Instrumentation & Controls Standards

Document Number AM 2832

Contents
1. General Requirements 4
1.1 Acronyms and Abbreviations 4
1.2 Scope 5
1.3 Standards 6
1.4 Quality of Workmanship 6
1.5 Materials, Equipment and Component 6
1.6 Labelling 6
1.7 Drawings and Integration 6
1.8 Pre-Construction Submissions 6
2. Installation Requirements 7
3. Instrumentation 7
3.1 Installation 7
3.1.1 Arrangement ..............................................................................................7
3.1.2 Field Enclosures and cabinets ....................................................................7
3.1.3 Instruments within Buildings .......................................................................8
3.1.4 Instrument Panel Layouts ...........................................................................8
3.1.5 Support ......................................................................................................8
3.1.6 Electrical Isolation ......................................................................................8
3.1.7 Instrument Clean Earth...............................................................................8
3.1.8 Piping .........................................................................................................8
3.1.9 Identification ...............................................................................................9
3.1.10 Transmission ..............................................................................................9
3.1.11 Surge Protection.........................................................................................9
3.2 FLOW METERS 9
3.2.1 Selection ....................................................................................................9
3.2.2 Installation: Technician Requirements ........................................................9
3.2.3 Cables ......................................................................................................10
3.2.4 Potting ......................................................................................................10
3.2.5 Sensor Location .......................................................................................10
3.2.6 Sizing / Ranges ........................................................................................10
3.2.7 Transmitter location ..................................................................................10
3.2.8 Transmitter Connection to RTU / PLC ......................................................11
3.2.9 Lightning Protection..................................................................................11
3.2.10 Transducer Termination ...........................................................................11
3.2.11 Fasteners .................................................................................................12
3.2.12 Cathodic Protection ..................................................................................12

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3.2.13 Earthing / Bonding ....................................................................................12
3.2.14 Bypass Piping ..........................................................................................14
3.3 Underground 14
3.3.1 Location ...................................................................................................14
3.3.2 Wrap and Backfilling .................................................................................15
3.4 Above Ground 15
3.4.1 Location ...................................................................................................15
3.5 Transmitter 16
3.5.1 Lightning Protection..................................................................................16
3.5.2 UV Protection ...........................................................................................16
3.6 Magnetic Flowmeters 16
3.6.1 Arrangement ............................................................................................16
3.6.2 Pit Considerations ....................................................................................16
3.6.3 Supply Voltage .........................................................................................16
3.6.4 Verification ...............................................................................................17
3.7 PRESSURE INSTRUMENTS 17
3.7.1 Gauges ....................................................................................................17
3.7.2 Pressure Transmitters ..............................................................................17
3.8 Measurement Units 17
3.8.1 Accuracy ..................................................................................................18
3.8.2 Calibration ................................................................................................18
3.8.3 Ranges.....................................................................................................18
3.8.4 Instrument Zero Reading ..........................................................................18
3.9 Installation Requirements 18
3.9.1 General ....................................................................................................18
4. Verification / Documentation 19
4.1 Verification 19
4.2 Documentation 19
5. PLC & RTU Installation 19
5.1 General 19
5.2 IO Termination 20
5.3 IO Segregation 20
5.4 IO Surge Protection 20
Appendix A – Equipment Identification 21
Appendix B – Instrument Calibration Record 22
Appendix C - Flow Meter Installation Details 23

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Document Control
Rev Date Revision Details
AM2832- Instrumentation Clause Author
& Controls Standards Approved
0 13/08/20 The EIC committee had All EIC Committee A. Gabriel
reviewed various sections of
C. Paxman
this Standard on 5 occasions.
We have set revision to rev 0.
We have decided to segregate
the original AM2714 into
separate standards, namely:
AM2714 – Electrical
Standards
 AM2832 –
Instrumentation &
Controls Standards (this
document)
 AM2847 –
Communications
Standards
 AM2851 – EIC Inspection,
Testing & Completions
Standards
 AM2848 – Approved EIC
Equipment List

0.1 22/7/2021 Instrument Accessibility 3.9.1 J. Street EICC

Committee

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 AM2832- Instrumentation & Controls Standards

