reflections, absorption, sound velocity variations, sensor detection area,
temperature fluctuations, specific gravity changes and condensation.

If turbulence exists, shielding, stilling tubes or other measures shall be

provided to avoid effects on the measurement.

The performance of the measuring system shall be as given below or better:-

 Accuracy + 0.25% of calibrated span.
 Repeatability + 0.1% at maximum span.
 Stability + 0.1% of span over 6 month
period.
 Over pressure Sustain a 200% over pressure
without
damage.
 RF1/EM1 Less than 1% of span with 500
MHz at
5 Watts direct contact.
 Power supply variation 0.01% per volt variation.
 Load variation effect + 0.0002% per Ohm of loop
resistance
variation.
 Temperature -20oC to +82oC; total thermal
error of
0.75% of span over 0oC to 50oC.
Pressure gauges and transmitters
Pressure gauges shall comply with BS EN 837-1:1998. Pressure gauges and
transmitters shall have over range protection up to 1.5 times the maximum line
pressure and shall be capable of withstanding full line pressure on any side with
the other side vented to atmosphere without damage or effect on the calibration.
No plastic material shall be used in their construction. Internal parts shall be of
stainless steel, bronze or approved corrosion-resistant material.

Where necessary, a special diaphragm shall be used to segregate the

gauge tube from corrosive fluid media. In ammonia applications, the diaphragm
shall be in stainless steel. In chlorine applications, the diaphragm shall be in
silver or tantalum. In sulphur dioxide applications, the diaphragm shall be in
tantalum.

The minimum diameter for any pressure gauge shall be 150 mm unless
specified otherwise or where the gauge forms part of a standard item of equipment.

Where compensation of more than 2% of the instrument span is needed for the
difference in level between the instrument and the tapping point, the reading shall
be suitably adjusted and the amount of compensation shall be marked on the dial.

The zero and span of a pressure transmitter shall not change by more than +
0.1% of the span per 0C change in ambient temperature. After application for 10
minutes of pressure at 130% of maximum pressure, the change in zero and span
shall not exceed ｱ 0.1% of the span.

Pressure transmitters shall have an accuracy typically better than ｱ 0.25% of

span, depending on the application and shall be protected to BS EN 60529:1992, IP
65 standard or higher. For transmitters installed in locations liable to flooding or
underwater applications, they shall be to IP 68 standard and shall operate up a to
maximum submergence of 20 metres of water.

Pressure transmitters shall provide a 4 to 20mA d.c. output proportional to the

pressure range.

Energy Monitoring System

The Energy Monitors shall be communicating type and capable of indicating
the following parameters such as
Current per-phase
Neutral current
Voltage - phase-to-phase
Voltage - phase-to-neutral
Real Power (kW), per phase & three-phase total
Frequency readings
Real Energy (kWh)
Reactive Energy (kVARh)
Pump on/off status
Type of Measurement : True RMS Metering (Electrical parameters)
Measurement Accuracy : Class 1.0 as per IEC 61036 for 1 Amps
Class 0.5 as per IEC 60687 for 5 Amps
Power : 0.5%, Range 0 to 9999MW
Frequency : 0.1% Reading, Range 5 to 65 Hz
Power Factor : 0.5% reading, Range ±0.02 to 1.00

Input-Voltage characteristics
Measured Voltage : 40-276 VLN AC, 100 – 480 VLL AC
Inputs : V1, V2, V3, Vref
Overload : 2 times for continuous, 2500V ac for 1Sec
Power Consumption : < 3.5 W
Input-Current characteristics
Rated Inputs : 5A nominal, Range: 50mA to 6A
1A nominal, Range: 10mA to 1A
Permissible overload : for 5A meter: 10A for continuous, 100A for 1Sec
Burden : < 0.2VA
Inputs : I1, I2, I3
Frequency : 45 to 65 Hz
Communication, Protocol: RS 485, 2 wire, Half duplexed, optical isolated
Modbus RTU
Baud Rate : 1200 to 38400 bps
Environmental Temp. : -40 deg C to +85 deg C
Humidity : 5% to 95% non-condensing
Safety Standards : IEC61557-2
Residual chlorine meters
Residual chlorine meters shall comprise measuring cells, transmitters and
indicator units. These shall be arranged for continuous monitoring of the
residual in samples delivered to measuring cells from selected locations.

