2.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING AND
INFORMATION SYSTEM (DDCMIS)
The microprocessor based distributed digital control,
monitoring & information system(DDCMIS)shall be
provided for the safe and efficient operation of SG, TG,
balance of plant and all auxiliaries in all regimes of
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.
2.01.00 GENERAL REQUIREMENTS
2.01.01 The requirements for distributed digital control
monitoring and information system(DDCMIS) are indicated
on functional basis in this specification. Bidder shall
be responsible for engineering, selection and connection
of all components and sub-systems to form a complete
system whose performance is in accordance with
functional, hardware, parametric and other requirements
of this specifications. It is not the intent or purpose
of this specifications to specify all individual system
components since the bidder has full responsibility for
engineering and furnishing of a complete system.
2.01.02 SYSTEM CONFIGURATION
DDCMIS shall basically consist of control system of
boiler, turbine & balance of plant (namely SG-C&I,TG-C&I
& BOP-C&I including their respective measurement
system); Man-machine interface and plant information
system(MMIPIS); system programming & documentation
facility; data communication system(DCS);integrated
sequence of events recording system(SERS); Annunciation
system, and master & slave clock system.
The basic configuration of DDCMIS shall be as indicated
in the DDCMIS configuration drawing No.CED/STP/I/821,822,
2.01.03 SYSTEM EXPANDABILITY
Modular system design shall be adopted to facilitate
easy system expansion. The system shall have the
capability and facility for expansion through the
addition of controller modules, process I/O cards,
drive control modules, hand/auto stations, and push button
stations, peripherals like CRT/ Keyboards, printers etc.
while the existing system is fully operational. The
system shall have the capability to add any new control
loops groups/ sub-groups, in control system while the
existing system is fully operational.
2.01.04 ON LINE MAINTENANCE
It shall be possible to remove/ replace on line various
modules(like I/O module)from its slot for maintenance
purpose without switching off power supply to the
corresponding rack. System design shall ensure that
while doing so, undefined signaling and releases do not
occur and controller operation in any way is not
affected(including controller trip to manual, etc)
except that information related to removed module is not
available to controller. Further, it shall also be
possible to remove/ replace any of the redundant
controller module without switching off the power to
the corresponding rack and this will not result in
system disturbance or loss of any controller functions
for main controller. The on line removal/ insertion of
controller, I/O modules etc. shall in no way jeopardize
safety of plant and personnel.
2.01.05 FAULT DIAGNOSTICS
The DDCMIS shall include on line self surveillance,
monitoring and diagnostic facility so that a failure/
malfunction can be diagnosed automatically down to the
level of individual channels of modules giving the
details of the fault on the programmer station CRT
displays supplies, sensor fault, any channel fault in
2V3 channels etc. These faults on CRTs as well as local
indication on the faulty channel/module and on
corresponding rack/ cubicle shall be available. The
diagnostic system shall ensure that the faults are
detected before any significant change in any controller
output has taken place. Failure of any I/O modules,
controller etc.shall be suitably grouped and annunciated
to annunciation facia and to OWS(Operator work Station).
2.02.06 FAULT TOLERANCE
The DDCMIS shall provide safe operation under all plant
disturbances and on component failure so that under no
condition the safety of plant, personnel or equipment is
jeopardized. Control system shall be designed to prevent
abnormal swings due to loss of control system power
supply, failure of any control system component, open
circuits/ short circuits, instrument air supply failure
etc. On any of these failures the controlled
equipment/parameter shall either remain in last position
before failure or shall come to fully Open/ Close or
ON/OFF state as required for the safety of plant/
personnel/ equipment and as finalised during detailed
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
2.01.08 SIGNAL EXCHANGE
All the signal exchange between various functional
groups of each control group ( i.e. within SG, TG & BOP
C&I) shall be implemented through redundant main system
bus (The main bus connecting various sub-systems)and
local system bus within a sub-system as per the
standard practice of the bidder. It shall be ensured
that any single failure in electronics involved for such
communication, e.g. communication controllers, bus
interface modules, physical communication media, etc.
does not result in loss of such signal exchange and
there in no deterioration in specified system response
and system parametric requirements. In case a
controller utilizes some inputs generated/ processed by
any other controllers/functional group and the
requirement of controller response time as specified in
Clause 2.04.02 is not met due to inadequate
communication rate/ procedure, then the bidder shall
provide hardwired signal exchange for such inputs.
Bidder shall furnish documentary evidence through its
standard catalogues and drawings explaining as to how
this requirement is being met by them. Bidder shall
also furnish along with the above documents, list of
coal fired thermal power stations where the proposed
scheme for such signal exchange is already working.
Further, bidder to note that if his offered system
cannot meet the above requirement of communication
redundancy and specified system response & parametric
requirements then all the signal exchange, analog as
well as binary among various functional groups shall be
carried out through hardwiring only and not through bus
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
2.01.09 No single failure either of equipment or power source
shall be capable of rendering any part/ system/sub-
system of DDCMIS in operative to any degree.
2.01.10 SYSTEM SPARE CAPACITY
Over and above the equipment and accessories required to
meet the fully implemented system as per specification
requirements. DDCMIS shall have spare capacity and
necessary hardware/ equipment/accessories to meet
following requirement for future expansion at site.
2.01.10.01 10% spare channels in each of the input/output
modules, fully wired up to marshalling cabinets.
2.01.10.02 Wired in space for 20% modules in each of the system
cabinets for mounting electronic modules wired up to
corresponding spare terminals in marshalling cabinets
such that implementation of any additional control loop/
logic can be achieved only by insertion of necessary
electronic modules(s) in system cabinets, configuration
of corresponding controller and connection of
inputs/outputs at field end of marshalling cabinets/
logic cabinets as applicable.
2.01.10.03 MMIPIS shall be provided with capacity to handle 25%
or at least 1 No.of each type of peripherals
additionally, like CRTs, keyboards, printers, PCs etc.,
over and above already specified, without any additional
hardware or software.
2.01.10.04 each controller shall have 30% spare functional
capacity to implement additional function blocks, over
and above implemented logics/loops, further each
controller shall have spare capacity to handle minimum
20% additional inputs/outputs of each type(including
2.01.10.01 & 02 above), over and above implemented
capacity. Each of the corresponding communication
controller shall also have same spare capacity as that
2.01.10.05 The data communication system (including main system
bus and other bus system)shall have the capacity to
handle the additions mentioned in clause Nos.2.01.10.01
to 2.01.10.05. This will be in addition to 50% spare
capacity specified under this clause.
2.01.10.06 20% spare relays of each type and rating, mounted and
wired in relays cabinets. All contacts of relays shall
be terminated in terminal blocks of relay cabinets. In
each of the relay cabinets 20% spares terminal blocks
shall be provided so that additional relays can be
mounted and wired.
2.01.11 the spare capacity as specified above shall be uniformly
distributed throughout all cubicles. The system design
shall ensure that above mentioned additions shall not
require any additional controller/ processor/ peripheral
drivers Power supply module, software etc. in the
system delivered at site. Further, these additions
shall not deteriorate the system response time/duty
cycle etc.from those stipulated in the specification.
2.01.12 DDCMIS shall meet system performance and parametric
requirements as stipulated under specification.
2.02.00 SYSTEM DESCRIPTION
The DDCMIS shall include following main systems/sub-
systems. The DDCMIS shall work in full integration &
conjunction with field equipments/drives like pumps,
motors, valves, actuators, dampers, hydraulic control
systems(eg.for HP/LP bypass etc.)and field instruments
to be provided by the Bidder. The DDCMIS
hardware(controllers, modules/ cards etc.)shall be
housed in cabinets located in control equipment
room(CER) except for operation interfaces located in UCD
& UCP in unit control room.