1. General Requirements
1.1 Acronyms and Abbreviations
All abbreviations and acronyms used in additional documentation, shall follow the conventions
used through this and other related project documents.
Acronym Description
ABS Acrylonitrile Butadiene Styrene
AD Active Directory
AI Analogue Input
AO Analogue Output
COTS Commercial Off The Shelf
Cu Copper
DI Digital Input
DIN German Institute for Standards (Deutsches Institut für Normung)
DNP3 Distributed Network Protocol (version 3)
DO Digital Output
ELV Extra Low Voltage
EMC Electromagnetic Compatibility
FAT Factory Acceptance Test
FDS Functional Description Specification
HMI Human Machine Interface
IEC International Electrotechnical Commission
iLO Integrated Lights Out
IO Input Output
IP Ingress Protection
ITP Inspection Test Plan
LCD Liquid Crystal Display
LED Light Emitting Diode
LV Low Voltage
mAHD Metre Australian Height Datum
NTP Network Time Protocol
OTDR Optical Time Domain Reflectometer
P&ID Process & Instrumentation Diagram
PC Personal Computer
PLC Programmable Logic Controller
PSU Power Supply Unit

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 AM2832- Instrumentation & Controls Standards

PTC Positive Temperature Coefficient

PVC Polyvinyl Chloride
RCD Residual Current Device
RTU Remote Telemetry Unit
SAL Site Alarm List
SAT Site Acceptance Test
SCADA Supervisory Control And Data Acquisition
SDM System Design Matrix
SEW South East Water
SFP Small Form Pluggable
STP Sewage Treatment Plant
TBA To be advised
TBC To Be Confirmed
TFT Thin Film Transistor
TTP Tertiary Treatment Plant
UF Ultra Filtration
UPS Uninterruptable Power Supply
UPVC Unplasticised Polyvinyl Chloride
UV Ultra Violet
VLAN Virtual Local Area Network
VPN Virtual Private Network
VSD Variable Speed Drive
WAN Wide Area Network

1.2 Scope
This specification outlines South East Water’s minimum standards for the selection, fabrication,
delivery, installation and testing of instrumentation and controls equipment, associated items
used at new or renewed water and sewerage infrastructure sites.
Excluded from the scope of this specification are:
a. South East Water assets not containing water and sewerage infrastructure (e.g.,
WatersEdge office, depots)
b. Functional or operational requirements relating to electrical assets.
c. Monitoring, protection, control and communication system design, configuration and
programming. This is covered by other South East Water standards such as
AM2779_Treatment Plant Monitoring and Control Specification.
d. Civil, mechanical arrangements, pump selection, pump performance or hydraulic
assessment.
e. Work practices associated with the management of electrical risks during construction
and installation works.

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 AM2832- Instrumentation & Controls Standards

1.3 Standards
The following standards shall apply in the given order of preference:
a) Australian Standards or its IEC/ISO equivalent
b) OH&S Regulations 2017 (Victoria)
c) Electricity Safety (Installations) Regulations (Victoria)
d) Victorian Service & Installation Rules
e) Essential Services Commission Electricity Distribution Code
f) Requirements of the Electricity Distribution Company
g) Electricity Safety Act (Victoria)
h) Manufacturer’s Guidelines
i) Water Industry Standards, including:
i. WSA04 Sewage Pumping Station Code Of Australia
ii. South East Water supplementary manual to WSA04
iii. South East Water Standard Electrical Drawings
iv. AM2779_Treatment Plant Monitoring and Control Specification (SEW)
v. AM2717_Generator Specification (SEW)
vi. AM2522_O&M Manual Specification (SEW)
vii. AM2755_Testing, Commissioning and Handover Plan (SEW)
viii. AM2739_Corrosion Mitigation Specification (SEW)
ix. AM2727_Covers for Underground Structures (SEW)
x. AM 2758_Noise Specification (SEW)
xi. AM2775_Watershed Collection Details (SEW)
xii. AM2776.3_Air Treatment Unit Specification and Commissioning (SEW)
xiii. AM2488_2D and 3D Drafting
The order of precedence of documents shall be as follows:
a) Legislated requirements
b) Project specific specifications
c) Project specific drawings
d) South East Water standards
e) South East Water standard drawings
f) Water Industry Standards (WSAA)

1.4 Quality of Workmanship

Please refer to AM2714.

1.5 Materials, Equipment and Component

Please refer to AM2714 and AM2848.

1.6 Labelling
Please refer to AM2775.

1.7 Drawings and Integration

Please refer to AM2714.

1.8 Pre-Construction Submissions

Please refer to AM2714.

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 AM2832- Instrumentation & Controls Standards

2. Installation Requirements
Please refer to AM2714.
All works shall be done by appropriately* qualified, competent, recognised and approved by SEW
representative instrument technician/personnel or vendor subject matter expert specific to the
task.
*Shall be determined by SEW. Minimum requirements would be to undergo the following
Swagelok trainings for instrument fitters:

 Instrument Pipe Work fittings. – technician must have completed Swagelok Tube bending
essentials course & Tube Fitting Installation Course.
 Calibration and setup of instruments – must be carried out by qualified Instrument or
Instrument/Electrical Technician or Vendor Representative.