The residual measuring cells shall be either located in floor-standing

plastic/composite cabinets of modular construction or in wall mounted cabinets of
the same construction. Each measuring unit shall include a bi-metallic cell
generating a micro-ampere signal proportional to the residual chlorine in the
sample passed through the cell. Where necessary, each unit shall incorporate
the facility for addition of a buffer solution to minimise the effect of pH
variations on cell output or to increase cell output at high pH. The sample flow-rate
through the cell shall be adjustable by means of a spring and diaphragm
regulator or similar device. The materials of construction and sealing shall be
compatible with the sample fluid. Cells shall incorporate means of maintaining
the electrodes free from fouling.

Each cell shall be capable of measuring both free available chlorine and total
chlorine. Where required, a facility for addition of a buffer solution containing
potassium iodide shall be installed.

Where reagents are used, they shall require replenishment not more
frequently than once per 10 days. The reagent feed shall be stopped automatically
in the event that sample flow is lost.

Unless otherwise specified, means shall be provided of detecting that sample

flow is healthy and, where applicable, that a reagent supply is available. Volt-free
contacts shall be provided for remote signalling of these conditions and/or alarm
initiation.

The transmitter shall incorporate an integral indicator and produce a 4–

20mA signal proportional to residual chlorine. The unit shall be housed in a
surface mounting enclosure protected to IP 54. The fascia shall have indicator
lights for high and low alarm conditions, alarm set-point adjustment, lamp-test
facility and volt-free changeover contacts for re-transmission of high and low
alarm conditions.

The overall accuracy of the residual chlorine meter shall be better than
ｱ 0.04 ﾗ M mg/l and the repeatability shall be better than ｱ 0.02 ﾗ M mg/l where M
is the maximum value of the selected meter range. Subject to replenishment
of reagents, where applicable, the meter performance shall be maintained
without manual intervention for a minimum period of 30 days.

8.2 TURBIDITY METER. ( In case of surface water as source)

Turbidity meters shall be continuous flow, continuous reading, on-line

instruments using the nephelometric principle of measurement. They shall utilise a
single silicon photodiode to detect the level of light scattered by particles at 900 to
the incident light beam which in turn coverts it to an electrical signal for display.
The turbidity meter shall be provided with an auto-ranging digit display with
automatic decimal point positioning to eliminate range-setting and reading errors.
Tow fully-adjustable volt-free turbidity alarm contacts and instrument failure alarm
contacts shall be provided.
A 4mA to 20mA dc output signal programmed to cover any part of the instrument
range shall be provided.
Each instrument shall be provided with an integral bubble trap.
Means shall be provided for the checking and adjusting of the instrument
calibration which does not require the use of standard solutions and reduces the
maintenance of the measuring cell to a minimum.
Enclosures for the turbidity meter and control unit for indoor use shall provide a
degree of protection against dust, falling dirt and dripping non-corrosive liquids
(NEMA-12) or an equivalent approved by the Engineer.
The overall accuracy shall be better than ± 5% of reading of 0.25 NTU
whichever is greater and the repeatability shall be better than ± 2.5% of reading or
± 0.1 NTU whichever is grater. The instrument performance shall be maintained
without manual intervention for a minimum period of 30 days.

Programmable Logic Controllers / Remote Terminal Units

General
a. A programmable logic controller (PLC) shall be any digitally-operating
electronic apparatus which uses a programmable memory for the internal
storage of instructions for performing particular operations (e.g., logic,
sequencing, timing, counting, analogue and arithmetic). This apparatus shall
control, via digital and/or analogue input/output modules, various items of plant or
processes and provide inputs to other controllers and to associated data acquisition
systems. A PLC shall comprise a central processor, input/output interfaces,
logic memory, data storage memory and a programming device and shall have the
necessary input and output facilities to provide correct interfacing with plant to
achieve the specified system operation. The PLC shall have 400 hours meantime
between failure. The advantages of RTU should be provided in PLC also. In case of
PLC failed in one place, the datas in the previous period should be retrieved.

