INSTRUMENTATION VENDERS November 27, 2009
Air Filter Regulator
|
1.CHART RECORDERS
1.Eurotherm,UK
2.CHINO JAPAN
3.ABB,UK
4.YOKOGAWA,JAPAN
2.
1.SPECIFICATION OF INSTRUMENTATION October 17, 2008
1.00.00 DESIGN CRITERIA
The Bidder shall provide Control & Instrumentation
System for control, monitoring and operation of entire
Plant in all regimes of operation in safe and most
Efficient manner. The Bidder shall provide all systems,
Equipment, accessories and associated equipment in a
Fully operational condition acceptable to the Owner.
The bidder shall also provide all material, equipment
and services which may not be specifically stated in
The specifications but are required for completeness of
The equipments/systems furnished by the bidder and for
Meeting the intent and requirements of this
Specifications. The work shall be consistent with
Modern power plant practices and shall be in compliance
With all applicable codes, standards, guidelines and
Safety requirements in force on the date of award of the
contract. The requirements of statutory authorities
(e.g. MOEF, Inspector of Factories, IBR,TAC, CPCB/SPCB
etc. with regard to various plant areas like main plant,
fuel oil plant/system, chlorination plant, fire fighting
system, Emission measurements etc.)shall be complied
even if not actually spelt out.
The bidder shall provide all systems/ equipments
described in this specification for one unit. There are
Two Units are in the scope of bidder.
1.01.00 Reliability and Availability
Each component & system offered by the bidder shall be
of established reliability. The minimum target
reliability of each piece of equipment like each
electronic module/card. Power supply, peripheral etc.
shall be established by the Bidder, considering its
failure rate/mean time between failure(MTBF), meantime
to repair(MTTR), such that the availability of the
Complete C&I system is assured for 99.7% or better.
Further the bidder shall ensure that all equipment/part
of his system, that is not listed under recommended
spares shall have normal life expectancy exceeding the
expected life of the plant i.e. thirty (30) years.
In order to ensure the target reliability the Bidder
shall ensure selection of proper materials, control
manufacturing process, use quality controlled components
and parts, take adequate design margins & Derating of
Electronic components and parts and carry out necessary
tests etc.
The bidder shall submit detailed reliability calculations
for each system/ equipment which (with the help of a
schematic of various sub-system connected in series or
in parallel as the case may be and MTBF & MTTR values
for the various equipments) shall show that availability
calculation is as per IEEE standard- P 1046 or
equivalent. This shall be submitted by bidder along with
bid.
1.01.01 When more than one device uses the same measurement or
control signal, the transmitter and other components/
module shall be fully equipped to provide all signal
requirements. The system shall be arranged so that the
failure of any monitoring device or control components
or spurious intermediate grounding in the signal path
shall not open the signal loop nor cause the loss or
malfunction of signal to other devices using the same
signal.
1.01.02 To ensure availability, adequate redundancy in system
design shall be provided. Redundancy of components and
system shall be dictated by availability criteria in
Cl.1.01.00, to ensure that the system availability
target as well as safety considerations in critical
applications are fully met.
To ensure the availability of control system, suitable
redundancy shall be provided at sensor sensor level,
hardware and software. For the protection system
independent sensing device shall be provided to ensure
adequate safety of plant equipment.
1.02.00 Standardization
To ensure smooth and optimal maintenance including
efficient spare parts management of various C&I
instruments/ equipments like vibration monitoring
systems, all 4-20 mA electronic transmitters/
transducers, control valves, actuators and other
instruments/ local devices etc. being furnished by the
bidder for SG, TG and other plant auxiliaries for
similar applications, the bidder shall ensure that they
are of the same make series and family of hard wares.
1.03.00 Operability & Maintainability
1. The design of the control systems and related equipments
shall adhere to the principle of `Fail Safe’ operation
wherever safety of personnel/ plant equipment is
involved. `Fail Safe’ operation signifies that the loss
of signal, loss of excitation or failure of any
component shall not cause a hazardous condition however,
at shall also be ensured that occurrence of false trips
are avoided/ minimized.
The types of failure, which shall be taken into account
for ensuring operability of the plant shall include but
not limited to -
- Failure of sensor or transmitter
- Failure of controller other modules during automatic
operation
- Loss of motive power to final control element
- Loss of control power
- Loss of instrument air
2. The choice of hardware shall also take into account
sound maintainability principles and techniques. The
same shall include but shall not be limited to the
following :-
- Standardization of parts
- Minimum use of special tools
- Grouping of functions
- Interchangeability
- Malfunction identification facility facility/self
surveillance facility
- Easy modular replacement
- Fool proof design providing proper identification and
other features to preclude improper mounting and
installation.
- Appropriate Derating of electronic components and
parts
3. Equipment/ devices which require maintenance shall be
suitably located to ensure easy accessibility.
4. The bidder shall supply all necessary furniture
including ergonomically designed chairs & desks for use
at the room desks and various programming stations. All
the equipment like programmers stations, PC’s various
peripherals & similar devices shall be complete with
desks, stands and other mounting accessories.
All necessary furniture such as table, desks, chairs
etc. shall also be furnished to set up maintenance &
calibration equipment laboratories and the same shall be
completely erected & commissioned by the bidder.
1.04.00 The equipment shall employ latest state of the art
technology to guard against obsolescence. In any case,
bidder shall be required to ensure supply of spare
parts for lifetime of the plant. In case, it is felt
by the bidder that certain equipment/ component is
likely to become obsolete the bidder shall clearly bring
out the same in his bid and indicate steps proposed to
deal with such obsolescence.
1.05.00 Colour Shade
1.05.01 Colour shade of panel/ desk and Local panel, cabinets,
LIE etc.
a) External colour – RAL 7032
b) Interior – Briliant White
1.05.02 Colour of instrument Junction Boxes – Sky Blue
1.05.03 Colour of Electrical Actuator – Blue
1.05.04 Colour of instrument cable – Sky Blue
1.06.00 Environmental Conditions
Instruments, devices and equipment for location in
outdoor/indoor conditions area shall be designed to suit
the environmental conditions indicated below and shall
suitable for continuous operation in the operating
condition of coal fired utility.
1.06.01 Outdoor Location
a) Temp.Range – 0-55 Deg.C
b) Relative Humidity – 0-100%
c) Atmosphere – Dirty air
1.06.02 Indoor Location
a) Temp. Range – 0-50 Deg.C
b) Relative Humidity – 5-95 %
1.06.03 DCS, PLC etc shall design for operation in ambient
Temperature ranges 0- 50 Deg.C.
1.07.00 Grounding
Grounding System for DDCMIS, PLC, P A System etc. shall be prefer as per IEEE standard and separate from Electrical grounding.
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2.DISTRIBUTED DIGITAL CONTROL,MONITORING INFORMATION SYSTEM(DDCMIS) October 17, 2008
2.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING AND
INFORMATION SYSTEM (DDCMIS)
The microprocessor based distributed digital control,
monitoring & information system(DDCMIS)shall be
provided for the safe and efficient operation of SG, TG,
balance of plant and all auxiliaries in all regimes of
Operation.
The following standards shall be followed for design, manufacturing, installation and commissioning of the Distributed Control System:
a) ANSI/ISA84.01 1996 – Application of Safety Instrumented
System.
b) IEC – 61151 - Functional Safety- Safety Instrumented
System for Process Sector.
c) IEEE – 1046 – IEEE Application guide for Distributed
Digital Control Monitoring for Power Plant.
d) ANSI/ ISA – 77.13.01 – Fossil Fuel Power Plant Steam
Turbine By-pass System.
e) NUREG – 700 – Human- System Interface Design Review
Guidelines.
f) ANSI/ISA-18.1-Annunciation Sequence and Specification.
2.01.00 GENERAL REQUIREMENTS
2.01.01 The requirements for distributed digital control
monitoring and information system(DDCMIS) are indicated
on functional basis in this specification. Bidder shall
be responsible for engineering, selection and connection
of all components and sub-systems to form a complete
system whose performance is in accordance with
functional, hardware, parametric and other requirements
of this specifications. It is not the intent or purpose
of this specifications to specify all individual system
components since the bidder has full responsibility for
engineering and furnishing of a complete system.
2.01.02 SYSTEM CONFIGURATION
DDCMIS shall basically consist of control system of
boiler, turbine & balance of plant (namely SG-C&I,TG-C&I
& BOP-C&I including their respective measurement
system); Man-machine interface and plant information
system(MMIPIS); system programming & documentation
facility; data communication system(DCS);integrated
sequence of events recording system(SERS); Annunciation
system, and master & slave clock system.
The basic configuration of DDCMIS shall be as indicated
in the DDCMIS configuration drawing No.CED/STP/I/821,822,
823.
2.01.03 SYSTEM EXPANDABILITY
Modular system design shall be adopted to facilitate
easy system expansion. The system shall have the
capability and facility for expansion through the
addition of controller modules, process I/O cards,
drive control modules, hand/auto stations, and push button
stations, peripherals like CRT/ Keyboards, printers etc.
while the existing system is fully operational. The
system shall have the capability to add any new control
loops groups/ sub-groups, in control system while the
existing system is fully operational.
2.01.04 ON LINE MAINTENANCE
It shall be possible to remove/ replace on line various
modules(like I/O module)from its slot for maintenance
purpose without switching off power supply to the
corresponding rack. System design shall ensure that
while doing so, undefined signaling and releases do not
occur and controller operation in any way is not
affected(including controller trip to manual, etc)
except that information related to removed module is not
available to controller. Further, it shall also be
possible to remove/ replace any of the redundant
controller module without switching off the power to
the corresponding rack and this will not result in
system disturbance or loss of any controller functions
for main controller. The on line removal/ insertion of
controller, I/O modules etc. shall in no way jeopardize
safety of plant and personnel.
2.01.05 FAULT DIAGNOSTICS
The DDCMIS shall include on line self surveillance,
monitoring and diagnostic facility so that a failure/
malfunction can be diagnosed automatically down to the
level of individual channels of modules giving the
details of the fault on the programmer station CRT
displays supplies, sensor fault, any channel fault in
2V3 channels etc. These faults on CRTs as well as local
indication on the faulty channel/module and on
corresponding rack/ cubicle shall be available. The
diagnostic system shall ensure that the faults are
detected before any significant change in any controller
output has taken place. Failure of any I/O modules,
controller etc.shall be suitably grouped and annunciated
to annunciation facia and to OWS(Operator work Station).
2.02.06 FAULT TOLERANCE
The DDCMIS shall provide safe operation under all plant
disturbances and on component failure so that under no
condition the safety of plant, personnel or equipment is
jeopardized. Control system shall be designed to prevent
abnormal swings due to loss of control system power
supply, failure of any control system component, open
circuits/ short circuits, instrument air supply failure
etc. On any of these failures the controlled
equipment/parameter shall either remain in last position
before failure or shall come to fully Open/ Close or
ON/OFF state as required for the safety of plant/
personnel/ equipment and as finalised during detailed
engineering.
2.01.07 DDCMIS shall meet all requirements stipulated under
other sub-sections/sections of the specification
including general technical conditions. General
technical requirements, quality assurance, parametric
requirements etc.
2.01.08 SIGNAL EXCHANGE
All the signal exchange between various functional
groups of each control group ( i.e. within SG, TG & BOP
C&I) shall be implemented through redundant main system
bus (The main bus connecting various sub-systems)and
local system bus within a sub-system as per the
standard practice of the bidder. It shall be ensured
that any single failure in electronics involved for such
communication, e.g. communication controllers, bus
interface modules, physical communication media, etc.
does not result in loss of such signal exchange and
there in no deterioration in specified system response
and system parametric requirements. In case a
controller utilizes some inputs generated/ processed by
any other controllers/functional group and the
requirement of controller response time as specified in
Clause 2.04.02 is not met due to inadequate
communication rate/ procedure, then the bidder shall
provide hardwired signal exchange for such inputs.
Bidder shall furnish documentary evidence through its
standard catalogues and drawings explaining as to how
this requirement is being met by them. Bidder shall
also furnish along with the above documents, list of
coal fired thermal power stations where the proposed
scheme for such signal exchange is already working.
Further, bidder to note that if his offered system
cannot meet the above requirement of communication
redundancy and specified system response & parametric
requirements then all the signal exchange, analog as
well as binary among various functional groups shall be
carried out through hardwiring only and not through bus
system.
However, if in the opinion of the employer, a few
signal exchanges are found required to be hardwired,
the same shall be provided by the bidder. Control &
protection signal exchange between control systems of SG,
TG and BOP C&I shall be hardwired only. Protection
signals like MFT/Turbine/Generator or tripping of unit
shall necessarily be hardwired and redundant even
for exchange within the same sub-system, as stipulated
in NFPA 85. Signal to or from BOP shall be galvanized or
optically isolated.
2.01.09 No single failure either of equipment or power source
shall be capable of rendering any part/ system/sub-
system of DDCMIS in operative to any degree.
2.01.10 SYSTEM SPARE CAPACITY
Over and above the equipment and accessories required to
meet the fully implemented system as per specification
requirements. DDCMIS shall have spare capacity and
necessary hardware/ equipment/accessories to meet
following requirement for future expansion at site.
2.01.10.01 10% spare channels in each of the input/output
modules, fully wired up to marshalling cabinets.
2.01.10.02 Wired in space for 20% modules in each of the system
cabinets for mounting electronic modules wired up to
corresponding spare terminals in marshalling cabinets
such that implementation of any additional control loop/
logic can be achieved only by insertion of necessary
electronic modules(s) in system cabinets, configuration
of corresponding controller and connection of
inputs/outputs at field end of marshalling cabinets/
logic cabinets as applicable.
2.01.10.03 MMIPIS shall be provided with capacity to handle 25%
or at least 1 No.of each type of peripherals
additionally, like CRTs, keyboards, printers, PCs etc.,
over and above already specified, without any additional
hardware or software.
2.01.10.04 each controller shall have 30% spare functional
capacity to implement additional function blocks, over
and above implemented logics/loops, further each
controller shall have spare capacity to handle minimum
20% additional inputs/outputs of each type(including
2.01.10.01 & 02 above), over and above implemented
capacity. Each of the corresponding communication
controller shall also have same spare capacity as that
of controller.
2.01.10.05 The data communication system (including main system
bus and other bus system)shall have the capacity to
handle the additions mentioned in clause Nos.2.01.10.01
to 2.01.10.05. This will be in addition to 50% spare
capacity specified under this clause.
2.01.10.06 20% spare relays of each type and rating, mounted and
wired in relays cabinets. All contacts of relays shall
be terminated in terminal blocks of relay cabinets. In
each of the relay cabinets 20% spares terminal blocks
shall be provided so that additional relays can be
mounted and wired.
2.01.11 the spare capacity as specified above shall be uniformly
distributed throughout all cubicles. The system design
shall ensure that above mentioned additions shall not
require any additional controller/ processor/ peripheral
drivers Power supply module, software etc. in the
system delivered at site. Further, these additions
shall not deteriorate the system response time/duty
cycle etc.from those stipulated in the specification.
2.01.12 DDCMIS shall meet system performance and parametric
requirements as stipulated under specification.
2.02.00 SYSTEM DESCRIPTION
The DDCMIS shall include following main systems/sub-
systems. The DDCMIS shall work in full integration &
conjunction with field equipments/drives like pumps,
motors, valves, actuators, dampers, hydraulic control
systems(eg.for HP/LP bypass etc.)and field instruments
to be provided by the Bidder. The DDCMIS
hardware(controllers, modules/ cards etc.)shall be
housed in cabinets located in control equipment
room(CER) except for operation interfaces located in UCD
& UCP in unit control room.
2.02.01 CONTROL SYSTEM
The control system along with its measurement system,
shall perform functions of closed loop control, sequence
control, interlock & protection of SG TG and auxiliaries
in all regimes of Unit operation.
The measurement system of control system shall perform
the functions of signal acquisition, conditioning and
signal distribution of various types of inputs/outputs
like analog (4-20 mA DC, thermocouple, RTD)binary pulse
etc. The inputs, which are required for only information
& monitoring purposes shall be distributed suitably in
various groups of the measurement system.
2.02.02 MAN-MACHINE INTERFACE & PLANT INFORMATION SYSTEM
(MMIPIS)
The MMIPIS shall perform control, monitoring & operation
of SG,TG & auxiliaries in all regimes of unit operation,
interacting with the control system. For this MMIPIS
shall primarily perform following functions.
i) Operator interface for control system.
ii) Plant Supervisory functions like displays, alarm
monitoring & reporting(reports & logs, calculations,
trend recording, historical and long term data storage &
retrieval etc.).
2.02.03 SYSTEM PROGRAMMING & DOCUMENTATION FACILITY
The programmer stations shall be provided for -
i) On line configuration & tuning of control system.
ii) On line program development/ modifications in MMIPIS.
In addition, latest state of the art workstation based
system documentation for the complete plant.
2.02.04 DATA COMMUNICATION SYSTEM (DCS)
The data communication system shall be provided for
communication between control system & MMIPIS
communication & signal exchange between various
functional groups as well as communication between
various units & off site/ off line systems.
2.02.05 SEQUENCE OF EVENTS RECORDING SYSTEM(SERS)
The DDCMIS shall be capable of carrying out sequence of
event recording function to scan & record events in the
sequence of occurrence within a resolution of 1 milli sec.
2.02.06 MASTER AND SLAVE CLOCK SYSTEM
Master & slave clock system shall be provided to ensure
uniform time indication throughout the various plants
facilities and time synchronization between controls
system, MMIPIS, switchyard disturbance recorder, PLC’s
etc.
2.02.07 ANNUNCIATION SYSTEM
A facia annunciation system shall be provided with lamp
boxes in the unit control room. The annunciation logic
will be implemented as a part of DDCMIS through which
the lamp boxes shall be driven. However, additional
facility to drive stand-alone printer in case of total
MMIPIS & system bus failure shall be provided.
2.03.00 MEASUREMENT FUNCTIONS OF CONTROL SYSTEM
2.03.01 All the signals coming into/going out of the control
system shall be connected either directly or routed
through marshalling cabinets. The input/output modules
employed in the control system shall be separate from
controller hardware.
2.03.02 ANALOG SIGNAL CONDITIONING & PROCESSING
2.03.02.1 the conditioning and processing functions to be
performed as a minimum for the analog input coming for
control & information purposes are :-
i) Galvanic isolation of input & output signals wherever
required.
ii) Transmitter power supply with per point fuse
protection or current limiting and power supply
monitoring.
iii)Transducer/transmitter signal output limit check.
iv) Implementation of multiple measurement schemes.
v) Square root extraction
vi) Pressure & temp.compensation.
vii)On line ADC gain & drift monitoring & correction at
periodic intervals.
viii)Linearisation of thermocouple signals.
ix) Reasonability check for all analog inputs.
2.03.02.2 all analog signals for control purpose shall be
acquired, validated, processed and their respective data
base updated at a maximum interval of 250 milli
secs.except for some fast acting control loops for which
the above-referred time shall be as per process
requirement. For signals required for information only,
the above functions shall be performed at an interval of
1 sec. The validated analog inputs shall be converted
into engineering units on a per point basis.
2.03.02.3 The 4-20 mA input analog cards shall be suitable for
interfacing transmitters giving 4-20 mA analog signal
along with super imposed HART interface signals. 4-20 mA
DC signal will only be used for control purpose & super
imposed HART signal will be used for configuration,
maintenance diagnostic & record keeping facility for
electronic transmitters & analyzers etc.
2.03.03 BINARY SIGNAL CONDITIONING & PROCESSING
2.03.03.1 The changeover type contacts (i.e.NC + NO together)
shall be wired to the control system for all the binary
inputs required for control purposes, except for input
from MCC/SWGR, actuators and inputs related to hardwired
signal exchange among various functional groups for which
non-changeover type contract(NC or NO)shall be wired to
the control system. The binary input required for
information purposes only shall be wired to control
system in the form of non-changeover type contacts.
2.03.03.2 The conditioning and processing functions to be
performed as a minimum for the binary input coming for
control & information purposes are :-
i) 24 V DC power supply for contact interrogation for
all potential free contacts with per point fuse
protection or suitable current limit feature/
isolation through optocoupler.
ii) Contact bounce filtering delay time of 15 milli secs.
iii) Facility for pegging the binary signal to logic
one/zero or last correct value in case of failure of
binary input module.
iv) Binary signal distribution to different user shall
be in such a way so as to ensure that a short/ground
fault on one user is not reflected to the other
user.
v) Implementation of multiple measurement schemes for
signals for control purpose.
vi) All binary signals shall be acquired validated
processed, alarm checked and their database updated
within 1 sec. In addition to this requirement,
binary signals required for SOE shall have a
resolution of 1 milli sec.
vii)Checking for excessive No.of status changes for all
binary/contact inputs.
viii)Facility to delete any binary input from scan or to
return to scan on operator demand.
ix) The non-coincidence monitoring shall be provided
for binary inputs for all changeover signals,
namely process actuated switches required for
control purpose.
x) All relay contacts shall be hermitically sealed.