3. Instrumentation
3.1 Installation
3.1.1 Arrangement
Instruments shall be arranged so that adjustments can be readily made in the field. Permanent
access shall be provided for all field indicators, transmitters, analysers, actuators and points of
calibration or challenge testing. Where applicable provide drain and 1/4 inch test points with
associated isolation valves for in situ calibration without the requirement to dismantle supports
or pipework.

3.1.2 Field Enclosures and cabinets

Mount field instruments within enclosures between 800 and 1500 mm above ground providing
the following degree of protection.
 IP 56 minimum for all equipment above the ground
 IP 67 minimum for all equipment in the pits, e.g. valve pits,
 IP 68 for the equipment subject to submergence.
Enclosures shall be constructed from 316 stainless steel construction, powder coated finish.
Locking systems to conform to AM2714. Provide adequate ventilation where applicable.
Cabinets shall be:
 G62 river gum in colour unless all equipment around it is not painted.
 Fitted with approved SEW locks refer to AM2714
 Fitted with cross ventilation with vermin/insect protection.
 Fitted with stainless steel or aluminium rain hood.

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 AM2832- Instrumentation & Controls Standards
3.1.3 Instruments within Buildings
Mount instruments collectively on a common panel. Panel material to be non-metallic, 10mm
Grey PVC or equivalent.

3.1.4 Instrument Panel Layouts

Instrument panels shall be built as per SEW standard drawings.

3.1.5 Support
Where applicable instruments shall be mounted using brackets as supplied by the
manufacturer. No instrument shall be installed dependent only on its impulse piping, process or
electrical connection.

3.1.6 Electrical Isolation

Instruments supplied by a voltage equal to or greater than low voltage shall be fitted with a local
isolator. Local isolation shall include lockable isolators for hard wired equipment or plug socket
combinations.

3.1.7 Instrument Clean Earth

An Instrument Clean Earth shall be installed at the location of each field instrumentation
enclosure. The Instrument Clean Earth shall be isolated from the site structure and other metal
work. The Instrument Clean Earth shall be bonded to the main electrical earthing system at a
single point only. The Instrument Clean Earth shall be labelled accordingly.
Instrument signal cabling containing an earth screen shall be left floating in the field end. It shall
be electrically continuous from the field equipment and be connected to the Instrument clean
Earth bar in the receiving switchboard.

3.1.8 Piping
Provide pipe unions, isolation valves, test and drain points to enable removal or in situ calibration
of in line instruments with threaded connections such as pressure transmitter switches, and
gauges, rotameters etc.
All small bore fittings shall be per AM2848 Approved EIC Equipment List e.g., Swagelok
gaugeable fitting.
All threaded joints shall be BSP threads. NTP threading, BSB tapered and BSP parallel threading
may be required for connection of some components.
All cock valves shall be Swagelok quarter turn ball valves. All needle valves shall be Swagelok
screwed bonnet needle valves.
All piping and impulse tubing shall be stainless steel or flexible nylon. Flexible nylon tubing shall
be rated to 1.5 times the maximum measurement value and be fitted with Swagelok gaugeable
fittings.
Where piping or tube is exposed to the elements or installed in an area with a run greater than
1m shall be stainless steel.

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 AM2832- Instrumentation & Controls Standards
3.1.9 Identification
All equipment and instruments shall be identified by means of 316 stainless steel corrosion
resistant tags permanently affixed adjacent to the instrument by means of 316 stainless steel
screws or rivets.

3.1.10 Transmission
All instruments shall be capable of transmitting the output signal by loop powered 4-20mA
analogue current loop. The output signal shall be linear with a proportional increase in the
measured variable. Each transmitter shall be fitted with a configurable local indicator. The
indicator shall be integral to the transmitter assembly. The local indicator shall display the
measured value in engineering units.
Signal transmission shall be HART protocol compatible. A series resistor of 250 ohms shall be
connected within the signal loop located adjacent to the instrument to allow connection of a Hart
configurator/ calibrator. Consideration to minimum operating voltage (loop power instruments)
and total loop resistance shall be consider when adding series resistance.
NOTE: Burn-in/burn-out or fail-low/fail-high transmitter settings must be documented

3.1.11 Surge Protection

Provide lightning surge protection to instrument loops > 5m installed in field locations. Direct
mount the protection device on the instrument or install modular protection enclosed in a cubicle
within 1m of the instrument. Provide modular protection at the PLC, RTU, receiving device loop.
Protection: Multi stage 10kA max discharge surge current for an 8/20 micro-second pulse (8
micro-second rise time, 20 micro-second exponential decay time) for line-to-line and line-to-
earth transients and arranged to fail to the short circuit condition.