2.02.01 CONTROL SYSTEM
The control system along with its measurement system,
shall perform functions of closed loop control, sequence
control, interlock & protection of SG TG and auxiliaries
in all regimes of Unit operation.
The measurement system of control system shall perform
the functions of signal acquisition, conditioning and
signal distribution of various types of inputs/outputs
like analog (4-20 mA DC, thermocouple, RTD)binary pulse
etc. The inputs, which are required for only information
& monitoring purposes shall be distributed suitably in
various groups of the measurement system.
2.02.02 MAN-MACHINE INTERFACE & PLANT INFORMATION SYSTEM
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 &
2.02.03 SYSTEM PROGRAMMING & DOCUMENTATION FACILITY
The programmer stations shall be provided for –
i) On line configuration & tuning of control system.
ii) On line program development/ modifications in MMIPIS.
In addition, latest state of the art workstation based
system documentation for the complete plant.
2.02.04 DATA COMMUNICATION SYSTEM (DCS)
The data communication system shall be provided for
communication between control system & MMIPIS
communication & signal exchange between various
functional groups as well as communication between
various units & off site/ off line systems.
2.02.05 SEQUENCE OF EVENTS RECORDING SYSTEM(SERS)
The DDCMIS shall be capable of carrying out sequence of
event recording function to scan & record events in the
sequence of occurrence within a resolution of 1 milli sec.
2.02.06 MASTER AND SLAVE CLOCK SYSTEM
Master & slave clock system shall be provided to ensure
uniform time indication throughout the various plants
facilities and time synchronization between controls
system, MMIPIS, switchyard disturbance recorder, PLC’s
2.02.07 ANNUNCIATION SYSTEM
A facia annunciation system shall be provided with lamp
boxes in the unit control room. The annunciation logic
will be implemented as a part of DDCMIS through which
the lamp boxes shall be driven. However, additional
facility to drive stand-alone printer in case of total
MMIPIS & system bus failure shall be provided.
2.03.00 MEASUREMENT FUNCTIONS OF CONTROL SYSTEM
2.03.01 All the signals coming into/going out of the control
system shall be connected either directly or routed
through marshalling cabinets. The input/output modules
employed in the control system shall be separate from
2.03.02 ANALOG SIGNAL CONDITIONING & PROCESSING
2.03.02.1 the conditioning and processing functions to be
performed as a minimum for the analog input coming for
control & information purposes are :-
i) Galvanic isolation of input & output signals wherever
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
viii)Linearisation of thermocouple signals.
ix) Reasonability check for all analog inputs.
2.03.02.2 all analog signals for control purpose shall be
acquired, validated, processed and their respective data
base updated at a maximum interval of 250 milli
secs.except for some fast acting control loops for which
the above-referred time shall be as per process
requirement. For signals required for information only,
the above functions shall be performed at an interval of
1 sec. The validated analog inputs shall be converted
into engineering units on a per point basis.
2.03.02.3 The 4-20 mA input analog cards shall be suitable for
interfacing transmitters giving 4-20 mA analog signal
along with super imposed HART interface signals. 4-20 mA
DC signal will only be used for control purpose & super
imposed HART signal will be used for configuration,
maintenance diagnostic & record keeping facility for
electronic transmitters & analyzers etc.
2.03.03 BINARY SIGNAL CONDITIONING & PROCESSING
2.03.03.1 The changeover type contacts (i.e.NC + NO together)
shall be wired to the control system for all the binary
inputs required for control purposes, except for input
from MCC/SWGR, actuators and inputs related to hardwired
signal exchange among various functional groups for which
non-changeover type contract(NC or NO)shall be wired to
the control system. The binary input required for
information purposes only shall be wired to control
system in the form of non-changeover type contacts.
2.03.03.2 The conditioning and processing functions to be
performed as a minimum for the binary input coming for
control & information purposes are :-
i) 24 V DC power supply for contact interrogation for
all potential free contacts with per point fuse
protection or suitable current limit feature/
isolation through optocoupler.
ii) Contact bounce filtering delay time of 15 milli secs.
iii) Facility for pegging the binary signal to logic
one/zero or last correct value in case of failure of
binary input module.
iv) Binary signal distribution to different user shall
be in such a way so as to ensure that a short/ground
fault on one user is not reflected to the other
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
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
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
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
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
2.03.07.1 Each of the dual triple redundant binary & analog
inputs shall be wired to separate input modules. In
addition, for functions employing 2V3 controllers like
BMS/Turbine protection, each of the redundant binary &
analog signals shall be wired to separate input modules
associated with each controller in line with
configuration drawing of BMS & TPS & meeting requirement
stipulated under clauses 2.04.01 of this section.
Similarly each of the dual redundant binary & analog
inputs shall be wired to separate input modules. These
redundant modules shall be placed in different racks,
which will have separately fused power supply
distribution. Implementation of multiple measurements
scheme of these inputs will be performed in the
redundant hardware loss of one input modules shall not
affect the signal to other module and also other channels
of these modules can be used by other inputs of the same
2.03.07.2 the single binary & analog signal required for control
purposes shall be wired as follows :-
i) The limit & torque switches and the MCC / SWGR
check backs shall be wired to drive control modules
wherever provided. For the drives where DCM are not
provided, these signals shall be connected to input
ii) Other single analog & binary inputs shall be wired to
single input modules.
2.03.08 The binary and analog outputs from one sub-system of the
control system to other which are required in these
systems for control purposes shall be made available
from triple/dual redundant binary and analog output
modules. However, redundancy in binary & analog outputs
to indicators/ recorders, SERS and Annunciation facia
lamps are not required.
2.03.09 The signal conditioning functions like multiple
measurement schemes square root extraction for flow
signals, pressure & temperature compensation, limit
value computation can be performed either in the
controllers or in signal conditioning and processing
hardware outside controllers.
2.03.10 The maximum No.of inputs/outputs to be connected to
each type of module shall be as follows:-
1. Analog input module – 16
2. Analog output module – 16
3. Binary input module – 32
4. Binary output module – 32
5. Analog input & output(combined)- 16
6. Binary input & output(combined)- 32
(Note:- For Binary inputs, one changeover contact is
counted as 2 inputs)
Further, minimum 10% spare channels shall be kept in
each of the input/output modules.
2.03.11 The following requirements shall be met :
2.03.11.1 Input filters to attenuate noise shall be provided.
2.03.11.2 All analog/ binary input shall be capable of
withstanding 500 V DC common mode and 500 V AC peak to
peak. All analog outputs shall be short circuit proof.
2.03.11.3 Common mode noise rejection for analog inputs shall
be minimum 120 db at 50 Hz.
2.03.11.4 Normal mode noise rejection for all analog inputs
shall be 60 db at 50 Hz.
2.03.11.5 Surge Switch stand as per IEEE 472.
2.03.11.6 Any single sensor/transducer/transmitter failure alarm
shall be provided on I&C maintenance or program CRTs
for all sensors/transducers/transmitters. Similarly
sensor break alarm for thermocouples etc. shall also be
displayed on the CRTs.
2.04.00 CONTROL SYSTEM REQUIREMENTS
2.04.00.1 The control system shall be broadly divided into SG
C&I, TG C&I and BOP C&I as already elaborated in clause
2.04.00.2 The SG C&I system shall perform the following :-
i) Burner Management System(BMS)including control &
protection of coal mills, fuel oil system etc.
ii) Analog control functions pertaining to secondary
air damper control, Aux.PRDS pressure &
iii) Soot Blower Control.