b. The Remote Terminal Units (RTUs) shall be micro-processor based units of

modern field proven design. RTUs must be modular in design to allow expansion of
communications and I/O interfaces and capable of a variety of data transfer
methods using various communications media and protocols. The RTUs shall
comply with
1) IEC 61131 – for programming software
2) EN 55022; EN 1326-1; CE – for EMI emission
3) EN 61326-1 (EN 61326-4-2, 3, 4, 6); CE – for EMC immunity
4) EN 61010-1 (IEC 1010); CE – for Electrical safety
5) IEEE-472 (ANSI C37.90) – for surge withstanding
6) IEC 68-2-6 – for vibration
7) UL 1604. CSA C22.2/213 – for Hazardous environment
8) IEEE 472 – for surge withstanding capability
 A PLC/RTU shall have immunity to mains-borne and radiated electrical
interference. Input interfaces shall be optically isolated and digital integrated
circuits shall use the latest hybrid semiconductor technology in keeping with
industry standards.

The highest possible level of "user friendliness" shall make PLC/RTU

programming, interrogation and operation simple and easy to understand.
A PLC/RTU shall have diagnostic routines to identify any component and
circuit failure and to neutralise the effects of any such failure.

10.6.2 Memory
PLC/RTU program and data memory shall be provided with a minimum of
twelve months integral battery back-up.

A minimum of 100% spare programme memory and 200% spare data register
memory shall be available when final commissioning is complete. In addition,
the memory shall be expandable, using expansion modules, to provide a
further increase in capacity of at least 100% for future use.

10.6.3 Diagnostics
PLC/RTU shall be provided with remote diagnostic capabilities to identify
failures to the circuit board level. Diagnostic indication shall as a minimum,
consist of notification of processor failure, input or output module failure,
communications failure, and battery low. these conditions shall also be
available as outputs from the outstation for panel indication. These diagnostics
shall all be available as digital outputs for remote indication.

10.6.4 Communications
PLC/RTU shall be capable of connection and incorporation into a network
of devices for data communication. The communication protocol shall include a
state-of-the-art error detection scheme to ensure error-free data transmission
and reception. The communication protocol shall include repeated attempts at
error-free transmission before a network device (node) is declared as "failed".
Where dual redundant communication facilities have been specified, interface
facilities shall be provided in all PLC/RTU for connection to the dual redundant
communication system ( GPRS and Ethernet Radio Modem ). The
communication system shall automatically take action such that a single interface
failure does not render the PLC/RTU unable to communicate.
Communication failure at a network node shall not effect communications at
any other node.
Software development facilities shall be provided for defining, modifying and
monitoring the communication network.
PLC/RTU shall contain sufficient communication ports such that a portable
programming device may be connected and operated without disconnecting other
wiring. Ethernet connection shall be provided to connect VFD.
PLC/RTU shall have 100% spare communication ports for expansion and trial of
alternative communication system.
10.6.5 Input/output
PLC/RTU shall be fitted with input and output circuits to interface with
field devices for data acquisition and control. Input and output circuits shall
be arranged on plug-in modules to facilitate replacement. Plug-in input and
output modules shall be fitted with connects which allow replacement of the
module without disconnection of field interface wiring. All field inputs, both
analogue and digital, shall be optically isolated.

Inputs and outputs for any particular set of duty/standby equipment shall
be arranged over multiple I/O cards wherever possible such that a failure of a
single I/O card does not prevent the operation or monitoring by the PLC/RTU of more
than one device of the set.

When commissioning is complete, PLC/RTU shall have a minimum of

100% spare inputs and outputs of each type (ie digital inputs, digital outputs,
analogue inputs and analogue outputs). Input and output capacity shall be
expandable, using additional input and output modules, to give a minimum of a
further 100% additional inputs and outputs of each type for future use.

The Contractor shall be responsible for considering each output load in detail
to ensure that the loading capabilities of the PLC/RTU are adequate.

10.6.6 Operator interface

All programming of a PLC/RTU shall be possible via integral or portable
plug-in programming devices which shall be supplied with each instrument.
The programming device shall also provide local manual control as well as the
facility to interrogate the PLC/RTU for more detailed diagnostics than those
previously mentioned.

The programmer keyboard shall have keys for controlling and editing
functions and for entering arithmetic, timer, counter, basic and special
instructions and numerical values. Programming shall be simple to understand
and carry out. A key switch or other approved security facility shall be provided to
restrict access to the program to authorised persons.