3.2 FLOW METERS

3.2.1 Selection
Flow meters shall be selected from the SEW approved products list from AM2848 - Approved
EIC Equipment List.
South East Water M&E Department and Design Team’s approval is required for any deviation
from the selected.

3.2.2 Installation: Technician Requirements

All Manufacture Installation Guidelines shall be followed.
All flow meters shall be wired by the Manufacturer representative or Qualified Instrument
Technician.
Where practical, the cables may be installed and potted by the supplier before delivery.
Flow meter wiring / conduit shall be installed by a Qualified Electrical or Instrument Technician.
The flowmeter sensor tube shall installed by Civil or Mechanical Tradespeople. If buried, prior to
backfill a verification of the flowmeter’s operation shall be performed. Protective wrapping and
backfilling shall be witnessed by a Qualified Electrical or Instrument Technician.

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 AM2832- Instrumentation & Controls Standards
3.2.3 Cables
All cables from the sensor to the transmitter shall be continuous in length with no joints.
All connections and approved cable type shall be as per manufacturer’s guidelines.

3.2.4 Potting
All sensors must be potted with the manufacture recommended potting mix. Any unused cable
glands must be sealed with appropriate o’ring sealed, threaded plastic conduit plugs.

3.2.5 Sensor Location

Position of the flow sensor tube shall factor in disturbances upstream or downstream of the
sensor.
Flow sensor shall be installed as per the recommended distances by the manufacture, if not
stated the below must be used.
 Straight Pipe Minimum 5 x Diameter of pipe before, 2 x Diameter of pipe
after
 Before a Bend Minimum 2 x Diameter of pipe
 After a Tee or Valve Minimum 10 x Diameter of pipe
 After a Tee or Valve Minimum 10 x Diameter of pipe
 Before a Valve Minimum 10 x Diameter of pipe
 Before a Control Valve Minimum 5 x Diameter of pipe
 After a PRV Minimum 25 x Diameter of pipe( Recommendation to always
install before a PRV)
 After a Pump Minimum 10 x Diameter of pipe
If chemical dosing injection points are installed on the same pipeline then they shall be at least
20 Diameter lengths, of the pipe downstream. Consideration shall be made in the PLC code to
reduce the backflow of the chemical by stopping a dosing pump before a fluid transfer pump is
stopped.

3.2.6 Sizing / Ranges

Flow meters sizing must be selected for the correct size of the station requirements.
- Sized higher than the sites maximum flow.
- Sized adequately to detect any low flow requirements
- Transmitters must be programmed to the correct flow requirements of the site

3.2.7 Transmitter location

Transmitter must be mounted in the recommend locations below, otherwise approved by SEW
representative.

Water & Sewer sites

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 AM2832- Instrumentation & Controls Standards
 If the flow meter signal converter (transducer) resides near a building then the transmitter
must be mounted on the internal side wall of the building wall between 1.5m and 1m, with
the flow rate programmed onto the site HMI and to SCADA.

 If the site only has a cabinet the transmitter must be mounted either in its own
tier/compartment or with station control with the flow rate programmed onto the site HMI
and to SCADA.

 Direct Mounting may be allowed as advised by SEW M&E Team, with station control with
the flow rate programmed onto the site HMI and to SCADA. This will normally only be
considered if the flow meter is indoors and the display can be accessible from the ground.

Treatment Plants
 If the flow meter signal converter (transducer) resides near a building then the transmitter
must be mounted on the internal side wall of the building wall between 1.5m and 1m, with
the flow rate programmed onto the site SCADA and to Remote SCADA
 If the flow meter signal converter (transducer) is remote it must be installed in a vented
S/S or Aluminum River gum enclosure painted G62 Rivergum.
 Direct Mounting may be allowed as advised by SEW M&E team, with station control with
the flow rate programmed onto the site SCADA and to Remote SCADA. This will normally
only be considered if the flow meter is indoors and the display can be accessible from the
ground.

3.2.8 Transmitter Connection to RTU / PLC

All transmitters to be supplied with 4-20mA feedback, Modbus comms or HART Communication
unless approved by SEW. Pulse output required in some cases.