2.04.00.3 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
2.04.00.4 The balance of plant C&I system shall perform the
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
2.04.00.5 The No.of Functional groups(FGs)shown in elsewhere in
the specification, these are the minimum
required. However, splitting of any functional group in
more than one FGs due to any limitation in bidder’s
system shall be acceptable, subject to employer’s
approval. For each of the FGs, separate sets of
controllers, I/O modules, communication controllers,
power packs/modules etc. shall be provided. Mixing of
hardware of two or more FGs shall not be acceptable.
2.04.00.6 The minimum functions to be realized in each
of the above-mentioned controls systems shall be as per
requirements specified under subsequent clauses of this
specifications. The bidder shall provide all
hardware/software, whether or not specifically indicated
in this specification to fully meet operational/
maintenance/ safety requirement as well as statutory/
international standard and proven practices.
2.04.00.7 The control system shall function reliably under the
environmental conditions as specified under Part-C
“General Technical Requirement” of this specification.
It shall be immune from the interferences resulting from
disturbances in power supply feeders signal lines,
inputs, outputs etc. as experienced in a coal fired
2.04.00.8 The control system shall have on line simulation &
testing facility. Further, it shall be possible to on
line configure & tune controllers through configuration
& tuning station for control system.
2.04.00.9 The system shall have the flexibility to easily
reconfigure any controller at any time without requiring
additional hardware or system wiring changes & without
disabling other devices from their normal operation
mode. Modifications shall not require switching off
power to any part of the system.
2.04.00.10 The remote manual operation from hardwired back-up
A/M stations & push button(PB)stations(wherever
provided)shall be independent of availability of
controllers & power supply to controllers.
2.04.00.11 The executive programs for the controller modules
shall be firmware based, which shall be non-volatile &
shall not be alterable except by replacement of parts.
The application programs for the functional controllers
shall be software based which shall be maintained
through power supply failure. The application program
shall be alterable through the configuration and tuning
station for all configuration and strategy changes,
etc. and through the operator’s console for set
point/ bias changes, device selection, etc. Parts
replacement or parts removal shall not be required in
order to accomplish changes in application programs
including system tuning.
2.04.00.12 All the 100% hot/redundant back-up controllers shall
be identical in hardware and software implementation to
their corresponding main controllers & shall be able to
perform all its tasks. The back-up controller shall
track its corresponding main controller. There shall be
an automatic and bump less switchover from the main
controller to its corresponding back-up controller in
case of main controller failure and vice versa without
resulting in any change in control status. In case of
switchover from main controller to the 100% hot back up
controller, the back-up controller shall work as the
Facility shall also be provided for manual switchover
from main to 100% hot back-up controller and vice versa
from the programmer’s console.
2.04.00.13 The control system hardware design shall be such that
it is able to withstand power line disturbances.
2.04.00.14 The control system for SH/RH Attemp. Temp.control
shall be state controller with observer.
2.04.00.15 The hardware design shall be such that it is able to
withstand power line disturbance.The system shall conform
to ANSI/IEEE C 62.4 (Immunity to power supply line disturbance).
2.04.01 BURNER MANAGEMENT SYSTEM (BMS)
2.04.01.1 Fully proven microprocessor based system, based on
hardware and software specifically designed and proven
for Burner Management application for the same being
offered for shall be provided to achieve the Boiler
protection action e.g.master fuel trip(MFT), control of
mills & fuel oil systems etc. BMS shall meet all
applicable relevant safety requirement including those
stipulated in NFPA- 8502.
2.04.01.2 The BMS shall be provided with automatic self
monitoring facility. All modules to be used in this
system shall be of fail-safe design. Any single fault
in either primary sensor, I/O modules, multifunction
controllers etc. should not result in loss of safety
function. All faults should be annunciated to the
operator right at the of its occurrence and also for
alarm annunciation facia.
2.04.01.3 The MFT functions shall be implemented in a fault
tolerant 2 out of 3 triple redundant configuration. Each
of the three independent channels shall have its own
dedicated processors, multifunction controllers,
communication controllers, I/O modules, interface etc.
All safety related process inputs shall be fed to each
of the 3 channels. All the primary sensors for
unit/boiler protection shall be triple redundant.
2.04.01.4 The acquisition and conditioning of binary and analog
protection criteria signals for MFT shall be carried out
in each of the three triple redundant channels. Each
channel shall compute the 2 out of 3 voting logic and
issue a trip command. The trip signals of the three
channels shall be fed to a fail 2 out of 3 relay
tripping unit for each drive. The protection criteria
for tripping shall be executed by a program which shall
be identical in each of the triple redundant channel.
The check back contact signals of each relay of the 2
out of 3 relays tripping unit shall be fed back to each
of the triple redundant channels & shall be
continuously monitored for equivalence in each of them.
2.04.01.5 The functionality of operation of mills. oil etc.shall
be similar to that of OLCS described in clause 2.04.03
2.04.02 TURBINE PROTECTION SYSTEM (TPS) FUNCTIONS
2.04.02.1 Fully proven microprocessor based system, based on
hardware and software specifically designed for Turbine
protection application for the same turbine being
offered for this project, shall be provided to achieve
the turbine protection action.
2.04.02.2 The Turbine protection system shall meet all
applicable safety standards/requirements including those
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
2.04.02.3 Bidder shall provide two independent trip channels,
each having its dedicated processing module with
hot back up. Two out of three voting logic will
be implemented in each of the channels and the
output of each channel to be fed to each of the two
turbine trip relays.
2.04.02.4 All the input signals (trip signals etc. from the
field devices) shall be fed in parallel to all the
three/ both the redundant channels of protection system
as mentioned above via signal conditioning cards
designed for such application. Further, the computation
of field input voting logics i.e. 2 out of 3 etc. shall
also be performed in the controllers of all the three/
two channels of protection system , which will then
perform the computation of field input voting logics
i.e. 2 out of 3 etc.shall also be performed in the
controllers of all the three/two channels of protection
system, which will then perform the computation of 2 out
of 3 voting logic independently.
2.04.02.5 Bidder shall provide all the required primary sensors
etc. required for protection system as per his standard
and proven practices. All trip signal input required
for the safety of the turbine shall be be based on 2 out
of 3 logics.
2.04.02.6 The system shall include turbine lock-out relays,
redundant turbine trip solenoids and necessary hardware
required for testing.
The tripping devices shall be designed to operate on DC
supply. The trip coils shall be monitored continuously
for healthiness and failure shall be alarmed.
2.04.02.7 Turbine Protection System shall meet all applicable
relevant safety requirement including those stipulated
in ASME- TDP-1, VDE 0116, Sec8.7; VDE 0160 etc.
2.04.02.8 TURBINE STRESS CONTROL SYSTEM (TSCS)
Bidder shall provide a proven Turbine Stress Control
system which will work in conjunction with turbine
governing system and ATRS and achieve the following
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
2.04.03.1 The OLCS shall include sequence control, interlock &
protection for various plant auxiliaries/ valves/
dampers/ drives etc. The sequence control shall provide
safe and automatic startup and shutdown of plant and
of plant items associated with a plant group. The
interlock and protection system shall ensure safe
operation of plant/ plant items at all times & shall
automatically shut down plant/ plant items when unsafe
2.04.03.2 The OLCS shall be arranged in the hierarchical
control structure consisting of unit level group level,
subgroup level & drive level(as applicable).
It shall be possible to perform automatic unit startup &
shutdown by issuing minimum No.of command from the OWS.
Thus, the unit level shall control all the control
system blocks and issue appropriate startup & shutdown
commands to various blocks of control system.
The group level shall control a set of functional sub-
groups of drives. Appropriate start-up and shut down
commands shall be issued to the sub-group control &
various check backs shall be received from sub-groups or
drives. Each sub-group shall execute the sequential
start-up and shut down programme of a set of
inter-related drives along with system interlocks and
protections associated with that sub-group as well as
basic interlocks & protections related to individual
drive falling under that sub-group. The drive level
shall accept commands from the sub-groups, push buttons
etc. & transmit them to the respective drive, after
taking into account various interlocks & protections and
the safety of that particular drive.
