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17.Control Philosophy
14.Type Test




   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



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




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


         –  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


         –  Appropriate  Derating of electronic  components  and



     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.













Filed under: control,instrumentation,thermal power plant — shivajichoudhury @ 7:22 am
17.Control Philosophy
14.Type Test


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





                                         2.CHINO JAPAN






Filed under: Uncategorized — shivajichoudhury @ 6:19 am





         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




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 


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


      f) ANSI/ISA-18.1-Annunciation Sequence and Specification.




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.




         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,






         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.





         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.




         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).





         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




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.




         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




         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.




         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.   10%  spare  channels in each  of  the   input/output


         modules, fully wired up to marshalling cabinets.  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.  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.   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


  &  02  above), over  and  above  implemented


         capacity.   Each  of  the  corresponding   communication


         controller  shall also have same spare capacity as  that


         of controller.

  The data communication system (including main  system


         bus  and  other bus system)shall have  the  capacity  to


         handle the additions mentioned in clause  Nos.


         to  This will be in addition to  50%  spare


         capacity specified under this clause.  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.




         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.




         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.





         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.).




         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.




         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.




         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.




         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






         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.




2.03.01  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  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



         ii) Transmitter  power  supply  with  per  point   fuse

             protection  or  current limiting  and  power  supply



         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. 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.  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  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.  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     




      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




2.03.07  Wiring  scheme for inputs to control system shall be  as


         follows :-  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.  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 : Input filters to attenuate noise shall be provided.  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.  Common  mode noise rejection for analog inputs  shall


         be  minimum 120 db at 50 Hz.  Normal  mode  noise rejection for  all  analog  inputs


         shall be 60 db at 50 Hz.  Surge Switch stand as per IEEE 472.  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  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.   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.

    The  TG  C&I  system  shall  perform   the   following



         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

     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.  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.


  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.  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.  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.  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.

  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.   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.  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.  The control system hardware design shall be such that


         it is able to withstand power line disturbances.  The  control system for  SH/RH  Attemp.  Temp.control


         shall be  state controller with observer. 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)  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.  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.  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.

   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.  The functionality of operation of mills. oil etc.shall


         be  similar to that of OLCS described in clause  2.04.03




2.04.02  TURBINE PROTECTION SYSTEM (TPS) FUNCTIONS 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.  The   Turbine   protection  system  shall   meet   all


         applicable safety standards/requirements including those




         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.       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.


    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.

  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.  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. Turbine  Protection  System shall meet  all  applicable


         relevant safety  requirement including those  stipulated


         in ASME- TDP-1, VDE 0116, Sec8.7; VDE 0160 etc.  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




       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




         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  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.  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.  Sequence Control   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.  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.  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.   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.  Open or close priority shall be  selectable for each


             drive.   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 




     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.  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’.  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.     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.  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.

  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.  The sequence interlock & protection requirements shall


         be  finalised during detailed engineering and the   same


         shall be subject to employer’s approval.    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.       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  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.  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. 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.  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.  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.  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.  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.  For safety reasons, switchover logics associated  with


         the  modulating control loops, shall be performed within


         the closed loop control equipment.  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.   Time  supervision  facility  shall  be  provided  to


         monitor the final control element.  It shall be possible to block the  controller  output


         on a pre-programmed basis.   All  controllers shall be freely  configurable  with


         respect  to requisite control algorithms.   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.




         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.  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



      b) HP Bypass system shall conform to ANSI/ISA 77.13.01.  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.  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.






2.05.01  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




      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  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




         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.  (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




     (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.



         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.  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.  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




      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 All the primary  instruments, cable, hardware,  software


         whatever    required   for    efficiency/    performance


         calculations shall be in the Bidder’s scope.   Other Calculations


         Variable alarm limit calculations, heat rate deviations


         and  revenue  calculations,  frequency  excursion   time


         integration etc.shall also be provided.

  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.  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




         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




         a) Control displays(group/sub-group/               500


         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.  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




       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.  Log Generation Utility


         The  Bidder  shall  offer a log  generation  utility  to


         generate  a log/report having following facilities as  a




      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




      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




         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.  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.  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.  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.    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          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





         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.  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.  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.  Power Fail Auto Restart(PFAR) facility with  automatic


         time update shall be provided.  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. Man Machine Interface (Unit wise)


      a) Unit Control Room PC


      i) Operator Work Station      8 Nos.

     ii) Large Video Screen         5 Nos.


      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.  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. 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.  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).   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.   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. (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.   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/




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.




2.07.01  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.  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.  If  the  system bus requires a master  bus  controller


         philosophy,   it  shall  employ  redundant  master   bus


         controller with automatic switchover facility.   Built-in diagnostics shall be provided for easy fault


         detection. Communication error detection and  correction


         facility  (ECC)  shall  be provided  at  all  levels  of




         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.   The design and installation of the  system bus  shall


         take care of the  environmental conditions and hazardous


         area classification as applicable  to similar services.  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.  Passive coaxial cables or fiber optic cables shall  be 


         employed for system bus.   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.  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.  The Data Hiways shall be  power  surge  protected  and


         conform to IEC – 801-5. 


2.07.02.  Station  Wide  Network  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.

    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. There shall be continual monitoring of network performance


         and station.




2.08.01  SER  FUNCTION  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.  The system shall also include provision for historical


         storage  and  retrieval  of SOE  reports  for 12  months


         period or One thousand SOE alarm pages.  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.   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. SOE System shall have  dedicated VDU (21”)with KBD and


         placed in computer Room.


2.08.02  ANNUNCIATION SYSTEM FUNCTION  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. The annunciation sequence shall confirm to ANSI/ISA- 


         18.1(1979) with first up facility.   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.  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.  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.




2.09.01 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.




2.11.01  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 




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.




2.12.01  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.  HARDWARE DOCUMENTATION  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.  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  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.  The software listings shall be submitted by the bidder


         for source code of  application software and all special


         to project data files. 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.




2.16.01  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.




         SG, TG AND STATION – C & I)


2.17.01  S G SYSTEM


     a)  MFT– 1, MFT- 2, MFT-3,   (Three Single Processors- 2/3 


     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.




Filed under: Uncategorized — shivajichoudhury @ 5:14 am






         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




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




         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. 




         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-                 




      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.




         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.




         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.




         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.




         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






     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 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




         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




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




     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.










Filed under: Uncategorized — shivajichoudhury @ 7:52 am



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




         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




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



     (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




     (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




         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



     (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


     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



   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.


     ii) Type of RTD         – 4 wire- Pt RTD 100 ohm(as per DIN-



   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



   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


                               60 Deg.C +/-2 Deg.C for type R


   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


   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



                           ii) For  Mill classifier outlet  long

                               life solidsintered tungsten carbide

                               material    of    high    abrasion



                          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


         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



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


      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.