3.2.9 Lightning Protection

If available from the manufacturer, lightning protection shall be installed in the flow meter sensor
and transmitter. Note: needs to be made at the transmitter to indicate lightning protection is
installed at the sensor end for insulation resistance testing of an appropriate voltage.

3.2.10 Transducer Termination

Where multiple cables enter a flow meter sensor, they shall enter via separate glands and be
run in separate conduits with a minimum size of 25mm HD conduits.
Conduits must be overlapped onto the sensor cable glands by resin heat shrink or flexible
expansion couplings similar to Clipsal F251/25.
Where buried, the final point of connection from conduit to sensor junction box should be of HD
corrugated conduit with enough allowance for minor movement or settling of the surrounding area.
Conduits are to be sealed to prevent ingress of moisture.
Terminations to be carried out as per manufacturer’s guidelines.
Where the sensor is connected to the transmitter with two or more cables, they shall be installed
in separate conduits separated by the width of the trench or a minimum distance of 200mm to
prevent cross-talk, particularly on cable runs in excess of 20m. Sensors connected by a single
multicore proprietary cable shall be installed in conduits in the centre of the trench.

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 AM2832- Instrumentation & Controls Standards
All sensor cables shall be run away from any other services or cabling systems and where they
need to cross, it shall be at right angles to that service.

3.2.11 Fasteners
All bolts/ nuts / washers shall be stainless steel 316 coated with nickel-based anti-seize.

3.2.12 Cathodic Protection

All flowmeters installed on a cathodic protected pipeline shall be installed as per manufacturer’s
guidelines. With the sensor isolated from the cathodic pipe. Installation must include the below:
 Isolating sleeves and washers for all bolts
 Gaskets are to be non-conductive
 Grounding rings to be isolated from the pipe and connected to the flow meter flange only
 Electrode and coils shield to be terminated at the transmitter end only
 Transmitter to be 24V DC and powered from an isolated supply
 Transmitter to be isolated from ground.
 Bypass strap between outside mating flanges

3.2.13 Earthing / Bonding

Sensor tubes shall be bonded between the tube and the adjoining pipe, Bonds shall also be
installed from the two adjoining pipes similar to the below. If earthling rings are installed they
shall also be bonded.
Sensors shall not be connected to grounding spikes.
Earthling rings shall be installed on all plastic or combination of metal/plastic pipelines.
Refer to manufacturer’s guidelines.

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 AM2832- Instrumentation & Controls Standards

Metal Pipe Bonding Not including Full Bond above

Plastic Pipe Bonding Not including Full Bond above

Combination of Metal and Plastic Pipes Bonding Not including Full Bond above

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 AM2832- Instrumentation & Controls Standards

3.2.14 Bypass Piping

Flowmeters installed at the below locations must have bypass piping installed around the
flowmeter with appropriate valving for flow meter isolation, removal and system bypassing.

 Sewer Pump stations - with a PDWF (Peak Dry Weather Flow) of equal to or
greater than 25 l/s
 Water Booster Pump stations - All
 Treatment Plants - Critical flow paths lines

Waste Water Treatment Plants including Class-A,C Treatment

Bypass of flow meters where immediate replacement of the flow meter is required and/or where
the process flow cannot be readily isolated.
Preference for all flowmeters to be installed in pits.

Potable Water Pumping / Distribution including Class-A,C

Bypass of flow meters where immediate replacement of the flow meter is required and/or where
the process flow cannot be readily isolated, e.g., booster pump station
Preference for all flow meters to be direct buried.

Waste Water Pumping / Distribution

Bypass of flow meters where immediate replacement of the flow meter is required and/or where
the process flow cannot be readily isolated.
Preference for all flowmeters to be installed in pits.

3.3 Underground
3.3.1 Location
A preference is not to bury flow sensors, pits need to be considered as per requirements in
AM2714.

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 AM2832- Instrumentation & Controls Standards
All underground sensors shall have marker 1.5mm x 60mm dia. or greater S/S engraved round
plate mounted on the concrete/road or on level buried 300mm x 300mm concrete surrounds. With
clear labeling below including its watershed ID. The label shall be fixed using a high quality, single
component joint sealant / high adhesive strength such as ‘Soudal Fix All High Tack’ or ‘Sikaflex
11FC’.