2.03.04 Two out of Three Measurement
a)Triple measurement scheme for analog inputs employing
three independent transmitters connected to separate
tapping points shall be employed for the most critical
measurements used in analog control functions including
the following but not limited to furnace draft, feed
water flow, throttle pressure, turbine first stage
pressure, drum level, drum pressure, deaerator level,
turbine speed. Turbine control valve position, power
measuring device LP & HP Heater Level, PA Header
pressure etc.
b) The three signals shall be auctioneered to determine the
median/average value , which will be used for control
purpose. In case one transmitter fails or shows
excessive deviation with respect to others, it will be
removed from computation of medium/ average value & the
average of the other two transmitter outputs shall be
used for controls. The control loop shall trip to
manual when any two of the three transmitter outputs
shall be used for controls. The control loop shall trip
to manual when any two of the three transmitter signals
fail. The operator shall be able to select any of the
transmitters or the median/average value from the
control desk. The outputs of the transmitters shall be
continuously monitored for excessive deviation which
shall be displayed, logged & alarmed.
c) For MFT/ Turbine/Generator/Unit tripping;Triple Sensor shall
be provided.
d) For auto starting of pumps, pump tripping due to very Low
level of water, Triple Sensor shall be provided.
2.03.05 One Out of Two Measurement
a) Dual measurement scheme for analog inputs employing two
independent transmitters, connected to separate tapping
points/ temp. element shall be employed for the
remaining measurements used for analog control functions.
The output of the redundant transmitters shall be
continuously monitored for excessive deviation. In case
the deviation is within limits, the mean value shall be
used for the control loop. If the deviation becomes
high (with both transmitters remaining healthy), the
other transmitter remains healthy, then the output of
the healthy transmitter shall be used for control. If
the other transmitter also fails, loop shall trip to
manual. The outputs of the transmitters shall be
continuously monitored for extensive operation which
shall be displayed and logged and alarmed.
Individual transmitter signal, their status and selected
value for control/measurement shall be available on OWS.
b) All sensor other than MFT(Boiler)Tripping,Turbine Tripping,
Generator Tripping etc. for safety interlock.
c) All pressure/ Temperature/Level Switches in Control loop.
d) All Water/ oil Tank level alarm for Very low.
e) All non critical Measurement for Control loops.
f) Any other service recommended by equipment manufacture or
IEC/ISA/ASME/Standard/ code .
2.03.06 For Binary and analog inputs required in furnace &
turbine protection triple sensing devices shall be
provided. Binary and analog inputs which are required
for protection of more than one equipment (e.g. flame
failure, deaerator level very low, etc.) as well as
protection signals for MDBFP, triple sensing
devices shall be provided. For other critical binary
and analog inputs required for protection and interlock
purpose of other equipment, dual sensors shall be
provided.
2.03.07 Wiring scheme for inputs to control system shall be as
follows :-
2.03.07.1 Each of the dual triple redundant binary & analog
inputs shall be wired to separate input modules. In
addition, for functions employing 2V3 controllers like
BMS/Turbine protection, each of the redundant binary &
analog signals shall be wired to separate input modules
associated with each controller in line with
configuration drawing of BMS & TPS & meeting requirement
stipulated under clauses 2.04.01 of this section.
Similarly each of the dual redundant binary & analog
inputs shall be wired to separate input modules. These
redundant modules shall be placed in different racks,
which will have separately fused power supply
distribution. Implementation of multiple measurements
scheme of these inputs will be performed in the
redundant hardware loss of one input modules shall not
affect the signal to other module and also other channels
of these modules can be used by other inputs of the same
functional group.
2.03.07.2 the single binary & analog signal required for control
purposes shall be wired as follows :-
i) The limit & torque switches and the MCC / SWGR
check backs shall be wired to drive control modules
wherever provided. For the drives where DCM are not
provided, these signals shall be connected to input
module only.
ii) Other single analog & binary inputs shall be wired to
single input modules.
2.03.08 The binary and analog outputs from one sub-system of the
control system to other which are required in these
systems for control purposes shall be made available
from triple/dual redundant binary and analog output
modules. However, redundancy in binary & analog outputs
to indicators/ recorders, SERS and Annunciation facia
lamps are not required.
2.03.09 The signal conditioning functions like multiple
measurement schemes square root extraction for flow
signals, pressure & temperature compensation, limit
value computation can be performed either in the
controllers or in signal conditioning and processing
hardware outside controllers.
2.03.10 The maximum No.of inputs/outputs to be connected to
each type of module shall be as follows:-
1. Analog input module - 16
2. Analog output module - 16
3. Binary input module - 32
4. Binary output module - 32
5. Analog input & output(combined)- 16
6. Binary input & output(combined)- 32
(Note:- For Binary inputs, one changeover contact is
counted as 2 inputs)
Further, minimum 10% spare channels shall be kept in
each of the input/output modules.
2.03.11 The following requirements shall be met :
2.03.11.1 Input filters to attenuate noise shall be provided.
2.03.11.2 All analog/ binary input shall be capable of
withstanding 500 V DC common mode and 500 V AC peak to
peak. All analog outputs shall be short circuit proof.
2.03.11.3 Common mode noise rejection for analog inputs shall
be minimum 120 db at 50 Hz.
2.03.11.4 Normal mode noise rejection for all analog inputs
shall be 60 db at 50 Hz.
2.03.11.5 Surge Switch stand as per IEEE 472.
2.03.11.6 Any single sensor/transducer/transmitter failure alarm
shall be provided on I&C maintenance or program CRTs
for all sensors/transducers/transmitters. Similarly
sensor break alarm for thermocouples etc. shall also be
displayed on the CRTs.
2.04.00 CONTROL SYSTEM REQUIREMENTS
2.04.00.1 The control system shall be broadly divided into SG
C&I, TG C&I and BOP C&I as already elaborated in clause
2.01.02.
2.04.00.2 The SG C&I system shall perform the following :-
i) Burner Management System(BMS)including control &
protection of coal mills, fuel oil system etc.
ii) Analog control functions pertaining to secondary
air damper control, Aux.PRDS pressure &
temp.control etc.
iii) Soot Blower Control.
2.04.00.3 The TG C&I system shall perform the following
functions.
i) Turbine Protection System function(TPS)
ii) Turbine Governing System for main Turbine
iii) Turbine Stress Control System (TSCS)
iv) Automatic Turbine Testing (ATT)
v) Automatic Turbine Run up System (ATRS)
vi) HP/LP Bypass Control System
vii) Turbine Generator Control System
2.04.00.4 The balance of plant C&I system shall perform the
following functions:
i) Analog control functions performing to the other plant
areas like coordinated master control, furnace draft
control, FW flow control etc.
ii) Binary control functions pertaining to other plant
auxiliaries like FD/ID/PA/APH/BFP etc. and electrical
breakers etc.
2.04.00.5 The No.of Functional groups(FGs)shown in elsewhere in
the specification, these are the minimum
required. However, splitting of any functional group in
more than one FGs due to any limitation in bidder’s
system shall be acceptable, subject to employer’s
approval. For each of the FGs, separate sets of
controllers, I/O modules, communication controllers,
power packs/modules etc. shall be provided. Mixing of
hardware of two or more FGs shall not be acceptable.
2.04.00.6 The minimum functions to be realized in each
of the above-mentioned controls systems shall be as per
requirements specified under subsequent clauses of this
specifications. The bidder shall provide all
hardware/software, whether or not specifically indicated
in this specification to fully meet operational/
maintenance/ safety requirement as well as statutory/
international standard and proven practices.
2.04.00.7 The control system shall function reliably under the
environmental conditions as specified under Part-C
“General Technical Requirement” of this specification.
It shall be immune from the interferences resulting from
disturbances in power supply feeders signal lines,
inputs, outputs etc. as experienced in a coal fired
power station.
2.04.00.8 The control system shall have on line simulation &
testing facility. Further, it shall be possible to on
line configure & tune controllers through configuration
& tuning station for control system.
2.04.00.9 The system shall have the flexibility to easily
reconfigure any controller at any time without requiring
additional hardware or system wiring changes & without
disabling other devices from their normal operation
mode. Modifications shall not require switching off
power to any part of the system.
2.04.00.10 The remote manual operation from hardwired back-up
A/M stations & push button(PB)stations(wherever
provided)shall be independent of availability of
controllers & power supply to controllers.
2.04.00.11 The executive programs for the controller modules
shall be firmware based, which shall be non-volatile &
shall not be alterable except by replacement of parts.
The application programs for the functional controllers
shall be software based which shall be maintained
through power supply failure. The application program
shall be alterable through the configuration and tuning
station for all configuration and strategy changes,
etc. and through the operator’s console for set
point/ bias changes, device selection, etc. Parts
replacement or parts removal shall not be required in
order to accomplish changes in application programs
including system tuning.
2.04.00.12 All the 100% hot/redundant back-up controllers shall
be identical in hardware and software implementation to
their corresponding main controllers & shall be able to
perform all its tasks. The back-up controller shall
track its corresponding main controller. There shall be
an automatic and bump less switchover from the main
controller to its corresponding back-up controller in
case of main controller failure and vice versa without
resulting in any change in control status. In case of
switchover from main controller to the 100% hot back up
controller, the back-up controller shall work as the
main controller.
Facility shall also be provided for manual switchover
from main to 100% hot back-up controller and vice versa
from the programmer’s console.
2.04.00.13 The control system hardware design shall be such that
it is able to withstand power line disturbances.
2.04.00.14 The control system for SH/RH Attemp. Temp.control
shall be state controller with observer.
2.04.00.15 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).
2.04.01 BURNER MANAGEMENT SYSTEM (BMS)
2.04.01.1 Fully proven microprocessor based system, based on
hardware and software specifically designed and proven
for Burner Management application for the same being
offered for shall be provided to achieve the Boiler
protection action e.g.master fuel trip(MFT), control of
mills & fuel oil systems etc. BMS shall meet all
applicable relevant safety requirement including those
stipulated in NFPA- 8502.
2.04.01.2 The BMS shall be provided with automatic self
monitoring facility. All modules to be used in this
system shall be of fail-safe design. Any single fault
in either primary sensor, I/O modules, multifunction
controllers etc. should not result in loss of safety
function. All faults should be annunciated to the
operator right at the of its occurrence and also for
alarm annunciation facia.
2.04.01.3 The MFT functions shall be implemented in a fault
tolerant 2 out of 3 triple redundant configuration. Each
of the three independent channels shall have its own
dedicated processors, multifunction controllers,
communication controllers, I/O modules, interface etc.
All safety related process inputs shall be fed to each
of the 3 channels. All the primary sensors for
unit/boiler protection shall be triple redundant.
2.04.01.4 The acquisition and conditioning of binary and analog
protection criteria signals for MFT shall be carried out
in each of the three triple redundant channels. Each
channel shall compute the 2 out of 3 voting logic and
issue a trip command. The trip signals of the three
channels shall be fed to a fail 2 out of 3 relay
tripping unit for each drive. The protection criteria
for tripping shall be executed by a program which shall
be identical in each of the triple redundant channel.
The check back contact signals of each relay of the 2
out of 3 relays tripping unit shall be fed back to each
of the triple redundant channels & shall be
continuously monitored for equivalence in each of them.
2.04.01.5 The functionality of operation of mills. oil etc.shall
be similar to that of OLCS described in clause 2.04.03
below.
2.04.02 TURBINE PROTECTION SYSTEM (TPS) FUNCTIONS
2.04.02.1 Fully proven microprocessor based system, based on
hardware and software specifically designed for Turbine
protection application for the same turbine being
offered for this project, shall be provided to achieve
the turbine protection action.
2.04.02.2 The Turbine protection system shall meet all
applicable safety standards/requirements including those
stipulated.
The system design shall be such that safety function of
the total system must not be jeopardized on occurrence
of fault. Any single fault in either primary sensor,
input/ output modules, controller module etc. shall in
no way jeopardized the safety of the turbine. All
modules to be used in this system shall be of fail safe
design.
2.04.02.3 Bidder shall provide two independent trip channels,
each having its dedicated processing module with
hot back up. Two out of three voting logic will
be implemented in each of the channels and the
output of each channel to be fed to each of the two
turbine trip relays.
2.04.02.4 All the input signals (trip signals etc. from the
field devices) shall be fed in parallel to all the
three/ both the redundant channels of protection system
as mentioned above via signal conditioning cards
designed for such application. Further, the computation
of field input voting logics i.e. 2 out of 3 etc. shall
also be performed in the controllers of all the three/
two channels of protection system , which will then
perform the computation of field input voting logics
i.e. 2 out of 3 etc.shall also be performed in the
controllers of all the three/two channels of protection
system, which will then perform the computation of 2 out
of 3 voting logic independently.
2.04.02.5 Bidder shall provide all the required primary sensors
etc. required for protection system as per his standard
and proven practices. All trip signal input required
for the safety of the turbine shall be be based on 2 out
of 3 logics.
2.04.02.6 The system shall include turbine lock-out relays,
redundant turbine trip solenoids and necessary hardware
required for testing.
The tripping devices shall be designed to operate on DC
supply. The trip coils shall be monitored continuously
for healthiness and failure shall be alarmed.
2.04.02.7 Turbine Protection System shall meet all applicable
relevant safety requirement including those stipulated
in ASME- TDP-1, VDE 0116, Sec8.7; VDE 0160 etc.
2.04.02.8 TURBINE STRESS CONTROL SYSTEM (TSCS)
Bidder shall provide a proven Turbine Stress Control
system which will work in conjunction with turbine
governing system and ATRS and achieve the following
functional requirements.
a) Continuous on-line monitoring of thermal stress levels
in all critical parts of the turbine such as main stop
valves, control valves, HP casing, HP shaft and IP shaft
etc.
b) Continuous on line computation of stress margins
available for the above mentioned critical components of
the turbine during various regimes of operation i.e.
run-up, synchronization, loading, load maneuvering,
normal operation, run backs, unloading, shutdown etc.
c) Computation of the limits of speed and load changes
allowable at any particular instant before
synchronization and after synchronization respectively.
d) Carry out a fatigue analysis for all affected
components of the turbine and also to compute the
percentage service life consumption of the turbine.
e) Display the stress margins etc. on a separate dedicated
colour VDU/ Printer as well as on OWS for operator
guidance and storage of necessary data such as
percentage service life consumption etc.
f) Store long term data & carry out Residual Life
Analysis.
The system shall be complete including measuring
transducers for generator load and wall temp. measured
value processing modules, microprocessor based
controllers for stress calculations and turbine life
calculations etc. dedicated colour CRT monitor etc.
2.04.03 BINARY CONTROLS/OPEN LOOP CONTROL SYSTEM(OLCS)FUNCTION
2.04.03.1 The OLCS shall include sequence control, interlock &
protection for various plant auxiliaries/ valves/
dampers/ drives etc. The sequence control shall provide
safe and automatic startup and shutdown of plant and
of plant items associated with a plant group. The
interlock and protection system shall ensure safe
operation of plant/ plant items at all times & shall
automatically shut down plant/ plant items when unsafe
conditions arise.
2.04.03.2 The OLCS shall be arranged in the hierarchical
control structure consisting of unit level group level,
subgroup level & drive level(as applicable).
It shall be possible to perform automatic unit startup &
shutdown by issuing minimum No.of command from the OWS.
Thus, the unit level shall control all the control
system blocks and issue appropriate startup & shutdown
commands to various blocks of control system.
The group level shall control a set of functional sub-
groups of drives. Appropriate start-up and shut down
commands shall be issued to the sub-group control &
various check backs shall be received from sub-groups or
drives. Each sub-group shall execute the sequential
start-up and shut down programme of a set of
inter-related drives along with system interlocks and
protections associated with that sub-group as well as
basic interlocks & protections related to individual
drive falling under that sub-group. The drive level
shall accept commands from the sub-groups, push buttons
etc. & transmit them to the respective drive, after
taking into account various interlocks & protections and
the safety of that particular drive.
2.04.03.3 Sequence Control
2.04.03.3.1 A sequence shall be used to move a set of groups,
sub-groups from an initial steady state (for instance
`OFF’) to a final steady state (for instance `ON’). The
sequence initiating command for the unit & group level
shall be issued from CRT/KBD.
2.04.03.3.2 A sequence shall be made of steps. The steps shall
be executed in predetermined order according to logic
criteria and monitoring time consisting of the interlock
& protection requirements and check back of previous step
which shall act as preconditions before the sequence
control can execute the command for that step.
2.04.03.3.3 Each step shall have a “waiting time” implying that
the subsequent step would not be executed unless the
specified time elapses. A monitoring time shall also be
defined as the maximum time required in executing the
commands of any step and the time required for
appearance of checks backs signals. In case, this is not
completed within the specified time, a message shall be
displayed and program will not proceed further.
2.04.03.3.4 Manual intervention shall be possible at any stage
of operation and the sequence control shall be able to
continue at the correct point in the program on return
to automatic control. Protection commands shall have
priority over manual commands, and manual commands shall
prevail over auto commands.
2.04.03.3.5 Open or close priority shall be selectable for each
drive.
2.04.03.3.6 The sequence start-up mode shall be of the
following types.
i) Automatic Mode
In this mode of operation, the sequence shall progress
without involving any action from the operator. The
sequence start/stop command shall be issued from the
CRT/KBDs.
ii) Semi-Automatic Mode
In this mode of operation, once the sequence is
initialized, the step progressing shall be displayed
on the CRT. But the step execution command shall be
prevented and shall be sent by the operator via the
keyboards. It shall be possible to bypass and/ or
simulate one or more criteria to enable the program to
proceed. This facility shall allow the program to be
executed even if some criteria are not fulfilled because
of defective switching device, etc. while the plant
condition is satisfactory. It shall be possible to put
the system on the Auto-mode after operating it on semi-
automatic mode for some steps or vice-versa, without
disturbance to the sequence operation.
iii) Operator Test Mode
It shall be possible top use the sequential control in
operator guide mode/ test mode i.e. the complete system
runs & receives input from the plant and the
individual push button stations (where provided)/
keyboards but its command output is blocked. the whole
program, in this case shall run in manual mode. This
mode shall allow the operator to practice manual
operation using step and criteria indications. The
actual protection should remain valid during this mode
of operation also.
2.04.03.4 The sequence shall be started by putting the sequence
on `Auto’ and on receipt of `Start’ command from the OWS
or from a higher level group/ protection action as
defined. The sequence shall then progress as per the
defined logics. It should be possible to select
alternative operation in the same sequence depending on
certain process/ equipment condition. Some step can be
automatically bypassed also based on certain process/
equipment condition. When the expected results of the
sequence is reached the sequence is considered as ‘End’.
2.04.03.5 If during sequence initialization or sequence
progressing or during normal running of the drive, a
shutdown criteria is present, the sequence shall be
stopped and the shutdown sequence initiated.
2.04.03.6 For the drives, the command shall be provided through
redundant O/P module and inputs (Status, SWGR & process)
shall be acquired through input modules. The inputs &
output modules used in relation to drives shall not be
mixed with inputs & output modules for other
applications. The drive logic shall be implemented in
the redundant controller.
The status of the HT drives and some other important
drives(total approximately 40 Nos. per unit)shall also
be wired in parallel to redundant input modules so that
on failure of the single input modules, the information
regarding the status of the affected drive remains
available in OLCS.
2.04.03.7 The output modules shall have the feature that
ensures that in case of failure, all the outputs are
driven to zero. The 24 V DC command outputs to drives
for ON/ OPEN, OFF/ CLOSE shall be separate and
independent and inverted outputs shall not be
employed. For inching type of drives, position
transmitter power supply and monitoring of position
transmitter signal shall be provided.
2.04.03.8 The termination for OPEN/ CLOSE command for the drive
actuator shall be performed in the actuators specified
elsewhere in the specification. However, OPEN/ CLOSE
and disturbance status as a minimum shall be monitored
in OLCS.
2.04.03.9 The sequence interlock & protection requirements shall
be finalised during detailed engineering and the same
shall be subject to employer’s approval.
2.04.03.10 The OLCS shall also include the control of
electrical systems in addition to the auxiliaries of
boiler & turbine performing functions such as OPEN/
CLOSE or ON/ OFF etc. of various electrical systems such
as breakers and isolators, raise/ lower for equipment
like transformers tap changer, synchronization of unit,
etc. All the features and specification requirements as
specified above shall also be applicable for electrical
system. Control and all the operation shall be
performed through CRT/KBDs of OWS. However, 100%
hardwired backup miniaturized switches shall also be
provided on UCP for electrical systems.
2.04.03.11 Operator Interface for SIS & Sequence Control
Following status information shall be available to operator
on OWS or Console.
i) Where the process is in its sequence.
ii) Indication that SIS protective action has occurred.
iii) Indication that protective action is bypassed.
iv) Status of sensors, final drive, diagnostic features etc.