2.04.03.3 Sequence Control
2.04.03.3.1 A sequence shall be used to move a set of groups,
sub-groups from an initial steady state (for instance
`OFF’) to a final steady state (for instance `ON’). The
sequence initiating command for the unit & group level
shall be issued from CRT/KBD.
2.04.03.3.2 A sequence shall be made of steps. The steps shall
be executed in predetermined order according to logic
criteria and monitoring time consisting of the interlock
& protection requirements and check back of previous step
which shall act as preconditions before the sequence
control can execute the command for that step.
2.04.03.3.3 Each step shall have a “waiting time” implying that
the subsequent step would not be executed unless the
specified time elapses. A monitoring time shall also be
defined as the maximum time required in executing the
commands of any step and the time required for
appearance of checks backs signals. In case, this is not
completed within the specified time, a message shall be
displayed and program will not proceed further.
2.04.03.3.4 Manual intervention shall be possible at any stage
of operation and the sequence control shall be able to
continue at the correct point in the program on return
to automatic control. Protection commands shall have
priority over manual commands, and manual commands shall
prevail over auto commands.
2.04.03.3.5 Open or close priority shall be selectable for each
2.04.03.3.6 The sequence start-up mode shall be of the
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.
2.04.03.4 The sequence shall be started by putting the sequence
on `Auto’ and on receipt of `Start’ command from the OWS
or from a higher level group/ protection action as
defined. The sequence shall then progress as per the
defined logics. It should be possible to select
alternative operation in the same sequence depending on
certain process/ equipment condition. Some step can be
automatically bypassed also based on certain process/
equipment condition. When the expected results of the
sequence is reached the sequence is considered as ‘End’.
2.04.03.5 If during sequence initialization or sequence
progressing or during normal running of the drive, a
shutdown criteria is present, the sequence shall be
stopped and the shutdown sequence initiated.
2.04.03.6 For the drives, the command shall be provided through
redundant O/P module and inputs (Status, SWGR & process)
shall be acquired through input modules. The inputs &
output modules used in relation to drives shall not be
mixed with inputs & output modules for other
applications. The drive logic shall be implemented in
the redundant controller.
The status of the HT drives and some other important
drives(total approximately 40 Nos. per unit)shall also
be wired in parallel to redundant input modules so that
on failure of the single input modules, the information
regarding the status of the affected drive remains
available in OLCS.
2.04.03.7 The output modules shall have the feature that
ensures that in case of failure, all the outputs are
driven to zero. The 24 V DC command outputs to drives
for ON/ OPEN, OFF/ CLOSE shall be separate and
independent and inverted outputs shall not be
employed. For inching type of drives, position
transmitter power supply and monitoring of position
transmitter signal shall be provided.
2.04.03.8 The termination for OPEN/ CLOSE command for the drive
actuator shall be performed in the actuators specified
elsewhere in the specification. However, OPEN/ CLOSE
and disturbance status as a minimum shall be monitored
2.04.03.9 The sequence interlock & protection requirements shall
be finalised during detailed engineering and the same
shall be subject to employer’s approval.
2.04.03.10 The OLCS shall also include the control of
electrical systems in addition to the auxiliaries of
boiler & turbine performing functions such as OPEN/
CLOSE or ON/ OFF etc. of various electrical systems such
as breakers and isolators, raise/ lower for equipment
like transformers tap changer, synchronization of unit,
etc. All the features and specification requirements as
specified above shall also be applicable for electrical
system. Control and all the operation shall be
performed through CRT/KBDs of OWS. However, 100%
hardwired backup miniaturized switches shall also be
provided on UCP for electrical systems.
2.04.03.11 Operator Interface for SIS & Sequence Control
Following status information shall be available to operator
on OWS or Console.
i) Where the process is in its sequence.
ii) Indication that SIS protective action has occurred.
iii) Indication that protective action is bypassed.
iv) Status of sensors, final drive, diagnostic features etc.
2.04.04 ANALOG CONTROLS/ CLOSED LOOP CONTROL SYSTEM(CLCS)FUNCTIONS
2.04.04.1 The CLCS shall continuously act on valves, dampers or
other mechanical devices such as hydraulic couplings
etc.which alter the plant operation conditions. The
system shall be designed to give stable control action
in steady state condition and for load changes in step/
ramp over the load range of 60% to 100% MCR with
variation or parameters within permissible limits to be
finalised during detailed engineering state. The system
shall have the following minimum features.
2.04.04.2 The loop reaction time (from change of output of the
sensor of the transmitter/ temperature element to the
corresponding control command output) shall be within
500 m/secs. However, for faster loops such as feed
water, furnace draft, P A header pressure control loop
etc. the same shall be based on actual process
requirement but shall not be more than 250 milli secs. The loop response time shall be as per IEEE-1046.
2.04.04.3 The control system shall be bumplessly transferred to
manual on the following conditions as a minimum and as
a minimum and as finalised during detailed engineering.
Control power supply failure, failure of redundant
controllers, field input signal not available, analog
input exceeding preset value etc.
2.04.04.4 Any switch over from auto to manual, manual to auto
and switchover from CRT operation to H/A Station
operation and vice versa shall be bumpless & without
resulting in any change in the plant regulations and
the same shall be reported to the operator.
2.04.04.5 Buffered analog output of 4-20mA DC shall be provide
from CLCS to the respective E/P converters. For
electrical actuators, type output(bound less
control) shall be preferred. CLCS shall also provide
all the necessary outputs for indicators& recorders with
output loop resistance of 500 Ohms for each channel of
the output module.
For the drives, the command shall be provided through
redundant O/P module and inputs(position feed back &
process) shall be acquired through input modules. The
inputs & output modules used in relation to drives shall
not be mixed with inputs & output modules for other
applications. The drive logic shall be implemented in
the redundant controller.
2.04.04.6 The functional requirement of the CLCS loops as well as
the detailed schemes shall be finalised during detailed
engineering stage and shall be subject to employer’s
2.04.04.7 The system being supplied shall be such that when
permissible limits are exceeded, an automatic switchover
from an operation governed by maximum efficiency, to an
operation governed by safety and availability is
2.04.04.8 For safety reasons, switchover logics associated with
the modulating control loops, shall be performed within
the closed loop control equipment.
2.04.04.9 Where the equipments are controlled by a group of
regulators acting in parallel, the relative position
of individual actuator associated with them shall be
capable of being adjusted with respect to one another
and to the common automatic signal.
2.04.04.10 Time supervision facility shall be provided to
monitor the final control element.
2.04.04.11 It shall be possible to block the controller output
on a pre-programmed basis.
2.04.04.12 All controllers shall be freely configurable with
respect to requisite control algorithms.
2.04.04.13 Whenever, alternate measurement is available for a
control input the alternate measurement value will be
automatically substituted in the control loop in case
of loss of control input. All necessary software for
switching and reconfiguration shall be provided. In
addition, such substitution shall be balance less and
bumpless and shall be reported to the operator.
2.04.05 HP/LP BYPASS SYSTEM
2.04.05.1 LP BYPASS CONTROL SYSTEM
The LP Bypass control system shall consists of steam
pressure control loop and steam temp.control loop. The
LP Bypass control shall be implemented through a set of
redundant controller modules, I/O modules etc. The LP
Bypass control shall suitably interface with other TG
control like HP Bypass, EHG etc. Further condenser
exhaust hood spray valve shall be interlocked to open
whenever LP Bypass comes into operation.
