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Logically organized specifications allow the reader to find information they need. A standard industry method of organizing specifications available to design engineers is CSI’s “MasterFormat”. MasterFormat includes content, organization, and section numbering of the specification. The CSI created a numbering sequence in 1995 called “MasterFormat 1995”, which created 16 divisions for technical specifications. The organization was revised in 2004 to align more closely with architectural organization format, and a new numbering sequence was established with 44 divisions. Organization of the 1995 specification was not revised in the numbering change implemented in 2004. The CSI format consists of the following three specification topics: general, products, and execution. MasterFormat provides a consistent document form for owners, engineers, and contractors to locate project information. The CSI format continues to evolve and has been republished as “MasterFormat 2010” with additional divisions.

The CSI manual of practice originally developed in 1948 is a construction industry standard used by professionals to improve and organize construction documents, including project manuals, product data, and cost estimates. The CSI’s primary focus has been on information classification and format of presentation. Format documents (i.e., MasterFormat™, UniFormat™, SectionFormat™, and PageFormat™) and principles outlined in The Project Resource Manual (CSI, 2005) are the results of this classification. The CSI continues to be vital to the construction industry by remaining committed to the maintenance and ongoing improvement of standards to meet the changing needs of the construction industry. The CSI is supported through license fees for their documents.

The “general” section (Part I) of the specification consists of the following:

• An outline of the overall work and requirements for equipment and services to be provided;

• Related work or requirements specified elsewhere; for example, supervisory control and data acquisition (SCADA) system components may be furnished from multiple specification sections, including packaged systems. A transmitter may be supplied by one party, mechanically installed by a second, and electrically wired by a third. References to related work help describe the equipment’s final installed condition;

• Submittal requirement from the contractor, including

Bill of materials;

Manufacturers’ catalog sheets;

Manufacturers’ data sheets showing options selected and calibration data;

Loop diagrams showing each loop, with all terminations identified (ISA, 1991);

Wiring schematics with point-to-point wiring tables and diagrams;

Panel and console drawings showing the layout of front-panel-mounted and internal-panel-mounted devices;

Diagrams and lists of software programs developed for programmed devices (e.g., programmable logic controllers [PLCs] or computers);

Software submittals documenting the implementation of control system narratives;

Requirements for equipment samples and shop drawing submittals;

Manufacturers’ calibration certifications or test reports; and

As-built drawings and wiring tables;

• Operations and maintenance (O&M) manuals furnished by the contractor, including

Record drawings reflecting final as-built condition of the installed system;

Copies of certifications and test reports, with shop and field tests;

Copies of manufacturers’ instrumentation and technical bulletins, installation instructions, O&M instructions, troubleshooting instructions, repair instructions, spare parts lists, and device configuration;

Instrument schedule, including device tag, type, service, location, calibrated range, and setpoints;

Control narratives and logic descriptions; and

Electrical interconnection diagrams;

• Spare parts; and

• Special tools.

The “products” section (Part II) contains the following required data that must be edited to reflect materials, accuracy, performance, and other project-specific requirements for each specified control system device, network component, hardware, software, control system narrative, and instrument:

• Control system hardware and software;

• Control system narratives;

• Communications equipment;

• Networking components;

• Database configuration requirements;

• Process display requirements;

• Report requirements;

• Historical data collection requirements;

• Instrument type;

• Pipe size (for in-line instruments);

• Minimum and maximum operating data (e.g., flow, pressure, temperature, and pH);

• Environmental requirements (e.g., temperature, humidity, and corrosive or explosive atmosphere);

• Method of connection to physical system (e.g., flange and fitting size);

• Special installation hardware required;

• Tagging requirements;

• Range of measurement;

• Accuracy;

• Precision;

• Enclosure;

• Process or wetted part requirements;

• Electrical voltage requirements;

• Signal output;

• Local or remote indication;

• Diagnostics and testing;

• Application vendor options;

• Maintenance and calibration requirements;

• Input signal required;

• Type of setpoint adjustment (e.g., fixed or adjustable), if applicable;

• Alarm switch with limit settings and the amount of deadband required when switches return to normal;

• Construction materials;

• References to standards (e.g., ISA, Underwriters’ Laboratory, and National Electrical Code); and

• Appurtenances (e.g., mounting hardware, special tools, or calibration equipment).

The “execution” section (Part III) of the specification details the requirement for implementation, including field testing, quality control, and others. Before the owner accepts a new or modified process control system, the system or modifications should pass the following three performance tests consistent with the size of the project:

• Factory acceptance test (FAT),

• System availability test (SAT), and

• Site demonstration test.

The FAT demonstrates that the control system is built to the project’s requirements (including specifications), that the system is in accordance with the manufacturer’s shop drawings, and that the system is properly configured and ready for shipment to the job site. After field installation, instrumentation testing should be integrated to SAT, which typically duplicates FAT testing at the job site using installed devices to completely test control system hardware, software, wiring, and communications media.

Test criteria for these tests is developed by the design engineer, but the system integrator develops detailed test procedures for each control system because testing requirements may be unique based on the site and custom SCADA system. Testing is conducted by the system integrator and witnessed by the owner or design engineer. Instruments may be tested at the factory or in the field. Individual instruments (i.e., transmitters) and groups of devices (e.g., control panels) can be tested.

During startup of the process control system, the contractor may have to tune control loops and demonstrate that the instrument works properly. For some devices (e.g., magnetic flow meters, mass meters, specialized analytical instruments, emission monitoring systems, etc.), a trained representative of the instrument manufacturer should commission the equipment for the contractor to properly demonstrate operation.

Training specifications may require a minimum number of training hours and trainers’ resumés and require the contractor to submit a detailed outline for each course. These training courses should cover process control system hardware, software, and instrumentation.

Specifications should also require the contractor(s) to provide the following control system documentation:

• Corrected as-built drawings,

• Shop drawings,

• Panel drawings,

• Fiber-optic patch panel drawings,

• Loop drawings,

• Application program documentation,

• Hardware configuration documentation,

• Control system hardware and software,

• Control system interconnection drawings,

• Communications equipment hardware and software,

• Manufacturers’ data sheets for all instruments, and

• O&M manuals.

As part of final documentation, these documents should be furnished in a searchable, editable electronic format and in paper copies. Electronically formatted data can then be incorporated to the facility’s documentation or maintenance management systems. The type of documentation must be specified to enforce requirements for the contractor.

Specifications should also require the following types of schedules:

• Instrument lists (field and panel);

• Device nameplate or tag engraving;

• Reports (process and regulatory);

• Human–machine interface or OIT graphical screens;

• Programmable logic controllers’ I/O;

• Data register mapping;

• Historian data;

• Network configuration settings; and

• Device names.