2.04.04 ANALOG CONTROLS/ CLOSED LOOP CONTROL SYSTEM(CLCS)FUNCTIONS
2.04.04.1 The CLCS shall continuously act on valves, dampers or
other mechanical devices such as hydraulic couplings
etc.which alter the plant operation conditions. The
system shall be designed to give stable control action
in steady state condition and for load changes in step/
ramp over the load range of 60% to 100% MCR with
variation or parameters within permissible limits to be
finalised during detailed engineering state. The system
shall have the following minimum features.
2.04.04.2 The loop reaction time (from change of output of the
sensor of the transmitter/ temperature element to the
corresponding control command output) shall be within
500 m/secs. However, for faster loops such as feed
water, furnace draft, P A header pressure control loop
etc. the same shall be based on actual process
requirement but shall not be more than 250 milli secs. The loop response time shall be as per IEEE-1046.
2.04.04.3 The control system shall be bumplessly transferred to
manual on the following conditions as a minimum and as
a minimum and as finalised during detailed engineering.
Control power supply failure, failure of redundant
controllers, field input signal not available, analog
input exceeding preset value etc.
2.04.04.4 Any switch over from auto to manual, manual to auto
and switchover from CRT operation to H/A Station
operation and vice versa shall be bumpless & without
resulting in any change in the plant regulations and
the same shall be reported to the operator.
2.04.04.5 Buffered analog output of 4-20mA DC shall be provide
from CLCS to the respective E/P converters. For
electrical actuators, type output(bound less
control) shall be preferred. CLCS shall also provide
all the necessary outputs for indicators& recorders with
output loop resistance of 500 Ohms for each channel of
the output module.
For the drives, the command shall be provided through
redundant O/P module and inputs(position feed back &
process) shall be acquired through input modules. The
inputs & output modules used in relation to drives shall
not be mixed with inputs & output modules for other
applications. The drive logic shall be implemented in
the redundant controller.
2.04.04.6 The functional requirement of the CLCS loops as well as
the detailed schemes shall be finalised during detailed
engineering stage and shall be subject to employer’s
approval.
2.04.04.7 The system being supplied shall be such that when
permissible limits are exceeded, an automatic switchover
from an operation governed by maximum efficiency, to an
operation governed by safety and availability is
effected.
2.04.04.8 For safety reasons, switchover logics associated with
the modulating control loops, shall be performed within
the closed loop control equipment.
2.04.04.9 Where the equipments are controlled by a group of
regulators acting in parallel, the relative position
of individual actuator associated with them shall be
capable of being adjusted with respect to one another
and to the common automatic signal.
2.04.04.10 Time supervision facility shall be provided to
monitor the final control element.
2.04.04.11 It shall be possible to block the controller output
on a pre-programmed basis.
2.04.04.12 All controllers shall be freely configurable with
respect to requisite control algorithms.
2.04.04.13 Whenever, alternate measurement is available for a
control input the alternate measurement value will be
automatically substituted in the control loop in case
of loss of control input. All necessary software for
switching and reconfiguration shall be provided. In
addition, such substitution shall be balance less and
bumpless and shall be reported to the operator.
2.04.05 HP/LP BYPASS SYSTEM
2.04.05.1 LP BYPASS CONTROL SYSTEM
The LP Bypass control system shall consists of steam
pressure control loop and steam temp.control loop. The
LP Bypass control shall be implemented through a set of
redundant controller modules, I/O modules etc. The LP
Bypass control shall suitably interface with other TG
control like HP Bypass, EHG etc. Further condenser
exhaust hood spray valve shall be interlocked to open
whenever LP Bypass comes into operation.
2.04.05.2 HP BYPASS CONTROL SYSTEM
a) The system shall consists of steam pressure control
loop & steam temp.control loop. HP Bypass system shall
be implemented through a set of redundant controller
modules, I/O modules etc. The system shall be supplied
with redundant 2 out of 3, primary sensor & suitably
interface with other TG C&I controls like LP Bypass, EHG
etc.
b) HP Bypass system shall conform to ANSI/ISA 77.13.01.
2.04.05.3 OTHER SG C&I FUNCTIONS
The SG control functions shall also consist of Secondary
Air Damper Control soot blower control, Auxiliary PRDs
etc. in addition to the burner Management system and
described above.
2.04.05.4 OTHER T G C&I FUNCTIONS
The TG control functions shall also, consist of Turbine
Generator control system like seal oil, primary water,
hydrogen system etc. interlock & protection.
2.05.00 MAN-MACHINE INTERFACE SYSTEM AND PLANT INFORMATION
SYSTEM (MMIPIS) REQUIREMENTS
2.05.01 Man-Machine interface system shall be designed and
engineered for safe, efficient, reliable and convenient
operation. MMIPIS shall employ high-performance, non-
proprietary architecture to ensure fast access and
response time and compatibility with other system.
MMIPIS shall be used primarily for the following
functions.
a) As operator interface for control operation of the plant
or accepting data from and issuing commands to SG C&I,
TG C&I and Station C&I system etc.
b) To perform plant supervisory, monitoring and information
functions. The plant data pertaining to are unit shall
be available in the MMIPIS of the respective unit. Data
from common system shall be available in the MMIPIS of
both units.
2.05.02 OPERATOR INTERFACE TO THE CONTROL SYSTEM
2.05.02.1 The operator interface of the MMIPIS shall consist of
21 inch colour TFT Monitor/KBDs of OWS (Operator Work
Station), colour Laser Printers, large video screen(LVS),
console etc. Each Operator workstation (OWS) shall include
one TFT Monitor, one keyboard and touch screen or mouse for
ease of operation. The TFT Monitor operation shall employ
powerful menu-driven and window supported input facilities
for operational ease and comfort.
No single failure in MMIPIS shall lead to non
availability of more than one OWS and two printers. In
such an event i.e., single failure leading to non
availability of any OWS, it shall be possible to operate
the entire plant in all regimes of operation including
emergency conditions from each of the other available
OWS.
Operator functions displays, structure of the keyboard
assembly and key assignment shall be finalised during
detailed engineering. Further all frequently called
important functions including major control loop display
shall be assigned to dedicated function keys for the
convenience of the operator.
2.05.02.2 (a) Operator Functions
The operator functions for control on each OWS shall as
a minimum include control system operation, alarm
acknowledge, call control displays, demand/ printout of
various displays, logs, summaries etc.
The display selection process shall be optimized so that
the desired display can be selected with the barest
minimum No.of key strokes/ steps by the operator.
The control related display on the CRT/ TFT Monitor
shall as a minimum include mimic displays, overview
displays, area displays, individual loop/ drive display,
closed loop control displays, open loop control displays
etc. Operator’s function allowed the control of
drives/equipments, viewing of all displays, changing
certain pre-selected parameters like set points, bias
etc. printing of report.
However following functions are prohibited for
operator.
(i) Modification of control parameters. Modification of
logic/loops/ data base/ MMI or software.
(ii) Changing of assignments of logs & trend etc.
(b) Programmer Functions
The programmer (Administrator) functions allows viewing
of all display, changing of all set points, bias etc.
printing of all report, modification of all control
loops/logic/data base and values. Modification of
MMIPIS software.
2.05.03 PLANT SUPERVISORY, MONITORING & INFORMATION FUNCTIONS
OF MMIPIS
The MMIPIS shall be designed as an on line system which
shall process, display & store information to provide
the operator, either automatically or on demand, the
relevant information as indicated in subsequent clauses.
The following functions shall be performed by MMIPIS as
a minimum.
2.05.03.1 BASIC CALCULATIONS
All the algebraic/logical calculations related to
analog points(e.g. sum/difference/average/integration
etc.) digital point, transformations, flow calculations,
time projection or rate of change calculations,
frequency etc.shall be provided. All the calculated
values of the plant shall be available in the database.
2.05.03.2 PERFORMANCE CALCULATIONS
a) The performance calculations shall use FORTRAN or
equivalent high-level language. An extensive set of
steam property sub-routines based on 1967 ASME steam
tables shall be included in the system. The
calculation shall be carried out at 30% unit load or
higher. The calculation frequency shall be selectable at
site from 10 minutes to 1 hour, with a step of 10
minutes. The performance calculations shall be broadly
subdivided into two classes.
Class I : Equipment protection calculations
Class II: Plant/ equipment efficiency calculation.
b) The Class I calculations are generally for the purpose
of detecting & alarming unit malfunctions.
These shall include cold reheat steam approach to
saturation temp.SH spray outlet approach to saturation
temp. turbine steam metal temp. differences, turbine
metal temp. rates of change, feed water heater terminal
temp.difference, feed water heater drain cooler
approach and LMTD,excess air deviation from standard, feed
water heater temp. deviation from standard, drum water
saturation temp.rate of change, metal temp. difference
for SH `Y’ and RH `Y’ piece etc.
c) The class-II performance calculations shall be
performed to determine the performance of individual
items of equipment and the overall unit. The
periodicity of this calculation shall be selectable
from 10 minutes to 60 minutes in increments of 10
minutes. These shall include calculations for Boiler
efficiency, Gross turbine generator heat rate, gross
unit heat rate, net unit heat rate, operating hours,
plant load/availability factors, HP/IP/LP turbine
enthalpy drop efficiency, condenser/deaerator/economizer
performance, air heater performance, unit availability
calculations, deviation from expected values for each
calculation shall also be computed. The performance
calculation shall be as per following ASME code or BS
standard.
i) Boiler Efficiency - BS-2885(By Heat Loss Method)
ii) Steam Turbine - ASME PTC-6
iii) Air Pre- Heater - ASME PTC-4.3
iv) Feed Water Heater - ASME PTC-12.1
v) Deaerator - ASME PTC-12.3
vi) Condenser - ASME PTC-12.2
2.05.03.3 All the primary instruments, cable, hardware, software
whatever required for efficiency/ performance
calculations shall be in the Bidder’s scope.
2.05.03.4 Other Calculations
Variable alarm limit calculations, heat rate deviations
and revenue calculations, frequency excursion time
integration etc.shall also be provided.
2.05.03.5 Alarm Monitoring and Reporting
The system shall display history of alarms in
chronological order of occurrence on any of the OWS. The
MMIPIS shall have the capability to store a minimum of
1000 alarms pages, each with paging features allowing
the operator to view any page. The OWS keyboard shall
have all alarm functions and related function keys like
alarm acknowledge, reset, paging, summaries etc. Other
design features like prioritization, set point/ dead
band adjustments, alarm report format etc. shall be as
finalised during detailed engineering.
2.05.03.6 Displays
Various displays on the CRTs shall as a minimum include
P & ID displays or mimic, bar chart displays, X-Y & X-T
plot(trend) displays, operator guidance message
displays, group displays, plant start-up/shutdown
message displays, generator capability curves, heat rate
deviation displays, system status displays etc. No.of
displays and the exact functionality shall be on a
required basis and as finalised during detailed
engineering.
Other types of displays as applicable for convenience of
operation shall be provided by Bidder. However, the
minimum quantity of major types of displays shall be as
follows:-
a) Control displays(group/sub-group/ 500
sequence/loop)
b) P&ID/ mimic display 300
c) Bar chart 100
d) X-Y/X-T Plot 200
e) Operator guidance message 100
f) Plant starting/ shutdown guidance message 100
g) Other Misc. Display 100
h) System status & other diagnostic on as required
basis display.
The system shall have adequate storage capacity for
storing the last 72 Hrs.of data at scan rate 1 sec.for a
minimum 500 Analog points(operator selectable for use
in trend displays.
The system shall have adequate storage capacity for
storing the last 8 hrs.of data at scan rate 1 Min.for
all analog points of unit and status changes of 1000
binary points.
2.05.03.7 Logs/ Summaries
The system shall generate three basic types of
reports/logs i.e. Event activated, time activated and
operator demand log & summaries. The log format and
point assignment for each logs/report and other design
features shall be as finalised during detailed Engg.
The system shall have the facility for viewing of time
activated and operator demand logs/ summaries on the
MMIPIS CRT(s).
a) Event Activitated
The trip analysis log shall record a minimum of 30
pretrip and 30 post-trip readings for the pre-defined
parameters but not less than 250 points, sub-divided
into 25 groups. The data collection rate shall be
variable, i.e. faster near the trip point and gradually
slower with time. The exact details shall as finalised
during detailed engineering.
The system shall be capable of generating and printing
SG & TG start-up shutdown logs.
b) Time Activated
Time activated logs shall as a minimum include hourly,
shift log and daily log. Each of these shall provide
hourly record of a minimum 100 points sub divided into
10 groups.
c) Operator Demand Log
Operator demand logs shall include, as a minimum, trend
log, maintenance data log, summary log, performance logs
and some special logs as decided during detailed
Engineering stage.
The system shall be capable of generating and printing
trend log for a minimum of 80 groups of 15 points each.
Maintenance data log shall provide schedule of
preventive maintenance and routine equipments
inspection.
d)Various summaries shall include off scan summary,
constants summary, point quality summary, substituted
values summary, peripheral status summary etc.
e)The assignment of logs to any of the printers shall be
possible from MMIPIS CRTs/ keyboards and programmer
station.
2.05.03.8 Log Generation Utility
The Bidder shall offer a log generation utility to
generate a log/report having following facilities as a
minimum.
a) Define format of the log like header information, time,
date etc.
b) Selection of any point(scanned & calculated)from the
data base and assign it to a log group.
c) Selection of log data collection process initiating
event, collection intervals(1,2,3,5,10,30 & 60 minutes)
for each point of a particular log group. Facility shall
also be provided for selection of 100 points at a
collection intervals of 1,2,3,5,10,20,30 seconds.
d) Assignment of log printout initiation on event or time
including, selection of the printing interval for
particular log group and time of printing.(For time
initiated logs).
e) Assignment of No.of samples to be collected for each
point.
f) Select points for which minimum, maximum accumulation
over a selected period, average etc. values can be
printed. Also facility shall be provided to tag the
time at which the parameter passed through
maximum/minimum.
It shall be possible to define 100 log groups of 15
points each. Any log group can have any point from the
Database. One log shall include at the maximum 10 such
groups.
2.05.03.9 Historical Storage and Retrieval System(HSRS)
The HSRS shall collect, store and process system data
from MMIPIS database. The data shall be saved on line
on hard disk and automatically transferred to erasable
dual Magneto-optical disk (removable type)once in every
24 hours periodically for long-term storage. Provision
shall be made to notify the operator when optical disk
is certain percentage full.
The data to be stored in the above system shall include
alarm and event list, periodic plant data, selected
logs/report such as event activated logs, trip analysis
log, start-up log etc. The data/ information to be
stored & frequency of storage and retrieval shall be as
finalised during detailed engineering.
The system shall provide operator function to retrieve
the data from historical storage. The operator shall be
able to retrieve the selected data on OWS and any other
CRT which are connected with system bus or printer and
suitable index files/ directories shall be provided to
facilitate the same.
In addition to the HSRS the system shall also have
facility to store & retrieve important plant data for a
very long duration(plant life) on MODs.
The System shall have adequate memory capacity for
storing the plant life data (minimum 30 years) at scan
rate 30 secs.for minimum 500 analog points and shall
have adequate storage capacity the last 5 year data at
the scan rate of 5 secs.for minimum 500 analog points.
However these points may increase as per recommendation
of original manufacturer of equipment.
2.05.03.10 Quality Tag
The system shall identity and tag the quality of all
data (scanned & calculated points)is a way that makes
all users(control, calculations, logs displays etc.)
aware of its quality. Quality of data other than good
shall be clearly identified in all printouts and
displays by appending quality character to the value/
status of point. The quality tagging shall include
good, bad, substitute, doubtful, suspect etc.
2.05.03.11 a) DDCMIS shall provide fault alarm analysis guiding
the operator to the most likely cause of fault. The
alarm system shall be designed in such a manner that
main auxiliaries tripping can be traced to the
originating cause.
b) Trend alarms shall be provided in DDCMIS for slowly
varying process parameters, so that appropriate
corrective actions are taken in time. These alarms
shall be suitably provided in OWS, which will be
decided during detailed engineering stage.
2.05.03.12 An integrated unit startup system shall be
implemented in DDCMIS incorporating all operational
curves for SG, TG and auxiliaries. This shall guide the
operator to take appropriate actions at appropriate time
to bring the rated parameters safely within the
specified time.
2.05.04 MMIPIS HARDWARE
2.05.04.1 The MMIPIS as specified shall be based on latest
state of the art work stations and servers and
technology suitable for industrial application & power
plant environment. The quantity of peripherals, main &
bulk memory etc. as shown in the referred drawing is the
minimum the bidder has to provide. The workstations
other than OWS shall be configured in such a way that
loss of one workstation does not result in loss of any
function.
The actual size of the main and bulk memory shall be
sufficient to meet the functional and parametric
requirements as specified with 25% additional working
memory and 50% additional bulk memory over and above
the memory capacity required for system implementation.
The exact system configuration and sizing shall be as
approved by employer.
2.05.04.2 The work station/ servers employed for MMIPIS
implementation shall be based on industry standard
hardware and software which will ensure easy
connectivity with other systems and portability of
employer developed and third party software. These will
be 64 bit machines.
2.05.04.3 Redundant sets of communication controllers shall be
provided to handle all the communication between the
MMIPIS and redundant system bus and to ensure specified
system response time and parametric requirements. Each
communication controller shall have message checking
facility.
2.05.04.4 Power Fail Auto Restart(PFAR) facility with automatic
time update shall be provided.
2.05.04.5 All the peripherals shall confirm to the following
minimum requirement but the exact make & model shall be
as approved by employer during detailed engineering.
a) All the monitor shall be 21” colour TFT and
suitable for mounting in tabletop arrangement. Processor
processor, Power Supply, Communication port of OWS shall be
redundant. All OWS shall be Industrial grade,interchangeable.
The configuration shall be fault tolerant. OWS shall have
Following minimum specification.
(i) Resolution (1600x 1200)
(ii) Display Colour (128)
(iii) RAM Capacity (1 GB)
b) The printers shall be heavy-duty lasers(minimum printing
speed 8 pages, minimum printing speed of 20 pages for
laser printer). The laser printer should have provision
of printing computer paper apart from cut sheets.
e) Five No. Large video screens (LVS), each with 67 inches
Diagonal graphic controller and other hardware shall be
Provided. It shall have facility of integrating the CCTV
Signal & RGB video signal from field.
2.05.04.06 Man Machine Interface (Unit wise)
a) Unit Control Room PC
i) Operator Work Station - 8 Nos.
ii) Large Video Screen - 5 Nos.
(67”)
b) Computer Room PC
i) Historian PC - 2 Nos.
ii) Programmer PC - 3 Nos.
iii)Colour Laser printer - 1 No.
(size A 3)
iv) Laser printer(A 4 , B/W) - 1 No.
c) Shift Engineer PC - 1 No.
+ Laser printer
(size A 4, B/W)
d) PC at different location - 3 Nos.
Of unit + Laser
printer (Size A 4,B/W)
e) Colour Laser Printer
(size A 3)
i) Log Printer - 1 No.
ii) SOE Printer - 1 No.
iii) Alarm Printer - 1 No.
f) Dot Matrix Printer - 2 Nos.
2.05.04.07 Man Machine Interface (Common for two Units)
PC Station - 10 Nos.
The above PC stations are to be located at various plants
location (to be decided during detailed engineering).
All PC Station shall be with B/W laser printer(size A4).
The function of above
PC’s are to view the alarm, display, and generate reports of
both the units.
2.05.04.08 O&M Head PC Station (Common for two units)
O&M Head PC shall be located at O&M head office and
connected to system bus. The function of above PC to
view & print alarm, display and generate reports. This
PC shall have one laser printer and one scanner. The size
of printer and scanner shall be A3. The system shall also
include all required software and hardware for printing
of CAD drawing and documents.
2.05.04.09 Station Head PC (Common for both the units)
This PC shall be located at Station head office and
shall be connected to system bus. The function of above
PC is to view the alarm, displays and generate reports
of all units. The PC shall be with laser
printer(size A4).
2.05.04.10 The detail documentation of Boiler, Turbine,
Electrical, Instrumentation CHP, AHP etc. shall be
available in shift Engineer PC, Station head PC, O&M
head PC and other 10 Nos.PC. The documentation shall be
in text & drawing form (Minimum 2000 pages and 100
drawings/ image size of A3. However the above quantity
may increase as per actual requirement. The system
shall include all required software & hardware.
2.05.04.11 Bidder shall supply 3 PC Station + B/W Laser printer
(size A 4) per unit with network capability and cable
etc. The location of PC shall be decided during detailed
engineering shall be connected through telephone
Exchange with system bus.
2.05.04.12 (a) The hardware of all work station/ PC shall be same
configuration make & Model No.as OWS.
(b) All laser printers shall be same make and with inbuilt
network capability.
2.5.04.13 The bidder shall provide consumable i.e. tonner,
paper for Laser printers for one year, considering
consumption rate 30 papers per day per printer. Bidder
Shall also provide formatted, 100 CD with each PC Station/
OWS.