South East Water

FLOW METER UNDERNEATH
(Watershed ID No)

3.3.2 Wrap and Backfilling

All Buried flow sensors shall be packed with Denso mastic (400), then wrapped in denso tape
(600) followed by Denso PVC overwrap tape (931) or equivalent, ensuring the body and
terminal box, flanges and bolts are completely covered.
The void around the sensor and conduit connection shall be backfilled with 3% stabilised sand
and in compliance with AM2714. To a height above the top part of the sensor and junction box
of not less than 300mm and then covered with a high impact plastic cable marker that extends
beyond the flanges of the pipe at either end by 500mm and the sides of the sensor by 100mm
or greater before backfilling.
Trenches containing conduits shall also be backfilled with a 300mm layer of washed sand and
marked with electrical trench tape.

3.4 Above Ground

3.4.1 Location
If a sensor is installed above ground and the transmitter is fitted directly to sensor. All
instrumentation shall be mounted between 800mm to 1400mm to the centre of the display. So it
is not accessible by a ladder. If this cannot be accomplished then the transmitter shall be
separated from the sensor. The flow meter is required to be labelled with SEW asset number.
Flow converter shall be installed mounted on the wall in an easily accessible waist height. There
shall be no obstruction between the instruments. It must be located in accessible locations in the
ground.
All transmitters with displays shall be installed outside confined/restricted spaces.

Water:
 Refer to Standard drawings

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 AM2832- Instrumentation & Controls Standards
 Wall mounting in bldg. or cabinet

Sewer:
 Refer to Standard drawings

3.5 Transmitter
3.5.1 Lightning Protection
If available from the manufacturer, lighting protection shall be installed in the flow meter sensor
and transmitter.

3.5.2 UV Protection
All transmitters not installed indoors shall be fitted with an aluminium or s/s cabinet refer to
AM2714.
If a transmitter is installed directly on the sensor outdoors it shall be fitted with stainless steel or
aluminium hinged cover. This cover shall cover the full transmitter height.

3.6 Magnetic Flowmeters

3.6.1 Arrangement
Arrangement of full bore flowmeters, in pits, direct buried, bypassed or non-bypassed shall be
considered specific to each application. Where practicable, the preferred location of flowmeters
shall be above ground level or within a facility substructure e.g. pump station pump pit. Where
not practicable the standard arrangements shall be as follows unless directed otherwise.

3.6.2 Pit Considerations

Considerations to the feasibility of flowmeters installed in pits include.
 Criticality of flowmeter and ease of replacement.
 Size of pit to accommodate flowmeter, reducers, dismantling joints and worker
access.
 Water table level.
 Drainage. Immersed flowmeters shall be coated with a petrolatum based mastic.
 Trafficable areas.
 Location to other services.
 Direct buried flowmeters <1.2m depth (measured to flowmeter underside) pit
optional.
 Direct buried flowmeters >1.2m depth (measured to flowmeter underside) pit
mandatory.

3.6.3 Supply Voltage

The flowmeter supply voltage shall be 24VDC.

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 AM2832- Instrumentation & Controls Standards
3.6.4 Verification
After installation a verification test (wet) and report shall be conducted on each electromagnetic
flowmeter. The test shall verify the installation and flowmeter are functioning within defined
factory test values to ensure flowmeter accuracy. The verification shall consist of a transmitter
test, flowmeter insulation test and flowmeter sensor magnetism test.

3.7 PRESSURE INSTRUMENTS

3.7.1 Gauges
Pressure gauges shall be industrial Bourdon tube gauges, or Scaffer diaphragm gauges, and
shall be suitable for the service specified. The scale range shall be approximately twice the
normal operating pressure.
Gauges shall have a nominal diameter of 150mm and shall be fitted with a 10mm (3/8 BSP)
threaded connection.

3.7.2 Pressure Transmitters

Pressure transmitters shall include but not limited to the following.
• Minimum reference accuracy of ±0.075% of calibrated span.
• Stability ±0.10% of upper range limit for 3 years
• Ability to measure either gage or differential pressure.
• Transmitter output, 4–20 mA dc/Digital HART Protocol
• Process connection 316L SS , 1/2–14 NPT female
• Stainless steel mounting bracket with SS bolts
• 8 x 6 character display. Ability to configure measured value in mWG
• Polyurethane aluminum housing
Pressure transmitter process fittings shall be arranged to either SEW standard drawing E-PRV-
STD-005, E-WP-STD-005 or E-WT-STD-005.
Transmitters fitted with a flange connection or flange remote seal in non-potable, solids or
viscous applications shall be fitted with a flushing ring to eliminated medium formed deposits or
blockages.

