13.CONTROL & INSTRUMENTATION FOR PLANT AUXILIARY

13.00.00 CONTROL & INSTRUMENTATION FOR PLANT AUXILIARY

        PACKAGES

 

13.01.00 Bidder shall provide complete and independent control

 

         and   instrumentation   system  with   all   accessories

 

         auxiliaries  associated  equipment and cable  for  safe,

 

         efficient operation of plant  auxiliary system.

    

13.02.00 Bidder  shall  include in his proposal  all  instruments

 

         and  devices  which are needed for the  completeness  of

 

         the  plant auxiliary system/ equipment supplied  by  the

 

         bidder,  even if the same is not specifically  appearing

 

         in specification and measurement shall be to meet actual

 

         system requirement subject to owner’s approval.

 

13.03.00 Bidder  shall  provided independent control  system  for

 

         safe,   efficient  and  reliable  operation   of   plant

 

         auxiliary systems the type of control system shall be as

 

         follows :-

 

13.03.01 Hot Redundant PLC Based Control without OWS

 

      i) Compressed Air System

     ii) Air Conditioning System

 

13.03.02 Relay Based Control System

 

      i) Fuel oil Handling and Storage System

     ii) Ventilation System

    iii) Mill Reject Handling System

     iv) Miscellaneous Pump

 

13.03.03 Microprocessor Based

 

         Fire detection and protection system.

 

13.04.00 The  control  monitoring operation of all  above   plant

 

         Aux.System shall be carried out from control panel/desk.

 

13.05.00 Bidder   shall  provide all interlock for  safe  reliable

 

         operation of each plant Aux.system.  The protection  and

 

         interlock system shall be subject to approval of owner.

 

 

 

 

13.06.00 Primary Instruments

 

13.06.01 All  instrument  used measurement of Hydrogen  shall  be

 

         intrinsic  safe and explosion proof as per  NEC  Article

 

         500, Class-1, Division-1.

 

13.06.02 All primary instrument used for measurement of HFO,  LDO

 

         shall be flame proof.

 

13.06.03 The protection Class of all primary instrument shall  be 

 

         IP 65 or better.

 

13.06.04 The protection Class of primary instrument installed  in

 

         minus floor shall IP 68.

 

13.06.05 For HT Motors/Important LT Motors command shall be provided

         through redundant I/O. The Status of important drive  and

         HT Motor shall wired in parallel to redundant input module.  

 

13.07.00 Desk / Panel  

 

13.07.01 The control monitoring operation of all plant Aux.system

 

         shall  carried  out from control panel/desk  only.   The

 

         control  panel  shall have mimic  diagram,  push  button

 

         indicators, recorder, indicating  lamps selector switch,

 

         control   switch,  ammeters,  voltmeters  etc.  as   per

 

         requirement.

 

13.07.02 Mimic plate shall be  polyester based fiber laminated.

 

         Mimic shall be  7 mm thick.

 

13.07.03 Painting & Colour Shade

 

         Treatment  as per IS-6005. Two coats primer followed  by

 

         powder painting with final shade of RAL 7032.

 

13.08.00 Relay Based Control System

 

13.08.01 Panel Construction

 

      a) Fabrication from cold rolled stainless steel

      b) Frame thickness       - 2.00  mm

      c) Enclosure thickness   - 1.6 mm

      d) Gland plate thickness – 3.0 mm

     

13.08.02 Convention type relay based panel shall be vertical free

 

         standing  with hinged doors.

 

13.08.03  a) Contactors

             Electro magnetic air break type

          b) Utilization Category

             AC – II for AC application

             DC – II for DC application

 c) Fuse – HRC Cartridge with visual operation indicator

    (IS 9224).

 

13.08.04  Terminal Block  -  650 V grade

 

13.08.05 a) Relay shall have good in plant track record.

 

         b) 20%  Spare  Relay each type and  rating  wired  up  to

 

            terminals.

         c) All relay contacts shall be hermitically sealed.

 

13.08.06   PVC  FRLS insulated stranded copper wire  meeting  the

 

          requirement of VDE 0815.

 

13.08.07  Control & Switching

 

          2 Nos. of  415 Volts ,3ph supply shall be given which  shall  be stepped  down to 220/110 V for controls. Redundant power pack  of 24 V DC shall be provided to energize  coupling relays in MCC.

 

13.08.08 Bidder shall provide Annunciation system, all  condition

 

         used   for  trip  shall  be  provided  with   pre   trip

 

         annunciation in control panel.

 

13.09.00  PLC Based Control System

 

13.09.01 Each PLC unit shall be provided with two  processor(main

 

         processor unit and memories and one for normal operation

 

         and  one  as hot standby. Incase of failure  of  working

 

         processor,  there  shall  be an  appropriate  alarm  and

 

         simultaneous  the hot standby processor shall take  over

 

         the complete plant operation automatically.