2.04.05.2 HP BYPASS CONTROL SYSTEM
a) The system shall consists of steam pressure control
loop & steam temp.control loop. HP Bypass system shall
be implemented through a set of redundant controller
modules, I/O modules etc. The system shall be supplied
with redundant 2 out of 3, primary sensor & suitably
interface with other TG C&I controls like LP Bypass, EHG
b) HP Bypass system shall conform to ANSI/ISA 77.13.01.
2.04.05.3 OTHER SG C&I FUNCTIONS
The SG control functions shall also consist of Secondary
Air Damper Control soot blower control, Auxiliary PRDs
etc. in addition to the burner Management system and
2.04.05.4 OTHER T G C&I FUNCTIONS
The TG control functions shall also, consist of Turbine
Generator control system like seal oil, primary water,
hydrogen system etc. interlock & protection.
2.05.00 MAN-MACHINE INTERFACE SYSTEM AND PLANT INFORMATION
SYSTEM (MMIPIS) REQUIREMENTS
2.05.01 Man-Machine interface system shall be designed and
engineered for safe, efficient, reliable and convenient
operation. MMIPIS shall employ high-performance, non-
proprietary architecture to ensure fast access and
response time and compatibility with other system.
MMIPIS shall be used primarily for the following
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
2.05.02 OPERATOR INTERFACE TO THE CONTROL SYSTEM
2.05.02.1 The operator interface of the MMIPIS shall consist of
21 inch colour TFT Monitor/KBDs of OWS (Operator Work
Station), colour Laser Printers, large video screen(LVS),
console etc. Each Operator workstation (OWS) shall include
one TFT Monitor, one keyboard and touch screen or mouse for
ease of operation. The TFT Monitor operation shall employ
powerful menu-driven and window supported input facilities
for operational ease and comfort.
No single failure in MMIPIS shall lead to non
availability of more than one OWS and two printers. In
such an event i.e., single failure leading to non
availability of any OWS, it shall be possible to operate
the entire plant in all regimes of operation including
emergency conditions from each of the other available
Operator functions displays, structure of the keyboard
assembly and key assignment shall be finalised during
detailed engineering. Further all frequently called
important functions including major control loop display
shall be assigned to dedicated function keys for the
convenience of the operator.
2.05.02.2 (a) Operator Functions
The operator functions for control on each OWS shall as
a minimum include control system operation, alarm
acknowledge, call control displays, demand/ printout of
various displays, logs, summaries etc.
The display selection process shall be optimized so that
the desired display can be selected with the barest
minimum No.of key strokes/ steps by the operator.
The control related display on the CRT/ TFT Monitor
shall as a minimum include mimic displays, overview
displays, area displays, individual loop/ drive display,
closed loop control displays, open loop control displays
etc. Operator’s function allowed the control of
drives/equipments, viewing of all displays, changing
certain pre-selected parameters like set points, bias
etc. printing of report.
However following functions are prohibited for
(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
2.05.03 PLANT SUPERVISORY, MONITORING & INFORMATION FUNCTIONS
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
2.05.03.1 BASIC CALCULATIONS
All the algebraic/logical calculations related to
analog points(e.g. sum/difference/average/integration
etc.) digital point, transformations, flow calculations,
time projection or rate of change calculations,
frequency etc.shall be provided. All the calculated
values of the plant shall be available in the database.
2.05.03.2 PERFORMANCE CALCULATIONS
a) The performance calculations shall use FORTRAN or
equivalent high-level language. An extensive set of
steam property sub-routines based on 1967 ASME steam
tables shall be included in the system. The
calculation shall be carried out at 30% unit load or
higher. The calculation frequency shall be selectable at
site from 10 minutes to 1 hour, with a step of 10
minutes. The performance calculations shall be broadly
subdivided into two classes.
Class I : Equipment protection calculations
Class II: Plant/ equipment efficiency calculation.
b) The Class I calculations are generally for the purpose
of detecting & alarming unit malfunctions.
These shall include cold reheat steam approach to
saturation temp.SH spray outlet approach to saturation
temp. turbine steam metal temp. differences, turbine
metal temp. rates of change, feed water heater terminal
temp.difference, feed water heater drain cooler
approach and LMTD,excess air deviation from standard, feed
water heater temp. deviation from standard, drum water
saturation temp.rate of change, metal temp. difference
for SH `Y’ and RH `Y’ piece etc.
c) The class-II performance calculations shall be
performed to determine the performance of individual
items of equipment and the overall unit. The
periodicity of this calculation shall be selectable
from 10 minutes to 60 minutes in increments of 10
minutes. These shall include calculations for Boiler
efficiency, Gross turbine generator heat rate, gross
unit heat rate, net unit heat rate, operating hours,
plant load/availability factors, HP/IP/LP turbine
enthalpy drop efficiency, condenser/deaerator/economizer
performance, air heater performance, unit availability
calculations, deviation from expected values for each
calculation shall also be computed. The performance
calculation shall be as per following ASME code or BS
i) Boiler Efficiency – BS-2885(By Heat Loss Method)
ii) Steam Turbine – ASME PTC-6
iii) Air Pre- Heater – ASME PTC-4.3
iv) Feed Water Heater – ASME PTC-12.1
v) Deaerator – ASME PTC-12.3
vi) Condenser – ASME PTC-12.2
2.05.03.3 All the primary instruments, cable, hardware, software
whatever required for efficiency/ performance
calculations shall be in the Bidder’s scope.
2.05.03.4 Other Calculations
Variable alarm limit calculations, heat rate deviations
and revenue calculations, frequency excursion time
integration etc.shall also be provided.
2.05.03.5 Alarm Monitoring and Reporting
The system shall display history of alarms in
chronological order of occurrence on any of the OWS. The
MMIPIS shall have the capability to store a minimum of
1000 alarms pages, each with paging features allowing
the operator to view any page. The OWS keyboard shall
have all alarm functions and related function keys like
alarm acknowledge, reset, paging, summaries etc. Other
design features like prioritization, set point/ dead
band adjustments, alarm report format etc. shall be as
finalised during detailed engineering.
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
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
2.05.03.7 Logs/ Summaries
The system shall generate three basic types of
reports/logs i.e. Event activated, time activated and
operator demand log & summaries. The log format and
point assignment for each logs/report and other design
features shall be as finalised during detailed Engg.
The system shall have the facility for viewing of time
activated and operator demand logs/ summaries on the
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
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
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
2.05.03.8 Log Generation Utility
The Bidder shall offer a log generation utility to
generate a log/report having following facilities as a
a) Define format of the log like header information, time,
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
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
2.05.03.9 Historical Storage and Retrieval System(HSRS)
The HSRS shall collect, store and process system data
from MMIPIS database. The data shall be saved on line
on hard disk and automatically transferred to erasable
dual Magneto-optical disk (removable type)once in every
24 hours periodically for long-term storage. Provision
shall be made to notify the operator when optical disk
is certain percentage full.
The data to be stored in the above system shall include
alarm and event list, periodic plant data, selected
logs/report such as event activated logs, trip analysis
log, start-up log etc. The data/ information to be
stored & frequency of storage and retrieval shall be as
finalised during detailed engineering.
The system shall provide operator function to retrieve
the data from historical storage. The operator shall be
able to retrieve the selected data on OWS and any other
CRT which are connected with system bus or printer and
suitable index files/ directories shall be provided to
facilitate the same.
In addition to the HSRS the system shall also have
facility to store & retrieve important plant data for a
very long duration(plant life) on MODs.
The System shall have adequate memory capacity for
storing the plant life data (minimum 30 years) at scan
rate 30 secs.for minimum 500 analog points and shall
have adequate storage capacity the last 5 year data at
the scan rate of 5 secs.for minimum 500 analog points.