2.06.01 The system shall have the facility to generate the
associated documentation for both the control system &
MMIPIS. The bidder shall furnish detailed information
about system documentation facilities in his offered
system along with the bid. The document, to be generated
by the system shall include P&ID drawings, control loop
drawings, sequence drawings, signal distribution
list/drawings, system interconnection drawings,
cabinets general arrangement drawings, measurement
list, drive schedule, alarm schedule, system hardware
and functional configuration drawings for displays,
logs, trends, graphics etc. The system shall also
include all required software and hardware tools for
creating, modifying and printing CAD drawings to achieve
paperless documentation for DDCMIS.
2.06.02 To realize all of the functions mentioned above the
Bidder shall provide standalone stations for
configuration & tuning functions of control system and
MMIPIS programming, hardware of which shall be separate
from the hardware of the respective system and
connected to System Bus. The bidder shall provide 2
Nos. of programmer station for control system and 1 No.
programmer Station for MMIPIS.. Each of the programmers
station shall also have a colour laser printer. The
hardware for system documentation facility(specified at
Cl.2.06.04 above)may be a part of either configuration
and tuning unit for Control System or MMIPIS programmer
if all the functions specified above can be achieved in
these programmer stations. Two separate workstation,
colour laser printer, scanner shall be
provided for documentation facility with necessary
software for other than DDCMIS. The size of printer,
plotter, scanner shall be A 3. The system shall also
includes all required hardware & software tools for
creating, modifying and printing CAD drawings to
achieve paperless documentation. The hardware of work
station shall be same as that of OWS.
2.07.00 DATA COMMUNICATION SYSTEM (DCS)
2.07.01 The DCS shall include a redundant main system bus &
local system buses for major subsystems with hot back-up
and other applicable bus systems like cubicle bus,
local bus, I/O bus etc. The DCS shall have the
following minimum features.
2.07.01.1 Redundant communication controllers shall be provided
to handle the communication between each functional
group of controllers of control system and the system
bus. The design shall be such as to minimize
interruption of signals. It shall ensure that a single
failure anywhere in the media shall cause no more than
a single message to be disrupted and that message shall
automatically be retransmitted. Any failure or physical
removal of any station/ module connected to the system
bus shall not result in loss of any communication
function to and from any other station/module.
2.07.01.2 If the system bus requires a master bus controller
philosophy, it shall employ redundant master bus
controller with automatic switchover facility.
2.07.01.3 Built-in diagnostics shall be provided for easy fault
detection. Communication error detection and correction
facility (ECC) shall be provided at all levels of
communication.
Failure of one bus and change over to the standby system
bus shall be automatic and completely bumpless and the
same shall be suitably alarmed/logged.
2.07.01.4 The design and installation of the system bus shall
take care of the environmental conditions and hazardous
area classification as applicable to similar services.
2.07.01.5 Data transmitting speed shall be sufficient to meet
the responses of the system in terms of displays,
control etc. plus 25% spare capacity shall be available
for future expansion.
2.07.01.6 Passive coaxial cables or fiber optic cables shall be
employed for system bus.
2.07.01.7 The redundant buses shall be physically separate and
shall be routed separately.
The bidder shall furnish details regarding the
communication system like communication protocol, bus
utilization calculations etc.
2.07.01.8 In case of any distance or other limitation in the DCS
bidder will provide suitable repeaters, MODEMS,
amplifiers, special type of cables like optical fibers
as required to make the DCS fully operational.
2.07.01.9 The Data Hiways shall be power surge protected and
conform to IEC – 801-5.
2.07.02. Station Wide Network
2.07.02.1 The servers/Ethernet LAN of the unit shall be
connected to a station wide Ethernet Wide Area Network
(WAN). Various common system & off-site plants and PCs
at various plant locations & PLC/PC based systems
provided both by bidder as well as by employer shall be
connected to this station wide Ethernet WAN through
TCP/IP protocol. The station head/ O&M head & shift
in charge stations shall be located in this WAN to
monitor data of all units as well as of the common plant
location and off-site plants.
2.07.02.2 Further, this station wide WAN will have a PC
connected to act as a gateway to off-line WAN of the
entire station (not under this package)connected to
other station off-line services like administration,
materials etc. This gateway will also be able to
communicate with employer’s corporate office through a
satellite link(provided by employer). The exact details
shall be as finalised during detailed engineering and as
approved by employer. Bidder has to furnish all
necessary hardware and software for this purpose.
2.07.02.3 There shall be continual monitoring of network performance
and station.
2.08.00 SEQUENCE OF EVENTS RECORDING/ ANNUNCIATION FUNCTIONS
2.08.01 SER FUNCTION
2.08.01.1 The system shall monitor 250 SOE inputs (Tentative-
considering only cause of tripping of unit) with a
resolution of one milli second at all times for all
inputs including spare inputs. That is, all SOE points
entering status change shall be reported and time tagged
within 1(one)milli second of their occurrence. Input
card shall be equipped with digital filters with filter
delay of minimum 4 ms (identical for all points) to
eliminate contact bounce such that field contact which
is changing state must remain in the new state for
successive 4 ms to be reported to OWS within 1 sec.of
SOE data collection initiation. The system shall also
have provision of rejection of chattering inputs.
2.08.01.2 The system shall also include provision for historical
storage and retrieval of SOE reports for 12 months
period or One thousand SOE alarm pages.
2.08.01.3 The SOE report collection shall begin on occurrence of
change of status of any SOE point and shall be printed
after an operator selectable time interval of 1 to 3
Min. or 100 status changes have taken place after the
first event.
2.08.01.4 The SOE reports shall include a list of cause of unit
trip in chronological order and include the points which
initiated SOE collection and other statistical data sheet.
2.08.01.5 SOE System shall have dedicated VDU (21”)with KBD and
placed in computer Room.
2.08.02 ANNUNCIATION SYSTEM FUNCTION
2.08.02.1 The annunciation system shall be implemented as an
inbuilt function of the DDCMIS. The field contacts
shall be acquired through DDCMIS only. The annunciation
sequence logic shall be implemented as a part of the
DDCMIS controllers. The annunciation window lamps
mounted on unit control panel shall be driven through
contact output modules of the control system of DDCMIS.
In case, the annunciation sequence logic is not
performed within the controllers for MFT(BMS), TPS etc.,
then these signals can be transmitted through some other
controller through bus and processed therein.
However, the annunciation system shall have the facility
of driving independent prints/ lamp box in the event of
failure of MMIPIS/ system bus in case the annunciation
system is affected due to the same.
2.08.02.2 The annunciation sequence shall confirm to ANSI/ISA-
18.1(1979) with first up facility.
2.08.02.3 The annunciation system lamp boxes shall be suitably
mounted on unit control panel as decided during detailed
engineering stage keeping in view the operational
requirements. It shall be preferable to have each window
as mosaic compatible. The lamp box shall have removable
impact polystyrene window of snap-on type. The minimum
size of each window shall be 50 mm x 75 mm with 5 mm
size inscription in black lettering on white background.
Each annunciation window shall be backlighted with two
long life lamps/super LED. The changing of lamps shall
be conveniently done from the front by simple removal
of windows.
2.08.02.4 Audible devices for alarm shall be cone type speaker
or metallic horn type and shall be driven by electronic
tone generator of adjustable pitch and sound level.
Bidder shall provide redundant audible devices with
selector switches. The trip alarms audible & ring back
audible shall be differentiated from other alarms.
2.08.02.5 The alarm annunciation system to be provided in unit
control room shall have sufficient capacity to cover all
pre-trip and trip alarms related to the unit and its
auxiliaries. The number of annunciation facia windows
and the provision for original input will be on as
required basis. However, the minimum number of facia
windows, signal input to the annunciation system shall
be 450 Nos.
2.09.00 MASTER & SLAVE CLOCK SYSTEM
2.09.01 a) The Bidder shall provide a date insensitive master and
slave clock system with adequate No.of output signal to
provide uniform timing throughout the various plant
facilities supplied by bidder as well as those not a
bidder’s scope. The system shall be complete with
receiving antennae (for receiving time from Satellite &
Radio signal), receiver and associated electronics,
redundant master clocks, slave clocks, interconnecting
cables, cubicles, power supplies & any other
accessories. However, a provision shall be kept for
synchronization of the master clock with other source as
decided during detailed engineering.
b) The system shall designed in accordance to IEEE 1344.
2.09.02 The master clock shall drive the slave display units. It
shall be ensured that loss of any slave display unit
does not affect the display of any other slave unit.
The MMIPIS, shall be synchronized with the master
clock once in every hour The switchyard event
recorder and other plant PLCs shall be synchronized
with the master clock once every minute.
2.09.03 The master clock shall be located in the control room
and shall have facility for automatic synchronizing with
GPS for IST.
2.09.04 The bidder shall provide a minimum 25 Nos.per unit of
slave clocks which shall be located at the various
plant facilities as finalised during detailed
engineering stage. System shall have expandable up to 30
Nos. slave digital clock.
2.09.05 The system include two Master Clock in 100% redundancy configuration (one working other standby). Power supply module for each Master Clock shall be redundant.
2.09.06 The cable from Master Clock to all Aux.plant PLC and slave clock shall be in bidder’s scope.
2.10.00 GROUNDING
2.10.01 All panels, desks cabinets shall be provided with a
continuous bare copper ground bus. The ground bus shall
be bolted/ welded to the panel structure and efficiently
ground the entire structure. All individual cabinet
grounds shall be connected to separate earthling riser
to be provided for C&I system signal grounding, as per
IEEE standard No.1050. “IEEE guide for
Instrumentation and control system grounding in
generating station.” The grounding requirements of
various parts of the C&I system shall be separate from
plant earthing. The exact grounding scheme shall be as
finalised during detailed engineering.
2.11.00 SYSTEM SOFTWARE REQUIRMENTS
2.11.01 The bidder shall provide all software required by the
system for meeting the intent and functional/ parametric
requirements of the specification.
2.11.02 Industry standard operating system like UNIX/WINDOWS
NT/OPEN-VMS etc. to ensure openness and connectivity with
other system in industry standard protocols(TCP-IP
etc.)shall be provided. The system shall have user
oriented programming language & graphic user interface.
2.11.03 All system related software including Real Time
Operating System, File management software, screen
editor, database management software. On line
diagnostics/debug software, peripheral drivers software
and High-level language compilers for FORTRAN, C, PASCAL
etc.latest versions of standard PC-based software like
latest WINDOWS based packages/ Unix, SQL, RDBMS,
Antivirous etc. and any other standard language offered
shall be furnished as a minimum.
2.11.04 All application software for control system functioning
like input scanning, acquisition, conditioning
processing & control along with communication among
various control system functional blocks, MMIPIS and
system bus, MMIPIS software for operator interface of
monitors, displays trends, curves, bar charts etc.
performance calculations (with steam properties routines
utilities) Historical storage and retrieval utility,
sequence of events recording system functions shall be
provided.
2.11.05 The bidder shall provide software/ hardware locks and
passwords to Employer/ Project Manager at site for all
operating & application software in order to prevent
unauthorized access and only Employer’s authorized
representatives are able to do modifications at site.
2.11.06 Multiple sets of back-up software on media, on CD ROM
shall be provided by bidder.
2.11.07 The bidder shall provide software license for all
software being used in DDCMIS/ Computer. All licenses
shall valid for continuous service life of plant.
2.12.00 SYSTEM DOCUMENTATION
2.12.01 The Bidder shall furnish detailed system and equipment
documentation. It shall include detailed system and
components description covering the installation,
operation care and maintenance of all system components.
All final system documentation for DDCMIS hardware and
related software shall be furnished. The same shall be
complete, accurate and fully representative of the
supplied system and its elements. All documentation/
catalogues etc. shall be furnished in English language.
In addition to the hard copies, CD ROM based
documentation system shall also be provided. The same
should be compatible to the On-line document generation
facility.
2.12.01.1 HARDWARE DOCUMENTATION
2.12.01.2 Detailed technical literature, reference manuals,
user’s guide/ manuals for the complete hardware like
control system hardware like control system hardware,
MMIPIS hardware, I/O hardware, bulk memory units,
peripherals and their controllers, communication
hardware including controllers, man-machine interfaces
programmers unit, power supply modules etc., shall be
furnished by the Bidder.
2.12.01.3 Operation and Maintenance Manuals
a)The operation and maintenance manuals shall include all
information required for trouble shooting, repair and
maintenance information regarding all equipments
furnished for the completeness of the system. Sufficient
documentation including block diagrams, component level
circuit diagram with all component value, make, model,
type, detailed wiring and external connection drawing
etc., shall be provided to carryout trouble shooting and
repair of all electronic cards(PCB), power supply
modules at component level.
b) Bidder shall provide safety Instrumentation System operation
and maintenance documentation as per IEC- 61511.
2.12.02 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
2.12.02.1 All technical manuals, reference manuals, user’s guide
etc.in English required for modification/ editing/
addition/ deletion of features in the software of the
DDCMIS shall be furnished. The bidder shall furnish a
comprehensive list of all system/ application software
documentation after system finalization for employer’s
review and approval.
2.12.02.2 The software listings shall be submitted by the bidder
for source code of application software and all special
to project data files.
2.12.02.3 Bidder shall provide as build drawings and documents to
MPPGCL, in hard & soft copies.
2.13.00 TRAINING
2.13.01 Further to the relevant clauses regarding training
specified elsewhere, Bidder’s experienced personnel
engineers shall also provide training courses on offered
DDCMIS to employer’s engineers in the following areas :-
1. Operator Training
2. Hardware Maintenance Training
3. Software Training
4. Any other specialized training as required for
system operation and maintenance.
2.13.02 The maintenance training shall include lectures and
hands on experience on a similar type of equipment/
system at manufacturers works and recently commissioned
operating plant and/ or Training Simulator. The
employer shall require training of three hardware and
three software engineers and the duration of each
course shall be four months minimum. The details of
hardware and software training shall be as finalised
during detailed engineering and shall be subject to
employer’s approval.
2.14.00 WARRANTY
2.14.01 The bidder shall provide and unlimited warranty on all
equipment and software for one year after the start of
the warranty period, i.e. after satisfactory completion
of initial operations. This warranty shall include
repair, replacement or correction of identified
software or hardware discrepancies at no cost to Owner.
2.14.02 No repairs/ replacement shall normally be carried out by
the employer when the plant is under the supervision
of bidder’s supervisory engineers. If in the event of
any emergency, in the judgment of the employer, delay
would cause serious loss or damage, repairs may be made
by the employer or a third party chosen by the employer
without advance notice to the bidder and the cost of
such work shall be paid by the bidder.
2.14.03 The Bidder shall provide warranty spares and an
exhaustive list of warranty spares including components
for system hardware and instrumentation and peripherals
based on (and keeping adequate margin over) normally
experienced failure rate shall be submitted by the
bidder for employer’s review regarding adequacy of the
same. The Bidder must furnish the list before inviting
owner personnel for acceptance test. The warranty
spares as per the list mentioned above will be
dispatched by the bidder along with the main equipment
consignment. The bidder shall also provide expandable
items for the warranty period.
2.14.04 In case of any hardware failure which hamper normal
operation, the bidder during the warranty period must
provide on-site technical expertise to repair/ rectify
the problem within 6 Hrs. and if any component is not
available at site, the bidder must arrange to supply
these components at site within additional 48 Hrs.if a
software problem is identified, this problem shall be
corrected within 24 Hrs.
2.14.05 After six months of DDCMIS operation the bidder shall
provide the list of spare parts and expandable utilized
during this period. The same information will also be
provided at expiry of the warranty.
2.14.06 In order to discharge the warranty responsibility, the
bidder shall include in his proposal lump sum price for
the provisions of a team of service personnel at site
who will be fully qualified to perform the required
duties throughout the warranty period of 1 year. The
bidder shall deploy at least one engineer, two
supervisors and four technicians in the team. The
exact numbers & composition of team members shall be
approved by the employer. In case, the team is unable
to rectify hardware or software problems, the bidder
shall depute and/or station additional specialist to
rectify the problem top ensure 99.7% availability of
system. The availability of system shall be calculated
as per specifications.
2.14.07 If any system is not working for more than one week then warranty period will be extended for duration for which the system was not available.
2.16.00 REMOTE DIAGNOSTIC STATION (OPTIONAL ITEM)
2.16.01 Bidder will indicate the price for the hardware &
software required for connecting the DDCMIS system to
bidder’s remote service center, through which the
diagnostics & fault analysis of the DDCMIS system can be
carried out. The method of connection shall be as per
Bidder’s standard practice. However, it is preferred to
have the connection through a single point
(i.e.Telephone line) in the plant’s DDCMIS system.
2.16.02 This price will not be considered for evaluation
purpose. However, bidder will include all technical
details of the proposed system for Employer’s review
and inclusion of the same in the award.
2.17.00 DDCMIS CONTROLLER GROUPING (OLCS x CLCS COMBINED FOR
SG, TG AND STATION – C & I)
2.17.01 S G SYSTEM
a) MFT– 1, MFT- 2, MFT-3, (Three Single Processors- 2/3
Voting)
b) Purge and Common Logic
c) Oil A & B
d) Oil CD & Oil EF
e) COAL A & B
f) COAL C & D
g) COAL E & F
h) SADC
i) SBC, PR and Drain Temperature Control
j) APRDS
k) HPBP
2.17.02 T G SYSTEM –
a) TSC
b) EHTC
c) LPBP, GSPC
d) Turbine Protection – A
e) Turbine Protection – B
f) ATT
g) ATRS SGC Turbine and SLC Drains
h) ATRS SGC Oil and Fire Protection
i) ATRS SGC Cond. & EAVC
j) GAMP
2.17.03 STATION C & I PACKAGE
a) IDF-A/FDF-A/Furnace Pressure /ESP-A & B
b) IDF-B/FDF-B/Fuel & Air Flow Control
c) P A Fan-A/AH-A/SCAPH-A/P A HDR Pr. Control
d) P A Fan-B/AH-B/SCAPH-B
e) CMC/Furnace Temp. Probe/Oil System/Misc. Drives
f) Mill-A & B Controls, PLOS- A, B
g) Mill-C & D Controls, PLOS- C, D
h) Mill-E & F Controls, PLOS- E, F
i) Drum Level Control/ CBD
j) SH/RH Controls/ Burner Tilt
k) Steam drains & vents/ Ejector/Misc. Drives
l) BFP–A/BCWP-A/TACW-A/Misc.Drives
m) BFP–B/BCWP-B/TACW-B/Misc.Drives
n) BFP–C/BCWP-C/TACW-C/Misc.Drives
o) Condenser, Deareator Drives/Misc. Drives
p) HPH, COLTCS, SCS, Misc. Drives
q) LPH/Extr.Steam/ Analysers/Misc.Drives
r) Electrical
s) Electrical
t) Electrical
Note:- (1) All function groups have 1 Pair of redundant Digital
Processing units(DPU), except Function Groups MFT–1,
MFT- 2, MFT-3.
(2) The above required functional groups are minimum
required if due to limitation of controllers
on as per bidder’s standard. Practice more groups
are required. Same shall be provided without any
extra cost.
(3)The functional group for mills are depends on No. of
mills actually used.
2.18.00 Bidder shall provide soft link between Aux. Plant PLC(supplied by other bidder Approx.10 Nos.) and DDCMIS for following only for Monitoring purpose.
(a) CHP
(b) AHP
(c) D M Plant
(d) Switchyard
(e) C W System etc
All hardware/Software/Cable/erection/ Commissioning etc. shall
be in the scope of Contractor.
3.OTHER SG/TG RELATED CONTROL & INSTRUMENTATION October 17, 2008
3.00.00 OTHER SG/TG RELATED CONTROL & INSTRUMENTATION
SYSTEM/ EQUIPMENTS
3.01.01 FLAME MONITORING SYSTEM
The purpose of the system is :
i) To detect the individual flame and to enhance the
boiler/furnace safety.
ii) To avoid spurious and unwarranted trips.
iii) To increase operational reliability, availability and
efficiency of the steam generator such that the
consumption of fuel oil shall be reduced to optimal
minimum.
3.01.02 a) Fail Safe easily maintainable flame monitoring System
shall be provided which shall include flame detectors of
proven design for the type of fuel, environmental
condition and other conditions of established
reliability at all loads of the steam generator. It
shall be designed to work under all adverse conditions
such as wide variation in fuel/ air input ratio, wide
variation in fuel characteristics, variation in
operating temperature, maximum temp.under interruption
of cooling air supply.
b) The system shall conform to NFPA recommendation and
location of detectors as per NEC requirements. The detector (photo cell) shall be UV/IR type .Flame detector shall be working on the dynamic and static properties of primary combustion zone of each type of fuel and flicker frequency of flame. It shall pick up only the flame to which it is assigned and shall not respond to the adjacent and background flame or other radiations generated in the furnace. The design shall also take into account the absorption by a coal shroud, recirculated dust or other deposition on the
flame detector head.
c) The complete system shall provide the discrimination
between oil and coal flame intensity indicators for main
flame shall be provided. Also isolated 4-20 A DC
signals shall be provided and looked at DDCMIS.