 

13.09.02 Memory – Programme memory shall be in Non Volatile memory.

        

13.09.03 PLC  shall be  time synchronized with  DDCMIS/  Master

 

         clock.

 

13.09.04 A hand held/pc programmer shall be provided for programming

 

         of PLC.

 

13.09.05 Input/ Output Modules -

 

      a) Input/Output Modules as required in the  control  system

 

         for all type of field input (4-20 mA, RTD,  T/C  Digital

 

         contacts  etc.) and output from the control system   are

 

         to be provided as per requirement.

 

      b) Electrical  isolation  for 1.5 KV with  optical  coupler

 

         between  the plant input/output and surge protection as per  

         IEEE 472.                                                          c) The hardware design shall be such that  it is able to  

         withstand power line disturbance. The system shall conform

         to ANSI/IEEE C 62.4 (Immunity to power supply line disturbance).

 

d) Bidder   shall  provide  at least  25%   spare   capacity

 

         available  on  input, output and  CPU,  memory  modules,

 

         power   supply   module  over  and  above   the   system

 

         requirement.

 

 

13.09.06 Bidder shall provide built in diagnostic for easy  fault

         detection.

 

13.09.07 System  shall  able to operate  in  non  air conditioned 

 

         area. 

 

13.09.08 Bidder  may  provide  Annunciation  System  as integral

 

         part of PLC. Field contacts shall be acquired through PLC

 

         only. The Annunciation sequence logic shall be implemented 

 

         as a part of PLC controllers.

 

         The  No.of  Annunciation facia windows and provision  of

 

         original input will be  on as required basis.   However,

 

         minimum  No.of  facia window, signal input to  input  to

 

         Annunciation System shall be 50 Nos.

 

13.09.09 Power Supply for PLC System

 

      (a)For PLC, redundant 24 V DC power supply system shall  be

 

         provided   by  bidder.   Necessary  redundant   capacity

 

         charger(2×125%  load) 24 V DC, one set of  PLANTE  Lead

 

         Acid  Batteries, shall be  provided by bidder.  Capacity

 

         of charger shall be sized to meet 100% load  requirement

 

         plus  recharge  the  fully discharge  battery  within  8

 

         (Eight)hours. The batteries shall able to provide  back-

 

         up  for  1 (one) hours at  full  load  requirement  of

 

         complete system.

 

      (b)Bidder  shall  provide  2×125/capacity  redundant  power

 

         supply module/ card required for PLC cabinet. 

 

13.09.10(a)Contractor shall provide current Transducer for HT or important motors current measurement(4-20 mA)

      (b)Bidder  shall  provide  32 Nos. of  potential  free

 

         binary and eight No. of 4-20 mA Analog signals from each 

 

         plant auxiliary  system for monitoring of important 

 

         parameter to  DDCMIS.   Bidder shall provide  necessary 

 

         interface hardware  for inter connection of each plant.

 

         However exact  No. shall be  decided during detail Engg.

 

13.09.11 Grounding

 

         Bidder shall provide electronic grounding for PLC  which

 

         shall be separate from Electrical grounding as per IS or IEEE Standard.

 

13.10.00 All important tripping in plant auxiliary shall be  from

 

         2 out of 3 sensor.

 

13.11.00 All instrument required for performance guaranty test of

 

         plant Aux. system, shall be in the scope of bidder.

 

13.12.00 Bidder  shall provide redundant data bus,  communication

 

         processor.

 

13.13.00 Tests

 

13.13.01 Factory Acceptance Test

 

     (i) P L C

 

      a) Hardware & Software as per BOM

      b) Spare capacity in cabinet for new module

      c) Current & Power Consumption

      d) Power Failure Test

      e) Healthiness of Hardware/all module

      f) On line removal of I/O card

      g) Accuracy Test

      h) Diagnostic Test

      i) Functional  Test

      j) Verification of Software

      k) Redundancy Test of Controller

      l) Redundancy Test of power supply

      m) CPU loading duty cycle

      n) Power failure auto restart

         Any other Test as per QAP

 

   (ii) Safety Instrumentated Systems (SIS)

 

         The factory acceptance test for SIS shall be conform to    

         IEC-61511 – 1 – Clause No.13.

13.13.02 TYPE TEST

         Contractor shall submit following Type Test report for  

         review.

     (i) Surge with stand capability (SWC) 

    (ii) Dry Heat Test (IEC-68.2.2)

    (iii)Dump Heat Test(IEC-68.2.3)

    (iv) Vibration Test(IEC-68.2.8)

     (v) EMC Test (IEC-61000.4.2)

13.13.03 Bidder shall submit following documentation along with

         factory test for review.

     (a) Internal test report along with heat run test

         (Temperature elevated test – 48 Hrs. at 50 Deg.C)

     (b) Calibration certificate of  measuring instruments.

13.13.04 Installation, Commissioning, verification, Prestartup test  

         at site for  Safety instrumented system shall be as per  

         ISA 84.01.