18.01.00 FACTORY TESTS
18.01.01 INTERNAL TESTS
The Contractor shall prepare a Quality Assurance Plan (QAP) for carrying out various Internal Tests at the its own facility or Sub Vendors manufacturing facility for different C&I equipment’s being offered in this Project. This QAP will be reviewed by MPPGCL before the same is implemented. MPPGCL will mark the important stages of manufacturing / testing where MPPGCL or its representative will carry out the stage wise inspection of different equipment’s being manufactured. Contractor shall inform the start of all important activities as marked in the QAP MPPGCL at least 15 days in advance for its witnessing the tests. / stage wise Inspection.
( To be conducted for Both Units)
i. Before shipment, the Contractor shall perform a complete functional test of the C&I system, including all peripherals and accessories at the factory using the final program and simulated inputs or simulated process if available. MPPGCL or its representative shall participate in the simulation and to introduce random upsets as desired. The details of the factory test program shall be provided with the Bid Proposal.
ii. Prior to system simulation test, Contractor shall perform a heat run test on the assembled system. The heat run test shall be carried out as per applicable standards. The duration of the heat run test shall be at least 100 hours. After the heat run test, the assembled system shall experience five days of power‑on operation. In addition to the assembled system’s heat run test, system sub-assemblies identical in design and construction shall undergo test without malfunction or degradation of performance under ambient temperature conditions as specified herein
iii. Subassemblies shall constitute control and display modules, input/output modules, control and indication stations, amplifiers, memory modules, drive units, power units, A/D and D/A modules, etc. In addition, the complete system shall be proven to have successfully undergone complete functional system tests over the ambient temperature, voltage, and frequency ranges specified herein. Contractor shall furnish certified proof to MPPGCL that these tests have been performed on this or a similar system.
iv. Upon satisfactory completion of the system tests, the equipment shall be considered completed and no hardware shall be changed, replaced, substituted, or otherwise altered except upon written agreement with MPPGCL. Under no circumstance may the system hardware be used to supply parts for testing or substitution in other systems in the Contractor’s facilities. The system may be used by the Contractor’s and / or Mppgcl programmers to continue the program debugging and entry during the period between completion of the test and shipment to the site.
v. All tests shall be performed on electrical interfaces to the equipment, i.e., inputs, outputs, power supplies, data communication buses, etc., in accordance with applicable ANSI standards. The electrical test shall demonstrate freedom from grounds and accuracy of the wiring of all cubicle-mounted devices. The test shall include point-to-point continuity test and electrical insulation test in accordance with applicable ANSI standards. Contractor shall be responsible for proper protection of instruments and devices that may be damaged by high-voltage tests.
vi. Power Source
Power inputs to the equipment shall be tested to demonstrate that the equipment can operate throughout the range of the specified power source voltages for the indicated periods within all of their specifications.
The communications tests shall demonstrate proper operation of all aspects of the equipment’s communication capability, including modems, security checking, and message protocols. The data modems or signaling equipment shall be exercised to verify that they operate correctly and reliably on the type of channel for which they are designed. The tests shall by conducted under conditions that duplicate as closely as possible the specification for the channel.
The communications tests shall exercise all message protocols and formats to which the equipment is designed to respond. The tests shall also demonstrate that any error detection or correction capabilities function properly, and that the equipment does not respond to erroneous commands.
viii) The Contractor shall perform a full functional test of the system to ensure the correctness of the wiring and the proper functioning of all apparatus. Any as‑built drawing changes required to correct functional or wiring errors shall be immediately incorporated in the system drawings and issued to the MPPGCL
ix) MPPGCL reserves the right to refuse shipment of the system until a satisfactory system test has been demonstrated.
( To be conducted for Both Units)
The Contractor shall set-up a Calibration laboratory with all latest Test Equipment’s. All Test Instruments used in the Contractors Calibration lab shall have valid Calibration Certificate issued by recognized National / International Calibration Laboratory and should be traceable to International calibration standard. These calibration certificates will be checked by MPPGCL before giving approval for starting any calibration activity by Contractor at Site.
The calibration of all instruments shall be checked by the Contractor and calibration records shall be submitted for review by MPPGCL. If the instruments require re calibration, Contractor shall recalibrate the instruments and revise the calibration records and submit to MPPGCL.
18.02.02 Installation, Commissioning and Pre-start-up Acceptance Test
All equipment shall be installed as per Design.
The Commissioning activities shall include but may not be limited to
confirmation that the following are installed as per the detailed design
documents and performing as specified in specification.
· Equipment and wiring are properly installed.