3.01.03 The system should be easily maintainable and include
automatic self test facility at regular interval. The
Bidder shall also provide a portable flame detector
testing kit with built in stabilizers, capable of
simulating both oil and coal flame, and testing of flame
detector head unit at field. The testing kit shall have
facility for testing all type of electronic cards as
being used in the flame monitoring system.
3.01.04 In case of tangentially fired burner, the bidder shall
arrange flame detectors one in each corner in such a
manner that coal flame detectors are available both
above and below each of the coal elevation and separate
oil flame detectors, one at each corner, for each oil
elevation. In case the Bidder provides discriminating
flame detector capable to detect and discriminate both
oil and coal flame, the same can also be utilized for
monitoring both oil flame in respective elevations and
also the coal flame of adjacent coal elevation. For any
other type of Boiler the flame detectors shall be
provided for each coal and oil burner responding only to
the flame of its associated burner.
Bidder shall also furnish the details of the flame
detector locations and justification for the same.
3.01.05 Site Tests
a)The Bidder shall demonstrate the complete performance of
flame detectors in cold start up test and load condition
test.
In cold start up test, capability of detectors to detect
oil flame under varying oil pressure shall be checked.
In load test, the detector shall be able to detect when
only oil is present, only coal is present and both coal
and oil are present. It shall be ensured that the
detectors are able to detect the proven flame at very
low load with oil GUNS Withdrawn.
The above tests shall be performed for every coal and
oil elevation. Contractor shall submit test results for
review & approval.
3.02.00 Provision of scanner air for cooling the flame detectors
by 100% redundant scanner air fans, one AC and
other DC operated, shall be provided. The emergency and
discharge dampers shall be pneumatically operated with
DC solenoid valves.
3.03.00 GRAVIMETRIC BELT TYPE COAL FEEDERS CONTROL AND INSTRUMENTATION
Bidder shall provide a microprocessor based coal feeder
C&I (explosion proof, meeting NEMA requirements) system
having the following feature. It is preferable to use
the same family of hardware as that of CLCS for implemen-
tation.
1) Bidder shall provide a minimum of two independent speed
sensors, pulsar units and associated amplifiers, etc.for
each of the coal feeders. Output from the speed
sensors will be used to provide at least four 4-20 mA DC
analog signals and any other signals required for the
control of the coal feeder.
In addition, one pulsar unit shall also be provided with
two pulse outputs-one for use in Control system and the
other for remote integrator.
Each coal feeder shall receive signals from DDCMIS for
feeder speed/mill level control. The signal to be
provided by DDCMIS shall be in the form of galvanically
isolated 4-20 mA DC. All required power amplifier
units/interface devices to accept this 4-20 mA signal
shall be included.
2) All associated electronics like buffer amplifiers,
frequency to current converter etc. shall be provided
for each RC feeder with local and remote speed
indicators and integrators. The speed sensors and
pulsar unit shall be totally enclosed, fire, dust and
weather proof, suitable for the service conditions. All
the necessary paddle switches and other detectors to
monitor coal on belt, feeder discharge plugged and other
protection and interlocks for safe operation of the
feeder is to be provided.
3) The control cabinet shall be provided with individual
lights to signal the individual internal trip
conditions. Necessary electronics/ push buttons shall be
provided in the control cabinet for resetting feeders
internal trip. In addition to the internal trips,
there shall be overload trip associated with feeder
motor starter. Provision for resetting the same shall
also be provided. Each feeder shall be provided with a
four position switch located at the feeder for remote,
off, local run (when there is no coal on conveyor)and
calibration purpose.
4) If there is any electronic modules mounted local to the
feeder body then these shall be suitable for operating
in a non air-conditioned area.
5) Coal feeders shall compensate for coal density and feeder volumetric efficiency effects by maintaining coal weight flow to coal burner to match air flow.
3.04.00 ELECTROMATIC SAFETY VALVES
The Electromatic safety valve shall be an automatic,
electrically actuated pressure relief valve. It shall
be possible to set the value for 1% or less differential
between opening and closing pressure. The Electromatic
safety valve shall be provided complete with all
accessories like pressure measuring devices, controller
units, solenoid assembly, impulse piping etc. The
Electromatic safety valves shall be provided with a
local controllers and a miniature remote control station
suitable for mounting on the UCP along with indicating
lights and switches to facilitate auto/remote manual
operation of the valve. The operation of the valve
shall be accomplished by use of a switch or by means of
pressure sensitive element which shall precisely and
automatically relieve the pressures within very close
limits. Bidder shall furnish complete details of the
Electromatic safety valves along with its technical
catalogue, list of accessories etc. In his proposal for
MPPGCL’s approval.
3.05.00 FURNACE TEMPERATURE PROBES
Bidder shall provide 2 Knockoff furnace temp.probes
before platen superheater and/ or before reheater
regions. These furnace temp.probes shall be electrically
operated, fully retractable type. The furnace
temp.probes shall be furnished with complete actuating
mechanism and all the logics required for the actuating
mechanism. The probe shall be provided with position
transmitters, limit switch & indicator for remote
indication. The temp.probe shall have a duplex
thermocouple suitable for the measurement range. Bidder
shall furnish complete details of the temp.probe
alongwith all the technical catalogues including the
details of the actuating mechanism, position transmitters
and limit switch which shall be subject to MPPGCL’s
approval. The logic for the furnace temp.shall
preferably be implemented in the DDCMIS.
3.06.00 BOILER FLAME ANALYSING SYSTEM
To assist in optimization of combustion efficiency with
variation in loads and fuel qualities, betterment in
flame stability and to limit Slagging and unburnt
carbon, NOx level to an acceptable limit through
efficient flame monitoring, analysis and combustion
management system.
The system shall consist of furnace flame cameras(semi
conductor type, one per each coal burner), flame image
processors & a PC based management system, along with
all required accessories. The system shall be capable
to provide information about (i)ignition point position
on fuel stream, (ii)height of fuel steam, (iii) upper
and lower flash point in the combustion area covered by
the corresponding camera as a minimum. Each camera
shall be able to view up to two and half meter or better
of the fuel flow coming from the burner.
The flame image processor shall be housed in a
standalone cabinet to be located in control equipment
room. I shall analyse the images received from each
cameras and shall produce flame parameters every second
in order to provide continuous monitoring of combustion
as well as detection of alarm conditions.
The Pentium PC based management system along with all
required software shall consist of 21″ TFT Monitor PC with
I/O cards, associated keyboard etc. Display of live/frozen flame of the complete furnace as well as live/frozen flame of the selected camera shall be available. The configuration of PC shall be fault tolerant and time synchronized from Master Clock.
The system shall also provide information about average
intensity of the flame, the total intensity of the
analysis area, stability of ignition etc.
The bidder shall provide all hardware and soft wares as
may be required to make the system complete.
The system shall be of proven design and its performance
must be proven for at least two 210 MW rating boilers
using similar type of fuel for a period of two years.
The components to be located at boiler area shall be
able to withstand the stringent environmental condition
expected at such locations with operating boiler.
Adequate cooling arrangement for the cameras and the
components to be located at the furnace area along with
automatic lenses cleaning facility shall be provided.
3.07.00 COAL BUNKER LEVEL MONITORING SYSTEM
Complete Coal Bunker Level Monitoring System consisting
of strain gauge sensors electronic units, bar graph type
displays mounted in Coal Handling Plant Control Room (to
be supplied loose)any necessary intermediate
electronics, interconnecting cables etc. The No.&
location of the strain gauge sensors shall be selected
by the bidder to ensure that overall accuracy (including
sensors & electronic unit)of the system is +/- 10% or
better in spite of possible interaction between support
systems of adjacent bunkers.
The electronic units shall be mounted in a cubicle
located in CER. These shall provide two isolated 4-20 mA DC
output for the bargraph type displays as well as for
DDCMIS.
3.08.00 WATER LEVEL MONITORING SYSTEM
a) Electronic Remote Drum Level Monitoring System
For Boiler drum in order to measure & monitor drum
level, bidder shall provide Electronic Remote Drum Level
Monitoring System working on principle of difference in
electrical conductivity between steam and water. The
monitoring system shall meet the requirements as
indicated below.
(i) Each end of the drum shall have independent pressure
vessels with 16 No. of electrodes covering the
entire range for indication for each end of drum.
Bidder shall provide High & Low and Trip contacts (Very
High, Very Low) with validation and 4-20 mA signal for
Drum level measurement.
(ii) The sensing electrodes shall be placed in equal pitch.
The maximum distance(gap) between two electrodes shall be
50 mm and the electrodes shall be arranged in such a way
that the last and the first electrode shall not be at
any alarm or trip level. In any case, the No.of
electrodes shall not be less than 16 for indication.
(iii) The system shall be proven and approved by Factory
mutual, USA of equivalent, IBR etc.
3.09.00 Conductivity Type Level Switching System
3.09.01 For Deaerator, Condenser hotwell and HP & LP
heaters alarms/protections, level switching systems
employing conductivity probes shall be provided. Each of
the switching systems shall be furnished complete with
at least 4 Nos. conductivity probes column for mounting
the conductivity probes, isolating valves, drain valves
vent valves, electronic units, twisted & shielded pair
interconnecting cables. The conductivity probes & the
column for mounting these probes shall be designed for
the respective pressure and temp.conditions.
The electrodes shall be designed in such a manner that
they sense the rising water level and that they do not
give faulty indication due to falling condensate on the
electrodes. Also, each system shall incorporate proper
validation circuits that eliminate spurious or unwanted
alarm/ trip actions due to a single channel fault.
3.09.02 Bidder shall provide Conductivity type level switches in
drain pots of MS, HRH, CRH pipes etc. as per ASME TDP-1.
3.10.00 TURBINE SUPERVISORY SYSTEM (TSS)
3.10 01 The Turbine supervisory equipment shall be complete
including sensors, transmitters, converters, limit value
monitors, measuring and amplifier modules, power
supplies etc.with the required accessories including
twisted and shielded instrumentation cables,
compensating cables, junction boxes etc. Following
measurements shall be provided as minimum.
i) Shaft Eccentricity Detection
ii) Absolute as well as relative shaft vibration
measurement, of each bearing in both X & Y direction.
iii) Differential expansion of rotor and cylinder for HPT,
IPT and LPT and LPT.
iv) Over all expansion of HPT and IPT.
v) Absolute bearing vibration measurement of each bearing
in both X & Y directions.
vi) Stator winding vibration vibration measurement in radial
and tangential directions.
vii) Axial shift of the rotor
viii) Turbine Speed
ix) Emergency stop and control valve position
x) Main Steam and Hot Reheat Steam Inlet Temp. and Pressure
xi) Bearing metal and drain oil Temp.
xii) Turbine metal Temp.
xiii) In case of vibration, shaft mounted reference detectors
and required supervisory instrument circuitry shall also
be provided.
xiv) Any other measurement recommended by the Turbine
manufacturer or required for the safe and reliable
operation.
The system shall be provided with suitable hardware for
necessary signal processing. The system should be
capable of signal distribution and interfacing with
other Control Systems. The system should suitably
interface with MMIPIS system supplied by bidder.
3.10.02 For all vibration measurements indicated in
items(ii)and(v)v.z.absolute bearing vibration relative
shaft vibration and absolute shaft vibration as
indicated under Clause 3.9.01 above, redundant
microprocessor/fault tolerant computer based system and time synchronized from Master Clock shall also be
provided to achieve the following functions :-
(i) On line spectrum/harmonic analysis.
(ii) Identification of the exact nature of failure resulting
in increase in bearing vibration and direct message on
the CRT indicating the exact nature of fault
e.g.Misc.shaft crack bearing looseness etc.
(iii) Storage and comparative analysis of vibrations.
(iv) Generation/ analysis of Bode Plot/Orbit Plot and time
waveform/ nyquist plot/ shaft center like plat/
cascade and water fall plot.
All the vibration parameters as well as Turbine
supervisory parameters shall also be fed to the DCS
through hardwiring so that all these parameters are
suitably displayed on the OWS. All required I/O cards and
other processing modules etc. shall be provided for this
purpose.
3.10.03 Test calibration jigs for site calibration of all
sensors of TSS shall be provided. Telephone jacks
shall be incorporated in all the TSS cubicles for
communication during site calibration etc.
3.10.04 Environmental limits for Turbine Turbovisory
instruments.
a) Operating Temperature for sensor and Extension cable.
0 – 177 Deg.C
b) Relative Humidity - 0- 95%
c) Corrosion Resistance
Probe Operation shall not effected by direct contact
with water or lub oil.
d) Sensor to Junction box extension cable shall be FRLS,
screened, armoured, twisted, oil resistant.
e) The system shall be designed accordance to
recommendation of API-670.
3.11.00 The configuration of all PC shall be fault tolerant and
Time synchronized with master clock.
4.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) October 16, 2008
4.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
4.00.01 Measuring instruments/equipment and sub-systems offered
by the bidder shall be from reputed experienced
manufacturers of specified type and range of equipment,
whose guaranteed and trouble free operation has been
proven in not less than two coal fired power station of
similar capacity for a period of at least two years.
Further all instruments shall be of proven reliability,
accuracy, repeatability requiring a minimum of
maintenance. They shall comply with the acceptable
international standards and shall be subject to MPPGCL’s
approval.
All instrumentation equipment and accessories under this
specification shall be furnished as per technical
specifications, ranges makes/ Nos. as approved by the
MPPGCL during detailed Engg.
4.00.02 Every panel mounted instrument requiring power supply
shall be provided with a pair of easily replaceable
glass cartridge fuses of suitable rating. Every
instrument shall be provided with a grounding terminal
and shall be suitably connected to the panel grounding
bus.
4.00.03 (a) All local gauges as well as transmitters, sensors
and switches for parameters like pressure temp., level
flow etc. as required for the safe and efficient
operation and maintenance as well as provision of
operator and management information including all
computation of equipment under the scope of
specification shall be provided. The necessary root
valves, impulse piping, drain cocks, gauge-zeroing
cocks, valve manifolds and all the other accessories
required for mounting/ erection of these local
instruments shall be furnished even if not
specifically asked for. The contacts of equipment
mounted instruments, sensors switches etc. for external
connection including spare contacts shall be wired out
in flexible/ rigid conduits, independently to suitably
located common junction boxes. The proposal shall
include the necessary cables, flexible conduits,
junction boxes and accessories for the above purpose.
Double root valves shall be provided for all pressure
tapings where the pressure exceeds 40 Kg/Sq.Cm.
(b) All field mounted primary instrument shall be IP-65 or
better.
(c) All primary instruments used for measurement of Hydrogen
shall be intrinsically safe and explosion proof as NEC,
Article 500, Class-I, Division-I.
(d) All primary instrument used for measurement of HFO, LDO
and Turbine Lub oil System shall be flame proof(IEC-79.1
Part-I).
(e) All primary instrument installed at ” Minus level or
floor” shall be protection level IP-68.
(f) All Thermocouple/ RTD shall be duplex.
(g) Following instrument cable termination shall be plug in
connection type.
i) Valve, Dampers/Drive(Internal Junction Box)
ii)Transmitter, E/P converter process actuated switches.
iii)RTD, Thermocouple
(h) All field instrument used in acid or alkaline
atmosphere, shall be with standard Anti corrosion
coating i.e. the combination of polyurethane and epoxy
resin baked coating(ANSI/ ISA-71.04).
(i) Where the process fluids are corrosive, viscous, solid
bearing or slurry type diaphragm seal shall be provided
for transmitters, Local gauges, process actuated
switches. Points below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm
shall be completely filled with an inner liquid suitable
for application.
4.00.04 HART Management System
Centralized configuration, maintenance, diagnostics &
record keeping facility for Electronic Transmitters.
The bidder shall provide a dedicated and standalone PC
based system with suitable software for each of the
generating units for centralized configuration,
maintenance, diagnostics & record keeping for all
electronic transmitters.
For this system, suitable HART interface modules, power
supply modules etc.shall be provided suitably mounted in
cabinets for heating up to a dedicated 21” TFT PC & Laser
Printer (B/W, Size A 4) to be provided by the Bidder.
The processor, power supply, communication port shall be
redundant. The configuration of PC shall be fault tolerant
and time synchronized from master clock.
Each of the transmitters shall be terminated in
marshalling cabinets through maxi terminal connections on
special twin terminal blocks to be provided by the
bidder. The transmitter signals from each of the
transmitters shall be wired in parallel to Control
System and to HART interface modules. The control
system will necessarily use 4-20 mA analog signals and
superimposed digital signal shall be used in HART
interface modules.
The multiplexed signal from HART interface modules shall
be hooked up to a PC station through associated
communication modules, converters etc. The
communication module shall provide data on RS-485 link
at a minimum speed of 19.2 K baud. If the bidder’s
standard HART interface module has integral
communication module to provide RS-485 link, the same
shall also be acceptable. In all HART interface
modules, provision for connecting at least 20% extra
transmitters shall be kept.
A RS-485 to RS-232 Converter shall be provided for
interfacing HART data of transmitters to a P C station.
This converter shall also provide proper isolation to
ensure data integrity.
Any failure/ short/ open circuit and/or removal of any
of the cards/ devices/ cables in this centralized
configuration, maintenance diagnostics and record
keeping system, including failure removal of HART
interface modules, communication modules, converter etc.
shall in no way affect the 4-20 mA analog signals being
used in control systems.
Suitable redundant 24 V DC power supply packs/modules
and redundant feeders shall be provided to feed all
modules/ devices. These power supply packs/ modules
shall be fed from redundant feeders of Bidder’s UPS
system.
All modules/ cards/ power supplies shall be mounted in
cabinets to be located in control equipment room. The
PC and printer shall be located in programmer’s room.
Communication protocol converter shall be suitably
mounted in proper enclosure either at CER or in
programmer’s room.
All cables/ links for connecting system described above
shall be provided by the bidder on as required basis
within quoted price.
The bidder shall also provide following facilities shall
be available as a minimum through software.
(a) Constant scanning to monitor faults of changes to
instrument configuration.
(b) MPPGCL defined and standard calibration and
configuration procedures for all transmitters.
(c) Constant signal data collection facilities to maintain
continuously updated records in accordance with ISO 9000
quality standards.
(d) Automatic tracking of configuration changes made in the
field, such as may be introduced by hand-held
communicator. All configuration function associated
with hand-held communicators shall be available in the
system.
(e) Event and log reports on screen as well as on printer.
(f) Any addition/ deletion of transmitter will be reported
on printer and logged in hard disk.
4.01.00 Specification for Electronic Transmitters for Pressure,
DP, Flow, Level
i) Type of Transmitter – Microprocessor based 2 wire type,
HART protocol compatible.
ii) Accuracy - +/- 0.1 % of span
iii) Output Signal Range – 4-20 mA DC(Analog)superimposed
digital on HART protocol
iv) Turn Down Ratio - 100:1
v) Stability - +/-0.1% of calibrated span for six
months up to 70 Kg/Sq.Cm and
+/- 0.25% for range more than 70
Kg/Sq.Cm(g).
vi) Zero and span drift – +/- 0.015% per Deg.C at max. span
and 0.11% per Deg.C at min. span
vii) Load Impedance - 500 ohm (Min)
viii) Housing - Weather proof as per IP-65 with
durable corrosion resistant coating
ix) Over Pressure - 150 % of Max. operating pressure
x) Connection(Electrical- Plug and socket type
xi) Process Connection - 1/2 inch NPT (F)
xii) Span and Zero - Continuous, tamper proof, Remote
Adjustability as well as manual from instrument
with zero suppression and
elevation facility.
xiii) Accessories i) Diaphragm seal, pulsation dampeners
syphon etc. as required by service
and operating condition.
ii) 2/3/5 Valve manifold as applicable
xiv) Diagnostics - Self Indicating Feature
xv) Power Supply - 24 V DC +/- 10%
xvi) Adjustment/ - Centralized PC based system as per
Calibration Clause 4.00.04. In addition total
Maintenance ten(10) Nos. of hand hold
calibrators for two units shall be
provided.
Note:- (1)Displacer type or guided Radar type Level Transmitter
shall be provided for level measurement of condenser
hotwell level, LP Heater I,II,III and Vacuum services.
(2) Guided wave Radar Transmitter shall be provided for
Level measurement of Turbine oil tank.
(3) LVDT Type transmitter is not acceptable.
(4) Where the process fluids are corrosive, viscous, solid
bearing or slurry type, diaphragm seals shall be provided.
Parts below the diaphragm shall be removable for cleaning.
The entire volume above the diaphragm shall be completely
Filled with an inert liquid suitable for the application.
