SPEC INSTRUMENTATION

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1.SPECIFICATION OF INSTRUMENTATION October 17, 2008

2.DISTRIBUTED DIGITAL CONTROL,MONITORING    
1.DESIGN CRITERIA -INSTRUMENTATION
3.OTHER SG/TG RELATED CONTROL & INST
8.CONTROL VALVES& ACTUATORS
6.UNIT CONTROL DESK, UNIT CONTROL PANELS
5.STEAM & WATER ANALYSIS SYSTEM (SWA
4.00.00 MEASURING INSTRUMENTS (PRIMARY A
17.Control Philosophy
10.CONTROL AND INSTRUMENTATION CABLE
16.EPABX
13.CONTROL & INSTRUMENTATION FOR PLA
18.TESTING (INSTRUMENTATION)
15.ELECTRICAL ACTUATOR
12.PUBLIC ADDRESS SYSTEM
INSTRUMENTATION VENDERS
9.MAINTENANCE AND CALIBRATION EQUIPMENTS
14.Type Test
11.PROCESS CONNECTION , PIPING AND INSTA
7.ELECTRIC POWER SUPPLY

 

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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INDEX- SPEC INSTRUMENTATION December 14, 2009

Filed under: control,instrumentation,thermal power plant — shivajichoudhury @ 7:22 am
Tags:
2.DISTRIBUTED DIGITAL CONTROL,MONITORING
1.DESIGN CRITERIA -INSTRUMENTATION
3.OTHER SG/TG RELATED CONTROL & INST
8.CONTROL VALVES& ACTUATORS
6.UNIT CONTROL DESK, UNIT CONTROL PANELS
5.STEAM & WATER ANALYSIS SYSTEM (SWA
4.00.00 MEASURING INSTRUMENTS (PRIMARY A
17.Control Philosophy
About
10.CONTROL AND INSTRUMENTATION CABLE
16.EPABX
13.CONTROL & INSTRUMENTATION FOR PLA
18.TESTING (INSTRUMENTATION)
15.ELECTRICAL ACTUATOR
12.PUBLIC ADDRESS SYSTEM
INSTRUMENTATION VENDERS
9.MAINTENANCE AND CALIBRATION EQUIPMENTS
14.Type Test
11.PROCESS CONNECTION , PIPING AND INSTA
7.ELECTRIC POWER SUPPLY
 

INSTRUMENTATION VENDERS November 27, 2009

Filed under: instrumentation — shivajichoudhury @ 10:21 am
Tags:
Air Filter Regulator

              PLACKA,CHENNAI

 

1.CHART RECORDERS

                                        1.Eurotherm,UK

                                         2.CHINO JAPAN

                                         3.ABB,UK

                                         4.YOKOGAWA,JAPAN

2.

 

2.DISTRIBUTED DIGITAL CONTROL,MONITORING INFORMATION SYSTEM(DDCMIS) October 17, 2008

Filed under: Uncategorized — shivajichoudhury @ 6:19 am
Tags:


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

Filed under: Uncategorized — shivajichoudhury @ 5:14 am
Tags:

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

Filed under: Uncategorized — shivajichoudhury @ 7:52 am

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