3.8 Measurement Units

Instruments, protective devices and indicating devices shall be calibrated in the following metric
units.
Parameter Unit Name Symbol

Pressure Kilopascals kPa

Pressure (Water Applications) Metres Water Gauge mWG
Level Metres m
Flow (Site) Litres/second l/s
Flow (Telemetry Host) Mega litres/day Mld

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 AM2832- Instrumentation & Controls Standards
3.8.1 Accuracy
Unless otherwise specified, all instruments shall have a measuring accuracy of ± 0.5% of range.

3.8.2 Calibration
Conduct calibration of instruments against a reference instrument, test pressure or standard.
Calibrate instrument at 0, 25, 50, 75 and 100% of nominated range.
Provide a calibration report for each function indicating instrument uncertainty, error and
adjustment.
Calibrated measurements are to be compared against the manufacturer's specification.
Provide manufactures calibration certificates stating the instrument compliance against the
instrument specification.

3.8.3 Ranges
Unless otherwise specified the instrument range shall be from zero (0) to 1.5 times the expected
maximum measurement value.

3.8.4 Instrument Zero Reading

Provide instrument zero readings referenced to a known relative level. Relative levels include
cover level, bottom level, pipe centre line or invert level.

3.9 Temperature Instruments

3.9.1 Themowells
All Temperature sensors installed into the process must be fitted with thermowells to allow for
easy removal and verification/calibration. All cables to be long enough to allow removal without
disconnection.

3.10 Installation Requirements

3.10.1 General
Installation of all cables shall follow installation standards in this document and AM2714.
The order of precedence of documents shall be as follows;
 Legislative and AS/NZS Standards
 Job specific specifications
 Job specific drawings
 Standard South East Water specifications (This document)
 Other standard South East Water specifications
 Standard drawings

Fibre optic cables and structured copper cabling shall be terminated in a patch panel located
either in an existing 19 inch server rack or control cabinet / panel.

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 AM2832- Instrumentation & Controls Standards
All Instruments must be installed in areas that are accessible without requiring technicians /
operators to climb under or over structures. Where instruments are installed at heights higher
than eye level. Permanent platforms must be installed to service these instruments.
South East Water IT approval is required for any new racks cabinets or patch panels

4. Verification / Documentation
4.1 Verification
All instruments such as flowmeter, etc shall be verified by the manufacturer or by their approved
verification device.
If the verification comes back failed it is the contractor’s responsibility to excavate (if buried) and
rectify the problem

4.2 Documentation
Sensor locations shall marked on site CAD plans.
All underground Sensors shall be GPS marked and locations, cable runs updated on CAD
drawings.
All verification certifications shall be set through to SEW.
Output signals shall be setup and recorded on SEW standard calibration sheets and submitted.
Photo evidence shall be submitted for the below
 Location if reference to something in the background not likely to move
 Installed before Wrapping with cable connected
 Transmitter location
 Transmitter Cabinet with doors closed and open showing equipment
 After Sensor is wrapped
 Backfilled with washed sand
 Backfilled and area cleaned up.

The Flowmeter Installation Sheet in Appendix C shall be completed and submitted for all flow
meter installations.

5. PLC & RTU Installation

The following requirement outlines PLC or RTU installation for both new and retrofit. For retrofit
applications the requirement shall be met where practical.

5.1 General
PLC and RTU installations shall meet the following requirements:
 PLCs and RTUs shall be located within a separate compartment of the switchboard which
shall contain the programmable devices, relevant I/O, communications interfaces and
associated terminal strips and interposing relays. This compartment shall be designed and
installed in accordance with section 3 of AM2714.

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 AM2832- Instrumentation & Controls Standards
 Daisy chaining of Ethernet devices is not permitted e.g. between variable speed drives.
 PLC and RTU IO voltages shall nominally be 24 VDC.
 Analogue signal IO shall be 4 - 20mA.
 Space shall be allocated within the PLC and RTU sections of the switchboard to terminate
all spare slots (cards).
 A 240VAC double GPO shall be installed within the PLC cabinet. This is to be installed in
a location such that the 240VAC cabling will not be run with ELV (24 VDC) control cabling.
 Interposing relays shall be installed for all digital outputs.