· Energy sources are operational.
· All instruments have been calibrated.
· Field devices are operational.
· DCS, Logic solver, input/output are operational.
(c) Pre Startup Acceptance Test(PSAT)
Tests on devices (in addition to calibration) shall include but not be limited to the following:
i. All safety interlock & protection and Process connected switches/ instruments etc shall be checked for correct functioning , shall be verified and demonstrated to be as indicated on the instrument data sheet. and design documents/diagrams
ii. Controllers and control stations shall be checked for correct functioning of set point adjustment, and manual controls as applicable.
iii. Printers, keyboards and display stations shall be functionally tested and exercised using the manufacturer’s standard test routines and procedures.
iv. Pushbuttons and control switches, if furnished, shall be checked for correct functioning of operating mechanisms.
v. Annunciator function shall be checked for correct functioning in accordance with the requirements of this Specification.
The Contractor shall verify that the configuration of each loop is as indicated on the applicable loop diagram.
Pneumatic loops shall be checked for correctness of supply, input signal and output signal air tubing hookups.
Where possible, tests on devices shall be coordinated with tests on loops. (e.g. switch action with annunciator or control system response; set point or manual control operation with valve stroking etc.)
After commissioning of field Instruments, testing by simulation method from local field Instruments to DCS /PLC shall be carried out to check the proper functioning of Field Instruments, Field & Control Room wiring, Control System, Interlock & protection, Alarms etc. as per the design intent.
vi. Wherever possible subsystems and systems shall be functionally
tested using simulated inputs and with all display, printing and
recording devices, keyboards, alarm annunciator and final control
elements operating prior to tests in conjunction with associated
vii. Full functional and performance tests shall be carried out in accordance with the Contractor’s proposed documents as reviewed by Owner.
viii. Fine tuning of the response of control systems shall be carried out by initiating changes and minor upsets to mechanical equipment and processes and recording the response of the control system in bringing the equipment or process to the new operating point or back to the original operating point as applicable. Adjustments to the control characteristics and repeated tests shall be made until optimum control is achieved.
ix. A PSAT shall be satisfactorily completed prior to the introduction of
hazards the Safety Instrumentation System and other instrumentation
in design to prevent or mitigate or before starting of any equipment or
(d) Accuracy of calibration of test instruments used in PSAT shall consistent with the application.
(e) Test Results
Contractor shall submit test report. As a minimum the test report shall include following :-
· Identification of instrument that has been tested.
· Confirmation that Commissioning is complete.
· Date the PSAT was performed.
· Reference to the procedure used in the PSAT.
· Authorized signature that indicates PSAT has been satisfactorily completed.
(f) COMMISSIONING TEST
The Contractor shall perform commissioning tests for all instrumentation and control devices, loops, sub-systems and systems furnish by him. Commissioning tests for instrumentation and controls shall include but not be limited to:
i. Test on devices and loops
ii. Functional tests on subsystems and systems
iii. Performance tests on systems to demonstrate that it meets the guarantees as proposed by the Contractor
iv. Fine tuning of control systems
The satisfactory operation of the equipment / Instrument during continuous operation of 72 Hours at full capacity shall be established during this test.
18.02.03 AVAILABILITY TEST
This test shall be conducted only after TG, SG and Station DCS and other Control system are commissioned and integrated with Plant Balance of Plant Systems.
The Contractor shall guarantee 99.7 percent system availability for a continuous period of 180 days. An availability guarantee test shall be conducted to assure this level of availability. If the accrued downtime exceeds 0.3 percent of 180 days, during availability test run, a new 180 days test run shall be start at the time when the system becomes available again. Loss of availability (unavailable system) shall be defined as the loss of systems guaranteed accuracy and repeatability or of any system function, except however , that the loss of a function for not more than five percent of the points shall be treated as partial unavailability and the corresponding outage time shall be weighted with respect to the function and the percentage of the points for which the function is unavailable. Loss of each function shall have one weighing factor and unavailability of each equipment , peripheral device or process I/O card etc shall have another weighing factor. The guaranteed accuracy and repeatability and system parametric requirements shall be maintained for the entire 180 days run without any manual re calibration or any other changes made to the DCS.
Downtime shall start upon loss of a system function and shall end upon full restoration of the affected system function. A minimum of one hour downtime shall be charged for each loss of availability in determining system availability.
The Bidder shall submit the Availability Test procedure for MPPGCL approval. The details regarding outage time, weighing factors for various system functions equipment’s to calculate the downtime , test duration etc shall be discussed and finalized during detail engineering.