Complete software of the latest version and revision shall be provided,

fully loaded and operational, on the portable programming device.

10.6.7 Failure
Any control circuit output of a PLC/RTU shall be de-energised or neutralised
whenever a failure of a circuit, component or power supply occurs in the input or
output loop associated with the particular output. The equipment shall
automatically detect failures of input circuits and output devices and take action
to avoid any unsafe or operationally-undesirable condition.
10.6.8 Operating system:
The Operating System software shall be the latest version of Microsoft Windows
to provide system resource allocation and management in a Real-Time, multi user
environment.
The Operating System shall provide an orderly shutdown on loss of power or
low voltage and automatically restart the system, including processor and
peripherals, upon restoration of power without operator intervention. The power
failure protection shall protect against loss of program and/or work in progress at
the time of occurrence.
Software for server shall be Windows 2007 Server standard.
Software for PC shall be Windows XP standard.

10.7 Signal-conditioning devices

Signal-conditioning devices shall include isolators, amplifiers, current-to-
pulse and pulse-to-current converters, arithmetic modules, trip amplifiers and
similar units.

Each device shall be designed for mounting within an enclosure using a

mounting plate, rack or rail. The operating power supply shall be a nominal 220V ac
or 24V dc. An indication of ‘power supply on’ shall be provided at the front of each
unit.

Input and output circuits shall have impedances to suit the signal sources and
loads with which they operate. Each analogue input and output circuit shall have
independent zero and span adjustments. Set-points on the instrument front shall
be fully adjustable by means of a knob with an engraved lid. Input, output and
power circuits shall be mutually isolated up to 1000V rms and from earth.

The states of relays used in conjunction with digital inputs or outputs shall be
indicated at the front of the unit. Analogue inputs or outputs shall be indicated on
the front.

Each device shall be immune to normal industrial interference and RF up to

400MHz.

I/O Details /PLC

1) Analog input = 8 Nos

2) Digital input = Max 4 Nos

Supervisory Control and Data Acquisition System

Description of work
SCADA package will be used to deliver an effective plant monitoring and
control system. This system will be fast, efficient, and completely scalable with the
flexibility to choose own system design.

SCADA package with sufficient tags for development and customisation will
be installed in the computers, located at the Master Station.

Supervisory Control and Data Acquisition system (SCADA) will be used for
acquiring data from the field devices through RTU/ PLC.

SCADA Package for Monitoring & Data collection at Central station

SCADA software
i. Shall be installed in Server at Divisionoffice and should be capable of
controlling and monitoring at least 50 Remote Telemetry Units with a SCADA
development cum server software with min 700 tags.

ii. Shall be installed in client PC’s at the Division office, should be capable of
monitoring respective head works connected to the respective zone with a client
software with min 700 tags for each computer.

iii. Shall be installed in computers at Circle office,Regional Chief Engineer

office should be capable of controlling and monitoring respective headworks
connected to the respective scheme with Runtime software with min 300 tags for
each computer.

SCADA software should acquire data from all RTU’s/ PLC and display in the
HMI screen. In addition to the display action, the logs of each station should be
transferred using data export to database processing software (MS SQL, MS
ACCESS, EXCEL, etc.,).

Description of System
The supervisory data acquisition and control system (SCADA) specified herein
shall be designed, installed, tested and customized as follows:
• To collect, store and accurately analyze, reliable operating
information for present and future uses
• To perform Real-time process control.
• To assist plant operating personnel by noting and announcing
off-normal operating conditions and equipment failures
• To perform calculations based on sensor (automatic) / manual
operator data inputs
• To accumulate and store equipment running times
• Store and retrieve all operation information
• Compile and prepare daily, weekly and monthly reports
• Provide central or local control using clear, concise, resizable graphics
pages screens.
• Graphical control buttons to pages, to perform single or multiple tasks.
• Animations to display the operating status and performance of Water
Distribution Stations and OHT status.
• Display text messages and graphics to show the status of a process or
the state of an alarm.
• Monitor, control, log, and display all alarms.
• Provide historical and real-time trending in graphical format.
• Monitor performance and efficiency as it happens by using trend and
data logging facilities.