5.2 IO Termination
IO shall be terminated as follows:
 Where possible and for all new PLC or RTU installations, IO terminal strips shall be used
between field wiring and PLC IO terminals.
 Multicore cable with pre-numbered cores shall be used between PLC IO cards and IO
terminal strips, with numbered cable identification at the junction of each core at the IO
terminal strip.
 These terminal strips shall be DIN rail mounted.
 Terminal strips are to be labelled and segregated into a) input analogue, b) input digital,
c) output analogue, and d) output digital.
 In each terminal strip, order terminals in alphanumerical order in accordance with the
wire’s unique identification number.
 Digital inputs and outputs shall be individually fused at the IO terminal strip and a test link
for the common terminal; each common supplying a group of inputs shall also be
separately fused.
 Analogue input and output IO terminal strips shall have a fuse installed on the positive (+)
and a test link installed on the negative (-). In addition to this, each analogue IO point shall
contain a terminal for the connection of outgoing shield connection.
 Space shall be allocated within the PLC and RTU compartment of the switchboard to
terminate all spare slots (cards).
 Wiring colours shall follow AM2714.

5.3 IO Segregation
Where plant or equipment has operational redundancy, the control system IO shall be configured
to ensure the plant redundancy is maintained if there is a failure of a control system IO card. In
such cases, all PLC IO shall be segregated between IO cards / modules for each piece of
redundant plant equipment. E.g. Dosing pumps in a duty / standby arrangement shall have all
inputs / outputs for each pump connected to different IO cards in the PLC.
Where plant equipment has further redundancy employed such as redundant paths or
redundancy of entire plant processes, the IO should be segregated into different IO racks in
separate switchboard compartments that each comprises all of the equipment associated with
each redundant plant item.

5.4 IO Surge Protection

All field analogue input cables >5 metres long shall have surge protection both at the instrument
and PLC IO card end.

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 AM2832- Instrumentation & Controls Standards

Appendix A – Equipment Identification

Please refer to AM2714.

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 AM2832- Instrumentation & Controls Standards

Appendix B – Instrument Calibration

Record
Site ID: Site Description: Date:
Instrument Location: Watershed Tag No:
Instrument Function: SCADA Tag No:
Make: Model: Serial No:
Supplier: Instrument Supply Voltage:
Calibrated Range to Units Output to Units
Calibration Check ☐ Re-Range ☐ Verification ☐ Replacement Instrument Accuracy %
☐
Instrument Datum: Offset: Measuring Reference:
CALIBRATION RESULTS

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 AM2832- Instrumentation & Controls Standards
Input Desired Pre Cal Post Cal
Output Output Output Error
Span % Input units units Units Units Error % Units units % Units
0%
25%
50%
75%
100%
PRESSURE SWITCH

M.O.F Value B.O.F Value M.O.R Values Process Electrical

Contacts
Units Value/units
Post Pre Pre Post Pre Post

SCADA VALUES
Tag No Zero Full Scale
Office ☐ Plant Computer ☐
FLOW METER DETAILS
Flow Sensor Model: Flow Sensor Serial No:
Sensor Size: Cal Factor Insertion Depth:
Sensor Prom Code Number: Transmitter Serial No: Flow Direction Uni. Bi.
CALIBRATION EQUIPMENT
Input: Serial No: Calibration Date:
Output: Serial No: Calibration Date:
CALIBRATED BY
Technician Name: Company: Signature:
Comments: Pass ☐ Fail ☐
Action Raised ☐ Operator informed ☐

Appendix C - Flow Meter Installation Details

Flow Meter Installation

Site No _____________ Site Name _____________
Flowmeter New Install ☐ Replacement ☐

Existing Flow Meter

Existing Brand Siemens ☐ ABB ☐ Other __________
Model _________
Type Mag Tube ☐ Insertion Probe ☐ U/Sonic ☐
Other _______

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 AM2832- Instrumentation & Controls Standards
Pipe Size ___ mm Voltage 24VDC ☐ 240VAC ☐
Flow Meter Range ______ l/s
Flow Meter GPS Location _____________

Brand Siemens ☐ ABB ☐ Model __________

Type Mag Tube ☐ Insertion Probe ☐ U/Sonic ☐
Pipe Size ___ mm Pipe Material ________________
Voltage 24VDC ☐ 240VAC ☐
Installation
Has Cathodic Protection ☐ Is the Flow Tube Potted ☐ Cable Fitted by Manufacture ☐
Cable Length ____ M Earthing Rings Fitted ☐
Lighting Protection Fitted ☐ 240 V Surge Protection Required ☐
Flow Signal Required Forward ☐ Reverse ☐
Flow Analog to be connected to SCADA ☐
Flow Total Pulse Output to be connected to SCADA ☐
Flow Meter Range _______ l/s
Buried ☐ In a Pit ☐ Above Ground ☐
Location Plan Updated ☐
Completion and Underground Pictures Submitted ☐

Contractor Carrying Out Excavation Works

Company _____________ Name _______________ Phone _____________

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