However these points may increase as per recommendation
of original manufacturer of equipment.
2.05.03.10 Quality Tag
The system shall identity and tag the quality of all
data (scanned & calculated points)is a way that makes
all users(control, calculations, logs displays etc.)
aware of its quality. Quality of data other than good
shall be clearly identified in all printouts and
displays by appending quality character to the value/
status of point. The quality tagging shall include
good, bad, substitute, doubtful, suspect etc.
2.05.03.11 a) DDCMIS shall provide fault alarm analysis guiding
the operator to the most likely cause of fault. The
alarm system shall be designed in such a manner that
main auxiliaries tripping can be traced to the
b) Trend alarms shall be provided in DDCMIS for slowly
varying process parameters, so that appropriate
corrective actions are taken in time. These alarms
shall be suitably provided in OWS, which will be
decided during detailed engineering stage.
2.05.03.12 An integrated unit startup system shall be
implemented in DDCMIS incorporating all operational
curves for SG, TG and auxiliaries. This shall guide the
operator to take appropriate actions at appropriate time
to bring the rated parameters safely within the
2.05.04 MMIPIS HARDWARE
2.05.04.1 The MMIPIS as specified shall be based on latest
state of the art work stations and servers and
technology suitable for industrial application & power
plant environment. The quantity of peripherals, main &
bulk memory etc. as shown in the referred drawing is the
minimum the bidder has to provide. The workstations
other than OWS shall be configured in such a way that
loss of one workstation does not result in loss of any
The actual size of the main and bulk memory shall be
sufficient to meet the functional and parametric
requirements as specified with 25% additional working
memory and 50% additional bulk memory over and above
the memory capacity required for system implementation.
The exact system configuration and sizing shall be as
approved by employer.
2.05.04.2 The work station/ servers employed for MMIPIS
implementation shall be based on industry standard
hardware and software which will ensure easy
connectivity with other systems and portability of
employer developed and third party software. These will
be 64 bit machines.
2.05.04.3 Redundant sets of communication controllers shall be
provided to handle all the communication between the
MMIPIS and redundant system bus and to ensure specified
system response time and parametric requirements. Each
communication controller shall have message checking
2.05.04.4 Power Fail Auto Restart(PFAR) facility with automatic
time update shall be provided.
2.05.04.5 All the peripherals shall confirm to the following
minimum requirement but the exact make & model shall be
as approved by employer during detailed engineering.
a) All the monitor shall be 21” colour TFT and
suitable for mounting in tabletop arrangement. Processor
processor, Power Supply, Communication port of OWS shall be
redundant. All OWS shall be Industrial grade,interchangeable.
The configuration shall be fault tolerant. OWS shall have
Following minimum specification.
(i) Resolution (1600x 1200)
(ii) Display Colour (128)
(iii) RAM Capacity (1 GB)
b) The printers shall be heavy-duty lasers(minimum printing
speed 8 pages, minimum printing speed of 20 pages for
laser printer). The laser printer should have provision
of printing computer paper apart from cut sheets.
e) Five No. Large video screens (LVS), each with 67 inches
Diagonal graphic controller and other hardware shall be
Provided. It shall have facility of integrating the CCTV
Signal & RGB video signal from field.
2.05.04.06 Man Machine Interface (Unit wise)
a) Unit Control Room PC
i) Operator Work Station – 8 Nos.
ii) Large Video Screen – 5 Nos.
b) Computer Room PC
i) Historian PC – 2 Nos.
ii) Programmer PC – 3 Nos.
iii)Colour Laser printer – 1 No.
(size A 3)
iv) Laser printer(A 4 , B/W) – 1 No.
c) Shift Engineer PC – 1 No.
+ Laser printer
(size A 4, B/W)
d) PC at different location – 3 Nos.
Of unit + Laser
printer (Size A 4,B/W)
e) Colour Laser Printer
(size A 3)
i) Log Printer – 1 No.
ii) SOE Printer – 1 No.
iii) Alarm Printer – 1 No.
f) Dot Matrix Printer – 2 Nos.
2.05.04.07 Man Machine Interface (Common for two Units)
PC Station – 10 Nos.
The above PC stations are to be located at various plants
location (to be decided during detailed engineering).
All PC Station shall be with B/W laser printer(size A4).
The function of above
PC’s are to view the alarm, display, and generate reports of
both the units.
2.05.04.08 O&M Head PC Station (Common for two units)
O&M Head PC shall be located at O&M head office and
connected to system bus. The function of above PC to
view & print alarm, display and generate reports. This
PC shall have one laser printer and one scanner. The size
of printer and scanner shall be A3. The system shall also
include all required software and hardware for printing
of CAD drawing and documents.
2.05.04.09 Station Head PC (Common for both the units)
This PC shall be located at Station head office and
shall be connected to system bus. The function of above
PC is to view the alarm, displays and generate reports
of all units. The PC shall be with laser
2.05.04.10 The detail documentation of Boiler, Turbine,
Electrical, Instrumentation CHP, AHP etc. shall be
available in shift Engineer PC, Station head PC, O&M
head PC and other 10 Nos.PC. The documentation shall be
in text & drawing form (Minimum 2000 pages and 100
drawings/ image size of A3. However the above quantity
may increase as per actual requirement. The system
shall include all required software & hardware.
2.05.04.11 Bidder shall supply 3 PC Station + B/W Laser printer
(size A 4) per unit with network capability and cable
etc. The location of PC shall be decided during detailed
engineering shall be connected through telephone
Exchange with system bus.
2.05.04.12 (a) The hardware of all work station/ PC shall be same
configuration make & Model No.as OWS.
(b) All laser printers shall be same make and with inbuilt
2.5.04.13 The bidder shall provide consumable i.e. tonner,
paper for Laser printers for one year, considering
consumption rate 30 papers per day per printer. Bidder
Shall also provide formatted, 100 CD with each PC Station/
2.06.01 The system shall have the facility to generate the
associated documentation for both the control system &
MMIPIS. The bidder shall furnish detailed information
about system documentation facilities in his offered
system along with the bid. The document, to be generated
by the system shall include P&ID drawings, control loop
drawings, sequence drawings, signal distribution
list/drawings, system interconnection drawings,
cabinets general arrangement drawings, measurement
list, drive schedule, alarm schedule, system hardware
and functional configuration drawings for displays,
logs, trends, graphics etc. The system shall also
include all required software and hardware tools for
creating, modifying and printing CAD drawings to achieve
paperless documentation for DDCMIS.
2.06.02 To realize all of the functions mentioned above the
Bidder shall provide standalone stations for
configuration & tuning functions of control system and
MMIPIS programming, hardware of which shall be separate
from the hardware of the respective system and
connected to System Bus. The bidder shall provide 2
Nos. of programmer station for control system and 1 No.
programmer Station for MMIPIS.. Each of the programmers
station shall also have a colour laser printer. The
hardware for system documentation facility(specified at
Cl.2.06.04 above)may be a part of either configuration
and tuning unit for Control System or MMIPIS programmer
if all the functions specified above can be achieved in
these programmer stations. Two separate workstation,
colour laser printer, scanner shall be
provided for documentation facility with necessary
software for other than DDCMIS. The size of printer,
plotter, scanner shall be A 3. The system shall also
includes all required hardware & software tools for
creating, modifying and printing CAD drawings to
achieve paperless documentation. The hardware of work
station shall be same as that of OWS.
2.07.00 DATA COMMUNICATION SYSTEM (DCS)
2.07.01 The DCS shall include a redundant main system bus &
local system buses for major subsystems with hot back-up
and other applicable bus systems like cubicle bus,
local bus, I/O bus etc. The DCS shall have the
following minimum features.