4.02.00 Temp. Sensing Elements & CJC Boxes
(A) a) i) Type of Thermocouple -16 AWG wire of chromel-Alumel
(Type K)or 24 AWG wire Pt-Rhodium
Pt (Type R), ungrounded type
depending on operating temp.
range.
ii) Type of RTD - 4 wire- Pt RTD 100 ohm(as per DIN-
43760)
b) No.of Element - Duplex
c) Housing/ Head - IP-65/Diecast Alu.(Where applicable)
d) i) Sheathing of - Swaged type magnesium oxide
Thermocouple insulation
ii) Sheathing of - Metal sheathed, ceramic backed
R T D
e) Calibration and - As per IEC-751/ANSI-C-96,1
accuracy +/-0.5% of range for R T D
f) Characteristic - Linear with respect to temp.
within +/- 1/2 % of top range value
g) Accessories - Thermowell of 316 SS tapered,
solid bore, Temp.stub, compensating
cable upto CJC box.
plug in connectors.(Ref.Note)
Note:- For Fans/AH/Mill Bearing Temp.& Metal Temp.
measurement the screwed termination can be accepted if
plug in connection are not standard practice of the
bidder.
h) Standard - ANSI C 96.1 for Thermocouple and
ASME PTC- 19.3 for thermowell
i) CJC Box Ref.Temp. - 60 Deg.C +/-0.5 Deg.C for type K
Thermocouple
60 Deg.C +/-2 Deg.C for type R
Thermocouple
j) Effect of ambient - +/- 0.1% per 10 Deg.C
Temp.variation for
CJC boxes
k) Material of C J C - 2 mm thick sheet steel
boxes
l) Protection Class of – IP-65
CJC boxes
m) Cable entry - Bottom with gland plates suitable
for cables used
n) Temp.Control of CJC – Automatic with remote Temp.
boxes Monitoring
o) CJC Box power supply – 240 V AC 50 Hz
p) Thermowell General
i) One piece 316 SS, tapered, drilled
from bar stock (As per ASME PTC
19.3-1974).
ii) For Mill classifier outlet long
life solidsintered tungsten carbide
material of high abrasion
resistance.
iii) For Air & Flue gas 316 SS
protecting tube with welded cap.
iv) For furnace zone, impervious
ceramic protecting tube along with
incoloy supporting tubes and
adjustable flanges.
Bidder shall provide calculation for thermowell
As per ASME- PTC-19.3.
(B) For detection of leakage of various drain valve drain
pipe and Turbine metal temp. thermocouples shall be
provided as per the following specification to meet ASME-
TDP-1 Standard.
1. Measuring Medium - Metal Temperature
2. Metal of Thermocouple Element – Chromel Alumel Type K
3. Tyoe of Thermocouple - Duplex with separate
hot junctions,
ungrounded type.
4. Insulation - Mineral Insulation
Magnesium Oxide
5. Thermocouple wire gauges - 16 AWG
6. Protective sheath - SS 321
7. Protective sheath dia - 8 mm O.D.
8. Characteristics of Thermocouple- Special limits of
error as in ANSI MC
96.01.1975
9. Mounting Accessories - 1/2″ BSP SS sliding
end connector, weld
pad, weld on clamps
of heat resistant
steel SS 310.
10. Cold end sealing - SS pot seal with
colour coded PTFE
headed sleeve insulated
flexible tails. Sealing
Compound- Epoxy resin.
11. Minimum bending radius - 30 mm
12. Length of T/C - 30 Mtr.(Min)as per
requirement
4.03.00 Flue Gas Analyser
Bidder shall supply flue gas analyser instruments with
following common requirements :-
a) Output signals analog - 4-20 mA DC
Binary - 2NO + 2NC for high alarm
b) Zero & span adjustment - Available
c) Ambient Temp. - 60 Deg.C
d) Indication - Digital
e) Enclosure Type/Material - Weather & Dust proof
IP 65Die cast Alu./SS
f) Type of Electronics - Microprocessor Based
g) Digital Signal transmission – RS 232
protocol
h) Calibration - Auto & Manual(from Remote)
i) Error Diagnostic - To be provided
j) Others - It analyzer provides super-
imposed HART signal on
4-20 mA DC output, it
shall also be connected to
PC based station specified
under Clause 4.00.04.
4.03.01 SO2 Analyzer/Monitor shall be sampling type and based on
principle of measurement radiation absorption (UV) type.
a) Accuracy - +/- 1% of F.S.
b) Linearity - +/- 1% of F.S.
c) Response time - 10 Sec for 90% of FS
d) Drift - +/- 1% / 10 Deg.C
e) Sensor Type - Luminescence/ IR
f) Operating Range – 0-300 Deg.C
g) Filter - Sintered Bronze
5 Micron
h) Sampling System – With dual sampling through heavy duty
pumps, solenoids, filters etc.
along with coolers and flow meter and
level switch in gas coolers for auto
draining purpose.
i) Accessories - Yes
Purging System
j) Compensation for – Yes to be provided
Temp. moisture for
oxygen including
cables up to JB
k) Automatic zero - Yes
and span adjustment
4.03.02 NOX Analyzer/Monitor shall be sampling type and based on
principle of measurement radiation (UV/ IR) type.
a) Accuracy - +/- 1% of F.S.
b) Linearity - +/- 1% of F.S.
c) Response time - 10 Sec 90% of FS
d) Drift - +/- 1% / 10 Deg.C
e) Sensor Type - Luminescence/ IR/UV
f) Operating Range – 0-300 Deg.C
g) Filter - Sintered Bronze
5 Micron
h) Sampling System – With dual sampling through heavy duty
pumps, solenoids, filters etc.
along with coolers and flow meter and
level switch in gas coolers for auto
draining purpose.
i) Accessories - Yes
Purging System
j) Compensation for – Yes to be provided
Temp. moisture for
oxygen including
cables up to JB
k) Automatic zero - Yes
and span adjustment
4.03.03 Oxygen Analyzer/Monitor shall be non heated INSITU dry
type and based on principle partial pressure using
Zirconium oxide cell.
a) Accuracy - +/- 0.5% of F.S.
b) Linearity - +/- 1% of F.S.
c) Response time - 10 Sec for 90% FS
d) Drift - +/- 0.005%, 2 Deg.C
e) Sensor Type - High Temp.zirconium
oxide cell
f) Operating Range – 0-700 DEG C
g) Filter - Sintered Bronze
5 Micron
h) Accessories - Yes
Purging System
i) Compensation for – Yes to be provided
Temp. moisture for
oxygen including
cables up to JB
j) Automatic zero - Yes
and span adjustment
k) Filter Protection – Abrasive Shield
and Probe
4.03.04 CO Analyser/Monitor shall be INSITU type , based on
principle of measurement IR absorption type.
a) Accuracy - +/- 2% of F.S.
b) Linearity - +/- 1% of F.S.
c) Response time - 5 Sec for 90% of FS
d) Drift - +/- 1% / 10 Deg.C
e) Sensor Type - IR
f) Operating Range – 0-300 Deg.C
g) Filter - Sintered Bronze
5 Micron
h) Sampling System – as per requirement
i) Accessories - Yes
Purging System
j) Compensation for – Yes to be provided
Temp. moisture for
oxygen including
cables up to JB
k) Automatic zero - Yes
and span adjustment
4.03.05 Dust density Monitoring system shall be INSITU type
visible light type (through LED) and based on principle
of measurement transmission and absorption type.
a) Accuracy - +/- 2% of F.S.
b) Linearity - +/- 1% of F.S.
c) Response time - 5 Sec. or less
d) Drift - +/- 1% in 24 Hrs.
e) Sensor Type - Luminescence
f) Operating Range – 0-300 Deg.C
g) Filter - Sintered Bronze
5 Micron
h) Accessories - Yes
Purging System
i) Compensation for – Yes to be provided
Temp. moisture for
oxygen including
cables up to JB
j) Automatic zero - Yes
and span adjustment
k) Shutter solenoid for isolating lens during unit trip and
purge air failure automatically to be provided.
4.03.06 Following flue gas Analyzer measurement shall be
provided by bidder :-
i) Opacity Meter (Total 5 Nos.)
a) On Chimney - 1 No.
b) FG at ESP outlets - 4 Nos.
ii) CO Analyzer (Total 3 Nos.)
a) On Chimney - 1 No.
b) FG after ID Fan Discharge – 2 Nos.
iii) SOX/ NOX/CO2 Analyzer
a) On Chimney - 1 No.
iv) Oxygen Analyzer
a) Oxygen in FG at ECO – 2 Nos.
.
b) Oxygen in FG after APH - 2 Nos.
v) Oxygen Analyzer (HT Type)Total- 2 Nos.
a) Oxygen in FG after Platen SH (L) – 1 No.
b) Oxygen in FG after Platen SH (R) – 1 No.
vi) Velocity of Flue Gas at Chimney - 1 No.
4.03.07 a)Bidder shall provide calibration gas in cylinder for one
year for flue gas analyzers.
b)Any other Analyzer recommended by Boiler manufacture or
pollution board.
4.04.00 Vibration Monitoring System
Microprocessor based vibration monitoring system shall
be provided for ID, FD, PA Fans, CEP’s, BFPs, CW pumps
and all other pumps/ motors operating on 6.6 KV.
The No. of bearing locations to be monitored on each
fan/pump shall be as per requirement finalised during
detail engineering but not less than 2 bearing locations
for each fan/pump(except for vertical pumps for which
one bearing location may be sufficient). Vibration
measurement shall be carried out in 2 points, the
horizontal and vertical planes for each location of
measurement. The system shall be designed in
accordance to recommendation of API-670(Latest Edition).
The Vibration Monitoring System shall be furnished on a
system basis including vibration transducers with low
noise flexible cables in flexible conduit, terminated in
local terminal boxes, necessary pre-amplifier/
electronics mounted in local weatherproof boxes(IP-65)
vibration monitors & mounting racks/cabinets. The
Vibration-monitoring system shall include all power
supplies, inter-connecting cabling, calibration
equipment, indicators, integrating units, signal
conditioning devices and all other accessories required
for monitoring of Vibration at each point.
Bidder shall offer 2 channel vibration monitors for each
measurement location catering for horizontal and vertical
measurements. Offered vibration monitors shall be
modular in construction, plug in type and suitable for
19″ rack mounting.
Eddy current type proximity transducers shall be used.
However, the finally selected sensor type shall also
depend on recommendation of the equipment manufacturer &
suitable for application requirement. Transducers shall
be furnished in weatherproof housing suitable for field
conditions.
Vibration monitoring system shall give buffered output
of 4-20 mA DC for each point monitored. The signal
shall be suitable for use as an input to DDCMIS as well
as for analog recording & analysis, linear in proportion
to vibration velocity as well as displacement. Monitor
shall provide vibration indication calibrated in
velocity units along with provisions of changing to
displacement unit (field programmable)for each
measurement point in both horizontal & vertical planes.
The vibration monitor racks with power supplies shall be
mounted in unit control panel. However, for CW Pump the
rack cabinet shall be located in CW pump house on the CW
pump local control panel. The No.of racks & power
supplies shall be such that on failure of a single power
supply/ module, not more than four monitors shall be
affected.
The functional requirement for vibration monitoring
system shall include but not be limited to the
following:-
(a) Vibration monitor front face status indications shall be
available fr indications of healthy conditions of pick-
up circuit, monitor circuit and power supply. Also set
point indication with set point adjustment facility for
setting alarm & trip levels shall be provided.
(b) The facility shall be available from front of mounting
rack for functional checking of monitors with inhibition
of alarm of alarm and trip contact outputs during test.
(c) All vibration monitoring equipment shall be
functionally tested for circuit continuity and output
response. All the components & inter-connection cables
shall be tested to ensure compliance with the
specification requirements & all other applicable codes
and standards.
In case it is the proven standard practice to monitor
the vibration parameters from control/ monitoring CRTs
instead of dedicated monitors with the signal
conditioning equipment in control equipment room the
same shall also be acceptable. However, all relevant
functional requirements detailed above shall be met and
the system shall be subject to MPPGCL approval.
(d) The Temp.range of sensor shall be 0 to 121 Deg.C.
(e) The system shall be designed in accordance to the
recommendation of API-670.
4.05.00 Specification for Flow Elements
|
S. No. |
Features |
Essential / Minimum Requirements Orifice Flow Nozzle |
|
|
1
2
3
4
5
6
7
8
9
10
11
12
13
|
Type
Material
Thickness
Beta Ratio
Tappings
Assembly Drg.& flow Vs DP curve
Beta Ratio Calculation to be submi- tted
Material of Branch pipe
Accessories
Root valve Type
Root valve Material
Root valve Size
Impulse pipe of same material upto root valve |
Concentric as per ASME PTC-19.5(Part-II),ISA RP-3.2, 1060 or BS-1042
316 SS
3mm for main pipe diameter up to 300 mm and 6 mm for main pipe dia above 300 mm
0.34 to 0.7
Flanged weld neck 3 Nos.of 316 tappings
YES
YES
Same as main pipe
Root valves,flanges,vent/ Drain hole (As required)
Globe
316 SS
Half inch
Required
|
Long radius, welded type as per ASME PTC-19.5 (Part-III)or BS-1042
316 SS
Suitable for intended application
Around 0.7
D and D/2 (3 Nos. of Tappings)
YES
YES
Same as main pipe
Root valves, vent and Drain hole
Globe
316 SS
Half inch
Required
|
(a) IMPACT HEAD TYPE FLOW ELEMENT
The impact head type element (annubar) shall be tubular insert type with four impact ports facing upstream direction, located precisely for determination of average flow velocity and shall be of 316 SS.
Accuracy shall be +/- 1.0 % of actual value or better. Repeatability shall be +/- 0.01 % of actual value or better.
The elements shall be supplied complete with mounting hardware, end support plugs and CS valve manifold (1/2” NPT connection) for instrument connections. All pertinent data including MPPGCL’s instrument Tag No. for the flow element shall be punched on a stainless steel plate and affixed to the element.
Bidder shall submitted certified flow calculation and differential pressure Vs. flow curves for each element for MPPGCL’s approval. Sizing calculation, precise flow calculation for all the flow elements, fabrication and assembly drawings and installation drawings shall be submitted for MPPGCL’s approval.
On line retracting facility and flushing arrangement shall be provided.
Anubar Type flow element shall be used for measurement
of C W flow.
Bidder shall submit all sizing calculations, precise flow calculations, fabrication and assembly drawings, installation drawings for all the flow elements for MPPGCL’s review and approval.
(b) Coriolis Type Mass Flow Meter
(i) Accuracy - 0.2% of F S
(ii)Repeatability - 0.1%
(iii)Output - 4-20 mA
(iv) Protection - IP-65
(v) Hazardous Area- Flame proof
Classification
Bidder shall provide Coriolis type Mass Flow Meter for flow measurement of HFO (Main & Return) and LDO.
(c)Bidder shall submit all sizing calculation, precise flow calculation fabrication and assembly drawing, installation drawing for all the flow elements for MPPGCL’s review and approval.
(d)Bidder shall provide three Tappings per flow elements. Bidder shall provide three Flow Transmitters for M S Flow and Feed water flow, for all other services, bidder shall provide two flow transmitters.
(e) Testing Flow Element
(i) Factory Acceptance Test
· Tag No./ Type
· Dimension, surface finish
· Hydraulic test as per IBR
(ii) Type Test Report (Document Review)
· IBR Certificate
· Sizing Calculation
· Material Test certificates
· Wet calibration shall be carried out as per type test
on each size and design of flow element as per ASME
PTC or BS 1042.
4.06.00 Specification for Pr.Gauge, D P Gauge, Temp.Gauge and
Level Gauge
Temp./Pressure/ Level Gauges shall be provided for local
supervision wherever required.
|
S. No. |
Features |
Essential / Minimum Requirements Pr.Gauge / D P Gauge Temp. Gauge
|
|
|
1
2
3
4
5
6
7
8
9
10
11
12
13
14 |
Sensing Element & material
Body Material
Dial Size
End Connection
Accuracy
Scale
Range Selection
Over Range test
Housing
Zero/span
Identification
Accessories
Material of Bourdon Movement
Standard
|
Bourdon for high Pr., Diaphragm /bellow for low Pr. of 316 SS
Die-cast Aluminium
150 mm
Half inch NPT(F)
+/- 1% of span
Linear, 270 Deg. Arc Graduated in metric units
Cover 125 % of Max. of scale
YES
Weather and dust proof As Per IP-65
Adjustment
Engraved with service legend or engraved phenolic laminated tag Plate
BBlow out disc, syphon, snubber, pulsation dampener, chemical seal (if required by process) gauge isolation valve
316 SS / 304 SS
ASME B 40.1 |
Mercury in steel below 450 Deg.C and insert gas Actuated for above 450 Deg.C of SS bulb and Capillary
Die-cast Aluminum
150 mm
3/4″ NPT (F)
+/- 1% of span
Linear, 270 Deg. Arc Graduated in Deg.C
Cover 125 % of Max. of scale
YES
Weather and dust proof as Per IP-65
Provided
Engraved with service legend or laminated phenolic nameplate
SS Thermowell
316 SS / 304 SS |
LEVEL GAUGES
(a) The tempered toughened borosilicate gauge glass steel armoured reflex / transparent or float type arrow type level gauges shall be equipped with gauge valves including a safety ball check. Length of gauge glass shall not be more than 1400 mm. If the vessel is higher, multiple gauge glasses with 50 mm over lapping shall be provided.
(b)Bidder shall provide roller type Bi- colour level gauges for
drum.
(c)Bidder shall provide magnetic level gauges for Hotwell,
flash tank, LP & HP Heaters, Deaerator, Turbine oil tanks,
Cond surge tank ,gland cooler .
4.07.00 Process Actuated Switches
|
S. No. |
Features Essential / Minimum Requirements Pr.Switch DP Temp.Switch Level Switch Limit Switch |
||||
|
1
2
|
Sensing Element
Material
|
Piston Actuated for High Pr.and Diaphragm or Bellows for Low Pr.vacuum
316 SS |
Vapour Pr. Sensing, Liquid filled bellow type with bulb and capillary
316 SS/304 SS |
Float type orAs per note
316 SS |
Micro- Switch
Silver Plated high Conductivity non-corrosive |
|
3
4
5
6
7
8
9
10
11
12
|
Repeata-bility
End Connection
Over Range Proof Pr.
No. of Contacts
Rating of Contacts (Hermati- cally sealed)
Enclosure
Elect. Connection
Set Point/ Dead
Accessories
Mounting |
+/- 0.5% for full range
Half inch NPT(F)
150% of Max. design Pr.
2NO+2NC,SPDT snapaction dry contact
5A,240 V AC or 0.25 A, 220 V DC
Weather and dust proof as per IP-65
Plug in socket
Provided
Syphon, Snubber, Chemical Seal pulsation Dampener, as required by process)
Suitable for Enclosure/ Rack mounting |
+/- 0.5% for full range
Half inch NPT(F)
–
2NO+2NC,SPDT snapaction dry contact
5A,240 V AC or 0.25 A, 220 V DC
Weather and dust proof as per IP-65
Plug in socket
Provided
Thermowell of 316 SS & packing glands
Suitable for Rack mounting vertically |
+/- 0.5% for full range
Manufacturer Standard
150% of Max. design Pr.
2NO+2NC,SPDT snapaction dry contact
5A,240 V AC or 0.25 A, 220 V DC
Weather and dust proof as per IP-65
Plug in socket
Provided
All mounting Accessories
– |
+/- 0.5%
–
–
2NO+2NC,SPDT
5A,240 V AC or 0.25 A, 220 V DC
Weather and dust proof as per IP-65
Plug in socket
Provided
–
Direct factory Mounting on Valves, equip- ment with pro- vision for adjusting at site |
Note for Level Switches –
(a) Capacitance types for turbine oil and dirty medium,
application.
(b) Capacitance/ Conductivity/ Ultrasonic type for acid and alkali
application.
(c) Radio-frequency/Ultrasonic type for ash hopper, ash-slurry
application.
4.08.00 Indicators, Recorders
a) All remote receiver indicators for pressure,
Diff.pressure, level, temp. and flow indicators shall
have accuracy of +/- 0.1% to +/- 1% digit of full
scale. All analog indicators shall be 4-20 mA input type
and all Digital Indicators shall be universal input
type.
b) All Recorders shall be Microprocessor Based Chartless,
shall be universal input type. Accuracy shall be +/-0.3%
or better. All recorder shall be with 2 GB flash memory
card.
c) The Indicators, Recorders, Ammeters etc. shall be
mounted on vertical portion of unit control desk.
4.09.00 INTEGRATORS
Integrators shall have totalizer display of six digits,
4 mm high. Totalizer mechanism shall be as per
manufacturer’s standard. It shall have an accuracy of
+/- 0.5% of span. Input shall be 4-20 mA DC.