18.02.04 Performance requirement of the Closed loop
i. The closed loop control system shall permit the performance of the following dynamic load tests while maintaining safe furnace conditions, major process parameters and without endangering other equipment. All tests shall be performed with the system in automatic mode:
a) Drop 50 percent of the maximum load capability from approximately full load at a rate of 10 percent per minutes.
b) Drop load from full rated output to the lowest runback limit, at a rate corresponding to the fastest run back rate.
c) Pick up 50 percent of the maximum load capability from approximately 50 percent load at the rate of 10 percent per minute.
During transient conditions causing deviation of process variables, the control system furnished under the specification shall not permit deviations which exceed those permitted by the manufacturers of the controlled process equipment, for load changes as indicated above. The control loops shall perform to return the controlled variable to the set point in a stable manner without cycling in the shortest possible time and without any loop interactions or cycling of generation when generation matches unit load demand.
ii. The Contractor shall also guarantee that the Control System provided by him will be responsive and stable and will maintain the deviation of controlled variables from set point within the limits specified so that the equipment being controlled will operate as specified over the range required. The controls shall operate automatically, with no assistance from the operator. The contractor shall successfully demonstrate the performance of closed loop Control systems before accepting and taking over this system by MPPGCL.
18.02.05 Parametric Tests
(1) The parametric test shall also be conducted under worst case loading conditions (which is basically equivalent to a trip condition – details of which shall be as approved by MPPGCL during detailed engineering)
i. For Control System
– CPU loading, Cycle time / controller reaction time and spare
ii. For MMIPIS
– CPU loading , spare duty cycle, spare memory capacity.
iii. Spare duty cycle for system bus.
iv. Various display response time
v. CRT update time
For the parametric test, the following requirements shall be met:
18.02.05 (a) Processor Spare Duty Cycle ( Free Time)
· Under worst case loading of MMIPIS and system bus each MMIPIS processor shall have 40% free time when measured over any two second period and 50% free time when measured over any one minute period.
· Under worst case loading conditions of control system, control system processor shall have 20% free time when measured over any one minute period.
18.02.05 (b) System Bus Spare Duty Cycle (Free Time)
· The Contractor shall furnish all necessary data to fully satisfy the Purchaser that the processor spare duty cycle figures quoted by the Contractor are realistic and based on configuration and computation capability of the offered system and these shall be actually achieved in the fully implemented system as commissioned at project site.
The system bus shall have minimum 50% free time during the worst case loading conditions of control systems MMIPIS and the system Bus, measured over any 2 seconds interval.
18.02.06 Display Response Time
The system shall acknowledge all operator requests in one of the following manner within one second of pressing of the last button:
Commencement of the requested display
Acknowledgement of operator request in a suitable manner
The display response time as defined above, under the worst case loading conditions shall not be worse than the following:
All control related displays
Point Details Display (single point)
Bar chart display ( 20 points, current data
Operator guide / plant start-up guide message Display ( full screen of alphanumeric information And a maximum of ten numbers of dynamic Data items)
Plant mimic display of fair complexity With a minimum of 120 numbers of Dynamic data items e.g. values, macros, Line segment etc.
Group review display ( current value of twenty points)
X-Y plot display ( 2 X-Y plots and A single display requiring both Historical as well as current data)
X-T plot display ( Trend of 6 analog Points and a single display requiring Both historical as well as current data
Plant Summary display ( e.g. bad point Summary , limit check removed Point summary. Assume the whole data Base search is required and the summary Display contains ten points only)
The response time for screen update after the execution of the control command from the time the command is issued ( for example command to start a motor to the time the screen is updated) shall be two seconds ( excluding the drive actuation time).
18.02.07 System Accuracy Requirements
The overall system accuracy from signal input terminals to output presentation on CRT display and printers for the least accurate input range and maximum scan rate shall be not worst than ± 0.1% of full scale of the engineering process range. For this purpose, the number of decimal places on CRT display for testing purpose shall be sufficient to cover 0.01% of full scale range.
18.02.08 CRT Updated Rates
All CRT displays shall be updated at least every two seconds.
¨ The spare capacities of working and bulk memory shall meet the
requirements as per the specifications.
The operating capabilities of the plant as listed elsewhere in this
specification shall also be demonstrated along with other
parameters / capabilities specified under guarantees.
18.02.09 Acceptance test for Steam Turbine speed control system shall be as per
18.04.00 Handover test
Before completion of warranty period , the Contractor shall demonstrate to MPPGCL that all measurement & control systems in his scope are healthy and systems are functioning as per design intent in all modes of operation.