2.07.01.1 Redundant communication controllers shall be provided
to handle the communication between each functional
group of controllers of control system and the system
bus. The design shall be such as to minimize
interruption of signals. It shall ensure that a single
failure anywhere in the media shall cause no more than
a single message to be disrupted and that message shall
automatically be retransmitted. Any failure or physical
removal of any station/ module connected to the system
bus shall not result in loss of any communication
function to and from any other station/module.
2.07.01.2 If the system bus requires a master bus controller
philosophy, it shall employ redundant master bus
controller with automatic switchover facility.
2.07.01.3 Built-in diagnostics shall be provided for easy fault
detection. Communication error detection and correction
facility (ECC) shall be provided at all levels of
Failure of one bus and change over to the standby system
bus shall be automatic and completely bumpless and the
same shall be suitably alarmed/logged.
2.07.01.4 The design and installation of the system bus shall
take care of the environmental conditions and hazardous
area classification as applicable to similar services.
2.07.01.5 Data transmitting speed shall be sufficient to meet
the responses of the system in terms of displays,
control etc. plus 25% spare capacity shall be available
for future expansion.
2.07.01.6 Passive coaxial cables or fiber optic cables shall be
employed for system bus.
2.07.01.7 The redundant buses shall be physically separate and
shall be routed separately.
The bidder shall furnish details regarding the
communication system like communication protocol, bus
utilization calculations etc.
2.07.01.8 In case of any distance or other limitation in the DCS
bidder will provide suitable repeaters, MODEMS,
amplifiers, special type of cables like optical fibers
as required to make the DCS fully operational.
2.07.01.9 The Data Hiways shall be power surge protected and
conform to IEC – 801-5.
2.07.02. Station Wide Network
2.07.02.1 The servers/Ethernet LAN of the unit shall be
connected to a station wide Ethernet Wide Area Network
(WAN). Various common system & off-site plants and PCs
at various plant locations & PLC/PC based systems
provided both by bidder as well as by employer shall be
connected to this station wide Ethernet WAN through
TCP/IP protocol. The station head/ O&M head & shift
in charge stations shall be located in this WAN to
monitor data of all units as well as of the common plant
location and off-site plants.
2.07.02.2 Further, this station wide WAN will have a PC
connected to act as a gateway to off-line WAN of the
entire station (not under this package)connected to
other station off-line services like administration,
materials etc. This gateway will also be able to
communicate with employer’s corporate office through a
satellite link(provided by employer). The exact details
shall be as finalised during detailed engineering and as
approved by employer. Bidder has to furnish all
necessary hardware and software for this purpose.
2.07.02.3 There shall be continual monitoring of network performance
2.08.00 SEQUENCE OF EVENTS RECORDING/ ANNUNCIATION FUNCTIONS
2.08.01 SER FUNCTION
2.08.01.1 The system shall monitor 250 SOE inputs (Tentative-
considering only cause of tripping of unit) with a
resolution of one milli second at all times for all
inputs including spare inputs. That is, all SOE points
entering status change shall be reported and time tagged
within 1(one)milli second of their occurrence. Input
card shall be equipped with digital filters with filter
delay of minimum 4 ms (identical for all points) to
eliminate contact bounce such that field contact which
is changing state must remain in the new state for
successive 4 ms to be reported to OWS within 1 sec.of
SOE data collection initiation. The system shall also
have provision of rejection of chattering inputs.
2.08.01.2 The system shall also include provision for historical
storage and retrieval of SOE reports for 12 months
period or One thousand SOE alarm pages.
2.08.01.3 The SOE report collection shall begin on occurrence of
change of status of any SOE point and shall be printed
after an operator selectable time interval of 1 to 3
Min. or 100 status changes have taken place after the
2.08.01.4 The SOE reports shall include a list of cause of unit
trip in chronological order and include the points which
initiated SOE collection and other statistical data sheet.
2.08.01.5 SOE System shall have dedicated VDU (21”)with KBD and
placed in computer Room.
2.08.02 ANNUNCIATION SYSTEM FUNCTION
2.08.02.1 The annunciation system shall be implemented as an
inbuilt function of the DDCMIS. The field contacts
shall be acquired through DDCMIS only. The annunciation
sequence logic shall be implemented as a part of the
DDCMIS controllers. The annunciation window lamps
mounted on unit control panel shall be driven through
contact output modules of the control system of DDCMIS.
In case, the annunciation sequence logic is not
performed within the controllers for MFT(BMS), TPS etc.,
then these signals can be transmitted through some other
controller through bus and processed therein.
However, the annunciation system shall have the facility
of driving independent prints/ lamp box in the event of
failure of MMIPIS/ system bus in case the annunciation
system is affected due to the same.
2.08.02.2 The annunciation sequence shall confirm to ANSI/ISA-
18.1(1979) with first up facility.
2.08.02.3 The annunciation system lamp boxes shall be suitably
mounted on unit control panel as decided during detailed
engineering stage keeping in view the operational
requirements. It shall be preferable to have each window
as mosaic compatible. The lamp box shall have removable
impact polystyrene window of snap-on type. The minimum
size of each window shall be 50 mm x 75 mm with 5 mm
size inscription in black lettering on white background.
Each annunciation window shall be backlighted with two
long life lamps/super LED. The changing of lamps shall
be conveniently done from the front by simple removal
2.08.02.4 Audible devices for alarm shall be cone type speaker
or metallic horn type and shall be driven by electronic
tone generator of adjustable pitch and sound level.
Bidder shall provide redundant audible devices with
selector switches. The trip alarms audible & ring back
audible shall be differentiated from other alarms.
2.08.02.5 The alarm annunciation system to be provided in unit
control room shall have sufficient capacity to cover all
pre-trip and trip alarms related to the unit and its
auxiliaries. The number of annunciation facia windows
and the provision for original input will be on as
required basis. However, the minimum number of facia
windows, signal input to the annunciation system shall
be 450 Nos.
2.09.00 MASTER & SLAVE CLOCK SYSTEM
2.09.01 a) The Bidder shall provide a date insensitive master and
slave clock system with adequate No.of output signal to
provide uniform timing throughout the various plant
facilities supplied by bidder as well as those not a
bidder’s scope. The system shall be complete with
receiving antennae (for receiving time from Satellite &
Radio signal), receiver and associated electronics,
redundant master clocks, slave clocks, interconnecting
cables, cubicles, power supplies & any other
accessories. However, a provision shall be kept for
synchronization of the master clock with other source as
decided during detailed engineering.
b) The system shall designed in accordance to IEEE 1344.
2.09.02 The master clock shall drive the slave display units. It
shall be ensured that loss of any slave display unit
does not affect the display of any other slave unit.
The MMIPIS, shall be synchronized with the master
clock once in every hour The switchyard event
recorder and other plant PLCs shall be synchronized
with the master clock once every minute.
2.09.03 The master clock shall be located in the control room
and shall have facility for automatic synchronizing with
GPS for IST.
2.09.04 The bidder shall provide a minimum 25 Nos.per unit of
slave clocks which shall be located at the various
plant facilities as finalised during detailed
engineering stage. System shall have expandable up to 30
Nos. slave digital clock.
2.09.05 The system include two Master Clock in 100% redundancy configuration (one working other standby). Power supply module for each Master Clock shall be redundant.
2.09.06 The cable from Master Clock to all Aux.plant PLC and slave clock shall be in bidder’s scope.
2.10.01 All panels, desks cabinets shall be provided with a
continuous bare copper ground bus. The ground bus shall
be bolted/ welded to the panel structure and efficiently
ground the entire structure. All individual cabinet
grounds shall be connected to separate earthling riser
to be provided for C&I system signal grounding, as per
IEEE standard No.1050. “IEEE guide for
Instrumentation and control system grounding in
generating station.” The grounding requirements of
various parts of the C&I system shall be separate from
plant earthing. The exact grounding scheme shall be as
finalised during detailed engineering.