4.10.00 ELECTRICAL METERING INSTRUMENTS/ TRANSDUCERS
Electrical metering instruments Ammeters, voltmeter
etc./ transducers shall be provided by bidder for
mounting on UCD/ UCP. Application standard for
electrical metering instruments shall be as per IS:1248-
1968 (Revised). Suitable magnetic shielding and other
protections etc.(wherever required)for these instruments
shall be provided by the bidder. Ammeter shall be provided on UCD for DDCMIS control. HT/LT drives it will cover all HT drives, critical LT Motors, including DC operated motor.
The transducers having 4-20 mA dual isolated outputs for current measurement shall be provided and located in respective SWGR/MCC.
4.11.00 Solenoid Valve
All solenoid valve coils shall be class 4 high temperature
Or class `F’ insulation temp rise class B , construction as application and shall be
Designed for continuous duty and endures shall IP-65 or better.
4.12.00 Relays
All the relays shall be suitable for control supply of 24 V DC. Each relay shall have 4 changeover type hermitically sealed contacts. Rating of contacts shall be 5 Amp. at 220 V AC & 0.2 Amp. at 220 V DC. All relay contacts shall be wired up to terminal blocks.
4.13.00 Rotameter
The Rotameter shall be variable area linear scale type, with
+/-2% accuracy and magnetic float indication. Flange; orifice
in case bypass Rotameter(for line size above 50 mm).
4.14.00 Electric to Pneumatic (E/P) Converters
E/P converters and associated accessories shall be furnished in accordance with the specifications given below :-
Air Supply : 1.5 Kg/Cm.Sq. Input signal 4-20 mA DC (as required by the design of control system), output signal 0.2 to 1.0 Kg/Cm.Sq, Linearity 0.5% of span or better, Hysteresis 0.1% Of span or better, Ambient Temp. effect less than 0.02% of span per Deg.C between –20 to +60 Deg.C. Mounting: Close to actuator (but not on the actuator), output capacity to suit the actuator, protection class IP-65.
On loss of control signal, the last set point pressure shall be maintained so that the associated control valve remains in stayput position without using any solenoid valve. The allowable drift rate shall be +/- 2% of set point/ hour maximum.
5.STEAM & WATER ANALYSIS SYSTEM (SWAS) October 16, 2008
5.00.00 STEAM & WATER ANALYSIS SYSTEM (SWAS)
5.01.00 A SWAS room shall be provided to house the sample coolers and anlyser racks for the steam and water analyser system. The system shall be designed in accordance to the recommendation of ASME PTC 19.11
Part-II, water & steam in power cycle.
5.02.00 The SWAS system shall be supplied as a composite system
including sample piping, valves, grab sample collection
facility, gauge/indicators, coolers, chillers and on
line analysers.
5.03.00 Primary cooler racks are located out side the SWAS room.
Primary coolers shall bring down the sample temp. to 50
Deg.C (Approx). Secondary coolers shall bring down, the
temp. to approx. Cooling Water Temp.+ 3 Deg.C.
However sizing of cooler shall consider total flow plus 500
ml/Min grab sample & fouling factor of 0.2 & inlet cooling
water temp 33 Deg c and pressure of CW shall be 3 kg/cm2.
The cooler shall be protected by safety relief valve.
5.04.00 Sample conditioning panel(Wet panel) housing
secondary coolers, bulkhead fitting, pressure regulating
valves, grab sample flow rate control, flow indicator,
pressure and temp.gauges, cells and analysers of PH,
conductivity, cation column etc.
5.05.00 Analyser panel (Dry panel) housing all display units
(Digital panel meters for PH & conductivity signals)
analysers for sodium, phosphate, hydrazine, silica etc.
and annunciation system. Further, two 4-20 mA isolated
analog signal for each measurement including PH &
conductivity shall be fed to DDCMIS for monitoring.
Necessary signal distributors, if required shall be
Provided .
5.06.0 Sample Piping System
a) All process connection , piping, valve etc of SWAS analysers shall be conform to ANSI/ISA SP 77.70- 1994 (R 2005) “Fossil Fuel Power Plant Instrument Piping Installation”, ANSI B 31.1 “Power Piping”, PTC 19.11.1997,& IBR.
b) All sample piping shall be three fourth inch NB seamless type of material ASTM A213 TP 316H, conforming to ANSI
B 36.19.
c) All fitting shall be socket welding type and of material ASTMA 182 F316 H conforming to ANSI B 16.11.
d) Single and multi tubes shall run with the minimum No. of changes in direction. Suitable identification tags shall be provided for easy check up and for proper connections.
e) The valves to be used in sample piping shall be of globe type, forged construction and stainless steel conforming to ASTM A182. The pressure Temp. ratings shall be as per ANSI B 16.34. The valve design shall be such that the seats can be reconditioned and stem and disc can be replaced without removing valve body from the line. Blow down valve shall be gradual open type.
f) All samples shall be passed through cartridge type filter
before Secondary cooler.
5.07.00 The exact sample points, their location, type of
chemical analysis to be carried out for each sample,
measurement ranges etc. shall be subject to the
approval of the owner.
5.08.00 Following analytical measurement have been envisaged not
limited to -
5.08.01 D M Make-up to Condenser
i) Specific Conductivity
ii) Cat Conductivity
iii) Silica
5.08.02 Hotwell
i) Conductivity (insertion type)on both side
5.08.03 Cond. Pump Discharge
i) Cat Conductivity
ii) PH
iii) Disolved Oxygen
iv) Specific Conductivity
v) Silica
vi) Sodium
5.08.04 Condenser Cooling Water
i) PH
ii) Specific Conductivity
5.08.05 Deaerator Inlet
i) PH
ii) Disolved Oxygen
iii) Specific Conductivity
5.05.06 Deaerator Outlet
i) Disolved Oxygen
5.08.07 Feed Water at ECO I/L
i) Hydrazine
ii) Specific Conductivity
iii) Phosphate
iv) PH
a) Disolved Oxygen
5.08.08 Drum Water
i) Specific Conductivity
ii) PH
iii) Sodium
iv) Silica
5.08.09 Saturated Steam (SH out)
i) Specific Conductivity
ii) Cat Conductivity
iii) PH
5.08.10 Main Steam
i) Specific Conductivity
ii) PH
iii) Silica
5.08.11 HRH Steam
i) Specific Conductivity
ii) PH
5.08.12 CBD – Phosphate
5.08.13 Any other Analyzer recommended by Boiler/ Turbine
Manufacture or pollution board.
5.09.00 All the analysers/ cells shall have -
(A) a) Open Corrosion resistant drain to waste header.
b) Automatic Temp. compensation shall be provided. The
protection class of all analysers shall be IP- 65 &
operating Temp range shall be 0- 50 deg C.
(B) All chemical re-agents and required.
for 12 months operation is to be supplied.
(C) Analysers/ Monitors/ Cells shall be suitable for
operating under the conditions specified.
(C) The Analyzer supplies shall indicate the preparation
procedure/ formula of Regent to be used in Analyzer’s
System.
(E) Bidder shall submit cooler sizing, calculation, PID diagrams
etc. of SWAS system for approval during detail Engineering.
(F) Any Analyzer required inlet sample Temp. less than CW inlet Temp. + 3 Deg.C., the required chiller unit & cooler shall be In the bidder’s scope. The chiller unit and pump shall
be 100% redundant.
(G) Bidder shall provide startup kit for Analyzers, Buffer
solution for PH, Conductivity simulator etc.
TABLE - 5.1
SPECIFICATION OF SWAS ANALYZER
S.No. |
REQUIRE MENT |
HYDRAZINE |
SILICA |
SODIUM |
DISSOLVED OXYGEN |
CONDUCTI-VITY |
PH |
PHOSPHATE |
CHLORIDE
|
|
1. |
Type |
Continuous electro–chemical
|
Continuous colorimetric
|
Continuous |
Continuous |
Flow through |
Flow through |
Clorometric |
Continuous flow through |
|
2. |
Accuracy
|
± 5% |
± 5% |
± 10% |
± 5% |
± 1% |
± 1% |
± 5% |
± 5% |
|
3. |
Response time |
£ 1 min |
£ 10 min (for multi stream ) |
2 min |
< 30 Sec |
1 Sec. |
- |
£ 10 Min |
< 15 Min
|
|
4. |
No.of streams |
Single |
Multi – stream |
Multi stream |
Single |
Single |
Single |
Single |
Single |
6.UNIT CONTROL DESK, UNIT CONTROL PANELS October 16, 2008
6.00.00 UNIT CONTROL DESK, UNIT CONTROL PANELS, SYSTEM
CABINETS,LOCAL PANELS & TRANSMITTERS ENCLOSURES/
RACKS
6.01.00 GENERAL
6.01.01 All unit control desk/panels, system cabinets, local
panels & local instrument enclosures/racks shall be
furnished fully wired with necessary provision for
convenience outlets, internal lighting,
grounding, ventilation, space heating, anti vibration
pads, internal piping & accessories as per specn.as
required for completeness of the system.
6.01.02 All panels/desk/cabinets shall be free standing type &
have bottom entry for cables unless otherwise specified.
The bottom of desk panel/cabinet/enclosures shall be
sealed with bottom plate, compression cable glands and
fire proof sealing material to prevent ingress of dust
and propagation of fire.
6.01.03 All electronic system cabinets shall be designed for 50
Deg.C.operating under maximum ambient temperature
without air conditioning system in service. Further
cabinets/panels shall be so designed that temp.rise due
to heat load does not exceed 10 Deg.C above ambient
temp. under all operating conditions. Necessary
louvers/fans, limited packing density, adequate spacing
between instruments/ devices etc.shall be provided to
maintain temp.rise within permissible limits.
6.01.04 Desk/Boards/panels/cabinets enclosures wiring and piping
shall be arranged to enable the removal of
instruments/devices without unduly disturbing them.
6.01.05 All panels/desk/enclosures interiors shall be
illuminated with rapid start fluorescent strip fixtures
with door actuated switches. Door switch terminals
shall be shrouded. All illuminated lights shall be
provided with individual switch in parallel with door
switch.
6.01.06 Sufficient No.of power receptacles with disconnect
switches shall be installed within
panels/desk/enclosure & racks.
6.01.07 Bidder shall provide the unit control desk(UCD)and unit
control panel(UCP) to be mounted in the central control
rooms.
6.01.08 The local instrument enclosures/racks shall be provided
locally for mounting of electronic transmitters and
switches, etc.
6.01.09 All panels/desk/cabinets shall be properly grounded.
The grounding scheme shall be as approved by Employer.
6.01.10 Exterior steel surface shall be sand blasted, ground
smooth, filled, primed, sanded and smooth enamel painted
to give a good finish subject at minimum paint thickness
of 65-75 microns for sheet thickness of 3 mm and 50
microns for sheet thickness of 2 mm. Minimum 2 coats of
primer and two sprays of final finish colour shall be
applied to all surfaces.
6.01.11 The colour of the panels shall be brilliant white in
the panel interior. External colour of the panels will
be as RAL 7032 for UCB/UCD,LIE/LIR and other CER &
offsite mounted system cabinets, etc.
6.01.12 Due consideration shall be given to the ergonomics of
unit control desk, unit control panel and the control
room design.
6.02.00 CONTROL DESK/ PANEL
6.02.01 GENERAL
6.02.01.01 The exact dimensions, material, construction details
etc.of control desk/panels etc. shall be as per the
actual requirement and shall be finalised during
detailed engineering. The general arrangement of the
desk/ panel shall also be finalised during detailed
engineering, subject to employer’s approval.
6.02.01.02 The design of all control panels shall take due regard
of the actual application of various devices. It is
important that controls and indications required by the
operator for a particular operation should be grouped
together.
6.02.01.03 The bidder must pay particular attention in the
positioning of desk mounted CRT’s and large video
screens in relation to control room lighting in order to
minimize reflections.
6.02.01.04 For board/ panels/desk mounted instruments/devices,
etc. which are to be powered from UPS, all required
conversion of interface equipments/ accessories to make
such devices compatible with UPS supply shall be
provided. All necessary hardware like input
switches/fuse unit for each feeder as well as switch
fuse unit for each instrument/ device on the power
supply line shall be provided. From UPS, two feeders
shall be provided along with suitably rated MCB and
provision of fast auto changeover of UPS feeders. Power
supply distribution scheme shall be as approved by
employer during detailed Engg.stage.
6.02.02 UNIT CONTROL DESK (UCD)
Unit control desk shall be free standing table top type
with doors at the back and shall be constructed of 3 mm
thick CRCA steel plates. All operators CRT’s &
keyboards shall be mounted on this UCD. PA System hand
sets, telephone sets and alarm annunciation PBs shall
also be mounted. Few A/M stations & PB stations and
lamps may also be mounted on the control desk on mosaic
grid structure if found necessary. The desk shall be
arranged in an continuous arc shape. The exact profile
of the desk, dimension and the radius of curvature shall
also be finalised during detailed engineering stage.
To achieve durable & water resistant finish, a coat of
“Polyuthesive crystal clear” on the surface of unit
control desk shall be provided. Final paint finish
with proper smoothening is to be ensured. Final finish
of UCD should be in line with relevant international
standards.
6.02.03 UNIT CONTROL PANEL (UCP)
UCP shall be free standing vertical panel with double
leaf hinged doors at the back. It shall be constructed of
3 mm thick CRCA steel plates with mosaic grid structure
on front surface. The mosaic grid tiles shall be of 24
mm x 48 mm (or 25 mm x 50 mm) size, made of heat & flame
retardant, self extinguishing and non-hygroscopic
material with flat matt finish without glare and non
reflecting type. The UCP shall also be arranged is an
continuous arc shape. The profile and dimensions i.e.
radius of curvatures shall be decided during detailed
engineering.
All conventional back up devices/instruments and large
video screen shall be provided on UCP. For mounting
items, like PB stations, A/M station, miniaturized
control switches, indicators, recorders annunciation
windows, electrical mimic diagram, on mosaic grid, the
size of all these devices/instruments shall be
compatible to mosaic grid on UCP.
The mosaic grid construction should be flexible enough
to allow easy shifting at site of any instrument on
mosaic grid (including indicators & recorders) to any
other free location on the UCP without any need of
cutting or special equipment/ tool.
6.02.04 The status indication and repeat annunciation for
locally controlled systems like service air &
instrument air compressors, DM water pumps etc. shall
be provided on UCP of unit No.1 with important
parameters being duplicated in unit No.2 also. All
required miniaturized control switches, electrical
meters, associated mimic diagram for achieving the
control of station electrical system shall be provided
in the UCP of unit. The exact number & location of these
shall be as finalised during detailed engineering
state.
6.03.00 CABINETS/ ENCLOSURES/ PANELS
6.03.01 Smoke detectors shall be provided inside the CER
mounted system cabinets.
6.03.02 The cabinets/ panels shall be provided with eye bolts
for fitting.
6.03.03 Feeder failure/healthy indication shall be provided in
each cabinet & remote indication shall be hooked up to
DDCMIS/annunciation & suitably grouped.
6.03.04 The dimensions & load of all panels, cabinets &
enclosures shall be clearly brought out in the offer &
the same shall be supplied as per employer approved
drawings during detailed engineering.
6.03.05 The local panel/ system cabinet sheet steel thickness
shall not be less than 2.0 mm & that of enclosure shall
not be les than 3.0 mm unless otherwise specified.
6.03.06 All panels/ enclosures/ system cabinets/ marshalling
cabinets shall be provided with a minimum of 20% spare
terminations and system cabinets shall be provided with
spare space for 20% additional modules fully wired with
connectors etc. in excess of the total requirement of
the system design when the cabinets are delivered. The
spare space capacity shall be distributed evenly
throughout the cabinets.
6.04.00 LOCAL INSTRUMENT ENCLOSURE AND RACKS
6.04.01 Transmitters and switches, devices etc. mounted in the
field shall be suitably grouped together and mounted
(i) Local instruments enclosure in case of open areas of
the plant like boiler area, etc.& (ii)In local
instrument racks in case of covered areas. These local
instrument enclosures & racks shall be furnished as per
the actual requirements finalised during detailed
engineering stage.
6.04.02 The enclosures shall be constructed of 3 mm sheet plate
& shall be of modular construction with one or more
modules & two end assemblies bolted together to form an
enclosure. The enclosure construction & material shall
be generally as indicated. Gaskets shall be used
between all mating sections to achieve protection class
of IP-65.
6.04.03 The instrument racks shall be free standing type
Constructed of suitable 5 mm thick channel frame of
steel and shall be provided with a canopy to protect
the equipment mounted in racks from falling objects,
water etc. The canopy shall not be less than 3 mm
thick steel, and extended beyond the ends of the rack.
Bulk heads, especially designed to provide isolation from
process line vibration shall be provided. Exact
fabrication details shall be as finalised during
detailed Engg.stage. However, the same shall be
generally as indicated. The junction box for racks also
shall conform to IP-65 protection class.
6.04.04 It shall be possible to start Turbine/Gen DC oil pumps from control desk control room in the event of failure of DCS.
6.04.05 (a)Minimum No.of back-up instrumentation and UCP mounted
secondary instruments per unit to be provided as a
minimum are given below. However, bidder has to supply
all the required back-up instruments and UCP mounted
secondary instruments on as required basis as finalized
during detailed engineering.
1. Hand/ Auto Stations : 80 Nos.
2. Dual scale Indicator(48×48 mm) : 80 Nos.
3. Single side Indicator(48×48 mm) : 15 Nos.
4. Digital Indicator(24×48 mm) : 15 Nos.
5. Control Switches : 5 Nos.
6. Indicating Lights : 35 Nos.
7. P B Stations : 75 Nos.
8. Push to glow lamps : 30 Nos.
9. LED Indicating Tiles : 45 Nos.
10. Selector Switches : 5 Nos.
11. 10 Position Miniaturized : 5 Nos.
Selector Switch
12. 3 Pen Recorder : 6 Nos.
13. 6 Point Recorder(Chartless) : 6 Nos.
14. 30 Point Microprocessor : 6 Nos.
based Recorders (Chartless)
15. Indicator Analog Digital : 60 Nos.
16. Motor Current Ammeters : 50 Nos.
(b)The size of all above instruments shall be as per DIN Standard.
6.04.06 Monitoring Philosophy
(a) Indicator/Recorder shall be provided on UCP only for few
critical parameter satisfying the following guide lines.
i) All Analog parameters which are responsible for
tripping of unit, Boiler, Turbine, generator, G T.
ii) All Turbovisory parameters of turbine.
iii) Few important parameters.
iv) Parameter corresponding to important control loops.
v) Parameter which are responsible for improving plant
efficiency.
vi) Ammeter for all 6.6 KV, motor pump/ fan and AC/DC oil
pumps motor for generator, turbine etc.
vii) Recommended by equipment manufacturer.
(b) In addition to CRT/KB, for safe shutdown of plant, for
handling of emergency for safety of plant, miniaturized
push button, important A/M Station, Lamps, Selector
Switch and instrument recommended by equipment
manufacturer, shall be provided on UCD/UCP.
6.04.07 Philosophy for Analog/ Digital Indicators
(a) For slow changing parameter i.e. SH/RH Temp.Digital
indicator shall be provided.
(b) For fast changing parameter analog indicator shall be
provided i.e. drum level, furnace draft.
6.04.08 Terminal block
All terminal blocks shall be screwless cage clamp type of wage/ phoenix make.
6.04.09 Door lock & hinges shall be provided for all cabinets/panels/ junction boxes.
6.04.10 Cooling fan & filters – In case where cooling fans are required to keep the cabinet electronics at reasonable operating temperature. Bidder shall provide 100% redundant fan. Bidder shall provide fire retarded, washable filter to remove air borne contamination.
6.05.00 All cabinets/ Panels/ Racks shall be with suitable
canopy at all the top to prevent ingress of dripping
water.
6.06.00 Protection class for Panels/Cabinets/Junction Boxes.
a) Outdoor Location - IP 65
b) Indoor Location - (Non Air Condition)
i) Non Ventilated – IP 54
ii) Ventilated - IP 42
c) Air Conditioned Areas (in side Control Room) – IP 22.
7.ELECTRIC POWER SUPPLY October 16, 2008
7.00.00 ELECTRIC POWER SUPPLY
7.01.00 The requirements of Electric Power Supply system are
specified herein on system basis. The contractor shall
be fully responsible for engineering and furnishing a
complete and operational system fully meeting the intent
and requirements of this specification and owner
approved drawings. All equipment and accessories
requires for completeness of this system shall be
furnished by the contractor whether these are
specifically mentioned herein or not. All the
equipments and sub-systems offered shall be from reputed
experienced manufacturer. All system cabinets,
enclosures & distribution boards shall be manufactured,
assembled, wired and fully tested as a complete assembly
as per the requirements of this specification at the
manufacturer’s works.
7.02.00 The power supply system shall be designed to meet the
electric power requirements of various C&I systems
including DDCMIS and shall be configured as described
below:-
a) For MMIPIS portion of DDCMIS including peripherals
like CRT’s. printers, disks etc.and other systems such
as SWAS, panel instruments, requiring stabilized AC
power, the bidder shall furnish a redundant UPS
system.
b) The power supply to each DDCMIS system cabinets is fed
through dual 240 V AC Feeder from UPS.
7.03.00 The UPS system in the above mentioned configurations
employed float cum boost chargers, battery banks, static
inverters, static switches. AC/DC distribution boards etc.
shall meet the following specification requirements as a
minimum.
7.04.00 Uninterruptible Power Supply(UPS) System
The UPS system shall have 2×100% parallel redundant
chargers and inverters, 2×100% battery bank, bypass line
transformers and voltage stabilizer, static switch,
manual bypass switch, AC/DC distribution boards, other
necessary protective devices and accessories and shall
meet the following requirements as a minimum.
(1) The KVA rating of UPS shall be as required by expected
loads and include 10% spare capacity guaranteed at 50
Deg.C Amb. However, for bidding purpose, a minimum
capacity of 125 KVA shall be considered. If UPS KVA
rating is applicable at a lower ambient temperature than
specified 50 Deg.C, the bidder shall consider Derating
factor of at least 1.5% Deg.C for arriving at the
specified UPS capacity at 50 Deg.C ambient. The UPS
shall have an over load capacity of 125% rated capacity
for 10 minutes and 150% rated capacity for 10 secs. The
inverter shall have sufficient I2t capability to clear
fault in the maximum rated branch circuit. The sizing
of UPS shall be based on the power factor of the loads
being fed subject to a maximum of 0.8.
(2) Each of the redundant chargers & batteries shall meet
the specification requirements as per clause 7.05.00
above.
(3) The UPS system shall be capable of operating without DC
battery in circuit under all conditions of load and the
performance of various components of UPS like inverter,
charger static switch etc. shall be guaranteed without
the battery in circuit.
(4) The UPS system design shall ensure that in case of
failure of mains input power supply to one of the
chargers, the other charger whose mains input power
supply is healthy, shall feed to one or both the
inverters as the case may be as per manufacturer’s
standard practice & continue to charge the DC battery at
all load conditions. The bidder should note that this
situation should not in any way load to the discharge of
the DC battery.
(5) Static Inverters
(i) The static inverter shall be solid state type using
proven pulse width modulation(PWM) quasi square
wave/step wave technique. The inverter equipment shall
include all necessary circuitry and devices to conform
to requirements like voltage regulation, current
limiting, wave shaping, transient recovery, automatic
synchronization etc. The steady state voltage regulation
shall be +/- 1% and transient voltage regulation(on
application/ removal of 100% load)shall be +/-2%. Time
to recover from transient to normal voltage shall not
be more than 50 m sec. Frequency regulation for all
conditions of input supplies, loads and temperature
occurring simultaneously or in any combination shall be
better than +/-0.5%(automatically controlled). The total
harmonic content shall be 5% maximum and content of any
single harmonic shall be 2.5 % maximum. The inverter
efficiency shall be at least 85% on full load and 80% on
50% load. The synchronization limit for maintenance of
synchronization between the inverter and stand by AC
source shall be 48-52 Hz, field adjustable in steps of
0.5 Hz. DC input window of each inverter shall be either
315 – 434 or 320-450 V DC.
(ii) Over load, short circuit and load loss
The inverter shall be provided with suitable HRC fuses
at the input and output which will permit proper
coordination with other protective devices and at the
same time protect the inverter against damage due to
internal faults. However, if the Bidder’s system
design does not use fuses then the fuse free circuit
breaker may also be permitted provided it meets the
specification requirements. All necessary equipment
shall be provided to protect the inverter against over
load, short circuit and 100% loss of load. The inverter
shall be self protecting against damage if energized
with full load connected.
(iii)Inverter equipment shall include all solid state
circuitry and devices including stable oscillator etc. to
enable inverters to operate satisfactorily in parallel
sharing mode each inverter taking 50% load during
normal operation. In case of failure of either
inverter, 100% load shall automatically be transferred
to healthy inverter without any break and degradation in
the quality of UPS output and disconnecting the faulty
inverter automatically.
(iv)The inverter failure shall be alarmed and the healthy
inverter shall get synchronizing signal from the standby
AC source and remain synchronized within the set
limits. The limits for the synchronization between
healthy inverter and standby AC source shall be field
adjustable.
(v) On failure of both inverters, the loads shall be
transferred to standby AC power without a break if
within synchronization limits. Provision of synchronous
transfer with a break in case of inverter being out of
synchronization limits shall also be there with standby
source.
(6) Static Switch and Manual Bypass Switch
The static switch shall be provided to perform the
function of transferring UPS loads automatically without
any break from (i) faulty inverter to standby AC source
in case of failure of both the inverters and (ii)from
faulty inverter to standby AC source in case of failure
of both the inverters.
Manual bypass switch shall be employed for isolating the
UPS during maintenance.
(7) Step Down Transformer and Voltage Stabilizer
The transformer shall be of low impedance type and the
rating shall be such that extremely fast fault clearance
is achieved, even in the largest rated branch circuit.
The winding shall be electrolyte grade copper with F class
insulation with temp rise limited to class B .
The over load capacity of the transformer/ stabilizer
shall not be less than 300% for 200 ms. The stabilizer
shall employ silicon solid state circuitry and the
output voltage regulation shall be +/- 2%. The
efficiency of the stabilizer shall be 95% or better.
7.05.00 (1) Float cum boost chargers:
Bidder shall provide 2×100% redundant chargers. The charge
Shall sized to meet the 100% load requirements of the
control system plus recharge the fully discharged
battery within 8 hours.
The chargers shall be self regulating, solid state
silicon controlled, full-wave rectifier type designed
for single and parallel operation with battery and shall
have automatic voltage regulators for a close voltage
stability even when AC supply voltage and DC load
fluctuates, effective current limiting features and
filters on both input and output to minimize harmonics.
The charger output regulation shall be +/- 1% from no
load to full load with an input power supply variation
of +/- 10% in voltage and +/- 5% in frequency. In
addition to alarms on charger panel, potential free
contacts for alarms like charger O/P voltage high etc.
shall also be provided for use in DDCMIS. Further
isolated 4-20 mA signals shall be provided for important
parameters like charger voltage etc.
(2) Batteries
The batteries shall be heavy duty Lead Acid PLANTE type
and shall be sized for one hours of full load operation.
The PLANTE Lead Acid batteries shall conform to
IS:1652. For all sizing calculation, an aging factor of
0.8 and a temperature correction factor of 0.935(based
on temperature characteristics curve to be submitted by
the contractor and at a temperature of 1 Deg.C).
Capacity factor and end cell voltage 1.85 V after one
hour shall be taken into consideration, if applicable
and ambient temperature shall be considered as the
electrolytic temperature. The battery sizing
calculations shall be as per IEEE-485.
7.06.00 AUXILIARY EQUIPMENTS
All required auxiliary equipment/materials as finalised
during detailed engineering shall be furnished with
each charger/inverter/ battery bank and shall include as
a minimum various meters(AC/DC voltage /current, KVA
power factor, frequency meters etc., circuit breakers,
selector switches, push buttons indicating lights,
ground detector system, battery accessories like inter
cell connectors, inter step connectors, battery racks
etc.)further, isolated 4-20 mA signals for important
parameters and potential free contacts for important
alarms shall be provided for use in DDCMIS.
7.07.00 Bidder shall furnish the power supply distribution
scheme, single line diagram, all calculations such as
charger/inverter rating calculations, battery sizing
calculation etc., during detailed engineering for
MPPGCL’s review and approval.
7.08.00 The winding of transformer shall be electrolyte grade copper
with F class insulation with temp rise limited to class B.
7.09.00 Bidder shall provide following minimum accessories per Battery set for maintenance of battery and safety equipment for maintenance personals.
a) Hydrometer - 5 Nos.
b) Thermometer - 5 Nos.
c) Cell Tester(Voltmeter) - 5 Nos.
d) Alkali Mixing Jar - 5 Nos.
e) Rubber Apron - 5 Nos.
f) Rubber Gloves - 5 Pair
g) Set of Spanners - 5 Pair
h) Spare acid in Container - 25% of Total acid
i) Other accessories as per
Recommendation of Battery manufacturer
j) Specific gravity correction chart - 2 Nos.
7.10.01 U P S (Factory Acceptance Test)
a) Power Efficiency (IEC 146-2, IEC 146)at 100%load,50%load
b) Load Test(Approved Procedure)- Load regulation Test
c) Audible Noise Test (IEC 146-2)
d) Fuse Clearing Capability (Approved Procedure)
e) Relative Harmonic content (IEC-146.2)
f) Synchronous transfer and Synchronization Test (IEC 146-4)
g) Temp. rise test without redundant fans(IEC-146.2)
h) Input voltage Variation Test (Approved Procedure)
i) Over load test on inverter & charger(Approved Procedure)
j) Insulation Test (IEC 146)
k) Restart Test (IEC 146-2)
l) Short Circuit current capability (IEC 146-4- Clause 5.10)
m) Output voltage & frequency tolerance (IEC 146-2)
n) Voltage Current Division (IEC 146-2)
o) Relative Harmonic content (IEC 146-2)
p) Parallel Redundancy Test (* Simulation of parallel redundant
fault (IEC-146.4)
q) Over load Test (Final acceptance Test)
r) Any other required as per National/International standard
or QAP.
7.10.02 Battery Charger
a) Short Circuit current capability (IEC 146-2)
b) Temp. rise test without redundant fans(Approved Procedure)
c) S W C Test (Approved Procedure)
d) Efficiency / PF (IEC 146-2, IEC 146)
e) Audible Noise Test (IEC 146-2)
f) Fuse Clearing Capability (Approved Procedure)
g) Relative Harmonic content (Approved Procedure)
h) Temp. rise test without redundant fans(IEC 146-2)
i) Over load test on charger (Approved Procedure)
j) Restart Test (IEC 146-2)
k) Output voltage tolerance (Approved Procedure)
l) Output Voltage Harmonic content (Approved Procedure)
The above test Clause No.7.10.01 & 7.10.02 shall be witness
By owner / owner’s representative.
7.10.03 Testing at site
Full load test shall be demonstrated after commissioning of
UPS and charger with batteries at site for 72 Hrs.
7.10.04 Type Test
Bidder shall submit following Type Test Report along with
final acceptance report.
a) Battery as per IS – 1652
b) UPS/ Charger
i) IP degree
ii)Surge with stand capability (SWC)
iii)Dry heat Test (IEC – 68.2.2)
iv) Dump heat Test(IEC – 68.2.3)
v) Vibration Test (IEC- 68.2.8)
vi) EMC Test (IEC- 61000.4.2)
The above all Type Test shall be conducted at National/
International Laboratories only.
7.11.05 Bidder shall submit following documents along with factory
acceptance test (FAT) Report –
a) Internal Test Report along with heat run test report.
b) Calibration certificate of measuring instruments.
7.11.06 The contractor shall submit all above test results for
Review and approval.
8.CONTROL VALVES& ACTUATORS October 16, 2008
8.00.00 CONTROL VALVES, ACTUATORS & ACCESSORIES
8.01.00 GENERAL REQUIREMENTS
a) The control valves and accessories equipment furnished
by the bidder shall be designed. constructed and tested
in accordance with the latest applicable requirements of
code for pressure piping ANSI, the ASME Boiler &
pressure vessel code, Indian Boiler Regulation(IBR), ISA
and other standards specified elsewhere as well as in
accordance with all applicable requirements of the
“Federal Occupational Safety and Health standards, USA”
or acceptable equal standards. All the Control Valves,
their actuators and accessories to be furnished under
this section will be fully suitable and compatible with
the modulating loops covered under SG C&I, TG C&I and
closed loop control system of the specification.
b) All the control vales and accessories offered by the
bidder, shall be from reputed experienced manufacturers
of specified type and range of valves.
8.02.00 CONTROL VALVE SIZING & CONSTRUCTION
8.02.01 The design of all valve bodies shall meet the
specification requirements and shall conform to the
requirements of ANSI(USA) for dimensions, material
thickness and material specification for their
respective pressure classes.
8.02.02 The valve sizing shall be suitable for obtaining maximum
flow conditions with valve opening at approximately 80%
of total valve stem travel and minimum flow conditions
with valve stem travel not less than 10% of total valve
stem travel. All the valves shall be capable of
handling at least 120% of the required maximum flow.
Further, the valve stem travel range from minimum flow
condition to maximum flow shall not be less than 50% of
the total valve stem travel. The sizing shall be in
accordance with the latest edition of ISA standard
“ANSI/ ISA-75.01.01, Flow Equations for sizing of
control valves.” While deciding the size of valves,
bidder shall ensure that valves outlet velocity does not
exceed 8 m/sec for liquid services, 150 m/sec for steam
services and 50% of sonic velocity for flashing
services. Bidder shall furnish the sizing calculations
clearly indicating the outlet velocity achieved with the
valve size selected by him as well as noise
calculations as per ISA-75-17-1989 “Control valve
Aerodynamic Noise Prediction” which will be subject to
Owner’s approval during detailed engineering.
8.02.03 (a)Control valves for steam and water applications shall be
designed to prevent cavitations, wire drawing, flashing
on the downstream side of valve and down stream side of
valve and down stream piping. Thus for cavitations/
flashing service, only valve with anti cavitations trim
shall be provided. Detailed calculations as per ISA-RP-
75-23-1995 “Consideration for evaluating control valve
cavitations” to establish whether cavitations and erosion
will occur or not for any given application shall be
furnished.
(a) The liquid pressure recovery factor (FL) shall be 0.995 or better for severe flashing/cavitation services.
(b) The liquid pressure recovery factor (FL) shall be 0.985 or better for low flashing/cavitation services.
8.02.04 Leakage Class
Control valves for application such as HP/LP Heater
emergency level control, SH spray & RH spray control,
Emergency makeup to Hotwell, deaerator drain to condenser
hotwell, & heavy oil heating, HFO & LDO and pressuring and
control system, condenser normal make-up and valve shall
have permissible leakage rate as per leakage Class – V
(ANSI/ FCI). All other control valves such as low and high
range feed control valves, LP/HP heaters normal/ level
control valves etc. shall have leakage rate as per leakage
Class-IV. All SH/RH Block valves, shut-off valve of LDO &
HFO and BFP recirculation valve shall have leakage class
MSS-SP-61.
8.02.05 The control valve induced noise shall be limited to 85
db A at 1 Mtr. from the valve surface under actual
operating conditions. The noise abatement shall be
achieved by valve body and trim design and not by use of
silencers.
8.02.06 The characteristic of the control valves shall be
determined based on the application/ service.
8.02.07 Valve Construction
i) All valves shall be of globe body design & straightaway
pattern with single or double port. Unless other wise
specified or recommended by the manufacturer to be of
angle body type. Rotary valve may alternatively be
offered when pressure and pressure drops permit.
ii) Valves with high lift cage guided plugs & quick change
trims shall be supplied.
iii) Cast iron valves & asbestos packing are not acceptable.
iv) Bonnet joints for all control valves shall be of the
flanged and bolted type or other construction
acceptable to the MPSEB. Bonnet joints of the internal
threaded or union type will not be acceptable.
v) Plug shall be of one-piece construction either cast,
forged or machined from solid bar stock. Plug shall be
screwed and pinned to valve stems or shall be integral
with the valve stems.
vi) All valves connected to vacuum on down stream side shall
be provided with packing suitable for vacuum
applications(e.g. double vee type chevron packing). For
other valves packing material shall be Grafoil/double.
vii) Valve characteristic shall match with the process
characteristics.
viii) Extension bonnets shall be provided when the maximum
temperature of flowing fluid is greater than 280 Deg.C.
ix) Flanged valves shall be rated at no less than ANSI press
class of 300 lbs.
x) If the down stream is subjected to vacuum, flow
direction of fluid shall be to close.
xi) The control valve for low load feed control valve, SH &
RH Attemp.Temp.Control Valve, Recirculation valve of BFP
shall be multipath, multistage, velocity head loss type.
8.03.00 VALVE MATERIALS
The control valve body/trim material shall be –
(i) Non corrosive, non flushing and non cavitation service
below 280 Deg.C like Aux.steam flow to deaerator, cond.
flow to deaerator, CRH flow to deaerator.
a) Body Material - The body material shall be carbon steel
ASTM-A 216 Gr.WC B except CRH flow to deaerator and
alloy steel ASTM A 217 Gr.WC 9 for CRH flow to deaerator.
b) Trim Material - The trim material shall be 316 SS
stellite faced guide and bushings.
(ii) Severe flashing/cavitation services like feed control
valve, spray control valve (SH & RH Spray control
and block valve) L P heater & H P heaters. Emergency level
control valve, HPBP Spray control valve, deaerator over
drain etc.
a) Body Material shall be ASTM A 217 WC 9.
a) Trim material shall be 17-4 PH SS
(iii) Low flashing/ cavitations service like HP heater/ LP
heater normal level control, Condensate/feed water below
280 Deg.C etc.
a) Body Material shall be Alloy Steel as per ASTM A 217 WC6.
b) Trim material shall be 17-4 PH SS
(iv) Normal & Emergency make up D M water control
a) Body Material shall be A 351 Gr CF 8M
b) Trim Material shall be 316 SS +ST
(v) Fuel oil and atomising steam service
a) Body Material shall be Alloy Steel ASTM A 216 WCB.
b) Trim material shall be 316 SS stellite.
However, bidder may offer valves with body and trim
materials better than specified materials and in such,
cases bidder shall furnish the comparison of properties
including cavitation resistance, hardness, tensile
strength, strain energy, corrosion resistance and
erosion resistance etc. of the offered material vis-a-
vis the specified material for MPPGCL’s consideration and
approval.
8.04.00 END PREPARATION
Valve body ends shall be either butt welded/ socket
welded, flanged or screwed as finalised during detailed
engineering and as per MPPGCL approval. The welded
ends wherever required shall be butt welded type as per
ANSI B 16.25 for control valves of sizes 65 mm and
above. For valves sizes 50 mm and below welded ends
shall be socket welded as per ANSI B 16.11. Flanged
ends wherever required shall be of ANSI pressure
temperature class equal to or greater than that of the
control valve body.
8.05.00 VALVE ACTUATORS
(a)All control valves shall be furnished with pneumatic
actuators. The Bidder shall be responsible for proper
selection and sizing of valve actuators in accordance
with the pressure drop and maximum shut off pressure and
leakage class requirements. The valve actuators shall
be capable of operating at 60 Deg.C. continuously. Valve
actuators and stems shall be adequate to handle the
unbalanced forces occurring under the specified flow
conditions or the maximum differential pressure
specified. An adequate allowance for stem force,
atleast 0.15 Kg/Sq.Cm.per linear millimeter of seating
surface, shall be provided in the selection of the
actuator to ensure tight seating unless otherwise
specified. The travel time of the actuators shall not
exceed 10 secs.
(b) All valve control valve shall be provided with smart digital valve positioners and connect with hart management system.
8.06.00 CONTROL VALVE ACCESSORY DEVICES
All control valve accessories such as air locks,
handwheels/hand-jacks, torque/ Position limit switches
positioners,
solenoid valves, diffusers, external volume chambers,
position transmitters(capacitance or resistance type
only), tubing and air sets and junction boxes air filter
regulator, local position indicator, volume booster, fail
freeze type IP Converter etc. shall be provided as per the
requirements. All positioners shall be Smart Type. All field
instrument mounted on the Control Valve shall be IP- 65.
8.07.00 TEST AND EXAMINATION
8.07.01 All valves shall be tested in accordance with the
quality assurance programme agreed between the MPPGCL
and contractor which shall meet the requirements of IBR
and other applicable codes mentioned elsewhere in the
specifications. The tests shall include but not be
limited to the following:-
1) Non Destructive Test as per ANSI B-16.34
2) Hydrostatic shell Test in accordance with ANSI B 16.34
prior to seat leakage test.
3) Valve closure test and seat leakage test in accordance
with ANSI-B 16.34 and leakage class test as per ANSI/FCI
70.2.1998.
4) Functional Test : The fully assembled valves including
actuators control devices and accessories shall be
functionally tested to demonstrate times from open to
close position.
5) CV Test: CV & FL(Liquid Pressure Recovery Factor) test
shall be carried out as type test on each size, type
and design of the valves as per ISA 75.02 standard.
The above tests shall be witness by MPPGCL.
8.07.02 Bidder shall submit material test certificate, Radiographic Evaluation report, ultra sonic test report, heat treat report etc. as per IBR/ASME for review and approval along with Factory Acceptance Test Report.
8.08.00 Bidder shall furnish all the control valves as finalised
during detailed Engg.stage without any price
repercussions whatsoever depending on the process
requirements including the systems under SG C&I and TG
C&I. All the control valves provided by the bidder for
this project shall meet the specifications requirements
specified herein. Specification for control valves in
this section has to be read in conjunction with other
relevant sections of the specification for this project.
8.09.00 Bidder shall provide all type of gasket, gland packing
with each control valves as spare.
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