2.11.00 SYSTEM SOFTWARE REQUIRMENTS
2.11.01 The bidder shall provide all software required by the
system for meeting the intent and functional/ parametric
requirements of the specification.
2.11.02 Industry standard operating system like UNIX/WINDOWS
NT/OPEN-VMS etc. to ensure openness and connectivity with
other system in industry standard protocols(TCP-IP
etc.)shall be provided. The system shall have user
oriented programming language & graphic user interface.
2.11.03 All system related software including Real Time
Operating System, File management software, screen
editor, database management software. On line
diagnostics/debug software, peripheral drivers software
and High-level language compilers for FORTRAN, C, PASCAL
etc.latest versions of standard PC-based software like
latest WINDOWS based packages/ Unix, SQL, RDBMS,
Antivirous etc. and any other standard language offered
shall be furnished as a minimum.
2.11.04 All application software for control system functioning
like input scanning, acquisition, conditioning
processing & control along with communication among
various control system functional blocks, MMIPIS and
system bus, MMIPIS software for operator interface of
monitors, displays trends, curves, bar charts etc.
performance calculations (with steam properties routines
utilities) Historical storage and retrieval utility,
sequence of events recording system functions shall be
2.11.05 The bidder shall provide software/ hardware locks and
passwords to Employer/ Project Manager at site for all
operating & application software in order to prevent
unauthorized access and only Employer’s authorized
representatives are able to do modifications at site.
2.11.06 Multiple sets of back-up software on media, on CD ROM
shall be provided by bidder.
2.11.07 The bidder shall provide software license for all
software being used in DDCMIS/ Computer. All licenses
shall valid for continuous service life of plant.
2.12.00 SYSTEM DOCUMENTATION
2.12.01 The Bidder shall furnish detailed system and equipment
documentation. It shall include detailed system and
components description covering the installation,
operation care and maintenance of all system components.
All final system documentation for DDCMIS hardware and
related software shall be furnished. The same shall be
complete, accurate and fully representative of the
supplied system and its elements. All documentation/
catalogues etc. shall be furnished in English language.
In addition to the hard copies, CD ROM based
documentation system shall also be provided. The same
should be compatible to the On-line document generation
2.12.01.1 HARDWARE DOCUMENTATION
2.12.01.2 Detailed technical literature, reference manuals,
user’s guide/ manuals for the complete hardware like
control system hardware like control system hardware,
MMIPIS hardware, I/O hardware, bulk memory units,
peripherals and their controllers, communication
hardware including controllers, man-machine interfaces
programmers unit, power supply modules etc., shall be
furnished by the Bidder.
2.12.01.3 Operation and Maintenance Manuals
a)The operation and maintenance manuals shall include all
information required for trouble shooting, repair and
maintenance information regarding all equipments
furnished for the completeness of the system. Sufficient
documentation including block diagrams, component level
circuit diagram with all component value, make, model,
type, detailed wiring and external connection drawing
etc., shall be provided to carryout trouble shooting and
repair of all electronic cards(PCB), power supply
modules at component level.
b) Bidder shall provide safety Instrumentation System operation
and maintenance documentation as per IEC- 61511.
2.12.02 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
2.12.02.1 All technical manuals, reference manuals, user’s guide
etc.in English required for modification/ editing/
addition/ deletion of features in the software of the
DDCMIS shall be furnished. The bidder shall furnish a
comprehensive list of all system/ application software
documentation after system finalization for employer’s
review and approval.
2.12.02.2 The software listings shall be submitted by the bidder
for source code of application software and all special
to project data files.
2.12.02.3 Bidder shall provide as build drawings and documents to
MPPGCL, in hard & soft copies.
2.13.01 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
2.14.01 The bidder shall provide and unlimited warranty on all
equipment and software for one year after the start of
the warranty period, i.e. after satisfactory completion
of initial operations. This warranty shall include
repair, replacement or correction of identified
software or hardware discrepancies at no cost to Owner.
2.14.02 No repairs/ replacement shall normally be carried out by
the employer when the plant is under the supervision
of bidder’s supervisory engineers. If in the event of
any emergency, in the judgment of the employer, delay
would cause serious loss or damage, repairs may be made
by the employer or a third party chosen by the employer
without advance notice to the bidder and the cost of
such work shall be paid by the bidder.
2.14.03 The Bidder shall provide warranty spares and an
exhaustive list of warranty spares including components
for system hardware and instrumentation and peripherals
based on (and keeping adequate margin over) normally
experienced failure rate shall be submitted by the
bidder for employer’s review regarding adequacy of the
same. The Bidder must furnish the list before inviting
owner personnel for acceptance test. The warranty
spares as per the list mentioned above will be
dispatched by the bidder along with the main equipment
consignment. The bidder shall also provide expandable
items for the warranty period.
2.14.04 In case of any hardware failure which hamper normal
operation, the bidder during the warranty period must
provide on-site technical expertise to repair/ rectify
the problem within 6 Hrs. and if any component is not
available at site, the bidder must arrange to supply
these components at site within additional 48 Hrs.if a
software problem is identified, this problem shall be
corrected within 24 Hrs.
2.14.05 After six months of DDCMIS operation the bidder shall
provide the list of spare parts and expandable utilized
during this period. The same information will also be
provided at expiry of the warranty.
2.14.06 In order to discharge the warranty responsibility, the
bidder shall include in his proposal lump sum price for
the provisions of a team of service personnel at site
who will be fully qualified to perform the required
duties throughout the warranty period of 1 year. The
bidder shall deploy at least one engineer, two
supervisors and four technicians in the team. The
exact numbers & composition of team members shall be
approved by the employer. In case, the team is unable
to rectify hardware or software problems, the bidder
shall depute and/or station additional specialist to
rectify the problem top ensure 99.7% availability of
system. The availability of system shall be calculated
as per specifications.
2.14.07 If any system is not working for more than one week then warranty period will be extended for duration for which the system was not available.
2.16.00 REMOTE DIAGNOSTIC STATION (OPTIONAL ITEM)
2.16.01 Bidder will indicate the price for the hardware &
software required for connecting the DDCMIS system to
bidder’s remote service center, through which the
diagnostics & fault analysis of the DDCMIS system can be
carried out. The method of connection shall be as per
Bidder’s standard practice. However, it is preferred to
have the connection through a single point
(i.e.Telephone line) in the plant’s DDCMIS system.
2.16.02 This price will not be considered for evaluation
purpose. However, bidder will include all technical
details of the proposed system for Employer’s review
and inclusion of the same in the award.
2.17.00 DDCMIS CONTROLLER GROUPING (OLCS x CLCS COMBINED FOR
SG, TG AND STATION – C & I)
2.17.01 S G SYSTEM
a) MFT– 1, MFT- 2, MFT-3, (Three Single Processors- 2/3
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
i) SBC, PR and Drain Temperature Control
2.17.02 T G SYSTEM –
c) LPBP, GSPC
d) Turbine Protection – A
e) Turbine Protection – B
g) ATRS SGC Turbine and SLC Drains
h) ATRS SGC Oil and Fire Protection
i) ATRS SGC Cond. & EAVC
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
o) Condenser, Deareator Drives/Misc. Drives
p) HPH, COLTCS, SCS, Misc. Drives
q) LPH/Extr.Steam/ Analysers/Misc.Drives
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
(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.
(c) D M Plant
(e) C W System etc
All hardware/Software/Cable/erection/ Commissioning etc. shall
be in the scope of Contractor.